AD Boivin SH-MAN-2007 Shop Manual Download

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SNOW-HAWK

800 HO

2007

MANUEL DE RÉPARATION

Incluant :

- Conseils de sécurité
- Fonctionnement du véhicule
- Entretien du véhicule
- Manuel de pièces

SHOP MANUAL

Include:

- Safety
- Vehicle information
- Maintenance information
- Parts catalog

PART #: SH-MAN-2007

Summary of Contents for SH-MAN-2007

Page 1: ...7 MANUEL DE R PARATION Incluant Conseils de s curit Fonctionnement du v hicule Entretien du v hicule Manuel de pi ces SHOP MANUAL Include Safety Vehicle information Maintenance information Parts catal...

Page 2: ...AD Boivin Design 700 Jean Marchand Street L vis Qu bec G6V 9G6 Tel 418 838 3783 Fax 418 838 3957 www adboivin com Warranty Policies SNOW HAWK 800HO MY2007 June 6 2007...

Page 3: ...IN WARRANTY COVERAGE 4 2 5 WHAT AD BOIVIN WILL DO 4 2 6 EXCLUSIONS 5 2 7 LIMITATIONS OF LIABILITY 5 2 8 TRANSFER 6 2 9 CONSUMER ASSISTANCE 6 3 WARRANTY INFORMATION 7 3 1 WEAR ITEMS 7 3 2 LABOUR TIME 7...

Page 4: ...ance outlined in the Snow Hawk Manual s must be timely performed in order to maintain warranty coverage AD Boivin reserves the right to make warranty coverage contingent upon proof of proper maintenan...

Page 5: ...of its products and also that of its consumers and the general public Routine maintenance outlined in the Snow Hawk Manual must be timely performed in order to maintain the warranty coverage AD Boivin...

Page 6: ...es or damages of any kind including without limitation towing storage telephone rental taxi inconvenience insurance coverage loan payments loss time loss income and Damage resulting from studs install...

Page 7: ...following way a The former owner contacts AD Boivin at the phone number below or an authorized Snow Hawk dealer gives the coordinates of the new owner or b AD Boivin or an authorized Snow Hawk dealer...

Page 8: ...submitted to AD Boivin via form AD CLAIM available in appendix 1 You can also request an electronic copy ericferland adboivin com and return it to us by email or fax While reviewing your claim AD Boi...

Page 9: ...to AD Boivin within 7 days after receipt of shipment AD Boivin will not cover these claims under warranty but will make sure your request is properly processed by the carrier Please call AD Boivin Ask...

Page 10: ...r a minimum of 90 days from the claim credit date Any or all parts can be requested for further analysis by the manufacturer within this period Failure to provide these parts upon request will automat...

Page 11: ...the defect In this case you should keep the rest of the track properly tagged for 90 days since we might need to examine it ii If the track is replaced for shrinkage stretching and or excessive vibra...

Page 12: ...AD BOIVIN WARRANTY POLICIES __________________________________________________________ June 2007 AD Boivin Design Inc Page 11 of 12 APPENDIX 1 Warranty Claim Sheet...

Page 13: ...ent Signature Year Model P N Qty Dealer Unit Cost Total Parts Subtotal Time Flat rate Total Labour Subtotal Notes Description VIN DateDamaged SnowHawk WarrantyClaimSheet General Information Total Clai...

Page 14: ...e man uvre pouvant tre dangereuse Ne pas permettre l utilisation du v hicule un individu qui n a pas pr alablement pris connaissance des pr cautions prendre N utiliser le v hicule que sur la neige Ne...

Page 15: ...rugs Avoid any hazardous maneuvers Do not let anyone else drive your vehicle unless they are aware of the precautions to take Do not operate the vehicle on water dirt or any other terrain conditions e...

Page 16: ...libration of a vehicle like atmospheric pressure and humidity Ft m Main 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 Pilot 0 305 610 914 1219 1524 1829 2134 2438 2743 3048 o C 30 500 500 490 4...

Page 17: ...WIRE CABLE AND HOSE ROUTING 16 1 CHAPTER 16 WIRE CABLE AND HOSE ROUTING...

Page 18: ...S AND MPEM When changing the ignition coil or either of the ignition wires it is important that the wires are re installed in exactly the same position o The two ignition wires must be installed as sh...

Page 19: ...that the bolt AND locknut securing the ground connection s ring lug to the chassis is well tightened in in full contact with the chassis A bad ground connection can cause other component failures The...

Page 20: ...The grey sheathed wire then travels upward between the MAG side intake socket and the MAG side chassis as shown at right The 2 circuit housing from the CPS BL and WT YL wires is connected to the main...

Page 21: ...two 1 circuit connectors YL and BK WT wires This cable is routed under the MAG side intake socket around the vertical coolant tube and then under the PTO side intake socket and then directly to the t...

Page 22: ...wrap for compactness as shown at right From here the tail lamp wire WT BK and RD wires must pass under the engine impulse hose and along the MAG side chassis towards the rear as shown at right The en...

Page 23: ...switch BK and BK YL wires connects to the 2 circuit connector on the main wiring harness BK and BK YL wires 4 Emergency stop switch The 2 circuit connector from the emergency stop switch BK and BK YL...

Page 24: ...eath the hood is attached to the hood in three places 1 On the PTO side installation screw 2 On the PTO vent grill 3 On a cable tie block fixed to the rear grill CABLE ROUTING Throttle Cable 1 The upp...

Page 25: ...cally upwards under the main wiring harness and is then attached to the small oil reservoir with a nylon tie wrap as shown at right The cable then passes completely under the steering plate and up to...

Page 26: ...that all hoses are well attached at both ends that they are in good physical condition that they are well away from any moving part or heat source If ANY surface cracks are present replace the hose i...

Page 27: ...te and is attached with one nylon tie wrap at the corner o The second tie wrap is located in a hole just above the triangular cut out in the PTO side of the chassis o The hose is then routed out throu...

Page 28: ...the rear of the vehicle and is then connected via a reducer to the 1 4 in clear fuel line that goes into the fuel tank The clear line must pass between the fuel tank and the airbox ENSURE that the fu...

Page 29: ...and the engine Fuel Tank The fuel tank overflow line is routed from the gas cap itself under the handlebar and through the top plate of the steering column The hose is then tied to the rest of the ha...

Page 30: ...wo carburetors under the PTO most coolant hose through the triangular PTO chassis cut out and is then secured to the chassis with a nylon tie wrap near the brake system Ensure that the hose does not b...

Page 31: ...DIMENSIONS AND TOLERANCES 15 1 CHAPTER 15 DIMENSIONS AND TOLERANCES...

