BRP ski-doo MACH Z 1000 SDI Handbook Download Page 403

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SECTION 09 - 2005 800 MOD ENGINE KIT

MMC2005-001_09A (TOOLS).FM

09-5

A33C0MS

150 cc oil

(injection oil)

Gasket P/N 420 931 565

Cover P/N 420 810 825

WARNING:

Note that the engine water pump

gear oil cavity has to be filled with 150 mL of oil

by removing oil pump block off plate and venting

(opening empty bottle) then add 70 mL to bottle.

(Best done when engine is on the work bench

with the exhaust side facing work bench).

You must eliminate the two (2)

oil injection holes.

(use plugs or hoses)

Summary of Contents for ski-doo MACH Z 1000 SDI

Page 1: ...Mmc 2005 001 Racing FH8 Wed Sep 15 15 27 01 2004 Page 1 C M Y CM MY CY CMY K...

Page 2: ...ook and or contact organization you will be competing in WARNING This information relates to the preparation and use of snowmobiles in competitive events Bombardier Inc disclaims liability for all dam...

Page 3: ...E mail steve cowing brp com Race Program Race Resumes Race Sleds Allocation Media Relations Press Events Dealer Programs Tom Lawrence Race Coordinator 7575 Bombardier Court Wausau WI 54401 Phone 715...

Page 4: ...Despaties Race Manager Assistant 565 de la Montagne Valcourt QC J0E 2L0 Phone 450 532 2211 Ext 5075 Fax 450 532 6175 E mail helene despaties brp com T I P Sheet Distribution See T I P Sheet Applicatio...

Page 5: ...ceive the T I P sheets by e mail send an e mail to the following and mention to add your name on the tip sheet distribution list Please add my name to your list of recipients for the T I P sheets to b...

Page 6: ...Exp Date _______ SHIPPING CONDITIONS RED ______ BLUE _______ GROUND ______ DESCRIPTION PART OR CLOTHING PART QTY B O 3 ONLY FAXED ORDERS WILL BE ACCEPTED COMPLETELY FILLED 2 Phone call orders or shipp...

Page 7: ..._ MASTER CARD ___ __________________________ Exp Date _______ SHIPPING CONDITIONS RED ______ BLUE _______ GROUND ______ DESCRIPTION PART OR CLOTHING PART QTY B O ALL B O PARTS WILL BE CANCELLED REORDE...

Page 8: ...1 SECTION 02 2005 MODELS TECHNICAL DATA TABLE OF CONTENTS 0 MX Z X 440 RACING 02 2 MX Z 600 HO 800 HO 02 5 MX Z 380F 550F 02 10 SUMMIT 600 HO 800 HO 02 14 MACH Z 1000 SDI SUMMIT 1000 SDI 02 19 TECHNI...

Page 9: ...Connecting rod big end axial play Wear Limit mm in 1 2 0472 Maximum crankshaft end play 2 mm in 0 3 0118 Maximum crankshaft deflection at PTO mm in 0 06 0024 Reed Valve P N 420 924 810 FUEL SYSTEM Ca...

Page 10: ...ype of drive pulley TRA 3 Light Ramp identification 435 10 Spring color White White Spring length 1 5 mm 0 060 in 137 44 5 41 Engagement speed 200 RPM 5400 Drive pulley calibration screw position or c...

Page 11: ...1022 40 Ski stance mm in 1080 42 5 Mass dry kg lb 199 438 Ground contact area cm2 in2 6670 1034 Ground contact pressure kPa PSI 2 93 0 425 Frame material Aluminum Bottom pan material Impact Copolymer...

Page 12: ...mm in 0 105 0 013 0041 0005 0 125 0 022 0049 0009 Piston cylinder wall clearance Wear limit mm in 0 18 0071 0 20 0079 Maximum crankshaft end play 2 New mm in 0 3 012 Maximum crankshaft deflection at P...

Page 13: ...erica R M 2 87 or higher Pump octane number Outside North America RON 91 or higher Gas oil ratio Injection Injection oil XP S mineral injection oil COOLING SYSTEM Type Liquid Ethyl glycol water mix 50...

Page 14: ...0 787 X mm in 37 0 0 5 1 457 0 2 Offset Y X mm in 0 82 0032 Drive belt part number P N 417 300 197 417 300 166 Width mm in 37 3 1 327 37 7 1 484 Drive belt Wear limit mm in 34 9 1 374 35 3 1 390 Defl...

Page 15: ...art 211 kg 464 lb Mass dry Trail Electric start 223 kg 491 lb Adrenaline mm in 2882 113 464 Renegade mm in 3055 120 276 Length Trail mm in 2882 113 464 Width mm in 1217 48 1105 43 5 Height mm in 1105...

Page 16: ...ail L U S oz 4 9 165 7 Injection oil reservoir L U S oz 3 5 118 TIGHTENING TORQUE engine cold Drive pulley retaining screw 5 Exhaust manifold nuts or bolts 22 N m 16 lbf ft Magneto ring nut 125 N m 92...

Page 17: ...in 0 2 0079 New mm in 0 070 0 016 0028 0006 0 147 0 026 0058 0010 Piston cylinder wall clearance Wear limit mm in 0 2 0079 Maximum crankshaft end play 2 New mm in 0 3 012 Maximum crankshaft deflectio...

Page 18: ...oil ratio Injection Injection oil XP S mineral injection oil COOLING SYSTEM Type Fan Deflection mm in 9 5 0 5 374 020 Axial fan belt adjustment Force kg lbf 5 0 11 0 Thermostat opening temperature N...

Page 19: ...eight mm in Europe 25 4 1 0 Europe 31 8 1 25 Deflection mm in 30 to 35 1 3 16 to 1 3 8 Track Adjustment Force 9 kg lbf 7 3 16 Track SC 3 121 Suspension type Ski R A S A Arm BRAKE Brake fluid reservoir...

Page 20: ...oil reservoir L U S oz 3 5 118 4 TIGHTENING TORQUE engine cold Drive pulley retaining screw 5 Exhaust manifold nuts or bolts 22 N m 16 lbf ft Magneto ring nut 105 N m 77 lbf ft M6 N A Crankcase nuts o...

Page 21: ...n 0 105 0 013 0041 0005 0 125 0 022 0049 0009 Piston cylinder wall clearance Wear limit mm in 0 18 0071 0 20 0079 Maximum crankshaft end play 2 New mm in 0 3 012 Maximum crankshaft deflection at PTO W...

Page 22: ...rica R M 2 87 or higher 91 Pump octane number Outside North America RON 91 or higher 95 Gas oil ratio Injection Injection oil XP S mineral injection oil COOLING SYSTEM Type Liquid Ethyl glycol water m...

Page 23: ...line 144 47 44 X 44 Driven pulley type Cam angle X 144 44 40 Pulley distance Z mm in 20 0 787 X mm in 37 0 0 5 1 457 0 2 Offset Y X mm in 0 82 0032 Drive belt part number P N 417 300 197 417 300 166 W...

Page 24: ...Electric start 234 kg 515 lb 151 Manual start 224 kg 493 lb 151 Electric start 236 kg 519 lb 159 Manual start 226 kg 497 lb Mass dry X 159 Electric start 238 kg 524 lb 144 3125 mm 123 031 in Adrenali...

Page 25: ...olymer Hood material Surlyn CAPACITIES Fuel tank L U S gal 40 10 6 Chaincase gearbox mL U S oz 250 8 5 144 4 59 L 152 2 U S oz Adrenaline 151 4 9 L 165 7 U S oz X 4 59 L 152 2 U S oz Cooling system X...

Page 26: ...inder wall clearance Wear limit mm in Maximum crankshaft end play 2 New mm in 0 3 012 Maximum crankshaft deflection at PTO Wear limit mm in 0 06 0024 New mm in 0 23 to 0 62 0091 to 0244 Connecting rod...

Page 27: ...Mixture Use coolant specifically designed for aluminum engines Coolant Premixed P N 219 700 362 12 x 1 L Thermostat opening temperature C F N A Radiator cap opening pressure kPa PSI 90 13 DRIVE Chainc...

Page 28: ...Profile height mm in 31 8 1 25 58 8 2 313 Adjustment Deflection mm in 30 to 35 1 181 to 1 378 Track adjustment Force 9 kg lbf 7 3 16 Track SC 4 SC 162 Suspension type Ski R A S A arm BRAKE Brake flui...

Page 29: ...oil reservoir L U S oz 3 7 125 112 TIGHTENING TORQUE engine cold Drive pulley retaining screw 120 N m 89 lbf ft Exhaust manifold nuts or bolts 11 N m 97 lbf in Magneto ring nut 130 N m 96 lbf ft M6 9...

Page 30: ...only 10 Lever with roller pin P N 417 003 900 3 At 3500 RPM with headlamp turned on 11 Minimum allowable width may not be less than 3 0 mm 1 8 in of new drive belt 4 All resistance measurements must...

Page 31: ...RIDE HEIGHT 03 30 TRACK GUIDES 03 31 SKIS AND RUNNERS 03 31 BUMP STEER 03 32 SKI LEG CAMBER 03 32 SKI TOE OUT 03 33 CHASSIS TUNING GUIDELINES 03 34 STEERING SYSTEM 03 36 DISASSEMBLY AND ASSEMBLY 03 38...

Page 32: ...reases The skis then tend to lift more during acceleration and more weight is placed on the track We can vary angle A within limits by adjusting the length of the limiter strap The limiter strap is ju...

Page 33: ...vide less ski pressure and will be used on lighter vehicles while stiffer springs will provide more ski pressure and be used on heavier vehicles NOTE Shock absorber valving and the type of shock used...

Page 34: ...doubled If the reading is more than doubled then you have a progressive spring If you can compress the spring another 1 inch 3 inches total do not exceed maximum scale rating or damage may occur the...

Page 35: ...e stiffer and softer springs for most applications The preload on a torsional spring is controlled by the free opening angle and the installed opening angle If a torsional spring must be twisted more...

Page 36: ...r 3 Free length Type S barrel shape on one end Single Rate Spring 1 Color code stripes 2 Wire diameter 3 Free length Type T barrel shape on both ends Single Rate Spring 1 Color code stripes 2 Wire dia...

Page 37: ...rrel shape on both ends Dual Rate Spring 1 Color code stripes 2 Wire diameter 3 Free length Type 4 barrel shape on both ends with positioning tab at the color code coils end Dual Rate Spring 1 Color c...

Page 38: ...070 762 MX Z TRAIL 505 071 129 505 071 257 505 070 762 MX Zx 505 071 129 505 071 388 505 070 762 MX Zx RENEGADE 505 071 129 505 071 388 505 070 762 MX Z RENEGADE 505 071 129 505 071 257 505 070 762 MX...

Page 39: ...9 325 503 189 659 MX Zx RENEGADE 503 189 812 503 190 476 503 190 478 503 190 476 503 190 480 MX Z RENEGADE 503 189 812 503 190 476 503 190 478 503 190 476 503 190 480 MX Z FAN 503 189 659 503 189 686...

Page 40: ...03 190 779 LH 503 190 777 RH 503 190 775 LH 503 190 773 RH MX Zx RENEGADE 503 190 714 LH 503 190 712 RH 503 190 494 LH 503 190 492 RH 503 190 775 LH 503 190 773 RH MX Z RENEGADE 503 190 714 LH 503 190...

Page 41: ...71 RD SI YL BLACK 503 189 812 2 125 200 250 8 41 BL GR YL BLACK 503 189 988 U 215 64 6 35 GD GD YL BLACK 503 189 990 R 275 189 9 19 GD WH YL BLACK 503 189 999 R 325 189 9 52 GD SI YL BLACK 503 190 29...

Page 42: ...LLOW 505 070 760 Y 95 280 8 25 BL GD BK YELLOW 505 070 762 T 105 300 8 71 GR GD BK YELLOW 505 070 852 4 40 85 340 7 49 RD GR RD YELLOW 505 070 941 T 150 315 9 52 RD SI BK YELLOW 505 071 162 2 55 320 7...

Page 43: ...189 327 RH 503 189 329 LH 11 89 100 385 1 51 SI 503 189 334 RH 503 189 335 LH 11 11 105 400 1 12 YL GD 503 189 338 RH 503 189 339 LH 11 11 90 400 1 13 GN GN 503 189 342 RH 503 189 343 LH 10 6 80 400...

Page 44: ...SPRING RATE FT LBS DEG COLOR CODE P N WIRE DIAMETER mm OPENING ANGLE 7 LENGTH mm SPRING RATE FT LBS DEG COLOR CODE 486 400 021 RH 486 400 022 LH 9 14 75 390 1 00 RD YL YL 486 400 023 RH 486 400 024 LH...

Page 45: ...By having a sway bar in the suspension softer springs can be used to achieve a good ride be cause the bar will help control roll in a corner The bar has no affect on ride when traveling straight ahea...

Page 46: ...This is because re bound dampening must resist the force of the spring and because piston speeds are much slow er during rebound At low piston speeds the number of bleed slits will have a fairly larg...

Page 47: ...152 1 254 2 0 203 This means it will take 2 4 114 mm shims to have the same dampening as 1 152 mm shim Obviously you can t use a fraction of a shim so you must find the lowest common denominator For...

Page 48: ...esult in the same low speed dampening but the medium and high speed damping will be increased The following graph represents the effect of changing the total thick ness of small shims which determine...

Page 49: ...just add or remove 1 or 2 large shims from the ap propriate side to fine tune the overall stiffness NOTE Always use 30 mm diameter shims against the piston for compression dampening and 26 mm diamete...

Page 50: ...or 5 minutes before releasing the gas This 5 minute period will allow most of the gas to separate from the oil and min imize oil spray 1 Schrader valve 1 5 2 N m 13 17 lbf in 2 Schrader cap 5 6 5 N m...

Page 51: ...Oil flows Discard old oil into storage container Never reuse damper oil during shock rebuild Remove Schrader valve core Using compressed air pressure carefully remove floating piston from damper body...

Page 52: ...using a vernier caliper or a micrometer NOTE All shims should be carefully inspected and any bent or broken shims must be replaced for the shock to function properly The damper rod is constructed of...

Page 53: ...eads 1 Rebound dampening shim pack 2 Rebound dampening shim pack 3 Piston 4 Compression dampening shim 5 Compression dampening shim pack 6 Stopper Rebound A minimum of 0 203 mm 008 in clearance must b...

Page 54: ...amper rod assembly taking care to properly assemble shim packs as required for your dampening needs Ensure that the shaft piston is installed with the slits larger intake holes facing the rebound shim...

