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NTRODUCTION

mmr2005-109

XXI

Summary of Contents for 2005 MACH Z

Page 1: ...epair Manual Thank You for your purchase eBay seller foxmoto951 is the only authorized seller for this software If you have received this manual from any other eBay seller send it back for a refund co...

Page 2: ......

Page 3: ...2005 Shop Manual RT SERIES BOMBARDIER RECREATIONAL PRODUCTS INC...

Page 4: ...ks of Bombardier Recreational Products Inc BRP or its affiliates Trademark of Bombardier Inc used under license This document contains the trademarks of the following companies Crest is a trademark of...

Page 5: ...CHART 1 02 STORAGE 3 GENERAL 3 ENGINE 3 FUEL SYSTEM 4 DRIVE SYSTEM 4 STEERING FRONT SUSPENSION 5 SUSPENSION 5 ELECTRICAL 5 VEHICLE 5 03 PRESEASON PREPARATION 7 ENGINE 7 FUEL SYSTEM 7 DRIVE SYSTEM 8 E...

Page 6: ...AL 53 COMPONENT REMOVAL WITH THE ENGINE INSTALLED 53 DISASSEMBLY 53 CLEANING 54 INSPECTION 55 ASSEMBLY 56 08 BOTTOM END 61 TROUBLESHOOTING 64 GENERAL 64 PREPARATION 64 CLEANING 64 DISASSEMBLY 64 INSPE...

Page 7: ...TER INSTALLATION 105 IN LINE FUEL FILTER REMOVAL 106 IN LINE FUEL FILTER INSTALLATION 106 FUEL TANK REMOVAL 106 FUEL TANK INSTALLATION 107 FLOAT TYPE FUEL LEVEL GAUGE REMOVAL INSTALLATION 107 ELECTRIC...

Page 8: ...TMENT 135 GENERAL 135 FUEL SYSTEM 135 ELECTRICAL SYSTEM 136 TESTING PROCEDURES 140 ELECTRIC FUEL PUMP 140 FUEL INJECTORS 140 ENGINE CONTROL MODULE ECM 144 ENGINE WIRING HARNESS 145 THROTTLE BODY 145 T...

Page 9: ...181 HEATING ELEMENTS 181 RELAY 181 SPEEDOMETER 182 SPEED SENSOR 183 TACHOMETER 183 TAILLIGHT 184 VISOR OUTLET 184 06 DRIVE SYSTEM 01 DRIVE BELT 185 APPLICATION CHART 185 INSPECTION 185 CHECKING NEUTRA...

Page 10: ...CYLINDER 217 BRAKE PADS 218 CALIPER 219 BRAKE DISC 220 BRAKE LIGHT SWITCH 221 06 CHAINCASE 223 GENERAL 225 CHAINCASE OIL LEVEL 225 OIL CHANGE 225 DRIVE CHAIN ADJUSTMENT 225 CHAINCASE COVER 225 TENSIO...

Page 11: ...ON INSTALLATION 254 RIDE ADJUSTMENT 254 LUBRICATION 254 02 SC 4 SUSPENSION 255 AXLE SELF LOCKING SCREW REMOVAL 259 REAR AXLE REMOVAL 259 REAR AXLE INSTALLATION 259 REAR SHOCK ABSORBER REMOVAL 259 REAR...

Page 12: ...ELD 306 ACCESS PANEL 306 INDICATOR PANEL 306 CONSOLE 307 SEAT 307 PLASTIC MAINTENANCE AND REPAIR 308 02 FRAME 311 FRAME CLEANING 311 FRAME WELDING 311 FRAME COMPONENT REPLACEMENT 311 10 TECHNICAL DATA...

Page 13: ...butor 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 docum...

Page 14: ...A TYPICAL 1 Vehicle identification number Identification Number Meaning A00A8HA 2 B P S B X 5 A 9 Y 1 0 0 0 0 0 1 Model number Serial number Model year y 2000 1 2001 2 2002 etc ENGINE SERIAL NUMBER En...

Page 15: ...track m meter MAG magneto Max maximum Min minimum mL milliliter ABBREVIATION MEANING mm millimeter M E millennium edition MPEM multi purpose electronic module MPH mile per hour N newton N A not appli...

Page 16: ...this part Tightening torque nearby fastener In this case nut must be torqued to 4 N m or 35 lbf in This Shop Manual uses technical terms wich may be slightly different from the ones in the parts cata...

Page 17: ...small bushing installation Coat bushing outside diameter with Loctite 609 P N 413 703 100 Install bushing as following photo A03D1YA 529 031 300 529 031 200 A03D1ZA 529 031 300 529 031 200 Cam Coat c...

Page 18: ...ioned in the metric system Most fasteners are metric and must not be replaced by customary fasteners or vice versa Mismatched or incorrect fasteners could cause damage to the vehicle or possible perso...

Page 19: ...ngagement area Position nut and tighten as required Blind Holes A00A3MA 1 2 1 On threads 2 On threads and at the bottom of hole Clean threads bolt and hole with solvent Apply Loctite Primer N P N 293...

Page 20: ...on exist ing equipment retighten nuts and apply proper strength Loctite on bolt nut contact surfaces Adjusting Screw A00A3PA 1 2 1 Apply here 2 Plunger Adjust screw to proper setting Apply drops of pr...

Page 21: ...0 Use a mechanical mean if necessary NOTE Avoid grinding Clean both mating surfaces with solvent Spray Loctite Primer N on both mating surfaces and on both sides of gasket Allow to dry 1 or 2 minutes...

Page 22: ...teners to torque mentioned in explod ed views and or text When they are not specified refer to following table The table also gives the metric conversion WARNING Torque wrench tightening specification...

Page 23: ...5 N m 35 44 lbf in M5 3 3 5 N m 27 31 lbf in 4 5 5 5 N m 40 47 lbf in 7 8 5 N m 62 75 lbf in 8 10 N m 71 89 lbf in M6 6 5 8 5 N m 58 75 lbf in 8 12 N m 71 106 lbf in 10 5 15 N m 93 133 lbf in 16 N m...

Page 24: ...n q Name Address City and State Prov Date Zip code Postal code BRP SERVICE PUBLICATIONS REPORT Publication title and year Page Machine Report of error q Suggestion q Name Address City and State Prov D...

Page 25: ...court Quebec Canada J0E 2L0 AFFIX PROPER POSTAGE Technical Publications After Sales Service 565 de la Montagne Street Valcourt Quebec Canada J0E 2L0 AFFIX PROPER POSTAGE Technical Publications After S...

Page 26: ...I I I 02 10 Coolant I R 02 10 Crankshaft PTO Seal 4 I Section 02 see the appropriate subsection E RAVE actuator 4 A A 02 06 Injection oil filter I R 02 12 Oil injection pump A A A 02 12 Rags in air in...

Page 27: ...nts A AS REQUIRED Suspension 2 I I L I L Suspension stopper strap I I Section 07 or 08 see the appropriate subsection ELECTRICAL EMS fault codes 4 I I 04 03 Spark plugs 1 4 I I R 05 01 Battery if so e...

Page 28: ...column from MAINTENANCE CHART jointly with the present storage proce dure in order to cover each and every aspect of the snowmobile storage procedure Any worn broken or damaged parts should be replac...

Page 29: ...and exhaust system hole us ing clean rags FUEL SYSTEM Fuel Stabilizer It is critical to use the fuel stabilizer P N 413 408 600 250 mL to prevent fuel deterioration gum formation and fuel system compo...

Page 30: ...ition of Skis and Runners Inspect skis and runners for wear deterioration or damage replace if necessary SUSPENSION Rear Suspension Lubrication Inspect rear suspension components for wear de teriorati...

Page 31: ...ir any damage Touch up all metal spots with touch up paint where paint has been scratched off Spray all bare metal parts including shock chromed rods with BOMBARDIER LUBE P N 293 600 016 Wax the hood...

Page 32: ...ing System Inspect cooling system for leaks to perform a cooling system leak test refer to ENGINE section Check coolant level in coolant reservoir Add coolant if necessary If engine is cold refill up...

Page 33: ...ds for proper thickness Refer to DRIVE TRAIN section and the appropriate subsec tion Remove any rust built up on braking surfaces Clean brake disk braking surfaces with pulley flange cleaner P N 413 7...

Page 34: ...295 000 076 10 vacuum pressure pump kit 529 021 800 9 LEAK TEST Use vacuum pressure pump kit P N 529 021 800 to pressure test engine The following gives veri fication procedures for liquid cooled engi...

Page 35: ...boots 2 Intake plugs Using a small hose pincher P N 295 000 076 block impulse hose 295 000 076 A35C3LA 1 2 1 Impulse line 2 Hose pincher Block inlet and outlet fitting of oil injection system with ru...

Page 36: ...AVE plates P N 529 036 003 529 036 003 A35C3OA 1 1 RAVE plates Execute the test Refer to PROCEDURE further in this section To perform the second test the RAVE cover must be in place A35C3PA 1 1 RAVE c...

Page 37: ...ter balancing shaft outer seals and their filling tubes crankshaft seals PTO and MAG sides oil injection pump mounting flange O ring coolant pump housing crankcase grease reservoir fitting Small injec...

Page 38: ...p 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 Disassemble engine and carefully check for de...

Page 39: ...R IN CRANKCASE IS RESERVOIR LEAKING UNSEAL PTO CYLINDER AND MAG CYLINDER SEPARATELY BY REMOVING THE APPROPRIATE SPARK PLUG IS RESERVOIR LEAKING IS RESERVOIR LEAKING CHECK LEAKAGE AT LEAK INDICATOR HOL...

Page 40: ...Section 02 ENGINE Subsection 02 AIR INTAKE SYSTEM AIR INTAKE SYSTEM A35C02S mmr2005 149 15...

