User Manuals: BRP ski-doo MACH Z 1000 SDI Snowmobile

Manuals and User Guides for BRP ski-doo MACH Z 1000 SDI Snowmobile. We have 1 BRP ski-doo MACH Z 1000 SDI Snowmobile manual available for free PDF download: Handbook

BRP ski-doo MACH Z 1000 SDI Handbook

BRP ski-doo MACH Z 1000 SDI Handbook (493 pages)

Brand: BRP | Category: Offroad Vehicle | Size: 30.25 MB

Table of Contents

2005 Racing Handbook

2
- Table of Contents
  2
- Contacting the Race Department
  3
MX Z X 440 Racing/MX Z 600 Ho/800Ho

8
- Models Technical Data
  9
- MX Z X 440 Racing
  9
- MX Z 600 Ho/800Ho
  12
- MX Z 380F/550F
  17
- Summit 600 Ho/800Ho
  21
- Mach Z 1000 Sdi/Summit 1000 Sdi
  26
- Technical Data Legend
  30
Table of Contents

31
- Suspension Operation/ Weight Transfer
  32
- Springs
  33
- Spring Description
  
  36
  - COIL SPRINGS (Compression)
    36
  - Torsion Springs
    37
- Spring Applications
  
  38
- Spring Specifications
  
  41
- Cornering Dynamics
  
  45
  - Shocks
    46
  - Chassis Set-Up
    57
  - Brakes
    59
  - Adjusting Ride Height
    60
  - Track Guides
    61
  - Skis and Runners
    61
  - Bump Steer
    62
  - Ski Leg Camber
    62
  - Ski Toe-Out
    63
  - Chassis Tuning Guidelines
    64
- Steering System
  
  66
  - Disassembly and Assembly
    68
  - Inspection
    71
  - Adjustment
    71
  - Steering Adjustment (Skis)
    75
  - Lubrication
    77
- Body
  
  78
  - Headlamp Beam Aiming
    78
  - Bulb Replacement
    78
  - Decal
    79
  - Windshield
    79
  - Guard
    80
  - Wiring Harness
    80
  - Cables
    80
  - Tubing
    80
  - Maintenance
    80
  - Repair
    81
- Frame
  
  82
  - Frame Cleaning
    82
  - Frame Welding
    82
  - Frame Replacement
    82
Suspension Sc-3 Sc-4 - Ras

83
- Front Suspension
  
  84
  - General Inspection
    85
  - Disassembly
    85
  - Inspection
    89
  - Installation
    89
- Sc-10 III Suspension
  
  94
  - Component Removal and Installation
    97
  - Suspension Assembly Removal
    98
  - Disassembly and Assembly
    99
  - Shock Absorber Inspection
    101
  - Hpg T/A Shock Servicing
    102
  - Installation
    110
  - Ride Adjustment
    110
  - Lubrication
    110
  - Internal Floating Piston Measurement
    111
  - Shock Rebuild Procedure
    113
  - C-36 Hpg
    116
  - Shock Calibration Work Sheet
    117
- Sc IV Rear Suspension
  
  118
  - On Rider Forward Vehicle
    120
  - Construction
    121
Engine Preparation

125
- Accessories
  126
  - Engine Tuning Cautions
    128
  - Basic Engine Theory
    128
  - Operation of the Rave Valve
    131
  - Carburetion
    135
  - Mikuni VM and Tm Type Carburetors
    139
  - Ignition Systems, Spark Plugs
    151
- Carburetor - VM Type
  
  154
  - Identification
    155
  - Removal
    155
  - Cleaning and Inspection
    155
  - Disassembly and Assembly
    155
  - Carburetor Float Level Adjustment
    156
  - Carburetor Adjustment
    157
  - Installation
    158
  - Choke
    159
- Carburetor Tm Type
  
  161
  - Identification
    162
  - Removal
    162
  - Cleaning and Inspection
    163
  - Disassembly and Assembly
    164
  - Carburetor Adjustment
    165
  - Installation
    167
- Dpm
  
  168
  - Testing
    168
  - Parts Removal and Installation
    168
  - Dpm Manifold Testing
    169
- Throttle Cable
  
