AD Boivin 2002 Snow Hawk Service Manual Download Page 52

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ENGINE / CYLINDERS AND CYLINDER HEADS 7 - 2

Ref.

P/N

Qty

Cylinders and cylinder heads / Rotax 503

Part Descriptions

420 8318 58

Gasket, 0.5mm

420 8236 49

Cylinder and cylinder sleeve

420 8505 40

O-ring

420 8236 64

Cylinder head

420 2503 11

8.4mm washer

228 0810 45

M8 Hex screw

420 8422 03

M8 X 47 distance nut

420 8318 49

Gasket, Exhaust manifold, 1mm

420 9731 28

Exhaust manifold

224 7811 40

8mm Lock washer

222 9830 65

M8 X 30 allen bolt

420 8318 66

Intake gasket, 1mm

420 8674 08

Intake socket Assy.

420 9457 52

8mm Lock washer

420 8406 81

M8 X 40 allen bolt

420 9942 38

Engine gasket set

420 2501 65

O-ring, 64mm

420 8319 50

Oil seal

420 8318 58

Gasket, 0.5mm

420 8505 40

O-ring

420 8318 43

Gasket, 1mm

420 8318 66

Gasket, Intake, 1mm

404 1466 00

Gasket

Summary of Contents for 2002 Snow Hawk

Page 1: ...2002 03 Set up service and repair Manual Snow Hawk...

Page 2: ...ed to call attention to particular instructions and procedures which if not followed to the letter could cause injury and even fatal accidents t t CAUTION This symbol is designed to call attention to...

Page 3: ...hile the motor is running can be dangerous Injuries could result from contact with moving parts Make sure you turn off the motor before working on the vehicle u u WARNING Working on this vehicle witho...

Page 4: ...ealant 243 Non permanent threadlocker blue 262 Permanent threadlocker red Brake fluid DOT 4 Fork oil S A E 10W Rear suspension shock oil Kayaba Silicone grease P N 420 8970 61 Molybdenum Grease 88162...

Page 5: ...NE CYLINDER AND CYLINDER HEADS PRIMARY TRANSMISSION SYSTEM SECONDARY TRANSMISSION SYSTEM BRAKE SYSTEM FRONT FORK AND SKI REAR SUSPENSION SHOCKS AND TRACK CHASSIS AND STEERING ELECTRICAL SYSTEM DIMENSI...

Page 6: ...mind the speed of the vehicle the snow conditions and how quickly you want to change direction u uWARNING Some people enter a turn by stretching out a leg on the inside of the turn and letting the fo...

Page 7: ...ff tether 5 Gas tank cap 6 Dimmer switch 7 Choke control 8 Emergency stop button 9 Hood latches 4 10 Rear module latches 4 11 Bellypan latches 6 12 Kick stand 13 Headlight 14 Stop and tail light 15 Re...

Page 8: ...the proportion of oil is too low will cause piston failure On the other hand a mixture in which the proportion of oil is too high will cause excessive carbon deposits that will result in fouled spark...

Page 9: ...ust return to its original position as soon as it is released o Turn the twist throttle control a few times to make sure it functions properly The control must return automatically to the idle positio...

Page 10: ...t A new drive belt must be submitted to a 5 hour break in period Avoid high speed driving and brisk accelerations during this period Inspection 10 hours A general inspection is recommended after the f...

Page 11: ...ure that they will not interfere let them hang loose at the base of the fork leg o Remove the circular fork disc o De latch the two rubber latches on the sides of the belly pan towards the rear of the...

Page 12: ...nsion V A V A Secondary drive belt cog belt V V Cog sprockets V V Taper Locks V V Brake fluid V F Brake pads V V R V R Front Fork F F F Fork cushion V R R Ski and runners V V R Suspension V V Shocks V...

Page 13: ...ust be cleaned at least once a year or more often under severe usage conditions Clean the filters in a solution containing a non flammable cleaning solvant such as hot soapy water Once they have dried...

Page 14: ...specially the presence of cuts or tears If in doubt as to the condition of the belt replace with a new one The belt must show a deflection of 9 5 mm 3 8 in when a 5 Kg 11 lb perpendicular force is app...

Page 15: ...to mis alignment of the pulleys excessive speed when the track is frozen quick acceleration without preliminary warming up a scratched or rusted pulley oil on the belt or a twisted replacement belt If...

Page 16: ...id Check to see if the brake fluid level is above the mimimum mark see illustration If not add fluid t t CAUTION Use only DOT 4 brake fluid from a sealed container Do not use any other type of brake f...

Page 17: ...ski section t t CAUTION It is advisable to change the fork fluid when preparing the vehicle for storage The presence of condensation in the suspension fluid could cause rusting to occur during the st...

Page 18: ...ng to occur during the storage period Track Check the condition alignment and tension of the track With the engine turned off and the rear end of the machine raised from the ground rotate the track ma...

