Ski-Doo FORMULA III 1997 Shop Manual Download Page 78

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Section 03

ENGINE

Sub-Section 04

(CDI SYSTEM)

03-04-2

NOTE:

The following procedures can be done

without removing the engine from chassis. To fa-
cilitate magneto removal, hold drive pulley with
tool (P/N 529 0276 00).

CDI means Capacitor Discharge System.

CLEANING

Clean all metal components in a non-ferrous met-
al cleaner.

DISASSEMBLY

2,5, Magneto and Magneto Flywheel Nut

To gain access to magneto assembly, remove the
following parts as needed on different engines:

– tuned pipes and muffler

– rewind starter

– starting pulley

– flywheel no. 4 on 699 engine (mark position be-

fore removal)

To remove magneto flywheel retaining nut:

Use magneto puller ring (P/N 420 8760 80) modi-
fied as shown.

1. Cut by 25 mm (1 in)

Install puller with its tab in magneto housing open-
ing.

TYPICAL

1. Tab in magneto housing opening

– Remove magneto flywheel nut, using a 30 mm

socket machined to 40 mm (1.580 in) outside
diameter by 16 mm (5/8 in) long.

NOTE:

To correctly remove a threadlocked fasten-

er 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
flywheel from its taper.

6,7, Trigger Coil and Screw

Magneto and stator plate must be removed be-
fore trigger coil removal.

To replace trigger coil:

– Disconnect trigger coil connector housing.

– Remove grommet from crankcase where trig-

ger coil wire exits magneto housing.

– Remove retaining screws.

– Remove trigger coil and carefully pull wires.

– Thread magneto harness through crankcase

hole before trigger coil harness.

CAUTION

Clean stator and magneto using only a clean
cloth.

A06E23A

A06E22A

Summary of Contents for FORMULA III 1997

Page 1: ......

Page 2: ...I 1997 Shop Manual VOLUME 3 FORMULA III III LT MACH 1 Z Z LT ...

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

Page 4: ...arter 03 07 1 08 Carburetor and fuel pump 03 08 1 09 Fuel tank and throttle cable 03 09 1 04 TRANSMISSION 01 Table of contents 04 01 1 02 Drive belt 04 02 1 03 Drive pulley 04 03 1 04 Driven pulley 04 04 1 05 Pulley distance and alignment 04 05 1 06 Brake 04 06 1 07 Chaincase 04 07 1 08 Drive chain 04 08 1 05 ELECTRICAL 01 Table of contents 05 01 1 02 Wiring diagrams see Annexes at the end of this...

Page 5: ...IV 09 TECHNICAL DATA 01 SI metric information guide 09 01 1 02 Engines 09 02 1 03 Vehicles 09 03 1 04 Technical data legends 09 04 1 ANNEXES wiring diagrams SECTION SUB SECTION PAGE TABLE OF CONTENTS ...

Page 6: ... The engines and the corresponding components identified in this document should not be utilized on product s other than those mentioned in this document Torque wrench tightening specifications must be strictly adhered to Locking devices ex locking tab elastic stop nut etc must be installed or replaced with new ones when damaged If the efficiency of a locking device is impaired it must be renewed ...

Page 7: ... 1 Z Z LT TYPICAL F SERIES MODELS MODEL NUMBER FORMULA III CANADA 1148 FORMULA III U S 1149 FORMULA III EUROPE 1150 FORMULA III LT CANADA 1151 FORMULA III LT U S 1152 FORMULA III LT EUROPE 1153 MACH 1 CANADA 1177 MACH 1 U S 1178 MACH 1 EUROPE 1179 MACH Z CANADA 1180 MACH Z U S 1181 MACH Z EUROPE 1182 MACH Z LT CANADA 1183 MACH Z LT U S 1184 MACH Z LT EUROPE 1185 A06A09A 1997 BOMBARDIER SNOWMOBILES...

Page 8: ...he manual is divided into 09 major sections 01 LUBRICATION AND MAINTENANCE 02 TROUBLESHOOTING 03 ENGINE 04 TRANSMISSION 05 ELECTRICAL 06 REAR SUSPENSION 07 STEERING FRONT SUSPENSION 08 BODY FRAME 09 TECHNICAL DATA ANNEXES Each section is divided in various sub sections and again each sub section has one or more divi sion A00A0DA Model no Vehicle no 0000 00000 A06H01A 1 A00C1QA 1 1997 BOMBARDIER SN...

Page 9: ...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 A01A1QS Illustration number for publishing process Sub section title indicates beginning of the sub section Drop represents a liquid product to be applied to a surface In this case ...

Page 10: ...lection Reinstall the pulley on the countershaft by rever sing the removal procedure A03D1YA 529 0313 00 529 0312 00 A03D1ZA 529 0313 00 529 0312 00 Cam Coat cam no 18 interior with anti seize lubricant ASSEMBLY Came Slider Shoe Section 05 TRANSMISSION Sub Section 03 DRIVEN PULLEY When replacing slider shoes no 4 always install a new set 3 shoes to maintain equal pressure on the cam Assemble drive...

Page 11: ...d photos show the typical con struction of the different assemblies and in all cases may not reproduce the full detail or exact shape of the parts shown however they repre sent parts which have the same or a similar func tion As many of the procedures in this manual are in terrelated we suggest that before undertaking any task you read and thoroughly understand the entire section or sub section in...

Page 12: ...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 N m FASTENER SIZE 8 8 Lbf ft 39 29 40 30 41 30 42 31 43 M10 32 44 M10 32 45 M10 33 46 M10 34 47 M10 35 48 M10 35 49 M10 36 50 M10 37 51 M10 38 52 M10 38 53 M10 39 54 40 55 41 56 41 57 42 58 43 59 44 60 44 61 45 62 46 63 46 64 47 65 48 66 49 67 49 68 50 69 51 70 52 71 52 72 ...

Page 13: ...3 113 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 93 127 M14 94 128 M14 94 N m FASTENER SIZE 8 8 Lbf ft 129 M14 95 130 M14 96 131 M14 97 132 M14 97 133 M14 98 134 M14 99 135 M14 100 136 M14 100 137 M14 101 138 M14 102 139 M14 103 140 M14 103 141 M14 104 142 M14 105 143 M14 105 144 M14 106 145 M14 107 146 M14 108 147 M14 108 148...

Page 14: ...ment Sub section 03 08 Throttle Cable Inspection Sub section 03 09 Air Filter Cleaning This section no 4 Drive Belt Condition This section no 5 Condition of Drive and Driven Pulleys Sub sections 04 03 and 04 04 Cleaning of Drive and Driven Pulleys Sub sections 04 03 and 04 04 Retorquing of Drive Pulley Screw Sub section 04 03 Driven Pulley Preload Sub section 04 04 Brake Condition Sub section 04 0...

Page 15: ...hours or 500 km 300 mi Suspension Adjustments AS REQUIRED Section 06 See appropriate sub section and Operator s Guide Suspension Lubrication 2 Section 06 See appropriate sub section Suspension Condition Section 06 See appropriate sub section Suspension Stopper Strap Condition Section 06 See appropriate sub section Track Condition Sub section 06 04 Track Tension and Alignment AS REQUIRED Sub sectio...

Page 16: ... Follow manufac turer s instructions for proper use If above fuel stabilizer is not used drain fuel sys tem including fuel tank and carburetor s NO 3 FUEL FILTER REPLACEMENT Drain fuel tank Remove fuel line grommet from fuel tank and pull out inlet fuel line from tank TYPICAL 1 Inlet fuel line 2 Position of grommet when installing 3 Fuel filter Replace fuel filter To facilitate the fuel line insta...

Page 17: ...rts with a thick coat of grease use Endust import ed by Bristol Myers available at hardware stores or supermarkets To clean the entire vehicle including metallic parts with a thin coat of grease use Simple Green from Sunshine Makers Inc available at hardware stores or at automotive parts retailer To remove scratches on windshield or hood Start with Slip Streamer Motorcycle Windshield Heavy Duty Sc...

Page 18: ...TENTS ENGINE 02 02 1 FUEL AND OIL SYSTEMS 02 03 1 TRANSMISSION AND BRAKE SYSTEMS 02 04 1 TRANSMISSION 02 04 1 BRAKE SYSTEM 02 04 8 MECHANICAL BRAKE 02 04 8 HYDRAULIC BRAKE 02 04 9 MECHANICAL AND HYDRAULIC BRAKES 02 04 9 ELECTRICAL SYSTEM 02 05 1 SUSPENSION SYSTEM AND TRACK 02 06 1 ...

Page 19: ...st Inspection 1 Check spark plug s a Carbon accumulation caused by defective spark plug s Clean carbon accumulation and replace spark plug s 2 Check cooling system a Loose fan belt Adjust or replace fan belt refer to TECHNICAL DATA 09 b Low antifreeze level Adjust antifreeze level Then check clamps or hoses c Defective tank cap or thermostat Replace d Air in system Bleed system 3 Check ignition ti...

Page 20: ...ed fuel lines Replace defective lines c Fuel does not flow through carburetor s plastic particles in needle area and or varnish formation in carburetor s Clean carburetor s d Spark plug heat range is too warm Install spark plug s with appropriate heat range refer to TECHNICAL DATA 09 e Improper ignition timing Adjust according to specifications refer to TECHNICAL DATA 09 f Restriction in exhaust s...

Page 21: ...oil damaged oil line or defective injection pump Replace defective part s 6 Grooves on intake side of piston only a Oil film eliminated by water snow infiltration in engine Replace piston s and check if intake system leaks 7 Piston color is dark due to seizure on intake and exhaust sides a Broken or loose fan belt Replace fan belt or adjust its tension refer to TECHNICAL DATA 09 b Cooling system l...

Page 22: ...n fuel a There is water in fuel Drain fuel system then fill it with appropriate fuel 3 Check items listed in Engine runs out of fuel refer to fuel and oil system sub section 02 4 Check carburetor adjustments and cleanliness a Inadequate carburetor adjustments or dirt accumulation Adjust according to specifications refer to TECHNICAL DATA 09 or clean 5 Check drive belt a Worn belt Replace belt if w...