Page 32: ...imit mm 0 2 in 0 0079 Piston Cylinder wall clearance new mm 0 125 0 022 in 0 049 0 0009 wear limit mm 0 2 in 0 0079 Connecting rod big edn axial play new mm 0 310 to 0 677 in 0 0122 to 0 0267 wear lim...

Page 33: ...125 92 Axial fan nut N A Primary clutch bolt 90 66 Secondary clutch bolt 31 7 23 Taper Lock installation setscrews 14 10 4 Spark plugs 27 20 Handlebar mounting bolts 36 5 27 Fork leg bolts in triple...

Page 34: ...erall height mm 1233 in 48 Dry weight kg 170 lb 375 Track width mm 308 in 12 Track length ST LT mm 3074 3495 in 121 136 Track adjustment Deflection mm 40 50 in 1 5 2 Force kg freely hanging lbf freely...

Page 35: ...ELECTRICAL SYSTEM 14 1 CHAPTER 14 ELECTRICAL SYSTEM...

Page 36: ...ELECTRICAL SYSTEM 14 2 CDI SYSTEM 11 12 13 14 15 16 17 18 19 21 22 23 20 23 27 N m 20 lbf ft 2 75 kg m 240 lbf in 243 648 Sikaflex Black 221 P N 293530011 243 22 N m 16 lbf ft 2 25 kg m 192 lbf in 4...

Page 37: ...Washer 8mm 10 207 182 044 1 Hex Head Screw M8x20 11 512 059 552 2 BR9ECS Spark Plug 12 2 Spark plug cap 13 512 059 696 1 Spark plug wire 375mm with cap 14 512 059 695 1 Spark plug wire 300mm with cap...

Page 38: ...ELECTRICAL SYSTEM 14 4 WIRING DIAGRAM...

Page 39: ...in P N 515175665 278000632 10 Female Terminal used in Deutsch connectors 515175670 1 Female Housing 2 circuit MPEM Deutsch 515175673 1 Female Housing 6 circuit MPEM Deutsch 409209900 1 Female Housing...

Page 40: ...wheel To gain access to magneto assembly remove the following parts o All body panels o rewind starter o starting pulley no 8 To remove magneto flywheel retaining nut on the end of the crankshaft not...

Page 41: ...g o Remove retaining screws no 6 o Remove trigger coil and carefully pull wires o Install new trigger coil and other parts removed ASSEMBLY 2 Stator o Position stator No 2 at right so that its wire pr...

Page 42: ...ngine break in retard timing for the Snow Hawk 600HO is as follows the first hour of operation TYPICAL 1 TDC gauge on MAG side 2 MAG side piston at TDC NOTICE Between 3000 and 4000 RPM the spark advan...

Page 43: ...y Snow Hawk you can use the upper threaded hole in the crank case as a mounting position indicated by the white arrow o With the TDC gauge indicating specified timing shown at right scribe a mark on t...

Page 44: ...he timing is retarded or advanced Tolerance is 0 5 Changing Timing As a Snow Hawk dealer there is no immediate way to alter the MPEM s internal timing settings other than to send the unit back to us a...

Page 45: ...proximately 20 C 68 F room temperature otherwise the readings could be distorted Analysis of Readings Voltage Readings When testing the different magneto components it is important to take into consid...

Page 46: ...in 2 ELECTRICAL CONNECTOR TESTING Make sure that none of the connectors are disconnected 3 ENGINE CUT OFF SWITCH TESTING Disconnect connector housings and check the resistance as indicated in IGNITION...

Page 47: ...nnect multimeter probes to appropriate wires and measure the resistance Refer to the corresponding IGNITION AND ELECTRICAL SYSTEM TESTING table in this subsection o Compare readings with those appeari...

Page 48: ...t this operation 3 times o Compare these readings with those appearing in the IGNITION table 6 MPEM VOLTAGE TESTING o Disconnect the housing between the module and the high voltage coil o Connect the...

Page 49: ...in the resistance column of the IGNITION table Set the multimeter as indicated LIGHTING GENERATOR COIL VOLTAGE TESTING o Disconnect the housing from the engine YELLOW and GREEN wires o Connect the mu...

Page 50: ...ng resistance spark plug wires removed Male terminal to male terminal 9 6 k to 14 4 k With spark plug wires removed from high voltage coil Secondary winding voltage BK and engine 1 5 2 5 Vdc Do not pr...

Page 51: ...CHASSIS STEERING SYSTEM AND BODY 13 1 CHAPTER 13 CHASSIS STEERING AND BODY...

Page 52: ...CHASSIS STEERING SYSTEM AND BODY 13 2 CHASSIS AND STEERING SYSTEM...

Page 53: ...CHASSIS STEERING SYSTEM AND BODY 13 3 CHASSIS AND STEERING SYSTEM...

Page 54: ...CHASSIS STEERING SYSTEM AND BODY 13 4 CHASSIS AND STEERING SYSTEM...

Page 55: ...CHASSIS STEERING SYSTEM AND BODY 13 5 CHASSIS AND STEERING SYSTEM...

Page 56: ...CHASSIS STEERING SYSTEM AND BODY 13 6 CHASSIS AND STEERING SYSTEM 66 67 61 62 63 65 64 4x 60 57 59 58 94 4x 92 4x 91 4x 90 4x 92 4x 93 4x 95 4x 46...

Page 57: ...38 1 Front chassis spacer 20 SH 020 2 Long chassis spacer 21 SH 021 1 Short chassis spacer 22 SH 120 1 Carburator support 23 SH11 SAG 1 Left Foot peg grip PTO 24 SH11 SAD 1 Right Foot peg grip MAG 25...

Page 58: ...5266HAWK 1 Handle bar 69 SH 016 4 Handle bar clamp 70 SH 054 4 Rubber steering damper 71 SH 049 4 Plastic half steering bushing 72 SH 089 1 Lower handle bar stiffener 73 SH 008 1 Upper handle bar stif...

Page 59: ...pop rivet 3 16 long 111 053 8 40 8 Hexagon head cap screw M8 x 1 25 x 40MM 112 21653P 3 Socket head cap screw M8 x 1 25 x 30MM 113 057 8 30 8 Hexagon head cap screw M8 x 1 25 x 30MM 114 21110P 8 Lock...

Page 60: ...CHASSIS STEERING SYSTEM AND BODY 13 10 BODY HOOD...

Page 61: ...CHASSIS STEERING SYSTEM AND BODY 13 11 BODY HOOD...

