Ski-Doo GRAND TOURING 500 1997 Manuals

Manuals and User Guides for Ski-Doo GRAND TOURING 500 1997. We have 1 Ski-Doo GRAND TOURING 500 1997 manual available for free PDF download: Shop Manual

Ski-Doo GRAND TOURING 500 1997 Shop Manual (352 pages)

VOLUME 2

Brand: Ski-Doo | Category: Offroad Vehicle | Size: 27.06 MB

Table of Contents

4
Troubleshooting

21
- Table of Contents
  21
- Engine
  22
- Fuel and Oil Systems
  32
- Transmission and Brake Systems
  35
  - Transmission
    35
    
    Brake System
    42
    
    Mechanical Brake
    42
    
    Hydraulic Brake
    43
    
    Mechanical and Hydraulic Brakes
    43
- Electrical System
  44
- Suspension System and Track
  53
Engine

56
- Table of Contents
  56
- 443 And 503 Engine Types
  
  59
  - Engine Removal and Installation
    59
    
    Engine Removal and Installation
    60
    
    Tuned Pipe Identification
    60
- Top End
  
  63
  - Cleaning
    64
  - Disassembly
    64
  - Assembly
    65
  - Inspection
    65
- Bottom End
  
  69
  - Assembly
    70
  - Cleaning
    70
  - Disassembly
    70
  - Inspection
    70
- Engine Support and Muffler
  
  72
- Top End
  
  75
  - Cleaning
    76
  - Disassembly
    76
  - Inspection
    76
  - Assembly
    77
- Bottom End
  
  81
  - Assembly
    82
  - Cleaning
    82
  - Disassembly
    82
  - Inspection
    82
- Leak Test and Engine Dimension Measurement
  
  85
- Leak Test
  
  85
  - Preparation
    85
  - Procedure
    85
  - Finalizing Reassembly
    88
  - Cooling System Leak Test
    88
  - Engine Leak Verification Flow Chart
    89
- Engine Dimension Measurement
  
  90
  - Cylinder Taper
    90
  - Cylinder out of Round
    90
  - Cylinder/Piston Clearance
    90
  - Ring/Piston Groove Clearance
    91
  - Ring End Gap
    91
  - Crankshaft Deflection
    91
  - Connecting Rod Big End Axial Play
    92
  - Connecting Rod/Piston Pin Clearance
    92
  - Connecting Rod/Crankpin Clearance
    93
  - Crankshaft End-Play
    93
  - Crankcase/Rotary Valve Gap
    93
  - Checking Surface Flatness
    94
  - Rectifying Surfaces
    94
  - Checking Crankshaft Alignment
    94
- Nippondenso Trigger Coil Ignition System
  
  95
  - Cleaning
    96
  - Disassembly
    96
  - Assembly
    98
- CDI System
  
  95
- Ducati Ignition System
  
  99
  - Cleaning
    100
  - Disassembly
    100
  - Repair
    100
  - Assembly
    101
- Oil Injection Pump
  
  102
  - Oil Pump Identification
    104
  - Cleaning
    104
  - Assembly
    104
  - Adjustment
    104
  - Checking Operation
    106
- Oil Injection System
  
  102
- Axial Fan Cooling System
  
  107
  - Removal
    109
    
    Cleaning
    109
    
    Disassembly and Assembly
    109
- Liquid Cooling System
  
  111
  - Inspection
    113
    
    Disassembly and Assembly
    113
    
    Draining the System
    113
    
    Cooling System Refilling Procedure
    114
- Rotary Valve, Coolant Pump and Reservoir
  
  116
  - General
    117
    
    Cleaning
    117
    
    Disassembly
    117
    
    Assembly
    118
    
    Inspection
    118
- Rewind Starter
  
  124
  - Removal
    125
    
    Assembly
    125
    
    Disassembly
    125
    
    Installation
    126
- Carburetor and Fuel Pump
  
  128
  - Removal
    129
    
    Cleaning and Inspection
    129
    
    Identification
    129
    
    Carburetor Float Level Adjustment
    130
    
    Disassembly and Assembly
    130
    
    Installation
    132
    
    Carburetor Adjustments
    133
    
    Preliminary Idle Speed Adjustment
    134
    
    Choke
    135
    
    Idle Speed Final Adjustment
    135
    
    Hac System
    136
- Fuel Pump
  
  137
  - Cleaning and Inspection
    138
  - Installation
    138
  - Pump Verification
    138
  - Removal
    138
- Fuel Tank and Throttle Cable
  
