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Ski-Doo Formula 500 1998, Shop Manual

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Ski-Doo Formula 500 1998 Shop Manual Download Page 4

I

SECTION

SUBSECTION

PAGE

SAFETY NOTICE  ..................................................................................................................................

III

WHAT’S NEW .......................................................................................................................................

IV

INTRODUCTION ..................................................................................................................................

V

01

SERVICE TOOLS AND
SERVICE PRODUCTS

01 – Service tools............................................................................. 01-01-1
02 – Service products....................................................................... 01-02-1

02

LUBRICATION
AND MAINTENANCE

01 – Lubrication and maintenance chart .......................................... 02-01-1

03

TROUBLESHOOTING

01 – Table of contents...................................................................... 03-01-1
02 – Engine ...................................................................................... 03-02-1
03 – Fuel and oil systems................................................................. 03-03-1
04 – Transmission and brake systems ............................................. 03-04-1
05 – Electrical system ...................................................................... 03-05-1
06 – Suspension system and track .................................................. 03-06-1

04

ENGINE

01 – Table of contents...................................................................... 04-01-1
02 – 443 and 503 engine types ........................................................ 04-02-1
03 – 494, 583 and 670 engine types ................................................ 04-03-1
04 – Leak test and engine dimension measurement ....................... 04-04-1
05 – CDI system............................................................................... 04-05-1
06 – Oil injection system.................................................................. 04-06-1
07 – Axial fan cooling system........................................................... 04-07-1
08 – Liquid cooling system............................................................... 04-08-1
09 – Rotary valve, coolant pump and reservoir ................................ 04-09-1
10 – Rewind starter.......................................................................... 04-10-1
11 – Carburetor and fuel pump ........................................................ 04-11-1
12 – Fuel tank and throttle cable ...................................................... 04-12-1

05

TRANSMISSION

01 – Table of contents...................................................................... 05-01-1
02 – Drive belt .................................................................................. 05-02-1
03 – Drive pulley............................................................................... 05-03-1
04 – Driven pulley............................................................................. 05-04-1
05 – Pulley distance and alignment.................................................. 05-05-1
06 – Brake ........................................................................................ 05-06-1
07 – Chaincase ................................................................................. 05-07-1
08 – Gearbox .................................................................................... 05-08-1
09 – Drive chain................................................................................ 05-09-1

06

ELECTRICAL

01 – Table of contents...................................................................... 06-01-1
02 – Ignition timing........................................................................... 06-02-1
03 – Spark plugs............................................................................... 06-03-1
04 – Battery...................................................................................... 06-04-1
05 – Electric starter .......................................................................... 06-05-1
06 – Testing procedure .................................................................... 06-06-1

TABLE OF CONTENTS

Summary of Contents for Formula 500 1998

Page 1: ......

Page 2: ...1998 Shop Manual VOLUME 2 MX Z 440 500 583 670 FORMULA 500 500 DE LUXE 583 DE LUXE Z 583 Z 670 SUMMIT 500 583 670 GRAND TOURING 500 583 SKANDIC WT SWT WT LC ...

Page 3: ...in Canada Registered trademarks of Bombardier Inc This document contains the trademarks of the following companies Kimtowels is a trademark of Kimberly Clark 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 Vers...

Page 4: ... 03 1 04 Leak test and engine dimension measurement 04 04 1 05 CDI system 04 05 1 06 Oil injection system 04 06 1 07 Axial fan cooling system 04 07 1 08 Liquid cooling system 04 08 1 09 Rotary valve coolant pump and reservoir 04 09 1 10 Rewind starter 04 10 1 11 Carburetor and fuel pump 04 11 1 12 Fuel tank and throttle cable 04 12 1 05 TRANSMISSION 01 Table of contents 05 01 1 02 Drive belt 05 02...

Page 5: ...ERING FRONT SUSPENSION 01 Table of contents 08 01 1 02 Steering system 08 02 1 03 Suspension and ski system 08 03 1 09 BODY FRAME 01 Table of contents 09 01 1 02 Body 09 02 1 03 Frame 09 03 1 10 TECHNICAL DATA 01 SI metric information guide 10 01 1 02 Engines 10 02 1 03 Vehicles 10 03 1 04 Technical data legends 10 04 1 11 WIRING DIAGRAMS 01 Wiring diagrams 11 01 1 SECTION SUBSECTION PAGE TABLE OF...

Page 6: ...ubt 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 re...

Page 7: ...D FUEL PUMP 04 11 New procedure for choke plunger adjustment This procedure is the same as in the Service Bulletin 96 30 CHAINCASE 05 07 Countershaft bearing sealed side is facing cover GEARBOX 05 08 S Series Countershaft bearing sealed side is facing cover Skandic WT Series New procedure TESTING PROCEDURE 06 06 Complete new testing procedures using only a multimeter FORMULA Z 670 SUSPENSION 07 03...

Page 8: ...00 DE LUXE Europe 1248 FORMULA 583 DE LUXE Canada 1249 FORMULA 583 DE LUXE U S 1250 FORMULA Z 583 Canada 1251 FORMULA Z 583 U S 1252 MODELS MODEL NUMBER FORMULA Z 670 Canada 1253 FORMULA Z 670 U S 1254 FORMULA Z 670 Europe 1306 SUMMIT 500 Canada 1256 SUMMIT 500 U S 1257 SUMMIT 500 Europe 1258 SUMMIT 583 Canada 1259 SUMMIT 583 U S 1260 SUMMIT 670 Canada 1261 SUMMIT 670 U S 1262 SUMMIT 670 Europe 12...

Page 9: ...els TYPICAL SKANDIC WT SERIES VEHICLE SERIAL NUMBER Vehicle Serial Number Location TYPICAL 1 Vehicle serial number Serial Number Meaning ENGINE SERIAL NUMBER Engine Serial Number Location Fan Cooled Engines TYPICAL FAN COOLED ENGINES 1 Engine serial number Liquid Cooled Engines TYPICAL LIQUID COOLED ENGINES 1 Engine serial number A03A0DA A29A03A A03H2AA 1 A00A0DA Model no Vehicle no 0000 00000 A03...

Page 10: ...ODUCTS 02 LUBRICATION AND MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 TRANSMISSION 06 ELECTRICAL 07 REAR SUSPENSION 08 STEERING FRONT SUSPENSION 09 BODY FRAME 10 TECHNICAL DATA 11 WIRING DIAGRAMS Each section is divided in various subsections and again each subsection has one or more divi sion INTRODUCTION ...

Page 11: ...kg kilogram km h kilometer per hour kPa Kilopascal L liter lb pound lbf pound force lbf in pound per square inch LH left hand LO low LT long track m meter MAG magneto Max maximum Min minimum mL milliliter mm millimeter MPH mile per hour N newton N A not applicable no number 00 0 continuity 0 L overload open circuit O D outside diameter OPT optional oz ounce P N part number PSI pound per square inc...

Page 12: ...case nut must be torqued to 4 N m or 35 lbf in This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog Exploded view assists you in identifying parts and related positions TYPICAL PAGE A01A28S Illustration number for publishing process Subsection title indicates beginning of the subsection Drop represents a liquid product to be applied to a surface I...

Page 13: ...oval 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 Subsection 03 DRIVEN PULLEY When replacing slider shoes no 4 always install a new set 3 shoes to maintain equal pressure on the cam Assemble driven pulley components by reversing the disassembly procedure Always apply...

Page 14: ...ce 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 subsection in which the proce dure is contained A number of procedures throughout the book re quire the use of spe...

Page 15: ... ed views and text When they are not specified refer to following table 1 A03A0CA 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 20 15 21 M8 15 22 M8 16 23 M8 17 24 M8 18 25 M8 18 26 19 27 20 28 21 29 21 30 22 31 23 32 24 33 24 34 25 35 26 36 27 37 27 38 28 39 29 40 30 INTRODUCTI...

Page 16: ...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 80 109 80 110 81 111 82 112 83 113 83 114 84 115 85 116 86 117 86 118 87 119 88 120 89 121 M14 89 122 M14 90 123 M14 91 124 M14 91 125 M14 92 126 M14 93 1...

Page 17: ...32 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 INTRODUCTION ...

Page 18: ..._______________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Name ______________________________________________________ Address ________________________________...

Page 19: ...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 20: ...ice Products both mandatory and optional are not part of any kit and must all be ordered separately If you need to replace or add to your tool inventory these items can be ordered through the regular parts channel NOTE The numbers outlined in black example are reference numbers to tools from other divi sions Sea Doo Watercraft and or Sea Doo Jet Boats Matching reference numbers indicate the same t...

Page 21: ...1 4 0 1 5 0 1 6 0 1 7 0 1 8 0 1 9 0 2 0 0 2 1 0 2 2 0 2 3 0 2 4 0 2 5 0 2 6 0 2 7 0 2 8 0 2 9 0 3 0 0 3 1 0 320 330 340 350 360 2 3 Magneto puller ring P N 420 8760 80 A00C1R4 APPLICATION All engines Magneto puller P N 529 0225 00 A00C1A4 APPLICATION All engines Aligning pin qty 4 P N 529 0189 00 A00A1D4 APPLICATION 494 engine Pusher washer behind the impeller P N 529 0207 00 A00C3H4 APPLICATION R...

Page 22: ...1B2D4 APPLICATION All engines 11 12 14 1 2 4 6 5 3 Choke plunger tool P N 529 0321 00 A01C5D4 APPLICATION All models equipped with chokes Piston pin puller P N 529 0290 00 A01B4H4 APPLICATION All engines Rubber pad P N 529 0234 00 A01B4C4 APPLICATION All cageless bearing engines 19 16 1 2 4 3 17 Rotary valve circlip tool P N 529 0291 00 A00C3I4 APPLICATION All rotary valve engines Fluke multimeter...

Page 23: ... N 420 9407 55 For either or pullers 3 Screw M8 x 40 qty 4 P N 420 8406 81 puller MAG side puller MAG and PTO side 4 Screw M8 x 70 qty 4 P N 420 8412 01 puller only PTO side 5 Crankshaft protector PTO P N 420 8765 52 or puller all engines 6 Crankshaft protector MAG P N 420 8765 57 or puller all engines 7 Distance ring PTO P N 420 8765 69 puller 443 503 and 583 engines 8 Puller ring P N 420 9774 90...

Page 24: ...on circlip 203 Ring compressor A P N 420 8760 90 62 mm B P N 420 8769 70 72 mm C P N 420 8769 72 76 mm D P N 529 0308 00 78 mm A01B1T4 APPLICATION A 443 engine B 503 engine C 583 engine D 670 engine Magneto coil centering ring P N 420 8769 22 A01B1V4 APPLICATION All engines with Nippondenso CDI 160 W 204 206 207 262 209 Crankshaft feeler gauge P N 420 8766 20 A00C114 APPLICATION 443 and 503 engine...

Page 25: ...it tester continuity light P N 414 0122 00 A00C214 APPLICATION All vehicles 220 221 222 223 Stroboscopic timing light P N 529 0319 00 A00B4F4 APPLICATION All engines RAVE movement indicator P N 861 7258 00 A18B014 APPLICATION All RAVE equipped engines 225 226 Air pressure gauge 0 200 inch of water P N 529 0104 00 A18B034 APPLICATION For pressure testing gauge Dial indicator TDC gauge P N 414 1047 ...

Page 26: ... 494 583 and 670 engines Digital induction type tachometer P N 529 0145 00 F01B1G4 APPLICATION All engines 234 235 237 Injection jig magneto seal P N 420 8765 14 A00C3U4 APPLICATION 494 and 670 engines Handle for insertion jig P N 420 8776 50 A00C3V4 APPLICATION 494 and 670 engines 248 249 Exhaust spring installer remover P N 529 0281 00 A00C3S4 APPLICATION All models Large hose pincher P N 529 03...

