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AD Boivin 2002 Snow Hawk Manual

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2002-03
Set-up, service and repair
Manual
Snow Hawk™

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Summary of Contents for AD Boivin 2002 Snow Hawk

  • Page 1 2002-03 Set-up, service and repair Manual Snow Hawk™...
  • Page 2 HIGH ALTITUDE TECHNICAL DATA...
  • Page 3 2002 Snow Hawk Hi-Altitude Carburetor and Clutching Set-up: GENERAL Since the 2002 Snow Hawk uses individual carburetor filters, carburetor inlet temperature is not always the same as outside temperature, thus jetting is not. Influences from engine heat and the exhaust system have a tendency to increase the engine bay temperature relative to outside air temperature.
  • Page 4 PROCEDURE – CLUTCHING As a rule of thumb, it is recommended to remove one weight from each arm of the primary clutch for each 2000ft increase in elevation. As a reference, the sea level (0 ft elevation) set-up has nine weights at each of the three primary clutch arms.
  • Page 7 MAIN JET CHART @CARB °C 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 Feet °F 1219 1524 1829 2134 2438 2743 3048 Meter These values are suggestions only, tuners are reminded to pay very close attention to plug color and performance NOTE: feel in order to avoid lean burndown.
  • Page 8 SPECIFICATIONS 18 - 1 SPECIFICATIONS SNOW HAWK SPECIFICATIONS ENGINE Engine type Rotax 503, fan cooled, piston port No. of cylinders Displacement 496.7 (cc) / 30.3 (in Bore 72 (mm) / 2.8 (in) Stroke 61 (mm) / 2.4 (in) Carburation 2 x Mikuni VM 34 ( choke ) Exhaust Sytem Tuned pipe and silencer DRIVE SYSTEM...
  • Page 9 SPÉCIFICATIONS 18 - 2 DIMENSIONS Overall length 2698 (mm) / 105 (in) Overall width 835 (mm) / 32.5 (in) Overall height 1233 (mm) / 48 (in) Official dry weight 350 (lbs) / 160 (kg) Seat height 860 (mm) / 33.5 (in) Ground clearance 283 (mm) / 11 (in) Ski length...
  • Page 10 WIRE, CABLE AND HOSE ROUTING 17-1 WIRE, CABLE AND HOSE ROUTING u u WARNING Make sure that all the wires are well set in the terminals and that the connector holders are well installed. Keep the wires away from any rotating, moving, heating or vibrating part.
  • Page 11 WIRE, CABLE AND HOSE ROUTING 17-2 Under the transversal shaft (No. 1) of the chassis, the wiring separates into two segments, one going toward the front of the vehicle and the other going toward the back Using a tie wrap, secure the wiring that goes toward the front of the vehicle in the cable attachment (No.
  • Page 12 WIRE, CABLE AND HOSE ROUTING 17-3 The forward wiring section comes up inside the steering column plate of the vehicle and is anchored with a tie wrap in the nylon cable fastener (No. 1). 1. Nylon cable fastener After the nylon cable fastener, the wiring divides into five segments (A-E).
  • Page 13 WIRE, CABLE AND HOSE ROUTING 17-4 1. On the retaining screw of the light (No. 1) 2. On the protective screen (grille) (No. 2) 3. On a nylon cable attachment secured to the back protective screen (grille) of the cabin (No. 3). CABLE ROUTING Throttle cable The throttle cable is secured in the accelerator (No.
  • Page 14 WIRE, CABLE AND HOSE ROUTING 17-5 Run the cables along the gas tank and pass them through the hole in the plate of the steering column (see the arrow on the photograph). Pass the choke cables under the electric wires and over the carburetor cables.
  • Page 15 WIRE, CABLE AND HOSE ROUTING 17-6 HOSE ROUTING u u WARNING Always make sure that the conduits are well secured to the connectors, that they are neither perforated nor mixed-up, and that they are well positioned, far from any rotating, moving, heating or vibrating parts. In addition, check to make sure there are no leaks.
  • Page 16 WIRE, CABLE AND HOSE ROUTING 17-7 Fuel feeder lines: The fuel pump (No. 1) has two intakes and two outlets. The two intakes are: 1. The gas tank feed (No. 4) 2. The vacuum (No. 2) The two outlets are: 1.
  • Page 17 WIRE, CABLE AND HOSE ROUTING 17-8 Hose (No. 3) passes under the choke cable and the throttle cable, and connects to the MAG side carburetor. Hose (No. 5) passes along the base of the engine housing and over the two carburetor intake adapters. It goes around the throttle cable and the choke cable, and connects to the PTO side carburetor.
  • Page 18 WIRE, CABLE AND HOSE ROUTING 17-9 The hoses go along the chassis and are attached to the nylon cable fastener by a tie wrap.
  • Page 19 SPECIAL TOOLS 16 - 1 SPECIAL TOOLS Item Description X-1756 Primary Clutch Puller 529 027 300 Spring Compressor 43990092 Belt Tensioning Tool 529 027 600 Primary Clutch Tool 529 031 103 Application Plate 529 031 102 Extractor 529 031 200 Secondary slider installation tool 529 031 300 Secondary slider installation tool...
  • Page 20 DIMENSIONS AND TOLERANCES 15 - 1 DIMENSIONS AND TOLERANCES ENGINE Engine type Rotax 503 Bore 72.00 (in) (2.835) Stroke 61.00 (in) (2.402) Displacement 496.70 (30.31) Compression Ratio 6.20 Max RPM Range 7000-7200 Piston ring type ST/R Piston ring opening (new) (in) (0.008) (wear limit)
  • Page 21 DIMENSIONS AND TOLERANCES 15 - 2 CARBURETION Carburator type Mikuni VM34 Main jet (MAG/PTO) 205 / 220 Jet needle P-O (#159) Pilot jet Needle # 6DH2-3 Slide cutaway Float height 23.9mm (in) (0.94) Airscrew position 1.5 turns Idle RPM 1500 Fuel type Unleaded, 86 Octane COOLING SYSTEM...
  • Page 22 DIMENSIONS AND TOLERANCES 15 - 3 Primary transmission belt P/N 10-251 Width of primary trans. Belt (new) (in) (1.34) (wear limit) 31.75 (in) (1.25) Drive belt adjustment Deflection (in) (1.25) Force (lbf) (15) SECONDARY TRANSMISSION Drive sprocket number of teeth Driven sprocket number of teeth Secondary transmission belt P/N 8M 1280-36...
  • Page 23 DIMENSIONS AND TOLERANCES 15 - 4 FLUIDS Fuel tank capacity 17.5 U.S. gal.
