BRP MX Z (Adrenaline) Manuals

Manuals and User Guides for BRP MX Z (Adrenaline). We have 1 BRP MX Z (Adrenaline) manual available for free PDF download: Manual

BRP MX Z (Adrenaline) Manual

BRP MX Z (Adrenaline) Manual (502 pages)

Snowmobile BRP EXPEDITION; GSX; GTX; MX Z; MX Z (Adrenaline); MX Z; SUMMIT

Brand: BRP | Category: Offroad Vehicle | Size: 59 MB

Table of Contents

Table of Contents
2
Safety Notice

12
Introduction

12
- Vehicle Identification Number
  13
- Engine Serial Number
  13
- Arrangement of this Manual
  15
- General Information
  17
- Illustrations and Procedures
  17
- Self-Locking Fasteners Procedure
  17
- Loctite Application Procedure
  18
- Threadlocker
  18
- Stripped Thread Repair
  19
- Gasket Compound
  20
- Mounting on Shaft
  20
- Case-In Components
  21
- Tightening Torque
  22
Maintenance

23
- Maintenance Chart
  
  23
- Storage
  
  25
  - General
    25
  - Engine
    25
    
    Service Tools
    25
    
    Service Products
    25
  - Fuel System
    26
  - Drive System
    26
  - Steering/Front Suspension
    27
  - Suspension
    27
  - Electrical
    27
  - Vehicle
    27
- Preseason Preparation
  
  29
  - Engine
    29
  - Fuel System
    29
  - Drive System
    30
  - Electrical System
    30
  - Vehicle
    30
Troubleshooting

31
- Engine
  
  31
- Fuel and Oil Systems
  
  42
- Drive and Brake Systems
  
  45
  - Drive System
    45
  - Brake System
    52
- Electrical System
  
  53
- Steering and Suspension
  
  63
Engines

66
- Leak Test
  
  66
- Preparation
  66
- Procedure
  67
- Finalizing Reassembly
  68
- Engine Leak Verification Flow Chart
  69
Exhaust System

70
- 377 And 552 Engines
  71
- Ho, 593 Ho Sdi and 793 Ho Engines
  72
  - Tuned Pipe
    73
  - Manifold
    74
  - Muffler
    74
Engine Removal and Installation

75
- Removal from Vehicle
  77
- Inspection
  81
- Installation
  81
- Removal from Vehicle
  83
- Inspection
  87
- Installation
  87
Magneto System

88
- General
  93
- Magneto Flywheel
  93
- Stator
  95
- Cps/Trigger Coil
  95
Top End

97
- Troubleshooting
  100
- Cleaning
  100
- Disassembly
  100
- Inspection
  102
- Assembly
  102
- Reed Valve
  107
- Troubleshooting
  114
- Component Removal with the Engine Installed
  114
- Cleaning
  114
- Rave Valve Basic Operation
  114
- Disassembly
  114
- Inspection
  119
- Assembly
  120
Bottom End

125
- Cleaning
  128
- Disassembly
  128
- Inspection
  129
- Assembly
  129
- Break-In
  134
- Cleaning
  138
- Disassembly
  138
- Inspection
  139
- Assembly
  139
- Break-In
  144
Engine Measurement

145
- Cylinder Head Warpage
  145
- Cylinder Taper
  145
- Cylinder out of Round
  145
- Combustion Chamber Volume Measurement
  146
- Used Piston Measurement
  147
- Cylinder/Piston Clearance
  147
- Ring/Piston Groove Clearance
  149
- Ring End Gap
  149
- Crankshaft Deflection
  149
  - Connecting Rod Big End Axial Play
    150
  - Checking Crankshaft Alignment
    150
  - Cooling System
    151
- 8 Cooling System
  
  154
  - Cooling Fan Removal and Installation
    154
  - Cooling Fan Bearing Replacement
    154
  - Fan Belt Replacement and Deflection Adjustment
    155
  - Liquid Cooling System
    158
  - Cooling System Leak Test
    161
  - Inspection
    161
  - Draining the System
    161
  - Disassembly and Assembly
    161
  - Cooling System Refilling Procedure
    162
- Rewind Starter
  
  163
  - Inspection
    166
  - Removal
    166
  - Rope Replacement
    166
  - Disassembly
    167
  - Assembly
    167
  - Installation
    170
- Oil Injection System
  