Page 27: ...ines Forks qty 3 P N 529 0055 00 A16B014 APPLICATION All vehicles equipped with a TRA drive pulley 51 75 55 57 Drive belt installer P N 529 0172 00 A00A1A4 APPLICATION All vehicles except Skandic WT Series Transmission alignment bar A P N 529 0267 00 B P N 529 0355 02 A01B4D4 APPLICATION A S Series B Skandic WT WT LC SWT Spring scale hook long P N 529 0309 00 A00B4A4 APPLICATION S Series 58 78 84 ...

Page 28: ... N 529 0186 00 Parts included in the kit Spring compressor P N 529 0151 00 A01B334 APPLICATION S Series driven pulley All TRA pulley Tension tester P N 414 3482 00 A00C074 APPLICATION All models 64 74 Countershaft bearing installer P N 529 0302 00 A00A194 APPLICATION S Series Countershaft bearing remover P N 529 0301 00 A00A274 APPLICATION S Series 83 82 ...

Page 29: ...1B2O4 APPLICATION All vehicles Parts included in the kit 1 Block with threads P N 529 0107 00 2 Block without threads P N 529 0108 00 3 Plate P N 529 0106 00 4 Bolt M10 2 P N 222 0075 65 5 Allen screw M8 2 P N 222 9830 65 6 Screw M8 2 P N 222 0825 65 NOTE When the tool is to be use between tunnel and sprocket use screw M8 Transmission adjuster P N 529 0303 00 A03D1T4 APPLICATION Vehicles equipped ...

Page 30: ...ND PRODUCTS Subsection 01 SERVICE TOOLS 01 01 11 SUSPENSION MANDATORY SERVICE TOOLS Shock spring removal kit P N 529 0355 04 Replacement clevis pin P N 414 5284 00 A01B4O4 APPLICATION All suspensions with coil spring 65 ...

Page 31: ...e used Suggestion K D tool no 2968 A06B024 APPLICATION All DSA front suspensions 254 343 Track tension gauge P N 529 0215 00 A00B3X4 APPLICATION All models Track cleat installer Narrow P N 529 0085 00 A01B1M4 APPLICATION All models 342 347 Drill bit P N 529 0318 00 A01B564 APPLICATION All 3 16 inch rivets Spring installer bar P N 529 0050 00 A00C1I4 APPLICATION All SC 10 suspensions Drive axle hol...

Page 32: ...RVICE TOOLS 01 01 13 VEHICLES RECOMMENDED SERVICE TOOLS Protective mat P N 529 0306 00 A01B45W APPLICATION All vehicles 503 Dolly P N 529 0299 00 A00B4CJ APPLICATION All models 348 Snowmobile jack P N 529 0200 00 A01A1JJ APPLICATION All models 341 ...

Page 33: ...02 1 SERVICE PRODUCTS 0 NOTE The numbers outlined in black example are reference to tool numbers from other divisions Sea Doo Watercraft and or Sea Doo Jet Boats Matching reference numbers indicate the same tool is being used even if the part numbers are different 1 ...

Page 34: ...TITE RC 609 152 Medium strength threadlocker P N 413 7030 00 Loctite 242 Threadlocker 10 mL blue medium strength A00B324 APPLICATION Flywheel nut crankcase studs etc High strength threadlocker P N 413 7074 00 Loctite 271 Threadlocker 10 mL red high strength A00B2U4 APPLICATION Fasteners and studs up to 1 inch diameter 154 LOCTITE LOCTITE LOCTITE REMOVABLE THREADLOCKER 242 155 LOCTITE LOCTITE LOCTI...

Page 35: ...ed Loctite primer P N 413 7081 00 Loctite 764 56 Primer N 170 g 6 oz A00B3N4 APPLICATION To prepare mating surfaces before applying paste gasket retaining compound or threadlockers Silicone compound P N 420 8970 61 Dow Corning MS4 A00B3R4 APPLICATION Lubricate pawl and pawl lock of rewind starter 158 159 ...

Page 36: ...13 8007 00 A00B1Z4 APPLICATION Roller round shaft drive pulleys 350 DOW CORNING 4 Electrical Insulating Compound 351 GRAISSE LMZ No 1 352 Chaincase oil 16 x 250 mL P N 413 8019 00 A00B2R4 APPLICATION Chaincase lubricant for fan cooled engine models except Skandic WT series Synthetic chaincase oil 12 x 355 mL P N 413 8033 00 A01B4Q4 APPLICATION Chaincase lubricant for liquid cooled engine models an...

Page 37: ...U S quart BOMBARDIER Two stroke Two Stroke Oil SYNTHETIQUE FORMULA XP S Two Stroke Oil 1 liter 1 05 U S qt Synthetic BOMBARDIER FORMULA XP S 358 High temperature threadlocker P N 420 8997 88 Loctite 648 green 5 g A00B3D4 APPLICATION For TRA spring cover bushing Anti seize lubricant P N 413 7010 00 Loctite anti seize lubricant 454 g 16 oz F01B174 APPLICATION Unpainted surfaces of drive pulley count...

Page 38: ...oot or grip 365 366 367 Stripped threads repair kit P N 413 7086 00 Loctite 81668 Form A thread 81668 A00A1J4 APPLICATION Repair damaged threads of grade 5 SAE or 8 8 metric maximum Do not use in applications where temperatures will exceed 149 C 300 F or on critical assemblies HYLOMAR sealant 100 g P N 413 7071 00 A00B3F4 APPLICATION To form an oil resistant seal ex gearbox 368 369 Paint for frame...

Page 39: ...0B3W4 APPLICATION Rotary valve shaft seals BOMBARDIER LUBE 12 x 14 oz P N 293 6000 16 A01B4P4 APPLICATION Steering ball joints on all models Super Lube grease P N 293 5500 14 A00B474 APPLICATION Tie rod bushings 376 DOW CORNING 111 378 LUBE Penetrating lubricant Excellent for salt water and high humidity environments Lubrifiant pénétrant ou humide Excellent en milieu salin Marins Products Marine P...

Page 40: ...03 Injection Oil Filter Condition Subsection 04 06 Injection Oil Filter Replacement Subsection 04 06 Oil Injection Pump Adjustment Subsection 04 06 Fuel Stabilizer This section no 2 Fuel Filter Replacement This section no 3 Fuel Lines and Connections Subsection 04 12 Carburetor Adjustment Subsection 04 11 Throttle Cable Inspection Subsection 04 12 Air Filter Cleaning This section no 4 Drive Belt C...

Page 41: ... See appropriate Subsection Suspension Stopper Strap Condition Section 07 See appropriate Subsection Track Condition Subsection 07 06 Track Tension and Alignment AS REQUIRED Subsection 07 06 Spark Plugs Subsection 06 03 Engine Timing Subsection 06 02 Battery Condition Subsection 06 04 Headlight Beam Aiming Subsection 09 02 Wiring Harnesses Cables and Lines Subsection 09 02 Operation of Lighting Sy...

Page 42: ...nt 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 prevent fuel deterio...

Page 43: ... 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 44: ...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 16 Wax the hood and the painted portion of the frame for better protection NOTE Apply wax on glossy finish onl...

Page 45: ... 1 ENGINE LEAK VERIFICATION FLOW CHART 03 02 10 FUEL AND OIL SYSTEMS 03 03 1 TRANSMISSION AND BRAKE SYSTEMS 03 04 1 TRANSMISSION 03 04 1 BRAKE SYSTEM 03 04 7 MECHANICAL BRAKE 03 04 7 HYDRAULIC BRAKE 03 04 7 MECHANICAL AND HYDRAULIC BRAKES 03 04 8 ELECTRICAL SYSTEM 03 05 1 SUSPENSION AND TRACK 03 06 1 ...

Page 46: ...USE Test Inspection 1 Check spark plugs a Carbon accumulation caused by defective spark plug s Clean carbon accumulation and replace spark plugs 2 Check cooling system a Loose fan belt Adjust or replace fan belt refer to TECHNICAL DATA 10 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 a...

Page 47: ...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 plugs with appropriate heat range refer to TECHNICAL DATA 10 e Improper ignition timing Adjust according to specifications refer to TECHNICAL DATA 10 f Restriction in exhaust sy...

Page 48: ...gine 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 10 b Cooling system leaks and lowers coolant level Tighten clamps or replace defective parts Add antifreeze in cooling system until appropriate level is reached c Accumulation of foreign pa...

Page 49: ...nd or improper alignment Align track and adjust its tension to specifications refer to TECHNICAL DATA 10 7 Check drive pulley a Improper calibration screw adjustments TRA pulley and or worn bushing s Adjust according to specifications refer to TECHNICAL DATA 10 and or replace bushing s 8 Check driven pulley a Worn bushing and or spring tension Replace spring and or adjust its tension according to ...

Page 50: ...INE TURNS OVER BUT FAILS TO START CONDITION NORMAL USE Test Inspection 1 Check switches a Ignition switch emergency cut out switch or tether switch is in the OFF position Place all switches in the RUN or ON position 2 Check fuel level a Mixture not rich enough to start cold engine Check fuel tank level and use primer 3 Check spark plug a Defective spark plug no spark Replace spark plugs 4 Check am...

Page 51: ... to specifications refer to TECHNICAL DATA 10 7 Perform engine leak test a Leaking gaskets allow air to enter in engine Replace defective parts SYMPTOM HIGH ENGINE OPERATING TEMPERATURE CONDITION NORMAL USE Test Inspection 1 Check temperature gauge sensor a False reading Replace 2 Check fan belt a Belt slides because it is too loose Adjust according to specifications refer to TECHNICAL DATA 10 3 V...

Page 52: ...ications refer to TECHNICAL DATA 10 11 Check if there are leaks at air intake silencer and or engine crankcase a Leak s Repair or replace 12 Check condition and heat range of spark plugs 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...

Page 53: ...ording to specifications 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...

Page 54: ...tio 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 and or broken supports or interference between support s and chassis Retighten to specification refer to TECHNICAL DATA 10 or replace 2 Check ...

Page 55: ...R 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 SEAL OF ROTAR...

Page 56: ...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 10 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 57: ...ocate 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 pum...

Page 58: ...ir fittings or are improperly routed 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 59: ...flection according to specifications refer to TECHNICAL DATA 10 3 Check driven pulley sliding half play a Jammed sliding half Replace 4 Check spring tension of driven pulley sliding half a Sliding half rotation is accelerated when spring tension is too weak Adjust according to specifications refer to TECHNICAL DATA 10 5 Refer to VIBRATIONS ORIGINATING FROM DRIVEN PULLEY and check items listed 6 Ch...

Page 60: ...er 2 Check tightening torque of drive pulley screw a Moving governor cup Retighten screw 3 Spring cover screws a Spring cover moves and restrains sliding half movement Retighten screws 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 slide...

Page 61: ...ion 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 05 SYMPTOM UNEVEN BELT WEAR ON ONE SIDE ONLY CONDITION NORMAL USE Test Inspection A00D09Y 1 Check tightening torque of engine mount ...

Page 62: ...an a Oil on pulley surfaces Clean pulley halves 4 Check pulley calibration a Improper pulley calibration Calibrate according to specifications SYMPTOM BELT WORN EXCESSIVELY IN TOP WIDTH CONDITION NORMAL USE Test Inspection A00D0BY 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 identification...

Page 63: ...een pulleys a Incorrect pulley distance Readjust according to specifications A00D0CY 7 Check belt deflection a Deflection is too small Adjust according to specifications SYMPTOM BELT SIDES WORN CONCAVE CONDITION NORMAL USE Test Inspection A00D0DY 1 Check pulley half surfaces a Rough or scratched pulley half surfaces Repair or replace 2 Check drive belt identification number a Unspecified type of b...