Page 23: ...l is low cap fails to pressurize system or air circulates through lines Adjust level replace cap or bleed cooling system SYMPTOM ENGINE DETONATION AT MAXIMUM RPM CONDITION NORMAL USE Test Inspection 1 Check which type of fuel is used a Octane number is too low and or alcohol level is too high Use recommended fuel type 2 Check spark plug type a Improper spark plug heat range Install recommended spa...

Page 24: ...times Install clean dry spark plug Start engine following usual starting procedure 5 Check fuel lines a No fuel to the engine spark plug dry when removed Check fuel tank level turn fuel valve on if applicable check fuel filter replace if clogged check condition of fuel and impulse lines and their connections 6 Check engine compression a Insufficient engine compression Replace defective part s ex p...

Page 25: ...lace 2 Check fan belt a Belt slides because it is too loose Adjust according to specifications refer to TECHNICAL DATA 09 3 Verify antifreeze level and check if there is air infiltration in the system or if there are leaks in gasket areas a Low antifreeze level or air in system b Add antifreeze until recommended level is reached bleed system and or tighten clamps at fitting 4 Check if antifreeze f...

Page 26: ...engine crankcase a Leak s Repair or replace 12 Check condition and heat range of spark plug s a Melted spark plug tip or inadequate heat range Replace SYMPTOM ENGINE EQUIPPED WITH RAVE VALVE DOES NOT REACH ITS FULL OPERATING RPM 500 TO 1000 RPM SLOWER CONDITION NORMAL USE Test Inspection 1 Check RAVE valve pistons a Valve piston s is are too far out Screw valve piston s to bottom 2 Check RAVE valv...

Page 27: ... 3 Check RAVE valve movement RAVE movement indicator P N 861 7258 00 a Valve s is are stuck in open position Clean SYMPTOM REWIND STARTER ROPE DOES NOT REWIND CONDITION NORMAL USE Test Inspection 1 Check rewind spring a Broken spring Replace spring SYMPTOM REWIND STARTER PAWL DOES NOT ENGAGE CONDITION NORMAL USE Test Inspection 1 Check stopper spring a Broken stopper spring Replace 2 Check pawl an...

Page 28: ...n ratio a Compression ratio is too high Replace inadequate part s to obtain manufacturer s recommended compression ratio or use a higher grade fuel SYMPTOM ENGINE GENERATES A LOT OF VIBRATIONS CONDITION NORMAL USE Test Inspection 1 Check engine supports a Loose broken supports or interference between support s and chassis Retighten to specification refer to TECHNICAL DATA 09 or replace 2 Check dri...

Page 29: ...Fuel flows through primer while engine runs Replace primer 4 Check float height in carburetor s a Fuel level is too high in float bowl s Adjust according to specifications refer to TECHNICAL DATA 09 5 Check needle valve a Foreign particles prevent needle valve s from closing and or worn seating area Clean or replace needle valve s then clean seating area 6 Check H A C system a Connection to atmosp...

Page 30: ...locate or replace 4 Check fuel pump flow a Dried diaphragm Replace 5 Check if carburetor s is are clean a Varnish Clean SYMPTOM HIGH INJECTION OIL CONSUMPTION CONDITION NORMAL USE Test Inspection 1 Check oil injection pump adjustment a Oil injection pump adjusted too rich Adjust 2 Check injection oil lines and their fitting a Leaking lines and or cover Replace defective part s 3 Check injection pu...

Page 31: ...r fittings or are improperly rooted Replace or properly relocate lines 3 Check fuel pump outlet flow a Dirt clogging fuel pump lines or torn membrane Clean or replace fuel pump 4 Check carburetor needle valve s a Dirt varnish foreign particle clogging fue 1 b I line inlets Clean 5 Check main jet a Dirt varnish foreign particle accumulation at main jet Clean 6 Check float height in carburetor bowl ...

Page 32: ...8 less than a new one refer to TECHNICAL DATA 09 2 Check distance between pulleys and or drive belt deflection a Distance is too small between pulleys or deflection is too high drive belt engagement is higher in drive pulley Adjust distance between pulleys and or drive belt deflection according to specifications refer to TECHNICAL DATA 09 3 Check driven pulley sliding half play a Jammed sliding ha...

Page 33: ...djust according to specification refer to TECHNICAL DATA 09 3 Check position of the calibration screws TRA drive pulley a Selected numbers are too high Adjust according to specification refer to TECHNICAL DATA 09 4 Refer to Vibrations originating from driven pulley and check items listed SYMPTOM LOOSENESS IS FELT IN DRIVE SYSTEM WHEN ACCELERATING DECELERATING CONDITION NORMAL USE Test Inspection 1...

Page 34: ...estrains sliding half movement Retighten bolts 4 Check spring cover TRA TYPE and or outer half bushings a Excessive gap between bushings and inner half shaft thus restraining sliding half movements Replace bushing s 5 Check sliding half slider shoes a Worn slider shoes Replace SYMPTOM VIBRATIONS ORIGINATING FROM DRIVEN PULLEY CONDITION NORMAL USE Test Inspection 1 Check sliding half play a Sliding...

Page 35: ...sion is too weak Replace SYMPTOM IT IS DIFFICULT TO ENGAGE TRANSMISSION IN FORWARD OR REVERSE GEAR CONDITION NORMAL USE Test Inspection 1 Check position of gear shift lever adjustment screw a Improper adjustment Adjust according to specifications refer to TRANSMISSION 04 SYMPTOM UNEVEN BELT WEAR ON ONE SIDE ONLY CONDITION NORMAL USE Test Inspection A00D09Y 1 Check tightening torque of engine mount...

Page 36: ...eck if pulley halves are clean a Oil on pulley surfaces Clean pulley halves 4 Check pulley calibration a Improper pulley calibration Calibrate according to specification SYMPTOM BELT WORN EXCESSIVELY IN TOP WIDTH CONDITION NORMAL USE Test Inspection A00D0BY 1 Check drive pulley a Excessive slippage due to irregular outward actuation movement of drive pulley Carry out drive pulley inspection 2 Chec...

Page 37: ...a Engine idle speed too high Adjust according to specification 5 Check drive belt length a Incorrect belt length Replace belt with an appropriate drive belt refer to TECHNICAL DATA 09 6 Check distance between pulleys a Incorrect pulley distance Readjust according to specification A00D0CY 7 Check belt deflection a Deflection is too small Adjust according to specification SYMPTOM BELT SIDES WORN CON...

Page 38: ...CONDITION NORMAL USE Test Inspection A00D0FY 1 Check pulley alignment a Pulley misalignment Align pulley according to specifications refer to TECHNICAL DATA 09 SYMPTOM FLEX CRACKS BETWEEN COGS CONDITION NORMAL USE Test Inspection A00D0GY 1 Check drive belt condition a Considerable use belt wearing out Replace SYMPTOM SHEARED COGS COMPRESSION SECTION FRACTURED OR TORN CONDITION NORMAL USE Test Insp...

Page 39: ...drive belt SYMPTOM BRAKE DOES NOT ADJUST AUTOMATICALLY CONDITION NORMAL USE Test Inspection 1 Check ratchet wheel spring a Broken ratchet wheel tag Replace 2 Check mobile pad stud a Stud rotates in pad Replace SYMPTOM BRAKE HANDLE DOES NOT RETURN COMPLETELY CONDITION NORMAL USE Test Inspection 1 Check brake return spring a Broken return spring Replace 2 Check if brake cable moves freely in its hou...

Page 40: ...luid and bleed system If problem still occurs replace master cylinder SYMPTOM BRAKE FLUID LEAKING CONDITION NORMAL USE Test Inspection 1 Check for loosen hose connectors Retighten 2 Check for damaged hose master cylinder and caliper Replace part s and check for proper mounting SYMPTOM BRAKE SYSTEM IS NOISY CONDITION NORMAL USE Test Inspection 1 Check brake pad thickness a Pads are worn up to wear ...

Page 41: ...een starter switch and solenoid a Open circuit between starter switch and solenoid switch Repair SYMPTOM STARTER TURNS BUT DOES NOT CRANK THE ENGINE CONDITION NORMAL USE Test Inspection 1 Check battery capacity a Shorted battery cell s Replace 2 Check battery charge a Weak battery Recharge 3 Check wire connection a Inadequate connection too much resistance Clean and reconnect 4 Check solenoid swit...

Page 42: ...ted armature Repair or replace armature 12 Check tension of brush springs a Weak brush spring tension Replace springs 13 Check yoke assembly magnets a Weak magnets Replace yoke assembly 14 Check if bushings are worn a Worn bushings Replace bushings SYMPTOM STARTER TURNS BUT OVERRUNNING CLUTCH PINION DOES NOT MESH WITH RING GEAR CONDITION NORMAL USE Test Inspection 1 Check clutch pinion gear a Worn...

Page 43: ...k on splines Clean 3 Check ignition switch a Ignition switch does not return to its ON position or is short circuited Adjust retaining screw or replace switch 4 Check solenoid a Shorted solenoid switch winding s Replace solenoid switch 5 Check solenoid switch contacts a Melted solenoid switch contacts Replace solenoid switch 6 Check starter switch a Starter switch returns poorly Replace ignition s...

Page 44: ...ectric starter a Shorted solenoid wiring harness or eroded contact washer Replace SYMPTOM HEADLAMP NOT LIGHTING CONDITION WHITE BULB Test Inspection 1 Check bulb a Gas leak Replace bulb CONDITION BROKEN ELEMENT Test Inspection 1 Check for loose headlamp housing and bulb socket a Vibration problem Tighten headlamp mounting screws Lock bulb in socket Replace bulb CONDITION MELTED FILAMENT ENDS OF EL...

Page 45: ... a Faulty installation of optional equipment Find optional equipment connected directly to DC ground BK wire or chassis or to any DC hot wire RD RD BL Disconnect and reconnect to AC current YL and YL BK wires 5 Verify if optional electric accessories are overloading the magneto generator a Excessive electrical load to magneto generator Reduce the electrical load by removing excess accessories Reco...

