Ski-Doo FORMULA III Shop Manual Download

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Section 05

TRANSMISSION

Sub-Section 07

(GEARBOX)

05-07-2

REMOVAL

1,2, Cable and Cable Housing

Remove screw from underneath top portion of
transmission. Remove cable barrel from shifter :
see last photo.

1. Remove this screw

Pull out cable from underneath top portion of
transmission.

1. Cable

ADJUSTMENT

6, Tie Rod

Slacken tie rod lock nut.

Unfasten tie rod end by removing its clip.

1. Clip
1. Lock nut

Adjust tie rod length in a way that gear shift lever
do not contact console. Check 2

gear position.

Retighten ball joint lock nuts.

1, Cable

With gear shift lever in neutral position, there
should be no cable free play.

Adjust reverse lock out cable by cable housing ad-
juster

no. 2

. If more adjustment is needed, slack-

en or tighten cable barrel accordingly.

1. Cable barrel
2. No free play

A22D0SA

A22D0ZA

A22D0QA

A22D01A

Summary of Contents for FORMULA III

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Page 12: ...ce TOOIS Degree wheel P N 4143529 00 AOOB334 APPLICATION All rotary valve engines Hose pincher 2 p N 5290099 00 H A01B214 APPLICATION All vehicles Fan holder P N 4208763 57 a Q c1 o AOOCOQ4 APPLICATIO...

Page 13: ...OOCOX4 APPLICATION Rotary valve engines Bearing pusher rotary valve m p N 4208765 00 AOOB2J4 APPLICATION Rotary valve engines Engine leak tester kit m A P N 86 I 7491 00 Q 5 o b o 1 e 3 Q Q 52 Q o 4 A...

Page 14: ...1 Locating sleeve 3 P N 5290238 00 2 Expansion sleeve 3 p N 5290237 00 3 Adaptor p N 5290236 00 4 U bushing p N 5290277 03 Rubber pad p N 5290234 00 m r o 0 0 0 o 0 0 0 J A01B4C4 APPLICATION All cage...

Page 15: ...16 X 1 5 X 150 p N 4209407 55 m Use with both or pullers 3 Screw M8 x 40 4 P N 420 840681 m puller MAG side puller MAG and PTO side 4 Screw M8 x 70 4 P N 420 841201 Puller only PTO side m C 5 Cranksha...

Page 16: ...90 m A 62 mm B p N4208769 74 m o 69 5 mm Q p N 4208769 70 m O 72 mm D p N 420876972 m t 76 mm E p N 4208769 75 m 8 67 5 mm m F p N 5290308 00 78 mm A01B1T4 APPLICATION A 377 engines B 467 engines C 50...

Page 17: ...stance m gauge 1 2 7 mm P N 4208768 24 AOOC3A4 APPLICATION 503 engine Cylinder aligning tool A p N 4208769 02 m o on exhaust side B p N 4208761 71 m on intake side AOOBOB4 APPLICATION A 467 536 537 58...

Page 18: ...OOB2E4 APPLICATION All engines Seal protector sleeve A p N4208769 80 for 10 mm shaft m B p N 4208764 90 for 12 mm shaft m D AOOCOD4 APPLICATION 467 582 583 and 670 engines Magneto puller m p N 4209762...

Page 19: ...4209779 00 AOOCON4 APPLICATION 247 engine Fluke multimeter m A p N 5290220 FO1B1O4 APPLICATION All models MAG seal pusher m A p N 4202778 75 AOOCOV4 APPLICATION 277 engine PTO seal pusher m P N 42087...

Page 20: ...ICATION All models Bearing simulator m c P N 4208761 55 AOOC1H4 APPLICATION 253 305 343 402 and 440 en gines Rotary valve seal and m shaft pusher p N 4208766 05 AOOCOY4 APPLICATION Rotary valve engine...

Page 21: ...Section 01 SERVICE TOOLS AND SERVICE PRODUCTS Sub Section 01 SERVICE TOOLS ENG NE Optional Serv Large hose pincher p N 5290304 00 F01B234 2 APPLICATION All vehicles ce Tools 01 01 10...

Page 22: ...ISSION Mandatory Service Tools TRA drive pulley puller m P N 5290079 00 25 mm A18B044 APPLICATION TRA drive pulley except 599 670 and 779 engines Forks 3 p N 5290055 00 m A16B014 APPLICATION All vehic...

Page 23: ...l Parts included in the kit p N 5290180 00 1 Spring compressor EXTERIOR flare tool p N 5290151 P N 5290181 00 oNOTE Letter A stamper on tools B INTERIOR flare tool p N 5290182 00 EXTERIOR flare tool P...

Page 24: ...t bearing installer p N 5290302 00 m I AOOA194 APPLICATION S Series and F Series TRANSMISSION Mandatory Service Tools Countershaft bearing m remover p N 5290301 00 Q Q AOOA274 APPLICATION S Series and...

Page 25: ...gear box Countershaft bearing m o installer p N 5290188 00 o AOOA194 APPLICATION PRS chassis Cam pusher m o P N 5290129 00 A18B064 APPLICATION Tundra II LT Countershaft bearing m t remover P N 5290187...

Page 26: ...220825 65 m o 2 Plate 3 Half ring 2 m 8A P N 4208763 30 4 Ring p N 4209774 80 m t 1 ti o o o GIB o 0 3 4 e AOOC1B4 APPLICATION Alpine II 3 speed transmission Driven pulley support m I extractor p N 52...

Page 27: ...xcept 454 670 and 779 engines Drive pulley puller m J t p N 8604142 00 square shaft metric Consist of 529003000 529002800 A AOOC095 APPLICATION Square shaft metric threads drive pulley Drive axle spro...

Page 28: ...ND SERVICE PRODUCTS Sub Section 01 SERVICE TOOLS SUSPENSION Mandatory Service Tools Shock spring remove kit p N 5290271 00 Replacement clevis pin P N 4145284 00 I 1 A01B404 APPLICATION All suspensions...

Page 29: ...B 1994 and newer except Elan and Tundra Il Camber angle tool m A p N 5290216 00 oNOTE Angle finder with a magnetic base must be used Suggestion K D tool no 2968 IQ A06B024 APPLICATION All DSA front s...

Page 30: ...ons Spring cam adjuster key p N 8617317 00 k 1 T 3 2 A25BOD4 APPLICATION Safari A arm suspension spring Replacement parts 1 Adjustment key p N 5290138 00 2 Handle p N 5290140 3 Key extension P N 52901...

Page 31: ...p N 5290147 00 A19B024 APPLICATION Safari and Skandic prior to 1995 Suspension adjustment m wrench P N 5290122 00 A25A014 APPLICATION Rear suspension Suspension adjustment m wrench P N 5290098 00 9 A...

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Page 33: ...mpound m p N 4137031 00 Loctite RC 609 Retaining compound 1 O mL green AOOB2S4 APPLICATION Used for retaining bushings bear ings in slightly worn housing or on shaft Paste gasket m p N 4137027 00 Loct...

Page 34: ...ent m p N 4137082 00 Loctite 755 59 340 g 12 Oz 6 I7 a m 4 AOOB3M4 APPLICATION Clean carburetor parts and de grease all oily surfaces 17 MANDATORY SERVICE PRODUCTS Loctite primer m P N 4137081 00 Loct...

Page 35: ...transfer the heat build up and to assure a good ground Clutch lube m 4 Oz P N413 8007 00 AOOB1Z4 APPLICATION Roller round shaft drive pulleys OPTIONAL SERVICE PRODUCTS Chaincase oil m p N413 8019 00...