Page 55: ...Bombardier HPG shock oil P N 413 711 806 to approximately 10 mm 393 in from the base of seal carrier threads 1 Fill to 10 mm 393 in NOTE Although we do not measure the exact amount of oil added to the...

Page 56: ...e 1 5 2 N m 13 17 lbf in 2 Schrader cap 5 6 5 N m 44 57 lbf in Adding Gas Pressure Nitrogen N2 can now be added to damper body NOTE Never substitute another gas for nitrogen Nitrogen has been selected...

Page 57: ...reductions here can provide mea surable improvements in top speed Good chassis set up starts with accurate align ment of the drive axle countershaft suspension system and chassis Use the following pr...

Page 58: ...e more than 1 5 mm 060 in from side to side Ideally the axle has 0 25 0 50 mm 010 020 in TOP VIEW 1 Countershaft 2 Shim position on end bearing housing side 3 Shim position on chaincase side 4 Drive a...

Page 59: ...looser Ratcheting of the drive sprockets during hard ac celeration can occur if the track is too loose Con versely heavily studded tracks may need to be tighter to achieve top speed because the extra...

Page 60: ...l have very little preload when the sus pension is in its topped out position and it may be necessary to safety wire the spring collars into position and use additional limiter devices like straps cha...

Page 61: ...track There are two special tools which greatly enhance the removal and addition of guide clips P N 529 028 700 Guide clip remover P N 529 008 500 Guide clip crimper SKIS AND RUNNERS The skis on your...

Page 62: ...of concrete blocks set on a line about 50 mm 2 inches away from the edge of the ski and parallel to the ski works nicely Lift the ski up to its upper travel limit Using a mea suring tape measure the d...

Page 63: ...more comfortable driving position when in a corner Whatever handlebar you prefer should be positioned as you prefer it when going down a straightaway before you begin your toe out adjustment Use a ru...

Page 64: ...e negative camber of ski legs Increase center spring preload Sharpen add track studs c Inside ski lifts Reduce the amount of negative camber on the ski legs Check for free operation of stabilizer bar...

Page 65: ...ad This is a preliminary setting only Increase and decrease the preload adjustments to fine tune for your preference The center spring and ski springs will have the most affect on handling but if the...

Page 66: ...s 2 25 N m 18 lbf ft 5 1 Suspension synthetic grease 53 N m 39 lbf ft 7 25 N m 18 lbf ft 15 9 16 17 18 11 7 53 N m 39 lbf ft 41 N m 30 lbf ft Bombardier Lube Suspension synthetic grease 7 8 6 18 N m 1...

Page 67: ...HO Summit X Highmark X Highmark Xtreme A33G1BS 8 N m 71 lbf in 10 28 11 N m 97 lbf in 27 12 13 29 5 1 Suspension synthetic grease 4 25 N m 18 lbf ft 25 N m 18 lbf ft 22 27 8 N m 71 lbf in 4 25 N m 18...

Page 68: ...rom throttle lever then pull out throttle cable housing from throttle lever housing no 21 Unscrew screws no 10 and remove J hook no 12 from end of grip on so equipped models Loosen screw no 20 retaini...

Page 69: ...lation Installation is the opposite procedure of the re moval but pay attention to the following Clean handlebar ends and inside of heating grip with isopropyl alcohol Let dry before installation WARN...

Page 70: ...ter cylinder has been removed from handlebar note that its clamp no 27 must be installed with the embossed arrow pointing downward Torque screws to 8 N m 71 lbf in beginning with the bottom screw 1 A3...

Page 71: ...g sys tem components for wear Replace if necessary Heating Grip Element Refer to TESTING PROCEDURE for checking heating element no 13 of grip Ball Joint left hand and right hand threads Inspect ball j...

Page 72: ...onsole to gain access to electrical con nector housings Unplug the 2 large connector housings and then separate 3 wire connector 1 A33H07A TYPICAL 1 Large connector housings Remove console Remove 2 bo...

Page 73: ...MN Reinstall windshield assembly to handlebar Refer to WINDSHIELD ADJUSTMENT below 1 A33H04A ONE SIDE SHOWN FORWARD POSITION 1 Bolts retaining windshield assembly Readjust throttle lever housing no 21...

Page 74: ...NOT adjusting the handle bar too high Readjust throttle lever housing no 21 and switch housing accordingly to optimal angle so that you will not need to release your grip to operate levers WARNING Adj...

Page 75: ...otect the rubber band Retaining clip and hardware must be installed in the same position on both strap ends J Hook Adjustment Some Models Position J hook so that its curved end is pointing downward an...

Page 76: ...ed track and measure the distance between front and rear of ski bridge MODEL TOTAL TOE OUT 1 mm 3 64 in All REV Series 2 5 64 NOTE To reduce tolerance when measuring set one ski to proper toe out half...

Page 77: ...e distance is more than the specified distance on one side then check for bent parts LUBRICATION WARNING Do not lubricate throttle cable or housing Use suspension synthetic grease P N 293 550 033 on G...

Page 78: ...PICAL 1 Headlamp center line A 381 cm 12 ft 6 in B 25 mm 1 in below center line A02E07A 2 A 1 3 1 Headlamp horizontal 2 Light beam high beam projected on the wall 3 Light beam center A 25 mm 1 in Requ...

Page 79: ...he taillight bulb is burnt expose the bulb by re moving red plastic lens To remove unscrew the 2 retaining screws Verify all lights after replace ment DECAL To remove a decal heat old decal with a hea...

Page 80: ...ds and secure them in place Pay attention to route them properly away from any rotat ing moving heating or vibrating parts TUBING WARNING Always ensure that the fuel vent primer im pulse injection oil...

Page 81: ...affecting the plastic components and the vehicle finish REPAIR The very first step before repairing plastic materi als is to find out exactly which type of material is involved CAUTION Some repair pr...

Page 82: ...g MPEM On models equipped with a battery also un plug the negative cable This will protect the electronic box and battery against damage caused by flowing current when welding A32E0WB TYPICAL MPEM UNP...

Page 83: ...LY REMOVAL 04 16 DISASSEMBLY AND ASSEMBLY 04 17 SHOCK ABSORBER INSPECTION 04 19 HPG T A SHOCK SERVICING 04 20 INSTALLATION 04 28 RIDE ADJUSTMENT 04 28 LUBRICATION 04 28 INTERNAL FLOATING PISTON MEASUR...

Page 84: ...19 17 18 16 48 N m 35 lbf ft 15 25 16 N m 142 lbf in 21 22 23 7 24 29 30 14 6 10 9 60 N m 44 lbf ft 60 N m 44 lbf ft 32 31 13 12 11 28 2 5 32 N m 24 lbf ft 28 8 26 Suspension synthetic grease 4 48 N...

Page 85: ...off the ground from the frame to release the suspension Firmly grab lower part of ski leg and try to move sideways to feel the free play If excessive play is felt replace the faulty com ponent DISASS...

Page 86: ...is pin 2 Bar 3 Handle horizontal Push down on the handle until it locks Remove spring stopper then release handle Some Models At installation cap opening no 30 must be 180 from spring stopper no 29 op...

Page 87: ...llel with ski leg Remove lower arm no 14 from frame For front screw no 17 removal hold nut no 18 from engine compartment To remove ball joint proceed as follows Remove snap ring no 13 Install ball joi...

Page 88: ...d ball joint housing and unscrew nut no 16 then re move ball joint from upper arm Remove upper arm no 14 from frame For screws no 19 removal hold nuts no 20 from engine compartment 1 A33F21A 1 Remove...

Page 89: ...replace as necessary Check condition of ski stopper no 26 Replace it when deteriorated To check condition of shock absorber refer to SUSPENSION then look for SHOCK ABSORBER INSPECTION INSTALLATION Fo...

Page 90: ...ar Prior to installing ball joint in lower arm ensure to clean the tapered surfaces with the Pulley flange cleaner product P N 413 711 809 Surface con tacts must be clean and free of dirt oil and grea...

Page 91: ...ng NOTE The upper arm ball joint has to be removed in order to use this tool Also remove the small screw from top of ball joint to allow proper seating of tool A32F3XA TYPICAL Stabilizer Bar Notice th...

Page 92: ...d releasing suspension 1 A33F2EA 1 Temporarily rotate block by 180 for its insertion 1 A33F2FA 1 Push block on bar end beyong lower arm then rotate back to its normal position Shock Absorber Ensure to...

Page 93: ...P N 293 550 033 between bushing no 28 and spacer no 27 and also on inner tube of ski leg Summit Only Install bushing no 29 and spacer no 30 inward on each ski leg for the wide ski stance Install outw...

Page 94: ...04 12 MMC2005 001_04A FM SECTION 04 SUSPENSION SC 3 SC 4 RAS SC 10 III SUSPENSION SC 10 III A33F40S 7 48 N m 35 lbf ft 10 N m 89 lbf in 24 N m 18 lbf ft 2 5 N m 23 lbf in 13 21 7 4 N m 35 lbf in 11...

Page 95: ...SPENSION SC 3 SC 4 RAS MMC2005 001_04A FM 04 13 A33F41S 3 N m 27 lbf in 85 N m 63 lbf ft 3 1 22 12 19 19 Suspension synthetic grease Suspension synthetic grease 15 17 15 17 15 16 85 N m 63 lbf ft 24 N...

Page 96: ...ON 04 SUSPENSION SC 3 SC 4 RAS Suspension synthetic grease A33F42S 48 N m 35 lbf ft Models with up side down shocks 23 2 4 2 3 4 8 9 85 N m 63 lbf ft 48 N m 35 lbf ft 7 N m 62 lbf in 48 N m 35 lbf ft...

Page 97: ...ting bolt Make sure to reinstall washer on each side of run ner A03F1LA TYPICAL Rear Shock Lift rear of vehicle A32F4BA TYPICAL Remove nut on top end of shock no 23 A33F44A Remove nut on bottom end of...

Page 98: ...ground Loosen track tension Decrease spring preload by turning cams no 19 accordingly Slightly turn adjusting cam to expose spring end Using spring installer P N 529 005 000 remove both springs from a...

Page 99: ...gas pressure shocks to facilitate the suspension removal it is necessary to remove the rear shock no 23 All Models Remove both self locking screws no 2 retaining front arm to tunnel A33F47A Remove sus...

Page 100: ...ed above stoppers 1 A32F15A 2 1 Protrusion 2 Stoppers Dowel Pin and Block Guide Dowel pin no 15 must exceed block guide no 16 by 2 to 2 3 mm 079 to 091 in At installation insert dowel pin into pivot a...

Page 101: ...A A 7 N m 62 lbf in Slider Shoe Molding line is the wear limit indicator 1 A03F3SA 2 TYPICAL 1 Slider shoe 2 Molding line wear limit indicator Replace slider shoes no 11 when wear limit is reached CAU...

Page 102: ...chamber and gas chamber check shock as fol lows Install shock in a vise clamping on its bottom eye let with its rod upward Let it stand for 5 minutes Completely push down the shock rod then re lease R...

Page 103: ...unt shock in a vise with HPG shock holding tool P N 529 035 769 529 035 769 A32F2DA Tire Valve Type Shock Remove tire valve cap and push on center rod of valve to release gas pressure A06F18B 2 1 1 Ti...

Page 104: ...with a shop cloth to capture possible overflow oil while removing the damper piston 1 A27F0AA 1 Oil flows Discard old oil into storage container Never reuse damper oil during shock rebuild All Types o...

Page 105: ...NG Whenever using compressed air use an O S H A approved air gun and wear protec tive eye wear Thoroughly clean with a typical cleaning solution and blow dry using low pressure air Carefully in spect...

Page 106: ...for non O E M use Loctite 271 on nut each time This these spacer washer s must be used as shown to ensure damper rod nut does not bottom out or contact shaft threads Rebound valve stopper with round e...

Page 107: ...llation distance for floating piston installation SHOCK P N INSTALLATION DISTANCE OF FLOATING PISTON mm 505 070 903 44 5 505 070 904 44 5 505 070 937 44 5 505 070 938 44 5 503 190 016 128 503 190 247...

Page 108: ...into damper body Slight up and down movement may be required on short stroke to allow all air to pass through piston as sembly The gentle tapping of a small wrench on the shock eye may help dislodge...

Page 109: ...egulator delivery pressure range 2070 kPa 300 PSI 3 High pressure cylinder filled with industrial grade nitrogen 4 Valve tip P N 529 035 570 permanently installed NOTE Never substitute another gas for...

Page 110: ...must be corrected before con tinuing Damper gas pressure cannot be confirmed by using a pressure gauge The volume of gas in the shock is very small and the amount lost during gauge installation will...

Page 111: ...er 503 189 974 Shock ass y rear 486 140 026 Stop ring spring protector right left 486 140 027 Collar spring protector right left 486 140 028 Rubber bush top eye 486 140 029 Valve ass y base valve adju...

Page 112: ...the bumps that create low speed movement in the suspension The low speed adjuster has 4 turns of adjustment Turning the adjuster clockwise increases the dampening High speed compression adjuster The h...

Page 113: ...Using a 12 mm wrench slowly remove air valve allowing the gas inside the reservoir to escape 3 Remove top seal cap using a 36 mm wrench Pull shaft valve stack assembly out of main shock body 4 Dispos...

Page 114: ...ock components using Bombardier Sheave Cleaner DO NOT MIX SHIMS AND WASHERS TOGETHER 11 Assemble valve shims washers and piston in proper order and place them back onto shock shaft 12 Torque the rod n...

Page 115: ...and gently push into main shock body 21 Stroke the piston and valve stack slowly to re move any trapped air Using a small hammer or wrench gently tap on the shaft mounting eyelet to help remove air 22...

Page 116: ...24 114 10 P N SIZE MOQ minimum order quantity 414 888 304 0 slit 1 414 888 305 2 slits 2 414 888 306 4 slits 1 414 888 307 6 slits 1 1 slit P N SIZE mm MOQ minimum order quantity 503 189 011 22 114 5...

Page 117: ...__________________________________________________________________________________ __________________________________________________________________________________________________ __________________...

Page 118: ...04 36 MMC2005 001_04A FM SECTION 04 SUSPENSION SC 3 SC 4 RAS SC IV REAR SUSPENSION 0...

Page 119: ...tionally designed suspensions work very well in most riding conditions however weight trans fer and bump absorption in the deepest moguls could be made even better This is where the SC IV comes in it...

Page 120: ...d over the center arm Conversely on accel eration weight transfer is more difficult since the rider and vehicle s mass are moved farther forward compaired to conventional vehicle The motion ratio curv...

Page 121: ...under acceleration is enhanced from 0 30 mph and is decreased at higher trail speeds These changes were accom plished by linking the front shock through a pivot ing mechanism to the rear arm The front...

