Ski-Doo Formula MACH 1, Shop Manual

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Page 2: ...Section 00 SECTION NAME Subsection 00 SUB SECTION NAME 00 00 I 1998 Shop Manual VOLUME 3 GRAND TOURING 700 SE FORMULA III 600 600 R 600 LT 700 700 R MACH 1 1 R Z Z R Z LT Z LT R...

Page 3: ...in Canada Registered trademarks of Bombardier Inc This document contains the trademarks of the following companies Kimtowels is a trademark of Kimberly Clark Loctite is a trademark of Loctite Corporat...

Page 4: ...on measurement 04 03 1 04 CDI system 04 04 1 05 Oil injection system 04 05 1 06 Liquid cooling system 04 06 1 07 Rewind starter 04 07 1 08 Carburetor and fuel pump 04 08 1 09 Fuel tank and throttle ca...

Page 5: ...system 08 03 1 09 BODY FRAME 01 Table of contents 09 01 1 02 Body 09 02 1 03 Frame 09 03 1 10 TECHNICAL DATA 01 SI metric information guide 10 01 1 02 Engines 10 02 1 03 Vehicles 10 03 1 04 Technical...

Page 6: ...bt The engines and the corresponding components identified in this document should not be utilized on product s other than those mentioned in this document Torque wrench tightening specifications must...

Page 7: ...me measurement Procedure for cylinder head warpage measurement CARBURETOR AND FUEL PUMP 04 08 All Models Except Mach Z Series and Grand Touring SE New procedure for choke plunger adjustment This proce...

Page 8: ...a 1296 FORMULA III 700 R U S 1297 MACH 1 Canada 1202 MACH 1 U S 1311 MACH 1 Europe 1203 MACH 1 R Canada 1295 MACH 1 R U S 1314 MACH Z Canada 1200 MACH Z U S 1312 MACH Z Europe 1290 MACH Z R Canada 129...

Page 9: ...Engine serial number ARRANGEMENT OF THE MANUAL The manual is divided into 11 major sections 01 SERVICE TOOLS AND SERVICE PRODUCTS 02 LUBRICATION AND MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 TRANSM...

Page 10: ...kilogram km h kilometer per hour kPa Kilopascal L liter lb pound lbf pound force lbf in pound per square inch LH left hand LO low LT long track m meter MAG magneto Max maximum Min minimum mL millilit...

Page 11: ...case nut must be torqued to 4 N m or 35 lbf in This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog Exploded view assists you in identifying parts an...

Page 12: ...val procedure A03D1YA 529 0313 00 529 0312 00 A03D1ZA 529 0313 00 529 0312 00 Cam Coat cam no 18 interior with anti seize lubricant ASSEMBLY Came Slider Shoe Section 05 TRANSMISSION Subsection 03 DRIV...

Page 13: ...s and in all cases may not reproduce the full detail or exact shape of the parts shown However they repre sent parts which have the same or a similar func tion As many of the procedures in this manual...

Page 14: ...ed in explod ed views and text When they are not specified refer to following table 1 A03A0CA 2 N m FASTENER SIZE 8 8 Lbf in 1 9 2 M4 18 3 M4 27 4 M5 35 5 44 6 53 7 62 8 M6 71 9 M6 80 10 M6 89 11 M6 9...

Page 15: ...55 76 M12 56 77 M12 57 78 M12 58 79 M12 58 80 M12 59 81 M12 60 82 M12 60 83 M12 61 84 M12 62 85 63 86 63 87 64 88 65 89 66 90 66 91 67 92 68 93 69 94 69 95 70 96 71 97 72 98 72 99 73 100 74 101 74 10...

Page 16: ...32 M14 97 133 M14 98 134 M14 99 135 M14 100 136 M14 100 137 M14 101 138 M14 102 139 M14 103 140 M14 103 141 M14 104 142 M14 105 143 M14 105 144 M14 106 145 M14 107 146 M14 108 147 M14 108 148 M14 109...

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Page 18: ...E Bombardier Inc Technical Publications After Sales Service Valcourt Quebec Canada J0E 2L0 Bombardier Inc Technical Publications After Sales Service Valcourt Quebec Canada J0E 2L0 Bombardier Inc Techn...

Page 19: ...he list of Service Prod ucts both mandatory and optional are not part of any kit and must all be ordered separately If you need to replace or add to your tool inventory these items can be ordered thro...

Page 20: ...ster kit P N 861 7491 00 A01B2D4 APPLICATION All engines Choke plunger tool P N 529 0321 00 A01C5D4 APPLICATION All CK3 models except Mach Z series 14 1 2 4 6 5 3 19 1 Piston pin puller P N 529 0355 0...

Page 21: ...MANDATORY SERVICE TOOLS Fluke multimeter P N 529 0220 00 F01B1O4 APPLICATION All models Choke and DESS nut tool P N 529 0346 00 TYPICAL A01B554 APPLICATION All models equipped with a choke and or a D...

Page 22: ...P N 420 8776 35 A01B545 APPLICATION 599 699 and 809 engines 250 3 3 5 6 2 8 11 9 10 12 1 2 2 Bolt M16 x 1 5 x 150 P N 420 9407 55 3 Screw M8 x 40 qty 4 P N 420 8406 81 5 Crankshaft protector PTO P N...

Page 23: ...B2F4 APPLICATION All models 202 Piston circlip 203 222 Circuit tester continuity light P N 414 0122 00 A00C214 APPLICATION All models Stroboscopic timing light P N 529 0319 00 A00B4F4 APPLICATION All...

Page 24: ...G4 APPLICATION All engines Injection jig magneto seal P N 420 8765 14 A00C3U4 APPLICATION 599 699 and 809 engines 237 248 Handle for insertion jig P N 420 8776 50 A00C3V4 APPLICATION 599 699 and 809 e...

Page 25: ...nstaller P N 529 0172 00 A00A1A4 APPLICATION All models 51 75 57 58 Transmission alignment bar P N 529 0355 27 A01B4D4 APPLICATION All models Spring scale hook long P N 529 0309 00 A00B4A4 APPLICATION...

Page 26: ...tion 01 SERVICE TOOLS AND PRODUCTS Subsection 01 SERVICE TOOLS 01 01 8 TRANSMISSION continued MANDATORY SERVICE TOOLS Countershaft bearing remover installer P N 529 0355 54 A01B5C4 APPLICATION CK3 Ser...

Page 27: ...educe repair time Drive axle sprocket adjuster P N 861 7257 00 A01B2O4 APPLICATION All models Parts included in the kit 1 Block with threads P N 529 0107 00 2 Block without threads P N 529 0108 00 3 P...

Page 28: ...ORY SERVICE TOOLS Shock spring removal kit P N 529 0355 04 Replacement clevis pin P N 414 5284 00 NOTE The previous shock spring removal kit P N 529 0271 00 can be upgraded by replacing the stop per w...

Page 29: ...base must be used Suggestion K D tool no 2968 A06B024 APPLICATION All models 254 343 Track tension gauge P N 529 0215 00 A00B3X4 APPLICATION All models Track cleat installer Narrow P N 529 0085 00 A01...

Page 30: ...1 SERVICE TOOLS 01 01 12 VEHICLES RECOMMENDED SERVICE TOOLS Protective mat P N 529 0306 00 A01B45W APPLICATION All models 503 Dolly P N 529 0299 00 A00B4CJ APPLICATION All models 348 Snowmobile jack P...

Page 31: ...01 02 1 SERVICE PRODUCTS 0 NOTE The numbers outlined in black example are reference to tool numbers from other divisions Sea Doo Watercraft and or Sea Doo Jet Boats Matching reference numbers indicate...

Page 32: ...LOCTITE RC 609 152 Medium strength threadlocker P N 413 7030 00 Loctite 242 Threadlocker 10 mL blue medium strength A00B324 APPLICATION Flywheel nut crankcase studs etc High strength threadlocker P N...

Page 33: ...inued Loctite primer P N 413 7081 00 Loctite 764 56 Primer N 170 g 6 oz A00B3N4 APPLICATION To prepare mating surfaces before applying paste gasket retaining compound or threadlockers Silicone compoun...

Page 34: ...al Insulating Compound 351 GRAISSE LMZ No 1 Synthetic chaincase oil 12 x 355 mL P N 413 8033 00 A01B4Q4 APPLICATION Chaincase lubricant for liquid cooled engine models and Skandic WT series Blizzard o...

