Ski-Doo Ski Doo MX Z 2005 [1098/1429] Section 04 engine 4 tec subsection 06 crankshaft drive gears

Содержание

• Mmr 2005 s rie rev ang fh8 wed dec 01 10 21 46 2004 page 1 1
• Rev models 1
• Electrical system 33 05 steering and suspension 43 4
• Engine 9 02 fuel and oil systems 21 03 drive and brake systems 25 4
• Engines 4
• Introduction xii 4
• Leak test 47 4
• Maintenance 4
• Maintenance chart 1 02 storage 3 4
• Preseason preparation 7 4
• Safety notice xi 4
• Table of contents 4
• Troubleshooting 4
• Vehicle identification number xiv engine serial number xiv list of abbreviations used in this manual xiv arrangement of this manual xvi general information xviii illustrations and procedures xviii self locking fasteners procedure xviii loctite application procedure xix threadlocker xix stripped thread repair xx gasket compound xxi mounting on shaft xxi case in components xxii tightening torque xxiii 4
• Bottom end 109 5
• Engine measurement 129 5
• Engine removal and installation 57 5
• Exhaust system 51 377 and 552 engines 52 593 593 ho 593 ho sdi and 793 ho engines 53 5
• Magneto system 71 5
• Table of contents 5
• Top end 81 5
• Carburetors throttle and choke cables 175 carburetor vm type 176 6
• Cooling system 135 6
• Diaphragm fuel pump 172 6
• Fuel system 6
• Fuel tank and fuel pump 165 6
• Oil injection system 155 6
• Rewind starter 147 6
• Table of contents 6
• Carburetor tm type 184 7
• Component inspection replacement and adjustment 213 general 213 7
• Diagnostic procedures 205 7
• Dpm system 193 7
• Engine management power tek 7
• Engine management system 216 7
• Overview 199 operating principle 200 7
• Table of contents 7
• Air induction system 254 8
• Component inspection replacement and adjustment 249 general 249 fuel system 249 electrical system 250 8
• Diagnostic procedures 241 8
• Electronic management 265 8
• Engine management sdi 8
• Engine management system ems 234 8
• Fuel delivery 257 8
• Overview 231 operating principle 232 8
• Table of contents 8
• Accessories 307 9
• Design symbols used in ngk spark plugs 292 02 charging system 293 9
• Drive belt 317 9
• Drive pulley 323 bombardier lite 324 9
• Drive system 9
• Electrical system 9
• Ignition system 279 9
• Starting system 299 9
• Table of contents 9
• Tra iii 328 9
• Brake 353 hydraulic brake 354 10
• Chaincase 361 10
• Drive axle 367 10
• Driven pulley 339 10
• Pulley alignment 349 10
• Table of contents 10
• Rear suspension 11
• Sc 3 suspension 395 11
• Sc suspension 381 11
• Table of contents 11
• Track 375 11
• Body 461 installation and adjustment 461 12
• Body frame 12
• Front suspension 447 12
• Sc 4 suspension 409 12
• Shock absorber inspection and servicing 423 12
• Steering front suspension 12
• Steering system 433 12
• Table of contents 12
• Fan cooled models 465 02 liquid cooled models 471 03 liquid cooled sdi models 479 13
• Frame 463 13
• Plastic maintenance and repair 462 13
• Table of contents 13
• Technical data 13
• Wiring diagram 13
• Wiring diagrams 485 13
• Safety notice 14
• Warning 14
• Introduction 15
• Introduction 16
• Engine serial number 17
• Engine serial number location 17
• Identification number meaning 17
• Introduction 17
• List of abbreviations used in this manual 17
• Vehicle identification number 17
• Vehicle identification number location 17
• Introduction 18
• Arrangement of this manual 19
• Introduction 19
• Mmr2005 059 19
• Introduction 20
• General information 21
• Illustrations and procedures 21
• Introduction 21
• Self locking fasteners procedure 21
• Blind holes 22
• Introduction 22
• Loctite application procedure 22
• Stud in blind holes 22
• Threadlocker 22
• Uncovered holes bolts and nuts 22
• Adjusting screw 23
• Introduction 23
• Preassembled parts 23
• Stripped thread repair 23
• Stripped threads 23
• All parts 24
• Gasket compound 24
• Introduction 24
• Mounting on shaft 24
• Mounting with a press 24
• Case in components 25
• Introduction 25
• Metallic gaskets 25
• Introduction 26
• Tightening torque 26
• Warning 26
• Hour or 500 km 300 mi inspection to be performed by dealer 27
• Km 3700 mi 27
• Maintenance chart 27
• Monthly or every 800 km 500 mi 27
• Once a year or every 3200 km 2000 mi 27
• Part task refer to section s and subsection s 27
• Preseason preparation to be performed by dealer 27
• Section 01 maintenance 27
• Sections 27
• Storage to be performed by dealer 27
• Subsection 01 maintenance chart 27
• Weekly or every 240 km 150 mi 27
• 1 to be performed by an authorized ski doo dealer 28
• 2 lubricate whenever the vehicle is used in wet conditions wet snow rain puddles 28
• 3 before installing new spark plugs at preseason preparation it is suggested to burn excess storage oil by starting the engine with the old spark plugs only perform this operation in a well ventilated area 28
• 4 emission related 28
• Hour or 500 km 300 mi inspection to be performed by dealer 28
• Km 3700 mi 28
• Monthly or every 800 km 500 mi 28
• Once a year or every 3200 km 2000 mi 28
• Part task refer to section s and subsection s 28
• Preseason preparation to be performed by dealer 28
• Section 01 maintenance subsection 01 maintenance chart 28
• Storage to be performed by dealer 28
• Weekly or every 240 km 150 mi 28
• Engine 29
• Engine lubrication 29
• Engine motor mounts 29
• Exhaust system 29
• General 29
• Rewind starter and rope 29
• Service products 29
• Service tools 29
• Storage 29
• Warning 29
• Brake fluid 30
• Cooling system 30
• Crankshaft pto seal 30
• Drive and driven pulley 30
• Drive system 30
• Fuel stabilizer 30
• Fuel system 30
• Injection oil filter 30
• Rags in air intake and exhaust system 30
• Section 01 maintenance subsection 02 storage 30
• Warning 30
• Battery if so equipped 31
• Chaincase oil 31
• Countershaft 31
• Drive axle end bearing 31
• Drive chain tension 31
• Electrical 31
• Engine compartment 31
• Rear suspension lubrication 31
• Section 01 maintenance 31
• Steering and front suspension mechanism lubrication 31
• Steering front suspension 31
• Subsection 02 storage 31
• Suspension 31
• Suspension stopper strap 31
• Vehicle 31
• Vehicle cleaning 31
• Wear and condition of skis and runners 31
• Wiring harnesses cables and lines 31
• Section 01 maintenance subsection 02 storage 32
• Vehicle protection 32
• Carburetor if so equipped 33
• Cooling system 33
• Engine 33
• Fuel filter 33
• Fuel lines fuel rails and connections 33
• Fuel system 33
• Oil injection pump 33
• Preseason preparation 33
• Rags in air intake and exhaust system 33
• Rewind starter and rope 33
• Service products 33
• Throttle cable 33
• Warning 33
• Air filter 34
• Battery if so equipped 34
• Brake fluid 34
• Brake hose pads and disk 34
• Chaincase oil 34
• Drive and driven pulley 34
• Drive belt 34
• Drive system 34
• Electrical system 34
• Headlamp beam aiming 34
• Injection oil 34
• Section 01 maintenance subsection 03 preseason preparation 34
• Spark plugs 34
• Throttle body sdi 34
• Track tension and alignment 34
• Vehicle 34
• Warning 34
• Engine 35
• Section 02 troubleshooting 35
• Subsection 01 engine 35
• The following chart is provided to help diagnose the probable source of troubles it should be used as a guideline some causes or corrections may not apply to a specific model note for engine management system troubleshooting sdi and power tek engines refer to appropri ate subsection 35
• Section 02 troubleshooting subsection 01 engine 36
• Section 02 troubleshooting 37
• Subsection 01 engine 37
• Section 02 troubleshooting subsection 01 engine 38
• Section 02 troubleshooting 39
• Subsection 01 engine 39
• Section 02 troubleshooting subsection 01 engine 40
• Section 02 troubleshooting 41
• Subsection 01 engine 41
• Section 02 troubleshooting subsection 01 engine 42
• Section 02 troubleshooting 43
• Subsection 01 engine 43
• Section 02 troubleshooting subsection 01 engine 44
• Section 02 troubleshooting 45
• Subsection 01 engine 45
• Fuel and oil systems 46
• Section 02 troubleshooting 46
• Subsection 02 fuel and oil systems 46
• The following chart is provided to help diagnose the probable source of troubles it should be used as a guideline some causes or corrections may not apply to a specific model note for the sdi and power tek engines also refer to appropriate engine management section 46
• Section 02 troubleshooting subsection 02 fuel and oil systems 47
• Section 02 troubleshooting 48
• Subsection 02 fuel and oil systems 48
• Drive and brake systems 49
• Drive system 49
• Section 02 troubleshooting 49
• Subsection 03 drive and brake systems 49
• The following chart is provided to help diagnose the probable source of troubles it should be used as a guideline some causes or corrections may not apply to a specific model 49
• Section 02 troubleshooting subsection 03 drive and brake systems 50
• Section 02 troubleshooting 51
• Subsection 03 drive and brake systems 51
• Section 02 troubleshooting subsection 03 drive and brake systems 52
• Considerable use 53
• New belt 53
• Section 02 troubleshooting 53
• Subsection 03 drive and brake systems 53
• Section 02 troubleshooting subsection 03 drive and brake systems 54
• Section 02 troubleshooting 55
• Subsection 03 drive and brake systems 55
• Brake system 56
• Section 02 troubleshooting subsection 03 drive and brake systems 56
• Electrical system 57
• Section 02 troubleshooting 57
• Subsection 04 electrical system 57
• The following chart is provided to help diagnose the probable source of troubles it should be used as a guideline some causes or corrections may not apply to a specific model 57
• Section 02 troubleshooting subsection 04 electrical system 58
• Section 02 troubleshooting 59
• Subsection 04 electrical system 59
• Section 02 troubleshooting subsection 04 electrical system 60
• Section 02 troubleshooting 61
• Subsection 04 electrical system 61
• Section 02 troubleshooting subsection 04 electrical system 62
• Section 02 troubleshooting 63
• Subsection 04 electrical system 63
• Section 02 troubleshooting subsection 04 electrical system 64
• Section 02 troubleshooting 65
• Subsection 04 electrical system 65
• Section 02 troubleshooting subsection 04 electrical system 66
• Section 02 troubleshooting 67
• Steering and suspension 67
• Subsection 05 steering and suspension 67
• The following chart is provided to help diagnose the probable source of troubles it should be used as a guideline some causes or corrections may not apply to a specific model 67
• Section 02 troubleshooting subsection 05 steering and suspension 68
• Section 02 troubleshooting 69
• Subsection 05 steering and suspension 69
• Leak test 70
• Preparation 70
• Section 03 engines 70
• Service tools 70
• Subsection 01 leak test 70
• Engine 71
• Procedure 71
• Pump shaft oil gear reservoir 71
• Section 03 engines subsection 01 leak test 71
• Finalizing reassembly 72
• Section 03 engines 72
• Subsection 01 leak test 72
• Engine leak verification flow chart 73
• Section 03 engines subsection 01 leak test 73
• Exhaust spring installer remover 529 035 401 54 55 74
• Exhaust system 74
• Rtv sealant 293 800 090 55 74
• Section 03 engines 74
• Service products 74
• Service tools 74
• Subsection 02 exhaust system 74
• And 552 engines 75
• Section 03 engines subsection 02 exhaust system 75
• 593 ho 593 ho sdi and 793 ho engines 76
• Section 03 engines 76
• Subsection 02 exhaust system 76
• Identification 77
• Inspection 77
• Installation 77
• Removal 77
• Section 03 engines subsection 02 exhaust system 77
• Tuned pipe 77
• Identification 78
• Inspection 78
• Installation 78
• Manifold 78
• Muffler 78
• Removal 78
• Section 03 engines 78
• Subsection 02 exhaust system 78
• Engine removal and installation 79
• Engine removal hook 529 035 829 69 pump 529 035 880 65 small hose pincher 295 000 076 60 spark plug lift ring 529 035 830 68 79
• Loctite 243 blue 293 800 060 63 69 79
• Section 03 engines 79
• Service products 79
• Service tools 79
• Subsection 03 engine removal and installation 79
• Fan cooled engines 80
• Section 03 engines subsection 03 engine removal and installation 80
• Removal from vehicle 81
• Section 03 engines 81
• Subsection 03 engine removal and installation 81
• Vehicule and engine preparation 81
• Warning 81
• Section 03 engines subsection 03 engine removal and installation 82
• Section 03 engines 83
• Subsection 03 engine removal and installation 83
• Section 03 engines subsection 03 engine removal and installation 84
• Inspection 85
• Installation 85
• Section 03 engines 85
• Subsection 03 engine removal and installation 85
• Liquid cooled engines 86
• Section 03 engines subsection 03 engine removal and installation 86
• Removal from vehicle 87
• Section 03 engines 87
• Subsection 03 engine removal and installation 87
• Vehicle and engine preparation 87
• Warning 87
• Section 03 engines subsection 03 engine removal and installation 88
• Section 03 engines 89
• Subsection 03 engine removal and installation 89
• Section 03 engines subsection 03 engine removal and installation 90
• Inspection 91
• Installation 91
• Section 03 engines 91
• Subsection 03 engine removal and installation 91
• Crankshaft protector 420 876 557 77 magneto puller 529 035 547 77 puller ring 420 876 080 76 92
• Loctite 243 blue 293 800 060 77 78 silicone dielectric grease 293 550 004 77 92
• Magneto system 92
• Section 03 engines 92
• Service products 92
• Service tools 92
• Subsection 04 magneto system 92
• And 552 engines 93
• Section 03 engines subsection 04 magneto system 93
• Engines 94
• Section 03 engines 94
• Subsection 04 magneto system 94
• Ho and 793 ho engines 95
• Section 03 engines subsection 04 magneto system 95
• Ho sdi engines 96
• Section 03 engines 96
• Subsection 04 magneto system 96
• Cleaning 97
• General 97
• Magneto flywheel 97
• Removal 97
• Section 03 engines subsection 04 magneto system 97
• Warning 97
• Ignition timing 98
• Installation 98
• Section 03 engines 98
• Subsection 04 magneto system 98
• Cleaning 99
• Cps trigger coil 99
• Inspection 99
• Installation 99
• Removal 99
• Section 03 engines subsection 04 magneto system 99
• Stator 99
• Section 03 engines 100
• Subsection 04 magneto system 100
• Section 03 engines 101
• Service products 101
• Service tools 101
• Subsection 05 top end 101
• Top end 101
• Engine 102
• Section 03 engines subsection 05 top end 102
• Engine 103
• Section 03 engines 103
• Subsection 05 top end 103
• Cleaning 104
• Component removal with the engine installed 104
• Disassembly 104
• Section 03 engines subsection 05 top end 104
• Troubleshooting 104
• Section 03 engines 105
• Subsection 05 top end 105
• Assembly 106
• Inspection 106
• Note 0 5 and 0 mm oversized pistons are available if necessary use a locking tie to fasten all needles and thrust washers along with locating sleeve 106
• Note refer to table below to find top end en gine dimension specifications for dimension measurement procedures refer to engine mea surement 106
• Remove piston from connecting rod install locating sleeve then push needle bearings along with thrust washers and sleeve 106
• Section 03 engines subsection 05 top end 106
• To ease piston installation heat piston using bear ing heater p n 529 035 969 106
• Section 03 engines 107
• Subsection 05 top end 107
• Section 03 engines subsection 05 top end 108
• Section 03 engines 109
• Subsection 05 top end 109
• Section 03 engines subsection 05 top end 110
• Reed valve 111
• Section 03 engines 111
• Subsection 05 top end 111
• Section 03 engines subsection 05 top end 112
• Engine 113
• Section 03 engines 113
• Subsection 05 top end 113
• Ho engine 114
• Section 03 engines subsection 05 top end 114
• Ho sdi engine 115
• Section 03 engines 115
• Subsection 05 top end 115
• Ho engine 116
• Section 03 engines subsection 05 top end 116
• Ho engine power tek 117
• Section 03 engines 117
• Subsection 05 top end 117
• Cleaning 118
• Component removal with the engine installed 118
• Disassembly 118
• Rave valve basic operation 118
• Rave valves 118
• Section 03 engines subsection 05 top end 118
• Troubleshooting 118
• Section 03 engines 119
• Subsection 05 top end 119
• Warning 119
• Reed valve 120
• Section 03 engines subsection 05 top end 120
• Cylinder 121
• Cylinder head 121
• Cylinder head cover 121
• Piston 121
• Section 03 engines 121
• Subsection 05 top end 121
• Section 03 engines subsection 05 top end 122
• Inspection 123
• Rave valves 123
• Section 03 engines 123
• Subsection 05 top end 123
• Apply sealing compound drei bond p n 420 297 906 in the groove of valve base and in the piston valve groove then install bellows install rave valve with its mention top as illustrat ed in the following photo 124
• Assembly 124
• Cylinder boring precaution 124
• Cylinder head cylinder and piston 124
• Engine in its stock configuration the rave valve guillo tine has a minimum of 0 mm 20 in clearance to the cylinder bore measured at the center line of the cylinder this is the minimum production clearance 124
• Piston 124
• Rave valves 124
• Section 03 engines subsection 05 top end 124
• Tighten red cap screw no 28 to bottom 124
• When installing a new cageless bearing replace half plastic cages with sleeve note cageless bearing contains 28 needles on all engines 124
• Section 03 engines 125
• Subsection 05 top end 125
• Section 03 engines subsection 05 top end 126
• Cylinder head cover cylinder head and cylinder 127
• Reed valve 127
• Section 03 engines 127
• Subsection 05 top end 127
• Section 03 engines subsection 05 top end 128
• Bottom end 129
• Section 03 engines 129
• Service products 129
• Service tools 129
• Subsection 06 bottom end 129
• Engine 130
• Section 03 engines subsection 06 bottom end 130
• Engine 131
• Section 03 engines 131
• Subsection 06 bottom end 131
• Cleaning 132
• Disassembly 132
• Section 03 engines subsection 06 bottom end 132
• Assembly 133
• Caution never use any air impact tool for tightening the puller bolt lubricate the puller bolt and then proceed with tightening the puller bolt until the bearing comes out follow the same procedure for the inner bearing note in the case of damaged bearing or less clearance between crankshaft counterbalance and the bearing or on the mag side bearing use bearing separator snap on tool p n cj951 or spx otc tool p n 1124 to facilitate the removal 133
• Clean crankshaft end with sand paper no 180 and remove all residue using pulley flange cleaner p n 413 711 809 133
• Crankshaft preparation 133
• Inspection 133
• Procedure for mag side bearings no 4 is same as of pto side with the exception of the crankshaft protector p n 420 876 557 133
• Refer to table below to find bottom end engine di mension specifications for dimension measure ment procedures refer to engine measure ment 133
• Section 03 engines 133
• Smear anti seize lubricant p n 413 701 000 on part of crankshaft where bearing fits 133
• Subsection 06 bottom end 133
• Crankshaft bearing preparation 134
• Section 03 engines subsection 06 bottom end 134
• Warning 134
• Crankshaft bearing installation 135
• Section 03 engines 135
• Subsection 06 bottom end 135
• Crankshaft installation 136
• Section 03 engines subsection 06 bottom end 136
• Crankcase assembly 137
• Section 03 engines 137
• Subsection 06 bottom end 137
• After rebuilding an engine always observe a break in period as described in operator s guide 138
• Break in 138
• Engine 138
• Screw all crankcase bolts in place in the following sequence and to the appropriate torque through a two steps torquing first screw bolts up to 60 of the final torque 13 n m 115 lbf in for m8 bolts then tighten to the required torque i e 22 n m 16 lbf ft 138
• Section 03 engines subsection 06 bottom end 138
• Engine 139
• Section 03 engines 139
• Subsection 06 bottom end 139
• Ho engine 140
• Section 03 engines subsection 06 bottom end 140
• Ho sdi and 793 ho engines 141
• Section 03 engines 141
• Subsection 06 bottom end 141
• Cleaning 142
• Crankshaft bearing 142
• Disassembly 142
• General 142
• Section 03 engines subsection 06 bottom end 142
• Assembly 143
• Coat lip of all seals with petamo grease p n 420 899 271 143
• Crankshaft preparation 143
• Follow the same procedure for the inner bearing note in the case of damaged bearing or less clearance between crankshaft counterbalance and the bearing or on the mag side bearing use a bearing separator such as snap on tool cj 951 or spx otc tool 1124 to facilitate the removal 143
• Inspect crankshaft ends for damage clean crankshaft ends with sand paper no 180 to remove possible seal marks and debris 143
• Inspection 143
• Refer to table below to find bottom end engine di mension specifications for dimension measure ment procedures refer to engine measure ment 143
• Remove all residue using pulley flange cleaner p n 413 711 809 smear anti seize lubricant p n 413 701 000 on part of crankshaft where bearing fits 143
• Section 03 engines 143
• Subsection 06 bottom end 143
• Crankshaft bearing preparation 144
• Section 03 engines subsection 06 bottom end 144
• Warning 144
• Crankshaft bearing installation 145
• Section 03 engines 145
• Subsection 06 bottom end 145
• Crankshaft installation 146
• Section 03 engines subsection 06 bottom end 146
• Crankcase assembly 147
• Section 03 engines 147
• Subsection 06 bottom end 147
• After rebuilding an engine always observe a break in period as described in operator s guide 148
• Break in 148
• Ho 593 ho sdi and 793 ho engines install oil seal cover 148
• Screw all crankcase bolts in place in the following sequence and to the appropriate torque this must be done in two steps torquing first screw bolts up to 60 of the final torque 18 n m 13 lbf ft for most of the bolts then tighten to the required torque i e 29 n m 21 lbf ft 148
• Section 03 engines subsection 06 bottom end 148
• Use a plexiglass plate and apply some sealant on it use a soft rubber roller 50 75 mm 2 3 in available in arts products suppliers for printmak ing and roll the sealant to get a thin uniform coat on the plate spread as necessary when ready apply the sealant on crankcase mating surfaces 148
• Cylinder head warpage 149
• Cylinder out of round 149
• Cylinder taper 149
• Engine measurement 149
• Section 03 engines 149
• Service tools 149
• Subsection 07 engine measurement 149
• Combustion chamber volume measurement 150
• Section 03 engines subsection 07 engine measurement 150
• Cylinder piston clearance 151
• Section 03 engines 151
• Subsection 07 engine measurement 151
• Used and new pistons 151
• Used piston measurement 151
• Section 03 engines subsection 07 engine measurement 152
• Crankshaft deflection 153
• Measuring in crankcase 153
• Measuring on bench 153
• Ring end gap 153
• Ring piston groove clearance 153
• Section 03 engines 153
• Subsection 07 engine measurement 153
• Checking crankshaft alignment 154
• Connecting rod big end axial play 154
• Section 03 engines subsection 07 engine measurement 154
• Cooling system 155
• Section 03 engines 155
• Service products 155
• Service tools 155
• Subsection 08 cooling system 155
• Axial fan cooling system 156
• Section 03 engines subsection 08 cooling system 156
• Section 03 engines 157
• Subsection 08 cooling system 157
• Cooling fan bearing replacement 158
• Cooling fan removal and installation 158
• Section 03 engines subsection 08 cooling system 158
• Fan belt replacement and deflection adjustment 159
• Section 03 engines 159
• Subsection 08 cooling system 159
• Fan belt deflection adjustment 160
• Section 03 engines subsection 08 cooling system 160
• Finalizing reassembly 161
• Section 03 engines 161
• Subsection 08 cooling system 161
• Carbureted models except summit 162
• Liquid cooling system 162
• Section 03 engines subsection 08 cooling system 162
• Sdi models 163
• Section 03 engines 163
• Subsection 08 cooling system 163
• Section 03 engines subsection 08 cooling system 164
• Summit models 164
• Coolant pump 165
• Coolant tank 165
• Cooling system leak test 165
• Disassembly and assembly 165
• Draining the system 165
• Front radiator 165
• Inspection 165
• Pressure cap 165
• Section 03 engines 165
• Sender and plug 165
• Subsection 08 cooling system 165
• Warning 165
• Cooling system refilling procedure 166
• Radiator and radiator protector 166
• Rear radiator and rear radiator protector 166
• Refilling procedure 166
• Section 03 engines subsection 08 cooling system 166
• System capacity 166
• Thermostat 166
• Molykote pg 54 420 899 763 151 153 167
• Rewind starter 167
• Section 03 engines 167
• Service products 167
• Subsection 09 rewind starter 167
• Rewind starter on fan cooled models 168
• Section 03 engines subsection 09 rewind starter 168
• Rewind starter on liquid cooled models 169
• Section 03 engines 169
• Subsection 09 rewind starter 169
• Inspection 170
• Removal 170
• Rope replacement 170
• Section 03 engines subsection 09 rewind starter 170
• Assembly 171
• Disassembly 171
• Section 03 engines 171
• Subsection 09 rewind starter 171
• Warning 171
• Section 03 engines subsection 09 rewind starter 172
• Section 03 engines 173
• Subsection 09 rewind starter 173
• Installation 174
• Section 03 engines subsection 09 rewind starter 174
• Oil injection system 175
• Section 03 engines 175
• Service products 175
• Service tools 175
• Subsection 10 oil injection system 175
• Fan cooled models 176
• Section 03 engines subsection 10 oil injection system 176
• Liquid cooled models 177
• Section 03 engines 177
• Subsection 10 oil injection system 177
• General 178
• Oil system leak test 178
• Oil type 178
• Section 03 engines subsection 10 oil injection system 178
• Warning 178
• Check valve 179
• Checking operation 179
• Cleaning 179
• Oil pump 179
• Oil pump identification 179
• Section 03 engines 179
• Subsection 10 oil injection system 179
• Disassembly 180
• Injection oil filter 180
• Injection oil level sensor 180
• Injection oil pump 180
• Injection oil reservoir 180
• Oil reservoir check valve 180
• Section 03 engines subsection 10 oil injection system 180
• Assembly 181
• Check valve 181
• Injection oil filter 181
• Injection oil level sensor 181
• Injection oil pump 181
• Injection oil reservoir 181
• Oil pump gear 181
• Section 03 engines 181
• Subsection 10 oil injection system 181
• Adjustment 182
• Bleeding procedure 182
• Oil pump cable 182
• Section 03 engines subsection 10 oil injection system 182
• Warning 182
• Section 03 engines 183
• Subsection 10 oil injection system 183
• Fuel tank and fuel pump 184
• Section 04 fuel system 184
• Service tools 184
• Subsection 01 fuel tank and fuel pump 184
• All models except sdi 185
• Section 04 fuel system subsection 01 fuel tank and fuel pump 185
• Sdi models 186
• Section 04 fuel system 186
• Subsection 01 fuel tank and fuel pump 186
• In line fuel filter 187
• In tank fuel filter 187
• Replacement 187
• Section 04 fuel system subsection 01 fuel tank and fuel pump 187
• Warning 187
• Fuel tank 188
• Removal 188
• Section 04 fuel system 188
• Subsection 01 fuel tank and fuel pump 188
• Float type fuel level gauge 189
• Installation 189
• Section 04 fuel system subsection 01 fuel tank and fuel pump 189
• Warning 189
• Electric fuel level sensor 190
• Fuel system pressurization 190
• High pressure test electric fuel pump circuit 190
• Inspection 190
• Section 04 fuel system 190
• Subsection 01 fuel tank and fuel pump 190
• All models except sdi 191
• Diaphragm fuel pump 191
• Section 04 fuel system subsection 01 fuel tank and fuel pump 191
• Sdi models 192
• Section 04 fuel system 192
• Subsection 01 fuel tank and fuel pump 192
• Cleaning and inspection 193
• Installation 193
• Pump verification 193
• Removal 193
• Section 04 fuel system subsection 01 fuel tank and fuel pump 193
• Warning 193
• Carburetors throttle and choke cables 194
• Section 04 fuel system 194
• Service tools 194
• Subsection 02 carburetors throttle and choke cables 194
• Carburetor vm type 195
• Section 04 fuel system subsection 02 carburetors throttle and choke cables 195
• Cleaning and inspection 196
• Disassembly and assembly 196
• E clip and needle 196
• Identification 196
• Removal 196
• Section 04 fuel system 196
• Subsection 02 carburetors throttle and choke cables 196
• Warning 196
• Carburetor adjustments 197
• Float arm 197
• Float bowl 197
• Main jet 197
• Needle valve assembly 197
• Pilot jet 197
• Section 04 fuel system subsection 02 carburetors throttle and choke cables 197
• E clip and needle 198
• Section 04 fuel system 198
• Subsection 02 carburetors throttle and choke cables 198
• Air screw adjustment 199
• Section 04 fuel system subsection 02 carburetors throttle and choke cables 199
• Throttle slide height preliminary idle speed adjustment 199
• Carburetor synchronization 200
• Installation 200
• Section 04 fuel system 200
• Subsection 02 carburetors throttle and choke cables 200
• Choke plunger adjustment 201
• Idle speed adjustment 201
• Section 04 fuel system subsection 02 carburetors throttle and choke cables 201
• Section 04 fuel system 202
• Subsection 02 carburetors throttle and choke cables 202
• Carburetor tm type 203
• Section 04 fuel system subsection 02 carburetors throttle and choke cables 203
• Carburetors 204
• Identification 204
• Removal 204
• Section 04 fuel system 204
• Subsection 02 carburetors throttle and choke cables 204
• Throttle oil pump cable 204
• Throttle position sensor tps 204
• Section 04 fuel system subsection 02 carburetors throttle and choke cables 205
• Warning 205
• Cleaning and inspection 206
• Disassembly and assembly 206
• Float and needle valve assembly 206
• Float bowl 206
• Main jet 206
• Section 04 fuel system 206
