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BOMBARDIER ALPINE 503 3341 1985, Shop Manual

The Bombardier Alpine 503 3341 1985 Shop Manual is a comprehensive guide for maintaining and repairing your snowmobile. This manual includes detailed instructions and diagrams to help you keep your vehicle running smoothly. Download this manual for free from manualshive.com and keep your snowmobile in top condition.

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Summary of Contents for ALPINE 503 3341 1985

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Page 4: ...4th trimester 1984 National Library of Canada All rights reserved No parts of this manual may be reproduced in any form without the prior written per mission of Bombardier Inc Bombardier Inc 1984 Prin...

Page 5: ...and or distributor assistance should be sought in case of doubt Torque wrench tightening specifications must be strictly adhered by locking devi ces ex tab lock nylon lock must be installed or replace...

Page 6: ...14 FORMULA MX 3720 FORMULA PLUS 3721 ALPINE 503 3341 MIRAGE Ill 5147 Furthermore each vehicle has its particular veh1cle seri al number Serial number 0000 model number A00000000 1 The eng1 ne also has...

Page 7: ...ication Bombardier Inc however maintains a policy of continuous improvement of its products with out imposing upon itself any obligation to install them on products previously manufactured Bombardier...

Page 8: ...ad and thoroughly understand the entire sec tion or sub section in which the procedure is contained A number of procedures throughout the book require the use of special tools Where a special tool1s i...

Page 9: ...elt 03 02 1 03 Drive pulley 03 03 1 04 Driven pulley 03 04 1 05 Pulley alignment 03 05 1 06 Brake 03 06 1 07 Chaincase 03 07 1 08 Gearbox 03 08 1 09 Drive cha1n 03 09 1 04 ELECTRICAL 01 Electric chart...

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Page 11: ...n adjustment key Socket 11113 mm Socket 27 26 mm short H E lrt G K A001001016 1985 MODELS Elan C1 tat1on LS E Tundra LT Skandic 377 R Safari 377 E 447 Mirage Ill Safan GL Formula SS Formula SP Formula...

Page 12: ......

Page 13: ...ster 414 3482 00 A000002007 JJD Section 01 TOOLS Sub section 02 SERVICE TOOLS SERVICE TOOLS USE Engine timing to determtne T D C 4000001001 Engine timing static Continuity tests Engine electrical comp...

Page 14: ...420 276 900 Water pump seal sleeve 462 467 532 537 water pump 420 876 490 rotary valve 420 876 495 A000002013 Rotary valve shaft pusher 420876610 01 02 2 To remove drive pulley from crankshaft A00000...

Page 15: ...e l Puller assembly 420 876 296 With 145 mm screw accessories g A000002017 A0000020t8 Section 01 TOOLS Sub section 02 SERVICE TOOLS All engine types 01 02 3...

Page 16: ...X Screw M8 x 40 121 420 840 680 X X X X X Crankshaft proteciOr PTO 420 876 550 X X X X X X X X Crankshaft proteciOr MAG 420 876 557 X X X X Crank sraft xotector MAG 420 876 555 X X X Distance ring 42...

Page 17: ...420 977 900 A 000002023 Degree wheel 414 35 2 900 A000002025 420 876 171 420 876 175 420 876 570 420 240 275 Section 01 TOOLS Sub section 02 SERVICE TOOLS A0000020 11 Cylinder aligning tools A0000040...

Page 18: ...sher 420 977 920 A0000020J1 Seal pusher 420 876 510 Bearing pusher 420 876 500 A0000020 33 01 02 6 420 876 355 420 876 357 Fan holder Protect crankshaft end when using bearing puller Protect o Oc A000...

Page 19: ...0 A 000002037 Crankshaft locking tool 420 876 640 A000002039 Section 01 TOOLS Sub section 02 SERVICE TOOLS To install rotary valve shaft seal To install polyamid ring in crankcase A0000020J6 On PTO si...

Page 20: ...67 532 537 engines 420 277 900 A000002042 Magneto puller rtng All engine types except 247 42 0 876 080 A000002044 Magneto puller 247 engine 253 377 447 462 467 503 532 537 engines A OCOOOlC46 01 02 8...

Page 21: ...TOOLS To remove the bearings from the drive shaft and the lay shaft 1 screw MB x 25 2 420 240 275 2 plate 420 977 700 3 half ring 2 420 876 330 4 ring 420 977 480 Transmission cover index rod ball ins...

Page 22: ...900 2 pressure plate 529 004 400 3 washer 121 391 302 900 4 hexagonal screw 121 1 2 20 X 6 391 717 200 5 bending block no 529 004 100 lw1de cleats bending block no 2 narrow 529 004 200 cleats bending...

Page 23: ...1nstall suspension sprmgs To hold drive axle during installation or removal of chaincase and or end bearing housing All torque reaction slide suspensions except C1tation LS E and Formula MX Pius All...

Page 24: ...J...

Page 25: ...VICE PRODUCTS For threadlocking threadsealing gasketing bonding and retaining applications on engines pulleys and fasteners etc A medrum strength adhesive for threadlocking and threadsealing Vibratron...

Page 26: ...es and parts should be assembled as soon as possible after adhesive is applied Creates a foaming action that lifts gaskets off in minutes Protects moving and stationay parts aga1nst high temperature s...

Page 27: ...ubrication at low tempera tures For roller round shaft drive pulleys_ Rotary valve lubricant Chaincase lubricant on all models Specially formulated oil that meets All models lubrication requirements o...

Page 28: ......

Page 29: ...V 1 1 2 3 17 2 1 e 2 3 0 I l 20 22 1 3 1 Section 02 ENGINE Sub section 01 247 ENGINE TYPE 247 ENGINE TYPE ENGINE REMOVAL INSTALLATION Engine support and muffler 16 N m 11 42 lbf nl 02 01 1...

Page 30: ...Elastic stop nut 318 24 141 22 Washer 141 23 Elastic stop nut 5116 24 141 24 Engine support 25 Lock washer 10 mm 141 26 Hexagonal nut 10 mm 141 27 Cross support 121 28 Vibration damper 141 29 Threaded...

Page 31: ...10 Decompressor knob 11 Nut 8mm 14 12 Washer 8 4 mm 141 13 Cylinder head Section 02 ENGINE Sub section 01 247 ENGINE TYPE TOP END I 1 1a 19 _ ____ _ _ 25 14 Head gasket 15 Srud M8 x 79 5 121 16 Tab lo...

Page 32: ...AX Cylinder taper NA NA OBmm 0031 1 Cylinder out of N A NA 05 mm round 0020 1 Cylinder piston 065 mm 20 mm 20 mm clearance 1 0026 1 L0079 l 1 0079 Ring piston groove 04 mm 20 mm 20 mm clearance 1 002...

Page 33: ...ompressor switch on off posttion If there is some end gap be tween cable housing and decompressor valve lever turn the adjustment screw counterclockwise until you elimi nate that end gap Beware not to...

Page 34: ...3 0 5 1 0 mm 7 Ball bearing 6305 121 8 Crankcase gasket 9 Dowel rube 10 mm x 15 121 10 Stud MB x 171 141 II Crankcase half mag side 12 Lock washer 8 mm 1 51 Hexagonal nut 8 mm crankcase with studs f5...

Page 35: ...NE TYPE TOLERANCES MEASUREMENTS FITTING NEW PARTS WEAR LIMIT IMIN I IMAX I Crankshaft NA N A 10 mm deflection 0039 1 Connect1 ng rod b1 g 20 mm 53 mm 1 0 mm end axial play 10079 1 1 0 208 1 1 0394 1 C...

Page 36: ...seal damage See Tool Section Apply a light coat of lithium grease on seal lip Spray some new injection oil on all moving parts of the crankshaft CAUTION To ensure appropriate crankshaft T bearing lubr...

Page 37: ...______ 48 ff 47 4S 46 48 53 13 52 50 I 51 2 tb Section 02 ENGINE Sub section 01 247 ENGINE TYPE MAGNETO COOLING SYSTEM 02 01 9...

Page 38: ...eto retaining nut Lock crankshaft with magneto housing holder ser vice tool as illustrated Remove magneto retaining nut 02 01 10 29 L1ghting calf w1th 2 cables 30 Phillips head screw M5 x 28 2 31 C m...

Page 39: ...Whenever a coil is replaced the air gap distance be tween magnet and coil end must be adjusted To check air gap 1nsert a feeler gauge of 0 25 0 38 mm 010 015 between magnet and co11 ends If neces sary...

Page 40: ...then torque retaining nut to 85 N m 63 lbf ft 48 53 Protection cap mass cable At reassembly coat all electric connections with silicone dielectric grease to prevent corrosion or moisture from penetra...

Page 41: ...then torque retaining nut to 85 N m 63 lbf ft 48 53 Protection cap mass cable At reassembly coat all electric connections with silicone dielectric grease to prevent corrosion or moisture from penetra...

Page 42: ...NG Before disconnecting any electrical wire in starter system always first disconnect the battery cable muffler hood retaining cable oil mject1on pump cable electrical connectors clamp retaining carbu...

Page 43: ...7 a 21 N m 9 _ ti5 i l5 1 b foftl 10 cJ Section 02 ENGINE Sub section 02 253 ENGINE TYPE Q 11 eJ 12 14 u 10 15 TOP END 02 02 3...

Page 44: ...clips from piston Drive the gudgeon pin out of piston using a suitable drive punch and hammer W CAUTION When tapping out gudgeon pins hold T piston firmly in place to eliminate the possibilities of tr...

Page 45: ...lip break AOOI002002 CAUTION Circlips must not move freely in the T groove after installation If so replace them 1 Head cylinder Before inserting piston in head cylinder lubricate it with now injectio...

Page 46: ...2 ENGINE TYPE Section 0 25533 E NG I NE Sub section 02 BOTTOM END 3 4 I 1 s QDd 9 N m 180 lbf inl...

Page 47: ...al without locating ring or without spacing legs ensure to maintain the specified gap between shim bearing retainer and the seal Section 02 ENGINE Sub section 02 253 ENGINE TYPE 9 Sh1m las rf quiredl...

Page 48: ...refer to Engine dimensions measurement sect1on 02 10 ASSEMBLY General r CAUTION Before engine reassembly make sure T there is no axial pressure on crankshaft and that the crankshaft end play is proper...

Page 49: ...30 I 10 14 15 19 Section 02 ENGINE Sub section 02 253 ENGINE TYPE MAGNETO 1 61 1 0 I I _ 6 18 j I I 22 1 J J 21 1 6 16 27 55 N m 41 lbf ftl 02 02 9...

Page 50: ...To remove magneto flywheel retaining nut lock crankshaft with crankshaft locking tool P N 420 876 640 A003001005 02 02 10 Crankshaft lockmg tool 16 Loc lte 221 rv oler 17 Screw M5 x 18 121 18 Generarm...

Page 51: ...nnector to the black yel low striped wire To install the ground connector of the armature plate tape the new black lead to the old one and pull it under the lighting coil with the old wire Solder an e...

Page 52: ...e T the loose epoxy from harness ASSEMBLY 23 28 29 30 Armature plate magneto flywheel lock washer nut Position the armature plate on the crankcase aligning the marks on both parts Clean crankshaft ext...

Page 53: ...18 Section 02 ENGINE Sub section 02 253 ENGINE TYPE COOLING SYSTEM 16 I 16 1 13 02 02 13...

Page 54: ...ve sh1m s between pulley halves Install excess shim s be tween fan and lock washer 1 4 Ball bearing fan housing It is first necessary to heat bearing housing to 65 C 150 F to remove or install bearing...

Page 55: ...JECTION PUMP RESERVOIR 48 J 47 2 I 3 o i 10 f1 t l 1 111 q 11 21 Y 12 1 19 I lzo 4 I 14 I 19 w J OI 11 31 18 I 16 25 l _ 1 q 14 24 1 u 23 I 14 26 j 28 22 jf l 29 Parts in 11 ustraoon marked with are n...

Page 56: ...876 690 tool J PiN 420 876 690 Gear holder A0030020 0 02 02 16 26 Oil banta gasket 121 27 BanJO 2B Banjo bolt 29 01i line 73 330 mml 30 Clamp 121 37 Taptl e screw MS x 20 141 32 0 nng 33 Plate 34 Scre...

Page 57: ...es should be full of oil If required bleed the main oil line between tank and pump by loosening the bleeder screw until all air has escaped from the line Make sure the tank is suff1ciently filled Chec...

Page 58: ......

Page 59: ...TYPE 377 ENGINE TYPE ENGINE REMOVAL 8t INSTALLATION n l 14 l 1 I o a 12 I 5 filf 13 D I 17 d16 A 1 19 22 I 20 I 18 i I _ Q I I 28 31 28 1 30 I 22 Nom 27 f 16 lbfoft Engine support muffler Safari 377...

Page 60: ...p screw M6 x 20 30 Lock washer 8 mm 141 10 Washer 6 mm 31 Gasket 141 11 Muffler attachment 32 Rubber mounr 141 12 Bushing 33 Washer 10 5 mm 141 13 Cap screw M6 x 16 121 34 Lock washer 10 mm 141 14 Ela...

