Page 2 ® 1998 Shop Manual VOLUME 1 TUNDRA II LT TOURING E/LE FORMULA S/S ELECTRIC/SL SKANDIC 380/500...
Page 3 Legal deposit: National Library of Quebec trimester 1997 National Library of Canada1997 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 1997 Technical Publications Bombardier Inc.
Page 4: Table Of Contents
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 LUBRICATION 01 – Lubrication and maintenance chart .......... 02-01-1 AND MAINTENANCE TROUBLESHOOTING 01 – Table of contents..............03-01-1 02 –...
Page 5 TABLE OF CONTENTS SECTION SUBSECTION PAGE STEERING/ 01 – Table of contents ..............08-01-1 FRONT SUSPENSION 02 – Steering system............... 08-02-1 03 – Suspension and ski system ............. 08-03-1 BODY/FRAME 01 – Table of contents ..............09-01-1 02 – Body..................09-02-1 03 –...
Page 6: Safety Notice
SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair some 1998 Ski-Doo snowmo- biles. See model list on next page. This edition was primarily published to be used by snowmobile mechanics who are already familiar with all service procedures relating to Bombardier made snowmobiles.
Page 7: Introduction
INTRODUCTION INTRODUCTION This Shop Manual VOLUME 1 covers the follow- Touring E/LE ing Bombardier made 1998 snowmobiles: Skandic 380/500 Formula S/SL MODEL MODELS NUMBER These are S-Series models. TUNDRA* II LT ........ 3270 SKANDIC* 380 (Canada) ....1240 SKANDIC* 380 (U.S.) ...... 1241 SKANDIC* 380 (Europe) ....
Page 8 INTRODUCTION ENGINE SERIAL NUMBER Engine Serial Number Location A03A0BA TYPICAL — FAN-COOLED ENGINES 1. Engine serial number ARRANGEMENT OF THE MANUAL The manual is divided into 11 major sections: 01 SERVICE TOOLS AND SERVICE PRODUCTS 02 LUBRICATION AND MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 TRANSMISSION 06 ELECTRICAL...
Page 9 INTRODUCTION LIST OF ABBREVIATIONS USED Min. minimum IN THIS MANUAL milliliter millimeter ampere mile per hour ampere newton A•h ampere-hour N.A. not applicable alternate current number bottom dead center 00.0 continuity BTDC before top dead denter overload (open circuit) °C Celsius O.D.
Page 10 INTRODUCTION This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog. TYPICAL PAGE Page heading indicates section and subsection detailed. Subsection title indicates beginning of the Section 07 REAR SUSPENSION subsection. Subsection 01 (SUPENSION SC-10 SPORT, TOURING AND MOUNTAIN) SUSPENSION SC-10 SPORT, TOURING AND MOUNTAIN...
Page 11 INTRODUCTION TYPICAL PAGE Section 05 TRANSMISSION Subsection 03 (DRIVEN PULLEY) Title indicates Turn puller handle and sliding half at once to extract main procedure INSTALLATION the bushing. to be carried-out. Countershaft CAUTION Always apply anti-seize lubricant (P/N 413 7010 Italic bold face type 00) on the countershaft before final pulley setting indicates a installation.
Page 12 INTRODUCTION GENERAL INFORMATION CAUTION The information and component/system descrip- Most components of those vehicles are built tions contained in this manual are correct at time with parts dimensioned in the metric sys- of publication. Bombardier Inc. however, main- tem. Most fasteners are metric and must not tains a policy of continuous improvement of its be replaced by customary fasteners or vice- products without imposing upon itself any obliga-...
Page 13 INTRODUCTION TIGHTENING TORQUES N•m FASTENER SIZE (8.8) Lbf•ft Tighten fasteners to torque mentioned in explod- ed views and text. When they are not specified refer to following table. N•m FASTENER SIZE (8.8) Lbf•in N•m FASTENER SIZE (8.8) Lbf•ft...
Page 14 INTRODUCTION N•m FASTENER SIZE (8.8) Lbf•ft N•m FASTENER SIZE (8.8) Lbf•ft TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS...
Page 15 Bombardier SERVICE PUBLICATIONS REPORT Publication title and year ________________________ 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 16 AFFIX PROPER POSTAGE Bombardier Inc. Technical Publications After Sales Service Valcourt, (Quebec) Canada, J0E 2L0 AFFIX PROPER POSTAGE Bombardier Inc. Technical Publications After Sales Service Valcourt, (Quebec) Canada, J0E 2L0 AFFIX PROPER POSTAGE Bombardier Inc. Technical Publications After Sales Service Valcourt, (Quebec) Canada, J0E 2L0...
Page 17: Service Tools And Service Products
Subsection 01 (SERVICE TOOLS) SERVICE TOOLS This is a list of tools to properly service Ski-Doo snowmobile models specified on cover page. The list includes both the mandatory tools and the optional tools that are ordered separately. The list of Service Products, both mandatory and optional, are not part of any kit and must all be ordered separately.
Page 18 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE — MANDATORY SERVICE TOOLS Hose pincher (2) Engine leak tester kit Rubber pad (P/N 529 0099 00) (P/N 861 7491 00) (P/N 529 0234 00) A01B4C4 A01B2I4 APPLICATION APPLICATION All cageless bearing engines (277 All vehicles.
Page 19 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — RECOMMENDED SERVICE TOOLS The following tools are highly recommended to optimize your basic tool kit and reduce repair time. 1-2) Crankshaft bearing Use with crankshaft bearing pullers (P/N 420 8762 98) or puller with screw (P/N 420 8776 35).
Page 20 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — RECOMMENDED SERVICE TOOLS Piston circlip installer Magneto coil centering Crankshaft distance ring gauge (12.7 mm) A) (P/N 529 0169 00) (P/N 420 8769 22) (P/N 420 8768 24) Piston circlip A01B1P4...
Page 21 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — RECOMMENDED SERVICE TOOLS Circuit tester Dial indicator MAG seal pusher (continuity light) (TDC gauge) (P/N 420 2778 75) (P/N 414 0122 00) (P/N 414 1047 00) A00C0V4 APPLICATION A00C214...
Page 22 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) TRANSMISSION — MANDATORY SERVICE TOOLS Clutch holder Forks (3) Spring scale hook (long) (P/N 529 0064 00) (P/N 529 0055 00) (P/N 529 0309 00) A01B154 APPLICATION All TRA drive pulleys. A00B4A4 A16B014 Clutch holder...
Page 23 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) TRANSMISSION (continued) — MANDATORY SERVICE TOOLS Spring compressor Countershaft bearing Spring cover tool installer (P/N 529 0186 00) (P/N 529 0273 00) (P/N 529 0302 00) Parts included in the kit: 1) Spring compressor (P/N 529 0151 00) A01B4M4...
Page 24 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) TRANSMISSION (continued) — RECOMMENDED SERVICE TOOLS The following tools are highly recommended to optimize your basic tool kit and reduce repair time. Cam pusher Transmission adjuster (P/N 529 0129 00) (P/N 529 0303 00) A03D1T4 APPLICATION...
Page 25 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) SUSPENSION — MANDATORY SERVICE TOOLS Shock spring removal kit (P/N 529 0271 00) Replacement clevis pin (P/N 414 5284 00) A01B4O4 APPLICATION All suspensions with coil spring. 01-01-9...
Page 26 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) SUSPENSION (continued) — RECOMMENDED SERVICE TOOLS A) Track cleat remover Camber angle tool Track cleat installer (P/N 529 0082 00) (P/N 529 0216 00) A) (P/N 529 0085 00) Narrow NOTE: Angle finder with a mag- Pins...
Page 27 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) SUSPENSION (continued) — RECOMMENDED SERVICE TOOLS Spring installer (bar) (P/N 529 0050 00) A00C1I4 APPLICATION Tundra II LT and S-Series. Drive axle holder (P/N 529 0072 00) A01B1E4 APPLICATION All models.
Page 28 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 01 (SERVICE TOOLS) VEHICLES — RECOMMENDED SERVICE TOOLS Protective mat (P/N 529 0306 00) A01B45W APPLICATION All models. Dolly Snowmobile jack (P/N 529 0299 00) (P/N 529 0200 00) A01A1JJ A00B4CJ APPLICATION APPLICATION All models.
Page 29 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) SERVICE PRODUCTS NOTE: The numbers outlined in black (example: ) are reference to tool numbers from other divisions (Sea-Doo Watercraft and/or Sea-Doo Jet Boats). Matching reference numbers indicate the same tool is being used, even if the part numbers are different.
Page 30 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) MANDATORY SERVICE PRODUCTS (continued) ® Loctite primer (P/N 413 7081 00) ® Loctite 764-56 Primer N 170 g (6 oz) A00B3N4 APPLICATION To prepare mating surfaces before applying paste gasket, retaining compound or threadlockers.
Page 31 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS Silicone dielectric grease Synthetic chaincase oil Injection oil (3 oz) (12 x 355 mL) (P/N 413 8029 00) (P/N 413 7017 00) (P/N 413 8033 00) (12 x 1 liter) (P/N 413 8030 00) (3 x 4 liter)
Page 32 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS (continued) Bombardier-Rotax Formula XP-S Bearing grease Degreaser synthetic injection oil (400 g) (P/N 413 7084 00) ® (P/N 413 7105 00) (P/N 413 7061 00) Permatex 48 TA (12 x 1 liter) 433 g (15 oz)
Page 33 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS (continued) Paint for frame touch-up BOMBARDIER LUBE Stripped threads (12 x 14 oz) repair kit (P/N 413 4010 00) (P/N 293 6000 16) (P/N 413 7086 00) Black semi-gloss (spray can) Loctite 81668...
Page 34: Lubrication And Maintenance Chart
Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) LUBRICATION AND MAINTENANCE CHART SYSTEM PART/TASK REFER TO Rewind Starter Lubrication and Rope Subsection 04-08 Condition Appropriate section: Engine Head Nuts See Top End Appropriate section: Engine Mount Nuts See ENGINE REMOVAL Appropriate section: Exhaust System...
Page 35 Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) SYSTEM PART/TASK REFER TO Drive Chain Tension Subsections 05-07 and 05-08 Countershaft Lubrication (S Series) Subsection 05-06 Chaincase/Gearbox Oil Level Subsections 05-07 and 05-08 Chaincase/Gearbox Oil Change Subsections 05-07 and 05-08 Lubrication of drive axle bearing Subsection 07-04 Handlebar Bolts.
Page 36 Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) NO. 1 ENGINE LUBRICATION All Models Restart engine and run at idle speed. Engine internal parts must be lubricated to protect Inject storage oil until the engine stalls or until a them from possible rust formation during the stor- sufficient quantity of oil has entered the engine age period.
Page 37 Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) A03I0GA TYPICAL 1. Inlet fuel line 2. Position of grommet when installing 3. Fuel filter Replace fuel filter. To facilitate the fuel line instal- lation, slide grommet on fuel line about 50 mm (2 in) away from elbow then install grommet on fuel tank and push elbow through grommet.
Page 38 Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) NO. 5 DRIVE BELT CONDITION To clean the entire vehicle, including metallic parts ® with a thin coat of grease, use Simple Green Inspect belt for cracks, fraying or abnormal wear from Sunshine Makers Inc., available at hardware (uneven wear, wear on one side, missing cogs, stores or at automotive parts retailer.
Page 39: Troubleshooting
Section 03 TROUBLESHOOTING Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS ENGINE ..........................03-02-1 ENGINE LEAK VERIFICATION FLOW CHART ..............03-02-10 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 40: Engine
Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) ENGINE The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM ENGINE BACKFIRES.
Page 41 Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM ENGINE SUDDENLY TURNS OFF. CONDITION NORMAL USE. Test/Inspection 1. Perform engine leak test. Refer to engine leak verification flow chart. Check possible piston seizure. a. Damaged gasket and/or seal. Replace defective parts. 2. “Four-corner” seizure of piston(s). a.