Page 41: ...CER INSTALLATION BODY SIDE Position lower section of air intake silencer on LH side panel using locating holes A35C05A 1 1 Locating holes Install air filter on air intake silencer NOTE Make sure air f...

Page 42: ...nel Remove air intake silencer engine side refer to procedure above Unscrew clamps from throttle body Remove adaptor plate 1 2 A35C08A 1 Clamps 2 Adaptor plate ADAPTOR PLATE INSTALLATION The installat...

Page 43: ...Section 02 ENGINE Subsection 02 AIR INTAKE SYSTEM Remove intake deflector and filter 1 2 3 4 A35C0AA 1 Air filter 2 Push nut 3 Intake filter 4 Intake deflector 18 mmr2005 149...

Page 44: ...RVICE TOOLS Description Part Number Page exhaust spring installer remover 529 035 401 23 exhaust spring installer remover 529 035 989 21 22 SERVICE PRODUCTS Description Part Number Page Loctite 767 an...

Page 45: ...Section 02 ENGINE Subsection 03 EXHAUST SYSTEM A35C1NS 11 N m 97 lbf in 8 7 6 5 1 4 2 Loctite 767 antiseize RTV sealant 3 20 mmr2005 114...

Page 46: ...ed If the efficiency of a locking device is impaired it must be renewed TUNED PIPE Identification Each tuned pipe is identified by a number To use the proper tuned pipe with the proper vehi cle check...

Page 47: ...s heat screws for 30 seconds before loosening to prevent screw breakage manifold no 6 gaskets no 7 Inspection Check if the manifold is cracked or damaged Re place if necessary Installation Install the...

Page 48: ...o 9 Use exhaust spring installer remover P N 529 035 401 Remove the muffler Inspection Check the muffler for cracks or other damages Installation For installation reverse the removal procedure If the...

Page 49: ...ND INSTALLATION SERVICE TOOLS Description Part Number Page engine removal hook 529 035 829 30 hose pincher 295 000 076 31 spark plug lift ring 529 035 830 30 SERVICE PRODUCTS Description Part Number P...

Page 50: ...O ring 19 5 N m 173 lbf in 37 N m 27 lbf ft 5 N m 44 lbf in 19 5 N m 173 lbf in 37 N m 27 lbf ft 2 N m 18 lbf in 29 N m 21 lbf ft To T fitting heat exchanger To coolant tank 4 5 N m 40 lbf in 29 N m...

Page 51: ...st It is recommended to disconnect elec trical connections prior to disconnecting fuel lines Remove tuned pipe and muffler Refer to EX HAUST SYSTEM sub section A35C1VA 1 REMOVE 1 Tuned pipe and muffle...

Page 52: ...L 1 Nuts 2 Engine support On Left Side of Vehicle do the Following Remove belt guard drive belt drive pulley refer to DRIVE PULLEY sub section driven pulley refer to DRIVEN PULLEY sub section air inta...

Page 53: ...ews 2 Fuel rail Unplug injectors and remove fuel rail from plastic retaining plate Put fuel rail aside CAUTION Take care not to damage fuel injec tors A35C22A 1 2 FUEL RAIL DISASSEMBLY 1 Fuel rail 2 P...

Page 54: ...0 Using the engine removal hook P N 529 035 829 lift engine until engine supports are free from rub ber mount studs 529 035 829 A35C25A 2 1 PTO ENGINE SUPPORT LIFTED 1 Engine support 2 Rubber mount st...

Page 55: ...6 NOTE For oil inlet hose use a standard 1 4 inch ratchet extension to block up hose Secure hose with existing clamp A35C28A 2 3 1 BLOCK UP OIL INLET HOSE 1 Oil inlet hose 2 Standard 1 4 inch ratchet...

Page 56: ...ay attention to the follow ing PTO Engine Support Lower engine as close as possible to its original position First position PTO engine support on engine and insert front tab of PTO engine support on r...

Page 57: ...section Fuel Injectors Lubricate fuel injectors O ring with Molykote 111 P N 413 707 000 before fuel rail installation Respect the following tightening torque specifica tions DESCRIPTION TIGHTENING T...

Page 58: ...ription Part Number Page crankshaft protector 420 876 557 37 magneto puller 529 035 547 37 puller ring 529 036 001 37 SERVICE PRODUCTS Description Part Number Page Loctite 243 blue 293 800 060 36 Loct...

Page 59: ...section 05 MAGNETO SYSTEM A35C1QS 2 7 b a 6 a 4 5 1 3 a a 21 N m 15 lbf ft 9 N m 80 lbf in 7 N m 63 lbf in 130 N m 96 lbf ft 5 N m 44 lbf in a Loctite 243 blue P N 293 800 060 b Loctite 5910 P N 293 8...

Page 60: ...e specified If the efficiency of a locking device is impaired it must be renewed MAGNETO FLYWHEEL Cleaning Clean all metal components in a non ferrous metal cleaner CAUTION Clean magneto flywheel usin...

Page 61: ...of housing otherwise housing seal will be damaged Ignition Timing Check as described in IGNITION TIMING STATOR Inspection Always check stator no 4 before changing it Re fer to CHARGING SYSTEM Cleaning...

Page 62: ...move or disconnect the fol lowing magneto flywheel no 1 grommet from crankcase where CPS wire exits magneto housing retaining screws no 7 CPS no 6 and carefully pull wires Installation For installatio...

Page 63: ...NGINE Subsection 06 E RAVE SYSTEM E RAVE SYSTEM SERVICE PRODUCTS Description Part Number Page Loctite 243 293 800 060 42 Molykote 111 413 707 000 42 XPS synthetic blend Injection oil 293 600 071 42 mm...

Page 64: ...n 06 E RAVE SYSTEM A35C0CS 1 9 N m 80 lbf in 5 4 5 3 b 11 b 2 5 N m 22 lbf in 10 7 b c c a 2 8 6 9 a Molykote 111 P N 413 707 000 b Loctite 243 P N 293 800 060 c XPS synthetic blend Injection oil P N...

Page 65: ...e a wide base snowmobile stand with a rear deflector panel when the track is raised off the ground on ly run it at the lowest possible speed Centrifugal force could cause debris dam aged or loose stud...

Page 66: ...n Reverse removal steps However pay attention to the following Connect E RAVE cables as per following photo A35C0QA 1 2 CABLE POSITIONS 1 Cable ends in top holes 2 Cable ends in bottom holes Tighten n...

Page 67: ...or engine performance Remove DESS key and wait until lights of speedometer turn off ECM must be off NOTE Ensure there is no VCK supply harness connected to the EMS diagnostic connector Ensure cable ad...

Page 68: ...t pulley should turn to the Close position A35C0GA Readjust top closing cable as necessary Remove relay jumper Tighten bottom cable adjuster opening cable to remove play in cable A35C0IB 1 1 Bottom op...

Page 69: ...oval Remove retaining screws no 5 A35C0JA Remove cover no 11 Inspection Check seal condition If it is cracked or hard re place seal Check cover condition A35C0KA 1 1 Seal Installation Follow this tigh...

Page 70: ...ion Reverse removal steps However pay attention to the following When installing new bearing on shaft use an ap propriate pusher that seats against the inner race of bearing Drive shaft in housing unt...

Page 71: ...es no 4 Cover no 11 NOTE E RAVE housing with shaft and E RAVE valves can be removed altogether if desired A35C0NA Drive gears no 7 Inspection Check housing condition Installation Reverse removal steps...

Page 72: ...irclip installer 529 035 998 57 piston pin puller installer 529 036 002 54 SERVICE PRODUCTS Description Part Number Page Loctite 243 293 800 060 52 Loctite 5910 293 800 081 52 Loctite Chisel 413 708 5...

Page 73: ...30 lbf ft 6 b b b a 5 2 c 9 N m 80 lbf in 3 d 14 10 a a b c 13 a b c 1 c 9 7 25 N m 18 lbf ft 8 25 N m 18 lbf ft a a 15 N m 45 11 lbf ft a Molykote 111 P N 413 707 000 b XP S synthetic blend injection...

Page 74: ...s sis for top end repair To proceed with engine re moval refer to REMOVAL AND INSTALLATION COMPONENT REMOVAL WITH THE ENGINE INSTALLED The following engine components can be re moved with engine on ve...

Page 75: ...toward rear to withdraw Piston With a pointed tool inserted in piston notch re move circlips no 11 from piston no 6 A02C29A TYPICAL Using piston pin puller installer P N 529 036 002 extract piston pin...

Page 76: ...ce of broken ring INSPECTION NOTE For dimension measurement procedures refer to ENGINE MEASUREMENT Reed Valve There must not be any play between any blade and valve body when exerting a finger pressur...

Page 77: ...There is no oversize piston available This engine uses pistons with 2 tolerance groups therefore when a piston needs to be replaced it is important to correctly identify its tolerance group before pr...

Page 78: ...ew circlips Use a piston circlip installer to install mono hook circlips no 11 ENGINE TOOL 995 Piston circlip installer P N 529 035 998 Insert circlip into support so that when installed in piston gro...

Page 79: ...Cylinder Block If combustion chamber no 14 was removed en sure its contact surface is clean before installing it A35C11A Ensure to properly align mounting holes Choose the right gasket thickness accor...

Page 80: ...cylinder head and torque screws following this sequence A35C15A 10 4 6 8 7 5 3 9 1 2 11 12 LH and RH side intake adapters are different In stall as shown A35C14A Properly seat adapters against engine...

Page 81: ...76 552 65 crankshaft protector 420 876 557 65 half rings 420 977 479 64 oil seal protector 529 035 822 68 oil seal pusher 529 035 757 67 puller ring 420 977 494 64 screws 420 840 681 65 temperature in...

