Page 12 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 01 (SERVICE TOOLS) SERVICE TOOLS NOTE : The numbers outlined in black (example : ) are reference numbers to tools from other divisions used even if the part numbers are differem. Magneto puller Fan holder Degree wheel (P/ N 4208763 57)
Page 13 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 01 (SERVICE TOOLS) ENGINE (Mandatory Service Tools) Rotary valve shaft pusher : Rotary valve shaft seal Engine leak tester kit pusher (P/ N 86 I 7491 00) (p/ N 4208766 12) (outer, water pump side) (p/ N 4208770 50) “...
Page 14 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 01 (SERVICE TOOLS) (Mandatory Service Rotary valve circlip tool Rubber pad Piston pin puller (p/N 5290291 (P/ N 5290290 00) (p/ N 5290234 00) B) (p / N 529020800 A01B4C4 APPLICATION APPLICATION All cageless bearing engines (277 A) 454 and 670 engines.
Page 15 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 01 (SERVICE TOOLS) ENGINE (Optional Service Tools) The following tools are highly recommended to optimize your basic tool kit and reduce repair time. Tools to be used with crankshaft bearing pullers N (P/N 4208762 98) and 1-2 Crankshaft bearing ~ puller with screw (p/ N 4208762 98)
Page 16 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 01 (SERVICE TOOLS) ENGINE (Optional Service Tools) Ring compressor Seal protector sleeve Piston circlip installer A) (P / N 5290169 00) A)(P/N4208760 90) (62 mm) B) (p / N 2908770 16) B)(p/N4208769 74) (p/ N 4202769 00) (69.5 mm) D) (p / N 420876972)
Page 17 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS ENGINE (Optional Service Tools) Magneto holder Crankshaft distance (continuity light) (p/ N 4209765 50) (P/ N 4208768 24) (p/ N 4140122 00) AOOC1V4 APPLICATION APPLICATION 247 engine. All vehicles. AOOC3A4 APPLICATION Crankshaft feeler gauge . Piston ring expander 503 engine.
Page 18 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 01 (SERVICE TOOLS) ENGINE (Optional Service Tools) Dial indicator Injection pump gear RAVE movement holder indicator (p/ N 2950001 43) (p/ N 4208766 95) (p/ N 8617258 00) AOOB2E4 APPLICATION AOOB314 All engines. APPLICATION 253, 377, 447 and 503 engines.
Page 19 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 01 (SERVICE TOOLS) ENGINE (Optional Service Tools) Base puller plate kit Digital / induction type Fluke multimeter tachometer 5290220 ()()) (p/ N 5290249 00) (p/ N 5290145 00) A05COM4 APPLICATION APPLICATION 277 engine. All engines.
Page 20 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 01 (SERVICE TOOLS) ENGINE (Optional Service Tools) Insertion jig Exhaust spring installer/ ~ Seal pusher (rotary valve) ~ (Magneto seal) remover (p/ N 4208765 10) (P/ N 4208765 14) (p/ N 5290281 00) N E W N E W APPLICATION...
Page 21 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 01 (SERVICE TOOLS) ENG NE (Optional Serv ce Tools Large hose pincher (p/ N 5290304 00) F01B234 APPLICATION All vehicles. 01-01-10...
Page 22 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 01 (SERVICE TOOLS) TRANSMISSION (Mandatory Service Tools) Clutch holder Transmission alignment bar (p/N 5290267 (P/ N 5290079 00) (25 mm) (p/ N 5290064 ()()) B) (p / N 5290269 00) D) (p / N 5290268 00) A01B154 APPLICATION APPLICATION...
Page 23 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 01 (SERVICE TOOLS) TRANSMISSION (Mandatory Service Tools) 2) TRA clutch spring cover bush- Spring scale hook (long) : J Spring compressor / ing flare tool (p/ N 5290309 ()()) (P/ N 5290186 00) A) INTERIOR flare tool Parts included in the kit: (p/ N 5290180 00)
Page 24 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 01 (SERVICE TOOLS) TRANSMISSION (Mandatory Service Tools) T r a n s m i s s i o n a d j u s t e r . Burnishing bar remover (p/ N 5290285 00) (p/ N 5290264 02) (p/ N 5290301 00) N E W...
Page 25 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 01 (SERVICE TOOLS) TRANSMISSION (Optional Service Tools) The following tools are highly recommended to optimize your basic tool kit and reduce repair time. Transmission ball Alignment tool mounting pin remover (p/ N 4204760 10) (P/ N 5290187 00) (p/ N 4204760 20) APPLICATION...
Page 26 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 01 (SERVICE TOOLS) TRANSMISSION (Optional Service Tools) Driven pulley support 3-speed transmission bearing Alignment bar extractor A) (P/N 5290256 00) 1) Screw M8 x 25 (2) (p/ N 5290135 ()()) B) (p/N 5290282 00) (p/ N 2220825 65) C) (P/N 5290283 00) 2) Plate...
Page 27 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 01 (SERVICE TOOLS) (Optional Service Tools) Drive axle sprocket Drive pulley retainer adjuster (27 mm) (p/ N 5290017 00) (p/ N 8617257 00) (p/ N 5290101 00) APPLICATION APPLICATION Round shaft drive pulley. except 454, 670 and 779 Transmission shifter engines.
Page 28 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 01 (SERVICE TOOLS) SUSPENSION (Mandatory Service Tools) Shock spring remove kit (p/ N 5290271 00) Replacement clevis pin : (P/ N 4145284 00) A01B404 APPLICATION All suspensions with coil spring. 01-01-17...
Page 29 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS SUSPENSION (Optional Service Tools) Track cleat installer A) Track cleat remover Camber angle tool 5290216 00) 5290082 00) Narrow Pins NOTE : Angle finder with B) (p / N 5290288 00) a magnetic base must be (p/ N 5290082 04) Narrow used.
Page 30 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 01 (SERVICE TOOLS) SUSPENSION Service Piston guide Spring installer (bar) Bushing installer / remover (P/ N 5290050 00) (p/ N 5290266 00) (p/ N 5290119 00) A06F1C4 APPLICATION APPLICATION Tundra II LT, Scout and MX Z T / A shocks.
Page 31 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 01 (SERVICE TOOLS) SUSPENSION (Optional Service Tools) Adjustment wrench Drive axle holder S u s p e n s i o n a d j u s t m e n t . wrench (p/ N 5290072 00) (p/ N 8617439 00)
Page 33 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 02 (SERVICE PRODUCTS) SERVICE PRODUCTS MANDATORY SERVICE PRODUCTS NOTE : The numbers outlined in black (example : ) are reference to tool numbers from other divisions used, even if the part numbers are different. Dow Corning@ is a trademarks of Dow Corning Corporation.
Page 34 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 02 (SERVICE PRODUCTS) MANDATORY SERVICE PRODUCTS G a s k e t / p a i n t r e m o v e r . (P/ N 4137081 00) (p/ N 4137085 00) 510 g (18 Primer N 170 g (6...
Page 35 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 02 (SERVICE PRODUCTS) OPTIONAL SERVICE PRODUCTS Blizzard oil Silicone dielectric grease ~ (12 x 500 mL) (3 Oz) (p/ N413 8019 00) (p/ N 4138031 00) (p/ N 4137017 00) AOOB1X4 APPLICATION On all electric connections.
Page 36 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 02 (SERVICE PRODUCTS) OPTIONAL SERVICE PRODUCTS Pipe sealant Anti-seize lubricant Storage oil (350 g spray can) (P/ N 4137010 00) (p/ N 4137023 00) (p/ N 4960141 00) lubricant 454 g (16 OZ) AOOB2W4 APPLICATION Engine plugs and senders.
Page 37 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 02 (SERVICE PRODUCTS) OPTIONAL SERVICE PRODUCTS Paint for frame touch-up ~ instant adhesive Stripped threads repair kit (p/ N413 4010 00) (p/ N413 7083 00) (p/ N413 7086 ()()) Black semi-gloss 20 g (.70 (spray can) Form-A-thread 81668 AOOB304...
Page 38 Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub-Section 02 (SERVICE PRODUCTS) OPTIONAL SERVICE PRODUCTS Sealant 736 Dow Corning ~ Shock oil Super Lube (grease) (P/ N 2935500 14) (p/ N 4137092 00) (P/ N413 7094 00) N E W AOOB3U4 APPLICATION All models.
Page 39 Section 02 LUBRIFICATION AND MAINTENANCE Sub-Section 01 (LUBRICATION AND MAINTENANCE CHART) LUBRICATION AND MAINTENANCE CHART REFER TO Starting Rope Condition — Engine Head Nuts Appropriate section : See Top End Engine Mount Nuts Appropriate section : See ENGINE SUPPORT AND MUFFLER Exhaust System Appropriate section : See ENGINE SUPPORT AND MUFFLER...
Page 40 Section 02 LUBRIFICATION AND MAINTENANCE Sub-Section 01 (LUBRICATION AND MAINTENANCE CHART) REFER TO Handlebar Bolts. Retorque to Page 08-01-1 26 N•m (19 Ibf•ft) Steering and Front Suspension Mechanism Sub-sections 08-01 and 08-02 Wear and Condition of Skis and Runners Sub-section 08-02 Steering and Ski Leg Camber Adjustment Sub-section 08-01 Suspension Adjustments...
Page 41 Section 02 LUBRIFICATION AND MAINTENANCE Sub-Section 01 (LUBRICATION AND MAINTENANCE CHART) NO. 1 ENGINE LUBRICATION With the engine stopped, remove the spark plug and spray storage oil (P / N 496 0141 00) into each Engine internal parts must be lubricated to protect cylinder.
Page 42 Section 02 LUBRIFICATION AND MAINTENANCE Sub-Section 01 (LUBRICATION AND MAINTENANCE CHART) 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. NO.
Page 43 Section 02 LUBRIFICATION AND MAINTENANCE Sub-Section 01 (LUBRICATION AND MAINTENANCE CHART) NO. 8 CLEANING Remove any dirt or rust. To clean the entire vehicle, use only flannel ® clothes or Kimtowels wipers no. 58-380 from Kimberly-Clark. CAUTION : It is necessary to use flannel cloths or “Kimtowels”...
Page 45 Section 03 TROUBLESHOOTING Sub-Section 01 (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 46 Section 03 TROUBLESHOOTING Sub-Section 01 (ENGINE) SYMPTOM ENGINE SUDDENLY TURNS OFF. CONDITION NORMAL USE. Test / Inspection 1. Perform engine leak test (tool P / N 861 7390 00). Refer to engine leak verifica- tion flow chart. Check possible piston seizure. a.
Page 47 Section 03 TROUBLESHOOTING Sub-Section 01 (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 48 Section 03 TROUBLESHOOTING Sub-Section 01 (ENGINE) SYMPTOM ENGINE DOES NOT OFFER MAXIMUM POWER AND / OR DOES NOT REACH MAXIMUM OPERATING RPM. CONDITION NORMAL USE. Test / Inspection 1. Check spark plug condition. a.Fouled spark plug(s). Replace. 2. Check if there is water in fuel. a.There is water in fuel.
Page 49 Section 03 TROUBLESHOOTING Sub-Section 01 (ENGINE) SYMPTOM ENGINE DETONATION AT MAXIMUM RPM. CONDITION NORMAL USE. Test / Inspection 1. Check which type of fuel is used. a. Octane number is too low and / or alcohol level is too high. Use recommended fuel type.
Page 50 Section 03 TROUBLESHOOTING Sub-Section 01 (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 51 Section 03 TROUBLESHOOTING Sub-Section 01 (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 inad- equate component(s).
Page 52 Section 03 TROUBLESHOOTING Sub-Section 01 (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 53 Section 03 TROUBLESHOOTING Sub-Section 01 (ENGINE) SYMPTOM ENGINE PINGING. CONDITION NORMAL USE. Test / Inspection 1. Check fuel lines. a. Bent fuel lines (preventing fuel from flowing through). Relocate or replace fuel lines. 2. Check if carburetor(s) is (are) clean. a.
Page 54 Section 03 TROUBLESHOOTING Sub-Section 01 (ENGINE) 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 OR OIL MOVING...