  • Page 24 ELECTRICAL SYSTEM 14 - 1 ELECTRICAL SYSTEM / ENGINE 25 – 30 N-m (2.5 - 30 kg-m, 18 – 21.5 lbf-ft) 22 N-m (2.2 kg-m, 16.2 lbf-ft)
  • Page 25 ELECTRICAL SYSTEM 14 - 2 Electrical System Ref. Part Descriptions 1 - 5 420 8862 55 Magneto (Ducati) 12V240W 420 9968 20 Flywheel 2 - 5 420 8866 05 Stator plate Assy. 12V240W Stator plate P12W 160/240 420 9457 50 5 mm Lock washer 420 9408 80 M5 x 30 allen bolt...
  • Page 26 ELECTRICAL SYSTEM 14 - 3 ELECTRICAL DIAGRAM / OVERVIEW OF ELECTRICAL PARTS...
  • Page 27 ELECTRICAL SYSTEM 14 - 4 Electrical System / Accessories Ref. Part Descriptions 01-120-02 Dimmer switch 110 4671 91 Brake microswitch AN-125 Head lamp Assy. 70321 Tail lamp Assy. Voltage regulator (see exploded view section #3) Electronic box (see previous exploded view) Stator plate (see previous exploded view) 410 1067 00 Tether switch...
  • Page 28 ELECTRICAL SYSTEM 14 - 5 l NOTICE: It is not necessary to remove the engine from the chassis to carry out the following operations. l NOTICE: Clean all metal parts with a solvent for non-ferrous metal. t t CAUTION Always use a clean cloth to clean the stator plate. DISMANTLING To reach the magneto, remove the following parts.
  • Page 29 ELECTRICAL SYSTEM 14 - 6 Remove the fixing screws retaining the coil. Remove the starting coil and gently pull the wire. Install the new starting coil. Re-install the parts that had been removed, proceeding in the reverse order. Positioning the starting coil When removing or replacing the starting coil or the magnetic flywheel, it is important to verify and to adjust the gap between the starting coil and the bulge on the flywheel.
  • Page 30 ELECTRICAL SYSTEM 14 - 7 Reassembling Clean the end of the crankshaft (taper). Coat the taper with Loctite 242 (blue). Place the woodruff key, the flywheel and the lock washer on the crankshaft. Clean the threads of the nut and coat it with Loctite 242 (blue) before tightening it to 105 N-m (10.5 kg-m, 77 lbf-ft).
  • Page 31 ELECTRICAL SYSTEM 14 - 8 3. Install the TDC indicator in the spark plug opening (on the magneto side) and carry out the following adjustment : 1) Adapter lock nut 2) Indicator on the cylinder on the MAG side Place the flywheel approximately at the TDC Set the adapter indicator and tighten the lock nut of the roller.
  • Page 32 ELECTRICAL SYSTEM 14 - 9 l NOTICE: During the verification of the ignition, for certain operations, the flywheel must be turned in a clockwise direction when placed facing the magneto. If for some reason, the flywheel must be turned back (in a counter-clockwise direction), turn it at least a quarter turn counter-clockwise, and then turn it clockwise.
  • Page 33 ELECTRICAL SYSTEM 14 - 10 6. Trace a new mark on the flywheel and proceed as follows: Remove the cover of the engine fan. Hold the flywheel so that the old marks are lined up. Trace a mark on the flywheel so that it is in line with the arrow of the housing: (see the illustration).
  • Page 34 ELECTRICAL SYSTEM 14 - 11 l NOTICE: To avoid inaccurate readings caused by a parallax, stand directly facing the adjustment marks on the flywheel and the housing when observing them. 2. Start the engine and increase its speed to 2000 RPM while observing the adjustment marks (see the illustration).
  • Page 35 ELECTRICAL SYSTEM 14 - 12 POWER OF THE STARTER COIL 1. Disconnect the connector of the RED wire close to the area of the ignition module. 2. Plug in the wires of the ignition timing tester, then place the switch and the dials in the following positions: N (2) White/Red wire of Engine ground...
  • Page 36 ELECTRICAL SYSTEM 14 - 13 3) Start the motor and check to see that if the “Indicator" light is illuminated. 4) Push the "RESET" button and repeat step 3 twice more. Results: a) The "Indicator" light comes on: The power created generator ignition...
  • Page 37 ELECTRICAL SYSTEM 14 - 14 4) Push the "RESET" button and repeat step 3 twice more. Results: a) The "Indicator" light comes on: The ignition system is as it should be. b) The "Indicator" light does not come on: The problem is a result of a defect in the coil or in the ignition.
  • Page 38 ELECTRICAL SYSTEM 14 - 15 3) Start the motor and check the "Indicator" 4) Push the "RESET" button and repeat step 3 twice more. Results: a) The "Indicator" light comes on: The power created generator lighting coil corresponds to the prescribed tolerances. b) The "Indicator"...
  • Page 39 ELECTRICAL SYSTEM 14 - 16 Verification Check the regulator ground to make sure that the circuit is complete. If need be, connect a ground wire from the regulator to the engine. l NOTICE: Use a voltmeter that can measure alternating current (AC). To get precise readings, use a voltmeter with an effective tension voltmeter (RAMS).
  • Page 40 CHASSIS AND STEERING SYSTEM 13-1 CHASSIS AND STEERING SYSTEM...
  • Page 41 CHASSIS AND STEERING SYSTEM 13-2 Frame right side (MAG) exploded view...
  • Page 42 CHASSIS AND STEERING SYSTEM 13-3 Frame left side (PTO) exploded view...
  • Page 43 CHASSIS AND STEERING SYSTEM 13-4 Engine support plate exploded view Fork tube assembly exploded view...
  • Page 44 CHASSIS AND STEERING SYSTEM 13-5 Steering column exploded view...
  • Page 45 CHASSIS AND STEERING SYSTEM 13-6 Ref. Part Descriptions SH 001 Frame right side SH 002 Frame left side SH 006 Handle bar plate support SH 003L Rear frame left side SH 003R Rear frame right side SH 033R Right front chassis extension SH 033L Left front chassis extension SH 032L...
  • Page 46 CHASSIS AND STEERING SYSTEM 13-7 339.163Al 1/2'' shoulder screw socket screw SH 110 Kickstand adaptor 02.108 Kickstand spring 404-339AI Button socket cap screw 5/16'' x 3/4'' (L) 404-337AI Button socket cap screw 5/16'' x 1/2'' (L) 23164F Elastic hex nut M8 (flange head) 22214Al Button head M8x20 SH 015...
