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BRP EXPEDITION Manual

Snowmobile brp expedition; gsx; gtx; mx z; mx z (adrenaline); mx z; summit
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Table of Contents

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2006
2005
Shop Manual
Shop Manual
REV SERIES
BOMBARDIER RECREATIONAL PRODUCTS INC.

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Summary of Contents for BRP EXPEDITION

  • Page 1 2006 2005 Shop Manual Shop Manual REV SERIES BOMBARDIER RECREATIONAL PRODUCTS INC.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SAFETY NOTICE ................. .. XI INTRODUCTION ..
  • Page 3 TABLE OF CONTENTS 02 – EXHAUST SYSTEM..................51 377 AND 552 ENGINES .
  • Page 4 TABLE OF CONTENTS CONNECTING ROD BIG END AXIAL PLAY ..............134 CHECKING CRANKSHAFT ALIGNMENT .
  • Page 5 TABLE OF CONTENTS CHOKE ......................182 CARBURETOR TM TYPE ..
  • Page 6 TABLE OF CONTENTS ENGINE MANAGEMENT (SDI) 01 – OVERVIEW ....................231 OPERATING PRINCIPLE .
  • Page 7 TABLE OF CONTENTS CAPACITOR......................275 ENGINE START/RER SWITCH VERIFICATION .
  • Page 8 TABLE OF CONTENTS GENERAL ......................329 REMOVAL .
  • Page 9 TABLE OF CONTENTS ASSEMBLY ......................372 LUBRICATION .
  • Page 10 TABLE OF CONTENTS FRONT ARM INSTALLATION ..................405 REAR ARM/PIVOT ARM REMOVAL .
  • Page 11 TABLE OF CONTENTS WINDSHIELD..................... . . 461 GUARD.

  • Page 12: Introduction

    INTRODUCTION MODEL ENGINE MODEL NUMBER EXPEDITION 550F FJ5A, FJ5B 380F DG5B 550F DF5A 500 SS DC5A, DC5B 600 HO DB5A, DB5B 600 HO SDI DD5A, DD5B, DE5A, DE5B 800 HO DPM Power Tek DA5A, DA5B 380F EM5A, EM5B 550F EL5A, EL5B...

  • Page 13: Vehicle Identification Number

    INTRODUCTION VEHICLE IDENTIFICATION NUMBER Vehicle Identification Number Location TYPICAL — 2–STROKE LIQUID-COOLED ENGINES 1. Engine serial number TYPICAL 1. Vehicle identification number Identification Number Meaning LIST OF ABBREVIATIONS USED IN THIS MANUAL ABBREVIATION MEANING ampere ampere A•h ampere-hour alternate current ENGINE SERIAL NUMBER acceleration and control modulator...
  • Page 14 INTRODUCTION ABBREVIATION MEANING ABBREVIATION MEANING °F degree Fahrenheit N.A. not applicable number fan cooled fl. oz fluid ounce continuity foot open line (open circuit) O.D. outside diameter ground optional H.A.C. high altitude compensator ounce hal. halogen part number high pound per square inch internal floating piston power take off imp.

  • Page 15: Arrangement Of This Manual

    INTRODUCTION ARRANGEMENT OF THIS MANUAL This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog. Page heading indicates section and subsection detailed. Subsection title indicates Section 07 REAR SUSPENSION beginning of the subsection.
  • Page 16 INTRODUCTION Section 05 TRANSMISSION Title indicates main procedure Turn puller handle and sliding half at once to extract the bushing. to be carried-out. CAUTION: Italic bold face type setting indicates a particular procedure A-Series and B-Series Only concerning a model. Should installation procedure be required, refer to BRAKE then look for Italic bold face setting...

  • Page 17: General Information

    Due to late changes, it may have some differences between the manufactured product and the de- scription and/or specifications in this document. BRP reserves the right at any time to discontinue or change specifications, designs, features, mod- els or equipment without incurring obligation.

  • Page 18: 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 19: 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 20: 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 21: Case-In Components

    INTRODUCTION CASE-IN COMPONENTS Metallic Gaskets A00A3VA 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 22: Tightening Torque

    INTRODUCTION TIGHTENING TORQUE In order to avoid a poor assembling, tighten screws, bolts or nuts in accordance with the Tighten fasteners to torque mentioned in explod- following procedure: ed views and/or text, When they are not specified, – Manually screw all screws, bolts and/or nuts. refer to following table.

  • Page 23: 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) MONTHLY OR EVERY 800 KM (500 mi) L: LUBRICATE ONCE A YEAR OR EVERY 3200 KM (2000 mi) R: REPLACE...
  • Page 24 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) MONTHLY OR EVERY 800 KM (500 mi) L: LUBRICATE ONCE A YEAR OR EVERY 3200 KM (2000 mi) R: REPLACE...

  • Page 25: Storage

    Section 01 MAINTENANCE Subsection 02 (STORAGE) STORAGE SERVICE TOOLS Description Part Number Page cleat remover................ 529 028 700 ..........5 narrow-cleat installer ............529 028 800 ..........5 SERVICE PRODUCTS Description Part Number Page anti-seize lubricant ..............293 800 070 ..........5 BOMBARDIER LUBE ............

  • Page 26: Fuel System

    Section 01 MAINTENANCE Subsection 02 (STORAGE) Rags in Air Intake and Exhaust System Proceed as follows: Start the engine and allow it to run at idle speed Block air intake hole and exhaust system hole us- until the engine reaches its operating tempera- ing clean rags.

  • Page 27: Steering/Front Suspension

    Section 01 MAINTENANCE Subsection 02 (STORAGE) SUSPENSION Drive Chain Tension Check drive chain tension and adjust if necessary, Rear Suspension Lubrication refer to DRIVE SYSTEM section. Inspect rear suspension components for wear, de- Chaincase Oil terioration or damage, replace defective parts if necessary.
  • Page 28 Section 01 MAINTENANCE Subsection 02 (STORAGE) To clean the entire vehicle, including bottom pan and metallic parts use heavy duty cleaner (spray can 400 g) (P/N 293 110 001) or heavy duty cleaner (4 L) (P/N 293 110 002). CAUTION: Do not use Heavy duty cleaner on decals or vinyl.

  • Page 29: Preseason Preparation

    Section 01 MAINTENANCE Subsection 03 (PRESEASON PREPARATION) PRESEASON PREPARATION SERVICE PRODUCTS Description Part Number Page pulley flange cleaner............. 413 711 809 ..........8 XP-S chaincase oil..............413 801 900 ..........8 XP-S synthetic chaincase oil ..........413 803 300 ..........8 Proper vehicle preparation is necessary after the Check coolant level in coolant reservoir.

  • Page 30: Drive System

    Section 01 MAINTENANCE Subsection 03 (PRESEASON PREPARATION) Air Filter Remove any rust built-up on braking surfaces. Clean brake disk braking surfaces with pulley Check that inside of air silencer is clean and dry flange cleaner (P/N 413 711 809). then properly reinstall the filter. CAUTION: These snowmobiles have been cal- Chaincase Oil ibrated with the filter installed.

  • Page 31: Troubleshooting

    Section 02 TROUBLESHOOTING Subsection 01 (ENGINE) ENGINE 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. NOTE: For engine management system troubleshooting (SDI and Power Tek engines), refer to appropri- ate subsection.
  • Page 32 Carburetor calibration is too lean. Adjust according to specifications (refer to TECHNICAL DATA). j. Improper reed valve adjustment or damage. Adjust according to specifications (refer to appropriate ENGINE subsection) and/or install BRP’s recommended reed valve. k. Poor quality oil.
  • Page 33 Section 02 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM ENGINE SUDDENLY TURNS OFF. CONDITION NORMAL USE. TEST/INSPECTION 4. Melted and/or perforated piston dome; melted section at ring end gap. a. When piston reaches TDC, mixture is ignited by heated areas in combustion chamber. This is due to an incomplete combustion of a poor quality oil.
  • Page 34 Section 02 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH MAXIMUM OPERATING RPM. CONDITION NORMAL USE. TEST/INSPECTION 1. Check spark plug condition and gap. a. Fouled spark plugs or wrong spark plug gap. Replace or readjust gap.
  • Page 35 Section 02 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM ENGINE DETONATION AT MAXIMUM RPM. CONDITION NORMAL USE. TEST/INSPECTION 1. Check which type of fuel is used. a. Octane number is too low and/or alcohol level is too high. Use recommended fuel type. 2.
  • Page 36 Section 02 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM ENGINE TURNS OVER BUT FAILS TO START. CONDITION NORMAL USE. TEST/INSPECTION 1. Check switches. a. Ignition switch, emergency cut-out switch or tether switch is OFF. Place all switches in the RUN or ON position. If it still does not work, connect DESS switch BK/GN and BK/WH wires together (harness side).
  • Page 37 Section 02 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM IRREGULAR ENGINE IDLE. CONDITION NORMAL USE AFTER ENGINE WARM UP. TEST/INSPECTION 1. Check choke. a. Choke plunger may be partially opened. Readjust. 2. Check carburetor adapter. a. Air enters through a crack. Replace. 3.
  • Page 38 Foreign particles and/or broken coolant pump impeller. Clean cooling system and/or replace coolant pump impeller. 5. Check antifreeze concentration. a. Antifreeze concentration is too high. Adjust concentration according to BRP’s recommendations. 6. Check thermostat. a. Thermostat reacts slowly or not at all. Replace.
  • Page 39 Section 02 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM HIGH ENGINE OPERATING TEMPERATURE. CONDITION NORMAL USE. TEST/INSPECTION Liquid-Cooled Engines (cont'd) 11. Check ignition timing. a. Ignition timing is too advanced. Adjust according to specifications (refer to TECHNICAL DATA). 12. Check if there are leaks at air intake silencer and/or engine crankcase. a.
  • Page 40 Section 02 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM ENGINE EQUIPPED WITH RAVE. ENGINE HESITATES AT LOW OR MID-SPEED AND REACHES MAXIMUM PERFORMANCE ONLY AFTER A WHILE. CONDITION NORMAL USE. TEST/INSPECTION 1. Check RAVE valve spring(s). a. Spring tension is too low or spring(s) is (are) broken. Replace.
  • Page 41 Section 02 TROUBLESHOOTING Subsection 01 (ENGINE) SYMPTOM ENGINE PINGING. CONDITION NORMAL USE. TEST/INSPECTION 1. Check for proper fuel octane number according to engine type. a. Too low fuel octane number. Use appropriate fuel octane number (Refer to Operator's Guide). 2. Check fuel lines. a.

  • Page 42: Fuel And Oil Systems

    Section 02 TROUBLESHOOTING Subsection 02 (FUEL AND OIL SYSTEMS) FUEL AND OIL SYSTEMS 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. NOTE: For the SDI and Power Tek engines, also refer to appropriate ENGINE MANAGEMENT section.
  • Page 43 Section 02 TROUBLESHOOTING Subsection 02 (FUEL AND OIL SYSTEMS) SYMPTOM ENGINE LACKS POWER OR STALLS AT HIGH RPM (MODELS WITH CARBURETOR ONLY). CONDITION NORMAL USE TEST/INSPECTION 1. Check fuel tank vent hose. Kinked or clogged hose. Relocate or replace. 2. Check in-tank fuel filter. Clogged filter.
  • Page 44 Section 02 TROUBLESHOOTING Subsection 02 (FUEL AND OIL SYSTEMS) SYMPTOM ENGINE LACKS FUEL/WILL NOT RESTART (SDI MODELS ONLY). CONDITION AFTER RUNNING OUT OF FUEL TEST/INSPECTION 1. Fuel tank is not filled up. Electric fuel pump reservoir inside fuel tank is empty. Fill up fuel tank or pull start engine several times to activate diaphragm fuel pump.

  • Page 45: Drive And Brake Systems

    Section 02 TROUBLESHOOTING Subsection 03 (DRIVE AND BRAKE SYSTEMS) DRIVE AND BRAKE SYSTEMS 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. DRIVE SYSTEM SYMPTOM THE SNOWMOBILE ACCELERATES SLOWLY, ESPECIALLY FROM A STANDING START.
  • Page 46 Section 02 TROUBLESHOOTING Subsection 03 (DRIVE AND BRAKE SYSTEMS) SYMPTOM LOOSE IN DRIVE SYSTEM WHEN ACCELERATING/DECELERATING. CONDITION NORMAL USE TEST/INSPECTION 1. Check drive chain tension. a. Drive chain is too loose. Adjust. 2. Check radial play of driven pulley. a. Worn splines. Replace pulley.
  • Page 47 Section 02 TROUBLESHOOTING Subsection 03 (DRIVE AND BRAKE SYSTEMS) SYMPTOM PULLEYS DO NOT DOWN SHIFT PROPERLY. CONDITION NORMAL USE TEST/INSPECTION 1. Check driven pulley spring tension. a. Spring tension is too low. Adjust according to specifications (refer to TECHNICAL DATA) or replace spring. 2.
  • Page 48 Section 02 TROUBLESHOOTING Subsection 03 (DRIVE AND BRAKE SYSTEMS) SYMPTOM BELT TOO NARROW ON ONE SECTION. CONDITION NORMAL USE TEST/INSPECTION 1. Check for frozen track. a. Frozen track. Free track from ice. 2. Check parking brake. a. Parking brake is engaged. Release parking brake.
  • Page 49 Section 02 TROUBLESHOOTING Subsection 03 (DRIVE AND BRAKE SYSTEMS) SYMPTOM BELT WORN EXCESSIVELY IN TOP WIDTH. CONDITION NORMAL USE TEST/INSPECTION 1. Check drive pulley. a. Excessive slippage due to jamming of drive pulley. Considerable Inspect drive pulley. 2. Check drive belt identification number. a.
  • Page 50 Section 02 TROUBLESHOOTING Subsection 03 (DRIVE AND BRAKE SYSTEMS) SYMPTOM FATIGUE CRACKS BETWEEN COGS. CONDITION NORMAL USE TEST/INSPECTION 1. Check drive belt condition. a. Belt considerably worn, worn out. Replace. b. Distortion of natural belt shape due to improper storage. Store properly.
  • Page 51 Section 02 TROUBLESHOOTING Subsection 03 (DRIVE AND BRAKE SYSTEMS) SYMPTOM SLIDER SHOES WEAR OUT PREMATURELY/OR TRACK CLEATS BECOME BLUE. CONDITION NORMAL USE TEST/INSPECTION 1. Check track tension. a. Pressure is too great on slider shoes. Adjust according to specifications (refer to TECHNICAL DATA). Replace defective parts. 2.

  • Page 52: Brake System

    Section 02 TROUBLESHOOTING Subsection 03 (DRIVE AND BRAKE SYSTEMS) BRAKE SYSTEM SYMPTOM SPONGY BRAKE CONDITION. CONDITION NORMAL USE TEST/INSPECTION 1. Contaminated brake fluid. Replace brake fluid and bleed system. If the problem persists, replace master cylinder. SYMPTOM BRAKE FLUID LEAKAGE. CONDITION NORMAL USE TEST/INSPECTION...

  • Page 53: Electrical System

    Section 02 TROUBLESHOOTING Subsection 04 (ELECTRICAL SYSTEM) ELECTRICAL SYSTEM 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. SYMPTOM STARTER DOES NOT TURN.
  • Page 54 Section 02 TROUBLESHOOTING Subsection 04 (ELECTRICAL SYSTEM) SYMPTOM STARTER TURNS BUT DOES NOT CRANK THE ENGINE. CONDITION NORMAL USE TEST/INSPECTION 1. Check battery capacity. a. Shorted battery cell(s). Replace. 2. Check battery charge. a. Low battery. Recharge battery and check recharge system and wires. 3.
  • Page 55 Section 02 TROUBLESHOOTING Subsection 04 (ELECTRICAL SYSTEM) SYMPTOM STARTER TURNS, BUT OVERRUNNING CLUTCH PINION DOES NOT MESH WITH RING GEAR. CONDITION NORMAL USE TEST/INSPECTION 1. Check clutch pinion gear. a. Worn clutch pinion gear. Replace clutch. 2. Check clutch. a. Defective clutch. Replace clutch.
  • Page 56 Section 02 TROUBLESHOOTING Subsection 04 (ELECTRICAL SYSTEM) SYMPTOM ELECTRIC STARTER KEEPS TURNING WHEN ENGINE IS STARTED. CONDITION NORMAL USE TEST/INSPECTION 1. Check clutch. a. Jammed clutch pinion gear. Replace or clean. 2. Check movement of clutch on splines. a. Clutch is stuck on splines. Clean.
  • Page 57 Section 02 TROUBLESHOOTING Subsection 04 (ELECTRICAL SYSTEM) SYMPTOM ELECTRIC STARTER SOMETIMES DOES NOT WORK WHEN ACTIVATED. CONDITION NORMAL USE TEST/INSPECTION 1. Check battery cables and starter wires. a. Corroded and/or loose connection(s). Clean and/or retighten. 2. Check fuse. a. Oxidized or burnt fuse. Clean or replace.
  • Page 58 2. Check injection oil consumption. a. Injection pump flow is too high. Adjust according to specifications or replace. 3. Check oil quality. a. Poor quality oil (creation of deposits). Use BRP XP-S injection oil. 4. Check engine compression. a. Leaking piston ring(s). Replace. MMR2005-066...
  • Page 59 2. Check spark plug heat range. a. Spark plug heat range is too high. Replace by BRP's recommended spark plug (refer to TECHNICAL DATA). 3. Check if air intake silencer leaks. a. Air surplus coming from opening(s) located between halves.
  • Page 60 Excessive electrical load to magneto/generator. Reconnect as recommended by manufacturer. 7. BRP heating grips: Verify if the return wires of the elements were grounded to the chassis by mistake. a. Faulty installation of optional equipment. Reconnect as recommended by manufacturer.
  • Page 61 Section 02 TROUBLESHOOTING Subsection 04 (ELECTRICAL SYSTEM) SYMPTOM FALSE FUEL AND/OR TEMPERATURE GAUGE READINGS. CONDITION NORMAL USE TEST/INSPECTION 1. On ( fan-cooled models ), verify if gauge was connected on DC current by mistake (in case of optional installation). a. Faulty installation of optional equipment. Find optional wires connected directly to DC ground (BLACK wire to chassis) or to any DC hot wire (RED or RED/BLUE).
  • Page 62 Section 02 TROUBLESHOOTING Subsection 04 (ELECTRICAL SYSTEM) SYMPTOM TACHOMETER DOES NOT WORK. CONDITION NORMAL USE TEST/INSPECTION 1. Check continuity of wires. a. Corroded terminals and/or broken wires. Replace terminal(s) or crimp defective wires. 2. Check tachometer part number. a. Models with 360 W magneto have a different tachometer. Replace with appropriate one.

