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Ski-Doo FORMULA S 1997, Shop Manual

The Ski-Doo FORMULA S 1997 is a high-performance snowmobile built for speed and agility on the slopes. To ensure you can properly maintain and repair your machine, download the free Shop Manual from manualshive.com. This comprehensive manual provides step-by-step instructions for servicing your Ski-Doo to keep it running at its best.

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Section 05

ELECTRICAL

Sub-Section 01

(TABLE OF CONTENTS)

05-01-2

CLEANING AND INSPECTION ..........................................................................................05-06-6
CLEANING ..........................................................................................................................05-06-6
INSPECTION .......................................................................................................................05-06-6
SOLENOID SWITCH .......................................................................................................

05-06-8

STARTER REMOVAL ...................................................................................................... 05-06-10
STARTER DISASSEMBLY .............................................................................................. 05-06-10
CLEANING ...................................................................................................................... 05-06-11
PARTS INSPECTION....................................................................................................... 05-06-11
STARTER ASSEMBLY .................................................................................................... 05-06-12
STARTER INSTALLATION .............................................................................................. 05-06-13

TESTING PROCEDURE ......................................................................................................

05-07-1

GENERAL........................................................................................................................

05-07-1

USE OF BOMBARDIER IGNITION TESTER ..................................................................

05-07-2

NIPPONDENSO CDI TRIGGER COIL SYSTEM TESTING.............................................

05-07-4

TRIGGER COIL OUTPUT................................................................................................

05-07-4

IGNITION COIL OUTPUT ...............................................................................................

05-07-4

IGNITION MODULE........................................................................................................

05-07-5

MAGNETO OUTPUT
(IGNITION GENERATOR COIL) .....................................................................................

05-07-6

LIGHTING GENERATOR COIL OUTPUT .......................................................................

05-07-6

SUMMARY TABLE .........................................................................................................

05-07-8

RESISTANCE MEASUREMENTS ..................................................................................

05-07-9

DUCATI CDI SYSTEM TESTING .................................................................................... 05-07-10
TRIGGER COIL OUTPUT................................................................................................ 05-07-10
MAGNETO OUTPUT ...................................................................................................... 05-07-10
IGNITION COIL OUTPUT ............................................................................................... 05-07-11
IGNITION MODULE........................................................................................................ 05-07-11
LIGHTING GENERATOR COIL OUTPUT ....................................................................... 05-07-11
SUMMARY TABLE ......................................................................................................... 05-07-12
RESISTANCE MEASUREMENTS .................................................................................. 05-07-13

VOLTAGE REGULATOR INSPECTION........................................................................... 05-07-14
TESTING PROCEDURE .................................................................................................. 05-07-14

INSPECTION OF AC CIRCUIT ISOLATION.................................................................... 05-07-15
INSPECTION ................................................................................................................... 05-07-15

INSPECTION OF HEATING ELEMENTS ........................................................................ 05-07-16

Summary of Contents for FORMULA S 1997

Page 1: ......

Page 2: ...Section 00 Sub Section 0 00 0 1 1997 Shop Manual VOLUME 1 TUNDRA II LT TOURING E LE LE LT SLE FORMULA S SL SKANDIC 380 500...

Page 3: ...ombardier Inc Valcourt Quebec Canada Printed in Canada Registered trademarks of Bombardier Inc This document contains the trademarks of the following companies Loctite is a trademark of Loctite Corpor...

Page 4: ...08 1 09 Carburetor and fuel pump 03 09 1 10 Fuel tank and throttle cable 03 10 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...

Page 5: ...08 01 1 02 Body 08 02 1 03 Frame 08 03 1 09 TECHNICAL DATA 01 SI metric information guide 09 01 1 02 Engines 09 02 1 03 Vehicles 09 03 1 04 Technical data legends 09 04 1 ANNEXES wiring diagrams SECTI...

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...

Page 7: ...rope 1119 TOURING E Canada 1115 TOURING E LT Canada 1116 TOURING E LT Europe 1186 TOURING LE Canada 1112 TOURING LE U S 1113 TOURING LE Europe 1114 TOURING SLE Canada 1110 TOURING SLE U S 1111 FORMULA...

Page 8: ...manual is divided into 10 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 TECH...

Page 9: ...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 positi...

Page 10: ...ection 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 lubrican...

Page 11: ...semblies 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 CAUTION Most components of those...

Page 12: ...5 21 M8 15 22 M8 16 23 M8 17 24 M8 18 25 M8 18 26 19 27 20 28 21 29 21 30 22 31 23 32 24 33 24 34 25 35 26 36 27 37 27 38 28 39 29 40 30 41 30 42 31 43 M10 32 44 M10 32 45 M10 33 46 M10 34 47 M10 35 4...

Page 13: ...17 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 1...

Page 14: ...on 03 09 Throttle Cable Inspection Sub section 03 10 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 Cle...

Page 15: ...opriate sub section and Operator s Guide Suspension Lubrication Section 06 See appropriate sub section Suspension Condition Section 06 See appropriate sub section Suspension Stopper Strap Condition Se...

Page 16: ...r bore All Models 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...

Page 17: ...ecessary 1 Intake silencer 2 Air filter S Series Lift hood and remove air filter from air intake si lencer TYPICAL 1 Filter To clean the filter shake the snow out of it then dry it out NO 5 DRIVE BELT...

Page 18: ...ratches on windshield or hood Start with Slip Streamer Motorcycle Windshield Heavy Duty Scratch Remover Finish with Slip Streamer Motorcycle Cleaner and Polish NOTE The latest product may be use alone...

Page 19: ...NE 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 7 MECHANICAL BRAKE 02 04 7 HYDRAULIC BRAKE 02 04 7 MECHANICAL AND HYDRAULIC BRAKE...

Page 20: ...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 21: ...d 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 t...

Page 22: ...gine Replace piston s and check if intake system leaks 7 Piston color is dark due to seizure on intake and exhaust sides a Broken or loose fan belt Replace fan belt or adjust its tension refer to TECH...

Page 23: ...and or improper alignment Align track and adjust its tension to specifications refer to TECHNICAL DATA 09 7 Check drive pulley a Improper calibration screw adjustments TRA pulley and or worn bushing s...

Page 24: ...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 25: ...to specifications refer to TECHNICAL DATA 09 7 Perform engine leak test a Leaking gaskets allow air to enter in engine Replace defective parts SYMPTOM HIGH ENGINE OPERATING TEMPERATURE CONDITION NORMA...

Page 26: ...ications refer to TECHNICAL DATA 09 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 27: ...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 28: ...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 29: ...R RESERVOIR IN CRANKCASE ARE SEALS LEAKING CHECK CRANKSHAFT OUTER SEAL OF PTO AND MAG SIDES PRESSURIZE ROTARY VALVE GEAR RESERVOIR IN CRANKCASE IS RESERVOIR LEAKING UNSEAL PTO CYLINDER AND MAG CYLINDE...

Page 30: ...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 09 5...

Page 31: ...ocate or replace 4 Check fuel pump flow a Dried diaphragm Replace 5 Check if carburetor s is are clean a Varnish Clean SYMPTOM HIGH INJECTION OIL CONSUMPTION CONDITION NORMAL USE Test Inspection 1 Che...

Page 32: ...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 33: ...flectionaccordingtospecifications refer to TECHNICAL DATA 09 3 Check driven pulley sliding half play a Jammed sliding half Replace 4 Check spring tension of driven pulley sliding half a Sliding half r...

Page 34: ...ber 2 Check tightening torque of drive 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 co...

Page 35: ...ion is too weak Replace SYMPTOM IT IS DIFFICULT TO ENGAGE TRANSMISSION IN FORWARD OR REVERSE GEAR CONDITION NORMAL USE Test Inspection 1 Check position of gear shift lever adjustment screw a Improper...

Page 36: ...Check 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 EXCESSIVEL...

Page 37: ...een 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 CONCAVE...

Page 38: ...R TORN CONDITION NORMAL USE Test Inspection A00D0HY 1 Check drive belt rotational direction a Improper belt installation Replace 2 Check if drive belt rubs against components a Belt rubbing on station...

Page 39: ...return spring Replace 2 Check if brake cable moves freely in its housing a Brake cable movement is limited due to oxidation or dirt accumulation Replace 3 Check distance between brake lever and calip...

Page 40: ...G Sub Section 04 TRANSMISSION AND BRAKE SYSTEMS 02 04 8 MECHANICAL AND HYDRAULIC BRAKES SYMPTOM BRAKE SYSTEM IS NOISY CONDITION NORMAL USE Test Inspection 1 Check brake pad thickness a Pads are worn u...

Page 41: ...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 42: ...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 43: ...cts a Melted solenoid switch contacts Replace solenoid switch 6 Check starter switch a Starter switch returns poorly Replace ignition switch SYMPTOM NOISE OCCURENCE WHEN STARTING ENGINE CONDITION NORM...

Page 44: ...in lighting circuit Replace voltage regulator and ensure proper grounding Retest SYMPTOM HEADLAMP DIMING CONDITION NORMAL USE Test Inspection 1 Check voltage at headlamp at different speeds It must no...

Page 45: ...ating grips installation overloads the magneto generator capacity a Excessive electrical load to magneto generator Reduce the electrical load by removing accessories SYMPTOM FALSE FUEL AND OR TEMPERAT...

Page 46: ...icone dielectric grease 4 Verify trigger coil resistance with an ohmmeter and connector condition a Defective coil Corroded connector terminals Replace defective coil Clean terminals and apply silicon...

Page 47: ...timing light unplug connec tors between magneto generator and vehicle wiring harness to isolate prob lem Check condition of connectors a Defective spark plug and or cables caps Defective electrical s...

Page 48: ...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 49: ...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 50: ...OME 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 suspensio...

Page 51: ...per 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 HANDLEB...

Page 52: ...nsion 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...

Page 53: ...FROM CHASSIS 03 02 4 CLEANING 03 02 4 DISASSEMBLY 03 02 4 INSPECTION 03 02 5 ASSEMBLY 03 02 5 BOTTOM END 03 02 7 CLEANING 03 02 8 DISASSEMBLY 03 02 8 INSPECTION 03 02 8 ASSEMBLY 03 02 8 377 443 AND 5...

Page 54: ...PLAY 03 04 7 CONNECTING ROD PISTON PIN CLEARANCE 03 04 7 CONNECTING ROD CRANKPIN CLEARANCE 03 04 8 CRANKSHAFT END PLAY 03 04 8 CHECKING SURFACE FLATNESS 03 04 10 RECTIFYING SURFACES 03 04 10 CHECKING...

Page 55: ...1 REMOVAL 03 09 2 CLEANING AND INSPECTION 03 09 2 IDENTIFICATION 03 09 2 DISASSEMBLY AND ASSEMBLY 03 09 2 CARBURETOR FLOAT LEVEL ADJUSTMENT 03 09 3 INSTALLATION 03 09 4 CARBURETOR ADJUSTMENTS 03 09 5...

Page 56: ...E Sub Section 02 277 ENGINE TYPE 03 02 1 277 ENGINE TYPE 2 ENGINE REMOVAL AND INSTALLATION A05C0KS 4 10 48 N m 35 lbf ft 48 N m 35 lbf ft 16 25 N m 18 lbf ft 21 N m 15 lbf ft 48 N m 35 lbf ft 736 RTV...

Page 57: ...nifold screws no 16 to 25 N m 18 lbf ft Torque the engine support screws nos 4 and 10 to 48 N m 35 lbf ft Torque the engine mount screws to 21 N m 15 lbf ft INSTALLATION ON VEHICLE To install engine o...

Page 58: ...Section 03 ENGINE Sub Section 02 277 ENGINE TYPE 03 02 3 TOP END A05C0SS 22 N m 16 lbf ft Grease 1 2 3 4 5 6 8 7 26 N m 19 lbf ft FLAT RATE PARTS...

Page 59: ...dome using a wooden spatula NOTE The letters AUS over an arrow on the piston dome must be visible after clean ing Clean the piston ring grooves with a groove clean er tool or with a piece of broken r...

Page 60: ...hen 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...

Page 61: ...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 1 Place circlip in 2 Restrain 3 Oil 1 Piston notch 2 Circlip br...

Page 62: ...Section 03 ENGINE Sub Section 02 277 ENGINE TYPE 03 02 7 BOTTOM END A05C0TS 1 3 5 6 4 2 7 22 N m 16 lbf ft Lithium grease Anti seize compound Lithium grease FLAT RATE PARTS...

Page 63: ...under screw heads and extract PTO side crankcase half no 1 1 Plate 2 Flat washer Heat to 110 120 C 230 248 F all around bearing seat on MAG side Install puller with plate long bolts M8 x 110 mm and fl...

Page 64: ...SUREMENT 03 04 To install new seal nos 3 and 4 into crankcase use oil seal pusher P N 420 9779 20 1 Crankcase half Prior to crankcase adjoining install a protector sleeve on each crankshaft extension...

Page 65: ...Section 03 ENGINE Sub Section 02 277 ENGINE TYPE 03 02 10 Torque the screws no 7 to 22 N m 16 lbf ft fol lowing illustrated sequence A02C04A 5 2 1 3 4...

Page 66: ...D 503 ENGINE TYPES 03 03 1 377 443 AND 503 ENGINE TYPES 3 ENGINE REMOVAL AND INSTALLATION 377 and 443 Engine Types A03C12S Skandic 380 Touring E LE Formula S 37 N m 27 lbf ft 35 N m 26 lbf ft 17 N m 1...

Page 67: ...Section 03 ENGINE Sub Section 03 377 443 AND 503 ENGINE TYPES 03 03 2 503 Engine Type A03C13S 37 N m 27 lbf ft 35 N m 26 lbf ft 17 N m 150 lbf in 28 N m 21 lbf ft FLAT RATE PARTS...

Page 68: ...ive cable from battery on electric starting models belt guard drive belt drive pulley using appropriate puller refer to 04 03 DRIVE PULLEY air silencer and carburetors impulse line from engine crankca...

Page 69: ...NE Sub Section 03 377 443 AND 503 ENGINE TYPES 03 03 4 TOP END 22 N m 16 lbf ft 22 N m 16 lbf ft Grease 503 S Series only 22 N m 16 lbf ft 22 N m 16 lbf ft A23C05S 1 2 1 2 1 2 3 4 5 5 8 9 10 7 7 6 6 F...

Page 70: ...clip from piston no 8 To remove piston pin no 9 use piston pin puller P N 529 0210 00 as follows Fully screw puller handle Insert puller end into piston pin Screw LH threads extracting nut Hold puller...

Page 71: ...NGINE DIMENSIONS MEASUREMENT 03 04 ASSEMBLY 503 Engine When reinstalling original needle bearings make sure that 31 needles are inserted between expan sion sleeve and locating sleeve 1 Expansion sleev...

Page 72: ...At assembly place the pistons over the connect ing rods with the letters AUS over an arrow on the piston dome facing in the direction of the ex haust port 1 Exhaust All Engines Except 503 To center t...

Page 73: ...pressor on piston assem bly NOTE The ring compressor will not fit on over size pistons Check flatness of intake sockets no 6 Refer to ENGINE DIMENSION MEASUREMENT 03 04 and look for checking surface f...

Page 74: ...st 2 Distance nuts 503 ENGINE TYPE 1 Distance nuts Cross torque cylinder head nuts nos 1 and 2 to 22 N m 16 lbf ft torque each cylinder head in dividually Install armature plate fan housing and then a...

Page 75: ...443 AND 503 ENGINE TYPES 03 03 10 BOTTOM END A03C1IS Anti seize lubricant 22 N m 16 lbf ft 503 22 N m 16 lbf ft 377 10 N m 89 lbf in 11 9 8 7 6 5 2 4 10 3 2 1 3 Anti seize lubricant Anti seize lubric...

Page 76: ...kshaft use a protective cap and a special puller as illus trated 1 PTO side 2 MAG side INSPECTION Refer to ENGINE DIMENSIONS MEASUREMENT 03 04 ASSEMBLY Smear anti seize lubricant P N 413 7010 00 on pa...

Page 77: ...of mating surfaces Let it dry for 10 to 20 minutes Apply paste gasket P N 413 7027 00 no 5 on the other mating surface NOTE Primer N allows Loctite 515 to fully cure on aluminum surfaces It increases...

Page 78: ...alve 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 such as engine oil will dam...

Page 79: ...urfaces and screw stud threads of engine spark plug base insulator cylinder head cylinder base crankcase halves joint rotary valve cover oil injection pump mounting flange O ring seal coolant pump hou...

Page 80: ...ry 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 Bloc...

Page 81: ...ngs 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 TES...

Page 82: ...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...

Page 83: ...d 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 positi...

Page 84: ...lection 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 f...

Page 85: ...arts catalog thicknesses available 0 10 mm 004 in 0 20 mm 008 in 0 30 mm 012 in 0 50 mm 020 in 1 00 mm 040 in micrometer caliper Total shim thickness needed for the end play ad justment is determined...

Page 86: ...is the actual crankshaft end play that must be within specification If the result is over specification add adjustment shim s to reach this specification If the result is under specification remove ad...

Page 87: ...r 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 crankshaft...

Page 88: ...EM 5 NIPPONDENSO IGNITION SYSTEM WITH SINGLE GENERATING COIL 277 Engine A25C0OS Dielectric grease 5 Loctite 242 6 7 Loctite 242 8 2 3 4 9 Loctite 242 1 7 N m 62 lbf in Loctite 242 11 10 90 N m 66 lbf...

Page 89: ...in outside diameter by 16 mm 5 8 in long NOTE To correctly remove a threadlocked fastener it is first necessary to tap on the fas tener to break threadlocker bond This will eliminate the possibility o...

