Ski-Doo MACH Z 1997 Manuals

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

Ski-Doo MACH Z 1997 Shop Manual (219 pages)

Brand: Ski-Doo | Category: Snowmobiles | Size: 18.16 MB

Section 1

53
- Table of Contents
  53
- 599, 699 and 809 Engine Types
  
  55
  - Removal from Vehicle
    56
  - Installation on Vehicle
    56
- Top End
  
  57
  - Component Removal
    58
  - Cleaning
    58
  - Disassembly
    58
  - Inspection
    59
  - Assembly
    59
- Bottom End
  
  63
  - Cleaning
    64
  - Disassembly
    64
  - Inspection
    64
  - Assembly
    65
- Leak Test and Engine Dimension Measurement
  
  67
- Leak Test
  
  67
  - Preparation
    67
  - Procedure
    67
  - Finalizing Reassembly
    70
  - Cooling System Leak Test
    70
  - Engine Leak Verification Flow Chart
    71
- Engine Dimension Measurement
  
  72
  - Cylinder Taper
    72
  - Cylinder out of Round
    72
  - Cylinder/Piston Clearance
    72
  - Ring/Piston Groove Clearance
    73
  - Ring End Gap
    73
  - Crankshaft Deflection
    73
  - Connecting Rod Big End Axial Play
    74
  - Connecting Rod/Piston Pin Clearance
    74
  - Connecting Rod/Crankpin Clearance
    75
  - Crankshaft End-Play
    75
  - Checking Surface Flatness
    75
  - Rectifying Surfaces
    75
  - Checking Crankshaft Alignment
    75
- CDI System
  
  77
- Nippondenso Trigger Coil Ignition System
  
  77
  - Disassembly
    78
  - Assembly
    80
  - Adjustment
    82
  - Checking Operation
    84
- Liquid Cooling System
  
  85
  - Inspection
    86
  - Draining the System
    86
  - Disassembly and Assembly
    86
  - Cooling System Refilling Procedure
    87
- Rewind Starter
  
  88
  - Removal
    89
  - Disassembly
    89
  - Assembly
    89
  - Installation
    91
- Carburetor and Fuel Pump
  
  92
  - Removal
    94
  - Cleaning and Inspection
    94
  - Identification
    94
  - Disassembly and Assembly
    95
  - Carburetor Float Level Adjustment
    96
  - Installation
    97
  - Carburetor Adjustments
    98
  - Preliminary Idle Speed Adjustment
    101
  - Idle Speed Final Adjustment
    101
  - Choke
    101
- Fuel Pump
  
  105
  - Removal
    106
  - Pump Verification
    106
  - Cleaning and Inspection
    106
  - Installation
    106
- Fuel Tank and Throttle Cable
  
  107
Section 2

109
- Drive Belt
  
  111
- 1997 Application Chart
  
  111
  - Rotation Direction
    111
  - Drive Belt Deflection Measurement
    112
  - Deflection Adjustment
    113
- Drive Pulley
  
  114
- Tra
  
  114
  - General
    115
  - Removal
    115
  - Disassembly
    116
  - Cleaning
    117
  - Inspection
    118
  - Assembly
    119
  - Installation
    121
  - Drive Pulley Adjustment
    122
- Driven Pulley
  
  124
  - Removal
    125
  - Disassembly
    125
  - Cleaning
    125
  - Inspection
    125
  - Assembly
    127
  - Installation
    127
  - Adjustment
    128
- Pulley Distance and Alignment
  
  130
  - General
    130
  - General Procedure
    130
  - Pulley Alignment and Distance Specifications Chart
    131
- Brake
  
  133
- Hydraulic Disc Brake
  
  133
  - Removal
    134
  - Inspection
    135
  - Gear Ratio Modification
    139
  - Installation
    139
  - Drive Chain Adjustment
    140
  - Adjustment
    141
- Drive Chain
  
  142
  - Silent Chain
    142
Section 3

143
- Wiring Diagrams
  
  144
  - Chart Codes
    144
  - Unpluging Connectors
    146
  - Tab and Receptacle Connectors Removal
    146
  - Tab and Receptacle Connectors Installation
    146
  - Accessories Installation
    147
- Ignition Timing
  
