BOMBARDIER ski-doo Tundra Scandic 2004 Series Shop Manual Download

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Section 01

SERVICE TOOLS AND SERVICE PRODUCTS

Subsection 01

(SERVICE TOOLS)

01-01-20

MMR2004_102_01_01A.FM

TRANSMISSION (continued) — RECOMMENDED SERVICE TOOLS

Burnishing bar

(P/N 529 026 402)

A00B464

APPLICATION

Tundra II LT, Safari L and Skandic.

Bushing extractor/installer

A) (P/N 529 031 300)

(TYPICAL)

A01B5G4

APPLICATION

A) TRA drive pulley spring cover

with repleacable bushing.

Large bushing extractor

(P/N 529 031 100)

A00B4I4

APPLICATION

Formula type driven pulley.

NOTE:

Use this tool only with

former puller (P/N 529 018 600)
that has regular threads.

Large bushing extractor

(P/N 529 035 576)

A02D1Q4

APPLICATION

Formula type driven pulley.

NOTE:

Use this tool only with new

puller (P/N 529 035 524) that has
Acme threads and support plate
included with extractor (P/N 529
031 100).

Large bushing extractor

(P/N 529 035 575)

A02D1Q4

APPLICATION

LPV 27 driven pulley.

NOTE:

Use this tool only with new

puller (P/N 529 035 524) that has
Acme threads and support plate in-
cluded with extractor (P/N 529 031
100).

Sliding half bushing remover/
installer

(P/N 529 035 931)

A00B6L4

APPLICATION

TRA III and TRA IV.

NEW

Summary of Contents for ski-doo Tundra Scandic 2004 Series

Page 1: ...Mmr 2004 tundra skandic ang FH8 Tue Sep 30 08 28 41 2003 Page 1 C M Y CM MY CY CMY K...

Page 2: ...2004 Shop Manual TUNDRA SKANDIC LT LT E WT SWT WT LC SUV 550 SUV 600...

Page 3: ...t Quebec Canada Printed in Canada Registered trademarks of Bombardier Inc This document contains the trademarks of the following companies Comet is a trademark of Hoffco Comet Industries Inc Kimtowels...

Page 4: ...03 443 and 552 engine types 04 03 1 04 593 engine type 04 04 1 05 Leak test and engine dimension measurement 04 05 1 06 CDI system 04 06 1 07 Oil injection system 04 07 1 08 Axial fan cooling system 0...

Page 5: ...08 STEERING FRONT SUSPENSION 01 Table of contents 08 01 1 02 Steering system 08 02 1 03 Suspension and ski system 08 03 1 09 BODY FRAME 01 Table of contents 09 01 1 02 Body 09 02 1 03 Frame 09 03 1 1...

Page 6: ...ht in case of doubt The engines and the corresponding components identified in this document should not be utilized on product s other than those mentioned in this document Torque wrench tightening sp...

Page 7: ...LOW CANADA 2681 SKANDIC E LT 440F R YELLOW USA 2684 SKANDIC E WT 550F R YELLOW CANADA 2233 SKANDIC E WT 550F R YELLOW USA 2234 SKANDIC E SWT 550F R YELLOW CANADA 2240 SKANDIC E SWT 550F R YELLOW USA 2...

Page 8: ...iption Decal Meaning VEHICLE DESCRIPTION DECAL 1 Manufacturer name and address 2 Manufacturing date 3 Vehicle identification number VIN 4 Model name 5 Option package 6 Engine type 7 Model year 8 Color...

Page 9: ...NGINE SERIAL NUMBER Engine Serial Number Location Fan Cooled Engines TYPICAL FAN COOLED ENGINES 1 Engine serial number Liquid Cooled Engines TYPICAL LIQUID COOLED ENGINES 1 Engine serial number A03A0B...

Page 10: ...und H A C high altitude compensator hal halogen HI high imp oz imperial ounce in inch in square inch in cubic inch k kilo thousand kg kilogram km h kilometer per hour kPa Kilopascal L liter lb pound l...

Page 11: ...er In this 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 identifyi...

Page 12: ...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 13: ...with parts dimensioned in the metric system Most fasteners are metric and must not be replaced by customary fasteners or vice versa Mismatched or incorrect fasteners could cause damage to the vehicle...

Page 14: ...tite threadlocker 4 Fit bolt in the hole 5 Apply a few drops of threadlocker at proposed tightened nut engagement area 6 Position nut and tighten as required Blind Holes 1 On threads 2 On threads and...

Page 15: ...s 4 Apply drops of proper strength Loctite on bolt nut contact surfaces 5 Avoid touching metal with tip of flask NOTE For preventive maintenance on existing equipment retighten nuts and apply proper s...

Page 16: ...D All Parts 1 Proper strength Loctite 2 Loctite Primer N P N 413 708 100 and Gasket Eliminator 515 P N 413 702 700 on both sides of gasket 3 Loctite Primer N only 1 Remove old gasket and other contami...

Page 17: ...NENTS Metallic Gaskets 1 Proper strength Loctite 1 Clean inner housing diameter and outer gasket diameter 2 Spray housing and gasket with Loctite Primer N P N 293 800 041 3 Apply a strip of proper str...

Page 18: ...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 M10 35 49 M10 36 50 M10 37 51 M10 38 52 M10 38 53 M10 39 76 M12 56 77 M12 57 78 M12 58 79 M12 58 8...

Page 19: ..._____________________________________________________ ____________________________________________________________ ____________________________________________________________ ________________________...

Page 20: ...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...

Page 21: ...E TOOLS 0 This is a list of tools to properly service Ski Doo snowmobiles The list includes both the mandatory tools and the recommended tools If you need to replace or add to your tool inventory thes...

Page 22: ...0 1 5 0 1 6 0 1 7 0 1 8 0 1 9 0 2 0 0 2 1 0 2 2 0 2 3 0 2 4 0 2 5 0 2 6 0 2 7 0 2 8 0 2 9 0 3 0 0 3 1 0 320 330 340 350 360 Hose pincher 2 P N 295 000 076 A01B2I4 APPLICATION All vehicles NOTE Only t...

Page 23: ...e P N 529 035 972 2 10 Manifold plug 57 mm 2 1 4 in P N 529 021 100 11 Manifold plug 63 mm 2 1 2 in P N 529 035 961 12 Manifold plug 70 mm 2 3 4 in P N 529 021 200 13 Exhaust plate P N 529 021 300 2 1...

Page 24: ...A00B5G4 APPLICATION All models equipped with a DESS Supply harness P N 529 035 869 A00B674 APPLICATION All DESS equipped models Vehicle Communication Kit P N 529 035 844 F12H0A4 APPLICATION All model...

Page 25: ...0 4 P N 420 841 201 4 Crankshaft protector P N 420 976 890 247 engine 5 Crankshaft protector PTO P N 420 876 552 All engines except 247 6 Crankshaft protector MAG P N 420 876 557 All engines except 24...

Page 26: ...CATION A 552 engine type B 493 and 593 engine type C 593 HO 593 SDI 693 and 793 D 793 HO and 793 HO SDI NEW NEW Hand pump P N 529 021 800 V00B084 APPLICATION All models Leak down tester P N 529 035 66...

Page 27: ...mm B P N 529 035 562 20 mm A00B4Y4 APPLICATION A All engines except 593 670 693 and 793 NOTE This tool replaces circlip in staller P N 529 016 900 B 2001 and older 593 670 and 693 engines NOTE This to...

Page 28: ...y valve shaft seal pusher inner water pump side P N 420 876 512 A00C374 APPLICATION Rotary valve engines 1991 and newer with a 10 mm impeller shaft Rotary valve seal pusher valve side P N 420 876 607...

Page 29: ...04B094 APPLICATION A 1004 engine B 1503 engine NEW NEW Ring compressor Not sold by Bombardier Snap on RC980 V04B084 APPLICATION 1503 engine Special pliers for valve stem seal removal Not sold by Bomba...

Page 30: ...00B4O4 APPLICATION Mini Z Attachment P N 529 035 522 A00B4P4 APPLICATION Mini Z Pilot 22 mm P N 529 035 523 A00B4Q4 APPLICATION Mini Z Carburetor tool kit P N 404 112 000 A00B2F4 APPLICATION All model...

Page 31: ...ION A Rotary valve engines with 10 mm shaft B Rotary valve engines with 12 mm shaft Magneto puller P N 420 976 235 F01B294 APPLICATION 247 engine Injection pump gear holder P N 420 876 695 A00B314 APP...

Page 32: ...to seal P N 420 876 514 A00C3U4 APPLICATION 454 494 599 670 699 and 809 engines Handle for insertion jig P N 420 877 650 A00C3V4 APPLICATION 454 494 599 670 699 779 and 809 engines Oil pump seal insta...

Page 33: ...emale terminal 2 P N 409 015 100 3 Female lock P N 515 175 246 4 Male housing P N 409 207 000 5 Male terminal 2 P N 278 000 631 6 Male lock P N 409 207 600 7 RED wire in position 1 4 wire connector an...

Page 34: ...7 engines Forks 3 P N 529 005 500 A16B014 APPLICATION All vehicles equipped with a TRA drive pulley Alignment bar A P N 529 035 530 B P N 529 035 831 A01B4D4 APPLICATION A S Series and ZX series with...

Page 35: ...01 SERVICE TOOLS MMR2004_102_01_01A FM 01 01 15 TRANSMISSION continued MANDATORY SERVICE TOOLS Driven pulley spring compressor P N 529 035 300 A05B034 APPLICATION Tundra R Spring cover tool P N 529 0...

Page 36: ...APPLICATION TRA drive pulley 27 mm shaft ex cept 454 670 and 779 engines Tapered tool P N 529 035 826 A32B0M4 APPLICATION Skandic LT NEW Spider tool P N 529 025 200 A32B0N4 APPLICATION Skandic LT Dri...

Page 37: ...K3 series with RER NOTE This tool replaces driven pul ley opening tool P N 529 019 500 Driven pulley opening tool P N 529 034 200 A05B044 APPLICATION Tundra R Alignment tool P N 420 476 010 A00C1D4 AP...

Page 38: ...5 699 A00B5K4 APPLICATION ZX and CK3 Series NOTE This tool replaces CK3 se ries countershaft bearing remover installer P N 529 035 554 Countershaft bearing installer P N 529 030 200 A00A194 APPLICATIO...

Page 39: ...I and Skandic WT 2 1 Alignment bar A P N 529 025 600 B P N 529 028 200 C P N 529 028 300 D P N 529 026 800 E P N 529 031 000 F P N 529 035 808 G P N 529 035 586 H P N 529 031 000 I P N 529 035 594 J P...

Page 40: ...pe driven pulley NOTE Use this tool only with former puller P N 529 018 600 that has regular threads Large bushing extractor P N 529 035 576 A02D1Q4 APPLICATION Formula type driven pulley NOTE Use thi...

Page 41: ...l pusher P N 529 035 584 A00B504 APPLICATION S F CK3 and ZX series NOTE This tool replaces chain case upper seal pusher P N 529 032 300 Drive axle sprocket adjuster P N 861 725 700 A01B2O4 Parts inclu...

Page 42: ...SUSPENSION MANDATORY SERVICE TOOLS Shock spring removal kit P N 529 035 504 Replacement clevis pin P N 414 528 400 A01B4O4 APPLICATION All suspensions with coil spring NOTE The previous shock spring r...

Page 43: ...r except lan and Tundra II Camber angle tool P N 529 021 600 NOTE Angle finder with a magnetic base must be used Suggestion K D tool no 2968 A06B024 APPLICATION All DSA front suspensions Track tension...

Page 44: ...APPLICATION 2002 and 2003 MX Z x 440 LC NEW NEW NEW Shock wrench P N 529 035 727 A00F224 APPLICATION All T A shocks HPG shock holding tool P N 529 035 769 A01B5H4 APPLICATION All HPG shocks Piston gu...

Page 45: ...B074 APPLICATION REV Series Extension to torque ball joint nut P N 529 035 876 A33B024 APPLICATION REV Series REV ball joint lock P N 529 035 945 A32F2W4 APPLICATION REV Series Ball joint remover supp...

Page 46: ...wrench P N 529 017 100 A15B094 APPLICATION 1992 and old Formula C 7 Suspension adjustment wrench P N 529 032 900 A02F114 APPLICATION ARM and SC 10 II suspensions Suspension adjustment wrench P N 529...

Page 47: ...t for oil container P N 414 837 300 F04B044 APPLICATION All models Adjustment wrench P N 529 035 603 APPLICATION To remove and install fuel tank nut on ZX series Terminal Packard remover Not sold by B...

Page 48: ...000 070 F01D174 APPLICATION Some models Adjustment wrench P N 529 035 891 A33B084 APPLICATION REV series NEW Fuel pump nut wrench P N 529 035 899 A32B0Y4 APPLICATION 2 TEC and 1004 engine equipped mo...

Page 49: ...D SERVICE TOOLS Heated grips insertion tool A P N 529 035 897 B P N 529 035 936 A32G2B4 APPLICATION A ZX liquid cooled models with straight grips B Models with J hook type grips Crimp pliers P N 529 0...