Page 36: ...79 engines Anti seize lubricant m P N 4137010 00 Loctite anti seize lubricant 454 g 16 OZ F01B174 APPLICATION Unpainted surfaces of drive pul ley countershaft Bearing grease m 400 g P N 4137061 00 AOO...

Page 37: ...3 7086 Loctite 81668 Form A thread 81668 AOOA1J4 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 cri...

Page 38: ...el stabilizer p N413 4086 00 AOOB3V4 APPLICATION All models Molykote 111 p N 4137070 00 I AOOB3W4 APPLICATION Rotary valve shaft seals Shock oil 1 liter P N413 7094 00 B A06FOP4 APPLICATION MX Z T A s...

Page 39: ...ction no 2 Fuel Filter Replacement This section no 3 Fuel Lines and Connections Sub section 04 09 Carburetor Adjustment Page 04 08 8 Throttle Cable Inspection Sub section 04 09 Air Filter Cleaning Thi...

Page 40: ...Ski Leg Camber Adjustment Sub section 08 01 Suspension Adjustments Except lan AS REQUIRED Section 07 See appropriate sub section and Operator s Guide Suspension Lubrication Section 07 See appropriate...

Page 41: ...els Restart engine and run at idle speed Inject storage oil until the engine stalls or until a sufficient quantity of oil has entered the engine approximately half a can With the engine stopped remove...

Page 42: ...dry it out F Series Lift hood and remove air filter s from air intake silencer TYPICAL 1 Air intake silencer 2 Air filter s Shake the snow out of filter s then dry it out All Models Check that the ai...

Page 43: ...icle including metallic parts 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...

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Page 45: ...E Test Inspection 1 Check spark plug s a Carbon accumulation caused by defective spark plug s Clean carbon accumulation and replace spark plug s 2 Check cooling system a Loose fan belt Adjust or repla...

Page 46: ...connections 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 t...

Page 47: ...eizure 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 replac...

Page 48: ...and 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...

Page 49: ...E 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 o...

Page 50: ...cations refer to TECHNICAL DATA 10 7 Perform engine leak test tool P N 861 7390 00 a Leaking gaskets allow air to enter in engine Replace defective parts SYMPTOM HIGH ENGINE OPERATING TEMPERATURE COND...

Page 51: ...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 plug s a Melted spa...

Page 52: ...Fully tighten 3 Check RAVE valve movement RAVE movement indicator P N 861 7258 00 a Valve s is are stuck in open position Clean SYMPTOM REWIND STARTER ROPE DOES NOT REWIND CONDITION NORMAL USE Test In...

Page 53: ...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 CONDITIO...

Page 54: ...NKCASE 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 RE...

Page 55: ...uel 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...

Page 56: ...cate 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 Chec...

Page 57: ...ir 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 nee...

Page 58: ...eflection according to specifi cations 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 h...

Page 59: ...ve pulley screw a Moving governor cup Retighten bolt 3 Spring cover bolts a Spring cover moves and restrains sliding half movement Retighten bolts 4 Check spring cover TRA TYPE and or outer half bushi...

Page 60: ...s 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 adjus...

Page 61: ...pulley halves are clean a Oil on pulley surfaces Clean pulley halves A00D0AY 4 Check pulley calibration a Improper pulley calibration Calibrate according to specification SYMPTOM BELT WORN EXCESSIVEL...

Page 62: ...tion 6 Check belt deflection a Deflection is too small Adjust according to specification A00D0CY 7 Check if parking brake is released a Parking brake is engaged Release parking brake SYMPTOM BELT SIDE...

Page 63: ...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 stationa...

Page 64: ...urn 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...

Page 65: ...NG Sub Section 03 TRANSMISSION AND BRAKE SYSTEM 03 03 8 MECHANICAL AND HYDRAULIC BRAKES SYMPTOM BRAKE SYSTEM IS NOISY CONDITION NORMAL USE Test Inspection 1 Check brake pad thickness a Pads are worn u...

Page 66: ...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 ch...

Page 67: ...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 T...

Page 68: ...tarter 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...

Page 69: ...ions a Heating rotating or sharp part in contact with harness Improper harness routing Repair replace damaged wires and or terminals Reroute harness where necessary 3 On manual start models Verify if...

Page 70: ...f 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 ac...

Page 71: ...parts Clean terminals and apply silicone dielectric grease Replace defective parts CONDITION NORMAL USE Test Inspection 1 Verify misfiring by observing flash of stroboscopic timing light unplug connec...

Page 72: ...N 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 recommen...

Page 73: ...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...

Page 74: ...COME BLUE 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 suspens...

Page 75: ...ication 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 TU...

Page 76: ...n 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 mod...

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Page 81: ...Section 04 ENGINE Sub Section 01 503 ENGINE TYPE 04 01 1 503 ENGINE TYPE 1 ENGINE REMOVAL AND INSTALLATION Skandic WT A22C0FS 21 N m 15 lbf ft...

Page 82: ...e battery ca ble on electric starting models negative cable from battery Positive cable and wire from starter then from engine belt guard drive belt drive pulley using appropriate puller refer to 05 0...

Page 83: ...tion 04 ENGINE Sub Section 01 503 ENGINE TYPE 04 01 3 TOP END A22C0GS 2 22 N m 16 lbf ft 2 22 N m 16 lbf ft 1 1 2 22 N m 16 lbf ft 1 3 4 5 6 7 8 15 16 17 11 9 12 10 9 22 N m 16 lbf ft 22 N m 16 lbf ft...

Page 84: ...N 529 0210 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 N...

Page 85: ...gs Before inserting piston in cylinder lubricate the cylinder with new injection oil or equivalent Install proper ring compressor on piston assem bly NOTE The ring compressor will not fit on over size...

Page 86: ...2 Nut and Distance Nut Position distance nuts as illustrated 503 ENGINE TYPE 1 Distance nuts Cross torque cylinder head nuts to 22 N m 16 lbf ft torque each cylinder head individually Install armatur...

Page 87: ...Section 04 ENGINE Sub Section 01 503 ENGINE TYPE 04 01 7 BOTTOM END A22C0HS 1 2 4 4 3 3 3 10 4 2 9 11 8 6 7 22 N m 16 lbf ft 22 N m 16 lbf ft 503 22 N m 16 lbf ft 5 22 N m 16 lbf ft 503...

Page 88: ...ENGINE DIMENSIONS MEASUREMENT 04 03 ASSEMBLY 3 4 Anti seize Lubricant and Ball Bearing Smear anti seize lubricant P N 413 7010 00 on part of crankshaft where bearing fits PTO Side Bearings To check pr...

Page 89: ...Spray Activator P N 413 7081 00 on mating surfaces to ensure paste gas ket will fully cured It increases cure speed and gap filling capability Then apply paste gasket P N 413 7027 00 on crankcase mat...

Page 90: ...AND MUFFLER All Models A06C3AS MX Z 440 583 and 670 S Series Formula SS Formula SS 454 and 670 engines MX Z 440 583 and 670 3 3 3 3 736 RTV 736 RTV 5 Loctite 271 1 23 N m 17 lbf ft 2 48 N m 35 lbf ft...

Page 91: ...d 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 t...

Page 92: ...Pipe sealant P N 413 7023 00 2 Grease Grease Loctite 242 583 engine type only Grease 30 N m 22 lbf ft Loctite 242 30 N m 22 lbf ft Grease Loctite 242 454 and 670 engine types only 10 N m 89 lbf in 1 1...

Page 93: ...on 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...