Page 61: ...1 Section 02 ENGINE Sub section 03 377 ENGINE TYPE ENGINE REMOVAL INSTALLATION tTiu r1 31 n 32 33 Engine support muffler Skandic 377 Skandic 377R 8 55 N m 140 lbf ftl 02 03 3...

Page 62: ...02 03 4 18 Cup 121 19 Lock washer 10 mm 12 20 Gasker 141 2 1 Exhaust mandold 22 Spnng 61 23 Connector 24 Lock washer 8 mm 1 41 25 Allen screw M8 x 30 141 26 Exhaust washer 27 Sprmg 28 Spnng 2 29 Muffl...

Page 63: ...m I 15 lbf ftl 11 0 20N m 15 lbf hl r 12 13 17 Section 02 ENGINE Sub section 03 377 ENGINE TYPE 23 N m 117 lbf ltl 23 N m 17 lbf f l I 1 2 1 I _1 1 _3 I 0 19 0 20 0 _21 r l u I 22 I 23 24 TOP END 02...

Page 64: ...h and hammer rCAUTION When tapping out gudgeon pins hold Y piston firmly in place to eliminate the possibilities of transmitting shock and pressure to the connecting rod INSPECTION The inspection of t...

Page 65: ...align1ng tool to secure sealing of mtake manifold and exhaust Isee Tools section before tight ening cylinder head nuts 4 009002001 Section 02 ENGINE Sub section 03 377 ENGINE TYPE 1 2 Nuts distance nu...

Page 66: ...Section o2 Sub section O N I EENGINE TYPE BOTTOM END 02 03 8 21 Nom i 15 bf of tl 38 Nom t28 lbfoft l 18 22 f 23 24 25 12 11 O l J i rr _ I 1 7 26a 7 I 28 9 Nom 21 Nom t7 lbf l l 29 I 15 lbfoft l...

Page 67: ...02017 Section 02 ENGINE Sub section 03 377 ENGINE TYPE 16 Hex Nut 22 x 1 5 17 0 ring 18 Lower crankcase 79 Loctite 51 5 20 Lock washer 8 mm 110 2 7 Hex screw M8 x 45 1 21 22 Locrtre 242 23 Stud M 10 x...

Page 68: ...on oil on all the moving parts of the crankshaft 0 NOTE Prior to apply1ng Loctite 515 it IS possible to use primer N P N 413 7053 OOl or primer NF P N 413 7020 001 Th1s mcreases cure speed and gap fil...

Page 69: ...11 12 9 28 Section 02 ENGINE Sub section 03 377 ENGINE TYPE MAGNETO 23 02 03 11...

Page 70: ...pulleys 0 NOTE Before disassembling magneto plate in dexing marks should be located to facilitate reas sembly To remove magneto flywheel retaming nut lock crankshaft with crankshaft locking tool PIN 4...

Page 71: ...ed without crankshaft locking tool PIN 420 876 065 PIN 420 876 080 A009002083 REPAIR 26 Generating coil To replace generating coil Heat the armature plate to 93 C 1200 Fl around the screw holes to bre...

Page 72: ...ubes splice con nectors lighting coil screws To replace lighting coil Heat the armature plate to 93 C 1200 Fi around the screw holes to break the Locttte bond A001002003 02 03 14 Heat Protect harness...

Page 73: ...on crankshaft Clean nut threads and apply Loctite 242 blue medium strength before tighten1ng nut to 85 Nom 63 lbf ftl At reassembly coat all electric connections with sili cone dielectnque grease P N...

Page 74: ...g strip 6 Cylinder cowl 7 Spnng nut 4 8 16 8 Washer 161 9 Screw 8 x 16 6 10 Woodruff key 3 x 5 11 Fan shaft 12 Ball beahng 6203 121 13 Shrm 12 02 03 16 12 116 17 f 65Nm 14 Crrclrp 15 Fan housrng 16 Dr...

Page 75: ...en pulley halves Install excess sh imls between fan and lock washer 12 15 Ball bearing fan housing It is first necessary to heat bearing housing to 65 C 1150 F to remove or rnstall bearrng 24 25 26 Ai...

Page 76: ...UMP RESERVOIR Oil injection pump 39 52 Gasket set 3 t 1 l I 12 f 14 11 1 21 1 9 120 16 1 13 14 19 17 30 I 34 28 I t J T 1 _ r 29 27 33 I I 2s 6 I v d 32 2s 3o oP l 29 22 02 0318 33 OEJ 23 y 31 I 37 Pa...

Page 77: ...iers then lock gear in place using no 420 876 690 tool Gear ho dcr AOOJ002009 I I J P N 420 8 ti 69 1 Section 02 ENGINE Sub section 03 377 ENGINE TYPE 28 BanJO oil gasker 41 29 Banjo 121 30 Ban1o bolt...

Page 78: ...etighten the adjuster nut A001002008 02 03 20 Marks tn l ne Bleeder screw To bleed oil lines All oil lines should be full of oil If required bleed the main oil line between tank and pump by lqosen1ng...

Page 79: ...Section 02 ENGINE Sub section 04 447 ENGINE TYPE 447 ENGINE TYPE ENGINE REMOVAL INSTALLATION Engine support muffler 11 TI 9 I 14 I 0 12 I l7 21 Nom 115 lbfof _ 33 34 EF 38 N m 35 128 lbf ft I 02 04 1...

Page 80: ...er cable Wiring harness Engine support nuts under engine support 2 9 35 Engine support nuts manifold bolts Torque the engine support nuts to 38 N m 28 lbf ft Torque the manifold bolts to 21 N m 115 lb...

Page 81: ...21 N m 115 lbf ft l 13 2 1 N om 1 15 lbf ft l Section 02 ENGINE Sub section 04 447 ENGINE TYPE 23 N m 111 or tn 2 I I 23 N m UJJ 111 lof ftl 3 I 0 19 0 20 21 rbo 22 I 24 23 TOP END 02 04 3...

Page 82: ...tool inserted in piston notch remove circlips from piston Drive the gudgeon pin out of piston using a suitable drive punch and hammer W CAUTION When tapping out gudgeon pins hold f piston firmly in pl...

Page 83: ...in the T groove after installation If so replace them 19 20 Semi trapez rectangular rings Check piston rings position 7 Cylinder Before inserting piston in cylinder lubr1cate the cylinder with new In...

Page 84: ...P T 0 side cylinder Install armature plate fan housmg and then air deflector 8 Gasket Install a gasket on each s1 de of the air deflector 9 11 13 Intake manifold screws MB x 40 MB X 74 Install intake...

Page 85: ...m 115 lbl f ll 19 _ r v 9 Sub Section 02 section 04 447 EN ENGINE GINE TYPE BOTTOM END 12 11 1 13 rb l I o JeJ 24 27 I I 16 0 17 25_ D 29 l N n1 Y _ _ __ _ 11 5t llf fll 2 8 9N m 28 l80 tt lf inl 02 0...

Page 86: ...P T O side t Magneto s1de Q l o A000002017 02 04 8 16 Hexagonal nur 22 x 1 5 77 0 rmg 18 Lower crankcase 19 Loewe 515 20 Lock washer 8 mm IIOJ 21 Hexagonal screw M8 x 45 121 22 LocMe 242 23 Stud M 10...

Page 87: ...arts of the crankshaft 0 NOTE Prior to apply Loctite 515 it is possible to use primer N PIN 413 7053 001 or primer NF WIN 413 7024 001 It increases cure speed and gap filling ca pability Refer to supp...

Page 88: ...y 11 Protection hose 161 12 Splice connecwr 161 13 Armature plare ass y 14 Washer 5 5 mm 121 15 Lock washer 5 mm 1 4 02 04 10 25 10 11 _ 1 12 16 ocme 242 17 Allen screw M5 x 18 121 18 Magneto flywheel...

Page 89: ...1s will eliminate the possibility of thread breakage remove magneto retaining nut lllJ 1 I A009002011 Crankshaft locking tool P N 420 876 640 Section 02 ENGINE Sub section 04 447 ENGINE TYPE 18 Magnet...

Page 90: ...e coil and apply Loctite 242 lblue medium strength to screws before assembly CAUTION Before reinstalling the magneto re move the loose epoxy from harness 02 04 12 11 12 28 29 Protector tube splice con...

Page 91: ...ock washer on crank shaft Clean nut threads and apply Loctite 242 blue medium strength before lightening nut to 85 N m 63 lbf ft At reassembly coat all electnc connections with silicone dielectric gre...

Page 92: ...nce sleeve I screw 16 h If 1 Hexagona 8 mm 131 I 7 Pulley a MB 6 5 0 0 5 mm onat screw F 3 0 9 6 mm 20 M 6 5 Sealtng smp 21 Hexagona 6 Cylinder 4 8 16 2 2 V be 7 Spnng nut 23 Fan cover B w 61 6 2 Scre...

Page 93: ...es Install excess shimlsl between fan and lock washer 12 15 Ball bearing fan housing It is first necessary to heat bearmg hous1 ng to 65 C i150 F to remove or 1nstall bearing 24 25 26 Air duct washer...

Page 94: ...37_ 0 36 50 I _ c I 44 V 45 52 v 43 lb 146 q J I 4 t 48 co sr 149 1 40 7 I 41 3 42 I M i J 39 yltvf1j 1 12 02 04 16 I 27 19 I 26 1 25 Cf v _ Yj 14 dl 16 cr 1 14 I 13 14 21 I192o liJ 19 17 30 r 18 I I...

Page 95: ...e in the pump mounting flange 14 15 33 Spring clip clamp Always check for spring clips and clamps tightness CLEANING Clean all metal components in a non ferrous metal clean er DISASSEMBLY 0 NOTE Some...

Page 96: ...accordingly Retighten the adjuster nut A001002008 To bleed oil lines All oil lines should be full of oil If required bleed the main oil line between tank and pump by loosening the blee der screw unti...

Page 97: ...I 14 18 Section 02 ENGINE Sub section 05 462 ENGINE TYPE 462 ENGINE TYPE ENGINE REMOVAL INSTALLATION 21 N m 115 lbf fU 33 J 40 _ _ 41 p 37 38 39 J 35 N ITl 1 126 lbf ft I 35 02 05 1...

Page 98: ...retor and intake manifold 02 05 2 24 Oil me 25 Sprmg 26 Gear clamp 141 27 Elbow male connecror 28 Grommet 12 29 male connector 30 Oil me 31 Sprmg 32 Engine Rotax 462 33 Elastic stop nut M10 x 1 5 141...

Page 99: ...23 N m 117 lbf ftl Section 02 ENGINE Sub section 05 462 ENGINE TYPE TOP END 2 02 05 3...

Page 100: ...nate the possibilities of transmitting shock and pressure to the connecting rod INSPECTION The 1nspection of the engine top end must include the following measurements 02 05 4 I I Cylmdericrankcase ga...

Page 101: ...e same color 19 Cylinder studs Because of cap nuts cylinder studs have to be screwed into the crilnkcase so that they do not protrude by more than 151 mm 5 950 Longest threaded part should be in the c...

Page 102: ...Section 02 ENGINE Sub section 05 462 ENGINE TYPE BOTTOM END 5 12 OQ l 10 I 0 10 I ll 02 05 6...

Page 103: ...1 25 Drstance sleeve 15 mm 1 4 26 Lock washer 10 mm 14 27 Hex nut M10 141 28 Hex screw MB x 70 fBI 29 Allen bole MB x 40 14 30 Lock washer 8 mm 14 31 Hex screw M6 x 35 121 32 Lock washer 6 mm 121 INSP...

Page 104: ...the moving parts of the crankshaft Then apply a light coat of loctite 515 413 7027 001 on matmg surfaces 02 05 8 0 NOTE Pnor to applying Loctite 515 1t is possible to use primer N PIN 413 7053 001 or...

Page 105: ...threads prior to assembly 2 Stud Because of cap nuts cylinder studs have to be screwed into the crankcase so that they do not exceed further than 151 mm 15 950 1 Longest threaded end should be in the...

Page 106: ...Section 02 462 ENGINE ENGINE TYPE Sub section 05 MAGNETO 02 05 10 30 22 21 1l j 18...

Page 107: ...king tool service tool as illustrated magneto side p1ston must be at top dead center 0 NOTE It should be noted that to correctly remove a Loctite locked fastener it is first necessary to tap on the fa...

Page 108: ...e Insert the new w ires into the old connector houstng and install conn ec tors Insert new w1res A 00 1002004 02 05 12 11r CAUTION Replace the old wires in the connec tor with the same color coded new...

Page 109: ...this clip A001002005 W CAUTION Before reinstalling magneto remove T the loose epoxy from harness Section 02 ENGINE Sub section 05 462 ENGINE TYPE 1 9 10 11 19 Armature plate lock washers washers Locti...

Page 110: ...Section 02 ENGINE Sub section 05 462 ENGINE TYPE COOLING SYSTEM I 24 02 05 14 I 4 23...

