Ski-Doo FORMULA 500 1997 Shop Manual Download Page 9

Page: 9 / 352

ARRANGEMENT OF THE
MANUAL

The manual is divided into 09 major sections:

01 LUBRICATION AND MAINTENANCE

02 TROUBLESHOOTING

03 ENGINE

04 TRANSMISSION

05 ELECTRICAL

06 REAR SUSPENSION

07 STEERING/FRONT SUSPENSION

08 BODY/FRAME

09 TECHNICAL DATA

ANNEXES

Each section is divided in various sub-sections,
and again, each sub-section has one or more divi-
sion.

1997 BOMBARDIER SNOWMOBILES
SHOP MANUAL

Summary of Contents for FORMULA 500 1997

Page 1: ......

Page 2: ...Section 00 Sub Section 0 00 0 1 1997 Shop Manual VOLUME 2 MX Z 440F 440 583 670 FORMULA 500 500 DELUXE 583 Z SUMMIT 500 583 670 GRAND TOURING 500 583 SKANDIC WT SWT WT LC ...

Page 3: ...Bombardier Inc Valcourt Quebec Canada Printed in Canada Registered trademarks of Bombardier Inc This document contains the trademarks of the following companies Loctite is a trademark of Loctite Corporation Metton is a trademark of Hercules Inc Molykote is a trademark of Dow Corning Corporation Silastic is a trademark of Dow Corning Corporation Snap on is a trademark of Snap on Tools Corporation V...

Page 4: ...em 03 07 1 08 Liquid cooling system 03 08 1 09 Rotary valve coolant pump and reservoir 03 09 1 10 Rewind starter 03 10 1 11 Carburetor and fuel pump 03 11 1 12 Fuel tank and throttle cable 03 12 1 04 TRANSMISSION 01 Table of contents 04 01 1 02 Drive belt 04 02 1 03 Drive pulley 04 03 1 04 Driven pulley 04 04 1 05 Pulley distance and alignment 04 05 1 06 Brake 04 06 1 07 Chaincase 04 07 1 08 Gearb...

Page 5: ...sion and ski system 07 03 1 08 BODY FRAME 01 Table of contents 08 01 1 02 Body 08 02 1 03 Frame 08 03 1 09 TECHNICAL DATA 01 SI metric information guide 09 01 1 02 Engines 09 02 1 03 Vehicles 09 03 1 04 Technical data legends 09 04 1 ANNEX Wiring Diagrams SECTION SUB SECTION PAGE TABLE OF CONTENTS ...

Page 6: ... 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 elastic stop nut etc must be installed or replaced with new ones where specified If the efficiency of a locking device is impaired it must be renew...

Page 7: ...ULA 500 DELUXE Canada 1191 FORMULA 500 DELUXE U S 1192 FORMULA 583 Canada 1141 FORMULA 583 U S 1142 FORMULA Z Canada 1145 FORMULA Z U S 1146 MODELS MODEL NUMBER SUMMIT 500 Canada 1157 SUMMIT 500 U S 1158 SUMMIT 583 Canada 1159 SUMMIT 583 U S 1160 SUMMIT 583 Europe 1161 SUMMIT 670 Canada 1162 SUMMIT 670 U S 1163 GRAND TOURING 500 Canada 1123 GRAND TOURING 500 U S 1124 GRAND TOURING 500 Europe 1125 ...

Page 8: ...ICAL S SERIES Each vehicle has its particular vehicle serial number Serial Number Meaning TYPICAL 1 Vehicle serial number The engine also has a serial number Fan Cooled Engines 1 Engine serial number Liquid Cooled Engines 1 Engine serial number A03H1UA A00A0DA Model no Vehicle no 0000 00000 A06H01A 1 A07C01A 1 A00C1QA 1 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL ...

Page 9: ...INTENANCE 02 TROUBLESHOOTING 03 ENGINE 04 TRANSMISSION 05 ELECTRICAL 06 REAR SUSPENSION 07 STEERING FRONT SUSPENSION 08 BODY FRAME 09 TECHNICAL DATA ANNEXES Each section is divided in various sub sections and again each sub section has one or more divi sion 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL ...

Page 10: ...e torqued to 4 N m or 35 lbf in This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog Exploded view assists you in identifying parts and related positions TYPICAL PAGE A01A1QS Illustration number for publishing process Sub section title indicates beginning of the sub section Drop represents a liquid product to be applied to a surface In this case L...

Page 11: ...flection Reinstall the pulley on the countershaft by rever sing the removal procedure A03D1YA 529 0313 00 529 0312 00 A03D1ZA 529 0313 00 529 0312 00 Cam Coat cam no 18 interior with anti seize lubricant ASSEMBLY Came Slider Shoe Section 05 TRANSMISSION Sub Section 03 DRIVEN PULLEY When replacing slider shoes no 4 always install a new set 3 shoes to maintain equal pressure on the cam Assemble driv...

Page 12: ...ferent assemblies and in all cases may not reproduce the full detail or exact shape of the parts shown however they repre sent parts which have the same or a similar func tion 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 sub section in which the proce dure is contained A number of pro...

Page 13: ... TORQUES Tighten fasteners to torque mentioned in explod ed views and text When they are not specified refer to following table A06G07B 1 2 N m FASTENER SIZE 8 8 Lbf in 1 9 2 M4 18 3 M4 27 4 M5 35 5 44 6 53 7 62 8 M6 71 9 M6 80 10 M6 89 11 M6 97 12 M6 106 13 115 14 124 15 133 16 142 17 150 18 159 19 168 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL ...

Page 14: ...38 52 M10 38 53 M10 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 71 52 72 53 73 54 74 55 75 55 76 M12 56 77 M12 57 78 M12 58 79 M12 58 80 M12 59 81 M12 60 82 M12 60 83 M12 61 84 M12 62 85 63 86 63 87 64 88 65 89 66 90 66 91 67 92 68 93 69 94 69 95 70 96 71 97 72 98 72 99 73 100 74 101 74 102 75 103 76 104 77 105 77 106 78 107 79 108 80 10...

Page 15: ...1 125 M14 92 126 M14 93 127 M14 94 128 M14 94 129 M14 95 130 M14 96 131 M14 97 132 M14 97 133 M14 98 134 M14 99 135 M14 100 136 M14 100 137 M14 101 138 M14 102 139 M14 103 140 M14 103 141 M14 104 142 M14 105 143 M14 105 144 M14 106 145 M14 107 146 M14 108 147 M14 108 148 M14 109 149 M14 110 150 M14 111 N m FASTENER SIZE 8 8 Lbf ft 1997 BOMBARDIER SNOWMOBILES SHOP MANUAL ...

Page 16: ... section 03 11 Throttle Cable Inspection Sub section 03 12 Air Filter Cleaning This section no 4 Drive Belt Condition This section no 5 Condition of Drive and Driven Pulleys Sub sections 04 03 and 04 04 Cleaning of Drive and Driven Pulleys Sub sections 04 03 and 04 04 Retorquing of Drive Pulley Screw Sub section 04 03 Driven Pulley Preload Sub section 04 04 Brake Condition Sub section 04 06 Brake ...

Page 17: ...s or 500 km 300 mi Suspension Adjustments AS REQUIRED Section 06 See appropriate sub section and Operator s Guide Suspension Lubrication 2 Section 06 See appropriate sub section Suspension Condition Section 06 See appropriate sub section Suspension Stopper Strap Condition Section 06 See appropriate sub section Track Condition Sub section 06 05 Track Tension and Alignment AS REQUIRED Sub section 06...

Page 18: ... until a sufficient quantity of oil has entered the engine approximately half a can With the engine stopped remove the spark plug and spray storage oil P N 496 0141 00 into each cylinder Crank slowly 2 or 3 revolutions to lubricate cylin ders Reinstall the spark plugs and the outlet primer hose or air silencers NO 2 FUEL STABILIZER A fuel stabilizer P N 413 4086 00 can be added in fuel tank to pre...

Page 19: ...f it then dry it out NO 5 DRIVE BELT CONDITION Inspect belt for cracks fraying or abnormal wear uneven wear wear on one side missing cogs cracked fabric If abnormal wear is noted proba ble cause could be pulley misalignment exces sive RPM with frozen track fast starts without warm up period burred or rusty sheave oil on belt or distorted spare belt Check the drive belt width Replace the drive belt...

Page 20: ...rcycle Cleaner and Polish NOTE The latest product may be use alone if only light scratches are noticeable Inspect the hood and repair any damage Touch up all metal spots where paint has been scratched off Spray all metal parts including shock chromed rods with Bombardier Lube P N 293 6000 06 Wax the hood and the painted portion of the frame for better protection NOTE Apply wax on glossy finish onl...

Page 21: ...ENTS 0 ENGINE 02 02 1 FUEL AND OIL SYSTEMS 02 03 1 TRANSMISSION AND BRAKE SYSTEMS 02 04 1 TRANSMISSION 02 04 1 BRAKE SYSTEM 02 04 8 MECHANICAL BRAKE 02 04 8 HYDRAULIC BRAKE 02 04 9 MECHANICAL AND HYDRAULIC BRAKES 02 04 9 ELECTRICAL SYSTEM 02 05 1 SUSPENSION SYSTEM AND TRACK 02 06 1 ...

Page 22: ...SE Test Inspection 1 Check spark plug s a Carbon accumulation caused by defective spark plug s Clean carbon accumulation and replace spark plug s 2 Check cooling system a Loose fan belt Adjust or replace fan belt refer to TECHNICAL DATA 09 b Low antifreeze level Adjust antifreeze level Then check clamps or hoses c Defective tank cap Replace cap d Air in system Bleed system 3 Check ignition timing ...

Page 23: ...ed fuel lines Replace defective lines c Fuel does not flow through carburetor s plastic particles in needle area and or varnish formation in carburetor s Clean carburetor s d Spark plug heat range is too warm Install spark plug s with appropriate heat range refer to TECHNICAL DATA 09 e Improper ignition timing Adjust according to specifications refer to TECHNICAL DATA 09 f Restriction in exhaust s...

Page 24: ...oil damaged oil line or defective injection pump Replace defective part s 6 Grooves on intake side of piston only a Oil film eliminated by water snow infiltration in engine Replace piston s and check if intake system leaks 7 Piston color is dark due to seizure on intake and exhaust sides a Broken or loose fan belt Replace fan belt or adjust its tension refer to TECHNICAL DATA 09 b Cooling system l...

Page 25: ...n fuel a There is water in fuel Drain fuel system then fill it with appropriate fuel 3 Check items listed in Engine runs out of fuel refer to fuel and oil system sub section 02 4 Check carburetor adjustments and cleanliness a Inadequate carburetor adjustments or dirt accumulation Adjust according to specifications refer to TECHNICAL DATA 09 or clean 5 Check drive belt a Worn belt Replace belt if w...

Page 26: ...l is low cap fails to pressurize system or air circulates through lines Adjust level replace cap or bleed cooling system SYMPTOM ENGINE DETONATION AT MAXIMUM RPM CONDITION NORMAL USE Test Inspection 1 Check which type of fuel is used a Octane number is too low and or alcohol level is too high Use recommended fuel type 2 Check spark plug type a Improper spark plug heat range Install recommended spa...

Page 27: ...times Install clean dry spark plug Start engine following usual starting procedure 5 Check fuel lines a No fuel to the engine spark plug dry when removed Check fuel tank level turn fuel valve on if applicable check fuel filter replace if clogged check condition of fuel and impulse lines and their connections 6 Check engine compression a Insufficient engine compression Replace defective part s ex p...

Page 28: ...place 2 Check fan belt a Belt slides because it is too loose Adjust according to specifications refer to TECHNICAL DATA 09 3 Verify antifreeze level and check if there is air infiltration in the system or if there are leaks in gasket areas a Low antifreeze level or air in system Add antifreeze until recommended level is reached bleed system and or tighten clamps at fitting 4 Check if antifreeze fl...

Page 29: ...engine crankcase a Leak s Repair or replace 12 Check condition and heat range of spark plug s a Melted spark plug tip or inadequate heat range Replace SYMPTOM ENGINE EQUIPPED WITH RAVE VALVE DOES NOT REACH ITS FULL OPERATING RPM 500 TO 1000 RPM SLOWER CONDITION NORMAL USE Test Inspection 1 Check RAVE valve pistons a Valve piston s is are too far out Screw valve piston s to bottom 2 Check RAVE valv...

Page 30: ... Fully tighten 3 Check RAVE valve movement RAVE movement indicator P N 861 7258 00 a Valve s is are stuck in open position Clean SYMPTOM REWIND STARTER ROPE DOES NOT REWIND CONDITION NORMAL USE Test Inspection 1 Check rewind spring a Broken spring Replace spring SYMPTOM REWIND STARTER PAWL DOES NOT ENGAGE CONDITION NORMAL USE Test Inspection 1 Check stopper spring a Broken stopper spring Replace 2...

Page 31: ...n ratio a Compression ratio is too high Replace inadequate part s to obtain manufacturer s recommended compression ratio or use a higher grade fuel SYMPTOM ENGINE GENERATES A LOT OF VIBRATIONS CONDITION NORMAL USE Test Inspection 1 Check engine supports a Loose broken supports or interference between support s and chassis Retighten to specification refer to TECHNICAL DATA 09 or replace 2 Check dri...

Page 32: ...Fuel flows through primer while engine runs Replace primer 4 Check float height in carburetor s a Fuel level is too high in float bowl s Adjust according to specifications refer to TECHNICAL DATA 09 5 Check needle valve a Foreign particles prevent needle valve s from closing and or worn seating area Clean or replace needle valve s then clean seating area 6 Check H A C system a Connection to atmosp...

Page 33: ...locate or replace 4 Check fuel pump flow a Dried diaphragm Replace 5 Check if carburetor s is are clean a Varnish Clean SYMPTOM HIGH INJECTION OIL CONSUMPTION CONDITION NORMAL USE Test Inspection 1 Check oil injection pump adjustment a Oil injection pump adjusted too rich Adjust 2 Check injection oil lines and their fitting a Leaking lines and or cover Replace defective part s 3 Check injection pu...

Page 34: ...eir fittings or are improperly rooted Replace or properly relocate lines 3 Check fuel pump outlet flow a Dirt clogging fuel pump lines or torn membrane Clean or replace fuel pump 4 Check carburetor needle valve s a Dirt varnish foreign particle clogging fuel line inlets Clean 5 Check main jet a Dirt varnish foreign particle accumulation at main jet Clean 6 Check float height in carburetor bowl s a...

Page 35: ...1 8 less than a new one refer to TECHNICAL DATA 09 2 Check distance between pulleys and or drive belt deflection a Distance is too small between pulleys or deflection is too high drive belt engagement is higher in drive pulley Adjust distance between pulleys and or drive belt deflection according to specifications refer to TECHNICAL DATA 09 3 Check driven pulley sliding half play a Jammed sliding ...

Page 36: ...ording to specification refer to TECHNICAL DATA 09 3 Check position of the calibration screws TRA drive pulley a Selected numbers are too high Adjust according to specification refer to TECHNICAL DATA 09 4 Refer to Vibrations originating from driven pulley and check items listed SYMPTOM LOOSENESS IS FELT IN DRIVE SYSTEM WHEN ACCELERATING DECELERATING CONDITION NORMAL USE Test Inspection 1 Check dr...

Page 37: ...estrains sliding half movement Retighten bolts 4 Check spring cover TRA TYPE and or outer half bushings a Excessive gap between bushings and inner half shaft thus restraining sliding half movements Replace bushing s 5 Check sliding half slider shoes a Worn slider shoes Replace SYMPTOM VIBRATIONS ORIGINATING FROM DRIVEN PULLEY CONDITION NORMAL USE Test Inspection 1 Check sliding half play a Sliding...

Page 38: ...sion is too weak Replace SYMPTOM IT IS DIFFICULT TO ENGAGE TRANSMISSION IN FORWARD OR REVERSE GEAR CONDITION NORMAL USE Test Inspection 1 Check position of gear shift lever adjustment screw a Improper adjustment Adjust according to specifications refer to TRANSMISSION 04 SYMPTOM UNEVEN BELT WEAR ON ONE SIDE ONLY CONDITION NORMAL USE Test Inspection 1 Check tightening torque of engine mount bolts a...

Page 39: ...f pulley halves are clean a Oil on pulley surfaces Clean pulley halves 4 Check pulley calibration a Improper pulley calibration Calibrate according to specification SYMPTOM BELT WORN EXCESSIVELY IN TOP WIDTH CONDITION NORMAL USE Test Inspection 1 Check drive pulley a Excessive slippage due to irregular outward actuation movement of drive pulley Carry out drive pulley inspection 2 Check drive belt ...

Page 40: ... a Engine idle speed too high Adjust according to specification 5 Check drive belt length a Incorrect belt length Replace belt with an appropriate drive belt refer to TECHNICAL DATA 09 6 Check distance between pulleys a Incorrect pulley distance Readjust according to specification 7 Check belt deflection a Deflection is too small Adjust according to specification SYMPTOM BELT SIDES WORN CONCAVE CO...

