Ski-Doo 2005 SUMMIT HIGHMARK Shop Manual
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Ski-Doo 2005 SUMMIT HIGHMARK Shop Manual

Ski-Doo 2005 SUMMIT HIGHMARK Shop Manual

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  • Page 1 Ski Doo Service Repair Manual Thank You for your purchase eBay seller foxmoto951 is the only authorized seller for this software If you have received this manual from any other eBay seller send it back for a refund & contact foxmoto951...
  • Page 3 2005 Shop Manual RT SERIES BOMBARDIER RECREATIONAL PRODUCTS INC.
  • Page 4 Legal deposit: National Library of Quebec National Library of Canada 2004 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Recreational Products Inc. (BRP) © Bombardier Recreational Products Inc. (BRP) 2004 Technical Publications Bombardier Recreational Products Inc.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SAFETY NOTICE ................. .. IX INTRODUCTION ..
  • Page 6 TABLE OF CONTENTS TUNED PIPE ......................21 MANIFOLD .
  • Page 7 TABLE OF CONTENTS INSPECTION......................85 DRAINING THE SYSTEM .
  • Page 8 TABLE OF CONTENTS CHARGING SYSTEM....................118 IGNITION SYSTEM.
  • Page 9 TABLE OF CONTENTS BATTERY ......................166 CABLE TERMINAL INSTALLATION.
  • Page 10 TABLE OF CONTENTS BUSHING REPLACEMENT ..................205 HPV VSA .
  • Page 11 TABLE OF CONTENTS TRACTION ENHANCING PRODUCTS (STUDS)..............241 REAR SUSPENSION 01 –...
  • Page 12 TABLE OF CONTENTS DISASSEMBLY AND ASSEMBLY ................. 270 STEERING/FRONT SUSPENSION 01 –...

  • Page 13: Safety Notice

    SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair some 2005 Ski-Doo snowmo- biles. See model list below. This edition was primarily published to be used by snowmobile mechanic technicians who are already familiar with all service procedures relating to BRP made snowmobiles.

  • Page 14: Introduction

    INTRODUCTION INTRODUCTION Identification Number Meaning This shop manual covers the following BRP made 2005 RT Series models: ENGINE SERIAL NUMBER Engine Serial Number Location TYPICAL — RT SERIES ENGINE MODEL MODEL NUMBER TYPE MACH Z 995 SDI AB5A, AB5B, AB5C SUMMIT 995 SDI CD5A, CD5B, CD5C...
  • Page 15 INTRODUCTION ABBREVIATION MEANING ABBREVIATION MEANING capacitor discharge ignition millimeter center M.E. millennium edition multi-purpose electronic centimeter MPEM module cm² square centimeter mile per hour cm³ cubic centimeter newton direct current N.A. not applicable digitally encoded security DESS number system continuity digital performance management open line (open circuit)

  • Page 16: Arrangement Of This Manual

    INTRODUCTION ARRANGEMENT OF THIS MANUAL This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog. Page heading indicates section and subsection detailed. Subsection title indicates Section 07 REAR SUSPENSION beginning of the subsection.
  • Page 17 INTRODUCTION Section 05 TRANSMISSION Title indicates main procedure Turn puller handle and sliding half at once to extract the bushing. to be carried-out. CAUTION: Italic bold face type setting indicates a particular procedure A-Series and B-Series Only concerning a model. Should installation procedure be required, refer to BRAKE then look for Italic bold face setting...

  • Page 18: General Information

    INTRODUCTION GENERAL INFORMATION The information and component/system descrip- tions contained in this manual are correct at time of publication. BRP however, maintains a policy of continuous improvement of its products with- out imposing upon itself any obligation to install them on products previously manufactured. Due to late changes, it may have some differences between the manufactured product and the de- scription and/or specifications in this document.

  • Page 19: Loctite Application Procedure

    INTRODUCTION LOCTITE APPLICATION Blind Holes PROCEDURE The following describes the most common ap- plication procedures when working with Loctite products. NOTE: Always use proper strength Loctite prod- uct as recommended in this shop manual. THREADLOCKER Uncovered Holes (bolts and nuts) 1.

  • Page 20: Stripped Thread Repair

    INTRODUCTION Adjusting Screw – Apply several drops of proper strength Loctite on stud threads. – Install stud. – Install cover, etc. – Apply drops of proper strength Loctite on un- covered threads. – Tighten nuts as required. Preassembled Parts 1. Apply here 2.

  • Page 21: Gasket Compound

    INTRODUCTION – If a plate is used to align bolt: – Spray Loctite Primer N on both mating surfaces and on both sides of gasket. Allow to dry 1 or • Apply release agent on mating surfaces. 2 minutes. • Put waxed paper or similar film on the sur- –...

  • Page 22: Case-In Components

    INTRODUCTION CASE-IN COMPONENTS TIGHTENING TORQUE Tighten fasteners to torque mentioned in explod- Metallic Gaskets ed views and/or text, When they are not specified, refer to following table. The table also gives the metric conversion. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (ex.: locking tabs, elastic stop nuts, self-lock- ing fasteners, etc.) must be installed or replaced with new ones, where specified.
  • Page 23 INTRODUCTION FASTENER GRADE/TORQUE FASTENER SIZE 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade 1.5 – 2 N•m 2.5 – 3 N•m 3.5 – 4 N•m 4 – 5 N•m (13 – 18 lbf•in) (22 – 27 lbf•in) (31 – 35 lbf•in) (35 –...
  • Page 24 INTRODUCTION mmr2005-109...
  • Page 25 INTRODUCTION XXII mmr2005-109...

  • Page 26: Maintenance

    Section 01 MAINTENANCE Subsection 01 (MAINTENANCE CHART) MAINTENANCE CHART 10-HOUR OR 500 KM (300 mi) INSPECTION (to be performed by dealer) A: ADJUST WEEKLY OR EVERY 240 KM (150 mi) I: INSPECT MONTHLY OR EVERY 800 KM (500 mi) L: LUBRICATE ONCE A YEAR OR EVERY 3200 KM (2000 mi) R: REPLACE 6000 KM (3700 mi)
  • Page 27 Vehicle cleaning and protection 01-02 (1) To be performed by an authorized ski-doo dealer. (2) Lubricate whenever the vehicle is used in wet conditions (wet snow, rain, puddles). (3) Before installing new spark plugs at preseason preparation, it is suggested to burn excess storage oil by starting the engine with the old spark plugs.

  • Page 28: Storage

    Section 01 MAINTENANCE Subsection 02 (STORAGE) STORAGE SERVICE TOOLS Description Part Number Page cleat remover................ 529 028 700 ..........5 narrow-cleat installer ............529 028 800 ..........5 SERVICE PRODUCTS Description Part Number Page anti-seize lubricant ..............293 800 070 ..........5 BOMBARDIER LUBE ............

  • Page 29: Fuel System

    Section 01 MAINTENANCE Subsection 02 (STORAGE) FUEL SYSTEM Proceed as follows: Start the engine and allow it to run at idle speed Fuel Stabilizer until the engine reaches its operating tempera- ture. It is critical to use the fuel stabilizer (P/N 413 408 600) (250 mL) to prevent fuel deterioration, gum WARNING formation and fuel system components corrosion.

  • Page 30: Steering/Front Suspension

    Section 01 MAINTENANCE Subsection 02 (STORAGE) SUSPENSION Drive Chain Tension Summit Models Rear Suspension Lubrication Check drive chain tension and adjust if necessary, Inspect rear suspension components for wear, de- refer to DRIVE SYSTEM section. terioration or damage, replace defective parts if Mach Z necessary.
  • Page 31 Section 01 MAINTENANCE Subsection 02 (STORAGE) To clean the entire vehicle, including bottom pan and metallic parts use heavy duty cleaner (spray can 400 g) (P/N 293 110 001) or heavy duty cleaner (4 L) (P/N 293 110 002). CAUTION: Do not use Heavy duty cleaner on decals or vinyl.

  • Page 32: Preseason Preparation

    Section 01 MAINTENANCE Subsection 03 (PRESEASON PREPARATION) PRESEASON PREPARATION SERVICE PRODUCTS Description Part Number Page pulley flange cleaner............. 413 711 809 ......... 7–8 XP-S synthetic chaincase oil ..........413 803 300 ..........8 Oil Injection Pump Proper vehicle preparation is necessary after the summer months or when a vehicle has not been Make sure oil injection pump is properly adjusted, used for more than one month.

  • Page 33: Drive System

    Section 01 MAINTENANCE Subsection 03 (PRESEASON PREPARATION) DRIVE SYSTEM Track Tension and Alignment Verify track tension and alignment, refer to DRIVE Drive Belt SYSTEM section and the appropriate subsection. Inspect belt for cracks, fraying or abnormal wear. NOTE: Track tension and alignment are interrelat- Replace if necessary.

  • Page 34: Engine

    Section 02 ENGINE Subsection 01 (LEAK TEST) LEAK TEST SERVICE TOOLS Description Part Number Page exhaust plates ..............529 035 999 ..........9 intake plugs ................529 036 000 ........... 10 RAVE plates ................529 036 003 ........... 11 small hose pincher..............295 000 076 ........... 10 vacuum/pressure pump kit ...........
  • Page 35 Section 02 ENGINE Subsection 01 (LEAK TEST) Install intake plugs (P/N 529 036 000) in the intake rubber boots. 1. Impulse line 2. Hose pincher Block inlet and outlet fitting of oil injection system with rubber cap. 1. Intake rubber boots 2.

  • Page 36: Procedure

    Section 02 ENGINE Subsection 01 (LEAK TEST) 1. RAVE plates Execute the test. Refer to PROCEDURE further NOTE: If necessary, lubricate air pump piston with in this section. mild soap. To perform the second test, the RAVE cover must CAUTION: Using hydrocarbon lubricant (such be in place.
  • Page 37 Section 02 ENGINE Subsection 01 (LEAK TEST) • If there is no leak at the tested location, con- Check for air bubbles or oil column going toward tinue pumping to maintain pressure and con- pump. It indicates defective check valve in injec- tinue with next items until leak is found.

  • Page 38: Finalizing Reassembly

    Section 02 ENGINE Subsection 01 (LEAK TEST) 1. Leak indicator hole If there is a leak, it indicates that a pump shaft is defective (oil seal beside coolant ceramic seal). – Leaks can be also on oil pump side. Check mounting area for leaks.

  • Page 39: Engine Leak Verification Flow Chart

    Section 02 ENGINE Subsection 01 (LEAK TEST) 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 40: Air Intake System

    Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) AIR INTAKE SYSTEM mmr2005-149...

  • Page 41: Air Filter/Air Intake Silencer Removal (Body Side)

    Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) AIR FILTER/AIR INTAKE SILENCER REMOVAL (BODY SIDE) Open LH side panel. Unplug air pressure sensor connector. Remove screws retaining air intake silencer to LH side panel. Remove air intake silencer (body side). 1.

  • Page 42: Air Intake Silencer Installation (Engine Side)

    Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) 1. Adaptor plate 2. Locking tab 1. Clamps 3. Air intake silencer 2. Adaptor plate AIR INTAKE SILENCER ADAPTOR PLATE INSTALLATION INSTALLATION (ENGINE SIDE) The installation is the reverse of the removal pro- The installation is the reverse of the removal pro- cedure.
  • Page 43 Section 02 ENGINE Subsection 02 (AIR INTAKE SYSTEM) Remove intake deflector and filter. 1. Air filter 2. Push nut 3. Intake filter 4. Intake deflector mmr2005-149...

  • Page 44: Exhaust System

    Section 02 ENGINE Subsection 03 (EXHAUST SYSTEM) EXHAUST SYSTEM SERVICE TOOLS Description Part Number Page exhaust spring installer/remover ......... 529 035 401 ........... 23 exhaust spring installer/remover ......... 529 035 989 ........21–22 SERVICE PRODUCTS Description Part Number Page Loctite 767 antiseize ............293 800 070 ........... 23 RTV sealant ................
  • Page 45 Section 02 ENGINE Subsection 03 (EXHAUST SYSTEM) mmr2005-114...

  • Page 46: Tuned Pipe

    Section 02 ENGINE Subsection 03 (EXHAUST SYSTEM) GENERAL During assembly/installation, use torque values and service products as shown in exploded view(s). Clean threads before applying a threadlocker. Re- fer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure.

  • Page 47: Manifold

    Section 02 ENGINE Subsection 03 (EXHAUST SYSTEM) Install tuned pipe. MUFFLER 1. Align notches Identification If the gaskets are damaged, replace them. Each muffler is identified by a number. To use the Use RTV sealant (P/N 293 800 090) on doughnut proper muffler with the proper vehicle, check the gasket prior to install tuned pipe.
  • Page 48 Section 02 ENGINE Subsection 03 (EXHAUST SYSTEM) Remove springs no. 8 retaining the muffler no. 9. Use exhaust spring installer/remover (P/N 529 035 401). Remove the muffler. Inspection Check the muffler for cracks or other damages. Installation For installation, reverse the removal procedure. If the EGTS plug on muffler was removed, use Loctite 767 antiseize (P/N 293 800 070).