Page 46: ...rify spark plug condition a Defective improperly set worn out fouled Identify source of problem and correct Replace spark plug 2 Verify spark plug cap resistance with an ohmmeter a Defective part Replace cap 3 Verify if problem originated from electrical system wiring harness and or accessories and or ignition cut out switches by unplugging the 4 wire connectors between the magneto generator and t...

Page 47: ... MISFIRING ERRATIC SPARK AT SPARK PLUG CONDITION RIDING ON WET SNOW Test Inspection 1 Verify if spark plug wires and or spark plug cap seals are sealing out moisture a Defective wires and or seals Replace defective part 2 Verify if ignition system wiring harness connectors are in good condition and or are sealing out moisture a Loose connectors corroded terminals or defective parts Clean terminals...

Page 48: ...cifications refer to TECHNICAL DATA 09 2 Check injection oil consumption a Injection pump flow is too high Adjust according to specification or replace 3 Check oil quality a Poor oil quality that creates deposits Use Bombardier oil 4 Check engine compression a Leaking piston ring s Replace SYMPTOM SPARK PLUG TIP S IS ARE LIGHT GREY CONDITION NORMAL USE Test Inspection 1 Refer to Engine slows down ...

Page 49: ...GHT BULB FLASHES CONDITION NORMAL USE Test Inspection 1 Check bulb tightness in housing a Looseness at bulb contact elements Install bulb correctly 2 Check if rear light is properly connected a Connector housing is partially connected Install connector housing properly 3 Check continuity of wires a Corroded terminals and or broken wires Replace terminal s or crimp defective wires SYMPTOM TACHOMETE...

Page 50: ...AL DATA 09 Replace defective parts SYMPTOM TRACK CLEATS BECOME BLUE CONDITION NORMAL USE Test Inspection 1 Check track tension a Pressure is too great on cleats Adjust according to specifications refer to TEHNICAL DATA 09 2 Check slider shoes and or suspension retaining screws a Worn slider shoes or lost retaining screws Replace defective parts and or tighten loose screws SYMPTOM NOISE OR VIBRATIO...

Page 51: ...ght Adjust 2 Check if axles are properly lubricated a Improper lubrication and or contaminated grease sticky oil sludge Clean and or lubricate 3 Check rear spring preload a Insufficient preload Increase preload using shock adjustment cams SYMPTOM WHEN HANDLEBAR IS TURNED SNOWMOBILE UNDERSTEERS CONDITION NORMAL USE Test Inspection 1 Check ski runner condition a Worn ski runners Replace 2 Check tens...

Page 52: ...ension is weak more weight is transferred to the skis Increase spring preload 4 Check condition of ball joints a Corrosion restrains movement Lubricate or replace 5 Check swing arm camber liquid cooled models a Too much ski leg inclination Adjust camber to 0 5 SYMPTOM THE SNOWMOBILE IS UNSTABLE IT MOVES FROM LEFT TO RIGHT AND VICE VERSA CONDITION NORMAL USE Test Inspection 1 Check ski runner condi...

Page 53: ... PROCEDURE 03 03 1 FINALIZING REASSEMBLY 03 03 4 COOLING SYSTEM LEAK TEST 03 03 4 ENGINE LEAK VERIFICATION FLOW CHART 03 03 5 ENGINE DIMENSION MEASUREMENT 03 03 6 CYLINDER TAPER 03 03 6 CYLINDER OUT OF ROUND 03 03 6 CYLINDER PISTON CLEARANCE 03 03 6 RING PISTON GROOVE CLEARANCE 03 03 7 RING END GAP 03 03 7 CRANKSHAFT DEFLECTION 03 03 7 CONNECTING ROD BIG END AXIAL PLAY 03 03 8 CONNECTING ROD PISTO...

Page 54: ...URE 03 06 3 REWIND STARTER 03 07 1 REMOVAL 03 07 2 DISASSEMBLY 03 07 2 ASSEMBLY 03 07 2 INSTALLATION 03 07 4 CARBURETOR AND FUEL PUMP 03 08 1 REMOVAL 03 08 3 CLEANING AND INSPECTION 03 08 3 IDENTIFICATION 03 08 3 DISASSEMBLY AND ASSEMBLY 03 08 4 CARBURETOR FLOAT LEVEL ADJUSTMENT 03 08 5 INSTALLATION 03 08 6 CARBURETOR ADJUSTMENTS 03 08 7 PRELIMINARY IDLE SPEED ADJUSTMENT 03 08 10 IDLE SPEED FINAL ...

Page 55: ...599 699 AND 809 ENGINE TYPES 03 02 1 599 699 AND 809 ENGINE TYPES 0 ENGINE REMOVAL AND INSTALLATION All Models ROTAX A06C0TS 37 N m 27 lbf ft 35 N m 26 lbf ft 29 N m 21 lbf ft 15 N m 133 lbf in 10 N m 98 lbf in 1 2 3 4 PARTS FLAT RATE ...

Page 56: ...impulse lines from engine 1 2 3 4 Engine Support Nut and Manifold Screw Torque the engine support nuts to 35 N m 26 lbf ft Torque rubber mount support bracket to 29 N m 21 lbf ft Torque rubber mount support nuts to 37 N m 27 lbf ft Torque manifold screws to 10 N m 89 lbf in INSTALLATION ON VEHICLE To install engine on vehicle reverse removal pro cedure However pay attention to all appropriate comp...

Page 57: ...02 3 TOP END A06C3MS 10 N m 89 lbf in 30 N m 22 lbf ft Loctite 242 P N 413 7030 00 29 N m 21 lbf ft Grease 29 N m 21 lbf ft Grease 809 only 809 only Molykote 111 P N 413 7070 00 10 N m 89 lbf in 12 1 2 13 14 10 8 17 6 5 4 3 7 Grease 11 15 16 9 Grease FLAT RATE PARTS ...

Page 58: ...on no 12 Use piston pin puller P N 529 0210 00 Unscrew puller in order to remove piston pin no 14 and cage bearing no 15 from piston Remove piston from connecting rod 809 Engine On this engine piston pin needle bearing no 16 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 crankcas...

Page 59: ...Passages NOTE Oil dripping from draining hole indicates a loosen clamp or damaged bellows 17 Bellows Check for cracked dried or perforated bellows 5 Spring ASSEMBLY RAVE System Install rave valve with its mention top as illustrat ed in the removal photo Tighten red cap screw to bottom 11 12 Cylinder and Piston NOTE Be sure to restore the chamfer around all cylinder sleeve port openings Before inse...

Page 60: ...all piston pin puller P N 529 0210 00 and turn handle until piston pin is correctly posi tioned in piston Remove piston pin puller 809 Engine When reinstalling original needle bearings make sure that 31 needles are inserted between expan sion sleeve and locating sleeve 1 Expansion sleeve 2 31 needles 3 Locating sleeves Grease thrust washers and install them on each end of needles Using a 21 mm 826...

Page 61: ...e halves Use piston pin puller P N 529 0210 00 to insert piston pin Plastic halves should come off piston If not pull them using long nose pliers All Engines To minimize the effect of acceleration forces on circlip install each circlip so the circlip break is at 6 o clock as illustrated Use piston circlip installer P N 529 0169 00 TYPICAL 1 Place circlip in 2 Restrain 3 Oil TYPICAL 1 Circlip break...

Page 62: ... check for proper cylinder alignment At assembly torque cylinder head screws in the following illustrated sequence Tightening torques are M6 screws 12 N m 106 Ibf in M8 screws 30 N m 22 Ibf ft TYPICAL A06C1PA A06C1QA 16 A06C0GA 18 14 5 2 3 9 8 12 17 19 15 13 20 4 1 6 11 7 10 ...

Page 63: ...e lubricant P N 413 7010 00 A06C3PS Loctite 242 Loctite 648 Molykote 111 P N 413 7070 00 Silicone 732 RTV 10 N m 90 lbf in Loctite 242 Loctite 242 Primer N Loctite 515 M6 12 N m 106 lbf in M8 30 N m 22 lbf ft 1 2 2 3 3 3 Grease 4 7 10 N m 90 lbf in 599 and 699 only 4 6 8 9 5 FLAT RATE PARTS ...

Page 64: ...l puller as illustrated 1 PTO side 2 MAG side INSPECTION NOTE Refer to LEAK TEST AND ENGINE DI MENSIONS MEASUREMENT 03 03 1 Reed Valve With blade stopper removed check reed valve for proper tightness There must be no play between blade and valve body when exerting a finger pres sure on blade at blade stopper location In case of a play turn blade up side down and re check If there is still a play r...

Page 65: ...ctory matched and therefore are not inter changeable as single halves Prior to joining of crankcase halves spray some new injection oil or equivalent on all 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 on the other mating surface NOTE Primer N allows Loctite 515 to fully cure on aluminum s...

Page 66: ... mix ture will lubricate water pump bearings by scav enging 6 Screw Apply Loctite 242 on screw threads Install the screw retaining oil line clip first If experiencing leaks at carburetor adaptor use primer N and Loc tite 515 on sealing surfaces of crankcase and adaptor 7 Seal Install seal using pusher P N 420 8765 16 8 9 Plastic Gear and Steel Gear Apply grease to needle bearing of each gear Insta...

Page 67: ...NOTE Do not block large hoses of rotary 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 B D C Bottom Dead Center on side where the pump is installed This will open exhaust port 9 Activate pump and pressurize engine to 34 kPa 5 PSI Do not exceed this pressure 10 Engine...

Page 68: ...surfaces and screw stud threads of engine spark plug base insulator cylinder head cylinder base crankcase halves joint rotary valve cover oil injection pump mounting flange O ring seal coolant pump housing bleed screws plugs 2 Small injection oil lines coming from pump 1 Banjo fittings 2 Small injection oil lines Check for air bubbles or oil column going toward pump It indicates defective check va...

