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BOMBARDIER ski-doo Tundra Scandic 2004 Series Shop Manual

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Summary of Contents for BOMBARDIER ski-doo Tundra Scandic 2004 Series

Page 2 2004 Shop Manual TUNDRA SKANDIC LT/LT E/WT/SWT/WT LC/SUV 550/SUV 600...
Page 3 National Library of Quebec trimester 2003 National Library of Canada 2003 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 2003 Technical Publications Bombardier Inc.
Page 4 TABLE OF CONTENTS SECTION SUBSECTION PAGE SAFETY NOTICE ............................ INTRODUCTION ............................ SERVICE TOOLS AND 01 – Service tools .................. 01-01-1 SERVICE PRODUCTS 02 – Service products ................01-02-1 MAINTENANCE 01 – Table of contents ................02-01-1 02 – Maintenance chart ................. 02-02-1 03 –...
Page 5 TABLE OF CONTENTS SECTION SUBSECTION PAGE REAR SUSPENSION 01 – Table of contents................07-01-1 02 – Torque reaction suspension ............07-02-1 03 – Skandic WT suspension ..............07-03-1 04 – Skandic SUV suspension ............... 07-04-1 05 – Drive axle..................07-05-1 06 –Track ....................
Page 6 Always use common shop safety practice. Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the contents. We strongly recommend that any services be carried out and/or verified by a highly skilled professional mechanic.
Page 7 INTRODUCTION INTRODUCTION INTRODUCTION This Shop Manual covers the following Bombardier made 2004 snowmobiles: MODEL PACKAGE ENGINE COLOR MARKET MODEL NUMBER CANADA TUNDRA N.A. 280F (R) YELLOW 3282 CANADA TUNDRA N.A. 280F (R) BLACK 3283 SKANDIC 440F (R) YELLOW CANADA 2250...
Page 8 INTRODUCTION Tundra TYPICAL 1. Vehicle description decal Vehicle Description Decal Meaning A05A0EA TYPICAL — TUNDRA Skandic LT Skandic LT E Skandic WT Skandic SWT Skandic WT LC Skandic SUV 550 Skandic SUV 600 These are Skandic series models. VEHICLE DESCRIPTION DECAL 1.
Page 9 INTRODUCTION ENGINE SERIAL NUMBER Engine Serial Number Location Fan-Cooled Engines A03A0BA TYPICAL — FAN-COOLED ENGINES 1. Engine serial number Liquid-Cooled Engines TYPICAL — LIQUID-COOLED ENGINES 1. Engine serial number MMR2004-101_00_02A.FM...
Page 10 INTRODUCTION LIST OF ABBREVIATIONS USED IN THIS MANUAL long track meter ampere mile ampere magneto A•h ampere-hour Max. maximum alternate current Min. minimum acceleration and control modulator milliliter advance ride management millimeter bottom dead center MPEM multi-purpose electronic module BTDC before top dead center mile per hour °C...
Page 11 INTRODUCTION This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog. Page heading indicates section and subsection detailed. Subsection title indicates Section 07 REAR SUSPENSION beginning of the subsection. SUSPENSION SC-10 SPORT, TOURING AND MOUNTAIN Italic subtitle above exploded view...
Page 12 INTRODUCTION Section 05 TRANSMISSION Title indicates main procedure Turn puller handle and sliding half at once to extract the bushing. to be carried-out. CAUTION: Italic bold face type setting indicates a particular procedure A-Series and B-Series Only concerning a model. Should installation procedure be required, refer to BRAKE then look for Italic bold face setting...
Page 13 Due to late changes, it may have some differences between the manufactured product and the de- scription and/or specifications in this document. Bombardier Inc. reserves the right at any time to discontinue or change specifications, designs, features, models or equipment without incurring obligation.
Page 14 INTRODUCTION LOCTITE Blind Holes APPLICATION PROCEDURE The following describes the most common appli- cation procedures when working with Loctite products. NOTE: Always use proper strength Loctite prod- uct as recommended in this Shop Manual. THREADLOCKER Uncovered Holes (bolts and nuts) 1.
Page 15 INTRODUCTION Adjusting Screw 1. Clean threads (stud and hole) with solvent. 2. Apply Loctite Primer N (P/N 293 800 041) on threads and allow to dry. 3. Put several drops of proper strength Loctite threadlocker on female threads and in hole. 4.
Page 16 INTRODUCTION Standard Thread Repair 1. Remove old gasket and other contaminants with Loctite Chisel remover (P/N 413 708 500). 1. Follow instructions on Loctite FORM-A-THREAD Use a mechanical mean if necessary. (P/N 413 708 600) package. NOTE: Avoid grinding. 2. If a plate is used to align bolt: 2.
Page 17 INTRODUCTION Standard 1. Clean inner housing diameter and outer gasket diameter. 1. Clean shaft external part and element internal part. 2. Spray housing and gasket with Loctite Primer N (P/N 293 800 041). 2. Apply a strip of proper strength Loctite on shaft circumference at insert or engagement point.
Page 18 INTRODUCTION TIGHTENING TORQUES FASTENER SIZE N•m Lbf•ft (8.8 grade) Tighten fasteners to torque mentioned in exploded views and text. When they are not specified refer to following table. All torques apply to 8.8 grade fasteners. Bold face size (e.g. ) indicates nomi- nal value (mean value).
Page 19 Page______ ❏ ❏ Machine___________________ Report of error Suggestion ____________________________________________________________ We would be pleased if you could ____________________________________________________________ communicate to Bombardier any sug- gestions you may have concerning ____________________________________________________________ our publications. ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Name ______________________________________________________ Address ____________________________________________________ City and State/Prov. ________________________...
Page 20 AFFIX PROPER POSTAGE Technical Publications After Sales Service 565 de la Montagne Street Valcourt, Quebec, Canada J0E 2L0 AFFIX PROPER POSTAGE Technical Publications After Sales Service 565 de la Montagne Street Valcourt, Quebec, Canada J0E 2L0 AFFIX PROPER POSTAGE Technical Publications After Sales Service 565 de la Montagne Street Valcourt, Quebec, Canada J0E 2L0...
Page 21 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) SERVICE TOOLS This is a list of tools to properly service Ski-Doo snowmobiles. The list includes both the mandatory tools and the recommended tools. If you need to replace or add to your tool inventory these items can be ordered through the regular parts channel.
Page 22 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE — MANDATORY SERVICE TOOLS Exhaust spring installer/remover Hose pincher (2) Magneto puller (P/N 529 035 401) (P/N 295 000 076) (P/N 529 035 547) A00C1A4 APPLICATION A01B2I4 All engines except 247. A01B584 APPLICATION NOTE: The previous extractor (P/N...
Page 23 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — MANDATORY SERVICE TOOLS Engine leak tester kit 1) Piston pin puller (P/N 861 749 100) (P/N 529 035 503) Bearing heater NOTE: Should be used with hand pump (P/N 529 021 800).
Page 24 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — MANDATORY SERVICE TOOLS 9-volt adaptor Vehicle Communication Kit Lifting ring (2) (P/N 529 035 675) (P/N 529 035 844) (P/N 529 035 830) A33B064 APPLICATION Liquid cooled engines except 4-TEC.
Page 25 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE — RECOMMENDED SERVICE TOOLS The following tools are highly recommended to optimize your basic tool kit and reduce repair time. Crankshaft bearing 1) Screw M16 x 1.5 x 150 (P/N 420 940 755) puller with screw (1) 2) Screw M8 x 40 (4)
Page 26 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — RECOMMENDED SERVICE TOOLS Hand pump (P/N 529 021 800) Support plate Crankshaft locking tool (P/N 529 035 976) (P/N 529 035 821) F18B064 APPLICATION Elite. A00B6K4 Engine support bearing installer APPLICATION (P/N 529 035 952)
Page 27 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — RECOMMENDED SERVICE TOOLS Piston circlip installer Pusher (55/59 mm) (P/N 529 035 913) A) (P/N 529 035 561) 18 mm 4-Tooth socket B) (P/N 529 035 562) 20 mm (P/N 529 035 960) A32B134 A00B4Y4...
Page 28 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — RECOMMENDED SERVICE TOOLS Rotary valve shaft seal pusher Bearing pusher (inner, water pump side) (rotary valve) Water pump ceramic seal installer (P/N 420 876 512) (P/N 420 876 500) (P/N 529 035 766) A00B2J4 APPLICATION...
Page 29 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — RECOMMENDED SERVICE TOOLS Ring compressor Oil VAC Crankshaft distance gauge (12.7 mm) Not sold by Bombardier (P/N 529 035 880) (P/N 420 876 824) Snap-on RC980 V04B084 APPLICATION A00C3A4 1503 engine.
Page 30 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — RECOMMENDED SERVICE TOOLS Cylinder aligning tool Pilot 22 mm Float level gauge (P/N 529 035 523) (P/N 529 035 520) A) (P/N 420 876 904) (on exhaust side) B) (P/N 420 876 171) (on intake side) A00B084...
Page 31 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — RECOMMENDED SERVICE TOOLS RAVE movement indicator Magneto puller Multimeter (P/N 861 725 800) (P/N 420 976 235) (P/N 529 035 868) F01B294 APPLICATION 247 engine. A18B014 APPLICATION Injection pump gear holder All RAVE equipped engines.
Page 32 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — RECOMMENDED SERVICE TOOLS PTO seal pusher Insertion jig Rotary valve seal and (magneto seal) shaft pusher (P/N 420 876 660) (P/N 420 876 514) (P/N 420 876 605) A00C0V4 APPLICATION A00C0Y4...
Page 33 F01B234 APPLICATION A00B6B4 All vehicles. APPLICATION 2-Stroke engines. Homemade adaptor Engine stand Not sold by Bombardier A00B5J4 Required parts: 1) Female housing (P/N 515 175 245) 2) Female terminal (2) (P/N 409 015 100) 3) Female lock (P/N 515 175 246)
Page 34 Elite. Drive pulley puller (P/N 529 022 400) Spring scale hook (long) (P/N 529 035 557) A06B014 (TYPICAL) APPLICATION 2003 and up Bombardier Lite drive pulley. A00A1A4 Most TRA drive pulleys. APPLICATION TRA III. Most models. TRA IV. A00B4A4...
Page 35 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) TRANSMISSION (continued) — MANDATORY SERVICE TOOLS Driven pulley spring compressor Spring cover tool (P/N 529 035 300) (P/N 529 027 300) A01B4M4 APPLICATION Bombardier Lite drive pulley. A05B034 APPLICATION Tundra R. 01-01-15 MMR2004_102_01_01A.FM...
Page 36 Governor cup extractor APPLICATION (P/N 529 035 894) Skandic LT. A18B044 APPLICATION Drive pulley puller 2002 and older Bombardier Lite drive pulley, except Élan. (P/N 529 025 000) TRA drive pulley puller (27 mm) (P/N 529 010 100) A29B034 APPLICATION Skandic LT.
Page 37 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) TRANSMISSION (continued) — RECOMMENDED SERVICE TOOLS Driven pulley opening tool Countershaft bearing installer (P/N 529 035 501) (P/N 529 018 800) Short dial indicator (P/N 295 000 143) A03D2P4 APPLICATION A00A194 S and CK3 series with RER.
Page 38 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) TRANSMISSION (continued) — RECOMMENDED SERVICE TOOLS Drive pulley puller Countershaft bearing installer Countershaft bearing remover (P/N 529 023 100) (P/N 529 030 200) (P/N 529 018 700) A00C3J4 A00A194 APPLICATION APPLICATION Élan.
Page 39 Skandic WT. F) Skandic LT. A) 1994 models and older G) S-Series and ZX series except Alpine II. with Bombardier Lite and RER. B) Tundra II LT. H) Skandic WT LC/SWT. I) CK3 series with RER and C) F-Series and S-Series Elite model.
Page 40 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) TRANSMISSION (continued) — RECOMMENDED SERVICE TOOLS Burnishing bar Large bushing extractor Large bushing extractor (P/N 529 026 402) (P/N 529 031 100) (P/N 529 035 575) A00B464 A02D1Q4 A00B4I4 APPLICATION APPLICATION APPLICATION...
Page 41 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) TRANSMISSION (continued) — RECOMMENDED SERVICE TOOLS Large bushing installer and Drive axle sprocket adjuster small bushing extractor (P/N 861 725 700) A) (P/N 529 031 200) B) (P/N 529 035 931) (TYPICAL) A01B2O4 Parts included in the kit:...
Page 42 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) SUSPENSION — MANDATORY SERVICE TOOLS Shock spring removal kit (P/N 529 035 504) Replacement clevis pin (P/N 414 528 400) A01B4O4 APPLICATION All suspensions with coil spring. NOTE: The previous shock spring removal kit (P/N 529 027 100) can be upgraded by replacing the stop- per with a wider stopper (P/N 529...
Page 43 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) SUSPENSION — RECOMMENDED SERVICE TOOLS A) Track cleat remover Camber angle tool Track cleat installer (P/N 529 008 200) (P/N 529 021 600) A) (P/N 529 008 500) Narrow Pins NOTE: Angle finder with a magnetic base must be used.
Page 44 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) SUSPENSION (continued) — RECOMMENDED SERVICE TOOLS Shock wrench Gas shock valve tool (tire valve type) (P/N 529 035 727) Floating piston puller (P/N 529 035 570) (P/N 529 035 901) A00F224 APPLICATION A02F134...
Page 45 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) SUSPENSION (continued) — RECOMMENDED SERVICE TOOLS Spring installer (bar) Ball joint installer (P/N 529 005 000) A) (P/N 529 035 874) Extension to torque ball joint nut (P/N 529 035 876) B) (P/N 529 035 975) A00C1I4 APPLICATION...
Page 46 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) SUSPENSION (continued) — RECOMMENDED SERVICE TOOLS Kayaba shock adjustment tool Adjustment wrench (P/N 529 035 582) (P/N 861 743 900) Consists of: A00A1K4 APPLICATION C-7 suspension. A00B4B4 APPLICATION Suspension adjustment wrench 1998 and older models with T/A (P/N 529 017 100) shock.
Page 47 Subsection 01 (SERVICE TOOLS) VEHICLES — RECOMMENDED SERVICE TOOLS Protective mat Template for hood drilling Multilock-terminal housing connector extraction tool (P/N 529 030 600) (P/N 529 034 400) Not sold by Bombardier 755430-2 A02H154 -AMP APPLICATION A00B654 S-Series. APPLICATION NOTE: To drill new hood prior to install meters.
Page 48 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) VEHICLES (continued) — RECOMMENDED SERVICE TOOLS Crimper die Fuel pump nut wrench Oil pressure gauge (P/N 529 035 899) (P/N 529 035 709) A) (P/N 529 035 828) B) (P/N 529 035 906) C) (P/N 529 035 908) (TYPICAL) A32B0Y4...
Page 49 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) VEHICLES (continued) — RECOMMENDED SERVICE TOOLS Heated grips insertion tool A) (P/N 529 035 897) Insert pliers B) (P/N 529 035 936) (P/N 295 000 162) A00B6N4 APPLICATION 6 mm insert equipped models. A32G2B4 APPLICATION A) ZX liquid-cooled models with...
Page 50 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) SERVICE PRODUCTS MANDATORY SERVICE PRODUCTS Retaining compound High strength threadlocker Paste gasket (P/N 413 703 100) (P/N 293 800 005) (P/N 413 702 700) Loctite ® RC/609: Loctite ® 271: Threadlocker (10 mL) Loctite ®...
Page 51 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) MANDATORY SERVICE PRODUCTS (continued) Loctite ® primer Molykote PG 54 Petamo grease (P/N 293 800 041) (P/N 420 899 763) (P/N 420 899 271) (10 g) Primer N 128 g (5 oz) A00B5F4 APPLICATION To lubricate pawl and pawl lock of...