  • Page 49: Engine Removal And Installation

    Section 02 ENGINE Subsection 04 (ENGINE REMOVAL AND INSTALLATION) ENGINE REMOVAL AND INSTALLATION SERVICE TOOLS Description Part Number Page engine removal hook ............529 035 829 ........... 30 hose pincher ................. 295 000 076 ........... 31 spark plug lift ring ..............529 035 830 ........... 30 SERVICE PRODUCTS Description Part Number...
  • Page 50 Section 02 ENGINE Subsection 04 (ENGINE REMOVAL AND INSTALLATION) mmr2005-115...

  • Page 51: Removal From Vehicle

    Section 02 ENGINE Subsection 04 (ENGINE REMOVAL AND INSTALLATION) REMOVAL FROM VEHICLE Place vehicle at workstation that will have access to an engine-lifting hoist. Remove the following: – windshield – RH and LH side panels. NOTE: On LH side panel, unplug APS (Air Pres- sure Sensor) connector.
  • Page 52 Section 02 ENGINE Subsection 04 (ENGINE REMOVAL AND INSTALLATION) Remove the following: – air intake silencer (engine side), refer to AIR IN- TAKE SYSTEM section. Remove LH handlebar support. REWIND STARTER HANDLE REMOVAL 1. Rewind starter handle NOTE: As an alternative method, the rewind starter can be removed from the engine and put aside.
  • Page 53 Section 02 ENGINE Subsection 04 (ENGINE REMOVAL AND INSTALLATION) FUEL RAIL DISASSEMBLY 1. Fuel rail 2. Plastic retainer plate THROTTLE BODY REMOVAL 1. Clamps Unscrew E-RAVE actuator from frame. 2. Throttle body Unplug connector and put E-RAVE actuator on top Unplug fuel filter line from fuel rail.
  • Page 54 Section 02 ENGINE Subsection 04 (ENGINE REMOVAL AND INSTALLATION) PTO ENGINE SUPPORT LIFTED 1. Engine support 2. Rubber mount stud ENGINE SUPPORT NUTS REMOVAL 1. Nuts Remove PTO engine support. 2. Engine support Remove both spark plugs. Install in the MAG side spark plug hole the spark plug lift ring (P/N 529 035 830).

  • Page 55: Inspection

    Section 02 ENGINE Subsection 04 (ENGINE REMOVAL AND INSTALLATION) BLOCK UP OIL INLET HOSE 1. Oil inlet hose 2. Standard 1/4 inch ratchet extension 3. Spring clamp DETACH AND UNPLUG 1. Detach oil pump cable 2. Unplug oil return hose Remove engine from vehicle.

  • Page 56: Installation

    Section 02 ENGINE Subsection 04 (ENGINE REMOVAL AND INSTALLATION) INSERT FRONT TAB FIRST 1. Front tab 2. PTO engine support ENGINE SUPPORTS Secure PTO engine support. 1. LH support 2. RH supports 3. Rubber mounts 4. Engine stopper INSTALLATION To install engine in vehicle, reverse the removal procedure.
  • Page 57 Section 02 ENGINE Subsection 04 (ENGINE REMOVAL AND INSTALLATION) INSERT REAR TAB 1. Rear tab RH SIDE — MAGNETO HARNESS ROUTING 2. Rubber mount Make sure RH side engine supports are properly Oil Pump Adjustment positioned on rubber mounts. After engine installation, verify oil pump adjust- ment, adjust if necessary.

  • Page 58: Magneto System

    Section 02 ENGINE Subsection 05 (MAGNETO SYSTEM) MAGNETO SYSTEM SERVICE TOOLS Description Part Number Page crankshaft protector ............. 420 876 557 ........... 37 magneto puller..............529 035 547 ........... 37 puller ring................529 036 001 ........... 37 SERVICE PRODUCTS Description Part Number Page Loctite 243 (blue)..............
  • Page 59 Section 02 ENGINE Subsection 05 (MAGNETO SYSTEM) a) Loctite 243 (blue) (P/N 293 800 060) b) Loctite 5910 (P/N 293 800 081) mmr2005-116...

  • Page 60: General

    Section 02 ENGINE Subsection 05 (MAGNETO SYSTEM) GENERAL NOTE: The following procedures can be done without removing the engine. To facilitate mag- neto removal, hold drive pulley with the appropri- ate tool. During assembly/installation, use the torque val- ues and service products as in the exploded views.

  • Page 61: Stator

    Section 02 ENGINE Subsection 05 (MAGNETO SYSTEM) STATOR Inspection Always check stator no. 4 before changing it. Re- fer to CHARGING SYSTEM. Cleaning Clean all metal components in a non-ferrous metal cleaner. CAUTION: Clean stator using only a clean cloth. Removal Remove: –...

  • Page 62: Cps

    Section 02 ENGINE Subsection 05 (MAGNETO SYSTEM) Inspection Always check CPS before changing it. Refer to ENGINE MANAGEMENT. Removal To replace the CPS, remove or disconnect the fol- lowing: – magneto flywheel no. 1 – grommet from crankcase where CPS wire exits magneto housing –...

  • Page 63: E-Rave System

    Section 02 ENGINE Subsection 06 (E-RAVE SYSTEM) E-RAVE SYSTEM SERVICE PRODUCTS Description Part Number Page Loctite 243................293 800 060 ........... 42 Molykote 111................ 413 707 000 ........... 42 XPS-synthetic blend Injection oil .......... 293 600 071 ........... 42 mmr2005-148...
  • Page 64 Section 02 ENGINE Subsection 06 (E-RAVE SYSTEM) a. Molykote 111 (P/N 413 707 000) b. Loctite 243 (P/N 293 800 060) c. XPS-synthetic blend Injection oil (P/N 293 600 071) mmr2005-148...

  • Page 65: General

    Section 02 ENGINE Subsection 06 (E-RAVE SYSTEM) GENERAL The E-RAVE system can be serviced with engine on vehicle. During assembly/installation, use torque values and service products as shown in exploded view. Clean threads before applying a threadlocker. Re- fer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure.
  • Page 66 Section 02 ENGINE Subsection 06 (E-RAVE SYSTEM) Detach cables from E-RAVE shaft pulley no. 2. CABLE POSITIONS 1. Cable ends in top holes 2. Cable ends in bottom holes Tighten nut of each cable to E-RAVE shaft pulley bracket. Ensure cables are parallel to each other. Installation Reverse removal steps.
  • Page 67 Section 02 ENGINE Subsection 06 (E-RAVE SYSTEM) Turn E-RAVE shaft pulley clockwise to the Close position. WRONG Insert cables in E-RAVE actuator pulley. Remove the headlight relay (R2). NOTE: To prevent battery discharge, headlight fuse (F8) can be removed. Bypass relay with a jumper. This will turn the E-RAVE shaft pulley to the adjustment position.

  • Page 68: E-Rave Actuator

    Section 02 ENGINE Subsection 06 (E-RAVE SYSTEM) Press START/RER button. E-RAVE shaft pulley should turn to the Close position. 1. Jumper 2. Headlight fuse Readjust top (closing) cable as necessary. Remove relay jumper. Tighten bottom cable adjuster (opening cable) to remove play in cable.

  • Page 69: E-Rave Cover

    Section 02 ENGINE Subsection 06 (E-RAVE SYSTEM) Removal Inspection Remove retaining screw no. 5. Check seal condition. If it is cracked or hard, re- place seal. Check cover condition. 1. Remove screw 1. Seal Slide E-RAVE actuator no. 3 out. Disconnect electrical connector.
  • Page 70 Section 02 ENGINE Subsection 06 (E-RAVE SYSTEM) Removal When installing drive gears no. 7, ensure to mesh gears as shown. Remove the following: E-RAVE cables no. 4. Pulley no. 2. Seal then snap ring no. 8. Drive gears no. 7. CENTER VALVE 1.

  • Page 71: E-Rave Housing

    Section 02 ENGINE Subsection 06 (E-RAVE SYSTEM) E-RAVE VALVES Removal Remove the following: Cover no. 11. Drive gears no. 7. Housing no. 10. Inspection Clean carbon deposits on parts. Check gears con- dition. Installation 1. Gears aligned Reverse removal steps. After assembly, check for smooth mechanical movement of the E-RAVE system.

  • Page 72: Top End

    Section 02 ENGINE Subsection 07 (TOP END) TOP END SERVICE TOOLS Description Part Number Page Piston circlip installer ............529 035 998 ........... 57 piston pin puller/installer ............529 036 002 ........... 54 SERVICE PRODUCTS Description Part Number Page Loctite 243................293 800 060 ........... 52 Loctite 5910................
  • Page 73 Section 02 ENGINE Subsection 07 (TOP END) a. Molykote 111 (P/N 413 707 000) b. XP-S synthetic blend injection oil (P/N 293 600 071) c. Loctite 243 (P/N 293 800 060) d. Loctite 5910 (P/N 293 800 081) mmr2005-117...

  • Page 74: Troubleshooting

    Section 02 ENGINE Subsection 07 (TOP END) TROUBLESHOOTING Fuel Rail Remove fuel rail no. 10. Refer to ENGINE MAN- Before completely disassembling the engine, pro- AGEMENT. ceed with an engine leak test. Refer to LEAK TEST. REED Valve Unscrew reed valve screws no. 1 then remove GENERAL reed valves.

  • Page 75: Cleaning

    Section 02 ENGINE Subsection 07 (TOP END) CAUTION: Do not pry out combustion cham- ber. It could damage the surface contact of cylinder head. A02C29A TYPICAL Using piston pin puller/installer (P/N 529 036 002), extract piston pin from piston. Cylinder Block Unscrew cylinder block screws no.

  • Page 76: Inspection

    Section 02 ENGINE Subsection 07 (TOP END) Scrape off carbon formation from cylinder block exhaust port, cylinder head and piston dome. NOTE: The letters “A or B” (beside an arrow on the piston dome) must be visible after cleaning. Clean the piston ring groove with a groove cleaner tool or with a piece of broken ring.

  • Page 77: Assembly

    Section 02 ENGINE Subsection 07 (TOP END) Cylinder Head, Cylinder Block and Piston TOLERANCES ENGINE NEW PARTS WEAR MEASUREMENT (min.) (max.) LIMIT Cylinder head 44.84 cc 48.97 cc N.A. volume 0.04 mm 0.10 mm Cylinder taper N.A. (.0016 in) (.004 in) 0.008mm 0.015 mm 0.08 mm...

  • Page 78: Piston Circlip Installer

    Section 02 ENGINE Subsection 07 (TOP END) With round end of pusher, position circlip perpen- dicularly to the support axis. 1. Arrow pointing toward exhaust port Install piston pin puller/installer and turn handle un- til piston pin is correctly positioned in piston. With the other end of the pusher, push circlip into the support groove.
  • Page 79 Section 02 ENGINE Subsection 07 (TOP END) CIRCLIP READY TO BE INSTALLED ON PISTON Using a plastic hammer, tap pusher to put circlip in place. Make sure to install new circlips with tab toward top as per following photo. Ensure to properly align mounting holes. Choose the right gasket thickness according to combustion chamber volume.
  • Page 80 Section 02 ENGINE Subsection 07 (TOP END) Properly seat adapters against engine flanges and torque screws no. 1 in a criss-cross sequence. Install cylinder head and torque screws following this sequence. LH and RH side intake adapters are different. In- stall as shown.

  • Page 81: Bottom End

    Section 02 ENGINE Subsection 08 (BOTTOM END) BOTTOM END SERVICE TOOLS Description Part Number Page bearing heater............... 529 035 969 ........... 70 bearing puller ................ 529 036 004 ........... 65 ceramic seal installer ............529 036 014 ........68–69 crankshaft protector ............. 420 876 552 ........... 65 crankshaft protector .............

  • Page 82: Molykote 111

    Section 02 ENGINE Subsection 08 (BOTTOM END) a. Loctite 243 (P/N 293 800 060) b. Loctite 648 (P/N 413 711 400) c. Molykote 111 grease, 150 g (P/N 413 707 000) d. Loctite 5910 (P/N 293 800 081) e. Injection oil f.
  • Page 83 Section 02 ENGINE Subsection 08 (BOTTOM END) a. Loctite 243 (P/N 293 800 060) b. Loctite 648 (P/N 413 711 400) c. Molykote 111 grease, 150 g (P/N 413 707 000) d. Loctite 5910 (P/N 293 800 081) e. Injection oil f.

  • Page 84: Troubleshooting

    Section 02 ENGINE Subsection 08 (BOTTOM END) TROUBLESHOOTING CAUTION: Never use a sharp object to scrape away old sealant as score marks incurred are Before completely disassembling the engine, pro- harmful to crankcase sealing. Do not wipe with ceed with an engine leak test. Refer to LEAK rags.
  • Page 85 Section 02 ENGINE Subsection 08 (BOTTOM END) Counterbalance Drive Gear NOTE: To remove/install bearing no. 6 and gear no. 7 from crankshaft, refer to a specialized shop. Special tools and accurate procedures are re- quired. CAUTION: Do not attempt to remove inner bearing or gear.
  • Page 86 Section 02 ENGINE Subsection 08 (BOTTOM END) – Bearing housing screws no. 12. From injection oil pump side, push shaft out while turning shaft to release it from worm gear. 1. M8 nut 2. Shaft CAUTION: When removing coolant pump shaft, always replace ceramic seal no.
  • Page 87 Section 02 ENGINE Subsection 08 (BOTTOM END) 1. Outer part of ceramic seal Push oil seal no. 15 out. Remove sealant from bearing housing with sand paper no. 180. Carefully press the outer part of ceramic seal out. NOTE: Use a mandrel with diameter of approxi- 1.
  • Page 88 Section 02 ENGINE Subsection 08 (BOTTOM END) CAUTION: Never use a hammer for the ceram- Press bearing no. 16 into bearing housing no. 13. ic seal installation. Only use a press to avoid damaging the ceramic component. Put oil seal protector (P/N 529 035 822) on coolant/oil pump shaft no.