  • Page 63: Steering And Suspension

    Section 02 TROUBLESHOOTING Subsection 05 (STEERING AND SUSPENSION) STEERING AND SUSPENSION 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. SYMPTOM SUSPENSION IS TOO LOW.
  • Page 64 Section 02 TROUBLESHOOTING Subsection 05 (STEERING AND SUSPENSION) SYMPTOM REAR SUSPENSION IS TOO STIFF. CONDITION NORMAL USE TEST/INSPECTION 1. Check rear spring preload. a. Too much preload. Adjust to a softer position. 2. Check springs. a. Springs installed are too stiff. Install optional softer springs, refer to service bulletin SPRING REFERENCE ACCORDING TO LOAD.
  • Page 65 Section 02 TROUBLESHOOTING Subsection 05 (STEERING AND SUSPENSION) SYMPTOM HANDLEBAR IS DIFFICULT TO TURN. CONDITION NORMAL USE TEST/INSPECTION 1. Check if the handlebar turns freely when skis are off the ground. a. Ball joints corrosion restrains movement. Lubricate or replace the ball joint. b.

  • Page 66: Engines

    Section 03 ENGINES Subsection 01 (LEAK TEST) LEAK TEST SERVICE TOOLS Description Part Number Page hose pincher ................. 295 000 076 ........... 47 vacum/pressure pump kit ............. 529 021 800 ........... 47 PREPARATION Use vacum/pressure pump kit (P/N 529 021 800) to pressure test engine.

  • Page 67: Procedure

    Section 03 ENGINES Subsection 01 (LEAK TEST) • cylinder crankcase halves (joint) • oil injection pump mounting flange (O-ring) • coolant pump housing • bleed screws/plugs • crankcase grease reservoir fitting. – Small injection oil lines coming from pump. – Activate pump and pressurize engine to 34 kPa (5 PSI).

  • Page 68: Finalizing Reassembly

    Section 03 ENGINES Subsection 01 (LEAK TEST) If pressure drops, it indicates a defective crank- 1. Weep hole shaft inner seal. If there is a leak, it indicates that a pump shaft is defective (oil seal beside coolant ceramic seal). –...

  • Page 69: Engine Leak Verification Flow Chart

    Section 03 ENGINES Subsection 01 (LEAK TEST) 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 INJECTION PUMP AIR BUBBLES FOUND...

  • Page 70: Exhaust System

    Section 03 ENGINES Subsection 02 (EXHAUST SYSTEM) EXHAUST SYSTEM SERVICE TOOLS Description Part Number Page exhaust spring installer/remover .......... 529 035 401 ........54–55 SERVICE PRODUCTS Description Part Number Page RTV sealant ................293 800 090 ........... 55 mmr2005-069...

  • Page 71: 377 And 552 Engines

    Section 03 ENGINES Subsection 02 (EXHAUST SYSTEM) 377 AND 552 ENGINES mmr2005-069...

  • Page 72: Ho, 593 Ho Sdi And 793 Ho Engines

    Section 03 ENGINES Subsection 02 (EXHAUST SYSTEM) 593, 593 HO, 593 HO SDI AND 793 HO ENGINES 593 engines Other engines mmr2005-069...

  • Page 73: Tuned Pipe

    This number depicts the 6 last numbers of BRP part number. A01B58A – tuned pipe no. 2 –...

  • Page 74: Manifold

    Install all exhaust springs using exhaust spring in- number on the welded clamp at the end of muffler. staller/remover (P/N 529 035 401). This number depicts the 6 last numbers of BRP part number. MANIFOLD Removal Remove: –...

  • Page 75: Engine Removal And Installation

    Section 03 ENGINES Subsection 03 (ENGINE REMOVAL AND INSTALLATION) ENGINE REMOVAL AND INSTALLATION SERVICE TOOLS Description Part Number Page engine removal hook ............529 035 829 ........... 69 pump ..................529 035 880 ........... 65 small hose pincher ............... 295 000 076 ........... 60 spark plug lift ring ..............
  • Page 76 Section 03 ENGINES Subsection 03 (ENGINE REMOVAL AND INSTALLATION) Fan-Cooled Engines mmr2005-070...

  • Page 77: Removal From Vehicle

    Section 03 ENGINES Subsection 03 (ENGINE REMOVAL AND INSTALLATION) REMOVAL FROM VEHICLE Vehicule and Engine Preparation Place vehicle at workstation that will have access to an engine-lifting hoist. Then start with initial preparation of vehicle by doing the following. Remove the RH and the LH side panels. Disconnect BLACK (-) cable from battery, then the RED (+) cable.
  • Page 78 Section 03 ENGINES Subsection 03 (ENGINE REMOVAL AND INSTALLATION) 552 ENGINE SHOWN 1. Hose pincher 1. Oil pump 2. Inlet oil line 2. Rewind starter housing Unscrew engine support bolts no. 4 and no. 5. Unplug both outlet hoses from oil pump. 1.
  • Page 79 Section 03 ENGINES Subsection 03 (ENGINE REMOVAL AND INSTALLATION) 1. Front brace 1. Carburetor clamps Unscrew the rear brace. Unscrew and remove the engine stopper. Do not remove rubber end no. 8 only, unscrew the screwed rod no. 9 completely. 1.
  • Page 80 Section 03 ENGINES Subsection 03 (ENGINE REMOVAL AND INSTALLATION) Remove the engine support bolts no. 11 and Install the homemade lifting tool. no. 12. Use the following illustration to make the tool. 1. Rear engine support bolt 2. Front engine support bolt Remove headlamp adjusting knob from its sup- port.

  • Page 81: Inspection

    Section 03 ENGINES Subsection 03 (ENGINE REMOVAL AND INSTALLATION) Torque engine support bolts to 48 N•m (35 lbf•ft). Hand torque engine stopper no. 9 then torque its nut no. 16 to 50 N•m (37 lbf•ft). Reinstall all removed parts by using the appropri- ate component/system reinstallation procedures described in this shop.
  • Page 82 Section 03 ENGINES Subsection 03 (ENGINE REMOVAL AND INSTALLATION) Liquid-Cooled Engines 593 engines mmr2005-070...

  • Page 83: Removal From Vehicle

    Section 03 ENGINES Subsection 03 (ENGINE REMOVAL AND INSTALLATION) REMOVAL FROM VEHICLE Unplug from the coolant reservoir the hose going to the engine. Vehicle and Engine Preparation Place vehicle at workstation that will have access to an engine-lifting hoist. Then start with initial preparation of vehicle by doing the following.
  • Page 84 Section 03 ENGINES Subsection 03 (ENGINE REMOVAL AND INSTALLATION) Unplug heather carburetor hose from coolant reservoir. Unscrew oil injection reservoir then separate coolant reservoir. On left side of vehicle, do the following: Unplug magneto and trigger coil connectors. Remove: – LH side panel –...
  • Page 85 Section 03 ENGINES Subsection 03 (ENGINE REMOVAL AND INSTALLATION) Unplug RAVE valve line from solenoid. 1. Solenoid TYPICAL — 793 HO ENGINE TYPE SHOWN 2. RAVE valve line 1. Reed valve 3. Thermostat housing Unplug magneto connector from MPEM. Separate carburetors or throttle body from engine. Detach oil pump cable from oil pump.
  • Page 86 Section 03 ENGINES Subsection 03 (ENGINE REMOVAL AND INSTALLATION) 1. Knock sensor connector Remove spark plugs and install the spark plug lift Detach upper thermostat hose from thermostat ring (P/N 529 035 830) at the farthest spark plug housing. hole. 1.

  • Page 87: Inspection

    Section 03 ENGINES Subsection 03 (ENGINE REMOVAL AND INSTALLATION) Unscrew engine support nuts no. 3 then separate support no. 4 from engine. INSPECTION Check if engine support no. 4 is cracked, bent or LEFT SIDE OF VEHICLE otherwise damaged. Replace if necessary. 1.

  • Page 88: Magneto System

    Section 03 ENGINES Subsection 04 (MAGNETO SYSTEM) MAGNETO SYSTEM SERVICE TOOLS Description Part Number Page crankshaft protector ............. 420 876 557 ........... 77 magneto puller..............529 035 547 ........... 77 puller ring................420 876 080 ........... 76 SERVICE PRODUCTS Description Part Number Page Loctite 243 (blue)..............
  • Page 89 Section 03 ENGINES Subsection 04 (MAGNETO SYSTEM) 377 and 552 Engines mmr2005-071...
  • Page 90 Section 03 ENGINES Subsection 04 (MAGNETO SYSTEM) 593 Engines mmr2005-071...
  • Page 91 Section 03 ENGINES Subsection 04 (MAGNETO SYSTEM) 593 HO and 793 HO Engines mmr2005-071...
  • Page 92 Section 03 ENGINES Subsection 04 (MAGNETO SYSTEM) 593 HO SDI Engines mmr2005-071...

  • Page 93: General

    Section 03 ENGINES Subsection 04 (MAGNETO SYSTEM) GENERAL NOTE: The following procedures can be done without removing the engine. To facilitate mag- neto removal, hold drive pulley with the appropri- ate tool. During assembly/installation, use the torque val- ues and service products as in the exploded views.
  • Page 94 Section 03 ENGINES Subsection 04 (MAGNETO SYSTEM) CAUTION: Use only M8 x 20 mm screws to bolt puller to magneto flywheel. When a counter- weight is installed on magneto flywheel use M8 x 30 mm screws. Tighten puller bolt and at the same time, tap on bolt head using a hammer to release magneto fly- wheel from its taper.

  • Page 95: Stator

    Section 03 ENGINES Subsection 04 (MAGNETO SYSTEM) STATOR Inspection Always check stator no. 3 before changing it. Re- fer to CHARGING SYSTEM. Cleaning Clean all metal components in a non-ferrous metal cleaner. CAUTION: Clean stator using only a clean cloth. Removal Remove: –...
  • Page 96 Section 03 ENGINES Subsection 04 (MAGNETO SYSTEM) NOTE: It is important to remove the old silicon at CPS/trigger coil location then apply new silicon. Screw CPS/trigger coil then stick the CPS/trigger coil wires in the silicon. mmr2005-071...

  • Page 97: Top End

    Section 03 ENGINES Subsection 05 (TOP END) TOP END SERVICE TOOLS Description Part Number Page bearing heater............... 529 035 969 ........86, 105 centering tool................ 529 009 100 ........... 87 piston circlip installer ............529 035 561 ........... 87 piston circlip installer ............529 035 686 ........89, 106 piston pin puller ..............
  • Page 98 Section 03 ENGINES Subsection 05 (TOP END) 377 Engine mmr2005-072...
  • Page 99 Section 03 ENGINES Subsection 05 (TOP END) 552 Engine mmr2005-072...

  • Page 100: Troubleshooting

    Section 03 ENGINES Subsection 05 (TOP END) TROUBLESHOOTING Before completely disassemble engine, proceed with an engine leak test. Refer to LEAK TEST. Component Removal with the Engine Installed Most engine components can be removed with engine on vehicle such as: –...
  • Page 101 Section 03 ENGINES Subsection 05 (TOP END) 552 Engine Extract piston pin no. 10 by unscrewing puller until shouldered sleeve end is flush with thrust washer PULLER SLEEVE KIT LOCATING of piston pin bearing. ENGINE SLEEVE P/N 529 035 542 529 035 503 529 023 800 (20 mm)

  • Page 102: Inspection

    Section 03 ENGINES Subsection 05 (TOP END) TOLERANCES ENGINE NEW PARTS WEAR MEASUREMENT (min.) (max.) LIMIT Cylinder head volume 19.55 cc 21.15 cc N.A. 377 engine Cylinder head volume 34.34 cc 36.74 cc N.A. 552 engine 0.5 mm Cylinder head warpage N.A.
  • Page 103 Section 03 ENGINES Subsection 05 (TOP END) Insert circlip in tool at an angle. 1. Circlip CAUTION: Piston temperature must not exceed Square it up using a finger. 46°C (115°F). NEVER USE DIRECT FLAME to heat the piston and never freeze the pin. In- appropriate heating procedure(s) may damage the piston.
  • Page 104 Section 03 ENGINES Subsection 05 (TOP END) A02C2OA TYPICAL 1. Circlip break facing down A02C2MA Hold tool firmly against piston then strike on round end of tool with a plastic hammer. Circlip will Using square end of tool, push circlip in until it move from tool groove to piston groove.
  • Page 105 Section 03 ENGINES Subsection 05 (TOP END) A02C2GA A02C2IA TYPICAL TYPICAL — SHOULDERED SLEEVE INSTALLATION 1. Sleeve Install piston pin puller and turn handle until piston Grease thrust washers and install them on each pin is correctly positioned in piston. end of needles.
  • Page 106 Section 03 ENGINES Subsection 05 (TOP END) CIRCLIP READY TO BE INSTALLED ON PISTON With round end of pusher, position circlip perpen- dicular to the support axis. Using a plastic hammer, tap pusher to insert circlip in place. Take care to install new circlips with tab toward top as per following photo.

  • Page 107: Reed Valve

    Section 03 ENGINES Subsection 05 (TOP END) CAUTION: Always install a gasket of the proper thickness. Failure to do so may cause detona- tion and severe engine damage. NOTE: Be sure to restore the chamfer around all cylinder sleeve port openings. Before inserting piston in cylinder no.
  • Page 108 Section 03 ENGINES Subsection 05 (TOP END) 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 109 Section 03 ENGINES Subsection 05 (TOP END) 593 Engine mmr2005-072...
  • Page 110 Section 03 ENGINES Subsection 05 (TOP END) 593 HO Engine mmr2005-072...
  • Page 111 Section 03 ENGINES Subsection 05 (TOP END) 593 HO SDI Engine mmr2005-072...
  • Page 112 Section 03 ENGINES Subsection 05 (TOP END) 793 HO Engine mmr2005-072...
  • Page 113 Section 03 ENGINES Subsection 05 (TOP END) 793 HO Engine (Power Tek) mmr2005-072...

  • Page 114: Troubleshooting

    Section 03 ENGINES Subsection 05 (TOP END) TROUBLESHOOTING Before completely disassembling the engine, pro- ceed with an engine leak test. Refer to LEAK TEST. COMPONENT REMOVAL WITH THE ENGINE INSTALLED Most engine components can be removed with engine on vehicle such as: –...
  • Page 115 Section 03 ENGINES Subsection 05 (TOP END) WARNING Firmly hold cover to valve base no. 6. The compression spring no. 7 inside the valve is applying pressure against the cover. TYPICAL 1. Allen socket screws 2. RAVE valve base Unscrew and remove the guillotine no. 9 from the valve piston no.
  • Page 116 Section 03 ENGINES Subsection 05 (TOP END) TYPICAL 1. Bellows 2. Small spring 3. Valve base TYPICAL Remove bellows from valve base. 1. Spring 2. Valve piston 3. Bellows Remove valve piston. TYPICAL REED Valve TYPICAL 593 Engine Remove intake resonator on top of reed valves Remove the small spring no.
  • Page 117 Section 03 ENGINES Subsection 05 (TOP END) Cylinder Head Cover All Engines Except 793 HO Unplug spark plug cables. Disconnect the knock sensor no. 19 (593 HO SDI engine). Unplug coolant hose from upper thermostat hous- ing no. 20. Unscrew all cylinder head cover screws no. 21. Cylinder Head All Engines except 793 HO Remove the cylinder head cover no.
  • Page 118 Section 03 ENGINES Subsection 05 (TOP END) 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 Remove puller.

  • Page 119: Inspection

    (All models 420 239 941 Blue 0.8 (.031) 52.5 (2.07) oil used. except Summit) BRP suggests annual cleaning of the valve. If a 793 HO 420 239 942 Black 0.8 (.031) 42.5 (1.67) customer uses lower quality oil, than recommend- (Summit) ed, more frequent cleaning may be required.

  • Page 120: Assembly

    Section 03 ENGINES Subsection 05 (TOP END) ASSEMBLY Cylinder Head, Cylinder and Piston RAVE Valves TOLERANCES ENGINE Apply sealing compound Drei Bond (P/N 420 297 NEW PARTS WEAR MEASUREMENT 906) in the groove of valve base and in the piston (min.) (max.) LIMIT valve groove, then install bellows.
  • Page 121 Section 03 ENGINES Subsection 05 (TOP END) Lubricate needle bearings and thrust washers with injection oil then install washers on each end of needles. Insert cageless bearing into connecting rod. 1. Exhaust Install shouldered sleeve. TYPICAL — CAGELESS BEARING AND SLEEVE INSTALLED Heat piston using bearing heater (P/N 529 035 969).
  • Page 122 Section 03 ENGINES Subsection 05 (TOP END) To minimize the effect of acceleration forces on circlip, install each circlip so the circlip break is at 6 o’clock as illustrated. Use appropriate piston circlip installer to install mono-hook circlips no. 25. ENGINE TOOL piston circlip installer...
  • Page 123 Section 03 ENGINES Subsection 05 (TOP END) CAUTION: Always install new mono-hook cir- clips. If circlip installation fails at the first at- tempt, always retry with a new one because, on a second attempt, the circlip will lose its nor- mal retaining capabilities.
  • Page 124 Section 03 ENGINES Subsection 05 (TOP END) All Engines Except 793 HO Check distance from blade stopper no. 29 outer edge and distance from center of reed valve block. TYPICAL A. 18.7 - 0, + 0.75 mm (.736 - 0, + .030 in) Bent blade stopper as required to obtain the prop- er distance.

  • Page 125: Bottom End

    Section 03 ENGINES Subsection 06 (BOTTOM END) BOTTOM END SERVICE TOOLS Description Part Number Page bearing heater............... 529 035 969 ......... 114, 124 bearing puller ................ 420 877 635 ......... 112, 122 crankshaft protector ............. 420 876 552 ......... 112, 122 crankshaft protector .............
  • Page 126 Section 03 ENGINES Subsection 06 (BOTTOM END) 377 Engine mmr2005-073...
  • Page 127 Section 03 ENGINES Subsection 06 (BOTTOM END) 552 Engine mmr2005-073...

  • Page 128: Cleaning

    Section 03 ENGINES Subsection 06 (BOTTOM END) Remove engine from chassis. Refer to REMOVAL Apply synthetic grease (P/N 413 711 500) on the AND INSTALLATION. crankshaft end and install crankshaft protector (P/N 420 876 552). Remove engine fan cowls, cylinder heads and cylinders.