Page 55 Section 03 TROBLESHOOTING Sub-Section 02 (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 56 Section 03 TROBLESHOOTING Sub-Section 02 (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 57 Section 03 TROBLESHOOTING Sub-Section 02 (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 58 Section 03 TROUBLESHOOTING Sub-Section 03 (TRANSMISSION AND BRAKE SYSTEM) TRANSMISSION AND BRAKE SYSTEM 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 59 Section 03 TROUBLESHOOTING Sub-Section 03 (TRANSMISSION AND BRAKE SYSTEM) 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 60 Section 03 TROUBLESHOOTING Sub-Section 03 (TRANSMISSION AND BRAKE SYSTEM) SYMPTOM PULLEYS DO NOT DOWN SHIFT PROPERLY. CONDITION NORMAL USE. Test / Inspection 1. Check driven pulley spring tension. a. Spring tension is too weak. Adjust according to specifications (refer to TECHNICAL DATA 10). 2.
Page 61 Section 03 TROUBLESHOOTING Sub-Section 03 (TRANSMISSION AND BRAKE SYSTEM) SYMPTOM BELT GLAZED EXCESSIVELY OR HAVING BAKED APPEARANCE. CONDITION NORMAL USE. Test / Inspection 1. Check if drive pulley bushings are worn. a. Insufficient pressure on belt sides. Replace bushing. 2. Check condition of drive pulley fixed half shaft. a.
Page 62 Section 03 TROUBLESHOOTING Sub-Section 03 (TRANSMISSION AND BRAKE SYSTEM) SYMPTOM BELT WORN NARROW IN ONE SECTION. CONDITION NORMAL USE. Test / Inspection 1. Check track tension / alignment. a. Frozen or too tight track. Liberate track from ice or check track tension and alignment. 2.
Page 63 Section 03 TROUBLESHOOTING Sub-Section 03 (TRANSMISSION AND BRAKE SYSTEM) 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). A00D0FY SYMPTOM FLEX CRACKS BETWEEN COGS. CONDITION NORMAL USE.
Page 64 Section 03 TROUBLESHOOTING Sub-Section 03 (TRANSMISSION AND BRAKE SYSTEM) BRAKE SYSTEM MECHANICAL BRAKE SYMPTOM BRAKE DOES NOT ADJUST AUTOMATICALLY. CONDITION NORMAL USE. Test / Inspection 1. Check ratchet wheel spring. a. Broken ratchet wheel tag. Replace. 2. Check mobile pad stud. a.
Page 65 Section 03 TROUBLESHOOTING Sub-Section 03 (TRANSMISSION AND BRAKE SYSTEM) 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. 03-03-8...
Page 66 Section 03 TROUBLESHOOTING Sub-Section 04 (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 67 Section 03 TROUBLESHOOTING Sub-Section 04 (ELECTRICAL SYSTEM) 9. Check height of commutator mica. a.Commutator mica too high. Undercut mica. 10. Check field coil resistance. a.Shorted field coil. Repair or replace yoke. 11. Check armature resistance. a.Shorted armature. Repair or replace armature. 12.
Page 68 Section 03 TROUBLESHOOTING Sub-Section 04 (ELECTRICAL SYSTEM) SYMPTOM ELECTRIC STARTER KEEPS TURNING WHEN ENGINE IS STARTED. CONDITION NORMAL USE. Test / Inspection 1. Check clutch. a. Jammed clutch pinion gear. Replace or clean. 2. Check movement of clutch on splines. a.
Page 69 Section 03 TROUBLESHOOTING Sub-Section 04 (ELECTRICAL SYSTEM) SYMPTOM HEADLAMP NOT LIGHTING. CONDITION WHITE BULB. Test / Inspection 1. Check bulb. a. Gas leak. Replace bulb. CONDITION BROKEN ELEMENT. Test / Inspection 1. Check for loose headlamp housing and bulb socket. a.
Page 70 Section 03 TROUBLESHOOTING Sub-Section 04 (ELECTRICAL SYSTEM) 8. Verify if heating grips installation overloads the magneto / generator capacity (ex : Élan). a. Excessive electrical load to magneto / generator. Reduce the electrical load by removing accessories. SYMPTOM FALSE FUEL AND / OR TEMPERATURE GAUGE READINGS. CONDITION NORMAL USE.
Page 71 Section 03 TROUBLESHOOTING Sub-Section 04 (ELECTRICAL SYSTEM) SYMPTOM ENGINE STALLS. CONDITION AT LOW SPEED. Test / Inspection 1. Verify items 4, 5 and 6 above. SYMPTOM IRREGULAR ENGINE SPEED. CONDITION AT HIGH SPEED. Test / Inspection 1. Verify items 4, 5 and 6 above. CONDITION AT LOW SPEED.
Page 72 Section 03 TROUBLESHOOTING Sub-Section 04 (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.
Page 73 Section 03 TROUBLESHOOTING Sub-Section 04 (ELECTRICAL SYSTEM) SYMPTOM REAR LIGHT BULB FLASHES. CONDITION NORMAL USE. Test / Inspection 1. Check bulb tightness in housing. a. Looseness at bulb contact elements. Install bulb correctly. 2. Check if rear light is properly connected. a.
Page 74 Section 03 TROUBLESHOOTING Sub-Section 05 (SUSPENSION SYSTEM AND TRACK) SUSPENSION SYSTEM AND TRACK The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM REAR SUSPENSION BOTTOMS OUT.
Page 75 Section 03 TROUBLESHOOTING Sub-Section 05 (SUSPENSION SYSTEM AND TRACK) SYMPTOM DERAILING TRACK. CONDITION NORMAL USE. Test / Inspection 1. Check track tension. a. Track is too loose. Adjust. 2. Check if track and slider shoes are properly aligned. a. Improper alignment. Adjust.
Page 76 Section 03 TROUBLESHOOTING Sub-Section 05 (SUSPENSION SYSTEM AND TRACK) SYMPTOM HANDLE BAR IS DIFFICULT TO TURN. CONDITION NORMAL USE. Test / Inspection 1. Check position of front spring adjustment cams. a. More pressure on the ground when cam increases spring preload. Reduce front spring preload.
Page 81 Section 04 ENGINE Sub-Section 01 (503 ENGINE TYPE) 503 ENGINE TYPE ENGINE REMOVAL AND INSTALLATION Skandic WT 21 N•m (15 lbf•ft) A22C0FS 04-01-1...
Page 82 Section 04 ENGINE Sub-Section 01 (503 ENGINE TYPE) ENGINE REMOVAL AND INSTALLATION Disconnect or remove the following : WARNING : Before disconnecting any electrical wire in starter system always first disconnect the BLACK negative battery ca- ble (on electric starting models). –...
Page 83 Section 04 ENGINE Sub-Section 01 (503 ENGINE TYPE) 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) 22 N•m (16 lbf•ft) A22C0GS 04-01-3...
Page 84 Section 04 ENGINE Sub-Section 01 (503 ENGINE TYPE) NOTE : The following procedures can be NOTE : 0.25 and 0.5 mm oversized piston done without removing the engine from and rings are available if necessary. chassis. INSPECTION CLEANING Refer to ENGINE DIMENSIONS MEASUREMENT Discard all gaskets.
Page 85 Section 04 ENGINE Sub-Section 01 (503 ENGINE TYPE) To minimize the effect of acceleration forces on Install proper ring compressor on piston assem- circlip, install each circlip so the circlip break is at bly. 6 o’clock as illustrated. Use piston circlip installer RING COMPRESSOR (P / N 529 0086 00).
Page 86 Section 04 ENGINE Sub-Section 01 (503 ENGINE TYPE) A17C02A A17C06A 1. Or use exhaust manifold to align cylinders 503 ENGINE TYPE 1. Distance nuts 3,4,6, Noise Damper Cross torque cylinder head nuts to 22 N•m (16 For proper position of noise dampers, refer to the lbf•ft) ;...
Page 87 Section 04 ENGINE Sub-Section 01 (503 ENGINE TYPE) BOTTOM END 22 N•m (16 lbf•ft) 503 : 503 : 22 N•m 22 N•m (16 lbf•ft) (16 lbf•ft) 22 N•m (16 lbf•ft) A22C0HS 04-01-7...
Page 88 Section 04 ENGINE Sub-Section 01 (503 ENGINE TYPE) ASSEMBLY NOTE : Engine must be removed from chassis to perform the following proce- dures. 3,4, Anti-seize Lubricant and Ball Bearing CLEANING Smear anti-seize lubricant (P / N 413 7010 00) on part of crankshaft where bearing fits.
Page 89 Section 04 ENGINE Sub-Section 01 (503 ENGINE TYPE) 6,7,8,11, Crankcase Bolt Torque bolts to 22 N•m (16 lbf•ft) following illus- trated sequence. A17C07A 14 10 1. Bearing A17C08A 2. Feeler gauge 3. Plain oil seal A. 1 mm (.040 in) To install magneto, refer to CDI MAGNETO 04-04.
Page 90: Table Of Contents
Section 04 ENGINE Sub-Section 02 (454, 583 AND 670 ENGINE TYPES) 454, 583 AND 670 ENGINE TYPES ENGINE SUPPORT AND MUFFLER All Models 583 and 670 S-Series MX Z 440 Formula SS 736 RTV Loctite Formula SS 454 and 670 engines 23 N•m...
Page 91 Section 04 ENGINE Sub-Section 02 (454, 583 AND 670 ENGINE TYPES) REMOVAL FROM VEHICLE Second number sequence of P / N is stamped on part. Disconnect or remove the following from vehicle. – air intake silencer – belt guard and drive belt –...
Page 92: M (17 Lbf•Ft)
Section 04 ENGINE Sub-Section 02 (454, 583 AND 670 ENGINE TYPES) TOP END Pipe sealant (P / N 413 7023 00) Loctite 10 N•m Grease (89 lbf•in) Grease 583 engine type only 10 N•m (89 lbf•in) Grease 30 N•m (22 lbf•ft) 30 N•m Grease (22 lbf•ft)
Page 93 Section 04 ENGINE Sub-Section 02 (454, 583 AND 670 ENGINE TYPES) NOTE : The following procedures can be RAVE System done without removing the engine from NOTE : RAVE stands for Rotax Adjustable chassis. Variable Exhaust. CLEANING 3,5,6, Spring Clip, Cover and Spring Discard all gaskets and O-rings.
Page 94: 583 And
Section 04 ENGINE Sub-Section 02 (454, 583 AND 670 ENGINE TYPES) ASSEMBLY RAVE System Check valve rod housing and cylinder for clogged 22,23,24, Piston Pin, Circlip and Piston passages. At assembly, place the pistons over the connect- ing rods with the letters “AUS” (over an arrow on the piston dome) facing in direction of the exhaust port.
Page 95 Section 04 ENGINE Sub-Section 02 (454, 583 AND 670 ENGINE TYPES) A01C02B TYPICAL F01D13A 1. Circlip break TYPICAL CAUTION : Circlips must not move freely A. Torque screws to 30 N•m (22 lbf•ft) after installation if so, replace them. 21, Gasket 27, Cylinder 583 Only When reassembling the cylinders to the crank-...
Page 96 Section 04 ENGINE Sub-Section 02 (454, 583 AND 670 ENGINE TYPES) Torque cylinder head screws following illustrated 11,12,13,14, Cylindrical Screw, Lock sequence. Longer screws go on intake side. Washer, Valve Rod Housing and Gasket Install gasket and valve rod housing with their pas- sages toward bottom.
Page 97: Loctite
Section 04 ENGINE Sub-Section 02 (454, 583 AND 670 ENGINE TYPES) BOTTOM END Lithium grease engines only Loctite Anti-seize lubricant engines Anti-seize only lubricant Loctite 24 N•m (18 lbf•ft) Except and 670. Loctite See CDI 10 N•m SYSTEM (89 lbf•in) Loctite 38 N•m Loctite...
Page 98 Section 04 ENGINE Sub-Section 02 (454, 583 AND 670 ENGINE TYPES) ASSEMBLY NOTE : Engine must be removed from chassis to perform the following proce- dures. 2,4,5,6,9, Crankshaft Bearing and Labyrinth Sleeve CLEANING Smear anti-seize lubricant (P / N 413 7010 00) on part of crankshaft where bearing fits.
Page 99 Section 04 ENGINE Sub-Section 02 (454, 583 AND 670 ENGINE TYPES) 1,8, Upper Crankcase and Lower Crankcase Crankcase halves are factory matched and there- fore, are not interchangeable or available as single halves. Prior to joining of crankcase halves spray some new injection oil (or equivalent) on all moving parts of the crankshaft.