Page 50: ...crankcase studs etc NOTE This product replaces Loc tite 242 P N 293 800 015 High strength threadlocker P N 293 800 005 Loctite 271 Threadlocker 10 mL red high strength A00B2U4 APPLICATION Fasteners a...

Page 51: ...8 500 Loctite Chisel 510 g 18 oz A00B574 APPLICATION Clean mating surfaces of cylinders and crankcase Remove carbon in combustion chambers Molykote PG 54 P N 420 899 763 10 g A00B5F4 APPLICATION To lu...

Page 52: ...XP S II synthetic injection oil P N 293 600 045 12 x 1 liter A00B5T4 P N 293 600 046 3 x 4 liter A00B5U4 P N 293 600 047 205 liter APPLICATION All engines NOTE This synthetic injection oil replaces X...

Page 53: ...PPLICATION All models NOTE Only the P N has been changed This product is identical to the P N 496 014 100 Synthetic chaincase oil P N 413 803 300 12 x 355 mL A00B5Z4 APPLICATION Chaincase lubricant on...

Page 54: ...CATION Crankshaft seals on all engines ex cept ZX series ones 111 Brake fluid SRF DOT 4 P N 293 600 063 1 L A33A0T4 APPLICATION All models with hydraulic brake Brake fluid GTLMA DOT 4 P N 293 600 062...

Page 55: ...ngine crankcase joining surfaces pulleys and any greasy surfaces Heavy duty cleaner P N 293 110 001 400 g P N 293 110 002 4 L A00B614 APPLICATION All models Plastic vinyl cleaner P N 413 711 200 6 x 1...

Page 56: ...3O4 APPLICATION Isolating foam and rubber strip General purpose instant adhesive P N 293 800 021 Loctite 495 3 g A00B2V4 APPLICATION Rubber to metal bonding and most hard plastic NOTE Only the P N has...

Page 57: ...ion 01 SERVICE TOOLS AND SERVICE PRODUCTS Subsection 02 SERVICE PRODUCTS 01 02 8 MMR2004_102_01_02A FM RECOMMENDED SERVICE PRODUCTS continued Scratch remover P N 861 774 800 A00B6G4 APPLICATION All mo...

Page 58: ...UBRICATION 02 03 1 COUNTERSHAFT LUBRICATION 02 03 2 PULLEY PROTECTION 02 03 2 VEHICLE PROTECTION 02 03 2 RAGS IN AIR INTAKE AND EXHAUST SYSTEM 02 03 2 PRESEASON PREPARATION 02 04 1 FUEL FILTER REPLACE...

Page 59: ...4 03 04 04 and 04 05 Injection Oil Filter I R Subsection 04 07 Oil Injection Pump A A A Subsection 04 07 Fuel Stabilizer R Subsection 02 03 Fuel Filter R Subsection 02 04 Fuel Lines and Connections I...

Page 60: ...tion 07 06 Track Tension and Alignment A AS REQUIRED Subsection 07 06 Spark Plugs I I R Subsection 06 03 Battery if so equipped I I I I Subsection 06 04 Headlamp Beam Aiming A A Subsection 09 02 Wirin...

Page 61: ...ct the hood and repair any damage Touch up all metal spots with touch up paint where paint has been scratched off Spray all bare metal parts including shock chromed rods with BOMBARDIER LUBE P N 293 6...

Page 62: ...ating on the countershaft for efficient operation Lubricate with anti seize lubricant P N 293 800 070 CAUTION Do not lubricate excessively as lu bricant could contact and soil brake pads and or drive...

Page 63: ...al parts Do not hesitate to replace any jets having gum or varnish on their surfaces AIR FILTER CLEANING Check that inside of air silencer is clean and dry then properly reinstall the filter CAUTION T...

Page 64: ...NGINE 03 02 1 ENGINE LEAK VERIFICATION FLOW CHART 03 02 13 FUEL AND OIL SYSTEMS 03 03 1 TRANSMISSION AND BRAKE SYSTEMS 03 04 1 TRANSMISSION 03 04 1 BRAKE SYSTEM 03 04 7 MECHANICAL BRAKE 03 04 7 HYDRAU...

Page 65: ...specifications refer to TECHNICAL DATA 3 Check carburetor a Fuel passages obstructed Clean carburetor and install new filter s b Fuel level too low Adjust float level according to specifications 4 Che...

Page 66: ...aged fuel lines Replace defective lines c Fuel does not flow through carburetor s foreign particles in needle area and or varnish formation in carburetor s Clean carburetor s and install new filter s...

Page 67: ...snow infiltration in engine This can also be caused by running engine on choke for too long Excessive fuel will remove the oil film on the piston and make marks Replace piston s and check if intake sy...

Page 68: ...ain fuel system then fill with appropriate fuel 3 Check items listed in ENGINE RUNS OUT OF FUEL refer to FUEL AND OIL SYSTEMS subsection 4 Check carburetor adjustments and cleanliness a Inadequate car...

Page 69: ...r opening Replace or adjust Refer to proper engine subsection SYMPTOM ENGINE DETONATION AT MAXIMUM RPM CONDITION NORMAL USE Test Inspection 1 Check which type of fuel is used a Octane number is too lo...

Page 70: ...oke or primer 4 Check spark plug a Defective spark plug no spark or wrong spark plug gap Replace spark plugs or readjust gap 5 Check amount of fuel on spark plug a Flooded engine spark plug wet when r...

Page 71: ...ifications refer to TECHNICAL DATA 4 Check dimension of pilot jet a Inadequate fuel air mixture Adjust according to specifications refer to TECHNICAL DATA 5 Check reed valve a Improper tightness and o...

Page 72: ...cations refer to TECHNICAL DATA 5 Check if there are leaks at air intake silencer and or engine crankcase a Leak s Repair or replace 6 Check condition and heat range of spark plugs a Melted spark plug...

Page 73: ...nents Adjust according to specifications refer to TECHNICAL DATA or replace inadequate component s 8 Check cylinder head gaskets a Worn gaskets Replace 9 Check ignition timing a Ignition timing is too...

Page 74: ...Replace 6 Check RAVE pressure holes a Clogged holes Clean 7 Check clamps or sleeves a Damaged clamp s or sleeve s Replace 8 Check exhaust tightness a Exhaust system is leaking leading to a too low bac...

Page 75: ...at Replace 3 Check pawl and rope sheave a Pawl and rope sheave have stuck together because of heat Replace SYMPTOM ENGINE PINGING CONDITION NORMAL USE Test Inspection 1 Check fuel lines a Bent fuel li...

Page 76: ...ghten to specification refer to TECHNICAL DATA or replace 2 Check drive pulley refer to VIBRATIONS ORIGINATING FROM DRIVE PULLEY 3 Check carburetors synchronization a Throttle slide height is not the...

Page 77: ...KET PRESSURIZE PUMP SHAFT GEAR RESERVOIR IN CRANKCASE ARE SEALS LEAKING CHECK CRANKSHAFT OUTER SEAL OF PTO AND MAG SIDES PRESSURIZE PUMP SHAFT GEAR RESERVOIR IN CRANKCASE IS RESERVOIR LEAKING UNSEAL P...

Page 78: ...el tank and carburetor s a Leaking fittings Replace defective part 3 Check choke adjustment a Fuel flows through choke circuit while engine runs Readjust choke 4 Check float height in carburetor s a F...

Page 79: ...ing impulse hose Replace b Dried diaphragm Replace 5 Check if carburetor s is are clean a Varnish Clean SYMPTOM HIGH INJECTION OIL CONSUMPTION CONDITION NORMAL USE Test Inspection 1 Check oil injectio...

Page 80: ...ove freely a Corrosion due to oxidation at installation Replace fuel filter 2 Check if lines are perforated or kinked or if they leak at fittings a Lines are too big for their fittings or are improper...

Page 81: ...oo rich or too poor a Possible damage to DPM If DPM does not operate properly unplug compensation solenoid connector while engine is running The carburetion is now identical to that of carburetors wit...

Page 82: ...iding half Replace 4 Check spring tension of driven pulley sliding half a Sliding half rotation is accelerated when spring tension is too weak Adjust according to specifications refer to TECHNICAL DAT...

Page 83: ...ring cover screws a Spring cover moves and restrains sliding half movement Retighten screws 4 Check spring cover TRA type and or sliding half bushings a Excessive gap between bushings and fixed half s...

Page 84: ...1 Check pulley distance and alignment a Improper adjustment Adjust according to specifications refer to PULLEY DISTANCE AND ALIGNMENT and make sure that torque rod is resting against engine Check eng...

Page 85: ...o specifications SYMPTOM BELT WORN EXCESSIVELY IN TOP WIDTH CONDITION NORMAL USE Test Inspection A00D0BY 1 Check drive pulley a Excessive slippage due to jammed of drive pulley Inspect drive pulley 2...

Page 86: ...ct Adjust according to specifications SYMPTOM BELT SIDES WORN CONCAVE CONDITION NORMAL USE Test Inspection A00D0DY 1 Check pulley half surfaces a Rough or scratched pulley half surfaces Repair or repl...

Page 87: ...ge Store properly SYMPTOM TOOTH CHUNK OUT CONDITION NORMAL USE Test Inspection A00D0HY 1 Check drive belt rotational direction a Improper belt installation Replace 2 Check if drive belt rubs against c...

Page 88: ...ing Replace 2 Check if brake cable moves freely in its housing a Brake cable movement is limited due to oxidation or dirt accumulation Replace 3 Check distance between brake lever and caliper a Distan...

Page 89: ...4 8 MMR2004 108_03_04A FM MECHANICAL AND HYDRAULIC BRAKES SYMPTOM BRAKE SYSTEM IS NOISY CONDITION NORMAL USE Test Inspection 1 Check brake pad thickness a Pads are worn up to wear warner Replace 2 Che...

Page 90: ...ions may not apply to a specific model SYMPTOM STARTER DOES NOT TURN CONDITION NORMAL USE Test Inspection 1 Check 30 A fuse located near battery a Burnt fuse Check wiring condition and replace 30 A fu...

Page 91: ...ing a Open circuit of starter relay pull in winding Replace starter relay 7 Check continuity of starter relay hold in winding a Open circuit of starter relay hold in winding Replace starter relay 8 Ch...

Page 92: ...h a Defective clutch Replace clutch 3 Check brackets a Worn or broken brackets Replace brackets 4 Check movement of clutch on splines a Poor movement of clutch on splines Clean and correct 5 Check clu...

Page 93: ...h 5 Check starter relay a Shorted starter relay winding s Replace starter relay 6 Check starter relay contacts a Melted starter relay contacts Replace starter relay 7 Check starter switch a Starter sw...

Page 94: ...Clean and or retighten SYMPTOM ELECTRIC STARTER SOMETIMES DOES NOT WORK WHEN ACTIVATED CONDITION NORMAL USE Test Inspection 1 Check battery cables and starter wires a Corroded and or loose connection...

Page 95: ...necessary Replace defective switch es Clean terminals and apply silicone dielectric grease 4 Verify trigger coil resistance with an ohmmeter and connector condition a Defective coil Corroded connector...

Page 96: ...cone dielectric grease Replace defective parts CONDITION NORMAL USE Test Inspection 1 Verify misfiring by observing flash of stroboscopic timing light unplug connectors between magneto generator and v...

Page 97: ...ty oil Use BOMBARDIER injection oil 4 Check engine compression a Leaking piston ring s Replace SYMPTOM SPARK PLUG TIP S IS ARE LIGHT GREY CONDITION NORMAL USE Test Inspection 1 Refer to ENGINE SLOWS D...

Page 98: ...ions or damaged wires Clean or replace 6 Check MPEM a Faulty MPEM Replace CONDITION AT HIGH ALTITUDE Test Inspection 1 Check high altitude cap continuity a Broken jumper inside high altitude cap Repla...

Page 99: ...uipment connected directly to DC ground BK wire or chassis or to any DC hot wire RD RD BU Disconnect and reconnect to AC current YL and YL BK wires 4 Verify if optional electric accessories are overlo...

Page 100: ...m position a Defective or damaged part Correct or replace sender unit 4 Verify sender unit gauge wiring harness condition a Heating rotating or sharp part in contact with harness Improper harness rout...

Page 101: ...wires a Corroded terminals and or broken wires Replace terminal s or crimp defective wires SYMPTOM TACHOMETER DOES NOT WORK CONDITION NORMAL USE Test Inspection 1 Check continuity of wires a Corroded...

Page 102: ...preload to the recommended position 3 Check springs a Installed springs are too soft Install optional stiffer springs refer to Service Bulletin SPRING REFERENCE ACCORDING TO LOAD SYMPTOM REAR SUSPENSI...

Page 103: ...ear shock motion ratio to soft position 4 Check track tension a Track is too tight Adjust 5 Check if axles are properly lubricated a Improper lubrication and or contaminated grease sticky oil sludge C...

Page 104: ...strap a Too much weight when stopper strap is short Lengthen front arm stopper strap 4 Check position of front arm spring adjustment cam s a When spring tension is weak more weight is transferred to t...