  • Page 47 CHASSIS AND STEERING SYSTEM 13-8 20238P Hex head cap screw M10x60 506.151.495 LH ball joint 506.151.492 RH ball joint 250.100.016 LH jam nut M10 732.610.010 RH jam nut M10 053.10.55 Hex head cap screw M10x55 SH 01SA Fork tube assembly 057.6.20 Hex head cap screw M6x20 503.183.300...
  • Page 48 REAR SUSPENSION, SHOCKS AND TRACK 12 - 1 REAR SUSPENSION, SHOCKS AND TRACK...
  • Page 49 REAR SUSPENSION, SHOCKS AND TRACK 12 - 2 Reference # Part Number Description 20235P M10x45 HEX HEAD CAP SCREW 21111P M10 SPLIT SPRING LOCK WASHER 181-188 3/8" ID HIGH STRENGTH WASHER SH416 OUTER BUSHING SF-2836-20 OILITE BUSHING SH43-SAG BUSHING HOUSING 21683P M10x40 SOCKET HEAD CAP SCREW 20159P...
  • Page 50 REAR SUSPENSION, SHOCKS AND TRACK 12 - 3 Référence # Part Number Description 001-00X LOWER LIMITER SHAFT SH410 UPPER LIMITER SHAFT 503 1637 00 LOWER SHOCK EYE STEEL BUSHING 414 9423 00 LOWER SHOCK EYE RUBBER BUSHING No Reference REAR SHOCK ASSY SH-423 BLACK PLASTIC SLEEVE 014-00...
  • Page 51 REAR SUSPENSION, SHOCKS AND TRACK 12 - 4 REAR SUSPENSION, SHOCKS AND TRACK...
  • Page 52 REAR SUSPENSION, SHOCKS AND TRACK 12 - 5 Rear suspension, shocks and track Ref. Part Descriptions 1 - 13 11300-10252-1 Shock Assy. 11303-21209 Rod Assy. 11301-05056 Shock body 11301-03303 Floating piston 11301-03006 O-ring 11301-03805 Piston bushing 11302-09919 Compressed air valve 11201-90604 Screw 11301-03021...
  • Page 53 REAR SUSPENSION, SHOCKS AND TRACK 12 - 6 REAR SUSPENSION ADJUSTMENT The rear suspension can be adjusted in three places 1- Adjustment of the spring preload 2- Adjustment of the softness drawbar (coupling) 3- Adjustment of the limiter strap Spring tension Loosen the jam nut (No.
  • Page 54 REAR SUSPENSION, SHOCKS AND TRACK 12 - 7 Limiter straps When the length of the limiter straps are adjusted, the position of the front of the slide rail is modified. (Angle of attack) To change the length of the limiter straps, simply unscrew the nuts (No.1), remove the bolts and then position them in one of the holes labelled No.
  • Page 55 REAR SUSPENSION, SHOCKS AND TRACK 12 - 8 MAINTENANCE OF SHOCK ABSORBERS This type of shock absorber can be completely rebuilt. It can be calibrated, the shims can be replaced, or the sealing rings can be replaced as need be. The driver can choose the precise adjustment that corresponds to his or her driving style.
  • Page 56 REAR SUSPENSION, SHOCKS AND TRACK 12 - 9 l NOTICE: Pull the rod of the shock absorber out gently to avoid spilling oil or damaging the top cap and seal with the threads on the body of the shock absorber. Wrap it in a cloth when removing the shock absorber piston to soak up any oil that might run down the sides.
  • Page 57 REAR SUSPENSION, SHOCKS AND TRACK 12 - 10 After removing the parts, always lay them out in the order in which they were dismantled. l NOTICE: In general, it is recommended that the lock nut from the shock absorber rod be replaced after the absorber has been reassembled 4 times to ensure adequate locking friction.
  • Page 58 REAR SUSPENSION, SHOCKS AND TRACK 12 - 11 REBOUND Leave a play of about 0.203 mm (0.008 in) between the stack of shims and the lock nut. When adjusting the shock absorber to increase the rebound damping, always use shims measuring 26 mm (1.02 in) against the piston to close the piston openings well.
  • Page 59 REAR SUSPENSION, SHOCKS AND TRACK 12 - 12 GENERAL INFORMATION Calibrating the shock absorber so that there is too much Original Configuration damping is a frequent error. When this is done, the suspension Rear Shocks has too much give. The suspension cannot carry out a Shim Stack (Compression) 414 8883 35 3 Damping shim Ø15 x 0.203...
  • Page 60 REAR SUSPENSION, SHOCKS AND TRACK 12 - 13 l NOTICE: Carry out a meticulous inspection of the shims and replace any bent shims in order to get perfect calibration. Not having enough damping might lead to believe that bubbles have formed in the shock absorber because the gas pressure is not high enough.
  • Page 61 REAR SUSPENSION, SHOCKS AND TRACK 12 - 14 l NOTICE: Using G-N Molykote Paste (P/N 413 7037 00) lubricate the inside of the piston guide. Install the piston to a depth of A = 141.0 mm (5.55 in). Measure this distance starting from the upper end of the shock absorber. l NOTICE: If the floating piston is installed too far down in the body of the shock absorber, a light pressure exerted through the hole in the...
  • Page 62 REAR SUSPENSION, SHOCKS AND TRACK 12 - 15 Insert the shock absorber rod (complete) in the body of the shock absorber. Lightly lubricate the ring seal of the piston with shock absorber oil to make installation easier. Install the ring seal housing near the piston. Check the shock absorber oil capacity to make sure there is no air in the body of the shock absorber when it is being reassembled.
  • Page 63 REAR SUSPENSION, SHOCKS AND TRACK 12 - 16 ADJUSTING THE NITROGEN PRESSURE Nitrogen (N ) can now be added to the body of the shock absorber. Replace the needle valve. Adjust the pressure regulator to 2070 KPa (300 lb/in ) of nitrogen.
  • Page 64 REAR SUSPENSION, SHOCKS AND TRACK 12 - 17 MISCELLANEOUS INFORMATION Never replace nitrogen by another gas. Nitrogen was chosen for its qualities as an inert gas: since it is dry (no humidity) it does not contaminate the gas chamber of the shock absorber.
  • Page 65 REAR SUSPENSION, SHOCKS AND TRACK 12 - 18 Track Alignment t t CAUTION The track of each SNOW HAWK was aligned and adjusted in the factory but it is recommended that the following be checked. The alignment of the track 1.
  • Page 66 FRONT FORK AND SKI 11 – 1 FRONT FORK...
  • Page 67 FRONT FORK AND SKI 11 – 2 Fork Ref. Part Descriptions Fork leg Assy. 849,350,102 Cartridge Assy. 849,310,511 Inner tube 849,340,059 Fork seal and bushing kit 849,311,568 Top cap Assy. 849,350,103 Compression valve Assy. 949,409,760 Outer tube 949,603,733 Lower spring seat 949,313,954 Spring...
  • Page 68 FRONT FORK AND SKI 11 – 3 FRONT FORK ASSEMBLY...
