Ski-Doo 2005 MACH Z Manuals

Manuals and User Guides for Ski-Doo 2005 MACH Z. We have 1 Ski-Doo 2005 MACH Z manual available for free PDF download: Shop Manual

Ski-Doo 2005 MACH Z Shop Manual

Ski-Doo 2005 MACH Z Shop Manual (343 pages)

Brand: Ski-Doo | Category: Offroad Vehicle | Size: 82 MB

Table of Contents

Table of Contents
5
Safety Notice

13
Introduction

14
- Vehicle Identification Number
  14
- Engine Serial Number
  14
- List of Abbreviations Used in this Manual
  14
- Arrangement of this Manual
  16
- General Information
  18
- Illustrations and Procedures
  18
- Self-Locking Fasteners Procedure
  18
- Loctite Application Procedure
  19
- Threadlocker
  19
- Stripped Thread Repair
  20
- Gasket Compound
  21
- Mounting on Shaft
  21
- Case-In Components
  22
- Tightening Torque
  22
Maintenance

26
- Maintenance Chart
  
  26
- Storage
  
  28
  - General
    28
  - Engine
    28
  - Fuel System
    29
  - Drive System
    29
  - Steering/Front Suspension
    30
  - Suspension
    30
  - Electrical
    30
  - Vehicle
    30
- Preseason Preparation
  
  32
  - Engine
    32
  - Fuel System
    32
  - Drive System
    33
  - Electrical System
    33
  - Vehicle
    33
Engine

34
- Leak Test
  
  34
  - Preparation
    34
  - Procedure
    36
  - Finalizing Reassembly
    38
  - Engine Leak Verification Flow Chart
    39
- Air Intake System
  
  40
Engine Removal and Installation

49
- Removal from Vehicle
  51
- Inspection
  55
- Installation
  56
Magneto System

58
- General
  60
- Magneto Flywheel
  60
- Stator
  61
- Cps
  62
E-Rave System

63
- General
  65
- E-Rave System Dynamic Test
  65
- E-Rave Cables
  65
- E-Rave Actuator
  68
- E-Rave Cover
  69
- E-Rave Shaft
  69
- E-Rave Housing
  71
- E-Rave Valves
  71
Top End

72
- Troubleshooting
  74
- General
  74
- Component Removal with the Engine Installed
  74
- Disassembly
  74
- Cleaning
  75
- Inspection
  76
- Assembly
  77
- Piston Circlip Installer
  78
Bottom End

81
- Service Products
  81
- Description Part Number Page
  81
- Loctite Chisel
  81
- Molykote 111
  82
- Troubleshooting
  84
- General
  84
- Preparation
  84
- Cleaning
  84
- Disassembly
  84
- Inspection
  89
- Assembly
  89
- Break-In
  93
Engine Measurement

94
- Cylinder Head Warpage
  94
- Cylinder Taper
  94
- Cylinder out of Round
  94
- Combustion Chamber Volume Measurement
  95
- Used Piston Measurement
  96
- Cylinder/Piston Clearance
  97
- Ring/Piston Groove Clearance
  98
- Ring End Gap
  98
- Crankshaft Deflection
  98
- Connecting Rod Big End Axial Play
  99
- Checking Crankshaft Alignment
  99
Cooling System

101
- Cooling System Leak Test
  103
  - Inspection
    103
  - Draining the System
    103
  - Disassembly and Assembly
    104
  - Cooling System Refilling Procedure
    105
- Rewind Starter
  
  106
  - General
    108
  - Inspection
    108
  - Removal
    108
  - Rope Replacement
    108
  - Disassembly
    108
  - Assembly
    109
  - Installation
    111
- Oil Injection System
  
  112
  - General
    114
  - Oil Type
    114
  - Oil System Leak Test
    114
  - Oil Pump Identification
    115
  - Cleaning
    115
  - Removal
    115
  - Checking Operation
    116
  - Installation
    116
  - Bleeding Procedure
    117
  - Adjustment
    118
Fuel System

119
- Fuel Tank and Fuel Pumps
  
  119
- Fuel Tank
  120
  - In-Tank Fuel Filter Removal
    121
  - In-Tank Fuel Filter Installation
    121
  - In-Line Fuel Filter Removal
    122
  - In-Line Fuel Filter Installation
    122
  - Fuel Tank Removal
    122
  - Fuel Tank Installation
    123
  - Float-Type Fuel Level Gauge Removal/Installation
    123
  - Electric Fuel Level Sensor Inspection
    124
  - Fuel System Pressurization
    124
- Electric Fuel Pump
  125
  - Diagnostic Flow Chart
    125
  - Electric Fuel Pump Pressure Test
    126
- Electric Fuel Pump
  127
- Diaphragm Fuel Pump
  130
Engine Management (Sdi)

