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BRP ski-doo MX Z X 440 RACING Handbook

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Page 2: Table Of Contents
2005 RACING HANDBOOK TABLE OF CONTENTS Section CONTACTING THE RACE DEPARTMENT ................01-1 2005 MODELS TECHNICAL DATA..................02-1 CHASSIS PREPARATION ......................03-1 SUSPENSION SC-3 SC-4 - RAS....................04-1 ENGINE PREPARATION ......................05-1 DRIVE SYSTEM ........................06-1 2005 MX Z X 440 ........................07-1 2005 MX Z 550 AND 380 FC ....................
Page 3: Contacting The Race Department
Steve Cowing Competition and Media Relations Manager 24078 Greenway Rd. Unit #4 Forest Lake MN. 55025 Phone: 651 982-6223 Fax:651 982-6225 E-mail: steve.cowing@brp.com • Race Program • Race Resumes • Race Sleds Allocation • Media Relations • Press Events • Dealer Programs...
Page 4 CDN RACERS (FRENCH SPEAKING RACERS ONLY) Marcel Imbeault Race Manager 565, de la Montagne Valcourt, QC J0E 2L0 Phone: 450-532-2211 Ext. 5479 Fax: 450-532-6175 E-mail: marcel.imbeault@brp.com • Race Program • Race Resumes • Race Sleds Allocation Hélène Despaties Race Manager Assistant 565, de la Montagne Valcourt, QC J0E 2L0 Phone: 450-532-2211 Ext.
Page 5 Name: City: To receive the T.I.P. sheets by e-mail, send an e-mail to the following: helene.despaties@brp.com and mention to add your address on the tip sheet distribution list ******* To receive the T.I.P. sheets by fax, send a fax to the following: Fax to: Hélène Despaties at (450) 532-6175...
Page 6 (1) 15% fee will be char ged on returned parts - Written Return Authorization Required (2) Phone call orders or shippin g requests will not be accepted ( 3) ONLY FAXED ORDERS WILL BE ACCEPTE D (COMPLETELY FILLED) eric.arsenault@brp.com 01-4 MMC2005-001_01A.FM...
Page 7 SECTION 01 - CONTACTING THE RACE DEPARTMENT O O RDER FORM Race Support Truck DATE: Page 1 of____ Phone : 320-251-2882 Fax: 320-251-3733 If you are a dealer: SHIP TO: (name & complete address) Name: Number: Signature: PHONE #: FAX #: VISA ___ MASTER CARD ___ # __________________________ Exp.
Page 8 SECTION 02 - 2005 MODELS TECHNICAL DATA TABLE OF CONTENTS MX Z X 440 RACING ......................... 02-2 MX Z 600 HO/800 HO ........................ 02-5 MX Z 380F/550F ......................... 02-10 SUMMIT 600 HO/800 HO ......................02-14 MACH Z 1000 SDI/SUMMIT 1000 SDI..................02-19 TECHNICAL DATA LEGEND .....................
Page 9: Mx Z X 440 Racing
SECTION 02 - 2005 MODELS TECHNICAL DATA MX Z X 440 RACING MODEL MX Z X 440 Racing ENGINE Engine type Number of cylinders Bore mm (in) 65.0 (2.56) Stroke mm (in) 65.8 (2.59) Displacement 436.7 (26.6) Maximum power engine speed [1] ±100 RPM 8400 Semi-trapezoidal...
Page 10 SECTION 02 - 2005 MODELS TECHNICAL DATA MODEL MX Z X 440 Racing ELECTRICAL Magneto generator output Ignition type Spark plug make and type [6] NGK BR9ECS Spark plug gap ± 0.05 mm (± 0.002 in) 0.45 (.018) Ignition timing BTDC [3] mm (in) 3.00 (.1181) Trigger coil [4]...
Page 11 SECTION 02 - 2005 MODELS TECHNICAL DATA MODEL MX Z X 440 Racing GENERAL SPECIFICATIONS Length mm (in) 2882 (113) Width mm (in) 1217 (47.9) Height mm (in) 1022 (40) Ski stance mm (in) 1080 (42.5) Mass (dry) kg (lb) 199 (438) Ground contact area 6670 (1034)
Page 12: Mx Z 600 Ho/800Ho
SECTION 02 - 2005 MODELS TECHNICAL DATA MX Z 600 HO/800HO MX Z MODEL 600 HO 800 HO ENGINE Engine type 593 HO 793 HO Number of cylinder Bore Standard mm (in) 72 (2.835) 82 (3.228) Stroke mm (in) 73 (2.874) 75.70 (2.980) Displacement 594.40 (36.273)
Page 13 SECTION 02 - 2005 MODELS TECHNICAL DATA MX Z MODEL 600 HO 800 HO Starter solenoid Fuse Fuel level sensor — FUEL SYSTEM TM40–B319 Carburetor/throttle body type TM40 – B316 Power TEK: TM40–B322 Main jet Power TEK: 440 Needle jet P-0M Pilot jet 17.5...
Page 14 SECTION 02 - 2005 MODELS TECHNICAL DATA MX Z MODEL 600 HO 800 HO Clutch engagement ± 100 RPM 3800 Spring color Purple/Blue Violet/Green Spring length mm (in) 114.6 (4.5) 133.5 (5.256) Weight — Block — Drive pulley calibration — Solid (P/N 417 004 308) Solid (P/N 417 222 594) Ramp...
Page 15 SECTION 02 - 2005 MODELS TECHNICAL DATA MX Z MODEL 600 HO 800 HO Adrenaline SC 3 121” Track Renegade SC 3 136” Suspension type Trail SC 3 121” — R.A.S. A-arm BRAKE Brake fluid reservoir mL (U.S. oz) 60 (2.0) GTLMA (DOT 4) (P/N 293 600 062) Brake fluid (P/N) Racing brake fluid SRF (DOT 4) (P/N 293 600 063)
Page 16 SECTION 02 - 2005 MODELS TECHNICAL DATA MX Z MODEL 600 HO 800 HO CAPACITIES Fuel tank L (U.S. gal) 40 (10.6) Chaincase/gearbox mL (U.S. oz) 250 (8.5) Adrenaline L (U.S. oz) 4.9 (165.7) Cooling system Renegade L (U.S. oz) 5.17 (174.8) Trail L (U.S.
Page 17: Mx Z 380F/550F
SECTION 02 - 2005 MODELS TECHNICAL DATA MX Z 380F/550F MX Z MODEL 380 F 550 F ENGINE Engine type Number of cylinder Bore Standard mm (in) 62 (2.441) 76 (2.992) Stroke mm (in) 61.00 (2.402) Displacement 368.30 (22.475 in) 553.40 (33.771) Compression ratio 11.2 ±...
Page 18 SECTION 02 - 2005 MODELS TECHNICAL DATA MX Z MODEL 380 F 550 F Starter solenoid N.A. Fuse Fuel level sensor N.A. FUEL SYSTEM Carburetor type VM30–213 VM34–617 Main jet Needle jet Pilot jet Needle identification 6DEY13-3 6BCY40-4 Slide cut-away Float adjustment mm (in) 23.90 ±...
Page 19 SECTION 02 - 2005 MODELS TECHNICAL DATA MX Z MODEL 380 F 550 F Type Formula RER Driven pulley Spring preload N.A. Cam angle 44° Pulley distance mm (in) 17.5 (0.689) mm (in) 33.4 ± 0.5 (1.315 ± 0.2) Offset Y –...
Page 20 SECTION 02 - 2005 MODELS TECHNICAL DATA MX Z MODEL 380 F 550 F CAPACITIES Fuel tank L (U.S. gal) 40 (10.6) Chaincase/gearbox mL (U.S. oz) 250 (8.5) Cooling system L (U.S. oz) N.A. Injection oil reservoir L (U.S. oz) 3.5 (118.4) TIGHTENING TORQUE (engine cold) Drive pulley retaining screw...
Page 21: Summit 600 Ho/800Ho
SECTION 02 - 2005 MODELS TECHNICAL DATA SUMMIT 600 HO/800HO SUMMIT MODEL 600 HO 800 HO ENGINE Engine type 593 HO 793 HO Number of cylinder Bore Standard mm (in) 72 (2.835) 82 (3.228) Stroke mm (in) 73 (2.874) 75.70 (2.980) Displacement 594.40 (36.273) 799.50 (48.789)
Page 22 SECTION 02 - 2005 MODELS TECHNICAL DATA SUMMIT MODEL 600 HO 800 HO Starter solenoid — Fuse Fuel level sensor — FUEL SYSTEM Carburetor/throttle body type TM40 – B325 TM40 – B328 Main jet Needle jet P-0M Pilot jet 17.5 Needle identification 9DGK11–58 9EGY2–58...
Page 23 SECTION 02 - 2005 MODELS TECHNICAL DATA SUMMIT MODEL 600 HO 800 HO Clutch engagement ± 100 RPM 3600 3800 Spring color Purple/White Violet/Yellow Spring length mm (in) 98.5 (3.878) 157.9 (6.217) Weight — Block — Drive pulley calibration — Solid (P/N 417 222 478) Solid (P/N 417 222 707) Pin (with roller (P/N 417 003 900))
Page 24 SECTION 02 - 2005 MODELS TECHNICAL DATA SUMMIT MODEL 600 HO 800 HO SC 144” Adrenaline — SC 151” Track — SC 144” Suspension type — SC 151” — SC 159” R.A.S. A-arm BRAKE Brake fluid reservoir mL (U.S. oz) 60 (2.0) GTLMA (DOT 4) (P/N 293 600 062) Brake fluid (P/N)
Page 25 SECTION 02 - 2005 MODELS TECHNICAL DATA SUMMIT MODEL 600 HO 800 HO 144” 2.41 kPa (.349 PSI) Adrenaline 151” — 2.30 kPa (.334 PSI) 144” Manual start — 2.41 kPa (.349 PSI) 144” Electric start — 2.54 kPa (.368 PSI) Ground contact pressure 151”...
Page 26: Mach Z 1000 Sdi/Summit 1000 Sdi
SECTION 02 - 2005 MODELS TECHNICAL DATA MACH Z 1000 SDI/SUMMIT 1000 SDI MACH Z SUMMIT MODEL 1000 SDI 1000 SDI ENGINE Engine type 995 SDI Number of cylinder Bore Standard mm (in) 88 (3.465) Stroke mm (in) 82 (3.228) Displacement 997.47 (60.869) Compression ratio...
Page 27 SECTION 02 - 2005 MODELS TECHNICAL DATA 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 Pump octane number Outside North America...
Page 28 SECTION 02 - 2005 MODELS TECHNICAL DATA MACH Z SUMMIT MODEL 1000 SDI 1000 SDI Type HPV Roller HPV VSA Driven pulley type Spring preload Cam angle 44°/33° 44°/30° Pulley distance mm (in) 27.5 (1.083) mm (in) 37.0 ± 0.5 (1.457 ± 0.2) Offset Y –...
Page 29 SECTION 02 - 2005 MODELS TECHNICAL DATA MACH Z SUMMIT MODEL 1000 SDI 1000 SDI CAPACITIES Fuel tank L (U.S. gal) 40 (10.6) Chaincase/gearbox mL (U.S. oz) 250 (8.5) Cooling system L (U.S. oz) 6.4 (216.4) 7.4 (250.2) Injection oil reservoir L (U.S.
Page 30: Technical Data Legend
SECTION 02 - 2005 MODELS TECHNICAL DATA TECHNICAL DATA LEGEND BTDC: Before Top Dead Center R.A.S.: Response Angle Suspension RER: Rotax Electronic Reverse CDI: Capacitor Discharge Ignition MAG: Magneto RPM: Revolution Per Minute N.A.: Not Applicable TRA: Total Range Adjustable P/N: Part Number VSA:...
Page 31 SECTION 03 - CHASSIS PREPARATION TABLE OF CONTENTS SUSPENSION OPERATION/ WEIGHT TRANSFER ..............03-2 SPRINGS ............................ 03-3 SPRING DESCRIPTION ......................... 03-6 COIL SPRINGS (compression) ....................03-6 TORSION SPRINGS........................03-7 SPRING APPLICATIONS ....................... 03-8 SPRING SPECIFICATIONS ......................03-11 CORNERING DYNAMICS ......................03-15 SHOCKS .............................
Page 32: Suspension Operation/ Weight Transfer
SECTION 03 - CHASSIS PREPARATION SUSPENSION OPERATION/ If we keep force “C” constant, we can then vary the size of the vertical and horizontal forces at the WEIGHT TRANSFER front arm by varying angle “A”. As angle “A” is made smaller, force “X” decreases, and force “Z” The purpose of any suspension system is to iso- increases.
Page 33: Springs
SECTION 03 - CHASSIS PREPARATION Contrary to popular belief, it is not necessary to have the skis 2 feet off the ground to achieve good weight transfer. In fact, the energy used to lift the Number front of the vehicle is not available to push the ve- of coils hicle forward.
Page 34 SECTION 03 - CHASSIS PREPARATION Coil Springs The free length of a coil spring is the length with no load applied to the spring. 1" 1" The spring rate of a coil spring is defined as the amount of force required to compress the spring one inch.
Page 35 SECTION 03 - CHASSIS PREPARATION Dual Rate Spring Formula × Spring 1 Spring 2 -------------------------------------------------- - Spring 1 Spring 2 A Dual Rate Spring will assume the rate of the heavier rate spring when the lighter spring bot- toms or coil binds. Example: Spring 1 100# Rate Free opening angle...
Page 36: Spring Description
SECTION 03 - CHASSIS PREPARATION SPRING DESCRIPTION Type T (barrel shape on both ends) COIL SPRINGS (compression) (Single Rate Spring) NOTE: Read color when spring is upright and stripes are down. Type R (straight on both ends) (Single Rate Spring) A06F02A 1.
Page 37: Torsion Springs
SECTION 03 - CHASSIS PREPARATION Type Y Type 4 (barrel shape on both ends with (barrel shape on both ends with positioning tab at the color code coils end) positioning tab at the color code coils end) (Single Rate Spring) (Dual Rate Spring) 1.
Page 38: Spring Applications
SECTION 03 - CHASSIS PREPARATION SPRING APPLICATIONS 2005 FRONT SPRINGS 2005 MODEL (P/N) SOFTER SPRING (P/N) STANDARD (P/N) HARDER SPRING MACH Z 505 071 492 505 071 447 505 070 536 MX Z ADRENALINE 505 071 129 505 071 257 505 070 762 MX Z TRAIL 505 071 129...
Page 39 SECTION 03 - CHASSIS PREPARATION 2005 CENTER SPRINGS 2005 MODEL (P/N) SOFTER SPRING (P/N) STANDARD (P/N) HARDER SPRING 503 189 659 MACH Z 503 189 325 503 189 686 503 190 476 503 190 476 MX Z ADRENALINE 503 189 812 503 190 480 503 190 478 MX Z TRAIL...
Page 40 SECTION 03 - CHASSIS PREPARATION 2005 REAR SPRINGS 2005 MODEL (P/N) SOFTER SPRING (P/N) STANDARD (P/N) HARDER SPRING 503 190 775 LH 503 190 718LH 503 191 000 LH MACH Z 503 190 716 RH 503 190 999 RH 503 190 773 RH 503 190 718 LH 503 190 714 LH 503 190 775 LH...
Page 41: Spring Specifications
SECTION 03 - CHASSIS PREPARATION SPRING SPECIFICATIONS Coil Springs Specifications-Steel SPRING FREE WIRE COLOR CODE COLOR OF TYPE RATE LENGTH DIAMETER STRIPES SPRING (lb/in) ± 10 (mm) ± 3 (mm) ± .05 415 070 100 7,82 GD/YL/YL BLACK 415 070 500 8,41 BL/YL/YL BLACK...
Page 42 SECTION 03 - CHASSIS PREPARATION SPRING FREE WIRE COLOR CODE COLOR OF TYPE RATE LENGTH DIAMETER STRIPES SPRING (lb/in) ± 10 (mm) ± 3 (mm) ± .05 505 070 392 55-85 7,77 RD/GD/YL BLACK 505 070 393 55-85 7,77 RD/BL/RD YELLOW 505 070 394 7,49...
Page 43 SECTION 03 - CHASSIS PREPARATION Torsion Spring Specification-Steel-Round Wire OPENING WIRE DIAMETER LENGTH SPRING RATE ANGLE COLOR CODE (MM) (MM) FT. LBS/DEG + - 7 486 071 100 RH 10,3 0,82 YL/YL 486 071 200 LH 486 071 300 RH 10,3 0,81 WH/WH...
Page 44 SECTION 03 - CHASSIS PREPARATION OPENING WIRE DIAMETER LENGTH SPRING RATE ANGLE COLOR CODE (MM) (MM) FT. LBS/DEG + - 7 503 189 881 RH 11.11 1,05 YL/BL 503 189 883 LH 503 189 898 RH 11.5 1,36 GD/GD/GD 503 189 900 LH 503 189 902 RH 10.6 0,94...
Page 45: Cornering Dynamics
SECTION 03 - CHASSIS PREPARATION CORNERING DYNAMICS By having a sway bar in the suspension, softer springs can be used to achieve a good ride be- The ideal situation, while going through a turn, is cause the bar will help control roll in a corner. The to keep the snowmobile as flat as possible without bar has no affect on ride when traveling straight the skis or track losing contact with the driving sur-...
Page 46: Shocks
SECTION 03 - CHASSIS PREPARATION SHOCKS EFFECT OF BLEED SLITS Valving and Dampening bleeds Rebound 2 bleeds In the HPG shock, the piston passages are cov- 4 bleeds 6 bleeds ered by a stack of thin metal shims of various thicknesses and diameters.
Page 47 SECTION 03 - CHASSIS PREPARATION As mentioned earlier, the configuration of the shim stack will control most of the dampening of the shock. There are several methods to tuning shim stacks. The first and most commonly used is to increase or decrease the overall stiffness of the stack.
Page 48 SECTION 03 - CHASSIS PREPARATION Shim Comparator Formula Thickness³ or cubed. Example: .152 x .152 x .152 The large shims are only able to deflect .203 mm instead of .610 mm thus reducing the flow area of the piston. This will result in the same low speed dampening, but the medium and high speed Another method of changing dampening is by con- damping will be increased.
Page 49 SECTION 03 - CHASSIS PREPARATION As you can see, low speed dampening remains – Under dampening may be due to an aerated the same until the shim stack bottoms out against shock due to low gas pressure and/or old, used the valve stopper.
Page 50 SECTION 03 - CHASSIS PREPARATION 1. Schrader valve 1.5-2 N•m (13-17 lbf•in) 2. Schrader cap 5-6.5 N•m (44-57 lbf•in) NOTE: Before unscrewing pre-load rings, mea- sure the compressed length of the installed spring and mark position for reinstallation. For factory ad- justment refer to the end of this section.
Page 51 SECTION 03 - CHASSIS PREPARATION Holding damper assembly in bench vise with alumi- Remove Schrader valve core. Using compressed num jaw protectors, unthread seal assembly from air pressure, carefully remove floating piston from damper body using a 32 mm (1.25 in) spanner damper body.
Page 52 SECTION 03 - CHASSIS PREPARATION NOTE: If revalving is to be done, it is imperative that you identify the original shim pack (size and number of shims). The seal carrier need not be removed if only revalving is to be done. Shims can be measured by using a vernier caliper or a micrometer.
Page 53 SECTION 03 - CHASSIS PREPARATION A06F0XA 1. Damper nut 2. Spacer A06F0YA 3. Washer 4. Shim pack 1. Rebound dampening shim pack 2. Rebound dampening shim pack CAUTION: The damper rod nut can only be re- 3. Piston 4. Compression dampening shim used 4 times, then, must be replaced.
Page 54 SECTION 03 - CHASSIS PREPARATION Compression Whenever tuning for more compression dampen- ing always use 30 mm (1.18 in) shims against pis- ton to properly close piston orifice holes. Two thin shims will offer more control than one thick shim of the equal thickness.
Page 55 SECTION 03 - CHASSIS PREPARATION On all HPG take apart shocks from 1996 on. The floating piston is installed hollow side up. 1. Fill to 10 mm (.393 in) NOTE: Although we do not measure the exact amount of oil added to the damper, approximately 106 mL (3.58 oz U.S.) will be used.