  • Page 89: Inspection

    Section 02 ENGINE Subsection 08 (BOTTOM END) NOTE: During installation support the ceramic seal using the ceramic seal installer (P/N 529 036 014) as shown on the following illustration. Reinstall oil injection pump. INSPECTION Refer to table below to find bottom end engine di- mension specifications.
  • Page 90 Section 02 ENGINE Subsection 08 (BOTTOM END) Crankshaft Bearing Preparation Heat up the bearing(s) using bearing heater (P/N 529 035 969). This will expand bearings and ease installation. If required, put a suitable plate or shim to avoid the direct contact between integrated seal with the heating surface.
  • Page 91 Section 02 ENGINE Subsection 08 (BOTTOM END) Crankshaft Bearing Installation NOTE: Normally it takes approximately 10 min- utes to heat up a bearing so in the event of replac- CAUTION: Never reinstall a bearing that has ing bearing, it’s recommended to start the bearing been removed.
  • Page 92 Section 02 ENGINE Subsection 08 (BOTTOM END) Counterbalance Gear Make sure to properly index gears of crankshaft and counterbalance shaft with the aligning marks. CAUTION: Marks on the gears must be aligned, otherwise engine will vibrate and premature wear will occur. Crankshaft Installation NOTE: Although not mandatory, it is recommend- ed to have the coolant/oil pump shaft installed pri-...

  • Page 93: Break-In

    Section 02 ENGINE Subsection 08 (BOTTOM END) CAUTION: Do not use Loctite Primer N with the Loctite 5910. Do not use Dreibond to seal crankcase. Using these products or non silicone-based sealant over a previously sealed crankcase with Loctite 5910 will lead to poor adhesion and possibly a leaking crankcase.

  • Page 94: Engine Measurement

    Section 02 ENGINE Subsection 09 (ENGINE MEASUREMENT) ENGINE MEASUREMENT SERVICE TOOLS Description Part Number Page degree wheel ............... 529 035 607 ........... 80 TDC gauge ................414 104 700 ........76, 80 NOTE: This subsection explains the procedures to correctly measure engine components. For the engine technical specifications, refer to INSPEC- TION in the appropriate ENGINE subsection.

  • Page 95: Combustion Chamber Volume Measurement

    Section 02 ENGINE Subsection 09 (ENGINE MEASUREMENT) 1. Bring piston to TDC – Obtain a graduated burette (capacity 0 - 50 cc) and fill with an equal part (50/50) of gasoline and injection oil. 1. Piston pin position 2. Measures to be compared A.

  • Page 96: Used Piston Measurement

    Section 02 ENGINE Subsection 09 (ENGINE MEASUREMENT) 1. Top of spark plug hole NOTE: The liquid level in cylinder must not drop 1. Piston dome 2. Piston measurement for a few seconds after filling. If so, there is a leak between piston and cylinder. The recorded Using a micrometer, measure piston skirt at volume would be false.

  • Page 97: Cylinder/Piston Clearance

    Section 02 ENGINE Subsection 09 (ENGINE MEASUREMENT) CYLINDER/PISTON CLEARANCE Used and New Pistons IMPORTANT: Make sure used piston is not worn more than specified. See USED PISTON MEA- SUREMENT above. Take the measurement on the piston dome. 1. Use the micrometer to set the cylinder bore gauge 2.

  • Page 98: Ring/Piston Groove Clearance

    Section 02 ENGINE Subsection 09 (ENGINE MEASUREMENT) RING END GAP 1. Measuring perpendicularly (90°) to piston pin axis Position ring halfway between transfer ports and A. 33 mm (1.3 in) intake port. Read the measurement on the cylinder bore NOTE: In order to correctly position the ring in the gauge.

  • Page 99: Connecting Rod Big End Axial Play

    Section 02 ENGINE Subsection 09 (ENGINE MEASUREMENT) Measuring in Crankcase First, check deflection with crankshaft crankcase. If deflection exceeds the specified tol- erance, recheck deflection using V-shaped blocks to determine the defective part(s). See below. Measuring on Bench Once engine is disassembled, check crankshaft deflection on V-shaped blocks.
  • Page 100 Section 02 ENGINE Subsection 09 (ENGINE MEASUREMENT) Remove TDC gauge and install it in spark plug hole on PTO side. Bring PTO piston to top dead center. Degree wheel must rotate with crankshaft. Interval between cylinders must be 180° ± 0.5. Any other reading indicates a misaligned (twisted) crankshaft.

  • Page 101: Cooling System

    Section 02 ENGINE Subsection 10 (COOLING SYSTEM) COOLING SYSTEM SERVICE TOOLS Description Part Number Page engine leak tester kit ............861 749 100 ........... 85 hose pincher ................. 295 000 076 ........... 85 siphon tool ................529 035 880 ........... 85 special coolant tank cap............
  • Page 102 Section 02 ENGINE Subsection 10 (COOLING SYSTEM) Summit mmr2005-120...

  • Page 103: Cooling System Leak Test

    Section 02 ENGINE Subsection 10 (COOLING SYSTEM) COOLING SYSTEM LEAK TEST Remove coolant tank cap. Lift front of the vehicle and remove bottom pan WARNING cap. To prevent burning yourself, do not remove the coolant tank cap if the engine is hot. Install special coolant tank cap (P/N 529 021 400) included in the engine leak tester kit (P/N 861 749 100) on coolant tank.

  • Page 104: Disassembly And Assembly

    Section 02 ENGINE Subsection 10 (COOLING SYSTEM) 1. Disconnect engine outlet hose TEMPERATURE SENSOR Respect the following tightening torque specifica- 1. Apply Loctite 5910 tion: Pressure Cap DESCRIPTION TIGHTENING TORQUE Engine drain plug 24 N•m (18 lbf•ft) Check if coolant tank cap pressurizes the system for 3 minutes.

  • Page 105: Cooling System Refilling Procedure

    Section 02 ENGINE Subsection 10 (COOLING SYSTEM) Rear Cap Heat Exchanger Refilling Procedure Summit Models Only IMPORTANT: USE THE PREMIXED COOLANT (P/N 293 600 038). Do not reinstall pressure cap. For disassembly, drain cooling system. With engine cold, refill coolant tank up to COLD Remove rear hose cover.

  • Page 106: Rewind Starter

    Section 02 ENGINE Subsection 11 (REWIND STARTER) REWIND STARTER SERVICE PRODUCTS Description Part Number Page Molykote PG 54..............420 899 763 ........92–93 mmr2005-121...
  • Page 107 Section 02 ENGINE Subsection 11 (REWIND STARTER) mmr2005-121...

  • Page 108: General

    Section 02 ENGINE Subsection 11 (REWIND STARTER) GENERAL REMOVAL During assembly/installation, use torque values Using a small screwdriver, extract rope knot from and service products as shown in exploded starter grip. Cut rope close to knot. Tie a knot view(s). near starter.

  • Page 109: Assembly

    Section 02 ENGINE Subsection 11 (REWIND STARTER) CAUTION: It is of the utmost importance that the rewind starter spring be lubricated period- ically using Molykote PG 54 (P/N 420 899 763). Otherwise, rewind starter component life will be shortened and/or rewind starter will not op- erate properly under very cold temperatures.
  • Page 110 Section 02 ENGINE Subsection 11 (REWIND STARTER) To install rope no. 5, insert rope into sheave no. 4 Lubricate pawl no. 6 with Molykote PG 54 orifice and lock it by making a knot, leaving behind (P/N 420 899 763) then install over rope sheave. a free portion of about 25 mm in length.

  • Page 111: Installation

    Section 02 ENGINE Subsection 11 (REWIND STARTER) A01C18A 1. Step collar TYPICAL 2. O-ring 3. Locking element Position a new push nut no. 11. INSTALLATION Thread starter rope no. 5 through rope guide when applicable. A03C0VA TYPICAL Reinstall rewind starter assembly on engine. Prior to installing starter grip on new rope, it is first necessary to fuse the rope end with a lit match.

  • Page 112: Oil Injection System

    Section 02 ENGINE Subsection 12 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM SERVICE TOOLS Description Part Number Page hose pincher ................. 295 000 076 ........... 97 leak testing kit ..............529 033 100 ........... 97 small hose pincher..............295 000 076 ........... 97 spark plug lift ring ..............
  • Page 113 Section 02 ENGINE Subsection 12 (OIL INJECTION SYSTEM) mmr2005-122...

  • Page 114: General

    Section 02 ENGINE Subsection 12 (OIL INJECTION SYSTEM) GENERAL During assembly/installation, use the torque val- ues and service products as in the exploded views. Clean threads before applying a threadlocker. Re- fer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for Install hose pincher (P/N 295 000 076) on oil reser- complete procedure.

  • Page 115: Oil Pump Identification

    Section 02 ENGINE Subsection 12 (OIL INJECTION SYSTEM) TYPICAL 1. Hose pinchers on outlet hoses 1. Upper reservoir screw 2. Location of cooling reservoir Connect leak testing kit pump to special cap. On Right Side of Vehicle: Pressurize oil system to 21 kPa (3 PSI). That pres- sure must not drop during 3 minutes.

  • Page 116: Checking Operation

    Section 02 ENGINE Subsection 12 (OIL INJECTION SYSTEM) Injection Oil Pump Unplug sensor connector. Pull injection oil level sensor no. 8 out of reservoir. Lift engine. Before replacing the injection oil level sensor Remove oil pump screws no. 13 no. 8, check it according to the following proce- Unplug all hoses connected to oil pump no.

  • Page 117: Bleeding Procedure

    Section 02 ENGINE Subsection 12 (OIL INJECTION SYSTEM) Injection Oil Level sensor For installation, reverse the removal procedure. Injection Oil Filter For installation, reverse the removal procedure. NOTE: The filter must be installed with the arrow pointing toward the pump. Injection Oil Pump For installation, reverse the removal procedure.

  • Page 118: Adjustment

    Section 02 ENGINE Subsection 12 (OIL INJECTION SYSTEM) 1. Bleeder screw 2. Oil pump lever Reinstall all parts. Bleed the small oil line between pump and engine by running engine at idle while holding the pump TYPICAL lever in fully open position. 1.

  • Page 119: Fuel System

    Section 03 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMPS) FUEL TANK AND FUEL PUMPS SERVICE TOOLS Description Part Number Page engine removal hook ............529 035 829 ......... 115 hose pincher ................. 295 000 076 ......... 105, 115 leak tester kit ................

  • Page 120: Fuel Tank

    Section 03 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMPS) FUEL TANK mmr2005-123...

  • Page 121: In-Tank Fuel Filter Removal

    Section 03 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMPS) WARNING Fuel lines remain under pressure at all times. Always proceed with care and use appro- priate safety equipment when working on pressurized fuel system. Wear safety glasses and work in a well ventilated area. Do not allow fuel to spill on hot engine parts and/or on electrical connectors.

  • Page 122: In-Line Fuel Filter Removal

    Section 03 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMPS) To facilitate the installation, grommet should be on smaller diameter of male connector. Install grommet on fuel tank and push male con- nector through grommet. IN-LINE FUEL FILTER REMOVAL Fuel filter, inlet and outlet hoses come as an as- sembly.

  • Page 123: Fuel Tank Installation

    Section 03 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMPS) Unplug the following hoses: – fuel tank outlet hose – fuel pump module inlet hose – fuel pump module outlet hose from fuel filter line ass'y – fuel tank vent hose. Unplug fuel pump module connector.

  • Page 124: Electric Fuel Level Sensor Inspection

    Section 03 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMPS) For reinstallation, proceed as follows: – Install grommet halfway on gauge. – Insert grommet in fuel tank until it bottoms. – Firmly push gauge in grommet until it bottoms and so that its red line aligns with the line on the fuel tank.

  • Page 125: Electric Fuel Pump

    Section 03 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMPS) ELECTRIC FUEL PUMP DIAGNOSTIC FLOW CHART NOTE: Before proceeding with any test, make sure that diaphragm fuel pump works properly. Connect tether cord, activate Fuel pump does not run Fuel pump runs cut-out switch, press START/RER for 2 sec.

  • Page 126: Electric Fuel Pump Pressure Test

    Section 03 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMPS) ELECTRIC FUEL PUMP PRESSURE TEST Before proceeding to the pressure test, ensure the battery is fully charged. Battery voltage must be over 12 volts. Release the fuel pressure in the system using B.U.D.S.

  • Page 127: Electric Fuel Pump

    Section 03 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMPS) ELECTRIC FUEL PUMP mmr2005-123...

