User Manuals: Ski-Doo Mach Z R Snowmobile

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

Ski-Doo Mach Z R Shop Manual

Ski-Doo Mach Z R Shop Manual (304 pages)

Brand: Ski-Doo | Category: Snowmobiles | Size: 42 MB

Table of Contents

Table of Contents

4
- Section Subsection Page
  5
- Safety Notice
  6
- What's New
  7
- Introduction
  8
- 01 Service Tools and Service Products
  9
- Service Tools
  19
- Service Products
  31
- Lubrication and Maintenance Chart
  38
Troubleshooting/Engine

44
- Electrical System
  44
- Engine
  44
- Fuel and Oil Systems
  44
- Table of Contents
  44
- Transmission and Brake Systems
  44
- Troubleshooting
  44
- Engine
  45
- Engine Leak Verification Flow Chart
  55
- Transmission
  59
- Transmission and Brake Systems
  59
- Brake System
  65
- Hydraulic Brake
  65
- Electrical System
  66
- Suspension and Track
  76
Table of Contents

80
- 599, 699 and 809 Engine Types
  83
- Engine Removal and Installation
  83
- Removal from Vehicle
  84
- Installation on Vehicle
  85
- Top End
  86
- Cleaning
  87
- Component Removal
  87
- Disassembly
  87
- Assembly
  88
- Inspection
  88
- Bottom End
  92
- Cleaning
  93
- Disassembly
  93
- Inspection
  93
- Assembly
  94
- Leak Test
  96
- Leak Test and Engine Dimension Measurement
  96
- Preparation
  96
- Procedure
  96
- Cooling System Leak Test
  99
- Finalizing Reassembly
  99
- Engine Leak Verification Flow Chart
  100
- Combustion Chamber Volume Measurement
  101
- Cylinder Head Warpage
  101
- Cylinder out of Round
  101
- Cylinder Taper
  101
- Engine Dimension Measurement
  101
- Cylinder/Piston Clearance
  103
- Used Piston Measurement
  103
- Ring End Gap
  104
- Ring/Piston Groove Clearance
  104
- Connecting Rod Big End Axial Play
  105
- Crankshaft Deflection
  105
- Checking Surface Flatness
  106
- Connecting Rod/Crankpin Clearance
  106
- Connecting Rod/Piston Pin Clearance
  106
- Crankshaft End-Play
  106
- Rectifying Surfaces
  106
- CDI System
  108
- Nippondenso Trigger Coil Ignition System
  108
- Cleaning
  109
- Disassembly
  109
- Assembly
  111
- Oil Injection System
  112
- Assembly
  113
- Cleaning
  113
- Disassembly
  113
- Oil Injection Pump
  113
- Oil Pump Identification
  113
- Adjustment
  114
- Checking Operation
  115
- Liquid Cooling System
  116
- Disassembly and Assembly
  117
- Draining the System
  117
- Inspection
  117
- Cooling System Refilling Procedure
  118
- Rewind Starter
  119
- Assembly
  120
- Disassembly
  120
- Removal
  120
- Installation
  122
- Carburetor and Fuel Pump
  123
- Cleaning and Inspection
  125
- Removal
  125
- Disassembly and Assembly
  126
- Identification
  126
- Carburetor Float Level Adjustment
  127
- Installation
  128
- Carburetor Adjustments
  129
- Choke
  132
- Idle Speed Final Adjustment
  132
- Preliminary Idle Speed Adjustment
  132
- Dpm
  136
- Method
  137
- Overall System Operation
  137
- Purpose
  137
- Dpm Module Operation
  138
- Air Pump Operation
  143
- Dpm Manifold Operation
  143
- Testing Procedure
  145
- Fuel Pump
  147
- Cleaning and Inspection
  148
- Installation
  148
- Pump Verification
  148
- Removal
  148
- Fuel Tank and Throttle Cable
  149
Table of Contents