Page 111: ...container Remove coolant tank cap and lift the rear of the vehi cle to drain the heat exchangers When the coolant level is low enough remove the hose from thermostat hous1ng Section 02 ENGINE Sub sect...

Page 112: ...ecifically recommanded for aluminum engines To refill cooling system Remove drain hose and reinstall initial one Place rear of vehicle on the ground Refill coolant tank slowly until coolant overfills...

Page 113: ...2 1 N m 115 lbl ftl Section 02 ENGINE Sub section 05 462 ENGINE TYPE ROTARY VALVE COOLANT PUMP OIL RESERVOIR 31 22 3 34 35 i 14 36 02 05 17...

Page 114: ...usher tool P N 420 876 610 11 12 Spring holder cup circlip If it is necessary to disassemble components of rotary valve shaft assembly compress spring retaining cup in order to remove circlip 02 05 18...

Page 115: ...de must be facing crankshaft 14 15 Oil seal distance ring To install seals proceed as follows A 0 3002011 Apply lithrum grease on seal lips First seal sits on bearing outer ring Align the distance rin...

Page 116: ...Pusher PIN 420 876 605 22 Hexagonal screw Apply Loctite 242 on threads 25 Rotary valve Rotary valve adjustment when replacing crankcase having no ttming marks Angle fond er 414 3529 001 A00000 1089 0...

Page 117: ...stallation position Spray some injection oil on rotary valve before closing rotary valve cover 30 Screw MB x 20 Torque the four cover screws to 21 N m 15 lbf ftl Section 02 ENGINE Sub section 05 462 E...

Page 118: ...INE TYPE OIL INJECTION PUMP RESERVOIR 1 EJ 2 i I 1 9 3 4 C 6 I 5 rt 7 8 I I 9 I 11 a r r 10 1 13 I G 121 i _flt 14 15 f t 16 2 Parts in Illustration marked with are nor available as spare pans 18 17 f...

Page 119: ...se 79 2 mm 29 Support 30 Hex screw M6 x 12 151 31 CI P 32 Lock washer 6 mm 151 33 Washer 6 4 mm 151 34 Elast c srop nut f 15 131 35 Washer 6 2 mm ill 36 Rubber 11ng 37 Nur6 mm 38 Washer 6 2 mm 121 39...

Page 120: ...us engien damage To bleed oil lines All oil lines should be full of oil To bleed the main oil line between tank and pump loosen the bleeder screw do not start engine and let the air escape until oil s...

Page 121: ...35 34 33 U11 30 Section 02 ENGINE Sub section 06 467 ENGINE TYPE 467 ENGINE TYPE ENGINE REMOVAL INSTALLATION Engine supports muffler I 42 48 N m 1 35 lbf ltl 02 06 1...

Page 122: ...engine supports on frame ENGINE SUPPORTS MUFFLER DISASSEMBLY ASSEMBLY 22 26 Engine support screw manifold screw Torque the engine supports screws to 48 N m 35 lbf ftl Torque the man1fold screws to 21...

Page 123: ...l 11 lvf i2 R Gask r tO rmy J r21 9 Ga kHr l lJ 10 Cap n ur MB Bi 17 Flai WiJSht t 8 1 1 81 Section 02 ENGINE Sub section 06 467 ENGINE TYPE c 14 c J 15 16 17 J 18 1 Cv mdcr t2 3 Cylmder crar g 3sk _...

Page 124: ...ents TOLERANCES MEASUREMENTS FITIING NEW PARTS WEAR LIMIT MIN t MAX t Cylinder taper N A NA 08 mm 10031 1 Cylinder out of N A N A 05 mm round 10020 1 Cylinder piston 10 mm 12 mm 20 mm clearance 1 0039...

Page 125: ...her between cylinder head and cap nut Shorter threaded part of stud should be screwed into cylinder Shorter threaded parI AOI500101 A Section 02 ENGINE Sub section 06 467 ENGINE TYPE 10 12 Crankcase c...

Page 126: ...Section 02 ENGINE Sub section 06 467 ENGINE TYPE BOTTOM END 6 I 7 A I 8 tiJ ro 1 r 0 1 0 tYO I 0 16 I 17 1 16 02 06 6...

Page 127: ...JOO 108 2 Section 02 ENGINE Sub section 06 467 ENGINE TYPE 17 0 nng 1 8 0 nng 1 2 19 Locltle 515 20 Ctar kcase lower hJif 2 1 Lock washer 6 rnm 1 21 22 He screw lv16 x 35 121 23 Screw lv18 x 40 1 4 24...

Page 128: ...lve gear is well en gaged with rotary valve shaft gear Position the crankcase halves together and torque bolts by hand then install armature plate tighten on magneto side to correctly align crankcase...

Page 129: ...14 Hexagonal screw M8 x 16 13 15 Washer 55 mm 121 Section 02 ENGINE Sub section 06 467 ENGINE TYPE 24 j to 25 16 Lock washer 5 mm 121 17 Allen screw M5 x 18 121 18 Cable grommet 19 Lock washer 22 mm 2...

Page 130: ...0 NOTE It should be noted tha t to correctly remove a Loctite locked fas tener it is first necessary to tap on the fastener to break Loctite bond This will el1minate the possibility of thread breakag...

Page 131: ...new cotl and apply Loctite 242 blue med1um strength to screws before assembly W CAUTION Before reinstalling the magneto re T move the loose epoxy from harness Section 02 ENGINE Sub section 06 467 ENGI...

Page 132: ...on screw threads and tighten Clean crankshaft extension ltaperl Apply Loctite 242 on taper 7 11 19 20 Loctite 242 flywheel lock washer nut Position woodruff key magneto flywheel lock washer on cranksh...

Page 133: ...al raplire washer head screw M5 x 15 121 10 Hose clamp IBJ 11 U hose 13 I 10 d J Section 02 ENGINE Sub section 06 467 ENGINE TYPE I t I I 10 c f1 I 12 Engme infer hose 13 Radtaror infer hose 14 Radtat...

Page 134: ...hes 3JOC l98 FL Install the hole in thermostat on top of the housing REFILLING THE SYSTEM Capacity Approximately 4 2 liters 148 Imp oz 142 U S oz 55 antifreeze 45 water W CAUTION To prevent rust forma...

Page 135: ...01 20 Seal 1 2 2 1 Distance ring 31 I Section 02 ENGINE Sub section 06 467 ENGINE TYPE ROTARY VALVE COOLANT PUMP RESERVOIR 32 33 28 22 Pump housmg 23 Gasket 24 Pump 1mpeller 25 Washer 81 mm 26 Washer...

Page 136: ...p A01JCX 2012 02 06 16 11 12 Distance sleeve Loctite 271 To remove the distance sleeve use a bearing puller IEx Snap on no CJ 9501 and pusher IPIN 420 876 6101 as illustrated Heat the distance sleeve...

Page 137: ...hium grease or equivalent on seal lips Post lion all seals with shielded portion towards water pump using pusher PIN 420 876 510 Align distance ring open ing with crankcase draining hole see note and...

Page 138: ...ion on genuine crankcase with mark ridge A0000010l9 REQUIRED TOOL Crankshaft locking tool PIN 420 876 640 To correctly install the rotary valve proceed as follows Turning crankshaft counterclockwise d...

Page 139: ...2 A01J002027 To correctly install the rotary valve disc proceed as follows Turning crankshaft counterclockwise drive pulley side bring magneto side piston to Top Dead Center using a T D C gauge Positi...

Page 140: ...1 019 must be main tained between the rotary valve and the crankcase To measure this gap use a feeler gage inserted between rotary valve an upper crankcase with the rotary valve cover in place without...

Page 141: ...ction 06 467 ENGINE TYPE OIL INJECTION PUMP 8t RESERVOIR 16 9N m 17 180 lbfo n l I e 26 25 I I _ 22 f 2o I 20 27 21 29 1s Cj v 40523 28 19 27 T 28 1 24 j 29 1 31 30 30 il Part rn 1llustrarron marked w...

Page 142: ...r wrench 25 Lock washer 6 mm 171 26 Cyltndrical slorred screw M6 x 20 Ill 2 7 011 banjo gasket 1 41 28 Banjo 121 29 Banjo bolt M6 x 16 121 30 Oil line 170 mm 1 21 3 1 Clamp 141 32 Rera1ner 33 0 nng 34...

Page 143: ...erform carburetor adjustment prior to oil injection pump adjustment To synchronize pump with carburetor Eliminate the throttle cable free play by pressing the throttle lever until a light resistance i...

Page 144: ......

Page 145: ...25 23 21 Nom 15 lbfoftl Section 02 ENGINE Sub section 07 503 ENGINE TYPE 503 ENGINE TYPE ENGINE REMOVAL INSTALLATION 45 I i 40 15 i I 14 10 R 13 Jl 02 07 1...

Page 146: ...ne remove steermg shaft transmission rod speed cable on speedo brake cable on caliper throttle cable from carburetor and handlebar console upper column engine mount nuts 02 07 2 27 Hexagonal head cap...

Page 147: ...21 Nom 21 Nom 11 J lbf hl Section 02 ENGINE Sub section 07 503 ENGINE TYPE TOP END 2 1 I l JJ 8 15 ibf ftl 24 02 07 3...

Page 148: ...d hammer CAUTION When tapping out gudgeon pins T hold piston firmly in place to eliminate the pos sibilities of transmitting shock and pressure to the con necting rod 02 07 4 I4 Intake manifold cover...

Page 149: ...ve freely in the T groove after installation If so replace them 2 21 Cylinders pistons Before inserting piston 1n cyl1nder lubricate the cylinder with new injection oil or equivalent 2 4 Cylinders cyl...

Page 150: ...17002006 Cross torque cylinder head nuts to 21 N m 115 lbf ft torque each cylinder head individually Install armature plate fan housing and then air deflector 9 Intake manifold gaskets Install a gaske...

Page 151: ...2 15 11 Y 12ro 13 I 12 1 11 21 N m 115 lbf fll Section 02 ENGINE Sub section 07 503 ENGINE TYPE BOTTOM END c 02 07 7...

Page 152: ...l bearing 6207 16 0 ring 17 Seal mag side 18 Woodruff key 19 Locrite 242 INSPECTION The inspection of the engine bottom end must include the following measurements TOLERANCES MEASUREMENTS FITTING NEW...

Page 153: ...pply Loctite 515 it is possible to use primer N PIN 413 7053 QQ or pnmer NF PIN 413 7024 00 It increases cure speed and gap filling capabi lity Refer to supplier instructions Position the crankcase ha...

Page 154: ...61 10 Protecror rube II Flywheel 12 Washer 5 5 mm 12 13 Lock washer 5 mm 121 14 Allen screw M5 8 1 2 02 07 10 1o U I 9 25 15 V be 1 pulley 16 S1amng pulley 17 Lock washer 8 mm 3 18 Allen screw MB x 12...

Page 155: ...a Loctite locked fastener 11 is f1 rst necessary to tap on the fastener to break Loct1 te bond This will elimmate the possibiltty of thread breakage Section 02 ENGINE Sub section 07 503 ENGINE TYPE 11...

Page 156: ...ew coil on the armature plate remove the shipping nuts from the cotl and apply Locttte 242 blue medium strength to screws before assembly CAUTION Before reinstalling the magneto re T move the loose ep...

Page 157: ...Position wc odruff key magneto flywheel and lockwasher on crankshaft 7 20 Loctite 242 nut Clean nut threads and apply Loct1 te 242 blue medium strength before tightening nut to 85 N m 163 lbf ft 8 21...

Page 158: ...x 1 5 74 v Belr 15 Fan cover 16 Cylinder cowl lower half exhaust s1 de 17 Cylmder cowl lower half carburetor s1de 02 07 14 18 18 Taprite screw M6 x 12 19 Spring nur V4 8 181 20 Cylinder cowl upper ha...

Page 159: ...lock washer 1 4 Fan housing bearings It is first necessary to heat bearing housing to 65 C 150 F to remove or install b ea r ng 23 27 Upper fan cowl screws fan housing screws At assembly apply a light...

Page 160: ......

Page 161: ...0 28 I I 13 16 Section 02 ENGINE Sub section 08 532 ENGINE TYPE 532 ENGINE TYPE ENGINE REMOVAL INSTALLATION 15 2 1 Nom 115 lbf fll Engine support muffler 4 5 6 38 N m I 128 lbf fl l 02 08 1...

Page 162: ...t hoses at engine Rotary valve oil reservoir Disconnect rew1nd starter and cab retainer cable at engine 02 08 2 78 Female ball JOint 19 Exhaust washer 20 Muffler supporr 21 Muffler attachment 22 Hexag...

Page 163: ...Gasket 10 rmgl 121 9 Gasket 121 10 Cap nut MB 181 11 Flat washer 8 4 181 Section 02 ENGINE Sub section 08 532 ENGINE TYPE 2 1 N m 115 lbl l li 12 12 Cyltnder 121 13 Cvlmder crankcase gasket 121 14 L f...

Page 164: ...surements TOLERANCES FITTING NEW PARTS WEAR MEASUREMENTS MIN MAX LIMIT Cyl1 nder NA N A 08 mm taper 0031 1 C vl nder out of NA N A 05 mm round 10020 1 Cvlinderipislor 10 mm 12 mm 20 mm clearance I 003...