Page 41: ...N NORMAL USE Test Inspection 1 Check pulley alignment a Pulley misalignment Align pulley according to specifications refer to TECHNICAL DATA 09 SYMPTOM FLEX CRACKS BETWEEN COGS CONDITION NORMAL USE Test Inspection 1 Check drive belt condition a Considerable use belt wearing out Replace SYMPTOM SHEARED COGS COMPRESSION SECTION FRACTURED OR TORN CONDITION NORMAL USE Test Inspection 1 Check drive bel...

Page 42: ...lt SYMPTOM BRAKE DOES NOT ADJUST AUTOMATICALLY CONDITION NORMAL USE Test Inspection 1 Check ratchet wheel spring a Broken ratchet wheel tag Replace 2 Check mobile pad stud a Stud rotates in pad Replace SYMPTOM BRAKE HANDLE DOES NOT RETURN COMPLETELY CONDITION NORMAL USE Test Inspection 1 Check brake return spring a Broken return spring Replace 2 Check if brake cable moves freely in its housing a B...

Page 43: ...luid and bleed system If problem still occurs replace master cylinder SYMPTOM BRAKE FLUID LEAKING CONDITION NORMAL USE Test Inspection 1 Check for loosen hose connectors Retighten 2 Check for damaged hose master cylinder and caliper Replace part s and check for proper mounting SYMPTOM BRAKE SYSTEM IS NOISY CONDITION NORMAL USE Test Inspection 1 Check brake pad thickness a Pads are worn up to wear ...

Page 44: ...een starter switch and solenoid a Open circuit between starter switch and solenoid switch Repair SYMPTOM STARTER TURNS BUT DOES NOT CRANK THE ENGINE CONDITION NORMAL USE Test Inspection 1 Check battery capacity a Shorted battery cell s Replace 2 Check battery charge a Weak battery Recharge 3 Check wire connection a Inadequate connection too much resistance Clean and reconnect 4 Check solenoid swit...

Page 45: ...ted armature Repair or replace armature 12 Check tension of brush springs a Weak brush spring tension Replace springs 13 Check yoke assembly magnets a Weak magnets Replace yoke assembly 14 Check if bushings are worn a Worn bushings Replace bushings SYMPTOM STARTER TURNS BUT OVERRUNNING CLUTCH PINION DOES NOT MESH WITH RING GEAR CONDITION NORMAL USE Test Inspection 1 Check clutch pinion gear a Worn...

Page 46: ...k on splines Clean 3 Check ignition switch a Ignition switch does not return to its ON position or is short circuited Adjust retaining screw or replace switch 4 Check solenoid a Shorted solenoid switch winding s Replace solenoid switch 5 Check solenoid switch contacts a Melted solenoid switch contacts Replace solenoid switch 6 Check starter switch a Starter switch returns poorly Replace ignition s...

Page 47: ...ectric starter a Shorted solenoid wiring harness or eroded contact washer Replace SYMPTOM HEADLAMP NOT LIGHTING CONDITION WHITE BULB Test Inspection 1 Check bulb a Gas leak Replace bulb CONDITION BROKEN ELEMENT Test Inspection 1 Check for loose headlamp housing and bulb socket a Vibration problem Tighten headlamp mounting screws Lock bulb in socket Replace bulb CONDITION MELTED FILAMENT ENDS OF EL...

Page 48: ... a Faulty installation of optional equipment Find optional equipment connected directly to DC ground BK wire or chassis or to any DC hot wire RD RD BL Disconnect and reconnect to AC current YL and YL BK wires 5 Verify if optional electric accessories are overloading the magneto generator a Excessive electrical load to magneto generator Reduce the electrical load by removing excess accessories Reco...

Page 49: ...rify spark plug condition a Defective improperly set worn out fouled Identify source of problem and correct Replace spark plug 2 Verify spark plug cap resistance with an ohmmeter a Defective part Replace cap 3 Verify if problem originated from electrical system wiring harness and or accessories and or ignition cut out switches by unplugging the 4 wire connectors between the magneto generator and t...

Page 50: ... MISFIRING ERRATIC SPARK AT SPARK PLUG CONDITION RIDING ON WET SNOW Test Inspection 1 Verify if spark plug wires and or spark plug cap seals are sealing out moisture a Defective wires and or seals Replace defective part 2 Verify if ignition system wiring harness connectors are in good condition and or are sealing out moisture a Loose connectors corroded terminals or defective parts Clean terminals...

Page 51: ...cifications refer to TECHNICAL DATA 09 2 Check injection oil consumption a Injection pump flow is too high Adjust according to specification or replace 3 Check oil quality a Poor oil quality that creates deposits Use Bombardier oil 4 Check engine compression a Leaking piston ring s Replace SYMPTOM SPARK PLUG TIP S IS ARE LIGHT GREY CONDITION NORMAL USE Test Inspection 1 Refer to Engine slows down ...

Page 52: ...GHT BULB FLASHES CONDITION NORMAL USE Test Inspection 1 Check bulb tightness in housing a Looseness at bulb contact elements Install bulb correctly 2 Check if rear light is properly connected a Connector housing is partially connected Install connector housing properly 3 Check continuity of wires a Corroded terminals and or broken wires Replace terminal s or crimp defective wires SYMPTOM TACHOMETE...

Page 53: ...AL DATA 09 Replace defective parts SYMPTOM TRACK CLEATS BECOME BLUE CONDITION NORMAL USE Test Inspection 1 Check track tension a Pressure is too great on cleats Adjust according to specifications refer to TEHNICAL DATA 09 2 Check slider shoes and or suspension retaining screws a Worn slider shoes or lost retaining screws Replace defective parts and or tighten loose screws SYMPTOM NOISE OR VIBRATIO...

Page 54: ...ght Adjust 2 Check if axles are properly lubricated a Improper lubrication and or contaminated grease sticky oil sludge Clean and or lubricate 3 Check rear spring preload a Insufficient preload Increase preload using shock adjustment cams SYMPTOM WHEN HANDLEBAR IS TURNED SNOWMOBILE UNDERSTEERS CONDITION NORMAL USE Test Inspection 1 Check ski runner condition a Worn ski runners Replace 2 Check tens...

Page 55: ...ension is weak more weight is transferred to the skis Increase spring preload 4 Check condition of ball joints a Corrosion restrains movement Lubricate or replace 5 Check swing arm camber liquid cooled models a Too much ski leg inclination Adjust camber to 0 5 SYMPTOM THE SNOWMOBILE IS UNSTABLE IT MOVES FROM LEFT TO RIGHT AND VICE VERSA CONDITION NORMAL USE Test Inspection 1 Check ski runner condi...

Page 56: ...N 03 02 12 ASSEMBLY 03 02 12 454 494 583 AND 670 ENGINE TYPES 03 03 1 ENGINE SUPPORT AND MUFFLER 03 03 1 REMOVAL FROM VEHICLE 03 03 2 ENGINE SUPPORT AND MUFFLER DISASSEMBLY AND ASSEMBLY 03 03 2 INSTALLATION ON VEHICLE 03 03 2 TOP END 03 03 4 CLEANING 03 03 5 DISASSEMBLY 03 03 5 INSPECTION 03 03 5 ASSEMBLY 03 03 6 BOTTOM END 03 03 10 CLEANING 03 03 11 DISASSEMBLY 03 03 11 INSPECTION 03 03 11 ASSEMB...

Page 57: ... ROTARY VALVE GAP 03 04 9 CHECKING SURFACE FLATNESS 03 04 10 RECTIFYING SURFACES 03 04 10 CHECKING CRANKSHAFT ALIGNMENT 03 04 10 CDI SYSTEM 03 05 1 NIPPONDENSO TRIGGER COIL IGNITION SYSTEM 03 05 1 CLEANING 03 05 2 DISASSEMBLY 03 05 2 ASSEMBLY 03 05 4 DUCATI IGNITION SYSTEM 03 05 5 CLEANING 03 05 6 DISASSEMBLY 03 05 6 REPAIR 03 05 6 ASSEMBLY 03 05 7 OIL INJECTION SYSTEM 03 06 1 OIL INJECTION PUMP 0...

Page 58: ...03 10 2 DISASSEMBLY 03 10 2 ASSEMBLY 03 10 2 INSTALLATION 03 10 3 CARBURETOR AND FUEL PUMP 03 11 1 REMOVAL 03 11 2 CLEANING AND INSPECTION 03 11 2 IDENTIFICATION 03 11 2 DISASSEMBLY AND ASSEMBLY 03 11 3 CARBURETOR FLOAT LEVEL ADJUSTMENT 03 11 3 INSTALLATION 03 11 5 CARBURETOR ADJUSTMENTS 03 11 6 PRELIMINARY IDLE SPEED ADJUSTMENT 03 11 7 IDLE SPEED FINAL ADJUSTMENT 03 11 8 CHOKE 03 11 8 HAC SYSTEM ...

Page 59: ...E Sub Section 02 443 AND 503 ENGINE TYPES 03 02 1 443 AND 503 ENGINE TYPES 2 ENGINE REMOVAL AND INSTALLATION 443 Engine Type A03C13S 37 N m 27 lbf ft 35 N m 26 lbf ft 17 N m 150 lbf in 28 N m 21 lbf ft PARTS FLAT RATE ...

Page 60: ...gine crankcase 4 connector housing exhaust pipe and exhaust cooling hose on so equipped models oil pump inlet tube and plug it oil pump cable rewind cable tie a knot near rewind housing and remove starting grip TUNED PIPE IDENTIFICATION This part is identified on welded support Second number sequence of P N is stamped on part 1 Identification 0464 for 514 0464 00 WARNING Before disconnecting any e...

Page 61: ...Section 03 ENGINE Sub Section 02 443 AND 503 ENGINE TYPES 03 02 3 Skandic WT SWT 503 Engine Type A22C0FS 21 N m 15 lbf ft PARTS FLAT RATE ...

Page 62: ...lley using appropriate puller refer to 04 03 DRIVE PULLEY air silencer and carburetor impulse line from engine crankcase 4 connector housing exhaust pipe and exhaust cooling hose oil pump inlet tube and plug it oil pump cable rewind cable tie a knot near rewind housing and remove starting grip WARNING Before disconnecting any electrical wire in starter system always first disconnect the BLACK nega...

Page 63: ...3 ENGINE TYPES 03 02 5 TOP END A22C0KS 2 22 N m 16 lbf ft 3 1 2 22 N m 16 lbf ft 2 22 N m 16 lbf ft 4 5 7 6 8 8 13 14 15 Grease 443 only 11 9 12 10 9 22 N m 16 lbf ft 22 N m 16 lbf ft 10 10 22 N m 16 lbf ft 503 only 443 only 1 1 FLAT RATE PARTS ...

Page 64: ... Engine On this 443 engine piston pin needle bearing is mounted without a cage Use piston pin puller P N 529 0210 00 along with expansion sleeve and locating sleeve Place a clean cloth or rubber pad P N 529 0234 00 over crankcase to prevent circlips no 15 from falling into crankcase Then with a pointed tool inserted in piston no 13 notch remove piston circlip on side where piston pin no 14 puller ...

Page 65: ...210 00 as follows Fully screw puller handle Insert puller end into piston pin Screw LH threads extracting nut Hold puller firmly and rotate puller handle coun terclockwise to pull piston pin NOTE The PTO cylinder or fan housing have to be removed to give access to MAG piston pin with the puller NOTE 0 25 and 0 5 mm oversized piston and rings are available if necessary INSPECTION Refer to ENGINE DI...

Page 66: ...eve needles are held in place by 2 inner plastic cage halves Use piston pin puller P N 529 0210 00 to insert piston pin Plastic halves should come off pis ton If not pull them out using long nose pliers Install circlips as described below 503 Engine To center the piston pin with the connecting rod bearing use centering tool P N 529 0091 00 NOTE The circlip on the opposite side can be installed bef...

Page 67: ...ns Check flatness of intake sockets no 10 Refer to ENGINE DIMENSION MEASUREMENT 03 04 and look for checking surface flatness At cylinder no 7 and or cylinder head no 5 instal lation use aligning tool or exhaust manifold itself to ensure sealing of intake manifold and exhaust before tightening cylinder head nuts 1 Or use exhaust manifold to align cylinders CAUTION Circlips must not move freely in t...

Page 68: ...d 2 to 22 N m 16 lbf ft torque each cylinder head indi vidually For proper position of noise dampers nos 3 4 and 6 refer to the following illustrations 1 Noise dampers 2 PTO side cylinder Install armature plate fan housing and then air de flector Install a gasket on each side of the air deflector Torque intake socket bolts to 22 N m 16 lbf ft A17C06A 1 1 1 A17C0SA 2 ...

Page 69: ...AND 503 ENGINE TYPES 03 02 11 BOTTOM END A03C1IT Anti seize lubricant Anti seize lubricant Anti seize lubricant 22 N m 16 lbf ft 503 22 N m 16 lbf ft 443 10 N m 89 lbf in 11 9 8 7 6 5 2 4 3 3 2 1 10 10 Loctite 242 FLAT RATE FLAT RATE PARTS ...

Page 70: ...EASUREMENT 03 04 ASSEMBLY Smear anti seize lubricant P N 413 7010 00 on part of crankshaft where bearing fits To check proper clearance between bearing no 3 and counterweight use feeler gauge P N 420 8766 20 Mount second bearing with distance gauge P N 420 8768 22 for 443 engine and P N 420 8768 24 for 503 engine for proper positioning 1 Feeler gauge 2 Distance gauge Prior to installation place be...

Page 71: ... one of mating surfaces Let it dry for 10 to 20 minutes Apply paste gasket P N 413 7027 00 no 5 on the other mating surface NOTE Primer N allows Loctite 515 to fully cure on aluminum surfaces It increases fill ing capacity and reduces curing time Position the crankcase halves together and tight en bolts by hand then install and tighten armature plate on magneto side to correctly align the crank ca...

Page 72: ...E SUPPORT AND MUFFLER All Models 5 3 4 3 A03C1NS 440 and 494 583 and 670 454 494 and 670 engines 23 N m 17 lbf ft 48 N m 35 lbf ft 25 N m 18 lbf ft 40 N m 30 lbf ft 25 N m 18 lbf ft 24 N m 18 lbf ft Loctite 271 736 RTV Loctite 271 MX Z 440 583 and 670 40 N m 30 lbf ft 2 40 N m 30 lbf ft 1 FLAT RATE FLAT RATE PARTS ...

Page 73: ...he engine support screws to 48 N m 35 lbf ft Torque the manifold screws to 23 N m 17 lbf ft INSTALLATION ON VEHICLE To install engine on vehicle reverse removal pro cedure However pay attention to the following Check tightness of engine rubber mount nuts Torque to 25 N m 18 lbf ft After throttle cable installation check carbure tor maximum throttle opening and oil injection pump adjustment Check p...

Page 74: ...ES 03 03 3 3 Tuned Muffler This part is identified on welded support Second number sequence of P N is stamped on part 1 Identification Should a light exhaust leak be experienced at any ball joints Dow Corning sealer no 736 RTV P N 413 7092 00 can be used A03C1KA 1 ...

Page 75: ...nt P N 413 7023 00 Pipe sealant P N 413 7023 00 Grease P N 413 7061 00 29 N m 21 lbf ft 10 N m 89 lbf in 29 N m 21 lbf ft 494 engine only 583 engine type only 1 2 1 Grease Loctite 242 Grease 17 20 22 21 19 Loctite 242 Grease 29 N m 21 lbf ft Grease 29 N m 21 lbf ft Loctite 242 10 N m 89 lbf in 29 N m 21 lbf ft 18 16 12 11 13 14 15 10 9 7 6 5 3 8 4 FLAT RATE PARTS ...

Page 76: ...move piston pin no 19 use piston pin puller P N 529 0290 00 as follows Fully screw puller handle Insert puller end into piston pin Install adaptor P N 529 0236 00 then screw extracting nut LH threads Hold puller firmly and rotate puller handle coun terclockwise to pull piston pin NOTE 0 25 mm oversize piston and rings are available if necessary except for 454 en gine RAVE System NOTE RAVE stands f...

Page 77: ... direction of the exhaust port 1 Exhaust Use piston pin puller P N 529 0210 00 to ease piston pin installation 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 P N 529 0169 00 for all engines except 670 and P N 290 8770 16 for 670 engine 1 Place circlip in 2 Restrain 3 Oil ENGINE TYPE SPRI...

Page 78: ...tite 242 to screw threads Properly torque cylinders screws 3 Lay down cylinder head and insert aligning pins in holes as shown NOTE If pins can not be inserted in cylinder head holes enlarge them with a 8 75 mm 11 32 in drill bit 4 Install 4 screws in center holes Torque to 10 N m 89 lbf in 1 Pins 2 Screws 5 Remove pins and install remaining screws 6 Tighten all screws in recommended above se quen...

Page 79: ...h up with the studs Cylinder head itself can be used to align the cylinders Prior to torquing crankcase cylinder nuts install exhaust manifold to properly align ex haust flanges or use exhaust flange aligning tool P N 420 8769 02 Apply Loctite 242 P N 413 7030 00 on cylinder screw threads Install and torque screws in a criss cross se quence for each cylinder to 29 N m 21 lbf ft For 454 and 670 eng...