Page 69: ...ary Valve Gear Reservoir Block one hose of rotary valve gear lubrication system with a hose pincher and install an adapter in remaining hose Install air pump on adapter and pressurize as be fore 1 Blocked hose 1 Remove a spark plug or any plug of leak tester kit on PTO side If pressure drops it indicates defective crank shaft inner seal on PTO side 2 Remove a spark plug or any plug of leak tester ...

Page 70: ...ings Pay attention to tapped holes which may go through engine sealed area and thus leading to leakage FINALIZING REASSEMBLY After reassembling engine always recheck for leakage COOLING SYSTEM LEAK TEST Install special plug radiator cap P N 529 0214 00 and hose pincher P N 529 0099 00 on overflow hose Pressurize all system through coolant reser voir to 15 PSI Check all hoses and cylinder base for ...

Page 71: ...TARY VALVE GEAR RESERVOIR IN CRANKCASE ARE SEALS LEAKING CHECK CRANKSHAFT OUTER SEAL OF PTO AND MAG SIDES PRESSURIZE ROTARY VALVE GEAR RESERVOIR IN CRANKCASE IS RESERVOIR LEAKING UNSEAL PTO CYLINDER AND MAG CYLINDER SEPARATELY IS RESERVOIR LEAKING IS RESERVOIR LEAKING CHECK LEAKAGE AT DRAIN HOLE BELOW COOLANT PUMP HOUSING ANY LEAK FOUND REPLACE DEFECTIVE SEAL S REPLACE DEFECTIVE SEAL S REPLACE OIL...

Page 72: ... from top of cylinder with a cylinder gauge check if the cylinder out of round is more than the specified dimension If larger cylinder should be rebored and honed or should be replaced NOTE Be sure to restore the chamfer around all cylinder sleeve port openings 1 Piston pin position 2 Measures to be compared A 16 mm 5 8 in CYLINDER PISTON CLEARANCE Measurement used parts Check cylinder taper and o...

Page 73: ...nd groove Replace piston If clearance exceeds specified tolerance Refer to TECHNICAL DATA 09 02 RING END GAP Position ring half way between transfer ports and intake port On rotary valve engines position ring just below transfer ports NOTE In order to correctly position the ring in the cylinder use piston as a pusher Using a feeler gauge check ring end gap Replace ring If gap exceeds specified tol...

Page 74: ...aft NOTE Crankshaft deflection can not 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 measure distance between thrust washer and crankshaft counterweight If the distance exceeds specified tolerance repair or replace the crankshaft TYPICAL CONNECTING R...

Page 75: ... the sand paper Rub manifold mating surface on sand paper using 8 figure movements Sand until mating surface is perfectly straight CHECKING CRANKSHAFT ALIGNMENT Install a degree wheel P N 414 3529 00 on crank shaft end Remove all spark plugs Install a TDC gauge P N 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 ali...

Page 76: ...AK TEST AND ENGINE DIMENSION MEASUREMENT 03 03 10 Interval between cylinders must be exactly 120 Proceed the same for MAG side piston Any other reading indicates a misaligned twisted crankshaft 0 90 80 70 60 50 40 30 20 10 180 0 A06C1TA ...

Page 77: ...OIL IGNITION SYSTEM 599 699 and 809 Engines A06E29S Dielectric grease P N 413 7017 00 Dielectric grease P N 413 7017 00 Silastic 732 1 7 6 Loctite 242 4 22 N m 195 lbf in Loctite 242 5 125 N m 92 lbf ft Loctite 648 2 Loctite 242 Dielectric grease P N 413 7017 00 699 Only FLAT RATE PARTS ...

Page 78: ... in magneto housing opening Remove magneto flywheel nut using a 30 mm socket machined to 40 mm 1 580 in outside diameter by 16 mm 5 8 in long NOTE To correctly remove a threadlocked fasten er 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...

Page 79: ...eler gauge of 0 75 mm 030 in min 0 55 mm 022 in and max 1 45 mm 057 in thick check air gap between center pole of trig ger coil and flywheel protrusion 3 If necessary adjust by slackening retaining screws and moving trigger coil toward or away of protrusion 4 Retighten screws and recheck air gap ADJUSTING TRIGGER COIL AIR GAP 1 Trigger coil 2 Flywheel protrusion 3 Measure at center pole of trigger...

Page 80: ...aper then position Woodruff key flywheel and lock washer on crankshaft Clean nut threads and apply Loctite 242 blue then tighten nut 125 N m 92 lbf ft At reassembly coat all electric connections with silicone dielectric grease P N 413 7017 00 to pre vent corrosion or moisture penetration Ignition Timing Check as described in IGNITION TIMING 05 03 A15E0OA 1 A06C1BA 420 8765 14 CAUTION Do not use si...

Page 81: ...tion 03 ENGINE Sub Section 05 OIL INJECTION SYSTEM 03 05 1 OIL INJECTION SYSTEM 0 OIL INJECTION PUMP 599 699 and 809 Engines A06C3IS 1 2 Loctite 648 6 6 6 6 7 5 N m 44 lbf in Loctite 242 3 FLAT RATE PARTS ...

Page 82: ...low tem perature grease P N 413 7061 00 on gear teeth 5 6 Spring Clip and Clamp Always check for spring clips tightness 3 Screw Torque to 5 N m 44 lbf in Make sure cable barrel is well seated in oil pump lever Secure barrel with plastic washer and circlip Verify cable and oil pump lever operation ADJUSTMENT Prior to adjusting the pump make sure all carbu retor adjustments are completed Synchronizi...

Page 83: ...il lines 2 Bleeder screw 3 Main oil line Reinstall all parts 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 Make a J hook out of mechanical wire to lift the lever TYPICAL ENGINE AT IDLE CAUTION Proper oil injection pump adjustment is very important Any delay in the opening of the pump can result in seriou...

Page 84: ... AT IDLE 1 Oil columns advancing 2 Fully open position If not remove pump assembly and check the pump gear and drive shaft if applicable for de fects replace as necessary Test pump as de scribes below NOTE Through normal use oil level must not drop in small tubes If oil drops verify check valve operation in injection nozzle Replace as neces sary Oil Pump Test Bench Connect a hose filled with injec...

Page 85: ...Section 03 ENGINE Sub Section 06 LIQUID COOLING SYSTEM 03 06 1 LIQUID COOLING SYSTEM 0 599 699 and 809 Engines ROT A06C3HS 1 2 4 5 3 Loctite 592 6 7 FLAT RATE PARTS ...

Page 86: ... Protector Insert radiator protector into radiator C rail and crimp C rail at both ends Refer to FRAME 08 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 The thermostat is a double action type a Its function is to give faster warm up of the en gine by controlling a circuit water pump en...

Page 87: ...f 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 09 Refilling Procedure With vehicle on a flat surface engine cold refill coolant tank up to cold level mark Wait a few min utes then refill to mark Install pressure cap Run engine until thermostat opens ...

Page 88: ...Sub Section 07 REWIND STARTER 03 07 1 REWIND STARTER 0 All Models A06C3GS 12 11 10 9 8 6 7 5 4 13 2 3 1 Silicone compound grease Silicone compound grease 10 N m 89 lbf in Molykote G n paste or equivalent FLAT RATE PARTS ...

Page 89: ... 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 guide it may fly out when rewind is handled...

Page 90: ... accessible through starter housing orifice Pull the rope out of the starter housing 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 rin...

Page 91: ...pe no 6 through rope guide when applicable Reinstall rewind starter assembly on engine Prior to installing starter grip no 13 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 A01C18A ...

Page 92: ...ection 03 ENGINE Sub Section 08 CARBURETOR AND FUEL PUMP 03 08 1 CARBURETOR AND FUEL PUMP 0 Formula III III LT and Mach 1 A03C1MT 6 13 10 8 11 12 9 7 1 2 3 4 5 14 To other carburetors 15 FLAT RATE PARTS ...

Page 93: ...Section 03 ENGINE Sub Section 08 CARBURETOR AND FUEL PUMP 03 08 2 A06C38T 1 2 4 3 7 5 10 13 12 8 9 6 Carburetor TM 38 C159 FLAT RATE PARTS ...

Page 94: ...ip condition 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 idle speed screw straightness Replace as necessary Check for fuel soaked into float no 12 replace as necessary Check float for cracks or other damages af...

Page 95: ...carburetor raise throttle slide half way then unscrew Allen screws 1 Allen screw 2 Arm moved aside 3 Locking screw and adjusting nut removed All Models The position of the needle in the throttle slide is adjustable by means of an E clip inserted into 1 of 5 grooves located on the upper part of the needle Position 1 at top is the leanest 5 at bottom the richest NOTE The last digit of the needle ide...

Page 96: ...loat arm is symetric not dis tored Remove float bowl and gasket from carburetor All Models Except Mach Z Z LT With carburetor chamber upside down on a lev el surface measure height H between bowl seat and top edge of float arm Keep ruler per fectly vertical and in line with main jet hole TYPICAL H Float height including float arm thickness 1 Ruler vertical and in line with main jet Mach Z Z LT Do ...

Page 97: ...buretor and air intake silencer if applicable with notch of adaptor s On applicable models in stall adaptor with up mark facing up Install clamps in a way that their tightening bolts are staggered 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 ...

Page 98: ...turning it out counterclockwise leans mixture Refer to TECHNICAL DATA 09 02 for the specifi cations Carburetor Synchronization All Models Except Mach Z Z LT All carburetor slides must start to open at the same time Completely unscrew idle speed screw on all car buretors Unlock cable adjustment lock nut then screw in adjuster until throttle slide bottoms out Proceed the same for all carburetors Uns...

Page 99: ... for MAG carb and turn adjust ing nuts accordingly Tighten locking screws and recheck synchroniza tion 1 No adjustment on MAG side carburetor 2 Locking screws 3 Adjusting nut NOTE When using a vacuum gauge or a cylinder balancer or a Unisyn tool for checking carburetor synchronization always remove 3 carburetor cov ers Full Throttle Adjustment To avoid stress on throttle cable when throttle le ver...

