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IV

LMR2003-001_002A.FM

Subsection 04    (MAGNETO SYSTEM)

03-04-1

F01D4WS

Loctite

243

Loctite

243

Loctite

243

Loctite

243

Loctite

243

Loctite

648

145 N•m

(107 lbf•ft)

Anti-seize

lubricant

Page heading

indicates section

and subsection

detailed.

Exploded view assits

you in identifying

parts and related

positions.

TYPICAL PAGE

F01A0CS

Illustration number

for publishing

process.

Subsection title

indicates

beginning of the

subsection.

Dotted box

contains parts of

a particular

model or an

exploded view.

Page numbering system:

03: ENGINE section

04: MAGNETO SYSTEM subsection

  1: First page of this subsection

Italic sub-title

above exploded

view indicate

pertaining models.

Drop represents

a liquid product

to be applied to a

surface. In this case

Loctite 243 to

screw threads.

Bold face number

indicates special

procedure

concerning this part.

INTRODUCTION

Summary of Contents for 5768

Page 1: ......

Page 2: ...Shop Manual SPORTSTER 4 TEC ...

Page 3: ...ny form without the prior written permission of Bombardier Inc Bombardier Inc 2003 Technical Publications Bombardier Inc Valcourt Quebec Canada Printed in Canada Registered trademarks of Bombardier Inc Loctite is a trademark of Loctite Corporation Snap on is a trademark of Snap on Tools Corporation Gelcote is a trademark of Gelcote International Limited ...

Page 4: ...gine block 04 09 1 05 ENGINE MANAGEMENT 4 TEC 01 Table of contents 05 01 1 02 Overview 05 02 1 03 Component inspection and adjustment 05 03 1 04 Diagnostic procedures 05 04 1 06 COOLING SYSTEM 01 Table of contents 06 01 1 02 Circuit components and care 06 02 1 07 FUEL SYSTEM 01 Table of contents 07 01 1 02 Fuel circuit 07 02 1 03 Air intake 07 03 1 08 ELECTRICAL SYSTEM 01 Table of contents 08 01 1...

Page 5: ...gly recommended when considering replacement of any com ponent Dealer and or distributor assistance should be sought in case of doubt The engines and the corresponding components identified in this document should not be utilized on product s other than those mentioned in this document Torque wrench tightening specifications must be strictly adhered to Locking devices ex locking tab self locking f...

Page 6: ... manual is divided into 13 major sections 01 SERVICE TOOLS AND PRODUCTS 02 MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 4 TEC 05 ENGINE MANAGEMENT 4 TEC 06 COOLING SYSTEM 07 FUEL SYSTEM 08 ELECTRICAL SYSTEM 09 PROPULSION SYSTEM 10 STEERING SYSTEM 11 HULL DECK 12 TECHNICAL DATA 13 WIRING DIAGRAMS Several sections are divided in various subsec tions There is a table of contents at the beginning of many ...

Page 7: ...01A0CS Illustration number for publishing process Subsection title indicates beginning of the subsection Dotted box contains parts of a particular model or an exploded view Page numbering system 03 ENGINE section 04 MAGNETO SYSTEM subsection 1 First page of this subsection Italic sub title above exploded view indicate pertaining models Drop represents a liquid product to be applied to a surface In...

Page 8: ...e stay in place other wise it must be timed Remove carburetors from intake manifold Disconnect fuel bypass line between carburetors twin carburetors Remove carburetor s from rotary valve cover DISASSEMBLY AND INSPECTION Using a suitable pump gauge tester perform the fol lowing test proceeding as follows Install pump gauge tester P N 295 000 083 on pulse nipple Pump tester until it reaches 28 kPa 4...

Page 9: ...Electronic Control Unit EGT Exhaust Gas Temperature EMS Engine Management System EPA Environmental Protection Agency USA HP Horse Power KS Knock Sensor MAG Magneto MAPS Manifold Air Pressure Sensor MATS Manifold Air Temperature Sensor MPH Mile Per Hour MPI Multi Protocol Interface N A Not Applicable OPS Oil Pressure Sensor OPT Optional OSPS Oil Separator Pressure Sensor P N Part Number PFD Persona...

Page 10: ...ts may be from the imperial system When replacing fasteners make sure to use only those recommended by Bombardier As many of the procedures in this manual are in terrelated we suggest that before undertaking any task you read and thoroughly understand the entire section or subsection in which the proce dure is contained A number of procedures throughout the book re quire the use of special tools B...

Page 11: ...tion on this subject you may contact the following locations VIA U S POSTAL SERVICE Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group 6403J 401 M St NW Washington DC 20460 VIA EXPRESS or COURIER MAIL Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group 6403J 501 3rd St NW Washington DC 20001 EPA INTERNET W...

Page 12: ...e Primer N P N 293 800 041 on threads and allow to dry 3 Put several drops of proper strength Loctite threadlocker on female threads and in hole 4 Apply several drops of proper strength Loctite on stud threads 5 Install stud 6 Install cover etc 7 Apply drops of proper strength Loctite on un covered threads 8 Tighten nuts as required Preassembled Parts 1 Apply here 2 Do not apply 1 Clean bolts and ...

Page 13: ...gent on mating surfaces b Put waxed paper or similar film on the surfac es 3 Twist bolt when inserting it to improve thread conformation NOTE NOT intended for engine stud repairs Repair of Small Holes Fine Threads Option 1 Enlarge damaged hole then follow Standard Thread Repair procedure Option 2 Apply FORM A THREAD on the screw and insert in damaged hole Permanent Stud Installation light duty 1 U...

Page 14: ...of proper strength Loctite on shaft circumference at insert or engagement point NOTE Retaining compound is always forced out when applied on shaft 3 DO NOT use anti seize Loctite or any similar product 4 No curing period is required Mounting in Tandem 1 Apply retaining compound on internal element bore 2 Continue to assemble as shown above CASE IN COMPONENTS Metallic Gaskets 1 Proper strength Loct...

Page 15: ...06 13 115 14 124 15 133 16 142 17 150 18 159 19 168 N m FASTENER SIZE 8 8 grade Lbf ft 20 15 21 15 22 16 23 M8 17 24 18 25 18 26 19 27 20 28 21 29 21 30 22 31 23 32 24 33 24 34 25 35 26 36 27 37 27 38 28 39 29 40 30 41 30 42 31 43 32 44 32 45 33 46 34 47 35 48 M10 35 49 36 50 37 51 38 52 38 53 39 54 40 55 41 56 41 57 42 58 43 59 44 60 44 61 45 62 46 63 46 64 47 65 48 66 49 67 49 68 50 69 51 70 52 ...

Page 16: ...4 101 74 102 75 103 76 104 77 105 77 106 78 107 79 108 80 109 80 110 81 111 82 112 83 113 83 114 84 115 85 N m FASTENER SIZE 8 8 grade Lbf ft 116 86 117 86 118 87 119 88 120 89 121 89 122 90 123 91 124 91 125 92 126 93 127 94 128 94 129 95 130 96 131 97 132 97 133 98 134 99 135 M14 100 136 100 137 101 138 102 139 103 140 103 141 104 142 105 143 105 144 106 145 107 146 108 147 108 148 109 149 110 1...

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