Brp grand touring 583 мануал

  • #1

Помогите с мануалом Bombardier grand touring 600 s Задрало поршневую в начале сезона, купил новую ремонтную надо собирать.

  • #4

Тот же вопрос, спустя 8 лет, хотябы мануал на похожий снегоход!?

  • #5

Последнее редактирование: 28 Янв 2018

  • #7

Добрый вечер, Друзья!
Пожалуйста, подскажите где у него находится блок предохранителей??
Найти не могу хоть убей:ohmy:
BRP Grand Touring 600 2004

  • #8

Блока нет, там всего 1-5 предохранителей, на жгутах смотри, на туринге 583 один всего

  • #9

как сделать, чтобы можно было это посмотреть?? пишет что недостаточно прав..

  • #10

Блока нет, там всего 1-5 предохранителей, на жгутах смотри, на туринге 583 один всего

понял)) то-то я и думаю что найти ничего не могу)))

  • #11

Ссылка на яндекс диск , там мануал на старые года , может поможет

Источник

Ski-Doo Grand Touring 500 1998 Shop Manual

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Summary of Contents for Ski-Doo Grand Touring 500 1998

  • Page 2
    ® 1998 Shop Manual VOLUME 2 MX Z 440/500/583/670 FORMULA 500/500 DE LUXE/583 DE LUXE/Z 583/Z 670 SUMMIT 500/583/670 GRAND TOURING 500/583 SKANDIC WT/SWT/WT LC…
  • Page 3
    Legal deposit: National Library of Quebec trimester 1997 National Library of Canada1997 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 1997 Technical Publications Bombardier Inc.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION SUBSECTION PAGE SAFETY NOTICE ……………………..WHAT’S NEW ……………………….INTRODUCTION ……………………..SERVICE TOOLS AND 01 – Service tools…………….01-01-1 SERVICE PRODUCTS 02 – Service products…………… 01-02-1 LUBRICATION 01 – Lubrication and maintenance chart ………. 02-01-1 AND MAINTENANCE TROUBLESHOOTING 01 –…

  • Page 5
    TABLE OF CONTENTS SECTION SUBSECTION PAGE REAR SUSPENSION 01 – Table of contents …………..07-01-1 02 – SC-10 suspensions (all versions)……….07-02-1 03 – Formula Z 670 suspension…………07-03-1 04 – Skandic WT suspension…………07-04-1 05 – Drive axle …………….. 07-05-1 06 –…

  • Page 6: Safety Notice

    SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair some 1998 Ski-Doo snowmo- biles. See model list on next page. This edition was primarily published to be used by snowmobile mechanics who are already familiar with all service procedures relating to Bombardier made snowmobiles.

  • Page 7: What’s New

    WHAT’S NEW WHAT’S NEW INTRODUCTION • List of abbreviations used in this manual. SERVICE TOOLS AND SERVICE PRODUCTS 01 • Complete new section. LEAK TEST AND ENGINE DIMENSION MEASUREMENT 04-04 • Procedure for cylinder/piston clearance measurement. • Procedure for combustion chamber volume measurement. •…

  • Page 8: Introduction

    INTRODUCTION INTRODUCTION This Shop Manual Volume 2 covers the following Bombardier made 1998 snowmobiles: MODEL MODEL MODELS MODELS NUMBER NUMBER MX Z 440 (Canada)……1264 FORMULA* Z 670 (Canada) … 1253 MX Z 440 (U.S.) ……. 1265 FORMULA* Z 670 (U.S.)….1254 MX Z 440 (Europe) ……

  • Page 9
    INTRODUCTION MX Z 440/583/670 Serial Number Meaning Formula 500/500 De Luxe/583 De Luxe Formula Z 583/Z 670 Summit 500/583/670 Grand Touring 500/583 0000 00000 These are S-Series models. Model no. Vehicle no. A00A0DA ENGINE SERIAL NUMBER Engine Serial Number Location Fan-Cooled Engines A03A0DA TYPICAL —…

  • Page 10: 01 Service Tools And Service Products

    INTRODUCTION ARRANGEMENT OF THE MANUAL The manual is divided into 11 major sections: 01 SERVICE TOOLS AND SERVICE PRODUCTS 02 LUBRICATION AND MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 TRANSMISSION 06 ELECTRICAL 07 REAR SUSPENSION 08 STEERING/FRONT SUSPENSION 09 BODY/FRAME 10 TECHNICAL DATA 11 WIRING DIAGRAMS Each section is divided in various subsections, and again, each subsection has one or more divi-…

  • Page 11
    INTRODUCTION LIST OF ABBREVIATIONS USED IN THIS MANUAL ampere left hand ampere A•h ampere-hour long track alternate current meter acceleration and control modulator magneto bottom dead center Max. maximum BTDC before top dead denter Min. minimum °C Celsius milliliter capacitor discharge ignition millimeter center mile per hour…
  • Page 12
    INTRODUCTION This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog. TYPICAL PAGE Page heading indicates section and subsection detailed. Subsection title indicates beginning of the Section 07 REAR SUSPENSION subsection. Subsection 01 (SUPENSION SC-10 SPORT, TOURING AND MOUNTAIN) SUSPENSION SC-10 SPORT, TOURING AND MOUNTAIN…
  • Page 13
    INTRODUCTION TYPICAL PAGE Section 05 TRANSMISSION Subsection 03 (DRIVEN PULLEY) Title indicates Turn puller handle and sliding half at once to extract INSTALLATION main procedure the bushing. to be carried-out. Countershaft CAUTION Always apply anti-seize lubricant (P/N 413 7010 Italic bold face type 00) on the countershaft before final pulley setting indicates a installation.
  • Page 14
    INTRODUCTION GENERAL INFORMATION ILLUSTRATIONS AND PROCEDURES The information and component/system descrip- tions contained in this manual are correct at time Illustrations and photos show the typical con- of publication. Bombardier Inc. however, main- struction of the different assemblies and, in all tains a policy of continuous improvement of its cases, may not reproduce the full detail or exact products without imposing upon itself any obliga-…
  • Page 15
    INTRODUCTION The use of RIGHT and LEFT indications in the text, TIGHTENING TORQUES always refers to driving position (when sitting on Tighten fasteners to torque mentioned in explod- vehicle). ed views and text. When they are not specified refer to following table. N•m FASTENER SIZE (8.8) Lbf•in…
  • Page 16
    INTRODUCTION N•m FASTENER SIZE (8.8) Lbf•ft N•m FASTENER SIZE (8.8) Lbf•ft XIII…
  • Page 17
    INTRODUCTION N•m FASTENER SIZE (8.8) Lbf•ft TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS…
  • Page 18
    Bombardier SERVICE PUBLICATIONS REPORT Publication title and year ________________________ Page______ Machine___________________ Report of error Suggestion ____________________________________________________________ We would be pleased if you could ____________________________________________________________ communicate to Bombardier any sug- gestions you may have concerning ____________________________________________________________ our publications. ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Name ______________________________________________________ Address ____________________________________________________ City and State/Prov.
  • Page 19
    AFFIX PROPER POSTAGE Bombardier Inc. Technical Publications After Sales Service Valcourt, (Quebec) Canada, J0E 2L0 AFFIX PROPER POSTAGE Bombardier Inc. Technical Publications After Sales Service Valcourt, (Quebec) Canada, J0E 2L0 AFFIX PROPER POSTAGE Bombardier Inc. Technical Publications After Sales Service Valcourt, (Quebec) Canada, J0E 2L0…

  • Page 20: Service Tools

    Subsection 01 (SERVICE TOOLS) SERVICE TOOLS This is a list of tools to properly service Ski-Doo snowmobiles. The list includes both the mandatory tools and the optional tools which are ordered separately. The list of Service Products, both mandatory and optional, are not part of any kit and must all be ordered separately.

  • Page 21
    Section 01 TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE — MANDATORY SERVICE TOOLS Degree wheel Magneto puller ring Rotary valve shaft pusher (P/N 414 3529 00) (P/N 420 8760 80) (P/N 420 8766 12) A00C0F4 APPLICATION Rotary valve engines with a 10 mm impeller shaft.
  • Page 22
    Section 01 TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — MANDATORY SERVICE TOOLS Rotary valve shaft Choke plunger tool Rotary valve circlip tool seal pusher (P/N 529 0321 00) (P/N 529 0291 00) (outer, water pump side) (P/N 420 8770 50) A00C3I4 APPLICATION A01C5D4…
  • Page 23
    Section 01 TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — RECOMMENDED SERVICE TOOLS The following tools are highly recommended to optimize your basic tool kit and reduce repair time. 1-2) Crankshaft bearing Use with crankshaft bearing pullers (P/N 420 8762 98) or puller with screw (P/N 420 8776 35).
  • Page 24
    Section 01 TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — RECOMMENDED SERVICE TOOLS Piston circlip installer Ring compressor Crankshaft feeler gauge (P/N 420 8766 20) A) (P/N 529 0169 00) A) (P/N 420 8760 90) (62 mm) B) (P/N 290 8770 16) B) (P/N 420 8769 70) (72 mm) C) (P/N 420 8769 72)
  • Page 25
    Section 01 TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — RECOMMENDED SERVICE TOOLS Cylinder aligning tool Stroboscopic timing light Air pressure gauge, 0-200 inch of water (P/N 529 0319 00) A) (P/N 420 8769 02) (P/N 529 0104 00) (on exhaust side) B) (P/N 420 8761 71) (on intake side)
  • Page 26
    Section 01 TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — RECOMMENDED SERVICE TOOL Injection pump gear Injection jig Exhaust spring installer/ holder (magneto seal) remover (P/N 420 8766 95) (P/N 420 8765 14) (P/N 529 0281 00) A00B314 A00C3S4 APPLICATION APPLICATION…
  • Page 27
    Section 01 TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) TRANSMISSION — MANDATORY SERVICE TOOLS Clutch holder Drive belt installer Drive belt tension adjuster tool (P/N 529 0064 00) (P/N 529 0172 00) (P/N 529 0087 00) A01B154 APPLICATION All TRA drive pulleys. TRA drive pulley puller A15B044 A00A1A4…
  • Page 28
    Section 01 TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) TRANSMISSION (continued) — MANDATORY SERVICE TOOLS Spring compressor/ Countershaft bearing TRA clutch flare tool installer (P/N 529 0186 00) (P/N 529 0302 00) Parts included in the kit: Spring compressor (P/N 529 0151 00) A00A194 APPLICATION S-Series.
  • Page 29
    Section 01 TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) TRANSMISSION (continued) — RECOMMENDED SERVICE TOOLS The following tools are highly recommended to optimize your basic tool kit and reduce repair time. Drive axle sprocket adjuster (P/N 861 7257 00) A01B2O4 APPLICATION All vehicles.
  • Page 30
    Section 01 TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) SUSPENSION — MANDATORY SERVICE TOOLS Shock spring removal kit (P/N 529 0355 04) Replacement clevis pin: (P/N 414 5284 00) A01B4O4 APPLICATION All suspensions with coil spring. 01-01-11…
  • Page 31
    Section 01 TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) SUSPENSION (continued) — RECOMMENDED SERVICE TOOLS Track cleat remover Track tension gauge Drill bit (P/N 529 0287 00) (P/N 529 0215 00) (P/N 529 0318 00) A01B564 APPLICATION A01F224 All 3/16 inch rivets. APPLICATION All models.
  • Page 32
    Section 01 TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) VEHICLES — RECOMMENDED SERVICE TOOLS Protective mat (P/N 529 0306 00) A01B45W APPLICATION All vehicles. Dolly Snowmobile jack (P/N 529 0299 00) (P/N 529 0200 00) A01A1JJ A00B4CJ APPLICATION APPLICATION All models. All models.

  • Page 33: Service Products

    Section 01 TOOLS AND PRODUCTS Subsection 02 (SERVICE PRODUCTS) SERVICE PRODUCTS NOTE: The numbers outlined in black (example: ) are reference to tool numbers from other divisions (Sea-Doo Watercraft and/or Sea-Doo Jet Boats). Matching reference numbers indicate the same tool is being used, even if the part numbers are different.

  • Page 34
    Section 01 TOOLS AND PRODUCTS Subsection 02 (SERVICE PRODUCTS) MANDATORY SERVICE PRODUCTS ® Loctite is a trademarks of Loctite Corporation. ® Dow Corning is a trademarks of Dow Corning Corporation. Retaining compound Medium-strength Gasket/paint remover threadlocker (P/N 413 7031 00) (P/N 413 7085 00) (P/N 413 7030 00) ®…
  • Page 35
    Section 01 TOOLS AND PRODUCTS Subsection 02 (SERVICE PRODUCTS) MANDATORY SERVICE PRODUCTS (continued) ® Loctite primer (P/N 413 7081 00) ® Loctite 764-56 Primer N 170 g (6 oz) A00B3N4 APPLICATION To prepare mating surfaces before applying paste gasket, retaining compound or threadlockers.
  • Page 36
    Section 01 TOOLS AND PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS Silicone dielectric grease Chaincase oil Blizzard oil (3 oz) (16 x 250 mL) (12 x 500 mL) (P/N 413 7017 00) (P/N 413 8019 00) (P/N 413 8031 00) DOW CORNING ®…
  • Page 37
    Section 01 TOOLS AND PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS (continued) Bombardier-Rotax Formula XP-S High temperature Bearing grease synthetic injection oil threadlocker (400 g) (P/N 413 7110 00) (P/N 420 8997 88) (P/N 413 7061 00) (3 x 4 liters) Loctite 648 (green) (P/N 413 7107 00) (5 g)
  • Page 38
    Section 01 TOOLS AND PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS (continued) Degreaser Stripped threads Paint for frame touch-up (P/N 413 7084 00) repair kit (P/N 413 4010 00) ® Permatex 48TA (P/N 413 7086 00) Black semi-gloss 433 g (15 oz) Loctite 81668 (spray can) Form-A-thread 81668…
  • Page 39
    Section 01 TOOLS AND PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS (continued) Sealant Molykote 111 (P/N 413 7103 00) (P/N 413 7070 00) Loctite 179 (80 mL) DOW CORNING ® A00B3W4 APPLICATION Rotary valve shaft seals. BOMBARDIER LUBE (12 x 14 oz) (P/N 293 6000 16) A02B044 L U BE…

  • Page 40: Lubrication And Maintenance Chart

    Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) LUBRICATION AND MAINTENANCE CHART SYSTEM PART/TASK REFER TO Rewind Starter Lubrication and Rope Subsection 04-10 Condition Appropriate section: Engine Head Nuts See Top End Appropriate section: Engine Mount Nuts See ENGINE REMOVAL Appropriate section: Exhaust System…

  • Page 41
    Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) SYSTEM PART/TASK REFER TO Handlebar Bolts. Retorque to 26 N•m Subsection 08-02 (19 Ibf•ft) Steering and Front Suspension Subsections 08-02 and 08-03 Mechanism Wear and Condition of Skis and Subsection 08-03 Runners Steering and Ski Leg Camber…
  • Page 42
    Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) NO. 1 ENGINE LUBRICATION Models with a Choke Remove air silencers to spray storage oil into each Engine internal parts must be lubricated to protect carburetor bore. them from possible rust formation during the stor- age period.
  • Page 43
    Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) NO. 3 FUEL FILTER REPLACEMENT Drain fuel tank. Remove fuel line grommet from fuel tank and pull out inlet fuel line from tank. A03H0LA TYPICAL 1. Filter To clean the filter, shake the snow out of it then, dry it out.
  • Page 44
    Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) NO. 8 VEHICLE CLEANING AND NOTE: The latest product may be use alone if only light scratches are noticeable. PROTECTION Remove any dirt or rust. CAUTION To clean the entire vehicle, use only flannel Never clean plastic parts or hood with ®…

  • Page 45: Troubleshooting

    Section 03 TROUBLESHOOTING Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS ENGINE ……………………..03-02-1 ENGINE LEAK VERIFICATION FLOW CHART …………..03-02-10 FUEL AND OIL SYSTEMS………………… 03-03-1 TRANSMISSION AND BRAKE SYSTEMS………………03-04-1 TRANSMISSION …………………… 03-04-1 BRAKE SYSTEM …………………… 03-04-7 MECHANICAL BRAKE ………………….. 03-04-7 HYDRAULIC BRAKE ………………….