Page 52 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS BOMBARDIER FORMULA XP-S II BOMBARDIER injection oil synthetic injection oil (P/N 413 802 900) SYNTHETIC BOMBARDIER (P/N 293 600 045) (12 x 1 liter) 4-STROKE engine oil 0W-40...
Page 53 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS (continued) Fuel stabilizer Storage oil Grease LMZ no. 1 (P/N 413 408 600) CANADA (P/N 413 711 600) (P/N 413 707 500) (12 x 8 oz) U.S.A.
Page 54 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS (continued) BOMBARDIER LUBE Shock oil (P/N 293 600 016) (P/N 293 600 035) Brake fluid SRF (DOT 4) (12 x 14 oz) (32 oz) (P/N 293 600 063)
Page 55 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS (continued) Silicone dielectric grease Heavy duty cleaner High temperature and strength re- taining compound (P/N 293 550 004) (P/N 293 110 001) (3 oz) (400 g) (P/N 413 711 400) (P/N 293 110 002) Loctite 648 (5 mL) (green)
Page 56 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS (continued) Loctite 5150 Gel instant adhesive High temperature RTV sealant (P/N 293 800 086) (P/N 413 708 300) (P/N 293 800 090) Loctite 454-40 20 g (.70 oz) Ultra Copper (80 mL) A00B5S4 A00B3O4...
Page 57 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS (continued) Scratch remover (P/N 861 774 800) A00B6G4 APPLICATION All models. 01-02-8 MMR2004_102_01_02A.FM...
Page 58: Table Of Contents
Section 02 MAINTENANCE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS MAINTENANCE CHART ......................02-02-1 STORAGE..........................02-03-1 GENERAL ........................... 02-03-1 VEHICLE CLEANING......................02-03-1 ENGINE COMPARTMENT ....................02-03-1 BATTERY ..........................02-03-1 FUEL STABILIZER ......................02-03-1 ENGINE LUBRICATION ..................... 02-03-1 COUNTERSHAFT LUBRICATION ..................02-03-2 PULLEY PROTECTION ......................
Page 59: Maintenance Chart
Section 02 MAINTENANCE Subsection 02 (MAINTENANCE CHART) MAINTENANCE CHART SYSTEM PART/TASK REFER TO Rewind Starter and Rope I,L,C Subsection 04-10 Section 4, see the appropriate Engine Nuts and Screws subsection Subsections 04-02, 04-03 or 04-04 Exhaust System See REMOVAL FROM VEHICLE Engine Lubrication Subsection 02-03 Cooling System...
Page 60 Section 02 MAINTENANCE Subsection 02 (MAINTENANCE CHART) SYSTEM PART/TASK REFER TO Suspension Subsections 07-02, 07-03 or 07-04 Suspension Stopper Strap Subsections 07-02, 07-03 or 07-04 Track Subsection 07-06 Track Tension and Alignment AS REQUIRED Subsection 07-06 Spark Plugs* Subsection 06-03 Battery (if so equipped) Subsection 06-04 Headlamp Beam Aiming...
Page 61: Storage
Spray all bare metal parts including shock used for more than one month. chromed rods with BOMBARDIER LUBE (P/N 293 Refer to storage column from MAINTENANCE 600 016). CHART jointly with the present storage procedure...
Page 62: Countershaft Lubrication
(straight coupling). or drive belt. PULLEY PROTECTION After inspection and interior cleaning of pulleys, spray BOMBARDIER LUBE (P/N 293 600 016) on sheaves. Do not reinstall drive belt. VEHICLE PROTECTION Protect the vehicle with a cover to prevent dust accumulation during storage.
Page 63: Preseason Preparation
Section 02 MAINTENANCE Subsection 04 (PRESEASON PREPARATION) PRESEASON PREPARATION CARBURETOR CLEANING Proper vehicle preparation is necessary after the summer months or when a vehicle has not been Disassemble carburetor(s) in order to clean all in- used for more than one month. ternal parts.
Page 64 Section 03 TROUBLESHOOTING Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS ENGINE ..........................03-02-1 ENGINE LEAK VERIFICATION FLOW CHART ..............03-02-13 FUEL AND OIL SYSTEMS..................... 03-03-1 TRANSMISSION AND BRAKE SYSTEMS ................... 03-04-1 TRANSMISSION ........................ 03-04-1 BRAKE SYSTEM ........................ 03-04-7 MECHANICAL BRAKE ....................... 03-04-7 HYDRAULIC BRAKE ......................
Page 65: Engine
Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) ENGINE The following chart is provided to help diagnose the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM ENGINE BACKFIRES. CONDITION NORMAL USE.
Page 66 Adjust according to specifications (refer to TECHNICAL DATA). i. Improper reed valve adjustment or damage. Adjust according to specifications (refer to appropriate ENGINES TYPES) and/or install Bombardier’s recommended reed valve. j. Poor quality oil. Use BOMBARDIER injection oil. k. Leaks at air intake silencer.
Page 67 This is due to an incomplete combustion of a poor quality oil. Clean residue accumulation in combustion chamber and replace piston(s). Use BOMBARDIER injection oil. b. Spark plug heat range is too high. Install recommended dry properly gapped spark plugs (refer to TECHNICAL DATA).
Page 68 NORMAL USE. Test/Inspection 1. Check oil quality. a. Poor quality oil. Use BOMBARDIER injection 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) and/or replace hoses.
Page 69 Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH SYMPTOM MAXIMUM OPERATING RPM. CONDITION NORMAL USE. 9. Check exhaust system. a. Restriction or exhaust system leakage. Replace or reseal with Ultra Copper. 10. Check ignition timing. a.
Page 70 Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM ENGINE TURNS OVER BUT FAILS TO START. CONDITION NORMAL USE. Test/Inspection 1. Check switches. a. Ignition switch, emergency cut-out switch or tether switch is OFF. Place all switches in the RUN or ON position. If it still does not work, connect DESS switch BK/GN and BK/WH wires together (harness side).
Page 71 Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM IRREGULAR ENGINE IDLE. CONDITION NORMAL USE AFTER ENGINE WARM UP. Test/Inspection 1. Check choke. a. Choke plunger may be partially opened. Readjust. 2. Check carburetor adapter. a. Air enters through a crack. Replace. 3.
Page 72 Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM HIGH ENGINE OPERATING TEMPERATURE. CONDITION NORMAL USE. Test/Inspection Fan-Cooled Engines 1. Check cooling system. a. Loose fan belt. Adjust or replace fan belt (refer to AXIAL FAN COOLING SYSTEM). b. Dirty cooling fins or blocked air ducts. Clean.
Page 73 HIGH ENGINE OPERATING TEMPERATURE. CONDITION NORMAL USE. 5. Check antifreeze concentration. a. Antifreeze concentration is too high. Adjust concentration according to Bombardier’s recommendations. 6. Check tank cap. a. Cap does not hold pressure. Replace. 7. Check carburetion. a. Improperly adjusted or inadequate carburetor components.
Page 74 Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM ENGINE EQUIPPED WITH RAVE VALVE DOES NOT REACH ITS FULL OPERATING RPM (500 TO 1000 RPM SLOWER). CONDITION NORMAL USE. Test/Inspection 1. Check RAVE valve pistons. a. Valve piston(s) is (are) not screwed to the bottom. Screw valve piston(s) to bottom.
Page 75 Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM REWIND STARTER ROPE DOES NOT REWIND. CONDITION NORMAL USE. Test/Inspection 1. Check rewind spring. a. Broken spring. Replace spring. SYMPTOM REWIND STARTER PAWL DOES NOT ENGAGE. CONDITION NORMAL USE. Test/Inspection 1. Check stopper spring. a.
Page 76 Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM ENGINE GENERATES A LOT OF VIBRATIONS. CONDITION NORMAL USE. Test/Inspection 1. Check engine supports and stopper. a. Loose and/or broken supports or interference between support(s) and chassis. Retighten to specification (refer to TECHNICAL DATA) or replace. 2.
Page 77: Engine Leak Verification Flow Chart
Section 03 TROUBLESHOOTING Subsection 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 REPLACE INJECTION CHECK VALVE(S)
Page 78: Fuel And Oil Systems
Section 03 TROUBLESHOOTING Subsection 03 (FUEL AND OIL SYSTEMS) FUEL AND OIL SYSTEMS The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM HIGH FUEL CONSUMPTION OR RICH MIXTURE.
Page 79 Section 03 TROUBLESHOOTING Subsection 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 vent hose. Relocate or replace. 2. Check fuel filter. a.
Page 80 Section 03 TROUBLESHOOTING Subsection 03 (FUEL AND OIL SYSTEMS) SYMPTOM HIGH INJECTION OIL CONSUMPTION. CONDITION NORMAL USE. 6. Check pump. a. Leaking pump. Replace. 7. Check oil pump cable. a. Cable stuck in open position. Replace cable. 8. On liquid-cooled models, test pump shaft gear reservoir for leaks. a.
Page 81 Section 03 TROUBLESHOOTING Subsection 03 (FUEL AND OIL SYSTEMS) SYMPTOM DPM SEEMS TO BE DEFECTIVE. CONDITION NORMAL USE. Test/Inspection 1. Check electrical connections. a. Corroded terminals. Clean or replace. 2. Fuel mixture is too rich or too poor. a. Possible damage to DPM. If DPM does not operate properly, unplug compensation solenoid connector while engine is running.
Page 82: Transmission And Brake Systems
Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) TRANSMISSION AND BRAKE SYSTEMS0 The following charts are provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. TRANSMISSION SYMPTOM THE SNOWMOBILE ACCELERATES SLOWLY, ESPECIALLY WHEN IT IS STOPPED.
Page 83 Section 03 TROUBLESHOOTING Subsection 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 radial play of driven pulley. a.
Page 84 Section 03 TROUBLESHOOTING Subsection 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). 2.
Page 85 Section 03 TROUBLESHOOTING Subsection 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. Slipping due to insufficient pressure on belt sides. Replace bushing. 2.
Page 86 Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT TOO NARROW ON ONE SECTION. CONDITION NORMAL USE. Test/Inspection 5. Check idle speed. a. Engine idle speed is too high. Adjust according to specifications. 6. Check drive belt length. a.
Page 87 Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELTCORD POPPED OUT. CONDITION NORMAL USE. Test/Inspection 1. Check pulley alignment. a. Pulley misalignment. Align pulley according to specifications (refer to TECHNICAL DATA). A00DOFY SYMPTOM FLEX CRACKS BETWEEN COGS. CONDITION NORMAL USE.
Page 88: Brake System
Section 03 TROUBLESHOOTING Subsection 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 spring tab. Replace. 2. Check mobile pad stud. a.
Page 89: Mechanical And Hydraulic Brakes
Section 03 TROUBLESHOOTING Subsection 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. 2. Check key/keyway or splines. a.
Page 90: Electrical System
Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) ELECTRICAL SYSTEM The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM STARTER DOES NOT TURN.
Page 91 Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM STARTER TURNS BUT DOES NOT CRANK THE ENGINE. CONDITION NORMAL USE. Test/Inspection 1. Check engine. a. Engine seized. Rebuild engine. 2. Check wire connection. a. Inadequate connection (too much resistance). Clean and reconnect. 3.
Page 92 Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM STARTER TURNS, BUT OVERRUNNING CLUTCH PINION DOES NOT MESH WITH RING GEAR. CONDITION NORMAL USE. Test/Inspection 1. Check clutch pinion gear and small return spring. a. Worn clutch pinion gear or damaged small return spring. Replace damaged part(s).
Page 93 Section 03 TROUBLESHOOTING Subsection 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. Clutch is stuck on splines. Clean.
Page 94 Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM OPTIONAL ELECTRIC STARTER DOES NOT WORK WHEN TURNING IGNITION SWITCH. CONDITION NORMAL USE. Test/Inspection 1. Check connection of BLACK wire (starter relay ground) in 3-wire housing com- ing from magneto (white housing). a.
Page 95 Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM ENGINE 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 plugs. 2.
Page 96 Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM IRREGULAR ENGINE SPEED. CONDITION AT HIGH SPEED. Test/Inspection 1. Verify items 4, 5 and 6 above. CONDITION AT LOW SPEED. Test/Inspection 1. Verify items 4 and 5 above and trigger coil/flywheel protrusion air gap. a.
Page 97 2. Check spark plug heat range. a. Spark plug heat range is too high. Replace by Bombardier’s recommended spark plug (refer to TECHNICAL DATA). 3. Check if air intake silencer leaks. a. Air surplus coming from opening(s) located between halves.
Page 98 Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM RER (ROTAX ELECTRONIC REVERSE) DOES NOT WORK. CONDITION NORMAL USE. Test/Inspection 1. Check idle speed. a. Wrong idle speed. Adjust according to specification (refer to TECHNICAL DATA). 2. Check spark plug. a. Faulty spark plug. Replace.
Page 99 5. Hot Grips brand: Verify if they were connected in parallel by mistake. a. Excessive electrical load to magneto/generator. Reconnect as recommended by manufacturer. 6. Bombardier heating grips: Verify if the return wires of the elements were grounded to the chassis by mistake. a. Faulty installation of optional equipment.
Page 100 Section 03 TROUBLESHOOTING Subsection 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/BU).
Page 101 Section 03 TROUBLESHOOTING Subsection 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. Connector housing is partially connected. Install connector housing properly.
Page 102: Suspension And Track
Section 03 TROUBLESHOOTING Subsection 06 (SUSPENSION AND TRACK) SUSPENSION AND TRACK The following chart is provided to help diagnose the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM SUSPENSION IS TOO LOW.
Page 103 Section 03 TROUBLESHOOTING Subsection 06 (SUSPENSION AND TRACK) SYMPTOM REAR SUSPENSION IS TOO STIFF. CONDITION NORMAL USE. Test/Inspection 1. Check rear spring preload. a. Too much preload. Adjust to a softer position. 2. Check springs. a. Springs installed are too stiff. Install optional softer springs, refer to Service Bulletin SPRING REFERENCE AC- CORDING TO LOAD.
Page 104 Section 03 TROUBLESHOOTING Subsection 06 (SUSPENSION AND TRACK) SYMPTOM HANDLEBAR IS DIFFICULT TO TURN. CONDITION NORMAL USE. Test/Inspection 1. Check if the handle bar turns freely when skis are off the ground. a. Ball joints corrosion restrains movement. Lubricate or replace the ball joint. b.
Page 105 Section 03 TROUBLESHOOTING Subsection 06 (SUSPENSION AND TRACK) SYMPTOM SLIDER SHOES WEAR OUT PREMATURELY/OR TRACK CLEATS BECOME BLUE. CONDITION NORMAL USE. Test/Inspection 1. Check track tension. a. Pressure is too great on slider shoes. Adjust according to specifications (refer to TECHNICAL DATA). Replace defective parts.
Page 106 Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS 277 ENGINE TYPE ......................... 04-02-1 ENGINE REMOVAL AND INSTALLATION................ 04-02-1 REMOVAL FROM VEHICLE ....................04-02-2 ENGINE SUPPORT AND MUFFLER DISASSEMBLY AND ASSEMBLY......04-02-2 INSTALLATION ON VEHICLE.................... 04-02-2 TOP END ..........................04-02-3 TROUBLESHOOTING ......................
Page 107 Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) TOP END ..........................04-04-2 GENERAL..........................04-04-3 COMPONENT REMOVAL....................04-04-3 CLEANING .......................... 04-04-3 DISASSEMBLY ........................04-04-3 INSPECTION ........................04-04-7 ASSEMBLY ......................... 04-04-7 BOTTOM END ........................04-04-12 CLEANING .......................... 04-04-13 DISASSEMBLY ........................04-04-13 INSPECTION ........................04-04-14 ASSEMBLY .........................
Page 108 Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) OIL INJECTION SYSTEM ...................... 04-07-1 OIL INJECTION PUMP ...................... 04-07-1 OIL TYPE ..........................04-07-5 OIL SYSTEM LEAK TEST ....................04-07-5 OIL PUMP IDENTIFICATION ..................... 04-07-5 CLEANING ......................... 04-07-5 DISASSEMBLY........................04-07-5 ASSEMBLY......................... 04-07-6 ADJUSTMENT ........................
