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Mach 1 R
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Ski-Doo Mach 1 R Shop Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
Section Subsection Page
Safety Notice
What's New
Introduction
01 Service Tools and Service Products
Service Tools
Service Products
Lubrication and Maintenance Chart
Troubleshooting/Engine
Electrical System
Engine
Fuel and Oil Systems
Table of Contents
Transmission and Brake Systems
Troubleshooting
Engine
Engine Leak Verification Flow Chart
Transmission
Transmission and Brake Systems
Brake System
Hydraulic Brake
Electrical System
Suspension and Track
Table of Contents
599, 699 and 809 Engine Types
Engine Removal and Installation
Removal from Vehicle
Installation on Vehicle
Top End
Cleaning
Component Removal
Disassembly
Assembly
Inspection
Bottom End
Cleaning
Disassembly
Inspection
Assembly
Leak Test
Leak Test and Engine Dimension Measurement
Preparation
Procedure
Cooling System Leak Test
Finalizing Reassembly
Engine Leak Verification Flow Chart
Combustion Chamber Volume Measurement
Cylinder Head Warpage
Cylinder out of Round
Cylinder Taper
Engine Dimension Measurement
Cylinder/Piston Clearance
Used Piston Measurement
Ring End Gap
Ring/Piston Groove Clearance
Connecting Rod Big End Axial Play
Crankshaft Deflection
Checking Surface Flatness
Connecting Rod/Crankpin Clearance
Connecting Rod/Piston Pin Clearance
Crankshaft End-Play
Rectifying Surfaces
CDI System
Nippondenso Trigger Coil Ignition System
Cleaning
Disassembly
Assembly
Oil Injection System
Assembly
Cleaning
Disassembly
Oil Injection Pump
Oil Pump Identification
Adjustment
Checking Operation
Liquid Cooling System
Disassembly and Assembly
Draining the System
Inspection
Cooling System Refilling Procedure
Rewind Starter
Assembly
Disassembly
Removal
Installation
Carburetor and Fuel Pump
Cleaning and Inspection
Removal
Disassembly and Assembly
Identification
Carburetor Float Level Adjustment
Installation
Carburetor Adjustments
Choke
Idle Speed Final Adjustment
Preliminary Idle Speed Adjustment
Dpm
Method
Overall System Operation
Purpose
Dpm Module Operation
Air Pump Operation
Dpm Manifold Operation
Testing Procedure
Fuel Pump
Cleaning and Inspection
Installation
Pump Verification
Removal
Fuel Tank and Throttle Cable
Table of Contents
1998 Application Chart
Drive Belt
Rotation Direction
Drive Belt Deflection Measurement
Deflection Adjustment
Drive Pulley
Tra
General
Removal
Disassembly
Cleaning
Inspection
Assembly
Installation
Drive Pulley Adjustment
Driven Pulley
Cleaning
Disassembly
Removal
Inspection
Assembly
Adjustment
Installation
General
General Procedure
Pulley Distance and Alignment
Pulley Alignment and Distance Specifications Chart
Brake
Hydraulic Disc Brake
Cleaning
Disassembly
Inspection
Installation
Removal
Adjustment
Bleeding
Chaincase
Gear Ratio Modification
Inspection
Installation
Removal
Drive Chain Adjustment
Adjustment
Gearbox
Assembly
Disassembly
Inspection
Adjustment
Oil Change
Drive Chain
Silent Chain
Table of Contents
Ignition Timing
Nippondenso Trigger Coil System
Ngk Spark Plug
Ngk Spark Plug Numbering System
Reference Chart
Spark Plugs
Design Symbols Used in Ngk Spark Plugs
Disassembly
Fouling
Heat Range
Spark Plug Analysis
Spark Plug Installation
Spark Plug Tightening Torque
Battery
Cleaning
Removal
Hydrometer Test
Inspection
Activation of New Battery
Battery Storage
Servicing
Tips for Charging a Used Battery
Battery Charging Equipment
Installation of Battery
Electric Starter
Installation
Removal
Solenoid Switch
General
Testing Procedure
Electrical Connector Testing
Ignition System Testing Sequence
Lighting System Testing Sequence
Sparking
System Testing
Ignition Switch, Tether Cord Switch and Emergency Switch Testing
Ignition Generator Coil Voltage Testing
Ignition Module Voltage Testing
Trigger Coil Testing
High Voltage Coil Voltage Testing
Mpem Supply Voltage Testing
Mpem Testing
Conclusion
Electric Accessories Testing
Lighting Generator Coil Voltage Testing
Inspection
Inspection of Ac Circuit Isolation
Inspection of Heating Elements
Table of Contents
Sc-10 Suspension
Component Removal and Installation
Disassembly and Assembly
Removal
Shock Absorber Inspection
Installation
Ride Adjustment
Lubrication
Drive Axle
Assembly
Disassembly
Removal
Axial Play
Installation
Adjustment
Lubrication
General
Inspection
Installation
Removal
Track
Track Type Application
Table of Contents
Steering System
Disassembly and Assembly
Inspection
Steering Adjustment (Skis)
Lubrication
Suspension and Ski System
Disassembly
Inspection
Installation
Adjustment
Table of Contents
Body
Bulb Replacement
Headlamp Beam Aiming
Installation and Adjustment
Decal
Hood
Windshield Installation
Half Bottom Pan
Belt Guard
Cables
Piping
Wiring Harness
Maintenance
Plastic Maintenance
Frame
Frame Cleaning
Frame Component Replacement
Frame Welding
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