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Ski-Doo Scandic Series Shop Manual

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Page 1 Ski Doo Service Repair Manual Thank You for your purchase eBay seller foxmoto951 is the only authorized seller for this software If you have received this manual from any other eBay seller send it back for a refund & contact foxmoto951...
Page 3 2005 Shop Manual TUNDRA SKANDIC LT/LT E/WT/SWT/WT LC/SUV 550/SUV 600 EXPEDITION TUV 600 HO SDI/TUV V-1000 BOMBARDIER RECREATIONAL PRODUCTS INC.
Page 4: Table Of Contents
TABLE OF CONTENTS SAFETY NOTICE ................. . XIII INTRODUCTION ..
Page 5 TABLE OF CONTENTS CYLINDER AND CYLINDER HEAD ................. 19 CRANKSHAFT .
Page 6 TABLE OF CONTENTS GENERAL ......................89 TROUBLESHOOTING.
Page 7 TABLE OF CONTENTS 07 – AXIAL FAN COOLING SYSTEM................141 REMOVAL .
Page 8 TABLE OF CONTENTS WATER PUMP IMPELLER..................189 IGNITION COVER .
Page 9 TABLE OF CONTENTS ENGINE MANAGEMENT (2-TEC) 01 – OVERVIEW ....................257 OPERATING PRINCIPLE .
Page 10 TABLE OF CONTENTS IGNITION TIMING ....................295 ENGINE START/RER BUTTON VERIFICATION .
Page 11 TABLE OF CONTENTS CRANKING SYSTEM ....................340 TRANSMISSION 01 –...
Page 12 TABLE OF CONTENTS DISASSEMBLY ..................... 379 CLEANING .
Page 13 TABLE OF CONTENTS ELECTRICAL 01 – IGNITION TIMING ................... 421 .
Page 14 TABLE OF CONTENTS INSPECTION OF AC CIRCUIT ISOLATION ............. . 479 INSPECTION.
Page 15 TABLE OF CONTENTS ON-VEHICLE COMPONENT VERIFICATION ..............535 DISASSEMBLY ..
Page 16: Safety Notice
SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair some 2005 Ski-Doo snowmo- ® biles. See model list in introduction. This edition was primarily published to be used by snowmobile mechanic technicians who are already familiar with all service procedures relating to BRP made snowmobiles.
Page 17: Introduction
INTRODUCTION INTRODUCTION This Shop Manual covers the following BRP made 2005 snowmobiles: MODEL ENGINE COLOR MARKET MODEL NUMBER TUNDRA 280F (R) YELLOW CANADA USA FK5A TUNDRA 280F (R) BLACK CANADA USA FK5B SKANDIC LT 440F (R) YELLOW CANADA FH5B 440F (R) FH5A SKANDIC LT YELLOW...
Page 18: Vehicle Description Decal
INTRODUCTION Tundra Expedition TUV 600 HO SDI Expedition TUV V-1000 A05A0EA TYPICAL — TUNDRA Skandic LT Skandic LT E Skandic WT TYPICAL — EXPEDITION SERIES Skandic SWT Skandic WT LC Skandic SUV 550 VEHICLE DESCRIPTION DECAL Skandic SUV 600 Location Vehicle description decal is located on right hand side of tunnel.
Page 19: Vehicle Identification Number (Vin)
INTRODUCTION ENGINE SERIAL NUMBER Description Location VEHICLE DESCRIPTION DECAL 1. Manufacturer name and address 2. Manufacturing date 3. Vehicle identification number (VIN) 4. Model name 5. Option package 6. Engine type A03A0BA 7. Model year 8. Color codes TYPICAL — 2–STROKE FAN-COOLED ENGINES 1.
Page 20: List Of Abbreviations Used In This Manual
INTRODUCTION LIST OF ABBREVIATIONS USED ABREVIATION MEANING IN THIS MANUAL long track ABREVIATION MEANING meter ampere mile ampere magneto A•h ampere-hour Max. maximum alternate current Min. minimum acceleration and control modulator milliliter advance ride management millimeter bottom dead center MPEM multipurpose electronic module BTDC before top dead center...
Page 21: Arrangement Of This Manual
INTRODUCTION ARRANGEMENT OF THIS MANUAL Shop Manual Section 07 REAR SUSPENSION SUSPENSION SC-10 SPORT, TOURING AND MOUNTAIN A-Series and B-Series only Long track models only Short track models only CAUTION: XVIII mmr2005-001...
Page 22 INTRODUCTION Section 05 TRANSMISSION CAUTION: A-Series and B-Series Only All Models TYPICAL — TOP VIEW 1. Shim (P/N 504 108 200) (as required) 2. Contact A. 0 to 1 mm (0 to 3/64 in) mmr2005-001...
Page 23: General Information
INTRODUCTION GENERAL INFORMATION The information and component/system descrip- tions contained in this manual are correct at time of publication. BRP however, maintains a policy of continuous improvement of its products with- out imposing upon itself any obligation to install them on products previously manufactured. Due to late changes, it may have some differences between the manufactured product and the de- scription and/or specifications in this document.
Page 24: Loctite Application Procedure
INTRODUCTION LOCTITE APPLICATION Blind Holes PROCEDURE The following describes the most common ap- plication procedures when working with Loctite products. NOTE: Always use proper strength Loctite prod- uct as recommended in this Shop Manual. THREADLOCKER Uncovered Holes (bolts and nuts) 1.
Page 25: Stripped Thread Repair
INTRODUCTION Adjusting Screw – Apply several drops of proper strength Loctite on stud threads. – Install stud. – Install cover, etc. – Apply drops of proper strength Loctite on un- covered threads. – Tighten nuts as required. Preassembled Parts 1. Apply here 2.
Page 26: Gasket Compound
INTRODUCTION – If a plate is used to align bolt: – Spray Loctite Primer N on both mating surfaces and on both sides of gasket. Allow to dry 1 or – Apply release agent on mating surfaces. 2 minutes. – Put waxed paper or similar film on the sur- –...
Page 27: Case-In Components
INTRODUCTION CASE-IN COMPONENTS Metallic Gaskets 1. Proper strength Loctite – Clean inner housing diameter and outer gasket diameter. – Spray housing and gasket with Loctite Primer N (P/N 293 800 041). – Apply a strip of proper strength Loctite on lead- ing edge of outer metallic gasket diameter.
Page 28: Tightening Torque
INTRODUCTION TIGHTENING TORQUE Tighten fasteners to torque mentioned in exploded views and/or text, When they are not specified, refer to following table. The table also gives the metric conversion. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (ex.: lock- ing tabs, elastic stop nuts, self-locking fasteners, etc.) must be installed or replaced with new ones, where specified.
Page 29 INTRODUCTION XXVII mmr2005-001...
Page 30 INTRODUCTION XXVIII mmr2005-001...
Page 31: Maintenance
Section 01 MAINTENANCE Subsection 01 (MAINTENANCE CHART) MAINTENANCE CHART 10-HOUR OR 500 KM (300 mi) INSPECTION (to be performed by dealer) A: ADJUST WEEKLY OR EVERY 240 KM (150 mi) I: INSPECT (clean, inspect, repair, adjust, lubricate) MONTHLY OR EVERY 800 KM (500 mi) L: LUBRICATE ONCE A YEAR OR EVERY 3200 KM (2000 mi) R: REPLACE...
Page 32 Section 01 MAINTENANCE Subsection 01 (MAINTENANCE CHART) 10-HOUR OR 500 KM (300 mi) INSPECTION (to be performed by dealer) A: ADJUST WEEKLY OR EVERY 240 KM (150 mi) I: INSPECT (clean, inspect, repair, adjust, lubricate) MONTHLY OR EVERY 800 KM (500 mi) ONCE A YEAR OR EVERY 3200 KM (2000 mi) L: LUBRICATE R: REPLACE...
Page 33: Storage
Section 01 MAINTENANCE Subsection 02 (STORAGE) STORAGE SERVICE PRODUCTS Description Part Number Page anti-seize lubricant ..............293 800 070 ..........5 BOMBARDIER LUBE ............293 600 016 ......... 3, 5 BOMBARDIER premixed coolant ......... 293 600 038 ..........5 BOMBARDIER Scratch Remover Kit........861 774 800 ..........3 fuel stabilizer (250 mL) ............
Page 34: Battery
Section 01 MAINTENANCE Subsection 02 (STORAGE) BATTERY Engine internal parts must be lubricated to protect them from possible rust formation during the stor- Remove battery, clean its tray and its exterior sur- age period. To protect appropriately the engine face. Charge battery as explained in BATTERY use storage oil (Canada) (P/N 413 711 600) or stor- section.
Page 35: Cooling System
Section 01 MAINTENANCE Subsection 02 (STORAGE) VEHICLE PROTECTION Crank slowly 2 or 3 revolutions to lubricate cylin- ders. Protect the vehicle with a cover to prevent dust Reinstall the spark plugs and the outlet primer accumulation during storage. hose or air silencers. CAUTION: The snowmobile has to be stored WARNING in a cool and dry place and covered with an...
Page 36: Preseason Preparation
Section 01 MAINTENANCE Subsection 03 (PRESEASON PREPARATION) PRESEASON PREPARATION Proper vehicle preparation is necessary after the V-1000 and 593 SDI Engine Equipped Models Only summer months or when a vehicle has not been used for more than one month. Fuel filter, inlet and outlet hoses come as an as- sembly.
Page 37: Rags In Air Intake And Exhaust System
Section 01 MAINTENANCE Subsection 03 (PRESEASON PREPARATION) RAGS IN AIR INTAKE AND EXHAUST SYSTEM Remove rags that were installed during STORAGE preparation. ENGINE LUBRICATION All Models except 4-TEC Add 500 mL (17 U.S. oz) of recommended injec- tion oil to the first full filled fuel tank. CLEANING OF DRIVE AND DRIVEN PULLEYS Clean drive and driven pulleys sheaves with pulley...
Page 38: Troubleshooting Guide
Section 02 TROUBLESHOOTING GUIDE Subsection 01 (ENGINE (2-STROKE)) ENGINE (2-STROKE) The following chart is provided to help diagnose the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. ENGINE BACKFIRES.
Page 39: Technical Data
Section 02 TROUBLESHOOTING GUIDE Subsection 01 (ENGINE (2-STROKE)) ENGINE SUDDENLY TURNS OFF. Symptom: (cont’d) 3. Piston(s) seizure on exhaust side (color on piston dome is correct). Kinked fuel tank vent tube. Relocate fuel tank vent tube. Leaks at fuel line connections or damaged fuel lines. Replace defective lines. Fuel does not flow through carburetor(s) (foreign particles in needle area and/or varnish formation in carburetor(s)).
Page 40 Section 02 TROUBLESHOOTING GUIDE Subsection 01 (ENGINE (2-STROKE)) PISTON RING AND CYLINDER SURFACES ARE SCRATCHED. Symptom: 1. Check oil quality. Poor quality oil. Use XP-S injection oil. 2. Check injection pump and its hoses. Inadequate injection pump adjustment and/or defective hoses. Adjust pump according to spec- ifications (refer to ENGINE) and/or replace hoses.
Page 41 Section 02 TROUBLESHOOTING GUIDE Subsection 01 (ENGINE (2-STROKE)) ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH Symptom: MAXIMUM OPERATING RPM. (cont’d) 14. Check reed valve. Improper tightness and/or opening. Replace or adjust. Refer to proper engine subsection. ENGINE DETONATION AT MAXIMUM RPM. Symptom: 1.
Page 42 Section 02 TROUBLESHOOTING GUIDE Subsection 01 (ENGINE (2-STROKE)) ENGINE TURNS OVER BUT FAILS TO START (MANUAL START). Symptom: (cont’d) 7. Check engine compression. Insufficient engine compression. Replace defective part(s) (ex.: piston(s), ring(s), etc.). IRREGULAR ENGINE IDLE (NORMAL USE AFTER ENGINE WARM UP). Symptom: 1.
Page 43 Section 02 TROUBLESHOOTING GUIDE Subsection 01 (ENGINE (2-STROKE)) HIGH ENGINE OPERATING TEMPERATURE (LIQUID COOLED ENGINES). Symptom: 1. Check temperature gauge sensor. False reading. Check terminal connections. If problem persists, replace sensor. 2. Check if heat exchangers are clean. Dirty heat exchangers. Clean heat exchangers. 3.
Page 44 Section 02 TROUBLESHOOTING GUIDE Subsection 01 (ENGINE (2-STROKE)) ENGINE EQUIPPED WITH RAVE VALVE DOES NOT REACH ITS FULL OPERAT- Symptom: ING RPM (500 TO 1000 RPM SLOWER). (cont’d) 5. Check tension of RAVE springs. Inadequate spring tension. Replace. 6. Check RAVE pressure holes. Clogged holes.
Page 45 Section 02 TROUBLESHOOTING GUIDE Subsection 01 (ENGINE (2-STROKE)) ENGINE PINGING. Symptom: (cont’d) 5. Check compression ratio. Compression ratio is too high. Replace inadequate part(s) to obtain manufacturer's recommend- ed compression ratio or use a higher grade fuel. ENGINE GENERATES A LOT OF VIBRATIONS. Symptom: 1.
Page 46: Engine (4-Tec)
Section 02 TROUBLESHOOTING GUIDE Subsection 02 (ENGINE (4-TEC)) ENGINE (4-TEC) COOLING SYSTEM HIGH ENGINE OPERATING TEMPERATURE. Symptom: 1. Check coolant level. Coolant level lower than recommended. Check for leakage. Coolant leaking from control bore means a damaged water pump rotary seal. Replace rotary seal (refer to COOLING SYSTEM and CRANKCASE).
Page 47: Lubrication
Section 02 TROUBLESHOOTING GUIDE Subsection 02 (ENGINE (4-TEC)) LUBRICATION LOW OR NO OIL PRESSURE. Symptom: 1. Check oil level and search for leakage on crankcase and/or sealing parts. Oil drain plug on engine bottom is loosed and/or gasket ring is missing. Retighten the plug and/or place gasket ring.