Page 165: ...ween cylinder nead and cap nut Shorter threaded part of slurl should t e screwerl 1nto cyl inder AV 150 C 0 8 Section 02 ENGINE Sub section 08 532 ENGINE TYPE 10 12 Crankcase cylinder nuts cylinders W...

Page 166: ...ENG NE P E Section 02 532 ENGINE Sub section 08 BOTTOMEN D 02 08 6 35 N m 126 Jbfoftl 25 28 9 Nom lBO lbf 1nl 8 6 II I 1 J...

Page 167: ...ecial puller as illustrated Special puller A000001087 Section 02 ENGINE Sub section 08 532 ENGINE TYPE 19 Seal 20 0 rtng 12 21 0 ring 22 0 rmg 12 23 Lc CIIte 51 5 24 Crt 1nkcasP jo v11 er half 25 Lt c...

Page 168: ...case halves be Y sure that crankshaft rotary valve gear is well en gaged with rotary valve shaft gear Posit1 on the crankcase halves together and torque bolts by hand then install armature plate tight...

Page 169: ...n ENGINE Section ON2GINE TYPE 8 532E Sub section 0 15 8 J _g 10 v 11 I 2 6 27 28 MAGNETO 95 N m i70 lbf ftl 02 08 9...

Page 170: ...l as illsutrated magneto s1de piston must be at top dead center remove magneto retain ing nut AOl 5002008 02 08 10 19 LocA washer 22 mm 20 Hexagonal nur 22 x I 5 mm 2 7 C O box 22 Hexagonal sc1 ew M i...

Page 171: ...connector to the lead and fasten it under the wire retaintng clip Section 02 ENGINE Sub section 08 532 ENGINE TYPE Eve connector A00 1002005 5 7 Generating coil screw Loctite 242 To install the new c...

Page 172: ...ure plate on the crankcase al1gning the marks on both parts Put a drop of Loctite 242 on screw threads and t1 ghten Clean crankshaft extension ltaperl Apply Loctite 24 2 on taper 7 11 19 20 Loctite 24...

Page 173: ...p 9 Over low hose 10 Cltp I 1 R H radiator 12 L H radiator 13 R1ver 1401 14 Radiator protector 121 8 V Section 02 ENGINE Sub section 08 532 ENGINE TYPE COOLING SYSTEM 18 16 I 1 15 Hexagonalraortre was...

Page 174: ...ter temperature reaches 43 Cill0 Fl Install the thermostat with its hole on top of the housing REFILLING THE SYSTEM Capacity Approximately 5 liters I 1 1 Imp gaLl I 1 3 U S gal 60 ant1freeze 40 water...

Page 175: ...30 Section 02 ENGINE Sub section 08 532 ENGINE TYPE ROTARY VALVE COOLANT PUMP OIL RESERVOIR 14 02 08 15...

Page 176: ...76 610 11 12 Spring retaining cup circlip If it is necessary to disassemble components of rotary valve shaft assembly compress spring retaining cup in order to remove circlip 02 08 16 23 Loctite 242 2...

Page 177: ...ball bearing 6201 use ball bearing pusher P N 420 876 5001 A01l002028 Ball bearing pusher Tool 420876 500 _ 0 NOTE Ball bearing shielded must be facing rotary valve 14 15 Seals distance ring To instal...

Page 178: ...90 22 23 Pump housing bolts Loctite 242 Apply Loctite 242 on bolts thread 30 Rotary valve cover bolts Torque the rotary valve cover bolts to 20 N m 151bf ft 25 Rotary valve Installation on genuine cra...

Page 179: ...MING MARKS opening closing 532 For example 132 opening 52 closing Section 02 ENGINE Sub section 08 532 ENGINE TYPE Using angle finder mark crankcase at 132 from bottom edge of magneto side inlet port...

Page 180: ...r 30 Rotary valve cover bolts The rotary valve cover bolts must be torque to 20 N m 15 lbf ft 02 08 20 INSPECTION 25 28 Rotary valve cover rotary valve A gap of 0 27 0 48 mm 011 019 must be mam tained...

Page 181: ...tion 08 532 ENGINE TYPE OIL INJECTION PUMP RESERVOIR 52 J Gasket set 40 i i It 39 38 C 37 T 5 I 6 __ 4 rfl I 3 I 1 r 1 I 15 f Nf 18 dl 19 1 18 I 16 18 lil I II 54 2 I Parts wirh an are not available a...

Page 182: ...lock nut To remove retaining nut lock gear using no 420 277 900 tool s PIN 420 277 900 A000001085 02 08 22 28 Cyl1ndncal slorred screw M5 x 16 121 29 Lock washer 6 mm 141 30 Cyhndncal slotted screw M6...

Page 183: ...STMENT Always perform carburetor adjustment prior to oil injec tion pump adjustment To synchronize pump with carburetor Eliminate the throttle cable free play by pressing the throttle lever until a li...

Page 184: ......

Page 185: ...INSTALLATION 29 1 3 34 33 32 I 30 25 N m 11 8 1 1 1 11 11 48 N m 14 13 1bl ltl 22 I I 1 15 21 16 I n J 20 y I I I __ Yi u 2 I 13 12 if l N 9 1181bl lt 3 2tl N c 1 1 1 11s lbt ttl 1 a G 1 6 4 17 7 38...

Page 186: ...rts on frame ENGINE SUPPORT MUFFLER DISASSEMBLY ASSEMBLY 22 26 Engine support screw manifold screw Torque the engine support screws to 48 Nom 35 lbfoft Torque manifold screws to 21 N m 15 lbf ftl 02 0...

Page 187: ...20 N m 115 lbl ltl 11 20 i Section 02 ENGINE Sub section 09 537 ENGINE TYPE 20 N m 11 5 lbl ltl TOP END 02 09 3...

Page 188: ...and hammer rCAUTION When tapping gudgeon pin or out of T piston hold piston firmly in place to eliminate the possibilities of transmitting shock and pressure to the connecting rod INSPECTION The insp...

Page 189: ...y Loctite 242 blue medium strength on the thread ed end of the studs going into the crankcase Section 02 ENGINE Sub section 09 537 ENGINE TYPE 12 21 Cylinder cylinder head stud Because of cap nuts cyl...

Page 190: ...Section 02 ENGINE Sub section 09 537 ENGINE TYPE 1 Cylinder head nut Torque cylinder head nuts to 20 N m 15 lbf ftl follow ing illustrated sequence 0 e e Q 41U4ft Ofl 2 9 __6 8 A O1 002004 02 09 6...

Page 191: ...S ub se1ccttion o 02 ENGINE ENGINE TYPE 8 I 7 I I 7 Qty I j VoCOo 11 I 16 BOTTOM END 12 I 13 _6 o T 13 22 9 N m 80 lbf in Y I j 0 0 Ol 18 02 09 7...

Page 192: ...ft use a protective cap and special puller as illustrated A000001092 02 09 8 17 0 nng 18 O nng 121 19 Locttte 515 20 Crankcase lower half 21 Lock washer 6 mm 121 22 Hex screw M6 x 35 121 23 Screw M8 x...

Page 193: ...halves together and torque bolts by hand then install armature plate tightenI on magneto side to correctly align crankcase halves Torque bolts as spec1fied following illustrated sequence A01 5002006 F...

Page 194: ...eel 72 Starting pullev 13 Lock washer MB x 16 i31 14 Hexagonal screw lv18 x 16 131 15 Was er 5 5 m m 76 Lock washer 5 mm 1 21 02 09 10 5 77 Allen screw M5 x 18 21 18 Cable grommet 19 Lock washer 22 mm...

Page 195: ...orrectly remove a Loctite locked fastener 1t IS f1rst necessary to tap on thl fastenr r to break thr Loct1te bond Th1s will ele minate the possib1l11y of thread breakage Section 02 ENGINE Sub section...

Page 196: ...ew coil on the armature plate remove the shipping nuts from the new coil and apply Loctite 242 blue medium strength to screws before assembly W CAUTION Before reinstalling the magneto re T move the lo...

Page 197: ...e 242 flywheel lock washer nut Pos1tion w Jodruff key magneto flywheel lock washer on crankshaft Clean nut threads and apply Loctite 242 Iblue medium strength before tightening nut to 95 N m 170 lbf f...

Page 198: ...mm Clip Radiator 1 2 Ri et Radrator protecror 121 hexagonal tapute washer head screw M5 x 15 1 2 Hose clamp 1701 U hose En ine infer hose 02 09 14 14 I I 73 14 75 76 17 18 19 20 2 1 22 23 I Engine our...

Page 199: ...he system If not 1nstall a new 90 kPa I13 PSI cap do not exceed 90 kPa 113 lbs of pressure Section 02 ENGINE Sub section 09 537 ENGINE TYPE 16 Thermostat To check thermostat put 1t m water and heat th...

Page 200: ...rear of vehicle on the ground Refill coolant tank slowly until coolant overfills at bleed hole Re1 nstall bleed screw Continue to pour coolant in the tank until level rea ches 25 mm 1 below filler nec...

Page 201: ...1 Distance slee e 24 5 mm Shun 0 5 nJm 0flng Gear Spong Spring retaining cup Circlip Bearing 620 1 Seal 121 Distance nng 22 23 24 25 26 27 28 29 30 3 1 32 33 34 35 36 37 38 39 40 41 42 28 Cl29 Pump ho...

Page 202: ...istance sleeve Loctite 271 To remove the distance sleeve use a beanng puller ex Snap On no CJ 950 and pusher IP N 420 876 610 as illustrated Heat the distance sleeve to break the Loc tite bond 93 C 12...

Page 203: ...grease or equrvalent on seal lips Po sition all seals w1th shielded portion towards water pump us1ng pusher IP N 420 876 5101 Align d1stance r ng op ening with crankcase drarn1ng hole see note and ill...

Page 204: ...ation on genuine crankcase with mark ridge REQUIRED TOOL AOOOOOlOOl To correctly install the rotary valve proceed as follows Turning crankshaft counter clockwise drive pulley side bring magneto side t...

Page 205: ...52 A01J00 012 To correctly install the rotary valve disc proceed as follows Tum1ng crankshaft counterclockwise idrive pulley SI de bring magneto s1de p1ston 10 top dead center us1ng a T D C gauge Pos...

Page 206: ...11 019 must be main tained between the rotary valve and the crankcase To measure this gap use a feeler gage inserted between rotary valve and upper crankcase with the rotary valve cover in place witho...

Page 207: ..._ h 3 14 I l 12 I l l f 13 4 47 Section 02 ENGINE Sub section 09 537 ENGINE TYPEl OIL INJECTION PUMP RESERVOIR I 11 I _ 10 Paris 1n liluslrat on marked with are nor ava fab e as spare paris 02 09 23...

Page 208: ...S 02 09 24 25 Lock washer 6 mm 17 26 Cyllndtical slorterl sctew M6 x 20 171 27 0 11 ban1o gasket 141 28 Banjo 121 29 Banjo bolr M6 x 16 121 30 Oil l1ne 170 mm 121 3 1 Clamp 141 32 Retainer 33 0 ring 3...

Page 209: ...Always perform carburetor adJustment prior to oil injec tion pump adjustment To synchronize pump with carburetor Eliminate the throttle cable free play by press1ng the throttle lever unt1l a l1ght re...

Page 210: ......

Page 211: ...CYLINDER OUT OF ROUND ENGINE TYPE MAXIMUM 253 0 10 mm 004 All other 1985 0 05 mm eng1nes 002 l Measunng 16 mm 5 8 from top of cylinder with a cylinder gauge check if the cylinder out of round is more...

Page 212: ...IMUM wear limitl All 1985 engines 0 04 mm 0 20 mm 002 008 Using a feeler gauge check clearance between rectangu lar ring and groove If clearance exceeds specified tolerance replace piston 02 10 2 0 NO...

Page 213: ...08 1 039 467 532 537 0 40 mm 1 20 mm 1016 047 1 Usi11g a feeler gauge measure distance between thrust washer and crankshaft balancer If the distance exceeds specified tolerance repa ir or replace the...

Page 214: ...re distance between bearing shoulders on crankshaft M5l 02 10 4 A 0010020Jl di Measure the distance r1ng and adjustment shims thick ness IM7 and Mal Add these measurements to ob tain dimension B e Fro...

Page 215: ...gauge adjustment shims refer to parts catalog Thickness available 0 10 mm 004 1 0 20 mm 1008 0 30 mm 012 1 0 50 mm 1020 bearing simulator PiN 420 876 155 Total shim thickness needed for the end play...

Page 216: ...the specified end play by repeating the procecures Install MAG side bearing Refer to 253 engine type section 02 02 Bottom end portion 377 447 462 467 503 532 537 engine types These engrne types do no...

Page 217: ...E MIKUNI NO 247 VM 28 242 253 VM34 319 377 Safnri 377 E Mirage Ill VM 34 309 3 77 Skandic A VM 34 276 447 VM34 3 10 462 VM 34 334 467 MAG VM 34 321 PTO VM 34 320 503 VM 34 297 532 VM 311 31 2 537 MAG...