  • Page 46: Engine

    Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) ENGINE The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM ENGINE BACKFIRES.

  • Page 47
    Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM ENGINE SUDDENLY TURNS OFF. CONDITION NORMAL USE. Test/Inspection 1. Perform engine leak test. Refer to ENGINE LEAK VERIFICATION FLOW CHART. Check possible piston seizure. a. Damaged gasket and/or seal. Replace defective parts. 2. “Four-corner” seizure of piston(s). a.
  • Page 48
    Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) 4. Melted and/or perforated piston dome; melted section at ring end gap. a. When piston reaches TDC, mixture is ignited by heated areas in combustion chamber. This situation is due to an incomplete combustion of a poor quality oil. Clean residue accumulation in combustion chamber and replace piston(s).
  • Page 49
    Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH MAXIMUM OPERATING RPM. CONDITION NORMAL USE. Test/Inspection 1. Check spark plug condition. a. Fouled spark plugs. Replace. 2. Check if there is water in fuel. a.
  • Page 50
    Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM ENGINE DETONATION AT MAXIMUM RPM. CONDITION NORMAL USE. Test/Inspection 1. Check which type of fuel is used. a. Octane number is too low and/or alcohol level is too high. Use recommended fuel type. 2.
  • Page 51
    Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM IRREGULAR ENGINE IDLE. CONDITION NORMAL USE AFTER ENGINE WARM UP. Test/Inspection 1. Check primer. a. Fuel leaks at primer nipple which is mounted to carburetor. Replace. 2. Check choke. a. Choke plunger may be partially opened. Readjust.
  • Page 52
    Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) 6. Check antifreeze concentration. a. Antifreeze concentration is too high. Adjust concentration according to Bombardier’s recommendations. 7. Check tank cap. a. Cap does not hold pressure. Replace. 8. Check carburetion. a. Improperly adjusted or inadequate carburetor components. Adjust according to specifications (refer to TECHNICAL DATA 10) or replace inadequate component(s).
  • Page 53
    Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM ENGINE EQUIPPED WITH RAVE. ENGINE HESITATES AT MID-SPEED AND REACH- ES MAXIMUM PERFORMANCE ONLY AFTER A WHILE. CONDITION NORMAL USE. Test/Inspection 1. Check RAVE valve spring(s). a. Spring tension is too weak or spring(s) is (are) broken. Replace.
  • Page 54
    Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM ENGINE PINGING. CONDITION NORMAL USE. Test/Inspection 1. Check fuel lines. a. Bent fuel lines (preventing fuel from flowing through). Relocate or replace fuel lines. 2. Check if carburetor(s) is (are) clean. a. Dirt prevents fuel from flowing through. Clean.

  • Page 55: Engine Leak Verification Flow Chart

    Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) ENGINE LEAK VERIFICATION FLOW CHART ENGINE LEAK VERIFICATION FLOW CHART PRESSURIZE ENGINE IS ENGINE LEAKING? CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS. MOUNTING FLANGES ETC. REPLACE GASKET OR O-RING, ANY LEAK FOUND? RE-SEAL LEAKING AREA CHECK SMALL OIL LINES OF INJECTION PUMP AIR BUBBLES FOUND…

  • Page 56: Fuel And Oil Systems

    Section 03 TROUBLESHOOTING Subsection 03 (FUEL AND OIL SYSTEMS) FUEL AND OIL SYSTEMS The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM HIGH FUEL CONSUMPTION OR RICH MIXTURE.

  • Page 57
    Section 03 TROUBLESHOOTING Subsection 03 (FUEL AND OIL SYSTEMS) SYMPTOM ENGINE LACKS POWER OR STALLS AT HIGH RPM. CONDITION NORMAL USE. Test/Inspection 1. Check fuel tank vent hose. a. Kinked or clogged hose. Relocate or replace. 2. Check fuel filter. a.
  • Page 58
    Section 03 TROUBLESHOOTING Subsection 03 (FUEL AND OIL SYSTEMS) SYMPTOM ENGINE RUNS OUT OF FUEL (OR LEAN MIXTURE). CONDITION NORMAL USE. Test/Inspection 1. Check fuel filter ball located in fuel tank. Ball must move freely. a. Corrosion due to oxidation at installation. Replace fuel filter.

  • Page 59: Transmission And Brake Systems

    Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) TRANSMISSION AND BRAKE SYSTEMS0 The following charts are provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. TRANSMISSION SYMPTOM THE SNOWMOBILE ACCELERATES SLOWLY, ESPECIALLY WHEN IT IS STOPPED.

  • Page 60
    Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM LOOSENESS IS FELT IN DRIVE SYSTEM WHEN ACCELERATING/DECELERATING. CONDITION NORMAL USE. Test/Inspection 1. Check drive chain tension. a. Drive chain is too loose. Adjust. 2. Check play of driven pulley Woodruff key (aluminum frame models) a.
  • Page 61
    Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM PULLEYS DO NOT DOWN SHIFT PROPERLY. CONDITION NORMAL USE. Test/Inspection 1. Check driven pulley spring tension. a. Spring tension is too weak. Adjust according to specifications (refer to TECHNICAL DATA 10). 2.
  • Page 62
    Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT GLAZED EXCESSIVELY OR HAVING BAKED APPEARANCE. CONDITION NORMAL USE. Test/Inspection 1. Check if drive pulley bushings are worn. a. Insufficient pressure on belt sides. Replace bushing. 2. Check condition of drive pulley fixed half shaft. a.
  • Page 63
    Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT WORN NARROW IN ONE SECTION. CONDITION NORMAL USE. Test/Inspection 1. Check if parking brake is released. a. Parking brake is engaged. Release parking brake. 2. Check track tension/alignment. a. Frozen or too tight track. Liberate track from ice or check track tension and alignment.
  • Page 64
    Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT EDGE CORD BREAKAGE. CONDITION NORMAL USE. Test/Inspection 1. Check pulley alignment. a. Pulley misalignment. Align pulley according to specifications (refer to TECHNICAL DATA 10). A00DOFY SYMPTOM FLEX CRACKS BETWEEN COGS. CONDITION NORMAL USE.

  • Page 65: Brake System

    Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) BRAKE SYSTEM MECHANICAL BRAKE SYMPTOM BRAKE DOES NOT ADJUST AUTOMATICALLY. CONDITION NORMAL USE. Test/Inspection 1. Check ratchet wheel spring. a. Broken ratchet wheel tag. Replace. 2. Check mobile pad stud. a. Stud rotates in pad. Replace.

  • Page 66: Mechanical And Hydraulic Brakes

    Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) MECHANICAL AND HYDRAULIC BRAKES SYMPTOM BRAKE SYSTEM IS NOISY. CONDITION NORMAL USE. Test/Inspection 1. Check brake pad thickness. a. Pads are worn up to wear warner. Replace. 03-04-8…

  • Page 67: Electrical System

    Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) ELECTRICAL SYSTEM The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM STARTER DOES NOT TURN.

  • Page 68
    Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) 9. Check height of commutator mica. a. Commutator mica too high. Undercut mica. 10. Check field coil resistance. a. Shorted field coil. Repair or replace yoke. 11. Check armature resistance. a. Shorted armature. Repair or replace armature.
  • Page 69
    Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM ELECTRIC STARTER KEEPS TURNING WHEN ENGINE IS STARTED. CONDITION NORMAL USE. Test/Inspection 1. Check clutch. a. Jammed clutch pinion gear. Replace or clean. 2. Check movement of clutch on splines. a. Clutch is stuck on splines. Clean.
  • Page 70
    Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) 4. Check ignition switch. a. Defective contacts in ignition switch. Replace. 5. Check solenoid of electric starter. a. Shorted solenoid wiring harness or eroded contact washer. Replace. SYMPTOM HEADLAMP NOT LIGHTING. CONDITION WHITE BULB. Test/Inspection 1.
  • Page 71
    Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) 5. Verify if optional electric accessories are overloading the magneto/generator. a. Excessive electrical load to magneto/generator. Reduce the electrical load by removing excess accessories. Reconnect as recommended by manufacturer. 6. Hot Grips brand: Verify if they were connected in parallel by mistake. a.
  • Page 72
    Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM ENGINES DOES NOT START — NO SPARK AT SPARK PLUG. CONDITION AT ENGINE CRANKING. Test/Inspection 1. Verify spark plug condition. a. Defective, improperly set, worn-out, fouled. Identify source of problem and correct. Replace spark plugs. 2.
  • Page 73
    Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM ENGINE IS MISFIRING — ERRATIC SPARK AT SPARK PLUG. CONDITION RIDING ON WET SNOW. Test/Inspection 1. Verify if spark plug wires and/or spark plug cap seals are sealing out moisture. a. Defective wires and/or seals. Replace defective part.
  • Page 74
    Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM FOULED (BLACK) SPARK PLUG TIP. CONDITION NORMAL USE. Test/Inspection 1. Check carburetor(s). a. Carburetion is too rich. Adjust according to specifications (refer to TECHNICAL DATA 10). 2. Check injection oil consumption. a. Injection pump flow is too high. Adjust according to specifications or replace.
  • Page 75
    Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM REAR LIGHT BULB FLASHES. CONDITION NORMAL USE. Test/Inspection 1. Check bulb tightness in housing. a. Looseness at bulb contact elements. Install bulb correctly. 2. Check if rear light is properly connected. a. Connector housing is partially connected. Install connector housing properly.

  • Page 76: Suspension System And Track

    Section 03 TROUBLESHOOTING Subsection 06 (SUSPENSION AND TRACK) SUSPENSION AND TRACK The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM REAR SUSPENSION BOTTOMS OUT.

  • Page 77
    Section 03 TROUBLESHOOTING Subsection 06 (SUSPENSION AND TRACK) SYMPTOM DERAILING TRACK. CONDITION NORMAL USE. Test/Inspection 1. Check track tension. a. Track is too loose. Adjust. 2. Check if track and slider shoes are properly aligned. a. Improper alignment. Adjust. SYMPTOM REAR SUSPENSION IS LOW OR TOO STIFF.
  • Page 78
    Section 03 TROUBLESHOOTING Subsection 06 (SUSPENSION AND TRACK) SYMPTOM HANDLE BAR IS DIFFICULT TO TURN. CONDITION NORMAL USE. Test/Inspection 1. Check position of front spring adjustment cams. a. More pressure on the ground when cam increases spring preload. Reduce front spring preload. 2.

  • Page 79: Engine

    Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS 443 AND 503 ENGINE TYPES………………..04-02-1 ENGINE REMOVAL AND INSTALLATION……………. 04-02-1 ENGINE REMOVAL AND INSTALLATION ……………. 04-02-2 TUNED PIPE IDENTIFICATION ………………04-02-2 ENGINE REMOVAL AND INSTALLATION ……………. 04-02-4 TOP END ……………………..04-02-5 CLEANING …………………….

  • Page 80
    Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) ENGINE DIMENSION MEASUREMENT …………….04-04-6 CYLINDER HEAD WARPAGE ………………… 04-04-6 CYLINDER TAPER………………….. 04-04-6 CYLINDER OUT OF ROUND ………………..04-04-6 COMBUSTION CHAMBER VOLUME MEASUREMENT ……….. 04-04-6 USED PISTON MEASUREMENT………………04-04-8 CYLINDER/PISTON CLEARANCE ………………04-04-8 RING/PISTON GROOVE CLEARANCE …………….
  • Page 81
    Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) LIQUID COOLING SYSTEM ………………..04-08-1 INSPECTION ……………………04-08-3 DRAINING THE SYSTEM ………………..04-08-3 DISASSEMBLY AND ASSEMBLY ………………04-08-3 COOLING SYSTEM REFILLING PROCEDURE …………..04-08-4 ROTARY VALVE, COOLANT PUMP AND RESERVOIR…………04-09-1 GENERAL ……………………… 04-09-2 CLEANING …………………….

  • Page 82: 443 And 503 Engine Types

    Section 04 ENGINE Subsection 02 (443 AND 503 ENGINE TYPES) 443 AND 503 ENGINE TYPES ENGINE REMOVAL AND INSTALLATION 443 Engine Type 28 N•m (21 lbf•ft) 17 N•m (150 lbf•in) 37 N•m (27 lbf•ft) 35 N•m (26 lbf•ft) A03C13S PARTS FLAT RATE 04-02-1…

  • Page 83: Tuned Pipe Identification

    Section 04 ENGINE Subsection 02 (443 AND 503 ENGINE TYPES) ENGINE REMOVAL AND TUNED PIPE IDENTIFICATION INSTALLATION This part is identified on welded support. Disconnect or remove the following: Second number sequence of P/N is stamped on part. WARNING Before disconnecting any electrical wire in starter system always first disconnect the BLACK negative battery cable (on electric starting models).

  • Page 84
    Section 04 ENGINE Subsection 02 (443 AND 503 ENGINE TYPES) Skandic WT/SWT 503 Engine Type 21 N•m (15 lbf•ft) A22C0FS PARTS FLAT RATE 04-02-3…
  • Page 85
    Section 04 ENGINE Subsection 02 (443 AND 503 ENGINE TYPES) ENGINE REMOVAL AND INSTALLATION Disconnect or remove the following: WARNING Before disconnecting any electrical wire in starter system always first disconnect the BLACK negative battery cable (on electric starting models). –…

  • Page 86: Top End

    Section 04 ENGINE Subsection 02 (443 AND 503 ENGINE TYPES) TOP END 22 N•m 22 N•m (16 lbf•ft) (16 lbf•ft) 2 22 N•m (16 lbf•ft) only 22 N•m (16 lbf•ft) 22 N•m only (16 lbf•ft) 22 N•m (16 lbf•ft) Grease only A22C0KS PARTS…

  • Page 87: Cleaning

    Section 04 ENGINE Subsection 02 (443 AND 503 ENGINE TYPES) NOTE: The following procedures can be done without removing the engine from chassis. CLEANING Discard all gaskets. Use Gasket Remover (P/N 413 7085 00) to clean mating surfaces. Clean all metal components in a non-ferrous met- al cleaner.

  • Page 88: Inspection

    Section 04 ENGINE Subsection 02 (443 AND 503 ENGINE TYPES) NOTE: The PTO cylinder or fan housing have to be removed to give access to MAG piston pin with the puller. NOTE: 0.25 and 0.5 mm oversize piston and rings are available if necessary.

