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  Section 00 SECTION NAME Subsection 00 (SUB-SECTION NAME) ® 1998 Shop Manual VOLUME 3 GRAND TOURING 700/SE FORMULA III 600/600 R/600 LT/700/700 R MACH 1/1 R/Z/Z R/Z LT/Z LT R 00-00-I…
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  Legal deposit: National Library of Quebec trimester 1997 National Library of Canada1997 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 1997 Technical Publications Bombardier Inc.

• Page 4: Table Of Contents

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

• Page 5: Section Subsection Page

  TABLE OF CONTENTS SECTION SUBSECTION PAGE STEERING/ 01 – Table of contents …………..08-01-1 FRONT SUSPENSION 02 – Steering system…………… 08-02-1 03 – Suspension and ski system …………. 08-03-1 BODY/FRAME 01 – Table of contents …………..09-01-1 02 – Body………………09-02-1 03 –…

• Page 6: Safety Notice

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

• Page 7: What’s New

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

• Page 8: Introduction

  INTRODUCTION INTRODUCTION This Shop Manual Volume 3 covers the following Bombardier made 1998 snowmobiles: MODEL MODEL MODELS MODELS NUMBER NUMBER FORMULA* III 600 (Canada)… 1334 MACH* Z LT SV TRACK (Canada).. 1303 FORMULA* III 600 (U.S.) ….1335 MACH* Z LT SV TRACK (U.S.) ..1316 FORMULA* III 600 R (Canada) ..

• Page 9: 01 Service Tools And Service Products

  INTRODUCTION Grand Touring 700/SE ENGINE SERIAL NUMBER Formula III 600/600 R/600 LT/700/700 R Engine Serial Number Location Mach 1/1 R/Z/Z R/Z LT/Z LT R These are CK3 Series models. A30A0AA A30C01A TYPICAL — CK3 SERIES 1. Engine serial number VEHICLE SERIAL NUMBER…

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

• Page 19: Service Tools

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

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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE — MANDATORY SERVICE TOOLS Hose pincher (qty 2) Engine leak tester kit 1) Piston pin puller (P/N 529 0099 00) (P/N 861 7491 00) (P/N 529 0355 03) A01B594 A01B2I4 APPLICATION 2) Sleeve kit 18 mm…
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — MANDATORY SERVICE TOOLS Fluke multimeter (P/N 529 0220 00) F01B1O4 APPLICATION All models. Choke and DESS nut tool (P/N 529 0346 00) (TYPICAL) A01B554 APPLICATION All models equipped with a choke and/or a DESS.
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  A00I094 Use with half rings (P/N 420 9774 75 or 420 2760 25). APPLICATION 9) Half ring (2) (P/N 420 9774 75) Grand Touring 700/SE. For 72 mm O.D. bearings. 10) Half ring (P/N 420 2760 25) Adaptor (P/N 529 0338 00) For 62 mm O.D.
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — RECOMMENDED SERVICE TOOLS Piston circlip installer Circuit tester Air pressure gauge, (continuity light) 0-200 inch of water (P/N 529 0169 00) (P/N 414 0122 00) (P/N 529 0104 00) Piston circlip A00C214…
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) ENGINE (continued) — RECOMMENDED SERVICE TOOLS Digital/induction type Handle for insertion jig tachometer (P/N 420 8776 50) (P/N 529 0145 00) F01B1G4 APPLICATION All engines. A00C3V4 APPLICATION Injection jig 599, 699 and 809 engines. (magneto seal) (P/N 420 8765 14) Exhaust spring installer/…
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) TRANSMISSION — MANDATORY SERVICE TOOLS Clutch holder Transmission alignment bar Spring compressor/ TRA clutch flare tool (P/N 529 0064 00) (P/N 529 0355 27) (P/N 529 0186 00) Parts included in the kit: Spring compressor A01B4D4 A01B154…
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) TRANSMISSION (continued) — MANDATORY SERVICE TOOLS Countershaft bearing remover/installer (P/N 529 0355 54) A01B5C4 APPLICATION CK3 Series. 01-01-8…
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) TRANSMISSION (continued) — RECOMMENDED SERVICE TOOLS The following tools are highly recommended to optimize your basic tool kit and reduce repair time. Drive axle sprocket adjuster (P/N 861 7257 00) A01B2O4 APPLICATION All models.
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) SUSPENSION — MANDATORY SERVICE TOOLS Shock spring removal kit (P/N 529 0355 04) Replacement clevis pin: (P/N 414 5284 00) NOTE: The previous shock spring removal kit (P/N 529 0271 00) can be upgraded by replacing the stop- per with a wider stopper (P/N 529 0355 51).
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) SUSPENSION (continued) — RECOMMENDED SERVICE TOOLS Track cleat remover Track tension gauge Drill bit (P/N 529 0287 00) (P/N 529 0215 00) (P/N 529 0318 00) A01B564 APPLICATION A01F224 All 3/16 inch rivets. APPLICATION All models.
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 01 (SERVICE TOOLS) VEHICLES — RECOMMENDED SERVICE TOOLS Protective mat (P/N 529 0306 00) A01B45W APPLICATION All models. Dolly Snowmobile jack (P/N 529 0299 00) (P/N 529 0200 00) A01A1JJ A00B4CJ APPLICATION APPLICATION All models.

• Page 31: Service Products

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

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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE PRODUCTS) MANDATORY SERVICE PRODUCTS ® Loctite is a trademarks of Loctite Corporation. ® Dow Corning is a trademarks of Dow Corning Corporation. Retaining compound Medium-strength Gasket/paint remover threadlocker (P/N 413 7031 00) (P/N 413 7085 00) (P/N 413 7030 00) ®…
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE PRODUCTS) MANDATORY SERVICE PRODUCTS (continued) ® Loctite primer (P/N 413 7081 00) ® Loctite 764-56 Primer N 170 g (6 oz) A00B3N4 APPLICATION To prepare mating surfaces before applying paste gasket, retaining compound or threadlockers.
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS Silicone dielectric grease Synthetic chaincase oil Injection oil (3 oz) (12 x 355 mL) (P/N 413 8029 00) (P/N 413 7017 00) (P/N 413 8033 00) (12 x 1 liter) (P/N 413 8030 00) (3 x 4 liters) DOW CORNING ®…
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS (continued) BOMBARDIER-ROTAX Formula Anti-seize lubricant Storage oil XP-S synthetic injection oil (350 g spray can) (P/N 413 7010 00) (12 x 350 g) (P/N 413 7105 00) Loctite anti-seize (P/N 413 7116 00) (12 x 1 liter)
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS (continued) Gel instant adhesive HYLOMAR sealant Sealant (100 g) (P/N 413 7083 00) (P/N 413 7103 00) (P/N 413 7071 00) Loctite 454-40 Loctite 179 (80 mL) 20 g (.70 oz) A00B3F4 A00B3O4…
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  Section 01 SERVICE TOOLS AND PRODUCTS Subsection 02 (SERVICE PRODUCTS) RECOMMENDED SERVICE PRODUCTS (continued) Molykote 111 (P/N 413 7070 00) DOW CORNING ® A00B3W4 APPLICATION Rotary valve shaft seals. BOMBARDIER LUBE (12 x 14 oz) (P/N 293 6000 16) L U BE P e n etr ating lub ric a n t E x c…

• Page 38: Lubrication And Maintenance Chart

  Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) LUBRICATION AND MAINTENANCE CHART SYSTEM PART/TASK REFER TO Rewind Starter Lubrication and Rope Subsection 04-07 Condition Appropriate section: Engine Head Nuts See Top End Appropriate section: Engine Mount Nuts See ENGINE REMOVAL Appropriate section: Exhaust System…

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  Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) SYSTEM PART/TASK REFER TO Handlebar Bolts. Retorque to 26 N•m Subsection 08-02 (19 Ibf•ft) Steering and Front Suspension Subsections 08-02 and 08-03 Mechanism Wear and Condition of Skis and Subsection 08-03 Runners Steering and Ski Leg Camber…
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  Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) NO. 1 ENGINE LUBRICATION Models with a Choke Remove air silencer to spray storage oil into each Engine internal parts must be lubricated to protect carburetor bore. them from possible rust formation during the stor- age period.
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  Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) NO. 3 FUEL FILTER Check that the air box is clean and dry then prop- erly reinstall the filter. REPLACEMENT Drain fuel tank. Remove fuel line grommet from fuel tank and pull out inlet fuel line from tank.
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  Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) A30H0XA NO. 5 DRIVE BELT CONDITION A30H0SA Inspect belt for cracks, fraying or abnormal wear TYPICAL (uneven wear, wear on one side, missing cogs, 1. Stick bottom edge first cracked fabric).
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  Section 02 LUBRICATION AND MAINTENANCE Subsection 01 (LUBRICATION AND MAINTENANCE CHART) NO. 8 VEHICLE CLEANING AND NOTE: The latest product may be use alone if only light scratches are noticeable. PROTECTION Remove any dirt or rust. CAUTION To clean the entire vehicle, use only flannel Never clean plastic parts or hood with ®…

• Page 44: Troubleshooting

  Section 03 TROUBLESHOOTING Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS ENGINE ……………………..03-02-1 ENGINE LEAK VERIFICATION FLOW CHART …………..03-02-11 FUEL AND OIL SYSTEMS………………… 03-03-1 TRANSMISSION AND BRAKE SYSTEMS …………….03-04-1 TRANSMISSION …………………… 03-04-1 BRAKE SYSTEM …………………… 03-04-7 HYDRAULIC BRAKE ………………….03-04-7 ELECTRICAL SYSTEM………………….