Page 100 Section 04 ENGINE Sub-Section 02 (454, 583 AND 670 ENGINE TYPES) 10,11, Pipe Sealant and Angular Tube Apply pipe sealant (P / N 413 7023 00) on threads prior to assembly angular tube. 12, Crankcase Stud At assembly on crankcase, apply medium strength threadlocker (P / N 413 7030 00) on stud threads.
Page 101 Section 04 ENGINE Sub-Section 03 (599 AND 779 ENGINE TYPES) 599 AND 779 ENGINE TYPES ENGINE REMOVAL AND INSTALLATION Formula III / III LT and Mach Z / Z LT 10 N•m (98 lbf•in) 15 N•m (133 lbf•in) 37 N•m (27 lbf•ft) 35 N•m (26 lbf•ft)
Page 102 Section 04 ENGINE Sub-Section 03 (599 AND 779 ENGINE TYPES) REMOVAL FROM VEHICLE INSTALLATION ON VEHICLE Remove or unplug the following then lift off en- To install engine on vehicle, reverse removal pro- gine from engine compartment. cedure. However, pay attention, to all appropriate component / system reinstallation procedures de- NOTE : 3-cylinder engine is more heavy scribed throughout this Shop Manual and to the...
Page 103 Section 04 ENGINE Sub-Section 03 (599 AND 779 ENGINE TYPES) TOP END 10 N•m (89 lbf•in) 30 N•m (22 lbf•ft) Grease Molykote 111 (P / N 413 07070 00) only 10 N•m Loctite 242 (89 lbf•in) (P / N 413 7030 00) 599 only Loctite 648 Grease...
Page 104 Section 04 ENGINE Sub-Section 03 (599 AND 779 ENGINE TYPES) COMPONENT REMOVAL 3,4,5, Spring Clip, Cover and Spring Remove spring clip, cover and spring. Most engine components can be removed with engine on vehicle such as : 6,7, Valve Piston and Clamp 50 mm –...
Page 105 Section 04 ENGINE Sub-Section 03 (599 AND 779 ENGINE TYPES) ASSEMBLY RAVE System Check valve rod housing and cylinder for clogged RAVE SYSTEM passages. 779 Only 10,11,12,13,14, Valve Rod, O-ring, Washer, Distance Nut and Exhaust Valve Fully screw distance nut, with its notch first, on valve rod longer threaded portion.
Page 106 Section 04 ENGINE Sub-Section 03 (599 AND 779 ENGINE TYPES) 1,2,16, Cylinder Head Cover, Cylinder Head and Cylinder Check flatness of part sealing surfaces. 529 0169 00 Refer to LEAK TEST AND ENGINE DIMENSION MEASUREMENT 04-04 and look for Checking Surface Flatness.
Page 107 Section 04 ENGINE Sub-Section 03 (599 AND 779 ENGINE TYPES) Also check for proper cylinder alignment. A06C1QA At assembly, torque cylinder head screws in the following illustrated sequence. Tightening torques are : M6 screws : 12 N•m (106 Ibf•in) M8 screws : 30 N•m (22 Ibf•ft) A06C0GA TYPICAL 04-03-7...
Page 108 Section 04 ENGINE Sub-Section 03 (599 AND 779 ENGINE TYPES) BOTTOM END Formula III / III LT Loctite Silicone Loctite Formula III / III LT 10 N•m (90 lbf•in) Anti-seize lubricant (P / N 413 7010 00) Molykote 111 (P / N 413 7070 00) Loctite Primer NF Loctite 515...
Page 109 Section 04 ENGINE Sub-Section 03 (599 AND 779 ENGINE TYPES) NOTE : Engine must be removed from chas- 1, Reed Valve sis to perform the following procedures. With blade stopper removed, check reed valve for proper tightness. There must be no play between CLEANING blade and valve body when exerting a finger pres- sure on blade at blade stopper location.
Page 110 Section 04 ENGINE Sub-Section 03 (599 AND 779 ENGINE TYPES) ASSEMBLY Before joining crankcase halves, spray some acti- vator (P / N 413 7076 00) on one of mating surfac- es. Apply paste gasket Loctite 515 (P / N 413 2,3, Crankshaft Bearing, Anti-seize 7027 00) to the other mating surface.
Page 111 Section 04 ENGINE Sub-Section 03 (599 AND 779 ENGINE TYPES) 8,9, Plastic Gear and Steel Gear 4 9 11 Install plastic gear on oil pump side. Steel gear goes on water side, its shoulder first. A06C2HA 599 ENGINE 1. Oil level plug Add chaincase synthetic oil (P / N 413 8028 00) into water pump housing until oil level reach bot- tom of plug hole.
Page 112 Section 04 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) LEAK TEST AND ENGINE DIMENSION MEASUREMENT S Series and F Series 10. Engine must stand this pressure during 3 min- utes. LEAK TEST If pressure drops before 3 minutes, check tester kit by spraying a soapy solution on pump piston, all The following gives verification procedures for liq- plugs and fittings.
Page 113 Section 04 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Engine Check the following : 1. All jointed surfaces and screw / stud threads of engine : – spark plug base, insulator – cylinder head – decompressor valve (247 and 277 types only) –...
Page 114 Section 04 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) If pressure drops, it indicates defective crank- shaft inner seal on PTO side. 2. Remove a spark plug or any plug of leak tester kit on MAG side. If pressure drops, it indicates defective crank- shaft inner seal on MAG side.
Page 115 Section 04 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) COOLING SYSTEM LEAK TEST Use special plug (radiator cap) (P / N 529 0214 00) and pressurize to 15 PSIG (100 kPa). Check all hoses and cylinder / base for coolant leaks.
Page 116 Section 04 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) ENGINE DIMENSION MEASUREMENT This section covers all engine types. NOTE : Be sure to restore the chamfer around all cylinder sleeve port openings. 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.
Page 117 Section 04 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) A01C0PA RING END GAP Position ring half way between transfer ports and intake port. On rotary valve engines, position ring just below transfer ports. NOTE : In order to correctly position the ring in the cylinder, use piston as a pusher.
Page 118 Section 04 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) CONNECTING ROD BIG END First, check deflection with crankshaft in engine. If deflection exceeds the specified tolerance, it AXIAL PLAY can be either bearing wear or bent crankshaft. Re- move crankshaft bearings and check deflection ENGINE NEW PARTS...
Page 119 Section 04 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) CAUTION : Always install end-play ad- ENGINE NEW PARTS WEAR justment shims on the magneto side be- TYPE MIN. – MAX. LIMIT tween bearing and crankshaft counterweight. 0.03 – 0.012 mm 0.015 mm The following is required for the adjustment (.0001 –...
Page 120 Section 04 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) A01C0UA 1. Bearing thickness c. Measure distance between bearing shoulders on crankshaft (M A01C0WA A02C0LA 1. End-play is adjusted with shims d. Measure the distance ring (M ) and adjustment 2.
Page 121 Section 04 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) A13C0OA F01D3PA TYPICAL TYPICAL 1. Solder The gap can be measured with the engine in- stalled on vehicle. Use 45° bent blade feeler CHECKING SURFACE FLATNESS gauge (Snap-On FB300A) inserted through intake socket of valve cover.
Page 122 Section 04 ENGINE Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) CHECKING CRANKSHAFT ALIGNMENT Install a degree wheel (P / N 414 3529 00) on crankshaft end. Remove both spark plugs. Install a TDC gauge (P / N 414 1047 00) in spark plug hole on MAG side.
Page 123 Section 04 ENGINE Sub-Section 05 (CDI SYSTEM) CDI SYSTEM NIPPONDENSO TRIGGER COIL IGNITION SYSTEM 454, 583, and 670 Engines Dielectric grease (P / N 413 7017 00) 454 and 670 engines Loctite Loctite Loctite Loctite All engines except 454 Loctite and 670 Dielectric grease (P / N 413 7017 00)
Page 124 Section 04 ENGINE Sub-Section 05 (CDI SYSTEM) 599 and 779 Engines Dielectric grease (P / N 413 7017 00) Dielectric grease (P / N 413 7017 00) Silastic Loctite 242 22 N•m (195 lbf•in) 125 N•m (92 lbf•ft) Loctite 242 Loctite Loctite Dielectric...
Page 125 Section 04 ENGINE Sub-Section 05 (CDI SYSTEM) NOTE : The following procedures can be done without removing the engine from chassis. To facilitate magneto removal, hold drive pulley with tool (P / N 529 0276 00). CLEANING Clean all metal components in a non-ferrous met- al cleaner.
Page 126 Section 04 ENGINE Sub-Section 05 (CDI SYSTEM) A25E1AA 1. Magneto harness through crankcase hole – Install new trigger coil and other parts re- moved. Adjustment A15E0NA Whenever the trigger coil or the magneto fly- ADJUSTING TRIGGER COIL AIR-GAP wheel is removed or replaced, the air-gap be- 1.
Page 127 Section 04 ENGINE Sub-Section 05 (CDI SYSTEM) At reassembly coat all electric connections with silicone dielectric grease (P / N 413 7017 00) to prevent corrosion or moisture penetration. CAUTION : Do not use silicone “sealant”, this product will corrode contacts. Ignition Timing Check as described in IGNITION TIMING 06-02.
Page 128 Section 04 ENGINE Sub-Section 05 (CDI SYSTEM) DUCATI IGNITION SYSTEM 503 Engine Dielectric grease (P / N 413 7017 00) Dielectric grease (P / N 413 7017 00) Loctite 242 Loctite 242 Loctite 242 105 N•m (77 lbf•ft) 22 N•m (195 lbf•in) A22E0HS 04-05-6...
Page 129 Section 04 ENGINE Sub-Section 05 (CDI SYSTEM) NOTE : The following procedures can be done without removing the engine from chassis. CLEANING Clean all metal components in a non-ferrous met- al cleaner. CAUTION : Clean stator and magneto us- ing only a clean cloth. DISASSEMBLY 420 8760 65 3, Magneto Flywheel Nut...
Page 130 Section 04 ENGINE Sub-Section 05 (CDI SYSTEM) ASSEMBLY 3. If necessary, adjust by slackening retaining screws and moving trigger coil toward or away of protrusion. 2,3, Magneto Flywheel and Nut 4. Retighten screws and recheck air-gap. Clean crankshaft extension (taper). Apply Loctite 242 (blue) on taper.
Page 131 Section 04 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM OIL INJECTION PUMP 454, 583 and 670 Engines O i l p u t s e t g a s k e temperarure grease Loctite Loctite S series Parts in illustration marked with X are not available as single parts.
Page 132 Section 04 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) 503 Engine Loctite 242 Loctite Low temperature grease A22C0DS 04-06-2...
Page 133 Section 04 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) 599 and 779 Engines 599 engine Loctite 242 Loctite 648 779 engine Loctite 648 779 engine only 5 N•m (44 lbf•in) Loctite 242 A06C32S 04-06-3...
Page 134 Section 04 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) OIL PUMP IDENTIFICATION 7, Pump Lever 420 2779 05 Different engines need different pumps. Oil pumps are identified by their levers. CAUTION : Always mount proper pump on engine. OIL PUMP ENGINE TYPE IDENTIFICATION A00C17A TYPICAL...
Page 135 Section 04 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) Make sure cable barrel is well seated in oil pump Check also for proper oil lever adjustment. Marks lever. must aligned when throttle lever is activated just enough to take all cable play. Secure barrel with plastic washer and circlip.
Page 136 Section 04 ENGINE Sub-Section 06 (OIL INJECTION SYSTEM) CHECKING OPERATION Oil Pump Test Bench Connect a hose filled with injection oil to main line On Vehicle fitting. Insert other hose end in an injection oil container. Using a counterclockwise rotating drill NOTE : Main oil line must be full of oil.
Page 137 Section 04 ENGINE Sub-Section 07 (AXIAL FAN COOLING SYSTEM) AXIAL FAN COOLING SYSTEM 503 Engine 13 14 15 16 55 N•m (41 lbf•ft) A22C0IS 04-07-1...