Page 42 Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) 4. Melted and/or perforated piston dome; melted section at ring end gap. a. When piston reaches TDC, mixture is ignited by heated areas in combustion chamber. This situation is due to an incomplete combustion of a poor quality oil. Clean residue accumulation in combustion chamber and replace piston(s).
Page 43 Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH MAXIMUM OPERATING RPM. CONDITION NORMAL USE. Test/Inspection 1. Check spark plug condition. a. Fouled spark plug(s). Replace. 2. Check if there is water in fuel. a.
Page 44 Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM ENGINE DETONATION AT MAXIMUM RPM. CONDITION NORMAL USE. Test/Inspection 1. Check which type of fuel is used. a. Octane number is too low and/or alcohol level is too high. Use recommended fuel type. 2.
Page 45 Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM IRREGULAR ENGINE IDLE. CONDITION NORMAL USE AFTER ENGINE WARM UP. Test/Inspection 1. Check primer. a. Fuel leaks at primer nipple which is mounted to carburetor. Replace. 2. Check choke. a. Choke plunger may be partially opened. Readjust.
Page 46 Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) 6. Check antifreeze concentration. a. Antifreeze concentration is too high. Adjust concentration according to Bombardier’s recommendations. 7. Check tank cap. a. Cap does not hold pressure. Replace. 8. Check carburetion. a. Improperly adjusted or inadequate carburetor components. Adjust according to specifications (refer to TECHNICAL DATA 10) or replace inadequate component(s).
Page 47 Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM ENGINE EQUIPPED WITH “RAVE”. ENGINE HESITATES AT MID-SPEED AND REACHES MAXIMUM PERFORMANCE ONLY AFTER A WHILE. CONDITION NORMAL USE. Test/Inspection 1. Check “RAVE” valve spring(s). a. Spring tension is too weak or spring(s) is (are) broken. Replace.
Page 48 Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM ENGINE PINGING. CONDITION NORMAL USE. Test/Inspection 1. Check fuel lines. a. Bent fuel lines (preventing fuel from flowing through). Relocate or replace fuel lines. 2. Check if carburetor(s) is (are) clean. a. Dirt prevents fuel from flowing through. Clean.
Page 49 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 AIR BUBBLES FOUND...
Page 50: 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 51 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 hose. Relocate or replace. 2. Check fuel filter. a.
Page 52 Section 03 TROUBLESHOOTING Subsection 03 (FUEL AND OIL SYSTEMS) SYMPTOM ENGINE RUNS OUT OF FUEL (OR LEAN MIXTURE). CONDITION NORMAL USE. Test/Inspection 1. Check fuel filter ball located in fuel tank. Ball must move freely. a. Corrosion due to oxidation at installation. Replace fuel filter.
Page 53: 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 54 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 play of driven pulley Woodruff key (aluminum frame models) a.
Page 55 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 10). 2.
Page 56 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. Insufficient pressure on belt sides. Replace bushing. 2. Check condition of drive pulley fixed half shaft. a.
Page 57 Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT WORN NARROW IN ONE SECTION. CONDITION NORMAL USE. Test/Inspection 1. Check if parking brake is released. a. Parking brake is engaged. Release parking brake. 2. Check track tension/alignment. a. Frozen or too tight track. Liberate track from ice or check track tension and alignment.
Page 58 Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT EDGE CORD BREAKAGE. CONDITION NORMAL USE. Test/Inspection 1. Check pulley alignment. a. Pulley misalignment. Align pulley according to specifications (refer to TECHNICAL DATA 10). A00DOFY SYMPTOM FLEX CRACKS BETWEEN COGS. CONDITION NORMAL USE.
Page 59 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 tag. Replace. 2. Check mobile pad stud. a. Stud rotates in pad. Replace.
Page 60 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. 03-04-8...
Page 61: 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 62 Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) 9. Check height of commutator mica. a. Commutator mica too high. Undercut mica. 10. Check field coil resistance. a. Shorted field coil. Repair or replace yoke. 11. Check armature resistance. a. Shorted armature. Repair or replace armature.
Page 63 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 64 Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) 4. Check ignition switch. a. Defective contacts in ignition switch. Replace. 5. Check solenoid of electric starter. a. Shorted solenoid wiring harness or eroded contact washer. Replace. SYMPTOM HEADLAMP NOT LIGHTING. CONDITION WHITE BULB. Test/Inspection 1.
Page 65 Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) 5. Verify of optional electric accessories are overloading the magneto/generator. a. Excessive electrical load to magneto/generator. Reduce the electrical load by removing excess accessories. Reconnect as recommended by manufacturer. 6. Hot Grips brand : Verify if they were connected in parallel by mistake. a.
Page 66 Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM ENGINES DOES NOT START – NO SPARK AT SPARK PLUG. CONDITION AT ENGINE CRANKING. Test/Inspection 1. Verify spark plug condition. a. Defective, improperly set, worn-out, fouled. Identify source of problem and correct. Replace spark plug. 2.
Page 67 Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM ENGINE IS MISFIRING – ERRATIC SPARK AT SPARK PLUG. CONDITION RIDING ON WET SNOW. Test/Inspection 1. Verify if spark plug wires and/or spark plug cap seals are sealing-out moisture. a. Defective wires and/or seals. Replace defective part.
Page 68 Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM FOULED (BLACK) SPARK PLUG TIP. CONDITION NORMAL USE. Test/Inspection 1. Check carburetor(s). a. Carburetion is too rich. Adjust according to specifications (refer to TECHNICAL DATA 10). 2. Check injection oil consumption. a. Injection pump flow is too high. Adjust according to specification or replace.
Page 69 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 70: Suspension And Track
Section 03 TROUBLESHOOTING Subsection 06 (SUSPENSION AND TRACK) SUSPENSION AND TRACK The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM REAR SUSPENSION BOTTOMS OUT.
Page 71 Section 03 TROUBLESHOOTING Subsection 06 (SUSPENSION AND TRACK) SYMPTOM DERAILING TRACK. CONDITION NORMAL USE. Test/Inspection 1. Check track tension. a. Track is too loose. Adjust. 2. Check if track and slider shoes are properly aligned. a. Improper alignment. Adjust. SYMPTOM REAR SUSPENSION IS LOW OR TOO STIFF.
Page 72 Section 03 TROUBLESHOOTING Subsection 06 (SUSPENSION AND TRACK) SYMPTOM HANDLE BAR IS DIFFICULT TO TURN. CONDITION NORMAL USE. Test/Inspection 1. Check position of front spring adjustment cams. a. More pressure on the ground when cam increases spring preload. Reduce front spring preload. 2.
Page 73: Table Of Contents
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 74 Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) ENGINE DIMENSION MEASUREMENT ................04-04-6 CYLINDER TAPER....................... 04-04-6 CYLINDER OUT OF ROUND ....................04-04-6 USED PISTON MEASUREMENT..................04-04-6 CYLINDER/PISTON CLEARANCE ..................04-04-7 RING/PISTON GROOVE CLEARANCE ................04-04-8 RING END GAP........................04-04-8 CRANKSHAFT DEFLECTION ..................... 04-04-8 CONNECTING ROD BIG END AXIAL PLAY ..............
Page 75 Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) REWIND STARTER ........................ 04-08-1 REMOVAL........................... 04-08-3 DISASSEMBLY........................04-08-3 INSPECTION ........................04-08-3 ASSEMBLY......................... 04-08-3 INSTALLATION ........................04-08-5 CARBURETOR AND FUEL PUMP..................04-09-1 REMOVAL........................... 04-09-2 CLEANING AND INSPECTION..................04-09-2 IDENTIFICATION ....................... 04-09-2 DISASSEMBLY AND ASSEMBLY ..................04-09-2 CARBURETOR FLOAT LEVEL ADJUSTMENT ..............
Page 76: 277 Engine Type
Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) 277 ENGINE TYPE ENGINE REMOVAL AND INSTALLATION 48 N•m (35 lbf•ft) 48 N•m (35 lbf•ft) 21 N•m (15 lbf•ft) 25 N•m (18 lbf•ft) 48 N•m (35 lbf•ft) A05C0KS PARTS FLAT RATE 04-02-1...
Page 77: Removal From Vehicle
Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) REMOVAL FROM VEHICLE INSTALLATION ON VEHICLE Remove or disconnect the following then lift en- To install engine on vehicle, reverse removal pro- gine from vehicle: cedure. However, pay attention to the following: –...
Page 78: Top End
Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) TOP END 26 N•m (19 lbf•ft) 22 N•m (16 lbf•ft) Grease A05C0SS PARTS FLAT RATE 04-02-3...
Page 79: Troubleshooting
Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) TROUBLESHOOTING DISASSEMBLY Before completely disassemble engine, check air- 5, Piston tightness. Refer to LEAK TEST AND ENGINE DI- On this engine, piston pin needle bearing no. 6 is MENSION MEASUREMENT 04-04. mounted without a cage. NOTE: The following procedures can be done Use piston pin puller (P/N 529 0290 00) along with without removing the engine from chassis.
Page 80: Inspection
Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) Screw in puller in order to remove it from piston. – Grease thrust washers and install them on each end of needles. Remove piston from connecting rod. – Using a 21 mm (.826 in) diameter pusher, insert Install locating sleeve.
Page 81 Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) Remove piston pin puller and expansion sleeve. When installing new needle bearing, insert nee- dles with thrust washers. Instead of expansion sleeve, needles are held in place by 2 inner plastic cage halves. Use piston pin puller (P/N 529 0290 00) to insert piston pin.
Page 82: Bottom End
Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) BOTTOM END Lithium grease Anti-seize compound Lithium grease 22 N•m (16 lbf•ft) A05C0TT PARTS FLAT RATE 04-02-7...
Page 83: 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 met- al cleaner. DISASSEMBLY General To remove drive pulley, refer to DRIVE PULLEY...
Page 84 Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) Prior to installation, place bearings into an oil con- Using a press, install crankshaft into MAG side tainer and heat the oil to 75°C (167°F) for 5 to 10 crankcase half. min. This will expand bearings and ease installa- tion.
Page 85 Section 04 ENGINE Subsection 02 (277 ENGINE TYPE) Torque the screws no. 7 to 22 N•m (16 lbf•ft) fol- lowing illustrated sequence. A02C04A 04-02-10...
Page 86: 377, 443 And 503 Engine Types
Section 04 ENGINE Subsection 03 (377, 443 AND 503 ENGINE TYPES) 377, 443 AND 503 ENGINE TYPES ENGINE REMOVAL AND INSTALLATION 377 and 443 Engine Types Skandic 380 Touring E/LE Formula S 28 N•m (21 lbf•ft) 17 N•m (150 lbf•in) 37 N•m (27 lbf•ft) 35 N•m...
Page 87 Section 04 ENGINE Subsection 03 (377, 443 AND 503 ENGINE TYPES) 503 Engine Type 28 N•m (21 lbf•ft) 17 N•m (150 lbf•in) 37 N•m (27 lbf•ft) 35 N•m (26 lbf•ft) A03C13S PARTS FLAT RATE 04-03-2...
Page 88: Engine Removal And Installation
Section 04 ENGINE Subsection 03 (377, 443 AND 503 ENGINE TYPES) ENGINE REMOVAL AND INSTALLATION Disconnect or remove the following: WARNING Before disconnecting any electrical wire in starter system always first disconnect the BLACK negative battery cable (on electric starting models). –...