Page 82: ...9 lbf in 10 a 11 14 13 c 12 f 15 16 18 e 17 20 d 20 b c 29 N m 21 lbf ft a a 19 b a Loctite 243 P N 293 800 060 b Loctite 648 P N 413 711 400 c Molykote 111 grease 150 g P N 413 707 000 d Loctite 5910...

Page 83: ...g f f 6 7 4 f a 8 8 9 21 g a Loctite 243 P N 293 800 060 b Loctite 648 P N 413 711 400 c Molykote 111 grease 150 g P N 413 707 000 d Loctite 5910 P N 293 800 081 e Injection oil f Petamo grease GHY13...

Page 84: ...r to MAGNETO SYSTEM CLEANING Discard all oil seals gaskets O rings and sealing rings Clean all metal components in a non ferrous metal cleaner Crankcase mating surfaces are best cleaned using a combin...

Page 85: ...tightening the puller bolt Lubricate the bolt with BOMBARDIER LUBE P N 293 600 016 to avoid damaging the threads Screw in the puller bolt until the bearing comes out Counterbalance Drive Gear NOTE To...

Page 86: ...d to coolant and or oil leaking NOTE For disassembly assembly procedure a press is required Protect the threads of shaft with a suitable M8 nut Properly support bearing housing and push shaft out A35C...

Page 87: ...Outer part of ceramic seal Remove sealant from bearing housing with sand paper no 180 A35C4EA 1 1 Remove sealant To extract bearing no 17 either use a hammer puller or an appropriate pusher Assembly...

Page 88: ...4HA CAUTION Never use a hammer for the ceram ic seal installation Only use a press to avoid damaging the ceramic component Put oil seal protector P N 529 035 822 on coolant oil pump shaft no 18 A35C4I...

Page 89: ...housing screws in the following sequence A35C1HA 5 1 3 7 6 4 2 8 Reinstall oil injection pump INSPECTION Refer to table below to find bottom end engine di mension specifications For dimension measure...

Page 90: ...ater P N 529 035 969 This will expand bearings and ease installation If required put a suitable plate or shim to avoid the direct contact between integrated seal with the heating surface A32CB7A CAUTI...

Page 91: ...aring with bare hands Always wear heat resisting gloves before handling the heated bearing s Crankshaft Bearing Installation CAUTION Never reinstall a bearing that has been removed NOTE To install bea...

Page 92: ...s on gears aligned Apply 40 mL 1 4 on of Isoflex grease on counter balance shaft gear no 9 and 5 mL 2 on on drive gear no 7 Repeat on each side PTO MAG CAUTION Use only the recommended Isoflex grease...

Page 93: ...2 3 in available in arts products suppliers for printmak ing and roll the sealant to get a thin uniform coat on the plate spread as necessary When ready apply the sealant on crankcase mating surfaces...

Page 94: ...the new part CYLINDER TAPER Compare cylinder diameter 33 mm 1 3 in from top of cylinder to just below its intake port area If the difference exceeds the specified dimension the cylinder should be rebo...

Page 95: ...mbustion chamber volume engine must be cold piston must be free of carbon deposits and cylinder head must be lev eled Remove both spark plugs and bring one pis ton to Top Dead Center a using a TDC gau...

Page 96: ...ole it includes an amount of 2 25 cc corresponding to the spark plug well Repeat the procedure for the other cylinder Install a thicker or thinner cylinder crankcase gasket refer to Parts Catalogs in...

Page 97: ...crometer to the specified val ue on the piston dome F00B08A 1 1 Micrometer set to the piston dimension With the micrometer set to the piston dimension adjust a cylinder bore gauge to the micrometer di...

Page 98: ...position as with the micrometer otherwise the reading will be false RING PISTON GROOVE CLEARANCE Using a feeler gauge check clearance between rectangular ring and groove Replace piston if clearance ex...

Page 99: ...crankshaft should be repaired or replaced CONNECTING ROD BIG END AXIAL PLAY Using a feeler gauge measure distance between thrust washer and crankshaft counterweight If the distance exceeds specified...

Page 100: ...Remove TDC gauge and install it in spark plug hole on PTO side Bring PTO piston to top dead center Degree wheel must rotate with crankshaft Interval between cylinders must be 180 0 5 Any other readin...

Page 101: ...Number Page engine leak tester kit 861 749 100 85 hose pincher 295 000 076 85 siphon tool 529 035 880 85 special coolant tank cap 529 021 400 85 SERVICE PRODUCTS Description Part Number Page Loctite 5...

Page 102: ...Subsection 10 COOLING SYSTEM A35C3AS 24 N m 18 lbf ft Loctite 592 Pipe sealant 2 N m 18 lbf in 5 5 N m 49 lbf in 5 5 N m 49 lbf in Loctite 592 Pipe sealant Loctite 592 Pipe sealant Summit Loctite 591...

Page 103: ...eneral condition of hoses and clamp tight ness Check all hoses and cylinder base for coolant leaks Spray a soap water solution and look for air bub bles Check weep hole for leaks NOTE Oil leak from we...

Page 104: ...not exceed this pressure Coolant Tank For removal drain cooling system before remov ing coolant tank Remove all hoses from coolant tank Slide up coolant tank to disengage it from oil tank Check if the...

Page 105: ...hibitors specifically recommended for aluminum engines System Capacity Refer to TECHNICAL DATA Refilling Procedure IMPORTANT USE THE PREMIXED COOLANT P N 293 600 038 Do not reinstall pressure cap With...

Page 106: ...Section 02 ENGINE Subsection 11 REWIND STARTER REWIND STARTER SERVICE PRODUCTS Description Part Number Page Molykote PG 54 420 899 763 92 93 mmr2005 121 89...

Page 107: ...Section 02 ENGINE Subsection 11 REWIND STARTER A35C2HS 8 N m 71 lbf in 2 11 10 9 8 7 6 5 4 3 1 Loctite 243 Molykote grease PG54 Molykote grease PG54 Molykote grease PG54 90 mmr2005 121...

Page 108: ...30 cm 1 ft of rope pulled If not dis assemble rewind starter clean and check for dam aged plastic parts Replace as required lubricate reassemble and recheck Always replace O ring no 9 every time rewi...

Page 109: ...the utmost importance that the rewind starter spring be lubricated period ically using Molykote PG 54 P N 420 899 763 Otherwise rewind starter component life will be shortened and or rewind starter w...

Page 110: ...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 111: ...pe guide when applicable A03C0VA TYPICAL Reinstall rewind starter assembly on engine Prior to installing starter grip on new rope it is first necessary to fuse the rope end with a lit match Pass rope...

Page 112: ...Number Page hose pincher 295 000 076 97 leak testing kit 529 033 100 97 small hose pincher 295 000 076 97 spark plug lift ring 529 035 830 99 SERVICE PRODUCTS Description Part Number Page Loctite 648...

Page 113: ...ubsection 12 OIL INJECTION SYSTEM A35C2JS 4 2 6 16 9 11 16 10 15 Loctite 648 5 N m 44 lbf in 3 13 17 15 Loctite 648 14 Molykote 111 12 5 3 N m 27 lbf in 4 5 N m 40 lbf in Loctite 243 7 4 5 N m 40 lbf...

Page 114: ...XP S synthetic 2 stroke oil and the XP S synthetic blend 2 stroke oil are specially formulated and tested for the severe requirement of these engines Use of any other brand two stroke oil may void th...

Page 115: ...ys mount proper pump on en gine ENGINE TYPE OIL PUMP IDENTIFICATION 995 07 CLEANING Clean all metal components in a non ferrous metal cleaner REMOVAL Injection Oil Reservoir On Left Side of Vehicle Re...

Page 116: ...d remove it Injection Oil Pump Lift engine Remove oil pump screws no 13 Unplug all hoses connected to oil pump no 12 NOTE Mark hose locations for installation Disconnect the oil pump cable Remove oil...

Page 117: ...just cable Check Valve Prior to coating the check valve no 15 with Loc tite make sure check valve body is clean and dry Clean from dirt or oil if any with pulley flange cleaner P N 413 711 809 Apply...

Page 118: ...until the cable is under tension but throttle body are not yet opened Using a feeler gauge measure the visible distance between throttle lever and the end of cable hous ing A33C3QA 1 A 2 3 TYPICAL 1...

Page 119: ...scription Part Number Page engine removal hook 529 035 829 115 hose pincher 295 000 076 105 115 leak tester kit 529 033 100 108 pressure gauge 529 035 591 110 spark plug lift ring 529 035 830 115 vacu...

Page 120: ...Section 03 FUEL SYSTEM Subsection 01 FUEL TANK AND FUEL PUMPS FUEL TANK A35C34S 11 N m 97 lbf in 7 N m 62 lbf in 104 mmr2005 123...

Page 121: ...m always disconnect BLACK cable from bat tery then the RED cable WARNING Always disconnect battery or starter cables exactly in the specified order BLACK cable first It is recommended to disconnect el...

Page 122: ...m fuel sys tem Refer to COMPONENT INSPECTION RE PLACEMENT AND ADJUSTMENT Disconnect both ends of fuel filter line ass y Unscrew fuel filter support nut then remove the filter A35I06A 1 1 Unscrew fuel...

Page 123: ...g wiring harness to fuel tank at rear A35E0EA 1 1 Cut locking tie Slightly lift console then remove fuel tank FUEL TANK INSTALLATION Installation is reverse of removal procedure Pay attention to the f...

Page 124: ...l tank Install on fuel tank the special cap of leak tester kit P N 529 033 100 Using vacuum pressure pump kit P N 529 021 800 inject air into fuel tank See next photo A32CBJA 1 2 TYPICAL 1 Special cap...

Page 125: ...Check tether cord cap connection Check fuel pump operation Repair or replace if necessary Fuel pressure is 400 kPa 58 PSI Fuel pressure more than 400 kPa 58 PSI Fuel pressure less than 400 kPa 58 PSI...