  • Page 69 FRONT FORK AND SKI 11 – 4 Fork Assy. Ref. Part Descriptions 791.464.018 Front fork leg USD 46 mm PAIOLI SH 028 Triple clamp SH 024 Aluminum fork adaptor SH 019 Lower clamp Assy. SH 059 Fork shaft SH 066 Fork lower steering bushing 061.6.30 M6 x 30 Hex head flange bolt...
  • Page 70 FRONT FORK AND SKI 11 – 5 SKI ASSEMBLY zzzzz...
  • Page 71 FRONT FORK AND SKI 11 – 6 Front Ski Assy. Ref. Part Descriptions SH 301 SH 302 Ski tip reinforcement and loop SH 052 Plastic ski support SH 303 Ski adaptor 570.048.800 Rubber ski cushion SH 306 Steel runner SH 305 60 degree carbide runner SH 304 90 degree carbide runner...
  • Page 72 FRONT FORK AND SKI 11 – 7 FRONT FORK Removal Loosen the fork leg top cap before removing the leg from its supports. Disassembly Clean the fork. l NOTICE: The Paioli tool kit (P/N 449 450 020) is needed to service the fork.
  • Page 73 FRONT FORK AND SKI 11 – 8 Unscrew the lock nut (C) from the piston rod and remove the fork leg top cap (B). Remove the upper spring retainer (R), the lock nut (C), the fork spring guide (G) and the O-ring (F). l NOTICE: When the fork leg is turned upside down, the push rod, the needle and the return spring will fall from the piston rod.
  • Page 74 FRONT FORK AND SKI 11 – 9 Install the lower part of the inner tube in a vise. t t CAUTION Exerting too much pressure on the lower part of the inner tube can damage it and affect the stability of the ride. Do not overtighten.
  • Page 75 FRONT FORK AND SKI 11 – 10 t t CAUTION Scratches on the outer tube will cause oil leaks. Be careful not to scratch the outer tube while removing the dust seal. Use a flat screwdriver to remove the dust seal. Remove the stop ring.
  • Page 76 FRONT FORK AND SKI 11 – 11 Reassembling Remove all the elements from the inner tube, one at a time, and clean the tube. Replace the seals and bushings with new ones, following the prescribed sequence. (See the illustration) l NOTICE: While installing seals, wrap the end of the strut with a band of adhesive tape so that the seals will not be damaged by the sharp edge.
  • Page 77 FRONT FORK AND SKI 11 – 12 Once the bushings (S & R) are correctly installed, use the other end of the special tool (W) to insert the washer (Q), and then the oil seal (T). Re-install the stop ring (O). Re-install the dust seal (M).
  • Page 78 FRONT FORK AND SKI 11 – 13 l NOTICE: Before adjusting the torque, make sure the special tool (T) is well fitted into the socket at the end of the cartridge. Re-install the rubber cap (M). Install the spring stop washer (S). Make sure the O-ring (OR) is still in place.
  • Page 79 FRONT FORK AND SKI 11 – 14 With the fork leg still in a vertical position and fully compressed, adjust the fluid level. Recommended level: X = 100 mm (3-5/16 in) l NOTICE: It may be necessary to add or to take out some fluid to reach the recommended level.
  • Page 80 FRONT FORK AND SKI 11 – 15 The top cap (B) must be screwed on until the piston rod (G) touches the bottom of the cap (B) before the cap comes into contact with the lock nut (C). The space between the cap (B) and the nut (C) must be between 1 - 2 mm (0.040 –...
  • Page 81 FRONT FORK AND SKI 11 – 16 Rebound Using a screwdriver, it is possible to choose a precise setting for the speed of rebound from a range of 28 positions, depending on the conditions of the terrain and the purpose for which the vehicle is used. à...
  • Page 82 HYDRAULIC BRAKE SYSTEM 10 - 1 HYDRAULIC BRAKE SYSTEM 13 13 13 cpcpccp 25 N-m (2.5 kg-m, 220lbf-in) 14 N-m (1.4 kg-m, 125lbf-in) 14 N-m (1.4 kg-m, 125 lbf-in) (Follow the suggested sequence)
  • Page 83 HYDRAULIC BRAKE SYSTEM 10 - 2 Secondary transmission system Ref. Parts Description 10.6707.81 Master Cylinder 20.6951.50 Caliper 107.6949.11 Replacement Brake Pads (set of 2) SH024 Brake Hub 08MQ004 Brake Disc SH039 Brake Caliper Spacer 053.8.45 M8 x 45 Hex Bolt 23164 M8 Locknut 1215X30...
  • Page 84 HYDRAULIC BRAKE SYSTEM 10 - 3 Removal/Installation of Brake Disc and/or Hub To gain access to the brake system, the cab and bellypan must be completely removed. See Chapter 1 for details. To remove the brake disc and/or hub, the brake caliper must Retainer first be rotated up and out of the way.
  • Page 85 HYDRAULIC BRAKE SYSTEM 10 - 4 Verify that the thickness of the pad material (as shown between the arrows in the photo at the right) is greater than 1 mm (1/32 in). If the thickness is found to be less than this, replace the pads.
  • Page 86 HYDRAULIC BRAKE SYSTEM 10 - 5 Re-/Installation of Brake Disc and/or Hub Brake Disc Only: Install the five M6 x 16 button head bolts with Loctite 243 and torque to 14 N-m (125 lbf-in). (Reference No. 10 in the exploded view at the beginning of this chapter) Brake Disc and Hub: Follow the procedure outlined on page 9-4 of Chapter 9 –...
  • Page 87 HYDRAULIC BRAKE SYSTEM 10 - 6 Brake Fluid Level Refer to Section 2.5 of Chapter 2 – Periodic Maintenance for details.
  • Page 88 SECONDARY TRANSMISSION SYSTEM 9 - 1 SECONDARY TRANSMISSION SYSTEM 14 N-m (1.4 kg-m, 125 lbf-in) (Follow the suggested sequence) 14 N-m (1.4 kg-m, 125 lbf-in) (Follow the suggested sequence)
  • Page 89 SECONDARY TRANSMISSION SYSTEM 9 - 2 Secondary transmission system Ref. Parts Description SH201 Drive Sprocket 28T SH203 Tensioner Sprocket 28T SH205 Drive Sprocket 56T SH204 Tensioner shaft 184-153 Retaining Ring 6004-2RS KML Roller bearing, tensioner 409.716 Washer 441.1 Split spring lock washer 20238P Hex Bolt, M10 X 60mm 90974 A116...
  • Page 90 SECONDARY TRANSMISSION SYSTEM 9 - 3 Removal of Cog Belt To gain access to the entire secondary transmission system, you must first completely remove the cab and bellypan. See Chapter 1 for details. Loosen the bolt that holds the tensioner sprocket in place. (Ref. No.