Page 105: ...g screws Replace defective parts and or tighten loose screws SYMPTOM DERAILING TRACK CONDITION NORMAL USE Test Inspection 1 Check track tension a Track is too loose Adjust 2 Check if track and slider...

Page 106: ...02 4 DISASSEMBLY 04 02 4 INSPECTION 04 02 6 ASSEMBLY 04 02 6 BOTTOM END 04 02 10 CLEANING 04 02 11 DISASSEMBLY 04 02 11 INSPECTION 04 02 11 ASSEMBLY 04 02 12 443 AND 552 ENGINE TYPES 04 03 1 ENGINE R...

Page 107: ...04 05 4 ENGINE DIMENSION MEASUREMENT 04 05 5 CYLINDER HEAD WARPAGE 04 05 5 CYLINDER TAPER 04 05 5 CYLINDER OUT OF ROUND 04 05 5 COMBUSTION CHAMBER VOLUME MEASUREMENT 04 05 5 USED PISTON MEASUREMENT 04...

Page 108: ...BLY 04 08 2 INSTALLATION 04 08 3 FAN BELT REPLACEMENT AND DEFLECTION ADJUSTMENT 04 08 3 LIQUID COOLING SYSTEM 04 09 1 COOLING SYSTEM LEAK TEST 04 09 2 INSPECTION 04 09 2 DRAINING THE SYSTEM 04 09 2 DI...

Page 109: ...R FLOAT LEVEL ADJUSTMENT 04 11 6 CARBURETOR ADJUSTMENTS 04 11 7 INSTALLATION 04 11 8 IDLE SPEED FINAL ADJUSTMENT 04 11 10 CHOKE 04 11 10 FUEL PUMP 04 11 12 REMOVAL 04 11 12 PUMP VERIFICATION 04 11 12...

Page 110: ...ENGINE TYPE 0 ENGINE REMOVAL AND INSTALLATION A05C1BS 10 N m 89 lbf in 1 48 N m 35 lbf ft Super Lube grease 10 2 4 16 10 25 N m 18 lbf ft 48 N m 35 lbf ft 48 N m 35 lbf ft Loctite 30542 Loctite 243 L...

Page 111: ...upport screws no 4 to 15 N m 133 lbf in and nuts no 1 to 48 N m 35 lbf ft Torque the engine support screws and nut no 10 to 48 N m 35 lbf ft Apply Loctite 243 P N 293 800 060 on threads of screw no 2...

Page 112: ...Section 04 ENGINE Subsection 02 277 ENGINE TYPE MMR2004 111_04_02A FM 04 02 3 TOP END Molykote 111 A05C1CS 1 22 N m 16 lbf ft 2 3 4 5 8 7 6 26 N m 19 lbf ft...

Page 113: ...aust port cylinder head and piston dome using a wood en spatula NOTE The letters AUS over an arrow on the piston dome must be visible after cleaning Clean the piston ring grooves with a groove clean e...

Page 114: ...Shouldered sleeve Pull out piston pin no 7 by unscrewing puller until shouldered sleeve end is flush with thrust washer of piston pin bearing TYPICAL PISTON PIN EXTRACTION TYPICAL 1 Sleeve inside bear...

Page 115: ...r to LEAK TEST AND ENGINE DIMENSIONS MEASUREMENT ASSEMBLY When reinstalling original needle bearings make sure that 31 needles are inserted between sleeve and locating sleeve When installing a new cag...

Page 116: ...l piston pin is correctly positioned in piston TYPICAL Remove piston pin puller and sleeve kit To minimize the effect of acceleration forces on circlip install each circlip so the circlip break is at...

Page 117: ...square end of tool push circlip in until it rests in groove 1 Circlip in groove Mount tool in piston making sure that circlip break is facing down TYPICAL 1 Circlip break facing down Hold tool firmly...

Page 118: ...clips must not move freely in the groove after installation If so replace them Before inserting piston in the cylinder lubricate the cylinder with new injection oil or equivalent Position cylinder hea...

Page 119: ...Section 04 ENGINE Subsection 02 277 ENGINE TYPE 04 02 10 MMR2004 111_04_02A FM BOTTOM END A05C1DS 1 22 N m 16 lbf ft 3 5 4 6 2 7 Molykote 111 Loctite 76732 Molykote 111 Loctite 648 Molykote 111...

Page 120: ...876 298 to plate P N 529 024 900 with flat washer under screw heads and extract PTO side crank case half no 1 1 Plate 2 Flat washer Heat to 110 120 C 230 248 F all around bear ing seat on MAG side Ins...

Page 121: ...rankshaft extension For the crankshaft end play adjustment procedure refer to LEAK TEST AND ENGINE DIMENSION MEASUREMENT Prior to crankcase adjoining install a protector sleeve on each crankshaft exte...

Page 122: ...GINE Subsection 03 443 AND 552 ENGINE TYPES MMR2004 112_04_03A FM 04 03 1 443 AND 552 ENGINE TYPES 0 ENGINE REMOVAL AND INSTALLATION Skandic LT 443 Engine Type A29C2BS High temperature RTV sealant 39...

Page 123: ...Section 04 ENGINE Subsection 03 443 AND 552 ENGINE TYPES 04 03 2 MMR2004 112_04_03A FM Skandic WT SWT SUV 552 Engine Type A29C2US 39 N m 29 lbf ft...

Page 124: ...uretors impulse line from engine crankcase electrical connector housings exhaust pipe oil pump inlet line and plug it oil pump cable rewind cable tie a knot near rewind housing and remove starting gri...

Page 125: ...ion 03 443 AND 552 ENGINE TYPES 04 03 4 MMR2004 112_04_03A FM TOP END Skandic LT 443 Engine Type A29C2VS 22 N m 16 lbf ft 2 1 3 21 N m 15 lbf ft Anti seize Loctite 21 N m 15 lbf ft 4 5 5 6 22 N m 16 l...

Page 126: ...04 ENGINE Subsection 03 443 AND 552 ENGINE TYPES MMR2004 112_04_03A FM 04 03 5 Skandic WT SWT SUV 552 Engine Type A32C67S 22 N m 16 lbf ft 2 2 3 21 N m 15 lbf ft 4 8 9 10 13 12 11 11 5 N m 44 lbf in...

Page 127: ...he pis ton dome must be visible after cleaning Clean the piston ring grooves with a groove clean er tool or with a piece of broken ring DISASSEMBLY Remove top fan cowl intake sockets and lower fan cow...

Page 128: ...LLATION OF SLEEVE KIT 1 Sleeve 2 Shouldered sleeve Pull out piston pin no 10 by unscrewing puller un til shouldered sleeve end is flush with thrust wash er of piston pin bearing TYPICAL PISTON PIN EXT...

Page 129: ...thrust washers along with locating sleeve INSPECTION Refer to ENGINE DIMENSION MEASUREMENT ASSEMBLY 443 and 552 Engines When reinstalling original needle bearings make sure that 31 needles in case of...

Page 130: ...e the pin Inappropriate heating procedure s may damage the piston Mount piston over connecting rod with the letters AUS over an arrow on the piston dome facing in the direction of exhaust port 1 Exhau...

Page 131: ...rclip so the circlip break is at 6 o clock as illustrated Use piston circlip installer P N 529 035 561 Insert circlip in tool at an angle 1 Circlip Square it up using a finger 1 Circlip Continue to sq...

Page 132: ...CAUTION Circlips must not move freely in the groove after installation If so replace them NOTE Be sure to restore the chamfer around all cylinder sleeve port openings 552 Engine Use circlip installer...

Page 133: ...ccording to combustion chamber volume Refer to LEAK TEST AND ENGINE DIMENSION MEASUREMENT Install it on crankcase Coat gas ket with Loctite 518 CAUTION Always install a gasket of the proper thickness...

Page 134: ...shape Install with their curve facing reed block With blade stopper no 13 removed check reed valve for proper tightness There must be no play between blade and valve body when exerting a finger pressu...

Page 135: ...3A FM BOTTOM END Skandic LT 443 Engine Type A29C2WS Anti seize lubricant 22 N m 16 lbf ft 503 22 N m 16 lbf ft 443 10 N m 89 lbf in 5 2 4 3 2 1 3 Anti seize lubricant Anti seize lubricant 22 N m 16 lb...

Page 136: ..._04_03A FM 04 03 15 Skandic WT SWT SUV 552 Engine Type A29C2XS 1 2 3 Isoflex 11 N m 8 lbf ft Anti seize lubricant 3 4 2 Loctite 243 Engine oil 5 Loctite 243 27 N m 20 lbf ft Anti seize lubricant Anti...

Page 137: ...trace of Loctite from crankshaft taper Remove old sealant from crankcase mating sur faces with Bombardier gasket remover P N 413 708 500 CAUTION Never use a sharp object to scrape away old sealant as...

Page 138: ...se of damaged bearing or less clearance between crankshaft counterbalance and the bearing use bearing separator Snap On tool P N CJ951 or SPX OTC tool P N 1124 to fa cilitate the removal 1 Bearing sep...

Page 139: ...ings and ease instal lation If required put a suitable plate or shim to avoid the direct contact between integrated seal and the heating surface CAUTION Bearing should not be heated to more than 80 C...

Page 140: ...to end posi tion BEARING TO END POSITION Install the O ring Make a bearing locator tool using support plate P N 529 035 976 and distance gauge P N 529 035 965 1 Support plate 2 Distance gauge Install...

Page 141: ...ngs lubrication When installing crankshaft position drive pins no 6 as illustrated TYPICAL 1 Drive pins Skandic WT SWT SUV 552 Engine Type CAUTION Use only the recommended Isoflex grease P N 293 550 0...

Page 142: ...compound Spread a seam of 1 2 mm 1 16 in maximum in diameter on surface of lower crankcase half TYPICAL As far as possible sealing compound must be ap plied in one run to avoid any risks of leaking t...

Page 143: ...HTENING SEQUENCE FOR 443 ENGINE TYPE A 10 N m 89 lbf in All the other screws are torqued to 22 N m 16 lbf ft All Engines To install magneto refer to CDI MAGNETO BREAK IN After rebuilding an engine alw...

Page 144: ...njection inlet line at oil injection pump install hose pincher oil pump cable coolant hoses between cylinder head and radiator coolant by pass hose coolant hose at front of coolant reservoir engine su...

Page 145: ...13_04_04A FM TOP END A29C2SS 29 N m 21 lbf ft 4 3 29 N m 21 lbf ft 9 N m 80 lbf in 2 18 21 20 19 17 16 M8 23 N m 17 lbf ft 1 Injection oil Loctite 243 10 12 6 7 8 9 5 13 14 11 15 Dreibond 7 N m 62 lbf...

Page 146: ...O rings Clean all metal components in a non ferrous metal cleaner Scrape off carbon formation from cylinder exhaust port cylinder head and piston dome using a wood en spatula NOTE The letters AUS ove...

Page 147: ...13 TYPICAL 1 Allen socket screws 2 RAVE valve base Unscrew and remove the guillotine no 15 from the valve piston no 9 than remove the gasket no 14 1 Guillotine 2 Gasket 3 Valve piston Remove spring n...

Page 148: ...cover no 2 then cylinder head no 3 18 Piston Place a clean cloth or rubber pad P N 529 023 400 over crankcase Then with a pointed tool inserted in piston notch remove both circlips no 20 from piston n...

Page 149: ...ller rod TYPICAL INSTALLATION OF SLEEVE KIT 1 Sleeve 2 Shouldered sleeve Screw LH threads extracting nut Pull out piston pin no 19 by unscrewing puller un til shouldered sleeve end is flush with thrus...

Page 150: ...ried or perforated bellows 8 Spring ASSEMBLY RAVE System Apply sealing compound Dreibond P N 420 297 906 in the groove of valve base and in the piston valve groove then install bellows Install RAVE va...

Page 151: ...le bearing with injection oil Grease thrust washers and install them on each end of needles Insert cageless bearing into connecting rod TYPICAL CAGELESS BEARING AND SLEEVE INSTALLED Heat piston using...

Page 152: ...Use circlip installer P N 529 035 686 to install new mono hook circlips no 20 Insert circlip into support in such a way that when installed in piston groove the tab will face upward With round end of...

Page 153: ...93 800 038 Choose the right gasket thick ness according to combustion chamber volume Refer to LEAK TEST AND ENGINE DIMENSION MEASUREMENT Install it on crankcase Coat gas ket with Loctite 518 CAUTION A...

Page 154: ...e must be no play between blade and valve body when exerting a finger pressure on blade at blade stopper location In case of a play turn blade upside down and re check If there is still a play replace...

Page 155: ...29 N m 21 lbf ft 2 Petamo Anti seize lubricant Anti seize lubricant Petamo Anti seize lubricant Anti seize lubricant Isoflex Petamo 2 3 Loctite 242 Loctite 242 Molykote 111 Petamo Loctite 648 Loctite...

Page 156: ...g P N 420 977 490 on the bearing 1 Half ring 2 Puller ring Apply synthetic grease P N 413 711 500 on the crankshaft end and install protective cap P N 420 876 552 Using screws P N 420 840 681 Install...