Page 126: ...sure gauge P N 529 035 591 be tween disconnected hoses in line installation 529 035 591 Remove tether cord cap Depress START RER button and observe fuel pressure Do not crank engine Repeat twice Relea...

Page 127: ...Section 03 FUEL SYSTEM Subsection 01 FUEL TANK AND FUEL PUMPS ELECTRIC FUEL PUMP A35I09S To fuel filter line ass y 27 N m 20 lbf ft From diaphragm fuel pump mmr2005 123 111...

Page 128: ...uch as possible Disconnect fuel supply hose from fuel filter line ass y Disconnect fuel pump electrical connector A33C5RA 2 1 1 Disconnect fuel filter line ass y 2 Unplug connector Disconnect hose com...

Page 129: ...pump fitting CAUTION Make sure that hose clamps are tight to avoid that they turn on their fittings Manual Start Models NOTE When fuel tank is completely emptied it may require up to 25 30 pull on rew...

Page 130: ...Section 03 FUEL SYSTEM Subsection 01 FUEL TANK AND FUEL PUMPS DIAPHRAGM FUEL PUMP From fuel tank To in tank reservoir electric fuel pump Engine impulse A35I03S 5 N m 44 lbf in 114 mmr2005 123...

Page 131: ...all a hose pincher P N 295 000 076 on inlet and outlet hoses 295 000 076 Unplug inlet and outlet hoses then remove fuel pump A35I0BA 1 1 2 2 1 Install hose pincher 2 Unplug hoses DIAPHRAGM FUEL PUMP V...

Page 132: ...h point such as gasoline naphtha benzol etc should not be used as each is flammable and explosive Inspect diaphragm The pumping area should be free of holes tears or imperfections Replace as needed DI...

Page 133: ...system FR FI CPS CTS TPS ATS APS KS LEGEND APS ATS CPS ECM FI FR KS TPS CTS Air pressure sensor Air temperature sensor Crankshaft position sensor Engine control module Fuel injector Fuel rail Knock s...

Page 134: ...ignition coil has two separate windings one for each spark plug Ignition coil induces voltage to a high level in the secondary windings to produce a spark at the spark plug Two separate windings circ...

Page 135: ...e system The fuel pump module is located inside the fuel tank The module includes the fuel pump and the fuel pressure regulator The fuel pump inlet in cludes a filter A33C5PA The fuel pressure regulat...

Page 136: ...ould be replaced annu ally A33I08A TYPICAL ENGINE MANAGEMENT SYSTEM EMS The EMS Engine Management System is equipped with an engine control module ECM A32E3AA TYPICAL ECM The ECM is mounted in the fro...

Page 137: ...nagement System pow ers the ECM the fuel pump the ignition coil the injectors and the gauges The battery is required to supply current mainly to the fuel pump to allow a fuel pressure buildup An easy...

Page 138: ...electric fuel pump and starting system relay R1 a second for the lighting system and the acces sories R2 and a third for the capacitor circuit R4 Electric Start Models The system uses 2 relays an ign...

Page 139: ...ig nition mappings for optimum ignition timing un der all operating conditions Using engine operat ing conditions provided by the sensors the ECM controls the ignition timing for optimum engine op era...

Page 140: ...CM receives signals from the crankshaft po sition sensor CPS for the following functions Forward engine rotation Reverse engine rotation Crankshaft position and engine RPM The ECM recognizes a signal...

Page 141: ...normal operation to come back If it does not work try removing and reinstalling the tether cord cap on DESS post These performance reduced modes allow the rid er to go back home which would not be po...

Page 142: ...njection related problem Check the chart in TROUBLESHOOTING section to have an overview of problems and suggested so lutions Check if the engine management system EMS pilot lamp lights up If so use th...

Page 143: ...rogram key into ECM 3 short beeps per second Engine overheating pilot lamp also blinks Engine is overheating Stop engine immediately and allow to cool Check cooling system 1 long beep 2 seconds every...

Page 144: ...ange Following problems can be caused by a TPS Adaption Failure Idle speed is out of range Engine stops when throttle is released quickly Engine runs inconsistent in low partload or low RPM POSSIBLE C...

Page 145: ...attery P1676 OFF OFF Relay 2 open circuit or shorted to ground P1148 OFF OFF Safety fuel cut off detected P1611 OFF OFF P Test of ISC output signal failed P0513 OFF OFF Incorrect DESS key P0601 OFF OF...

Page 146: ...tery P0079 BLINK OFF RAVE solenoid open circuit or shorted to ground P0326 BLINK OFF Knock sensor signal below minimum noise P1502 BLINK OFF TOPS functional problem P0351 BLINK OFF No ignition output...

Page 147: ...engine management and fuel injection related problems 529 035 981 NOTE The MPEM programmer does not work on SDI models Ensure to use the latest version of B U D S avail able on BOSSWeb B U D S BRP Ut...

Page 148: ...ic cable from VCK to supply harness NOTE SDI engines already have a 12 V battery they do not need any external 9 V or 12 V power to allow programming and troubleshooting The use of the supply harness...

Page 149: ...shows the KW2000 and the number 1 to the right To communicate with the ECM number 1 must be displayed Number 1 means that one module is connected with the PC F18H0WA kW2000 ONE MODULE IS CONNECTED If...

Page 150: ...sent good transmission system operation good engine compression and properly operat ing mechanical components no leaks etc fuel pump connection and fuel lines without leaks When replacing a component...

Page 151: ...FUEL INJECTORS in this section WARNING Ensure to verify fuel line connections for damage and that NO fuel line is disconnect ed prior to installing the tether cord cap on the DESS post Always perform...

Page 152: ...tics purposes use Vehicle Communication Kit VCK See DIAGNOSTIC PROCEDURES for proper connectors adaptors After a problem has been solved ensure to clear the fault s in the ECM using the VCK Refer to D...

Page 153: ...perature It does not validate the over temperature functionality To test it the sensor could be removed from the engine air si lencer and heated with a heat gun while it is still connected to the harn...

Page 154: ...be dis connected reconnected repeatedly Engine Vehicle Connector Use this illustration to locate the terminal numbers on the engine vehicle connector of the wiring har ness when performing tests 6 A3...

Page 155: ...the ECM connector B If there is no continuity the problem is in the harness Other wise try a new ECM FUEL INJECTORS NOTE Two different types of fuel injectors per cylinder are used A35C3ZA 1 2 1 MAG...

Page 156: ...ensure your reading from the burette is appropriate pay attention to the division lines Ensure fuel tank is full Test for leaks in fuel sys tem fuel pump pressure filter condition in line and in tank...

Page 157: ...table below 6 A32C9IA 7 8 5 1 2 3 4 ENGINE VEHICLE CONNECTOR COMPONENT CONTACT LOCATION Fuel injector MAG outer 4 Engine vehicle connector and A 15 ECM connector Fuel injector MAG inner 3 Engine vehi...

Page 158: ...e following details NOTE Pay attention not to mix up the inner and outer injectors Refer to table and illustration above Replace O rings with new ones NOTE A thin film of engine oil should be applied...

Page 159: ...ECM can still communicate it must be read inside B U D S prior to removing it from the vehicle to carry vehicle information and history to the new ECM ECM Replacement Disconnect battery cables WARNING...

Page 160: ...the wiring harness or the ECM as diagnosed Removal Remove air intake silencer Disconnect the wiring harness from all sensors actuators Disconnect the connector from the ECM Cut all locking tie which...

Page 161: ...ical Inspection Refer to THROTTLE POSITION SENSOR TPS in this section Replacement Removal To remove the throttle body from engine proceed as follows Disconnect connectors from ATS Air Tempera ture Sen...

Page 162: ...tion stopper screw the capped one or the idle speed adjustment would be impaired Be sides no adjustment could be performed by the dealer nor the factory to correct the zero po sition stopper screw The...

Page 163: ...s propor tional to the throttle shaft angle A32C9RA TYPICAL THROTTLE POSITION SENSOR TPS IMPORTANT Prior to testing the TPS ensure that mechanical components adjustments are adequate according to THRO...

Page 164: ...HROTTLE IDLE POSITION WIDE OPEN THROTTLE POSITION TERMINAL TERMINAL RESISTANCE A 24 A 25 2500 1000 A 25 A 39 1600 2400 1600 2400 A 24 A 39 1000 2500 NOTE The resistance value should change smoothly an...

Page 165: ...in the Setting section of B U D S Re power up the ECM by pushing the START RER button momentarily The throttle opening displayed in B U D S should be 0 00 0 1 maximum If TPS is not within the allowed...

Page 166: ...sistance value be tween terminals 5 and 19 If resistance value is correct try a new ECM Re fer to ENGINE CONTROL MODULE ECM in this section If resistance value is incorrect repair the connec tors or r...

Page 167: ...erature sensor CTS Resistance Test Disconnect the plug connector from the CTS and check the resistance of the sensor itself A32C9WA 4 3 1 2 The resistance between terminal 1 and 2 is used for temperat...

Page 168: ...rrectly installed on air intake si lencer Otherwise the APS could generate a fault code Remove sensor and check for oil or dirt on its end and if problem persists check the wiring harness Perform the...

Page 169: ...heck continuity of circuit as per following table CIRCUIT NUMBER ECM CONNECTOR A KS CONNECTOR A 22 TERMINAL 1 A 8 TERMINAL 2 If test is not good repair the connector or replace the wiring harness betw...

Page 170: ...t working actuator can be caused by a com munication problem between ECM and E RAVE actuator If no power goes to the E RAVE actuator no com munication can take place If B U D S works it validates the...

Page 171: ...41 cylinder 1 or 1 cylinder 2 and of igni tion coil connector terminal 3 and terminal 1 re spectively If wiring harness is defective repair the connector or replace the wiring harness between ECM con...

Page 172: ...e may be generat ed in the capacitor after a while Always dis charge capacitor before servicing Removal Remove the 30 A fuse Connect a test light to capacitor terminals during a complete minute to dis...