Page 19: ...bolts must be checked and tightened as need be When doing this refer to the table entitled TORQUES at the end of this section 2 9 ELECTRICAL SYSTEM Spark plug Check the general condition of the plug t...

Page 20: ...ture too lean Stale gasoline Plug temperature rating too low No is too big Plug gap too close Air fuel mixture too rich Oil fuel mixture too rich Light Grey Overheated Blackish fouled t t CAUTION The...

Page 21: ...l alloy Designed for racing V notch central electrode racing Half temp rating Standard central electrode Electrode with precious metal core Booster gap V notch central electrode SECTIONAL VIEW AND TYP...

Page 22: ...92 Magneto nut 105 10 5 77 924 Axial fan nut 65 6 5 48 576 Recoil starter housing bolt 10 1 7 84 Primary clutch bolt 90 9 66 792 Secondary clutch bolt 31 7 3 17 23 276 Taper Lock installation setscrew...

Page 23: ...FUEL SYSTEM 3 1 FUEL SYSTEM 3...

Page 24: ...screw M6x45 11 414 415 200 2 Spring clamp 12 23162 1 M6 nylon locknut 13 515 163 800 1 Voltage regulator rectifier 14 394 103 300 1 Lock washer 15 414 977 200 1 Plastic nut 16 414 967 000 1 Choke cabl...

Page 25: ...FUEL SYSTEM 3 3 FUEL SYSTEM CARBURETOR VM34...

Page 26: ...404 107 400 2 Drain plug 18 404 102 300 2 Idle mixture adjustment screw 19 404 101 800 2 Idle mixture adjustment screw spring 20 404 101 700 2 Idle speed adjustment screw spring 21 404 125 200 2 Idle...

Page 27: ...FUEL SYSTEM 3 5 FUEL SYSTEM FUEL PUMP 1 2 3 8 7 6 5 5 6 4 7...

Page 28: ...mp Rotax 503 Part Descriptions 1 403 801 100 1 Fuel pump assembly 2 404 131 600 4 Screw 3 404 903 000 1 Filter 4 404 902 300 2 Gasket 5 404 902 100 2 Rubber washer 6 275 500 042 2 Valve 7 404 902 200...

Page 29: ...o Loosen the hose clamps holding the fuel inlet lines and then remove the carburetors from the engine l NOTICE An opening in the chassis through which a screwdriver can be inserted is provided to give...

Page 30: ...lly sealed Replace the float if necessary Dismantling and assembling l NOTICE To facilitate the dismantling and re assembling of the carburetor it is recommended to use a tool kit P N 404 1120 00 Cali...

Page 31: ...ur and or the piston crown to determine the appropriate jet size to be used Adjustment of float level In order for the engine to deliver its full power it is essential that the level of the fuel in th...

Page 32: ...tude and temperature Installation t t CAUTION Never allow throttle slides to close abruptly To re install the carburetors carry out the removal operations in reverse order inspecting first the acceler...

Page 33: ...sed to synchronize the carburetors The cables must be adjusted so that both plungers start moving at the same time 1 Plunger 2 Adaptor 3 Lock nut The plungers must come into contact with the adaptors...

Page 34: ...h carburetors and then tighten the lock nuts Both carburetor slides must start opening simultaneously Turn the accelerator handle to make sure it is functioning properly and if need be turn the cable...

Page 35: ...be screwed or unscrewed the same number of turns Adjustment of the idle mixture screw Turn mixture screw clockwise until it just closed then open 1 5 turns Turn the mixture screw clockwise for a riche...

Page 36: ...r and plug the aeration hole on the top cover Blow air in and out of the tube with your mouth to make sure there are no leaks either in the diaphragm or in the gasket DISMANTLING Do not dismantle the...

Page 37: ...n with a rotating motion until it reaches its seating position 1 Valve 2 Lubricate the tip 3 Pump body When re assembling the pump make sure the components are installed in the initial order Refer to...

Page 38: ...our bolts No 2 securing the hood supports and pull the supports towards the nose of the vehicle to increase the space between the exhaust pipe and these parts o Remove the two springs at the outlet of...

Page 39: ...o With a small screwdriver push the knot out of the recess in the starter handle Since it is often easier cut the cord just before the knot while holding the cord securely so that it does not slip fro...

Page 40: ...two mounting screws No 1 There is one on each side of the chassis Carburetors o Remove the air filters o Insert a screwdriver into the slots on each side of the chassis to unscrew the hose clamps ret...

Page 41: ...he instructions above in the reverse order However pay particular attention to the following points o Ensure that all engine mount bolts are securely tightened 325 lbf in 27 lbf ft o After installatio...

Page 42: ...RECOIL STARTER 5 1 RECOIL STARTER 5...

