Ski-Doo Ski Doo GSX 2005 [502/1429] Rev carburetor manual start

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

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