• Subsection 02 carburetors throttle and choke cables 206
• Warning 206
• Pilot jet 207
• Section 04 fuel system subsection 02 carburetors throttle and choke cables 207
• Throttle slide 207
• Warning 207
• Carburetor adjustments 208
• Carburetors 208
• Installation 208
• Section 04 fuel system 208
• Subsection 02 carburetors throttle and choke cables 208
• Throttle oil pump cable 208
• Carburetor synchronization and throttle slide height preliminary idle speed adjustment 209
• Pilot screw adjustment 209
• Section 04 fuel system subsection 02 carburetors throttle and choke cables 209
• Adjustment 210
• Choke cable 210
• Idle speed adjustment 210
• Section 04 fuel system 210
• Subsection 02 carburetors throttle and choke cables 210
• Throttle cable adjustment 210
• Section 04 fuel system subsection 02 carburetors throttle and choke cables 211
• Dpm system 212
• Engine leak test kit 529 021 800 196 212
• Section 04 fuel system 212
• Service tools 212
• Subsection 03 dpm system 212
• Section 04 fuel system subsection 03 dpm system 213
• Air temperature sensor 214
• Overview 214
• Parts removal and installation 214
• Section 04 fuel system 214
• Solenoid 214
• Solenoid and mpem 214
• Subsection 03 dpm system 214
• System testing 214
• Dpm manifold testing 215
• Leak testing 215
• Section 04 fuel system subsection 03 dpm system 215
• Visual inspection 215
• Section 04 fuel system 216
• Subsection 03 dpm system 216
• Section 04 fuel system subsection 03 dpm system 217
• Overview 218
• Section 05 engine management power tek 218
• Service tools 218
• Subsection 01 overview 218
• Vck vehicle communication kit 529 035 981 202 203 218
• Carburetors and dpm system 219
• Engine management system ems 219
• Fuel delivery system 219
• Fuel pump 219
• Operating principle 219
• Section 05 engine management power tek subsection 01 overview 219
• Ems engine management system functions 220
• Section 05 engine management power tek 220
• Subsection 01 overview 220
• Digitally encoded security system dess 221
• Electronically controlled rave 221
• Engine rpm limiter 221
• Ignition system 221
• Knock sensor 221
• Power distribution 221
• Section 05 engine management power tek subsection 01 overview 221
• Diagnostic mode 222
• Engine starting 222
• High coolant temperature warning device 222
• Low oil level warning device 222
• Monitoring system 222
• Rotax electronic reverse rer 222
• Section 05 engine management power tek 222
• Subsection 01 overview 222
• Diagnostic procedures 223
• General 223
• Monitoring beeper and light coded signals 223
• Section 05 engine management power tek 223
• Service tools 223
• Subsection 02 diagnostic procedures 223
• Troubleshooting 223
• 1 see ems fault code table for more details 224
• Ems fault codes 224
• Fault code p0336 this code occurs when engine rpm goes too high which could happen under some mechanical related circumstances and is not necessarily related to a problem with the engine management system 224
• Fault code p0654 if this code occurs and tachometer works normally disregard this fault code 224
• General 224
• Section 05 engine management power tek subsection 02 diagnostic procedures 224
• Supplemental information 224
• The faults registered in the ecm engine control module are kept when the battery is disconnected important after a problem has been solved ensure to clear the fault s in the ecm using the vck this will properly reset their states many fault codes at the same time is likely to be burnt fuse s for more information pertaining to the code faults status and report refer to b u d s online help or to the ems fault code table 224
• When using the service action suggested in the fault section of b u d s the system circuits are referred to as da 41 which means connector on the ecm and the circuit 41 224
• Fault code p1102 tps out of range fault it is caused by the sensor reading going out of its allowable range this fault can occur during the whole range of movement of the throttle to diagnose this fully it is recommended to operate the throttle through its full range it is also recom mended to release the throttle quickly as this may also reveal a fault that is intermittent 225
• Fault code p1104 tps adaptation failure fault it is caused by the idle position moving out of an acceptable range following problems can be caused by a tps adaption failure idle speed is out of range engine stops when throttle is released quickly engine runs inconsistent in low partload or low rpm 225
• Section 05 engine management power tek 225
• Subsection 02 diagnostic procedures 225
• Ems fault code table 226
• Section 05 engine management power tek subsection 02 diagnostic procedures 226
• Connecting vck to vehicle 227
• General 227
• Section 05 engine management power tek 227
• Subsection 02 diagnostic procedures 227
• Vck supply 227
• Vck vehicle communication kit 227
• Warning 227
• Section 05 engine management power tek subsection 02 diagnostic procedures 228
• Section 05 engine management power tek 229
• Subsection 02 diagnostic procedures 229
• Component inspection replacement and adjustment 230
• Electrical system 230
• General 230
• Section 05 engine management power tek 230
• Service tools 230
• Subsection 03 component inspection replacement and adjustment 230
• Ecm connector 231
• Resistance measurement 231
• Section 05 engine management power tek subsection 03 component inspection replacement and adjustment 231
• Dpm digital performance management 232
• Fuel system 232
• Refer to fuel system as necessary check that the throttle slides move freely and smoothly when depressing throttle lever before replacing any part check the following as these could be causing the fault perform the test while the engine is not running throttle cable adjustment too tight or there is not enough free play not returning fully to idle stop throttle idle set screw is loose or worn tps is loose corroded or damaged wiring or connectors throttle cable or carburetor s has ve been re placed and the closed throttle reset has not been performed ecm has been replaced and the closed throt tle reset has not been performed 232
• Section 05 engine management power tek 232
• Subsection 03 component inspection replacement and adjustment 232
• The resistance value of a temperature sensor may test good at a certain temperature but it might be defective at other temperatures if in doubt try a new sensor also remember this validates the operation of the sensor at room temperature it does not validate the over temperature functionality to test it the sensor could be removed from the engine air si lencer and heated with a heat gun while it is still connected to the harness to see if the ecm will detect the high temperature condition and gener ate a fault code 232
• To test dpm manifold refer to fuel system the dpm solenoid verification is covered in this section 232
• Ecm replacement 233
• Engine control module ecm 233
• Engine management system 233
• General 233
• Power relay 233
• Section 05 engine management power tek subsection 03 component inspection replacement and adjustment 233
• Warning 233
• General 234
• Section 05 engine management power tek 234
• Subsection 03 component inspection replacement and adjustment 234
• Throttle position sensor tps 234
• Wear test 234
• Section 05 engine management power tek subsection 03 component inspection replacement and adjustment 235
• Voltage test 235
• Replacement 236
• Resistance test 236
• Section 05 engine management power tek 236
• Subsection 03 component inspection replacement and adjustment 236
• Closed throttle reset tps 237
• Section 05 engine management power tek subsection 03 component inspection replacement and adjustment 237
• Air temperature sensor ats 238
• Dynamic test 238
• Section 05 engine management power tek 238
• Subsection 03 component inspection replacement and adjustment 238
• Coolant temperature sensor cts 239
• Dynamic test 239
• Replacement 239
• Resistance test 239
• Section 05 engine management power tek subsection 03 component inspection replacement and adjustment 239
• Air pressure sensor aps 240
• Dynamic test 240
• Replacement 240
• Section 05 engine management power tek 240
• Subsection 03 component inspection replacement and adjustment 240
• Dynamic test 241
• Knock sensor ks 241
• Replacement 241
• Section 05 engine management power tek subsection 03 component inspection replacement and adjustment 241
• E rave solenoid 242
• Heating element 242
• Replacement 242
• Section 05 engine management power tek 242
• Subsection 03 component inspection replacement and adjustment 242
• Dpm solenoid 243
• Electrical test 243
• Ignition coil 243
• Replacement 243
• Section 05 engine management power tek subsection 03 component inspection replacement and adjustment 243
• Engine start rer switch 244
• Resistance test 244
• Section 05 engine management power tek 244
• Subsection 03 component inspection replacement and adjustment 244
• Digitally encoded security system dess 245
• Rer operation 245
• Section 05 engine management power tek subsection 03 component inspection replacement and adjustment 245
• Dess post verification tether cord cap on dess post 246
• Dess post verification tether cord cap removed 246
• Section 05 engine management power tek 246
• Subsection 03 component inspection replacement and adjustment 246
• Overview 247
• Air induction 248
• Charging system 248
• Ignition system 248
• Operating principle 248
• Section 06 engine management sdi subsection 01 overview 248
• Diaphragm fuel pump 249
• Electric fuel pump and fuel pressure regulator 249
• Fuel delivery system 249
• Fuel injectors 249
• Fuel rail 249
• In line fuel filter 249
• Section 06 engine management sdi 249
• Subsection 01 overview 249
• Throttle body 249
• Engine management system ems 250
• Section 06 engine management sdi subsection 01 overview 250
• Automatic power shut down 251
• Digitally encoded security system dess 251
• Ecm general functions 251
• Section 06 engine management sdi 251
• Subsection 01 overview 251
• Engine rpm limiter 252
• Engine starting 252
• Gauges current supply 252
• High coolant temperature warning device 252
• Low oil level warning device 252
• Power distribution 252
• Section 06 engine management sdi subsection 01 overview 252
• Electronic fuel injection 253
• Ems engine management system functions 253
• Section 06 engine management sdi 253
• Subsection 01 overview 253
• Electronically controlled rave 254
• Engine modes of operation 254
• Flooded engine drowned mode 254
• Ignition timing 254
• Knock sensor 254
• Limp home modes 254
• Monitoring system 254
• Section 06 engine management sdi subsection 01 overview 254
• Diagnostic mode 255
• Rotax electronic reverse rer 255
• Section 06 engine management sdi 255
• Subsection 01 overview 255
• Diagnostic procedures 256
• General 256
• Monitoring beeper coded signals 256
• Section 06 engine management sdi 256
• Service tools 256
• Subsection 02 diagnostic procedures 256
• Troubleshooting 256
• Many other codes use the engine pilot lamp and the beeper to indicate a problem refer to b u d s for possible causes and service actions 257
• Section 06 engine management sdi subsection 02 diagnostic procedures 257
• Section 06 engine management sdi 258
• Subsection 02 diagnostic procedures 258
• Section 06 engine management sdi subsection 02 diagnostic procedures 259
• Connecting vck to vehicle 260
• Section 06 engine management sdi 260
• Subsection 02 diagnostic procedures 260
• Vck supply 260
• Vck vehicle communication kit 260
• Warning 260
• Section 06 engine management sdi subsection 02 diagnostic procedures 261
• General 262
• Section 06 engine management sdi 262
• Subsection 02 diagnostic procedures 262
• Supplemental information 262
• Tec system fault codes 262
• Tps throttle position sensor faults 262
• Writing in ecm 262
• It is caused by the idle position moving out of an acceptable range following problems can be caused by a tps adaption failure idle speed is out of range engine stops when throttle is released quickly engine runs inconsistent in low partload or low rpm 263
• It is caused by the sensor reading going out of its allowable range this fault can occur during the whole range of movement of the throttle to diagnose this fully it is recommended to operate the throttle through its full range it is also recom mended to release the throttle quickly as this may also reveal a fault that is intermittent 263
• Section 06 engine management sdi subsection 02 diagnostic procedures 263
• Tps adaptation failure fault 263
• Tps out of range fault 263
• Component inspection replacement and adjustment 264
• Fuel system 264
• General 264
• Service products 264
• Service tools 264
• Warning 264
• Electrical system 265
• Section 06 engine management sdi subsection 03 component inspection replacement and adjustment 265
• Warning 265
• Resistance measurement 266
• Section 06 engine management sdi 266
• Subsection 03 component inspection replacement and adjustment 266
• Warning 266
• Connector position 267
• Ecm connector 267
• Engine connector pin outs 267
• Section 06 engine management sdi subsection 03 component inspection replacement and adjustment 267
• The resistance value of a temperature sensor may test good at a certain temperature but it might be defective at other temperatures if in doubt try a new sensor also remember this validates the operation of the sensor at room temperature it does not validate the over temperature functionality to test it the sensor could be removed from the engine air si lencer and heated with a heat gun while it is still connected to the harness to see if the ecm will detect the high temperature condition and gener ate a fault code 267
• Use this diagram to locate the pin numbers on the ecm connector of the wiring harness when performing tests 267
• Engine connector 268
• Relay 2 268
• Section 06 engine management sdi 268
• Subsection 03 component inspection replacement and adjustment 268
• Air induction system 269
• Electrical inspection 269
• Mechanical inspection 269
• Replacement 269
• Section 06 engine management sdi subsection 03 component inspection replacement and adjustment 269
• Throttle body 269
• Adjustment 270
• Section 06 engine management sdi 270
• Subsection 03 component inspection replacement and adjustment 270
• Section 06 engine management sdi subsection 03 component inspection replacement and adjustment 271
• Fuel delivery 272
• Section 06 engine management sdi 272
• Subsection 03 component inspection replacement and adjustment 272
• Electric fuel pump 273
• Fuel pressure test 273
• Section 06 engine management sdi subsection 03 component inspection replacement and adjustment 273
• Warning 273
• Electric fuel pump replacement 274
• Electrical test 274
• In line fuel filter replacement 274
• Section 06 engine management sdi 274
• Subsection 03 component inspection replacement and adjustment 274
• Installation 275
• Section 06 engine management sdi subsection 03 component inspection replacement and adjustment 275
• Fuel pressure regulator replacement 276
• Fuel rail 276
• Fuel rail replacement 276
• Installation 276
• Section 06 engine management sdi 276
• Subsection 03 component inspection replacement and adjustment 276
• Warning 276
• Fuel injectors 277
• Leakage test and fuel flow measurement 277
• Section 06 engine management sdi subsection 03 component inspection replacement and adjustment 277
• Electrical test 278
• Resistance test 278
• Section 06 engine management sdi 278
• Subsection 03 component inspection replacement and adjustment 278
• Fuel injector replacement 279
• Section 06 engine management sdi subsection 03 component inspection replacement and adjustment 279
• Warning 279
• Ecm replacement 280
• Electronic management 280
• Engine wiring harness 280
• General 280
• Resistance test 280
• Section 06 engine management sdi 280
• Subsection 03 component inspection replacement and adjustment 280
• Warning 280
• General 281
• Installation 281
• Removal 281
• Section 06 engine management sdi subsection 03 component inspection replacement and adjustment 281
• Throttle position sensor tps 281
• Voltage test 281
• Wear test 281
• Closed throttle reset 282
• Replacement 282
• Resistance test 282
• Section 06 engine management sdi 282
• Subsection 03 component inspection replacement and adjustment 282
• Crankshaft position sensor cps 283
• Resistance test 283
• Section 06 engine management sdi subsection 03 component inspection replacement and adjustment 283
• Air temperature sensor ats 284
• Replacement 284
• Resistance test 284
• Section 06 engine management sdi 284
• Subsection 03 component inspection replacement and adjustment 284
• Coolant temperature sensor cts 285
• Replacement 285
• Resistance test 285
• Section 06 engine management sdi subsection 03 component inspection replacement and adjustment 285
• Air pressure sensor aps 286
• Exhaust gas temperature sensor egts 286
• Replacement 286
• Resistance test 286
• Section 06 engine management sdi 286
• Subsection 03 component inspection replacement and adjustment 286
• Voltage test 286
• Dynamic test 287
• Knock sensor ks 287
• Replacement 287
• Section 06 engine management sdi subsection 03 component inspection replacement and adjustment 287
• Continuity test 288
• Double ignition coil 288
• E rave solenoid 288
• Replacement 288
• Resistance test 288
• Section 06 engine management sdi 288
• Subsection 03 component inspection replacement and adjustment 288
• Voltage test 288
• Resistance test 289
• Section 06 engine management sdi subsection 03 component inspection replacement and adjustment 289
• Voltage test 289
• Warning 289
• Battery 290
• Battery charge testing 290
• Capacitor 290
• Ignition timing 290
• Inspection 290
• Removal 290
• Section 06 engine management sdi 290
• Subsection 03 component inspection replacement and adjustment 290
• Warning 290
• Engine start rer switch verification 291
• Installation 291
• Rer operation 291
• Section 06 engine management sdi subsection 03 component inspection replacement and adjustment 291
• Warning 291
• Dess post verification 292
• Section 06 engine management sdi 292
• Subsection 03 component inspection replacement and adjustment 292
• Tether cord cap on dess post 292
• Tether cord cap removed 292
• General 293
• Ignition system 293
• Ignition system testing sequence 293
• Section 07 electrical system 293
• Service products 293
• Service tools 293
• Subsection 01 ignition system 293
• Dess post or tether cut out switch 294
• Electrical connector 294
• Engine cut out switch 294
• Ignition switch or start rer button 294
• Section 07 electrical system subsection 01 ignition system 294
• Spark testing 294
• Disconnect housing between the magneto and the mpem compare readings with those appearing in the ig nition coil table during voltage testing when manually starting the engine while the spark plug is installed the engine will tend to accelerate beyond the compression point this will result in higher magneto output always repeat the procedure 3 times 295
• Fan cooled engines 295
• Ignition coil 295
• Liquid cooled engines 295
• Note for sdi engine refer to engine man agement check the resistance and the voltage for each trig ger coil 295
• Resistance 295
• Section 07 electrical system 295
• Subsection 01 ignition system 295
• Test probes 295
• Trigger coil 295
• Voltage 295
• Beeper 296
• Fan cooled engines if for any reason ignition timing accuracy is sus pected it can be verified as follows 296
• If a trigger coil is out of specification replace it 296
• Ignition timing 296
• Install probes on wires in accordance with the fol lowing table activate the manual starter and check values indi cated by the multimeter repeat test 3 times 296
• Note for sdi and power tek engines refer to engine management for more information concerning the engine control module ecm when other components have been tested above and are good the electronic module can be sus pected ensure wiring and connectors are in good condition and perform the following tests prior to replacing the electronic module disconnect the connector housing between mod ule and high voltage coil 296
• Refer to accessories 296
• Refer to accessories or engine manage ment power tek and sdi engines 296
• Section 07 electrical system subsection 01 ignition system 296
• Section 07 electrical system 297
• Subsection 01 ignition system 297
• Verifying magneto flywheel timing mark position 297
• Checking ignition timing 298
• Section 07 electrical system subsection 01 ignition system 298
• Scribing a timing mark 299
• Section 07 electrical system 299
• Subsection 01 ignition system 299
• Warning 299
• Checking ignition timing 300
• Section 07 electrical system subsection 01 ignition system 300
• Warning 300
• Changing timing 301
• Section 07 electrical system 301
• Subsection 01 ignition system 301
• Section 07 electrical system subsection 01 ignition system 302
• Section 07 electrical system 303
• Subsection 01 ignition system 303
• After the programmer has verified following mes sage will appear 304
• During a very short period of time the following message will appear 304
• If the new correction factor selected above is the good one select no and press enter otherwise select yes to choose an other correction factor 304
• Press any key 304
• Press enter 304
• Press menu scroll to no 7 save and quit 304
• Section 07 electrical system subsection 01 ignition system 304
• Installation 305
• Removal 305
• Section 07 electrical system 305
• Spark plug 305
• Subsection 01 ignition system 305
• Warning 305
• Design symbols used in ngk spark plugs 306
• Charging generator coil stator 307
• Charging system 307
• General 307
• Section 07 electrical system subsection 02 charging system 307
• Service products 307
• Service tools 307
• If the voltage regulator rectifier is within the spec ification the wiring harness between the voltage regulator rectifier and battery is defective if the voltage regulator rectifier is out of specification and the stator tests good the voltage regula tor rectifier is defective 308
• Section 07 electrical system subsection 02 charging system 308
• To test the voltage regulator rectifier use the fol lowing table 308
• Voltage regulator rectifier 308
• Battery 309
• Cleaning 309
• General 309
• Inspection 309
• Installation 309
• Removal 309
• Section 07 electrical system subsection 02 charging system 309
• Warning 309
• Activation of new battery 310
• Battery charge testing 310
• Battery charging 310
• Battery storage 310
• Section 07 electrical system subsection 02 charging system 310
• Warning 310
• Cable terminal installation 311
• Installation 311
• Section 07 electrical system subsection 02 charging system 311
• Warning 311
• Section 07 electrical system subsection 02 charging system 312
• Multimeter fluke 111 529 035 868 301 302 313
• Section 07 electrical system 313
• Service products 313
• Service tools 313
• Starting system 313
• Subsection 03 starting system 313
• Synthetic grease 413 711 500 303 305 313
• Section 07 electrical system subsection 03 starting system 314
• Battery 315
• Check the condition of engine cut out switch 315
• Engine cut out switch 315
• Fan cooled engines models disconnect switch housing using the multimeter fluke 111 p n 529 035 868 check between mag and grd terminals if the circuit is open o l in operating position and if it is closed 0 315
• If the switch functions correctly continue with the next tests 315
• Ignition switch 315
• In off position 315
• Liquid cooled engines models check if the start rer button works perfectly 315
• Make sure the charging fuse 30 a on battery and the mpem fuse 5 a on electrical harness are in good condition if the fuses test good continue with the next tests 315
• Refer to charging system to check battery condition if the test is good continue with the next tests 315
• Section 07 electrical system 315
• Start rer button 315
• Subsection 03 starting system 315
• Troubleshooting 315
• When the ignition switch is turned on or the start button is pressed a signal is sent to the starting solenoid the battery then supplies current to the starter through the starting solenoid to turn the engine in case of problems first ensure the problem is not related to engine mechanical components if not test the starting system causes of problems are not necessarily related to starter but may be due to a burnt fuse faulty bat tery start button or ignition switch engine cut out switch starting solenoid electrical cables and connections or the electronic module check these components before removing starter 315
• Electric starter 316
• Electrical cables and connections 316
• Electronic module 316
• Section 07 electrical system subsection 03 starting system 316
• Starter removal 316
• Starting solenoid 316
• Warning 316
• Section 07 electrical system 317
• Starter cleaning 317
• Starter disassembly 317
• Subsection 03 starting system 317
• Warning 317
• Section 07 electrical system subsection 03 starting system 318
• Starter inspection 318
• Section 07 electrical system 319
• Starter assembly 319
• Subsection 03 starting system 319
• Section 07 electrical system subsection 03 starting system 320
• Starter installation 320
• Warning 320
• Accessories 321
• General 321
• Lighting and accessories system testing 321
• Service tools 321
• Warning 321
• Beeper reverse alarm 322
• Installation 322
• Removal 322
• Section 07 electrical system subsection 04 accessories 322
• Volt power outlet cigarette lighter type 322
• Engine temperature gauge 323
• Installation 323
• Section 07 electrical system 323
• Subsection 04 accessories 323
• Bulb replacement 324
• Electric fuel gauge 324
• Headlamp 324
• Installation 324
• Removal 324
• Section 07 electrical system subsection 04 accessories 324
• Headlamp beam aiming 325
• Installation 325
• Removal 325
• Section 07 electrical system 325
• Subsection 04 accessories 325
• Continuity test 326
• Current measurement 326
• Handlebar grip heating element 326
• Heating elements 326
• Note all measurements must be performed at 21 c 70 f 326
• Position the red probe on the terminal 30 and the black probe on the terminal 87a 326
• Remove the relay from vehicle using the multimeter fluke 111 p n 529 035 868 select the beeper position 326
• Resistance measurement all models except sdi 326
• Sdi models 326
• Section 07 electrical system subsection 04 accessories 326
• Throttle lever heating element 326
• Voltage test 326
• When measuring resistance at terminals the ac tual value will be half the measurement in table the reason for that is the elements are connect ed in parallel therefore the total resistance is half the resistance of one element if the heating elements are good check connec tors and wiring harness 326
• Installation 327
• Removal 327
• Section 07 electrical system 327
• Speed sensor 327
• Speedometer 327
• Subsection 04 accessories 327
• Bulb replacement 328
• Section 07 electrical system subsection 04 accessories 328
• Tachometer 328
• Taillight 328
• Installation 329
• Removal 329
• Section 07 electrical system 329
• Subsection 04 accessories 329
• Visor outlet 329
• Application chart 330
• Checking neutral function 330
• Drive belt 330
• Inspection 330
• Rotation direction 330
• Service tools 330
• Warning 330
• Adjustment 331
• Drive belt height measurement and adjustment 331
• Measurement 331
• Section 08 drive system subsection 01 drive belt 331
• Section 08 drive system 332
• Subsection 01 drive belt 332
• Drive belt deflection measurement reference only 333
• Section 08 drive system subsection 01 drive belt 333
• To check tension 333
• Section 08 drive system 334
• Subsection 01 drive belt 334
• Drive pulley 335
• Section 08 drive system subsection 02 drive pulley 335
• Service products 335
• Service tools 335
• All fan cooled models note this drive pulley is lubrication free 336
• Bombardier lite 336
• Section 08 drive system subsection 02 drive pulley 336
• Disassembly 337
• General 337
• Removal 337
• Section 08 drive system subsection 02 drive pulley 337
• Warning 337
• Assembly 338
• Cleaning 338
• Inspection 338
• Section 08 drive system subsection 02 drive pulley 338
• Installation 339
• Section 08 drive system subsection 02 drive pulley 339
• Warning 339
• All liquid cooled models note these are lubrication free drive pulleys always refer to appropriate parts catalog for replacement part most parts of tra iii are not interchangeable with those of the tra 340
• Section 08 drive system subsection 02 drive pulley 340
• Tra iii 340
• Disassembly 341
• Fixed half 341
• General 341
• Removal 341
• Ring gear 341
• Section 08 drive system subsection 02 drive pulley 341
• Warning 341
• Section 08 drive system subsection 02 drive pulley 342
• Slider shoe and governor cup 342
• Spring cover 342
• Warning 342
• Bushings 343
• Cleaning 343
• Fixed and sliding halves 343
• Inspection 343
• Lever bolt and flanged bushing 343
• Section 08 drive system subsection 02 drive pulley 343
• Thrust washer and roller 343
• Fixed half and governor cup 344
• O ring and slider shoe 344
• Section 08 drive system subsection 02 drive pulley 344
• Sliding half and spring cover bushings 344
• Assembly 345
• Ring gear 345
• Section 08 drive system subsection 02 drive pulley 345
• Always use the same type of pin no 25 as original ly installed when servicing different types have different weights for calibration purpose refer to technical data 346
• Calibration screw washer and locking nut 346