Page 80: ...e rod housing with their pas sages toward bottom 1 Passages Torque cylindrical screws to 10 N m 90 lbf in Check free sliding action of valve Install bellows over valve rod housing groove and secure with a clamp 454 engine has no clamp Screw by hand valve piston on valve rod until it bottoms Secure bellows to valve piston with a clamp spring on 454 engine Install spring cover and spring clip Turn a...

Page 81: ... grease 3 4 454 494 and 670 engines only Anti seize lubricant Anti seize lubricant Loctite 515 Loctite 242 6 6 454 494 and 670 engines only 7 2 2 Except 454 494 and 670 See CDI SYSTEM 8 10 N m 89 lbf in Loctite 242 29 N m 21 lbf ft Loctite 242 10 11 13 38 N m 28 lbf ft Loctite 242 12 29 N m 21 lbf ft 2 2 FLAT RATE PARTS ...

Page 82: ...and special puller as illustrated 1 PTO side 2 MAG side INSPECTION Refer to ENGINE DIMENSIONS MEASUREMENT 03 04 ASSEMBLY 2 4 5 6 9 Crankshaft Bearing and Labyrinth Sleeve Smear anti seize lubricant P N 413 7010 00 on part of crankshaft where bearing fits Prior to installation place bearings into an oil con tainer filled with oil previously heated to 75 C 167 F This will expand bearing and ease ins...

Page 83: ...f the crankshaft Spray Primer N P N 413 7081 00 on one of mating surfaces Let it dry for 10 to 20 minutes Apply paste gasket P N 413 7027 00 no 5 on the other mating surface NOTE Primer N allows Loctite 515 to fully cure on aluminum surfaces It increases fill ing capacity and reduces curing time Position the crankcase halves together and tight en screws by hand then install and tighten arma ture p...

Page 84: ...agneto side to 10 N m 90 lbf in Apply pipe sealant P N 413 7023 00 on threads prior to assembly angular tube no 11 At assembly on crankcase apply medium strength threadlocker P N 413 7030 00 on stud threads no 12 Torque the crankcase engine bracket nut no 13 to 38 N m 28 lbf ft To install magneto refer to CDI MAGNETO 03 05 ...

Page 85: ...rotary valve gear lubrication system 7 Install air pump on any valve of exhaust plug NOTE If necessary lubricate air pump pis ton with mild soap 8 Rotate crankshaft so that piston goes to B D C Bottom Dead Center on side where the pump is installed This will open exhaust port 9 Activate pump and pressurize engine to 34 kPa 5 PSI Do not exceed this pressure 10 Engine must stand this pressure during...

Page 86: ...surfaces and screw stud threads of engine spark plug base insulator cylinder head cylinder base crankcase halves joint rotary valve cover oil injection pump mounting flange O ring seal coolant pump housing bleed screws plugs 2 Small injection oil lines coming from pump 1 Banjo fittings 2 Small injection oil lines Check for air bubbles or oil column going toward pump It indicates defective check va...

Page 87: ...ary Valve Gear Reservoir Block one hose of rotary valve gear lubrication system with a hose pincher and install an adapter in remaining hose Install air pump on adapter and pressurize as be fore 1 Blocked hose 1 Remove a spark plug or any plug of leak tester kit on PTO side If pressure drops it indicates defective crank shaft inner seal on PTO side 2 Remove a spark plug or any plug of leak tester ...

Page 88: ...ings Pay attention to tapped holes which may go through engine sealed area and thus leading to leakage FINALIZING REASSEMBLY After reassembling engine always recheck for leakage COOLING SYSTEM LEAK TEST Install special plug radiator cap P N 529 0214 00 and hose pincher P N 529 0099 00 on overflow hose Pressurize all system through coolant reser voir to 15 PSI Check all hoses and cylinder base for ...

Page 89: ...TARY VALVE GEAR RESERVOIR IN CRANKCASE ARE SEALS LEAKING CHECK CRANKSHAFT OUTER SEAL OF PTO AND MAG SIDES PRESSURIZE ROTARY VALVE GEAR RESERVOIR IN CRANKCASE IS RESERVOIR LEAKING UNSEAL PTO CYLINDER AND MAG CYLINDER SEPARATELY IS RESERVOIR LEAKING IS RESERVOIR LEAKING CHECK LEAKAGE AT DRAIN HOLE BELOW COOLANT PUMP HOUSING ANY LEAK FOUND REPLACE DEFECTIVE SEAL S REPLACE DEFECTIVE SEAL S REPLACE OIL...

Page 90: ... from top of cylinder with a cylinder gauge check if the cylinder out of round is more than the specified dimension If larger cylinder should be rebored and honed or should be replaced NOTE Be sure to restore the chamfer around all cylinder sleeve port openings 1 Piston pin position 2 Measures to be compared A 16 mm 5 8 in CYLINDER PISTON CLEARANCE Measurement used parts Check cylinder taper and o...

Page 91: ...nd groove Replace piston If clearance exceeds specified tolerance Refer to TECHNICAL DATA 09 02 RING END GAP Position ring half way between transfer ports and intake port On rotary valve engines position ring just below transfer ports NOTE In order to correctly position the ring in the cylinder use piston as a pusher Using a feeler gauge check ring end gap Replace ring If gap exceeds specified tol...

Page 92: ... between centers of a lathe If the deflection exceeds the specified tolerance 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 tolerance repair or replace the crankshaft TYPICAL CONNECTING ROD PISTON PIN CLEARANCE Measure piston pin with its needle b...

Page 93: ...Snap On FB300A inserted through intake socket of valve cover If gap is under tolerances rotary valve cover can be refaced to increase clearance If gap is over tolerances cover replacement may be necessary Check if surfaces on crankcase halves are damaged replacement wear plate is available Second Method Remove rotary valve cover and its O ring Use the following type of solder rosin core diameter 0...

Page 94: ...art try pushing down the other end If any play is felt part must be rectified RECTIFYING SURFACES Stick a fine sand paper sheet on the surface plate then lightly oil the sand paper Rub manifold mating surface on sand paper using 8 figure movements Sand until mating surface is perfectly straight CHECKING CRANKSHAFT ALIGNMENT Install a degree wheel P N 414 3529 00 on crank shaft end Remove both spar...

Page 95: ...es A15E0QU 7 6 3 Loctite 242 1 2 Loctite 242 Loctite 242 Loctite 648 4 Loctite 648 All engines except 454 494 and 670 22 N m 195 lbf in 5 Loctite 648 125 N m 92 lbf ft 6 7 Dielectric grease P N 413 7017 00 Dielectric grease P N 413 7017 00 454 494 and 670 engines 454 494 and 670 engines 583 engine 105 N m 77 lbf ft PARTS FLAT RATE ...

Page 96: ... to 40 mm 1 580 in outside diameter by 16 mm 5 8 in long NOTE To correctly remove a threadlocked fastener it is first necessary to tap on the fas tener to break threadlocker bond This will elimi nate the possibility of thread breakage To remove magneto flywheel install the puller P N 529 0225 00 Tighten puller bolt and at the same time tap on bolt head using a hammer to release magneto flywheel fr...

Page 97: ...eler gauge of 0 75 mm 030 in min 0 55 mm 022 in and max 1 45 mm 057 in thick check air gap between center pole of trig ger coil and flywheel protrusion 3 If necessary adjust by slackening retaining screws and moving trigger coil toward or away of protrusion 4 Retighten screws and recheck air gap ADJUSTING TRIGGER COIL AIR GAP 1 Trigger coil 2 Flywheel protrusion 3 Measure at center pole of trigger...

Page 98: ...el and lock washer on crankshaft Clean nut threads and apply Loctite 242 blue then tighten nut 125 N m 92 lbf ft for 454 494 and 670 engines Tighten nut to 105 N m 77 lbf ft for 583 engine At reassembly coat all electric connections with silicone dielectric grease P N 413 7017 00 to pre vent corrosion or moisture penetration Ignition Timing Check as described in IGNITION TIMING 05 03 A15E0OA 1 A06...

Page 99: ...ction 03 ENGINE Sub Section 05 CDI SYSTEM 03 05 5 DUCATI IGNITION SYSTEM 443 and 503 Engines A07C03S 1 2 3 5 4 Loctite 242 Dielectric grease 105 N m 77 lbf ft 22 N m 195 lbf in Loctite 242 FLAT RATE PARTS ...

Page 100: ...magneto flywheel from its taper REPAIR To replace generator coil no 1 Heat the armature plate to 93 C 200 F around the screw holes to break the threadlocker bond To replace trigger coil no 4 Disconnect trigger coil wire RED Remove grommet from crankcase where trig ger coil wire exits magneto housing Remove retaining screws no 9 Remove trigger coil and carefully pull wire Install new trigger coil a...

Page 101: ...rmature and carefully pull wires Install new parts and other parts removed ASSEMBLY Clean crankshaft extension taper Apply Loctite 242 blue on taper Position Woodruff key flywheel and lock washer on crankshaft Clean nut threads and apply Loctite 242 blue be fore tightening nut to 105 N m 77 lbf ft At reassembly coat all electric connections with silicone dielectric grease P N 413 7017 00 to pre ve...

Page 102: ... OIL INJECTION SYSTEM 6 OIL INJECTION PUMP 454 494 583 and 670 Engines Oil pump gasket set A03C1LS 1 Loctite 242 Molykote 111 3 6 5 Loctite 242 5 7 X X X X X X X X X Parts in illustration marked with X are not available as single parts 2 FLAT RATE FLAT RATE PARTS ...

Page 103: ...Section 03 ENGINE Sub Section 06 OIL INJECTION SYSTEM 03 06 2 443 and 503 Engines A22C0DS Loctite 242 3 2 6 Loctite 242 1 Molykote 111 4 6 5 5 FLAT RATE PARTS ...

Page 104: ...n the pump mounting flange 5 6 Spring Clip and Clamp Always check for spring clips and clamps tight ness 3 Screw Torque to 9 N m 80 lbf in Make sure cable barrel is well seated in oil pump lever Secure barrel with plastic washer and circlip Verify cable and oil pump lever operation ADJUSTMENT Prior to adjusting the pump make sure all carbu retor adjustments are completed Synchronizing Pump with Ca...

Page 105: ...play 1 Small oil line 2 Marks aligned 3 Main oil line Reinstall all parts except air silencer Bleed the small oil line between pump and intake manifold by running engine at idle while holding the pump lever in fully open position NOTE If the air silencer has been rein stalled make a J hook out of mechanical wire to lift the lever TYPICAL ENGINE AT IDLE S Series Only Reinstall air silencer CAUTION ...

Page 106: ...small oil lines TYPICAL ENGINE AT IDLE 1 Oil columns advancing 2 Washer on each side 3 Fully open position If not remove pump assembly and check the pump gear and drive shaft if applicable for de fects replace as necessary Test pump as de scribes below NOTE Through normal use oil level must not drop in small tubes If oil drops verify check valve operation in banjo fittings For 599 en gine check va...

Page 107: ...NE Sous section 07 AXIAL FAN COOLING SYSTEM 03 07 1 AXIAL FAN COOLING SYSTEM 7 443 Engine 1 3 5 18 13 12 14 15 16 443 and 503 engines only 17 47 N m 35 lbf ft 20 10 11 10 9 4 13 N m 115 lbf in A03C0WS PARTS FLAT RATE ...

Page 108: ...Section 03 ENGINE Sous section 07 AXIAL FAN COOLING SYSTEM 03 07 2 503 Engine A22C0IS 1 2 3 12 11 10 9 5 4 8 7 6 13 14 15 16 17 18 55 N m 41 lbf ft 20 13 N m 115 lbf in PARTS FLAT RATE ...

Page 109: ...embly torque nut to 65 N m 48 lbf ft TYPICAL Fan belt deflection must be as specified when ap plying the proper force midway between pulleys 1 Deflection To adjust tension add or remove shim s no 15 between pulley halves nos 14 and 16 Install ex cess shim s between distance sleeve no 13 and half pulley no 14 housing side 1 Unused shim s here 2 Adjust here 3 Positioning noses 4 Some engines only So...

Page 110: ...ing bearing To install press one bearing in place then install circlip and shims Press the other bearing from op posite side until it is flush with housing Press fan shaft from engine side of fan housing Check for free rolling action At assembly apply a light coat of Loctite 242 blue on screw no 1 threads A gasket must be placed on both sides inner and outer of intake and exhaust holes of cylinder...

Page 111: ...Section 03 ENGINE Sub Section 08 LIQUID COOLING SYSTEM 03 08 1 LIQUID COOLING SYSTEM 8 All S Series Engines A06C2VT 7 Loctite PST 3 5 4 1 6 PARTS FLAT RATE ...

Page 112: ...Section 03 ENGINE Sub Section 08 LIQUID COOLING SYSTEM 03 08 2 Skandic WT LC A29C0AS 1 Loctite PST 8 2 3 4 Loctite PST PARTS FLAT RATE ...

Page 113: ...adiator protector into radiator C rail and crimp C rail at both ends Refer to FRAME 09 02 for radiator removal 5 Thermostat To check thermostat put in water and heat water Thermostat should open when water tempera ture reaches the following degree On 454 494 583 and 670 engines the thermo stat is a double action type a Its function is to give faster warm up of the en gine by controlling a circuit ...

Page 114: ...09 03 Refilling Procedure S Series With vehicle on a flat surface engine cold refill coolant tank up to cold level mark Wait a few min utes then refill to mark Install pressure cap Run engine until thermostat opens then stop engine Refill up to mark To make sure coolant flows through radiators touch them by hand They must feel warm Reinstall pressure cap When engine has completely cooled down re c...

Page 115: ...t race engine If coolant level gets down add more coolant in filler neck Turn off engine and close cap IMPORTANT After first drive let engine com pletely cool down Check that coolant level is at top of filler neck Add coolant as necessary This is to ensure that coolant circulation from and back to overflow coolant tank works properly Overflow coolant tank should be half full when engine is cold ...

Page 116: ...ESERVOIR 03 09 1 ROTARY VALVE COOLANT PUMP AND RESERVOIR 9 454 494 583 and 670 Engines TYPICAL A06C2UT 18 17 14 15 16 12 19 11 9 10 8 7 5 6 4 3 2 1 22 N m 16 lbf ft Injection oil reservoir To rotary valve gear 13 Loctite 648 Loctite 242 Molykote 111 PARTS FLAT RATE ...

Page 117: ...ing at the end of this sub section Unscrew 4 retaining screws and withdraw rotary valve cover and valve 3 17 Circlip and Pump Impeller To remove rotary valve shaft assembly from crankcase first remove coolant pump impeller and circlip on valve side Using the suitable pusher P N 420 8766 12 and a fiber hammer push shaft assembly 8 9 10 Circlip and Spring Retaining Cup If it is necessary to disassem...

Page 118: ...k for scoring pitting chip ping or other evidence of wear Make sure plastic cage on bigger bearing is not melted Rotate them and make sure they turn smoothly Check for presence of brass fillings in gear hous ing Visually check gear wear pattern It should be even on tooth length all around Otherwise it could indicate a bent shaft check deflection Re place gear if damaged Refer to ENGINE DIMENSION M...

Page 119: ...y valve Refer to Rotary valve timing at the end of this sub section to properly install gear on rotary valve shaft 12 13 14 15 Seals Shim Rubber Washer and Molykote Grease To install seals on water pump side proceed as fol lows Apply Molykote 111 P N 413 7070 00 on lip both seals Position oil seal shielded portion towards pump impeller Drive in place with a seal pusher P N 420 8765 12 Position coo...

Page 120: ...rds pump impeller Use impeller support plate pusher P N 529 0207 00 for proper installation Install small thrust washer then friction washer positioning its grooves against pump impeller 1 Large shim 5 Friction washer 2 Rubber washer 6 Flange this side 3 Support plate 7 Grooves this side 4 Small thrust washer 8 Pump impeller 1 Support plate NOTE After seals installation check if the water pump end...

Page 121: ...dentification code on the valve To find out the duration place an angle finder on the valve and measure the valve cut out angle ROTARY VALVE TIMING At disassembly before removing rotary valve note original rotary valve timing it may be out of specifications by 1 to 4 degrees of retard or ad vance To do so bring MAG piston to TDC and scribe a mark on crankshaft end at top 12 o clock and also on upp...

Page 122: ...easure rotary valve opening and closing angles in relation with MAGneto side piston Degree wheel will be installed on rotary valve shaft for measurements Rotary valve must be set as specified in TECHNI CAL DATA 09 For the following instructions use these specifi cations as example OPENING 132 BTDC CLOSING 52 BTDC Proceed as follows Turning crankshaft bring MAGneto side piston to Top Dead Center as...

Page 123: ...haft and upper crankcase must align These marks were scribed to deter mine desynchronization Install brass gear on rotary valve shaft with its marked spline 4 positions splines away for one degree of desynchronization Turn in the opposite direction of desynchronization For instance a ro tary valve is retarded by 2 5 turn brass gear by 10 splines counterclockwise Second Method Turn crankshaft to br...