Page 43: ...dle 4 420 8522 83 1 Starter pulley 5 412 5001 00 1 Starter cord 2200 mm 6 420 8520 70 1 Key clamp 7 420 8522 90 1 Pawl 8 420 8523 01 1 Pawl lock 9 420 8453 00 1 E clip 10 420 9389 85 1 Locking spring...

Page 44: ...de turning it counter clockwise u u WARNING Because it is so tightly rolled inside the guide it is possible that the spring will pop out when it is being manipulated Always handle it with care l NOTIC...

Page 45: ...ousing making sure that the notch on the hub of the pulley is fitted into the hook of the return spring o Turn the pulley counter clockwise until the end of the cable is accessible through the opening...

Page 46: ...w cord fuse the strands of the cable together by burning the end with a match Pass the cord through the rubber stop and through the handle then tie a knot in it at the end Fuse the knot with a match P...

Page 47: ...COOLING SYSTEM 6 1 COOLING SYSTEM 6...

Page 48: ...16 420 9110 66 1 Cylinder housing Exhaust side 17 420 9110 67 1 Cylinder housing Intake side 18 420 2403 85 1 M6 x 12 screw 19 417 3000 05 8 Spring nut 20 420 9128 22 1 Cylinder housing Upper portion...

Page 49: ...e fan housing using a ring Remove the roller bearing by tapping all around the inside cage with a punch Keep the shims Remove the retaining ring and take out the second roller bearing To carry out the...

Page 50: ...the driven half pulleys If the tension must be corrected take advantage of the fact that the shaft can be turned by hand when the half pulleys are dismantled to make sure that the bearing of the fan...

Page 51: ...ENGINE CYLINDERS AND CYLINDER HEADS 7 1 ENGINE CYLINDERS AND CYLINDER HEADS 22 N m 2 2 kg m 16 lbf ft 22 N m 2 2 kg m 16 lbf ft 22 N m 2 2 kg m 16 lbf ft 7...

Page 52: ...3 4 M8 X 47 distance nut 8 420 8318 49 4 Gasket Exhaust manifold 1mm 9 420 9731 28 1 Exhaust manifold 10 224 7811 40 4 8mm Lock washer 11 222 9830 65 4 M8 X 30 allen bolt 12 420 8318 66 4 Intake gaske...

Page 53: ...ENGINE CYLINDERS AND CYLINDER HEADS 7 3 ENGINE HOUSING 503 22 N m 2 2 kg m 16 lbf ft Follow the recommended sequence 515...

Page 54: ...Descriptions 1 6 420 8867 13 1 Crankcase Assy 2 420 9457 52 14 8mm Lock washer 3 420 8412 01 6 M8 X 70 Hex Bolt 4 420 8415 61 2 M8 X 45 Allen bolt 5 420 8418 41 2 M8 X 65 Allen bolt 7 222 0845 65 4 M8...

Page 55: ...ENGINE CYLINDERS AND CYLINDER HEADS 7 5 ENGINE CRANKSHAFT AND PISTONS 242 105 N m 10 5 kg m 77 lbf ft A G A G...

Page 56: ...needle bearing 9 11 420 9962 45 2 Piston Assy 72 0 mm 420 9962 46 Opt Oversize Piston Assy 72 25 mm 420 9962 47 Opt Oversize Piston Assy 72 50 mm 10 420 9158 50 2 Rectangular ring 72 00 mm 420 9158 5...

Page 57: ...the arrow are visible after the cleaning Clean the grooves of the piston rings with a special tool or with an old piece of ring DISMANTLING The piston pins of the SNOW HAWK TM are equipped with needle...

Page 58: ...stener Inspection Taper of the cylinder Compare the diameter of the cylinder 16 mm 5 8 in from the top to its diameter just under the intake port If the difference is more than 0 8 mm 003 in the cylin...

Page 59: ...per edge Note the smaller of the two diameters The difference between these two measurements must be less than 0 2 mm 008 in Play between the piston ring and the groove Using a thickness gauge measure...

Page 60: ...tor P N 529 0210 00 then turn its handle until the piston pin is in the correct position in the piston o Remove the piston wrist pin extractor and the expansion socket o Install the circlips according...

Page 61: ...clips must not move freely in the groove after their installation If they do move replace them Use the piston circlip installation tool P N 529 0169 00 1 insert the circlip 2 Secure it 3 Oil it l NOTI...

Page 62: ...t before tightening the nuts of the cylinder head Place the spacer nuts as shown in the illustration Tighten the nuts of the cylinder head to 22 N m 16 lbf ft in a criss cross sequence Tighten each cy...

Page 63: ...ce of the sealer coating on the contact surfaces of the housing t t CAUTION Never use a sharp or pointed object which could leave scratches and thereby prevent the housing from being completely sealed...

Page 64: ...in the following illustration Distance A mm in Maximum PTO side mm in Maximum MAG side mm in 82 5 3 248 0 06 002 0 03 001 l NOTICE It is not possible to get an accurate measure of the camber of the c...