Page 100: ... the same amount All Models Except Mach Z Z LT Throttle slide must be flush or 1 0 mm 040 in lower than the top of carburetor oulet bore en gine side THROTTLE LEVER AGAINST HANDLE GRIP 1 Throttle cable adjuster 2 Throttle slide flush or 1 0 mm 040 in lower than carburetor oulet bore engine side Once carburetor adjustment is performed check that with the throttle lever fully depressed there is a fr...

Page 101: ...buretors to keep carburetors synchro nized Refer to TECHNICAL DATA 09 02 for the specifi cations CHOKE All Models Except Mach Z Z LT Choke Plunger Adjustment Set choke lever to fully open position CHOKE LEVER FULLY OPEN POSITION Insert choke plunger tool into choke air inlet of each carburetor WARNING This gap is very important If the throttle slide rests against the carburetor cover at full throt...

Page 102: ...Lift up protector cap and loosen choke cable lock nut as shown in the next photo 1 Lift up protector cap 2 Loosen lock nut Set choke lever to fully open position Turn choke cable adjustment nut by hand until tool properly seats under choke plunger NOTE A light pressure should be needed to posi tioned tool under plunger 1 Choke cable adjustment nut 2 Choke plunger tool Tighten choke cable lock nut ...

Page 103: ...c grease P N 413 7017 00 on choke rod and reinstall it with its retrun spring and spacer on PTO side Make sure that ferrule screws align with each rod hole Tighten screws to 2 N m 18 lbf in 1 Spacer and spring on PTO side 2 Ferrule screw aligned with rod hole 3 Dielectric grease Apply dielectric grease P N 413 7017 00 on cable housing end All 3 plungers must start to open at the same time Bend fer...

Page 104: ...ng er a rich condition will occur and throttle response will be affected if the gap is too great the plunger stroke will be reduced causing poor cold engine starting If adjustment is required loosen cable support on middle carburetor to change choke cable position 1 Choke cable support After adjustment retighten screw A06C2MB 1 A06C2OA 1 ...

Page 105: ...Section 03 ENGINE Sub Section 08 CARBURETOR AND FUEL PUMP 03 08 14 FUEL PUMP All Models A06C3SS ...

Page 106: ... 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 ...

Page 107: ...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 108: ... 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 cir cuitry Remove seat to...

Page 109: ... 5 ASSEMBLY 04 03 6 INSTALLATION 04 03 8 DRIVE PULLEY ADJUSTMENT 04 03 9 DRIVEN PULLEY 04 04 1 REMOVAL 04 04 2 DISASSEMBLY 04 04 2 CLEANING 04 04 2 INSPECTION 04 04 2 ASSEMBLY 04 04 4 INSTALLATION 04 04 4 ADJUSTMENT 04 04 5 PULLEY DISTANCE AND ALIGNMENT 04 05 1 GENERAL 04 05 1 GENERAL PROCEDURE 04 05 1 PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART 04 05 2 BRAKE 04 06 1 HYDRAULIC DISC BRAKE 04...

Page 110: ...ction 01 TABLE OF CONTENTS 04 01 2 CHAINCASE 04 07 1 REMOVAL 04 07 2 INSPECTION 04 07 2 GEAR RATIO MODIFICATION 04 07 2 INSTALLATION 04 07 2 DRIVE CHAIN ADJUSTMENT 04 07 3 ADJUSTMENT 04 07 4 DRIVE CHAIN 04 08 1 SILENT CHAIN 04 08 1 ...

Page 111: ...of rotation is respect ed CORRECT INCORRECT NOTE For used drive belt mark and reinstall in the same position MODEL PART NUMBER WIDTH NEW 0 25 mm 010 in MINIMUM WIDTH WEAR LIMIT FORMULA III III LT MACH 1 Z Z LT 415 0603 00 35 mm 1 3 8 33 mm 1 19 64 BOMBARDIER FABRIQUÉAU CANADA MADE IN CANADA BOMBARDIER FABRIQUÉAU CANADA MADE IN CANADA A01D2KA BOMBARDIER FABRIQUÉ AU CANADA MADE IN CANADA BOMBARDIER ...

Page 112: ...the accompanying chart FOR REFERENCE ONLY To Check Tension Position a reference rule on drive belt Wooden Stick and Spring Scale Method 1 Mark specified deflection Using spring scale and stick apply specified force on drive belt halfway between pulleys as shown 1 Force 2 Read deflection here 3 Reference rule Or use the belt tension tester P N 414 3482 00 1 Lower O ring 2 Upper O ring 3 Force Read ...

Page 113: ...s 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 Allen...

Page 114: ...ls NOTE This is a lubrication free drive pulley 12 N m 106 lbf in 13 N m 115 lbf in 95 N m 70 lbf ft 10 N m 89 lbf in Repair kit A06D1ZS 5 6 7 9 12 11 12 13 14 15 16 17 16 Loctite 648 18 Loctite 648 19 20 21 22 23 25 24 27 26 25 29 32 30 31 95 N m 70 lbf pi 28 Loctite 648 FLAT RATE PARTS ...

Page 115: ...y ass y and or fixed half from engine use puller P N 529 0224 00 CAUTION Such modifications should only be per formed by experienced mechanics since they can greatly affect vehicle performance Verify spring specifications before installa tion Do not only refer to the spring color code WARNING Any drive pulley repairs must be performed by an authorized Bombardier snowmobile dealer or other such qua...

Page 116: ...ry mark and arrows as indexing reference 25 29 Slider Shoe and Governor Cup Carefully lift governor cup until slider shoes come at their highest position into guides Hold a slider shoe set then carefully lift its housing and remove them Proceed the same way for other housings lifting one at a time 32 Cushion Drive 1 Hold slider shoes 2 Lift one housing at a time NOTE To ease disassembly forks P N ...

Page 117: ...eads and retaining screw threads Remove all harden oil deposits that have baked on crankshaft and pulley tapered surfaces with coarse or medium steel wool and or sand paper no 600 Reclean mounting surfaces with paper towel and cleaning solvent P N 413 7082 00 Wipe off the mounting surfaces with a clean dry paper towel 7 20 Bushing Only use petrol base cleaner when cleaning bush ings WARNING Clutch...

Page 118: ...is 0 5 mm 020 in measured at calibration screw radius Replace if required 7 20 Sliding Half and Spring Cover Bushing Visually inspect coating Replace if worn Sliding Half Bushing Replacement These bushings can be replaced using tools which are not available at time of printing Spring Cover Bushing Replacement Under normal use there is no need to replace this bushing Use tools P N 529 0313 00 and 5...

Page 119: ... screw make sure to in stall washer as shown 1 Washer Torque locking nut to 10 N m 89 lbf in 15 Pin Always use the same type of pin as originally in stalled when servicing Different types have dif ferent weights for calibration purpose Refer to TECHNICAL DATA 09 03 21 22 23 Ramp Dowel Tube and Screw Insert dowel tube from chamfered side Make sure ramp is centered on dowel tube 1 Chamfered side Pos...

Page 120: ...er arrow with sliding half mark 1 Align Install and torque screws to 13 N m 115 lbf in 6 25 29 Sliding Half Slider Shoe and Governor Cup To install governor cup use following tool Insert spring and slider shoes into governor cup so that groove in each slider shoe is vertical to properly slide in guides Install fork P N 529 0055 00 into slider shoe grooves to maintain them for governor cup instal l...

Page 121: ...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 122: ... screw has a notch on top of its head 1 Notch Governor cup has 6 positions numbered 2 to 6 Note that in position 1 there is no stamped num ber due to its location on casting See TECHNICAL DATA 09 03 for original setting 1 Position 1 not numbered Each number modifies maximum engine RPM by about 200 RPM Lower numbers decrease engine RPM in steps of 200 RPM and higher numbers increase it in steps of ...

Page 123: ...Section 04 TRANSMISSION Sub Section 03 DRIVE PULLEY 04 03 10 1 Loosen just enough to permit rotating of calibration screw A16D0HA 1 ...

Page 124: ...ION Sub Section 04 DRIVEN PULLEY 04 04 1 DRIVEN PULLEY 0 F Series A06D22S 14 15 2 3 19 18 5 4 8 Loctite 609 6 7 9 10 17 11 12 13 16 Anti seize lubricant P N 413 7010 00 Anti seize lubricant P N 413 7010 00 FLAT RATE PARTS ...

Page 125: ...e Bushing and Small Bushing During break in period about 10 hours of use te flon from bushing moves to cam or shaft surface A teflon over teflon running condition occurs leading to low friction So it is normal to see gray teflon deposit on cam or shaft Do not remove that deposit it is not dust When a dust deposit has to be removed from the cam or the shaft use dry cloth to avoid removing transferr...

Page 126: ... half Place puller P N 529 0311 02 below bushing 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 529 031...

Page 127: ...disassembly procedure 19 Cam Coat cam interior with anti seize lubricant INSTALLATION 14 15 Countershaft and Anti seize Lubricant Should installation procedure be required refer to BRAKE 04 06 then look for Brake Disc and Coun tershaft Bearing Adjustment Reinstall the pulley on the countershaft by revers ing the removal procedure Check end play of driven pulley on countershaft by pushing pulley to...

Page 128: ... with 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 s...

Page 129: ...o install proper cam Refer to TECHNI CAL DATA 09 03 Cam angle is identified on cam NOTE For high altitude regions the High Altitude Technical Data Booklet P N 484 0648 00 and 484 0545 00 for binder gives information about cali bration according to altitude CAUTION Drive belt and pulley adjustments must always be checked whenever pulleys have been re moved replaced or disassembled B O M BARDIER 6 5...

Page 130: ...e diameter of pul leys GENERAL PROCEDURE Remove belt guard and drive belt By turning and pushing the sliding half open the driven pulley Insert a straight bar 9 5 mm 375 in square 48 cm 19 in long or the proper alignment template into the opened driven pulley Measuring Procedure Using Straight Bar Always measure distances X and Y from the far ther straight bar side including its thickness to the f...