Page 157: ...ll expand bearings and ease instal lation If required put a suitable plate or shim to avoid the direct contact between integrated seal and the heating surface CAUTION Bearing should not be heated to m...

Page 158: ...h the integrated seal facing crankshaft Push bearing to end position Install the O rings Make a bearing locator tool using support plate P N 529 035 976 and distance gauge P N 529 035 966 1 Support pl...

Page 159: ...seal with Isoflex grease 1 PTO side inner seal filled with Isoflex grease Put 43 to 47 mL of grease in a syringe Withthesyringe filltheouterballbearingwithgrease BALLS COATED WITH A SEAM OF GREASE Coa...

Page 160: ...ng compound P N 420 297 905 Make sure surfaces are clean and degreased before ap plying sealing compound Spread a seam of 1 2 mm 1 16 in maximum in diameter on surface of lower crankcase half As far a...

Page 161: ...ew bolts up to 60 of the final torque 18 N m 13 5 lbf ft for most of the bolts then tighten to the required torque i e 29 N m 21 lbf ft A Torque bolts 1 through 16 to 29 N m 21 lbf ft B Torque bolts 1...

Page 162: ...d individually due to leakage from one cylinder to the other through labyrinth sleeve in center of crankshaft PREPARATION 1 Remove tuned pipe 2 Install plug over exhaust manifold 3 Remove carburetors...

Page 163: ...leak If there is no leak at the tested location contin ue pumping to maintain pressure and continue with next items until leak is found Engine Check the following 1 All jointed surfaces and screw stu...

Page 164: ...r 1 Leak indicator hole If there is a leak it indicates defective seal of pump shaft oil seal beside coolant ceramic seal 2 Leaks can be also on oil pump side Check mount ing area for leaks 1 Check mo...

Page 165: ...ESSURIZE PUMP SHAFT GEAR RESERVOIR IN CRANKCASE ARE SEALS LEAKING CHECK CRANKSHAFT OUTER SEAL OF PTO AND MAG SIDES PRESSURIZE PUMP SHAFT GEAR RESERVOIR IN CRANKCASE IS RESERVOIR LEAKING UNSEAL PTO CYL...

Page 166: ...p CYLINDER OUT OF ROUND Measuring 16 mm 5 8 in from top of cylinder with a cylinder gauge check if the cylinder out of round is more than the specified dimension If larger cyl inder should be rebored...

Page 167: ...gh the spark plug hole until liquid touches the top of the spark plug hole 1 Top of spark plug hole NOTE The liquid level in cylinder must not drop for a few seconds after filling If so there is a lea...

Page 168: ...ribed on piston dome Otherwise install a new piston CYLINDER PISTON CLEARANCE Used and New Pistons NOTE Make sure used piston is not worn more than specified See USED PISTON MEASURE MENT above Take th...

Page 169: ...nt on the cylinder bore gauge The result is the exact piston cylinder wall clear ance If clearance exceeds specified tolerance re place cylinder or rebore Refer to TECHNICAL DATA NOTE Make sure the cy...

Page 170: ...ce engine is disassembled check crankshaft deflection on V shaped blocks If deflection ex ceeds the specified tolerance it can be worn bear ings or a bent crankshaft Remove crankshaft bear ings and ch...

Page 171: ...the magneto side between bearing and crankshaft counterweight The following is required for the adjustment pro cedure adjustment shims refer to Parts Catalog thicknesses available 0 10 mm 004 in 0 20...

Page 172: ...he result is the actual crankshaft end play that must be within specification If the result is over specification add adjustment shim s to reach this specification If the result is under specification...

Page 173: ...on sand paper using 8 figure movements Sand until mating surface is perfectly straight CHECKING CRANKSHAFT ALIGNMENT Install a degree wheel P N 414 352 900 on crank shaft end Remove both spark plugs...

Page 174: ...4 115_04_06A FM 04 06 1 CDI SYSTEM 0 NIPPONDENSO TRIGGER COIL IGNITION SYSTEM 290 W on Skandic WT LC SUV 600 A29E0MT Loctite 243 6 5 4 3 2 Loctite 243 1 125 N m 92 lbf ft Loctite 243 Dielectric grease...

Page 175: ...GINE Subsection 06 CDI SYSTEM 04 06 2 MMR2004 115_04_06A FM DUCATI IGNITION SYSTEM 340 W on Skandic WT SWT SUV 550 Loctite 243 1 105 N m 77 lbf ft A03E2YT Dielectric grease Loctite 243 3 22 N m 195 lb...

Page 176: ...ion 04 ENGINE Subsection 06 CDI SYSTEM MMR2004 115_04_06A FM 04 06 3 RER IGNITION SYSTEM 240 W on Tundra R A05E0XT Dielectric grease 7 1 Loctite 243 2 5 4 22 N m 195 lbf in Loctite 243 3 105 N m 77 lb...

Page 177: ...tion 04 ENGINE Subsection 06 CDI SYSTEM 04 06 4 MMR2004 115_04_06A FM 240 W on Skandic LT A03E2ZU 6 5 1 4 105 N m 77 lbf ft Loctite 243 Loctite 243 3 Dielectric grease To main harness 2 22 N m 195 lbf...

Page 178: ...d muffler rewind starter starting pulley no 2 To remove magneto flywheel retaining nut no 1 Use magneto puller ring P N 420 876 080 Former puller has to be modified as shown 1 Cut by 25 mm 1 in Instal...

Page 179: ...ed ASSEMBLY 6 Stator Make sure to position stator in a way that its wire protectors are over recess of crankcase 1 Crankcase recess 2 Wire protectors 3 Magneto Flywheel Clean crankshaft extension tape...

Page 180: ...t Ignition timing must also be checked Re fer to IGNITION SYSTEM Proceed as follows 1 Rotate flywheel so that one protrusion aligns with trigger coil 2 Using a feeler gauge of 0 45 mm 018 in to 0 55 m...

Page 181: ...ion 04 ENGINE Subsection 07 OIL INJECTION SYSTEM MMR2004 116_04_07A FM 04 07 1 OIL INJECTION SYSTEM 0 OIL INJECTION PUMP 277 Engine A05C19S Injection oil Loctite 243 5 6 1 8 4 3 Loctite 243 Molykote 1...

Page 182: ...ion 04 ENGINE Subsection 07 OIL INJECTION SYSTEM 04 07 2 MMR2004 116_04_07A FM 443 Engine on Skandic LT LT E A21C0AS Injection oil 1 1 1 1 1 2 5 N m 44 lbf in 3 Loctite 243 8 2 4 7 Grease 6 5 Loctite...

Page 183: ...04 ENGINE Subsection 07 OIL INJECTION SYSTEM MMR2004 116_04_07A FM 04 07 3 552 Engine on Skandic WT SWT SUV 550 A21C0BS Recommended injection oil 1 1 1 Molykote 111 2 8 4 2 7 6 5 Loctite 243 5 N m 44...

Page 184: ...Section 04 ENGINE Subsection 07 OIL INJECTION SYSTEM 04 07 4 MMR2004 116_04_07A FM 593 Engine on Skandic WT LC SUV 600 A29C2OS 1 Injection oil 1 1 Loctite 648 2 4 3 2 Loctite 648 5 N m 44 lbf in 8...

Page 185: ...locate leak s and repair replace leaking component s OIL PUMP IDENTIFICATION All Models 4 Pump Lever Different engines need different pumps See iden tification on lever no 4 CAUTION Always mount prop...

Page 186: ...s area NOTE Prior to coating it with Loctite make sure check valve body is clean and dry Clean from dirt or oil if any with Pulley flange cleaner P N 413 711 809 APPLY LOCTITE ON THIS AREA ONLY Instal...

Page 187: ...minated on this model Because the oil pump is mounted low on engine it is very difficult to avoid parallax problem and set a good adjustment Parallax Problem When adjusting pump lever since the mechan...

Page 188: ...routing near original location Use a small round or oblong mirror to see the marks The second mark on pump lever must be aligned or up to 1 mm 039 in below pump casting mark If not loosen the adjuster...

Page 189: ...n is attained Reconnect small oil lines start engine and run at idle while holding the pump lever in fully open position Oil columns must advance into small oil lines If not remove pump assembly and c...

Page 190: ...8A FM 04 08 1 AXIAL FAN COOLING SYSTEM 0 443 and 552 Engines NOTE For 277 engine radial fan cooling system refer to CDI SYSTEM 1 3 5 18 13 12 14 15 16 17 47 N m 35 lbf ft 20 10 11 10 9 4 13 N m 115 lb...

Page 191: ...m 4 connector housing then fan housing ass y CLEANING Clean all metal components in a non ferrous metal cleaner DISASSEMBLY AND ASSEMBLY Using a flat screwdriver lift fan protector tabs as shown in th...

Page 192: ...tion INSTALLATION At assembly apply a light coat of Loctite 243 blue on screw no 1 threads A gasket must be placed on both sides inner and outer of intake and exhaust holes of cylinder cowl nos 4 and...

Page 193: ...assembly on fan shaft Temporarily tighten fan nut CAUTION When reinstalling fan assembly en sure that key is properly positioned into fan shaft keyway Fan Belt Deflection Adjustment Check fan belt def...

Page 194: ...elt is properly adjusted torque fan nut to 48 N m 35 lbf ft using holder wrench P N 420 876 357 as shown in the following photo NOTE Apply Loctite 243 blue on fan nut threads TORQUE FAN NUT USING HOLD...

Page 195: ...Section 04 ENGINE Subsection 09 LIQUID COOLING SYSTEM MMR2004 118_04_09A FM 04 09 1 LIQUID COOLING SYSTEM 0 593 Engine A29C2QS 1 9 5 3 2 4 Loctite 592...

Page 196: ...thread sealant on sender and plug to avoid leaks 1 Pressure Cap Check if the cap pressurizes the system If not install a new 90 kPa 13 PSI cap do not exceed this pressure 5 Thermostat To check thermo...

Page 197: ...E 50 50 PREMIXED COOL ANT 37 C 35 F P N 293 600 038 Do not reinstall pressure cap Lift front of vehicle until the tunnel is horizontal With engine cold refill coolant tank no 2 up to cold level line W...

Page 198: ...RTER MMR2004 119_04_10A FM 04 10 1 REWIND STARTER 0 Plastic Rewind Starter on Liquid Cooled Models 1 7 N m 62 lbf in 4 5 6 9 N m 80 lbf in 8 10 9 11 12 13 Molykote PG 54 15 Molykote PG 54 Molykote PG...

Page 199: ...ction 10 REWIND STARTER 04 10 2 MMR2004 119_04_10A FM Plastic Rewind Starter on Fan Cooled Models TYPICAL A03C3CT 10 N m 89 lbf in 13 12 11 10 9 8 7 5 4 6 2 1 7 N m 62 lbf in Molykote PG 54 15 Molykot...

Page 200: ...per spring preload or damages Readjust or replace as required When pulling starter grip 10 times in a row it must return freely If not check for damaged parts or lack of lubrication Replace parts or l...

Page 201: ...and then rope no 6 ASSEMBLY At assembly position spring no 4 outer end into spring guide notch then wind the spring counter clockwise into guide 1 Outer end into guide notch CAUTION It is of the utmos...

Page 202: ...oled Models Only To install rope no 6 insert rope into sheave no 5 orifice and lock it with the key no 7 as illustrated 1 Push to lock Lubricate housing post with silicone compound grease Install shea...

Page 203: ...that the sheave hub notch engages in the rewind spring hook Rotate the sheave counterclockwise until rope end is accessible through rope exit hole This will give 1 2 turn of preload Pull the rope out...

Page 204: ...NSTALLATION Fan Cooled Models Only Reinstall oil pump on rewind starter assembly All Models Thread starter rope no 6 through rope guide when applicable TYPICAL Reinstall rewind starter assembly on eng...

Page 205: ...Section 04 ENGINE Subsection 11 CARBURETOR AND FUEL PUMP MMR2004 120_04_11A FM 04 11 1 CARBURETOR AND FUEL PUMP 0 CARBURETOR Tundra A05C1AS 13 14 10 7 5 3 2 1 8 11 12 6...

Page 206: ...Section 04 ENGINE Subsection 11 CARBURETOR AND FUEL PUMP 04 11 2 MMR2004 120_04_11A FM Skandic LT LT E A21C0CS Choke equipped model only 15 13 7 6 5 3 2 1 29 8 10 11 12 4...

Page 207: ...Section 04 ENGINE Subsection 11 CARBURETOR AND FUEL PUMP MMR2004 120_04_11A FM 04 11 3 Skandic WT SWT SUV 550 SUV 600 TYPICAL Choke equipped model only A29C2RS 15 13 7 6 5 3 2 1 29 8 10 11 12...

Page 208: ...arburetor cover no 1 then pull out throttle slide no 5 from carburetor Disconnect throttle cable from throttle slide Untighten rubber flange clamps then remove car buretor from engine CLEANING AND INS...

Page 209: ...raw the needle The position of the needle in the throttle slide is adjustable by means of an E clip inserted into 1 of 5 grooves located on the upper part of the needle Position 1 at top is the leanes...