Page 124: ...3 10 1 REWIND STARTER 0 All Models TYPICAL A01C57T 12 11 10 9 13 8 6 5 4 15 16 17 3 1 14 Molykote G n paste or equivalent Silicone compound grease Silicone compound grease 2 1 10 N m 89 lbf in 7 583 MX Z 583 Summit and 670 engines only FLAT RATE PARTS ...

Page 125: ...ing no 4 outer end into spring guide notch then wind the spring counter clockwise into guide 1 Outer end into guide notch NOTE Due to dust accumulation rewind starter must be periodically cleaned inspect ed and relubricated Lubricate spring assembly with silicone com pound grease P N 420 8970 61 and position into starter housing as illustrated WARNING Since the spring is tightly wound inside the g...

Page 126: ...g and tem porarily make a knot to hold it One turn preload will give 7 turns of tension when fully extended Position pawl no 8 pawl lock no 9 and circlip no 10 Install locking spring no 11 and lubricate with MOLYKOTE G n paste from Dow Corning or equivalent 1 Spring coated with MOLYKOTE G n paste Install locking ring INSTALLATION On fan cooled models with oil injection pump re install oil pump on ...

Page 127: ...ind starter on damper ring matching notches and embosses 1 Notch Prior to installing starter grip no 16 on new rope it is first necessary to fuse the rope end with a lit match pass rope through rubber buffer no 15 and starter grip and tie a knot in the rope end fuse the knot with a lit match then insert rope end down and pull the starter grip over the knot TYPICAL A03C0VA A01C56A 1 A01C18A ...

Page 128: ... ENGINE Sub Section 11 CARBURETOR AND FUEL PUMP 03 11 1 CARBURETOR AND FUEL PUMP 1 All Models A03C1MS 6 13 10 8 11 12 9 7 1 2 3 4 5 14 To other carburetor MX Z 440 F and Skandic WT series only 15 FLAT RATE PARTS ...

Page 129: ...ondition If worn the inlet needle and seat must be replaced as a matched set NOTE Install needle valve for snowmobile carburetor only It is designed to operate with a fuel pump system Check throttle slide for wear Replace as neces sary Check idle speed screw straightness Replace as necessary Check for fuel soaked into float no 12 replace as necessary Check float for cracks or other damages affecti...

Page 130: ...pening 1 Low cut away low 2 Rich mixture 3 High cut away high 4 Lean mixture 8 Main Jet The main jet installed in the carburetor has been selected for a temperature of 20 C 0 F at sea level Different jetting can be installed to suit tem perature and or altitude changes Always check spark plug tip and or piston dome color to find out correct jetting CARBURETOR FLOAT LEVEL ADJUSTMENT 9 10 Float Arm ...

Page 131: ...der part of symbol corresponds to the opening mostly affected For instance throt tle slide cut away begins to function at closed po sition but it is most effective at 1 4 opening and decreases up to 1 2 opening A01C5AA H A01C5BA 1 CARBURETOR MODEL FLOAT HEIGHT H 1 mm 040 in MX Z 440 F 23 9 941 MX Z 440 23 9 941 MX Z 583 18 1 713 MX Z 670 18 1 713 Formula 500 500 DL 18 1 713 Formula 583 18 1 713 Fo...

Page 132: ...t aligned Hook throttle cable into the needle retainer plate NOTE Do not obstruct hole in throttle slide when installing needle retaining plate This is important to allow air escaping through and thus allowing a quick response CENTER POST TYPE 1 Throttle cable 2 Needle retaining plate 3 Throttle slide Make sure the nylon packing no 4 is installed on all applicable throttle slides CENTER POST TYPE ...

Page 133: ...k it and turn cable adjuster as required Check throttle slide position at wide open throttle Throttle slide must be flush or 1 mm 040 in low er than carburetor outlet bore At that same posi tion check that throttle slide does not contact carburetor cover Turn cable adjuster and recheck synchronization TYPICAL 1 Screw in and out until no cable free play exists 2 Check that throttle side does not mo...

Page 134: ... IDLE SPEED ADJUSTMENT Adjust throttle slide height see table by turning idle speed screw no 7 Final adjustment engine running at idle speed should be within 1 2 turn of idle speed screw from preliminary adjustment CAUTION On twin carburetor models make sure both carburetors start to operate simultaneously Beside do not interchange carburetors the jetting may be different on each side A red dot is...

Page 135: ... lock nut HAC SYSTEM Summit Only HAC High Altitude Compensator is a mainte nance free device No adjustment and verification can be done on HAC If HAC is suspected to be faulty replace it and check for improvement Hoses connected to HAC must not be altered in length or size Check for kinked or loose hoses Tighten or replace as necessary See below illus trations for routing Nut holding T fitting mus...

Page 136: ...Section 03 ENGINE Sub Section 11 CARBURETOR AND FUEL PUMP 03 11 9 HAC SYSTEM A03I0BS To magneto housing FLAT RATE PARTS ...

Page 137: ...Section 03 ENGINE Sub Section 11 CARBURETOR AND FUEL PUMP 03 11 10 FUEL PUMP A06C39T 443 503 engines 454 engine 583 599 670 and 779 engines FLAT RATE PARTS ...

Page 138: ...Check impulse diaphragm and gasket on high supply fuel pump with twin outlets as follows Connect a clean plastic tubing to the impulse nip ple and plug vent hole on top cover Either apply pressure or vacuum The diaphragm gasket must not leak CLEANING AND INSPECTION The entire pump should be cleaned with general purpose solvent before disassembly Fuel pump components should be cleaned in gen eral p...

Page 139: ...Lever TYPICAL 1 Circlip Other Models TYPICAL 1 Throttle cable housing 2 Throttle handle housing 3 Throttle handle 4 Circlip WARNING When draining a fuel tank or whenever a fuel line is disconnected obstruct line with a hose pincher P N 529 0099 00 or equivalent device Fuel is flammable and explosive un der certain conditions Ensure work area is well ventilated Do not smoke or allow open flames or ...

Page 140: ...o prevent corrosion at the connectors Operate the engine to see if the problem has been corrected If not remove fuel level sensor from fuel tank and check rod angle 100 7 resistance at full posi tion 3 2 Ω and resistance at empty position 110 7 Ω 1 Full position 3 2 Ω 2 Empty position 110 7 Ω 3 Loosen to adjust FUSE REPLACEMENT A 0 25 ampere fuse protects fuel level sensor circuitry Remove seat to...

Page 141: ...3 5 ASSEMBLY 04 03 6 INSTALLATION 04 03 8 DRIVE PULLEY ADJUSTMENT 04 03 9 DRIVEN PULLEY 04 04 1 REMOVAL 04 04 3 DISASSEMBLY 04 04 3 CLEANING 04 04 3 INSPECTION 04 04 3 ASSEMBLY 04 04 5 INSTALLATION 04 04 5 ADJUSTMENT 04 04 6 PULLEY DISTANCE AND ALIGNMENT 04 05 1 GENERAL 04 05 1 GENERAL PROCEDURE 04 05 1 PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART 04 05 2 BRAKE 04 06 1 HYDRAULIC DISC BRAKE 0...

Page 142: ...JUSTMENT 04 07 4 GEARBOX 04 08 1 3 SPEED GEARBOX SHIFTER MECHANISM 04 08 1 REMOVAL 04 08 2 ADJUSTMENT 04 08 2 3 SPEED GEARBOX 04 08 3 REMOVAL 04 08 4 DISASSEMBLY 04 08 4 INSPECTION 04 08 6 ASSEMBLY 04 08 6 INSTALLATION 04 08 7 OIL LEVEL 04 08 7 2 SPEED GEARBOX 04 08 8 DISASSEMBLY 04 08 9 INSPECTION 04 08 9 ASSEMBLY 04 08 9 ADJUSTMENT 04 08 11 OIL CHANGE 04 08 12 DRIVE CHAIN 04 09 1 SILENT CHAIN 04...

Page 143: ...L PART NUMBER WIDTH NEW 0 25 mm 010 in MINIMUM WIDTH WEAR LIMIT SUMMIT 583 670 AND MX Z 670 415 0603 00 35 mm 1 3 8 33 mm 1 19 64 SUMMIT 500 GRAND TOURING 500 583 FORMULA 500 500DL 583 Z AND MX Z 440 583 415 8607 00 34 7 mm 1 23 64 32 3 mm 1 17 64 SKANDIC WT SWT WT LC 414 6338 00 34 6 mm 1 23 64 32 mm 1 1 4 MX Z 440F 415 0606 00 34 7 mm 1 23 64 32 3 mm 1 17 64 BOMBARDIER FABRIQUÉAU CANADA MADE IN ...

Page 144: ...n the accompanying chart FOR REFERENCE ONLY To Check Tension Position a reference rule on drive belt Wooden Stick and Spring Scale Method 1 Mark specified deflection Using spring scale and stick apply specified force on drive belt halfway between pulleys as shown 1 Force 2 Read deflection here 3 Reference rule Or use the belt tension tester P N 414 3482 00 1 Lower O ring 2 Upper O ring 3 Force Rea...

Page 145: ...crews clock wise To decrease deflection turn Allen screws coun terclockwise NOTE Turn Allen screws 1 4 turn at a time then rotate driven pulley to allow drive belt to settle in pulley Check deflection repeat as re quired 1 Allen screw with jam nut Allen screws should be restrained while tighten ing jam nut to prevent throwing adjustment out Use drive belt tension adjuster P N 529 0087 00 Restrain ...

Page 146: ... a lubrication free drive pulley A03D2CS Repair kit 5 2 1 3 Loctite 271 6 7 Loctite 648 Loctite 648 Loctite 648 9 18 12 11 12 13 14 15 16 17 16 19 23 25 24 22 20 21 26 27 25 29 32 30 31 28 95 N m 70 lbf ft 10 N m 89 lbf in Loctite 648 12 N m 106 lbf in 27 N m 20 lbf ft 13 N m 115 lbf in PARTS FLAT RATE ...

Page 147: ...puller P N 529 0079 00 for 443 503 and 583 engines Use puller P N 529 0224 00 for 454 494 and 670 engines CAUTION Such modifications should only be per formed by experienced mechanics since they can greatly affect vehicle performance Verify spring specifications before installa tion Do not only refer to the spring color code WARNING Any drive pulley repairs must be performed by an authorized Bomba...

Page 148: ...y mark and arrows as indexing refer ence 25 29 Slider Shoe and Governor Cup Carefully lift governor cup until slider shoes come at their highest position into guides Hold a slider shoe set then carefully lift its housing and remove them Proceed the same way for other housings lifting one at a time 32 Cushion Drive 1 Hold slider shoes 2 Lift one housing at a time NOTE To ease disassembly forks P N ...

Page 149: ...eads and retaining screw threads Remove all harden oil deposits that have baked on crankshaft and pulley tapered surfaces with coarse or medium steel wool and or sand paper no 600 Reclean mounting surfaces with paper towel and cleaning solvent P N 413 7082 00 Wipe off the mounting surfaces with a clean dry paper towel 7 20 Bushing Only use petrol base cleaner when cleaning bush ings WARNING Clutch...

Page 150: ...is 0 5 mm 020 in measured at calibration screw radius Replace if required 7 20 Sliding Half and Spring Cover Bushing Visually inspect coating Replace if worn Sliding Half Bushing Replacement These bushings can be replaced using tools which are not available at time of printing Spring Cover Bushing Replacement Under normal use there is no need to replace this bushing Use tools P N 529 0313 00 and 5...

Page 151: ... screw make sure to in stall washer as shown 1 Washer Torque locking nut to 10 N m 89 lbf in 15 Pin Always use the same type of pin as originally in stalled when servicing Different types have dif ferent weights for calibration purpose Refer to TECHNICAL DATA 09 03 21 22 23 Ramp Dowel Tube and Screw Insert dowel tube from chamfered side Make sure ramp is centered on dowel tube 1 Chamfered side Pos...

Page 152: ...er arrow with sliding half mark 1 Align Install and torque screws to 13 N m 115 lbf in 6 25 29 Sliding Half Slider Shoe and Governor Cup To install governor cup use following tool Insert spring and slider shoes into governor cup so that groove in each slider shoe is vertical to properly slide in guides Install fork P N 529 0055 00 into slider shoe grooves to maintain them for governor cup instal l...

Page 153: ...rds drive pulley then install screw Use clutch holder See removal procedure Torque screw to 90 to 100 N m 66 to 74 lbf ft Install drive belt and belt guard Raise and block the rear of the vehicle and sup port it with a mechanical stand Accelerate the vehicle at low speed maximum 30 km h 20 MPH and apply the brake repeat 5 times CAUTION Make sure splines of both parts are fully en gaged A16B02A 529...

Page 154: ... screw has a notch on top of its head 1 Notch Governor cup has 6 positions numbered 2 to 6 Note that in position 1 there is no stamped num ber due to its location on casting See TECHNICAL DATA 09 03 for original setting 1 Position 1 not numbered Each number modifies maximum engine RPM by about 200 RPM Lower numbers decrease engine RPM in steps of 200 RPM and higher numbers increase it in steps of ...

Page 155: ...Section 04 TRANSMISSION Sub Section 03 DRIVE PULLEY 04 03 10 1 Loosen just enough to permit rotating of calibration screw A16D0HA 1 ...

Page 156: ... Sub Section 04 DRIVEN PULLEY 04 04 1 DRIVEN PULLEY 4 S Series A03D2FS Anti seize lubricant P N 413 7010 00 14 15 2 3 5 6 4 19 18 8 7 Loctite 609 11 13 16 17 12 10 9 All MX Z except 440 F All MX Z except 440 F FLAT RATE PARTS ...

Page 157: ...Section 04 TRANSMISSION Sub Section 04 DRIVEN PULLEY 04 04 2 Skandic WT SWT WT LC A22D11S Anti seize lubricant 4 5 19 2 FLAT RATE PARTS ...

Page 158: ...e 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 leading to low friction So it is normal to see gray teflon deposit on cam or shaft Do not remove that deposit it is not dust When a dust deposit has to be removed from the cam or the shaft use dry cloth to avoid removing transferr...

Page 159: ...rew head in a vise Turn pulley half by hand to extract old bushing Before bushing installation file sliding half bore to remove burrs from crimping areas Coat bushing outside diameter with Loctite 609 P N 413 7031 00 Place new bushing on sliding half and slightly tap to engage squarely the bush ing in the sliding Use tools P N 529 0312 00 and 529 0313 00 to install bushing Install 3 Allen screws n...

Page 160: ...nti seize Lubricant F Series and S Series Only Should installation procedure be required refer to BRAKE 04 06 then look for Brake Disc and Coun tershaft Bearing Adjustment Reinstall the pulley on the countershaft by revers ing the removal procedure All Models Check end play of driven pulley on countershaft by pushing pulley towards outer housing so that the inner shims P N 504 1082 00 contact it M...

Page 161: ...measurement when sliding half begins to turn Rotate sliding half to 10 mm 3 8 in of rota tion Hold fish scale at this position Slowly re lease tension from fish scale and take 2nd measurement when sliding half begins to return Spring pre load is the average measurement be tween these 2 TYPICAL Step 1st measurement Step 2nd measurement To adjust spring pre load relocate spring end in cam moving it ...

Page 162: ...o install proper cam Refer to TECHNI CAL DATA 09 03 Cam angle is identified on cam NOTE For high altitude regions the High Al titude Technical Data Booklet P N 484 0648 00 and 484 0545 00 for binder gives information about calibration according to altitude CAUTION Drive belt and pulley adjustments must always be checked whenever pulleys have been re moved replaced or disassembled B O M BARDIER 6 5...

Page 163: ...e diameter of pul leys GENERAL PROCEDURE Remove belt guard and drive belt By turning and pushing the sliding half open the driven pulley Insert a straight bar 9 5 mm 375 in square 48 cm 19 in long or the proper alignment template into the opened driven pulley Measuring Procedure Using Straight Bar Always measure distances X and Y from the far ther straight bar side including its thickness to the f...

Page 164: ...do not take into account allowed tolerances for alignment specifications They are used as GO NO GO gauges for quick alignment and pulley distance check and as templates to reach alignment nom inal values A06D0LA 1 2 CAUTION This section deals mainly with adjustment procedures For complete assembly require ments refer to the proper ENGINE or TRANSMISSION installation section MODEL PULLEY DISTANCE O...

Page 165: ...holes Move engine to obtain specified distance be tween pulleys Pulley Alignment Method Driven Pulley Movement When engine slotted mounting holes do not allow to set proper pulley offset X adjust with shims P N 504 1082 00 between pulley and counter shaft bearing support pulley pushed toward brake disc Engine Movement Loosen the 4 bolts retaining engine support to the frame Position engine to obta...

Page 166: ...IC DISC BRAKE S Series A03D2DS Loctite 242 7 MX Z 440 F Formula 500 500 Deluxe Summit 500 583 GT 500 583 only Anti seize lubricant All Models Except MX Z 440 F Formula 500 500 Deluxe Summit 500 583 GT 500 583 17 Anti seize lubricant 19 18 20 Black Max 24 FLAT RATE PARTS ...