  148
- Nippondenso Trigger Coil System
  
  148
- Spark Plugs
  
  151
- Ngk Spark Plug
  
  151
  - Ngk Spark Plug Numbering System
    151
  - 1997 Reference Chart
    151
- Design Symbols Used in Ngk Spark Plugs
  
  152
  - Disassembly
    153
  - Heat Range
    153
  - Fouling
    153
  - Spark Plug Analysis
    153
  - Spark Plug Installation
    154
  - Spark Plug Tightening Torque
    154
- Testing Procedure
  
  155
  - General
    155
  - Use of Bombardier Ignition Tester
    156
- Nippondenso CDI Trigger Coil System Testing
  
  157
  - Trigger Coil Output
    157
  - Ignition Coil Output
    157
  - Ignition Module
    158
  - Magneto Output (Ignition Generator Coil)
    159
  - Lighting Generator Coil Output
    159
  - Summary Table
    160
  - Resistance Measurements
    161
- Voltage Regulator Inspection
  
  162
  - Testing Procedure
    162
- Inspection of Ac Circuit Isolation
  
  163
  - Inspection
    163
- Inspection of Heating Elements
  
  164
Section 4

165
- Suspension (Hp Version)
  
  166
  - Component Removal and Installation
    167
  - Removal
    169
  - Disassembly and Assembly
    169
  - Shock Absorber Inspection
    171
  - Installation
    172
  - Ride Adjustment
    172
  - Lubrication
    172
- Drive Axle
  
  173
  - Removal
    174
  - Disassembly
    174
  - Assembly
    174
  - Axial Play
    176
  - Installation
    179
  - Lubrication
    179
  - Adjustment
    180
- Track
  
  181
  - Track Type Application
    181
  - General
    181
  - Inspection
    181
  - Removal
    181
  - Installation
    181
Section 5

184
- Steering System
  
  185
  - Inspection
    186
  - Disassembly and Assembly
    186
  - Inspection
    187
  - Adjustable Handlebar
    188
  - Steering Adjustment (Skis)
    189
  - Lubrication
    191
- Suspension and Ski System
  
  193
  - Disassembly
    194
  - Inspection
    195
  - Installation
    195
,14, Tie Rod and Lever

197
- Body
  
  198
- Installation and Adjustment
  
  198
  - Headlamp Beam Aiming
    198
  - Bulb Replacement
    198
  - Decal
    199
  - Windshield Installation
    199
  - Hood
    199
  - Belt Guard
    199
  - Wiring Harness
    199
  - Cables
    200
  - Piping
    200
- Plastic Maintenance and Repair
  
  201
  - Maintenance
    201
  - Repair
    202
  - Material Repair Procedure
    203
  - Repair Procedure for R.I.M. Urethane
    203
- Frame
  
  205
  - Frame Cleaning
    205
  - Frame Welding
    205
  - Frame Component Replacement
    205

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Ski-Doo MACH Z 1997 Manuals

Ski-Doo MACH Z 1997 Shop Manual (219 pages)

Table of Contents

Section 1

599, 699 and 809 Engine Types

Top End

Bottom End

Leak Test and Engine Dimension Measurement

Leak Test

Engine Dimension Measurement

CDI System

Nippondenso Trigger Coil Ignition System

Liquid Cooling System

Rewind Starter

Carburetor and Fuel Pump

Fuel Pump

Fuel Tank and Throttle Cable

Section 2

Drive Belt

1997 Application Chart

Drive Pulley

Tra

Driven Pulley

Pulley Distance and Alignment

Brake

Hydraulic Disc Brake

Drive Chain

Section 3

Wiring Diagrams

Ignition Timing

Nippondenso Trigger Coil System

Spark Plugs

Ngk Spark Plug

Design Symbols Used in Ngk Spark Plugs

Testing Procedure

Nippondenso CDI Trigger Coil System Testing

Voltage Regulator Inspection

Inspection of Ac Circuit Isolation

Inspection of Heating Elements

Section 4

Suspension (Hp Version)

Drive Axle

Track

Section 5

Steering System

Suspension and Ski System

,14, Tie Rod and Lever

Body

Installation and Adjustment

Plastic Maintenance and Repair

Frame

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