Page 35: ...r bushing Two Stroke Oil 1 liter 1 05 U S qt Synthetic BOMBARDIER FORMULA XP S 358 359 Anti seize lubricant P N 413 7010 00 Loctite anti seize lubricant 454 g 16 oz F01B174 APPLICATION Unpainted surfa...

Page 36: ...SAE or 8 8 metric maximum Do not use in applications where temperatures will exceed 149 C 300 F or on critical assemblies 366 367 368 HYLOMAR sealant 100 g P N 413 7071 00 A00B3F4 APPLICATION To form...

Page 37: ...6 A01B4P4 APPLICATION Steering ball joints on all models Super Lube grease P N 293 5500 14 A00B474 APPLICATION Tie rod bushings 376 DOW CORNING 111 378 LUBE Penetrating lubricant Excellent for salt wa...

Page 38: ...tion Oil Filter Condition Subsection 04 05 Injection Oil Filter Replacement Subsection 04 05 Oil Injection Pump Adjustment Subsection 04 05 Fuel Stabilizer This section no 2 Fuel Filter Replacement Th...

Page 39: ...02 Suspension Stopper Strap Condition Section 07 02 Track Condition Subsection 07 04 Track Tension and Alignment AS REQUIRED Subsection 07 04 Spark Plugs Subsection 06 03 Engine Timing Subsection 06 0...

Page 40: ...t quantity of oil has entered the engine approximately half a can With the engine stopped remove the spark plug and spray storage oil P N 496 0141 00 into each cylinder Crank slowly 2 or 3 revolutions...

Page 41: ...sh elbow through grommet NO 4 AIR FILTER CLEANING Remove air filter from air deflector by pulling it Lift hood and remove air filter from air intake si lencer To clean the filter shake the snow out of...

Page 42: ...se could be pulley misalignment exces sive RPM with frozen track fast starts without warm up period burred or rusty sheave oil on belt or distorted spare belt Check the drive belt width Replace the dr...

Page 43: ...cycle Cleaner and Polish NOTE The latest product may be use alone if only light scratches are noticeable Inspect the hood and repair any damage Touch up all metal spots where paint has been scratched...

Page 44: ...ABLE OF CONTENTS 0 ENGINE 03 02 1 ENGINE LEAK VERIFICATION FLOW CHART 03 02 11 FUEL AND OIL SYSTEMS 03 03 1 TRANSMISSION AND BRAKE SYSTEMS 03 04 1 TRANSMISSION 03 04 1 BRAKE SYSTEM 03 04 7 HYDRAULIC B...

Page 45: ...e spark plug s Clean carbon accumulation and replace spark plugs 2 Check cooling system a Loose fan belt Adjust or replace fan belt refer to TECHNICAL DATA 10 b Low antifreeze level Adjust antifreeze...

Page 46: ...o specifications refer to TECHNICAL DATA 10 f Restriction in exhaust system Replace g Compression ratio is too high Install genuine parts h Carburetor calibration is too lean Adjust according to speci...

Page 47: ...system until appropriate level is reached c Accumulation of foreign particles in needle and or main jet area Clean carburetor s 8 Cracked or broken piston s a Cracked or broken piston s due to excess...

Page 48: ...d or improper alignment Align track and adjust its tension to specifications refer to TECHNICAL DATA 10 7 Check drive pulley a Improper calibration screw adjustments TRA pulley and or worn bushing s A...

Page 49: ...ark plug heat range Install recommended spark plugs refer to TECHNICAL DATA 10 3 Check exhaust system a Too much restriction Replace 4 Check ignition timing a Timing is too advanced Adjust according t...

Page 50: ...Check spark plug a Defective spark plug no spark Replace spark plugs 4 Check amount of fuel on spark plug a Flooded engine spark plug wet when removed Do not overprime or overchoke Remove wet spark pl...

Page 51: ...apter a Air enters through a crack Replace 4 Check air screw position a Inadequate fuel air mixture Adjust according to specifications refer to TECHNICAL DATA 10 5 Check ignition system trigger coil a...

Page 52: ...broken coolant pump impeller Clean cooling system and or replace coolant pump impeller 5 Check thermostat a Thermostat reacts slowly or not at all Replace 6 Check antifreeze concentration a Antifreez...

Page 53: ...ged holes Clean 6 Check clamps or sleeves a Damaged clamp s or sleeve s Replace SYMPTOM ENGINE EQUIPPED WITH RAVE ENGINE HESITATES AT MID SPEED AND REACHES MAXIMUM PERFORMANCE ONLY AFTER A WHILE CONDI...

Page 54: ...from flowing through Clean 3 Check ignition timing a Timing is too advanced Adjust according to specifications refer to TECHNICAL DATA 10 4 Check compression ratio a Compression ratio is too high Rep...

Page 55: ...RESERVOIR IN CRANKCASE ARE SEALS LEAKING CHECK CRANKSHAFT OUTER SEAL OF PTO AND MAG SIDES PRESSURIZE ROTARY VALVE GEAR RESERVOIR IN CRANKCASE IS RESERVOIR LEAKING UNSEAL PTO CYLINDER AND MAG CYLINDER...

Page 56: ...r and carburetor fittings a Leaking fittings Replace defective part 3 Check primer a Fuel flows through primer while engine runs Replace primer 4 Check float height in carburetor s a Fuel level is too...

Page 57: ...cate or replace 4 Check fuel pump flow a Dried diaphragm Replace 5 Check if carburetor s is are clean a Varnish Clean SYMPTOM HIGH INJECTION OIL CONSUMPTION CONDITION NORMAL USE Test Inspection 1 Chec...

Page 58: ...rly routed Replace or properly relocate lines 2 Check fuel pump outlet flow a Dirt clogging fuel pump lines or torn membrane Clean or replace fuel pump 3 Check carburetor needle valve s a Dirt varnish...

Page 59: ...flection according to specifications refer to TECHNICAL DATA 10 3 Check driven pulley sliding half play a Jammed sliding half Replace 4 Check spring tension of driven pulley sliding half a Sliding hal...

Page 60: ...torque of drive pulley screw a Moving governor cup Retighten screw 3 Spring cover screws a Spring cover moves and restrains sliding half movement Retighten screws 4 Check spring cover TRA TYPE and or...

Page 61: ...on is too weak Replace SYMPTOM IT IS DIFFICULT TO ENGAGE TRANSMISSION IN FORWARD OR REVERSE GEAR CONDITION NORMAL USE Test Inspection 1 Check position of gear shift lever adjustment screw a Improper a...

Page 62: ...n a Oil on pulley surfaces Clean pulley halves 4 Check pulley calibration a Improper pulley calibration Calibrate according to specifications SYMPTOM BELT WORN EXCESSIVELY IN TOP WIDTH CONDITION NORMA...

Page 63: ...ngine idle speed too high Adjust according to specifications 5 Check drive belt length a Incorrect belt length Replace belt with an appropriate drive belt refer to TECHNICAL DATA 10 6 Check distance b...

Page 64: ...NDITION NORMAL USE Test Inspection A00DOFY 1 Check pulley alignment a Pulley misalignment Align pulley according to specifications refer to TECHNICAL DATA 10 SYMPTOM FLEX CRACKS BETWEEN COGS CONDITION...

Page 65: ...ified type of belt Replace belt with an appropriate drive belt SYMPTOM SPONGY BRAKE CONDITION CONDITION NORMAL USE Test Inspection Replace brake fluid and bleed system If problem still occurs replace...

Page 66: ...tween starter switch and solenoid a Open circuit between starter switch and solenoid switch Repair SYMPTOM STARTER TURNS BUT DOES NOT CRANK THE ENGINE CONDITION NORMAL USE Test Inspection 1 Check batt...

Page 67: ...ak magnets Replace yoke assembly 13 Check if bushings are worn a Worn bushings Replace bushings SYMPTOM STARTER TURNS BUT OVERRUNNING CLUTCH PINION DOES NOT MESH WITH RING GEAR CONDITION NORMAL USE Te...

Page 68: ...ter switch a Starter switch returns poorly Replace ignition switch SYMPTOM NOISE OCCURENCE WHEN STARTING ENGINE CONDITION NORMAL USE Test Inspection 1 Check if ring gear is well mounted to drive pulle...