Page 62: ...plate 12 S6 100P 21 A 3 16 Flat washer 13 400 288 4 A 8 32 hex elastic nut 14 400 579A 2 A 8 32 x 1 3 4 phillips 15 402 637 2 A 8 32 x 2 1 2 phillips 16 SH 257 2 Grill front cab 17 4204 1 Rubber butt...

Page 63: ...CHASSIS STEERING SYSTEM AND BODY 13 13 BODY BELLY PAN...

Page 64: ...CHASSIS STEERING SYSTEM AND BODY 13 14 BODY BELLY PAN 23 24...

Page 65: ...14 SH 610 1 Reflector MAG side 15 SH 611 1 Reflector PTO side 16 SH 170 1 Clutch protecteur 17 SH 121 1 Heat sheild 18 SH 140 1 Heat sheild front PTO 19 SH 137 1 Heat sheild front MAG 20 SH 807 D03 1...

Page 66: ...CHASSIS STEERING SYSTEM AND BODY 13 16 BODY REAR MODULE 1 6 4 3 10 13 2 3 10 6 4 1 5 7 7 11 12 14 MAG SIDE 10 8 8 10 8 10 15 PTO SIDE...

Page 67: ...5 336772 1 Rear lamp 6 284118 4 Rubber hook bungee 7 169 113 2 Push nut 8 333 105P 4 A 1 4 hex elastic nut 9 S6 100P 4 A 3 16 Flat washer 10 341 103P 4 Washer 11 SH 612 1 Reflector MAG side 12 SH 613...

Page 68: ...fuel pump 170 103 2 T screw ADB 101 FRONT 1 Front tunnel cover black ADB 101 REAR 1 Rear tunnel cover black 513032979 2 Spring clamp light green Pump 2 adaptor 513033022 1 1 Rubber hose Pump 2 adapto...

Page 69: ...REAR SUSPENSION SHOCKS AND TRACK 12 1 CHAPTER 12 REAR SUSPENSION SHOCK AND TRACK...

Page 70: ...REAR SUSPENSION SHOCKS AND TRACK 12 2 REAR SUSPENSION...

Page 71: ...REAR SUSPENSION SHOCKS AND TRACK 12 3 REAR SHOCK 53 67 68 69 70...

Page 72: ...REAR SUSPENSION SHOCKS AND TRACK 12 4 MIDDLE SHOCK 54 69 67 70...

Page 73: ...her M5 19 570 063 000 2 Rubber stopper 20 20200P 16 Hexagon head cap screw M8 x 1 25 x 25MM 21 22205P 2 Button head socket cap screw M6 x 1 0 x 25MM 22 21085P 4 Washer M6 23 517 078 700 9 Limiter stra...

Page 74: ...eel assy plastic 61 SH 420 1 Upper shaft 62 SH 426 1 Spacer 63 SH 427 2 Spacer 64 SH44 SA 1 Lower shock axle assy 65 SH43 SAD 1 Bushing housing Right side 66 013 00 3 Spring stopper 67 503 188 930 2 S...

Page 75: ...REAR SUSPENSION SHOCKS AND TRACK 12 7 SHOCK EXPLODED VIEW 11 10 11 9 2 12 13 7 6 8 1 5 3 4...

Page 76: ...03 1 Floating piston 4 11301 03006 1 O ring 5 11301 03805 1 Piston bushing 6 11302 09919 1 Compressed air valve 7 11201 90604 1 Screw 8 11301 03021 1 O ring 9 11201 92151 1 Label 10 11301 91030 1 Coll...

Page 77: ...REAR SUSPENSION SHOCKS AND TRACK 12 9 REAR PAD...

Page 78: ...tic flange nut M6 8 160 167P 3 Hexagon nut with free spinning washer M6 9 SH 822B L 1 Rear pad bended plate left 10 SH 822B R 1 Rear pad bended plate right 11 23193P 16 Button screw M5 X 16 12 23161P...

Page 79: ...hen the adjustment is finished tighten the jam nut 1 once more 1 Jam nut 2 Spring adjustment ring 3 Special tool Rear spring preload The adjustment of the rear spring makes it possible to stiffen the...

Page 80: ...ed Remove the shock absorber spring by unscrewing the pre load collar and jam nut then by removing the spring retainer hat To carry out these operations use tool P N 861 7439 00 Install the shock abso...

Page 81: ...t the floating piston from the body of the shock absorber Cover the opening of the shock absorber with a cloth to catch the floating piston Make sure there is enough space in the cloth for the piston...

Page 82: ...there is a leak in the ring seal it will be necessary to measure the camber of the rod which must not exceed 0 025 mm 001 in Once the new shims or the replacement shims have been selected reassemble e...

Page 83: ...r of grooves varies between 0 2 4 and 6 according to the rapidity of the rebound These grooves offer variations in the damping in relation to the shims COMPRESSION When adjusting the shock absorber to...

Page 84: ...ibrating the shock absorber so that there is not enough damping means the damping will either be insufficient or badly controlled In such a case the shock absorber moves up and down almost without any...

Page 85: ...g seal use a ring seal guide P N 529 0265 00 to guide the ring seal over the shock absorber rod Lubricate the guide before using it CAUTION The ring seal will be damaged if the guide is not used Reass...

Page 86: ...through the hole in the needle valve will push the piston up WARNING Be very careful when using compressed air Cover the opening in the shock absorber with a cloth to reduce any risk of injury WARNIN...

Page 87: ...n It might be necessary to jiggle the rod slightly to make it easier to place the piston in the bore of the body of the shock absorber Gently insert the piston into the body of the shock absorber A sl...

Page 88: ...itrogen This pressure will re establish the shock absorber pressure at its optimum level CAUTION Do not exceed the recommended pressure WARNING Always wear safety glasses when working with high pressu...

Page 89: ...ick as one thick shim but offer less resistance than the latter Refer to the table SHIM EQUIVALENCE FOR THE SAME DIAMETER as illustrated in this section o When stacking shims for rebound always use sh...

Page 90: ...about 40 mm 1 just below the lower pivot of the swing arm which is the midpoint of the rail when the rear of the vehicle is supported and the track is hanging freely REAR PAD The rear pad is essential...

Page 91: ...ched CAUTION If the Snow Hawk s rear pad is not curved and is not attached in deep snow conditions it could be dammaged as a result CAUTION If the engine overheat indicator lights up even while operat...

Page 92: ...RACK 12 24 EXTENSION PLATE ADJUSTMENT There are two possible positions for the extension plate The tilted position allow the snowhawk to improve its speed and its handling The right position gives bet...

Page 93: ...FRONT FORK AND SKI 11 1 CHAPTER 11 FRONT FORK AND TWIN AXIS SKI...

Page 94: ...FRONT FORK AND SKI 11 2 FORK LEG 1 1 3 5 2 2 4 3 6 7 8 9...