Page 122: ...er for a 26 decrease in vertical flex and a 30 im provement in lateral flex 3 Offset idler wheels on rail to reduce noise 4 Idler wheels are larger 141mm versus 135mm due to increased rail height 5 La...

Page 123: ...ustments 10 No coupling front to rear This reduces kick in downhill bumps and deceleration 11 Rear coupling area is larger allowing more weight transfer Mission accomplished The SC IV suspension was d...

Page 124: ...04 42 MMC2005 001_04A FM SECTION 04 SUSPENSION SC 3 SC 4 RAS...

Page 125: ...ENTIFICATION 05 38 REMOVAL 05 38 CLEANING AND INSPECTION 05 39 DISASSEMBLY AND ASSEMBLY 05 40 CARBURETOR ADJUSTMENT 05 41 INSTALLATION 05 43 DPM 05 44 TESTING 05 44 PARTS REMOVAL AND INSTALLATION 05 4...

Page 126: ...82 INSPECTION 05 85 INSTALLATION 05 85 TROUBLESHOOTING 05 88 COMPONENT REMOVAL WITH THE ENGINE INSTALLED 05 88 CLEANING 05 88 RAVE VALVE BASIC OPERATION 05 89 DISASSEMBLY 05 89 INSPECTION 05 93 ASSEMB...

Page 127: ...23 GENERAL 05 124 OIL TYPE 05 124 OIL SYSTEM LEAK TEST 05 124 OIL PUMP IDENTIFICATION 05 125 CLEANING 05 125 DISASSEMBLY 05 125 ASSEMBLY 05 126 ADJUSTMENT 05 127 CHECKING OPERATION 05 128 LIQUID COOLI...

Page 128: ...te Shop Manual BASIC ENGINE THEORY Terminology CYCLE In a combustion engine a cycle is accomplished when the four 4 phases intake compression ignition and exhaust are complete TDC Top Dead Center The...

Page 129: ...rates heat and pressure which in turn is transmitted by conduction to the contiguous portion of the unburned mixture When this portion has reached the point of self ignition it starts to burn releasin...

Page 130: ...occurs earlier than the timed spark the hot gases stay longer in the combustion chamber thus increasing cylinder head and piston temperatures to a dangerous level Usually the piston is subject to dam...

Page 131: ...ge losses When an engine of this design is run at a medium speed efficiency falls off quickly The relatively high exhaust port effectively shortens the useful power stroke and because the exhaust syst...

Page 132: ...agm The exhaust pressure must be high enough to overcome this pressure before the valve begins opening Item P2 is the pressure required to completely open the RAVE valve Between P1 and P2 the usable p...

Page 133: ...hecked by pres surizing the engine as one would when checking for crankcase leaks The engine must be sealed at all exhaust flanges all carburetor inlets and at the fuel pump impulse fitting Depending...

Page 134: ...3 twin cylinder engines This technology is beneficial in three ways 1 It uses less parts i e shafts rotary valve discs etc Resulting in a lighten engine package 2 This technology results in positive c...

Page 135: ...jetting must be established BASE GASKETS 453 P N 420 931 580 0 3 mm P N 420 931 581 0 4 mm P N 420 931 583 0 5 mm P N 420 931 582 0 6 mm P N 420 931 584 0 8 mm 493 P N 420 931 588 0 5 mm P N 420 931...

Page 136: ...or future use Example Testing established a 400 main jet at C R A D of 100 One week later the C R A D at the track is 110 Use the following formula to establish the new main jet New main jet 440 Recor...

Page 137: ...ur air density gauge now reads 105 This means you have gained 15 air density New density 105 Base line 90 105 90 15 Multiply your base line main jet by 115 Example 300 x 115 345 Round off to next high...

Page 138: ...forced into the smaller diameter of the venturi speed increas es V2 but pressure drops P2 Passages in the carburetor connect the venturi to a reservoir of fuel float bowl The float bowl is vented to...

Page 139: ...oad the maximum output with the throttle valve fully opened In order to meet the requirements for the proper mixture ratio under these varying condi tions a low speed fuel system the pilot system and...

Page 140: ...GINE PREPARATION Starter plunger MIKUNI CARBURETOR VM PRIMARY TYPE BLEED TYPE TYPE Float Starter jet Throttle valve Air jet Air screw Needle jet Main jet Needle valve Ring Pilot jet Pilot outlet By pa...

Page 141: ...Aperture of Carburetor One of the prerequisites for improving the output is to use a carburetor with as large an aperture as possible However a large aperture alone does not necessarily improve the o...

Page 142: ...d ditional turns 2 Start and warm up engine Adjust idle stop screw to 500 RPM above normal idle speed See Low Speed Fuel System 3 Turn air screw in or out using 1 4 turn incre ments until engine RPM p...

Page 143: ...as described above NOTE Since the pilot air system provides some fuel up to wide open throttle changes in this sys tem will affect the throttle valve jet needle needle jet and main jet metering syste...

Page 144: ...nt throt tle valve is opened 4 Increase or decrease throttle valve cut away size in 0 5 steps 5 Return air screw to its original setting and oper ate engine at low throttle settings Accelerate engine...

Page 145: ...a double taper and three letters mean there is a triple taper D Amount of taper at top of needle H Amount of taper at bottom of needle 7 Material type of coating and start of second taper on needle N...

Page 146: ...5 position and op eration is still lean a needle jet with a larger or ifice may be installed This may be done only after thoroughly checking the main jet jet nee dle and E ring positions NOTE Make sur...

Page 147: ...IPLES OF OPERATION 1 Jet needle 2 Metered here 3 Fuel 4 Air 5 Needle jet The main jet system starts to function when the throttle is approximately 1 4 open The mid range fuel is supplied by the main j...

Page 148: ...if fuel air mixture were too lean and increase jet size If operation improves continue to increase jet size to obtain peak performance If operation becomes worse decrease jet size to obtain peak perf...

Page 149: ...MMC2005 001_05A FM 05 25 Functional Range Effectiveness in Relation to Throttle Opening Pilot jet and pilot air screw A01C2TS Full open 3 4 1 2 1 4 1 8 Closed Main jet Jet needle Needle jet Throttle...

Page 150: ...4T Cap Spring Ring E Ring Guide holder Piston valve Needle Screw Nipple Spring Adjuster Spring Adjuster Float Pin Screw Main jet Pilot jet Holder Screw O Ring Plate Screw Plate Screw Venturi Screw Pac...

Page 151: ...mer that steps up the relatively low voltage 150 300 V of the generat ing coil to the 20 400 40 000 volts necessary to jump the spark plug gap and initiate the burning of the fuel air mixture in the c...

Page 152: ...grees of crankshaft rotation by the appropriate formulas Initial ignition timing procedures can be found in the Shop Manual for the particular model being worked on Ignition Timing Ignition timing is...

Page 153: ...r type 105 95 85 Ordinary plug Racing plugs None L H E F Letter 12 0 mm thread dia 18 mm 9 5 mm thread dia 14 mm 22 5 mm thread dia PF 1 2 in 14 mm 16 0 mm thread dia 7 8 in 18mm 11 2 mm 12 7 mm racin...

Page 154: ...05 30 MMC2005 001_05A FM SECTION 05 ENGINE PREPARATION CARBURETOR AND THROTTLE CABLE CARBURETOR VM TYPE To other carburetor A30C1XV 6 8 11 9 7 1 2 3 4 5 12 10...

Page 155: ...ash point such as gaso line naphtha benzol etc should not be used as they are flammable and explosive Check inlet needle tip condition If worn the inlet needle and seat must be replaced as a matched s...

Page 156: ...LEVEL ADJUSTMENT CAUTION Spark plugs will foul if float is ad justed too low Engine may be damaged if float is adjusted too high Float Arm Correct fuel level in float chamber is vital toward maximum...

Page 157: ...idle speed adjustment throttle cable adjustment carburetor synchronization final idle speed adjustment engine running oil pump and carburetor synchronization A02C09A 2 1 1 Idle speed screw 2 Air screw...

Page 158: ...eed screw no 7 Throttle slide height is measured on outlet side of carburetor engine side NOTE Make sure that throttle cable does not hold throttle slide Loosen cable adjuster accordingly Final idle s...

Page 159: ...w cable adjuster until all car buretor slides start to open at same time Cable play will be identical on all carburetors Retighten jam nut 1 A03C2VA 2 TYPICAL 1 Screw or unscrew adjuster 2 Check that...

Page 160: ...lever is set to half open position Set choke lever to close position and by pulling and pushing choke lever make sure there is no tension on cable free play Idle Speed Final Adjustment CAUTION Before...

Page 161: ...SECTION 05 ENGINE PREPARATION MMC2005 001_05A FM 05 37 CARBURETOR AND THROTTLE CABLE CARBURETOR TM TYPE A32C6ZT 12 PTO MAG 11 10 8 9 14 13 15 4 5 7 1 6 3 2 16 17 Loctite 243...

Page 162: ...r temperature sensor connector at air silencer 1 A33C1LA 1 Disconnect Disconnect DPM air vent hose nipple from air si lencer 1 A33C1KA 1 Disconnect here Non DPM Models Disconnect carburetor float bowl...

Page 163: ...ventilated Do not smoke or allow open flames or sparks in the vicinity Pinch heated carburetor coolant outlet line 1 A33C1QA 2 1 Outlet line 2 Pinch here Disconnect outlet line from carburetor assembl...

Page 164: ...ude changes A ser vice bulletin will give information about calibration according to altitude and temperature Main jet no 5 may be removed without remov ing float bowl no 6 by first removing drain scr...

Page 165: ...ove circlip no 14 retaining throttle slide 1 A32C6TB 1 Circlip At throttle slide assembly needle retainer must face carburetor body 1 A32C70A 2 1 Needle retainer 2 Ensure O ring gasket is properly sea...

Page 166: ...carburetor Use a drill bit to measure throttle slide height see following table on outlet side of carburetor en gine side Adjust by turning idle speed screw no 15 2 A32C72A 1 3 1 Adjust PTO carbureto...

Page 167: ...are no kinked hoses after reconnection Throttle Cable Adjustment To adjust throttle cable refer to THROTTLE CA BLE at the end of this section Choke Cable Adjustment Adjust choke cable as per followin...

Page 168: ...8 000 20 4 14 500 0 32 5 500 20 68 2 500 40 104 1 200 60 140 600 80 176 320 100 212 180 120 248 120 Solenoid and MPEM Static Test Unplug electric connector of solenoid no 20 and connect it to a 12 V b...

Page 169: ...cap firmly push until tabs click and lock on both sides in DPM DPM MANIFOLD TESTING Visual Inspection With DPM manifold removed from vehicle and all hoses disconnected from DPM manifold inspect for an...

Page 170: ...ting 2 T fitting 3 Vented to atmosphere Collect hose into one of the water column tubes leave the other tube at atmospheric pressure Testing Set pump to vacuum CAUTION Never use pump directly on DPM t...

Page 171: ...1 A33C2YA 1 Handle cover screw Unhook the cable sheath then remove the cable from handle Remove air intake silencer Disconnect the cable end from carburetors or throttle body Disconnect cable end from...

Page 172: ...ttle cable 2 Adjusting nut 3 Locking nut After throttle cable adjustment synchronized car buretors refer to CARBURETOR SYNCHRONIZA TION and adjusted oil pump cable refer to OIL INJECTION PUMP SDI Mode...

Page 173: ...to installation make sure that contact sur faces of the cylinder head and spark plug are free of grime CAUTION Do not adjust electrode gap of spark plug BR9ECS 1 Apply anti seize lubricant P N 293 80...

Page 174: ...k when checked with the timing light SCRIBING A TIMING MARK Clean the area around the MAG spark plug and remove it Install the TDC gauge in the spark plug hole magneto side and adjust as follows Posit...

Page 175: ...G IGNITION TIMING Use a timing light To check the ignition timing proceed as follows WARNING Place ski tips against a wall raise rear of ve hicle on a stand so that track does not con tact the ground...

Page 176: ...RETARDED BY ABOUT 1 A29E0WA TIMING ADVANCED BY ABOUT 2 CHANGING TIMING All Engine Types NOTE To change the timing on the SDI engines the VCK is mandatory The MPEM programmer cannot be used with these...

Page 177: ...A Vehicle information is transferred from MPEM to programmer A30E1YA T R A N S F E R P G M R M P E M NOTE In fact the programmer takes a copy of all vehicle parameters scribed in MPEM This copy will b...

Page 178: ...from 1 to 1 A30E2HA T I M I N G 1 8 5 IGNITION CORRECTION FACTOR CORRECTION FACTOR PROGRAMMED IN MPEM IGNITION TIMING CORRECTION 2 3 3 2 4 1 1 0 5 1 6 2 7 3 8 4 Press ENTER A30E2GA 2 E N G I N E S E R...

Page 179: ...following message will appear A30E2BA V E R I F Y P G M R M P E M V E R I F Y P G M R M P E M After the programmer has verified following mes sage will appear O P E R A T I O N S U C C E S S F U L L...

Page 180: ...ATION TESTING PROCEDURE GENERAL The following chart gives the engine types with their implemented system MODELS IGNITION SYSTEM CHARGING SYSTEM OUTPUT All REV liquid cooled except SDI models BOMBARDIE...

Page 181: ...5 001_05A FM 05 57 Bombardier DC 360 W A32E3PS 1 21 N m 16 lbf ft Loctite 243 9 N m 80 lbf in 2 3 Volt regulator Frame harness Calibration module 8 N m 71 lbf in Loctite 243 Loctite 648 693 engines 1...

Page 182: ...01_05A FM SECTION 05 ENGINE PREPARATION Bombardier DC 480 W A32E3OS 3 21 N m 16 lbf ft 8 N m 71 lbf in 9 N m 80 lbf in Loctite 243 Voltage regulator 1 2 Frame harness Loctite 243 1 ECM 2 Ignition coil...

Page 183: ...alibration program may be different When ordering a new MPEM always refer to appropriate model parts cata log The service P N published in parts cata logs are the ones with the good calibration pro gr...

Page 184: ...n is transferred from MPEM to programmer A30E1YA T R A N S F E R P G M R M P E M NOTE In fact the programmer takes a copy of all vehicle parameters scribed in MPEM This copy will be modified within th...

Page 185: ...796 Renegade 800 793 HO 512 059 853 512 059 854 512 059 799 Renegade X 800 793 HO 512 059 853 512 059 854 512 059 799 Trail 500 SS 593 512 059 848 512 059 849 512 059 795 Trail 500 SS R 593 512 059 8...