  • Page 128: Electric Fuel Pump Removal

    Section 03 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMPS) ELECTRIC FUEL PUMP REMOVAL With two screwdrivers or a bent rod holding the flange, unscrew fuel pump nut using fuel pump Remove seat, refer to BODY. nut wrench (P/N 529 035 899). Using B.U.D.S., release pressure from fuel sys- tem.

  • Page 129: Electric Fuel Pump Installation

    Section 03 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMPS) Disconnect pump electric connector. 1. Arrows 2. Torque wrench Disconnect hose from pump. A. 90° Use a new clamp to secure hose to fuel pump fitting. CAUTION: Make sure that hose clamps are tight to avoid that they turn on their fittings.

  • Page 130: Diaphragm Fuel Pump

    Section 03 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMPS) DIAPHRAGM FUEL PUMP mmr2005-123...

  • Page 131: Diaphragm Fuel Pump Removal

    Section 03 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMPS) DIAPHRAGM FUEL PUMP Install a hose pincher (P/N 295 000 076) on inlet and outlet hoses. REMOVAL Remove the following: – muffler, refer to ENGINE – belt guard – air silencer (engine side), refer to ENGINE –...

  • Page 132: Diaphragm Fuel Pump Cleaning And Inspection

    Section 03 FUEL SYSTEM Subsection 01 (FUEL TANK AND FUEL PUMPS) DIAPHRAGM FUEL PUMP CLEANING AND INSPECTION The entire pump should be cleaned with general purpose solvent before disassembly. Fuel pump components should be cleaned in gen- eral purpose solvent and dried with compressed air.

  • Page 133: Engine Management (Sdi)

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 01 (OVERVIEW) OVERVIEW E-RAVE actuator Capacitor RAVE system Ignition coil Fuel pump LEGEND APS – Air pressure sensor ATS – Air temperature sensor CPS – Crankshaft position sensor ECM – Engine control module FI – Fuel injector FR –...

  • Page 134: Operating Principle

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 01 (OVERVIEW) OPERATING PRINCIPLE For this SDI 2-stroke engine, a highly advanced en- gine management system (EMS) has been used to ensure a high power output combined with clean- er combustion. An ECM (Engine Control Module) calculates the proper air/fuel mixture and ignition timing for each cylinder separately.

  • Page 135: Fuel Delivery System

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 01 (OVERVIEW) FUEL DELIVERY SYSTEM Diaphragm Fuel Pump A conventional diaphragm fuel pump is used to supply fuel to the electric fuel pump reservoir lo- cated inside fuel tank. This reservoir is the fuel supply for the electric fuel pump.

  • Page 136: Engine Management System (Ems)

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 01 (OVERVIEW) Throttle Body It is a dual throttle body mounted on the engine in- take side. Fitted on this dual throttle body, there is a TPS (Throttle Position Sensor) that sends in- formation to the ECM. In-Line Fuel Filter The in-line 10 micron fuel filter is fastened under the steering console.
  • Page 137 Section 04 ENGINE MANAGEMENT (SDI) Subsection 01 (OVERVIEW) The ECM also stores general informations such Electric Start Models as: operating conditions, vehicle hours, serial When the START/RER switch is activated, it numbers, customer and maintenance informa- wakes up the EMS and power the starting sys- tion.

  • Page 138: Ems - Engine Management System Functions

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 01 (OVERVIEW) EMS — ENGINE MANAGEMENT SYSTEM FUNCTIONS SDI SYSTEM INPUTS OUTPUTS POWER DISTRIBUTION Gauges Current Supply Gauges are supplied with current for 30 seconds Accessories are protected by fuses located in the when connecting the tether cord cap on its post fuse holder.

  • Page 139: Fuel Injection

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 01 (OVERVIEW) FUEL INJECTION Knock Sensor A knock sensor is mounted on top of the cylinder The ECM receives the signals from different sen- head. It detects specific vibration that would be sors which indicate engine operating conditions at typically generated by engine detonation.

  • Page 140: Rotax Electronic Reverse (Rer)

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 01 (OVERVIEW) The tether cord cap contains a magnet and a ROM The ECM receives signals from the crankshaft po- chip. The magnet actually closes the reed switch sition sensor (CPS) for the following functions: inside the post which is the equivalent of a me- –...

  • Page 141: Diagnostic Mode

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 01 (OVERVIEW) NOTE: Sensor failures will not lead automatically to a limp home mode. The check engine LED will turn on and in some cases the beeper. The engine RPM may be limited if some critical components fail.

  • Page 142: Diagnostic Procedure

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 02 (DIAGNOSTIC PROCEDURE) DIAGNOSTIC PROCEDURE SERVICE TOOLS Description Part Number Page GRAY diagnostic key ............529 035 896 ......... 134 supply harness..............529 035 869 ......... 133 VCK (Vehicle Communication Kit) ......... 529 035 981 ......... 132 GENERAL Here is the basic order suggested to diagnose a suspected engine management or fuel injection related problem:...

  • Page 143: Troubleshooting

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 02 (DIAGNOSTIC PROCEDURE) TROUBLESHOOTING The following chart is provided to help in diagnosing the probable source of simple troubles. Monitoring Beeper Coded Signals CODED SIGNALS POSSIBLE CAUSE REMEDY 2 short beeps (when engine is started). Confirms that proper tether cord cap is No problem detected.
  • Page 144 Section 04 ENGINE MANAGEMENT (SDI) Subsection 02 (DIAGNOSTIC PROCEDURE) TPS “OUT OF RANGE” Fault It is caused by the sensor reading going out of its allowable range. This fault can occur during the whole range of movement of the throttle. To diagnose this fully, it is recommended to operate the throttle through its full range.
  • Page 145 Section 04 ENGINE MANAGEMENT (SDI) Subsection 02 (DIAGNOSTIC PROCEDURE) EMS Fault Code Table P CODE EMS PILOT LAMP BEEPER DESCRIPTION P0106 Air pressure sensor voltage out of range. P0337 No crankshaft signal detected. P0336 High engine RPM detected. P0339 Crankshaft signal fault. P0654 Tachometer RPM signal shorted to battery.
  • Page 146 Section 04 ENGINE MANAGEMENT (SDI) Subsection 02 (DIAGNOSTIC PROCEDURE) P CODE EMS PILOT LAMP BEEPER DESCRIPTION P0118 BLINK Engine temperature sensor voltage too high. P0116 BLINK Engine temperature sensor functional problem. P0112 BLINK Air temperature sensor voltage too low. P0113 BLINK Air temperature sensor voltage too high.

  • Page 147: Vck (Vehicle Communication Kit)

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 02 (DIAGNOSTIC PROCEDURE) P CODE EMS PILOT LAMP BEEPER DESCRIPTION P0601 BLINK TPS learns unlikely or checksum fault. P1102 BLINK Throttle position sensor adaptation failure. P1104 BLINK Throttle position sensor adaptation canceled. P1655 BLINK DESS shorted to battery.
  • Page 148 Section 04 ENGINE MANAGEMENT (SDI) Subsection 02 (DIAGNOSTIC PROCEDURE) 1. Remove connector from cap Connect supply harness (P/N 529 035 869), to ve- hicle 6-pin connector. Connect the 6 pin diagnostic cable from VCK to supply harness. NOTE: SDI engines already have a 12 V battery; they do not need any external 9 V or 12 V power to allow programming and troubleshooting.
  • Page 149 Section 04 ENGINE MANAGEMENT (SDI) Subsection 02 (DIAGNOSTIC PROCEDURE) ONE MODULE IS CONNECTED If an “X” is shown, this means that no communi- cation between the MPI and the ECM is possible. In this case possible causes are: – ECM is not powered-up –...

  • Page 150: Component Inspection, Replacement And Adjustment

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT SERVICE TOOLS Description Part Number Page ECM adapter................. 420 277 010 ......... 138 Fluke 111 ................529 035 868 ......... 137 hose pinchers ..............295 000 076 ......... 146 VCK (Vehicle Communication Kit) .........

  • Page 151: Electrical System

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) WARNING Ensure to verify fuel line connections for damage and that NO fuel line is disconnect- ed prior to installing the tether cord cap on the DESS post. Always perform the high pressure test if any component has been removed.
  • Page 152 Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) To perform verifications, a good quality multimeter The resistance value for usual resistor or windings such as Fluke 111 (P/N 529 035 868) should be (such as injectors) increases as the temperature used.
  • Page 153 Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Connector Identifications TEMPERATURE SENSOR TABLE TEMPERATURE RESISTANCE (OHMS) CTS FOR °C °F GAUGE 21.95 282.8 19.45 244.8 17.28 212.8 15.4 185.6 162.4 142.7 125.9 1. ECM A-connector 2. ECM B-connector 111.5 3.
  • Page 154 Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) CAUTION: Do not disconnect the ECM connec- tor needlessly. They are not designed to be dis- connected/reconnected repeatedly. Engine/Vehicle Connector Use this illustration to locate the terminal numbers on the engine/vehicle connector of the wiring har- ness when performing tests.

  • Page 155: Testing Procedures

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) If voltage does not read 12 V, check continuity of wire on supply side of relay. If faulty, repair wire/connector. If wire/connectors test good, re- fer to ELECTRICAL SYSTEM to test output side or relay.
  • Page 156 Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Energize each injector individually and measure the gas volume injected. Quantity of gas must be within the following specifications. VOLUME OF FUEL INJECTOR mL (US oz) Blue 16 ± 1 (.54 ± .03) Brown 21 ±...
  • Page 157 Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) CIRCUIT NUMBER TERMINAL 2 OF COMPONENT CONTACT LOCATION (ECM connector "A") INJECTOR HARNESS 4 (Engine/vehicle A-15 MAG (outer) Fuel injector, MAG connector) (outer) and A-15 A-33 PTO (outer) (ECM connector) A-14 MAG (inner)
  • Page 158 Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) NOTE: A thin film of engine oil should be applied to O-rings to ease fuel injector installation in fuel rail and cylinders. Insert injectors with your hand. Do not use any tool.

  • Page 159: Engine Control Module (Ecm)

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) WARNING Perform a fuel high pressure test and ensure that there is no leak. Refer to FUEL SYSTEM. ENGINE CONTROL MODULE (ECM) General Prior to replacing a suspected ECM, ensure that all the recommendations in the general introduction of this section have been followed.

  • Page 160: Engine Wiring Harness

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) ENGINE WIRING HARNESS Installation First connect the connector A to the ECM and the engine/vehicle connector to the vehicle wiring har- ness. Reconnect the wiring harness to all sensors/ actuators and reinstall all locking tie that have been removed.
  • Page 161 Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Mechanical Inspection Check that the throttle plate moves freely and smoothly when depressing throttle lever. IMPORTANT: The throttle body is designed to be tamper proof. Changing the zero position stop screw or synchronization screw or modifying them in any way will not increase performance but may cause poor startability and erratic idling.
  • Page 162 Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Before installation, clean throttle plates and bores with pulley flange cleaner (P/N 413 711 809). NOTE: The throttle body is designed as a single part for both cylinders. No synchronization is re- quired as it has already been done at the factory.

  • Page 163: Throttle Position Sensor (Tps)

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Tighten bottom nut to 4.5 N•m (40 lbf•in). TYPICAL — THROTTLE POSITION SENSOR (TPS) IMPORTANT: Prior to testing the TPS, ensure that mechanical components/adjustments are adequate according to THROTTLE BODY above. 1.
  • Page 164 Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) NOTE: The resistance value should change smoothly and proportionally to the throttle move- ment. Otherwise, replace TPS. If resistance values are correct, try a new ECM. Refer to ENGINE CONTROL MODULE (ECM) in this section.

  • Page 165: Crankshaft Position Sensor (Cps)

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) NOTE: Reset must be done each time the throttle Now, the idle speed screw has to be adjusted. position sensor (TPS) is loosened or removed or To do this, screw in the idle speed screw until throttle body or ECM is replaced.

  • Page 166: Air Temperature Sensor (Ats)

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) NOTE: Take into account that a CPS fault can be triggered by missing encoder wheel teeth. First check fault codes then check the teeth condition if necessary. See below. Disconnect CPS wiring harness connector.

  • Page 167: Coolant Temperature Sensor (Cts)

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) If out of specification, replace the sensor. If resistance tests good, reconnect the ATS and disconnect the connector A on the ECM. Using a multimeter, recheck resistance value be- tween terminals 7 and 21.

  • Page 168: Air Pressure Sensor (Aps)

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Voltage Test Refer to TEMPERATURE SENSOR TABLE at the beginning of this section to find the corresponding Check the voltage output from ECM to the APS. resistance value for this sensor temperature. Install the tether cord cap, turn OFF engine cut-out Recheck also resistance value between terminals switch and push START/RER button momentarily...

  • Page 169: Knock Sensor (Ks)

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) KNOCK SENSOR (KS) Replacement Unscrew and remove knock sensor from cylinder head. Clean contact surface, apply Loctite 5910 (P/N 293 800 081) on both contact surfaces on the knock sensor then install the new sensor.

  • Page 170: Double Ignition Coil

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) If no power goes to the E-RAVE actuator, no com- NOTE: munication can take place. If no fault code is displayed in B.U.D.S., the E-RAVE If B.U.D.S. works, it validates the ECM works and actuator can still be faulty.
  • Page 171 Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Voltage Test Resistance Test Remove spark plug cables from ignition coil. WARNING Using a multimeter, check the resistance of prima- When disconnecting coil from spark plug, al- ry winding. ways disconnect coil from main harness first.