• Dowel tube and ramp 346
• Insert dowel tube no 26 from chamfered side make sure ramp no 27 is centered on dowel tube 346
• Position dowel tube split at the angle a 346
• Section 08 drive system subsection 02 drive pulley 346
• The calibration screws should be installed at the following position 346
• Torque locking nut no 24 to 10 n m 89 lbf in 346
• Torque screws no 28 to 10 n m 89 lbf in 346
• When installing calibration screw no 22 make sure to install washer no 23 as shown 346
• Fixed half sliding half spring and spring cover 347
• Lever nut and cotter pin 347
• Section 08 drive system subsection 02 drive pulley 347
• Warning 347
• Section 08 drive system subsection 02 drive pulley 348
• Sliding half slider shoe and governor cup 348
• Drive pulley adjustment 349
• Drive pulley ass y 349
• Installation 349
• Section 08 drive system subsection 02 drive pulley 349
• Warning 349
• Section 08 drive system subsection 02 drive pulley 350
• Driven pulley 351
• Section 08 drive system 351
• Service products 351
• Service tools 351
• Subsection 03 driven pulley 351
• Formula rer and formula vsa r 352
• Section 08 drive system subsection 03 driven pulley 352
• Bushings 353
• Cleaning 353
• Countershaft 353
• Disassembly 353
• Inspection 353
• Large bushing and small bushing 353
• Pulley half cleaning 353
• Removal 353
• Section 08 drive system 353
• Subsection 03 driven pulley 353
• Warning 353
• Assembly 354
• Bushing replacement 354
• Cam slider shoe 354
• Large bushing 354
• Section 08 drive system subsection 03 driven pulley 354
• Slider shoe 354
• Cam and spring 355
• Countershaft 355
• Installation 355
• Pulley retaining screw 355
• Section 08 drive system 355
• Subsection 03 driven pulley 355
• Adjustment 356
• Pulley alignment and drive belt deflection 356
• Section 08 drive system subsection 03 driven pulley 356
• Spring 356
• Hpv vsa 357
• Section 08 drive system 357
• Subsection 03 driven pulley 357
• Assembly 358
• Cam slider shoe 358
• Cleaning 358
• Countershaft 358
• Disassembly 358
• Inspection 358
• Large bushing and small bushing 358
• Pulley half cleaning 358
• Removal 358
• Section 08 drive system subsection 03 driven pulley 358
• Slider shoe 358
• Warning 358
• Adjustment 359
• Countershaft 359
• Installation 359
• Screws 359
• Section 08 drive system 359
• Spring 359
• Subsection 03 driven pulley 359
• Pulley alignment and drive belt height 360
• Section 08 drive system subsection 03 driven pulley 360
• General 361
• Measuring procedure 361
• Pulley alignment 361
• Service tools 361
• Warning 361
• Always measure distances x and y from the far ther straight bar side including its thickness to the fixed half edge 362
• Exceed distance x to com pensate for the twist due to the engine torque 362
• If an alignment is necessary see alignment procedure below 362
• Insert the alignment bar p n 529 035 831 into the opened driven pulley 362
• Measure the distance between both pulleys to know if the engine and the frame are positioned correctly the distance pulley is not adjustable on the rev serie vehicles 362
• Section 08 drive system subsection 04 pulley alignment 362
• The distance 362
• Alignment procedure 363
• Section 08 drive system 363
• Subsection 04 pulley alignment 363
• Section 08 drive system 364
• Service products 364
• Service tools 364
• Subsection 05 brake 364
• Hydraulic brake 365
• Section 08 drive system subsection 05 brake 365
• Brake fluid 366
• Caliper 366
• Inspection 366
• Installation 366
• Master cylinder 366
• Removal 366
• Section 08 drive system 366
• Subsection 05 brake 366
• Brake pads 367
• Inspection 367
• Removal 367
• Section 08 drive system subsection 05 brake 367
• Brake disc 368
• Countershaft bearing 368
• Inspection 368
• Installation 368
• Removal 368
• Section 08 drive system 368
• Subsection 05 brake 368
• Warning 368
• Brake light switch 369
• Countershaft 369
• Inspection 369
• Installation 369
• Removal 369
• Section 08 drive system subsection 05 brake 369
• Bleeding 370
• Installation 370
• Section 08 drive system 370
• Subsection 05 brake 370
• Warning 370
• Chaincase 371
• Drive axle holder 529 007 200 364 371
• Loctite 271 red 293 800 005 365 xp s chaincase oil 413 801 900 363 xp s synthetic chaincase oil 413 803 300 363 371
• Section 08 drive system 371
• Service products 371
• Service tools 371
• Subsection 06 chaincase 371
• Section 08 drive system subsection 06 chaincase 372
• Chaincase oil level 373
• Draining procedure 373
• Filling procedure 373
• General 373
• Oil change 373
• Section 08 drive system 373
• Subsection 06 chaincase 373
• Warning 373
• Drive chain adjustment 374
• Removal and disassembly 374
• Section 08 drive system subsection 06 chaincase 374
• Warning 374
• Inspection 375
• Installation and assembly 375
• Section 08 drive system 375
• Silent chain 375
• Subsection 06 chaincase 375
• Drive axle 376
• Drive axle sprocket adjuster kit 861 725 700 373 376
• Section 08 drive system 376
• Service products 376
• Service tools 376
• Subsection 07 drive axle 376
• Suspension synthetic grease 293 550 033 373 376
• All fan cooled models 377
• Section 08 drive system subsection 07 drive axle 377
• Gsx limited and sport gtx limited and sport mx z adrenaline renegade renegade x and trail models 378
• Section 08 drive system 378
• Subsection 07 drive axle 378
• Mx z x summit adrenaline and summit x models 379
• Section 08 drive system subsection 07 drive axle 379
• Removal 380
• Section 08 drive system 380
• Sprocket and half sprocket 380
• Subsection 07 drive axle 380
• Assembly 381
• Drive axle and sprocket 381
• Section 08 drive system subsection 07 drive axle 381
• Adjustment 382
• Bearing 382
• Bearing protector 382
• Lubrication 382
• Section 08 drive system 382
• Sprocket track alignment 382
• Subsection 07 drive axle 382
• Adjustment 384
• General 384
• Inspection 384
• Installation 384
• Removal 384
• Service tools 384
• Tension 384
• Track tension and alignment 384
• Track type application 384
• Warning 384
• Alignment 385
• Section 08 drive system subsection 08 track 385
• Warning 385
• Important safety rules 386
• Installation 386
• Removal 386
• Section 08 drive system 386
• Subsection 08 track 386
• Track cleat 386
• Traction enhancing products studs 386
• Warning 386
• Effects of studding on the life of the snowmobile 387
• Installation 387
• Maintenance replacement 387
• Section 08 drive system subsection 08 track 387
• Warning 387
• Section 08 drive system 388
• Subsection 08 track 388
• Sc suspension 389
• Section 09 rear suspension 389
• Service products 389
• Subsection 01 sc suspension 389
• Suspension synthetic grease 293 550 033 393 389
• Section 09 rear suspension subsection 01 sc suspension 390
• Expedition sport gtx summit fan cooled models 391
• Section 09 rear suspension 391
• Subsection 01 sc suspension 391
• Section 09 rear suspension subsection 01 sc suspension 392
• Summit liquid cooled models 392
• Section 09 rear suspension 393
• Subsection 01 sc suspension 393
• Axle self locking screws removal 394
• Rear axle installation 394
• Rear axle removal 394
• Rear shock absorber removal 394
• Section 09 rear suspension subsection 01 sc suspension 394
• Front shock absorber installation 395
• Front shock absorber removal 395
• Rear shock absorber installation 395
• Section 09 rear suspension 395
• Subsection 01 sc suspension 395
• Rear spring installation 396
• Rear spring removal 396
• Section 09 rear suspension subsection 01 sc suspension 396
• Slider shoe verification 396
• Warning 396
• Section 09 rear suspension 397
• Slider shoe removal 397
• Subsection 01 sc suspension 397
• Section 09 rear suspension subsection 01 sc suspension 398
• Slider shoe installation 398
• Suspension removal 398
• Front arm installation 399
• Front arm removal 399
• Section 09 rear suspension 399
• Subsection 01 sc suspension 399
• Suspension installation 399
• Rear arm installation 400
• Rear arm pivot arm removal 400
• Section 09 rear suspension subsection 01 sc suspension 400
• Stopper strap 400
• Lubricate front and rear arms at grease fittings using suspension synthetic grease p n 293 550 033 401
• Lubrication 401
• Refer to the appropriate operator s guide 401
• Ride adjustment 401
• Section 09 rear suspension 401
• Subsection 01 sc suspension 401
• Sc 3 suspension 402
• Section 09 rear suspension subsection 02 sc 3 suspension 402
• Service products 402
• Suspension synthetic grease 293 550 033 406 402
• Section 09 rear suspension subsection 02 sc 3 suspension 403
• Section 09 rear suspension subsection 02 sc 3 suspension 404
• Section 09 rear suspension subsection 02 sc 3 suspension 405
• Axle self locking screws removal 406
• Rear axle installation 406
• Rear axle removal 406
• Rear shock absorber removal 406
• Section 09 rear suspension subsection 02 sc 3 suspension 406
• Front shock absorber installation 407
• Front shock absorber removal 407
• Rear shock absorber installation 407
• Rear spring removal 407
• Section 09 rear suspension subsection 02 sc 3 suspension 407
• Rear spring installation 408
• Section 09 rear suspension subsection 02 sc 3 suspension 408
• Warning 408
• Section 09 rear suspension subsection 02 sc 3 suspension 409
• Slider shoe removal 409
• Slider shoe verification 409
• Section 09 rear suspension subsection 02 sc 3 suspension 410
• Slider shoe installation 410
• Suspension removal 410
• Front arm removal 411
• Section 09 rear suspension subsection 02 sc 3 suspension 411
• Suspension installation 411
• Front arm installation 412
• Rear arm pivot arm installation 412
• Rear arm pivot arm removal 412
• Section 09 rear suspension subsection 02 sc 3 suspension 412
• Lubrication 413
• Ride adjustment 413
• Section 09 rear suspension subsection 02 sc 3 suspension 413
• Stopper strap 413
• Sc 4 suspension 415
• Section 09 rear suspension subsection 03 sc 4 suspension 415
• Service products 415
• Suspension synthetic grease 293 550 033 421 415
• Section 09 rear suspension subsection 03 sc 4 suspension 416
• Section 09 rear suspension subsection 03 sc 4 suspension 417
• Section 09 rear suspension subsection 03 sc 4 suspension 418
• Axle self locking screw removal 419
• Rear axle installation 419
• Rear axle removal 419
• Rear shock absorber removal 419
• Section 09 rear suspension subsection 03 sc 4 suspension 419
• Front shock absorber removal 420
• Rear shock absorber installation 420
• Section 09 rear suspension subsection 03 sc 4 suspension 420
• Front shock absorber installation 421
• Rear spring removal 421
• Section 09 rear suspension subsection 03 sc 4 suspension 421
• Warning 421
• Rear spring installation 422
• Section 09 rear suspension subsection 03 sc 4 suspension 422
• Slider shoe verification 422
• Section 09 rear suspension subsection 03 sc 4 suspension 423
• Slider shoe removal 423
• Front arm removal 424
• Section 09 rear suspension subsection 03 sc 4 suspension 424
• Slider shoe installation 424
• Suspension installation 424
• Suspension removal 424
• Front arm installation 425
• Rear arm pivot arm installation 425
• Rear arm pivot arm removal 425
• Section 09 rear suspension subsection 03 sc 4 suspension 425
• Warning 425
• Block installation 426
• Idler wheels installation 426
• Ride adjustment 426
• Section 09 rear suspension subsection 03 sc 4 suspension 426
• Stopper strap 426
• Lubrication 427
• Section 09 rear suspension subsection 03 sc 4 suspension 427
• Section 09 rear suspension 428
• Service products 428
• Service tools 428
• Shock absorber inspection and servicing 428
• Spring removal 428
• Subsection 04 shock absorber inspection and servicing 428
• Section 09 rear suspension subsection 04 shock absorber inspection and servicing 429
• Shock absorber inspection 429
• Disassembly and assembly 430
• Section 09 rear suspension 430
• Subsection 04 shock absorber inspection and servicing 430
• Warning 430
• Section 09 rear suspension subsection 04 shock absorber inspection and servicing 431
• Section 09 rear suspension 432
• Subsection 04 shock absorber inspection and servicing 432
• Warning 432
• Section 09 rear suspension subsection 04 shock absorber inspection and servicing 433
• Section 09 rear suspension 434
• Subsection 04 shock absorber inspection and servicing 434
• Warning 434
• Section 09 rear suspension subsection 04 shock absorber inspection and servicing 435
• Section 09 rear suspension 436
• Subsection 04 shock absorber inspection and servicing 436
• Warning 436
• Section 09 rear suspension subsection 04 shock absorber inspection and servicing 437
• Bombardier lube 293 600 016 446 suspension synthetic grease 293 550 033 446 438
• Section 10 steering front suspension 438
• Service products 438
• Steering system 438
• Subsection 01 steering system 438
• Linkage arrangement 439
• Section 10 steering front suspension subsection 01 steering system 439
• Handlebar arrangement 440
• Section 10 steering front suspension 440
• Subsection 01 steering system 440
• Section 10 steering front suspension subsection 01 steering system 441
• Disassembly and assembly 442
• Section 10 steering front suspension 442
• Subsection 01 steering system 442
• Section 10 steering front suspension subsection 01 steering system 443
• Warning 443
• Ball joint left hand and right hand threads 444
• Rh and lh swivel arm 444
• Section 10 steering front suspension 444
• Steering column 444
• Subsection 01 steering system 444
• Adjustment 445
• Ball joint left hand and right hand threads 445
• Hardened washer 445
• Heating grip element 445
• Inspection 445
• Section 10 steering front suspension subsection 01 steering system 445
• Steering column position adjustment 445
• Warning 445
• Section 10 steering front suspension 446
• Subsection 01 steering system 446
• Handlebar extension 447
• Section 10 steering front suspension subsection 01 steering system 447
• Warning 447
• Handlebar position adjustment 448
• Section 10 steering front suspension 448
• Subsection 01 steering system 448
• Warning 448
• Windshield adjustment 448
• Adjustments 449
• Definitions 449
• Hand guard adjustment 449
• Handlebar strap 449
• J hook adjustment 449
• Section 10 steering front suspension subsection 01 steering system 449
• Steering adjustment skis 449
• Section 10 steering front suspension 450
• Subsection 01 steering system 450
• Warning 450
• Lubrication 451
• Section 10 steering front suspension subsection 01 steering system 451
• Warning 451
• Front suspension 452
• Section 10 steering front suspension 452
• Service products 452
• Service tools 452
• Subsection 02 front suspension 452
• Section 10 steering front suspension subsection 02 front suspension 453
• Note the same procedure applies on both sides 454
• Section 10 steering front suspension 454
• Subsection 02 front suspension 454
• Disassembly 455
• General inspection 455
• Section 10 steering front suspension subsection 02 front suspension 455
• Shock absorber 455
• Section 10 steering front suspension 456
• Subsection 02 front suspension 456
• Lower arm 457
• Section 10 steering front suspension subsection 02 front suspension 457
• Section 10 steering front suspension 458
• Stabilizer bar 458
• Subsection 02 front suspension 458
• Tie rod 458
• Upper arm 458
• Inspection 459
• Section 10 steering front suspension subsection 02 front suspension 459
• Installation 460
• Section 10 steering front suspension 460
• Stabilizer bar 460
• Subsection 02 front suspension 460
• Upper arm 460
• Warning 460
• Lower arm 461
• Section 10 steering front suspension subsection 02 front suspension 461
• Section 10 steering front suspension 462
• Shock absorber 462
• Stabilizer bar 462
• Subsection 02 front suspension 462
• Section 10 steering front suspension subsection 02 front suspension 463
• Adjustment 464
• Section 10 steering front suspension 464
• Subsection 02 front suspension 464
• Warning 464
• Disassembly and assembly 465
• Inspection 465
• Installation and adjustment 465
• Warning 465
• Windshield 465
• Wiring harness 465
• Cables 466
• Maintenance 466
• Plastic maintenance and repair 466
• Repair 466
• Section 11 body frame subsection 01 body 466
• Tubing 466
• Warning 466
• Aluminum frame 467
• Drilling procedure 467
• Frame cleaning 467
• Frame component replacement 467
• Frame welding 467
• Seat cleaning 467
• Section 11 body frame 467
• Service products 467
• Service tools 467
• Subsection 02 frame 467
• Section 11 body frame subsection 02 frame 468
• Fan cooled models 469
• Section 12 technical data 469
• Subsection 01 fan cooled models 469
• Section 12 technical data subsection 01 fan cooled models 470
• Section 12 technical data 471
• Subsection 01 fan cooled models 471
• Section 12 technical data subsection 01 fan cooled models 472
• Section 12 technical data 473
• Subsection 01 fan cooled models 473
• Liquid cooled models 474
• Section 12 technical data 474
• Subsection 02 liquid cooled models 474
• Section 12 technical data subsection 02 liquid cooled models 475
• Section 12 technical data 476
• Subsection 02 liquid cooled models 476
• Section 12 technical data subsection 02 liquid cooled models 477
• Section 12 technical data 478
• Subsection 02 liquid cooled models 478
• Section 12 technical data subsection 02 liquid cooled models 479
• Section 12 technical data 480
• Subsection 02 liquid cooled models 480
• Section 12 technical data subsection 02 liquid cooled models 481
• Liquid cooled sdi models 482
• Section 12 technical data 482
• Subsection 03 liquid cooled sdi models 482
• Section 12 technical data subsection 03 liquid cooled sdi models 483
• Section 12 technical data 484
• Subsection 03 liquid cooled sdi models 484
• Section 12 technical data subsection 03 liquid cooled sdi models 485
• Section 12 technical data 486
• Subsection 03 liquid cooled sdi models 486
• Section 12 technical data subsection 03 liquid cooled sdi models 487
• Technical data legend 487
• Wiring diagrams 488
• Housing reference per area 489
• Section 13 wiring diagram subsection 01 wiring diagrams 489
• Wire location in connector housing 489
• Section 13 wiring diagram 490
• Subsection 01 wiring diagrams 490
• Section 13 wiring diagram subsection 01 wiring diagrams 491
• Symbols description 491
• Section 13 wiring diagram 492
• Subsection 01 wiring diagrams 492
• Tab and receptacle connectors removal 492
• Tab connector 492
• Throttle position sensor tps connector 492
• Unpluging connectors 492
• Locking receptacle connector 493
• Section 13 wiring diagram subsection 01 wiring diagrams 493
• Waterproof connector housing 493
• Multilock connector housing 494
• Section 13 wiring diagram 494
• Subsection 01 wiring diagrams 494
• Circuit connector housing 495
• Section 13 wiring diagram subsection 01 wiring diagrams 495
• Connector housing a and b on ecm 496
• Section 13 wiring diagram 496
• Subsection 01 wiring diagrams 496
• Section 13 wiring diagram subsection 01 wiring diagrams 497
• Section 13 wiring diagram 498
• Subsection 01 wiring diagrams 498
• Tab and receptacle connectors installation 498
• Section 13 wiring diagram subsection 01 wiring diagrams 499
• Warning 499
• Rreevv ssddii 500
• Section 13 wiring diagram 500
• Subsection 01 wiring diagrams 500
• Frame frame 501
• Headlamp a 501
• Regulator 501
• Regulator rectifier 501
• Rev fan cooled 501
• Rreevv ffaann ccoooolleedd 501
• Speedometer 501
• Starter 501
• Tail lamp 501
• Rev carburetor manual start 502
• Rev carburetor electric start 503
• Fuel pump 504
• Fuse 20a 504
• Rev sdi 504
• Rreevv ssddii 504
• Speedometer 504
• Starter 504
• Engine 505
• Fuse 20a 505
• Regulator 505
• Rev power tek manual start 505
• Rreevv ppoowweerrtteekk mmaannuuaall ssttaarrtt 505
• Speedometer 505
• Engine 506
• Fuse 20a 506
• Regulator 506
• Rev power tek electric start 506
• Rreevv ppoowweerrtteekk eelleeccttrriicc ssttaarrtt 506
• Speedometer 506
• Starter 506
• Mmr 2005 s rie rev ang fh8 wed dec 01 10 21 46 2004 page 1 507
• Mmr 2005 s rie rt ang fh8 mon dec 20 08 16 36 2004 page 1 508
• Air intake system 15 511
• Engine 511
• Introduction x 511
• Leak test 9 511
• Maintenance 511
• Maintenance chart 1 02 storage 3 511
• Preseason preparation 7 511
• Safety notice ix 511
• Table of contents 511
• Vehicle identification number x engine serial number x list of abbreviations used in this manual x arrangement of this manual xii general information xiv illustrations and procedures xiv self locking fasteners procedure xiv loctite application procedure xv threadlocker xv stripped thread repair xvi gasket compound xvii mounting on shaft xvii case in components xviii tightening torque xviii 511
• Bottom end 61 512
• Cooling system 83 512
• E rave system 41 512
• Engine measurement 75 512
• Engine removal and installation 25 512
• Magneto system 35 512
• Table of contents 512
• Top end 51 512
• Diaphragm fuel pump 114 513
• Electric fuel pump 109 513
• Electric fuel pump 111 513
• Engine management sdi 513
• Fuel system 513
• Fuel tank and fuel pumps 103 fuel tank 104 513
• Oil injection system 95 513
• Overview 117 operating principle 118 513
• Rewind starter 89 513
• Table of contents 513
• Component inspection replacement and adjustment 135 general 135 514
• Design symbols used in ngk spark plugs 164 02 charging system 165 514
• Diagnostic procedure 127 514
• Electrical system 514
• Engine management system ems 120 514
• Ignition system 159 514
• Table of contents 514
• Testing procedures 140 514
• Accessories and lighting system 177 515
• Drive belt 185 515
• Drive pulley 189 tra v 190 515
• Drive system 515
• Driven pulley 201 hpv roller 202 515
• Rotax electronic reverse rer 175 515
• Starting system 171 515
• Table of contents 515
• Brake 215 516
• Chaincase 223 516
• Drive axle 233 516
• Hpv vsa 208 516
• Pulley alignment 213 516
• Table of contents 516
• Track 239 516
• Rear suspension 517
• Sc 4 suspension 255 517
• Sc suspension 243 517
• Shock absorber inspection and servicing 269 517
• Table of contents 517
• Body 305 518
• Body frame 518
• Frame 311 518
• Front suspension 291 518
• Mach z summit 1000 sdi 317 518
• Steering front suspension 518
• Steering system 279 518
• Table of contents 518
• Technical data 518
• Wiring diagrams 518
• Wiring diagrams 323 518
• Safety notice 519
• Warning 519
• Engine serial number 520
• Engine serial number location 520
• Identification number meaning 520
• Introduction 520
• List of abbreviations used in this manual 520
• Vehicle identification number 520
• Vehicle identification number location 520
• Introduction 521
• Arrangement of this manual 522
• Introduction 522
• Mmr2005 109 522
• Introduction 523
• General information 524
• Illustrations and procedures 524
• Introduction 524
• Self locking fasteners procedure 524
• Blind holes 525
• Introduction 525
• Loctite application procedure 525
• Stud in blind holes 525
• Threadlocker 525
• Uncovered holes bolts and nuts 525
• Adjusting screw 526
• Introduction 526
• Preassembled parts 526
• Stripped thread repair 526
• Stripped threads 526
• All parts 527
• Gasket compound 527
• Introduction 527
• Mounting on shaft 527
• Mounting with a press 527
• Case in components 528
• Introduction 528
• Metallic gaskets 528
• Tightening torque 528
• Warning 528
• Introduction 529
• I ntroduction 530
• I ntroduction 531
• Hour or 500 km 300 mi inspection to be performed by dealer 532
• Km 3700 mi 532
• Maintenance chart 532
• Monthly or every 800 km 500 mi 532
• Once a year or every 3200 km 2000 mi 532
• Preseason preparation to be performed by dealer 532
• Section 01 maintenance 532
• Storage to be performed by dealer 532
• Subsection 01 maintenance chart 532
• System refer to section s and subsection s 532
• Weekly or every 240 km 150 mi 532
• 1 to be performed by an authorized ski doo dealer 533
• 2 lubricate whenever the vehicle is used in wet conditions wet snow rain puddles 533
• 3 before installing new spark plugs at preseason preparation it is suggested to burn excess storage oil by starting the engine with the old spark plugs only perform this operation in a well ventilated area 533
• 4 emission related 533
• 5 summit models only 533
• Hour or 500 km 300 mi inspection to be performed by dealer 533
• Km 3700 mi 533
• Monthly or every 800 km 500 mi 533
• Once a year or every 3200 km 2000 mi 533
• Preseason preparation to be performed by dealer 533
• Section 01 maintenance subsection 01 maintenance chart 533
• Storage to be performed by dealer 533
• System refer to section s and subsection s 533
• Weekly or every 240 km 150 mi 533
• Engine 534
• Engine lubrication 534
• Engine motor mounts 534
• Exhaust system 534
• General 534
• Rewind starter and rope 534
• Service products 534
• Service tools 534
• Storage 534
• Warning 534
• Brake fluid 535
• Cooling system 535
• Crankshaft pto seal 535
• Drive and driven pulley 535
• Drive system 535
• Fuel stabilizer 535
• Fuel system 535
• Injection oil filter 535
• Rags in air intake and exhaust system 535
• Section 01 maintenance subsection 02 storage 535
• Warning 535
• Battery if so equipped 536
• Chaincase oil 536
• Countershaft 536
• Drive axle end bearing 536
• Drive chain tension 536
• Electrical 536
• Engine compartment 536
• Rear suspension lubrication 536
• Section 01 maintenance 536
• Steering and front suspension mechanism lubrication 536
• Steering front suspension 536
• Subsection 02 storage 536
• Suspension 536
• Suspension stopper strap 536
• Vehicle 536
• Vehicle cleaning 536
• Wear and condition of skis and runners 536
• Wiring harnesses cables and lines 536
• Section 01 maintenance subsection 02 storage 537
• Vehicle protection 537
• Air filter air intake system 538
• Cooling system 538
• Engine 538
• Fuel filter 538
• Fuel lines fuel rails and connections 538
• Fuel system 538
• Oil injection pump 538
• Preseason preparation 538
• Rags in air intake and exhaust system 538
• Rewind starter and rope 538
• Service products 538
• Throttle body 538
• Throttle cable 538
• Warning 538
• Battery if so equipped 539
• Brake fluid 539
• Brake hose pads and disk 539
• Chaincase oil 539
• Drive and driven pulley 539
• Drive belt 539
• Drive pulley ramp and roller 539
• Drive system 539
• Electrical system 539
• Headlamp beam aiming 539
• Section 01 maintenance subsection 03 preseason preparation 539
• Spark plugs 539
• Tightening torque of drive pulley screw 539
• Tightening torque of ring gear screws 539
• Track tension and alignment 539
• Vehicle 539
• Warning 539
• Leak test 540
• Preparation 540
• Section 02 engine 540
• Service tools 540
• Subsection 01 leak test 540
• Block inlet and outlet fitting of oil injection system with rubber cap 541
• Install intake plugs p n 529 036 000 in the intake rubber boots 541
• Install the vacuum pressure pump on exhaust plate fitting 541
• Section 02 engine subsection 01 leak test 541
• Using a small hose pincher p n 295 000 076 block impulse hose 541
• Procedure 542
• Section 02 engine 542
• Subsection 01 leak test 542
• Section 02 engine subsection 01 leak test 543
• Finalizing reassembly 544
• Section 02 engine 544
• Subsection 01 leak test 544
• Engine leak verification flow chart 545
• Section 02 engine subsection 01 leak test 545
• Air intake system 546
• Air filter air intake silencer installation body side 547
• Air filter air intake silencer removal body side 547
• Air intake silencer removal engine side 547
• Section 02 engine subsection 02 air intake system 547
• Adaptor plate installation 548
• Adaptor plate removal 548
• Air intake silencer installation engine side 548
• Intake deflector filter removal 548
• Section 02 engine 548
• Subsection 02 air intake system 548
• Remove intake deflector and filter 549
• Section 02 engine subsection 02 air intake system 549
• Exhaust spring installer remover 529 035 401 23 exhaust spring installer remover 529 035 989 21 22 550
• Exhaust system 550
• Loctite 767 antiseize 293 800 070 23 rtv sealant 293 800 090 22 550
• Section 02 engine 550
• Service products 550
• Service tools 550
• Subsection 03 exhaust system 550
• Section 02 engine subsection 03 exhaust system 551
• General 552
• Identification 552
• Inspection 552
• Installation 552
• Removal 552
• Section 02 engine 552
• Subsection 03 exhaust system 552
• Tuned pipe 552
• Warning 552
• Identification 553
• Inspection 553
• Installation 553
• Manifold 553
• Muffler 553
• Removal 553
• Section 02 engine subsection 03 exhaust system 553
• Inspection 554
• Installation 554
• Section 02 engine 554
• Subsection 03 exhaust system 554
• Dielectric grease 293 550 004 33 molykote 111 413 707 000 33 555
• Engine removal and installation 555
• Engine removal hook 529 035 829 30 hose pincher 295 000 076 31 spark plug lift ring 529 035 830 30 555
• Section 02 engine 555
• Service products 555
• Service tools 555
• Subsection 04 engine removal and installation 555
• Section 02 engine subsection 04 engine removal and installation 556
• Removal from vehicle 557
• Section 02 engine 557
• Subsection 04 engine removal and installation 557
• Warning 557
• Section 02 engine subsection 04 engine removal and installation 558
• Section 02 engine 559
• Subsection 04 engine removal and installation 559
• Section 02 engine subsection 04 engine removal and installation 560
• Inspection 561
• Section 02 engine 561
• Subsection 04 engine removal and installation 561
• Installation 562
• Lower engine as close as possible to its original position first position pto engine support on engine and insert front tab of pto engine support on rubber mount 562
• Pto engine support 562
• Section 02 engine subsection 04 engine removal and installation 562