Page 69: ...tric starter a Shorted solenoid wiring harness or eroded contact washer Replace SYMPTOM HEADLAMP NOT LIGHTING CONDITION WHITE BULB Test Inspection 1 Check bulb a Gas leak Replace bulb CONDITION BROKEN...

Page 70: ...a Faulty installation of optional equipment Find optional equipment connected directly to DC ground BK wire or chassis or to any DC hot wire RD RD BL Disconnect and reconnect to AC current YL and YL B...

Page 71: ...t and or correct arm position a Defective or damaged part Correct or replace sender unit 3 Verify sender unit gauge wiring harness condition a Heating rotating or sharp part in contact with harness Im...

Page 72: ...tch es Clean terminals and apply silicone dielectric grease 4 Verify trigger coil resistance with an ohmmeter and connector condition a Defective coil Corroded connector terminals Replace defective co...

Page 73: ...tric grease Replace defective parts CONDITION NORMAL USE Test Inspection 1 Verify misfiring by observing flash of stroboscopic timing light unplug connectors between magneto generator and vehicle wiri...

Page 74: ...T GREY CONDITION NORMAL USE Test Inspection 1 Refer to ENGINE SLOWS DOWN OR STOPS AT HIGH RPM and check items listed 2 Check spark plug heat range a Spark plug heat range is too high Replace by Bombar...

Page 75: ...terminal s or crimp defective wires 2 Check tachometer part number a Models with 360 W magneto have a different tachometer Replace with appropriate one SYMPTOM INTENSITY MODULE DIMMER SWITCH DOES NOT...

Page 76: ...on is too low Increase rear arm spring preload SYMPTOM SLIDER SHOES WEAR OUT PREMATURELY CONDITION NORMAL USE Test Inspection 1 Check track tension a Pressure is too great on slider shoes Adjust accor...

Page 77: ...drive shaft sprockets are broken Replace sprocket s 5 Check track rods and or internal traction teeth a One or various track rods and or teeth are broken Replace track SYMPTOM DERAILING TRACK CONDITIO...

Page 78: ...on the ground Loosen spring tension SYMPTOM HANDLE BAR IS DIFFICULT TO TURN CONDITION NORMAL USE Test Inspection 1 Check position of front spring adjustment cams a More pressure on the ground when ca...

Page 79: ...VERSA CONDITION NORMAL USE Test Inspection 1 Check ski runner condition a Worn or bent ski runners Replace ski runners 2 Check ski alignment a Improper ski alignment Align skis in order to obtain prop...

Page 80: ...3 1 PROCEDURE 04 03 1 FINALIZING REASSEMBLY 04 03 4 COOLING SYSTEM LEAK TEST 04 03 4 ENGINE LEAK VERIFICATION FLOW CHART 04 03 5 ENGINE DIMENSION MEASUREMENT 04 03 6 CYLINDER HEAD WARPAGE 04 03 6 CYLI...

Page 81: ...ID COOLING SYSTEM 04 06 1 INSPECTION 04 06 2 DRAINING THE SYSTEM 04 06 2 DISASSEMBLY AND ASSEMBLY 04 06 2 COOLING SYSTEM REFILLING PROCEDURE 04 06 3 REWIND STARTER 04 07 1 REMOVAL 04 07 2 DISASSEMBLY...

Page 82: ...VERALL SYSTEM OPERATION 04 08 15 DPM MODULE OPERATION 04 08 16 AIR PUMP OPERATION 04 08 21 DPM MANIFOLD OPERATION 04 08 21 TESTING PROCEDURE 04 08 23 FUEL PUMP 04 08 25 REMOVAL 04 08 26 PUMP VERIFICAT...

Page 83: ...4 02 1 599 699 AND 809 ENGINE TYPES 0 ENGINE REMOVAL AND INSTALLATION All Models ROTAX A30C0KS Loctite 179 Loctite 179 Loctite 271 15 N m 133 lbf in 37 N m 27 lbf ft 29 N m 21 lbf ft 35 N m 26 lbf ft...

Page 84: ...lencer drive belt driven pulley speedometer cable from angle drive rewind starter handle drive pulley not necessary if engine has not to be disassemble hood refer to 09 02 BODY carburetors impulse hos...

Page 85: ...crews to 7 N m 62 lbf in Torque removable side member nut over counter shaft support to 15 N m 133 lbf in INSTALLATION ON VEHICLE To install engine on vehicle reverse removal pro cedure However pay at...

Page 86: ...4 TOP END 809 only Molykote 111 P N 413 7070 00 A30C0LS 10 N m 89 lbf in Loctite PST 30 N m 22 lbf ft 1 2 29 N m 21 lbf ft Grease 29 N m 21 lbf ft Grease 17 18 19 20 21 Grease 22 809 only 15 3 4 5 6...

Page 87: ...n no 18 Use piston pin puller P N 529 0210 00 Unscrew puller in order to remove piston pin no 19 and cage bearing no 21 from piston Remove piston from connecting rod 809 Engine On this engine piston p...

Page 88: ...SUREMENT 04 03 RAVE System Check valve rod housing and cylinder for clogged passages 1 Draining hole 2 Passages NOTE Oil dripping from draining hole indicates a loosen spring or damaged bellows 10 Bel...

Page 89: ...facing in the direction of exhaust port see illus tration below 1 Exhaust 599 and 699 Engines Install piston pin puller P N 529 0210 00 and turn handle until piston pin is correctly posi tioned in pis...

Page 90: ...y 2 inner plastic cage halves Use piston pin puller P N 529 0210 00 to insert piston pin Plastic halves should come off piston If not pull them using long nose pliers All Engines To minimize the effec...

Page 91: ...for same height Also check for proper cylinder alignment At assembly torque cylinder head screws in the following illustrated sequence Tightening torques are M6 screws 12 N m 106 Ibf in M8 screws 30...

Page 92: ...ubricant P N 413 7010 00 Molykote 111 P N 413 7070 00 Primer N Loctite 515 599 and 699 only A30C0MS Loctite 242 Loctite 648 Primer N Loctite 515 10 N m 90 lbf in Loctite 242 Loctite 242 M6 12 N m 106...

Page 93: ...er as illustrated 1 PTO side 2 MAG side INSPECTION NOTE Refer to LEAK TEST AND ENGINE DI MENSIONS MEASUREMENT 04 03 1 Reed Valve With blade stopper removed check reed valve for proper tightness There...

Page 94: ...ing of crankcase halves spray some new injection oil or equivalent on all moving parts of the crankshaft Spray Primer N P N 413 7081 00 on one of mating surfaces Let it dry for 10 to 20 minutes Apply...

Page 95: ...p bearings by scav enging 6 Screw Apply Loctite 242 on screw threads Install the screw retaining oil line clip first If experiencing leaks at carburetor adaptor use primer N and Loctite 515 on sealing...

Page 96: ...ry valve gear lubrication system 7 Install air pump on any valve of exhaust plug NOTE If necessary lubricate air pump piston with mild soap 8 Rotate crankshaft so that piston goes to BDC Bottom Dead C...

Page 97: ...rfaces and screw stud threads of engine spark plug base insulator cylinder head cylinder base crankcase halves joint rotary valve cover oil injection pump mounting flange O ring seal coolant pump hous...

Page 98: ...otary Valve Gear Reservoir Block one hose of rotary valve gear lubrication system with a hose pincher and install an adapter in remaining hose Install air pump on adapter and pressurize as be fore 1 B...

Page 99: ...n castings Pay attention to tapped holes which may go through engine sealed area and thus lead to leakage FINALIZING REASSEMBLY After reassembling engine always recheck for leakage COOLING SYSTEM LEAK...

Page 100: ...RY VALVE GEAR RESERVOIR IN CRANKCASE ARE SEALS LEAKING CHECK CRANKSHAFT OUTER SEAL OF PTO AND MAG SIDES PRESSURIZE ROTARY VALVE GEAR RESERVOIR IN CRANKCASE IS RESERVOIR LEAKING UNSEAL PTO CYLINDER AND...

Page 101: ...e intake port A 16 mm 5 8 in from top CYLINDER OUT OF ROUND Measuring 16 mm 5 8 in from top of cylinder with a cylinder gauge check if the cylinder out of round is more than the specified dimension If...