  171
  - General
    174
  - Oil Type
    174
  - Oil System Leak Test
    174
  - Oil Pump Identification
    175
  - Cleaning
    175
  - Checking Operation
    175
  - Disassembly
    176
  - Assembly
    177
  - Bleeding Procedure
    178
  - Adjustment
    178
Fuel System

180
- Fuel Tank and Fuel Pump
  
  180
  - In-Tank Fuel Filter
    183
  - In-Line Fuel Filter
    183
  - Fuel Tank
    184
  - Float-Type Fuel Level Gauge
    185
  - Electric Fuel Level Sensor
    186
  - Fuel System Pressurization
    186
  - Diaphragm Fuel Pump
    187
    
    Removal
    189
    
    Pump Verification
    189
    
    Cleaning and Inspection
    189
    
    Installation
    189
- Carburetors, Throttle and Choke Cables
  
  190
  - Carburetor - VM Type
    191
    
    Identification
    192
    
    Removal
    192
    
    Cleaning and Inspection
    192
    
    Disassembly and Assembly
    192
    
    Carburetor Adjustments
    193
    
    Installation
    196
    
    Choke
    197
  - Carburetor Tm Type
    199
    
    Identification
    200
    
    Removal
    200
    
    Cleaning and Inspection
    202
    
    Disassembly and Assembly
    202
    
    Installation
    204
    
    Carburetor Adjustments
    204
    
    Idle Speed Adjustment
    205
    
    Choke Cable
    206
- Dpm System
  
  208
  - Overview
    210
  - System Testing
    210
  - Parts Removal and Installation
    210
  - Dpm Manifold Testing
    211
Engine Management (Power Tek)

214
- Overview
  
  214
  - Operating Principle
    215
    
    Fuel Delivery System
    215
    
    Engine Management System (Ems)
    215
    
    Ems - Engine Management System Functions
    216
    
    Power Distribution
    217
    
    Ignition System
    217
    
    Electronically Controlled Rave
    217
    
    Digitally Encoded Security System (Dess)
    217
    
    Rotax Electronic Reverse (Rer)
    218
    
    Monitoring System
    218
    
    Diagnostic Mode
    218
- Diagnostic Procedures
  
  219
  - General
    219
  - Troubleshooting
    219
  - Ems Fault Codes
    220
  - Vck (Vehicle Communication Kit)
    223
- Component Inspection, Replacement and Adjustment
  
  226
  - General
    226
    
    Electrical System
    226
    
    Fuel System
    228
  - Engine Management System
    229
    
    Engine Control Module (Ecm)
    229
    
    Power Relay
    229
    
    Throttle Position Sensor (Tps)
    230
    
    Air Temperature Sensor (Ats)
    234
    
    Coolant Temperature Sensor (Cts)
    235
    
    Air Pressure Sensor (Aps)
    236
    
    Knock Sensor (Ks)
    237
    
    E-Rave Solenoid
    238
    
    Dpm Solenoid
    239
    
    Ignition Coil
    239
    
    Engine Start/Rer Switch
    240
    
    Digitally Encoded Security System (Dess)
    241
Engine Management (Sdi)

243
- Overview
  
  243
  - Operating Principle
    244
    
    Charging System
    244
    
    Ignition System
    244
    
    Air Induction
    244
    
    Fuel Delivery System
    245
  - Engine Management System (Ems)
    246
    
    Ecm - General Functions
    247
    
    Ems - Engine Management System Functions
    249
    
    Electronic Fuel Injection
    249
    
    Ignition Timing
    250
    
    Electronically Controlled Rave
    250
    
    Knock Sensor
    250
    
    Engine Modes of Operation
    250
    
    Flooded Engine (Drowned Mode)
    250
    
    Monitoring System
    250
    
    Limp Home Modes
    250
    
    Diagnostic Mode
    251
    
    Rotax Electronic Reverse (Rer)
    251
- Diagnostic Procedures
  
  252
  - General
    252
  - Troubleshooting
    252
  - Vck (Vehicle Communication Kit)
    256
  - 2-Tec System Fault Codes
    258
- Component Inspection, Replacement and Adjustment
  