Page 218: ...02 ENGINE Sub section 11 CARBURETOR FUEL PUMP Carburetors VM 34 276 VM 34 297 VM 34 309 VM 34 310 VM 34 312 3 Q 4 ij l o 15 7 e 19 20 21 0 10 22 a a 0L ___ j 02 11 2 r Formula SS only f 42 a 36 37 1 3...

Page 219: ...OR FUEL PUMP Carburetors VM 34 319 VM 34 320 VM 34 321 VM 34 334 VM 40 29 VM 40 30 1 ____ j Formula Plus only I oo 5 4 6 ij I 22 I I I L ___j 25 33 I I I I I I I I I I I 35 34 32 a 31 I 1 0 129 i 30 I...

Page 220: ...lash point such as gasoline naphtha benzol etc should not be used as they are flammable and explosive Check inlet needle tip condition If worn the inlet nee dle and seat must be replaced as a matched...

Page 221: ...s check spark plug tip color to find out correct Jetting Section 02 ENGINE Sub section 11 CARBURETOR FUEL PUMP MIKUNI CARBURETOR FLOAT LEVEL ADJUSTMENT 11 12 Float arm pin float arm Correct fuel level...

Page 222: ...ion Apply a thin layer of silicone sealant between carburetor rubber flange and intake cover on engine Apply Loctite Lock n Seal 242 on bolts retaining flange to intake cover Silicone Loct1te ILock n...

Page 223: ...tely close the air screw until a slight seating re sistance is felt then back off as spec1f1ed Refer to section 09 Technical data for the specifica tiOns 7 Throttle slide adjustment WARNING Ensure the...

Page 224: ...the jetting is different on each side Once carburetor adjustment is performed check that with the throttle lever fully depressed there is a free play of 1 16 between the cover sJ and throttle slide R...

Page 225: ...12 Section 02 ENGINE Sub section 11 CARBURETOR FUEL PUMP FIG AI 8 c 10 _ _ _ 2 6 2 J 0 9 5 o _ 7 11 FIG Bl 17 SINGLE OUTLET PUMP MIKUNI FUEL PUMP 02 11 9...

Page 226: ...older and lubri cate tip of holder with a drop of oil Push holder into pump body as illustrated A000002016 CLEANING INSPECTION The entire pump should be cleaned with general purpose solvent before dis...

Page 227: ...16 35 Section 02 ENGINE Sub section 12 AIR INTAKE SILENCER FUEL TANK AIR INTAKE SILENCER FUEL TANK ELAN 33 h t r u I 2 10 02 12 1...

Page 228: ...r1e 29 2 1750 mml 21 lsolaring tne 4 1102 mml 22 Tee 4 Tab lock Always bend tab lock over screws and replace if they seem worn 12 Spring clips Always reposition spring clips after any repair to preven...

Page 229: ...11 24 I I I I 9 n 23 20 I 10 p Section 02 ENGINE Sub section 12 AIR INTAKE SILENCER FUEL TANK CITATION LS LSE TUNDRA TUNDRA LT 36 27 I 7 6 02 12 3...

Page 230: ...ml 21 Fue l ne 14 1 356 mml 17 22 Spring clips Always reposit1on spring clips after any repair to prevent possible leaks 1 4 6 Rubber flange carburetor intake adaptor Always insert engine and carburet...

Page 231: ...Section 02 ENGINE Sub section 12 AIR INTAKE SILENCER FUEL TANK SKANDIC SKANDIC R I t 42 10 7 9 I I n 21 18 I p 2 3 25 lll 32 St 33 39 40 5 02 12 5...

Page 232: ...15 20 Spring clips Always reposition spring clips after any repair to prevent possible leaks Always insert engine tab into rubber flange notch Always install air intake adaptor in such away that its f...

Page 233: ...AIR INTAKE SILENCER FUEL TANK SAFARI 377 377E 447 GRAND LUXE LC MIRAGE Ill FORMULA SS SP 13 0 l 15 u 20 1g 21 l t __ _ 18 I 23 I safari Grand Luxe LC Formula SS SP 1 Optional on other models I I 1 _...

Page 234: ...aks 7 Elbow The air box elbow must be maintain upward in any con dition on fan cooled engines only 4 5 Air silencer adaptor Always insert tab of adaptor into notch of air silencer CAUTION Disregarding...

Page 235: ...Section 02 ENGINE Sub section 12 AIR INTAKE SILENCER FUEL TANK 27 44 FORMULA MX FORMULA PLUS I 31 B 8 I 1 Formula Plus 1 only I 41 I J 02 12 9...

Page 236: ...ine 5 1127 mml 1 21 20 Fuel fine 5 t l27 mml 21 Male connector 22 Grammer 12 13 Spring clips Always reposition spring clips after any repa1r to prevent leaks 02 12 10 23 Fuel llfle 12 24 Fuel Mrer 25...

Page 237: ...Section 02 ENGINE Sub section 12 AIR INTAKE SILENCER FUEL TANK ALPINE 02 12 11...

Page 238: ...ne side orifice and the rubber vent must be positioned on the side of the silencer box to allow cold air circulation A017002009 In temperature below 10 C l4 F and or powder snow the rubber plug must b...

Page 239: ...crew M6 x 14 4 Rewmd sprmg 5 Spring guide 6 Rope sheave 7 Sraner rope Section 02 ENGINE Sub section 13 REWIND STARTER REWIND STARTER All models 8 Key 9 Pawl 10 Pawl lock 11 C1rclip 12 Lock spr ng 13 L...

Page 240: ...13 2 Gently tap on key ASSEMBLY 4 5 Rewind spring spring guide At assembly position spring outer end into spring guide notch then wind the spring clockwise into guide A WARNING Since the spring is ti...

Page 241: ...pawl lock and circlip Section 02 ENGINE Sub section 13 REWIND STARTER 12 Lock spring Install lock spnng and lubricate wtth MOLYKOTE G N paste PIN 413 7037 00 Install lock rmg _ CAUTION This lubricant...

Page 242: ......

Page 243: ...play should exist be T tween drive pulley guard and frame bracket ADJUSTMENT Elan Citation LS LSE Tundra Tundra LT Skandic 377 R Alpine models Elan Alpine only The length of the uncompressed retainin...

Page 244: ......

Page 245: ...ection 03 TRANSMISSION Sub section 02 DRIVE BELTl DRIVE BELT APPLICATION CHART 1985 MODELS NUMBER MAX WIDTH MIN WIDTH NEW WEAR LIMIT 570 0411 00 30 mm 1 3116 27 mm 1 1116 414 5234 00 33 3 mm 1 5116 30...

Page 246: ...REMOVAL INSTALLATION _ CAUTION Do not force or use tools to pry the belt into place as this could cut or break the cords in the belt WARNING Do not operate snowmobile without drive belt or its guard i...

Page 247: ...adjust ed Check brake light operation Brake ltght __ 4 switch A007003024 Section 03 TRANSMISSION Sub section 02 DRIVE BELT To install the drive belt reverse the procedure W CAUTION Once belt is insta...

Page 248: ...02 4 Slip the belt out from the drive pulley and remove it com pletely from the veh1cle A00200J017 To install the drive belt reverse procedure Formula MX Plus only Unscrew the same Allen screw which...

Page 249: ...ten sion must be adjusted to 6 8 kg I 15 pounds with a de flection All models except Citation Tundra 32 rnm I 1 114 1 C1tat1on Tundra 30 2 mm to 38 1 mm 11 311 6 to 1 2 1 Section 03 TRANSMISSION Sub...

Page 250: ...haincase retaining nuts remove the clevis pin and pull out the threaded bushing from its bracket Adjust the pulley distance according to specif1ca11on and measure drive belt deflection Readjust the pu...

Page 251: ...N m 35 lbf ftl Check sup port nut and washers for tighteness They should be firmly 1n contact w ith the frame A008003006 Support nut Skandic 377 R Formula MX Plus The drive belt deflectiOn is adjuste...

Page 252: ...ley for worn or m1ssing flyweights rollers bl Clean shaft with steel wool and lubricate with low tem perature grease cl Clean pulley surfaces with fine emery cloth and clean cloth dl Incorrect centrif...

Page 253: ...properly ley cl Eng1ne 1dle speed too h1gh c Reduce engine R P M dl Incorrect belt length dl Using unspecified type of belt Replace belt with cor rect Bombardier belt el Incorrect pulley distance el R...

Page 254: ...10 CAUSE al Improper belt 1nstallat1on bl Belt rubb1ng stationary ob JeCt on pulleys cl V1olent engagement of dnve pulley CAUSE aI Pulley misalignment bl Using unspec1f1ed type of belt REMEDY al Refe...

Page 255: ...ing seal 9 Bearing 10 Inner hall 11 Shim l2 Nut Loctite 242 13 Counterweight 14 Roller 15 Shouldered pin 16 Shouldered bushing 17 Ortve pulley retainer PIN 529 001 7 00 14 N m 110 lbf ftl 1 Section 03...

Page 256: ...9 0017 00 10 Inner half Toremove the inner half slide a length of steel pipe over shaft Attach with a 5 16 nut and bolt as illustrated The inner half can then be removed with a pipe wrench IUnscrew co...

Page 257: ...cl le 242 A002003003 To tighten tnner half use a protective sleeve as shown in the removal procedure 5 Shim neutral This shtm IS used to obtain a neutral function of the drive pulley when engine is id...

Page 258: ...of the drive pulley when engine is idling Proceed as follows when retaining bolt is torqued With a new drive belt installed you should be able to insert a minimum of 0 80 mm 030 thick feeler gauge on...

Page 259: ...f 10 Nut Loctite 242 11 Lever 12 Roller 13 Shouldered pin 14 Shouldered bushing 15 Puller PIN 529 0028 00 16 Puller PIN 529 0030 00 17 Drive pulley retainer PIN 529 001 7 00 14 N m 110 lbf ftl Section...

Page 260: ...held firmly during governor retaining bolt re moval Use drive pulley retainer P N 529 0052 00 03 03 6 9 Inner half If it is necessary to remove inner half use drtve pulley puller no 529 002 800 529 0...

Page 261: ...weight ass y Apply Loctite 242 or equivalent on nu t threads then tor que nuts to 14 N m I 10 lbf ftl Section 03 TRANSMISSION Sub section 03 DRIVE PULLEY INSTALLATION Lock crankshaft in position as ex...

Page 262: ...bushmg 5 Hub plug 6 Cap screw 7 Internal tooth lock washer 8 Allen setscrew 9 Spring 10 Spnng sear I I Cap screw 72 Guarr 13 Outer half 14 Inner half 03 03 8 13 12 6 N m 153 1 n lbsl 15 Self lockmg s...

Page 263: ...the impulse hole of the eng1ne Slowly rotate the crankshaft until it locks into posit1on W CAUTION Do not use any type of pin other than the tool P N 420 876 640 Remove spark plug sl then bring P T 0...

Page 264: ...Inner outer half Inside of outer half should be cleaned with a clean cloth The square shaft can be cleaned with fine steel wool and a clean cloth 14 Inner half crankshaft Us1ng cleaner such as aceton...

Page 265: ...vernor cup must be in line 13 14 Inner outer half Lock crankshaft tn posttion as explamed in removal pro cedure Make sure crankshaf t is rota ted 45 counter clockwise from T D C position and that cyli...

Page 266: ...on bushing 9 Tab lock 10 Governor cup 1 1 Ramp 12 Cap screw 13 Spring seat 14 Sprinq 03 03 12 4 5 8 14 Loct te 242 17 75 Internal rooth lock washer 16 Cap screw Loctite 242 17 Shouldered washer 18 Tab...

Page 267: ...ection 03 DRIVE PULLEY Or Remove spark plug s then bring P T O piston at T D C position Rotate drive pulley 45 clockwise then insert enough starter rope into cylinder to fill it completely Remove the...

Page 268: ...his procedure must be performed in a well ventilated area W CAUTION Avoid contact between crankshaft T seal and acetone because damage may occur INSPECTION Drive pulley should be inspected annually 25...

Page 269: ...as explained in removal pro cedure Make sure crankshaft is rotated 45 counter clockwise from T D C positton and that cylinder is completely filled with a starter rope or use crankshaft locking tool In...

Page 270: ...r lth ckl 9 Puller PIN 529 0021 00 10 Outer flange 11 Guard 12 Cap screw 13 Hub plug 14 Cap screw 15 Tab lock 16 Dura on bushing 03 03 16 17 Ramp 85 Nom 163 lbfoftJ 18 Spring seat 19 Scring 20 Allen s...

Page 271: ...ate the crank shaft until it locks into position CAUTION Do not use any type of pin other than T the tool P N 420 876 640 Section 03 TRANSMISSION Sub section 03 DRIVE PULLEY Crankshaft PiN 420 876 640...

Page 272: ...suit able bearing puller A 0 1700300 1 03 03 18 Q NOTE The press fit is on the thicker spacer only CLEANING 4 10 Inner outer half Inside of outer half should be cleaned with a clean cloth The square...