  • Page 91 SECONDARY TRANSMISSION SYSTEM 9 - 4 Installation of Cog Belt Installation of a new cog belt is essentially the same as the steps outlined in the removal, but in reverse order. One must pay special attention to the re-installation of the taper lock system.
  • Page 92 SECONDARY TRANSMISSION SYSTEM 9 - 5 Inspection/Cleaning of Secondary Transmission System Check that the roller bearings in the tensioner sprocket bore are functioning properly. Check for excessive dry surface cracking of the rubber in the cog belt. If excessive surface cracks are present, replace belt.
  • Page 93 PRIMARY TRANSMISSION SYSTEM 8-1 PRIMARY TRANSMISSION SYSTEM / PRIMARY CLUTCH 10 N-m (1 kg-m , 7.4 lbf-ft, 125 lbf-in) 90 N-m (9.2 kg-m , 66 lbf-ft, 797 lbf-in) 1-14...
  • Page 94 PRIMARY TRANSMISSION SYSTEM 8-2 Primary Transmission / Primary Clutch Ref. Part Descriptions 1-14 0400-0077 Primary clutch Assy. 417 1212 00 Fixed sheave 417 1213 00 Moveable sheave 420 2453 70 Washer 417 1162 00 Guide washer V10-55-102-22 Spring 222 9640 66 M6 x 40 allen screw 417 1181 00 Centrifugal block...
  • Page 95 PRIMARY TRANSMISSION SYSTEM 8-3 PRIMARY TRANSMISSION SYSTEM / SECONDARY CLUTCH 25 N-m ( 18.4 lbf-ft 2.5 kg-m, 221 lbf-in) 13 12...
  • Page 96 PRIMARY TRANSMISSION SYSTEM 8-4 Primary Transmission / Secondary clutch Ref. Part Descriptions 1-15 8000-0001 Secondary clutch Assy. 504 1416 00 Fixed sheave 504 1432 00 Moveable sheave Assy. 414 9180 00 Cam slider 415 0112 00 Small Garlock bushing 860 4230 00 Large Garlock bushing 417 1264 22 Helix 50...
  • Page 97 PRIMARY TRANSMISSION SYSTEM 8-5 GENERAL INFORMATION Certain parts of the primary clutch can be replaced (recoil spring, calibration weights, etc.) to improve the performance of the vehicle at high altitude. The "High Altitude Technical Data" appendix at the rear of this manual contains all the information for calibration at high altitude.
  • Page 98 PRIMARY TRANSMISSION SYSTEM 8-6 CLEANING Clean the faces of the sheave and the shaft with very fine steel wool and a dry cloth. With a clean, dry cloth, clean the socket of the sliding sheave. INSPECTION Make sure the sliding sheave doesn't exhibit an excessive amount of play and that the shaft on which the half-pulley slides on is not damaged.
  • Page 99 PRIMARY TRANSMISSION SYSTEM 8-7 REMOVAL (SECONDARY CLUTCH) Remove the drive-belt of the vehicle. Remove assembly screw No. 19, lock washer No. 18, washer No. 17 and the No. 16 shims, then remove the secondary clutch from the jackshaft. Jackshaft If the jackshaft must be removed, see the section dealing with the Secondary Transmission System.
  • Page 100 PRIMARY TRANSMISSION SYSTEM 8-8 Replace the bushing if their diameter is greater than the prescribed limit of wear. SECONDARY CLUTCH BUSHING WEAR LIMITS mm (in) Small bushing Large bushing Sliders Check to see if the slider blocks are worn. Replace them when the thickness at the base is reduced to 1 mm (.039 in) or less.
  • Page 101 PRIMARY TRANSMISSION SYSTEM 8-9 Heat the part where the bushing is located. Turn the extractor handle and the sheave at the same time to remove the bushing. IMPORTANT : The screws and washers from the large bushing must be removed before the small bushing is installed. Coat the outside circumference of the bushing with Loctite 609 (P/N 413 7031 00).
  • Page 102 PRIMARY TRANSMISSION SYSTEM 8-10 ADJUSTMENT Spring Preload General information During the break-in period for the new spring, it is normal for it to settle slightly. The initial torsion of the spring is slightly higher to compensate for this setting. These characteristics apply after the break-in period (around 10 hours of use).
  • Page 103 PRIMARY TRANSMISSION SYSTEM 8-11 DRIVE BELT Table for the Snow Hawk belt MODEL NEW WIDTH MIN. WIDTH (WEAR LIMIT) SNOW HAWK 10-251 1.375 ± 0.030 1.250 ± 0.030 DIRECTION OF ROTATION In order for the drive-belt to last as long as possible it must be installed as is shown in the illustration respecting the direction of the rotation.
  • Page 104 PRIMARY TRANSMISSION SYSTEM 8-12 l l NOTICE: Contrary to a snowmobile, the belt of the Snow Hawk is pre- inserted into the secondary clutch from 1 to 3 mm. D – 1 to 3 mm Checking belt tension Place a ruler or straight edge on the drive belt. Use the tension gauge (P/N 414 3482 00) to verify the tension of the drive belt.
  • Page 105 PRIMARY TRANSMISSION SYSTEM 8-13 ADJUSTMENT OF THE DEFLECTION Then adjust the deflection using the Allen screws. See the illustration. To increase the deflection: turn the Allen screws clockwise. To decrease the deflection: turn the Allen screws counter- clockwise. 1. Allen screw and locknut l NOTICE: Turn the Allen screws a quarter turn at a time and then turn the secondary clutch to allow the drive belt to take its place in the...
  • Page 106 ENGINE / CYLINDERS AND CYLINDER HEADS 7 - 1 ENGINE / CYLINDERS AND CYLINDER HEADS 22 N-m (2.2 kg-m, 16 lbf-ft) 22 N-m (2.2 kg-m, 16 lbf-ft) 22 N-m (2.2 kg-m, 16 lbf-ft)
  • Page 107 ENGINE / CYLINDERS AND CYLINDER HEADS 7 - 2 Cylinders and cylinder heads / Rotax 503 Ref. Part Descriptions 420 8318 58 Gasket, 0.5mm 420 8236 49 Cylinder and cylinder sleeve 420 8505 40 O-ring 420 8236 64 Cylinder head 420 2503 11 8.4mm washer 228 0810 45...
  • Page 108 ENGINE / CYLINDERS AND CYLINDER HEADS 7 - 3 ENGINE / HOUSING 22 N-m (2.2 kg-m, 16 lbf-ft) (Follow the recommended sequence)
  • Page 109 ENGINE / CYLINDERS AND CYLINDER HEADS 7 - 4 Crankcase / Rotax 503 Ref. Part Descriptions 1 - 6 420 8867 13 Crankcase Assy. 420 9457 52 8mm Lock washer 420 8412 01 M8 X 70 Hex Bolt 420 8415 61 M8 X 45 Allen bolt 420 8418 41 M8 X 65 Allen bolt...
  • Page 110 ENGINE / CYLINDERS AND CYLINDER HEADS 7 - 5 ENGINE / CRANKSHAFT AND PISTONS 105 N-m (10.5 kg-m, 77 lbf-ft)
  • Page 111 ENGINE / CYLINDERS AND CYLINDER HEADS 7 - 6 Crankshaft and pistons / Rotax 503 Ref. Part Descriptions 420 9964 46 Crankshaft Assy. 420 8322 31 Roller bearing 6207 420 2501 65 O-ring, 64 mm 420 8319 50 Oil seal 420 2460 55 Woodruff key 420 9457 59...