Page 64: ...R TORN CONDITION NORMAL USE Test Inspection A00D0HY 1 Check drive belt rotational direction a Improper belt installation Replace 2 Check if drive belt rubs against components a Belt rubbing on stationary object Relocate components 3 Check drive pulley a Violent engagement of drive pulley Check drive pulley engagement speed drive pulley bushings and components SYMPTOM BELT FLIP OVER AT HIGH SPEED C...

Page 65: ...n return spring Replace 2 Check if brake cable moves freely in its housing a Brake cable movement is limited due to oxidation or dirt accumulation Replace 3 Check distance between brake lever and caliper a Distance is too wide Adjust according to specifications refer to TRANSMISSION 05 SYMPTOM SPONGY BRAKE CONDITION CONDITION NORMAL USE Test Inspection Replace brake fluid and bleed system If probl...

Page 66: ...ING Subsection 04 TRANSMISSION AND BRAKE SYSTEMS 03 04 8 MECHANICAL AND HYDRAULIC BRAKES SYMPTOM BRAKE SYSTEM IS NOISY CONDITION NORMAL USE Test Inspection 1 Check brake pad thickness a Pads are worn up to wear warner Replace ...

Page 67: ...r 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 switch contact disc a Burnt or poor contact of solenoid switch co...

Page 68: ...eak 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 clutch pinion gear Replace clutch 2 Check clutch a Defective clutch Replace clutch 3 Check movement of clutch on splines a Poor movement of clutch on s...

Page 69: ...acts a Melted solenoid switch contacts Replace solenoid switch 6 Check starter switch a Starter switch returns poorly Replace ignition switch SYMPTOM NOISE OCCURENCE WHEN STARTING ENGINE CONDITION NORMAL USE Test Inspection 1 Check if ring gear is well mounted to drive pulley inner half a Loose and or broken bolts Retighten bolts using thread locker or replace ring gear and drive pulley inner half...

Page 70: ...in lighting circuit Replace voltage regulator and ensure proper grounding Retest SYMPTOM HEADLAMP DIMING CONDITION NORMAL USE Test Inspection 1 Check voltage at headlamp at different speeds It must not be below 11 Vac a Insufficient voltage in lighting circuit Replace voltage regulator and retest 2 Visually inspect wiring harness for damaged and or melted wires and or bad wire terminal crimping an...

Page 71: ...eating grips installation overloads the magneto generator capacity a Excessive electrical load to magneto generator Reduce the electrical load by removing accessories SYMPTOM FALSE FUEL AND OR TEMPERATURE GAUGE READINGS CONDITION NORMAL USE Test Inspection 1 Verify if gauge was connected on DC current by mistake in case of optional installation a Faulty installation of optional equipment Find opti...

Page 72: ...icone dielectric grease 4 Verify trigger coil resistance with an ohmmeter and connector condition a Defective coil Corroded connector terminals Replace defective coil Clean terminals and apply silicone dielectric grease 5 Verify condition of ignition coil a Mechanically damaged part Vibration problem Electrically damaged part Tighten mounting screws Replace ignition coil 6 Verify condition of igni...

Page 73: ...c timing light unplug connectors between magneto generator and vehicle wiring harness to isolate problem Check condition of connectors a Defective spark plug s and or cable s cap s Defective electrical system wiring harness and or accessories and ignition cut out switches Condition of connector terminals Replace defective parts and or repair damaged wires Replace defective switch es Clean terminal...

Page 74: ... CONDITION NORMAL USE Test Inspection 1 Refer to ENGINE SLOWS DOWN OR STOPS AT HIGH RPM and check items listed 2 Check spark plug heat range a Spark plug heat range is too high Replace by Bombardier s recommended spark plug refer to TECHNICAL DATA 10 3 Check if air intake silencer leaks a Air surplus coming from opening s located between halves Seal 4 Check carburetor adapter collars a Loose colla...

Page 75: ...rroded terminals and or broken wires Replace terminal s or crimp defective wires SYMPTOM TACHOMETER DOES NOT WORK CONDITION NORMAL USE Test Inspection 1 Check continuity of wires a Corroded terminals and or broken wires Replace terminal s or crimp defective wires SYMPTOM HIGH BEAM PILOT LAMP LIGHTS UP WHEN LOW BEAM IS SELECTED CONDITION NORMAL USE Test Inspection 1 Check proper connections a YELLO...

Page 76: ...E CONDITION NORMAL USE Test Inspection 1 Check track tension a Pressure is too great on cleats Adjust according to specifications refer to TECHNICAL DATA 10 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 VIBRATIONS ORIGINATING FROM THE TRACK CONDITION NORMAL USE Test Inspectio...

Page 77: ...per lubrication and or contaminated grease sticky oil sludge Clean and or lubricate 3 Check rear spring preload a Insufficient preload Increase preload using 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 tension of front spring adjustment cams a Insufficient ski pressure o...

Page 78: ...on 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 condition...

Page 79: ...ON 04 02 12 ASSEMBLY 04 02 12 494 583 AND 670 ENGINE TYPES 04 03 1 ENGINE SUPPORT AND MUFFLER 04 03 1 REMOVAL FROM VEHICLE 04 03 2 ENGINE SUPPORT AND MUFFLER DISASSEMBLY AND ASSEMBLY 04 03 2 INSTALLATION ON VEHICLE 04 03 2 TOP END 04 03 4 CLEANING 04 03 5 DISASSEMBLY 04 03 5 INSPECTION 04 03 5 ASSEMBLY 04 03 6 BOTTOM END 04 03 10 CLEANING 04 03 11 DISASSEMBLY 04 03 11 INSPECTION 04 03 11 ASSEMBLY ...

Page 80: ...LEARANCE 04 04 11 CRANKSHAFT END PLAY 04 04 11 CRANKCASE ROTARY VALVE GAP 04 04 11 CHECKING SURFACE FLATNESS 04 04 12 RECTIFYING SURFACES 04 04 12 CHECKING CRANKSHAFT ALIGNMENT 04 04 13 CDI SYSTEM 04 05 1 NIPPONDENSO TRIGGER COIL IGNITION SYSTEM 04 05 1 CLEANING 04 05 2 DISASSEMBLY 04 05 2 ASSEMBLY 04 05 4 DUCATI IGNITION SYSTEM 04 05 5 CLEANING 04 05 6 DISASSEMBLY 04 05 6 REPAIR 04 05 6 ASSEMBLY ...

Page 81: ...4 10 3 DISASSEMBLY 04 10 3 ASSEMBLY 04 10 3 INSTALLATION 04 10 4 CARBURETOR AND FUEL PUMP 04 11 1 REMOVAL 04 11 2 CLEANING AND INSPECTION 04 11 2 IDENTIFICATION 04 11 2 DISASSEMBLY AND ASSEMBLY 04 11 3 CARBURETOR FLOAT LEVEL ADJUSTMENT 04 11 3 INSTALLATION 04 11 5 CARBURETOR ADJUSTMENTS 04 11 6 PRELIMINARY IDLE SPEED ADJUSTMENT 04 11 7 IDLE SPEED FINAL ADJUSTMENT 04 11 8 CHOKE 04 11 8 HAC SYSTEM 0...

Page 82: ...NE Subsection 02 443 AND 503 ENGINE TYPES 04 02 1 443 AND 503 ENGINE TYPES 0 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 FLAT RATE PARTS ...

Page 83: ...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 84: ...Section 04 ENGINE Subsection 02 443 AND 503 ENGINE TYPES 04 02 3 Skandic WT SWT 503 Engine Type A22C0FS 21 N m 15 lbf ft FLAT RATE PARTS ...

Page 85: ...lley using appropriate puller refer to 05 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 86: ...3 ENGINE TYPES 04 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 87: ...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 w...

Page 88: ...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 oversize piston and rings are available if necessary INSPECTION Refer to ENGINE DIM...

Page 89: ...e 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 in stalled befo...

Page 90: ...s Check flatness of intake sockets no 10 Refer to ENGINE DIMENSION MEASUREMENT 04 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 th...

Page 91: ...os 1 and 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 A03C1XA 2 1 1 A17C0SA 2 ...

Page 92: ...443 AND 503 ENGINE TYPES 04 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 PARTS ...

Page 93: ...ECTION Refer to ENGINE DIMENSIONS MEASUREMENT 04 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 g...

Page 94: ...ft 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 filling capacity and reduces curing time Position the crankcase halves together and tight en bolts by hand then install and tighten armature plate on magneto s...

Page 95: ...ENGINE SUPPORT AND MUFFLER All Models A03C1NT 494 583 and 670 494 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 Loctite 179 Loctite 271 MX Z 494 583 and 670 40 N m 30 lbf ft 2 40 N m 30 lbf ft 1 5 3 4 3 FLAT RATE PARTS ...

Page 96: ...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 pull...

Page 97: ...INE TYPES 04 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 Loctite 179 P N 413 7103 00 can be used A03C1KA 1 ...

Page 98: ...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 11 13 14 15 10 9 7 6 5 3 8 4 FLAT RATE PARTS ...

Page 99: ... remove 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 RAVE System NOTE RAVE stands for Rotax Adjustable ...

Page 100: ...ration 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 TYPICAL 1 Circlip break 22 Cylinder 494 Only To avoid pinching or cutting of O ring no 18 be tween cylinder and cylinder head it is necessary to use a special ...

Page 101: ...es 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 the above recommended sequence and torque as specified Position O rings over cylinders then install cylinder head with its temperature senso...

Page 102: ...ed 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 670 engine longer screws go on exhaust side TYPICAL A Torque scre...

Page 103: ...sket and valve 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 Screw by hand valve piston on valve rod until it bottoms Secure bellows to valve piston with a clamp Install spring cover and spring clip Turn adjust ment screw by hand until i...

Page 104: ...ease 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 105: ...t use a pro tective cap and special puller as illustrated 1 PTO side 2 MAG side INSPECTION Refer to ENGINE DIMENSIONS MEASUREMENT 04 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 exp...

Page 106: ...ll moving parts of 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 filling capacity and reduces curing time Position the crankcase halves together and tight en screws by hand then install and tig...

Page 107: ...eto 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 04 05 ...

Page 108: ...ary valve gear lubrication system 7 Install air pump on any valve of exhaust plug NOTE If necessary lubricate air pump piston with mild soap 8 Rotate crankshaft so that piston goes to BDC 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 3 min...

Page 109: ...urfaces 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 val...

Page 110: ...Rotary 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 test...

Page 111: ...in castings Pay attention to tapped holes which may go through engine sealed area and thus lead 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 ...

Page 112: ...ARY 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 113: ...ake port A 16 mm 5 8 in from top CYLINDER OUT OF ROUND Measuring 16 mm 5 8 in from top of cylinder with a cylinder gauge check if the cylinder out of round is more than the specified dimension If larger 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 i...

Page 114: ...rette content through the spark plug hole until liquid touches the top spark plug hole 1 Top of spark plug hole NOTE The liquid level in cylinder must not drop for a few seconds after filling If so there is a leak between piston and cylinder The recorded vol ume would be false 5 Let burette stand upward for about 10 minutes until liquid level is stabilized 6 Read the burette scale to obtain the qu...

Page 115: ...NDER PISTON CLEARANCE Used and New Pistons NOTE Make sure used piston is not worn See USED PISTON MEASUREMENT above Take the measurement on the piston dome 1 Piston dome 2 Piston measurement Adjust and lock a micrometer to the specified val ue on the piston dome 1 Micrometer set to the piston dimension With the micrometer set to the piston dimension adjust a cylinder bore gauge to the micrometer d...