Page 90: ...Heat the armature plate to 93 C 200 F around the screw holes to break the threadlocker bond 1 Protect harness from flame 2 Heat CAUTION Protect harness from flame Remove screws Uncrimp and unsolder Y...

Page 91: ...flywheel no 9 and lock washer no 12 on crankshaft Clean nut threads and apply Loctite 242 blue be fore tightening nut no 13 Torque nut to 90 N m 66 lbf ft At reassembly coat all electric connections...

Page 92: ...on 03 ENGINE Sub Section 05 CDI SYSTEM 03 05 5 DUCATI IGNITION SYSTEM 377 443 and 503 Engines A07C03S 1 2 3 5 4 Loctite 242 Dielectric grease 105 N m 77 lbf ft 22 N m 195 lbf in Loctite 242 FLAT RATE...

Page 93: ...t the same time tap on bolt head using a hammer to release magneto flywheel from its taper REPAIR To replace generator coil no 1 Heat the armature plate to 93 C 200 F around the screw holes to break t...

Page 94: ...mature and carefully pull wires Install new parts and other parts removed ASSEMBLY Clean crankshaft extension taper Apply Loctite 242 blue on taper Position Woodruff key flywheel and lock washer on cr...

Page 95: ...n 03 ENGINE Sub Section 06 OIL INJECTION SYSTEM 03 06 1 OIL INJECTION SYSTEM 6 OIL INJECTION PUMP 277 Engine A05C07S 1 7 3 4 5 Grease Grease Loctite 242 Oil pump gasket set X X X X X 2 X X 6 FLAT RATE...

Page 96: ...Section 03 ENGINE Sub Section 06 OIL INJECTION SYSTEM 03 06 2 377 443 and 503 Engines A03C17S 5 5 5 6 5 N m 44 lbf in 3 5 N m 44 lbf in Loctite 242 2 1 Loctite 242 4 Grease FLAT RATE PARTS...

Page 97: ...413 7061 00 on gear teeth The needle roller no 4 must be engaged as deep as possible in the pump mounting flange Always check for spring clips no 5 and clamps no 6 tightness Torque screws no 3 to 5 N...

Page 98: ...take manifold If required fill the lines by running the engine at idle speed while holding the pump lever in fully open position TYPICAL ENGINE AT IDLE 1 Fully open position WARNING Ensure not to oper...

Page 99: ...licable for de fects replace as necessary Test pump as de scribes below NOTE Through normal use oil level must not drop in small tubes If oil drops verify check valve operation in banjo fittings Repla...

Page 100: ...07 1 AXIAL FAN COOLING SYSTEM 7 NOTE For 277 engine radial fan cooling system refer to 277 engine type 03 02 377 443 and 503 Engines 1 3 5 18 13 12 14 15 16 443 and 503 engines only 17 47 N m 35 lbf...

Page 101: ...ly torque nut to 65 N m 48 lbf ft TYPICAL Fan belt deflection must be as specified when ap plying the proper force midway between pulleys 1 Deflection To adjust tension add or remove shim s no 15 betw...

Page 102: ...ng bearing To install press one bearing in place then install circlip and shims Press the other bearing from op posite side until it is flush with housing Press fan shaft from engine side of fan housi...

Page 103: ...8 REWIND STARTER 03 08 1 REWIND STARTER 8 277 377 443 and 503 Touring SLE A03C1GS Molykote G n Paste or Equivalent Silicone Compound Grease 1 2 3 4 5 6 7 8 9 10 11 12 Silicone Compound Grease 14 15 10...

Page 104: ...on 08 REWIND STARTER 03 08 2 503 Skandic 500 and Formula SL A21C08S 10 N m 89 lbf in Molykote G n Paste or Equivalent Silicone Compound Grease Silicone Compound Grease 8 N m 71 lbf in 15 6 7 5 4 1 3 8...

Page 105: ...nto spring guide notch then wind the spring counter clockwise into guide WARNING Since the spring is tightly wound inside the guide it may fly out when rewind is handled Always handle with care 1 Oute...

Page 106: ...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 an...

Page 107: ...grip no 15 on new rope it is first necessary to fuse the rope end with a lit match pass rope through rubber buffer no 14 and starter grip and tie a knot in the rope end fuse the knot with a lit match...

Page 108: ...CARBURETOR AND FUEL PUMP 03 09 1 CARBURETOR AND FUEL PUMP 9 A15C2AS 6 13 10 8 11 12 9 7 1 2 3 4 5 14 To other carburetor All Carburetors Except VM 34 443 Carburetors VM 30 190 VM 34 443 VM 34 467 VM...

Page 109: ...ING Solvent with a low flash point such as gasoline naphtha benzol etc should not be used as they are flammable and explosive Check inlet needle tip condition If worn the inlet needle and seat must be...

Page 110: ...suit tem perature and or altitude changes Always check spark plug tip and or piston dome color to find out correct jetting CARBURETOR FLOAT LEVEL ADJUSTMENT 9 10 Float Arm and Float Arm Pin Correct fu...

Page 111: ...ottle slide s to snap shut To install carburetor on engine inverse removal procedure However pay attention to the following Inspect throttle cable and housing prior to in stallation On applicable mode...

Page 112: ...r the specifications Carburetor Synchronization Twin Carburetor Models Only Both carburetor slides must start to open at the same time Completely unscrew idle speed screw on both carburetors Unlock ca...

Page 113: ...s Only Repeat on the other one This will ensure identical throttle slide preliminary idle setting Recheck car buretor synchronization Adjust idle by turning both idle speed screws of the same amount C...

Page 114: ...dle speed screw no 7 Final adjustment engine running at idle speed should be within 1 2 turn of idle speed screw from preliminary adjustment TYPICAL 1 Drill bit used as gauge for throttle slide height...

Page 115: ...justment Adjust cable length to obtain the following plunger adaptor distance Retighten lock nut 1 Plunger 2 Adaptor 3 Lock nut 4 Distance The above adjustment can be easily checked with a service too...

Page 116: ...Section 03 ENGINE Sub Section 09 CARBURETOR AND FUEL PUMP 03 09 9 FUEL PUMP A00C48S S Series Tundra LT 1 2 2 1 FLAT RATE PARTS...

Page 117: ...of leak test kit The inlet valve should re lease with pressure and hold under vacuum Repeat the same procedure at the outlet nipple This time the outlet valve should hold with pres sure and release un...

Page 118: ...needed High supply pump with twin outlets Thoroughly clean filter on top cover Replace filter if neces sary ASSEMBLY To install a new valve proceed as follows Place new valve flat on its seat Slightl...

Page 119: ...sparks in the vicinity Impulse Fuel Lines Spring Clips Always reposition spring clips after any repair to prevent possible leaks Throttle Cable Circlip at Handlebar Put silicone grease P N 413 7017 00...

Page 120: ...le tab until it sits properly 1 Throttle handle 2 Retainer 3 Cable barrel 4 Silicone grease Adjust throttle cable as specified in CARBURE TOR AND FUEL PUMP 03 09 Throttle Cable Routing CAUTION Check t...

Page 121: ...03 3 TRA 04 03 4 GENERAL 04 03 5 REMOVAL 04 03 5 DISASSEMBLY 04 03 5 CLEANING 04 03 6 INSPECTION 04 03 7 ASSEMBLY 04 03 9 INSTALLATION 04 03 11 DRIVE PULLEY ADJUSTMENT 04 03 12 DRIVEN PULLEY 04 04 1 R...

Page 122: ...ASSEMBLY 04 07 2 INSPECTION 04 07 2 GEAR RATIO MODIFICATION 04 07 2 ASSEMBLY 04 07 3 INSTALLATION 04 07 3 ADJUSTMENT 04 07 4 REMOVAL 04 07 6 INSPECTION 04 07 6 GEAR RATIO MODIFICATION 04 07 6 INSTALLA...

Page 123: ...respect ed CORRECT INCORRECT NOTE For used drive belt mark and rein stall in the same position MODEL PART NUMBER WIDTH NEW 0 25 mm 010 in MINIMUM WIDTH WEAR LIMIT TUNDRA II LT 414 8276 00 33 3 mm 1 5...

Page 124: ...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...

Page 125: ...PULLEY DISTANCE AND ALIGNMENT 04 05 and measure drive belt deflection Readjust pulley distance if required then tighten the 4 nuts Adjust driven pulley support and lock it to engine S Series Adjust pu...

Page 126: ...ust drive belt deflection using Allen screws as shown To increase deflection turn Allen screws clock wise To decrease deflection turn Allen screws coun terclockwise NOTE Turn Allen screws 1 4 turn at...

Page 127: ...03 1 DRIVE PULLEY 3 BOMBARDIER LITE NOTE This is a lubrication free drive pulley Tundra II LT and 377 Engine S Series A05D0IS 1 2 3 5 6 7 8 9 4 Loctite 271 10 11 377 Engine S Series 377 Engine S Seri...

Page 128: ...nstallation and assembly tolerances require strict adher ence to procedures detailed REMOVAL NOTE If disassembling drive pulley first straighten tab washer no 7 then untighten nut no 8 Use clutch hold...

Page 129: ...ligned with spring cover slot 1 Curved end 2 Spring cover slot A 2 to 3 mm 1 16 to 1 8 in Tighten nut no 8 to 128 N m 95 lbf ft INSTALLATION Torque screw to 90 to 100 N m 66 to 74 lbf ft Install drive...

Page 130: ...cation 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 m 70 lbf ft 10...

Page 131: ...crew 2 Insert in any slot NOTE Sliding half can be removed while fixed half remains on crankshaft WARNING Never use any type of impact wrench at drive pulley removal and instal lation Remove retaining...

Page 132: ...ithout the recommended tools Use spring compressor P N 529 0151 00 1 Washer must be here Install tools as shown Remove 3 Allen screws re taining spring cover then unscrew compressor CLEANING 5 6 Fixed...

Page 133: ...g and Slider Shoe Check if O rings are cracked cut or crushed Re place as required Check slider shoes for wear Replace if groove is not apparent on top 5 29 Fixed Half and Governor Cup Inspect splines...

Page 134: ...o replace this bushing Use tools P N 529 0313 00 and 529 0312 00 to remove old bushing CAUTION Bushing must be bonded with retaining compound Apply retaining compound outside of bushing then press it...

Page 135: ...ration Screw Washer and Locking Nut When installing calibration 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 or...

Page 136: ...lutch misbalancing will occur because of levers difference 1 Head on top 2 All on the same side CAUTION Lever assemblies must be in stalled so that cotter pins are on the same side Torque nuts to 12 N...

Page 137: ...n mark of governor cup with mark of fixed half Remove forks and push governor cup so that its splines engage with fixed half shaft splines CAUTION Make sure splines of both parts are fully engaged INS...

Page 138: ...be adjusted so that ac tual maximum engine RPM in vehicle matches with the maximum horsepower RPM given in TECHNICAL DATA 09 NOTE Use precision digital tachometer for engine RPM adjustment NOTE The a...

Page 139: ...NSMISSION Sub Section 03 DRIVE PULLEY 04 03 13 CAUTION Always adjust all 3 calibration screws and make sure they are all set at the same number 1 Loosen just enough to permit rotating of calibration s...

Page 140: ...ection 04 TRANSMISSION Sub Section 04 DRIVEN PULLEY 04 04 1 DRIVEN PULLEY 4 Tundra II LT A09D0QS 13 N m 115 lbf in 1 2 3 4 5 6 11 12 13 14 15 8 9 10 Anti seize lubricant P N 413 7010 00 FLAT RATE PART...

Page 141: ...ncer Disconnect impulse hose from engine Disconnect oil injection supply line at injection pump and plug line to prevent draining Remove screws retaining rear engine support to chassis Tip engine forw...

Page 142: ...Half Bushing Clean mounting surfaces with Loctite Safety Sol vent Using a press and a suitable pusher install bushing as illustrated 1 Install bushing from this side of sliding half 2 Bushing After b...

Page 143: ...TALLATION Driven Pulley and Chaincase Install a new upper chaincase oil seal and a new chaincase cover seal Reinstall the driven pulley on vehicle by reversing the removal procedure NOTE If chaincase...

Page 144: ...kwise to increase it 1 Decrease 2 Adjusting holes 3 Increase NOTE Always recheck torsional pre load after adjusting Chaincase Check oil level and refill as required Refer to CHAINCASE 04 07 Pulley Ali...

Page 145: ...Section 04 TRANSMISSION Sub Section 04 DRIVEN PULLEY 04 04 6 S Series 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 Loctite 609 PARTS FLAT RATE...

Page 146: ...is spring loaded 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 tef...

Page 147: ...11 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 bushin...

Page 148: ...ti seize Lubricant CAUTION Always apply anti seize lubri cant P N 413 7010 00 on the counter shaft before final pulley installation F Series and S Series Only Should installation procedure be required...

Page 149: ...ment Step 2nd measurement To adjust spring pre load relocate spring end in cam moving it clockwise to increase the pre load and counterclockwise to decrease it Refer to TECHNICAL DATA 09 03 NOTE If sp...

Page 150: ...04 DRIVEN PULLEY 04 04 11 NOTE For high altitude regions the High Altitude Technical Data Booklet P N 484 0648 00 and 484 0545 00 for binder gives infor mation about calibration according to altitude...

Page 151: ...vehicle 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 ba...

Page 152: ...he proper EN GINE or TRANSMISSION installation section PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART Alignment templates have been made according to pulley alignment nominal values However they d...

Page 153: ...Adjustment Method Slacken the 4 chaincase retaining bolts unlock and raise pulley support Move chaincase to obtain specific adjustment and adjust driven pulley support length accordingly light contact...

Page 154: ...ine loose prior to aligning 1 Loosen Pulley Distance Adjustment Method Engine Movement The engine support has slotted mounting holes Move engine to obtain specified distance be tween pulleys Pulley Al...

Page 155: ...ection 04 TRANSMISSION Sub Section 06 BRAKE 04 06 1 BRAKE 6 MECHANICAL DISC BRAKE Tundra II LT 4 N m 35 lbf in 24 N m 18 lbf ft A05D0QS 21 23 22 15 14 12 1 11 7 6 8 3 9 4 16 10 12 5 17 PARTS FLAT RATE...

Page 156: ...SMISSION Sub Section 06 BRAKE 04 06 2 Formula S Touring E E LT and Skandic 380 500 A03D27S 7 11 1 12 25 17 Loctite 242 19 20 9 5 14 15 16 Anti seize lubricant 2 Dielectric grease Anti seize lubricant...

Page 157: ...Section 04 TRANSMISSION Sub Section 06 BRAKE 04 06 3 HYDRAULIC DISC BRAKE Touring LE SLE Formula SL A03D26S 7 Loctite 242 Anti seize lubricant 17 18 19 20 24 Black Max PARTS FLAT RATE...

Page 158: ...Remove air silencer Unbolt bearing support from chassis Open chaincase and remove upper sprocket Pull countershaft toward driven pulley side to gain access to clip no 25 Remove clip no 25 on counters...

Page 159: ...incase Withdraw countershaft to ward chaincase Remove connecting pipe between tuned pipe and after muffler Disconnect brake line from caliper and plug it Unbolt caliper from chaincase Remove brake dis...

Page 160: ...ng tab no 4 over a flat of screw head 1 6 11 12 Locking Tab Inner Outer Caliper and Nut Tundra II LT Assemble both caliper halves Insert bolts no 9 locking tab no 20 then nuts Torque nuts to 24 N m 18...

Page 161: ...n Turn collar in direction of countershaft rotation un til collar and inner race lock together Insert a punch into collar hole and strike sharply in the same direction to lock firmly Apply Loctite 242...

Page 162: ...t should light up before brake pads touch brake disc To adjust unscrew nut no 10 until brake light goes on WARNING At least one full thread must exceed the elastic stop nut Check brake adjustment as d...

Page 163: ...Section 04 TRANSMISSION Sub Section 07 CHAINCASE 04 07 1 CHAINCASE 7 Tundra II LT A03D0QS 1 7 10 9 10 9 11 12 13 28 14 15 4 5 2 3 6 27 30 22 23 19 20 16 17 18 24 25 26 8 Lithium grease PARTS FLAT RATE...

Page 164: ...chain case to frame Save alignment shims no 8 for in stallation Release track tension use drive axle holder P N 529 0072 00 1 Drive axle 2 Suspension cross shaft Chaincase and Driven Pulley Assembly U...

Page 165: ...lar atten tion to the following Torque castellated nut no 7 to 14 N m 124 lbf in slacken then retorque to 0 5 2 5 N m 5 22 lbf in In case of a vehicle equipped with an 11 teeth sprocket check the wear...

Page 166: ...Section 04 TRANSMISSION Sub Section 07 CHAINCASE 04 07 4 ADJUSTMENT Pulley Alignment Refer to PULLEY DISTANCE AND ALIGNMENT 04 05 Track Tension and Alignment Refer to TRACK 06 05...

Page 167: ...t Reverse Gear A06D17S 2 1 3 Chaincase oil 4 5 6 7 27 Loctite 242 23 9 10 8 24 25 26 Loctite 609 11 20 Loctite 242 14 16 17 18 14 12 Loctite 271 15 13 46 N m 34 lbf ft 22 21 45 to 75 N m 33 to 55 lbf...

Page 168: ...d or missing links Check for worn or defective bear ings sprockets and chain tensioner components WARNING If chain deflection is greater than 38 mm 1 5 in without chain ten sioner replace chain and ch...

Page 169: ...ner adjustment screw Fully tighten tensioner adjustment screw by hand then back off only far enough for hair pin to engage in locking hole This initial adjustment should provide 3 5 mm 1 8 13 64 in fr...