Page 56 SECTION 03 - CHASSIS PREPARATION CAUTION: Use care when passing piston into damper body at damper body threads. Slight oscillation of damper rod may be required to allow piston to enter damper body bore. Slowly push piston into damper body. Slight up and down movement may be required to allow all air to pass through piston assembly.
Page 57: Chassis Set-Up
SECTION 03 - CHASSIS PREPARATION After recharging is complete and before installing Good chassis set up starts with accurate align- the spring the rebuilt shock should be bench-tested. ment of the drive axle, countershaft, suspension Stroke the shock to ensure full travel and smooth system, and chassis.
Page 58 SECTION 03 - CHASSIS PREPARATION Now check the axial play (side-to-side clearance) of the drive axle. The axle must not move more than 1.5 mm (.060 in) from side to side. Ideally, the axle has 0.25 – 0.50 mm (.010 – .020 in). A01D07C TYPICAL 1.
Page 59: Brakes
SECTION 03 - CHASSIS PREPARATION Rear Axle The idlers should be placed so that they run be- tween the left and right double rows of drive lugs. This will help maintain alignment of the track and lessen the chance of derailing. Use the spacing shown in the drawing.
Page 60: Adjusting Ride Height
SECTION 03 - CHASSIS PREPARATION NOTE: Some race organizations do not allow short- ening springs so a proper optional short spring would be used. Lowering the Front Suspension Make limiter straps from standard rubber limiter strap material or link chain and go from shock bolt to shock bolt (longer shock bolts will be required).
Page 61: Track Guides
SECTION 03 - CHASSIS PREPARATION Center There are two special tools which greatly enhance the removal and addition of guide clips. Shorten the limiter strap(s) to match the ride height of the front and rear and obtain the desired (P/N 529 028 700) Guide clip remover. amount of weight transfer.
Page 62: Bump Steer
SECTION 03 - CHASSIS PREPARATION When installing carbide inserts, start with 100 mm (4 in) of carbide in front of a line projected from the center line of the ski leg and 125 mm (5 in) behind the line. Always keep the amount of carbide be- hind the line longer than in front.
Page 63: Ski Toe-Out
SECTION 03 - CHASSIS PREPARATION Most oval racers set the left ski leg at 0° camber SKI TOE-OUT and the right at - 3° to - 5° camber. Trail riders and Most oval racers use modified handlebars with drag racers should set both ski legs at 0° camber loops or angles on the left end.
Page 64: Chassis Tuning Guidelines
SECTION 03 - CHASSIS PREPARATION CHASSIS TUNING GUIDELINES – Shorten limiter strap on center arm. 2. Problems encountered while going around or How to Deal with Handling Problems exiting a corner. a. Front end pushes coming out of corner (steer- There is usually never one adjustment that will cor- ing is not precise).
Page 65 SECTION 03 - CHASSIS PREPARATION a. The rear springs of the rear suspension should be adjusted as follows: – Fully extend the rear suspension. – Measure from the floor to the bottom of the rear grab handle (remember this dimen- sion).
Page 66: Steering System
SECTION 03 - CHASSIS PREPARATION STEERING SYSTEM GSX Series, Summit Adrenaline/Sport/Highmark Some models Some models Some models 03-36 MMC2005-001_03A.FM...
Page 67 SECTION 03 - CHASSIS PREPARATION MX Z 500 SS/600 HO/800 HO, Summit X/Highmark X/Highmark Xtreme 03-37 MMC2005-001_03A.FM...
Page 68: Disassembly And Assembly
SECTION 03 - CHASSIS PREPARATION DISASSEMBLY AND ASSEMBLY CAUTION: Pay attention not to damage wires with the wrench. Grip Using a plastic hammer, tap on the side of the wrench end to make the grip slide out. NOTE: These models feature an integrated heat- ing element in the plastic sleeve of the grip no.
Page 69 SECTION 03 - CHASSIS PREPARATION 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 70 SECTION 03 - CHASSIS PREPARATION Reinstall terminals and replug connectors. Test Grease fitting no. 16 of swivel arms no. 14 must grips to ensure they heat properly. face toward center of vehicle. Steering Column Unfasten windshield. Remove cap no. 3 or steer- ing padding no.
Page 71: Inspection
SECTION 03 - CHASSIS PREPARATION Heating Grip Element Refer to TESTING PROCEDURE for checking heating element no. 13 of grip. Ball Joint (left hand and right hand threads) Inspect ball joint ends no. 17 and no. 18 and small tie rod ends for wear or looseness, if excessive, replace them.
Page 72 SECTION 03 - CHASSIS PREPARATION TYPICAL 1. Large connector housings Remove console. 1. Cap Remove 2 bolts no. 5 retaining top of steering col- 2. Console cap umn. Unscrew 4 bolts retaining console. STEERING COLUMN IN REARWARD POSITION 1. Two bolts retaining top of steering column Move steering column to forward position.
Page 73 SECTION 03 - CHASSIS PREPARATION ONE SIDE SHOWN — FORWARD POSITION 1. Bolts retaining windshield assembly STEERING COLUMN IN FORWARD POSITION 1. Longer bolt Readjust throttle lever housing no. 21 and switch housing accordingly to optimal angle so that you Reinstall the 2 bolts no.
Page 74 SECTION 03 - CHASSIS PREPARATION 1. Torque to 25 N•m (18 lbf•ft) A. Equal gap all around CAUTION: Tighten the bolts equally in a criss- 1. Opening here cross sequence and ensure there is an equal 2. Extension against stopper gap on each side of the clamps no.
Page 75: Steering Adjustment (Skis)
SECTION 03 - CHASSIS PREPARATION Retaining clip and hardware must be installed in the same position on both strap ends. J-Hook Adjustment Some Models 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.
Page 76 SECTION 03 - CHASSIS PREPARATION Procedure: – Position handlebar so that it is in straight ahead position by measuring from the extremities of the grips to the rear most edge of the tunnel, as shown. NOTE: The reference point must be the same rel- ative to each side.
Page 77: Lubrication
SECTION 03 - CHASSIS PREPARATION RIGHT HAND SIDE SHOWN 1. Ski leg 2. Lower arm A. 2 mm (5/64 in) If the distance is more than the specified distance on one side then check for bent parts. LUBRICATION WARNING Do not lubricate throttle cable or housing. Use suspension synthetic grease (P/N 293 550 033) on: –...
Page 78: Body
SECTION 03 - CHASSIS PREPARATION BODY INSTALLATION AND BULB REPLACEMENT ADJUSTMENT Headlamp If any headlight bulb is burnt, proceed as follows. HEADLAMP BEAM AIMING Remove windshield. See below. Beam aiming is correct when center of high beam Pull out steering support cap. is 25 mm (1 in) below the headlamp horizontal cen- ter line, scribed on a test surface, 381 cm (12 ft 6 in) away.
Page 79: Decal
SECTION 03 - CHASSIS PREPARATION DECAL To remove a decal; heat old decal with a heat gun and peel off slowly. Using isopropyl alcohol, clean the surface and dry thoroughly. Apply liquid soap to new decal and carefully po- sition the decal. Using a sponge or a squeegee, remove the air bubbles and surplus water work- ing from the center toward the edges.
Page 80: Guard
SECTION 03 - CHASSIS PREPARATION CABLES WARNING Before installation, ensure that all cables are in perfect condition. Properly install the cable ends and secure them in place. Pay attention to route them properly, away from any rotat- ing, moving, heating or vibrating parts. TUBING WARNING Always ensure that the fuel, vent, primer, im-...
Page 81: Repair
SECTION 03 - CHASSIS PREPARATION – strong detergents – abrasive cleaners – waxes containing an abrasive or a cleaning agent in their formula. Apply wax on glossy finish only. Protect the ve- hicle with a cover to prevent dust accumulation during storage.
Page 82: Frame
SECTION 03 - CHASSIS PREPARATION FRAME FRAME CLEANING CAUTION: If welding is to be done near plastic material, it is recommended to either remove NOTE: For bare aluminum frames use only the part from the area or to protect it with alu- aluminum cleaner and follow instructions on con- minum foil to prevent damage.
Page 83: Suspension Sc-3 Sc-4 - Ras
SECTION 04 - SUSPENSION SC-3 SC-4 - RAS TABLE OF CONTENTS FRONT SUSPENSION ........................04-02 GENERAL INSPECTION ......................04-03 DISASSEMBLY........................... 04-03 INSPECTION ..........................04-07 INSTALLATION .......................... 04-07 SC-10 III SUSPENSION ......................... 04-12 COMPONENT REMOVAL AND INSTALLATION ..............04-15 SUSPENSION ASSEMBLY REMOVAL ..................04-16 DISASSEMBLY AND ASSEMBLY .....................
Page 84: Front Suspension
SECTION 04 - SUSPENSION SC-3 SC-4 - RAS FRONT SUSPENSION REV Series Summit models 04-2 MMC2005-001_04A.FM...
Page 85: General Inspection
SECTION 04 - SUSPENSION SC-3 SC-4 - RAS NOTE: The same procedure applies on both sides. Reduce spring preload by turning adjusting ring towards position 1 and continue until it stops. GENERAL INSPECTION Check for looseness, bent, worn out, rusted or other damage on components.
Page 86 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS For shock absorber spring disassembly use shock absorber spring remover (P/N 529 035 504) in a vise. Mount shock absorber in it and turn shock absorber so that spring coils match spring com- pressor.
Page 87 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS TYPICAL TYPICAL 1. Ball joint parallel with ski leg Remove lower arm no. 14 from frame. For front screw no. 17 removal, hold nut no. 18 from engine compartment. To remove ball joint, proceed as follows: –...
Page 88 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS Tie Rod Stabilizer Bar Refer to STEERING SYSTEM section and remove Remove shock absorbers, stabilizer bar slider tie rod from ski leg. blocks and unfasten lower ball joints from ski legs. Upper Arm Remove screws no.
Page 89: Inspection
SECTION 04 - SUSPENSION SC-3 SC-4 - RAS Lift front of vehicle enough so that stabilizer bar Check for straightness of lower and upper arms. no. 7 can be rotated downward to allow to slide it Replace as required. out. Check condition of ball joints.
Page 90 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS 1. Install bushing as shown Lower Arm Position lower arm below stabilizer bar. Prior to installing ball joint in lower arm, ensure to clean the tapered surfaces with the Pulley flange cleaner product (P/N 413 711 809). Surface con- tacts must be clean and free of dirt, oil and grease.
Page 91 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS To properly torque ball joint nut, use the A-arm nut wrench (P/N 529 035 876). Ensure to install the tool perpendicularly (90°) to torque wrench. TYPICAL Stabilizer Bar Notice that LH and RH sliding blocks are different. 1.
Page 92 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS – Install screws and nuts. GSX and MX Z Trail – Ensure blocks slide easily when compressing and releasing suspension. MX Z Adrenaline and Renegade 1. Temporarily rotate block by 180° for its insertion 1.
Page 93 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS MX Z X/Renegade X/Trail — Europe WARNING Install skis with proper side facing inward. Refer to warning on ski. Adjustment All Models Proceed with ski alignment. Refer to STEERING SYSTEM. Summit Readjust spring preload. Apply suspension synthetic grease (P/N 293 550 033) between bushing no.
Page 94: Sc-10 Iii Suspension
SECTION 04 - SUSPENSION SC-3 SC-4 - RAS SC-10 III SUSPENSION SC-10 III 04-12 MMC2005-001_04A.FM...
Page 95 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS 04-13 MMC2005-001_04A.FM...
Page 96 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS Models with up side down shocks 04-14 MMC2005-001_04A.FM...
Page 97: Component Removal And Installation
SECTION 04 - SUSPENSION SC-3 SC-4 - RAS COMPONENT REMOVAL AND INSTALLATION Lift rear of vehicle and support it off the ground. Rear Axle Remove screw on rear axle no. 21 on side of off- set wheel. Completely loosen track tension. Pull out rear axle from opposite side of offset inner wheel.
Page 98: Suspension Assembly Removal
SECTION 04 - SUSPENSION SC-3 SC-4 - RAS Rear Spring SUSPENSION ASSEMBLY REMOVAL Decrease spring preload by turning cams no. 19 accordingly. Slightly turn adjusting cam to expose spring end. Lift rear of vehicle and support it off the ground. Using spring installer (P/N 529 005 000), remove both springs from adjusting cams.
Page 99: Disassembly And Assembly
SECTION 04 - SUSPENSION SC-3 SC-4 - RAS Lift rear of vehicle at least 1 m (3 ft). Remove suspension. TYPICAL A. At least 1 m (3 ft) DISASSEMBLY AND ASSEMBLY Models with SC-10 III 121 in Suspension Inspect track thoroughly before reinstalling sus- In case of gas pressure shocks, to facilitate the pension.
Page 100 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS 1. Protrusion 2. Stoppers Center Rear Wheel and Top Idler Wheels Dowel Pin and Block Guide At installation on center rear wheel no. 13 and top idler wheels no. 14, circlip must face inner side. Dowel pin no.
Page 101: Shock Absorber Inspection
SECTION 04 - SUSPENSION SC-3 SC-4 - RAS TYPICAL 1. Slider shoe 2. Molding line (wear limit indicator) Replace slider shoes no. 11 when wear limit is reached. A01B4LA CAUTION: Slider shoes must always be re- 1. Clevis pin placed in pairs. 2.
Page 102: Hpg T/A Shock Servicing
SECTION 04 - SUSPENSION SC-3 SC-4 - RAS Secure the shock body end in a vise with its rod Install shock in a vise clamping on its bottom eye- upward. let with its rod upward. Let it stand for 5 minutes. Completely push down the shock rod then re- lease.
Page 103 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS SERVICING SHOCK SIZE (P/N) TOOL Piston guide 529 026 600 Seal guide 529 026 500 C-36 Shock wrench 529 035 727 Piston guide 529 035 608 Seal guide 529 035 728 C-46 529 035 727 Shock wrench Release N (nitrogen) pressure on any HPG T/A...
Page 104 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS Discard old oil into storage container. Never reuse damper oil during shock rebuild. All Types of Shocks except External Reservoir T/A Shocks Remove valve core. Using compressed air pressure, carefully remove floating piston from damper body.
Page 105 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS Place shock absorber in a position where external gas reservoir opened extremity is blocked. Refer to following photo. A06F0UA A. Remove damper nut Always arrange parts removed in the sequence of 1. Tool disassembly.
Page 106 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS NOTE: If revalving is to be done, it is imperative that you identify the original shim pack (size and number of shims). The seal carrier need not be removed if only revalving is to be done. Shims can be measured by using a vernier caliper or a micrometer.
Page 107 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS If floating piston has been removed, reinstall float- INSTALLATION ing piston into damper body (ensure that valve DISTANCE OF SHOCK P/N core has been removed). Use Molykote G-n paste FLOATING PISTON (P/N 711 297 433) to ease O-ring past damper body threads with floating piston guide.
Page 108 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS CAUTION: Moisture laden compressed air will NOTE: Some shock oil will overflow when in- contaminate the gas chamber and rust floating stalling damper. Wrap damper with shop cloth to piston. catch possible overflow oil. CAUTION: Use care when passing piston into WARNING damper body at damper body threads.
Page 109 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS When removing and retightening the tire valve acorn nut use minimal torque. When the cap is 1. High pressure hose over tightened and subsequently removed it may 2. 2 stage regulator, delivery pressure range 2070 kPa (300 PSI) 3.
Page 110: Installation
SECTION 04 - SUSPENSION SC-3 SC-4 - RAS Mount the shock on vise. Remove screw on top Damper gas pressure cannot be confirmed by of valve. Place the needle guide of gas refill tool using a pressure gauge. The volume of gas in the on the shock valve.
Page 111: Internal Floating Piston Measurement
SECTION 04 - SUSPENSION SC-3 SC-4 - RAS INTERNAL FLOATING PISTON 03-05 MX Z X 440 HPG C-36 MEASUREMENT SHOCK PART LIST DESCRIPTION MEASUREMENT SHOCK P/N 505 070 953 Shock ass'y left front 505 070 903 44.5 505 070 952 Shock ass'y right front 505 070 904 44.5 503 189 972 Shock ass'y center...
Page 112 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS 03-05 MX Z X 440 HPG C-36 SHOCKS Low speed compression adjuster The low speed adjustment is used to change the The 2005 MX ZX 440 REV will come equipped dampening force for relatively slow suspension with four C-36 HPG shocks.
Page 113: Shock Rebuild Procedure
SECTION 04 - SUSPENSION SC-3 SC-4 - RAS SHOCK REBUILD PROCEDURE 5. Push down the remote reservoir cover, remove the retaining clip. 1. Tightly secure the shock base in vise. DO NOT CLAMP ONTO SHOCK BODY. 2. Using a 12 mm wrench, slowly remove air valve, allowing the gas inside the reservoir to escape.
Page 114 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS 7. Remove the floating piston inside the remote 9. Carefully remove and layout shims, washers, reservoir. and piston from shaft. Play close attention to shim sequence and piston position. 10. Clean all shock components using Bombardier Sheave Cleaner.
Page 115 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS 16. Cup your hand and place it over the remote 22. Again, push the floating piston to the bottom reservoir. Pump with your hand to circulate oil of the remote reservoir. through the base valve (adjustment system) to 23.
Page 116: C-36 Hpg
SECTION 04 - SUSPENSION SC-3 SC-4 - RAS C-36 HPG C-46 SHIMS REAR SHOCK SHIMS SIZE (mm) (minimum SIZE (mm) (minimum order quantity) order quantity) 30 × .254 22 × .114 415 039 100 503 189 011 22 × .152 30 ×...
Page 117: Shock Calibration Work Sheet
SECTION 04 - SUSPENSION SC-3 SC-4 - RAS SHOCK CALIBRATION WORK SHEET MODEL: ___________________________________________________ DATE:______________________________ RIDING CONDITIONS: _____________________________________________________________________________ FRONT CENTER REAR OPTION PISTON SLITS IFP HEIGHT COMPRESSION REBOUND SPRING PRELOAD NOTES: __________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ 04-35 MMC2005-001_04A.FM...
Page 118: Sc Iv Rear Suspension
SECTION 04 - SUSPENSION SC-3 SC-4 - RAS SC IV REAR SUSPENSION 04-36 MMC2005-001_04A.FM...
Page 119 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS THE SC IV REAR SUSPENSION All suspensions in the past have been designed with the fact that the rider was sitting over the rear arm. With this in mind, engineers have designed most of the bump absorp- tion into the rear arm.
Page 120: On Rider Forward Vehicle
SECTION 04 - SUSPENSION SC-3 SC-4 - RAS ON RIDER FORWARD VEHICLE: In the bumps, on a rider forward vehicle, the front arm and center shock do more of the work, since the rider and most of the vehicle’s mass is concentrated over the center arm. Conversely, on accel- eration weight transfer is more difficult since the rider and vehicle’s mass are moved farther forward compaired to conventional vehicle.
Page 121: Construction
SECTION 04 - SUSPENSION SC-3 SC-4 - RAS CONSTRUCTION: This major change allows the front arm to be sup- ple in the little bumps and still resist bottoming if the rider encounters big ones. By designing the rear arm into a “slight” rising rate design, the weight transfer under acceleration is enhanced from 0-30 mph and is decreased at higher trail speeds.
Page 122 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS Here are some of the other highlights of this suspension: 1. Total weight of SC IV is 1.36 KG (3 lbs) less than the SC-3. 2. Rails are 3mm (1/8”) taller and slightly thicker for a 26% decrease in vertical flex and a 30% im- provement in lateral flex.
Page 123 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS 9. Coupling blocks can now be used on their 4 sides thus 4 different adjustments. 10.No coupling front to rear. This reduces kick in downhill bumps and deceleration. 11.Rear coupling area is larger allowing more weight transfer.
Page 124 SECTION 04 - SUSPENSION SC-3 SC-4 - RAS 04-42 MMC2005-001_04A.FM...
Page 125: Engine Preparation
SECTION 05 - ENGINE PREPARATION TABLE OF CONTENTS ENGINE TUNING CAUTIONS ....................05-4 BASIC ENGINE THEORY ......................05-4 OPERATION OF THE RAVE VALVE ................... 05-7 CARBURETION .......................... 05-11 MIKUNI VM AND TM TYPE CARBURETORS ................05-15 IGNITION SYSTEMS, SPARK PLUGS ..................05-27 CARBURETOR - VM TYPE ......................