Page 102: ...2 Obtain a graduated burette capacity 0 50 cc and fill with an equal part 50 50 of gasoline and injection oil 1 Graduated burette 0 50 cc 3 Open burette valve to fill its tip Add liquid in burette unt...

Page 103: ...is A See table below The measured dimension should be the same as the one scribed on piston dome If not install a new piston CYLINDER PISTON CLEARANCE Used and New Pistons NOTE Make sure used piston i...

Page 104: ...0 NOTE Make sure the cylinder bore gauge indica tor is set exactly at the same position as with the micrometer otherwise the reading will be false RING PISTON GROOVE CLEARANCE Using a feeler gauge che...

Page 105: ...int between the key and the first thread 2 Mid point of crankshaft bearing A See table below Crankshaft Deflection on PTO Side Crankshaft Deflection on MAG Side Crankshaft Deflection in Center of Cran...

Page 106: ...e cover can be checked for perfectly mating surfaces Lay part on a surface plate marble mirror or thick glass plate Holding down one end of part try pushing down the other end If any play is felt part...

Page 107: ...MAG piston at top dead center Rotate degree wheel not crankshaft so that 360 mark aligns with center of crankcase Scribe a mark on crankcase Remove TDC gauge and install it on center cylin der Bring c...

Page 108: ...ENSO TRIGGER COIL IGNITION SYSTEM 599 699 and 809 Engines A30E0IS Dielectric grease P N 413 7017 00 Loctite 242 5 125 N m 92 lbf ft Loctite 648 22 N m 195 lbf in Loctite 242 Dielectric grease P N 413...

Page 109: ...in magneto housing opening Remove magneto flywheel nut using a 30 mm socket machined to 40 mm 1 580 in outside diameter by 16 mm 5 8 in long NOTE To correctly remove a threadlocked fas tener it is fi...

Page 110: ...e of 0 75 mm 030 in min thick allowable range is 0 55 mm 022 in to 1 45 mm 057 in check air gap between cen ter pole of trigger coil and flywheel protrusion 3 If necessary adjust by loosening retainin...

Page 111: ...wheel and lock washer on crankshaft Clean nut threads and apply Loctite 242 blue then tighten nut 125 N m 92 lbf ft At reassembly coat all electric connections with silicone dielectric grease P N 413...

Page 112: ...tion 04 ENGINE Subsection 05 OIL INJECTION SYSTEM 04 05 1 OIL INJECTION SYSTEM 0 OIL INJECTION PUMP 599 699 and 809 Engines A30C0BS 1 2 Loctite 648 6 6 6 6 7 5 N m 44 lbf in Loctite 242 3 FLAT RATE PA...

Page 113: ...he nee dle roller with pliers then lock gear in place using one of the following gear holder TYPICAL ASSEMBLY 2 Oil Pump Gear At gear assembly apply a light coat of low tem perature grease P N 413 706...

Page 114: ...Adjuster nut 2 Marks in line To Bleed Oil Lines Bleed main oil line between tank and pump by loosening the bleeder screw until air has escaped from the line Add injection oil as required 1 Small oil...

Page 115: ...T IDLE 1 Oil columns advancing 2 Fully open position If not remove pump assembly and check the pump gear and drive shaft if applicable for de fects replace as necessary Test pump as de scribes below N...

Page 116: ...Section 04 ENGINE Subsection 06 LIQUID COOLING SYSTEM 04 06 1 LIQUID COOLING SYSTEM 0 599 699 and 809 Engines A30C0AS 1 2 7 Loctite 592 3 6 FLAT RATE PARTS...

Page 117: ...and Radiator Protector Insert radiator protector into radiator C rail and crimp C rail at both ends Refer to FRAME 09 03 for radiator removal 5 Thermostat To check thermostat put in water and heat wat...

Page 118: ...TA 10 Refilling Procedure Lift front of vehicle until the tunnel is horizontal With engine cold refill coolant tank up to cold lev el line Wait a few minutes then refill to line Install pressure cap R...

Page 119: ...Subsection 07 REWIND STARTER 04 07 1 REWIND STARTER 0 All Models A06C3GS 12 11 10 9 8 6 7 5 4 13 2 3 1 Silicone compound grease Silicone compound grease 10 N m 89 lbf in Molykote G n paste or equivale...

Page 120: ...then wind the spring counter clockwise into guide 1 Outer end into guide notch NOTE Due to dust accumulation rewind starter must be periodically cleaned inspected and relu bricated Lubricate spring as...

Page 121: ...ccessible through starter housing orifice Pull the rope out of the starter housing and tem porarily make a knot to hold it One turn preload will give 7 turns of tension when fully extended Position pa...

Page 122: ...ly on engine Prior to installing starter grip no 13 on new rope it is first necessary to fuse the rope end with a lit match Pass rope through starter grip and tie a knot in the rope end Fuse the knot...

Page 123: ...bsection 08 CARBURETOR AND FUEL PUMP 04 08 1 CARBURETOR AND FUEL PUMP 0 Formula Series GT 700 SE and Mach 1 Series To other carburetors A30C0ES 6 13 10 8 11 12 9 7 1 2 3 4 5 14 All models except GT SE...

Page 124: ...Section 04 ENGINE Subsection 08 CARBURETOR AND FUEL PUMP 04 08 2 Mach Z Series A30C0FS 1 2 3 4 5 6 7 8 9 10 12 13 FLAT RATE PARTS...

Page 125: ...nect throttle cable from throttle slide Mach Z Series Disconnect throttle cable from throttle shaft All Models Remove carburetors from engine CLEANING AND INSPECTION The entire carburetor should be cl...

Page 126: ...dle retaining plate to withdraw the needle Mach Z Series To remove needle or to change its position or to remove throttle slide remove caburetor cover Except for MAG side carburetor unscrew locking sc...

Page 127: ...fuel level in float chamber is vital toward maximum engine efficiency To check for correct float level proceed as follows Make sure that float arm is symetric not dis tored Remove float bowl and gaske...

Page 128: ...able and housing prior to in stallation On applicable models make sure to align tab of carburetor and air intake silencer if applicable with notch of adaptor s On applicable models in stall adaptor wi...

Page 129: ...xcept Mach Z Series 1 Idle speed screw 2 Air screw Mach Z Series TYPICAL 1 Idle speed screw 2 Air screw on each carburetor 6 Air Screw Adjustment All Models Completely close the air screw until a slig...

Page 130: ...zation TYPICAL 1 Screw in and out until no cable free play exists 2 Check that throttle side does not move 3 Idle speed screw completely unscrewed Mach Z Series All 3 carburetor slides must start to o...

Page 131: ...turning all idle speed screws of the same amount All Models Except Mach Z Series Throttle slide must be flush or 1 0 mm 040 in lower than the top of carburetor oulet bore en gine side THROTTLE LEVER A...

Page 132: ...e same amount on all carburetors to keep carburetors synchro nized Refer to TECHNICAL DATA 10 for the specifica tions CHOKE All Models Except Mach Z Series Choke Plunger Adjustment Set choke lever to...

Page 133: ...ift up protector cap and loosen choke cable lock nut as shown in the next photo 1 Lift up protector cap 2 Loosen lock nut Set choke lever to fully open position Turn choke cable adjustment nut by hand...

Page 134: ...ch carburetor Fill the grommet interior with dielectric grease P N 413 7017 00 Reinstall the grommets Apply dielectric grease P N 413 7017 00 on choke rod and reinstall it with its return spring and s...

Page 135: ...nd plunger when choke lever is not activated 1 0 3 mm 012 in gap maximum NOTE If there is no gap between tab and plung er a rich condition will occur and throttle response will be affected if the gap...

Page 136: ...Section 04 ENGINE Subsection 08 CARBURETOR AND FUEL PUMP 04 08 14 DPM Grand Touring SE A30C0GS Vent Engine FLAT RATE PARTS...

Page 137: ...alibrate the air fuel mixture in order to optimize the engine output while reducing fuel consumption METHOD The system makes the pressure vary within the carburetor bowl OVERALL SYSTEM OPERATION 1 DPM...

Page 138: ...y 3000 RPM the module goes from standby to compensation mode The air temperature must exceed 20 C 4 F and the air pressure must be lower than 1000 mbar Float bowls are now under vacuum and the air fue...