Page 170: ...Section 04 TRANSMISSION Sub Section 07 CHAINCASE 04 07 8 ADJUSTMENT Pulley Alignment Refer to PULLEY DISTANCE AND ALIGNMENT 04 04 Track Tension and Alignment Refer to TRACK 06 05...

Page 171: ...uring SLE and Skandic 380 500 A03D17S 15 N m 133 lbf in 7 8 5 28 31 40 48 N m 35 lbf ft Loctite 271 6 16 17 32 33 34 37 38 5 N m 44 lbf in 35 36 29 N m 21 lbf ft Loctite 242 Loctite 242 27 Grease 25 1...

Page 172: ...8 and then remove reverse axle no 20 1 Sliding gear screw 2 Reverse axle Remove coupling shaft no 33 44 tooth sprocket no 34 spacer no 38 and chain no 28 First unscrew castellated nut no 10 then remov...

Page 173: ...th sprocket Tighten nut no 37 to 5 N m 44 lbf in in a criss cross sequence Insert spring pin no 21 in reverse axle up to inside diameter Press needle bearing in 19 tooth sprocket Install ring no 24 an...

Page 174: ...t is still impossible check if the fork engages in the sliding gear or disassemble the cover to inspect components 3 Completely slacken ball joint lock nut on the gear shift linkage 4 Using tool P N 5...

Page 175: ...Clean cover interior NOTE It is normal to find metallic particles stuck to dipstick magnet If bigger pieces of metal are found disassemble and check all parts Reinstall cover as previously described...

Page 176: ...e cir clip must be on opposite side of chain rotation The circlip should also be facing the outer side of chaincase WARNING Always ensure that the con necting link circlip is in good condition and is...

Page 177: ...Link pin C Cranked link D Cotter pin E Outer link F Circlip LENGTHENING 1 LINK A Connecting link B Inner link C Outer link D Circlip A00D0NA A B C D E F A B C C D A00D0OA A LENGTHENING 1 1 2 LINK A Co...

Page 178: ...S 05 04 1 NGK SPARK PLUG 05 04 1 NGK SPARK PLUG NUMBERING SYSTEM 05 04 1 1997 REFERENCE CHART 05 04 1 DESIGN SYMBOLS USED IN NGK SPARK PLUGS 05 04 2 DISASSEMBLY 05 04 3 HEAT RANGE 05 04 3 FOULING 05 0...

Page 179: ...CDI SYSTEM TESTING 05 07 4 IGNITION COIL OUTPUT 05 07 4 IGNITION MODULE OUTPUT 05 07 4 MAGNETO OUTPUT 05 07 5 LIGHTING GENERATOR COIL OUTPUT 05 07 6 SUMMARY TABLE 05 07 7 RESISTANCE MEASUREMENTS 05 07...

Page 180: ...ripe Example YL BK is a YELLOW wire with a BLACK stripe MODEL WIRING DIAGRAM PAGE HEADLIGHT watt TAILLIGHT watt ELECTRICAL SYSTEM OUTPUT watt Tundra II LT Annex 1 60 55 hal 8 27 160 Formula S SL Skand...

Page 181: ...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 182: ...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 Pull this side Step Insert screwd...

Page 183: ...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 access...

Page 184: ...ark posi tion before checking ignition timing Verifying Magneto Flywheel Timing Mark Position 1 Disconnect spark plug wire and remove spark plug 2 Install and adjust TDC gauge on engine as follows Rot...

Page 185: ...nition components are affected by temper ature variation therefore timing must be checked when engine is cold after idling for a MAXIMUM of 20 seconds NOTE On applicable models turn heating grips off...

Page 186: ...NG ADJUSTMENT Timing is performed by moving armature plate clockwise to retard spark occurrence counter clockwise to advance TYPICAL 1 To retard 2 To advance To adjust loosen 3 armature plate retainin...

Page 187: ...er adjustment tighten armature plate retaining screws CAUTION Make sure armature plate screws are well secured Armature plate screws must have medium strength thread locker P N 413 7030 00 applied bef...

Page 188: ...gauge in the spark plug hole magneto generator side and adjust as follows a Position the magneto flywheel at approxi mately TDC INSTALLATION OF TDC GAUGE 1 Gauge on MAG side cylinder 2 Adaptor lock nu...

Page 189: ...g with a timing light a new mark must be scribed on magneto flywheel for this purpose 6 Scribe a new mark on magneto flywheel as fol lows a Remove the fan cover from the engine b Maintain magneto flyw...

Page 190: ...ned If the marks do not align a faulty trigger coil check proper grounding of coil or a faulty CDI module could be the cause substitute one part at a time and recheck timing marks check connec tors co...

Page 191: ...GK 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...

Page 192: ...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 Standar...

Page 193: ...n 1 Cold 2 Hot CAUTION Severe 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 shortin...

Page 194: ...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...

Page 195: ...harness connector Unfasten retaining strips Open strips and lift battery protective boot Remove vent tube Step Unfasten and open Step Lift protective boot Step Remove vent tube All Models Withdraw bat...

Page 196: ...ings for each 5 5 C 10 F above 27 C 80 F and by subtracting 004 point for every 5 5 C 10 F below 27 C 80 F This chart will be useful to find the correct read ing EXAMPLE NO 1 Temperature below 27 C 80...

Page 197: ...ecific gravity readings at least every 40 days As necessary keep the battery at its upper level line and near full charge as possible trickle charge ACTIVATION OF NEW BATTERY WARNING Never charge or b...

Page 198: ...ing feels hot discontinue charging tem porarily or reduce the charging rate WARNING Gases given off by a battery being charged are highly explosive Al ways charge in a well ventilated area Keep batter...

Page 199: ...battery SERVICING Electrolyte Level Since a battery has been activated see above add distilled water to top up electrolyte TIPS FOR CHARGING A USED BATTERY CAUTION Prior to charging the battery alway...

Page 200: ...s the charger leads are connected to the correct battery terminals A completely dis charged battery may not have enough voltage to activate this circuitry even though the leads are connected properly...

Page 201: ...ON OF BATTERY Ensure vent tube is properly installed on battery elbow Connect vent tube to vehicle fitting on front frame Route RED positive cable behind retaining strip and connect it to positive bat...

Page 202: ...Section 05 ELECTRICAL Sub Section 06 ELECTRIC STARTER 05 06 1 ELECTRIC STARTER 6 S Series with Electric Starting A03E13S 1 2 3 8 9 10 11 12 13 15 16 17 18 19 4 5 6 7 12 PARTS FLAT RATE...

Page 203: ...holder no 5 from yoke no 8 Insert blade of a small screwdriver between stop collars Twist screwdriver to separate stop collars no 12 thus giving access to circlip no 13 Remove outer collar circlip th...

Page 204: ...se the same bushing pusher as for drive housing bushing installation 6 Brush To replace brush no 6 proceed as follows Cut brush wire close to connector at the welded portion 1 Cut close to connector R...

Page 205: ...ches of collars Using a pair of pliers on each side of stop collars squeeze evenly until collars sit over circlip 1 Squeeze evenly Install thrust washer against outer stop collar Place drive lever ont...

Page 206: ...n Install hardened washers P N 503 0079 00 between engine and starter supports ac cordingly CAUTION All starter bracket fasteners must be secured with Loctite 271 P N 413 7074 00 1 Screwdriver pulling...

Page 207: ...ting 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 lathe enough to rem...

Page 208: ...n of an open circuit armature coil Field Windings and Brushes Test the Field Winding for Open Circuit Use growler test probes Place one test probe on the negative brush and the other test probe on the...

Page 209: ...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 210: ...2 wire connector BLACK and BLACK RED wires 277 Engine Ignition module stamped P N 070000 1960 Ignition coil stamped P N 129700 2480 Flywheel stamped P N 032700 4380 NIPPONDENSO CDI SINGLE COIL SYSTEM...

Page 211: ...ion module All Systems The first 2 items can be checked with known au tomotive equipment and other items as follows Engine Stop Tether Cut Out Switches Verification Engine Stop Switch Unplug stop swit...

Page 212: ...vestigated loose connec tions or components etc Indicator Lamp Lights at Lower Setting This indicates that the output is less than that de signed to operate in a satisfactory manner How ever before co...

Page 213: ...ollows TYPICAL 1 Engine ground 2 MAG side A 20 mm 3 4 in 3 Crank engine and observe indicator NOTE If engine starts allow it to idle while observing indicator Then shut engine off 4 Push reset button...

Page 214: ...ce Results a Indicator lamp lights Ignition module output is up to specifications The problem is a faulty ignition coil b Indicator lamp does not light Proceed to fol lowing test If magneto output tes...

Page 215: ...it can be test ed with the same tester 1 Disconnect wiring harness junction block at en gine the one with YELLOW and YELLOW BLACK wires 2 Connect tester wires then set switch and dial as follows TYPIC...

Page 216: ...following table for values and wire colors NOTE An ignition coil with good resistance measurement can still be faulty Voltage leak can occur at high voltage level which is not detect able with an ohmm...

Page 217: ...h WH BL 0 11 0 21 applicable to 277 engine type only 0 34 0 62 applicable to 503 Alpine II engine only Secondary winding spark plug cap removed BR with high tension wire applicable to 277 engine type...

Page 218: ...ults a Indicator 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 MAGNETO OUTPUT Ignition Generator Coil 1...

Page 219: ...MODULE Ignition module can not be tested with the Bom bardier ignition tester When other components test good the module is probably faulty Try a new module LIGHTING GENERATOR COIL OUTPUT NOTE The lig...

Page 220: ...Test to perform Tester wires Component wires Switch Dial Trigger coil output N RED wire of trigger coil LOW 45 P Engine ground Magneto output ignition generator coil N GREEN wire of magneto harness L...

Page 221: ...nce measurement can still be faulty Voltage leak can occur at high voltage level which is not detect able with an ohmmeter The primary winding of ignition coil can be measured because there is no exte...

Page 222: ...rminal 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 YEL...

Page 223: ...ken INSPECTION Disconnect regulator rectifier Connect one digital ohmmeter probe needle ohmmeter will not offer enough precision to frame and other probe to YELLOW or YELLOW BLACK magneto wires Measur...

Page 224: ...nt Measurement 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 05 to 14 95 ohms HIGH INTENSITY BROWN wi...

Page 225: ...N 06 03 1 COMPONENT REMOVAL AND INSTALLATION 06 03 2 REMOVAL 06 03 2 DISASSEMBLY AND ASSEMBLY 06 03 3 INSPECTION 06 03 4 INSTALLATION 06 03 5 RIDE ADJUSTMENT 06 03 5 LUBRICATION 06 03 7 DRIVE AXLE 06...

Page 226: ...02 1 TORQUE REACTION SUSPENSION 2 Tundra II LT A05F0HS 24 N m 18 lbf ft 19 N m 168 lbf in 1 2 3 4 5 48 N m 35 lbf ft 24 N m 18 lbf ft 6 48 N m 35 lbf ft 11 N m 97 lbf in 9 10 7 8 7 8 Loctite 271 24 N...

Page 227: ...opper Strap Inspect strap for wear or cracks bolt and nut for tightness If loose inspect hole for deformation Replace as required Make sure it is attached through the 3rd hole from the end Torque nut...

Page 228: ...n of rear suspension is adjustable for surface condition and steering effects The stopper strap is adjustable for vehicle weight transfer control The rear portion of rear suspension is adjustable for...

Page 229: ...STIFFEST ADJUSTMENT 1 Supporting edge farthest to hexagonal CAUTION Always turn the left side ad justment cams in a clockwise direction and the right side cams in a counterclockwise direction Left an...

Page 230: ...t according to driver s requirements field and or snow conditions CAUTION Whenever stopper strap length is changed track tension must be readjusted to prevent any possibility of operat ing vehicle wit...

Page 231: ...EAR SUSPENSION Sub Section 02 TORQUE REACTION SUSPENSION 06 02 6 LUBRICATION Lubricate front and rear arms at grease fittings using low temperature grease P N 413 7061 00 NOTE There are 4 grease fitti...

Page 232: ...S Series A03F24S Short track models only Long track models only SLE only Loctite 271 Loctite 271 Loctite 271 Loctite 271 Loctite 271 Loctite 271 Loctite 271 Loctite 271 Low temp grease 6 5 6 7 4 3 2...

Page 233: ...TION To avoid track damage spring supports must be mounted upward RIGHT SIDE SHOWN 1 Right position upward 2 Wrong position REMOVAL 19 Cam Decrease spring preload by turning LH cam clock wise and RH c...

Page 234: ...ng front arm to tun nel Remove suspension DISASSEMBLY AND ASSEMBLY Inspect track thoroughly before reinstalling sus pension Refer to 06 05 TRACK 1 Rear Arm At installation rear arm stroke limiter must...

Page 235: ...lation cap opening must be 180 from spring stopper opening 1 Spring stopper opening 2 Cap opening 20 Stopper Strap Inspect strap for wear or cracks bolt and nut for tightness If loose inspect hole for...

Page 236: ...be mounted upward RIGHT SIDE SHOWN 1 Right position upward 2 Wrong position RIDE ADJUSTMENT The stopper strap is adjustable for vehicle weight transfer control The rear portion of rear suspension is a...

Page 237: ...e direction and the right side cams in a counterclockwise direction Left and right adjustment cams must always be set at the same position LH SIDE SHOWN RH SIDE SHOWN Stopper Strap The function of the...

Page 238: ...wing a load it is suggested to adjust stopper strap to a shorter length and stiffen rear springs These adjustment will im prove steering ability Deep Snow Operation When operating the vehicle in deep...

Page 239: ...Section 06 REAR SUSPENSION Sub Section 04 DRIVE AXLE 06 04 1 DRIVE AXLE 4 Tundra II LT S Series A05D03S 2 9 3 11 5 8 6 9 5 A03F1CS 9 11 5 3 2 10 4 8 6 12...

Page 240: ...d remove with its spacer if applicable 8 9 Drive Axle and Sprocket Release drive axle sprocket from track and at the same time pulling the drive axle towards the end bearing housing side Remove drive...

Page 241: ...dexing marks of each sprocket when assembling TYPICAL 1 Indexing marks aligned The maximum desynchronization for the sprock ets is 1 5 mm 1 16 in To check this tolerance place axle assembly on a plane...

Page 242: ...aring by inner race The bearing on the splined side of axle must be pushed until it is seated on shaft shoulder The end bearing housing bearing must be flush with end of drive axle Each bearing must h...

Page 243: ...asy bearing installa tion CAUTION When installing one shim or more between chaincase and frame se cure with 50 mm long screws This chart can be use as a starting point to cor rect the chaincase perpen...

Page 244: ...le axial play is the difference between these 2 measurements Repeat this procedure 2 or 3 times to obtain an accurate measurement The allowable drive axle axial play is 0 to 1 5 mm 0 to 060 in The dri...

Page 245: ...ibute drive axle shims as follows INSTALLATION 4 Speedometer Drive Insert If the drive axle to be installed is a new part and the vehicle is equipped with a speedometer a cor rect size speedometer dri...

Page 246: ...to TRACK 06 05 and adjust track tension and carry out track alignment procedure LUBRICATION 15 Grease Fitting Lubricate end housing bearing with low tempera ture grease P N 413 7061 00 ADJUSTMENT Spro...

Page 247: ...muffler upper center idler ass y suspension end bearing housing drive axle seal drive axle outwards from end bearing housing track S Series Remove the following items speedometer cable muffler chainc...

Page 248: ...of gauge reaches line TYPICAL 1 Line NOTE Lightly oil track tension gauge cen ter pin to avoid sticking Tundra II LT 35 to 45 mm 1 3 8 to 1 25 32 in when exerting a downward pull of 7 3 kg 16 lb A 35...

Page 249: ...nds tools feet and clothing clear of track Ensure no one is standing in close proximity to the vehicle All Models With rear of vehicle supported off the ground start engine and allow the track to rota...

Page 250: ...ate track to expose a cleat to be replaced Using track cleat remover P N 529 0082 00 for Tundra II LT Use P N 529 0087 00 for all other models Installation NOTE Keep the same pitch between guide cleat...

Page 251: ...SASSEMBLY AND ASSEMBLY 07 02 3 INSPECTION 07 02 3 ADJUSTABLE HANDLEBAR 07 02 5 STEERING ADJUSTMENT SKIS 07 02 5 LUBRICATION 07 02 9 SUSPENSION AND SKI SYSTEM 07 03 1 ON VEHICLE COMPONENT REMOVAL 07 03...

Page 252: ...SYSTEM 2 Tundra II LT A05G0AS 8 5 4 2 3 2 6 24 N m 18 lbf ft 24 N m 18 lbf ft 1 8 21 9 9 21 10 13 15 53 N m 39 lbf ft 18 N m 159 lbf in 13 15 18 N m 159 lbf in 10 16 34 21 13 9 21 21 14 18 N m 159 lbf...

Page 253: ...5 4 6 9 40 N m 30 lbf ft 25 N m 18 lbf ft 2 21 21 16 13 14 25 N m 18 lbf ft 15 10 21 22 21 9 40 N m 30 lbf ft 26 52 N m 38 lbf ft 18 N m 159 lbf in 9 21 21 16 13 20 15 18 N m 159 lbf in 18 N m 159 lbf...

Page 254: ...ating Grip Element On vehicle equipped with heating grips grips might be unremovable as explained earlier in this case carefully proceed as follows to prevent damaging heating elements Locate the grip...

Page 255: ...cut off section of the ball joint must run parallel with the steering arm When tightening lock nuts restrain ball joint with appropriate size wrench Ensure not too many threads are kept outside of th...

