BOMBARDIER 1983 Elan, Shop Manual

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Page 3: ...1984 SHOP MANUAL snovvmobiles Bombardier ...

Page 4: ...mester 1983 National Library of Canada All rights reserved No parts of this manual may be reproduced in any form without the prior written per mission of Bombardier Inc Bombardier Inc 1983 Printed in Canada Registered trademarks of Bombardier Inc 1 1 ...

Page 5: ...aler and or distributor assistance should be sought in case of doubt Torque wrench tightening specifications must be strictly adhered by Locking devices ex tab lock nylon lock must be installed or replaced by new ones where specified If the efficiency of a locking device is impaired it must be renewed This manual emphasizes particular information denoted by the wording and symbols ARNING Identifie...

Page 6: ...03 Sonic LlC Furthermore each vehicle has its particular vehicle seri al number IV The engine also has a serial number Liquid cooled engines Fan cooled engines DEFINITION OF NUMBERING SYSTEMS The manual makes uses of a 2 part digital numbering system i e 01 01 in which the first digit represents the Section the second digit the Sub section 01 01 section sub section The numerotation at the bottom o...

Page 7: ...igation ILLUSTRATIONS PROCEDURES An exploded view is conveniently located at the beginn ing of each section and is meant to assist the user in iden tifying parts and components This Shop Manual uses technical terms which may be sligthly different from the ones of the parts catalogue When ordering parts always refer to the parts catalogue The illustrations show the typical construction of the dif f...

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Page 9: ...Engine type 129 08 Engine dimensions measurement 149 09 Carburetor and fuel pump 155 10 Air intake silencer and fuel tank 165 11 Rewind starter 181 01 Pulley guard 185 02 Drive belt 187 03 Drive pulley 197 04 Driven pulley 215 05 Pulley alignment 235 06 Brake 239 07 Chaincase 251 08 Gear box 263 09 Drive chain 275 01 Electric charts 279 02 Ignition timing 289 03 Spark plugs 297 04 Battery 305 05 E...

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Page 11: ...starter clip Suspension adjustment key Socket 11173 mm Socket 21126 mm short H F G K L 1984 MODELS Elan Citation Skandic Skandic R Safari 377IE 447 Grand Luxe Sonic LlC SS 25 Blizzard 5500 MX Blizzard 9700 Alpine SECTION 01 TOOLS SUB SECTION 01 BASIC TOOLS BASIC TOOLS c B 0_ D J o N r M1 fi o APPLICABLE TOOLS A B C D F H A B C D E G H J L A B C D E G H J L A B C D E G H J A B C D E G J o A B C D E...

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Page 13: ... 3482 00 I I ie sD SECTION 01 TOOLS SUB SECTION 02 SERVICE TOOLS SERVICE TOOLS USE Engine timing to determine T D C Engine timing static Continuity tests Engine electrical components tests For indexation of governor cup To adjust belt deflection and tension to specification APPLICABLE TO All engine types All engine types All engine types Square shaft drive pulley All engines PAGE 3 ...

Page 14: ...PTO 420 977 910 MAG 420 276 900 Water pump seal sleeve 462 534 water pump 420 876 490 rotary valve 420 876 495 Rotary valve shaft pusher 420876 610 PAGE 4 To remove drive pulley from crankshaft To avoid seal damage during crankshaft installation Seal sleeve on crankshaft Taper shaft engines Single cylinder engine types All engines types except 277 377 447 503 Liquid cooled Rotary valve engines ...

Page 15: ... ring Puller ring Half ring ass y Puller assembly 247 277 420841 200 420840680 x x 420876 550 x 420876 555 x 420876 560 420977 480 x x 420276020 x x 420876 565 420876 567 420977 490 x 420977 470 x 420876 296 x x SECTION 01 TOOLS SUB SECTION 02 SERVICE TOOLS All engine types ENG INE TYPES 377 447 462 503 534 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x...

Page 16: ... 377 503 engines 420 240 275 Connecting rod holder 420 977 900 Degree wheel 414 352 900 Fan holder 503 engine 377 447 engines PAGE 6 420 876 355 420 876 357 Connecting rod To mark timing position of rotary valve Cylinder aligning tool __l Fan holder Twin cylinder engines 247 and 277 engines 462 and 534 engines Twin cylinder fan cooled engines r r ...

Page 17: ...10 Bearing pusher 420 876 500 Rotary valve seal pusher 420 876 600 534 engine 420 876 605 462 engine SECTION 01 TOOLS SUB SECTION 02 SERVICE TOOLS Protect crankshaft end when using bearing puller Protection cap drll Seal pusher To install water pump bearing and seal To install rotary valve shaft seal All engine types 247 277 engine types 462 534 engine types 462 534 engines PAGE 7 ...

Page 18: ...er gauge 377 447 503 engines PTO 420 876 620 Crankshaft locking tool 420 876 640 Injection pump gear holder 277 377 447 503 Engine 420 876 690 462 engine 420 277 900 6 PAGE 8 To install polyamid ring in crankcase To lock crankshaft 277 engine PTO all 377 447 503 engines 277 377 447 462 503 534 engines All injection engines I ...

Page 19: ...3 speeds transmission bearings extractor i 1 i I a j 2 3 4 To remove magneto To remove magneto SECTION 01 TOOLS SUB SECTION 02 SERVICE TOOLS 277 377 447 462 503 and 534 engines 247 277 377 447 462 503 and 534 engines To remove the bearings from the drive shaft and the Alpine 3 speeds transmission lay shaft 1 screw M8 x 25 2 420 240 275 2 plate 420 977 700 3 half ring 2 420876 330 4 ring 420 977 48...

Page 20: ...omponents tests For track inserts installation 1 screw 5 16 11 x 6 529 003 900 2 pressure plate 529 004 400 3 washer 2 391 302 900 4 hexagonal screw 2 1 2 20 x 6 391 717 200 5 bending block no 1 wide cleats 529 004 100 bending block no 2 narrow 529 004 200 cleats bending block no 3 Moto Ski 529 004 300 cleats up to 1975 6 male block 529 004 000 7 hexagonal nut 2 389 804000 Alpine 3 speeds transmis...

Page 21: ...050 00 SECTION 01 TOOLS SUB SECTION 02 SERVICE TOOLS 420 876 065 To remove drive pulley from crankshaft use with puller screw 529 0028 00 To position crankshaft bearings P T O side To install suspension springs Twin cylinder engine types 277 engine type with square shaft drive pulley 462 engine All torque reaction slide suspensions PAGE 11 ...

Page 22: ...ON 01 TOOLS SUB SECTION 02 SERVICE TOOLS Drive axle holder 529 0051 00 PAGE 12 To hold drive axle during installation or removal of chaincase and or end bearing housing All torque reaction slide suspensions ...

Page 23: ... threadsealing gasketing bonding and retaining applications on engines pulleys and fasteners etc A medium strength adhesive for threadlocking and threadsealing Vibration proofs nuts bolts and screws Hi strength threadlocking threadsealing adhesive for large parts A balanced blend of molybdenum disulfide and other lubricating solids to handle extreme pressure Reduces frictional force and surface da...

Page 24: ...led as soon as possible after adhesive is applied Creates a foaming action that lifts gaskets off in minutes Protects moving and stationary parts against high temperature seizing Prevents rust and corro sion on parts exposed to high heat Special dielectric grease that pre vents moisture and corrosion build up in electric connections Multi purpose Lithium based grease containing zinc monoxide which...

Page 25: ...lly formulated oil that meets lubrication requirements of the Bombardier Rotax engine This oil will flow at 40 C 40oFl Compounded of base oils and additives specially selected to provide outstanding lubrication engine cleanliness and minimum spark plugs fouling Fully efficient for INJECTION PRE MIX ROTARY VALVE Multi purpose lithium based grease It is an antifriction anticorrosion and water resis ...

Page 26: ...6 General purpose primer Primer N assures fixturing of parts in 15 30 minutes and full cure in 12 hours or less On part life is 30 days but it is recommended that parts be joined within 10 minutes after adhesive is applied over primer Mainly used when assembling engine and transmission crankcases ...

Page 27: ...E TYPE 247 ENGINE TYPE ENGINE REMOVAL AND INSTALLATION ttl 5 6 17 I I I _ ___ _ Engine support and muffler 22 N m J c _ U 1 6 O lb V 19 20 13 I I 14 U I 15 0 18 IIQ ti oi 21 9 23 _ _ _ _ _ 1 I 22 27 i i 25 26 35 N m 1 26 ft lbs 1 31 16 PAGE 17 ...

Page 28: ...stance sleeve 22 mm 4 20 Stud M70 x 42 4 27 Elastic stop nut 3 8 24 4 22 Washer 4 23 Elastic stop nut 5176 24 4 24 Engine support 25 Lockwasher 70 mm 4 26 Hexagonal nut 70 mm 4 27 Cross support 2 28 Vibration damper 4 29 Threaded spacer 4 30 Carriage bolt 3 8 24 4 37 Knurled screw 5176 24 4 32 Rotax engine 247 ENG INE SUPPORT AND MUFFLER DISASSEMBLY ASSEMBLY 10 23 26 Manifold nuts engine support n...

Page 29: ...essor cable 74 Head gasket Screw M4 x 7 2 75 Stud M8 x 79 5 2 Lockwasher 4 mm 2 76 Tab lock 2 Reinforcement spring 2 77 Nut 8 mm 2 Switch spring 78 Decompressor Lock spring 79 Locking sleeve Switch housing 20 Cylinder Spacer 27 Flange gasket Cap nut M72 22 Rectangular ring 2 Decompressor knob 23 Piston Nut 8 mm 4 24 Circlip 2 Washer 8 4 mm 4 25 Needle beanng Cylinder head 26 Gudgeon pin PAGE 19 ...

Page 30: ...SUREMENTS FITTING NEW PARTS WEAR LIMIT MIN MAX Cylinder taper NA NA 08 mm 0031 Cylinder out of NA N A 05 mm round 0018 Cylinder piston 065 mm 20 mm 20 mm clearance 0026 10079 0079 Ring piston groove 05 mm 20 mm 20 mm clearance 0018 10079 0079 Ring end gap 20 mm 35 mm 1 0 mm 0079 0138 10394 O OTE For the measurement procedures refer to Engine Tolerances Measurement section 02 sub section 08 PAGE 20...

Page 31: ...ompressor switch on off position If there is some end gap be tween cable housing and decompressor valve lever turn the adjustment screw counterclockwise until you elimi nate that end gap Beware not to compress the valve lever Switch on off position Adjustment screw Valve Valve lever body P Ip Cable housing SECTION 02 ENGINE SUB SECTION 01 247 ENG INE TYPE PAGE 2 1 ...

Page 32: ... 0 mm 7 Ball bearing 6305 2 B Crankcase gasket 9 Dowel rube 10 mm x 75 2 10 Stud MB x 171 4 11 Crankcase half mag side 12 Lockwasher B mm 5 Hexagonal nut B mm crankcase with studs 5 PAGE 22 10 I 73 Labyrinth ring 74 Siorred head screw M6 x 10 4 75 Sea112 3 22 N m 16 ft lbs 13 I 14 16 Stud MB x 46 crankcase with studs 3 Hexagonal cap screw MB x 55 crankcase with screws 3 77 Locrite 242 7B Crankshaf...

Page 33: ...TION 01 247 ENGINE TYPE TOLERANCES MEASUREMENTS FITTING NEW PARTS WEAR LIMIT MIN MAX Crankshaft N A NA 10 mm deflection 0039 Connecting rod big 20 mm 53 mm 1 0 mm end axial play 0079 0208 0394 Crankshaft end play 20 mm 40 mm NA 0079 0158 O NOTE For the measurement procedures refer to Engine Tolerances Measurement section 02 sub section 08 ASSEMBLY 7 Bearings Prior to installation place bearings in...

Page 34: ... See Tool Section Apply a light coat of lithium grease on seal lip Spray some new injection oil on all moving parts of the crankshaft _ CAUTION To ensure appropriate crankshaft bearing lubrication seal outer surface must be pressed on seal crankcase shoulder PAGE 24 3 12 16 Studs or bolts nuts Torque the nuts or bolts to 22 N m 16 ft lbs follow ing illustrated sequence 22 Engine mount nuts Torque ...

Page 35: ... 1 tf 47 49 y 1 13 53 52 50 I 51 SECTION 02 ENG INE SUB SECTION 01 247 ENGINE TYPE MAGNETO AND COOLING SYSTEM 19 PAGE 25 ...

Page 36: ...k crankshaft with magneto housing holder ser vice tool as illustrated Remove magneto retaining nut PAGE 26 2B Female connecror 6 3 5J 29 Lighring coil wirh 2 cables 30 Phillips head screw M5 x 2B 2J 37 Cam spring washer 32 Breaker cam spring 33 Hexagonal cap screw M6 x 22 4J 34 Lockwasher 6 mm BJ 35 Bearing screw M6 36 Cenmfugal weight 37 Centrifugal weighr spring 3B Hexagonal nur M6 4J 39 Hexagon...

Page 37: ...ng coil Whenever a coil is replaced the air gap distance be tween magnet and coil end must be adjusted To check air gap insert a feeler gauge of 0 25 0 38 mm 010 0 15 between magnet and coil ends If neces sary to adjust slacken retaining screws and relocate coil SECTION 02 ENG INE SUB SECTION 01 247 ENGINE TYPE Checking air gap Feeler gauge ASSEMBLY Clean crankshaft extension taper Apply Loctite 2...

Page 38: ...e 242 then torque retaining nut to 85 N m 63 ft Ibs 48 53 Protection cap mass cable At reassembly coat all electric connections with silicone dielectric grease to prevent corrosion or moisture from penetrating CAUTION Do not use silicone sealant this product will corrode contacts For ignition timing refer to section 04 sub section 02 PAGE 28 ...

Page 39: ... 02 ENG INE SUB SECTION 02 277 ENGINE TYPE 277 ENGINE TYPE ENGINE REMOVAL AND INSTALLATION 7 rifJ 2 3 2 4_ W1 J 5 6 22 N m 116 ft lbs 13 20 21 U r 23 _24 22 11 25 26 v 17 12 10 18 14 55 N m 140 ft lbs PAGE 29 ...

Page 40: ... securing engine support to chassis ENGINE SUPPORT AND MUFFLER ASSEMBLY 6 16 Exhaust manifold bolts crankcase to engine support bolts Torque to 22 N m 16 ft Ibs 9 14 Engine support nuts bolts Torque to 55 N m 40 ftelbsl INSTALLATION ON VEHICLE To install engine on vehicle inverse removal procedure However pay attention to the following Check tightness of engine mount nuts and drive pul ley bolt Af...

Page 41: ...6 10 22 N m 16 ft lbs 12 13 16 14 1 2 15 I 16 I 17 SECTION 02 ENGINE SUB SECTION 02 277 ENGINE TYPE TOP END PAGE 31 ...

Page 42: ... in serted in piston notch remove circiips from piston Drive the gudgeon pin out of piston using a suitable drive punch and hammer _ CAUTION When tapping out gudgeon pins hold piston firmly in place to eliminate the possibilities of transmitting shock and pressure to the connecting rod PAGE 32 76 Circlip 2 17 Needle bearing 18 Lock spring 79 Switch spring 20 Reinforcement spring 27 Screw M4 x 7 2 ...

Page 43: ...in stall each circlip so the circlip break is at 6 0 clock as il lustrated Remove any burrs on piston caused through cir clip installation with very fine emery cloth Piston notch Circiip break 6 Cylinder Before inserting piston in cylinder lubricate the cylinder with new injection oil or equivalent SECTION 02 ENG INE SUB SECTION 02 277 ENGINE TYPE 5 Insulating rubber Position insulating rubber as ...

Page 44: ...put the decompressor switch on off position If there is some end gap between cable housing and decompressor valve lever turn the adjustment screw counterclockwise until you eliminate that end gap Beware not to compress the valve lever Switch on off position Valve Valve lever body P l Cable housing PAGE 34 ...

Page 45: ...ide 70 Shim 0 7 0 2 0 3 or 0 5 mm 6 7 SECTION 02 ENG INE SUB SECTION 02 277 ENGINE TYPE BOTTOM END l Q 1 15 20 J I oA I J0 ij 9 10 12 l 77 Ball bearing 620 6 Mag side 72 Gasket 73 Polyamid ring Mag side 74 Seal Mag side 75 Stud M8 x 775 4 76 Crankcase half mag side 77 Lockwasher B mm 5 7B Hexagonal screw MB x 74 2 79 Hexagonal screw MB x 55 3 20 Loctite 242 16 21 N m 15 ft lbs I i 18 o 19 I 21 N m...

Page 46: ...SPECTION The inspection of the engine bottom end must include the following measurements PAGE 36 TOLERANCES MEASUREMENTS FITTING NEW PARTS WEAR LIMIT MIN MAX Crankshaft N A N A 08 mm deflection 003 Connecting rod big 20 mm 53 mm 1 0 mm end axial play 0079 0208 0394 Crankshaft end play 20 mm 40 mm N A 0079 0158 O NOTE For the measurement proce ures refer to Engine Tolerances Measurement section 02 ...

Page 47: ...eals push from inside towards the outside of the crankcase Oil seal pusher No 420 277 875 MAG No 420876 660 PTO Apply a light coat of lithium grease on seal lip Spray some new injection oil or equivalent on all moving parts of the crankshaft SECTION 02 ENG INE SUB SECTION 02 277 ENGINE TYPE 18 19 Crankcase bolts M8 x 74 M8 x 55 At assembly torque to 21 N m 15 ft lbs following il lustrated sequence...

Page 48: ...SECTION 02 ENGINE SUB SECTION 02 277 ENGINE TYPE MAGNETO AND COOLING SYSTEM 1 I II 2 5 3 PAGE 38 ...

Page 49: ... NOTE Before disassembling magneto plate in dexing marks should be located to facilitate re as sembly 23 Flywheel nut 22 x 1 5 To remove magneto flywheel retaining nut lock crankshaft with crankshaft locking tool service tool PIN 420 876 640 as illustrated piston must be at top dead center remove magneto retaining nut SECTION 02 ENG INE SUB SECTION 02 277 ENGINE TYPE 22 Lockwasher 22 mm 23 Nut 22 ...

Page 50: ... as close as possible to the coil body To pass new coil wires in harness tape the old wires to the end of new wires and pull them through the harness protector tube Insert the new wires into the old connector housing and install connectors _ CAUTION Replace the old wires in the connec tor with the same color coded new wires Install a new receptacle connector to the black yel low striped wire To in...

Page 51: ...r connections SECTION 02 ENG INE SUB SECTION 02 277 ENGINE TYPE 35 Lighting coil bolts Prior to assembly apply Loctite 242 blue medium strength Fasten retaining clip onto protector tubes The ground terminal from generating coil must be fast ened under this clip _ CAUTiON Before reinstalling magneto remove V the loose epoxy from harness ASSEMBLY Clean crankshaft extension taper Apply Loctite 242 on...

Page 52: ...SECTION 02 ENGINE SUB SECTION 02 277 ENGINE TYPE OIL INJECTION PUMP AND RESERVOIR Oil injection pump 33 134 1 35 1 34 _ Ol i 44 I 45 I 46 PAGE 42 15 I 1 Gasket set j 17 19 bl 18 20 I 0 22 c ...

Page 53: ...ts 33 35 Gear retaining nut oil pump gear To remove gear retaining nut first extract the needle rool with pliers then lock gear in place using no 420 876 690 tool PIN 420 876 690 Gear holder SECTION 02 ENG INE SUB SECTION 02 277 ENGINE TYPE 25 Support 26 Grommet 27 Male connecror 28 Spring clip 3 29 Oil line 38 mm 30 Filter 31 0 1 line 127 mm 32 Spring clip 33 Lock nut 6 mm 34 Washer 6 2 mm 2 35 O...

Page 54: ...st accordingly Retighten the adjuster nut Marks in line PAGE 44 Bleeder screw To bleed oil lines All oil lines should be full of oil If required bleed the main oil line between tank and pump by loosening the bleeder screw until all air has escaped from the line Make sure the tank is sufficiently filled Check the small oil lines between pump and intake man ifold If required fill the lines by runnin...

Page 55: ... 377 ENGINE TYPE ENGINE REMOVAL AND INSTALLATION 1 Engine support muffler 2 I p Safari 377 1 1 6 8 7 11 TI 9 I I r I I I 29 31 28 1 30 I 22 Nom 27 16 ftolbs 38 Nom 28 ftolbs 34 26 38 Nom 28 ftolbs I 37 Y 2 41 i 33 38 Nom 35 I 28 ftolbs PAGE 45 ...

Page 56: ...2 75 Muffler support 76 Plastic clamp 2 77 Hose 7B Elbow 79 Rivet 3 20 Plastic clamp 27 Connector ring PAGE 46 22 Connector 23 Rivet 6 24 Washer 6 25 Air duct 26 Rotax engine 377 27 Spring 2 2B Exhaust manifold 29 Allen screw MB x 3D 4 3 Lockwasher B mm 4 37 Gasket 4 32 Rubber mount 4 33 Washer 70 5 mm 4 34 Lock washer 70 mm 4 35 Hexagonal nut 70 mm 4 36 Internal tooth cup washer 2 37 Elastic stop...