Page 186: ...er and press ENTER following screen appears A00A5OA T O E N D P R E S S A N Y K E Y P L U G I N K E Y Simultaneously with the following operation a transfer will occur Trs At this point be ready to re...

Page 187: ...corresponding table If the reading is too low the part is considered to be defective and must be replaced Resistance Readings Place multimeter selector switch to in order to measure resistance Reading...

Page 188: ...close circuit 0 in off position NOTE For the next step no switch must be con nected to the main wiring harness Disconnect all switches from the main wiring har ness and check the continuity of each w...

Page 189: ...check values indicated by the multimeter Repeat operation 3 times Compare readings with those appearing in the IGNITION table 6 MPEM Voltage Testing Disconnect the housing between module and high volt...

Page 190: ...wire on positive tab 2 GREEN RED wire on negative tab Using jumper wires connect battery positive post to buzzer positive tab Connect battery negative post to buzzer negative tab See next photo CAUTIO...

Page 191: ...gs with those appearing in the LIGHTING table Conclusion If none of the above testing operations produced valid results it is strongly recommended to keep on testing according to the list appearing in...

Page 192: ...nge 00 0 00 5 Tether cap must be in place MPEM Ground connection BK and negative battery terminal or body 11 DA 3 F 00 0 or auto range 00 0 00 5 Power from battery RD GY and BK 11 DA 12 F 11 DA 3 F 00...

Page 193: ...DA 7 F 11 DA 3 F 00 0 Vdc Battery voltage When start RER switch is activated in all conditions Charging voltage Battery voltage to switch from 5 A fuse RD GY and negative battery terminal 12 HG 5 and...

Page 194: ...ltage All cranking tests are performed with the manual starter Faster cranking speeds may produce higher voltages Ignition and electric starter will not work if the Engine stop switches is in the kill...

Page 195: ...9 1 Homemade adaptor Connect supply cable P N 529 035 869 to diag nostic connector located on right side of the vehi cle Now the headlight and accessories systems are supplied with 12 volts Refer to a...

Page 196: ...05 72 MMC2005 001_05A FM SECTION 05 ENGINE PREPARATION FUEL TANK AND FUEL PUMP All Models except SDI 2 4 3 1 A33C2VS...

Page 197: ...of cen ter console this will allow lifting of console just enough to ease tank removal 1 A33F0YA 1 Remove this screw on both sides Remove both sides fuel tank aluminum braces by removing and discardi...

Page 198: ...s or sparks in the vicinity Unplug vent tube no 2 from tank Some Models Cut locking tie holding wiring harness to fuel tank at rear 1 A33F11A 1 Cut this locking tie Remove fuel tank no 3 and set it as...

Page 199: ...perate the engine to see if the problem has been cor rected Fuse Replacement Some Models A 0 25 ampere fuse protects fuel level sensor cir cuitry Remove seat to gain access FUEL LEVEL SENSOR SCREWS Al...

Page 200: ...05 76 MMC2005 001_05A FM SECTION 05 ENGINE PREPARATION FUEL PUMP All Models except SDI A32C1LS To carburetors Engine impulse From fuel tank...

Page 201: ...same procedure at the outlet nipple This time the outlet valve should hold with pres sure and also under vacuum NOTE Plug remaining outlet with finger while checking outlet valve Check impulse diaphr...

Page 202: ...MMC2005 001_05A FM SECTION 05 ENGINE PREPARATION 593 HO AND 793 HO ENGINE TYPES EXHAUST SYSTEM A33C24S 1 2 1 1 3 5 6 7 4 8 8 9 593 engines 22 N m 16 bf ft 593 HO 593 SDI and 793 HO engines 10 N m 89 l...

Page 203: ...both of its notches aligned with Y manifold protru sions If the gaskets are damaged replace them NOTE No RTV sealant required on doughnut shaped exhaust gaskets Install all exhaust springs MANIFOLD R...

Page 204: ...PREPARATION A33C2MA TYPICAL Removal Remove tuned pipe no 2 Remove springs no 8 retaining the muffler no 9 Remove the muffler Inspection Check the muffler for cracks or other damages Installation For...

Page 205: ...PARATION MMC2005 001_05A FM 05 81 ENGINE SYSTEM A33C25S Loctite 243 1 3 Loctite 243 35 N m 26 lbf ft 4 48 N m 35 lbf ft 5 4 593 engines 1 Loctite 243 Loctite 243 48 N m 35 lbf ft 50 N m 37 lbf ft 7 5...

Page 206: ...ollowing Remove windshield Remove the RH side panel From the Front of Vehicle Remove tuned pipe refer to EXHAUST SYSTEM A33C26A On right side of vehicle do the following Remove muffler Drain coolant r...

Page 207: ...ool box belt guard belt drive drive pulley refer to DRIVE PULLEY air intake silencer unplug ATS Air Temperature Sensor connector Separate carburetors or throttle body from engine Unplug coolant hose l...

Page 208: ...tat housing A33C2EA 1 1 Remove this hose Disconnect temperature sensor connectors A33C2FA Remove spark plugs and install spark plug lift ring P N 529 035 830 at the farthest spark plug hole 1 A33C18A...

Page 209: ...ngine support Replace them if brittle cracked or otherwise dam aged INSTALLATION To install engine in vehicle reverse the removal procedure However pay attention to the follow ing Install engine suppo...

Page 210: ...Bond 5 5 N m 49 lbf in 9 N m 80 lbf in 21 29 N m 21 lbf ft 20 7 5 N m 66 lbf in 29 N m 21 lbf ft 21 21 29 N m 21 lbf ft Sealing compound Drei Bond 1 2 14 5 5 N m 49 lbf in 5 4 7 10 12 13 8 6 11 9 3 Lo...

Page 211: ...in 5 5 N m 49 lbf in Sealing compound Drei Bond 29 N m 21 lbf ft 21 7 5 N m 66 lbf in 1 40 N m 30 lbf ft 22 40 N m 30 lbf ft 23 25 25 26 27 Engine oil 9 3 11 8 Sealing compound Drei Bond 14 6 9 N m 8...

Page 212: ...o 1 cylinder head no 2 cylinder s no 3 piston s piston ring s rewind starter oil pump water pump magneto flywheel RAVE valve s reed valve s CLEANING Discard all gaskets and O rings Clean all metal com...

Page 213: ...s or cleaners are required when cleaning the valve NOTE Make sure hoses are not kinked or dam aged Boring Precaution All Models In its stock configuration the RAVE valve guillo tine has a minimum of 0...

Page 214: ...lotine no 9 from the valve piston no 10 than remove the gasket no 11 2 A32C99A 3 1 TYPICAL 1 Guillotine 2 Gasket 3 Valve piston Remove spring no 12 retaining bellows no 13 to valve piston 1 A32C9AA 3...

Page 215: ...re sensor connector All Engine Types Unplug coolant hose from upper thermostat hous ing no 20 Unscrew all cylinder head cover screws no 21 Cylinder Head All Engine Types except 793 HO Remove the cylin...

Page 216: ...ve is the same that con tains new cageless bearing Insert piston pin puller P N 529 035 503 making sure it sits squarely against piston A02C2AA 1 TYPICAL 1 Properly seated all around Install sleeve th...

Page 217: ...on from connecting rod Install locating sleeve Then push needle bearings along with thrust washers and sleeve 1 A02C2FA 2 TYPICAL 1 Locating sleeve 2 Sleeve INSPECTION Cylinder Head Cover Cylinder Hea...

Page 218: ...m Apply sealing compound Drei Bond P N 420 297 906 in the groove of valve base and in the piston valve groove then install bellows Install RAVE valve with its mention top as illus trated in the follow...

Page 219: ...Exhaust Install shouldered sleeve A02C2IA TYPICAL SHOULDERED SLEEVE INSTALLATION Install piston pin puller and turn handle until piston pin is correctly positioned in piston A02C2JA TYPICAL All Models...

Page 220: ...usher position circlip perpen dicularly to the support axis A32B0BA With the other end of the pusher push circlip into the support groove A32B0CA A32B0DA 1 1 Groove A32B0EA CIRCLIP READY TO BE INSTALL...

Page 221: ...proper thickness Failure to do so may cause detona tion and severe engine damage Before inserting piston in cylinder lubricate the cylinder with new injection oil or equivalent Install cylinders Do n...

Page 222: ...r valve body Check distance from blade stopper outer edge and distance from center of reed valve block A06C36A A A TYPICAL A 18 7 0 0 75 mm 736 0 030 in Bent blade stopper as required to obtain the pr...

Page 223: ...f in Loctite 243 Injection oil Petamo grease Loctite 243 11 N m 97 lbf in Loctite 243 9 N m 80 lbf in 4 Loctite 243 125 N m 92 lbf ft Loctite 243 Petamo grease Isoflex grease Antiseize lubricant Antis...

Page 224: ...Drei Bond 11 N m 97 lbf in Loctite 243 Injection oil Petamo grease 5 5 N m 49 lbf in Loctite 243 11 N m 97 lbf in Loctite 243 9 N m 80 lbf in 4 Loctite 243 125 N m 92 lbf ft Loctite 243 Petamo grease...

Page 225: ...593 SDI and 793 HO Engine Types Remove oil seal cover no 1 A33C2OA TYPICAL Crankshaft Bearing To remove bearings no 2 and no 3 from crank shaft no 4 install half rings P N 420 977 479 and puller ring...

Page 226: ...removal 1 A32CB4A 1 Bearing separator INSPECTION Refer to LEAK TEST AND ENGINE DIMENSIONS MEASUREMENT ASSEMBLY Coat lip of all seals with Petamo grease P N 420 899 271 Crankshaft Bearing CAUTION Never...

Page 227: ...ing several times to obtain an even heat ing process NOTE Normally it takes approximately 10 min utes to heat up a bearing so in the event of replac ing bearing it s recommended to start the bearing h...

Page 228: ...upport plate P N 529 035 976 with appro priate distance gauge refer to following table DISTANCE GAUGE P N APPLICATION 529 035 966 593 engine 529 035 967 593 HO 529 035 968 593 SDI and 793 HO A32CBCA 2...

Page 229: ...grease between outside bearing race and half crankcase NOTE The 50 g tube corresponds to 50 cc of grease Put 50 to 55 mL of grease in a syringe CAUTION Do not exceed the recommended amount of grease...

Page 230: ...A32C0DA 1 Oil bath Crankcase Assembly IMPORTANT The total assembly sequence in cluding sealing compound spreading screwing and torquing of bolts according to the proper sequence must be performed with...

Page 231: ...st screw 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 11 A32C3FA B A 9 14 4 1 16 5 8 18 12 10 13 2 3 15 6 7 17 1...

Page 232: ...to 34 kPa 5 PSI Do not exceed this pressure Engine must stand this pressure during 3 min utes If pressure drops before 3 minutes check tester kit by spraying a soapy solution on pump cylinder all plu...

Page 233: ...ir bubbles or oil column going toward pump It indicates defective check valve in injec tion nipples Remove cooling system cap Check for air bubbles in antifreeze It indicates de fective cylinder head...

Page 234: ...ramic seal Leaks can be also on oil pump side Check mounting area for leaks A32C1GB 1 TYPICAL 1 Check mounting area If leak still persists it indicates a defective cast ing somewhere in engine Disasse...

Page 235: ...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 CYLINDER AND MAG CYLINDER SE...

Page 236: ...t can not be rebored NOTE Be sure to restore the chamfer around all cylinder sleeve port openings A A33C1BA 1 1 Below the intake port A 16 mm 5 8 in from top CYLINDER OUT OF ROUND ENGINE TYPE MAXIMUM...

Page 237: ...0 of gasoline and injection oil F00B0BA 1 1 Graduated burette 0 50 cc Open burette valve to fill its tip Add liquid in burette until level reaches 0 cc Inject the burette content through the spark plu...

Page 238: ...CHAMBER VOLUME cc for every 0 1 mm 004 in of gasket thickness 593 HO 0 41 793 HO 0 53 USED PISTON MEASUREMENT Note the measurement on the piston dome F00D0EA 2 1 1 Piston dome 2 Piston measurement Usi...

Page 239: ...asuring Position the dial bore gauge at 16 mm 5 8 in be low cylinder top edge F01D0KA 1 A 1 Measuring perpendicularly 90 to piston pin axis A 16 mm 5 8 in Read the measurement on the cylinder bore gau...

Page 240: ...cator Measuring in crankcase First check deflection with crankshaft in crankcase If deflection exceeds the specified tol erance recheck deflection using V shaped blocks to determine the defective part...

Page 241: ...ight If the distance exceeds specified tolerance repair or replace the crankshaft A01C0SA TYPICAL CRANKSHAFT END PLAY End play is not adjustable but it should be be tween 0 10 0 30 mm 004 012 in CHECK...

Page 242: ...ON 05 ENGINE PREPARATION MAGNETO SYSTEM A33E0MT To regulator Silastic 732 Loctite 243 22 N m 195 lbf in Loctite 243 125 N m 92 lbf ft 1 Air sensor DPM To main harness To main harness 2 Loctite 648 7 3...

Page 243: ...ARATION MMC2005 001_05A FM 05 119 480 W on REV Series A32C8JT 125 N m 92 lbf ft 9 N m 80 lbf in 6 Loctite 243 Frame harness Voltage regulator Loctite 5910 5 4 8 N m 71 lbf in 3 2 Loctite 243 21 N m 15...

Page 244: ...onents in a non ferrous metal cleaner CAUTION Clean stator and magneto flywheel using only a clean cloth DISASSEMBLY Magneto Flywheel To gain access to magneto flywheel no 3 assem bly remove the follo...

Page 245: ...eck trigger coils no 5 before changing them Refer to OVERVIEW section To replace the trigger coil s remove the following magneto flywheel no 3 Air intake silencer to allow an access to the trig ger co...

Page 246: ...n tighten nut no 1 to 125 N m 92 lbf ft for liquid cooled engines At reassembly coat all electric connections except Deutsch housings waterproof housing with sili cone dielectric grease P N 293 550 00...

Page 247: ...SECTION 05 ENGINE PREPARATION MMC2005 001_05A FM 05 123 OIL INJECTION SYSTEM A33D1CS 1 Loctite 648 Recommended injection oil 5 N m 44 lbf in 2 3 4 5 6 7 8 9 10 11 12 1 2 Loctite 648 1 14 13...

Page 248: ...ction oil 2 3 1 CAUTION The BOMBARDIER Formula XP S II synthetic injection oil is specially formulated and tested for the severe re quirement of these engines Use of any other brand two stroke oil may...

Page 249: ...ponents in a non ferrous metal cleaner DISASSEMBLY NOTE Some oil pump components are not avail able as single parts Injection Oil Reservoir Empty injection oil reservoir no 6 by siphoning injection oi...