Page 210: ...cal not distorted Remove float bowl and gasket from carburetor With carburetor chamber upside down on a lev el surface measure height H between bowl seat and top edge of float arm Keep ruler per fectl...

Page 211: ...e the air screw until a slight seat ing resistance is felt then back off as specified Turning screw in clockwise enriches mixture and conversely turning it out counterclockwise leans mixture Refer to...

Page 212: ...ottle slide s to snap shut Prior to installing carburetor adjust air screw and preliminary idle speed as described above To install carburetor on engine inverse removal procedure However pay attention...

Page 213: ...ime Unlock cable adjustment lock nut on one carburetor Screw or unscrew cable adjuster until both carbu retor slides start to open at same time Cable play will be identical on both carburetors Retight...

Page 214: ...djust idle speed to specifications by turning idle speed screw clockwise to increase engine speed or counterclockwise to decrease it NOTE On twin carburetor models turn adjust ment screw the same amou...

Page 215: ...n lock nut Turn choke cable adjustment nut by hand until tool properly sits under choke plunger NOTE A light pressure is be needed to position tool under plunger 1 Choke cable adjustment nut 2 Choke p...

Page 216: ...and gasket on high supply fuel pump equipped with twin outlets pro ceed as follows Connect a clean plastic tubing to the impulse nipple and plug vent hole on top cover Either apply pres sure or vacuu...

Page 217: ...pecified in CARBURETOR AND FUEL PUMP Throttle Cable Routing CAUTION Check that throttle cable is routed away from sharp edges hot or vibrating parts When turning handlebar while engine is run ning idl...

Page 218: ...RDIER LITE 05 03 1 GENERAL 05 03 2 REMOVAL 05 03 2 DISASSEMBLY 05 03 3 CLEANING 05 03 3 INSPECTION 05 03 3 ASSEMBLY 05 03 4 INSTALLATION 05 03 4 COMET 102C 05 03 5 GENERAL 05 03 6 MAINTENANCE 05 03 6...

Page 219: ...USTMENT 05 04 11 FORMULA VSA 05 04 12 REMOVAL 05 04 13 DISASSEMBLY 05 04 13 CLEANING 05 04 13 INSPECTION 05 04 14 ASSEMBLY 05 04 14 INSTALLATION 05 04 14 ADJUSTMENT 05 04 14 PULLEY DISTANCE AND ALIGNM...

Page 220: ...NT 05 07 3 REMOVAL 05 07 5 INSPECTION 05 07 5 GEAR RATIO MODIFICATION 05 07 5 INSTALLATION 05 07 5 DRIVE CHAIN ADJUSTMENT 05 07 6 ADJUSTMENT 05 07 6 GEARBOX 05 08 1 3 SPEED GEARBOX 05 08 1 REMOVAL 05...

Page 221: ...spect belt for cracks fraying or abnormal wear uneven wear wear on one side missing cogs cracked fabric If abnormal wear is noted proba ble cause could be pulley misalignment excessive RPM with frozen...

Page 222: ...specifica tions shown in the accompanying chart 1 Flush Adjustment Before adjusting the belt height ensure that a good condition proper belt refer to the APPLICATION CHART is installed Adjust pulley...

Page 223: ...i Before checking the belt deflection ensure that a good condition proper belt Refer to the APPLICA TION CHART is installed Adjust pulley distance and alignment Refer to PULLEY DISTANCE AND ALIGNMENT...

Page 224: ...o specified deflec tion 2 Slide upper O ring of tester until reaching mark 0 zero 3 Apply pressure until lower O ring is flush with edge of rule and read force on the upper scale at top edge of O ring...

Page 225: ...bsection 03 DRIVE PULLEY MMR2004_123_05_03A FM 05 03 1 DRIVE PULLEY 0 BOMBARDIER LITE NOTE This is a lubrication free drive pulley Tundra Skandic WT 550 SWT SUV 550 1 2 3 5 6 7 8 9 11 128 N m 94 lbf f...

Page 226: ...ng drive pulley first straight en tab washer no 7 then untighten nut no 8 Use holder P N 529 027 600 Remove retaining screw no 9 TYPICAL Insert drive pulley puller P N 529 022 400 then remove drive pu...

Page 227: ...pring cover tool P N 529 027 300 with puller P N 529 022 400 on spring cover 1 Puller tool 2 Spring cover tool Screw puller hand tight to hold spring cover and remove screws holding spring cover Slowl...

Page 228: ...ll drive belt and belt guard Raise and block the rear of the vehicle and support it with a mechanical stand Accelerate the vehicle at low speed maximum 30 km h 20 MPH and apply the brake repeat 5 time...

Page 229: ...R2004_123_05_03A FM 05 03 5 COMET 102C Skandic LT LT E 3 2 7 6 4 6 9 5 8 13 13 12 11 15 16 10 1 A29D2OS 14 12 N m 106 lbf in 68 N m 50 lbf ft 170 N m 125 lbf ft Primer N Loctite 271 Primer N Loctite 2...

Page 230: ...m 2000 m With drive pulley still installed on crankshaft re move one cam arm no 12 at a time Install parts included in Cam Arm Kit Proceed with remaining cam arms Loosen one turn all cover screws no 2...

Page 231: ...from ring gear no 19 CAUTION Retaining screws must be heated be fore disassembly Heating temperature must not exceed 150 C 300 F Skandic LT and Skandic LT E Mount tapered tool P N 529 035 826 in a vi...

Page 232: ...terior Replace cover if bushing is completely bronze instead of the origi nal teflon coating Check spider thrust buttons no 6 for proper sliding action Replace as required Check rollers no 7 for free...

Page 233: ...P N 293 800 005 must be applied to safely assemble ring gear Torque screws in a criss cross sequence to 27 N m 20 lbf ft INSTALLATION Install drive pulley on crankshaft Install a new lock washer Torq...

Page 234: ...er to appropriate parts catalog for replacement parts Most parts of TRA III are not interchangeable with those of the TRA A29D2NS 27 N m 20 lbf ft Loctite 271 5 6 12 11 12 14 12 N m 106 lbf in 13 15 1...

Page 235: ...e pulley ass y and or fixed half from engine use puller P N 529 022 400 CAUTION This pulley has metric threads Do not use imperial threads puller Always tighten puller by hand to ensure that the drive...

Page 236: ...rnor Cup Carefully lift governor cup until slider shoes come at their highest position into guides Hold a slider shoe set then carefully lift its housing and remove slider shoes Proceed the same way f...

Page 237: ...es with paper towel and cleaning solvent Wipe off the mounting surfaces with a clean and dry paper towel CAUTION Mounting surfaces must be free of any oil cleaner or towel residue 7 20 Bushing Only us...

Page 238: ...ool P N 529 035 931 to press out old bushing NOTE Make sure to use the tool P N 529 035 931 as marked to remove the bushing press using the side marked OUT as shown below in the picture Use a soft san...

Page 239: ...NOTE This drive pulley is lubrication free Do not lubricate any component 1 2 3 Screw Ring Gear and Loctite 271 Apply Loctite 271 P N 413 702 900 on threads and then torque to 27 N m 20 lbf ft 26 27...

Page 240: ...otter pin ends to sit perfectly against lever 1 Head on top 2 All on the same side CAUTION Lever assemblies must be installed so that cotter pins are on the same side Torque nuts to 12 N m 106 lbf in...

Page 241: ...es and that grooves are positioned vertically Install fork P N 529 005 500 into slider shoe grooves to maintain them for governor cup installation Pro ceed on 3 set of slider shoes Make sure to align...

Page 242: ...ion screws should be adjusted so that actu al maximum engine RPM in vehicle matches with the maximum horsepower RPM given in TECHNI CAL DATA NOTE Use precision digital tachometer for en gine RPM adjus...

Page 243: ...to position 5 So maximum engine RPM is increased by about 400 RPM To Adjust Just loosen locking nut enough to pull calibration screw partially out and adjust to desired position Do not completely remo...

Page 244: ...ction 05 TRANSMISSION Subsection 04 DRIVEN PULLEY MMR2004 124_05_04A FM 05 04 1 DRIVEN PULLEY 0 Tundra A05D1JS 15 N m 133 lbf in 1 2 3 4 Anti seize lubricant 6 9 10 6 5 11 12 13 14 15 15 N m 133 lbf i...

Page 245: ...ard just enough to allow driven pul ley removal from chaincase Block in this position NOTE In some cases chaincase retaining screws might have to be loosened to allow pivot ing of chaincase In this ca...

Page 246: ...when in side edge thickness of cam slider shoe slope base is 1 mm 039 in or less 1 Measure thickness of slope base here 2 Sliding pulley side 3 Slop base ASSEMBLY Assemble driven pulley components by...

Page 247: ...n procedure for Tundra driven pul ley at beginning of this subsection ADJUSTMENT 11 12 Shim NOTE The following adjustment must be per formed with a new drive belt For best performance particularly at...

Page 248: ...Section 05 TRANSMISSION Subsection 04 DRIVEN PULLEY MMR2004 124_05_04A FM 05 04 5 THRUST BUSHING Skandic WT SWT A29D2LS Anti seize lubricant 10 5 19 2 4 3 6...

Page 249: ...half 4 Slider Shoe Check cam slider shoes for wear Replace when inside edge of cam slider shoe slope base is worn to 1 mm 039 in or less 1 Measure thickness of slope base here 2 Sliding pulley side 3...

Page 250: ...To adjust spring pre load relocate spring end in cam moving it clockwise to increase the pre load and counterclockwise to decrease it Refer to TECHNICAL DATA NOTE Always recheck torsional pre load af...

Page 251: ...Section 05 TRANSMISSION Subsection 04 DRIVEN PULLEY 05 04 8 MMR2004 124_05_04A FM LPV 27 Skandic LT LT E A03D3PS Anti seize lubricant 2 4 3 5 6 7 8 9 Loctite 609 Loctite 609 Red Black 10 11 12 14 1...

Page 252: ...hing Remove Allen screws if applicable Heat to break Loctite bond Install support plate included in tool P N 529 031 100 inside sliding half Place extractor P N 529 035 575 below bushing TYPICAL 1 Sup...

Page 253: ...uard no 6 in cam no 5 then insert spring in adjusting hole no 3 mid hole into outer cam Compress outer cam using spring compressor P N 529 035 524 Install spacer no 4 then secure outer cam with half k...

Page 254: ...AFT BEARING ADJUSTMENT Reinstall the pulley on the countershaft by revers ing the removal procedure 14 Pulley Retaining Screw Torque to 25 N m 18 lbf ft ADJUSTMENT Pulley Alignment and Drive Belt Defl...

Page 255: ...on 04 DRIVEN PULLEY 05 04 12 MMR2004 124_05_04A FM FORMULA VSA Skandic WT LC SUV A32D1IS 1 Anti seize lubricant 2 7 3 4 5 9 Anti seize lubricant Loctite 609 6 10 11 12 22 N m 16 lbf ft Anti seize lubr...

Page 256: ...COUNTERSHAFT AND BRAKE DISC REMOVAL DISASSEMBLY Use spring compressor P N 529 018 600 Remove snap ring no 3 and washer no 4 to dis assemble the cam and the 2 pulley halves CLEANING 9 Large Bushing Dur...

Page 257: ...ys apply anti seize lubricant P N 293 800 070 on the countershaft before fi nal pulley installation Should installation procedure be required refer to BRAKE then look for BRAKE DISC AND COUN TERSHAFT...

Page 258: ...umbers shown in illustration are actual letters and numbers embossed on parts NOTE Always recheck torsional pre load after ad justing Pulley Alignment and Drive Belt Height Refer to PULLEY DISTANCE AN...

Page 259: ...ustment after suspension is adjusted All pulley alignment specifications refer to X Distance between straight bar and drive pul ley fixed half edge measured between pul leys Y Distance between straigh...

Page 260: ...bar TYPICAL 1 Contact alignment 2 Contact distance Tundra Only Bottom of alignment bar must not seat on shaft nor fixed half shoulder and shim s TYPICAL 1 Shaft 2 Alignment bar 3 Fixed half shoulder...

Page 261: ...ment must be done to provide the right frame width Loosen the 4 chaincase retaining bolts unlock and raise pulley support Move chaincase to obtain specific adjustment and adjust driven pulley support...

Page 262: ...o obtain specified pulley align ment torque engine support bolts to 55 N m 41 lbf ft and remove engine support positioner Driven Pulley Movement Shims can be mounted between chaincase and frame Use sh...

Page 263: ...Section 05 TRANSMISSION Subsection 06 BRAKE MMR2004 126_05_06A FM 05 06 1 BRAKE 0 MECHANICAL BRAKE Tundra A05D1LS 7 1 12 12 4 3 8 11 15 14 16 6 9 Dielectric grease Synthetic grease Loctite 76732...

Page 264: ...Section 05 TRANSMISSION Subsection 06 BRAKE 05 06 2 MMR2004 126_05_06A FM Skandic LT A03D3ZS Dielectric grease Loctite 767 Anti seize lubricant 12 7 11 1 14 16 15 19 20 9 2 5...