Page 48: Cylinder And Cylinder Head
Section 02 TROUBLESHOOTING GUIDE Subsection 02 (ENGINE (4-TEC)) OIL CONTAMINATION (WHITE APPEARANCE). Symptom: (cont’d) 4. Check oil for particles (may indicate possible engine internal damages). Oil contamination due to metal or plastic particles. Replace possibly damaged part(s) including oil and oil filter. Use recommended oil (refer to TECHNICAL DATA). CYLINDER AND CYLINDER HEAD UNUSUAL ENGINE NOISE AND/OR VIBRATIONS.
Page 49 Section 02 TROUBLESHOOTING GUIDE Subsection 02 (ENGINE (4-TEC)) STARTER DOES NOT TURN. Symptom: (cont’d) 3. Check 30 A and 5 A fuses. Burnt fuse. Check wiring condition and replace fuse. 4. Check continuity of starter switch contact points. Poor contact of starter switch contact points. Repair or replace switch. 5.
Page 50: Engine General
Section 02 TROUBLESHOOTING GUIDE Subsection 02 (ENGINE (4-TEC)) ENGINE GENERAL ENGINE BACKFIRES. Symptom: 1. Check spark plug. Carbon accumulation caused by defective spark plug. Clean carbon accumulation and replace spark plug. 2. Check fault codes in B.U.D.S. system. Check if electrical actuator(s) is/are defective. Replace defective part(s) (refer to COMPONENT INSPECTION AND ADJUSTMENT).
Page 51 Section 02 TROUBLESHOOTING GUIDE Subsection 02 (ENGINE (4-TEC)) ENGINE SUDDENLY TURNS OFF. Symptom: (cont’d) 6. Melted and/or perforated piston dome; melted section at ring end gap. Spark plug heat range is too hot. Install recommended spark plug (refer to TECHNICAL DATA). Coolant less than recommended level (engine gets too hot).
Page 52 Section 02 TROUBLESHOOTING GUIDE Subsection 02 (ENGINE (4-TEC)) ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH Symptom: MAXIMUM OPERATING RPM. (cont’d) 7. Perform engine leak test. Refer to ENGINE LEAK TEST procedure. Check for possible pis- ton seizure. Damaged head gasket and/or seal and/or leaking intake/exhaust valve(s).
Page 53: Fuel And Oil Systems (2-Stroke Engines)
Section 02 TROUBLESHOOTING GUIDE Subsection 03 (FUEL AND OIL SYSTEMS (2-STROKE ENGINES)) FUEL AND OIL SYSTEMS (2-STROKE ENGINES) 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. NOTE: For the SDI fuel and oil systems troubleshooting, also refer to appropriate ENGINE subsection.
Page 54 Section 02 TROUBLESHOOTING GUIDE Subsection 03 (FUEL AND OIL SYSTEMS (2-STROKE ENGINES)) HIGH INJECTION OIL CONSUMPTION. Symptom: 1. Check oil injection pump adjustment. Oil injection pump adjusted too rich. Adjust. 2. Check injection pump identification. Wrong pump installed. Replace with the appropriate pump. Refer to OIL INJECTION SYSTEM. 3.
Page 55 Section 02 TROUBLESHOOTING GUIDE Subsection 03 (FUEL AND OIL SYSTEMS (2-STROKE ENGINES)) DPM SEEMS TO BE DEFECTIVE. Symptom: (cont’d) 3. Check for DPM manifold leaking. DPM manifold is leaking. Repair or replace. mmr2005-006...
Page 56: Transmission And Brake Systems
Section 02 TROUBLESHOOTING GUIDE Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) TRANSMISSION AND BRAKE SYSTEMS The following charts are provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. TRANSMISSION THE SNOWMOBILE ACCELERATES SLOWLY, ESPECIALLY FROM A STANDING Symptom:...
Page 57 Section 02 TROUBLESHOOTING GUIDE Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) LOOSENESS IS FELT IN DRIVE SYSTEM WHEN ACCELERATING/DECELERAT- Symptom: ING. 1. Check drive chain tension. Drive chain is too loose. Adjust. 2. Check radial play of driven pulley. Worn key, keyway or splines. Replace. VIBRATIONS ORIGINATING FROM DRIVE PULLEY.
Page 58 Section 02 TROUBLESHOOTING GUIDE Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) IN REVERSE ENGINE FAILS AND DRIVEN PULLEY OPENS TOO FAST (DRIVE Symptom: BELT IS LOW IN DRIVEN PULLEY). 1. Check pulley distance and alignment. Improper adjustment. Adjust according to specifications (refer to PULLEY DISTANCE AND ALIGNMENT) and make sure that torque rod is resting against engine.
Page 59 Section 02 TROUBLESHOOTING GUIDE Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) BELT TOO NARROW ON ONE SECTION. Symptom: 1. Check for frozen track. Frozen track. Free track from ice. 2. Check parking brake. Parking brake is engaged. Release parking brake. 3. Check track tension/alignment. Track too tight.
Page 60: Brake System
Section 02 TROUBLESHOOTING GUIDE Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) TOOTH CHUNK OUT. Symptom: 1. Check drive belt rotational direction. Improper belt installation. Replace. 2. Check if drive belt rubs against components. Belt rubs against fixed components. Relocate components. 3. Check drive pulley. Violent engagement of drive pulley.
Page 61: Mechanical And Hydraulic Brakes
Section 02 TROUBLESHOOTING GUIDE Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) BRAKE FLUID LEAKING. Symptom: 1. Check for loosen hose connectors. Replace copper washers and retighten. MECHANICAL AND HYDRAULIC BRAKES BRAKE SYSTEM IS NOISY. Symptom: 1. Check brake pad thickness. Pads are worn up to wear warner. Replace. 2.
Page 62: Electrical System
Section 02 TROUBLESHOOTING GUIDE Subsection 05 (ELECTRICAL SYSTEM) ELECTRICAL SYSTEM The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. STARTER DOES NOT TURN.
Page 63 Section 02 TROUBLESHOOTING GUIDE Subsection 05 (ELECTRICAL SYSTEM) STARTER TURNS BUT DOES NOT CRANK THE ENGINE. Symptom: (cont’d) 13. Check tension of brush springs. Weak brush spring tension. Replace springs. 14. Check yoke assembly magnets. Weak magnets. Replace yoke assembly. 15.
Page 64 Section 02 TROUBLESHOOTING GUIDE Subsection 05 (ELECTRICAL SYSTEM) ELECTRIC STARTER KEEPS TURNING WHEN ENGINE IS STARTED. Symptom: (cont’d) 6. Check starter relay contacts. Melted starter relay contacts. Replace starter relay. 7. Check starter switch. Starter switch returns poorly. Replace ignition switch. NOISE OCCURENCE WHEN STARTING ENGINE.
Page 65 Section 02 TROUBLESHOOTING GUIDE Subsection 05 (ELECTRICAL SYSTEM) ENGINE DOES NOT START — NO SPARK AT SPARK PLUG. (AT ENGINE CRANK- Symptom: ING.) (cont’d) 3. Verify if problem originated from electrical system wiring harness and/or accessories and/or ignition cut-out switches by unplugging the 3-wire connectors between the magneto/generator and the vehicle wiring harness.
Page 66 Section 02 TROUBLESHOOTING GUIDE Subsection 05 (ELECTRICAL SYSTEM) ENGINE IS MISFIRING — ERRATIC SPARK AT SPARK PLUG (NORMAL USE). Symptom: 1. Verify misfiring by observing flash of stroboscopic timing light; unplug connectors between magneto/generator and vehicle wiring harness to isolate problem. Check condition of con- nectors.
Page 67 Section 02 TROUBLESHOOTING GUIDE Subsection 05 (ELECTRICAL SYSTEM) RER (ROTAX ELECTRONIC REVERSE) DOES NOT WORK. Symptom: 1. Check idle speed. Wrong idle speed. Adjust according to specification (refer to TECHNICAL DATA). 2. Check spark plug. Faulty spark plug. Replace. 3. Check drive belt deflection. Wrong deflection.
Page 68 Section 02 TROUBLESHOOTING GUIDE Subsection 05 (ELECTRICAL SYSTEM) HEADLAMP DIMING. Symptom: (cont’d) 4. Verify if there is an interconnection between AC and DC current (fan-cooled models). Faulty installation of optional equipment. Find optional equipment connected directly to DC ground (BK wire or chassis) or to any DC hot wire (RD, RD/BU). Disconnect and reconnect to AC current (YL and YL/BK wires).
Page 69 Section 02 TROUBLESHOOTING GUIDE Subsection 05 (ELECTRICAL SYSTEM) REAR LIGHT BULB FLASHES. Symptom: 1. Check bulb tightness in housing. Looseness at bulb contact elements. Install bulb correctly. 2. Check if rear light is properly connected. Connector housing is partially connected. Install connector housing properly. 3.
Page 70: Suspension And Track
Section 02 TROUBLESHOOTING GUIDE Subsection 06 (SUSPENSION AND TRACK) SUSPENSION AND TRACK The following chart is provided to help diagnose the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SUSPENSION IS TOO LOW.
Page 71: Steering System
Section 02 TROUBLESHOOTING GUIDE Subsection 06 (SUSPENSION AND TRACK) WHEN HANDLEBAR IS TURNED, SNOWMOBILE UNDERSTEERS. Symptom: (cont’d) 3. Check if front arm stopper strap is too long. Insufficient ski pressure on the ground. Shorten stopper strap. 4. Check front arm spring preload. Insufficient ski pressure on the ground.
Page 72 Section 02 TROUBLESHOOTING GUIDE Subsection 06 (SUSPENSION AND TRACK) DERAILING TRACK. Symptom: 1. Check track tension. Track is too loose. Adjust. 2. Check if track and slider shoes are properly aligned. Improper alignment. Adjust. NOISE OR VIBRATION COMING FROM THE TRACK. Symptom: 1.
Page 73: Engines (2-Stroke)
Section 03 ENGINES (2-STROKE) Subsection 01 (277 ENGINE TYPE) 277 ENGINE TYPE SERVICE TOOLS Description Part Number Page 18 mm sleeve kit ..............529 035 541 ........... 51 locating sleeve..............529 023 800 ........... 51 piston circlip installer ............529 035 561 ........... 54 piston pin puller ..............
Page 74: Engine Removal And Installation
Section 03 ENGINES (2-STROKE) Subsection 01 (277 ENGINE TYPE) ENGINE REMOVAL AND INSTALLATION mmr2005-010...
Page 75: Removal From Vehicle
Section 03 ENGINES (2-STROKE) Subsection 01 (277 ENGINE TYPE) REMOVAL FROM VEHICLE Remove or disconnect the following then lift en- gine from vehicle: – guard – drive belt – muffler – carburetor – oil injection pump cable – oil injection inlet line –...
Page 76: Top End
Section 03 ENGINES (2-STROKE) Subsection 01 (277 ENGINE TYPE) TOP END mmr2005-010...
Page 77: Troubleshooting
Section 03 ENGINES (2-STROKE) Subsection 01 (277 ENGINE TYPE) TROUBLESHOOTING Place a clean cloth or rubber pad (P/N 529 023 400) over crankcase to prevent circlips no. 8 from Before completely disassembling the engine, falling into crankcase. Then with a pointed tool check airtightness.
Page 78 Section 03 ENGINES (2-STROKE) Subsection 01 (277 ENGINE TYPE) Install sleeve then shouldered sleeve over puller rod. A02C2DA TYPICAL 1. Sleeve inside bearing A02C2BA 2. Thrust washer TYPICAL — INSTALLATION OF SLEEVE KIT 3. Shouldered sleeve end 1. Sleeve 2. Shouldered sleeve Remove puller.
Page 79: Inspection
Section 03 ENGINES (2-STROKE) Subsection 01 (277 ENGINE TYPE) Install locating sleeve. Then push needle bearings along with thrust washers and sleeve. TYPICAL 1. Locating sleeve 2. Sleeve A02C2GA NOTE: 0.25 and 0.5 mm oversize pistons and TYPICAL 1. Sleeve rings are available if necessary.
Page 80 Section 03 ENGINES (2-STROKE) Subsection 01 (277 ENGINE TYPE) Install shouldered sleeve. Insert circlip in tool at an angle. 1. Circlip A02C2IA Square it up using a finger. TYPICAL — SHOULDERED SLEEVE INSTALLATION Install piston pin puller and turn handle until piston pin is correctly positioned in piston.
Page 81 Section 03 ENGINES (2-STROKE) Subsection 01 (277 ENGINE TYPE) Continue to square it up using round end of circlip Mount tool in piston making sure that circlip break installer. is facing down. A02C2OA TYPICAL 1. Circlip break facing down A02C2MA Hold tool firmly against piston then strike on round end of tool.
Page 82 Section 03 ENGINES (2-STROKE) Subsection 01 (277 ENGINE TYPE) CAUTION: Circlips must not move freely in the groove after installation. If so, replace them. Before inserting piston in the cylinder, lubricate the cylinder with new injection oil or equivalent. Position cylinder head on cylinder with fins in line with crankshaft center line.
Page 83: Bottom End
Section 03 ENGINES (2-STROKE) Subsection 01 (277 ENGINE TYPE) BOTTOM END mmr2005-010...
Page 84: Cleaning
Section 03 ENGINES (2-STROKE) Subsection 01 (277 ENGINE TYPE) NOTE: Engine must be removed from chassis to M8 x 110 mm perform the following procedures. CLEANING Discard all oil seals and gaskets. Clean all metal components in a non-ferrous metal cleaner.
Page 85 Section 03 ENGINES (2-STROKE) Subsection 01 (277 ENGINE TYPE) Prior to installation, place bearings into an oil con- tainer and heat the oil to 75°C (167°F) for 5 to 10 min. This will expand bearings and ease installa- tion. Install bearings with groove outward. NOTE: Crankshaft end play requires adjustment only when crankshaft and/or crankcase is re- placed.
Page 86: 443 And 552 Engines
Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) 443 AND 552 ENGINES SERVICE TOOLS Description Part Number Page bearing heater............... 529 035 969 ........70, 79 circlip installer ............... 529 035 686 ........... 72 distance gauge ..............420 876 822 ........... 79 distance gauge ..............
Page 87: Engine Removal And Installation
Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) ENGINE REMOVAL AND INSTALLATION 443 Engine mmr2005-011...
Page 88 Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) 552 Engine mmr2005-011...
Page 89: Engine Removal And Installation
Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) ENGINE REMOVAL AND INSTALLATION Disconnect or remove the following: WARNING Before disconnecting any electrical wire in starter system always first disconnect the BLACK negative battery cable (on electric starting models). –...