  • Page 89
    Section 04 ENGINE Subsection 02 (443 AND 503 ENGINE TYPES) – When installing new needle bearing, insert nee- dles with thrust washers. Instead of expansion sleeve, needles are held in place by 2 inner plastic cage halves. – Use piston pin puller (P/N 529 0210 00) to insert piston pin.
  • Page 90
    Section 04 ENGINE Subsection 02 (443 AND 503 ENGINE TYPES) NOTE: The ring compressor will not fit on over- size pistons. Check flatness of intake sockets no. 10. Refer to ENGINE DIMENSION MEASUREMENT 04-04 529 0169 00 and look for CHECKING SURFACE FLATNESS. At cylinder no.
  • Page 91
    Section 04 ENGINE Subsection 02 (443 AND 503 ENGINE TYPES) Position distance nuts no. 2 as illustrated. A03C1XA 1. Exhaust side 2. Distance nuts A17C0SA Cross torque cylinder head nuts nos. 1 and 2 to 1. Noise dampers 22 N•m (16 lbf•ft); torque each cylinder head indi- 2.

  • Page 92: Bottom End

    Section 04 ENGINE Subsection 02 (443 AND 503 ENGINE TYPES) BOTTOM END Anti-seize lubricant Anti-seize lubricant Anti-seize lubricant Loctite 242 22 N•m (16 lbf•ft) 503: 22 N•m (16 lbf•ft) 443: 10 N•m (89 lbf•in) A03C1IT PARTS FLAT RATE 04-02-11…

  • Page 93: Cleaning

    Section 04 ENGINE Subsection 02 (443 AND 503 ENGINE TYPES) NOTE: Engine must be removed from chassis to ASSEMBLY perform the following procedures. Smear anti-seize lubricant (P/N 413 7010 00) on Remove engine from chassis. part of crankshaft where bearing fits. Remove fan guard, rewind starter, starting pulley, To check proper clearance between bearing no.

  • Page 94
    Section 04 ENGINE Subsection 02 (443 AND 503 ENGINE TYPES) At seal no. 2 assembly, apply a light coat of lithi- 503 Engine um grease on seal lip. Torque screws nos. 6, 7, 8 and 11 to 22 N•m (16 For bearing lubrication purpose, a gap of 1.0 mm lbf•ft) following illustrated sequence.

  • Page 95: 494, 583 And 670 Engine Types

    Section 04 ENGINE Subsection 03 (494, 583 AND 670 ENGINE TYPES) 494, 583 AND 670 ENGINE TYPES ENGINE SUPPORT AND MUFFLER All Models 583 and 670 Loctite Loctite 494 and 670 engines 23 N•m MX Z 494, (17 lbf•ft) 583 and 670 24 N•m (18 lbf•ft) Loctite…

  • Page 96: Removal From Vehicle

    Section 04 ENGINE Subsection 03 (494, 583 AND 670 ENGINE TYPES) REMOVAL FROM VEHICLE 3,4,5, Tuned Pipe, Tail Pipe and Muffler These parts are identified on welded hook. Disconnect or remove the following from vehicle. Second number sequence of P/N is stamped on –…

  • Page 97
    Section 04 ENGINE Subsection 03 (494, 583 AND 670 ENGINE TYPES) 3, Tuned Muffler This part is identified on welded support. Second number sequence of P/N is stamped on part. A03C1KA 1. Identification – Should a light exhaust leak be experienced at any ball joints, Loctite 179 (P/N 413 7103 00) can be used.

  • Page 98: Top End

    Section 04 ENGINE Subsection 03 (494, 583 AND 670 ENGINE TYPES) TOP END 583 and 670 engine types only 29 N•m Pipe sealant (21 lbf•ft) 494 engine only (P/N 413 7023 00) Pipe sealant Loctite Grease Grease (P/N 413 7023 00) 29 N•m (21 lbf•ft) 10 N•m…

  • Page 99: Cleaning

    Section 04 ENGINE Subsection 03 (494, 583 AND 670 ENGINE TYPES) NOTE: The following procedures can be done Remove spring clip no. 3, cover no. 5 and spring without removing the engine from chassis. no. 6. Cut clamp no. 8 (remove spring on 454) and un- CLEANING screw valve piston no.

  • Page 100: Assembly

    Section 04 ENGINE Subsection 03 (494, 583 AND 670 ENGINE TYPES) NOTE: Oil dripping from draining hole indicates a loosened clamp or damaged bellows. Check for cracked, dried or perforated bellows no. 9. 529 0169 00 6, Spring PRELOAD IN WIRE FREE N (LBF) AT…

  • Page 101
    Section 04 ENGINE Subsection 03 (494, 583 AND 670 ENGINE TYPES) A00A1DA NOTE: Neither exhaust manifold nor cylinder aligning tools (flat bars) must be installed on ex- haust flanges to perform this procedure. A00A1EA 1. Place a 0.43 mm (.017 in) feeler gauge be- 1.
  • Page 102
    Section 04 ENGINE Subsection 03 (494, 583 AND 670 ENGINE TYPES) 1, Screw Install and torque screws in a criss-cross se- quence for each cylinder to 29 N•m (21 lbf•ft). For Torque cylinder head cover screws to 10 N•m (90 670 engine longer screws go on exhaust side.
  • Page 103
    Section 04 ENGINE Subsection 03 (494, 583 AND 670 ENGINE TYPES) All Models RAVE SYSTEM Install exhaust valve in cylinder with its mention 2, Cylinder Head Screw TOP upward (see illustration at removal). ENGINE CYLINDER HEAD SCREWS Install gasket and valve rod housing with their pas- TYPE TIGHTENING TORQUE sages toward bottom.

  • Page 104: Bottom End

    Section 04 ENGINE Subsection 03 (494, 583 AND 670 ENGINE TYPES) BOTTOM END Lithium grease 454, 494 engines only Loctite 454, 494 Anti-seize lubricant engines Anti-seize only lubricant Loctite 29 N•m (21 lbf•ft) Except 454, 494 and 670. See CDI Loctite SYSTEM 10 N•m…

  • Page 105: Cleaning

    Section 04 ENGINE Subsection 03 (494, 583 AND 670 ENGINE TYPES) NOTE: Engine must be removed from chassis to INSPECTION perform the following procedures. Refer to ENGINE DIMENSIONS MEASUREMENT 04-04. CLEANING Discard all oil seals, gaskets, O-rings and sealing ASSEMBLY rings.

  • Page 106
    Section 04 ENGINE Subsection 03 (494, 583 AND 670 ENGINE TYPES) Install bearing drive pins no. 2 as illustrated. 1,8, Upper Crankcase and Lower Crankcase Crankcase halves are factory matched and there- fore, are not interchangeable or available as single halves.
  • Page 107
    Section 04 ENGINE Subsection 03 (494, 583 AND 670 ENGINE TYPES) NOTE: Torque the 2 smaller screws (15 and 16) on magneto side to 10 N•m (90 lbf•in). Apply pipe sealant (P/N 413 7023 00) on threads prior to assembly angular tube no. 11. At assembly on crankcase, apply medium strength threadlocker (P/N 413 7030 00) on stud threads no.

  • Page 108: Leak Test And Engine Dimension Measurement

    Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) LEAK TEST AND ENGINE DIMENSION MEASUREMENT LEAK TEST The following gives verification procedures for liq- 8. Rotate crankshaft so that piston goes to BDC uid cooled engines though it also applies to fan (Bottom Dead Center) on side where the cooled engines.

  • Page 109
    Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Engine Check the following: 1. All jointed surfaces and screw/stud threads of engine: – spark plug base, insulator – cylinder head – cylinder base – crankcase halves (joint) – rotary valve cover –…
  • Page 110
    Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) 4. Block both hoses of rotary valve gear lubrica- 1. Remove a spark plug or any plug of leak tester tion system with hose pinchers. kit on PTO side. If pressure drops, it indicates defective crank- shaft inner seal on PTO side.

  • Page 111: Finalizing Reassembly

    Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) 4. Remove rotary valve cover and check for leak COOLING SYSTEM LEAK TEST of rotary valve seal with soapy water. Install special plug (radiator cap) (P/N 529 0214 00) and hose pincher (P/N 529 0099 00) on overflow hose.

  • Page 112: Engine Leak Verification Flow Chart

    Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) ENGINE LEAK VERIFICATION FLOW CHART ENGINE LEAK VERIFICATION FLOW CHART PRESSURIZE ENGINE IS ENGINE LEAKING? CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS. MOUNTING FLANGES ETC. REPLACE GASKET OR O-RING, ANY LEAK FOUND? RE-SEAL LEAKING AREA CHECK SMALL OIL LINES OF INJECTION PUMP…

  • Page 113: Engine Dimension Measurement

    Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) ENGINE DIMENSION MEASUREMENT This section covers all engine types. Measuring 16 mm (5/8 in) from top of cylinder with a cylinder gauge, check if the cylinder out of CYLINDER HEAD WARPAGE round is more than the specified dimension.

  • Page 114
    Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) NOTE: When checking the combustion chamber 4. Inject the burette content through the spark volume, engine must be cold, piston must be free plug hole until liquid touches the top spark plug of carbon deposit and cylinder head must be lev- hole.

  • Page 115: Used Piston Measurement

    Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) USED PISTON MEASUREMENT Using a micrometer, measure piston at A perpendic- ularly (90°) to piston pin. F00D0EA 1. Piston dome 2. Piston measurement Adjust and lock a micrometer to the specified val- F01D0NA ue on the piston dome.

  • Page 116: Ring/Piston Groove Clearance

    Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Read the measurement on the cylinder bore gauge. The result is the exact piston/cylinder wall clearance. If clearance exceeds specified toler- ance, replace cylinder or rebore. Refer to TECHNI- CAL DATA 10.

  • Page 117: Crankshaft Deflection

    Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Crankshaft Deflection on PTO Side ENGINE DISTANCE A MAXIMUM ON PTO SIDE TYPE mm (in) mm (in) 75.5 (2.972) 0.05 (.002) 494 and 86 (3.386) 0.06 (.002) 82.5 (3.248) 100 (3.937) Crankshaft Deflection on MAG Side A01C0QA…

  • Page 118: Connecting Rod/Piston Pin Clearance

    Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) ENGINE NEW PARTS WEAR TYPE MIN. — MAX. LIMIT 0.03 — 0.012 mm 0.015 mm (.0001 — .0005 in) (.0006 in) CONNECTING ROD/CRANKPIN CLEARANCE ENGINE NEW PARTS WEAR TYPE MIN.

  • Page 119: Checking Surface Flatness

    Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) A13C0OA F01D3PA TYPICAL TYPICAL 1. Solder The gap can be measured with the engine in- stalled on vehicle. Use 45° bent blade feeler CHECKING SURFACE FLATNESS gauge (Snap-on FB300A) inserted through intake socket of valve cover.

  • Page 120: Checking Crankshaft Alignment

    Section 04 ENGINE Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) CHECKING CRANKSHAFT ALIGNMENT Install a degree wheel (P/N 414 3529 00) on crank- shaft end. Remove both spark plugs. Install a TDC gauge (P/N 414 1047 00) in spark plug hole on MAG side.

  • Page 121: Cdi System

    Section 04 ENGINE Subsection 05 (CDI SYSTEM) CDI SYSTEM NIPPONDENSO TRIGGER COIL IGNITION SYSTEM 494, 583 and 670 Engines Dielectric grease (P/N 413 7017 00) 494 and 670 engines Loctite Loctite Loctite Loctite All engines except 494 and 670 Loctite Dielectric grease (P/N 413 7017 00) 22 N•m…

  • Page 122: Cleaning

    Section 04 ENGINE Subsection 05 (CDI SYSTEM) NOTE: The following procedures can be done without removing the engine from chassis. To fa- cilitate magneto removal, hold drive pulley with tool (P/N 529 0276 00). CDI means Capacitor Discharge Ignition system. CLEANING Clean all metal components in a non-ferrous met- al cleaner.

  • Page 123
    Section 04 ENGINE Subsection 05 (CDI SYSTEM) A25E1AA 1. Magneto harness through crankcase hole – Install new trigger coil and other parts re- moved. Preliminary Adjustment A15E0NA NOTE: The final trigger coil adjustment will be PRELIMINARY TRIGGER COIL AIR GAP ADJUSTMENT done when checking ignition timing.

  • Page 124: Assembly

    Section 04 ENGINE Subsection 05 (CDI SYSTEM) 2,5, Magneto Flywheel and Nut Clean crankshaft extension (taper) and apply Loc- tite 242 (blue) on taper, then position Woodruff key, flywheel and lock washer on crankshaft. Clean nut threads and apply Loctite 242 (blue) then tighten nut to 125 N•m (92 lbf•ft) for 494 and 670 engines.

  • Page 125: Ducati Ignition System

    Section 04 ENGINE Subsection 05 (CDI SYSTEM) DUCATI IGNITION SYSTEM 443 and 503 Engines Dielectric grease Loctite 105 N•m (77 lbf•ft) Loctite 22 N•m (195 lbf•in) A07C03S PARTS FLAT RATE 04-05-5…

  • Page 126: Cleaning

    Section 04 ENGINE Subsection 05 (CDI SYSTEM) NOTE: The following procedures can be done To remove magneto flywheel , install the no. 2 without removing the engine from chassis. magneto puller (P/N 529 0225 00). – Tighten puller bolt and at the same time, tap on CLEANING bolt head using a hammer to release magneto flywheel from its taper.

  • Page 127: Assembly

    Section 04 ENGINE Subsection 05 (CDI SYSTEM) ASSEMBLY Clean crankshaft extension (taper). Apply Loctite 242 (blue) on taper. Position Woodruff key, flywheel and lock washer on crankshaft. Clean nut threads and apply Loctite 242 (blue) be- fore tightening nut to 105 N•m (77 lbf•ft). At reassembly coat all electric connections with silicone dielectric grease (P/N 413 7017 00) to pre- vent corrosion or moisture penetration.

  • Page 128: Oil Injection System

    Section 04 ENGINE Subsection 06 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM OIL INJECTION PUMP 494, 583 and 670 Engines Loctite Molykote Loctite Parts in illustration marked with X are not available as single parts. A03C1LS PARTS FLAT RATE 04-06-1…

  • Page 129
    Section 04 ENGINE Subsection 06 (OIL INJECTION SYSTEM) 443 and 503 Engines Loctite 242 Loctite Molykote 111 A22C0DS PARTS FLAT RATE 04-06-2…

  • Page 130: Oil Pump Identification

    Section 04 ENGINE Subsection 06 (OIL INJECTION SYSTEM) OIL PUMP IDENTIFICATION Different engines use different pumps. See iden- tification on lever no. 7. 420 2779 05 CAUTION Always mount proper pump on engine. OIL PUMP ENGINE TYPE IDENTIFICATION A00C17A 494 Skandic WT LC TYPICAL 494 Formula/GT/MX ASSEMBLY…

  • Page 131
    Section 04 ENGINE Subsection 06 (OIL INJECTION SYSTEM) Synchronizing Pump with Carburetor Eliminate the throttle cable free-play by pressing the throttle lever until a light resistance is felt, then hold in place. The aligning marks on the pump casting and on the lever must align. If not, loosen the adjuster nut and adjust accordingly.

  • Page 132: Checking Operation

    Section 04 ENGINE Subsection 06 (OIL INJECTION SYSTEM) CHECKING OPERATION If not, remove pump assembly and check the pump gear and drive shaft (if applicable) for de- fects, replace as necessary. Test pump as de- On Vehicle scribes below. NOTE: Main oil line must be full of oil. See bleed- NOTE: Through normal use, oil level must not ing procedure above.