Page 131: ...lley alignment nominal values However they do not take into account allowed tolerances for alignment specifications They are used as GO NO GO gauges for quick alignment and pulley distance check and as templates to reach alignment nom inal values A06D0LA 1 2 CAUTION This section deals mainly with adjustment procedures For complete assembly require ments refer to the proper ENGINE or TRANSMISSION i...

Page 132: ...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 the...

Page 133: ...Section 04 TRANSMISSION Sub Section 06 BRAKE 04 06 1 BRAKE 0 HYDRAULIC DISC BRAKE F Series A06D23S Loctite 242 7 Anti seize lubricant 17 Anti seize lubricant 19 18 20 Black Max 24 FLAT RATE PARTS ...

Page 134: ...e and disc Remove disc COUNTERSHAFT REMOVAL Proceed the same as for brake disc removal but unlock bearing collar no 18 on driven pulley side 1 Lock 2 Unlock Unbolt bearing support no 19 then install screw on countershaft 1 Screw Pull bearing to driven pulley side out of counter shaft using remover P N 529 0301 00 Begin with only the remover then add a spacer of differ ent width as the bearing come...

Page 135: ...hick or less TYPICAL 1 Fixed pad 2 Inner caliper A 1 mm 1 32 in minimum 17 Brake Disc Check for scoring cracking or bending replace as required ASSEMBLY 24 Brake Lever Lock Nut Tighten nut to 3 0 N m 27 lbf in Check free movement of brake lever Apply Loctite Black Max Gel Loctite item no 18398 over nut and on bolt threads CAUTION Do not clean brake pads in solvent Soiled brake pads must be replace...

Page 136: ...c more from one side than from the other Install disc with the long er exceeding portion toward driven pulley ADJUSTMENT Countershaft Bearing Insert countershaft with brake disc from chain case side through countershaft support driven pulley side then insert into chaincase Install countershaft bearing no 19 and ensure that countershaft is properly aligned then tighten 3 retaining screws NOTE A mis...

Page 137: ... 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 bleeder Route this hose to a container Pump a few times brake lever and while holding brake lever depressed open bleeder and check for air to escape Repeat with the same bleeder until no air appears in hose Proceed the s...

Page 138: ...0 F Series A06D17S 2 1 3 Chaincase oil 4 5 6 7 27 Loctite 242 23 9 10 8 24 25 26 Loctite 609 11 20 Loctite 242 14 16 17 18 14 12 Loctite 271 15 13 46 N m 34 lbf ft 22 21 45 to 75 N m 33 to 55 lbf ft SYNTHETIC CHAINCASE OIL HUILE SYNTHÉTIQUE POUR CARTER PARTS FLAT RATE ...

Page 139: ...ts and chain tensioner components GEAR RATIO MODIFICATION For particular applications the number of teeth of the sprockets can be increased or decreased on lower and upper sprockets Refer to TECHNICAL DATA 09 03 for gear ratios NOTE For high altitude regions the High Altitude Technical Booklet P N 484 0648 00 and P N 484 0545 00 for binder gives information about cali bration according to altitude...

Page 140: ...t 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 removing a cotter pin always replace with a ...

Page 141: ... CHAINCASE 04 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 04 05 Track Tension and Alignment Refer to TRACK 06 04 A03A03A 1 ...

Page 142: ...here are 2 types of silent chain One is 11 plate wide and the other stronger is 13 plate wide Do not interchange sprockets Fit chain on sprockets to make sure using right ones accord ing to width Refer to TECHNICAL DATA 09 03 NOTE No work separation lengthening can be done on the silent chain type ...

Page 143: ...ARK PLUGS 05 04 2 DISASSEMBLY 05 04 3 HEAT RANGE 05 04 3 FOULING 05 04 3 SPARK PLUG ANALYSIS 05 04 3 SPARK PLUG INSTALLATION 05 04 4 SPARK PLUG TIGHTENING TORQUE 05 04 4 TESTING PROCEDURE 05 05 1 GENERAL 05 05 1 USE OF BOMBARDIER IGNITION TESTER 05 05 2 NIPPONDENSO CDI TRIGGER COIL SYSTEM TESTING 05 05 3 TRIGGER COIL OUTPUT 05 05 3 IGNITION COIL OUTPUT 05 05 3 IGNITION MODULE 05 05 4 MAGNETO OUTPU...

Page 144: ...ire is the main color second color is the stripe Example YL BK is a YELLOW wire with a BLACK stripe MODEL WIRING DIAGRAM PAGE HEADLIGHT watt TAILLIGHT watt ELECTRICAL SYSTEM OUTPUT watt Formula III III LT Mach 1 Z Z LT Annex 1 60 55 hal 8 27 220 COLOR CODE BK BLACK WH WHITE RD RED BL BLUE YL YELLOW GN GREEN GY GREY VI VIOLET OR ORANGE BR BROWN ...

Page 145: ...beam Current returns by YELLOW BLACK wire connected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by YELLOW BLACK wire connected to oil level sensor BLUE 12 volts A C Fuel level indicator Current returns by YELLOW wire connected to fuel level sensor ORANGE...

Page 146: ... To remove Insert a screwdriver or Snap on TT 600 5 from opposite side of wire and pry locking tab While holding locking tab pried pull connector toward wire side Step Insert screwdriver here Step Pull this side Locking Receptacle Connector To remove Insert tool Snap on TT 600 5 in access opening then pull housing toward wire side TAB AND RECEPTACLE CONNECTORS INSTALLATION Prior to installing make...

Page 147: ...sso ries on any snowmobile connect their wires di rectly to the YELLOW and YELLOW BLACK lighting coil wires Even if manual start models have an AC ground to the chassis on voltage regulator all accesso ries utilize a ground wire isolated from chassis When an electric starter kit is installed the volt age regulator and its ground wire are replaced by a voltage rectifier regulator unit permitting a ...

Page 148: ...sition of the timing mark on the magneto flywheel or to scribe a timing mark pro ceed as follows 1 Clean the area around the spark plugs and re move them 2 Remove the rewind starter from the engine 3 Install the TDC gauge in the spark plug hole magneto side and adjust as follows a Position the magneto flywheel at approxi mately TDC TYPICAL 1 TDC gauge on MAG side 2 MAG side piston at TDC b Assembl...

Page 149: ... a critical check must al ways be in a clockwise direction to ensure that the slack in engine moving parts is taken up a Rotate the magneto flywheel counterclock wise one quarter turn then carefully rotate it clockwise until the needle indicates the specified measurement indicated in TECH NICAL DATA 09 02 b Make sure that the dot located on the side of the magneto flywheel protrusion perfectly ali...

Page 150: ...kcase timing mark Bring engine to 6000 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 ignition timing Tolerance is 1 If the marks still do not align a faulty trigger coil check proper grounding of coil or a faulty CDI module could be the caus...

Page 151: ...NGK SPARK PLUG NUMBERING SYSTEM Bombardier is using the NGK spark plug type on most of the 1997 snowmobile models The heat range identification system is High number hot plug Low number cold plug 1997 REFERENCE CHART NGK spark plugs used on 1997 Bombardier snow mobiles covered in this manual BR10ES ...

Page 152: ... 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 153: ...tion etc A too cold plug will result in fouling shorting the spark plug or may create carbon build up which can heat up red hot and cause pre ignition or detonation FOULING Fouling of the spark plug is indicated by irregular running of the engine decreased engine speed due to misfiring reduced performance and in creased fuel consumption This is due to a loss of compression Other possible causes ar...

Page 154: ... wire feeler gauge set electrode gap ac cording to TECHNICAL DATA 09 02 2 Apply anti seize lubricant P N 413 7010 00 over the spark plug threads to prevent possible seizure 3 Hand screw spark plug into cylinder head and tighten with a torque wrench and a proper socket 1 Proper socket 2 Improper socket SPARK PLUG TIGHTENING TORQUE Models Spark plugs Torque N m lbf ft All models NGK 27 20 A00E0BA 2 ...

Page 155: ...1 Separate high tension coils mounted on carburetor flanges 2 Three wire connector BLACK RED WHITE and RED Ignition System Testing Sequence When dealing with ignition problems the follow ing items should be verified in this order Nippondenso 1 Spark occurrence spark plug condition 2 Electrical connections 3 Engine stop tether cord switches 4 Ignition coil output 5 Ignition module output 6 Magneto ...

Page 156: ...ollowing order 1 Connect tester P and N clip leads as illustrated for each specific test 2 Follow test procedure sequence 3 After every test that lights the indicator lamp reset the indicator circuit by depressing the re set button Analysis of Test Results Indicator Lamp Lights at Specific Setting Output is as specified Test results should repeat 3 times If readings do not repeat output is erratic...

Page 157: ... paper clip of approximately 20 mm 3 4 in will be used as a test adapter for the following test 1 Install the test adapter to spark plug cable close to MAG side spark plug 2 Connect tester wires then set switch and dial as follows NOTE Different reading occurs if N tester wire is connected to PTO or MAG side spark plug cable TYPICAL 1 Engine ground 2 MAG side A 20 mm 3 4 in WARNING To prevent powe...

Page 158: ...plug s 3 Connect CDI module to replacement ignition coil 4 Slip plastic protector out of coil terminal 5 Connect tester wires to coil terminals then set switch and dial as follows NOTE If necessary use jumper wires from coil terminals to tester wires TYPICAL 6 Crank engine and observe indicator 7 Push reset button and repeat step 6 twice Results a Indicator lamp lights Ignition module out put is u...

Page 159: ...e same tester 1 Disconnect wiring harness junction block at en gine the one with YELLOW wires 2 Connect tester wires then set switch and dial as follows 3 Crank engine and observe indicator 4 Push reset button and repeat step 3 twice Results a Indicator lamp lights Lighting generator coil output is up to specifications b Indicator lamp does not light Lighting gen erator coil is faulty Tester wires...