Page 95: ...Inner tube 3 849 340 059 1 Fork seal and bushing kit 4 849 311 568 1 Top cap assembly 5 849 350 103 1 Compression valve assembly 6 949 409 761 1 Outer tube 7 949 603 733 1 Lower spring seat 8 949 313...

Page 96: ...FRONT FORK AND SKI 11 4 FORK ASSEMBLY 7 8 7 2 6 19 7 8 6 7 1 1 16 17 5 16 17 13 14 15 12 12 4 9 18 18 9 3 11 20 20 10 19 2 21 10 8 8...

Page 97: ...2F 8 Flanged locknut M6 9 SH 051 2 Steel bushing 10 21623P 4 Socket head bolt M6 x 20 mm 11 23162P 2 Locknut M6 12 20171P 2 Hexagone head bolt M6 x 75 mm 13 SH 060 1 End shaft bushing 14 342 121P 1 1...

Page 98: ...FRONT FORK AND SKI 11 6 ENSEMBLE DE SKI 12 12 11 11 8 7 8 4 10 9 3 12 9 13 13 13 13 2 1 6 6 5 5 15 15 14 14 16 16...

Page 99: ...0o 7 SH 145 1 Rubber positionner 8 P05000050090A 2 Polyurethane bushing RED 9 P05000050095A 2 Polyurethane bushing GOLD 10 20279P 1 Hexagone head bolt M12 x 80 mm 11 341 109P 2 Washer 12 23167F 3 Flan...

Page 100: ...a mild detergent or an automobile cleaning product to dislodge any dirt CAUTION An inadequate dismantling of the fork leg top cap may damage the rebound adjustment needle resulting in a malfunction o...

Page 101: ...upside down the push rod the needle and the return spring will fall from the piston rod It is possible to collect them by turning the strut over slowly and keeping a finger near the tip of the piston...

Page 102: ...one end provided with the maintenance tool kit into the cartridge head NOTICE Before unscrewing the cartridge make sure the special tool T is well fitted into the socket in the cartridge head o Empty...

Page 103: ...the dust seal o Use a flat screwdriver to remove the dust seal o Remove the stop ring o With a few sharp blows pull the outer tube P out to separate it from the inner tube A o The oil seal T the wash...

Page 104: ...of the strut with a band of adhesive tape so that the seals will not be damaged by the sharp edge o Make sure the bushings S R are well inserted in their respective positions by using the special tool...

Page 105: ...l W to insert the washer Q and then the oil seal T o Re install the stop ring O o Re install the dust seal M o Using a 14 mm allen key and the special tool T re install the cartridge L the compression...

Page 106: ...l position fully compressed and fill it with fork fluid up to 50 mm 2 in from the top of the outer tube Recommended fluid Cartridge fork fluid S A E 15W o Move the piston rod in and out in a series of...

Page 107: ...mmended level CAUTION The fluid level can be modified but must remain between 85 mm and 120 mm o Insert the needle return spring the needle and the push rod o Install the spring F inside the strut P N...

Page 108: ...ween 1 2 mm 0 040 0 080 in o Using your hand push the top part of the spring down to provide enough space to reach the lock nut C with the open end of a 17 mm wrench o Use a torque wrench and the spec...

Page 109: ...the speed of compression from a range of 26 positions depending on the conditions of the terrain and the purpose for which the vehicle is used Stiffer Slower Softer Faster o Rebound Using a screwdriv...

Page 110: ...mmended for deep powder snow condition o ALWAYS adjust the two locknuts together Loosening the nuts o Loosening the nuts No 1 above right will allow the polyurethane bushings to extend more and make t...

Page 111: ...nti darting mechanism IF you use your vehicle off trail or in powder snow conditions you can use the Snow tracker device or you can remove it we encourage to use whatever works best for you In certain...

Page 112: ...HYDRAULIC BRAKE SYSTEM 10 1 CHAPTER 10 HYDRAULIC BRAKE SYSTEM...

Page 113: ...DRAULIC BRAKE SYSTEM 10 2 HYDRAULIC BRAKE SYSTEM 12 11 11 7 6 7 6 2 14 1 3 15 5x 4 5 10 5x 9 16 16 8 8 13 14 N m 125 lbf in Follow the suggested sequence Chapter 9 25 N m 220 lbf in 14 N m 125 lbf in...

Page 114: ...ead cap screw M8 x 1 25 x 45MM 8 23164 2 Nylon nut M8 x 1 25 9 1215X30 1 Taper lock 10 22204P 5 Botton head cap screw M6 x 1 0 x 20MM 11 06 2196 13 2 Copper washer 12 06 2228 42 1 Banjo bolt 13 110 46...

Page 115: ...ove the bolt from inside the tunnel with a socket and ratchet Loosen the other upper bolt holding the caliper tight to the chassis as well then swing the caliper up and clear of the disc Re tighten th...

Page 116: ...emove the clip at the end of the pin shown in the picture on page 10 3 of this chapter o Using a steel punch and a hammer push the pin completely out of the brake caliper casting Be sure to push the p...

Page 117: ...sufficient amount of brake fluid in the reservoir at all times to avoid the creation of air bubbles in the system If air should become trapped in the system follow the procedure outlined below Pump t...

Page 118: ...SECONDARY TRANSMISSION SYSTEM 9 1 CHAPTER 9 SECONDARY TRANSMISSION SYSTEM...

Page 119: ...N SYSTEM 9 2 SECONDARY TRANSMISSION SYSTEM 12 10 3 11 14 14 4 5 6 2 13 7 8 1 11 14 14 18 14 N m 125 lbf in Follow the suggested sequence 14 N m 125 lbf in Follow the suggested sequence 19 19 6 6 6 5 4...

Page 120: ...441 1 1 Split spring lock washer 9 30632P 2 Hexagon head cap screw M10 x 1 5 x 65MM 10 90974 A116 1 Sliding T nut 11 1215X30 2 Taper lock 12 1360PTH8M 60 1 60MM Panther belt 13 SH 202 6 Flange 14 149...

Page 121: ...SECONDARY TRANSMISSION SYSTEM 9 4 TORQUE LIMITER SYSTEM 7 6x 3 4 6 8 2x 5 1 5 8 2x 6 4 2 6 N m 55 lbs in 10 N m 89 lbs in 10 N m 89 lbs in 9 9...

Page 122: ...threaded disk 4 TL 004 2 Outside pressure plate 5 TL 005 2 Inside pressure plate 6 6525K1 O D 5 2 Wearing pad 7 22320AI 6 Socket set screw M8 x 1 25 x 20MM 8 22097P 4 Flat head socket cap screw M6 x 1...