  • Page 133: Axial Fan Cooling System

    Section 04 ENGINE Subsection 07 (AXIAL FAN COOLING SYSTEM) AXIAL FAN COOLING SYSTEM 443 and 503 Engines 13 N•m (115 lbf•in) 443 and 503 engines only 47 N•m (35 lbf•ft) A03C0WS PARTS FLAT RATE 04-07-1…

  • Page 134: Removal

    Section 04 ENGINE Subsection 07 (AXIAL FAN COOLING SYSTEM) NOTE: The following procedures can be done without removing engine from chassis. REMOVAL NOTE: To facilitate further disassembly, fan nut may be removed before removing fan housing. Remove rewind starter, starting pulley, trigger coil wire from 4-connector housing then fan housing ass’y.

  • Page 135
    Section 04 ENGINE Subsection 07 (AXIAL FAN COOLING SYSTEM) Using a press, drive the fan shaft no. 9 out. Remove circlip no. 11 then remaining bearing. To install, press one bearing in place then install circlip and shims. Press the other bearing from op- posite side until it is flush with housing.

  • Page 136: Liquid Cooling System

    Section 04 ENGINE Subsection 08 (LIQUID COOLING SYSTEM) LIQUID COOLING SYSTEM All S-Series Engines Loctite A06C2VT PARTS FLAT RATE 04-08-1…

  • Page 137
    Section 04 ENGINE Subsection 08 (LIQUID COOLING SYSTEM) Skandic WT LC Loctite Loctite A29C0AS TYPICAL PARTS FLAT RATE 04-08-2…

  • Page 138: Inspection

    Section 04 ENGINE Subsection 08 (LIQUID COOLING SYSTEM) INSPECTION 6,7, Radiator and Radiator Protector Insert radiator protector into radiator C-rail and Check general condition of hoses and clamp tight- crimp C-rail at both ends. Refer to FRAME 09-02 ness. for radiator removal. DRAINING THE SYSTEM 5, Thermostat To check thermostat, put in water and heat water.

  • Page 139: Cooling System Refilling Procedure

    Section 04 ENGINE Subsection 08 (LIQUID COOLING SYSTEM) COOLING SYSTEM REFILLING PROCEDURE Recommended Coolant Use a blend of 60% antifreeze with 40% water. Do not reinstall pressure cap. CAUTION To prevent rust formation or freezing condi- tion, always replenish the system with 60% antifreeze and 40% water.

  • Page 140
    Section 04 ENGINE Subsection 08 (LIQUID COOLING SYSTEM) Skandic WT LC Open cap and fill filler neck no. 8 completely. Tilt seat and unscrew bleeding screw on top of connecting hose. Coolant must flow. Refill through filler neck no. 8 as necessary. Reinstall bleeding screw.

  • Page 141: Rotary Valve, Coolant Pump And Reservoir

    Section 04 ENGINE Subsection 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) ROTARY VALVE, COOLANT PUMP AND RESERVOIR 494, 583 and 670 Engines Injection oil reservoir Loctite To rotary valve gear Molykote Loctite 22 N•m (16 lbf•ft) A06C2UT TYPICAL PARTS FLAT RATE 04-09-1…

  • Page 142: General

    Section 04 ENGINE Subsection 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) NOTE: Some verifications can be performed with engine in vehicle. Refer to ENGINE DIMENSION MEASUREMENT 04-04. GENERAL Engine must be removed from vehicle to work on rotary valve shaft/components. Refer to Removal and Installation of appropriate engine for proce- dures.

  • Page 143: Inspection

    Section 04 ENGINE Subsection 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) To remove bearing, use a bearing puller (ex.: Snap-on no. CJ 950) and pusher (P/N 420 8766 12) as illus- trated. 420 8765 12 420 8766 12 A16C0OA INSPECTION Inspect rotary valve cover for warpage.

  • Page 144
    Section 04 ENGINE Subsection 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) 4,5,7, Rotary Valve Shaft, Seal and 11, Bearing 6201 Bearing 6203 To install bearing 6201, use bearing pusher (P/N 420 8765 00). At assembly apply lithium grease on seal lips. Po- sition the seal with shielded portion against splines of shaft.
  • Page 145
    Section 04 ENGINE Subsection 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) – Install rubber washer then support plate with its flange towards pump impeller. Use impeller support plate pusher (P/N 529 0207 00) for proper installation. – Install small thrust washer then friction washer positioning its grooves against pump impeller.
  • Page 146
    Section 04 ENGINE Subsection 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) 18,19, Pump Housing Bolt and Loctite 242 (Blue) Apply Loctite 242 (blue) on bolt threads. 420 8765 00 Rotary Valve The rotary valve controls the opening and closing of the inlet ports. Therefore its efficiency will de- pend on the precision of its installation.
  • Page 147
    Section 04 ENGINE Subsection 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) Installation To correctly install rotary valve, proceed as fol- lows: – Turning crankshaft, bring MAG side piston to Top Dead Center. Use a dial indicator (P/N 414 1047 00). 414 1047 00 A00B2EA A16C16A…
  • Page 148
    Section 04 ENGINE Subsection 09 (ROTARY VALVE, COOLANT PUMP AND RESERVOIR) To Time Rotary Valve Exactly to Specifications NOTE: If desynchronization (out of spec.) is un- known, install rotary valve to determine it before proceeding with the following. 132° First Method Turn crankshaft to bring MAG piston to TDC.

  • Page 149: Rewind Starter

    Section 04 ENGINE Subsection 10 (REWIND STARTER) REWIND STARTER All Liquid Cooled Models Molykote G-n paste or equivalent Silicone compound grease Silicone compound grease 10 N•m (89 lbf•in) 583 MX Z, 583 Summit and 670 engines only A01C5SS TYPICAL PARTS FLAT RATE 04-10-1…

  • Page 150
    Section 04 ENGINE Subsection 10 (REWIND STARTER) All Fan Cooled Engines 10 N•m (89 lbf•in) 8 N•m Molykote G-n (71 lbf•in) paste or equivalent Silicone compound grease Silicone compound grease A21C08S PARTS FLAT RATE 04-10-2…

  • Page 151: Removal

    Section 04 ENGINE Subsection 10 (REWIND STARTER) REMOVAL Using a small screwdriver, extract rope knot from starter grip no. 15. Cut rope close to knot. Tie a knot near starter. Remove screws no. 3 and washers no. 2 secur- ing rewind starter no. 1 to engine then remove re- wind starter.

  • Page 152: Installation

    Section 04 ENGINE Subsection 10 (REWIND STARTER) A01C0CA Position pawl no. 8, pawl lock no. 9 and circlip A01C14A no. 10. 1. Grease inside spring guide Install locking spring no. 11 and lubricate with MOLYKOTE G-n paste from Dow Corning ®…

  • Page 153
    Section 04 ENGINE Subsection 10 (REWIND STARTER) Prior to installing starter grip no. 15 on new rope, it is first necessary to fuse the rope end with a lit match. Pass rope through starter grip and tie a knot in the rope end. Fuse the knot with a lit match then insert rope end down and pull the starter grip over the knot.

  • Page 154: Carburetor And Fuel Pump

    Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) CARBURETOR AND FUEL PUMP All Models To other carburetor MX Z 440 and Skandic WT series only A03C1MS PARTS FLAT RATE 04-11-1…

  • Page 155: Removal

    Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) REMOVAL 15, Filter Check for clogged filter. Clean or replace as re- Remove air silencer(s). Refer to BATTERY 06-04. quired. Disconnect fuel inlet line. Check inlet needle tip condition. If worn, the inlet Disconnect primer line from carburetor on some needle and seat must be replaced as a matched models.

  • Page 156: Disassembly And Assembly

    Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) DISASSEMBLY AND ASSEMBLY The size of the throttle slide cut-away affects the fuel mixture between 1/8 to 1/2 throttle opening. NOTE: To ease the carburetor disassembly and assembly procedures it is recommended to use carburetor tool kit (P/N 404 1120 00).

  • Page 157
    Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) FLOAT HEIGHT H CARBURETOR ± 1 mm MODEL (±.040 in) MX Z 440 23.9 (.941) MX Z 494 18.1 (.713) MX Z 583 18.1 (.713) MX Z 670 18.1 (.713) Formula 500/500 DL 18.1 (.713) Formula 583 DL…

  • Page 158: Installation

    Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) NOTE: Do not obstruct hole in throttle slide when Throttle slide openings installing needle retaining plate. This is important to allow air escaping through and thus allowing a Wide quick response. open Close 13,6,…

  • Page 159: Carburetor Adjustments

    Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) CARBURETOR ADJUSTMENTS A02C09A A01C33A 1. Idle speed screw TYPICAL 2. Air screw 1. Screw in and out until no cable free play exists 2. Check that throttle side does not move 6, Air Screw Adjustment 3.

  • Page 160: Preliminary Idle Speed Adjustment

    Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) Twin Carburetor Models Only Repeat on the other one. This will ensure identical throttle slide preliminary idle setting. Recheck car- buretor synchronization. Adjust idle by turning both idle speed screws the same amount. CAUTION On twin carburetor models, make sure both carburetors start to operate simultaneously.

  • Page 161: Idle Speed Final Adjustment

    Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) NOTE: On twin-carburetor models: Turn adjust- Throttle Slide Height Models ment screw the same amount to keep carbure- mm (in) tors synchronized. MX Z 440 1.5 (.059) Refer to TECHNICAL DATA 10 for the specifica- MX Z 500 1.8 (.071) tions.

  • Page 162
    Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) A01C5EA A01C5GA AIR SILENCER SIDE SHOWN 1. Lift up protector cap 2. Loosen lock nut 1. Tool stopper within 1 mm (.040 in) of recess wall Turn choke cable adjustment nut by hand until tool properly seats under choke plunger.
  • Page 163
    Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) H.A.C. SYSTEM Summit Only H.A.C. (High Altitude Compensator) is a mainte- nance free device. No adjustment and verification can be done to H.A.C. If H.A.C. is suspected to be faulty, replace it and check for improvement.
  • Page 164
    Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) H.A.C. SYSTEM To magneto housing A03I0BS PARTS FLAT RATE 04-11-11…

  • Page 165: Fuel Pump

    Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) FUEL PUMP 443 and 503 engines 494, 583 and 670 engines A06C45S PARTS FLAT RATE 04-11-12…

  • Page 166: Removal

    Section 04 ENGINE Subsection 11 (CARBURETOR AND FUEL PUMP) REMOVAL CLEANING AND INSPECTION Install a hose pincer (P/N 529 0099 00) on fuel The entire pump should be cleaned with general supply line close to pump inlet. purpose solvent before disassembly. Fuel pump components should be cleaned in gen- eral purpose solvent and dried with compressed air.

  • Page 167: Fuel Tank And Throttle Cable

    Section 04 ENGINE Subsection 12 (FUEL TANK AND THROTTLE CABLE) FUEL TANK AND THROTTLE CABLE Fuel Tank Lines Models with Easy Action Throttle Lever WARNING When draining a fuel tank or whenever a fuel line is disconnected, obstruct line with a hose pincher (P/N 529 0099 00) or equivalent device.

  • Page 168
    Section 04 ENGINE Subsection 12 (FUEL TANK AND THROTTLE CABLE) Throttle Cable O-ring and Retaining Ring at Carburetor (some models) Locate O-ring outside of carburetor cover and re- taining ring inside. 100.7° A01E18A 1. Full position (3 ± 2 Ω ) 2.

  • Page 169: Transmission

    Section 05 TRANSMISSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS DRIVE BELT……………………..05-02-1 1998 APPLICATION CHART ………………..05-02-1 ROTATION DIRECTION…………………. 05-02-1 DRIVE BELT DEFLECTION MEASUREMENT …………..05-02-2 DEFLECTION ADJUSTMENT……………….. 05-02-3 DRIVE PULLEY……………………05-03-1 TRA ……………………….. 05-03-1 GENERAL ……………………… 05-03-2 REMOVAL………………………

  • Page 170
    Section 05 TRANSMISSION Subsection 01 (TABLE OF CONTENTS) CHAINCASE……………………..05-07-1 REMOVAL ……………………… 05-07-2 INSPECTION ……………………05-07-2 GEAR RATIO MODIFICATION……………….. 05-07-2 INSTALLATION ……………………05-07-2 DRIVE CHAIN ADJUSTMENT……………….. 05-07-3 ADJUSTMENT……………………05-07-4 GEARBOX……………………..05-08-1 3-SPEED GEARBOX ………………….05-08-1 REMOVAL ……………………… 05-08-2 DISASSEMBLY ……………………05-08-2 INSPECTION ……………………

  • Page 171: Drive Belt

    Section 05 TRANSMISSION Subsection 02 (DRIVE BELT) DRIVE BELT 1998 APPLICATION CHART PART WIDTH (NEW) MINIMUM WIDTH MODEL ± 0.25 mm (.010 in) NUMBER (WEAR LIMIT) SUMMIT 583/670, FORMULA Z 670 415 0990 00 35 mm (1-3/8) 33 mm (1-19/64) AND MX Z 670 SUMMIT 500, GRAND TOURING 500/583, FORMULA 500/500DL/583…

  • Page 172: Drive Belt Deflection Measurement

    Section 05 TRANSMISSION Subsection 02 (DRIVE BELT) DRIVE BELT DEFLECTION MEASUREMENT NOTE: The drive belt deflection measurement must be performed each time a new drive belt is installed. NOTE: To obtain an accurate drive belt deflection measurement, it is suggested to allow a break-in period of 50 km (30 mi).

  • Page 173: Deflection Adjustment

    Section 05 TRANSMISSION Subsection 02 (DRIVE BELT) A15D0WA 1. Allen screw with jam nut A00D08A Allen screws should be restrained while tighten- 1. Upper O-ring ing jam nut to prevent throwing adjustment out. 2. Force Use drive belt tension adjuster (P/N 529 0087 00). 3.

  • Page 174: Drive Pulley

    Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) DRIVE PULLEY All Models NOTE: This is a lubrication free drive pulley. 12 N•m Loctite Loctite Loctite (106 lbf•in) 27 N•m (20 lbf•ft) 13 N•m (115 lbf•in) Loctite 10 N•m (89 lbf•in) Loctite 95 N•m (70 lbf•ft) Repair kit…

  • Page 175: General

    Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) GENERAL Some drive pulley components (return spring, ramp) can be changed to improve vehicle perfor- mance in high altitude regions. The High Altitude and Sea Level Technical Data Booklet (P/N 484 0686 00 and 484 0545 00 for binder) gives infor- mation about calibration according to altitude.

  • Page 176: Disassembly

    Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) DISASSEMBLY 32, Cushion Drive 1,2, Screw and Ring Gear CAUTION CAUTION Do not disassemble cushion drive. Governor cup and cushion drive are factory balanced Retaining screws must be heated before dis- as an assembly. assembly.

  • Page 177: Cleaning

    Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) Remove all hardened oil deposits that have baked on crankshaft and pulley tapered surfaces with coarse or medium steel wool and/or sand paper no. 600. CAUTION Do not use any other type of abrasive. Reclean mounting surfaces with paper towel and cleaning solvent (P/N 413 7082 00).

  • Page 178: Assembly

    Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) 24,25, O-ring and Slider Shoe CAUTION Check if O-rings are cracked, cut or crushed. Re- place as required. Insert bushing from outside (governor side) of spring cover. Check slider shoes for wear. Replace if groove is not apparent on top.