Page 273: ...n 03 TRANSMISSION Sub section 03 DRIVE PULLEY Apply Loctite 277 on Duralon bushing Do not fill set screw holes w ith loct tte Apply Loctite 242 on set screw threads then tighten until screw slightly r...

Page 274: ...T assembly on square shaft of drive pulley to avoid scratches on Duralon bushing caused by square shaft edge 23 Governor cup Install governor cup making sure that the shaft end rests in governor cup s...

Page 275: ...washer 4 Sprocker 5 Driv1ng chain 6 Bearmg cone 7 Chamcase Section 03 TRANSMISSION Sub section 04 DRIVEN PULLEY DRIVEN PULLEY 8 F1xed half 9 Sliding half 10 Release spnng I 1 Outer cam I 2 Cam slider...

Page 276: ...ad should be 3 6 kg 8 lbs To correct pre load see ADJUSTMENT 03 04 2 12 Cam slider shoe Inspect outer cam for worn slider shoes ASSEMBLY Assemble dnven pulley by revers1ng disassembly pro cedure 12 Ca...

Page 277: ...ring Spring torsional pre load Spring tors1onal pre load should be 3 6 kg 1 8 lbsl i To correct sprmg pre load relocate spr1ng end 1 n sl1d1ng pulley half Section 03 TRANSMISSION Sub section 04 DRIVEN...

Page 278: ...R_A NSMISSION Section 03 T DD R IV E N P U L L_E_Y_l_____ I Sub section 04 Skandic 03 04 4...

Page 279: ...pport screws Remove support screws and drive axle screws Tilt support forward Driven pulley assembly Remove from vehicle DISASSEMBLY 12 Snap ring A WARNING The driven pulley cam is spring Tloaded Hold...

Page 280: ...itable pusher A 007003007 11 Brake disc capscrews Torque to 9 N m 1 6 lbf ft 03 04 6 8 Cam Slider Shoe When replacing slider shoes always install a new set of three shoes to maintain balanced pressure...

Page 281: ...For an accurate torque wrench reading you must use the following formulas Section 03 TRANSMISSION Sub section 04 DRIVEN PULLEY Torque wrench length em lin Correction factor Torque wrench length 4 44...

Page 282: ...Y Pulley alignment For pulley alignment procedure refer to section 03 05 2 Belt deflection sets screws At assembly the Allen screws must be set in accordance with the drive belt deflection specificati...

Page 283: ...rew _shim 12 Extension 13 Washer 74 Lock washer 114 11 Section 03 TRANSMISSION Sub section 04 DRIVEN PULLEY 6 I 15 Screw M8 x 55 16 Brake disc 17 Cork 18 Key 19 Countershafr 20 Key pulley ass yl 2 I A...

Page 284: ...3 Spring Spring torsional pre load Check pre load using a fish scale pOSitioned at 90 with the pulley axle The spring pre load should be 5 9 kg 113 lbsl 03 04 10 5 9 k llJ lbsl A007003006 To correct...

Page 285: ...threads 15 Pulley retaining screw Torque to 25 N m 118 lbf ftl ADJUSTMENT 3 Spring Spring torsional pre load To adjust spring pre load disJ olace spring end accordingly A00700301 2 10 Drive belt defle...

Page 286: ...threads 15 Pulley retaining screw Torque to 25 N m 118 lbf ftl ADJUSTMENT 3 Spring Spring torsional pre load To adjust spring pre load disJ olace spring end accordingly A00700301 2 10 Drive belt defle...

Page 287: ...p screw 1 1 20 x 314 5 Suppon bracket 5 flastic srop nut 20 7 Cap screw sn6 18 x 314 B Elastic srop nut 5 15 18 9 Beaflng supporr 10 Shim 03 04 12 TI Bearmg 12 Spacer 13 Fixed half 14 Roll Jin 15 Slid...

Page 288: ...Outer cam With sliding half and spring removed push the roll pin out of the shaft and remove the outer cam 0 NOTE If necessary heat hub of fixed pulley and outer cam to facilitate removal INSPECTION...

Page 289: ...llen set screw M6 x 20 2 Fixed half 3 Thrust washer 4 Sliding half 5 bushing 6 Spring 7 Slider shoe 8 Outer cam 9 C clip 10 Spacer II Support 03 04 14 12 Flanged ring 13 Snap ring 14 Grease fitting 15...

Page 290: ...pport Driven pulley assembly Remove from countershaft DISASSEMBLY 9 C clip Push outer cam and remove the C clips A WARNING Driven pulley cam is spring loaded T Hold it in place when removing the C cli...

Page 291: ...pport Driven pulley assembly Remove from countershaft DISASSEMBLY 9 C clip Push outer cam and remove the C clips A WARNING Driven pulley cam is spring loaded T Hold it in place when removing the C cli...

Page 292: ...edure Countershaft CAUTION Always apply anti seize compound on the countershaft before final pulley installa tion loctite anti seize lubricant P N 413 7010 001 03 04 16 ADJUSTMENT 6 Spring Spring tors...

Page 293: ...Section 03 TRANSMISSION Sub section 04 DRIVEN PULLEY Citation LS E Tundra LT Safari Formula SS SP Mirage Ill 29 I v 32 Citation Tundra 39 1s 1 S 14 I 13 I 12 03 04 17...

Page 294: ...sprockets and chain 5 11 Bearing spacer Remove from chaincase 12 13 Retaining nuts shims Remove the four chaincase retaining nuts and save aligning shims for installation 03 04 18 21 Shtm 22 Sliding h...

Page 295: ...Section 03 TRANSMISSION Sub section 04 DRIVEN PULLEY ASSEMBLY 23 Sliding half bushing Assemble a new bushing using a p ess and a su1table pusher A00700J007 Driven pulley chaincase Assemble by reversin...

Page 296: ...Section 03 TRANSMISSION Sub section 04 DRIVEN PULLEY Track tension alignment Refer to section 05 05 Drive belt deflection Refer to section 03 02 03 04 20...

Page 297: ...ard and drive belt By turning and push1ng the sliding pulley open the driven pulley Insert a stra1ght edge 9 5 mm 375 1 square into the driven pulley opened 0 NOTE Always measure distances x y from th...

Page 298: ...m PIN 504 0504 00 0 81 mm 032 1 thickness Citation LS E Tundra Tundra LT A00400 l003 1lllr CAUTION The rear suspension must be mounted T on the vehicle and track tension and alignment must be done to...

Page 299: ...e specification z 4143 mm 811 5 8 0 8 movement Pulley distance adjustment method Oversize holes on countershaft support and slotted lugs on chainca se casting allow movement of the counter shaft Cour...

Page 300: ...03 05 4 Pulley distance specification z 44 45 mm 6 1 314 1 6 8 1 Pulley distance adjustment method Engine mounting bracket is provided with slotted holes Move engine to obtain specified distance betwe...

Page 301: ...mm I 021 thickness FORMULA MX PLUS y A01500 3002 0 NOTE For proper measurin g driven pulley must be pushed toward disc brake 11 015003006 Push manually Pulley distance specification z 35 mm g 1378 0 6...

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Page 303: ...ur shoe 3 Nur 4 Brake lever 5 Nur 6 Cable lock 7 Spring B Brake l1ghr sw rch sprmg 9 Bolr cable 10 Bolr Brake shue 12 Bolr shoe 12 2 10 5 Section 03 TRANSMISSION Sub section 06 BRAKE BRAKE DRUM BRAKE...

Page 304: ...case bracket tighten nut until lever pivots freely and all side play is elimi nated LUBRICATION 0 NOTE Lubricate all moving metal parts of brake with light mach1ne oil WARNING Avoid getting oil on bra...

Page 305: ...23 I 1 1 9 8 Section 03 TRANSMISSION Sub section 06 BRAKE I 22 21 20 19 DISC BRAKE Skandic 377 1 03 06 3...

Page 306: ...BLY 4 23 Cotter pin Always re1nstall new cotter pin 19 Pulley shaft Install in outer hole of brake lever 22 Stop plate Make sure the guard lock tab is inserted in the brake lever hole 03 06 4 13 Tapt1...

Page 307: ...ger turn then back off the adjuster approximately 1 112 turns Recheck brake operation A007003017 Light switch A WARNING Whenever the brake is readjusted T the brake light switch operation must also be...

Page 308: ...Section 03 TRANSMISSION Sub section 06 BRAKE SELF ADJUSTING DISC BRAKE Safari Mirage Ill Alpine 03 06 6 12 14 I ra _ 13 I 1 3 1 2 I_...

Page 309: ...cable On ALPINE models disconnect brake light switch at connector Remove nuts and or bolts securing brake support to chaincase Slide brake cal1per ass y from brake support Section 03 TRANSMISSION Sub...

Page 310: ...klick is no longer neard Secure brake cable housing to lever with the circlip on the inner side of the lever Slide spring over cable then attach cable to housing with adjuster nut ADJUSTMENT Brake co...

Page 311: ...Skandic R only I 1 2 Formula MX Plus only 14 Section 03 TRANSMISSION Sub section 06 BRAKE SELF ADJUSTING DISC BRAKE 15 Skandic 377 R Formula MX Plus kandic R only 25 Formula MX Plus only 03 06 9...

Page 312: ...round head base REMOVAL Brake assembly The splitted caliper type brake must be removed from ve hicle as an asssembly Proceed as follows Skandic R 3 Brake support Remove support bolts and slide assembl...

Page 313: ...ollow1ng A WARNING Avoid getting oil on brake shoe Do T not lubricate or apply anti rust or anti freeze solu tions into cable Caliper assembly Slide cahper ass y with spnngs onto 1 ts support then sec...

Page 314: ......

Page 315: ...15_ 40 41 Section 03 TRANSMISSION Sub section 07 CHAINCASE CHAINCASE Elan 03 07 1...

Page 316: ...rain oil Brake cable Disconnect from chaincase 30 Lower sprocket cotter pin Pry out lower access plug remove cotter pin and spacer 16 Threaded rod Disconnect from chaincase 35 39 U clamp bracket From...

Page 317: ...TRANSMISSION Sub section 07 CHAINCASE 1 Oil seal Using an appropriate pusher press oil seal into chain case hub Oil seal must sit flush with case hub edge 28 Sprocket Place lower sprocket with longer...

Page 318: ...Section 03 TRANSMISSION Sub section 07 CHAINCASE ADJUSTMENT Pulley alignment Refer to Pulley distance and alignment sub section 05 Brake operation brake light Refer to Brake sub section 06 03 07 4...

Page 319: ...l 28 21 2 9 Section 03 TRANSMISSION Sub section 07 CHAINCASE Citation LS LSE Tundra Tundra LT I 25 I 26 11 I 03 07 5...

Page 320: ...m chaincase 03 07 6 16 Cap screw M6 x I x 40 17 Taprite screw M6 x I x 16 I B Sh1m 19 Flat washer 8 4 mm except C1tat10n LSE 20 Lock washer 8 mm 2 1 Cap screw MB x 1 25 x 25 22 S1ngle sprocket 23 Circ...

Page 321: ...rs Inspect for defective bearing sprockets INSTALLATION Reverse removal procedure Pay particular attention to the following 10 Cap screw Torque to 10 N m 17 lbf ftl 29 Chaincase oil Refill with chainc...

Page 322: ...acer 7 Spring 8 Cham renstOner 9 Corter p1n I 0 Casrellared nur 7I Spnng washer 72 Sprocket 73 Driv1ng cha1n 74 Chaincase 75 Beanng 03 07 8 6 Torque to 10 Nom 17 lbfoft 12 23 25 24 16 Seal I 7 Sropper...

Page 323: ...ol P N 529 0051 00 and pull chaincase out of vehicle A00o4003002 INSPECTION Suspension cross shaft Visually inspect the chain for cracked damaged or miSS ing link rollers Inspect for defective bearing...

Page 324: ...TRANSMISSION Section 03 CH iAA IN CA SE _l_ ___ _ Sub section 07 SP Mirage Ill Ss Formula F rmula All Safan o 13 03 07 10 30 12 I...

Page 325: ...link rollers Inspec t for defecttve bearing sprockets etc INSTALLATION Reverse removal procedure and pay attention to the fol lowing 24 27 Spacers Install the thtcker spacer on the chatncase stde of t...

Page 326: ...ANSMISSION Section 03 TR CCIH A IN C A SE _ Sub section 07 I PLUS MX Formu a Formula 1 I 2 3 J 11 14 fe_ I 15 l 1 31 30 N I I s 03 07 12...

Page 327: ...e chain si rT ultaneously Remove shims 26 27 28 29 30 Cap screw washers Remove cap screws 15 Three 131cap screws are behtnd the lower sprocket location Caliper retaining bolts and nuts Unscrew two 12I...

Page 328: ......

Page 329: ...23 Section 03 TRANSMISSION Sub section 08 GEAR BOX GEAR BOX 3 SPEEDS GEAR BOX SHIFTER MECHANISM 17 I I 22 f l t r t ft I 22 I 21 Alpine 5 I I I 8 03 08 1...