Page 167: ...nly Pull countershaft toward driven pulley side to gain access to clip no 25 Remove clip no 25 on countershaft S Series Pull countershaft toward driven pulley side to free from chaincase and disc Remove disc Skandic WT SWT WT LC Remove caliper by unscrewing M6 Allen screws through disc hole 1 Allen screw through disc hole Unbolt disc COUNTERSHAFT REMOVAL S Series Proceed the same as for brake disc...

Page 168: ...ed 1 Spacer DISASSEMBLY Only brake pads are available as spare parts If cal iper or master cylinder are damaged replace each of them as an assembly CLEANING Clean all metal components in a general purpose solvent Thoroughly dry all components before as sembling INSPECTION 7 Brake Pad Brake pads must be replaced when lining is 1 mm 1 32 in thick or less A03D29A 1 A03D1JA 529 0301 00 1 CAUTION Do no...

Page 169: ...To install brake reverse removal procedure paying attention to the following 7 Brake Pad All Models with Hydraulic Brake After brake pads installation brake disc must be centered in caliper Apply brake then check for proper brake disc positioning Push on appropriate caliper piston in order to move pad inward allowing proper brake disc posi tioning CAUTION Brake disc should never be machined WARNIN...

Page 170: ...rity Adjustment Torque castellated nut of upper sprocket to 53 N m 39 lbf ft Slide collar no 18 towards bearing and turn by hand to engage the eccentric This should require about a quarter turn Turn collar in direction of countershaft rotation un til collar and inner race lock together Insert a punch into collar hole and strike sharply in the same direction to lock firmly Apply Loctite 242 P N 413...

Page 171: ...ion 04 TRANSMISSION Sub Section 06 BRAKE 04 06 6 1 Open bleeder 2 Clear hose to catch used brake fluid Brake Light There is no adjustment on these models Check that switch is securely installed A06D0JA 2 1 ...

Page 172: ... Without Reverse Gear A06D17S 2 1 3 Chaincase oil 4 5 6 7 27 Loctite 242 23 9 10 8 24 25 26 Loctite 609 11 20 Loctite 242 14 16 17 18 14 12 Loctite 271 15 13 46 N m 34 lbf ft 22 21 45 to 75 N m 33 to 55 lbf ft SYNTHETIC CHAINCASE OIL HUILE SYNTHÉTIQUE POUR CARTER FLAT RATE PARTS ...

Page 173: ... Check for worn or defective bear ings sprockets and chain tensioner components GEAR RATIO MODIFICATION For particular applications the number of teeth of the sprockets can be increased or decreased on lower and upper sprockets Refer to TECHNICAL DATA 09 03 for gear ratios NOTE For high altitude regions the High Al titude Technical Booklet P N 484 0648 00 and P N 484 0545 00 for binder gives infor...

Page 174: ...age in locking hole This initial adjustment should provide 3 5 mm 1 8 13 64 in free play when measured at the out er circumference of the brake disc 22 Chaincase Oil Pour 250 mL 8 5 fl oz of synthetic chaincase oil P N 413 8033 00 into chaincase NOTE Chaincase oil capacity is 250 mL 8 5 fl oz Check oil level with the dipstick then add if re quired Remove metal particles from magnet CAUTION When re...

Page 175: ... CHAINCASE 04 07 4 TYPICAL 1 Dipstick NOTE Chaincase must be in its proper posi tion when checking oil level ADJUSTMENT Pulley Alignment Refer to PULLEY DISTANCE AND ALIGNMENT 04 05 Track Tension and Alignment Refer to TRACK 06 05 A03A03A 1 ...

Page 176: ...Section 04 TRANSMISSION Sub Section 08 GEARBOX 04 08 1 GEARBOX 8 3 SPEED GEARBOX SHIFTER MECHANISM Skandic WT WT LC A22D0YS 7 4 4 5 6 5 3 2 1 FLAT RATE PARTS ...

Page 177: ...oosen tie rod lock nut Remove clip Unfasten tie rod end 1 Clip 2 Lock nut Adjust tie rod length in a way that gear shift lever does not contact console Check 2nd gear posi tion Retighten ball joint lock nuts 1 Cable With gear shift lever in neutral position there should be no cable free play Adjust reverse lock out cable by cable housing ad juster no 2 If more adjustment is needed slack en or tigh...

Page 178: ...n 04 TRANSMISSION Sub Section 08 GEARBOX 04 08 3 3 SPEED GEARBOX Skandic WT SWT WT LC 1 2 3 4 8 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 14 21 22 23 23 24 25 26 29 30 31 17 28 27 28 5 A22D0CS FLAT RATE PARTS ...

Page 179: ...sc side 1 RH side driven pulley side 2 LH side brake disc side 3 4 7 14 16 20 Dipstick Top Cover Gasket O ring Upper Side Cover and Lower Side Cover Remove dipstick Unfasten top cover upper side cover and lower side cover from gearbox housing 1 Top cover 2 Upper side cover 3 Lower side cover Discard O rings and top gasket 5 6 Fork and Fork Axle Using a pusher drive out from LH side both fork axles...

Page 180: ...en Pulley Shaft and Shim Pry oil seal out of gearbox housing Remove snap ring Drive out driven pulley shaft Use alignment tool P N 420 4760 10 as a supporting plate to extract last gear and bearing Spacer will fall into gearbox housing 21 22 29 30 Screw Washer Intermediate Gear and Intermediate Axle Remove screws and washers from both interme diate axles Fasten a long M8 x 1 25 screw in axle end t...

Page 181: ... Output Shaft Install output shaft with its hollow side no splines on RH side 25 29 Lower Gear and Intermediate Gear Install all gears with their shoulder towards RH side 1 Gear shoulder towards RH side 18 19 26 27 28 Reverse Shaft LH Side Bearing Brake Shaft Sleeve and Gear Install brake shaft taking care that gear shoulders face RH side 1 Gear shoulders face RH side Install reverse shaft its sma...

Page 182: ...irclip 5 6 Fork and Fork Axle Mount forks and fork axles using a screwdriver to hold index ball See illustration for fork axle posi tions INSTALLATION Reverse removal procedure Check pulley align ment OIL LEVEL To check pull dipstick Oil should reach level mark TYPICAL 1 Level mark 2 Filler plug To fill remove filler plug from top of transmission Refill as required using Bombardier synthetic chain...

Page 183: ...rand Touring 500 583 A03D17S 15 N m 133 lbf in 7 8 5 28 31 40 48 N m 35 lbf ft Loctite 271 6 16 17 32 33 34 37 38 5 N m 44 lbf in 35 36 29 N m 21 lbf ft Loctite 242 Loctite 242 27 Grease 25 14 Loctite 271 26 15 18 19 20 21 22 23 24 10 9 11 12 13 Grease 4 29 PARTS FLAT RATE ...

Page 184: ...8 and then remove reverse axle no 20 1 Sliding gear screw 2 Reverse axle Remove coupling shaft no 33 44 tooth sprocket no 34 spacer no 38 and chain no 28 First unscrew castellated nut no 10 then remove 22 tooth sprocket no 12 Force 2 spring pins no 16 out to disengage fork no 17 from its axle INSPECTION 14 Chain Slider Replace slider if maximum wear is 1 0 mm 039 in at contact point Bearings Check...

Page 185: ...oth sprocket Tighten nut no 37 to 5 N m 44 lbf in in a criss cross sequence Insert spring pin no 21 in reverse axle up to in side diameter Press needle bearing in 19 tooth sprocket Install ring no 24 and 19 tooth sprocket on reverse axle 1 Reverse axle ass y 2 Sliding gear ass y Install shim no 13 22 tooth sprocket drive no 12 and washer no 11 then tighten castellated nut no 10 and conical spring ...

Page 186: ...t is still impossible check if the fork engages in the slid ing gear or disassemble the cover to inspect com ponents 3 Completely slacken ball joint lock nut on the gear shift linkage 4 Using tool P N 529 0303 00 to push and hold down tie rod plate to make sure transmission is in reverse gear Pull shifter handle in reverse position making sure all slack is removed Lengthen tie rod until it contact...

Page 187: ...t Clean cover interior NOTE It is normal to find metallic particles stuck to dipstick magnet If bigger pieces of metal are found disassemble and check all parts Reinstall cover as previously described during as sembly Fill housing with chaincase oil P N 413 8019 00 Oil capacity is 250 mL 8 5 oz Check oil level with dipstick With dipstick un screwed oil level must be between MIN and MAX marks 1 Dip...

Page 188: ...here are 2 types of silent chain One is 11 plate wide and the other stronger is 13 plate wide Do not interchange sprockets Fit chain on sprockets to make sure using right ones accord ing to width Refer to TECHNICAL DATA 09 03 NOTE No work separation lengthening can be done on the silent chain type ...

Page 189: ...STEM 05 04 1 1997 REFERENCE CHART 05 04 1 DESIGN SYMBOLS USED IN NGK SPARK PLUGS 05 04 2 DISASSEMBLY 05 04 3 HEAT RANGE 05 04 3 FOULING 05 04 3 SPARK PLUG ANALYSIS 05 04 3 SPARK PLUG INSTALLATION 05 04 4 SPARK PLUG TIGHTENING TORQUE 05 04 4 BATTERY 05 05 1 REMOVAL 05 05 1 CLEANING 05 05 2 INSPECTION 05 05 3 HYDROMETER TEST 05 05 3 BATTERY STORAGE 05 05 4 ACTIVATION OF NEW BATTERY 05 05 4 SERVICING...

Page 190: ... 05 07 4 TRIGGER COIL OUTPUT 05 07 4 IGNITION COIL OUTPUT 05 07 4 IGNITION MODULE 05 07 5 MAGNETO OUTPUT IGNITION GENERATOR COIL 05 07 6 LIGHTING GENERATOR COIL OUTPUT 05 07 6 SUMMARY TABLE 05 07 8 RESISTANCE MEASUREMENTS 05 07 9 DUCATI CDI SYSTEM TESTING 05 07 10 TRIGGER COIL OUTPUT 05 07 10 MAGNETO OUTPUT 05 07 10 IGNITION COIL OUTPUT 05 07 11 IGNITION MODULE 05 07 11 LIGHTING GENERATOR COIL OUT...

Page 191: ... watt ELECTRICAL SYSTEM OUTPUT watt MX Z 440 F Annex 1 60 55 hal 8 27 240 MX Z 440 583 670 Annex 2 60 55 hal 8 27 220 Formula 500 DELUXE Annex 3 60 55 hal 8 27 220 Formula 500 583 Summit 500 583 670 Annex 4 60 55 hal 8 27 220 Formula Z Annex 5 60 55 hal 8 27 220 Grand Touring 550 583 Annex 6 60 55 hal 8 27 220 Skandic WT SWT Annex 7 60 55 hal 8 27 240 Skandic WT LC Annex 8 60 55 hal 8 27 240 COLOR...

Page 192: ...beam Current returns by YELLOW BLACK wire connected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by YELLOW BLACK wire connected to oil level sensor BLUE 12 volts A C Fuel level indicator Current returns by YELLOW wire connected to fuel level sensor ORANGE...

Page 193: ... 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 Step Insert screwdriver here Step Pull this side Locking Receptacle Connector To remove Insert tool Snap on TT 600 5 in access opening then pull housing toward wire side TAB AND RECEPTACLE CONNECTORS INSTALLATION Prior to installing make...

Page 194: ...sso ries on any snowmobile connect their wires di rectly to the YELLOW and YELLOW BLACK lighting coil wires Even if manual start models have an AC ground to the chassis on voltage regulator all accesso ries utilize a ground wire isolated from chassis When an electric starter kit is installed the volt age regulator and its ground wire are replaced by a voltage rectifier regulator unit permitting a ...

Page 195: ...emove the rewind starter from the engine 3 Install the TDC gauge in the spark plug hole magneto generator side and adjust as follows a Position the magneto flywheel at approxi mately TDC INSTALLATION OF TDC GAUGE 1 Adaptor lock nut 2 Gauge on MAG side cylinder b Assemble the gauge to the adaptor and tight en the roller lock nut Do not tighten the adaptor lock nut c Screw the adaptor into the spark...

Page 196: ...eto fly wheel and trigger coil part numbers and check Woodruff key condition If all parts are the appropriate ones and if Woodruff key is in good condition continue the procedure 1 Trigger coil mark 2 Magneto flywheel mark NOTE These marks cannot be used to check dynamic with engine running ignition timing with a timing light a new mark must be scribed on magneto flywheel for this purpose 6 Scribe...

Page 197: ...n a faulty trigger coil check proper grounding of coil or a faulty CDI module could be the cause substitute one part at a time and recheck timing marks check connec tors condition prior to substituting any part NOTE Ignition timing may be verified when engine speed is anywhere within 2000 6000 RPM CHECKING IGNITION TIMING 1 Timing light pick up on MAG side 2 Crankcase arrow 3 Magneto flywheel mark...

Page 198: ...g mark pro ceed as follows 1 Clean the area around the spark plugs and re move them 2 Remove the rewind starter from the engine 3 Install the TDC gauge in the spark plug hole magneto side and adjust as follows a Position the magneto flywheel at approxi mately TDC TYPICAL 1 TDC gauge on MAG side 2 MAG side piston at TDC b Assemble the gauge to the adaptor and tight en the roller lock nut Do not tig...

Page 199: ...ter of trigger coil core 2 Retard 3 Advance 454 494 AND 670 ENGINES 1 Advance 2 Retard NOTE These marks can not be used to check dynamic with engine running ignition timing with a timing light an other mark is scribed on magneto flywheel or damper for this purpose When flywheel protrusion dot aligns with center of trigger coil core flywheel mark and crankcase center mark must be aligned Checking I...

Page 200: ...ligned with center mark If not move trigger coil as explained above and recheck ignition timing Tolerance is 1 If the marks still do not align a faulty trigger coil check proper grounding of coil or a faulty CDI module could be the cause substitute one part at a time and recheck timing marks check connec tors condition prior to substituting any part A06E27A 1 2 ...

Page 201: ... SPARK PLUG NUMBERING SYSTEM Bombardier is using the NGK spark plug type on most of the 1997 snowmobile models The heat range identification system is High number hot plug Low number cold plug 1997 REFERENCE CHART NGK spark plugs used on 1997 Bombardier snow mobiles covered in this manual BR8ES BR9ES ...

Page 202: ... 10 Cold 18 mm 14 mm 10 mm 12 mm 8 mm 12 mm x 19 mm Reach A B C D E J Special Design Single Ground Special Alloy Dual Ground Special Alloy Racing Type Racing Version of V Type Half Heat Range Standard Center Electrode Fine Wire Center Electrode Booster Gap V Grooved Center Electrode A GV B C G L S V X Y Blank 18 mm ø 12 mm 31 64 14 mm ø 9 5 mm 3 8 Compact Type Projected Insulator Type Resistor Typ...

Page 203: ...tion etc A too cold plug will result in fouling shorting the spark plug or may create carbon build up which can heat up red hot and cause pre ignition or detonation FOULING Fouling of the spark plug is indicated by irregular running of the engine decreased engine speed due to misfiring reduced performance and in creased fuel consumption This is due to a loss of compression Other possible causes ar...

Page 204: ... wire feeler gauge set electrode gap ac cording to TECHNICAL DATA 09 02 2 Apply anti seize lubricant P N 413 7010 00 over the spark plug threads to prevent possible seizure 3 Hand screw spark plug into cylinder head and tighten with a torque wrench and a proper socket 1 Proper socket 2 Improper socket SPARK PLUG TIGHTENING TORQUE Models Spark plugs Torque N m lbf ft All models NGK 27 20 A00E0BA 2 ...

Page 205: ...ep Remove vent tube On all models a special vented rivet is fixed to the chassis in order to plug the vented tube from the battery Skandic WT Remove air intake silencer 1 Loosen clamp 1 Remove bolt and lock nut Unfasten battery brackets and remove battery WARNING Battery BLACK negative cable must always be disconnected first and connected last WARNING Never charge or boost battery while in stalled...

Page 206: ...ry from vehicle being careful not lean it so that electrolyte flows out of vent tube CLEANING Clean the battery battery casing vent tube caps cables and battery posts using a solution of baking soda and water A22E0GA 1 A29E0DA CAUTION Should any electrolyte spillage occur imme diately wash off with a solution of baking soda and water to prevent damage to vehi cle components CAUTION Do not allow cl...

Page 207: ...st hydrometers give a true reading at 27 C 80 F In order to obtain correct readings adjust the ini tial reading by adding 004 points to the hydrom eter readings for each 5 5 C 10 F above 27 C 80 F and by subtracting 004 point for every 5 5 C 10 F below 27 C 80 F This chart will be useful to find the correct read ing WARNING Should the battery casing be damaged wear a suitable pair of non absorbent...

Page 208: ...ays As necessary keep the battery at its upper level line and near full charge as possible trickle charge ACTIVATION OF NEW BATTERY A new battery is factory fresh dry charged For storage purposes it is fitted with a temporary sealing tube Do not remove the sealing tube or loosen battery caps unless activation is desired In case of accidental premature removal of caps or sealing tube battery should...