133
- Overview
  
  133
  - Operating Principle
    134
    
    Charging System
    134
    
    Ignition System
    134
    
    Air Induction
    134
    
    Fuel Delivery System
    135
  - Engine Management System (Ems)
    136
    
    Ems - Engine Management System Functions
    138
    
    Power Distribution
    138
    
    Fuel Injection
    139
    
    Ignition System
    139
    
    Electronically Controlled Rave (E-Rave)
    139
    
    Digitally Encoded Security System (Dess)
    139
    
    Rotax Electronic Reverse (Rer)
    140
    
    Monitoring System
    140
    
    Diagnostic Mode
    141
- Diagnostic Procedure
  
  142
  - General
    142
  - Troubleshooting
    143
  - Ems Fault Codes
    143
  - Vck (Vehicle Communication Kit)
    147
- Component Inspection, Replacement and Adjustment
  
  150
  - General
    150
    
    Fuel System
    150
    
    Electrical System
    151
  - Testing Procedures
    155
    
    Electric Fuel Pump
    155
    
    Fuel Injectors
    155
    
    Engine Control Module (Ecm)
    159
    
    Engine Wiring Harness
    160
    
    Throttle Body
    160
    
    Throttle Position Sensor (Tps)
    163
    
    Crankshaft Position Sensor (Cps)
    165
    
    Air Temperature Sensor (Ats)
    166
    
    Coolant Temperature Sensor (Cts)
    167
    
    Air Pressure Sensor (Aps)
    168
    
    Knock Sensor (Ks)
    169
    
    E-Rave Actuator
    169
    
    Double Ignition Coil
    170
    
    Battery
    172
    
    Capacitor
    172
    
    Engine Start/Rer Switch Verification
    173
    
    Dess Post Verification
    173
Electrical System

174
- Ignition System
  
  174
  - General
    174
  - Ignition Timing
    175
  - Spark Plug
    177
  - Design Symbols Used in Ngk Spark Plugs
    179
- Charging System
  
  180
  - General
    180
  - Charging Generator Coil (Stator)
    180
  - Voltage Regulator/Rectifier
    181
  - Battery
    181
  - Cable Terminal Installation
    183
- Starting System
  
  185
  - General
    185
  - Component Testing
    185
  - Starter Removal
    188
  - Starter Installation
    188
- Rotax Electronic Reverse (Rer)
  
  189
  - Troubleshooting
    189
- Accessories and Lighting System
  
  190
  - General
    190
  - 12-Volt Power Outlet (Cigarette-Lighter Type)
    191
  - Beeper (Reverse Alarm)
    191
  - Engine Temperature Gauge
    192
  - Electric Fuel Gauge
    192
  - Headlamp
    193
  - Headlamp Beam Aiming
    194
  - Heating Elements
    194
  - Relay
    194
  - Speedometer
    195
  - Speed Sensor
    196
  - Tachometer
    196
  - Taillight
    197
  - Visor Outlet
    197
Drive System

198
- Drive Belt
  
  198
  - Application Chart
    198
  - Inspection
    198
  - Checking Neutral Function
    198
  - Rotation Direction
    198
  - Drive Belt Height Measurement and Adjustment
    199
  - Drive Belt Deflection Measurement (Reference Only)
    200
- Drive Pulley
  
  202
  - General
    204
  - Removal
    204
  - Disassembly
    204
  - Cleaning
    206
  - Inspection
    206
  - Assembly
    208
  - Installation
    211
  - Drive Pulley Adjustment
    212
- Driven Pulley
  
  214
  - Hpv Roller
    215
    
    General
    216
    
    Removal
    216
    
    Disassembly
    216
    
    Cleaning
    217
    
    Inspection
    217
    
    Assembly
    218
    
    Installation
    218
  - Bushing Replacement
    218
  - Hpv Vsa
    221
    
    General
    222
    
    Removal
    222
    
    Disassembly
    222
    
    Cleaning
    222
    
    Inspection
    222
    
    Assembly
    223
    
    Installation
    223
    
    Adjustment
    223
Pulley Alignment

226
- General
  226
- Measuring Procedure
  226
- Alignment Procedure
  227
Brake