Page 126: Accessories
SECTION 05 - ENGINE PREPARATION HEALIGHT AND ACCESSORIES SYSTEM TESTING ............... 05-71 FUEL TANK AND FUEL PUMP ...................... 05-72 FUEL FILTER ..........................05-73 FUEL TANK ..........................05-73 IMPULSE/FUEL LINES SPRING CLIPS (ALL MODELS) ............05-74 FLOAT TYPE FUEL LEVEL GAUGE ................... 05-75 ELECTRIC FUEL LEVEL SENSOR ....................
Page 127 SECTION 05 - ENGINE PREPARATION CRANKSHAFT DEFLECTION..................... 05-116 CONNECTING ROD BIG END AXIAL PLAY ................05-117 CRANKSHAFT END PLAY ......................05-117 CHECKING CRANKSHAFT ALIGNMENT.................. 05-117 MAGNETO SYSTEM ........................05-118 GENERAL ........................... 05-120 CLEANING ..........................05-120 DISASSEMBLY........................... 05-120 ASSEMBLY..........................05-121 OIL INJECTION SYSTEM ......................05-123 GENERAL ...........................
Page 128: Engine Tuning Cautions
SECTION 05 - ENGINE PREPARATION ENGINE TUNING CAUTIONS BASIC ENGINE THEORY Here are a few items to keep in mind when work- Terminology ing with your engine. CYCLE In a combustion engine, a cycle is If you are in stock classes, know what adjust- accomplished when the four (4) ments are legal.
Page 129 SECTION 05 - ENGINE PREPARATION Combustion Process NORMAL COMBUSTION Since the beginning of this study we have spoken of air/fuel mixture combustion rather than explo- sion. This combustion is a slow then accelerated burning of the mixture within the combustion chamber.
Page 130 SECTION 05 - ENGINE PREPARATION With all operating parameters correct, normal Spark plug heat range too high. combustion will take place. However, if for some Ignition timing too far advanced. reason the temperature inside the cylinder is in- a. Initial timing incorrect. creased during combustion, abnormal combustion b.
Page 131: Operation Of The Rave Valve
SECTION 05 - ENGINE PREPARATION Theory For a two-stroke-cycle engine to have high power capacity at high crankshaft speeds, a high volu- metric or breathing efficiency is required and the fresh charge losses must be minimized. The result is achieved by opening the exhaust port early (94.5°...
Page 132 SECTION 05 - ENGINE PREPARATION To the outside of the return spring is a red plastic Item P1 in the illustration is the pressure of the adjustment knob (item 5). Turning the adjustment return spring against the diaphragm. The exhaust in or out changes the preload on the return spring pressure must be high enough to overcome this which, in turn, will change the RPM at which the...
Page 133 SECTION 05 - ENGINE PREPARATION AVAILABLE RAVE SPRINGS Bench Test for Checking RAVE Valve Operation Free Preload in N (LBF) Wire Dia. The operation of the valve can be checked by pres- Length Spring P/N Compressed surizing the engine as one would when checking Length of for crankcase leaks.
Page 134 SECTION 05 - ENGINE PREPARATION The movement indicator must be turned all the NOTE: Due to the low pressure conditions when way in to provide maximum spring pre-load. As using the leak tester kit (P/N 861 749 100) to check you begin pressurizing the engine using engine the RAVE valve operation, install a gauge with a leak tester kit (P/N 861 749 100), you will find the...
Page 135: Carburetion
SECTION 05 - ENGINE PREPARATION CARBURETION BASE GASKETS P/N 420 931 580 0.3 mm Carburetor Main Jet Correction Chart P/N 420 931 581 0.4 mm CARBURETOR MAIN JET CORRECTION CHART P/N 420 931 583 0.5 mm P/N 420 931 582 0.6 mm P/N 420 931 584 0.8 mm...
Page 136 SECTION 05 - ENGINE PREPARATION Jetting, horsepower, and B.S.F.C. data can be ob- Record the C.R.A.D. when correct jetting has tained with dyno testing but also confirmed with been established. This is the baseline for future field testing. The tried and true method of deter- use.
Page 137 SECTION 05 - ENGINE PREPARATION Most racers use an air density gauge. This gauge SATURATION PRESSURE (CHART 1) is fairly inexpensive. It basically establishes S.P. = SATURATION PRESSURE C.R.A.D. for you by combining the variables on any T = TEMP. (°F) (in-Hg) given day.
Page 138 SECTION 05 - ENGINE PREPARATION Exhaust Gas Temperature Probe Air entering the bell of the carburetor has a speed of V and pressure of P . As the air is forced into Location the smaller diameter of the venturi, speed increas- es (V ) but pressure drops (P Passages in the carburetor connect the venturi to...
Page 139: Mikuni Vm And Tm Type Carburetors
SECTION 05 - ENGINE PREPARATION A01C4BA 1. Jet needle 2. Needle jet 3. Main jet 4. Air jet MIKUNI VM AND TM TYPE CARBURETORS Snowmobile engines are operated under a wide range of conditions, from idling with the throttle valve remaining almost closed to the full load (the maximum output) with the throttle valve fully opened.
Page 140 SECTION 05 - ENGINE PREPARATION 05-16 MMC2005-001_05A.FM...
Page 141 SECTION 05 - ENGINE PREPARATION Starting Device (enrichner) Selection of the Aperture of Carburetor Instead of a choke, the enrichner system is used One of the prerequisites for improving the output on some Mikuni carburetors. In the starter type, is to use a carburetor with as large an aperture as fuel and air for starting the engine are metered possible.
Page 142 SECTION 05 - ENGINE PREPARATION Carburetor Test NOTE: This procedure may be performed for sin- gle and dual carburetors. Never adjust screws Once the aperture of the carburetor is determined, more than 1/4 turn at a time. a test to select the proper jet should be made. The 1.
Page 143 SECTION 05 - ENGINE PREPARATION b. To determinate the fully closed position of Pilot jets are numbered from no. 15 (the smallest) the air screw, turn the air screw slightly. Ex- to no. 80 (the largest). The number corresponds to cessive tightening of the air screw would fuel flow and not necessarily to drill size or damage the seat.
Page 144 SECTION 05 - ENGINE PREPARATION CHECKING AND SELECTING THROTTLE Jet Needle VALVE PRINCIPLES OF OPERATION Throttle valve opening (%) A01C2WA Throttle valve opening (%) A01C2YA 1. Operate engine at low throttle settings, accel- The jet needle works with the needle jet to in- erating from idle to 1/4 throttle.
Page 145 SECTION 05 - ENGINE PREPARATION LEAN RICH Number stamped here A01C2ZA Example: 6DH7 Basic length of needle. DH - A single letter would indicate a single taper 1. E-ring of the needle, double letter a double taper, 2. Needle jet and three letters mean there is a triple taper.
Page 146 SECTION 05 - ENGINE PREPARATION POSITIONING THE E-RING Needle Jet PRINCIPLES OF OPERATION 1 to 5 = E-ring position 1. Check for a rich or lean setting by examining exhaust manifold. A very light brown or white color indicates a lean mixture. A very dark The needle jet works in combination with the jet brown or black color indicates a rich mixture.
Page 147 SECTION 05 - ENGINE PREPARATION Main Jet System PRINCIPLES OF OPERATION 1. Jet needle 2. Metered here 3. Fuel 4. Air 5. Needle jet The main jet system starts to function when the throttle is approximately 1/4 open. The mid range fuel is supplied by the main jet and regulated by the needle jet/jet needle combination.
Page 148 SECTION 05 - ENGINE PREPARATION TUNING THE MAIN JET SYSTEM 1. When the air/fuel mixture is too rich: a. The engine noise is full and intermittent (four stroking). b. The condition grows worse when the enrich- ner is opened. c. The condition grows worse when the engine gets hot.
Page 149 SECTION 05 - ENGINE PREPARATION Functional Range Effectiveness in Relation to Throttle Opening THROTTLE VALVE OPENING Full open Closed Pilot jet and pilot air screw Throttle valve Needle jet Jet needle Main jet A01C2TS 05-25 MMC2005-001_05A.FM...
Page 150 SECTION 05 - ENGINE PREPARATION 2005 MX Z X 440 05-26 MMC2005-001_05A.FM...
Page 151: Ignition Systems, Spark Plugs
SECTION 05 - ENGINE PREPARATION Mikuni TMX Carburetor (tuning parts) IGNITION SYSTEMS, SPARK PLUGS DESCRIPTION Two-stroke engines in snowmobiles rely on an 486 212 400 Pilot Jet, 15 electric spark to initiate combustion of the fuel/air charge which has been inducted into the cylinder. 486 212 500 Pilot Jet, 17.5 For the engine to operate efficiently, the spark...
Page 152 SECTION 05 - ENGINE PREPARATION Flame speed is directly proportional to piston Spark Plug Heat Range speed in an almost linear fashion. Though it is not Spark plug heat ranges are selected by measuring completely understood why this relationship ex- actual combustion chamber temperatures.
Page 153 SECTION 05 - ENGINE PREPARATION Design Symbols Used on NGK Spark Plugs B P 6 E 05-29 MMC2005-001_05A.FM...
Page 154: Carburetor - Vm Type
SECTION 05 - ENGINE PREPARATION CARBURETOR AND THROTTLE CABLE CARBURETOR — VM TYPE 05-30 MMC2005-001_05A.FM...
Page 155: Identification
SECTION 05 - ENGINE PREPARATION IDENTIFICATION WARNING Solvent with a low flash point such as gaso- All carburetors are identified on their body. line, naphtha, benzol, etc., should not be used as they are flammable and explosive. Check inlet needle tip condition. If worn, the inlet needle and seat must be replaced as a matched set.
Page 156: Carburetor Float Level Adjustment
SECTION 05 - ENGINE PREPARATION NOTE: The last digit of the needle identification – With carburetor chamber upside-down on a number gives the recommended calibrated posi- level surface, measure height H between bowl tion of the E-clip from the top of the needle. seat and top edge of float arm.
Page 157: Carburetor Adjustment
SECTION 05 - ENGINE PREPARATION Adjustments should be performed following this sequence: – air screw no. 6 adjustment – throttle slide no. 5 height (preliminary idle speed adjustment) – throttle cable adjustment – carburetor synchronization – final idle speed adjustment (engine running) –...
Page 158: Installation
SECTION 05 - ENGINE PREPARATION Final idle speed adjustment (engine running at idle speed) should be within 1/2 turn of idle speed screw from preliminary adjustment. THROTTLE SLIDE HEIGHT MODELS (drill bit size) ± 0.1 mm (± .004 in) MX Z 550 FAN 1.6 (0.063) A00C1TA CENTER POST TYPE...
Page 159: Choke
SECTION 05 - ENGINE PREPARATION To install carburetor on engine, inverse removal CAUTION: If the throttle slide rests against the carburetor cover at full throttle opening, this procedure. will create too much strain and may damage However, pay attention to the following: the throttle cable or other components in throt- On applicable models, make sure to align tab of tle mechanism.
Page 160 SECTION 05 - ENGINE PREPARATION If tool tip does not seat under choke plunger no. 12, adjust as follows: Make sure choke lever is at half open position. Turn choke cable adjustment nut by hand until tool properly seats under choke plunger. NOTE: A light pressure should be needed to posi- tion tool under plunger.
Page 161: Carburetor Tm Type
SECTION 05 - ENGINE PREPARATION CARBURETOR AND THROTTLE CABLE CARBURETOR TM TYPE 05-37 MMC2005-001_05A.FM...
Page 162: Identification
SECTION 05 - ENGINE PREPARATION IDENTIFICATION TM type dual carburetor ass’y is identified on PTO side carburetor body. 1. Disconnect here Non-DPM Models Disconnect carburetor float bowl vent hose nipple from air silencer. DPM Models TYPICAL 1. Identification: TM 40-B112 Unhook DPM manifold from its support.
Page 163: Cleaning And Inspection
SECTION 05 - ENGINE PREPARATION 1. Outlet line 1. Inlet line 2. Pinch here 2. Valve 3. OFF Disconnect outlet line from carburetor assembly Disconnect heated carburetor coolant inlet line taking care to recuperate coolant. taking care to recuperate coolant. CLEANING AND INSPECTION All Models Disconnect throttle and choke cables.
Page 164: Disassembly And Assembly
SECTION 05 - ENGINE PREPARATION Pilot Jet WARNING Use narrow screwdriver from carburetor tool kit Solvent with a low flash point such as gaso- (P/N 404 112 000) to unfasten pilot jet no. 7. line, naphtha, benzol, etc., should not be used as they are flammable and explosive.
Page 165: Carburetor Adjustment
SECTION 05 - ENGINE PREPARATION Turn dual carburetor ass’y upside down to free needle no. 10. Take care not to loose plastic washer no. 11 under needle circlip no. 12. 1. Circlip 1. Plastic washer At throttle slide assembly, needle retainer must Unscrew throttle slide cover screws no.
Page 166 SECTION 05 - ENGINE PREPARATION – oil pump and carburetor synchronization – final idle speed adjustment (engine running). 1. Adjust PTO carburetor first 2. Drill bit used as a gauge to measure throttle height 3. Idle speed screw 1. Idle speed screw For MAG carburetor use synchronization screw.
Page 167: Installation
SECTION 05 - ENGINE PREPARATION Choke Cable Adjustment THROTTLE SLIDE HEIGHT Adjust choke cable as per following procedure: MODELS (drill bit size) Loosen choke cable housing adjusting and locking ± 0.1 mm (± .004 in) nuts. GSX 500 ss Sport Connect choke cable on starter lever no.
Page 168: Dpm
SECTION 05 - ENGINE PREPARATION Start engine and allow it to warm then adjust TEMPERATURE RESISTANCE idle speed to specifications by turning idle speed (OHMS) °C °F screw clockwise to increase engine speed or counterclockwise to decrease it. - 30 - 22 28 000 Refer to TECHNICAL DATA for the specifications.
Page 169: Dpm Manifold Testing
SECTION 05 - ENGINE PREPARATION INSIDE DIAMETER mm (in) MODEL LEAN VENT JET GSX 800 R Limited MX Z 600 R Renegade MX Z 800 R Adrenaline/Renegade/ 1.2 (.047) 2.0 (.079) Renegade X/X Summit 600 R Adrenaline/X Summit 800 R Adrenaline/ 1.
Page 170 SECTION 05 - ENGINE PREPARATION Connecting the Pump, DPM Manifold and Water Column Connect hoses as shown. 1. 3.5 mm (9/64 in) ID hose 2. 6.0 mm (15/64 in) ID hose 3. 6.0 mm (15/64 in) T-fitting Water Column Preparation Mount water column vertically and secure it to a wall or workbench.
Page 171: Throttle Cable
SECTION 05 - ENGINE PREPARATION If water level drops to an even level in less than 10 seconds, the DPM manifold is defective. Replace DPM manifold parts, (refer to Parts Catalog) and re-test. If test fails again, replace DPM manifold. If you are unable to attain any amount of vacuum (water level increases and decreases immediately in tube), check your set-up and re-do the test.
Page 172 SECTION 05 - ENGINE PREPARATION 1. Throttle cable 2. Adjusting nut 3. Locking nut After throttle cable adjustment, synchronized car- buretors (refer to CARBURETOR SYNCHRONIZA- TION) and adjusted oil pump cable (refer to OIL INJECTION PUMP). SDI Models Refer to COMPONENT INSPECTION AND AD- JUSTMENT in ENGINE MANAGEMENT (2-TEC).
Page 173: Spark Plugs
SECTION 05 - ENGINE PREPARATION SPARK PLUGS DISASSEMBLY SPARK PLUG TIGHTENING TORQUE First unscrew the spark plug 1 turn. Clean the spark plug and cylinder head with pres- SPARK TORQUE MODEL surized air, then completely unscrew. PLUGS N•m (lbf•ft) WARNING All models 27 (20) Whenever using compressed air, always...
Page 174: Ignition Timing
SECTION 05 - ENGINE PREPARATION IGNITION TIMING 593, 593 HO, 593 HO SDI and 793 HO Engines Normally ignition timing adjustment should not be required. It has been set at factory and it should remain correctly adjusted since every part is fixed and not adjustable.
Page 175: Checking Ignition Timing
SECTION 05 - ENGINE PREPARATION 1. Pointer 1. TIMING MARK IN LINE WITH POINTER END • With the TDC gauge indicating specified timing, CHECKING IGNITION TIMING scribe a mark on drive pulley inner half in line Use a timing light. with pointer end.
Page 176: Changing Timing
SECTION 05 - ENGINE PREPARATION Start the engine and point timing light on timing mark. Bring engine to 3500 RPM for a brief in- stant. TIMING ADVANCED BY ABOUT 2° CHANGING TIMING All Engine Types The timing mark must be aligned with pointer end. If such is not the case, note if timing is retarded or NOTE: To change the timing on the SDI engines, advanced.
Page 177 SECTION 05 - ENGINE PREPARATION MPEM Programmer NOTE: In fact the programmer takes a copy of all vehicle parameters scribed in MPEM. This All Engine Types except SDI copy will be modified within the programmer then Timing can also be changed using the MPEM pro- transferred to the MPEM.
Page 178 SECTION 05 - ENGINE PREPARATION Select YES using the key ↔. Press ENTER. Press ENTER. Select a timing correction factor corresponding to correction needed. Example: Timing mark as verified with a timing light at 3500 RPM was too early by 2°. The cor- rection factor programmed is no.
Page 179 SECTION 05 - ENGINE PREPARATION Scroll to no. 7 SAVE AND QUIT. O P E R A T I O N S U C C E S S F U L L P R E S S A N Y K E Y . . . A00A3EA Press any key.
Page 180: Testing Procedure
SECTION 05 - ENGINE PREPARATION TESTING PROCEDURE GENERAL The following chart gives the engine types with their implemented system. CHARGING IGNITION MODELS SYSTEM SYSTEM OUTPUT All REV liquid BOMBARDIER cooled except DC 360 W SDI models BOMBARDIER SDI models DC 480 W 05-56 MMC2005-001_05A.FM...
Page 181 SECTION 05 - ENGINE PREPARATION Bombardier DC 360 W 693 engines 1. MPEM 2. Ignition coil 3. Trigger coils 05-57 MMC2005-001_05A.FM...
Page 182 SECTION 05 - ENGINE PREPARATION Bombardier DC 480 W 1. ECM 2. Ignition coil 3. Trigger coil 05-58 MMC2005-001_05A.FM...
Page 183: Checking Calibration Program
SECTION 05 - ENGINE PREPARATION Multi-Purpose Electronic Module CHECKING CALIBRATION (MPEM) Connections PROGRAM Bombardier 360 W Using VCK (Vehicle Communication Kit) All Models The VCK (P/N 529 035 981 ) can be used with the B.U.D.S. software to check the calibration. De- tailed information about the B.U.D.S.
Page 184 SECTION 05 - ENGINE PREPARATION NOTE: In fact the programmer takes a copy of all vehicle parameters scribed in MPEM. This copy will be modified within the programmer then transferred to the MPEM. Select no. 4. ENGINE PARAMETER. TYPICAL Select no. 3 CALIBRATION. When cables are connected a beeping signal from the reverse buzzer will be heard (if vehicle is so equipped).
Page 185 SECTION 05 - ENGINE PREPARATION Check for proper calibration number. See table Stop engine when using WITH ENGINE RUNNING below. procedure. Select NO and press ENTER. Press MENU twice; ← Trs then turn off program- mer, unplug it from MPEM. Remove 9-volt adap- tor.
Page 186: Changing Mpem Calibration Program
SECTION 05 - ENGINE PREPARATION CHANGING MPEM CALIBRATION PROGRAM T R A N S F E R Using VCK (Vehicle Communication Kit) All Models V E R I F Y The VCK (P/N 295 035 981) can be used with the B.U.D.S.
Page 187: System Testing
SECTION 05 - ENGINE PREPARATION The reading must be 3 times within or above the range indicated in the corresponding table. If the reading is too low, the part is considered to be defective and must be replaced. • Resistance Readings Place multimeter selector switch to in order to measure resistance.
Page 188 SECTION 05 - ENGINE PREPARATION Disconnect all switches from the main wiring har- ness and check the continuity of each wire by con- necting probes to the end of wires of the same color. Repeat with all other wires. It is impor- tant to mention that all wires of the same color within a given harness are connected together.