Page 209: ...e 1 Battery electrolyte 6 Connect a 2 A battery charger for 10 to 20 hours A17E0FA 1 A17E0GA 1 A17E0HA CAUTION If charging rate raises higher than 2 4 A re duce it immediately If cell temperature rises higher than 50 C 122 F if the casing feels hot discontinue charging temporarily or re duce the charging rate WARNING Gases given off by a battery being charged are highly explosive Always charge in ...

Page 210: ... gravity 1 260 9 Let battery settles for one hour 1 60 minutes 10 Allow gas bubbles to escape by lightly shake battery 11 Readjust electrolyte level 1 Battery electrolyte 12 Reinstall caps and clean any electrolyte spill age using a solution of baking soda and water 1 Baking soda A17E0IB 1 3 2 A17E0JA 1 A17E0KA 1 A17E0HA A17E0RA 1 A17E0LA 1 ...

Page 211: ...ry to begin accepting measurable current will also vary Charging a Very Flat or Completely Discharged Battery Unless this procedure is properly followed a good battery may be needlessly replaced Measure the voltage at the battery posts with an accurate voltmeter If it is below 10 volts the battery will accept current at very low rate in term of milliamperes because electrolyte is nearly pure water...

Page 212: ...ts supply shops and they are suitable for use with most chargers if the peak current is to be held below 2 amps If you need an accurate ammeter we recommend the use of SHURITE 5202 0 to 3 amps or 5203 0 to 5 amps available from electronic parts supply shops 1 Charger 2 Rheostat 12Ω 50W 3 Ammeter 4 Battery For a service application and a permanent installa tion both ammeter and rheostat can be buil...

Page 213: ...proper bat tery installation AIR SILENCER INSTALLATION SKANDIC WT 1 Locking tie All Models Ensure that vent tube is not kinked or blocked then install protective boot over battery Close and fasten retaining strips Reinstall air silencer Fasten spark plug cables to fan housing Reinstall throttle cable to air silencer See removal illustration CAUTION Negative battery terminal should always be discon...

Page 214: ...ection 05 ELECTRICAL Sub Section 06 ELECTRIC STARTER 05 06 1 ELECTRIC STARTER 6 S Series with Electric Starting and Skandic WT SWT A03E13S 1 2 3 8 9 10 11 12 13 15 16 17 18 19 4 5 6 7 12 PARTS FLAT RATE ...

Page 215: ...no 8 Insert blade of a small screwdriver between stop collars Twist screwdriver to separate stop collars no 12 thus giving access to circlip no 13 Remove outer collar circlip then inner collar Remove overrunning clutch no 11 Check the wear on bushing no 18 by measuring the amount of radial play between the armature shaft and the bushing The radial play should not exceed 0 20 mm 0 008 in If greater...

Page 216: ...e to rotate tap until the bushing comes free 1 Turn until bushing goes out 2 12 mm tap To install new bushing use the same bushing pusher as for drive housing bushing installation 6 Brush To replace brush no 6 proceed as follows Cut brush wire close to connector at the welded portion 1 Cut close to connector Remove burrs with a file on the remaining welded portion Place spare brush plate edge agai...

Page 217: ...ace drive lever onto overrunning clutch then in sert into drive housing 1 Install on overrunning clutch 2 Install thrust washer Slide yoke over armature Install brush holder then brushes in their hous ings Insert springs as follows place one end of spring against brush compress then push the other end of spring onto its housing Repeat for remaining springs 1 This end first 2 Push this end to compl...

Page 218: ...on Install hardened washers P N 503 0079 00 between engine and starter supports ac cordingly 1 Screwdriver pulling starter pinion 2 Ring gear 3 No excessive backlash A 0 5 to 1 5 mm 020 to 060 in Connect the RED battery cable and the red wire to the large terminal of the solenoid Connect RED GREEN wire to small terminal of solenoid Connect BLACK cable to battery CAUTION All starter bracket fastene...

Page 219: ...ace If necessary turn the commutator on a lathe enough to remove grime only Check the commutator for mica depth If the depth is less than 0 20 mm 0 008 in undercut the mica Be sure that no burrs are left and no copper dust remains between the segments after the undercutting operation is completed 1 Commutator undercut 0 20 mm 008 in Check the commutator out of round condition with V Blocks and an ...

Page 220: ...tion of an open circuit armature coil Field Windings and Brushes Test the Field Winding for Open Circuit Use growler test probes Place one test probe on the negative brush and the other test probe on the yoke If growler lamp does not turn on the field winding has an open circuit The yoke has to be repaired or replaced 1 Test probes Check the dynamic brake winding for open circuit by placing one te...

Page 221: ...ction If defec tive replace Check the pinion teeth for wear and damage If defective replace SOLENOID SWITCH Inspect connections and clean as necessary Sole noid switch condition can be checked with an ohmmeter Install test probes on large connec tors of solenoid when it is activated on RED GREEN wire and on solenoid body IMPORTANT No current must be present on large cables when using ohmmeter othe...

Page 222: ...5 ELECTRICAL Sub Section 06 ELECTRIC STARTER 05 06 9 Skandic WT LC A29E09S 12 11 10 9 6 8 7 1 2 3 4 5 5 N m 44 lbf in Dielectric grease Loctite 271 Ground cable Dielectric grease 22 N m 16 lbf ft FLAT RATE PARTS ...

Page 223: ...ICAL 1 Trace indexing marks Remove starter support nuts then through bolts Separate end frame from yoke assembly With draw yoke assembly from armature Brush holder can be removed from end frame by unscrewing nut retaining terminal Check that the radial play between the armature shaft and end frame is not greater than 0 20 mm 008 in Replace end frame if so 6 7 8 Circlip Spring and Pinion Stop Colla...

Page 224: ... on a lathe enough to resurface only Check commutator for mica depth If depth is less than 0 20 mm 008 in undercut mica Be sure that no burrs are left and no copper dust remains between segments after undercutting operation is completed 1 Commutator undercut 0 20 mm 008 in Check commutator out of round condition with V shaped blocks and an indicator If commutator out of round is more than 0 40 mm ...

Page 225: ...ing coat sliding surfaces on ar mature shaft splines overrunning clutch and bushing with G E Versilube G 341 M or ESSO Beacon 325 lubricant or equivalent Apply motor oil on metal bushings 6 8 Circlip and Pinion Stop Collar After placing stop collar on armature shaft fit cir clip into armature shaft then make sure that it is properly secured Slide stop collar over circlip and secure in place by pun...

Page 226: ...ARTER INSTALLATION Installation is essentially the reverse of removal procedure However pay particular attention to the following Make sure that starter and engine mating surfac es are free of debris Serious trouble may arise if starter is not properly aligned F01H0SA 1 F01H0TA 1 CAUTION Make sure end frame fits perfectly on yoke WARNING Always connect RED positive cable first then BLACK negative ...

Page 227: ...P N 129700 2982 Flywheel stamped P N 032000 7860 454 494 and 670 Engines Ignition module stamped P N 070000 2421 Ignition coil stamped P N 129700 2982 Flywheel stamped P N 032700 5900 NIPPONDENSO CDI TRIGGER COIL SYSTEM 1 Separate ignition coil mounted on reservoir cluster 2 Three wire connector RED BLACK RED and BLACK Ducati The DUCATI CDI system has a combined ignition module ignition coil which...

Page 228: ...omotive equipment and other items as follows Engine Stop Tether Cut Out Switches Verification Engine Stop Switch Unplug stop switch connector from main harness then using an ohmmeter connect test probes to BLACK YELLOW and BLACK wires Measure resistance it must be an open circuit in its operating position and close to 0 ohm when depressed Tether Cut Out Switch Unplug tether cut out switch connecto...

Page 229: ...nvestigated loose connec tions or components etc Indicator Lamp Lights at Lower Setting This indicates that the output is less than that de signed to operate in a satisfactory manner How ever before coming to the conclusion of a faulty condition be certain that correct engine cranking conditions were met before condemning the test ed part Indicator Lamp Does Not Light One component is defective Pr...

Page 230: ...ad grounding IGNITION COIL OUTPUT A paper clip of approximately 20 mm 3 4 in will be used as a test adapter for the following test 1 Install the test adapter to spark plug cable close to MAG side spark plug 2 Connect tester wires then set switch and dial as follows NOTE Different reading occurs if N tester wire is connected to PTO or MAG side spark plug cable WARNING To prevent powerful electric s...

Page 231: ... At assembly secure with new locking ties 2 Connect an ignition coil known as being in good condition to the spark plug s 3 Connect CDI module to replacement ignition coil paying attention to connect the WHITE BLUE wire to the positive terminal and the BLACK wire to the negative terminal 1 Black 2 White Blue 4 Slip plastic protectors out of coil terminals 5 Connect tester wires to coil terminals t...

Page 232: ...neto harness At installation secure with new locking ties 2 Connect tester wires then set switch and dial as follows TYPICAL 3 Crank engine and observe indicator 4 Push reset button and repeat step 3 twice LIGHTING GENERATOR COIL OUTPUT NOTE The lighting generator coil is not part of the ignition system It is a separate sys tem that supplies current to the lighting system and AC powered devices Ho...

Page 233: ...ush reset button and repeat step 3 twice Results a Indicator lamp lights Lighting generator coil output is up to specifications b Indicator lamp does not light Lighting gen erator coil is faulty Tester wires Component wires Tester switch position Tester dial position N YELLOW wire of magneto harness LOW 75 P YELLOW wire of magneto harness N Yellow A15E0VA Yellow ...

Page 234: ...wire of trigger coil Ignition coil output N Engine ground LOW 45 P Test adapter on MAG spark plug cable Ignition module output N WHITE BLUE wire of ignition coil LOW 85 P BLACK wire of ignition coil Magneto output ignition generator coil N RED wire of magneto harness LOW 85 P BLACK RED wire of magneto harness Lighting generator coil output N YELLOW wire of magneto harness LOW 75 P YELLOW wire of m...

Page 235: ...nt can still be faulty Voltage leak can occur at high voltage level which is not detect able with an ohmmeter Infinity extremely large number PART NAME WIRE COLOR RESISTANCE OHM REMARKS MAGNETO Trigger coil BL YL with WH YL 190 300 No display change means open circuit Ignition generator coil RD with BK RD 10 17 Lighting generator coil YL with YL 0 20 0 35 IGNITION COIL Primary winding BK with WH B...

Page 236: ... Generator Coil 1 Disconnect the 2 wire connector between igni tion module and magneto harness 2 Connect tester wires then set switch and dial as follows 1 Green 2 White 3 Crank engine and observe indicator 4 Push reset button and repeat step 3 twice Results a Indicator lamp lights Ignition generator coil output up to specifications b Indicator lamp does not light The problem is a faulty ignition ...

Page 237: ...e IGNITION MODULE Ignition module can not be tested with the Bom bardier ignition tester When other components test good the module is probably faulty Try a new module LIGHTING GENERATOR COIL OUTPUT NOTE The lighting generator coil is not part of the ignition system It is a separate sys tem that supplies current to the lighting system and AC powered devices However it can be test ed with the same ...

Page 238: ...E Test to perform Tester wires Component wires Switch Dial Trigger coil output N WHITE RED wire of trigger coil LOW 45 P Engine ground Magneto output ignition generator coil N GREEN wire of magneto harness LOW 80 P WHITE wire of magneto harness Ignition coil output N Test adapter on MAG spark plug cable LOW 70 P Engine ground Lighting generator coil output N YELLOW wire of magneto harness LOW 80 P...

Page 239: ...nce measurement can still be faulty Voltage leak can occur at high voltage level which is not detect able with an ohmmeter The primary winding of ignition coil can not be measures because there is no external connection PART NAME WIRE COLOR RESISTANCE OHM REMARKS MAGNETO Trigger coil RD with engine ground 140 180 No display change means open circuit Ignition generator coil WH with GN 230 330 Light...

Page 240: ...ter to a BLACK YELLOW wire Connect the other wire of the voltmeter to a YEL LOW wire Lift the rear of vehicle and support with a mechan ical stand Start the engine at an idle without opening the throttle Slowly open the throttle and accelerate the en gine to increase the RPM If the meter reads over 15 volts the regulator is defective and must be replaced NOTE Whatever the voltmeter type used peak ...

Page 241: ... weaken INSPECTION Disconnect regulator rectifier Connect one digital ohmmeter probe needle ohmmeter will not offer enough precision to frame and other probe to one of 2 yellow magneto wires Measured resistance must be infinite If such is not the case it means there is a connection be tween AC circuit and DC circuit Disconnect one accessory at the time to identify the faulty circuit ...

Page 242: ...t When measuring resistance at terminals the actual value will be half the measurement in table The reason for that is the elements are connected in parallel Therefore the total resistance is half the resistance of one element HIGH INTENSITY YELLOW BLACK wire BROWN wire 1 96 to 3 64 ohms LOW INTENSITY YELLOW BLACK wire BROWN YELLOW wire 8 05 to 14 95 ohms HIGH INTENSITY BROWN wire 0 23 Amp minimum...

Page 243: ...R SERVICING 06 02 11 INSTALLATION 06 02 19 RIDE ADJUSTMENT 06 02 19 LUBRICATION 06 02 19 SKANDIC WT SUSPENSION 06 03 1 REMOVAL 06 03 2 DISASSEMBLY AND ASSEMBLY 06 03 2 SHOCK ABSORBER SERVICING 06 03 3 DRIVE AXLE 06 04 1 REMOVAL 06 04 3 DISASSEMBLY 06 04 3 ASSEMBLY 06 04 4 AXIAL PLAY 06 04 6 INSTALLATION 06 04 8 LUBRICATION 06 04 9 ADJUSTMENT 06 04 9 TRACK 06 05 1 TRACK TYPE APPLICATION 06 05 1 GEN...

Page 244: ...S 06 02 1 SC 10 SUSPENSIONS ALL VERSIONS 2 SC 10 Sport on MX Z 440 F Formula 500 500 DELUXE 583 A03F26S 21 Loctite 271 7 1 2 3 4 5 7 19 Low temp grease 8 9 6 16 12 13 14 15 25 11 10 Loctite 271 11 16 20 17 Loctite 271 Loctite 271 Loctite 271 18 Loctite 271 FLAT RATE PARTS ...

Page 245: ...LL VERSIONS 06 02 2 SC 10 Cross country on MX Z 440 583 670 A03F27S 21 Loctite 271 7 2 3 7 5 4 6 16 Low temp grease 8 9 15 12 13 14 25 16 20 10 Loctite 271 MX Z 440 only 11 18 Loctite 271 Loctite 271 Loctite 271 22 23 Loctite 271 24 17 Front arm 1 FLAT RATE PARTS ...

Page 246: ...NS ALL VERSIONS 06 02 3 SC 10 High performance on Formula Z and Grand Touring 583 A03F28S 21 7 1 2 3 4 5 Loctite 271 6 16 9 8 Low temp grease Front arm 12 13 14 25 15 11 16 20 17 10 Loctite 271 18 Loctite 271 Loctite 271 24 22 23 Loctite 271 7 FLAT RATE PARTS ...

Page 247: ...PENSIONS ALL VERSIONS 06 02 4 SC 10 Mountain on Summit 500 583 670 A03F29S Loctite 271 7 2 4 3 5 7 1 Loctite 271 19 8 9 16 6 Low temp grease 12 13 14 15 25 11 16 20 11 17 10 Loctite 271 Loctite 271 18 Loctite 271 Loctite 271 Loctite 271 FLAT RATE PARTS ...

Page 248: ...SPENSIONS ALL VERSIONS 06 02 5 SC 10 Touring on Grand Touring 500 A03F2AS Loctite 271 7 1 2 3 5 7 Loctite 271 4 6 16 19 8 9 Low temp grease 12 13 14 15 25 11 11 16 20 17 10 Loctite 271 Loctite 271 18 Loctite 271 Loctite 271 Loctite 271 FLAT RATE PARTS ...

Page 249: ...sassemble threaded rod ass y needlessly Lift rear of vehicle Unhook rear springs Unscrew threaded rod nut Remove through bolt from shackle Swing shackle rearward Collapse suspension in order to disengage thread ed rod from its support 1 Block ass y Allen screw 2 Schackle Unscrew block ass y Allen screws 1 Marks 2 Roll pin 3 Smaller washer 4 Larger washer 23 Cushion Separate pivot block Remove cush...

Page 250: ...tion illustration below Installation is reverse of removal procedure To easily compress gas shock absorber use a pry bar and locking pliers as a stopper 1 Locking pliers 2 Pry bar All Models 12 Front Shock Unfasten one end of stopper strap Unbolt shock and remove it MX Z 440 Only At installation Schrader valve must face rearward and rubber boot opening forward All Models 2 Rear Spring Remove sprin...

Page 251: ...support it off the ground Loosen track tension 7 Screw Unscrew rear arm top axle from chassis NOTE To prevent axle from turning when unscrewing screws assembled with thread locker proceed as follows Knock on screw head and or heat to break threadlocker bond Loosen one screw then retighten Remove the opposite screw Remove the first one Unscrew center idler wheel axle from tunnel then remove Lift re...