Page 173: ...o negative ter minal and RED WHITE to positive terminal WARNING Always respect the polarity when connecting the capacitor Install the 30 A fuse ENGINE START RER SWITCH VERIFICATION Refer to STARTING S...

Page 174: ...ehicle since readings would then be distorted Intermittent Ignition Problems It is difficult to make a diagnostic in the case of in termittent ignition problems Thus problems oc curring only when the...

Page 175: ...position Crankshaft Position Sensor CPS NOTE Refer to ENGINE MANAGEMENT IGNITION TIMING Normally ignition timing adjustment should not be required It has been set at factory and it should remain corre...

Page 176: ...e one quarter turn then carefully rotate it clockwise until the needle indicates the specified mea surement ENGINE MEASUREMENT 995 SDI 7 87 mm 0 310 in With the TDC gauge indicating specified timing s...

Page 177: ...s usage is available under its Help section SPARK PLUG Removal First unscrew the spark plug 1 turn Clean the spark plug and cylinder head with pres surized air then completely unscrew WARNING Whenever...

Page 178: ...RICAL SYSTEM Subsection 01 IGNITION SYSTEM A00E0BA 2 1 TYPICAL 1 Proper socket 2 Improper socket Use the following table to torque the spark plugs ENGINE SPARK PLUG TORQUE N m lbf ft 995 SDI NGK 27 20...

Page 179: ...Section 05 ELECTRICAL SYSTEM Subsection 01 IGNITION SYSTEM DESIGN SYMBOLS USED IN NGK SPARK PLUGS A01E4DS 164 mmr2005 127...

Page 180: ...sidered to be defective and must be replaced CAUTION When taking measurements it is useless to try to start the vehicle since readings would then be distorted It is difficult to make a diagnostic in...

Page 181: ...tage regula tor rectifier is defective Removal MODEL LOCATION All models of RT series Under engine and behind muffler All Models Disconnect battery Remove muffler Unplug all connectors located on conn...

Page 182: ...ct battery posts for security of mounting Battery Charge Testing Voltmeter Test NOTE To determine the battery state of charge these sealed batteries have to be tested with a voltmeter They also need t...

Page 183: ...its internal resistance may be too high to charge at a normal charging voltage Therefore it may be necessary to raise the volt age of the battery initially to 25 V as a maximum and charge for approxim...

Page 184: ...ermi nal already installed on wire A32E2TA CRIMPING OF WIRE A32E2UA PROPERLY CRIMPED WIRE To verify if the wire is properly crimped apply some pulling force on wire and the terminal at the same time f...

Page 185: ...e 30 A on battery and the ECM fuse 5 A on electrical harness are in good condition If the fuses test good continue with the next tests Battery Check battery voltage Make sure battery cables are cleane...

Page 186: ...SWITCH TEST Running insulation Continuity in STOP position TEST PROBES BLACK YELLOW and BLACK wires BLACK YELLOW and BLACK wires RESISTANCE O L 00 0 to 00 5 VOLTAGE NOTE Engine cut out switch must be...

Page 187: ...inal and the negative probe to the starter housing Volt A35E0CA Crank engine and record the result The voltage reading should not drop below 9 volts If the result is under 9 volts the starter is defec...

Page 188: ...ve tuned pipe Disconnect RED cable from starter Disconnect ground cable from starter Unbolt and remove starter from engine STARTER INSTALLATION Use new teflon washers on the 3 bolts retaining starter...

Page 189: ...ratically Check engine compression A low compres sion engine may result in RER working erratical ly making you think the problem is an electronic problem Check piston condition Remove exhaust sys tem...

Page 190: ...SELF LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure WARNING Torque wrench tightening specifications must be strictly be adhered to Locking de vices e...

Page 191: ...large nut then remove the 12 Volt power outlet Test Remove power outlet Unplug the power outlet connectors Using the multimeter FLUKE 111 P N 529 035 868 measure the voltage between RED YELLOW and BL...

Page 192: ...ocedure Check connectors position ENGINE TEMPERATURE GAUGE Test Check fuse connectors and harness Check the condition of relay 2 by using the BUDS software Check temperature sensor Replace the gauge R...

Page 193: ...plug burnt bulb connector Remove the rubber boot Turn bulb retainer ring counterclockwise to unlock Detach the bulb and replace A32H44A TYPICAL CAUTION Never touch glass portion of an halogen bulb wit...

Page 194: ...m projected on the wall 3 Light beam center A 25 mm 1 in HEATING ELEMENTS NOTE All measurements must be performed at 21 C 70 F Throttle Lever Heating Element Resistance Measurement THROTTLE LEVER HEAT...

Page 195: ...4 1 Terminal 30 2 Terminal 87 3 Terminal 85 4 Terminal 86 The continuous signal should be audible If not replace the relay SPEEDOMETER Removal Insert a little flat screwdriver into the slot at the bot...

Page 196: ...he battery voltage Measure the voltage between BLACK BLUE and GREEN WHITE wires The obtained value should be 1 volt under battery voltage Dynamic Test Install 3 pins in each speed sensor connector Ins...

Page 197: ...OA NOTE Note the location of each wire Summit Highmark and Summit Highmark X Unscrew the screws retaining the rack to the side of frame Unscrew the other screws that attach the rack near the radiator...

Page 198: ...ve belt if width is under minimum recommended width see table above CHECKING NEUTRAL FUNCTION WARNING Always check neutral function when servic ing Apply parking brake Vehicle must be on the ground an...

Page 199: ...Y ALIGN MENT To obtain maximum vehicle performance the belt height must be adjusted according to specifica tions shown in the accompanying chart MODEL BELT HEIGHT All models Top edge of drive belt cor...

Page 200: ...r to the APPLICATION CHART Adjust pulley distance and alignment Refer to PULLEY DISTANCE AND ALIGNMENT To obtain maximum vehicle performance the belt tension must be adjusted according to specifica ti...

Page 201: ...Section 06 DRIVE SYSTEM Subsection 01 DRIVE BELT A00D08A 2 1 3 4 5 1 Upper O ring force 2 Force 3 Lower O ring deflection 4 Reference rule 5 Deflection 188 mmr2005 131...

Page 202: ...r 529 035 674 191 198 drive pulley puller 529 022 400 191 slider shoe fork 529 005 500 192 197 sliding half bushing remover installer 529 035 931 194 195 spring compressor 529 035 524 192 194 195 197...

Page 203: ...arts Most parts of TRA V are not interchangeable with other TRA models A35D0VS 4 53 N m 39 lbf ft Loctite 609 10 N m 89 lbf in 8 14 21 13 12 10 15 Starter electric models Loctite 271 5 6 1 3 2 88 N m...

Page 204: ...ar screws Torque them if necessary CAUTION All 995 engines are equipped with a ring gear even though the vehicle does not have an electric starter The ring gear is used as a damper Do not remove it RE...

Page 205: ...r cup no 7 until slider shoes no 9 come at their highest position into guides Hold a slider shoe set then carefully lift its housing and install a slider shoe fork P N 529 005 500 Proceed the same way...

Page 206: ...ove all hardened oil deposits that have baked on crankshaft and pulley tapered surfaces with coarse or medium steel wool and or sand paper no 600 CAUTION Do not use any other type of abra sive Reclean...

Page 207: ...lf Bushing Replacement NOTE In case of worn out bushing it is advisable to replace whole sliding half assembly as replac ing just the bushing may reduce the drive pulley performance Remove circlip no...

Page 208: ...rked IN to press in a new bushing A32D2XA TYPICAL NOTE Make sure that the bushing is well seated on the sliding half A32D2YA 1 1 Bushing Install the circlip 1 A32D2ZA TYPICAL 1 Circlip Spring Cover Bu...

Page 209: ...EL ENGINE POSITION Mach Z 995 SDI 6 Summit Canada and U S A 995 SDI 4 Summit Europe 995 SDI 3 Torque locking nut no 24 to 10 N m 89 lbf in Pin Always use the same type of pin no 25 as original ly inst...

Page 210: ...al ways replace all 3 at the same time Other wise drive pulley misbalancing will occur because of levers difference Torque lever bolts no 19 as per the exploded view CAUTION Lever assembly and rollers...

Page 211: ...as described in CLEAN ING above Drive Pulley Assembly The following installation procedure must be strictly adhered Install drive pulley on crankshaft extension Install a new conical spring washer no...

Page 212: ...libration screw has a notch on top of its head A16D0FA 1 TYPICAL 1 Notch Governor cup has 6 positions numbered 1 to 6 See the CALIBRATION SCREW POSITION table above in this section for original settin...

Page 213: ...Section 06 DRIVE SYSTEM Subsection 02 DRIVE PULLEY A16D0HA 1 TYPICAL 1 Loosen just enough to permit rotating of calibration screw 200 mmr2005 132...

Page 214: ...36 012 203 206 crankshaft protector 420 876 552 206 large bushing extractor 529 031 100 205 large bushing extractor 529 035 575 206 spring scale hook 529 006 500 211 SERVICE PRODUCTS Description Part...

Page 215: ...DRIVEN PULLEY HPV ROLLER Mach Z Models A35D10S 5 23 N m 17 lbf ft Loctite 380 7 N m 63 lbf in 4 6 12 13 7 N m 63 lbf in 8 11 N m 97 lbf in Loctite 271 16 14 10 N m 89 lbf in 11 7 10 9 3 Antiseize lubr...

Page 216: ...riven pulley is a precisely balanced unit Never replace parts with used parts from an other driven pulley REMOVAL Driven Pulley Remove belt guard and drive belt Remove driven pulley bolt no 1 and shou...

Page 217: ...moved from the cam or the shaft use dry cloth to avoid removing transferred teflon INSPECTION NOTE Inner flanges threads countershaft and all surfaces which have contacts with other moving parts must...