• Secure pto engine support 562
• To install engine in vehicle reverse the removal procedure however pay attention to the follow ing 562
• Using a pry bar position rear tab of pto engine support in place on rubber mount 562
• After engine installation verify oil pump adjust ment adjust if necessary refer to oil injec tion system sub section 563
• Fuel injectors 563
• Heat exchanger outlet hose 563
• Lubricate fuel injectors o ring with molykote 111 p n 413 707 000 before fuel rail installation respect the following tightening torque specifica tions 563
• Magneto harness 563
• Make sure rh side engine supports are properly positioned on rubber mounts 563
• Make sure that heat exchanger outlet hose is rout ed as per photo 563
• Make sure to apply the following product on the appropriate parts 563
• Make sure to position magneto harness in place before lowering engine 563
• Oil pump adjustment 563
• Reinstall all removed parts by using the appropri ate component system reinstallation procedures described in this shop 563
• Section 02 engine 563
• Subsection 04 engine removal and installation 563
• Crankshaft protector 420 876 557 37 magneto puller 529 035 547 37 puller ring 529 036 001 37 564
• Loctite 243 blue 293 800 060 36 loctite 5910 293 800 081 36 silicone dielectric grease 293 550 004 38 564
• Magneto system 564
• Section 02 engine 564
• Service products 564
• Service tools 564
• Subsection 05 magneto system 564
• Section 02 engine subsection 05 magneto system 565
• Cleaning 566
• General 566
• Magneto flywheel 566
• Removal 566
• Section 02 engine 566
• Subsection 05 magneto system 566
• Warning 566
• Cleaning 567
• Ignition timing 567
• Inspection 567
• Installation 567
• Removal 567
• Section 02 engine subsection 05 magneto system 567
• Stator 567
• Inspection 568
• Installation 568
• Removal 568
• Section 02 engine 568
• Subsection 05 magneto system 568
• E rave system 569
• Loctite 243 293 800 060 42 molykote 111 413 707 000 42 xps synthetic blend injection oil 293 600 071 42 569
• Section 02 engine 569
• Service products 569
• Subsection 06 e rave system 569
• Section 02 engine subsection 06 e rave system 570
• E rave cables 571
• E rave system dynamic test 571
• General 571
• Removal 571
• Section 02 engine 571
• Subsection 06 e rave system 571
• Warning 571
• Installation 572
• Section 02 engine subsection 06 e rave system 572
• Adjustment 573
• Section 02 engine 573
• Subsection 06 e rave system 573
• E rave actuator 574
• Inspection 574
• Section 02 engine subsection 06 e rave system 574
• E rave cover 575
• E rave shaft 575
• Inspection 575
• Installation 575
• Removal 575
• Section 02 engine 575
• Subsection 06 e rave system 575
• Installation 576
• Removal 576
• Section 02 engine subsection 06 e rave system 576
• E rave housing 577
• E rave valves 577
• Inspection 577
• Installation 577
• Removal 577
• Section 02 engine 577
• Subsection 06 e rave system 577
• Section 02 engine 578
• Service products 578
• Service tools 578
• Subsection 07 top end 578
• Top end 578
• Section 02 engine subsection 07 top end 579
• Component removal with the engine installed 580
• Cylinder head 580
• Disassembly 580
• Fuel rail 580
• General 580
• Rave system 580
• Reed valve 580
• Section 02 engine 580
• Subsection 07 top end 580
• Troubleshooting 580
• Warning 580
• Cleaning 581
• Cylinder block 581
• Decompressor 581
• Piston 581
• Section 02 engine subsection 07 top end 581
• Decompressor 582
• Inspection 582
• Reed valve 582
• Section 02 engine 582
• Subsection 07 top end 582
• Assembly 583
• At assembly place the pistons over the connect ing rods with the arrow pointing toward the ex haust port 583
• Cylinder head cylinder block and piston 583
• Lubricate needle bearings and insert into connect ing rod 583
• Note a cylinder block may use pistons of 2 differ ent tolerance groups always match piston a with cylinder a and piston b with cylinder b when a cylinder block needs to be replaced the replacement part is provided with 2 matching pis tons 583
• Piston 583
• Piston and cylinder block replacement note there is no oversize piston available this engine uses pistons with 2 tolerance groups therefore when a piston needs to be replaced it is important to correctly identify its tolerance group before proceeding with its replacement the pistons and cylinders are identified by the let ters a or b 583
• Section 02 engine subsection 07 top end 583
• Section 02 engine 584
• Subsection 07 top end 584
• Cylinder head and cylinder block 585
• Section 02 engine subsection 07 top end 585
• Install cylinder head and torque screws following this sequence 586
• Lh and rh side intake adapters are different in stall as shown 586
• Properly seat adapters against engine flanges and torque screws no 1 in a criss cross sequence 586
• Section 02 engine 586
• Subsection 07 top end 586
• Bottom end 587
• Section 02 engine 587
• Service products 587
• Service tools 587
• Subsection 08 bottom end 587
• Section 02 engine subsection 08 bottom end 588
• Section 02 engine 589
• Subsection 08 bottom end 589
• Cleaning 590
• Crankcase 590
• Crankshaft bearing 590
• Disassembly 590
• General 590
• Preparation 590
• Pto seal 590
• Section 02 engine subsection 08 bottom end 590
• Troubleshooting 590
• Warning 590
• Coolant injection oil pump shaft 591
• Counterbalance drive gear 591
• Section 02 engine 591
• Subsection 08 bottom end 591
• Section 02 engine subsection 08 bottom end 592
• Section 02 engine 593
• Subsection 08 bottom end 593
• Section 02 engine subsection 08 bottom end 594
• Assembly 595
• Clean crankshaft ends with sand paper no 180 to remove possible seal marks and debris 595
• Crankshaft preparation 595
• Inspect crankshaft ends for damage 595
• Inspection 595
• Installation pour 50 ml 2 u s oz of injection oil in the pan under worm gear to lubricate pump gearing install pump shaft assembly in crankcase half while turning shaft to mesh gears torque housing screws no 12 after impeller installation ensure shaft turns prop erly torque impeller housing screws in the following sequence 595
• Note during installation support the ceramic seal using the ceramic seal installer p n 529 036 014 as shown on the following illustration 595
• Refer to table below to find bottom end engine di mension specifications for dimension measure ment procedures refer to engine measure ment 595
• Reinstall oil injection pump 595
• Remove oil seal protector from coolant oil pump shaft 595
• Section 02 engine 595
• Subsection 08 bottom end 595
• Crankshaft bearing preparation 596
• Section 02 engine subsection 08 bottom end 596
• Crankshaft bearing installation 597
• Section 02 engine 597
• Subsection 08 bottom end 597
• Warning 597
• Counterbalance gear 598
• Crankcase assembly 598
• Crankshaft installation 598
• Section 02 engine subsection 08 bottom end 598
• After rebuilding an engine always observe a break in period as described in operator s guide 599
• Break in 599
• Caution do not use loctite primer n with the loctite 5910 do not use dreibond to seal crankcase using these products or non silicone based sealant over a previously sealed crankcase with loctite 5910 will lead to poor adhesion and possibly a leaking crankcase these products are chemically incompatibles even after cleaning these products would leave incompatible microscopic particles use a plexiglass plate and apply some sealant on it use a soft rubber roller 50 75 mm 2 3 in available in arts products suppliers for printmak ing and roll the sealant to get a thin uniform coat on the plate spread as necessary when ready apply the sealant on crankcase mating surfaces 599
• Ensure snap ring no 2 is properly installed in crankcase 599
• Section 02 engine 599
• Subsection 08 bottom end 599
• Torque crankcase screws in the following se quence initially torque m10 screws half the final torque then tighten all screws to the required torque 599
• Torque heat exchanger cover screws no 19 fol lowing this sequence 599
• Cylinder head warpage 600
• Cylinder out of round 600
• Cylinder taper 600
• Engine measurement 600
• Section 02 engine 600
• Service tools 600
• Subsection 09 engine measurement 600
• Combustion chamber volume measurement 601
• Section 02 engine subsection 09 engine measurement 601
• Section 02 engine 602
• Subsection 09 engine measurement 602
• Used piston measurement 602
• Cylinder piston clearance 603
• Section 02 engine subsection 09 engine measurement 603
• Used and new pistons 603
• Crankshaft deflection 604
• Ring end gap 604
• Ring piston groove clearance 604
• Section 02 engine 604
• Subsection 09 engine measurement 604
• Checking crankshaft alignment 605
• Connecting rod big end axial play 605
• Measuring in crankcase 605
• Measuring on bench 605
• Section 02 engine subsection 09 engine measurement 605
• Section 02 engine 606
• Subsection 09 engine measurement 606
• Cooling system 607
• Section 02 engine 607
• Service products 607
• Service tools 607
• Subsection 10 cooling system 607
• Section 02 engine subsection 10 cooling system 608
• Cooling system leak test 609
• Draining the system 609
• Inspection 609
• Section 02 engine 609
• Subsection 10 cooling system 609
• Warning 609
• Bleed hose elbow fitting 610
• Coolant pump 610
• Coolant tank 610
• Disassembly and assembly 610
• Pressure cap 610
• Rear heat exchanger 610
• Section 02 engine subsection 10 cooling system 610
• Temperature sensor 610
• Cooling system refilling procedure 611
• Heat exchanger protector 611
• Rear cap heat exchanger 611
• Refilling procedure 611
• Section 02 engine 611
• Subsection 10 cooling system 611
• System capacity 611
• Thermostat 611
• Molykote pg 54 420 899 763 92 93 612
• Rewind starter 612
• Section 02 engine 612
• Service products 612
• Subsection 11 rewind starter 612
• Section 02 engine subsection 11 rewind starter 613
• Disassembly 614
• General 614
• Inspection 614
• Removal 614
• Rope replacement 614
• Section 02 engine 614
• Subsection 11 rewind starter 614
• Warning 614
• Assembly 615
• Section 02 engine subsection 11 rewind starter 615
• Warning 615
• Section 02 engine 616
• Subsection 11 rewind starter 616
• Installation 617
• Section 02 engine subsection 11 rewind starter 617
• Oil injection system 618
• Section 02 engine 618
• Service products 618
• Service tools 618
• Subsection 12 oil injection system 618
• Section 02 engine subsection 12 oil injection system 619
• General 620
• Oil system leak test 620
• Oil type 620
• Section 02 engine 620
• Subsection 12 oil injection system 620
• Warning 620
• Cleaning 621
• Injection oil level sensor 621
• Injection oil reservoir 621
• Oil pump identification 621
• Removal 621
• Section 02 engine subsection 12 oil injection system 621
• Check valve 622
• Checking operation 622
• Injection oil filter 622
• Injection oil pump 622
• Injection oil reservoir 622
• Installation 622
• Oil pump 622
• Oil reservoir check valve 622
• Section 02 engine 622
• Subsection 12 oil injection system 622
• Bleeding procedure 623
• Check valve 623
• Injection oil filter 623
• Injection oil level sensor 623
• Injection oil pump 623
• Section 02 engine subsection 12 oil injection system 623
• Adjustment 624
• Oil pump cable 624
• Section 02 engine 624
• Subsection 12 oil injection system 624
• Warning 624
• Fuel tank and fuel pumps 625
• Section 03 fuel system 625
• Service tools 625
• Subsection 01 fuel tank and fuel pumps 625
• Fuel tank 626
• Section 03 fuel system subsection 01 fuel tank and fuel pumps 626
• In tank fuel filter installation 627
• In tank fuel filter removal 627
• Section 03 fuel system 627
• Subsection 01 fuel tank and fuel pumps 627
• Warning 627
• Fuel tank removal 628
• In line fuel filter installation 628
• In line fuel filter removal 628
• Section 03 fuel system subsection 01 fuel tank and fuel pumps 628
• Float type fuel level gauge removal installation 629
• Fuel tank installation 629
• Section 03 fuel system 629
• Subsection 01 fuel tank and fuel pumps 629
• Warning 629
• Electric fuel level sensor inspection 630
• Fuel system pressurization 630
• High pressure test electric fuel pump circuit 630
• Section 03 fuel system subsection 01 fuel tank and fuel pumps 630
• Diagnostic flow chart 631
• Electric fuel pump 631
• Note before proceeding with any test make sure that diaphragm fuel pump works properly 631
• Section 03 fuel system 631
• Subsection 01 fuel tank and fuel pumps 631
• Electric fuel pump pressure test 632
• Section 03 fuel system subsection 01 fuel tank and fuel pumps 632
• Warning 632
• Electric fuel pump 633
• Section 03 fuel system 633
• Subsection 01 fuel tank and fuel pumps 633
• Electric fuel pump removal 634
• Section 03 fuel system subsection 01 fuel tank and fuel pumps 634
• Electric fuel pump installation 635
• Electric fuel pump pressure regulator removal installation 635
• Section 03 fuel system 635
• Subsection 01 fuel tank and fuel pumps 635
• Diaphragm fuel pump 636
• Section 03 fuel system subsection 01 fuel tank and fuel pumps 636
• Diaphragm fuel pump removal 637
• Diaphragm fuel pump verification 637
• Section 03 fuel system 637
• Subsection 01 fuel tank and fuel pumps 637
• Diaphragm fuel pump cleaning and inspection 638
• Diaphragm fuel pump installation 638
• Section 03 fuel system subsection 01 fuel tank and fuel pumps 638
• Warning 638
• Overview 639
• Air induction 640
• Charging system 640
• Ignition system 640
• Operating principle 640
• Section 04 engine management sdi subsection 01 overview 640
• Diaphragm fuel pump 641
• Electric fuel pump and fuel pressure regulator 641
• Fuel delivery system 641
• Fuel injectors 641
• Fuel rail 641
• Section 04 engine management sdi 641
• Subsection 01 overview 641
• Engine management system ems 642
• In line fuel filter 642
• Section 04 engine management sdi subsection 01 overview 642
• Throttle body 642
• Section 04 engine management sdi 643
• Subsection 01 overview 643
• Automatic power shut down 644
• Ems engine management system functions 644
• Gauges current supply 644
• Power distribution 644
• Digitally encoded security system dess 645
• Electronically controlled rave e rave 645
• Engine rpm limiter 645
• Flooded engine mode drowned mode 645
• Fuel injection 645
• Ignition system 645
• Knock sensor 645
• Section 04 engine management sdi 645
• Subsection 01 overview 645
• Engine starting 646
• High coolant temperature warning device 646
• Limp home mode 646
• Low oil level warning device 646
• Monitoring system 646
• Rotax electronic reverse rer 646
• Section 04 engine management sdi subsection 01 overview 646
• Diagnostic mode 647
• Section 04 engine management sdi 647
• Subsection 01 overview 647
• Diagnostic procedure 648
• General 648
• Section 04 engine management sdi 648
• Service tools 648
• Subsection 02 diagnostic procedure 648
• Ems fault codes 649
• Faults which are reported in b u d s fall into two groups tps faults and adaption faults these are dis played on the b u d s system as tps out of range and tps adaptation failure 649
• General 649
• Many other codes use the engine pilot lamp and the beeper to indicate a problem refer to b u d s for possible causes and service actions 649
• Monitoring beeper coded signals 649
• Section 04 engine management sdi subsection 02 diagnostic procedure 649
• The faults registered in the ecm engine control module are kept when the battery is disconnected important after a problem has been solved ensure to clear the fault s in the ecm using the vck this will properly reset the appropriate counter s this will also record that the problem has been fixed in the ecm memory many fault codes at the same time is likely to be burnt fuse s for more information pertaining to the code faults state count first etc and report refer to b u d s online help 649
• The following chart is provided to help in diagnosing the probable source of simple troubles 649
• Tps throttle position sensor faults 649
• Troubleshooting 649
• Manual start models fault code p0616 this code will always be present disregard this code as it is not applicable since the starter relay wiring is factory installed the ecm detects an open circuit because the starting relay is not installed 650
• Section 04 engine management sdi 650
• Subsection 02 diagnostic procedure 650
• Supplemental information 650
• Tps adaptation failure fault it is caused by the idle position moving out of an acceptable range following problems can be caused by a tps adaption failure idle speed is out of range engine stops when throttle is released quickly engine runs inconsistent in low partload or low rpm 650
• Tps out of range fault it is caused by the sensor reading going out of its allowable range this fault can occur during the whole range of movement of the throttle to diagnose this fully it is recommended to operate the throttle through its full range it is also recom mended to release the throttle quickly as this may also reveal a fault that is intermittent 650
• When using the service action suggested in the fault section of b u d s the system circuits are referred to as da 41 which means connector a on the ecm and the circuit 41 650
• Ems fault code table 651
• Section 04 engine management sdi subsection 02 diagnostic procedure 651
• Section 04 engine management sdi 652
• Subsection 02 diagnostic procedure 652
• Connecting vck to vehicle 653
• Section 04 engine management sdi subsection 02 diagnostic procedure 653
• Vck supply 653
• Vck vehicle communication kit 653
• Warning 653
• Section 04 engine management sdi 654
• Subsection 02 diagnostic procedure 654
• Section 04 engine management sdi subsection 02 diagnostic procedure 655
• Writing in ecm 655
• Component inspection replacement and adjustment 656
• Fuel system 656
• General 656
• Service products 656
• Service tools 656
• Warning 656
• Electrical system 657
• Fuel rail and hose 657
• Section 04 engine management sdi subsection 03 component inspection replacement and adjustment 657
• Warning 657
• Caution ensure all terminals are properly crimped on wires and connector housings are properly fastened before replacing an ecm always check electrical connections make sure that they are very tight and they make good contact and that they are corrosion free check if wiring harness shows any signs of scoring particularly check ecm ground connections ensure that contacts are good and clean a defective module could possibly be repaired simply by unplugging and replugging the ecm the voltage and current might be too weak to go through dirty wire terminals check careful ly if terminals show signs of moisture corrosion or if they look dull clean terminals properly and then coat them prior to assembling as follows if the newly replaced ecm works try the old one and recheck if it works ensure that all electronic components are genuine any modification on the wiring harness may lead to generate fault codes or bad operation note for diagnostics purposes use vehicle communication kit vck see dia 658
• Resistance measurement 658
• Section 04 engine management sdi 658
• Subsection 03 component inspection replacement and adjustment 658
• The resistance value for usual resistor or windings such as injectors increases as the temperature increases however some of our temperature sensors are ntc types negative temperature co efficient and work the opposite which means that the resistance value decreases as the tempera ture increases take it into account when mea suring at temperatures different from 20 c 68 f use this table for resistance variation relative to temperature for temperature sensors 658
• To perform verifications a good quality multimeter such as fluke 111 p n 529 035 868 should be used pay particular attention to ensure that terminals are not out of their connectors or out of shape the troubleshooting procedures cover problems not resulting from one of these causes 658
• When measuring the resistance with an ohmme ter all values are given for a temperature of 20 c 68 f the resistance value of a resistance varies with the temperature do not touch the sensor itself it may cause wrong result during measure ment because of body heat 658
• Connector identifications 659
• Disconnect the desired connector from ecm and reconnect on the tool connector probe required terminals directly in the tool holes 659
• Ecm connectors 659
• Section 04 engine management sdi subsection 03 component inspection replacement and adjustment 659
• The most recommended and safest method to probe ecm connector terminals is to use the ecm adapter p n 420 277 010 this tool will prevent deforming or enlarging terminals which would lead to bad ecm terminal contact creating intermittent or permanent problems 659
• The resistance value of a temperature sensor may test good at a certain temperature but it might be defective at other temperatures if in doubt try a new sensor also remember this validates the operation of the sensor at room temperature it does not validate the over temperature functionality to test it the sensor could be removed from the engine air si lencer and heated with a heat gun while it is still connected to the harness to see if the ecm will detect the high temperature condition and gener ate a fault code 659
• Engine vehicle connector 660
• Relay 2 660
• Section 04 engine management sdi 660
• Subsection 03 component inspection replacement and adjustment 660
• Electric fuel pump 661
• Electrical test 661
• Fuel injectors 661
• Leakage test and fuel flow measurement 661
• Section 04 engine management sdi subsection 03 component inspection replacement and adjustment 661
• Testing procedures 661
• Electrical test 662
• Section 04 engine management sdi 662
• Subsection 03 component inspection replacement and adjustment 662
• Disconnect the injector from the wiring harness and check the resistance of the injector itself the resistance should be around 14 663
• Fuel injector replacement 663
• If it does not read 12 v check the corresponding fuse s relay and continuity of circuit if continuity is faulty repair wiring harness 663
• If resistance value is correct check wiring of cor responding relay if good try a new ecm refer to ecm replacement procedures elsewhere in this section if resistance value is incorrect repair the wiring harness connectors or replace the wiring harness between ecm connector and fuel injector 663
• If resistance value is incorrect replace the injector reconnect the injector and disconnect the con nector a from the ecm as well as the engine vehicle connector using a multimeter check resistance value be tween terminals as shown in the table below 663
• Removal release the fuel pressure in the system using b u d s look in the activation tab disconnect fuel hose at the connector wrap a rag around the hose end to prevent rail draining 663
• Resistance test 663
• Section 04 engine management sdi subsection 03 component inspection replacement and adjustment 663
• The resistance should be around 14 663
• Section 04 engine management sdi 664
• Subsection 03 component inspection replacement and adjustment 664
• Ecm replacement 665
• Engine control module ecm 665
• General 665
• Section 04 engine management sdi subsection 03 component inspection replacement and adjustment 665
• Warning 665
• Engine wiring harness 666
• Installation 666
• Removal 666
• Resistance test 666
• Section 04 engine management sdi 666
• Subsection 03 component inspection replacement and adjustment 666
• Throttle body 666
• Adjustment 667
• Electrical inspection 667
• Mechanical inspection 667
• Replacement 667
• Section 04 engine management sdi subsection 03 component inspection replacement and adjustment 667
• Section 04 engine management sdi 668
• Subsection 03 component inspection replacement and adjustment 668
• General 669
• Section 04 engine management sdi subsection 03 component inspection replacement and adjustment 669
• Throttle position sensor tps 669
• Voltage test 669
• Wear test 669
• Closed throttle reset 670
• Replacement 670
• Resistance test 670
• Section 04 engine management sdi 670
• Subsection 03 component inspection replacement and adjustment 670
• Crankshaft position sensor cps 671
• Section 04 engine management sdi subsection 03 component inspection replacement and adjustment 671
• Air temperature sensor ats 672
• Replacement 672
• Resistance test 672
• Section 04 engine management sdi 672
• Subsection 03 component inspection replacement and adjustment 672
• Coolant temperature sensor cts 673
• Replacement 673
• Resistance test 673
• Section 04 engine management sdi subsection 03 component inspection replacement and adjustment 673
• Air pressure sensor aps 674
• Replacement 674
• Section 04 engine management sdi 674
• Subsection 03 component inspection replacement and adjustment 674
• Voltage test 674
• Dynamic test 675
• E rave actuator 675
• Knock sensor ks 675
• Replacement 675
• Section 04 engine management sdi subsection 03 component inspection replacement and adjustment 675
• Communication test 676
• Double ignition coil 676
• Dynamic test replacement and cable adjustment 676
• Section 04 engine management sdi 676
• Subsection 03 component inspection replacement and adjustment 676
• Voltage test 676
• Resistance test 677
• Section 04 engine management sdi subsection 03 component inspection replacement and adjustment 677
• Voltage test 677
• Warning 677
• Battery 678
• Battery charge testing 678
• Capacitor 678
• Inspection 678
• Removal 678
• Section 04 engine management sdi 678
• Subsection 03 component inspection replacement and adjustment 678
• Warning 678
• Dess post verification 679
• Engine start rer switch verification 679
• Installation 679
• Section 04 engine management sdi subsection 03 component inspection replacement and adjustment 679
• Tether cord cap on dess post 679
• Tether cord cap removed 679
• Warning 679
• General 680
• Ignition coil 680
• Ignition system 680
• Ignition system testing sequence 680
• Section 05 electrical system 680
• Service products 680
• Service tools 680
• Spark testing 680
• Subsection 01 ignition system 680
• Assemble the gauge to the adaptor and tight en the roller lock nut do not tighten the adaptor lock nut 681
• Check the condition of engine cut out switch 681
• Clean the area around the mag spark plug and remove it install the tdc gauge in the spark plug hole magneto side and adjust as follows position the mag piston at approximately tdc 681
• Crankshaft position sensor cps 681
• Dess post 681
• Engine cut out switch 681
• If readings do not correspond to the above men tioned indications replace post 681
• Ignition timing 681
• Normally ignition timing adjustment should not be required it has been set at factory and it should remain correctly adjusted since every part is fixed and not adjustable the only time the ignition tim ing might have to be changed would be when re moving and reinstalling the magneto housing re placing the crankshaft the magneto flywheel the cps or the ecm if the ignition timing is found incorrect first check for proper crankshaft align ment this might be the indication of a twisted crankshaft refer to leak test and engine di mension measurement the ignition timing can be checked with either the engine hot or cold also the ignition timing is to be checked at 3500 rpm with a timing light note between 3000 and 4000 rpm the spark advance does not change so when checking igni tion timing at 3500 rpm a change in engine speed within 500 rpm will not affect the timing mark when checked with the timing light 681
• Note refer to engine management 681
• Scribing a timing mark 681
• Section 05 electrical system subsection 01 ignition system 681
• Checking ignition timing 682
• Section 05 electrical system 682
• Subsection 01 ignition system 682
• Warning 682
• Changing timing 683
• Installation 683
• Removal 683
• Section 05 electrical system subsection 01 ignition system 683
• Spark plug 683
• Warning 683
• Section 05 electrical system 684
• Subsection 01 ignition system 684
• Use the following table to torque the spark plugs 684
• Design symbols used in ngk spark plugs 685
• Charging generator coil stator 686
• Charging system 686
• General 686
• Section 05 electrical system subsection 02 charging system 686
• Service products 686
• Service tools 686
• Battery 687
• General 687
• Installation 687
• Removal 687
• Section 05 electrical system subsection 02 charging system 687
• Voltage regulator rectifier 687
• Warning 687
• Activation of new battery 688
• Battery charge testing 688
• Battery storage 688
• Cleaning 688
• Inspection 688
• Section 05 electrical system subsection 02 charging system 688
• Warning 688
• Battery charging 689
• Cable terminal installation 689
• Installation 689
• Section 05 electrical system subsection 02 charging system 689
• Warning 689
• Section 05 electrical system subsection 02 charging system 690
• Battery 691
• Component testing 691
• General 691
• Section 05 electrical system 691
• Service tools 691
• Start rer switch 691
• Starting solenoid 691
• Starting system 691
• Subsection 03 starting system 691
• Electrical cables and connections 692
• Engine control module ecm 692
• Engine cut out switch 692
• Section 05 electrical system subsection 03 starting system 692
• Electric starter 693
• Section 05 electrical system subsection 03 starting system 694
• Starter installation 694
• Starter removal 694
• Warning 694
• Rer does not response when depressing start rer button 695
• Rer works erratically 695
• Rotax electronic reverse rer 695
• Section 05 electrical system 695
• Subsection 04 rotax electronic reverse rer 695
