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VI

MMR2003_018_00_02A.FM

MMR2000_042_00-02A.FM

A16D0IA

1

2

A

1

A-Series and B-Series Only

Should  installation  procedure  be  required,  refer

to BRAKE then look for 

Brake Disc and Countershaft

Bearing Adjustment

.

All Models

Check end play of driven pulley on countershaft by

pushing pulley towards outer housing so that the inner

shims (P/N 504 108 200) contact it. Measure end play

at the mounting screw end between shim(s) and puley.

See illustration.

TYPICAL — TOP VIEW

1. Shim (P/N 504 108 200) (as required)

2. Contact

A. 0 to 1 mm (0 to 3/64 in)

Torque retaining screw 

no. 13

 to 25 N•m (18 lbf•ft).

ADJUSTMENT

Refer to PULLEY DISTANCE AND ALIGNMENT to adjust

pulley  distance.  Adjust  drive  belt  height  be-

tween  pulley  halves  to  obtain  specified  belt

deflection.

Reinstall  the  pulley  on  the  countershaft  by  rever-

sing the removal procedure.

CAUTION:

 Always apply anti-seize lubricant (P/N

413 701 000) on the countershaft before final pulley

installation.

05-03-5

Turn puller handle and sliding half at once to extract

the bushing.

INSTALLATION

Countershaft

IMPORTANT:

  Large  bushing  retaining  screws  and

washers  must  be  removed  before  small  bushing

installation.
Coat  bushing  outside  diameter  with  Loctite  609

(P/N 413 703 100).
Install bushing as following photo.

A03D1YA

529 031 300

529 031 200

A03D1ZA

529 031 300

529 031 200

Cam

Coat  cam 

no.  18

  interior  with  anti-seize  lubricant.

ASSEMBLY

Came Slider Shoe

Section 05    TRANSMISSION

Subsection 03   (DRIVEN PULLEY)

When replacing slider shoes 

no. 4

, always install a new

set (3 shoes) to maintain equal pressure on the cam.
Assemble  driven  pulley  components  by  reversing

the disassembly procedure.

TYPICAL PAGE

Title indicates

main procedure

to be carried-out.

Reference to look

up a certain section

and subsection.

In this case it concerns

pulleys adjustment.

Italic bold face setting

in this case indicates

that particular

procedure for

A and B-Series is

finished, so from

this point, all models

are concerned.

Illustration always

follows text to which

it pertains.

Subtitle indicates

a particular procedure

for the named part.

Bold face number following part

name refers to exploded view

at beginning of subsection.

Call-outs for

above illustration.

Italic bold face type

setting indicates a

particular procedure

concerning a model.

“TYPICAL” caption

indicates a general

view which does

not represent full

detail.

“TOP VIEW”

caption helps you

in understanding

illustration.

A01A2BS

INTRODUCTION

Summary of Contents for 2637

Page 1: ......

Page 2: ...2003 Shop Manual Supplement 4 TECTM LEGEND V 1000 SPORT GRAND TOURING V 1000 SPORT This supplement must be used in conjunction with the 2003 ZX Series Shop Manual P N 484 200 042...

Page 3: ...nted in Canada Registered trademarks of Bombardier Inc This document contains the trademarks of the following companies Loctite is a trademark of Loctite Corporation Molykote is a trademark of Dow Cor...

Page 4: ...GINE MANAGEMENT 01 Table of contents 04 01 1 02 Overview 04 02 1 03 Component inspection and adjustment 04 03 1 04 Diagnostic procedures 04 04 1 05 TRANSMISSION 01 Table of contents 05 01 1 02 Drive b...

Page 5: ...t strongly recommended when considering replacement of any com ponent Dealer and or distributor assistance should be sought in case of doubt The engines and the corresponding components identified in...

Page 6: ...R COUNTRY MODEL NUMBER GRAND TOURING E SPORT V 1000 2 tone Blue U S CDN 2638 GRAND TOURING E SPORT V 1000 2 tone Blue EUR 2644 LEGEND E SPORT V 1000 2 tone Blue U S CDN 2637 A32H0DA 1 2 B P S 1 5 9 2...

Page 7: ...er square inch LH left hand LO low LT long track m meter MAPS manifold air pressure sensor Max maximum Min minimum mL milliliter mm millimeter mn minute MPH mile per hour MPI multi protocol interface...

Page 8: ...case nut must be torqued to 4 N m or 35 lbf in This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog Exploded view assists you in identifying parts a...

Page 9: ...oved before small bushing installation Coat bushing outside diameter with Loctite 609 P N 413 703 100 Install bushing as following photo A03D1YA 529 031 300 529 031 200 A03D1ZA 529 031 300 529 031 200...

Page 10: ...replaced by customary fasteners or vice versa Mismatched or incorrect fasteners could cause damage to the vehicle or possible personal injury As many of the procedures in this manual are in terrelate...

Page 11: ...s bolt and nut and allow to dry for 30 seconds 3 Choose proper strength Loctite threadlocker 4 Apply several drops along the threaded hole and at the bottom of the hole 5 Apply several drops on bolt t...

Page 12: ...EAD REPAIR Stripped Threads 1 Release agent 2 Stripped threads 3 Form A Thread 4 Tape 5 Cleaned bolt 6 Plate 7 New threads 8 Threadlocker Standard Thread Repair 1 Follow instructions on Loctite FORM A...

Page 13: ...ket on mating surfaces and assemble immediately NOTE If the cover is bolted to blind holes above apply proper strength Loctite in the hole and on threads Tighten If holes are sunken apply proper stren...

Page 14: ...trength Loctite on lead ing edge of outer metallic gasket diameter NOTE Any Loctite product can be used here A low strength liquid is recommended as normal strength and gap are required 4 Install acco...

Page 15: ...2 M4 18 3 M4 27 4 M5 35 8 M6 71 9 M6 80 10 M6 89 11 M6 97 12 M6 106 N m FASTENER SIZE 8 8 grade Lbf ft 21 M8 15 22 M8 16 23 M8 17 24 M8 18 25 M8 18 43 M10 32 44 M10 32 45 M10 33 46 M10 34 47 M10 35 48...

Page 16: ..._____________________________________________________ ____________________________________________________________ ____________________________________________________________ ________________________...

Page 17: ...ions After Sales Service 565 de la Montagne Street Valcourt Quebec Canada J0E 2L0 Technical Publications After Sales Service 565 de la Montagne Street Valcourt Quebec Canada J0E 2L0 Technical Publicat...

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