Page 139: ...pulses through the MPEM multi purpose electronic module ignition system GRAY GREEN wire The DPM module then comes on by reading the engine temperature through the sensor located on the cylinder head T...

Page 140: ...kes place during no more than approximately 1 1 2 min utes Once the engine is started the module reduces the solenoid duty cycle The warmer the engine the shorter the enrichment mode If the throttle o...

Page 141: ...sation Mode 1 Air jet 2 Needle jet air inlet Three conditions must be met for the compensation mode to operate 1 The engine must operate at over 3000 RPM Signal received by the GRAY GREEN wire 2 The a...

Page 142: ...igher the air temperature the leaner the air fuel mixture The lower the atmospheric pressure the leaner the air fuel mixture NOTE The atmospheric pressure decreases as the altitude increases A06I0MS F...

Page 143: ...gulator is fed directly by the crankcase pressure DPM MANIFOLD OPERATION TYPICAL 1 Manifold The DPM manifold consists of 2 tubes Depend ing on the mode the upper tube distribution gal lery distributes...

Page 144: ...whole cycle The duty cycle depends on the en gine temperature The colder the engine the longer the duty cycle Therefore the solenoid will stay open longer thus giving way to pressure 1 Engine temperat...

Page 145: ...ng P N 414 2225 00 Install that T fitting between a U tube and air pump outlet A 400 50 mm of water 1 T fitting P N 414 2225 00 2 Jet P N 270 5001 57 Start engine and note water height DPM Module Sole...

Page 146: ...test several times At reassembly ensure that solenoid seals are in place 1 Plastic seal 2 O rings Dynamic Test When checking the enrichment solenoid discon nect engine temperature sensor connector The...

Page 147: ...Section 04 ENGINE Subsection 08 CARBURETOR AND FUEL PUMP 04 08 25 FUEL PUMP All Models A30C0JS From fuel tank Engine impulse line To carburetors FLAT RATE PARTS...

Page 148: ...win outlets as follows Connect a clean plastic tubing to the impulse nip ple and plug vent hole on top cover Either apply pressure or vacuum The diaphragm gasket must not leak CLEANING AND INSPECTION...

Page 149: ...ver TYPICAL 1 Circlip Other Models TYPICAL 1 Throttle cable housing 2 Throttle handle housing 3 Throttle handle 4 Circlip WARNING When draining a fuel tank or whenever a fuel line is disconnected obst...

Page 150: ...Connections must be clean and tight and wiring free of damage Re pair as necessary Use silicone dielectric grease to prevent corrosion at the connectors Operate the engine to see if the problem has be...

Page 151: ...ON 05 03 4 ASSEMBLY 05 03 6 INSTALLATION 05 03 8 DRIVE PULLEY ADJUSTMENT 05 03 9 DRIVEN PULLEY 05 04 1 REMOVAL 05 04 2 DISASSEMBLY 05 04 2 CLEANING 05 04 2 INSPECTION 05 04 3 ASSEMBLY 05 04 4 INSTALLA...

Page 152: ...OVAL 05 07 2 INSPECTION 05 07 2 GEAR RATIO MODIFICATION 05 07 2 INSTALLATION 05 07 2 DRIVE CHAIN ADJUSTMENT 05 07 3 ADJUSTMENT 05 07 4 GEARBOX 05 08 1 DISASSEMBLY 05 08 2 INSPECTION 05 08 2 ASSEMBLY 0...

Page 153: ...direction of rotation is respect ed CORRECT INCORRECT NOTE For used drive belt mark and reinstall in the same position MODEL PART NUMBER WIDTH NEW 0 25 mm 010 in MINIMUM WIDTH WEAR LIMIT mm in CK3 Ser...

Page 154: ...e accompanying chart FOR REFERENCE ONLY To Check Tension Position a reference rule on drive belt Wooden Stick and Spring Scale Method 1 Mark specified deflection Using spring scale and stick apply spe...

Page 155: ...screws as shown To increase deflection turn Allen screws clock wise To decrease deflection turn Allen screws coun terclockwise NOTE Turn Allen screws 1 4 turn at a time then rotate driven pulley to a...

Page 156: ...is a lubrication free drive pulley 12 N m 106 lbf in 13 N m 115 lbf in 95 N m 70 lbf ft 10 N m 89 lbf in Repair kit A30D0JS 5 6 7 9 12 11 12 13 14 15 17 16 Loctite 648 18 Loctite 648 19 20 21 22 23 25...

Page 157: ...529 0224 00 To Remove Drive Pulley Ass y Retain drive pulley with clutch holder Install puller in pulley shaft then tighten CAUTION Such modifications should only be per formed by experienced mechani...

Page 158: ...up until slider shoes come at their highest position into guides Hold a slider shoe set then carefully lift its housing and remove slider shoes Proceed the same way for other housings lifting one at a...

Page 159: ...cleaning solvent P N 413 7082 00 Wipe off the mounting surfaces with a clean dry paper towel 7 20 Bushing Only use petrol base cleaner when cleaning bush ings INSPECTION Drive pulley should be inspec...

Page 160: ...ushing is not replacable If worn out replace sliding half ass y Spring Cover Bushing Replacement Under normal use there is no need to replace this bushing Use tools P N 529 0313 00 and 529 0312 00 to...

Page 161: ...s for calibration purpose Refer to TECHNICAL DATA 10 03 21 22 23 Ramp Dowel Tube and Screw Insert dowel tube from chamfered side Make sure ramp is centered on dowel tube 1 Chamfered side Position dowe...

Page 162: ...kshaft Lift sliding half against spring cover and align spring cover arrow with sliding half mark 1 Align Install and torque screws to 13 N m 115 lbf in 6 25 29 Sliding Half Slider Shoe and Governor C...

Page 163: ...w Use clutch holder See removal procedure Torque screw to 90 to 100 N m 66 to 74 lbf ft Install drive belt and belt guard Raise and block the rear of the vehicle and sup port it with a mechanical stan...

Page 164: ...rew Locking Nut and Governor Cup Calibration screw has a notch on top of its head 1 Notch Governor cup has 6 positions numbered 2 to 6 Note that in position 1 there is no stamped num ber due to its lo...

Page 165: ...Section 05 TRANSMISSION Subsection 03 DRIVE PULLEY 05 03 10 1 Loosen just enough to permit rotating of calibration screw A16D0HA 1...

Page 166: ...RIVEN PULLEY 05 04 1 DRIVEN PULLEY 0 CK3 Series A30D0GS Loctite 609 1 Anti seize lubricant 2 7 3 4 5 8 9 Anti seize lubricant Loctite 609 6 10 11 12 13 24 N m 18 lbf ft Some models only Some models on...

Page 167: ...Brake Disc Removal DISASSEMBLY Use spring compressor P N 529 0186 00 Remove snap ring no 3 and washer no 4 to dis assemble the outer cam and the 2 pulley halves CLEANING 9 10 Large Bushing and Small...

Page 168: ...am slider shoes for wear Replace when inside edge of cam slider shoe slope base is worn to 1 mm 039 in or less 1 Measure thickness of slope base here 2 Sliding pulley side 3 Slope base Bushing Replace...

Page 169: ...he new bushing Small Bushing NOTE Following procedure can be done with a press using the same tools Install puller in a vise Heat bushing area Turn puller handle and sliding half at once to ex tract t...

Page 170: ...k P N 529 0065 00 and a spring scale Remove drive belt Install the hook on the sliding half Preventing fixed half from turning pull sliding half with the spring scale perpendicularly with pulley axle...

Page 171: ...05 02 to perform adjust ments 5 Outer Cam Make sure to install proper cam Refer to TECHNI CAL DATA 10 03 Cam angle is identified on cam NOTE For high altitude regions the High Altitude and Sea Level T...

Page 172: ...eter of pul leys GENERAL PROCEDURE Remove belt guard and drive belt By turning and pushing the sliding half open the driven pulley Insert a straight bar 9 5 mm 375 in square 48 cm 19 in long or the pr...

Page 173: ...lley alignment nominal values However they do not take into account allowed tolerances for alignment specifications They are used as GO NO GO gauges for quick alignment and pulley distance check and a...

Page 174: ...g 1 Loosen Pulley Distance Adjustment Method Engine Movement The engine support has slotted mounting holes Move engine to obtain specified distance be tween pulleys Pulley Alignment Method Engine Move...