Page 250: ...o remove oil or dirt Heat check valve no 2 then pull it out of crankcase ASSEMBLY NOTE During installation always check for spring clips no 1 tightness Injection Oil Reservoir For installation reverse...

Page 251: ...adjusting the pump make sure throttle cable adjustment is completed and engine is stopped Stretch the adjusting cable through a maximum force of 32 N m 7 2 lbf ft NOTE It is better to have two person...

Page 252: ...engine and run at idle while holding the pump lever in fully open po sition Oil columns must advance into small oil lines If not remove pump assembly and check the pump gear and drive shaft if applica...

Page 253: ...SECTION 05 ENGINE PREPARATION MMC2005 001_05A FM 05 129 LIQUID COOLING SYSTEM All Models except Summit A33C1GT Loctite 592 4 7 6 3 5 2 1 8 2 Loctite 592 10 10 13 12 14 11...

Page 254: ...05 130 MMC2005 001_05A FM SECTION 05 ENGINE PREPARATION All Summit Models A33C30S 5 1 6 12 2 11 8 2 Loctite 592 10 13 10 14...

Page 255: ...der and Plug Apply Loctite 592 P N 293 800 018 thread sealant on sender no 3 and plug no 4 to avoid leaks Pressure Cap Check if the cap no 1 pressurizes the system for 3 minutes If not install a new 9...

Page 256: ...eck thermostat put in water and heat water Thermostat should start to open when water tem perature reaches the following degree ENGINE TEMPERATURE All 42 C 108 F It will be almost fully open at 50 C 1...

Page 257: ...engine Refill up to line while engine is idling until rear radiators are warm to the touch about 4 to 5 minutes Always monitor coolant level while filling tank to avoid emptying Install pressure cap...

Page 258: ...MMC2005 001_05A FM SECTION 05 ENGINE PREPARATION REWIND STARTER A33C2ZS 1 Molykote PG 54 7 5 N m 66 lbf in 9 N m 80 lbf in 2 3 4 5 6 7 8 9 10 11 Molykote PG 54 Molykote PG 54 Molykote PG 54 Molykote...

Page 259: ...stopper and stay against it If not check for proper 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...

Page 260: ...ng Molykote PG 54 P N 420 899 763 Otherwise rewind starter component life will be shortened and or rewind starter will not op erate properly under very cold temperatures Lubricate spring assembly and...

Page 261: ...ousing making sure 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...

Page 262: ...ent Install a new push nut no 5 INSTALLATION Fuse rope end with a lit match Thread starter rope no 1 through rope guide when applicable A03C0VA TYPICAL Reinstall rewind starter assembly on engine Prio...

Page 263: ...06 17 INSTALLATION 06 21 DRIVE PULLEY ADJUSTMENT 06 21 KIT P N 486 400 003 TRA III WEIGHT SET UP FOR PIN 06 23 TRA SPRINGS CHART 06 28 EFFECTS OF THE DRIVEN PULLEY SPRING 06 30 HPV 27 VSA CLUTCH SPRIN...

Page 264: ...06 58 CHAINCASE GEARING 06 59 MXZ 440 GEAR RATIO VS SPEED 06 61 CHAINCASE GEARS AND CHAINS 06 62 TRANSMISSION TUNING TEST SHEET 06 64 RACERS LOG 06 65 HYDRAULIC BRAKE 06 66 BRAKE FLUID TYPE 06 67 CALI...

Page 265: ...s dictated by the load on the drive axle The speed diagram illustrates what the goal of good clutch calibration is POWER CURVES MILDLY TUNED VS RACE TUNED In the speed diagram the inclined line labell...

Page 266: ...s true be cause of the relation of the force to the square of the engine speed Also the radius from the axis of rotation to the center of mass of the counter weights increases as the roller is allowed...

Page 267: ...s the peak RPM of the engine down to 6800 RPM Curve C illustrates the effect of using three 16 gram roller pins Again the additional weight has little effect on the engagement RPM but further reduces...

Page 268: ...CTION 06 DRIVE SYSTEM Drive Clutch Roller Pins 10 000 9 000 8 000 7 000 6 000 5 000 4 000 3 000 2 000 1 000 10 20 30 40 50 60 70 80 90 100 A01D0XS A B C RPM MPH A 10 gram roller pins B 14 gram roller...

Page 269: ...e drive belt at each diameter of the pulley As discussed before the centrifugal force gener ated by the lever arm assembly increases at higher ratios This is why the ramp profile is much steep er at t...

Page 270: ...PM with each number On the snow mobile however depending on the operating con ditions a change of one adjuster position may not show up on the tachometer but the shift speed of the pulley will have ch...

Page 271: ...SECTION 06 DRIVE SYSTEM MMC2005 001_06A FM 06 9 RAMP CHARACTERISTICS A01D2IS Taller ramp Higher engagement RPM Steeper angle Higher shift RPM Shallower angle More RPM at lower MPH slower shift...

Page 272: ...gs kept constant When the engine pulley is in its highest ratio position the spring will be compressed to 41 mm 1 6 in The pressure the spring applies at this length will de termine the RPM required t...

Page 273: ...rive Clutch Spring Effect at Engagement LOAD AT 74 mm 2 9 in LOAD AT 41 mm 1 6 in A 311 N 70 lb 1157 N 260 lb B 712 N 160 lb 1201 N 270 lb 10 000 9 000 8 000 7 000 6 000 5 000 4 000 3 000 2 000 1 000...

Page 274: ...Drive Clutch Spring Effect at Top Speed 10 000 9 000 8 000 7 000 6 000 5 000 4 000 3 000 2 000 1 000 10 20 30 40 50 60 70 80 90 100 MPH B A A01D1VS RPM LOAD AT 74 mm 2 9 in LOAD AT 41 mm 1 6 in A 311...

Page 275: ...improved efficiency belt life is also extended The TRA III clutch must be matched with a VSA type driven clutch and belt to achieve maximum performance TUNING COMPONENTS As mentioned earlier few tunin...

Page 276: ...g for replacement part Most parts of TRA III are not interchangeable with those of the TRA A33D16T 95 N m 70 lbf ft 31 Loctite 271 30 10 N m 89 lbf in 28 25 26 27 22 21 20 19 16 N m 142 lbf in For 793...

Page 277: ...er Always tight en puller by hand to ensure that the drive pulley has the same type of threads metric vs imperi al prior to fully tightening To Remove Drive Pulley Ass y Retain drive pulley with clutc...

Page 278: ...1 Hold slider shoes 2 Lift one housing at a time NOTE To ease disassembly forks P N 529 005 500 should be used to hold slider shoes prior to removing governor cup 19 Spring Cover Ass y It is pushed b...

Page 279: ...quired CAUTION Ensure rollers are in good condition Replace as required 9 12 Fitting Bolt Ass y and Flanged Bushing Check for wear replace as required 24 25 O Ring and Slider Shoe Check if O rings are...

Page 280: ...iffer ent weights for calibration purpose Refer to TECH NICAL DATA 21 22 23 Screw Dowel Tube and Ramp Insert dowel tube from chamfered side Make sure ramp is centered on dowel tube 1 Chamfered side Po...

Page 281: ...that cotter pins are on the same side Torque nuts to 12 N m 106 lbf in CAUTION Lever ass y and rollers must move easily after installation 5 6 18 19 Fixed Half Sliding Half Spring Spring Cover and Scr...

Page 282: ...e in each slider shoe is vertical to prop erly slide in guides CAUTION Make sure O rings are installed on slider shoes and that grooves are positioned vertically Install fork P N 529 005 500 into slid...

Page 283: ...efined RPM Fac tors such as ambient temperature altitude or sur face condition may vary this critical engine RPM thus affecting snowmobile efficiency This adjustable drive pulley allows setting maxi m...

Page 284: ...00 RPM and higher numbers increase it in steps of 200 RPM Example Calibration screw is set at position 3 and is changed to position 5 So maximum engine RPM is increased by about 400 RPM To Adjust Just...

Page 285: ...mm 417 222 595 12 4 1 Set screw 6 mm 206 260 699 0 73 1 Set screw 12 mm 206 261 299 1 68 1 A32D3B4 15 54 GRAMS SET UP PART DESCRIPTION PART NUMBER WEIGHT G QTY Pin 35 75 mm 417 222 595 12 4 1 Set scre...

Page 286: ...417 222 595 12 4 1 Set screw 20 mm 206 262 099 3 02 1 Set screw 6 mm 206 260 699 0 73 2 A32D3K4 16 94 GRAMS SET UP PART DESCRIPTION PART NUMBER WEIGHT G QTY Pin 35 75 mm 417 222 595 12 4 1 Set screw 2...

Page 287: ...Set screw 12 mm 206 261 299 1 68 1 A32D3Q4 18 90 GRAMS SET UP PART DESCRIPTION PART NUMBER WEIGHT G QTY Pin 35 75 mm 417 222 595 12 4 1 Set screw 6 mm 206 260 699 0 73 2 Slug 14 mm 486 400 004 5 044 1...

Page 288: ...N 06 DRIVE SYSTEM TRA III RAMP PROFILES 414 A01D3BA 417 222 546 419 A01D3CA 417 222 556 410 A01D3DA 417 222 596 411 A01D3EA 417 222 514 412 A01D3FA 417 222 515 413 A01D3GA 417 222 508 415 A01D3HA 417...

Page 289: ...SECTION 06 DRIVE SYSTEM MMC2005 001_06A FM 06 27 422 A01D3JA 417 222 562 427 A01D3KA 417 222 677...

Page 290: ...5 41 0 218 0 213 102 4 0 100 260 414 742 100 YELLOW GREEN 5 72 5 94 0 225 0 234 96 3 8 100 290 414 818 000 YELLOW BLUE 5 94 0 234 97 3 8 100 320 414 678 400 YELLOW PURPLE 6 35 6 17 0 250 0 243 93 3 7...

Page 291: ...0 PINK PINK 5 54 0 218 143 5 6 230 380 414 991 400 PINK WHITE OLD RED WHITE 5 94 5 72 0 234 0 225 128 134 5 0 5 3 230 390 415 019 600 GREEN 5 94 0 234 126 5 0 230 410 415 019 700 RED 5 94 0 234 120 4...

Page 292: ...is preload tension will vary from 4 kg 9 Ib to 7 5 kg 17 Ib on models equipped with the TRA clutch The preload figure given in our specifications is quoted in kg Ib of force for each machine not in in...

Page 293: ...recheck torsional pre load after ad justing By experimenting with them you may find a more efficient combination of minimum side pressure yet adequate back shifting for your particular rac ing applic...

Page 294: ...hile the driven pulley signals the downshift largely because of the effect of the cam The standard factory cam will probably work well for most woods type cross countries while a smaller angled cam ma...

Page 295: ...7 126 580 VSA 50 47 Anod 860 427 600 56 50 417 126 748 RER 47 Anod 860 427 500 56 47 417 126 749 RER 50 Anod 417 126 740 27 53 50 Anod 860 427 400 56 44 417 126 750 RER 48 44 Anod 417 126 741 27 53 47...

Page 296: ...m can be used in place of a Formula RER or VSA cam providing the reverse function has been disabled The Formula RER and VSA cams are interchangeable The difference be tween the two types is the number...

Page 297: ...VE SYSTEM MMC2005 001_06A FM 06 35 DRIVEN PULLEY 0 FORMULA VSA 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 lubricant Loctite 243...

Page 298: ...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 During break in peri...

Page 299: ...ize lubricant P N 293 800 070 on the countershaft before final pulley installation Should installation procedure be required refer to BRAKE then look for BRAKE DISC AND COUN TERSHAFT BEARING ADJUSTMEN...

Page 300: ...llustration 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 AND ALIGNMENT and D...

Page 301: ...SECTION 06 DRIVE SYSTEM MMC2005 001_06A FM 06 39 HPV27 VSA A32D1JS 6 7 10 1 22 N m 16 lbf ft 11 5 4 8 9 12 3 Red Black Anti seize lubricant Loctite 243 Anti seize lubricant 13...

Page 302: ...9 Large Bushing and Small Bushing During break in period about 10 hours of use te flon from bushing moves to cam or shaft surface A teflon over teflon running condition occurs lead ing to low friction...

Page 303: ...lways 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 COUNTER SHA...

Page 304: ...1 130032 1 Ring Retaining Basic Ext 1 500 Yes 2 285275 1 Spider 38T 10 75 Mach No 3 460079 2 Roller Clutch Yes 4 150151 2 Washer Thrust Yes 5 130059 2 Ring Retaining E Ring Ext 375 Yes 6 430063 1 Was...

Page 305: ...one the angle is constantly changing The angle will remain constant once the shift pattern passes through the transition zone A32D32S Angles constantly change from 1st to 2nd angle on cam through enti...

Page 306: ...rive clutch ramp and weight combination the re sult should be a fast efficient cool running clutch setup Relationship Between Drive Clutch Ramps Weight And Spring In Maintaining Operating RPM The driv...

Page 307: ...itial starting ratio will be too high re sulting in performance loss This is due to the belt rising too high in the drive clutch sheaves upon engagement Belt riding below top of sheave Not Enough Belt...

Page 308: ...ation of the skip tooth on the spider assembly for installation The skip tooth is marked with an X on the spider that should match the skip tooth found on the clutch shaft The X should also line up wi...

Page 309: ...e selection Starting angle will effect how fast the clutch opens from a dead stop Ex 70 44 46 a 70 starting angle will shift ex tremely fast If the sled will not pull RPM until farther out in the shif...

Page 310: ...pots on ramps Worn out buttons in the clutch towers Worn out bushing on moveable clutch sheave and clutch cover If the weights are too heavy or spring rate too low the engine RPM will be low and the d...

Page 311: ...420400 60 38 46 60 36 46 420401 56 40 46 56 38 46 420403 60 44 46 60 42 46 420402 70 40 46 70 38 46 420404 66 40 46 66 38 46 420405 54 38 46 E 54 40 46 E 420406 54 40 46 E 54 42 46 E 420407 58 38 46...

Page 312: ...6 420529 64 44 46 64 40 46 420530 58 44 46 E 420531 46 34 F 48 34 F 420532 64 48 46 54 44 F 420533 66 44 56 54 42 F 420534 68 44 46 54 42 F 420535 54 34 46 64 42 46 420536 54 34 46 48 34 F 420537 66 4...

Page 313: ...pulley fixed half edge measured between pulleys Y Distance between straight bar and drive pul ley fixed half edge measured at the end of straight bar Z Pulley distance is not adjustable on the REV Se...