  • Page 129: Inspection

    Section 03 ENGINES Subsection 06 (BOTTOM END) INSPECTION Refer to table below to find bottom end engine di- mension specifications. For dimension measure- ment procedures, refer to ENGINE MEASURE- MENT. TOLERANCES ENGINE NEW PARTS WEAR MEASUREMENT (min.) (max.) LIMIT 0.06 mm Crankshaft deflection N.A.
  • Page 130 Section 03 ENGINES Subsection 06 (BOTTOM END) NOTE: Normally it takes approximately 10 min- utes to heat up a bearing so in the event of replac- ing bearing, it’s recommended to start the bearing heating process prior to removal operation. Two bearings can be heated at the same time on one bearing heater.
  • Page 131 Section 03 ENGINES Subsection 06 (BOTTOM END) Crankshaft Bearing Installation 377 Engine To check proper clearance between bearing no. 3 and crankshaft counterbalance , use feeler gauge (P/N 420 876 620). Mount second bearing with distance gauge (P/N 420 876 822) for proper positioning. BEARING TO END POSITION Install the O-ring.
  • Page 132 Section 03 ENGINES Subsection 06 (BOTTOM END) Crankshaft Installation When installing crankshaft, position drive pins no. 6 as illustrated. Slide in the heated outer PTO bearing onto the crankshaft. A03C1HA TYPICAL 1. Drive pins At seal no. 2 assembly, apply a light coat of lithium grease on seal lip.
  • Page 133 Section 03 ENGINES Subsection 06 (BOTTOM END) IMPORTANT: The total assembly sequence, in- cluding sealing compound spreading, screwing and torquing of bolts according to the proper sequence must be performed within 10 minutes. Do not wait between each bolt torquing. All bolts must be torqued in a row.

  • Page 134: Break-In

    Section 03 ENGINES Subsection 06 (BOTTOM END) 552 Engine TYPICAL TIGHTENING SEQUENCE FOR 552 ENGINE TYPE Screw all crankcase bolts in place in the following sequence and to the appropriate torque through a BREAK-IN two steps torquing: first, screw bolts up to 60% After rebuilding an engine always observe a break- of the final torque 13 N•m (115 lbf•in) for M8 in period as described in Operator’s Guide.
  • Page 135 Section 03 ENGINES Subsection 06 (BOTTOM END) 593 Engine mmr2005-073...
  • Page 136 Section 03 ENGINES Subsection 06 (BOTTOM END) 593 HO Engine mmr2005-073...
  • Page 137 Section 03 ENGINES Subsection 06 (BOTTOM END) 593 HO SDI and 793 HO Engines mmr2005-073...

  • Page 138: Cleaning

    Section 03 ENGINES Subsection 06 (BOTTOM END) CLEANING Discard all oil seals, gaskets, O-rings and sealing rings. Clean all metal components in a non-ferrous met- al cleaner. Use Loctite Chisel (P/N 413 708 500) accordingly. Remove old paste gasket from crankcase mating surfaces using also Loctite Chisel.

  • Page 139: Inspection

    Section 03 ENGINES Subsection 06 (BOTTOM END) ASSEMBLY Follow the same procedure for the inner bearing NOTE: In the case of damaged bearing or less Coat lip of all seals with Petamo grease (P/N 420 clearance between crankshaft counterbalance and 899 271).
  • Page 140 Section 03 ENGINES Subsection 06 (BOTTOM END) NOTE: Normally it takes approximately 10 min- utes to heat up a bearing so in the event of replac- ing bearing, it’s recommended to start the bearing heating process prior to removal operation. Two bearings can be heated at the same time on one bearing heater.
  • Page 141 Section 03 ENGINES Subsection 06 (BOTTOM END) Crankshaft Bearing Installation CAUTION: Never reinstall a bearing that has been removed. Slide in the inner PTO bearing with the integrated seal facing crankshaft. Push bearing to end posi- tion. 1. Support plate 2.
  • Page 142 Section 03 ENGINES Subsection 06 (BOTTOM END) TYPICAL 1. Position pins Pour 50 mL (2 U.S. oz) of injection oil in the pan under central gear to lubricate pump gearing as per photo. Slide-in the second bearing until it contacts the first one.
  • Page 143 Section 03 ENGINES Subsection 06 (BOTTOM END) TYPICAL — FILL WITH GREASE AND SET IN PLACE PTO SIDE BEARING FILLED WITH ISOFLEX GREASE Apply 6 mL of grease to MAG side outer bearing. With the syringe, fill the outer ball bearing and in- ner side of outer seal with 40 to 45 mL of Isoflex NOTE: If replaced with new bearing, do not apply grease.

  • Page 144: Break-In

    Section 03 ENGINES Subsection 06 (BOTTOM END) 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 145: Engine Measurement

    Section 03 ENGINES Subsection 07 (ENGINE MEASUREMENT) ENGINE MEASUREMENT SERVICE TOOLS Description Part Number Page degree wheel ............... 529 035 607 ......... 134 TDC gauge ................414 104 700 ......... 130, 134 NOTE: This subsection explains the procedures to correctly measure engine components. For the engine technical specifications, refer to INSPEC- TION in the appropriate engine subsection.

  • Page 146: Combustion Chamber Volume Measurement

    Section 03 ENGINES Subsection 07 (ENGINE MEASUREMENT) 1. Piston pin position 2. Measures to be compared A. 16 mm (5/8 in) 1. Bring piston to TDC – Obtain a graduated burette (capacity 0 - 50 cc) COMBUSTION CHAMBER and fill with an equal part (50/50) of gasoline and VOLUME MEASUREMENT injection oil.

  • Page 147: Used Piston Measurement

    Section 03 ENGINES Subsection 07 (ENGINE MEASUREMENT) 1. Top of spark plug hole 1. Piston dome 2. Piston measurement NOTE: The liquid level in cylinder must not drop Using a micrometer, measure piston skirt at for a few seconds after filling. If so, there is a 15 mm (.590 in) perpendicularly (90°) to piston leak between piston and cylinder.
  • Page 148 Section 03 ENGINES Subsection 07 (ENGINE MEASUREMENT) 1. Piston dome 1. Use the micrometer to set the cylinder bore gauge 2. Piston measurement 2. Dial bore gauge Adjust and lock a micrometer to the specified val- ue on the piston dome. 1.

  • Page 149: Ring/Piston Groove Clearance

    Section 03 ENGINES Subsection 07 (ENGINE MEASUREMENT) NOTE: In order to correctly position the ring in the cylinder, use piston as a pusher. Using a feeler gauge, check ring end gap. Replace ring if gap exceeds specified tolerance. F01D0KA 1. Measuring perpendicularly (90°) to piston pin axis A.

  • Page 150: Connecting Rod Big End Axial Play

    Section 03 ENGINES Subsection 07 (ENGINE MEASUREMENT) Remove both spark plugs. Install a TDC gauge (P/N 414 104 700) in spark plug hole on MAG side. TYPICAL 1. Measure at mid point between the key and the first thread A. 3 mm (1/8 in) NOTE: Crankshaft deflection cannot be correctly measured between centers of a lathe.

  • Page 151: Cooling System

    Section 03 ENGINES Subsection 08 (COOLING SYSTEM) COOLING SYSTEM SERVICE TOOLS Description Part Number Page engine leak tester kit ............861 749 100 ......... 145 Holder wrench ..............420 876 357 ......... 138 Holder wrench ..............529 036 006 ......... 138 hose pincher .................
  • Page 152 Section 03 ENGINES Subsection 08 (COOLING SYSTEM) Axial Fan Cooling System 550F models 380F models mmr2005-074...
  • Page 153 Section 03 ENGINES Subsection 08 (COOLING SYSTEM) 12 14 mmr2005-074...

  • Page 154: Cooling Fan Removal And Installation

    Section 03 ENGINES Subsection 08 (COOLING SYSTEM) COOLING FAN REMOVAL AND ENGINE TOOL INSTALLATION Holder wrench (P/N 420 876 357) Remove the tuned pipe to gain access. Refer to Holder wrench (P/N 529 036 006) EXHAUST SYSTEM. Unscrew the 2 screws no. 1 and no. 2 of inlet duct no.

  • Page 155: Fan Belt Replacement And Deflection Adjustment

    Section 03 ENGINES Subsection 08 (COOLING SYSTEM) FAN BELT REPLACEMENT AND Remove support fan housing no. 7. Refer to TOP END and MAGNETO SYSTEM. DEFLECTION ADJUSTMENT Using a press, drive the fan shaft no. 8 out. Remove tuned pipe and muffler. Refer to EX- HAUST SYSTEM.
  • Page 156 Section 03 ENGINES Subsection 08 (COOLING SYSTEM) Fan Belt Deflection Adjustment Check fan belt deflection using a ruler and a fish scale positioned midway between pulleys as per following photo. A03C23A 1. Keep shims 2. Leave second half pulley in place Install new fan belt on bottom pulley first then po- sition onto fan shaft, as shown in the next photo.
  • Page 157 Section 03 ENGINES Subsection 08 (COOLING SYSTEM) Install the air inlet duct no. 3 with screws no. 1 and no. 2. Reinstall tuned pipe and muffler. Refer to EX- HAUST SYSTEM. TYPICAL 1. Unused shim(s) here 2. Adjust here 3. Positioning noses 4.

  • Page 158: Liquid Cooling System

    Section 03 ENGINES Subsection 08 (COOLING SYSTEM) LIQUID COOLING SYSTEM Carbureted Models except Summit mmr2005-074...
  • Page 159 Section 03 ENGINES Subsection 08 (COOLING SYSTEM) SDI Models mmr2005-074...
  • Page 160 Section 03 ENGINES Subsection 08 (COOLING SYSTEM) Summit Models mmr2005-074...

  • Page 161: Cooling System Leak Test

    Section 03 ENGINES Subsection 08 (COOLING SYSTEM) COOLING SYSTEM LEAK TEST DISASSEMBLY AND ASSEMBLY WARNING Coolant Pump To prevent burning yourself, do not remove Refer to BOTTOM END section. the radiator cap if the engine is hot. Sender and Plug Install special radiator cap (P/N 529 021 400) in- Apply Loctite 592 (P/N 293 800 018) thread sealant cluded in the engine leak tester kit (P/N 861 749...

  • Page 162: Cooling System Refilling Procedure

    Put vehicle back on ground and add coolant up to ing condition, always replenish the system 15 mm (1/2 in) over COLD LEVEL line. with the BRP premixed coolant or with 50% When engine has completely cooled down, antifreeze and 50% water. Pure antifreeze recheck coolant level in coolant tank and refill up without water freezes (like slush ice).

  • Page 163: Rewind Starter

    Section 03 ENGINES Subsection 09 (REWIND STARTER) REWIND STARTER SERVICE PRODUCTS Description Part Number Page Molykote PG 54..............420 899 763 ......... 151, 153 mmr2005-075...
  • Page 164 Section 03 ENGINES Subsection 09 (REWIND STARTER) Rewind Starter on Fan Cooled Models 11 10 TYPICAL mmr2005-075...
  • Page 165 Section 03 ENGINES Subsection 09 (REWIND STARTER) Rewind Starter on Liquid Cooled Models mmr2005-075...

  • Page 166: Inspection

    Section 03 ENGINES 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 167: Disassembly

    Section 03 ENGINES 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 168 Section 03 ENGINES 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 169 Section 03 ENGINES 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 170: Installation

    Section 03 ENGINES Subsection 09 (REWIND STARTER) A01C18A 1. Step collar TYPICAL 2. O-ring 3. Locking element Fan Cooled Models Only Position a new push nut no. 13. Reinstall oil pump with gear case (552 engine). Refer to LUBRICATION SYSTEM. INSTALLATION Thread starter rope no.

  • Page 171: Oil Injection System

    Section 03 ENGINES Subsection 10 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM SERVICE TOOLS Description Part Number Page gear holder................420 876 695 ......... 161 hose pincher ................. 295 000 076 ......... 158, 160 leak testing kit ..............529 033 100 ......... 158 small hose pincher..............
  • Page 172 Section 03 ENGINES Subsection 10 (OIL INJECTION SYSTEM) Fan-cooled Models 377 engines 552 engines mmr2005-076...
  • Page 173 Section 03 ENGINES Subsection 10 (OIL INJECTION SYSTEM) Liquid-cooled Models mmr2005-076...

  • Page 174: General

    Section 03 ENGINES Subsection 10 (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 no. 1 and all other component of oil sys- views.

  • Page 175: Oil Pump Identification

    Section 03 ENGINES Subsection 10 (OIL INJECTION SYSTEM) CHECKING OPERATION Oil Pump On Vehicle NOTE: Main oil line must be full of oil. See bleed- ing procedure below. Lift rear of vehicle and support with a mechanical stand. Unplug small oil lines from pump. Start engine and stop it as soon as it fires.

  • Page 176: Disassembly

    Section 03 ENGINES Subsection 10 (OIL INJECTION SYSTEM) Oil Reservoir Check Valve It allows air to get into the reservoir. To verify this one-way check valve, remove it along with the hose. Make sure that it holds pressure and that it does not let air go through.

  • Page 177: Assembly

    Section 03 ENGINES Subsection 10 (OIL INJECTION SYSTEM) ASSEMBLY Liquid-cooled Models Remove: CAUTION: Always bleed oil pump when the system has been opened. – air box – carburetor or throttle body NOTE: During installation, always check for spring clips no. 19 tightness. –...

  • Page 178: Bleeding Procedure

    Section 03 ENGINES Subsection 10 (OIL INJECTION SYSTEM) Reinstall all parts. Bleed the small oil line between pump and engine by running engine at idle while holding the pump lever in fully open position. NOTE: Make a J hook out of mechanical wire to lift the lever.
  • Page 179 Section 03 ENGINES Subsection 10 (OIL INJECTION SYSTEM) Liquid-cooled Models Before processing with the oil pump cable adjust- ment, verify throttle cable adjustment. Refer to CARBURETOR AND THROTTLE CABLE or COM- PONENT INSPECTION, REPLACEMENT AND AD- JUSTMENT (SDI models). Depress the throttle lever lightly until the cable is under tension but carburetors or throttle body are not yet opened.

  • Page 180: Fuel System

    Section 04 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) FUEL TANK AND FUEL PUMP SERVICE TOOLS Description Part Number Page hose pincher ................. 295 000 076 ......... 168, 174 leak tester kit ................ 529 033 100 ......... 171 vacum/pressure pump kit .............
  • Page 181 Section 04 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) All Models except SDI mmr2005-078...
  • Page 182 Section 04 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) SDI Models mmr2005-078...

  • Page 183: In-Tank Fuel Filter

    Section 04 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) IN-TANK FUEL FILTER Replace fuel filter and grommet. To facilitate the installation, grommet should be on smaller diam- Replacement eter of male connector. Install grommet on fuel tank and push male connector through grommet. Drain fuel tank.

  • Page 184: Fuel Tank

    Section 04 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) FUEL TANK Removal Remove seat, refer to BODY. Remove fuel tank cap. Remove filler neck plastic nut using wrench (P/N 529 035 891). 1. Remove this screw on both sides Remove both sides fuel tank aluminum braces: –...

  • Page 185: Float-Type Fuel Level Gauge

    Section 04 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) 1. Cut this locking tie FUEL TANK REMOVED 1. Hose pincher installed on fuel line Remove fuel tank no. 3 and set it aside. SDI Models Installation Release fuel pressure of the system. Refer to COMPONENT INSPECTION, REPLACEMENT...

  • Page 186: Electric Fuel Level Sensor

    Section 04 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) – Insert grommet in fuel tank until it bottoms. Install on fuel tank, the special cap of leak tester kit (P/N 529 033 100). – Firmly push gauge in grommet until it bottoms and so that its red line aligns with the line on Using vacum/pressure pump kit (P/N 529 021 the fuel tank.

  • Page 187: Diaphragm Fuel Pump

    Section 04 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) DIAPHRAGM FUEL PUMP All Models except SDI mmr2005-078...
  • Page 188 Section 04 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) SDI Models mmr2005-078...

  • Page 189: Removal

    Section 04 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMP) NOTE: The following instructions are applicable Connect a clean plastic tubing to the impulse nip- on SDI models for the diaphram fuel pump. See ple and plug vent hole on top cover on so equipped COMPONENT INSPECTION, REPLACEMENT...

  • Page 190: Carburetors, Throttle And Choke Cables

    Section 04 FUEL SYSTEM Subsection 02 (CARBURETORS, THROTTLE AND CHOKE CABLES) CARBURETORS, THROTTLE AND CHOKE CABLES SERVICE TOOLS Description Part Number Page carburetor tool kit ..............404 112 000 ....177–178, 187–188 choke plunger tool ..............529 035 602 ......... 182 float gauge................

  • Page 191: Carburetor - Vm Type

    Section 04 FUEL SYSTEM Subsection 02 (CARBURETORS, THROTTLE AND CHOKE CABLES) CARBURETOR — VM TYPE mmr2005-077...

  • Page 192: Identification

    Section 04 FUEL SYSTEM Subsection 02 (CARBURETORS, THROTTLE AND CHOKE CABLES) 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 193: Carburetor Adjustments

    Section 04 FUEL SYSTEM Subsection 02 (CARBURETORS, THROTTLE AND CHOKE CABLES) Float Bowl CAUTION: Oil pump cable must be readjusted whenever throttle cable or idle speed adjust- Unscrew drain plug of float bowl. Recover the re- ment are changed, otherwise serious engine maining fuel in a container.
  • Page 194 Section 04 FUEL SYSTEM Subsection 02 (CARBURETORS, THROTTLE AND CHOKE CABLES) A00C03A TYPICAL 1. Contact tab TYPICAL — VM TYPE E-Clip and Needle 1. Ruler vertical and in line with main jet The position of the needle in the throttle slide is Float level height can be checked using float adjustable by means of an E-clip no.
  • Page 195 Section 04 FUEL SYSTEM Subsection 02 (CARBURETORS, THROTTLE AND CHOKE CABLES) Air Screw Adjustment Completely close the air screw no. 6 (until a slight seating resistance is felt) then back off as speci- fied. A00C1TA CENTER POST TYPE 1. Throttle cable 2.

  • Page 196: Installation

    Section 04 FUEL SYSTEM Subsection 02 (CARBURETORS, THROTTLE AND CHOKE CABLES) CAUTION: The rubber intake adapter must THROTTLE SLIDE be checked for cracks and/or damage. At as- HEIGHT ENGINE sembly, the intake adapater must be perfectly (drill bit size) matched with carburetor and engine otherwise ±...

  • Page 197: Choke

    Section 04 FUEL SYSTEM Subsection 02 (CARBURETORS, THROTTLE AND CHOKE CABLES) Idle Speed Adjustment CAUTION: Before starting engine for the final idle adjustment, make sure that oil pump is adjusted. The oil injection pump adjustment must be checked after each time carburetor idle is adjusted.
  • Page 198 Section 04 FUEL SYSTEM Subsection 02 (CARBURETORS, THROTTLE AND CHOKE CABLES) CUT-AWAY (ENGINE SIDE SHOWN) 1. Choke plunger 2. Tool properly seated under choke plunger If tool tip does not seat under choke plunger no. 12, adjust as follows: Make sure choke lever is at half open position. Turn choke cable adjustment nut by hand until tool properly seats under choke plunger.