Page 65: ...easure the piston pin with its needle bearing Compare to the inside diameter of the connecting rod New part MIN MAX Wear limit 0 030 0 12 mm 0001 0005 po 0 15 mm 0006 po Play between the connecting ro...

Page 66: ...hium grease on the lip of the ring seal To make sure the bearings are lubricated there must be a space of 1 0 mm 0 040 in between the ring seals and the bearings If installing solid ring seals ones wi...

Page 67: ...exhaust pipe and the exhaust manifold 2 Place plugs on the exhaust flanges and tighten them using the screws that were removed previously 3 Remove the carburetors 4 Insert plugs into the intake flange...

Page 68: ...mmended that the following be tried before undertaking to service the engine since there may possibly be more than one leak in the When the section being checked does not show any leaks continue pumpi...

Page 69: ...PRIMARY TRANSMISSION SYSTEM 8 1 16 8 9 14 2 3 5 6 10 13 7 4 11 12 17 15 10 N m 1 kg m 7 4 lbf ft 125 lbf in 90 N m 9 2 kg m 66 lbf ft 797 lbf in 1 14 PRIMARY TRANSMISSION SYSTEM PRIMARY CLUTCH...

Page 70: ...ve 4 420 2453 70 3 Washer 5 417 1162 00 1 Guide washer 6 V10 55 102 22 1 Spring 7 222 9640 66 3 M6 x 40 allen screw 8 417 1181 00 3 Centrifugal block 9 0130 0142 18 Calibration weight 10 417 1214 00 1...

Page 71: ...PRIMARY TRANSMISSION SYSTEM 8 3 9 15 7 10 6 4 3 5 8 11 2 14 13 12 16 17 19 18 25 N m 18 4 lbf ft 2 5 kg m 221 lbf in PRIMARY TRANSMISSION SYSTEM SECONDARY CLUTCH...

Page 72: ...5 0112 00 1 Small Garlock bushing 6 860 4230 00 1 Large Garlock bushing 7 417 1264 22 1 Helix 50o 44o 8 414 8208 00 1 Key 9 371 9031 00 1 Retaining ring 10 414 5589 00 1 Release Spring beige 11 504 14...

Page 73: ...edure and respect the assembly tolerances REMOVAL PRIMARY CLUTCH If removing the primary clutch first tighten the snap washer No 11 then unscrew the nut No 12 Use the primary clutch tool P N 529 0276...

Page 74: ...e to place the arrow on the cap in line with the corresponding mark on the sliding sheave and that of the fixed sheave Tighten the end cap nut No 12 to 128 N m 95 lbf ft INSTALLATION Tighten the prima...

Page 75: ...arge bushing and small bushing During the break in period about 10 hours of use the teflon of the bushing moves toward the surface of the helix or of the shaft The result is a light constant friction...

Page 76: ...actor P N 529 0311 02 under the bushing Install the extractor screw head in a vise Turn the half pulley manually to take out the old bushing Before installing the bushing file the bore of the sliding...

Page 77: ...or dismantling them Helix Coat the inside of the helix with anti seize compound INSTALLATION Jackshaft and anti seize compound t t CAUTION Always apply anti seize compound P N 413 7010 00 on the jacks...

Page 78: ...begins to turn Let it turn 10 mm 3 8 in Hold the spring scale in this position Gently slacken the tension on the spring scale and take the second measurement when the sliding sheave begins to close Th...

Page 79: ...he same direction MEASURING THE DEFLECTION OF THE DRIVE BELT l l NOTICE The deflection must be measured each time a new drive belt is installed l l NOTICE To get a precise measurement when verifying t...

Page 80: ...n gauge P N 414 3482 00 to verify the tension of the drive belt 1 Lower ring 2 Upper ring 3 Force 4 Deflection 1 Slide the lower ring of the deflection scale to the required measurement 2 Slide the up...

Page 81: ...se 1 Allen screw and locknut l NOTICE Turn the Allen screws a quarter turn at a time and then turn the secondary clutch to allow the drive belt to take its place in the pulley Verify the deflection an...

Page 82: ...SECONDARY TRANSMISSION SYSTEM 9 1 243 243 14 N m 1 4 kg m 125 lbf in Follow the suggested sequence 14 N m 1 4 kg m 125 lbf in Follow the suggested sequence SECONDARY TRANSMISSION SYSTEM 9 13...

Page 83: ...oner Sprocket 28T 3 SH205 1 Drive Sprocket 56T 4 SH204 1 Tensioner shaft 5 184 153 1 Retaining Ring 6 6004 2RS KML 2 Roller bearing tensioner 7 409 716 1 Washer 8 441 1 1 Split spring lock washer 9 20...