Page 138 Section 04 ENGINE Sub-Section 07 (AXIAL FAN COOLING SYSTEM) NOTE : The following procedures can be done without removing engine from chassis. CLEANING Clean all metal components in a non-ferrous met- al cleaner. DISASSEMBLY AND ASSEMBLY 17, Fan Nut Remove fan protector. To remove or install fan pulley retaining nut, lock fan pulley with special holder wrench (P / N 420 A09C0JA...
Page 139 Section 04 ENGINE Sub-Section 07 (AXIAL FAN COOLING SYSTEM) 9, Fan Shaft 10,11, Bearing and Circlip Using a press, drive the fan shaft out. Remove circlip 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 140 Section 04 ENGINE Sub-Section 08 (LIQUID COOLING SYSTEM) LIQUID COOLING SYSTEM S Series with 454, 583 and 670 Engines Loctite A03C1DS 04-08-1...
Page 141 Section 04 ENGINE Sub-Section 08 (LIQUID COOLING SYSTEM) F Series with 583 and 670 Engines Loctite A06C37S 04-08-2...
Page 142 Section 04 ENGINE Sub-Section 08 (LIQUID COOLING SYSTEM) 599 and 779 Engines Loctite A06C0NS 04-08-3...
Page 143 Section 04 ENGINE Sub-Section 08 (LIQUID COOLING SYSTEM) INSPECTION 5, Thermostat To check thermostat, put in water and heat water. Check general condition of hoses and clamp tight- Thermostat should open when water tempera- ness. ture reaches the following degree. DRAINING THE SYSTEM ENGINE TEMPERATURE...
Page 144 Section 04 ENGINE Sub-Section 08 (LIQUID COOLING SYSTEM) COOLING SYSTEM REFILLING PROCEDURE Recommended Coolant Use a blend of 60 % antifreeze with 40 % water. Do not reinstall pressure cap. CAUTION : To prevent rust formation or freezing condition, always replenish the system with 60 % antifreeze and 40 % water.
Page 145 Section 04 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) ROTARY VALVE, COOLANT PUMP AND RESERVOIR 454, 583 and 670 Engines Injection oil reservoir Loctite To rotary valve gear Molykote Loctite 22 N•m (16 lbf•ft) A06C2UT 04-09-1...
Page 146 Section 04 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) NOTE : Some verifications can be per- 8,9,10, Circlip and Spring Retaining Cup formed with engine in vehicle. Refer to EN- If it is necessary to disassemble components of GINE DIMENSION MEASUREMENT 04-03.
Page 147 Section 04 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) ASSEMBLY CAUTION : Ensure that the rotary valve shaft is perfectly perpendicular with the Assembly is essentially the reverse of disassem- press tip or damage will occur. bly procedures. However pay particular attention to the following.
Page 148 Section 04 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) 11, Bearing 6201 To install bearing 6201 use bearing pusher (P / N 420 8765 00). 420 8765 00 420 8765 12 420 8770 50 A16C0WA 1. Rotary valve side 2.
Page 149 Section 04 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) – Install small thrust washer then friction washer positioning its grooves against pump impeller. 420 8765 00 A16C19A A16C0XA 1. Large shim 5. Friction washer 2. Rubber washer 6. Flange this side 4,6, Rotary Valve Shaft and Loctite 648 3.
Page 150 Section 04 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) 18,19, Pump Housing Bolt and Loctite These marks will be useful to time rotary valve ex- actly to the specifications. 242 (Blue) NOTE : Tolerance of rotary valve timing is Apply Loctite 242 (blue) on bolt threads.
Page 151 Section 04 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) – Turning crankshaft, bring MAGneto side piston – Position rotary valve on shaft splines to have to Top Dead Center as done before with a edges as close as possible to marks. crankcase having a ridge.
Page 152 Section 04 ENGINE Sub-Section 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) A16C18A 1. Position of mark when brass gear disengage worm gear 2. Advanced by 2° 3. Position of mark before installation (about 10 splines from original position) 1,2, Screw and Rotary Valve Cover Install O-ring and cover then torque screws to 22 N•m (16 lbf•ft) in a criss-cross sequence.
Page 153 Section 04 ENGINE Sub-Section 10 (REWIND STARTER) REWIND STARTER All Models Molykote G-n paste or equivalent Silicone compound grease Silicone compound grease 10 N•m (89 lbf•in) 670 engine only A01C57S TYPICAL 04-10-1...
Page 154 Section 04 ENGINE Sub-Section 10 (REWIND STARTER) REMOVAL 16, Starter Grip Using a small screwdriver, extract rope knot from starter grip. Cut rope close to knot. Tie a knot near starter housing. All Engines Except 670 1,2,3, Starter Housing, Lock Washer and Screw Remove screws and washers securing rewind starter to engine then remove rewind starter.
Page 155 Section 04 ENGINE Sub-Section 10 (REWIND STARTER) CAUTION : It is of the utmost importance To adjust rope tension : that the rewind starter spring(s) be lubri- Wind rope on sheave and place rope sheave into cated periodically using specific lubricants. starter housing making sure that the sheave hub Otherwise, rewind starter component life will notch engages in the rewind spring hook.
Page 156 Section 04 ENGINE Sub-Section 10 (REWIND STARTER) Install locking ring. 16, Starter Grip CAUTION : This lubricant must NOT be Prior to installing starter grip on new rope, it is first used on rewind springs as it does not stay necessary to fuse the rope end with a lit match.
Page 157 Section 04 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) CARBURETOR AND FUEL PUMP MIKUNI FLOAT CARBURETOR NOTE : Refer to TECHNICAL DATA section 10 for carburetor application. VM 32-269 A22C0JS 04-11-1...
Page 158 Section 04 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) Carburetors VM 34-469 VM 36-172 VM 34-470 VM 36-173 VM 36-172 VM 36-174 VM 36-173 only VM 36-174 VM 38-319 VM 38-320 To other VM 40-76 carburetors VM 40-77 VM 40-79 VM 40-81 VM 40-82 VM 40-83...
Page 159 Section 04 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) Carburetor TM 38 C133 A06C38S 04-11-3...
Page 160 Section 04 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) REMOVAL 11,12, Cap and Float Check for fuel inside float. Remove air silencer(s). For S-Series, see BAT- TERY 06-04. If fuel is noticed : Disconnect fuel inlet line. – Check cap for fuel tightness ; replace as neces- sary.
Page 161 Section 04 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) Lean Rich A00B2GA 1. Lean 2. Rich 5, Throttle Slide The size of the throttle slide cut-away affects the fuel mixture between 1/8 to 1/2 throttle opening. A06C0KA A certain amount of richness is needed for that 1.
Page 162 Section 04 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) CARBURETOR FLOAT LEVEL To Adjust Height H : ADJUSTMENT – Bend the contact tab of float arm until the spec- ified height is reached. 9,10, Float Arm and Float Arm Pin Correct fuel level in float chamber is vital toward maximum engine efficiency.
Page 163 Section 04 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) INSTALLATION 3,4, Needle and Nylon Packing CAUTION : Never allow throttle slide(s) to snap shut. To install carburetor on engine, inverse removal procedure. However, pay attention to the following : – Inspect throttle cable and housing prior to in- stallation.
Page 164 Section 04 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) Carburetor Synchronization For maximum performance, correct carburetor throttle slide adjustment is critical. Both carburetor slides must start to open at the The following method should be used with engine same time. turned off : Completely unscrew idle speed screw on both Unscrew idle screw until it does not contact throt-...
Page 165 Section 04 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) Throttle Slide Height Models ± 0.2 mm (± 0.008 in) MX Z 440 (.071) MX Z 583 (.059) MX Z 670 (.083) Summit 583 / 670 (.090) Formula Z (.071) Formula SS (.074)
Page 166 Section 04 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) NOTE : On twin carburetor models : Turn adjustment screw the same amount to keep carburetors synchronized. Refer to TECHNICAL DATA section 10 for the specifications. CAUTION : Do not attempt to set the idle speed by using the air screw.
Page 167 Section 04 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) HAC SYSTEM Summit Only HAC (High Altitude Compensator) is a mainte- nance free device. No adjustment and verification can be done on HAC. If HAC is suspected to be faulty, replace it and check for improvement.
Page 168 Section 04 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) HAC SYSTEM A03I0BS 04-11-12...
Page 169 Section 04 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) FUEL PUMP 503 engine 454 engine 583, 599, 670 and 779 engines A06C39S 04-11-13...
Page 170 Section 04 ENGINE Sub-Section 11 (CARBURETOR AND FUEL PUMP) REMOVAL CLEANING AND INSPECTION Install a hose pincer (P / N 529 0099 00) on fuel The entire pump should be cleaned with general supply line close to pump inlet. purpose solvent before disassembly. Fuel pump components should be cleaned in gen- eral purpose solvent and dried with compressed air.
Page 171 Section 04 ENGINE Sub-Section 12 (FUEL TANK AND THROTTLE CABLE) FUEL TANK AND THROTTLE CABLE All Models Fuel Tank Lines WARNING : When draining a fuel tank or whenever a fuel line is disconnected, ob- struct line with a hose pincher (P / N 529 0099 00) or equivalent device.
Page 172 Section 04 ENGINE Sub-Section 12 (FUEL TANK AND THROTTLE CABLE) A02C0DA 1. Carburetor cover 2. Throttle cable housing A01E18A 3. Retaining ring 1. Full position (3 ± 2 Ω ) 2. Empty position (110 ± 7 Ω ) Adjust throttle cable as specified in CARBURE- 3.
Page 175 1996 APPLICATION CHART PART WIDTH (NEW) MINIMUM WIDTH MODEL ± 0.25 mm (.010 in) NUMBER (WEAR LIMIT) MX Z 440 / 583 FORMULA Z 414 8607 00 35 mm (1-3/8’’) 32.5 mm (1-9/32’’) SUMMIT 583 SKANDIC WT 414 6175 00 34.6 mm (1-3/8’’)
Page 176 Section 05 TRANSMISSION Sub-Section 01 (DRIVE BELT) Before checking the belt deflection, ensure vehi- Or use the belt tension tester (P / N 414 3482 00). cle has the proper belt (Refer to the application chart). Adjust pulley distance and alignment. Refer to 05- 04 PULLEY DISTANCE AND ALIGNMENT.
Page 177 Section 05 TRANSMISSION Sub-Section 01 (DRIVE BELT) NOTE : Turn Allen screws 1/4 turn at a time, then rotate driven pulley to allow drive belt to settle in pulley. Check deflection, repeat as re- quired. A15D0WA 1. Allen screw with jam nut Allen screws should be restrained while tighten- ing jam nut to prevent throwing adjustment out.
Page 178 Section 05 TRANSMISSION Sub-Section 02 (DRIVE PULLEY) 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...
Page 179 Section 05 TRANSMISSION Sub-Section 02 (DRIVE PULLEY) GENERAL Some drive pulley components (return spring, ramp) can be changed to improve vehicle perfor- mance in high altitude regions. The High Altitude Technical Data booklet (P / N 484 0624 00 and 484 0545 00 for binder) gives information about cali- bration according to altitude.
Page 180 Section 05 TRANSMISSION Sub-Section 02 (DRIVE PULLEY) DISASSEMBLY 1,2, Screw and Ring Gear CAUTION : Retaining screws must be heated before disassembly. 5,6, Fixed and Sliding Half CAUTION : Do not tap on governor cup. Screw puller into fixed half shaft about 13 mm (1/ 2 in).
Page 181 Section 05 TRANSMISSION Sub-Section 02 (DRIVE PULLEY) Remove all harden oil deposits that have baked on crankshaft and pulley tapered surfaces with coarse or medium steel wool and / or sand paper no. 600. CAUTION : Do not use any other type of abrasive.
Page 182 Section 05 TRANSMISSION Sub-Section 02 (DRIVE PULLEY) 7,20, Sliding Half and Spring Cover Then flare bushing. Kahrlon Bushing Visually inspect kahrlon coating. Replace if worn. Sliding Half Bushing Replacement Use a suitable pusher to remove the old bushing. Clean sliding half with ethyl alcohol. CAUTION : Bushing must be bonded with re-taining compound (P / N 413 7031 00) then flared to prevent displacement in sliding...
Page 183 Section 05 TRANSMISSION Sub-Section 02 (DRIVE PULLEY) 420 8765 12 529 0313 00 529 0312 00 A01B41A TOOL REMOVAL A01D2NA CAUTION : Do not install sliding half on a 1. Note upper tool side vise to remove remaining tool. Press bushing. Spring Cover Bushing Replacement Under normal use there is no need to replace this bushing.