Page 265: ...Section 05 TRANSMISSION Subsection 06 BRAKE MMR2004 126_05_06A FM 05 06 3 HYDRAULIC BRAKE Skandic WT SWT WT LC SUV 550 SUV 600 8 N m 71 lbf in A29D2QS 7 Loctite 243 17 24 5...

Page 266: ...remove lever no 15 Fixed pad is riveted to chaincase on these models Caliper must be split to remove moving pad To remove fixed pad drill out its rivet no 2 then pry disc in order to free fixed pad In...

Page 267: ...UV 550 SUV 600 Remove caliper by unscrewing M10 Allen screws Unbolt disc Skandic LT Remove caliper Remove guard belt and driven pulley Remove air silencer Unbolt bearing support no 19 from chassis Ope...

Page 268: ...LY 14 Ratchet Wheel Apply synthetic grease P N 413 711 500 on threads and spring seat prior to installing Fully tighten then back off one turn 16 Pin Install so that it can only be removed upward Lock...

Page 269: ...N m 18 lbf ft Bend lock ing tab over a flat of each nut 5 12 Brake Cable and Nut Insert brake cable into upper hole in brake lever and caliper Install nut and tighten until a few threads exceed 24 Upp...

Page 270: ...scribed above NOTE If brake light adjustment is unattainable while respecting brake adjustment ratchet wheel may be too far out If so tighten ratchet wheel Models with Hydraulic Brake There is no adju...

Page 271: ...MISSION Subsection 07 CHAINCASE MMR2004 127_05_07A FM 05 07 1 CHAINCASE 0 Tundra A05D1KS 7 10 9 1 10 9 11 12 13 28 14 15 4 5 2 3 6 27 30 22 23 19 17 18 25 26 Loctite 20166 Chaincase oil Synthetic grea...

Page 272: ...to 6 then simultaneously remove chain no 18 and both sprockets Remove the 4 cap screws no 26 securing chain case to frame Chaincase and Driven Pulley Assembly Using 2 large prybars inserted between c...

Page 273: ...install it making sure it does not shift from its correct position Tighten bolts evenly NOTE Bottom pan has an emboss below chain case housing to ease installation Chaincase Oil Remove filler cap and...

Page 274: ...4 127_05_07A FM Skandic LT Chaincase oil A03D3YS 1 2 Loctite 271 12 10 60 N m 44 lbf ft 3 5 26 14 19 17 27 18 14 19 Loctite 515 16 15 46 N m 34 lbf ft Loctite 271 13 Loctite 271 20 Loctite 243 27 25 1...

Page 275: ...ings sprockets and chain tensioner components GEAR RATIO MODIFICATION For particular applications the number of teeth of the sprockets can be increased or decreased on lower and upper sprockets Refer...

Page 276: ...s no 10 on tensioner adjust ment screw Fully tighten tensioner adjustment screw by hand then back off only far enough for hair pin to engage in locking hole This initial adjustment should provide 3 5...

Page 277: ...OX 0 3 SPEED GEARBOX Skandic WT SWT WT LC SUV A29D2MT 4 9 9 10 11 39 10 8 17 33 34 35 36 9 37 28 29 30 28 27 10 9 31 26 23 22 16 18 21 8 8 16 18 38 20 9 13 14 15 8 10 Loctite 243 Loctite 243 19 1 2 3...

Page 278: ...Remove air silencer and carburetor s then remove driven pulley Remove brake caliper brake disc Unfasten shift ing rod and unplug reverse switch Remove rear suspension Remove angle drive and square pin...

Page 279: ...pulley side 2 LH side brake disc side Remove dipstick no 17 Unfasten cover no 2 from gearbox housing Remove nut no 3 retaining pin no 6 1 Cover 2 Nut Unfasten sleeve nuts no 4 remove spring no 7 then...

Page 280: ...brake shaft oil seal and then circlip 1 Brake shaft Proceeding from right side drive brake shaft out of gearbox housing Remove sleeve no 23 NOTE Brake shaft gears remain in gearbox hous ing Remove be...

Page 281: ...ch the RH gear of driven pulley shaft no 15 This will allow the driven pulley shaft to be pushed out enough for bearing removal 1 Sleeve dog not touching right gear 2 Brake shaft gears are still in ge...

Page 282: ...move washer Push driven pulley shaft no 15 out of gearbox un til its LH gear no 14 is against gearbox inner wall Use a puller to extract bearing no 12 Remove circlip then gear no 14 Now driven pul ley...

Page 283: ...diate shafts no 30 Fasten a long M8 x 1 25 screw in axle end then drive it out beginning with top one Remove intermediate gears and spacers 1 Spacer 1 Spacer Do not disassemble bearings of intermediat...

Page 284: ...Using a press drive out lower shaft no 36 from RH side CAUTION Do not push against inner bearing race INSPECTION Check bearing condition There must be no discol oration missing rollers or balls broken...

Page 285: ...rated in removal procedure Beveled side of spacers goes against gearbox wall Install RH side bearing of brake and reverse shafts Partially assemble brake shaft gears nos 24 and 25 with shoulder facing...

Page 286: ...ing no 19 then finalize brake shaft no 26 insertion 1 Finalizing brake shaft insertion Install driven pulley shaft no 15 with the sliding sleeve loosely inserted Gear no 14 must be at its place 1 Slid...

Page 287: ...EARINGS SHIMS CIRCLIPS AND PLUGS INSTALLATION Reverse removal procedure Check pulley alignment OIL LEVEL To check pull dipstick Oil should reach level mark NOTE After first outing oil level will decre...

Page 288: ...lip must be on opposite side of chain rotation The circlip should also be facing the outer side of chaincase TYPICAL 1 Rotation CHAIN SEPARATION When separating an endless chain always use a chain bea...

Page 289: ...ng link B Link pin C Cranked link D Cotter pin E Outer link F Circlip LENGTHENING 1 LINK A Connecting link B Inner link C Outer link D Circlip LENGTHENING 1 1 2 LINKS A Connecting link B Outer link C...

Page 290: ...03 3 FOULING 06 03 3 SPARK PLUG ANALYSIS 06 03 3 SPARK PLUG INSTALLATION 06 03 4 SPARK PLUG TIGHTENING TORQUE 06 03 4 BATTERY 06 04 1 GENERAL 06 04 1 REMOVAL 06 04 1 CLEANING 06 04 2 INSPECTION 06 04...

Page 291: ...GE TESTING 06 06 10 CONCLUSION 06 06 10 LIGHTING GENERATOR COIL VOLTAGE TESTING 06 06 10 CONCLUSION 06 06 10 RER DUAL TRIGGER COIL CDI SYSTEM TESTING 06 06 13 IGNITION SYSTEM TESTING SEQUENCE 06 06 13...

Page 292: ...factory tim ing mark 4 To detect a wrong magneto flywheel corre sponding to a different engine type Always verify magneto flywheel timing mark posi tion before checking ignition timing Verifying Magn...

Page 293: ...requiring auxiliary power supply is used on manual start models use a separate battery to power tim ing light TIMING LIGHT P N 529 031 900 1 Connect timing light pick up to the spark plug lead Use a d...

Page 294: ...he position of the timing mark on the magneto flywheel proceed as follows 1 Clean the area around the spark plugs and re move them 2 Remove the rewind starter from the engine 3 Install the TDC gauge i...

Page 295: ...the marks do not align check magneto fly wheel and trigger coil part numbers and check Woodruff key condition If all parts are the appropriate ones and if Woodruff key is in good condition continue th...

Page 296: ...t a time and recheck timing marks check connectors condition prior to substituting any part NOTE Ignition timing may be verified when en gine speed is anywhere within 3000 4000 RPM 1 Timing light pick...

Page 297: ...tops moving only as the piston is changing direction b Rotate the dial face so that 0 zero is in line with the needle when it stops moving c Again slowly rotate the magneto flywheel back and forth acr...

Page 298: ...hat previous marks remain aligned c Scribe or punch a mark on magneto flywheel so that it aligns perfectly with the arrow on crankcase refer to illustration This new tim ing mark should be used for fu...

Page 299: ...on timing adjustment should not be required It has been set at factory and it should remain correctly adjusted since every part is fixed and not adjustable The only time the ignition tim ing might hav...

Page 300: ...ing the needle Note that the needle stops moving only as the pis ton is changing direction b Rotate the dial face so that 0 is in line with the needle when it stops moving c Again slowly rotate the dr...

Page 301: ...to a spark plug cable Connect a digital induction type tachometer P N 529 014 500 TACHOMETER P N 529 014 500 2 Start the engine and point timing light on timing mark Bring engine to 3500 RPM for a bri...

Page 302: ...to supply cable P N 529 035 869 and supply cable to diag nostic connector Connect MPEM programmer to DESS post Turn on programmer then enter password From main menu select no 3 INFO VEHICLE Vehicle in...

Page 303: ...t 3500 RPM was too early by 2 The correc tion factor programmed is no 4 Select correction factor no 5 This will retard the timing by 2 because the difference between cor rection factor no 4 and no 5 i...

Page 304: ...ess ENTER Press ENTER During a very short period of time the following message will appear A30E2GA 2 E N G I N E S E R I A L 1 T I M I N G A D J U S T 3 C A L I B R A T I O N A30E24A T I M I N G 1 8 5...

Page 305: ...mes sage will appear Press any key Press any key Unplug supply cable and 9 volt adaptor O P E R A T I O N S U C C E S S F U L L P R E S S A N Y K E Y A00A3EA I F T E R M I N A T E D Y O U C A N U N P...

Page 306: ...MR2004 131_06_03A FM 06 03 1 SPARK PLUGS 0 NGK SPARK PLUG All Models NGK SPARK PLUG NUMBERING SYSTEM Bombardier uses NGK brand spark plugs on all its snowmobile models The heat range identification sy...

Page 307: ...Section 06 ELECTRICAL Subsection 03 SPARK PLUGS 06 03 2 MMR2004 131_06_03A FM DESIGN SYMBOLS USED IN NGK SPARK PLUGS A01E4DS...

Page 308: ...a wrong heat range plug is used A too hot plug will result in overheating and pre ignition etc A too cold plug will result in fouling shorting the spark plug or may create carbon build up which can he...

Page 309: ...me 1 Using a wire feeler gauge set electrode gap ac cording to TECHNICAL DATA 2 Apply anti seize lubricant P N 293 800 070 over the spark plug threads to prevent possible sei zure 3 Hand screw spark p...

Page 310: ...Air silencer cover and tube plate removed 2 Collars loosened Unbolt battery cover steel strip and remove battery cover TYPICAL 1 Battery cover Unplug vent tube from battery vent nipple Disconnect the...

Page 311: ...unting Inspect for cracked or damaged battery caps re place defective caps BATTERY CHARGE TESTING Skandic LT E Hydrometer Test 1 Specific gravity 1 265 A hydrometer measures the charge of a battery in...

Page 312: ...show the state of charge Load Test All Models This is the best test of battery condition under a starting load Use a load testing device that has an adjustable load Apply a load of 3 times the ampere...

Page 313: ...ttery every month if stored at a tem perature below 15 C 60 F Charge the battery every two weeks if stored at a temperature above 15 C 60 F ACTIVATION OF NEW BATTERY Skandic WT SWT SUV 550 SUV 600 Ref...

Page 314: ...122 F if the casing feels hot discontinue charging temporarily or reduce the charging rate 7 Disconnect battery charger 8 Test battery state of charge Use a hydrometer 1 Specific gravity 1 265 9 Let b...

Page 315: ...frozen battery If the battery charge is very low the battery may freeze If it is suspect ed to be frozen keep it in a heated area for about 2 hours before charging Time required to charge a battery w...

Page 316: ...y should be replaced If the charging current is measurable before the end or at the end of about 10 hours the battery is good and charging should be completed in the normal manner as specified in Acti...

Page 317: ...or sharp blade knife A 10 mm 1 2 in NOTE Make sure not to cut wire strands while stripping the wire Install the appropriate terminal on the wire accord ing to the requirement Refer to appropriate par...

Page 318: ...minal at the same time from both directions CAUTION Never weld the wire to the terminal Welding can change the property of the wire and it can become brittle and break Install the protective heat shri...

Page 319: ......

Page 320: ...Section 06 ELECTRICAL Subsection 05 ELECTRIC STARTER MMR2004 133_06_05A FM 06 05 1 ELECTRIC STARTER 0 Skandic WT SWT LT E SUV 550 A03E31S A03E31S 1 2 3 4 7 5 6 8 10 13 9 11 12 12 15 18 19 16 17...

Page 321: ...ion 05 ELECTRIC STARTER 06 05 2 MMR2004 133_06_05A FM Skandic WT LC SUV 600 16 17 7 15 5 N m 44 lbf in 4 5 N m 40 lbf in 11 N m 97 lbf in A29E0ZS 14 12 9 13 10 11 9 8 6 5 4 3 2 1 Synthetic grease 28 N...

Page 322: ...o 9 with drive lever no 15 Remove insulator no 4 then brush springs no 7 being careful not to lose them since they will be projected out Pull brush holder no 5 from yoke no 8 Insert blade of a small s...