Page 175: ...Section 05 TRANSMISSION Subsection 06 BRAKE 05 06 1 BRAKE 0 HYDRAULIC DISC BRAKE A30D0OS 1 37 N m 27 lbf ft 2 3 4 Anti seize lubricant Anti seize lubricant FLAT RATE PARTS...

Page 176: ...urpose solvent Thoroughly dry all components before as sembling INSPECTION 1 Brake Pad Brake pads must be replaced when lining is 1 mm 1 32 in thick or less TYPICAL 1 Fixed pad 2 Inner caliper A 1 mm...

Page 177: ...lt in dif ficulty to center the bearing in its support Refer to DRIVE AXLE 07 03 then look Chaincase Perpendicularity Adjustment Torque castellated nut of upper sprocket to 60 N m 44 lbf ft Close chai...

Page 178: ...CASE OIL HUILE SYNTH TIQUE POUR CARTER A30D0LS 1 2 7 19 14 21 20 14 16 18 17 15 12 13 5 6 3 4 11 9 8 10 23 22 Loctite 242 Lithium grease 45 to 75 N m 33 to 55 lbf ft 44 N m 32 lbf ft Synthetic chainca...

Page 179: ...for cracked damaged or missing links Check for worn or defective bear ings sprockets and chain tensioner components GEAR RATIO MODIFICATION For particular applications the number of teeth of the sproc...

Page 180: ...in free play when measured at the out er circumference of the brake disc 21 Chaincase Oil Pour 250 mL 8 5 U S oz of synthetic chaincase oil P N 413 8033 00 into chaincase NOTE Chaincase oil capacity...

Page 181: ...Subsection 07 CHAINCASE 05 07 4 NOTE Chaincase must be in its proper position when checking oil level ADJUSTMENT Pulley Alignment Refer to PULLEY DISTANCE AND ALIGNMENT 05 05 Track Tension and Alignme...

Page 182: ...ARBOX 05 08 1 GEARBOX 0 All CK3 Models with a Reverse 5 N m 44 lbf in Synthetic chaincase oil 36 38 36 38 A30D0NS Loctite 271 29 15 23 21 24 18 16 17 5 22 20 19 4 7 8 6 5 27 13 12 9 10 28 31 40 37 34...

Page 183: ...ove reverse axle no 20 1 Sliding gear screw 2 Reverse axle Remove coupling shaft no 33 sprocket no 34 spacer no 38 and chain no 28 First unscrew castellated nut no 10 then remove sprocket no 12 Force...

Page 184: ...a criss cross sequence Insert spring pin no 21 in reverse axle up to in side diameter Press needle bearing in 19 tooth sprocket Install ring no 24 and 19 tooth sprocket on reverse axle 1 Reverse axle...

Page 185: ...om pan gearbox side Unbolt gear shift linkage from fork axle Unbolt and remove cover by separating it from housing and by moving it toward the front in order to re lease fork from sliding sprocket Cle...

Page 186: ...RIVE CHAIN 0 SILENT CHAIN All CK3 models are equipped with a 13 plate wide silent chain Fit chain on sprockets to make sure using right ones according to width Refer to TECHNICAL DATA 10 NOTE No work...

Page 187: ...OVAL 06 04 1 CLEANING 06 04 1 INSPECTION 06 04 2 HYDROMETER TEST 06 04 2 BATTERY STORAGE 06 04 3 ACTIVATION OF NEW BATTERY 06 04 3 SERVICING 06 04 6 TIPS FOR CHARGING A USED BATTERY 06 04 6 BATTERY CH...

Page 188: ...4 7 HIGH VOLTAGE COIL VOLTAGE TESTING 06 06 5 8 MPEM SUPPLY VOLTAGE TESTING 06 06 5 9 MPEM TESTING 06 06 5 CONCLUSION 06 06 6 LIGHTING GENERATOR COIL VOLTAGE TESTING 06 06 6 CONCLUSION 06 06 6 ELECTRI...

Page 189: ...ition of the timing mark on the magneto flywheel or to scribe a timing mark pro ceed as follows 1 Clean the area around the spark plugs and re move them 2 Remove the rewind starter from the engine 3 I...

Page 190: ...a critical check must al ways be in a clockwise direction to ensure that the slack in engine moving parts is taken up a Rotate the magneto flywheel counterclock wise one quarter turn then carefully r...

Page 191: ...ase timing mark Bring engine to 6000 RPM for a brief instant TYPICAL 1 Timing light pick up on MAG side 2 Timing inspection hole The magneto damper mark must be aligned with center mark If not move tr...

Page 192: ...odels NGK SPARK PLUG NUMBERING SYSTEM Bombardier uses NGK brand spark plugs on all its snowmobile models The heat range identification system is REFERENCE CHART NGK spark plugs used on Bombardier snow...

Page 193: ...9 10 Cold 18 mm 14 mm 10 mm 12 mm 8 mm 12 mm x 19 mm Reach A B C D E J Special Design Single Ground Special Alloy Dual Ground Special Alloy Racing Type Racing Version of V Type Half Heat Range Standar...

Page 194: ...ion etc A too cold plug will result in fouling shorting the spark plug or may create carbon build up which can heat up red hot and cause pre ignition or det onation FOULING Fouling of the spark plug i...

Page 195: ...wire feeler gauge set electrode gap ac cording to TECHNICAL DATA 10 2 Apply anti seize lubricant P N 413 7010 00 over the spark plug threads to prevent possible seizure 3 Hand screw spark plug into c...

Page 196: ...ve air intake silencer Unfasten battery retaining strips Open strips Remove vent tube Withdraw battery from vehicle being careful not lean it so that electrolyte flows out of vent tube CLEANING Clean...

Page 197: ...hydrometers give a true reading at 27 C 80 F In order to obtain correct readings adjust the ini tial reading by adding 004 points to the hydrom eter readings for each 5 5 C 10 F above 27 C 80 F and by...

Page 198: ...ays As necessary keep the battery at its upper level line and near full charge as possible trickle charge ACTIVATION OF NEW BATTERY A new battery is factory fresh dry charged For storage purposes it i...

Page 199: ...1 Battery electrolyte 6 Connect a 2 A battery charger for 10 to 20 hours A17E0FA 1 A17E0GA 1 A17E0HA CAUTION If charging rate raises higher than 2 4 A re duce it immediately If cell temperature rises...

Page 200: ...gravity 1 260 9 Let battery settle for 1 hour 1 60 minutes 10 Allow gas bubbles to escape by lightly shake battery 11 Readjust electrolyte level 1 Battery electrolyte 12 Reinstall caps and clean any...

Page 201: ...ey can supply Therefore time required for the battery to begin accepting measurable current will also vary Charging a Very Flat or Completely Discharged Battery Unless this procedure is properly follo...

Page 202: ...from electronic parts supply shops and they are suit able for use with most chargers if the peak cur rent is to be held below 2 A If you need an accurate ammeter we recommend the use of SHURITE 5202...

Page 203: ...cone dielectric grease P N 413 7017 00 on battery posts and connectors Ensure vent tube is properly installed on battery elbow and chassis fitting Close and fasten retaining strips and ensure that RED...

Page 204: ...Section 06 ELECTRICAL Subsection 05 ELECTRIC STARTER 06 05 1 ELECTRIC STARTER 0 A30E0GS FLAT RATE PARTS...

Page 205: ...pulling starter pinion 2 Ring gear 3 No excessive backlash A 0 5 to 1 5 mm 020 to 060 in Connect the RED battery cable and the RED wire to the large terminal of the solenoid Connect BLACK cable to bat...

Page 206: ...Trigger coil 10 04 housing 4 DESS switch housing 10 03 5 DESS pilot lamp and ignition kill switches 10 01 housing The Bombardier 360 W MPEM receives DC elec tricity produced by the unique coil TYPICA...

Page 207: ...le If the reading is too low the part is considered to be de fective and must be replaced Resistance Readings Place multimeter selector switch to in order to measure resistance Readings must be within...

Page 208: ...next step If readings are inadequate individually check each switch as follows DESS Switch Unplug 10 03 housing connected to main wiring harness Check using a multimeter by connecting probes to BLACK...

Page 209: ...to and the scale to 00 0VAC 3 Activate the manual starter and check values in dicated by the multimeter 4 Repeat operation 3 times 5 Compare readings with those appearing in the IGNITION table 5 TRIGG...