Page 184 Section 05 TRANSMISSION Sub-Section 02 (DRIVE PULLEY) A16D07A 1. Washer A16D09A Torque locking nut to 10 N•m (89 lbf•in). 1. Equal distance 15, Pin Torque screws to 10 N•m (89 lbf•in). Always use the same type of pin as originally in- 9,11,13,14, Screw, Lever Ass’y, Nut and stalled when servicing.
Page 185 Section 05 TRANSMISSION Sub-Section 02 (DRIVE PULLEY) CAUTION : Lever ass’y and rollers must Insert spring and slider shoes into governor cup move easily after installation. so that groove in each slider shoe is vertical to properly slide in guides. 5,6,18,19, Fixed Half, Sliding Half, Spring, Spring Cover and Screw To install spring cover, use spring compressor (P /...
Page 186 Section 05 TRANSMISSION Sub-Section 02 (DRIVE PULLEY) INSTALLATION CAUTION : Make sure O-rings are in- stalled on slider shoes and their grooves WARNING : Do not apply anti-seize or any are positioned vertically. lu-bricant on crankshaft and drive pulley Install fork (P / N 529 0055 00) into slider shoe tapers.
Page 187 Section 05 TRANSMISSION Sub-Section 02 (DRIVE PULLEY) This adjustable drive pulley allows setting maxi- Each number modifies maximum engine RPM by mum engine RPM in the vehicle to maintain max- about 200 RPM. imum power. Lower numbers decrease engine RPM in steps of Calibration screws should be adjusted so that ac- 200 RPM and higher numbers increase it in steps tual maximum engine RPM in vehicle matches...
Page 188 Section 05 TRANSMISSION Sub-Section 03 (DRIVEN PULLEY) DRIVEN PULLEY S-Series and F-Series Anti-seize lubricant (P / N 413 7010 00) Loctite Loctite A15D1DS 05-03-1...
Page 189 Section 05 TRANSMISSION Sub-Section 03 (DRIVEN PULLEY) Skandic WT Anti-seize lubricant A22D11S 05-03-2...
Page 190 Section 05 TRANSMISSION Sub-Section 03 (DRIVEN PULLEY) REMOVAL CLEANING Belt Guard and Drive Belt 6,7, Large Bushing and Small Bushing Remove from vehicle. During break-in period (about 10 hours of use), te- flon from bushing moves to cam or shaft surface. 11,12,13,16,17, Washer, Lock Washer, A teflon over teflon running condition occurs, Screw, Shim and Extension...
Page 191 Section 05 TRANSMISSION Sub-Section 03 (DRIVEN PULLEY) Replace bushing(s) if worn more than specified. DRIVEN PULLEY BUSHING WEAR LIMIT mm (in) Small bushing 38.30 (1.299) 529 0311 02 Large bushing 89.15 (3.510) 529 0311 03 4, Slider Shoe Check cam slider shoes for wear. Replace when inside edge of cam slider shoe slope base is worn to 1 mm (.039 in) or less.
Page 192 Section 05 TRANSMISSION Sub-Section 03 (DRIVEN PULLEY) INSTALLATION 14,15, Countershaft and Anti-seize Lubricant CAUTION : Always apply anti-seize lubri- 529 0313 00 cant (P / N 413 7010 00) on the counter- shaft before final pulley installation. F-Series and S-Series Only 529 0312 00 Should installation procedure be required, refer to BRAKE 05-05 then look for Brake Disc and Coun-...
Page 193 Section 05 TRANSMISSION Sub-Section 03 (DRIVEN PULLEY) 5, Spring Spring Torsional Pre-Load To check spring pre-load adjustment, use spring scale hook (P / N 529 0065 00) and a spring scale. Remove drive belt. Install the hook on the sliding half. Preventing 3 2 1 fixed half from turning, pull sliding half with the spring scale perpendicularly with pulley axle.
Page 194 Section 05 TRANSMISSION Sub-Section 03 (DRIVEN PULLEY) NOTE : For high altitude regions, the High Altitude Technical Data Booklet (P / N 484 0624 00 and 484 0545 00 for binder) gives infor- mation about calibration according to altitude. 05-03-7...
Page 195 Section 05 TRANSMISSION Sub-Section 04 (PULLEY DISTANCE AND ALIGNMENT) PULLEY DISTANCE AND ALIGNMENT GENERAL Measuring Procedure Using Straight Bar : The pulley distance we will refer to, in this sec- tion, is the space separating the drive and driven Always measure distances X and Y from the far- pulley outside diameters (Z measure).
Page 196 Section 05 TRANSMISSION Sub-Section 04 (PULLEY DISTANCE AND ALIGNMENT) Drive Belt Deflection NOTE : When pulley distance and alignment are adjusted to specifications, refer to DRIVE BELT 05-01 to adjust drive belt deflection. CAUTION : This section deals mainly with ad-justment procedures.
Page 197 Section 05 TRANSMISSION Sub-Section 04 (PULLEY DISTANCE AND ALIGNMENT) Pulley Distance Adjustment Method Engine Movement The engine bracket 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 198 Section 05 TRANSMISSION Sub-Section 05 (BRAKE) BRAKE Summit 583 Dielectric grease Anti-seize lubricant Anti-seize lubricant Loctite A03D12S 05-05-1...
Page 199 Section 05 TRANSMISSION Sub-Section 05 (BRAKE) MX Z 440 / 583 / 670, Summit 670, Formula Z / SS / III / III LT and Mach Z / Z LT Loctite Anti-seize lubricant Black Max A06D1VS 05-05-2...
Page 200 Section 05 TRANSMISSION Sub-Section 05 (BRAKE) Skandic WT A22D12S 05-05-3...
Page 201 Section 05 TRANSMISSION Sub-Section 05 (BRAKE) REMOVAL Call-out BRAKE DISC REMOVAL Summit 583 Brake disc can be withdraw without removing cal- iper. Proceed as follows : – Remove belt guard, belt and driven pulley. – Remove air silencer. – Remove clip no. 25 on countershaft. A22D13A COUNTERSHAFT REMOVAL Mechanical Brake Models...
Page 202 Section 05 TRANSMISSION Sub-Section 05 (BRAKE) – Slacken set screw and unlock collar no. 18 if bearing is needed to be disassembled. See above S-Series illustration and procedure. – Remove 3 retaining screws no. 20 from coun- tershaft bearing housing. –...
Page 203 Section 05 TRANSMISSION Sub-Section 05 (BRAKE) Assemble outer caliper. Install locking tab then nuts. Torque nuts to 24 N•m (18 lbf•ft). Bend lock- ing tab over a flat of each nut. 5,10, Brake Cable and Nut Insert brake cable into upper hole in brake lever and caliper.
Page 204 Section 05 TRANSMISSION Sub-Section 05 (BRAKE) Brake Light Mechanical Brake Models Brake light should light up before brake pads touch brake disc. To adjust, unscrew nut no. 10 until brake light goes on. WARNING : At least one full thread must ex-ceed the elastic stop nut.
Page 205 Section 05 TRANSMISSION Sub-Section 06 (CHAINCASE) CHAINCASE S Series and F Series Without Reverse Gear Loctite Chaincase 45 to 75 N•m (33 to 55 lbf•ft) 46 N•m Loctite Loctite 609 (34 lbf•ft) Loctite 242 SYNTHETIC CHAINCASE OIL HUILE SYNTHÉTIQUE POUR CARTER A06D17S 05-06-1...
Page 206 Section 05 TRANSMISSION Sub-Section 06 (CHAINCASE) REMOVAL To remove chaincase proceed as follows. 529 0072 00 Remove tuned exhaust pipe and muffler. WARNING : Never remove exhaust com- ponents when engine is hot. 8,9,12, Hair Pin, Adjustment Screw and Chain Tensioner Remove hair pin.
Page 207 Section 05 TRANSMISSION Sub-Section 06 (CHAINCASE) INSTALLATION Reverse removal procedure and pay attention to the following. Replace oil seals, gaskets and O- rings. Refer to DRIVE AXLE 07-04 for drive axle axial play adjustment. 11, Oil Seal A02D08A Clean chaincase bore with Loctite Safety Solvent 1.
Page 208 Section 05 TRANSMISSION Sub-Section 06 (CHAINCASE) Track Tension and Alignment Refer to TRACK 07-05. A06D1OA 1. Dipstick 2. Oil lever 3. Level between marks 05-06-4...
Page 209 Section 05 TRANSMISSION Sub-Section 07 (GEARBOX) GEARBOX 3-SPEED GEARBOX (SHIFTER MECHANISM) Skandic WT A22D0YS 05-07-1...
Page 210 Section 05 TRANSMISSION Sub-Section 07 (GEARBOX) REMOVAL 1,2, Cable and Cable Housing Remove screw from underneath top portion of transmission. Remove cable barrel from shifter : see last photo. A22D0QA 1. Clip 1. Lock nut Adjust tie rod length in a way that gear shift lever do not contact console.
Page 211 Section 05 TRANSMISSION Sub-Section 07 (GEARBOX) Skandic WT A22D0CS 05-07-3...
Page 212 Section 05 TRANSMISSION Sub-Section 07 (GEARBOX) REMOVAL Remove brake disc and driven pulley. Unfasten shifting rod and cable. See above CABLE RE- MOVAL. Remove rear suspension. Remove angle drive and square pin. Remove RH end bearing then push drive axle to- ward right side.
Page 213 Section 05 TRANSMISSION Sub-Section 07 (GEARBOX) Drive out driven pulley shaft. Use alignment tool (P / N 420 4760 10) as a supporting plate to ex- tract last gear and bearing. Spacer will fall into gearbox housing. 420 4760 10 A22D0FA 18,19,26,27,28, Reverse Shaft, LH Side A22D0HA...
Page 214 Section 05 TRANSMISSION Sub-Section 07 (GEARBOX) 18,19,26,27,28, Reverse Shaft, LH Side Bearing, Brake Shaft, Sleeve and Gear Install brake shaft taking care that gear shoulders face RH side. A22D0JA 1. Push against gear shoulder INSPECTION Check bearing condition. There must be no discol- oration, missing rollers or balls, broken cages, etc.
Page 215 Section 05 TRANSMISSION Sub-Section 07 (GEARBOX) A22D0NA 1. Sliding sleeve 1. Gears mesh Install shim, bearing and circlip. 5,6, Fork and Fork Axle A22D0BA Mount forks and fork axles using a screwdriver to TYPICAL hold index ball. See illustration for fork axle posi- 1.
Page 216 Section 05 TRANSMISSION Sub-Section 08 (DRIVE CHAIN) DRIVE CHAIN SILENT CHAIN There are 2 types of silent chain. One is 11-link wide and the other (stronger) is 13-link wide. Do not interchange sprockets. Fit chain on sprockets to make sure using right ones according to width. Refer to TECHNICAL DATA 10.
Page 219 TAILLIGHT SYSTEM MODEL DIAGRAM (watt) (watt) OUTPUT PAGE (watt) MX Z 440 / 583 / 670 Annex 1 60 / 55 hal. 8 / 27 Summit 583 / 670 Annex 2 60 / 55 hal. 8 / 27 Formula Z Annex 3 60 / 55 hal.
Page 220 Section 06 ELECTRICAL Sub-Section 01 (WIRING DIAGRAMS) Following table shows wire colors related to electrical circuits. WIRE COLORS ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK / YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch –...
Page 221 Section 06 ELECTRICAL Sub-Section 01 (WIRING DIAGRAMS) Connector Location Connectors on wiring diagrams carry the letter C followed by a number. Use this code with wiring diagram legend to find connector location on vehi- cle. UNPLUGING CONNECTORS Always unplug connectors by pulling on housing not on wire.
Page 222 Section 06 ELECTRICAL Sub-Section 01 (WIRING DIAGRAMS) A00E1GA 1. Tab 2. Housing A00E1CA Step : Insert screwdriver here Step : Pull this side Locking Receptacle Connector To remove : – Insert Snap-on tool TT 600-5 in access opening then pull housing. A00E1FA 1.
Page 223 Section 06 ELECTRICAL Sub-Section 01 (WIRING DIAGRAMS) WARNING : Never secure electrical wires / cables with fuel lines. Keep wires away from any rotating, moving, heating, vibrating or sharp edge. Use proper fastening devices as required. 06-01-5...