Page 189 SECTION 05 - ENGINE PREPARATION – Activate the manual starter and check values indicated by the multimeter. – Repeat operation 3 times. – Compare readings with those appearing in the IGNITION table. 5. Trigger Coil Testing Resistance Testing – Connect probes to appropriate wires from trig- ger coil housing.
Page 190 SECTION 05 - ENGINE PREPARATION – Connect other multimeter wire to engine Connect battery negative post to buzzer negative (ground), then place selector switch to V and tab. See next photo. scale to 0.00 Vac. CAUTION: To avoid buzzer damage, ensure that polarity is respected.
Page 191 SECTION 05 - ENGINE PREPARATION TYPICAL – Compare readings with those appearing in the LIGHTING table. Conclusion If none of the above testing operations produced valid results, it is strongly recommended to keep on testing according to the list appearing in the RESISTANCE column of IGNITION or LIGHTING table.
Page 192 SECTION 05 - ENGINE PREPARATION NOTE: For the 480 W models, use B.U.D.S. software. 360 W MODEL (ignition and electrical system testing) MULTIMETER RESISTANCE VOLTAGE V TEST TO BE WIRE PART PROBE NOTE MULTIMETER VALUE MULTIMETER VALUE PERFORMED COLOR CONNECTION SCALE (ohms) SCALE...
Page 193 SECTION 05 - ENGINE PREPARATION 360 W MODEL (ignition and electrical system testing) MULTIMETER RESISTANCE VOLTAGE V TEST TO BE WIRE PART PROBE NOTE MULTIMETER VALUE MULTIMETER VALUE PERFORMED COLOR CONNECTION SCALE (ohms) SCALE (volt) Primary winding WH/BU 11–DC-2–F 00.0 or auto Disconnect the ignition coil from 00.2 to 0.5...
Page 194: Inspection Of Heating Elements
SECTION 05 - ENGINE PREPARATION 360 W MODEL (ignition and electrical system testing) MULTIMETER RESISTANCE VOLTAGE V TEST TO BE WIRE PART PROBE NOTE MULTIMETER VALUE MULTIMETER VALUE PERFORMED COLOR CONNECTION SCALE (ohms) SCALE (volt) WH/GN 5–RC-85–F 10.5 to Coil —...
Page 195 SECTION 05 - ENGINE PREPARATION HEADLIGHT AND ACCESSORIES SYSTEM TESTING 360 W Models Only Make an homemade adaptor as shown below. 1. Black wire in position no. 1 2. Red wire in position no. 2 3. P/N 278 001 671 4.
Page 196: Fuel Tank And Fuel Pump
SECTION 05 - ENGINE PREPARATION FUEL TANK AND FUEL PUMP All Models except SDI 05-72 MMC2005-001_05A.FM...
Page 197: Fuel Filter
SECTION 05 - ENGINE PREPARATION FUEL FILTER For fuel filter servicing, refer to PRESEASON PREPARATION. FUEL TANK Removal Remove seat, refer to BODY. Remove fuel tank cap. Remove filler neck plastic nut using special tool (P/N 529 035 891). 1. Remove this screw on both sides Remove both sides fuel tank aluminum braces: –...
Page 198: Impulse/Fuel Lines Spring Clips (All Models)
SECTION 05 - ENGINE PREPARATION 1. Cut this locking tie FUEL TANK REMOVED 1. Hose pincher installed on fuel line Remove fuel tank no. 3 and set it aside. SDI Models Installation Release fuel pressure of the system. Refer to COMPONENT INSPECTION AND ADJUSTMENT.
Page 199: Float Type Fuel Level Gauge
SECTION 05 - ENGINE PREPARATION FUEL LEVEL SENSOR SCREWS FLOAT-TYPE FUEL LEVEL GAUGE All Models except SDI To remove gauge no. 4 from fuel tank, pull gauge Torque fuel level sensor retaining screws to 1 N•m out of its grommet then remove grommet. (8 lbf•in) in a criss-cross sequence and then to 2.4 For reinstallation, proceed as follows: N•m (21 lbf•in), using the same sequence.
Page 200: Fuel Pump
SECTION 05 - ENGINE PREPARATION FUEL PUMP All Models except SDI 05-76 MMC2005-001_05A.FM...
Page 201: Pump Verification
SECTION 05 - ENGINE PREPARATION CLEANING AND INSPECTION NOTE: The following instructions are not applica- ble on SDI models. See COMPONENT INSPEC- The entire pump should be cleaned with general TION AND ADJUSTMENT concerning fuel pump purpose solvent before disassembly. procedure on these models.
Page 202: Exhaust System
SECTION 05 - ENGINE PREPARATION 593 HO AND 793 HO ENGINE TYPES EXHAUST SYSTEM 593 engines 593 HO, 593 SDI and 793 HO engines 05-78 MMC2005-001_05A.FM...
Page 203: Tuned Pipe
SECTION 05 - ENGINE PREPARATION TUNED PIPE Installation Install doughnut shaped exhaust gasket no. 3 with Identification both of its notches aligned with Y-manifold protru- Each tuned pipe is identified by a number. To sions. use the proper tuned pipe with the proper vehi- If the gaskets are damaged, replace them.
Page 204 SECTION 05 - ENGINE PREPARATION TYPICAL Removal Remove tuned pipe no. 2. Remove springs no. 8 retaining the muffler no. 9. Remove the muffler. Inspection Check the muffler for cracks or other damages. Installation For installation, reverse the removal procedure. 05-80 MMC2005-001_05A.FM...
Page 205: Engine System
SECTION 05 - ENGINE PREPARATION ENGINE SYSTEM 593 engines 05-81 MMC2005-001_05A.FM...
Page 206: Removal From Vehicle
SECTION 05 - ENGINE PREPARATION REMOVAL FROM VEHICLE Vehicle and Engine Preparation Place vehicle at workstation that will have access to an engine-lifting hoist. Then start with initial preparation of vehicle by doing the following. Remove windshield. Remove the RH side panel. From the Front of Vehicle Remove tuned pipe, refer to EXHAUST SYSTEM.
Page 207 SECTION 05 - ENGINE PREPARATION Separate carburetors or throttle body from engine. Unplug coolant hose located between cylinder head and radiator. Remove rewind starter handle. 1. Coolant hose between cylinder head and radiator Remove reed valves with their gaskets. Unplug heather carburetor hose from coolant reservoir.
Page 208 SECTION 05 - ENGINE PREPARATION Remove spark plugs and install spark plug lift ring (P/N 529 035 830) at the farthest spark plug hole. Unplug spark plug cables. Detach upper thermostat hose from thermostat housing. 1. Spark plug lift ring Remove RAVE valves.
Page 209: Inspection
SECTION 05 - ENGINE PREPARATION A. Do not apply Loctite in this area, ± 10 mm (.39 in) B. Loctite area, ± 8 mm (.31 in) Torque engine support bolts to 48 N•m (35 lbf•ft). Hand torque engine stopper no. 2 then torque its nut no.
Page 210 SECTION 05 - ENGINE PREPARATION 593 HO Engine Types 05-86 MMC2005-001_05A.FM...
Page 211 SECTION 05 - ENGINE PREPARATION 793 HO Engine Types 05-87 MMC2005-001_05A.FM...
Page 212: Troubleshooting
SECTION 05 - ENGINE PREPARATION TROUBLESHOOTING Before completely disassembling the engine, check airtightness. Refer to LEAK TEST AND ENGINE DIMENSION MEASUREMENT. COMPONENT REMOVAL WITH THE ENGINE INSTALLED Most engine components can be removed with engine on vehicle such as: – cylinder head cover no. 1 –...
Page 213: Rave Valve Basic Operation
SECTION 05 - ENGINE PREPARATION RAVE VALVE BASIC OPERATION Maintenance All Models There are no wear parts anywhere in the system and there are no adjustments to be periodically checked. The only possible maintenance required would be cleaning of carbon deposits from the guillotine slide.
Page 214 SECTION 05 - ENGINE PREPARATION TYPICAL 1. Allen socket screws TYPICAL 2. RAVE valve base 1. Spring 2. Valve piston Unscrew and remove the guillotine no. 9 from the 3. Bellows valve piston no. 10 than remove the gasket no. 11. Remove valve piston.
Page 215 SECTION 05 - ENGINE PREPARATION Cylinder Head Cover All Engine Types Unplug spark plug cables. 793 HO Engine Types Disconnect the temperature sensor connector. All Engine Types Unplug coolant hose from upper thermostat hous- ing no. 20. Unscrew all cylinder head cover screws no. 21. Cylinder Head All Engine Types except 793 HO TYPICAL...
Page 216 SECTION 05 - ENGINE PREPARATION A02C29A TYPICAL TYPICAL 1. Properly seated all around All engines are equipped with cageless piston pin Install sleeve then shouldered sleeve over puller bearings. rod. Use piston pin puller (P/N 529 035 503) along with A02C2BA 20 mm sleeve kit (P/N 529 035 542).
Page 217: Inspection
SECTION 05 - ENGINE PREPARATION Remove piston from connecting rod. Install locating sleeve. Then push needle bearings along with thrust washers and sleeve. A02C2CA TYPICAL — PISTON PIN EXTRACTION TYPICAL 1. Locating sleeve 2. Sleeve INSPECTION Cylinder Head Cover, Cylinder Head and Cylinder Refer to LEAK TEST AND ENGINE DIMENSIONS MEASUREMENT.
Page 218: Assembly
SECTION 05 - ENGINE PREPARATION Piston Check for cracked, dried or perforated bellows no. 13. When installing a new cageless bearing, replace Check if the compression springs no. 7 are in half plastic cages with sleeve. specifications. NOTE: 593, 593 HO, 593 SDI and 793 HO engine cageless bearings have 28 needles.
Page 219 SECTION 05 - ENGINE PREPARATION A02C2IA CAUTION: Piston temperature must not exceed TYPICAL — SHOULDERED SLEEVE INSTALLATION 46°C (115°F). Never use direct flame to heat the Install piston pin puller and turn handle until piston piston and never freeze the pin. pin is correctly positioned in piston.
Page 220 SECTION 05 - ENGINE PREPARATION Insert circlip into support so that, when installed in piston groove, the tab faces upward. 1. Groove With round end of pusher, position circlip perpen- dicularly to the support axis. CIRCLIP READY TO BE INSTALLED ON PISTON Using a plastic hammer, tap pusher to put circlip in place.
Page 221 SECTION 05 - ENGINE PREPARATION CAUTION: Always install new mono-hook cir- clips. If circlip installation fails at the first at- tempt, always retry with a new one because, on a second attempt, the circlip will lose its nor- mal retaining capabilities. CAUTION: Circlips must not move freely after installation;...
Page 222 SECTION 05 - ENGINE PREPARATION In case of a play, turn blade upside down and recheck. If there is still a play, replace blade and/or valve body. Check distance from blade stopper outer edge and distance from center of reed valve block. TYPICAL A.
Page 223 SECTION 05 - ENGINE PREPARATION 593 HO Engine Types 05-99 MMC2005-001_05A.FM...
Page 224 SECTION 05 - ENGINE PREPARATION 793 HO Engine Types 05-100 MMC2005-001_05A.FM...
Page 225: Cleaning
SECTION 05 - ENGINE PREPARATION NOTE: Engine must be removed from chassis to perform the following procedures. CLEANING Discard all oil seals, gaskets, O-rings and sealing rings. Clean all metal components in a non-ferrous metal cleaner. Use gasket remover (P/N 413 708 500) accordingly.
Page 226: Inspection
SECTION 05 - ENGINE PREPARATION Follow the same procedure for the inner bearing NOTE: In the case of damaged bearing or less clearance between crankshaft counterbalance and the bearing or on the MAG side bearing, use a bearing separator such as Snap-On tool CJ 951 or SPX/OTC tool 1124 to facilitate the removal.
Page 227 SECTION 05 - ENGINE PREPARATION Heat up the bearing(s) using bearing heater 1. Bearings (P/N 529 035 969). This will expand bearings and ease installation. If required, put a suitable Probe the inner race of the bearing with the tem- plate or shim to avoid the direct contact between perature indicator stick (P/N 529 035 970).
Page 228 SECTION 05 - ENGINE PREPARATION NOTE: Heated bearings will slide onto the crank- shaft. If required, push with a steel tube on the inner ring of the bearing. Pay special attention to correct positioning of the drive pins and/or 1. Support plate retaining discs.
Page 229 SECTION 05 - ENGINE PREPARATION NOTE: The 50 g tube corresponds to 50 cc of grease. Put 50 to 55 mL of grease in a syringe. CAUTION: Do not exceed the recommended amount of grease Fill inner side of PTO side bearing with Isoflex grease (about 10 mL).
Page 230 SECTION 05 - ENGINE PREPARATION 1. Oil bath Crankcase Assembly IMPORTANT: The total assembly sequence, in- TYPICAL — FILL WITH GREASE AND SET IN PLACE cluding sealing compound spreading, screwing Apply 6 mL of grease to MAG side outer bearing. and torquing of bolts according to the proper sequence, must be performed within 10 minutes.
Page 231: Break-In
SECTION 05 - ENGINE PREPARATION SEAMING COMPLETED — CONTACT SURFACES COVERED AND SCREW HOLES SURROUNDED Screw all crankcase bolts in place in the following sequence and to the appropriate torque; this must be done in two steps torquing: first, screw bolts up to 60% of the final torque (18 N•m (13.5 lbf•ft) for most of the bolts), then, tighten to the required torque (i.e.
Page 232: Engine Leak Test And Dimension Measurement
SECTION 05 - ENGINE PREPARATION ENGINE LEAK TEST AND DIMENSION MEASUREMENT LEAK TEST The following gives verification procedures for 593 and 793 types of engines. PREPARATION – Remove tuned pipe. – Install plug over exhaust manifold. – Remove carburetors/throttle body assembly (as applicable).
Page 233 SECTION 05 - ENGINE PREPARATION Engine Pump Shaft Oil Gear Reservoir Check the following: Install air pump on adapter and pressurize as above. – All jointed surfaces and screw/stud threads of engine: • spark plug base, insulator • cylinder head •...
Page 234: Finalizing Reassembly
SECTION 05 - ENGINE PREPARATION – Check weep hole below coolant pump housing with soapy water. 1. Weep 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 235: Engine Leak Verification Flow Chart
SECTION 05 - ENGINE PREPARATION 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 REPLACE INJECTION NIPPLE(S)
Page 236: Engine Dimension Measurement
SECTION 05 - ENGINE PREPARATION ENGINE DIMENSION CYLINDER OUT OF ROUND MEASUREMENT ENGINE TYPE MAXIMUM This section covers all engine types. 0.08 mm (.003 in) CYLINDER HEAD WARPAGE Measuring 16 mm (5/8 in) from top of cylinder with a cylinder gauge, check if the cylinder out of round ENGINE TYPE MAXIMUM is more than the specified dimension.
Page 237 SECTION 05 - ENGINE PREPARATION 1. Combustion chamber NOTE: When checking the combustion chamber volume, engine must be cold, piston must be free of carbon deposits and cylinder head must be lev- eled. – Remove both spark plugs and bring one piston to Top Dead Center a using a TDC gauge.
Page 238: Used Piston Mesurement
SECTION 05 - ENGINE PREPARATION NOTE: When the combustion chamber is filled to top of spark plug hole, it includes an amount of 2.25 cc corresponding to the spark plug well. – Repeat the procedure for the other cylinder. COMBUSTION CHAMBER ENGINE VOLUME (cc) TYPE...
Page 239 SECTION 05 - ENGINE PREPARATION Adjust and lock a micrometer to the specified value on the piston dome. 1. Micrometer set to the piston dimension 1. Indicator set to 0 (zero) With the micrometer set to the piston dimension, IMPORTANT: Always remove cylinders from adjust a cylinder bore gauge to the micrometer crankcase before measuring.
Page 240: Ring/Piston Grove Clearance
SECTION 05 - ENGINE PREPARATION RING/PISTON GROOVE Measuring (in crankcase) CLEARANCE First, check deflection with crankshaft crankcase. If deflection exceeds the specified tol- Using a feeler gauge check clearance between erance, recheck deflection using V-shaped blocks rectangular ring and groove. Replace piston if to determine the defective part(s).
Page 241: Connecting Rod Big End Axial Play
SECTION 05 - ENGINE PREPARATION CHECKING CRANKSHAFT Crankshaft Deflection in Center of Crankshaft ALIGNMENT ENGINE MAXIMUM IN CENTER OF Install a degree wheel (P/N 529 035 607) on crank- TYPE CRANKSHAFT mm (in) shaft end. 0.08 (.0031) Remove both spark plugs. NOTE: Crankshaft deflection cannot be correctly Install a TDC gauge (P/N 414 104 700) in spark plug measured between centers of a lathe.
Page 242: Magneto System
SECTION 05 - ENGINE PREPARATION MAGNETO SYSTEM models 05-118 MMC2005-001_05A.FM...
Page 243 SECTION 05 - ENGINE PREPARATION 480 W on REV Series 05-119 MMC2005-001_05A.FM...
Page 244: General
SECTION 05 - ENGINE PREPARATION GENERAL NOTE: The following procedures can be done without removing the engine. To facilitate mag- neto removal, hold drive pulley with tool (P/N 529 027 600). During assembly/installation, use the torque val- ues and service products as in the exploded views.
Page 245: Assembly
SECTION 05 - ENGINE PREPARATION – Disconnect trigger coil connector housing(s). – grommet from crankcase where trigger coil wire(s) exit(s) magneto housing. – retaining screws no. 4. – trigger coil(s) and carefully pull wires. ASSEMBLY Trigger Coil For installation, reverse the removal procedure. NOTE: It is important to remove the old silicon at trigger coil location then apply new silicon.
Page 246 SECTION 05 - ENGINE PREPARATION Magneto Flywheel Clean crankshaft extension (taper) and apply Loc- tite 243 (blue) on taper, then position Woodruff key, magneto flywheel no. 3 and lock washer on crankshaft. Clean magneto flywheel nut threads and apply Loctite 243 (blue) then tighten nut no. 1 to 125 N•m (92 lbf•ft) for liquid cooled engines.
Page 247: Oil Injection System
SECTION 05 - ENGINE PREPARATION OIL INJECTION SYSTEM 05-123 MMC2005-001_05A.FM...
Page 248: General
SECTION 05 - ENGINE PREPARATION GENERAL (1) CAUTION: The BOMBARDIER Formula XP-S II synthetic injection oil is specially During assembly/installation, use the torque val- formulated and tested for the severe re- ues and service products as in the exploded quirement of these engines. Use of any views.
Page 249: Oil Pump Identification
SECTION 05 - ENGINE PREPARATION DISASSEMBLY NOTE: Some oil pump components are not avail- able as single parts. Injection Oil Reservoir Empty injection oil reservoir no. 6 by siphoning injection oil. Remove: – air box – upper screw (near reservoir cap) –...
Page 250: Assembly
SECTION 05 - ENGINE PREPARATION ASSEMBLY NOTE: During installation, always check for spring clips no. 1 tightness. Injection Oil Reservoir For installation, reverse the removal procedure. 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.
Page 251: Adjustment
SECTION 05 - ENGINE PREPARATION Stretch the adjusting cable through a maximum force of 32 N•m (7.2 lbf•ft). NOTE: It is better to have two persons to check the cable distance. One stretching the cable and other taking measurements. Check the visible distance of the stretched cable, while one person is stretching it and other check- ing the distance.
Page 252: Checking Operation
SECTION 05 - ENGINE PREPARATION Check that oil in small oil lines has been sucked up (this will be indicated by a clear section of small oil lines). Repeat the procedure until this condition is attained. Reconnect small oil lines, start engine and run at idle while holding the pump lever in fully open po- sition.
Page 253: Liquid Cooling System
SECTION 05 - ENGINE PREPARATION LIQUID COOLING SYSTEM All Models except Summit 05-129 MMC2005-001_05A.FM...
Page 254 SECTION 05 - ENGINE PREPARATION All Summit Models 05-130 MMC2005-001_05A.FM...