Page 57: ...22 N m 16 ft lbs 28 SECTION 02 ENGINE SUB SECTION 03 377 TYPE ENGINE REMOVAL AND INSTALLATION Engine support muffler Skandic 377 55 N m 40 ft lbs 38 N m 28 ft lbs 55 N m 40 ft lbs PAGE 47 ...

Page 58: ...anifold Pulsation line Rewind starter cable WARNING Before disconnecting any electrical wire in starter system always first disconnect the battery cable PAGE 48 7B Cup 2 19 Lockwasher 10 mm 2 20 Gasker 4 2 I Exhausr manifold 22 Spring 6 23 Connecror 24 Lockwasher B mm 4 25 AI en screw MB x 30 4 26 Exhausr washer 27 Spring 2B Spring 2 29 Muffler 30 Cap screw M6 x 40 37 Muffler supporr 32 Spring 33 ...

Page 59: ...removal pro cedure However pay attention to the following Check tightness of engine mount nuts After throttle cable installation check maximum throt tle slide opening Check pulley alignment and drive belt tension SECTION 02 ENGINE SUB SECTION 03 377 TYPE PAGE 49 ...

Page 60: ...SECTION 02 ENGINE SUB SECTION 03 377 TYPE TOP END 20N m I I 15 ft lbs 12 13 PAGE 50 17 23 N m 23 N m 1 7 ft lbs 1 7 ft lbs I I 1 2 I I ffi1 lUJ 3 0 19 0 20 21 S o u e I I 22 23 24 ...

Page 61: ...ible after cleaning Clean the piston ring grooves with a groove cleaner tool or with a piece of broken ring DISASSEMBLY 21 22 23 Piston gudgeon pin circlips Place a clean cloth over crankcase to prevent circlips from falling into crankcase Then with a pointed tool in serted in piston notch remove cliclips from piston Drive the gudgeon pin out of piston using a suitable drive punch and hammer CAUTI...

Page 62: ...e PIN 420 876 171 aligning tool to secure sealing of intake mani fold and exhaust see Tools section before tightening cylinder head nuts 1 2 Nuts distance nuts Position nuts and distance nuts as illustrated PAGE 52 Distance nuts Cross torque cylinder head nuts to 23 N m 17 ft lbs torque each cylinder head individually 6 Dampers Position noise damper as per following illustration P T O side cylinde...

Page 63: ...22 J 23 ___ 24 38N m _25_ 28 ft lbs LV SECTION 02 ENGINE SUB SECTION 03 377 TYPE 11 I 0 1 1 17 o 4 o A I R 27 27 29 26 I I 28 9 N m 7 ft lbs 21 N m 15 ft lbs BOTTOM END 12 I PAGE 53 ...

Page 64: ... Locrire 242 23 Stud M10 x 25 4 24 Lock washer 10 mm 4 25 Hex nut M10 4 26 Hex screw MB x 70 B 27 Lock washer 6 mm B 2B Hex screw M6 x 40 4 29 AI en screw M6 x 30 4 30 Ring gear INSPECTION The inspection of the engine bottom end must include the following measurements TOLERANCES MEASUREMENTS FITTING NEW PARTS WEAR LIMiT MIN MAX Crankshaft N A NA 08 mm deflection 10032 Connecting rod big 20 mm 53 m...

Page 65: ...tighten nuts or bolts by hand then install armature plate tighten on magneto side to correctly align the crankcase halves Torque bolts to proper torque following illustrated se quence Follow sequence shown All the other bolts are torque to 21 N m 15 ft lbs 9 N m 7 ft lbs 9 N m 7 ft lbs 21 26 Screws M8 x 45 M8 x 70 The bigger screws have to be torqued to 21 N m 15 ft lbs 28 Screws M6 x 40 The small...

Page 66: ...SECTION 02 ENGINE SUB SECTION 03 377 TYPE MAGNETO 25 PAGE 56 ...

Page 67: ...V belt pulley starting pulley nut To gain access to magneto assembly remove injection oil line safari rewind starter starting and V belt pulleys O NOTE Before disassembling magneto plate in dexing marks should be located to facilitate reas sembly SECTION 02 ENGINE SUB SECTION 03 377 TYPE 1 1titJl PIN 420 876 640 Crankshaft locking tool To remove magneto flywheel retaining nut 18 Magneto flywheel l...

Page 68: ...ires 5 o r PAGE 58 _ CAUTION Replace the old wires in the connec tor with the same color coded new wires Install a new receptacle connector to the black yellow striped wire To install the ground connector of the armature plate tape the new black lead to the old one and pull it under the lighting coil with the old wire Solder an eye connector to the lead and fasten it under the wire retaining clip ...

Page 69: ...8 21 22 Armature plate magneto flywheel lock washer nut Position the armature plate on the crankcase aligning the marks on both parts Clean crankshaft extension taper Apply Loctite 242 blue medium strength on taper Position key magneto flywheel and lockwasher on crankshaft Clean nut threads and apply Loctite 242 blue medium strength before tightening nut to 85 N m 63 ft Ibs At reassembly coat all ...

Page 70: ...aling strip 6 Cylinder cowl 7 Spring nut 4 8 6 8 Washer 6 9 Screw 8 x 76 6 7O Woodruff key 3 x 5 77 Fan shaft 72 Ball bearing 6203 2 73 Shim 2 PAGE 60 26 25 74 Circlip 75 Fan housing 76 Distance sleeve 77 Pulley half 78 Shim 0 5 mm 79 Fan 20 Lock washer 76 mm 27 Hex nut M76 x 7 5 22 V belt 23 Fan cover 24 Air duct 25 Washer 26 Rivet closed end ...

Page 71: ...es Install ex cess shim s between fan and lockwasher 12 1 5 Ball bearing fan housing It is first necessary to heat bearing housing to 65 C 150 F to remove or install bearing 24 25 26 Air duct washer rivet closed end Air duct can be removed by drilling out rivets _ CAUTION At reassembly use only closed end rivets to avoid rivet ends from falling into magneto 6 Cylinder cowl A gasket must be placed ...

Page 72: ...INJECTION PUMP AND RESERVOIR Oil injection pump 54 I Gasket I set I I I 41 3 6 vf115 I I 12 JUY 14 I 16 Vf 14 I 13 14 21 8 l I 1 19 1 20 19 17 9 26 I I 36 30 I t I 18 dP I 25 0 I _ 1 I 3 29 35 I 30 Q J 28 a J _34 PAGE 62 27 32 IV d 122 23 y 33 I 37 ...

Page 73: ...J PIN 420 876690 SECTION 02 ENGINE SUB SECTION 03 377 TYPE 3D Banjo oil gasket 4 37 Banjo 2 32 Banjo bolt 2 33 Oil line 325 mm 34 Oil line 325 mm 35 Clamp 4 36 Taptite screw M5 x 76 4 37 Rubber ring 38 Retainer 39 0 ring 40 Plate 47 Screw with lockwasher 8 42 Srop Pin 43 Gasket 44 Plate 45 Washer 46 Hex screw M6 x 7 47 Spring 48 Washer 49 Lever 50 Lockwasher 6 mm 57 Nut 6 mm 52 Seal 53 Gasket set ...

Page 74: ...mp casting and on the lever must align If not loosen the adjuster nut and adjust accordingly Retighten the adjuster nut Adjuster I rt nut in line PAGE 64 To bleed oil lines All oil lines should be full of oil If required bleed the main oil line between tank and pump by loosening the bleeder screw until all air has escaped from the line Make sure the tank is sufficiently filled Check the small oil ...

Page 75: ...INE TYPE 447 ENGINE TYPE ENGINE REMOVAL AND INSTALLATION 1 _ Engine support and muffler 1 6_ _8 f b 9 C 10 14 I 0 12 i 5 11 15 I 16 17 d16 19 A O 1 II 2 20 I 18 t _ U I 27 I 31 28 I 30 22 N m 116 ft lbsl _26 38 N m 128 ft lbs I 37 41 PAGE 65 ...

Page 76: ...sconnecting any electrical wire in starter system always first disconnect the battery cable Wiring harness Engine support nuts under engine support 29 35 Engine support nuts manifold bolts Torque the engine support nuts to 38 N m 28 ft lbs Torque the manifold bolts to 22 N m 16 ft Ibs PAGE 66 22 Connector 23 Rivet 6 24 Washer 6 25 Air duct 26 Motor ass y 27 Spring 2 2B Exhaust manifold 29 Allen sc...

Page 77: ......

Page 78: ...ed tool in serted in piston notch remove circlips from piston Drive the gudgeon pin out of piston using a suitable drive punch and hammer _ CAUTION When tapping out gudgeon pins hold piston firmly in place to eliminate the possibilities of transmitting shock and pressure to the connecting rod INSPECTION The inspection of the engine top end must include the following measurements PAGE 68 73 Hexagon...

Page 79: ...19 20 Semi trapez rectangular rings Check piston rings position 7 Cylinder Before inserting piston in cylinder lubricate the cylinder with new injection oil or equivalent 4 7 Cylinder head cylinder At cylinder andlor cylinder head installation use PIN 420 876171 aligning tool to secure sealing of intake manifold and exhaust See Tools section before tightening cyl inder head nuts SECTION 02 ENGINE ...

Page 80: ... O side cylinder Install armature plate fan housing and then air deflector 8 Gasket Install a gasket on each side of the air deflector 9 11 13 Intake manifold screws M8 x 40 M8 x 74 Install intake manifold with identifications marks towards cylinder head and torque the four manifold screws to 22 N m 16 ft Ibs PAGE 70 ...

Page 81: ... ft lbs 21 6 9 18 SUB SECTION 04S CTION 02 ENGINE 447 ENGINE TYPE BOTTOM END 12 I 13 J ill 11 22 il 0 r r _1 23 _ __ _ 2 0 __ i 38 N m 24 __ A 17 I 28 ft lbs 25 _ 27 b 21 N m a 15 ft lbs _ _ 28 9 N m 26 7 ft lbs PAGE 71 ...

Page 82: ...P T D side t qo Magneto side a o PAGE 72 76 Hexagonal nur 22 x 7 5 77 0 ring 78 Lower crankcase 79 Locrire 575 20 Lockwasher 8 mm 70 27 Hexagonal screw M8 x 45 2 22 Locrire 242 23 Stud M7o x 25 4 24 Lockwasher 70 mm 4 25 Hexagonal nur M7D 4 26 Hexagonal screw M8 x 70 8 27 Lockwasher 6 mm 8 28 Hexagonal screw M6 x 40 4 29 Allen screw M6 x 3D 4 30 Ring gear INSPECTION The inspection of the engine bo...

Page 83: ...o joining of crankcase halves spray some new in jection oil on all the moving parts of the crankshaft Then apply Loctite 515 no 413 7027 on mating surfaces Position the crankcase halves together and tighten nuts or bolts by hand then install armature plate tighten on magneto side to correctly align the crankcase halves Torque bolts to proper torque following illustrated sequence SECTION 02 ENG INE...

Page 84: ...e ass y 77 Protection hose 6 72 Splice connector 6 73 Armature plate ass y 74 Washer 5 5 mm 2 75 Lockwasher 5 mm 4 PAGE 74 26 25 13 1 8 t 16 f 29 76 Loctite 242 77 Allen screw M5 x 78 2 78 Magneto flywheel 79 V belt pulley 20 Starting pulley 27 Lockwasher 22 mm 22 Hexagonal nut 22 x 7 5 23 Screw M8 x 72 3 24 Lockwasher 8 mm 3 25 Armature plate 26 Coil kit primary 27 Combined screw M5 x 35 2 28 Lig...

Page 85: ...fastener to break Loctite bond This will eliminate the possibility of thread breakage remove magneto retaining nut Crankshaft locking tool SECTION 02 ENG INE SUB SECTION 04 447 ENGINE TYPE 18 Magneto flywheel To remove magneto housing flywheel lock crankshaft with crankshaft locking tool service tool and adjust magneto housing puller and puller ring service tool as illustrated r I I I e I I tJ I I...

Page 86: ...ing nuts from the coil and apply Loctite 242 blue medium strength to screws before assembly _ CAUTION Before reinstalling the magneto re Y move the loose epoxy from harness PAGE 76 11 12 28 29 Protector tube splice connector lighting coil screw To replace lighting coil Heat the armature plate around the screw holes to break the Loctite bond 200 F Heat Protect harness from flame CAUTION Protect har...

Page 87: ...ckwasher on crankshaft Clean nut threads and apply Loctite 242 blue medium strength before tightening nut to 85 N m 63 ft lbs At reassembly coat all electric connections with silicone dielectric grease to prevent corrosion or moisture pene tration CAUTION Do not use silicone sealant this pro duct will corrode contacts O NOTE For ignition timing procedure refer to Igni tion timing section 04 sub se...

Page 88: ...ng strip 6 Cylinder cowl 7 Spring nut 4 B 6 8 Washer 6 9 Screw B x 76 6 70 Woodruff key 3 x 5 77 Fan shaft 72 Ball bearing 6203 2 73 Shim 2 PAGE 78 r 3 7 74 Circlip 75 Fan housing 76 Distance sleeve 77 Pulley half 7B Shim 0 5 mm 79 Fan 20 Lockwasher 76 mm 27 Hexagonal nut M76 22 V belt 23 Fan cover 24 Air duct 25 Washer 26 River closed end 9 23 21 J 65 N m 48 ft lbsl ...

Page 89: ... cess shim s between fan and lockwasher 12 15 Ball bearing fan housing It is first necessary to heat bearing housing to 65 C 1 50 0 F to remove or install bearing 24 25 26 Air duct washer rivet closed end Air duct can be removed by drilling out rivets CAUTION At reassembly use only closed end rivets to avoid rivet ends from falling into magne to 6 Cylinder cowl A gasket must be placed on both side...

Page 90: ...SECTION 02 ENGINE SUB SECTION 04 447 ENGINE TYPE OIL INJECTION PUMP AND RESERVOIR Oil injection pump 53 I 41 Gasket set ii 40 39 0 PAGE 80 ...

Page 91: ...k gear in place using no 420 876 690 tool PIN 420 876 690 Gear holder SECTION 02 ENG INE SUB SECTION 04 447 ENGINE TYPE 30 Banjo oil gasket 4J 37 Banjo 2 32 Banjo bolt 2 33 Gil line 325 mm 34 Gil line 325 mm 35 Clamp 4J 36 Taptite screw M5 x 76 4J 37 Rubber ring 38 Retainer 39 0 ring 40 Plate 47 Screw with lockwasher BJ 42 Stop pin 43 Gasket 44 Plate 45 Washer 46 Hexagonal screw M6 x 7 47 Spring 4...

Page 92: ...djust accordingly Retighten the adjuster nut Adjuster t iT tft U nut To bleed oil lines All oil lines should be full of oil If required bleed the main oil line between tank and pump by loosening the bleeder screw until all air has escaped from the line Make sure the tank is sufficiently filled Check the small oil lines between pump and intake mani fold If required fill the lines by running the eng...

Page 93: ...I 4 5 W tf 18 SECTION 02 ENGINE SUB SECTION 05 462 ENGINE TYPE 462 ENGINE TYPE ENGINE REMOVAL AND INSTALLATION PAGE 83 ...

Page 94: ...t nut under engine support clamp between carburator and intake manifold ENGINE SUPPORT AND MUFFLER DISASSEMBLY AND ASSEMBLY 17 39 Manifold bolts engine nuts Torque the engine support nuts under engine support to 38 N m 28 ft lbs Torque the manifold bolts to 22 N m 16 ft lbs PAGE 84 23 Rotary valve oil tank 24 Oil line 25 Spring 26 Gear clamp 4 27 Elbow male connector 28 Grommet 2 29 Male connector...

Page 95: ...SECTION 02 ENGINE SUB SECTION 05 462 ENGINE TYPE TOP END 15 PAGE 85 ...

Page 96: ...o eliminate the possibilities of transmitting shock and pressure to the connecting rod INSPECTION The inspection of the engine top end must include the following measurements PAGE 86 77 Cylindericrankcase gasket 2 72 L ring 73 Rectangular ring 74 Piston 75 Needle bearing 76 Gudgeon pin 77 Circlip 4 7S Augu ar tube oil inlet 79 Cylinder stud MS x 775 S TOLERANCES MEASUREMENTS FITTING NEW PARTS WEAR...

Page 97: ... Because of cap nuts cylinder studs have to be screwed into the crankcase so that they do not protrude by more than 151 mm 5 950 Longest threaded part should be in the crankcase T 151 MM Longuest threaded end in the crankcase SECTION 02 ENGINE SUB SECTION 05 462 ENGINE TYPE 10 Cylinder When reassembling the cylinders to the crankcase it is important to have them properly aligned so that the cyl in...

Page 98: ...SUB SECTION 05 462 ENGINE TYPE BOTTOM END 12 00 1 10 I 0 10 I 11 12 14 I 0 OID i lIh 020 iJ n A 23 a U 16 1 l I r 21 17 24 fJ 30 4 0 25 21_ U 26 28 r 29 32 38 N m _ _ 11 31 _ 9 N m 28 ft lbs 27 dl f S 7 ft lbs PAGE 88 J ...

Page 99: ...4 Srud MIO x 42 4 25 Disrance sleeve 15 mm 4 26 Lockwasher 10 mm 4 27 Hex nur MIO 4 2B Hex screw MB x 70 B 29 Allen bo r MB x 40 4 30 Lockwasher B mm 4 31 Hex screw M6 x 35 2 32 Lockwasher 6 mm 2 INSPECTION The inspection of the engine bottom end must include the following measurements TOLERANCES MEASUREMENTS FITTING NEW PARTS WEAR LIMIT MIN MAX Crankshaft N A NA 08 mm deflection 0031 Connecting r...

Page 100: ...e as single halves Prior to joining of crankcase halves spray some new in jection oil or equivalent on all the moving parts of the crankshaft Then apply a light coat of Loctite 515 413 7027 00 on mating surfaces _ CAUTION Before joining of crankcase halves Y be sure that crankshaft rotary valve gear is well engaged with rotary valve shaft gear Position the crankcase halves together and torque bolt...

Page 101: ...Loctite 271 on threads prior to assembly 2 Stud Because of cap nuts cylinder studs have to be screwed into the crankcase so that they do not exceed further than 5 mm 5 950 Longest threaded end should be in the crankcase t SECTION 02 ENGINE SUB SECTION 05 462 ENGINE TYPE PAGE 91 ...

Page 102: ...SECTION 02 ENGINE SUB SECTION 05 462 ENGINE TYPE MAGNETO GENERATOR 12V 140W 7 i PAGE 92 7 23 r 24 I 25 14 ...

Page 103: ...3 02 ENGINE SECTIO GINE TYPE SUB SECTION 05 4_6_2_E___ 12V 160W 30 15 1 19 J 17 18 9 J10 J 19 11 PP AAGGE 93 ...

Page 104: ...ewind starter starting pulley 12 O NOTE Before disassembling magneto plate in dexing marks should be located to facilitate re as sembly 29 Hexagonal nut To remove magneto flywheel retaining nut lock crankshaft with crankshaft locking tool service tool as illustrated magneto side piston must be at top dead center PAGE 94 77 Lock washer 5 mm 2 78 Screw M5 x 35 2 79 Loctite 242 20 Wire ass y 27 Cable...

Page 105: ... into the old connector housing and install connectors CAUTION Replace the old wires in the connec tor with the same color coded new wires SECTION 02 ENGINE SUB SECTION 05 462 ENGINE TYPE Install a new receptacle connector to the red black wire on 140W 4 4P models only Install the ground connector to the armature plate as illustrated To install the new coli on the armature plate remove the shippin...

Page 106: ...ark Clean crankshaft extension taper Apply Loctite 242 blue medium strength on taper Position key and magneto housing on crankshaft 29 Hexagonal nut Clean nut threads and apply Loctite 242 before tight ening nut to 95 N m 70 ft Ibs 3 4 6 20 Amplifier box ignition coil spark plug protector ass y wire ass y At reassembly coat all electric connections with silicone dielectric grease to prevent corros...

Page 107: ...24 11 I I I I 17 I 6 15 16 14 I I 13 I I iii I I I SECTION 02 ENGINE SUB SECTION 05 462 ENGINE TYPE i I I I 5 I I c 20 I COOLING SYSTEM 21 22 23 PAGE 97 ...

Page 108: ...76 Hex nut 77 Grommet 78 Thermostat 79 Hose 20 Rivet 78 21 Radiator 22 Radiator protector 2 23 Taptite screw M5 x 75 2 24 Plug DISASSEMBLY AND ASSEMBLY 13 24 Plug sender Apply Loctite pipe thread sealant to avoid leaks 7 Pressure cap Check that the cap pressurizes the system If not install a new 13 Ibs cap do not exceed 13 Ibs of pressure 18 Thermostat To check thermostat put it in water and heat ...

Page 109: ... more Stop engine and check coolant level refills as necessary WARNING Before removing the cap place a cloth over the coolant tank and release the cap to the first step to release the pressure Loss of fluid and possibility of sever burns could occur if this notice is dissegarded SECTION 02 ENGINE SUB SECTION 05 462 ENGINE TYPE PAGE 99 ...