Page 109 Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) CARBURETOR FLOAT LEVEL ADJUSTMENT..............04-11-6 CARBURETOR ADJUSTMENTS..................04-11-7 INSTALLATION ........................04-11-8 IDLE SPEED FINAL ADJUSTMENT................... 04-11-10 CHOKE ..........................04-11-10 FUEL PUMP ........................04-11-12 REMOVAL ........................... 04-11-12 PUMP VERIFICATION......................04-11-12 CLEANING AND INSPECTION ..................04-11-12 INSTALLATION ........................
Page 110: 277 Engine Type
Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) 277 ENGINE TYPE ENGINE REMOVAL AND INSTALLATION 04-02-1 MMR2004-111_04_02A.FM...
Page 111: Removal From Vehicle
Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) REMOVAL FROM VEHICLE Remove or disconnect the following then lift en- gine from vehicle: – guard – drive belt – muffler – carburetor – oil injection pump cable – oil injection inlet line –...
Page 112: Top End
Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) TOP END 04-02-3 MMR2004-111_04_02A.FM...
Page 113: Troubleshooting
Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) TROUBLESHOOTING Place a clean cloth or rubber pad (P/N 529 023 400) over crankcase to prevent circlips no. 8 from fall- Before completely disassembling the engine, ing into crankcase. Then with a pointed tool insert- check airtightness.
Page 114 Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) Install sleeve then shouldered sleeve over puller rod. A02C2DA TYPICAL A02C2BA 1. Sleeve inside bearing 2. Thrust washer TYPICAL — INSTALLATION OF SLEEVE KIT 3. Shouldered sleeve end 1. Sleeve 2. Shouldered sleeve Remove puller.
Page 115: Inspection
Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) Install locating sleeve. Then push needle bearings along with thrust washers and sleeve. TYPICAL 1. Locating sleeve 2. Sleeve A02C2GA NOTE: 0.25 and 0.5 mm oversize pistons and rings TYPICAL are available if necessary. 1.
Page 116 Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) Install shouldered sleeve. Insert circlip in tool at an angle. 1. Circlip Square it up using a finger. A02C2IA TYPICAL — SHOULDERED SLEEVE INSTALLATION Install piston pin puller and turn handle until piston pin is correctly positioned in piston.
Page 117 Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) Continue to square it up using round end of circlip Mount tool in piston making sure that circlip break installer. is facing down. A02C2OA TYPICAL 1. Circlip break facing down A02C2MA Hold tool firmly against piston then strike on round end of tool.
Page 118 Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) A01C02A 1. Piston notch 2. Circlip break CAUTION: Circlips must not move freely in the groove after installation. If so, replace them. Before inserting piston in the cylinder, lubricate the cylinder with new injection oil or equivalent. Position cylinder head on cylinder with fins in line with crankshaft center line.
Page 119: Bottom End
Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) BOTTOM END 04-02-10 MMR2004-111_04_02A.FM...
Page 120: Cleaning
Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) NOTE: Engine must be removed from chassis to perform the following procedures. M8 x 110 mm CLEANING Discard all oil seals and gaskets. Clean all metal components in a non-ferrous metal cleaner. DISASSEMBLY General To remove drive pulley, refer to DRIVE PULLEY.
Page 121: Assembly
Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) ASSEMBLY Press down PTO side crankcase half onto crank- shaft using appropriate spacer(s). Install connecting rod with its lubrication slot on big end facing exhaust side. Smear anti-seize lubricant (P/N 293 800 070) on part of crankshaft where bearing fits.
Page 122: 443 And 552 Engine Types
Section 04 ENGINE Subsection 03 (443 AND 552 ENGINE TYPES) 443 AND 552 ENGINE TYPES ENGINE REMOVAL AND INSTALLATION Skandic LT 443 Engine Type 04-03-1 MMR2004-112_04_03A.FM...
Page 123 Section 04 ENGINE Subsection 03 (443 AND 552 ENGINE TYPES) Skandic WT/SWT/SUV 552 Engine Type 04-03-2 MMR2004-112_04_03A.FM...
Page 124: Engine Removal And Installation
Section 04 ENGINE Subsection 03 (443 AND 552 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 start- ing models). –...
Page 125: Top End
Section 04 ENGINE Subsection 03 (443 AND 552 ENGINE TYPES) TOP END Skandic LT 443 Engine Type 04-03-4 MMR2004-112_04_03A.FM...
Page 126 Section 04 ENGINE Subsection 03 (443 AND 552 ENGINE TYPES) Skandic WT/SWT/SUV 552 Engine Type 04-03-5 MMR2004-112_04_03A.FM...
Page 127: General
Section 04 ENGINE Subsection 03 (443 AND 552 ENGINE TYPES) GENERAL CAUTION: While performing any engine related procedure, always make sure that the working area is clean and free from dust or particles to reduce the risk of damaging the engine. TROUBLESHOOTING Before completely disassemble engine, check air- tightness.
Page 128 Section 04 ENGINE Subsection 03 (443 AND 552 ENGINE TYPES) A02C2CA TYPICAL — PISTON PIN EXTRACTION TYPICAL 1. Properly seated all around Install sleeve then shouldered sleeve over puller rod. A02C2DA TYPICAL 1. Sleeve inside bearing 2. Thrust washer 3. Shouldered sleeve end Remove puller.
Page 129: Inspection
Section 04 ENGINE Subsection 03 (443 AND 552 ENGINE TYPES) Remove piston from connecting rod. Install locating sleeve. Then push needle bearings along with thrust washers and sleeve. TYPICAL 1. Locating sleeve A02C2GA 2. Sleeve TYPICAL NOTE: 0.25 and 0.5 mm oversized piston and 1.
Page 130 Section 04 ENGINE Subsection 03 (443 AND 552 ENGINE TYPES) Heat piston using bearing heater (P/N 529 035 969). A02C2IA TYPICAL — SHOULDERED SLEEVE INSTALLATION Install piston pin puller and turn handle until piston CAUTION: Piston temperature must not exceed pin is correctly positioned in piston.
Page 131 Section 04 ENGINE Subsection 03 (443 AND 552 ENGINE TYPES) 443 Engine Continue to square it up using round end of circlip installer. To minimize the effect of acceleration forces on circlip, install each circlip so the circlip break is at 6 o’clock as illustrated.
Page 132 Section 04 ENGINE Subsection 03 (443 AND 552 ENGINE TYPES) Mount tool in piston making sure that circlip break is facing down. With round end of pusher, position circlip perpen- dicular to the support axis. A02C2OA TYPICAL 1. Circlip break facing down Hold tool firmly against piston then strike on round end of tool with a plastic hammer.
Page 133 Section 04 ENGINE Subsection 03 (443 AND 552 ENGINE TYPES) CAUTION: Always install a gasket of the proper thickness. Failure to do so may cause detona- tion and severe engine damage. All Models Before inserting piston in cylinder no. 4, lubricate the cylinder with new injection oil or equivalent.
Page 134 Section 04 ENGINE Subsection 03 (443 AND 552 ENGINE TYPES) With blade stopper no. 13 removed, check reed valve for proper tightness. There must be no play between blade and valve body when exerting a finger pressure on blade at blade stopper location. In case of a play, turn blade upside down and re- check.
Page 135: Bottom End
Section 04 ENGINE Subsection 03 (443 AND 552 ENGINE TYPES) BOTTOM END Skandic LT 443 Engine Type 04-03-14 MMR2004-112_04_03A.FM...
Page 136 Section 04 ENGINE Subsection 03 (443 AND 552 ENGINE TYPES) Skandic WT/SWT/SUV 552 Engine Type 04-03-15 MMR2004-112_04_03A.FM...
Page 137: Cleaning
Remove all trace of Loctite from crankshaft taper. Remove old sealant from crankcase mating sur- faces with Bombardier gasket remover (P/N 413 708 500). CAUTION: Never use a sharp object to scrape away old sealant as score marks incurred are detrimental to crankcase sealing.
Page 138: Inspection
Section 04 ENGINE Subsection 03 (443 AND 552 ENGINE TYPES) INSPECTION Secure the bearing puller in a vise by one of its rib. Refer to ENGINE DIMENSIONS MEASUREMENT. ASSEMBLY Clean crankshaft end with sand paper no. 180 and remove all residue using pulley flange cleaner (P/N 413 711 809).
Page 139 Section 04 ENGINE Subsection 03 (443 AND 552 ENGINE TYPES) Skandic LT 443 Engine Type CAUTION: Bearing should not be heated to more than 80°C (176°F). Do not heat bearing with To check proper clearance between bearing no. 3 direct flame or heat gun or heated oil. Inappro- and crankshaft counterbalance, use feeler gauge priate heating procedure(s) may cause inner seal (P/N 420 876 620).
Page 140 Section 04 ENGINE Subsection 03 (443 AND 552 ENGINE TYPES) Make a bearing locator tool using support plate WARNING (P/N 529 035 976) and distance gauge (P/N 529 035 965). Do not touch heated bearing with bare hands. Wear heat resisting gloves before handling the heated bearing(s).
Page 141 Section 04 ENGINE Subsection 03 (443 AND 552 ENGINE TYPES) Slide in the heated outer PTO bearing onto the All Models crankshaft. Bearings are pressed on crankshaft until they rest against radius. These radius maintain the gap needed for bearings lubrication. When installing crankshaft, position drive pins no.
Page 142 Section 04 ENGINE Subsection 03 (443 AND 552 ENGINE TYPES) All Models At seal no. 2 assembly, apply a light coat of lithium grease on seal lip. For bearing lubrication purpose, a gap of 1.0 mm (.040 in) must be maintained between seals and bearings.
Page 143: Break-In
Section 04 ENGINE Subsection 03 (443 AND 552 ENGINE TYPES) 443 Engine Type 10 8 A09C05A TIGHTENING SEQUENCE FOR 443 ENGINE TYPE A. 10 N•m (89 lbf•in) All the other screws are torqued to 22 N•m (16 lbf•ft) All Engines To install magneto, refer to CDI MAGNETO.
Page 144: 593 Engine Type
Section 04 ENGINE Subsection 04 (593 ENGINE TYPE) 593 ENGINE TYPE Skandic WT LC/SUV 600 REMOVAL FROM VEHICLE Open hood. Remove tuned pipe and muffler. Drain engine coolant. Remove or unplug the following then lift off engine from engine compartment. NOTE: Use of a hoist is recommended.
Page 145: Top End
Section 04 ENGINE Subsection 04 (593 ENGINE TYPE) TOP END 04-04-2 MMR2004-113_04_04A.FM...
Page 146: General
Section 04 ENGINE Subsection 04 (593 ENGINE TYPE) GENERAL WARNING CAUTION: While performing any engine related Firmly hold cover to valve base. The com- procedure, always make sure that the working pression spring inside the valve is applying area is clean and free from dust or particles to pressure against the cover.
Page 147 Section 04 ENGINE Subsection 04 (593 ENGINE TYPE) Unscrew the Allen socket screws no. 22 then re- Remove spring no. 10 retaining bellows no. 11 to move the RAVE valve base no. 13. valve piston. TYPICAL 1. Allen socket screws 1.
Page 148 Section 04 ENGINE Subsection 04 (593 ENGINE TYPE) 18, Piston Remove the small spring no. 12 retaining bellows to valve base. Place a clean cloth or rubber pad (P/N 529 023 400) over crankcase. Then with a pointed tool inserted in piston notch, remove both circlips no.
Page 149 Section 04 ENGINE Subsection 04 (593 ENGINE TYPE) Insert piston pin puller (P/N 529 035 503) making sure it sits squarely against piston. A02C2CA TYPICAL — PISTON PIN EXTRACTION TYPICAL 1. Properly seated all around Install sleeve then shouldered sleeve over puller rod. A02C2DA TYPICAL 1.
Page 150: Inspection
Section 04 ENGINE Subsection 04 (593 ENGINE TYPE) 11, Bellows Remove piston from connecting rod. Install locating sleeve. Then push needle bearings Check for cracked, dried or perforated bellows. along with thrust washers and sleeve. 8, Spring Engine type Spring 420 239 948 Wire diameter mm (in)
Page 151 Section 04 ENGINE Subsection 04 (593 ENGINE TYPE) 2,3,4, Cylinder Head Cover, Cylinder Heat piston using bearing heater (P/N 529 035 969). Head and Cylinder Check flatness of part sealing surfaces. Refer to LEAK TEST AND ENGINE DIMENSION MEASURE- MENT and look for CHECKING SURFACE FLAT- NESS.
Page 152 Section 04 ENGINE Subsection 04 (593 ENGINE TYPE) Install shouldered sleeve. With round end of pusher, position circlip perpen- dicular to the support axis. A02C2IA TYPICAL — SHOULDERED SLEEVE INSTALLATION Install piston pin puller and turn handle until piston pin is correctly positioned in piston. With the other end of the pusher, push circlip into the support groove.
Page 153 Section 04 ENGINE Subsection 04 (593 ENGINE TYPE) CAUTION: Always install a gasket of the proper thickness. Failure to do so may cause detona- tion and severe engine damage. Before inserting piston in cylinder, lubricate the cylinder with new injection oil or equivalent. Install cylinders.
Page 154 Section 04 ENGINE Subsection 04 (593 ENGINE TYPE) Apply Loctite 243 (P/N 293 800 060) on screws Check distance from blade stopper inner edge and threads. Install outlet socket and tighten screws to distance from center of reed valve block. 12 N•m (106 Ibf•in).
Page 155: Bottom End
Section 04 ENGINE Subsection 04 (593 ENGINE TYPE) BOTTOM END 04-04-12 MMR2004-113_04_04A.FM...
Page 156: Cleaning
Section 04 ENGINE Subsection 04 (593 ENGINE TYPE) NOTE: Engine must be removed from chassis to Using screws (P/N 420 840 681) Install bearing perform the following procedures. puller (P/N 420 877 635) on the half rings. Secure the bearing puller in a vise by one of its rib. CLEANING Discard all oil seals, gaskets, O-rings and sealing rings.
Page 157: Inspection
Section 04 ENGINE Subsection 04 (593 ENGINE TYPE) INSPECTION NOTE: Refer to LEAK TEST AND ENGINE DIMEN- SIONS MEASUREMENT. ASSEMBLY Coat lip of all seals with Petamo grease (P/N 420 899 271). 2, Crankshaft Bearing Clean crankshaft end with sand paper no. 180 and remove all residue using pulley flange cleaner (P/N 413 711 809).
Page 158 Section 04 ENGINE Subsection 04 (593 ENGINE TYPE) Probe the inner race of the bearing with the tem- perature indicator stick (P/N 529 035 970). Stick will liquefy when the bearing reach the proper temperature. 1. Support plate 2. Distance gauge WARNING Install bearing locator tool.
Page 159 Section 04 ENGINE Subsection 04 (593 ENGINE TYPE) Install the MAG side heated bearing. CAUTION: Use only the recommended Isoflex grease. Make sure not to push Isoflex grease be- tween outside bearing race and half crankcase. NOTE: The 50 g tube corresponds to 50 cc of grease. Fill PTO side inner seal with Isoflex grease.
Page 160 Section 04 ENGINE Subsection 04 (593 ENGINE TYPE) Drop 50 mL (2 U.S. oz) of injection oil in the pan As far as possible, sealing compound must be ap- under central gear to lubricate pump gearing as per plied in one run to avoid any risks of leaking through photo.
Page 161: Break-In
Section 04 ENGINE Subsection 04 (593 ENGINE TYPE) Screw all crankcase bolts in place in the following sequence and to the appropriate torque through a two steps torquing: first, screw bolts up to 60% of the final torque (18 N•m (13.5 lbf•ft) for most of the bolts), then, tighten to the required torque (i.e.
Page 162: Leak Test And Engine Dimension Measurement
Section 04 ENGINE Subsection 05 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) LEAK TEST AND ENGINE DIMENSION MEASUREMENT LEAK TEST 6. Using hose pinchers (P/N 295 000 076), block pump shaft oil hose and lubrication nipple on PTO The following gives verification procedures for liq- side.