• Page 45: Engine

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

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  Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM ENGINE SUDDENLY TURNS OFF. CONDITION NORMAL USE. Test/Inspection 1. Perform engine leak test. Refer to ENGINE LEAK VERIFICATION FLOW CHART. Check possible piston seizure. a. Damaged gasket and/or seal. Replace defective parts. 2. “Four-corner” seizure of piston(s). a.
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  Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) 5. Seized piston all around the circumference (dry surface). a. Lack of oil, damaged oil line or defective injection pump. Replace defective part(s). 6. Grooves on intake side of piston only. a. Oil film eliminated by water (snow infiltration in engine). Replace piston(s) and check if intake system leaks.
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  Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH MAXIMUM OPERATING RPM. CONDITION NORMAL USE. Test/Inspection 1. Check spark plug condition. a. Fouled spark plugs. Replace. 2. Check if there is water in fuel. a.
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  Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM ENGINE DETONATION AT MAXIMUM RPM. CONDITION NORMAL USE. Test/Inspection 1. Check which type of fuel is used. a. Octane number is too low and/or alcohol level is too high. Use recommended fuel type. 2.
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  Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM ENGINE TURNS OVER BUT FAILS TO START. CONDITION NORMAL USE. Test/Inspection 1. Check switches. a. Ignition switch, emergency cut-out switch or tether switch is in the OFF position. Place all switches in the RUN or ON position. If it still does not work, connect DESS switch BK/GN and BK/WH wires together (harness side).
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  Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM IRREGULAR ENGINE IDLE. CONDITION NORMAL USE AFTER ENGINE WARM UP. Test/Inspection 1. Check primer. a. Fuel leaks at primer nipple which is mounted to carburetor. Replace. 2. Check choke. a. Choke plunger may be partially opened. Readjust.
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  Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM HIGH ENGINE OPERATING TEMPERATURE. CONDITION NORMAL USE. Test/Inspection 1. Check temperature gauge sensor. a. False reading. Check terminal connections. If problem still persists, replace sensor. 2. Check fan belt. a. Belt slides because it is too loose. Adjust according to specifications (refer to TECHNICAL DATA 10).
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  Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM ENGINE EQUIPPED WITH RAVE VALVE DOES NOT REACH ITS FULL OPERATING RPM (500 TO 1000 RPM SLOWER). CONDITION NORMAL USE. Test/Inspection 1. Check RAVE valve pistons. a. Valve piston(s) is (are) too far out. Screw valve piston(s) to bottom.
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  Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) SYMPTOM REWIND STARTER PAWL DOES NOT ENGAGE. CONDITION NORMAL USE. Test/Inspection 1. Check stopper spring. a. Broken stopper spring. Replace. 2. Check pawl and pawl lock. a. Pawl and pawl lock have stuck together because of heat. Replace.

• Page 55: Engine Leak Verification Flow Chart

  Section 03 TROUBLESHOOTING Subsection 02 (ENGINE) ENGINE LEAK VERIFICATION FLOW CHART ENGINE LEAK VERIFICATION FLOW CHART PRESSURIZE ENGINE IS ENGINE LEAKING? CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS. MOUNTING FLANGES ETC. REPLACE GASKET OR O-RING, ANY LEAK FOUND? RE-SEAL LEAKING AREA CHECK SMALL OIL LINES OF INJECTION PUMP AIR BUBBLES FOUND…
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  Section 03 TROUBLESHOOTING Subsection 03 (FUEL AND OIL SYSTEMS) FUEL AND OIL SYSTEMS The following chart is provided to help in diagnosing the probable source of troubles. It should be used as a guideline. Some causes or corrections may not apply to a specific model. SYMPTOM HIGH FUEL CONSUMPTION OR RICH MIXTURE.
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  Section 03 TROUBLESHOOTING Subsection 03 (FUEL AND OIL SYSTEMS) SYMPTOM ENGINE LACKS POWER OR STALLS AT HIGH RPM. CONDITION NORMAL USE. Test/Inspection 1. Check fuel tank vent hose. a. Kinked or clogged hose. Relocate or replace. 2. Check fuel filter. a.
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  Section 03 TROUBLESHOOTING Subsection 03 (FUEL AND OIL SYSTEMS) SYMPTOM ENGINE RUNS OUT OF FUEL (OR LEAN MIXTURE). CONDITION NORMAL USE. Test/Inspection 1. Check if lines are perforated or kinked and make sure they do not leak at fittings. a. Lines are too big for their fittings or are improperly routed. Replace or properly relocate lines.

• Page 59: Transmission And Brake Systems

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

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  Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM LOOSENESS IS FELT IN DRIVE SYSTEM WHEN ACCELERATING/DECELERATING. CONDITION NORMAL USE. Test/Inspection 1. Check drive chain tension. a. Drive chain is too loose. Adjust. 2. Check play of driven pulley splines. a.
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  Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM PULLEYS DO NOT DOWN SHIFT PROPERLY. CONDITION NORMAL USE. Test/Inspection 1. Check driven pulley spring tension. a. Spring tension is too weak. Adjust according to specifications (refer to TECHNICAL DATA 10). 2.
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  Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT GLAZED EXCESSIVELY OR HAVING BAKED APPEARANCE. CONDITION NORMAL USE. Test/Inspection 1. Check if drive pulley bushings are worn. a. Insufficient pressure on belt sides. Replace bushing. 2. Check condition of drive pulley fixed half shaft. a.
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  Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT WORN NARROW IN ONE SECTION. CONDITION NORMAL USE. Test/Inspection 1. Check if parking brake is released. a. Parking brake is engaged. Release parking brake. 2. Check track tension/alignment. a. Frozen or too tight track. Liberate track from ice or check track tension and alignment.
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  Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT DISINTEGRATION. CONDITION NORMAL USE. Test/Inspection 1. Check drive belt identification number. a. Excessive belt speed. Using unspecified type of belt. Replace belt with proper type of belt (refer to TECHNICAL DATA 10). 2.

• Page 65: Brake System

  Section 03 TROUBLESHOOTING Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS) SYMPTOM BELT “FLIP-OVER” AT HIGH SPEED. CONDITION NORMAL USE. Test/Inspection 1. Check pulley alignment. a. Pulley misalignment. Align pulley according to specifications (refer to TECHNICAL DATA 10). 2. Check drive belt identification number. a.

• Page 66: Electrical System

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

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  Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) 8. Check height of commutator mica. a. Commutator mica too high. Undercut mica. 9. Check field coil resistance. a. Shorted field coil. Repair or replace yoke. 10. Check armature resistance. a. Shorted armature. Repair or replace armature.
• Page 68
  Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM ELECTRIC STARTER KEEPS TURNING WHEN ENGINE IS STARTED. CONDITION NORMAL USE. Test/Inspection 1. Check clutch. a. Jammed clutch pinion gear. Replace or clean. 2. Check movement of clutch on splines. a. Clutch is stuck on splines. Clean.
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  Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM ELECTRIC STARTER SOMETIMES DOES NOT WORK WHEN TURNING IGNITION SWITCH. CONDITION NORMAL USE. Test/Inspection 1. Check battery cables and starter wires. a. Corroded and/or loose connection(s). Clean and/or retighten. 2. Check fuse. a.
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  Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM HEADLAMP DIMING. CONDITION NORMAL USE. Test/Inspection 1. Check voltage at headlamp at different speeds. It must not be below 11 Vac. a. Insufficient voltage in lighting circuit. Replace voltage regulator and retest. 2.
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  Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM FALSE FUEL AND/OR TEMPERATURE GAUGE READINGS. CONDITION NORMAL USE. Test/Inspection 1. Verify if gauge was connected on DC current by mistake (in case of optional installation). a. Faulty installation of optional equipment. Find optional wires connected directly to DC ground (BK wire to chassis) or to any DC hot wire (RD, RD/BL).
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  Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM ENGINES DOES NOT START — NO SPARK AT SPARK PLUG. CONDITION AT ENGINE CRANKING. Test/Inspection 1. Verify spark plug condition. a. Defective, improperly set, worn-out, fouled. Identify source of problem and correct. Replace spark plugs. 2.
• Page 73
  Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM IRREGULAR ENGINE SPEED. CONDITION AT HIGH SPEED. Test/Inspection 1. Verify items 4, 5 and 6 above. CONDITION AT LOW SPEED. Test/Inspection 1. Verify items 4 and 5 above and trigger coil/flywheel protrusion air gap. a.
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  Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM FOULED (BLACK) SPARK PLUG TIP. CONDITION NORMAL USE. Test/Inspection 1. Check carburetor(s). a. Carburetion is too rich. Adjust according to specifications (refer to TECHNICAL DATA 10). 2. Check injection oil consumption. a. Injection pump flow is too high. Adjust according to specifications or replace.
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  Section 03 TROUBLESHOOTING Subsection 05 (ELECTRICAL SYSTEM) SYMPTOM REAR LIGHT BULB FLASHES. CONDITION NORMAL USE. Test/Inspection 1. Check bulb tightness in housing. a. Looseness at bulb contact elements. Install bulb correctly. 2. Check if rear light is properly connected. a. Connector housing is partially connected. Install connector housing properly.

• Page 76: Suspension And Track

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

• Page 77
  Section 03 TROUBLESHOOTING Subsection 06 (SUSPENSION AND TRACK) SYMPTOM NOISE OR VIBRATIONS ORIGINATING FROM THE TRACK. CONDITION NORMAL USE. Test/Inspection 1. Check slide suspension retaining bolts. a. Missing bolt(s) allowing movement of certain components which in turn interfere with track rotation. Replace missing bolt(s).
• Page 78
  Section 03 TROUBLESHOOTING Subsection 06 (SUSPENSION AND TRACK) SYMPTOM WHEN HANDLEBAR IS TURNED, SNOWMOBILE UNDERSTEERS. CONDITION NORMAL USE. Test/Inspection 1. Check ski runner condition. a. Worn ski runners. Replace. 2. Check tension of front spring adjustment cams. a. Insufficient ski pressure on the ground. Increase spring preload.
• Page 79
  Section 03 TROUBLESHOOTING Subsection 06 (SUSPENSION AND TRACK) SYMPTOM THE SNOWMOBILE IS UNSTABLE (IT MOVES FROM LEFT TO RIGHT AND VICE VERSA). CONDITION NORMAL USE. Test/Inspection 1. Check ski runner condition. a. Worn or bent ski runners. Replace ski runners. 2.
• Page 80
  Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS 599, 699 AND 809 ENGINE TYPES………………04-02-1 ENGINE REMOVAL AND INSTALLATION……………. 04-02-1 REMOVAL FROM VEHICLE ………………..04-02-2 INSTALLATION ON VEHICLE ……………….. 04-02-3 TOP END ……………………..04-02-4 COMPONENT REMOVAL ………………..04-02-5 CLEANING …………………….
• Page 81
  Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) CDI SYSTEM……………………… 04-04-1 NIPPONDENSO TRIGGER COIL IGNITION SYSTEM…………04-04-1 CLEANING …………………….. 04-04-2 DISASSEMBLY ……………………04-04-2 ASSEMBLY ……………………. 04-04-4 OIL INJECTION SYSTEM………………….. 04-05-1 OIL INJECTION PUMP ………………….. 04-05-1 OIL PUMP IDENTIFICATION ………………..04-05-2 CLEANING ……………………..
• Page 82
  Section 04 ENGINE Subsection 01 (TABLE OF CONTENTS) DPM ………………………. 04-08-14 PURPOSE ……………………… 04-08-15 METHOD ……………………..04-08-15 OVERALL SYSTEM OPERATION ………………04-08-15 DPM MODULE OPERATION ………………… 04-08-16 AIR PUMP OPERATION………………… 04-08-21 DPM MANIFOLD OPERATION ………………04-08-21 TESTING PROCEDURE ………………… 04-08-23 FUEL PUMP ……………………