Page 116: ...TE Make sure the cylinder bore gauge indica tor is set exactly at the same position as with the micrometer otherwise the reading will be false RING PISTON GROOVE CLEARANCE Using a feeler gauge check clearance between rectangular ring and groove Replace piston if clearance exceeds specified tolerance Refer to TECHNICAL DATA 10 02 RING END GAP Position ring half way between transfer ports and intake...

Page 117: ...etween the key and the first thread A See table below Crankshaft Deflection on PTO Side Crankshaft Deflection on MAG Side Crankshaft Deflection in Center of Crankshaft NOTE Crankshaft deflection cannot be correctly measured 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 me...

Page 118: ...E GAP First Method To measure this gap use a feeler gauge inserted between rotary valve and upper crankcase with the rotary valve cover in place without its O ring Check the most surface as possible Follow the same procedure with the lower crankcase A01C0SA A01C3GA A01C3HA ENGINE TYPE NEW PARTS MIN MAX WEAR LIMIT All 0 03 0 012 mm 0001 0005 in 0 015 mm 0006 in ENGINE TYPE NEW PARTS MIN MAX WEAR LI...

Page 119: ... mm 1 2 in long of sol der directly on rotary valve one above and one be low rotary valve gear Apply grease to hold solder in position Reinstall cover in place WITHOUT its O ring and torque screws to 20 N m 15 lbf ft Remove cover then clean and measure com pressed solder thickness it must be within the specified tolerance TYPICAL 1 Solder CHECKING SURFACE FLATNESS Intake manifold intake manifold c...

Page 120: ... 414 1047 00 in spark plug hole on MAG side Bring MAG piston at top dead center Rotate degree wheel not crankshaft so that 360 mark aligns with center of crankcase Scribe a mark on crankcase Remove TDC gauge and install it on PTO side Bring PTO piston to top dead center Interval between cylinders must be exactly 180 Any other reading indicates a misaligned twisted crankshaft 0 90 80 70 60 50 40 30...

Page 121: ...ngines A15E0QV 7 6 3 Loctite 242 1 2 Loctite 242 Loctite 242 Loctite 648 4 Loctite 648 All engines except 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 00 494 and 670 engines 494 and 670 engines 583 engine 105 N m 77 lbf ft FLAT RATE PARTS ...

Page 122: ...hined to 40 mm 1 580 in outside diameter by 16 mm 5 8 in long NOTE To correctly remove a threadlocked fas tener it is first necessary to tap on the fastener to break threadlocker bond This will eliminate 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 flywhee...

Page 123: ...ligns with trigger coil 2 Using a feeler gauge of 0 75 mm 030 in thick allowable range is 0 55 mm 022 in to 1 45 mm 057 in check air gap between cen ter pole of trigger coil and flywheel protrusion 3 If necessary adjust by loosening retaining screws and moving trigger coil toward or away of protrusion 4 Retighten screws and recheck air gap PRELIMINARY TRIGGER COIL AIR GAP ADJUSTMENT 1 Trigger coil...

Page 124: ...Clean nut threads and apply Loctite 242 blue then tighten nut to 125 N m 92 lbf ft for 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 06 02 CAUTION Make sure oil seal is fully pushed agai...

Page 125: ...ction 04 ENGINE Subsection 05 CDI SYSTEM 04 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 126: ...mature 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 and other parts re moved Preliminary Adjustment NOTE The final trigger coil adjust...

Page 127: ...mature 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 ven...

Page 128: ...4 06 1 OIL INJECTION SYSTEM 0 OIL INJECTION PUMP 494 583 and 670 Engines 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 Oil pump gasket set FLAT RATE PARTS ...

Page 129: ...Section 04 ENGINE Subsection 06 OIL INJECTION SYSTEM 04 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 130: ... gear holder TYPICAL ASSEMBLY 2 Oil Pump Gear At gear assembly apply a light coat of Molykote 111 P N 413 7070 00 on gear teeth 4 Needle Roller fan cooled engine only The needle roller must be engaged as deep as possible in 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 i...

Page 131: ...jection oil as required Check also for proper pump lever adjustment Marks must be aligned when throttle lever is acti vated just enough to take all cable 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 ...

Page 132: ...lever in fully open position Oil columns must advance into 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...

Page 133: ...Subsection 07 AXIAL FAN COOLING SYSTEM 04 07 1 AXIAL FAN COOLING SYSTEM 0 443 and 503 Engines 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 FLAT RATE PARTS ...

Page 134: ...mbly 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 Som...

Page 135: ...ng 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 136: ...Section 04 ENGINE Subsection 08 LIQUID COOLING SYSTEM 04 08 1 LIQUID COOLING SYSTEM 0 All S Series Engines A06C2VT 7 Loctite PST 3 5 4 1 6 FLAT RATE PARTS ...

Page 137: ...Section 04 ENGINE Subsection 08 LIQUID COOLING SYSTEM 04 08 2 Skandic WT LC TYPICAL A29C0AS 1 Loctite PST 8 2 3 4 Loctite PST FLAT RATE PARTS ...

Page 138: ...ert radiator 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 494 583 and 670 engines the thermostat is a double action type a Its function is to give faster warm up of the en gine by controlling a circuit ...

Page 139: ...elief valve in the pres sure cap COOLING SYSTEM REFILLING PROCEDURE Recommended Coolant Use a blend of 60 antifreeze with 40 water Do not reinstall pressure cap System Capacity Refer to TECHNICAL DATA 10 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 t...

Page 140: ...oolant flows through radiators touch them by hand They must feel warm Turn engine off Let it cool down for 15 to 20 min utes Open cap and refill filler neck completely Start engine and let it idle Do not 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...

Page 141: ... RESERVOIR 04 09 1 ROTARY VALVE COOLANT PUMP AND RESERVOIR 0 494 583 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 FLAT RATE PARTS ...

Page 142: ...ing at the end of this subsection 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 disassemb...

Page 143: ... fine sand paper on a surface plate Surface part against oiled sand paper Inspect bearings Check 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 co...

Page 144: ...aring 6201 use bearing pusher P N 420 8765 00 NOTE Bearing shielded side must be facing rota ry valve Refer to Rotary Valve Timing at the end of this subsection 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 of both seals Position oil seal shiel...

Page 145: ...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 2 Rubber washer 3 Support plate 4 Small thrust washer 5 Friction washer 6 Flange this side 7 Grooves this side 8 Pump impeller 1 Support plate NOTE After seals installation check if the water pump end...

Page 146: ...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 upper crankcase h...

Page 147: ...measure rotary valve opening and closing angles in relation with MAG side piston Degree wheel will be installed on rotary valve shaft for measure ments Rotary valve must be set as specified in TECHNI CAL DATA 10 For the following instructions use these specifi cations as an example OPENING 132 BTDC CLOSING 52 BTDC Proceed as follows Turning crankshaft bring MAG side piston to Top Dead Center as do...

Page 148: ...pper 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 bring MAG pi...

Page 149: ... REWIND STARTER 0 All Liquid Cooled Models TYPICAL A01C5SS 12 11 10 9 13 8 6 5 4 15 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 150: ...ection 10 REWIND STARTER 04 10 2 All Fan Cooled Engines A21C08S 10 N m 89 lbf in Molykote G n paste or equivalent Silicone compound grease Silicone compound grease 8 N m 71 lbf in 15 6 7 5 4 1 3 8 9 10 12 11 FLAT RATE PARTS ...

Page 151: ...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 inspected and relu bricated 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 152: ...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 153: ... Install rewind starter on damper ring matching notches and embosses 1 Notch Prior to installing starter grip no 15 on new rope it is first necessary to fuse the rope end with a lit match Pass rope through 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 154: ...04 ENGINE Subsection 11 CARBURETOR AND FUEL PUMP 04 11 1 CARBURETOR AND FUEL PUMP 0 All Models A03C1MS 6 13 10 8 11 12 9 7 1 2 3 4 5 14 To other carburetor MX Z 440 and Skandic WT series only 15 FLAT RATE PARTS ...

Page 155: ...ition If worn the inlet needle and seat must be replaced as a matched set NOTE Install needle valve for snowmobile carbu retor only It is designed to operate with a fuel pump system Check throttle slide for wear Replace as neces sary Check that idle speed screw is straight Replace as necessary Check for fuel soaked into float no 12 replace as necessary Check float for cracks or other damages affec...

Page 156: ...ning 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 an...

Page 157: ...ponds 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 23 9 941 MX Z 494 18 1 713 MX Z 583 18 1 713 MX Z 670 18 1 713 Formula 500 500 DL 18 1 713 Formula 583 DL 18 1 713 Formula Z 583 18 1 713 For...

Page 158: ...ed not 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 ...

Page 159: ... it and turn cable adjuster as required Check throttle slide position at wide open throttle Throttle slide must be flush or 1 0 mm 040 in lower than carburetor outlet bore At that same position 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 mov...

Page 160: ...Y 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 Do not interchange carburetors the jetting may be different on each side A red dot is print...

Page 161: ...stment Set choke lever to fully open position CHOKE LEVER FULLY OPEN POSITION Use small diameter of tool for VM 34 carburetors Insert choke plunger tool into choke air inlet of each carburetor Tool stopper may not lean against recess wall Though it must be within 1 mm 040 in of recess wall Models Throttle Slide Height mm in MX Z 440 1 5 059 MX Z 500 1 8 071 MX Z 583 2 0 078 MX Z 670 2 1 083 Formul...

Page 162: ...hoto 1 Lift up protector cap 2 Loosen lock nut Turn choke cable adjustment nut by hand until tool properly seats under choke plunger NOTE A light pressure should be needed to posi tion tool under plunger 1 Choke cable adjustment nut 2 Choke plunger tool Tighten choke cable lock nut and reinstall protec tor cap Set choke lever to close and open positions and ensure that tool properly seats under pl...

Page 163: ...evice No adjustment and verification can be done to H A C If H A C is suspected to be faulty replace it and check for improvement Hoses connected to H A C must not be altered in length or size Check for kinked or loose hoses Tighten or replace as necessary See below illus tration for routing Nut holding T fitting must be torqued to 6 N m 53 lbf in ...

Page 164: ...Section 04 ENGINE Subsection 11 CARBURETOR AND FUEL PUMP 04 11 11 H A C SYSTEM A03I0BS To magneto housing FLAT RATE PARTS ...

Page 165: ...Section 04 ENGINE Subsection 11 CARBURETOR AND FUEL PUMP 04 11 12 FUEL PUMP A06C45S 443 and 503 engines 494 583 and 670 engines FLAT RATE PARTS ...

Page 166: ...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 167: ...ever 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 s...

Page 168: ...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 169: ...3 4 ASSEMBLY 05 03 5 INSTALLATION 05 03 8 DRIVE PULLEY ADJUSTMENT 05 03 9 DRIVEN PULLEY 05 04 1 REMOVAL 05 04 3 DISASSEMBLY 05 04 3 CLEANING 05 04 3 INSPECTION 05 04 3 ASSEMBLY 05 04 5 INSTALLATION 05 04 5 ADJUSTMENT 05 04 6 PULLEY DISTANCE AND ALIGNMENT 05 05 1 GENERAL 05 05 1 GENERAL PROCEDURE 05 05 1 PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART 05 05 2 BRAKE 05 06 1 HYDRAULIC DISC BRAKE 0...

Page 170: ...2 DRIVE CHAIN ADJUSTMENT 05 07 3 ADJUSTMENT 05 07 4 GEARBOX 05 08 1 3 SPEED GEARBOX 05 08 1 REMOVAL 05 08 2 DISASSEMBLY 05 08 2 INSPECTION 05 08 9 ASSEMBLY 05 08 9 INSTALLATION 05 08 12 OIL LEVEL 05 08 12 2 SPEED GEARBOX 05 08 13 DISASSEMBLY 05 08 14 INSPECTION 05 08 14 ASSEMBLY 05 08 14 ADJUSTMENT 05 08 16 OIL CHANGE 05 08 17 DRIVE CHAIN 05 09 1 SILENT CHAIN 05 09 1 ...