Page 255: Cooling System Leak Test
SECTION 05 - ENGINE PREPARATION COOLING SYSTEM LEAK TEST DISASSEMBLY AND ASSEMBLY WARNING Coolant Pump To prevent burning yourself, do not remove Refer to BOTTOM END section. the radiator cap if the engine is hot. Sender and Plug Install special radiator cap (P/N 529 021 400) in- Apply Loctite 592 (P/N 293 800 018) thread sealant cluded in engine leak tester kit (P/N 861 749 100) on sender no.
Page 256 SECTION 05 - ENGINE PREPARATION Rear Radiator and Rear Radiator Protector Refer to FRAME for rear radiator removal/installa- tion procedures. For cleaning and inspection refer to FRONT RADI- ATOR. Radiator and Radiator Protector Insert radiator protector no. 7 into radiator C-rail and crimp C-rail at rear end.
Page 257: Cooling System Refilling Procedure
SECTION 05 - ENGINE PREPARATION COOLING SYSTEM REFILLING PROCEDURE CAUTION: To prevent rust formation or freez- ing condition, always replenish the system with the Bombardier premixed coolant or with 50% antifreeze and 50% water. Pure antifreeze without water freezes (like slush ice). Always use ethylene glycol antifreeze containing cor- rosion inhibitors specifically recommended for aluminum engines.
Page 258: Rewind Starter
SECTION 05 - ENGINE PREPARATION REWIND STARTER 05-134 MMC2005-001_05A.FM...
Page 259: Inspection
SECTION 05 - ENGINE PREPARATION INSPECTION NOTE: Due to dust accumulation, rewind starter must be periodically cleaned, inspected and relu- bricated. 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 260: Assembly
SECTION 05 - ENGINE PREPARATION Take out knot and then pull out rope no. 1. ASSEMBLY At assembly, position spring no. 11 outer end into spring guide notch then wind the spring counter- clockwise into guide. WARNING Since the spring is tightly wound inside the guide it may fly out when rewind is handled.
Page 261 SECTION 05 - ENGINE PREPARATION TYPICAL Lubricate pawl no. 9 with Molykote PG 54 (P/N 420 899 763) then install over rope sheave. FREE PORTION Lubricate pawl lock no. 8 with Molykote PG 54 (P/N 420 899 763). Install over pawl. FREE PORTION INSERTED INTO SHEAVE Lubricate housing post with Molykote PG 54 .
Page 262: Installation
SECTION 05 - ENGINE PREPARATION 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. Pass rope through starter grip and tie a knot in Install step collar no.
Page 263: Drive System
SECTION 06 - DRIVE SYSTEM TABLE OF CONTENTS BASIC FUNCTIONS OF THE SYSTEM ..................06-3 EFFECTS OF THE DRIVE PULLEY LEVER ARM, ROLLER AND ROLLER PIN WEIGHT ..06-4 EFFECTS OF THE RAMP PROFILE ON THE SHIFT FORCE ............. 06-7 RAMP CHARACTERISTICS .......................
Page 264 SECTION 06 - DRIVE SYSTEM MEASURING BELT DEFLECTION ..................... 06-45 TEAM SECONDARY CLUTCH MAINTENANCE/ADJUSTMENT ..........06-46 INSTALLATION .......................... 06-47 TROUBLESHOOTING ......................... 06-47 GENERAL............................ 06-51 GENERAL PROCEDURE......................06-51 PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART ......... 06-52 APPLICATION CHART ........................06-55 DRIVE BELTS ..........................06-53 INSPECTION ..........................
Page 265: Basic Functions Of The System
SECTION 06 - DRIVE SYSTEM BASIC FUNCTIONS OF THE POWER CURVES MILDLY TUNED VS. RACE TUNED SYSTEM In the speed diagram, the inclined line labelled low ratio indicates the vehicle speed at each RPM The TRA Clutch when locked into the 3.8:1, low gear ratio. At 8000 We call it a clutch but that set of pulleys is a lot RPM, the vehicle speed would be just under 20 more than simply a clutch.
Page 266: Effects Of The Drive Pulley Lever Arm, Roller And Roller Pin Weight
SECTION 06 - DRIVE SYSTEM The major factor controlling centrifugal force is en- gine RPM. Because the force increases with the square of this speed, you can quickly have too much force if heavy weights are used on a clutch fitted to a high RPM engine.
Page 267 SECTION 06 - DRIVE SYSTEM Curve A shows a clutch set up with three 10-gram type roller pins. This amount of weight will govern the engine to 7200 RPM and allow engagement of the clutch at 4000 RPM. Curve B illustrates the effect of exchanging the three 10-gram pins for three 14-gram roller pins.
Page 268 SECTION 06 - DRIVE SYSTEM Drive Clutch Roller Pins 10,000 9,000 8,000 7,000 6,000 5,000 4,000 3,000 2,000 1,000 A: 10 gram roller pins B: 14 gram roller pins C: 16 gram roller pins A01D0XS 06-6 MMC2005-001_06A.FM...
Page 269: Effects Of The Ramp Profile On The Shift Force
SECTION 06 - DRIVE SYSTEM The weight of the lever arms will have a similar Remember, it is the angle of the ramp at the point effect on the shift RPM. of roller contact that will help determine the shift force at any given ratio.
Page 270 SECTION 06 - DRIVE SYSTEM In clinical condition such as on a dynamometer, moving the adjusters up will result in a 150 to 200 RPM increase with each position change. Lowering the adjuster positions will result in a decrease of 150 to 200 RPM with each number.
Page 271: Ramp Characteristics
SECTION 06 - DRIVE SYSTEM RAMP CHARACTERISTICS Taller ramp = Higher engagement RPM Steeper angle = Higher shift RPM Shallower angle = More RPM at lower MPH (slower shift) A01D2IS 06-9 MMC2005-001_06A.FM...
Page 272: Effects Of The Drive Pulley Spring
SECTION 06 - DRIVE SYSTEM EFFECTS OF THE DRIVE PULLEY As you look through the spring chart, you will see that springs are available with equal pressures at SPRING 74 mm (2.9 in), but very different pressures at 41 mm (1.6 in). You will also note varying pres- The purpose of the clutch release spring is to re- sures at 74 mm (2.9 in) and equal pressures at turn the sliding half of the engine pulley and the...
Page 273 SECTION 06 - DRIVE SYSTEM Drive Clutch Spring Effect at Engagement 10,000 9,000 8,000 7,000 6,000 5,000 4,000 3,000 2,000 1,000 A01D1US LOAD AT LOAD AT 74 mm (2.9 in) 41 mm (1.6 in) 311 N (70 lb) 1157 N (260 lb) 712 N (160 lb) 1201 N (270 lb) 06-11...
Page 274 SECTION 06 - DRIVE SYSTEM Drive Clutch Spring Effect at Top Speed 10,000 9,000 8,000 7,000 6,000 5,000 4,000 3,000 2,000 1,000 A01D1VS LOAD AT LOAD AT 74 mm (2.9 in) 41 mm (1.6 in) 311 N (70 lb) 756 N (170 lb) 311 N (70 lb) 1157 N (260 lb) 06-12...
Page 275: Vsa
SECTION 06 - DRIVE SYSTEM TRA III Some 2004 models come equipped with a TRA III style drive clutch. They include most models with the 600 and 800 cc engines. This style of clutch is the “next” generation of engineering develop- ment from Ski-Doo and will certainly be used in more models as years go on.
Page 276: Drive Pulley Tra Iii
SECTION 06 - DRIVE SYSTEM DRIVE PULLEY TRA III All REV Series Models NOTE: This is a lubrication free drive pulley. Always refer to appropriate parts catalog for replacement part. Most parts of TRA III are not interchangeable with those of the TRA. Electric start models only 593 HO only...
Page 277: General
SECTION 06 - DRIVE SYSTEM GENERAL To remove drive pulley ass’y and/or fixed half from engine, use puller (P/N 529 022 400) for liquid Some drive pulley components (return spring, cooled models. ramp) can be changed to improve vehicle perfor- CAUTION: These pulleys have metric threads.
Page 278 SECTION 06 - DRIVE SYSTEM 32, Cushion Drive Use spring compressor (P/N 529 035 524). Install support guide. CAUTION: Do not disassemble cushion drive. Governor cup and cushion drive are factory bal- anced as an assembly. 25,29, Slider Shoe and Governor Cup Carefully lift governor cup until slider shoes come at their highest position into guides.
Page 279: Cleaning
SECTION 06 - DRIVE SYSTEM CLEANING 9,12, Fitting Bolt Ass’y and Flanged Bushing 5,6, Fixed and Sliding Half Check for wear, replace as required. Clean pulley faces and shaft with fine steel wool 24,25, O-Ring and Slider Shoe and dry cloth. Check if O-rings are cracked, cut or crushed.
Page 280 SECTION 06 - DRIVE SYSTEM 26,27,28, Calibration Screw, Washer Position dowel tube split at the angle A. and Locking Nut When installing calibration screw, make sure to in- stall washer as shown. MODEL ANGLE (A) A16D07A With TRA III 45 ± 3° 1.
Page 281 SECTION 06 - DRIVE SYSTEM 593 HO Engine Equipped Models Only Always install lever assemblies so that cotter pins are on the shown side. Besides install cotter pin head on top when lever is sat at bottom of sliding half. Bend cotter pin ends to sit perfectly against lever.
Page 282 SECTION 06 - DRIVE SYSTEM 793 Engine Equipped Models Only 6,25,29, Sliding Half, Slider Shoe and Governor Cup To install governor cup, use following tool: Insert spring and slider shoes into governor cup so that groove in each slider shoe is vertical to prop- erly slide in guides.
Page 283: Installation
SECTION 06 - DRIVE SYSTEM Use holder. See removal procedure. Torque screw to 80 to 100 N•m (59 to 74 lbf•ft). Install drive belt and guard. Raise and block the rear of the vehicle and support it with a mechanical stand. WARNING Ensure that the track is free of particles which could be thrown out while track is rotating.
Page 284 SECTION 06 - DRIVE SYSTEM 26,28,29, Calibration Screw, Locking Example: Nut and Governor Cup Calibration screw is set at position 3 and is changed to position 5. So maximum engine RPM is increased Calibration screw has a notch on top of its head. by about 400 RPM.
Page 285: Kit P/N 486 400 003 Tra Iii Weight Set-Up For Pin
SECTION 06 - DRIVE SYSTEM KIT P/N 486 400 003 TRA III WEIGHT SET-UP FOR PIN From 12.4 to 22.15 grams 16.21 GRAMS SET-UP PART PART WEIGHT PART PART WEIGHT DESCRIPTION NUMBER DESCRIPTION NUMBER Pin 35.75 mm 417 222 595 12.4 Pin 35.75 mm 417 222 595...
Page 286 SECTION 06 - DRIVE SYSTEM 15.42 GRAMS SET-UP 16.94 GRAMS SET-UP PART PART WEIGHT PART PART WEIGHT DESCRIPTION NUMBER DESCRIPTION NUMBER Pin 35.75 mm 417 222 595 12.4 Pin 35.75 mm 417 222 595 12.4 Set screw 20 mm 206 262 099 3.02 Set screw 25 mm 206 262 599 3.81...
Page 287 SECTION 06 - DRIVE SYSTEM 22.15 GRAMS SET-UP 19.85 GRAMS SET-UP PART PART WEIGHT PART PART WEIGH DESCRIPTION NUMBER DESCRIPTION NUMBER T (G) Pin 35.75 mm 417 222 595 12.4 Pin 35.75 mm 417 222 595 12.4 Set screw 6 mm 206 260 699 0.73 Set screw 6 mm 206 260 699...
Page 288 SECTION 06 - DRIVE SYSTEM TRA III RAMP PROFILES 06-26 MMC2005-001_06A.FM...
Page 289 SECTION 06 - DRIVE SYSTEM 06-27 MMC2005-001_06A.FM...
Page 290: Tra Springs Chart
SECTION 06 - DRIVE SYSTEM TRA SPRINGS CHART FORCE @ WIRE DIA. FREE LENGTH POUNDS ± 5% COLOR CODE 74 mm - 41 mm BOMBARDIER 2.9 in - 1.6 in 5.26 0.207 70 - 170 414 689 800 RED - RED 5.00 0.197 70 - 200...
Page 291 SECTION 06 - DRIVE SYSTEM FORCE @ WIRE DIA. FREE LENGTH POUNDS ± 5% COLOR CODE 74 mm - 41 mm BOMBARDIER 2.9 in - 1.6 in 5.72 0.225 160 - 320 414 817 900 PURPLE - PURPLE 5.94 0.234 5.94 0.234 160 - 350...
Page 292: Effects Of The Driven Pulley Spring
SECTION 06 - DRIVE SYSTEM EFFECTS OF THE DRIVEN PULLEY SPRING The driven pulley spring is needed to keep the plastic slider buttons in contact with the cam and to provide enough side force on the belt in the low gear position to allow initial acceleration while the torque rises to a point where the torque sensing cam begins to take over.
Page 293: Hpv 27 Vsa Clutch Springs
SECTION 06 - DRIVE SYSTEM • Next add the two readings together and di- FORMULA DRIVEN CLUTCH PRELOAD vide by two. This is the number we use as our reference. WHITE SPRING/LBS • Recording only the pull reading and this will POSITION definitely allow the driven pulley tension to be too low.
Page 294: Effects Of The Driven Pulley Cam
SECTION 06 - DRIVE SYSTEM EFFECTS OF THE DRIVEN PULLEY Multi-angle cams are sometimes used by racers needing a good holeshot. They generally work best on vehicles where no track spin is encoun- tered. As a vehicle idles on the starting line, the The purpose of the driven pulley cam is to sense exhaust temperature cools thus slightly lowering the torque requirements of the drive axle and feed...
Page 295: Driven Clutch Cams
SECTION 06 - DRIVE SYSTEM DRIVEN CLUTCH CAMS FORMULA - STD FORMULA RER & VSA HPV 27 & VSA PART PART PART NUMBER ANGLE TYPE ANGLE TYPE ANGLE NUMBER NUMBER 860 424 800 417 126 715 44 Alu. 417 126 445 44 Anod.
Page 296 SECTION 06 - DRIVE SYSTEM FORMULA - STD FORMULA RER & VSA HPV 27 & VSA PART PART PART NUMBER ANGLE TYPE ANGLE TYPE ANGLE NUMBER NUMBER 860 425 900 44-40 860 425 800 44-37 860 425 600 42-37 860 425 500 40-44 860 425 400 40-37...
Page 297: Formula Vsa
SECTION 06 - DRIVE SYSTEM DRIVEN PULLEY FORMULA VSA 06-35 MMC2005-001_06A.FM...
Page 298: Removal
SECTION 06 - DRIVE SYSTEM REMOVAL DISASSEMBLY Remove guard and drive belt from vehicle. Use spring compressor (P/N 529 018 600). Remove cap screw no. 12 and shouldered washer no. 11 then pull the driven pulley from the coun- tershaft. Note shouldered washer position for reinstallation.
Page 299: Inspection
SECTION 06 - DRIVE SYSTEM INSPECTION ASSEMBLY 9,10, Bushings 6, Cam Slider Shoe Check for cracks, scratch and for free movement When replacing slider shoes, always install a new when assembled to fixed half. set (3 shoes) to maintain equal pressure on the cam. Using a dial bore gauge measure bushing diame- Assemble driven pulley components by reversing ter.
Page 300 SECTION 06 - DRIVE SYSTEM Take 1 measurement when sliding half begins to turn. Rotate sliding half to 10 mm (3/8 in) of rotation. Hold spring scale at this position. Slowly release ten- sion from spring scale and take 2 measurement when sliding half begins to return.
Page 301: Hpv27 Vsa
SECTION 06 - DRIVE SYSTEM HPV27 VSA 06-39 MMC2005-001_06A.FM...
Page 302: Removal
SECTION 06 - DRIVE SYSTEM REMOVAL Remove half keys no. 6 and washer no. 7 to dis- assemble the cam and the 2 pulley halves. Remove guard and drive belt from vehicle. WARNING Remove cap screw no. 1 and shouldered washer no.
Page 303: Assembly
SECTION 06 - DRIVE SYSTEM ASSEMBLY Driven pulley end-play is 0 (zero). 1, Pulley Retaining Screw 10, Cam Slider Shoe Torque to 22 N•m (16 lbf•ft). When replacing slider shoes, always install a new set (3 shoes) to maintain equal pressure on the cam. ADJUSTMENT Install slider shoes as per following photo.
Page 304 SECTION 06 - DRIVE SYSTEM TEAM PERFORMANCE DRIVEN CLUTCH (All TEAM Performance Clutch Parts must be ordered from the Valcourt Race Dept. or Ski Doo Parts Support Truck) ITEM NO. PART NUMBER QUANTITY DESCRIPTION SERVICEABLE 130032 Ring, Retaining Basic Ext. 1.500 285275 Spider, 38T 10.75 Mach.
Page 305 SECTION 06 - DRIVE SYSTEM The two pictures shown below are showing how the helix angles are called out and how they are mea- sured. The first picture shown is a full progressive stamped as "F" on a helix (example 54-40- F). The second picture refers to a partial or .46 as most of our helix's are called out (example 58-44.46.
Page 306: Springs
SECTION 06 - DRIVE SYSTEM SPRINGS Relationship Between Drive Clutch Ramps, Weight, And Spring In The springs used in the TEAM Performance Driv- Maintaining Operating RPM en Clutch are measured differently because of the The drive clutch is a RPM sensing unit designed use of a compression spring instead of a torsion to transfer the maximum amount of horsepower spring.
Page 307: Belt Removal On Team Roller Secondary
SECTION 06 - DRIVE SYSTEM 3. Tighten the jam nut after the belt adjustment Too Much Belt Deflection has been made. See arrow. If the belt is too long or the center distance is too short, the initial starting ratio will be too high, re- sulting in performance loss.
Page 308: Team Secondary Clutch Maintenance/Adjustment
SECTION 06 - DRIVE SYSTEM 1. Measure belt deflection with both clutches at 2. Once you have tension on the spider assembly, rest and in their full neutral position. remove the snap ring. 2. Place a straight edge on the belt and apply 3.
Page 309: Installation
SECTION 06 - DRIVE SYSTEM INSTALLATION 3. Helix angle selection. Starting angle will effect how fast the clutch opens from a dead stop. Ex. 1. Install proper number of spacer washers on (70-44.46, a 70° starting angle will shift ex- jackshaft between clutch and jackshaft bearing.
Page 310 SECTION 06 - DRIVE SYSTEM 7. When inspecting the rest of the clutching components the primary clutch should be checked for four things: • "Worn out rollers and bushings • "Flat spots on ramps • "Worn out buttons in the clutch towers •...
Page 311 SECTION 06 - DRIVE SYSTEM TEAM INDUSTRIES DRIVEN CLUTCH PARTS (All TEAM Ind. Clutch Parts must be ordered from the Valcourt Race Dept. or the Ski Doo Parts Support Truck) SPRINGS HELIX PART NUMBER RATE LBS COLOR PART NUMBER TWIN TRAX ANGLE 210180 100-150 Red/Yellow...
Page 312 SECTION 06 - DRIVE SYSTEM HELIX HELIX PART NUMBER TWIN TRAX ANGLE PART NUMBER TWIN TRAX ANGLE 420500 70-48-36 66-44-46 420539 68-44-46 52-42-F 420501 42-36-F 50-36-46 420540 70-48-46 54-44-F 420502 52-38-F 58-38-46 420541 58-42-46-E 420503 52-36-F 58-36-46 420542 62-42-46-E 420504 48-40-F 56-40-46 420543 62-46-46-E...
Page 313: General
SECTION 06 - DRIVE SYSTEM PULLEY DISTANCE AND ALIGNMENT GENERAL Untighten torque rod using a long hexagonal key. Both pulley distance and pulley alignment must be checked out to ensure the highest efficiency of the transmission system. Furthermore, optimum drive belt operation and minimal wear will be ob- tained only with proper pulley alignment.
Page 314: Pulley Alignment And Distance Specifications Chart
SECTION 06 - DRIVE SYSTEM Measuring Procedure The distance Y must exceed distance X to com- pensate for the twist due to the engine torque. Using Straight Bar Always measure distances X and Y from the far- Drive Belt Deflection ther straight bar side (including its thickness to the NOTE: When pulley distance and alignment are fixed half edge).
