2001 Ski Doo PDF

2001
Shop Manual
VOLUME 1
SKANDIC LT/WT/SWT/WT LC
TOURING CARGO 380/500
TOURING FAN 380/500
FORMULA DELUXE FAN 380/500
MX Z FAN 380/440/500
SUMMIT FAN 500
Legal deposit:
National Library of Quebec
3rd trimester 2000
National Library of Canada 2000
All rights reserved. No parts of this manual may be reproduced in any
form without the prior written permission of Bombardier Inc.
©Bombardier Inc. 2000
Technical Publications
Bombardier Inc.
Valcourt (Quebec) Canada
Printed in Canada
®*Registered trademarks of Bombardier Inc.
This document contains the trademarks of the following companies:

Crest® is a trademark of Crest Industries Inc.
Comet® is a trademark of Hoffco/Comet Industries Inc.
Kimtowels® is a trademark of Kimberly-Clark
Loctite® is a trademark of Loctite Corporation
Molykote® is a trademark of Dow Corning Corporation
Silastic® is a trademark of Dow Corning Corporation
Snap-on® is a trademark of Snap-on Tools Corporation
Versilube® is a trademark of General Electric Company
SupertaniumTM is a trademark of Premier Industrial Corporation
TABLE OF CONTENTS
SECTION SUBSECTION PAGE
SAFETY NOTICE .................................................................................................................................. III
WHAT’S NEW ....................................................................................................................................... IV
INTRODUCTION .................................................................................................................................. V
01 SERVICE TOOLS AND 01 – Service tools............................................................................. 01-01-1

SERVICE PRODUCTS 02 – Service products....................................................................... 01-02-1
02 LUBRICATION 01 – Lubrication and maintenance chart .......................................... 02-01-1

AND MAINTENANCE
03 TROUBLESHOOTING 01 – Table of contents...................................................................... 03-01-1

02 – Engine ...................................................................................... 03-02-1
03 – Fuel and oil systems................................................................. 03-03-1
04 – Transmission and brake systems ............................................. 03-04-1
05 – Electrical system ...................................................................... 03-05-1
06 – Suspension and track ............................................................... 03-06-1
04 ENGINE 01 – Table of contents...................................................................... 04-01-1

02 – 377, 443 and 503 engine types ................................................ 04-02-1
03 – 593 engine type ....................................................................... 04-03-1
04 – Leak test and engine dimension measurement ....................... 04-04-1
05 – CDI system............................................................................... 04-05-1
06 – Oil injection system.................................................................. 04-06-1
07 – Axial fan cooling system........................................................... 04-07-1
08 – Liquid cooling system............................................................... 04-08-1
09 – Rewind starter.......................................................................... 04-09-1
10 – Carburetor and fuel pump ........................................................ 04-10-1
11 – Fuel tank and throttle cable ...................................................... 04-11-1
05 TRANSMISSION 01 – Table of contents...................................................................... 05-01-1

02 – Drive belt .................................................................................. 05-02-1
03 – Drive pulley............................................................................... 05-03-1
04 – Driven pulley............................................................................. 05-04-1
05 – Pulley distance and alignment.................................................. 05-05-1
06 – Brake ........................................................................................ 05-06-1
07 – Chaincase ................................................................................. 05-07-1
08 – Gearbox .................................................................................... 05-08-1
09 – Drive chain................................................................................ 05-09-1
06 ELECTRICAL 01 – Table of contents...................................................................... 06-01-1

02 – Ignition timing........................................................................... 06-02-1
03 – Spark plugs............................................................................... 06-03-1
04 – Battery...................................................................................... 06-04-1
05 – Electric starter .......................................................................... 06-05-1
06 – Testing procedure .................................................................... 06-06-1
I
TABLE OF CONTENTS
07 REAR SUSPENSION 01 – Table of contents ..................................................................... 07-01-1

02 – SC-10 suspensions (All versions) ............................................. 07-02-1
03 – Skandic WT suspension........................................................... 07-03-1
04 – Drive axle ................................................................................. 07-04-1
05 – Track ........................................................................................ 07-05-1
08 STEERING/ 01 – Table of contents ..................................................................... 08-01-1

FRONT SUSPENSION 02 – Steering system....................................................................... 08-02-1
03 – Suspension and ski system ..................................................... 08-03-1
09 BODY/FRAME 01 – Table of contents ..................................................................... 09-01-1

02 – Body......................................................................................... 09-02-1
03 – Frame....................................................................................... 09-03-1
10 TECHNICAL DATA 01 – SI metric information guide...................................................... 10-01-1