Page 110: ...SECTIO O 2 SUB_SECTIO NGINE 05 462 ENGINE TYPE ROTARY VALVE COOLANT PUMP AN ____ D O L R ESERVOIR 31 42 33 T f2 U 32 _ 36 40 34 r PAGE 100 3 4 35 36 _ 2 7 28 ...

Page 111: ...10 11 12 Spring holder cup circlip If it is necessary to disassemble components of rotary valve shaft assembly compress spring retaining cup in order to remove circlip SECTION 02 ENGINE SUB SECTION 05 462 ENGINE TYPE 22 Hex screw M6 x 25 4 23 Locrire 242 24 Locking ring 25 Rorary valve 26 Gasket ring 6 mm 41 27 0 ring 28 Cover 29 Lock washer 8 mm 4 30 Hex screw M8 x 20 4 37 Cap 32 Sealing ring 33 ...

Page 112: ...g crankshaft 14 15 Oil seal distance ring To install seals proceed as follows Draining hole Apply lithium grease on seal lips First seal sits on bearing outer ring The come the distance ring with the opening in line with crankcase draining hole The second seal sit on the distance ring The spring side of the seals must face toward crankshaft O NOTE 35 of the distance between first and se cond seals...

Page 113: ...pply Loctite 242 on threads 25 Rotary valve Rotary valve adjustment when replacing crankcase having no timing marks Angle finder 414 3529 001 REOUIRED TOOLS SECTION 02 ENGINE SUB SECTION 05 462 ENGINE TYPE ENGINE TYPE 462 For example 1400 opening 510 closing TIMING MARKS opening closing 1400 51 0 Using angle finder mark crankcase at 1400 from bot tom edge of magneto side inlet port MARK HERE From ...

Page 114: ...tioning each side of disc on gear to determine best installation position Spray some injection oil on rotary valve before closing rotary valve cover 30 Screw M8 x 20 Torque the four cover screws to 20 N m 15 ft Ibs PAGE 104 INSPECTiON 25 28 Rotary valve rotary valve cover A gap of 27 48 mm 0 011 0 019 must be maintain between the rotary valve and the crankcase To mesure this gap you can use a fee ...

Page 115: ... a 7 I Gasket set caax 8 o 9 I 11 r 10 I 13 x x I e I 12 1 I lIl r 1 xi 14 x I 15 0 16 ill II 2 SECTION 02 ENGINE SUB SECTION 05 462 ENGINE TYPE OIL INJECTION PUMP AND RESERVOIR 18 _ 9 21 29 I 6 33 32 31 y 30 34 35 PAGE 105 ...

Page 116: ...8 PIN 420 277 900 PAGE 106 Pump gear wrench 27 HIrer 28 Hose 79 2 mm 29 Suppon 30 Hex screw M6 x 72 S 37 Clip 32 Lockwasher 6 mm S 33 Washer 6 4 mm S 34 Elasric scop nuc MS 3 3S Washer 6 2 mm 3 36 Rubber ring 37 Nur 6 mm 38 Washer 6 2 mm 2 39 Oil pump gear 44 ceech 40 Oil pump mouming flange 47 0 ring 42 Lockwasher 6 mm 4 43 Screw M6 x 20 4 44 Oil pump 4S Oil banjo gaskec 4 46 Banjo 2 47 Banjo bol...

Page 117: ...d be full of oil To bleed the main oil line between thank and pump loosen the bleeder screw do not start engine and let the air escape until oil starts to flow out Make sure tank has enough oil To bleed the small injector of lines start the engine and let it run at idle speed Move injection pump lever to ful ly open position until lines are full of oil SECTION 02 ENGINE SUB SECTION 05 462 ENGINE T...

Page 118: ......

Page 119: ...2 ENGINE SUB SECTION 06 503 ENGINE TYPE 503 ENGINE TYPE ENGINE REMOVAL AND INSTALLATION 33 I 22 N m 16 ft bsl I 34 flJ 23 18 19 r J I Engine support and muffler Blizzard 5500 MX 36 N m 26 ft bsl 70 10 30 30 10 PAGE 109 ...

Page 120: ...retaining cable Rewind starter cable Wiring harness Engine support and reinforcing cross support nuts ENGINE SUPPORT AND MUFFLER DISASSEMBLY AND ASSEMBLY PAGE 110 40 Hexagonal socker head cap screw M8 x 3D 4 47 Spring 3 42 Spring 43 Muffler 44 Spring 6 45 Connecror pipe 46 Rubber mount 47 Isolaring washer 48 Washer 49 Hexagonal elasric srop nut 5 16 78 50 Spring 57 Spring seat 52 Exhausr grommer 5...

Page 121: ... 53 I 52 59 I 44 _______ S U B SSIECTION 06S E5 TION 02 ENGINE 3 ENGINE TYPE 43 76 I I J 26 I I 70 I 25 n11 24 73 I 72 l 5 6 7 36 N m __ 15 26 ft lbs PAGE 111 ...

Page 122: ...able on caliper Throttle cable on carburator Console Upper column Engine mount nuts ENGINE SUPPORT AND MUFFLER DISASSEMBLY AND ASSEMBLY 7 40 Crankcase engine bracket nuts ex haust manifold bolts Torque the crankcase engine bracket nut to 36 N m 26 ft Ibs Torque the exhaust manifold bolt to 22 N m 16 ft Ibs INSTALLATION ON VEHICLE To install engine on vehicle inverse removal pro cedure However pay ...

Page 123: ...YPE 22 N m 16 ft lbs I 22 N m 16 ft lbs 22 N m 16 ft lbs 8_ 6 UJJ 5 22 N m 16 ft lbs 8 P i _________ _ ___ _____ 23 I 22N m I 16 ft lbs 27 22 22 N m 16 ft lbs 8 7 4 16ft lbs J _ cJ 28 24 I Blizzard 5500 MX L _____________________ TOP END PAGE 113 ...

Page 124: ...ve punch and hammer _ CAUTION When tapping out gudgeon pins hold piston firmly in place to eliminate the possibilities of transmitting shock and pressure to the connecting rod INSPECTION The inspection of the engine top end must include the following measurements PAGE 114 75 Hexagonal bolt M8 x 64 mm 2 76 Lockwasher 6 mm 2 77 Hexagonal bolt M6 x 30 mm 2 78 Noise damper 79 NOise damper shon 4 20 No...

Page 125: ...icate the cylinder with new injection oil or equivalent 2 4 Cylinders cylinder heads At cylinder and or cylinder head installation use PIN 420876 171 aligning tool or exhaust manifold to en sure sealing of intake manifold and exhaust See Tools Section before tightening cylinder head nuts PIN 420876171 I O __ 6____ _ o_ _ e 1 SECTION 02 ENGINE SUB SECTION 06 503 ENGINE TYPE Or use exhaust manifold ...

Page 126: ...ce nuts as illustrated Cross torque cylinder head nuts to 22 N m 16 ft Ibs torque each cylinder head individually Install armature plate fan housing and then air deflec tor 9 Intake manifold gaskets Install a gasket on each side of the air deflector 12 15 28 Intake manifold bolts Torque intake manifold bolts to 22 N m 16 ft Ibs ...

Page 127: ...7 2 14 1 l 3 0 22 N m n 22 N m 16 ft lbs 4 5 16 ft lbs 7 SECTION 02 ENGINE SUB SECTION 06 503 ENGINE TYPE BOTTOM END PAGE 117 ...

Page 128: ...surements PAGE 118 77 Ball beanng 6206 2 72 Shim 7 mm 2 73 Spacer 74 Seal P T 0 side 75 Ball bearing 6207 76 G ring 77 Seal mag side 78 Woodruff key 79 Loctite 242 TOLERANCES MEASUREMENTS FITTING NEW PARTS WEAR LIMIT MIN MAX Crankshaft N A NA 08 mm deflection 0031 Connecting rod big 20 mm 53 mm 1 0 mm end axial play 0079 0208 0394 O NOTE For the measurement procedures refer to Engine Tolerances Me...

Page 129: ...rts of the crankshaft Then apply Loctite 515 413 7027 on crankcases mating surfaces Position the crankcase halves together and tighten bolts by hand then install armature plate tighten on magneto side to correctly align the crankcase halves 4 5 Crankcases bolts Torque bolts to 22 N m 16 ft Ibs following illustrated sequence To install magneto refer to Magneto in this section SECTION 02 ENGINE SUB ...

Page 130: ...6 70 Protector tube 77 Flywheel 72 Washer 5 5 mm 2 73 Lockwasher 5 mm 2 74 Allen screw M5 x 78 2 PAGE 120 25 75 V belt pulley 76 Starting pulley 77 Lockwasher 8 mm 3 78 Allen screw M8 x 72 3 79 Lockwasher 22 mm 20 Hexagonal nut 22mm x 2 0 27 C D box 22 Hexagonal screw M6 x 2 0 mm 2 23 Lockwasher 6 mm 2 24 Washer 6 4 mm 2 25 Ignition coil 26 Hexagonal head taptite screw M5 x 25 2 27 Spark plug prot...

Page 131: ... NOTE It should be noted that to correctly remove a Loctite locked fastener it is first necessary to tap on the fastener to break Loctite bond This will eliminate the possibility of thread breakage SECTION 02 ENGINE SUB SECTION 06 503 ENGINE TYPE 11 Magneto housing flywheel To remove magneto housing flywheel lock crankshaft with crankshaft locking tool service tool and adjust magneto housing pulle...

Page 132: ...on the armature plate remove the shipping nuts from the coil and apply Loctite 242 blue medium strength to screws before assembly _ CAUTION Before reinstalling the magneto remove the loose epoxy from harness PAGE 122 5 Lighting coil To replace lighting coil Heat the armature plate around the screw holes to break the Loctite bond 200 F Heat Protect harness from flame CAUTION Protect harness from fl...

Page 133: ...n woodruff key magneto flywheel and lockwasher on crankshaft 7 20 Loctite 242 nut Clean nut threads and apply Loctite 242 blue me dium strength before tightening nut to 85 N m 63 ft lbs 8 21 25 27 Harness C D Box Ignition coil spark plug protectors At reassembly coat all electric connections with silicone dielectric grease to prevent corrosion or moisture penetration _ CAUTION Do not use silicone ...

Page 134: ...16 16 Cylinder cowl lower half exhaust side 17 Cylinder cowl lower half carburetor side PAGE 124 4 33 I ir i9 10 11 I I u J J I 48 tt lbs 14 78 Taprire screw M6 x 72 79 Spring nut V4 8 B 20 Cylinder cowl upper half 21 Sealing strip 440 mm 22 Lockwasher B 4 23 Hexagonal screw MB x 76 4 24 Washer 4 x 75 B 8 25 Screw B4 B x 76 B 26 Lockwasher 6 4 27 Cylindrical screw M6 x 30 4 28 Air duct 29 R H reta...

Page 135: ...NE SUB SECTION 06 503 ENGINE TYPE 1 4 Fan housing bearings It is first necessary to heat bearing housing to 65 C 150 F to remove or install bearing 23 27 Upper fan cowl screws fan housing screws At assembly apply a light coat of Loctite 242 on threads It should be noted that to correctly remove a Loctite locked screw it is first necessary to slightly tap on head screw to break Loctite bond The scr...

Page 136: ... 06 503 ENGINE TYPE OIL INJECTION PUMP AND RESERVOIR Oil injection pump 43 42 41 0 40 43 I 48 Gasket set 47 10 I 13 10 5 i I I 6 8 I 19 12 10 14 yY17 26 I Jn1 I 15 31 24 1 I 23 v o 1 I 16 r I 0 28 tJ 20 29 27 e I 30 PAGE 126 9 G s ...

Page 137: ...YPE 25 Banjo 2 26 Banjo bolt 2 27 Oil line 230 mm 28 Ol Iine 360 mm 29 Clamp 4 30 Rubber ring 2 37 Taptite screw M5 x 76 4 32 Spring 33 Washer 34 Lever 35 Lockwasher 6 mm 36 Hex nut 6 mm 37 Washer 38 Hex head screw M6 x 7 39 Seal 40 Retainer 47 O Ring 42 Plate 43 Screw with lockwasher 8 44 StOP pin 45 Gasket 46 Cam casing plate 47 Oil injection 48 Gasket set ASSEMBLY 18 Oil PUrllP gear At gear ass...

Page 138: ...lines All oil lines should be full of oil If required bleed the main oil line between tank and pump by loosening the bleeder screw until all air has escaped from the line PAGE 128 Make sure the tank is sufficiently filled Check the small oil lines between pump and intake manifold If required fill the lines by running the engine at idle speed while holding the pump lever in ful ly open position TYP...

Page 139: ... I 22 N m 42 16 ft lbs I 50 SECTION 02 ENGINE SUB SECTION 07 534 ENGINE TYPE 534 ENGINE TYPE ENGINE REMOVAL AND INSTALLATION Engine support and muffler 8 l 11 12 13 14 15 16 17 18 19 20 21 I 38 N m I 28 ft lbs 22 0 15 14 PAGE 129 ...

Page 140: ...isconnect hoses at engine Rotary valve oil reservoir Disconnect rewind starter at engine PAGE 130 26 Hex elastic SlOp nut 3 8 x 16 2 27 Imernal lOoth dished washer 2 2B Brace 29 Cross support 30 Carriage bolt 3 8 16 xli 4 2 31 Hook 32 Hex nut 3 8 16 33 Spring 2 34 Tuned pipe P T O Side 35 Sealing nng 4 36 Spong 4 37 Starrer grip 3B Rubber buffer 39 Gasker 2 40 Lockwasher B mm 4 41 Allen screw MB x...

Page 141: ...6 2 B Gaskee 0 ring 2 9 Gaskee 2 70 Cap nue MB B 77 Flae washer B 4 BI SECTION 02 ENGINE SUB SECTION 07 534 ENGINE TYPE 1 22 N m 16 ft lbs 12 I 13 72 Cylinder 2 73 Cylinder crankcase gaskee 2 74 L ring 75 Receangular nng 76 P scon 77 Gudgeon pin 7B Circlip 4 79 Needle beanng 20 Cylinder scud MB x 79 B 27 Scud head MB x 50 72 TOP END PAGE 131 ...

Page 142: ...CTION The inspection of the engine top end must include the following measurements TOLERANCES MEASUREMENTS FITTING NEW PARTS WEAR LIMIT MIN MAX Cylinder taper N A N A 08 mm 0031 Cylinder out of NA NA 05 mm round 1 0020 Cylinder piston 10 mm 12 mm 20 mm clearance 0039 0047 0079 Ring end gap 20 mm 35 mm 1 0 mm 0079 1 0138 1 0394 ONOTE For the measurement procedures refer to Engine Tolerances Measure...

Page 143: ...o obtain this length add a washer between cylinder head and cap nut Shorter threaded part of stud should be screwed into cylinder Shorter threaded part SECTION 02 ENGINE SUB SECTION 07 534 ENGINE TYPE 10 12 Crankcase cylinder nuts and cylinders When reassembling the cylinders to the crankcase it is important to have them properly aligned so that the cyl inder head holes will match up with the stud...

Page 144: ...SECTION 02 E 1 5 4 ENGINE TYPE SUB SECTION BOTTOM END 1 __ 10 I I 12 00 rJo L 10 21 I 20 PAGE 134 35 38 Nom 28 ftolbs 26 9 Nom 7 ftolbs 24 8 6 II I l Ql ...

Page 145: ...ive cap and special puller as illustrated Protective cap Special puller SECTION 02 ENGINE SUB SECTION 07 534 ENGINE TYPE 79 Seal 20 0 ring 2 27 0 ring 22 0 ring 2 23 Loctite 575 24 Crankcase lower half 25 Lockwasher 6 mm 2 26 Hex screw M6 x 35 2 27 Screw M8 x 40 4 28 Lockwasher 8 mm 4 29 Angular tube oil outlet 30 Lockwasher 8 mm 70 37 Hex screw M8 x 64 8 32 Hex screw M8 x 45 2 33 Stud M70 x 42 4 ...

Page 146: ...magneto side to correctly align crankcase halves Tor que bolts as specified following illustrated sequence 15 16 PAGE 136 Follow sequence shown 1 to 14 22 N m 16 ft lbsl 15 and 16 9 N m 7 ft lbsl O NOTE Torque the two smaller bolts 15 and 16 on magneto side to 9 N m 7 ft Ibs 1 3 8 29 Loctite 242 angular tubes oil inlet oil outlet cover screws Apply Loctite 242 on threads prior to assembly angular ...

Page 147: ...ew M5 x 78 2 14 Generating cOil 15 Lighting cOil 16 Lockwasher 5 mm 2 SECTION 02 ENGINE SUB SECTION 07 534 ENGINE TYPE MAGNETO rN 4 18 I 19 20 17 Cylindrical slotted head screw M5 x 35 2 18 Flywheel 19 Flywheel counterweight 20 Staning pulley 21 Lockwasher 22 mm 22 Hex nut 22 x 1 5 mm 23 Harness 24 Protector tube 25 Splice connector 26 Screw M6 x 25 2 27 Lockwasher 8 mm 3 28 Hex screw M8 x 20 3 29...

Page 148: ...magneto retaining nut Impulse hose fitting Crankshaft O NOTE It should be noted that to correctly remove a Loctite locked fastener it is first necessary to tap on the fastener to break Loctite bond This will eliminate the possibility of thread breakage PAGE 138 18 Flywheel To remove magneto housing flywheel lock crankshaft with crankshaft locking tool service tool as illustrated adjust magneto hou...

Page 149: ...ve the shipping nuts from the new coil and apply Loctite 242 blue medium strength to screws before assembly CAUTION Before reinstalling the magneto remove the loose epoxy from harness SECTION 02 ENGINE SUB SECTION 07 534 ENGINE TYPE To replace lighting coil Heat the armature plate around the screw holes to break the Loctite bond 200 0 F Heat Protect harness from flame CAUTION Protect harness from ...

Page 150: ... threads and tighten Clean crankshaft extension taper Apply Loctite 242 on taper 12 18 21 22 Loctite 242 flywheel lockwasher nut Position woodruff key magneto flywheel lockwasher on crankshaft Clean nut threads and apply Loctite 242 blue me dium strength before tightening nut to 95 N m 70 ft Ibs At reassembly coat ali electric connections with silicone dielectric grease to prevent corrosion or moi...

Page 151: ...8 Hose 9 Hose 70 Rivet 77 U hose 72 Radiator protector 2 SECTION 02 ENGINE SUB SECTION 07 534 ENGINE TYPE f 3 S0 4 _ _ _ 5 COOLING SYSTEM 8 G I 6 73 Hex washer head self tapping screw 70 24 x 1 2 2 74 Radiator 2 75 Coolam tank 76 Hex elastic stop nut 70 24 4 77 Clamp 2 78 Hose 495 mm 79 Thermostat 20 Hose 98 6 mm 27 Sender 22 Plug 23 Grommet PAGE 141 ...

Page 152: ...voking a circuit water pump engine reser voir This is done by closing the heat exchanger cir cuit PAGE 142 B When the liquid is warmed to 50 C 122 F the thermostat opens the circuit water pump engine heat exchangers reservoir to keep the liquid at the desired temperature See the diagram to the ex ploded view These two function have the advantage of preventing a massive entry of cold water into the...

Page 153: ...620 3 70 Shim 0 5 mm 77 Locrire 277 72 Disrance sleeve 24 5 mm 73 Shim 0 5 mm 74 0 ring 75 Gear 76 Spring 77 Spring reraining cup 7B Orclip 79 Bearing 620 7 20 Seal 2 27 Disrance ring 22 Pump housing 23 Gasker 24 Pump impeller 25 Washer 8 4 mm 26 Washer 6 2 mm 27 Nur M6 2B Bo r M6 x 25 4 29 Locrire 242 3D Oil rank 37 Hexagonal washer head powerlock screw 1 4 20 x 12 32 Grammer 2 33 Male connecror ...

Page 154: ...te 271 distance sleeve To remove the distance sleeve use a bearing puller Ex Snap On no CJ 950 and pusher PIN 420876 610 as illustrated Heat the distance sleeve to break the Loc tite bond 200 F and proceed as illustrated II Press Heat the Bearing puller Snap on CJ 9501 _ CAUTION Ensure that the rotary valve shaft is perfectly perpendicular with the press tip or damage will occur Clean rotary valve...

Page 155: ... on seal lips Position all seals with shielded portion towards water pump using pusher PIN 420 876 510 Align distance ring opening with crankcase draining hole see note and illustration Push seals and distance ring assembly against bearing ONOTE 35 of the distance between first and se cond seals must be filled with lithium grease or equivalent ONOTE The draining hole is use to detect seals malfunc...

Page 156: ...follow with the suitable pusher PIN 420 876 600 28 29 Pump housing bolts Loctite 242 Apply Loctite 242 on bolts thread 2 Rotary valve cover bolts Torque the rotary valve cover bolts to 20 N m 15 ft lbs PAGE 146 5 Rotary valve Rotary valve adjustment when replacing crankcase having no timing marks REQUIRED TOOLS ENGINE TYPE 534 Angle finder 414 3529 00 TIMING MARKS opening closing For example 1400 ...