Page 90: Top End
Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) TOP END 443 Engine mmr2005-011...
Page 91 Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) 552 Engine mmr2005-011...
Page 92: General
Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) GENERAL CAUTION: While performing any engine relat- ed procedure, always make sure that the work- ing area is clean and free from dust or particles to reduce the risk of damaging the engine. TROUBLESHOOTING Before completely disassemble engine, check air- tightness.
Page 93 Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) A02C2CA TYPICAL — PISTON PIN EXTRACTION TYPICAL 1. Properly seated all around Install sleeve then shouldered sleeve over puller rod. A02C2DA TYPICAL 1. Sleeve inside bearing 2. Thrust washer 3. Shouldered sleeve end A02C2BA TYPICAL —...
Page 94: Inspection
Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) ASSEMBLY Remove puller. Pull out shouldered sleeve care- fully. 443 and 552 Engines When reinstalling original needle bearings, make sure that 31 needles (in case of 443 engine) or 34 (in case of 552 engine) are inserted between sleeve and locating sleeve.
Page 95 Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) Heat piston using bearing heater (P/N 529 035 969). A02C2IA TYPICAL — SHOULDERED SLEEVE INSTALLATION Install piston pin puller and turn handle until piston CAUTION: Piston temperature must not exceed pin is correctly positioned in piston.
Page 96 Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) 443 Engine To minimize the effect of acceleration forces on circlip, install each circlip so the circlip break is at 6 o'clock as illustrated. Use piston circlip installer (P/N 529 035 561). Insert circlip in tool at an angle.
Page 97 Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) Mount tool in piston making sure that circlip break is facing down. With round end of pusher, position circlip perpen- dicular to the support axis. A02C2OA TYPICAL 1. Circlip break facing down Hold tool firmly against piston then strike on round end of tool with a plastic hammer.
Page 98 Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) CAUTION: Always install a gasket of the proper thickness. Failure to do so may cause detona- tion and severe engine damage. All Engines Before inserting piston in cylinder no. 4, lubricate the cylinder with new injection oil or equivalent.
Page 99 Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) With blade stopper no. 13 removed, check reed valve for proper tightness. There must be no play between blade and valve body when exerting a finger pressure on blade at blade stopper location. In case of a play, turn blade upside down and recheck.
Page 100: Bottom End
Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) BOTTOM END 443 Engine mmr2005-011...
Page 101 Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) 552 Engine mmr2005-011...
Page 102: Cleaning
Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) NOTE: Engine must be removed from chassis to perform the following procedures. Remove engine from chassis. Remove fan guard, rewind starter, starting pulley, trigger coil wire from 4-connector housing, mag- neto flywheel then fan housing.
Page 103: Inspection
Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) INSPECTION Refer to ENGINE DIMENSIONS MEASUREMENT. ASSEMBLY Clean crankshaft end with sand paper no. 180 and remove all residue using pulley flange cleaner (P/N 413 711 809). BEARING PULLER SECURED IN THE VISE CAUTION: Never use any air impact tool to tighten the puller bolt.
Page 104 Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) 443 Engine CAUTION: Bearing should not be heated to more than 80°C (176°F). Do not heat bearing To check proper clearance between bearing no. 3 with direct flame or heat gun or heated oil. and crankshaft counterbalance, use feeler gauge Inappropriate heating procedure(s) may cause (P/N 420 876 620).
Page 105 Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) WARNING Do not touch heated bearing with bare hands. Wear heat resisting gloves before handling the heated bearing(s). Slide in the inner PTO bearing with the integrated seal facing crankshaft. Push bearing to end posi- tion.
Page 106 Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) A03C1HA TYPICAL 1. Drive pins 552 Engine CAUTION: Use only the recommended Isoflex grease (P/N 293 550 021). Make sure not to push Isoflex grease between outside bearing race and half crankcase. Install the MAG side heated bearing.
Page 107 Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) When installing plain oil seals (seal without locat- CAUTION: Do not use Loctite 515 or 518 to seal crankcase. Do not use Loctite Primer N with ing ring or without spacing legs), ensure to main- the Loctite 5910.
Page 108: Break-In
Section 03 ENGINES (2-STROKE) Subsection 02 (443 AND 552 ENGINES) BREAK-IN NOTE: Do not use Loctite Primer N with this sealant. The sealant curing time is similar to the After rebuilding an engine always observe a break- Loctite 518 without using the Primer N, which is in period as described in Operator's Guide.
Page 109: 593 And 593 Ho Sdi Engines
Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) 593 AND 593 HO SDI ENGINES SERVICE TOOLS Description Part Number Page 20 mm sleeve kit ..............529 035 542 ........... 93 bearing heater............... 529 035 969 ........96, 104 bearing puller ................
Page 110: Removal From Vehicle
Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) Skandic WT LC/SUV 600/Expedition – Seal exhaust ball joints with Ultra Copper TUV 600 HO SDI (P/N 413 710 300). REMOVAL FROM VEHICLE Open hood. Expedition TUV 600 HO SDI Using B.U.D.S.
Page 111: Top End
Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) TOP END 593 Engine mmr2005-012...
Page 112 Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) 593 HO SDI Engine mmr2005-012...
Page 113: General
Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) GENERAL CAUTION: While performing any engine relat- ed procedure, always make sure that the work- ing area is clean and free from dust or particles to reduce the risk of damaging the engine. TROUBLESHOOTING Before completely disassembling the engine, check airtightness.
Page 114: Disassembly
Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) Maintenance All Engines There are no wear parts anywhere in the system and there are no adjustments to be periodically checked. The only possible maintenance required would be cleaning of carbon deposits from the guillotine slide.
Page 115 Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) TYPICAL 1. Allen socket screws 1. Spring 2. RAVE valve base 2. Valve piston 3. Bellows Unscrew and remove the guillotine no. 15 from the valve piston no. 9 than remove the gasket Remove the valve piston.
Page 116 Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) All Engines Unplug coolant hose from upper thermostat hous- ing no. 30. Unscrew all cylinder head cover screws no. 24. Cylinder Head Remove the cylinder head cover no. 2. Disconnect the temperature sensor connector.
Page 117 Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) This engine is equipped with cageless piston pin bearings. A02C2BA TYPICAL — INSTALLATION OF SLEEVE KIT 1. Sleeve 2. Shouldered sleeve Use piston pin puller (P/N 529 035 503) along with 20 mm sleeve kit (P/N 529 035 542) and locating Screw (LH threads) extracting nut.
Page 118: Inspection
Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) TYPICAL 1. Locating sleeve A02C2DA 2. Sleeve TYPICAL 1. Sleeve inside bearing 2. Thrust washer Exhaust Manifold 3. Shouldered sleeve end 593 HO SDI Engine Remove puller. Pull out shouldered sleeve care- Upon removal of the exhaust manifold no.
Page 119: Assembly
Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) TYPICAL 1. Draining hole 1. Locking tie 2. Passages 2. Spring NOTE: Oil dripping from draining hole indicates a Install RAVE valve with its mention “TOP” as illus- loosen spring or damaged bellows.
Page 120 Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) When installing a new cageless bearing, replace half plastic cages with sleeve. NOTE: 593 engine cageless bearings have 28 nee- dles. TYPICAL CAUTION: Piston temperature must not exceed 46°C (115°F).
Page 121 Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) With round end of pusher, position circlip perpen- dicular to the support axis. A02C2IA TYPICAL — SHOULDERED SLEEVE INSTALLATION Install piston pin puller and turn handle until piston pin is correctly positioned in piston.
Page 122 Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) CAUTION: Always install a gasket of the proper thickness. Failure to do so may cause detona- tion and severe engine damage. Before inserting piston no. 18 in cylinder no. 4, lu- bricate the cylinder with new injection oil or equiv- alent.
Page 123 Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) In case of a play, turn blade upside down and recheck. If there is still a play, replace blade and/or valve body. TYPICAL Tighten exhaust manifold bolts in a criss-cross se- A06C0FA quence as per the following table.
Page 124: Bottom End
Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) BOTTOM END 593 Engine mmr2005-012...
Page 125 Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) 593 HO SDI Engine mmr2005-012...
Page 126: Cleaning
Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) NOTE: Engine must be removed from chassis to perform the following procedures. CLEANING Discard all oil seals, gaskets, O-rings and sealing rings. Clean all metal components in a non-ferrous met- al cleaner.
Page 127: Inspection
Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) NOTE: In the case of damaged bearing or less clearance between crankshaft counterbalance and the bearing or on the MAG side bearing, use bearing separator (Snap-On tool (P/N CJ951) or (P/N SPX/OTC) tool (P/N 1124) to facilitate the removal.
Page 128 Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) Heat up the bearing(s) using bearing heater Probe the inner race of the bearing with the tem- (P/N 529 035 969). This will expand bearings perature indicator stick (P/N 529 035 970). Stick and ease installation.
Page 129 Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) Install support plate (P/N 529 035 976) with appro- priate distance gauge; refer to following table. DISTANCE GAUGE P/N ENGINE APPLICATION 529 035 966 529 035 968 593 HO SDI Slide-in the second bearing until it contacts the first one.
Page 130 Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) Put 50 to 55 mL of Isoflex grease (P/N 293 550 021) in a syringe. CAUTION: Do not exceed the recommended amount of grease. Fill inner side of PTO side bearing with Isoflex grease (P/N 293 550 021) (about 10 mL).
Page 131 Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) Use a plexiglass plate and apply some sealant on it. Use a soft rubber roller (50 - 75 mm (2 - 3 in)) (available in arts products suppliers for printmak- ing) and roll the sealant to get a thin uniform coat on the plate (spread as necessary).
Page 132: Break-In
Section 03 ENGINES (2-STROKE) Subsection 03 (593 AND 593 HO SDI ENGINES) Screw all crankcase bolts in place in the following sequence and to the appropriate torque through a two steps torquing: first, screw bolts up to 60% of the final torque (18 N•m (13.5 lbf•ft) for most of the bolts), then, tighten to the required torque (i.e.
Page 133: Leak Test And Engine Dimension Measurement
Section 03 ENGINES (2-STROKE) Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) LEAK TEST AND ENGINE DIMENSION MEASUREMENT SERVICE TOOLS Description Part Number Page degree wheel................ 414 352 900 ......... 121 dial indicator................414 104 700 ......... 118, 121 hose pincher ................. 295 000 076 ......... 109 vacuum/pressure pump............
Page 134: Procedure
Section 03 ENGINES (2-STROKE) Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) PROCEDURE NOTE: A flow chart has been prepared as a visual reference. See last page of this chapter. Using flow chart and following text, pressurize area to be tested and spray soapy solution at the indicated location.
Page 135 Section 03 ENGINES (2-STROKE) Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Check for air bubbles or oil column going toward pump. It indicates defective check valve in injec- tion nipples. – Remove cooling system cap. Check for air bubbles in antifreeze. It indicates de- fective cylinder head O-ring or cylinder base gas- ket.
Page 136: Finalizing Reassembly
Section 03 ENGINES (2-STROKE) Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) 1. Check mounting area – If leak still persists, it indicates a defective cast- ing somewhere in engine. – Disassemble engine and carefully check for de- fects in castings. Pay attention to tapped holes which may go through engine sealed area and thus lead to leakage.
Page 137: Engine Leak Verification Flow Chart
Section 03 ENGINES (2-STROKE) Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) ENGINE LEAK VERIFICATION FLOW CHART ENGINE LEAK VERIFICATION FLOW CHART PRESSURIZE ENGINE IS ENGINE LEAKING? CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS. MOUNTING FLANGES ETC. REPLACE GASKET OR O-RING, ANY LEAK FOUND? RE-SEAL LEAKING AREA CHECK SMALL OIL LINES OF...
Page 138: Engine Dimension Measurement
Section 03 ENGINES (2-STROKE) Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) CYLINDER OUT OF ROUND ENGINE DIMENSION MEASUREMENT ENGINE TYPE MAXIMUM This section covers all engine types. 0.08 mm (.003 in) CYLINDER HEAD WARPAGE Measuring 16 mm (5/8 in) from top of cylinder with a cylinder gauge, check if the cylinder out of round ENGINE TYPE MAXIMUM...
Page 139 Section 03 ENGINES (2-STROKE) Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) 1. Combustion chamber NOTE: When checking the combustion chamber volume, engine must be cold, piston must be free of carbon deposit and cylinder head must be lev- eled. –...
Page 140: Engine Type
Section 03 ENGINES (2-STROKE) Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) NOTE: When the combustion chamber is filled to top of spark plug hole, it includes an amount of 2.25 cc corresponding to the spark plug well. – Repeat the procedure for the other cylinder. COMBUSTION CHAMBER VOLUME (cc) ENGINE TYPE...
Page 141: Technical Data
Section 03 ENGINES (2-STROKE) Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Adjust and lock a micrometer to the specified val- ue on the piston dome. 1. Micrometer set to the piston dimension 1. Indicator set to 0 (zero) With the micrometer set to the piston dimension, IMPORTANT: Always remove cylinders from adjust a cylinder bore gauge to the micrometer crankcase before measuring.
Page 142: Ring/Piston Groove Clearance
Section 03 ENGINES (2-STROKE) Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) RING/PISTON GROOVE Measuring (in crankcase) CLEARANCE First, check deflection with crankshaft in engine. If deflection exceeds the specified tolerance, Using a feeler gauge check clearance between up- recheck deflection using V-shaped blocks to de- per compression ring and groove.
Page 143: Connecting Rod Big End Axial Play
Section 03 ENGINES (2-STROKE) Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) CRANKSHAFT END-PLAY Crankshaft Deflection in Center of Crankshaft 277 Engine Type MAXIMUM IN CENTER ENGINE TYPE MINIMUM MAXIMUM ENGINE TYPE OF CRANKSHAFT mm (in) 0.10 mm .030 mm (.004 in) (.012 in) 0.08 (.0031)
Page 144: Checking Surface Flatness
Section 03 ENGINES (2-STROKE) Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) The result is the actual crankshaft end-play that must be within specification. If the result is over specification, add adjustment shim(s) to reach this specification. If the result is under specification, remove adjust- ment shim(s) to reach this specification.
Page 145: Rectifying Surfaces
Section 03 ENGINES (2-STROKE) Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Lay part on a surface plate (marble, mirror or thick glass plate). Holding down one end of part, try pushing down the other end. If any play is felt, part must be rectified. RECTIFYING SURFACES Stick a fine sand paper sheet on the surface plate then lightly oil the sand paper.