  • Page 199: Carburetor Tm Type

    Section 04 FUEL SYSTEM Subsection 02 (CARBURETORS, THROTTLE AND CHOKE CABLES) CARBURETOR TM TYPE Power Tek mmr2005-077...

  • Page 200: Identification

    Section 04 FUEL SYSTEM Subsection 02 (CARBURETORS, THROTTLE AND CHOKE CABLES) IDENTIFICATION TM type dual carburetor ass’y is identified on PTO side carburetor body. TYPICAL Remove the handle cover. TYPICAL 1. Identification: TM 40-B112 REMOVAL Throttle Position Sensor (TPS) 793 HO Power Tek Engine Only For replacement procedure, refer to COMPO- NENT INSPECTION, REPLACEMENT AND AD- JUSTMENT in ENGINE MANAGEMENT (Power...
  • Page 201 Section 04 FUEL SYSTEM Subsection 02 (CARBURETORS, THROTTLE AND CHOKE CABLES) DPM Models Disconnect air temperature sensor connector at air intake silencer. 1. Disconnect All Models Loosen clamps retaining air intake silencer adapter to carburetors and remove air intake silencer. DPM Models Unhook DPM manifold from its support.

  • Page 202: Cleaning And Inspection

    Section 04 FUEL SYSTEM Subsection 02 (CARBURETORS, THROTTLE AND CHOKE CABLES) WARNING Solvent with a low flash point such as gaso- line, naphtha, benzol, etc., should not be used as they are flammable and explosive. Check throttle slide for wear. Replace as neces- sary.
  • Page 203 Section 04 FUEL SYSTEM Subsection 02 (CARBURETORS, THROTTLE AND CHOKE CABLES) Pilot Jet Use narrow screwdriver from carburetor tool kit (P/N 404 112 000) to unscrew pilot jet no. 7. Throttle Slide WARNING It is critical to the free operation of the throttle slide that the 2 connecting plates as assem- bled in one carburetor be of the exact same length.

  • Page 204: Installation

    Section 04 FUEL SYSTEM Subsection 02 (CARBURETORS, THROTTLE AND CHOKE CABLES) Carburetors CAUTION: Never allow throttle slide(s) to snap shut. Install throttle cable to cam lever no. 16. Install choke cable to cam lever no. 4. Install dual carburetor assembly. Make sure dual carburetor assembly is proper- ly inserted into intake adapters, hold it in place and tighten retaining clamps.

  • Page 205: Idle Speed Adjustment

    Section 04 FUEL SYSTEM Subsection 02 (CARBURETORS, THROTTLE AND CHOKE CABLES) 1. Adjust PTO carburetor first 1. Idle speed screw 2. Drill bit used as a gauge to measure throttle height 2. Pilot screw (one on each carburetor) 3. Idle speed screw Pilot Screw Adjustment For MAG carburetor use synchronization screw.

  • Page 206: Choke Cable

    Section 04 FUEL SYSTEM Subsection 02 (CARBURETORS, THROTTLE AND CHOKE CABLES) Also ensure that, when throttle is released to idle THROTTLE position, the idle adjusting screw end touches its SLIDE HEIGHT MODELS stopper. No tension should be applied to throttle (drill bit size) ±...
  • Page 207 Section 04 FUEL SYSTEM Subsection 02 (CARBURETORS, THROTTLE AND CHOKE CABLES) While choke lever is fully open, pull choke cable until cam lever reaches the stopper. Tighten cable housing adjusting and locking nuts in this position. As a confirmation, the gap between the stopper and the cam lever should be within 0 and 0.5 mm (0 and 1/64 in).

  • Page 208: Dpm System

    Section 04 FUEL SYSTEM Subsection 03 (DPM SYSTEM) DPM SYSTEM SERVICE TOOLS Description Part Number Page Engine leak test kit ............... 529 021 800 ......... 196 mmr2005-104...
  • Page 209 Section 04 FUEL SYSTEM Subsection 03 (DPM SYSTEM) 1. TM carburetor 4. Negative pressure tubes connected to venturi 2. DPM manifold 5. Float bowl tubes 3. DPM solenoid 6. Vent tube connected to air intake silencer mmr2005-104...

  • Page 210: Overview

    Section 04 FUEL SYSTEM Subsection 03 (DPM SYSTEM) OVERVIEW TEMPERATURE RESISTANCE (OHMS) NOTE: For Power TEK engines, refer to ENGINE °C °F MANAGEMENT. - 30 - 22 28 000 The carburetors are calibrated to operate at -20°C - 20 14 500 (-4°F), at sea level.

  • Page 211: Dpm Manifold Testing

    Section 04 FUEL SYSTEM Subsection 03 (DPM SYSTEM) Prior to installing DPM cap, ensure O-ring is in good condition. To install cap, firmly push until tabs click and lock on both sides in DPM. DPM MANIFOLD TESTING All DPM Models Visual Inspection With DPM manifold removed from vehicle and all hoses disconnected from DPM manifold, inspect...
  • Page 212 Section 04 FUEL SYSTEM Subsection 03 (DPM SYSTEM) Connecting the Pump, DPM Manifold and Water Column Connect hoses as shown. 1. 3.5 mm (9/64 in) ID hose 2. 6.0 mm (15/64 in) ID hose 3. 6.0 mm (15/64 in) T-fitting Water Column Preparation Mount water column vertically and secure it to a wall or workbench.
  • Page 213 Section 04 FUEL SYSTEM Subsection 03 (DPM SYSTEM) If water level drops to an even level in less than 10 seconds, the DPM manifold is defective. Replace DPM manifold parts, (refer to Parts Catalog) and re-test. If test fails again, replace DPM manifold. If you are unable to attain any amount of vacuum (water level increases and decreases immediately in tube), check your set-up and re-do the test.

  • Page 214: Engine Management (Power Tek)

    Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 01 (OVERVIEW) OVERVIEW SERVICE TOOLS Description Part Number Page VCK (Vehicle Communication Kit) ......... 529 035 981 ......... 202–203 1. Engine control module (ECM) including air pressure sensor (APS) 2. TM carburetors 3. DPM manifold 4.

  • Page 215: Operating Principle

    Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 01 (OVERVIEW) OPERATING PRINCIPLE As air temperature and altitude change, the ECM uses its 3D mapping to maintain the air/fuel mix- Power TEK ture at an optimum. The acronym Power TEK refers to the following The ECM begins to lean fuel mixture when engine technologies found on this engine: RPM is above approximately 3500 RPM.

  • Page 216: Ems - Engine Management System Functions

    Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 01 (OVERVIEW) Manual Start Models Electric Start Models At cranking, the magneto sends AC current to the The ECM is directly powered by the battery. voltage regulator/rectifier that in turn, supplies the When the start switch is activated, it wakes up ECM with DC current.

  • Page 217: Power Distribution

    Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 01 (OVERVIEW) POWER DISTRIBUTION ELECTRONICALLY CONTROLLED RAVE Accessories are protected by fuses. ECM dis- tributes current to low-power devices. The electronically controlled RAVE (e-RAVE) offers two performance enhancements to conventional IMPORTANT: Engine-related sensors and actua- RAVE system.

  • Page 218: Rotax Electronic Reverse (Rer)

    Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 01 (OVERVIEW) Low-Oil Level Warning Device NOTE: If desired, a tether cord cap can be used on other vehicle equipped with the DESS. It only When the oil falls under a certain level, the low oil needs to be programmed for that vehicle.

  • Page 219: Diagnostic Procedures

    Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 02 (DIAGNOSTIC PROCEDURES) DIAGNOSTIC PROCEDURES SERVICE TOOLS Description Part Number Page 12V battery supply cable ............529 035 997 ......... 210 9V battery supply cable ............529 035 675 ......... 210 supply harness..............529 035 869 ......... 209 VCK (Vehicle Communication Kit) .........

  • Page 220: Ems Fault Codes

    Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 02 (DIAGNOSTIC PROCEDURES) WARNING SIGNALS POSSIBLE CAUSE REMEDY BEEPER CODE WARNING DESS/RER HI-TEMP 1 long beep per second. Blink Reverse is selected. Normal condition. No problem detected. Vehicle can be driven in reverse. 1 short beep every 1.5 seconds Bad DESS system connection.
  • Page 221 Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 02 (DIAGNOSTIC PROCEDURES) Fault code P1102 (TPS “Out of Range” Fault) It is caused by the sensor reading going out of its allowable range. This fault can occur during the whole range of movement of the throttle. To diagnose this fully, it is recommended to operate the throttle through its full range.
  • Page 222 Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 02 (DIAGNOSTIC PROCEDURES) EMS Fault Code Table FAULT BLINKING CODE BEEPER DESCRIPTION LAMP/LED (P-CODE) P0079 Warning light 1 short beep followed by 1 long beep R.A.V.E. ® selenoïd open circuit or shorted to ground. P0080 Warning light 1 short beep followed by 1 long beep...

  • Page 223: Vck (Vehicle Communication Kit)

    Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 02 (DIAGNOSTIC PROCEDURES) VCK (VEHICLE COMMUNICATION KIT) General The VCK (Vehicle Communication Kit) (P/N 529 035 981) is the primary tool to diagnose engine management related problems. Connect supply harness (P/N 529 035 869), to ve- hicle 6-pin connector.
  • Page 224 Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 02 (DIAGNOSTIC PROCEDURES) CAUTION: Connecting VCK directly to vehicle connector (without supply harness) will dam- age the ECM. Always use the proper supply harness 9V BATTERY SUPPLY CABLE NOTE: The 9V battery allows programming keys, setting ignition timing, reset closed throttle, etc.
  • Page 225 Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 02 (DIAGNOSTIC PROCEDURES) NOTE: After disconnecting ECM connector for a test and then reconnecting it, it will be neces- sary to READ data from vehicle again to re-enable B.U.D.S. communication. Otherwise, the follow- ing message will occur.

  • Page 226: Component Inspection, Replacement And Adjustment

    Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT SERVICE TOOLS Description Part Number Page Fluke 111 ................529 035 868 ......... 213 small hose pinchers ............. 295 000 076 ......... 218, 225 GENERAL Check related-circuit fuse solidity and condition with an ohmmeter.
  • Page 227 Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Before replacing an ECM, always check electrical connections. Make sure that they are very tight and they make good contact and that they are corrosion- free. Particularly check ECM ground connections.

  • Page 228: Fuel System

    Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) TEMPERATURE SENSOR TABLE TEMPERATURE SENSOR TABLE TEMPERATURE RESISTANCE (ohms) TEMPERATURE RESISTANCE (ohms) CTS FOR CTS FOR °C °F °C °F GAUGE GAUGE 384.8 9565 63.71 5500 314.3 7418 57.49 258.4...

  • Page 229: Engine Management System

    Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) ENGINE MANAGEMENT IMPORTANT: Pay particular attention when typing the VIN and model numbers. Once Write Data SYSTEM button is pressed, numbers cannot be modified. Reprogram DESS tether cord(s) in Keys tab. ENGINE CONTROL MODULE (ECM) Perform Closed throttle and Ignition offset in...

  • Page 230: Throttle Position Sensor (Tps)

    Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) 1. Throttle position sensor (TPS) LH SIDE OF VEHICLE IMPORTANT: Prior to testing the TPS, ensure 1. Relay that mechanical components/adjustments are 2. Power relay connector adequate according to CARBURETOR in AIR IN- Connect a voltmeter between wires as indicated DUCTION SYSTEM above.
  • Page 231 Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Slowly and regularly depress the throttle. Ob- NOTE: To disconnect TPS connector, firmly press serve the needle movement. It must change locking tab on top outer side of connector to re- gradually and regularly as you move the throttle.
  • Page 232 Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Validation of Pins 1 and 3 Reconnect ECM connector. Connect a voltmeter between pin 1 and 3 in TPS connector of wiring harness. Voltage should be 5 V. Otherwise, disconnect ECM connector and check continuity of wires between TPS connector and ECM connector.
  • Page 233 Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) 1. Idle screw CARBURETOR 2. Throttle lever stopper 1. Throttle position sensor (TPS) 2. Screws A. Gap required here Install the new TPS. Activate throttle lever 2 – 3 times to make sure Apply Loctite 243 on the TPS retaining screws, throttle slides are fully closed.

  • Page 234: Air Temperature Sensor (Ats)

    Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) AIR TEMPERATURE SENSOR (ATS) Adjust throttle cable as required to be within this value. Ensure that some free-play remains in the throttle cable at idle position. 1. Air temperature sensor (ATS) As a preliminary setup, tighten idle screw until 4% appears under Throttle opening in Setting tab of Dynamic Test...

  • Page 235: Coolant Temperature Sensor (Cts)

    Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Resistance Test Dynamic Test Refer to TEMPERATURE SENSOR TABLE at the Connect vehicle communication kit (VCK) and use beginning of this section. B.U.D.S. software. Disconnect sensor connector and measure sensor Look engine temperature in Monitoring tab of resistance.

  • Page 236: Air Pressure Sensor (Aps)

    Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) If resistance value is incorrect, repair the connec- tors or replace the wiring harness between ECM connector and the CTS. CTS Sensor for Temperature Gauge Disconnect sensor connector and measure resis- tance value between BLACK and VIOLET wires of sensor.

  • Page 237: Knock Sensor (Ks)

    Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Ensure pressure orifice is free of snow, ice and Disconnect connector DA form the ECM and dirt. Temporarily remove the orifice filter and check continuity of circuit as per following table. clean the area.

  • Page 238: E-Rave Solenoid

    Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) E-RAVE SOLENOID If the solenoid does not work, disconnect the con- nector from the solenoid. Measure voltage between pin 2 (on harness side) and battery ground (engine ground on manual start models).

  • Page 239: Dpm Solenoid

    Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) This will validate the solenoid mechanical and elec- trical operation. Listen to or touch relay to feel it clicks. If the solenoid does not work, disconnect the con- nector from the solenoid.

  • Page 240: Engine Start/Rer Switch

    Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) 1. Ignition coil 2. Terminals For primary winding, check the resistance be- tween terminals on ignition coil. The resistance should be between 0.41 and .46 at 20°C (68°F). 1.

  • Page 241: Digitally Encoded Security System (Dess)

    Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) RER Operation When RER works erratically or engine stalls, do the following. – Check both trigger coils and corresponding wiring. Refer to TESTING PROCEDURES – Check engine compression. A low compres- 1.
  • Page 242 Section 05 ENGINE MANAGEMENT (POWER TEK) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) DESS Post Verification — Tether Cord Cap Removed Connect test probes to switch BLACK/GREEN and BLACK/WHITE wires. Measure resistance, there should be NO continuity (open circuit). Connect one test probe to the WHITE/GREY wire and the other test probe to the switch top termi- nal.

  • Page 243: Engine Management (Sdi)

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 01 (OVERVIEW) OVERVIEW SEMI-DIRECT INJECTION 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 244: Operating Principle

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 01 (OVERVIEW) OPERATING PRINCIPLE For this SDI 2-stroke engine, a highly advanced en- gine management system (EMS) has been used to ensure a high power output combined with clean- er combustion. An ECM (Engine Control Module) calculates the proper air/fuel mixture and ignition timing for each cylinder separately.

  • Page 245: Fuel Delivery System

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 01 (OVERVIEW) FUEL DELIVERY SYSTEM Diaphragm Fuel Pump A conventional diaphragm fuel pump is used to supply fuel to the electric fuel pump reservoir lo- cated inside fuel tank. This reservoir is the fuel supply for the electric fuel pump.

  • Page 246: Engine Management System (Ems)

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 01 (OVERVIEW) The ECM is directly powered by the battery. It is responsible for the following engine manage- ENGINE MANAGEMENT ment/electrical functions: SYSTEM (EMS) – interpreting information – distributing information The EMS (Engine Management System) is equipped with an ECM which controls the ig- –...

  • Page 247: Ecm - General Functions

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 01 (OVERVIEW) Digitally Encoded Security Waking-up the Engine Management System pow- System (DESS) ers the ECM, the fuel pump, the ignition coil, the injectors, and the gauges. The following components are specially designed The battery is required to supply current mainly to for this system: ECM, tether cord cap and DESS the fuel pump to allow a fuel pressure buildup.
  • Page 248 Section 06 ENGINE MANAGEMENT (SDI) Subsection 01 (OVERVIEW) Gauges Current Supply Electric Start Models Gauges are supplied with current for 30 sec- The system uses 2 relays: an ignition/injectors, onds when connecting the tether cord cap on its fuel pump and starting system relay (R1) and a postand momentarily pressing the START/RER headlights and accessories relay (R2).

  • Page 249: Ems - Engine Management System Functions

    Section 06 ENGINE MANAGEMENT (SDI) 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 250: Ignition Timing

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 01 (OVERVIEW) IGNITION TIMING With tether cord cap on its post while engine is stopped, press completely and HOLD throttle The ECM is programmed with data (it contains ig- lever. nition mappings) for optimum ignition timing un- Manual Start Models der all operating conditions.

  • Page 251: Diagnostic Mode

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 01 (OVERVIEW) DIAGNOSTIC MODE The malfunctions are recorded in the memory of the ECM. The memory of the ECM can be checked using the VCK (Vehicle Communication Kit) (P/N 529 035 981) to see the fault codes. Re- fer to the DIAGNOSTIC PROCEDURES section.

  • Page 252: Diagnostic Procedures

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 02 (DIAGNOSTIC PROCEDURES) DIAGNOSTIC PROCEDURES SERVICE TOOLS Description Part Number Page GRAY diagnostic key ............529 035 896 ......... 246 supply harness..............529 035 869 ......... 245 VCK (Vehicle Communication Kit) ......... 529 035 981 ......... 245 GENERAL Here is the basic order suggested to diagnose a suspected engine management or fuel injection related problem:...
  • Page 253 Section 06 ENGINE MANAGEMENT (SDI) Subsection 02 (DIAGNOSTIC PROCEDURES) CODED SIGNALS POSSIBLE CAUSE REMEDY 1 long beep (2 seconds) every 15 minutes. Low battery voltage. Check battery and charging system. 4 short beeps every 2 minutes. Oil Low oil level on 2-TEC models. Check oil level and replenish as soon pilot lamp also lights up.
  • Page 254 Section 06 ENGINE MANAGEMENT (SDI) Subsection 02 (DIAGNOSTIC PROCEDURES) P CODE EMS PILOT LAMP BEEPER DESCRIPTION Engine temperature lamp open circuit or shorted P1647 to ground. P0648 DESS lamp shorted to battery. P0648 DESS lamp open circuit or shorted to ground. P1654 Oil lamp shorted to battery.
  • Page 255 Section 06 ENGINE MANAGEMENT (SDI) Subsection 02 (DIAGNOSTIC PROCEDURES) P CODE EMS PILOT LAMP BEEPER DESCRIPTION Injector cyl. # 2 OR outer PTO injector P0264 BLINK (2 cyl.), open circuit or shorted to ground. Injector cyl. # 3 OR inner MAG injector P0268 BLINK (2 cyl.), shorted to battery.