Page 157: ...ng each side of disc on gear to determine best installation position Magneto side piston must be at T D C Spray some injection oil on rotary valve before closing the rotary valve cover 2 Rotary valve cover bolts The rotary valve cover bolts must be torque to 20 N m 1 5 ft lbs SECTION 02 ENGINE SUB SECTION 07 534 ENGINE TYPE INSPECTION 1 5 Rotary valve cover rotary valve To measure this gap you can...

Page 158: ... J ...

Page 159: ...eck if the cylinder out of round is more than 0 05 mm 002 If larger cylinder should be rebored and honed or should be replaced 16 mm saA Gudgeon pin direction Measures to be compared CYLINDER PISTON CLEARANCE ENGINE PISTON TO WALL CLEARANCE WEAR TYPE MINIMUM MAXIMUM LIMIT 247 0 065 0 200 mm 0 20 mm 0026 OOS 100079 277 0 070 0 090 mm 0 20 mm 002S 0035 10 0079 377 O OSO 0 10 mm 0 20 mm 0031 0039 100...

Page 160: ...g All 1984 0 20 0 35 mm engines L008 014 1 0 mm L039 Position ring half way between transfer ports and intake port On rotary valve engines position ring just below tra nsfer ports ONOTE In order to correctly position the ring in the cylinder use piston as a pusher PAGE 150 Using a feeler gauge check ring end gap If gap exceeds specified tolerance the ring should be replaced CRANKSHAFT DEFLEXION TY...

Page 161: ... the magneto side between bearing and crankshaft counterweight The following is required for the adjustment procedure adjustment shims refer to parts catalog thicknesses available 0 10 mm 004 0 20 mm L008 0 30 mm L012 0 50 mm L020 1 00 mm L040 247 only micrometer vernier Total shim thickness needed for the end play adjustment is determined with the following procedure a Measure crankcase halves as...

Page 162: ...ft end play that must be within specification If the result is over specification add adjustment shim s If the result is under specification remove adjustment shim s TO SUMMARIZE 247 277 engine type A M M2 M3 B M4 M5 M6 M7 Ms A B actual end play that must be within specification Ms is the dimension that must be adjusted to obtain the specified crankshaft end play PAGE 152 t M3 I I II I Ml M2 I I I...

Page 163: ...EASUREMENT To measure this gap you can use a feeler gage inserted between rotary valve and upper crankcase with the rotary valve cover in place without it s 0 ring Check the most surface you can Follow the same procedure with the lower crankcase PAGE 153 ...

Page 164: ... D ...

Page 165: ...RET JJr CARBURETOR AND FUEL PUMt 3 D 5 4 I 7 I 8 L ___ J MIKUNICARBURETOR ALL MODELS Except VM 28 VM 40 1 1 r I SS 25 Sonic LIe I I 20 2 1 0 fr10 22_ 11 12 IJ I I 14 0 15 25 26 9 I I 36 37 I I I 1 38 I l_ j I 39 I PAGE 155 ...

Page 166: ...N 02 ENGINE JB SECTION 09 CARBURETOR AND FUEL PUMP Carburetor VM 28 242 Elan 2 3 0 5 4 6 iil 7 tj 8 PAGE 156 0 14 15 16 17 I Y Carburetor VM 40 23 24 Blizzard 9700 5 6 6 25 U 35 I 34 18 33 1 32 I I o _ 26 ...

Page 167: ...h a low flash point such as gasoline naphtha benzol etc should not be used as they are flammable and explosive Check inlet needle tip condition If worn the inlet nee dle and seat must be replaced as a matched set Check throttle slide for wear Replace as necessary CAUTION Heavy duty carburetor cleaner may be harmful to the float material and to the rubber parts O ring etc Therefore it is recommende...

Page 168: ...ciency To check for correct float level proceed as follows Remove float chamber and gasket from carbuteror With carburetor chamber upside down measure height H between float chamber flange rib and top edge of float arm Ex VM 36 carburetor PAGE 158 Float arm height dimensions CARBURETOR VM 28 VM 34 VM 40 DIMENSION H inch 59 66 86 94 67 75 mm 15 17 22 24 17 19 O NOTE As a general rule the float arm ...

Page 169: ...must be perfectly matched with the air intake manifold or severe engine damage will occur When installing throttle cable end in throttle slide hook up cable by using the stopper at the extremity of the cable Throttle cable end Throttle side 4 6 Needle nylon packing Nylon packing 1 Needle Make sure the nylon packing is installed on all applica ble throttle slides _ CAUTION Serious engine damage can...

Page 170: ...ors start to operate simultaneously PAGE 160 WARNING It is important that the throttle slide adjustment be performed to ensure proper func tioning of throttle mechanism _ CAUTION On twin carburetor model with rotary valve Blizzard 9700 do not interchange carbure tors the jetting is different on each side Once carburetor adjustment is performed check that with the throttle lever fully depressed the...

Page 171: ...ke lever until you feel a light resistance You must maintain a free play of 1 5 mm 0 060 on off position 1 cr n f _Adjustment nut c DoI Lock nut Carburetor To acheive that adjustment on carburetor unlock the lock nut unscrew the adjustment nut to reduce the free play or screw the adjustment to increase the free play PAGE 161 ...

Page 172: ...SECTION 02 ENG INE SUB SECTION 09 CARBURETOR AND FUEL PUMP MIKUNI FUEL PUMP 12 PAGE 162 FIG A 8 G 10 J 2_ o 6 2 4 5 0 9 f 5 _ _ 0 4 3 7 11_ FIG B ONE OUTLET PUMP ...

Page 173: ...bri cate tip of holder with a drop of oil Push holder into pump body as illustrated Pin punch ___ il Valve holder Lubricate tip CLEANING INSPECTION The entire pump should be cleaned with general purpose solvent before disassembly Fuel pump components should be cleaned in general pur pose solvent and dried with compressed air WARNING Solvent with a low flash point such as gasoline naphtha benzol et...

Page 174: ... ID ...

Page 175: ...SECTION 02 ENGINE SUB SECTION 10 AIR INTAKE SILENCER AND FUEL TANK AIR INTAKE SILENCER AND FUEL TANK Elan Citation Skandic Safari SS 25 Sonic LlC Blizzard 5500 MX Blizzard 9700 Alpine PAGE 165 ...

Page 176: ...SECTION 02 ENGINE SUB SECTION 10 AIR INTAKE SILENCER AND FUEL TANK ELAN PAGE 166 33 I 31 r 32 U 21 1 25 24 43 19 7 I 5 39 10 ...

Page 177: ... 29 1 2 750 mm 27 Isolating line 4 70 2 mm 22 Tee 4 Tab lock Always bend tab lock over screws and replace if they seem worn 12 Spring clips Always reposition spring clips after any repair to prevent possible leaks 23 Fuel tank 24 Grommer 25 Male connector 26 Fuel ftlrer 27 Fuel tank cap 28 Gasket 29 Air vent fitting 30 Air vent tube 27 586 mm 37 Primer tube 78 1 2 470 mm 32 Primer tube 7 778 mm 33...

Page 178: ...SECTION 02 ENG INE SUB SECTION 10 AIR INTAKE SILENCER AND FUEL TANK CITATION 3500 9 0 _ i 17 18 I 15 f 22 4 1 I U 3 I _ 1 l v 7 1 I 22 I 12 I 1W QI 1 IN 1 2 4 6 5 2 PAGE 168 ...

Page 179: ...1 280 mm 17 Spring clip 18 Fuel line 20 508 mm 19 Fuel line 20 508 mm 20 Fuel line 15 380 mm 21 Fuel line 14 356 mm 17 22 Spring clips Always reposition spring clips after any repair to prevent possible leaks 22 Spring clip 2 23 Tee 24 Male connecror 25 Grommet 26 Fuel filter 27 Fuel tank 28 Air vent fitting 29 Hexagonal nut 5 76 18 30 Air vent tube 62 1575 mm 31 Primer rube 20 508 mm 7 178 mm 32 ...

Page 180: ...SECTION 02 ENG INE SUB SECTION 10 AIR INTAKE SILENCER AND FUEL TANK SKANDIC 9 8 J 20 PAGE 170 10 42 II 7 I 11 4 6 125 5 ...

Page 181: ... Fuel line 20 508 mm 77 Fuel line 20 508 mm 78 Fuel line 75 380 mm 79 Fuel line 74 356 mmj 20 Spring clip 2 27 Tee 15 20 Spring clips Always reposition spring clips after any repair to prevent possible leaks 22 Male connector 23 Grommet 24 Fuel filter 25 Fuel tank 26 Air vent fitting 27 Hexagonal nut 5 6 78 28 Air vent tube 29 Primer tube 7 778 mmj 30 Primer tube amorceur 20 508 mmj 37 Primer valv...

Page 182: ...SUB SECTION 10 AIR INTAKE SILENCER AND FUEL TANK SS 25 SONIC UC SAFARI 377 447 GRAND LUXE 14 0 PAGE 172 16 11 28 13 I 2s lr A 21 V zo 22 I r l I SS 25 Sonic LlC Optional on other models I I I I J I Q5 39 40 Sl 31 41 G 46 ...

Page 183: ...6 Spring clip 22 26 Spring clips Always reposition spring clips after any repair to prevent possible leaks 7 Elbow The air box elbow must be maintain upward in any condition 27 Tee 28 Male connector 29 Grommer 3D Fuel filrer 37 Fuel rank 32 Air vem firring 33 Hexagonal nut 5 6 78 34 Air vem rube 65 7665 mm 35 Primer rube 7 0 7 77 mm 36 Primer rube 76 5 479 mm 37 Fuel line 77 38 Primer valve 39 Cli...

Page 184: ...AND FUEL TANK BLIZZARD 5500 MX 9 44 1 38 8 36 1 ldi 35 34 I N 32 l 33 29 W 31 7 l 41 1 t I f 25 1 fJl 1l J42 y l 21 17 25 I 11 P 2 9 i 1 1 I 10 41 15 Q 21 rY 28 16 I I I 1 t 46 22 I 24 I 40 I 18 23 I 29 47 I Y f 37 r I J l j 3 l ij I I 5 I 1 2 3 2 PAGE 174 ...

Page 185: ...el line 20 508 mm 20 Fuel gauge 7 37 787 mm 27 Spring clip 2 22 Cable clip 23 Tee 24 Fuel tank 11 21 Spring clips Always reposition spring clips after any repair to prevent possible leaks 25 Grommet 3 26 Male connecror 27 Fuel Mer 28 Back plate 29 Male connecror 2 30 Fuel tank cap 37 Cap holder 32 Gasket 33 Air vent fitting 34 Air vent tube 58 7473 mm 35 Primer tube 24 670 mm 36 Primer tube 37 788...

Page 186: ...SECTION 02 ENGINE SUB SECTION 10 AIR INTAKE SILENCER AND FUEL TANK BLIZZARD 9700 PAGE 176 9 16 50 4s 49 7 51 I 44 I 31 ...

Page 187: ...mm 22 Fuel gauge 7 37 187 mm 23 Spring clip 24 Clip 25 Tee 26 Fuel tank 27 Grommet 3 3 Tab lock Always bend tab lock over screws and replace if they seem worn 13 23 53 Spring clips Always reposition spring clips after any repair to prevent possible leaks 28 Male connector 29 Fuel filter 30 Back plate 31 Male connector 2 32 Fuel tank cap 33 Gasket 34 Air vent fitting 35 Air vent rube 58 1473 mm 36 ...

Page 188: ...SECTION 02 ENG INE SUB SECTION 10 AIR INTAKE SILENCER AND FUEL TANK ALPINE 47 I 8 I j 7 I I 31 PAGE 178 ...

Page 189: ...he engine side orifice and the rubber vent must be positioned on the side of the silencer box to allow cold air circulation In temperature below 1aoe 14 F and or powder snow the rubber plug must block the entry of fresh air on the side of the silencer box and the rubber vent must allow the warm air being emitted from the engine to be directed over the carburetor _ CAUTION Observe temperature chang...

Page 190: ...lD ID ...

Page 191: ...___ __ cm _ _ WARNING No lateral free play should exist be tween drive pulley guard and frame bracket ADJUSTMENT Elan Citation Skandic Alpine models The length of the uncompressed retaining pin spring should not be less than 47 mm 1 7 8 An uncompressed front guard spring should not be less than 20 mm 13 16 When assembling adjust length as illustrated below 1 r 0 3 threads SECTION 03 TRANSMISSION S...

Page 192: ... ...

Page 193: ...ARD 9700 SECTION 03 TRANSMISSION SUB SECTION 02 DRIVE BELT DRIVE BELT APPLICATION CHART 1984 MODELS NUMBER MAX WIDTH MIN WIDTH NEW WEAR LIMIT 5700411 00 30 mm 1 3 16 27 mm 1 1 1 6 414375800 33 3 mm 1 5 16 30 mm 1 3 16 414 5233 00 35 mm 1 3 8 32 mm 1 1 4 414505900 35 mm 1 3 8 32 mm 1 1 4 PAGE 187 ...

Page 194: ...l in the same rotation direction REMOVAL INSTALLATION _ CAUTION Do not force or use tools to pry the belt into place as this could cut or break the cords in the belt WARNING Do not operate snowmobile without drive belt or its guard installed Serious bodily in jury could occur Tilt cab and remove pulley or belt guard PAGE 188 Citation Skandic models Loosen the countershaft bearing retaining screw a...

Page 195: ... the brake is well adjust ed Check brake light operation Brake light t switch Brake disc I M I SECTION 03 TRANSMISSION SUB SECTION 02 DRIVE BELT To install the drive belt reverse the procedure _ CAUTION Once belt is installed be sure to secure the countershaft bearing by closing the bearing cage and firmly tightening the retaining screw Safari SS 25 Sonic LlC models Unlock and raise the driven pul...

Page 196: ...g and pushing the sliding half Hold in fully open position Slip the belt over the top edge of the fixed half PAGE 190 Slip the belt out from the drive pulley and remove com pletely from the vehicle To install the drive belt reverse procedure Alpine model To remove belt from pulleys follow the Elan proce dure To remove belt from vehicle Remove the two bolts holding brake support to the frame Remove...

Page 197: ...n To obtain maximum vehicle performance the belt ten sion must be adjusted to 6 8 kg 15 pounds with a de flection of 32 mm 1 1 4 To check tension Position a reference rule on drive belt Wooden stick and fish scale method Mark one end I I 32 mm 1 1 4 SECTION 03 TRANSMISSION SUB SECTION 02 DRIVE BELT Apply a 9 8 kg 15 pounds pressure on drive belt Deflection must be 32 mm 1 1 4 Using the belt tensio...

Page 198: ...3 Allen screws located to the outer face of the driven fixed half pulley To add deflection equally screw the three Allen screws To remove deflection equally unscrew the three Allen screws O NOTE At drive belt deflection adjustment turn the Allen screws 1 4 turn at a time PAGE 192 Safari SS 25 Sonic models Drive belt deflection is adjusted with the movement of the chaincase countershaft assembly To...

Page 199: ...Alpine model The deflection is adjusted by moving engine bracket To do so loosen engine bracket nuts and adjust distance between pulleys SECTION 03 TRANSMISSION SUB SECTION 02 DRIVE BELT PAGE 193 ...

Page 200: ...AUSE a Excessive slippage due to irregular outward actuation movement of drive pulley b Rough or scratched pulley surfaces c Improper belt angle d Considerable use REMEDY a Tighten engine mount nuts equally b Align pulleys c Repair or replace pulley half REMEDY a Check drive pulley for worn or missing flyweights rollers b Clean shaft with steel wool and lubricate with low tem perature grease c Cle...

Page 201: ... ley c Engine idle speed too high c Reduce engine R P M d Incorrect belt length d Using unspecified type of belt Replace belt with car rect Bombardier belt e Incorrect pulley distance e Readjust to specifications CAUSE REMEDY a Rough or scratched pulley a Repair or replace surfaces b Unspecified type of belt b Replace belt with correct Bombardier belt CAUSE REMEDY a Excessive belt speed a Using un...

Page 202: ...USE a Improper belt installation b Belt rubbing stationary ob ject on pulleys c Violent engagement of drive pulley CAUSE a Pulley misalignment b Using unspecified type of belt REMEDY a Refer to Installation sec tion b Check drive components c Grease replace spring or drive pulley REMEDY a Align pulleys b Replace belt with correct Bombardier belt ...

Page 203: ...ring 7O Inner half 77 Shim 72 Nut Loctite 242 73 Counterweight 74 Roller 75 Shouldered pin 76 Shouldered bushing ass y 77 Drive pullev retainer PIN 529 0077 00 17 r j 7 14 N m 10 ft lbs SECTION 03 TRANSMISSION SUB SECTION 03 DRIVE PULLEY DRIVE PULLEY ROLLER ROUND SHAFT TYPE 5 Elan 1 I Gl 4 I I 3 1 61 N m 45 ft lbs PAGE 197 ...

Page 204: ...1700 10 Inner half To remove the inner half slide a length of steel pipe over shaft Attach with a 5116 nut and bolt as il lustrated The inner half can then be removed with a pipe wrench Unscrew counter clockwise _ Protective sleeve ____ 5 16 bolt PAGE 198 DISASSEMBLY _ CAUTION Do not disassemble counterweights unless replacement is necessary 9 10 Bearing To disassemble bearing from inner half use ...

Page 205: ... the unthreaded portion and Loctite 242 or equivalent on threads as illustrated then install inner half on exten sion Crankshaft extension Anti seize Loctite 242 To tighten inner half use a protective sleeve as shown in the removal procedure 5 Shim neutral This shim is used to obtain a neutral function of the drive pulley when engine is idling use as required maximum of two 2 Refer to ADJUSTMENT 6...

Page 206: ...a neutral function of the drive pulley when engine is idling Proceed as follows when retaining bolt is torqued With a new drive belt installed you should be able to insert a minimum of 0 80 mm 030 thick feeler gauge on each side of the drive belt simultaneously pushing drive belt to sit on bearing Shim 5 located between governor cup and drive pulley shaft will help in obtaining correct adjustment ...

Page 207: ...nner half 10 Nur Locrire 242 11 Lever 12 Roller 13 Shouldered pin 14 Shouldered bushing 15 Puller PIN 529 0028 00 16 Puller PIN 529 0030 00 9 I 8 10 14 N m 10 ft lbs 17 Drive pulley rerainer PIN 529 0017 00 7 6 SECTION 03 TRANSMISSION SUB SECTION 03 DRIVE PULLEY ROUND SHAFT TAPER TYPE Citation 3500 I 17 1 PAGE 201 ...

Page 208: ...e that the gover nor cup be held firmly during governor retaining bolt removal Use drive pulley retainer PIN 529001700 PAGE 202 9 Inner half If it is necessary to remove inner half use drive pulley puller no 529 002 800 529 003 000 t 529003000 Metric threads 529002800 _ CAUTION This pulley has metric threads Do not use standard thread puller To block engine crankshaft Remove starter rope blocking ...

Page 209: ...as explained in removal pro cedure Make sure crankshaft is rotated 45 counter clockwise from T D C position and that cylinder is completely filled with a starter rope 9 Inner half Lubricate lightly pulley shaft drive pulley lubricant PIN 413800700 SECTION 03 TRANSMISSION SUB SECTION 03 DRIVE PULLEY 8 Shim neutral This skim is used to obtain neutral function of the drive pulley when engine is idlin...

Page 210: ...ley when engine is idling Proceed as follows when retaining bolt is torqued With a new drive belt installed you should be able to insert a minimum of 0 80 mm 1 030 thick feeler gauge on each side of the drive belt simultaneously when pushing drive belt to sit on inner half shaft PAGE 204 0 80 mm feeler gauge 0 80 mm feeler gauge Shim 8 located between governor cup and drive pulley shaft will help ...

Page 211: ...8 Allen setscrew Loctite 242 9 Spring 1O Spring seat 1 7 Capscrew 12 Guart 13 Outer half 13 Skandic 377 R Safari 377 447 Safari Grand Luxe Blizzard 5500 MX Gil 1 i5 6 N m 11 53 in lbs 74 Inner half 15 Self locking screw Locrite 271 16 Starter gear 17 Nut Loctite 242 18 Counterweight 19 Shouldered pin 20 Roller 27 Bushing 22 Puller PIN 529 0027 00 23 Puller PIN 529 002800 24 Puller pin PIN 529 0030...

Page 212: ...e crankshaft until it locks into position CAUTION Do not use any type of pin other than the tool PIN 420 876 640 PAGE 206 TYPICAl Crankshaft locking tool I QlIll M Or Impulse hole Remove spark plug s then bring P T O piston at T D C position Rotate drive pulley 45 clockwise then insert enough starter rope into cylinder to fill it completely Remove the capscrew 14 Inner half To remove inner half on...

Page 213: ... disassembly hold hub plug firmly against outer half until the two 2 bolts are completely remov ed This will prevent damage of the outer half threads 4 5 8 Duralon bushing To disassembly duralon bushing from hub plug remove set screw and use a suitable pusher and hammer or press _ CAUTION Do not disassemble counterweights unless replacement is necessary CLEANING 13 14 Inner Outer half Inside of ou...