Page 89: Top End
Section 04 ENGINE Subsection 03 (377, 443 AND 503 ENGINE TYPES) TOP END 22 N•m 22 N•m (16 lbf•ft) (16 lbf•ft) 22 N•m (16 lbf•ft) 22 N•m (16 lbf•ft) Grease 503 S-Series only A23C05S 04-03-4 PARTS FLAT RATE...
Page 90: Cleaning
Section 04 ENGINE Subsection 03 (377, 443 AND 503 ENGINE TYPES) NOTE: The following procedures can be done NOTE: The PTO cylinder or fan housing have to without removing the engine from chassis. be removed to give access to MAG piston pin with the puller.
Page 91: Inspection
Section 04 ENGINE Subsection 03 (377, 443 AND 503 ENGINE TYPES) – Screw in puller in order to remove it from pis- ton. – Remove piston from connecting rod. – Install locating sleeve. Then push needle bear- ings along with thrust washers using a 21 mm (.826 in) diameter pusher.
Page 92 Section 04 ENGINE Subsection 03 (377, 443 AND 503 ENGINE TYPES) A01C01A 1. Exhaust All Engines Except 503 To center the piston pin with the connecting rod A21C01A bearing, use centering tool (P/N 529 0091 00). – Remove piston pin puller and expansion sleeve.
Page 93 Section 04 ENGINE Subsection 03 (377, 443 AND 503 ENGINE TYPES) At cylinder no. 4 and/or cylinder head no. 3 instal- lation, use aligning tool or exhaust manifold itself to ensure sealing of intake manifold and exhaust before tightening cylinder head nuts. ALIGNING TOOL ENGINE TYPE 377, 443 and 503...
Page 94 Section 04 ENGINE Subsection 03 (377, 443 AND 503 ENGINE TYPES) Position distance nuts no. 2 as illustrated. A03C1XA 1. Exhaust 2. Distance nuts Cross torque cylinder head nuts nos. 1 and 2 to 22 N•m (16 lbf•ft); torque each cylinder head indi- vidually.
Page 95: Bottom End
Section 04 ENGINE Subsection 03 (377, 443 AND 503 ENGINE TYPES) BOTTOM END Anti-seize lubricant Anti-seize lubricant Anti-seize lubricant 22 N•m (16 lbf•ft) 503: 22 N•m (16 lbf•ft) 377: 10 N•m (89 lbf•in) 22 N•m (16 lbf•ft) A03C1IS 04-03-10 PARTS FLAT RATE...
Page 96: Cleaning
Section 04 ENGINE Subsection 03 (377, 443 AND 503 ENGINE TYPES) NOTE: Engine must be removed from chassis to To check proper clearance between bearing no. 3 perform the following procedures. and counterweight, use feeler gauge (P/N 420 8766 20). Remove engine from chassis.
Page 97 Section 04 ENGINE Subsection 03 (377, 443 AND 503 ENGINE TYPES) For bearing lubrication purpose, a gap of 1.0 mm 503 Engine Type (.040 in) must be maintained between seals and Torque screws nos. 6, 7, 8 and 11 to 10 N•m (89 bearings.
Page 98: Leak Test And Engine Dimension Measurement
Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) LEAK TEST AND ENGINE DIMENSION MEASUREMENT LEAK TEST The following gives verification procedures for liq- 8. Rotate crankshaft so that piston goes to BDC uid cooled engines though it also applies to fan (Bottom Dead Center) on side where the cooled engines.
Page 99 Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Engine Check the following: 1. All jointed surfaces and screw/stud threads of engine: – spark plug base, insulator – cylinder head – cylinder base – crankcase halves (joint) – rotary valve cover –...
Page 100 Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) 4. Block both hoses of rotary valve gear lubrica- 1. Remove a spark plug or any plug of leak tester tion system with hose pinchers. kit on PTO side. If pressure drops, it indicates defective crank- shaft inner seal on PTO side.
Page 101: Finalizing Reassembly
Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) 4. Remove rotary valve cover and check for leak COOLING SYSTEM LEAK TEST of rotary valve seal with soapy water. Install special plug (radiator cap) (P/N 529 0214 00) and hose pincher (P/N 529 0099 00) on overflow hose.
Page 102: Engine Leak Verification Flow Chart
Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) ENGINE LEAK VERIFICATION FLOW CHART ENGINE LEAK VERIFICATION FLOW CHART PRESSURIZE ENGINE IS ENGINE LEAKING? CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS. MOUNTING FLANGES ETC. REPLACE GASKET OR O-RING, ANY LEAK FOUND? RE-SEAL LEAKING AREA CHECK SMALL OIL LINES OF INJECTION PUMP...
Page 103 Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) ENGINE DIMENSION MEASUREMENT This section covers all engine types. CYLINDER TAPER ENGINE TYPE MAXIMUM 0.08 mm (.003 in) Compare cylinder diameter 16 mm (5/8 in) from top of cylinder to just below its intake port area. On rotary valve engines, measure just below aux- iliary transfer port, facing exhaust port.
Page 104 Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) CYLINDER/PISTON CLEARANCE Used and New Pistons NOTE: Make sure used piston is not worn. See USED PISTON MEASUREMENT above. Take the measurement on the piston dome. F00B09A 1. Use the micrometer to set the cylinder bore gauge 2.
Page 105 Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Read the measurement on the cylinder bore gauge. The result is the exact piston/cylinder wall clearance. If clearance exceeds specified toler- ance, replace cylinder or rebore. Refer to TECHNI- CAL DATA 10.
Page 106 Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Crankshaft Deflection on PTO Side ENGINE DISTANCE A MAXIMUM ON PTO SIDE TYPE mm (in) mm (in) 377, 443 75.5 (2.972) 0.05 (.002) 82.5 (3.248) 0.06 (.002) Crankshaft Deflection on MAG Side MAXIMUM ON MAG SIDE ENGINE TYPE mm (in)
Page 107 Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) ENGINE NEW PARTS WEAR CAUTION TYPE MIN. - MAX. LIMIT Always install end-play adjustment shims 0.03 - 0.012 mm 0.015 mm on the magneto side between bearing and (.0001 - .0005 in) (.0006 in) crankshaft counterweight.
Page 108 Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) b. Measure the thickness of each bearing (M A01C0UA MEASURING M AND M 1. Bearing thickness c. Measure distance between bearing shoulders on crankshaft (M A01C0WA 1. End-play is adjusted with shims 2.
Page 109 Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) RECTIFYING SURFACES CHECKING CRANKSHAFT ALIGNMENT Stick a fine sand paper sheet on the surface plate then lightly oil the sand paper. Install a degree wheel (P/N 414 3529 00) on crank- shaft end.
Page 110: Cdi System
Section 04 ENGINE Subsection 05 (CDI SYSTEM) CDI SYSTEM NIPPONDENSO IGNITION SYSTEM WITH SINGLE GENERATING COIL 277 Engine Dielectric grease Dielectric grease Loctite 242 Loctite 242 Loctite Dielectric grease 90 N•m (66 lbf•ft) 7 N•m (62 lbf•in) Loctite A25C0OS PARTS FLAT RATE 04-05-1...
Page 111 Section 04 ENGINE Subsection 05 (CDI SYSTEM) NOTE: The following procedures can be done To remove magneto flywheel no. 9, install the without removing the engine from chassis. magneto puller (P/N 529 0225 00). CLEANING Clean all metal components in a non-ferrous met- al cleaner.
Page 112 Section 04 ENGINE Subsection 05 (CDI SYSTEM) – Remove screws. To replace lighting generator coil no. 7 – Uncrimp and unsolder BLACK/RED wire from – Heat the armature plate to 93°C (200°F) around coil terminal. the screw holes to break the threadlocker bond.
Page 113 Section 04 ENGINE Subsection 05 (CDI SYSTEM) – Position new coil, crimp and solder all wires. Position Woodruff key, magneto flywheel no. 9 and lock washer on crankshaft. no. 12 – Prior to assembly, apply Loctite 242 (blue). Clean nut threads and apply Loctite 242 (blue) be- Use magneto coil centering tool (P/N 420 8769 fore tightening nut no.
Page 114 Section 04 ENGINE Subsection 05 (CDI SYSTEM) DUCATI IGNITION SYSTEM 377, 443 and 503 Engines Dielectric grease Loctite 105 N•m (77 lbf•ft) Loctite 22 N•m (195 lbf•in) A07C03S PARTS FLAT RATE 04-05-5...
Page 115 Section 04 ENGINE Subsection 05 (CDI SYSTEM) NOTE: The following procedures can be done To remove magneto flywheel , install the no. 2 without removing the engine from chassis. magneto puller (P/N 529 0225 00). – Tighten puller bolt and at the same time, tap on CLEANING bolt head using a hammer to release magneto flywheel from its taper.
Page 116 Section 04 ENGINE Subsection 05 (CDI SYSTEM) ASSEMBLY Clean crankshaft extension (taper). Apply Loctite 242 (blue) on taper. Position Woodruff key, flywheel and lock washer on crankshaft. Clean nut threads and apply Loctite 242 (blue) be- fore tightening nut to 105 N•m (77 lbf•ft). At reassembly coat all electric connections with silicone dielectric grease (P/N 413 7017 00) to pre- vent corrosion or moisture penetration.
Page 117: Oil Injection System
Section 04 ENGINE Subsection 06 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM OIL INJECTION PUMP 277 Engine Loctite Grease Grease A05C07T PARTS FLAT RATE 04-06-1...
Page 118 Section 04 ENGINE Subsection 06 (OIL INJECTION SYSTEM) 377, 443 and 503 Engines Loctite Loctite 5 N•m 5 N•m (44 lbf•in) (44 lbf•in) Grease A03C17T 04-06-2 PARTS FLAT RATE...
Page 119 Section 04 ENGINE Subsection 06 (OIL INJECTION SYSTEM) OIL PUMP IDENTIFICATION Different engines need different pumps. See identification on pump lever no. 7. CAUTION Always mount proper pump on engine. OIL PUMP ENGINE TYPE IDENTIFICATION 135 T 377 (Formula S) 420 8766 95 A10C01A 377 (Formula S Elec.,...
Page 120 Section 04 ENGINE Subsection 06 (OIL INJECTION SYSTEM) Retighten the adjuster nut. Check the small oil lines (between pump and in- take manifold). If required, fill the lines by running the engine at idle speed while holding the pump lever in fully open position. A15C1QA TYPICAL —...
Page 121 Section 04 ENGINE Subsection 06 (OIL INJECTION SYSTEM) Reconnect banjo fittings with a washers on each side, start engine and run at idle while holding the pump lever in fully open position. Oil columns must advance into small oil lines. A15C18A TYPICAL 1.
Page 122: Axial Fan Cooling System
Section 04 ENGINE Subsection 07 (AXIAL FAN COOLING SYSTEM) AXIAL FAN COOLING SYSTEM NOTE: For 277 engine radial fan cooling system, refer to CDI SYSTEM 04-05. 377, 443 and 503 Engines 13 N•m (115 lbf•in) 443 and 503 engines only 47 N•m (35 lbf•ft) A03C0WS...
Page 123 Section 04 ENGINE Subsection 07 (AXIAL FAN COOLING SYSTEM) NOTE: The following procedures can be done without removing engine from chassis. REMOVAL NOTE: To facilitate further disassembly, fan nut may be removed before removing fan housing. Remove rewind starter, starting pulley, trigger coil wire from 4-connector housing then fan housing ass’y.
Page 124 Section 04 ENGINE Subsection 07 (AXIAL FAN COOLING SYSTEM) Using a press, drive the fan shaft no. 9 out. Remove circlip no. 11 then remaining bearing. To install, press one bearing in place then install circlip and shims. Press the other bearing from op- posite side until it is flush with housing.
Page 125: Rewind Starter
Section 04 ENGINE Subsection 08 (REWIND STARTER) REWIND STARTER 277, 377 and 443 Molykote G-n Paste or Equivalent Silicone Compound Grease Silicone Compound Grease 10 N•m (89 lbf•in) A03C1GS PARTS FLAT RATE 04-08-1...
Page 126 Section 04 ENGINE Subsection 08 (REWIND STARTER) 503 Skandic 500 and Formula SL 10 N•m (89 lbf•in) 8 N•m Molykote G-n (71 lbf•in) paste or equivalent Silicone compound grease Silicone compound grease A21C08S 04-08-2 PARTS FLAT RATE...
Page 127 Section 04 ENGINE Subsection 08 (REWIND STARTER) REMOVAL WARNING Using a small screwdriver, extract rope knot from Since the spring is tightly wound inside the starter grip no. 15. Cut rope close to knot. Tie a guide it may fly out when rewind is handled. knot near starter.
Page 128 Section 04 ENGINE Subsection 08 (REWIND STARTER) Pull the rope out of the starter housing and tem- porarily make a knot to hold it. One turn preload will give 7 turns of tension when fully extended. A01C14A 1. Grease inside spring guide A01C0CA Position pawl no.