  • Page 179
    Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) 1,2,3, Screw, Ring Gear and Loctite 271 30 ± 5° Apply Loctite 271 (P/N 413 7029 00) on threads and then torque to 27 N•m (20 lbf•ft). 26,27,28, Calibration Screw, Washer and Locking Nut When installing calibration screw, make sure to in- stall washer as shown.
  • Page 180
    Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) A16D0BA A16D0DA 1. Head on top 1. Align 2. All on the same side Install and torque screws to 13 N•m (115 lbf•in). CAUTION 6,25,29, Sliding Half, Slider Shoe and Governor Cup Lever assemblies must be installed so that cotter pins are on the same side.

  • Page 181: Installation

    Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) INSTALLATION WARNING 529 0055 00 Do not apply anti-seize or any lubricant on crankshaft and drive pulley tapers. WARNING Never use any type of impact wrench at drive pulley removal and installation. A16B02A Clean mounting surfaces as described in CLEAN- ING above.

  • Page 182: Drive Pulley Adjustment

    Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) Recheck the torque of 90 to 100 N•m (66 to 74 See TECHNICAL DATA 10-03 for original setting. lbf•ft). WARNING After 10 hours of operation the transmission system of the vehicle must be inspected to en- sure the retaining screw is properly torqued.

  • Page 183
    Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) A16D0HA 1. Loosen just enough to permit rotating of calibration screw 05-03-10…

  • Page 184: Driven Pulley

    Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) DRIVEN PULLEY S-Series Anti-seize lubricant (P/N 413 7010 00) Loctite 609 MX Z 583/670 only MX Z 583/670 only A03D2FT PARTS FLAT RATE 05-04-1…

  • Page 185
    Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) Skandic WT/SWT/WT LC Anti-seize lubricant A22D11S 05-04-2 PARTS FLAT RATE…

  • Page 186: Removal

    Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) REMOVAL CLEANING Remove belt guard and drive belt from vehicle. 6,7, Large Bushing and Small Bushing Remove the cap screw no. 13, lock washer During break-in period (about 10 hours of use), te- no.

  • Page 187
    Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) Replace bushing(s) if worn more than specified. Use tool (P/N 529 0311 00). Install support plate inside sliding half. DRIVEN PULLEY BUSHING WEAR LIMIT Place puller below bushing. mm (in) Small bushing 38.30 (1.508) Large bushing 89.15 (3.510) 4, Slider Shoe…

  • Page 188: Assembly

    Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) Install puller in a vise. All Models Heat bushing area. 19, Cam Turn puller handle and sliding half at once to ex- Coat cam interior with anti-seize lubricant. tract the bushing. INSTALLATION 14,15, Countershaft and Anti-seize Lubricant 529 0313 00 CAUTION…

  • Page 189: Adjustment

    Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) ADJUSTMENT Refer to PULLEY DISTANCE AND ALIGNMENT 05-05 to adjust pulley distance. Adjust drive belt 529 0065 00 height in driven pulley to obtain specified belt de- flection. Turn Allen screws no. 10 equally accord- ingly.

  • Page 190
    Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) Pulley Alignment and Drive Belt Deflection Refer to PULLEY DISTANCE AND ALIGNMENT 05-05 and DRIVE BELT 05-02 to perform adjust- ments. CAUTION Drive belt and pulley adjustments must always be checked whenever pulleys have been re- moved, replaced or disassembled.

  • Page 191: Pulley Distance And Alignment

    Section 05 TRANSMISSION Subsection 05 (PULLEY DISTANCE AND ALIGNMENT) PULLEY DISTANCE AND ALIGNMENT GENERAL GENERAL PROCEDURE The pulley distance we will refer to in this section, Remove belt guard and drive belt. is the space separating the drive and driven pulley By turning and pushing the sliding half, open the outside diameters (Z measurement).

  • Page 192: Pulley Alignment And Distance Specifications Chart

    Section 05 TRANSMISSION Subsection 05 (PULLEY DISTANCE AND ALIGNMENT) Refer to chart below for proper alignment tem- Drive Belt Deflection plate. NOTE: When pulley distance and alignment are adjusted to specifications, refer to DRIVE BELT 05-02 to adjust drive belt deflection. CAUTION This section deals mainly with adjustment procedures.

  • Page 193
    Section 05 TRANSMISSION Subsection 05 (PULLEY DISTANCE AND ALIGNMENT) S-Series Pulley Distance Adjustment Method Engine Movement The engine support has slotted mounting holes. Move engine to obtain specified distance be- tween pulleys. Pulley Alignment Method Driven Pulley Movement When engine slotted mounting holes do not allow to set proper pulley offset X, adjust with shims (P/N 504 1082 00) between pulley and counter- shaft bearing support (pulley pushed toward…

  • Page 194: Brake

    Section 05 TRANSMISSION Subsection 06 (BRAKE) BRAKE HYDRAULIC DISC BRAKE S-Series Loctite Anti-seize lubricant Black Max MX Z 440, Formula 500/500 DL/583 DL, Summit 500/583 and All models except GT 500/583 only MX Z 440, Formula 500/500 DL/583 DL, Summit 500/583 and Anti-seize lubricant GT 500/583 A03D2DT…

  • Page 195: Removal

    Section 05 TRANSMISSION Subsection 06 (BRAKE) REMOVAL COUNTERSHAFT REMOVAL S-Series BRAKE DISC REMOVAL Proceed the same as for brake disc removal but S-Series unlock bearing collar no. 18 on driven pulley side. Brake disc can be withdrawn without removing caliper. Proceed as follows: –…

  • Page 196: Disassembly

    Section 05 TRANSMISSION Subsection 06 (BRAKE) Pull bearing to driven pulley side out of counter- DISASSEMBLY shaft, using remover (P/N 529 0301 00). Begin Only brake pads are available as spare parts. If cal- with only the remover then add a spacer of differ- iper or master cylinder are damaged, replace each ent width as the bearing comes out.

  • Page 197: Assembly

    Section 05 TRANSMISSION Subsection 06 (BRAKE) 17, Brake Disc 7, Brake Pad Check for scoring, cracking or heat discoloration, After brake pads installation, brake disc must be replace as required. centered in caliper. Apply brake then check for proper brake disc positioning. CAUTION Push on appropriate caliper piston in order to move pad inward allowing proper brake disc posi-…

  • Page 198: Adjustment

    Section 05 TRANSMISSION Subsection 06 (BRAKE) ADJUSTMENT Install a hose on left side bleeder. Route this hose to a container. Countershaft Bearing Pump a few times brake lever and while holding brake lever depressed, open bleeder and check S-Series for air to escape. Insert countershaft (with brake disc) from chain- Repeat with the same bleeder until no air appears case side through countershaft support (driven…

  • Page 199: Chaincase

    Section 05 TRANSMISSION Subsection 07 (CHAINCASE) CHAINCASE S-Series without Reverse Gear Loctite Chaincase 45 to 75 N•m (33 to 55 lbf•ft) Loctite 46 N•m (34 lbf•ft) Loctite Loctite SYNTHETIC CHAINCASE OIL HUILE SYNTHÉTIQUE POUR CARTER A03D2OS PARTS FLAT RATE 05-07-1…

  • Page 200: Removal

    Section 05 TRANSMISSION Subsection 07 (CHAINCASE) REMOVAL INSPECTION To remove chaincase proceed as follows. Visually inspect the chain for cracked, damaged or missing links. Check for worn or defective bear- Remove tuned exhaust pipe and muffler. ings, sprockets and chain tensioner components. WARNING WARNING Never remove exhaust components when…

  • Page 201: Drive Chain Adjustment

    Section 05 TRANSMISSION Subsection 07 (CHAINCASE) 5,16, Sprockets 18, Circlip Position the sprockets with the writing facing the CAUTION chaincase cover. It is of the utmost importance to install the 27, Conical Spring Washer circlip otherwise damage to the chaincase Install washer with its concave side towards drive components may occur.

  • Page 202: Adjustment

    Section 05 TRANSMISSION Subsection 07 (CHAINCASE) A03A03A TYPICAL 1. Dipstick NOTE: Chaincase must be in its proper position when checking oil level. ADJUSTMENT Pulley Alignment Refer to PULLEY DISTANCE AND ALIGNMENT 05-05. Track Tension and Alignment Refer to TRACK 07-06. 05-07-4…

  • Page 203: Gearbox

    Section 05 TRANSMISSION Subsection 08 (GEARBOX) GEARBOX 3-SPEED GEARBOX Skandic WT/SWT/WT LC Loctite 242 Loctite Loctite A29D0KS PARTS FLAT RATE 05-08-1…

  • Page 204: Removal

    Section 05 TRANSMISSION Subsection 08 (GEARBOX) REMOVAL Drain gearbox oil. A29D0NA 1. RH end bearing Unbolt gearbox from chassis. A29D0LA 1. Bottom pan drain hole nearby gearbox drain plug Remove belt guard, drive belt. Remove air silenc- er, carburetor(s) then, driven pulley. Remove brake caliper, brake disc.

  • Page 205
    Section 05 TRANSMISSION Subsection 08 (GEARBOX) A29D0PA 1. RH side driven pulley side 2. LH side brake disc side Remove dipstick no. 17. Unfasten cover no. 2 from gearbox housing. Remove nut no. 3 retaining pin no. 6. A29D0RA 1. Pin Completely remove shaft no.
  • Page 206
    Section 05 TRANSMISSION Subsection 08 (GEARBOX) Remove all circlips no. 9. A29D0VA A29D0TA IMPORTANT: Note all shims quantity and loca- tion. Remove brake shaft oil seal then, circlip. A29D0WA Remove sleeve no. 23. NOTE: Brake shaft gears remain in gearbox hous- ing.
  • Page 207
    Section 05 TRANSMISSION Subsection 08 (GEARBOX) A29D0ZA 1. Sleeve dog not touching right gear 2. Brake shaft gears are still in gearbox Use a puller to extract LH reverse shaft bearing. A29D0XA Drive reverse shaft no. 38 out until its LH side bearing is free.
  • Page 208
    Section 05 TRANSMISSION Subsection 08 (GEARBOX) A29D11A A29D13A 1. Circlip Use a puller to extract bearing no. 12. 2. Sliding sleeve Use a puller to extract bearing no. 19. A29D14A Remove circlip then, gear no. 14. Now driven pul- A29D12A ley shaft can be pulled out from gearbox.
  • Page 209
    Section 05 TRANSMISSION Subsection 08 (GEARBOX) A29D16A 1. Sliding sleeve 2. Spring 3. Balls A29D19A 1. Spacer A29D17A DRIVEN PULLEY SHAFT COMPONENTS Remove screws no. 16 from intermediate shafts no. 30. Fasten a long M8 x 1.25 screw in axle end then drive it out, beginning with top one.
  • Page 210
    Section 05 TRANSMISSION Subsection 08 (GEARBOX) Do not disassemble bearings of intermediate gears needlessly. Pry out bottom seal no. 33 from gearbox housing. Remove sleeve no. 32 then, circlip no. 9. A29D1DA Using a press, drive out lower shaft no. 36 from RH side.

  • Page 211: Inspection

    Section 05 TRANSMISSION Subsection 08 (GEARBOX) INSPECTION Check bearing condition. There must be no discol- oration, missing rollers or balls, broken cages, etc. Check sprocket teeth. ASSEMBLY Install lower gear no. 34 with its shoulder facing RH side. A29D1GA Install intermediate gears no. 29 with their shoul- der towards LH side.

  • Page 212
    Section 05 TRANSMISSION Subsection 08 (GEARBOX) Install brake shaft no. 26 into gearbox then, loose- ly install gear no. 22 with its shoulder facing bear- ing no. 21. Do not push brake shaft into bearing no. 21 at this time. Install reverse shaft ass’y no.
  • Page 213
    Section 05 TRANSMISSION Subsection 08 (GEARBOX) Position gear no. 22 against bearing RH side bear- Install balls no. 18 and spring no. 16 into driven ing no. 19 then, finalize brake shaft no. 26 inser- pulley shaft. tion. A29D1NA 1. Push on ball with a screwdriver then move sliding sleeve to the right Finalize driven pulley shaft insertion.

  • Page 214: Installation

    Section 05 TRANSMISSION Subsection 08 (GEARBOX) A29D1OA READY TO INSTALL BEARINGS, SHIMS, CIRCLIPS AND PLUGS INSTALLATION Reverse removal procedure. Check pulley align- ment. A29D0IA 1. Full level mark OIL LEVEL 2. Lower level mark To fill, remove filler plug from top of transmission. To check, pull dipstick.

  • Page 215: 2-Speed Gearbox

    Section 05 TRANSMISSION Subsection 08 (GEARBOX) 2-SPEED GEARBOX Grand Touring 500/583 Grease Loctite 15 N•m (133 lbf•in) Grease 48 N•m (35 lbf•ft) Loctite 29 N•m (21 lbf•ft) 5 N•m Loctite (44 lbf•in) Loctite A03D17S PARTS FLAT RATE 05-08-13…

  • Page 216: Disassembly

    Section 05 TRANSMISSION Subsection 08 (GEARBOX) DISASSEMBLY First remove 19-tooth reverse gear no. 18 and then remove reverse axle no. 20. NOTE: It is possible to see the sliding gear in mo- tion through oil gauge hole. Unbolt gear shift linkage from shifter. Unscrew cover screws no.

  • Page 217
    Section 05 TRANSMISSION Subsection 08 (GEARBOX) Do not reuse removed oil seals. Replace them Install shim no. 13, 22-tooth sprocket (drive) with new ones. no. 12 and washer no. 11 then tighten castellated nut no. 10 and conical spring washer. Secure with Install drive axle with track then bearing and circlip a new cotter pin.

  • Page 218: Adjustment

    Section 05 TRANSMISSION Subsection 08 (GEARBOX) 5,7,8, Screws and Locking Tab Tighten screws in a criss-cross sequence starting with the one above reverse axle. Install reverse axle screw and bend locking tab against screw head flat. Bolt shift linkage to shifter. ADJUSTMENT 28, Chain Fully tighten adjustment screw by hand, then…

  • Page 219: Oil Change

    Section 05 TRANSMISSION Subsection 08 (GEARBOX) A06D1QA OIL CHANGE Place a container under bottom pan (gearbox A03A03A side). 1. Dipstick Unbolt gear shift linkage from fork axle. Unbolt and remove cover by separating it from housing Shifter can be put in reverse position to ease re- and by moving it toward the front in order to re- moval of dipstick.

  • Page 220: Drive Chain

    Section 05 TRANSMISSION Subsection 09 (DRIVE CHAIN) DRIVE CHAIN SILENT CHAIN For 1998 there are 2 types of silent chain. One is 11-plate wide and the other (stronger) is 13-plate wide. Do not interchange sprockets. Fit chain on sprockets to make sure using right ones accord- ing to width.

  • Page 221: Electrical

    Section 06 ELECTRICAL Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS IGNITION TIMING ……………………. 06-02-1 DUCATI CDI SYSTEM………………….06-02-1 NIPPONDENSO TRIGGER COIL SYSTEM……………. 06-02-4 SPARK PLUGS……………………06-03-1 NGK SPARK PLUG………………….06-03-1 NGK SPARK PLUG NUMBERING SYSTEM …………..06-03-1 REFERENCE CHART ………………….06-03-1 DESIGN SYMBOLS USED IN NGK SPARK PLUGS…………

  • Page 222
    Section 06 ELECTRICAL Subsection 01 (TABLE OF CONTENTS) CLEANING AND INSPECTION ………………06-05-6 CLEANING …………………….. 06-05-6 INSPECTION ……………………06-05-6 SOLENOID SWITCH ………………….06-05-8 STARTER REMOVAL ………………….06-05-10 STARTER DISASSEMBLY ………………..06-05-10 CLEANING …………………….. 06-05-11 PARTS INSPECTION………………….06-05-11 STARTER ASSEMBLY ………………….06-05-12 STARTER INSTALLATION ………………..