  • Page 172: Battery

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) BATTERY WARNING Manual Start Models Capacitor may be charged. Once discharged, a transient recovery voltage may be generat- These models are equipped with a YT4L-BS type ed in the capacitor after a while. Always dis- battery that requires a specific charging procedure charge capacitor before servicing.

  • Page 173: Engine Start/Rer Switch Verification

    Section 04 ENGINE MANAGEMENT (SDI) Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT) Connect a switch (in OFF position) between a 12 V Connect one test probe to the WHITE/GREY wire battery positive post and the capacitor positive and the other test probe to the switch top ter- post.

  • Page 174: Electrical System

    Section 05 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) IGNITION SYSTEM SERVICE TOOLS Description Part Number Page digital/inductive type tachometer ......... 529 014 500 ......... 161 Vehicle Communication Kit (VCK) ......... 529 035 981 ......... 159, 162 SERVICE PRODUCTS Description Part Number Page antiseize lubricant ..............

  • Page 175: Ignition Timing

    Section 05 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) IGNITION TIMING IGNITION COIL Secondary Normally ignition timing adjustment should not be Secondary winding Primary winding required. It has been set at factory and it should resistance spark TEST winding resistance spark remain correctly adjusted since every part is fixed plug wires and resistance...
  • Page 176 Section 05 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) – Screw the adaptor into the spark plug hole WARNING and tighten to prevent movement in the plug Place ski tips against a wall, raise rear of ve- hole. hicle on a stand, so that track does not con- –...

  • Page 177: Spark Plug

    Section 05 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) TIMING RETARDED BY ABOUT 1° Detailed information about the B.U.D.S. software and its usage is available under its Help section. SPARK PLUG Removal First unscrew the spark plug 1 turn. Clean the spark plug and cylinder head with pres- surized air, then completely unscrew.
  • Page 178 Section 05 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) TYPICAL 1. Proper socket 2. Improper socket Use the following table to torque the spark plugs. SPARK TORQUE ENGINE PLUG N•m (lbf•ft) 27 (20) 995 SDI mmr2005-127...

  • Page 179: Design Symbols Used In Ngk Spark Plugs

    Section 05 ELECTRICAL SYSTEM Subsection 01 (IGNITION SYSTEM) DESIGN SYMBOLS USED IN NGK SPARK PLUGS mmr2005-127...

  • Page 180: Charging System

    Section 05 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) CHARGING SYSTEM SERVICE TOOLS Description Part Number Page crimp pliers ................529 035 730 ......... 169 multimeter FLUKE 111 ............529 035 868 ......... 165 SERVICE PRODUCTS Description Part Number Page silicone dielectric grease ............293 550 004 ......... 167–168 GENERAL In most cases when problems are caused by tem- perature or vibrations, these can only be solved by...

  • Page 181: Voltage Regulator/Rectifier

    Section 05 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) All Models STATOR Disconnect battery. TEST Output Coil insulation Remove muffler. YELLOW, TEST YELLOW and Unplug all connectors located on connector sup- YELLOW and PROBES ENGINE port. GREEN Remove nuts that attach the voltage regulator/rec- 00.0 to 00.5 RESISTANCE O.L.
  • Page 182 Section 05 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) Slide off rubber boot from RED (+) cable and dis- WARNING connect it. Should the battery casing be damaged, wear Unscrew the bracket retaining nut and lift bracket a suitable pair of rubber gloves when remov- to remove it.

  • Page 183: Cable Terminal Installation

    Section 05 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) Battery Charging If the charger ammeter shows no change in cur- rent after 5 minutes, you need a new battery. Cur- WARNING rent flowing into the battery at high voltage can become excessive. Monitor amperage and adjust Always wear safety glasses and charge in voltage as necessary to keep current at the bat- a ventilated area.
  • Page 184 Section 05 ELECTRICAL SYSTEM Subsection 02 (CHARGING SYSTEM) INSTALLATION OF TERMINAL Follow the instructions provided with the crimp pli- ers (P/N 529 035 730) to select the proper position of the tool. CRIMPING OF WIRE NOTE: Different wires require different crimp pli- ers settings, so make sure to follow the instruction supplied with the tool.

  • Page 185: Starting System

    Section 05 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) STARTING SYSTEM SERVICE TOOLS Description Part Number Page multimeter FLUKE 111 ............529 035 868 ......... 171 GENERAL START/RER Switch Check if the start/RER switch works normally. When the start button is pressed, a signal is sent to the starting solenoid.
  • Page 186 Section 05 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) If the solenoid does not receive a signal and the A voltage drop test can be performed in order to start switch test good, make sure it is not a bad find a poor connection, defective wire or compo- connection between the engine control module nent, causing parasite resistance in the system.
  • Page 187 Section 05 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) TEST 4 – Measure voltage to starter. Place the positive probe to the starter positive terminal and the negative probe to the starter housing. – Crank engine and record the result. – The voltage reading should not drop below 9 volts.

  • Page 188: Starter Removal

    Section 05 ELECTRICAL SYSTEM Subsection 03 (STARTING SYSTEM) If the starter turns, ensure wiring harness and con- nectors between battery and starter are in good condition. See procedure above. If the starter does not turn, replace it. STARTER REMOVAL Disconnect BLACK (-) cable from battery then the RED (+) cable.

  • Page 189: Rotax Electronic Reverse (Rer)

    Section 05 ELECTRICAL SYSTEM Subsection 04 (ROTAX ELECTRONIC REVERSE (RER)) ROTAX ELECTRONIC REVERSE (RER) TROUBLESHOOTING RER Does Not Response When Depressing START/RER Button – Check for faults using the vehicle communica- tion kit (VCK) and B.U.D.S. software. – Check if engine START/RER button works nor- mally, refer to ENGINE MANAGEMENT.

  • Page 190: Accessories And Lighting System

    Section 05 ELECTRICAL SYSTEM Subsection 05 (ACCESSORIES AND LIGHTING SYSTEM) ACCESSORIES AND LIGHTING SYSTEM SERVICE TOOLS Description Part Number Page multimeter FLUKE 111 ............529 035 868 ......178, 182–184 supply cable................529 035 997 ......... 177, 183 supply harness..............529 035 869 ......177–178, 183 VCK (Vehicle Communication Kit) .........

  • Page 191: 12-Volt Power Outlet (Cigarette-Lighter Type)

    Section 05 ELECTRICAL SYSTEM Subsection 05 (ACCESSORIES AND LIGHTING SYSTEM) The obtained value should be between 12 and 14.5 Vdc. Connect the supply harness (P/N 529 035 869) – No voltage: to diagnostic connector, located on right side of the vehicle. Now the headlight and accessories •...

  • Page 192: Engine Temperature Gauge

    Section 05 ELECTRICAL SYSTEM Subsection 05 (ACCESSORIES AND LIGHTING SYSTEM) Installation To install beeper, reverse the removal procedure. Check connectors position. ENGINE TEMPERATURE GAUGE Test Check fuse, connectors and harness. Check the condition of relay 2 by using the BUDS software.

  • Page 193: Headlamp

    Section 05 ELECTRICAL SYSTEM Subsection 05 (ACCESSORIES AND LIGHTING SYSTEM) HEADLAMP Bulb Replacement If any headlight bulb is burnt, proceed as follows. Remove windshield. Pull out steering support cap. TYPICAL 1. Remove screws Place the accessories panel out of way. Unplug burnt bulb connector.

  • Page 194: Headlamp Beam Aiming

    Section 05 ELECTRICAL SYSTEM Subsection 05 (ACCESSORIES AND LIGHTING SYSTEM) HEATING ELEMENTS Disconnect headlamps. On RH side of vehicle, remove the push nut then NOTE: All measurements must be performed at remove the headlamp housing. 21°C (70°F). Installation Throttle Lever Heating Element Reverse the removal procedure.

  • Page 195: Speedometer

    Section 05 ELECTRICAL SYSTEM Subsection 05 (ACCESSORIES AND LIGHTING SYSTEM) Continuity Test Remove the relay from vehicle. Using the multimeter FLUKE 111 (P/N 529 035 868), select the beeper position. 1. Terminal 30 2. Terminal 87 3. Terminal 85 4. Terminal 86 The continuous signal should be audible.

  • Page 196: Speed Sensor

    Section 05 ELECTRICAL SYSTEM Subsection 05 (ACCESSORIES AND LIGHTING SYSTEM) The Speedometer Is Lighted But the Needle Does Not Move Check the speed sensor and the wiring harness. If the speed sensor and the wiring harness are good, change the speedometer. Installation The installation is the reverse of the removal pro- cedure.

  • Page 197: Taillight

    Section 05 ELECTRICAL SYSTEM Subsection 05 (ACCESSORIES AND LIGHTING SYSTEM) NOTE: Note the location of each wire. Summit Highmark and Summit Highmark X Unscrew the screws retaining the rack to the side of frame. Crazy Needle Unscrew the other screws that attach the rack Check wire connections on pin 18, 19, 20 and 21 near the radiator.

  • Page 198: Drive System

    Section 06 DRIVE SYSTEM Subsection 01 (DRIVE BELT) DRIVE BELT SERVICE TOOLS Description Part Number Page belt tension tester ..............414 348 200 ......... 187 APPLICATION CHART Release parking brake. Vehicle must not creep when engine is idling. Otherwise, make sure that: MINIMUM WIDTH –...

  • Page 199: Drive Belt Height Measurement And Adjustment

    Section 06 DRIVE SYSTEM Subsection 01 (DRIVE BELT) TYPICAL 1. Flush INCORRECT Adjustment NOTE: For used drive belt, mark and reinstall in Before adjusting the belt height, ensure that a the same position. good-condition proper belt (refer to the APPLICA- TION CHART) is installed.

  • Page 200: Drive Belt Deflection Measurement (Reference Only)

    Section 06 DRIVE SYSTEM Subsection 01 (DRIVE BELT) Wooden Stick and Spring Scale Method 1. Mark specified deflection Using spring scale and stick, apply specified force on drive belt halfway between pulleys as shown. DRIVEN PULLEY NOTCHES Turn the adjustment ring up to one notch, tighten the screws, then rotate driven pulley to allow drive belt to settle in pulley.
  • Page 201 Section 06 DRIVE SYSTEM Subsection 01 (DRIVE BELT) A00D08A 1. Upper O-ring — force 2. Force 3. Lower O-ring — deflection 4. Reference rule 5. Deflection mmr2005-131...

  • Page 202: Drive Pulley

    Section 06 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) DRIVE PULLEY SERVICE TOOLS Description Part Number Page bushing remover/installer ............. 529 031 200 ......... 194 drive pulley holder ..............529 035 674 ......... 191, 198 drive pulley puller..............529 022 400 ......... 191 slider shoe fork ..............
  • Page 203 Section 06 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) TRA V NOTE: This is a lubrication free drive pulley. Always refer to appropriate parts catalog for replacement parts. Most parts of TRA V are not interchangeable with other TRA models. Starter electric models mmr2005-132...

  • Page 204: General

    (P/N 529 WARNING 022 400). Any drive pulley repairs must be performed by an authorized Ski-Doo dealer. Subcompo- nent installation and assembly tolerances re- quire strict adherence to procedures detailed. Retain drive pulley with the drive pulley holder...
  • Page 205 Section 06 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) To separate fixed half no. 4 from sliding half no. 8, heat the stop plate with a heat gun then screw puller into fixed half shaft about 13 mm (1/2 in). Raise drive pulley and hold it by the sliding half 529 005 500 while knocking on puller head to disengage fixed half.

  • Page 206: Cleaning

    Section 06 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) CLEANING Fixed and Sliding Halves Parts must be at room temperature before clean- ing. Clean pulley halves and shaft with fine steel wool and dry cloth. Using a paper towel with pulley flange cleaner (P/N 413 711 809), clean crankshaft tapered end and the taper inside the fixed half of the drive pulley, crankshaft threads and retaining screw...
  • Page 207 Section 06 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) CAUTION: Ensure rollers are in good condition. Replace as required. Lever Bolt and Flanged Bushing Check the flanged bushing no. 18 for wear. Re- place if necessary. Check lever bolts no. 19 for wear, replace as re- quired.

  • Page 208: Assembly

    Section 06 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) 1. Bushing Clean sliding half bushing mounting surface with Install the circlip. pulley flange cleaner (P/N 413 711 809). To install a new bushing, secure the spring com- pressor (P/N 529 035 524) in a vice and mount the sliding half .
  • Page 209 Section 06 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) Torque ring gear screws. Apply Loctite 609 (P/N 413 703 100) between pin and lever when assembling. CAUTION: Do not use other screws than rec- ommended ones in the parts catalog. Never Dowel Tube and Ramp use bolts coming from another type of pulley.
  • Page 210 Section 06 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) Lever, Roller and Set Screw Fixed Half, Sliding Half, Spring and Spring Cover CAUTION: Although rollers of TRA V drive pul- ley can be replaced by other rollers from other To install spring cover, use spring compressor TRA drive pulleys, such modifications should (P/N 529 035 524).

  • Page 211: Installation

    Section 06 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) INSTALLATION Insert O-rings no. 20 and slider shoes no. 9 into governor cup no. 7 so that groove in each slider CAUTION: Do not apply antiseize or any lubri- shoe is vertical to properly slide in guides. cant on crankshaft and drive pulley tapers.