Page 129 Section 04 ENGINE Subsection 08 (REWIND STARTER) INSTALLATION On fan cooled models with oil injection pump, re- install oil pump on rewind starter assembly. Reinstall rewind starter assembly on engine. Thread starter rope no. 6 through rope guide when applicable. A03C0VA Prior to installing starter grip no.
Page 130: Carburetor And Fuel Pump
Section 04 ENGINE Subsection 09 (CARBURETOR AND FUEL PUMP) CARBURETOR AND FUEL PUMP Carburetors VM 30-193 VM 34-508 VM 34-511 VM 34-512 VM 34-513 VM 34-514 To other carburetor All carburetors except VM-30-193 A03C1WS PARTS FLAT RATE 04-09-1...
Page 131 Section 04 ENGINE Subsection 09 (CARBURETOR AND FUEL PUMP) REMOVAL NOTE: Install needle valve for snowmobile carbu- retor only. It is designed to operate with a fuel Remove air silencer(s). For S-Series, see BAT- pump system. TERY 06-05. Check throttle slide for wear. Replace as neces- Disconnect fuel inlet line.
Page 132 Section 04 ENGINE Subsection 09 (CARBURETOR AND FUEL PUMP) 2,3, E-clip and Needle 8, Main Jet Remove screws from needle retaining plate to The main jet installed in the carburetor has been withdraw the needle. selected for a temperature of -20°C (0°F) at sea level.
Page 133 Section 04 ENGINE Subsection 09 (CARBURETOR AND FUEL PUMP) Throttle slide openings Wide open Close 13,6, Pilot jet and air screw Throttle slide cut-away Needle taper and needle position Needle jet Main jet A00C04A VIEW FROM AIR INTAKE OPENING A01C5BA NOTE: For fine tuning refer to TECHNICAL DATA 1.
Page 134 Section 04 ENGINE Subsection 09 (CARBURETOR AND FUEL PUMP) NOTE: Do not obstruct hole in throttle slide when CARBURETOR ADJUSTMENTS installing needle retaining plate. This is important to allow air escaping through and thus allowing a quick response. A02C09A 1. Idle speed screw 2.
Page 135 Section 04 ENGINE Subsection 09 (CARBURETOR AND FUEL PUMP) CAUTION On twin carburetor models, make sure both carburetors start to operate simultaneously. Beside do not interchange carburetors, the jetting may be different on each side. A red dot is printed on one carburetor and on the engine.
Page 136 Section 04 ENGINE Subsection 09 (CARBURETOR AND FUEL PUMP) Throttle Slide Height Models mm (in) Tundra II LT, Skandic 380, 1.3 (.051) Touring E/LE, Formula S/S Electric Skandic 500, Formula SL, 1.5 (.059) Touring LE A00C3FA THROTTLE LEVER AGAINST HANDLE GRIP 1.
Page 137 Section 04 ENGINE Subsection 09 (CARBURETOR AND FUEL PUMP) CHOKE Touring E/LE, Skandic 380/500 and Formula S/S Elec./SL Choke Plunger Adjustment Set choke lever to fully open position. A01C5FA CUTAWAY (ENGINE SIDE SHOWN) 1. Choke plunger 2. Tool properly seated under choke plunger If tool tip does not seat under choke plunger no.
Page 138 Section 04 ENGINE Subsection 09 (CARBURETOR AND FUEL PUMP) A01C5IA 1. Choke cable adjustment nut 2. Choke plunger tool Tighten choke cable lock nut and reinstall protec- tor cap. Set choke lever to close and open positions and ensure that tool properly seats under plunger only when lever is set to fully open position.
Page 139 Section 04 ENGINE Subsection 09 (CARBURETOR AND FUEL PUMP) FUEL PUMP S-Series Tundra LT A00C48S 04-09-10 PARTS FLAT RATE...
Page 140 Section 04 ENGINE Subsection 09 (CARBURETOR AND FUEL PUMP) REMOVAL Install a hose pincher (P/N 529 0099 00) on fuel supply line close to pump inlet. A00C3CA HIGH-SUPPLY FUEL PUMP WITH TWIN OUTLETS 1. Inlet 2. Outlets A01B2JB 3. Impulse 1.
Page 141 Section 04 ENGINE Subsection 09 (CARBURETOR AND FUEL PUMP) CLEANING AND INSPECTION INSTALLATION The entire pump should be cleaned with general To install, inverse removal procedure. purpose solvent before disassembly. WARNING Fuel pump components should be cleaned in gen- eral purpose solvent and dried with compressed Pressure test to ensure there is no leak in air.
Page 142: Fuel Tank And Throttle Cable
Section 04 ENGINE Subsection 10 (FUEL TANK AND THROTTLE CABLE) FUEL TANK AND THROTTLE CABLE Fuel Tank Lines Models with Easy Action Throttle Lever WARNING When draining a fuel tank or when-ever a fuel line is disconnected, obstruct line with a hose pincher (P/N 529 0099 00) or equivalent device.
Page 143 Section 04 ENGINE Subsection 10 (FUEL TANK AND THROTTLE CABLE) Throttle Cable Retainer Tundra II LT Models The retainer must be pushed on the throttle han- dle tab until it sits properly. A02C0EA 1. Throttle handle 2. Retainer 3. Cable barrel 4.
Page 144 Section 05 TRANSMISSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS DRIVE BELT..........................05-02-1 1998 APPLICATION CHART ....................05-02-1 CLEANING ......................... 05-02-1 ROTATION DIRECTION...................... 05-02-1 DRIVE BELT DEFLECTION MEASUREMENT ..............05-02-2 DEFLECTION ADJUSTMENT.................... 05-02-3 DRIVE PULLEY........................05-03-1 BOMBARDIER LITE ......................05-03-1 GENERAL ...........................
Page 145 Section 05 TRANSMISSION Subsection 01 (TABLE OF CONTENTS) PULLEY DISTASNCE AND ALIGNMENT ................05-05-1 GENERAL..........................05-05-1 GENERAL PROCEDURE..................... 05-05-1 PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART ......... 05-05-3 BRAKE............................. 05-06-1 MECHANICAL BRAKE......................05-06-1 HYDRAULIC BRAKE ......................05-06-3 REMOVAL ........................... 05-06-4 DISASSEMBLY ........................05-06-5 CLEANING ..........................
Page 146: Drive Belt
Section 05 TRANSMISSION Subsection 02 (DRIVE BELT) DRIVE BELT 1998 APPLICATION CHART PART WIDTH (NEW) MINIMUM WIDTH MODEL ± 0.25 mm (.010 in) NUMBER (WEAR LIMIT) TUNDRA II LT 414 8276 00 33.3 mm (1-5/16 in) 30 mm (1-3/16 in) S-SERIES 415 0606 00 34.3 mm (1-27/64 in)
Page 147 Section 05 TRANSMISSION Subsection 02 (DRIVE BELT) DRIVE BELT DEFLECTION MEASUREMENT NOTE: The drive belt deflection measurement must be performed each time a new drive belt is installed. NOTE: To obtain an accurate drive belt deflection measurement, it is suggested to allow a break-in period of 50 km (30 mi).
Page 148 Section 05 TRANSMISSION Subsection 02 (DRIVE BELT) To do so, loosen the 4 chaincase retaining nuts, unlock and raise driven pulley support. A00D08A 1. Upper O-ring 2. Force 3. Lower O-ring 4. Reference rule 5. Deflection DEFLECTION ADJUSTMENT Tundra II LT Drive belt deflection is adjusted by moving chain- case.
Page 149 Section 05 TRANSMISSION Subsection 02 (DRIVE BELT) A15D0WA 1. Allen screw with jam nut Allen screws should be restrained while tighten- ing jam nut to prevent throwing adjustment out. Use drive belt tension adjuster (P/N 529 0087 00). 529 0087 00 A15B05B Restrain Allen screws with the wrench and tight- en nut with the socket using socket handle provid-...
Page 150: Drive Pulley
Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) DRIVE PULLEY BOMBARDIER LITE NOTE: This is a lubrication free drive pulley. Tundra II LT Loctite 271 128 N•m (95 lbf•ft) 95 N•m (70 lbf•ft) A05D0TS 05-03-1 PARTS FLAT RATE...
Page 151 Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) 377 Engine S-Series 128 N•m (95 lbf•ft) 95 N•m (70 lbf•ft) A03D2GT PARTS FLAT RATE 05-03-2...
Page 152 Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) GENERAL Insert drive pulley puller (P/N 529 0314 00) then remove drive pulley. Some drive pulley components (return spring, cal- ibration disk) can be changed to improve vehicle performance in high altitude regions. The High Al- titude Technical Data booklet (P/N 484 0686 00 and 484 0545 00 for binder) gives information about calibration according to altitude.
Page 153 Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) A05D0LA 1. Identify A03D2HA 2, Cap, Washer and Disk 1. Puller tool 2. Spring cover tool These are calibration parts. Refer to TECHNICAL Screw puller (hand tight) to hold spring cover and DATA 10. remove screws holding spring cover.
Page 154 Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) A05D0NA 1. Curved end 2. Spring cover slot A. 2 to 3 mm (1/16 to 1/8 in) All Models Tighten nut no. 8 to 128 N•m (95 lbf•ft). INSTALLATION Torque screw to 90 to 100 N•m (66 to 74 lbf•ft). Install drive belt and belt guard.
Page 155 Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) All Models NOTE: This is a lubrication free drive pulley. 12 N•m (106 lbf•in) Loctite 12 N•m Loctite Loctite (106 lbf•in) Loctite 10 N•m (89 lbf•in) Loctite 95 N•m (70 lbf•ft) 10 N•m (89 lbf•in) Repair kit A19D07T...
Page 156 Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) GENERAL NOTE: Sliding half can be removed while fixed half remains on crankshaft. Some drive pulley components (return spring, ramp) can be changed to improve vehicle perfor- WARNING mance in high altitude regions. The High Altitude Technical Data booklet (P/N 484 0686 00 and 484 Never use any type of impact wrench at 0545 00 for binder) gives information about cali-...
Page 157 Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) NOTE: To ease disassembly, forks (P/N 529 0055 00) should be used to hold slider shoes prior to removing governor cup. 529 0055 00 A16D01A 1. Puller A16B02A 2. Holding sliding half NOTE: No components marking is required be- 19, Spring Cover Ass’y fore disassembling this drive pulley since it has It is pushed by clutch spring pressure.
Page 158 Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) CLEANING CAUTION 5,6, Fixed and Sliding Half Do not use acetone to clean bushing. Clean pulley faces and shaft with fine steel wool and dry cloth. INSPECTION 5, Fixed Half and Crankshaft End Drive pulley should be inspected annually.
Page 159 Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) 529 0313 00 529 0313 00 529 0312 00 529 0312 00 A01D2MA A01D2OA 1. Note upper tool side CAUTION ASSEMBLY Bushing must be bonded with retaining NOTE: This drive pulley is lubrication free. Do not compound.
Page 160 Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) 15, Pin Torque screws to 10 N•m (89 lbf•in). Always use the same type of pin as originally 9,11,13,14, Screw, Lever Ass’y, Nut and installed when servicing. Different types have Cotter Pin different weights for calibration purpose. Refer to TECHNICAL DATA 10.
Page 161 Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) Assemble fixed and sliding halves. Note that fixed Install fork (P/N 529 0055 00) into slider shoe halves have different cone angle. Match cone an- grooves to maintain them for governor cup instal- gle with crankshaft.
Page 162 Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) INSTALLATION Recheck the torque of 90 to 100 N•m (66 to 74 lbf•ft). WARNING WARNING Do not apply anti-seize or any lubricant on After 10 hours of operation the transmission crankshaft and drive pulley tapers. system of the vehicle must be inspected to ensure the retaining screw is properly torqued.
Page 163 Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) Governor cup has 6 positions numbered 2 to 6. Note that in position 1 the number is substituted by a dot (due to its location on casting). See TECHNICAL DATA 10 for original setting. A16D0HA 1.
Page 164: Driven Pulley
Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) DRIVEN PULLEY Tundra II LT 13 N•m (115 lbf•in) Anti-seize lubricant (P/N 413 7010 00) A09D0QS PARTS FLAT RATE 05-04-1...
Page 165 Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) NOTE: Driven pulley components (support, cam, Disconnect oil injection supply line at injection shoes, etc.) can be serviced without removing the pump and plug line to prevent draining. whole driven pulley from chaincase. Refer to the Remove screws retaining rear engine support to following procedures but neither remove brake chassis.