Page 323: ...ollows Using a 12 mm tap cut threads into bushing so that the tap contacts the end frame Continue to rotate tap until the bushing comes free 1 Turn until bushing goes out 2 12 mm tap To install new bu...

Page 324: ...earing or replace starter If parts are in good con dition then coat with synthetic grease P N 413 711 500 before reinstalling them Push back the collar no 3 using a screwdriver Remove snap ring no 2 R...

Page 325: ...t 0 20 mm 008 in Check the commutator out of round condition with V Blocks and an indicator If the commutator out of round is more than 0 40 mm 016 in the com mutator should be turned on a lathe Check...

Page 326: ...t turn on the field winding has an open circuit The yoke has to be repaired or replaced 1 Test probes Check the dynamic brake winding for open circuit by placing one test probe on the positive brush a...

Page 327: ...1 500 Proceed as follows for assembly Install overrunning clutch onto armature shaft In sert inner collar onto shaft Install a new circlip CAUTION Always install a new circlip when ser vicing Insert o...

Page 328: ...lide collar no 3 over snap ring no 2 and secure in place by punching it at two or three places 1 Armature shaft 2 Snap ring 3 Collar 4 Punch Starter Housing Assembly and Starter Housing Align previous...

Page 329: ...asteners must be secured with Loctite 271 P N 293 800 005 Al ways install new self locking fasteners 1 Screwdriver pulling starter pinion 2 Ring gear 3 No excessive backlash A 0 5 to 1 5 mm 020 to 060...

Page 330: ...switch is activated MPEM cuts off ignition and engine rev drops at approximately 700 RPM for 277 engine Tundra MPEM fires a spark at a great advance creating a thrust which reverses engine rotation Se...

Page 331: ...ction 06 ELECTRICAL Subsection 06 TESTING PROCEDURE 06 06 2 MMR2004 134_06_06A FM RER DUAL TRIGGER COIL CDI SYSTEM SINGLE CYLINDER 1 MPEM 2 Trigger coils 3 4 DB housing BLACK and RED wires A05E0WS 1 2...

Page 332: ...trigger coil CDI system has an igni tion coil integrated to the MPEM which is mount ed on oil reservoir MPEM is connected to a single ignition generator coil via a 3 connector housing BLACK and RED w...

Page 333: ...on 06 ELECTRICAL Subsection 06 TESTING PROCEDURE 06 06 4 MMR2004 134_06_06A FM RER DUAL TRIGGER COIL CDI SYSTEM TWIN CYLINDER 1 MPEM 2 Trigger coils 3 3 connector housing BLACK and RED wires A03E2WS 1...

Page 334: ...ailable start engine Turn on programmer then enter password Increase engine speed to 2000 2500 RPM then follow the same procedure as WITH ENGINE STOPPED CAUTION Engine must run till the end of the pro...

Page 335: ...9 volt adaptor Stop engine when using WITH ENGINE RUNNING procedure Changing MPEM Calibration Program Proceed the same as for checking MPEM calibra tion but select YES to MODIFY and press ENTER follo...

Page 336: ...completed ensure engine idle speed with engine hot is 1700 2100 RPM Stop the engine DUCATI TRIGGER COIL CDI SYSTEM TESTING Skandic WT SWT SUV 550 IGNITION SYSTEM TESTING SEQUENCE In case of ignition p...

Page 337: ...nd must be replaced CAUTION When taking measurements it is use less to try to start the vehicle since readings would then be distorted Intermittent Ignition Problems It is difficult to make a diagnost...

Page 338: ...itch block connected to main wiring har ness Check using a multimeter by connecting probes to 6 03 B M and 6 03 A M wires The mul timeter should indicate an open circuit 0 L M in operating position an...

Page 339: ...r 4 Repeat operation 3 times 5 Compare readings with those appearing in the IGNITION table CONCLUSION If none of the above testing operations produced valid results it is strongly recommended to keep...

Page 340: ...and BK YL 0 L 00 0 M All switches must be in run position Continuity in stop position BK and BK YL 00 0 00 5 00 0 At least one stop switch must be operational Ignition generator coil Output WH and GN...

Page 341: ...ow voltage is therefore normal under a low cranking force Perform testing in the prescribed order and replace any parts not performing according to specifications It is important to resume all tests w...

Page 342: ...Analysis of Readings Voltage Readings When testing the different magneto components it is important to take into consideration that read ings vary according to the force applied onto the manual starte...

Page 343: ...next step If readings are inadequate individually check each switch as follows Ignition Switch key Disconnect switch housing Using a multimeter check between MAG and GRD terminals if the cir cuit is o...

Page 344: ...d therefore have a closed circuit On the other hand BLACK and BLACK YELLOW wires must have an open circuit 0 L M Repair or replace if necessary 4 IGNITION GENERATOR COIL VOLTAGE TESTING General When m...

Page 345: ...to buzzer negative tab CAUTION To avoid buzzer damage ensure that polarity is respected 12 VOLT BATTERY PLUGGED TO BUZZER MPEM CONNECTORS To ease electrical readings on MPEM connectors connector cap...

Page 346: ...witch must be operational Continuity in STOP position BK BK YL 4 MOC M 4 MOA M 00 0 00 5 00 0 Only one stop switch must be operational Test them one after the other Ignition generator coil Output RD B...

Page 347: ...not performing according to specifications It is important to resume all tests when replacing a component If not specified the probe connecting sequence is not important LIGHTING SYSTEM TESTING Tundra...

Page 348: ...ULTIMETER SCALE Stopswitch Running insulation BK BK YL 0 L 00 0 M All switches must be in run position Continuity in STOP position BK BK YL 00 0 00 5 00 0 Only one stop switch must be in stop position...

Page 349: ...order and replace any parts not performing according to specifications It is important to resume all tests when replacing a component If not specified the probe connecting sequence is not important LI...

Page 350: ...0 0 Only one stop switch must be in stop position Test one at a time Insulation in stop position BK GN and BK WH 0 L 00 0 M Tether cord cap must be off Running continuity BK GN and BK WH 00 0 00 5 00...

Page 351: ...neto wires Measured resistance must be infinite If such is not the case it means there is a connection be tween AC circuit and DC circuit Disconnect one accessory at the time to identify the faulty ci...

Page 352: ...07 03 1 REMOVAL 07 03 2 DISASSEMBLY AND ASSEMBLY 07 03 2 SHOCK ABSORBER SERVICING 07 03 3 INSTALLATION 07 03 4 RIDE ADJUSTMENT 07 03 4 SKANDIC SUV SUSPENSION 07 04 1 REMOVAL 07 04 2 DISASSEMBLY AND AS...

Page 353: ...Tundra 2 5 N m 23 lbf in A05F12S 1 24 N m 18 lbf ft 3 2 4 5 6 7 7 Synthetic grease Synthetic grease Synthetic grease Synthetic grease 10 9 11 24 N m 18 lbf ft Loctite 271 24 N m 18 lbf ft Loctite 243...

Page 354: ...other screw Remove the first one 1 2 3 4 Cross Shaft Idler Wheel Spacer and Screw Remove idler wheel ass y Suspension Ass y Lift rear of vehicle and support it off the ground Unscrew 4 screws retainin...

Page 355: ...he assembly INSPECTION 6 Stopper Strap Inspect strap for wear or cracks bolt and nut for tightness If loose inspect hole for deformation Replace as required Shock Absorber Refer to SUSPENSION AND SKI...

Page 356: ...s a good choice of spring preload To adjust rear suspension with the adjustment cams use special key supplied in vehicle tool box Turning adjustment cam moves edges of cam sup porting spring rod The s...

Page 357: ...on must be readjusted to prevent any possibility of operating vehicle with a too loose or too tight track tension For normal use locate bolt through 3rd hole from strap end 1 1st hole 2 3rd hole A 11...

Page 358: ...ON Subsection 03 SKANDIC WT SUSPENSION MMR2004 136_07_03A FM 07 03 1 SKANDIC WT SUSPENSION 0 Skandic LT WT SWT WT LC TYPICAL A22F1GS 6 5 7 4 2 Loctite 243 Loctite 243 Loctite 243 Loctite 243 SWT only...

Page 359: ...move the temporary installed non self locking screw If it doesn t work heat bolt head to melt thread locker Remove suspension assembly DISASSEMBLY AND ASSEMBLY 1 Extension Remove nuts and conical wash...

Page 360: ...washer For trail riding with passenger and or weight install 1 washer under each rubber stoppers For trail riding with heavy load and or pulling a load use 2 washers under each rubber stoppers 7 Shock...

Page 361: ...rew is installed Use a metal brush or a screwtap to clean the hole properly then use asolvent Methyl Chloride let act during 30 minutes and wipe off The solvent utilization is to ensure the adhesive w...

Page 362: ...Subsection 04 SKANDIC SUV SUSPENSION MMR2004 137_07_04A FM 07 04 1 SKANDIC SUV SUSPENSION 0 Skandic SUV TYPICAL A29F0GT Loctite 271 80 N m 59 lbf ft Loctite 271 54 N m 40 lbf ft 6 2 1 5 7 8 3 4 Synthe...

Page 363: ...emporary installed non self locking screw If it doesn t work heat bolt head to melt thread locker Remove suspension assembly DISASSEMBLY AND ASSEMBLY 1 Extension Remove nuts and conical washers from t...

Page 364: ...ils rests against spring compressor jaw Close and lock the bar Place handle horizontally by changing the position of the clevis pin 1 Clevis pin 2 Bar 3 Handle horizontal Push down on the handle until...

Page 365: ...uter side of top idler wheel 1 Spacers 4 Coupling Tube At assembly install coupling tube with its grease fitting facing outward 1 Grease fitting facing outward 5 Stopper Strap Fasten stopper strap to...

Page 366: ...04 SKANDIC SUV SUSPENSION MMR2004 137_07_04A FM 07 04 5 LUBRICATION Lubricate front and rear arms at grease fittings us ing synthetic grease P N 413 711 500 NOTE There is 9 grease fittings RIDE ADJUST...

Page 367: ...Section 07 REAR SUSPENSION Subsection 05 DRIVE AXLE MMR2004 138_07_05A FM 07 05 1 DRIVE AXLE 0 Tundra A05D1BS 2 3 5 6 9 8 11 12 9 Synthetic grease...

Page 368: ...Section 07 REAR SUSPENSION Subsection 05 DRIVE AXLE 07 05 2 MMR2004 138_07_05A FM Skandic LT LT E A29D2GS 12 8 6 13 9 13 11 2 5 14 10 7 4 1 Synthetic grease Synthetic grease...

Page 369: ...FM 07 05 3 Skandic WT SWT WT LC SUV A29D2MT 4 9 9 10 11 39 10 8 17 33 34 35 36 9 37 28 29 30 28 27 10 9 31 26 23 22 16 18 21 8 8 16 18 38 20 9 13 14 15 8 10 Loctite 243 Loctite 243 19 1 2 3 5 6 7 12 S...

Page 370: ...the drive axle towards the end bearing housing side Remove drive axle from vehicle Skandic WT SWT WT LC SUV 550 SUV 600 Drain gearbox Remove angle drive no 1 and square pin no 4 Raise and block rear...

Page 371: ...the same type ASSEMBLY 8 9 13 Drive Axle and Sprocket To assemble press fit sprockets use a press and a suitable pipe as illustrated Sprockets must be assembled according to the following dimensions...

Page 372: ...1 Gearbox side A 105 0 mm 4 016 in B 207 0 mm 8 150 in C 449 0 mm 17 677 in D 551 0 mm 21 693 in All Models Ensure to align indexing marks of each sprocket when assembling TYPICAL 1 Indexing marks ali...

Page 373: ...ctive use a new sprocket 6 8 Drive Axle and Seal When assembling drive axle always position a new seal on each end of drive axle if applicable Locate seal lip as illustrated 1 Grease seal type 2 Oil s...

Page 374: ...f bearing housing and each seal SIDE VIEW 1 Bearing 2 Seal 3 Housing 4 Seal lip A 2 mm 080 in approximately 3 Retainer Ring Make sure that welded nuts are toward inside of tunnel Lock drive axle sproc...

Page 375: ...ack Skandic LT LT E Remove the following parts speedometer cable muffler chaincase cover suspension drive axle seal end bearing housing sprockets and chain drive axle toward end bearing housing track...

Page 376: ...ow er loss and excessive stresses on suspension components To adjust track tension Remove the tether cord cap Loosen the rear idler wheel retaining screws Loosen the lock nuts on so equipped models th...

Page 377: ...eck alignment Reposition snowmobile on ground Track Cleat Removal Raise rear of vehicle off the ground and lift snow guard then rotate track to expose a cleat to be replaced Using track cleat remover...

Page 378: ...02 5 HANDLEBAR POSITION ADJUSTMENT 08 02 7 STEERING ADJUSTMENT SKIS 08 02 8 LUBRICATION 08 02 11 SUSPENSION AND SKI SYSTEM 08 03 1 ON VEHICLE COMPONENT REMOVAL 08 03 2 DISASSEMBLY 08 03 2 INSPECTION...