Page 256: ...by NOT adjusting the handlebar too high WARNING Make sure that the steering pad and all controls are properly fixed to their normal location on the handlebar CAUTION Plastic alloy components such as...

Page 257: ...f its bracket Check if handlebar is horizontal To adjust loosen lock nuts of short tie rod and turn it accordingly 1 Pivot arm centered in slot 2 Slot 3 Turn to adjust WARNING Maximum ball joint exter...

Page 258: ...e out ad justment distance at front of ski must be 3 0 mm 1 8 in more than at rear on both sides for a total toe out of 6 mm 1 4 in TYPICAL 1 3 0 mm 1 8 in more at front than at rear 2 Straight edge 1...

Page 259: ...on one side to shorten its length Lengthen the other one by turning it exactly the same amount so that toe out is not changed WARNING Never lengthen tie rod so that threated portion of ball joint exce...

Page 260: ...re three grease fittings Oil ball joints and steering column bushings NOTE There are 8 lubrication points Other grease fittings require low temperature grease P N 413 7061 00 injected with a grease gu...

Page 261: ...Section 07 STEERING FRONT SUSPENSION Sub Section 02 STEERING SYSTEM 07 02 10 S Series A06G08S If so equipped PARTS FLAT RATE...

Page 262: ...SUSPENSION Sub Section 03 SUSPENSION AND SKI SYSTEM 07 03 1 SUSPENSION AND SKI SYSTEM 3 Tundra II LT A05G0JS 1 13 N m 115 lbf in 2 4 3 5 6 7 Grease 13 4 14 Grease 15 16 17 12 9 8 9 10 11 29 N m 21 lbf...

Page 263: ...n cover 2 Spring Pull out spring then check shock as described be low in inspection Suspension Free Operation Remove cover and check for free movement of ski leg by lifting end of ski DISASSEMBLY Lift...

Page 264: ...ay Re new as necessary 8 Shock Absorber Secure the shock body end in a vise 1 Clamp CAUTION Do not clamp directly on shock body Examine each shock for leaks Extend and com press the piston several tim...

Page 265: ...STEERING FRONT SUSPENSION Sub Section 03 SUSPENSION AND SKI SYSTEM 07 03 4 Steering arm notch must face outside of vehicle 1 Recess facing outside 16 17 Seal Install seal before reinstalling ski leg...

Page 266: ...Section 07 STEERING FRONT SUSPENSION Sub Section 03 SUSPENSION AND SKI SYSTEM 07 03 5 S Series A03G0CS 5 Loctite 242 11 8 8 7 7 6 1 4 3 2 FLAT RATE PARTS...

Page 267: ...hanging position of clevis pin Push down on handle until il locks Remove spring stopper and cap then release handle At installation cap opening must be 180 from spring stopper opening 1 Spring stopper...

Page 268: ...en oil chamber and gas chamber check shock as follows Install shock in a vise clamping on its bottom eye let with its rod upward Let it stand for 5 minutes Completely push down the shock rod then re l...

Page 269: ...ECAL 08 02 2 WINDSHIELD INSTALLATION 08 02 2 BELT GUARD 08 02 2 WIRING HARNESS 08 02 2 CABLES 08 02 2 PIPING 08 02 2 PLASTIC MAINTENANCE AND REPAIR 08 02 3 MAINTENANCE 08 02 3 REPAIR 08 02 3 MATERIAL...

Page 270: ...Conditions 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 R...

Page 271: ...For additional information ex ex ploded view refer to the correspondent parts catalog WARNING Engine should be running only with belt guard and or pulley guard well secured in place Inspection Check b...

Page 272: ...so propyl alcohol only Never use cleaners or products containing chlorine Apply wax on glossy finish only Protect the vehi cle with a cover to prevent dust accumulation dur ing storage CAUTION If for...

Page 273: ...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 with Crest Hi Solv product Apply a flexible primer such...

Page 274: ...876 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...

Page 275: ...nic box On models equipped with a battery also un plug the negative cable This will protect the electronic box and battery against damage caused by flowing current when welding TYPICAL 1 Unplug before...

Page 276: ...ear Cap Grind rivet heads from top of rear cap and under neath for side retaining rivets 1 Rivets heads ground 2 Rivets to be ground from underneath To remove rivet strike with a punch from rivet head...

Page 277: ...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 one thousand one hundr...

Page 278: ...k Plug Gap mm in 0 45 018 0 45 018 0 45 018 0 45 018 Ignition Timing BTDC mm in 2 52 099 1 68 066 1 68 066 1 66 065 Generating Coil Low Speed 40 76 N A N A N A High Speed N A 230 330 230 330 230 330 L...

Page 279: ...5 38 1 15 38 1 15 Length cm in 354 139 307 121 345 136 Adjustment Deflection mm in 35 45 1 3 8 1 3 4 40 55 1 9 16 2 5 32 40 55 1 9 16 2 5 32 Force kg lbf 7 3 16 7 3 16 7 3 16 Suspension Type Track Tor...

Page 280: ...5 136 345 136 345 136 307 121 Adjustment Deflection mm in 40 55 1 9 16 2 5 32 40 55 1 9 16 2 5 32 40 55 1 9 16 2 5 32 40 55 1 9 16 2 5 32 Force kg lbf 7 3 16 7 3 16 7 3 16 7 3 16 Suspension Type Track...

Page 281: ...dels except Tundra II LT Specification is giv en for verification purposes only Drive pulley retaining screw torque to 90 to 100 N m 66 to 74 lbf ft install drive belt ac celerate the vehicle at low s...

Page 282: ...______________________________________________________ ____________________________________________________________ ____________________________________________________________ _______________________...

Page 283: ...E Bombardier Inc Technical Publications After Sales Service Valcourt Quebec Canada J0E 2L0 Bombardier Inc Technical Publications After Sales Service Valcourt Quebec Canada J0E 2L0 Bombardier Inc Techn...

Page 284: ...TUNDRA II LT ANNEX 1 mmr9737a fm5 Page 2 Thursday May 8 1997 4 37 PM...

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Page 287: ...FORMULA S SL SKANDIC 380 500 ANNEX 2 mmr9737a fm5 Page 4 Thursday May 8 1997 4 37 PM...

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Page 290: ...TOURING E E LT TOURING LE SLE ANNEX 3 mmr9737a fm5 Page 6 Thursday May 8 1997 4 37 PM...

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Page 294: ...Section 00 Sub Section 0 00 0 1 1997 Shop Manual VOLUME 2 MX Z 440F 440 583 670 FORMULA 500 500 DELUXE 583 Z SUMMIT 500 583 670 GRAND TOURING 500 583 SKANDIC WT SWT WT LC...

Page 295: ...ombardier Inc Valcourt Quebec Canada Printed in Canada Registered trademarks of Bombardier Inc This document contains the trademarks of the following companies Loctite is a trademark of Loctite Corpor...

Page 296: ...m 03 07 1 08 Liquid cooling system 03 08 1 09 Rotary valve coolant pump and reservoir 03 09 1 10 Rewind starter 03 10 1 11 Carburetor and fuel pump 03 11 1 12 Fuel tank and throttle cable 03 12 1 04 T...

Page 297: ...ion and ski system 07 03 1 08 BODY FRAME 01 Table of contents 08 01 1 02 Body 08 02 1 03 Frame 08 03 1 09 TECHNICAL DATA 01 SI metric information guide 09 01 1 02 Engines 09 02 1 03 Vehicles 09 03 1 0...

Page 298: ...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...

Page 299: ...LA 500 DELUXE Canada 1191 FORMULA 500 DELUXE U S 1192 FORMULA 583 Canada 1141 FORMULA 583 U S 1142 FORMULA Z Canada 1145 FORMULA Z U S 1146 MODELS MODEL NUMBER SUMMIT 500 Canada 1157 SUMMIT 500 U S 11...

Page 300: ...CAL S SERIES Each vehicle has its particular vehicle serial number Serial Number Meaning TYPICAL 1 Vehicle serial number The engine also has a serial number Fan Cooled Engines 1 Engine serial number L...

Page 301: ...NTENANCE 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 secti...

Page 302: ...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 positi...

Page 303: ...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 lubrica...

Page 304: ...erent 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...

Page 305: ...TORQUES Tighten fasteners to torque mentioned in explod ed views and text When they are not specified refer to following table A06G07B 1 2 N m FASTENER SIZE 8 8 Lbf in 1 9 2 M4 18 3 M4 27 4 M5 35 5 44...

Page 306: ...8 52 M10 38 53 M10 39 54 40 55 41 56 41 57 42 58 43 59 44 60 44 61 45 62 46 63 46 64 47 65 48 66 49 67 49 68 50 69 51 70 52 71 52 72 53 73 54 74 55 75 55 76 M12 56 77 M12 57 78 M12 58 79 M12 58 80 M12...

Page 307: ...125 M14 92 126 M14 93 127 M14 94 128 M14 94 129 M14 95 130 M14 96 131 M14 97 132 M14 97 133 M14 98 134 M14 99 135 M14 100 136 M14 100 137 M14 101 138 M14 102 139 M14 103 140 M14 103 141 M14 104 142 M...

Page 308: ...section 03 11 Throttle Cable Inspection Sub section 03 12 Air Filter Cleaning This section no 4 Drive Belt Condition This section no 5 Condition of Drive and Driven Pulleys Sub sections 04 03 and 04 0...

Page 309: ...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 Se...

Page 310: ...until a sufficient quantity of oil has entered the engine approximately half a can With the engine stopped remove the spark plug and spray storage oil P N 496 0141 00 into each cylinder Crank slowly 2...

Page 311: ...it then dry it out NO 5 DRIVE BELT CONDITION Inspect belt for cracks fraying or abnormal wear uneven wear wear on one side missing cogs cracked fabric If abnormal wear is noted proba ble cause could...

Page 312: ...cycle Cleaner and Polish NOTE The latest product may be use alone if only light scratches are noticeable Inspect the hood and repair any damage Touch up all metal spots where paint has been scratched...

Page 313: ...NTS 0 ENGINE 02 02 1 FUEL AND OIL SYSTEMS 02 03 1 TRANSMISSION AND BRAKE SYSTEMS 02 04 1 TRANSMISSION 02 04 1 BRAKE SYSTEM 02 04 8 MECHANICAL BRAKE 02 04 8 HYDRAULIC BRAKE 02 04 9 MECHANICAL AND HYDRA...

Page 314: ...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 315: ...d 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 t...

Page 316: ...il 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 i...

Page 317: ...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 adjus...

Page 318: ...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...

Page 319: ...imes 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 app...

Page 320: ...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...

Page 321: ...ngine 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 R...

Page 322: ...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 323: ...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 324: ...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 09 5...

Page 325: ...ocate or replace 4 Check fuel pump flow a Dried diaphragm Replace 5 Check if carburetor s is are clean a Varnish Clean SYMPTOM HIGH INJECTION OIL CONSUMPTION CONDITION NORMAL USE Test Inspection 1 Che...

Page 326: ...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 327: ...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...

Page 328: ...rding 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...

Page 329: ...strains 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 Rep...

Page 330: ...ion is too weak Replace SYMPTOM IT IS DIFFICULT TO ENGAGE TRANSMISSION IN FORWARD OR REVERSE GEAR CONDITION NORMAL USE Test Inspection 1 Check position of gear shift lever adjustment screw a Improper...

Page 331: ...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...

Page 332: ...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...

Page 333: ...NORMAL USE Test Inspection 1 Check pulley alignment a Pulley misalignment Align pulley according to specifications refer to TECHNICAL DATA 09 SYMPTOM FLEX CRACKS BETWEEN COGS CONDITION NORMAL USE Tes...

Page 334: ...t 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...

Page 335: ...uid 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 h...

Page 336: ...en 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...

Page 337: ...ed 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 bus...

Page 338: ...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...

Page 339: ...ctric 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 BROKE...

Page 340: ...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 B...

Page 341: ...ify 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 Repla...

Page 342: ...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 Repl...

Page 343: ...ifications 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 creat...

Page 344: ...HT 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 Connect...

Page 345: ...L 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...

Page 346: ...ht 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 Increas...

Page 347: ...nsion 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...

Page 348: ...03 02 12 ASSEMBLY 03 02 12 454 494 583 AND 670 ENGINE TYPES 03 03 1 ENGINE SUPPORT AND MUFFLER 03 03 1 REMOVAL FROM VEHICLE 03 03 2 ENGINE SUPPORT AND MUFFLER DISASSEMBLY AND ASSEMBLY 03 03 2 INSTALL...

Page 349: ...ROTARY VALVE GAP 03 04 9 CHECKING SURFACE FLATNESS 03 04 10 RECTIFYING SURFACES 03 04 10 CHECKING CRANKSHAFT ALIGNMENT 03 04 10 CDI SYSTEM 03 05 1 NIPPONDENSO TRIGGER COIL IGNITION SYSTEM 03 05 1 CLEA...

Page 350: ...3 10 2 DISASSEMBLY 03 10 2 ASSEMBLY 03 10 2 INSTALLATION 03 10 3 CARBURETOR AND FUEL PUMP 03 11 1 REMOVAL 03 11 2 CLEANING AND INSPECTION 03 11 2 IDENTIFICATION 03 11 2 DISASSEMBLY AND ASSEMBLY 03 11...

Page 351: ...Sub Section 02 443 AND 503 ENGINE TYPES 03 02 1 443 AND 503 ENGINE TYPES 2 ENGINE REMOVAL AND INSTALLATION 443 Engine Type A03C13S 37 N m 27 lbf ft 35 N m 26 lbf ft 17 N m 150 lbf in 28 N m 21 lbf ft...

Page 352: ...ine crankcase 4 connector housing exhaust pipe and exhaust cooling hose on so equipped models oil pump inlet tube and plug it oil pump cable rewind cable tie a knot near rewind housing and remove star...

Page 353: ...Section 03 ENGINE Sub Section 02 443 AND 503 ENGINE TYPES 03 02 3 Skandic WT SWT 503 Engine Type A22C0FS 21 N m 15 lbf ft PARTS FLAT RATE...

Page 354: ...ley using appropriate puller refer to 04 03 DRIVE PULLEY air silencer and carburetor impulse line from engine crankcase 4 connector housing exhaust pipe and exhaust cooling hose oil pump inlet tube an...

Page 355: ...ENGINE TYPES 03 02 5 TOP END A22C0KS 2 22 N m 16 lbf ft 3 1 2 22 N m 16 lbf ft 2 22 N m 16 lbf ft 4 5 7 6 8 8 13 14 15 Grease 443 only 11 9 12 10 9 22 N m 16 lbf ft 22 N m 16 lbf ft 10 10 22 N m 16 l...

Page 356: ...Engine On this 443 engine piston pin needle bearing is mounted without a cage Use piston pin puller P N 529 0210 00 along with expansion sleeve and locating sleeve Place a clean cloth or rubber pad P...

Page 357: ...10 00 as follows Fully screw puller handle Insert puller end into piston pin Screw LH threads extracting nut Hold puller firmly and rotate puller handle coun terclockwise to pull piston pin NOTE The P...

Page 358: ...ve needles are held in place by 2 inner plastic cage halves Use piston pin puller P N 529 0210 00 to insert piston pin Plastic halves should come off pis ton If not pull them out using long nose plier...

Page 359: ...s Check flatness of intake sockets no 10 Refer to ENGINE DIMENSION MEASUREMENT 03 04 and look for checking surface flatness At cylinder no 7 and or cylinder head no 5 instal lation use aligning tool o...

Page 360: ...2 to 22 N m 16 lbf ft torque each cylinder head indi vidually For proper position of noise dampers nos 3 4 and 6 refer to the following illustrations 1 Noise dampers 2 PTO side cylinder Install armat...

Page 361: ...ND 503 ENGINE TYPES 03 02 11 BOTTOM END A03C1IT Anti seize lubricant Anti seize lubricant Anti seize lubricant 22 N m 16 lbf ft 503 22 N m 16 lbf ft 443 10 N m 89 lbf in 11 9 8 7 6 5 2 4 3 3 2 1 10 10...

Page 362: ...ASUREMENT 03 04 ASSEMBLY Smear anti seize lubricant P N 413 7010 00 on part of crankshaft where bearing fits To check proper clearance between bearing no 3 and counterweight use feeler gauge P N 420 8...

Page 363: ...one of mating surfaces Let it dry for 10 to 20 minutes Apply paste gasket P N 413 7027 00 no 5 on the other mating surface NOTE Primer N allows Loctite 515 to fully cure on aluminum surfaces It increa...

Page 364: ...SUPPORT AND MUFFLER All Models 5 3 4 3 A03C1NS 440 and 494 583 and 670 454 494 and 670 engines 23 N m 17 lbf ft 48 N m 35 lbf ft 25 N m 18 lbf ft 40 N m 30 lbf ft 25 N m 18 lbf ft 24 N m 18 lbf ft Lo...

Page 365: ...e engine support screws to 48 N m 35 lbf ft Torque the manifold screws to 23 N m 17 lbf ft INSTALLATION ON VEHICLE To install engine on vehicle reverse removal pro cedure However pay attention to the...

Page 366: ...S 03 03 3 3 Tuned Muffler This part is identified on welded support Second number sequence of P N is stamped on part 1 Identification Should a light exhaust leak be experienced at any ball joints Dow...

Page 367: ...t P N 413 7023 00 Pipe sealant P N 413 7023 00 Grease P N 413 7061 00 29 N m 21 lbf ft 10 N m 89 lbf in 29 N m 21 lbf ft 494 engine only 583 engine type only 1 2 1 Grease Loctite 242 Grease 17 20 22 2...

