Ski-Doo TOURING SLE 1997 Snowmobile Parts Manuals

Manuals and User Guides for Ski-Doo TOURING SLE 1997 Snowmobile Parts. We have 1 Ski-Doo TOURING SLE 1997 Snowmobile Parts manual available for free PDF download: Shop Manual

Ski-Doo TOURING SLE 1997 Shop Manual (926 pages)

Brand: Ski-Doo | Category: Snowmobiles | Size: 72 MB

Table of Contents

4
- Safety Notice
  6
Table of Contents

19
- Engine
  20
- Fuel and Oil Systems
  30
- Transmission and Brake Systems
  33
  - Transmission
    33
  - Brake System
    39
  - Mechanical Brake
    39
  - Hydraulic Brake
    39
  - Mechanical and Hydraulic Brakes
    40
- Electrical System
  41
- Suspension System and Track
  50
Table of Contents

53
- Engine Removal and Installation
  
  56
- 277 Engine Type
  
  56
- Top End
  
  58
  - Troubleshooting
    59
  - Top End Removal (Without Removing Engine from Chassis)
    59
  - Cleaning
    59
  - Disassembly
    59
  - Inspection
    60
  - Assembly
    60
- Bottom End
  
  62
  - Cleaning
    63
  - Disassembly
    63
  - Inspection
    63
  - Assembly
    63
- 377, 443 and 503 Engine Types
  
  66
- Engine Removal and Installation
  
  66
  - Engine Removal and Installation
    68
- Leak Test and Engine Dimension Measurement
  
  78
- Leak Test
  
  78
  - Preparation
    78
  - Procedure
    78
  - Finalizing Reassembly
    81
  - Cooling System Leak Test
    81
- Engine Dimension Measurement
  
  82
  - Cylinder Taper
    82
  - Cylinder out of Round
    82
  - Cylinder / Piston Clearance
    82
  - Ring / Piston Groove Clearance
    83
  - Ring End Gap
    83
  - Crankshaft Deflection
    83
  - Connecting Rod Big End Axial Play
    84
  - Connecting Rod / Piston Pin Clearance
    84
  - Connecting Rod / Crankpin Clearance
    85
  - Crankshaft End-Play
    85
  - Checking Surface Flatness
    87
  - Rectifying Surfaces
    87
  - Checking Crankshaft Alignment
    87
- Nippondenso Ignition System with Single Generating Coil
  
  88
  - Cleaning
    89
  - Disassembly
    89
  - Repair
    89
  - Assembly
    91
- CDI System
  
  88
- Ducati Ignition System
  
  92
  - Cleaning
    93
  - Disassembly
    93
  - Repair
    93
  - Assembly
    94
- Oil Injection System
  
  95
- Oil Injection Pump
  
  95
  - Oil Pump Identification
    97
  - Cleaning
    97
  - Disassembly
    97
  - Assembly
    97
  - Adjustment
    97
  - Checking Operation
    98
- Axial Fan Cooling System
  
  100
  - Removal
    101
  - Cleaning
    101
  - Disassembly and Assembly
    101
- Rewind Starter
  
  103
  - Removal
    105
  - Disassembly
    105
  - Assembly
    105
  - Installation
    106
- Carburetor and Fuel Pump
  
  108
  - Removal
    109
  - Cleaning and Inspection
    109
  - Identification
    109
  - Disassembly and Assembly
    109
  - Carburetor Float Level Adjustment
    110
  - Installation
    111
  - Carburetor Adjustments
    112
  - Preliminary Idle Speed Adjustment
    114
  - Idle Speed Final Adjustment
    114
  - Choke
    115
- Fuel Pump
  
  116
  - Removal
    117
  - Pump Verification
    117
  - Disassembly
    117
  - Cleaning and Inspection
    117
  - Assembly
    118
  - Installation
    118
- Fuel Tank and Throttle Cable
  
  119
Table of Contents

121
- 1997 Application Chart
  
  123
  - Rotation Direction
    123
  - Drive Belt Deflection Measurement
    124
  - Deflection Adjustment
    125
- Drive Belt
  