  260
  - Electrical System
    261
    
    Resistance Measurement
    262
    
    Engine Connector Pin-Outs
    263
    
    Relay
    264
  - Air Induction System
    265
    
    Throttle Body
    265
  - Fuel Delivery
    268
    
    Electric Fuel Pump
    269
    
    Fuel Rail
    272
    
    Fuel Injectors
    273
  - Electronic Management
    276
    
    Ecm Replacement
    276
    
    Engine Wiring Harness
    276
    
    Throttle Position Sensor (Tps)
    277
    
    Crankshaft Position Sensor (Cps)
    279
    
    Air Temperature Sensor (Ats)
    280
    
    Coolant Temperature Sensor (Cts)
    281
    
    Air Pressure Sensor (Aps)
    282
    
    Exhaust Gas Temperature Sensor (Egts)
    282
    
    Knock Sensor (Ks)
    283
    
    E-Rave Solenoid
    284
    
    Double Ignition Coil
    284
    
    Ignition Timing
    286
    
    Battery
    286
    
    Capacitor
    286
    
    Engine Start/Rer Switch Verification
    287
    
    Dess Post Verification
    288
Electrical System

289
- Ignition System
  
  289
  - General
    289
  - Ignition Timing
    292
  - Spark Plug
    301
  - Design Symbols Used in Ngk Spark Plugs
    302
- Charging System
  
  303
  - General
    303
  - Charging Generator Coil (Stator)
    303
  - Voltage Regulator/Rectifier
    304
  - Battery
    305
  - Cable Terminal Installation
    307
- Starting System
  
  309
  - Troubleshooting
    311
- Accessories
  
  317
  - General
    317
  - 12-Volt Power Outlet (Cigarette-Lighter Type)
    318
  - Beeper (Reverse Alarm)
    318
  - Engine Temperature Gauge
    319
  - Electric Fuel Gauge
    320
  - Headlamp
    320
  - Headlamp Beam Aiming
    321
  - Heating Elements
    322
  - Relay
    322
  - Speedometer
    323
  - Speed Sensor
    323
  - Tachometer
    324
  - Taillight
    324
  - Visor Outlet
    325
Drive System

326
- Drive Belt
  
  326
  - Application Chart
    326
  - Inspection
    326
  - Checking Neutral Function
    326
  - Rotation Direction
    326
  - Drive Belt Height Measurement and Adjustment
    327
  - Drive Belt Deflection Measurement (Reference Only)
    329
- Drive Pulley
  
  331
  - Bombardier Lite
    332
    
    General
    333
    
    Removal
    333
    
    Disassembly
    333
    
    Cleaning
    334
    
    Inspection
    334
    
    Assembly
    334
    
    Installation
    335
  - Tra III
    336
    
    General
    337
    
    Removal
    337
    
    Disassembly
    337
    
    Cleaning
    339
    
    Inspection
    339
    
    Assembly
    341
    
    Installation
    345
    
    Drive Pulley Adjustment
    345
- Driven Pulley
  
  347
  - Formula Rer and Formula Vsa-R
    348
  - Removal
    349
  - Disassembly
    349
  - Cleaning
    349
  - Inspection
    349
  - Bushing Replacement
    350
  - Assembly
    350
  - Installation
    351
  - Adjustment
    352
  - Hpv Vsa
    353
  - Removal
    354
  - Disassembly
    354
  - Cleaning
    354
  - Inspection
    354
  - Assembly
    354
  - Installation
    355
  - Adjustment
    355
- Pulley Alignment
  
  357
  - General
    357
  - Measuring Procedure
    357
  - Alignment Procedure
    359
- Brake
  
  360
  - Hydraulic Brake
    361
    
    Brake Fluid
    362
    
    Master Cylinder
    362
    
    Caliper
    362
    
    Brake Pads
    363
    
    Brake Disc
    364
    
    Countershaft Bearing
    364
    
    Countershaft
    365
    
    Brake Light Switch
    365
    
    Bleeding
    366
- Chaincase
  
  367
  - General
    369
  - Chaincase Oil Level
    369
  - Oil Change
    369
  - Drive Chain Adjustment
    370
  - Removal and Disassembly
    370
  - Inspection
    371
  - Installation and Assembly
    371
  - Silent Chain
    371
- Drive Axle
  
  372
  - Removal
    376
  - Assembly
    377
  - Lubrication
    378
  - Adjustment
    378
- Track
  
  380
  - Track Type Application
    380
  - General
    380
  - Inspection
    380
  - Removal
    380
  - Installation
    380
  - Adjustment
    380
  - Track Cleat
    382
  - Traction Enhancing Products (Studs)
    382
Rear Suspension