Page 368: ...ove piston pin no 19 use piston pin puller P N 529 0290 00 as follows Fully screw puller handle Insert puller end into piston pin Install adaptor P N 529 0236 00 then screw extracting nut LH threads H...

Page 369: ...direction of the exhaust port 1 Exhaust Use piston pin puller P N 529 0210 00 to ease piston pin installation To minimize the effect of acceleration forces on circlip install each circlip so the circl...

Page 370: ...ite 242 to screw threads Properly torque cylinders screws 3 Lay down cylinder head and insert aligning pins in holes as shown NOTE If pins can not be inserted in cylinder head holes enlarge them with...

Page 371: ...up with the studs Cylinder head itself can be used to align the cylinders Prior to torquing crankcase cylinder nuts install exhaust manifold to properly align ex haust flanges or use exhaust flange a...

Page 372: ...rod housing with their pas sages toward bottom 1 Passages Torque cylindrical screws to 10 N m 90 lbf in Check free sliding action of valve Install bellows over valve rod housing groove and secure wit...

Page 373: ...grease 3 4 454 494 and 670 engines only Anti seize lubricant Anti seize lubricant Loctite 515 Loctite 242 6 6 454 494 and 670 engines only 7 2 2 Except 454 494 and 670 See CDI SYSTEM 8 10 N m 89 lbf i...

Page 374: ...nd special puller as illustrated 1 PTO side 2 MAG side INSPECTION Refer to ENGINE DIMENSIONS MEASUREMENT 03 04 ASSEMBLY 2 4 5 6 9 Crankshaft Bearing and Labyrinth Sleeve Smear anti seize lubricant P N...

Page 375: ...the crankshaft Spray Primer N P N 413 7081 00 on one of mating surfaces Let it dry for 10 to 20 minutes Apply paste gasket P N 413 7027 00 no 5 on the other mating surface NOTE Primer N allows Loctit...

Page 376: ...gneto side to 10 N m 90 lbf in Apply pipe sealant P N 413 7023 00 on threads prior to assembly angular tube no 11 At assembly on crankcase apply medium strength threadlocker P N 413 7030 00 on stud th...

Page 377: ...otary valve gear lubrication system 7 Install air pump on any valve of exhaust plug NOTE If necessary lubricate air pump pis ton with mild soap 8 Rotate crankshaft so that piston goes to B D C Bottom...

Page 378: ...urfaces and screw stud threads of engine spark plug base insulator cylinder head cylinder base crankcase halves joint rotary valve cover oil injection pump mounting flange O ring seal coolant pump hou...

Page 379: ...ry 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 Bloc...

Page 380: ...ngs 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 TES...

Page 381: ...ARY VALVE GEAR RESERVOIR IN CRANKCASE ARE SEALS LEAKING CHECK CRANKSHAFT OUTER SEAL OF PTO AND MAG SIDES PRESSURIZE ROTARY VALVE GEAR RESERVOIR IN CRANKCASE IS RESERVOIR LEAKING UNSEAL PTO CYLINDER AN...

Page 382: ...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...

Page 383: ...d 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 positi...

Page 384: ...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 t...

Page 385: ...nap On FB300A inserted through intake socket of valve cover If gap is under tolerances rotary valve cover can be refaced to increase clearance If gap is over tolerances cover replacement may be necess...

Page 386: ...rt try pushing down the other end If any play is felt part must be rectified RECTIFYING SURFACES Stick a fine sand paper sheet on the surface plate then lightly oil the sand paper Rub manifold mating...

Page 387: ...s A15E0QU 7 6 3 Loctite 242 1 2 Loctite 242 Loctite 242 Loctite 648 4 Loctite 648 All engines except 454 494 and 670 22 N m 195 lbf in 5 Loctite 648 125 N m 92 lbf ft 6 7 Dielectric grease P N 413 701...

Page 388: ...to 40 mm 1 580 in outside diameter by 16 mm 5 8 in long NOTE To correctly remove a threadlocked fastener it is first necessary to tap on the fas tener to break threadlocker bond This will elimi nate t...

Page 389: ...ler 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 scr...

Page 390: ...l and lock washer on crankshaft Clean nut threads and apply Loctite 242 blue then tighten nut 125 N m 92 lbf ft for 454 494 and 670 engines Tighten nut to 105 N m 77 lbf ft for 583 engine At reassembl...

Page 391: ...tion 03 ENGINE Sub Section 05 CDI SYSTEM 03 05 5 DUCATI IGNITION SYSTEM 443 and 503 Engines A07C03S 1 2 3 5 4 Loctite 242 Dielectric grease 105 N m 77 lbf ft 22 N m 195 lbf in Loctite 242 FLAT RATE PA...

Page 392: ...agneto flywheel from its taper REPAIR To replace generator coil no 1 Heat the armature plate to 93 C 200 F around the screw holes to break the threadlocker bond To replace trigger coil no 4 Disconnect...

Page 393: ...mature and carefully pull wires Install new parts and other parts removed ASSEMBLY Clean crankshaft extension taper Apply Loctite 242 blue on taper Position Woodruff key flywheel and lock washer on cr...

Page 394: ...OIL INJECTION SYSTEM 6 OIL INJECTION PUMP 454 494 583 and 670 Engines Oil pump gasket set A03C1LS 1 Loctite 242 Molykote 111 3 6 5 Loctite 242 5 7 X X X X X X X X X Parts in illustration marked with X...

Page 395: ...Section 03 ENGINE Sub Section 06 OIL INJECTION SYSTEM 03 06 2 443 and 503 Engines A22C0DS Loctite 242 3 2 6 Loctite 242 1 Molykote 111 4 6 5 5 FLAT RATE PARTS...

Page 396: ...the pump mounting flange 5 6 Spring Clip and Clamp Always check for spring clips and clamps tight ness 3 Screw Torque to 9 N m 80 lbf in Make sure cable barrel is well seated in oil pump lever Secure...

Page 397: ...lay 1 Small oil line 2 Marks aligned 3 Main oil line Reinstall all parts except air silencer Bleed the small oil line between pump and intake manifold by running engine at idle while holding the pump...

Page 398: ...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 399: ...E Sous section 07 AXIAL FAN COOLING SYSTEM 03 07 1 AXIAL FAN COOLING SYSTEM 7 443 Engine 1 3 5 18 13 12 14 15 16 443 and 503 engines only 17 47 N m 35 lbf ft 20 10 11 10 9 4 13 N m 115 lbf in A03C0WS...

Page 400: ...Section 03 ENGINE Sous section 07 AXIAL FAN COOLING SYSTEM 03 07 2 503 Engine A22C0IS 1 2 3 12 11 10 9 5 4 8 7 6 13 14 15 16 17 18 55 N m 41 lbf ft 20 13 N m 115 lbf in PARTS FLAT RATE...

Page 401: ...mbly torque nut to 65 N m 48 lbf ft TYPICAL Fan belt deflection must be as specified when ap plying the proper force midway between pulleys 1 Deflection To adjust tension add or remove shim s no 15 be...

Page 402: ...ng bearing To install press one bearing in place then install circlip and shims Press the other bearing from op posite side until it is flush with housing Press fan shaft from engine side of fan housi...

Page 403: ...Section 03 ENGINE Sub Section 08 LIQUID COOLING SYSTEM 03 08 1 LIQUID COOLING SYSTEM 8 All S Series Engines A06C2VT 7 Loctite PST 3 5 4 1 6 PARTS FLAT RATE...

Page 404: ...Section 03 ENGINE Sub Section 08 LIQUID COOLING SYSTEM 03 08 2 Skandic WT LC A29C0AS 1 Loctite PST 8 2 3 4 Loctite PST PARTS FLAT RATE...

Page 405: ...diator protector into radiator C rail and crimp C rail at both ends Refer to FRAME 09 02 for radiator removal 5 Thermostat To check thermostat put in water and heat water Thermostat should open when w...

Page 406: ...9 03 Refilling Procedure S Series With vehicle on a flat surface engine cold refill coolant tank up to cold level mark Wait a few min utes then refill to mark Install pressure cap Run engine until the...

Page 407: ...race engine If coolant level gets down add more coolant in filler neck Turn off engine and close cap IMPORTANT After first drive let engine com pletely cool down Check that coolant level is at top of...

Page 408: ...SERVOIR 03 09 1 ROTARY VALVE COOLANT PUMP AND RESERVOIR 9 454 494 583 and 670 Engines TYPICAL A06C2UT 18 17 14 15 16 12 19 11 9 10 8 7 5 6 4 3 2 1 22 N m 16 lbf ft Injection oil reservoir To rotary va...

Page 409: ...ng at the end of this sub section Unscrew 4 retaining screws and withdraw rotary valve cover and valve 3 17 Circlip and Pump Impeller To remove rotary valve shaft assembly from crankcase first remove...

Page 410: ...for scoring pitting chip ping or other evidence of wear Make sure plastic cage on bigger bearing is not melted Rotate them and make sure they turn smoothly Check for presence of brass fillings in gea...

Page 411: ...valve Refer to Rotary valve timing at the end of this sub section to properly install gear on rotary valve shaft 12 13 14 15 Seals Shim Rubber Washer and Molykote Grease To install seals on water pum...

Page 412: ...ds pump impeller Use impeller support plate pusher P N 529 0207 00 for proper installation Install small thrust washer then friction washer positioning its grooves against pump impeller 1 Large shim 5...

Page 413: ...entification code on the valve To find out the duration place an angle finder on the valve and measure the valve cut out angle ROTARY VALVE TIMING At disassembly before removing rotary valve note orig...

Page 414: ...asure rotary valve opening and closing angles in relation with MAGneto side piston Degree wheel will be installed on rotary valve shaft for measurements Rotary valve must be set as specified in TECHNI...

Page 415: ...aft and upper crankcase must align These marks were scribed to deter mine desynchronization Install brass gear on rotary valve shaft with its marked spline 4 positions splines away for one degree of d...

Page 416: ...10 1 REWIND STARTER 0 All Models TYPICAL A01C57T 12 11 10 9 13 8 6 5 4 15 16 17 3 1 14 Molykote G n paste or equivalent Silicone compound grease Silicone compound grease 2 1 10 N m 89 lbf in 7 583 MX...

Page 417: ...ng no 4 outer end into spring guide notch then wind the spring counter clockwise into guide 1 Outer end into guide notch NOTE Due to dust accumulation rewind starter must be periodically cleaned inspe...

Page 418: ...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 lubricat...

Page 419: ...nd starter on damper ring matching notches and embosses 1 Notch Prior to installing starter grip no 16 on new rope it is first necessary to fuse the rope end with a lit match pass rope through rubber...

Page 420: ...ENGINE Sub Section 11 CARBURETOR AND FUEL PUMP 03 11 1 CARBURETOR AND FUEL PUMP 1 All Models A03C1MS 6 13 10 8 11 12 9 7 1 2 3 4 5 14 To other carburetor MX Z 440 F and Skandic WT series only 15 FLAT...

Page 421: ...ndition If worn the inlet needle and seat must be replaced as a matched set NOTE Install needle valve for snowmobile carburetor only It is designed to operate with a fuel pump system Check throttle sl...

Page 422: ...ening 1 Low cut away low 2 Rich mixture 3 High cut away high 4 Lean mixture 8 Main Jet The main jet installed in the carburetor has been selected for a temperature of 20 C 0 F at sea level Different j...

Page 423: ...er part of symbol corresponds to the opening mostly affected For instance throt tle slide cut away begins to function at closed po sition but it is most effective at 1 4 opening and decreases up to 1...

Page 424: ...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 425: ...it and turn cable adjuster as required Check throttle slide position at wide open throttle Throttle slide must be flush or 1 mm 040 in low er than carburetor outlet bore At that same posi tion check...

Page 426: ...IDLE SPEED ADJUSTMENT Adjust throttle slide height see table by turning idle speed screw no 7 Final adjustment engine running at idle speed should be within 1 2 turn of idle speed screw from prelimina...

Page 427: ...lock nut HAC SYSTEM Summit Only HAC High Altitude Compensator is a mainte nance free device No adjustment and verification can be done on HAC If HAC is suspected to be faulty replace it and check for...

Page 428: ...Section 03 ENGINE Sub Section 11 CARBURETOR AND FUEL PUMP 03 11 9 HAC SYSTEM A03I0BS To magneto housing FLAT RATE PARTS...

Page 429: ...Section 03 ENGINE Sub Section 11 CARBURETOR AND FUEL PUMP 03 11 10 FUEL PUMP A06C39T 443 503 engines 454 engine 583 599 670 and 779 engines FLAT RATE PARTS...

Page 430: ...heck 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 v...

Page 431: ...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 obs...

Page 432: ...e to 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 ti...

Page 433: ...5 ASSEMBLY 04 03 6 INSTALLATION 04 03 8 DRIVE PULLEY ADJUSTMENT 04 03 9 DRIVEN PULLEY 04 04 1 REMOVAL 04 04 3 DISASSEMBLY 04 04 3 CLEANING 04 04 3 INSPECTION 04 04 3 ASSEMBLY 04 04 5 INSTALLATION 04...

Page 434: ...USTMENT 04 07 4 GEARBOX 04 08 1 3 SPEED GEARBOX SHIFTER MECHANISM 04 08 1 REMOVAL 04 08 2 ADJUSTMENT 04 08 2 3 SPEED GEARBOX 04 08 3 REMOVAL 04 08 4 DISASSEMBLY 04 08 4 INSPECTION 04 08 6 ASSEMBLY 04...

Page 435: ...L PART NUMBER WIDTH NEW 0 25 mm 010 in MINIMUM WIDTH WEAR LIMIT SUMMIT 583 670 AND MX Z 670 415 0603 00 35 mm 1 3 8 33 mm 1 19 64 SUMMIT 500 GRAND TOURING 500 583 FORMULA 500 500DL 583 Z AND MX Z 440...

Page 436: ...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...

Page 437: ...rews 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...

Page 438: ...a lubrication free drive pulley A03D2CS Repair kit 5 2 1 3 Loctite 271 6 7 Loctite 648 Loctite 648 Loctite 648 9 18 12 11 12 13 14 15 16 17 16 19 23 25 24 22 20 21 26 27 25 29 32 30 31 28 95 N m 70 lb...

Page 439: ...uller P N 529 0079 00 for 443 503 and 583 engines Use puller P N 529 0224 00 for 454 494 and 670 engines CAUTION Such modifications should only be per formed by experienced mechanics since they can gr...

Page 440: ...mark and arrows as indexing refer ence 25 29 Slider Shoe and Governor Cup Carefully lift governor cup until slider shoes come at their highest position into guides Hold a slider shoe set then careful...

Page 441: ...ads 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 surf...

Page 442: ...s 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 bush...

Page 443: ...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 fere...

Page 444: ...r 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 sli...

Page 445: ...ds 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 s...

Page 446: ...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 fo...

Page 447: ...Section 04 TRANSMISSION Sub Section 03 DRIVE PULLEY 04 03 10 1 Loosen just enough to permit rotating of calibration screw A16D0HA 1...

Page 448: ...Sub Section 04 DRIVEN PULLEY 04 04 1 DRIVEN PULLEY 4 S Series A03D2FS Anti seize lubricant P N 413 7010 00 14 15 2 3 5 6 4 19 18 8 7 Loctite 609 11 13 16 17 12 10 9 All MX Z except 440 F All MX Z exce...

Page 449: ...Section 04 TRANSMISSION Sub Section 04 DRIVEN PULLEY 04 04 2 Skandic WT SWT WT LC A22D11S Anti seize lubricant 4 5 19 2 FLAT RATE PARTS...

Page 450: ...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 i...

Page 451: ...ew 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...

Page 452: ...ti seize Lubricant F Series and S Series Only Should installation procedure be required refer to BRAKE 04 06 then look for Brake Disc and Coun tershaft Bearing Adjustment Reinstall the pulley on the c...

Page 453: ...easurement 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 slid...

Page 454: ...install proper cam Refer to TECHNI CAL DATA 09 03 Cam angle is identified on cam NOTE For high altitude regions the High Al titude Technical Data Booklet P N 484 0648 00 and 484 0545 00 for binder gi...

Page 455: ...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 t...

Page 456: ...o 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 valu...

Page 457: ...oles 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...

Page 458: ...C DISC BRAKE S Series A03D2DS Loctite 242 7 MX Z 440 F Formula 500 500 Deluxe Summit 500 583 GT 500 583 only Anti seize lubricant All Models Except MX Z 440 F Formula 500 500 Deluxe Summit 500 583 GT...

Page 459: ...ly Pull countershaft toward driven pulley side to gain access to clip no 25 Remove clip no 25 on countershaft S Series Pull countershaft toward driven pulley side to free from chaincase and disc Remov...

Page 460: ...d 1 Spacer DISASSEMBLY Only brake pads are available as spare parts If cal iper or master cylinder are damaged replace each of them as an assembly CLEANING Clean all metal components in a general purp...

Page 461: ...o install brake reverse removal procedure paying attention to the following 7 Brake Pad All Models with Hydraulic Brake After brake pads installation brake disc must be centered in caliper Apply brake...

Page 462: ...ity Adjustment Torque castellated nut of upper sprocket to 53 N m 39 lbf ft Slide collar no 18 towards bearing and turn by hand to engage the eccentric This should require about a quarter turn Turn co...

Page 463: ...on 04 TRANSMISSION Sub Section 06 BRAKE 04 06 6 1 Open bleeder 2 Clear hose to catch used brake fluid Brake Light There is no adjustment on these models Check that switch is securely installed A06D0JA...