Page 146: Magneto System
Section 03 ENGINES (2-STROKE) Subsection 05 (MAGNETO SYSTEM) MAGNETO SYSTEM SERVICE TOOLS Description Part Number Page clutch holder ................. 529 027 600 ......... 128 crankshaft protector ............. 420 876 557 ......... 129 magneto puller..............529 035 547 ......... 129 magneto puller ring............... 420 876 080 ......... 128 SERVICE PRODUCTS Description Part Number...
Page 147 Section 03 ENGINES (2-STROKE) Subsection 05 (MAGNETO SYSTEM) 277 Engine mmr2005-014...
Page 148 Section 03 ENGINES (2-STROKE) Subsection 05 (MAGNETO SYSTEM) 443 and 552 Engines mmr2005-014...
Page 149 Section 03 ENGINES (2-STROKE) Subsection 05 (MAGNETO SYSTEM) 593 Engine mmr2005-014...
Page 150 Section 03 ENGINES (2-STROKE) Subsection 05 (MAGNETO SYSTEM) 593 SDI Engine mmr2005-014...
Page 151: General
Section 03 ENGINES (2-STROKE) Subsection 05 (MAGNETO SYSTEM) GENERAL NOTE: The following procedures can be done without removing the engine from chassis. To facilitate magneto removal, hold drive pulley with clutch holder (P/N 529 027 600). During assembly/installation, use the torque val- ues and service products as in the exploded views.
Page 152: Assembly
Section 03 ENGINES (2-STROKE) Subsection 05 (MAGNETO SYSTEM) – Remove grommet from crankcase where trig- ger coil wire exits magneto housing. – Remove retaining screws no. 4. – Remove trigger coil and carefully pull wires. – Install new trigger coil and other parts removed. ASSEMBLY Trigger Coil For installation, reverse the removal procedure.
Page 153 Section 03 ENGINES (2-STROKE) Subsection 05 (MAGNETO SYSTEM) Clean nut threads and apply Loctite 243 (P/N 293 800 060) then tighten nut to 105 N•m (77 lbf•ft) for fan-cooled engines and to 125 N•m (92 lbf•ft) for liquid-cooled engines. At reassembly coat all electric connections except Deutsch housings (waterproof gray housing) with silicone dielectric grease (P/N 293 550 004) to pre- vent corrosion or moisture penetration.
Page 154: Oil Injection System
Section 03 ENGINES (2-STROKE) Subsection 06 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM SERVICE TOOLS Description Part Number Page gear holder................420 876 695 ......... 137 hose pinchers ............... 295 000 076 ......... 136 leak testing kit ..............529 033 100 ......... 136 SERVICE PRODUCTS Description Part Number...
Page 155: Oil Injection Pump
Section 03 ENGINES (2-STROKE) Subsection 06 (OIL INJECTION SYSTEM) OIL INJECTION PUMP 277 Engine mmr2005-015...
Page 156 Section 03 ENGINES (2-STROKE) Subsection 06 (OIL INJECTION SYSTEM) 443 Engine mmr2005-015...
Page 157 Section 03 ENGINES (2-STROKE) Subsection 06 (OIL INJECTION SYSTEM) 552 Engine Recommended mmr2005-015...
Page 158 Section 03 ENGINES (2-STROKE) Subsection 06 (OIL INJECTION SYSTEM) 593 and 593 HO SDI Engines mmr2005-015...
Page 159: General
Section 03 ENGINES (2-STROKE) Subsection 06 (OIL INJECTION SYSTEM) GENERAL OIL SYSTEM LEAK TEST During assembly/installation, use the torque val- The following test will indicate any leak from oil ues and service products as in the exploded reservoir to the banjo fitting(s). views.
Page 160: Cleaning
Section 03 ENGINES (2-STROKE) Subsection 06 (OIL INJECTION SYSTEM) 5,6, Gear Retaining Nut and Oil Pump OIL PUMP ENGINE TYPE Gear IDENTIFICATION 277, 443 and 552 Engines 132K To remove gear retaining nut, first extract the nee- dle roller with pliers then lock gear in place using gear holder (P/N 420 876 695).
Page 161: Adjustment
Section 03 ENGINES (2-STROKE) Subsection 06 (OIL INJECTION SYSTEM) 3, Screw Torque to 5 N•m (44 lbf•in). Cable plastic elbow must be fastened and fully inserted. Make sure cable barrel is well seated in oil pump lever. Secure barrel with plastic washer and circlip. Install cable lock washer on lever side.
Page 162: Oil Pump Adjustment
Section 03 ENGINES (2-STROKE) Subsection 06 (OIL INJECTION SYSTEM) Loosen the adjuster nut and adjust accordingly. Depress the throttle lever lightly until the cable is under tension but carburetors or throttle body are Retighten the adjuster nut. not yet opened. NOTE: Throttle cable visible distance “A”...
Page 163: Bleeding Oil Lines
Section 03 ENGINES (2-STROKE) Subsection 06 (OIL INJECTION SYSTEM) CHECKING OPERATION Oil Pump On Vehicle NOTE: Main oil line must be full of oil. See bleed- ing procedure above. Lift rear of vehicle and support with a mechani- cal stand. Disconnect small oil lines from pump. Start engine and stop it as soon as it fires.
Page 164: Axial Fan Cooling System
Section 03 ENGINES (2-STROKE) Subsection 07 (AXIAL FAN COOLING SYSTEM) AXIAL FAN COOLING SYSTEM SERVICE TOOLS Description Part Number Page holder wrench............... 420 876 357 ......... 144, 146 SERVICE PRODUCTS Description Part Number Page holder wrench for the 443 engine ........420 876 357 ......... 143 holder wrench for the 5‘52 engine ........
Page 165 Section 03 ENGINES (2-STROKE) Subsection 07 (AXIAL FAN COOLING SYSTEM) 443 and 552 Engines NOTE: For 277 engine radial fan cooling system, refer to CDI SYSTEM. mmr2005-016...
Page 166: Removal
Section 03 ENGINES (2-STROKE) Subsection 07 (AXIAL FAN COOLING SYSTEM) NOTE: The following procedures can be done without removing engine from chassis. REMOVAL NOTE: To facilitate further disassembly, fan nut may be removed before removing fan housing. Remove rewind starter, starting pulley, trigger coil wire from 4-connector housing then fan housing ass'y.
Page 167: Installation
Section 03 ENGINES (2-STROKE) Subsection 07 (AXIAL FAN COOLING SYSTEM) 552 Engine Using holder wrench (P/N 529 036 006), remove fan nut. All Engines Remove fan with pulley half. A23C07A 1. Ring supporting fan housing Remove circlip no. 11 then remaining bearing. To install, press one bearing in place then install circlip and shims.
Page 168 Section 03 ENGINES (2-STROKE) Subsection 07 (AXIAL FAN COOLING SYSTEM) Reassembly Install fan belt on bottom pulley first then position onto fan shaft, as shown in the next photo. A03C2AA FAN BELT PROPERLY INSTALLED ON BOTTOM PULLEY AND FAN SHAFT 1.
Page 169 Section 03 ENGINES (2-STROKE) Subsection 07 (AXIAL FAN COOLING SYSTEM) Finalizing Reassembly Reinstall rewind starter. CAUTION: When installing rewind starter, en- sure that oil pump shaft is properly positioned. Do not force shaft insertion. Turn fan until oil pump shaft slides in place, as shown in the fol- lowing photo.
Page 170: Liquid Cooling System
Section 03 ENGINES (2-STROKE) Subsection 08 (LIQUID COOLING SYSTEM) LIQUID COOLING SYSTEM SERVICE TOOLS Description Part Number Page engine leak tester kit ............861 749 100 ......... 149 hose pincher ................. 295 000 076 ......... 149 siphon tool ................529 035 880 ......... 149 special radiator cap ...............
Page 171 Section 03 ENGINES (2-STROKE) Subsection 08 (LIQUID COOLING SYSTEM) 593 Engine mmr2005-017...
Page 172: Cooling System Leak Test
Section 03 ENGINES (2-STROKE) Subsection 08 (LIQUID COOLING SYSTEM) COOLING SYSTEM LEAK TEST 3,4 Sender and Plug or Elbow Apply Loctite 592 (P/N 293 800 018) thread sealant Install special radiator cap (P/N 529 021 400) in- on sender no. 3 and plug or elbow no. 4 to avoid cluded in engine leak tester kit (P/N 861 749 100) leaks.
Page 173 Section 03 ENGINES (2-STROKE) Subsection 08 (LIQUID COOLING SYSTEM) A16C02A TYPICAL — CLOSED THERMOSTAT, COLD ENGINE 1. To reservoir 2. From cylinders – When the liquid is warmed enough, the ther- 1. Hose mostat opens progressively the circuit, water 2. Clamp pump —...
Page 174: Cooling System Refilling Procedure
Section 03 ENGINES (2-STROKE) Subsection 08 (LIQUID COOLING SYSTEM) COOLING SYSTEM REFILLING PROCEDURE CAUTION: To prevent rust formation or freez- ing condition, always replenish the system with the Bombardier premixed coolant or with 50% antifreeze and 50% water. Pure antifreeze without water freezes (like slush ice).
Page 175: Rewind Starter
Section 03 ENGINES (2-STROKE) Subsection 09 (REWIND STARTER) REWIND STARTER SERVICE PRODUCTS Description Part Number Page Molykote PG 54..............420 899 763 ......... 157, 159 mmr2005-018...
Page 176 Section 03 ENGINES (2-STROKE) Subsection 09 (REWIND STARTER) Rewind Starter on Fan Cooled Models 11 10 TYPICAL mmr2005-018...
Page 177 Section 03 ENGINES (2-STROKE) Subsection 09 (REWIND STARTER) Rewind Starter on Liquid Cooled Models mmr2005-018...
Page 178: Inspection
Section 03 ENGINES (2-STROKE) Subsection 09 (REWIND STARTER) INSPECTION NOTE: Due to dust accumulation, rewind starter must be periodically cleaned, inspected and relu- bricated. CAUTION: It is of the utmost importance that the rewind starter spring be lubricated peri- odically using specific lubricant. Otherwise, rewind starter component life will be short- ened and/or rewind starter will not operate properly under very cold temperatures.
Page 179: Disassembly
Section 03 ENGINES (2-STROKE) Subsection 09 (REWIND STARTER) DISASSEMBLY ASSEMBLY Undo knot previously tied at removal. Let sheave At assembly, position spring no. 4 outer end into get free to release spring preload. spring guide notch then wind the spring counter- clockwise into guide.
Page 180 Section 03 ENGINES (2-STROKE) Subsection 09 (REWIND STARTER) A01C15A 1. Push to lock Lubricate housing post with silicone compound grease. Install sheave. TYPICAL 1. Molykote PG 54 inside spring guide Liquid Cooled Models Only To install rope no. 6, insert rope into sheave no. 5 orifice and lock it by making a knot, leaving behind a free portion of about 25 mm in length.
Page 181 Section 03 ENGINES (2-STROKE) Subsection 09 (REWIND STARTER) FREE PORTION INSERTED INTO SHEAVE Lubricate pawl lock no. 9 with Molykote PG 54 Lubricate housing post with silicone compound (P/N 420 899 763). Install over pawl. grease. Install sheave. To adjust rope tension: Wind rope on sheave and place rope sheave into starter housing making sure that the sheave hub notch engages in the rewind spring hook.
Page 182: Installation
Section 03 ENGINES (2-STROKE) Subsection 09 (REWIND STARTER) A01C18A 1. Step collar TYPICAL 2. O-ring 3. Locking element Position a new push nut no. 13. INSTALLATION Fan Cooled Models Only Reinstall oil pump on rewind starter assembly. All Models Thread starter rope no. 6 through rope guide when applicable.
Page 183: Fuel System
Section 03 ENGINES (2-STROKE) Subsection 10 (FUEL SYSTEM) FUEL SYSTEM SERVICE TOOLS Description Part Number Page carburetor tool kit ..............404 112 000 ......... 165 choke plunger tool ..............529 032 100 ......... 171 float level gauge ..............529 035 520 ......... 167 hose pincher .................
Page 184: Carburetor
Section 03 ENGINES (2-STROKE) Subsection 10 (FUEL SYSTEM) CARBURETOR Tundra mmr2005-019...
Page 185 Section 03 ENGINES (2-STROKE) Subsection 10 (FUEL SYSTEM) Skandic LT/LT E Choke equipped model only TYPICAL mmr2005-019...
Page 186 Section 03 ENGINES (2-STROKE) Subsection 10 (FUEL SYSTEM) Skandic WT/SUV/SWT Choke equipped model only mmr2005-019...
Page 187: Identification
Section 03 ENGINES (2-STROKE) Subsection 10 (FUEL SYSTEM) IDENTIFICATION CAUTION: Heavy duty carburetor cleaner may be harmful to the float material and to the rub- All carburetors are identified on their body. ber parts, O-rings, etc. Therefore, it is recom- mended to remove those parts prior to clean- ing.
Page 188: Carburetor Adjustments
Section 03 ENGINES (2-STROKE) Subsection 10 (FUEL SYSTEM) E-Clip and Needle – air screw no. 6 adjustment – throttle slide no. 5 height (preliminary idle Remove screws from needle retaining plate to re- speed adjustment) move the needle no. 3. –...
Page 189 Section 03 ENGINES (2-STROKE) Subsection 10 (FUEL SYSTEM) A00C03A 1. Contact tab Air Screw Adjustment 1. Ruler vertical and in line with main jet Completely close the air screw no. 6 (until a slight Float level height can be checked using float level seating resistance is felt) then back off as speci- gauge (P/N 529 035 520).
Page 190: Installation
Section 03 ENGINES (2-STROKE) Subsection 10 (FUEL SYSTEM) Final idle speed adjustment (engine running at idle speed) should be within 1/2 turn of idle speed screw from preliminary adjustment. THROTTLE MODELS SLIDE HEIGHT ± 0.1 mm ( ± .004 in) Tundra Skandic WT/ SWT/WT LC/ SUV 550/ 1.5 (.
Page 191 Section 03 ENGINES (2-STROKE) Subsection 10 (FUEL SYSTEM) Install clamps in a way that their tightening bolts At full opening, throttle slide must be flush or are staggered — not aligned. 1.0 mm (.040 in) lower than the top of carbure- tor outlet bore (engine side).
