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MACH 1 1997
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Ski-Doo MACH 1 1997 Shop Manual
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Contents
Table of Contents
Bookmarks
Table of Contents
Section 1
Table of Contents
599, 699 and 809 Engine Types
Removal from Vehicle
Installation on Vehicle
Top End
Component Removal
Cleaning
Disassembly
Inspection
Assembly
Bottom End
Cleaning
Disassembly
Inspection
Assembly
Leak Test and Engine Dimension Measurement
Leak Test
Preparation
Procedure
Finalizing Reassembly
Cooling System Leak Test
Engine Leak Verification Flow Chart
Engine Dimension Measurement
Cylinder Taper
Cylinder out of Round
Cylinder/Piston Clearance
Ring/Piston Groove Clearance
Ring End Gap
Crankshaft Deflection
Connecting Rod Big End Axial Play
Connecting Rod/Piston Pin Clearance
Connecting Rod/Crankpin Clearance
Crankshaft End-Play
Checking Surface Flatness
Rectifying Surfaces
Checking Crankshaft Alignment
CDI System
Nippondenso Trigger Coil Ignition System
Disassembly
Assembly
Adjustment
Checking Operation
Liquid Cooling System
Inspection
Draining the System
Disassembly and Assembly
Cooling System Refilling Procedure
Rewind Starter
Removal
Disassembly
Assembly
Installation
Carburetor and Fuel Pump
Removal
Cleaning and Inspection
Identification
Disassembly and Assembly
Carburetor Float Level Adjustment
Installation
Carburetor Adjustments
Preliminary Idle Speed Adjustment
Idle Speed Final Adjustment
Choke
Fuel Pump
Removal
Pump Verification
Cleaning and Inspection
Installation
Fuel Tank and Throttle Cable
Section 2
Drive Belt
1997 Application Chart
Rotation Direction
Drive Belt Deflection Measurement
Deflection Adjustment
Drive Pulley
Tra
General
Removal
Disassembly
Cleaning
Inspection
Assembly
Installation
Drive Pulley Adjustment
Driven Pulley
Removal
Disassembly
Cleaning
Inspection
Assembly
Installation
Adjustment
Pulley Distance and Alignment
General
General Procedure
Pulley Alignment and Distance Specifications Chart
Brake
Hydraulic Disc Brake
Removal
Inspection
Gear Ratio Modification
Installation
Drive Chain Adjustment
Adjustment
Drive Chain
Silent Chain
Section 3
Wiring Diagrams
Chart Codes
Unpluging Connectors
Tab and Receptacle Connectors Removal
Tab and Receptacle Connectors Installation
Accessories Installation
Ignition Timing
Nippondenso Trigger Coil System
Spark Plugs
Ngk Spark Plug
Ngk Spark Plug Numbering System
1997 Reference Chart
Design Symbols Used in Ngk Spark Plugs
Disassembly
Heat Range
Fouling
Spark Plug Analysis
Spark Plug Installation
Spark Plug Tightening Torque
Testing Procedure
General
Use of Bombardier Ignition Tester
Nippondenso CDI Trigger Coil System Testing
Trigger Coil Output
Ignition Coil Output
Ignition Module
Magneto Output (Ignition Generator Coil)
Lighting Generator Coil Output
Summary Table
Resistance Measurements
Voltage Regulator Inspection
Testing Procedure
Inspection of Ac Circuit Isolation
Inspection
Inspection of Heating Elements
Section 4
Suspension (Hp Version)
Component Removal and Installation
Removal
Disassembly and Assembly
Shock Absorber Inspection
Installation
Ride Adjustment
Lubrication
Drive Axle
Removal
Disassembly
Assembly
Axial Play
Installation
Lubrication
Adjustment
Track
Track Type Application
General
Inspection
Removal
Installation
Section 5
Steering System
Inspection
Disassembly and Assembly
Inspection
Adjustable Handlebar
Steering Adjustment (Skis)
Lubrication
Suspension and Ski System
Disassembly
Inspection
Installation
,14, Tie Rod and Lever
Body
Installation and Adjustment
Headlamp Beam Aiming
Bulb Replacement
Decal
Windshield Installation
Hood
Belt Guard
Wiring Harness
Cables
Piping
Plastic Maintenance and Repair
Maintenance
Repair
Material Repair Procedure
Repair Procedure for R.I.M. Urethane
Frame
Frame Cleaning
Frame Welding
Frame Component Replacement
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Chapters
Section 1
53
Section 2
109
Section 3
143
Section 4
165
Section 5
184
,14, Tie Rod and Lever
197
Table of Contents
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