• Troubleshooting 695
• Accessories and lighting system 696
• General 696
• Lighting and accessories system testing 696
• Service tools 696
• Warning 696
• Beeper reverse alarm 697
• Installation 697
• Removal 697
• Section 05 electrical system subsection 05 accessories and lighting system 697
• Volt power outlet cigarette lighter type 697
• Electric fuel gauge 698
• Engine temperature gauge 698
• Installation 698
• Removal 698
• Section 05 electrical system 698
• Subsection 05 accessories and lighting system 698
• Bulb replacement 699
• Headlamp 699
• Removal 699
• Section 05 electrical system subsection 05 accessories and lighting system 699
• Beam aiming is correct when center of high beam is 25 mm 1 in below the headlamp horizontal cen ter line scribed on a test surface 381 cm 12 ft 6 in away 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 measure headlamp center distance from ground scribe a line at this height on test surface wall or screen light beam center should be 25 mm 1 in below scribed line 700
• Disconnect headlamps on rh side of vehicle remove the push nut then remove the headlamp housing 700
• Handlebar grip heating element 700
• Headlamp beam aiming 700
• Heating elements 700
• If the heating elements are good check connec tors and wiring harness 700
• Installation 700
• Note all measurements must be performed at 21 c 70 f 700
• Resistance measurement 700
• Reverse the removal procedure 700
• Section 05 electrical system 700
• Subsection 05 accessories and lighting system 700
• Throttle lever heating element 700
• Voltage test 700
• Continuity test 701
• Removal 701
• Section 05 electrical system subsection 05 accessories and lighting system 701
• Speedometer 701
• Installation 702
• Section 05 electrical system 702
• Speed sensor 702
• Subsection 05 accessories and lighting system 702
• Tachometer 702
• Bulb replacement 703
• Installation 703
• Removal 703
• Section 05 electrical system subsection 05 accessories and lighting system 703
• Taillight 703
• Visor outlet 703
• Application chart 704
• Checking neutral function 704
• Drive belt 704
• Inspection 704
• Rotation direction 704
• Service tools 704
• Warning 704
• Adjustment 705
• Drive belt height measurement and adjustment 705
• Measurement 705
• Section 06 drive system subsection 01 drive belt 705
• Drive belt deflection measurement reference only 706
• Section 06 drive system 706
• Subsection 01 drive belt 706
• To check tension 706
• Section 06 drive system subsection 01 drive belt 707
• Drive pulley 708
• Section 06 drive system subsection 02 drive pulley 708
• Service products 708
• Service tools 708
• Note this is a lubrication free drive pulley always refer to appropriate parts catalog for replacement parts most parts of tra v are not interchangeable with other tra models 709
• Section 06 drive system subsection 02 drive pulley 709
• Disassembly 710
• Fixed half 710
• General 710
• Removal 710
• Ring gear 710
• Section 06 drive system subsection 02 drive pulley 710
• Warning 710
• Section 06 drive system subsection 02 drive pulley 711
• Slider shoe and governor cup 711
• Spring cover 711
• Warning 711
• Bushings 712
• Cleaning 712
• Fixed and sliding halves 712
• Inspection 712
• Ring gear 712
• Section 06 drive system subsection 02 drive pulley 712
• Thrust washer and roller 712
• Lever bolt and flanged bushing 713
• O ring and slider shoe 713
• Section 06 drive system subsection 02 drive pulley 713
• Sliding half and spring cover bushings 713
• Assembly 714
• Ring gear 714
• Section 06 drive system subsection 02 drive pulley 714
• Calibration screw washer and locking nut 715
• Dowel tube and ramp 715
• Section 06 drive system subsection 02 drive pulley 715
• Fixed half sliding half spring and spring cover 716
• Lever roller and set screw 716
• Section 06 drive system subsection 02 drive pulley 716
• Sliding half slider shoe and governor cup 716
• Warning 716
• Drive pulley assembly 717
• Installation 717
• Section 06 drive system subsection 02 drive pulley 717
• Warning 717
• Drive pulley adjustment 718
• Section 06 drive system subsection 02 drive pulley 718
• Driven pulley 720
• Section 06 drive system 720
• Service products 720
• Service tools 720
• Subsection 03 driven pulley 720
• Hpv roller 721
• Mach z models 721
• Section 06 drive system subsection 03 driven pulley 721
• Countershaft and countershaft bearing 722
• Disassembly 722
• Driven pulley 722
• General 722
• Removal 722
• Section 06 drive system 722
• Subsection 03 driven pulley 722
• Warning 722
• Bushings 723
• Bushings and cam 723
• Cleaning 723
• Inspection 723
• Pulley halves 723
• Rollers 723
• Section 06 drive system subsection 03 driven pulley 723
• Assembly 724
• Bushing replacement 724
• Installation 724
• Large bushing 724
• Section 06 drive system 724
• Subsection 03 driven pulley 724
• Section 06 drive system subsection 03 driven pulley 725
• Small bushing 725
• Hpv vsa 727
• Section 06 drive system subsection 03 driven pulley 727
• Summit highmark and summit highmark x models 727
• Cleaning 728
• Countershaft 728
• Disassembly 728
• General 728
• Inspection 728
• Large bushing and small bushing 728
• Pulley half cleaning 728
• Removal 728
• Section 06 drive system 728
• Slider shoe 728
• Subsection 03 driven pulley 728
• Warning 728
• Adjustment 729
• Assembly 729
• Bushings 729
• Cam slider shoe 729
• Installation 729
• Screws 729
• Section 06 drive system subsection 03 driven pulley 729
• Section 06 drive system 730
• Spring 730
• Subsection 03 driven pulley 730
• Pulley alignment and drive belt height 731
• Section 06 drive system subsection 03 driven pulley 731
• General 732
• Measuring procedure 732
• Pulley alignment 732
• Service tools 732
• Warning 732
• Alignment procedure 733
• Always measure distances x and y from the far ther straight bar side including its thickness to the fixed half edge 733
• Exceed distance x to com pensate for the twist due to the engine torque 733
• If an alignment is necessary see alignment procedure below if the alignment is good hand torque the torque rod so it slightly contacts engine crankcase do not over tighten it will disalign pulleys when the alignment is done refer to drive belt to adjust the drive belt deflection 733
• Insert the alignment bar p n 529 035 831 into the opened driven pulley 733
• Remove driven pulley and add or remove spacer s as required to obtain the specified alignment 733
• Section 06 drive system subsection 04 pulley alignment 733
• The distance 733
• Use the following table to choose the proper shim s 733
• When the alignment is done refer to drive belt to adjust the drive belt deflection 733
• Dot 4 brake fluid gtlma 293 600 062 217 dot 4 brake fluid srf 293 600 063 217 loctite 609 413 703 100 221 734
• Section 06 drive system 734
• Service products 734
• Subsection 05 brake 734
• Section 06 drive system subsection 05 brake 735
• Bleeding 736
• Brake fluid 736
• Countershaft 736
• Countershaft bearing 736
• Draining 736
• General 736
• Master cylinder 736
• Removal 736
• Section 06 drive system 736
• Subsection 05 brake 736
• Warning 736
• Brake pads 737
• Inspection 737
• Installation 737
• Removal 737
• Section 06 drive system subsection 05 brake 737
• Caliper 738
• Installation 738
• Removal 738
• Section 06 drive system 738
• Subsection 05 brake 738
• Brake disc 739
• Inspection 739
• Installation 739
• Removal 739
• Section 06 drive system subsection 05 brake 739
• Brake light switch 740
• Installation 740
• Removal 740
• Section 06 drive system 740
• Subsection 05 brake 740
• Chaincase 741
• Countershaft bearing remover installer 529 036 010 230 231 countershaft measurement tool 529 036 009 230 741
• Loctite 271 red 293 800 005 228 xp s chaincase oil 413 801 900 225 xp s synthetic chaincase oil 413 803 300 225 741
• Section 06 drive system 741
• Service products 741
• Service tools 741
• Subsection 06 chaincase 741
• Section 06 drive system subsection 06 chaincase 742
• Chaincase cover 743
• Chaincase oil level 743
• Draining procedure 743
• Drive chain adjustment 743
• Filling procedure 743
• General 743
• Oil change 743
• Removal 743
• Section 06 drive system 743
• Subsection 06 chaincase 743
• Warning 743
• Inspection 744
• Installation 744
• Removal 744
• Section 06 drive system subsection 06 chaincase 744
• Tensioner 744
• Tensioner roller bearing 744
• Drive chain and sprockets 745
• Inspection 745
• Installation 745
• Removal 745
• Section 06 drive system 745
• Subsection 06 chaincase 745
• Chaincase housing 746
• Inspection 746
• Installation 746
• Removal 746
• Section 06 drive system subsection 06 chaincase 746
• Chaincase housing bearings 747
• Countershaft 747
• Countershaft bearing 747
• Inspection 747
• Installation 747
• Removal 747
• Section 06 drive system 747
• Subsection 06 chaincase 747
• Installation 748
• Removal 748
• Section 06 drive system subsection 06 chaincase 748
• Section 06 drive system 749
• Subsection 06 chaincase 749
• Drive axle 750
• Drive axle sprocket adjuster kit 861 725 700 238 750
• Section 06 drive system 750
• Service products 750
• Service tools 750
• Subsection 07 drive axle 750
• Synthetic grease 219 700 417 238 750
• Mach z models 751
• Section 06 drive system subsection 07 drive axle 751
• Section 06 drive system 752
• Subsection 07 drive axle 752
• Summit highmark and summit highmark x models 752
• Assembly 753
• Drive axle and sprocket 753
• Removal 753
• Section 06 drive system subsection 07 drive axle 753
• Sprocket and half sprocket 753
• Bearing 754
• Bearing protector 754
• Section 06 drive system 754
• Subsection 07 drive axle 754
• Adjustment 755
• Lubrication 755
• Section 06 drive system subsection 07 drive axle 755
• Sprocket track alignment 755
• Adjustment 756
• General 756
• Inspection 756
• Installation 756
• Removal 756
• Service tools 756
• Tension 756
• Track tension and alignment 756
• Track type application 756
• Warning 756
• Alignment 757
• Section 06 drive system subsection 08 track 757
• Warning 757
• Important safety rules 758
• Installation 758
• Removal 758
• Section 06 drive system 758
• Subsection 08 track 758
• Track cleat 758
• Traction enhancing products studs 758
• Warning 758
• Effects of studding on the life of the snowmobile 759
• Installation 759
• Maintenance replacement 759
• Section 06 drive system subsection 08 track 759
• Warning 759
• Sc suspension 760
• Section 07 rear suspension 760
• Service products 760
• Subsection 01 sc suspension 760
• Suspension synthetic grease 293 550 033 254 760
• Section 07 rear suspension subsection 01 sc suspension 761
• Section 07 rear suspension 762
• Subsection 01 sc suspension 762
• Section 07 rear suspension subsection 01 sc suspension 763
• Axle self locking screws removal 764
• Rear axle installation 764
• Rear axle removal 764
• Rear shock absorber removal 764
• Section 07 rear suspension 764
• Subsection 01 sc suspension 764
• Front shock absorber installation 765
• Front shock absorber removal 765
• Rear shock absorber installation 765
• Section 07 rear suspension subsection 01 sc suspension 765
• Rear spring installation 766
• Rear spring removal 766
• Section 07 rear suspension 766
• Subsection 01 sc suspension 766
• Warning 766
• Section 07 rear suspension subsection 01 sc suspension 767
• Slider shoe removal 767
• Slider shoe verification 767
• Front arm removal 768
• Section 07 rear suspension 768
• Slider shoe installation 768
• Subsection 01 sc suspension 768
• Front arm installation 769
• Rear arm installation 769
• Rear arm pivot arm removal 769
• Section 07 rear suspension subsection 01 sc suspension 769
• 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 proper hole from the end 770
• Lift rear of vehicle and support it off the ground completely loosen track tension remove rear arm top axle bolts from chassis remove bolts retaining front arm to tunnel 770
• Lift rear of vehicle until front arm as enough clear ance to pass underneath tunnel 770
• Section 07 rear suspension 770
• Stopper strap 770
• Subsection 01 sc suspension 770
• Suspension removal 770
• Lubrication 771
• Ride adjustment 771
• Section 07 rear suspension subsection 01 sc suspension 771
• Suspension installation 771
• Sc 4 suspension 772
• Section 07 rear suspension subsection 02 sc 4 suspension 772
• Service products 772
• Suspension synthetic grease 293 550 033 267 772
• Section 07 rear suspension subsection 02 sc 4 suspension 773
• Section 07 rear suspension subsection 02 sc 4 suspension 774
• Section 07 rear suspension subsection 02 sc 4 suspension 775
• Axle self locking screw removal 776
• Rear axle installation 776
• Rear axle removal 776
• Rear shock absorber removal 776
• Section 07 rear suspension subsection 02 sc 4 suspension 776
• Front shock absorber removal 777
• Rear shock absorber installation 777
• Section 07 rear suspension subsection 02 sc 4 suspension 777
• Front shock absorber installation 778
• Rear spring removal 778
• Section 07 rear suspension subsection 02 sc 4 suspension 778
• Warning 778
• Rear spring installation 779
• Section 07 rear suspension subsection 02 sc 4 suspension 779
• Slider shoe verification 779
• Section 07 rear suspension subsection 02 sc 4 suspension 780
• Slider shoe removal 780
• Front arm installation 781
• Front arm removal 781
• Rear arm pivot arm removal 781
• Section 07 rear suspension subsection 02 sc 4 suspension 781
• Slider shoe installation 781
• Warning 781
• Block installation 782
• Idler wheels installation 782
• Rear arm pivot arm installation 782
• Section 07 rear suspension subsection 02 sc 4 suspension 782
• Stopper strap 782
• Ride adjustment 783
• Section 07 rear suspension subsection 02 sc 4 suspension 783
• Suspension installation 783
• Suspension removal 783
• Lubrication 784
• Section 07 rear suspension subsection 02 sc 4 suspension 784
• Section 07 rear suspension 785
• Service products 785
• Service tools 785
• Shock absorber inspection and servicing 785
• Spring removal 785
• Subsection 03 shock absorber inspection and servicing 785
• Disassembly and assembly 786
• Section 07 rear suspension subsection 03 shock absorber inspection and servicing 786
• Shock absorber inspection 786
• Warning 786
• Section 07 rear suspension 787
• Subsection 03 shock absorber inspection and servicing 787
• Section 07 rear suspension subsection 03 shock absorber inspection and servicing 788
• Section 07 rear suspension 789
• Subsection 03 shock absorber inspection and servicing 789
• Section 07 rear suspension subsection 03 shock absorber inspection and servicing 790
• Warning 790
• Section 07 rear suspension 791
• Subsection 03 shock absorber inspection and servicing 791
• Section 07 rear suspension subsection 03 shock absorber inspection and servicing 792
• Warning 792
• Section 07 rear suspension 793
• Subsection 03 shock absorber inspection and servicing 793
• Section 08 steering front suspension 794
• Service products 794
• Steering system 794
• Subsection 01 steering system 794
• Suspension synthetic grease 293 550 033 289 794
• Linkage arrangement 795
• Section 08 steering front suspension subsection 01 steering system 795
• Handlebar arrangement 796
• Section 08 steering front suspension 796
• Subsection 01 steering system 796
• Disassembly and assembly 797
• Section 08 steering front suspension subsection 01 steering system 797
• Section 08 steering front suspension 798
• Subsection 01 steering system 798
• Warning 798
• Section 08 steering front suspension subsection 01 steering system 799
• Steering column 799
• Ball joint left hand and right hand threads 800
• Rh and lh swivel arm 800
• Section 08 steering front suspension 800
• Subsection 01 steering system 800
• Adjustment 801
• Ball joint left hand and right hand threads 801
• Handlebar extension 801
• Hardened washer 801
• Heating grip element 801
• Inspection 801
• Section 08 steering front suspension subsection 01 steering system 801
• Warning 801
• Handlebar position adjustment 802
• Handlebar strap 802
• Section 08 steering front suspension 802
• Subsection 01 steering system 802
• Warning 802
• J hook adjustment 803
• Section 08 steering front suspension subsection 01 steering system 803
• Steering adjustment skis 803
• Toe out 803
• Lubrication 804
• Section 08 steering front suspension 804
• Subsection 01 steering system 804
• Warning 804
• Front suspension 805
• Section 08 steering front suspension 805
• Service products 805
• Service tools 805
• Subsection 02 front suspension 805
• Section 08 steering front suspension subsection 02 front suspension 806
• Summit 806
• Mach z 807
• Section 08 steering front suspension 807
• Subsection 02 front suspension 807
• Note the same procedure applies on both sides 808
• Section 08 steering front suspension subsection 02 front suspension 808
• Summit and mach z 808
• Disassembly 809
• General inspection 809
• Section 08 steering front suspension 809
• Shock absorber 809
• Subsection 02 front suspension 809
• Lower arm 810
• Section 08 steering front suspension subsection 02 front suspension 810
• Section 08 steering front suspension 811
• Subsection 02 front suspension 811
• Anti sway bar 812
• Section 08 steering front suspension subsection 02 front suspension 812
• Tie rod 812
• Upper arm 812
• Section 08 steering front suspension 813
• Subsection 02 front suspension 813
• Anti sway bar 814
• Inspection 814
• Installation 814
• Section 08 steering front suspension subsection 02 front suspension 814
• Warning 814
• Lower arm 815
• Section 08 steering front suspension 815
• Subsection 02 front suspension 815
• Upper arm 815
• Anti sway bar 816
• Section 08 steering front suspension subsection 02 front suspension 816
• Ensure to reinstall shock absorber in the proper position according to model 817
• Mach z secure anti sway bar to link rod as per next illus tration 817
• Section 08 steering front suspension 817
• Shock absorber 817
• Subsection 02 front suspension 817
• Adjustment 818
• Section 08 steering front suspension subsection 02 front suspension 818
• Warning 818
• Front bumper 819
• Installation 819
• Removal 819
• Section 09 body frame 819
• Service tools 819
• Subsection 01 body 819
• Access panel 820
• Bottom pan 820
• Indicator panel 820
• Installation 820
• Removal 820
• Section 09 body frame subsection 01 body 820
• Windshield 820
• Cleaning 821
• Console 821
• Installation 821
• Removal 821
• Section 09 body frame 821
• Subsection 01 body 821
• Cover replacement 822
• Installation 822
• Maintenance 822
• Plastic maintenance and repair 822
• Repair 822
• Section 09 body frame subsection 01 body 822
• Caution some repair products are not com patible with certain plastics 823
• For hood repair refer to a specialized shop the following company provides a complete line of products to repair plastic materials 823
• Polycarbonate windshields must never be re paired by welding or otherwise 823
• Section 09 body frame 823
• Subsection 01 body 823
• Warning 823
• Aluminum frame 824
• Drilling procedure 824
• Frame cleaning 824
• Frame component replacement 824
• Frame welding 824
• Section 09 body frame 824
• Service products 824
• Service tools 824
• Subsection 02 frame 824
• Front cross member 825
• Lower a arm bracket 825
• Section 09 body frame subsection 02 frame 825
• Section 09 body frame 826
• Subsection 02 frame 826
• Section 09 body frame subsection 02 frame 827
• Engine support 828
• Section 09 body frame 828
• Subsection 02 frame 828
• Mach z summit 1000 sdi 829
• Section 10 technical data 829
• Subsection 01 mach z summit 1000 sdi 829
• Section 10 technical data subsection 01 mach z summit 1000 sdi 830
• Section 10 technical data 831
• Subsection 01 mach z summit 1000 sdi 831
• Section 10 technical data subsection 01 mach z summit 1000 sdi 832
• Section 10 technical data 833
• Subsection 01 mach z summit 1000 sdi 833
• Technical data legend 833
• Wiring diagrams 834
• Housing reference per area 835
• Section 11 wiring diagrams subsection 01 wiring diagrams 835
• Wire location in connector housing 835
• Section 11 wiring diagrams 836
• Subsection 01 wiring diagrams 836
• Section 11 wiring diagrams subsection 01 wiring diagrams 837
• Symbols description 837
• Locking receptacle connector 838
• Section 11 wiring diagrams 838
• Subsection 01 wiring diagrams 838
• Tab and receptacle connectors removal 838
• Tab connector 838
• Unplugging connectors 838
• Waterproof connector housing 838
• Multilock connector housing 839
• Section 11 wiring diagrams subsection 01 wiring diagrams 839
• Circuit connector housing 840
• Section 11 wiring diagrams 840
• Subsection 01 wiring diagrams 840
• Circuit connector housing 841
• Connector housing a and b on ecm 841
• Section 11 wiring diagrams subsection 01 wiring diagrams 841
• Section 11 wiring diagrams 842
• Subsection 01 wiring diagrams 842
• Section 11 wiring diagrams subsection 01 wiring diagrams 843
• Section 11 wiring diagrams 844
• Subsection 01 wiring diagrams 844
• Tab and receptacle connectors installation 844
• Warning 844
• Mmr 2005 s rie rt ang fh8 mon dec 20 08 16 36 2004 page 1 849
• Shop manual 851
• Engine 2 stroke 9 02 engine 4 tec 17 853
• Introduction xiv 853
• Maintenance 853
• Maintenance chart 1 02 storage 3 853
• Preseason preparation 7 853
• Safety notice xiii 853
• Table of contents 853
• Troubleshooting guide 853
• Vehicle description decal xv vehicle identification number vin xvi engine serial number xvi list of abbreviations used in this manual xvii arrangement of this manual xviii general information xx illustrations and procedures xx self locking fasteners procedure xx loctite application procedure xxi threadlocker xxi stripped thread repair xxii gasket compound xxiii mounting on shaft xxiii case in components xxiv tightening torque xxv 853
• 277 engine type 47 engine removal and installation 48 854
• 443 and 552 engines 61 engine removal and installation 62 854
• 593 and 593 ho sdi engines 85 854
• Bottom end 57 854
• Bottom end 75 854
• Electrical system 35 06 suspension and track 43 854
• Engines 2 stroke 854
• Fuel and oil systems 2 stroke engines 25 04 transmission and brake systems 29 transmission 29 brake system 33 854
• Table of contents 854
• Top end 50 854
• Top end 65 854
• Top end 87 854
• Bottom end 100 855
• Engine dimension measurement 114 855
• Leak test and engine dimension measurement 109 leak test 109 855
• Magneto system 123 855
• Oil injection system 131 oil injection pump 132 855
• Table of contents 855
• Axial fan cooling system 141 856
• Cooling system 183 856
• Engine 4 tec 856
• Fuel pump 172 856
• Fuel system 161 carburetor 162 856
• Fuel tank 173 856
• Leak test 175 856
• Leak test procedure 175 856
• Liquid cooling system 147 856
• Removal and installation 177 856
• Rewind starter 153 856
• Table of contents 856
• Crankcase 247 857
• Crankshaft drive gears 231 857
• Cylinder and cylinder head 209 857
• Lubrication system 195 857
• Table of contents 857
• Air induction system 274 858
• Charging system 264 ignition system 264 858
• Component inspection and adjustment 269 general 269 fuel system 269 electrical system 270 858
• Diagnostic procedure 265 858
• Electronic management 285 858
• Engine management 2 tec 858
• Engine management system ems 259 858
• Fuel delivery 277 858
• Fuel delivery system 258 858
• Overview 257 operating principle 258 858
• Table of contents 858
• Air induction system 315 859
• Component inspection and adjustment 311 859
• Diagnostic procedure 305 859
• Electronic management 300 859
• Electronic management 325 859
• Engine management 4 tec 859
• Fuel delivery 318 859
• Monitoring beeper coded signals 306 859
• Overview 297 operating principle of engine management 298 air induction 298 fuel delivery system 298 859
• Table of contents 859
• Drive belt 341 860
• Drive pulley 345 bombardier lite 346 860
• Driven pulley 369 860
• Table of contents 860
• Transmission 860
• Brake 387 mechanical brake 388 hydraulic brake 390 861
• Chaincase 397 861
• Drive chain 419 861
• Gearbox 405 3 speed gearbox 406 861
• Pulley distance and alignment 381 861
• Table of contents 861
• Alternator 437 862
• Battery 439 862
• Cleaning and inspection 456 862
• Design symbols used in ngk spark plugs 434 862
• Electric starter 449 862
• Electrical 862
• Ignition timing 421 862
• Spark plugs 433 ngk spark plug 433 862
• Table of contents 862
• Testing procedure 463 862
• Articulating slide suspension 489 863
• Drive axle 499 863
• Inspection of ac circuit isolation 479 863
• Inspection of heating elements 479 863
• Rear suspension 863
• Steering front suspension 863
• Steering system 515 863
• Suspension and ski system 529 863
• Suv suspension 493 863
• Table of contents 863
• Torque reaction suspension 481 863
• Track 511 863
• Body 541 installation and adjustment 541 864
• Body frame 864
• Engines 549 02 vehicles 559 03 technical data legends 567 864
• Frame 547 864
• Plastic maintenance and repair 543 864
• Table of contents 864
• Technical data 864
• Wiring diagrams 569 864
• Wring diagrams 864
• Safety notice 865
• Warning 865
• E electric start r reverse 866
• Introduction 866
• This shop manual covers the following brp made 2005 snowmobiles 866
• Introduction 867
• Location 867
• Vehicle description decal 867
• Description 868
• Engine serial number 868
• Introduction 868
• Location 868
• Vehicle identification number vin 868
• Vin is scribed on vehicle description decal see above it is also embossed on tunnel near vehicle description decal 868
• Introduction 869
• List of abbreviations used in this manual 869
• Arrangement of this manual 870
• Introduction 870
• Mmr2005 001 870
• Introduction 871
• General information 872
• Illustrations and procedures 872
• Introduction 872
• Self locking fasteners procedure 872
• Blind holes 873
• Introduction 873
• Loctite application procedure 873
• Stud in blind holes 873
• Threadlocker 873
• Uncovered holes bolts and nuts 873
• Adjusting screw 874
• Introduction 874
• Preassembled parts 874
• Stripped thread repair 874
• Stripped threads 874
• All parts 875
• Gasket compound 875
• Introduction 875
• Mounting on shaft 875
• Mounting with a press 875
• Case in components 876
• Introduction 876
• Metallic gaskets 876
• Introduction 877
• Tightening torque 877
• Warning 877
• Introduction 878
• Introduction 879
• Hour or 500 km 300 mi inspection to be performed by dealer 880
• Km 3700 mi 880
• Maintenance chart 880
• Monthly or every 800 km 500 mi 880
• Once a year or every 3200 km 2000 mi 880
• Part task refer to section s and subsection s 880
• Preseason preparation to be performed by dealer 880
• Section 01 maintenance 880
• Storage to be performed by dealer 880
• Subsection 01 maintenance chart 880
• Weekly or every 240 km 150 mi 880
• 1 before installing new spark plugs at pre season preparation it is suggested to burn excess storage oil by starting the engine with the old spark plugs only perform this operation in a well ventilated area 2 lubricate whenever the vehicle is used in wet conditions wet snow rain puddles 881
• 3 change oil every 3200 km 2000 mi 881
• 4 emission related 881
• Hour or 500 km 300 mi inspection to be performed by dealer 881
• Km 3700 mi 881
• Monthly or every 800 km 500 mi 881
• Once a year or every 3200 km 2000 mi 881
• Part task refer to section s and subsection s 881
• Preseason preparation to be performed by dealer 881
• Section 01 maintenance subsection 01 maintenance chart 881
• Storage to be performed by dealer 881
• Weekly or every 240 km 150 mi 881
• Engine compartment 882
• General 882
• Service products 882
• Storage 882
• Vehicle cleaning 882
• Warning 882
• Battery 883
• Engine lubrication 883
• Fuel stabilizer 883
• Section 01 maintenance subsection 02 storage 883
• Warning 883
• Cooling system 884
• Countershaft lubrication 884
• Engine oil change and filter 884
• Pulley protection 884
• Rags in air intake and exhaust system 884
• Section 01 maintenance 884
• Subsection 02 storage 884
• Vehicle protection 884
• Warning 884
• Air filter cleaning 885
• Carburetor cleaning on so equipped models 885
• Fuel filter replacement 885
• Preseason preparation 885
• Throttle body cleaning on so equipped models 885
• Warning 885
• Cleaning of brake disk 886
• Cleaning of drive and driven pulleys 886
• Drive belt condition 886
• Engine lubrication 886
• Rags in air intake and exhaust system 886
• Section 01 maintenance subsection 03 preseason preparation 886
• Spark plugs 886
• Engine 2 stroke 887
• Engine backfires 887
• Engine suddenly turns off 887
• Engine suddenly turns off at high rpm and or with light load 887
• Section 02 troubleshooting guide 887
• Subsection 01 engine 2 stroke 887
• Symptom 887
• The following chart is provided to help diagnose the probable source of troubles it should be used as a guideline some causes or corrections may not apply to a specific model 887
• Cont d 888
• Engine suddenly turns off 888
• Section 02 troubleshooting guide subsection 01 engine 2 stroke 888
• Symptom 888
• Engine does not offer maximum power and or does not reach maximum operating rpm 889
• Piston ring and cylinder surfaces are scratched 889
• Section 02 troubleshooting guide 889
• Subsection 01 engine 2 stroke 889
• Symptom 889
• Cont d 890
• Engine detonation at maximum rpm 890
• Engine does not offer maximum power and or does not reach maximum operating rpm 890
• Engine turns over but fails to start manual start 890
• Section 02 troubleshooting guide subsection 01 engine 2 stroke 890
• Symptom 890
• Cont d 891
• Engine turns over but fails to start manual start 891