Page 218: ...screws to 11 N m 97 lbf in Make sure to install the proper cam The cam an gle is indicated on the cam Refer to TECHNICAL DATA to know which cam must be used A35D16A During cam installation make sure t...

Page 219: ...with the clutch spring compres sor P N 529 036 012 A35D19A Coat bushing outside diameter with Loctite 380 Black MAX P N 413 408 300 Place new bush ing on sliding half and slightly tap to engage square...

Page 220: ...Section 06 DRIVE SYSTEM Subsection 03 DRIVEN PULLEY A35D1BA Install circlip mmr2005 133 207...

Page 221: ...Subsection 03 DRIVEN PULLEY HPV VSA Summit Highmark and Summit Highmark X Models A35D0ZS 5 23 N m 17 lbf ft Loctite 380 10 N m 89 lbf in 6 7 8 9 10 13 12 11 Black Red 3 2 1 Loctite 243 4 Antiseize lu...

Page 222: ...y no 3 from the countershaft Note shouldered washer position for reinstalla tion Take care not to lose spacer no 4 Countershaft Should countershaft removal be required refer to CHAINCASE DISASSEMBLY U...

Page 223: ...for reverse and black ones for forward A30D0WA 1 1 2 2 2 1 1 BLACK slider shoe 2 RED slider shoe Screws Screws no 11 are machined at their end With the adjustment ring steel to position 0 zero screw...

Page 224: ...ng scale at this position Slow ly release tension from spring scale and take sec ond measurement when sliding half begins to re turn Spring preload is the average measurement between these 2 First mea...

Page 225: ...ERS AND NUMBERS EMBOSSED ON PARTS NOTE Always recheck torsional preload after ad justing Pulley Alignment and Drive Belt Height Refer to PULLEY ALIGNMENT and DRIVE BELT to perform adjustments CAUTION...

Page 226: ...ctly perform pulley alignment may cause the vehicle to creep forward at idle All Pulley Alignment Specifications Refer to X Distance between straight bar and drive pulley fixed half edge measured betw...

Page 227: ...an alignment is necessary see ALIGNMENT PROCEDURE below If the alignment is good hand torque the torque rod so it slightly contacts engine crankcase Do not over tighten it will disalign pulleys When...

Page 228: ...6 DRIVE SYSTEM Subsection 05 BRAKE BRAKE SERVICE PRODUCTS Description Part Number Page DOT 4 brake fluid GTLMA 293 600 062 217 DOT 4 brake fluid SRF 293 600 063 217 Loctite 609 413 703 100 221 mmr2005...

Page 229: ...Section 06 DRIVE SYSTEM Subsection 05 BRAKE A35D02S 8 11 9 3 10 12 16 13 10 15 14 4 5 1 2 7 6 17 24 N m 18 lbf ft 1 N m 9 lbf in 8 N m 71 lbf in 24 N m 18 lbf ft 48 N m 35 lbf ft 216 mmr2005 135...

Page 230: ...brake fluid must be changed in accordance with the maintenance chart Use recommended DOT 4 brake fluid SRF P N 293 600 063 or DOT 4 brake fluid GTLMA P N 293 600 062 CAUTION Use only DOT 4 brake flui...

Page 231: ...procedure but pay attention at the follow ing Install the master cylinder holder no 7 with the arrow pointing downwards A35D03A Torque the lower screw first to 8 N m 71 lbf in then the upper screw to...

Page 232: ...no 13 must be centered in caliper Apply brake then check for proper brake disc po sitioning Push on appropriate caliper piston in order to move pad inward allowing proper brake disc po sitioning 1 A03...

Page 233: ...pacer A35D09A 3 2 1 1 Cotter pin 2 Brake disc nut 3 Spacer Unscrew caliper bolts no 16 and place caliper out of the way CAUTION Do not let the caliper hang by the hose and do not stretch or twist the...

Page 234: ...ads with the clamp screw If there is resistance to the advance of the clamp screw use a proper wrench NOTE In case of switch body breaking during the unscrewing activity act mechanical restoring the t...

Page 235: ...umber Page countershaft bearing remover installer 529 036 010 230 231 countershaft measurement tool 529 036 009 230 SERVICE PRODUCTS Description Part Number Page Loctite 271 red 293 800 005 228 XP S c...

Page 236: ...42 N m 31 lbf ft Loctite 243 42 N m 31 lbf ft 26 42 N m 31 lbf ft 6 N m 53 lbf in 23 33 29 17 Loctite 271 48 N m 35 lbf ft 16 15 12 11 15 13 10 14 4 5 36 N m 27 lbf ft Hand torque Mach Z series Summit...

Page 237: ...es from magnet Refill to upper mark using XP S chaincase oil P N 413 801 900 or the XP S synthetic chaincase oil P N 413 803 300 CAUTION Do not use unrecommended types of oil when servicing Do not mix...

Page 238: ...tension by unscrewing the tensioner bolt no 5 A35D0EA 3 2 1 1 Lock nut 2 Tensioner bolt 3 Tensioner lever Pull tensioner lever no 10 out of chaincase hous ing Inspection Check if the roller no 11 turn...

Page 239: ...orque nut Install the caliper Torque bolts Apply parking brake Remove the lower sprocket bolt no 16 and its washer no 17 A35D0JA Release parking brake and remove caliper and brake disc On Summit serie...

Page 240: ...n be done on the silent chain type The installation is the reverse of the removal pro cedure Pay attention to the following details Reinstall the brake disc and the caliper to torque the lower sprocke...

Page 241: ...pulley and its shims refer to DRIV EN PULLEY Unscrew the bearing flange bolts no 34 and re move the bearing flange no 35 A35D0OA 4 1 2 3 2 1 Bearing flange 2 Bearing flange bolts 3 Countershaft 4 Coun...

Page 242: ...Shimming Procedure To perform the measurement of shims install the countershaft measurement tool P N 529 036 009 instead of the countershaft bearing no 36 and in stall the bearing flange no 35 A35D0QA...

Page 243: ...shim s then place the new countershaft bearing on countershaft Install the countershaft bearing remover installer P N 529 036 010 and push bearing in its location A35D0SA Install all other removed par...

Page 244: ...Subsection 07 DRIVE AXLE DRIVE AXLE SERVICE TOOLS Description Part Number Page drive axle sprocket adjuster kit 861 725 700 238 SERVICE PRODUCTS Description Part Number Page synthetic grease 219 700...

Page 245: ...Section 06 DRIVE SYSTEM Subsection 07 DRIVE AXLE MACH Z Models A33D1RS 1 Suspension synthetic grease 11 N m 97 lbf in 4 2 3 9 8 5 6 Suspension synthetic grease 7 7 234 mmr2005 137...

Page 246: ...tion 06 DRIVE SYSTEM Subsection 07 DRIVE AXLE Summit Highmark and Summit Highmark X Models A33D1SS 1 Suspension synthetic grease 11 N m 97 lbf in 4 2 3 9 8 5 6 Suspension synthetic grease mmr2005 137...

Page 247: ...sprockets then circlip from right side Release drive axle sprocket from track and at the same time push the drive axle no 5 toward the right side Drive axle bearing in chaincase will fall off Sprocke...

Page 248: ...Summit Highmark and Summit Highmark X Models A33D1VA A C B MEASURE FROM END OF DRIVE SHAFT A 132 2 mm 5 205 in B 178 1 mm 7 0118 in C 310 4 mm 12 220 in Ensure to align indexing marks of each sprocket...

Page 249: ...e LUBRICATION Lubricate end housing bearing with synthetic grease P N 219 700 417 Continue lubricat ing until grease flows out of the pilot hole on speedometer sensor A32D44A 1 TYPICAL 1 Lubricate unt...

Page 250: ...ing cleat remover P N 529 028 700 Use narrow cleat installer P N 529 028 800 529 028 700 529 028 800 WARNING Do not operate a snowmobile with a cut torn or damaged track REMOVAL Remove the following p...

Page 251: ...loss and excessive stresses on suspension components To Adjust Tension Remove wheel caps Loosen the rear idler wheel retaining screws Turn adjustment screws to adjust A30F03A 1 2 3 TYPICAL 1 Adjustme...

Page 252: ...position on the track and using the narrow cleat installer P N 529 028 800 bend cleat then push tabs into rubber Re open installer then position cleat tabs on open end of tool and squeeze tabs until t...

Page 253: ...ively worn or not installed the gas tank could be punc tured causing a fire A33A35A APPROVED TRACKS CAN BE IDENTIFIED BY THIS SYMBOL Maintenance Replacement A visual inspection of the track should be...

Page 254: ...Section 07 REAR SUSPENSION Subsection 01 SC SUSPENSION SC SUSPENSION SERVICE PRODUCTS Description Part Number Page suspension synthetic grease 293 550 033 254 mmr2005 147 243...

Page 255: ...Section 07 REAR SUSPENSION Subsection 01 SC SUSPENSION A35F05S 2 5 N m 23 lbf in 4 N m 35 lbf in 4 5 N m 40 lbf in RAILS AND IDLER WHEELS 244 mmr2005 147...

Page 256: ...C SUSPENSION A33F56S Suspension synthetic grease 19 5 N m 173 lbf in 19 5 N m 173 lbf in 3 N m 27 lbf in Suspension synthetic grease 3 N m 27 lbf in 19 N m 168 lbf in 21 N m 15 lbf ft 11 N m 97 lbf in...

Page 257: ...ENSION Subsection 01 SC SUSPENSION A33F55S Suspension synthetic grease 2 5 N m 22 lbf in 2 5 N m 22 lbf in 3 N m 27 lbf in Suspension synthetic grease 3 N m 27 lbf in REAR ARM SPRINGS AND TOP IDLER WH...