  • Page 256: Vck (Vehicle Communication Kit)

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 02 (DIAGNOSTIC PROCEDURES) VCK (VEHICLE COMMUNICATION KIT) The VCK (Vehicle Communication Kit) (P/N 529 035 981) is the primary tool to diagnose engine management and fuel injection related problems. Connect supply harness (P/N 529 035 869), to ve- hicle 6-pin connector.
  • Page 257 Section 06 ENGINE MANAGEMENT (SDI) Subsection 02 (DIAGNOSTIC PROCEDURES) CAUTION: Always use the proper supply har- ness and cables. Ensure to respect polarity when connecting cable clips to battery. Match RED cables together. Set engine cut-out switch to OFF. Install the GRAY diagnostic key (P/N 529 035 896) or any DESS cap onto the vehicle DESS post.

  • Page 258: 2-Tec System Fault Codes

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 02 (DIAGNOSTIC PROCEDURES) 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 displayed on the B.U.D.S. system as TPS OUT OF RANGE and TPS ADAPTION FAILURE.
  • Page 259 Section 06 ENGINE MANAGEMENT (SDI) Subsection 02 (DIAGNOSTIC PROCEDURES) TPS “OUT OF RANGE” Fault It is caused by the sensor reading going out of its allowable range. This fault can occur during the whole range of movement of the throttle. To diagnose this fully, it is recommended to operate the throttle through its full range.

  • Page 260: Component Inspection, Replacement And Adjustment

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT SERVICE TOOLS Description Part Number Page Fluke 111 ................529 035 868 ......... 251 hose pinchers ..............295 000 076 ......... 254 pressure gauge..............529 035 591 ......... 258 VCK (Vehicle Communication Kit) .........

  • Page 261: Electrical System

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT 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 262: Resistance Measurement

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) RESISTANCE MEASUREMENT WARNING All electrical actuators (injectors, fuel pump, When measuring the resistance with an ohmme- ignition coils and starter solenoid) are con- ter, all values are given for a temperature of 20°C tinuously supplied by the battery when the (68°F).

  • Page 263: Engine Connector Pin-Outs

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) The resistance value of a temperature sensor may TEMPERATURE SENSOR TABLE test good at a certain temperature but it might be TEMPERATURE RESISTANCE (OHMS) defective at other temperatures. If in doubt, try a new sensor.

  • Page 264: Relay

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) RELAY CAUTION: Probe on top of terminal only. Do not try to probe inside terminal or to use a pa- per clip to probe inside terminal, it will dam- Relay 2 age the square-shaped terminal and this could Connect vehicle communication kit (VCK) and use...

  • Page 265: Air Induction System

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) AIR INDUCTION SYSTEM Replacement Removal THROTTLE BODY To remove the throttle body from engine, proceed as follows: – Disconnect connectors from ATS (Air Tempera- ture Sensor) and APS (Air Pressure Sensor). –...
  • Page 266 Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Adjustment Throttle Body Synchronization CAUTION: It is not allowed to perform any change on the synchronization screw. Before installation, clean throttle plates and bores with pulley flange cleaner (P/N 413 711 809). NOTE: The throttle body is designed as a single part for both cylinders.
  • Page 267 Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Tighten bottom nut to 4.5 N•m (40 lbf•in). 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.

  • Page 268: Fuel Delivery

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) FUEL DELIVERY 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 269: Electric Fuel Pump

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) ELECTRIC FUEL PUMP NOTE: For the diaphragm fuel pump, refer to FUEL SYSTEM. Fuel Pressure Test Before proceeding to the pressure test, ensure the battery is fully charged. Battery voltage must be over 12 volts.
  • Page 270 Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Electrical Test When depressing the START/RER button, the fuel pump should run for 2 seconds to build up the pressure in the system. If the pump does not work, disconnect the plug connector from the fuel pump.
  • Page 271 Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Disconnect pump electric connector. Disconnect hose from pump. 1. Electrical connect 2. Pump hose Installation For installation, reverse the removal process but pay attention to the following. Install a new gasket. Align the arrow on fuel pump assembly with the one on fuel tank.

  • Page 272: Fuel Rail

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Use a new clamp to secure hose to fuel pump fitting. CAUTION: Make sure that hose clamps are tight to avoid that they turn on their fittings. Fuel Bleeding Procedure Manual Start Models When fuel tank is completely emptied, it may re- quire up to 25-30 pull on rewind starter to fill the...

  • Page 273: Fuel Injectors

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) FUEL INJECTORS Leakage Test and Fuel Flow Measurement Preparation First ensure fuel pressure is within specifications. The injectors and fuel rail have to be removed to- gether from the engine. Do not remove injectors from the fuel rail.
  • Page 274 Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Energize each injector individually and measure CIRCUIT NUMBER PIN 2 OF INJECTOR the gas volume injected. Quantity of gas must be (ECM CONNECTOR «A») HARNESS within the following specifications. A-15 MAG external VOLUME of FUEL...
  • Page 275 Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT 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 Installation...

  • Page 276: Electronic Management

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT 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 277: Throttle Position Sensor (Tps)

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT 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 278 Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Check the continuity between pin 3 on wiring har- ness TPS connector and pin 24 on wiring harness ECM connector. If tests are good, replace the TPS. If voltage tests are not good, continue to check the resistance of the rest of the TPS circuit.

  • Page 279: Crankshaft Position Sensor (Cps)

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Start engine and make sure it operates normally through its full engine RPM range. If fault codes appear, refer to SYSTEM FAULT CODES in the DI- AGNOSTIC PROCEDURES section for more infor- mation.

  • Page 280: Air Temperature Sensor (Ats)

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT 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 1.

  • Page 281: Coolant Temperature Sensor (Cts)

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) If resistance value is incorrect, repair the connec- tors or replace the wiring harness between ECM connector and the ATS. Replacement Unplug ATS connector. Pull the ATS out of the air intake silencer. Spray soapy water on grommet.

  • Page 282: Air Pressure Sensor (Aps)

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) If resistance value is incorrect, repair the connec- If tests are not good, continue to check the conti- tors or replace the wiring harness between ECM nuity of the rest of the APS circuit on the harness. connector and the CTS.

  • Page 283: Knock Sensor (Ks)

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Refer to TEMPERATURE SENSOR TABLE at the Start the engine and bring engine RPM above beginning of this section to find the corresponding 6000 RPM. If no fault code occurs, the knock resistance value for this sensor temperature.

  • Page 284: E-Rave Solenoid

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Replacement Torque screw to 24 N•m (18 lbf•ft). Remove the air intake silencer. Unplug the sole- CAUTION: Improper torque might prevent sen- sor to work properly and lead engine to severe noid connector and all hoses.
  • Page 285 Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT 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 286: Ignition Timing

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) For primary winding, check the resistance be- BATTERY STANDARD QUICK CHARGE tween terminal 15 and terminal 1a (cylinder 1) TYPE CHARGE of the ignition coil and between terminal 15 and 0.3 Amps/hour 3.0 Amps/hour terminal 1b (cylinder 2) respectively.

  • Page 287: Engine Start/Rer Switch Verification

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) ENGINE START/RER SWITCH WARNING VERIFICATION Always respect the polarity when connecting the capacitor. All Models A quick operation test can be done using the ve- Wait 5 minutes, then measure capacitor voltage. hicle communication kit (VCK) with the B.U.D.S.

  • Page 288: Dess Post Verification

    Section 06 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) – Check piston condition. Remove exhaust sys- tem and reed valves on intake side. Verify pis- ton condition through the intake and exhaust ports. Look for scoring on piston skirts. Scored piston skirts may result in RER working errati- cally making you think the problem is an elec- tronic problem.

  • Page 289: Electrical System

    Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) IGNITION SYSTEM SERVICE TOOLS Description Part Number Page 9-volt adaptor................ 529 035 675 ......... 288 digital/inductive type tachometer ......... 529 014 500 ......... 284, 287 MPEM programmer.............. 529 035 878 ......... 288 supply harness..............
  • Page 290 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) In most cases when problems are caused by tem- Disconnect all switches from the main wiring har- perature or vibrations, these can only be solved by ness and check the continuity of each wire by con- replacing parts.
  • Page 291 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) ENGINE CUT-OUT SWITCH IGNITION COIL TEST Open circuit Continuity FAN-COOLED ENGINES TEST BLACK/YELLOW and BLACK/YELLOW and Secondary Ground Cable PROBES BLACK wires BLACK wires TEST Output winding continuity resistance voltage RESISTANCE O.L. 00.0 to 00.5 RED and BLACK wire...

  • Page 292: Ignition Timing

    Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) TRIGGER COIL MPEM ON VEHICLE WITH MANUAL STARTER FAN-COOLED ENGINES Ground Power from Voltage to ignition TEST connection regulator coil TEST Continuity Output BLACK wire and TEST Trigger coil Trigger coil Trigger coil Trigger coil RED/BLUE and WHITE/BLUE and...
  • Page 293 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Verifying Magneto Flywheel Timing – Screw the adaptor into the spark plug hole Mark Position and tighten to prevent movement in the plug hole. Prior to checking the timing, it may be necessary –...
  • Page 294 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) A17E10A TYPICAL 1. Trigger coil mark 2. Magneto flywheel mark NOTE: These marks cannot be used to check dy- TYPICAL namic (with engine running) ignition timing with a 1. Crankcase arrow 2. Scribe a mark here timing light: a new mark must be scribed on mag- 3.
  • Page 295 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Liquid-Cooled Engines WARNING Normally ignition timing adjustment should not be Do not allow anyone in front of or behind the required. It has been set at factory and it should vehicle while engine is running. Keep clear remain correctly adjusted since every part is fixed of track and do not wear loose clothing which and not adjustable.
  • Page 296 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) 1. Pointer TYPICAL 1. TDC gauge on MAG side • With the TDC gauge indicating specified timing, scribe a mark on drive pulley inner half in line – Assemble the gauge to the adaptor and tight- with pointer end.
  • Page 297 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Connect the timing light pick-up to a spark plug cable. Connect the digital/inductive type tachometer (P/N 529 014 500). TIMING RETARDED BY ABOUT 1° TACHOMETER Start the engine and point timing light on timing mark.
  • Page 298 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Vehicle information is transferred from MPEM to programmer. Detailed information about the B.U.D.S. software and its usage is available under its Help section. MPEM Programmer All Engines except SDI and Power TEK Timing can also be changed using the MPEM pro- NOTE: In fact the programmer takes a copy of grammer (P/N 529 035 878).
  • Page 299 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Now the display shows the engine timing correc- tion factor that is programmed in the MPEM. In the following example timing correction factor is no. 4. IGNITION CORRECTION FACTOR CORRECTION FACTOR IGNITION TIMING PROGRAMMED IN CORRECTION MPEM...
  • Page 300 Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) T R A N S F E R P G M R M P E M A00A42A If the new correction factor selected above is the During a very short period of time the following good one select NO and press ENTER.

  • Page 301: Spark Plug

    Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) Unplug supply harness and 9-volt adaptor. Recheck ignition timing with timing light when completed. TYPICAL SPARK PLUG 1. Proper socket 2. Improper socket Removal Use the following table to torque the spark plugs. First unscrew the spark plug 1 turn.

  • Page 302: Design Symbols Used In Ngk Spark Plugs

    Section 07 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) DESIGN SYMBOLS USED IN NGK SPARK PLUGS mmr2005-082...

  • Page 303: Charging System

    Section 07 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) CHARGING SYSTEM SERVICE TOOLS Description Part Number Page crimp pliers ................529 035 730 ......... 297 multimeter FLUKE 111 ............529 035 868 ......... 293 SERVICE PRODUCTS Description Part Number Page silicone dielectric grease ............293 550 004 ......... 296–297 GENERAL In most cases when problems are caused by tem- perature or vibrations, these can only be solved by...

  • Page 304: Voltage Regulator/Rectifier

    Section 07 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) FAN-COOLED ENGINES WITH ELECTRIC STARTER FAN-COOLED ENGINES TEST Charging voltage Current to battery PART Charging generator coil RED/GREEN and Ground TEST TEST Power Insulation negative battery RED and RED/WHITE continuity PROBES terminal TEST YELLOW and YELLOW...

  • Page 305: Battery

    Cleaning battery. Clean the battery, battery casing, cables and bat- tery posts using a solution of baking soda and wa- SUPPLIER P/N BRP P/N ter. YTX20L-BS 515 175 642 Remove corrosion from battery cable terminals and battery posts using a firm wire brush. Bat-...
  • Page 306 Section 07 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) Battery Charging WARNING Should the battery casing be damaged, wear WARNING a suitable pair of non-absorbent gloves when Always wear safety glasses and charge in removing the battery by hand. a ventilated area. Never charge or boost battery while installed on vehicle.

  • Page 307: Cable Terminal Installation

    Section 07 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) If the charger ammeter shows no change in cur- rent after 5 minutes, you need a new battery. Cur- rent flowing into the battery at high voltage can become excessive. Monitor amperage and adjust voltage as necessary to keep current at the bat- tery’s standard amp rating.
  • Page 308 Section 07 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) CRIMPING OF WIRE PROPERLY CRIMPED WIRE To verify, if the wire is properly crimped, apply some pulling force on wire and the terminal at the same time from both directions. CAUTION: Never solder the wire to the termi- nal.

  • Page 309: Starting System

    Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) STARTING SYSTEM SERVICE TOOLS Description Part Number Page multimeter FLUKE 111 ............529 035 868 ......... 301–302 SERVICE PRODUCTS Description Part Number Page synthetic grease ..............413 711 500 ......... 303, 305 mmr2005-084...
  • Page 310 Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) ELECTRIC STARTER mmr2005-084...

  • Page 311: Troubleshooting

    Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) TROUBLESHOOTING START/RER BUTTON ON VEHICLES WITH ELECTRIC STARTER When the ignition switch is turned on or the start All engines except SDI button is pressed, a signal is sent to the starting solenoid.
  • Page 312 Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) Replace any chafed wires. ENGINE CUT-OUT SWITCH ON VEHICLE WITH ELECTRIC STARTER If wires, harnesses and connections are good, check the electric starter. Running Continuity in TEST insulation STOP position Electric Starter BLACK/YELLOW BLACK/YELLOW WIRE COLOR...
  • Page 313 Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) Check the radial play between the armature shaft and end frame bearing. Replace the end frame bearing or replace starter. If parts are in good con- dition then coat with synthetic grease (P/N 413 711 500) before reinstalling them.
  • Page 314 Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) NOTE: Bushings or bearings must not be cleaned MODEL WEAR LIMIT with grease dissolving agents. All models 27 mm (1.063 in) Immerse all metal components in cleaning solu- tion. Dry using a clean and dry cloth. Test for Ground Circuit in the Armature Use growler test probes.
  • Page 315 Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) Test the Armature for Open Circuit Use growler test probes. Place one test probe on a commutator bar and the other test probe on the neighboring bar. Repeat this operation for all bars, moving one test probe at a time. If the growler lamp does not turn on, the armature cir- cuit between these 2 bars is opened.
  • Page 316 Section 07 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) 1. Armature shaft 2. Snap ring 3. Collar 4. Punch Starter Housing Assembly and Starter Housing 1. Brush holder Align previously traced indexing marks. To ease end frame installation, retain brush holder with a small screwdriver while installing armature assembly.

  • Page 317: Accessories

    Section 07 ELECTRICAL SYSTEM Subsection 04 (ACCESSORIES) ACCESSORIES SERVICE TOOLS Description Part Number Page multimeter FLUKE 111 ............529 035 868 ....308, 312, 314–315 supply cable................529 035 997 ......... 307, 313 supply harness..............529 035 869 ......... 307, 313 VCK (Vehicle Communication Kit) .........

  • Page 318: 12-Volt Power Outlet (Cigarette-Lighter Type)

    Section 07 ELECTRICAL SYSTEM Subsection 04 (ACCESSORIES) 480 W Models (SDI engines) Connect the VCK (Vehicle Communication Kit) (P/N 529 035 981). In BUDS, click on the relay 2 (R2) button to supply lighting system with 12 volts. The obtained value should be between 12 and 14.5 Vdc.

  • Page 319: Engine Temperature Gauge

    Section 07 ELECTRICAL SYSTEM Subsection 04 (ACCESSORIES) ENGINE TYPE TAB LOCATION All carburetor equipped BEIGE/BLACK engines except Power on positive tab BLACK on negative tab RED/GREEN on positive tab SDI engines BEIGE/BLACK on negative tab RED/YELLOW on positive tab Power Tek BEIGE/BLACK on negative tab TYPICAL —...

  • Page 320: Electric Fuel Gauge

    Section 07 ELECTRICAL SYSTEM Subsection 04 (ACCESSORIES) Check temperature sensor. Remove windshield. Replace the gauge. Pull out steering support cap. Removal Remove the accessories panel. Remove the ring around the gauge by pressing both tabs. Unscrew the central nut and remove the support. Unplug connector.

  • Page 321: Headlamp Beam Aiming

    Section 07 ELECTRICAL SYSTEM Subsection 04 (ACCESSORIES) Disconnect headlamps. On RH side of vehicle, remove the push nut then remove the headlamp housing. Installation Reverse the removal procedure. HEADLAMP BEAM AIMING Beam aiming is correct when center of high beam is 25 mm (1 in) below the headlamp horizontal cen- ter line, scribed on a test surface, 381 cm (12 ft 6 in) away.

  • Page 322: Heating Elements

    Section 07 ELECTRICAL SYSTEM Subsection 04 (ACCESSORIES) HEATING ELEMENTS RELAY NOTE: All measurements must be performed at Voltage Test 21°C (70°F). RELAY Throttle Lever Heating Element TEST Coil Contact Current Measurement WIRE WHITE/GREEN BLACK/YELLOW COLOR and BLACK and BLACK 0.23 A HIGH BROWN wire INTENSITY...

  • Page 323: Speedometer

    Section 07 ELECTRICAL SYSTEM Subsection 04 (ACCESSORIES) A continuous signal should be audible. If not, re- place the relay. If a signal is audible, apply 12 volts on terminals 85 and 86 then place the RED probe on terminal 30 and the BLACK on the terminal 87. If the speedometer stays off, change it.