• High engine operating temperature fan cooled engines 891
• Irregular engine idle normal use after engine warm up 891
• Section 02 troubleshooting guide 891
• Subsection 01 engine 2 stroke 891
• Symptom 891
• Engine equipped with rave valve does not reach its full operat ing rpm 500 to 1000 rpm slower 892
• High engine operating temperature liquid cooled engines 892
• Section 02 troubleshooting guide subsection 01 engine 2 stroke 892
• Symptom 892
• Cont d 893
• Engine equipped with rave engine hesitates at low or mid speed and reaches maximum performance only after a while 893
• Engine equipped with rave valve does not reach its full operat ing rpm 500 to 1000 rpm slower 893
• Engine pinging 893
• Rewind starter pawl does not engage 893
• Rewind starter rope does not rewind 893
• Section 02 troubleshooting guide 893
• Subsection 01 engine 2 stroke 893
• Symptom 893
• Cont d 894
• Engine generates a lot of vibrations 894
• Engine pinging 894
• Section 02 troubleshooting guide subsection 01 engine 2 stroke 894
• Symptom 894
• Alternator 895
• Cooling system 895
• Engine 4 tec 895
• High engine operating temperature 895
• Not charging at all or charging voltage inadequate 895
• Section 02 troubleshooting guide 895
• Subsection 02 engine 4 tec 895
• Symptom 895
• Low or no oil pressure 896
• Lubrication 896
• Oil contamination white appearance 896
• Section 02 troubleshooting guide subsection 02 engine 4 tec 896
• Symptom 896
• Cont d 897
• Crankshaft 897
• Cylinder and cylinder head 897
• Electric starter 897
• Oil contamination on cylinder and or cylinder head 897
• Oil contamination white appearance 897
• Section 02 troubleshooting guide 897
• Starter does not turn 897
• Subsection 02 engine 4 tec 897
• Symptom 897
• Unusual engine noise and or vibrations 897
• Cont d 898
• Section 02 troubleshooting guide subsection 02 engine 4 tec 898
• Starter does not turn 898
• Starter turns but engine does not crank 898
• Starter turns slowly 898
• Symptom 898
• Engine backfires 899
• Engine general 899
• Engine suddenly turns off 899
• Section 02 troubleshooting guide 899
• Subsection 02 engine 4 tec 899
• Symptom 899
• Cont d 900
• Engine does not offer maximum power and or does not reach maximum operating rpm 900
• Engine suddenly turns off 900
• Section 02 troubleshooting guide subsection 02 engine 4 tec 900
• Symptom 900
• Cont d 901
• Engine cranks but fails to start 901
• Engine does not offer maximum power and or does not reach maximum operating rpm 901
• Engine does not start no spark at spark plug refer to engine management system 901
• Section 02 troubleshooting guide 901
• Subsection 02 engine 4 tec 901
• Symptom 901
• Engine lacks power or stalls at high rpm 902
• Fuel and oil systems 2 stroke engines 902
• Fuel leaks in engine base when engine is stopped 902
• High fuel consumption or rich mixture 902
• Section 02 troubleshooting guide 902
• Subsection 03 fuel and oil systems 2 stroke engines 902
• Symptom 902
• The following chart is provided to help in diagnosing the probable source of troubles it should be used as a guideline some causes or corrections may not apply to a specific model note for the sdi fuel and oil systems troubleshooting also refer to appropriate engine subsection 902
• Dpm seems to be defective 903
• Engine lacks fuel or lean mixture 903
• High injection oil consumption 903
• Section 02 troubleshooting guide subsection 03 fuel and oil systems 2 stroke engines 903
• Symptom 903
• Engine maximum rpm is too high and top speed is not reached 905
• Section 02 troubleshooting guide 905
• Subsection 04 transmission and brake systems 905
• Symptom 905
• The following charts are provided to help in diagnosing the probable source of troubles it should be used as a guideline some causes or corrections may not apply to a specific model 905
• The snowmobile accelerates slowly especially from a standing start 905
• Transmission 905
• Transmission and brake systems 905
• Looseness is felt in drive system when accelerating decelerat ing 906
• Pulleys do not down shift properly 906
• Section 02 troubleshooting guide subsection 04 transmission and brake systems 906
• Symptom 906
• Vibrations originating from drive pulley 906
• Vibrations originating from driven pulley 906
• Belt glazed excessively or having baked appearance 907
• Belt worn excessively in top width 907
• In reverse engine fails and driven pulley opens too fast drive belt is low in driven pulley 907
• Section 02 troubleshooting guide 907
• Subsection 04 transmission and brake systems 907
• Symptom 907
• Uneven belt wear on one side only 907
• Belt disintegration 908
• Belt sides worn concave 908
• Belt too narrow on one section 908
• Beltcord popped out 908
• Fatigue cracks between cogs 908
• Section 02 troubleshooting guide subsection 04 transmission and brake systems 908
• Symptom 908
• Belt flip over at high speed 909
• Brake does not adjust automatically 909
• Brake handle does not return completely 909
• Brake system 909
• Hydraulic brake 909
• Mechanical brake 909
• Section 02 troubleshooting guide 909
• Spongy brake condition 909
• Subsection 04 transmission and brake systems 909
• Symptom 909
• Tooth chunk out 909
• Brake fluid leaking 910
• Brake system is noisy 910
• Mechanical and hydraulic brakes 910
• Section 02 troubleshooting guide subsection 04 transmission and brake systems 910
• Symptom 910
• Electrical system 911
• Section 02 troubleshooting guide 911
• Starter does not turn 911
• Starter turns but does not crank the engine 911
• Subsection 05 electrical system 911
• Symptom 911
• The following chart is provided to help in diagnosing the probable source of troubles it should be used as a guideline some causes or corrections may not apply to a specific model 911
• Cont d 912
• Electric starter keeps turning when engine is started 912
• Section 02 troubleshooting guide subsection 05 electrical system 912
• Starter turns but does not crank the engine 912
• Starter turns but overrunning clutch pinion does not mesh with ring gear 912
• Symptom 912
• Cont d 913
• Electric starter keeps turning when engine is started 913
• Electric starter sometimes does not work when activated 913
• Engine does not start no spark at spark plug at engine crank ing 913
• Noise occurence when starting engine 913
• Optional electric starter does not work when turning ignition switch 913
• Regulator black wire is melted harness side 913
• Section 02 troubleshooting guide 913
• Subsection 05 electrical system 913
• Symptom 913
• Cdi mpem module does not work 914
• Cont d 914
• Engine does not start no spark at spark plug at engine crank ing 914
• Engine is misfiring erratic spark at spark plug riding on wet snow 914
• Engine stalls at low speed 914
• Irregular engine speed at high speed 914
• Irregular engine speed at low speed 914
• Section 02 troubleshooting guide subsection 05 electrical system 914
• Symptom 914
• Engine is misfiring erratic spark at spark plug normal use 915
• Engine is misfiring erratic spark at spark plug riding in deep and thick snow 915
• Fouled black spark plug tip 915
• Section 02 troubleshooting guide 915
• Spark plug tip s is are light grey 915
• Subsection 05 electrical system 915
• Symptom 915
• Headlamp diming 916
• Headlamp not lighting broken element 916
• Headlamp not lighting melted filament ends of element hold er and black bulb 916
• Headlamp not lighting white bulb 916
• Rer rotax electronic reverse does not work 916
• Rer rotax electronic reverse does not work at high altitude 916
• Section 02 troubleshooting guide subsection 05 electrical system 916
• Symptom 916
• Brake light remains on 917
• Cont d 917
• False fuel and or temperature gauge readings 917
• Headlamp diming 917
• Section 02 troubleshooting guide 917
• Subsection 05 electrical system 917
• Symptom 917
• With engine idling no electrical accessories work 917
• High beam pilot lamp lights up when low beam is selected 918
• Rear light bulb flashes 918
• Section 02 troubleshooting guide subsection 05 electrical system 918
• Symptom 918
• Tachometer does not work 918
• Rear suspension bottoms out 919
• Rear suspension is too stiff 919
• Section 02 troubleshooting guide subsection 06 suspension and track 919
• Suspension and track 919
• Suspension is too low 919
• Symptom 919
• The following chart is provided to help diagnose the probable source of troubles it should be used as a guideline some causes or corrections may not apply to a specific model 919
• When handlebar is turned snowmobile understeers 919
• Cont d 920
• Handlebar is difficult to turn 920
• Section 02 troubleshooting guide subsection 06 suspension and track 920
• Slider shoes wear out prematurely or track cleats become blue 920
• Symptom 920
• The snowmobile zigzags 920
• When handlebar is turned snowmobile understeers 920
• Derailing track 921
• Noise or vibration coming from the track 921
• Section 02 troubleshooting guide subsection 06 suspension and track 921
• Symptom 921
• Engine type 922
• Section 03 engines 2 stroke 922
• Service products 922
• Service tools 922
• Subsection 01 277 engine type 922
• Engine removal and installation 923
• Section 03 engines 2 stroke subsection 01 277 engine type 923
• Engine support and muffler disassembly and assembly 924
• Installation on vehicle 924
• Removal from vehicle 924
• Section 03 engines 2 stroke 924
• Subsection 01 277 engine type 924
• Section 03 engines 2 stroke subsection 01 277 engine type 925
• Top end 925
• Cleaning 926
• Disassembly 926
• Piston 926
• Section 03 engines 2 stroke 926
• Subsection 01 277 engine type 926
• Top end removal without removing engine from chassis 926
• Troubleshooting 926
• Section 03 engines 2 stroke subsection 01 277 engine type 927
• Assembly 928
• Inspection 928
• Section 03 engines 2 stroke 928
• Subsection 01 277 engine type 928
• Section 03 engines 2 stroke subsection 01 277 engine type 929
• Section 03 engines 2 stroke 930
• Subsection 01 277 engine type 930
• Section 03 engines 2 stroke subsection 01 277 engine type 931
• Bottom end 932
• Section 03 engines 2 stroke 932
• Subsection 01 277 engine type 932
• 6 crankcase half 933
• Assembly 933
• Cleaning 933
• Disassembly 933
• General 933
• Inspection 933
• Section 03 engines 2 stroke subsection 01 277 engine type 933
• Section 03 engines 2 stroke 934
• Subsection 01 277 engine type 934
• And 552 engines 935
• Section 03 engines 2 stroke 935
• Service products 935
• Service tools 935
• Subsection 02 443 and 552 engines 935
• Engine 936
• Engine removal and installation 936
• Section 03 engines 2 stroke subsection 02 443 and 552 engines 936
• Engine removal and installation 938
• Section 03 engines 2 stroke subsection 02 443 and 552 engines 938
• Warning 938
• Engine 939
• Section 03 engines 2 stroke 939
• Subsection 02 443 and 552 engines 939
• Top end 939
• Engine 940
• Section 03 engines 2 stroke subsection 02 443 and 552 engines 940
• Cleaning 941
• Disassembly 941
• General 941
• Section 03 engines 2 stroke 941
• Subsection 02 443 and 552 engines 941
• Troubleshooting 941
• Section 03 engines 2 stroke subsection 02 443 and 552 engines 942
• Assembly 943
• Inspection 943
• Section 03 engines 2 stroke 943
• Subsection 02 443 and 552 engines 943
• Section 03 engines 2 stroke subsection 02 443 and 552 engines 944
• Section 03 engines 2 stroke 945
• Subsection 02 443 and 552 engines 945
• Section 03 engines 2 stroke subsection 02 443 and 552 engines 946
• Section 03 engines 2 stroke 947
• Subsection 02 443 and 552 engines 947
• Reed valve 948
• Section 03 engines 2 stroke subsection 02 443 and 552 engines 948
• Bottom end 949
• Engine 949
• Section 03 engines 2 stroke 949
• Subsection 02 443 and 552 engines 949
• Engine 950
• Section 03 engines 2 stroke subsection 02 443 and 552 engines 950
• Cleaning 951
• Disassembly 951
• Section 03 engines 2 stroke 951
• Subsection 02 443 and 552 engines 951
• Assembly 952
• Inspection 952
• Section 03 engines 2 stroke subsection 02 443 and 552 engines 952
• Section 03 engines 2 stroke 953
• Subsection 02 443 and 552 engines 953
• Section 03 engines 2 stroke subsection 02 443 and 552 engines 954
• Warning 954
• Section 03 engines 2 stroke 955
• Subsection 02 443 and 552 engines 955
• Section 03 engines 2 stroke subsection 02 443 and 552 engines 956
• After rebuilding an engine always observe a break in period as described in operator s guide 957
• All engines to install magneto refer to magneto system 957
• Break in 957
• Engine 957
• Note do not use loctite primer n with this sealant the sealant curing time is similar to the loctite 518 without using the primer n which is 4 to 24 hours screw all crankcase bolts in place in the following sequence and to the appropriate torque through a two steps torquing first screw bolts up to 60 of the final torque 13 n m 115 lbf in for m8 bolts then tighten to the required torque i e 22 n m 16 lbf ft 957
• Section 03 engines 2 stroke 957
• Subsection 02 443 and 552 engines 957
• And 593 ho sdi engines 958
• Section 03 engines 2 stroke 958
• Service products 958
• Service tools 958
• Subsection 03 593 and 593 ho sdi engines 958
• Installation on vehicle 959
• Removal from vehicle 959
• Section 03 engines 2 stroke subsection 03 593 and 593 ho sdi engines 959
• Engine 960
• Section 03 engines 2 stroke 960
• Subsection 03 593 and 593 ho sdi engines 960
• Top end 960
• Ho sdi engine 961
• Section 03 engines 2 stroke subsection 03 593 and 593 ho sdi engines 961
• Cleaning 962
• Component removal 962
• General 962
• Rave valve basic operation 962
• Section 03 engines 2 stroke 962
• Subsection 03 593 and 593 ho sdi engines 962
• Troubleshooting 962
• Boring precaution 963
• Disassembly 963
• Maintenance 963
• Rave system 963
• Section 03 engines 2 stroke subsection 03 593 and 593 ho sdi engines 963
• Warning 963
• Section 03 engines 2 stroke 964
• Subsection 03 593 and 593 ho sdi engines 964
• Cylinder 965
• Cylinder head 965
• Cylinder head cover 965
• Piston 965
• Reed valve 965
• Section 03 engines 2 stroke subsection 03 593 and 593 ho sdi engines 965
• Section 03 engines 2 stroke 966
• Subsection 03 593 and 593 ho sdi engines 966
• Cylinder head cover cylinder head and cylinder 967
• Exhaust manifold 967
• Inspection 967
• Rave system 967
• Section 03 engines 2 stroke subsection 03 593 and 593 ho sdi engines 967
• Assembly 968
• Bellows 968
• Cylinder and piston 968
• Cylinder head cover cylinder head and cylinder 968
• Rave system 968
• Section 03 engines 2 stroke 968
• Spring 968
• Subsection 03 593 and 593 ho sdi engines 968
• Section 03 engines 2 stroke subsection 03 593 and 593 ho sdi engines 969
• Section 03 engines 2 stroke 970
• Subsection 03 593 and 593 ho sdi engines 970
• Section 03 engines 2 stroke subsection 03 593 and 593 ho sdi engines 971
• Reed valve 972
• Section 03 engines 2 stroke 972
• Subsection 03 593 and 593 ho sdi engines 972
• Bottom end 973
• Engine 973
• Section 03 engines 2 stroke subsection 03 593 and 593 ho sdi engines 973
• Ho sdi engine 974
• Section 03 engines 2 stroke 974
• Subsection 03 593 and 593 ho sdi engines 974
• Cleaning 975
• Crankshaft bearing 975
• Disassembly 975
• General 975
• Section 03 engines 2 stroke subsection 03 593 and 593 ho sdi engines 975
• Assembly 976
• Crankshaft bearing 976
• Inspection 976
• Section 03 engines 2 stroke 976
• Subsection 03 593 and 593 ho sdi engines 976
• Section 03 engines 2 stroke subsection 03 593 and 593 ho sdi engines 977
• Warning 977
• Section 03 engines 2 stroke 978
• Subsection 03 593 and 593 ho sdi engines 978
• Section 03 engines 2 stroke subsection 03 593 and 593 ho sdi engines 979
• Section 03 engines 2 stroke 980
• Subsection 03 593 and 593 ho sdi engines 980
• After rebuilding an engine always observe a break in period as described in operator s guide 981
• Break in 981
• Ho sdi engine install oil seal cover 981
• Screw all crankcase bolts in place in the following sequence and to the appropriate torque through a two steps torquing first screw bolts up to 60 of the final torque 18 n m 13 lbf ft for most of the bolts then tighten to the required torque i e 29 n m 21 lbf ft 981
• Section 03 engines 2 stroke subsection 03 593 and 593 ho sdi engines 981
• Leak test 982
• Leak test and engine dimension measurement 982
• Preparation 982
• Section 03 engines 2 stroke 982
• Service tools 982
• Subsection 04 leak test and engine dimension measurement 982
• Engine 983
• Procedure 983
• Section 03 engines 2 stroke subsection 04 leak test and engine dimension measurement 983
• Pump shaft oil gear reservoir 984
• Section 03 engines 2 stroke 984
• Subsection 04 leak test and engine dimension measurement 984
• Finalizing reassembly 985
• Section 03 engines 2 stroke subsection 04 leak test and engine dimension measurement 985
• Engine leak verification flow chart 986
• Section 03 engines 2 stroke 986
• Subsection 04 leak test and engine dimension measurement 986
• Combustion chamber volume measurement 987
• Cylinder head warpage 987
• Cylinder out of round 987
• Cylinder taper 987
• Engine dimension measurement 987
• Section 03 engines 2 stroke subsection 04 leak test and engine dimension measurement 987
• Section 03 engines 2 stroke 988
• Subsection 04 leak test and engine dimension measurement 988
• Cylinder piston clearance 989
• Section 03 engines 2 stroke subsection 04 leak test and engine dimension measurement 989
• Used piston measurement 989
• Section 03 engines 2 stroke 990
• Subsection 04 leak test and engine dimension measurement 990
• Crankshaft deflection 991
• Crankshaft deflection on mag side 991
• Crankshaft deflection on pto side 991
• Measuring in crankcase 991
• Measuring on bench 991
• Ring end gap 991
• Ring piston groove clearance 991
• Section 03 engines 2 stroke subsection 04 leak test and engine dimension measurement 991
• A standard compressed crankcase gasket will have a 0 0 mm 12 in thickness 992
• Add these measurements to obtain dimension a 992
• Adjustment crankshaft end play is adjusted with shims locat ed between crankshaft and magneto side bearing 992
• Caution always install end play adjustment shims on the magneto side between bearing and crankshaft counterweight the following is required for the adjustment pro cedure adjustment shims refer to parts catalog 992
• Connecting rod big end axial play 992
• Crankshaft deflection in center of crankshaft 992
• Crankshaft end play 992
• Engine type 992
• Micrometer caliper total shim thickness needed for the end play ad justment is determined with the following proce dure measure crankcase halves as illustrated 992
• Note crankshaft deflection cannot be correctly measured between centers of a lathe note if the deflection exceeds the specified tol erance crankshaft should be repaired or replaced 992
• Section 03 engines 2 stroke 992
• Subsection 04 leak test and engine dimension measurement 992
• Using a feeler gauge measure distance between thrust washer and crankshaft counterweight if the distance exceeds specified tolerance repair or replace the crankshaft 992
• Checking surface flatness 993
• Section 03 engines 2 stroke subsection 04 leak test and engine dimension measurement 993
• Checking crankshaft alignment 994
• Rectifying surfaces 994
• Section 03 engines 2 stroke 994
• Subsection 04 leak test and engine dimension measurement 994
• Clutch holder 529 027 600 128 crankshaft protector 420 876 557 129 magneto puller 529 035 547 129 magneto puller ring 420 876 080 128 995
• Loctite 243 293 800 060 129 130 silicone dielectric grease 293 550 004 130 995
• Magneto system 995
• Section 03 engines 2 stroke subsection 05 magneto system 995
• Service products 995
• Service tools 995
• Engine 996
• Section 03 engines 2 stroke subsection 05 magneto system 996
• And 552 engines 997
• Section 03 engines 2 stroke subsection 05 magneto system 997
• Engine 998
• Section 03 engines 2 stroke subsection 05 magneto system 998
• Sdi engine 999
• Section 03 engines 2 stroke subsection 05 magneto system 999
• Cleaning 1000
• Disassembly 1000
• General 1000
• Magneto flywheel 1000
• Section 03 engines 2 stroke subsection 05 magneto system 1000
• Warning 1000
• Assembly 1001
• Magneto flywheel 1001
• Section 03 engines 2 stroke subsection 05 magneto system 1001
• Stator 1001
• Trigger coil 1001
• Ignition timing 1002
• Section 03 engines 2 stroke subsection 05 magneto system 1002
• Gear holder 420 876 695 137 hose pinchers 295 000 076 136 leak testing kit 529 033 100 136 1003
• Loctite 648 green 413 711 400 138 molykote 111 413 707 000 137 pulley flange cleaner 413 711 809 138 1003
• Oil injection system 1003
• Section 03 engines 2 stroke 1003
• Service products 1003
• Service tools 1003
• Subsection 06 oil injection system 1003
• Engine 1004
• Oil injection pump 1004
• Section 03 engines 2 stroke subsection 06 oil injection system 1004
• Engine 1005
• Section 03 engines 2 stroke 1005
• Subsection 06 oil injection system 1005
• Engine 1006
• Section 03 engines 2 stroke subsection 06 oil injection system 1006
• And 593 ho sdi engines 1007
• Section 03 engines 2 stroke 1007
• Subsection 06 oil injection system 1007
• General 1008
• Oil pump identification 1008
• Oil system leak test 1008
• Oil type 1008
• Pump lever 1008
• Section 03 engines 2 stroke subsection 06 oil injection system 1008
• Warning 1008
• 6 gear retaining nut and oil pump gear 1009
• Assembly 1009
• Cleaning 1009
• Disassembly 1009
• Injection oil pump 1009
• Needle roller fan cooled engine only 1009
• Oil pump gear 1009
• Section 03 engines 2 stroke 1009
• Spring clip 1009
• Subsection 06 oil injection system 1009
• Adjustment 1010
• Check valve 1010
• Section 03 engines 2 stroke subsection 06 oil injection system 1010
• Section 03 engines 2 stroke 1011
• Subsection 06 oil injection system 1011
• Bleeding oil lines 1012
• Check valve 1012
• Checking operation 1012
• Oil pump 1012
• Section 03 engines 2 stroke subsection 06 oil injection system 1012
• Warning 1012
• Axial fan cooling system 1013
• Holder wrench 420 876 357 144 146 1013
• Holder wrench for the 443 engine 420 876 357 143 holder wrench for the 5 52 engine 529 036 006 143 loctite 243 blue 293 800 060 144 146 1013
• Section 03 engines 2 stroke 1013
• Service products 1013
• Service tools 1013
• Subsection 07 axial fan cooling system 1013
• And 552 engines note for 277 engine radial fan cooling system refer to cdi system 1014
• Section 03 engines 2 stroke subsection 07 axial fan cooling system 1014
• Cleaning 1015
• Disassembly and assembly 1015
• Removal 1015
• Section 03 engines 2 stroke 1015
• Subsection 07 axial fan cooling system 1015
• Fan belt replacement and deflection adjustment 1016
• Installation 1016
• Section 03 engines 2 stroke subsection 07 axial fan cooling system 1016
• Warning 1016
• Fan belt deflection adjustment 1017
• Reassembly 1017
• Section 03 engines 2 stroke 1017
• Subsection 07 axial fan cooling system 1017
• Finalizing reassembly 1018
• Section 03 engines 2 stroke subsection 07 axial fan cooling system 1018
• Warning 1018
• Liquid cooling system 1019
• Section 03 engines 2 stroke 1019
• Service products 1019
• Service tools 1019
• Subsection 08 liquid cooling system 1019
• Engine 1020
• Section 03 engines 2 stroke subsection 08 liquid cooling system 1020
• Coolant pump 1021
• Coolant tank 1021
• Cooling system leak test 1021
• Disassembly and assembly 1021
• Draining the system 1021
• Inspection 1021
• Pressure cap 1021
• Radiators 1021
• Section 03 engines 2 stroke 1021
• Subsection 08 liquid cooling system 1021
• Thermostat 1021
• Warning 1021
• Section 03 engines 2 stroke subsection 08 liquid cooling system 1022
• Cooling system refilling procedure 1023
• Refilling procedure 1023
• Section 03 engines 2 stroke 1023
• Subsection 08 liquid cooling system 1023
• System capacity 1023
• Molykote pg 54 420 899 763 157 159 1024
• Rewind starter 1024
• Section 03 engines 2 stroke 1024
• Service products 1024
• Subsection 09 rewind starter 1024
• Rewind starter on fan cooled models 1025
• Section 03 engines 2 stroke subsection 09 rewind starter 1025
• Rewind starter on liquid cooled models 1026
• Section 03 engines 2 stroke 1026
• Subsection 09 rewind starter 1026
• Inspection 1027
• Removal 1027
• Rope replacement 1027
• Section 03 engines 2 stroke subsection 09 rewind starter 1027
• Assembly 1028
• Disassembly 1028
• Section 03 engines 2 stroke 1028
• Subsection 09 rewind starter 1028
• Warning 1028
• Section 03 engines 2 stroke subsection 09 rewind starter 1029
• Section 03 engines 2 stroke 1030
• Subsection 09 rewind starter 1030
• Installation 1031
• Section 03 engines 2 stroke subsection 09 rewind starter 1031
• Carburetor tool kit 404 112 000 165 choke plunger tool 529 032 100 171 float level gauge 529 035 520 167 hose pincher 295 000 076 172 173 vacuum pressure pump kit 529 021 800 172 1032
• Fuel system 1032
• Section 03 engines 2 stroke 1032
• Service products 1032
• Service tools 1032
• Silicone grease 293 550 004 169 1032
• Subsection 10 fuel system 1032
• Carburetor 1033
• Section 03 engines 2 stroke subsection 10 fuel system 1033
• Tundra 1033
• Section 03 engines 2 stroke 1034
• Skandic lt lt e 1034
• Subsection 10 fuel system 1034
• Section 03 engines 2 stroke subsection 10 fuel system 1035
• Skandic wt suv swt 1035
• Cleaning and inspection 1036
• Disassembly and assembly 1036
• Identification 1036
• Removal 1036
• Section 03 engines 2 stroke 1036
• Subsection 10 fuel system 1036
• Warning 1036
• Carburetor adjustments 1037
• E clip and needle 1037
• Float arm 1037
• Main jet 1037
• Section 03 engines 2 stroke subsection 10 fuel system 1037
• Air screw adjustment 1038
• Section 03 engines 2 stroke 1038
• Subsection 10 fuel system 1038
• Throttle slide height 1038
• Installation 1039
• Section 03 engines 2 stroke subsection 10 fuel system 1039
• Section 03 engines 2 stroke 1040
• Subsection 10 fuel system 1040
• Throttle cable adjustment 1040
• Throttle cable circlip at handlebar 1040
• Throttle cable routing 1040
• Warning 1040
• Carburetor synchronization 1041
• Choke plunger adjustment 1041
• Idle speed final adjustment 1041
• Idle speed screw 1041
• Section 03 engines 2 stroke subsection 10 fuel system 1041
• Warning 1041
• Section 03 engines 2 stroke 1042
• Subsection 10 fuel system 1042
• Cleaning and inspection 1043
• Fuel pump 1043
• Pump verification 1043
• Removal 1043
• Section 03 engines 2 stroke subsection 10 fuel system 1043
• Fuel tank 1044
• Fuel tank lines 1044
• Impulse fuel lines spring clips 1044
• Installation 1044
• Section 03 engines 2 stroke 1044
• Subsection 10 fuel system 1044
• Warning 1044
• Leak test 1045
• Leak test procedure 1045
• Preparation 1045
• Preparation and test 1045
• Verification 1045
• Warning 1045
• Installation 1046
• Preparation 1046
• Section 04 engine 4 tec subsection 01 leak test 1046
• Removal and installation 1047
• Section 04 engine 4 tec 1047
• Subsection 02 removal and installation 1047
• Engine removal 1048
• Section 04 engine 4 tec subsection 02 removal and installation 1048
• Warning 1048
• Section 04 engine 4 tec 1049
• Subsection 02 removal and installation 1049
• Engine installation 1050
• Section 04 engine 4 tec subsection 02 removal and installation 1050
• Section 04 engine 4 tec 1051
• Subsection 02 removal and installation 1051
• Cooling system 1052
• Section 04 engine 4 tec 1052
• Service products 1052
• Service tools 1052
• Subsection 03 cooling system 1052
• Section 04 engine 4 tec subsection 03 cooling system 1053
• Section 04 engine 4 tec 1054
• Subsection 03 cooling system 1054
• Coolant replacement 1055
• Cooling system leak test 1055
• Draining the system 1055
• Inspection 1055
• Recommended coolant 1055
• Section 04 engine 4 tec subsection 03 cooling system 1055
• System capacity 1055
• Warning 1055
• Refilling the system 1056
• Section 04 engine 4 tec 1056
• Subsection 03 cooling system 1056
• Coolant hoses 1057
• Inspection 1057
• Installation 1057
• Removal 1057
• Section 04 engine 4 tec subsection 03 cooling system 1057
• Water pump housing thermostat 1057
• Ignition cover 1058
• Inspection 1058
• Installation 1058
• Removal 1058
• Section 04 engine 4 tec 1058
• Subsection 03 cooling system 1058
• Warning 1058
• Water pump impeller 1058
• Inspection 1059
• Installation 1059
• Removal 1059
• Section 04 engine 4 tec subsection 03 cooling system 1059
• Warning 1059
• Water pump shaft 1059
• Section 04 engine 4 tec 1060
• Subsection 03 cooling system 1060
• Inspection 1061
• Installation 1061
• Section 04 engine 4 tec subsection 03 cooling system 1061
• Pressure cap 1062
• Radiators 1062
• Section 04 engine 4 tec 1062
• Subsection 03 cooling system 1062
• Lubrication system 1063
• Section 04 engine 4 tec 1063
• Service products 1063
• Service tools 1063
• Subsection 04 lubrication system 1063
• Section 04 engine 4 tec subsection 04 lubrication system 1064
• Section 04 engine 4 tec 1065
• Subsection 04 lubrication system 1065
• Engine oil pressure test 1066
• General 1066
• Oil level check 1066
• Section 04 engine 4 tec subsection 04 lubrication system 1066
• Warning 1066
• Inspection 1067
• Installation 1067
• Oil change 1067
• Oil filter 1067
• Removal 1067
• Section 04 engine 4 tec 1067
• Subsection 04 lubrication system 1067
• System capacity 1067
• Inspection 1068
• Installation 1068
• Oil tank 1068
• Removal 1068
• Section 04 engine 4 tec subsection 04 lubrication system 1068
• Engine oil pressure regulator 1069
• Inspection 1069
• Installation 1069
• Oil filter housing 1069
• Removal 1069
• Section 04 engine 4 tec 1069
• Subsection 04 lubrication system 1069