Page 464: ...Without Reverse Gear A06D17S 2 1 3 Chaincase oil 4 5 6 7 27 Loctite 242 23 9 10 8 24 25 26 Loctite 609 11 20 Loctite 242 14 16 17 18 14 12 Loctite 271 15 13 46 N m 34 lbf ft 22 21 45 to 75 N m 33 to 5...

Page 465: ...Check for worn or defective bear ings sprockets and chain tensioner components GEAR RATIO MODIFICATION For particular applications the number of teeth of the sprockets can be increased or decreased on...

Page 466: ...ge in locking hole This initial adjustment should provide 3 5 mm 1 8 13 64 in free play when measured at the out er circumference of the brake disc 22 Chaincase Oil Pour 250 mL 8 5 fl oz of synthetic...

Page 467: ...CHAINCASE 04 07 4 TYPICAL 1 Dipstick NOTE Chaincase must be in its proper posi tion when checking oil level ADJUSTMENT Pulley Alignment Refer to PULLEY DISTANCE AND ALIGNMENT 04 05 Track Tension and A...

Page 468: ...Section 04 TRANSMISSION Sub Section 08 GEARBOX 04 08 1 GEARBOX 8 3 SPEED GEARBOX SHIFTER MECHANISM Skandic WT WT LC A22D0YS 7 4 4 5 6 5 3 2 1 FLAT RATE PARTS...

Page 469: ...osen tie rod lock nut Remove clip Unfasten tie rod end 1 Clip 2 Lock nut Adjust tie rod length in a way that gear shift lever does not contact console Check 2nd gear posi tion Retighten ball joint loc...

Page 470: ...04 TRANSMISSION Sub Section 08 GEARBOX 04 08 3 3 SPEED GEARBOX Skandic WT SWT WT LC 1 2 3 4 8 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 14 21 22 23 23 24 25 26 29 30 31 17 28 27 28 5 A22D0CS FLAT RATE...

Page 471: ...c side 1 RH side driven pulley side 2 LH side brake disc side 3 4 7 14 16 20 Dipstick Top Cover Gasket O ring Upper Side Cover and Lower Side Cover Remove dipstick Unfasten top cover upper side cover...

Page 472: ...n Pulley Shaft and Shim Pry oil seal out of gearbox housing Remove snap ring Drive out driven pulley shaft Use alignment tool P N 420 4760 10 as a supporting plate to extract last gear and bearing Spa...

Page 473: ...Output Shaft Install output shaft with its hollow side no splines on RH side 25 29 Lower Gear and Intermediate Gear Install all gears with their shoulder towards RH side 1 Gear shoulder towards RH sid...

Page 474: ...rclip 5 6 Fork and Fork Axle Mount forks and fork axles using a screwdriver to hold index ball See illustration for fork axle posi tions INSTALLATION Reverse removal procedure Check pulley align ment...

Page 475: ...and Touring 500 583 A03D17S 15 N m 133 lbf in 7 8 5 28 31 40 48 N m 35 lbf ft Loctite 271 6 16 17 32 33 34 37 38 5 N m 44 lbf in 35 36 29 N m 21 lbf ft Loctite 242 Loctite 242 27 Grease 25 14 Loctite...

Page 476: ...and then remove reverse axle no 20 1 Sliding gear screw 2 Reverse axle Remove coupling shaft no 33 44 tooth sprocket no 34 spacer no 38 and chain no 28 First unscrew castellated nut no 10 then remove...

Page 477: ...th sprocket Tighten nut no 37 to 5 N m 44 lbf in in a criss cross sequence Insert spring pin no 21 in reverse axle up to in side diameter Press needle bearing in 19 tooth sprocket Install ring no 24 a...

Page 478: ...is still impossible check if the fork engages in the slid ing gear or disassemble the cover to inspect com ponents 3 Completely slacken ball joint lock nut on the gear shift linkage 4 Using tool P N...

Page 479: ...Clean cover interior NOTE It is normal to find metallic particles stuck to dipstick magnet If bigger pieces of metal are found disassemble and check all parts Reinstall cover as previously described...

Page 480: ...ere 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...

Page 481: ...TEM 05 04 1 1997 REFERENCE CHART 05 04 1 DESIGN SYMBOLS USED IN NGK SPARK PLUGS 05 04 2 DISASSEMBLY 05 04 3 HEAT RANGE 05 04 3 FOULING 05 04 3 SPARK PLUG ANALYSIS 05 04 3 SPARK PLUG INSTALLATION 05 04...

Page 482: ...05 07 4 TRIGGER COIL OUTPUT 05 07 4 IGNITION COIL OUTPUT 05 07 4 IGNITION MODULE 05 07 5 MAGNETO OUTPUT IGNITION GENERATOR COIL 05 07 6 LIGHTING GENERATOR COIL OUTPUT 05 07 6 SUMMARY TABLE 05 07 8 RES...

Page 483: ...watt ELECTRICAL SYSTEM OUTPUT watt MX Z 440 F Annex 1 60 55 hal 8 27 240 MX Z 440 583 670 Annex 2 60 55 hal 8 27 220 Formula 500 DELUXE Annex 3 60 55 hal 8 27 220 Formula 500 583 Summit 500 583 670 An...

Page 484: ...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 485: ...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...

Page 486: ...so 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...

Page 487: ...move the rewind starter from the engine 3 Install the TDC gauge in the spark plug hole magneto generator side and adjust as follows a Position the magneto flywheel at approxi mately TDC INSTALLATION O...

Page 488: ...to fly wheel and trigger coil part numbers and check Woodruff key condition If all parts are the appropriate ones and if Woodruff key is in good condition continue the procedure 1 Trigger coil mark 2...

Page 489: ...a faulty trigger coil check proper grounding of coil or a faulty CDI module could be the cause substitute one part at a time and recheck timing marks check connec tors condition prior to substituting...

Page 490: ...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...

Page 491: ...er of trigger coil core 2 Retard 3 Advance 454 494 AND 670 ENGINES 1 Advance 2 Retard NOTE These marks can not be used to check dynamic with engine running ignition timing with a timing light an other...

Page 492: ...igned 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...

Page 493: ...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 REF...

Page 494: ...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 Standar...

Page 495: ...ion 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...

Page 496: ...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...

Page 497: ...p Remove vent tube On all models a special vented rivet is fixed to the chassis in order to plug the vented tube from the battery Skandic WT Remove air intake silencer 1 Loosen clamp 1 Remove bolt and...

Page 498: ...y from vehicle being careful not lean it so that electrolyte flows out of vent tube CLEANING Clean the battery battery casing vent tube caps cables and battery posts using a solution of baking soda an...

Page 499: ...t hydrometers give a true reading at 27 C 80 F In order to obtain correct readings adjust the ini tial reading by adding 004 points to the hydrom eter readings for each 5 5 C 10 F above 27 C 80 F and...

Page 500: ...ys As necessary keep the battery at its upper level line and near full charge as possible trickle charge ACTIVATION OF NEW BATTERY A new battery is factory fresh dry charged For storage purposes it is...

Page 501: ...1 Battery electrolyte 6 Connect a 2 A battery charger for 10 to 20 hours A17E0FA 1 A17E0GA 1 A17E0HA CAUTION If charging rate raises higher than 2 4 A re duce it immediately If cell temperature rises...

Page 502: ...gravity 1 260 9 Let battery settles for one hour 1 60 minutes 10 Allow gas bubbles to escape by lightly shake battery 11 Readjust electrolyte level 1 Battery electrolyte 12 Reinstall caps and clean an...

Page 503: ...y to begin accepting measurable current will also vary Charging a Very Flat or Completely Discharged Battery Unless this procedure is properly followed a good battery may be needlessly replaced Measur...

Page 504: ...s supply shops and they are suitable for use with most chargers if the peak current is to be held below 2 amps If you need an accurate ammeter we recommend the use of SHURITE 5202 0 to 3 amps or 5203...

Page 505: ...roper bat tery installation AIR SILENCER INSTALLATION SKANDIC WT 1 Locking tie All Models Ensure that vent tube is not kinked or blocked then install protective boot over battery Close and fasten reta...

Page 506: ...ction 05 ELECTRICAL Sub Section 06 ELECTRIC STARTER 05 06 1 ELECTRIC STARTER 6 S Series with Electric Starting and Skandic WT SWT A03E13S 1 2 3 8 9 10 11 12 13 15 16 17 18 19 4 5 6 7 12 PARTS FLAT RAT...

Page 507: ...o 8 Insert blade of a small screwdriver between stop collars Twist screwdriver to separate stop collars no 12 thus giving access to circlip no 13 Remove outer collar circlip then inner collar Remove o...

Page 508: ...to rotate tap until the bushing comes free 1 Turn until bushing goes out 2 12 mm tap To install new bushing use the same bushing pusher as for drive housing bushing installation 6 Brush To replace br...

Page 509: ...ce drive lever onto overrunning clutch then in sert into drive housing 1 Install on overrunning clutch 2 Install thrust washer Slide yoke over armature Install brush holder then brushes in their hous...

Page 510: ...n Install hardened washers P N 503 0079 00 between engine and starter supports ac cordingly 1 Screwdriver pulling starter pinion 2 Ring gear 3 No excessive backlash A 0 5 to 1 5 mm 020 to 060 in Conne...

Page 511: ...ce If necessary turn the commutator on a lathe enough to remove grime only Check the commutator for mica depth If the depth is less than 0 20 mm 0 008 in undercut the mica Be sure that no burrs are le...

Page 512: ...ion of an open circuit armature coil Field Windings and Brushes Test the Field Winding for Open Circuit Use growler test probes Place one test probe on the negative brush and the other test probe on t...

Page 513: ...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 514: ...ELECTRICAL Sub Section 06 ELECTRIC STARTER 05 06 9 Skandic WT LC A29E09S 12 11 10 9 6 8 7 1 2 3 4 5 5 N m 44 lbf in Dielectric grease Loctite 271 Ground cable Dielectric grease 22 N m 16 lbf ft FLAT...

Page 515: ...CAL 1 Trace indexing marks Remove starter support nuts then through bolts Separate end frame from yoke assembly With draw yoke assembly from armature Brush holder can be removed from end frame by unsc...

Page 516: ...on a lathe enough to resurface only Check commutator for mica depth If depth is less than 0 20 mm 008 in undercut mica Be sure that no burrs are left and no copper dust remains between segments after...

Page 517: ...ng coat sliding surfaces on ar mature shaft splines overrunning clutch and bushing with G E Versilube G 341 M or ESSO Beacon 325 lubricant or equivalent Apply motor oil on metal bushings 6 8 Circlip a...

Page 518: ...RTER INSTALLATION Installation is essentially the reverse of removal procedure However pay particular attention to the following Make sure that starter and engine mating surfac es are free of debris S...

Page 519: ...N 129700 2982 Flywheel stamped P N 032000 7860 454 494 and 670 Engines Ignition module stamped P N 070000 2421 Ignition coil stamped P N 129700 2982 Flywheel stamped P N 032700 5900 NIPPONDENSO CDI T...

Page 520: ...motive equipment and other items as follows Engine Stop Tether Cut Out Switches Verification Engine Stop Switch Unplug stop switch connector from main harness then using an ohmmeter connect test probe...

Page 521: ...vestigated loose connec tions or components etc Indicator Lamp Lights at Lower Setting This indicates that the output is less than that de signed to operate in a satisfactory manner How ever before co...

Page 522: ...d grounding IGNITION COIL OUTPUT A paper clip of approximately 20 mm 3 4 in will be used as a test adapter for the following test 1 Install the test adapter to spark plug cable close to MAG side spark...

Page 523: ...At assembly secure with new locking ties 2 Connect an ignition coil known as being in good condition to the spark plug s 3 Connect CDI module to replacement ignition coil paying attention to connect t...

Page 524: ...eto harness At installation secure with new locking ties 2 Connect tester wires then set switch and dial as follows TYPICAL 3 Crank engine and observe indicator 4 Push reset button and repeat step 3 t...

Page 525: ...sh 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...

Page 526: ...ire of trigger coil Ignition coil output N Engine ground LOW 45 P Test adapter on MAG spark plug cable Ignition module output N WHITE BLUE wire of ignition coil LOW 85 P BLACK wire of ignition coil Ma...

Page 527: ...nt can still be faulty Voltage leak can occur at high voltage level which is not detect able with an ohmmeter Infinity extremely large number PART NAME WIRE COLOR RESISTANCE OHM REMARKS MAGNETO Trigge...

Page 528: ...Generator Coil 1 Disconnect the 2 wire connector between igni tion module and magneto harness 2 Connect tester wires then set switch and dial as follows 1 Green 2 White 3 Crank engine and observe indi...

Page 529: ...IGNITION MODULE Ignition module can not be tested with the Bom bardier ignition tester When other components test good the module is probably faulty Try a new module LIGHTING GENERATOR COIL OUTPUT NO...

Page 530: ...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 531: ...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 532: ...er to a BLACK YELLOW wire Connect the other wire of the voltmeter to a YEL LOW wire Lift the rear of vehicle and support with a mechan ical stand Start the engine at an idle without opening the thrott...

Page 533: ...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 534: ...When measuring resistance at terminals the actual value will be half the measurement in table The reason for that is the elements are connected in parallel Therefore the total resistance is half the...

Page 535: ...SERVICING 06 02 11 INSTALLATION 06 02 19 RIDE ADJUSTMENT 06 02 19 LUBRICATION 06 02 19 SKANDIC WT SUSPENSION 06 03 1 REMOVAL 06 03 2 DISASSEMBLY AND ASSEMBLY 06 03 2 SHOCK ABSORBER SERVICING 06 03 3...

Page 536: ...06 02 1 SC 10 SUSPENSIONS ALL VERSIONS 2 SC 10 Sport on MX Z 440 F Formula 500 500 DELUXE 583 A03F26S 21 Loctite 271 7 1 2 3 4 5 7 19 Low temp grease 8 9 6 16 12 13 14 15 25 11 10 Loctite 271 11 16 2...

Page 537: ...L VERSIONS 06 02 2 SC 10 Cross country on MX Z 440 583 670 A03F27S 21 Loctite 271 7 2 3 7 5 4 6 16 Low temp grease 8 9 15 12 13 14 25 16 20 10 Loctite 271 MX Z 440 only 11 18 Loctite 271 Loctite 271 L...

Page 538: ...S ALL VERSIONS 06 02 3 SC 10 High performance on Formula Z and Grand Touring 583 A03F28S 21 7 1 2 3 4 5 Loctite 271 6 16 9 8 Low temp grease Front arm 12 13 14 25 15 11 16 20 17 10 Loctite 271 18 Loct...

Page 539: ...ENSIONS ALL VERSIONS 06 02 4 SC 10 Mountain on Summit 500 583 670 A03F29S Loctite 271 7 2 4 3 5 7 1 Loctite 271 19 8 9 16 6 Low temp grease 12 13 14 15 25 11 16 20 11 17 10 Loctite 271 Loctite 271 18...

Page 540: ...PENSIONS ALL VERSIONS 06 02 5 SC 10 Touring on Grand Touring 500 A03F2AS Loctite 271 7 1 2 3 5 7 Loctite 271 4 6 16 19 8 9 Low temp grease 12 13 14 15 25 11 11 16 20 17 10 Loctite 271 Loctite 271 18 L...

Page 541: ...assemble threaded rod ass y needlessly Lift rear of vehicle Unhook rear springs Unscrew threaded rod nut Remove through bolt from shackle Swing shackle rearward Collapse suspension in order to disenga...

Page 542: ...ion illustration below Installation is reverse of removal procedure To easily compress gas shock absorber use a pry bar and locking pliers as a stopper 1 Locking pliers 2 Pry bar All Models 12 Front S...

Page 543: ...upport it off the ground Loosen track tension 7 Screw Unscrew rear arm top axle from chassis NOTE To prevent axle from turning when unscrewing screws assembled with thread locker proceed as follows Kn...

Page 544: ...screw 11 Axle Note position of axles at disassembly Axles with a paint stripe serve as idler wheel axles These are more precise than those used as pivot axles Idler wheel axles can be used as pivot ax...

Page 545: ...DATA 09 03 Torque nut to 11 N m 97 lbf in 1 1st hole 2 2nd hole A 11 N m 97 lbf in 17 Slider Shoe Replace slider shoes when it is worn to the line 1 Wear limit line 18 Spring Support RIGHT SIDE SHOWN...

Page 546: ...hock in a vise clamping on its bottom eye let with its rod upward Let it stand for 5 minutes Completely push down the shock rod then re lease Rod must comes out at a steady speed If speed suddenly inc...

Page 547: ...assembly removed slowly lift and remove damper rod assembly from the damper body NOTE Remove damper rod assembly slow ly to reduce oil spillage and prevent piston seal damage by damper body threads W...

Page 548: ...nut after 4 rebuilds to ensure good locking friction NOTE If revalving is to be done it is imper ative that you identify the original shim pack size and number of shims The seal carrier need not be re...

Page 549: ...1 18 in shims no 7 against piston to properly close piston orifice holes Two thin shims will offer less damping than one thick shims of the equal thickness Tuning for less damping it is important to...

Page 550: ...1 A06F12A 529 0265 00 FRONT QTY D mm in Thick mm in Spacer 1 12 mm 0 472 in 0 023 mm 0 008 in Extension shims 5 26 mm 1 020 in 0 203 mm 0 008 in Piston slit 4 Compression shims 8 30 mm 1 180 in 0 152...

Page 551: ...ce 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 fl...

Page 552: ...to damper body Slight up and down movement may be required to allow all air to pass through piston assembly NOTE Fast installation of the damper rod may displace the floating piston from its orig inal...