Page 84: ...r sprocket Remove the two setscrews that hold the taper lock and the 28 tooth drive sprocket in place Position 1 Using a steel punch tap the hub 2 3 times to loosen the grip between the taper lock and...

Page 85: ...result in personal injury Lightly tighten the tensioner sprocket bolt Ref No 9 in the exploded view of the secondary transmission system and then proceed to re apply tension to the system by tightenin...

Page 86: ...ssive dry surface cracking of the rubber in the cog belt If excessive surface cracks are present replace belt o Check that the secondary transmission system is dry and free of dirt grime or debris If...

Page 87: ...BRAKE SYSTEM 10 1 131313cpcpccp 3 4 5 6 2 7 8 13 10 9 12 14 1 11 14 N m 1 4 kg m 125 lbf in Follow the suggested sequence 243 14 N m 1 4 kg m 125lbf in 243 25 N m 2 5 kg m 220lbf in HYDRAULIC BRAKE S...

Page 88: ...1 Replacement Brake Pads set of 2 4 SH024 1 Brake Hub 5 08MQ004 1 Brake Disc 6 SH039 2 Brake Caliper Spacer 7 053 8 45 2 M8 x 45 Hex Bolt 8 23164 2 M8 Locknut 9 1215X30 1 Taper Lock c w setscrews 10 2...

Page 89: ...de the tunnel with a socket and ratchet Loosen the other upper bolt holding the caliper tight to the chassis as well then swing the caliper up and clear of the disc Re tighten the upper bolt and nut e...

Page 90: ...emove the clip at the end of the pin shown in the picture on page 10 3 of this chapter o Using a steel punch and a hammer push the pin completely out of the brake caliper casting Be sure to push the p...

Page 91: ...id each year It is very important to have a sufficient amount of brake fluid in the reservoir at all times to avoid the creation of air bubbles in the system If air should become trapped in the system...

Page 92: ...HYDRAULIC BRAKE SYSTEM 10 6 Brake Fluid Level Refer to Section 2 5 of Chapter 2 Periodic Maintenance for details...

Page 93: ...FRONT FORK AND SKI 11 1 4 3 6 7 1 8 5 2 3 1 FRONT FORK 11...

Page 94: ...rk leg Assy 1 849 350 102 2 Cartridge Assy 2 849 310 511 2 Inner tube 3 849 340 059 2 Fork seal and bushing kit 4 849 311 568 2 Top cap Assy 5 849 350 103 2 Compression valve Assy 6 949 409 760 2 Oute...

Page 95: ...FRONT FORK AND SKI 11 3 z 2 7 8 7 8 6 1 2 7 6 8 16 17 1 16 17 13 14 15 5 4 9 18 3 11 19 18 9 11 10 12 12 FRONT FORK ASSEMBLY...

Page 96: ...ower steering bushing 7 061 6 30 8 M6 x 30 Hex head flange bolt 8 23162F 8 M6 flanged locknut 9 SH 051 2 Steel T bushing 10 084 6 2 4 M6 x 20 Button head bolt 11 23162 2 M6 locknut 12 20169P 2 M6 x 65...

Page 97: ...FRONT FORK AND SKI 11 5 zzzzz 15 15 9 9 3 7 6 8 11 12 10 17 16 1 2 5 14 13 14 13 4 SKI ASSEMBLY...

Page 98: ...0 1 Rubber ski cushion 6 SH 306 2 Steel runner 7 SH 305 2 60 degree carbide runner 8 SH 304 1 90 degree carbide runner 9 22106Al 3 M6 x 30 button head cap screw 10 23162 3 M6 locknut 11 333 107 10 5 1...

Page 99: ...amage the rebound adjustment needle resulting in a malfunction of the system To prevent such a situation set the rebound adjustment to its fastest position by turning it counterclockwise before taking...

Page 100: ...upside down the push rod the needle and the return spring will fall from the piston rod It is possible to collect them by turning the strut over slowly and keeping a finger near the tip of the piston...

Page 101: ...one end provided with the maintenance tool kit into the cartridge head NOTICE Before unscrewing the cartridge make sure the special tool T is well fitted into the socket in the cartridge head o Empty...

Page 102: ...the dust seal o Use a flat screwdriver to remove the dust seal o Remove the stop ring o With a few sharp blows pull the outer tube P out to separate it from the inner tube A o The oil seal T the wash...

Page 103: ...of the strut with a band of adhesive tape so that the seals will not be damaged by the sharp edge o Make sure the bushings S R are well inserted in their respective pos itions by using the special to...

Page 104: ...l W to insert the washer Q and then the oil seal T o Re install the stop ring O o Re install the dust seal M o Using a 14 mm allen key and the special tool T re install the cartridge L the compression...

Page 105: ...l position fully compressed and fill it with fork fluid up to 50 mm 2 in from the top of the outer tube Recommended fluid Cartridge fork fluid S A E 10W o Move the piston rod in and out in a series of...