  • Page 223: Ignition Timing

    Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) IGNITION TIMING DUCATI CDI SYSTEM 443 and 503 Engine Types Proper ignition timing is determined by trigger coil position. If for any reason, ignition timing accuracy is sus- pected, it can be checked as follows. Verifying Magneto Flywheel Timing Mark Position Prior to checking the timing, it may be necessary…

  • Page 224
    Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) 4. Locate the piston TDC position as follows: a. Slowly rotate the magneto flywheel back and forth across TDC while observing the needle. Note that the needle stops moving only as the piston is changing direction. b.
  • Page 225
    Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) 2. Start the engine and raise the engine speed to at least 2000 RPM while observing the timing marks, refer to illustration. The magneto fly- wheel mark scribed previously and the crank- case arrow should be perfectly aligned. If the marks do not align, a faulty trigger coil (check proper grounding of coil) or a faulty CDI module could be the cause: substitute one part at a…

  • Page 226: Nippondenso Trigger Coil System

    Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) NIPPONDENSO TRIGGER COIL SYSTEM 494, 583, and 670 Engine Types Ignition timing is adjusted by movement of trigger coil. On 583 engine raising position of trigger coil retards ignition. Lowering position of trigger ad- vances ignition.

  • Page 227
    Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) 5. Verify the position of the timing mark on the magneto flywheel as follows: NOTE: When checking timing, certain procedures require that the magneto flywheel be turned in a clockwise direction, viewed facing the magneto. If it is necessary to turn back (counterclockwise) for any reason, rotate the magneto flywheel at least 1/4 turn counterclockwise, and then rotate it…
  • Page 228
    Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) NOTE: These marks cannot be used to check dy- namic (with engine running) ignition timing with a timing light: another mark is scribed on magneto flywheel or damper for this purpose. When fly- wheel protrusion dot aligns with center of trigger coil core, flywheel mark and crankcase center mark must be aligned.

  • Page 229: Spark Plugs

    Section 06 ELECTRICAL Subsection 03 (SPARK PLUGS) SPARK PLUGS NGK SPARK PLUG All Models NGK SPARK PLUG NUMBERING SYSTEM Bombardier uses NGK brand spark plugs on all its snowmobile models. The heat range identification system is: Low number hot plug High number cold plug REFERENCE CHART…

  • Page 230: Design Symbols Used In Ngk Spark Plugs

    Section 06 ELECTRICAL Subsection 03 (SPARK PLUGS) DESIGN SYMBOLS USED IN NGK SPARK PLUGS PREFIX SUFFIX WIDE GAP 10: 1.0 mm (.040″) 11: 1.1 mm (.044″) B R 9 E S 13: 1.3 mm (.050″) 14: 1.4 mm (.055″) 15: 1.5 mm (.060″) 20: 2.0 mm (.080″) Thread Heat rating…

  • Page 231: Disassembly

    Section 06 ELECTRICAL Subsection 03 (SPARK PLUGS) DISASSEMBLY CAUTION First unscrew the spark plug 1 turn. Severe engine damage might occur if a Clean the spark plug and cylinder head with pres- wrong heat range plug is used. surized air, then completely unscrew. A too hot plug will result in overheating and pre- WARNING ignition, etc.

  • Page 232: Spark Plug Installation

    Section 06 ELECTRICAL Subsection 03 (SPARK PLUGS) SPARK PLUG INSTALLATION Prior to installation make sure that contact surfac- es of the cylinder head and spark plug are free of grime. 1. Using a wire feeler gauge, set electrode gap ac- cording to TECHNICAL DATA 10.

  • Page 233: Battery

    Section 06 ELECTRICAL Subsection 04 (BATTERY) BATTERY REMOVAL Unfasten retaining strips. Open strips and lift battery protective boot. All Models Remove vent tube. WARNING Battery BLACK negative cable must always be disconnected first and connected last. WARNING Never charge or boost battery while in- stalled on vehicle.

  • Page 234: Inspection

    Section 06 ELECTRICAL Subsection 04 (BATTERY) HYDROMETER TEST A17E0LA 1. Baking soda A17E0JA Remove corrosion from battery cable terminals 1. Specific gravity 1.260 and battery posts using a firm wire brush. A hydrometer measures the charge of a battery in terms of specific gravity of the electrolyte.

  • Page 235: Battery Storage

    Section 06 ELECTRICAL Subsection 04 (BATTERY) EXAMPLE NO. 1 Clean battery terminals and cable connections us- Temperature below 27°C (80°F): ing a wire brush. Apply a light coat of dielectric Hydrometer Reading: 1.250 grease (P/N 413 7017 00) or petroleum jelly on ter- Electrolyte temperature: −7°C (20°F) minals.

  • Page 236
    Section 06 ELECTRICAL Subsection 04 (BATTERY) 5. Readjust the electrolyte level to the UPPER LEVEL line. A17E0FA 1. Battery electrolyte A17E0RA 2. Remove caps and fill battery to UPPER LEVEL 1. Battery electrolyte line with electrolyte (specific gravity: 1.260 at 20°C (68°F)).
  • Page 237
    Section 06 ELECTRICAL Subsection 04 (BATTERY) 7. Disconnect battery charger. 10. Allow gas bubbles to escape by lightly shake battery. A17E0IB A17E0HA 8. Test battery state of charge. Use a hydrometer. 11. Readjust electrolyte level. A17E0JA 1. Specific gravity 1.260 9.

  • Page 238: Servicing

    Section 06 ELECTRICAL Subsection 04 (BATTERY) – State of charge: Because the electrolyte is CAUTION nearly pure water in a completely discharged battery, it cannot accept current as well as elec- Do not allow cleaning solution to enter battery trolyte. This is the reason the battery will not interior since it will destroy the electrolyte.

  • Page 239: Battery Charging Equipment

    Section 06 ELECTRICAL Subsection 04 (BATTERY) – If the charging current is not up to a measurable For a service application and a permanent installa- amount at the end of about 10 hours, the bat- tion, both ammeter and rheostat can be built into tery should be replaced.

  • Page 240
    Section 06 ELECTRICAL Subsection 04 (BATTERY) Apply silicone dielectric grease (P/N 413 7017 00) on battery posts and connectors. A03H1SA BATTERY CONNECTION 1. Vent tube on fitting Ensure that vent tube is not kinked or blocked then install protective boot over battery. Close and fasten retaining strips.

  • Page 241: Electric Starter

    Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) ELECTRIC STARTER S-Series with Electric Starting and Skandic WT/SWT A03E13S PARTS FLAT RATE 06-05-1…

  • Page 242: Removal

    Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) REMOVAL Check the wear on bushing no. 18 by measuring the amount of radial play between the armature – Disconnect BLACK ground cable from battery. shaft and the bushing. – Disconnect RED positive cable from battery. The radial play should not exceed 0.20 mm (.008 in).

  • Page 243
    Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) Install bushing cover no. 19 then, using a punch, stake bushing cover in place. A19E05A 1. Cut close to connector Remove burrs with a file on the remaining welded portion. A19E02A 1. Stake bushing cover CAUTION 2.

  • Page 244: Cleaning And Inspection

    Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) CLEANING AND INSPECTION Refer to the end of this subsection. ASSEMBLY Prior to assembling, coat sliding surfaces and moving parts on armature shaft splines, overrun- ning clutch, solenoid switch plunger, drive lever and bushings with G.E. Versilube G 321 (P/N 413 7040 00) lubricant.

  • Page 245: Installation

    Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) A19E09A 1. Shorter stud 2. Bare wire INSTALLATION Make sure that starter and engine mating surfac- A09E0PA es are free of grime. Serious trouble may arise if 1. Screwdriver pulling starter pinion starter is not properly aligned. 2.

  • Page 246: Cleaning And Inspection

    Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) CLEANING AND INSPECTION CLEANING CAUTION Armature starter yoke ass’y and drive unit assembly must not be immersed in cleaning solvent. Clean brushes and holder with a clean cloth F01H0RA soaked in solvent. Brushes must be dried thor- 1.

  • Page 247
    Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) Field Windings and Brushes Test the Field Winding for Open Circuit: Use growler test probes. Place one test probe on the negative brush and the other test probe on the yoke. If growler lamp does not turn on, the field winding has an open-circuit.

  • Page 248: Solenoid Switch

    Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) A03E05A TYPICAL 1. New 2. Wear limit Overrunning Clutch The pinion of the overrunning clutch should turn smoothly in a clockwise direction, and should not slip in a counterclockwise direction. If defective, replace. Check the pinion teeth for wear and damage.

  • Page 249
    Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) Skandic WT LC 5 N•m (44 lbf•in) Dielectric grease Loctite 271 Ground cable 22 N•m Dielectric grease (16 lbf•ft) A29E09S PARTS FLAT RATE 06-05-9…

  • Page 250: Starter Removal

    Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) STARTER REMOVAL Disconnect BLACK cable ground connection from battery. WARNING Always disconnect ground cable first and re- connect last. Remove tuned pipe. Cut locking tie retaining cable to starter. F01H0PA TYPICAL 1. Trace indexing marks Remove starter support nuts then through bolts.

  • Page 251: Cleaning

    Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) CLEANING CAUTION Yoke ass’y and drive unit assembly must not be immersed in cleaning solvent. Discard all O-rings and gasket. F01H0RA Clean brushes and holders with a clean cloth soaked in solvent. Brushes must be dried thor- 1.

  • Page 252: Starter Assembly

    Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) A03E05A A03E0EA 1. New 1. Armature shaft 2. Wear limit, 8.5 mm (.335 in) 2. Circlip 3. Pinion stop collar 4. Punch Overrunning Clutch 1,10, Housing and Yoke Ass’y Pinion of overrunning clutch should turn smoothly in a clockwise direction, and should not slip in a Align previously traced indexing marks.

  • Page 253: Starter Installation

    Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) F01H0SA 1. Locating protrusion is the higher one F01H0UA Step : Retaining brush holder with a screwdriver Step : Align here Align end frame notch with brush holder notch/ yoke protrusion. CAUTION F01H0TA 1.

  • Page 254: Testing Procedure

    Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) TESTING PROCEDURE GENERAL The following chart gives the engine types with their implemented system. CHARGING ENGINE IGNITION SYSTEM TYPE SYSTEM OUTPUT NIPPONDENSO 494, 583 (CDI) and 670 TRIGGER COIL 443 and 503 DUCATI (CDI) CDI System Identification Nippondenso The NIPPONDENSO CDI system has a separate…

  • Page 255
    Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) A17E0TA DUCATI CDI SYSTEM 1. Combined ignition module/ignition coil mounted on air silencer below carburetor 2. Two-wire connector (GREEN and WHITE wires) 06-06-2…

  • Page 256: Nippondenso Cdi System Testing

    Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) NIPPONDENSO CDI SYSTEM TESTING S-Series Liquid Cooled Models and Skandic Resistance Readings WT LC Place multimeter selector switch to Ω in order to measure resistance. Readings must be within the IGNITION SYSTEM TESTING indicated range.

  • Page 257: Ignition Switch, Tether Cord Switch And Emergency Switch Testing

    Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) 3. IGNITION SWITCH, TETHER If readings do not correspond to the above-mentioned indications, replace switch. CORD SWITCH AND If readings are acceptable, check other switches. EMERGENCY SWITCH TESTING Emergency Switch Disconnect connector housing from engine and Unplug switch block connected to main wiring check resistance as indicated in IGNITION table.

  • Page 258: Ignition Generator Coil Voltage Testing

    Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) 5. Compare readings with those appearing in the IGNITION table. 5. IGNITION MODULE VOLTAGE TESTING 1. Disconnect the 2-wire connector between module and high voltage coil. 2. Connect multimeter probes to module. Place V ˜…

  • Page 259: Conclusion

    Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) A05E0DA A05E0EA 6. Compare readings with those appearing in the 5. Compare readings with those appearing in the IGNITION table. LIGHTING table. CONCLUSION CONCLUSION If none of the above testing operations produced If none of the above testing operations produced valid results, it is strongly recommended to keep valid results, it is strongly recommended to keep on testing according to the list appearing in the…

  • Page 260
    Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) IGNITION SYSTEM TESTING (S-Series liquid cooled models and Skandic WT LC) Resistance Ω Voltage V Multimeter Test to be Wire Part probe Note Value Multimeter Value Multimeter performed color connection (Ohms) scale (Volts) scale Stop switch 2-01C-F…
  • Page 261
    Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) NOTE: Stop switches include the ignition switch, the tether cord switch and the emergency cut-out switch. It is important to take note that voltage measurements must be taken while starting the vehicle using the manual starter.

  • Page 262: Ducati Cdi System Testing

    Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) DUCATI CDI SYSTEM TESTING S-Series and Skandic WT/SWT Resistance Readings Place multimeter selector switch to Ω in order to IGNITION SYSTEM TESTING measure resistance. Readings must be within the SEQUENCE indicated range. Otherwise, the part is considered to be defective and must be replaced.

  • Page 263: Ignition Switch, Tether Cord Switch And Emergency Switch Testing

    Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) 3. IGNITION SWITCH, TETHER If readings do not correspond to the above-men- tioned indications, replace switch. CORD SWITCH AND If readings are acceptable, check other switches. EMERGENCY SWITCH TESTING Emergency Switch Disconnect connector housing 2-01 from engine, Unplug switch block connected to main wiring and using a multimeter, check resistance as indi- harness.

  • Page 264: Ignition Generator Coil Voltage Testing

    Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) 4. Repeat operation 3 times. A05E09A TYPICAL If readings do not correspond to the above men- A03E1JA tioned indications, replace switch. 5. Compare readings with those appearing in the If readings are acceptable, check other switches. IGNITION table.

  • Page 265: Conclusion

    Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) LIGHTING GENERATOR COIL VOLTAGE TESTING NOTE: The lighting generator coil is not part of the ignition system. It is a self-contained system used to supply current to the lighting system and to other devices working on alternating current. However, this system can be tested using a mul- timeter.

  • Page 266
    Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) IGNITION SYSTEM TESTING (fan-equipped S-Series and Skandic WT/SWT) Resistance Ω Voltage V Multimeter Test to be Wire Part probe Note Value Multimeter Value Multimeter performed color connection (Ohms) scale (Volts) scale Stop switch 2-01-D-M Running BK and…
  • Page 267
    Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) LIGHTING SYSTEM TESTING (fan-equipped S-Series and Skandic WT/SWT) Resistance Ω Voltage V Multimeter Test to be Wire Part probe Note Value Multimeter Value Multimeter performed color connection (Ohms) scale (Volts) scale Lighting 2-01-B-F YL and 00.0 generator…

  • Page 268: Inspection Of Ac Circuit Isolation

    Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) INSPECTION OF AC CIRCUIT ISOLATION All Electric Start Models If AC circuit is not isolated from frame, headlamp beam will weaken. INSPECTION Disconnect regulator/rectifier. Connect one digital ohmmeter probe (needle ohmmeter will not offer enough precision) to frame and other probe to one of 2 YELLOW mag- neto wires.