Page 553: ...noth er gas product The nitrogen gas has been se lected because of its inert qualities As well as being a dry gas moisture free it will not con taminate the gas chamber portion of the damp er When sel...

Page 554: ...rst Insert rear portion of suspension into track Bolt front arm rear arm then center top idler wheel axle Adjust track tension RIDE ADJUSTMENT Refer to Operator s Guide LUBRICATION Lubricate front and...

Page 555: ...Section 06 REAR SUSPENSION Sub Section 03 SKANDIC WT SUSPENSION 06 03 1 SKANDIC WT SUSPENSION 3 Skandic WT SWT WT LC A22F18S 1 2 3 7 4 5 6 8 FLAT RATE PARTS...

Page 556: ...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 557: ...pin Unbolt front idler wheel axle Remove idler wheel on side where axle retaining plate is not welded Remove springs 1 Circlips 6 Support Plate Drill rivets to remove support plate Use a 8 mm 21 64 in...

Page 558: ...smoothly and with uniform resistance Pay attention to the following conditions that will denote a faulty shock A skip or a hang back when reversing stroke at mid travel Seizing or binding condition e...

Page 559: ...Section 06 REAR SUSPENSION Sub Section 04 DRIVE AXLE 06 04 1 DRIVE AXLE 4 S Series A03D20S 12 6 4 9 13 10 2 3 5 11 13 8 Summit and MX Z only FLAT RATE PARTS...

Page 560: ...Section 06 REAR SUSPENSION Sub Section 04 DRIVE AXLE 06 04 2 Skandic WT A22D14S 13 6 9 3 2 5 4 FLAT RATE PARTS...

Page 561: ...e same time pulling the drive axle towards the end bearing housing side Remove drive axle from vehicle Skandic WT SWT WT LC Only Drain gearbox Raise and block rear of vehicle off the ground Remove sus...

Page 562: ...MBLY 8 9 13 Drive Axle and Sprocket To assemble press fit sprockets use a press and a suitable pipe as illustrated Sprockets must be assembled according to the following dimen sions 1 Pipe S Series A...

Page 563: ...f drive axle if applicable Locate seal lip as illustrated 1 Grease seal type 2 Oil seal type 11 Bearing Protector At assembly flat side of bearing protector must be against bearing 5 12 Bearing Always...

Page 564: ...lockwise TYPICAL 1 Set screw 2 Slacken 3 Tighten Extract bearing from its support Wrong chaincase perpendicularity will make it dif ficult to correctly install the bearing in its support due to the co...

Page 565: ...rive axle pushed toward chaincase 1 No gap all around Pull drive axle toward the end bearing housing and take note of the measurement between sprocket and tunnel The drive axle axial play is the diffe...

Page 566: ...h side exceeds 3 mm 1 8 in redistribute drive axle shims as fol lows INSTALLATION 4 Speedometer Drive Insert If the drive axle to be installed is a new part and the vehicle is equipped with a speedome...

Page 567: ...DATA 09 03 Install the suspension Refer to TRACK 06 05 and adjust track tension and carry out track alignment procedure LUBRICATION 15 Grease Fitting Lubricate end housing bearing with low tempera tu...

Page 568: ...r suspension muffler RH drive axle end bearing angle drive and square pin Move transmission sideway Do not remove brake mechanism nor driven pulley Refer to SKANDIC WT SUSPENSION 06 03 Remove drive ax...

Page 569: ...YPICAL 1 Retaining screw 2 Adjuster bolt Alignment All Models With rear of vehicle supported off the ground start engine and allow the track to rotate slowly Check that the track is well centered equa...

Page 570: ...ise 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...

Page 571: ...02 3 DISASSEMBLY AND ASSEMBLY 07 02 3 INSPECTION 07 02 4 ADJUSTABLE HANDLEBAR 07 02 5 STEERING ADJUSTMENT SKIS 07 02 6 LUBRICATION 07 02 9 SUSPENSION AND SKI SYSTEM 07 03 1 DISASSEMBLY 07 03 2 INSPEC...

Page 572: ...31 8 3 1 5 4 6 9 40 N m 30 lbf ft 25 N m 18 lbf ft 2 21 21 16 13 14 25 N m 18 lbf ft 15 10 21 22 21 9 40 N m 30 lbf ft 26 52 N m 38 lbf ft 18 N m 159 lbf in 9 21 21 16 13 20 15 18 N m 159 lbf in 18 N...

Page 573: ...Section 07 STEERING FRONT SUSPENSION Sub Section 02 STEERING SYSTEM 07 02 2 Skandic WT A22G0KS 7 25 23 24 31 5 3 8 2 10 15 1 17 21 9 20 15 21 16 20 21 9 9 21 10 15 25 N m 18 lbf ft 6 FLAT RATE PARTS...

Page 574: ...er the engine from the steering column 17 Steering Arm To maintain correct steering geometry for reas sembling punch mark the steering arm and ski leg before disassembly TYPICAL 1 Punch marks 31 Heati...

Page 575: ...d 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 explo...

Page 576: ...Tighten ball joint nuts and jam nuts to specified torque see exploded view 9 Vehicles with a Castle Nut After proper torque has been applied to the ball joint nut insert a cotter pin through the hole...

Page 577: ...t where applicable STEERING ADJUSTMENT SKIS Definitions TOE OUT A difference measured between the front edge of the skis A and rear edge B as viewed from the top It is adjustable CAUTION Tighten the n...

Page 578: ...ign and retighten the jam nuts to 18 N m 159 lbf in 1 Tie rod no 14 2 Center of pivot arm in line with bolt end CAMBER NOTE On vehicles without adjustable radi us arms no 7 the camber is not adjustabl...

Page 579: ...ivet Adjustment is performed by adjusting length of left and right tie rods no 20 Procedure Loosen jam nuts no 13 and no 15 of both tie rods no 20 Turn the tie rod on one side to shorten its length Le...

Page 580: ...position place a straight edge against pre adjusted track and measure the distance be tween front and rear of skis and straight edge Distances should be equal After the ski toe out adjustment distanc...

Page 581: ...Section 07 STEERING FRONT SUSPENSION Sub Section 02 STEERING SYSTEM 07 02 10 S Series A06G08S If so equipped PARTS FLAT RATE...

Page 582: ...PENSION AND SKI SYSTEM 3 S Series A03G0HS 14 13 25 N m 18 lbf ft Loctite 242 29 N m 21 lbf ft Some models MX Z 440 Some models 10 4 3 2 1 6 5 7 8 17 5 N m 159 lbf in 5 5 40 N m 29 lbf ft 9 11 14 N m 1...

Page 583: ...tion of the clevis pin Push down on the handle until it locks Remove spring stopper and cap then release handle When installing the cap opening must be 180 from the spring stopper opening 1 Cap openin...

Page 584: ...ary Check condition of ski stopper Replace it when deteriorated To check condition of shock refer to SC 10 SUS PENSIONS 06 02 then look for Shock Absorber Inspection INSTALLATION For assembly reverse...

Page 585: ...Section 07 STEERING FRONT SUSPENSION Sub Section 03 SUSPENSION AND SKI SYSTEM 07 03 4 WRONG POSITION A06G0XA...

Page 586: ...Section 07 STEERING FRONT SUSPENSION Sub Section 03 SUSPENSION AND SKI SYSTEM 07 03 5 Skandic WT A22G0NS 1 2 3 4 5 6 7 8 9 13 N m 115 lbf in 9 11 18 12 10 17 16 14 15 4 13 Grease 19 FLAT RATE PARTS...

Page 587: ...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 588: ...t 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 wa...

Page 589: ...Extend and com press the piston several times over its entire stroke with its rod upward Check that it moves smoothly and with uniform resistance Pay attention to the following conditions that will de...

Page 590: ...Section 07 STEERING FRONT SUSPENSION Sub Section 03 SUSPENSION AND SKI SYSTEM 07 03 9 TYPICAL 1 Bent angle toward the bottom 16 17 Seal Install seal before reinstalling ski leg A05G0CB 1...

Page 591: ...2 1 DECAL 08 02 2 WINDSHIELD INSTALLATION 08 02 2 HOOD 08 02 2 BELT GUARD 08 02 3 WIRING HARNESS 08 02 3 CABLES 08 02 3 PIPING 08 02 3 PLASTIC MAINTENANCE AND REPAIR 08 02 4 MAINTENANCE 08 02 4 REPAIR...

Page 592: ...nditions 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 REP...

Page 593: ...es Position the windshield on the hood then push it down until the tabs are fully inserted into the hood slots Lock the windshield tabs in position using latches as shown S SERIES 1 Latch 2 Temporary...

Page 594: ...imped on the wires and that all connector housings are properly fastened Keep wires away from any rotating moving heating and vi brating parts Use proper fastening devices as required WARNING Before i...

Page 595: ...aning agent in their formula Apply wax on glossy finish only Protect the vehi cle with a cover to prevent dust accumulation dur ing storage CAUTION Do not apply isopropyl alcohol or acetone directly o...

Page 596: ...UTION 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 597: ...k no AP F Wait 10 minutes Repaint air dry during 72 hours approximate ly Large Crack Sand and scuff outside and inside area by ex ceeding it 31 7 mm 1 1 4 in on each side and 12 7 mm 1 2 in at each en...

Page 598: ...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 599: ...6 in size and shipped in packs of 2 For proper drilling instructions and to prevent pre mature wear follow the procedure below Always use a variable speed electric drill It is not necessary to center...

Page 600: ...de retaining rivets 1 Rivets heads ground 2 Rivets to be ground from underneath To remove rivet strike with a punch from rivet head side Make a chamfer from underneath on all 4 corner holes CAUTION Hi...

Page 601: ...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 one thousand one hundr...

Page 602: ...Gap mm in 0 45 018 0 45 018 0 45 018 0 45 018 Ignition Timing BTDC mm in 1 68 066 1 48 058 1 75 069 1 75 069 Trigger Coil 140 180 190 300 190 300 190 300 Generating Coil 230 330 10 17 10 17 10 17 Lig...

Page 603: ...rk Plug Gap mm in 0 45 018 0 45 018 0 45 018 0 45 018 Ignition Timing BTDC mm in 1 81 071 1 81 071 1 75 069 1 75 069 Trigger Coil 190 300 190 300 190 300 190 300 Generating Coil 10 17 10 17 10 17 10 1...

Page 604: ...ug Gap mm in 0 45 018 0 45 018 0 45 018 0 45 018 Ignition Timing BTDC mm in 1 81 071 1 75 069 1 93 076 1 81 071 Trigger Coil 190 300 190 300 190 300 190 300 Generating Coil 10 17 10 17 10 17 10 17 Lig...

Page 605: ...BR8ES NGK BR9ES Spark Plug Gap mm in 0 45 018 0 45 018 0 45 018 Ignition Timing BTDC mm in 1 75 069 1 66 065 1 81 071 Trigger Coil 190 300 140 180 190 300 Generating Coil 10 17 230 330 10 17 Lighting...

Page 606: ...m in 38 1 15 38 1 15 0 38 1 15 0 38 1 15 0 Length cm in 307 121 307 121 307 121 307 121 Adjustment Deflection mm in 40 55 1 9 16 2 5 32 40 55 1 9 16 2 5 32 35 40 1 3 8 1 3 4 35 40 1 3 8 1 3 4 Force kg...

Page 607: ...Track Width cm in 38 1 15 0 38 1 15 0 38 1 15 0 38 1 15 0 Length cm in 307 121 307 121 307 121 307 121 Adjustment Deflection mm in 40 55 1 9 16 1 11 64 40 55 1 9 16 1 11 64 30 40 1 9 16 1 3 4 35 40 1...

Page 608: ...Width cm in 38 1 15 0 38 1 15 0 38 1 15 0 38 1 15 0 Length cm in 345 5 136 345 5 136 345 5 136 345 5 136 Adjustment Deflection mm in 45 50 1 3 4 1 31 32 45 50 1 3 4 1 31 32 45 50 1 3 4 1 31 32 40 55 1...

Page 609: ...0 0 19 7 60 0 23 6 50 0 19 7 Length cm in 345 5 136 394 155 1 394 155 1 394 155 1 Adjustment Deflection mm in 40 55 1 9 16 2 5 32 40 50 1 9 16 1 31 32 40 50 1 9 16 1 31 32 40 50 1 9 16 1 31 32 Force k...

Page 610: ...rts 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...

Page 611: ...______________________________________________________ ____________________________________________________________ ____________________________________________________________ _______________________...

Page 612: ...E Bombardier Inc Technical Publications After Sales Service Valcourt Quebec Canada J0E 2L0 Bombardier Inc Technical Publications After Sales Service Valcourt Quebec Canada J0E 2L0 Bombardier Inc Techn...

Page 613: ...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...

Page 614: ...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...

Page 615: ......

Page 616: ......

Page 617: ...nnected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by...

Page 618: ...nnected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by...

Page 619: ......

Page 620: ......

Page 621: ...nected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by...

Page 622: ...nected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns by...

Page 623: ......

Page 624: ......

Page 625: ...o 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 B...

Page 626: ...o 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 B...

Page 627: ......

Page 628: ......

Page 629: ...e connected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current return...

Page 630: ...e connected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current return...

Page 631: ......

Page 632: ......

Page 633: ...ected 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 Y...

Page 634: ...ected 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 Y...

Page 635: ......

Page 636: ......

Page 637: ...onnected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns b...

Page 638: ...onnected to headlamp VIOLET GREY 12 volts A C Low beam WHITE 12 volts A C Brake light Current returns by YELLOW BLACK wire connected to taillight WHITE RED 12 volts A C Low oil level Current returns b...

Page 639: ...ANNEX 7...

Page 640: ...ANNEX 7...

Page 641: ...SKANDIC WT LC ANNEX 8...

Page 642: ...BEAM YL GN BR WH GY YL GN GY HEADLAMP GY YL WH GY GY YL YL BK BK YL BK BK YL YL GN YL GN YL BL BL FUEL LEVEL GAUGE YL BK RD YL YL BL FUEL LEVEL SENSOR FUSE 0 25 A YL BK BL YL GN WH WH RD RESISTOR 30...

Page 643: ...BEAM YL GN BR WH GY YL GN GY HEADLAMP GY YL WH GY GY YL YL BK BK YL BK BK YL YL GN YL GN YL BL BL FUEL LEVEL GAUGE YL BK RD YL YL BL FUEL LEVEL SENSOR FUSE 0 25 A YL BK BL YL GN WH WH RD RESISTOR 30...

Page 644: ......

Page 645: ...I 1997 Shop Manual VOLUME 3 FORMULA III III LT MACH 1 Z Z LT...

Page 646: ...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 trade...

Page 647: ...rter 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...

Page 648: ...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 649: ...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...

Page 650: ...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...

Page 651: ...e 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 TE...

Page 652: ...e torqued to 4 N m or 35 lbf in This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog Exploded view assists you in identifying parts and related posit...

Page 653: ...ection 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 lubrican...

Page 654: ...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 sam...

Page 655: ...5 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...

Page 656: ...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...

Page 657: ...ent 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...

Page 658: ...ours 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 Conditio...

Page 659: ...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...

Page 660: ...ts 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 Si...

Page 661: ...ENTS 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 HYDRAU...

Page 662: ...t 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 fa...

Page 663: ...d 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 t...

Page 664: ...il 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 i...

Page 665: ...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 adjus...

Page 666: ...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...

Page 667: ...imes 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 app...

Page 668: ...ace 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...

Page 669: ...ngine 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 R...

Page 670: ...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 Che...

Page 671: ...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 672: ...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 09 5...

Page 673: ...ocate or replace 4 Check fuel pump flow a Dried diaphragm Replace 5 Check if carburetor s is are clean a Varnish Clean SYMPTOM HIGH INJECTION OIL CONSUMPTION CONDITION NORMAL USE Test Inspection 1 Che...

Page 674: ...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 needl...

Page 675: ...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...

Page 676: ...just 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 TECHNI...

Page 677: ...strains 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 Rep...

Page 678: ...ion is too weak Replace SYMPTOM IT IS DIFFICULT TO ENGAGE TRANSMISSION IN FORWARD OR REVERSE GEAR CONDITION NORMAL USE Test Inspection 1 Check position of gear shift lever adjustment screw a Improper...

Page 679: ...ck 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 I...

Page 680: ...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...

Page 681: ...ONDITION 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 CONDITIO...

Page 682: ...rive 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...

Page 683: ...uid 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 h...

Page 684: ...en 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...

Page 685: ...ed 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 bus...

Page 686: ...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...

Page 687: ...ctric 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 BROKE...

Page 688: ...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 B...

Page 689: ...ify 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 Repla...

Page 690: ...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 Repl...

Page 691: ...ifications 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 creat...

Page 692: ...HT 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 Connect...

Page 693: ...L 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...

Page 694: ...ht 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 Increas...

Page 695: ...nsion 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...

Page 696: ...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...

Page 697: ...RE 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 IDENTIFICAT...

Page 698: ...99 699 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...

Page 699: ...mpulse 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 su...

Page 700: ...2 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...

Page 701: ...n 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 p...

Page 702: ...assages 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...

Page 703: ...ll 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 3...

Page 704: ...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 forc...

Page 705: ...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...

Page 706: ...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...

Page 707: ...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 T...

Page 708: ...tory 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...

Page 709: ...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 pr...

Page 710: ...OTE 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 t...

Page 711: ...urfaces and screw stud threads of engine spark plug base insulator cylinder head cylinder base crankcase halves joint rotary valve cover oil injection pump mounting flange O ring seal coolant pump hou...

Page 712: ...ry 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 Bloc...

Page 713: ...ngs 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 TES...