Page 160: ...utput N Engine ground LOW 45 P Test adapter on MAG spark plug cable Ignition module output N WHITE BLUE wire of ignition coil LOW 85 P BLACK wire of ignition coil Magneto output ignition generator coil N WHITE wire of magneto harness LOW 75 P BLACK RED wire of magneto harness N WHITE wire of magneto harness LOW 85 P RED wire of magneto harness Lighting generator coil output N YELLOW wire of magnet...

Page 161: ...ement can still be faulty Voltage leak can occur at high voltage level which is not detectable with an ohmmeter Infinity extremely large number PART NAME WIRE COLOR RESISTANCE OHM REMARKS MAGNETO Trigger coil BL YL with WH YL 190 300 No display change means open circuit Ignition generator coil Low speed WH with RD 49 75 High speed WH with BK RD 2 8 4 3 IGNITION COIL Primary winding BK with WH BL 0...

Page 162: ...d alternating current AC For accurate reading use a RMS voltmeter Connect a wire of the voltmeter to a YELLOW BLACK wire Connect the other wire of the voltmeter to a YEL LOW wire Lift the rear of vehicle and support with a mechan ical stand Start the engine at an idle without opening the throttle Slowly open the throttle and accelerate the en gine to increase the RPM If the meter reads over 15 vol...

Page 163: ... weaken INSPECTION Disconnect regulator rectifier Connect one digital ohmmeter probe needle ohmmeter will not offer enough precision to frame and other probe to one of 2 yellow magneto wires Measured resistance must be infinite If such is not the case it means there is a connection be tween AC circuit and DC circuit Disconnect one accessory at the time to identify the faulty circuit ...

Page 164: ...e will be half the measurement in table The reason for that is the elements are connected in parallel Therefore the total resistance is half the resistance of one element HIGH INTENSITY YELLOW BLACK wire BROWN wire 1 96 to 3 64 ohms LOW INTENSITY YELLOW BLACK wire BROWN YELLOW wire 8 05 to 14 95 ohms HIGH INTENSITY BROWN wire 0 23 Amp minimum LOW INTENSITY BROWN YELLOW wire 0 13 Amp minimum HIGH I...

Page 165: ...BLY AND ASSEMBLY 06 02 4 SHOCK ABSORBER INSPECTION 06 02 6 INSTALLATION 06 02 7 RIDE ADJUSTMENT 06 02 7 LUBRICATION 06 02 7 DRIVE AXLE 06 03 1 REMOVAL 06 03 2 DISASSEMBLY 06 03 2 ASSEMBLY 06 03 2 AXIAL PLAY 06 03 4 INSTALLATION 06 03 7 LUBRICATION 06 03 7 ADJUSTMENT 06 03 8 TRACK 06 04 1 TRACK TYPE APPLICATION 06 04 1 GENERAL 06 04 1 INSPECTION 06 04 1 REMOVAL 06 04 1 INSTALLATION 06 04 1 ...

Page 166: ...02 1 SC 10 SUSPENSION HP VERSION 0 SC 10 High Performance on Formula III III LT and Mach 1 Z Z LT 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 167: ...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 cushion Apply ...

Page 168: ...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 12 Front Shock Unfasten one end of stopper strap Unbolt shock and remove it 2 Rear Spring Remove spring ends from adjusting cams Unbolt re...

Page 169: ... 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 idler wheel axle from tunnel then remove Lift rear of vehicle at least 1 m 3 ft 1 At least 1 m 3 ft 6 Screw Remove both screws retaining front arm to tun nel Remove suspension...

Page 170: ...t axles Idler wheel axles can be used as pivot axles but the opposite is not true 12 13 14 Front Shock Spring Stopper and Cap Use shock spring remover P N 529 0271 00 in a vise Mount shock in it and turn shock so that spring coils matched spring 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...

Page 171: ...he line 1 Wear limit line 18 Spring Support RIGHT SIDE SHOWN 1 Right position upward 2 Wrong position SHOCK ABSORBER INSPECTION Secure the shock body end in a vise with its rod upward 1 Clamp NOTE Gas pressurized shocks are light gray painted 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...

Page 172: ...ows Place shock in a freezer temperature below 0 C 32 F for 4 hours Push down on rod and note its resistance com pare to a new shock If shock is frozen it will be much more difficult to compress than for the new one 25 Protector At assembly mount protector with its notch to ward front 1 Notch INSTALLATION Install assembled suspension into track with front portion first Insert rear portion of suspe...

Page 173: ...Section 06 REAR SUSPENSION Sub Section 03 DRIVE AXLE 06 03 1 DRIVE AXLE 0 F Series A06D24S 10 2 3 12 8 4 13 9 13 5 11 Lithium grease 6 PARTS FLAT RATE ...

Page 174: ...ling the drive axle towards the end bearing housing side Remove drive axle from vehicle DISASSEMBLY 4 Speedometer Drive Insert Remove speedometer drive insert 5 12 Bearing To remove bearings use puller assembly ring and half rings as illustrated 9 13 Sprocket and Half Sprocket To remove press fit sprockets use a press and a suitable support as illustrated TYPICAL 1 Support sprocket near hub NOTE T...

Page 175: ... on a plane surface and measure the gap between sprocket tooth and surface 1 Plane surface A 1 5 mm 1 16 in MAXIMUM 6 8 Drive Axle and Seal When assembling drive axle always position a new seal on each end of drive axle if applicable Locate seal lip as illustrated 1 Grease seal type 2 Oil seal type 11 Bearing Protector At assembly flat side of bearing protector must be against bearing A06D1XA A B ...

Page 176: ...attempting to adjust the drive axle axial play check the chaincase perpendicularity as fol lows CHAINCASE PERPENDICULARITY ADJUSTMENT Remove driven pulley Slacken bearing collar set screw and working from the driven pulley side turn bearing collar clockwise TYPICAL 1 Set screw 2 Slacken 3 Tighten Extract bearing from its support Wrong chaincase perpendicularity will make it dif ficult to correctly...

Page 177: ...1 Countershaft 2 Shim position on end bearing housing side 3 Shim position on chaincase side 4 Drive axle 5 Axial play 6 Shim between sprocket and spacer Push the drive axle toward chaincase and take note of the distance between the sprocket and tunnel 1 Distance between sprocket and tunnel 2 Drive axle pushed toward chaincase BEARING POSITION A TOWARD FRONT OF VEHICLE B TOWARD REAR OF VEHICLE C T...

Page 178: ...tween the chaincase and the drive axle bearing there must be same quantity of shims between the drive chain sprock et and spacer 1 Chaincase 2 Spacer 3 Same quantity Doublecheck drive axle axial play as described above Modify total shim thickness as required Reinstall track and suspension Adjust track tension and alignment NOTE Center the track suspension to ensure that the alignment check made in...

Page 179: ... if applicable making sure that a gap of approximately 2 mm 1 16 in exists between end of bearing housing and each seal SIDE VIEW 1 Bearing 2 Seal 3 Housing 4 Seal lip A 2 mm approx 3 Retainer Ring Make sure that welded nuts are toward inside of tunnel Lock drive axle sprocket with a circlip Reinstall the chaincase cover Refill with chaincase oil Refer to TECHNICAL DATA 09 03 Install the suspensio...

Page 180: ...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 CAUTION Do not temper with sprocket track alignment if frame or suspension is damaged A01B2PA ...

Page 181: ...rack INSTALLATION 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 06 03 Track Tension and Alignment Track tension and alignment are inter related Do not adjust one without checking the other Track tension procedure must be carried out prior to track alignment Tens...

Page 182: ...ff the ground start engine and allow the track to rotate slowly Check that the track is well centered equal dis tance on both sides between edges of track guides and slider shoes 1 Guides 2 Slider shoes 3 Equal distance CAUTION Too much tension will result in power loss and excessive stress on suspension compo nents If too loose the track will have a ten dency to thump A01B4KA 1 WARNING Before che...

Page 183: ...aise rear of vehicle off the ground and lift snowguard then rotate track to expose a cleat to be replaced Using track cleat remover P N 529 0087 00 for all models Installation NOTE Keep the same pitch between guide cleats Place new cleat in position and using small track cleat installer P N 529 0085 00 bend cleat then push tabs into rubber TYPICAL 1 First step 2 Second step to push tabs into rubbe...

Page 184: ...E OF CONTENTS STEERING SYSTEM 07 02 1 INSPECTION 07 02 2 DISASSEMBLY AND ASSEMBLY 07 02 2 INSPECTION 07 02 3 ADJUSTABLE HANDLEBAR 07 02 4 STEERING ADJUSTMENT SKIS 07 02 5 LUBRICATION 07 02 7 SUSPENSION AND SKI SYSTEM 07 03 1 DISASSEMBLY 07 03 2 INSPECTION 07 03 3 INSTALLATION 07 03 3 ...

Page 185: ...18 lbf ft 25 N m 18 lbf ft 25 N m 18 lbf ft 18 N m 159 lbf in 40 N m 30 lbf ft Lithium grease 40 N m 30 lbf ft 40 N m 30 lbf ft 18 N m 159 lbf in 18 N m 159 lbf in 40 N m 30 lbf ft 5 4 2 6 1 3 24 8 23 9 21 21 16 13 14 15 10 21 22 9 26 21 9 16 13 20 15 10 21 17 11 9 21 18 N m 159 lbf in 21 52 N m 38 lbf ft FLAT RATE PARTS ...

Page 186: ...tach the short tie rod under 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 24 Heating Grip Element The grips might be unremovable as explained above in this case carefully proceed as follows to prevent damaging the heating elements Locate the element wires ...

Page 187: ...chart TYPICAL The ball joint should be restrained when tighten ing the tie rod end 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 WARNING Never use lubricant...

Page 188: ...see exploded view ADJUSTABLE HANDLEBAR 1 3 Steering Column and Handlebar If applicable remove the steering clamp and nuts holding the handlebar to the steering column 2 4 5 6 Handlebar Support Steering Clamp Bolt and Nut Install the handlebar support steering clamp the 4 screws and nuts to the column as illustrated See applicable exploded view Adjust the steering handlebar to the desired posi tion...