Page 224 Section 06 ELECTRICAL Sub-Section 02 (IGNITION TIMING) IGNITION TIMING NIPPONDENSO TRIGGER COIL SYSTEM 454, 583, 599, 670 and 779 Engine Types Ignition timing is adjusted by movement of trigger coil. Raising position of trigger coil retards igni- tion. Lowering position of trigger advances igni- tion.
Page 225 Section 06 ELECTRICAL Sub-Section 02 (IGNITION TIMING) NOTE : When checking timing, certain pro- cedures require that the magneto flywheel be turned in a clockwise direction, viewed facing the magneto. If it is necessary to turn back (coun- terclockwise) for any reason, rotate the magneto flywheel at least one-quarter turn counterclock- wise, and then rotate it clockwise.
Page 226 Section 06 ELECTRICAL Sub-Section 02 (IGNITION TIMING) NOTE : To avoid an incorrect reading due to parallax, view the magneto flywheel and the crankcase timing marks in a straight line. 2. Start the engine and point timing light straight in line with the crankcase timing mark. Bring engine to 6000 RPM for a brief instant.
Page 227 Section 06 ELECTRICAL Sub-Section 02 (IGNITION TIMING) DUCATI CDI SYSTEM 503 Engine Type 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 to verify the position of the timing mark on the...
Page 228 Section 06 ELECTRICAL Sub-Section 02 (IGNITION TIMING) NOTE : When checking timing, certain pro- c. Scribe or punch a mark on magneto flywheel cedures require that the magneto flywheel so that it perfectly aligns with the arrow on be turned in a clockwise direction, viewed facing crankcase, refer to illustration.
Page 229 Section 06 ELECTRICAL Sub-Section 03 (SPARK PLUGS) SPARK PLUGS NGK SPARK PLUG NGK SPARK PLUG NUMBERING SYSTEM The heat range identification system is : High number cold plug Low number hot plug 1996 REFERENCE CHART NGK spark plugs used on 1996 Bombardier snowmobiles : –...
Page 230 Section 06 ELECTRICAL Sub-Section 03 (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...
Page 231 Section 06 ELECTRICAL Sub-Section 03 (SPARK PLUGS) DISASSEMBLY A too “cold” plug will result in fouling (shorting the spark plug) or may create carbon build up First unscrew the spark plug 1 turn. which can heat up red-hot and cause pre-ignition or detonation.
Page 232 Section 06 ELECTRICAL Sub-Section 03 (SPARK PLUGS) SPARK PLUG INSTALLATION Prior to installation make sure that contact surfac- es of the cylinder head and spark plug are free of grime. 1. Using a wire feeler gauge, set electrode gap ac- cording to TECHNICAL DATA 10.
Page 233 Section 06 ELECTRICAL Sub-Section 04 (BATTERY) BATTERY REMOVAL F Series with Electric Starting Remove air intake silencer. All Models All Models Except Skandic WT WARNING : Battery BLACK negative ca- ble must always be disconnected first and Unfasten retaining strips. connected last.
Page 234 Section 06 ELECTRICAL Sub-Section 04 (BATTERY) A17E0LA 1. Baking soda A22C0AA Remove corrosion from battery cable terminals 1. Remove bolt and lock nut and battery posts using a firm wire brush. Unfasten battery brackets. INSPECTION Visually inspect battery casing for cracks or other possible damage.
Page 235 Section 06 ELECTRICAL Sub-Section 04 (BATTERY) BATTERY STORAGE A hydrometer measures the charge of a battery in terms of specific gravity of the electrolyte. Most Disconnect and remove battery from the vehicle. hydrometers give a true reading at 27°C (80°F). Check electrolyte level in each cell, add distilled In order to obtain correct readings, adjust the ini- water up to upper level line.
Page 236 Section 06 ELECTRICAL Sub-Section 04 (BATTERY) 1. Remove the sealing tube from the vent elbow. Install vent tube, included in the battery kit, to battery elbow. WARNING : Failure to remove the sealing tube could result in an explosion. A17E0HA 5.
Page 237 Section 06 ELECTRICAL Sub-Section 04 (BATTERY) CAUTION : If charging rate raises higher than 2.4 A reduce it immediately. If cell temperature rises higher than 50°C (122°F) (if the casing feels hot) discontinue charging tem- porarily or reduce the charging rate. WARNING : Gases given off by a battery being charged are highly explosive.
Page 238 Section 06 ELECTRICAL Sub-Section 04 (BATTERY) – State of charge : Because the electrolyte is nearly pure water in a completely discharged battery, it cannot accept current as well as elec- trolyte. This is the reason the battery will not accept current when the charging cycle first be- gins.
Page 239 Section 06 ELECTRICAL Sub-Section 04 (BATTERY) – If the charging current is measurable before the CAUTION : Adequate ventilation MUST end or at the end of about 10 hours, the battery be provided to cool the rheostat. is good and charging should be completed in Charging 2 or More Batteries at a Time the normal manner as specified in Activation of a new battery.
Page 240 Section 06 ELECTRICAL Sub-Section 04 (BATTERY) Connect vent tube to vehicle fitting on front S Series With Electric Starting frame. Fasten spark plug cables to fan housing. Route RED positive cable behing retaining strip Reinstall throttle cable and primer hose attach- and connect it to positive battery terminal.
Page 241 Section 06 ELECTRICAL Sub-Section 05 (ELECTRIC STARTER) ELECTRIC STARTER Skandic WT, S Series and F Series with Electric Starting A24E01S 06-05-1...
Page 242 Section 06 ELECTRICAL Sub-Section 05 (ELECTRIC STARTER) REMOVAL – Disconnect BLACK ground cable from battery. – Disconnect RED positive cable from battery. WARNING : Always disconnect ground cable first and connect last. – Disconnect RED cable and RED / GREEN wire from starter solenoid switch.
Page 243 Section 06 ELECTRICAL Sub-Section 05 (ELECTRIC STARTER) A19E0AA A19E02A BUSHING PUSHER 1. Stake bushing cover 2. Support A. 16 mm (5/8 in) dia. B. 13 mm (1/2 in) C. 11 mm (7/16 in) 3, Bushing (End Frame) D. 11 mm (.433 in) dia. Check the wear on bushing by measuring the amount of radial play between the armature shaft and the bushing.
Page 244 Section 06 ELECTRICAL Sub-Section 05 (ELECTRIC STARTER) ASSEMBLY Prior to assembling, coat sliding surfaces and moving parts on armature shaft splines, overrun- ning clutch, solenoid switch plunger, drive lever and bushings with G.E. Versilube G 321 (P / N 413 7040 00) lubricant.
Page 245 Section 06 ELECTRICAL Sub-Section 05 (ELECTRIC STARTER) 10,15,17, Solenoid, Drive Lever and Drive Housing Insert solenoid plunger inside of drive lever fork and secure to drive housing. Connect starter bare wire to solenoid. NOTE : Connect this wire on the shorter so- lenoid stud.
Page 246 Section 06 ELECTRICAL Sub-Section 05 (ELECTRIC STARTER) A09E0PA 1. Screwdriver pulling starter pinion 2. Ring gear 3. No excessive backlash A. 0.5 to 1.5 mm (.020 to .060 in) Connect the RED battery cable and the red wire to the large terminal of the solenoid. Connect RED / GREEN wire to small terminal of solenoid.
Page 247 Section 06 ELECTRICAL Sub-Section 05 (ELECTRIC STARTER) CLEANING AND INSPECTION CLEANING Check the commutator out-of-round condition with V- Blocks and an indicator. If the commutator CAUTION : Armature starter yoke ass’y out-of-round is more than 0.40 mm (.016 in), the and drive unit assembly must not be im- commutator should be turned on a lathe.
Page 248 Section 06 ELECTRICAL Sub-Section 05 (ELECTRIC STARTER) Test Armature for Shorted Winding : When the armature is rotated in the growler with a steel strip (hack-saw blade) held above it, the strip will vibrate over that area of the armature which has short circuited.
Page 249 Section 06 ELECTRICAL Sub-Section 05 (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 250 Section 06 ELECTRICAL Sub-Section 06 (TESTING PROCEDURE) TESTING PROCEDURE GENERAL The following chart gives the engine types with their implemented system. CHARGING ENGINE IGNITION SYSTEM TYPE SYSTEM OUTPUT 454, 494, NIPPONDENSO 582, 583 (CDI) and 670 TRIGGER COIL NIPPONDENSO (CDI) 599 and 779 TRIGGER COIL WITH 3 H.T.
Page 251 Section 06 ELECTRICAL Sub-Section 06 (TESTING PROCEDURE) A17E0TA DUCATI CDI SYSTEM 1. Combined ignition module / ignition coil mounted on air silencer below carburetor 2. Two-wire connector (GREEN / WHITE wires) Ignition System Testing Sequence When dealing with ignition problems, the follow- ing items should be verified in this order.
Page 252 Section 06 ELECTRICAL Sub-Section 06 (TESTING PROCEDURE) Engine Stop / Tether Cut-Out Switches Test values listed are taken against compression Verification Always crank vigorously as in actual starting. Engine Stop Switch Always proceed in the following order : Unplug stop switch connector from main harness then using an ohmmeter, connect test probes to 1.
Page 253 Section 06 ELECTRICAL Sub-Section 06 (TESTING PROCEDURE) NIPPONDENSO CDI TRIGGER COIL SYSTEM TESTING Applicable to 454, 583, 599, 670 and 779 b. Indicator lamp does not light : The problem Engine Types is a faulty trigger coil or bad grounding. NOTE : Ensure ignition cut-out switches are IGNITION COIL OUTPUT properly working and they are in the ON po-...
Page 254 Section 06 ELECTRICAL Sub-Section 06 (TESTING PROCEDURE) 3. Crank engine and observe indicator. NOTE : If engine starts, allow it to idle while observing indicator. Then, shut engine off. 4. Push reset button and repeat step 3 twice. Results : a.
Page 255 Section 06 ELECTRICAL Sub-Section 06 (TESTING PROCEDURE) LIGHTING GENERATOR COIL All Engines Except 599 and 799 OUTPUT Tester Tester Tester Component switch dial NOTE : The lighting generator coil is not part wires wires position position of the ignition system. It is a separate sys- tem that supplies current to the lighting system and AC-powered devices.
Page 256 Section 06 ELECTRICAL Sub-Section 06 (TESTING PROCEDURE) SUMMARY TABLE Tester Test to perform Components wires Switch Dial wires BLUE / YELLOW (All except wire of 599 and 779) trigger coil Trigger coil output WHITE / YELLOW (599 and 779) wire of trigger coil (All except Engine ground...
Page 257 Section 06 ELECTRICAL Sub-Section 06 (TESTING PROCEDURE) RESISTANCE MEASUREMENTS Disconnect connector at ignition coil and magneto junction. Measure resistance between each ter- As an alternate method, magneto system compo- minal. Refer to the following table for values and nents can be checked with a digital ohmmeter. wire colors.
Page 258 Section 06 ELECTRICAL Sub-Section 06 (TESTING PROCEDURE) DUCATI CDI SYSTEM TESTING (Applicable to 503 Engine Type) MAGNETO OUTPUT NOTE : Ensure ignition cut-out switches are properly working and they are in the ON po- (Ignition Generator Coil) sition prior to performing the following tests. 1.
Page 259 Section 06 ELECTRICAL Sub-Section 06 (TESTING PROCEDURE) IGNITION MODULE 2. Connect tester wires then set switch and dial as follows : Ignition module can not be tested with the Bom- bardier ignition tester. When other components Tester Tester Tester Component switch dial test good, the module is probably faulty.
Page 260 Section 06 ELECTRICAL Sub-Section 06 (TESTING PROCEDURE) Results : a. Indicator lamp lights : Lighting generator coil output is up to specifications. b. Indicator lamp does not light : Lighting generator coil is faulty. SUMMARY TABLE Test to Tester Component Switch Dial perform...
Page 261 Section 06 ELECTRICAL Sub-Section 06 (TESTING PROCEDURE) RESISTANCE MEASUREMENTS Disconnect connector at ignition coil and magneto junction. Measure resistance between each ter- As an alternate method, magneto system compo- minal. Refer to the following table for values and nents can be checked with a digital ohmmeter. wire colors.