  • Page 212: Drive Pulley Adjustment

    Section 06 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) DRIVE PULLEY ADJUSTMENT The drive pulley is factory calibrated to transmit maximum engine power at a predefined RPM. Factors such as ambient temperature, altitude or surface condition may vary this critical engine RPM thus affecting snowmobile efficiency.
  • Page 213 Section 06 DRIVE SYSTEM Subsection 02 (DRIVE PULLEY) A16D0HA TYPICAL 1. Loosen just enough to permit rotating of calibration screw mmr2005-132...

  • Page 214: Driven Pulley

    Section 06 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) DRIVEN PULLEY SERVICE TOOLS Description Part Number Page bushing extractor/installer ............ 529 031 300 ......... 206 clutch spring compressor ............. 529 035 524 ......... 209 clutch spring compressor ............. 529 036 012 ......... 203, 206 crankshaft protector .............

  • Page 215: Hpv Roller

    Section 06 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) HPV ROLLER Mach Z Models mmr2005-133...

  • Page 216: General

    Section 06 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) GENERAL During assembly/installation, use the torque val- ues and the service products as in the exploded views. Clean threads before applying a threadlocker. Re- fer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure.

  • Page 217: Cleaning

    Section 06 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) Remove the rollers axles in sliding half no. 16 by unscrewing the roller axle screws no. 8. Heat screws to break the threadlocker. CLEANING Pulley Halves Using a paper towel with pulley flange cleaner (P/N 413 711 809), clean pulley halves.

  • Page 218: Assembly

    Section 06 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) ROLLER DIAMETER SERVICE LIMIT Inner diameter 12.5 mm (.492 in) 23.5 mm (.925 in) Outer diameter Measure the roller thickness. During cam installation, make sure to align the cam slides with the rollers. INSTALLATION The installation is the reverse of the removal pro- cedure.
  • Page 219 Section 06 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) On threaded rod install both sleeves and one spacer included with the clutch spring compres- sor (P/N 529 036 012). Coat bushing outside diameter with Loctite 380 (Black MAX) (P/N 413 408 300). Place new bush- ing on sliding half and slightly tap to engage squarely the bushing in the sliding.
  • Page 220 Section 06 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) Install circlip. mmr2005-133...

  • Page 221: Hpv Vsa

    Section 06 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) HPV VSA Summit Highmark and Summit Highmark X Models mmr2005-133...

  • Page 222: General

    Section 06 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) GENERAL During assembly/installation, use the torque val- ues and the service products as in the exploded views. Clean threads before applying a threadlocker. Re- fer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure.

  • Page 223: Assembly

    Section 06 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) Screws Screws no. 11 are machined at their end. With the adjustment ring steel to position 0 (zero), screw ends are flush with inner side of fixed pulley half no. 12 when tighten. CAUTION: If any of these screws is not flush with inner side of sliding pulley no.
  • Page 224 Section 06 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) Take first measurement when sliding half begins to turn. Rotate sliding half to 10 mm (3/8 in) of rotation. Hold spring scale at this position. Slow- ly release tension from spring scale and take sec- ond measurement when sliding half begins to re- turn.
  • Page 225 Section 06 DRIVE SYSTEM Subsection 03 (DRIVEN PULLEY) LETTERS AND NUMBERS SHOWN IN ILLUSTRATION ARE ACTUAL LETTERS AND NUMBERS EMBOSSED ON PARTS NOTE: Always recheck torsional preload after ad- justing. Pulley Alignment and Drive Belt Height Refer to PULLEY ALIGNMENT and DRIVE BELT to perform adjustments.

  • Page 226: Pulley Alignment

    Section 06 DRIVE SYSTEM Subsection 04 (PULLEY ALIGNMENT) PULLEY ALIGNMENT SERVICE TOOLS Description Part Number Page alignment bar................ 529 035 831 ......... 214 driven pulley opening tool............. 529 017 200 ......... 213 GENERAL Pulley alignment must be checked out to ensure the highest efficiency of the transmission system.

  • Page 227: Alignment Procedure

    Section 06 DRIVE SYSTEM Subsection 04 (PULLEY ALIGNMENT) ALIGNMENT PROCEDURE Insert the alignment bar (P/N 529 035 831) into the opened driven pulley. Remove driven pulley and add or remove spacer(s) as required to obtain the specified alignment. TYPICAL — ALIGNMENT BAR IN PULLEYS Always measure distances X and Y from the far- ther straight bar side (including its thickness to the fixed half edge).

  • Page 228: Brake

    Section 06 DRIVE SYSTEM Subsection 05 (BRAKE) BRAKE SERVICE PRODUCTS Description Part Number Page DOT 4 brake fluid GTLMA ............ 293 600 062 ......... 217 DOT 4 brake fluid SRF ............293 600 063 ......... 217 Loctite 609................413 703 100 ......... 221 mmr2005-135...
  • Page 229 Section 06 DRIVE SYSTEM Subsection 05 (BRAKE) mmr2005-135...

  • Page 230: General

    Section 06 DRIVE SYSTEM Subsection 05 (BRAKE) GENERAL Install a clear hose on caliper bleed valve no. 3. Route this hose to a container. During assembly/installation, use torque values Loosen bleed valve and pump brake lever until no and service products as in the exploded view. more fluid flows out of bleed valve.

  • Page 231: Brake Pads

    Section 06 DRIVE SYSTEM Subsection 05 (BRAKE) Remove the Banjo bolt no. 4 and discard the seal- ing rings no. 5. Unscrew master cylinder screws no. 6 from the master cylinder holder no. 7 then remove master cylinder from handlebar. Inspection Check master cylinder for cracks or leakage.

  • Page 232: Caliper

    Section 06 DRIVE SYSTEM Subsection 05 (BRAKE) The brake disc no. 13 must be centered in caliper. Apply brake then check for proper brake disc po- sitioning. Push on appropriate caliper piston in order to move pad inward allowing proper brake disc po- sitioning.

  • Page 233: Brake Disc

    Section 06 DRIVE SYSTEM Subsection 05 (BRAKE) 1. Banjo bolt 1. Cotter pin 2. Sealing ring 2. Brake disc nut 3. Caliper bolt 3. Spacer Remove caliper. Unscrew caliper bolts no. 16 and place caliper out of the way. Inspection CAUTION: Do not let the caliper hang by the Check caliper for cracks or leakages.

  • Page 234: Brake Light Switch

    Section 06 DRIVE SYSTEM Subsection 05 (BRAKE) NOTE: In case of switch body breaking during the unscrewing activity, act mechanical restoring the threads on master cylinder seat and then go on with the installation procedure. Installation NOTE: The brake light switch is not adjustable. Put the switch on the seat, rotating it only for 1 or 1.5 turns.

  • Page 235: Chaincase

    Section 06 DRIVE SYSTEM Subsection 06 (CHAINCASE) CHAINCASE SERVICE TOOLS Description Part Number Page countershaft bearing remover/installer......... 529 036 010 ......... 230–231 countershaft measurement tool ........... 529 036 009 ......... 230 SERVICE PRODUCTS Description Part Number Page Loctite 271 (red) ..............293 800 005 ......... 228 XP-S chaincase oil..............
  • Page 236 Section 06 DRIVE SYSTEM Subsection 06 (CHAINCASE) Mach Z series Summit series Summit Mach Z series series Summit series mmr2005-136...

  • Page 237: General

    Section 06 DRIVE SYSTEM Subsection 06 (CHAINCASE) GENERAL OIL CHANGE During assembly/installation, use the torque val- Draining Procedure ues and service products as in the exploded view. Place a drain pan under chaincase drain plug area. Clean threads before applying a threadlocker. Re- Remove dipstick no.

  • Page 238: Tensioner

    Section 06 DRIVE SYSTEM Subsection 06 (CHAINCASE) Remove battery, battery rack and toe hold to allow Check tensioner lever for cracks or other dam- a better access. ages, replace if necessary. Remove the brake disc. Refer to BRAKE. Installation Unscrew the chaincase cover screws no. 6 then The installation is the reverse of the removal pro- remove chaincase cover no.

  • Page 239: Drive Chain And Sprockets

    Section 06 DRIVE SYSTEM Subsection 06 (CHAINCASE) Installation The installation is the reverse of the removal pro- cedure. However, pay attention to the following. Release parking brake and remove caliper and The needle bearing must be installed with the en- brake disc.

  • Page 240: Chaincase Housing

    Section 06 DRIVE SYSTEM Subsection 06 (CHAINCASE) Check if O-ring no. 21 is brittle, hard or damaged. Replace if necessary. Check splines inside spacer no. 20 for wear. Re- place if necessary. Check if the bearing no. 19 turns smoothly and freely.

  • Page 241: Chaincase Housing Bearings

    Section 06 DRIVE SYSTEM Subsection 06 (CHAINCASE) CHAINCASE HOUSING BEARINGS Inspection The bearings must turn smoothly and freely. If not, replace them. Removal To remove the upper bearing no. 28, remove the circlip no. 32 and pull the bearing out of the hous- ing.
  • Page 242 Section 06 DRIVE SYSTEM Subsection 06 (CHAINCASE) Check if the bearing turns smoothly and freely. Replace bearing if any damage is detected. Removal Remove the countershaft. Install the countershaft bearing remover/installer (P/N 529 036 010) on the end of countershaft to remove the bearing.
  • Page 243 Section 06 DRIVE SYSTEM Subsection 06 (CHAINCASE) Install shim(s) then place the new countershaft bearing on countershaft. Install the countershaft bearing remover/installer (P/N 529 036 010) and push bearing in its location. Install all other removed parts in the reverse order of their removal.

  • Page 244: Drive Axle

    Section 06 DRIVE SYSTEM Subsection 07 (DRIVE AXLE) DRIVE AXLE SERVICE TOOLS Description Part Number Page drive axle sprocket adjuster kit ..........861 725 700 ......... 238 SERVICE PRODUCTS Description Part Number Page synthetic grease ..............219 700 417 ......... 238 mmr2005-137...
  • Page 245 Section 06 DRIVE SYSTEM Subsection 07 (DRIVE AXLE) MACH Z Models mmr2005-137...
  • Page 246 Section 06 DRIVE SYSTEM Subsection 07 (DRIVE AXLE) Summit Highmark and Summit Highmark X Models mmr2005-137...

  • Page 247: Removal

    Section 06 DRIVE SYSTEM Subsection 07 (DRIVE AXLE) REMOVAL Remove battery, battery rack and toe-hold to gain access. Drain oil from chaincase. Remove chaincase cov- er. On Summit series, release drive chain ten- sion. Raise and block rear of vehicle off the ground. Remove suspension.
  • Page 248 Section 06 DRIVE SYSTEM Subsection 07 (DRIVE AXLE) Summit Highmark and Summit Highmark X Models MEASURE FROM END OF DRIVE SHAFT A. 132.2 mm (5.205 in) B. 178.1 mm (7.0118 in) C. 310.4 mm (12.220 in) Ensure to align indexing marks of each sprocket when assembling.

  • Page 249: Lubrication

    Section 06 DRIVE SYSTEM Subsection 07 (DRIVE AXLE) TYPICAL 1. Lubricate until grease flows out here ADJUSTMENT Sprocket/Track Alignment CAUTION: Do not tamper with sprocket/track alignment if frame or suspension is damaged. Sprockets may be repositioned to fit lugs without The bearing no.

  • Page 250: Track

    Section 06 DRIVE SYSTEM Subsection 08 (TRACK) TRACK SERVICE TOOLS Description Part Number Page belt tension tester ..............414 348 200 ......... 240 cleat remover................ 529 028 700 ......... 239, 241 narrow-cleat installer ............529 028 800 ......... 239, 241 TRACK TYPE APPLICATION WARNING Do not operate a snowmobile with a cut, torn...
  • Page 251 Section 06 DRIVE SYSTEM Subsection 08 (TRACK) Allow the rear suspension to fully extend and check gap halfway between front and rear idler wheels. Measure between slider shoe bottom and inside of track. The gap should be as given in SPECIFICATIONS. If the track tension is too loose, track will have a tendency to thump.

  • Page 252: Track Cleat

    Section 06 DRIVE SYSTEM Subsection 08 (TRACK) To correct, stop engine, loosen rear wheel screws, then tighten the adjustment screw on side where the slider shoe is the farthest from the track insert guides. 1. Guides TYPICAL 2. Slider shoes 1.
  • Page 253 Section 06 DRIVE SYSTEM Subsection 08 (TRACK) Effects of Studding on the Life – studs that are torn off the track of the Snowmobile – missing track guide(s). The use of traction enhancing products can in- Replace broken or damaged studs immediately. If crease the load and the stress on certain snow- the track shows signs of deterioration, it must be mobile components, as well as the vibration lev-...