Page 192: Injection Pump
Section 03 ENGINES (2-STROKE) Subsection 10 (FUEL SYSTEM) CAUTION: If the throttle slide rests against the WARNING carburetor cover at full throttle opening, this This gap is very important. If the throttle slide will create too much strain and may damage rests against the carburetor cover at full throt- the throttle cable or other components in throt- tle opening, this will create too much strain...
Page 193 Section 03 ENGINES (2-STROKE) Subsection 10 (FUEL SYSTEM) A01C5FA CHOKE LEVER — FULLY OPEN POSITION CUT-AWAY (ENGINE SIDE SHOWN) 1. Choke plunger 2. Tool properly seated under choke plunger Insert choke plunger tool (P/N 529 032 100) into choke air inlet of each carburetor. Tool stopper If tool tip does not sit under choke plunger no.
Page 194: Fuel Pump
Section 03 ENGINES (2-STROKE) Subsection 10 (FUEL SYSTEM) FUEL PUMP REMOVAL Install a hose pincher (P/N 295 000 076) on fuel supply line close to pump inlet. 295 000 076 A01C5IA 1. Choke cable adjustment nut 2. Choke plunger tool Tighten choke cable lock nut and reinstall protector A01B2JA cap.
Page 195: Installation
Section 03 ENGINES (2-STROKE) Subsection 10 (FUEL SYSTEM) Impulse/Fuel Lines Spring Clips Fuel pump components should be cleaned in gen- eral purpose solvent and dried with compressed Always reposition spring clips after any repair to air. prevent possible leaks. WARNING Solvent with a low flash point such as gaso- line, naphtha, benzol, etc., should not be used as each is flammable and explosive.
Page 196: Engine (4-Tec)
Section 04 ENGINE (4-TEC) Subsection 01 (LEAK TEST) LEAK TEST VERIFICATION Remove: – radiator cap. Before performing the cylinder leak test, verify the following: Unplug and remove ignition coil. – clamp(s) tightness Remove spark plug from cylinder head. – radiator and hoses NOTE: Ignition coil can help removing spark plug.
Page 197: Installation
Section 04 ENGINE (4-TEC) Subsection 01 (LEAK TEST) Preparation Diagnose Using a dial gauge set the crankshaft and the pis- Listen for air leaks. ton to precisely ignition TDC. If a dial gauge is not – air escaping on intake port/carburetor means available, use a screwdriver or another similarly leaking intake valve(s) suitable tool.
Page 198: Removal And Installation
Section 04 ENGINE (4-TEC) Subsection 02 (REMOVAL AND INSTALLATION) REMOVAL AND INSTALLATION mmr2005-022...
Page 199: Engine Removal
Section 04 ENGINE (4-TEC) Subsection 02 (REMOVAL AND INSTALLATION) ENGINE REMOVAL Use B.U.D.S. to release fuel pressure. Refer to B.U.D.S. instructions. Disconnect battery. WARNING Battery BLACK (-) cable must always be dis- connected first and connected last. WARNING Never charge or boost battery while installed. Battery contains sulfuric acid which is corro- sive and poisonous.
Page 200 Section 04 ENGINE (4-TEC) Subsection 02 (REMOVAL AND INSTALLATION) 1. Oil drain plug Drain the engine oil. 1. ECM 2. Main harness Put back vehicle on the ground. Remove muffler and pipes. Loosen collar screw on air silencer grommet. Remove coolant reservoir cap. Siphon as much Disconnect blow-by hose from air silencer.
Page 201: Engine Installation
Section 04 ENGINE (4-TEC) Subsection 02 (REMOVAL AND INSTALLATION) ENGINE INSTALLATION 1. Air temperature sensor Remove air silencer. Before engine installation, make sure that the front deflectors no. 7 are positioned as per fol- Remove guard, drive belt, drive pulley. lowing illustration.
Page 202 Section 04 ENGINE (4-TEC) Subsection 02 (REMOVAL AND INSTALLATION) Check pulley alignment and drive belt height. Install doughnut shaped exhaust gasket with both notches aligned with Y-manifold protrusions. NOTE: No sealant required on doughnut shaped exhaust gasket. Torque screws no. 4 of engine supports to 37 N•m (27 lbf•ft).
Page 203: Cooling System
Section 04 ENGINE (4-TEC) Subsection 03 (COOLING SYSTEM) COOLING SYSTEM SERVICE TOOLS Description Part Number Page engine leak tester kit ............861 749 100 ......... 186 hand pump................529 021 800 ......... 186 hose pincher ................. 295 000 076 ......... 186 oil seal pusher...............
Page 204 Section 04 ENGINE (4-TEC) Subsection 03 (COOLING SYSTEM) mmr2005-023...
Page 205 Section 04 ENGINE (4-TEC) Subsection 03 (COOLING SYSTEM) mmr2005-023...
Page 206: Cooling System Leak Test
Section 04 ENGINE (4-TEC) Subsection 03 (COOLING SYSTEM) COOLING SYSTEM LEAK TEST WARNING To prevent burning yourself, do not work on cooling system when the engine is hot. Remove pressure cap no. 30. Install special radiator cap (P/N 529 021 400) in- cluded in engine leak tester kit (P/N 861 749 100) on coolant tank no.
Page 207 Section 04 ENGINE (4-TEC) Subsection 03 (COOLING SYSTEM) CAUTION: Never allow coolant tank to be emp- ty during the filling procedure. Let engine idling for about 10 minutes or until radi- ators are warm — which means that the thermo- stat is open.
Page 208: Coolant Hoses
Section 04 ENGINE (4-TEC) Subsection 03 (COOLING SYSTEM) Inspection After the first few kilometers (miles) of running recheck level. Check the water pump housing for cracks or other damage. COOLANT HOSES Replace water pump housing if damaged. Any damaged/leaky or brittle coolant hose or com- ponent must be replaced.
Page 209: Water Pump Impeller
Section 04 ENGINE (4-TEC) Subsection 03 (COOLING SYSTEM) Installation The installation is the opposite of the removal pro- cedure. Pay attention to the following details. CAUTION: Be careful not to damage impeller wings during installation. Tighten impeller to 7 N•m (62 lbf•in). IGNITION COVER Removal Remove:...
Page 210: Water Pump Shaft
Section 04 ENGINE (4-TEC) Subsection 03 (COOLING SYSTEM) Inspection Place new ball bearing in freezer for 10 minutes before installation. Check oil supply hole/support bearing for scorings or other damages. There are no plain bearings in NOTE: Do not use any striking tool to insert the the ignition cover.
Page 211 Section 04 ENGINE (4-TEC) Subsection 03 (COOLING SYSTEM) CAUTION: When removing water pump shaft, always replace rotary seal with water pump shaft no. 7 and oil seal no. 4 (behind rotary seal). 1. Water pump gear 2. Thrust washer behind water pump gear WATER PUMP SHAFT WITH ROTARY SEAL –...
Page 212 Section 04 ENGINE (4-TEC) Subsection 03 (COOLING SYSTEM) 1. Oil seal for the water pump shaft Inspection 2. Oil seal pusher (P/N 529 035 757) 3. Handle for insertion jig (P/N 420 877 255) Inspect water pump gear for wear and damage on Install the water pump shaft assembly using the the snap mechanism to the needle pin.
Page 213: Pressure Cap
Section 04 ENGINE (4-TEC) Subsection 03 (COOLING SYSTEM) PRESSURE CAP Check if cap pressurizes the system. If not, install a new 110 kPa (16 PSI) cap (do not exceed this pressure). RADIATORS Refer to CHASSIS for radiators no. 27 removal and installation.
Page 214: Lubrication System
Section 04 ENGINE (4-TEC) Subsection 04 (LUBRICATION SYSTEM) LUBRICATION SYSTEM SERVICE TOOLS Description Part Number Page dial indicator................414 104 700 ......... 203 fuel line remover..............529 035 714 ......... 198 oil pressure adapter .............. 529 035 652 ......... 198 oil pressure gauge ..............
Page 215 Section 04 ENGINE (4-TEC) Subsection 04 (LUBRICATION SYSTEM) mmr2005-024...
Page 216 Section 04 ENGINE (4-TEC) Subsection 04 (LUBRICATION SYSTEM) 23 24 29 36 mmr2005-024...
Page 217: General
Section 04 ENGINE (4-TEC) Subsection 04 (LUBRICATION SYSTEM) GENERAL Prior to changing the oil, ensure vehicle is on a level surface. Oil and oil filter must be replaced at the same time. Oil change and oil filter replacement should be done with a warm engine. WARNING The engine oil can be very hot.
Page 218: Oil Change
Section 04 ENGINE (4-TEC) Subsection 04 (LUBRICATION SYSTEM) Inspection NOTE: Oil pressure switch works between 20 kPa (2.9 PSI) and 40 kPa (5.8 PSI). Oil condition gives information about the engine The engine oil pressure should be within the fol- condition.
Page 219: Oil Tank
Section 04 ENGINE (4-TEC) Subsection 04 (LUBRICATION SYSTEM) Inspection Check and clean the oil filter inlet and outlet area for dirt and other contaminations. 1. Inlet bore from the oil pump to the oil filter 2. Outlet bore to the engine oil providing system 1.
Page 220: Oil Filter Housing
Section 04 ENGINE (4-TEC) Subsection 04 (LUBRICATION SYSTEM) Replace oil filter housing if damaged. Installation The installation is the opposite of the removal pro- cedure. Pay attention to the following details. NOTE: Always replace gasket no. 1. Torque oil filter housing screws to 9 N•m (80 lbf•in).
Page 221: Spring Free Length
Section 04 ENGINE (4-TEC) Subsection 04 (LUBRICATION SYSTEM) Fit the engine oil pressure regulator by pushing it carefully with an aluminum or brass rod. The en- gine oil pressure regulator must be flush with the crankcase. Following installation check the pres- sure regulator piston for easy movement.
Page 222: Service Limit
Section 04 ENGINE (4-TEC) Subsection 04 (LUBRICATION SYSTEM) 1. Outer rotor 2. Inner rotor 1. Oil pump gear 2. Needle pin 3. Drive gear of crankshaft OUTER AND INNER ROTORS 4. Oil pump cover screws CLEARANCE MM (IN) SERVICE LIMIT Inspection Inspect oil pump shaft assembly and the oil pump cover for marks or other damages.
Page 223 Section 04 ENGINE (4-TEC) Subsection 04 (LUBRICATION SYSTEM) Installation For installation, reverse the removal procedure. Pay attention to the following details. CAUTION: The outer rotor no. 28 and the oil pump shaft with inner rotor no. 27 are marked on the upper side. When installing, make sure that the position of the outer rotor is not re- versed.
Page 224: Suction Oil Pump
Section 04 ENGINE (4-TEC) Subsection 04 (LUBRICATION SYSTEM) 1. Marking Torque oil pump housing screws to 9 N•m (80 lbf•in) as per following sequence. Final Test After engine is completely reassembled, start en- gine and make sure oil pressure is within specifi- cations.
Page 225: Oil Nozzle
Section 04 ENGINE (4-TEC) Subsection 04 (LUBRICATION SYSTEM) OIL NOZZLE The oil nozzles no. 38 are located within the crankcase. Each piston is equipped with a sepa- rate oil nozzle. 1. Oil nozzle 2. Crankcase 1. Oil nozzle 3. Contact surface NOTE: If the engine has to be disassembled with- NOTE: If the oil nozzles are damaged or bent dur- in the scope of repair work, take this opportunity...
Page 226: Reed Valve
Section 04 ENGINE (4-TEC) Subsection 04 (LUBRICATION SYSTEM) Check sieves for cracks or other damage. NOTE: If the engine has to be disassembled with- in the scope of repair work, take this opportunity NOTE: Replace sieves if damaged. to clean the reed valve, using a rag. Installation Inspection NOTE: During assembly always replace both...
Page 227: Cylinder And Cylinder Head
Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) CYLINDER AND CYLINDER HEAD SERVICE TOOLS Description Part Number Page camshaft locking tool............529 035 839 ......... 220 ........ 213–214, crankshaft locking tool............529 035 900 219–220, 222, 227–228 valve spring compressor clamp ..........529 035 764 ......... 223 valve spring compressor cup..........
Page 228: Cylinder/Cylinder Head 1 (Front-Side)
Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) CYLINDER/CYLINDER HEAD 1 (FRONT-SIDE) 13 11 mmr2005-025...
Page 229: Cylinder/Cylinder Head 2 (Rear-Side)
Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) CYLINDER/CYLINDER HEAD 2 (REAR-SIDE) mmr2005-025...
Page 230: General
Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) GENERAL SPARK PLUG NOTE: Components which are identical for both Removal cylinders/cylinder heads are identified in the two Unplug the stick coil connector. exploded views by the same number. Com- ponents which are different or which are, for Remove the stick coil no.
Page 231: Valve Cover
Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) Inspection Inspection Check the temperature sensor for damage or leak- Check the profile sealing ring on the valve cover age. For electrical inspection refer to COMPO- and the rubber bushing on the valve cover screws NENT INSPECTION AND ADJUSTMENT.
Page 232 Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) 1. Rocker arm shaft 1. Cylinder head 2. Rocker arms (exhaust side) 2. Spark plug tube 3. Rocker arm (intake side) – rocker arm shaft screws no. 45 (discard screws) 1.
Page 233 Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) – rocker arm shaft no. 42 with rocker arm assem- bly (exhaust side no. 43 and intake side no. 44). Inspection Spark Plug Tube Check seals on spark plug tube. If seals are brittle, cracked or hard, replace spark plug tube.
Page 234: Chain Tensioner
Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) CAUTION: For this assembly, stretch screws ROCKER ARM SHAFT DIAMETER are used. As the screws have been stretched MINIMUM (NEW) 19.980 mm (.7866 in) from the previous installation, it is very im- portant to use new screws at assembly.
Page 235: Breather
Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) 1. Chain tensioner plug Check chain tension guides no. 24 for wear. Re- place as necessary. WARNING Check spring condition. Replace if broken or Never perform this operation immediately af- worn.
Page 236: Decompressor
Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) – air silencer then move vehicle harness away – thrust washer no. 34 from engine – cover no. 33 – remove breather hose then unscrew breather – centrifugal weight no. 32 screws no.