Page 262 Section 06 ELECTRICAL Sub-Section 06 (TESTING PROCEDURE) VOLTAGE REGULATOR INSPECTION A faulty voltage regulator is often responsible for B) Voltmeter Test frequent burned bulbs. NOTE : Use a voltmeter able to read alter- CAUTION : Never run an engine with a nating current (AC).
Page 263 Section 06 ELECTRICAL Sub-Section 06 (TESTING PROCEDURE) INSPECTION OF AC CIRCUIT ISOLATION All Electric Start Models If AC circuit is not isolated from frame, headlamp beam will weaken. INSPECTION Disconnect regulator / rectifier. Connect one digital ohmmeter probe (needle ohmmeter will not offer enough precision) to frame and other probe to one of 2 yellow magneto wires.
Page 264 Section 06 ELECTRICAL Sub-Section 06 (TESTING PROCEDURE) INSPECTION OF HEATING ELEMENTS All Models Except Skandic WT All measurement must be performed at 21°C (70°F). Throttle Lever Heating Element Handlebar Grip Heating Element HIGH YELLOW / BLACK wire 1.96 to HIGH YELLOW / BLACK wire 8.73 to INTENSITY...
Page 266 Summit temp. Summit Loctite grease only Except MX Z 583 and 670 Except Front Summit Except Summit Loctite Summit only Loctite Except Summit Loctite Loctite Loctite 271 Summit only Except Summit Loctite MX Z 440 Except only Summit A03F1KS 07-01-1...
Page 267 Section 07 REAR SUSPENSION Sub-Section 01 (SUSPENSION SC-10 HIGH PERFORMANCE, CROSS-COUNTRY AND COMPONENT REMOVAL AND INSTALLATION Lift rear of vehicle and support it off the ground. 21, Rear Axle Completely loosen track tension. Unscrew one rear idler wheel screw. Pull out rear axle from opposite side of offset in- ner wheel.
Page 268 Section 07 REAR SUSPENSION Sub-Section 01 (SUSPENSION SC-10 HIGH PERFORMANCE, CROSS-COUNTRY AND 25, MCA Support Remove threaded rod. Loosen rear axle screw on one side and rear shackle screws. Unbolt MCA support and remove it. Remove cup. 15, Rear Shock Lift rear of vehicle.
Page 269 Section 07 REAR SUSPENSION Sub-Section 01 (SUSPENSION SC-10 HIGH PERFORMANCE, CROSS-COUNTRY AND A03F0TA RH SIDE SHOWN Lift rear of vehicle and support it off the ground. Loosen track tension. 7, Screw A03F1QA TYPICAL Unscrew rear arm top axle from chassis. At reassembly, wheel circlip must face outward.
Page 270 Section 07 REAR SUSPENSION Sub-Section 01 (SUSPENSION SC-10 HIGH PERFORMANCE, CROSS-COUNTRY AND 6, Screw 11, Axle Remove both screws retaining front arm to tun- Note position of axles at disassembly. Axles with nel. a paint stripe serve as idler wheel axles. These are more precise than those used as pivot axles.
Page 271 When released, the shock will extend unassisted. Renew as required. HPG, T / A (Take Apart) Shock Servicing MX Z 440 Only This damper is completely rebuildable. It offers the options of replacing valves or revalving and / or the option of replacing seals (should it be need- ed).
Page 272 Section 07 REAR SUSPENSION Sub-Section 01 (SUSPENSION SC-10 HIGH PERFORMANCE, CROSS-COUNTRY AND A06FOTA TYPICAL Holding damper assembly in bench vise, unthread seal assembly from damper body using a 32 mm (1.25 in) spanner wrench. This assembly uses a right hand thread. NOTE : Before unscrewing pre-load rings, mark position for reinstallation.
Page 273 Section 07 REAR SUSPENSION Sub-Section 01 (SUSPENSION SC-10 HIGH PERFORMANCE, CROSS-COUNTRY AND A27F0AA 1. Oil flows Discard old oil into storage container. Never reuse damper oil during shock rebuild. Remove Schrader valve core. Using compressed air pressure, carefully remove floating piston from A06F0UB damper body.
Page 274 Section 07 REAR SUSPENSION Sub-Section 01 (SUSPENSION SC-10 HIGH PERFORMANCE, CROSS-COUNTRY AND NOTE : If revalving is to be done, it is imper- Rebound damping options from Bombardier in- ative that you identify the original shim pack clude a x-country kit. (size and number of shims).
Page 275 Section 07 REAR SUSPENSION Sub-Section 01 (SUSPENSION SC-10 HIGH PERFORMANCE, CROSS-COUNTRY AND 5. One 0.114 mm spacer washers minimum (2 or more recommended) should always be used between shim stack and valve stopper washer. This will allow needed room for the valve shims to function.
Page 276 Section 07 REAR SUSPENSION Sub-Section 01 (SUSPENSION SC-10 HIGH PERFORMANCE, CROSS-COUNTRY AND 2. Rebound shim pack. CENTER 3. Piston. Thick 4. Compression shim pack. (in) (in) 5. O-ring visual inspection seal carrier assembly. 6. Damper rod. 12 mm 0.023 mm Spacer (0.472 in) (0.008 in)
Page 277 Section 07 REAR SUSPENSION Sub-Section 01 (SUSPENSION SC-10 HIGH PERFORMANCE, CROSS-COUNTRY AND WARNING : Whenever using compressed Seal carrier should be installed close to piston as- air exercise extreme caution, cover damp- sembly. Careful inspection of damper oil capacity er opening with shop cloth to reduce chance of is required to insure that no air is in damper body possible injury.
Page 278 Section 07 REAR SUSPENSION Sub-Section 01 (SUSPENSION SC-10 HIGH PERFORMANCE, CROSS-COUNTRY AND A06F18A 1. Schrader valve 1.5-2 N•m (13-17 lbf•in) 2. Schrader cap 5-6.5 N•m (44-57 lbf•in) Gas Pressure Adjustment Nitrogen (N ) can now be added to damper body. Reinstall Schrader valve using teflon tape on valve threads into damper body.
Page 279 Section 07 REAR SUSPENSION Sub-Section 01 (SUSPENSION SC-10 HIGH PERFORMANCE, CROSS-COUNTRY AND INSTALLATION – When selecting shim stacks, 2 thin shims of equal thickness to one thick shim will offer less Install assembled suspension into track with front resistance than one thick shim. Refer to SHIM portion first.
Page 280 Section 07 REAR SUSPENSION Sub-Section 02 (SKANDIC WT SUSPENSION) SKANDIC WT SUSPENSION Skandic WT A22F18S 07-02-1...
Page 281 Section 07 REAR SUSPENSION Sub-Section 02 (SKANDIC WT SUSPENSION) REMOVAL Release track tension. Lift rear of vehicle and support it off the ground. Unbolt front arm then rear arm. NOTE : To prevent cross shaft from turning when unscrewing screws assembled with threadlocker, proceed as follows : –...
Page 282 Section 07 REAR SUSPENSION Sub-Section 02 (SKANDIC WT SUSPENSION) Tighten nut 3/4 turn after contacting washers for better deep snow performance. Maximum pre- load is 3 turns after nut touching washers. This last adjustment is for trail riding with or without a load and for pulling a load.
Page 283 Section 07 REAR SUSPENSION Sub-Section 02 (SKANDIC WT SUSPENSION) Examine each shock for leaks. Extend and com- press the piston several times over its entire stroke then check that it moves smoothly and with uniform resistance. Pay attention to the following conditions that will denote a faulty shock : –...
Page 284 Section 07 REAR SUSPENSION Sub-Section 03 (IMPROVED C-7 SUSPENSION) IMPROVED C-7 SUSPENSION Formula III / III LT and Mach Z / Z LT 48 N•m (35 lbf•ft) Grease 48 N•m (35 lbf•ft) 48 N•m (35 lbf•ft) Loctite Loctite Loctite Grease Loctite A06F1FS 03-03-1...
Page 285 Section 07 REAR SUSPENSION Sub-Section 03 (IMPROVED C-7 SUSPENSION) REMOVAL NOTE : Slider shoe minimum thickness : 10 mm (25/64 in). NOTE : To prevent cross shaft from turning when unscrewing screws assembled with threadlocker, proceed as follows : – Loosen one screw then retighten. –...
Page 286 Section 07 REAR SUSPENSION Sub-Section 03 (IMPROVED C-7 SUSPENSION) Position notch in outer spacer forward and inward onto the rear axle. 10,12,13,14,15, Screw Clean all screw threads and axle hole threads. Pri- or to assembly, apply low temperature grease (P / N 413 7061 00) on axles and Loctite 271 (P / N 413 7074 00) on screw threads.
Page 287 Section 07 REAR SUSPENSION Sub-Section 03 (IMPROVED C-7 SUSPENSION) A01B4LA 1. Clevis pin 2. Bar 3. Handle horizontal At installation, position spring stopper slit on op- posite side of spring coil end. SHOCK ABSORBER SERVICING Because of gas pressure, strong resistance is felt when compressing shock.
Page 288 Section 07 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) DRIVE AXLE S-Series and F-Series Summit and MX Z only A03D20S 07-04-1...
Page 289 Section 07 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) Skandic WT A22D14S 07-04-2...
Page 290 Section 07 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) REMOVAL Remove angle drive and square pin from bottom of gearbox. All Models Except Skandic WT Remove belt guard and belt. Drain oil from chaincase or gearbox. Release drive Loosen gearbox retaining screws then move chain tension.
Page 291 Section 07 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) 5,12, Bearing To remove bearings, use puller assembly, ring and half rings as illustrated. A00F07A 1. Pipe S-Series and F-Series A00C44A 9,13, Sprocket and Half-Sprocket To remove press fit sprockets, use a press and a suitable support as illustrated.
Page 292 Section 07 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) Skandic WT A00F0AA 1. Plane surface A. 1.5 mm (1/16 in) MAXIMUM CAUTION : The same sprocket must not be pressed twice on the axle. If synchroni- zation is found to be defective, use a new sprocket.
Page 293 Section 07 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) 5,12, Bearing Always push bearing by inner race. A00F0DA The bearing on the splined side of axle must be pushed until it is seated on shaft shoulder. The A01D05A end bearing housing bearing must be flush with TYPICAL end of drive axle.
Page 294 Section 07 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) AXIAL PLAY ADJUSTMENT BEARING POSITION TOWARD TOWARD TOWARD TOWARD FRONT REAR BOTTOM OF VEHICLE OF VEHICLE OF VEHICLE OF VEHICLE SHIM LOWER UPPER UPPER LOWER LOCATION This chart can be use as a “starting point” to cor- rect the chaincase perpendicularity.
Page 295 Section 07 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) 414 6053 00 501 0205 00 A01D09A 506 0414 00 1. No gap all around A01D0BA – Pull drive axle toward the end bearing housing 1. Chaincase and take note of the measurement between 2.
Page 296 Section 07 REAR SUSPENSION Sub-Section 04 (DRIVE AXLE) If the difference between each side exceeds 3 3, Retainer Ring mm (1/8 in), redistribute drive axle shims as Make sure that welded nuts are toward inside of follows : tunnel. Lock drive axle sprocket with a circlip. DIFFERENCE DRIVE AXLE SHIM BETWEEN...
Page 297 Section 07 REAR SUSPENSION Sub-Section 05 (TRACK) TRACK TRACK TYPE APPLICATION Move transmission sideway. Do not remove brake mechanism nor driven pulley. Refer to Refer to TECHNICAL DATA section10. SKANDIC WT SUSPENSION 07-02. Remove drive axle then track. GENERAL INSTALLATION This section gives guidelines for track removal.
Page 298 Section 07 REAR SUSPENSION Sub-Section 05 (TRACK) Insert pre-setted gauge between slider shoe and track. Allow gauge to settle by forcing track up and down. Track tension is as specified when edge of gauge reaches lign. A19F05A TYPICAL 1. Retaining screw 2.
Page 299 Section 07 REAR SUSPENSION Sub-Section 05 (TRACK) To correct, stop engine then tighten the adjuster TRACK CLEAT bolt on side where guides are farthest to slide. Re- Removal check alignment. – Raise rear of vehicle off the ground and lift snowguard then rotate track to expose a cleat to be replaced.