Page 123: ...emove the two setscrews that hold the taper lock and the 28 tooth upper drive sprocket in place Position 1 Using a punch hit the taper lock 2 3 times in the shaded zone shown at right Position 5 to lo...

Page 124: ...Loctite 243 must be used for both installation setscrews to prevent them from loosening under use Failure to do so could result in personal injury Hand tighten the tensioner sprocket bolt Ref No 9 in...

Page 125: ...ive dry surface cracking of the rubber in the cog belt If excessive surface cracks are present replace belt o Check that the secondary transmission system is dry and free of dirt grime or debris If ne...

Page 126: ...ponents should be clean before reassembly The parts can be cleaned using brake cleaner INSPECTION NOTICE Because so much dirt and dust accumulates inside the torque limiter it should be periodically c...

Page 127: ...INSTALLATION Install the torque limiter as described in the previous section on installation of the secondary drive cog belt o Lift up and immobilize the rear of the vehicle and place it on a mechani...

Page 128: ...PRIMARY TRANSMISSION SYSTEM 8 1 CHAPTER 8 PRIMARY TRANSMISSION SYSTEM...

Page 129: ...PRIMARY TRANSMISSION SYSTEM 8 2 PRIMARY TRANSMISSION SYSTEM PRIMARY CLUTCH 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 16 15 18 19 20 21 21 23 24 28 25 26 27 26 29 22 30 31 32 Color 2 Color 1 33 33...

Page 130: ...1 Ramp 14 250400009 1 Rolled pin 10 x 32 15 417222362 2 Slider shoe 16 732401030 2 O ring 17 417005700 1 Spring 18 417 222 213 1 Governor cup 19 417005500 1 Calibration screw 20 417 005 600 1 Washer...

Page 131: ...PRIMARY TRANSMISSION SYSTEM 8 4 PRIMARY TRANSMISSION SYSTEM SECONDARY CLUTCH 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 13 20 21 22 28 23 24 25 26 26 27...

Page 132: ...ont cam slider shoe 13 210 251 180 2 Hexagon forming screw M5x11 14 417 126 698 1 Cover 15 417 126 909 1 Sliding flange ass y 16 504 099 600 1 Stopper washer 17 504 112 300 1 Shim 18 417 126 807 1 Fix...

Page 133: ...n Do not only refer to the spring color code NOTICE TRA drive pulley stands for Total Range Adjustable drive pulley WARNING Any drive pulley repairs must be performed by an authorized Snow Hawk dealer...

Page 134: ...pulley shaft then tighten DISASSEMBLY Screw and Ring Gear CAUTION Retaining screws must be heated before disassembly Do not exceed 150 C 300 F 1 2 Fixed and Sliding Half CAUTION Do not tap on governor...

Page 135: ...efully lift governor cup until slider shoes come at their highest position into guides o Hold a slider shoe set then carefully lift its housing and remove slider shoes Proceed the same way for other h...

Page 136: ...nds support guide These support guides will prevent bushing damages o Remove 3 Allen screws retaining spring cover then unscrew compressor 1 Support guide CLEANING 1 2 Fixed and Sliding Half Clean pul...

Page 137: ...nkshaft and pulley tapered surfaces with coarse or medium steel wool and or sand paper no 600 CAUTION Do not use any other type of abrasive Reclean mounting surfaces with paper towel and cleaning solv...

Page 138: ...r replace as required 15 16 O Ring and Slider Shoe Check if O rings are cracked cut or crushed Replace as required Check slider shoes for wear Replace if groove is not apparent on top 1 18 Fixed Half...

Page 139: ...CAUTION Bushing must be bonded with retaining compound o Apply retaining compound Loctite 609 outside of bushing then press it down to counterbore from outside end CAUTION Insert bushing from sliding...

Page 140: ...ut to 10 N m 89 lbf in 28 Pin Always use the same type of pin as originally installed when servicing Different types have different weights for calibration purpose Refer to TECHNICAL DATA 1 Washer 12...

Page 141: ...ter pins are on the shown side Besides install cotter pin head on the top when lever is sat at bottom of sliding half Bend cotter pin ends to sit perfectly against lever WARNING Whenever replacing cen...

Page 142: ...ch cone angle with crankshaft o Lift sliding half against spring cover and align spring cover arrow with sliding half mark o Tighten screws to proper torque as mentioned in exploded view 1 Align 2 15...

Page 143: ...has no mark align governor cup mark with segment no 1 of inner half Segments are identified on engine side o Carefully slide governor cup into sliding half Align mark of governor cup with mark of fix...

Page 144: ...pring washer and or screw with jobber ones Always use Snow hawk genuine parts for this particular case o Use holder See removal procedure o Torque screws to 80 to 100 N m 59 to 74 lbf ft o Install dri...

Page 145: ...ulley allows setting maximum engine RPM in the vehicle to maintain maximum power Calibration screws should be adjusted so that actual maximum engine RPM in vehicle matches with the maximum horsepower...

Page 146: ...hanged to position 5 So maximum engine RPM is increased by about 400 RPM To adjust Just loosen locking nut enough to pull calibration screw partially out and adjust to desired position Do not complete...

Page 147: ...BRAKE DISC REMOVAL DISASSEMBLY o Use spring compressor P N 529 035 524 o Remove half key no 1 and washer no 2 to disassemble the cam and the 2 pulley halves WARNING Driven pulley cam is spring loaded...

Page 148: ...er shoes always install a new set 3 shoes to maintain equal pressure on the cam o Install slider shoes as per following photo RED slider shoes are being used for reverse and BLACK ones for forward 1 B...

Page 149: ...r to BRAKE then look for BRAKE DISC and COUNTERSHAFT BEARING ADJUSTMENT o Reinstall the pulley on the countershaft by reversing the removal procedure o Driven pulley end play is 0 zero 24 Pulley Retai...

Page 150: ...ays be checked whenever pulleys have been removed replaced or disassembled 3 Cam o Make sure to install proper cam Refer to TECHNICAL DATA o Cam angle is identified on cam NOTE For high altitude regio...

Page 151: ...TMENT Measurement NOTE The drive belt height measurement must be performed each time a new drive belt is installed NOTE To obtain an accurate drive belt height measurement it is suggested to allow a b...

Page 152: ...ews o To raise belt in driven pulley turn ring clockwise and tighten the adjustment screws 1 Screws 2 Adjustment ring o Turn the adjustment ring up to one notch tighten the screws then rotate driven p...

Page 153: ...r ring 2 Upper ring 3 Force 4 Deflection o Slide the lower ring of the deflection scale to the required measurement o Slide the upper ring of the deflection force scale to zero o Exert pressure until...