  139
Transmission

141
- Table of Contents
  141
- 1997 Application Chart
  
  143
  - Rotation Direction
    143
  - Drive Belt Deflection Measurement
    144
  - Deflection Adjustment
    145
- Drive Belt
  
  143
- Tra
  
  146
  - General
    147
  - Removal
    147
  - Disassembly
    148
  - Cleaning
    149
  - Inspection
    150
  - Assembly
    151
  - Installation
    153
  - Drive Pulley Adjustment
    154
- Drive Pulley
  
  146
- Driven Pulley
  
  156
  - Removal
    158
    
    Cleaning
    158
    
    Disassembly
    158
    
    Inspection
    158
    
    Bushing Replacement
    159
    
    Assembly
    160
    
    Installation
    160
    
    Adjustment
    161
- Pulley Distance and Alignment
  
  163
  - General
    163
    
    General Procedure
    163
    
    Pulley Alignment and Distance Specifications Chart
    164
- Hydraulic Disc Brake
  
  166
  - Removal
    167
  - Disassembly
    168
  - Cleaning
    168
  - Inspection
    168
  - Assembly
    169
  - Installation
    169
  - Adjustment
    170
  - Bleeding
    170
- Brake
  
  166
- Chaincase
  
  172
  - Removal
    173
    
    Gear Ratio Modification
    173
    
    Inspection
    173
    
    Installation
    173
    
    Drive Chain Adjustment
    174
    
    Adjustment
    175
- 3-Speed Gearbox (Shifter Mechanism)
  
  176
  - Removal
    177
  - Adjustment
    177
- Gearbox
  
  176
- 3-Speed Gearbox
  
  178
  - Removal
    179
  - Disassembly
    179
  - Inspection
    181
  - Assembly
    181
  - Installation
    182
  - Oil Level
    182
- 2-Speed Gearbox
  
  183
  - Disassembly
    184
  - Inspection
    184
  - Assembly
    184
  - Adjustment
    186
  - Oil Change
    187
- Drive Chain
  
  188
  - Silent Chain
    188
Electrical

189
- Table of Contents
  189
  - Tab and Receptacle Connectors Installation
    193
  - Tab and Receptacle Connectors Removal
    193
  - Unpluging Connectors
    193
  - Accessories Installation
    194
- Ducati CDI System
  
  195
- Ignition Timing
  
  195
- Nippondenso Trigger Coil System
  
  198
- Spark Plugs
  
  201
- Ngk Spark Plug
  
  201
  - Ngk Spark Plug Numbering System
    201
  - 1997 Reference Chart
    201
- Design Symbols Used in Ngk Spark Plugs
  
  202
  - Disassembly
    203
  - Heat Range
    203
  - Fouling
    203
  - Spark Plug Analysis
    203
  - Spark Plug Installation
    204
  - Spark Plug Tightening Torque
    204
- Battery
  
  205
  - Removal
    205
    
    Cleaning
    206
    
    Hydrometer Test
    207
    
    Inspection
    207
    
    Activation of New Battery
    208
    
    Battery Storage
    208
    
    Servicing
    211
    
    Tips for Charging a Used Battery
    211
    
    Battery Charging Equipment
    212
    
    Installation of Battery
    212
- Electric Starter
  
  214
  - Removal
    215
    
    Disassembly
    215
    
    Assembly
    217
    
    Cleaning and Inspection
    217
    
    Installation
    218
- Cleaning and Inspection
  
  219
  - Cleaning
    219
  - Inspection
    219
  - Solenoid Switch
    221
  - Starter Removal
    223
  - Starter Disassembly
    223
  - Cleaning
    224
  - Parts Inspection
    224
  - Starter Assembly
    225
  - Starter Installation
    226
- Testing Procedure
  
  227
  - General
    227
  - Use of Bombardier Ignition Tester
    228
- Nippondenso CDI Trigger Coil System Testing
  
  230
  - Trigger Coil Output
    230
  - Ignition Coil Output
    230
  - Ignition Module
    231
  - Magneto Output (Ignition Generator Coil)
    232
  - Lighting Generator Coil Output
    232
  - Summary Table
    234
  - Resistance Measurements
    235
- Ducati CDI System Testing
  