Page 166 Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) 6,9, Sliding Half Bushing and Bushing To disassemble a worn bushing (small), use a press and a suitable pusher. A25D0LA 1. Install bushing from this side of sliding half A25D0KA 2. Bushing TYPICAL After bushing installation, try fixed half shaft in- side bushing.
Page 167 Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) 12, Fixed Half Shaft NOTE: If chaincase screws have been slackened, chaincase can be reinstalled to its initial position Thoroughly clean the fixed half shaft. Remove by securing driven pulley support before tighten- rust with no.
Page 168 Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) Spring Torsional Pre-Load To check spring pre-load adjustment, use spring scale hook (P/N 529 0065 00) and a spring scale. Install the hook on the sliding half, making sure the spring scale is perpendicular to the pulley axle. Take a measurement when opening driven pulley and another one when driven pulley begins to close after a rotation of 10 mm (3/8 in).
Page 169 Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) S-Series Anti-seize lubricant (P/N 413 7010 00) Loctite Loctite A15D1DS PARTS FLAT RATE 05-04-6...
Page 170 Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) REMOVAL CLEANING Remove belt guard and drive belt from vehicle. 6,7, Large Bushing and Small Bushing Remove the cap screw no. 13, lock washer During break-in period (about 10 hours of use), te- no.
Page 171 Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) Replace bushing(s) if worn more than specified. Install support plate (P/N 529 0311 03) inside slid- ing half. DRIVEN PULLEY BUSHING WEAR LIMIT Place puller (P/N 529 0311 02) below bushing. mm (in) Small bushing 38.30 (1.508) Large bushing...
Page 172 Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) 19, Cam Turn puller handle and sliding half at once to ex- tract the bushing. Coat cam interior with anti-seize lubricant. INSTALLATION 14,15, Countershaft and Anti-seize Lubricant 529 0313 00 CAUTION 529 0312 00 Always apply anti-seize lubricant (P/N 413 7010 00) on the countershaft before final pul- ley installation.
Page 173 Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) ADJUSTMENT Refer to PULLEY DISTANCE AND ALIGNMENT 05-05 to adjust pulley distance. Adjust drive belt 529 0065 00 height between pulley halves to obtain specified belt deflection. 5, Spring General It is usual to experience spring setting during breaking period of a new spring.
Page 174 Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) Pulley Alignment and Drive Belt Deflection Refer to PULLEY DISTANCE AND ALIGNMENT 05-05 and DRIVE BELT 05-02 to perform adjust- ments. CAUTION Drive belt and pulley adjustments must always be checked whenever pulleys have been re- moved, replaced or disassembled.
Page 175 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 belt guard and drive belt. is the space separating the drive and driven pulley By turning and pushing the sliding half, open the outside diameters (Z measurement).
Page 176 Section 05 TRANSMISSION Subsection 05 (PULLEY DISTANCE AND ALIGNMENT) Tundra II LT Only Refer to below chart for proper alignment tem- plate. Bottom of alignment template must not seat on shaft nor fixed half shoulder and shim(s). A25D0QA TYPICAL 1. Shaft 2.
Page 177 Section 05 TRANSMISSION Subsection 05 (PULLEY DISTANCE AND ALIGNMENT) PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART PULLEY ALIGNMENT OFFSET DISTANCE TEMPLATE MODEL + 0, − 1 mm ± 0.50 mm (+ 0, − .040 in) (.020 in) 37.0 36.0 0 to 1.5 mm Tundra II LT 529 0269 00 (1.460)
Page 178 Section 05 TRANSMISSION Subsection 05 (PULLEY DISTANCE AND ALIGNMENT) 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 179 Section 05 TRANSMISSION Subsection 05 (PULLEY DISTANCE AND ALIGNMENT) Pulley Distance Adjustment Method Engine Movement The engine support has slotted mounting holes. Move engine to obtain specified distance be- tween pulleys. Pulley Alignment Method Driven Pulley Movement When engine slotted mounting holes do not allow to set proper pulley offset X, adjust with shims (P/N 504 1082 00) between pulley and counter- shaft bearing support (pulley pushed toward...
Page 180 Section 05 TRANSMISSION Subsection 06 (BRAKE) BRAKE MECHANICAL BRAKE Tundra II LT 4 N•m (35 lbf•in) 24 N•m (18 lbf•ft) A05D0SS PARTS FLAT RATE 05-06-1...
Page 181 Section 05 TRANSMISSION Subsection 06 (BRAKE) Formula S/S Elec., Touring E and Skandic 380/500 Dielectric grease Anti-seize lubricant Anti-seize lubricant Loctite A03D27S PARTS FLAT RATE 05-06-2...
Page 182 Section 05 TRANSMISSION Subsection 06 (BRAKE) HYDRAULIC BRAKE Touring LE and Formula SL Loctite Anti-seize lubricant Black Max A03D26S PARTS FLAT RATE 05-06-3...
Page 183 Section 05 TRANSMISSION Subsection 06 (BRAKE) REMOVAL Countershaft Removal S-Series with Mechanical Brake Tundra II LT Proceed the same as for brake disc removal but The split caliper type brake should be removed unlock bearing collar on driven pulley side. from chaincase as an assembly.
Page 184 Section 05 TRANSMISSION Subsection 06 (BRAKE) – Loosen set screw and unlock collar no. 18 if bearing is needed to be disassembled. See 529 0301 00 above S-Series illustration and procedure. – Remove 3 retaining screws no. 20 from coun- tershaft bearing housing.
Page 185 Section 05 TRANSMISSION Subsection 06 (BRAKE) CLEANING Brake Disc Check for scoring, cracking or heat discoloration, Clean all metal components in a general purpose replace as required. Refer to DRIVEN PULLEY 05- solvent. Thoroughly dry all components before as- 04 for replacement procedures on Tundra II LT. sembling.
Page 186 Section 05 TRANSMISSION Subsection 06 (BRAKE) A03D13A A20D04A 1. Raised edge upward and same side of nuts 7, Brake Pad CAUTION After brake pads installation, brake disc must be centered in caliper. Apply brake then check for Positioning of rubber slider is important to proper brake disc positioning.
Page 187 Section 05 TRANSMISSION Subsection 06 (BRAKE) Countershaft Bearing Adjustment ADJUSTMENT S-Series Brake Insert countershaft (with brake disc) from chain- Models with Mechanical Brake case side through countershaft support (driven pulley side), then insert into chaincase. Fully depress brake handle several times to obtain 13 mm (1/2 in) between brake handle and handle- Install countershaft bearing no.
Page 188 Section 05 TRANSMISSION Subsection 06 (BRAKE) A06D0JA TYPICAL 1. Open bleeder 2. Clear hose to catch used brake fluid Brake Light Models with Mechanical Brake Except Tundra II LT Brake light should light up before brake pads touch brake disc. To adjust, unscrew nut no. 10 until brake light goes on.
Page 189 Section 05 TRANSMISSION Subsection 07 (CHAINCASE) CHAINCASE Tundra II LT Lithium grease A03D0QS PARTS FLAT RATE 05-07-1...
Page 190 Section 05 TRANSMISSION Subsection 07 (CHAINCASE) REMOVAL Remove the 4 cap screws no. 26 securing chain- case to frame. Save alignment shims no. 8 for in- Chaincase and driven pulley can be removed from stallation. the vehicle as an assembly. Release track tension, use drive axle holder (P/N Remove belt guard and drive belt.
Page 191 Section 05 TRANSMISSION Subsection 07 (CHAINCASE) INSTALLATION The chain length may be affected depending the combination of lower/upper sprockets as follows: Reverse removal procedure. Pay particular atten- tion to the following: GEAR RATIO/ CHAIN LENGTH CHART Torque castellated nut no. 7 to 14 N•m (124 lbf•in), slacken then retorque to 0.5 - 2.5 N•m (5 - GEAR CHAIN LENGTH...
Page 192 Section 05 TRANSMISSION Subsection 07 (CHAINCASE) ADJUSTMENT Pulley Alignment Refer to PULLEY DISTANCE AND ALIGNMENT 05-05. Track Tension and Alignment Refer to TRACK 07-05. PARTS FLAT RATE 05-07-4...
Page 193 Section 05 TRANSMISSION Subsection 07 (CHAINCASE) S-Series Without Reverse Gear Loctite Chaincase 45 to 75 N•m (33 to 55 lbf•ft) Loctite 46 N•m (34 lbf•ft) Loctite Loctite SYNTHETIC CHAINCASE OIL HUILE SYNTHÉTIQUE POUR CARTER A03D2OS PARTS FLAT RATE 05-07-5...
Page 194 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 exhaust pipe and muffler. ings, sprockets and chain tensioner components. WARNING WARNING Never remove exhaust components when...
Page 195 Section 05 TRANSMISSION Subsection 07 (CHAINCASE) 5,16, Sprockets 18, Circlip Position the sprockets with the writing facing the CAUTION chaincase cover. It is of the utmost importance to install the 27, Conical Spring Washer circlip otherwise damage to the chaincase Install washer with its concave side towards drive components may occur.
Page 196 Section 05 TRANSMISSION Subsection 07 (CHAINCASE) A03D2MA TYPICAL 1. Dipstick 2. Oil level 3. Level between marks NOTE: Chaincase must be in its proper position when checking oil level. ADJUSTMENT Pulley Alignment Refer to PULLEY DISTANCE AND ALIGNMENT 05-04. Track Tension and Alignment Refer to TRACK 07-05.
Page 197 Section 05 TRANSMISSION Subsection 08 (GEARBOX) GEARBOX Skandic 380/500 Grease Loctite 15 N•m (133 lbf•in) Grease 48 N•m (35 lbf•ft) Loctite 29 N•m (21 lbf•ft) 5 N•m Loctite (44 lbf•in) Loctite A03D17S PARTS FLAT RATE 05-08-1...
Page 198 Section 05 TRANSMISSION Subsection 08 (GEARBOX) DISASSEMBLY First remove 19-tooth reverse gear no. 18 and then remove reverse axle no. 20. NOTE: It is possible to see the sliding gear in mo- tion through oil gauge hole. Unbolt gear shift linkage from shifter. Unscrew cover screws no.
Page 199 Section 05 TRANSMISSION Subsection 08 (GEARBOX) Install drive axle with track then bearing and circlip Install chain no. 28, 44-tooth sprocket no. 34 and in chaincase bore. Install spacer no. 38 with its its spacer no. 38. Spacer’s large outer diameter large outer diameter against sprocket, 44-tooth must be against sprocket.
Page 200 Section 05 TRANSMISSION Subsection 08 (GEARBOX) 5,7,8, Screws and Locking Tab Tighten screws in a criss-cross sequence starting with the one above reverse axle. Install reverse axle screw and bend locking tab against screw head flat. Bolt shift linkage to shifter. ADJUSTMENT 28, Chain Fully tighten adjustment screw by hand, then...
Page 201 Section 05 TRANSMISSION Subsection 08 (GEARBOX) A06D1QA OIL CHANGE Place a container under bottom pan (gearbox side). A03A03A TYPICAL Unbolt gear shift linkage from fork axle. Unbolt 1. Dipstick and remove cover by separating it from housing and by moving it toward the front in order to re- Shifter can be put in reverse position to ease re- lease fork from sliding sprocket.
Page 202 Section 05 TRANSMISSION Subsection 09 (DRIVE CHAIN) DRIVE CHAIN GENERAL Bombardier drive chains exist in 2 types, for prop- er use refer to TECHNICAL DATA 10. A00D0RA TYPICAL 1. Rotation CHAIN SEPARATION When separating an endless chain, always use a chain bearing pin extractor.
Page 203 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 204 Section 06 ELECTRICAL Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS WIRING DIAGRAMS......................06-02-1 CHART CODES........................06-02-1 UNPLUGING CONNECTORS .................... 06-02-3 TAB AND RECEPTACLE CONNECTORS REMOVAL ............06-02-3 TAB AND RECEPTACLE CONNECTORS INSTALLATION ..........06-02-4 ACCESSORIES INSTALLATION ..................06-02-5 IGNITION TIMING ......................... 06-03-1 NIPPONDENSO CDI SYSTEM (WITHOUT TRIGGER COIL) ..........
Page 205 Section 06 ELECTRICAL Subsection 01 (TABLE OF CONTENTS) ELECTRIC STARTER ......................06-06-1 REMOVAL ........................... 06-06-2 DISASSEMBLY ........................06-06-2 CLEANING AND INSPECTION ..................06-06-4 ASSEMBLY ......................... 06-06-4 INSTALLATION ........................06-06-5 CLEANING AND INSPECTION ..................06-06-6 CLEANING .......................... 06-06-6 INSPECTION ........................06-06-6 SOLENOID SWITCH ......................