Page 94: ...n direction of the exhaust port 1 Exhaust NOTE Spare parts pistons and cylinders are identified with a green or red dot it is important to match the piston with the cylinder of the same color Use pist...

Page 95: ...st 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 cros...

Page 96: ...jam the assembly Install O ring Install exhaust valve assembly in cylinder with its cut away downward see illustration at re moval 11 12 13 14 Cylindrical Screw Lock Washer Valve Rod Housing and Gask...

Page 97: ...4 5 Lithium grease 3 4 454 and 670 engines only Anti seize lubricant Anti seize lubricant Loctite 515 Loctite 242 6 6 454 and 670 engines only 7 2 2 Except 454 and 670 See CDI SYSTEM 8 10 N m 89 lbf...

Page 98: ...y refer to DRIVE PULLEY 05 02 To remove magneto refer to CDI MAGNETO 04 05 2 4 6 9 Crankshaft Bearing To remove bearings from crankshaft use a pro tective cap and special puller as illustrated 1 PTO s...

Page 99: ...joining of crankcase halves spray some new injection oil or equivalent on all moving parts of the crankshaft Spray Activator P N 413 7081 00 on one of the mating surface to ensure paste gasket will fu...

Page 100: ...e sealant P N 413 7023 00 on threads prior to assembly angular tube 12 Crankcase Stud At assembly on crankcase apply medium strength threadlocker P N 413 7030 00 on stud threads 13 Crankcase Engine Br...

Page 101: ...3 599 AND 779 ENGINE TYPES 04 03 1 599 AND 779 ENGINE TYPES 3 ENGINE REMOVAL AND INSTALLATION Formula III III LT and Mach Z Z LT A06C0TS 37 N m 27 lbf ft 35 N m 26 lbf ft 29 N m 21 lbf ft 15 N m 133 l...

Page 102: ...lse 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 suppo...

Page 103: ...END A06C33S 10 N m 89 lbf in 30 N m 22 lbf ft Loctite 242 P N 413 7030 00 17 1 2 29 N m 21 lbf ft Grease 18 19 29 N m 21 lbf ft Grease 599 only 14 12 13 11 10 14 779 only 9 8 15 6 5 4 3 7 Molykote 111...

Page 104: ...pointed tool inserted in piston notch remove cir clip from piston Use piston pin puller P N 529 0210 00 Screw in puller in order to remove it from piston Remove piston from connecting rod NOTE 0 25 mm...

Page 105: ...valve rod into ex haust valve until following distance is respected Distance between RAVE valve and valve rod end is 58 mm 1 mm 2 283 039 in 779 ENGINE ONLY A 58 1 mm 2 283 039 in Back off distance n...

Page 106: ...lus tration below 1 Exhaust Install piston pin puller P N 529 0210 00 and turn handle until piston pin is correctly posi tioned in piston Remove piston pin puller To minimize the effect of acceleratio...

Page 107: ...o 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 TYPICA...

Page 108: ...III III LT Formula III III LT 1 1 4 6 Loctite 242 Loctite 648 2 3 3 2 Anti seize lubricant P N 413 7010 00 Molykote 111 P N 413 7070 00 Silicone 732 RTV 10 N m 90 lbf in 5 7 Loctite 242 779 only Loct...

Page 109: ...To remove magneto refer to CDI MAGNETO 04 05 2 3 Crankshaft Bearing To remove bearings from crankshaft use a pro tective cap and special puller as illustrated 1 PTO side 2 MAG side INSPECTION NOTE Re...

Page 110: ...as il lustrated 779 ENGINE 1 Drive pins A 8 mm 5 16 in 599 ENGINE 1 Drive pins Before joining crankcase halves spray some acti vator P N 413 7076 00 on one of mating surfac es Apply paste gasket Locti...

Page 111: ...e After that fuel oil mixture will lubricate water pump bearings by scavenging 6 Screw Apply Loctite 242 on screw threads Install the screw retaining oil line clip first If experiencing leaks at carbu...

Page 112: ...f rotary valve gear lubrication system 7 Install air pump on any valve of exhaust plug NOTE If necessary lubricate air pump pis ton with mild soap CAUTION Using hydrocarbon lubricant suchasengineoil w...

Page 113: ...lator cylinder head decompressor valve 247 and 277 types only cylinder base crankcase halves joint rotary valve cover oil injection pump mounting flange O ring seal coolant pump housing bleed screws p...

Page 114: ...h a hose pincer 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 pressu...

Page 115: ...s 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 Use special plug radiator cap...

Page 116: ...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 rest...

Page 117: ...heck 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...

Page 118: ...ld 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...

Page 119: ...mm 020 in 1 00 mm 040 in micrometer vernier Total shim thickness needed for the end play ad justment is determined with the following procedure a Measure crankcase halves as illustrated M1 and M2 A st...

Page 120: ...M1 M2 M3 B M4 M5 M6 M7 M8 A B Actual end play that must be within speci fication M8 is the dimension that must be adjusted to ob tain the specified crankshaft end play 1 End play is adjusted with shi...

Page 121: ...3 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...

Page 122: ...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 a...

Page 123: ...GNITION SYSTEM 454 583 and 670 Engines A15E0QT 7 6 3 Loctite 242 1 2 Loctite 242 Loctite 242 Loctite 648 4 Loctite 648 All engines except 454 and 670 22 N m 195 lbf in 5 Loctite 648 125 N m 92 lbf ft...

Page 124: ...04 05 2 599 and 779 Engines A06E21S Dielectric grease P N 413 7017 00 Dielectric grease P N 413 7017 00 Loctite 242 Loctite 242 Loctite 242 Dielectric grease P N 413 7017 00 22 N m 195 lbf in 1 2 6 7...

Page 125: ...heel 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 fastener it is first necessary to tap on the fas tener to break t...

Page 126: ...lows 1 Rotate flywheel so that the protrusion aligns with trigger coil 2 Using a feeler 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 tri...

Page 127: ...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...

Page 128: ...Section 05 CDI SYSTEM 04 05 6 DUCATI IGNITION SYSTEM 503 Engine A22E0HS Dielectric grease P N 413 7017 00 Dielectric grease P N 413 7017 00 1 2 3 4 5 22 N m 195 lbf in Loctite 242 Loctite 242 Loctite...

Page 129: ...own TYPICAL Tighten puller bolt and at the same time tap on bolt head using a hammer to release magneto flywheel from its taper REPAIR 4 9 Trigger Coil and Screw To replace trigger coil Disconnect tri...

Page 130: ...where mag neto harness exits magneto housing Remove armature plate retaining screws Remove armature plate with armature and carefully pull wires Install new parts and other parts removed ASSEMBLY 2 3...

Page 131: ...06 1 OIL INJECTION SYSTEM 6 OIL INJECTION PUMP 454 583 and 670 Engines Oil pump gasket set A15C1OT 1 2 Loctite 242 Low temperarure grease 3 6 5 Loctite 242 5 7 X X X X X X X X X Parts in illustration...

Page 132: ...Section 04 ENGINE Sub Section 06 OIL INJECTION SYSTEM 04 06 2 503 Engine A22C0DS Loctite 242 3 2 6 Loctite 242 1 Low temperature grease 4 6 5 5...

Page 133: ...n 04 ENGINE Sub Section 06 OIL INJECTION SYSTEM 04 06 3 599 and 779 Engines A06C32S 1 Loctite 648 779 engine 599 engine Loctite 242 2 6 6 6 6 Loctite 648 5 5 7 5 779 engine only Loctite 242 5 N m 44 l...