Page 237: Camshaft Timing Gear
Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) NOTE: Engage the edge of centrifugal weight into the decompressor shaft groove then put the parts in place. 1. Hole in cover fits to pin of timing gear CAUTION: Before and after cover installation, 1.
Page 238: Timing Chain
Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) CYLINDER HEAD NOTE: Secure camshaft chain no. 27 with a re- taining wire. Removal Inspection The removal procedure is the same for both cylin- Check camshaft timing gear for wear or deteriora- der heads no.
Page 239: Service Limit
Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) Installation NOTE: The cylinder heads are not identical in de- sign. Do not invert the cylinder heads at assem- bly. For installation, reverse the removal procedure. Pay attention to the following details. NOTE: At installation, replace gasket no.
Page 240: Camshaft
Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) Remove crankshaft locking tool (P/N 529 035 900) then install plug with sealing ring. CAMSHAFT NOTE: The engine is equipped with two different camshafts no. 22 and no. 66. 1. Camshaft lock 2.
Page 241: Valve Springs
Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) CAMSHAFT LOBE - EXHAUST VALVE MINIMUM (NEW) 31.435 mm (1.237 in) MAXIMUM (NEW) 31.635 mm (1.245 in) SERVICE LIMIT 31.400 mm (1.236 in) CAMSHAFT LOBE - INTAKE VALVE MINIMUM (NEW) 31.654 mm (1.246 in) MAXIMUM (NEW) 31.854 mm (1.254 in)
Page 242 Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) A. Valve spring length VALVE SPRING FREE LENGTH 1. Valve spring compressor clamp (P/N 529 035 764) OUTER VALVE SPRING 2. Valve spring compressor cup (P/N 529 035 724) NOMINAL (NEW) 45.45 mm (1.789 in) SERVICE LIMIT 43 mm (1.693 in)
Page 243: Valve
Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) 1. Position of the valve spring 2. Valve cotters Inspection VALVE Valve Stem Seal NOTE: Inspection of valve stem seals is not need- Removal ed because new seals should always be installed Remove valve springs.
Page 244 Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) Valve Face and Seat A. Valve stem diameter VALVE STEM DIAMETER 1. Valve seat 2. Exhaust valve contaminated area 3. Valve face (contact surface to valve seat) MINIMUM (NEW) Exhaust 5.946 mm (.2341 in) Check valve face and seat for burning or pittings and replace valve or cylinder head if there are signs...
Page 245: Cylinder
Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) 1. Sealing lips of valve stem seal To ease installation of cotters, apply oil or grease on them so that they remain in place while releas- ing the spring. A. Valve face contact width After spring is installed, ensure it is properly B.
Page 246 Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) CYLINDER OUT OF ROUND MAXIMUM (NEW) 0.01 mm (.0002 in) SERVICE LIMIT 0.02 mm (.0008 in) CAUTION: Always replace gasket no. 1 before installing the cylinder. Installation For installation, reverse the removal procedure. 1.
Page 247: Piston
Section 04 ENGINE (4-TEC) Subsection 05 (CYLINDER AND CYLINDER HEAD) 1. Timing chain NOTE: Put timing chain through the chain pit then put the cylinder in place. Install cylinder head and the other parts in accor- dance with the proper installation procedures. PISTON Refer to CRANKSHAFT/DRIVE GEARS.
Page 248: Crankshaft/Drive Gears
Section 04 ENGINE (4-TEC) Subsection 06 (CRANKSHAFT/DRIVE GEARS) CRANKSHAFT/DRIVE GEARS SERVICE TOOLS Description Part Number Page crankshaft locking tool............529 035 900 ......... 235, 241 piston circlip installer ............529 035 765 ......... 244 protection mushroom ............420 876 552 ......... 235 SERVICE PRODUCTS Description Part Number...
Page 249 Section 04 ENGINE (4-TEC) Subsection 06 (CRANKSHAFT/DRIVE GEARS) mmr2005-026...
Page 250 Section 04 ENGINE (4-TEC) Subsection 06 (CRANKSHAFT/DRIVE GEARS) mmr2005-026...
Page 251: Timing Chain
Section 04 ENGINE (4-TEC) Subsection 06 (CRANKSHAFT/DRIVE GEARS) TIMING CHAIN The engine is equipped with two timing chains no. 28 and no. 29. One of the timing chains is located on the engine alternator side behind the ignition cover. The second is located on the PTO side behind the PTO cover.
Page 252 Section 04 ENGINE (4-TEC) Subsection 06 (CRANKSHAFT/DRIVE GEARS) 1. Crankshaft drive gear 2. Gear puller 1. Crankshaft drive gear 3. Protection mushroom (P/N 420 876 552) 2. Oil pump gears 3. Generator gear 4. Double gear – generator gear no. 18 and thrust washer no. 23 5.
Page 253: Trigger Wheel
Section 04 ENGINE (4-TEC) Subsection 06 (CRANKSHAFT/DRIVE GEARS) Location Pins 1. Trigger wheel Removal Remove: 1. Location pins – oil tank (refer to LUBRICATION SYSTEM) NOTE: Inspect all pins for wear and damage. The – PTO cover (refer to CRANKCASE) pins are firmly pressed into the crankcase but may –...
Page 254 Section 04 ENGINE (4-TEC) Subsection 06 (CRANKSHAFT/DRIVE GEARS) Connecting Rod Big End Axial Play Using a feeler gauge, measure distance between butting face of connecting rods and crankshaft counterweight. If the distance exceeds specified tolerance, replace the crankshaft. 1. Crankshaft –...
Page 255: Piston Pin Diameter
Section 04 ENGINE (4-TEC) Subsection 06 (CRANKSHAFT/DRIVE GEARS) A. Piston pin diameter in the area of the bushing CONNECTING ROD SMALL END DIAMETER NEW MINIMUM 23.01 mm (.9059 in) NEW MAXIMUM 23.02 mm (.9063 in) SERVICE LIMIT 23.07 mm (.908 in) PISTON PIN DIAMETER NEW MINIMUM 22.996 mm (.9053 in)
Page 256 Section 04 ENGINE (4-TEC) Subsection 06 (CRANKSHAFT/DRIVE GEARS) Crankshaft Radial Play Alternator Side Measure crankshaft on alternator side. Compare to inside diameter of alternator bushing (refer to CRANKCASE). 1. Micrometer 2. Crankshaft area for PTO bushing 1. Micrometer CRANKSHAFT JOURNAL PTO DIAMETER 2.
Page 257 Section 04 ENGINE (4-TEC) Subsection 06 (CRANKSHAFT/DRIVE GEARS) NOTE: Use NEW bushings no. 3, when connect- CRANKSHAFT JOURNAL DIAMETER ing rod big end diameter is out of specification. (PTO SUPPORT BEARING) Put bushings correctly in place and clean the split NEW MINIMUM 37.984 mm (1.4954 in) surface on both sides (cracked area) carefully.
Page 258: Crankshaft Locking Tool
Section 04 ENGINE (4-TEC) Subsection 06 (CRANKSHAFT/DRIVE GEARS) CAUTION: Install crankshaft locking tool (P/N 529 035 900) (refer to CRANKSHAFT LOCKING TOOL) right away to put crankshaft in TDC position before installing the camshaft and rockers (refer to CYLINDER AND CYLIN- DER HEAD).
Page 259 Section 04 ENGINE (4-TEC) Subsection 06 (CRANKSHAFT/DRIVE GEARS) – cylinder (refer to CYLINDER AND CYLINDER HEAD). Place a rag under piston. Remove one piston circlip no. 13 and discard it. 1. Measuring perpendicularly (90°) to piston pin A. 18 mm (.709 in) The measurement should be as in the following table.
Page 260: Piston Pin
Section 04 ENGINE (4-TEC) Subsection 06 (CRANKSHAFT/DRIVE GEARS) NOTE: Make sure the cylinder bore gauge indica- tor is set exactly at the same position as with the micrometer, otherwise the reading will be false. Piston Pin Using synthetic abrasive woven, clean piston pin from deposits.
Page 261: Piston Rings
Section 04 ENGINE (4-TEC) Subsection 06 (CRANKSHAFT/DRIVE GEARS) NOTE: Replace connecting rod if diameter of con- necting rod small end is out of specifications. Installation For installation, reverse the removal procedure. Pay attention to the following details. NOTE: Apply engine oil on the piston pin. Insert piston pin into piston and connecting rod.
Page 262 Section 04 ENGINE (4-TEC) Subsection 06 (CRANKSHAFT/DRIVE GEARS) Ring End Gap RING/PISTON GROOVE CLEARANCE MM (IN) NEW MINIMUM RING END GAP UPPER COMPRESSION NEW MINIMUM 0.025 mm (.001 in) RING (rectangular) UPPER COMPRESSION 0.30 mm (.012 in) LOWER COMPRESSION 0.015 mm (.0006 in) RING (rectangular) RING (taper-face) LOWER COMPRESSION...
Page 263 Section 04 ENGINE (4-TEC) Subsection 06 (CRANKSHAFT/DRIVE GEARS) CAUTION: Ensure that top and second rings are not interchanged. NOTE: Use a ring expander to prevent breakage during installation. The oil ring must be installed by hand. Check that rings rotate smoothly after installation. Space the piston ring end gaps 120°...
Page 264: Crankcase
Section 04 ENGINE (4-TEC) Subsection 07 (CRANKCASE) CRANKCASE SERVICE TOOLS Description Part Number Page bearing installer/remover ............529 035 913 ......... 253 bearing installer/remover ............529 035 914 ......... 250 PTO cover oil seal installer ........... 529 035 910 ......... 250 support sleeve ..............
Page 265 Section 04 ENGINE (4-TEC) Subsection 07 (CRANKCASE) mmr2005-027...
Page 266: General
Section 04 ENGINE (4-TEC) Subsection 07 (CRANKCASE) GENERAL To remove crankcase, the engine removal is nec- essary. For installation, use the torque values and Loctite products indicated in the exploded view. Clean threads before using Loctite when installing screws. PTO COVER Removal 1.
Page 267 Section 04 ENGINE (4-TEC) Subsection 07 (CRANKCASE) Bearing Installation Procedure NOTE: Unless otherwise instructed, never use hammer to install plain bearings. Use press ma- chine only. Install plain bearings with the proper plain bearing installer/remover (P/N 529 035 914). Fit the plain bearings with Petamo grease (P/N 420 899 271).
Page 268: Crankcase
Section 04 ENGINE (4-TEC) Subsection 07 (CRANKCASE) Tightening sequence for screws on PTO cover is as per following illustration. Fit the screw no. 17A with Loctite 243 (P/N 293 800 060). 1. Six screws M8 x 90 2. Eight screws M6 x 65 A.
Page 269 Section 04 ENGINE (4-TEC) Subsection 07 (CRANKCASE) 1. Plain bearing 2. Oil bore A. Plain bearing inside diameter to be measured in area of oil bore PLAIN BEARING INSIDE DIAMETER (ALTERNATOR SIDE) Service limit 55.020 mm (2.1661 in) POSITION FOR PLASTIC HAMMER PLAIN BEARING INSIDE DIAMETER (PTO side) Service limit 55.020 mm (2.1661 in)
Page 270 Section 04 ENGINE (4-TEC) Subsection 07 (CRANKCASE) PLAIN BEARING REMOVER Alternator side 529 035 913 PTO side SUPPORT SLEEVE PTO side 529 035 944 1. Ball bearing 2. Bearing puller Remove plain bearings no. 6, no. 7, no. 18 and no.
Page 271 Section 04 ENGINE (4-TEC) Subsection 07 (CRANKCASE) NOTE: Carefully press-in the plain bearings in the same direction as during disassembly, from the case inside towards the outside. NOTE: Place the proper support sleeve (P/N 529 035 944) under PTO crankcase half before in- stalling the plain bearings.
Page 272 Section 04 ENGINE (4-TEC) Subsection 07 (CRANKCASE) NOTE: At installation, replace gasket rings no. 15. Slightly grease the gasket rings no. 15 before as- sembly using Molykote 111 (P/N 413 707 000). Torque cover screws no. 14 to 9 N•m (80 lbf•in). mmr2005-027...
Page 273: Overview
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 01 (OVERVIEW) OVERVIEW ENGINE MANAGEMENT SYSTEM OVERVIEW FUEL TANK ELECTRIC MUFFLER FUEL PUMP EGTS IGNITION COIL WTS APS e-RAVE BATTERY LEGEND APS – Air pressure sensor ATS – Air temperature sensor CPS – Crankshaft position sensor ECM –...
Page 274: Operating Principle
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 01 (OVERVIEW) OPERATING PRINCIPLE The fuel pump module is located inside the fuel tank. The module includes the fuel pump and the For this SDI 2-stroke engine, a highly advanced en- fuel level sensor. gine management system (EMS) has been used to ensure a high power output combined with clean- est combustion.
Page 275: Engine Management System (Ems)
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 01 (OVERVIEW) 1. Fuel tank 2. Fuel pickups In-Line Fuel Filter TYPICAL — ECM The in-line 10 micron fuel filter is fastened under The ECM is directly powered by the battery. It the steering console. It comes as a complete as- is responsible for the following engine manage- sembly.
Page 276: Ems - General Functions
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 01 (OVERVIEW) EMS — GENERAL FUNCTIONS The memory of the ECM features two self-diag- nostic modes for the DESS operation. Refer to Automatic Power Shut-Down DIAGNOSTIC PROCEDURES section for more in- formation. The ECM is equipped with an automatic power shut-down.
Page 277 Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 01 (OVERVIEW) High Muffler Temperature Warning Device When the muffler temperature is getting to high, the ECM will extend the injection period temporar- ily, until the temperature of the muffler will de- crease. If the temperature still increases, the high tem- perature LED will be illuminated and further the ECM will limit the engine speed to maximum 5250 RPM.
Page 278: Ems - Engine Management System Functions
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 01 (OVERVIEW) EMS — ENGINE MANAGEMENT SYSTEM FUNCTIONS SDI SYSTEM INPUTS OUTPUTS ELECTRONIC FUEL INJECTION This engine management system controls the fuel injection, the ignition timing and the electronically The ECM receives the signals from different sen- controlled RAVE.
Page 279: Ignition Timing
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 01 (OVERVIEW) IGNITION TIMING FLOODED ENGINE (DROWNED MODE) The ECM is programmed with data (it contains ig- nition mappings) for optimum ignition timing un- If the engine does not start and it is fuel-flooded, der all operating conditions.