  • Page 112: Top End

    ENGINE / CYLINDERS AND CYLINDER HEADS 7 - 7 TOP END l NOTICE: The engine must be removed from the chassis to carry out the following operations. CLEANING Throw away all the seals. Use a seal cleaning agent to clean all the contact surfaces.
  • Page 113 ENGINE / CYLINDERS AND CYLINDER HEADS 7 - 8 Take the piston pin out by unscrewing the extractor until the first thread of the rod and the mark 503 are in line with one another. 1. Mark 503 of the extractor Turn the extractor as shown to take the piston out.
  • Page 114 ENGINE / CYLINDERS AND CYLINDER HEADS 7 - 9 Play between the cylinder and the piston Before measuring the play between the piston and the cylinder, verify the taper and the ovalization of the cylinder. To determine exactly how much play there is between the piston and the cylinder, measure the piston under the pin opening and at a 90 angle to the piston pin.
  • Page 115 ENGINE / CYLINDERS AND CYLINDER HEADS 7 - 10 Reassembling When reinstalling the needle bearings, make sure there are 31 Expansion needles between the expansion socket and the positioning socket socket. Grease the stop washers and install them at the ends of the needles.
  • Page 116 ENGINE / CYLINDERS AND CYLINDER HEADS 7 - 11 When reassembling, place the pistons over the connecting rods so that the arrow under the letters "AUS" is facing the exhaust port. EXHAUST l NOTICE: The pistons and the replacement cylinders have a red or green mark on them.
  • Page 117 ENGINE / CYLINDERS AND CYLINDER HEADS 7 - 12 Verify the evenness of the intake connectors. When installing a cylinder and/or a cylinder head, use the alignment tool or the exhaust manifold to verify the seal between the intake manifold and the exhaust before tightening the nuts of the cylinder head.
  • Page 118 ENGINE / CYLINDERS AND CYLINDER HEADS 7 - 13 BOTTOM END Cleaning Throw away the ring seals, the gaskets and the O-rings. Clean all the metal parts with a solvent for non-ferrous metal. necessary, use a sealer cleaner. Remove any traces of Loctite at the conical end of the crankshaft.
  • Page 119 ENGINE / CYLINDERS AND CYLINDER HEADS 7 - 14 Inspection Camber of the crankshaft The camber of the crankshaft must be less than 0.08 mm (.0031 in.). The camber of the crankshaft can also be measured at each end using a dial indicator. First, measure the camber while the crankshaft is installed in the engine.
  • Page 120 ENGINE / CYLINDERS AND CYLINDER HEADS 7 - 15 Play between the connecting rod and the piston pin Measure the piston pin with its needle bearing. Compare to the inside diameter of the connecting rod. New part Wear limit MIN. - MAX 0.030 - 0.12 mm 0.15 mm (.0001 - .0005 po)
  • Page 121 ENGINE / CYLINDERS AND CYLINDER HEADS 7 - 16 Reassambling Apply an anti-seize compound (P/N 413 7010 00) to the part of the crankshaft that takes the bearing. To verify whether or not the play between the bearing and the counterweight is adequate, use a thickness gauge (P/N 420 8766 20).
  • Page 122 ENGINE / CYLINDERS AND CYLINDER HEADS 7 - 17 Tighten the nuts to 22 N-m (16 lbf-ft) in the order indicated in the illustration. To install the primary clutch, see the "Primary transmission" section. To install the magneto, see the "Electrical system" section. CHECKING FOR LEAKS When dealing with a 2-cylinder engine, it is not possible to check each cylinder individually because of the leaks at the position of...
  • Page 123 ENGINE / CYLINDERS AND CYLINDER HEADS 7 - 18 8. Turn on the pump increasing the pressure to 35.4 kPa (5 PSI). Do not exceed this pressure. 9. The engine must maintain this pressure for 3 minutes. If the pressure falls before 3 minutes, check the testing apparatus by spraying a soapy solution on the pump piston, on all the plugs and on the connections.
  • Page 124 COOLING SYSTEM 6 - 1 COOLING SYSTEM...
  • Page 125 COOLING SYSTEM 6 - 2 Cooling System / Rotax 503 Ref. Part Descriptions 420 9115 40 Fan housing 420 9458 80 Retaining ring 420 2445 85 1mm Shim 405 4061 00 6203 Roller Bearing 420 9379 40 Fan shaft 420 2460 15 Woodruff key 420 8276 50 Spacer...
  • Page 126 COOLING SYSTEM 6 - 3 Assembly and disassembly Remove the fan guard. To remove or install the bolt securing the fan, immobilize the pulley using the special nut removal tool. (P/N 420 8763 57). When assembling, tighten the bolt to 65 N- M (6.5 kg-m, 48 lbf-ft).
  • Page 127 COOLING SYSTEM 6 - 4 Apply a coat of LOCTITE 243 to the threads of the fan shaft. The deflection of the belt must be 9.5mm (3/8 of an inch) when a force of 5 kg (11lb) is applied). 1. Deflection If the deflection is different, the tension must be corrected by adding or removing one or more shims between the driven half- pulleys.
  • Page 128 RECOIL STARTER 5 - 1 RECOIL STARTER...
  • Page 129 RECOIL STARTER 5 - 2 Recoil Starter / Rotax 503 Ref. Part Descriptions 420 9100 68 Recoil starter housing 420 9391 15 Rewind spring 420 8521 76 Starter handle 420 8522 83 Starter pulley 412 5001 00 Starter cord, 2200 mm 420 8520 70 Key clamp 420 8522 90...
  • Page 130 RECOIL STARTER 5 - 3 Removal Remove the screws and the washers that attach the recoil starter to the engine, then remove the recoil starter. Dismantling To free the cord from the recoil starter mechanism : Remove the retaining ring, the snap spring, the E-clip and the pawl.
  • Page 131 RECOIL STARTER 5 - 4 Lubricate the spring with silicone compound and place it in the Grease the interior of starter housing, as illustrated. the spring guide t t CAUTION Do NOT use this lubricant (silicone compound) on the snap spring of the starter because the spring does not stay in place when submitted to vibrations.
  • Page 132 RECOIL STARTER 5 - 5 Before installing the starter handle on the new cord, fuse the strands of the cable together by burning the end with a match. Pass the cord through the rubber stop and through the handle then tie a knot in it at the end. Fuse the knot with a match. Push the knot into the recess on the starter handle and draw tight.