Page 134: ...hen lock gear in place using one of the following gear holder TYPICAL ASSEMBLY 2 Oil Pump Gear At gear assembly apply a light coat of low tem perature grease P N 413 7061 00 on gear teeth 4 Needle Rol...

Page 135: ...of the pump can result in serious engine damage To Bleed Oil Lines S Series Only Remove air silencer and move carburetors aside All Models Bleed main oil line between tank and pump by loosening the b...

Page 136: ...mall 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...

Page 137: ...Section 04 ENGINE Sub Section 07 AXIAL FAN COOLING SYSTEM 04 07 1 AXIAL FAN COOLING SYSTEM 7 503 Engine A22C0IS 1 2 3 12 11 10 9 5 4 8 7 6 13 14 15 16 17 18 55 N m 41 lbf ft...

Page 138: ...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 between pulley halves Install excess shim s between...

Page 139: ...d Cylinder Cowl At assembly apply a light coat of Loctite 242 blue on threads It should be noted that to cor rectly remove a threadlocked screw it is first nec essary to slightly tap on screw head to...

Page 140: ...Section 04 ENGINE Sub Section 08 LIQUID COOLING SYSTEM 04 08 1 LIQUID COOLING SYSTEM 8 S Series with 454 583 and 670 Engines A03C1DS Loctite PST 1 2 7 4 5...

Page 141: ...Section 04 ENGINE Sub Section 08 LIQUID COOLING SYSTEM 04 08 2 F Series with 583 and 670 Engines A06C37S 1 2 4 Loctite PST 3 7 6 5...

Page 142: ...Section 04 ENGINE Sub Section 08 LIQUID COOLING SYSTEM 04 08 3 599 and 779 Engines A06C0NS Loctite 592 5 3 4 1 2 6 7...

Page 143: ...this pressure 6 7 Radiator and Radiator Protector Insert 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 thermosta...

Page 144: ...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 CAUTION To prevent rust formation or freezi...

Page 145: ...NT PUMP AND RESERVOIR 04 09 1 ROTARY VALVE COOLANT PUMP AND RESERVOIR 9 454 583 and 670 Engines 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...

Page 146: ...and valve 3 17 Circlip and Pump Impeller CAUTION Bottom end must be opened to remove rotary valve shaft To remove rotary valve shaft assembly from crankcase first remove coolant pump impeller and circ...

Page 147: ...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 sh...

Page 148: ...ry valve Drive in place with the rotary valve shaft seal pusher P N 420 8770 50 1 Rotary valve side 2 Oil seal 3 Coolant seal Make sure not to obstruct draining hole Position seals so that hole is bet...

Page 149: ...water pump end bearing is correctly posi tioned with bearing pusher P N 420 8765 00 4 6 Rotary Valve Shaft and Loctite 648 CAUTION Crankcase halves must be separated and crankshaft must not be presen...

Page 150: ...cases do not have timing marks ridge the second method is required Take note that the second method is more accu rate and may be used any time Installation To correctly install rotary valve proceed as...

Page 151: ...g rotary valve cover To Time Rotary Valve Exactly to Specifications NOTE If desynchronization out of spec is unknown install rotary valve to determinate it before proceeding with the following First M...

Page 152: ...osition of mark when brass gear disengage worm gear 2 Advanced by 2 3 Position of mark before installation about 10 splines from original position 1 2 Screw and Rotary Valve Cover Install O ring and c...

Page 153: ...10 REWIND STARTER 04 10 1 REWIND STARTER 0 All Models TYPICAL A01C57S 12 11 10 9 13 8 6 5 4 15 16 17 3 1 14 Molykote G n paste or equivalent Silicone compound grease Silicone compound grease 2 1 10 N...

Page 154: ...To remove rope from rewind starter mechanism Untie the knot while holding sheave Allow sheave to turn slowly clockwise 8 9 10 11 12 Pawl Pawl Lock Circlip Locking Spring and Locking Ring First remove...

Page 155: ...e Starter Rope and Key To install a new rope insert rope into sheave ori fice and lock it with the key as illustrated 1 Push to lock To adjust rope tension Wind rope on sheave and place rope sheave in...

Page 156: ...bly on engine 670 Engine Only Install rewind starter on damper ring matching notches and emboss of damper ring 1 Notch All Models 6 Starter Rope Thread starter rope through rope guide when ap plicable...

Page 157: ...NE Sub Section 11 CARBURETOR AND FUEL PUMP 04 11 1 CARBURETOR AND FUEL PUMP 1 MIKUNI FLOAT CARBURETOR NOTE Refer to TECHNICAL DATA section 10 for carburetor application A22C0JS 5 3 2 1 14 6 7 13 10 11...

Page 158: ...VM 34 469 VM 34 470 VM 40 81 VM 40 82 only VM 40 76 VM 40 77 VM 40 79 VM 40 83 VM 40 84 VM 40 85 only VM 36 172 VM 36 173 VM 36 174 VM 38 319 VM 38 320 only 9 8 11 12 7 1 5 2 3 4 14 VM 34 469 VM 34 4...

Page 159: ...Section 04 ENGINE Sub Section 11 CARBURETOR AND FUEL PUMP 04 11 3 A06C38S 1 2 4 3 7 5 10 13 12 8 9 6 Carburetor TM 38 C133...

Page 160: ...as they are flammable and explosive Check inlet needle tip condition If worn the inlet needle and seat must be replaced as a matched set NOTE Install needle valve for snowmobile carburetor only It is...

Page 161: ...cation of the E clip from top 1 Lean 2 Rich 5 Throttle Slide The size of the throttle slide cut away affects the fuel mixture between 1 8 to 1 2 throttle opening A certain amount of richness is needed...

Page 162: ...tion below shows which part of the carburetor begins and to stops to function at dif ferent throttle slide openings Note that the wider part of symbol corresponds to the opening mostly affected For in...

Page 163: ...to 0 5 to 0 8 N m 4 5 to 7 2 lbf in Center Post Retaining All Models Hook throttle cable into the needle retainer plate NOTE Do not obstruct hole in throttle slide when installing needle retaining pla...

Page 164: ...chanism Throttle Slide Adjustment CAUTION Ensure the engine is turned OFF prior to performing the throttle slide adjustment For maximum performance correct carburetor throttle slide adjustment is crit...

Page 165: ...E 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...

Page 166: ...nut Mach Z Z LT Choke Plunger Adjustment The 3 plungers must be properly synchronized Make sure set screws of tabs are in the sliding rod holes If adjustment is required slightly bent the choke plunge...

Page 167: ...on middle carburetor to change choke cable posi tion 1 Choke cable support After adjustment retighten screw HAC SYSTEM Summit Only HAC High Altitude Compensator is a mainte nance free device No adjus...

Page 168: ...Section 04 ENGINE Sub Section 11 CARBURETOR AND FUEL PUMP 04 11 12 HAC SYSTEM A03I0BS...

Page 169: ...Section 04 ENGINE Sub Section 11 CARBURETOR AND FUEL PUMP 04 11 13 FUEL PUMP A06C39S 503 engine 454 engine 583 599 670 and 779 engines...

Page 170: ...mpulse 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...

Page 171: ...eposition spring clips after any repair to prevent possible leaks Throttle Cable Circlip at Handlebar All Models Put silicone grease P N 413 7017 00 around ca ble barrel Locate circlip as per illustra...

Page 172: ...wiring throughout the circuit Connections must be clean and tight and wiring free of damage Re pair as necessary Use silicone dielectric grease to prevent corrosion at the connectors Operate the engin...