Page 106: ...ecommended level CAUTION The fluid level can be modified but must remain between 85 mm and 120 mm o Insert the needle return spring the needle and the push rod o Install the spring F inside the strut...

Page 107: ...wrench and the special tool to adjust the torque to 18 20 N m 1 8 2 0 kg m 13 2 14 75 lbf in o Screw the strut top cap onto o the outer tube Again use the torque wrench and the special tool to adjust...

Page 108: ...Using a screwdriver it is possible to choose a precise setting for the speed of rebound from a range of 28 positions depending on the conditions of the terrain and the purpose for which the vehicle is...

Page 109: ...REAR SUSPENSION SHOCKS AND TRACK 12 1 REAR SUSPENSION SHOCKS AND TRACK...

Page 110: ...ONAL SPRING RIGHT 1 20 825 8CP M8x25 HEX HEAD CAP SCREW 16 21 22105AI M6x25 BUTTON HEAD S S 2 22 21085P 6mm ID WASHER 4 23 517 0787 00 LIMITER STRAP WASHER 8 24 20165P M6x45 HEX HEAD CAP SCREW 2 25 02...

Page 111: ...ER SHAFT SPACER 2 57 062 01 UPPER SHOCK EYE BUSHING 4 58 SH419 SPACER 2 59 018 00 NYLATRON SHIM 2 60 SH422 SOFTNESS ROD EYE BUSHING 2 61 SH420 UPPER SHAFT 1 62 SH42 SA SOFTNESS DRAWBAR ROD 1 63 030 00...

Page 112: ...REAR SUSPENSION SHOCKS AND TRACK 12 4 REAR SUSPENSION SHOCKS AND TRACK 1 4 3 5 11 10 11 9 2 13 12 6 8 7...

Page 113: ...d Assy 2 11301 05056 1 Shock body 3 11301 03303 1 Floating piston 4 11301 03006 1 O ring 5 11301 03805 1 Piston bushing 6 11302 09919 1 Compressed air valve 7 11201 90604 1 Screw 8 11301 03021 1 O rin...

Page 114: ...pecial tool The adjustment of the spring makes it possible to stiffen the suspension if it reaches the limit of its displacement and to make it feel softer if the driver is the one absorbing the shock...

Page 115: ...e suspension slightly you will be able to push the bolts through the remaining leg of the strap that runs up and over the upper shaft and then re install the nuts and washers to hold this position If...

Page 116: ...sses is necessary Remove the shock absorber spring by unscrewing the pre load collar and jam nut then by removing the spring retainer hat To carry out these operations use tool P N 861 7439 00 Install...

Page 117: ...ct the floating piston from the body of the shock absorber Cover the opening of the shock absorber with a cloth to catch the floating piston Make sure there is enough space in the cloth for the piston...

Page 118: ...here is a leak in the ring seal it will be necessary to measure the camber of the rod which must not exceed 0 025 mm 001 in Once the new shims or the replacement shims have been selected reassemble ev...

Page 119: ...r of grooves varies between 0 2 4 and 6 according to the rapidity of the rebound These grooves offer variations in the damping in relation to the shims COMPRESSION When adjusting the shock absorber to...

Page 120: ...ibrating the shock absorber so that there is not enough damping means the damping will either be insufficient or badly controlled In such a case the shock absorber moves up and down almost without any...

Page 121: ...seal use a ring seal guide P N 529 0265 00 to guide the ring seal over the shock absorber rod Lubricate the guide before using it t t CAUTION The ring seal will be damaged if the guide is not used Rea...

Page 122: ...ough the hole in the needle valve will push the piston up u u WARNING Be very careful when using compressed air Cover the opening in the shock absorber with a cloth to reduce any risk of injury u u WA...

Page 123: ...ton It might be necessary to jiggle the rod slightly to make it easier to place the piston in the bore of the body of the shock absorber Gently insert the piston into the body of the shock absorber A...

Page 124: ...he recommended pressure u u WARNING Always wear safety glasses when working with high pressure gas Never point gas under pressure at anyone l NOTICE Make sure there are no gas or oil leaks Carry out a...

Page 125: ...ims for rebound always use shims measuring 22 mm 1 02 in in diameter against the piston Use at least 3 shims for the stack to avoid bending or breaking Leave a play of about 0 203 mm 0 008 in between...

Page 126: ...ted in the factory but it is recommended that the following be checked o The alignment of the track 1 Guides 2 Hyfax slides 3 Equal distance o Track tension The track must have a maximum deflection of...

Page 127: ...CHASSIS AND STEERING SYSTEM 13 1 CHASSIS AND STEERING SYSTEM...

Page 128: ...CHASSIS AND STEERING SYSTEM 13 2 Frame right side MAG exploded view...

Page 129: ...CHASSIS AND STEERING SYSTEM 13 3 Frame left side PTO exploded view...