Page 379: ...G0OT 24 N m 18 lbf ft 5 8 2 8 2 3 Synthetic grease 6 24 N m 18 lbf ft 8 N m 71 lbf in 16 15 14 13 10 9 53 N m 39 lbf ft 21 17 21 10 13 15 16 15 18 N m 159 lbf in 21 9 10 13 9 53 N m 39 lbf ft 9 9 21 2...

Page 380: ...N Subsection 02 STEERING SYSTEM 08 02 2 MMR2004 140_08_02A FM Skandic LT LT E A29G0RS 7 23 24 25 2 5 8 2 3 31 11 6 1 24 N m 18 lbf ft Synthetic grease 20 N m 15 lbf ft 9 53 N m 39 lbf ft 10 13 20 15 1...

Page 381: ...G SYSTEM MMR2004 140_08_02A FM 08 02 3 Skandic WT SWT WT LC 20 N m 15 lbf ft A29G16S 15 1 10 11 7 6 16 20 N m 15 lbf ft 7 8 3 2 31 Synthetic grease 16 15 13 13 20 20 Suspension synthetic grease 53 N m...

Page 382: ...MMR2004 140_08_02A FM Skandic SUV 550 SUV 600 A29G17S 24 N m 18 lbf ft 20 N m 15 lbf ft Suspension synthetic grease 53 N m 39 lbf ft 53 N m 39 lbf ft 53 N m 39 lbf ft Loctite 243 Loctite 243 Loctite...

Page 383: ...lebar and twist grip while pulling it out The grips might not be removable as explained above in this case carefully proceed as follows to prevent damaging the heating elements Start cutting and immed...

Page 384: ...threaded end of the ball joint into the tie rod The maximum external threaded length not engaged in the tie rod must not exceed 20 mm 25 32 in TYPICAL A 20 mm 25 32 in maximum The ball joint should be...

Page 385: ...g arm at mid travel position when handlebar and skis are facing straight ahead TYPICAL Skandic SUV 550 SUV 600 Steering arm must be installed parallel to ski 9 13 15 Ball Joint Nut and Jam Nut Tighten...

Page 386: ...front edge of the skis A and rear edge B as viewed from the top It is adjustable CAMBER A specific inward or outward tilt angle of ski leg compared to a vertical line when viewing the ve hicle from fr...

Page 387: ...the ground Loosen lock nuts of long tie rods and turn each tie rod so that skis are in a straight ahead position To adjust toe out slightly turn both tie rods exactly the same amount Make sure extern...

Page 388: ...HANDLEBAR PIVOT ARM POSITIONING Turn handlebar until pivot arm is pointing straight forward Check if handlebar is horizontal To adjust loosen lock nuts of short tie rod and turn it accordingly A 20 m...

Page 389: ...gth of left and right tie rods no 20 Handlebar centering is done at same time by turning tie rods accordingly Procedure Loosen jam nuts no 13 and no 15 of both tie rods no 20 Close front of skis manua...

Page 390: ...A Skandic LT LT E WT SWT WT LC Lubricate front suspension posts Pump five strokes of grease gun on each post Use synthetic grease P N 413 711 500 NOTE There are 2 grease fittings Apply BOMBARDIER LUBE...

Page 391: ...SKI SYSTEM MMR2004 141_08_03A FM 08 03 1 SUSPENSION AND SKI SYSTEM 0 Tundra A05G0SS 13 N m 115 lbf in 1 29 N m 21 lbf ft 2 3 4 5 6 7 8 9 9 10 15 N m 133 lbf in 15 N m 133 lbf in 11 29 N m 21 lbf ft 12...

Page 392: ...Pull out spring then check shock as described be low in INSPECTION DISASSEMBLY Lift front of vehicle and support off the ground 1 2 3 5 6 7 9 11 Bolt LockWasher Cover Stopper Bushing Cushion and Nut...

Page 393: ...ith its rod upward 1 Clamp CAUTION Do not clamp directly on shock body Examine each shock for leaks Extend and com press the piston several times over its entire stroke checking that it moves smoothly...

Page 394: ...3 SUSPENSION AND SKI SYSTEM 08 03 4 MMR2004 141_08_03A FM Skandic LT LT E WT SWT WT LC TYPICAL 13 N m 115 lbf in LT only A29G1AS 13 15 14 17 10 12 11 9 9 8 7 6 5 19 3 2 1 16 18 29 N m 21 lbf ft Except...

Page 395: ...8 66 in B 180 mm 7 09 in C 70 mm 2 75 in D 25 mm 1 0 in E 15 mm 0 59 in F 9 mm 0 35 in Unfasten rod nut then pull out shock from bottom Check shock as described below in INSPECTION At installation mak...

Page 396: ...p 13 14 16 17 Ski Leg Bushing and Seal Pull up ski leg Steering arm will not interfere 1 Pull up ski leg 2 Steering arm in place Remove seal Drive out bushing if worn out INSPECTION All Models Suspens...

Page 397: ...troke at mid travel Seizing or binding condition except at extreme end of either stroke Oil leakage A gurgling noise after completing one full com pression and extension stroke Renew if any faults are...

Page 398: ...8 MMR2004 141_08_03A FM Skandic SUV 550 600 TYPICAL A29G19S 1 25 N m 18 lbf ft Loctite 243 Synthetic grease Synthetic grease 4 3 6 50 N m 37 lbf ft 10 32 N m 24 lbf ft Synthetic grease 18 N m 160 lbf...

Page 399: ...vehicle and support it off the ground Remove cap no 4 circlip no 3 Scribe mark the steering arm and ski leg before disassembly Then loosen steering arm bolt and pull up steering arm Ski leg may fall...

Page 400: ...033 to ski leg components Install steering stopper no 6 as per following photo TYPICAL 1 Steering stopper Longer bolts for shock and swing arm go on upper attachments Tighten nuts and screws to prope...

Page 401: ...ADJUSTMENT 09 02 1 HEADLAMP BEAM AIMING 09 02 1 BULB REPLACEMENT 09 02 1 DECAL 09 02 2 BELT GUARD 09 02 2 WIRING HARNESS 09 02 2 CABLES 09 02 2 TUBING 09 02 2 PLASTIC MAINTENANCE AND REPAIR 09 02 3 M...

Page 402: ...ions Place the vehicle on a flat surface perpendicular to test surface wall or screen and 381 cm 12 ft 6 in away from it Rider or equivalent weight must be on the vehicle Select high beam BULB REPLACE...

Page 403: ...T GUARD Disassembly and Assembly NOTE For additional information ex exploded view refer to the corresponding Parts Catalog Inspection All Models Check belt guard mounting bosses clips and re tainers f...

Page 404: ...mula Apply wax on glossy finish only Protect the vehi cle with a cover to prevent dust accumulation dur ing storage CAUTION If for some reason the snowmobile has to be stored outside it is preferable...

Page 405: ...10 minutes Repaint air dry during 72 hours approximately Large Crack Sand and scuff outside and inside area by ex ceeding it 31 7 mm 1 1 4 in on each side and 12 7 mm 1 2 in at each end Make a V groo...

Page 406: ...N Avoid use of harsh detergents such as strong soaps degreasing solvents abrasive cleaners paint thinners etc that may cause damage to the seat cover FRAME WELDING Steel Frame electric welding amperag...

Page 407: ...erature pressure torque speed meter kilogram newton liter Celsius kilopascal newton meter kilometer per hour m kg N L C kPa N m km h PREFIXES PREFIX SYMBOL MEANING VALUE kilo centi milli micro k c m o...

Page 408: ...ming BTDC mm in 3 61 142 2 79 110 Trigger Coil Air Gap mm in 0 50 0 70 020 028 0 45 0 55 018 022 Trigger Coil 160 180 Generating Coil Low Speed N A N A High Speed 5 1 6 2 6 3 7 7 Lighting Coil 0 17 0...

Page 409: ...TDC mm in 2 77 109 3 00 118 Trigger Coil Air Gap mm in 0 40 0 60 016 024 N A Trigger Coil 160 180 190 300 Generating Coil Low Speed N A 17 5 42 5 High Speed 6 3 7 7 2 4 5 8 Lighting Coil 0 145 0 175 0...

Page 410: ...Belt Adjustment Deflection 5 mm 13 64 in 32 1 1 4 Force kg lbf 6 8 15 11 3 25 Track Width mm in 381 15 0 Length mm in 3540 139 3968 156 2 Profile Height mm in 18 4 724 25 1 Adjustment Deflection mm i...

Page 411: ...1 1 4 Force kg lbf 11 3 25 11 3 25 Track Width mm in 381 15 0 500 19 7 Length mm in 3968 156 2 3968 156 2 Profile Height mm in 25 1 23 5 925 Adjustment Deflection mm in 40 50 1 9 16 1 31 32 40 50 1 9...

Page 412: ...25 11 3 25 Track Width mm in 600 23 6 500 19 7 500 19 7 Length mm in 3968 156 2 3968 156 2 3968 156 2 Profile Height mm in 23 5 925 31 8 1 250 23 5 925 Adjustment Deflection mm in 40 50 1 9 16 1 31 32...

Page 413: ...justment Deflection 5 mm 13 64 in 32 1 1 4 Force kg lbf 11 3 25 Track Width mm in 500 19 7 Length mm in 3968 156 2 Profile Height mm in 31 8 1 250 Adjustment Deflection mm in 40 50 1 9 16 1 31 32 Forc...

Page 414: ...for Skandic LT LT E Comet drive pulley Retaining screw 60 to 68 N m 44 to 50 lbf ft Spider 170 N m 125 lbf ft Cover screws 12 5 N m 110 lbf in Pivot bolts and nuts 5 6 N m 50 lbf in Drive pulley reta...

Page 415: ...ctor location in housing Tundra only WIRE COLORS AND CIRCUIT The first color of a wire is the main color second color is the stripe Example YL BK is a YELLOW wire with a BLACK stripe WARNING Ensure al...

Page 416: ...motor RED GREEN 12 volts DC For starter solenoid RED BLUE 12 volts DC Rectifier output GREY 12 volts AC High beam Current returns by YELLOW BLACK wire connected to headlamp VIOLET GREY 12 volts AC Low...

Page 417: ...r reference If there are many connectors in the same area this helps identify which wire is in which connector WIRE CONNECTOR LOCATION IN HOUSING Tundra Only The third portion of the connector identif...

Page 418: ...C B 12 11 10 9 8 7 1 2 3 4 5 6 12 11 10 9 8 7 1 2 3 4 5 6 1 2 3 1 2 3 6 5 4 6 5 4 1 2 4 3 4 3 1 2 2 1 1 2 A B A B A B 2 1 85 87 30 86 87a A B C A B C A B A C B A B A B C A B C A B B A A B C A D C B B...

Page 419: ...ronic module Meter Electric motor Low level sensor Buzzer Ignition coil Normally close switch Male terminal on instrument Engine ground Spark plug Meter movement Bulb Pilot Analog sensor Solenoid valv...

Page 420: ...ing tab on its side Removal is done by squeezing this tab TAB CONNECTOR 1 Locking tab To remove Insert a screwdriver or Snap on TT 600 5 from op posite side of wire and pry locking tab While holding l...

Page 421: ...ing a small hook pull out the lock 1 Lock 1 Lock Pry tab to free connector then pull wire out of housing MALE CONNECTOR HOUSING CUT AWAY TAB AND RECEPTACLE CONNECTOR INSTALLATION Prior to installing a...

Page 422: ...n installing accesso ries on any snowmobile connect their wires di rectly to the both YELLOW lighting coil wires Even if manual start models have an AC ground to the chassis on voltage regulator all a...

Page 423: ...A29Z09 A05Z02...

Page 424: ...ENGINE CUT OUT SWITCH DIMMER SWITCH BK YL 1 5 BK YL 1 5 YL 1 5 YL 0 75 YL 0 75 YL 0 75 YL 0 75 WH GR 1 5 HEADLAMP GR 1 5 GR 0 75 HIGH BEAM INDICATOR TAIL LIGHT BK 1 5 YL GN 1 5 YL GN 0 75 YL GN 0 75...

Page 425: ...CH OIL LEVEL INDICATOR BU 0 75 WH 0 75 YL 0 75 TACHOMETER DESS INDICATOR BK 1 5 INSTRUMENTS HEATING ELEMENTS YL GN 1 5 YL GN 0 75 YL GN 0 75 YL GN 0 75 YL GN 0 75 POWER OUTLET FUEL LEVEL SENSOR YL GN...

Page 426: ...T YL GN 0 75 WH RD 0 75 BRAKE SWITCH OIL LEVEL SWITCH OIL LEVEL INDICATOR YL GN 0 75 YL 0 75 WH 0 75 50 OHMS REVERSE ALARM REVERSE LIGHT REVERSE SWITCH YL 0 75 YL 0 75 YL GN 0 75 YL GN 0 75 RD YL 0 75...

Page 427: ...Mmr 2004 tundra skandic ang FH8 Tue Sep 30 08 28 41 2003 Page 1 C M Y CM MY CY CMY K...

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