  123
- Drive Pulley
  
  127
- Bombardier Lite
  
  127
  - General
    128
  - Removal
    128
  - Disassembly
    128
  - Cleaning
    129
  - Inspection
    129
  - Assembly
    129
  - Installation
    129
- Tra
  
  130
  - General
    131
  - Removal
    131
  - Disassembly
    131
  - Cleaning
    132
  - Inspection
    133
  - Assembly
    135
  - Installation
    137
  - Drive Pulley Adjustment
    138
- Driven Pulley
  
  140
  - Removal
    141
  - Disassembly
    141
  - Inspection
    142
  - Assembly
    142
  - Installation
    143
  - Adjustment
    143
  - Removal
    146
  - Disassembly
    146
  - Cleaning
    146
  - Inspection
    146
  - Assembly
    148
  - Installation
    148
  - Adjustment
    149
- Pulley Distance and Alignment
  
  151
  - General
    151
  - General Procedure
    151
  - Pulley Alignment and Distance Specifications Chart
    152
- Brake
  
  155
- Mechanical Disc Brake
  
  155
- Hydraulic Disc Brake
  
  157
  - Removal
    158
  - Disassembly
    159
  - Cleaning
    159
  - Inspection
    160
  - Assembly
    160
  - Installation
    160
  - Adjustment
    161
- Chaincase
  
  163
  - Removal
    164
  - Disassembly
    164
  - Inspection
    164
  - Gear Ratio Modification
    164
  - Assembly
    165
  - Installation
    165
  - Adjustment
    166
  - Removal
    168
  - Inspection
    168
  - Installation
    168
  - Drive Chain Adjustment
    169
  - Adjustment
    170
- 2-Speed Gearbox
  
  171
  - Disassembly
    172
  - Inspection
    172
  - Assembly
    172
  - Adjustment
    174
  - Oil Change
    175
- Gearbox
  
  171
- Drive Chain
  
  176
  - General
    176
  - Silent Chain
    176
  - Chain Attachment
    176
  - Chain Separation
    176
Table of Contents

178
- Tab and Receptacle Connectors Installation
  182
- Accessories Installation
  183
- Ignition Timing
  
  184
- Nippondenso CDI System (Without Trigger Coil)
  
  184
- Ducati CDI System
  
  188
- Ngk Spark Plug
  
  191
  - Ngk Spark Plug Numbering System
    191
  - 1997 Reference Chart
    191
- Spark Plugs
  
  191
- Design Symbols Used in Ngk Spark Plugs
  
  192
  - Disassembly
    193
  - Heat Range
    193
  - Fouling
    193
  - Spark Plug Analysis
    193
  - Spark Plug Installation
    194
  - Spark Plug Tightening Torque
    194
- Battery
  
  195
  - Removal
    195
  - Cleaning
    195
  - Inspection
    196
  - Hydrometer Test
    196
  - Battery Storage
    197
  - Activation of New Battery
    197
  - Servicing
    199
  - Tips for Charging a Used Battery
    199
  - Battery Charging Equipment
    200
  - Installation of Battery
    201
- Electric Starter
  
  202
  - Removal
    203
  - Disassembly
    203
  - Cleaning and Inspection
    205
  - Installation
    206
- Cleaning and Inspection
  
  207
  - Cleaning
    207
  - Inspection
    207
  - Solenoid Switch
    209
- Testing Procedure
  
  210
  - General
    210
  - Use of Bombardier Ignition Tester
    211
- Nippondenso CDI System Testing
  
  213
  - Ignition Coil Output
    213
  - Ignition Module Output
    213
  - Magneto Output
    214
  - Lighting Generator Coil Output
    215
  - Summary Table
    216
  - Resistance Measurements
    216
- Ducati CDI System Testing
  
  218
  - Trigger Coil Output
    218
  - Magneto Output
    218
  - Ignition Coil Output
    219
  - Ignition Module
    219
  - Lighting Generator Coil Output
    219
  - Summary Table
    220
  - Resistance Measurements
    221
- Voltage Regulator Inspection
  
  222
- Inspection of Ac Circuit Isolation
  
  223
  - Inspection
    223
- Inspection of Heating Elements
  
  224
Table of Contents

225
- Torque Reaction Suspension
  
  226
  - Component Removal
    227
  - Removal
    227
  - Disassembly and Assembly
    227
  - Inspection
    228
  - Ride Adjustment
    228
- Lubrication
  