Page 301 Section 08 STEERING / FRONT SUSPENSION Sub-Section 01 (STEERING SYSTEM) STEERING SYSTEM S-Series 25 N•m 25 N•m (18 lbf•ft) (18 lbf•ft) A22G0KS A22G0KS 08-01-1...
Page 302 Section 08 STEERING / FRONT SUSPENSION Sub-Section 01 (STEERING SYSTEM) F-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 52 N•m (159 lbf•in) (38 lbf•ft) 40 N•m (30 lbf•ft) 40 N•m (30 lbf•ft) 18 N•m (159 lbf•in)
Page 303 Section 08 STEERING / FRONT SUSPENSION Sub-Section 01 (STEERING SYSTEM) Skandic WT 25 N•m 25 N•m (18 lbf•ft) (18 lbf•ft) A22G0KS A22G0KS 08-01-3...
Page 304 Section 08 STEERING / FRONT SUSPENSION Sub-Section 01 (STEERING SYSTEM) INSPECTION Check skis and runner shoes for wear, replace as necessary. (See section 08-02). 17, Steering Arm and Ski Leg Make sure steering arm and ski leg splines inter- lock. WARN IN G : Any p ar ts h a vin g w o rn splines have to be replaces with new ones.
Page 305 Section 08 STEERING / FRONT SUSPENSION Sub-Section 01 (STEERING SYSTEM) To install, stick the heating element to the handle- For proper torque specifications refer to the spe- bar making sure the wires do not interfere with cific exploded view for the vehicle being serviced. operation of the accelerator or brake handle.
Page 306 Section 08 STEERING / FRONT SUSPENSION Sub-Section 01 (STEERING SYSTEM) Skandic WT Only Install special washers (locking disks) with teeth facing each others. A22G0LA 9,13,15, Ball Joint Nut and Jam Nut A22G0MA Tighten ball joint, nuts and jam nuts to specified torque (see exploded view).
Page 307 Section 08 STEERING / FRONT SUSPENSION Sub-Section 01 (STEERING SYSTEM) See applicable exploded view for each model. Adjust the steering handlebar to the desired posi- tion. Lock the handlebar in place by tightening the 4 nuts as specified in the illustrations. CAUTION : Tighten the nuts equally in a criss-cross sequence and ensure there is an equal gap on each side of the clamps.
Page 308 Section 08 STEERING / FRONT SUSPENSION Sub-Section 01 (STEERING SYSTEM) Adjustments NOTE : Identical adjustments are required on both sides of the vehicle. F and S-Series – Make sure the vehicle is leveled by placing an Adjustments should be performed following this angle finder under the main frame member as sequence : shown on the following illustration.
Page 309 Section 08 STEERING / FRONT SUSPENSION Sub-Section 01 (STEERING SYSTEM) If a control arm is to be assembled, respect the A Procedure : center-to-center measurement. – Loosen jam nuts no. 13 and no. 15 of both tie rods no. 20. –...
Page 310 Section 08 STEERING / FRONT SUSPENSION Sub-Section 01 (STEERING SYSTEM) A06G03A TYPICAL 1. Straight edge 2. Measure here LUBRICATION WARNING : Do not lubricate throttle and / or brake cable, housing and spring cou- pler bolts. 26, Grease Fittings Only use low temperature grease (P / N 413 7061 00).
Page 311 Section 08 STEERING / FRONT SUSPENSION Sub-Section 01 (STEERING SYSTEM) S-Series and F-Series If so equipped A06G08S 08-01-11...
Page 312 Section 08 STEERING / FRONT SUSPENSION Sub-Section 02 (SUSPENSION AND SKI SYSTEM) SUSPENSION AND SKI SYSTEM F Series and S Series Some models 29 N•m (21 lbf•ft) 25 N•m (18 lbf•ft) 80 N•m (59 lbf•ft) Loctite Some models 40 N•m (29 lbf•ft) 17.5 N•m (159 lbf•in)
Page 313 Section 08 STEERING / FRONT SUSPENSION Sub-Section 02 (SUSPENSION AND SKI SYSTEM) DISASSEMBLY 5, Shock Lift front of vehicle and support it off the ground. Reduce spring preload by turning adjusting ring accordingly with the adjustment wrench in vehi- cle tool box. A03F12A 1.
Page 314 Section 08 STEERING / FRONT SUSPENSION Sub-Section 02 (SUSPENSION AND SKI SYSTEM) 7,8, Upper and Lower Half Arms Position half arms and tie rods horizontally before tightening nuts. 9,10,11, Bolt, Nut and Link Plate Attach link plate to frame with additional nuts and bolts, if applicable.
Page 315 Section 08 STEERING / FRONT SUSPENSION Sub-Section 02 (SUSPENSION AND SKI SYSTEM) A06G0XA WRONG POSITION 08-02-4...
Page 316 Section 08 STEERING / FRONT SUSPENSION Sub-Section 02 (SUSPENSION AND SKI SYSTEM) Skandic WT 13 N•m (115 lbf•in) Grease A22G0NS 08-02-5...
Page 317 Section 08 STEERING / FRONT SUSPENSION Sub-Section 02 (SUSPENSION AND SKI SYSTEM) ON-VEHICLE COMPONENT VERIFICATION 8, Shock Lift front of vehicle and support off the ground. Remove ski bolt and nut. Remove steel bushing from ski using a pusher. See pusher dimensions below. A22G0IA 1.
Page 318 Section 08 STEERING / FRONT SUSPENSION Sub-Section 02 (SUSPENSION AND SKI SYSTEM) A05G0CA 1. Allen screws A05G0DA NOTE : These washers and stopper can be 1. Washers and stopper wedged in cover wedged in cap. 2. Spring Pull out spring. 4,13,14,16,17, O-ring, Ski Leg, Bushing and Seal Suspension Free Operation...
Page 319 Section 08 STEERING / FRONT SUSPENSION Sub-Section 02 (SUSPENSION AND SKI SYSTEM) 8, Shock Absorber Secure the shock body end in a vise. A14F0BA 1. Clamp CAUTION : Do not clamp directly on shock body. Examine each shock for leaks. Extend and com- press the piston several times over its entire stroke then check that it moves smoothly and with uniform resistance.
Page 320 Section 08 STEERING / FRONT SUSPENSION Sub-Section 02 (SUSPENSION AND SKI SYSTEM) A05G0CB TYPICAL 1. Bent angle toward the bottom 16,17, Seal Install seal before reinstalling ski leg. 08-02-9...
Page 322 Section 09 BODY / FRAME Sub-Section 01 (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 is 25 mm (1 in) below the headlamp horizontal in) away from it.
Page 323 Section 09 BODY / FRAME Sub-Section 01 (BODY) DECAL HOOD To remove a decal ; heat old decal with a heat gun S Series and peel off slowly. Working from within engine compartment, re- Using isopropyl alcohol, clean the surface and dry move exterior nuts retaining both hinges.
Page 324 Section 09 BODY / FRAME Sub-Section 01 (BODY) BELT GUARD Disassembly and Assembly NOTE : For additional information (ex. : ex- ploded view) refer to the correspondent parts catalog. WARNING : Engine should be running only with belt guard and / or pulley guard well secured in place.
Page 325 Section 09 BODY / FRAME Sub-Section 01 (BODY) PLASTIC MAINTENANCE AND REPAIR MAINTENANCE Clean the vehicle thoroughly, removing all dirt and grease accumulation. To clean use a soft clean cloth and either soapy water or isopropyl alcohol. To remove grease, oil or glue use isopropyl alco- hol.
Page 326 Section 09 BODY / FRAME Sub-Section 01 (BODY) REPAIR The very first step before repairing plastic materials is to find out exactly which type of material is in- volved. Refer to following chart. CAUTION : Consult chart and repair kit instructions carefully, some repair products are not compatible with certain plastics.
Page 327 Section 09 BODY / FRAME Sub-Section 01 (BODY) MATERIAL REPAIR PROCEDURE – Apply a flexible primer such as Crest Prima Flex stock no. AP-F. Fiberglass – Wait 10 minutes. This material is repairable and repaintable, using – Repaint (air dry during 72 hours (approximate- any one of several kits available on the market.
Page 328 Section 09 BODY / FRAME Sub-Section 01 (BODY) CREST MAIN OFFICE AND MANUFACTURING PLANT CREST INDUSTRIES, INC. Phone : 313-283-4100 Toll Free : 1-800-822-4100 3841 13 Street Fax : 1-800-344-4461 Wyandotte, Michigan 48192 Fax : 313-283-4461 Crest products used in R.I.M. repair procedure are available from following locations : DISTRIBUTOR WAREHOUSE LOCATIONS UNITED STATES CANADA...
Page 329 Section 09 BODY / FRAME Sub-Section 02 (FRAME) FRAME FRAME CLEANING FRAME WELDING NOTE : For aluminum frames use only alu- Steel Frame : minum cleaner and follow instructions on – electric welding container. (Dursol cleaner or equivalent). – amperage : 70-110 A Clean frame and tunnel with appropriate cleaners –...
Page 330 Section 09 BODY / FRAME Sub-Section 02 (FRAME) FRAME COMPONENT REPLACEMENT DSA Suspension Models CAUTION : Do not attempt to drill hard- ened self-piercing rivets. Always grind rivet heads for removal. Rear Cap Grind rivet heads from top of rear cap and under- neath for side retaining rivets.
Page 331 Section 10 TECHNICAL DATA Sub-Section 01 (TECHNICAL DATA) TECHNICAL DATA SI* METRIC INFORMATION GUIDE BASE UNITS DESCRIPTION UNIT SYMBOL length meter mass kilogram force newton liquid liter temperature Celsius °C pressure kilopascal torque newton•meter N•m speed kilometer per hour km /h PREFIXES PREFIX SYMBOL...
Page 332 Section 10 TECHNICAL DATA Sun-Section 02 (ENGINES) VEHICLE MODEL SKANDIC MX Z MX Z MX Z SUMMIT ENGINE TYPE 583 HAC Number of Cylinders Bore 72.00 67.50 76.00 78.00 76.00 (in) (2.835) (2.657) (2.992) (3.071) (2.992) Stroke 61.00 61.00 64.00 70.00 64.00 (in)
Page 333 Section 10 TECHNICAL DATA Sub-Section 02 (ENGINES) VEHICLE MODEL SUMMIT FORMULA FORMULA FORMULA MACH Z / III / III LT Z LT ENGINE TYPE 670 HAC Number of Cylinders Bore 78.00 76.00 78.00 64.50 69.50 (in) (3.071) (2.992) (3.071) (2.539) (2.736) Stroke 70.00...
Page 334 Section 10 TECHNICAL DATA Sub-Section 03 (VEHICLES) VEHICLE MODEL SKANDIC WT MX-Z MX-Z MX-Z ENGINE TYPE 26/44 Chain Drive Ratio N.A. 23/44 25/44 Chain Pitch (in) N.A. Type, Links – Plates Qty N.A. Silent 72 – 13 Silent 74 – 13 Silent 74 –...
Page 335 Section 10 TECHNICAL DATA Sub-Section 03 (VEHICLES) VEHICLE MODEL SUMMIT SUMMIT FORMULA FORMULA SS ENGINE TYPE Chain Drive Ratio 22/44 23/44 25/44 26/44 Chain Pitch (in) Type / Links – Plates Qty Silent 72 – 13 Silent 72 – 13 Silent Silent 74 –...
Page 336 Section 10 TECHNICAL DATA Sub-Section 03 (VEHICLES) VEHICLE MODEL FORMULA III FORMULA III LT MACH Z MACH Z LT ENGINE TYPE Chain Drive Ratio 25/44 23/44 26/44 25/44 Chain Pitch (in) Type, Links – Plates Qty Silent 74 – 13 Silent 72 –...
Page 337 Section 10 TECHNICAL DATA Sub-Section 04 (TECHNICAL DATA LEGENDS) ENGINE LEGEND VEHICLE LEGEND BTDC : Before Top Dead Center DSA : Direct Shock Action CDI : Capacitor Discharge Ignition HPG : High Pressure Gas CTR : Center PRS : Progressive Rate Suspension Kilo (×...

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Summary of Contents for Ski-Doo MX Z 440

Page 90: Table Of Contents

Page 92: M (17 Lbf•Ft)

Page 94: 583 And

Page 97: Loctite

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