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Page 175: ...ch time a new drive belt is installed NOTE To obtain an accurate drive belt de flection measurement it is suggested to al low a break in period of 50 km 30 mi MODEL PART NUMBER WIDTH NEW 0 25 mm 010 i...

Page 176: ...belt tension tester P N 414 3482 00 1 Lower O ring 2 Upper O ring 3 Force read down 4 Deflection read up 1 Slide lower O ring of deflection scale to speci fied measure 2 Slide upper O ring to zero on...

Page 177: ...ten ing jam nut to prevent throwing adjustment out Use drive belt tension adjuster P N 529 0087 00 Restrain Allen screws with the wrench and tight en nut with the socket using socket handle provid ed...

Page 178: ...This is a lubrication free drive pulley A19D07S 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...

Page 179: ...rson Sub component installation and assembly tolerances require strict adherence to procedures detailed REMOVAL 30 31 Conical Spring Washer and Screw Use clutch holder P N 529 0064 00 TYPICAL 1 Retain...

Page 180: ...vernor 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 oth...

Page 181: ...urfaces with paper towel and cleaning solvent P N 413 7082 00 Wipe off the mounting surfaces with a clean dry paper towel CAUTION Mounting surfaces must be free of any oil cleaner or towel residue 7 2...

Page 182: ...then flared to prevent displacement in sliding half To flare bushing use spring compressor P N 529 0151 00 and appropriate flare tools Apply retaining compound P N 413 7031 00 outside of bushing then...

Page 183: ...essor P N 529 0151 00 and appropriate flare tools CAUTION Insert bushing from sliding half side inner of spring cover Start driving bushing into spring cover 1 Note upper tool side Press bushing 1 Not...

Page 184: ...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 at the shown side Besides install cotter pin head on...

Page 185: ...halves Note that fixed halves have different cone angle Match cone an gle with crankshaft Lift sliding half against spring cover and align spring cover arrow with sliding half mark 1 Align Install and...

Page 186: ...red to as follows Lock crankshaft in position as explained in remov al procedure Install drive pulley on crankshaft extension Install conical washer with its concave side to wards drive pulley then in...

Page 187: ...he number is substituted by a dot due to its location on casting See TECHNICAL DATA 10 for original setting 1 Position 1 not numbered Each number modifies maximum engine RPM by about 200 RPM Lower num...

Page 188: ...05 TRANSMISSION Sub Section 03 DRIVEN PULLEY 05 03 1 DRIVEN PULLEY 3 S Series and F Series p A15D1DS 14 2 19 18 8 6 5 15 4 7 9 10 16 11 17 12 13 Anti seize lubricant P N 413 7010 00 Loctite 609 Locti...

Page 189: ...Section 05 TRANSMISSION Sub Section 03 DRIVEN PULLEY 05 03 2 Skandic WT A22D11S Anti seize lubricant 4 5 19 2...

Page 190: ...ded use above mentioned tool CLEANING 6 7 Large 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 c...

Page 191: ...crew 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 60...

Page 192: ...pulley installation F Series and S Series Only Should installation procedure be required refer to BRAKE 05 05 then look for Brake Disc and Coun tershaft Bearing Adjustment Reinstall the pulley on the...

Page 193: ...crease the pre load and counterclockwise to decrease it Refer to 10 TECHNICAL DATA NOTE If spring pre load can not be adjust ed try to relocate the other end of spring in sliding pulley holes A B C Le...

Page 194: ...ISSION Sub Section 03 DRIVEN PULLEY 05 03 7 NOTE For high altitude regions the High Altitude Technical Data Booklet P N 484 0624 00 and 484 0545 00 for binder gives infor mation about calibration acco...

Page 195: ...cle to creep forward at idle All pulley alignment specifications refer to X Distance between straight bar and drive pul ley fixed half edge measured between pul leys Y Distance between straight bar an...

Page 196: ...N installation section PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART Alignment templates have been made according to pulley alignment nominal values However they do not take into account allowed...

Page 197: ...e 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...

Page 198: ...Section 05 TRANSMISSION Sub Section 05 BRAKE 05 05 1 BRAKE 5 Summit 583 A03D12S 7 11 1 12 25 17 Loctite 242 19 20 9 5 14 15 16 2 Dielectric grease Anti seize lubricant Anti seize lubricant...

Page 199: ...Section 05 TRANSMISSION Sub Section 05 BRAKE 05 05 2 MX Z 440 583 670 Summit 670 Formula Z SS III III LT and Mach Z Z LT A06D1VS 7 Loctite 242 Anti seize lubricant 17 18 19 20 24 Black Max...

Page 200: ...Section 05 TRANSMISSION Sub Section 05 BRAKE 05 05 3 Skandic WT A22D12S 1 15 16 12 17 5 11 7 9...

Page 201: ...rip from bumper on brake disc side Remove screw from output shaft Unbolt caliper from gearbox then remove brake disc and caliper as an assembly COUNTERSHAFT REMOVAL Mechanical Brake Models Proceed the...

Page 202: ...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 w...

Page 203: ...ke Models Fully depress brake handle several times to obtain 13 mm 1 2 in between brake handle and handle bar grip when brake is fully applied A 13 mm 1 2 in approx Should this adjustment be unattaina...

Page 204: ...pads touch brake disc To adjust unscrew nut no 10 until brake light goes on WARNING At least one full thread must ex ceed the elastic stop nut Check brake adjustment as described above NOTE If brake...

Page 205: ...and F Series Without Reverse Gear SYNTHETIC CHAINCASE OIL HUILE SYNTH TIQUE POUR CARTER 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...

Page 206: ...ws 21 Drive Axle Holder Release track tension use drive axle holder P N 529 0072 00 TYPICAL 1 Drive axle 2 Suspension cross shaft 20 Drive Axle Oil Seal Pry out from chaincase Pull chaincase from driv...

Page 207: ...pin will rub on chain case cover if installed otherwise 1 New 2 Fold cotter pin over castellated nut flats only 18 Circlip CAUTION It is of the utmost importance to install the circlip otherwise damag...

Page 208: ...Section 05 TRANSMISSION Sub Section 06 CHAINCASE 05 06 4 Track Tension and Alignment Refer to TRACK 07 05 1 Dipstick 2 Oil lever 3 Level between marks 1 1 2 3 A06D1OA...

Page 209: ...Section 05 TRANSMISSION Sub Section 07 GEARBOX 05 07 1 GEARBOX 7 3 SPEED GEARBOX SHIFTER MECHANISM Skandic WT A22D0YS 7 4 4 5 6 5 3 2 1...

Page 210: ...en tie rod lock nut Unfasten tie rod end by removing its clip 1 Clip 1 Lock nut Adjust tie rod length in a way that gear shift lever do not contact console Check 2nd gear position Retighten ball joint...

Page 211: ...Section 05 TRANSMISSION Sub Section 07 GEARBOX 05 07 3 Skandic WT 1 2 3 4 8 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 14 21 22 23 23 24 25 26 29 30 31 17 28 27 28 5 A22D0CS...

Page 212: ...disc side 1 RH side driven pulley side 2 LH side brake disc side 3 4 7 14 16 20 Dipstick Top Cover Gasket O ring Upper Side and Lower Side Cover Remove dipstick Unfasten top cover upper side cover and...

Page 213: ...Pry oil seal out of gearbox housing Remove snap ring Drive out driven pulley shaft Use alignment tool P N 420 4760 10 as a supporting plate to ex tract last gear and bearing Spacer will fall into gear...