151
- 1998 Application Chart
  153
- Drive Belt
  153
- Rotation Direction
  153
- Drive Belt Deflection Measurement
  154
- Deflection Adjustment
  155
- Drive Pulley
  156
- Tra
  156
- General
  157
- Removal
  157
- Disassembly
  158
- Cleaning
  159
- Inspection
  159
- Assembly
  161
- Installation
  163
- Drive Pulley Adjustment
  164
- Driven Pulley
  166
- Cleaning
  167
- Disassembly
  167
- Removal
  167
- Inspection
  168
- Assembly
  169
- Adjustment
  170
- Installation
  170
- General
  172
- General Procedure
  172
- Pulley Distance and Alignment
  172
- Pulley Alignment and Distance Specifications Chart
  173
- Brake
  175
- Hydraulic Disc Brake
  175
- Cleaning
  176
- Disassembly
  176
- Inspection
  176
- Installation
  176
- Removal
  176
- Adjustment
  177
- Bleeding
  177
- Chaincase
  178
- Gear Ratio Modification
  179
- Inspection
  179
- Installation
  179
- Removal
  179
- Drive Chain Adjustment
  180
- Adjustment
  181
- Gearbox
  182
- Assembly
  183
- Disassembly
  183
- Inspection
  183
- Adjustment
  185
- Oil Change
  185
- Drive Chain
  186
- Silent Chain
  186
Table of Contents

187
- Ignition Timing
  189
- Nippondenso Trigger Coil System
  189
- Ngk Spark Plug
  192
- Ngk Spark Plug Numbering System
  192
- Reference Chart
  192
- Spark Plugs
  192
- Design Symbols Used in Ngk Spark Plugs
  193
- Disassembly
  194
- Fouling
  194
- Heat Range
  194
- Spark Plug Analysis
  194
- Spark Plug Installation
  195
- Spark Plug Tightening Torque
  195
- Battery
  196
- Cleaning
  196
- Removal
  196
- Hydrometer Test
  197
- Inspection
  197
- Activation of New Battery
  198
- Battery Storage
  198
- Servicing
  201
- Tips for Charging a Used Battery
  201
- Battery Charging Equipment
  202
- Installation of Battery
  202
- Electric Starter
  204
- Installation
  205
- Removal
  205
- Solenoid Switch
  205
- General
  206
- Testing Procedure
  206
- Electrical Connector Testing
  207
- Ignition System Testing Sequence
  207
- Lighting System Testing Sequence
  207
- Sparking
  207
- System Testing
  207
- Ignition Switch, Tether Cord Switch and Emergency Switch Testing
  208
- Ignition Generator Coil Voltage Testing
  209
- Ignition Module Voltage Testing
  209
- Trigger Coil Testing
  209
- High Voltage Coil Voltage Testing
  210
- Mpem Supply Voltage Testing
  210
- Mpem Testing
  210
- Conclusion
  211
- Electric Accessories Testing
  211
- Lighting Generator Coil Voltage Testing
  211
- Inspection
  217
- Inspection of Ac Circuit Isolation
  217
- Inspection of Heating Elements
  218
Table of Contents

219
- Sc-10 Suspension
  220
- Component Removal and Installation
  222
- Disassembly and Assembly
  224
- Removal
  224
- Shock Absorber Inspection
  226
- Installation
  227
- Ride Adjustment
  227
- Lubrication
  228
- Drive Axle
  229
- Assembly
  230
- Disassembly
  230
- Removal
  230
- Axial Play
  232
- Installation
  234
- Adjustment
  235
- Lubrication
  235
- General
  236
- Inspection
  236
- Installation
  236
- Removal
  236
- Track
  236
- Track Type Application
  236
Table of Contents

239
- Steering System
  240
- Disassembly and Assembly
  241
- Inspection
  245
- Steering Adjustment (Skis)
  246
- Lubrication
  249
- Suspension and Ski System
  250
- Disassembly
  251
- Inspection
  252
- Installation
  252
- Adjustment
  253
Table of Contents

254
- Body
  255
- Bulb Replacement
  255
- Headlamp Beam Aiming
  255
- Installation and Adjustment
  255
- Decal
  256
- Hood
  256
- Windshield Installation
  256
- Half Bottom Pan
  257
- Belt Guard
  258
- Cables
  258
- Piping
  258
- Wiring Harness
  258
- Maintenance
  259
- Plastic Maintenance
  259
- Frame
  260
- Frame Cleaning
  260
- Frame Component Replacement
  260
- Frame Welding
  260

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