Page 252: ... screw 11 Axle Note position of axles at disassembly Axles with a paint stripe serve as idler wheel axles These are more precise than those used as pivot axles Idler wheel axles can be used as pivot axles but the opposite is not true 12 13 14 Front Shock Spring Stopper and Cap Use shock spring remover P N 529 0271 00 in a vise Mount shock in it and turn shock so that spring coils matched spring co...

Page 253: ...L DATA 09 03 Torque nut to 11 N m 97 lbf in 1 1st hole 2 2nd hole A 11 N m 97 lbf in 17 Slider Shoe Replace slider shoes when it is worn to the line 1 Wear limit line 18 Spring Support RIGHT SIDE SHOWN 1 Right position upward 2 Wrong position SHOCK ABSORBER INSPECTION All Models Equipped with Hydraulic Shock NOTE Hydraulic shocks are black or dark gray painted A03F12A 1 2 A03F0QA A 1 2 CAUTION Sli...

Page 254: ...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 Rod must comes out at a steady speed If speed suddenly increases particularly at end of exten sion replace shock If suspecting a frozen gas shock proceed as fol lows Place shock in a freezer temperature below 0 C 32 F for 4 hours Push down on rod and note i...

Page 255: ...l assembly removed slowly lift and remove damper rod assembly from the damper body NOTE Remove damper rod assembly slow ly to reduce oil spillage and prevent piston seal damage by damper body threads Wrap the damper body with a shop cloth to capture possi ble overflow oil while removing the damper pis ton 1 Oil flows Discard old oil into storage container Never reuse damper oil during shock rebuil...

Page 256: ... nut after 4 rebuilds to ensure good locking friction NOTE If revalving is to be done it is imper ative that you identify the original shim pack size and number of shims The seal carrier need not be removed if only revalving is to be done Shims can be measured by using a vernier caliper or a micrometer The damper rod is constructed of a plated shaft design This damper shaft must be inspected for a...

Page 257: ...m 1 18 in shims no 7 against piston to properly close piston orifice holes Two thin shims will offer less damping than one thick shims of the equal thickness Tuning for less damping it is important to re member never use less than 3 shims against piston This will guard against fatigue breakage One 0 114 mm spacer washers no 8 minimum 2 or more recommended should always be used between shim stack a...

Page 258: ...4 1 A06F12A 529 0265 00 FRONT QTY D mm in Thick mm in Spacer 1 12 mm 0 472 in 0 023 mm 0 008 in Extension shims 5 26 mm 1 020 in 0 203 mm 0 008 in Piston slit 4 Compression shims 8 30 mm 1 180 in 0 152 mm 0 006 in Spacer 2 15 mm 0 590 0 114 mm 0 0045 in CENTER QTY D mm in Thick mm in Spacer 1 12 mm 0 472 in 0 023 mm 0 008 in Extension shims 8 26 mm 1 020 in 0 152 mm 0 006 in Piston slit 4 Compress...

Page 259: ...nce Install floating piston to depth of 151 mm 5 94 in for front damper 190 mm 7 48 in for rear damp er and 141 mm 5 55 in for center damper Mea sure from the top edge of the damper body NOTE If the floating piston is installed too far into the damper body light air pressure through Schrader valve with core removed will move piston outward Replace shock oil with Bombardier HPG shock oil P N 413 70...

Page 260: ...nto damper body Slight up and down movement may be required to allow all air to pass through piston assembly NOTE Fast installation of the damper rod may displace the floating piston from its orig inal position This must not occur if the damper is expected to perform as designed With damper rod piston into oil volume re top damper oil volume Oil level should be to damper body thread base Seal carr...

Page 261: ...anoth er gas product The nitrogen gas has been se lected because of its inert qualities As well as being a dry gas moisture free it will not con taminate the gas chamber portion of the damp er When selecting shim stacks 2 thin shims of equal thickness to one thick shim will offer less resistance than one thick shim Refer to SHIM EQUIVALENCE FOR SAME DIAMETER table above Whenever building a rebound...

Page 262: ...irst Insert rear portion of suspension into track Bolt front arm rear arm then center top idler wheel axle Adjust track tension RIDE ADJUSTMENT Refer to Operator s Guide LUBRICATION Lubricate front and rear arms at grease fittings us ing low temperature grease P N 413 7061 00 SC 10 SPORT MOUNTAIN AND TOURING 4 GREASE FITTING SC 10 XC AND HP 7 GREASE FITTINGS 1 Only the GT 583 has this 8th grease f...

Page 263: ...Section 06 REAR SUSPENSION Sub Section 03 SKANDIC WT SUSPENSION 06 03 1 SKANDIC WT SUSPENSION 3 Skandic WT SWT WT LC A22F18S 1 2 3 7 4 5 6 8 FLAT RATE PARTS ...

Page 264: ...er bond Loosen one screw then retighten Remove the opposite screw Remove the first one Remove suspension ass y DISASSEMBLY AND ASSEMBLY 1 Extension Remove nuts and conical washers from the eye bolt adjuster Remove bolt retaining eye bolt ad juster to support Remove rear idler wheel on appropriate side Remove idler wheel from support Unbolt extension from its support 1 Support 2 Conical Washer At i...

Page 265: ... pin Unbolt front idler wheel axle Remove idler wheel on side where axle retaining plate is not welded Remove springs 1 Circlips 6 Support Plate Drill rivets to remove support plate Use a 8 mm 21 64 in drill bit Rivets can be substitued by M8 x 20 bolts and nuts 8 Stopper Strap Bolt Install it in center hole of front arm 3 Horse Shoe Washer For deep snow riding do not install washer nor rubber sto...

Page 266: ...s smoothly and with uniform resistance Pay attention to the following conditions that will denote a faulty shock A skip or a hang back when reversing stroke at mid travel Seizing or binding condition except at extreme ends of stroke Oil leakage A gurgling noise after completing one full com pression and extension stroke Renew if any fault is present CAUTION Do not clamp directly on shock body ...

Page 267: ...Section 06 REAR SUSPENSION Sub Section 04 DRIVE AXLE 06 04 1 DRIVE AXLE 4 S Series A03D20S 12 6 4 9 13 10 2 3 5 11 13 8 Summit and MX Z only FLAT RATE PARTS ...

Page 268: ...Section 06 REAR SUSPENSION Sub Section 04 DRIVE AXLE 06 04 2 Skandic WT A22D14S 13 6 9 3 2 5 4 FLAT RATE PARTS ...

Page 269: ...he same time pulling the drive axle towards the end bearing housing side Remove drive axle from vehicle Skandic WT SWT WT LC Only Drain gearbox Raise and block rear of vehicle off the ground Remove suspension Refer to SKANDIC WT SUS PENSION 06 03 Remove muffler Unfasten screw from drive axle end Loosen both Allen screws from end bearing Remove 3 screws retaining end bearing then re move inner plat...

Page 270: ...EMBLY 8 9 13 Drive Axle and Sprocket To assemble press fit sprockets use a press and a suitable pipe as illustrated Sprockets must be assembled according to the following dimen sions 1 Pipe S Series A 65 8 mm 2 19 32 in B 159 3 mm 6 17 64 in C 282 3 mm 11 7 64 in D 375 8 mm 14 51 64 in Skandic WT SWT WT LC 1 Gearbox side A 93 mm 3 21 32 in B 156 5 mm 6 5 32 in C 398 5 mm 15 11 16 in D 462 mm 18 3 ...

Page 271: ...of drive axle if applicable Locate seal lip as illustrated 1 Grease seal type 2 Oil seal type 11 Bearing Protector At assembly flat side of bearing protector must be against bearing 5 12 Bearing Always push bearing by inner race The bearing on the splined side of axle must be pushed until it is seated on shaft shoulder The end bearing housing bearing must be flush with end of drive axle Each beari...

Page 272: ...clockwise TYPICAL 1 Set screw 2 Slacken 3 Tighten Extract bearing from its support Wrong chaincase perpendicularity will make it dif ficult to correctly install the bearing in its support due to the countershaft and support misalign ment TYPICAL Add shim s P N 504 0398 00 between chain case and frame to obtain easy bearing installa tion This chart can be use as a starting point to cor rect the cha...

Page 273: ...Drive axle pushed toward chaincase 1 No gap all around Pull drive axle toward the end bearing housing and take note of the measurement between sprocket and tunnel The drive axle axial play is the difference between these 2 measurements Repeat this procedure 2 or 3 times to obtain an accurate measurement The allowable drive axle axial play is 0 to 1 5 mm 0 to 060 in The drive axle axial play as cal...

Page 274: ...ch side exceeds 3 mm 1 8 in redistribute drive axle shims as fol lows INSTALLATION 4 Speedometer Drive Insert If the drive axle to be installed is a new part and the vehicle is equipped with a speedometer a cor rect size speedometer drive insert must be in stalled into the axle end Ensure that insert is flush with end of axle Position drive axle assembly into location Install end bearing housing I...

Page 275: ...L DATA 09 03 Install the suspension Refer to TRACK 06 05 and adjust track tension and carry out track alignment procedure LUBRICATION 15 Grease Fitting Lubricate end housing bearing with low tempera ture grease P N 413 7061 00 ADJUSTMENT Sprocket Track Alignment Sprockets might be repositioned to fit lugs with out removing drive axle Use drive axle sprocket adjuster kit P N 861 7257 00 TYPICAL A00...

Page 276: ...ar suspension muffler RH drive axle end bearing angle drive and square pin Move transmission sideway Do not remove brake mechanism nor driven pulley Refer to SKANDIC WT SUSPENSION 06 03 Remove drive axle then track INSTALLATION All Models Reverse the removal procedure NOTE When installing the track respect ro tation direction indicated by an arrow on track thread Check sprocket track alignment as ...

Page 277: ...TYPICAL 1 Retaining screw 2 Adjuster bolt Alignment All Models With rear of vehicle supported off the ground start engine and allow the track to rotate slowly Check that the track is well centered equal dis tance on both sides between edges of track guides and slider shoes 1 Guides 2 Slider shoes 3 Equal distance CAUTION Too much tension will result in power loss and excessive stress on suspension...

Page 278: ...aise rear of vehicle off the ground and lift snowguard then rotate track to expose a cleat to be replaced Using track cleat remover P N 529 0087 00 for all models Installation NOTE Keep the same pitch between guide cleats Place new cleat in position and using small track cleat installer P N 529 0085 00 bend cleat then push tabs into rubber TYPICAL 1 First step 2 Second step to push tabs into rubbe...

Page 279: ...7 02 3 DISASSEMBLY AND ASSEMBLY 07 02 3 INSPECTION 07 02 4 ADJUSTABLE HANDLEBAR 07 02 5 STEERING ADJUSTMENT SKIS 07 02 6 LUBRICATION 07 02 9 SUSPENSION AND SKI SYSTEM 07 03 1 DISASSEMBLY 07 03 2 INSPECTION 07 03 3 INSTALLATION 07 03 3 ON VEHICLE COMPONENT VERIFICATION 07 03 6 DISASSEMBLY 07 03 7 INSPECTION 07 03 8 INSTALLATION 07 03 8 ...

Page 280: ... 31 8 3 1 5 4 6 9 40 N m 30 lbf ft 25 N m 18 lbf ft 2 21 21 16 13 14 25 N m 18 lbf ft 15 10 21 22 21 9 40 N m 30 lbf ft 26 52 N m 38 lbf ft 18 N m 159 lbf in 9 21 21 16 13 20 15 18 N m 159 lbf in 18 N m 159 lbf in 10 21 17 9 25 N m 18 lbf ft 40 N m 30 lbf ft 12 7 18 N m 159 lbf in 40 N m 30 lbf ft 21 11 FLAT RATE PARTS ...

Page 281: ...Section 07 STEERING FRONT SUSPENSION Sub Section 02 STEERING SYSTEM 07 02 2 Skandic WT A22G0KS 7 25 23 24 31 5 3 8 2 10 15 1 17 21 9 20 15 21 16 20 21 9 9 21 10 15 25 N m 18 lbf ft 6 FLAT RATE PARTS ...

Page 282: ...der the engine from the steering column 17 Steering Arm To maintain correct steering geometry for reas sembling punch mark the steering arm and ski leg before disassembly TYPICAL 1 Punch marks 31 Heating Grip Element On vehicles is equipped with heating the grips might be unremovable as explained above in this case carefully proceed as follows to prevent damaging the heating elements Locate the el...

Page 283: ...nd lock nut Align it so the tie rod end is parallel to the steering arm when assem bled on the vehicle refer to the following illustra tion For proper torque specifications refer to the spe cific exploded view for the vehicle being serviced TYPICAL 1 Parallel with steering arm 2 Steering arm 21 Hardened Washer All Models Except Skandic WT Install a hardened washer on each side of the arm TYPICAL 1...

Page 284: ...t Tighten ball joint nuts and jam nuts to specified torque see exploded view 9 Vehicles with a Castle Nut After proper torque has been applied to the ball joint nut insert a cotter pin through the hole in the tie rod end bending the ends around the nut as shown in the following illustration 1 New 2 Fold cotter pin over castellated nut flats only 11 12 Steering Arm Nut and Bolt Tighten steering arm...

Page 285: ...lt where applicable STEERING ADJUSTMENT SKIS Definitions TOE OUT A difference measured between the front edge of the skis A and rear edge B as viewed from the top It is adjustable CAUTION Tighten the nuts equally in a criss cross se quence and ensure there is an equal gap on each side of the clamps WARNING Avoid contact between the brake handle and the windshield by NOT adjusting the handle bar to...

Page 286: ...lign and retighten the jam nuts to 18 N m 159 lbf in 1 Tie rod no 14 2 Center of pivot arm in line with bolt end CAMBER NOTE On vehicles without adjustable radi us arms no 7 the camber is not adjustable NOTE Identical adjustments are required on both sides of the vehicle Make sure the vehicle is leveled by placing an angle finder under the main frame member as shown on the following illustration 1...

Page 287: ...rivet Adjustment is performed by adjusting length of left and right tie rods no 20 Procedure Loosen jam nuts no 13 and no 15 of both tie rods no 20 Turn the tie rod on one side to shorten its length Lengthen the other one by turning it exactly the same amount so that toe out is not changed Close front of skis manually to take all slack from steering mechanism NOTE A rubber cord must be hooked in f...

Page 288: ...d position place a straight edge against pre adjusted track and measure the distance be tween front and rear of skis and straight edge Distances should be equal After the ski toe out adjustment distance must be equal All Models To reduce tolerance when measuring set one ski to proper toe out then measure from that ski to the opposite ski TYPICAL 1 Straight edge 2 Measure here LUBRICATION 26 Grease...

Page 289: ...Section 07 STEERING FRONT SUSPENSION Sub Section 02 STEERING SYSTEM 07 02 10 S Series A06G08S If so equipped PARTS FLAT RATE ...

Page 290: ...SPENSION AND SKI SYSTEM 3 S Series A03G0HS 14 13 25 N m 18 lbf ft Loctite 242 29 N m 21 lbf ft Some models MX Z 440 Some models 10 4 3 2 1 6 5 7 8 17 5 N m 159 lbf in 5 5 40 N m 29 lbf ft 9 11 14 N m 124 lbf in 10 N m 98 lbf in 80 N m 59 lbf ft 15 N m 136 lbf in Loctite 242 PARTS FLAT RATE ...

Page 291: ...ition of the clevis pin Push down on the handle until it locks Remove spring stopper and cap then release handle When installing the cap opening must be 180 from the spring stopper opening 1 Cap opening 2 Spring stopper opening 1 Swing Arm Lift front of vehicle and support it off the ground Remove cap circlip then slacken steering arm bolt and pull up steering arm Note shim positions Ski leg may f...

Page 292: ...sary Check condition of ski stopper Replace it when deteriorated To check condition of shock refer to SC 10 SUS PENSIONS 06 02 then look for Shock Absorber Inspection INSTALLATION For assembly reverse the disassembly proce dure However pay attention to the following Apply low temperature grease P N 413 7061 00 to ski leg components Tighten nuts and screws to proper torque as men tioned in exploded...

Page 293: ...Section 07 STEERING FRONT SUSPENSION Sub Section 03 SUSPENSION AND SKI SYSTEM 07 03 4 WRONG POSITION A06G0XA ...

Page 294: ...Section 07 STEERING FRONT SUSPENSION Sub Section 03 SUSPENSION AND SKI SYSTEM 07 03 5 Skandic WT A22G0NS 1 2 3 4 5 6 7 8 9 13 N m 115 lbf in 9 11 18 12 10 17 16 14 15 4 13 Grease 19 FLAT RATE PARTS ...

Page 295: ...180 mm 7 09 in C 70 mm 2 75 in D 25 mm 1 0 in E 15 mm 59 in F 9 mm 35 in Unfasten rod nut then pull out shock from bottom Check shock as described below in inspection At installation make sure bushings are in place 1 Bushings 7 Spring Unscrew shock piston pin nut then remove washer Unscrew 3 Allen screws retaining cover no 3 then remove stopper no 5 washers no 6 washer no 19 1 Allen screws NOTE Th...