Page 314: ...ecifications refer to DRIVE BELT to adjust drive belt deflection CAUTION This section deals mainly with ad justment procedures For complete assembly requirements refer to the proper ENGINE or TRANSMIS...

Page 315: ...he more important changes in drive belts has been the introduction of Kevlar Fiber B to re place fiberglass or polyester cord in the tensile lay er of modern drive belts This material is much stronger...

Page 316: ...n cold weather than earlier belts 1 Use Ski Doo tool P N 414 348 200 Proper belt deflection and alignment are extreme ly important Included is a page on proper align ment procedures and deflection mea...

Page 317: ...ach vehicle tether cord to your clothing Stand aside of vehicle then start engine Release parking brake Vehicle must not creep when engine is idling Otherwise make sure that idle speed is as specified...

Page 318: ...rformance the belt height must be adjusted according to specifica tions shown in the accompanying chart 1 Flush Adjustment Before adjusting the belt height ensure that a good condition proper belt ref...

Page 319: ...turn adjustment ring counterclockwise and tighten the screws To raise belt in driven pulley turn ring clockwise and tighten the adjustment screws DRIVEN PULLEY NOTCHES Turn the adjustment ring up to...

Page 320: ...EY DISTANCE AND ALIGNMENT To obtain maximum vehicle performance the belt tension must be adjusted according to specifica tions shown in the accompanying chart FOR REFERENCE ONLY To Check Tension Posit...

Page 321: ...ere geared to attain a full shift under av erage conditions and then the vehicle were run on a perfectly smooth frozen surface it would easily shift out to its geared top speed Since the drag is so lo...

Page 322: ...tch surfaces If it has shifted the belt all the way to the top you may be able to pull one or two more teeth on the top sprocket Experiment If it is down about 1 2 in or more from the top you could co...

Page 323: ...3 1 79 74 101 112 23 43 1 87 74 96 107 22 43 1 95 74 92 103 21 43 2 05 74 88 98 20 43 2 15 74 84 93 19 43 2 26 72 80 89 27 44 1 63 76 111 123 26 44 1 69 76 107 118 25 44 1 76 76 103 114 24 44 1 83 76...

Page 324: ...04 085 300 27 504 148 400 BOTTOM 40 504 089 000 41 42 43 504 148 500 486 104 600 44 504 085 500 45 504 152 379 486 104 700 45 504 152 518 clutch gear 46 47 486 104 800 15 WIDE OF TEETH STEEL POWDER AL...

Page 325: ...RPM Pin weight and ramp angle are interrelated but can be varied to achieve certain results A 16 5 gram pin and the adjuster set in 5 may produce the same full throttle RPM as a 14 5 gram pin with the...

Page 326: ...T 3 TEST 4 TEST 5 Cam angle Spring color code Spring preload lb Spring position ex A 4 Chaincase gearing Lever arm and pin type Weight each assembly Ramp identification No of set screws added if used...

Page 327: ...notes Lever arm pin type Pin weight Ramp identification TRA adjuster position Spring identification Spring pressure engagement Spring pressure full shift Engagement RPM Shift RPM Drive belt identifica...

Page 328: ..._06A FM SECTION 06 DRIVE SYSTEM BRAKE 0 HYDRAULIC BRAKE A33D0RS 22 N m 16 lbf ft Loctite 243 2 8 N m 71 lbf in 4 3 6 Anti seize lubricant 42 N m 31 lbf ft 7 1 8 14 N m 10 lbf ft 24 N m 17 lbf ft Break...

Page 329: ...from the brake disc Installation Install caliper on the brake disc Install locking tab BRAKE PADS REPLACEMENT Brake pads must be replaced when lining is 1 mm 1 32 in thick or less CAUTION Brake pads m...

Page 330: ...KE DISC REMOVAL Brake disc can be removed without removing chain case Proceed as follows Remove belt guard belt and driven pulley Remove air silencer Loosen the carburetor Unbolt bearing support no 2...

Page 331: ...one side than from the other Install disc with the longer exceeding portion toward driven pulley 7 Brake Pad After brake pads installation brake disc must be centered in caliper Apply brake then check...

Page 332: ...se on bleeder Route this hose to a con tainer Open bleeder Pump brake lever until no air escapes from hose Close bleeder 1 Open bleeder 2 Clear hose to catch used brake fluid 5 Brake Light Switch Ther...

Page 333: ...m 62 lbf in Loctite 243 42 N m 31 lbf ft Sealed side Stamped end this side Synthetic grease Loctite 271 10 Synthetic chaincase oil 9 42 N m 31 lbf ft 22 23 7 19 12 11 1 13 2 16 42 N m 31 lbf ft 14 24...

Page 334: ...TYPICAL 3 Drive axle 4 Suspension front arm upper axle Pry out drive axle oil seal no 19 from chaincase Pull chaincase from drive axle and countershaft Using 2 large prybars inserted between chaincas...

Page 335: ...wise 1 New 2 Fold cotter pin over castellated nut flats only 18 Circlip CAUTION It is of the utmost importance to in stall the circlip otherwise damage to the chain case components may occur DRIVE CHA...

Page 336: ...CAL 1 Dipstick 2 Oil level 3 Level between marks 4 Magnet NOTE Chaincase must be in its proper position when checking oil level ADJUSTMENT Pulley Alignment Refer to PULLEY DISTANCE AND ALIGNMENT Track...

Page 337: ...SECTION 06 DRIVE SYSTEM MMC2005 001_06A FM 06 75 DRIVE AXLE 0 REV Series Models A32D1KS 15 N m 133 lbf in Synthetic grease 1 2 3 11 10 9 8 7 5 6 6 5 4 Synthetic grease...

Page 338: ...place of center idler wheel axle 1 Rod Remove speed sensor no 11 outer flange no 10 and circlip no 9 from left side 1 Circlip Apply parking brake Remove chain and sprockets then circlip from right si...

Page 339: ...C 274 0 mm 10 787 in D 376 5 mm 14 822 in Ensure to align indexing marks of each sprocket when assembling TYPICAL 1 Indexing marks aligned The maximum desynchronization for the sprockets is 1 5 mm 1 1...

Page 340: ...he sprocket The bearing no 1 must have its shield facing right side cover LUBRICATION Lubricate end housing bearing with synthetic grease P N 413 711 500 ADJUSTMENT Sprocket Track Alignment CAUTION Do...

Page 341: ...ck respect rotation direction indicated by an arrow on track thread Check sprocket track alignment as described in DRIVE AXLE ADJUSTMENT Track Tension and Alignment Track tension and alignment are int...

Page 342: ...ten the adjustment screw on side where the slider shoe is the farthest from the track insert guides 1 Guides 2 Slider shoes 3 Tighten on this side Restart engine rotate track slowly and recheck alignm...

Page 343: ...SYSTEM MMC2005 001_06A FM 06 81 Re open installer then position cleat tabs on open end of tool and squeeze tabs until they are indented in rubber TYPICAL 1 First step 2 Second step to push tabs into r...

Page 344: ...7 2005 MX Z X 440 INFORMATION TABLE OF CONTENTS 0 2005 MX Z X 440 LC REV 07 02 ENGINE 07 02 IGNITION SYSTEM 07 02 HOLESHOT BUTTON 07 02 DRIVETRAIN 07 02 TRACK TRACTION 07 03 SC 4 REAR SUSPENSION 07 03...

Page 345: ...urve B is pro grammed for racing using 104 octane fuel and whenever the Holeshot button is NOT pushed the engine runs on this curve Curve A is referred to as the default curve and is used primarily wh...

Page 346: ...torsional load on the drive sprockets and shaft ISR rules prohibit an optional track in the stock 440 class this year Track changes may be done in the Mod Classes the recommended track is similar to t...

Page 347: ...239 948 Gray 1 00 38 00 0 039 1 496 COOLING Cooling system type Thermostat opening temp Cap opening pressure C kPa F PSI Liquid 42 90 107 60 13 05 ENGINE Piston ring end gap New min New max Wear limit...

Page 348: ...O MAG Identification number Carburetor part number Jet needle Clip position no Needle jet Throttle slide cut away Needle valve and seat Idle throttle slide position Main jet Pilot Jet Idle air mixture...

Page 349: ...nkcase nuts screws M8 Crankcase engine sup studs Crankcase engine sup nuts Cylinder head nuts screws Water pump screws Magneto ring nut Exhaust manifold screws Intake manifold screws Magneto flywheel...

Page 350: ...lley spring color Driven pulley spring rate Driven pulley cam angle Cam part number Pulleys center distance Z distance Without torque rod preload X offset Y X difference mm kg lb deg mm mm mm mm in 0...

Page 351: ...ar spring part number mm mm mm in in in RH LH SC 4 121 369 00 369 00 8 x 141 mm 5 55 4 x 180 mm 7 09 Stopper strap 4 1 1 High Pressure gas H P G Racing Clicker 503 190 582 503 191 019 Variable Spring...

Page 352: ...andle color Hood material Hood color Side panels material Side panels color Windshield material Windshield color Front bumper material Front bumper color Rear bumper material Rear bumper color Suspens...

Page 353: ...125 1 2 0 STANDARD OPTIONAL EQUIPMENT Tachometer Speedometer Mirrors kit Quick ajustment kit STD STD OPT OPT 861 784 500 860 306 500 Bridge fastener plastic ski Bridge fastener plastic ski Plastic sk...

Page 354: ...SEMBLY 08 09 INSPECTION 08 11 ASSEMBLY 08 11 BOTTOM END 08 18 CLEANING 08 20 DISASSEMBLY 08 20 INSPECTION 08 21 ASSEMBLY 08 21 BREAK IN 08 26 OIL INJECTION SYSTEM 08 27 GENERAL 08 28 OIL TYPE 08 28 OI...

Page 355: ...DRIVE PULLEY 08 39 BOMBARDIER LITE 08 39 GENERAL 08 40 REMOVAL 08 40 DISASSEMBLY 08 40 CLEANING 08 41 INSPECTION 08 41 ASSEMBLY 08 41 INSTALLATION 08 41 IGNITION TIMING 08 43 VERIFYING MAGNETO FLYWHEE...

Page 356: ...rm SC 3 1 503 189 861 Bushing Pivot Arm SC 3 2 503 190 232 Idler Wheel Rear 180 mm SC 3 2 503 182 900 Spacer Aluminium Short SC 3 2 503 156 000 Spacer Aluminium Long SC 3 1 503 167 900 Axle Rear SC 3...

Page 357: ...265 Deflector Support RH 1 517 303 266 Deflector Support LH 1 250 000 172 Screw Socket Head M6 x 16 4 515 175 817 Terminal Housing Male 8 Circuits 1 515 175 332 Tubing 1 4 X 1200mm 515 175 662 Termina...

Page 358: ...08A FM 08 5 377 AND 552 ENGINE TYPES ENGINE REMOVAL AND INSTALLATION 377 and 552 Engine Types A32C6JT 37 N m 27 lbf ft 37 N m 27 lbf ft 39 N m 29 lbf ft RTV sealant RTV sealant 377 engine 552 engine 2...

Page 359: ...silencer and carburetors 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 re...

Page 360: ...MX Z 550 AND 380 FC MMC2005 001_08A FM 08 7 TOP END 377 Engine Type A03C3WS 22 N m 16 lbf ft 2 2 1 3 4 5 7 5 6 8 9 10 7 Grease 22 N m 16 lbf ft 22 N m 16 lbf ft 21 N m 15 lbf ft 21 N m 15 lbf ft Anti...

Page 361: ...08 8 MMC2005 001_08A FM SECTION 08 2005 MX Z 550 AND 380 FC 552 Engine Types 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 11 6 6...

Page 362: ...letters AUS and arrow on the piston dome must be visible after cleaning Clean the piston ring grooves with a groove cleaner tool or with a piece of broken ring DISASSEMBLY Remove top fan cowl intake...

Page 363: ...ert piston pin puller P N 529 035 503 making sure it sits squarely against piston A02C2AA 1 TYPICAL 1 Properly seated all around Install sleeve then shouldered sleeve over puller rod 1 A02C2BA 2 TYPIC...

Page 364: ...needles and thrust washers along with locating sleeve INSPECTION Refer to ENGINE DIMENSIONS MEASUREMENT ASSEMBLY 552 Engine When reinstalling original needle bearings make sure that 34 needles are ins...

Page 365: ...ver connecting rod with the letters AUS over an arrow on the piston dome facing in the direction of exhaust port A01C01A AUS 1 1 Exhaust Install shouldered sleeve A02C2IA TYPICAL SHOULDERED SLEEVE INS...

Page 366: ...t cannot be installed as described above To minimize the effect of acceleration forces on circlip install each circlip so the circlip break is at 6 o clock as illustrated Use piston circlip installer...

Page 367: ...hammer Circlip will move from tool groove to piston groove 1 2 A01C02A 1 Piston notch 2 Circlip break at 6 o clock CAUTION Circlips must not move freely in the groove after installation If so replace...

Page 368: ...abilities CAUTION Circlips must not move freely after installation if so replace them Clean cylinders and crankcase mating surfaces with Loctite Chisel P N 413 708 500 Coat crankcase mating surface wi...

Page 369: ...use exhaust manifold to align cylinders Position distance nuts no 2 as shown below A03C1XA 2 1 1 Exhaust 2 Distance nuts Cross torque cylinder head nuts no 1 and no 2 to 22 N m 16 lbf ft torque each c...

Page 370: ...per inner edge and distance from center of reed valve block A06C36A A A TYPICAL A 14 75 0 0 75 mm 580 0 030 in Bent blade stopper as required to obtain the proper distance Blade stoppers may slightly...

Page 371: ...MX Z 550 AND 380 FC BOTTOM END 377 Engine Type A03C3XS Anti seize lubricant 27 N m 20 lbf ft 11 N m 97 lbf in 5 2 4 6 2 1 3 40 N m 29 lbf ft Loctite 243 Sealing compound 3 6 Loctite 243 27 N m 20 lbf...

Page 372: ...01_08A FM 08 19 552 Engine Types 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 seize lubricant 6 6 6...

Page 373: ...43 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 score marks in...

Page 374: ...een crankshaft counterbalance and the bearing or on the MAG side bearing use bearing separator SNAP ON tool P N CJ951 or SPX OTC tool P N 1124 to facilitate the removal 1 A32CB4A 1 Bearing separator P...

Page 375: ...d put a suitable plate or shim to avoid the direct contact between integrated seal with the heating surface A32CB7A CAUTION Bearing should not be heated to more than 80 C 176 F Do not heat bearing wit...

Page 376: ...inner PTO bearing with the integrated seal facing crankshaft Push bearing to end posi tion A32CBAA A32CBBA BEARING TO END POSITION Install the O ring Make a bearing locator tool using support plate P...