Page 171: ...BER WIDTH NEW 0 25 mm 010 in MINIMUM WIDTH WEAR LIMIT SUMMIT 583 670 FORMULA Z 670 AND MX Z 670 415 0990 00 35 mm 1 3 8 33 mm 1 19 64 SUMMIT 500 GRAND TOURING 500 583 FORMULA 500 500DL 583 DL Z 583 AND MX Z 500 583 415 8607 00 35 3 mm 1 3 8 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 440 415 0606 00 34 7 mm 1 23 64 32 3 mm 1 17 64 BOMBARDIER FABRIQUÉAU CANADA ...

Page 172: ...he 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 read d...

Page 173: ...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 required 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 A...

Page 174: ... 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 FLAT RATE PARTS ...

Page 175: ...es Use puller P N 529 0224 00 for 494 and 670 engines To Remove Drive Pulley Ass y Retain drive pulley with clutch holder Install puller in pulley shaft then tighten 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 d...

Page 176: ...es Hold a slider shoe set then carefully lift its housing and remove slider shoes 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 529 0055 00 should be used to hold slider shoes prior to removing governor cup 19 Spring Cover Ass y It is pushed by clutch spring pressure Use spring comp...

Page 177: ...d 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 INSPECTION Drive pulley should be inspected annually 16 17 Thrust Washer and Roller Check roller for roundness of external diameter Check thrust washer for thickness wear Replace as required 9 12 Fitting Bolt Ass y and Flanged Bushing Chec...

Page 178: ...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 529 0312 00 to remove old bushing Apply retaining compound Loctite 648 outside of bushing then press it down to counterbore from outside end Use spring compressor P N 529 0151 00 and appropriate tools Start driving bushing into spring cover ...

Page 179: ...ICAL DATA 10 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 Position dowel tube split at the illustrated angle 1 Equal distance Torque screws to 10 N m 89 lbf in 9 11 13 14 Screw Lever Ass y Nut and Cotter Pin Always install lever assemblies so that cotter pins are on the shown side Besides install cotter pin he...

Page 180: ... 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 lation Proceed on 3 set of slider shoes CAUTION Leve...

Page 181: ...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 182: ...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 10 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 2...

Page 183: ...Section 05 TRANSMISSION Subsection 03 DRIVE PULLEY 05 03 10 1 Loosen just enough to permit rotating of calibration screw A16D0HA 1 ...

Page 184: ...SION Subsection 04 DRIVEN PULLEY 05 04 1 DRIVEN PULLEY 0 S Series A03D2FT 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 MX Z 583 670 only MX Z 583 670 only FLAT RATE PARTS ...

Page 185: ...Section 05 TRANSMISSION Subsection 04 DRIVEN PULLEY 05 04 2 Skandic WT SWT WT LC A22D11S Anti seize lubricant 4 5 19 2 FLAT RATE PARTS ...

Page 186: ...ng 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 transferred tefl...

Page 187: ...low bushing 1 Support plate 2 Puller Mount puller screw 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...

Page 188: ...ALLATION 14 15 Countershaft and Anti seize Lubricant S Series Only Should installation procedure be required refer to BRAKE 05 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 ...

Page 189: ...h pulley axle Take 1st 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 sprin...

Page 190: ...ll proper cam Refer to TECHNI CAL DATA 10 03 Cam angle is identified on cam NOTE For high altitude regions the High Altitude and Sea Level Technical Data Booklet P N 484 0686 00 and 484 0545 00 for binder gives infor mation 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 BARD...

Page 191: ...Z Distance between outside 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 includi...

Page 192: ... 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 nominal values A06D0LA 1 2 CAUTION This section deals mainly with adjustment procedures For complete assembly require ments refer to the proper ENGINE or TRANS MISSION installation section MODEL PULLEY DISTANCE OFF...

Page 193: ...les 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 obtain...

Page 194: ...C BRAKE S Series A03D2DT Loctite 242 7 MX Z 440 Formula 500 500 DL 583 DL Summit 500 583 and GT 500 583 only Anti seize lubricant All models except MX Z 440 Formula 500 500 DL 583 DL Summit 500 583 and GT 500 583 17 Anti seize lubricant 19 18 20 Black Max 24 FLAT RATE PARTS ...

Page 195: ...583 and GT 500 583 Only 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 M10 Allen screws Unbolt disc COUNTERSHAFT REMOVAL S Series Proceed the same as for brake disc removal but unlock bearing c...

Page 196: ...ads 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 TYPICAL 1 Fixed pad 2 Inner caliper A 1 mm 1 32 in minimum A03D1JA 529 0301 00 1 ...

Page 197: ... in order to move pad inward allowing proper brake disc posi tioning 1 Brake disc not centered 2 Brake disc centered 3 Apply brake before checking Apply brake then recheck 17 Brake Disc S Series Apply anti seize lubricant P N 413 7010 00 on shaft The disc hub exceeds the disc more from one side than from the other Install disc with the long er exceeding portion toward driven pulley Skandic WT SWT ...

Page 198: ...lock together Insert a punch into collar hole and strike sharply in the same direction to lock firmly Apply Loctite 242 P N 413 7030 00 on set screw threads then tighten Close chaincase referring to CHAINCASE 05 07 BLEEDING Change brake fluid once a year Bleed brake system as follows Keep sufficient DOT 4 DOT 3 for normal use brake fluid in reservoir at all times Install a hose on left side bleede...

Page 199: ...ithout Reverse Gear SYNTHETIC CHAINCASE OIL HUILE SYNTHÉTIQUE POUR CARTER A03D2OS Chaincase oil 2 1 45 to 75 N m 33 to 55 lbf ft 3 27 4 5 6 23 7 Loctite 242 12 46 N m 34 lbf ft 15 Loctite 271 14 13 16 17 14 21 22 Loctite 242 18 20 11 Loctite 609 28 26 10 9 24 25 8 FLAT RATE PARTS ...

Page 200: ...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 10 03 for gear ratios NOTE For high altitude regions the High Altitude and Sea Level Technical Data Booklet P N 484 0686 00 and P N 484 0545 00 for binder gives information about calibrat...

Page 201: ...ge 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 rem...

Page 202: ... CHAINCASE 05 07 4 TYPICAL 1 Dipstick NOTE Chaincase must be in its proper position when checking oil level ADJUSTMENT Pulley Alignment Refer to PULLEY DISTANCE AND ALIGNMENT 05 05 Track Tension and Alignment Refer to TRACK 07 06 A03A03A 1 ...

Page 203: ...1 GEARBOX 0 3 SPEED GEARBOX Skandic WT SWT WT LC A29D0KS 4 9 9 10 11 16 10 8 17 32 33 9 34 35 36 Loctite 648 9 37 28 29 30 28 30 27 10 9 31 26 25 24 23 22 16 18 21 8 8 16 18 38 20 9 13 14 15 8 10 Loctite 242 Loctite 242 19 1 2 3 5 6 7 12 FLAT RATE PARTS ...

Page 204: ...caliper brake disc Unfasten shift ing rod and unplug reverse switch Remove rear suspension Remove angle drive and square pin from bottom of gearbox Remove muffler Unbolt RH end bearing then pull drive axle toward right side 1 RH end bearing Unbolt gearbox from chassis DISASSEMBLY For the following procedure right hand side refers to driven pulley side and left hand side to brake disc side A29D0LA ...

Page 205: ... cover no 2 from gearbox housing Remove nut no 3 retaining pin no 6 1 Cover 2 Nut Unfasten sleeve nut no 4 remove spring no 7 then partially pull shaft no 5 and remove pin no 6 1 Pin Completely remove shaft no 5 Drill a 10 mm 3 8 in dia hole through all plugs no 8 Remove all plugs no 8 from gearbox A29D0PA 1 2 A29D0QA 1 2 A29D0RA 1 A29D0SA ...

Page 206: ...uantity and loca tion Remove brake shaft oil seal then circlip 1 Brake shaft Proceeding from right side drive brake shaft out of gearbox housing Remove sleeve no 23 NOTE Brake shaft gears remain in gearbox hous ing Remove bearing no 27 from brake shaft no 23 using a press A29D0TA A29D0UA 1 A29D0VA A29D0WA ...

Page 207: ...so its sliding sleeve dog will not touch the RH gear of driven pulley shaft no 15 This will allow the driven pulley shaft to be pushed out enough for bearing removal 1 Sleeve dog not touching right gear 2 Brake shaft gears are still in gearbox Use a puller to extract LH reverse shaft bearing 1 Extract reverse shaft LH side bearing To remove sliding sleeve from reverse shaft first remove circlip A2...

Page 208: ...ft screw no 11 and re move washer Push driven pulley shaft no 15 out of gearbox un til its LH gear no 14 is against gearbox inner wall Use a puller to extract bearing no 12 Remove circlip then gear no 14 Now driven pul ley shaft can be pulled out from gearbox Remove sliding sleeve taking care not to lose balls no 18 and spring no 16 A29D11A 1 2 A29D12A A29D13A A29D14A ...

Page 209: ...alls DRIVEN PULLEY SHAFT COMPONENTS Remove screws no 16 from intermediate shafts no 30 Fasten a long M8 x 1 25 screw in axle end then drive it out beginning with top one Remove intermediate gears and spacers 1 Spacer 1 Spacer A29D16A 1 2 3 A29D17A A29D18A M8 x 1 25 A29D19A 1 A29D1AA 1 ...

Page 210: ...iate gears needlessly Pry out bottom seal no 33 from gearbox housing Remove sleeve no 32 then circlip no 9 Drive out plug no 37 Remove circlip no 9 from LH side Using a press drive out lower shaft no 36 from RH side A29D1BA A29D1CA CAUTION Do not push against inner bearing race A29D1DA A29D1EA ...

Page 211: ...side Install lower shaft no 36 with its hollow side no splines on RH side Align key with lower gear no 34 keyway Install intermediate gears no 29 with their shoul der towards LH side Position spacers no 28 as illustrated in removal procedure Bevelded side of spacers goes against gearbox wall Install RH side bearing of brake and reverse shafts Partially assemble brake shaft gears nos 24 and 25 with...

Page 212: ...nd of sleeve is flush with shaft end 1 Flush Install brake shaft no 26 into gearbox then loose ly install gear no 22 with its shoulder facing bear ing no 21 Do not push brake shaft into bearing no 21 at this time Install reverse shaft ass y no 38 into its RH side bearing no 19 1 Reverse shaft installed in its RH bearing A29D1IA 1 2 A29D1JA 1 A29D1KA 1 ...

Page 213: ...rted Gear no 14 must be at its place 1 Sliding sleeve loosely inserted 2 Gear no 14 in place Install balls no 18 and spring no 16 into driven pulley shaft 1 Push on ball with a screwdriver then move sliding sleeve to the right Finalize driven pulley shaft insertion Make sure that gears mesh during insertion Install circlip no 20 1 Circlip Install LH side bearings nos 12 19 and 21 shims no 8 circli...

Page 214: ...EL To check pull dipstick Oil should reach level mark NOTE After first outing oil level will decrease as the upper oil cavity fills with oil Recheck oil level and refill as required 1 Full level mark 2 Lower level mark To fill remove filler plug from top of transmission Refill as required using BOMBARDIER SYNTHETIC CHAINCASE OIL P N 413 8028 00 12 x 250 mL A29D1OA A29D0IA 1 2 ...

Page 215: ...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 FLAT RATE PARTS ...

Page 216: ... 18 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 Che...

Page 217: ... their spring no 36 on 44 tooth 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 n...