  171
- Spark Plugs
  
  173
  - Disassembly
    173
  - Spark Plugs Installation
    173
  - Spark Plugs Tightening
    173
- Ignition Timing
  
  174
  - Checking Ignition Timing
    175
  - Changing Timing
    176
- Testing Procedure
  
  180
  - Checking Calibration Program
    183
  - Changing Mpem Calibration Program
    186
  - System Testing
    187
  - Inspection of Heating Elements
    194
  - Mmc2005-001_05A.fm
    194
- Fuel Tank and Fuel Pump
  
  196
  - Fuel Filter
    197
  - Fuel Tank
    197
  - Impulse/Fuel Lines Spring Clips (All Models)
    198
  - Float Type Fuel Level Gauge
    199
  - Electric Fuel Level Sensor
    199
  - Fuel Level Sensor Screws
    199
  - Fuel System Pressurization
    199
  - Fuel Pump
    200
  - Pump Verification
    201
  - Cleaning and Inspection
    201
- Exhaust System
  
  202
  - Tuned Pipe
    203
  - Manifold
    203
  - Muffler
    203
- Engine System
  
  205
  - Removal from Vehicle
    206
  - Inspection
    209
  - Installation
    209
  - Troubleshooting
    212
  - Component Removal with the Engine Installed
    212
  - Cleaning
    212
  - Rave Valve Basic Operation
    213
  - Disassembly
    213
  - Inspection
    217
  - Assembly
    218
  - Cleaning
    225
  - Disassembly
    225
  - Inspection
    226
  - Assembly
    226
  - Break-In
    231
- Engine Leak Test and Dimension Measurement
  
  232
  - Leak Test
    232
  - Preparation
    232
  - Procedure
    232
  - Finalizing Reassembly
    234
  - Engine Leak Verification Flow Chart
    235
  - Engine Dimension Measurement
    236
  - Cylinder Head Warpage
    236
  - Cylinder out of Round
    236
  - Combustion Chamber Volume Mesurement
    236
  - Used Piston Mesurement
    238
  - Cylinder/Piston Clearance
    238
  - Ring/Piston Grove Clearance
    240
  - Ring End Gap
    240
  - Crankshaft Deflection
    240
  - Connecting Rod Big End Axial Play
    241
  - Crankshaft End Play
    241
  - Checking Crankshaft Alignment
    241
- Magneto System
  
  242
  - General
    244
  - Cleaning
    244
  - Disassembly
    244
  - Assembly
    245
- Oil Injection System
  
  247
  - General
    248
  - Oil Type
    248
  - Oil System Leak Test
    248
  - Oil Pump Identification
    249
  - Cleaning
    249
  - Disassembly
    249
  - Assembly
    250
  - Adjustment
    251
  - Checking Operation
    252
- Liquid Cooling System
  
  253
  - Cooling System Leak Test
    255
  - Inspection
    255
  - Draining the System
    255
  - Disassembly and Assembly
    255
  - Cooling System Refilling Procedure
    257
- Rewind Starter
  
  258
  - Inspection
    259
  - Removal
    259
  - Rope Replacement
    259
  - Disassembly
    259
  - Assembly
    260
  - Installation
    262
Drive System

263
- Basic Functions of the System
  265
- Effects of the Drive Pulley Lever Arm, Roller and Roller Pin Weight
  266
- Effects of the Ramp Profile on the Shift Force
  269
- Ramp Characteristics
  271
- Effects of the Drive Pulley Spring
  272
- Tuning Components
  275
- Vsa
  275
- Drive Pulley Tra III
  
  276
  - General
    277
  - Removal
    277
  - Disassembly
    277
  - Cleaning
    279
  - Inspection
    279
  - Assembly
    279
  - Installation
    283
  - Drive Pulley Adjustment
    283
  - Kit P/N 486 400 003 Tra III Weight Set-Up for Pin
    285
  - Tra Springs Chart
    290
  - Effects of the Driven Pulley Spring
    292
  - Hpv 27 Vsa Clutch Springs
    293
  - Effects of the Driven Pulley Cam
    294
  - Driven Clutch Cams
    295
- Formula Vsa
  
  297
  - Removal
    298
  - Disassembly
    298
  - Cleaning
    298
  - Inspection
    299
  - Assembly
    299
  - Installation
    299
  - Adjustment
    299
- Hpv27 Vsa
  