228
- General
  230
- Countershaft Bearing
  230
- Countershaft
  230
- Brake Fluid
  230
- Draining
  230
- Bleeding
  230
- Master Cylinder
  230
- Brake Pads
  231
- Caliper
  232
- Brake Disc
  233
- Brake Light Switch
  234
Chaincase

235
- General
  237
- Chaincase Oil Level
  237
- Oil Change
  237
- Drive Chain Adjustment
  237
- Chaincase Cover
  237
- Tensioner
  238
- Tensioner Roller Bearing
  238
- Drive Chain and Sprockets
  239
- Chaincase Housing
  240
- Chaincase Housing Bearings
  241
- Countershaft
  241
- Countershaft Bearing
  241
Drive Axle

244
- Removal
  247
- Assembly
  247
- Lubrication
  249
- Adjustment
  249
Track

250
- Track Type Application
  250
- General
  250
- Inspection
  250
- Removal
  250
- Installation
  250
- Adjustment
  250
- Track Cleat
  252
- Traction Enhancing Products (Studs)
  252
Rear Suspension

254
- Sc Suspension
  
  254
  - Axle Self-Locking Screws Removal
    258
  - Rear Axle Removal
    258
  - Rear Axle Installation
    258
  - Rear Shock Absorber Removal
    258
  - Rear Shock Absorber Installation
    259
  - Front Shock Absorber Removal
    259
  - Front Shock Absorber Installation
    259
  - Rear Spring Removal
    260
  - Rear Spring Installation
    260
  - Slider Shoe Verification
    261
  - Slider Shoe Removal
    261
  - Slider Shoe Installation
    262
  - Front Arm Removal
    262
  - Front Arm Installation
    263
  - Rear Arm/Pivot Arm Removal
    263
  - Rear Arm Installation
    263
  - Stopper Strap
    264
  - Suspension Removal
    264
  - Suspension Installation
    265
  - Ride Adjustment
    265
  - Lubrication
    265
- Sc 4 Suspension
  
  266
  - Axle Self-Locking Screw Removal
    270
  - Rear Axle Removal
    270
  - Rear Axle Installation
    270
  - Rear Shock Absorber Removal
    270
  - Rear Shock Absorber Installation
    271
  - Front Shock Absorber Removal
    271
  - Front Shock Absorber Installation
    272
  - Rear Spring Removal
    272
  - Rear Spring Installation
    273
  - Slider Shoe Verification
    273
  - Slider Shoe Removal
    274
  - Slider Shoe Installation
    275
  - Front Arm Removal
    275
  - Front Arm Installation
    275
  - Rear Arm/Pivot Arm Removal
    275
  - Rear Arm/Pivot Arm Installation
    276
  - Block Installation
    276
  - Idler Wheels Installation
    276
  - Stopper Strap
    276
  - Suspension Removal
    277
  - Suspension Installation
    277
  - Ride Adjustment
    277
  - Lubrication
    278
- Shock Absorber Inspection and Servicing
  
  279
  - Spring Removal
    279
  - Shock Absorber Inspection
    279
  - Disassembly and Assembly
    280
Steering/Front Suspension

288
- Steering System
  
  288
  - Disassembly and Assembly
    291
  - Steering Column
    293
  - Inspection
    295
  - Adjustment
    295
  - Steering Adjustment (Skis)
    297
  - Lubrication
    298
- Front Suspension
  
  299
  - General Inspection
    303
  - Disassembly
    303
  - Inspection
    308
  - Installation
    308
Body/Frame

313
- Body
  
  313
  - Decal
    313
  - Hood
    313
  - Front Bumper
    313
  - Bottom Pan
    314
  - Windshield
    314
  - Access Panel
    314
  - Indicator Panel
    314
  - Console
    315
  - Seat
    315
  - Plastic Maintenance and Repair
    316
- Frame
  
  318
  - Frame Cleaning
    318
  - Frame Component Replacement
    318
  - Frame Welding
    318
Technical Data

323
- Mach Z/Summit 1000 Sdi
  
  323
  - Technical Data Legend
    327
- 1 Wiring Diagrams
  
  328
Wiring Diagrams

328
- Wiring Diagram Legend
  328
- Wire Colors
  328
- Connector Housing Area
  328
- Housing Reference Per Area
  329
- Wire Location in Connector Housing
  329
- Symbols Description
  331
- Unplugging Connectors
  332
- Tab and Receptacle Connectors Removal
  332
- Tab and Receptacle Connectors Installation
  338

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