Page 214: ...r at one end to ease bushing assembly and push into hub plug as illustrated Grind Taper 17 18 19 20 Counterweight ass y Apply Loctite 242 on threads and torque to 14 N m 10 ft lbs _ CAUTION Be careful when installing outer half assembly on square shaft of drive pulley to avoid scratches on Ouralon bushing caused by square shaft edge 5 6 7 13 Hub plug Apply Loctite 242 on threads of bolts then torq...

Page 215: ... Incorrect seating of shaft end in governor cup can cause crankshaft bending When pulley halves to make sure that the pulley is properly installed Distance must be 76 mm 3 2 Lock tab Push on outer half towards governor cup to remove all possible slack when measuring Lift rear of vehicle off the ground Install drive belt and pulley gl lard then start engine and apply throttle and brake 2 3 times St...

Page 216: ...EY SQUARE SHAFT WITH THREE COUNTERWEIGHT ASSEMBLIES Alpine 503 Blizzard 9700 SS 25 Sonic LlC I I I I I I I SS 25 Sonic lie 19 I 15 20 I 17 I I 22 Two 2 counterweight each side on ALPINE model PAGE 210 12 12 N m 9 ft lbs 4 r 7 6 I 6 1 85 N m 63 ft lbs ...

Page 217: ...ARKS IN LINE i 2 1 Inner half 2 Outer half 3 Governor cup 4 Hub plug SECTION 03 TRANSMISSION SUB SECTION 03 DRIVE PULLEY 18 Staner ring gear 19 Flat slotted head self locking screw 20 Damper flng 21 Nut 22 Counterweight 23 Nylon washer 5 1 mm 20 0 thickness 24 Shouldered Pin 25 Bushing 26 Nylon washer 3 3 mm 130 thickness 27 Bushing 28 Spacer thick 29 Beanng 30 Ring 31 Spacer thin 32 Drive pulley ...

Page 218: ...from vehicle front side pan retainer nut drive pulley retaining capscrew access hole OISASSEMBLY Pull returning screws ONOTE Some bolts of the drive pulley have Loc tite on their threads it is advisable to break the Loctite seal before attempting to unscrew PAGE 212 3 16 Outer half assembly governor cup CAUTION Do not tap on the governor cup The governor cup can be easily removed by inserting two ...

Page 219: ... bushing Inspect the Duralon bushing condition by checking the free play of the sliding half pulley This is achieved by restraining the inner half and checking if the sliding half moves in the direction of the arrows more than 3 mm 1 8 point on both halves Maximum free play 3 mm 1 S SECTION 03 TRANSMISSION SUB SECTION 03 DRIVE PULLEY _ CAUTION Ensure rollers are in good condition Replace as requir...

Page 220: ...oval pro cedure Make sure crankshaft is rotated 45 counter clockwise from T O C position and that cylinder is completely filled with a starter rope or use crankshaft locking tool Install inner half on crankshaft extension then position outer half assembly on fixed half square shaft _ CAUTION Be careful when installing outer half assembly on square shaft of drive pulley to avoid scratches on Duralo...

Page 221: ...sher 4 Sprocket 5 Driving chain 6 Bearing cone 7 Chaincase SECTION 03 TRANSMISSION SUB SECTION 04 DRIVEN PULLEY DRIVEN PULLEY ELAN 6 4 3 2 1 o o 8 Fixed half 9 Sliding half 10 Release spring 11 Outer cam 12 Cam slider shoe 13 Roll pin PAGE 215 ...

Page 222: ...ing pre load should be 3 6 kg 8 Ibs To correct pre load see ADJUSTMENT PAGE 216 12 Cam slider shoe Inspect outer cam for worn slider shoes ASSEMBLY Assemble driven pulley by reversing disassembly pro cedure 12 Cam Slider Shoe When replacing slider shoes always install a set of new shoes to maintain balanced pressures on the cam INSTALLATION Reinstall the driven pulley on vehicle by reversing the r...

Page 223: ...T 10 Spring torsional pre load Spring torsional pre load should be 3 6 kg 8 Ibs To correct spring pre load relocate spring end in sliding pulley half SECTION 03 TRANSMISSION SUB SECTION 04 DRIVEN PULLEY PAGE 217 ...

Page 224: ...SECTION 03 TRANSMISSION SUB SECTION 04 DRIVEN PULLEY CITATION SKANDIC 39 6 PAGE 218 I i I I I I I I I ...

Page 225: ... puller 35 36 41 Support and screws Remove support screws and drive axle screws Tilt support forward Driven pulley assembly Remove from vehicle DISASSEMBLY 12 Scrap ring WARNING The driven pulley cam is spring loaded Hold in place when removing the shap ring SECTION 03 TRANSMISSION SUB SECTION 04 DRIVEN PULLEY 23 Bushing 24 Spring 25 Roll pin 26 Cap screw MB x 35 2 7 Bearing housing lower half 28 ...

Page 226: ...nd a suitable pusher 11 Brake disc capscrews Torque to 9 N m 6 ft Ibs PAGE 220 8 Cam Slider Shoe When replacing slider shoes always install a new set of three shoes to maintain balanced pressures on the cam INSTALLATION Reinstall the driven pulley on countershaft by reversing the removal procedure 13 Thrust washer Must be installed as illustrated to provide thrust area for the pulley snap ring 18 ...

Page 227: ...ou must use the following formulas SECTION 03 TRANSMISSION SUB SECTION 04 DRIVEN PULLEY Torque wrench length cm in Correction factor Torque wrench length 4 44 cm 1 750 in T o rq u e w reTn c 7h r_e_a_d_in g_ _ __ Real reading Correction factor Ex Torque wrench length 25 4 cm 10 in Torque wrench reading 60 N m 45 ft Ibs Correction factor 251 4 c m l O i n r 7 0 85 25 4 cm 10 in 4 44 cm 1 750 in Rea...

Page 228: ...EY Pulley alignment For pulley alignment procedure refer to section 03 05 2 Belt deflection set crews At assembly the Allen screws must be set in accordance with the drive belt deflection specification see section 03 sub section 02 Drive Belt PAGE 222 ...

Page 229: ...r 4 Extension 5 Shim 6 Set screw 7 Fixed half B Key cam 9 Thrust washer 70 Sliding half 77 Bushing 72 Slider shoe 73 Spnng 74 Outer cam 25 20 75 Snap nng 76 Shim 77 Screw 5116 7B x 51 8 7B Clip 79 Elastic stop nut 5116 7B 20 Bearing flange 27 Bearing 22 Collar 23 Socket set screw 1 1 4 20 X 1 1 4 24 Key pulley assy 25 Courtershaft 26 Elastic stop nut 70 32 27 Screw 70 32 X 31 4 1 PAGE 223 ...

Page 230: ...ISASSEMBLY 15 Snap ring Remove one nut Remove snapring to disassemble the outer cam and the two pulley halves 11 Sliding half bushing To disassemble a worn bushing use a press and a suitable pusher PAGE 224 INSPECTION u 11 Sliding half bushing Check bushing wear replace if wear is excessive 12 Slider shoe Check for excessive wear 13 Spring torsional pre load Check pre load using a fish scale posit...

Page 231: ...ar Lock the slide fit bearing on countershaft with the ex centric collar 23 Socket set screw Lock excentric collar in position with the set screw and apply Loctite 242 blue medium strength on threads SECTION 03 TRANSMISSION SUB SECTION 04 DRIVEN PULLEY 1 Pulley retaining screw Torque to 10 N m 7 ft lbs ADJUSTMENT 13 Spring torsional pre load To adjust spring pre load displace spring end accor ding...

Page 232: ... Cap screw 7 4 20 X 3 4 5 Support bracket 6 Elastic SlOp nut 7 4 20 7 Cap screw 5176 78 x 3 4 8 Elastic SlOp nut 5176 78 9 Bearing support 70 Shim PAGE 226 77 Bearing 72 Spacer 73 Fixed half 74 Roll pin 75 Sliding half 76 Spring 77 Slider shoe 78 Roll pin 79 Outer cam 20 Transmission input shaft ...

Page 233: ...04 DRIVEN PULLEY 19 Outer cam With sliding half and spring removed push the roll pin out of the shaft and remove the outer cam O NOTE If necessary heat hub of fixed pulley and outer cam to facilitate removal INSPECTION 16 Spring torsional load In order to measure driven pulley spring tension the pulley halves must be separated To do this insert a length of 1 8 dia rod between the halves Check ten ...

Page 234: ...half 3 Thrust washer 4 Sliding half 5 bushing 6 Spring 7 Slider shoe B Outer cam 9 C clip 10 Spacer 11 Support PAGE 228 12 Flanged ring 13 Snap ng 14 Grease fitting 15 Ring terminal 16 Wli e 10 2 mm 17 Ring terminal lB Hair pin 19 Nut MB x 1 25 x 6 20 Clevis pin 21 Support bracket 22 Support clamp ...

Page 235: ...move circlip and using a suitable puller remove coun tershaft support Driven pulley assembly Remove from countershaft DISASSEMBLY 9 C clip Push outer cam and remove the C clips Remove C clips SECTION 03 TRANSMISSION SUB SECTION 04 DRIVEN PULLEY 5 Sliding half bushing To disassemble a worn bushing use a press and a suitable pusher INSPECTION 5 Bushing Check sliding half bushing wear replace bushing...

Page 236: ...procedure Countershaft _ CAUTION Always apply anti seize compound Y on the countershaft before final pulley installa tion Loctite anti seize lubricant PIN 41 3 7010 00 PAGE 230 ADJUSTMENT 5 Spring torsional pre load To adjust spring pre load displace spring end accor dingly 1 Drive belt deflection adjustment set screws At assembly the Allen screws must be set in accor dance with the drive belt def...

Page 237: ...28 I 25 19 I SECTION 03 TRANSMISSION SUB SECTION 04 DRIVEN PULLEY SS 25 SAFARI SONIC LIC 39 r I 15 I 14 I 13 I 12 I 9 8 7 PAGE 231 ...

Page 238: ...ng Remove cotter pin and upper sprocket castellated nut Remove sprockets and chain 5 11 Bearing and spacer Remove from chaincase 12 13 Retaining nuts and shims Remove the four chaincase retaining nuts and save aligning shims for installation PAGE 232 27 Shim 22 Sliding half 23 Bushing 24 Spring 25 Outer cam 26 Slider shoe 27 Roll pin 28 Spacer 29 Support 30 Snap ring 37 Nut 32 Ball joint 33 Clevis...

Page 239: ...3 TRANSMISSION SUB SECTION 04 DRIVEN PULLEY ASSEMBLY 23 Sliding half bushing Assemble a new busing using a press and a suitable pusher I bushing sliding hal f I 0 Driven pulley and chaincase Assemble by reversing the disassembly procedure 19 Fixed half shaft _ CAUTION Always apply anti seize compound on the pulley shaft before final pulley installa tion Loctite anti seize lubricant PIN 413 701000 ...

Page 240: ...SECTION 03 TRANSMISSION SUB SECTION 04 DRIVEN PULLEY Track tension and alignment Refer to section 05 05 Drive belt deflection Refer to section 03 02 PAGE 234 ...

Page 241: ...or TRANSMISSION installation section ELAN 250 Shims 44 45 5 1 3 4 S16 Driven pulley movement Driven pulley movement t 34 mm 1 11132 I c 1 5 mm 1 16 max 101 Pulley distance specification 44 45 mm g 1 3 4 ggg Pulley distance adjustment method With the threaded rod and nut located between chaincase and frame shift chaincase to obtain the specified distance Pulley alignment specification 34 mm 75 1 11...

Page 242: ...er to the illustra tion Pulley alignment method Driven pulley alignment An adjuster nut and a spring are mounted on the counter shaft to align the driven pulley Align driven pulley to obtain specified dimensions For proper tightening of the adjuster and jam nuts refer to Driven Pulley section 03 04 PAGE 236 SKANDIC 377R U 1 5 mm 1116 max 101 34 mm 1 11 32 screws 1 Drive pulley movement Floating dr...

Page 243: ...distance between pulleys Pulley alignment specification 34 mm 75 1 11 32 1132 O NOTE A tolerance up to 1 5 mm 1 16 is allowed on the offset measurement to compensate for the twist due to the drive pulley torque Refer to the illustra tion Pulley alignment method Move engine to obtain the specified pulley alignment SS 25 SONIC LIC SAFARI 447 377 38 1 1 2 8 mil i _ J Engine r _movement _ L Driven pul...

Page 244: ...lley alignment specification BLIZZARD 5500 MX 31 8 mm 1 5 1 1 4 1 16 0 0 PAGE 238 BLIZZARD 9700 33 mm 1 5 1 19 64 1116 0 0 O NOTE A tolerance up to 1 5 mm 1 16 is allowed on the offset measurement to compensate for the twist due to the drive pulley torque Refer to the illustra tion Pulley alignment method O NOTE The floating type driven pulley must have a 3 mm liS maximum free play and the offset ...

Page 245: ...shoe 3 Nut 4 Brake lever 5 Nut 6 Cable lock 7 Spring 8 Brake light switch spring 9 Bolt cable 70 Bolt 77 Brake shoe 12 Bolt shoe I 12 10 7 5 SECTION 03 TRANSMISSION SUB SECTION 06 BRAKE BRAKE DRUM BRAKE Elan PAGE 239 ...

Page 246: ...n attaching brake lever assembly to chaincase bracket tighten nut until lever pivots freely and all side play is elimi nated LUBRICATION O NOTE Lubricate all moving metal parts of brake with light machine oil WARNING Avoid getting oil on brake shoe PAGE 240 ADJUSTMENT Brake lever control Adjust so that brake applies fully when lever is 25 mm 1 from handlebar grip O NOTE Prior to cable installation...

Page 247: ...1 1 1 9 8 I 22 21 SECTION 03 TRANSMISSION SUB SECTION 06 BRAKE DISC BRAKE Citation 3500 Skandic 377 III 1 20 19 III 2 PAGE 241 ...

Page 248: ...ect for excessive wear 1 Cable Inspect for frayed braids ASSEMBLY 4 23 Cotter pin Always reinstall new cotter pin 19 Pulley shaft Install in outer hole of brake lever 22 Stop plate Make sure the guard lock tab is inserted in the brake lever hole PAGE 242 13 Taptite screw M4 x 8 14 Bushing 15 Release spring 76 Brake lever and pad 17 Flat washer 10 mm 18 Elastic stop nut 70 mm 19 Pulley shaft 20 Spr...

Page 249: ... no longer turn then back off the adjuster approximately 1 1 2 turns Recheck brake operation Light switch WARNING Whenever the brake is readjusted the brake light switch operation must also be checked and adjusted To adjust disconnect switch at terminal loosen lock nut and screw switch as required Brake light _ _ _ switch r Lock nut Check brake light operation and tighten lock nut SECTION 03 TRANS...

Page 250: ...SECTION 03 TRANSMISSION SUB SECTION 06 BRAKE SELF ADJUSTING DISC BRAKE Safari 55 25 Sonic LlC Blizzard Alpine PAGE 244 ...

Page 251: ... ALPINE models disconnect brake light switch at connector Remove nuts and or bolts securing brake support to chaincase Slide brake caliper ass y from brake support SECTION 03 TRANSMISSION SUB SECTION 06 BRAKE 74 Brake mounting bracket 75 Nylon nut 3 8 76 76 Flat washer 3 8 x 7 8 x 060 77 Bushing 78 Caliper 79 Cap screw 5116 78 x 3 4 20 Shoes 27 Pin 22 Release spring 23 Ratchet wheel 24 Ratchet spr...

Page 252: ...ure brake cable housing to lever slide spring over cable then attach cable to housing with adjuster nut ADJUSTMENT Brake control lever Using adjuster nut adjust until there is no free play be tween the brake lever and its housing and there is a gap of 57 mm 3 2 1 4 1 8 between lever and cali per PAGE 246 No play O NOTE On Alpine models it may be necessary to change brake light switch support posit...

Page 253: ...TION 03 TRANSMISSION SUB SECTION 06 BRAKE SELF ADJUSTING DISC BRAKE 18 19 20 21 6 I 24 N m p 7 I 5 J I 4 73 Lockwasher MS 74 Cap screw MS x 7 25 x 76 75 Cap screw MS x 7 25 x 50 76 Inner caliper half 77 Parking brake cable and housing 7S Service brake cable and housing 79 Caliper support spring 20 Snap nflg 27 Spring 22 Elastic stop nut MS x 7 25 23 Elastic stop nut 70 24 Skandic 377 R 2 I PAGE 24...

Page 254: ...nt angle drive Pull brake assembly out of vehicle INSPECTION 8 9 Brake lining thickness Brake linings are servicable when fixed shoe projects a minimum of 1 mm 1 32 from caliper PAGE 248 ASSEMBLY 4 Ratchet wheel Inner _ caliper half minimum Apply low temperature grease on threads and spring seat prior to installation Fully tighten then back off 1 2 turn 10 11 Inner shoe bolt tab lock Tighten bolt ...

Page 255: ...to housing with adjuster nut 17 18 Brake cables The service brake cable must be installed in the lever upper hole ADJUSTMENT Lever travel To insure optimum self adjusting function of the rat chet screw the adjuster nut until there is a gap of 57 mm 3 2 1 4 1 8 between lever and cable sup port lug Brake control lever Using adjuster nut screw until there is no free play bet ween the brake lever and ...

Page 256: ... ...

Page 257: ...40 1 15_ 16 32 1 33 34 II 35 I a 18 I V 41 5 I SECTION 03 TRANSMISSION SUB SECTION 07 CHAINCASE CHAINCASE ELAN 31 PAGE 251 ...

Page 258: ... and drain oil Brake cable Disconnect from chaincase 30 Lower sprocket cotter pin Pry out lower access plug remove cotter pin and spacer 16 Threaded rod Disconnect from chaincase 35 39 U clamp bracket From the inner side of the frame remove the nut secur ing chaincase lower bracket and remove bracket Re move the nuts washers and u clamp holding the chain case to frame 36 Shims Remove and save for ...

Page 259: ...RANSMISSION SUB SECTION 07 CHAINCASE 1 Oil seal Using an appropriate pusher press oil seal into chain case hub Oil seal must sit flush with case hub edge 28 Sprocket Place lower sprocket with longer flange toward track side of chaincase For proper sprocket and chain use see Technical Data INSTALLATION Longer flange toward track side To install chaincase driven pulley assembly reverse removal proce...

Page 260: ...SECTION 03 TRANSMISSION SUB SECTION 07 CHAINCASE ADJUSTMENT Pulley alignment Refer to Pulley Distance and Alignment sub section 05 Brake operation brake light Refer to Brake sub section 06 PAGE 254 ...

Page 261: ...aincase 75 Bearing 4 5 20 SECTION 03 TRANSMISSION SUB SECTION 07 CHAINCASE CITATION 3500 SKANDIC 377 Torque to 10 N m 7 ft lbs 6 7 10 9 23 11 24 76 Seal 12 77 Stopper spacer 78 Snap ring 79 Plug 20 Chaincase cover 27 Bushing 22 Spacer 23 Snap ring 24 Sprocket 25 Spacer 26 Cap screw M8 x 25 27 Lockwasher 8 mm 28 Flatwasher 8 mm 29 Drive axle holder 13 30 Chaincase oil 200 ml 7 oz 14 15 16 17 18 28 ...

Page 262: ...se to frame 29 Drive axle holder Remove track tension on drive axle using tool PIN 529 0051 00 and pull chaincase out of vehicle INSPECTION Drive axle holder Suspension cross shaft Visually inspect the chain for cracked damaged or miss ing link rollers Inspect for defective bearing sprockets PAGE 256 INSTALLATION Reverse removal procedure Pay particular attention to the following 10 11 Castellated...

Page 263: ...screw 14 20 x 7 75 O ring 16 20 19 29 1 30 7 SECTION 03 TRANSMISSION SUB SECTION 07 CHAINCASE 8 22 76 Cap screw 14 20 77 Spacer 78 Spring 79 Chain tensioner 20 Bushing 27 Snap ring 22 Sprocket 40 teeth 23 Lower spacer 24 Elastic stop nut 14 20 25 Cap screw 5 6 78 x 7 26 Brass washer 27 Flat washer 28 Elastic stop nut 5 6 78 29 Drive axle holder 30 Chaincase 0 200 ml 7 oz BLIZZARD 9 10 12 13 PAGE 2...

Page 264: ...ining bolts Remove bolts and or nuts securing the chaincase to the frame 29 Drive axle holder Release track tension or use drive axle holder PIN 529 0051 00 Drive axle holder Pull chaincase out of vehicle PAGE 258 Suspension cross shaft INSPECTION Visually inspect the chain for cracked damaged or miss ing link rollers Inspect for defective bearing sprockets etc INSTALLATION Reverse removal procedu...

Page 265: ...us trated _ CAUTION Lock tab should be replaced if bent more than twice If in doubt replace _ CAUTION It is of the upmost importance to install the snap ring otherwise damage to the chaincase components may occur 30 Chaincase oil Refill with 200 ml 7 oz of chaincase oil SECTION 03 TRANSMISSION SUB SECTION 07 CHAINCASE PAGE 259 ...

Page 266: ...SECTION 03 TRANSMISSION SUB SECTION 07 CHAINCASE SAFARI SS 25 SONIC UC 22 I 23 I v I 31 PAGE 260 24 1 0 Q 19 27 28 29 30 ...