  • Page 269: Inspection Of Heating Elements

    Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) INSPECTION OF HEATING ELEMENTS All Models Except Skandic WT/SWT/WT LC All measurements must be performed at 21°C (70°F). Throttle Lever Heating Element Resistance Measurement HIGH YELLOW BLACK wire 1.96 to INTENSITY 3.64 ohms BROWN wire YELLOW BLACK wire…

  • Page 270: Rear Suspension

    Section 07 REAR SUSPENSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS SC-10 SUSPENSIONS (ALL VERSIONS) …………….07-02-1 COMPONENT REMOVAL AND INSTALLATION ………….. 07-02-5 REMOVAL……………………… 07-02-7 DISASSEMBLY AND ASSEMBLY ………………07-02-8 SHOCK ABSORBER INSPECTION ………………07-02-10 INSTALLATION ……………………07-02-11 RIDE ADJUSTMENT………………….07-02-11 LUBRICATION ……………………

  • Page 271: Suspensions (All Versions)

    Section 07 REAR SUSPENSION Subsection 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) SC-10 SUSPENSIONS (ALL VERSIONS)0 SC-10 Sport on MX Z 440 and Formula 500/500 DE LUXE/583 DE LUXE temp. grease Loctite Loctite Loctite Loctite Loctite Loctite A03F26S PARTS FLAT RATE 07-02-1…

  • Page 272
    Section 07 REAR SUSPENSION Subsection 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) SC-10 High-performance on Formula Z 583 and Grand Touring 583 SC-10 Cross-country on MX Z 583/670 Front temp. grease Loctite Loctite Loctite Loctite Loctite A03F28S PARTS FLAT RATE 07-02-2…
  • Page 273
    Section 07 REAR SUSPENSION Subsection 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) SC-10 Mountain on Summit 500/583/670 Loctite Loctite temp. grease Loctite Loctite Loctite Loctite Loctite A03F29S PARTS FLAT RATE 07-02-3…
  • Page 274
    Section 07 REAR SUSPENSION Subsection 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) SC-10 Touring on Grand Touring 500 Loctite Loctite temp. grease Loctite Loctite Loctite Loctite Loctite A03F2AS PARTS FLAT RATE 07-02-4…

  • Page 275: Component Removal And Installation

    Section 07 REAR SUSPENSION Subsection 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) COMPONENT REMOVAL AND INSTALLATION Lift rear of vehicle and support it off the ground. 21, Rear Axle Completely loosen track tension. Unscrew one rear idler wheel screw. Pull out rear axle from opposite side of offset in- ner wheel.

  • Page 276
    Section 07 REAR SUSPENSION Subsection 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) 25, ACM Support CAUTION Remove threaded rod ass’y. Loosen rear axle screw on one side and rear shackle screws. Take care not to damage grease fitting. Unbolt ACM support and remove it. Remove cup.

  • Page 277: Removal

    Section 07 REAR SUSPENSION Subsection 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) All Models Remove locking rings (spacers on fan cooled models) and top idler wheels. Remove springs. A03F0TA RH SIDE SHOWN Lift rear of vehicle and support it off the ground. Loosen track tension.

  • Page 278: Disassembly And Assembly

    Section 07 REAR SUSPENSION Subsection 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) 6, Screw 11, Axle Remove both screws retaining front arm to tun- Note position of axles at disassembly. Axles with nel. a paint stripe serve as idler wheel axles. These are more precise than those used as pivot axles.

  • Page 279
    Section 07 REAR SUSPENSION Subsection 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) At installation, cap opening must be 180° from spring stopper opening. A01F2MA TYPICAL 1. Slider shoe A03F12A 2. Molding line (this line is not the wear limit) 1. Cap opening A.

  • Page 280: Shock Absorber Inspection

    Section 07 REAR SUSPENSION Subsection 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) SHOCK ABSORBER INSPECTION Install shock in a vise clamping on its bottom eye- let with its rod upward. All Models Equipped with Hydraulic Shock Let it stand for 5 minutes. NOTE: Hydraulic shocks are painted black or dark Completely push down the shock rod then re- gray.

  • Page 281: Installation

    Section 07 REAR SUSPENSION Subsection 02 (SC-10 SUSPENSIONS (ALL VERSIONS)) INSTALLATION Install assembled suspension into track with front portion first. Insert rear portion of suspension into track. Bolt front arm, rear arm then center top idler wheel axle. Adjust track tension. RIDE ADJUSTMENT Refer to Operator’s Guide .

  • Page 282: Formula Z 670 Suspension

    Section 07 REAR SUSPENSION Subsection 03 (FORMULA Z 670 SUSPENSION) FORMULA Z 670 SUSPENSION Formula Z 670 105 N•m (77 lbf•ft) 48 N•m (35 lbf•ft) 48 N•m (35 lbf•ft) 24 N•m (18 lbf•ft) 2.5 N•m (22 lbf•in) 135 N•m (100 lbf•ft) Loctite 271 48 N•m (35 lbf•ft) A03F2XT…

  • Page 283: Component Removal And Installation

    Section 07 REAR SUSPENSION Subsection 03 (FORMULA Z 670 SUSPENSION) COMPONENT REMOVAL AND INSTALLATION 1,2, Shock and Spring Lift swing arm to facilitate long torque rod nut removal. A03F2YS 1. Lift 07-03-2…

  • Page 284
    Section 07 REAR SUSPENSION Subsection 03 (FORMULA Z 670 SUSPENSION) When reinstalling, push circlip into its groove. CAUTION Outer top idler wheels no. 4 must be mount- ed on their shaft with the mention THIS SIDE OUT facing outside. Center wheel circlip must face left side.
  • Page 285
    Section 07 REAR SUSPENSION Subsection 03 (FORMULA Z 670 SUSPENSION) 4, Top Idler Wheel Axle When assembling, the hollow side of small torque rod no. 6 must face inner side. A03F34A 1. Hollow side A01B4LA Note position of all 6 friction washers. There is TYPICAL one each side of long tie rod no.
  • Page 286
    Section 07 REAR SUSPENSION Subsection 03 (FORMULA Z 670 SUSPENSION) 7, Swing Arm Remove both shock/springs, strap axle, long spac- er then M14 screws. When assembling, both arms must run parallel. Tighten nuts to 48 N•m (35 lbf•ft). A03F36A 1. Parallel A.
  • Page 287
    Section 07 REAR SUSPENSION Subsection 03 (FORMULA Z 670 SUSPENSION) Remove rear axle idler wheel. A03F3BA Unscrew remaining axles. 07-03-6…
  • Page 288
    Section 07 REAR SUSPENSION Subsection 03 (FORMULA Z 670 SUSPENSION) A03F3DS When assembling, both rails must run parallel. Tighten nuts to 24 N•m (18 lbf•ft). A03F38S 1. Parallel A. 24 N•m (18 lbf•ft) 07-03-7…
  • Page 289
    Section 07 REAR SUSPENSION Subsection 03 (FORMULA Z 670 SUSPENSION) 8, Slider Shoe Apply BOMBARDIER LUBE (P/N 293 6000 16 — 12 x 14 oz) on rail surface. This will ease new slid- Remove screw retaining slider shoe to rail front er shoe installation.

  • Page 290: Inspection

    Section 07 REAR SUSPENSION Subsection 03 (FORMULA Z 670 SUSPENSION) Minimum thickness must be 2 mm (.080 in). A03F3EA 1. Screw in bushing hole INSPECTION A01F2MA TYPICAL Shock Absorber 1. Slider shoe 2. Molding line (this line is not the wear limit) Refer to SUSPENSION AND SKI SYSTEM 08-03 A.

  • Page 291: Installation

    Section 07 REAR SUSPENSION Subsection 03 (FORMULA Z 670 SUSPENSION) INSTALLATION CAUTION Before installing suspension, small torque rod no. 5 and strap axle lever must be “bent” down- ward. A03F2YT 1. Torque rod and lever “bent” downward 07-03-10…

  • Page 292: Ride Adjustment

    Section 07 REAR SUSPENSION Subsection 03 (FORMULA Z 670 SUSPENSION) RIDE ADJUSTMENT Refer to Operator’s Guide . LUBRICATION Lubricate front axle, strap axle and swing arm lower axle using synthetic grease (P/N 413 7115 00). A03F2YU 07-03-11…

  • Page 293: Skandic Wt Suspension

    Section 07 REAR SUSPENSION Subsection 04 (SKANDIC WT SUSPENSION) SKANDIC WT SUSPENSION Skandic WT/SWT/WT LC A22F18T TYPICAL PARTS FLAT RATE 07-04-1…

  • Page 294: Removal

    Section 07 REAR SUSPENSION Subsection 04 (SKANDIC WT SUSPENSION) REMOVAL Release track tension. Lift rear of vehicle and support it off the ground. Unbolt front arm then rear arm. NOTE: To prevent cross shaft from turning when unscrewing screws assembled with threadlocker, proceed as follows: –…

  • Page 295: Shock Absorber Servicing

    Section 07 REAR SUSPENSION Subsection 04 (SKANDIC WT SUSPENSION) 4, Rear Spring Rivets can be substitued by M8 x 20 bolts and nuts. Remove top idler wheels. Unscrew one end of shock. 3, Horse-Shoe Washer Remove spring. For deep snow riding, do not install washer nor rubber stoppers.

  • Page 296: Installation

    Section 07 REAR SUSPENSION Subsection 04 (SKANDIC WT SUSPENSION) CAUTION Do not clamp directly on shock body. Examine each shock for leaks. Extend and com- press the piston several times over its entire stroke then check that it moves smoothly and with uniform resistance.

  • Page 297: Drive Axle

    Section 07 REAR SUSPENSION Subsection 05 (DRIVE AXLE) DRIVE AXLE S-Series Summit and MX Z 583/670 only A03D20T PARTS FLAT RATE 07-05-1…

  • Page 298
    Section 07 REAR SUSPENSION Subsection 05 (DRIVE AXLE) Skandic WT/SWT/WT LC A22D14S PARTS FLAT RATE 07-05-2…

  • Page 299: Removal

    Section 07 REAR SUSPENSION Subsection 05 (DRIVE AXLE) REMOVAL Remove drive axle. All Models Except Skandic WT/SWT/WT LC DISASSEMBLY Drain oil from chaincase or gearbox. Release drive 4, Speedometer Drive Insert chain tension. Remove chaincase cover. Raise and block rear of vehicle off the ground. Remove speedometer drive insert.

  • Page 300: Assembly

    Section 07 REAR SUSPENSION Subsection 05 (DRIVE AXLE) ASSEMBLY Skandic WT/SWT/WT LC 8,9,13, Drive Axle and Sprocket To assemble press fit sprockets, use a press and a suitable pipe as illustrated. Sprockets must be assembled according to the following dimen- sions.

  • Page 301: Axial Play

    Section 07 REAR SUSPENSION Subsection 05 (DRIVE AXLE) A00F0AA A00F0DA 1. Plane surface The bearing on the splined side of axle must be A. 1.5 mm (1/16 in) MAXIMUM pushed until it is seated on shaft shoulder. The end bearing housing bearing must be flush with CAUTION end of drive axle.

  • Page 302
    Section 07 REAR SUSPENSION Subsection 05 (DRIVE AXLE) BEARING POSITION TOWARD TOWARD TOWARD TOWARD FRONT REAR BOTTOM OF VEHICLE OF VEHICLE OF VEHICLE OF VEHICLE SHIM LOWER UPPER UPPER LOWER LOCATION This chart can be use as a “starting point” to cor- rect the chaincase perpendicularity.
  • Page 303
    Section 07 REAR SUSPENSION Subsection 05 (DRIVE AXLE) AXIAL PLAY ADJUSTMENT A01D09A 1. No gap all around – Pull drive axle toward the end bearing housing and take note of the measurement between sprocket and tunnel. A01D04A The drive axle axial play is the difference between TOP VIEW these 2 measurements.

  • Page 304: Installation

    Section 07 REAR SUSPENSION Subsection 05 (DRIVE AXLE) When installing shims between the chaincase and the drive axle bearing, there must be same quantity of shims between the drive chain sprock- et and spacer. A01D0AA 1. Distance between guide cleat and slider shoe 414 6053 00 2.

  • Page 305: Lubrication

    Section 07 REAR SUSPENSION Subsection 05 (DRIVE AXLE) ADJUSTMENT Sprocket/Track Alignment CAUTION Do not tamper with sprocket/track alignment if frame or suspension is damaged. Sprockets might be repositioned to fit lugs with- out removing drive axle. Use drive axle sprocket adjuster kit (P/N 861 7257 00).

  • Page 306: Track

    Section 07 REAR SUSPENSION Subsection 06 (TRACK) TRACK TRACK TYPE APPLICATION Skandic WT/SWT/WT LC Remove the following parts: Refer to TECHNICAL DATA section 10-03. – rear suspension GENERAL – muffler Drain gearbox. This section gives guidelines for track removal. Some components require more detailed disas- Remove drive axle then track.

  • Page 307
    Section 07 REAR SUSPENSION Subsection 06 (TRACK) Insert preset gauge between slider shoe and track. Allow gauge to settle by forcing track up and down. Track tension is as specified when edge of gauge reaches line. A19F05A TYPICAL 1. Retaining screw 2.
  • Page 308
    Section 07 REAR SUSPENSION Subsection 06 (TRACK) A01F05A 1. Guides 2. Slider shoes 3. Equal distance A19F05B WARNING TYPICAL 1. Retighten Before checking track alignment, ensure that the track is free of all particles which could Restart engine, rotate track slowly and recheck be thrown out while track is rotating.

  • Page 309: Table Of Contents

    Section 08 STEERING/FRONT SUSPENSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS STEERING SYSTEM ………………….08-02-1 INSPECTION ……………………08-02-4 DISASSEMBLY AND ASSEMBLY ………………08-02-4 INSPECTION ……………………08-02-5 ADJUSTABLE HANDLEBAR ………………… 08-02-7 STEERING ADJUSTMENT (SKIS) ………………08-02-8 LUBRICATION ……………………08-02-10 SUSPENSION AND SKI SYSTEM ………………08-03-1 DISASSEMBLY……………………

  • Page 310: Steering System

    Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) STEERING SYSTEM S-Series 25 N•m (18 lbf•ft) 40 N•m 10 N•m (30 lbf•ft) (89 lbf•in) 15 N•m (133 lbf•in) 18 N•m (159 lbf•in) 18 N•m (159 lbf•in) 52 N•m (38 lbf•ft) 40 N•m (30 lbf•ft) 40 N•m (30 lbf•ft)

  • Page 311
    Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) MX Z 670 10 N•m (89 lbf•in) 52 N•m (38 lbf•ft) Loctite 15 N•m (133 lbf•in) 18 N•m 52 N•m (159 lbf•in) (38 lbf•ft) 18 N•m (159 lbf•in) 52 N•m (38 lbf•ft) Loctite 48 N•m (35 lbf•ft)
  • Page 312
    Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) Skandic WT/SWT/WT LC 25 N•m (18 lbf•ft) A22G0KS TYPICAL PARTS FLAT RATE 08-02-3…

  • Page 313: Inspection

    Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) INSPECTION Check skis and runner shoes for wear, replace as necessary. (See section 08-03). 17, Steering Arm and Ski Leg Make sure steering arm and ski leg splines inter- lock. WARNING Any parts having worn splines have to be re- placed with new ones.