• Inspection 1070
• Installation 1070
• Oil pumps 1070
• Pressure oil pump 1070
• Removal 1070
• Section 04 engine 4 tec subsection 04 lubrication system 1070
• Inspection 1071
• Section 04 engine 4 tec 1071
• Subsection 04 lubrication system 1071
• Installation 1072
• Section 04 engine 4 tec subsection 04 lubrication system 1072
• Final test 1073
• Inspection 1073
• Installation 1073
• Removal 1073
• Section 04 engine 4 tec 1073
• Subsection 04 lubrication system 1073
• Suction oil pump 1073
• Cleaning and inspection 1074
• Installation 1074
• Oil nozzle 1074
• Oil sieves 1074
• Section 04 engine 4 tec subsection 04 lubrication system 1074
• Warning 1074
• Inspection 1075
• Installation 1075
• Reed valve 1075
• Section 04 engine 4 tec 1075
• Subsection 04 lubrication system 1075
• Cylinder and cylinder head 1076
• Section 04 engine 4 tec 1076
• Service products 1076
• Service tools 1076
• Subsection 05 cylinder and cylinder head 1076
• Cylinder cylinder head 1 front side 1077
• Section 04 engine 4 tec subsection 05 cylinder and cylinder head 1077
• Cylinder cylinder head 2 rear side 1078
• Section 04 engine 4 tec 1078
• Subsection 05 cylinder and cylinder head 1078
• General 1079
• Inspection 1079
• Installation 1079
• Removal 1079
• Section 04 engine 4 tec subsection 05 cylinder and cylinder head 1079
• Spark plug 1079
• Temperature sensor 1079
• Inspection 1080
• Installation 1080
• Removal 1080
• Removal cylinder 1 front side 1080
• Rocker arm 1080
• Section 04 engine 4 tec 1080
• Subsection 05 cylinder and cylinder head 1080
• Valve cover 1080
• Removal cylinder 2 rear side 1081
• Section 04 engine 4 tec subsection 05 cylinder and cylinder head 1081
• Inspection 1082
• Section 04 engine 4 tec 1082
• Subsection 05 cylinder and cylinder head 1082
• Chain tensioner 1083
• Installation 1083
• Removal 1083
• Section 04 engine 4 tec subsection 05 cylinder and cylinder head 1083
• Warning 1083
• Breather 1084
• Inspection 1084
• Installation 1084
• Removal 1084
• Section 04 engine 4 tec 1084
• Subsection 05 cylinder and cylinder head 1084
• Warning 1084
• Decompressor 1085
• Inspection 1085
• Installation 1085
• Removal 1085
• Section 04 engine 4 tec subsection 05 cylinder and cylinder head 1085
• Camshaft timing gear 1086
• Removal 1086
• Section 04 engine 4 tec 1086
• Subsection 05 cylinder and cylinder head 1086
• Cylinder head 1087
• Inspection 1087
• Installation 1087
• Removal 1087
• Section 04 engine 4 tec subsection 05 cylinder and cylinder head 1087
• Timing chain 1087
• Inspection 1088
• Installation 1088
• Section 04 engine 4 tec 1088
• Subsection 05 cylinder and cylinder head 1088
• Camshaft 1089
• Cleaning 1089
• Inspection 1089
• Removal 1089
• Section 04 engine 4 tec subsection 05 cylinder and cylinder head 1089
• Installation 1090
• Removal 1090
• Section 04 engine 4 tec 1090
• Subsection 05 cylinder and cylinder head 1090
• Valve springs 1090
• Warning 1090
• Inspection 1091
• Installation 1091
• Section 04 engine 4 tec subsection 05 cylinder and cylinder head 1091
• Inspection 1092
• Removal 1092
• Section 04 engine 4 tec 1092
• Subsection 05 cylinder and cylinder head 1092
• Check valve face and seat for burning or pittings and replace valve or cylinder head if there are signs of damage ensure to seat valves properly apply some lap ping compound to valve face and work valve on its seat with a lapping tool measure valve face contact width note the location of contact area should be in center of valve seat measure valve seat width using a caliper 1093
• If valve seat contact width is too wide or has dark spots replace the cylinder head 1093
• Replace cylinder head if valve guide is out of spec ification or has other damages such as wear or traces of friction 1093
• Section 04 engine 4 tec subsection 05 cylinder and cylinder head 1093
• Valve face and seat 1093
• Cylinder 1094
• Inspection 1094
• Installation 1094
• Removal 1094
• Section 04 engine 4 tec 1094
• Subsection 05 cylinder and cylinder head 1094
• Installation 1095
• Section 04 engine 4 tec subsection 05 cylinder and cylinder head 1095
• Piston 1096
• Section 04 engine 4 tec 1096
• Subsection 05 cylinder and cylinder head 1096
• Crankshaft drive gears 1097
• Crankshaft locking tool 529 035 900 235 241 piston circlip installer 529 035 765 244 protection mushroom 420 876 552 235 1097
• Loctite 243 293 800 060 241 molykote 111 413 707 000 241 1097
• Section 04 engine 4 tec 1097
• Service products 1097
• Service tools 1097
• Subsection 06 crankshaft drive gears 1097
• Section 04 engine 4 tec subsection 06 crankshaft drive gears 1098
• Section 04 engine 4 tec 1099
• Subsection 06 crankshaft drive gears 1099
• Drive gears 1100
• Inspection 1100
• Installation 1100
• Removal of alternator side timing chain 1100
• Removal of pto side timing chain 1100
• Section 04 engine 4 tec subsection 06 crankshaft drive gears 1100
• Timing chain 1100
• Inspection 1101
• Removal 1101
• Section 04 engine 4 tec 1101
• Subsection 06 crankshaft drive gears 1101
• Warning 1101
• Crankshaft 1102
• Inspection 1102
• Installation 1102
• Removal 1102
• Section 04 engine 4 tec subsection 06 crankshaft drive gears 1102
• Trigger wheel 1102
• Inspection 1103
• Section 04 engine 4 tec 1103
• Subsection 06 crankshaft drive gears 1103
• Section 04 engine 4 tec subsection 06 crankshaft drive gears 1104
• Crankshaft radial play alternator side measure crankshaft on alternator side compare to inside diameter of alternator bushing refer to crankcase 1105
• Crankshaft radial play pto side measure crankshaft on pto side compare to inside diameter of pto bushing refer to crankcase 1105
• Crankshaft radial play pto side support bearing measure crankshaft on pto side journal for sup port bearing compare to inside diameter of pto support bearing refer to pto cover in crankcase section 1105
• Section 04 engine 4 tec 1105
• Subsection 06 crankshaft drive gears 1105
• Installation 1106
• Section 04 engine 4 tec subsection 06 crankshaft drive gears 1106
• Crankshaft locking tool 1107
• Installation 1107
• Piston 1107
• Removal 1107
• Section 04 engine 4 tec 1107
• Subsection 06 crankshaft drive gears 1107
• Inspection 1108
• Section 04 engine 4 tec subsection 06 crankshaft drive gears 1108
• Section 04 engine 4 tec 1109
• Subsection 06 crankshaft drive gears 1109
• Inspection 1110
• Piston rings 1110
• Removal 1110
• Section 04 engine 4 tec subsection 06 crankshaft drive gears 1110
• For installation reverse the removal procedure pay attention to the following details note install the oil scraper ring first with o fac ing up then the lower compression taper face ring with the word top facing up then the up per compression rectangular ring with the word top facing up 1111
• Installation 1111
• Measure position for ring end gap in the area of 8 to 16 mm 15 to 30 in from top of cylinder note in order to correctly position the ring in the cylinder use piston as a pusher using a feeler gauge check ring end gap replace ring if gap exceeds above described specified tol erance 1111
• Ring end gap 1111
• Section 04 engine 4 tec 1111
• Subsection 06 crankshaft drive gears 1111
• Section 04 engine 4 tec subsection 06 crankshaft drive gears 1112
• Crankcase 1113
• Section 04 engine 4 tec 1113
• Service products 1113
• Service tools 1113
• Subsection 07 crankcase 1113
• Section 04 engine 4 tec subsection 07 crankcase 1114
• General 1115
• Inspection 1115
• Pto cover 1115
• Removal 1115
• Section 04 engine 4 tec 1115
• Subsection 07 crankcase 1115
• Installation 1116
• Section 04 engine 4 tec subsection 07 crankcase 1116
• Crankcase 1117
• Disassembly 1117
• Section 04 engine 4 tec 1117
• Subsection 07 crankcase 1117
• Inspection 1118
• Section 04 engine 4 tec subsection 07 crankcase 1118
• Warning 1118
• Section 04 engine 4 tec 1119
• Subsection 07 crankcase 1119
• Warning 1119
• Assembly 1120
• Section 04 engine 4 tec subsection 07 crankcase 1120
• Note at installation replace gasket rings no 15 slightly grease the gasket rings no 15 before as sembly using molykote 111 p n 413 707 000 torque cover screws no 14 to 9 n m 80 lbf in 1121
• Section 04 engine 4 tec 1121
• Subsection 07 crankcase 1121
• Overview 1122
• Air induction 1123
• Component description 1123
• Fuel delivery system 1123
• Fuel injectors 1123
• Fuel pickups 1123
• Fuel pump and fuel pressure regulator 1123
• Fuel rail 1123
• General 1123
• Operating principle 1123
• Section 05 engine management 2 tec subsection 01 overview 1123
• Throttle body 1123
• Engine management system ems 1124
• In line fuel filter 1124
• Section 05 engine management 2 tec 1124
• Subsection 01 overview 1124
• Antidrive feature 1125
• Automatic power shut down 1125
• Digitally encoded security system dess 1125
• Ems general functions 1125
• Engine rpm limiter 1125
• Engine starting 1125
• Gauges current supply 1125
• High coolant temperature warning device 1125
• Low oil level warning device 1125
• Section 05 engine management 2 tec subsection 01 overview 1125
• High muffler temperature warning device 1126
• Power distribution 1126
• Section 05 engine management 2 tec 1126
• Subsection 01 overview 1126
• Electronic fuel injection 1127
• Ems engine management system functions 1127
• Section 05 engine management 2 tec subsection 01 overview 1127
• Electronically controlled rave 1128
• Engine modes of operation 1128
• Flooded engine drowned mode 1128
• Ignition timing 1128
• Knock sensor 1128
• Limp home modes 1128
• Monitoring system 1128
• Section 05 engine management 2 tec 1128
• Subsection 01 overview 1128
• Charging system 1129
• Diagnostic mode 1129
• Double ignition coil 1129
• Ignition system 1129
• Section 05 engine management 2 tec subsection 01 overview 1129
• Trigger coil 1129
• Diagnostic procedure 1130
• General 1130
• Section 05 engine management 2 tec 1130
• Service tools 1130
• Subsection 02 diagnostic procedure 1130
• Monitoring beeper coded signals 1131
• Section 05 engine management 2 tec subsection 02 diagnostic procedure 1131
• Troubleshooting 1131
• Vck vehicle communication kit 1131
• Warning 1131
• Ecm supply 1132
• General 1132
• Section 05 engine management 2 tec 1132
• Subsection 02 diagnostic procedure 1132
• Supplemental information 1132
• Tec system fault codes 1132
• Vck supply 1132
• Writing in ecm 1132
• Faults which are reported in b u d s fall into two groups tps faults and adaption faults these are dis played on the b u d s system as tps out of range and tps adaption failure 1133
• It is caused by the idle position moving out of an acceptable range following failures can be effected by a tps adaption failure idle speed is out of range engine stops when throttle is released quickly engine runs inconsistent in low partload or low rpm 1133
• It is caused by the sensor reading going out of its allowable range this fault can occur during the whole range of movement of the throttle to diagnose this fully it is recommended to operate the throttle through its full range it is also recom mended to release the throttle quickly as this may also reveal a fault that is intermittent 1133
• Section 05 engine management 2 tec subsection 02 diagnostic procedure 1133
• Tps adaptation failure fault 1133
• Tps out of range fault 1133
• Tps throttle position sensor faults 1133
• Component inspection and adjustment 1134
• Fuel system 1134
• General 1134
• Service products 1134
• Service tools 1134
• Warning 1134
• Electrical system 1135
• Section 05 engine management 2 tec subsection 03 component inspection and adjustment 1135
• Warning 1135
• Resistance measurement 1136
• Section 05 engine management 2 tec 1136
• Subsection 03 component inspection and adjustment 1136
• Warning 1136
• Section 05 engine management 2 tec subsection 03 component inspection and adjustment 1137
• The resistance value of a temperature sensor may test good at a certain temperature but it might be defective at other temperatures if in doubt try a new sensor also remember this validates the operation of the sensor at room temperature it does not validate the over temperature functionality to test it the sensor could be removed from the engine air si lencer and heated with a heat gun while it is still connected to the harness to see if the ecm will detect the high temperature condition and gener ate a fault code 1137
• Caution do not disconnect the ecm connec tor needlessly they are not designed to be dis connected reconnected repeatedly 1138
• Caution probe on top of terminal only do not try to probe inside terminal or to use a pa per clip to probe inside terminal it will dam age the square shaped terminal and this could lead to improper function of the engine man agement system 1138
• Connector position 1138
• Ecm connector 1138
• Engine connector 1138
• Engine connector pin outs 1138
• Section 05 engine management 2 tec 1138
• Subsection 03 component inspection and adjustment 1138
• Use this diagram to locate the pin numbers on the ecm connector of the wiring harness when performing tests 1138
• Use this illustration to locate the pin numbers on the engine connector of the wiring harness when performing tests 1138
• Air induction system 1139
• Electrical inspection 1139
• Mechanical inspection 1139
• Replacement 1139
• Section 05 engine management 2 tec subsection 03 component inspection and adjustment 1139
• Throttle body 1139
• Adjustment 1140
• Section 05 engine management 2 tec 1140
• Subsection 03 component inspection and adjustment 1140
• Section 05 engine management 2 tec subsection 03 component inspection and adjustment 1141
• Fuel delivery 1142
• Section 05 engine management 2 tec 1142
• Subsection 03 component inspection and adjustment 1142
• Electrical test 1143
• Fuel pressure test 1143
• Fuel pump 1143
• Section 05 engine management 2 tec subsection 03 component inspection and adjustment 1143
• Warning 1143
• Fuel pump module replacement 1144
• Section 05 engine management 2 tec 1144
• Subsection 03 component inspection and adjustment 1144
• Installation 1145
• Section 05 engine management 2 tec subsection 03 component inspection and adjustment 1145
• Fuel hose kit 1146
• Pump ass y kit 1146
• Section 05 engine management 2 tec 1146
• Subsection 03 component inspection and adjustment 1146
• Fuel rail replacement 1147
• Fuel rails 1147
• Regulator kit 1147
• Section 05 engine management 2 tec subsection 03 component inspection and adjustment 1147
• Warning 1147
• Electrical test 1148
• Fuel injectors 1148
• Leakage test 1148
• Section 05 engine management 2 tec 1148
• Subsection 03 component inspection and adjustment 1148
• Fuel injector replacement 1149
• Section 05 engine management 2 tec subsection 03 component inspection and adjustment 1149
• Warning 1149
• Ecm replacement 1150
• Electronic management 1150
• Engine wiring harness 1150
• General 1150
• Resistance test 1150
• Section 05 engine management 2 tec 1150
• Subsection 03 component inspection and adjustment 1150
• Warning 1150
• General 1151
• Installation 1151
• Removal 1151
• Section 05 engine management 2 tec subsection 03 component inspection and adjustment 1151
• Throttle position sensor tps 1151
• Voltage test 1151
• Wear test 1151
• Closed throttle reset 1152
• Replacement 1152
• Resistance test 1152
• Section 05 engine management 2 tec 1152
• Subsection 03 component inspection and adjustment 1152
• Crankshaft position sensor cps 1153
• Resistance test 1153
• Section 05 engine management 2 tec subsection 03 component inspection and adjustment 1153
• Air temperature sensor ats 1154
• Replacement 1154
• Resistance test 1154
• Section 05 engine management 2 tec 1154
• Subsection 03 component inspection and adjustment 1154
• Coolant temperature sensor cts 1155
• Replacement 1155
• Resistance test 1155
• Section 05 engine management 2 tec subsection 03 component inspection and adjustment 1155
• Air pressure sensor aps 1156
• Exhaust gas temperature sensor egts 1156
• Replacement 1156
• Section 05 engine management 2 tec 1156
• Subsection 03 component inspection and adjustment 1156
• Voltage test 1156
• Dynamic test 1157
• Knock sensor ks 1157
• Replacement 1157
• Resistance test 1157
• Section 05 engine management 2 tec subsection 03 component inspection and adjustment 1157
• Continuity test 1158
• Double ignition coil 1158
• E rave solenoid 1158
• Replacement 1158
• Resistance test 1158
• Section 05 engine management 2 tec 1158
• Subsection 03 component inspection and adjustment 1158
• Voltage test 1158
• Resistance test 1159
• Section 05 engine management 2 tec subsection 03 component inspection and adjustment 1159
• Voltage test 1159
• Warning 1159
• Dess switch verification 1160
• Disassembly 1160
• Engine start rer button verification 1160
• Ignition timing 1160
• Section 05 engine management 2 tec 1160
• Spark plug installation 1160
• Spark plugs 1160
• Subsection 03 component inspection and adjustment 1160
• Tether cord cap on dess post 1160
• Tether cord cap removed 1160
• Warning 1160
• Cranking system 1161
• Section 05 engine management 2 tec subsection 03 component inspection and adjustment 1161
• See above for start stop switch and the dess post testing 1161
• Overview 1162
• Air induction 1163
• Basic operation 1163
• Fuel delivery system 1163
• Operating principle of engine management 1163
• Section 06 engine management 4 tec subsection 01 overview 1163
• Fuel injector 1164
• Fuel pickups 1164
• Fuel pressure regulator 1164
• Fuel pump 1164
• Fuel pump module 1164
• Fuel rail 1164
• In line fuel filter 1164
• Intake manifold 1164
• Section 06 engine management 4 tec 1164
• Subsection 01 overview 1164
• Throttle body 1164
• Anti drive feature 1165
• Digitally encoded security system dess 1165
• Electronic management 1165
• Ems engine management system 1165
• Ems general functions 1165
• Section 06 engine management 4 tec subsection 01 overview 1165
• Engine rpm limiter 1166
• High coolant temperature warning device 1166
• Low oil pressure warning device 1166
• Section 06 engine management 4 tec 1166
• Subsection 01 overview 1166
• Ems engine management functions 1167
• Section 06 engine management 4 tec subsection 01 overview 1167
• This engine management system controls both the fuel injection and the ignition timing as shown in the 1004 4 tec control system illustration the ecm is the central point of the fuel injection system it reads the inputs makes computations uses pre determined parameters and sends the proper signals to the outputs for proper engine management the ecm also stores the fault codes and general information such as operating conditions vehicle hours serial numbers customer and maintenance information 1167
• Electronic fuel injection 1168
• Engine modes of operation 1168
• Flooded engine drowned mode 1168
• Ignition coils 1168
• Ignition system 1168
• Ignition timing 1168
• Limp home mode 1168
• Section 06 engine management 4 tec 1168
• Subsection 01 overview 1168
• Warning 1168
• Diagnostic mode 1169
• Monitoring system 1169
• Section 06 engine management 4 tec subsection 01 overview 1169
• Shutdown mode 1169
• Diagnostic procedure 1170
• General 1170
• Section 06 engine management 4 tec 1170
• Service tools 1170
• Subsection 02 diagnostic procedure 1170
• Terminology 1170
• Monitoring beeper coded signals 1171
• Section 06 engine management 4 tec subsection 02 diagnostic procedure 1171
• The vck vehicle communication kit p n 529 035 981 is the primary tool to diagnose engine management and fuel injection related problems 1171
• Vck vehicle communication kit 1171
• Ecm supply 1172
• General 1172
• Tec system fault codes 1172
• Vck supply 1172
• Warning 1172
• Writing in ecm 1172
• Section 06 engine management 4 tec subsection 02 diagnostic procedure 1173
• Supplemental information 1173
• Tec tps fault tables 1173
• Tps adaptation failure fault 1173
• Tps out of range fault 1173
• Tps throttle position sensor faults 1173
• Section 06 engine management 4 tec 1174
• Subsection 02 diagnostic procedure 1174
• Component inspection and adjustment 1175
• Fuel system 1175
• General 1175
• Service products 1175
• Service tools 1175
• Warning 1175
• Electrical system 1176
• Section 06 engine management 4 tec subsection 03 component inspection and adjustment 1176
• Warning 1176
• Resistance measurement 1177
• Section 06 engine management 4 tec 1177
• Subsection 03 component inspection and adjustment 1177
• Warning 1177
• Connector position 1178
• Connectors on engine 1178
• Ecm connector 1178
• Engine connector 1178
• Engine connector pin outs 1178
• Removal 1178
• Section 06 engine management 4 tec subsection 03 component inspection and adjustment 1178
• Air induction system 1179
• Electrical inspection 1179
• Mechanical inspection 1179
• Section 06 engine management 4 tec 1179
• Subsection 03 component inspection and adjustment 1179
• Throttle body 1179
• Replacement 1180
• Section 06 engine management 4 tec subsection 03 component inspection and adjustment 1180
• Section 06 engine management 4 tec 1181
• Subsection 03 component inspection and adjustment 1181
• Warning 1181
• Fuel delivery 1182
• Section 06 engine management 4 tec subsection 03 component inspection and adjustment 1182
• Fuel pressure test 1183
• Fuel pump 1183
• Section 06 engine management 4 tec 1183
• Subsection 03 component inspection and adjustment 1183
• Warning 1183
• Electrical test 1184
• Fuel pump module replacement 1184
• Section 06 engine management 4 tec subsection 03 component inspection and adjustment 1184
• Warning 1184
• Section 06 engine management 4 tec 1185
• Subsection 03 component inspection and adjustment 1185
• Fuel hose kit 1186
• Section 06 engine management 4 tec subsection 03 component inspection and adjustment 1186
• Fuel rail replacement 1187
• Fuel rails 1187
• Pump ass y kit 1187
• Regulator kit 1187
• Section 06 engine management 4 tec 1187
• Subsection 03 component inspection and adjustment 1187
• Electrical test 1188
• Fuel injectors 1188
• Leakage test 1188
• Section 06 engine management 4 tec subsection 03 component inspection and adjustment 1188
• Warning 1188
• Ecm replacement 1189
• Electronic management 1189
• Fuel injector replacement 1189
• General 1189
• Section 06 engine management 4 tec 1189
• Subsection 03 component inspection and adjustment 1189
• Warning 1189
• Ecm replacement 1190
• Engine wiring harness 1190
• Resistance test 1190
• Section 06 engine management 4 tec subsection 03 component inspection and adjustment 1190
• Warning 1190
• Section 06 engine management 4 tec 1191
• Subsection 03 component inspection and adjustment 1191
• General 1192
• Section 06 engine management 4 tec subsection 03 component inspection and adjustment 1192
• Throttle position sensor tps 1192
• Voltage test 1192
• Wear test 1192
• Replacement 1193
• Resistance test 1193
• Section 06 engine management 4 tec 1193
• Subsection 03 component inspection and adjustment 1193
• Closed throttle and idle actuator reset 1194
• Idle bypass valve 1194
• Resistance test 1194
• Section 06 engine management 4 tec subsection 03 component inspection and adjustment 1194
• Crankshaft position sensor cps 1195
• Resistance test 1195
• Section 06 engine management 4 tec 1195
• Subsection 03 component inspection and adjustment 1195
• Visual inspection 1195
• Warning 1195
• Camshaft position sensor caps 1196
• Replacement 1196
• Section 06 engine management 4 tec subsection 03 component inspection and adjustment 1196
• Trigger wheel inspection 1196
• Voltage test harness 1197
• Air temperature sensor ats 1198
• Replacement 1198
• Resistance test 1198
• Section 06 engine management 4 tec subsection 03 component inspection and adjustment 1198
• Coolant temperature sensor cts 1199
• Manifold air pressure sensor maps 1199
• Replacement 1199
• Resistance test 1199
• Section 06 engine management 4 tec 1199
• Subsection 03 component inspection and adjustment 1199
• Voltage test 1199
• Oil pressure switch ops 1200
• Oil pressure test 1200
• Replacement 1200
• Resistance test 1200
• Section 06 engine management 4 tec subsection 03 component inspection and adjustment 1200
• Verification test 1200
• Ignition coils 1201
• Section 06 engine management 4 tec 1201
• Subsection 03 component inspection and adjustment 1201
• Voltage test 1201
• Warning 1201
• Engine start switch verification 1202
• Resistance test 1202
• Section 06 engine management 4 tec subsection 03 component inspection and adjustment 1202
• Warning 1202
• Dess switch verification 1203
• Disassembly 1203
• Section 06 engine management 4 tec 1203
• Spark plug installation 1203
• Spark plugs 1203
• Subsection 03 component inspection and adjustment 1203
• Tether cord cap on dess post 1203
• Tether cord cap removed 1203
• Warning 1203
• Cranking system 1204
• Section 06 engine management 4 tec subsection 03 component inspection and adjustment 1204
• See above for start switch and the dess post test ing 1204
• Application chart 1205
• Checking neutral function 1205
• Cleaning 1205
• Drive belt 1205
• Inspection 1205
• Service products 1205
• Service tools 1205
• Warning 1205
• Drive belt height measurement and adjustment 1206
• Measurement 1206
• Rotation direction 1206
• Section 07 transmission subsection 01 drive belt 1206
• Drive belt deflection measurement reference only 1207
• Section 07 transmission 1207
• Subsection 01 drive belt 1207
• Or use the belt tension tester p n 414 348 200 1208
• Section 07 transmission subsection 01 drive belt 1208
• Slide lower o ring of tester to specified deflec tion 2 slide upper o ring of tester until reaching mark 0 zero 3 apply pressure until lower o ring is flush with edge of rule and read force on the upper scale at top edge of o ring 1208
• Drive pulley 1209
• Section 07 transmission subsection 02 drive pulley 1209
• Service products 1209
• Service tools 1209
• Bombardier lite 1210
• Note this is a lubrication free drive pulley 1210
• Section 07 transmission subsection 02 drive pulley 1210
• Tundra skandic wt 550 swt suv 550 1210
• Disassembly 1211
• General 1211
• Removal 1211
• Section 07 transmission subsection 02 drive pulley 1211
• Warning 1211
• Assembly 1212
• Cap washer and disk 1212
• Cleaning 1212
• Inspection 1212
• Section 07 transmission subsection 02 drive pulley 1212
• Installation 1213
• Section 07 transmission subsection 02 drive pulley 1213
• Warning 1213
• Section 07 transmission subsection 02 drive pulley 1214
• Skandic lt lt e 1214
• Cam arm bushing 1215
• Cam arm pivot nut 1215
• General 1215
• Maintenance 1215
• Removal 1215
• Section 07 transmission subsection 02 drive pulley 1215
• Warning 1215
• Disassembly 1216
• Section 07 transmission subsection 02 drive pulley 1216
• Assembly 1217
• Cleaning 1217
• Inspection 1217
• Section 07 transmission subsection 02 drive pulley 1217
• Installation 1218
• Section 07 transmission subsection 02 drive pulley 1218
• Warning 1218
• All liquid cooled models except 4 tec models note these are lubrication free drive pulleys always refer to appropriate parts catalog for replacement part most parts of tra iii are not interchangeable with those of the tra 1219
• Section 07 transmission subsection 02 drive pulley 1219
• Tra iii 1219
• Section 07 transmission subsection 02 drive pulley 1220
• Tec models note this is a lubrication free drive pulleys always refer to appropriate parts catalog for replacement part most parts of tra iv are not interchangeable with those of the tra tra iii 1220
• Tra iv 1220
• 31 conical spring washer and screw 1221
• General 1221
• Removal 1221
• Section 07 transmission subsection 02 drive pulley 1221
• Warning 1221
• 2 screw and ring gear 1222
• 29 slider shoe and governor cup 1222
• 6 fixed and sliding halves 1222
• Cushion drive 1222
• Disassembly 1222
• Section 07 transmission subsection 02 drive pulley 1222
• 29 fixed half crankshaft end and governor cup fixed half post 1223
• 6 fixed and sliding halves 1223
• Cleaning 1223
• Section 07 transmission subsection 02 drive pulley 1223
• Spring cover ass y 1223
• Warning 1223
• 12 fitting bolt ass y and flanged bushing 1224
• 17 thrust washer and roller 1224
• 20 bushing 1224
• 20 sliding half and spring cover bushing 1224
• 25 o ring and slider shoe 1224
• 29 fixed half and governor cup 1224
• Inspection 1224
• Section 07 transmission subsection 02 drive pulley 1224
• Section 07 transmission subsection 02 drive pulley 1225
• 2 3 screw ring gear and loctite 271 1226
• 22 23 screw dowel tube and ramp 1226
• 27 28 calibration screw washer and locking nut 1226
• Assembly 1226
• Section 07 transmission subsection 02 drive pulley 1226
• 11 13 14 screw lever ass y nut and cotter pin 1227
• Section 07 transmission subsection 02 drive pulley 1227
• Warning 1227
• 25 29 sliding half slider shoe and governor cup 1228
• 6 18 19 fixed half sliding half spring spring cover and screw 1228
• Section 07 transmission subsection 02 drive pulley 1228
• Section 07 transmission subsection 02 drive pulley 1229
• Drive pulley ass y 1230
• Installation 1230
• Section 07 transmission subsection 02 drive pulley 1230
• Warning 1230
• 28 29 calibration screw locking nut and governor cup 1231
• Drive pulley adjustment 1231
• Section 07 transmission subsection 02 drive pulley 1231
• Warning 1231
• Section 07 transmission subsection 02 drive pulley 1232
• Driven pulley 1233
• Section 07 transmission 1233
• Service products 1233
• Service tools 1233
• Subsection 03 driven pulley 1233
• Section 07 transmission subsection 03 driven pulley 1234
• Tundra 1234
• Chaincase 1235
• Disassembly 1235
• Removal 1235
• Section 07 transmission 1235
• Subsection 03 driven pulley 1235
• Warning 1235