Page 189: ...Jam Nut Tie Rod and Pivot Arm With handlebar in straight ahead position the cen ter 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 WARNING Make sure that the steering pad and ...

Page 190: ... at ski leg hous ing Turn tie rod half turn at a time to obtain a vertical ski leg 0 0 5 Bolt upper control arms HANDLEBAR AND SKI TOE OUT Check that handlebar is horizontal when skis are in straight ahead position by measuring from the extremities of the grips to the rearmost edge of the tunnel as shown NOTE The reference point must be the same rel ative to each side TYPICAL 1 Equal distance A on...

Page 191: ...l After the ski toe out adjustment distance must be equal To reduce tolerance when measuring set one ski to proper toe out then measure from that ski to the opposite ski TYPICAL 1 Straight edge 2 Measure here LUBRICATION 26 Grease Fittings Only use low temperature grease P N 413 7061 00 The following symbols will be used to show what type of lubricant should be used at the suitable locations 1 Low...

Page 192: ...Section 07 STEERING FRONT SUSPENSION Sub Section 02 STEERING SYSTEM 07 02 8 F Series A06G08S If so equipped FLAT RATE PARTS ...

Page 193: ...on 03 SUSPENSION AND SKI SYSTEM 07 03 1 SUSPENSION AND SKI SYSTEM 0 F Series A06F2HS 10 N m 98 lbf in 11 25 N m 18 lbf ft 10 5 9 8 6 7 14 13 1 4 3 2 Loctite 242 14 N m 124 lbf in 40 N m 29 lbf ft 80 N m 59 lbf ft 17 5 N m 159 lbf in FLAT RATE PARTS ...

Page 194: ...ck For shock spring disassembly use shock spring remover P N 529 0271 00 in a vise Mount shock in it and turn shock so that spring coils matched spring compressor Close and lock the bar Adjust the handle horizon tal position by changing the position of the clevis pin 1 Clevis pin 2 Bar 3 Handle horizontal Push down on the handle until it locks Remove spring stopper and cap then release handle When...

Page 195: ... steering arm Replace as required Check for straightness of swing arm Replace as required Check for clogged grease fittings Clean or re place as required Check for proper action of sliding blocks in swing arm Check skis and runners for wear replace as nec essary Check condition of ski stopper Replace it when deteriorated To check condition of shock refer to SC 10 SUS PENSION 06 02 then look for Sh...

Page 196: ...tion 07 STEERING FRONT SUSPENSION Sub Section 03 SUSPENSION AND SKI SYSTEM 07 03 4 13 14 Tie Rod and Lever Install levers on both sides at same angle about horizontal TYPICAL WRONG POSITION A06G0WA A06G0XA ...

Page 197: ...2 1 DECAL 08 02 2 WINDSHIELD INSTALLATION 08 02 2 HOOD 08 02 2 BELT GUARD 08 02 2 WIRING HARNESS 08 02 2 CABLES 08 02 3 PIPING 08 02 3 PLASTIC MAINTENANCE AND REPAIR 08 02 4 MAINTENANCE 08 02 4 REPAIR 08 02 5 MATERIAL REPAIR PROCEDURE 08 02 6 REPAIR PROCEDURE FOR R I M URETHANE 08 02 6 FRAME 08 03 1 FRAME CLEANING 08 03 1 FRAME WELDING 08 03 1 FRAME COMPONENT REPLACEMENT 08 03 1 ...

Page 198: ...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 199: ...cable wiring harnesses then retaining cables Unbolt front molding and unclip it Close hood Remove molding Remove hinge pin At installation half close hood to install front molding BELT GUARD Disassembly and Assembly NOTE For additional information ex exploded view refer to the correspondent parts catalog Inspection Check belt guard and or pulley guard mounting bosses clips and retainers for wear W...

Page 200: ... ble ends and secure them in place Pay at tention to route them properly away from any rotating moving heating or vibrating parts WARNING Always ensure that the fuel vent primer impulse injection oil and rotary valve oil lines are properly fixed to their connectors that they are not perforated or kinked and that they are properly routed away from any rotating moving heating or vibrating parts Also...

Page 201: ...eaning agent in their formula Apply wax on glossy finish only Protect the vehi cle with a cover to prevent dust accumulation dur ing storage CAUTION Do not apply isopropyl alcohol or acetone directly on decals CAUTION The following products must not be used to clean or wax any of the plastic components used on the vehicles CAUTION Clean R I M Metton with isopropyl alcohol only Never use cleaners o...

Page 202: ... to following chart CAUTION 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 F Series A06H194 BOTTOM PAN F Series A06H1A4 SIDE PANEL AND REAR MOLDING F Series A06H1B4 ...

Page 203: ...ours 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 isopropyl alcohol or Crest Hi Solv product Repair inside surf...

Page 204: ... 1 800 552 0876 Fax 404 288 4658 Mailing Address P O Box 254 Decatur Georgia 30031 CREST INDUSTRIES INC CREST MID WEST 231 Larkin Williams Ind Court St Louis Missouri 63026 Phone 314 349 4800 Toll Free 1 800 733 2737 Fax 314 349 4888 Toll Free Fax 1 800 776 2737 CREST MID WEST Regional Branch Warehouses CREST INDUSTRIES INC P O Box 635 Mountain Home Arkansas 72653 Phone 501 491 5583 Toll Free 1 80...

Page 205: ... 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 incr...

Page 206: ...ide retaining rivets 1 Rivets heads ground 2 Rivets to be ground from underneath To remove rivet strike with a punch from rivet head side Make a chamfer from underneath on all 4 corner holes CAUTION High speed drilling will cause excessive heat which may destroy the cutting edge of the bit therefore avoid using pneumatic drills A06H0XA 1 2 ...

Page 207: ...ue speed meter kilogram newton liter Celsius kilopascal newton meter kilometer per hour m kg N L C kPa N m km h PREFIXES PREFIX SYMBOL MEANING VALUE kilo centi milli micro k c m µ one thousand one hundredth one thousandth one millionth 1 000 0 01 0 001 0 000001 CONVERSION FACTORS TO CONVERT TO MULTIPLY BY in in in2 in3 ft oz lb lbf lbf in lbf ft lbf ft PSI lbf in2 imp oz imp oz imp gal imp gal U S...

Page 208: ...tion Timing BTDC mm in 2 18 086 2 18 086 2 11 083 Trigger Coil Ω 190 300 190 300 190 300 Generating Coil Low Speed Ω 49 75 49 75 49 75 High Speed Ω 2 8 4 3 2 8 4 3 2 8 4 3 Lighting Coil Ω 0 20 0 35 0 20 0 35 0 20 0 35 High Tension Coil Primary Ω 0 2 0 5 0 2 0 5 0 2 0 5 Secondary kΩ 6 13 6 13 6 13 Carburetor Type PTO CTR MAG VM 36 176 177 178 VM 38 356 357 358 3 x TM 38 C159 Main Jet PTO CTR MAG 33...

Page 209: ... cm in 38 1 15 38 1 15 38 1 15 0 38 1 15 0 Length cm in 307 121 345 5 136 307 121 307 121 Adjustment Deflection mm in 35 40 1 3 8 1 9 16 35 40 1 3 8 1 9 16 35 40 1 3 8 1 3 4 35 40 1 3 8 1 3 4 Force kg lbf 7 3 16 7 3 16 7 3 16 7 3 16 Suspension Type Track SC10 HP SC10 HP SC10 HP SC10 HP Ski DSA DSA DSA DSA Length cm in 272 0 107 1 291 0 114 6 272 0 107 1 272 5 107 3 Width cm in 115 9 45 6 118 2 46 ...

Page 210: ... 0 1 3 8 Drive Belt Adjustment Deflection 5 mm 13 64 in 32 1 1 4 Force kg lbf 11 3 25 Track Width cm in 38 1 15 0 Length cm in 345 5 136 Adjustment Deflection mm in 35 40 1 3 8 1 3 4 Force kg lbf 7 3 16 Suspension Type Track SC10 HP Ski DSA Length cm in 291 114 6 Width cm in 118 2 46 5 Height cm in 108 42 5 Ski Stance cm in 104 2 41 Mass dry kg lb 261 574 Ground Contact Area cm2 in2 7549 1170 Grou...

Page 211: ...h parts at room temperature ap prox 20 C 68 F Temperature greatly affects resistance measurements Force applied midway between pulleys to ob tain specified tension deflection Drive pulley retaining screw torque to 90 to 100 N m 66 to 74 lbf ft install drive belt accelerate 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 7...

Page 212: ...ond color is the stripe Example YL BK is a YELLOW wire with a BLACK stripe MODEL WIRING DIAGRAM PAGE HEADLIGHT watt TAILLIGHT watt ELECTRICAL SYSTEM OUTPUT watt Formula III III LT Mach 1 Z Z LT Annex 1 60 55 hal 8 27 220 COLOR CODE BK BLACK WH WHITE RD RED BL BLUE YL YELLOW GN GREEN GY GREY VI VIOLET OR ORANGE BR BROWN ...

Page 213: ...YELLOW BLACK wire connected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by YELLOW BLACK wire connected to oil level sensor BLUE 12 volts A C Fuel level indicator Current returns by YELLOW wire connected to fuel level sensor ORANGE 12 volts A C Heated gri...

Page 214: ...ond color is the stripe Example YL BK is a YELLOW wire with a BLACK stripe MODEL WIRING DIAGRAM PAGE HEADLIGHT watt TAILLIGHT watt ELECTRICAL SYSTEM OUTPUT watt Formula III III LT Mach 1 Z Z LT Annex 1 60 55 hal 8 27 220 COLOR CODE BK BLACK WH WHITE RD RED BL BLUE YL YELLOW GN GREEN GY GREY VI VIOLET OR ORANGE BR BROWN ...

Page 215: ...YELLOW BLACK wire connected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by YELLOW BLACK wire connected to oil level sensor BLUE 12 volts A C Fuel level indicator Current returns by YELLOW wire connected to fuel level sensor ORANGE 12 volts A C Heated gri...

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Ski-Doo FORMULA III 1997, Shop Manual

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