  231
- Sport and Touring Suspension
  
  232
  - Component Removal and Installation
    233
  - Removal
    233
  - Disassembly and Assembly
    234
  - Inspection
    235
  - Installation
    236
  - Ride Adjustment
    236
  - Lubrication
    238
- Drive Axle
  
  239
  - Removal
    240
  - Disassembly
    240
  - Assembly
    240
  - Axial Play
    242
  - Installation
    245
  - Lubrication
    246
  - Adjustment
    246
- Track
  
  247
  - Track Type Application
    247
  - General
    247
  - Inspection
    247
  - Removal
    247
  - Installation
    247
  - Track Cleat
    250
Table of Contents

251
- Steering System
  
  252
  - Inspection
    254
  - Disassembly and Assembly
    254
  - Adjustable Handlebar
    256
  - Steering Adjustment (Skis)
    256
  - Lubrication
    260
- Suspension and Ski System
  
  262
  - On-Vehicle Component Removal
    263
  - Disassembly
    263
  - Inspection
    264
  - Installation
    264
  - Disassembly
    267
  - Inspection
    268
  - Installation
    268
Table of Contents

269
- Installation and Adjustment
  
  270
  - Headlamp Beam Aiming
    270
  - Bulb Replacement
    270
  - Decal
    271
  - Windshield Installation
    271
  - Belt Guard
    271
  - Wiring Harness
    271
  - Cables
    271
  - Piping
    271
- Body
  
  270
- Plastic Maintenance and Repair
  
  272
  - Maintenance
    272
  - Repair
    272
  - Material Repair Procedure
    273
  - Repair Procedure for R.I.M. Polyurethane
    273
- Frame
  
  275
  - Frame Cleaning
    275
  - Frame Welding
    275
  - Frame Component Replacement
    275
  - Lubrication and Maintenance Chart
    308
Troubleshooting

313
- Table of Contents
  313
  - Engine
    314
  - Fuel and Oil Systems
    324
  - Transmission and Brake Systems
    327
    
    Transmission
    327
    
    Brake System
    334
    
    Mechanical Brake
    334
    
    Hydraulic Brake
    335
    
    Mechanical and Hydraulic Brakes
    335
  - Electrical System
    336
  - Suspension System and Track
    345
Table of Contents

348
- 443 And 503 Engine Types
  
  351
- Engine Removal and Installation
  
  351
  - Engine Removal and Installation
    352
  - Tuned Pipe Identification
    352
  - Engine Removal and Installation
    354
- Top End
  
  355
  - Cleaning
    356
  - Disassembly
    356
  - Inspection
    357
  - Assembly
    357
- Bottom End
  
  361
  - Cleaning
    362
  - Disassembly
    362
  - Inspection
    362
  - Assembly
    362
- Engine Support and Muffler
  
  364
- Top End
  
  367
  - Cleaning
    368
  - Disassembly
    368
  - Inspection
    368
  - Assembly
    369
- Bottom End
  
  373
  - Cleaning
    374
  - Disassembly
    374
  - Inspection
    374
  - Assembly
    374
- Leak Test
  
  377
  - Preparation
    377
  - Procedure
    377
  - Finalizing Reassembly
    380
  - Cooling System Leak Test
    380
  - Engine Leak Verification Flow Chart
    381
- Leak Test and Engine Dimension Measurement
  
  377
- Engine Dimension Measurement
  
  382
  - Cylinder Taper
    382
  - Cylinder out of Round
    382
  - Cylinder/Piston Clearance
    382
  - Ring/Piston Groove Clearance
    383
  - Ring End Gap
    383
  - Crankshaft Deflection
    383
  - Connecting Rod Big End Axial Play
    384
  - Connecting Rod/Piston Pin Clearance
    384
  - Connecting Rod/Crankpin Clearance
    385
  - Crankshaft End-Play
    385
  - Crankcase/Rotary Valve Gap
    385
  - Checking Surface Flatness
    386
  - Rectifying Surfaces
    386
  - Checking Crankshaft Alignment
    386
- CDI System
  