Page 163: Procedure
Section 04 ENGINE Subsection 05 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) 8. Activate pump and pressurize engine to 34 kPa 2. Small injection oil lines coming from pump. (5 PSI). Do not exceed this pressure. 9. Engine must stand this pressure during 3 min- utes.
Page 164: Finalizing Reassembly
Section 04 ENGINE Subsection 05 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) If pressure drops, it indicates a defective crank- If there is a leak, it indicates defective seal of shaft inner seal. pump shaft (oil seal beside coolant ceramic seal). 2.
Page 165: Engine Leak Verification Flow Chart
Section 04 ENGINE Subsection 05 (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 166: Engine Dimension Measurement
Section 04 ENGINE Subsection 05 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) ENGINE DIMENSION CYLINDER OUT OF ROUND MEASUREMENT ENGINE TYPE MAXIMUM This section covers all engine types. 0.08 mm (.003 in) CYLINDER HEAD WARPAGE Measuring 16 mm (5/8 in) from top of cylinder with a cylinder gauge, check if the cylinder out of round ENGINE TYPE MAXIMUM...
Page 167 Section 04 ENGINE Subsection 05 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) NOTE: When checking the combustion chamber 6. Open burette valve to fill its tip. Add liquid in volume, engine must be cold, piston must be free burette until level reaches 0 cc. of carbon deposit and cylinder head must be lev- 7.
Page 168: Used Piston Measurement
Section 04 ENGINE Subsection 05 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) USED PISTON MEASUREMENT CYLINDER/PISTON CLEARANCE Note the measurement on the piston dome. Used and New Pistons NOTE: Make sure used piston is not worn more than specified. See USED PISTON MEASURE- MENT above.
Page 169: Ring/Piston Groove Clearance
Section 04 ENGINE Subsection 05 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Read the measurement on the cylinder bore gauge. The result is the exact piston/cylinder wall clear- ance. If clearance exceeds specified tolerance, re- place cylinder or rebore. Refer to TECHNICAL DATA. NOTE: Make sure the cylinder bore gauge indica- tor is set exactly at the same position as with the micrometer, otherwise the reading will be false.
Page 170: Ring End Gap
Section 04 ENGINE Subsection 05 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) RING END GAP Position ring half-way between transfer port and intake port. NOTE: In order to correctly position the ring in the cylinder, use piston as a pusher. Using a feeler gauge, check ring end gap. Replace ring if gap exceeds specified tolerance.
Page 171: Connecting Rod Big End Axial Play
Section 04 ENGINE Subsection 05 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) CONNECTING ROD BIG END Adjustment AXIAL PLAY Crankshaft end-play is adjusted with shims locat- ed between crankshaft and magneto side bearing. ENGINE NEW PARTS WEAR TYPE (min. - max.) LIMIT 277, 443 0.20 - 0.53 mm...
Page 172 Section 04 ENGINE Subsection 05 (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 173: Checking Surface Flatness
Section 04 ENGINE Subsection 05 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) CHECKING SURFACE FLATNESS CHECKING CRANKSHAFT ALIGNMENT Intake manifold, intake manifold cover can be checked for perfectly mating surfaces. Install a degree wheel (P/N 414 352 900) on crank- shaft end. Lay part on a surface plate (marble, mirror or thick glass plate).
Page 174: Cdi System
Section 04 ENGINE Subsection 06 (CDI SYSTEM) CDI SYSTEM NIPPONDENSO TRIGGER COIL IGNITION SYSTEM 290 W on Skandic WT LC/SUV 600 04-06-1 MMR2004-115_04_06A.FM...
Page 175: Ducati Ignition System
Section 04 ENGINE Subsection 06 (CDI SYSTEM) DUCATI IGNITION SYSTEM 340 W on Skandic WT/SWT/SUV 550 04-06-2 MMR2004-115_04_06A.FM...
Page 176: Rer Ignition System
Section 04 ENGINE Subsection 06 (CDI SYSTEM) RER IGNITION SYSTEM 240 W on Tundra R 04-06-3 MMR2004-115_04_06A.FM...
Page 177 Section 04 ENGINE Subsection 06 (CDI SYSTEM) 240 W on Skandic LT 04-06-4 MMR2004-115_04_06A.FM...
Page 178: Cleaning
Section 04 ENGINE Subsection 06 (CDI SYSTEM) NOTE: The following procedures can be done CAUTION: Use only M8 x 20 mm screws to bolt without removing the engine from chassis. To fa- puller to magneto. cilitate magneto removal, hold drive pulley with proper holding tool.
Page 179: Assembly
Section 04 ENGINE Subsection 06 (CDI SYSTEM) ASSEMBLY To remove magneto flywheel, install appropriate protective cap included in crankshaft bearing pull- er on crankshaft end. Screw puller (P/N 529 022 500) 6, Stator into puller ring. Make sure to position stator in a way that its wire protectors are over recess of crankcase.
Page 180: Adjustment
Section 04 ENGINE Subsection 06 (CDI SYSTEM) ADJUSTMENT Skandic WT/SWT Only Whenever the trigger coil or the magneto flywheel is removed or replaced, the air-gap between the trigger coil and the flywheel protrusion must be checked and adjusted. The purpose of this adjust- ment is to obtain the minimum clearance between these parts —...
Page 181: Oil Injection System
Section 04 ENGINE Subsection 07 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM OIL INJECTION PUMP 277 Engine 04-07-1 MMR2004-116_04_07A.FM...
Page 182 Section 04 ENGINE Subsection 07 (OIL INJECTION SYSTEM) 443 Engine on Skandic LT/LT E 04-07-2 MMR2004-116_04_07A.FM...
Page 183 Section 04 ENGINE Subsection 07 (OIL INJECTION SYSTEM) 552 Engine on Skandic WT/SWT/SUV 550 Recommended 04-07-3 MMR2004-116_04_07A.FM...
Page 184 Section 04 ENGINE Subsection 07 (OIL INJECTION SYSTEM) 593 Engine on Skandic WT LC/SUV 600 04-07-4 MMR2004-116_04_07A.FM...
Page 185: Oil Type
Section 04 ENGINE Subsection 07 (OIL INJECTION SYSTEM) CAUTION: Always mount proper pump on en- WARNING gine. Wipe off any oil spills. Oil is highly flammable. OIL PUMP ENGINE TYPE IDENTIFICATION OIL TYPE 132K All Models Use recommended injection oil as per vehicle Op- erator’s Guide.
Page 186: Assembly
Section 04 ENGINE Subsection 07 (OIL INJECTION SYSTEM) ASSEMBLY Install the check valve in the correct position as de- scribed on next photo into the crankcase lower side. 1, Spring Clip Always check for spring clips tightness. 6, Oil Pump Gear At gear assembly, apply a light coat of Molykote 111 (P/N 413 707 000) on gear teeth.
Page 187 Section 04 ENGINE Subsection 07 (OIL INJECTION SYSTEM) Retighten the adjuster nut. Parallax Problem When adjusting pump lever, since the mechanic can not view the pump perpendicularly, the adjustment will not be accurate. Following photos show three different views of the same properly adjusted pump. A05C0YA TYPICAL —...
Page 188 Section 04 ENGINE Subsection 07 (OIL INJECTION SYSTEM) VIEW WITH AIR SILENCER, CARBURETORS AND FUEL PUMP REMOVED 1. Oil pump 2. Mirror VIEW TOO LOW — ADJUSTMENT SEEMS TO BE TOO LEAN 3. Lever WHEN BOTTOM OF BODY’S PROTRUSION CAN BE SEEN 4.
Page 189: Bleeding Oil Lines
Section 04 ENGINE Subsection 07 (OIL INJECTION SYSTEM) CHECKING OPERATION Oil Pump On Vehicle NOTE: Main oil line must be full of oil. See bleed- ing procedure above. Lift rear of vehicle and support with a mechanical stand. Disconnect small oil lines from pump. Start engine and stop it as soon as it fires.
Page 190: Axial Fan Cooling System
Section 04 ENGINE Subsection 08 (AXIAL FAN COOLING SYSTEM) AXIAL FAN COOLING SYSTEM 443 and 552 Engines NOTE: For 277 engine radial fan cooling system, refer to CDI SYSTEM. 04-08-1 MMR2004-117_04_08A.FM...
Page 191: Removal
Section 04 ENGINE Subsection 08 (AXIAL FAN COOLING SYSTEM) NOTE: The following procedures can be done with- out 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 192: Installation
Section 04 ENGINE Subsection 08 (AXIAL FAN COOLING SYSTEM) Support fan housing no. 12 with a ring. With a punch, Using fan holder tool (P/N 420 876 357), remove fan working all around bearing no. 10 inner race, drive nut. bearing out of fan housing.
Page 193 Section 04 ENGINE Subsection 08 (AXIAL FAN COOLING SYSTEM) Reassembly Install fan belt on bottom pulley first then position onto fan shaft, as shown in the next photo. A03C2AA FAN BELT PROPERLY INSTALLED ON BOTTOM PULLEY AND FAN SHAFT 1. Bottom pulley 2.
Page 194 Section 04 ENGINE Subsection 08 (AXIAL FAN COOLING SYSTEM) Finalizing Reassembly To adjust deflection tension, add or remove shim(s) no. 15 between pulley halves nos. 14 and 16. In- Reinstall rewind starter. stall excess shim(s) between distance sleeve no. 13 CAUTION: When installing rewind starter, ensure and pulley half no.
Page 195: Liquid Cooling System
Section 04 ENGINE Subsection 09 (LIQUID COOLING SYSTEM) LIQUID COOLING SYSTEM 593 Engine 04-09-1 MMR2004-118_04_09A.FM...
Page 196: Cooling System Leak Test
Section 04 ENGINE Subsection 09 (LIQUID COOLING SYSTEM) COOLING SYSTEM LEAK TEST 1, Pressure Cap Check if the cap pressurizes the system. If not, Install special radiator cap (P/N 529 021 400) in- install a new 90 kPa (13 PSI) cap (do not exceed this cluded in engine leak tester kit (P/N 861 749 100) pressure).
Page 197: Cooling System Refilling Procedure
Section 04 ENGINE Subsection 09 (LIQUID COOLING SYSTEM) A16C03A TYPICAL — OPEN THERMOSTAT, WARM ENGINE 1. To radiators 2. From cylinders These 2 functions have the advantage of prevent- ing a massive entry of cold water into the engine. COOLING SYSTEM REFILLING PROCEDURE CAUTION: To prevent rust formation or freezing condition, always replenish the system with rec-...
Page 198: Rewind Starter
Section 04 ENGINE Subsection 10 (REWIND STARTER) REWIND STARTER Plastic Rewind Starter on Liquid Cooled Models 04-10-1 MMR2004-119_04_10A.FM...
Page 199 Section 04 ENGINE Subsection 10 (REWIND STARTER) Plastic Rewind Starter on Fan Cooled Models 11 10 TYPICAL 04-10-2 MMR2004-119_04_10A.FM...
Page 200: Inspection
Section 04 ENGINE Subsection 10 (REWIND STARTER) INSPECTION NOTE: Due to dust accumulation, rewind starter must be periodically cleaned, inspected and relu- bricated. CAUTION: It is of the utmost importance that the rewind starter spring be lubricated period- ically using specific lubricant. Otherwise, re- wind starter component life will be shortened and/or rewind starter will not operate properly under very cold temperatures.
Page 201: Disassembly
Section 04 ENGINE Subsection 10 (REWIND STARTER) DISASSEMBLY Liquid Cooled Models Only Take out the knot and then rope no. 6. Undo knot previously tied at removal. Let sheave get free to release spring preload. ASSEMBLY Cut push nut no. 13 and discard. Remove locking element no.
Page 202 Section 04 ENGINE Subsection 10 (REWIND STARTER) Fan Cooled Models Only To install rope no. 6, insert rope into sheave no. 5 orifice and lock it with the key no. 7 as illustrated. A01C15A TYPICAL 1. Push to lock 1. Molykote PG 54 inside spring guide Lubricate housing post with silicone compound grease.
Page 203 Section 04 ENGINE Subsection 10 (REWIND STARTER) Lubricate pawl no. 8 with Molykote PG 54 (P/N 420 899 763) then install over rope sheave. FREE PORTION INSERTED INTO SHEAVE Lubricate housing post with silicone compound grease. Install sheave. Lubricate pawl lock no. 9 with Molykote PG 54 To adjust rope tension: (P/N 420 899 763).
Page 204: Installation
Section 04 ENGINE Subsection 10 (REWIND STARTER) Install step collar no. 10 with its sleeve first. Lubri- Reinstall rewind starter assembly on engine. cate a new O-ring no. 11 and locking element no. 9 Prior to installing starter grip no. 15 on new rope, with Molykote PG 54 (P/N 420 899 763).
Page 205: Carburetor And Fuel Pump
Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) CARBURETOR AND FUEL PUMP CARBURETOR Tundra 04-11-1 MMR2004-120_04_11A.FM...
Page 206 Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) Skandic LT/LT E Choke equipped model only 04-11-2 MMR2004-120_04_11A.FM...
Page 207 Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) Skandic WT/SWT/SUV 550/SUV 600 Choke equipped model only TYPICAL 04-11-3 MMR2004-120_04_11A.FM...
Page 208: Identification
Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) IDENTIFICATION NOTE: For proper calibration refer to TECHNICAL DATA and to SPARK PLUG. All carburetors are identified on their body. NOTE: For high altitude regions, a Service Bulletin will give information about calibration according to altitude and temperature.
Page 209 Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) NOTE: Install needle valve for snowmobile carbu- Example 6DH4-3 retor only. It is designed to operate with a fuel Recommended pump system. Needle position. identification Check throttle slide no. 5 for wear. Replace as of the E-clip from top necessary.
Page 210: Carburetor Float Level Adjustment
Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) CARBURETOR FLOAT LEVEL ADJUSTMENT CAUTION: Spark plugs will foul if float is ad- justed too low. Engine may be damaged if float is adjusted too high. 9,10, Float Arm and Float Arm Pin Correct fuel level in float chamber is vital toward maximum engine efficiency.
Page 211: Carburetor Adjustments
Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) To Adjust Height H 6, Air Screw – Bend the contact tab of float arm until the spec- Completely close the air screw (until a slight seat- ified height is reached. ing resistance is felt) then back off as specified.
Page 212: Installation
Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) A00C3MA CENTER POST TYPE A01C3NA 1. E-clip 2. Needle retaining plate TYPICAL 3. Screw 4. Needle 1. Drill bit used as gauge for throttle slide height 5. Nylon packing INSTALLATION Using a drill bit as a gauge, adjust throttle slide height (see following table) by turning idle speed CAUTION: Never allow throttle slide(s) to snap screw no.
Page 213 Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) At full opening, throttle slide must be flush or 1.0 mm WARNING (.040 in) lower than the top of carburetor outlet bore This gap is very important. If the throttle slide (engine side).
Page 214: Idle Speed Final Adjustment
Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) CAUTION: On dual carburetor models, make sure both carburetors start to operate simulta- neously. Do not interchange carburetors as the jetting may be different on each side. A red dot is printed on one carburetor and on the engine. Match the carburetor and the engine dots when applicable.
Page 215 Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) NOTE: A light pressure is be needed to position tool under plunger. A01C5FA A01C5IA CUT-AWAY (ENGINE SIDE SHOWN) 1. Choke cable adjustment nut 1. Choke plunger 2. Choke plunger tool 2. Tool properly seated under choke plunger Tighten choke cable lock nut and reinstall protec- If tool tip does not sit under choke plunger no.
Page 216: Fuel Pump
Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) FUEL PUMP To check impulse diaphragm and gasket on high- supply fuel pump equipped with twin outlets, pro- REMOVAL ceed as follows: Connect a clean plastic tubing to the impulse nipple Install a hose pincer (P/N 295 000 076) on fuel sup- and plug vent hole on top cover.