• Page 83: 599, 699 And 809 Engine Types

  Section 04 ENGINE Subsection 02 (599, 699 AND 809 ENGINE TYPES) 599, 699 AND 809 ENGINE TYPES ENGINE REMOVAL AND INSTALLATION All Models Loctite Loctite 179 28 N•m (21 lbf•ft) Loctite 15 N•m (133 lbf•in) Loctite 35 N•m 10 N•m 37 N•m (26 lbf•ft) (89 lbf•in)

• Page 84: Removal From Vehicle

  Section 04 ENGINE Subsection 02 (599, 699 AND 809 ENGINE TYPES) REMOVAL FROM VEHICLE – exhaust pipes using exhaust spring remover/ installer (P/N 529 0354 00) Open hood and close fuel shut-off valve. Drain engine coolant. Remove or unplug the following then lift off en- gine from engine compartment.

• Page 85: Installation On Vehicle

  Section 04 ENGINE Subsection 02 (599, 699 AND 809 ENGINE TYPES) INSTALLATION ON VEHICLE To install engine on vehicle, reverse removal pro- cedure. However, pay attention, to all appropriate component/system reinstallation procedures de- scribed throughout this Shop Manual and to the following: –…

• Page 86: Top End

  Section 04 ENGINE Subsection 02 (599, 699 AND 809 ENGINE TYPES) TOP END 10 N•m Loctite (89 lbf•in) 30 N•m (22 lbf•ft) Grease 10 N•m (89 lbf•in) 809 only Molykote 111 (P/N 413 7070 00) 29 N•m (21 lbf•ft) Grease 29 N•m (21 lbf•ft) Grease…

• Page 87: Component Removal

  Section 04 ENGINE Subsection 02 (599, 699 AND 809 ENGINE TYPES) COMPONENT REMOVAL Place a clean cloth or rubber pad (P/N 529 0234 00) over crankcase to prevent circlips no. 20 from Most engine components can be removed with falling into crankcase. Then with a pointed tool in- engine on vehicle such as: serted in piston notch, remove circlips from pis- ton no.

• Page 88: Inspection

  Section 04 ENGINE Subsection 02 (599, 699 AND 809 ENGINE TYPES) RAVE System Check valve rod housing and cylinder for clogged passages. A21C04A 1. Pusher 21mm (.826 in) RAVE System NOTE: RAVE stands for Rotax Adjustable Variable Exhaust. A06C3OA Remove spring clip no. 3, cover no. 6 and spring 1.
• Page 89
  Section 04 ENGINE Subsection 02 (599, 699 AND 809 ENGINE TYPES) 17,18, Cylinder and Piston NOTE: Be sure to restore the chamfer around all cylinder sleeve port openings. Before inserting piston in cylinder, lubricate the cylinder with new injection oil or equivalent. 1,2,17, Cylinder Head Cover, Cylinder Head and Cylinder Check flatness of part sealing surfaces.
• Page 90
  Section 04 ENGINE Subsection 02 (599, 699 AND 809 ENGINE TYPES) Install piston pin puller (P/N 529 0210 00) and turn All Engines handle until piston pin is correctly positioned in To minimize the effect of acceleration forces on piston. circlip, install each circlip so the circlip break is at 6 o’clock as illustrated.
• Page 91
  Section 04 ENGINE Subsection 02 (599, 699 AND 809 ENGINE TYPES) Install cylinders and check for same height. At assembly, torque cylinder head screws in the following illustrated sequence. Tightening torques are: M6 screws: 12 N•m (106 Ibf•in) M8 screws: 30 N•m (22 Ibf•ft) A06C1PA Also check for proper cylinder alignment.

• Page 92: Bottom End

  Section 04 ENGINE Subsection 02 (599, 699 AND 809 ENGINE TYPES) BOTTOM END 599 and 699 only 10 N•m (90 lbf•in) Loctite Loctite 10 N•m Primer N (90 lbf•in) Loctite 515 Anti-seize lubricant (P/N 413 7010 00) Molykote 111 (P/N 413 7070 00) Primer N Loctite 515 Loctite…

• Page 93: Cleaning

  Section 04 ENGINE Subsection 02 (599, 699 AND 809 ENGINE TYPES) NOTE: Engine must be removed from chassis to 1, Reed Valve perform the following procedures. With blade stopper removed, check reed valve for proper tightness. There must be no play between CLEANING blade and valve body when exerting a finger pres- sure on blade at blade stopper location.

• Page 94: Assembly

  Section 04 ENGINE Subsection 02 (599, 699 AND 809 ENGINE TYPES) ASSEMBLY Crankcase halves no. 4 and water pump housing are factory matched and therefore, are not inter- changeable as single halves. 2,3, Crankshaft Bearing, Anti-seize Lubricant and Labyrinth Sleeve Prior to joining of crankcase halves, spray some new injection oil (or equivalent) on all moving Smear anti-seize lubricant (P/N 413 7010 00) on…

• Page 95
  Section 04 ENGINE Subsection 02 (599, 699 AND 809 ENGINE TYPES) 7, Seal 10 12 Install seal using pusher (P/N 420 8765 16). CAUTION Make sure oil seal is fully pushed against stator shoulder. 420 8765 16 3 9 11 A06C3RA 809 ENGINE 1.

• Page 96: Leak Test And Engine Dimension Measurement

  Section 04 ENGINE Subsection 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) LEAK TEST AND ENGINE DIMENSION MEASUREMENT LEAK TEST The following gives verification procedures for liq- 8. Rotate crankshaft so that piston goes to BDC uid cooled engines though it also applies to fan (Bottom Dead Center) on side where the cooled engines.

• Page 97
  Section 04 ENGINE Subsection 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Engine Check the following: 1. All jointed surfaces and screw/stud threads of engine: – spark plug base, insulator – cylinder head – cylinder base – crankcase halves (joint) – rotary valve cover –…
• Page 98
  Section 04 ENGINE Subsection 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) 4. Block both hoses of rotary valve gear lubrica- 1. Remove a spark plug or any plug of leak tester tion system with hose pinchers. kit on PTO side. If pressure drops, it indicates defective crank- shaft inner seal on PTO side.

• Page 99: Finalizing Reassembly

  Section 04 ENGINE Subsection 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) 4. Remove rotary valve cover and check for leak COOLING SYSTEM LEAK TEST of rotary valve seal with soapy water. Install special plug (radiator cap) (P/N 529 0214 00) and hose pincher (P/N 529 0099 00) on overflow hose.

• Page 100: Engine Leak Verification Flow Chart

  Section 04 ENGINE Subsection 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) ENGINE LEAK VERIFICATION FLOW CHART ENGINE LEAK VERIFICATION FLOW CHART PRESSURIZE ENGINE IS ENGINE LEAKING? CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS. MOUNTING FLANGES ETC. REPLACE GASKET OR O-RING, ANY LEAK FOUND? RE-SEAL LEAKING AREA CHECK SMALL OIL LINES OF INJECTION PUMP…

• Page 101: Engine Dimension Measurement

  Section 04 ENGINE Subsection 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) ENGINE DIMENSION MEASUREMENT CYLINDER OUT OF ROUND This section covers all engine types. CYLINDER HEAD WARPAGE ENGINE TYPE MAXIMUM 599 and 699 0.05 mm (.002 in) ENGINE TYPE MAXIMUM 0.08 mm (.003 in) 0.05 mm (.002 in) per 50 mm (2 in) of surface…

• Page 102
  Section 04 ENGINE Subsection 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) F01D5VA 1. Combustion chamber F00B0BA NOTE: When checking the combustion chamber 1. Graduated burette (0-50 cc) volume, engine must be cold, piston must be free of carbon deposit and cylinder head must be lev- 3.

• Page 103: Used Piston Measurement

  Section 04 ENGINE Subsection 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) 5. Let burette stand upward for about 10 minutes, CYLINDER/PISTON CLEARANCE until liquid level is stabilized. Used and New Pistons 6. Read the burette scale to obtain the quantity of NOTE: Make sure used piston is not worn.

• Page 104: Ring/Piston Groove Clearance

  Section 04 ENGINE Subsection 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Read the measurement on the cylinder bore gauge. The result is the exact piston/cylinder wall clearance. If clearance exceeds specified toler- ance, replace cylinder or rebore. Refer to TECHNI- CAL DATA 10.

• Page 105: Crankshaft Deflection

  Section 04 ENGINE Subsection 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Crankshaft Deflection on PTO Side ENGINE DISTANCE A MAXIMUM ON PTO SIDE TYPE mm (in) mm (in) 599 and 105.9 (4.169) 0.03 (.0012) 94.4 (3.717) Crankshaft Deflection on MAG Side MAXIMUM ON MAG SIDE ENGINE TYPE mm (in)

• Page 106: Connecting Rod/Piston Pin Clearance

  Section 04 ENGINE Subsection 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) ENGINE NEW PARTS WEAR TYPE MIN. — MAX. LIMIT 0.003 — 0.012 mm 0.015 mm (.0001 — .0005 in) (.0006 in) CONNECTING ROD/CRANKPIN CLEARANCE ENGINE NEW PARTS WEAR TYPE MIN.