Page 214: ...splines on RH side 25 29 Lower Gear and Intermediate Gear Install all gears with their shoulder towards RH side 1 Gear shoulder towards RH side 18 19 26 27 28 Reverse Shaft LH Side Bearing Brake Shaf...

Page 215: ...ver to hold index ball See illustration for fork axle posi tions INSTALLATION Reverse removal procedure Check pulley align ment OIL LEVEL To check pull dipstick Oil should reach level mark TYPICAL 1 L...

Page 216: ...e are 2 types of silent chain One is 11 link wide and the other stronger is 13 link wide Do not interchange sprockets Fit chain on sprockets to make sure using right ones according to width Refer to T...

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Page 219: ...DEL WIRING DIAGRAM PAGE HEADLIGHT watt TAILLIGHT watt ELECTRICAL SYSTEM OUTPUT watt MX Z 440 583 670 Annex 1 60 55 hal 8 27 220 Summit 583 670 Annex 2 60 55 hal 8 27 220 Formula Z Annex 3 60 55 hal 8...

Page 220: ...eam 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...

Page 221: ...ng by a spring tab on its side Removal is done by squeezing this tab 1 Locking tab To remove Insert a screwdriver or Snap on TT 600 5 from side opposite of wire and pry locking tab While holding locki...

Page 222: ...TALLATION On all electric start models The direct current DC utilizes the snowmobile frame as ground wire while all alternating current AC consum ers lights heated grips fuel gauge etc utilize a separ...

Page 223: ...CAL Sub Section 01 WIRING DIAGRAMS 06 01 5 WARNING Never secure electrical wires cables with fuel lines Keep wires away from any rotating moving heating vibrating or sharp edge Use proper fastening de...

Page 224: ...e position 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 engin...

Page 225: ...NGINES 1 Advance 2 Retard NOTE These marks can not be used to check dynamic with engine running ignition timing with a timing light an other mark is scribed on magneto flywheel or damper for this purp...

Page 226: ...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 an...

Page 227: ...n the spark plug hole magneto generator side and adjust as follows a Position the magneto flywheel at approxi mately TDC INSTALLATION OF TDC GAUGE 1 Adaptor lock nut 2 Gauge on MAG side cylinder b Ass...

Page 228: ...ark 2 Magneto flywheel mark NOTE These marks can not be used to check dynamic with engine running ignition timing with a timing light a new mark must be scribed on magneto flywheel for this purpose 6...

Page 229: ...GS 03 03 1 SPARK PLUGS 3 NGK SPARK PLUG NGK SPARK PLUG NUMBERING SYSTEM The heat range identification system is High number cold plug Low number hot plug 1996 REFERENCE CHART NGK spark plugs used on 1...

Page 230: ...9 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 Standa...

Page 231: ...re engine damage might occur if a wrong heat range plug is used A too hot plug will result in overheating and pre ignition etc A too cold plug will result in fouling shorting the spark plug or may cre...

Page 232: ...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 c...

Page 233: ...throttle cable and primer hose attach ment from air silencer Unplug CDI box harness connector Slacken collar on carburetor adaptors Remove air silencer CDI box will come along with 1 Attachment 2 CDI...

Page 234: ...ery interior since it will destroy the electrolyte 1 Baking soda Remove corrosion from battery cable terminals and battery posts using a firm wire brush INSPECTION Visually inspect battery casing for...

Page 235: ...ic grease P N 413 7017 00 or petroleum jelly on terminals Clean battery casing and caps using a solution of baking soda and water Do not allow cleaning so lution to enter battery otherwise it will des...

Page 236: ...move caps and fill battery to UPPER LEVEL line with electrolyte specific gravity 1 260 at 20 C 68 F 3 Allow the battery to stand for 30 minutes MIN IMUM so that electrolyte soak through battery cells...

Page 237: ...Keep battery away from cigarettes or open flames Always turn battery charger off prior to discon necting cables Otherwise a spark will occur and battery might explode 7 Disconnect battery charger 8 Te...

Page 238: ...ent to rise which makes the electro lyte a better conductor and then the battery will accept a higher charging rate Type of charger Battery chargers vary in the amount of voltage and current that they...

Page 239: ...nd they are suitable for use with most chargers if the peak current is to be held below 2 amps If you need an accurate ammeter we recommend the use of SHURITE 5202 0 to 3 amps or 5203 0 to 5 amps avai...

Page 240: ...ed or bent tube will restrict ventilation and create gas accumulation that might result in an explosion S Series With Electric Starting Fasten spark plug cables to fan housing Reinstall throttle cable...

Page 241: ...Section 06 ELECTRICAL Sub Section 05 ELECTRIC STARTER 06 05 1 ELECTRIC STARTER 5 Skandic WT S Series and F Series with Electric Starting A24E01S 1 2 3 8 9 10 11 12 13 14 15 16 17 18 19 4 5 6 7 12...

Page 242: ...se thrust washer at shaft end 4 5 7 Insulator Brush Holder and Spring Remove insulator then brush springs being care ful not to lose them since they will be projected out Pull brush holder from yoke 1...

Page 243: ...nt of radial play between the armature shaft and the bushing The radial play should not exceed 0 20 mm 008 in If greater replace bushing as follows Using a 12 mm tap cut threads into bushing so that t...

Page 244: ...arts on armature shaft splines overrun ning clutch solenoid switch plunger drive lever and bushings with G E Versilube G 321 P N 413 7040 00 lubricant Proceed as follows for assembling Secure drive ho...

Page 245: ...tighten screws 10 15 17 Solenoid Drive Lever and Drive Housing Insert solenoid plunger inside of drive lever fork and secure to drive housing Connect starter bare wire to solenoid NOTE Connect this wi...

Page 246: ...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 Con...

Page 247: ...e following testing procedures except for the one concerning the shorted windings in the arma ture Check the commutator for roughness burnt or scored surface If necessary turn the commutator on a lath...

Page 248: ...pen circuited 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 I...

Page 249: ...tion If defec tive replace Check the pinion teeth for wear and damage If defective replace SOLENOID SWITCH Inspect connections and clean as necessary Sole noid switch condition can be checked with an...

Page 250: ...7860 454 494 and 670 Engines Ignition module stamped P N 070000 2281 Ignition coil stamped P N 129700 2982 Flywheel stamped P N 032700 5900 NIPPONDENSO CDI TRIGGER COIL SYSTEM 1 Separate ignition coi...

Page 251: ...EN WHITE wires 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 Electric...

Page 252: ...llowing 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 b...

Page 253: ...lamp lights Trigger coil output is up to specifications b Indicator lamp does not light The problem is a faulty trigger coil or bad grounding IGNITION COIL OUTPUT A paper clip of approximately 20 mm 3...

Page 254: ...Slip plastic protectors out of coil terminals 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 TYPICA...

Page 255: ...follows 1 Yellow 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 lam...

Page 256: ...dule output N WHITE BLUE wire of ignition coil LOW 85 P BLACK wire of ignition coil Magneto output ignition generator coil All engines except 599 and 779 N RED wire of magneto harness LOW 85 P BLACK R...

Page 257: ...evel which is not detect able with an ohmmeter Infinity extremely large number PART NAME WIRE COLOR RESISTANCE OHM REMARKS MAGNETO Trigger coil BL YL with WH YL 190 300 No display change means open ci...

Page 258: ...prob lem is a faulty trigger coil or bad grounding MAGNETO OUTPUT Ignition Generator Coil 1 Disconnect the 2 wire connector between igni tion module and magneto harness 2 Connect tester wires then se...