  • Page 324: Tachometer

    Section 07 ELECTRICAL SYSTEM Subsection 04 (ACCESSORIES) TACHOMETER Test No light but the needle moves tachometer supplied through speedometer. Check the voltage between pins 9 and 10 of speedometer. The obtained value should be the battery voltage. If not, check connections and wiring harness. If the voltage is good, replace the tachometer.

  • Page 325: Visor Outlet

    Unscrew taillight lens and pull the wire. Installation The installation is the reverse of the removal pro- cedure. On all GTX models and the EXPEDITION SPORT, pay attention to the following details. Install the seat studs with the slot inside.

  • Page 326: Drive System

    Section 08 DRIVE SYSTEM Subsection 01 (DRIVE BELT) DRIVE BELT SERVICE TOOLS Description Part Number Page belt tension tester ..............414 348 200 ......... 320 drive belt tension adjuster ............ 529 008 700 ......... 319 APPLICATION CHART MINIMUM WIDTH (wear limit) MODEL PART NUMBER mm (in)

  • Page 327: Drive Belt Height Measurement And Adjustment

    Section 08 DRIVE SYSTEM Subsection 01 (DRIVE BELT) Before checking the belt height, ensure that a good-condition proper belt (refer to the APPLICA- TION CHART) is installed. Adjust pulley distance and alignment. Refer to PULLEY DISTANCE AND ALIGNMENT. To obtain maximum vehicle performance, the belt height must be adjusted according to specifica- tions shown in the accompanying chart.
  • Page 328 Section 08 DRIVE SYSTEM Subsection 01 (DRIVE BELT) Models Equipped with HPV Type Driven Pulley A06D20A TYPICAL 1. Allen screws with jam nuts Allen screws must be restrained while tightening jam nut to prevent throwing adjustment out. Use 1. Screws drive belt tension adjuster (P/N 529 008 700).

  • Page 329: Drive Belt Deflection Measurement (Reference Only)

    Section 08 DRIVE SYSTEM Subsection 01 (DRIVE BELT) DRIVE BELT DEFLECTION MEASUREMENT (REFERENCE ONLY) NOTE: The drive belt deflection measurement must be performed each time a new drive belt is installed. NOTE: To obtain an accurate drive belt deflection measurement, it is suggested to allow a break-in period of 50 km (30 miles).
  • Page 330 Section 08 DRIVE SYSTEM Subsection 01 (DRIVE BELT) A00D08A 1. Upper O-ring — force 2. Force 3. Lower O-ring — deflection 4. Reference rule 5. Deflection mmr2005-086...

  • Page 331: Drive Pulley

    Section 08 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) DRIVE PULLEY SERVICE TOOLS Description Part Number Page bushing remover/installer ............. 529 031 200 ......... 332 drive pulley holder ..............529 027 600 ......... 325, 327 drive pulley holder ..............529 035 674 ......... 329, 337 drive pulley puller..............

  • Page 332: Bombardier Lite

    Section 08 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) BOMBARDIER LITE All Fan-cooled Models NOTE: This drive pulley is lubrication free. Models with electric starter mmr2005-087...

  • Page 333: General

    Section 08 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) GENERAL Some drive pulley components (return spring, cal- ibration disk) can be changed to improve vehicle performance in high altitude regions. A service bulletin gives information about calibration accord- ing to altitude. CAUTION: Such modifications should only be performed by experience mechanics since they can greatly affect vehicle performance.

  • Page 334: Cleaning

    Section 08 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) CAUTION: If another tool than a heat gun is used, do not exceed 150°C (300°F). NOTE: The ring gear removal is not necessary to disassemble the drive pulley. Unscrew nut no. 5. Remove washer no. 6. Remove the drive puller cap no.

  • Page 335: Installation

    Section 08 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) Make sure to install blocks no. 8 at their original Accelerate the vehicle at low speed (maximum position and with their curved end toward gover- 30 km/h (20 MPH)) and apply the brake, repeat 5 nor cup.

  • Page 336: Tra Iii

    Section 08 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) TRA III All Liquid-cooled 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. Models with 793 HO electrical starter...

  • Page 337: General

    Section 08 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) GENERAL Remove the drive pulley bolt no. 2 and its conical spring washer no. 3. WARNING To remove drive pulley no. 1 and/or fixed half no. 4 Never use any type of impact wrench at drive from engine, use the drive pulley puller (P/N 529 pulley removal and installation.
  • Page 338 Section 08 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) 529 005 500 A16B02A When all slider shoes are held with the forks, re- A16D01A move the governor cup. TYPICAL 1. Puller Spring Cover 2. Holding sliding half To remove the spring cover no. 10, always use the NOTE: No components marking is required before spring compressor (P/N 529 035 524).

  • Page 339: Cleaning

    Section 08 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) CLEANING Fixed and Sliding Halves Parts must be at room temperature before clean- ing. Clean pulley halves and shaft with fine steel wool and dry cloth. Using a paper towel with pulley flange cleaner (P/N 413 711 809), clean crankshaft tapered end and the taper inside the fixed half of the drive pulley, crankshaft threads and retaining screw...
  • Page 340 Section 08 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) Check lever bolts no. 19 for wear, replace as re- quired. O-ring and Slider Shoe Check if O-rings no. 20 are cracked, cut or crushed. Replace as required. Check slider shoes no. 9 for wear. Replace if groove is not apparent on top.

  • Page 341: Assembly

    Section 08 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) 1. Bushing Clean sliding half bushing mounting surface with Install the circlip. pulley flange cleaner (P/N 413 711 809). To install a new bushing, secure the spring com- pressor (P/N 529 035 524) in a vice and mount the sliding half.
  • Page 342 Section 08 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) Dowel Tube and Ramp RING GEAR ON TRA III Insert dowel tube no. 26 from chamfered side. ENGINES TORQUE Make sure ramp no. 27 is centered on dowel tube. All models except 37 N•m (27 lbf•ft) 793 HO All 793 HO...
  • Page 343 Section 08 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) Lever, Nut and Cotter Pin 593 /HO/SDI Engine Equipped Models Only NOTE: While installing lever no. 29 make sure that the curved sides of the levers are outwards as shown. Always install lever assemblies so that cotter pins no.
  • Page 344 Section 08 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) 793 HO Engine Equipped Models Insert spring no. 31 and slider shoes no. 9 into governor cup no. 7 so that groove in each slider shoe is vertical to properly slide in guides. CAUTION: Make sure O-rings are installed on slider shoes.

  • Page 345: Installation

    NOTE: The adjustment has an effect on high RPM WARNING only. Never substitute conical spring washer To adjust, modify ramp end position by turning cal- and/or bolt with jobber ones. Always use ibration screws. BRP genuine parts for this particular case. mmr2005-087...
  • Page 346 Section 08 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) Calibration screw has a notch on top of its head. CAUTION: Do not completely remove calibra- tion screw otherwise its inside washer will fall off. CAUTION: Always adjust all 3 calibration screws and make sure they are all set at the same number.

  • Page 347: Driven Pulley

    Section 08 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) DRIVEN PULLEY SERVICE TOOLS Description Part Number Page clutch spring compressor ............. 529 035 524 ......341–343, 346 large bushing extractor ............529 031 100 ......... 342 large bushing extractor ............529 035 575 ......... 342 spring scale hook..............

  • Page 348: Formula Rer And Formula Vsa-R

    Section 08 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) FORMULA RER AND FORMULA VSA-R mmr2005-088...

  • Page 349: Removal

    Section 08 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) REMOVAL CLEANING Remove guard and drive belt from vehicle. Large Bushing and Small Bushing Remove pulley retaining screw no. 14 and shoul- During break-in period (about 10 hours of use), dered washer no. 12 then pull the driven pulley teflon from bushing no.

  • Page 350: Bushing Replacement

    Section 08 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) DRIVEN PULLEY BUSHING WEAR LIMIT mm (in) Small bushing 38.30 (1.508) Large bushing 108.2 (4.260) Slider Shoe Black slider shoe = forward. Red slider shoe = reverse. Check cam slider shoes no. 10 and no. 11 for wear.

  • Page 351: Installation

    Section 08 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) Compress outer cam using the clutch spring com- pressor (P/N 529 035 524). Install washer no. 4 then secure outer cam with circlip no. 3. CAUTION: Ensure that circlip is properly insert- ed into shaft groove and that spacer recess is facing circlip.

  • Page 352: Adjustment

    Section 08 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) ADJUSTMENT 529 006 500 Make sure to install proper cam. Refer to TECH- NICAL DATA. Cam angle is identified on cam. Spring To check spring preload adjustment, use the spring scale hook (P/N 529 006 500) and a spring scale.

  • Page 353: Hpv Vsa

    Section 08 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) HPV VSA mmr2005-088...

  • Page 354: Removal

    Section 08 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) REMOVAL Remove half keys no. 6 and washer no. 7 to dis- assemble the cam and the 2 pulley halves. Remove guard and drive belt from vehicle. WARNING Remove cap screw no. 1 and shouldered washer no.

  • Page 355: Installation

    Section 08 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) ADJUSTMENT Install slider shoes as per following photo. Red slider shoes are being used for reverse and black ones for forward. Make sure to install proper cam no. 11. Refer to TECHNICAL DATA. Cam angle is identified on cam.
  • Page 356 Section 08 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) Install the hook on the sliding half. Preventing fixed half from turning, pull sliding half with the spring scale perpendicularly with pulley axle. Take first measurement when sliding half begins to turn. Rotate sliding half to 10 mm (3/8 in) of rotation.

  • Page 357: Pulley Alignment

    Section 08 DRIVE SYSTEM Subsection 04 (PULLEY ALIGNMENT) PULLEY ALIGNMENT SERVICE TOOLS Description Part Number Page alignment bar................ 529 035 831 ......... 350 driven pulley opening tool............. 529 017 200 ......... 349 GENERAL Pulley alignment must be checked out to ensure the highest efficiency of the transmission system.
  • Page 358 Section 08 DRIVE SYSTEM Subsection 04 (PULLEY ALIGNMENT) ALIGNMENT BAR IN PULLEYS Always measure distances X and Y from the far- ther straight bar side (including its thickness to the DRIVEN PULLEY OPENING TOOL fixed half edge). Measure the distance between both pulleys to know if the engine and the frame are positioned correctly.

  • Page 359: Alignment Procedure

    Section 08 DRIVE SYSTEM Subsection 04 (PULLEY ALIGNMENT) If the alignment is good, hand torque the torque rod so it slightly contacts engine crankcase. Do not over tighten, it will disalign pulleys. When the alignment is done, refer to DRIVE BELT to adjust the drive belt deflection.

  • Page 360: Brake

    Section 08 DRIVE SYSTEM Subsection 05 (BRAKE) BRAKE SERVICE TOOLS Description Part Number Page countershaft bearing remover/installer......... 529 035 699 ......... 357–358 SERVICE PRODUCTS Description Part Number Page antiseize lubricant ..............293 800 070 ......... 357 DOT 4 brake fluid GTLMA ............ 293 600 062 ......... 355, 359 DOT 4 brake fluid SRF ............

  • Page 361: Hydraulic Brake

    Section 08 DRIVE SYSTEM Subsection 05 (BRAKE) HYDRAULIC BRAKE X models mmr2005-090...

  • Page 362: Brake Fluid

    Section 08 DRIVE SYSTEM Subsection 05 (BRAKE) BRAKE FLUID CALIPER The brake fluid must be changed in accordance Removal with the maintenance chart. Unscrew screws no. 21 and remove locking tab Use recommended DOT 4 brake fluid SRF no. 20 to pull out caliper no. 6 from chaincase. (P/N 293 600 063) or DOT 4 brake fluid GTLMA (P/N 293 600 062).

  • Page 363: Brake Pads

    Section 08 DRIVE SYSTEM Subsection 05 (BRAKE) Install the Banjo bolt no. 7 with two new sealing rings no. 8. Fasten caliper on chaincase. Do not forget to in- stall and fold locking tab over caliper bolt. Fill the brake system and bleed it. Refer to BLEEDING at the end of this section.

  • Page 364: Brake Disc

    Section 08 DRIVE SYSTEM Subsection 05 (BRAKE) – Unbolt bearing support no. 15 from chassis. TYPICAL 1. Bearing support 1. Brake pad – Unscrew caliper from chaincase. Installation – Open chaincase and remove upper sprocket. Install: – Pull countershaft no. 16 toward driven pulley side to free from chaincase and disc.

  • Page 365: Countershaft

    Section 08 DRIVE SYSTEM Subsection 05 (BRAKE) 1. Screws replacing bearing support screws 1. Washers use as a 3 mm (1/8 in) spacer 2. Original retaining screw and shouldered washer Tighten the countershaft bearing remover/installer 3. Bearing against circlip bolt to pull the bearing out of it housing. Ensure that countershaft is properly aligned, then tighten 3 retaining screws.

  • Page 366: Bleeding

    Section 08 DRIVE SYSTEM Subsection 05 (BRAKE) BLEEDING Take out the master cylinder from the handlebar. Overturn the master cylinder so that the bottom is Bleed brake system as follows: on the top. Keep sufficient recommended DOT 4 brake fluid Fix the master cylinder in a rigid way preferably in SRF (P/N 293 600 063) or DOT 4 brake fluid a vise.

  • Page 367: Chaincase

    Section 08 DRIVE SYSTEM Subsection 06 (CHAINCASE) CHAINCASE SERVICE TOOLS Description Part Number Page drive axle holder ..............529 007 200 ......... 364 SERVICE PRODUCTS Description Part Number Page Loctite 271 (red) ..............293 800 005 ......... 365 XP-S chaincase oil..............413 801 900 ......... 363 XP-S synthetic chaincase oil ..........
  • Page 368 Section 08 DRIVE SYSTEM Subsection 06 (CHAINCASE) mmr2005-091...

  • Page 369: General

    Section 08 DRIVE SYSTEM Subsection 06 (CHAINCASE) GENERAL NOTE: It is normal to find metallic particles stuck to dipstick magnet. If bigger pieces of metal are During assembly/installation, use the torque val- found, remove the chaincase cover and inspect ues and service products as in the exploded view. the chaincase parts.

  • Page 370: Drive Chain Adjustment

    Section 08 DRIVE SYSTEM Subsection 06 (CHAINCASE) All Models Remove 3 nuts no. 15. Check oil level with the dipstick and add oil if nec- Unfold locking tab then remove caliper retaining essary. The level must be between lower and up- screws.

  • Page 371: Inspection

    Section 08 DRIVE SYSTEM Subsection 06 (CHAINCASE) Position the sprockets no. 9 and no. 11 with the backside of writing facing the chaincase cover. Sprocket hub faces toward chaincase. Install the castellated nut no. 8 and torque to 60 N•m (44 lbf•ft). Apply Loctite 271 (red) (P/N 293 800 005) on low- er sprocket screw threads and torque to 48 N•m (35 lbf•ft).

  • Page 372: Drive Axle

    Section 08 DRIVE SYSTEM Subsection 07 (DRIVE AXLE) DRIVE AXLE SERVICE TOOLS Description Part Number Page drive axle sprocket adjuster kit ..........861 725 700 ......... 373 SERVICE PRODUCTS Description Part Number Page suspension synthetic grease ..........293 550 033 ......... 373 mmr2005-092...
  • Page 373 Section 08 DRIVE SYSTEM Subsection 07 (DRIVE AXLE) All Fan-cooled Models mmr2005-092...
  • Page 374 Section 08 DRIVE SYSTEM Subsection 07 (DRIVE AXLE) GSX Limited and Sport, GTX Limited and Sport, MX-Z Adrenaline, Renegade, Renegade X and Trail Models mmr2005-092...
  • Page 375 Section 08 DRIVE SYSTEM Subsection 07 (DRIVE AXLE) MX-Z X, Summit Adrenaline and Summit X Models mmr2005-092...

  • Page 376: Removal

    Section 08 DRIVE SYSTEM Subsection 07 (DRIVE AXLE) REMOVAL Remove battery (if so equipped) to gain access, refer to CHARGING section. Drain oil from chaincase. Remove chaincase cov- er. Release drive chain tension. 1. Circlip Apply parking brake. Remove chain and sprockets then circlip from right side.

  • Page 377: Assembly

    Section 08 DRIVE SYSTEM Subsection 07 (DRIVE AXLE) ASSEMBLY GSX Limited and Sport, GTX Limited and Sport, MX-Z Adrenaline, Renegade, Renegade X and Trail Models Drive Axle and Sprocket To assemble press fit sprockets no. 6 and no. 7, use a press and a suitable pipe as illustrated. Sprockets must be assembled according to the following dimensions measured from drive axle end.

  • Page 378: Lubrication

    Section 08 DRIVE SYSTEM Subsection 07 (DRIVE AXLE) The bearing no. 9 must have its shield facing the sprocket. The drive axle bearing in chaincase must have its shield facing right side (cover). Index speedometer magnetic adapter no. 4 in drive axle and push until it is completely inserted in its hole.
  • Page 379 Section 08 DRIVE SYSTEM Subsection 07 (DRIVE AXLE) mmr2005-092...

  • Page 380: Track

    Section 08 DRIVE SYSTEM Subsection 08 (TRACK) TRACK SERVICE TOOLS Description Part Number Page belt tension tester ..............414 348 200 ......... 376 cleat remover................ 529 028 700 ......... 375, 377 narrow-cleat installer ............529 028 800 ......... 375, 377 TRACK TYPE APPLICATION WARNING Do not operate a snowmobile with a cut, torn...
  • Page 381 Section 08 DRIVE SYSTEM Subsection 08 (TRACK) Allow the rear suspension to fully extend and check gap halfway between front and rear idler wheels. Measure between slider shoe bottom and inside of track. The gap should be as given in SPECIFICATIONS. If the track tension is too loose, track will have a tendency to thump.

  • Page 382: Track Cleat

    Section 08 DRIVE SYSTEM Subsection 08 (TRACK) To correct, stop engine, loosen rear wheel screws, then tighten the adjustment screw on side where the slider shoe is the farthest from the track insert guides. 1. Guides TYPICAL 2. Slider shoes 1.
  • Page 383 Section 08 DRIVE SYSTEM Subsection 08 (TRACK) Effects of Studding on the Life – studs that are torn off the track of the Snowmobile – missing track guide(s). The use of traction enhancing products can in- Replace broken or damaged studs immediately. If crease the load and the stress on certain snow- the track shows signs of deterioration, it must be mobile components, as well as the vibration lev-...
  • Page 384 3.07 m (121 in) — Standard 20 mm (25/32 in) — MX-Z 20 mm (25/32 in) Standard 31.8 mm (1.25 in) Expedition (fan-cooled) 12.9 mm (1/2 in) Required — Required 20 mm (25/32 in) 3.45 m (136 in) — MX-Z Standard...