Page 296: ...ut bushings and ski Unscrew shock piston pin nut then remove wash er Shock will fall off the ski leg Unscrew 3 Allen screws retaining cover then re move stopper and washers 1 Allen screws NOTE These washers and stopper can be wedged in cap 4 13 14 16 17 O ring Ski Leg Bushing and Seal Pull up ski leg Steering arm will not interfere 1 Pull up ski leg 2 Steering arm in place Remove seal and O rings ...

Page 297: ... Extend and com press the piston several times over its entire stroke with its rod upward Check that it moves smoothly and with uniform resistance Pay attention to the following conditions that will denote a defective shock A skip or a hang back when reversing stroke at mid travel Seizing or binding condition except at extreme end of either stroke Oil leakage A gurgling noise after completing one ...

Page 298: ...Section 07 STEERING FRONT SUSPENSION Sub Section 03 SUSPENSION AND SKI SYSTEM 07 03 9 TYPICAL 1 Bent angle toward the bottom 16 17 Seal Install seal before reinstalling ski leg A05G0CB 1 ...

Page 299: ...02 1 DECAL 08 02 2 WINDSHIELD INSTALLATION 08 02 2 HOOD 08 02 2 BELT GUARD 08 02 3 WIRING HARNESS 08 02 3 CABLES 08 02 3 PIPING 08 02 3 PLASTIC MAINTENANCE AND REPAIR 08 02 4 MAINTENANCE 08 02 4 REPAIR 08 02 5 MATERIAL REPAIR PROCEDURE 08 02 6 REPAIR PROCEDURE FOR R I M URETHANE 08 02 6 FRAME 08 03 1 FRAME CLEANING 08 03 1 FRAME WELDING 08 03 1 FRAME COMPONENT REPLACEMENT 08 03 1 ...

Page 300: ...onditions Place the vehicle on a flat surface perpendicular to test surface wall or screen and 381 cm 12 ft 6 in away from it Rider or equivalent weight must be on the vehicle Select high beam BULB REPLACEMENT If headlamp bulb is burnt tilt cab and unplug the connector from the headlamp Remove the rub ber boot and unfasten the bulb retainer clips or locking ring TYPICAL 1 Locking ring Replace bulb...

Page 301: ...les Position the windshield on the hood then push it down until the tabs are fully inserted into the hood slots Lock the windshield tabs in position using latches as shown S SERIES 1 Latch 2 Temporary remove headlamp molding for windshield installation HOOD S Series Working from within engine compartment re move exterior nuts retaining both hinges Then close hood and remove interior nuts through t...

Page 302: ...rimped on the wires and that all connector housings are properly fastened Keep wires away from any rotating moving heating and vi brating parts Use proper fastening devices as required WARNING Before installation ensure that all cables are in perfect condition Properly install the ca ble ends and secure them in place Pay at tention to route them properly away from any rotating moving heating or vi...

Page 303: ...eaning agent in their formula Apply wax on glossy finish only Protect the vehi cle with a cover to prevent dust accumulation dur ing storage CAUTION Do not apply isopropyl alcohol or acetone directly on decals CAUTION The following products must not be used to clean or wax any of the plastic components used on the vehicles CAUTION Clean R I M Metton with isopropyl alcohol only Never use cleaners o...

Page 304: ...AUTION Consult chart and repair kit instructions carefully some repair products are not compatible with certain plastics WARNING Polycarbonate windshields must never be repaired by welding or otherwise REPAIRABLE PART MODEL FIBERGLASS R I M URETHANE POLYETHYLENE HOOD Skandic WT SWT WT LC S Series A06H194 BOTTOM PAN Skandic WT SWT WT LC S Series A06H1A4 SIDE PANEL AND REAR MOLDING S Series A06H1B4 ...

Page 305: ...ck no AP F Wait 10 minutes Repaint air dry during 72 hours approximate ly Large Crack Sand and scuff outside and inside area by ex ceeding it 31 7 mm 1 1 4 in on each side and 12 7 mm 1 2 in at each end Make a V groove appr 90 on both sides of hood using a knife or a rough round file Enlarge the crack to 2 4 mm 3 32 in 3 2 mm 1 8 in using a sharp knife Clean outside and inside surface with isoprop...

Page 306: ... 1 800 552 0876 Fax 404 288 4658 Mailing Address P O Box 254 Decatur Georgia 30031 CREST INDUSTRIES INC CREST MID WEST 231 Larkin Williams Ind Court St Louis Missouri 63026 Phone 314 349 4800 Toll Free 1 800 733 2737 Fax 314 349 4888 Toll Free Fax 1 800 776 2737 CREST MID WEST Regional Branch Warehouses CREST INDUSTRIES INC P O Box 635 Mountain Home Arkansas 72653 Phone 501 491 5583 Toll Free 1 80...

Page 307: ...16 in size and shipped in packs of 2 For proper drilling instructions and to prevent pre mature wear follow the procedure below Always use a variable speed electric drill It is not necessary to center punch the rivet head simply center the drill bit on the rivet and drill Maintain a slow to medium speed at all times when drilling The proper speed is attained when a constant chip is ejected NOTE To...

Page 308: ...ide retaining rivets 1 Rivets heads ground 2 Rivets to be ground from underneath To remove rivet strike with a punch from rivet head side Make a chamfer from underneath on all 4 corner holes CAUTION High speed drilling will cause excessive heat which may destroy the cutting edge of the bit therefore avoid using pneumatic drills A06H0XA 1 2 ...

Page 309: ...ue speed meter kilogram newton liter Celsius kilopascal newton meter kilometer per hour m kg N L C kPa N m km h PREFIXES PREFIX SYMBOL MEANING VALUE kilo centi milli micro k c m µ one thousand one hundredth one thousandth one millionth 1 000 0 01 0 001 0 000001 CONVERSION FACTORS TO CONVERT TO MULTIPLY BY in in in2 in3 ft oz lb lbf lbf in lbf ft lbf ft PSI lbf in2 imp oz imp oz imp gal imp gal U S...

Page 310: ... mm in 0 45 018 0 45 018 0 45 018 0 45 018 Ignition Timing BTDC mm in 1 68 066 1 48 058 1 75 069 1 75 069 Trigger Coil Ω 140 180 190 300 190 300 190 300 Generating Coil Ω 230 330 10 17 10 17 10 17 Lighting Coil Ω 0 23 0 28 0 2 0 35 0 2 0 35 0 2 0 35 High Tension Coil Primary Ω N A 0 3 0 7 0 3 0 7 0 3 0 7 Secondary kΩ 5 1 6 3 8 16 8 16 8 16 Carburetor Type PTO MAG VM 34 479 480 VM 34 492 493 VM 40 ...

Page 311: ...lug Gap mm in 0 45 018 0 45 018 0 45 018 0 45 018 Ignition Timing BTDC mm in 1 81 071 1 81 071 1 75 069 1 75 069 Trigger Coil Ω 190 300 190 300 190 300 190 300 Generating Coil Ω 10 17 10 17 10 17 10 17 Lighting Coil Ω 0 20 0 35 0 20 0 35 0 20 0 35 0 20 0 35 High Tension Coil Primary Ω 0 3 0 7 0 3 0 7 0 3 0 7 0 3 07 Secondary kΩ 8 16 8 16 8 16 8 16 Carburetor Type PTO MAG VM 38 345 346 VM 38 345 34...

Page 312: ...Gap mm in 0 45 018 0 45 018 0 45 018 0 45 018 Ignition Timing BTDC mm in 1 81 071 1 75 069 1 93 076 1 81 071 Trigger Coil Ω 190 300 190 300 190 300 190 300 Generating Coil Ω 10 17 10 17 10 17 10 17 Lighting Coil Ω 0 20 0 35 0 20 0 35 0 20 0 35 0 20 0 35 High Tension Coil Primary Ω 0 3 0 7 0 3 0 7 0 3 0 7 0 3 0 7 Secondary kΩ 8 16 8 16 8 16 8 16 Carburetor Type PTO MAG VM 38 HAC 363 364 VM 38 HAC 3...

Page 313: ...ES NGK BR9ES Spark Plug Gap mm in 0 45 018 0 45 018 0 45 018 Ignition Timing BTDC mm in 1 75 069 1 66 065 1 81 071 Trigger Coil Ω 190 300 140 180 190 300 Generating Coil Ω 10 17 230 330 10 17 Lighting Coil Ω 0 2 0 35 0 23 0 28 0 20 0 35 High Tension Coil Primary Ω 0 3 0 7 N A 0 3 0 7 Secondary kΩ 8 16 5 1 6 3 8 16 Carburetor Type PTO MAG VM 38 349 350 VM 32 VM 34 Main Jet PTO MAG 280 270 230 260 2...

Page 314: ...cm in 38 1 15 38 1 15 0 38 1 15 0 38 1 15 0 Length cm in 307 121 307 121 307 121 307 121 Adjustment Deflection mm in 40 55 1 9 16 2 5 32 40 55 1 9 16 2 5 32 35 40 1 3 8 1 3 4 35 40 1 3 8 1 3 4 Force kg lbf 7 3 16 7 3 16 7 3 16 7 3 16 Suspension Type Track SC10 Sport SC10 XC SC10 XC SC10 XC Ski DSA DSA DSA DSA Length cm in 272 5 107 3 272 5 107 3 272 5 107 3 272 5 107 3 Width cm in 114 3 45 0 116 9...

Page 315: ... Track Width cm in 38 1 15 0 38 1 15 0 38 1 15 0 38 1 15 0 Length cm in 307 121 307 121 307 121 307 121 Adjustment Deflection mm in 40 55 1 9 16 1 11 64 40 55 1 9 16 1 11 64 30 40 1 9 16 1 3 4 35 40 1 3 8 1 3 4 Force kg lbf 7 3 16 7 3 16 7 3 16 7 3 16 Suspension Type Track SC 10 Sport SC 10 Sport SC 10 Sport SC10 HP Ski DSA DSA DSA DSA Length cm in 272 5 107 3 272 5 107 3 272 5 107 3 272 5 107 3 W...

Page 316: ... Width cm in 38 1 15 0 38 1 15 0 38 1 15 0 38 1 15 0 Length cm in 345 5 136 345 5 136 345 5 136 345 5 136 Adjustment Deflection mm in 45 50 1 3 4 1 31 32 45 50 1 3 4 1 31 32 45 50 1 3 4 1 31 32 40 55 1 9 16 2 5 32 Force kg lbf 7 3 16 7 3 16 7 3 16 7 3 16 Suspension Type Track SC 10 Mountain SC 10 Mountain SC 10 Mountain SC 10 Touring Ski DSA DSA DSA DSA Length cm in 291 9 114 9 291 9 114 9 291 9 1...

Page 317: ...50 0 19 7 60 0 23 6 50 0 19 7 Length cm in 345 5 136 394 155 1 394 155 1 394 155 1 Adjustment Deflection mm in 40 55 1 9 16 2 5 32 40 50 1 9 16 1 31 32 40 50 1 9 16 1 31 32 40 50 1 9 16 1 31 32 Force kg lbf 7 3 16 7 3 16 7 3 16 7 3 16 Suspension Type Track SC 10 Touring Skandic WT Skandic WT Skandic WT Ski DSA Telescopic Strut Telescopic Strut Telescopic Strut Length cm in 291 9 114 9 302 0 118 9 ...

Page 318: ...arts at room temperature ap prox 20 C 68 F Temperature greatly affects resistance measurements Force applied midway between pulleys to ob tain specified tension deflection Drive pulley retaining screw torque to 90 to 100 N m 66 to 74 lbf ft install drive belt ac celerate the vehicle at low speed maximum 30 km h 20 MPH and apply the brake repeat 5 times Recheck the torque of 90 to 100 N m 66 to 74 ...

Page 319: ..._______________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Name ______________________________________________________ Address ________________________________...

Page 320: ...GE Bombardier Inc Technical Publications After Sales Service Valcourt Quebec Canada J0E 2L0 Bombardier Inc Technical Publications After Sales Service Valcourt Quebec Canada J0E 2L0 Bombardier Inc Technical Publications After Sales Service Valcourt Quebec Canada J0E 2L0 ...

Page 321: ...e connected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by YELLOW BLACK wire connected to oil level sensor BLUE 12 volts A C Fuel level indicator Current returns by YELLOW wire connected to fuel level sensor ORANGE 12 volts A C Heated grips max Current r...

Page 322: ...e connected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by YELLOW BLACK wire connected to oil level sensor BLUE 12 volts A C Fuel level indicator Current returns by YELLOW wire connected to fuel level sensor ORANGE 12 volts A C Heated grips max Current r...

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Page 325: ...onnected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by YELLOW BLACK wire connected to oil level sensor BLUE 12 volts A C Fuel level indicator Current returns by YELLOW wire connected to fuel level sensor ORANGE 12 volts A C Heated grips max Current retu...

Page 326: ...onnected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by YELLOW BLACK wire connected to oil level sensor BLUE 12 volts A C Fuel level indicator Current returns by YELLOW wire connected to fuel level sensor ORANGE 12 volts A C Heated grips max Current retu...

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Page 329: ...nnected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by YELLOW BLACK wire connected to oil level sensor BLUE 12 volts A C Fuel level indicator Current returns by YELLOW wire connected to fuel level sensor ORANGE 12 volts A C Heated grips max Current retur...

Page 330: ...nnected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by YELLOW BLACK wire connected to oil level sensor BLUE 12 volts A C Fuel level indicator Current returns by YELLOW wire connected to fuel level sensor ORANGE 12 volts A C Heated grips max Current retur...

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Page 333: ...to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by YELLOW BLACK wire connected to oil level sensor BLUE 12 volts A C Fuel level indicator Current returns by YELLOW wire connected to fuel level sensor ORANGE 12 volts A C Heated grips max Current returns by YE...

Page 334: ...to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by YELLOW BLACK wire connected to oil level sensor BLUE 12 volts A C Fuel level indicator Current returns by YELLOW wire connected to fuel level sensor ORANGE 12 volts A C Heated grips max Current returns by YE...

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Page 336: ......

Page 337: ...re connected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by YELLOW BLACK wire connected to oil level sensor BLUE 12 volts A C Fuel level indicator Current returns by YELLOW wire connected to fuel level sensor ORANGE 12 volts A C Heated grips max Current ...

Page 338: ...re connected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by YELLOW BLACK wire connected to oil level sensor BLUE 12 volts A C Fuel level indicator Current returns by YELLOW wire connected to fuel level sensor ORANGE 12 volts A C Heated grips max Current ...

Page 339: ......

Page 340: ......

Page 341: ...nected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by YELLOW BLACK wire connected to oil level sensor BLUE 12 volts A C Fuel level indicator Current returns by YELLOW wire connected to fuel level sensor ORANGE 12 volts A C Heated grips max Current return...

Page 342: ...nected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by YELLOW BLACK wire connected to oil level sensor BLUE 12 volts A C Fuel level indicator Current returns by YELLOW wire connected to fuel level sensor ORANGE 12 volts A C Heated grips max Current return...

Page 343: ......

Page 344: ......

Page 345: ...connected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by YELLOW BLACK wire connected to oil level sensor BLUE 12 volts A C Fuel level indicator Current returns by YELLOW wire connected to fuel level sensor ORANGE 12 volts A C Heated grips max Current ret...

Page 346: ...connected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by YELLOW BLACK wire connected to oil level sensor BLUE 12 volts A C Fuel level indicator Current returns by YELLOW wire connected to fuel level sensor ORANGE 12 volts A C Heated grips max Current ret...

Page 347: ...ANNEX 7 ...

Page 348: ...ANNEX 7 ...

Page 349: ...SKANDIC WT LC ANNEX 8 ...

Page 350: ...H BEAM YL GN BR WH GY YL GN GY HEADLAMP GY YL WH GY GY YL YL BK BK YL BK BK YL YL GN YL GN YL BL BL FUEL LEVEL GAUGE YL BK RD YL YL BL FUEL LEVEL SENSOR FUSE 0 25 A YL BK BL YL GN WH WH RD RESISTOR 30 OHM WH RD BR YL YL YL BK BK RD BL WH YL GN YL GN OIL LEVEL SENSOR TAILLIGHT YL YL GN WH 1 2 3 YL GN RD BK YL YL GN YL GN YL TEMPERATURE SENSOR VI YL GN BK YL BK WH GENERATOR COIL BR YL BK YL BK BK YL...

Page 351: ...H BEAM YL GN BR WH GY YL GN GY HEADLAMP GY YL WH GY GY YL YL BK BK YL BK BK YL YL GN YL GN YL BL BL FUEL LEVEL GAUGE YL BK RD YL YL BL FUEL LEVEL SENSOR FUSE 0 25 A YL BK BL YL GN WH WH RD RESISTOR 30 OHM WH RD BR YL YL YL BK BK RD BL WH YL GN YL GN OIL LEVEL SENSOR TAILLIGHT YL YL GN WH 1 2 3 YL GN RD BK YL YL GN YL GN YL TEMPERATURE SENSOR VI YL GN BK YL BK WH GENERATOR COIL BR YL BK YL BK BK YL...

Page 352: ......

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Summary of Contents for FORMULA 500 1997

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Ski-Doo FORMULA 500 1997, Shop Manual, Page: 9 / 352

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Summary of Contents for FORMULA 500 1997

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