Page 267: ...rocedure and pay attention to the fol lowing 24 27 Spacers Install the thicker spacer on the chaincase side of the sprocket 10 Castellated nut Torque to 12 17 N m 9 12 ft lbs Loosen the nut and retorque to a maximum value of 10 15 N m 7 11 ft lbs 11 Cotter pin Install a new cotter pin 28 Snap ring CAUTION It is of the upmost importance to install the snap ring otherwise damage to the chaincase com...

Page 268: ... ...

Page 269: ...3O 29 28 27_ 26 I I I I I I 23 17 I 1 22 I 21 SECTION 03 TRANSMISSION SUB SECTION 08 GEARBOX GEAR BOX 3 SPEEDS GEARBOX ALPINE 15 I 10 I 11 I 12 Shifter mechanism 5 I 7 I 9 I 8 PAGE 263 ...

Page 270: ...asket is properly positioned 20 Gearbox retaining nuts Torque to 22 N m 16 ft lbs 8 Cotter pin Reinstall a new cotter pin ADJUSTMENT 10 11 Turnbuckle With gearbox lever properly engaged in gear adjust so that shifter lever fits correctly in corresponding gear groove To adjust loosen jam nut and adjust turnbuckle as re quired Retighten jam nut PAGE 264 Jam nut Turnbuckle 16 Bolt 114 20 x 1 114 17 T...

Page 271: ...66 Loctite 515 64 Oil 23 21 o 4l 1 22 e24 I 45 67 SECTION 03 TRANSMISSION SUB SECTION 08 GEARBOX 3 speeds gearbox Alpine 23 N m 17 ft lbsl PAGE 265 ...

Page 272: ...se installa tion position Reverse front then rear bogie wheel sets Remove rear axles PAGE 266 35 Washer 36 Ball bearing 6005 37 90 links rriple roller chain 3B Layshafr ass y 39 Disrance sleeve 40 Shim 25 5 34 7 47 Shim 42 Ball bearing 6005 43 Washer 44 Seal 45 Drive shafr 46 23 leerh shifr sprocker 47 Shim 4B Ball bearing 6205 49 Seal 50 Gear change shafr 57 Shim 52 STUd MB x 56 53 STUd MB x 52 5...

Page 273: ...N 03 TRANSMISSION SUB SECTION 08 GEARBOX 45 Drive shaft and components To reinstall the drive shaft components on the drive shaft proceed as follows Install the driven pulley shaft side bearing PIN 420 432040 on the shaft using the following suggested tool cylindrical steel tube Material cylindrical steel tube 32 mm 1 1 4 O D 26 8 mm 1 055 I D Install the circlip over the bearing Install the remai...

Page 274: ...ay PAGE 268 _ CAUTION The finger of the gear change shaft must not block the gear change fork 17 18 20 Gear change fork components Mount gear change fork and index rod with index spring and ball To do this press ball and index spring into the bore of gear change using a ball mounting bolt PIN 420 476020 then the ball mounting bolt is pushed through with the index rod and the index rod is screwed i...

Page 275: ...ecure housings to frame Install seals O NOTE A gap of approximately 1 6 mm 1 16 should exist between the end of bearing housing and seal SECTION 03 TRANSMISSION SUB SECTION 08 GEARBOX Install rear axle and bogie wheel sets to their original po sition 68 Chaincase oil Fill gearbox with 450 ml 16 Imp ounces of Bombar dier chaincase oil Adjustments Shifter arm position Set the shifter lever to NEUTRA...

Page 276: ...I 66 o 57 1 17 12 I 56 64 a 65 55 1 1 8 19 20 dP 63 17 I I r 62 1 40 21 A _ I tfjJ I 22 59 49 so 38 t I 5 8 I I 2 1 3 24 N m 51 37 54 53 I I 48 f _36 I j 16 I Dl fJ I 45 41 I r 26 52 47 46 I I 24 e Jr 126ft lbs I t9 i CC 35 N m I I 33 44 Crr 12 N m 34 19 ft lbs I I 43 42 74 fit e 75 Oil PAGE 270 24 N m 18 ft lbs I G 24 N m 29 O 118 ft lbs ...

Page 277: ... from fork shaft Countershaft support Disconnect from support clamp by removing hair pin and clevis pin 65 Chain tension Remove chain tension and remove transmission cover SECTION 03 TRANSMISSION SUB SECTION 08 GEARBOX 39 Loctite 262 40 Planet wheel shaft 47 Chain 92 links 42 Flanged ring 43 Sprocket 40 teeth 44 Flanged ring 45 Spacer 46 Needle bearing 47 Tensioner roller 48 Spacer 49 Tensioner sh...

Page 278: ... use a press and a suitable pusher 15 96 mm 5 8 0 max 21 Planet carrier bearing Remove snap ring and use a suitable pusher to press bearing out of carrier 25 Blocking wheel reverse driving hub Loctite mounted screws may require heat for disas sembly For easier disassembly heat up to 150 C 300 F CLEANING 27 60 Transmission cover case Remove Loctite residue from cover and case mating surfaces INSPEC...

Page 279: ...ft 11 Countershaft Press countershaft with the assembled ball bearing into the transmission case bore 56 Studs Assemble studs in transmission case with Loctite 262 and torque to 5 N m 44 in Ibsl SECTION 03 TRANSMISSION SUB SECTION 08 GEARBOX 6 Transmission lever handle Put Loctite 242 on handle threads 47 Tensioner ass y Ensure that roller turns freely 67 Grease fitting At grease fitting assembly ...

Page 280: ...ollows Apply Locquic Primer N on both case and cover flanges and in the cover o ring groove Allow 5 minu tes to dry Put Loctite 515 in the o ring cover groove install o ring and install cover to case PAGE 274 Install cover lockwasher and nuts and torque to 24 N m 18 ft lbs O NaTE Cover must be installed within ten minutes from LOCTITE application O NaTE Allow a drying period of two 2 hours before ...

Page 281: ...ENT When joining chain ends the open end of the circlip must be on opposite side of chain rotation The circlip should also be facing the outer side of chaincase Circlip CONNECTING LINK 318 DOUBLE 112 SINGLE 318 TRIPLE SECTION 03 TRANSMISSION SUB SECTION 09 DRIVE CHAIN DRIVE CHAIN CHAIN SEPARATION When separating an endless chain always use a chain bearing pin extractor Also make sure to remove one...

Page 282: ...G 1 2 LINK 3 8 DOUBLE c Q Q E 0 t F A Connecting link B Link pin C Cranked link D Cotter pin E Outer link F Cir clip LENGTHENING 1 LINK 3 8 TRIPLE M OC 0 A Connecting link B Inner link C Outer link D Circlip PAGE 276 1 2 SINGLE 3 8 TRIPLE A A B c c r o 3 8 DOUBLE ...

Page 283: ...e E 3 8 DOUBLE G SECTION 03 TRANSMISSION SUB SECTION 09 DRIVE CHAIN LENGTHENING 1 1 2 LINK 112 SING LE 3 8 TRIPLE A Connecting link 8 Outer link C Cranked link D Link pin E Circlip F Cotter pin G Double cranked link PAGE 277 ...

Page 284: ...1D ...

Page 285: ...To find out the difference between 140W 4 4P and 160W 4 5P look in section 02 sub section 05 pages 92 93 CHART CODES WIRING COLOUR CODE First color of a wire is the main color second color is the stripe Example YLlBK is a yellow wire with a black stripe CONNECTOR POSITION CODE Numbers are printed at the back of the connectors housings They correspond to the numbers on connectors of the electrical ...

Page 286: ...E RD RED BL BLUE YL YELLOW GN GREEN GY GREY VI VIOLET OR ORANGE BR BROWN WII Yl BK WHI IYl y GYN BRAK liGHT SWHCt4 H ADlAMP r __ B K IGNITION SWITCH OfF ON OR K TETHER 8K CuT OU T SWITCH VI EMERGENCY VI WH CUT OUT SWITCH I I O ___ I lIGHl GY VI I 1 GY VI SWITCH G Y I GY WARNING Ensure all terminals are properly crimped on the w ires and all connector housings are proper ly fastened OOCf em CXJ i 0...

Page 287: ... BRAKE LIGHT SWITCH I I IGNITION SWITCH Irl OfF BK 9 ON SK ORI OK VI WH VI WH Yl Yl GY VI GY Yl SK BK Yl Yl SK SK SK BK Yl Yl 0 TETHER cur OUT SWITCH COLOUR CODE BK BLACK WH WHITE RD RED BL BLUE YL YELLOW GN GREEN GY GREY VI V IOLET OR ORANGE BR BROWN WARNING Ensure all terminals are properly crimped on the wires and all connector housings are proper ly fastened Cf c OJ I Cf m n I a ZCf om n I rna...

Page 288: ...NERATOR COIL CD IGNITION COIL oAMPLIFIER BULB 5 21W BULB 60 60 W CD BULB 5 W LAMP FUSE 0 1 A RESISTOR 30 SL VL YL YL WH WH BK BK ADIYl RD YL BK BK RO VL SPEEDOMETER OPTIONAL FOR 3771 AQ Yl AD Yl YL r ____________ WH RO HEADlAMP WH AO FUEL GAUGE L _____ t JY Lt IOPTIONAl FOR 3771 GY WH AD _ l ____________ B K_ IOPT 8 LB 3771 BL COLOUR CODE BK BLACK WH WHITE RD RED BL BLUE YL YELLOW 16 GA GN GREEN G...

Page 289: ...R BK K ROfY l 11111 GV BK 1111 1 COLOUR CODE BK BLACK WH WHITE RD RED BL BLUE YL YELLOW 16 GA GN GREEN GY GREY VI VIOLET OR ORANGE BR BROWN WARNING Ensure all terminals are properly crimped on the wires and all connector housings are proper ly fastened I HEADLAMP x CDLIGHTING COIL 160W Q GENERATOR CO IL G IGNITION CO IL 0 AMPLIF IER BULB 5 21 W eULB 60 60 W G eULB 5 W LAMP BULB 2 W STARTER SOLENOi...

Page 290: ...ENCY CUT OUl SWITCH DIMMER SWITCH BRAKE LIGHT SWITCH AD Yl 1 RD YL Yl BK OK TACHOMETER BK VL n n n WH r iil HEAOlAMP VL Yl DK WH AD COLOUR CODE BK BLACK WH WHITE RD RED BL BLUE YL YELLOW 16 GA GN GREEN GY GREY VI VIOLET OR ORANGE BR BROWN RO YL 7 AOlYl 8 AD Yl BK uSPEEDDMETER BK RD YL RD Yl VL FUEL VL GAuGE V RO vl VI TEMPERA TURE VL GAUGE BKl all LEVEL 1 7 BK HIGH BEAM BL WARNING Ensure all termi...

Page 291: ...PEEDOMETER FUEL GAUGE W w_ W Y I YL BK V I RD Yl TEMPERATURE GAUGE CD LIGHTING COIL CD GENERATOR COIL CD IGNITION COIL CD AMPLIFIER BULB 5 21 W BULB 60 60 W BULB 5 W FUSE 0 1 A RES ISTOR 30 TEMPERATURE SENSOR oj HEADlAMP r COLOUR CODE BK BLACK WH WHITE RD RED BL BLUE YL YELLOW 16 GA GN GREEN GY GREY VI VIOLET OR ORANGE BR BROWN BK BK VL BK O L LEVEL HIGH BEAM BL WARNING Ensure all terminals are pr...

Page 292: ... LIGHT SWITCH TACHOMETER OPTIONAL SPEEDOMETER YL YlIBK YLIOK Yl lLYl WH BK OR BK BK OFF VI WH YL YL YlIBK SEE NOTE o II GN 8K I UJJ OIL LEVEL SENSOR VOLTAGE REGULATOR ONOTE The green wire from ta chometer must be connected to COLOUR CODE J the speedometer black wire __ v BK _ BLACK GN _ GREEN WH WH ITE GY GREY WARNING Ensure all terminals RD _ RED VI _ VIOLET are properly crimped on the wires BL _...

Page 293: ... HO SPEED VOLTA TEMPE TEMPE COIL 160 W GV VI GY GV OR COIL 1 H v l 4 lIWH COIL WII 1 Yl 2 WH R 8 K P 5 21W YVl Vl I P 60 60 W I J Yl N BK t 1M PILOT LAMP r 8 K BK _ V SA Yl I A CO f II _ 4 lL RD B l l i I IT 1 11 IT C AIITrU l J GN L Vl 8 Vl J0 WARNING Ensure all terminals are properly crimped on the wires and all connector housings are proper ly fastened l 0 Vl Vl 1 L4_ _ B K_ i 4 r r a I 0 0 al ...

Page 294: ...N GREEN GR GREY BL BLUE YL YELLOW 1S GA VI VIOLET OR ORANGE BR BROWN BK e i BK RD GN GN Yl Yl WH RD WH BR ROfOl WARNING Ensure all terminals are properly crimped on the wires and all connector housings are proper ly fastened l ol l t a a r LIGHT SWITCH v I Q GY OFF OR BK BK IGNITION SWITCH GNIWH TETHER CUT OU SWITCH EMERGENCV CUT OUT SWITCH OIMMEA SWITCI I BRAKE LIGHT SWITCH HORN CD SPEEDOMETER HE...

Page 295: ...rtion of the engine 5 Turn timing instrument ON and rotate crankshaft un til timing marks align Slacken the three 3 armature plate retaining screws then rotate armature plate until timing light fluctuates Retighten retaining screws at this position Too early Too late Turn armature Turn armature plate clockwise plate counter clockwise ONOTE Ignition timing can change upon tightening Always recheck ...

Page 296: ...timing light fluctu ates Retighten retaining screws O NOTE For 247 engine type hold advance mecha nism centrifugal lever in full advance position to ward magneto rim PAGE 290 position advance position O NOTE Ignition timing can change upon tightening Always recheck after tightening Edge gap verification By following either of the two procedures herein men tioned the edge gap will automatically be ...

Page 297: ...uter ring of dial and turn it until 0 on dial aligns with pointer Lock outer ring in position 4 Rotate the crankshaft by the fan counter clockwise until the piston is at Up to serial number 3 376 857 INDIRECT TIMING 2 85 mm 0 112 B T D C Serial number 3 376 858 above INDIRECT TIMING 2 6 mm 0 102 B T D C DIRECT TIMING 2 3 mm 0 090 B T D C BTDC Before top dead center At this point the crankcase mark...

Page 298: ...ine is running Keep clear of track and other moving parts O NOTE Turn headlamp ON when checking the timing Start the engine and point timing light straight in line with the fan cowl timing mark Cold engine Marks must align PAGE 292 Bring engine to 6000 R P M for a brief instant Check timing mark alignment If flywheel mark aligns within housing marks timing is correct Stop engine If the marks do no...

Page 299: ...orrespond to the specification scribe a new mark on the flywheel Fan cover removed Marks alignment SECTION 04 ELECTRICAL SUB SECTION 02 IGNITION TIMING Stroboscopic timing light ONOTE Timing can be checked using a strobosco pic timing light Snap On MT 212 or Electro Spe ciality model 978 The ignition components are affected by temperature variation therefore timing must be check ed when engine is ...

Page 300: ...f rotate counter clockwise piston to 462 engine type 2 52 mm 0 099 BTDC for 140W ignition unit 1 76 mm 0 069 BTDC for 160W ignition unit 534 engine type 1 75 mm 0 069 BTDC BTDC before top dead center How to easily distinguish the 140W 160W magneto 140W 4 4P 160W 4 5P Amplifier box part no 070000 680 070000 0770 Amplifier box connectors 3 2 qty Starting pulley retaining 4 3 screw qty Magneto poles ...

Page 301: ...igns within housing marks timing is correct Stop engine j I t tJr Housing marks If flywheel mark did not align within magneto housing marks armature plate must be adjusted Armature plate will have to be moved to advance or retard timing SECTION 04 ElECTR ICAl SUB SECTION 02 IGNITION TIMING _____ Timing too advanced _ turn armature plate I C I clock wise To adjust remove rewind starter assembly and...

Page 302: ... ...

Page 303: ...park plugs The new code is shorter there fore easier to use The following charts will assist you in making the change over easily and effectively IMPORTANT The new code has a different heat range identification system High number Low number hot plug cold plug 1984 CROSS REFERENCE CHART List of Bosch spark plugs used on 1984 Bombardier snowmobiles New number Old number M7A M 175 T 1 SECTION 04 ELEC...

Page 304: ...ical seat E Surface gap C D ignition G Glide air gap spark plug with control electrode K Mini plug with special connector KA Mini plug V Booster gap Thread M M 18 x 1 5 1 U M lOx 1 W M14xl 25 X M12xl 25 Z 7 8 18 SAE PAGE 298 EXPLANATION NEW SYSTEM Example X wide gap 044 1 1 mm Y wide gap D ii 5mml 4 designs 5 Thread Reach A Thread reach 460 standard electrode B Thread reach 460 extended tip electr...

Page 305: ...rdier is using the NGK spark plug type on most of the 1984 snowmobile models The heat range identification system is High number cold plug Low number hot plub 1984 CROSS REFERENCE CHART List of NGK spark plugs used on 1984 Bombardier snow mobiles BR 7ES BR 8ES SECTION 04 ELECTRICAL SYSTEM SUB SECTION 03 SPARK PLUGS PAGE 299 ...

Page 306: ...8 mm 12 mm 14 mm fJ 9 5 mm 3 8 WIDE GAP 10 1 0 mm 040 11 1 1 mm 044 13 1 3 mm 050 14 1 4 mm 055 15 1 5 mm 060 20 2 0 mm 080 Construction A Special Design B Special Design for Honda CVCC G Racing use GV Special Construction of V Type Racing Use K 2 Ground electrode Special for Toyota L Half heat range See Heat range chart LM Compact type for Lawn Mower M 2 Ground electrode For Mazda Rotary Eng N Ra...

Page 307: ... 5 mm 3 8 14 mm Thread 1984 CROSS REFERENCE CHART List of Nippondenso spark plugs used on 1984 Bombar dier snowmobiles W 24 ESR U W 16 E X u 11 wIDE 9 0 9 10 1 0 11 1 1 13 1 3 15 1 5 SPECIAL DESIGN Letter Description GU Gold palladium with U electrode U With U grooved ground electrode V Fine center electrode S Special type for MITSUBISHI L Special type For Honda CVCC Engines Extra projected type f...

Page 308: ...s indicated by irregular running of the engine decreasing engine speed due to misfiring reduced performance and increased fuel consumption This is due to a loss of compression Other possible causes are prolonged idling running the engine with the PAGE 302 choke on or running on a too rich a mixture due to a faulty carburetor adjustment or incorrect fuel and or fuel mixing The plug face of a fouled...

Page 309: ...xe 447 SS 25 462 Sonic LlC 462 Blizzard 5500 MX 503 Blizzard 9700 534 Alpine 503 Spark plugs Bosch M 175 T 1 M 7 A NGK BR SES NGK BR SES Nippondenso W 24 ESR U Nippondenso W 24 ESR U Nippondenso W 24 ESR U NGK BR SES NGK BR SES NGK BR 7ES NGK BR SES NGK BR 7ES SECTION 04 ELECTRICAL SYSTEM SUB SECTION 03 SPARK PLUGS PAGE 303 ...

Page 310: ... ...

Page 311: ... hydrometer measures a battery s state of charge in terms of specific gravity Most hydrometers only read true at 27 C 80 F In order to obtain correct readings adjust the initial reading by adding 004 points to the hydrometer readings for each 55 C 10 F above 27 C 80 F and by sub tracting 004 points for every 5 5 C 10 F below 27 C 80 F THE ILLUSTRATION WILL AID YOU IN FINDING THE CORRECT READING C ...

Page 312: ...y charged For storage purposes it is fitted with a temporary sealing tube Do not remove the sealing tube or loosen battery caps un less activation is desired In case of accidental premature removal of caps or seal ing tube battery should be given a full charge Perform the following at pre delivery operations and anytime you have to install a new battery 1 Remove the sealing tube from the vent elbo...

Page 313: ...2 Ohm 50 watt rheostats such as OHMITE 0314 or MALLORY 50K 12P are avail able from electronic parts supply shops and they are suitable for use with most chargers if the peak current is held below 2 amps If you need an accurate ammeter we recommend the use of SHURITE 5202 0 to 3 amps or 5203 0 to 5 amps available from electronic parts supply shops Rheostat 12 50 watt Charger Ammeter Battery l I For...

Page 314: ...E SHOOTING Symptom Cause Discharged or 1 Faulty rectifier weak battery 2 Faulty charging coil 3 Loose or bad ground connections 4 Battery poles and or cable terminals oxidized 5 Faulty battery cracked casing damaged or loose posts To test the charging system disconnect positive cable at the battery install an ammeter between cable and bat tery post If the reading indicates that the charging system...

Page 315: ...ckwasher 8 mm 9 Hexagonal nut 8 mm 10 Hexagonal nut 8 mm 11 Shim 12 Snap ring 13 Clutch stop collar SECTION 04 ELECTRICAL SUB SECTION 05 ELECTRIC STARTER ELECTRIC STARTER 8 bi i J 14 16 I 14 Clutch 15 Armature 16 Washer 17 Yoke 18 Brush 19 Rubber packing 20 Rubber seal 21 Through bolt 22 Lockwasher 23 End frame 24 Bushing 25 Bushing cover PAGE 309 ...