Page 217: Fuel Tank And Throttle Cable
Section 04 ENGINE Subsection 12 (FUEL TANK AND THROTTLE CABLE) FUEL TANK AND THROTTLE CABLE Fuel Tank Lines WARNING If this procedure is disregarded, throttle lever WARNING might be half-open at normally closed position When draining a fuel tank or whenever a fuel and the engine will speed up when starting.
Page 218 INSPECTION ........................05-02-1 ROTATION DIRECTION ..................... 05-02-1 DRIVE BELT HEIGHT MEASUREMENT AND ADJUSTMENT......... 05-02-2 DRIVE BELT DEFLECTION MEASUREMENT (reference only)........05-02-3 DRIVE PULLEY........................05-03-1 BOMBARDIER LITE ......................05-03-1 GENERAL ........................... 05-03-2 REMOVAL........................... 05-03-2 DISASSEMBLY........................05-03-3 CLEANING ......................... 05-03-3 INSPECTION ........................
Page 219 Section 05 TRANSMISSION Subsection 01 (TABLE OF CONTENTS) INSTALLATION ........................05-04-4 ADJUSTMENT........................05-04-4 THRUST BUSHING ......................05-04-5 REMOVAL ........................... 05-04-6 DISASSEMBLY ........................05-04-6 CLEANING .......................... 05-04-6 INSPECTION ........................05-04-6 ASSEMBLY ......................... 05-04-6 INSTALLATION ........................05-04-6 ADJUSTMENT........................05-04-6 LPV 27 ..........................05-04-8 DISASSEMBLY ........................
Page 220 Section 05 TRANSMISSION Subsection 01 (TABLE OF CONTENTS) CHAINCASE ........................... 05-07-1 REMOVAL........................... 05-07-2 DISASSEMBLY........................05-07-2 INSPECTION ........................05-07-2 ASSEMBLY......................... 05-07-2 INSTALLATION ........................05-07-3 ADJUSTMENT ........................05-07-3 REMOVAL........................... 05-07-5 INSPECTION ........................05-07-5 GEAR RATIO MODIFICATION ................... 05-07-5 INSTALLATION ........................05-07-5 DRIVE CHAIN ADJUSTMENT ................... 05-07-6 ADJUSTMENT ........................
Page 221: Drive Belt
Section 05 TRANSMISSION Subsection 02 (DRIVE BELT) DRIVE BELT APPLICATION CHART MINIMUM WIDTH MODEL PART NUMBER (wear limit) Tundra 414 827 600 30.0 mm (1.181 in) Skandic LT/LT E/WT/SWT/WT LC/SUV 550 414 633 800 32.0 mm (1.260 in) Skandic WT LC/SUV 600 414 300 155 34.7 mm (1.366 in) CHECKING NEUTRAL FUNCTION...
Page 222: Drive Belt Height Measurement And Adjustment
Section 05 TRANSMISSION Subsection 02 (DRIVE BELT) 1. Flush Adjustment INCORRECT NOTE: For used drive belt, mark and reinstall in Before adjusting the belt height, ensure that a good- the same position. condition proper belt (refer to the APPLICATION CHART) is installed. DRIVE BELT HEIGHT Adjust pulley distance and alignment.
Page 223: Drive Belt Deflection Measurement (Reference Only)
Section 05 TRANSMISSION Subsection 02 (DRIVE BELT) Allen screws must be restrained while tightening To Check Tension jam nut to prevent throwing adjustment out. Use Position a reference rule on drive belt. drive belt tension adjuster (P/N 529 008 700). Wooden Stick and Spring Scale Method 1.
Page 224 Section 05 TRANSMISSION Subsection 02 (DRIVE BELT) 1. Slide lower O-ring of tester to specified deflec- tion. 2. Slide upper O-ring of tester until reaching mark 0 (zero). 3. Apply pressure until lower O-ring is flush with edge of rule and read force on the upper scale at top edge of O-ring.
Page 225: Drive Pulley
Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) DRIVE PULLEY BOMBARDIER LITE NOTE: This is a lubrication free drive pulley. Tundra/Skandic WT 550/SWT/SUV 550 05-03-1 MMR2004_123_05_03A.FM...
Page 226: General
CAUTION: Such modifications should only be performed by experienced mechanics since they can greatly affect vehicle performance. WARNING Any drive pulley repairs must be performed by an authorized Bombardier snowmobile dealer. Sub-component installation and assembly tol- erances require strict adherence to procedures A05D0JB detailed.
Page 227: Disassembly
Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) DISASSEMBLY 2, Cap, Washer and Disk These are calibration parts. Refer to TECHNICAL Unscrew nut. Remove tab washer. DATA. Check for alignment marks for proper indexing at Install spring cover tool (P/N 529 027 300) with reassembly.
Page 228: Assembly
Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) ASSEMBLY Install spring seat no. 11 then the spring and its cover no. 5. Make sure to install blocks in their original position and with their curved end toward governor cup. See following illustration. 1.
Page 229: Comet 102C
Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) COMET ® 102C Skandic LT/LT E 18 17 Skandic LT E 05-03-5 MMR2004_123_05_03A.FM...
Page 230: General
Use holder (P/N 529 006 400). Make sure holder Any drive pulley repairs must be performed by hook is positioned on top of tower. an authorized Bombardier snowmobile dealer. Sub-component installation and assembly tol- erances require strict adherence to procedures detailed.
Page 231: Disassembly
Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) Install holder (P/N 529 006 400) in a way to limit pulley clockwise rotation. Insert drive pulley puller (P/N 529 025 000) then turn puller clockwise to free drive pulley from crankshaft taper. Remove driven pulley to make room for drive pul- ley removal.
Page 232: Cleaning
Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) Heat spider no. 5 to melt threadlocker. Check cover bushing interior. Replace cover if bushing is completely bronze instead of the origi- Install spider tool (P/N 529 025 200) then, unscrew nal teflon coating. spider no.
Page 233: Installation
Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) Install spring no. 4, cover no. 3. NOTE: It is of the utmost importance to use thick flat washers no. 18 with self-tapping screws Tighten cover screws no. 2 to 12 N•m (106 lbf•in). no.
Page 234 Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) TRA III Skandic WT 600/WT LC/SUV 600 NOTE: This is a lubrication free drive pulley. Always refer to appropriate parts catalog for replacement parts. Most parts of TRA III are not interchangeable with those of the TRA. 12 11 27 25 05-03-10...
Page 235: General
Always tighten Any drive pulley repairs must be performed by puller by hand to ensure that the drive pulley an authorized Bombardier snowmobile dealer. has the same type of threads (metric vs imperi- Sub-component installation and assembly tol- al) prior to fully tightening.
Page 236 Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) 5,6, Fixed and Sliding Half NOTE: To ease disassembly, forks (P/N 529 005 500) should be used to hold slider shoes prior to CAUTION: Do not tap on governor cup. removing governor cup. Screw puller into fixed half shaft about 13 mm (1/2 in).
Page 237: Cleaning
Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) Install sliding half then a second support guide. These CAUTION: Do not use any other type of abrasive. support guides will prevent bushing damages. Reclean mounting surfaces with paper towel and cleaning solvent. Wipe off the mounting surfaces with a clean and dry paper towel.
Page 238 Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) Sliding Half Bushing Replacement NOTE: Make sure to use the tool (P/N 529 035 931) as marked; to remove the bushing press using the NOTE: If the bushing is worn out, it is recom- side marked “OUT”, as shown below in the picture.
Page 239: Assembly
Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) Spring Cover Bushing Replacement Under normal use there is no need to replace this bushing. If it must be replaced, it is recommended to re- place the spring cover ass’y. ASSEMBLY NOTE: This drive pulley is lubrication free. Do not lubricate any component.
Page 240 Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) 21,22,23, Screw, Dowel Tube and Ramp 9,11,13,14, Screw, Lever Ass’y, Nut and Cotter Pin Insert dowel tube from chamfered side. Make sure ramp is centered on dowel tube. Always install lever assemblies so that cotter pins are on the shown side.
Page 241 Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) Lift sliding half against spring cover and align spring cover arrow with sliding half mark. 529 005 500 A16B02A Make sure to align governor cup arrow with sliding half and fixed half mark. NOTE: If fixed half has no mark, align governor 1.
Page 242 26,28,29, Calibration Screw, Locking Nut and Governor Cup Never substitute conical spring washer and/or screw with jobber ones. Always use Bombardier Calibration screw has a notch on top of its head. genuine parts for this particular case. Use holder. See removal procedure.
Page 243 Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) 1. Position 1 (not numbered) Each number modifies maximum engine RPM by about 200 RPM. Lower numbers decrease engine RPM in steps of 200 RPM and higher numbers increase it in steps of 200 RPM. Example: Calibration screw is set at position 3 and is changed to position 5.
Page 244 Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) DRIVEN PULLEY Tundra 05-04-1 MMR2004-124_05_04A.FM...
Page 245 Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) NOTE: Driven pulley components (support, cam, shoes, etc.) can be serviced without removing the whole driven pulley from chaincase. Refer to the following procedures but neither remove brake caliper nor open chaincase for those cases. REMOVAL To remove driven pulley from chaincase, follow this procedure.
Page 246 Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) ASSEMBLY Assemble driven pulley components by reversing the disassembly procedure except for the following. 2,9, Slider Shoe When replacing slider shoes, always install a new set (3 shoes) to maintain equal pressure on the cam. Install slider shoes as per following photo.
Page 247: Installation
Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) 2,4,5, Roller Pin, Outer Cam and Spring ADJUSTMENT Insert spring in adjusting hole no. 3 into sliding half, 11,12, Shim as illustrated. NOTE: The following adjustment must be per- formed with a new drive belt. For best performance, particularly at starting, top of drive belt should be flush with top of driven pul- ley halves.
Page 248: Thrust Bushing
Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) THRUST BUSHING Skandic WT/SWT 05-04-5 MMR2004-124_05_04A.FM...
Page 249: Removal
Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) REMOVAL Remove guard and drive belt from vehicle. Remove the screw, and washer then pull the driv- en pulley from the shaft. DISASSEMBLY Use spring compressor (P/N 529 035 524). A15D0OA Remove snap ring no. 2 and washer no. 3 to dis- 1.
Page 250 Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) Pulley Alignment and Drive Belt Spring Torsional Pre-Load Deflection To check spring pre-load adjustment, use spring scale hook (P/N 529 006 500) and a spring scale. Refer to PULLEY DISTANCE AND ALIGNMENT and DRIVE BELT to perform adjustments. Remove drive belt.
Page 251: Lpv 27
Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) LPV 27 Skandic LT/LT E 05-04-8 MMR2004-124_05_04A.FM...
Page 252: Disassembly
Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) DISASSEMBLY Use spring compressor (P/N 529 035 524). 529 035 524 A15D0OA 1. Measure thickness of slope base here 2. Sliding pulley side 3. Slope base Bushing Replacement Large Bushing Remove Allen screws if applicable. Heat to break Loctite bond.
Page 253: Assembly
Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) ASSEMBLY Position guard no. 6 in cam no. 5 then insert spring in adjusting hole no. 3 (mid-hole) into outer cam. 10,11, Cam Slider Shoe Compress outer cam using spring compressor (P/N 529 035 524). When replacing slider shoes, always install a new set (3 shoes) to maintain equal pressure on the cam.
Page 254: Adjustment
Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) TYPICAL 1. Spacer 2. Shoulder on this side Should installation procedure be required, refer to BRAKE then look for BRAKE DISC and COUNTER- SHAFT BEARING ADJUSTMENT. Reinstall the pulley on the countershaft by revers- ing the removal procedure.
Page 255: Formula Vsa
Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) FORMULA VSA Skandic WT LC/SUV 05-04-12 MMR2004-124_05_04A.FM...
Page 256: Removal
Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) REMOVAL Remove guard and drive belt from vehicle. Remove cap screw no. 12 and shouldered washer no. 11 then pull the driven pulley from the coun- tershaft. Note shouldered washer position for reinstallation. Take care not to lose spacer no.
Page 257: Inspection
Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) INSPECTION ASSEMBLY 9,10, Bushings 6, Cam Slider Shoe Check for cracks, scratch and for free movement When replacing slider shoes, always install a new when assembled to fixed half. set (3 shoes) to maintain equal pressure on the cam. Using a dial bore gauge measure bushing diame- Assemble driven pulley components by reversing ter.
Page 258 Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) Take 1 measurement when sliding half begins to turn. Rotate sliding half to 10 mm (3/8 in) of rotation. Hold spring scale at this position. Slowly release ten- sion from spring scale and take 2 measurement when sliding half begins to return.
Page 259: Pulley Distance And Alignment
Section 05 TRANSMISSION Subsection 05 (PULLEY DISTANCE AND ALIGNMENT) PULLEY DISTANCE AND ALIGNMENT GENERAL GENERAL PROCEDURE The pulley distance we will refer to in this section, Remove guard. is the space separating the drive and driven pulley Tundra outside diameters (Z measurement). Use driven pulley opening tool (P/N 529 034 200).
Page 260 Section 05 TRANSMISSION Subsection 05 (PULLEY DISTANCE AND ALIGNMENT) Mean Value Procedure and Quick Tundra Only Alignment and Distance Check Bottom of alignment bar must not seat on shaft nor fixed half shoulder and shim(s). Alignment bar tabs must fully contact fixed half of drive pulley.
Page 261: Pulley Alignment And Distance Specifications Chart
Section 05 TRANSMISSION Subsection 05 (PULLEY DISTANCE AND ALIGNMENT) PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART PULLEY ALIGNMENT OFFSET DISTANCE MODELS ➀ 37.0 ± 0.50 mm 36.0 ± 0.50 mm 0 to 1.5 mm TUNDRA 529 026 900 (1.457 ± .020 in) (1.417 ±...
Page 262 Section 05 TRANSMISSION Subsection 05 (PULLEY DISTANCE AND ALIGNMENT) Pulley Alignment Method Skandic LT/LT E Tundra Engine Movement Loosen the support retaining bolts. Move the engine to obtain specified pulley align- ment, torque engine support bolts to 55 N•m (41 lbf•ft) and remove engine support positioner. Driven Pulley Movement Shims can be mounted between chaincase and frame.
Page 263: Brake
Section 05 TRANSMISSION Subsection 06 (BRAKE) BRAKE MECHANICAL BRAKE Tundra 05-06-1 MMR2004-126_05_06A.FM...
Page 264 Section 05 TRANSMISSION Subsection 06 (BRAKE) Skandic LT 05-06-2 MMR2004-126_05_06A.FM...
Page 265: Hydraulic Brake
Section 05 TRANSMISSION Subsection 06 (BRAKE) HYDRAULIC BRAKE Skandic WT/SWT/WT LC/SUV 550/SUV 600 05-06-3 MMR2004-126_05_06A.FM...
Page 266: Brake Fluid Type
Section 05 TRANSMISSION Subsection 06 (BRAKE) BRAKE FLUID TYPE Use recommended brake fluid SRF (DOT 4) (P/N 293 600 063) or GTLMA (DOT 4) (P/N 293 600 062). BRAKE PADS REPLACEMENT Models with Mechanical Brake A. 1 mm (1/32 in) minimum Brake pads must be replaced when fixed pad Removal projects only 1 mm (1/32 in) from caliper.
Page 267: Removal
Section 05 TRANSMISSION Subsection 06 (BRAKE) Installation – Pull countershaft assembly toward driven pul- ley side to gain access to clip no. 25. – Install new brake pads. – Remove clip no. 25 on countershaft. – Install spring and push 2 pins to lock the brake pads.
Page 268: Inspection
Section 05 TRANSMISSION Subsection 06 (BRAKE) INSPECTION ASSEMBLY 7, Brake Pad 14, Ratchet Wheel Apply synthetic grease (P/N 413 711 500) on threads Models with Mechanical Brake and spring seat prior to installing. Fully tighten then Brake pads must be replaced when fixed pad back off one turn.