Page 206: Wiring Diagrams
Section 06 ELECTRICAL Subsection 02 (WIRING DIAGRAMS) WIRING DIAGRAMS ELECTRICAL WIRING HEADLIGHT TAILLIGHT SYSTEM MODEL DIAGRAM (watt) (watt) OUTPUT PAGE (watt) Tundra II LT Annex 1 60/55 hal. 8/27 Skandic 380/500 Annex 2 60/55 hal. 8/27 Formula S Annex 3 60/55 hal.
Page 207 Section 06 ELECTRICAL Subsection 02 (WIRING DIAGRAMS) Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch – Emergency switch BLACK (small) Ground for shut off BLACK (big)
Page 208: Unpluging Connectors
Section 06 ELECTRICAL Subsection 02 (WIRING DIAGRAMS) Connector Location To remove: – Insert a screwdriver or Snap-on TT 600-5 from Connectors on wiring diagrams carry the letter C opposite side of wire and pry locking tab. followed by a number. Use this code with wiring diagram legend to find connector location on vehi- –...
Page 209: Tab And Receptacle Connectors Installation
Section 06 ELECTRICAL Subsection 02 (WIRING DIAGRAMS) Waterproof Connector Housing Female Connector Housing To remove: – Insert tool Snap-on TT 600-5 under lock and twist to lift it. A01E34A 1. Lock – Pry tab to free connector then pull wire out of housing.
Page 210: Accessories Installation
Section 06 ELECTRICAL Subsection 02 (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 211: Ignition Timing
Section 06 ELECTRICAL Subsection 03 (IGNITION TIMING) IGNITION TIMING NIPPONDENSO CDI SYSTEM (WITHOUT TRIGGER COIL) 277 Engine Type The 277 engine type uses a single coil ignition system. Refer to CDI SYSTEM 04-05 for more in- formations. This section is mainly divided in 2 parts, the first one using a Top Dead Center gauge to verify the magneto flywheel timing mark position.
Page 212 Section 06 ELECTRICAL Subsection 03 (IGNITION TIMING) A05E03A 1. Fan cowl timing mark 2. Yellow fin A00B4FA If marks do not align, there is something wrong TIMING LIGHT (P/N 529 0319 00) with fan mounting. Check Woodruff key and fan. The ignition components are affected by temper- ature variation, therefore, timing must be checked CAUTION...
Page 213 Section 06 ELECTRICAL Subsection 03 (IGNITION TIMING) Connect tachometer wire to spark plug wire or IGNITION TIMING ADJUSTMENT aim tachometer toward spark plug wire without Timing is performed by moving armature plate, using any connection wire. clockwise to retard spark occurrence, counter- clockwise to advance.
Page 214 Section 06 ELECTRICAL Subsection 03 (IGNITION TIMING) In this case, turn armature plate clockwise. A25E0RB 1. Turn clockwise to retard When the yellow fin is on right side of fan cowl timing mark, it indicates retarded timing. In this case, turn armature plate counterclock- wise.
Page 215: Ducati Cdi System
Section 06 ELECTRICAL Subsection 03 (IGNITION TIMING) DUCATI CDI SYSTEM 377, 443 and 503 Engine Types Proper ignition timing is determined by trigger coil position. If for any reason, ignition timing accuracy is sus- pected, it can be verified as follows. Verifying Magneto Flywheel Timing Mark Position Prior to checking the timing, it may be necessary...
Page 216 Section 06 ELECTRICAL Subsection 03 (IGNITION TIMING) 5. Verify the position of the timing mark on the b. Maintain magneto flywheel so that previous magneto flywheel as follows: marks remain aligned. NOTE: When checking timing, certain procedures c. Scribe or punch a mark on magneto flywheel require that the magneto flywheel be turned in a so that it perfectly aligns with the arrow on clockwise direction, viewed facing the magneto/...
Page 217 Section 06 ELECTRICAL Subsection 03 (IGNITION TIMING) To check the ignition timing, refer to illustration and proceed as follows: NOTE: Engine should be cold when checking tim- ing. Do not idle engine for more than 20 seconds and make checks quickly. WARNING Place ski tips against a wall, raise rear of ve- hicle on a stand, so that track does not con-...
Page 218: Spark Plugs
Section 06 ELECTRICAL Subsection 04 (SPARK PLUGS) SPARK PLUGS NGK SPARK PLUG All Models NGK SPARK PLUG NUMBERING SYSTEM Bombardier is using the NGK spark plug type on all its snowmobile models. The heat range identification system is: Low number hot plug High number cold plug...
Page 219: Design Symbols Used In Ngk Spark Plugs
Section 06 ELECTRICAL Subsection 04 (SPARK PLUGS) DESIGN SYMBOLS USED IN NGK SPARK PLUGS PREFIX SUFFIX WIDE GAP 10: 1.0 mm (.040") 11: 1.1 mm (.044") B R 9 E S 13: 1.3 mm (.050") 14: 1.4 mm (.055") 15: 1.5 mm (.060") 20: 2.0 mm (.080") Thread Heat rating...
Page 220: Disassembly
Section 06 ELECTRICAL Subsection 04 (SPARK PLUGS) DISASSEMBLY CAUTION First unscrew the spark plug 1 turn. Severe engine damage might occur if a Clean the spark plug and cylinder head with pres- wrong heat range plug is used. surized air, then completely unscrew. A too “hot”...
Page 221: Spark Plug Installation
Section 06 ELECTRICAL Subsection 04 (SPARK PLUGS) SPARK PLUG INSTALLATION Prior to installation make sure that contact surfac- es of the cylinder head and spark plug are free of grime. 1. Using a wire feeler gauge, set electrode gap ac- cording to TECHNICAL DATA 10.
Page 222: Battery
Section 06 ELECTRICAL Subsection 05 (BATTERY) BATTERY REMOVAL Unfasten retaining strips. Open strips and lift battery protective boot. All Models Remove vent tube. WARNING Battery BLACK negative cable must always be disconnected first and connected last. WARNING Never charge or boost battery while in- stalled on vehicle.
Page 223: Inspection
Section 06 ELECTRICAL Subsection 05 (BATTERY) HYDROMETER TEST A17E0LA 1. Baking soda A17E0JA Remove corrosion from battery cable terminals 1. Specific gravity 1.260 and battery posts using a firm wire brush. A hydrometer measures the charge of a battery in terms of specific gravity of the electrolyte.
Page 224: Battery Storage
Section 06 ELECTRICAL Subsection 05 (BATTERY) EXAMPLE NO. 2 Clean battery casing and caps using a solution of Temperature above 27°C (80°F): baking soda and water. Do not allow cleaning so- Hydrometer Reading: 1.235 lution to enter battery, otherwise it will destroy the electrolyte.
Page 225 Section 06 ELECTRICAL Subsection 05 (BATTERY) 5. Readjust the electrolyte level to the UPPER LEVEL line. A17E0FA 1. Battery electrolyte A17E0RA 2. Remove caps and fill battery to UPPER LEVEL 1. Battery electrolyte line with electrolyte (specific gravity: 1.260 at 20°C (68°F)).
Page 226 Section 06 ELECTRICAL Subsection 05 (BATTERY) 7. Disconnect battery charger. A17E0HA A17E0IB 11. Readjust electrolyte level. 8. Test battery state of charge. Use a hydrometer. A17E0JA A17E0RA 1. Specific gravity 1.260 1. Battery electrolyte 9. Let battery settle for 1 hour. 12.
Page 227: Servicing
Section 06 ELECTRICAL Subsection 05 (BATTERY) – State of charge: Because the electrolyte is CAUTION nearly pure water in a completely discharged battery, it cannot accept current as well as elec- Do not allow cleaning solution to enter battery trolyte. This is the reason the battery will not interior since it will destroy the electrolyte.
Page 228 Section 06 ELECTRICAL Subsection 05 (BATTERY) – If the charging current is not up to a measurable For a service application and a permanent installa- amount at the end of about 10 hours, the bat- tion, both ammeter and rheostat can be built into tery should be replaced.
Page 229 Section 06 ELECTRICAL Subsection 05 (BATTERY) A03H1SA BATTERY CONNECTION 1. Vent tube on fitting Ensure that vent tube is not kinked or blocked then install protective boot over battery. Close and fasten retaining strips. Reinstall air silencer. Fasten spark plug cables to fan housing. Reinstall throttle cable to air silencer.
Page 230: Electric Starter
Section 06 ELECTRICAL Subsection 06 (ELECTRIC STARTER) ELECTRIC STARTER S-Series with Electric Starting A03E13S PARTS FLAT RATE 06-06-1...
Page 231: Removal
Section 06 ELECTRICAL Subsection 06 (ELECTRIC STARTER) REMOVAL Check the wear on bushing no. 18 by measuring the amount of radial play between the armature – Disconnect BLACK ground cable from battery. shaft and the bushing. – Disconnect RED positive cable from battery. The radial play should not exceed 0.20 mm (0.008 in).
Page 232 Section 06 ELECTRICAL Subsection 06 (ELECTRIC STARTER) Install bushing cover no. 19 then, using a punch, stake bushing cover in place. A19E05A 1. Cut close to connector Remove burrs with a file on the remaining welded portion. A19E02A 1. Stake bushing cover CAUTION 2.
Page 233: Cleaning And Inspection
Section 06 ELECTRICAL Subsection 06 (ELECTRIC STARTER) Install thrust washer against outer stop collar. CAUTION Place drive lever onto overrunning clutch then in- sert into drive housing. Do not overheat and quickly perform solder- ing to prevent solder from flowing to the brush through the wire.
Page 234: Installation
Section 06 ELECTRICAL Subsection 06 (ELECTRIC STARTER) A19E09A 1. Shorter stud 2. Bare wire INSTALLATION Make sure that starter and engine mating surfac- A09E0PA es are free of grime. Serious trouble may arise if 1. Screwdriver pulling starter pinion starter is not properly aligned. 2.
Page 235: Cleaning And Inspection
Section 06 ELECTRICAL Subsection 06 (ELECTRIC STARTER) CLEANING AND INSPECTION CLEANING CAUTION Armature starter yoke ass’y and drive unit assembly must not be immersed in cleaning solvent. Clean brushes and holder with a clean cloth F01H0RA soaked in solvent. Brushes must be dried thor- 1.
Page 236 Section 06 ELECTRICAL Subsection 06 (ELECTRIC STARTER) Field Windings and Brushes Test the Field Winding for Open Circuit Use growler test probes. Place one test probe on the negative brush and the other test probe on the yoke. If growler lamp does not turn on, the field winding has an open-circuit.
Page 237: Solenoid Switch
Section 06 ELECTRICAL Subsection 06 (ELECTRIC STARTER) A03E05A TYPICAL 1. New 2. Wear limit Overrunning Clutch The pinion of the overrunning clutch should turn smoothly in the clockwise direction, and should not slip in a counterclockwise direction. If defec- tive, replace. Check the pinion teeth for wear and damage.
Page 238: Testing Procedure
Section 06 ELECTRICAL Subsection 07 (TESTING PROCEDURE) TESTING PROCEDURE GENERAL Two types of ignition systems are found on ROTAX engines covered by this manual; both are Capaci- tor Discharge Ignition (CDI) systems. The follow- ing chart gives the engine types with their implemented system.
Page 239 Section 06 ELECTRICAL Subsection 07 (TESTING PROCEDURE) A17E0TA DUCATI CDI SYSTEM 1. Combined ignition module/ignition coil mounted on air silencer below carburetors 2. 4-wire connector 06-07-2...
Page 240: Nippondenso Cdi System Testing
Section 06 ELECTRICAL Subsection 07 (TESTING PROCEDURE) NIPPONDENSO CDI SYSTEM TESTING Tundra II LT Resistance Readings Place multimeter selector switch to Ω in order to IGNITION SYSTEM TESTING measure resistance. Readings must be within the SEQUENCE indicated range. Otherwise, the part is considered to be defective and must be replaced.
Page 241: Ignition Switch, Tether Cord Switch And Emergency Switch Testing
Section 06 ELECTRICAL Subsection 07 (TESTING PROCEDURE) 3. IGNITION SWITCH, TETHER If readings do not correspond to the above-men- tioned indications, replace switch. CORD SWITCH AND If readings are acceptable, check other switches. EMERGENCY SWITCH TESTING Emergency Switch Disconnect connector housing 1-04 from engine Unplug switch block connected to main wiring and check resistance as indicated in IGNITION ta- harness.
Page 242: Ignition Generator Coil Voltage Testing