Page 259: ...hen other components test good the module is probably faulty Try a new module LIGHTING GENERATOR COIL OUTPUT NOTE The lighting generator coil is not part of the ignition system It is a separate sys te...

Page 260: ...Test to perform Tester wires Component wires Switch Dial Trigger coil output N WHITE RED wire of trigger coil LOW 45 P Engine ground Magneto output ignition generator coil N GREEN wire of magneto har...

Page 261: ...ce measurement can still be faulty Voltage leak can occur at high voltage level which is not detect able with an ohmmeter The primary winding of ignition coil can not be measures because there is no e...

Page 262: ...nal indicates a good and working regulator B Voltmeter Test NOTE Use a voltmeter able to read alter nating current AC For accurate reading use a RMS voltmeter Connect a wire of the voltmeter to a BLAC...

Page 263: ...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 r...

Page 264: ...performed at 21 C 70 F Throttle Lever Heating Element Handlebar Grip Heating Element HIGH INTENSITY YELLOW BLACK wire BROWN wire 1 96 to 3 64 ohms LOW INTENSITY YELLOW BLACK wire BROWN YELLOW wire 8 0...

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Page 266: ...Z Z LT A03F1KS Summit only Except Summit Summit only Except Summit Loctite 271 Loctite 271 Low temp grease Front arm MX Z 440 only 21 Except Summit Summit only Except MX Z 583 and 670 Except Summit E...

Page 267: ...lt Align spacer hole with adjusting bolt TYPICAL All Models Except Summit 22 Threaded Rod Remove adjusting nut then unscrew threaded rod from pivot block Remove threaded rod 23 Cushion After threaded...

Page 268: ...ng 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 CAUTION Take...

Page 269: ...icle 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 thread locker proceed as...

Page 270: ...se than those used as pivot axles Idler wheel axles can be used as pivot axles but the opposite is not true 12 13 14 Front Shock Spring Stopper and Cap Use shock spring remover P N 529 0271 00 in a vi...

Page 271: ...felt when compressing shock When released the shock will extend unassisted Renew as required HPG T A Take Apart Shock Servicing MX Z 440 Only This damper is completely rebuildable It offers the option...

Page 272: ...Holding damper assembly in bench vise unthread seal assembly from damper body using a 32 mm 1 25 in spanner wrench This assembly uses a right hand thread NOTE Before unscrewing pre load rings mark pos...

Page 273: ...ever using compressed air use an O S H A approved air gun and wear protective eye wear Thoroughly clean with a typical cleaning solution and blow dry using low pressure air Carefully in spect the damp...

Page 274: ...own 4 NOTE Rebound shim stack must not reach into threads of damper shaft Wash er under damper shaft nut is used to prevent damper shaft nut from bottoming on threads Rebound damping options from Bomb...

Page 275: ...ions The most noticeable symptom will be a bouncing of the snowmobile when encountering bumps NOTE Careful inspection of the damping shims should be completed Any bent shims must be replaced to insure...

Page 276: ...Install floating piston to depth of 151 mm 5 94 in for front damper 190 mm 7 48 in for rear damp er and 141 mm 5 55 in for center damper Mea sure from the top edge of the damper body NOTE If the floa...

Page 277: ...capacity is required to insure that no air is in damper body during assembly NOTE Some shock oil will overflow when installing damper for assembly Wrap damp er with shop cloth to catch possible overfl...

Page 278: ...corrected before continuing Damper gas pressure can be confirmed by using a pressure gauge available through your local in dustrial gas supplier 1 Automotive type air pressure hose 2 Two stage regulat...

Page 279: ...r shims against the piston No less than 3 shims should be used in any valve stack to prevent bending or breakage One 114 mm spacer washer min imum 2 or more recommended should be used between shim sta...

Page 280: ...Section 07 REAR SUSPENSION Sub Section 02 SKANDIC WT SUSPENSION 07 02 1 SKANDIC WT SUSPENSION 2 Skandic WT A22F18S 1 2 3 7 4 5 6 8...

Page 281: ...r bond Loosen one screw then retighten Remove the opposite screw Remove the first one Remove suspension ass y DISASSEMBLY AND ASSEMBLY 1 Extension Remove nuts and conical washers from the eye bolt adj...

Page 282: ...wheel axle Remove idler wheel on side where axle retaining plate is not welded Remove springs 1 Circlips 6 Support Plate Drill rivets to remove support plate Use a 8 mm 21 64 in drill bit Rivets can...

Page 283: ...en check that it moves smoothly and with uniform resistance Pay attention to the following conditions that will denote a faulty shock A skip or a hang back when reversing stroke at mid travel Seizing...

Page 284: ...NSION 03 03 1 IMPROVED C 7 SUSPENSION 3 Formula III III LT and Mach Z Z LT 14 48 N m 35 lbf ft 7 6 5 16 16 16 16 16 48 N m 35 lbf ft 13 16 13 48 N m 35 lbf ft Loctite 271 Loctite 271 10 Loctite 271 8...

Page 285: ...19 and spring clamps no 18 on axle no 17 until stopper strap is in line with its tensioner mounted on front arm See illustration below 1 2 3 4 Slider Shoe Bolt Washer and Nut To replace a worn shoe re...

Page 286: ...ng Lubricate until grease appears at joints using low temperature grease P N 412 7061 00 Front arm upper and lower axles Rear arm upper and lower axles Rear shackle NOTE There are 7 lubrication points...

Page 287: ...al At installation position spring stopper slit on op posite side of spring coil end SHOCK ABSORBER SERVICING Because of gas pressure strong resistance is felt when compressing shock When released the...

Page 288: ...Section 07 REAR SUSPENSION Sub Section 04 DRIVE AXLE 07 04 1 DRIVE AXLE 4 S Series and F Series A03D20S 12 6 13 9 13 10 2 3 5 11 4 8 Summit and MX Z only...

Page 289: ...Section 07 REAR SUSPENSION Sub Section 04 DRIVE AXLE 07 04 2 Skandic WT A22D14S 9 8 9 3 2 5...

Page 290: ...ease drive axle sprocket from track and at the same time pulling the drive axle towards the end bearing housing side Remove drive axle from vehicle Skandic WT Only Drain gearbox Raise and block rear o...

Page 291: ...et near hub NOTE Two different types of sprocket press fit can be found Ensure to replace ring reinforced sprockets with the same type ASSEMBLY 8 9 13 Drive Axle and Sprocket To assemble press fit spr...

Page 292: ...le assembly on a plane surface and measure the gap between sprocket tooth and surface 1 Plane surface A 1 5 mm 1 16 in MAXIMUM CAUTION The same sprocket must not be pressed twice on the axle If synchr...

Page 293: ...efore attempting to adjust the drive axle axial play check the chaincase perpendicularity as follows CHAINCASE PERPENDICULARITY ADJUSTMENT Remove driven pulley Slacken bearing collar set screw and wor...

Page 294: ...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 n...

Page 295: ...n installing shims between 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 d...

Page 296: ...l 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 c...

Page 297: ...d end bearing housing track Skandic WT Remove the following parts rear suspension muffler RH drive axle end bearing angle drive and square pin Move transmission sideway Do not remove brake mechanism n...

Page 298: ...olts located on the inner side of the rear idler wheels TYPICAL 1 Retaining screw 2 Adjuster bolt Alignment WARNING Before checking track ten sion ensure that the track is free of all par ticles which...

Page 299: ...AL 1 Retighten Restart engine rotate track slowly and recheck alignment TRACK CLEAT Removal Raise rear of vehicle off the ground and lift snowguard then rotate track to expose a cleat to be replaced U...