385
- Sc Suspension
  
  385
  - Axle Self-Locking Screws Removal
    390
  - Rear Axle Removal
    390
  - Rear Axle Installation
    390
  - Rear Shock Absorber Removal
    390
  - Rear Shock Absorber Installation
    391
  - Front Shock Absorber Removal
    391
  - Front Shock Absorber Installation
    391
  - Rear Spring Removal
    392
  - Rear Spring Installation
    392
  - Slider Shoe Verification
    392
  - Slider Shoe Removal
    393
  - Slider Shoe Installation
    394
  - Suspension Removal
    394
  - Suspension Installation
    395
  - Front Arm Removal
    395
  - Front Arm Installation
    395
  - Rear Arm/Pivot Arm Removal
    396
  - Rear Arm Installation
    396
  - Stopper Strap
    396
  - Ride Adjustment
    397
  - Lubrication
    397
- Sc 3 Suspension
  
  398
  - Axle Self-Locking Screws Removal
    402
  - Rear Axle Removal
    402
  - Rear Axle Installation
    402
  - Rear Shock Absorber Removal
    402
  - Rear Shock Absorber Installation
    403
  - Front Shock Absorber Removal
    403
  - Front Shock Absorber Installation
    403
  - Rear Spring Removal
    403
  - Rear Spring Installation
    404
  - Slider Shoe Verification
    405
  - Slider Shoe Removal
    405
  - Slider Shoe Installation
    406
  - Suspension Removal
    406
  - Suspension Installation
    407
  - Front Arm Removal
    407
    
    Front Arm Installation
    408
    
    Rear Arm/Pivot Arm Removal
    408
    
    Rear Arm/Pivot Arm Installation
    408
    
    Stopper Strap
    409
    
    Ride Adjustment
    409
    
    Lubrication
    409
- Sc 4 Suspension
  
  411
  - Axle Self-Locking Screw Removal
    415
  - Rear Axle Removal
    415
  - Rear Axle Installation
    415
  - Rear Shock Absorber Removal
    415
  - Rear Shock Absorber Installation
    416
  - Front Shock Absorber Removal
    416
  - Front Shock Absorber Installation
    417
  - Rear Spring Removal
    417
  - Rear Spring Installation
    418
  - Slider Shoe Verification
    418
  - Slider Shoe Removal
    419
  - Slider Shoe Installation
    420
  - Suspension Removal
    420
  - Suspension Installation
    420
  - Front Arm Removal
    420
  - Front Arm Installation
    421
  - Rear Arm/Pivot Arm Removal
    421
  - Rear Arm/Pivot Arm Installation
    421
  - Block Installation
    422
  - Idler Wheels Installation
    422
  - Stopper Strap
    422
  - Ride Adjustment
    422
  - Lubrication
    423
- Shock Absorber Inspection and Servicing
  
  424
  - Spring Removal
    424
  - Shock Absorber Inspection
    425
  - Disassembly and Assembly
    426
Steering/Front Suspension

434
- Steering System
  
  434
  - Disassembly and Assembly
    438
  - Inspection
    441
  - Adjustment
    441
  - Steering Adjustment (Skis)
    445
  - Lubrication
    447
- Front Suspension
  
  448
  - General Inspection
    451
  - Disassembly
    451
  - Inspection
    455
  - Installation
    456
  - Stabilizer Bar
    458
Body/Frame

461
- Body
  
  461
  - Installation and Adjustment
    461
    
    Decal
    461
    
    Windshield
    461
    
    Guard
    461
    
    Wiring Harness
    461
    
    Cables
    462
    
    Tubing
    462
  - Plastic Maintenance and Repair
    462
    
    Maintenance
    462
    
    Repair
    462
- Frame
  
  463
  - Frame Cleaning
    463
  - Frame Welding
    463
  - Frame Component Replacement
    463
Technical Data

465
- Fan Cooled Models
  
  465
- Liquid Cooled Models
  
  470
- Liquid Cooled (Sdi) Models
  
  478
Wiring Diagram

484
Wiring Diagrams

484
- Wiring Diagram Legend
  484
- Wire Colors
  484
- Connector Housing Area
  484
- Housing Reference Per Area
  485
- Wire Location in Connector Housing
  485
- Symbols Description
  487
- Unpluging Connectors
  488
- Tab and Receptacle Connectors Removal
  488
- Tab and Receptacle Connectors Installation
  494

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