Page 130: ...CHASSIS AND STEERING SYSTEM 13 4 Engine support plate exploded view Fork tube assembly exploded view...

Page 131: ...CHASSIS AND STEERING SYSTEM 13 5 Steering column exploded view...

Page 132: ...1 SH 005 2 Fork clamp support 22 SH 043 2 Fork steel bushing 23 SH 050 2 Fork MOS2 bushing 24 SH 066 2 Fork bushing 25 21655P 8 Socket head screw M8x40 26 SH 038 1 Front chassis spacer 27 SH 037 1 Rea...

Page 133: ...1 Belt holder spare 72 SH 252 1 Jackshaft alignment collar 73 504 108 200 1 Shim 74 061 8 30 9 Hex head flange bolt M8x30 75 SH 055 1 Threaded aluminum drive rod 76 23166 2 Hex elastic nut M10 77 2017...

Page 134: ...M10 105 732 610 010 1 RH jam nut M10 106 053 10 55 2 Hex head cap screw M10x55 107 SH 01SA 2 Fork tube assembly 108 057 6 20 3 Hex head cap screw M6x20 109 503 183 300 2 Washer 10MM special 110 057 6...

Page 135: ...ELECTRICAL SYSTEM 14 1 25 30 N m 2 5 30 kg m 18 21 5 lbf ft 242 242 22 N m 2 2 kg m 16 2 lbf ft ELECTRICAL SYSTEM ENGINE 14...

Page 136: ...M5 x 18 allen bolt 8 420 9657 62 1 Pickup Assy 9 420 8278 00 2 5 5 mm washer 10 420 9419 25 2 M5x 16 Taptite screw 11 420 9804 85 1 V Belt pulley 12 420 8524 12 1 Starting pulley 13 420 8453 10 3 Loc...

Page 137: ...D GR GREEN VI VIOLET BR BROWN BK BK BK YL BK YL BK BK BK BK YL BK YL BK YL BK BK BK BK YL BK YL BK YL A BK B BK YL BK BK YL BK YL YL BR BR TOWARDS MOTOR REAR VIEW MOTOR STOP SWITCH 8 BK BK YL YL RD RD...

Page 138: ...er switch 2 110 4671 91 1 Brake microswitch 3 AN 125 1 Head lamp Assy 4 70321 1 Tail lamp Assy 5 1 Voltage regulator see exploded view section 3 6 1 Electronic box see previous exploded view 7 1 Stato...

Page 139: ...er To remove the fixing nut of the magnetic flywheel install the stator plate puller P N 420 8760 80 and M8 x 20 screws Remove the nut from the magnetic flywheel using a 30 mm socket To remove the mag...

Page 140: ...line with the starting coil o Using a 0 45 mm 018 in to 0 55 mm 022 in thickness gauge check the gap between the central pole of the starting coil and the flywheel offset 1 Flywheel offset 2 Starting...

Page 141: ...e precision of the ignition adjustment it can be verified in the following way Checking the position of the adjustment mark on the flywheel Before checking the adjustment it may be necessary to check...

Page 142: ...until the needle starts to move and push it in an additional 5 to 6 mm around 1 4 in Tighten the adapter lock nut manually 4 To determine the TDC of the piston proceed as follows o Slowly turn the fl...

Page 143: ...eel a quarter turn counter clockwise and then turn it gently again clockwise until the needle indicates 1 66 mm 0 065 in o Make sure the mark on the flywheel is correctly lined up with the mark on the...

Page 144: ...erifying the ignition adjustment Use a stroboscopic lamp P N 529 0092 00 To verify the ignition adjustment see the illustration and proceed as follows l NOTICE The engine must be cold during the adjus...

Page 145: ...nectors before replacing any of the parts l NOTICE It is possible to verify the ignition adjustment when the speed of the engine is between 2000 and 6000 r p m 1 Plug of the stroboscopic lamp MAG side...

Page 146: ...ight does not come on The problem is a result of a defect in the starter coil or a bad ground POWER OF THE MAGNETO Generator ignition coil 1 Unplug the 2 wire connectors between the ignition module an...

Page 147: ...or the following verification 1 Fix the test adapter around the spark plug cable in other words near the spark plug on the MAG side 2 Connect the tester wires then place the switch and the dial in the...

Page 148: ...ATOR LIGHTING COIL The generator lighting coil is not part of the ignition system It is a separate system designed to supply power to the lighting system as well as other mechanisms controlled by alte...

Page 149: ...Consult the following table to see the resistances and the colours of the wires l NOTICE An ignition coil may be defective in spite of an adequate resistance reading A drop in voltage can occur under...

Page 150: ...t turn at low speed without touching the accelerator u u WARNING Make sure that no debris is blocking the track since it could be thrown into the air Keep hands tools feet and clothes away from the tr...