Page 315: Drive Belts
SECTION 06 - DRIVE SYSTEM TYPICAL 1. Contact 1. Spacers NOTE: After alignment hand tighten torque rod so it slightly contacts engine crankcase. Do not over tighten, it will disalign pulleys. DRIVE BELTS The drive belt is the critical link in transmitting pow- er from one clutch to the other.
Page 316 SECTION 06 - DRIVE SYSTEM Always break in a new belt by running it easy for 10-15 miles. Vary the vehicle speed and throttle setting without going over 2/3 throttle. It is also a good idea to mark the direction of rotation on the belt.
Page 317: Inspection
SECTION 06 - DRIVE SYSTEM DRIVE BELT APPLICATION CHART MINIMUM WIDTH (wear limit) MODEL PART NUMBER mm (in) 2005 440 REV 417 300 288 34.70 (1.366) 2004 440 REV 417 300 253 34.70 (1.366) All 593 HO engine equipped models 417 300 197 33.35 (1.313) All 793 HO engine equipped models...
Page 318: Drive Belt Height Measurement And Adjustment
SECTION 06 - DRIVE SYSTEM 1. Flush Adjustment INCORRECT NOTE: For used drive belt, mark and reinstall in the Before adjusting the belt height, ensure that a same position. good-condition proper belt (refer to the Application Chart) is installed. DRIVE BELT HEIGHT Adjust pulley distance according to specification, MEASUREMENT AND refer to PULLEY DISTANCE AND ALIGNMENT.
Page 319 SECTION 06 - DRIVE SYSTEM Models Equipped with HPV27 VSA Type Driven Pulley A06D20A TYPICAL 1. Allen screws with jam nuts Allen screws must be restrained while tightening jam nut to prevent throwing adjustment out. Use drive belt tension adjuster (P/N 529 008 700). 1.
Page 320: Drive Belt Deflection Measurement (Reference Only)
SECTION 06 - DRIVE SYSTEM DRIVE BELT DEFLECTION MEASUREMENT (reference only) NOTE: The drive belt deflection measurement must be performed each time a new drive belt is installed. NOTE: To obtain an accurate drive belt deflection measurement, it is suggested to allow a break-in period of 50 km (30 m).
Page 321: Chaincase Gearing
SECTION 06 - DRIVE SYSTEM 1. Slide lower O-ring of deflection scale to speci- Most snowmobiles are geared on the high side fied measure. from the factory. They are usually geared for 8 -16 km/h (5-10 MPH) more than they would reach in 2.
Page 322 SECTION 06 - DRIVE SYSTEM For oval racing, the small benefit you may achieve in top end speed would probably be lost by the loss of acceleration on the start and out of the cor- ners on a tight oval circuit. This holds true for cross-country and snow cross- ers also.
Page 323 SECTION 06 - DRIVE SYSTEM × engine RPM teeth, top sprocket (pitch of track No. of teeth on drive sprocket) × × × -------------------------------- - ------------------------------------------------------------ - ---------------------------------------------------------------------------------------------------------------------------- - ------------ - top speed in MPH clutch ratio teeth, bottom sprocket 5280 A little known fact that can seriously impair a rac- MXZ GEAR RATIO VS SPEED...
Page 324: Chaincase Gears And Chains
SECTION 06 - DRIVE SYSTEM CHAINCASE GEARS AND CHAINS 15 WIDE 13 WIDE # OF # OF STEEL POWDER ALUMINUM STEEL POWDER ALUMINUM TEETH TEETH 486 092 600 504 152 030 504 152 031 504 151 911 486 070 700 504 152 328 504 152 044 504 151 913 504 151 500 504 096 200 486 074 600 504 151 914...
Page 325 SECTION 06 - DRIVE SYSTEM TRANSMISSION CALIBRATION • Pin weight and ramp angle are interrelated, but can be varied to achieve certain results. PROCEDURE A 16.5 gram pin and the adjuster set in #5 1. A new vehicle should be broken-in before fine may produce the same full throttle RPM as a tuning the transmission.
Page 326: Transmission Tuning Test Sheet
SECTION 06 - DRIVE SYSTEM TRANSMISSION TUNING TEST SHEET DATE: VEHICLE: SHEET NO.: ____________ TEST SITE: TEMPERATURE: SURFACE COND.: _______ TEST 1 TEST 2 TEST 3 TEST 4 TEST 5 Cam angle Spring color code Spring preload, lb Spring position ex.: (A-4) Chaincase gearing Lever arm and pin type Weight each assembly...
Page 327: Racers Log
SECTION 06 - DRIVE SYSTEM RACERS LOG VEHICLE: DATE: SHEET NUMBER: LOCATION: SURFACE CONDITIONS: TEMPERATURE: BAROMETRIC PRESSURE: HUMIDITY: CARBURETOR SIZE: FUEL: C.R.A.D.: Carburetion notes: Main jet Needle jet Jet needle E-clip position Slide cut-away Pilot jet Drive pulley Clutching notes: Lever arm/pin type Pin weight Ramp identification...
Page 328: Hydraulic Brake
SECTION 06 - DRIVE SYSTEM BRAKE HYDRAULIC BRAKE 06-66 MMC2005-001_06A.FM...
Page 329: Brake Fluid Type
SECTION 06 - DRIVE SYSTEM BRAKE FLUID TYPE Removal Brake pads removal procedure is as follows: Use recommended brake fluid SRF (DOT 4) (P/N 293 600 063) or GTLMA (DOT 4) (P/N 293 600 062). – Remove 2 retainers from the pins. –...
Page 330: Removal
SECTION 06 - DRIVE SYSTEM Installation – Open chaincase and remove upper sprocket. – Pull countershaft no. 3 toward driven pulley side – Install new brake pads. to free from chaincase and disc. – Install spring and push 2 pins to lock the brake –...
Page 331: Disassembly
SECTION 06 - DRIVE SYSTEM DISASSEMBLY 7, Brake Pad Only brake pads are available as spare parts. If cal- iper or master cylinder are damaged, replace each of them as an assembly. CLEANING Clean all metal components in a general purpose solvent.
Page 332: Adjustment
SECTION 06 - DRIVE SYSTEM Ensure that countershaft is properly aligned, then 5, Brake Light Switch tighten 3 retaining screws. There is no adjustment on these models. Check that NOTE: A misaligned countershaft will result in dif- switch is securely installed. ficulty to center the bearing in its support.
Page 333 SECTION 06 - DRIVE SYSTEM CHAINCASE 06-71 MMC2005-001_06A.FM...
Page 334: Removal And Disassembly
SECTION 06 - DRIVE SYSTEM REMOVAL AND DISASSEMBLY Pry out drive axle oil seal no. 19 from chaincase. Pull chaincase from drive axle and countershaft. To remove chaincase proceed as follows. Using 2 large prybars inserted between chaincase Remove hair pin no. 8. Release drive chain ten- housing no.
Page 335: Installation And Assembly
SECTION 06 - DRIVE SYSTEM INSTALLATION AND ASSEMBLY Reverse removal and disassembly procedure and pay attention to the following. Replace oil seals, gas- kets O-rings and drain plug. 25, Hardened Washer 1. New Make sure to install a hardened washer on each 2.
Page 336: Adjustment
SECTION 06 - DRIVE SYSTEM TYPICAL 1. Dipstick 2. Oil level 3. Level between marks 4. Magnet NOTE: Chaincase must be in its proper position when checking oil level. ADJUSTMENT Pulley Alignment Refer to PULLEY DISTANCE AND ALIGNMENT. Track Tension and Alignment Refer to TRACK.
Page 337 SECTION 06 - DRIVE SYSTEM DRIVE AXLE REV Series Models 06-75 MMC2005-001_06A.FM...
Page 338: Removal
SECTION 06 - DRIVE SYSTEM REMOVAL Remove battery (if so equipped) to gain access, refer to BATTERY section. Drain oil from chaincase. Remove chaincase cov- er. Release drive chain tension. 1. Circlip Apply parking brake. Remove chain and sprockets then circlip from right side.
Page 339: Assembly
SECTION 06 - DRIVE SYSTEM ASSEMBLY Ensure to align indexing marks of each sprocket when assembling. 3,5,6, Drive Axle and Sprocket To assemble press fit sprockets, use a press and a suitable pipe as illustrated. Sprockets must be as- sembled according to the following dimensions. TYPICAL 1.
Page 340: Lubrication
SECTION 06 - DRIVE SYSTEM 7, Bearing Protector LUBRICATION At assembly, flat side of bearing protector must be Lubricate end housing bearing with synthetic grease against bearing. (P/N 413 711 500). 8, Bearing ADJUSTMENT Always push bearing by inner race. Sprocket/Track Alignment CAUTION: Do not temper with sprocket/track alignment if frame or suspension is damaged.
Page 341: Track Type Application
SECTION 06 - DRIVE SYSTEM TRACK TRACK TYPE APPLICATION INSTALLATION Refer to TECHNICAL DATA. Reverse the removal procedure. NOTE: When installing the track, respect rotation GENERAL direction indicated by an arrow on track thread. Check sprocket/track alignment as described in This section gives guidelines for track removal.
Page 342 SECTION 06 - DRIVE SYSTEM A01F05A 1. Guides 2. Slider shoes 3. Equal distance 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.
Page 343 SECTION 06 - DRIVE SYSTEM – Re-open installer, then position cleat tabs on open end of tool and squeeze tabs until they are indented in rubber. TYPICAL 1. First step 2. Second step (to push tabs into rubber) 06-81 MMC2005-001_06A.FM...
Page 344 SECTION 07 - 2005 MX Z X 440 INFORMATION TABLE OF CONTENTS 2005 MX Z X 440 LC REV......................07-02 ENGINE ............................07-02 IGNITION SYSTEM........................07-02 HOLESHOT BUTTON ........................ 07-02 DRIVETRAIN ..........................07-02 TRACK & TRACTION ......................... 07-03 SC-4 REAR SUSPENSION......................07-03 2005 OPTION PACKAGE COLOR....................
Page 345: 2005 Mx Z X 440 Lc Rev
SECTION 07 - 2005 MX Z X 440 INFORMATION 2005 MX Z X 440 LC REV The following areas provide a brief overview and HOLESHOT BUTTON improvements to the new 440-race sled. For de- As stated above, the Holeshot button determines tailed information, you will be instructed to consult which ignition curve, B or C, the motor uses.
Page 346: Track & Traction
SECTION 07 - 2005 MX Z X 440 INFORMATION TRACK & TRACTION The track used on the 2005 MX Z X 440 REV is similar to past years but with some improve- ments. The lug pattern and height are the same as the 2004 MX Z X 440 REV with the lug height being 1¾"...
Page 347: 2005 Option Package Color
SECTION 07 - 2005 MX Z X 440 INFORMATION 2005 OPTION PACKAGE COLOR 2005 MX Z X 440 RACING BLACK - YELLOW MODEL NUMBER CDN / U.S. : BM5A (1.75” TRACK) ENGINE Engine manufacturer Rotax Engine type no. Lubrication type Premix Number of cylinders Bore...
Page 348 SECTION 07 - 2005 MX Z X 440 INFORMATION 2005 OPTION PACKAGE COLOR 2005 MX Z X 440 RACING BLACK - YELLOW MODEL NUMBER CDN / U.S. : BM5A (1.75” TRACK) ENGINE (SUITE) Con. rod big end axial clearance New, min. 0.390 0.0154 New, max.
Page 349 SECTION 07 - 2005 MX Z X 440 INFORMATION 2005 OPTION PACKAGE COLOR 2005 MX Z X 440 RACING BLACK - YELLOW MODEL NUMBER CDN / U.S. : BM5A (1.75” TRACK) ENGINE ELECTRICAL SYSTEM Ignition system manufacturer Denso Corporation Ignition system type C.D.I.
Page 350 SECTION 07 - 2005 MX Z X 440 INFORMATION 2005 OPTION PACKAGE COLOR 2005 MX Z X 440 RACING BLACK - YELLOW MODEL NUMBER CDN / U.S. : BM5A (1.75” TRACK) POWER TRAIN (Drive Clutch) Drive pulley manufacturer CVTECH-IBC INC Drive pulley type Cushion drive T.R.A.
Page 351 SECTION 07 - 2005 MX Z X 440 INFORMATION 2005 OPTION PACKAGE COLOR 2005 MX Z X 440 RACING BLACK - YELLOW MODEL NUMBER CDN / U.S. : BM5A (1.75” TRACK) FRONT SUSPENSION Front suspension type R.A.S. A-Arm Front suspension travel mm in 242.00 Sway bar type...
Page 352 SECTION 07 - 2005 MX Z X 440 INFORMATION 2005 OPTION PACKAGE COLOR 2005 MX Z X 440 RACING BLACK - YELLOW MODEL NUMBER CDN / U.S. : BM5A (1.75” TRACK) GENERAL SPECIFICATIONS Vehicle overall length 113.465 2882.00 Chassis overall length 2157.00 84.921 Vehicle overall width...
Page 353 SECTION 07 - 2005 MX Z X 440 INFORMATION 2005 OPTION PACKAGE COLOR 2005 MX Z X 440 RACING BLACK - YELLOW MODEL NUMBER CDN / U.S. : BM5A (1.75” TRACK) LIQUIDS SPECIFICATIONS Fuel tank (SAE J288a rated) US gal Recommended fuel type Race Fuel Minimum octane number...
Page 354 SECTION 08 - 2005 MX Z 550 and 380 FC TABLE OF CONTENTS 05 MXZ 550 F/C PERFORMANCE KITS ..................08-03 STAGE 1 - 860 428 500 ......................08-03 STAGE 2 - 860 428 600 ......................08-04 377 AND 552 ENGINE TYPE ......................08-05 ENGINE REMOVAL AND INSTALLATION ................
Page 355 SECTION 08 - 2005 MX Z 550 AND 380 FC DRIVE PULLEY ..........................08-39 BOMBARDIER LITE ........................08-39 GENERAL............................ 08-40 REMOVAL ........................... 08-40 DISASSEMBLY ........................... 08-40 CLEANING ..........................08-41 INSPECTION ..........................08-41 ASSEMBLY ..........................08-41 INSTALLATION .......................... 08-41 IGNITION TIMING .......................... 08-43 VERIFYING MAGNETO FLYWHEEL TIMING MARK POSITION..........
Page 356 SECTION 08 - 2005 MX Z 550 AND 380 FC 05 MXZ 550 F/C PERFORMANCE KITS STAGE 1 - 860 428 500 PART # DESCRIPTION PART # DESCRIPTION 503 190 563 Strap, Limiter, SC-3 505 070 703 Shock, HPG Piggy Back, Front LH 224 081 301 Washer, Limiter Strap 505 070 702...
Page 357 SECTION 08 - 2005 MX Z 550 AND 380 FC STAGE 2 - 860 428 600 PART # DESCRIPTION PART # DESCRIPTION Terminal Housing, Male 6 517 303 160 Windshield, 440 X 515 175 662 Circuits 293 150 089 Plastic Rivet, Push thru 512 059 537 Housing, Bottom 516 001 738...
Page 358: And 552 Engine Type
SECTION 08 - 2005 MX Z 550 AND 380 FC 377 AND 552 ENGINE TYPES ENGINE REMOVAL AND INSTALLATION 377 and 552 Engine Types 377 engine 552 engine 08-5 MMC2005-001_08A.FM...
Page 359 SECTION 08 - 2005 MX Z 550 AND 380 FC ENGINE REMOVAL AND INSTALLATION Disconnect or remove the following: WARNING Before disconnecting any electrical wire in starter system always first disconnect the BLACK negative battery cable (on electric starting models). –...
Page 360: Top End
SECTION 08 - 2005 MX Z 550 AND 380 FC TOP END 377 Engine Type 08-7 MMC2005-001_08A.FM...
Page 361 SECTION 08 - 2005 MX Z 550 AND 380 FC 552 Engine Types 08-8 MMC2005-001_08A.FM...
Page 362: General
SECTION 08 - 2005 MX Z 550 AND 380 FC GENERAL CAUTION: While performing any engine re- lated procedure, always make sure that the working area is clean and free from dust or particles to reduce the risk of damaging the engine.
Page 363 SECTION 08 - 2005 MX Z 550 AND 380 FC NOTE: The PTO cylinder or fan housing have to be Pull out piston pin no. 10 by unscrewing puller removed to give access to MAG piston pin with until shouldered sleeve end is flush with thrust the puller.
Page 364: Inspection
SECTION 08 - 2005 MX Z 550 AND 380 FC When installing a new cageless bearing, replace half plastic cages by sleeve. A02C2EA TYPICAL Remove piston from connecting rod. Install locating sleeve. Then push needle bearings along with thrust washers and sleeve. A02C2GA TYPICAL 1.
Page 365 SECTION 08 - 2005 MX Z 550 AND 380 FC A02C2IA CAUTION: Piston temperature must not exceed TYPICAL — SHOULDERED SLEEVE INSTALLATION 46°C (115°F). NEVER USE DIRECT FLAME to Install piston pin puller and turn handle until piston heat the piston and never freeze the pin. In- pin is correctly positioned in piston.
Page 366 SECTION 08 - 2005 MX Z 550 AND 380 FC 529 009 100 A01B1SA NOTE: The circlip on the opposite side can be in- stalled before pin installation, the tool will easily go out. Use piston pin puller (P/N 529 035 503) to install a piston pin that cannot be installed as described A02C2LA above.
Page 367 SECTION 08 - 2005 MX Z 550 AND 380 FC A01C02A 1. Piston notch 2. Circlip break at 6 o’clock 1. Circlip in groove CAUTION: Circlips must not move freely in the Mount tool in piston making sure that circlip break groove after installation.
Page 368 SECTION 08 - 2005 MX Z 550 AND 380 FC Using a plastic hammer, tap pusher to insert circlip in place. Take care to install new circlips with tab toward top as per following photo. With the other end of the pusher, push circlip into the support groove.
Page 369 SECTION 08 - 2005 MX Z 550 AND 380 FC Position distance nuts no. 2 as shown below. RING COMPRESSOR ENGINE TYPE 420 876 090 420 876 972 NOTE: The ring compressor will not fit on over size pistons. Check flatness of intake sockets no. 6. Refer to ENGINE DIMENSION MEASUREMENT and look for CHECKING SURFACE FLATNESS.
Page 370 SECTION 08 - 2005 MX Z 550 AND 380 FC A06C0FA 1. No play Check distance from blade stopper inner edge and distance from center of reed valve block. TYPICAL A. 14.75 - 0, + 0.75 mm (.580 - 0, + .030 in) Bent blade stopper as required to obtain the proper distance.
Page 371: Bottom End
SECTION 08 - 2005 MX Z 550 AND 380 FC BOTTOM END 377 Engine Type 08-18 MMC2005-001_08A.FM...
Page 372 SECTION 08 - 2005 MX Z 550 AND 380 FC 552 Engine Types 08-19 MMC2005-001_08A.FM...
Page 373: Cleaning
SECTION 08 - 2005 MX Z 550 AND 380 FC NOTE: Engine must be removed from chassis to Apply synthetic grease (P/N 413 711 500) on the perform the following procedures. crankshaft end and install protective cap (P/N 420 876 552). Remove engine from chassis.
Page 374: Inspection
SECTION 08 - 2005 MX Z 550 AND 380 FC INSPECTION Refer to ENGINE DIMENSIONS MEASUREMENT. ASSEMBLY Clean crankshaft end with sand paper no. 180 and remove all residue using Pulley flange cleaner (P/N 413 711 809). BEARING PULLER SECURED IN THE VISE CAUTION: Never use any air impact tool for tightening the puller bolt.
Page 375 SECTION 08 - 2005 MX Z 550 AND 380 FC To check proper clearance between bearing no. 3 CAUTION: Bearing should not be heated to more than 80°C (176°F). Do not heat bearing and crankshaft counterbalance , use feeler gauge with direct flame or heat gun or heated oil.
Page 376 SECTION 08 - 2005 MX Z 550 AND 380 FC WARNING Do not touch heated bearing with bare hands. Wear heat resisting gloves before handling the heated bearing(s). Slide in the inner PTO bearing with the integrated seal facing crankshaft. Push bearing to end posi- tion.
Page 377 SECTION 08 - 2005 MX Z 550 AND 380 FC TYPICAL — BALLS COATED WITH A SEAM OF GREASE All Engines Bearings are pressed on crankshaft until they rest against radius. These radius maintain the gap Install the MAG side heated bearing. needed for bearings lubrication.
