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Ski-Doo Manuals
Offroad Vehicle
2005 MACH Z
Shop manual
Ski-Doo 2005 MACH Z Shop Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
Safety Notice
Introduction
Vehicle Identification Number
Engine Serial Number
List of Abbreviations Used in this Manual
Arrangement of this Manual
General Information
Illustrations and Procedures
Self-Locking Fasteners Procedure
Loctite Application Procedure
Threadlocker
Stripped Thread Repair
Gasket Compound
Mounting on Shaft
Case-In Components
Tightening Torque
Maintenance
Maintenance Chart
Storage
General
Engine
Fuel System
Drive System
Steering/Front Suspension
Suspension
Electrical
Vehicle
Preseason Preparation
Engine
Fuel System
Drive System
Electrical System
Vehicle
Engine
Leak Test
Preparation
Procedure
Finalizing Reassembly
Engine Leak Verification Flow Chart
Air Intake System
Air Filter/Air Intake Silencer Removal (Body Side)
Air Filter/Air Intake Silencer Installation (Body Side)
Air Intake Silencer Removal (Engine Side)
Air Intake Silencer Installation (Engine Side)
Adaptor Plate Removal
Adaptor Plate Installation
Intake Deflector/Filter Removal
Exhaust System
Tuned Pipe
Manifold
Muffler
Engine Removal and Installation
Removal from Vehicle
Inspection
Installation
Magneto System
General
Magneto Flywheel
Stator
Cps
E-Rave System
General
E-Rave System Dynamic Test
E-Rave Cables
E-Rave Actuator
E-Rave Cover
E-Rave Shaft
E-Rave Housing
E-Rave Valves
Top End
Troubleshooting
General
Component Removal with the Engine Installed
Disassembly
Cleaning
Inspection
Assembly
Piston Circlip Installer
Bottom End
Service Products
Description Part Number Page
Loctite Chisel
Molykote 111
Troubleshooting
General
Preparation
Cleaning
Disassembly
Inspection
Assembly
Break-In
Engine Measurement
Cylinder Head Warpage
Cylinder Taper
Cylinder out of Round
Combustion Chamber Volume Measurement
Used Piston Measurement
Cylinder/Piston Clearance
Ring/Piston Groove Clearance
Ring End Gap
Crankshaft Deflection
Connecting Rod Big End Axial Play
Checking Crankshaft Alignment
Cooling System
Cooling System Leak Test
Inspection
Draining the System
Disassembly and Assembly
Cooling System Refilling Procedure
Rewind Starter
General
Inspection
Removal
Rope Replacement
Disassembly
Assembly
Installation
Oil Injection System
General
Oil Type
Oil System Leak Test
Oil Pump Identification
Cleaning
Removal
Checking Operation
Installation
Bleeding Procedure
Adjustment
Fuel System
Fuel Tank and Fuel Pumps
Fuel Tank
In-Tank Fuel Filter Removal
In-Tank Fuel Filter Installation
In-Line Fuel Filter Removal
In-Line Fuel Filter Installation
Fuel Tank Removal
Fuel Tank Installation
Float-Type Fuel Level Gauge Removal/Installation
Electric Fuel Level Sensor Inspection
Fuel System Pressurization
Electric Fuel Pump
Diagnostic Flow Chart
Electric Fuel Pump Pressure Test
Electric Fuel Pump
Electric Fuel Pump Removal
Electric Fuel Pump Installation
Electric Fuel Pump Pressure Regulator Removal/Installation
Diaphragm Fuel Pump
Diaphragm Fuel Pump Removal
Diaphragm Fuel Pump Verification
Diaphragm Fuel Pump Cleaning and Inspection
Diaphragm Fuel Pump Installation
Engine Management (Sdi)
Overview
Operating Principle
Charging System
Ignition System
Air Induction
Fuel Delivery System
Engine Management System (Ems)
Ems - Engine Management System Functions
Power Distribution
Fuel Injection
Ignition System
Electronically Controlled Rave (E-Rave)
Digitally Encoded Security System (Dess)
Rotax Electronic Reverse (Rer)
Monitoring System
Diagnostic Mode
Diagnostic Procedure
General
Troubleshooting
Ems Fault Codes
Vck (Vehicle Communication Kit)
Component Inspection, Replacement and Adjustment
General
Fuel System
Electrical System
Testing Procedures
Electric Fuel Pump
Fuel Injectors
Engine Control Module (Ecm)
Engine Wiring Harness
Throttle Body
Throttle Position Sensor (Tps)
Crankshaft Position Sensor (Cps)
Air Temperature Sensor (Ats)
Coolant Temperature Sensor (Cts)
Air Pressure Sensor (Aps)
Knock Sensor (Ks)
E-Rave Actuator
Double Ignition Coil
Battery
Capacitor
Engine Start/Rer Switch Verification
Dess Post Verification
Electrical System
Ignition System
General
Ignition Timing
Spark Plug
Design Symbols Used in Ngk Spark Plugs
Charging System
General
Charging Generator Coil (Stator)
Voltage Regulator/Rectifier
Battery
Cable Terminal Installation
Starting System
General
Component Testing
Starter Removal
Starter Installation
Rotax Electronic Reverse (Rer)
Troubleshooting
Accessories and Lighting System
General
12-Volt Power Outlet (Cigarette-Lighter Type)
Beeper (Reverse Alarm)
Engine Temperature Gauge
Electric Fuel Gauge
Headlamp
Headlamp Beam Aiming
Heating Elements
Relay
Speedometer
Speed Sensor
Tachometer
Taillight
Visor Outlet
Drive System
Drive Belt
Application Chart
Inspection
Checking Neutral Function
Rotation Direction
Drive Belt Height Measurement and Adjustment
Drive Belt Deflection Measurement (Reference Only)
Drive Pulley
General
Removal
Disassembly
Cleaning
Inspection
Assembly
Installation
Drive Pulley Adjustment
Driven Pulley
Hpv Roller
General
Removal
Disassembly
Cleaning
Inspection
Assembly
Installation
Bushing Replacement
Hpv Vsa
General
Removal
Disassembly
Cleaning
Inspection
Assembly
Installation
Adjustment
Pulley Alignment
General
Measuring Procedure
Alignment Procedure
Brake
General
Countershaft Bearing
Countershaft
Brake Fluid
Draining
Bleeding
Master Cylinder
Brake Pads
Caliper
Brake Disc
Brake Light Switch
Chaincase
General
Chaincase Oil Level
Oil Change
Drive Chain Adjustment
Chaincase Cover
Tensioner
Tensioner Roller Bearing
Drive Chain and Sprockets
Chaincase Housing
Chaincase Housing Bearings
Countershaft
Countershaft Bearing
Drive Axle
Removal
Assembly
Lubrication
Adjustment
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Table of Contents
Troubleshooting
TROUBLESHOOTING
74
TROUBLESHOOTING
84
TROUBLESHOOTING
143
ROTAX ELECTRONIC REVERSE (RER)
189
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