Page 714: ...ARY VALVE GEAR RESERVOIR IN CRANKCASE ARE SEALS LEAKING CHECK CRANKSHAFT OUTER SEAL OF PTO AND MAG SIDES PRESSURIZE ROTARY VALVE GEAR RESERVOIR IN CRANKCASE IS RESERVOIR LEAKING UNSEAL PTO CYLINDER AN...

Page 715: ...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...

Page 716: ...d 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 positi...

Page 717: ...ft 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 EN...

Page 718: ...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 o...

Page 719: ...K 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...

Page 720: ...IL 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 f...

Page 721: ...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 fir...

Page 722: ...ler 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 scr...

Page 723: ...per 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 s...

Page 724: ...ion 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 PA...

Page 725: ...ow 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 pu...

Page 726: ...l 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...

Page 727: ...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...

Page 728: ...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 729: ...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...

Page 730: ...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 R...

Page 731: ...ub 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 equivale...

Page 732: ...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 as...

Page 733: ...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 p...

Page 734: ...e 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 Pas...

Page 735: ...ction 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 PART...

Page 736: ...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 737: ...p 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 thrott...

Page 738: ...arburetor 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...

Page 739: ...oat 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...

Page 740: ...uretor 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...

Page 741: ...urning 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...

Page 742: ...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 g...

Page 743: ...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...

Page 744: ...uretors 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 CHOK...

Page 745: ...ift 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...

Page 746: ...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 an...

Page 747: ...g 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 ca...

Page 748: ...Section 03 ENGINE Sub Section 08 CARBURETOR AND FUEL PUMP 03 08 14 FUEL PUMP All Models A06C3SS...

Page 749: ...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...

Page 750: ...ver 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 obst...

Page 751: ...to 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 tio...

Page 752: ...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 0...

Page 753: ...tion 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 CHAI...

Page 754: ...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...

Page 755: ...he accompanying chart FOR REFERENCE ONLY To Check Tension Position a reference rule on drive belt Wooden Stick and Spring Scale Method 1 Mark specified deflection Using spring scale and stick apply sp...

Page 756: ...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 repe...

Page 757: ...s 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...

Page 758: ...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 s...

Page 759: ...y 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 careful...

Page 760: ...ads 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 surf...

Page 761: ...s 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 bush...

Page 762: ...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 fere...

Page 763: ...r 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 sli...

Page 764: ...ds 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 s...

Page 765: ...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 fo...

Page 766: ...Section 04 TRANSMISSION Sub Section 03 DRIVE PULLEY 04 03 10 1 Loosen just enough to permit rotating of calibration screw A16D0HA 1...

Page 767: ...ON 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 413 701...

Page 768: ...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 i...

Page 769: ...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 fro...

Page 770: ...isassembly 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 loo...

Page 771: ...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 tak...

Page 772: ...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 giv...

Page 773: ...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 t...

Page 774: ...ley 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...

Page 775: ...ove 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...

Page 776: ...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 777: ...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 sc...

Page 778: ...ick 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 2...

Page 779: ...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 th...

Page 780: ...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 ho...

Page 781: ...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 SY...

Page 782: ...s 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...

Page 783: ...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 chainca...

Page 784: ...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 Al...

Page 785: ...ere 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...

Page 786: ...RK 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 GENER...

Page 787: ...re 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...

Page 788: ...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 789: ...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...

Page 790: ...so 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...

Page 791: ...ition 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 I...

Page 792: ...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 ro...

Page 793: ...case 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 t...

Page 794: ...GK 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...

Page 795: ...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 Standar...

Page 796: ...ion 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...

Page 797: ...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...

Page 798: ...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 shou...

Page 799: ...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 800: ...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 s...

Page 801: ...lug 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...

Page 802: ...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 rese...

Page 803: ...tput 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...

Page 804: ...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 Trig...

Page 805: ...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 vehic...

Page 806: ...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 807: ...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 wi...

Page 808: ...LY 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...

Page 809: ...2 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 Loc...

Page 810: ...hreaded 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...

Page 811: ...f 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 ba...

Page 812: ...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 f...

Page 813: ...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 tu...

Page 814: ...e 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...

Page 815: ...ws 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 f...

Page 816: ...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 817: ...ing 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...

Page 818: ...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...

Page 819: ...ttempting 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 f...

Page 820: ...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 821: ...ween 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 a...

Page 822: ...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 Mak...

Page 823: ...DJUSTMENT 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 spro...

Page 824: ...ack 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...

Page 825: ...f 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 shoe...

Page 826: ...ise 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...

Page 827: ...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...

Page 828: ...8 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...

Page 829: ...ach 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 TYPIC...

Page 830: ...hart 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 follo...

Page 831: ...ee 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...

Page 832: ...am 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...

Page 833: ...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 a...

Page 834: ...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 Measu...

Page 835: ...Section 07 STEERING FRONT SUSPENSION Sub Section 02 STEERING SYSTEM 07 02 8 F Series A06G08S If so equipped FLAT RATE PARTS...

Page 836: ...n 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...

Page 837: ...k 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 hand...

Page 838: ...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 sw...

Page 839: ...ion 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 A06...

Page 840: ...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...

Page 841: ...nditions 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 REP...

Page 842: ...able 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 Disassembl...

Page 843: ...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 a...

Page 844: ...aning agent in their formula Apply wax on glossy finish only Protect the vehi cle with a cover to prevent dust accumulation dur ing storage CAUTION Do not apply isopropyl alcohol or acetone directly o...

Page 845: ...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...

Page 846: ...urs 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...

Page 847: ...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 848: ...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...

Page 849: ...de retaining rivets 1 Rivets heads ground 2 Rivets to be ground from underneath To remove rivet strike with a punch from rivet head side Make a chamfer from underneath on all 4 corner holes CAUTION Hi...

Page 850: ...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 one thousand one hundr...

Page 851: ...Ignition Timing BTDC mm in 2 18 086 2 18 086 2 11 083 Trigger Coil 190 300 190 300 190 300 Generating Coil Low Speed 49 75 49 75 49 75 High Speed 2 8 4 3 2 8 4 3 2 8 4 3 Lighting Coil 0 20 0 35 0 20 0...

Page 852: ...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...

Page 853: ...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 1...

Page 854: ...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 scr...

Page 855: ...nd 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...

Page 856: ...ELLOW 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...

Page 857: ...nd 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...

Page 858: ...ELLOW 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...

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Page 863: ...I 7 1997 Shop Manual Supplement GRAND TOURING SE...

Page 864: ...f Canada1996 All rights reserved No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc Bombardier Inc 1996 Technical Publications Bombardier Inc...

Page 865: ...belt Drive pulley Driven pulley Pulley distance and alignment Brake Gearbox Drive chain 03 ELECTRICAL SYSTEM Table of contents Wiring diagrams 08 1 Ignition timing Spark plugs 360 watt magneto system...

Page 866: ...1 Theory and operation 05 1 Testing procedure 05 10 06 AIR SUSPENSION SYSTEM Table of contents SC 10 Suspension Touring Drive axle Track Component location 06 1 Theory and operation 06 1 Testing proce...

Page 867: ...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 sto...

Page 868: ...as well as the procedures to test them 1 Magneto system 2 Heating elements switches system 3 Headlamp dimmer switch system 4 DESS 5 Digital performance management system DPM 6 Air suspension Troublesh...

Page 869: ...erial Number Meaning TYPICAL 1 Vehicle serial number The engine also has a serial number Liquid Cooled Engines 1 Engine serial number MODELS MODEL NUMBER GRAND TOURING SE CANADA 1129 GRAND TOURING SE...

Page 870: ...29 0333 00 These wires ensure continuity between the bat tery and loads without the engine running All ac cessories are ON except for the buzzer FLUKE MULTIMETER P N 529 0220 00 A00B4HA A00I09A COM VA...

Page 871: ...TY SYSTEM Always start by checking the fuse DIGITAL PERFORMANCE MANAGEMENT DPM SYSTEM Always start by checking the fuse If the DPM seems to be defective unplug fuse 1A while the engine is running The...

Page 872: ...nly The negative wire black is connected to ground regulator housing and to the frame while the positive wire is RED BLUE Positive Negative 1 Magneto All accessories are fed with direct current NOTE T...

Page 873: ...S code Finally the MPEM controls load supply head lamp taillight dashboard gauges heated compo nents etc If the key is left in the ON position without the engine running the MPEM will not supply curre...

Page 874: ...ng 5 different heating levels from the heating elements heated grips and heated throttle Each time the engine is started the lowest heat ing intensity is selected Press switch at the desired position...

Page 875: ...ght from high to low beam light will return to high beam position automatically after 10 seconds Intensity Control Module This module controls the headlamp circuit ground TESTING PROCEDURE This module...

Page 876: ...verify tether cord switch A continuous beep and DESS pilot lamp blinking rapidly mean that a wrong tether cord is installed Vehicle can not be driven Check that you have both good vehicle and tether c...

Page 877: ...to buzzer connectors Observe po larity the and signs are printed on the buzzer Replace the buzzer if it remains silent Buzzer Supply With the engine running connect a jumper be tween ground and buzze...

Page 878: ...1 housing Switch Wire Continuity Check Check continuity null resistance between switch center terminal and WHITE GRAY wire 6 01A Check continuity null resistance between switch side ring and BLACK GRE...

Page 879: ...1 DPM module 2 Manifold 3 Pump 4 Engine temperature sensor 5 Air temperature sensor THEORY AND OPERATION PURPOSE Calibrate the air fuel mixture in order to optimize the engine output while reducing f...

Page 880: ...05 2 Section 05 DIGITAL PERFORMANCE MANAGEMENT DPM SYSTEM OVERALL SYSTEM OPERATION 1 DPM module 2 Carburetor bowls 3 Distribution gallery upper tube A06I0PS 1 2 3...

Page 881: ...y 3000 RPM the module goes from standby to compensation mode The air temperature must exceed 20 C 4 F and the air pressure must be lower than 1000 mbar Float bowls are now under vacuum and the air fue...

Page 882: ...through the MPEM multi purpose elec tronic module ignition system GRAY GREEN wire The DPM module then comes on by reading the engine temperature through the sensor located on the cylinder head The DP...

Page 883: ...he solenoid duty cycle The warm er the engine the shorter the enrichment mode If the throttle opening exceeds one quarter the enrichment mode is interrupted during the start ing process which allows u...

Page 884: ...o operate 1 The engine must operate at over 3000 RPM Signal received by the GRAY GREEN wire 2 The air temperature must exceed 20 C 4 F 3 The atmospheric pressure must be lower than 1000 mbar The syste...

Page 885: ...e air temperature the leaner the air fuel mixture The lower the atmospheric pressure the leaner the air fuel mixture NOTE The atmospheric pressure decreases as the altitude increases A06I0MS FROM CARB...

Page 886: ...regulator is fed directly by the crank case pressure DPM MANIFOLD OPERATION 1 Manifold The DPM manifold consists of 2 tubes Depend ing on the mode the upper tube distribution gal lery distributes pum...

Page 887: ...cle The duty cycle depends on the en gine temperature The colder the engine the longer the duty cycle Therefore the solenoid will stay open longer thus giving way to pressure 1 Engine temperature sens...

Page 888: ...tion TESTING PROCEDURE Pump Pressure test The pump must create a minimum pressure of 400 50 mm of water Connect a U tube to pump outlet Start engine and note water height 1 U tube 1 Pump outlet DPM Mo...

Page 889: ...ay open Repeat test several times At reassembly ensure that solenoid seals are in place 1 Plastic seal 2 O rings Dynamic test When checking the enrichment solenoid discon nect engine temperature senso...

Page 890: ...res sor and the release valve are controlled by a three way switch 1 Activates the release valve 2 Activates the compressor This shock absorber prevents the suspension from bouncing just like a conven...

Page 891: ...ystem pressure Compare the reading to the minimum value in the following table Disconnect ohmmeter Activate compressor dur ing 60 seconds Remove the ignition key Connect an ohmmeter to pressure sensor...

Page 892: ...9ES Spark Plug Gap mm in 0 45 018 Ignition Timing BTDC mm in 2 18 086 Trigger Coil 190 300 Generating Coil Low Speed N A High Speed N A Lighting Coil 0 20 0 35 High Tension Coil Primary 0 2 0 5 Second...

Page 893: ...elt 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 Ty...

Page 894: ...emperature 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...

Page 895: ...0 COMPONENT LOCATION 1 Starter wires 2 Magneto wires 3 MPEM ignition system and DESS 4 DPM module 1 MPEM 3 06 housing 2 MPEM 3 02 housing 3 DPM 3 07 housing 1 DPM enrichment switch HIGH TENSION COIL A...

Page 896: ...08 2 Section 08 WIRING DIAGRAM GAUGES A06H2YA...

Page 897: ...Engine speed signal from ADC to DPM GY VI Low beam YL Alternating current supply AC YL Direct current supply rear light and heated grip YL BR Compressor YL GN Release valve BK Engine ground frame DC b...

Page 898: ...OCATION 1 Frame and hood junction 2 Magneto 3 Carburetors 4 Rear of intake silencer 5 Near driven pulley 6 Under handlebar 7 Under hood 8 Near fuel tank 9 Rear of seat XX XX A00I04C 1 02D A06H33A 1 7...

Page 899: ...c module Meter Electric motor Low level sensor Buzzer Ignition coil Normally close switch Male terminal on instrument Engine ground Spark plug Meter movement Bulb Pilot light Analog sensor Solenoid va...

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Page 907: ...TING 4 03 ENGINE 4 GENERAL 4 LUBRICATION 4 LIQUID COOLING SYSTEM 5 04 TRANSMISSION 6 DRIVE PULLEY 6 DRIVEN PULLEY 6 BRAKE 6 05 ELECTRICAL 7 06 REAR SUSPENSION 7 07 STEERING FRONT SUSPENSION 7 STEERING...

Page 908: ...se of doubt 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 specificat...

Page 909: ...rication and cooling system Refer to section ENGINE from Shop Manual LUBRICATION Oil injection pump has been removed Premix fuel oil system is now being used FUEL RESERVOIR CAP Check rotary valve oil...

Page 910: ...SHOP MANUAL SUPPLEMENT MX Zx 440 LC PAGE 5 OF 18 LIQUID COOLING SYSTEM A15C2IS 1 2 PARTS...

Page 911: ...ighter TRA drive pulley is used Disassembly assembly and adjustment proce dures are identical to MX Z 440 LC NEW DESIGNED LIGHTER TRA DRIVE PULLEY DRIVEN PULLEY 1 position driven pulley mounted on a s...

Page 912: ...rical system is a Nippondenso CDI type with 12 V 220 W magneto generator Ignition switch has been removed A unique parallel circuit activates both heating throttle lever and handle grip 06 REAR SUSPEN...

Page 913: ...STEERING ADJUSTMENT SKIS A15C2JS 10 N m 7 lbf ft 52 N m 38 lbf ft Loctite 271 26 15 N m 11 lbf ft 52 N m 38 lbf ft 18 N m 13 lbf ft 52 N m 38 lbf ft 18 N m 13 lbf ft Loctite 271 48 N m 35 lbf ft Loct...

Page 914: ...amber angle to 2 0 5 Negative camber Tighten lock nuts and reinstall both upper con trol arms into ski leg housings 1 Lock nut of lower control arm 2 Lock nut of upper control arm 3 Ski leg housing 4...

Page 915: ...SHOP MANUAL SUPPLEMENT MX Zx 440 LC PAGE 10 OF 18 FRONT SUSPENSION AND SKIS TYPICAL LEFT SIDE SHOWN A15F3ES 18 N m 13 lbf ft 29 N m 21 lbf ft 24 N m 18 lbf ft 24 N m 18 lbf ft PARTS...

Page 916: ...SE PRESSURE FROM RESERVOIR Damper Disassembly Remove seal carrier assembly from damper body Slide out the damper rod assembly Refer to Shop Manual or Racing Handbook to change damper valving 1 Seal ca...

Page 917: ...shop cloth to catch excess oil 1 Adjustment knob set to position 4 2 Compressed air 3 Floating piston Reservoir Assembly Reinstall oil hose on both reservoir and damper Torque bolts to 30 N m 22 lbf...

Page 918: ...2 Damper body 3 Oil level Install damper rod assembly into the damper body Lightly oil damper piston seal ring with shock oil to ease installation NOTE Some shock oil may overflow when in stalling dam...

Page 919: ...m body while installing NOTE When reinstalling seal carrier oil must overflow This overflow indicates that damper is full of oil Reservoir Final Assembly NOTE If all previous procedures have been prop...

Page 920: ...mote reservoir 1 Remote reservoir 2 Adjusting knob 1 softer 4 stiffer Preload Adjustment Lift snowmobile to remove tension from shock absorber Perform preload adjustment on HPG shock ab sorbers by set...

Page 921: ...LEMENT MX Zx 440 LC PAGE 16 OF 18 08 BODY FRAME 0 Refer to 1997 ski doo Shop Manual volume 2 Newly designed waterproof seat WATERPROOF SEAT 09 TECHNICAL DATA 0 Refer to 1997 ski doo Shop Manual volume...

Page 922: ...d Type NGK BR9ES Spark Plug Gap mm in 0 45 018 Ignition Timing BTDC mm in 1 48 058 Trigger Coil 190 300 Generating Coil 10 17 Lighting Coil 0 2 0 35 High Tension Coil Primary 0 3 0 7 Secondary k 8 16...

Page 923: ...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 307 121 Adjustment Deflection mm in 30 35 1 3 16 1 3 8 Force kg lbf 7 3 16 Suspen...

Page 924: ...MX Zx 440 LC ANNEX 1...

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