Page 269: Adjustment
Section 05 TRANSMISSION Subsection 06 (BRAKE) 7, Brake Pad 24, Upper Clamp Models with Hydraulic Brake Models with Hydraulic Brake After brake pads installation, brake disc must be Install upper clamp with its arrow pointing at front centered in caliper. Apply brake then check for of vehicle.
Page 270: Bleeding
Section 05 TRANSMISSION Subsection 06 (BRAKE) Models with Hydraulic Brake Models with Hydraulic Brake Change brake fluid once a year. There is no adjustment on these models. Check that switch is securely installed. Bleed brake system as follows: Keep sufficient DOT 4 brake fluid in reservoir at all BLEEDING times.
Page 271: Chaincase
Section 05 TRANSMISSION Subsection 07 (CHAINCASE) CHAINCASE Tundra 14 15 05-07-1 MMR2004-127_05_07A.FM...
Page 272: Removal
Section 05 TRANSMISSION Subsection 07 (CHAINCASE) REMOVAL Remove chaincase cover no. 20 and drain oil. Remove right side drive axle bearing cover. Chaincase and driven pulley can be removed from Remove circlip no. 17. the vehicle as an assembly. Move drive axle and track together to the right Remove guard and drive belt.
Page 273: Installation
Section 05 TRANSMISSION Subsection 07 (CHAINCASE) 1, Oil Seal Using an appropriate pusher, press new oil seal no. 7 into chaincase hub. Oil seal must sit flush with case hub edge. INSTALLATION Reverse removal procedure. Pay particular atten- tion to the following: Torque castellated nut no.
Page 274 Section 05 TRANSMISSION Subsection 07 (CHAINCASE) Skandic LT 05-07-4 MMR2004-127_05_07A.FM...
Page 275: Removal
Section 05 TRANSMISSION Subsection 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 pipe and muffler. ings, sprockets and chain tensioner components. WARNING WARNING Never remove exhaust components when en-...
Page 276: Drive Chain Adjustment
Section 05 TRANSMISSION Subsection 07 (CHAINCASE) 26, Conical Spring Washer CAUTION: Free-play must not exceed 5 mm (13/64 in), readjust if necessary. Install washer with its concave side towards sprocket. WARNING If the specified free-play is not reached with the tensioner screw fully tightened, replace chain and check the condition of sprockets.
Page 277: Gearbox
Section 05 TRANSMISSION Subsection 08 (GEARBOX) GEARBOX 3-SPEED GEARBOX Skandic WT/SWT/WT LC/SUV Skandic WT/SWT Loctite Loctite 243 SWT/SUV only Synthetic grease Synthetic grease 05-08-1 MMR2004-128_05_08A.FM...
Page 278: Removal
Section 05 TRANSMISSION Subsection 08 (GEARBOX) REMOVAL Remove rear suspension. Remove angle drive and square pin from bottom of Drain gearbox oil. gearbox. Remove muffler. Unbolt RH end bearing then pull drive axle toward right side. 1. Bottom pan drain hole nearby gearbox drain plug Remove belt guard, drive belt.
Page 279: Disassembly
Section 05 TRANSMISSION Subsection 08 (GEARBOX) DISASSEMBLY Unfasten sleeve nuts no. 4, remove spring no. 7 then, partially pull shaft no. 5 and remove pin For the following procedure, right hand side refers no. 6. to driven pulley side and left hand side to brake disc side.
Page 280 Section 05 TRANSMISSION Subsection 08 (GEARBOX) Remove all circlips no. 9. Remove sleeve no. 23. IMPORTANT: Note all shims quantity and location. NOTE: Brake shaft gears remain in gearbox hous- ing. Remove brake shaft oil seal and then circlip. Remove bearing no. 27 from brake shaft no. 26 using a press.
Page 281 Section 05 TRANSMISSION Subsection 08 (GEARBOX) Make sure gears mesh. Use a puller to extract LH reverse shaft bearing. A29D0YA A29D10A 1. These gears must mesh as reverse shaft is driven out 1. Extract reverse shaft LH side bearing Shift in reverse gear. To remove sliding sleeve from reverse shaft, first remove circlip.
Page 282 Section 05 TRANSMISSION Subsection 08 (GEARBOX) Use a puller to extract bearing no. 19. Use a puller to extract bearing no. 12. Remove brake shaft gears. Remove circlip then, gear no. 14. Now driven pul- Unbolt driven pulley shaft screw no. 11 and re- ley shaft can be pulled out from gearbox.
Page 283 Section 05 TRANSMISSION Subsection 08 (GEARBOX) DRIVEN PULLEY SHAFT COMPONENTS Remove screws no. 39 from intermediate shafts no. 30. Fasten a long M8 x 1.25 screw in axle end then drive it out, beginning with top one. 1. Spacer Do not disassemble bearings of intermediate gears needlessly.
Page 284: Inspection
Section 05 TRANSMISSION Subsection 08 (GEARBOX) Drive out plug no. 37. INSPECTION Remove circlip no. 9 from LH side. Check bearing condition. There must be no discol- oration, missing rollers or balls, broken cages, etc. Check sprocket teeth. ASSEMBLY Install lower gear no. 34 with its shoulder facing RH side.
Page 285 Section 05 TRANSMISSION Subsection 08 (GEARBOX) Install lower shaft no. 36 with its hollow side (no splines) on RH side. Align key with lower gear no. 34 keyway. 1. Shoulder 2. Recess Install sleeve no. 23 on brake shaft no. 26 then, Apply synthetic grease (P/N 413 711 500) on inter- slide gears and sleeve until end of sleeve is flush mediate shaft O-rings.
Page 286 Section 05 TRANSMISSION Subsection 08 (GEARBOX) Install reverse shaft ass’y no. 38 into its RH side Install driven pulley shaft no. 15 with the sliding bearing no. 19. sleeve loosely inserted. Gear no. 14 must be at its place. 1. Sliding sleeve loosely inserted 2.
Page 287: Installation
1. Full level mark 2. Lower level mark To fill, remove filler plug from top of transmission. Refill as required using Bombardier synthetic A29D1OA chaincase oil (P/N 413 802 800 — 12 x 250 mL). READY TO INSTALL BEARINGS, SHIMS, CIRCLIPS AND PLUGS 05-08-11 MMR2004-128_05_08A.FM...
Page 288: Drive Chain
Section 05 TRANSMISSION Subsection 09 (DRIVE CHAIN) DRIVE CHAIN GENERAL Bombardier drive chains exist in 2 types, for proper use refer to TECHNICAL DATA. A00D0RA TYPICAL 1. Rotation CHAIN SEPARATION When separating an endless chain, always use a chain bearing pin extractor. Also, make sure to re- move one complete link.
Page 289 Section 05 TRANSMISSION Subsection 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 290 Section 06 ELECTRICAL Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS IGNITION TIMING ......................... 06-02-1 SINGLE CYLINDER RER CDI SYSTEM ................06-02-1 TWIN CYLINDER RER CDI SYSTEM ................. 06-02-3 DUCATI CDI SYSTEM......................06-02-5 NIPPONDENSO TRIGGER COIL SYSTEM................ 06-02-8 SPARK PLUGS ........................06-03-1 NGK SPARK PLUG......................
Page 291 Section 06 ELECTRICAL Subsection 01 (TABLE OF CONTENTS) TESTING PROCEDURE ......................06-06-1 GENERAL..........................06-06-1 DUCATI TRIGGER COIL CDI SYSTEM TESTING .............. 06-06-7 IGNITION SYSTEM TESTING SEQUENCE ............... 06-06-7 LIGHTING SYSTEM TESTING SEQUENCE ..............06-06-8 1. SPARKING ........................06-06-8 2. ELECTRICAL CONNECTOR TESTING ................06-06-8 3.
Page 292: Ignition Timing
Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) IGNITION TIMING SINGLE CYLINDER RER CDI SYSTEM Tundra 277 Engine Type This 277 engine type is equipped with a Rotax Electronic Reverse system (RER). It uses a single coil ignition system and 2 trigger coils. Refer to CDI SYSTEM for more information.
Page 293 Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) Check if red fin aligns with mark on fan cowl. 1. Connect timing light pick-up to the spark plug lead. Use a digital induction type tachometer (P/N 529 014 500). A05E0TA TACHOMETER (P/N 529 014 500) 1.
Page 294: Twin Cylinder Rer Cdi System
Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) 3. Check if the red fin aligns with the fan cowl tim- ing mark. Tolerance is ± 1°. If the red fin aligns with the fan cowl timing mark, timing is correct. If not the case, check for proper flywheel, trigger coil position or MPEM.
Page 295 Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) 5. Verify the position of the timing mark on the 6. Scribe a new mark on magneto flywheel as fol- magneto flywheel as follows: lows. NOTE: When checking timing, certain procedures a. Remove the fan cover from the engine. require that the magneto flywheel be turned in a b.
Page 296: Ducati Cdi System
Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) TACHOMETER (P/N 529 014 500) To check the ignition timing, refer to illustration and proceed as follows: WARNING Place ski tips against a wall, raise rear of ve- hicle on a stand, so that track does not contact the ground.
Page 297 Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) 2. To correctly locate and mark a timing mark on a 4. Locate the piston TDC position as follows: new service magneto flywheel. a. Slowly rotate the magneto flywheel back and 3. To verify the correct location of the factory tim- forth across TDC while observing the needle.
Page 298 Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) A17E10A 1. Trigger coil mark 2. Magneto flywheel mark NOTE: These marks cannot be used to check dy- namic (with engine running) ignition timing with a 1. Crankcase arrow timing light: a new mark must be scribed on mag- 2.
Page 299: Nippondenso Trigger Coil System
Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) NIPPONDENSO TRIGGER COIL To check the ignition timing, refer to illustration and proceed as follows: SYSTEM WARNING Skandic WT LC/SUV 600 Place ski tips against a wall, raise rear of ve- Normally ignition timing adjustment should not be hicle on a stand, so that track does not contact required.
Page 300 Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) d. “0” now indicates exact TDC. 4. Rotate the drive pulley clockwise, one-quarter turn then carefully rotate it counterclockwise until the needle indicates the specified mea- surement, indicated in TECHNICAL DATA. 5. Twist a wire as shown and use it as a pointer. Install the wire on upper starter bolt.
Page 301 Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) 1. Connect the timing light pick-up to a spark plug cable. Connect a digital induction type tachometer (P/N 529 014 500). TYPICAL TACHOMETER (P/N 529 014 500) 1. Timing mark in line with pointer end 2.
Page 302 Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) The timing mark must be aligned with pointer end. If such is not the case, note if timing is retarded or advanced. Tolerance is ± 1°. Connect MPEM programmer to DESS post. Turn on programmer then enter password. From main menu select no.
Page 303 Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) Select no. 4. ENGINE PARAMETER. Press ENTER. Select no. 1 TIMING ADJUSTMENT. Select a timing correction factor corresponding to correction needed. Example: Timing mark as verified with a timing light at 3500 RPM was too early by 2°. The correc- tion factor programmed is no.
Page 304 Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) Press ENTER. Scroll to no. 7 SAVE AND QUIT. Press ENTER. Press ENTER. The display confirms that correction factor has Press ENTER. been changed to no. 5. Press any key. T R A N S F E R P G M R M P E M A00A42A...
Page 305 Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) After the programmer has verified, following mes- sage will appear. O P E R A T I O N S U C C E S S F U L L P R E S S A N Y K E Y . . . A00A3EA Press any key.
Page 306: Spark Plugs
Subsection 03 (SPARK PLUGS) SPARK PLUGS NGK SPARK PLUG All Models NGK SPARK PLUG NUMBERING SYSTEM Bombardier uses NGK brand spark plugs on all its snowmobile models. The heat range identification system is: Low number hot plug High number cold plug 06-03-1 MMR2004-131_06_03A.FM...
Page 307: Design Symbols Used In Ngk Spark Plugs
Section 06 ELECTRICAL Subsection 03 (SPARK PLUGS) DESIGN SYMBOLS USED IN NGK SPARK PLUGS 06-03-2 MMR2004-131_06_03A.FM...
Page 308: Disassembly
Section 06 ELECTRICAL Subsection 03 (SPARK PLUGS) DISASSEMBLY CAUTION: Severe engine damage might occur if a wrong heat range plug is used. First unscrew the spark plug 1 turn. A too hot plug will result in overheating and pre- Clean the spark plug and cylinder head with pres- ignition, etc.
Page 309: Spark Plug Installation
Section 06 ELECTRICAL Subsection 03 (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.
Page 310: Battery
Section 06 ELECTRICAL Subsection 04 (BATTERY) BATTERY GENERAL Unbolt battery cover steel strip and remove battery cover. Skandic WT/SWT/SUV 550/SUV 600 Absorbed Glass Mat (AGM) battery is used for these SKI-DOO snowmobiles. AGM battery is sealed, non- spillable and maintenance free. REMOVAL All Models WARNING...
Page 311: Cleaning
Section 06 ELECTRICAL Subsection 04 (BATTERY) CLEANING BATTERY CHARGE TESTING Clean the battery, battery casing, vent tube, caps, Skandic LT E cables and battery posts using a solution of baking Hydrometer Test soda and water. CAUTION: Do not allow cleaning solution to en- ter battery interior since it will destroy the elec- trolyte.
Page 312: Battery Storage
Section 06 ELECTRICAL Subsection 04 (BATTERY) Unload Test EXAMPLE NO. 1 Temperature below 25°C (77°F): Skandic WT/SWT/SUV 550/SUV 600 Hydrometer Reading: 1.250 Check charge condition by using voltmeter. Volt- Electrolyte temperature: 7°C (20°F) meter readings appear instantly to show the state Subtract .019 Sp.
Page 313: Activation Of New Battery
Section 06 ELECTRICAL Subsection 04 (BATTERY) Clean battery casing and caps using a solution of In case of accidental premature removal of caps or baking soda and water. Do not allow cleaning so- sealing tube, battery should be given a full charge. lution to enter battery, otherwise it will destroy the Perform the following operations anytime a new electrolyte.
Page 314 Section 06 ELECTRICAL Subsection 04 (BATTERY) 4. Allow gas bubbles to escape by lightly shaking WARNING battery by hand. Gases given off by a battery being charged are highly explosive. Always charge in a well ventilated area. Keep battery away from cig- arettes or open flames.
Page 315: Servicing
Section 06 ELECTRICAL Subsection 04 (BATTERY) SERVICING 10. Allow gas bubbles to escape by lightly shake bat- tery. Electrolyte Level Since a battery has been activated (see above), add distilled water to top up electrolyte. TIPS FOR CHARGING A USED BATTERY CAUTION: Prior to charging the battery, always remove it from the vehicle to prevent electro-...
Page 316: Battery Charging Equipment
Section 06 ELECTRICAL Subsection 04 (BATTERY) Charging a Very Flat or Completely The battery charger must be equipped with an am- meter capable of accurately measuring current of Discharged Battery less than one ampere. Unless this procedure is properly followed, a good If the present charger is not adjustable to the prop- battery may be needlessly replaced.
Page 317: Cable Terminal Installation
Section 06 ELECTRICAL Subsection 04 (BATTERY) Connect BLACK negative cable LAST. NOTE: Make sure not to cut wire strands while stripping the wire. WARNING Install the appropriate terminal on the wire accord- Battery BLACK negative cable must always ing to the requirement. Refer to appropriate parts be disconnected first and connected last.
Page 318 Section 06 ELECTRICAL Subsection 04 (BATTERY) After positioning the crimp plier, crimp the termi- nal already installed on wire. CRIMPING OF WIRE PROPERLY CRIMPED WIRE To verify, if the wire is properly crimped, apply some pulling force on wire and the terminal at the same time from both directions.
Page 320: Electric Starter
Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) ELECTRIC STARTER Skandic WT/SWT/LT E/SUV 550 06-05-1 MMR2004-133_06_05A.FM...
Page 321 Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) Skandic WT LC/SUV 600 06-05-2 MMR2004-133_06_05A.FM...