Page 377: ...32 mL of Isoflex grease as shown be low A32CBGA TYPICAL BALLS COATED WITH A SEAM OF GREASE All Engines Bearings are pressed on crankshaft until they rest against radius These radius maintain the gap...

Page 378: ...ust be applied in one run to avoid any risks of leaking through the crankcase Align both crankcase halves before tightening screws Position the crankcase halves together and tighten bolts by hand then...

Page 379: ...5 11 3 1 13 7 9 A A A09C05A TIGHTENING SEQUENCE FOR 377 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...

Page 380: ...ended injection oil 377 engines 552 engines 13 13 12 5 N m 44 lbf in 15 16 1 Loctite 243 14 12 Molykote 111 5 N m 44 lbf in 12 1 14 12 15 Loctite 243 16 Molykote 111 4 3 4 5 N m 40 lbf in 2 2 N m 18 l...

Page 381: ...ION The BOMBARDIER Formula XP S II synthetic injection oil is specially formulated and tested for the severe re quirement of these engines Use of any other brand two stroke oil may void the limited wa...

Page 382: ...ection Oil Level Switch Before replacing the injection oil level switch no 6 check it according to the following proce dure Remove tuned pipe Disconnect switch connectors and place a jumper wire betwe...

Page 383: ...removal procedure Injection Oil Filter For installation reverse the removal procedure NOTE The filter must be installed with the arrow pointing toward the pump Injection Oil Pump For installation rev...

Page 384: ...ite 648 with a rag ADJUSTMENT Oil Pump Cable 377 and 552 Engines Prior to adjusting the pump make sure all car buretor adjustments are completed and engine is stopped Eliminate the throttle cable free...

Page 385: ...m check valve After restarting the en gine check that a clear section in small oil line is present Reconnect oil line Run engine at idle Oil column must advance If the check valve is faulty oil column...

Page 386: ...C2005 001_08A FM 08 33 AXIAL FAN COOLING SYSTEM 377 and 552 Engines 13 N m 115 lbf in 2 N m 18 lbf in 7 N m 62 lbf in 7 N m 62 lbf in 48 N m 35 lbf ft 9 N m 80 lbf in 7 N m 62 lbf in 19 20 5 12 13 14...

Page 387: ...ean all metal components in a non ferrous metal cleaner DISASSEMBLY AND ASSEMBLY Remove the tuned pipe to gain access Unscrew the 2 screws no 19 of inlet duct no 20 Remove the inlet duct by unclipping...

Page 388: ...ng from opposite side until it is flush with housing Press fan shaft from engine side of fan housing Check for free rolling action INSTALLATION At assembly apply a light coat of Loctite 243 blue on sc...

Page 389: ...ey first then position onto fan shaft as shown in the next photo A03C2AA 1 3 2 FAN BELT PROPERLY INSTALLED ON BOTTOM PULLEY AND FAN SHAFT 1 Bottom pulley 2 Fan shaft 3 Starting pulley Reinstall fan as...

Page 390: ...s between distance sleeve no 13 and pulley half no 14 housing side 1 2 3 4 A09C0VA TYPICAL 1 Unused shim s here 2 Adjust here 3 Positioning noses 4 Some engines only Select pulley halves so that the...

Page 391: ...insertion Turn fan until oil pump shaft slides in place as shown in the fol lowing photo A03C25A TURN FAN TO SLIDE OIL PUMP SHAFT IN PLACE Secure rewind starter with original screws Reinstall fan prot...

Page 392: ...01_08A FM 08 39 DRIVE PULLEY BOMBARDIER LITE NOTE This is a lubrication free drive pulley 377 and 552 Engines A32D1US 552 Engine type 1 2 3 5 6 7 8 128 N m 95 lbf ft 11 9 95 N m 70 lbf ft 27 N m 20 lb...

Page 393: ...dealer Sub component installation and as sembly tolerances require strict adherence to procedures detailed REMOVAL NOTE If disassembling drive pulley first straighten tab washer no 7 then untighten n...

Page 394: ...ing pressure Remove spring cover no 5 spring and spring seat no 11 CLEANING Clean pulley faces and shaft with fine steel wool and clean dry cloth Clean sliding half bushing with clean dry cloth INSPEC...

Page 395: ...tools feet and clothing clear of track Ensure nobody is standing near the ve hicle Accelerate the vehicle at low speed maximum 30 km h 20 MPH and apply the brake repeat 5 times Retorque screw to 90 t...

Page 396: ...ark plug hole magneto generator side and adjust as follows Position the magneto flywheel at approxi mately TDC A17E0YA 2 1 TYPICAL INSTALLATION OF TDC GAUGE 1 Adaptor lock nut 2 Gauge on MAG side cyli...

Page 397: ...magneto flywheel 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 the procedure A17E10A 2 1 TYPIC...

Page 398: ...line Connect tachometer wire to spark plug wire or aim tachometer toward spark plug wire without using any connection wire Start the engine and raise the engine speed at least to 3500 RPM 3000 to 400...

Page 399: ...MMC2005 001_09A TOOLS FM 09 1 SECTION 09 2005 800 MOD ENGINE KIT TABLE OF CONTENTS 0 2005 OPEN MOD SNOCROSS ENGINE SPECIFICATIONS PARTS 793 ROTAX 2 CYLINDERS 09 02 DRIVE CLUTCH PARTS LIST 09 04...

Page 400: ...ISTON RING CKS P N 420 815 360 PISTON PIN P N 420 916 370 CIRCLIP P N 420 845 106 BASE GASKET AVAILABLE 4 mm 5 mm 6 mm 7 mm 8 mm P N 420 931 836 P N 420 931 838 P N 420 931 837 P N 420 931 964 already...

Page 401: ...7 222 806 P N 417 222 557 P N 417 222 383 P N 417 222 595 P N 417 222 004 DRIVEN CLUTCH TEAM Cam Twin Trac 44 48 The TEAM driven clutch cam has 2 cam angle positions Set the Open Mod on 44 the stock 4...

Page 402: ...24 0 049 14 1 44 0 057 15 1 65 0 065 16 1 88 0 074 17 2 12 0 083 18 2 37 0 093 19 2 64 0 104 20 2 92 0 115 21 3 21 0 126 22 3 52 0 139 23 3 84 0 151 24 4 17 0 164 25 4 52 0 178 Engine Type 793 Stroke...

Page 403: ...25 WARNING Note that the engine water pump gear oil cavity has to be filled with 150 mL of oil by removing oil pump block off plate and venting opening empty bottle then add 70 mL to bottle Best done...

Page 404: ...nstall a new pop rivet to hold the muffler fastener 486 110 500 Steering reinforcement A33C0LA 486 130 003 Pipe Mag 486 130 017 Socket A33C0IA 420 931 850 Gasket 486 130 022 Donut 415 107 100 Spring 4...

Page 405: ...SECTION 09 2005 800 MOD ENGINE KIT MMC2005 001_09A TOOLS FM 09 7 A33C21A 2 1 16 1 1 2 Belt guard P N 486 130 010 A33C22A 4 x pop rivets P N 390 910 200...

Page 406: ...of 3 16 in the support of the hull and install a new pop rivet to hold the fasterner Tune Pipe Fastener Installation Update tune pipe fastener installation Use the black pop rivet 3 16 in x 690 in Mak...

Page 407: ...ET REPLACEMENT 10 10 2004 SKI DOO MX Z RACING TIP SHEET 10 14 SKI DOO RACING 7575 BOMBARDIER COURT WAUSAU WI 54401 8035 NUMBER 01 NOVEMBER 23 2003 10 14 SKI DOO RACING 7575 BOMBARDIER COURT WAUSAU WI...

Page 408: ...eed Spring part number Spring color Spring wire diameter Spring free length RPM mm mm in in 6500 7250 420 239 948 Gray 1 00 38 00 0 039 1 496 COOLING Cooling system type Thermostat opening temp Cap op...

Page 409: ...050 0 0009 0 0015 0 0020 CARBURETOR Carburetor manufacturer Carburetor quantity x type Mikuni 2 x TMX 34mm Choke PTO MAG Identification number Carburetor Jet needle Clip position no Needle jet Thrott...

Page 410: ...nkcase nuts screws M8 Crankcase engine sup studs Crankcase engine sup nuts Cylinder head nuts screws Water pump screws Magneto ring nut Exhaust manifold screws Intake manifold screws Magneto flywheel...

Page 411: ...external dia MIN Driven pulley cam angle Cam part number Pulleys center distance Z distance Without torque rod preload X offset Y X difference mm kg lbf deg mm mm mm mm in 0 7 1 5 in in in in Team Rap...

Page 412: ...qty type Front arm shock abs part number Standard front spring part number Optional spring s part number s Rear arm shock abs qty type Rear arm shock abs part number Standard rear spring part number O...

Page 413: ...181 1 378 16 094 GENERAL SPECIFICATIONS Vehicle overall length Chassis overall length Vehicle overall width Vehicle overall height Ski stance Carbides to carbides Ski protected length Ski overall leng...

Page 414: ...Plastic Black B 160 Black B 160 N A Black B 160 N A T M VEHICLE ELECTRICAL SYSTEM Headlamp bulb hi low beam Tail stop lamp bulb Tachometer bulb Lamp pilot oil level Lamp pilot high beam Lamp pilot te...

Page 415: ...idge fasteners plastic ski Mountain STD N A OPT 860 507 700 Ski soles Black B 160 Ski soles Black B 160 Ski soles Yellow B 190 Ski soles Red B 212 Ski soles Black B 160 Ski runner Ski runner With Carb...

Page 416: ...assembly will be provided by the Racing Department after the Duluth event Reason of this Bulletin Under severe racing conditions it may be possible for the drive sprockets to slip on drive axle In ord...

Page 417: ...drive shaft and remove shaft N N N NO O O OT T T TE E E E To remove press fitted sprocket use a press and a suitable support Remove speed sensor adapter Remove C clip and bearing from shaft discard b...

Page 418: ...n Install new retainer ring and clip push back sprocket using the press according to the following measures A32D4AS 1 1 A B Align arrow marks N N N NO O O OT T T TE E E E Sprockets must be assembled a...

Page 419: ...information W W W Wa a a ar r r rr r r ra a a an n n nt t t ty y y y I I I In n n nf f f fo o o or r r rm m m ma a a at t t ti i i io o o on n n n Campaign Number 2004 0006 Claim Type 07 Flat Rate Ti...

Page 420: ...to contact their local Ski Doo dealer regarding the proper procedure to perform the update IMPROVED CLUTCH SETUP 440 REV Set clicker adjuster on 4 position in the TRA III Drive clutch Install Delrin w...

Page 421: ...es the tether switch to malfunction and causes the en gine to run stall and run poorly CONTINGENCY PROGRAM To qualify for the Ski Doo program only 2003 and 2004 models qualify and you MUST display the...

Page 422: ...ear COOLANT HOSE CLAMPS 2004 MXZx 440 REV and Rolling Chassis To avoid coolant leakage and or a hose coming off please check all coolant hose clamps to make sure they are secure Tom Lawrence Ski Doo R...

Page 423: ...2 HILLCROSS 11 2 HILL CLIMBING 11 3 DRAG RACING ICE AND GRASS 11 3 SPEED RUNS 11 5 OVAL RACING 11 5 SUGGESTED SPARE PARTS 11 7 EQUIVALENT WEIGHTS AND MEASURES CHART 11 9 FUEL OIL RATIO CHARTS 11 10 ST...

Page 424: ...r reduce spring pressure and or shock compres sion Rear Suspension Again the rear shock has external adjusters for high and low speed compression Set adjusters so the suspension does not bottom out Th...

Page 425: ...stiffer spring settings to prevent the rear of the machine from pogoing Track Use a finger type track with a 1 75 to 2 00 lug height profile Beginning of season or fresh snow use a track with a 1 75 l...

Page 426: ...ld be used for a total of 200 250 studs 80 to 105 HP should need 6 to 7 picks per pitch for a total of 300 350 studs Over 110 HP will require 7 to 8 picks per pitch and possibly hooker plates welded t...

Page 427: ...in control at top speed Use standard trail carbide runners with the sharp edge worn down a bit This way you will have steering control without sacrificing speed Run with a very short limiter strap and...

Page 428: ...or requirements on handlebars You may also want to fabricate a stirrup for your right foot Transmission You need aggressive shifting to get a good hole shot but you also need good backshifting Here ag...

Page 429: ...sembly and components exhaust springs spark plugs spark plug caps and wires main jets chaincase chain and sprockets TRA clutch puller and forks TRA clutch rollers driven pulley circlip and keys brake...

Page 430: ...ube steering and front suspension ball joints check chain tension and oil level check clutch alignment and clean pulley faces coolant hose condition routing check electrical connections inspect track...

Page 431: ...ram 03527 Ounce 1 Pound 4536 Kilogram kg 1 Kilogram 2 2046 Pounds 1 Ton 907 Metric Ton t 1 Metric Ton 1 102 Tons VOLUME 1 Fl U S Ounce 29 574 Milliliters 2957 Deciliter 0296 Liter 1 Fl U S Pint 473 18...

Page 432: ...l of fuel 50 1 500 mL of oil 5 5 Imp gal of fuel 50 1 UNITED STATES 13 oz of oil 5 U S gal of fuel 50 1 500 mL of oil 6 6 U S gal of fuel 50 1 25 15 20 10 5 100 200 300 400 500 5 4 3 1 2 4 6 5 8 12 16...

Page 433: ...l 40 1 500 mL of oil 4 8 Imp gal of fuel 40 1 UNITED STATES 500 mL of oil 5 3 U S gal of fuel 40 1 10 2 8 6 4 8 2 8 16 33 8 24 5 4 3 1 2 8 16 24 32 35 2 6 7 8 8 15 20 10 5 100 250 300 400 500 METRIC S...

Page 434: ...el 33 1 UNITED STATES 19 4 oz of oil 5 U S gal of fuel 33 1 500 mL of oil 4 4 U S gal of fuel 33 1 A00A6KJ METRIC SI IMPERIAL UNITED STATES 30 40 10 500 700 1000 Milliliters of oil needed Liters of fu...

Page 435: ...gal of fuel 25 1 UNITED STATES 15 oz of oil 2 8 U S gal of fuel 25 1 500 mL of oil 3 2 U S gal of fuel 25 1 Imp oz of oil needed 5 2 5 8 16 24 32 35 2 Imp gal of fuel 1 liter 1 5 3 5 4 5 5 5 1 liter 6...