  387
- Nippondenso Trigger Coil Ignition System
  
  387
  - Cleaning
    388
  - Disassembly
    388
  - Assembly
    390
- Ducati Ignition System
  
  391
  - Cleaning
    392
  - Disassembly
    392
  - Repair
    392
  - Assembly
    393
- Oil Injection Pump
  
  394
  - Oil Pump Identification
    396
- Oil Injection System
  
  394
- Axial Fan Cooling System
  
  399
  - Removal
    401
  - Cleaning
    401
  - Disassembly and Assembly
    401
- Liquid Cooling System
  
  403
  - Inspection
    405
  - Draining the System
    405
  - Disassembly and Assembly
    405
  - Cooling System Refilling Procedure
    406
- Rotary Valve, Coolant Pump and Reservoir
  
  408
  - General
    409
  - Cleaning
    409
  - Disassembly
    409
  - Inspection
    410
  - Assembly
    410
- Rewind Starter
  
  416
  - Removal
    417
  - Disassembly
    417
  - Assembly
    417
  - Installation
    418
- Carburetor and Fuel Pump
  
  420
  - Removal
    421
  - Cleaning and Inspection
    421
  - Identification
    421
  - Disassembly and Assembly
    422
  - Carburetor Float Level Adjustment
    422
  - Installation
    424
  - Carburetor Adjustments
    425
  - Preliminary Idle Speed Adjustment
    426
  - Hac System
    428
- Fuel Pump
  
  429
  - Removal
    430
  - Pump Verification
    430
  - Cleaning and Inspection
    430
  - Installation
    430
- Fuel Tank and Throttle Cable
  
  431
Table of Contents

433
- 1997 Application Chart
  
  435
  - Rotation Direction
    435
  - Drive Belt Deflection Measurement
    436
  - Deflection Adjustment
    437
- Drive Belt
  
  435
- Drive Pulley
  
  438
  - General
    439
  - Removal
    439
  - Disassembly
    440
  - Cleaning
    441
  - Inspection
    442
  - Assembly
    443
  - Installation
    445
  - Drive Pulley Adjustment
    446
- Driven Pulley
  
  448
  - Removal
    450
  - Disassembly
    450
  - Cleaning
    450
  - Inspection
    450
  - Assembly
    452
  - Installation
    452
  - Adjustment
    453
- Pulley Distance and Alignment
  
  455
  - General
    455
  - General Procedure
    455
  - Pulley Alignment and Distance Specifications Chart
    456
- Brake
  
  458
- Hydraulic Disc Brake
  
  458
  - Removal
    459
  - Disassembly
    460
  - Cleaning
    460
  - Inspection
    460
  - Assembly
    461
  - Installation
    461
  - Adjustment
    462
  - Bleeding
    462
- Chaincase
  
  464
  - Removal
    465
  - Inspection
    465
  - Gear Ratio Modification
    465
  - Installation
    465
  - Drive Chain Adjustment
    466
  - Adjustment
    467
- Gearbox
  
  468
- 3-Speed Gearbox (Shifter Mechanism)
  
  468
  - Removal
    469
  - Adjustment
    469
- 3-Speed Gearbox
  
  470
  - Removal
    471
  - Disassembly
    471
  - Inspection
    473
  - Assembly
    473
  - Installation
    474
  - Oil Level
    474
  - Disassembly
    476
  - Inspection
    476
  - Assembly
    476
  - Adjustment
    478
  - Oil Change
    479
- Drive Chain
  
  480
  - Silent Chain
    480
Table of Contents

481
- Tab and Receptacle Connectors Installation
  485
- Tab and Receptacle Connectors Removal
  485
- Unpluging Connectors
  485
- Accessories Installation
  486
- Ducati CDI System
  
  487
- Ignition Timing
  
  487
- Nippondenso Trigger Coil System
  
  490
- Ngk Spark Plug
  
  493
  - Ngk Spark Plug Numbering System
    493
- Spark Plugs
  
  493
- Design Symbols Used in Ngk Spark Plugs
  
  494
  - Disassembly
    495
  - Heat Range
    495
  - Fouling
    495
  - Spark Plug Analysis
    495
  - Spark Plug Installation
    496
  - Spark Plug Tightening Torque
    496
- Battery
  