  236
  - Trigger Coil Output
    236
  - Magneto Output
    236
  - Ignition Coil Output
    237
  - Ignition Module
    237
  - Lighting Generator Coil Output
    237
  - Summary Table
    238
  - Resistance Measurements
    239
- Voltage Regulator Inspection
  
  240
  - Testing Procedure
    240
- Inspection of Ac Circuit Isolation
  
  241
  - Inspection
    241
- Inspection of Heating Elements
  
  242
Rear Suspension

243
- Table of Contents
  243
- Suspensions (All Versions)
  
  244
  - SC-10 Suspensions (All Versions)
    245
    
    Component Removal and Installation
    249
    
    Removal
    251
    
    Disassembly and Assembly
    252
    
    Shock Absorber Inspection
    253
    
    Shock Absorber Servicing
    254
    
    Installation
    262
    
    Lubrication
    262
    
    Ride Adjustment
    262
- Skandic WT Suspension
  
  263
  - Removal
    264
    
    Disassembly and Assembly
    264
    
    Shock Absorber Servicing
    265
- Drive Axle
  
  267
  - Removal
    269
    
    Disassembly
    269
    
    Assembly
    270
    
    Axial Play
    272
    
    Installation
    274
    
    Adjustment
    275
    
    Lubrication
    275
- Track
  
  276
  - Track Type Application
    276
    
    General
    276
    
    Inspection
    276
    
    Installation
    276
    
    Removal
    276
Table of Contents

279
- Steering System
  
  280
  - Inspection
    282
  - Disassembly and Assembly
    282
  - Inspection
    283
  - Adjustable Handlebar
    284
  - Steering Adjustment (Skis)
    285
  - Lubrication
    288
- Suspension and Ski System
  
  290
  - Disassembly
    291
  - Inspection
    292
  - Installation
    292
  - On-Vehicle Component Verification
    295
  - Disassembly
    296
  - Inspection
    297
  - Installation
    297
Table of Contents

299
- Body
  
  300
- Installation and Adjustment
  
  300
  - Headlamp Beam Aiming
    300
  - Bulb Replacement
    300
  - Decal
    301
  - Windshield Installation
    301
  - Hood
    301
  - Belt Guard
    302
  - Wiring Harness
    302
  - Cables
    302
  - Piping
    302
- Plastic Maintenance and Repair
  
  303
  - Maintenance
    303
  - Repair
    304
  - Material Repair Procedure
    305
  - Repair Procedure for R.I.M. Urethane
    305
- Frame
  
  307
  - Frame Cleaning
    307
  - Frame Welding
    307
  - Frame Component Replacement
    307
  - Technical Data
    309

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Ski-Doo GRAND TOURING 500 1997 Manuals

Ski-Doo GRAND TOURING 500 1997 Shop Manual (352 pages)

Table of Contents

Table of Contents

Troubleshooting

Engine

443 And 503 Engine Types

Top End

Bottom End

Engine Support and Muffler

Top End

Bottom End

Leak Test and Engine Dimension Measurement

Leak Test

Engine Dimension Measurement

Nippondenso Trigger Coil Ignition System

CDI System

Ducati Ignition System

Oil Injection Pump

Oil Injection System

Axial Fan Cooling System

Liquid Cooling System

Rotary Valve, Coolant Pump and Reservoir

Rewind Starter

Carburetor and Fuel Pump

Fuel Pump

Fuel Tank and Throttle Cable

Transmission

1997 Application Chart

Drive Belt

Tra

Drive Pulley

Driven Pulley

Pulley Distance and Alignment

Hydraulic Disc Brake

Brake

Chaincase

3-Speed Gearbox (Shifter Mechanism)

Gearbox

3-Speed Gearbox

2-Speed Gearbox

Drive Chain

Electrical

Ducati CDI System

Ignition Timing

Nippondenso Trigger Coil System

Spark Plugs

Ngk Spark Plug

Design Symbols Used in Ngk Spark Plugs

Battery

Electric Starter

Cleaning and Inspection

Testing Procedure

Nippondenso CDI Trigger Coil System Testing

Ducati CDI System Testing

Voltage Regulator Inspection

Inspection of Ac Circuit Isolation

Inspection of Heating Elements

Rear Suspension

Suspensions (All Versions)

Skandic WT Suspension

Drive Axle

Track

Table of Contents

Steering System

Suspension and Ski System

Table of Contents

Body

Installation and Adjustment

Plastic Maintenance and Repair

Frame

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