Page 210: ...able 8 MPEM SUPPLY VOLTAGE TESTING Grand Touring 700 SE only 1 Disconnect the 10 05 and 10 01 housings be tween module and main harness 2 Connect multimeter probes to RED BLUE and BLACK wires coming o...

Page 211: ...s system can be tested using a multimeter 1 Disconnect round 2 01 housing from engine YELLOW YELLOW wires 2 Connect multimeter probes to YELLOW wires then place selector switch to and scale to 0 00VAC...

Page 212: ...p 2 Connect bypass wires P N 529 0333 00 to the harness housing Install cap on the other by pass housing 1 Bypass wires connected 2 Cap in unoccupied housing 3 Turn bypass switch on All accessories ex...

Page 213: ...generator coil Output WH and RD 10 05 3 F 10 05 1 F 24 0 36 0 00 0 30 0 50 0 00 0VAC The test can be done on 2 03 housing but this would not validate the harness WH and BK RD 10 05 3 F 10 05 4 F 3 0...

Page 214: ...ding to specifications It is important to resume all tests when replacing a component If not specified the probe connecting sequence is not important LIGHTING SYSTEM TESTING CK3 series 290 W Part Test...

Page 215: ...B M 10 03C M 00 0 00 5 00 0 Tether cord cap must be in place MPEM supply Output RD BL and BK 10 05A M 10 01B M 2 00 3 50 00 0VAC The test can be done on 2 03A M housing of diagnostic post and engine b...

Page 216: ...to specifications It is important to resume all tests when replacing a component If not specified the probe connecting sequence is not important LIGHTING SYSTEM TESTING CK3 series 360 W Part Test to b...

Page 217: ...INSPECTION Disconnect regulator rectifier Connect one digital ohmmeter probe needle ohmmeter will not offer enough precision to frame and other probe to one of 2 YELLOW mag neto wires Measured resist...

Page 218: ...uring resistance at terminals the actual value will be half the measurement in table The reason for that is the elements are connected in parallel Therefore the total resis tance is half the resistanc...

Page 219: ...D ASSEMBLY 07 02 5 SHOCK ABSORBER INSPECTION 07 02 7 INSTALLATION 07 02 8 RIDE ADJUSTMENT 07 02 8 LUBRICATION 07 02 9 DRIVE AXLE 07 03 1 REMOVAL 07 03 2 DISASSEMBLY 07 03 2 ASSEMBLY 07 03 2 AXIAL PLAY...

Page 220: ...7 02 1 SC 10 SUSPENSION 0 SC 10 High performance on All CK3 Models A03F28T 21 7 1 2 3 4 5 Loctite 271 6 16 9 8 Low temp grease Front arm 12 13 14 25 15 11 16 20 17 10 Loctite 271 18 Loctite 271 Loctit...

Page 221: ...Section 07 REAR SUSPENSION Subsection 02 SC 10 SUSPENSION 07 02 2 Air Suspension Components on GT SE Only A30F05S FLAT RATE PARTS...

Page 222: ...threaded rod ass y needlessly Lift rear of vehicle Unhook rear springs Unscrew threaded rod nut Remove through bolt from shackle Swing shackle rearward Collapse suspension in order to disengage threa...

Page 223: ...bottom end to ease removing bolt gas shock only See installation illustration below Installation is reverse of removal procedure To easily compress gas shock absorber use a pry bar and locking pliers...

Page 224: ...n screwing screws assembled with threadlocker proceed as follows Knock on screw head and or heat to break threadlocker bond Loosen one screw then retighten Remove the opposite screw Remove the first o...

Page 225: ...r wheel axles can be used as pivot axles but the opposite is not true 12 13 14 Front Shock Spring Stopper and Cap Use shock spring remover P N 529 0271 00 and put it in a vise Mount shock in it and tu...

Page 226: ...he next photo Minimum thickness must be 2 mm 080 in TYPICAL 1 Slider shoe 2 Molding line this line is not the wear limit A Wear limit measurement must be at least 2 mm 080 in Replace slider shoes when...

Page 227: ...d Renew as required If suspecting an internal gas leak between oil chamber and gas chamber check shock as fol lows Install shock in a vise clamping on its bottom eye let with its rod upward Let it sta...

Page 228: ...02 SC 10 SUSPENSION 07 02 9 LUBRICATION Lubricate front and rear arms at grease fittings us ing synthetic grease P N 413 7115 00 SC 10 HP 7 GREASE FITTINGS 1 Only the GT 700 SE and all LT versions ha...

Page 229: ...Section 07 REAR SUSPENSION Subsection 03 DRIVE AXLE 07 03 1 DRIVE AXLE 0 Lithium grease A30D0MS 8 6 4 Synthetic grease 9 13 13 3 11 5 10 FLAT RATE PARTS...

Page 230: ...ng the drive axle towards the end bearing housing side Remove drive axle from vehicle DISASSEMBLY 4 Speedometer Drive Insert Remove speedometer drive insert 5 12 Bearing To remove bearings use puller...

Page 231: ...on a plane surface and measure the gap between sprocket tooth and surface 1 Plane surface A 1 5 mm 1 16 in MAXIMUM 6 8 Drive Axle and Seal When assembling drive axle always position a new seal on eac...

Page 232: ...incase perpendicularity as fol lows CHAINCASE PERPENDICULARITY ADJUSTMENT Remove driven pulley Unbolt bearing support Extract bearing from its support Wrong chaincase perpendicularity will make it dif...

Page 233: ...istance between sprocket and tunnel 2 Drive axle pushed toward chaincase 1 No gap all around Pull drive axle toward the end bearing housing and take note of the measurement between sprocket and tunnel...

Page 234: ...front axle If the difference between each side exceeds 3 mm 1 8 in redistribute drive axle shims as follows INSTALLATION 4 Speedometer Drive Insert If the drive axle to be installed is a new part and...

Page 235: ...NICAL DATA 10 Install the suspension Refer to TRACK 07 04 and adjust track tension and carry out track alignment procedure LUBRICATION 15 Grease Fitting Lubricate end housing bearing with low tempera...

Page 236: ...TALLATION Reverse the removal procedure NOTE When installing the track respect rotation direction indicated by an arrow on track thread Check sprocket track alignment as described in DRIVE AXLE 07 03...

Page 237: ...the ground start engine and allow the track to rotate slowly Check that the track is well centered equal dis tance on both sides between edges of track guides and slider shoes 1 Guides 2 Slider shoes...

Page 238: ...se rear of vehicle off the ground and lift snow guard then rotate track to expose a cleat to be replaced Using track cleat remover P N 529 0087 00 for all models Installation NOTE Keep the same pitch...

Page 239: ...8 01 1 TABLE OF CONTENTS 0 STEERING SYSTEM 08 02 1 DISASSEMBLY AND ASSEMBLY 08 02 2 INSPECTION 08 02 6 STEERING ADJUSTMENT SKIS 08 02 7 LUBRICATION 08 02 10 SUSPENSION AND SKI SYSTEM 08 03 1 DISASSEMB...

Page 240: ...15 16 2 7 7 7 7 9 10 21 7 7 12 6 4 5 19 20 Lithium grease 53 N m 39 lbf ft Lithium grease 10 N m 89 lbf in 15 N m 133 lbf in 18 N m 159 lbf in 53 N m 39 lbf ft 25 N m 18 lbf ft 48 N m 35 lbf ft Loctit...

Page 241: ...ly opposite the element wires and immediately peel it open to locate the gap in the heating ele ment as shown TYPICAL 1 Gap in the heating element opposite the wires Continue cutting along the gap and...

Page 242: ...ng Unplug all connector housings of handlebar switches Re move handlebar ass y HANDLEBAR ASS Y If intensity control module no 16 has to be re moved note that a lock washer may fall during removal At i...

Page 243: ...clamp Remove U bolt no 5 from steering support then pull steering column from top 1 U bolt nuts 17 Steering Arm To maintain correct steering geometry for reas sembling scribe mark the steering arm and...

Page 244: ...lowing illustra tion For proper torque specifications refer to the spe cific exploded view for the vehicle being serviced TYPICAL 1 Parallel with steering arm 2 Steering arm TIE ROD BALL JOINT PARALLE...