  • Page 133: Engine Removal

    ENGINE REMOVAL 4-1 ENGINE REMOVAL Unfasten or remove the following parts of the vehicle: Remove the all bodywork from the vehicle. Exhaust pipe Remove the fixation clamp of the exhaust pipe. (No. 1) Loosen the four bolts (No. 2) securing the hood supports and pull the supports towards the nose of the vehicle to increase the space between the exhaust pipe and these parts.
  • Page 134 ENGINE REMOVAL 4-2 Front fork Remove the nut retaining the forward tie-rod end of the steering shaft to the upper triple clamp. (No. 1) Then, remove the two fork pivot bolts and nuts (No. 4) that secure the front fork and remove it from the vehicle. Recoil starter With a small screwdriver, push the knot out of the recess in the starter handle.
  • Page 135 ENGINE REMOVAL 4-3 Secondary Clutch Remove the secondary clutch via the one bolt retaining it. (See the Secondary Transmission System section to remove the secondary clutch.) Carburetor supports Remove the plastic carburetor support by removing the two mounting screws (No. 1). There is one on each side of the chassis.

  • Page 136: Engine Installation

    ENGINE REMOVAL 4-4 Electrical connections Disconnect the wiring harness from the magneto via the four-wire connector coming from the MAG side of the engine. (Connector No.1 at right) Engine mounting bolts Remove the four bolts (No.1) on each side of the engine and then remove the engine (complete with the engine mounting plate) from the chassis.

  • Page 137: Fuel System

    FUEL SYSTEM 3 - 1 FUEL SYSTEM...
  • Page 138 FUEL SYSTEM 3 - 2 Fuel System / 503 Rotax Ref. Part Descriptions 122226-N1 Fuel tank assembly 5231K82 3/16" PVC overflow hose 07-241 Fuel filter 415 080 200-1 Fuel line (tank to pump) 570 135 100 Grommet 403 801 100 Fuel pump 414 554 800 Spring clamp...
  • Page 139 FUEL SYSTEM 3 - 3 FUEL SYSTEM / CARBURETOR (VM34)
  • Page 140 FUEL SYSTEM 3 - 4 Carburetor / Rotax 503 Ref. Part Descriptions 403 123 600 VM 34 Carburetor (PTO) VM 34 Carburetor (MAG) 403 123 700 404 103 700 404 154 800 Throttle slide spring 404 122 100 404 122 900 Retainer 404 121 300 Screw and lock washer...
  • Page 141 FUEL SYSTEM 3 - 5 FUEL SYSTEM / FUEL PUMP...
  • Page 142 FUEL SYSTEM 3 - 6 Fuel pump/ Rotax 503 Ref. Part Descriptions 403 801 100 Fuel pump assembly 404 131 600 Screw 404 903 000 Filter 404 902 300 Gasket 404 902 100 Rubber washer 275 500 042 Valve 404 902 200 Diaphragm 404 902 400 Gasket...
  • Page 143 FUEL SYSTEM 3 - 7 CARBURETORS Removal Remove the air filters. Disconnect the inlet fuel lines and the choke cables. Unscrew the carburetor top caps and pull out the throttle slides. u u WARNING Be careful not to scratch the slides; otherwise, they could get stuck in an open position while the engine is running.
  • Page 144 FUEL SYSTEM 3 - 8 u u WARNING The use of highly volatile solvents such as gasoline, naphtha, benzol, etc., is prohibited since these products are flammable and explosive. Verify the condition of the tip of the fuel inlet valve. If the tip is worn, replace both the valve and its seat.
  • Page 145 FUEL SYSTEM 3 - 9 l NOTICE: The last digit in the identification number of the needle indicates the recommended position of the E-clip from the top of the needle. Example: 6DH2-3 Recommended Needle position of the identification E-CLIP from the number Throttle slide With an opening of the throttle slide between 1/8 and 1/2, the...
  • Page 146 FUEL SYSTEM 3 - 10 The illustration on the right shows which parts of the CARBURETOR OPERATION VS. SLIDE OPENING carburetor start or stop functioning depending on the position Slide Position of the throttle slide. Wide Open Please note that the widest part of each symbol corresponds to the slide opening for which the influence of a particular component is the greatest.
  • Page 147 FUEL SYSTEM 3 - 11 t t CAUTION Needle retaining plate Make sure the nylon washer is correctly installed under E-CLIP the E-clip of the needle. Screw The engine may be severely damaged if this precaution is not taken. Nylon Needle washer Verification of the choke cables...
  • Page 148 FUEL SYSTEM 3 - 12 Carburetor synchronization Both carburetor slides must start opening simultaneously. Completely unscrew the idling speed adjustment screw from the two carburetors. 1. Idling speed adjustment screw 2. Idling mixture adjustment screw Loosen the lock nut of the throttle cable adjustment mechanism, and screw in the adjustment mechanism until the slide touches the bottom of the carburetor.

  • Page 149: Fuel Pump

    FUEL SYSTEM 3 - 13 Start the engine and let it warm up. Set the idling speed (1650 RPM ± 200) by turning the idle screw clockwise to increase the speed, and counter-clockwise to decrease the speed. The final idle adjustment must be the same, within ½ turn of the initial position (1.9 mm).
  • Page 150 FUEL SYSTEM 3 - 14 PUMP VERIFICATION Verify that the fuel pump is in good working order. To do this, hook a clean plastic tube to the inlet connector. Blow air in and out of the tube with your mouth. The valve should open when air is drawn out, and close when air is blown in.
  • Page 151 FUEL SYSTEM 3 - 15 RE-ASSEMBLY To install a new valve, proceed as follows: Place the new valve flat on its seat. Lightly oil the conical tip of the retaining rod. Push the retaining rod down with a rotating motion until it reaches its seating position.

  • Page 152: Cooling System

    PERIODIC MAINTENANCE 2 - 1 l NOTICE: Regular inspection and maintenance of the machine is of prime importance. Follow the guidelines in the following table. Suggested times must be reduced if the vehicle is subjected to severe usage conditions. Break-in 65 Hrs Interval (Hrs) 5 Hrs...
  • Page 153 SCHEDULED MAINTENANCE 2 - 2 2.1. CARBURETION Fuel lines and connections Check all hoses and connections in order to find and fix leaks or to prevent them. Carburetor adjustment For carburetor adjustment, refer to the "Fuel system" section. Throttle cable The throttle cable can be adjusted by setting the adjustment mechanism on the throttle control case.
  • Page 154 PERIODIC MAINTENANCE 2 - 3 Exhaust system Using a torque wrench, check the torque of the retaining bolts of the exhaust manifold. Apply a torque of 22 N-m (2.2 kg-m, 16.2 lbf-ft). Then, proceed to a visual inspection of the system to detect any leak or abnormality.
  • Page 155 SCHEDULED MAINTENANCE 2 - 4 Primary clutch bolt Check the torque on the primary clutch retaining bolt. Recommended torque: 90 - 100 N-m (9–10 kg-m, 66.4 lbf-ft). For more information, refer to the "Primary transmission" section. Pre-tension of the secondary clutch spring For more information, refer to the "Primary transmission"...