Page 151: ...Cylinder play new mm 0 08 in 0 031 wear limit mm 0 2 in 0 008 Maximum connecting rod axial play new mm 0 2 in 0 008 wear limit mm 1 00 in 0 039 Maximum crankshaft axial play mm 0 3 in 0 018 Maximum c...

Page 152: ...7 Primary clutch bolt 90 66 Secondary clutch bolt 31 7 23 Taper Lock installation setscrews 14 10 4 Spark plugs 25 18 Handlebar mounting bolts 36 5 27 Fork leg bolts in triple clamps 6 8 5 Fork pivot...

Page 153: ...6 Cog belt adjustment Deflection mm 7 3 in 0 288 Force kg 6 44 lbf 14 2 CHASSIS Overall length mm 2698 in 105 Overall width mm 835 in 32 5 Overall height mm 1233 in 48 Dry weight kg 160 lb 350 Track w...

Page 154: ...DIMENSIONS AND TOLERANCES 15 4 FLUIDS Fuel tank capacity L 17 5 U S gal 4 5...

Page 155: ...6 357 Cooling Fan Nut Removal Tool 529 021 000 Piston Wrist Pin Extractor 529 023 400 Rubber Cushion 529 016 900 Piston Circlip Installation Tool 420 876 970 Piston Ring Compressor 413 701 000 Anti Se...

Page 156: ...ONIC BOX 1 Nylon fasteners 2 Electronic box wires 3 Spark plug wires 4 Engine electrical power output When replacing the electronic box or the spark plug wires it is important that the wires be put ba...

Page 157: ...important that the wires be installed exactly where they are intended to avoid interference during operation Refer to the photograph on the right The section of the wiring harness going toward the re...

Page 158: ...Headlight wire B Accessories wire C Engine cutoff and emergency stop D Stop lamp microswitch E Dimmer switch Bring together the wires of the switch for the lights E of the switch for the stop light D...

Page 159: ...celerator cable to the retaining screw of the steering column No 2 u u WARNING Before installing them make sure the cables are in good condition Install the ends of the cables carefully and secure the...

Page 160: ...er the electric wires and over the carburetor cables o Then install the choke cables on the carburetors l NOTICE One of the two choke cables is longer than the other Install it on the carburetor that...

Page 161: ...ck to make sure there are no leaks Replace them if necessary Brake hose o The brake hose is secured to the brake master cylinder o Pass the hose in front of the handlebars and steering column o The ho...

Page 162: ...cuum No 2 The two outlets are 1 The carburetor feed on the MAG side No 3 2 The carburetor feed on the PTO side No 5 After leaving the pump the vacuum hose goes along the base of the engine under the t...

Page 163: ...e cable and connects to the PTO side carburetor Carefully install all the spring clamps Overflow hose and carburetor vent hoses The overflow hose is connected to the cap of the gas tank It is then rou...

Page 164: ...WIRE CABLE AND HOSE ROUTING 17 9 3 The hoses go along the chassis and are attached to the nylon cable fastener by a tie wrap...

Page 165: ...ocket teeth Drive sprocket diameter Brake system Secondary transmission 61 mm 2 4 in 2 x Mikuni VM 34 choke Tuned pipe and silencer IBC Power Bloc Rotax 503 fan cooled piston port 2 496 7 cc 30 3 in3...

Page 166: ...Ski width 835 mm 32 5 in 1233 mm 48 in 2698 mm 105 in DIMENSIONS Overall length Headlight high low beam MATERIALS Chassis Hood 2 x 30 30 W 6061 T6 Aluminium HMW Polyethylene Recommended fuel Recommend...

Page 167: ...HIGH ALTITUDE TECHNICAL DATA...

Page 168: ...o line and the MAX To line 5 The temperature values where each of these vertical lines intersect the horizontal carb inlet temperature axis are the approximate min median and max temperatures that are...

Page 169: ...of thumb it is recommended to remove one weight from each arm of the primary clutch for each 2000ft increase in elevation As a reference the sea level 0 ft elevation set up has nine weights at each o...

Page 170: ...3...

Page 171: ...4...

Page 172: ...000 2000 3000 4000 5000 6000 7000 8000 9000 10000 Feet F 0 305 610 914 1219 1524 1829 2134 2438 2743 3048 Meter 20 65 60 60 55 55 55 50 50 45 45 45 PTO 68 65 60 60 55 55 55 50 50 45 45 45 MAG 25 65 60...

Page 173: ...ce manual for future reference WARRANTY INFORMATION MAIL TO 700 rue Jean Marchand L vis QC Canada G6V 9G6 T l 418 838 3783 Fax 418 838 3957 Attn Warranty Claims VEHICLE SERIAL NUMBER PLACE OF PURCHASE...

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Summary of Contents for 2002 Snow Hawk

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AD Boivin 2002 Snow Hawk, Service Manual

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Summary of Contents for 2002 Snow Hawk

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