Page 245: ...ring arm and ski leg splines inter lock Check the general condition of the steering sys tem components for wear Replace if necessary 15 Heating Grip Element Refer to TESTING PROCEDURE 06 06 17 18 Ball...

Page 246: ...leg compared to a vertical line when viewing the ve hicle from front Adjustments Adjustments should be performed following this sequence Pivot arm centering Set camber angle Check for a horizontal han...

Page 247: ...r almost touching the plate Loosen the jam nuts on tie rod no 8 LH threads on steering column end and turn tie rod accord ingly Align and retighten the jam nuts to 18 N m 159 lbf in 1 Tie rod no 8 CAM...

Page 248: ...NOTE The reference point must be the same rel ative to each side TYPICAL 1 Equal distance A on each side 2 Same reference point Adjustment is performed by adjusting length of left and right tie rods n...

Page 249: ...the opposite ski 1 Straight edge 2 Measure at 220 mm 8 21 32 in from ski pivot axis LUBRICATION 26 Grease Fittings Only use synthetic grease P N 413 7115 00 The following symbols will be used to show...

Page 250: ...SYSTEM 0 CK3 Series A30G04S 48 N m 35 lbf ft 7 8 13 14 1 4 3 2 12 9 6 5 10 48 N m 35 lbf ft Loctite 271 35 N m 26 lbf ft 48 N m 35 lbf ft 48 N m 35 lbf ft 48 N m 35 lbf ft Super Lube 11 Synthetic Gre...

Page 251: ...emover P N 529 0271 00 in a vise Mount shock in it and turn shock so that spring coils matched spring compressor Close and lock the bar Adjust the handle horizon tal position by changing the position...

Page 252: ...heck skis and runners no 10 for wear replace as necessary Check condition of ski stopper no 9 Replace it when deteriorated To check condition of shock refer to SC 10 SUS PENSION 07 02 then look for Sh...

Page 253: ...03 SUSPENSION AND SKI SYSTEM 08 03 4 ADJUSTMENT 6 Stopper Adjust stopper against ski stopper to reduce dart ing unwanted vehicle side to side movement 1 Loosen nut adjust stopper against ski stopper t...

Page 254: ...EAM AIMING 09 02 1 BULB REPLACEMENT 09 02 1 DECAL 09 02 2 WINDSHIELD INSTALLATION 09 02 2 HOOD 09 02 2 HALF BOTTOM PAN 09 02 3 BELT GUARD 09 02 4 WIRING HARNESS 09 02 4 CABLES 09 02 4 PIPING 09 02 4 P...

Page 255: ...2 ft 6 in B 25 mm 1 in below center line 1 Headlamp horizontal 2 Light beam high beam projected on the wall 3 Light beam center A 25 mm 1 in Required Conditions Place the vehicle on a flat surface per...

Page 256: ...shield A soft clean cloth moistened with naphtha camp ing equipment fuel will easily remove the remain ing particles Position the windshield on the hood then push it down until the tabs are fully inse...

Page 257: ...vet retaining front bumper 1 Suspension tower bracket 2 Bottom pan screws nut and rivet Unfasten swing arm at rear pivot Drill all rivets retaining half bottom pan to be re moved At installation inser...

Page 258: ...on the wires and that all connector housings are properly fastened Keep wires away from any rotating moving heating and vibrating parts Use proper fastening devices as re quired WARNING Before install...

Page 259: ...agent in their formula Apply wax on glossy finish only Protect the vehicle with a cover to prevent dust accumulation during storage CAUTION Do not apply isopropyl alcohol or acetone directly on decal...

Page 260: ...drilling instructions and to prevent pre mature wear follow the procedure below Always use a variable speed electric drill It is not necessary to center punch the rivet head simply center the drill b...

Page 261: ...e retaining rivets 1 Rivets heads ground 2 Rivets to be ground from underneath To remove rivet strike with a punch from rivet head side Make a chamfer from underneath on all 4 corner holes CAUTION Hig...

Page 262: ...e speed meter kilogram newton liter Celsius kilopascal newton meter kilometer per hour m kg N L C kPa N m km h PREFIXES PREFIX SYMBOL MEANING VALUE kilo centi milli micro k c m one thousand one hundre...

Page 263: ...0 45 018 0 45 018 0 45 018 Ignition Timing BTDC mm in 2 18 086 2 18 086 2 18 086 2 18 086 Trigger Coil 190 300 190 300 190 300 190 300 Generating Coil Low Speed 49 75 49 75 49 75 49 75 High Speed 2 8...

Page 264: ...ES Spark Plug Gap mm in 0 45 018 0 45 018 Ignition Timing BTDC mm in 2 18 086 2 11 083 Trigger Coil 190 300 190 300 Generating Coil Low Speed 49 75 49 75 High Speed 2 8 4 3 2 8 4 3 Lighting Coil 0 20...

Page 265: ...38 1 15 0 38 1 15 0 38 1 15 0 38 1 15 0 Length cm in 345 5 136 345 5 136 307 4 121 307 4 121 Profile Height mm in 22 3 878 22 3 878 22 3 878 22 3 878 Adjustment Deflection mm in 35 40 1 3 8 1 3 4 35 4...

Page 266: ...n 38 1 15 0 38 1 15 0 38 1 15 0 38 1 15 0 Length cm in 345 5 136 307 4 121 307 4 121 307 4 121 Profile Height mm in 22 3 878 22 3 878 22 3 878 22 3 878 Adjustment Deflection mm in 35 40 1 3 8 1 3 4 35...

Page 267: ...1 15 0 38 1 15 0 38 1 15 0 38 1 15 0 Length cm in 307 4 121 307 4 121 307 4 121 345 5 136 Profile Height mm in 22 3 878 22 3 878 22 3 878 22 3 878 Adjustment Deflection mm in 35 40 1 3 8 1 3 4 35 40 1...

Page 268: ...in 38 1 1 2 38 1 1 2 Force kg lbf 11 5 25 11 5 25 Track Width cm in 38 1 15 0 38 1 15 0 Length cm in 345 5 136 345 5 136 Profile Height mm in 50 8 2 0 22 3 878 Adjustment Deflection mm in 35 40 1 3 8...

Page 269: ...ce measurements must be per formed with parts at room temperature ap prox 20 C 68 F Temperature greatly affects resistance measurements Drive pulley retaining screw torque to 90 to 100 N m 66 to 74 lb...

Page 270: ...ODEL WIRING DIAGRAM PAGE HEADLIGHT watt TAILLIGHT watt ELECTRICAL SYSTEM OUTPUT watt Formula III 600 600 R 600 LT 700 700 R Mach 1 1 R Annex 1 60 55 hal 8 27 290 Mach Z Z R Z LT Z LT R Annex 2 60 55 h...

Page 271: ...NECTOR LOCATION IN HOUSING AREA LOCATION 1 Front of engine compartment 2 Magneto 3 Carburetors 4 Near of intake silencer 5 Near driven pulley 6 Under console 7 Under hood 8 Near fuel tank 9 Rear of se...

Page 272: ...E0HS A B A B A B A B A B A B A D B C A B A B A B B A A D B C 85 87 A B A B A C A B A B A B B A 2 1 C C C B D A C C B C A D C B C 30 86 87a 2 1 1 2 A B C A B C 1 2 4 3 4 3 1 2 1 2 3 6 5 4 1 2 3 6 5 4 1...

Page 273: ...Electronic module Meter Electric motor Low level sensor Buzzer Ignition coil Normally close switch Male terminal on instrument Engine ground Spark plug Meter movement Bulb Pilot lamp Analog sensor So...

Page 274: ...n its side Removal is done by squeezing this tab TAB CONNECTOR 1 Locking tab To remove Insert a screwdriver or Snap on TT 600 5 from opposite side of wire and pry locking tab While holding locking tab...

Page 275: ...small hook pull out the lock 1 Lock 1 Lock Pry tab to free connector then pull wire out of housing MALE CONNECTOR HOUSING CUT AWAY TAB AND RECEPTACLE CONNECTORS INSTALLATION Prior to installing make s...

Page 276: ...esult When installing accesso ries on any snowmobile connect their wires di rectly to the YELLOW and YELLOW BLACK lighting coil wires Even if manual start models have an AC ground to the chassis on vo...

Page 277: ...FORMULA 111 600 600 R 600 LT 700 700 R MACH 1 1 R ANNEX 1...

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