Page 330: ...is properly positioned 20 Gearbox retaining nuts Torque to 22 N m 16 lbf ft 8 Cotter pin Reinstall a new cotter pin ADJUSTMENT 10 11 Turnbuckle With gearbox lever properly engaged in gear adjust so th...

Page 331: ...66 0 16 l 1 y 18 i w j 47 I 46 67 y 6 24 45 Section 0 8 GEAR BOX Sub sect1on 0 TRANSMISSION 3 SPEEDS GEAR BOX 23 N m 17 bl ft 28 Alpine 03 08 3...

Page 332: ...d to reverse installa tion position Reverse front then rear bogie wheel sets Remove rear axles 03 08 4 35 Washer 36 Ball bearing 6005 3 7 90 links triple roller cham 38 Lavshafr ass v 39 Distance slee...

Page 333: ...ION Sub section 08 GEAR BOX 45 Drive shaft components To reinstall the drive shaft components on the drive shaft proceed as follows Install the driven pulley shaft side bearing PIN 420 432 0401 on the...

Page 334: ...08 6 W CAUTION The finger of the gear change shaft T must not block the gear change fork 17 18 20 Gear change fork components Mount gear change fork and index rod with index spring and ball To do thi...

Page 335: ...ings to frame Install seals 0 NOTE A gap of approx1mately 1 6 mm 1116 1 should exist between the end of bearing housing and seal A01700J01l Install rear axle and bogie wheel sets to their original po...

Page 336: ...RANSMISSION Section 03 T GEAR BOX Sub section 08 2SPEEDSGEtAA R BO X ___________ Skandic 377R 74 14 75 Oil 03 08 B 8 1 24 N m I 18 ibf ftl 29 ao e...

Page 337: ...ect from lark shaft Countershaft support Disconnect from support clamp by remov1ng hair pin and pin b Chain tension Remove chain tension and remove transmission cover Section 03 TRANSMISSION Sub secti...

Page 338: ...ng from planet wheels use a press and a suitable pusher 15 96 mm 5 8 max 21 Planet carrier bearing Remove snap ring and use a suitable pusher to press bearing out of carrier _ 25 Blocking wheel revers...

Page 339: ...Countershaft Press countershaft with the assembled ball bearing into the transmission case bore 56 Studs Assemble studs in transmisSIOn case with Loctite 262 and torque to 5 N m 144 lbf in Section 03...

Page 340: ...o ring groove Allow 5 minutes to dry Put Loctite 515 1n the o rtng cover groove install a ring and install cover to case 03 08 12 Install cover lock washer and nuts and torque to 24 N m 18 lbf ftl 0...

Page 341: ...able and endless Section 03 TRANSMISSION Sub section 09 DRIVE CHAIN DRIVE CHAIN CHAIN ATTACHMENT When JOinmg cha1n ends the open end of the circlip must be on opposite side of chain rotation The circ1...

Page 342: ...B c A Connecting link B Link pin C Cranked link D Cotter pin VA a c D F E Outer link F Cl rclip A000003023 rro iro w3 1 8 DOUBU1JLE A c 5iQ c Wi c c Q o i I 1 2 SINGLE mAn nAn I l f V1f I 1 c OsO c c...

Page 343: ...E 318 DOUBLE aQ 0 G E Section 03 TRANSMISSION Sub section 09 DRIVE CHAIN LENGTHENING 1 112 LINK 112 SINGLE 3 8 TRIPLE A Connecting link 8 Outer link C Cranked link D Link pin E Circlip F Cotter pin G...

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Page 399: ...31 N m 123 lbf ftl 13 11 10 C C 1 t 8 6 Section 05 SUSPENSION Sub section 01 BOGIE WHEELS BOGIE WHEELS Elan 4 Wheels single spring Alpine 4 Wheels 2 springs 4 05 01 1...

Page 400: ...er may vary depending upon actual installation location 11 is important to identify the 1nstallation of each bogie wheel set Observe this position when reinstalling sets Repeat operation for remaining...

Page 401: ...Using an approprtate tool apply track ter sion by hook ing the link plate sprtngs into the anchors 0 NOTE If applicable place spring ends in middle positton of the 3 position slotted anchor A00200500...

Page 402: ......

Page 403: ...in 13 29 57 I Section 05 SUSPENSION Sub section 02 SLIDE SUSPENSION SLIDE SUSPENSION 11 TORQUE REACTION TYPE SUSPENSION 3 t Skandic 377 Skandic 377R Tundra Tundra LT 71 39 12 r sa I 9 1 43 N m 7 32 l...

Page 404: ...49 52 Screw adjustment screw Release track tension by loosening wheel retaining screw and adjustment screw located on inner side of rear idler wheel 05 02 2 3 7 Sltder pad 38 Slidtng support 39 Sptrol...

Page 405: ...e front arm supports cut off the rivet heads using a cold chisel At assembly position the rivet head on a surtable metal block and hold the assembly firmly in place With a flat head punch and hammer s...

Page 406: ...n models install the suspension ass y as shown Preparation 29 Stopper strap Detach the front stopper strap 05 02 4 26 36 42 Cotter pin shock absorber clevis pin Remove the cotter pin locking the shock...

Page 407: ...ove chaincase and oil injection reservoir vent hole plugs 0 NOTE On all models the holes in the trame pro vide the possibility of locating the suspension arms for easier track tension adjustment 13 mm...

Page 408: ...The front adJUStment cams are used for snow cond1t1on and the rear for driver s weight The front adJUStment cams should be posit1oned at the h1ghest elevat1on for deep snow condiTions A lower elevat1...

Page 409: ...YPE SUSPENSION 48 42 47 1 24 i I q i J f i 29 m _ I 48N m j 14 1 35 bl ftl 1 _ 113 l 48 N m 48 N m I 24 35 lbl h l f J 35 _ 12 i35 lbfof l 15 25 I 26 l J IE l 21 7 28129 32 14 48 N om I 135 lbl ltl X...

Page 410: ...r pad 121 35 Sild1ng suppon 121 37 Rear spring 121 38 Shock absorber cross shafl 39 Bushmg 40 Shock absorber 4 I Clevis p1n 42 Cocrer p1n 43 AdJUStment screw MIO x 75 121 44 Swp nul MIO 12 45 Square n...

Page 411: ...ocation Make sure to insert nylon bushing inside springs Front springs Midnight blue Rear spnngs Black INSTALLATION Preparation Prepare the suspension ass y as shown Section 05 SUSPENSION Sub section...

Page 412: ...nstall front portion of suspension into frame A003005007 05 02 10 Installing front portion of suspension 25 29 Upper front cross shaft screw Insert a screwdriver into one side of frame to maintain cro...

Page 413: ...rs on shaft ends Spacer A003005010 Upper rd ler w heels set Section 05 SUSPENSION Sub section 02 SLIDE SUSPENSION 0 NOTE When no more adjustment IS available from adjustment screws 11 is possible to m...

Page 414: ...ction 05 SUSPENSION Sub section 03 ITRS 6 SUSPENSION TRS 6 SUSPENSION Safari 377 E Safari 447 as Safari Grand Luxe LC 0 Formula SS W Mirage Ill f n l 76 80 82 86 8 59 I 78 I sa 1s I 77 81 44 Nom 32 lb...

Page 415: ...Center axle 41 Snap ring 121 42 Ball beannq 12 REMOVAL 81 84 Screw adjustment screw Release track tension by loosen1ng wheel retaining srews and adjustment screws located on inner side of rear idler w...

Page 416: ...ode the shoe rear wards out of the runner 8 11 Rivets adjustment plates To remove the rivets s ecur ng th e adjustment plate on the front arm supports cut off the rovet heads using a cold chisel Secti...

Page 417: ...377 377E Purple Mirage Ill Rea r Safari 447 Gold Grand Luxe LC Formula SS Brown 05 03 4 INSTALLATION Preparation 36 Stopper strap Detach the front stopper strap 50 54 55 Shock absorber clevis pin cott...

Page 418: ...1 on 35 Screws front rear arms Torque the four suspension reta1nmg bolts to 41 N m 30 lbf ft Apply downward pressure on the seat Section 05 SUSPENSION Sub section 03 TRS 6 SUSPENSION 50 54 55 Shock ab...

Page 419: ...ame position on each end front rear of the frame to avoid any damage to the suspen sion system and to the track AO XX Q5001 0 NOTE The front adjustment holes in the frame near footrest are not complet...

Page 420: ...rs preferred when negocia ting icy snow The rear adjuster blocks should be adjusted to rrder pre ference TYPICAL A007005013 W CAUTION Always turn left side adjustment cams T in a clockwise direction t...

Page 421: ......

Page 422: ...45 lbl fll 0 I 631 1 I J 7069 I 68 0 1 67 1 7 67 68 Section 05 SUSPENSION Sub section 04 SP SUSPENSION SP SUSPENSION 8 SP SUSPENSION 84 I 85 73 i 1 l 74 c oO A 75 79 81 i 86 L 52 77 51 7 8 i 76 80 42...

Page 423: ...as a clamping point 05 04 6 A01400S011 Clamp TCAUTION Do not clamp directly on shock body Compress and extend each shock by hand at various speeds and compare the resistance of one shock to the other...

Page 424: ...1150 to 180 lbl 3rd position for rider weight of 84 kg 1180 lbl and higher Section 05 SUSPENS Sub section 04 SP SUSPENSION W CAUTION Left and right adjuster cam must ai T ways be set at the same posi...

Page 425: ...s off the ground Remove the shock covers Remove the shock assemblies Remove the springs from the shocks Install the two 2 shock assemblies on vehicle torque the retainer bolts to 61 N m 45 lbf ftl Ref...

Page 426: ...For lronr PRS suspens1on refer to sect1on 06 02 Section 05 SUSPENSION Sub section 05 PRS SUSPENSION PRS SUSPENSION REAR PRS SUSPENSION 89 I lh m Formula MX Formula Plus 05 05 1...

Page 427: ...OTE Cross shafts are factory mounted with Loc tite on screw threads To prevent them from turning while unscrewing Loosen one then retighten it Loosen and remove the other one Remove the first one that...

Page 428: ...ew screws ilnd nuts from both shackles Remove nut from welded stopper Unscrew front swing arm nut then pull the bolt out Unscrew front arm nut then pull the bo lt out At assembly reverse the procedure...

Page 429: ...installing washer 99 each T end of the rear shackle lower axle Grease fotungs pointed forward 6 86 87 88 Screw inner spacer rear axle outer spacer To remove Unscrew retaining screw Pull idler wheel Re...

Page 430: ...at the same position on each side of the runner INSTALLATION INTO FRAME The rear of vehicle raised approximately to 850 mm 133 112 Section 05 SUSPENSION Sub section 05 PRS SUSPENSION Enter the front...

Page 431: ...ase fittings on idler wheels do not lubricate since ball bearings are sealed on both sides 0 NOTE To adjust the track tension and al1gnment refer to section 05 08 SHOCK ABSORBER SPRING REPLACEMENT W W...

Page 432: ...t the bottom of the shock If a stiffer or softer action 1s de s1red the spring preload may be increased or decreased by adjusting the ring Section 05 SUSPENSION Sub section 05 PRS SUSPENSION Hoqhesl e...

Page 433: ...th 241 3 mm 3mm 12 1 950 1 Spring rate 45 5 N mm 35 0 N mm 24 5 N mm 1 8 N mm 10 lb inl 1260 lbf in 200 lbflinl 140 lbf in Inside diameter 46 7 0 8 mm 0 big end 1 84 03 0 Wire diameter 9 19 mm 8 25 mm...

Page 434: ...1 18 37 1 Length extended 314 mm 326 mm 112 36 1 12 83 1 Shock description s s I ll 0 I 1 im J I f Rubber Spr rg bJmper retainer A01500o l7 For front shock absorber specificat1ons refer to section 06...

Page 435: ......

Page 436: ...e flange Lock nut Retamer washer Link plate spring Sleeve Hardened washer 14 10 11 12 13 14 15 16 17 13 Eye bolt Section 05 SUSPENSION Sub section 06 REAR AXLE REAR AXLE Elan Alpine Washer except for...

Page 437: ...o 2 screw drevers round bars pass the sprocket over flange Re verse change over procedure to install sprockets A00200S006 05 06 2 2 3 4 16 17 Rear axle sprocket mobile flange bolt nut Secure idler whe...

Page 438: ...12 Adjuster bolt Partially screw in the track a djuster bolts 5 6 Retainer washer lock nut Install retainer washers and part1 ally tighten the link plate spring lock nuts Carry out track tension and...

Page 439: ......

Page 440: ...10 Elan model onlyl I 9 e Citation LS LSE Tundra Tundra LT Section 05 SUSPENSION Sub section 07 DRIVE AXLE DRIVE AXLE Elan Alpine Alpine model only I 15 12 05 07 1...

Page 441: ...Section 05 SUSPENSI Sub section 07 DRIVE A E Skandic 3 8 3 2 7 _ _ I I _ I __ I 3 2 j I 4 7 Skandic R 05 07 2...