Page 280: Diagnostic Mode
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 01 (OVERVIEW) The engine RPM may be limited if some critical Two separate windings receive input from the components fail. In this case, releasing throttle ECM. Each winding provides high voltage to its and letting the engine returning to idle speed may corresponding spark plug.
Page 281: Diagnostic Procedure
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 02 (DIAGNOSTIC PROCEDURE) DIAGNOSTIC PROCEDURE SERVICE TOOLS Description Part Number Page GRAY diagnostic key ............529 035 896 ......... 267 supply cable................529 035 869 ......... 267 VCK (Vehicle Communication Kit) ......... 529 035 981 ......... 266 GENERAL Here is the basic order suggested to diagnose a suspected engine management or fuel injection related problem:...
Page 282: Troubleshooting
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 02 (DIAGNOSTIC PROCEDURE) TROUBLESHOOTING The following chart is provided to help in diagnosing the probable source of simple troubles. Monitoring Beeper Coded Signals CODED SIGNALS POSSIBLE CAUSE REMEDY 2 short beeps (when engine is started). Confirms that proper tether cord cap is installed.
Page 283: 2-Tec System Fault Codes
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 02 (DIAGNOSTIC PROCEDURE) 2-TEC SYSTEM FAULT CODES General The faults registered in the ECM (engine control module) are kept when the battery is disconnect- ONE MODULE IS CONNECTED IMPORTANT: After a problem has been solved, ensure to clear the fault(s) in the ECM using If an “X”...
Page 284: Possible Causes
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 02 (DIAGNOSTIC PROCEDURE) TPS (Throttle Position Sensor) Faults Faults which are reported in B.U.D.S. fall into two groups TPS faults and adaption faults. These are dis- played on the B.U.D.S. system as TPS OUT OF RANGE and TPS ADAPTION FAILURE. TPS “Out of Range”...
Page 285: Component Inspection And Adjustment
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) COMPONENT INSPECTION AND ADJUSTMENT SERVICE TOOLS Description Part Number Page Fluke 111 ................529 035 868 ......... 271 fuel pressure gauge ............. 529 035 868 ......... 278 supply cable................529 035 869 ......... 271 VCK (Vehicle Communication Kit) .........
Page 286: Electrical System
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) WARNING Ensure to verify fuel line connections for damage and that NO fuel line is disconnect- ed prior to installing the tether cord cap on the DESS post. Always perform the high pressure test if any component has been removed.
Page 287: Resistance Measurement
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Before replacing a ECM, always check electrical WARNING connections. Make sure that they are very tight All electrical actuators (injectors, fuel pump, and they make good contact and that they are cor- ignition coils and starter solenoid) may be rosion-free.
Page 288 Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) TEMPERATURE SENSOR TABLE TEMPERATURE SENSOR TABLE TEMPERATURE RESISTANCE (OHMS) TEMPERATURE RESISTANCE (OHMS) CTS FOR CTS FOR °C °F EGTS °C °F EGTS GAUGE GAUGE - 40 - 40 169.7 72412 111.5 - 35...
Page 289: Engine Connector Pin-Outs
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) ENGINE CONNECTOR PIN-OUTS Connector Position PROBE ONLY ON THE PIN NOZZLE OF FEMALE CONNECTOR CAUTION: Do not disconnect the ECM connec- tor needlessly. They are not designed to be dis- connected/reconnected repeatedly.
Page 290: Air Induction System
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) AIR INDUCTION SYSTEM Electrical Inspection Refer to THROTTLE POSITION SENSOR (TPS) in THROTTLE BODY ELECTRONIC MANAGEMENT below. Replacement Removal To remove the throttle body from engine, proceed as follows: –...
Page 291 Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) For TPS and E-RAVE solenoid replacement proce- dures, refer to the respective paragraph in ELEC- TRONIC MANAGEMENT below. Adjustment Throttle Body Synchronization CAUTION: It is not allowed to perform any change on the synchronization screw.
Page 292 Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) 1. Cable sheath 2. Upper nut 3. Lock washer 4. Lower nut 5. Throttle lever 6. Adjusting screw 7. Pull in this direction Activate the throttle lever a few times. Make sure throttle cam of throttle body rests against idle speed screw without any tension on the cable.
Page 293: Fuel Delivery
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL DELIVERY Fuel delivery system diagnostic flow chart - SDI models Connect tether cord, activate cut-out Fuel pump runs for 2 sec. switch, push START/RER Fuel pump does not run then stops button momentarily Install fuel pressure gauge on fuel...
Page 294: Fuel Pump
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL PUMP Crank or start engine and observe fuel pressure. The fuel pressure should be the same as above. Fuel Pressure Test If pressure is within limits, fuel pump and pressure Before proceeding to the pressure test, ensure regulator are working adequately.
Page 295 Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Check continuity between PINK/BLACK wire of the fuel pump connector on the vehicle harness side and terminal 29 of the ECM connector B. If there is no continuity the problem is in the har- ness.
Page 296 Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Installation For installation, reverse the removal process but pay attention to the following. Install a new gasket. Make sure that rear pickup hose is positioned as following illustration. 1. Bent rod Pull fuel pump module out of fuel tank to expose sensor body.
Page 297 Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Put the vehicle back on the ground. Do the above procedure three times. Stop the engine. The rear fuel pickup hose is now bled. Fuel Hose Kit Remove fuel pump module as explained above. Unfasten blue hose clamp retaining old fuel hose ass’y to pump inlet nipple.
Page 298: Fuel Rails
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) TYPICAL 1. Pump inlet nipple 2. Pump electric connector 3. Pump module flange nipple 4. E-clips Reverse removal procedure for installation. Install a new gasket, then reinstall fuel pump mod- 1.
Page 299: Fuel Injectors
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL INJECTORS CIRCUIT NUMBER INJECTOR NUMBER (ECM CONNECTOR «A») Leakage Test A-15 1/1 (MAG external) To perform a leakage test, the injectors and fuel A-33 2/1 (PTO external) rail have to be removed from the engine. Refer to REMOVAL in FUEL RAIL REPLACEMENT for the A-14 1/2 (MAG internal)
Page 300 Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL RAIL ASS’Y 1. Fuel injector 2. Injector clip 3. O-ring ECM CONNECTOR Then remove the injector clip. Now the fuel injec- tor can be easily pulled out of the fuel rail. COMPONENT CONTACT LOCATION 4 (Engine Connector)
Page 301: Electronic Management
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) ELECTRONIC MANAGEMENT Unscrew all retaining screws and remove the en- gine ECM from its support. ECM REPLACEMENT Install the new ECM to the support. Reconnect ECM connectors to ECM, and then bat- General tery cables.
Page 302: Throttle Position Sensor (Tps)
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Removal The ECM may generate several fault codes per- taining to the TPS. Refer to SYSTEM FAULT Remove air intake silencer. CODES in DIAGNOSTIC PROCEDURES section Disconnect the wiring harness from all sensors/ for more information.
Page 303 Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Check the continuity between pin 3 on wiring har- NOTE: When measuring between pins A-24 and ness TPS connector and pin 24 on wiring harness A-39, resistance value increases while depress- ECM connector.
Page 304: Crankshaft Position Sensor (Cps)
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) This reset is very important. The setting of the If throttle cable has been loosen during the proce- TPS will determine the basic parameters for all dure, adjust a throttle cable. fuel mapping and several ECM calculations in idle Start engine and make sure it operates normally speed control of the engine.
Page 305: Air Temperature Sensor (Ats)
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) AIR TEMPERATURE SENSOR (ATS) Using a multimeter, recheck resistance value be- tween terminals 5 and 19. If resistance value is correct, try a new ECM. Refer to ECM REPLACEMENT procedures elsewhere in this section.
Page 306: Coolant Temperature Sensor (Cts)
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) If resistance value is incorrect, repair the connec- tors or replace the wiring harness between ECM connector and the ATS. Replacement Disconnect the connector of the ATS. Pull the ATS out of the air intake silencer. Follow this procedure to install the ATS.
Page 307: Air Pressure Sensor (Aps)
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) If resistance value is incorrect, repair the connec- If tests are good, replace the APS. tors or replace the wiring harness between ECM If tests are not good, continue to check the conti- connector and the CTS.
Page 308: Knock Sensor (Ks)
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Resistance Test Using the vehicle communication kit (VCK) with the B.U.D.S. software, monitor the knock sensor Disconnect the plug connector from the EGTS and using the Faults section. check sensor resistance. Start the engine and bring engine RPM above Refer to TEMPERATURE SENSOR TABLE at the 6000 RPM.
Page 309: E-Rave Solenoid
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) CAUTION: Install screw and torque it within If test fail, repair connector or replace wiring har- 10 minutes to prevent the sealant to dry be- ness between ECM connector and solenoid. fore torquing.
Page 310 Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Voltage Test WARNING When disconnecting coil from spark plug, al- ways disconnect coil from main harness first. Never check for engine ignition spark from an open coil and/or spark plug in the engine compartment as spark may cause fuel vapor to ignite.
Page 311: Ignition Timing
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) DESS SWITCH VERIFICATION For primary winding, check the resistance be- tween terminal 15 and terminal 1a (cylinder 1) If 2 short beeps are not heard when starting the of the ignition coil and between terminal 15 and engine, refer to DIAGNOSTIC PROCEDURES.
Page 312: Cranking System
Section 05 ENGINE MANAGEMENT (2-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) 1. Proper socket 2. Improper socket SPARK ENGINE TORQUE PLUG mm (in) Hand tighten + 1/4 turn 593 SDI (.031) BR 9 ECS with a socket CRANKING SYSTEM See above for start/stop switch and the DESS post testing.
Page 313: Engine Management (4-Tec)
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 01 (OVERVIEW) OVERVIEW ENGINE MANAGEMENT SYSTEM - OVERVIEW ROTAX 4-TEC 1004 mmr2005-031...
Page 314: Operating Principle Of Engine Management
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 01 (OVERVIEW) OPERATING PRINCIPLE OF ENGINE MANAGEMENT A highly advanced engine management system (EMS) has been used to ensure a high power out- put with cleaner combustion. The EMS calculates the proper air/fuel mixture and ignition timing for each cylinder separately.
Page 315: Intake Manifold
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 01 (OVERVIEW) INTAKE MANIFOLD FUEL PUMP MODULE The fuel pump module is located inside the fuel tank. The module includes fuel pump, fuel pres- sure regulator and fuel level sensor. Fuel Pump INTAKE MANIFOLD It provides fuel pressure and flow rate to the sys- 1.
Page 316: Electronic Management
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 01 (OVERVIEW) The in-line fuel filter is fastened under the steering console. It comes as a complete assembly. ELECTRONIC MANAGEMENT EMS (ENGINE MANAGEMENT SYSTEM) The engine management system is controlled by the ECM. The ECM (engine control module) is directly pow- ered by the battery.
Page 317 Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 01 (OVERVIEW) High Coolant Temperature The tether cord cap contains a magnet and a ROM Warning Device chip. The magnet actually closes the reed switch inside the post which is the equivalent of a me- When the coolant temperature is getting to high, chanical ON/OFF switch.
Page 318: Ems - Engine Management Functions
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 01 (OVERVIEW) EMS — ENGINE MANAGEMENT FUNCTIONS 1004 4-TEC CONTROL SYSTEM INPUTS OUTPUTS This engine management system controls both the fuel injection and the ignition timing. As shown in the 1004 4-TEC CONTROL SYSTEM illustration, the ECM is the central point of the fuel injection system.
Page 319 Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 01 (OVERVIEW) Electronic Fuel Injection Ignition Timing The ECM reads the signals from different sensors The ECM is programmed with data (it contains ig- which indicate engine operating conditions at milli- nition mappings) for optimum ignition timing un- second intervals.
Page 320 Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 01 (OVERVIEW) Sensor failures will not lead to a limp home mode, warning will follow through the EMS pilot lamp and the buzzer. When minor fault occurs, the fault and mes- sage/buzzer disappear automatically when the condition no longer exists.
Page 321: Diagnostic Procedure
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURE) DIAGNOSTIC PROCEDURE SERVICE TOOLS Description Part Number Page gray key ................529 035 896 ......... 307 supply cable ................. 529 035 869 ......... 307 VCK (Vehicle Communication Kit) ......... 529 035 981 ......... 306 GENERAL TERMS USED IN OTHER TERMS USED IN...
Page 322: Monitoring Beeper Coded Signals
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURE) MONITORING BEEPER CODED SIGNALS CODED SIGNALS POSSIBLE CAUSE REMEDY 2 short beeps (when engine is started). Normal condition. Confirms that proper tether cord DESS/RER pilot lamp also blinks. cap is installed. Engine can rev above pulley engagement.
Page 323: 4-Tec System Fault Codes
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURE) ECM Supply NOTE: The MPEM programmer does not work on 4-TEC models. To power-up the ECM, push the START button Ensure to use the latest B.U.D.S. version available shortly while the engine cut-out switch is OFF and on BOSSWeb.
Page 324: 4-Tec Tps Fault Tables
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURE) For more information pertaining to the code faults – If everything is in good condition, try a new (state, count, first, etc.) and report, refer to ECM. B.U.D.S. online help. When using the service action suggested in the Fault section of B.U.D.S., the system circuits are Supplemental Information referred to as DA-41, which means connector...
Page 325 Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 02 (DIAGNOSTIC PROCEDURE) POSSIBLE CAUSES ACTION Sensor has been replaced and TPS closed position not reset Reset Closed Throttle and Idle Actuator. Throttle body has been replaced and TPS closed Reset Closed Throttle and Idle Actuator. position not reset ECM has been replaced and TPS closed position not reset Reset Closed Throttle and Idle Actuator.
Page 326: Component Inspection And Adjustment
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) COMPONENT INSPECTION AND ADJUSTMENT SERVICE TOOLS Description Part Number Page Fluke 111 ................529 035 868 ......... 313 fuel pump wrench ..............529 035 899 ......... 321–322 pressure gauge..............529 035 591 ......... 319 supply cable................
Page 327: Electrical System
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) WARNING Ensure to verify fuel line connections for damage and that NO fuel line is disconnected prior to installing the tether cord cap on the DESS post. Always perform the pressure test if any component has been removed.