Page 316: ...2 12 7 mm 0 5 Dl 4ooI1 Bushing pusher f N J Bushing 2 4 Drive lever set pin snap pin To pull out the armature with overrunning clutch assembly and the drive lever from the drive housing remove the hair pin and pullout the drive lever set pin 11 15 16 Shims armature washer Note the number and the position of the washers and shims located at both ends of the armature An end play of 0 050 to 0 35 mm ...

Page 317: ...t not be immersed in cleaning solvent Clean brushes and holders with a clean clotch soaked in solvent Brushes must be dried thoroughly with a clean cloth Blow brush holders clean using compressed air Remove dirt oil or grease from commutator using a clean cloth soaked in suitable solvent Dry well using a clean dry cloth Clean engine starter gear teeth and drive unit clutch O NOTE Bearing bushing o...

Page 318: ...he negative brush and the other test probe on the yoke If growler lamp does not turn on the field winding has an open circuit The yoke has to be repaired or replaced Check the dynamic brake winding for open circuit by placing one test probe on the positive brush and the other probe on the negative brush If growler lamp does not turn on the winding circuit is open circuit and thhe yoke has to be re...

Page 319: ... maintenance on the starting system Do not place tools on battery Connect black cable to battery SYMPTOM CAUSE REMEDY Starter does not turn Poor contact of starter switch Repair or replace switch contact points Starter turns but does Burnt or poor contact of solenoid Replace solenoid switch not crank the engine switch contact disc Open circuit of solenoid switch Replace solenoid switch pull in win...

Page 320: ... of clutch on splines Worn clutch bushing Worn starter bushing s Worn ring gear Starter motor keeps Shorted solenoid switch winding s running Melted solenoid switch contacts Starter switch returns poorly PAGE 314 Replace clutch Replace clutch Clean and correct Replace clutch Replace bushing s Replace ring gear Replace solenoid switch Replace solenoid switch Replace ignition switch ...

Page 321: ...e ignition system in a matter of minutes Always proceed in the following order 1 Connect tester P and N clip leads as illustrated 2 Follow test procedure sequence 3 After every test that lights the indicator lamp reset the indicator circuit by depressing the reset button SECTION 04 ELECTRICAL SUB SECTION 06 TESTING PROCEDURE TESTING PROCEDURE ANALYSIS OF TEST RESULTS Indicator lamp lights at speci...

Page 322: ...ons for sending the tester back to Electro Specialties Inc Battery replacement 1 Remove the four 4 screws securing cover to case 2 Carefully lift cover 3 Replace batteries with size C Alkaline batteries Be sure to observe polarity markings on battery holder or lamp will not light PAGE 316 4 Carefully install cover on case being certain that no wires are pinched between cover and case Secure cover ...

Page 323: ...tor lamp lights Coil output is up to specifi cations Repeat test at least three 3 times to veri fy reading and consistency b Indicator lamp does not light Coil is faulty SECTION 04 ELECTRICAL SUB SECTION 06 TESTING PROCEDURE 277 377 447 462 503 534 COl SYSTEMS VERIFICATION 1 High speed charging coil 1 Disconnect wire connectors from C D 1 electronic box harness at engine 2 Connect tester P test le...

Page 324: ...NING To prevent powerful electric shocks when engine is running do not touch any electro nic ignition components ignition coil high tension wire wire harness etc a Indicator lamp lights Low speed charging coil is up to specifications Repeat test at least three 3 times to verify reading and check for consistency b Indicator lamp does not light Low speed charging coil is faulty PAGE 318 3 Lighting c...

Page 325: ... RESISTANCE 1 4 2 6 2 8 4 2 fL B 125 235 n 0 120 180 L 0 09 0 2 0 0 21 0 3L 0 23 0 431 1 J Secondary Hig 1 tension wire 2 45 4 55K n 0 winding with high tension u z wire 0 E WH BL with core z BK with core Insulation WH BL with high tension wire BK with high tension wire 462 engine type 277 377 447 503 534 engine type all except 277 engine type 277 engine type only 377 and 503 engine type 3 0 5 6 K...

Page 326: ...t re sults with the diagnostic chart O NOTE The Bombardier COl checker is only appli cable to the Nippondenso COl systems used on the Bombardier recreational products PAGE 320 SPECIFICATION AND CONSTRUCTION Specification Power source AC 115 volts 60 Hz Power consumption Less than 50 watts Ambient temperature lOoC to 40 C for usage 30 C to 60 C for storage Dimensions 370 H x 230 W x 120 0 Weight Ap...

Page 327: ...ON 04 ELECTRICAL SUB SECTION 06 TESTING PROCEDURE TEST ITEM 1 4 4P Generator coil HI LO Harness A 462 2 4 5P 277 377 447 Harness B 462 503 534 To find out the difference between 140W 4 4P and 160W 4 5P look in section 02 sub section 05 pages 92 93 This checker tests the following items TEST CHECK POINT HI Output of high speed Generator coil test LO Output of high and low speed generator coil Contr...

Page 328: ...diode of 4 4P ignition type 462 engine type To find out the difference between 140W 4 4P and 160W 4 5P look in section 02 sub section 05 pages 92 93 O NaTE For lighting coil test refer to the Bombar dier Ignition tester procedure BEFORE TESTING To prevent engine from starting and erroneous indica tion on the LED level indicator remove the spark plug s _ CAUTION To prevent dust or foreign matter fr...

Page 329: ... applicable to older engine types 354 and 454 equipped with a Nippondenso COl system TEST a Turn the power switch on Then one LED or two LEOs will light to indicate the checker is operating Reset the indication circuit by depressing the reset switch then one LED will remain to indicate the checker is operating O NOTE After every test when the LED level indi cator holds its indication a few minutes...

Page 330: ...ep the distance 5 mm 3 16 or less between bare surface of the engine and end of high tension cable and depress the START SWITCH Then spark will take place between them Hold by insulator WARNING Do not touch the high tension wire while doing this procedure Hold high tension wire with an insulator Generator coil test a This test should be performed at both HI LO switch positions Switch LO position a...

Page 331: ...ST RESULT After every test perform the diagnosis comparing with the diagnostic chart as shown in below CODE IGNITION CHECK PART NO TYPE 0 Generator HI 4 4P coil LO Control unit Generator HI coil 2 4 5P Control unit Control unit diode 0 SECTION 04 ELECTRICAL SUB SECTION 06 TESTING PROCEDURE HARNESS ENGINE TYPE A 462 B 277 377 447 462 503 534 If the reading of the LED level indicator is higher or lo...

Page 332: ... NIPPONDENSO COl SYSTEMS L I_ _ SP_ARK_TE_ST_ I_ 5mm 3 16 SPARK TAKES PLACE IGNITION COIL AND HIGH TENSION WIRE ARE GOOD PAGE 326 5 mm 3116 SPARK DOES NOT TAKE PLACE FAULTY IGNITION COIL OR OR HIGH TENSION WIRE REPLACE IGNITION COIL OR HIGH TENSION WIRE PERFORM A NEW SPARK TEST ...

Page 333: ...E IN THE ROTOR MAGNET REPLACE GENERATOR COIL OR FLYWHEEL MALFUNCTION OF CHE CKER LOOSE CONNECTION OF CONNECTORS POWER SOURCE 1115 volts 60Hz IS FAUL TYI HAVE IT REPAIRED VERIFY CONN ECTIONS VERIFY POWER SOURCE en c OJ I en m n I o z en O m n n l l en 1 0 z zo G p U m Or Om nn m l 0 0 c on m _ r ...

Page 334: ...DE IS OPEN CIRCUITED I CONTROL UNIT DIODE TEST 4 5P only AFTER THE START SWITCH HAS BEEN DEPRESSED READING IS AT THE CORRECT VALUE CONTROL UNIT DIODE IS GOOD REPLACE CONTROL UNIT PERFORM A NEW CONTROL UNIT DIODE TEST READING CHANGES BUT IT IS LOWER THAN THE CORRECT VALUE THE CONTROL UNIT DIODE IS SHORT CIRCUITED ...

Page 335: ...r fault calling for repair con tact Nippondenso Canada Ltd It is strictly prohibited that the user should disassemble the instrument Be aware that some semiconductors may be damaged even by static electricity stored in the human body Also contact Nippondenso Canada Ltd for the sup ply of accessories Nippondenso Canada Ltd 4500 Sheppard Avenue East Unit 29 Agincourt Ontario Canada M1S 3R6 SECTION 0...

Page 336: ... J ...

Page 337: ...13 11 SECTION 05 SUSPENSION SUB SECTION 01 BOGIE WHEELS BOGIE WHEELS Elan and Alpine 4 Wheels single spring I 14 4 4 Wheels 2 springs PAGE 331 ...

Page 338: ...332 8 Inner flange 9 Bearing 7O Wheel tire 77 Outer flange 72 Bolt flange 73 Grease fitting 14 Elastic band Remove bogie wheel set O NOTE Since spring diameter may vary depending upon actual installation location it is important to identify the installation of each bogie wheel set Observe this position when reinstalling sets Repeat operation for remaining bogie wheel sets DISASSEMBLY ASSEMBLY 1 Wh...

Page 339: ...Elan models put the wider portion of bogie wheel to the front direction of vehicle ELAN 1iiI C Rear c Front Using an appropriate tool apply track tension by hook ing the link plate springs into the anchors O NOTE If applicable place spring ends in middle position of the 3 position slotted anchor SECTION 05 SUSPENSION SUB SECTION 01 BOGIE WHEELS 1 14 Wheel support elastic band On Alpine models it i...

Page 340: ......

Page 341: ... TRS 6 SUSPENSION I 57 53 IITORQUE REACTION TYPE SUSPENSION Citation 3500 I 44 i J I j r f jJ fiiJ 19 I I i 49 58 I I c k 64 15 I 1 60 59 I I o 1 47 16 1 oa 58 I 17 I 61 62 18 63 56 33 I I 34 42 ba _ I 1 ro 18 6 26 3 1 10 I 11 I I 43 I 112 28 I I 36 A I 35 37 3 1 t 5 PAGE 335 ...

Page 342: ...SECTION 05 SUSPENSION SUB SECTION 02 SLIDE MX TRS 6 SUSPENSION Skandic Skandic R PAGE 336 I 57 3 4 ...

Page 343: ... 54 Jr 28 56 I 45 I SECTION 05 SUSPENSION SUB SECTION 02 SLIDE MX TRS 6 SUSPENSION Blizzard 9700 44 I 55 I 53 11 3 26 I 18 66 P I 5 I 2 PAGE 337 ...

Page 344: ...stment screws Release track tension by loosening adjustment screws located on inner side of rear idler wheels TYPICAl Adjustment screws PAGE 338 36 Shock absorber 37 Slider pad 38 Slider suppon 39 Spiral pin 40 Rear arm 47 Clevis Pin 42 Clevis Pin 43 Rubber stopper 44 Rear axle 45 Tube 46 Tube 47 Idler 48 Washer 49 Screw Loctite 242 50 Nut 57 Nut 52 Adjustment screw 53 Bushing 54 Front spring 55 R...

Page 345: ...t plate on the front arm supports cut off the rivet heads using a cold chisel At assembly position the rivet head on a suitable metal block and hold the assembly firmly in place With a flat head punch and hammer secure the rivet in place Flat head punch 7 9 Rivets reinforcement bracket To remove rivet use a 3 16 dia drill At assembly secure reinforcement bracket to runner with two 2 10 32 x 1 2 bo...

Page 346: ...to the lowest position and fix the springs with a tape 47 Rear idler wheel Push the rear idler wheel forward TYPICAL Front stopper strap detached Installation Adjuster cam lowest position Place a carboard on the floor Plug the chaincase vent hole with a small wire to prevent leaks Tilt vehicle on one side PAGE 340 23 40 Front rear arm Attach fron suspension and the rear suspension arm to the frame...

Page 347: ...rms are at the same position on each end front rear of the frame to avoid any damage to the suspen sion system and to the track TYPICAl Rear hole Front hole _ o 18 Grease fittings If necessary lubricate the idler wheels at grease fittings until grease appears at joints Use low temperature grease only PIN 498028 100 TYPICAL oo E _ I Grease fittings ONOTE To adjust the track tension and alignment re...

Page 348: ...SPENSION REAR MX SUSPENSION Blizzard 5500 MX 83 54 I 68 N 65 I 61 N m 75 45 ft lbs PAGE 342 m 76 i I I I 81 8 i9 J 1 I J 69 I 84 79 I 53 I 41 42 I I 69 45 26 I I J 43 I 44 I 29 46 36 2 I I 8 52 42 N m 31 ft bs For front MX suspension refer to section 06 02 ...

Page 349: ...2 SLIDE MX TRS 6 SUSPENSION 42 Ball bearing 43 Circl p 44 Cap 45 Grease fiuing 46 Spacer rube 47 Lockwasher 48 Hexagonal head cap screw 49 Pivor arm 50 Pivor shafr 57 Lockwasher 52 Hexagonal head cap screw 53 Rear arm 54 Idler shafr 55 Idler 56 Spacer 57 Rear axle 58 Spacer rube 59 Spacer rube 60 Circlip 67 Ball bearing 62 Idler 63 Washer 64 Hexagonal head cap screw 65 Square nur 66 Flar washer 67...

Page 350: ... head punch and hammer secure the rivet in place Flat head punch PAGE 344 29 Adjustment cams At assembly position the adjustment cams at the lowest position Right hand side Lowest position Left hand side Lowest position INSTALLATION Lift the rear of vehicle off the ground 26 71 73 74 Front arm flat washer lockwasher cap screws Place suspension within the track and align front arm of suspension wit...

Page 351: ... CAUTION Do not clamp directly on shock body Compress and extend each shock by hand at various speeds and compare the resistance of one shock to the other ONOTE Obtain a known good shock for com parison purposes and keep in mind that the re bound resistance extending the shock is normally stronger than the compression resistance Pay attention to the following conditions that will denote a defectiv...

Page 352: ...ecom mendation may affect handling of the vehicle SUSPENSION SPRING IDENTIFICATION Shock springs Wire Inside diameter lI H 1 Slide suspension springs PAGE 346 Wire diameter length Inside diameter Shock specifications REAR SHOCK without spring Part number 414476600 Stroke 13 20 cm 5 200 Length collapsed 23 78 cm 9 360 Length extended 36 98 0 3 cm 14 560 0 125 Colour code Blue dot SHOCK LENGTH Rubbe...

Page 353: ...5 05 mm 6 65 05 mm N A 7 14 05 mm 10 31 mm 10 31 mm N A N A D IAMETER 10 262 002 J 10 262 002 1 10 281 002 1 IOA06 1 10 406 1 COMPRESSEO 10 79 em 8 38 em N A 10 89 em N A NA N A N A LENGTH 14 25 1 13 30 1 14 29 1 COLOUR CODE Green Red Green Blue NA Green Yellow Yellow Yellow N A N A G ShOCk Springs illustration CD Slide Suspension Springs illustration N A Not applicable OPTIONAL PARTS ILLUSTRATION...

Page 354: ...SECTION 05 SUSPENSION SUB SECTION 02 SLIDE MX TRS 6 SUSPENSION IITRS 6 TYPE SUSPENSION Safari 377IE Safari 447 Safari Grand Luxe SS 25 Sonic LlC PAGE 348 61 I 82 P SO 71 79 58 74 ...

Page 355: ...crews SECTION 05 SUSPENSION SUB SECTION 02 SLIDE MX TRS 6 SUSPENSION 41 Circlip 2 42 Ball bearing 2 43 Idler 2 44 Washer 2 45 Cap 2 46 Grease fitting 2 47 Spacer rube 2 4B Hex head cap screw M1D x 35 2 49 Swaged rube 50 Shock absorber 51 Auto lock bushing 52 Reinforcement bracket 4 53 Hex head cap screw M7D x 35 2 54 Clevis pin 55 Correr pin 56 Pivot arm 57 Pivot shaft 2 5B Hex washer head powerlo...

Page 356: ...ld chisel At assembly position the rivet head on a suitable metal block and hold the assembly firmly in place With a flat head punch and hammer secure the rivet in place Flat head punch Runner Metal block PAGE 350 7 8 52 Reinforcement strips rivets reinforcement bracket To remove rivet use a 3 16 dia drill At assembly secure reinforcement brackets to runner with two 2 10 32 x 1 2 bolts and nuts an...

Page 357: ...d on the floor Plug the chaincase vent hole with a small wire to prevent leaks Tilt vehicle on one side 25 29 Front arm rear arm Attach front suspension and the rear suspension arm to the frame Do not torque TYPICAL J I I b Tilt the vehicle on the other side 25 29 Front rear arm Attach the front then the rear suspension arm to frame EXEMPLE r iI Reposition vehicle on the ground 28 Adjuster cam Pos...

Page 358: ...en sion arms are at the same position on each end front rear of the frame to avoid any damage to the suspension system and to the track Front hole PAGE 352 O NOTE The front adjustment holes in the frame near footrest are not completely drilled If you have to re locate the front and rear arms you have to drill these holes 11 56 Adjustment plate pivot arm When repositionning front and rear suspensio...

Page 359: ... highest eleva tion for deep snow conditions A lower elevation is preferred when negociating icy snow The rear adjuster blocks should be adjusted to rider preference Weight on skis _ CAUTION Always turn left side adjustment cams in a clockwise direction the right side cams in a counter clockwise direction Left and right adjust ment cams of each adjustment front and rear must always be set at the s...

Page 360: ... ...

Page 361: ...flange 6 Nut flange 7 Link plate B Bearing 9 Seal SECTION 05 SUSPENSION SUB SECTION 03 REAR AXLE REAR AXLE Elan Alpine 70 Eye bolt 77 Hardener washer 72 Adjuster bolt 73 Washer except for Alpine 74 Sleeve 75 Link plate spring 76 Retainer washer 77 Lock nut PAGE 355 ...

Page 362: ...securing idler with a 1 4 dia drill To remove sprocket apply liquid soap or petroleum jel lyon sprocket bead and flange then with two 2 screw drivers round bars pass the sprocket over flange Re verse change over procedure to install sprockets PAGE 356 1 3 4 5 6 Rear axle sprockets mobile flanges bolt nut Secure idler wheels and flanges using bolts and nuts tightened in the following sequence to 3 ...

Page 363: ...gs If applicable hook springs into middle position of 3 position anchors 16 17 Retainer washers lock nuts Install retainer washers and partially tighten the link plate spring lock nuts Carry out track tension and alignment O NOTE To adjust the track tension and alignment refer to Section 05 05 2 Grease fittings If necessary lubricate idler wheels at grease fittings un til grease appears at joints ...

Page 364: ...lD ...

Page 365: ...1 Citation SUB 10 SUSPENSION SECTION 05 DRIVE AXLE SECTION 04 DRIVE AXLE Elan Alpine 5 9 PP AACGE 359 ...

Page 366: ...SECTION 05 SUSPENSION SUB SECTION 04 DRIVE AXLE Skandic Skandic R PAGE 360 27 6 I I I I I 9 ...

Page 367: ...28 17 I I Qj 12 I SECTION 05 SUSPENSION SUB SECTION 04 DRIVE AXLE SS 25 Sonic LlC Safari 377 377E 447 Grand Luxe 23 I 24 I 7 PAGE 361 ...

Page 368: ...SECTION 05 SUSPENSION SUB SECTION 04 DRIVE AXLE I I I i 5 fOJ l 9 7 r 1 Blizzard 9700 PAGE 362 10 5 8 9 11 e 21 20 a 14 12 17 19 13 14 22 21 20 14 4 ...

Page 369: ...circlip brake disc and key before removing end bearing housing 1 5 Drive axle sprockets Release drive sprockets teeth from track notches at the same time pulling the drive axle towards the end bear ing housing side of frame Remove drive axle from vehicle If applicable pullout shim located between bearing and lower chaincase sprocket DISASSEMBLY 10 Speedo drive insert Remove speedo drive insert if ...

Page 370: ...9 64 225 5 mm 8 7 S Safari 377E 447 Grand Luxe 104 5 mm 47 64 242 mm 9 17132 Bliuard 5500 MX 9700 104 5 mm 47 64 242 mm 9 17 32 Ensure to align indexing marks on each sprocket before assembling the second sprocket The maximum synchronization tolerance for the sprock ets is 1 5 mm 1 16 To check this tolerance place axle assembly on a plane surface and measure the gap between sprocket teeth and surf...

Page 371: ...SUSPENSION SUB SECTION 04 DRIVE AXLE INSTALLATION 10 Speedo drive insert If the drive axle to be installed is a new component and the vehicle is equipped with a speedometer a correct size speedometer drive insert must be installed into the axle end Ensure that insert is flush with end of axle Position drive axle assembly into location Install shim s between bearing and lower chaincase sprocket Ins...

Page 372: ... ...

Page 373: ... caliper Skandic R Circlip Skandic R Brake disc Skandic R Key Skandic R Drive axle shaft bearing housing left side SECTION 05 SUSPENSION SUB SECTION 05 TRACK TRACK Drive axle outwards from left side Upper center idler s assembly Track Blizzard Blizzard MX Remove the following items Speedometer cable and protector if so equipped Chaincase cover sprockets and chain Suspension Two drive axle seals Ch...