Page 154: ...your vehicle by the primary clutch Have your vehicle repaired as soon as possible o Attach the emergency starter cord to the starter grip and to the small plastic clip as shown at right NOTICE The sp...

Page 155: ...ENGINE CYLINDERS HEAD BASE EXHAUST 7 1 CHAPTER 7 ENGINE CYLINDERS HEADS BASE EXHAUST...

Page 156: ...ENGINE CYLINDERS HEAD BASE EXHAUST 7 2 ENGINE BOTTOM END...

Page 157: ...p collar 19 420 230 196 1 Oil seal A 10x26x7 NBR 20 420 232 100 1 Ball bearing 6000 10 26 8 21 420 650 370 1 Rotary seal 22 420 950 890 2 O ring 30x3 23 1 Waterpump oil pump shaft 24 420 840 511 2 All...

Page 158: ...ENGINE CYLINDERS HEAD BASE EXHAUST 7 4 ENGINE CRANKSHAFT AND PISTONS...

Page 159: ...931 285 1 Oil seal as 40x80x8 FPM 11 420 246 015 1 Woodruff key 3x5 12 420 832 428 2 Cageless needle bearing 20x25x23 13 14 420 889 456 2 Piston assembly 81 87 mm 14 420 815 360 2 Semi trapez ring is...

Page 160: ...ENGINE CYLINDERS HEAD BASE EXHAUST 7 6 ENGINE TOP END...

Page 161: ...5 17 420 640 524 4 Collar hexagone screw M10 x 80 18 420 640 534 4 Collar hexagone screw M10 x 120 19 420 931 590 2 Square ring 20 420 931 410 2 O ring 89x2 21 420 923 828 1 Cylinder head 22 420 941 6...

Page 162: ...ENGINE CYLINDERS HEAD BASE EXHAUST 7 8 ENGINE EXHAUST SYSTEM...

Page 163: ...7 234 161 471 8 Lock washer 6 mm 18 205 062 044 8 SHCS M6 x 20 19 514 053 487 1 Exhaust gasket 20 514 053 812 2 Exhaust gasket 21 415 107 100 11 Spring 22 22216P 1 BHCS M8 x 30 23 20231P 2 HHCS M10 x...

Page 164: ...tters AUS over an arrow on the piston dome must be visible after cleaning o Clean the piston ring groove with a groove cleaner tool or with a piece of broken ring DISASSEMBLY RAVE System NOTICE RAVE s...

Page 165: ...m sleeve kit P N 529 035 542 Use also a locating sleeve NOTICE The locating sleeve is the same that contains new cageless bearing Insert piston pin puller P N 529 035 503 making sure it sits squarely...

Page 166: ...er of piston pin bearing Remove puller Pull out shouldered sleeve carefully Remove piston from connecting rod Install locating sleeve Then push the needle bearings thrust washers and sleeve into the u...

Page 167: ...RAVE valve noting which is the top side when it was removed Tighten red cap no 15 screw to bottom 2 13 Cylinder and Piston Before inserting piston in cylinder lubricate the cylinder with new injectio...

Page 168: ...on installation to make the insertion of the pin much easier CAUTION Piston temperature must not exceed 46 C 115 F Never use direct flame to heat the piston and never freeze the pin At assembly place...

Page 169: ...is at 6 o clock as illustrated Use appropriate piston circlip installer Use circlip installer P N 529 035 686 to install new mono hook circlips no 16 Insert circlip into support so that when installed...

Page 170: ...ylinders and crankcase mating surfaces with Loctite Chisel P N 413708500 Coat crankcase mating surface with Loctite 518 P N 293800038 Choose the right gasket thickness according to combustion chamber...

Page 171: ...utlet socket and tighten screws to 12 N m 106 Ibf in Note position of longer screw 1 Longer screw 30 Reed Valve All Engines Blades have a curved shape Install with their curve facing reed block With b...

Page 172: ...emove drive pulley refer to Chapter 8 Primary Transmission System To remove magneto refer to CDI SYSTEM in Chapter 14 Electrical System 2 3 7 9 Crankshaft Bearings To remove bearings from crankshaft u...

Page 173: ...ll expand the bearing and ease installation Some bearings must be lubricated with Isoflex grease P N 293 550 021 CAUTION Use only the recommended Isoflex grease Make sure not to push Isoflex grease be...

Page 174: ...AG side outer bearing NOTICE If replaced with new bearing do not apply grease as new bearings come with grease already applied At crankshaft installation position drive pins as illustrated 1 Position...

Page 175: ...must be torqued in a row Before screwing together both parts of crankcase seal it with sealing compound P N 420 297 906 Make sure surfaces are perfectly clean and degreased before applying sealing co...

Page 176: ...lts up to 60 of the final torque 18 N m 13 5 lbf ft for most of the bolts then tighten to the required torque i e 29 N m 21 lbf ft A Torque bolts 1 through 16 to 29 N m 21 lbf ft B Torque bolts 17 thr...

Page 177: ...Activate pump and pressurize engine to 34 kPa 5 PSI Do not exceed this pressure 9 Engine must stand this pressure during 3 minutes If pressure drops before 3 minutes check tester kit by spraying a so...

Page 178: ...Check for air bubble or oil column going toward pump It indicates defective check valve in injection nipples 2 Remove cooling system cap Check for air bubbles in antifreeze It indicates defective cyli...

Page 179: ...e oil pump side which is blocked off on the Snow Hawk 600HO Check this mounting area and the two mounting bolts for leaks 3 If leak still persists it indicates a defective casting somewhere in the eng...

Page 180: ...ENGINE CYLINDERS HEAD BASE EXHAUST 7 26...

Page 181: ...Compare cylinder diameter 16 mm 5 8 in from top of cylinder to just below its intake port area If the difference exceeds the specified dimension the cylinder should be rebored and honed or should be r...

Page 182: ...cylinder sleeve port openings 1 Piston pin position 2 Measures to be compared A 16 mm 5 8 in COMBUSTION CHAMBER VOLUME MEASUREMENT The combustion chamber volume is the region in the cylinder head abov...

Page 183: ...The liquid level in cylinder must not drop for a few seconds after filling If so there is a leak between piston and cylinder The recorded volume would be false Reseal the piston ring gap and follow th...

Page 184: ...earest USED PISTON MEASUREMENT Note the measurement on the piston dome 1 Piston dome 2 Piston measurement Using a micrometer measure piston skirt at 15 mm 590 in perpendicularly 90 to piston pin 1 Mea...