Page 218: ... it is still impossi ble check if the fork engages in the sliding gear or disassemble the cover to inspect components 3 Completely loosen ball joint lock nut on the gear shift linkage 4 Use 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 to reverse position making sure all slack is removed Lengthen tie rod until it contacts ...

Page 219: ...erior 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 described previously during as sembly Fill housing with BOMBARDIER SYNTHETIC CHAINCASE OIL P N 413 8028 00 12 x 250 mL Oil capacity is 250 mL 8 5 oz Check oil level with dipstick With dipstick un screwed oil level must be between MIN and...

Page 220: ...98 there 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 10 NOTE No work separation lengthening can be done on a silent chain ...

Page 221: ...03 3 HEAT RANGE 06 03 3 FOULING 06 03 3 SPARK PLUG ANALYSIS 06 03 3 SPARK PLUG INSTALLATION 06 03 4 SPARK PLUG TIGHTENING TORQUE 06 03 4 BATTERY 06 04 1 REMOVAL 06 04 1 CLEANING 06 04 1 INSPECTION 06 04 2 HYDROMETER TEST 06 04 2 BATTERY STORAGE 06 04 3 ACTIVATION OF NEW BATTERY 06 04 3 SERVICING 06 04 6 TIPS FOR CHARGING A USED BATTERY 06 04 6 BATTERY CHARGING EQUIPMENT 06 04 7 INSTALLATION OF BAT...

Page 222: ... 4 4 IGNITION GENERATOR COIL VOLTAGE TESTING 06 06 5 5 IGNITION MODULE VOLTAGE TESTING 06 06 5 6 HIGH VOLTAGE COIL VOLTAGE TESTING 06 06 5 CONCLUSION 06 06 6 LIGHTING GENERATOR COIL VOLTAGE TESTING 06 06 6 CONCLUSION 06 06 6 DUCATI CDI SYSTEM TESTING 06 06 9 IGNITION SYSTEM TESTING SEQUENCE 06 06 9 LIGHTING SYSTEM TESTING SEQUENCE 06 06 9 1 SPARKING 06 06 9 2 ELECTRICAL CONNECTOR TESTING 06 06 9 3...

Page 223: ...e correct location of the factory tim ing mark 4 To detect a wrong magneto flywheel To verify the position of the timing mark on the magneto flywheel proceed as follows 1 Clean the area around the spark plugs and re move them 2 Remove the rewind starter from the engine 3 Install the TDC gauge in the spark plug hole magneto generator side and adjust as follows a Position the magneto flywheel at app...

Page 224: ...rection to ensure that the slack in engine moving parts is taken up a Rotate the magneto flywheel 1 4 turn coun terclockwise 1 4 turn then carefully rotate it clockwise until the needle indicates the specified measurement Refer to TECHNI CAL DATA 10 02 b Verify that the magneto flywheel mark per fectly aligns with the mark on the trigger coil refer to illustration c If the marks do not align check...

Page 225: ...g the timing marks refer to illustration The magneto fly wheel mark scribed previously and the crank case arrow should be perfectly aligned If the marks 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 NOTE Ignition timing may ...

Page 226: ...lugs 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 adapter and tight en the roller lock nut Do not tighten the adapter lock nut c Screw the adapter into the spark p...

Page 227: ...1 4 turn then carefully rotate it clockwise until the needle indicates the specified measurement indicated in TECH NICAL DATA 10 02 b Make sure that the dot located on the side of the magneto flywheel protrusion perfectly aligns with center of trigger coil core refer to illustration c If the marks do not align loosen trigger coil screws and move trigger coil to align dot with center of trigger coi...

Page 228: ... lax view the magneto flywheel and the crankcase timing marks in a straight line 2 Start the engine and point timing light straight in line with the crankcase timing mark Bring engine to 6 000 RPM for a brief instant TYPICAL 1 Timing light pick up on MAG side 2 Timing inspection hole The magneto damper mark must be aligned with center mark If not move trigger coil as explained above and recheck ig...

Page 229: ...Models NGK SPARK PLUG NUMBERING SYSTEM Bombardier uses NGK brand spark plugs on all its snowmobile models The heat range identification system is REFERENCE CHART NGK spark plugs used on Bombardier snowmo biles are covered in this manual BR9ES BR8ES Low number hot plug High number cold plug ...

Page 230: ... 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 231: ...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 det onation 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 a...

Page 232: ...a wire feeler gauge set electrode gap ac cording to TECHNICAL DATA 10 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 1 ...

Page 233: ...otective boot Step Remove vent tube All Models Withdraw battery 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 WARNING Battery BLACK negative cable must always be disconnected first and connected last WARNING Never charge or boost battery wh...

Page 234: ...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 235: ...days 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 shoul...

Page 236: ...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 237: ...c gravity 1 260 9 Let battery settle for 1 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 238: ...hey can supply Therefore time required for the battery 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 m...

Page 239: ...electronic parts supply shops and they are suit able for use with most chargers if the peak cur rent is to be held below 2 A If you need an accurate ammeter we recommend the use of SHURITE 5202 0 to 3 A or 5203 0 to 5 A available from electronic parts supply shops 1 Charger 2 Rheostat 12 Ω 50 W 3 Ammeter 4 Battery For a service application and a permanent installa tion both ammeter and rheostat ca...

Page 240: ... and connectors BATTERY CONNECTION 1 Vent tube on fitting 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 A03H1SA 1 ...

Page 241: ...Section 06 ELECTRICAL Subsection 05 ELECTRIC STARTER 06 05 1 ELECTRIC STARTER 0 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 FLAT RATE PARTS ...

Page 242: ...o 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 008 in If greater re...

Page 243: ...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 against yoke con nector edge welded portion Crimp plate over yoke connector...

Page 244: ...lip 1 Squeeze evenly Install thrust washer against outer stop collar Place 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...

Page 245: ... In stall hardened washers P N 503 0079 00 be tween engine and starter supports accordingly 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 fastener...

Page 246: ...face 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 008 in undercut the mica Be sure that no burrs are left and no copper dust remains between the segments after the un dercutting operation is completed 1 Commutator undercut 0 20 mm 008 in Check the commutator out of round condition with V Blocks and an ...

Page 247: ...on 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 test...

Page 248: ...tion If defective 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 otherw...

Page 249: ...6 ELECTRICAL Subsection 05 ELECTRIC STARTER 06 05 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 250: ...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 251: ...ator 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...

Page 252: ...ling 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 pu...

Page 253: ...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 254: ...oil via a 3 wire connector RED BLACK RED and BLACK wires NIPPONDENSO CDI TRIGGER COIL SYSTEM 1 Separate ignition coil mounted on reservoir support 2 Three wire connector RED BLACK RED and BLACK Ducati The DUCATI CDI system has a combined ignition module ignition coil which are mounted on oil res ervoir support 2 Ignition module is connected to the ignition generator coils via a 2 wire connector GR...

Page 255: ... 06 ELECTRICAL Subsection 06 TESTING PROCEDURE 06 06 2 DUCATI CDI SYSTEM 1 Combined ignition module ignition coil mounted on air silencer below carburetor 2 Two wire connector GREEN and WHITE wires A17E0TA 1 2 ...

Page 256: ...onding table If the reading is too low the part is considered to be de fective and must be replaced Resistance Readings Place multimeter selector switch to Ω in order to measure resistance Readings must be within the indicated range Otherwise the part is considered to be defective and must be replaced Intermittent Ignition Problems It is difficult to make a diagnostic in the case of intermittent i...

Page 257: ... to the above mentioned indications replace switch If readings are acceptable check other switches Emergency Switch Unplug switch block connected to main wiring harness Check using a multimeter Connect probes to BLACK YELLOW and BLACK wires The multimeter should indicate an open circuit 0 L MΩ in operating position and a closed circuit 0 Ω in off position TYPICAL If readings do not correspond to t...

Page 258: ... ac celerate beyond the compression point This will result in higher magneto output power 1 Disconnect the 3 wire housing between the ig nition module and the magneto wiring harness 2 Connect multimeter probes to BLACK and BLACK RED wires and bring the selector switch to and the scale to 00 0VAC 3 Activate the manual starter and check values in dicated by the multimeter 4 Repeat operation 3 times ...

Page 259: ... current to the lighting system and to other devices working on alternating current However this system can be tested using a mul timeter 1 Disconnect housing from engine YELLOW YELLOW and BLACK wires 2 Connect multimeter probes to YELLOW wires then place selector switch to and scale to 0 00VAC 3 Activate the manual starter and check values in dicated by the multimeter 4 Repeat operation 3 times 5...

Page 260: ... 00 5 00 0 Ω Ground continuity BK and engine 2 01C 1 F and engine 00 0 00 5 00 0 Ω The term engine refers to the engine metal parts connected to the magneto housing Ignition module Output voltage BK and WH BL 3 01 2 F and 3 01 1 F 4 5 8 0 00 0VAC High voltage coil Primary winding resistance BK and WH BL 3 01 2 M and 3 01 1 M 0 00 00 9 00 0 Ω DisconnectWH BL wire from coilin order to take measureme...

Page 261: ...ch and the emergency cut out switch It is important to take note that voltage measurements must be taken while starting the vehicle using the manual starter Voltages obtained upon starting are proportional to the force applied onto the manual starter A low voltage is therefore normal under a low cranking force Perform testing in the prescribed order and replace any parts not performing according t...

Page 262: ...he reading is too low the part is considered to be de fective and it must be replaced Resistance Readings Place multimeter selector switch to Ω in order to measure resistance Readings must be within the indicated range Otherwise the part is considered to be defective and must be replaced Intermittent Ignition Problems It is difficult to make a diagnostic in the case of intermittent ignition proble...

Page 263: ...respond to the above men tioned indications replace switch If readings are acceptable check other switches Emergency Switch Unplug switch block connected to main wiring harness Check using a multimeter Connect probes to 6 02 C M and 6 02 D M terminals The multimeter should indicate an open circuit 0 L MΩ in operating position and a closed circuit 0 Ω in off position TYPICAL If readings do not corr...

Page 264: ...pression point This will result in higher magneto output power 1 Disconnect the 4 wire housing between the ig nition module and the magneto wiring harness 4 20 2 Connect multimeter probes to GREEN and WHITE wires female end then bring selector to and scale to 00 0VAC 3 Activate the manual starter and check values in dicated by the multimeter 4 Repeat operation 3 times 5 Compare readings with those...

Page 265: ...current to the lighting system and to other devices working on alternating current However this system can be tested using a mul timeter 1 Disconnect housing from engine 2 01 2 Connect multimeter wires to YELLOW and YELLOW BLACK wires female side then place selector switch to and scale to 0 00VAC 3 Activate the manual starter and check values in dicated by the multimeter 4 Repeat operation 3 times...

Page 266: ...d BK YL 2 01 D M and 2 01 C M 00 0 00 5 00 0 Ω At least one stop switch must be operational Ignition generator coil Output BL and GR 4 20 B F and 4 20 A FA 230 0 330 0 00 0 Ω 30 0 60 0 00 0VAC No stop switch must be operational Ground continuity WH and engine 4 20 B F and engine 00 0 00 5 00 0 Ω The term engine refers to the engine metal parts connected to the magneto housing Ground continuity BR ...

Page 267: ...e Perform testing in the prescribed order and replace any parts not performing according to specifications It is important to resume all tests when replacing a component If not specified the probe connecting sequence is not important LIGHTING SYSTEM TESTING fan equipped S Series and Skandic WT SWT Part Test to be performed Wire color Multimeter probe connection Resistance Ω Voltage V Note Value Oh...

Page 268: ...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 mag neto wires Measured resistance must be infinite If such is not the case it means there is a connection be tween AC circuit and DC circuit Disconnect one accessory at the time to identify the faulty circuit ...