Page 328 Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) NOTE: Do not apply an other lubricant on the ECM WARNING connectors. All electrical actuators (idle bypass valve, in- Ensure that all electronic components are genuine jectors, fuel pump, ignition coils and starter —...
Page 329: Engine Connector Pin-Outs
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) ECM Connector The resistance value of a temperature sensor may test good at a certain temperature but it might be CAUTION: Probe on top of terminal only. Do defective at other temperatures. If in doubt, try a not try to probe inside terminal or to use a pa- new sensor.
Page 330: Air Induction System
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) IMPORTANT: The throttle body is designed to be tamper proof. Changing the idle stop or modify- ing it in any way will not increase performance or change the idle speed but may cause poor starta- bility and erratic idling.
Page 331 Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) – Disconnect connectors from idle bypass valve, and TPS. – Disconnect throttle cable. Installation Installation of the new throttle body is the reverse of the removal procedure. Pay attention for the following details.
Page 332 Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) The only thing that has to be performed when Closed Throttle and Idle Actuator Reset the throttle body has been replaced is the Closed Perform the Closed Throttle and Idle Actuator Throttle and Idle Actuator reset.
Page 333: Fuel Delivery
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL DELIVERY 4-TEC Connect tether cord, activate Fuel pump does not run Fuel pump runs cut-out switch, press START/RER for 2 sec. then stops button momentarily Check fuses and relays. Install fuel pressure gauge Check tether cord cap connection.
Page 334: Fuel Pump
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) FUEL PUMP Fuel Pressure Test Before proceeding to the pressure test ensure the battery is fully charged. Battery voltage must be over 12 volts. Release the fuel pressure in the system using B.U.D.S.
Page 335 Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) If pressure is within limits, fuel pump and pressure Drain fuel tank as much as possible. regulator are working adequately. Remove steering pad. Unbolt handlebar and A rapid pressure drop indicates leakage either move it forward.
Page 336 Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) TYPICAL 1. Fuel supply hose 2. Vent tube Remove seat. Unbolt fuel tank. TYPICAL TYPICAL 1. Fuel tank retaining screws Move fuel tank rearward, then unplug the fuel pump module electric connector. With two screwdrivers or a bent rod holding the flange, unscrew fuel pump nut using fuel pump nut fuel pump wrench (P/N 529 035 899).
Page 337 Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) TYPICAL 1. Arrows aligned 2. Torque wrench Installation A. 90° For installation, reverse the removal process but pay attention to the following. Bleed the fuel system as per following procedure. Install a new gasket.
Page 338: Fuel Rails
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Regulator Kit Remove fuel pump module as explained above. Remove 2 screws retaining regulator to pump module flange. Remove regulator from pump module flange. Replace O-rings with new ones. Install them in pump module flange bore.
Page 339: Fuel Injectors
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Unscrew rail retaining screws. Using the vehicle communication kit (VCK) with the B.U.D.S. software, energize the fuel injector Gently pull rail up by hand. from the Activation section. Pull rail out with fuel injector. If the injector does not work, disconnect the plug If necessary remove fuel injector as described be- connector from the injector.
Page 340: Electronic Management
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) ECM CONNECTOR COMPONENT CONTACT LOCATION 1 (engine connector) Fuel injector cylinder 1 and A-15 (ECM connector) 2 (engine connector) Fuel injector cylinder 2 and A-33 (ECM connector) FUEL RAIL ASS’Y 1.
Page 341: Engine Wiring Harness
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) ENGINE WIRING HARNESS IMPORTANT: When the ECM is replaced, the tether cord cap(s) and the Closed Throttle and Idle Actuator must be reprogrammed/reset. Re- fer to their specific section for adjustment. To allow transferring the previous recorded infor- mation from the old ECM to the new one, use the vehicle communication kit (VCK) with the B.U.D.S.
Page 342 Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) 1. Vehicle harness Disconnect the wiring harness from all sensors/ actuators. Disconnect the connector A from the ECM. Cut all locking ties which are holding the wiring harness in position. 1.
Page 343: Throttle Position Sensor (Tps)
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Connect the CPS, CTS and OPS to the wiring har- ness. NOTE: Routing of the harness for CAPS, CTS and OPS has to be between the intake manifold and cylinder 1, underneath the water hoses.
Page 344 Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Using a multimeter, check resistance value be- tween terminal A-25 and A-39. The resistance should be 1600 - 2400 . Check the resistance between terminal A-24 and Disconnect plug connector from throttle position terminal A-39 with the throttle plate in idle posi- sensor.
Page 345: Idle Bypass Valve
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Remove TPS. Click on the Reset button in the Setting section of B.U.D.S. NOTE: No message will be displayed if operation is successful. If operation is wrong, an error mes- sage will be displayed.
Page 346: Crankshaft Position Sensor (Cps)
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Check the resistance between pin 1 and pin 4 and Clean all remaining parts and install the idle bypass also between pin 3 and pin 2 of the idle bypass valve on the throttle body.
Page 347: Camshaft Position Sensor (Caps)
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Trigger Wheel Inspection Remove PTO cover. Refer to CRANKCASE sub- section in ENGINE section. Remove trigger wheel. Perform visual inspection of the trigger wheel for bent teeth and also check the mating surface for straightness.
Page 348 Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) Voltage Test (harness) Disconnect the connector from the CAPS. Install the tether cord cap, then depress the cut- out switch and push start button momentarily to activate the ECM. Probe pin 3 of CAPS connector (wiring harness side) and battery ground.
Page 349: Air Temperature Sensor (Ats)
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) The resistance should be between 2280 2740 at 20°C (68°F). Otherwise, replace the ATS. If resistance tests good, reconnect the ATS and disconnect the connector A from the ECM. 1.
Page 350: Coolant Temperature Sensor (Cts)
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) COOLANT TEMPERATURE If resistance value is incorrect, repair the connec- tors or replace the wiring harness between ECM SENSOR (CTS) connector and the CTS. Replacement Disconnect CTS connector and remove CTS. Install the new CTS and torque to 18 N•m (159 lbf•in).
Page 351: Oil Pressure Switch (Ops)
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) OIL PRESSURE SWITCH (OPS) Disconnect plug connector from MAPS and con- nect a voltmeter between pin 1 and 2. Install the tether cord cap, then depress the cut- out switch and push start button momentarily to activate the ECM.
Page 352: Ignition Coils
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) WARNING Never make a spark test with spark plug re- moved. Flammable vapors may be present in the engine compartment and ignited which could cause an explosion. Voltage Test If wiring harness is good, try a new ECM.
Page 353: Engine Start Switch Verification
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) NOTE: Prior to inserting the ignition coil to its lo- cation, apply some silicone lubricant (P/N 293 600 041) around the seal area that touches the spark plug hole. After installation, ensure the seal seats properly with engine top surface.
Page 354: Dess Switch Verification
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) SPARK PLUGS Test corresponding fuse, relay and wiring. Disconnect the connector of the steering harness. Disassembly Measure the resistance of the BLUE/RED and LIGHT BROWN wires for 0 . Depress start WARNING button and the reading should change from 0 Never remove ignition coil from the spark...
Page 355: Cranking System
Section 06 ENGINE MANAGEMENT (4-TEC) Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT) SPARK ENGINE TORQUE ± 0.05 mm PLUG (± .002 in) Hand tighten 1004 0.75 + 1/4 turn 4-TEC DCPR8-E (.030) with a socket CRANKING SYSTEM See above for start switch and the DESS post test- ing.
Page 356: Drive Belt
Section 07 TRANSMISSION Subsection 01 (DRIVE BELT) DRIVE BELT SERVICE TOOLS Description Part Number Page belt tension tester ..............414 348 200 ......... 344 drive belt tension adjuster ............ 529 008 700 ......... 343 SERVICE PRODUCTS Description Part Number Page Pulley flange cleaner.............
Page 357: Rotation Direction
Section 07 TRANSMISSION Subsection 01 (DRIVE BELT) DRIVE BELT HEIGHT Check the drive belt width. Replace the drive belt if width is less than the minimum width recom- MEASUREMENT AND mended (see table above). ADJUSTMENT ROTATION DIRECTION NOTE: The drive belt height measurement and adjustment must be performed each time a new The maximum drive belt life span is obtained drive belt is installed.
Page 358: Drive Belt Deflection Measurement (Reference Only)
Section 07 TRANSMISSION Subsection 01 (DRIVE BELT) DRIVE BELT DEFLECTION NOTE: Turn Allen screws 1/4 turn at a time, then rotate driven pulley to allow drive belt to settle in MEASUREMENT (REFERENCE pulley. Check height, repeat as required. ONLY) IMPORTANT: The drive belt deflection will be automatically set after performing the pulley dis- tance and belt height adjustments.
Page 359 Section 07 TRANSMISSION Subsection 01 (DRIVE BELT) A00D06A A00D08A 1. Force 1. Upper O-ring — force 2. Read deflection here 2. Force applied 3. Reference rule 3. Lower O-ring — deflection 4. Reference rule 5. Deflection Or use the belt tension tester (P/N 414 348 200). 1.
Page 360: Drive Pulley
Section 07 TRANSMISSION Subsection 02 (DRIVE PULLEY) DRIVE PULLEY SERVICE TOOLS Description Part Number Page COMET drive pulley puller............ 529 025 000 ......... 351, 354 drive pulley retainer .............. 529 035 674 ......... 357 driven pulley opening tool............. 529 017 200 ......... 351 fork ..................
Page 361: Bombardier Lite
Section 07 TRANSMISSION Subsection 02 (DRIVE PULLEY) BOMBARDIER LITE NOTE: This is a lubrication free drive pulley. Tundra/Skandic WT 550/SWT/SUV 550 mmr2005-035...
Page 362: General
Section 07 TRANSMISSION Subsection 02 (DRIVE PULLEY) GENERAL 529 027 600 Some drive pulley components (return spring, cal- ibration disk) can be changed to improve vehicle performance in high altitude regions. A Service Bulletin will give information about calibration ac- cording to altitude.
Page 363: Cleaning
Section 07 TRANSMISSION Subsection 02 (DRIVE PULLEY) A03D2IA A03D2HA 1. Alignment marks 1. Puller tool 2. Spring cover tool Identify blocks no. 1 and their respective positive Screw puller (hand tight) to hold spring cover and positions for reassembly. remove screws holding spring cover. Slowly unscrew puller to release spring pressure.
Page 364: Installation
Section 07 TRANSMISSION Subsection 02 (DRIVE PULLEY) 1. Curved end Tighten nut no. 8 to 128 N•m (94 lbf•ft). INSTALLATION Torque screw to 80 to 100 N•m (59 to 74 lbf•ft). Install drive belt and belt guard. Raise and block the rear of the vehicle and support it with a mechanical stand.
Page 365: Comet ® 102C
Section 07 TRANSMISSION Subsection 02 (DRIVE PULLEY) ® COMET 102C Skandic LT/LT E 18 17 Skandic LT E mmr2005-035...
Page 366: General
Section 07 TRANSMISSION Subsection 02 (DRIVE PULLEY) GENERAL REMOVAL Some drive pulley components can be changed WARNING to improve vehicle performance in high altitude Never use an impact wrench to remove or in- regions. A Service Bulletin will give information stall the drive pulley.
Page 367: Disassembly
Section 07 TRANSMISSION Subsection 02 (DRIVE PULLEY) Remove driven pulley to make room for drive pul- ley removal. Remove drive pulley. DISASSEMBLY Skandic LT E Only Remove retaining screws no. 17 and washers no. 18 from ring gear no. 19. 1.
Page 368 Section 07 TRANSMISSION Subsection 02 (DRIVE PULLEY) Check cover bushing interior. Replace cover if bushing is completely bronze instead of the origi- nal teflon coating. Check spider thrust buttons no. 6 for proper slid- ing action. Replace as required. Check rollers no. 7 for free action. Replace as required.
Page 369 Section 07 TRANSMISSION Subsection 02 (DRIVE PULLEY) Skandic LT E Only Secure ring gear no. 19 on inner fixed half using self-tapping screws no. 17 and thick M8 flat wash- ers no. 18. Apply Loctite 271 (P/N 293 800 005) on screw threads and between screw heads and thick flat washers.
Page 370 Section 07 TRANSMISSION Subsection 02 (DRIVE PULLEY) TRA III All Liquid Cooled Models except 4-TEC Models NOTE: These are lubrication free drive pulleys. Always refer to appropriate parts catalog for replacement part. Most parts of TRA III are not interchangeable with those of the TRA. 593 HO/SDI only Electric start models only Some models...
Page 371 Section 07 TRANSMISSION Subsection 02 (DRIVE PULLEY) TRA IV 4-TEC Models NOTE: This is a lubrication free drive pulleys. Always refer to appropriate parts catalog for replacement part. Most parts of TRA IV are not interchangeable with those of the TRA/TRA III. mmr2005-035...
Page 372: Installation
Section 07 TRANSMISSION Subsection 02 (DRIVE PULLEY) GENERAL Some drive pulley components (return spring, ramp) can be changed to improve vehicle perfor- mance in high altitude regions. A service bulletin will give information about calibration according to altitude. CAUTION: Such modifications should only be performed by experienced mechanics since they can greatly affect vehicle performance.
Page 373 Section 07 TRANSMISSION Subsection 02 (DRIVE PULLEY) DISASSEMBLY Models with TRA III 1,2, Screw and Ring Gear CAUTION: Retaining screws must be heated before disassembly. Do not exceed 150°C (300°F). 5,6, Fixed and Sliding Halves CAUTION: Do not tap on governor cup. Screw puller into fixed half shaft about 13 mm (1/2 in).
Page 374 Section 07 TRANSMISSION Subsection 02 (DRIVE PULLEY) NOTE: To ease disassembly, fork (P/N 529 005 Install sliding half then a second support guide. 500) should be used to hold slider shoes prior to These support guides will prevent bushing dam- removing governor cup.
Page 375 Section 07 TRANSMISSION Subsection 02 (DRIVE PULLEY) Remove all hardened oil deposits that have baked Sliding Half Bushing Replacement on crankshaft and pulley tapered surfaces with NOTE: In case of worn out bushing, it is advisable coarse or medium steel wool and/or sand paper to replace whole sliding half ass’y as replacing just no.
Page 376 Section 07 TRANSMISSION Subsection 02 (DRIVE PULLEY) Use a soft sand paper to clean sliding half bushing mounting surface. Clean sliding half bushing mounting surface with...

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