  • Page 254: Rear Suspension

    Section 07 REAR SUSPENSION Subsection 01 (SC SUSPENSION) SC SUSPENSION SERVICE PRODUCTS Description Part Number Page suspension synthetic grease ..........293 550 033 ......... 254 mmr2005-147...
  • Page 255 Section 07 REAR SUSPENSION Subsection 01 (SC SUSPENSION) 4.5 N•m (40 lbf•in) 4 N•m (35 lbf•in) RAILS AND IDLER WHEELS mmr2005-147...
  • Page 256 Section 07 REAR SUSPENSION Subsection 01 (SC SUSPENSION) ARMS AND SHOCK ABSORBERS mmr2005-147...
  • Page 257 Section 07 REAR SUSPENSION Subsection 01 (SC SUSPENSION) REAR ARM, SPRINGS AND TOP IDLER WHEELS mmr2005-147...

  • Page 258: Axle Self-Locking Screws Removal

    Section 07 REAR SUSPENSION Subsection 01 (SC SUSPENSION) AXLE SELF-LOCKING SCREWS REMOVAL CAUTION: These self-locking screws must al- ways be replaced by new ones everytime they are removed. NOTE: To prevent axle from turning when un- screwing self-locking screws, proceed as follows: –...

  • Page 259: Rear Shock Absorber Installation

    Section 07 REAR SUSPENSION Subsection 01 (SC SUSPENSION) 1. Loosen lock nut, turn adjuster knob counterclockwise Unbolt front shock from the top. TYPICAL 1. Upper/lower bolt and nut Remove front idler wheels to gain access to axle 2. Rear shock absorber retaining self-locking screws.

  • Page 260: Rear Spring Removal

    Section 07 REAR SUSPENSION Subsection 01 (SC SUSPENSION) DESCRIPTION TIGHTENING TORQUE Adjuster lock nut 19 N•m (168 lbf•in) Stopper straps nuts 21 N•m (15 lbf•ft) (on strap adjuster) Stopper strap(s) nuts 11 N•m (97 lbf•in) REAR SPRING REMOVAL Lift rear of vehicle and support it off the ground. Decrease spring preload by turning cams accord- ingly.

  • Page 261: Slider Shoe Verification

    Section 07 REAR SUSPENSION Subsection 01 (SC SUSPENSION) At assembly, respect THIS SIDE OUT inscription on top idler wheels. At assembly, make sure that spring end is in cam adjuster. TYPICAL 1. Slider shoe 2. Molding line (wear limit indicator) Replace slider shoes when wear limit is reached.

  • Page 262: Slider Shoe Installation

    Section 07 REAR SUSPENSION Subsection 01 (SC SUSPENSION) TYPICAL 1. Track window TYPICAL — PULL ON SLIDER SHOE TO REMOVE 2. Slider shoe Using a pry bar or screw driver, push slider shoe SLIDER SHOE INSTALLATION until it comes in contact with track. Installation is reverse of removal procedure.

  • Page 263: Front Arm Installation

    Section 07 REAR SUSPENSION Subsection 01 (SC SUSPENSION) Remove pivot arm. 1. Shock upper bolt and nut 2. Front arm lower bolts and washers 3. Unfasten one end of stopper straps TYPICAL 4. Front arm upper bolts, nuts and washers 1.

  • Page 264: Stopper Strap

    Section 07 REAR SUSPENSION Subsection 01 (SC SUSPENSION) DESCRIPTION TIGHTENING TORQUE Locking ring set screw 2.5 N•m (22 lbf•in) Rear arm shock upper nut 19.5 N•m (173 lbf•in) Throttle rod upper nut 19.5 N•m (173 lbf•in) STOPPER STRAP Inspect strap for wear or cracks, bolt and nut for tightness.

  • Page 265: Suspension Installation

    Section 07 REAR SUSPENSION Subsection 01 (SC SUSPENSION) TYPICAL — REMOVE SUSPENSION SUSPENSION INSTALLATION Installation is the reverse of removal procedure. Pay attention to the following details. Inspect track thoroughly before reinstalling sus- pension. Refer to TRACK. Install suspension into track with front portion first.

  • Page 266: Sc 4 Suspension

    Section 07 REAR SUSPENSION Subsection 02 (SC 4 SUSPENSION) SC 4 SUSPENSION SERVICE PRODUCTS Description Part Number Page suspension synthetic grease ..........293 550 033 ......... 267 mmr2005-139...
  • Page 267 Section 07 REAR SUSPENSION Subsection 02 (SC 4 SUSPENSION) RAILS AND IDLER WHEELS mmr2005-139...
  • Page 268 Section 07 REAR SUSPENSION Subsection 02 (SC 4 SUSPENSION) ARMS AND SHOCK ABSORBERS mmr2005-139...
  • Page 269 Section 07 REAR SUSPENSION Subsection 02 (SC 4 SUSPENSION) REAR ARM, SPRINGS AND IDLER WHEELS mmr2005-139...

  • Page 270: Axle Self-Locking Screw Removal

    Section 07 REAR SUSPENSION Subsection 02 (SC 4 SUSPENSION) AXLE SELF-LOCKING SCREW REMOVAL CAUTION: These self-locking screws must al- ways be replaced by new ones everytime they are removed. NOTE: To prevent an axle from turning when un- screwing self-locking screws, proceed as follows: –...

  • Page 271: Rear Shock Absorber Installation

    Section 07 REAR SUSPENSION Subsection 02 (SC 4 SUSPENSION) TYPICAL 1. Rear shock absorber 2. Remove bolts and nuts Using a punch, remove lower shock bar axle. Pay attention to plastic spacers. Remove shock. 1. Bar axle 2. Swivel bushings 3.

  • Page 272: Front Shock Absorber Installation

    Section 07 REAR SUSPENSION Subsection 02 (SC 4 SUSPENSION) TYPICAL 1. Front shock absorber 2. Remove bolts and nuts FRONT SHOCK ABSORBER INSTALLATION Installation is reverse of removal procedure. Pay attention to the following details. Shock absorber nuts should be on the RH side. Install shock adjustment ring towards the top, see photo.

  • Page 273: Rear Spring Installation

    Section 07 REAR SUSPENSION Subsection 02 (SC 4 SUSPENSION) – axle spring – top idler wheel – rear spring. ON BOTH SIDES 1. Spring end in cam adjuster CAUTION: To avoid track damage, spring sup- ports must be mounted upward. ON BOTH SIDES 1.

  • Page 274: Slider Shoe Removal

    Section 07 REAR SUSPENSION Subsection 02 (SC 4 SUSPENSION) TYPICAL TYPICAL 1. Slider shoe 1. Track window 2. Molding line (wear limit indicator) 2. Slider shoe Replace slider shoes when wear limit is reached. Using a pry bar or screw driver, push slider shoe until it comes in contact with track.

  • Page 275: Slider Shoe Installation

    Section 07 REAR SUSPENSION Subsection 02 (SC 4 SUSPENSION) PULL ON SLIDER SHOE TO REMOVE TYPICAL — SUSPENSION REMOVED FOR CLARITY 1. Shock upper bolt and nut SLIDER SHOE INSTALLATION 2. Front idler wheels 3. Spring supports 4. Front arm lower bolts and washers Installation is reverse of removal procedure.

  • Page 276: Rear Arm/Pivot Arm Installation

    Section 07 REAR SUSPENSION Subsection 02 (SC 4 SUSPENSION) BLOCK INSTALLATION For pivot arm removal, remove the following: – bolts, nuts and washers holding pivot arm to Both blocks are identified R or L (right or left) and runners. have position number (from 1 to 4). At installation make sure to install proper block on proper side with the same adjustment position on both sides.

  • Page 277: Suspension Removal

    Section 07 REAR SUSPENSION Subsection 02 (SC 4 SUSPENSION) Make sure it is attached through proper hole from the end. Torque nut to 11 N•m (97 lbf•in). 1. Enough clearance TYPICAL 1. 1 hole 2. 2 hole A. 11 N•m (97 lbf• in ) SUSPENSION REMOVAL Lift rear of vehicle and support it off the ground.

  • Page 278: Lubrication

    Section 07 REAR SUSPENSION Subsection 02 (SC 4 SUSPENSION) LUBRICATION Lubricate pivot arm and rear arm at grease fittings using suspension synthetic grease (P/N 293 550 033). mmr2005-139...

  • Page 279: Shock Absorber Inspection And Servicing

    Section 07 REAR SUSPENSION Subsection 03 (SHOCK ABSORBER INSPECTION AND SERVICING) SHOCK ABSORBER INSPECTION AND SERVICING SERVICE TOOLS Description Part Number Page gas fill tool kit (needle type)..........503 190 102 ......... 271, 276 Gas fill tool kit (needle type) ..........503 190 102 ......... 270 gas shock valve tool (tire valve type) ........

  • Page 280: Disassembly And Assembly

    Section 07 REAR SUSPENSION Subsection 03 (SHOCK ABSORBER INSPECTION AND SERVICING) SHOCK ABSORBER INSPECTION Gas Shock Because of gas pressure, strong resistance is felt when compressing shock. For the verification of stroke, or if suspecting an internal leak between oil chamber and gas cham- ber, check shock as follows: Install shock in a vise clamping on its bottom eye- let with its rod upward.
  • Page 281 Section 07 REAR SUSPENSION Subsection 03 (SHOCK ABSORBER INSPECTION AND SERVICING) Remove screw on top of valve. Place the needle guide of gas fill tool kit (needle type) (P/N 503 190 102) on the shock valve. Press the detent pin and push forward the needle assembly very slowly to- wards rubber of needle valve.
  • Page 282 Section 07 REAR SUSPENSION Subsection 03 (SHOCK ABSORBER INSPECTION AND SERVICING) Discard old oil into storage container. Never reuse damper oil during shock rebuild. Remove valve. Using compressed air pressure, carefully remove floating piston from damper body. Hold shop cloth over damper body opening to catch released floating piston.
  • Page 283 Section 07 REAR SUSPENSION Subsection 03 (SHOCK ABSORBER INSPECTION AND SERVICING) 1. Damper nut 2. Spacer 1. Rebound dampening shim pack 3. Stopper with its round edge facing nut 2. Rebound dampening shim pack 4. Shim pack 3. Piston 4. Compression dampening shim pack 5.
  • Page 284 Section 07 REAR SUSPENSION Subsection 03 (SHOCK ABSORBER INSPECTION AND SERVICING) If floating piston has been removed, reinstall float- INSTALLATION DISTANCE OF ing piston into damper body (ensure that valve has SHOCK P/N FLOATING PISTON been removed). Use Molykote G-n paste (P/N 711 mm (in) 297 433) to ease O-ring past damper body threads with floating piston guide.
  • Page 285 Section 07 REAR SUSPENSION Subsection 03 (SHOCK ABSORBER INSPECTION AND SERVICING) NOTE: Although we do not measure the exact Screw Cap Type HPG T/A Shock amount of oil added to the damper, approximately Seal carrier assembly can now be threaded into 252 mL (8.52 oz.
  • Page 286 Section 07 REAR SUSPENSION Subsection 03 (SHOCK ABSORBER INSPECTION AND SERVICING) Mount the shock on vise. Remove screw on top of valve. Place the needle guide of gas refill tool on the shock valve. While depressing the detent pin of the gas refill tool and pushing forward the needle assembly, insert the needle through the rubber core of the pressure valve assembly of the shock.
  • Page 287 Section 07 REAR SUSPENSION Subsection 03 (SHOCK ABSORBER INSPECTION AND SERVICING) Damper gas pressure cannot be confirmed by using a pressure gauge. The volume of gas in the shock is very small, and the amount lost during gauge installation will lower the pressure too much and require refilling.

  • Page 288: Steering/Front Suspension

    Section 08 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) STEERING SYSTEM SERVICE PRODUCTS Description Part Number Page suspension synthetic grease ..........293 550 033 ......... 289 mmr2005-141...
  • Page 289 Section 08 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) Linkage Arrangement mmr2005-141...
  • Page 290 Section 08 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) Handlebar Arrangement SUMMIT HIGHMARK MACH Z/SUMMIT HIGHMARK X MACH Z SUMMIT HIGHMARK X SUMMIT mmr2005-141...

  • Page 291: Disassembly And Assembly

    Section 08 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) DISASSEMBLY AND ASSEMBLY Using a plastic hammer, tap on the side of the wrench end to make the grip slide out. Grip NOTE: These models feature an integrated heat- ing element in the plastic sleeve of the grip no. 13. CAUTION: Removing grip from handlebar might damage the heating element.
  • Page 292 Section 08 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) MODEL TOOL PART NUMBER Models with straight 529 035 897 grips Models with J-hooks 529 035 936 1. Connectors unplugged Unplug LH harness on top of steering column. Cut locking ties retaining brake light switch/heat- ing grip harness to handlebar.

  • Page 293: Steering Column

    Section 08 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) Reinstall terminals and replug connectors. Test grips to ensure they heat properly. Steering Column Remove windshield. Remove steering padding no. 23. Remove screws retaining indicator support and in- dicator support door. TYPICAL 1.
  • Page 294 Section 08 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) 1. Arrow on clamp pointing downward FUEL GAUGE 2. Tighten bottom screw first 1. Unplug Refer to HANDLEBAR POSITION ADJUSTMENT Remove console. for handlebar reinstallation. Mach Z and Summit RH and LH Swivel Arm If applicable, cut locking ties retaining harnesses to steering column no.