Page 269: ... 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 resis tance 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 A minimum L...

Page 270: ...SION 07 03 1 COMPONENT REMOVAL AND INSTALLATION 07 03 2 INSPECTION 07 03 9 INSTALLATION 07 03 10 RIDE ADJUSTMENT 07 03 11 LUBRICATION 07 03 11 SKANDIC WT SUSPENSION 07 04 1 REMOVAL 07 04 2 DISASSEMBLY AND ASSEMBLY 07 04 2 SHOCK ABSORBER SERVICING 07 04 3 INSTALLATION 07 04 4 DRIVE AXLE 07 05 1 REMOVAL 07 05 3 DISASSEMBLY 07 05 3 ASSEMBLY 07 05 4 AXIAL PLAY 07 05 5 INSTALLATION 07 05 8 LUBRICATION ...

Page 271: ...2 1 SC 10 SUSPENSIONS ALL VERSIONS 0 SC 10 Sport on MX Z 440 and Formula 500 500 DE LUXE 583 DE LUXE 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 272: ... 2 SC 10 High performance on Formula Z 583 and Grand Touring 583 SC 10 Cross country on MX Z 583 670 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 273: ...PENSIONS ALL VERSIONS 07 02 3 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 274: ...SPENSIONS ALL VERSIONS 07 02 4 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 275: ...assemble 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 cushi...

Page 276: ...on bottom end of shock Pry up shock bottom end to ease removing bolt gas shock only See installation 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 All Models 2 Rear Spring Remove sprin...

Page 277: ...DE SHOWN RH SIDE SHOWN Lift rear of vehicle and support it off the ground Loosen track tension 7 Screw Unscrew rear arm top axle from chassis NOTE To prevent axle from turning when un screwing screws assembled with threadlocker 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 ...

Page 278: ...on hole must face adjustment 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 and put it in a vise Mount shock in it and turn shock...

Page 279: ... 11 N m 97 lbf in 1 1st hole 2 2nd hole A 11 N m 97 lbf in 17 Slider Shoe Measure slider shoes from the bottom to the 0 5 mm 020 in radius as shown on the next photo Minimum thickness must be 2 mm 080 in TYPICAL 1 Slider shoe 2 Molding line this line is not the wear limit A Wear limit measurement must be at least 2 mm 080 in Replace slider shoes when wear limit is reached 18 Spring Support RIGHT S...

Page 280: ...zed Shock NOTE Gas pressurized shocks are light gray paint ed Gas shock can be inspected as follows Because of gas pressure strong resistance is felt when compressing shock When released the shock will extend unassisted Renew as required If suspecting an internal gas leak between oil chamber and gas chamber check shock as fol lows Install shock in a vise clamping on its bottom eye let with its rod...

Page 281: ...pension 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 synthetic grease P N 413 7115 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 fitting A03F10A A03F1SB 1 ...

Page 282: ...LA Z 670 SUSPENSION 07 03 1 FORMULA Z 670 SUSPENSION 0 Formula Z 670 A03F2XT 24 N m 18 lbf ft 105 N m 77 lbf ft 10 3 1 2 4 5 6 7 8 9 2 5 N m 22 lbf in 135 N m 100 lbf ft 48 N m 35 lbf ft Loctite 271 48 N m 35 lbf ft 48 N m 35 lbf ft FLAT RATE PARTS ...

Page 283: ...ection 07 REAR SUSPENSION Subsection 03 FORMULA Z 670 SUSPENSION 07 03 2 COMPONENT REMOVAL AND INSTALLATION 1 2 Shock and Spring Lift swing arm to facilitate long torque rod nut removal 1 Lift A03F2YS 1 ...

Page 284: ...TO BE REMOVED When reassembling tighten long torque rod nut to bottom Install shock spring remover P N 529 0335 04 in a vise Mount shock in it and turn shock so that spring coils matched spring compressor Close and lock bar Adjust handle horizontal by changing position of clevis pin Push down on handle until it locks Remove spring stopper and cap then release handle 1 A03F2ZA 2 A03F30A CAUTION Out...

Page 285: ...no 6 must face inner side 1 Hollow side Note position of all 6 friction washers There is one each side of long tie rod no 3 One goes be tween left hand side shock eyelet and inner spac er Another goes between small torque rod and outer spacer There is one each side of right hand side shock eyelet When reassembling mount long torque rod no 3 at 188 mm 7 13 32 in from axle end A 188 mm 7 13 32 in CA...

Page 286: ... A 48 N m 35 lbf ft Install large washers with their concave side to ward swing arm Apply Loctite 271 on M14 screw threads and tighten to 135 N m 100 lbf ft 1 Concave side A 135 N m 100 lbf ft 9 Rail Remove swing arm Remove swing arm lower axle bushing and long spacer 1 Swing arm lower axle 2 Bushing 3 Long spacer Remove outer idler wheels Note position of spac er for reassembling 1 Spacer A03F36A...

Page 287: ...Section 07 REAR SUSPENSION Subsection 03 FORMULA Z 670 SUSPENSION 07 03 6 Remove rear axle idler wheel Unscrew remaining axles A03F3BA ...

Page 288: ...Section 07 REAR SUSPENSION Subsection 03 FORMULA Z 670 SUSPENSION 07 03 7 When assembling both rails must run parallel Tighten nuts to 24 N m 18 lbf ft 1 Parallel A 24 N m 18 lbf ft A03F3DS A03F38S 1 A ...

Page 289: ... er shoe ensure not to damage rail surface PUSH OUT SLIDER SHOE 1 Rail surface When reinstalling use a soft sand paper to smooth rail surface Apply BOMBARDIER LUBE P N 293 6000 16 12 x 14 oz on rail surface This will ease new slid er shoe installation Install new slider shoe and secure with new elas tic nut P N 228 5610 45 and original screw Repeat procedure for the other side 10 Rear Axle Remove ...

Page 290: ...n 8 Slider Shoe Measure slider shoes from the bottom to the 0 5 mm 020 in radius as shown on the next pho to Minimum thickness must be 2 mm 080 in TYPICAL 1 Slider shoe 2 Molding line this line is not the wear limit A Wear limit measurement must be at least 2 mm 080 in Replace slider shoes when wear limit is reached A03F3EA 1 CAUTION Slider shoes must always be replaced in pairs A01F2MA 1 2 A ...

Page 291: ...SPENSION Subsection 03 FORMULA Z 670 SUSPENSION 07 03 10 INSTALLATION 1 Torque rod and lever bent downward CAUTION Before installing suspension small torque rod no 5 and strap axle lever must be bent down ward A03F2YT 1 ...

Page 292: ... SUSPENSION Subsection 03 FORMULA Z 670 SUSPENSION 07 03 11 RIDE ADJUSTMENT Refer to Operator s Guide LUBRICATION Lubricate front axle strap axle and swing arm lower axle using synthetic grease P N 413 7115 00 A03F2YU ...

Page 293: ...Section 07 REAR SUSPENSION Subsection 04 SKANDIC WT SUSPENSION 07 04 1 SKANDIC WT SUSPENSION 0 Skandic WT SWT WT LC TYPICAL A22F18T 1 2 3 7 4 5 6 FLAT RATE PARTS ...

Page 294: ...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 installation position conical washers as shown WASHER QUANTITY AND MOUNTING POSITION Tighten nut 3 4 turn after ...

Page 295: ...g 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 3 Horse Shoe Washer For deep snow riding do not install washer nor rubber stoppers For trail riding with passenger and or weight in stall 1 washer under each rubber stoppers For trail riding with heavy load and or pull...

Page 296: ...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 INSTALLATION Use a tie down between front arm and spring axle to ease installation of front arm screws C...

Page 297: ...Section 07 REAR SUSPENSION Subsection 05 DRIVE AXLE 07 05 1 DRIVE AXLE 0 S Series A03D20T 12 6 4 9 13 10 2 3 5 11 13 8 Summit and MX Z 583 670 only FLAT RATE PARTS ...

Page 298: ...Section 07 REAR SUSPENSION Subsection 05 DRIVE AXLE 07 05 2 Skandic WT SWT WT LC A22D14S 13 6 9 3 2 5 4 FLAT RATE PARTS ...

Page 299: ...ds 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 07 04 Remove muffler Unfasten screw from drive axle end Loosen both Allen screws from end bearing 1 Allen screws 2 Screw Remove 3 screws retaining end bearing then re move inner plate Remove drive axl...

Page 300: ...2 3 mm 11 7 64 in D 375 8 mm 14 51 64 in Skandic WT SWT WT LC 1 Gearbox side A 93 5 mm 3 43 64 in B 157 mm 6 11 64 in C 399 mm 15 45 64 in D 462 5 mm 18 13 64 in All Models Ensure to align indexing marks of each sprocket when assembling TYPICAL 1 Indexing marks aligned The maximum desynchronization for the sprock ets is 1 5 mm 1 16 in To check this tolerance place axle assembly on a plane surface ...

Page 301: ... housing bearing must be flush with end of drive axle Each bearing must have its shield facing the sprocket 1 Bearing shield on this side 2 Flush with drive axle 3 Seated on shaft shoulder AXIAL PLAY S Series Ensure there is no deformation of the sheet metal around the end bearing housing Straighten as re quired Before attempting to adjust the drive axle axial play check the chaincase perpendicula...

Page 302: ...tered in its support and easy to install This chart can be use as a starting point to cor rect the chaincase perpendicularity TYPICAL 1 Upper shim location 2 50 mm long screws when installing one shim or more 3 Lower shim location Do not reinstall the driven pulley at this time CAUTION When installing one shim or more between chaincase and frame secure with 50 mm long screws 1 2 3 A01D05A A01D06A ...

Page 303: ... 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 calculated above should be within the allowable axial play add shim s accordingly Remove drive axle install required shim s as per the shim position chart...

Page 304: ... guide cleat and slider shoe 2 Suspension front axle If the difference between each 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...

Page 305: ...ICAL DATA 10 03 Install the suspension Refer to TRACK 07 06 and adjust track tension and carry out track alignment procedure LUBRICATION 15 Grease Fitting Lubricate end housing bearing with synthetic grease P N 513 7115 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 A00F0GA...

Page 306: ...using track Skandic WT SWT WT LC Remove the following parts rear suspension muffler Drain gearbox Remove drive axle then track INSTALLATION All Models Reverse the removal procedure NOTE When installing the track respect rotation direction indicated by an arrow on track thread Check sprocket track alignment as described in DRIVE AXLE 07 05 Track Tension and Alignment Track tension and alignment are...

Page 307: ...e rear idler wheels 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 CAUTION Too much tension will result in power loss and excessive stress on suspension compo nents If too l...

Page 308: ...eat Removal Raise 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 ta...

Page 309: ... 02 4 DISASSEMBLY AND ASSEMBLY 08 02 4 INSPECTION 08 02 5 ADJUSTABLE HANDLEBAR 08 02 7 STEERING ADJUSTMENT SKIS 08 02 8 LUBRICATION 08 02 10 SUSPENSION AND SKI SYSTEM 08 03 1 DISASSEMBLY 08 03 2 INSPECTION 08 03 3 INSTALLATION 08 03 3 ON VEHICLE COMPONENT VERIFICATION 08 03 5 DISASSEMBLY 08 03 6 INSPECTION 08 03 7 INSTALLATION 08 03 7 ...

Page 310: ... 5 4 6 9 40 N m 30 lbf ft 25 N m 18 lbf ft 2 21 21 16 13 14 15 N m 133 lbf in 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 10 N m 89 lbf in FLAT RATE PARTS ...