Page 258: ...d locker REAR AXLE REMOVAL Lift rear of vehicle and support it off the ground Remove screws on rear axle Completely loosen track tension A33F57A 1 1 Completely loosen track tension Remove the followin...

Page 259: ...VAL Lift rear of vehicle and support it off the ground Unfasten one end of stopper strap s or loosen the adjuster knob to release shock pressure A32E19B 1 1 Loosen lock nut turn adjuster knob counterc...

Page 260: ...g cams accord ingly A35F08A 1 DECREASE SPRING PRELOAD Unbolt rear arm top axle from chassis A33F59C 1 1 Unbolt rear arm Remove spring supports WARNING Supports are spring loaded A33F5PA TYPICAL REMOVE...

Page 261: ...spect the following tightening torque specifica tion DESCRIPTION TIGHTENING TORQUE Locking ring set screw 2 5 N m 22 lbf in SLIDER SHOE VERIFICATION Molding line is the wear limit indicator 1 A03F3SA...

Page 262: ...REMOVE SLIDER SHOE INSTALLATION Installation is reverse of removal procedure Pay attention to the following details Make sure to insert slider shoe end with hole first Respect the following tightening...

Page 263: ...ing shock upper bolt and nut throttle rod upper bolt and nut rear springs refer to procedure above in this section screws and washers holding rear arm to pivot arm Remove rear arm For pivot arm remova...

Page 264: ...er hole from the end A33F58B 2 1 1 No adjustment possible 2 3 adjustments possible DESCRIPTION TIGHTENING TORQUE Stopper strap nuts on strap adjuster 21 N m 15 lbf ft Stopper strap nuts 11 N m 97 lbf...

Page 265: ...tion to the following details Inspect track thoroughly before reinstalling sus pension Refer to TRACK Install suspension into track with front portion first Adjust track tension RIDE ADJUSTMENT Refer...

Page 266: ...Section 07 REAR SUSPENSION Subsection 02 SC 4 SUSPENSION SC 4 SUSPENSION SERVICE PRODUCTS Description Part Number Page suspension synthetic grease 293 550 033 267 mmr2005 139 255...

Page 267: ...SUSPENSION Subsection 02 SC 4 SUSPENSION A33F61S 4 5 N m 40 lbf in 4 5 N m 40 lbf in 4 5 N m 40 lbf in 4 5 N m 40 lbf in 4 5 N m 40 lbf in 2 5 N m 22 lbf in 2 5 N m 22 lbf in RAILS AND IDLER WHEELS 2...

Page 268: ...Section 07 REAR SUSPENSION Subsection 02 SC 4 SUSPENSION A35F0CS 85 N m 63 lbf ft 120 N m 89 lbf ft 120 N m 89 lbf ft 11 N m 97 lbf in 11 N m 97 lbf in ARMS AND SHOCK ABSORBERS mmr2005 139 257...

Page 269: ...ction 02 SC 4 SUSPENSION A33F63S 2 5 N m 22 lbf in 3 N m 27 lbf in Suspension synthetic grease Suspension synthetic grease 3 N m 27 lbf in Suspension synthetic grease 3 N m 27 lbf in REAR ARM SPRINGS...

Page 270: ...to melt thread locker REAR AXLE REMOVAL Lift rear of vehicle and support it off the ground Remove screws on rear axle Completely loosen track tension A33F5HA 1 1 Completely loosen track tension Remov...

Page 271: ...tention to the following details To ease shock installation secure upper shock first CAUTION Make sure shock bar axle is aligned with swivel bushings before inserting it A35F0BA 1 2 3 1 Bar axle 2 Swi...

Page 272: ...1 Adjustment ring REAR SPRING REMOVAL Lift rear of vehicle and support it off the ground Decrease spring preload by turning cams accord ingly Loosen rear arm top axle from chassis Remove idler wheels...

Page 273: ...THIS SIDE OUT inscription on top idler wheels At assembly make sure that spring end is in cam adjuster A33F5QA 1 ON BOTH SIDES 1 Spring end in cam adjuster CAUTION To avoid track damage spring sup por...

Page 274: ...off the ground Completely loosen track tension Remove nut and screw of each runner A33F5RA REMOVE NUT AND SCREW OF EACH RUNNER Align track window with slider shoe A33F5SA 2 1 TYPICAL 1 Track window 2...

Page 275: ...and wash ers Remove front arm A33F5XA 5 1 6 3 2 7 2 3 4 6 TYPICAL SUSPENSION REMOVED FOR CLARITY 1 Shock upper bolt and nut 2 Front idler wheels 3 Spring supports 4 Front arm lower bolts and washers...

Page 276: ...must exceed block guide by 2 to 2 3 mm 079 to 091 in Respect the following tightening torque specifica tions DESCRIPTION TIGHTENING TORQUE Pivot arm runners nut 25 N m 18 lbf ft Locking ring set screw...

Page 277: ...op bolts A35F01D 2 1 TYPICAL 1 Remove rear arm top axle screws 2 Remove front arm top bolts Lift rear of vehicle until front arm as enough clear ance to pass underneath tunnel A33F5VA 1 1 Enough clear...

Page 278: ...Section 07 REAR SUSPENSION Subsection 02 SC 4 SUSPENSION LUBRICATION Lubricate pivot arm and rear arm at grease fittings using suspension synthetic grease P N 293 550 033 A33F64A mmr2005 139 267...

Page 279: ...504 269 shock wrench 529 035 727 271 Shock wrench 529 035 727 270 SERVICE PRODUCTS Description Part Number Page Bombardier HPG shock oil 293 600 035 274 Loctite 271 293 800 005 272 Molykote G n paste...

Page 280: ...assisted Rod must come out at a steady speed If speed suddenly increases particularly at end of extension replace shock If suspecting a frozen shock proceed as follows Place shock in a freezer tempera...

Page 281: ...crew Cap Type HPG T A Shock Using appropriate size of shock wrench P N 529 035 727 unscrew seal carrier 529 035 727 A32F1NA TYPICAL Snap Ring Cap Type HPG T A Shock Using a flat tool pop out the cap C...

Page 282: ...the sequence of disassembly A06F0VA NOTE As a general rule we suggest replacing the damper rod lock nut after 4 rebuilds to ensure good Iocking friction and use Loctite 271 P N 293 800 005 each time N...

Page 283: ...threads of damper shaft Spacer under damper shaft nut is used to prevent damper shaft nut from bottoming on threads A32F1XA 1 2 3 4 5 6 1 Rebound dampening shim pack 2 Rebound dampening shim pack 3 Pi...

Page 284: ...iston installation SHOCK P N INSTALLATION DISTANCE OF FLOATING PISTON mm in 503 190 655 119 5 4 70 503 190 662 121 5 4 78 503 190 834 134 5 28 503 190 990 171 5 6 75 503 190 994 171 5 6 75 NOTE If the...

Page 285: ...ge air trapped in the submersed piston Be careful not to drive the shaft any deeper into the oil than is necessary to just cover the shim stack NOTE Fast installation of the damper rod may dis place t...

Page 286: ...02 on gas shock valve tool tire valve type P N 529 035 570 Set the regulator pressure on the nitrogen cylinder as per the shock require ment Mount the shock on vise Remove screw on top of valve Place...

Page 287: ...After recharging is complete the rebuilt shock should be bench tested Stroke the shock to ensure full travel and smooth compression and rebound action If the shaft moves in or out er ratically this co...

Page 288: ...Section 08 STEERING FRONT SUSPENSION Subsection 01 STEERING SYSTEM STEERING SYSTEM SERVICE PRODUCTS Description Part Number Page suspension synthetic grease 293 550 033 289 mmr2005 141 279...

Page 289: ...gement A35G01S 1 25 N m 18 lbf ft Suspension synthetic grease 3 N m 27 lbf in 18 N m 159 lbf in 5 25 N m 18 lbf ft 53 N m 39 lbf ft Suspension synthetic grease 7 8 15 6 17 11 18 7 53 N m 39 lbf ft 41...

Page 290: ...T HIGHMARK X MACH Z SUMMIT HIGHMARK X 24 19 21 20 22 27 25 N m 18 lbf ft 2 4 8 N m 71 lbf in 13 2 4 25 N m 18 lbf ft 8 N m 71 lbf in 12 10 28 11 N m 97 lbf in 23 24 19 21 20 22 27 13 25 N m 18 lbf ft...

Page 291: ...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 retaining throttle lever h...

Page 292: ...tion 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 WARNIN...

Page 293: ...Indicator support 3 Indicator support door 4 Center console Remove indicator support door A35H06A 1 INDICATOR SUPPORT DOOR 1 Locking tab Slightly lift console to gain access to electrical con nector...

Page 294: ...eering column from top If for any reason the master cylinder has been removed from handlebar note that its clamp no 27 must be installed with the embossed ar row pointing downward Torque screws to 8 N...

Page 295: ...ot engaged in the tie rod must not exceed 20 mm 25 32 in Hardened Washer Install a hardened washer no 7 on each side of the ski leg and each side of the steering column lever 1 1 A33G0EA TYPICAL 1 Har...

Page 296: ...the brake handle and the windshield by 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...

Page 297: ...traight ahead position by measuring from the extremities of the grips to the rear most edge of the tunnel as shown NOTE The reference point must be the same rel ative to each side A33A2BB 1 2 A A 2 1...

Page 298: ...ll joint ex ceeds 20 mm 25 32 in Once ski alignment is done check that ski leg rests against lower arm or is not more than 2 mm 5 64 in from lower arm when the handlebar is fully turned 1 2 A33G0HB A...

Page 299: ...installer 529 035 975 301 ball joint lock tool 529 035 945 302 ball joint remover 529 035 827 297 298 ball joint remover support 529 035 873 297 ball joint support 529 035 875 301 shock absorber spri...