• Page 107
  Section 04 ENGINE Subsection 03 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT) Bring center piston to top dead center. Degree wheel must rotate with crankshaft. A00A1LA CHECKING CRANKSHAFT ALIGNMENT Install a degree wheel (P/N 414 3529 00) on crank- A06C1TA shaft end. Remove both spark plugs.

• Page 108: Cdi System

  Section 04 ENGINE Subsection 04 (CDI SYSTEM) CDI SYSTEM NIPPONDENSO TRIGGER COIL IGNITION SYSTEM 599, 699 and 809 Engines Dielectric grease (P/N 413 7017 00) Silastic Loctite 242 5 125 N•m Dielectric grease (92 lbf•ft) (P/N 413 7017 00) Except GT 700/SE Loctite Loctite 648…

• Page 109: Cleaning

  Section 04 ENGINE Subsection 04 (CDI SYSTEM) NOTE: The following procedures can be done Install puller with its tab in magneto housing open- without removing the engine from chassis. To fa- ing. cilitate magneto removal, hold drive pulley with tool (P/N 529 0276 00). CDI means Capacitor Discharge System.

• Page 110
  Section 04 ENGINE Subsection 04 (CDI SYSTEM) A25E1AA 1. Magneto harness through crankcase hole – Install new trigger coil and other parts removed. Adjustment Whenever the trigger coil or the magneto fly- A15E0NA wheel is removed or replaced, the air-gap be- ADJUSTING TRIGGER COIL AIR-GAP tween the trigger coil and the flywheel protrusion 1.

• Page 111: Assembly

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

• Page 112: Oil Injection System

  Section 04 ENGINE Subsection 05 (OIL INJECTION SYSTEM) OIL INJECTION SYSTEM OIL INJECTION PUMP 599, 699 and 809 Engines Loctite 5 N•m (44 lbf•in) Loctite A30C0BS PARTS FLAT RATE 04-05-1…

• Page 113: Oil Injection Pump

  Section 04 ENGINE Subsection 05 (OIL INJECTION SYSTEM) OIL PUMP IDENTIFICATION 7, Pump Lever 420 2779 05 Different engines need different pumps. Oil pumps are identified by their levers. CAUTION Always mount proper pump on engine. OIL PUMP ENGINE TYPE IDENTIFICATION A00C17A TYPICAL…

• Page 114: Adjustment

  Section 04 ENGINE Subsection 05 (OIL INJECTION SYSTEM) ADJUSTMENT Prior to adjusting the pump, make sure all carbu- retor adjustments are completed. Synchronizing Pump with Carburetor Eliminate the throttle cable free-play by pressing the throttle lever until a light resistance is felt, then hold in place.

• Page 115: Checking Operation

  Section 04 ENGINE Subsection 05 (OIL INJECTION SYSTEM) If not, remove pump assembly and check the WARNING pump gear and drive shaft (if applicable) for de- fects, replace as necessary. Test pump as de- Ensure not to operate carburetor throttle scribes below.

• Page 116: Liquid Cooling System

  Section 04 ENGINE Subsection 06 (LIQUID COOLING SYSTEM) LIQUID COOLING SYSTEM 599, 699 and 809 Engines Loctite A30C0AS PARTS FLAT RATE 04-06-1…

• Page 117: Inspection

  Section 04 ENGINE Subsection 06 (LIQUID COOLING SYSTEM) INSPECTION 6,7, Radiator and Radiator Protector Insert radiator protector into radiator C-rail and Check general condition of hoses and clamp tight- crimp C-rail at both ends. Refer to FRAME 09-03 ness. for radiator removal. DRAINING THE SYSTEM 5, Thermostat To check thermostat, put in water and heat water.

• Page 118: Cooling System Refilling Procedure

  Section 04 ENGINE Subsection 06 (LIQUID COOLING SYSTEM) System Capacity Refer to TECHNICAL DATA 10. Refilling Procedure Lift front of vehicle until the tunnel is horizontal. With engine cold, refill coolant tank up to cold lev- el line. Wait a few minutes then refill to line. Install pressure cap.

• Page 119: Rewind Starter

  Section 04 ENGINE Subsection 07 (REWIND STARTER) REWIND STARTER All Models Molykote G-n paste or equivalent Silicone compound grease Silicone compound grease 10 N•m (89 lbf•in) A06C3GS PARTS FLAT RATE 04-07-1…

• Page 120: Removal

  Section 04 ENGINE Subsection 07 (REWIND STARTER) REMOVAL Using a small screwdriver, extract rope knot from starter grip no. 13. Cut rope close to knot. Tie a knot near starter. Remove screws no. 3 and washers no. 2 secur- ing rewind starter no. 1 to engine then remove re- wind starter.

• Page 121
  Section 04 ENGINE Subsection 07 (REWIND STARTER) A01C0CA Position pawl no. 8, pawl lock no. 9 and circlip A01C14A no. 10. 1. Grease inside spring guide Install locking spring no. 11 and lubricate with MOLYKOTE G-n paste from Dow Corning ®…

• Page 122: Installation

  Section 04 ENGINE Subsection 07 (REWIND STARTER) INSTALLATION Reinstall rewind starter assembly on engine. Prior to installing starter grip no. 13 on new rope, it is first necessary to fuse the rope end with a lit match. Pass rope through starter grip and tie a knot in the rope end.

• Page 123: Carburetor And Fuel Pump

  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) CARBURETOR AND FUEL PUMP Formula Series, GT 700/SE and Mach 1 Series All models except GT SE To other carburetors A30C0ES PARTS FLAT RATE 04-08-1…

• Page 124
  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) Mach Z Series A30C0FS PARTS FLAT RATE 04-08-2…

• Page 125: Removal

  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) REMOVAL Unhook latches then, remove air intake silencer. Disconnect fuel inlet lines. Remove air silencer from left hand side. Unplug DPM solenoid connectors. Disconnect air Grand Touring SE Only pump inlet at DPM manifold. Unplug air temperature sensor connector from air All Models Except Mach Z Series intake silencer and remove DPM module, as shown…

• Page 126: Identification

  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) NOTE: Install needle valve for snowmobile carbu- 2,3, E-clip and Needle retor only. It is designed to operate with a fuel All Models Except Mach Z Series pump system. Remove screws from needle retaining plate to Check throttle slide for wear.

• Page 127: Carburetor Float Level Adjustment

  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) All Models Except Mach Z Series – With carburetor chamber upside-down on a lev- Lean el surface, measure height H between bowl seat and top edge of float arm. Keep ruler per- fectly vertical and in line with main jet hole.

• Page 128: Installation

  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) To Adjust Height H INSTALLATION – Bend the contact tab of float arm until the spec- CAUTION ified height is reached. Never allow throttle slide(s) to snap shut. To install carburetor on engine, inverse removal procedure.

• Page 129: Carburetor Adjustments

  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) Make sure the nylon packing no. 4 is installed on CARBURETOR ADJUSTMENTS all applicable throttle slides. All Models Except Mach Z Series CAUTION Serious engine damage can occur if this no- tice is disregarded.
• Page 130
  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) Carburetor Synchronization Mach Z Series All 3 carburetor slides must start to open at the All Models Except Mach Z Series same time. All carburetor slides must start to open at the Visually check for simultaneous opening.
• Page 131
  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) All Models Except Mach Z Series Throttle slide must be flush or 1.0 mm (.040 in) lower than the top of carburetor oulet bore (en- gine side). A06C0LA TYPICAL — FULL THROTTLE POSITION 1.

• Page 132: Preliminary Idle Speed Adjustment

  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) IDLE SPEED FINAL ADJUSTMENT WARNING 7, Idle Speed Screw This gap is very important. If the throttle Start engine and allow it to warm then adjust idle slide rests against the carburetor cover at speed to specifications by turning idle speed full throttle opening, this will create too screw clockwise to increase engine speed or…

• Page 133
  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) If tool tip does not seat under choke plunger, ad- CAUTION just as follows: Lift up protector cap and loosen choke cable lock Make sure that tool stopper is properly lean on nut, as shown in the next photo.
• Page 134
  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) Set choke lever to close and open positions and ensure that tool properly seats under plunger only when lever is set to fully open position. Set choke lever to close position and, by pulling and pushing choke lever, make sure there is no tension on cable (free play).
• Page 135
  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) Air intake silencer must be reinstalled and choke cable properly routed before finalizing adjust- ment. Adjust choke cable to obtain a maximum gap of approximately 0.3 mm (.012 in) between tab and plunger when choke lever is not activated.

• Page 136: Dpm

  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) Grand Touring SE Vent Engine A30C0GS PARTS FLAT RATE 04-08-14…

• Page 137: Purpose

  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) PURPOSE Calibrate the air/fuel mixture in order to optimize the engine output while reducing fuel consumption. METHOD The system makes the pressure vary within the carburetor bowl. OVERALL SYSTEM OPERATION A06I0PS 1.

• Page 138: Dpm Module Operation

  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) Introduction DPM MODULE OPERATION The engine is being started using the electrical or General the manual starter. The DPM module increases pressure within all 3 carburetor bowls thus the air/fuel mixture is en- riched.

• Page 139
  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) Enrichment Mode (starting) A06I0QS When turning the ignition key to the ON position, the module is energized and goes on standby. The module uses no electricity when on standby. Once the engine begins to turn (using either the electrical or rewind starter), the module receives pulses through the MPEM (multi-purpose electronic module) ignition system GRAY/GREEN wire.
• Page 140
  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) CARBURETOR ACTIVE CALIBRATED JET CARBURETOR ENRICHMENT AIR JET SOLENOID COMPENSATION FROM AIR PUMP SOLENOID REAR VIEW A06I0NS TYPICAL This enrichment process of the air/fuel mixture takes place at start-up and during engine warm-up, and it depends on engine temperature.
• Page 141
  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) Following the enrichment mode, carburetors are operating normally, i.e. without additional pressure with- in bowls. NOTE: Calibration is exactly the same on engines with a DPM Module and those without. Compensation Mode A06I0US 1.
• Page 142
  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) FROM CARBURETOR (VENTURI) ACTIVE CALIBRATED JET FROM CARBURETOR (VENTURI) ENRICHMENT AIR JET SOLENOID COMPENSATION FROM FROM AIR SOLENOID CARBURETOR REAR VIEW PUMP (VENTURI) A06I0MS TYPICAL The compensation ratio will depend on the air temperature and the atmospheric pressure. The higher the air temperature, the leaner the air/fuel mixture.