Page 442: ...14 Section 05 SUSPENSION Sub section 07 DRIVE AXLE Formula SS SP Safari 377 377E 447 Grand Luxe Mirage Ill 7 I i i 05 07 3...

Page 443: ...g 10 End beaong housmg II Lock washer 5 6 12 Hexagonal head cap screw r 20 x 3 13 Hexagonal flanged elasr c srop nur 1 4 20 05 07 4 8 6 14 Grease fir lng 15 Mobile flange 16 Cable prorecror I 7 Hexago...

Page 444: ...ng s1de of frame Remove drive axle from vehicle If applicable pull out shim located between bearing and lower chaincase sprocket DISASSEMBLY 8 Speedo drive insert Remove speedo drive insert if applica...

Page 445: ...1 5 mm 1116 To check this tolerance place axle assembly on a plane surface and measure the gap between sprocket teeth and surface Even surface 4 000005010 1 5 mm 11115 MAXIMUM W CAUTION The same sproc...

Page 446: ...ter a correct size speedometer dnve insert must be installed into the axle end Ensure that insert is flush with end of axle Posit1on drive axle assembly 1nto location Install shim s between bearing an...

Page 447: ......

Page 448: ...ke disc ISkand1c R Key ISkandic R I Dnve axle shaft beanng housing left side Drive axle outwards from left sidel Upper center idler s assembly Track Section 06 SUSPENSION Sub section 08 TRACK TRACK Fo...

Page 449: ...s are in the middle position of the 3 position slotted anchors To correct track tens1on loosen link plate spring lock nuts on inner side of link plate springs Turn adjuster bolts clockwise to tighten...

Page 450: ...nut A00100S004 Rotate track slowly and recheck alignment and tension To correct alignment loosen link plate spring lock nut on side where track is closest to the lmk plate Turn track adjuster bolt on...

Page 451: ...d posi tion male jig on top of track insert Tighten installer bolt until track insert is locked in place CAUTION To prevent damages and for an easier T operation of the tool apply grease on male jig f...

Page 452: ......

Page 453: ...G SYSTEM STEERING SYSTEM 11 I 19 Aa T_y 10 29 3 2 35 f 0 20Nom I 30 15 lbfoft 36 30 37 25 25 25 Nom 118 lbfoftl 18 20 f 32 I 29 I 1 v I 44 I 45 40 31 45 30 37 Nom 177 lb oftl 40 38 4B g 30 40 25 25 No...

Page 454: ...if if1 8 2 1 49 12 61 1 19 l1 22 fi i18 23 68 25 N m 30 Cf 18 lbf ftl _ 68 I 30 i 26 27 I __ 24 31 1 28 r c __ 3 30 33 25 N m na tbl fl 20 N m 297 38 15 lbf ftl 3 p I _ 25 N m 3 37 30 18 lbf ftl I 29...

Page 455: ...61 N m 145 lbf ftl 36 19 Skandic R 52 Section 06 STEERING SKIS Sub section 01 STEERING SYSTEM I I 5 25 N m v 25 118 lbf ftl D 27 24 28 13 15 Skandic Skandic R Skandic R 06 01 3...

Page 456: ...377E 447 Grand Luxe LC Mirage Ill 9 5 N m 1 31 lbl inl 25 35 26 N m 3 1 0 3 1 5 I 3 23 a lbfoltl 2i I 9 5N m 1 1851bl inl 26 _ 1 88 XI 28 J I I 30 20 N m 3 I _ 33 32 29 ns lbloltl 25 N m I r1 _ I 11a...

Page 457: ...74 19 I 26 N m 119 lbt ttl I 68 6 23 I I _ 99 3 9 24 I I I 9 5 N m 68 28 185 lbf ml 27 29 Nom 68 1 21 lbf fll 214 23 I J I I 9 5 N m i2 ot 100 I 32 101 33 j 68 28 185 lbf inl 30 _ a I 66 _ _ I _ 1 29N...

Page 458: ...Section 06 STEERING SKIS Sub section 01 STEERING SYSTEMl Alpine 06 01 6 7 42N m 131 lbf ftl _ 47 I __ 1 3 53 I 61 N m 145 lbf lt _ 62 44 js 38 r I 6o 42 1 ll 81 Y 45 1 31 40 42 I 42 N m I 31 lbf ft 46...

Page 459: ...enng cover 6B Bush ng 69 Flat washer 8 4 x 25 70 Cap screw 71 Spong washer 72 Washer 7 8 73 Brake adaptor 74 Self rap1ng screw 75 Ser screw 76 Washer 77 Circ ip 7B Brake lighr sw1tch 79 Push nur BO Th...

Page 460: ...ock tabs over nuts See illustration 30 31 Steering arm nuts lock tabs Tighten steering arm nuts to specified torque and bend lock tabs over nuts ISee illustrat1on l 06 01 8 66 100 101 Screw stopper sc...

Page 461: ...Tighten Jam nuts firmly IMPORTANT Close front of sk1s manually to take all slack from steering mechan1sm Section 06 STEERING SKIS Sub section 01 STEERING SYSTEM All models except Alpine Formula MX For...

Page 462: ...nd ball joints TYPICAL 06 01 10 Formula MX Plus Lubricate regularly every month or 800 km 500 mi Penetrating lubricant is recommended on ball joints and movmg parts Example chain lube from Bardahl BCS...

Page 463: ...Q NOTE There are 33 places to lubricate A015006003 Section 06 STEERING SKIS Sub section 01 STEERING SYSTEM 06 01 11...

Page 464: ......

Page 465: ...Loctite 272 6 1 N m 145 lbl ll 6 1 Section 06 STEERING SKIS Sub section 02 SKI SYSTEM SKI SYSTEM LEAF SPRING SUSPENSION 50 N m 137 lbf ftl Elan 06 02 1...

Page 466: ...Section 06 STEERING SKIS Sub section 02 SKI SYSTEM Skandic Skandic R Citation LS LSE Tundra 06 02 2 A 54 Nom q_y 12 140 lbloll i 22 N rn 01 3 rl61bt tll X I 6...

Page 467: ...I 1 Section 06 STEERING SKIS Sub section 02 SKI SYSTEM Formula SS SP Safari 377 377 E 447 Grand Luxe Mirage Ill Tundra LT 22 N m 116 lbf ftl 3 2 6 06 02 3...

Page 468: ...f I Section 06 STEERING SKIS Sub section 02 SKI SYSTEM Alpine 61 N m 16 1 45 lbl ft 1 18 19 I d 36 N m 127 lbf ft I 23 I 18 5 25 I rr 26 27 06 02 4 14 9 9 9...

Page 469: ...lbf ftl 4 8 9 Main and auxiliary leaf springs W CAUTION When disassembling leaf coupler from T spring leaves be careful of leaf tension Section 06 STEERING SKIS Sub section 02 SKI SYSTEM 18 Spacer 19...

Page 470: ...5 1112 Iotti 0 121 lbloltl 35 I 1 ar I 41 I 34 28 _ 20 til 19 23 J I A 70 29 rN I 38 28 217 I r 29 Nom 33 26 12 1 lbfoltl ___ 48 Nom 1 31 I t35 tbfoft 30 I 14 I 32 1 1 r 1 85 Nom j f il 1 63 lbfohl 11...

Page 471: ...hing Detach steering arm open screw stopper remove nut screws and stopper bushing then take swing arm off While removing swing arm detach stabilizer bar Section 06 STEERING SKIS Sub section 02 SKI SYS...

Page 472: ...nstall longer distance between bell crank rod and pivot point of lower control arm at inside of belly pan Torque screw 12 to 52 N m 138 lbf ftl Torque nut 11 to 85 N m 163 lbf ftl Torque screw 45 to 2...

Page 473: ...ck A skip or a hang back when reversing stroke at mid travel Seizing or binding condition except at extreme end of either stroke Oil leakage A gurgling noise after complet1ng one full compres Sion and...

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Page 477: ...lacquers 1 Lucile h1gh gloss acryliC lacquer from Dupont for all bnght surfaces 0 NOTE Th1s lacquer can also be purchased tn a sat in fin1sh _Luc1te Plast1c Res1n no 1555 can be add ed 1n amounts not...

Page 478: ...SPRAY CAN MIXTURE P N Sica 33B 182 413 4010 00 Lacquer acrylic Enamel R M lnmont Super max 01 100 41 500 413 4026 00 42 700 43 1000 BRAND NAME PAINT MIXTURE P N Lacquer acrylic R M lnmont 01 100 413...

Page 479: ...install a r ngs on sec ond and seventh tabs 8 A000007002 Skandic 377 R Position windshield on the hood then push down until tabs are fully inserted into hood slots Lock windshield tabs in pOSition us...

Page 480: ...ce Two reference po1nts are necessary to achieve that ad justment see illustration below Operating lever must be located 13 0 mm 1 2 inch before cab slot end when headlamp housing is open Rack must ha...

Page 481: ...pair them refer to section 07 sub section Ol FRAME WELDING Steel frame Electric Welding Amperage 70 110 Amp Voltage 20 24 volts Rod E 7014 3132 Aluminum frame lrefer to specialized welding shopl Argon...

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Page 483: ...tion Properly install the cable ends and secure them in place Pay atten tion to route them properly away from any rotating moving heating or vibrating parts FUEL LINE CALL MODELS WARNING Always ensure...

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Page 485: ...UE kilo k one thousand 1 000 centi c one hundredth of a 0 01 milli m one thousandth of a 0 001 CONVERSION TABLE MULTIPLY BY TO OBTAIN meter 39 370 1nch kilogram 2 205 pound milliliter 0 0352 1mperial...

Page 486: ...tvei C t c aw _ N A NA N A N A N A 377 MIRAGE Ill 62 12 4401 12 4021 368 3 122 51 6 9 f 7S00 1ST 0 20 I 0081 0 039 0 080 0 100 I 0031 00391 N A N A 377 E SAFARI 62 12 4401 61 12 4021 368 3 _ _ _ 2 51...

Page 487: ...080 0 100 0 09 011 1 0031 00391 1 0028 00351 I 0031 00391 t 0031 00391 1 0031 00 391 I OOJS 00431 NA NA NA N A N A NA N A 0 27 048 0 27 0 48 0 27 0 48 0 27 0 48 017 0 48 LOll 0191 I 011 0191 L01 1 01...

Page 488: ...o NGK 8R 9 5 NGK BA 9ES ro Gk BR 9ES 0 40 0 40 040 I 016r IOHll I 01 1 2 31 2 31 231 10901 090 N A N A N A NA NA N A l S 120 180 L S 120 180 LS 120 180 H S 2 8 4 2 fi S 2 8 2 H S 2 8 2 021 0 31 N A 0...

Page 489: ...LA NA NA NA NA N A N A NA N A L S 120 lBO LS 120 180 L S 120 180 LS 120 180 l S 120 180 l s 120 180 l s 125 235 l s 235 H S 2 8 4 2 HS 2 a 2 HS 2 8 H S 2 8 2 HS 28 2 HS 2 8 4 2 HS 1 4 26 HS _ __ 2 6...

Page 490: ...def hoe and the bcmom soOe ol I act MIRAGE Ill 317 _ 1105 ou 1381 1381 81 9 132 21 17 9 13901 Ir b r en edgos o f track Quodes and s otJ shoes Trac kaligtVr lenl Alu Aluminum Poly Polycarbonate Fib Fi...

Page 491: ...R S S R R S S R 05 11831 U JI 1831 1eJ1 1 31 UIJI 1eJ1 tfiJI C8LH C8lH C7lM ABS Oli Oli ltl Yollow o 108 106 119 100 11 1 777 17 7 4 1731 4 1731 4 6851 13 9381 13 0 91 13 0591 13 0591 13 7911 3400360...

Page 492: ...A NA NA NA NA NA NA NA N A Magneto r tn lU I 8S 6 2t 8 t6 2J 8 51621 85 1621 es 1 621 fl S 621 85tfi21 851621 65 1 621 Ctankcase nuts or scr ew 21 ol 5 2111 5 1 901 9 1 M6 91 71 M6 9 11 M6 91 71 M6 9...

Page 493: ...42 2 2 1 290 90 90 90 90 102 102 80 86 LtQuKic l t o o rl rootp l L Q I rl ooii J Lq rn lt ltl l flc 4J 11101 43 tiiOo 4 1 10 d 11 41 1 18r 90 131 90 11 1 90 lJt 90 l lo 13 60 40 60 40 60 a 5545 95 17...

Page 494: ......

Page 495: ...aler at time of purchase 4 WARRANTY TRANSFER This warranty is transferable to subsequent owner s for remainder of warranty period from original date of sale 5 EXCLUSIONS ARE NOT WARRANTED Normal wear...

Page 496: ...pplicable this warranty is expressly in lieu of all other expressed or Implied warranties of BOMBARDIER its distributors and the selling dealer including any war ranty of merchantability of fitness fo...

Page 497: ...he Service Manager or Owner 2 1f this fails contact your area distributor listed in the Operator Manual 3 Then if your grievance still remains unsolved you may write to us Bombardier Inc Service Depar...

Page 498: ...l_ w l r _...

Page 499: ...I L J...

Page 500: ......

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