Page 300: ...ONT SUSPENSION Summit A35F07S 19 20 18 17 16 48 N m 35 lbf ft 15 25 16 N m 142 lbf in 21 22 23 7 24 14 6 10 9 60 N m 44 lbf ft 60 N m 44 lbf ft 32 31 13 12 11 8 48 N m 35 lbf ft 48 N m 35 lbf ft SUSPE...

Page 301: ...tion 02 FRONT SUSPENSION Mach Z A35F02S 20 48 N m 35 lbf ft 16 N m 142 lbf in 19 17 48 N m 35 lbf ft 23 22 21 7 48 N m 35 lbf ft 14 10 11 12 32 31 8 9 60 N m 44 lbf ft 60 N m 44 lbf ft 13 15 16 18 ARM...

Page 302: ...ch Z A35F03S 29 30 Mountain Ski Precision Ski 32 N m 24 lbf ft 18 N m 160 lbf in 3 3 1 33 34 4 5 2 18 N m 160 lbf in 4 5 26 32 N m 24 lbf ft 1 2 26 29 30 30 Suspension synthetic grease 28 27 28 SHOCK...

Page 303: ...ys to feel the free play If excessive play is felt replace the faulty com ponent DISASSEMBLY Ski Lift front of vehicle and support it off the ground Unscrew nut no 1 then pull screw no 2 out Re move s...

Page 304: ...is pin 1 A01B4LA 2 3 TYPICAL 1 Clevis pin 2 Bar 3 Handle horizontal Push down on the handle until it locks Remove spring stopper then release handle Mach Z At assembly cap opening no 30 must be 180 fr...

Page 305: ...allel with ski leg no 12 Install ball joint remover P N 529 035 827 and detach ball joint from ski leg 529 035 827 A33F1XA 1 A33F1YA TYPICAL 1 Ball joint parallel with ski leg Remove lower arm no 10 f...

Page 306: ...int no 15 from ski leg 529 035 827 A33F2BA Use a 11 mm 7 16 in open wrench to hold ball joint housing and unscrew nut no 16 then re move ball joint from upper arm Remove upper arm no 14 from frame For...

Page 307: ...e enough so that anti sway bar no 7 can be rotated downward to allow to slide it out A33F24A To remove bushing no 25 use a 13 mm 1 2 in open wrench and tap bushing out as shown 1 A33F25A 1 Use a 13 mm...

Page 308: ...section SHOCK ABSORBER INSPECTION AND SERVICING in section REAR SUSPENSION INSTALLATION For assembly reverse the disassembly procedure However pay attention to the following Tighten nuts and screws t...

Page 309: ...ley flange cleaner P N 413 711 809 Surface contacts must be clean and free of dirt oil and grease Apply the cleaner on a rag then use the rag to clean the surfaces of ball joint and ski leg To install...

Page 310: ...llow proper seating of tool A32F3XA TYPICAL Anti Sway Bar Summit Notice that LH and RH sliding blocks are different Look for their molded identification with LH or RH letters 1 A33F2DA 1 Molded identi...

Page 311: ...nd lower arm then rotate back to its normal position Mach Z Secure anti sway bar to link rod as per next illus tration 1 A35F06A 2 3 4 5 3 LOOKING FROM THE FRONT OF THE VEHICLE 1 Anti sway bar 2 Link...

Page 312: ...ease P N 293 550 033 between bushing no 28 and spacer no 27 and also on inner tube of ski leg Summit Install bushing no 29 and spacer no 30 inward on each ski leg for the wide ski stance Install outwa...

Page 313: ...a squeegee remove the air bubbles and surplus water work ing from the center toward the edges Allow to air dry CAUTION Do not apply isopropyl alcohol or solvent directly on decals Use only in a well...

Page 314: ...part of windshield until its pins come out of rubber grommets Installation The installation is the reverse of removal proce dure ACCESS PANEL Removal Open hood Remove windshield Remove retaining scre...

Page 315: ...reverse of removal proce dure SEAT Cleaning It is recommended to clean the seat with a solu tion of warm soapy water using a soft clean cloth CAUTION Avoid use of harsh detergents such as strong soap...

Page 316: ...se accumulation To clean use a soft clean cloth and either soapy water or isopropyl alcohol To remove grease oil or glue use isopropyl alco hol CAUTION Do not apply isopropyl alcohol or acetone direct...

Page 317: ...UTION Some repair products are not com patible with certain plastics WARNING Polycarbonate windshields must never be re paired by welding or otherwise For hood repair refer to a specialized shop The f...

Page 318: ...lectronic module On models equipped with a battery also unplug the negative cable This will pro tect the electronic module and battery against damage caused by flowing current when weld ing CAUTION If...

Page 319: ...and discard lower brackets For the Installation of Lower A arm Brackets do the Following Secure the new lower brackets to frame using the following fasteners QUANTITY FASTENERS DESCRIPTION 2 Hexagona...

Page 320: ...rod 2 Tie rod 3 Swivel bar bolt holding RH tie rod to swivel bar A35H0MA 1 1 RH tie rod bolt swivel bar with swivel arms front shock absorbers upper and lower A arms with tie rods and skis bolts and n...

Page 321: ...aining upper and lower cross mem ber Do not torque yet Install bolts and nuts that attach rear of lower cross member to frame Do not torque yet On each side install the following fasteners in stead of...

Page 322: ...ANTITY FASTENERS DESCRIPTION 4 Hexagonal flanged bolt M6 x 20 P N 207 662 044 4 Elastic flanged nut M6 P N 233 261 414 Install new bolts with their heads outside Install all removed parts Refer to CHA...

Page 323: ...45 to 0059 Piston cylinder wall clearance Wear limit mm in 0 20 0079 Maximum crankshaft end play 2 New mm in 0 30 0118 Maximum crankshaft deflection at PTO Wear limit mm in 0 030 0012 New mm in 0 23 t...

Page 324: ...9 700 362 12 x 1 L Thermostat opening temperature C F N A Radiator cap opening pressure kPa PSI 90 13 DRIVE Chaincase oil XP S Synthetic chaincase oil Chain drive ratio 29 49 21 49 EUR 23 49 Pitch in...

Page 325: ...DOT 4 P N 293 600 062 Racing brake fluid SRF DOT 4 P N 293 600 063 VEHICLE INFORMATIONS Manual start 236 kg 519 lb Mass dry Electric start 248 kg 546 lb 240 kg 529 lb Length mm in 2930 115 4 3435 135...

Page 326: ...TORQUE engine cold Drive pulley retaining screw 5 Exhaust manifold screws 21 5 N m 16 lbf ft Magneto ring nut 130 N m 96 lbf ft M6 9 N m 80 lbf in Crankcase nuts or screws M8 29 N m 21 lbf ft Crankca...

Page 327: ...on 4 All resistance measurements must be performed with parts at room temperature approx 20 C 68 F Temperature greatly affects resistance measurements 5 Drive pulley retaining screw torque to 100 to...

Page 328: ...tor location in housing WIRE COLORS 1 MC D A00I04F XX XX XX XX The first color of a wire is the main color second color is the stripe Example YL BK is a YELLOW wire with a BLACK stripe COLOR CODE BE B...

Page 329: ...REFERENCE PER AREA The next two letters of the connector identifica tion number represents a connector reference If there are many connectors in the same area this helps identify which wire is in whi...

Page 330: ...4 5 6 1 2 3 1 2 3 6 5 4 6 5 4 1 2 4 3 4 3 1 2 2 1 1 2 A B A B A B 2 1 A B C A B C B A A D C B B C A D A B A B C AMP A C B 5 6 7 8 1 1 1 3 2 1 3 2 A B KOSTAL 4 3 2 1 1 2 3 4 5 6 6 5 4 3 2 1 4 5 6 7 8 1...

Page 331: ...tric motor Low level sensor Buzzer Ignition coil Normally close switch Male terminal on instrument Engine ground Spark plug Meter movement Bulb Pilot Analog sensor Solenoid valve Magneto Delta 3 posit...

Page 332: ...B CONNECTOR 1 Locking tab To remove Insert a screwdriver or Snap on TT 600 5 from opposite side of wire and pry locking tab While holding locking tab pried pull connector toward wire side A00E1EA 2 1...

Page 333: ...CUT AWAY Male Connector Housing To remove Using a small hook pull out the lock A01E33A 1 1 Lock A01E34A 1 1 Lock Pry tab to free connector then pull wire out of housing A01E35A MALE CONNECTOR HOUSING...

Page 334: ...ing with sharp head pin Male Connector Housing A32Z04A To remove Insert tool AMP 755430 2 under lock and twist to lift it 1 A32Z05A MALE CONNECTOR HOUSING CUT AWAY 1 Lock 24 Circuit Connector Housing...

Page 335: ...y housing to release lock 1 A33Z04A 1 Lock Insert tool AMP 755430 2 under tab and pry it to free connector Pull on the female terminal wire to remove female terminal from housing 1 A33Z05A 8 CIRCUIT C...

Page 336: ...he probe into the housing as shown and locate the appropriate wire in the back of the housing You may have to slightly cam the probe against the locking tab to release it then remove the terminal from...

Page 337: ...To crimp a new connector terminal use the con nector crimping tool P N 529 035 909 and the crimper die P N 529 035 906 F00B0EA CRIMPING TOOL To properly crimp the wires strictly follow this pro cedur...

Page 338: ...ior to installing make sure locking tab is suffi ciently lifted to properly lock Insert tab and receptacle connectors in their re spective housings as shown in following illustra tions Push sufficient...

Page 339: ...Section 11 WIRING DIAGRAMS Subsection 01 WIRING DIAGRAMS A35Z01S 2005 MACH Z RT SUMMIT RT ENGINE 334 MMR2005 146...

Page 340: ...NOTES...

Page 341: ...NOTES...

Page 342: ...2005 MACH Z RT SUMMIT RT A35Z02...

Page 343: ......

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