Page 311: ...0 A15C2JT 10 N m 89 lbf in 52 N m 38 lbf ft Loctite 271 26 15 N m 133 lbf in 52 N m 38 lbf ft 18 N m 159 lbf in 52 N m 38 lbf ft Loctite 271 48 N m 35 lbf ft Loctite 271 25 N m 18 lbf ft 52 N m 38 lbf ft 31 8 9 21 21 21 22 21 21 21 15 15 18 N m 159 lbf in 21 10 21 17 FLAT RATE PARTS ...

Page 312: ... 08 STEERING FRONT SUSPENSION Subsection 02 STEERING SYSTEM 08 02 3 Skandic WT SWT WT LC TYPICAL 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 313: ...nder 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 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 elem...

Page 314: ...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 SWT WT LC Install a hardened washer on each side of the arm TY...

Page 315: ...he exploded view Skandic WT SWT WT LC Only Install steering arm at mid travel position when handlebar is facing straight ahead TYPICAL 9 13 15 Ball Joint Nut and Jam Nut 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...

Page 316: ... Equal gap all around 7 23 24 25 Steering Pad Bolt Nut and Rubber Attachment Properly fit the steering pad to the handlebar As semble using the 2 rubber attachments nuts and bolts where applicable 1 Rubber attachment 2 Nut and bolt where applicable 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 t...

Page 317: ...vot Arm With handlebar in straight ahead position the center of the pivot arm must be in line with the end of the bolt Loosen the jam nuts on tie rod no 14 LH threads on steering column end and turn tie rod accordingly Align 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 radius arms no 7 the cam...

Page 318: ...own NOTE The reference point must be the same rel ative to each side TYPICAL 1 Equal distance A on each side 2 Same reference point 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 ...

Page 319: ...skis are in a straight ahead position and the front of vehicle is lifted off the ground NOTE To make sure skis are in a straight ahead position place a straight edge against pre adjust ed track and measure the distance between 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 ...

Page 320: ...Section 08 STEERING FRONT SUSPENSION Subsection 02 STEERING SYSTEM 08 02 11 S Series A06G08T If so equipped If so equipped FLAT RATE PARTS ...

Page 321: ...3 1 SUSPENSION AND SKI SYSTEM 3 S Series A03G0IS 14 13 25 N m 18 lbf ft Loctite 242 29 N m 21 lbf ft Some models Some models 10 4 3 2 1 6 5 7 8 35 N m 26 lbf ft 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 FLAT RATE PARTS ...

Page 322: ...tion 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 loosen steering arm bolt and pull up steering arm Note shim positions Ski leg may fal...

Page 323: ... essary Check condition of ski stopper Replace it when deteriorated To check condition of shock refer to SC 10 SUS PENSION 07 02 then look for Shock Absorber Inspection INSTALLATION For assembly reverse the disassembly proce dure However pay attention to the following Apply synthetic grease P N 413 7115 00 to ski leg components Tighten nuts and screws to proper torque as men tioned in exploded vie...

Page 324: ... FRONT SUSPENSION Subsection 03 SUSPENSION AND SKI SYSTEM 08 03 4 Skandic WT SWT WT LC A22G0RS 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 Skandic SWT only Skandic SWT only FLAT RATE PARTS ...

Page 325: ...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 326: ...gs 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 Drive out...

Page 327: ...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 full com pression and exte...

Page 328: ...section 03 SUSPENSION AND SKI SYSTEM 08 03 8 Skandic SWT Only Steering arm with the bent angle toward the bot tom TYPICAL SKANDIC SWT ONLY 1 Bent angle toward the bottom 16 17 Seal All Models Install seal before reinstalling ski leg A05G0CB 1 ...

Page 329: ...02 1 DECAL 09 02 2 WINDSHIELD INSTALLATION 09 02 2 HOOD 09 02 2 BELT GUARD 09 02 3 WIRING HARNESS 09 02 3 CABLES 09 02 3 PIPING 09 02 3 PLASTIC MAINTENANCE AND REPAIR 09 02 4 MAINTENANCE 09 02 4 REPAIR 09 02 5 MATERIAL REPAIR PROCEDURE 09 02 6 REPAIR PROCEDURE FOR R I M URETHANE 09 02 6 FRAME 09 03 1 FRAME CLEANING 09 03 1 FRAME WELDING 09 03 1 FRAME COMPONENT REPLACEMENT 09 03 1 ...

Page 330: ...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 331: ...es 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 th...

Page 332: ...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 333: ...aning 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 or...

Page 334: ...N 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 WT LC Skandic SWT S Series A06H194 BOTTOM PAN Skandic WT SWT WT LC S Series A06H1A4 SIDE PANEL AND REAR MOLDING S Series A06H1...

Page 335: ...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 336: ...76 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 1 800 733 2737 CR...

Page 337: ...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 338: ...de 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 339: ...e 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 340: ...mm in 0 45 018 0 45 018 0 45 018 0 45 018 Ignition Timing BTDC mm in 1 38 054 1 81 071 1 75 069 1 93 076 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 20 0 35 0 20 0 35 0 20 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 34 509 510 VM 38 380 381 VM 4...

Page 341: ...R9ES NGK BR9ES NGK BR9ES Spark Plug Gap mm in 0 45 018 0 45 018 0 45 018 Ignition Timing BTDC mm in 1 81 071 1 75 069 1 75 069 Trigger Coil Ω 190 300 190 300 190 300 Generating Coil Ω 10 17 10 17 10 17 Lighting Coil Ω 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 Secondary kΩ 8 16 8 16 8 16 Carburetor Type PTO MAG VM 38 378 379 VM 38 386 387 VM 40 99 100 Main Je...

Page 342: ...ap mm in 0 45 018 0 45 018 0 45 018 0 45 018 Ignition Timing BTDC mm in 1 93 076 1 81 071 1 75 069 1 93 076 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 2 x VM 40 102 VM 38 H A C 384 ...

Page 343: ... Spark Plug 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 66 065 1 66 065 Trigger Coil Ω 190 300 190 300 140 180 140 180 Generating Coil Ω 10 17 10 17 230 330 230 330 Lighting Coil Ω 0 20 0 35 0 20 0 35 0 23 0 28 0 23 0 28 High Tension Coil Primary Ω 0 3 0 7 0 3 0 7 N A N A Secondary kΩ 8 16 8 16 5 1 6 3 5 1 6 3 Carburetor Type PTO MAG VM 38 382 383 V...

Page 344: ...CDI Spark Plug Make and Type NGK BR9ES Spark Plug Gap mm in 0 45 018 Ignition Timing BTDC mm in 1 81 071 Trigger Coil Ω 190 300 Generating Coil Ω 10 17 Lighting Coil Ω 0 20 0 35 High Tension Coil Primary Ω 0 3 0 7 Secondary kΩ 8 16 Carburetor Type PTO MAG VM 34 Main Jet PTO MAG 250 220 Needle Jet 159 P2 Pilot Jet 30 Needle Identification clip position 6DH4 3 Slide Cut away 2 5 Float Adjustment 1 m...

Page 345: ... 0 Length cm in 307 121 307 121 307 121 307 121 Profile Height mm in 18 4 724 23 2 913 23 2 913 23 2 913 Adjustment Deflection mm in 35 40 1 3 8 1 3 4 35 40 1 3 8 1 3 4 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 SC 10 Sport SC 10 XC SC 10 XC SC 10 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 ...

Page 346: ... 38 1 15 0 Length cm in 307 121 307 121 307 121 307 121 Profile Height mm in 18 4 724 18 4 724 23 2 913 23 2 913 Adjustment Deflection mm in 35 40 1 3 8 1 3 4 35 40 1 3 8 1 3 4 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 SC 10 Sport SC 10 Sport SC 10 Sport SC 10 HP Ski DSA DSA DSA DSA Length cm in 272 5 107 3 272 5 107 3 272 5 107 3 272 5 107 ...

Page 347: ...h cm in 307 121 345 5 136 345 5 136 345 5 136 Profile Height mm in 22 4 882 36 8 1 449 36 8 1 449 50 8 2 000 Adjustment Deflection mm in 35 40 1 3 8 1 3 4 35 40 1 3 8 1 3 4 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 FZ 670 SC 10 Mountain SC 10 Mountain SC 10 Mountain Ski DSA DSA DSA DSA Length cm in 272 5 107 3 293 9 115 7 293 9 114 9 293 9 1...

Page 348: ...in 345 5 136 345 5 136 396 8 156 2 394 155 1 Profile Height mm in 18 4 724 18 4 724 23 0 906 23 0 906 Adjustment Deflection mm in 35 40 1 3 8 1 3 4 35 40 1 3 8 1 3 4 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 SC 10 Touring Skandic WT Skandic WT Ski DSA DSA Telescopic Strut Telescopic Strut Length cm in 297 8 117 2 291 9 11...

Page 349: ...ustment Deflection 5 mm 13 64 in 32 1 1 4 Force kg lbf 11 3 25 Track Width cm in 50 0 19 7 Length cm in 396 8 156 2 Profile Height mm in 23 0 906 Adjustment Deflection mm in 40 50 1 9 16 1 31 32 Force kg lbf 7 3 16 Suspension Type Track Skandic WT Ski Telescopic Strut Length cm in 302 0 118 9 Width cm in 104 5 41 1 Height cm in 122 48 Ski Stance cm in 90 0 35 4 Mass dry kg lb 285 627 Ground Contac...

Page 350: ...ture 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 lbf ft VEHICLE LEGEN...

Page 351: ...andic WT SWT Annex 1 60 55 hal 8 27 240 Skandic WT LC Annex 2 60 55 hal 8 27 220 MX Z 440 Annex 3 60 55 hal 8 27 240 MX Z 500 583 670 Annex 4 60 55 hal 8 27 220 Formula Z 583 670 Annex 5 60 55 hal 8 27 220 Formula 500 DL 583 DL Annex 6 60 55 hal 8 27 220 Formula 500 Summit 500 583 670 Annex 7 60 55 hal 8 27 220 Grand Touring 500 583 Annex 8 60 55 hal 8 27 220 hal halogen WARNING Ensure all termina...

Page 352: ...igh beam Current returns by YELLOW BLACK wire connected to headlamp VIOLET GREY 12 volts AC Low beam WHITE 12 volts AC Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts AC Low oil level Current returns by YELLOW BLACK wire connected to oil level sensor BLUE 12 volts AC Fuel level indicator Current returns by YELLOW wire connected to fuel level sensor ORANGE...

Page 353: ...G AREA LOCATION 1 Front of engine compartment 2 Magneto 3 Carburetors 4 Near of intake silencer 5 Near driven pulley 6 Under console 7 Under hood 8 Near fuel tank 9 Rear of seat 10 Under engine XX XX A00I04C 1 02D A06H33B 1 7 6 9 8 4 5 3 2 10 XX XX A00I04D 1 02D A00E4WB B A B A B A C C B A B C D B C A A B C B C D A A ...

Page 354: ...terminal Electronic module Meter Electric motor Low level sensor Buzzer Ignition coil Normally close switch Male terminal on instrument Engine ground Spark plug Meter movement Bulb Pilot light Analog sensor Solenoid valve Magneto 3 position switch Heating element Fuse Trigger coil Battery Diode Normally open switch Frame ground Frame ...

Page 355: ...on its side Removal is done by squeezing this tab TAB CONNECTOR 1 Locking tab To remove Insert a screwdriver or Snap on TT 600 5 from 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 ...

Page 356: ... small hook pull out the lock 1 Lock 1 Lock Pry tab to free connector then pull wire out of housing MALE CONNECTOR HOUSING CUT AWAY TAB AND RECEPTACLE CONNECTORS INSTALLATION Prior to installing make sure locking tab is suffi ciently lifted to properly lock Insert tab and receptacle connectors in their re spective housings as shown in following illustra tions Push sufficiently so that they snap Tr...

Page 357: ...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 ...

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