• Page 143: Air Pump Operation

  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) AIR PUMP OPERATION DPM MANIFOLD OPERATION A06I0OA TYPICAL 1. Manifold The DPM manifold consists of 2 tubes. Depend- A06C3WA ing on the mode, the upper tube (distribution gal- 1. Regulator lery) distributes pump pressure or vacuum to 2.

• Page 144
  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) A06I0SA TYPICAL A06E2QA Enrichment Solenoid 1. Engine temperature sensor Solenoid Operating Principle Compensation Solenoid A solenoid is a winding coiled in order to produce NOTE: Read Operating Principle of a Solenoid at a magnetic field.

• Page 145: Testing Procedure

  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) A06I0XA A. 400 ± 50 mm of water A06E2PA 1. Air temperature sensor Manifold Air Jet This jet allows the atmospheric pressure to reach carburetor bowls when the DPM is on standby. See manifold ass’y illustration.

• Page 146
  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) Disconnect engine temperature sensor connec- tor. The DPM module now operates as though the engine temperature was -20°C (-4°F) to allow maximum mixture enrichment. Start the engine and observe the solenoid. A vi- brating solenoid indicates that the module is in good working order.

• Page 147: Fuel Pump

  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) FUEL PUMP All Models From fuel tank carburetors Engine impulse line A30C0JS PARTS FLAT RATE 04-08-25…

• Page 148: Removal

  Section 04 ENGINE Subsection 08 (CARBURETOR AND FUEL PUMP) REMOVAL Fuel pump components should be cleaned in gen- eral purpose solvent and dried with compressed Install a hose pincer (P/N 529 0099 00) on fuel air. supply line close to pump inlet. WARNING Solvent with a low flash point such as gaso- line, naphtha, benzol, etc., should not be used…

• Page 149: Fuel Tank And Throttle Cable

  Section 04 ENGINE Subsection 09 (FUEL TANK AND THROTTLE CABLE) FUEL TANK AND THROTTLE CABLE Fuel Tank Lines Models with Easy Action Throttle Lever WARNING When draining a fuel tank or whenever a fuel line is disconnected, obstruct line with a hose pincher (P/N 529 0099 00) or equivalent device.

• Page 150
  Section 04 ENGINE Subsection 09 (FUEL TANK AND THROTTLE CABLE) Throttle Cable O-ring and Retaining Fuel Level Sensor Ring at Carburetor (some models) Inspection Locate O-ring outside of carburetor cover and re- Visually inspect the condition of connectors and taining ring inside. wiring throughout the circuit.
• Page 151
  Section 05 TRANSMISSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS DRIVE BELT……………………..05-02-1 1998 APPLICATION CHART ………………..05-02-1 ROTATION DIRECTION…………………. 05-02-1 DRIVE BELT DEFLECTION MEASUREMENT …………..05-02-2 DEFLECTION ADJUSTMENT……………….. 05-02-3 DRIVE PULLEY……………………05-03-1 TRA ……………………….. 05-03-1 GENERAL ……………………… 05-03-2 REMOVAL………………………
• Page 152
  Section 05 TRANSMISSION Subsection 01 (TABLE OF CONTENTS) CHAINCASE……………………..05-07-1 REMOVAL ……………………… 05-07-2 INSPECTION ……………………05-07-2 GEAR RATIO MODIFICATION……………….. 05-07-2 INSTALLATION ……………………05-07-2 DRIVE CHAIN ADJUSTMENT……………….. 05-07-3 ADJUSTMENT……………………05-07-4 GEARBOX……………………..05-08-1 DISASSEMBLY ……………………05-08-2 INSPECTION ……………………05-08-2 ASSEMBLY ……………………. 05-08-2 ADJUSTMENT……………………

• Page 153: Drive Belt

  Section 05 TRANSMISSION Subsection 02 (DRIVE BELT) DRIVE BELT 1998 APPLICATION CHART MINIMUM WIDTH PART WIDTH (NEW) MODEL (WEAR LIMIT) ± 0.25 mm (.010 in) NUMBER mm (in) CK3 Series 415 0450 00 35.6 (1.400) 33 (1-19/64) ROTATION DIRECTION The maximum drive belt life span is obtained when the drive belt is installed as shown.

• Page 154: Drive Belt Deflection Measurement

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

• Page 155: Deflection Adjustment

  Section 05 TRANSMISSION Subsection 02 (DRIVE BELT) A06D20A A00D08A 1. Allen screw with jam nut 1. Upper O-ring 2. Force Allen screws must be restrained while tightening 3. Lower O-ring 4. Reference rule jam nut to prevent throwing adjustment out. Use 5.

• Page 156: Drive Pulley

  Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) DRIVE PULLEY All Models NOTE: This is a lubrication free drive pulley. Loctite 271 27 N•m (20 lbf•ft) Loctite 12 N•m (106 lbf•in) GT 700/SE only Loctite 13 N•m (115 lbf•in) 10 N•m (89 lbf•in) Loctite 95 N•m…

• Page 157: General

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

• Page 158: Disassembly

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

• Page 159: Cleaning

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

• Page 160
  Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) 24,25, O-ring and Slider Shoe Apply retaining compound Loctite 648 outside of bushing then press it down to counterbore from Check if O-rings are cracked, cut or crushed. Re- outside end. Use spring compressor (P/N 529 place as required.

• Page 161: Assembly

  Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) ASSEMBLY Position dowel tube split at the illustrated angle. NOTE: This drive pulley is lubrication free. Do not 30 ± 5° lubricate any component. 1,2,3, Screw, Ring Gear and Loctite 271 Apply Loctite 271 (P/N 413 7029 00) on threads and then torque to 27 N•m (20 lbf•ft).

• Page 162
  Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) A16D0BA A16D0DA 1. Head on top 1. Align 2. All on the same side Install and torque screws to 13 N•m (115 lbf•in). CAUTION 6,25,29, Sliding Half, Slider Shoe and Governor Cup Lever assemblies must be installed so that cotter pins are on the same side.

• Page 163: Installation

  Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) CAUTION CAUTION Make sure O-rings are installed on slider Make sure splines of both parts are fully en- shoes and their grooves are positioned ver- gaged. tically. INSTALLATION Install fork (P/N 529 0055 00) into slider shoe grooves to maintain them for governor cup instal- lation.

• Page 164: Drive Pulley Adjustment

  Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) Accelerate the vehicle at low speed (maximum 30 Governor cup has 6 positions numbered 2 to 6. km/h (20 MPH) and apply the brake, repeat 5 Note that in position 1 there is no stamped num- times.

• Page 165
  Section 05 TRANSMISSION Subsection 03 (DRIVE PULLEY) A16D0HA 1. Loosen just enough to permit rotating of calibration screw 05-03-10…

• Page 166: Driven Pulley

  Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) DRIVEN PULLEY CK3 Series Anti-seize lubricant Anti-seize lubricant Anti-seize lubricant Loctite Loctite 609 Some models only 24 N•m (18 lbf•ft) Some models only A30D0GS PARTS FLAT RATE 05-04-1…

• Page 167: Removal

  Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) REMOVAL 529 0186 00 Remove belt guard and drive belt from vehicle. Remove cap screw no. 13, lock washer no. 12 and shouldered washer no. 11 then pull the driv- en pulley from the countershaft. Note shouldered washer position for reinstalla- tion.

• Page 168: Inspection

  Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) INSPECTION 9,10, Bushings Check for cracks, scratch and for free movement when assembled to fixed half. Using a dial bore gauge measure bushing diame- ter. Measuring point must be at least 5 mm (1/4 in) from bushing edge.

• Page 169: Assembly

  Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) Heat bushing area. 529 0311 00 Turn puller handle and sliding half at once to ex- tract the bushing. 529 0313 00 529 0312 00 A03D1WC 1. Support plate A03D1YA 2. Puller IMPORTANT: Large bushing retaining screws and Mount puller screw head in a vise.

• Page 170: Installation

  Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) 5, Cam Take 1 measurement when sliding half begins to turn. Rotate sliding half to 10 mm (3/8 in) of rota- Coat cam interior with anti-seize lubricant. tion. Hold fish scale at this position. Slowly re- lease tension from fish scale and take 2 mea- INSTALLATION…

• Page 171
  Section 05 TRANSMISSION Subsection 04 (DRIVEN PULLEY) 5, Outer Cam Make sure to install proper cam. Refer to TECHNI- CAL DATA 10-03. Cam angle is identified on cam. 3 2 1 44° A18C0AA Letters and numbers shown in illustration are actual letters and numbers embossed on parts NOTE: Always recheck torsional pre-load after ad- justing.

• Page 172: Pulley Distance And Alignment

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

• Page 173: Pulley Alignment And Distance Specifications Chart

  Section 05 TRANSMISSION Subsection 05 (PULLEY DISTANCE AND ALIGNMENT) Drive Belt Deflection NOTE: When pulley distance and alignment are adjusted to specifications, refer to DRIVE BELT 05-02 to adjust drive belt deflection. CAUTION This section deals mainly with adjustment procedures. For complete assembly require- ments, refer to the proper ENGINE or TRANS- MISSION installation section.

• Page 174
  Section 05 TRANSMISSION Subsection 05 (PULLEY DISTANCE AND ALIGNMENT) Pulley Distance Adjustment Method Engine Movement The engine support has slotted mounting holes. Move engine to obtain specified distance be- tween pulleys. Pulley Alignment Method Engine Movement Loosen the 4 bolts retaining engine support to the frame.