  • Page 156: Brake System

    PERIODIC MAINTENANCE 2 - 5 Cog Sprockets Check the appearance of the cog sprockets. Make sure all the sprockets are there and are free of any accumulated dirt. Clean if necessary. Taper-locks Refer to the "Secondary transmission" section. 2.5. BRAKE SYSTEM Brake fluid Check to see if the brake fluid level is above the "mimimum"...

  • Page 157: Rear Suspension, Shocks And Track

    SCHEDULED MAINTENANCE 2 - 6 2.6. FRONT SUSPENSION AND SKI Front fork The air pressure inside the fork legs must be as close as possible to atmospheric pressure. Therefore, it is advisable to remove the bleeder screws from time to time to re-establish the pressure.

  • Page 158: Chassis And Steering

    PERIODIC MAINTENANCE 2 - 7 Shock absorbers Check around the shock guards for the presence of oil leaks. Shock oil must be replaced once a year. Refer to the "Rear suspension and track" section. t t CAUTION It is advisable to change the shock fluid when preparing the vehicle for storage.

  • Page 159: Electrical System

    SCHEDULED MAINTENANCE 2 - 8 Steering mechanism Verify the condition of the ball joints and check for excessive play in the pivots of the steering system. For alignment, refer to the "Chassis and steering" section. Assembly The chassis of the SNOW HAWK is different in that most of the assembly is done by bolting components rather than welding them.
  • Page 160 PERIODIC MAINTENANCE 2 - 9 Porcelain colour Probable cause - Plug temperature rating too high (No. is too small) Light Grey (Overheated) - Plug gap too wide - Air / fuel mixture too lean - Stale gasoline - Plug temperature rating too low (No.
  • Page 161 SCHEDULED MAINTENANCE 2 - 10 Symbols used on the NGK spark plugs GAP WIDTH PREFIX SUFFIX Thread size Temp. Thread Length Insulator type Rating Particular characteristic One ground electrode, Conical special alloy seat Two ground electrodes, special alloy Designed for racing length V-notch central electrode (racing)
  • Page 162 PERIODIC MAINTENANCE 2 - 11 Spark plug gap Refer to the "Electrical system" section. Bundle of wires and connections Electrical wires and connections should be inspected visually to quickly locate broken wires or faulty connections. Lighting system, stop light and engine cut-off switch Before each ride or excursion, it is recommended to verify that the lighting system, the stop/tail light and the engine cut-off switch are in good working order.
  • Page 163 GENERAL INSTRUCTIONS 1 - 1 FIRST CONTACT The SNOW HAWK™ is a brand new type of vehicle. Technically speaking, it is a cross between a snowmobile and a motorcycle. However, its behaviour depends on the conditions in which it is used.
  • Page 164 GENERAL INSTRUCTIONS 1 - 2 LOCATION OF MECHANISMS AND CONTROLS 1. Throttle control 2. Brake lever 3. Parking brake lever 4. Engine-cutoff (tether) 5. Gas tank cap 6. Dimmer switch 7. Choke control 8. Emergency-stop button 9. Hood latches (4) 10.
  • Page 165 GENERAL INSTRUCTIONS 1 - 3 FUEL This vehicle is powered by a two-stroke engine that uses a pre- mixed gasoline and oil mixture. Gasoline: Regular unleaded gas with a minimum octane rating of 87 (R+M)/2 Motor oil: Bombardier / ROTAX Pre-mixture oil Mixture ratio: 40 :1 Gasoline Gas tank capacity: 17.5 litres...
  • Page 166 GENERAL INSTRUCTIONS 1 - 4 OPERATING INSTRUCTIONS Pre-driving inspection u u WARNING A pre-driving inspection is of the utmost importance before using the vehicle. Do not start the machine until you are sure all mechanisms and controls are functioning properly. Failing to proceed in the prescribed manner may result in severe injuries or even death.
  • Page 167 GENERAL INSTRUCTIONS 1 - 5 Stopping the engine While the engine is idling, remove the engine cutoff cap (tether) or press the emergency-stop button. BREAK-IN PERIOD Engine t t CAUTION A break-in period of 10 to 15 hours is essential before using the vehicle at full power.
  • Page 168 GENERAL INSTRUCTIONS 1 - 6 Take off the fuel tank cap. Set the choke to the full position. Unplug the tail light connector located under the light itself, underneath the rear fender. Release the rear module from its four rubber latches, slip the rewind starter handle through the space provided and remove the rear module.

  • Page 169: Table Of Contents

    TABLE OF CONTENTS GENERAL INSTRUCTIONS PERIODIC MAINTENANCE FUEL SYSTEM ENGINE REMOVAL RECOIL STARTER COOLING SYSTEM ENGINE / CYLINDER AND CYLINDER HEADS PRIMARY TRANSMISSION SYSTEM SECONDARY TRANSMISSION SYSTEM BRAKE SYSTEM FRONT FORK AND SKI REAR SUSPENSION, SHOCKS AND TRACK CHASSIS AND STEERING ELECTRICAL SYSTEM DIMENSIONS AND TOLERANCES SPECIAL TOOLS...
  • Page 170 FOREWORD Congratulations, and thank you for buying an A.D. l NOTICE: Boivin design inc. Snow Hawk™ vehicle. The information in the NOTICES is designed to appreciate the confidence in our product that you explain maintenance procedures and to ensure the have demonstrated by making this purchase best possible use of the vehicle.
  • Page 171 arnings concerning maintenance u u WARNING u u WARNING Never have the motor running inside a building. Carrying out maintenance of this vehicle while The exhaust fumes contain carbon monoxide, a the motor is running can be dangerous. colourless, odourless gas which can cause Injuries could result from contact with moving death or severe injuries.
  • Page 172 PICTOGRAMS AND THEIR MEANINGS LocTite #515, Flange Sealant LocTite Ultra Copper, High Ultra Temperature Sealant Non-permanent threadlocker (blue) Permanent threadlocker (red) Brake fluid, DOT 4 Fork oil, S.A.E. 10W Rear suspension shock oil, Kayaba Silicone grease (P/N 420 8970 61) Molybdenum Grease (88162-74 / Dow corning) Tighten a bolt or nut to a specified...
  • Page 173 WARRANTY INFORMATION WARRANTY INFORMATION VEHICLE SERIAL NUMBER PLACE OF PURCHASE DATE OF PURCHASE REGISTERED OWNER ADDRESS CITY STATE/PROVINCE ZIP/POSTAL CODE Please complete and keep this copy of your warranty registration card in your service manual for future reference. VEHICLE SERIAL NUMBER PLACE OF PURCHASE DATE OF PURCHASE REGISTERED OWNER...

Table of Contents