  497
  - Removal
    497
  - Cleaning
    498
  - Inspection
    499
  - Hydrometer Test
    499
  - Battery Storage
    500
  - Activation of New Battery
    500
  - Servicing
    503
  - Tips for Charging a Used Battery
    503
  - Battery Charging Equipment
    504
  - Installation of Battery
    504
- Electric Starter
  
  506
  - Removal
    507
  - Disassembly
    507
  - Cleaning and Inspection
    509
  - Assembly
    509
  - Installation
    510
- Cleaning and Inspection
  
  511
  - Cleaning
    511
  - Inspection
    511
  - Solenoid Switch
    513
  - Starter Removal
    515
  - Starter Disassembly
    515
  - Cleaning
    516
  - Parts Inspection
    516
  - Starter Assembly
    517
  - Starter Installation
    518
  - General
    519
  - Use of Bombardier Ignition Tester
    520
- Nippondenso CDI Trigger Coil System Testing
  
  522
  - Trigger Coil Output
    522
  - Ignition Coil Output
    522
  - Ignition Module
    523
  - Magneto Output (Ignition Generator Coil)
    524
  - Lighting Generator Coil Output
    524
  - Summary Table
    526
  - Resistance Measurements
    527
- Ducati CDI System Testing
  
  528
  - Trigger Coil Output
    528
  - Magneto Output
    528
  - Ignition Coil Output
    529
  - Ignition Module
    529
  - Lighting Generator Coil Output
    529
  - Summary Table
    530
  - Resistance Measurements
    531
- Voltage Regulator Inspection
  
  532
  - Testing Procedure
    532
- Inspection of Ac Circuit Isolation
  
  533
  - Inspection
    533
- Inspection of Heating Elements
  
  534
Table of Contents

535
- Suspensions (All Versions)
  
  536
  - Component Removal and Installation
    541
  - Removal
    543
  - Disassembly and Assembly
    544
  - Shock Absorber Inspection
    545
  - Shock Absorber Servicing
    546
  - Installation
    554
  - Ride Adjustment
    554
  - Lubrication
    554
- Skandic Wt Suspension
  
  555
  - Removal
    556
  - Disassembly and Assembly
    556
  - Shock Absorber Servicing
    557
- Drive Axle
  
  559
  - Removal
    561
  - Disassembly
    561
  - Axial Play
    564
  - Installation
    566
  - Lubrication
    567
  - Adjustment
    567
- Track
  
  568
  - Track Type Application
    568
  - General
    568
  - Inspection
    568
  - Removal
    568
  - Installation
    568
Table of Contents

571
- Steering System
  572
- Disassembly and Assembly
  574
- Adjustable Handlebar
  576
- Steering Adjustment (Skis)
  577
- Lubrication
  580
- Disassembly
  583
- Inspection
  584
- Installation
  584
- On-Vehicle Component Verification
  587
- Disassembly
  588
- Inspection
  589
- Installation
  589
Table of Contents

591
- Installation and Adjustment
  
  592
  - Headlamp Beam Aiming
    592
  - Bulb Replacement
    592
  - Decal
    593
  - Windshield Installation
    593
  - Belt Guard
    594
  - Wiring Harness
    594
  - Cables
    594
  - Piping
    594
- Plastic Maintenance and Repair
  
  595
  - Maintenance
    595
  - Repair
    596
  - Material Repair Procedure
    597
  - Repair Procedure for R.I.M. Urethane
    597
- Frame
  
  599
  - Frame Cleaning
    599
  - Frame Component Replacement
    599
Table of Contents

661
- Engine
  662
- Fuel and Oil Systems
  672
- Transmission and Brake Systems
  675
  - Brake System
    682
    
    Mechanical Brake
    682
    
    Hydraulic Brake
    683
    
    Mechanical and Hydraulic Brakes
    683
- Electrical System
  684
- Suspension System and Track
  693
Engine

696
- Table of Contents
  696
- 599, 699 and 809 Engine Types
  
  698
  - Installation on Vehicle
    699
  - Removal from Vehicle
    699
- Top End
  