Section 06 ELECTRICAL Subsection 07 (TESTING PROCEDURE) If readings do not correspond to the above men- tioned indications, replace switch. If readings are acceptable, check other switches. If none of these verifications are conclusive, the problem finds its source in the main wiring har- ness.
Page 243: High Voltage Coil Voltage Testing
Section 06 ELECTRICAL Subsection 07 (TESTING PROCEDURE) 6. HIGH VOLTAGE COIL VOLTAGE LIGHTING GENERATOR COIL TESTING VOLTAGE TESTING 1. Disconnect spark plug cap from spark plug. NOTE: The lighting generator coil is not part of the ignition system. It is a self-contained system 2.
Page 244 Section 06 ELECTRICAL Subsection 07 (TESTING PROCEDURE) IGNITION SYSTEM TESTING (Tundra II LT) Resistance Ω Part Test to be Wire Voltage V Note Multimeter performed color probe Value Multimeter Value Multimeter connection (Ohms) scale (Volts) scale Stop switch 1-04-1-F Running BK and No stop switch must be 00.0...
Page 245 Section 06 ELECTRICAL Subsection 07 (TESTING PROCEDURE) LIGHTING SYSTEM TESTING (Tundra II LT) Resistance Ω Part Test to be Wire Multimeter Voltage V Note performed color probe Value Multimeter Value Multimeter connection (Ohms) scale (Volts) scale Lighting 1-03-A-M YL and 0.05 - 00.0 generator...
Page 246: Ducati Cdi System Testing
Section 06 ELECTRICAL Subsection 07 (TESTING PROCEDURE) DUCATI CDI SYSTEM TESTING Série S Resistance Readings Place multimeter selector switch to Ω in order to IGNITION SYSTEM TESTING measure resistance. Readings must be within the SEQUENCE indicated range. Otherwise, the part is considered to be defective and must be replaced.
Page 247: Ignition Switch, Tether Cord Switch
Section 06 ELECTRICAL Subsection 07 (TESTING PROCEDURE) 3. IGNITION SWITCH, TETHER If readings do not correspond to the above-men- tioned indications, replace switch. CORD SWITCH AND If readings are acceptable, check other switches. EMERGENCY SWITCH TESTING Emergency Switch Disconnect connector housing 2-01 from engine, Unplug switch block connected to main wiring and using a multimeter, check resistance as indi- harness.
Page 248: General
Section 06 ELECTRICAL Subsection 07 (TESTING PROCEDURE) 4. Repeat operation 3 times. A05E09A TYPICAL If readings do not correspond to the above men- A03E1JA tioned indications, replace switch. 5. Compare readings with those appearing in the If readings are acceptable, check other switches. IGNITION table.
Page 249: Conclusion
Section 06 ELECTRICAL Subsection 07 (TESTING PROCEDURE) LIGHTING GENERATOR COIL VOLTAGE TESTING NOTE: The lighting generator coil is not part of the ignition system. It is a self-contained system used to supply current to the lighting system and to other devices working on alternating current. However, this system can be tested using a mul- timeter.
Page 250 Section 06 ELECTRICAL Subsection 07 (TESTING PROCEDURE) IGNITION SYSTEM TESTING (fan-equipped S-Series) Resistance Ω Part Test to be Wire Multimeter Voltage V Note performed color probe Value Multimeter Value Multimeter connection (Ohms) scale (Volts) scale Stop switch 2-01-D-M Running BK and No stop switch must be 00.0 —...
Page 251 Section 06 ELECTRICAL Subsection 07 (TESTING PROCEDURE) LIGHTING SYSTEM TESTING (fan-equipped S-Series) Resistance Ω Part Test to be Wire Multimeter Voltage V Note performed color probe Value Multimeter Value Multimeter connection (Ohms) scale (Volts) scale Lighting 2-01-B-F YL and 0.05 - 00.0 generator Power...
Page 252: Voltage Regulator Inspection
Section 06 ELECTRICAL Subsection 07 (TESTING PROCEDURE) VOLTAGE REGULATOR INSPECTION A faulty voltage regulator is often responsible for B) Voltmeter Test frequent burned bulbs. NOTE: Use a voltmeter able to read alternating current (AC). For accurate reading, use a RMS CAUTION voltmeter.
Page 253: Inspection Of Ac Circuit Isolation
Section 06 ELECTRICAL Subsection 07 (TESTING PROCEDURE) INSPECTION OF AC CIRCUIT ISOLATION All Electric Start Models If AC circuit is not isolated from frame, headlamp beam will weaken. INSPECTION Disconnect regulator/rectifier. Connect one digital ohmmeter probe (needle ohmmeter will not offer enough precision) to frame and other probe to YELLOW or YEL- LOW/BLACK magneto wires.
Page 254: Inspection Of Heating Elements
Section 06 ELECTRICAL Subsection 07 (TESTING PROCEDURE) INSPECTION OF HEATING ELEMENTS Handlebar Grip Heating Element All measurements must be performed at 21°C (70°F). HIGH YELLOW BLACK wire 8.73 to Throttle Lever Heating Element INTENSITY 10.67 ohms ORANGE wire Resistance Measurement YELLOW BLACK wire 17.7 to...
Page 255 Section 07 REAR SUSPENSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS TORQUE REACTION SUSPENSION..................07-02-1 COMPONENT REMOVAL ....................07-02-2 REMOVAL........................... 07-02-2 DISASSEMBLY AND ASSEMBLY ..................07-02-2 INSPECTION ........................07-02-3 RIDE ADJUSTMENT......................07-02-4 LUBRICATION ........................07-02-6 SC-10 SPORT AND TOURING SUSPENSION ..............07-03-1 COMPONENT REMOVAL AND INSTALLATION ..............
Page 256: Torque Reaction Suspension
Section 07 REAR SUSPENSION Subsection 02 (TORQUE REACTION SUSPENSION) TORQUE REACTION SUSPENSION Tundra II LT 19 N•m (168 lbf•in) 19 N•m (168 lbf•in) 48 N•m (35 lbf•ft) 24 N•m (18 lbf•ft) 48 N•m (35 lbf•ft) Loctite 11 N•m (97 lbf•in) Loctite 24 N•m Loctite...
Page 257: Component Removal
Section 07 REAR SUSPENSION Subsection 02 (TORQUE REACTION SUSPENSION) COMPONENT REMOVAL 9,10,12, Nut, Slotted Screw and Slider Shoe Lift rear of vehicle and support it off the ground. To replace a worn shoe, remove the front screw and stop nut, then slide the shoe rearward out of 5, Rear Arm the runner.
Page 258: Inspection
Section 07 REAR SUSPENSION Subsection 02 (TORQUE REACTION SUSPENSION) A07F02A 1. Flat head punch 2. Support A01F2MA 3. Runner 4. Metal block TYPICAL 1. Slider shoe NOTE: Rivets can be substituted with 3/16 in x 2. Molding line (this line is not the wear limit) A.
Page 259: Ride Adjustment
Section 07 REAR SUSPENSION Subsection 02 (TORQUE REACTION SUSPENSION) Adjust track tension/alignment. Refer to TRACK 07-05. RIDE ADJUSTMENT The front portion of rear suspension is adjustable for surface condition and steering effects. The stopper strap is adjustable for vehicle weight transfer control.
Page 260 Section 07 REAR SUSPENSION Subsection 02 (TORQUE REACTION SUSPENSION) A05F0OA A05F0FA RH SIDE – Turn adjustment cam by hand to the desired po- sition. – Reinstall spring on its support making sure that it sits in the groove of support. Stopper Strap The function of the stopper strap is to control the transfer of vehicle weight during acceleration and...
Page 261: Lubrication
Section 07 REAR SUSPENSION Subsection 02 (TORQUE REACTION SUSPENSION) For normal use, locate bolt through 3 hole from LUBRICATION strap end. Lubricate front and rear arms at grease fittings using synthetic grease (P/N 413 7115 00). WARNING NOTE: There are 4 grease fittings. Always torque the nut to 11 N•m (97 lbf•in).
Page 262: Sport And Touring Suspension
Section 07 REAR SUSPENSION Subsection 03 (SC-10 SPORT AND TOURING SUSPENSION) SC-10 SPORT AND TOURING SUSPENSION S-Series temp. grease temp. Loctite grease Loctite temp. 18 N•m grease (160 lbf•in) Loctite only Loctite Long track models only Loctite Loctite Loctite Short track models only Loctite A03F24S PARTS...
Page 263: Component Removal And Installation
Section 07 REAR SUSPENSION Subsection 03 (SC-10 SPORT AND TOURING SUSPENSION) COMPONENT REMOVAL AND REMOVAL INSTALLATION 19, Cam Lift rear of vehicle and support it off the ground. Decrease spring preload by turning LH cam clock- wise and RH cam counterclockwise. 1, Rear Arm Release spring tension by unfastening spring sup- port.
Page 264: Disassembly And Assembly
Section 07 REAR SUSPENSION Subsection 03 (SC-10 SPORT AND TOURING SUSPENSION) NOTE: To prevent cross shaft from turning when unscrewing screws assembled with threadlocker, proceed as follows: – Knock on screw head and/or heat to break threadlocker bond. – Loosen 1 screw then retighten. –...
Page 265: Inspection
Section 07 REAR SUSPENSION Subsection 03 (SC-10 SPORT AND TOURING SUSPENSION) Close and lock bar. Adjust handle horizontal by INSPECTION changing position of clevis pin. Shock Absorber Push down on handle until il locks. Remove spring stopper and cap then release handle. Refer to SUSPENSION AND SKI SYSTEM 08-03 At installation, cap opening must be 180°...
Page 266: Ride Adjustment
Section 07 REAR SUSPENSION Subsection 03 (SC-10 SPORT AND TOURING SUSPENSION) A03F0ZA 1. Spacer 18, Spring Support Install spring supports to rails. CAUTION To avoid track damage, spring supports must be mounted upward. A03F0UA 1. Stopper strap for weight transfer 2.
Page 267 Section 07 REAR SUSPENSION Subsection 03 (SC-10 SPORT AND TOURING SUSPENSION) Slight suspension bottoming occurring under the CAUTION worst riding conditions indicates a good choice of springs preload. Always turn the left side adjustment cams in To adjust rear suspension adjustment cams, use a clockwise direction and the right side cams multi wrench supplied in vehicle tool box.
Page 268: Lubrication
Section 07 REAR SUSPENSION Subsection 03 (SC-10 SPORT AND TOURING SUSPENSION) The longer the belt, the greater will be the track Deep Snow Operation lead angle. A shorter belt will reduce track lead When operating the vehicle in deep snow, it may angle which may help when negotiating a particu- be necessary to change position of adjustment lar snow condition.
Page 269: Drive Axle
Section 07 REAR SUSPENSION Subsection 04 (DRIVE AXLE) DRIVE AXLE Tundra II LT A05D03S S-Series 11 5 A03F1CS PARTS FLAT RATE 07-04-1...
Page 270: Removal
Section 07 REAR SUSPENSION Subsection 04 (DRIVE AXLE) REMOVAL All Models Drain oil from chaincase or gearbox. Remove chaincase cover and release drive chain tension (if applicable). Raise and block rear of vehicle off the ground. Remove suspension. (Refer to REAR SUSPEN- SION 07).
Page 271 Section 07 REAR SUSPENSION Subsection 04 (DRIVE AXLE) S-Series A00F07A 1. Pipe Tundra II LT A03F1DA A. 159.3 mm (6-17/64 in) B. 282.3 mm (11-7/64 in) All Models Ensure to align indexing marks of each sprocket when assembling. A00F08A TYPICAL 1.
Page 272: Axial Play
Section 07 REAR SUSPENSION Subsection 04 (DRIVE AXLE) A00F0AA A00F0DA 1. Plane surface The bearing on the splined side of axle must be A. 1.5 mm (1/16 in) MAXIMUM pushed until it is seated on shaft shoulder. The end bearing housing bearing must be flush with CAUTION end of drive axle.
Page 273 Section 07 REAR SUSPENSION Subsection 04 (DRIVE AXLE) CAUTION When installing one shim or more between chaincase and frame, secure with 50 mm long screws. BEARING POSITION TOWARD TOWARD TOWARD TOWARD FRONT OF REAR OF BOTTOM TOP OF VEHICLE VEHICLE OF VEHICLE VEHICLE SHIM...
Page 274 Section 07 REAR SUSPENSION Subsection 04 (DRIVE AXLE) AXIAL PLAY ADJUSTMENT A01D09A 1. No gap all around – Pull drive axle toward the end bearing housing and take note of the measurement between sprocket and tunnel. A01D04A The drive axle axial play is the difference between TOP VIEW these 2 measurements.
Page 275: Installation
Section 07 REAR SUSPENSION Subsection 04 (DRIVE AXLE) When installing shims between the chaincase and the drive axle bearing, there must be same quantity of shims between the drive chain sprock- et and spacer. A01D0AA 1. Distance between guide cleat and slider shoe 414 6053 00 2.
Page 276: Lubrication
Section 07 REAR SUSPENSION Subsection 04 (DRIVE AXLE) ADJUSTMENT Sprocket/Track Alignment CAUTION Do not temper with sprocket/track alignment if frame or suspension is damaged. Sprockets might be repositioned to fit track holes (lugs on S-Series) without removing drive axle. Use drive axle sprocket adjuster kit (P/N 861 7257 00).