  • Page 385: Rear Suspension

    Section 09 REAR SUSPENSION Subsection 01 (SC SUSPENSION) SC SUSPENSION SERVICE PRODUCTS Description Part Number Page suspension synthetic grease ..........293 550 033 ......... 393 mmr2005-094...
  • Page 386 Section 09 REAR SUSPENSION Subsection 01 (SC SUSPENSION) 4.5 N•m (40 lbf•in) 4 N•m (35 lbf•in) RAILS AND IDLER WHEELS mmr2005-094...
  • Page 387 Section 09 REAR SUSPENSION Subsection 01 (SC SUSPENSION) Expedition (Sport)/GTX/Summit Fan Cooled Models ARMS AND SHOCK ABSORBERS mmr2005-094...
  • Page 388 Section 09 REAR SUSPENSION Subsection 01 (SC SUSPENSION) Summit Liquid Cooled Models ARMS AND SHOCK ABSORBERS mmr2005-094...
  • Page 389 Section 09 REAR SUSPENSION Subsection 01 (SC SUSPENSION) REAR ARM, SPRINGS AND TOP IDLER WHEELS mmr2005-094...

  • Page 390: Axle Self-Locking Screws Removal

    Section 09 REAR SUSPENSION Subsection 01 (SC SUSPENSION) AXLE SELF-LOCKING SCREWS REMOVAL CAUTION: These self-locking screws must al- ways be replaced by new ones everytime they are removed. NOTE: To prevent axle from turning when un- screwing self-locking screws, proceed as follows: –...

  • Page 391: Rear Shock Absorber Installation

    Section 09 REAR SUSPENSION Subsection 01 (SC SUSPENSION) NOTE: If necessary, to ease shock removal, un- fasten one end of stopper straps to release shock pressure. Remove rear shock absorber. SUMMIT LIQUID COOLED MODELS 1. Loosen lock nut, turn adjuster knob counterclockwise Unbolt front shock from the top.

  • Page 392: Rear Spring Removal

    Section 09 REAR SUSPENSION Subsection 01 (SC SUSPENSION) DESCRIPTION TIGHTENING TORQUE Adjuster lock nut 19 N•m (168 lbf•in) Stopper straps nuts 21 N•m (15 lbf•ft) (on Summit strap adjuster) Stopper strap(s) nuts 11 N•m (97 lbf•in) REAR SPRING REMOVAL Lift rear of vehicle and support it off the ground. Decrease spring preload by turning cams accord- ingly.

  • Page 393: Slider Shoe Removal

    Section 09 REAR SUSPENSION Subsection 01 (SC SUSPENSION) TYPICAL TYPICAL 1. Slider shoe 1. Track window 2. Molding line (wear limit indicator) 2. Slider shoe Replace slider shoes when wear limit is reached. Using a pry bar or screw driver, push slider shoe until it comes in contact with track.

  • Page 394: Slider Shoe Installation

    Section 09 REAR SUSPENSION Subsection 01 (SC SUSPENSION) TYPICAL TYPICAL — PULL ON SLIDER SHOE TO REMOVE 1. Rear arm bolts 2. Front arm bolts SLIDER SHOE INSTALLATION Lift rear of vehicle until front arm as enough clear- ance to pass underneath tunnel. Installation is reverse of removal procedure.

  • Page 395: Suspension Installation

    – shock upper bolt and nut – front arm lower bolts and washers – unfasten one end of stopper strap(s) EXPEDITION/GTX/SUMMIT FAN COOLED MODELS 1. Shock upper bolt and nut – remove front arm upper bolts, nuts and wash- 2. Front arm lower bolts and washers ers.

  • Page 396: Rear Arm/Pivot Arm Removal

    Section 09 REAR SUSPENSION Subsection 01 (SC SUSPENSION) REAR ARM INSTALLATION DESCRIPTION TIGHTENING TORQUE Stopper strap nuts Installation is reverse of removal procedure. Pay 21 N•m (15 lbf•ft) (on Summit strap adjuster) attention to the following details. Stopper strap nuts 11 N•m (97 lbf•in) At installation, rear arm stroke limiter must be on rear side.

  • Page 397: Ride Adjustment

    Lubricate front and rear arms at grease fittings using suspension synthetic grease (P/N 293 550 033). FAN COOLED MODELS 1. Front arm (top) 2. Front axle EXPEDITION/GTX/SUMMIT FAN COOLED MODELS 3. Rear of vehicle A. GTX/Expedition B. Summit C. GTX (EUR)/Summit (EUR) SUMMIT LIQUID COOLED MODELS TYPICAL —...

  • Page 398: Sc 3 Suspension

    Section 09 REAR SUSPENSION Subsection 02 (SC 3 SUSPENSION) SC 3 SUSPENSION SERVICE PRODUCTS Description Part Number Page suspension synthetic grease ..........293 550 033 ......... 406 mmr2005-095...
  • Page 399 Section 09 REAR SUSPENSION Subsection 02 (SC 3 SUSPENSION) RAILS AND IDLER WHEELS mmr2005-095...
  • Page 400 Section 09 REAR SUSPENSION Subsection 02 (SC 3 SUSPENSION) REAR ARM AND UPPER IDLER WHEELS mmr2005-095...
  • Page 401 Section 09 REAR SUSPENSION Subsection 02 (SC 3 SUSPENSION) FRONT ARM AND SHOCK ABSORBERS mmr2005-095...

  • Page 402: Axle Self-Locking Screws Removal

    Section 09 REAR SUSPENSION Subsection 02 (SC 3 SUSPENSION) AXLE SELF-LOCKING SCREWS REMOVAL CAUTION: These self-locking screws must al- ways be replaced by new ones everytime they are removed. NOTE: To prevent axle from turning when un- screwing self-locking screws, proceed as follows: –...

  • Page 403: Rear Shock Absorber Installation

    Section 09 REAR SUSPENSION Subsection 02 (SC 3 SUSPENSION) FRONT SHOCK ABSORBER NOTE: If necessary, to ease shock removal, un- fasten one end of stopper straps to release shock REMOVAL pressure. Lift rear of vehicle and support it off the ground. Remove rear arm shock.

  • Page 404: Rear Spring Installation

    Section 09 REAR SUSPENSION Subsection 02 (SC 3 SUSPENSION) Decrease spring preload by turning cams accord- Loosen set screw from locking rings. ingly. Remove the following on both sides: Loosen rear arm top axle from chassis. – locking ring Remove idler wheels to have access to spring sup- –...

  • Page 405: Slider Shoe Verification

    Section 09 REAR SUSPENSION Subsection 02 (SC 3 SUSPENSION) TYPICAL ON BOTH SIDES 1. Slider shoe 1. Spring end in cam adjuster 2. Molding line (wear limit indicator) CAUTION: To avoid track damage, spring sup- Replace slider shoes when wear limit is reached. ports must be mounted upward.

  • Page 406: Slider Shoe Installation

    Section 09 REAR SUSPENSION Subsection 02 (SC 3 SUSPENSION) TYPICAL 1. Track window TYPICAL — PULL ON SLIDER SHOE TO REMOVE 2. Slider shoe Using a pry bar or screw driver, push slider shoe SLIDER SHOE INSTALLATION until it comes in contact with track. Installation is reverse of removal procedure.

  • Page 407: Suspension Installation

    Section 09 REAR SUSPENSION Subsection 02 (SC 3 SUSPENSION) TYPICAL TYPICAL — REMOVE SUSPENSION 1. Rear arm bolts 2. Front arm bolts SUSPENSION INSTALLATION Lift rear of vehicle until front arm as enough clear- ance to pass underneath tunnel. Installation is reverse of removal procedure. Pay attention to the following details.

  • Page 408: Front Arm Installation

    Section 09 REAR SUSPENSION Subsection 02 (SC 3 SUSPENSION) TYPICAL 1. Shock upper bolt and nut 2. Front arm lower bolts and washers 3. Unfasten one end of stopper straps 4. Front arm upper bolts, nuts and washers 5. Front arm TYPICAL 1.

  • Page 409: Stopper Strap

    Section 09 REAR SUSPENSION Subsection 02 (SC 3 SUSPENSION) 1. Protrusion 2. Stoppers Dowel pin must exceed block guide by 2 to 2.3 mm (.079 to .091 in). 1. Front arm (top) At installation, insert dowel pin into pivot arm hole. 2.
  • Page 410 Section 09 REAR SUSPENSION Subsection 02 (SC 3 SUSPENSION) TYPICAL mmr2005-095...

  • Page 411: Sc 4 Suspension

    Section 09 REAR SUSPENSION Subsection 03 (SC 4 SUSPENSION) SC 4 SUSPENSION SERVICE PRODUCTS Description Part Number Page suspension synthetic grease ..........293 550 033 ......... 421 mmr2005-096...
  • Page 412 Section 09 REAR SUSPENSION Subsection 03 (SC 4 SUSPENSION) RAILS AND IDLER WHEELS mmr2005-096...
  • Page 413 Section 09 REAR SUSPENSION Subsection 03 (SC 4 SUSPENSION) ARMS AND SHOCK ABSORBERS mmr2005-096...
  • Page 414 Section 09 REAR SUSPENSION Subsection 03 (SC 4 SUSPENSION) REAR ARM, SPRINGS AND IDLER WHEELS mmr2005-096...

  • Page 415: Axle Self-Locking Screw Removal

    Section 09 REAR SUSPENSION Subsection 03 (SC 4 SUSPENSION) AXLE SELF-LOCKING SCREW REMOVAL CAUTION: These self-locking screws must al- ways be replaced by new ones everytime they are removed. NOTE: To prevent an axle from turning when un- screwing self-locking screws, proceed as follows: –...

  • Page 416: Rear Shock Absorber Installation

    Section 09 REAR SUSPENSION Subsection 03 (SC 4 SUSPENSION) 1. Rear shock absorber 2. Remove bolts and nuts Using a punch, remove lower shock bar axle. Pay attention to plastic spacers. Remove shock. 1. Bar axle 2. Swivel bushings 3. Shock reservoir position 4.

  • Page 417: Front Shock Absorber Installation

    Section 09 REAR SUSPENSION Subsection 03 (SC 4 SUSPENSION) 1. Front shock absorber 2. Remove bolts and nuts FRONT SHOCK ABSORBER INSTALLATION Installation is reverse of removal procedure. Pay attention to the following details. Shock absorber nuts should be on the RH side. Install shock adjustment ring towards the top and valve towards tunnel, see photo.

  • Page 418: Rear Spring Installation

    Section 09 REAR SUSPENSION Subsection 03 (SC 4 SUSPENSION) Loosen set screw from locking rings. Remove the following on both sides: – locking ring – axle spring – top idler wheel – rear spring. ON BOTH SIDES 1. Spring end in cam adjuster CAUTION: To avoid track damage, spring sup- ports must be mounted upward.

  • Page 419: Slider Shoe Removal

    Section 09 REAR SUSPENSION Subsection 03 (SC 4 SUSPENSION) TYPICAL TYPICAL 1. Slider shoe 1. Track window 2. Molding line (wear limit indicator) 2. Slider shoe Replace slider shoes when wear limit is reached. Using a pry bar or screw driver, push slider shoe until it comes in contact with track.

  • Page 420: Slider Shoe Installation

    Section 09 REAR SUSPENSION Subsection 03 (SC 4 SUSPENSION) PULL ON SLIDER SHOE TO REMOVE 1. Enough clearance SLIDER SHOE INSTALLATION Installation is reverse of removal procedure. Pay attention to the following details. Make sure to insert slider shoe end with hole first. Respect the following tightening torque specifica- tion: DESCRIPTION...

  • Page 421: Front Arm Installation

    Section 09 REAR SUSPENSION Subsection 03 (SC 4 SUSPENSION) Lift rear of vehicle and support it off the ground. DESCRIPTION TIGHTENING TORQUE Remove the following: Stopper straps nuts 11 N•m (97 lbf•in) – shock upper bolt and nut Front arm lower bolts 120 N•m (89 lbf•ft) –...

  • Page 422: Block Installation

    Section 09 REAR SUSPENSION Subsection 03 (SC 4 SUSPENSION) At installation, rear arm stroke limiter must be on rear side. Insert dowel pin into pivot arm hole, dowel pin must exceed block guide by 2 to 2.3 mm (.079 to .091 in).

  • Page 423: Lubrication

    Section 09 REAR SUSPENSION Subsection 03 (SC 4 SUSPENSION) LUBRICATION Lubricate pivot arm and rear arm at grease fittings using suspension synthetic grease (P/N 293 550 033). mmr2005-096...

  • Page 424: Shock Absorber Inspection And Servicing

    Section 09 REAR SUSPENSION Subsection 04 (SHOCK ABSORBER INSPECTION AND SERVICING) SHOCK ABSORBER INSPECTION AND SERVICING SERVICE TOOLS Description Part Number Page floating piston remover tool..........529 035 907 ......... 426 gas fill tool kit (needle type)..........503 190 102 ......425, 431–432 gas shock valve tool (tire valve type) ........

  • Page 425: Shock Absorber Inspection

    Section 09 REAR SUSPENSION Subsection 04 (SHOCK ABSORBER INSPECTION AND SERVICING) – A gurgling noise, after completing one full com- pression and extension stroke. Renew if any faults are present. Gas Shock Except Variable Rate Because of gas pressure, strong resistance is felt when compressing shock.

  • Page 426: Disassembly And Assembly

    Section 09 REAR SUSPENSION Subsection 04 (SHOCK ABSORBER INSPECTION AND SERVICING) DISASSEMBLY AND ASSEMBLY Remove screw on top of valve. Place the needle guide of gas fill tool kit (needle type) (P/N 503 190 High Pressure Gas Take Apart Shock (HPG T/A) 102) on the shock valve.
  • Page 427 Section 09 REAR SUSPENSION Subsection 04 (SHOCK ABSORBER INSPECTION AND SERVICING) Compress the carrier to access and remove the snap ring. All HPG T/A Shocks With the seal carrier removed, slowly lift and remove damper rod assembly from the damper body.
  • Page 428 Section 09 REAR SUSPENSION Subsection 04 (SHOCK ABSORBER INSPECTION AND SERVICING) A06F0UA 1. Tool 2. Reservoir opened extremity blocked by leaning on work bench A. Remove damper nut With a low pressure hand pump, pressurize shock Always arrange parts removed in the sequence of absorber until external reservoir piston pops-out.
  • Page 429 Section 09 REAR SUSPENSION Subsection 04 (SHOCK ABSORBER INSPECTION AND SERVICING) NOTE: If revalving is to be done, it is imperative that you identify the original shim pack (size and number of shims). There is no need to remove seal carrier if only revalving is to be done. Shims can be measured by using a vernier caliper or a micrometer.
  • Page 430 Section 09 REAR SUSPENSION Subsection 04 (SHOCK ABSORBER INSPECTION AND SERVICING) If floating piston has been removed, reinstall float- INSTALLATION DISTANCE OF ing piston into damper body (ensure that valve SHOCK P/N FLOATING PISTON core has been removed). Use Molykote G-n paste (P/N 711 297 433) to ease O-ring past damper body threads with floating piston guide.
  • Page 431 Section 09 REAR SUSPENSION Subsection 04 (SHOCK ABSORBER INSPECTION AND SERVICING) Slowly push piston into damper body. Slight up and down movement may be required on short stroke to allow all air to pass through piston as- sembly. The gentle tapping of a small wrench, on the shock eye, may help dislodge air trapped in the submersed piston.
  • Page 432 Section 09 REAR SUSPENSION Subsection 04 (SHOCK ABSORBER INSPECTION AND SERVICING) When removing and retightening the tire valve acorn nut use minimal torque. When the cap is 1. High pressure hose over tightened and subsequently removed it may 2. Stage regulator, delivery pressure range 2070 kPa (300 PSI) 3.
  • Page 433 Section 09 REAR SUSPENSION Subsection 04 (SHOCK ABSORBER INSPECTION AND SERVICING) Mount the shock on vise. Remove screw on top Damper gas pressure cannot be confirmed by of valve. Place the needle guide of gas refill tool using a pressure gauge. The volume of gas in the on the shock valve.

  • Page 434: Steering/Front Suspension

    Section 10 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) STEERING SYSTEM SERVICE PRODUCTS Description Part Number Page BOMBARDIER LUBE ............293 600 016 ......... 446 suspension synthetic grease ..........293 550 033 ......... 446 mmr2005-097...
  • Page 435 Section 10 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) Linkage Arrangement mmr2005-097...
  • Page 436 Section 10 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) Handlebar Arrangement GTX series GTX 500 SS/600 HO/800 HO Summit series Some models mmr2005-097...
  • Page 437 Section 10 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) GSX Series MX Z Fan Cooled MX Z Adrenaline/Trail MX Z Renegade Renegade X package series MX Z Summit Renegade mmr2005-097...

  • Page 438: Disassembly And Assembly

    Section 10 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) DISASSEMBLY AND ASSEMBLY CAUTION: Pay attention not to damage wires with the wrench. Grip Using a plastic hammer, tap on the side of the wrench end to make the grip slide out. NOTE: These models feature an integrated heat- ing element in the plastic sleeve of the grip no.
  • Page 439 Section 10 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) MODEL TOOL PART NUMBER Models with straight 529 035 897 grips Models with J-hooks 529 035 936 1. Connectors unplugged Unplug LH harness on top of steering column. Cut locking ties retaining brake light switch/heat- ing grip harness to handlebar.
  • Page 440 Section 10 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) Reinstall terminals and replug connectors. Test Grease fitting no. 16 of swivel arms no. 14 must grips to ensure they heat properly. face toward center of vehicle. Steering Column Unfasten windshield. Remove cap no. 3 or steer- ing padding no.

  • Page 441: Inspection

    Section 10 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) Heating Grip Element Refer to TESTING PROCEDURE for checking heating element no. 13 of grip. Ball Joint (left hand and right hand threads) Inspect ball joint ends no. 17 and no. 18 and small tie rod ends for wear or looseness, if excessive, replace them.
  • Page 442 Section 10 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) TYPICAL 1. Large connector housings Remove console. 1. Cap Remove 2 bolts no. 5 retaining top of steering col- 2. Console cap umn. Unscrew 4 bolts retaining console. STEERING COLUMN IN REARWARD POSITION 1.
  • Page 443 Section 10 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) ONE SIDE SHOWN — FORWARD POSITION 1. Bolts retaining windshield assembly STEERING COLUMN IN FORWARD POSITION 1. Longer bolt Readjust throttle lever housing no. 21 and switch housing accordingly to optimal angle so that you Reinstall the 2 bolts no.
  • Page 444 Section 10 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) 1. Torque to 25 N•m (18 lbf•ft) A. Equal gap all around CAUTION: Tighten the bolts equally in a criss- 1. Opening here cross sequence and ensure there is an equal 2. Extension against stopper gap on each side of the clamps no.