  700
  - Component Removal
    701
- Leak Test
  
  710
  - Procedure
    710
  - Finalizing Reassembly
    713
  - Cooling System Leak Test
    713
  - Engine Leak Verification Flow Chart
    714
- Leak Test and Engine Dimension Measurement
  
  710
- Engine Dimension Measurement
  
  715
  - Cylinder Taper
    715
  - Cylinder out of Round
    715
  - Cylinder/Piston Clearance
    715
  - Ring/Piston Groove Clearance
    716
  - Ring End Gap
    716
  - Crankshaft Deflection
    716
  - Connecting Rod Big End Axial Play
    717
  - Connecting Rod/Piston Pin Clearance
    717
  - Connecting Rod/Crankpin Clearance
    718
  - Crankshaft End-Play
    718
  - Checking Surface Flatness
    718
  - Rectifying Surfaces
    718
  - Checking Crankshaft Alignment
    718
- CDI System
  
  720
- Nippondenso Trigger Coil Ignition System
  
  720
  - Cleaning
    721
  - Oil Injection System
    724
  - Rewind Starter
    731
  - Carburetor and Fuel Pump
    735
  - Fuel Tank and Throttle Cable
    750
Transmission/Drive Belt

752
- Transmission
  
  752
  - Table of Contents
    752
  - Drive Belt
    752
  - Drive Pulley
    752
  - Driven Pulley
    752
  - Pulley Distance and Alignment
    752
    
    Rotation Direction
    754
    
    Drive Belt Deflection Measurement
    755
    
    Deflection Adjustment
    756
- Tra
  
  757
  - General
    758
  - Removal
    758
  - Disassembly
    759
  - Cleaning
    760
  - Inspection
    761
  - Installation
    764
  - Drive Pulley Adjustment
    765
  - Cleaning
    768
  - Disassembly
    768
  - Inspection
    768
  - Removal
    768
  - Assembly
    770
  - Installation
    770
  - Adjustment
    771
  - General
    773
  - General Procedure
    773
  - Pulley Alignment and Distance Specifications Chart
    774
- Brake
  
  776
- Hydraulic Disc Brake
  
  776
  - Removal
    777
  - Disassembly
    778
  - Cleaning
    778
  - Inspection
    778
  - Assembly
    778
  - Installation
    779
  - Adjustment
    779
  - Bleeding
    780
  - Chaincase
    781
    
    Gear Ratio Modification
    782
    
    Inspection
    782
    
    Installation
    782
    
    Drive Chain Adjustment
    783
    
    Adjustment
    784
  - Drive Chain
    785
    
    Silent Chain
    785
Table of Contents

786
- Electrical
  
  787
  - Wiring Diagrams (See Annexes at the End of this Manual)
    787
    
    Chart Codes
    787
    
    Tab and Receptacle Connectors Installation
    789
    
    Tab and Receptacle Connectors Removal
    789
    
    Unpluging Connectors
    789
    
    Accessories Installation
    790
- Ignition Timing
  
  791
- Nippondenso Trigger Coil System
  
  791
- Ngk Spark Plug
  
  794
  - Ngk Spark Plug Numbering System
    794
- Spark Plugs
  
  794
- Design Symbols Used in Ngk Spark Plugs
  
  795
  - Disassembly
    796
  - Heat Range
    796
  - Fouling
    796
  - Spark Plug Analysis
    796
  - Spark Plug Installation
    797
  - Spark Plug Tightening Torque
    797
- Testing Procedure
  
  798
  - General
    798
    
    Use of Bombardier Ignition Tester
    799
- Nippondenso CDI Trigger Coil System Testing
  
  800
  - Trigger Coil Output
    800
  - Ignition Coil Output
    800
  - Ignition Module
    801
  - Magneto Output (Ignition Generator Coil)
    803
  - Summary Table
    803
  - Resistance Measurements
    804
- Voltage Regulator Inspection
  
  805
  - Testing Procedure
    805
- Inspection of Ac Circuit Isolation
  
  806
  - Inspection
    806
- Inspection of Heating Elements
  
  807
Rear Suspension

808
- Table of Contents
  808
- Suspension (Hp Version)
  