Page 322: Removal
Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) REMOVAL Skandic WT/SWT/LT E – Disconnect BLACK ground cable from battery. – Disconnect RED positive cable from battery. WARNING Always disconnect ground cable first and con- nect last. – Disconnect RED cable and RED/GREEN wire from starter relay.
Page 323 Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) 1. Turn until bushing goes out 2. 12 mm tap To install new bushing, use the same bushing push- er as for drive housing bushing installation. 6, Brush 1. Press-in To replace brush no. 6, proceed as follows: 2.
Page 324: Cleaning And Inspection
Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) Crimp plate over housing connector with a pair of pliers. 1. Collar A19E06A 2. Snap ring 1. Plate edge Turn starter clutch no. 6 clockwise to remove it 2. Housing connector from armature assembly no. 11. 3.
Page 325: Inspection
Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) INSPECTION Test for Ground Circuit in the Armature Use growler test probes. Check between armature Armature core and the commutator bars. If growler lamp turns on, bars are grounded. If so, replace armature. All Models NOTE: An ohmmeter may be used for the follow- ing testing procedures, except for the one con-...
Page 326 Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) Brush Length Test the Armature for Open Circuit Use growler test probes. Place one test probe on All Models a commutator bar and the other test probe on the Measure brush length. If less than the specified neighboring bar.
Page 327: Relay
Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) Overrunning Clutch Install thrust washer against outer stop collar. Place drive lever onto overrunning clutch then in- All Models sert into drive housing. The pinion of the overrunning clutch should turn smoothly in a clockwise direction, and should not slip in a counterclockwise direction.
Page 328 Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) Starter Housing Assembly and Starter Housing Align previously traced indexing marks. A19E09A TYPICAL 1. Shorter stud 2. Bare wire 1. Aligned indexing marks Skandic WT LC/SUV 600 Open brushes and slide over commutator. Reverse the order of disassembly to reassemble Align end frame locating notch with yoke locating starter.
Page 329: Installation
Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) INSTALLATION Connect the RED battery cable and the RED wire to the large terminal of the relay. Connect RED/ Skandic WT/SWT/LT E/SUV 550 GREEN wire to small terminal of relay. Make sure that starter and engine mating surfaces Connect BLACK cable to battery.
Page 330: Testing Procedure
Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) TESTING PROCEDURE GENERAL The following chart gives the engine types with their implemented system. CHARGING ENGINE IGNITION SYSTEM TYPE SYSTEM OUTPUT ➀ RER dual trigger 277 on coil CDI Tundra (single cylinder) ➁ Ducati trigger coil 552 on Skandic WT/SWT/...
Page 331 Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) ➀ RER DUAL TRIGGER COIL CDI SYSTEM (SINGLE CYLINDER) 1. MPEM 2. Trigger coils 3. 4-DB housing (BLACK and RED wires) 06-06-2 MMR2004-134_06_06A.FM...
Page 332 Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) ➁ Ducati Trigger Coil CDI The DUCATI trigger coil CDI system has a com- bined ignition module/ignition coil which is mount- ed on air silencer, below carburetors. Ignition module is connected to the ignition gen- erator coil via a 4-connector housing (GREEN and WHITE wires).
Page 333 Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) ➂ RER DUAL TRIGGER COIL CDI SYSTEM (TWIN CYLINDER) 1. MPEM 2. Trigger coils 3. 3-connector housing (BLACK and RED wires) 06-06-4 MMR2004-134_06_06A.FM...
Page 334 Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) ➃ Nippondenso Trigger Coil CDI With Engine Running The NIPPONDENSO CDI system has a separate If the below mentioned tool is not available start ignition coil which is mounted on the reservoir engine. Turn on programmer then enter password. support.
Page 335 Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) Turn on programmer then enter password. From main menu select no. 3. VEHICLE INFO; Trs. And then following screen showing the actual cal- ibration number in the MPEM. Vehicle information is transferred from MPEM to programmer.
Page 336: Ducati Trigger Coil Cdi System Testing
Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) Enter new calibration number and press ENTER, following screen appears: O P E R A T I O N S U C C E S S F U L L P R E S S A N Y K E Y . . . A00A3EA Press any key, display will show followed by next screen:...
Page 337: Lighting System Testing Sequence
Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) 3. Ignition switch, DESS switch or tether cord switch Multiple Problems and engine cut-out switch. As a matter of fact, more that one component can 4. Ignition generator coil. be defective. As a result, if the problem remains although a part was replaced, start over the whole 5.
Page 338 Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) Ignition Switch (key) If readings do not correspond to the above- mentioned indications, replace switch. Disconnect switch housing. Using a multimeter, If readings are acceptable, check other switches. check between MAG and GRD terminals if the cir- cuit is open (0.L ) in operating position and if the MΩ...
Page 339: Ignition Generator Coil Voltage Testing
Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) 4. IGNITION GENERATOR COIL CONCLUSION VOLTAGE TESTING If none of the above testing operations produced valid results, it is strongly recommended to keep General on testing according to the list appearing in the When manually starting the engine while the Resistance column of the IGNITION table.
Page 340 Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) IGNITION SYSTEM TESTING (Skandic WT/SWT) RESISTANCE Ω VOLTAGE V TEST TO BE WIRE PART NOTE VALUE MULTIMETER VALUE MULTIMETER PERFORMED COLOR (ohms) SCALE (volts) SCALE BK and All switches must be in run 00.0 Running insulation —...
Page 341 Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) LIGHTING SYSTEM TESTING (Skandic WT/SWT) RESISTANCE Ω VOLTAGE V TEST TO BE WIRE PART NOTE VALUE MULTIMETER VALUE MULTIMETER PERFORMED COLOR (ohms) SCALE (volts) SCALE YL and 00.0 Power 0.05 - 0.6 2.5 - 7.0 00.0 —...
Page 342: Rer Dual Trigger Coil Cdi System Testing
Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) RER DUAL TRIGGER COIL CDI Testing Conditions SYSTEM TESTING Voltage measurements are always taken upon starting the vehicle. Readings taken when the en- Tundra R and Skandic LT/LT E gine is running will be higher than indicated range. Part temperature must be approximately 21°C (70°F) (room temperature), otherwise readings could be distorted.
Page 343: Sparking
Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) 1. SPARKING During this operation, it is important to use the snowmobile spark plug and not a new one. Bring the plug in contact with the engine. If no spark is produced, replace the spark plug with a new one and do the test again.
Page 344: Ignition Generator Coil Voltage Testing
Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) Tether Cord Switch 4. IGNITION GENERATOR COIL VOLTAGE TESTING Unplug switch block connected to main wiring har- ness. Check using a multimeter by connecting General probes to wires. The multimeter should indicate an open circuit (0.L ) in operating position and a MΩ...
Page 345: Buzzer Testing
Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) BUZZER TESTING MPEM CONNECTORS Using jumper wires, connect battery positive post To ease electrical readings on MPEM connectors, to buzzer positive tab. connector cap must be removed. Connect battery negative post to buzzer negative Hold connector in hands then lift both tabs to re- tab.
Page 346 Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) IGNITION SYSTEM TESTING (Tundra R 240 W) RESISTANCE Ω VOLTAGE V MULTIMETER TEST TO BE WIRE PART PROBE NOTE VALUE MULTIMETER VALUE MULTIMETER PERFORMED COLOR CONNECTION (ohms) SCALE (volts) SCALE Running 4-MOC-M No stop switch must 00.0 —...
Page 347 Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) LIGHTING SYSTEM TESTING (Tundra R 240 W) RESISTANCE Ω VOLTAGE V MULTIMETER TEST TO BE WIRE PART PROBE NOTE VALUE MULTIMETER VALUE MULTIMETER PERFORMED COLOR CONNECTION (ohms) SCALE (volts) SCALE 4-MOB-F 00.0 Power 00.0 - 00.6 3.0 - 7.0 00.0...
Page 348 Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) IGNITION SYSTEM TESTING (Skandic LT/LT E with RER 240 W) RESISTANCE Ω VOLTAGE V TEST TO BE WIRE PART NOTE VALUE MULTIMETER VALUE MULTIMETER PERFORMED COLOR (ohms) SCALE (volts) SCALE Running All switches must be in 00.0 —...
Page 349 Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) LIGHTING SYSTEM TESTING (Skandic LT/LT E with RER 240 W) RESISTANCE Ω VOLTAGE V TEST TO BE WIRE PART NOTE VALUE MULTIMETER VALUE MULTIMETER PERFORMED COLOR (ohms) SCALE (volts) SCALE 00.0 - 00.0 Power 3.0 - 7.0 00.0...
Page 350: Nippondenso Cdi System Testing
Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) NIPPONDENSO CDI SYSTEM TESTING 593 on Skandic WT LC/SUV IGNITION SYSTEM TESTING (Skandic WT LC/SUV 290 W) RESISTANCE Ω VOLTAGE V TEST TO BE WIRE PART NOTE VALUE MULTIMETER VALUE MULTIMETER PERFORMED COLOR (ohms) SCALE (volts)
Page 351: Inspection Of Ac Circuit Isolation
Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) LIGHTING SYSTEM TESTING (Skandic WT LC/SUV 290 W) RESISTANCE Ω VOLTAGE V TEST TO BE WIRE PART NOTE VALUE MULTIMETER VALUE MULTIMETER PERFORMED COLOR (ohms) SCALE (volts) SCALE 00.0 Output YL and YL 00.1 - 00.4 0.5 - 2.0 00.0...
Page 352 Section 07 REAR SUSPENSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS TORQUE REACTION SUSPENSION..................07-02-1 COMPONENT REMOVAL ....................07-02-2 SUSPENSION ASS’Y REMOVAL ..................07-02-2 DISASSEMBLY AND ASSEMBLY ..................07-02-2 INSPECTION ........................07-02-3 SUSPENSION ASS’Y INSTALLATION................07-02-3 RIDE ADJUSTMENT......................07-02-4 LUBRICATION ........................
Page 353: Torque Reaction Suspension
Section 07 REAR SUSPENSION Subsection 02 (TORQUE REACTION SUSPENSION) TORQUE REACTION SUSPENSION Tundra 07-02-1 MMR2004-135_07_02A.FM...
Page 354: Component Removal
Section 07 REAR SUSPENSION Subsection 02 (TORQUE REACTION SUSPENSION) COMPONENT REMOVAL Lift rear of vehicle and support it off the ground. 5, Rear Arm Release track tension. Release spring tension. Unfasten shock from rear arm. Remove 3 screws retaining rear arm. SUSPENSION ASS’Y REMOVAL Release track tension.
Page 355: Inspection
Section 07 REAR SUSPENSION Subsection 02 (TORQUE REACTION SUSPENSION) 7,8, Support and Front Arm Support To remove rivets securing the supports, cut rivet heads off using a cold chisel. At assembly, position the rivet head toward the outside of the assembly. Support the rivet head against a metal block, as shown, and use a flat head punch to secure the rivet in place.
Page 356: Ride Adjustment
Section 07 REAR SUSPENSION Subsection 02 (TORQUE REACTION SUSPENSION) RIDE ADJUSTMENT The stiffest adjustment is reached when the sup- porting edge of cam is the farthest to hexagonal The front portion of rear suspension is adjustable portion of cam. for surface condition and steering effects. The stopper strap is adjustable for vehicle weight transfer control.
Page 357: Lubrication
Section 07 REAR SUSPENSION Subsection 02 (TORQUE REACTION SUSPENSION) Stopper Strap NOTE: When towing a load, it is suggested to ad- just stopper strap to its shortest length, soften front The function of the stopper strap is to control the springs of rear suspension and stiffen rear springs.
Page 358: Skandic Wt Suspension
Section 07 REAR SUSPENSION Subsection 03 (SKANDIC WT SUSPENSION) SKANDIC WT SUSPENSION Skandic LT/WT/SWT/WT LC TYPICAL 07-03-1 MMR2004-136_07_03A.FM...
Page 359: Removal
Section 07 REAR SUSPENSION Subsection 03 (SKANDIC WT SUSPENSION) REMOVAL Release track tension. Lift rear of vehicle and support it off the ground. Unbolt front arm then rear arm. Self-Locking Screws CAUTION: These self-locking screws must al- ways be replaced by new ones everytime they are removed.
Page 360: Shock Absorber Servicing
Section 07 REAR SUSPENSION Subsection 03 (SKANDIC WT SUSPENSION) 4, Rear Spring Rivets can be substitued by M8 x 20 bolts and nuts. Remove top idler wheels. 3, Horse-Shoe Washer Unscrew one end of shock. For deep snow riding, do not install washer. Remove spring.
Page 361: Installation
Section 07 REAR SUSPENSION Subsection 03 (SKANDIC WT SUSPENSION) INSTALLATION Threaded holes must be cleaned before a self-locking screw is installed. Use a metal brush or a screwtap to clean the hole properly then use a solvent (Methyl- Chloride), let act during 30 minutes and wipe off. The solvent utilization is to ensure the adhesive works properly.
Page 362: Skandic Suv Suspension
Section 07 REAR SUSPENSION Subsection 04 (SKANDIC SUV SUSPENSION) SKANDIC SUV SUSPENSION Skandic SUV TYPICAL 07-04-1 MMR2004-137_07_04A.FM...
Page 363: Removal
Section 07 REAR SUSPENSION Subsection 04 (SKANDIC SUV SUSPENSION) REMOVAL Release track tension. Lift rear of vehicle and support it off the ground. Unbolt front arm then rear arm. Self-Locking Screws CAUTION: These self-locking screws must al- ways be replaced by new ones every time they are removed.
Page 364: Shock Absorber Inspection
Section 07 REAR SUSPENSION Subsection 04 (SKANDIC SUV SUSPENSION) 8, Rear Spring Unbolt top and bottom ends of shock. 7, Front Spring Unbolt top end of shock. Unbolt axle retaining bottom end of shock. At assembly, make sure that notch on both axle sleeves match rail rib.
Page 365: Installation
Section 07 REAR SUSPENSION Subsection 04 (SKANDIC SUV SUSPENSION) 5, Stopper Strap – A skip or a hang back when reversing stroke at mid travel. Fasten stopper strap to lower bracket hole. – Seizing or binding condition except at extreme ends of stroke.
Page 366: Lubrication
Section 07 REAR SUSPENSION Subsection 04 (SKANDIC SUV SUSPENSION) LUBRICATION Lubricate front and rear arms at grease fittings us- ing synthetic grease (P/N 413 711 500). NOTE: There is 9 grease fittings. RIDE ADJUSTMENT Refer to Operator’s Guide. 07-04-5 MMR2004-137_07_04A.FM...
Page 367: Drive Axle
Section 07 REAR SUSPENSION Subsection 05 (DRIVE AXLE) DRIVE AXLE Tundra Synthetic grease A05D1BS 07-05-1 MMR2004-138_07_05A.FM...
Page 368 Section 07 REAR SUSPENSION Subsection 05 (DRIVE AXLE) Skandic LT/LT E 5 14 07-05-2 MMR2004-138_07_05A.FM...
Page 369 Section 07 REAR SUSPENSION Subsection 05 (DRIVE AXLE) Skandic WT/SWT/WT LC/SUV Skandic WT/SWT Loctite Loctite 243 SWT/SUV only Synthetic grease Synthetic grease 07-05-3 MMR2004-138_07_05A.FM...
Page 370: Removal
Section 07 REAR SUSPENSION Subsection 05 (DRIVE AXLE) REMOVAL Remove 3 screws retaining ball bearing housing then, remove inner plate no. 3. Tundra R and Skandic LT/LT E Remove drive axle. Drain oil from chaincase. Release drive chain ten- sion. Remove chaincase cover. DISASSEMBLY Raise and block rear of vehicle off the ground.
Page 371: Assembly
Section 07 REAR SUSPENSION Subsection 05 (DRIVE AXLE) TYPICAL — ALL SKANDIC MODELS 1. Pipe TYPICAL — ALL SKANDIC MODELS Tundra NOTE: Two different types of sprocket press fit can be found. Ensure to replace ring reinforced sprockets with the same type. ASSEMBLY 8,9,13, Drive Axle and Sprocket To assemble press fit sprockets, use a press and...