Page 378 SECTION 08 - 2005 MX Z 550 AND 380 FC Align both crankcase halves before tightening screws. Position the crankcase halves together and tighten bolts by hand then install and tighten armature plate on magneto side to correctly align the crankcase halves. Screw the 4 central bolts (bolts no.
Page 379 SECTION 08 - 2005 MX Z 550 AND 380 FC 377 Engine Type 10 8 A09C05A TIGHTENING SEQUENCE FOR 377 ENGINE TYPE A. 10 N•m (89 lbf• in ) All the other screws are torqued to 22 N•m (16 lbf•ft) All Engines To install magneto, refer to CDI MAGNETO.
Page 380: Oil Injection System
SECTION 08 - 2005 MX Z 550 AND 380 FC OIL INJECTION SYSTEM 377 and 552 Engines 13 12 377 engines 552 engines 08-27 MMC2005-001_08A.FM...
Page 381: General
SECTION 08 - 2005 MX Z 550 AND 380 FC GENERAL (1) CAUTION: The BOMBARDIER Formula XP-S II synthetic injection oil is specially During assembly/installation, use the torque val- formulated and tested for the severe re- ues and service products as in the exploded quirement of these engines.
Page 382: Oil Pump Identification
SECTION 08 - 2005 MX Z 550 AND 380 FC Injection Oil Level Switch NOTE: An oil pump shaft test must be done to complete the oil system leak test. Refer to LEAK Before replacing the injection oil level switch TEST AND ENGINE DIMENSION MEASURE- no.
Page 383: Assembly
SECTION 08 - 2005 MX Z 550 AND 380 FC Injection Oil Reservoir Oil Pump Gear For installation, reverse the removal procedure. 377 and 552 Engines Remove the oil pump from engine. Injection Oil Level Switch To remove the gear retaining nut no. 15, first ex- For installation, reverse the removal procedure.
Page 384: Adjustment
SECTION 08 - 2005 MX Z 550 AND 380 FC ADJUSTMENT Oil Pump Cable 377 and 552 Engines Prior to adjusting the pump, make sure all car- buretor adjustments are completed and engine is stopped. Eliminate the throttle cable free-play by pressing the throttle lever until a light resistance is felt, then hold in place.
Page 385: Checking Operation
SECTION 08 - 2005 MX Z 550 AND 380 FC Test Bench Test Bench Test Bench Test Bench Test Bench Test Bench Test Bench Test Bench Test Bench Test Bench Test Bench Test Bench Test Bench Test Bench Test Bench Test Bench Test Bench Test Bench...
Page 386: Axial Fan Cooling System
SECTION 08 - 2005 MX Z 550 AND 380 FC AXIAL FAN COOLING SYSTEM 377 and 552 Engines 13 14 15 16 08-33 MMC2005-001_08A.FM...
Page 387: Removal
SECTION 08 - 2005 MX Z 550 AND 380 FC NOTE: The following procedures can be done without removing engine from chassis. REMOVAL NOTE: To facilitate further disassembly, fan nut may be removed before removing fan housing. Remove rewind starter, starting pulley, trigger coil wire from 4-connector housing then fan housing ass’y.
Page 388: Installation
SECTION 08 - 2005 MX Z 550 AND 380 FC A23C07A TYPICAL 1. Ring supporting fan housing Using a press, drive the fan shaft no. 9 out. Remove circlip no. 11 then remaining bearing. To install, press one bearing in place then install circlip and shims.
Page 389 SECTION 08 - 2005 MX Z 550 AND 380 FC A03C2AA FAN BELT PROPERLY INSTALLED ON BOTTOM A03C22A PULLEY AND FAN SHAFT 1. Bottom pulley 1. Remove fan with pulley half 2. Fan shaft 3. Starting pulley Remove fan belt. Reinstall fan assembly on fan shaft.
Page 390 SECTION 08 - 2005 MX Z 550 AND 380 FC TYPICAL 1. Unused shim(s) here 2. Adjust here 3. Positioning noses 4. Some engines only Select pulley halves so that the one with 2 posi- tioning noses will be on fan side. Ensure to insert these noses into fan notches.
Page 391 SECTION 08 - 2005 MX Z 550 AND 380 FC CAUTION: When installing rewind starter, en- sure that oil pump shaft is properly positioned. Do not force shaft insertion. Turn fan until oil pump shaft slides in place, as shown in the fol- lowing photo.
Page 392: Drive Pulley
SECTION 08 - 2005 MX Z 550 AND 380 FC DRIVE PULLEY BOMBARDIER LITE NOTE: This is a lubrication free drive pulley. 377 and 552 Engines Electrical start models only 552 Engine type 08-39 MMC2005-001_08A.FM...
Page 393: General
SECTION 08 - 2005 MX Z 550 AND 380 FC GENERAL 529 027 600 Some drive pulley components (return spring, cal- ibration disk) can be changed to improve vehicle performance in high altitude regions. A service bulletin will give information about calibration ac- cording to altitude.
Page 394: Cleaning
SECTION 08 - 2005 MX Z 550 AND 380 FC A03D2IA A03D2HA 1. Alignment marks 1. Puller tool 2. Spring cover tool Identify blocks no. 1 and their respective positive Screw puller (hand tight) to hold spring cover and positions for reassembly. remove screws holding spring cover.
Page 395 SECTION 08 - 2005 MX Z 550 AND 380 FC WARNING Make sure the track is free of particles that could be thrown out while track is rotating. Keep hands, tools, feet and clothing clear of track. Ensure nobody is standing near the ve- hicle.
Page 396: Ignition Timing
SECTION 08 - 2005 MX Z 550 AND 380 FC IGNITION TIMING 377 and 552 Engine Types If for any reason, ignition timing accuracy is sus- pected, it can be verified as follows. VERIFYING MAGNETO FLYWHEEL TIMING MARK POSITION Prior to checking the timing, it may be necessary to verify the position of the timing mark on the magneto flywheel, for the following reasons: •...
Page 397: Checking Ignition Timing
SECTION 08 - 2005 MX Z 550 AND 380 FC NOTE: When checking timing, certain procedures – Scribe or punch a mark on magneto flywheel require that the magneto flywheel be turned in so that it perfectly aligns with the arrow on a clockwise direction, viewed facing the mag- crankcase, refer to illustration.
Page 398 SECTION 08 - 2005 MX Z 550 AND 380 FC To check the ignition timing, refer to illustration and proceed as follows: • Place ski tips against a wall, raise rear of vehicle on a stand, so that track does not contact the ground.
Page 399: Mod Engine Kit
SECTION 09 - 2005 800 MOD ENGINE KIT TABLE OF CONTENTS 2005 OPEN MOD SNOCROSS ENGINE SPECIFICATIONS & PARTS 793 (ROTAX) 2 CYLINDERS ......................... 09-02 DRIVE CLUTCH PARTS LIST..................... 09-04 09-1 MMC2005-001_09A (TOOLS).FM...
Page 400 SECTION 09 - 2005 800 MOD ENGINE KIT 2005 OPEN MOD SNOCROSS ENGINE SPECIFICATIONS & PARTS 793 (ROTAX) 2 CYLINDERS PISTON PIN P/N 420 916 370 BORE 82 mm CIRCLIP P/N 420 845 106 STROKE 75.7 mm BASE GASKET AVAILABLE 799.2 cc .4 mm P/N 420 931 836...
Page 401 SECTION 09 - 2005 800 MOD ENGINE KIT Center w/slots P/N 420 924 905 REED VALVE Outside P/N 420 924 900 DRIVE CLUTCH Clutch ass’y - forged P/N 417 222 806 Ramp 419 pos. 4 P/N 417 222 557 Arm, std. aluminum P/N 417 222 383 •...
Page 402 SECTION 09 - 2005 800 MOD ENGINE KIT Engine Type: Engine Type: Stroke: 75.7 Stroke: 75.7 C.R. Length: C.R. Length: DEGREE PISTON POS. PISTON POS. DEGREE PISTON POS. PISTON POS. (mm) (inch) (mm) (inch) 0.000 4.88 0.192 0.01 0.000 5.25 0.207 0.03 0,001...
Page 403 SECTION 09 - 2005 800 MOD ENGINE KIT WARNING: 09-5 MMC2005-001_09A (TOOLS).FM...
Page 404 SECTION 09 - 2005 800 MOD ENGINE KIT To install the after muffler fastener: Remove a pop rivet to enlarge the hole to 5/16". Insert the fastener in the 5/16" hole. Make a new hole of 3/ 16" then install a new pop rivet to hold the muffler fastener.
Page 405 SECTION 09 - 2005 800 MOD ENGINE KIT 09-7 MMC2005-001_09A (TOOLS).FM...
Page 406 SECTION 09 - 2005 800 MOD ENGINE KIT Tune Pipe Support Make a new hole of 5/16 in. in the support hull. Insert the fastener of the tune pipe in that 5/16 in. hole. Make an other hole of 3/16 in. the support of the hull and install a new pop rivet to hold the fasterner. Tune Pipe Fastener Installation Update tune pipe fastener installation.
Page 407 SECTION 10 - 2004 MX Z X 440 TABLE OF CONTENTS 2004 MX Z X 440 REV ........................10-02 MX Z X 440 REV DRIVE SPROCKET REPLACEMENT..............10-10 2004 SKI-DOO MX Z RACING TIP SHEET..................10-14 SKI-DOO RACING, 7575 BOMBARDIER COURT, WAUSAU, WI 54401-8035 NUMBER: 01 NOVEMBER 23, 2003 .......................
Page 408 SECTION 10 - 2004 MX Z X 440 2004 OPTION PACKAGE COLOR 2004 MX Z X 440 RACING BLACK - YELLOW MODEL NUMBER CDN / U.S. : 2882 ENGINE Engine manufacturer Rotax Engine type no. Lubrication type Premix Number of cylinders Bore 65.00 2.559...
Page 409 SECTION 10 - 2004 MX Z X 440 2004 OPTION PACKAGE COLOR 2004 MX Z X 440 RACING BLACK - YELLOW MODEL NUMBER CDN / U.S. : 2882 ENGINE (SUITE) Crankshaft balance factor 42.5 % Pto: 29,6% Cr. deflection (MAG side) 0.050 0.0020 Cr.
Page 410 SECTION 10 - 2004 MX Z X 440 2004 OPTION PACKAGE COLOR 2004 MX Z X 440 RACING BLACK - YELLOW MODEL NUMBER CDN / U.S. : 2882 ENGINE ELECTRICAL SYSTEM Ignition system manufacturer Nippondenso Ignition system type C.D.I. Ig. timing BTDC (Dynamic) 2.79 0.1098 3500...
Page 411 SECTION 10 - 2004 MX Z X 440 2004 OPTION PACKAGE COLOR 2004 MX Z X 440 RACING BLACK - YELLOW MODEL NUMBER CDN / U.S. : 2882 DRIVE PULLEY Drive pulley manufacturer IBC Canada Drive pulley type Cushion drive T.R.A. III Light Drive pulley part number 417 222 616 Drive pulley diameter...
Page 412 SECTION 10 - 2004 MX Z X 440 2004 OPTION PACKAGE COLOR 2004 MX Z X 440 RACING BLACK - YELLOW MODEL NUMBER CDN / U.S. : 2882 DRIVE BELT (SUITE) Drive sprocket pitch diameter mm in 181.5 7.146 Drive sprocket number of teeth FRONT SUSPENSION Front suspension type R.A.S.
Page 413 SECTION 10 - 2004 MX Z X 440 2004 OPTION PACKAGE COLOR 2004 MX Z X 440 RACING BLACK - YELLOW MODEL NUMBER CDN / U.S. : 2882 TRACK Track # & profile height 504 152 361 44.5/41.1 1.752/1.625 Optional Track # - Sno X 504 152 168 44.5 1.752...
Page 414 SECTION 10 - 2004 MX Z X 440 2004 OPTION PACKAGE COLOR 2004 MX Z X 440 RACING BLACK - YELLOW MODEL NUMBER CDN / U.S. : 2882 MATERIALS AND COLORS Front member & frame material Aluminium Frame color Natural Aluminium Bottom pan material Impact resistant copolymer Bottom pan color...
Page 415 SECTION 10 - 2004 MX Z X 440 2004 OPTION PACKAGE COLOR 2004 MX Z X 440 RACING BLACK - YELLOW MODEL NUMBER CDN / U.S. : 2882 STANDARD/OPTIONAL EQUIPMENT Gauge (Tachometer (White facia)) Gauge (Speedometer (White facia)) Gauge (Fuel (electric) (White facia)) Gauge (Temp.
Page 416 SECTION 10 - 2004 MX Z X 440 Campaign(s) no. 2004–0006 2004-2 November 28, 2003 Drive Sprocket Replacement Date: Subject: SERIAL YEAR MODEL MODEL NUMBER NUMBER 2004 MX Z x 440 2882/2884 N N N N O O O O T T T T E E E E : : : : This modification applies ONLY to MX Z x 440, Racing Package units, that did not go ®...
Page 417 SECTION 10 - 2004 MX Z X 440 Drive Sprocket Replacement Procedure Validate that vehicle is equipped with suspect drive sprockets (black). Remove rear shock absorber to prevent damaging shock absorber rod. Remove rear suspension. Remove speed sensor and outer flange. Apply parking brake.
Page 418 SECTION 10 - 2004 MX Z X 440 Drive Sprocket Replacement N N N N O O O O T T T T E E E E : : : : Never support sprocket by the outside when pressing shaft in. Install new retainer ring and clip, push back sprocket using the press, according to the following measures.
Page 419 SECTION 10 - 2004 MX Z X 440 Drive Sprocket Replacement Warranty Coverage Submit a warranty claim using the following information: W W W W a a a a r r r r r r r r a a a a n n n n t t t t y y y y I I I I n n n n f f f f o o o o r r r r m m m m a a a a t t t t i i i i o o o o n n n n Campaign Number 2004–0006 Claim Type...
Page 420: Ski-Doo Racing, 7575 Bombardier Court, Wausau, Wi 54401-8035 Number
SECTION 10 - 2004 MX Z X 440 TIP SHEET 2004 SKI-DOO MX Zx RACING SKI-DOO RACING, 7575 BOMBARDIER COURT, WAUSAU, WI 54401-8035 NUMBER: 01 NOVEMBER 23, 2003 REAR SHOCK MOUNT UPDATE - 04 WARNING MXZx 440 This information relates to the preparation and Under severe racing conditions, the top mount of the use of snowmobiles in competitive events.
Page 421: Ski-Doo Racing, 7575 Bombardier Court, Wausau, Wi 54401 Number
SECTION 10 - 2004 MX Z X 440 TIP SHEET 2004 SKI-DOO MX Zx RACING SKI-DOO RACING, 7575 BOMBARDIER COURT, WAUSAU, WI 54401 NUMBER: 02 DECEMBER 03, 2003 TETHER SWITCH - 04 MXZx 440 REV WARNING and Rolling Chassis This information relates to the preparation and Remove the aluminum spacer between the panel use of snowmobiles in compétitive events.
Page 422: Ski-Doo Racing, 7575 Bombardier Court, Wausau, Wi 54401 Number
SECTION 10 - 2004 MX Z X 440 TIP SHEET 2004 SKI-DOO MX Zx RACING SKI-DOO RACING, 7575 BOMBARDIER COURT, WAUSAU, WI 54401 NUMBER: 03 DECEMBER 10, 2003 COOLANT HOSE CLAMPS - 2004 MXZx WARNING 440 REV and Rolling Chassis This information relates to the preparation and To avoid coolant leakage and/or a hose coming off, use of snowmobiles in compétitive events.
Page 423: Competition Preparation
SECTION 11 - COMPETITION PREPARATION TABLE OF CONTENTS SNO CROSS..........................11-2 HILLCROSS ..........................11-2 HILL CLIMBING.......................... 11-3 DRAG RACING (ICE AND GRASS) ................... 11-3 SPEED RUNS ..........................11-5 OVAL RACING..........................11-5 SUGGESTED SPARE PARTS..................... 11-7 EQUIVALENT WEIGHTS AND MEASURES CHART ..............11-9 FUEL/OIL RATIO CHARTS ......................
Page 424: Sno Cross
SECTION 11 - COMPETITION PREPARATION These are general guide lines for preparing a stock • Adjust spring pressure, with the rider in place, REV chassis for various forms of competition. Re- so the ACM block is in the center of the cou- fer to the appropriate section of the book for more pling window.
Page 425: Hill Climbing
SECTION 11 - COMPETITION PREPARATION Track Track • Best performance and speed is achieved by in- • Use a “finger” type track with a 1.75” to 2.00” stalling a 136” x 15” with 1.75” lug height. lug height profile. Beginning of season or fresh snow, use a track with a 1.75”...
Page 426 SECTION 11 - COMPETITION PREPARATION Center NOTE: The installation of hooker plates will re- quire modification to the tunnel protection system • Use stock springs but limit suspension travel and should be approached with caution. with limiter straps or stops to 76 mm (3 in), •...
Page 427: Speed Runs
SECTION 11 - COMPETITION PREPARATION Cooling OVAL RACING • Install a pair of hydraulic quick couplers in the Special Rules coolant hoses at a convenient location on the sled. Make a cooling cart using a cooler filled • Rear of tunnel must be enclosed per specifica- with ice and several winds of copper tubing in- tions in the l.S.R.
Page 428 SECTION 11 - COMPETITION PREPARATION Traction Transmission • Most rules limit maximum stud height to 3/8” • You need aggressive shifting to get a good hole- over the tallest part of the track. Track cutting is shot but you also need good backshifting. Here illegal.
Page 429: Suggested Spare Parts
SECTION 11 - COMPETITION PREPARATION SUGGESTED SPARE PARTS International 262-335-2401 PH Snowmobile Racing 262-335-9440 Fax You should have a self-contained parts supply. The World Snowmobile 651-209-7400 PH factory parts truck won't always be there to back Association 651-209-7447 Fax you up. Canadian Snowcross 905-476-7182 PH –...
Page 430 SECTION 11 - COMPETITION PREPARATION – tail light assembly – hood latch rubber – synthetic chaincase oil. Things to DOO Between Heats: – carefully remove ice and snow build up front and rear suspension – inspect suspension components – check/replace studs –...
Page 431: Equivalent Weights And Measures Chart
SECTION 11 - COMPETITION PREPARATION EQUIVALENT WEIGHTS AND MEASURES CHART LINEAR MEASURE 1 inch = 25.4 millimeters (mm) 1 millimeter = .03937 inch 1 inch = 2.54 centimeters (cm) 1 centimeter = .3937 inch 1 foot = .3048 meter (m) 1 meter = 3.2808 feet 1 yard = .914 meter (m) 1 meter = 1.093 yards...
Page 432: Fuel/Oil Ratio Charts
SECTION 11 - COMPETITION PREPARATION FUEL/OIL RATIO CHARTS 50/1 METRIC (SI) 500 mL of oil + 25 L of fuel = 50/1 IMPERIAL 16 oz of oil + 5 Imp. gal of fuel = 50/1 500 mL of oil + 5.5 Imp. gal of fuel = 50/1 UNITED STATES 13 oz of oil + 5 U.S.
Page 433 SECTION 11 - COMPETITION PREPARATION 40/1 METRIC (SI) 500 mL of oil + 20 L of fuel = 40/1 IMPERIAL 16 oz of oil + 4.0 Imp. gal of fuel = 40/1 500 mL of oil + 4.8 Imp. gal of fuel = 40/1 35.2 UNITED STATES 10.2...
Page 434 SECTION 11 - COMPETITION PREPARATION 33/1 METRIC (SI) 500 mL of oil + 16.5 L of fuel = 33/1 16.5 1000 IMPERIAL 24 oz of oil + 5 Imp. gal of fuel = 33/1 500 mL of oil + 3.6 Imp. gal of fuel = 33/1 17.6 35.2 UNITED STATES...
Page 435 SECTION 11 - COMPETITION PREPARATION 25/1 METRIC (SI) 500 mL of oil + 12.5 L of fuel = 25/1 12.5 IMPERIAL 16 oz of oil + 2.5 Imp. gal of fuel = 25/1 500 mL of oil + 2.7 Imp. gal of fuel = 25/1 35.2 UNITED STATES 15 oz of oil + 2.8 U.S.