  809
  - Component Removal and Installation
    810
  - Disassembly and Assembly
    812
  - Removal
    812
  - Shock Absorber Inspection
    814
  - Installation
    815
  - Lubrication
    815
  - Ride Adjustment
    815
- Drive Axle
  
  816
  - Removal
    817
    
    Assembly
    817
    
    Disassembly
    817
    
    Axial Play
    819
    
    Installation
    822
    
    Lubrication
    822
    
    Adjustment
    823
- Track
  
  824
  - General
    824
    
    Inspection
    824
    
    Installation
    824
    
    Removal
    824
Steering System/Suspension and Ski System

827
- Steering
  827
  - Table of Contents
    827
  - Steering System
    827
  - Suspension and Ski System
    827
    
    Disassembly and Assembly
    829
    
    Inspection
    829
    
    Inspection
    830
    
    Adjustable Handlebar
    831
    
    Lubrication
    834
    
    Disassembly
    837
    
    Inspection
    838
    
    Installation
    838
Table of Contents

840
- Installation and Adjustment
  
  841
  - Bulb Replacement
    841
  - Decal
    842
  - Windshield Installation
    842
  - Hood
    842
  - Belt Guard
    842
  - Wiring Harness
    842
  - Cables
    843
- Plastic Maintenance and Repair
  
  844
  - Maintenance
    844
  - Repair
    845
  - Material Repair Procedure
    846
  - Repair Procedure for R.I.M. Urethane
    846
- Frame
  
  848
  - Frame Cleaning
    848
  - Frame Component Replacement
    848
    
    Tools
    870
    
    Troubleshooting
    871
    
    360-Watt Magneto System
    872
    
    Theory and Operation
    872
    
    Heating Elements Switches System
    874
    
    Theory and Operation
    874
    
    Dimmer Switch System
    875
    
    Theory and Operation
    876
Table of Contents

907
- Safety Notice
  908
- 1 - Lubrication
  
  909
- 2 - Troubleshooting
  
  909
- 3 - Engine
  
  909
  - General
    909
  - Liquid Cooling System
    910
- 4 - Transmission
  
  911
  - Brake
    911
- 5 - Electrical
  
  912
- 6 - Rear Suspension
  
  912
- 7 - Steering/Front Suspension
  
  912
  - Steering Adjustment (Skis)
    913
  - Front Suspension and Skis
    915
  - Shock Absorber Servicing
    916
- 8 - Body/Frame
  
  921
- 9 - Technical Data
  
  921

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Table of Contents

Table of Contents

Table of Contents

Table of Contents

Engine Removal and Installation

277 Engine Type

Top End

Bottom End

377, 443 and 503 Engine Types

Engine Removal and Installation

Leak Test and Engine Dimension Measurement

Leak Test

Engine Dimension Measurement

Nippondenso Ignition System with Single Generating Coil

CDI System

Ducati Ignition System

Oil Injection System

Oil Injection Pump

Axial Fan Cooling System

Rewind Starter

Carburetor and Fuel Pump

Fuel Pump

Fuel Tank and Throttle Cable

Table of Contents

1997 Application Chart

Drive Belt

Drive Pulley

Bombardier Lite

Tra

Driven Pulley

Pulley Distance and Alignment

Brake

Mechanical Disc Brake

Hydraulic Disc Brake

Chaincase

2-Speed Gearbox

Gearbox

Drive Chain

Table of Contents

Ignition Timing

Nippondenso CDI System (Without Trigger Coil)

Ducati CDI System

Ngk Spark Plug

Spark Plugs

Design Symbols Used in Ngk Spark Plugs

Battery

Electric Starter

Cleaning and Inspection

Testing Procedure

Nippondenso CDI System Testing

Ducati CDI System Testing

Voltage Regulator Inspection

Inspection of Ac Circuit Isolation

Inspection of Heating Elements

Table of Contents

Torque Reaction Suspension

Lubrication

Sport and Touring Suspension

Drive Axle

Track

Table of Contents

Steering System

Suspension and Ski System

Table of Contents

Installation and Adjustment

Body

Plastic Maintenance and Repair

Frame

Troubleshooting

Table of Contents

443 And 503 Engine Types

Engine Removal and Installation

Top End

Bottom End

Engine Support and Muffler

Top End

Bottom End

Leak Test