  • Page 314: Inspection

    Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) To install, stick the heating element to the handle- For proper torque specifications refer to the spe- bar making sure the wires do not interfere with cific exploded view for the vehicle being serviced. operation of the accelerator or brake handle.

  • Page 315
    Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) Skandic WT/SWT/WT LC Only Skandic WT/SWT/WT LC Only Install special washers (locking disks) with teeth Install steering arm at mid-travel position when facing each others. handlebar is facing straight ahead. A22G0MA A22G0LA 1.

  • Page 316: Adjustable Handlebar

    Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) ADJUSTABLE HANDLEBAR WARNING 1,3, Steering Column and Handlebar Make sure that the steering pad and all con- If applicable, remove the steering clamp and nuts trols are properly fixed to their normal loca- holding the handlebar to the steering column.

  • Page 317: Steering Adjustment (Skis)

    Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) STEERING ADJUSTMENT (SKIS) 13,14,15,22, Jam Nut, Tie Rod and Pivot Arm Definitions With handlebar in straight-ahead position, the TOE-OUT: center of the pivot arm must be in line with the end of the bolt. Loosen the jam nuts on tie rod A difference measured between the front edge of no.

  • Page 318
    Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) NOTE: The reference point must be the same rel- ative to each side. A06G05A 1. Angle finder Using special tool (P/N 529 0216 00) mounted to the ski leg, position the angle finder on the tool as shown in the following illustration.

  • Page 319: Lubrication

    Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) MX Z 670 Only All Models In order to ease steering tie rod loosening, detach To reduce tolerance when measuring, set one ski rubber boot from snowmobile frame. Refer to the to proper toe-out then measure from that ski to following photo.

  • Page 320
    Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) S-Series If so equipped If so equipped A06G08T PARTS FLAT RATE 08-02-11…

  • Page 321: Suspension And Ski System

    Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) SUSPENSION AND SKI SYSTEM S-Series Some models Loctite 29 N•m (21 lbf•ft) 25 N•m (18 lbf•ft) 80 N•m (59 lbf•ft) Loctite 35 N•m 40 N•m (26 lbf•ft) (29 lbf•ft) Some models 14 N•m (124 lbf•in)

  • Page 322: Disassembly

    Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) DISASSEMBLY 5, Shock Lift front of vehicle and support it off the ground. Reduce spring preload by turning adjusting ring accordingly with the adjustment wrench in vehi- cle tool box. A03F12A 1.

  • Page 323: Inspection

    Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) 7,8, Upper and Lower Half Arms Position half arms and tie rods horizontally before tightening nuts. 9,10,11, Bolt, Nut and Link Plate Attach link plate to frame with additional nuts and bolts, if applicable.

  • Page 324
    Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) Skandic WT/SWT/WT LC 13 N•m (115 lbf•in) Grease Skandic SWT only Skandic SWT only A22G0RS PARTS FLAT RATE 08-03-4…

  • Page 325: On-Vehicle Component Verification

    Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) ON-VEHICLE COMPONENT VERIFICATION 8, Shock Lift front of vehicle and support off the ground. Remove ski bolt and nut. Remove steel bushing from ski using a pusher. See pusher dimensions below. A22G0IA 1.

  • Page 326: Disassembly

    Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) A05G0CA 1. Allen screws A05G0DA NOTE: These washers and stopper can be wedged 1. Washers and stopper wedged in cover in cap. 2. Spring Pull out spring. 4,13,14,16,17, O-ring, Ski Leg, Bushing and Seal Suspension Free Operation Pull up ski leg.

  • Page 327: Inspection

    Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) INSPECTION Pay attention to the following conditions that will denote a defective shock: All Models – A skip or a hang back when reversing stroke at mid travel. 13, Ski Leg –…

  • Page 328
    Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) Skandic SWT Only Steering arm with the bent angle toward the bot- tom. A05G0CB TYPICAL — SKANDIC SWT ONLY 1. Bent angle toward the bottom 16,17, Seal All Models Install seal before reinstalling ski leg. 08-03-8…

  • Page 329: Body/Frame

    Section 09 BODY/FRAME Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS BODY……………………….09-02-1 INSTALLATION AND ADJUSTMENT …………….09-02-1 HEADLAMP BEAM AIMING………………..09-02-1 BULB REPLACEMENT ………………….. 09-02-1 DECAL ……………………..09-02-2 WINDSHIELD INSTALLATION………………. 09-02-2 HOOD ……………………..09-02-2 BELT GUARD ……………………09-02-3 WIRING HARNESS ………………….09-02-3 CABLES ……………………..

  • Page 330: Body

    Section 09 BODY/FRAME Subsection 02 (BODY) BODY INSTALLATION AND ADJUSTMENT HEADLAMP BEAM AIMING Required Conditions Place the vehicle on a flat surface perpendicular to Beam aiming is correct when center of high beam test surface (wall or screen) and 381 cm (12 ft 6 in) is 25 mm (1 in) below the headlamp horizontal away from it.

  • Page 331: Decal

    Section 09 BODY/FRAME Subsection 02 (BODY) DECAL To remove a decal; heat old decal with a heat gun and peel off slowly. Using isopropyl alcohol, clean the surface and dry thoroughly. Apply liquid soap to new decal and carefully posi- tion the decal.

  • Page 332: Belt Guard

    Section 09 BODY/FRAME Subsection 02 (BODY) BELT GUARD CABLES Disassembly and Assembly WARNING NOTE: For additional information (ex.: exploded view) refer to the corresponding Parts Catalog . Before installation, ensure that all cables are in perfect condition. Properly install the ca- ble ends and secure them in place.

  • Page 333: Plastic Maintenance And Repair

    Section 09 BODY/FRAME Subsection 02 (BODY) PLASTIC MAINTENANCE AND REPAIR MAINTENANCE CAUTION Clean the vehicle thoroughly, removing all dirt and Clean R.I.M. Metton ® with isopropyl alcohol grease accumulation. only. Never use cleaners or products con- To clean use a soft clean cloth and either soapy taining chlorine.

  • Page 334: Repair

    Section 09 BODY/FRAME Subsection 02 (BODY) REPAIR The very first step before repairing plastic materials is to find out exactly which type of material is in- volved. Refer to following chart. CAUTION Consult chart and repair kit instructions carefully, some repair products are not compatible with certain plastics.

  • Page 335: Material Repair Procedure

    Section 09 BODY/FRAME Subsection 02 (BODY) MATERIAL REPAIR PROCEDURE – Heat the surface with a heater lamp placed at 38 cm (15 in) for a period of 15 minutes. Fiberglass – Sand the surface using a smooth dry sand pa- per.

  • Page 336
    Section 09 BODY/FRAME Subsection 02 (BODY) Crest products used in R.I.M. repair procedure are available from following locations: CREST MAIN OFFICE AND MANUFACTURING PLANT CREST INDUSTRIES, INC. Phone: 313-283-4100 Toll Free: 1-800-822-4100 3841 13 Street Fax: 1-800-344-4461 Wyandotte, Michigan Fax: 313-283-4461 48192 DISTRIBUTOR WAREHOUSE LOCATIONS UNITED STATES…

  • Page 337: Frame

    Section 09 BODY/FRAME Subsection 03 (FRAME) FRAME FRAME CLEANING NOTE: For aluminum frames use only aluminum cleaner and follow instructions on container. (Dur- sol cleaner or equivalent). Clean frame and tunnel with appropriate cleaners and rinse with high pressure hose. Touch up all metal spots where paint has been scratched off.

  • Page 338
    Section 09 BODY/FRAME Subsection 03 (FRAME) CAUTION High speed drilling will cause excessive heat which may destroy the cutting edge of the bit, therefore avoid using pneumatic drills. Grinding Procedure Rear Cap Grind rivet heads from top of rear cap and under- neath for side retaining rivets.

  • Page 339: Technical Data

    Section 10 TECHNICAL DATA Subsection 01 (SI METRIC INFORMATION GUIDE) TECHNICAL DATA SI* METRIC INFORMATION GUIDE BASE UNITS DESCRIPTION UNIT SYMBOL length …………… meter ……….. mass …………..kilogram ……….force …………..newton ……….liquid …………..liter …………temperature …………. Celsius ……….°C pressure …………

  • Page 340
    Section 10 TECHNICAL DATA Subsection 02 (ENGINES) VEHICLE MODEL MX Z 440 MX Z 500 MX Z 583 MX Z 670 ENGINE TYPE Number of Cylinders Bore mm (in) 67.5 (2.6575) 69.5 (2.736) 76.0 (2.992) 78.0 (3.071) Stroke mm (in) 61.0 (2.402) 65.8 (2.59) 64.0 (2.520)
  • Page 341
    Section 10 TECHNICAL DATA Subsection 02 (ENGINES) FORMULA 500 FORMULA 583 VEHICLE MODEL FORMULA 500 FORMULA Z 583 DE LUXE DE LUXE ENGINE TYPE Number of Cylinders Bore mm (in) 69.5 (2.736) 76.0 (2.992) 76.0 (2.992) Stroke mm (in) 65.8 (2.59) 64.0 (2.52) 64.0 (2.52) Displacement…
  • Page 342
    Section 10 TECHNICAL DATA Subsection 02 (ENGINES) VEHICLE MODEL FORMULA Z 670 SUMMIT 500 SUMMIT 583 SUMMIT 670 ENGINE TYPE Number of Cylinders Bore mm (in) 78.0 (3.071) 69.5 (2.736) 76.0 (2.992) 78.0 (3.071) Stroke mm (in) 70.0 (2.760) 65.8 (2.59) 64.0 (2.520) 70.0 (2.760) Displacement…
  • Page 343
    Section 10 TECHNICAL DATA Subsection 02 (ENGINES) GRAND TOURING GRAND TOURING VEHICLE MODEL SKANDIC WT SKANDIC SWT ENGINE TYPE Number of Cylinders Bore mm (in) 69.5 (2.736) 76.0 (2.992) 72.0 (2.835) 72.0 (2.835) Stroke mm (in) 65.8 (2.59) 64.0 (2.52) 61.0 (2.402) 61.0 (2.402) Displacement…
  • Page 344
    Section 10 TECHNICAL DATA Subsection 02 (ENGINES) VEHICLE MODEL SKANDIC WT LC ENGINE TYPE Number of Cylinders Bore mm (in) 69.5 (2.736) Stroke mm (in) 65.8 (2.59) Displacement 499.3 (30.47) Compression Ratio (corrected) Maximum Power Engine Speed ± 100 RPM 7000 Piston Ring Type ST/R…
  • Page 345
    Section 10 TECHNICAL DATA Subsection 03 (VEHICLES) VEHICLE MODEL MX Z 440 MX Z 500 MX Z 583 MX Z 670 ENGINE TYPE Chain Drive Ratio 22/44 23/43 25/43 26/43 Pitch Chain Type/Links Qty/Plates Qty Silent 72/11 Silent 72/13 Silent 74/13 Silent 74/13 Type of Drive Pulley Ramp Identification…
  • Page 346
    Section 10 TECHNICAL DATA Subsection 03 (VEHICLES) FORMULA 500 FORMULA 583 VEHICLE MODEL FORMULA 500 FORMULA Z 583 DE LUXE DE LUXE ENGINE TYPE Chain Drive Ratio 23/43 23/44 25/44 25/43 Pitch Chain Type/Links Qty/Plates Qty Silent 72/11 Silent 72/11 Silent 74/13 Silent 74/13 Type of Drive Pulley…
  • Page 347
    Section 10 TECHNICAL DATA Subsection 03 (VEHICLES) VEHICLE MODEL FORMULA Z 670 SUMMIT 500 SUMMIT 583 SUMMIT 670 ENGINE TYPE Chain Drive Ratio 26/43 22/43 22/44 23/43 Pitch Chain Type/Links Qty/Plates Qty Silent 74/13 Silent 72/11 Silent 72/13 Silent 72/13 Type of Drive Pulley Ramp Identification Calibration Screw Position or…
  • Page 348
    Section 10 TECHNICAL DATA Subsection 03 (VEHICLES) GRAND TOURING GRAND TOURING VEHICLE MODEL SKANDIC WT SKANDIC SWT ENGINE TYPE Chain Drive Ratio 23/44 23/44 N.A. N.A. Pitch N.A. N.A. Chain Type/Links Qty/Plates Qty Silent 72/11 Silent 72/13 N.A. N.A. Type of Drive Pulley Ramp Identification Calibration Screw Position or —…
  • Page 349
    Section 10 TECHNICAL DATA Subsection 03 (VEHICLES) VEHICLE MODEL SKANDIC WT LC ENGINE TYPE Chain Drive Ratio N.A. Pitch N.A. Chain Type/Links Qty/Plates Qty N.A. Type of Drive Pulley Ramp Identification Calibration Screw Position or — calibration disc quantity Drive Pulley Spring Color Yellow/Blue ±…

  • Page 350: Technical Data Legends

    Section 10 TECHNICAL DATA Subsection 04 (TECHNICAL DATA LEGENDS) ENGINE LEGEND VEHICLE LEGEND BTDC: Before Top Dead Center DSA: Direct Shock Action CDI: Capacitor Discharge Ignition RRIM: Reinforced Reaction Injection Molding CTR: Center TRA: Total Range Adjustable Kilo (× 1000) N.A.: Not Applicable MAG: Magneto Side…

  • Page 351: Wiring Diagrams

    Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) WIRING DIAGRAMS ELECTRICAL WIRING HEADLIGHT TAILLIGHT SYSTEM MODEL DIAGRAM (watt) (watt) OUTPUT PAGE (watt) Skandic WT/SWT Annex 1 60/55 hal. 8/27 Skandic WT LC Annex 2 60/55 hal. 8/27 MX Z 440 Annex 3 60/55 hal.

  • Page 352
    Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Following table shows wire colors related to electrical circuits. WIRE COLOR ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF Must be grounded to stop engine. – Key switch – Tether cord switch –…
  • Page 353
    Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) CONNECTOR HOUSING AREA CONNECTOR LOCATION IN HOUSING XX/XX 1-02D XX/XX 1-02D A00I04C A00I04D A06H33B AREA LOCATION Front of engine compartment Magneto Carburetors Near of intake silencer Near driven pulley Under console Under hood Near fuel tank Rear of seat Under engine…
  • Page 354
    Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) SYMBOLS DESCRIPTION Beam and tail light Female terminal Male terminal Electronic module Meter Electric motor Low level sensor Buzzer Ignition coil Normally close Normally open Male terminal switch switch on instrument Engine Frame Spark plug Meter movement…
  • Page 355
    Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) UNPLUGING CONNECTORS To remove: – Insert a screwdriver or Snap-on TT 600-5 from Always unplug connectors by pulling on housing opposite side of wire and pry locking tab. not on wire. – While holding locking tab pried, pull connector toward wire side.
  • Page 356
    Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Waterproof Connector Housing Female Connector Housing To remove: – Insert tool Snap-on TT 600-5 under lock and twist to lift it. A01E34A 1. Lock – Pry tab to free connector then pull wire out of housing.
  • Page 357
    Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) A00E1FA TYPICAL 1. Receptacle 2. Housing ACCESSORIES INSTALLATION On all electric start models: The direct current (DC) utilizes the snowmobile frame as ground “wire” while all alternating current (AC) consum- ers (lights, heated grips, fuel gauge, etc.) utilize a separate ground wire.

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Grand Touring 500/583, 1999

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