Page 436 SECTION 11 - COMPETITION PREPARATION 20/1 METRIC (SI) 500 mL of oil + 10 L of fuel = 20/1 IMPERIAL 16 oz of oil + 2 Imp. gal of fuel = 20/1 500 mL of oil + 2.2 Imp. gal of fuel = 20/1 35.2 UNITED STATES 16 oz of oil + 2.4 U.S.
Page 437: Stock Class Preparation
SECTION 11 - COMPETITION PREPARATION STOCK CLASS PREPARATION 4. Check piston to cylinder clearances, ring end gap, cylinder taper and out-of round. NOTE: Any machining and/or grinding is illegal in 5. Assemble the engine using the correct seal- stock class racing. Keep your machine legal ! ants where needed.
Page 438 ➀ The maximum horsepower RPM is applicable on the vehicle. It may be different under certain circumstances and BRP reserves the right to modify it without obligation. A) Ski Spring = 150 lb/in P/N 415 020 700 - 5 mm preload shock length = 360 mm B) Center Spring = std 2-1/4 in travel max.
Page 439 ➀ The maximum horsepower RPM is applicable on the vehicle. It may be different under certain circumstances and BRP reserves the right to modify it without obligation. A) Ski Spring = 150 lbs/in P/N 415 020 700 - 5 mm preload shock length = 360 mm B) Center Spring = std 2-1/4 in travel max.
Page 440 ➀ The maximum horsepower RPM is applicable on the vehicle. It may be different under certain circumstances and BRP reserves the right to modify it without obligation. A) Ski Spring = 150 lb/in P/N 415 020 700 - 5 mm preload shock length = 360 mm B) Center Spring = std 2-1/4 in travel max.
Page 441 160/240 160/260 62-48-46 Drive belt Part Number P/N 417 300 230 ➀ The maximum horsepower RPM is applicable on the vehicle. It may be different under certain circumstances and BRP reserves the right to modify it without obligation. 11-19 MMC2005-001_11A.FM...
Page 442 P/N 417 300 288 Calibration done at temperature of 0° Celcius ➀ The maximum horsepower RPM is applicable on the vehicle. It may be different under certain circumstances and BRP reserves the right to modify it without obligation. 11-20 MMC2005-001_11A.FM...
Page 443 P/N 417 300 288 Calibration done at temperature of 0° Celcius ➀ The maximum horsepower RPM is applicable on the vehicle. It may be different under certain circumstances and BRP reserves the right to modify it without obligation. 11-21 MMC2005-001_11A.FM...
Page 444 SECTION 11 - COMPETITION PREPARATION 2005 ISR FILED ENGINE SPECIFICATIONS 800 HO MXZ 550 F/C MXZ INSTALLED cc 38,5 ± 1,93 36,58 40,43 INSTALLED cc 35,3 ± 1,77 33,54 37,07 FLAT PLATE cc 39,1 ± 1,96 37,15 41,06 FLAT PLATE cc 34,6 ±...
Page 445: Service Tools
SECTION 12 - SERVICE TOOLS TABLE OF CONTENTS SERVICE TOOLS..........................12-02 SERVICE PRODUCTS ........................12-22 NEW TOOL FOR THE 2-TEC 1000 SDI ..................12-30 NEW TOOL TO USE WITH BUDS....................12-31 12-1 MMC2005-001_12A.FM...
Page 446 SECTION 12 - SERVICE TOOLS SERVICE TOOLS This is a list of tools to properly service Ski-Doo snowmobiles. The list includes both the mandatory tools and the recommended tools. If you need to replace or add your tool inventory these items can be ordered through the regular parts channel.
Page 447 SECTION 12 - SERVICE TOOLS ENGINE — MANDATORY TOOLS Exhaust spring installer/remover Magneto puller ring Fuel and oil system leak tester (P/N 529 035 401) (P/N 420 876 080) (P/N 529 033 100) APPLICATION All axial fan cooled engines. APPLICATION APPLICATION All models.
Page 448 SECTION 12 - SERVICE TOOLS Engine leak tester kit 14) Exhaust plate Supply harness (P/N 861 749 100) (P/N 529 035 869) (P/N 529 024 600) (2) NOTE: Should be used with 15) Exhaust plate hand pump (P/N 529 021 800). (P/N 529 035 962) (2) 16) Radiator cap (P/N 529 021 400)
Page 449 SECTION 12 - SERVICE TOOLS DESS KEY for BUDS Engine removal hook Lifting ring (2) (P/N 529 035 896) (P/N 529 035 829) (P/N 529 035 830) APPLICATION Liquid cooled engines except 4-TEC. APPLICATION REV series. APPLICATION All models equipped with a DESS.
Page 450 SECTION 12 - SERVICE TOOLS Leak down tester Engine support bearing sup- Crankshaft bearing puller N–> N–> (P/N 529 035 661) port (P/N 420 877 635) (P/N 529 035 953) APPLICATION 1503 engines. 4-Tooth socket N–> (P/N 529 035 960) APPLICATION 1004 and 1503 engines.
Page 451 SECTION 12 - SERVICE TOOLS Piston circlip installer Pusher (55/59 mm) Water pump ceramic seal N–> (P/N 529 035 765) (P/N 529 035 913) installer (P/N 529 035 766) APPLICATION 1004 and 1503 engines. Piston circlip installer APPLICATION 1004 engines. a.
Page 452 SECTION 12 - SERVICE TOOLS Crankshaft feeler gauge Valve spring compressor cup Valve stem seal installer (P/N 420 876 620) a) (P/N 529 035 764) (P/N 529 035 687) b) (P/N 529 035 725) N–> APPLICATION 377 and 443 engines. APPLICATION 1004 and 1503 engines.
Page 453 SECTION 12 - SERVICE TOOLS Torque angle gauge Attachment RAVE movement indicator Not sold by BOMBARDIER. (P/N 529 035 522) (P/N 861 725 800) Snap-On TA362 APPLICATION Mini Z. APPLICATION APPLICATION 1004 and 1503 engines. Pilot 22 mm All RAVE equipped engines. (P/N 529 035 523) Cylinder aligning tool Dial indicator (TDC gauge)
Page 454 SECTION 12 - SERVICE TOOLS Injection pump gear holder MAG seal pusher Oil pump seal installer (P/N 420 277 905) (P/N 420 277 875) (P/N 529 035 911) APPLICATION APPLICATION 277 engines. 1004 engines. APPLICATION PTO seal pusher Large hose pincher All liquid cooled engines except (P/N 420 876 660) (P/N 529 032 500)
Page 455 SECTION 12 - SERVICE TOOLS Engine stand Not sold by BOMBARDIER. APPLICATION 1503 engines. TRANSMISSION — MANDATORY TOOLS Drive pulley retainer TRA drive pulley puller (25 mm) Specific alignment bar (P/N 529 035 674) (P/N 529 007 900) (P/N 529 035 530) APPLICATION APPLICATION ZX series with TRA and RER.
Page 456 SECTION 12 - SERVICE TOOLS Pulley spring compressor Driven pulley opening tool Driven pulley spring compressor (P/N 529 035 524) (P/N 529 017 200) (P/N 529 035 300) APPLICATION Most models. Clutch holder (P/N 529 027 600) APPLICATION APPLICATION All models. Tundra.
Page 457 SECTION 12 - SERVICE TOOLS Drive pulley puller N–> Short dial indicator Alignment tool (P/N 529 025 000) (P/N 295 000 143) (P/N 420 476 010) APPLICATION Skandic LT. Governor cup APPLICATION (P/N 529 035 894) Skandic WT. Cam pusher (P/N 529 012 900) APPLICATION TRA IV and TRA IV HD.
Page 458 SECTION 12 - SERVICE TOOLS Countershaft bearing remover Transmission adjuster Alignment bar (P/N 529 035 812) (P/N 529 030 300) a. (P/N 529 035 808) b. (P/N 529 035 586) c. (P/N 529 035 594) d. (P/N 529 026 900) APPLICATION e.
Page 459 SECTION 12 - SERVICE TOOLS Bushing extractor/installer Large bushing extractor Sliding half bushing N–> (P/N 529 031 300) (P/N 529 035 576) remover/installer (P/N 529 035 931) APPLICATION Formula type driven pulley. APPLICATION APPLICATION NOTE: Use this tool only with TRA III and TRA IV.
Page 460 SECTION 12 - SERVICE TOOLS Drive axle sprocket adjuster Belt tension tool (P/N 861 725 700) (P/N 529 035 957) APPLICATION Elite. Parts included in the kit: 1) Block with threads (P/N 529 010 700) 2) Block without threads (P/N 529 010 800) 3) Plate (P/N 529 010 600) 4) Bolt M10 (2) (P/N 222 007 565)
Page 461 SECTION 12 - SERVICE TOOLS SUSPENSION — RECOMMENDED TOOLS a) Track cleat remover Camber angle tool Track cleat installer (P/N 529 008 200) (P/N 529 021 600) a. (P/N 529 028 800) narrow Pins NOTE: Angle finder with a mag- (P/N 529 008 204) netic base must be used.
Page 462 SECTION 12 - SERVICE TOOLS Shock wrench Gas shock valve tool (tire valve Spring installer (bar) (P/N 529 035 727) type) (P/N 529 005 000) (P/N 529 035 570) APPLICATION All T/A shocks. APPLICATION Tundra and all SC-10 suspen- sions. HPG shock holding tool (P/N 529 035 769) APPLICATION...
Page 463 SECTION 12 - SERVICE TOOLS Extension to torque ball joint Ball joint installer Adjustment wrench N–> N–> (P/N 529 035 975) (P/N 520 000 126) (P/N 529 035 876) APPLICATION SC-10 II and III (coupling blocks). APPLICATION REV series. APPLICATION 2004 REV series.
Page 464 SECTION 12 - SERVICE TOOLS VEHICLE — RECOMMENDED TOOLS Protective mat Adjustment wrench N–> Crimping tool (P/N 529 030 600) (P/N 529 035 603) (dies sold separately) (P/N 529 035 909) APPLICATION APPLICATION To remove and install fuel tank To crimp specific terminals. nut on ZX series.
Page 465 SECTION 12 - SERVICE TOOLS Adjustment wrench Fuel line remover Heated grips insertion tool (P/N 529 035 891) (P/N 529 035 714) a. (P/N 529 035 897) b. (P/N 529 035 936) APPLICATION APPLICATION REV series. 2-TEC, 1004 and 1503 engine equipped models.
Page 466 SECTION 12 - SERVICE TOOLS SERVICE PRODUCTS Retaining compound (P/N 413 703 100) Loctite ® RC/609: Retaining compound (10 mL) (green) APPLICATION Used for retaining bushings, bearings in slightly worn hous- ing or on shaft. Medium-strength threadlocker (P/N 293 800 060) Loctite ®...
Page 467 SECTION 12 - SERVICE TOOLS High strength threadlocker Paste gasket Gasket/paint remover (P/N 413 708 500) (P/N 293 800 005) (P/N 413 702 700) Loctite ® 271: Loctite ® 515: Loctite ® Chisel 510 g (18 oz) Threadlocker (10 mL) (red, high Gasket eliminator (50 mL) strength) APPLICATION...
Page 468 SECTION 12 - SERVICE TOOLS Isoflex grease SYNTHETIC BOMBARDIER BOMBARDIER FORMULA XP-S (P/N 293 550 021) 4-STROKE engine oil II synthetic injection oil (50 g) 0W-40 (P/N 293 600 045) (P/N 293 600 054) (12 x 1 liter) (12 x 1 L) (P/N 293 600 046) (3 x 4 liter) APPLICATION...
Page 469 SECTION 12 - SERVICE TOOLS BOMBARDIER injection oil Fuel stabilizer Storage oil (P/N 413 802 900) (P/N 413 408 600) CANADA: (P/N 413 711 600) (12 x 1 liter) (12 x 8 oz) U.S.A.: (P/N 413 711 900) (350 g spray can) (12 x 350 g) (P/N 413 803 000) (3 x 4 liters) (P/N 413 803 200)
Page 470 SECTION 12 - SERVICE TOOLS Grease LMZ no. 1 BOMBARDIER LUBE Brake fluid GTLMA (DOT 4) (P/N 413 707 500) (P/N 293 600 016) (P/N 293 600 062) (400 g) (12 x 14 oz) APPLICATION Mainly used between regulators or rectifiers and frame to trans- fer the heat build-up and to as- sure a good ground.
Page 471 SECTION 12 - SERVICE TOOLS Anti-seize lubricant Pulley flange cleaner Plastic & vinyl cleaner (P/N 293 800 070) (P/N 413 711 809) (P/N 413 711 200) Loctite anti-seize lubricant (320 g) (6 x 1 L) 236 mL (8 oz) APPLICATION APPLICATION Hood, bottom pan and seat.
Page 472 SECTION 12 - SERVICE TOOLS Pipe sealant RTV silicone sealant High temperature RTV sealant (P/N 293 800 018) (P/N 293 800 066) (P/N 293 800 090) Loctite 592 (50 mL) Loctite 5900 (300 mL) Ultra Copper (80 mL) APPLICATION APPLICATION Engine plugs and senders.
Page 473 SECTION 12 - SERVICE TOOLS Scratch remover N–> (P/N 861 774 800) APPLICATION All models. 12-29 MMC2005-001_12A.FM...
Page 474 SECTION 12 - SERVICE TOOLS NEW TOOL FOR THE 2-TEC 1000 SDI Piston circlip installer Intake plug (MANDATORY) New tool that replaces the previ- ous bearing puller (MANDATORY) P/N 529 036 000 P/N 420 877 636 P/N 529 035 998 Crankshaft bearing puller (OPTIONAL) P/N 529 036 004...
Page 475 SECTION 12 - SERVICE TOOLS NEW TOOL TO USE WITH BUDS Supplied Harness (MANDATORY) P/N 529 035 997 APPLICATION To supply 12V power from a bat- tery to a non-running unit. To use along with BUDS. Works with the supplied harness P/N 529 035 869.
Page 476 SECTION 13 - ACCESSORIES TABLE OF CONTENTS ACCESSORIES..........................13-02 13-1 MMC2005-001_13A.FM...
Page 477 SECTION 13 - ACCESSORIES Cover MXZ/GSX (Sp, Cover Mach Z (ADRN),Summit solution 280100060 280000144 Ad,Tr,Re,F),Summit nylon (Expedition) dyed ( Intense) (RT) (REV) Cover Mach Z (ADRN),Summit solution 280100061 Cover MXZ/GSX/Summit (Sp, dyed (Racing) (RT) 280000147 Ad,Tr,Re,F), solution dyed (Racing) Cover GTX ; Skandic Exp. Sport, (REV) 280100059 solution dyed( Intense) (REV)
Page 478 SECTION 13 - ACCESSORIES part # DESCRIPTION 860508800 A arm protector black for REV X X X X X X X X X X X X X X X X X X X X X X X 860509100 A arm protector orange for REV X X X X X X X X X X X X X X X X X X X X X X X 860509000 A arm protector yellow for REV X X X X X X X X X X X X X X X X X X X X X X X 415128917 Aluminum Backer 5/16 Pack 1000 X X X X X X X X X X...
Page 479 SECTION 13 - ACCESSORIES part # DESCRIPTION Cam anod. 44, Formula, Formula 417126718 417126445 Cam anod. 44, HPV, VSA X X X X X X X X X X X X 417126748 Cam anod. 47, Formula RER Cam anod. 47, Formula, Formula 417126707 417126577 Cam anod.
Page 480 SECTION 13 - ACCESSORIES part # DESCRIPTION 517302845 Console yellow (REV) X X X X X X X X X X X X X X X X X X X X Cover MXZ ( X, 440 ) , solution 280100062 dyed (intense) (REV) Pers.
Page 481 SECTION 13 - ACCESSORIES part # DESCRIPTION Cover MXZ ( X, 440 ), solution 280000143 dyed (Extreme) (REV) Cover MXZ ( X, 440 ), solution 280000142 dyed (Racing) (REV) Cover MXZ/GSX (Sp, Ad,Tr,Re,F), 280000146 X X X X X solution dyed (Extreme) (REV) Cover MXZ/GSX (Sp, Ad,Tr,Re,F), 280000145 Summit solution dyed (Intense)
Page 482 SECTION 13 - ACCESSORIES part # DESCRIPTION Cover Summit REV, Solution 280000085 X X X X dyed 280000095 Cover, bottom pan REV X X X X X X X X X X X X X X X X X X X X X 280000061 Cover, canevas, REV 440 280000128 Cover, compact travel cover REV X X X X X X X X X X X X X X X X X X X X X X X Cover, compact travel,...
Page 483 SECTION 13 - ACCESSORIES part # DESCRIPTION Decal, Extreme Skidoo (set of 3), 415128363 1(4"X15") 2(2¼"X7½") 415128364 Decal, Formula XPS-II, (3½"X9") Decal, Hornet (2 size) 415128365 (7½"X7½")(3"X3") Decal, Reflective hood graphics 415127747 (Mach Z) Decal, Reflective hood graphics 415127745 (MXZ 600 & 700) Decal, Rotax w/ flames (set of 2) 415128366 (2½"X13")
Page 484 SECTION 13 - ACCESSORIES part # DESCRIPTION Decal, Skidoo X for windshield 415128376 (6"X12¾") 415128120 Decal, Skidoo X team (set of 3) Decal, Skidoo X team racing (set 415128377 of 2) (3"X10") Decal, various skidoo decals (10/ 415128378 sheet) Decal, Windshield flames 415128379 graphics 415128960 Decal, wings Mach Z yellow...
Page 485 SECTION 13 - ACCESSORIES part # DESCRIPTION 415127972 Decal,Team Ski-Doo (24" X 8") Decal,Team Ski-Doo stickers 5 415127976 per sheet Decals, Trailer front spray 415127750 deflector graphic (Ski-Doo Racing) 38"x10" 860307000 Extension kit SC-10 (136) REVX X X X X X 861509700 Gauge, fuel Electr.
Page 486 SECTION 13 - ACCESSORIES part # DESCRIPTION 861787000 Knee deflector kit yellow (RT) 861783100 Knee deflector, orange (REV) X X X X X X X X X X X X X X X X X X X X 861783200 Knee deflector, yellow (REV) X X X X X X X X X X X X X X X X X X X X 861787100 Knee pad kit, black (RT), English...
Page 487 SECTION 13 - ACCESSORIES part # DESCRIPTION Nonskid strip kit, yellow (REVX 861802600 X X X X X X X X X 2004 121") Nonskid strip kit, yellow (REVX 861802400 X X X X X 2004 136" to 159" ) Plastic handle ski scarlet red B- 860506900 X X X X X X X X X X...
Page 488 SECTION 13 - ACCESSORIES part # DESCRIPTION Shock protector kit Scarlet red B- 861778000 X X X X X X X X X X X X X X X X 861775600 Shock Protector Kit, Black X X X X X X X X X X X X X X X X X X X X X X Shock protector kit, blue labr.
Page 489 SECTION 13 - ACCESSORIES part # DESCRIPTION Ski runner ( 5" Carbides ) plastic 860504900 X X X X X X X X X X X X X X X ski ( Precision ) Ski runner 6"/4" 60 degree, 860505200 X X X X X X X X X X X X X X X Precision...
Page 490 SECTION 13 - ACCESSORIES part # DESCRIPTION Tunnel protector kit ( REV X 121- 861786400 X X X X X X X X X X X X X X X 136" 1 1/4") Wheel 180mm for rear 860306900 X X X X X X X X X X S X X X X X X X X X X X X suspension kit Windshield low fix checker Bee 517303402...
Page 491 SECTION 13 - ACCESSORIES part # DESCRIPTION Windshield Med mobile red 517303405 X X X X X lightning (REV) 517302775 Windshield med, yellow (REV) X X X X X Windshield med. chrome DBD 517303000 X X X X X 517303028 Windshield mobile low Scorch X X X X X 517303029 Windshield mobile low Vector X X X X X...
Page 492 SECTION 13 - ACCESSORIES part # DESCRIPTION Woodies Gold Diggers 5/16 - 415128952 X X X X X X X X X X 1.075" Pack 144 Woodies Gold Diggers 5/16 - 415128953 X X X X X X X X X X 1.075"...

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