• Page 175: Brake

  Section 05 TRANSMISSION Subsection 06 (BRAKE) BRAKE HYDRAULIC DISC BRAKE 37 N•m (27 lbf•ft) Anti-seize lubricant Anti-seize lubricant A30D0OS PARTS FLAT RATE 05-06-1…

• Page 176: Removal

  Section 05 TRANSMISSION Subsection 06 (BRAKE) REMOVAL BRAKE DISC REMOVAL Brake disc can be withdraw without removing cal- iper. Proceed as follows: – Remove belt guard, belt and driven pulley. – Remove air silencer. – Unbolt bearing support no. 4 from chassis. –…

• Page 177: Adjustment

  Section 05 TRANSMISSION Subsection 06 (BRAKE) Push on appropriate caliper piston in order to CAUTION move pad inward allowing proper brake disc posi- tioning. Upper sprocket castellated nut must be tightened before bolting bearing support. Close chaincase. BLEEDING Change brake fluid once a year. Bleed brake system as follows: Keep sufficient DOT 4 (DOT 3 for normal use) brake fluid in reservoir at all times.

• Page 178: Chaincase

  Section 05 TRANSMISSION Subsection 07 (CHAINCASE) CHAINCASE Synthetic chaincase Lithium grease Loctite 45 to 75 N•m (33 to 55 lbf•ft) Loctite Loctite Synthetic chaincase 44 N•m SYNTHETIC CHAINCASE OIL HUILE SYNTHÉTIQUE POUR CARTER (32 lbf•ft) Loctite A30D0LS PARTS FLAT RATE 05-07-1…

• Page 179: Removal

  Section 05 TRANSMISSION Subsection 07 (CHAINCASE) REMOVAL Using 2 large screwdrivers inserted between chaincase no. 7 and frame, pry complete assem- To remove chaincase proceed as follows. bly from vehicle. Remove tuned pipes and muffler. INSPECTION WARNING Visually inspect the chain for cracked, damaged or missing links.

• Page 180: Drive Chain Adjustment

  Section 05 TRANSMISSION Subsection 07 (CHAINCASE) 5,16, Sprockets This initial adjustment should provide 3-5 mm (1/8-13/64 in) free-play when measured at the out- Position the sprockets with the writing facing the er circumference of the brake disc. chaincase cover. CAUTION 4, Upper Sprocket Castellated Nut Torque to 45 to 75 N•m (33 to 55 lbf•ft).

• Page 181: Adjustment

  Section 05 TRANSMISSION Subsection 07 (CHAINCASE) NOTE: Chaincase must be in its proper position when checking oil level. ADJUSTMENT Pulley Alignment Refer to PULLEY DISTANCE AND ALIGNMENT 05-05. Track Tension and Alignment Refer to TRACK 07-04. 05-07-4…

• Page 182: Gearbox

  Section 05 TRANSMISSION Subsection 08 (GEARBOX) GEARBOX All CK3 Models with a Reverse Loctite 242 Synthetic chaincase 5 N•m Loctite 271 (44 lbf•in) A30D0NS PARTS FLAT RATE 05-08-1…

• Page 183: Disassembly

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

• Page 184
  Section 05 TRANSMISSION Subsection 08 (GEARBOX) Install drive axle with track then bearing and circlip Install chain no. 28, sprocket no. 34 and its spac- in chaincase bore. Install spacer no. 38 with its er no. 38. Spacer’s large outer diameter must be large outer diameter against sprocket, sprocket against sprocket.

• Page 185: Adjustment

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

• Page 186: Drive Chain

  Section 05 TRANSMISSION Subsection 09 (DRIVE CHAIN) DRIVE CHAIN SILENT CHAIN All CK3 models are equipped with a 13-plate wide silent chain. Fit chain on sprockets to make sure using right ones according to width. Refer to TECHNICAL DATA 10. NOTE: No work (separation, lengthening) can be done on the silent chain type.

• Page 187
  Section 06 ELECTRICAL Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS IGNITION TIMING ……………………. 06-02-1 NIPPONDENSO TRIGGER COIL SYSTEM……………. 06-02-1 SPARK PLUGS……………………06-03-1 NGK SPARK PLUG………………….06-03-1 NGK SPARK PLUG NUMBERING SYSTEM …………..06-03-1 REFERENCE CHART ………………….06-03-1 DESIGN SYMBOLS USED IN NGK SPARK PLUGS…………06-03-2 DISASSEMBLY……………………
• Page 188
  Section 06 ELECTRICAL Subsection 01 (TABLE OF CONTENTS) 5. TRIGGER COIL TESTING ………………..06-06-4 6. IGNITION MODULE VOLTAGE TESTING …………..06-06-4 7. HIGH VOLTAGE COIL VOLTAGE TESTING …………..06-06-5 8. MPEM SUPPLY VOLTAGE TESTING …………….06-06-5 9. MPEM TESTING ………………….06-06-5 CONCLUSION……………………

• Page 189: Ignition Timing

  Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) IGNITION TIMING NIPPONDENSO TRIGGER COIL SYSTEM Ignition timing is adjusted by movement of trigger coil. Raising position of trigger coil retards igni- tion. Lowering position of trigger advances igni- tion. CAUTION Each time ignition timing is adjusted by mov- ing trigger coil, air-gap must be adjusted.

• Page 190
  Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) b. Rotate the dial face so that “0” is in line with the needle when it stops moving. c. Again, slowly rotate the magneto flywheel back and forth across TDC and adjust the dial face to “0”, until the needle always stops ex- actly at “0”…
• Page 191
  Section 06 ELECTRICAL Subsection 02 (IGNITION TIMING) Checking Ignition Timing Use timing light (P/N 529 0319 00). To check the ignition timing, refer to illustration and proceed as follows: NOTE: Engine should be cold when checking tim- ing. Do not idle engine for more than 20 seconds and make checks quickly.

• Page 192: Spark Plugs

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

• Page 193: Design Symbols Used In Ngk Spark Plugs

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

• Page 194: Disassembly

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

• Page 195: Spark Plug Installation

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

• Page 196: Battery

  Section 06 ELECTRICAL Subsection 04 (BATTERY) BATTERY REMOVAL All Models All Models WARNING Battery BLACK negative cable must always be disconnected first and connected last. WARNING Never charge or boost battery while installed on vehicle. Air Intake Silencer Removal A30C09A Grand Touring SE Only 1.

• Page 197: Inspection

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

• Page 198: Battery Storage

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

• Page 199
  Section 06 ELECTRICAL Subsection 04 (BATTERY) 5. Readjust the electrolyte level to the UPPER LEVEL line. A17E0FA 1. Battery electrolyte A17E0RA 2. Remove caps and fill battery to UPPER LEVEL 1. Battery electrolyte line with electrolyte (specific gravity: 1.260 at 20°C (68°F)).
• Page 200
  Section 06 ELECTRICAL Subsection 04 (BATTERY) 7. Disconnect battery charger. A17E0HA A17E0IB 11. Readjust electrolyte level. 8. Test battery state of charge. Use a hydrometer. A17E0JA A17E0RA 1. Specific gravity 1.260 1. Battery electrolyte 9. Let battery settle for 1 hour. 12.

• Page 201: Servicing

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

• Page 202: Battery Charging Equipment

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

• Page 203
  Section 06 ELECTRICAL Subsection 04 (BATTERY) A30E0AA A30E0CA 1. Move RED positive cable and wire 1. BLACK negative (–) battery cable and wires positioning Connect RED positive cable and RED wire to pos- itive battery terminal. Refer to the following photo WARNING for proper cable positioning.

• Page 204: Electric Starter

  Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) ELECTRIC STARTER A30E0GS PARTS FLAT RATE 06-05-1…

• Page 205: Removal

  Section 06 ELECTRICAL Subsection 05 (ELECTRIC STARTER) REMOVAL – Disconnect BLACK ground cable from battery. – Disconnect RED positive cable from battery. – Disconnect RED cable from starter solenoid switch. – Remove starter from engine. CAUTION Support drive housing adequately to pre- vent damage when pressing bushing.

• Page 206: Testing Procedure

  Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) TESTING PROCEDURE GENERAL The Bombardier 360 W MPEM receives DC elec- tricity produced by the unique coil. The following chart gives the engine types with their implemented system. CHARGING ENGINE IGNITION SYSTEM TYPE SYSTEM OUTPUT 599, 699…

• Page 207: System Testing

  Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) SYSTEM TESTING IGNITION SYSTEM TESTING Resistance Readings Place multimeter selector switch to Ω in order to SEQUENCE measure resistance. Readings must be within the In the case of ignition problems, check the follow- indicated range.

• Page 208: Ignition Switch, Tether Cord Switch And Emergency Switch Testing

  Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) 3. IGNITION SWITCH, TETHER CORD SWITCH AND EMERGENCY SWITCH TESTING Disconnect connector housing from engine and check resistance as indicated in IGNITION table. A30E0MA TYPICAL — HARNESS REMOVED FOR CLARITY 1. 10-03 housing disconnected 2.

• Page 209: Ignition Generator Coil Voltage Testing

  Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) 5. TRIGGER COIL TESTING All Models Resistance Testing 1. Connect probes to WHITE/YELLOW and BLUE/ YELLOW wires from trigger coil 10-04 housing. 2. Activate the manual starter and check values in- dicated by the multimeter. 3.

• Page 210: High Voltage Coil Voltage Testing

  6. Compare readings with those appearing in the IGNITION table. 8. MPEM SUPPLY VOLTAGE TESTING Grand Touring 700/SE only 1. Disconnect the 10-05 and 10-01 housings be- tween module and main harness. 2. Connect multimeter probes to RED/BLUE and BLACK wires coming out from harness. Place V ˜…

• Page 211: Conclusion

  TESTING Resistance column of the IGNITION table. Set the multimeter as indicated. Grand Touring 700/SE Only All accessories are supplied with electricity only LIGHTING GENERATOR COIL when engine is running at 800 RPM or faster.

