Ski-Doo FORMULA III, Shop Manual

Page: 202 / 356

Section 05 TRANSMISSION
Sub-Section 05 (BRAKE)
05-05-5
– Slacken set screw and unlock collar no. 18 if
bearing is needed to be disassembled. See
above S-Series illustration and procedure.
– Remove 3 retaining screws no. 20 from coun-
tershaft bearing housing.
– Unbolt coolant tank support to make room for
countershaft or brake disc removal.
– Pull countershaft toward driven pulley side to
free from chaincase. Withdraw countershaft to-
ward chaincase.
– Remove brake disc from countershaft.
– Remove connecting pipe between tuned pipe
and after muffler.
– Disconnect brake line from caliper and plug it.
– Unbolt caliper from chaincase.
To remove brake disc, refer to procedure on me-
chanical brake models.
INSTALLATION
To install brake, reverse removal procedure paying
attention to the following.
WARNING : Avoid getting oil on brake
pads. Do not lubricate or apply antirust or
antifreeze solution in brake cable.
17, Brake Disc
The brake disc must be floating on countershaft
for efficient operation of brake.
Apply anti-seize lubricant (P / N 413 7010 00) on
shaft and check that disc slides freely.
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.
Push O-rings inside disc hub.
Countershaft Bearing Adjustment
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 misaligned countershaft will result
in difficulty to center the bearing in its sup-
port.
Refer to DRIVE AXLE 05-03 then look Chaincase
Perpendicularity Adjustment.
Torque castellated nut of upper sprocket to 53
N•m (39 lbf•ft).
CAUTION : Upper sprocket castellated
nut must be tightened
before adjusting
bearing collar.
Slide collar no. 18 towards bearing and turn, by
hand, to engage the eccentric. This should require
about a quarter turn.
Turn collar in direction of countershaft rotation un-
til collar and inner race lock together.
Insert a punch into collar hole and strike sharply in
the same direction to lock firmly.
Apply medium strength threadlocker (P / N 413
7030 00) on set screw threads, then tighten.
Close chaincase referring to CHAINCASE 05-06.
1,11,12, Locking Tab, Outer Caliper and Nut
Mechanical Brake Models
Install caliper retaining bolts.
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A03D13A
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