Page 372 Section 07 REAR SUSPENSION Subsection 05 (DRIVE AXLE) Skandic LT/LT E All Models Ensure to align indexing marks of each sprocket when assembling. A. 47.0 mm (1.850 in) B. 148.0 mm (5.827 in) C. 271.0 mm (10.669 in) D. 372.0 mm (14.646 in) Skandic WT/WT LC/SUV 550/SUV 600 TYPICAL 1.
Page 373 Section 07 REAR SUSPENSION Subsection 05 (DRIVE AXLE) 11, Bearing Protector At assembly, flat side of bearing protector must be against bearing. 5,12, Bearing Always push bearing by inner race. A00F0DA TYPICAL — TUNDRA TYPICAL — ALL SKANDIC MODELS A. 1.5 mm (1/16 in) MAXIMUM CAUTION: The same sprocket must not be pressed twice on the axle.
Page 374: Installation
Section 07 REAR SUSPENSION Subsection 05 (DRIVE AXLE) The bearing on the splined side of axle must be Reinstall the chaincase cover. pushed until it is seated on shaft shoulder. The end Refill with chaincase oil. Refer to TECHNICAL DATA. bearing housing bearing must be flush with end of Install the suspension.
Page 375: Track
Section 07 REAR SUSPENSION Subsection 06 (TRACK) TRACK TRACK TYPE APPLICATION Skandic LT/LT E Remove the following parts: Refer to TECHNICAL DATA section. – speedometer cable GENERAL – muffler – chaincase cover This section gives guidelines for track removal. Some components require more detailed disas- –...
Page 376 Section 07 REAR SUSPENSION Subsection 06 (TRACK) Allow the suspension to extend normally and check gap half-way between front and rear idler wheels. Measure between slider shoe bottom and inside of track. The gap should be as given in SPECIFICATIONS at the end of this guide. If the track tension is too loose, track will have a tenden- cy to thump.
Page 377 Section 07 REAR SUSPENSION Subsection 06 (TRACK) Check that the track is well centered; equal dis- tance on both sides between edges of track guides and slider shoes. A01F05A 1. Guides 2. Slider shoes 3. Equal distance TYPICAL To adjust track alignment: 1.
Page 378 Section 08 STEERING/FRONT SUSPENSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS STEERING SYSTEM ......................08-02-1 INSPECTION ........................08-02-5 DISASSEMBLY AND ASSEMBLY ..................08-02-5 HANDLEBAR POSITION ADJUSTMENT................08-02-7 STEERING ADJUSTMENT (SKIS) ..................08-02-8 LUBRICATION ........................08-02-11 SUSPENSION AND SKI SYSTEM ..................08-03-1 ON-VEHICLE COMPONENT REMOVAL ................
Page 379: Steering System
Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) STEERING SYSTEM Tundra 08-02-1 MMR2004-140_08_02A.FM...
Page 380 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) Skandic LT/LT E 23 24 25 08-02-2 MMR2004-140_08_02A.FM...
Page 381 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) Skandic WT/SWT/WT LC 08-02-3 MMR2004-140_08_02A.FM...
Page 382 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) Skandic SUV 550/SUV 600 08-02-4 MMR2004-140_08_02A.FM...
Page 383: Inspection
Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) INSPECTION The grips might not be removable as explained above; in this case, carefully proceed as follows to Check skis and ski runner for wear, replace as nec- prevent damaging the heating elements. essary.
Page 384 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) Install rivet no. 11 if applicable. 1, Steering Column Remove steering pad then handlebar ass’y. Detach tie rod(s) from the steering column. To gain access to lower U-clamp or half bushing (as applicable), remove the air intake silencer and carburetor(s).
Page 385: Handlebar Position Adjustment
Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) 21, Hardened Washer on Ball Joint Stud Tundra and Skandic SUV 550/SUV 600 Install a hardened washer on each side of the arm. TYPICAL Skandic SUV 550/SUV 600 Steering arm must be installed parallel to ski. A25G0MA 9,13,15, Ball Joint Nut and Jam Nut TYPICAL...
Page 386: Steering Adjustment (Skis)
Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) STEERING ADJUSTMENT (skis) CAUTION: Tighten the nuts equally in a criss- cross sequence and ensure there is an equal Definitions gap on each side of the clamps no. 2. TOE-OUT: A difference measured between the front edge of the skis A and rear edge B as viewed from the top.
Page 387 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) Check if handlebar is horizontal. To adjust, loosen TOE-OUT ADJUSTMENT lock nuts of short tie rod and turn it accordingly. Raise front of vehicle so that skis are off the ground. Loosen lock nuts of long tie rods and turn each tie rod so that skis are in a straight ahead position.
Page 388 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) NOTE: To make sure skis are in straight-ahead po- Skandic SUV 550/SUV 600 sition, place a straight edge against pre-adjusted Adjustments should be performed following this track and measure distance between front and rear sequence: of skis and straight edge.
Page 389: Lubrication
Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) Skandic LT/LT E/WT/SWT/WT LC Toe-out adjustment is performed by adjusting length of left and right tie rods no. 20. Handlebar centering is done at same time by turning tie rods accordingly. Procedure: –...
Page 390 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) Tundra Apply BOMBARDIER LUBE (P/N 293 600 016) to ball joints. Lubricate front suspension posts and pivot arm at grease fittings. Pump five strokes of grease gun NOTE: There are 4 lubrication points.
Page 391: Suspension And Ski System
Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) SUSPENSION AND SKI SYSTEM Tundra 08-03-1 MMR2004-141_08_03A.FM...
Page 392: On-Vehicle Component Removal
Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) ON-VEHICLE COMPONENT DISASSEMBLY REMOVAL Lift front of vehicle and support off the ground. 8, Shock 1,2,3,5,6,7,9,11, Bolt, Lock Washer, Cover, Stopper, Bushing, Cushion and Nut Lift front of vehicle and support off the ground. Remove ski.
Page 393: Inspection
Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) Remove seal and O-rings. Drive out upper and low- Pay attention to the following conditions that will er cushions if worn out. denote a defective shock: – A skip or a hang back when reversing stroke at INSPECTION mid travel.
Page 394 Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) Skandic LT/LT E/WT/SWT/WT LC Except Skandic LT LT only Except Skandic LT WT LC only TYPICAL 08-03-4 MMR2004-141_08_03A.FM...
Page 395: On-Vehicle Component Verification
Section 08 STEERING/FRONT SUSPENSION Subsection 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. 1.
Page 396: Disassembly
Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) 13,14,16,17, Ski Leg, Bushing and Seal Pull up ski leg. Steering arm will not interfere. A05G0DA A05G0EA 1. Washers and stopper wedged in cover 2. Spring 1. Pull up ski leg 2.
Page 397: Installation
Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) 8, Shock Absorber INSTALLATION Secure the shock body end in a vise with its rod up- For assembly, reverse the disassembly procedure. ward. However, pay attention to the following. Apply suspension synthetic grease (P/N 293 550 033) as illustrated in exploded view above.
Page 398 Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) Skandic SUV 550/600 TYPICAL 08-03-8 MMR2004-141_08_03A.FM...
Page 399: Disassembly
Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) DISASSEMBLY Scribe mark the steering arm and ski leg before disassembly. 5, Shock Lift front of vehicle and support it off the ground. Reduce spring preload by turning adjusting ring ac- cordingly.
Page 400: Installation
Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) INSTALLATION 7,8, Upper and Lower Arms Position arms and tie rods horizontally before tight- For assembly, reverse the disassembly procedure. ening nuts. However, pay attention to the following. Bent portion of lower arm no. 6 must face down. Apply suspension synthetic grease (P/N 293 550 033) to ski leg components.
Page 401 Section 09 BODY/FRAME Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS BODY............................09-02-1 INSTALLATION AND ADJUSTMENT ................09-02-1 HEADLAMP BEAM AIMING....................09-02-1 BULB REPLACEMENT ....................... 09-02-1 DECAL ..........................09-02-2 BELT GUARD ........................09-02-2 WIRING HARNESS ......................09-02-2 CABLES ..........................09-02-2 TUBING ..........................
Page 402: Body
Section 09 BODY/FRAME Subsection 02 (BODY) BODY INSTALLATION AND BULB REPLACEMENT ADJUSTMENT Tundra If headlamp is burnt, tilt hood. Unplug connector HEADLAMP BEAM AIMING from headlamp. Remove protector cap and unfas- Beam aiming is correct when center of high beam ten bulb retainer clips.
Page 403: Decal
Section 09 BODY/FRAME Subsection 02 (BODY) BELT GUARD Skandic LT/SWT/WT LC/SUV 550/SUV 600 If headlamp bulb is burnt, tilt hood. Disassembly and Assembly Remove latches retaining plastic cover. Temporary reinstall the top two latches to retain windshield NOTE: For additional information (ex.: exploded during bulb replacement.
Page 404: Plastic Maintenance And Repair
Section 09 BODY/FRAME Subsection 02 (BODY) PLASTIC MAINTENANCE AND REPAIR REPAIR The very first step before repairing plastic materi- als is to find out exactly which type of material is MAINTENANCE involved. Refer to following chart. CAUTION: Consult chart and repair kit instruc- Clean the vehicle thoroughly, removing all dirt and tions carefully, some repair products are not grease accumulation.
Page 405: Repair Procedure For R.i.m. Urethane
Section 09 BODY/FRAME Subsection 02 (BODY) REPAIR PROCEDURE FOR R.I.M. Large Crack URETHANE – Sand and scuff outside and inside area by ex- ceeding it 31.7 mm (1-1/4 in) on each side and R.I.M. urethane is light colored (tan) on the inside 12.7 mm (1/2 in) at each end.
Page 406: Frame
Section 09 BODY/FRAME Subsection 03 (FRAME) FRAME FRAME CLEANING CAUTION: Before performing electrical welding anywhere on the vehicle, unplug the multiple NOTE: For bare aluminum frames use only alumi- connector at the electronic box. On models num cleaner and follow instructions on container. equipped with a battery, also unplug the nega- (Dursol cleaner or equivalent).
Page 407 Section 10 TECHNICAL DATA Subsection 01 (SI METRIC INFORMATION GUIDE) TECHNICAL DATA SI* METRIC INFORMATION GUIDE BASE UNITS DESCRIPTION UNIT SYMBOL length ............... meter ........... mass ..............kilogram ..........force ..............newton ..........liquid ..............liter ............temperature ............. Celsius ..........°C pressure ............
Page 408 Section 10 TECHNICAL DATA Subsection 02 (ENGINES) VEHICLE MODEL TUNDRA SKANDIC LT/LT E ENGINE TYPE Number of Cylinders Bore mm (in) 72.00 (2.835) 67.5 (2.6575) Stroke mm (in) 66.00 (2.598) 61.0 (2.402) Displacement 268.7 (16.40) 436.6 (26.64) ➀ ± 100 RPM 6900 Maximum Power Engine Speed Piston Ring Type...
Page 409 Section 10 TECHNICAL DATA Subsection 02 (ENGINES) VEHICLE MODEL SKANDIC WT/SWT/SUV 550 SKANDIC WT LC/SUV 600 ENGINE TYPE Number of Cylinders Bore mm (in) 76.00 (2.992) Stroke mm (in) 61.0 (2.402) 65.8 (2.591) Displacement 553.4 (33.78) 597.0 (36.43) ➀ ± 100 RPM 6950 7000 Maximum Power Engine Speed...
Page 410 Chain Drive Ratio 17/44 14/25 Pitch Chain Type/Links Qty/Plates Qty Single/62 Silent 70/11 Type of Drive Pulley Bombardier Lite Comet Ramp Identification N.A. 218311C ➀ 1143 – 1 x C, 5 x S3.4 – Calibration Screw Position or Calibration Part...
Page 411 17/44 N.A. Pitch N.A. Chain Type/Links Qty/Plates Qty Silent 70/11 N.A. Type of Drive Pulley Comet Bombardier Lite Ramp Identification 218311C – ➀ Calibration Screw Position or Calibration Part – 1 x S21, 4 x S3.4 Drive Pulley Spring Color...
Page 412 Pitch N.A. N.A. N.A. Chain Type/Links Qty/Plates Qty N.A. N.A. N.A. Type of Drive Pulley Bombardier Lite TRA III Bombardier Lite ➃ Ramp Identification – – ➀ 1 x S21, 4 x S3.4 1 x S21, 4 x S3.4 Calibration Screw Position or Calibration Part...
Page 413 Section 10 TECHNICAL DATA Subsection 03 (VEHICLES) VEHICLE MODEL SKANDIC SUV 600 ENGINE TYPE Chain Drive Ratio N.A. Pitch N.A. Chain Type/Links Qty/Plates Qty N.A. Type of Drive Pulley TRA III ➃ Ramp Identification ➀ Calibration Screw Position or Calibration Part Drive Pulley Spring Color Yellow/Red...
Page 414 (1 parts of antifreeze celerate the vehicle at low speed (maximum for 1 parts of distilled water). Bombardier pre- 30 km/h (20 MPH)) and apply the brake; repeat mixed coolant - 37°C (- 35°F) (16 x 1 L) (P/N 293 5 times.
Page 415 Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) WIRING DIAGRAMS Wiring diagrams can be found at the end of this sub- section. WIRING DIAGRAM LEGEND WARNING Ensure all terminals are properly crimped on the wires and all connector housings are prop- erly fastened.
Page 416 Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Following table shows wire colors related to electrical circuits. WIRE COLOR ELECTRICAL CIRCUIT ADDITIONAL INFORMATION ENGINE SHUT OFF – key switch BLACK/YELLOW Must be grounded to stop engine. – tether cord switch –...
Page 417 Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) CONNECTOR HOUSING AREA HOUSING REFERENCE PER AREA Tundra Only Tundra Only The first digit of the connector identification num- The next two letters of the connector identification ber presents the location of the connector on the number represent a connector reference.
Page 418 Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) 11-01-4 MMR2004-145_11_01A.FM...
Page 419 Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) SYMBOLS DESCRIPTION 11-01-5 MMR2004-145_11_01A.FM...
Page 420 Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) UNPLUGING CONNECTORS To remove: – Insert a screwdriver or Snap-on TT 600-5 from op- Always unplug connectors by pulling on housing not posite side of wire and pry locking tab. on wire. –...
Page 421 Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Waterproof Connector Housing Female Connector Housing To remove: – Insert tool Snap-on TT 600-5 under lock and twist to lift it. 1. Lock – Pry tab to free connector then pull wire out of housing.
Page 422 Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) A00E1FA TYPICAL 1. Receptacle 2. Housing 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 423 A29Z09 A05Z02...
Page 424 2004 SKANDIC LT 440 WH/YL BU/YL WH/YL BU/YL KEY SWITCH REGULATOR/ RECTIFIER MPEM START 50 OHMS FUSE 0.25A RD 1.5 RD/GN 1.5 IGNITION SYSTEM POWER SUPPLY STARTER AND IGNITION SWITCHES LIGHTING INSTRUMENTS HEATING ELEMENTS A29Z0C...
Page 425 2004 SKANDIC WT LC, SKANDIC SUV 600 WH/YL BU/YL RD 2.5 BK/RD 50 OHMS REGULATOR/ KEY SWITCH MPEM RECTIFIER START WH/RD 2.5 0.25A RD/GN 1.5 NO 1.5 IGNITION SYSTEM POWER SUPPLY STARTER AND IGNITION SWITCHES LIGHTING INSTRUMENTS HEATING ELEMENTS A29Z0D...
Page 426 2004 SKANDIC WT, SKANDIC SWT, SKANDIC SUV 550 RD 2.5 KEY SWITCH 50 OHMS REGULATOR IGNITION START MODULE WH/RD 0.25A RD/GN 1.5 IGNITION SYSTEM POWER SUPPLY STARTER AND IGNITION SWITCHES LIGHTING INSTRUMENTS HEATING ELEMENTS A29Z0E...

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