• Page 212
  Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) A30E0TA 1. Cap 2. Connect bypass wires (P/N 529 0333 00) to the harness housing. Install cap on the other by- pass housing. A30E0UA 1. Bypass wires connected 2. Cap in unoccupied housing 3.
• Page 213
  Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) IGNITION SYSTEM TESTING (CK3 series — 290 W) Resistance Ω Voltage V Multimeter Test to be Wire Part probe Note Value Multimeter Value Multimeter performed color connection (Ohms) scale (Volts) scale Stop switch Running BK and 10-05-2-F…
• Page 214
  Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) LIGHTING SYSTEM TESTING (CK3 series — 290 W) Resistance Ω Voltage V Multimeter Test to be Wire Part probe Note Value Multimeter Value Multimeter performed color connection (Ohms) scale (Volts) scale Lighting 2-01B-F YL and 00.0 — 00.0…
• Page 215
  Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) IGNITION SYSTEM TESTING (CK3 series — 360 W) Resistance Ω Voltage V Multimeter Test to be Wire Part probe Note Value Multimeter Value Multimeter performed color connection (Ohms) scale (Volts) scale Stop Running BK and 10-01B-F No stop switch must be…
• Page 216
  Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) LIGHTING SYSTEM TESTING (CK3 series — 360 W) Resistance Ω Voltage V Multimeter Test to be Wire Part probe Note Value Multimeter Value Multimeter performed color connection (Ohms) scale (Volts) scale Lighting 2-01(A,B,C)-F 00.0 — YL and 3.5 — 5.5…

• Page 217: Inspection Of Ac Circuit Isolation

  Section 06 ELECTRICAL Subsection 06 (TESTING PROCEDURE) INSPECTION OF AC CIRCUIT ISOLATION All CK3 Models If AC circuit is not isolated from frame, headlamp beam will weaken. INSPECTION Disconnect regulator/rectifier. Connect one digital ohmmeter probe (needle ohmmeter will not offer enough precision) to frame and other probe to one of 2 YELLOW mag- neto wires.

• Page 218: Inspection Of Heating Elements

  14.95 ohms BROWN YELLOW wire INTENSITY ORANGE wire 10.67 ohms Grand Touring and Mach Z Series Grand Touring 700/SE YELLOW/BLACK wire RED/YELLOW wire 53 to 63 ohms 6.5 to 8 ohms BROWN wire ORANGE wire When measuring resistance at terminals the…

• Page 219
  Section 07 REAR SUSPENSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS SC-10 SUSPENSION ………………….07-02-1 COMPONENT REMOVAL AND INSTALLATION ………….. 07-02-3 REMOVAL……………………… 07-02-5 DISASSEMBLY AND ASSEMBLY ………………07-02-5 SHOCK ABSORBER INSPECTION ………………07-02-7 INSTALLATION ……………………07-02-8 RIDE ADJUSTMENT………………….07-02-8 LUBRICATION ……………………

• Page 220: Sc-10 Suspension

  Section 07 REAR SUSPENSION Subsection 02 (SC-10 SUSPENSION) SC-10 SUSPENSION SC-10 High-performance on All CK3 Models Front temp. grease Loctite Loctite Loctite Loctite Lithium grease Loctite A03F28T PARTS FLAT RATE 07-02-1…

• Page 221
  Section 07 REAR SUSPENSION Subsection 02 (SC-10 SUSPENSION) Air Suspension Components on GT SE Only A30F05S PARTS FLAT RATE 07-02-2…

• Page 222: Component Removal And Installation

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

• Page 223
  Section 07 REAR SUSPENSION Subsection 02 (SC-10 SUSPENSION) 25, ACM Support Remove threaded rod ass’y. Loosen rear axle screw on one side and rear shackle screws. Unbolt ACM support and remove it. Remove cup. 15, Rear Shock Lift rear of vehicle. Slightly turn adjusting cam to expose spring end.

• Page 224: Removal

  Section 07 REAR SUSPENSION Subsection 02 (SC-10 SUSPENSION) At reassembly, wheel circlip must face outward. 7, Screw Unscrew rear arm top axle from chassis. REMOVAL NOTE: To prevent axle from turning when un- 19, Cam screwing screws assembled with threadlocker, proceed as follows: Decrease spring preload by turning LH cam clock- –…
• Page 225
  Section 07 REAR SUSPENSION Subsection 02 (SC-10 SUSPENSION) Close and lock bar. Adjust handle horizontal by changing position of clevis pin. Push down on handle until it locks. Remove spring stopper and cap then release handle. A03F13A 1. Stroke limiter on rear side 8,9, Pivot Arm and Flat Washer At installation pivot arm grease fitting must face rearward.

• Page 226: Shock Absorber Inspection

  Section 07 REAR SUSPENSION Subsection 02 (SC-10 SUSPENSION) 20, Stopper Strap Replace slider shoes when wear limit is reached. Inspect strap for wear or cracks, bolt and nut for CAUTION tightness. If loose, inspect hole for deformation. Replace as required. Make sure it is attached Slider shoes must always be replaced in through proper hole from the end.

• Page 227: Installation

  Section 07 REAR SUSPENSION Subsection 02 (SC-10 SUSPENSION) Push down on rod and note its resistance, com- CAUTION pare to a new shock. If shock is frozen it will be much more difficult to compress than for the new Do not clamp directly on shock body. one.

• Page 228: Lubrication

  Section 07 REAR SUSPENSION Subsection 02 (SC-10 SUSPENSION) LUBRICATION Lubricate front and rear arms at grease fittings us- ing synthetic grease (P/N 413 7115 00). A03F1SB SC-10 HP: 7 GREASE FITTINGS 1. Only the GT 700/SE and all LT versions have this 8 grease fitting 07-02-9…

• Page 229: Drive Axle

  Section 07 REAR SUSPENSION Subsection 03 (DRIVE AXLE) DRIVE AXLE Lithium grease Synthetic grease A30D0MS PARTS FLAT RATE 07-03-1…

• Page 230: Removal

  Section 07 REAR SUSPENSION Subsection 03 (DRIVE AXLE) REMOVAL 9,13, Sprocket and Half-Sprocket To remove press fit sprockets, use a press and a Drain oil from chaincase. Release drive chain ten- suitable support as illustrated. sion. Remove chaincase cover. Raise and block rear of vehicle off the ground. Remove suspension.

• Page 231
  Section 07 REAR SUSPENSION Subsection 03 (DRIVE AXLE) CK3 Series A00F0AA 1. Plane surface A. 1.5 mm (1/16 in) MAXIMUM CAUTION The same sprocket must not be pressed twice on the axle. If synchronization is found A06D1XA to be defective, use a new sprocket. A.

• Page 232: Axial Play

  Section 07 REAR SUSPENSION Subsection 03 (DRIVE AXLE) 5,12, Bearing Wrong chaincase perpendicularity will make it dif- ficult to correctly install the bearing in its support Always push bearing by inner race. due to the countershaft and support misalign- ment. A00F0DA The bearing on the splined side of axle must be pushed until it is seated on shaft shoulder.

• Page 233
  Section 07 REAR SUSPENSION Subsection 03 (DRIVE AXLE) A01D08A 1. Distance between sprocket and tunnel 2. Drive axle pushed toward chaincase A01D07A TYPICAL 1. Upper shim location 2. 50 mm long screws when installing one shim or more 3. Lower shim location –…

• Page 234: Installation

  Section 07 REAR SUSPENSION Subsection 03 (DRIVE AXLE) SHIM POSITION – To center, grasp the track suspension and move it sideways, left and right. Position the track Shim position is important to maintain proper suspension at the midpoint of its sideways move- sprocket alignment.

• Page 235: Lubrication

  Section 07 REAR SUSPENSION Subsection 03 (DRIVE AXLE) LUBRICATION 15, Grease Fitting Lubricate end housing bearing with low tempera- ture grease (P/N 413 7061 00). ADJUSTMENT Sprocket/Track Alignment CAUTION Do not temper with sprocket/track alignment A00F0GA if frame or suspension is damaged. SIDE VIEW 1.

• Page 236: Track

  Section 07 REAR SUSPENSION Subsection 04 (TRACK) TRACK TRACK TYPE APPLICATION INSTALLATION Refer to TECHNICAL DATA section 10. 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 237
  Section 07 REAR SUSPENSION Subsection 04 (TRACK) A19F05A TYPICAL A01B4KA 1. Retaining screw 2. Adjuster bolt TYPICAL 1. Line Alignment NOTE: Lightly oil track tension gauge center pin to avoid sticking. WARNING All Models Before checking track tension, ensure that Refer to TECHNICAL DATA 10 for proper tension the track is free of all particles which could values.
• Page 238
  Section 07 REAR SUSPENSION Subsection 04 (TRACK) Track Cleat WARNING Removal Before checking track alignment, ensure that – Raise rear of vehicle off the ground and lift snow- the track is free of all particles which could guard then rotate track to expose a cleat to be be thrown out while track is rotating.
• Page 239
  Section 08 STEERING/FRONT SUSPENSION Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS STEERING SYSTEM ………………….08-02-1 DISASSEMBLY AND ASSEMBLY ………………08-02-2 INSPECTION ……………………08-02-6 STEERING ADJUSTMENT (SKIS) ………………08-02-7 LUBRICATION ……………………08-02-10 SUSPENSION AND SKI SYSTEM ………………08-03-1 DISASSEMBLY……………………08-03-2 INSPECTION ……………………

• Page 240: Steering System

  Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) STEERING SYSTEM CK3 Series 53 N•m (39 lbf•ft) Lithium grease 10 N•m 48 N•m (89 lbf•in) (35 lbf•ft) Loctite 271 Lithium grease 53 N•m (39 lbf•ft) 15 N•m 53 N•m (133 lbf•in) (39 lbf•ft) 18 N•m (159 lbf•in)

• Page 241: Disassembly And Assembly

  Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) DISASSEMBLY AND ASSEMBLY 13, Grip Grips must be carefully removed to prevent dam- aging the heating elements. Heat grip with a heat gun. Apply tape to handlebar near the grip to protect paint.

• Page 242
  Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) Heat the grip with a heater gun or a spot light to ease installation. Insert new grip with compressed air. A30G0IA 1. Lock washer glued in place Cut locking tie retaining brake line and throttle ca- A30G0NA ble to steering column.
• Page 243
  Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) A30G0CA 1. Unbolt console Detach the short tie rod (under the engine) from A30G0GA the steering column. Note that a hardened flat 1. U-bolt nuts washer no. 7 goes on each side of steering col- umn lever.
• Page 244
  Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) The ball joint should be restrained when tighten- ing the tie rod end lock nut. Align it so the tie rod end is parallel to the steering arm when assem- bled on the vehicle, refer to the following illustra- tion.

• Page 245: Inspection

  Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) 7, Hardened Washer INSPECTION Install a hardened washer on each side of the arm. Check skis and runner shoes for wear, replace as necessary. Refer to FRONT SUSPENSION 08-03. 12, Steering Arm Make sure steering arm and ski leg splines inter- lock.