  • Page 295: Inspection

    Section 08 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) TYPICAL A. 20 mm (25/32 in) max. The ball joint no. 17 and no. 18 should be re- strained when tightening the tie rod end lock nut. TYPICAL Align it so the tie rod end is parallel to the steering 1.
  • Page 296 Section 08 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) TYPICAL 1. Torque to 25 N•m (18 lbf•ft) A. Equal gap all around 1. Opening here CAUTION: Tighten the bolts equally in a criss- 2. Extension against stopper cross sequence and ensure there is an equal gap on each side of the clamps no.

  • Page 297: Steering Adjustment (Skis)

    Section 08 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) J-Hook Adjustment Summit Position J-hook so that its curved end is pointing downward and is roughly vertical. Ensure to ad- just J-hooks at the same position each side. STEERING ADJUSTMENT (SKIS) Toe-Out A difference measured between the front edge of the ski bridge "A"...

  • Page 298: Lubrication

    Section 08 STEERING/FRONT SUSPENSION Subsection 01 (STEERING SYSTEM) RIGHT HAND SIDE SHOWN 1. Ski leg 2. Lower arm A. 2 mm (5/64 in) TYPICAL 1. Straight edge If the distance is more than the specified distance 2. Rubber cord on one side then check for bent parts. 3.

  • Page 299: Front Suspension

    Section 08 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) FRONT SUSPENSION SERVICE TOOLS Description Part Number Page A-arm nut wrench..............529 035 876 ......... 301 ball joint installer ..............529 035 975 ......... 301 ball joint lock tool ..............529 035 945 ......... 302 ball joint remover ..............
  • Page 300 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) Summit SUSPENSION ARMS, SKI LEG AND ANTI-SWAY BAR mmr2005-142...
  • Page 301 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) Mach Z ARMS, SKI LEG AND ANTI-SWAY BAR mmr2005-142...
  • Page 302 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) Summit and Mach Z Precision Ski Mountain Ski SHOCK ABSORBERS AND SKIS NOTE: The same procedure applies on both sides. mmr2005-142...

  • Page 303: General Inspection

    Section 08 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) GENERAL INSPECTION Check for looseness, bent, worn out, rusted or other damage on components. Ensure cotter pins are in good condition and properly secured. Re- place the faulty component. To check upper arm bushings and ball joint: –...
  • Page 304 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) Mount shock absorber in it and turn shock ab- sorber so that spring coils match spring compres- sor. Close and lock the bar. Adjust the handle at hori- zontal position by changing the position of the cle- vis pin.
  • Page 305 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) TYPICAL 1. Ball joint parallel with ski leg Remove lower arm no. 10 from frame. For front 1. Remove screw screw no. 17 removal, hold nut no. 18 from engine 2. Link rod 3.
  • Page 306 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) Use a 11 mm (7/16 in) open wrench to hold ball joint housing and unscrew nut no. 16, then re- move ball joint from upper arm. Remove upper arm no. 14 from frame. For screws no.
  • Page 307 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) Remove clamps no. 22 and bushings no. 23. To remove bushing no. 25, use a 13 mm (1/2 in) Using a 4.8 mm (3/16 in) drill bit, drill rivet no. 24 open wrench and tap bushing out as shown. out.

  • Page 308: Inspection

    Section 08 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) Nuts with a cotter pin: After applying the prop- er torque, continue tightening as necessary to al- low cotter pin insertion. Ensure to properly secure cotter pin. WARNING Always install new cotter pins at assembly and properly bend their ends.
  • Page 309 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) Prior to installing ball joint in lower arm, ensure to clean the tapered surfaces with the pulley flange cleaner (P/N 413 711 809). Surface contacts must be clean and free of dirt, oil and grease. Apply the cleaner on a rag then use the rag to clean the surfaces of ball joint and ski leg.
  • Page 310 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) Anti-Sway Bar Summit Notice that LH and RH sliding blocks are different. Look for their molded identification with LH or RH letters. 1. Tool perpendicular (90°) to torque wrench A. 90° 1. Molded identification for proper side installation Use ball joint lock tool (P/N 529 035 945) to restrain To install sliding blocks: ball joint during nut tightening.
  • Page 311 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) LOOKING FROM THE FRONT OF THE VEHICLE 1. Anti-sway bar 2. Link rod 3. Allen screw 4. Elastic nut 5. Lower A-arm 1. Temporarily rotate block by 180° for its insertion Shock Absorber Ensure to reinstall shock absorber in the proper position according to model.
  • Page 312 Section 08 STEERING/FRONT SUSPENSION Subsection 02 (FRONT SUSPENSION) Summit Install bushing no. 29 and spacer no. 30 inward on each ski leg for the wide ski stance. Install outward for narrow ski stance. WARNING Install skis with proper side facing inward. Refer to warning on ski.

  • Page 313: Body/Frame

    Section 09 BODY/FRAME Subsection 01 (BODY) BODY SERVICE TOOLS Description Part Number Page adjustment wrench............... 529 035 891 ......... 307 Supertanium™ drill bit ............529 031 800 ......... 306 DECAL FRONT BUMPER To remove a decal; heat old decal with a heat gun Removal and peel off slowly.

  • Page 314: Bottom Pan

    Section 09 BODY/FRAME Subsection 01 (BODY) Remove retaining screws, one on each sides. Remove front bumper. 1. Access panel screws 2. Rubber grommet for windshield Installation The installation is the reverse of removal proce- Installation dure. The installation is the reverse of removal proce- BOTTOM PAN dure.

  • Page 315: Console

    Section 09 BODY/FRAME Subsection 01 (BODY) CONSOLE Installation The installation is the reverse of removal proce- Removal dure. Remove the indicator panel. SEAT Remove the screws near headlamp. One on each side. Cleaning It is recommended to clean the seat with a solu- tion of warm soapy water, using a soft clean cloth.

  • Page 316: Plastic Maintenance And Repair

    Section 09 BODY/FRAME Subsection 01 (BODY) Cover Replacement CAUTION: The following products must not be used to clean or wax any of the plastic compo- Remove the old seat cover. Check the foam and nents used on the vehicles: replace it if necessary. –...
  • Page 317 Section 09 BODY/FRAME Subsection 01 (BODY) PLASTIC PARTS PARTS MATERIAL Access panel Polypropylene Bottom pan Polypropylene Console Surlyn Front bumper Polypropylene Hood Surlyn Indicator panel Polypropylene Side panel Surlyn CAUTION: Some repair products are not com- patible with certain plastics. WARNING Polycarbonate windshields must never be re- paired by welding or otherwise.

  • Page 318: Frame

    Section 09 BODY/FRAME Subsection 02 (FRAME) FRAME SERVICE TOOLS Description Part Number Page Supertanium™ drill bit ............529 031 800 ......... 311–312 SERVICE PRODUCTS Description Part Number Page XP-S synthetic chaincase oil ..........413 803 300 ......... 311 FRAME CLEANING FRAME COMPONENT REPLACEMENT NOTE: For bare aluminum frames use only alu-...
  • Page 319 Section 09 BODY/FRAME Subsection 02 (FRAME) For the Installation of Lower A-arm Brackets, do the Following: Secure the new lower brackets to frame using the following fasteners: QUANTITY FASTENERS DESCRIPTION Hexagonal flanged bolt M8 x 55 (P/N 207 685 044) Flanged nut M8 (P/N 233 081 416) NOTE: Bolt head should be on the RH side of the...
  • Page 320 Section 09 BODY/FRAME Subsection 02 (FRAME) – hood – muffler – tuned pipe – front bumper brace – pivot support 1. RH tie rod bolt – swivel bar with swivel arms – front shock absorbers – upper and lower A-arms (with tie-rods and skis) –...
  • Page 321 Section 09 BODY/FRAME Subsection 02 (FRAME) On each side, install the following fasteners in- stead of rivets. QUANTITY FASTENERS DESCRIPTION Hexagonal flanged bolt M6 x 20 (P/N 207 662 044) Elastic flanged nut M6 (P/N 233 261 414) Hexagonal flanged bolt M5 x 16 (P/N 207 151 644) Elastic flanged nut M5 (P/N 233 251 414)
  • Page 322 Section 09 BODY/FRAME Subsection 02 (FRAME) RH Support Unscrew engine and lift it. Remove the RH handle support. Remove chaincase housing. Refer to CHAIN- CASE. Drill all rivets holding engine support to frame. To install a new or existing engine support, reverse the removal procedure.

  • Page 323: Technical Data

    Section 10 TECHNICAL DATA Subsection 01 (MACH Z/SUMMIT 1000 SDI) MACH Z/SUMMIT 1000 SDI MACH Z SUMMIT MODEL 1000 SDI 1000 SDI ENGINE Engine 995 SDI Number of cylinders Bore Standard mm (in) 88 (3.465) Stroke mm (in) 82 (3.228) Displacement 997.47 (60.870) Compression ratio...
  • Page 324 Section 10 TECHNICAL DATA Subsection 01 (MACH Z/SUMMIT 1000 SDI) MACH Z SUMMIT MODEL 1000 SDI 1000 SDI Starter solenoid Fuse Fuel level sensor 0.25 N.A. FUEL SYSTEM Throttle body type Dell'Orto Idle speed ± 200 RPM 1600 Gas type Premium unleaded Inside North America (R+M)/2...
  • Page 325 Section 10 TECHNICAL DATA Subsection 01 (MACH Z/SUMMIT 1000 SDI) MACH Z SUMMIT MODEL 1000 SDI 1000 SDI Drive belt part number 417 300 189 Width (10) mm (in) 38.3 (1.51) Drive belt Wear limit mm (in) 35.9 (1.41) Deflection mm (in) 32 ±...
  • Page 326 Section 10 TECHNICAL DATA Subsection 01 (MACH Z/SUMMIT 1000 SDI) MACH Z SUMMIT MODEL 1000 SDI 1000 SDI TIGHTENING TORQUE (engine cold) Drive pulley retaining screw Exhaust manifold screws 21.5 N•m (16 lbf•ft) Magneto ring nut 130 N•m (96 lbf•ft) 9 N•m (80 lbf•in) Crankcase nuts or screws 29 N•m (21 lbf•ft)

  • Page 327: Technical Data Legend

    Section 10 TECHNICAL DATA Subsection 01 (MACH Z/SUMMIT 1000 SDI) TECHNICAL DATA LEGEND The maximum horsepower RPM applicable on BTDC: Before Top Dead Center the vehicle. It may be different under certain CDI: Capacitor Discharge Ignition circumstances and BRP reserves the right to modify it without obligation.

  • Page 328: Wiring Diagrams

    Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) WIRING DIAGRAMS SERVICE TOOLS Description Part Number Page connector crimping tool............529 035 909 ......... 332 crimper die................529 035 906 ......... 332 Wiring diagrams can be found at the end of this COLOR CODE subsection.

  • Page 329: Housing Reference Per Area

    Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) AREA LOCATION Right hand side of engine Engine Near right hand side footrest Near driven pulley Under console Under hood Near fuel tank Under engine Near steering column or on primary air intake silencer On handlebar Injection oil tank Secondary air intake silencer...
  • Page 330 Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) 10 9 MMR2005-146...

  • Page 331: Symbols Description

    Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) SYMBOLS DESCRIPTION MMR2005-146...

  • Page 332: Unplugging Connectors

    Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) UNPLUGGING CONNECTORS Always unplug connectors by pulling on housing not on wire. 1. Insert screwdriver here 2. Pull this side Locking Receptacle Connector To remove: TYPICAL – Insert tool Snap-on TT 600-5 in access opening then pull housing toward wire side.
  • Page 333 Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) 1. Lock – Pry tab to free connector then pull wire out of housing. – Pry tab to free connector then pull wire out of housing. MALE CONNECTOR HOUSING — CUT-AWAY FEMALE CONNECTOR HOUSING — CUT-AWAY Multilock Connector Housing Male Connector Housing Female Connector Housing...
  • Page 334 Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) MALE CONNECTOR HOUSING — CUT-AWAY 1. Lock 24-Circuit Connector Housing Push on both tabs to remove retainer. FEMALE CONNECTOR HOUSING — CUT-AWAY 1. Lock Receptacle connectors can be removed from fe- male housing with sharp head pin. Male Connector Housing 1.
  • Page 335 Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Lift the top plastic lock of the female terminal to be removed and hold in position. Lift the female terminal to unlock from the housing and push out of housing. 8-CIRCUIT CONNECTOR HOUSING — CUT-AWAY 1.
  • Page 336 Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Cut both locking ties that secure the harness to Insert the probe into the housing as shown, and the housing. locate the appropriate wire in the back of the housing. You may have to slightly cam the probe against the locking tab to release it, then remove the terminal from the housing.
  • Page 337 Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) When reinserting the connector, the locking tab must be installed facing the smaller cutout of the connector cavity. TYPICAL A. 3 mm (1/8 in) max. Position wire in terminal. Squeeze the terminal tabs with your fingers to temporarily retain terminal in place.

  • Page 338: Tab And Receptacle Connectors Installation

    Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) A00E1FA TYPICAL 1. Top of terminal tabs 1. Receptacle 2. Align tabs with pliers edge 2. Housing Crimp terminal. Ensure no tiny wire goes out of WARNING terminal. This might cause strange problems of Keep wires away from any rotating, moving, the electrical system.
  • Page 339 Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) MMR2005-146...
  • Page 340 NOTES...
  • Page 341 NOTES...
  • Page 342 2005 MACH Z RT/SUMMIT RT A35Z02...

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