  301
  - Removal
    302
  - Disassembly
    302
  - Cleaning
    302
  - Inspection
    302
  - Assembly
    303
  - Installation
    303
  - Adjustment
    303
  - Springs
    306
  - Adjusting Belt Deflection on the Team Roller Secondary
    306
  - Belt Removal on Team Roller Secondary
    307
  - Measuring Belt Deflection
    307
  - Team Secondary Clutch Maintenance/Adjustment
    308
  - Installation
    309
  - Troubleshooting
    309
  - General
    313
  - General Procedure
    313
  - Pulley Alignment and Distance Specifications Chart
    314
  - Drive Belts
    315
  - Inspection
    317
  - Checking Neutral Function
    317
  - Rotation Direction
    317
  - Drive Belt Height Measurement and Adjustment
    318
  - DRIVE BELT DEFLECTION MEASUREMENT (Reference Only)
    320
  - Chaincase Gearing
    321
  - Chaincase Gears and Chains
    324
  - Transmission Tuning Test Sheet
    326
  - Racers Log
    327
- Hydraulic Brake
  
  328
  - Brake Fluid Type
    329
  - Caliper
    329
  - Brake Pads Replacement
    329
  - Removal
    330
  - Disassembly
    331
  - Cleaning
    331
  - Inspection
    331
  - Installation
    331
  - Adjustment
    332
  - Bleeding
    332
  - Removal and Disassembly
    334
  - Inspection
    334
  - Gear Ratio Modification
    334
  - Installation and Assembly
    335
  - Drive Chain Adjustment
    335
  - Adjustment
    336
  - Removal
    338
  - Assembly
    339
  - Lubrication
    340
  - Adjustment
    340
  - Track Type Application
    341
  - General
    341
  - Inspection
    341
  - Removal
    341
  - Installation
    341
  - Adjustment
    341
2005 MX Z X 440 Lc Rev

344
- 2005 MX Z X 440 Lc Rev
  345
- Drivetrain
  345
- Engine
  345
- Holeshot Button
  345
- Ignition System
  345
- Sc-4 Rear Suspension
  346
- Track & Traction
  346
- 2005 Option Package Color
  347
Table of Contents

354
- And 552 Engine Type
  
  358
  - Engine Removal and Installation
    358
- Top End
  
  360
  - General
    362
  - Troubleshooting
    362
  - Cleaning
    362
  - Disassembly
    362
  - Inspection
    364
  - Assembly
    364
- Bottom End
  
  371
  - Cleaning
    373
  - Disassembly
    373
  - Inspection
    374
  - Assembly
    374
- Oil Injection System
  
  380
  - General
    381
  - Oil System Leak Test
    381
  - Oil Pump Identification
    382
  - Cleaning
    382
  - Disassembly
    382
  - Assembly
    383
  - Adjustment
    384
  - Checking Operation
    385
- Axial Fan Cooling System
  
  386
  - Removal
    387
  - Cleaning
    387
  - Disassembly and Assembly
    387
  - Installation
    388
  - Fan Belt Replacement and Deflection Adjustment
    388
- Drive Pulley
  
  392
  - Bombardier Lite
    392
  - General
    393
  - Removal
    393
  - Disassembly
    393
  - Cleaning
    394
  - Inspection
    394
  - Assembly
    394
  - Installation
    394
- Ignition Timing
  
  396
  - Verifying Magneto Flywheel Timing Mark Position
    396
  - Checking Ignition Timing
    397
  - Mod Engine Kit
    399
Table of Contents

407
- 1010 MX Z X 440 Rev Drive Sprocket Replacement
  
  420
- 2004 Ski-Doo MX Z Racing Tip Sheet
  
  420
Competition Preparation

423
- Hillcross
  424
- Sno Cross
  424
- Drag Racing (Ice and Grass)
  425
- Hill Climbing
  425
- Oval Racing
  427
- Speed Runs
  427
- Suggested Spare Parts
  429
- Equivalent Weights and Measures Chart
  431
- Fuel/Oil Ratio Charts
  432
- Stock Class Preparation
  437
  - Service Tools
    445

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