Page 185: ...the measurement on the piston dome 1 Piston dome 2 Piston measurement Adjust and lock a micrometer to the specified value on the piston dome 1 Micrometer set to the piston dimension With the micromet...

Page 186: ...mm 5 8 in Read the measurement on the cylinder bore gauge The result is the exact piston cylinder wall clearance If clearance exceeds specified tolerance replace cylinder NOTICE Make sure the cylinder...

Page 187: ...erances 1 Transfer port 2 Intake port CRANKSHAFT DEFLECTION Crankshaft deflection is measured with a dial indicator Measuring in crankcase First check deflection with crankshaft in crankcase If deflec...

Page 188: ...kshaft deflection cannot be correctly measured between centers of a lathe If the deflection exceeds the specified tolerance crankshaft should be repaired or replaced Connection Rod Big End Axial Play...

Page 189: ...Install a TDC gauge P N 414 104 700 in spark plug hole on MAG side o Bring MAG piston to top dead center o Rotate degree wheel not crankshaft so that 360 mark aligns with center of crankcase Scribe a...

Page 190: ...COOLING SYSTEM 6 1 CHAPTER 6 COOLING SYSTEM...

Page 191: ...COOLING SYSTEM 6 2 COOLING SYSTEM...

Page 192: ...1 Coolant tube 2 10 415080200 S 1 Overflow tube 11 414554800 1 Spring clamp black 12 408800400 12 Hose clamp geared 13 BN01 0618 17 3 16 Medium pop rivet 14 SH 262 2 Slide support 15 SH 165 1 Wear pa...

Page 193: ...76 on the overflow hose Using pump also included in the kit and pressurize the entire system through the coolant reservoir to 100 kPa 15 PSI o Check all hoses and cylinder base for coolant leaks Spray...

Page 194: ...nction is to give faster warm up of the engine by controlling a circuit water pump engine coolant tank This is done by bypassing the heat exchanger radiator circuit and using what it called a short ci...

Page 195: ...g tank to avoid emptying o Install pressure cap o Lift rear of vehicle and support it safely o Blip the throttle 3 4 times to bring engine speed to 7000 RPM o Apply the brake to stop the track o Lower...

Page 196: ...REWIND STARTER 5 1 CHAPTER 5 REWIND STARTER...

Page 197: ...REWIND STARTER 5 2 REWIND STARTER...

Page 198: ...pe sheave 6 412500200 1 Starter rope 2200mm 7 420852297 1 Pawl 8 420852305 1 Pawl lock 9 420847925 1 Stage sleeve 10 420250400 1 O ring 11 420852520 1 Lock ring 12 420845560 1 Locking element 13 1 Pos...

Page 199: ...lled If not disassemble rewind starter clean and check for damaged plastic parts Replace as required lubricate reassemble and recheck Always replace O ring 10 every time rewind starter is disassemble...

Page 200: ...spring preload o Cut locking element 12 and discard Remove lock ring 11 O ring 10 stepped sleeve 9 Pawl lock 8 and Pawl 7 o Remove sheave 5 from starter housing 3 Hold the spring with a screwdriver o...

Page 201: ...on o To install rope 6 insert rope into sheave 5 orifice and lock it by making a knot leaving behind a free portion of about 25 mm in length Fuse rope end with a lit match and insert it into sheave o...

Page 202: ...O ring 10 and lock ring 11 whit Molykote PG 54 Install over pawl lock 1 Stepped sleeve 2 O ring 3 Lock ring o Install the locking element nut 12 INSTALLATION o Fuse rope end with a lit match o Thread...

Page 203: ...ENGINE REMOVAL 4 1 CHAPTER 4 ENGINE REMOVAL...

Page 204: ...hicle Refer to Chapter 1 GENERAL INSTRUCTIONS Remove the two forward brackets P N SH 032 L R Remove tuned pipe primary muffler and secondary muffler Refer to chapter 7 ENGINE Front fork Use a crate or...

Page 205: ...ow it Carburators Remove the rubber latch retaining the fuel tank and place it as shown on the right to have free access to air box and carburators Remove the air box Remove the carburators to the eng...

Page 206: ...o prevent this from happening o Make a knot as shown at right Secondary Clutch o Open the secondary clutch using the the spacer tool P N 529 008 700 For more details see Chapter 8 Primary Transmission...

Page 207: ...re then passes down the height of the chassis towards the magneto and is attached to the tube that goes from the water pump oil reservoir to the water pump itself via a tie wrap Cut this tie wrap as w...

Page 208: ...t holds the forward cooling hose to the water pump housing inlet at the front of the engine With a bucket below this point let the coolant drain from the system completely o Loosen the hose clamp on t...

Page 209: ...ne to the inlet of the tunnel mounted heat exchangers and should remain connected to the engine when removing o Now that all of the peripheral equipment has been disconnected unscrew and remove the 4...

Page 210: ...e belt o Ensure that each cable wire and hose is properly connected and its original routing is used See Chapter 17 Wire Cable and Hose Routing for more details o Ensure that each coolant line is re i...

Page 211: ...FUEL SYSTEM 3 1 CHAPTER 3 FUEL SYSTEM...

Page 212: ...FUEL SYSTEM 3 2 33 FUEL SYSTEM 4 1 3 2 5 17 20 19 40 21 22 23 6 6 7 7 10 9 8 11 11 12 13 15 14 16 25 26 27 25 24 37 35 39 37 36 38 31 25 25 28 32 30 18 29 31 34...

Page 213: ...grip set 18 570 135 100 1 Grommet 19 414 580 700 1 Male connector 20 415 080 200 01 1 Hose 21 404 162 001 01 1 Hose 22 572 045 500 1 T fitting 23 404 162 001 02 1 Hose 24 403 901 811 1 Fuel pump 25 41...

Page 214: ...FUEL SYSTEM 3 4 CARBURET0RS TM 40...

Page 215: ...404 161 933 4 Screw 19 404 161 932 2 Float 20 404 161 960 2 Float Body 21 707 200 027 1 E ring 22 404 162 007 4 Plate 23 404 162 008 2 Holder 24 404 161 928 2 Screw 25 404 162 009 2 Lever 26 404 161...

Page 216: ...55 404 161 903 2 Screw 56 404 162 000 1 Bracket 57 404 161 901 1 Starter lever 58 404 161 899 2 Cap 59 404 161 898 2 Adjuster 60 404 161 897 2 Spring 61 404 161 896 2 Washer 62 404 161 895 2 Packing 6...

Page 217: ...tings of either Remove dual carburetor assembly pinch and disconnect fuel line Take care to recuperate fuel WARNING Fuel is flammable and explosive under certain conditions Always wipe off any fuel or...