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Page 301: ...n 01 STEERING SYSTEM 08 01 1 STEERING SYSTEM 1 S Series A22G0KS 7 25 23 24 31 5 3 8 15 20 21 15 16 21 9 20 21 9 15 10 2 25 N m 18 lbf ft 6 10 17 9 21 1 A22G0KS 7 25 23 24 31 5 3 8 15 20 21 15 16 21 9...

Page 302: ...7 25 8 31 5 1 9 21 14 13 16 9 21 15 26 9 21 10 16 13 20 12 15 10 17 11 21 9 25 N m 18 lbf ft 40 N m 30 lbf ft 25 N m 18 lbf ft 18 N m 159 lbf in 52 N m 38 lbf ft 40 N m 30 lbf ft 18 N m 159 lbf in 18...

Page 303: ...b Section 01 STEERING SYSTEM 08 01 3 Skandic WT A22G0KS 7 25 23 24 31 5 3 8 15 20 21 15 16 21 9 20 21 9 15 10 2 25 N m 18 lbf ft 6 10 17 9 21 1 A22G0KS 7 25 23 24 31 5 3 8 15 20 21 15 16 21 9 20 21 9...

Page 304: ...ove the air intake silencer and carburetor s Detach 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 s...

Page 305: ...the tie rod The maximum external threaded length not engaged in the tie rod must not exceed the value L in the following thread length chart TYPICAL The ball joint should be restrained when tighten in...

Page 306: ...ten ball joint nuts and jam nuts to specified torque see exploded view 9 F Series Vehicles with a Castle Nut After proper torque has been applied to the ball joint nut insert a cotter pin through the...

Page 307: ...ixed to their normal location on the handlebar 7 23 24 26 Steering Pad Bolt Nut and Rubber Attachment CAUTION Prior to installation perform handlebar adjustment Properly fit the steering pad to the ha...

Page 308: ...NOTE On vehicles without adjustable radi us arms no 7 the camber is not adjustable NOTE Identical adjustments are required on both sides of the vehicle Make sure the vehicle is leveled by placing an a...

Page 309: ...n Close front of skis manually to take all slack from steering mechanism NOTE A rubber cord must be hooked in front of skis to keep them closed Skandic WT Only Skis should have a toe out of 10 mm 3 8...

Page 310: ...se 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 temperature grease 2 Penetrating lubricant P...

Page 311: ...Section 08 STEERING FRONT SUSPENSION Sub Section 01 STEERING SYSTEM 08 01 11 S Series and F Series A06G08S If so equipped...

Page 312: ...ON AND SKI SYSTEM 2 F Series and S Series A06G14S 14 12 13 25 N m 18 lbf ft Loctite 242 29 N m 21 lbf ft Some models Some models Some models 10 4 3 2 1 6 5 7 8 17 5 N m 159 lbf in 5 5 15 N m 136 lbf i...

Page 313: ...ition of the clevis pin Push down on the handle until it locks Remove spring stopper and cap then release handle When installing the cap opening must be 180 from the spring stopper opening 1 Cap openi...

Page 314: ...when deteriorated To check condition of shock refer to IMPROVED C 7 SUSPENSION 07 02 then look for Shock Ser vicing INSTALLATION For assembly reverse the disassembly proce dure However pay attention...

Page 315: ...Section 08 STEERING FRONT SUSPENSION Sub Section 02 SUSPENSION AND SKI SYSTEM 08 02 4 WRONG POSITION A06G0XA...

Page 316: ...Section 08 STEERING FRONT SUSPENSION Sub Section 02 SUSPENSION AND SKI SYSTEM 08 02 5 Skandic WT A22G0NS 1 2 3 4 5 6 7 8 9 13 N m 115 lbf in 9 11 18 12 10 17 16 14 15 4 13 Grease...

Page 317: ...80 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...

Page 318: ...ut bushings and ski Unscrew shock piston pin nut then remove wash er Shock will fall off the ski leg Unscrew 3 Allen screws retaining cover then re move stopper and washers 1 Allen screws NOTE These w...

Page 319: ...shock body Examine each shock for leaks Extend and com press the piston several times over its entire stroke then check that it moves smoothly and with uniform resistance Pay attention to the followi...

Page 320: ...Section 08 STEERING FRONT SUSPENSION Sub Section 02 SUSPENSION AND SKI SYSTEM 08 02 9 TYPICAL 1 Bent angle toward the bottom 16 17 Seal Install seal before reinstalling ski leg A05G0CB 1...

Page 321: ......

Page 322: ...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 RE...

Page 323: ...sive under certain conditions Al ways manipulate in a well ventilated area Do not smoke or allow open flames or sparks in the vicinity Position the windshield on the hood then push it down until the t...

Page 324: ...away from any rotating moving heating and vibrating parts Use proper fastening de vices as required CABLES WARNING Before installation ensure that all cables are in perfect condition Properly install...

Page 325: ...components used on the vehicles gasoline brake fluid kerosene diesel fuel lighter fluid varsol naphtha acetone strong detergents abrasive cleaners waxes containing an abrasive or a cleaning agent in t...

Page 326: ...TION 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...

Page 327: ...Heat the surface with a heater lamp placed at 38 cm 15 in for a period of 15 minutes Sand the repair using a smooth dry sand paper Use the same product if a final finish is re quired Clean surface wi...

Page 328: ...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...

Page 329: ...UTION Avoid use of harsh detergent such as strong soaps degreasing sol vents abrasive cleaners paint thinners etc that may cause damage to the seat cover FRAME WELDING Steel Frame electric welding amp...

Page 330: ...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 four cor ner holes Radiator Grind outside rivet heads...

Page 331: ...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 m c one thousand one hundredth one...

Page 332: ...BR9ES NGK BR9ES NGK BR9ES NGK BR9ES Spark Plug Gap mm in 0 45 018 0 45 018 0 45 018 0 45 018 0 45 018 Ignition Timing BTDC mm in 1 66 065 1 48 058 1 75 069 1 93 076 1 75 069 Generating Coil Low Speed...

Page 333: ...k Plug Gap mm in 0 45 018 0 45 018 0 45 018 0 45 018 0 45 018 Ignition Timing BTDC mm in 1 93 076 1 75 069 1 93 076 2 18 086 2 11 083 Generating Coil Low Speed 10 17 10 17 10 17 49 75 49 75 High Speed...

Page 334: ...38 15 0 38 15 0 38 15 0 Length cm in 394 155 307 121 307 121 307 121 Adjustment Deflection mm in 40 45 1 9 16 1 3 4 45 50 1 3 4 1 31 32 45 50 1 3 4 1 31 32 45 50 1 3 4 1 31 32 Force kg lbf 7 3 16 7 3...

Page 335: ...38 15 0 38 15 0 38 1 15 0 38 1 15 Length cm in 345 136 345 136 307 121 307 121 Adjustment Deflection mm in 45 50 1 3 4 1 31 32 45 50 1 3 4 1 31 32 45 50 1 3 4 1 31 32 45 50 1 3 4 1 31 32 Force kg lbf...

Page 336: ...8 1 15 38 1 15 Length cm in 307 121 345 5 136 307 121 345 5 136 Adjustment Deflection mm in 45 50 1 3 4 1 31 32 45 50 1 3 4 1 31 32 45 50 1 3 4 1 31 32 45 50 1 3 4 1 31 32 Force kg lbf 7 3 16 7 3 16 7...

Page 337: ...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 All resistance measurements must be performed with parts at room temperature app...

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