• 4 5 roller pin outer cam and spring 1236
• 9 slider shoe 1236
• Assembly 1236
• Inspection 1236
• Large bushing 1236
• Section 07 transmission subsection 03 driven pulley 1236
• 12 shim 1237
• 14 15 fixed pulley half brake disc and screw 1237
• Adjustment 1237
• Installation 1237
• Pulley alignment and drive belt deflection 1237
• Section 07 transmission 1237
• Subsection 03 driven pulley 1237
• Section 07 transmission subsection 03 driven pulley 1238
• Skandic lt lt e 1238
• 11 slider shoe 1239
• Bushing replacement 1239
• Disassembly 1239
• Inspection 1239
• Section 07 transmission 1239
• Subsection 03 driven pulley 1239
• Warning 1239
• 11 cam slider shoe 1240
• 6 7 cam guard and spring 1240
• Assembly 1240
• Countershaft 1240
• Installation 1240
• Section 07 transmission subsection 03 driven pulley 1240
• Adjustment 1241
• Pulley alignment and drive belt deflection 1241
• Pulley retaining screw 1241
• Section 07 transmission 1241
• Subsection 03 driven pulley 1241
• Section 07 transmission subsection 03 driven pulley 1242
• Skandic wt wt lc swt suv expedition tuv 1242
• Adjustment 1243
• Assembly 1243
• Bushing 1243
• Cam slider shoe 1243
• Cleaning 1243
• Disassembly 1243
• Inspection 1243
• Installation 1243
• Pulley half cleaning 1243
• Removal 1243
• Section 07 transmission 1243
• Slider shoe 1243
• Spring 1243
• Subsection 03 driven pulley 1243
• Warning 1243
• Pulley alignment and drive belt deflection 1244
• Section 07 transmission subsection 03 driven pulley 1244
• General 1245
• General procedure 1245
• Measuring procedure 1245
• Pulley distance and alignment 1245
• Service tools 1245
• Warning 1245
• Drive belt height 1246
• Mean value procedure and quick alignment and distance check 1246
• Section 07 transmission subsection 04 pulley distance and alignment 1246
• Caution the rear suspension must be mounted on the vehicle and track tension and alignment must be done to provide the right frame width loosen the 4 chaincase retaining bolts unlock and raise pulley support 1247
• Move chaincase to obtain specific adjustment and adjust driven pulley support length accordingly light contact 1247
• Pulley alignment and distance specifications chart 1247
• Pulley distance adjustment method 1247
• Section 07 transmission 1247
• Subsection 04 pulley distance and alignment 1247
• Tundra 1247
• ➀ alignment bars have been made according to pulley alignment mean values however they do not take into account allowed tolerances for alignment specifications they are used as go nogo gauges for quick alignment and pulley distance check and as reference to reach alignment nominal values 1247
• Pulley alignment method 1248
• Section 07 transmission subsection 04 pulley distance and alignment 1248
• Section 07 transmission 1249
• Subsection 04 pulley distance and alignment 1249
• Section 07 transmission 1250
• Service products 1250
• Subsection 05 brake 1250
• Mechanical brake 1251
• Section 07 transmission subsection 05 brake 1251
• Tundra 1251
• Section 07 transmission 1252
• Skandic lt 1252
• Subsection 05 brake 1252
• Hydraulic brake 1253
• Section 07 transmission subsection 05 brake 1253
• Skandic wt swt wt lc suv expedition tuv 1253
• Brake fluid type 1254
• Brake pads replacement 1254
• Installation 1254
• Removal 1254
• Section 07 transmission 1254
• Subsection 05 brake 1254
• 15 16 23 brake pad brake lever pin and screw 1255
• Brake disc removal 1255
• Disassembly 1255
• Installation 1255
• Removal 1255
• Section 07 transmission subsection 05 brake 1255
• Warning 1255
• Assembly 1256
• Brake disc 1256
• Brake pad 1256
• Cleaning 1256
• Inspection 1256
• Installation 1256
• Ratchet wheel 1256
• Section 07 transmission 1256
• Subsection 05 brake 1256
• Warning 1256
• 11 12 locking tab outer caliper and nut 1257
• 12 brake cable and nut 1257
• Brake pad 1257
• Section 07 transmission subsection 05 brake 1257
• Upper clamp 1257
• Warning 1257
• Adjustment 1258
• Bleeding 1258
• Brake light 1258
• Section 07 transmission 1258
• Subsection 05 brake 1258
• Warning 1258
• Chaincase 1259
• Section 07 transmission 1259
• Service products 1259
• Service tools 1259
• Subsection 06 chaincase 1259
• Section 07 transmission subsection 06 chaincase 1260
• Tundra 1260
• Assembly 1261
• Chaincase and driven pulley assembly 1261
• Disassembly 1261
• Inspection 1261
• Removal 1261
• Section 07 transmission 1261
• Subsection 06 chaincase 1261
• Warning 1261
• Adjustment 1262
• Chaincase oil 1262
• Installation 1262
• Oil seal 1262
• Pulley alignment 1262
• Section 07 transmission subsection 06 chaincase 1262
• Track tension and alignment 1262
• Section 07 transmission 1263
• Skandic lt 1263
• Subsection 06 chaincase 1263
• 16 sprockets 1264
• Gear ratio modification 1264
• Inspection 1264
• Installation 1264
• Oil seal 1264
• Removal 1264
• Section 07 transmission subsection 06 chaincase 1264
• Warning 1264
• Adjustment 1265
• Chaincase oil 1265
• Circlip 1265
• Conical spring washer 1265
• Drive chain adjustment 1265
• O ring 1265
• Pulley alignment 1265
• Section 07 transmission 1265
• Subsection 06 chaincase 1265
• Track tension and alignment 1265
• Upper sprocket castellated nut 1265
• Warning 1265
• Gearbox 1266
• Section 07 transmission 1266
• Service products 1266
• Subsection 07 gearbox 1266
• Synthetic grease 413 711 500 415 xp s synthetic chaincase oil 413 802 800 418 1266
• Section 07 transmission subsection 07 gearbox 1267
• Skandic wt swt wt lc suv expedition tuv 1267
• Speed gearbox 1267
• Disassembly 1268
• General 1268
• Removal 1268
• Section 07 transmission 1268
• Subsection 07 gearbox 1268
• Section 07 transmission subsection 07 gearbox 1269
• Brake shaft 1270
• Section 07 transmission 1270
• Subsection 07 gearbox 1270
• Reverse shaft 1271
• Section 07 transmission subsection 07 gearbox 1271
• Pulley shaft 1272
• Section 07 transmission 1272
• Subsection 07 gearbox 1272
• Section 07 transmission subsection 07 gearbox 1273
• Intermediate shaft 1274
• Section 07 transmission 1274
• Subsection 07 gearbox 1274
• Assembly 1275
• Inspection 1275
• Section 07 transmission subsection 07 gearbox 1275
• Section 07 transmission 1276
• Subsection 07 gearbox 1276
• Section 07 transmission subsection 07 gearbox 1277
• Installation 1278
• Oil level 1278
• Section 07 transmission 1278
• Subsection 07 gearbox 1278
• Section 07 transmission subsection 07 gearbox 1279
• Chain attachment 1280
• Chain separation 1280
• Drive chain 1280
• General 1280
• Silent chain 1280
• Warning 1280
• Section 07 transmission subsection 08 drive chain 1281
• Ignition timing 1282
• Section 08 electrical 1282
• Service tools 1282
• Subsection 01 ignition timing 1282
• Verifying magneto flywheel timing mark position 1282
• Checking ignition timing 1283
• Section 08 electrical subsection 01 ignition timing 1283
• Warning 1283
• Section 08 electrical 1284
• Subsection 01 ignition timing 1284
• Verifying magneto flywheel timing mark position 1284
• Checking ignition timing 1285
• Section 08 electrical subsection 01 ignition timing 1285
• Section 08 electrical 1286
• Subsection 01 ignition timing 1286
• Warning 1286
• Scribing a timing mark 1287
• Section 08 electrical subsection 01 ignition timing 1287
• Checking ignition timing 1288
• Section 08 electrical 1288
• Subsection 01 ignition timing 1288
• Warning 1288
• Changing ignition timing 1289
• Section 08 electrical subsection 01 ignition timing 1289
• Section 08 electrical 1290
• Subsection 01 ignition timing 1290
• If the new correction factor selected above is the good one select no and press enter otherwise select yes to choose an other correction factor 1291
• Press any key 1291
• Press enter 1291
• Press menu scroll to no 7 save and quit 1291
• Section 08 electrical subsection 01 ignition timing 1291
• The display confirms that correction factor has been changed to no 5 1291
• Section 08 electrical 1292
• Subsection 01 ignition timing 1292
• Ngk spark plug 1293
• Ngk spark plug numbering system 1293
• Section 08 electrical 1293
• Service products 1293
• Spark plugs 1293
• Subsection 02 spark plugs 1293
• Design symbols used in ngk spark plugs 1294
• Disassembly 1295
• Fouling 1295
• Heat range 1295
• Section 08 electrical 1295
• Spark plug analysis 1295
• Subsection 02 spark plugs 1295
• Warning 1295
• Section 08 electrical subsection 02 spark plugs 1296
• Spark plug installation 1296
• Spark plug tightening torque 1296
• Alternator 1297
• Inspection 1297
• Installation 1297
• Removal 1297
• Section 08 electrical 1297
• Subsection 03 alternator 1297
• Battery 1298
• General 1298
• Removal 1298
• Service products 1298
• Service tools 1298
• Warning 1298
• Cleaning 1299
• Inspection 1299
• Section 08 electrical subsection 04 battery 1299
• Warning 1299
• A hydrometer measures the charge of a battery in terms of specific gravity of the electrolyte most hydrometers give a true reading at 25 c 77 f in order to obtain correct readings adjust the ini tial reading by adding 01 to the hydrometer read ings for each 2 c 3 f above 25 c 77 f and by subtracting 01 for every 2 c 3 f below 25 c 77 f this chart will be useful to find the correct reading 1300
• Battery charge testing 1300
• Example no 1 temperature below 25 c 77 f hydrometer reading 1 50 electrolyte tempera ture 7 c 20 f subtract 19 sp gr corrected sp gr is 1 31 example no 2 temperature above 25 c 77 f hydrometer reading 1 35 electrolyte tempera ture 38 c 100 f add 08 sp gr corrected sp gr is 1 43 1300
• Hydrometer test 1300
• Section 08 electrical 1300
• Skandic lt e 1300
• Subsection 04 battery 1300
• Activation of new battery 1301
• Battery storage 1301
• Section 08 electrical subsection 04 battery 1301
• Voltmeter test 1301
• Warning 1301
• Section 08 electrical 1302
• Subsection 04 battery 1302
• Warning 1302
• Section 08 electrical subsection 04 battery 1303
• Warning 1303
• Battery charging 1304
• Electrolyte level 1304
• Section 08 electrical 1304
• Servicing 1304
• Subsection 04 battery 1304
• Tips for charging a used battery 1304
• Warning 1304
• Charging a very flat or completely discharged battery 1305
• Installation of battery 1305
• Section 08 electrical subsection 04 battery 1305
• Warning 1305
• Cable terminal installation 1306
• Section 08 electrical 1306
• Subsection 04 battery 1306
• Warning 1306
• Section 08 electrical subsection 04 battery 1307
• Electric starter 1308
• Loctite 271 293 800 005 460 super lube grease 293 550 030 461 synthetic grease 413 711 500 458 459 1308
• Section 08 electrical 1308
• Service products 1308
• Subsection 05 electric starter 1308
• And 552 engines 1309
• Section 08 electrical subsection 05 electric starter 1309
• And 593 ho sdi engines 1310
• Section 08 electrical 1310
• Subsection 05 electric starter 1310
• Section 08 electrical subsection 05 electric starter 1311
• V 1000 engine 1311
• Disassembly 1312
• Removal 1312
• Section 08 electrical 1312
• Subsection 05 electric starter 1312
• Warning 1312
• Bushing end frame 1313
• Section 08 electrical subsection 05 electric starter 1313
• Section 08 electrical 1314
• Subsection 05 electric starter 1314
• Armature 1315
• Cleaning 1315
• Cleaning and inspection 1315
• Inspection 1315
• Section 08 electrical subsection 05 electric starter 1315
• Warning 1315
• Field windings and brushes 1316
• Section 08 electrical 1316
• Subsection 05 electric starter 1316
• Assembly 1317
• Brush holder 1317
• Brush length 1317
• End housing 1317
• Overrunning clutch 1317
• Section 08 electrical subsection 05 electric starter 1317
• Starter relay 1317
• Section 08 electrical 1318
• Subsection 05 electric starter 1318
• Installation 1319
• Section 08 electrical subsection 05 electric starter 1319
• Starter housing assembly and starter housing 1319
• Section 08 electrical 1320
• Subsection 05 electric starter 1320
• Warning 1320
• Engine 1321
• Section 08 electrical 1321
• Subsection 06 testing procedure 1321
• Testing procedure 1321
• And 552 engines 1322
• Section 08 electrical subsection 06 testing procedure 1322
• Engine 1323
• Section 08 electrical 1323
• Subsection 06 testing procedure 1323
• Ho sdi engine 1324
• Section 08 electrical subsection 06 testing procedure 1324
• General 1325
• Multi purpose electronic module mpem connections 1325
• Section 08 electrical 1325
• Subsection 06 testing procedure 1325
• Ignition system testing sequence 1326
• Lighting system testing sequence 1326
• Section 08 electrical subsection 06 testing procedure 1326
• Testing conditions 1326
• Analysis of readings 1327
• Electrical connector testing 1327
• Ignition switch dess switch or tether cord cut out switch and engine cut out switch testing 1327
• Ignition switch key if equipped 1327
• Section 08 electrical 1327
• Sparking 1327
• Subsection 06 testing procedure 1327
• Engine cut out switch 1328
• Section 08 electrical subsection 06 testing procedure 1328
• Tether cord switch 1328
• Ignition generator coil testing 1329
• Mpem voltage testing 1329
• Resistance testing 1329
• Section 08 electrical 1329
• Subsection 06 testing procedure 1329
• Trigger coil testing 1329
• Voltage testing 1329
• Buzzer testing 1330
• High voltage coil testing 1330
• Section 08 electrical subsection 06 testing procedure 1330
• Conclusion 1331
• Lighting generator coil voltage testing 1331
• Section 08 electrical 1331
• Subsection 06 testing procedure 1331
• Section 08 electrical subsection 06 testing procedure 1332
• Caution 1333
• Section 08 electrical 1333
• Subsection 06 testing procedure 1333
• Caution 1334
• Section 08 electrical subsection 06 testing procedure 1334
• Caution 1335
• Section 08 electrical 1335
• Subsection 06 testing procedure 1335
• Section 08 electrical subsection 06 testing procedure 1336
• All electric start models if ac circuit is not isolated from frame headlamp beam will weaken 1337
• All skandic models all measurements must be performed at 21 c 70 f 1337
• Current measurement 1337
• Disconnect regulator rectifier on models with hydraulic brake pull off the rubber boot from brake light microswitch assembly connect one digital ohmmeter probe needle ohm meter will not offer enough precision to frame and other probe to one of 2 yellow magneto wires measured resistance must be infinite if such is not the case it means there is a connection be tween ac circuit and dc circuit disconnect one accessory at the time to identify the faulty circuit 1337
• Handlebar grip heating element 1337
• Inspection 1337
• Inspection of ac circuit isolation 1337
• Inspection of heating elements 1337
• Resistance measurement 1337
• Section 08 electrical 1337
• Subsection 06 testing procedure 1337
• Throttle lever heating element 1337
• When measuring resistance at terminals the ac tual value will be half the measurement in table the reason for that is the elements are connect ed in parallel therefore the total resistance is half the resistance of one element 1337
• Section 09 rear suspension 1338
• Service products 1338
• Subsection 01 torque reaction suspension 1338
• Synthetic grease 293 550 033 487 1338
• Torque reaction suspension 1338
• Section 09 rear suspension subsection 01 torque reaction suspension 1339
• Tundra 1339
• 10 11 nut slotted screw and slider shoe 1340
• 2 3 4 cross shaft idler wheel spacer and screw 1340
• Component removal 1340
• Disassembly and assembly 1340
• Rear arm 1340
• Section 09 rear suspension 1340
• Stopper strap 1340
• Subsection 01 torque reaction suspension 1340
• Suspension ass y 1340
• Suspension ass y removal 1340
• 8 support and front arm support 1341
• Inspection 1341
• Section 09 rear suspension subsection 01 torque reaction suspension 1341
• Shock absorber 1341
• Slider shoe 1341
• Stopper strap 1341
• Suspension ass y installation 1341
• Ride adjustment 1342
• Section 09 rear suspension 1342
• Subsection 01 torque reaction suspension 1342
• Deep snow operation 1343
• Section 09 rear suspension subsection 01 torque reaction suspension 1343
• Stopper strap 1343
• Warning 1343
• Lubrication 1344
• Section 09 rear suspension 1344
• Subsection 01 torque reaction suspension 1344
• Articulating slide suspension 1345
• Section 09 rear suspension 1345
• Skandic lt wt swt wt lc 1345
• Subsection 02 articulating slide suspension 1345
• Conical washer 1346
• Disassembly and assembly 1346
• Extension 1346
• Removal 1346
• Section 09 rear suspension subsection 02 articulating slide suspension 1346
• Self locking screws 1346
• Front spring 1347
• Horse shoe washer 1347
• Rear spring 1347
• Section 09 rear suspension 1347
• Shock absorber servicing 1347
• Subsection 02 articulating slide suspension 1347
• Support plate 1347
• Installation 1348
• Ride adjustment 1348
• Section 09 rear suspension subsection 02 articulating slide suspension 1348
• Section 09 rear suspension subsection 03 suv suspension 1349
• Service products 1349
• Service tools 1349
• Shock spring removal kit 529 035 504 496 1349
• Suv suspension 1349
• Synthetic grease 413 711 500 498 1349
• Section 09 rear suspension subsection 03 suv suspension 1350
• Skandic suv expedition tuv 1350
• Conical washer 1351
• Disassembly and assembly 1351
• Extension 1351
• Removal 1351
• Section 09 rear suspension subsection 03 suv suspension 1351
• Self locking screws 1351
• Front spring 1352
• Rear spring 1352
• Section 09 rear suspension subsection 03 suv suspension 1352
• Shock absorber inspection 1352
• Coupling tube 1353
• Installation 1353
• Section 09 rear suspension subsection 03 suv suspension 1353
• Spacer 1353
• Stopper strap 1353
• Lubrication 1354
• Ride adjustment 1354
• Section 09 rear suspension subsection 03 suv suspension 1354
• Drive axle 1355
• Drive axle sprocket adjuster kit 861 725 700 509 1355
• Section 09 rear suspension 1355
• Service products 1355
• Service tools 1355
• Subsection 04 drive axle 1355
• Suspension synthetic grease 293 550 033 508 1355
• Section 09 rear suspension subsection 04 drive axle 1356
• Tundra 1356
• Section 09 rear suspension 1357
• Skandic lt lt e 1357
• Subsection 04 drive axle 1357
• Section 09 rear suspension subsection 04 drive axle 1358
• Skandic wt swt wt lc suv 1358
• Expedition tuv 1359
• Section 09 rear suspension 1359
• Subsection 04 drive axle 1359
• 12 bearing 1360
• 13 sprocket and half sprocket 1360
• 8 end bearing housing and seal 1360
• 9 13 drive axle and sprocket 1360
• Disassembly 1360
• Removal 1360
• Section 09 rear suspension subsection 04 drive axle 1360
• Speedometer drive insert 1360
• 9 13 drive axle and sprocket 1361
• Assembly 1361
• Section 09 rear suspension 1361
• Subsection 04 drive axle 1361
• All models ensure to align indexing marks of each sprocket when assembling 1362
• Expedition tuv 1362
• Section 09 rear suspension subsection 04 drive axle 1362
• Skandic lt lt e 1362
• Skandic swt 1362
• Skandic wt wt lc suv 1362
• Tundra 1362
• 12 bearing 1363
• 8 drive axle and seal 1363
• Bearing protector 1363
• Section 09 rear suspension 1363
• Subsection 04 drive axle 1363
• Adjustment 1364
• Grease fitting 1364
• Installation 1364
• Lubrication 1364
• Retainer ring 1364
• Section 09 rear suspension subsection 04 drive axle 1364
• Sprocket track alignment 1364
• Section 09 rear suspension 1365
• Subsection 04 drive axle 1365
• General 1366
• Inspection 1366
• Removal 1366
• Service tools 1366
• Track type application 1366
• Warning 1366
• Installation 1367
• Section 09 rear suspension subsection 05 track 1367
• Tension 1367
• Track tension and alignment 1367
• Alignment 1368
• Section 09 rear suspension 1368
• Subsection 05 track 1368
• Warning 1368
• Section 09 rear suspension subsection 05 track 1369
• Track cleat 1369
• Bombardier lube 293 600 016 527 528 suspension synthetic grease 293 550 033 527 synthetic grease 413 711 500 528 1370
• Section 10 steering front suspension 1370
• Service products 1370
• Steering system 1370
• Subsection 01 steering system 1370
• Section 10 steering front suspension subsection 01 steering system 1371
• Tundra 1371
• Section 10 steering front suspension 1372
• Skandic lt lt e 1372
• Subsection 01 steering system 1372
• Section 10 steering front suspension subsection 01 steering system 1373
• Skandic wt swt wt lc 1373
• Section 10 steering front suspension 1374
• Skandic suv expedition tuv 1374
• Subsection 01 steering system 1374
• 16 ball joint left hand and right hand threads 1375
• Disassembly and assembly 1375
• Heating grip element 1375
• Inspection 1375
• Section 10 steering front suspension subsection 01 steering system 1375
• Steering arm and ski leg 1375
• Warning 1375
• 16 ball joint left hand and right hand threads 1376
• Section 10 steering front suspension 1376
• Steering column 1376
• Subsection 01 steering system 1376
• Hardened washer on ball joint stud 1377
• Section 10 steering front suspension subsection 01 steering system 1377
• Steering arm 1377
• Warning 1377
• 13 15 ball joint nut and jam nut 1378
• Handlebar position adjustment 1378
• Section 10 steering front suspension 1378
• Subsection 01 steering system 1378
• Warning 1378
• Adjustments 1379
• Definitions 1379
• Section 10 steering front suspension subsection 01 steering system 1379
• Steering adjustment skis 1379
• Warning 1379
• Section 10 steering front suspension 1380
• Subsection 01 steering system 1380
• Warning 1380
• Section 10 steering front suspension subsection 01 steering system 1381
• Warning 1381
• Lubrication 1382
• Section 10 steering front suspension 1382
• Subsection 01 steering system 1382
• Warning 1382
• Section 10 steering front suspension subsection 01 steering system 1383
• Section 10 steering front suspension 1384
• Service products 1384
• Service tools 1384
• Shock spring removal kit 529 035 504 539 1384
• Subsection 02 suspension and ski system 1384
• Suspension and ski system 1384
• Suspension synthetic grease 293 550 033 532 537 540 1384
• Section 10 steering front suspension subsection 02 suspension and ski system 1385
• Tundra 1385
• 2 3 5 6 7 9 11 12 bolt lock washer cover stopper bushing cushion and nut 1386
• Disassembly 1386
• On vehicle component removal 1386
• Section 10 steering front suspension 1386
• Subsection 02 suspension and ski system 1386
• 13 14 16 17 o ring ski leg upper cushion lower cushion and seal 1387
• Grease fitting 1387
• Inspection 1387
• Installation 1387
• Section 10 steering front suspension subsection 02 suspension and ski system 1387
• Shock absorber 1387
• Ski leg 1387
• Stopper 1387
• Suspension free operation 1387
• 17 seal 1388
• Section 10 steering front suspension subsection 02 suspension and ski system 1389
• Skandic lt lt e wt swt wt lc 1389
• On vehicle component verification 1390
• Section 10 steering front suspension 1390
• Spring 1390
• Subsection 02 suspension and ski system 1390
• 14 16 17 ski leg bushing and seal 1391
• 2 3 5 6 9 11 12 bolt lock washer cover stopper bushing and nut 1391
• Disassembly 1391
• Grease fitting 1391
• Inspection 1391
• Section 10 steering front suspension subsection 02 suspension and ski system 1391
• Ski leg 1391
• Stopper 1391
• Suspension free operation 1391
• 17 seal 1392
• Installation 1392
• Section 10 steering front suspension 1392
• Shock absorber 1392
• Ski stopper 1392
• Subsection 02 suspension and ski system 1392
• Section 10 steering front suspension subsection 02 suspension and ski system 1393
• Skandic suv expedition tuv 1393
• Disassembly 1394
• Inspection 1394
• Section 10 steering front suspension 1394
• Subsection 02 suspension and ski system 1394
• Swing arm 1394
• 8 upper and lower arms 1395
• Installation 1395
• Section 10 steering front suspension subsection 02 suspension and ski system 1395
• Bulb replacement 1396
• Headlamp beam aiming 1396
• Installation and adjustment 1396
• Section 11 body frame 1396
• Subsection 01 body 1396
• Belt guard 1397
• Disassembly and assembly 1397
• Inspection 1397
• Section 11 body frame subsection 01 body 1397
• Warning 1397
• Cables 1398
• Maintenance 1398
• Plastic maintenance and repair 1398
• Repair 1398
• Section 11 body frame 1398
• Subsection 01 body 1398
• Tubing 1398
• Warning 1398
• Wiring harness 1398
• Deep scratches 1399
• Large crack 1399
• Repair procedure for r i m urethane 1399
• Section 11 body frame subsection 01 body 1399
• Small scratches 1399
• Warning 1399
• Crest products used in r i m repair procedure are available from following locations 1400
• Section 11 body frame 1400
• Subsection 01 body 1400
• Frame cleaning 1401
• Frame welding 1401
• Seat cleaning 1401
• Section 11 body frame 1401
• Subsection 02 frame 1401
• Electrical 1402
• Engine 1402
• Engine type 277 1402
• Engines 1402
• Section 12 technical data 1402
• Subsection 01 engines 1402
• Tundra 1402
• Axial fan belt adjustment 1403
• Cooling system 1403
• Engine type 277 1403
• Fuel system 1403
• Injection 1403
• Section 12 technical data subsection 01 engines 1403
• Tightening torque engine cold 1403
• Tundra 1403
• Electrical 1404
• Engine 1404
• Engine type 443 552 593 1404
• Lt wt swt suv suv wt lc 1404
• Section 12 technical data 1404
• Skandic 1404
• Subsection 01 engines 1404
• Cooling system 1405
• Engine type 443 552 593 1405
• Fuel system 1405
• Lt wt swt suv suv wt lc 1405
• Section 12 technical data subsection 01 engines 1405
• Skandic 1405
• Tightening torque engine cold 1405
• Electrical 1406
• Engine 1406
• Engine type 593 1406
• Ho sdi 1406
• Section 12 technical data 1406
• Skandic expedition tuv 1406
• Subsection 01 engines 1406
• Cooling system 1407
• Engine type 593 1407
• Fuel system 1407
• Ho sdi 1407
• Section 12 technical data subsection 01 engines 1407
• Skandic expedition tuv 1407
• Tightening torque engine cold 1407
• Engine 1408
• Engine type 1004 1408
• Section 12 technical data 1408
• Skandic expedition tuv v 1000 1408
• Subsection 01 engines 1408
• Engine cont d 1409
• Engine type 1004 1409
• Section 12 technical data subsection 01 engines 1409
• Skandic expedition tuv v 1000 1409
• Engine cont d 1410
• Engine type 1004 1410
• Fuel system 1410
• Section 12 technical data 1410
• Skandic expedition tuv v 1000 1410
• Subsection 01 engines 1410
• Cooling system 1411
• Engine type 1004 1411
• Section 12 technical data subsection 01 engines 1411
• Skandic expedition tuv v 1000 1411
• Tightening torque engine cold 1411
• Section 12 technical data 1412
• Subsection 02 vehicles 1412
• Tundra skandic lt 1412
• Vehicles 1412
• Capacities 1413
• Electrical 1413
• Section 12 technical data subsection 02 vehicles 1413
• Tundra skandic lt 1413
• Vehicle informations 1413
• Section 12 technical data 1414
• Skandic 1414
• Subsection 02 vehicles 1414
• Swt 552 1414
• Wt 552 1414
• Wt lc 593 1414
• Capacities 1415
• Electrical 1415
• Section 12 technical data subsection 02 vehicles 1415
• Skandic 1415
• Swt 552 1415
• Vehicle informations 1415
• Wt 552 1415
• Wt lc 593 1415
• Section 12 technical data 1416
• Skandic suv 1416
• Subsection 02 vehicles 1416
• Capacities 1417
• Electrical 1417
• Section 12 technical data subsection 02 vehicles 1417
• Skandic suv 1417
• Vehicle informations 1417
• Ho sdi 1418
• Section 12 technical data 1418
• Skandic expedition tuv 1418
• Subsection 02 vehicles 1418
• V 1000 4 tec 1418
• Capacities 1419
• Electrical 1419
• Ho sdi 1419
• Section 12 technical data subsection 02 vehicles 1419
• Skandic expedition tuv 1419
• V 1000 4 tec 1419
• Vehicle informations 1419
• Engine technical data legend 1420
• Section 12 technical data 1420
• Subsection 03 technical data legends 1420
• Technical data legends 1420
• Section 12 technical data subsection 03 technical data legends 1421
• Vehicle technical data legend 1421
• All models except expedition tuv 600 ho sdi and v 1000 the first color of a wire is the main color second color is the stripe example yl bk is a yellow wire with a black stripe 1422
• Section 13 wring diagrams 1422
• Subsection 01 wiring diagrams 1422
• Wire colors and circuit 1422
• Wiring diagrams 1422
• Wiring diagrams can be found at the end of this subsection 1422
• Break switch 1424
• Dimmer switch 1424
• Engine cut out switch 1424
• Fuel level indicator 1424
• Fuel level sensor 1424
• Fuse 0 5a 1424
• Headlamp 1424
• Heated lever 1424
• Heating grip switch 1424
• Heating lever switch 1424
• High beam indicator 1424
• Key switch 1424
• Mpem regulator rectifier off on 1424
• Oil level switch oil level indicator 1424
• Power supply 1424
• Reverse alarm 1424
• Reverse pilot lamp reverse switch 1424
• Skandic lt 440 1424
• Speedometer 1424
• Starter 1424
• Starter and ignition switches lighting instruments heating elements ignition system 1424
• Tail light 1424
• Tether cut out switch 1424
• Dimmer switch 1425
• Headlamps 1425
• High beam indicator 1425
• Ignition module 1425
• Ignition system instruments heating elements lighting power supply starter and ignition switches 1425
• Regulator 1425
• Skandic wt skandic swt skandic suv 550 1425
• Starter 1425
• Brake switch 1426
• Dess indicator 1426
• Dess switch 1426
• Dimmer switch 1426
• Engine cut out switch 1426
• Engine overheating 1426
• Fuel level indicator 1426
• Fuel level sensor 1426
• Headlamps 1426
• Heated lever 1426
• Heating grip 1426
• Heating grip switch 1426
• Heating lever switch 1426
• High beam indicator 1426
• Ignition system 1426
• Indicator 1426
• Instruments heating elements 1426
• Key switch 1426
• Lighting power supply starter and ignition switches 1426
• Oil level switch oil level indicator 1426
• Power outlet 1426
• Regulator rectifier 1426
• Reverse alarm 1426
• Reverse switch 1426
• Skandic wt lc skandic suv 600 1426
• Speedometer 1426
• Starter 1426
• Tachometer 1426
• Tail light 1426
• Temp gauge 1426
• Temp sensor 1426