Page 218: ...ondition of the tip of the fuel inlet valve If the tip is worn replace both the valve and its seat NOTICE Install only a snowmobile carburetor inlet valve as it is designed to function with a fuel pum...

Page 219: ...ture and or altitude changes A service bulletin will give information about calibration according to altitude and temperature Main jet 5 may be removed without removing float bowl 20 by first removing...

Page 220: ...e care not to loose plastic washer 9 under needle circlip 10 2 INTAKE SPICKET Unscrew throttle slide cover screws 70 Open throttle 3 4 wide and hold it there Lift throttle slide covers bottom first un...

Page 221: ...SCREW ADJUSTMENT Completely close the pilot screw until a slight seating resistance is felt then back off as specified Turning screw clockwise leans mixture and conversely turning it counter clockwis...

Page 222: ...retor proceed using the synchronization screw Use the same drill bit used for the PTO carburetor to measure throttle slide height Turn synchronization screw to adjust 1 PTO carburetor adjusted first 2...

Page 223: ...k to the lower shaft at the middle bottom of the carburetor assembly THROTTLE CABLE ADJUSTMENT Adjust throttle cable as per following procedure Loosen throttle cable housing adjusting and locking nuts...

Page 224: ...s position As a confirmation the gap between the stopper and the bracket should be within 0 and 0 5 mm 0 and 1 64 in A Within 0 and 0 5 mm 0 and 1 64 in Idle Speed Final Adjustment Start engine and al...

Page 225: ...ply pressure and vacuum with pump 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...

Page 226: ...d in general purpose solvent and dried with compressed air WARNING Solvent with a low flash point such as gasoline naphtha benzol etc should not be used as each is flammable and explosive Inspect diap...

Page 227: ...PERIODIC MAINTENANCE 2 1 Chapter 2 PERIODIC MAINTENANCE...

Page 228: ...imary and secondary clutch V V V C Primary clutch bolt V V Secondary clutch pre tension V A V A Secondary drive belt cog belt V V Cog sprockets V V Torque Limiter V V A Taper Locks V V Brake fluid V F...

Page 229: ...ore often under severe usage conditions Clean the filter in a solution containing a non flammable cleaning solvant such as hot soapy water Once dry apply some light engine to the filters to prevent th...

Page 230: ...he system to detect any leak or abnormality in the gasket material Cooling system Inspect the coolant level in the coolant reservoir located on the MAG side of the vehicle If the coolant level is belo...

Page 231: ...ft For more information refer to Chapter 8 Primary Transmission System Pre tension of the secondary clutch spring For more information refer to Chapter 8 Primary Transmission System Primary transmiss...

Page 232: ...transmission belt according to the instructions found in Chapter 9 Secondary Transmission System Cog Sprockets Check the appearance of the cog sprockets Make sure all the sprockets are there and are...

Page 233: ...when the vehicle is stored in a heated garage A visual inspection of the fork legs can reveal oil leaks that might indicate broken main seals If excessive oil is presest on the lower fork leg a seal...

Page 234: ...around the shock guards for the presence of oil leaks Shock oil must be replaced once a year Refer to Chapter 12 Rear suspension and Track CAUTION It is advisable to change the shock fluid when prepa...

Page 235: ...of the tie rod ends and check for excessive play in the pivots of the steering system For alignment refer to Chapter 13 Chassis and Steering Assembly The chassis of the SNOW HAWK is different in that...

Page 236: ...must be between 25 and 30 N m 18 and 21 5 lbf ft 2 5 and 3 0 kg m CAUTION The engine may be seriously damaged if the temperature rating of the spark plug is inadequate Refer to the NGK codification on...

Page 237: ...PERIODIC MAINTENANCE 2 11 Symbols used on the NGK spark plugs...

Page 238: ...se refer to the following table N m kg m lbf ft lbf in N m kg m lbf ft lbf in 6 10 1 7 84 15 1 5 11 132 8 25 2 5 18 216 36 3 6 27 324 10 49 4 9 36 432 72 7 2 53 636 12 85 8 5 63 756 125 12 5 92 1104 G...

Page 239: ...GENERAL INSTRUCTIONS 1 1 CHAPTER 1 GENERAL INSTRUCTION...

Page 240: ...ping in mind the speed of the vehicle the snow conditions and how quickly you want to change direction WARNING Some people enter a turn by stretching out a leg on the inside of the turn and letting th...

Page 241: ...off tether 5 Gas tank cap 6 Dimmer switch 7 Choke control 8 Emergency stop button 9 Temperature Light 10 Hood latches 4 11 Rear module latches 4 12 Bellypan latches 6 13 Kick stand 14 Headlight 15 Sto...

Page 242: ...proportion of oil is too low will cause piston failure On the other hand a mixture in which the proportion of oil is too high will cause excessive carbon deposits that will result in fouled spark plu...

Page 243: ...rn to its original position as soon as it is released o Turn the twist throttle control a few times to make sure it functions properly The control must return automatically to the idle position as soo...

Page 244: ...acceleration and frequent speed variations contribute to a good break in On the other hand periods of long high acceleration sustained high speed and engine overheating are harmful during the break in...

Page 245: ...check them regularly during this period REMOVAL OF THE BODY PANELS HOOD REAR MODULE AND BELLYPAN In order to work on the vehicle more easily and to access the anchor ties we suggest that you remove th...

Page 246: ...the sides of the belly pan towards the rear of the vehicle o De latch the four rubber latches on the bottom of the belly pan o Descend the belly pan to floor level most maintenance can be performed wi...

Page 247: ...INE CYLINDERS HEAD BASE EXHAUST PRIMARY TRANSMISSION SYSTEM SECONDARY TRANSMISSION SYSTEM HYDRAULIC BRAKE SYSTEM FRONT FORK AND TWIN AXIS SKI REAR SUSPENSION SHOCKS TRACK AND REAR PAD CHASSIS STEERING...

Page 248: ...ion to the boxes entitled WARNING and CAUTION as well as to the paragraphs preceded by the word NOTICE WARNING This symbol is designed to call attention to particular instructions and procedures which...

Page 249: ...the motor is running can be dangerous Injuries could result from contact with moving parts Make sure you turn off the motor before working on the vehicle WARNING Working on this vehicle without weari...

Page 250: ...e pour toute r f rence future NUM RO D IDENTIFICATION DU V HICULE ______________________ SIGNATURE DU PROPRI TAIRE SIGNATURE DU CONCESSIONNAIRE _____________________________________________ __________...

Page 251: ...__________________________ _____________________________________________ Warranty Card Please complete and mail this copy of your warranty registration card to us in order to activate the one year par...

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