  • Page 445: Steering Adjustment (Skis)

    Section 10 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) Retaining clip and hardware must be installed in the same position on both strap ends. J-Hook Adjustment Some Models Position J-hook so that its curved end is pointing downward and is roughly vertical. Ensure to ad- just J-hooks at the same position each side.
  • Page 446 Section 10 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) Procedure: – Position handlebar so that it is in straight ahead position by measuring from the extremities of the grips to the rear most edge of the tunnel, as shown. NOTE: The reference point must be the same rel- ative to each side.

  • Page 447: Lubrication

    Section 10 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) RIGHT HAND SIDE SHOWN 1. Ski leg 2. Lower arm A. 2 mm (5/64 in) If the distance is more than the specified distance on one side then check for bent parts. LUBRICATION WARNING Do not lubricate throttle cable or housing.

  • Page 448: Front Suspension

    Section 10 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) FRONT SUSPENSION SERVICE TOOLS Description Part Number Page A-arm nut wrench..............529 035 876 ......... 456 ball joint installer ..............529 035 975 ......... 456 ball joint lock tool ..............529 035 945 ......... 456 ball joint remover ..............
  • Page 449 Section 10 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) mmr2005-098...
  • Page 450 Section 10 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) Precision Ski Mountain Ski Plastic Ski NOTE: The same procedure applies on both sides. mmr2005-098...

  • Page 451: General Inspection

    Section 10 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) GENERAL INSPECTION Check for looseness, bent, worn out, rusted or other damage on components. Ensure cotter pins are in good condition and properly secured. Re- place the faulty component. To check upper arm bushings and ball joint: –...
  • Page 452 Section 10 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) Remove lower screw then upper screw of shock absorber. NOTE: To retain upper screw while unscrewing nut, remove access plug in engine compartment. A01B4LA TYPICAL 1. Clevis pin 2. Bar 3. Handle horizontal Push down on the handle until it locks.
  • Page 453 Section 10 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) Lower Arm Remove shock absorber. Remove sliding blocks no. 6 of stabilizer bar no. 7. TYPICAL 1. Ball joint parallel with ski leg Remove lower arm no. 10 from frame. For front screw no.
  • Page 454 Section 10 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) Use a 11 mm (7/16 in) open wrench to hold ball joint housing and unscrew nut no. 16, then re- move ball joint from upper arm. Remove upper arm no. 14 from frame. For screws no.

  • Page 455: Inspection

    Section 10 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) Using a 4.8 mm (3/16 in) drill bit, drill rivet no. 24 out. Remove cap. To remove bushing no. 25, use a 13 mm (1/2 in) open wrench and tap bushing out as shown. 1.

  • Page 456: Installation

    Section 10 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) Check condition of ball joints. Replace as re- quired. Check skis and runners no. 5 for wear, replace as necessary. Check condition of ski stopper no. 26. Replace it when deteriorated. To check condition of shock absorber, refer to sub-section SHOCK ABSORBER INSPECTION AND SERVICING in section REAR SUSPENSION.
  • Page 457 Section 10 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) To properly torque ball joint nut, use the A-arm nut wrench (P/N 529 035 876). Ensure to install the tool perpendicularly (90°) to torque wrench. Lower Arm Position lower arm below stabilizer bar. Prior to installing ball joint in lower arm, ensure to 1.

  • Page 458: Stabilizer Bar

    Section 10 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) – Install screws and nuts. – Ensure blocks slide easily when compressing and releasing suspension. TYPICAL Stabilizer Bar 1. Temporarily rotate block by 180° for its insertion Notice that LH and RH sliding blocks are different. Look for their molded identification with LH or RH letters.
  • Page 459 All X package MX Z Trail Adrenaline (Europe) Summit Adrenaline Trail (Europe) GSX 380F/550F GSX Limited GTX 380F/550F GTX Limited MX Z 380F/550F GTX 600 HO SDI Sport (Europe) Summit 550F MX Z Adrenaline Expedition Sport 550F MX Z Renegade mmr2005-098...
  • Page 460 Section 10 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) Summit Only Install bushing no. 29 and spacer no. 30 inward on each ski leg for the wide ski stance. Install outward for narrow ski stance. WARNING Install skis with proper side facing inward. Refer to warning on ski.

  • Page 461: Body/Frame

    Section 11 BODY/FRAME Subsection 01 (BODY) BODY INSTALLATION AND ADJUSTMENT DECAL To remove a decal; heat old decal with a heat gun and peel off slowly. Using isopropyl alcohol, clean the surface and dry thoroughly. Apply liquid soap to new decal and carefully po- sition the decal.

  • Page 462: Cables

    Section 11 BODY/FRAME Subsection 01 (BODY) CABLES – strong detergents – abrasive cleaners WARNING – waxes containing an abrasive or a cleaning Before installation, ensure that all cables are agent in their formula. in perfect condition. Properly install the cable Apply wax on glossy finish only.

  • Page 463: Frame

    The proper speed is attained when – No welds should be done on aluminum frame a constant chip is ejected. except if mentioned or required on a BRP bul- NOTE: To increase bit life, use XP-S synthetic letin.
  • Page 464 Section 11 BODY/FRAME Subsection 02 (FRAME) TYPICAL Cut rivet using a chisel. Remove riveted part. Drive out remaining rivet head using a punch. mmr2005-100...

  • Page 465: Technical Data

    Section 12 TECHNICAL DATA Subsection 01 (FAN COOLED MODELS) FAN COOLED MODELS EXPEDITION/SUMMIT/ GSX/GTX/MX Z GSX/GTX/MX Z MODEL 380 F 550 F ENGINE Engine type Number of cylinder Bore Standard mm (in) 62 (2.441) 76 (2.992) Stroke mm (in) 61.00 (2.402) Displacement 368.30 (22.475)
  • Page 466 Section 12 TECHNICAL DATA Subsection 01 (FAN COOLED MODELS) EXPEDITION/SUMMIT/ GSX/GTX/MX Z GSX/GTX/MX Z MODEL 380 F 550 F FUEL SYSTEM EXPEDITION — VM34–617 GSX/GTX/MX Z VM30–213 VM34–617 Carburetor type SUMMIT — VM34–616 SUMMIT (EUR) — VM34–617 EXPEDITION — GSX/GTX/MX Z...
  • Page 467 Section 12 TECHNICAL DATA Subsection 01 (FAN COOLED MODELS) EXPEDITION/SUMMIT/ GSX/GTX/MX Z GSX/GTX/MX Z MODEL 380 F 550 F GSX/MX Z 3300 3500 3300 3000 Clutch engagement ± 100 RPM EXPEDITION/SUMMIT — 3300 SUMMIT (EUR) — 3000 GSX/MX Z Blue/Pink...
  • Page 468 Section 12 TECHNICAL DATA Subsection 01 (FAN COOLED MODELS) EXPEDITION/SUMMIT/ GSX/GTX/MX Z GSX/GTX/MX Z MODEL 380 F 550 F GSX/GTX/MX Z 381 mm (15 in) SUMMIT — 381 mm (15 in) Width EXPEDITION/ — 406 mm (16 in) SUMMIT (EUR)
  • Page 469 Section 12 TECHNICAL DATA Subsection 01 (FAN COOLED MODELS) EXPEDITION/SUMMIT/ GSX/GTX/MX Z GSX/GTX/MX Z MODEL 380 F 550 F Ski stance (carbide to carbide) mm (in) 1080 (42.5) Toe-out mm (in) 0.00 Camber 0° EXPEDITION — 7968 cm (1235 in...

  • Page 470: Liquid Cooled Models

    Section 12 TECHNICAL DATA Subsection 02 (LIQUID COOLED MODELS) LIQUID COOLED MODELS GSX/GTX/MX Z GSX/GTX/MX Z/SUMMIT MODEL 500 SS 600 HO 800 HO ENGINE Engine type 593 HO 793 HO Number of cylinder Bore Standard mm (in) 76 (2.992) 72 (2.835) 82 (3.228) Stroke mm (in)
  • Page 471 Section 12 TECHNICAL DATA Subsection 02 (LIQUID COOLED MODELS) GSX/GTX/MX Z GSX/GTX/MX Z/SUMMIT MODEL 500 SS 600 HO 800 HO ELECTRICAL Battery 12 V, 18 A•h (if applicable) Headlamp 60/55 (H4) Taillight and stoplight 8/27 Tachometer and speedometer bulbs 2 x 3 Fuel and temperature gauge bulbs —...
  • Page 472 Section 12 TECHNICAL DATA Subsection 02 (LIQUID COOLED MODELS) GSX/GTX/MX Z GSX/GTX/MX Z/SUMMIT MODEL 500 SS 600 HO 800 HO DRIVE Chaincase oil XP-S Synthetic chaincase oil 22/43 23/43 21/43 23/45 Adrenaline 22/43 25/45 Ren./Ren. X — 21/43 23/43 Chain drive ratio MX Z Trail 22/43...
  • Page 473 Section 12 TECHNICAL DATA Subsection 02 (LIQUID COOLED MODELS) GSX/GTX/MX Z GSX/GTX/MX Z/SUMMIT MODEL 500 SS 600 HO 800 HO DRIVE Type HPV VSA Spring preload 44° 47°/44° 50°/40° 44° 47°/44° 47°/40° MX Z (Adrenaline) 44° 47°/44° 50°/40° MX Z (Ren./Ren. X) —...
  • Page 474 Section 12 TECHNICAL DATA Subsection 02 (LIQUID COOLED MODELS) GSX/GTX/MX Z GSX/GTX/MX Z/SUMMIT MODEL 500 SS 600 HO 800 HO DRIVE 25.4 mm (1.0 in) 22.3 mm (.878 in) GTX (EUR) 31.8 mm (1.25 in) — 31.8 mm (1.25 in) 25.4 mm (1.0 in) MX Z (Adrenaline) 31.8 mm (1.25 in)
  • Page 475 Section 12 TECHNICAL DATA Subsection 02 (LIQUID COOLED MODELS) GSX/GTX/MX Z GSX/GTX/MX Z/SUMMIT MODEL 500 SS 600 HO 800 HO VEHICLE INFORMATIONS Electric start 222 kg (488 lb) 225 kg (495 lb) 225 kg (495 lb) Electric start 231 kg (508 lb) 233 kg (513 lb) 238 kg (524 lb) Manual start...
  • Page 476 Section 12 TECHNICAL DATA Subsection 02 (LIQUID COOLED MODELS) GSX/GTX/MX Z GSX/GTX/MX Z/SUMMIT MODEL 500 SS 600 HO 800 HO VEHICLE INFORMATIONS Toe-out mm (in) 0.00 Camber 0° 6910.2 cm (1071 in 7596 cm (1177.382 in Adrenaline 6910.2 cm (1071 in Renegade —...
  • Page 477 Section 12 TECHNICAL DATA Subsection 02 (LIQUID COOLED MODELS) GSX/GTX/MX Z GSX/GTX/MX Z/SUMMIT MODEL 500 SS 600 HO 800 HO CAPACITIES Fuel tank L (U.S. gal) 40 (10.6) Chaincase/gearbox mL (U.S. oz) 250 (8.5) 4.9 L (165.7 U.S. oz) 5.17 L (174.8 U.S. oz) Adrenaline 4.9 L (165.7 U.S.

  • Page 478: Liquid Cooled (Sdi) Models

    Section 12 TECHNICAL DATA Subsection 03 (LIQUID COOLED (SDI) MODELS) LIQUID COOLED (SDI) MODELS GSX/GTX/MX Z MODEL 600 HO SDI ENGINE Engine type 593 HO Number of cylinder Bore Standard mm (in) 72 (2.835) Stroke mm (in) 73 (2.874) Displacement 594.40 (36.273) Compression ratio 12.25 ±...
  • Page 479 Section 12 TECHNICAL DATA Subsection 03 (LIQUID COOLED (SDI) MODELS) GSX/GTX/MX Z MODEL 600 HO SDI FUEL SYSTEM Throttle body type Dell'Orto Idle speed ± 200 RPM 1600 Gas type Unleaded Inside North America (R+M)/2 87 or higher Pump octane number Outside North America 91 or higher Gas/oil ratio...
  • Page 480 Section 12 TECHNICAL DATA Subsection 03 (LIQUID COOLED (SDI) MODELS) GSX/GTX/MX Z MODEL 600 HO SDI DRIVE Type HPV VSA Spring preload Driven pulley type GSX/GTX/MX Z (Adrenaline/X) 47°/44° Cam angle MX Z (Renegade/Renegade X) 44° Pulley distance mm (in) 20.0 (.787) mm (in) 37.0 ±...
  • Page 481 Section 12 TECHNICAL DATA Subsection 03 (LIQUID COOLED (SDI) MODELS) GSX/GTX/MX Z MODEL 600 HO SDI VEHICLE INFORMATIONS Electric start 229 kg (504 lb) GTX (Sport) Electric start 238 kg (524 lb) GTX (Limited) Electric start 242 kg (532 lb) Mass (dry) Manual start 215 kg (473 lb)
  • Page 482 Section 12 TECHNICAL DATA Subsection 03 (LIQUID COOLED (SDI) MODELS) GSX/GTX/MX Z MODEL 600 HO SDI CAPACITIES Fuel tank L (U.S. gal) 40 (10.6) Chaincase/gearbox mL (U.S. oz) 250 (8.5) 4.9 L (165.7 U.S. oz) 5.17 L (174.8 U.S. oz) Cooling system Adrenaline/X 4.9 L (165.7 U.S.
  • Page 483 BTDC: Before Top Dead Center (1) The maximum horsepower RPM applicable on the vehicle. It may be different under certain CDI: Capacitor Discharge Ignition circumstances and BRP reserves the right to Magneto MAG: modify it without obligation. N.A.: Not Applicable (2) Crankshaft end-play is not adjustable on these models.

  • Page 484: Wiring Diagram

    Section 13 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) WIRING DIAGRAMS SERVICE TOOLS Description Part Number Page connector crimping tool............529 035 909 ......... 494 crimper die................529 035 906 ......... 494 Wiring diagrams can be found at the end of this COLOR CODE subsection.

  • Page 485: Housing Reference Per Area

    Section 13 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) AREA LOCATION Right hand side of engine Engine Near right hand side footrest Near driven pulley Under console Under hood Near fuel tank Under engine Near steering column or on primary air intake silencer On handlebar Injection oil tank Secondary air intake silencer...
  • Page 486 Section 13 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) 10 9 mmr2005-102...

  • Page 487: Symbols Description

    Section 13 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) SYMBOLS DESCRIPTION mmr2005-102...

  • Page 488: Unpluging Connectors

    Section 13 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) UNPLUGING CONNECTORS Always unplug connectors by pulling on housing not on wire. TPS CONNECTOR UNPLUGGED 1. Release button TAB AND RECEPTACLE CONNECTORS REMOVAL TYPICAL Throttle Position Sensor (TPS) Tab Connector Connector It is locked in its housing by a spring tab on its side. Removal is done by squeezing this tab.
  • Page 489 Section 13 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) – Pry tab to free connector then pull wire out of housing. 1. Insert screwdriver here 2. Pull this side Locking Receptacle Connector To remove: – Insert tool Snap-on TT 600-5 in access opening then pull housing toward wire side.
  • Page 490 Section 13 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) 1. Lock – Pry tab to free connector then pull wire out of housing. FEMALE CONNECTOR HOUSING — CUT-AWAY 1. Lock Receptacle connectors can be removed from fe- MALE CONNECTOR HOUSING — CUT-AWAY male housing with sharp head pin.
  • Page 491 Section 13 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) Lift the top plastic lock of the female terminal to be removed and hold in position. Lift the female terminal to unlock from the housing and push out of housing. MALE CONNECTOR HOUSING — CUT-AWAY 1.
  • Page 492 Section 13 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) Cut both locking ties that secure the harness to the housing. 8-CIRCUIT CONNECTOR HOUSING — CUT-AWAY 1. Tab Connector housing A and B on ECM Terminal Removal Unlock the connector housing cover by pushing in the tabs on top of the housing with a flat screw- driver to be able to flip the top cover up.
  • Page 493 Section 13 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) Insert the probe into the housing as shown, and When re-inserting the connector, the locking tab locate the appropriate wire in the back of the must be installed facing the smaller cutout of the housing.

  • Page 494: Tab And Receptacle Connectors Installation

    Section 13 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) TYPICAL A. 3 mm (1/8 in) max. Position wire in terminal. 1. Top of terminal tabs 2. Align tabs with pliers edge Squeeze the terminal tabs with your fingers to temporarily retain terminal in place. Crimp terminal.
  • Page 495 Section 13 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) A00E1FA TYPICAL 1. Receptacle 2. Housing WARNING Keep wires away from any rotating, moving, heating, vibrating or sharp edge. Use proper fastening devices as required. mmr2005-102...
  • Page 496 Section 13 WIRING DIAGRAM Subsection 01 (WIRING DIAGRAMS) mmr2005-102...
  • Page 497 2005 REV FAN COOLED 2 2 0 0 0 0 5 5 R R E E V V F F A A N N C C O O O O L L E E D D SPYL SPYL SPBK/YL BK/YL 12-HG 12-HG SPBE/BK...
  • Page 498 2005 REV CARBURETOR MANUAL START A33Z0E...
  • Page 499 2005 REV CARBURETOR ELECTRIC START A33Z0D...
  • Page 500 2005 REV SDI RD/BR JTWH/VI JTRD/YL 2 2 0 0 0 0 5 5 R R E E V V S S D D I I WH/VI JTVI/RD VI/RD RD/OR JTRD/GY 1 JTRD/GY RD/GY 4-DB 4-DB SPOR/BU OR/BU OR/BU MAGNETO RD/YL 3-DI 4-DB...
  • Page 501 2005 REV POWER TEK MANUAL START 11-CF 11-FC 11-FC SPRD/BR JTRD/YL 1 RD/BR RD/BR RD/BR RD/YL RD/YL 2 2 0 0 0 0 5 5 R R E E V V P P O O W W E E R R T T E E K K M M A A N N U U A A L L S S T T A A R R T T FUSE (20A) SP RD/YL 2...
  • Page 502 2005 REV POWER TEK ELECTRIC START 11-CF 11-FC 11-FC SPRD/BR JTRD/YL 1 RD/BR RD/BR RD/BR RD/YL RD/YL 2 2 0 0 0 0 5 5 R R E E V V P P O O W W E E R R T T E E K K E E L L E E C C T T R R I I C C S S T T A A R R T T FUSE (20A) SP RD/YL 2...

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