• Page 246: Steering Adjustment (Skis)

  Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) STEERING ADJUSTMENT (SKIS) Definitions TOE-OUT: A difference measured between the front edge of the skis “A” and rear edge “B” as viewed from the top. It is adjustable. For all CK3 models, toe- out is measured at 220 mm (8-21/32 in) from ski pivot bolt axis.

• Page 247
  Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) 8,17,18,21, Tie Rod, Ball Joint and WARNING Bracket Never lengthen this tie rod so that threaded Remove steering pad. portion of ball joint exceeds 34 mm (1-11/32 in). Turn handlebar all the way to the right. Check that the right side bracket no.
• Page 248
  Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) Using special tool (P/N 529 0216 00) mounted to the ski leg, position the angle finder on the tool as shown in the following illustration. An alternate lo- cation for the angle finder if the special tool is not available is the outside of the ski leg housing.

• Page 249: Lubrication

  Section 08 STEERING/FRONT SUSPENSION Subsection 02 (STEERING SYSTEM) Toe-out must be as specified when skis are in a straight-ahead position and the front of vehicle is lifted off the ground. TOTAL TOE-OUT MODEL + 3 mm (+ 1/8 in) — 0 mm (- 0 in) Formula III 600 LT/700 GT 700/SE 12 (1/2)

• Page 250: Suspension And Ski System

  Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) SUSPENSION AND SKI SYSTEM CK3 Series 48 N•m (35 lbf•ft) 48 N•m (35 lbf•ft) Super Lube Loctite Loctite 48 N•m (35 lbf•ft) 48 N•m (35 lbf•ft) 35 N•m Synthetic (26 lbf•ft) Grease 48 N•m (35 lbf•ft)

• Page 251: Disassembly

  Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) DISASSEMBLY 5, Shock Lift front of vehicle and support it off the ground. Reduce spring preload by turning adjusting ring accordingly with the adjustment wrench in vehi- cle tool box. A01B4LA 1.

• Page 252: Inspection

  Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) Check skis and runners no. 10 for wear, replace as necessary. Check condition of ski stopper no. 9. Replace it when deteriorated. To check condition of shock, refer to SC-10 SUS- PENSION 07-02 then look for Shock Absorber Inspection.

• Page 253: Adjustment

  Section 08 STEERING/FRONT SUSPENSION Subsection 03 (SUSPENSION AND SKI SYSTEM) ADJUSTMENT 6, Stopper Adjust stopper against ski stopper to reduce dart- ing (unwanted vehicle side-to-side movement). A16G0AC 1. Loosen nut, adjust stopper against ski stopper then retighten nut to 14 N•m (124 lbf•in) 08-03-4…

• Page 254
  Section 09 BODY/FRAME Subsection 01 (TABLE OF CONTENTS) TABLE OF CONTENTS BODY……………………….09-02-1 INSTALLATION AND ADJUSTMENT …………….09-02-1 HEADLAMP BEAM AIMING………………..09-02-1 BULB REPLACEMENT ………………….. 09-02-1 DECAL ……………………..09-02-2 WINDSHIELD INSTALLATION………………. 09-02-2 HOOD ……………………..09-02-2 HALF BOTTOM PAN………………….09-02-3 BELT GUARD ……………………09-02-4 WIRING HARNESS ………………….

• Page 255: Body

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

• Page 256: Decal

  Section 09 BODY/FRAME Subsection 02 (BODY) WINDSHIELD INSTALLATION When peeling off the protective film some poly- ethylene particles may remain on the windshield. A soft clean cloth moistened with naphtha (camp- ing equipment fuel) will easily remove the remain- ing particles. WARNING Naphtha is flammable and explosive under certain conditions.

• Page 257: Half Bottom Pan

  Section 09 BODY/FRAME Subsection 02 (BODY) A30H17A A30H1AA Unplug wiring harnesses then retaining cables. 1. Bottom pan protector Remove hinge pins and hood. 2. Footrest 3. Tunnel HALF BOTTOM PAN Remove hood. Remove tuned pipes and tail pipes. Remove muf- fler when RH side half bottom pan has to be re- moved.

• Page 258: Belt Guard

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

• Page 259: Plastic Maintenance

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

• Page 260: Frame

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

• Page 261
  Section 09 BODY/FRAME Subsection 03 (FRAME) CAUTION High speed drilling will cause excessive heat which may destroy the cutting edge of the bit, therefore avoid using pneumatic drills. Grinding Procedure Rear Cap Grind rivet heads from top of rear cap and under- neath for side retaining rivets.
• Page 262
  Section 10 TECHNICAL DATA Subsection 01 (SI METRIC INFORMATION GUIDE) TECHNICAL DATA SI* METRIC INFORMATION GUIDE BASE UNITS DESCRIPTION UNIT SYMBOL length …………… meter ……….. mass …………..kilogram ……….force …………..newton ……….liquid …………..liter …………temperature …………. Celsius ……….°C pressure …………
• Page 263
  Section 10 TECHNICAL DATA Subsection 02 (ENGINES) GRAND TOURING GRAND TOURING FORMULA III FORMULA III VEHICLE MODEL 600/600 R/600 LT 700/700 R ENGINE TYPE Number of Cylinders Bore mm (in) 69.75 (2.746) 69.75 (2.746) 64.5 (2.5394) 69.75 (2.746) Stroke mm (in) 61.0 (2.402) 61.0 (2.402) 61.0 (2.402)
• Page 264
  Section 10 TECHNICAL DATA Subsection 02 (ENGINES) MACH Z/Z R/Z LT/Z VEHICLE MODEL MACH 1/1 R LT R ENGINE TYPE Number of Cylinders Bore mm (in) 69.75 (2.746) 70.50 (2.776) Stroke mm (in) 61.0 (2.402) 68.0 (2.677) Displacement 699.25 (42.67) 796.3 (48.59) Compression Ratio (corrected) Maximum Power Engine Speed…
• Page 265
  Section 10 TECHNICAL DATA Subsection 03 (VEHICLES) GRAND TOURING GRAND TOURING VEHICLE MODEL FORMULA III 600 FORMULA III 600 R ENGINE TYPE Chain Drive Ratio 24/44 24/44 25/43 25/44 Pitch Chain Type/Links Qty/Plates Qty Silent 72/13 Silent 72/13 Silent 72/13 Silent 72/13 Type of Drive Pulley Ramp Identification and Roller Pin Type…
• Page 266
  Section 10 TECHNICAL DATA Subsection 03 (VEHICLES) VEHICLE MODEL FORMULA III 600 LT FORMULA III 700 FORMULA III 700 R MACH 1 ENGINE TYPE Chain Drive Ratio 23/43 26/43 26/44 26/43 Pitch Chain Type/Links Qty/Plates Qty Silent 72/13 Silent 72/13 Silent 74/13 Silent 72/13 Type of Drive Pulley…
• Page 267
  Section 10 TECHNICAL DATA Subsection 03 (VEHICLES) VEHICLE MODEL MACH 1 R MACH Z MACH Z R MACH Z LT ENGINE TYPE Chain Drive Ratio 26/44 27/43 27/44 25/43 Pitch Chain Type/Links Qty/Plates Qty Silent 74/13 Silent 72/13 Silent 74/13 Silent 72/13 Type of Drive Pulley Ramp Identification and Roller Pin Type…
• Page 268
  Section 10 TECHNICAL DATA Subsection 03 (VEHICLES) MACH Z LT SV VEHICLE MODEL MACH Z LT R TRACK ENGINE TYPE Chain Drive Ratio 23/43 25/44 Pitch Chain Type/Links Qty/Plates Qty Silent 72/13 Silent 72/13 Type of Drive Pulley Ramp Identification and Roller Pin Type Calibration Screw Position or Calibration Disc Quantity Drive Pulley…
• Page 269
  Section 10 TECHNICAL DATA Subsection 04 (TECHNICAL DATA LEGENDS) ENGINE LEGEND VEHICLE LEGEND BTDC: Before Top Dead Center DSA: Direct Shock Action CDI: Capacitor Discharge Ignition TPO: Thermo Plastic Olefin CTR: Center TRA: Total Range Adjustable Kilo (× 1000) N.A.: Not Applicable MAG: Magneto Side Minimum allowable width may not be less than…
• Page 270
  Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) WIRING DIAGRAMS ELECTRICAL WIRING HEADLIGHT TAILLIGHT SYSTEM MODEL DIAGRAM (watt) (watt) OUTPUT PAGE (watt) Formula III 600/600 R/ 600 LT/700/700 R Annex 1 60/55 hal. 8/27 Mach 1/1 R Mach Z/Z R/Z LT/Z LT R Annex 2 60/55 hal.
• Page 271
  Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) A06H33B AREA LOCATION Front of engine compartment Magneto Carburetors Near of intake silencer Near driven pulley Under console Under hood Near fuel tank Rear of seat Under engine CONNECTOR LOCATION IN HOUSING XX/XX 1-02D A00I04D…
• Page 272
  Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) A30E0HS PARTS FLAT RATE 11-01-3…
• Page 273
  Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) SYMBOLS DESCRIPTION Beam and tail light Female terminal Male terminal Electronic module Meter Electric motor Low level sensor Buzzer Ignition coil Normally close Normally open Male terminal switch switch on instrument Engine Frame Spark plug Meter movement…
• Page 274
  Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) UNPLUGING CONNECTORS To remove: – Insert a screwdriver or Snap-on TT 600-5 from Always unplug connectors by pulling on housing opposite side of wire and pry locking tab. not on wire. – While holding locking tab pried, pull connector toward wire side.
• Page 275
  Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Waterproof Connector Housing Female Connector Housing To remove: – Insert tool Snap-on TT 600-5 under lock and twist to lift it. A01E34A 1. Lock – Pry tab to free connector then pull wire out of housing.
• Page 276
  Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) A00E1FA TYPICAL 1. Receptacle 2. Housing ACCESSORIES INSTALLATION On all electric start models: The direct current (DC) utilizes the snowmobile frame as ground “wire” while all alternating current (AC) consum- ers (lights, heated grips, fuel gauge, etc.) utilize a separate ground wire.