Page 436: ...2 2 Imp gal of fuel 20 1 UNITED STATES 16 oz of oil 2 4 U S gal of fuel 20 1 500 mL of oil 3 2 U S gal of fuel 20 1 METRIC SI IMPERIAL UNITED STATES 15 20 10 5 100 500 700 900 Milliliters of oil neede...

Page 437: ...p cylinder taper and out of round 5 Assemble the engine using the correct seal ants where needed Rotary valve timing should be set with the closing edge as close to specs as possible or slightly highe...

Page 438: ...a plastic washer to raise the needle P N 404 137 600 Slide cut away std std Pilot jet P N 404 110 300 25 25 Needle jet Pilot screw adjustment 1 8 turn 2 0 2 0 Needle valve std std Fuel minimum 100 oct...

Page 439: ...stic washer to raise the needle P N 404 137 600 Slide cut away std std Pilot jet P N 404 110 300 25 25 Needle jet Pilot screw adjustment 1 8 turn 2 0 2 0 Needle valve std std Fuel minimum 100 octane D...

Page 440: ...9 DG158 Needle clip position 3 3 Slide cut away std std Pilot jet 30 30 Needle jet Pilot screw adjustment 1 8 turn 1 0 1 0 Needle valve std std Fuel minimum 100 octane D R I V E R A T I O Drive ratio...

Page 441: ...adjustment 1 8 turn 1 0 1 0 Needle valve std std Fuel minimum 110 octane D R I V E R A T I O Drive ratio 22 45 Chain 74 links std Drive pulley Type of drive pulley TRA III Ramp identification 412 Cal...

Page 442: ...152 518 21 teeth 504 152 044 Chain 74 links std 504 151 932 Drive pulley Type of drive pulley TRA III Ramp identification 435 417 222 814 Calibration screw position no 5 Spring 250 lb 380 lb WHITE WHI...

Page 443: ...eth TEAM 504 152 518 21 teeth 504 152 044 Chain 74 links std 504 151 932 Drive pulley Type of drive pulley TRA III Ramp identification 419 417 222 556 Calibration screw position no 4 Spring 250 lb 380...

Page 444: ...7 85 SQUISH mm 1 30 0 30 1 00 1 60 SQUISH in 0 051 0 01 0 039 0 063 600 HO MXZ SUMMIT MIN MAX INSTALLED cc 28 6 1 43 27 17 30 03 FLAT PLATE cc 26 6 1 33 25 27 27 93 SQUISH mm 1 2 0 40 0 80 1 60 SQUISH...

Page 445: ...MMC2005 001_12A FM 12 1 SECTION 12 SERVICE TOOLS TABLE OF CONTENTS 0 SERVICE TOOLS 12 02 SERVICE PRODUCTS 12 22 NEW TOOL FOR THE 2 TEC 1000 SDI 12 30 NEW TOOL TO USE WITH BUDS 12 31...

Page 446: ...f 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 your tool inventory these items can be ordered throug...

Page 447: ...All axial fan cooled engines Magneto puller P N 529 035 547 APPLICATION All engines 7 N Bearing heater P N 529 035 969 APPLICATION All models N Temperature indicator P N 529 035 970 APPLICATION All m...

Page 448: ...0 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 14 Exhaust plate P N 529 024 600 2 15 Exhaust plate P N 529 035 962...

Page 449: ...xcept 4 TEC ENGINE RECOMMENDED TOOLS The following tools are highly recommended to optimize your basic tool kit and reduce repair time N Support plate P N 529 035 976 APPLICATION 552 engine type N Cra...

Page 450: ...haft bearing puller P N 420 877 635 2 3 1 2 3 5 4 6 9 10 7 8 11 12 13 1 Screw M16 x 1 5 x 150 P N 420 940 755 2 Screw M8 x 40 4 P N 420 840 681 3 Screw M8 x 70 4 P N 420 841 201 4 Crankshaft protector...

Page 451: ...r ing centering tool P N 529 009 100 NOTE New diameter is 9 65 mm 380 in APPLICATION All engines except cageless en gines Pusher 55 59 mm P N 529 035 913 APPLICATION 1004 engines Pusher 38 42 mm P N 5...

Page 452: ...cup a P N 529 035 764 N b P N 529 035 725 APPLICATION A 1004 engines B 1503 engines Ring compressor Not sold by BOMBARDIER Snap On RC980 APPLICATION 1004 and 1503 engines Special pliers for valve ste...

Page 453: ...Driver tool P N 529 035 521 APPLICATION Mini Z Attachment P N 529 035 522 APPLICATION Mini Z Pilot 22 mm P N 529 035 523 APPLICATION Mini Z Carburetor tool kit P N 404 112 000 APPLICATION All models...

Page 454: ...ICATION All engines MAG seal pusher P N 420 277 875 APPLICATION 277 engines PTO seal pusher P N 420 876 660 APPLICATION 277 engines Base puller plate kit P N 529 024 900 APPLICATION 277 engines Insert...

Page 455: ...ley puller P N 529 022 400 APPLICATION 2003 and up BOMBARDIER Lite drive pulley Most TRA TRA III and TRA IV drive pulleys TRA drive pulley puller 25 mm P N 529 007 900 APPLICATION TRA drive pulley for...

Page 456: ...ION Most models Clutch holder P N 529 027 600 APPLICATION BOMBARDIER Lite drive pulley Driven pulley spring compressor P N 529 035 300 APPLICATION Tundra Spring cover tool P N 529 027 300 APPLICATION...

Page 457: ...N TRA IV and TRA IV HD N Short dial indicator P N 295 000 143 APPLICATION TRA IV and TRA IV HD TRA IV drive pulley support P N 529 035 942 APPLICATION TRA IV and TRA IV HD Driven pulley opening tool P...

Page 458: ...N 529 008 700 Parts included 1 Hexagonal wrench P N 420 876 730 2 Socket wrench P N 529 015 000 2 1 APPLICATION All vehicles except Tundra and Skandic WT Alignment bar a P N 529 035 808 b P N 529 035...

Page 459: ...ler P N 529 035 524 that has Acme threads and sup port plate included with extrac tor P N 529 031 100 Large bushing extractor P N 529 035 575 APPLICATION LPV 27 driven pulley NOTE Use this tool only w...

Page 460: ...ate P N 529 010 600 4 Bolt M10 2 P N 222 007 565 5 Allen screw M8 2 P N 222 983 065 6 Screw M8 2 P N 222 082 565 NOTE When the tool is to be used between tunnel and sprocket use screw M8 APPLICATION A...

Page 461: ...b All models except Tundra Camber angle tool P N 529 021 600 NOTE Angle finder with a mag netic base must be used Suggestion K_D tool no 2968 APPLICATION All DSA front suspensions Track tension gauge...

Page 462: ...b C 46 T A shocks Gas shock valve tool tire valve type P N 529 035 570 APPLICATION Some 2000 and up T A shocks Gas fill tool kit needle type P N 503 190 102 APPLICATION 2003 and up T A shocks Drill bi...

Page 463: ...r support P N 529 035 873 APPLICATION REV series N Ball joint installer P N 529 035 975 APPLICATION 2004 REV series Ball joint installer support P N 529 035 875 APPLICATION REV series Hexagonal wrench...

Page 464: ...600 4 APPLICATION Models with Packard connec tors Multilock terminal housing con nector extractor tool Not sold by BOMBARDIER AMP 755430 2 AMP APPLICATION For AMP multilock terminals N DESS socket P N...

Page 465: ...29 035 714 APPLICATION 2 TEC 1004 and 1503 engine equipped models Oil pressure gauge P N 529 035 709 APPLICATION 1004 and 1503 engine equipped models Oil pressure adaptor P N 529 035 652 APPLICATION 1...

Page 466: ...09 Retaining compound 10 mL green APPLICATION Used for retaining bushings bearings in slightly worn hous ing or on shaft Medium strength threadlocker P N 293 800 060 Loctite 243 Threadlocker 10 mL blu...

Page 467: ...518 Gasket eliminator 50 mL APPLICATION Crankcase halves and gearbox mating surfaces Loctite primer P N 293 800 041 Primer N 128 g 5 oz APPLICATION To prepare mating surfaces be fore applying paste g...

Page 468: ...rankshaft seals and plain bearings on 4 TEC SYNTHETIC BOMBARDIER 4 STROKE engine oil 0W 40 P N 293 600 054 12 x 1 L APPLICATION 4 TEC Pre mix oil P N 413 803 100 12 x 500 mL APPLICATION All pre mix mo...

Page 469: ...413 711 802 Fuel stabilizer P N 413 408 600 12 x 8 oz APPLICATION All models Chaincase oil P N 413 801 900 16 x 250 mL APPLICATION Chaincase lubricant on all fan cooled models except Skandic WT serie...

Page 470: ...93 550 033 10 tubes of 400 g each APPLICATION For front and rear suspension components and drive axle bear ing BOMBARDIER LUBE P N 293 600 016 12 x 14 oz APPLICATION Steering ball joints on all models...

Page 471: ...as been changed This product is identi cal to the P N 413 701 700 Pulley flange cleaner P N 413 711 809 320 g APPLICATION Engine crankcase joining sur faces pulleys and any greasy surfaces Heavy duty...

Page 472: ...413 708 300 Loctite 454 40 20 g 70 oz APPLICATION Isolating foam and rubber strip General purpose instant adhe sive P N 293 800 021 Loctite 495 3 g APPLICATION Rubber to metal bonding and most hard p...

Page 473: ...SECTION 12 SERVICE TOOLS MMC2005 001_12A FM 12 29 N Scratch remover P N 861 774 800 APPLICATION All models...

Page 474: ...PPLICATION Two of these are required when doing a leak down test Piston pin puller installer MANDATORY P N 529 036 002 APPLICATION To remove and install the piston pin RAVE plug plate MANDA TORY P N 5...

Page 475: ...05 001_12A FM 12 31 NEW TOOL TO USE WITH BUDS Supplied Harness MANDATORY P N 529 035 997 APPLICATION To supply 12V power from a bat tery to a non running unit To use along with BUDS Works with the sup...

Page 476: ...MMC2005 001_13A FM 13 1 SECTION 13 ACCESSORIES TABLE OF CONTENTS 0 ACCESSORIES 13 02...

Page 477: ...N solution dyed Extreme RT 280000136 Cover Mach Z ADRN Summit solution dyed Intense RT 280000137 Cover Mach Z ADRN Summit nylon Expedition RT 280000139 Cover Mach Z ADRN Summit solution dyed Racing RT...

Page 478: ...A arm protector yellow for REV X X X X X X X X X X X X X X X X X X X X X X X 415128917 Aluminum Backer 5 16 Pack 1000 X X X X X X X X X X X X X X X X X 415128887 Aluminum Backer 5 16 Pack 144 X X X X...

Page 479: ...861301600 Ceramic coated brake pads kit X X X X X X X X X X S X X X X X X X X X X X X 861803200 Chassis reinforcement yellow REV 2004 X X X X X X X S X X X X X 861509300 Clear tail light S X X X X X X...

Page 480: ...80100061 Cover Mach Z ADRN Summit solution dyed Racing RT Pers X 280000139 Cover Mach Z ADRN Summit solution dyed Racing RT X 280000141 Cover MXZ X 440 solution dyed intense REV X X X X X X 280000140...

Page 481: ...1UP Solution dyed X X X X X X X X X X X 280000088 Cover REV sport Ultra X X X X X X X X X X X 280000078 Cover REV X 1UP nylon X X X X X 280000081 Cover REV X 1UP Solution dyed X X X X X 280000089 Cov...

Page 482: ...lug 415128692 Decal Bee Rotax 860702000 Decal Checkered windshield graphics Red 860702100 Decal Checkered windshield graphics Yellow 861775900 Decal Checkered windshield graphics carbon Fiber 86177580...

Page 483: ...from 7 to 36 415128373 Decal Skidoo w flames 40 LF RH 415128374 Decal Skidoo w racing flag bkgrd 5 X25 415128375 Decal Skidoo X set of 5 from 2 to 16 part DESCRIPTION RT REV REV REV REV REV REV REV R...

Page 484: ...ecal Ski Doo racing 4 per sheet 415127977 Decal Ski Doo sticker 10 per sheet 415127974 Decal Ski Doo sticker for window 24 X 5 12 X 2 415127970 Decal Ski Doo USA flag 24 X 3 part DESCRIPTION RT REV RE...

Page 485: ...60 X X X X X X X X X X X 517302852 Handlebar deflector orange B228 X X X X X X X X X X X 517302853 Handlebar deflector yellow B190 X X X X X X X X X X X 506151954 Handlebar pad Super Bee X X X X X 860...

Page 486: ...Light weight hood panels clear REV X X X X X X X X X X X X X X X X X X 861787400 Light weight hood panels SUMMIT REV X X X 504152020 Light Weight Cross Shaft REV 440 X 861802500 Nonskid strip kit bla...

Page 487: ...ewind handle scarlet red X X X X X X X X X X X X X X X X X X X X X X 572111209 Rewind handle Yellow X X X X X X X X X X X X X X X X X X X X X X 860602500 Riser kit REV 2003 X X X X X X X X X 510004141...

Page 488: ...t red B 212 X X X X X X X X X X X X X X X X X 505071050 Ski plastic PRECISION mix blk yel X X X X X X X X X X X X X X 505071051 Ski plastic PRECISION mix yel viper red X X X X X X X X X X X X X X 5050...

Page 489: ...REV X X X X X X X X X X X X X X X X X X X X 860306500 Suspenssion quick ajustment kit X X X X X X X X 860508500 Titanium front springs kit X package X X X X X X X X X X 860508600 Titanium front spring...

Page 490: ...7303406 Windshield Med fix Ski Doo X yellow Summit REV X X X X X X X X 517303419 Windshield Med fix Ski Doo X yellow Summit RT X 517303417 Windshield med fix yellow Mach Z X 517303404 Windshield Med m...

Page 491: ...8947 Woodies Gold Diggers 5 16 1 0 Pack 1000 X X 415128948 Woodies Gold Diggers 5 16 1 0 Pack 144 X X 415128949 Woodies Gold Diggers 5 16 1 0 Pack 24 X X 415128950 Woodies Gold Diggers 5 16 1 0 Pack 9...

Page 492: ...1 325 Pack 1000 X X X X X part DESCRIPTION RT REV REV REV REV REV REV REV REV REV REV REV REV REV REV REV REV REV RT REV REV REV REV Mach Z 1000 SDI R ADRENALINE MX Z 800HO R X MX Z 600HO R X MX Z 80...

Page 493: ...Mmc 2005 001 Racing FH8 Wed Sep 15 15 27 01 2004 Page 1 C M Y CM MY CY CMY K...

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