Page 374: ...er side of link plate springs Turn adjuster bolts clockwise to tighten track or counter clockwise to slacken Tighten link plate spring lock nuts PAGE 368 Tension bogie wheel Alpine With rear of vehicle blocked off the ground check the tension of each track 57 mm 2 1 4 between top in side edge and bolt of center wheel set retaining bolt To correct track tension loosen link plate spring lock nuts on...

Page 375: ...ACK To adjust loosen the rear idler wheel retaining screw and the adjuster bolt lock nut then loosen or tighten the ad juster bolts o NOTE If the track tension is too loose the track will have a tendency to thump Alignment bogie wheel all models With rear of vehicle supported off the ground start engine and allow the track to rotate slowly Check if track is well centered and turns evenly on rear s...

Page 376: ...d recheck alignment TYPICAL WARNING Before checking track alignment en sure that the track is free of all particles which could be thrown out while track is rotating Keep hands tools feet and clothing clear of track TRACK INSERT INSTALLATION Using 529 004 500 tool with two standard jigs Tilt vehicle on its side to expose the track notches then place insert into position O NOTE Skandic R track has ...

Page 377: ...EERING SYSTEM 11 I I 10 I 25 29 Y 35 j 3 3j i _ 35 I I I 20N o m I II 3 30 15ftolbs 30 37 25 25 30 25 Nom I 32 I 29 18 ftolbs 18 30 rQ 25 d5f o s I 7 45 44 4O Rj 31 5 Q 30 37 Nom I 27 ftolbs 4O 38 48 g 30 40 it 25 25 Nom J 42 18 ftolbs 41 Elan 15 16 I PAGE 371 ...

Page 378: ...S SUB SECTION 01 STEERING SYSTEM Citation 42 N m 31 ft lbs 35 34 PAGE 372 vr 52 19 20 N m 15 ft lbsl 11 10 iw o 67 26 N m 19 ft lbs 6 14 4 I 25f 1 i l 4917r II 1 44 I 49 2 13 I 15 8 26 Q 12 23 68 37 20 N m 15 ft lbs 40 46 29 ...

Page 379: ... 61 N m 45 ft lbsl 31 19 Skandic R 23 f 68 33 37 I I 20 27 I 20 N m 15 ft lbs 25 SECTION 06 STEERING SKIS SUB SECTION 01 STEERING SYSTEM r 15 Skandic Skandic R PAGE 373 ...

Page 380: ...SECTION 06 STEERING SKIS SUB SECTION 01 STEERING SYSTEM SS 25 Sonic LlC Safari 377 377E 447 Grand Luxe PAGE 374 30 I 10 9 8 11 I I I 81 80 I I 75 j Q 76 0 74 77 19 I ct 0 I 25 ...

Page 381: ...TEM 9 11 10 I 8 8 1 1 80 I Y 75 I 22 N m 16 ft lbs 25 I e 40 I 30 J 30 n_ 76 74 19 I 22 N m 24 23 j 6 I I m 0_ II I iD68 27 28 I I 84 30 2 9 32 85 _ 25 I 29 32 1r i rf 33 I 30 I 1 36 i 25 60 N m _ _ I I 45 ft lbs 83 37 24 Blizzard 5500 MX 14 I 15 PAGE 375 ...

Page 382: ...B SECTION 01 STEERING SYSTEM Blizzard 9700 I 29 32 20 Nom 15 ftolbs 37 PAGE 376 25 Nom 18 ftolbs 23 I 44 26 27 24 25 __ 30 25 25 Nom I I 18 ftolbs 32 __ __________ J 2938_ 45 1 I 5 J44 20 Nom 34 35 15 ftolbsl J1 43a 46 16 I 15 19 ...

Page 383: ... 58 9 I II h10 58 SECTION 06 STEERING SKIS SUB SECTION 01 STEERING SYSTEM 11 47 f 15 3 Alpine 14 OA 53 61 N m 45 ft lbs I _ 62 44 1 45 I 38 I 60 I 42 I 61 CCJI 45 I 31 42 I 40 42 N m 31 ft lbs 46 PAGE 377 ...

Page 384: ...lines interlock Check general condition of steering system Check general condition of steering system components for wear and replace if necessary PAGE 378 48 Rubber spacer 49 Housing cap 50 Screw 57 Steering arm extension 52 Turnbuckle 53 Spring 54 Steering shaft main 55 Steering housing 56 Bushing 57 Retainer bracket 58 Bolt 59 Nut 60 Ball bushing 67 Allen bolt 62 Nut 63 Cap screw 64 Rivet 65 Pa...

Page 385: ...1 Steering arm nuts lock tabs Tighten steering arm nuts to specified torque and bend lock tabs over nuts See illustration SECTION 06 STEERING SKIS SUB SECTION 01 STEERING SYSTEM Alpine 60 61 62 Ball bushing Allen bolt nut Affix the ball bushing to steering shaft using appropriate Allen head bolt Tighten bolt until there is approximate ly 6 mm 1 4 free play existing between ball bushing and steerin...

Page 386: ...ten jam nuts firmly IMPORTANT Close front of skis manually to take all slack from steering mechanism All models except Alpine Check that handlebar is horizontal while skis are parallel with the vehicle To correct loosen shorter tie rod jam nuts Turn tie rod manually until handlebar is horizontal Tighten jam nuts firmly PAGE 380 Alpine 38 39 Steering arm ski leg When assembling steering arm and ski...

Page 387: ...SECTION 06 STEERING SKIS SUB SECTION 02 SKI SYSTEM SKI SYSTEM LEAF SPRING SUSPENSION Elan 16 Loctite 271 61 N m 45 ft lbs I 50 N m 37 ft lbs 7 N m 13 ft lbs _ 3 7 6 I l1 I PAGE 381 ...

Page 388: ...SECTION 06 STEERING SKIS SUB SECTION 02 SKI SYSTEM Citation 23 PAGE 382 16 A 54 N m 1tJ1 12 40 ft lbs t 30 9 7 ...

Page 389: ...1 SECTION 06 STEERING SKIS SUB SECTION 02 SKI SYSTEM 54 N m 6 12 40 ft lbs I 22 N m 3 16 ft lbs 2 Skandic Skandic IJR 7 k 6 PAGE 383 ...

Page 390: ...TION 06 STEERING SKIS SUB SECTION 02 SKI SYSTEM SS 25 Sonic LIe Safari 377 377E 447 Grand Luxe 1 PAGE 384 32 I I _ _ C 1 54N m 5l 12 40 ft lbs t 30 I 15 rd I 61 N m 33 45 ft lbs 4 10 I 22 N m 2 16 ft lbs 6 ...

Page 391: ...1 36 N m 23 27 ft lbs 1822 7 21 15 61 N m SECTION 06 STEERING SKIS SUB SECTION 02 SKI SYSTEM Blizzard 9700 16 I I 145 1b 1 14 11 J 29 r 28 IV I 6 PAGE 385 ...

Page 392: ...SECTION 06 STEERING SKIS SUB SECTION 02 SKI SYSTEM Alpine PAGE 386 36 N m 27 ft lbs I 7 I 17 61 N m 15 45 ft lbs I 18 19 5 14 9 9 9 8 1 1 1 ...

Page 393: ...l of leaf tension 12 13 30 Nut bolt tab lock When assembling spring leaves cross each and tempo rarily insert one 1 nut and bolt for Elan Citation Skan dic Skandic R SS 25 Sonic LlC Safari 377 E 447 SECTION 06 STEERING SKIS SUB SECTION 02 SKI SYSTEM 78 Spacer 79 Retainer pin 20 Cup 27 Bolt 22 Washer 23 Nut 24 Rubber bushing 25 Protector tube 26 Screw 27 Nut 28 Rubber bumper 29 Rivet 30 Tab lock 37...

Page 394: ...SECTION 06 STEERING SKIS SUB SECTION 02 SKI SYSTEM MX SUSPENSION Blizzard 5500 MX PAGE 388 61 N m 45 ft lbs 6 39 38 43 5 1 I Ii Q 2 I 6 6 ...

Page 395: ...d pullout stabilizer bar 5 9 10 Shims lock tabs nuts Open lock tab and remove nuts lock tabs shims 1 7 Stabilizer tube swing arms Slip both swing arms from stabilizer tube SECTION 06 STEERING SKIS SUB SECTION 02 SKI SYSTEM 23 Shim 24 Friction cup 25 R H ski L H ski 26 Inner runner shoe 27 Outer runner shoe 28 Cup 29 Hexagonal eslock nut 30 Stop bonding 37 Rivet 32 Protector 33 Rivet 34 Hexagonal h...

Page 396: ...te RC 680 or equivalent on bushing and seat and push bushing in using appropriate pusher or a piece of wood Repeat for the other bushing 1 5 7 Stabilizer tube shims swing arms Reinstall stabilizer tube shims swing arms PAGE 390 1 10 Stabilizer tube nuts Hand tighten nuts so that stabilizer tube threads exceed equally on both sides Torque nut to 35 N m 26 ft lbs unscrew and retorque to 1 N m 0 7 ft...

Page 397: ... Do not put any grease in the friction cups SECTION 06 STEERING SKIS SUB SECTION 02 SKI SYSTEM e I I Install the ski leg coupler bolt and torque to obtain 5 7 kg 12 15 Ibs on the lift tube at the front of the ski O NOTE You must pull on the ski at an angle of 90 with the ski surface Front of vehicle Off the ground Torque to have 5 7 kg 12 15 pounds at the front of the ski with a fish scale 35 Elas...

Page 398: ...re 96 kmlh 60 M P H and more PAGE 392 Optional parts The front suspension may be tuned to the rider s specif ic requirement using the optional following parts Shock springs PIN 503 0694 00 see rear shock springs diagram section 05 02 Carbide runners PIN 414 1964 00 can replace the standard short runner or can be installed on the op tional skis _ CAUTION Optional parts are calibrated to be op erate...

Page 399: ...l lights after replacement SECTION 07 CHASSIS SUB SECTION 01 HOOD HOOD CAUTION Never touch glass portion of an halogen bulb with bare fingers it shorter it s oper ating life If by any mistake you have touch the glass portion clean it with a glass cleaner that won t leave a film on the bulb HOOD MAINTENANCE Clean the vehicle thoroughly removing all dirt and grease accumulation CAUTION Plastic alloy...

Page 400: ...tion plate glued on the inner side near the muffler For fiberglass parts different repair kits are available at your authorized dealer For R I M urethane parts you can use two 3M products 3M structural adhesive tube kit PIN 8101 3M flexible parts repair material PIN 05900 For deeply scratched or tears R 1 M surface PAGE 394 R LM POLYCARBONATE SURLYN X X X X X X X X X X Sand the damaged area with w...

Page 401: ...N 07 CHASSIS SUB SECTION 01 HOOD BRAND NAME MIXTURE R M Inmont Super Max enamel 01 100 41 420 42 580 43 820 850 1000 R M Inmont Super Max enamel 01 100 41 500 42 700 43 1000 R M Inmont Super Max enamel 01 100 21 575 41 836 66 964 94 1000 R M Inmont Super Max enamel 01 100 94 150 72 550 79 1000 R M Inmont Super Max enamel 01 100 72 738 79 963 94 1000 R M Inmont lacquer acrylic 90 100 172 642 190 74...

Page 402: ...eat the windshield in place Using windshield holes as a guide drill 5 mm dia 3 16 holes through the hood Clean the hood Peel off protective film from windshield Install the applicable windshield fixtures r Snap cap Screw 6rl Cap retainer Windshield 77 7 Z 7777 Hood Torque to 3 5 N m wasC III Elastic stop 2 3 ft lbs _ nut PAGE 396 WINDSHIELD TRIM INSTALLATION Elan Citation Skandic Blizzard 5500 MX ...

Page 403: ...cessary to achieve that ad justment see illustration below Operating lever must be located 13 0 mm 1 2 inch before cab slot end when headlamp housing is open Rack must have two teeth outside gear cover when headlamp housing is open Tighten gear cover Grease Operating lever SECTION 07 CHASSIS SUB SECTION 01 HOOD Two 2 teeth outside _ CAUTION Make sure that headlamp housing is lock in place when you...

Page 404: ... ...

Page 405: ...or not and how to repair them refer to section 07 sub section 01 FRAME WELDING Steel frame Electric Welding Amperage 70 110 Amp Voltage 20 24 volts Rod E 7014 3 32 Aluminum frame refer to specialized welding shop Argon oxygen acetylen welding Rod ER 4043 3 32 _ CAUTION When electrical welding is to be per formed anywhere on the vehicle unplug the mul tiple connector at the electronic box prior to ...

Page 406: ... ...

Page 407: ...them properly away of any rotating parts moving parts heating parts and vibrating parts SECTION 08 FUEL LINE WIRING HARNESS CABLE ROUTING FUEL LINE WIRING HARNESS CABLE ROUTING FUEL LINE ALL MODELS WARNING Always ensure that the fuel lines are properly fixed to the connectors that they are not perforated or kinked and that they are properly routed away of any rotating parts moving parts heating pa...

Page 408: ... ...

Page 409: ...ES PREFIX SYMBOL MEANING VALUE kilo k one thousand 1 000 centi c one hundredth of a 0 01 milli m one thousandth of a 0 001 CONVERSION TABLE MULTIPLY BY TO OBTAIN meter 39 370 inch kilogram 2 205 pound liter 0 264 U S gallon liter 0 220 Imperial gallon kilopascal 0 145 PSI Newton meter 0 738 ft Ibs kilometer 0 621 mile Degrees Celsius 5 x degrees Farenheit 32 9 THE INTERNATIONAL SYSTEM OF UNITS SYS...

Page 410: ...er mm minJmax 0 066 0 203 0 070 0 090 0 060 0 100 0 080 0 100 0 080 0 100 wall clearance linchI minJmax 0026 0079 0027 0035 0031 0039 0031 0039 0031 0039 Crankshaft mm minJmax 0 20 0 40 0 20 0 40 N A N A N A end play linchl minJmax 008 016 008 016 Rotary valve timing N A N A N A N A N A marks position Mikuni carburetor VM 28 242 VM 34 255 VM 34 276 VM 34 309 VM 34 310 Main jet 160 220 260 240 240 ...

Page 411: ...01 039 1 0 039 1 0 039 1 01 039 0 080 0 100 0 070 0 090 0 070 0 090 0 100 0 120 1 0031 0039 0027 0035 0027 0035 1 0039 0047 N A N A N A N A Opening 140 N A N A Opening 140 Closing 51 Closing 61 VM 34 311 VM 34 297 2 x VM 34 203 PTO VM 40 23 MAG VM 40 24 PTO 330 290 2SO 220 MAG 3SO 159 P 4 159 P 2 159 P 4 224 AA5 40 30 35 40 6FLl4 3 6DH3 3 6DH2 3 7DH2 3 3rd 3rd 3rd 3rd 3 0 2 0 3 0 2 5 11 2 1 1 2 11...

Page 412: ... amp N A amp N A INDIRECT MEASUREMENT B_T D C 277 CITATION 3500 160 CD NGK BR 8ES 0 40 016 2 31 1 090 2 6 102 N A loS 120 180 H S 2 8 4 2 0 21 0 31 N A 0 23 0 43 3 0 5 6 K 60 60 5 21 5 N A N A N A EDGE GAP 377 SKANDIC 160 CD NGK BR 8ES 0 40 0161 2 31 1 090 N A N A loS 120 180 H S 2 8 4 2 0 21 0 31 N A 0 23 0 43 2 45 4 55 K 60 60 5 21 5 N A N A N A 377 E 447 SAFARI SAFARI GRAND LUXE 160 160 CD CD N...

Page 413: ...e 1 76 2 29 2 29 1 75 44P OB5145P 1 0691 W901 0901 1 06BI N A N A N A N A N A N A N A N A L S 125 235 L S 120 lBO L S 120 lBO L S 120 lBO H S 1 4 2 6 H_S 2 B 4 2 H S 2 B 4 2 H S 2 B 4 2 0 09 0 20 0 21 0 31 0 21 0 31 0 21 0 31 N A N A N A N A 0 23 0 43 0 23 0 43 0 23 0 43 0 23 0 43 2 45 4 55 K 2 45 4 55 K 2 45 4 55 K 2 45 4 55 K 60 55 hal 60 60 60 60 60 60 5 21 5 21 5 21 5 21 5 5 5 5 N A 30 N A N A...

Page 414: ...e e C Spring length mm 1 5 81 3 104 7 100 100 lOS lOS in 0601 3 2001 4 1221 13 9381 3 9381 4 1731 4 1731 Clutch engagement 2QOO 2200 33OQ 3600 3700 3900 3700 3900 3400 3600 3400 3600 R P M Z Driven pulley spring kg 0 9 3 6 5 4 5 4 5 4 3 6 3 6 preload lbsl 2 81 121 121 121 81 81 a Pulley distance mm 42 85 44 45 41 27 44 40 41 27 44 40 41 27 44 40 36 6 38 1 36 6 38 1 t inchl 1 11116 1 3 41 15 8 13 4...

Page 415: ...1 1631 C7LH C7LH A8S C7LH A6S A3S ldoublel Yellow Yellow Orange Orange White Purple 100 100 81 96 5 87 3 73 6 13 9381 13 9381 13 1891 13 8001 13 4371 12 901 3500 3700 3500 3700 33OQ 3500 360 3800 4OOQ 44OO 200CJ 2200 3 6 3 6 3 6 5 9 5 9 5 9 181 181 181 1131 1131 1131 36 6 38 1 36 6 38 1 36 6 38 1 34 92 38 10 34 92 38 1 0 44 40 47 62 11 7 16 11 21 11 7116 1 1 21 117 16 11 21 11318 11 21 11318 11 21...

Page 416: ...5 N A Dimension X must never exceed dimension Y Dimension Y can exceed dimension X by 1 6 mm 1 16 PAGE 410 SKANDIC SKANDIC 377 377R 28 4 28 4 6 25 6 25 7 5 7 5 200 171 450 1161 N A N A N A N A N A N A Axial fan Axial fan N A N A N A N A N A N A N A N A 851621 851621 M6 9171 M6 9171 M8 21115 M8 21 15 21115 21115 381281 38 28 65148 651481 Elect Electric starter Man Manual starter Poly Polycarbonate ...

Page 417: ...mp oz 90 Imp oz 60 Imp oz SO Imp oz N A 86 U S 02 86 U S 02 86 U s oz 77 U S oz 77 U S oz Axial fan Axial fan Liquid cooled Axial fan Liquid cooled Axial fan 4 54 4 20 N A N A 160 N A 148 N A 154 142 N A N A 43 e 1100F N A sooe 122 F N A N A N A 90 kPa 13 PSI N A 90 kPa 13 PSI N A N A N A 60140 N A 60140 N A 85 62 85 62 95 70 85 62 95 70 85 62 M6 9 7 M6 9 7 M6 9 7 M6 9 7 21 15 21 15 M8 21 15 M8 21...

Page 418: ...1D ...

Page 419: ... at time of purchase 4 WARRANTY TRANSFER This warranty is transferable to subsequent owner s for remainder of warranty period from original date of sale 5 EXCLUSIONS ARE NOT WARRANTED Normal wear on all items such as but not limited to drive belts slider shoes spark plugs bulbs runners on skis Replacement parts and or accessories which are not genuine BOMBARDIER parts and or accessories Damage res...

Page 420: ... This warranty gives you specific rights and you may also have other legal rights which may vary from state to state or province to province Where applicable this warranty is expressly in lieu of all other expressed or implied warranties of BOMBARDIER its distributors and the selling dealer including any war ranty of merchantability of fitness for any particular purpose otherwise the implied warra...

Page 421: ...h the Service Manager or Owner 2 If this fails contact your area distributor listed in the Operator Manual 3 Then if your grievance still remains unsolved you may write to us Bombardier Inc Service Department Recreational Products Division Valcourt Quebec Canada JOE 2LO February 1983 80mbardier Inc Valcourt Quebec Canada JOE 210 Trademarks of Bombardier Inc PAGE 415 ...

Page 422: ...warranty is transferable to subsequent owner s for remainder of warranty period from original date of sale 5 EXCLUSIONS ARE NOT WARRANTED Normal wear on all items such as but not limited to drive belts slider shoes spark plugs bulbs runners on skis Replacement parts and or accessories which are not genuine BOMBARDIER parts and or accessories Damage resulting from installation of parts other than g...

Page 423: ...s and you may also have other legal rights which may vary from state to state or province to province Where applicable this warranty is expressly in lieu of all other expressed or implied warranties of BOMBARDIER its distributors and the selling dealer including any war ranty of merchantability of fitness for any particular purpose otherwise the implied warranty is limited to the duration of this ...

Page 424: ... the Service Manager or Owner 2 If this fails contact your area distributor listed in the Operator Manual 3 Then if your grievance still remains unsolved you may write to us Bombardier Inc Service Department Recreational Products Division Valcout Quebec Canada JOE 2LO February 1983 Bombardier Inc Valcourt Quebec Canada JOE 2LO i l Trademarks of Bombardier Inc PAGE 418 ...