Page 277: Track
Section 07 REAR SUSPENSION Subsection 05 (TRACK) TRACK TRACK TYPE APPLICATION S-Series Remove the following items: Refer to TECHNICAL DATA 10. – speedometer cable GENERAL – muffler – chaincase cover This section gives guidelines for track removal. Some components require more detailed disas- –...
Page 278 Section 07 REAR SUSPENSION Subsection 05 (TRACK) Tundra II LT 35 to 40 mm (1-3/8 to 1-9/16 in) when exerting a downward pull of 7.3 kg (16 lb). A01B4JA 1. Example 45 mm 2. Extrusion Insert pre-setted gauge between slider shoe and A05A01A track.
Page 279 Section 07 REAR SUSPENSION Subsection 05 (TRACK) All Models CAUTION Too much tension will result in power loss and excessive stress on suspension compo- nents. If too loose, the track will have a ten- dency to thump. To adjust, loosen the rear idler wheel retaining screws (1 side only on Tundra II LT and S-Series) A01F05A and the adjuster bolt lock nut;...
Page 280: Track Cleat
Section 07 REAR SUSPENSION Subsection 05 (TRACK) Installation NOTE: Keep the same pitch between guide cleats. – Place new cleat in position and using small track cleat installer (P/N 529 0085 00) for Tundra II LT or cleat installer (P/N 529 0288 00) for S- Series, bend cleat then push tabs into rubber.
Page 281 Section 08 STEERING/FRONT SUSPENSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS STEERING SYSTEM ......................08-02-1 INSPECTION ........................08-02-3 DISASSEMBLY AND ASSEMBLY ..................08-02-3 INSPECTION ........................08-02-4 ADJUSTABLE HANDLEBAR ..................... 08-02-5 STEERING ADJUSTMENT (SKIS) ..................08-02-6 LUBRICATION ........................08-02-10 SUSPENSION AND SKI SYSTEM ..................08-03-1 ON-VEHICLE COMPONENT REMOVAL................
Page 282: Steering System
Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) STEERING SYSTEM Tundra II LT 24 N•m 6 24 N•m (18 lbf•ft) (18 lbf•ft) 18 N•m 53 N•m (159 lbf•in) 7.5 N•m (39 lbf•ft) (66 lbf•in) 53 N•m (39 lbf•ft) 18 N•m (159 lbf•in) 18 N•m (159 lbf•in)
Page 283 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) S-Series 25 N•m (18 lbf•ft) 40 N•m (30 lbf•ft) 25 N•m (18 lbf•ft) 18 N•m (159 lbf•in) 18 N•m (159 lbf•in) 52 N•m (38 lbf•ft) 40 N•m (30 lbf•ft) 40 N•m (30 lbf•ft) 18 N•m (159 lbf•in) 18 N•m...
Page 284: Inspection
Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) INSPECTION Check skis and runner shoes for wear, replace as necessary. Refer to SUSPENSION AND SKI SYS- TEM 08-03. 17,36, Steering Arm and Ski Leg Make sure steering arm and ski leg splines inter- lock (if applicable).
Page 285: Inspection
Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) To install, stick heating element to handlebar mak- The cut-off section of the tie rod end must run par- ing sure wires do not interfere with operation of allel with the horizontal line of the steering arm accelerator or brake handle.
Page 286: Adjustable Handlebar
Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) 17,36, Steering Arm Lock the handle in place by tightening the 4 nuts to 26 N•m (19 lbf•ft). The steering arm angles should be equal on both sides when skis are parallel with vehicle. CAUTION Steering arm must run parallel to ski.
Page 287: Steering Adjustment (Skis)
Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) 7,23,24,25, Steering Pad, Bolt, Nut and Rubber Attachment CAUTION Prior to installation, perform handlebar ad- justment Properly fit the steering pad to the handlebar. As- semble using the 2 rubber attachments, nuts and bolts.
Page 288 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) A05G08A LONG TIE ROD SHOWN 1. Restrain tie rod to tighten lock nuts WARNING Ball joint sockets must run parallel with A05G0KA steering arm and pivot arm. Tie rod must be 1. Pivot arm centered in slot 2.
Page 289 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) NOTE: To make sure skis are in straight-ahead po- S-Series sition, place a straight edge against pre-adjusted Adjustments should be performed following this track and measure distance between front and sequence: rear of skis and straight edge. Distances should –...
Page 290 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) HANDLEBAR AND SKI TOE-OUT WARNING Check that handlebar is horizontal when skis are in straight ahead position by measuring from the Never lengthen tie rod so that threated por- extremities of the grips to the rear most edge of tion of ball joint exceeds 20 mm (25/32 in).
Page 291: Lubrication
Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) LUBRICATION WARNING Do not lubricate throttle and/or brake cable, housing and spring coupler bolts. The following symbols will be used to show what type of lubricant should be used at the suitable locations.
Page 292 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) S-Series If so equipped If so equipped A06G08T PARTS FLAT RATE 08-02-11...
Page 293: Suspension And Ski System
Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) SUSPENSION AND SKI SYSTEM Tundra II LT 13 N•m (115 lbf•in) Grease Grease Grease 29 N•m (21 lbf•ft) A05G0JS PARTS FLAT RATE 08-03-1...
Page 294: On-Vehicle Component Removal
Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) ON-VEHICLE COMPONENT Suspension Free Operation REMOVAL Remove cover and check for free movement of ski leg by lifting end of ski. 8, Shock DISASSEMBLY Lift front of vehicle and support off the ground. Unscrew shock piston pin nut then remove washer.
Page 295: Inspection
Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) 4,13,14,16,17, O-ring, Ski Leg, Bushing 13, Ski Leg and Seal Check that splines on ski leg and steering arm in- terlock properly with no excessive free play. Re- Pull up ski leg. Steering arm will not interfere. new as necessary.
Page 296: Installation
Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) INSTALLATION For assembly, reverse the disassembly proce- dure. However, pay attention to the following. Apply synthetic grease (P/N 413 7115 00) as illus- trated in exploded view above. Tighten nuts and screws to proper torque as men- tioned in exploded view.
Page 297 Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) S-Series Loctite 242 A03G0CS PARTS FLAT RATE 08-03-5...
Page 298: Disassembly
Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) DISASSEMBLY 5, Shock Lift front of vehicle and support it off the ground. On models so equipped reduce spring preload by turning adjusting ring accordingly with special key in vehicle tool box. A03F12A 1.
Page 299: Inspection
Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) INSPECTION 9,10,11, Bolt, Nut and Link Plate Attach link plate to frame with additional nuts and Check all rubber cushions for crack and wear. Re- bolts, if applicable. place as required. Check straightness of splines and proper inter- locking with steering arm.
Page 300 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 WINDSHIELD INSTALLATION................... 09-02-2 BELT GUARD ........................09-02-2 WIRING HARNESS ......................09-02-3 CABLES ..........................
Page 301: Body
Section 09 BODY/FRAME Subsection 02 (BODY) BODY INSTALLATION AND ADJUSTMENT HEADLAMP BEAM AIMING Required Conditions Place the vehicle on a flat surface perpendicular to Beam aiming is correct when center of high beam test surface (wall or screen) and 381 cm (12 ft 6 in) is 25 mm (1 in) below the headlamp horizontal cen- away from it.
Page 302: Decal
Section 09 BODY/FRAME Subsection 02 (BODY) DECAL To remove a decal; heat old decal with a heat gun and peel off slowly. Using isopropyl alcohol, clean the surface and dry thoroughly. Apply liquid soap to new decal and carefully posi- tion the decal.
Page 303: Wiring Harness
Section 09 BODY/FRAME Subsection 02 (BODY) WIRING HARNESS WARNING Ensure all terminals are properly crimped on the wires and that all connector housings are properly fastened. Keep wires away from any rotating, moving, heating and vi- brating parts. Use proper fastening devices as required.
Page 304: Plastic Repair
Section 09 BODY/FRAME Subsection 02 (BODY) PLASTIC REPAIR REPAIR The very first step before repairing plastic materi- als is to find out exactly which type of material is involved. Refer to following chart. CAUTION Consult chart and repair kit instructions carefully, some repair products are not com- patible with certain plastics.
Page 305: Material Repair Procedure
Section 09 BODY/FRAME Subsection 02 (BODY) MATERIAL REPAIR PROCEDURE – Clean surface with Crest Hi-Solv product. – Apply a flexible primer such as Crest Prima Flex R.I.M. polyurethane is light colored (tan) on the in- stock no. AP-F. side with a smooth surface. –...
Page 306 Section 09 BODY/FRAME Subsection 02 (BODY) Crest products used in R.I.M. repair procedure are available from following locations: CREST MAIN OFFICE AND MANUFACTURING PLANT CREST INDUSTRIES, INC. Phone: 313-283-4100 Toll Free: 1-800-822-4100 3841 13 Street Fax: 1-800-344-4461 Wyandotte, Michigan Fax: 313-283-4461 48192 DISTRIBUTOR WAREHOUSE LOCATIONS UNITED STATES...
Page 307: Frame
Section 09 BODY/FRAME Subsection 03 (FRAME) FRAME FRAME CLEANING NOTE: For aluminum frames use only aluminum cleaner and follow instructions on container. (Dur- sol cleaner or equivalent). Clean frame and tunnel with appropriate cleaners and rinse with high pressure hose. Touch up all metal spots where paint has been scratched off.
Page 308 Section 09 BODY/FRAME Subsection 03 (FRAME) It is not necessary to center punch the rivet head, simply center the drill bit on the rivet and drill. Maintain a slow to medium speed at all times when drilling. The proper speed is attained when a constant chip is ejected.
Page 309 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 310 Section 10 TECHNICAL DATA Subsection 02 (ENGINES) TOURING E, SKANDIC 380, SKANDIC 500, VEHICLE MODEL TUNDRA II LT TOURING LE FORMULA S, FORMULA SL FORMULA S ELEC. ENGINE TYPE Number of Cylinders Bore mm (in) 72.00 (2.835) 62.00 (2.441) 67.5 (2.66) 72.00 (2.835) Stroke mm (in)
Page 311 Section 10 TECHNICAL DATA Subsection 03 (VEHICLES) FORMULA S, VEHICLE MODEL TUNDRA II LT TOURING E FORMULA S ELEC. ENGINE TYPE Chain Drive Ratio 14/25 18/44 21/44 Chain Pitch Type/Links Qty/Plates Qty Single/62 Silent/70/11 Silent/72/11 Drive Pulley Type of Drive Pulley Bombardier Lite Bombardier Lite Bombardier Lite...
Page 312 Section 10 TECHNICAL DATA Subsection 03 (VEHICLES) VEHICLE MODEL TOURING LE SKANDIC 380 SKANDIC 500 FORMULA SL ENGINE TYPE Chain Drive Ratio 21/44 21/44 21/44 22/44 Chain Pitch Type/Links Qty/Plates Qty Silent/72/11 Silent/72/11 Silent/72/11 Silent/72/11 Drive Pulley Type of Drive Pulley Bombardier Lite TRAC TRAC...
Page 313 Section 10 TECHNICAL DATA Subsection 04 (TECHNICAL DATA LEGENDS) ENGINE TECHNICAL DATA VEHICLE TECHNICAL DATA LEGEND LEGEND BTDC: Before Top Dead Center DSA: Direct Shock Action CDI: Capacitor Discharge Ignition RRIM: Reinforced Reaction Injection Molding Kilo (x 1000) TRA: Total Range Adjustable drive pulley MAG: Magneto Side N.A.: Not Applicable N.A.: Not Applicable...

This manual is also suitable for:

Touring e 1998 Touring le 1998 Formula s 1998 Formula s electric 1998 Formula sl 1998 Skandic 380 1998 ... Show all

Ski-Doo Tundra II LT 1998 Shop Manual

Table of Contents

Troubleshooting

Table of Contents

Table of Contents

Table of Contents

Table of Contents

Table of Contents

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

Related Manuals for Ski-Doo Tundra II LT 1998

Summary of Contents for Ski-Doo Tundra II LT 1998

This manual is also suitable for:

Table of Contents