02 – Engines .................................................................................... 10-02-1
03 – Vehicles.................................................................................... 10-03-1
04 – Technical data legends............................................................. 10-04-1
11 WIRING DIAGRAMS 01 – Wiring diagrams ....................................................................... 11-01-1
II
SAFETY NOTICE
SAFETY NOTICE 0
This manual has been prepared as a guide to correctly service and repair some 2001 Ski-Doo snowmo-
biles. See model list below.
This edition was primarily published to be used by snowmobile mechanic technicians who are already
familiar with all service procedures relating to Bombardier made snowmobiles. Mechanic technicians
should intent to continuous training courses given by Bombardier Training Dept.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
This Shop Manual uses technical terms which may be slightly different from the ones used in the Parts
Catalog.
It is understood that this manual may be translated into another language. In the event of any discrepancy,
the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Service
and Warranty Bulletins may be published to update the content of this manual. Make sure to read and
understand these.
In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the
general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas
of the parts.
The use of Bombardier parts is most strongly recommended when considering replacement of any com-
ponent. Dealer and/or distributor assistance should be sought in case of doubt.
The engines and the corresponding components identified in this document should not be utilized on
product(s) other than those mentioned in this document.
Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking tab,
self-locking fasteners, etc.) must be installed or replaced with new ones. If the efficiency of a locking
device is impaired, it must be renewed.
This manual emphasizes particular information denoted by the wording and symbols:
 WARNING
Identifies an instruction which, if not followed, could cause serious personal injury including
possibility of death.
CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle compo-
nents.
NOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the
contents. We strongly recommend that any services be carried out and/or verified by a highly skilled
professional mechanic. It is understood that certain modifications may render use of the vehicle illegal
under existing federal, provincial and state regulations.
III
WHAT’S NEW
WHAT’S NEW 0
INTRODUCTION
• Procedure to change self-locking fasteners.
OIL INJECTION SYSTEM 04-06

• Different pump adjustments according to pump identification.
REWIND STARTER 04-09

• New type of lubricant is used on all moving parts.
IV
INTRODUCTION
INTRODUCTION 0
This Shop Manual Volume 1 covers the following Touring CARGO 380/500
Bombardier made 2001 snowmobiles: Touring FAN 380/500
Formula Deluxe FAN 380/500
MODEL MX Z FAN 380/440/500
MODELS
NUMBER These are S-series models.
SKANDIC* LT (Canada) ........................1816
SKANDIC* LT (U.S.) ..............................1817
SKANDIC* WT (Canada).......................1814
SKANDIC* WT (U.S.) ............................1815
SKANDIC* SWT (Canada) ....................1812
SKANDIC* SWT (U.S.) ..........................1813
SKANDIC* WT LC (Canada) .................1810
SKANDIC* WT LC (U.S.) .......................1811 A00A5PA
TOURING* FAN 380 (Canada) ..............1807 TYPICAL — S-SERIES
TOURING* FAN 380 (U.S.) ...................1808 Skandic LT

Skandic WT
TOURING* CARGO 380 (Canada) ........1854 Skandic SWT
TOURING* CARGO 380 (Europe).........1809 Skandic WT LC
TOURING* FAN 500 (Canada) ..............1804 These are Skandic Series models.
TOURING* FAN 500 (U.S.) ...................1805
TOURING* CARGO 500 (Canada) ........1852
TOURING* CARGO 500 (Europe).........1806
FORMULA* DELUXE FAN 380
(Canada).................................................1784
FORMULA* DELUXE FAN 380(U.S.) ...1785
FORMULA* DELUXE FAN 500
(Canada).................................................1782 A29A03A
FORMULA* DELUXE FAN 500 (U.S.) ..1783 TYPICAL — SKANDIC SERIES

MX Z FAN 380 (Canada) .......................1721
MX Z FAN 380 (U.S.) .............................1722
MX Z FAN 380 (EUROPE)......................1835
MX Z FAN 440 (Canada) .......................1821
MX Z FAN 440 (U.S.) .............................1822
MX Z FAN 500 (Canada) .......................1719
MX Z FAN 500 (U.S.) .............................1720
SUMMIT FAN 500 (Canada) .................1762
SUMMIT FAN 500 (U.S.) .......................1763
*Trademarks of Bombardier Inc.
V
INTRODUCTION
VEHICLE ENGINE SERIAL NUMBER

IDENTIFICATION NUMBER Engine Serial Number Location
Vehicle Identification Number Location Fan-Cooled Engines
1
A03H2AA 1
TYPICAL
1. Vehicle identification number
Vehicle Identification Number Meaning A03A0BA
2BPS15929Y1000001 TYPICAL — FAN-COOLED ENGINES

1. Engine serial number
Model number Serial number
Model year: y = 2000 Liquid-Cooled Engines
1 = 2001
2 = 2002
A00A6EA etc.
A32C01B 1
TYPICAL — LIQUID-COOLED ENGINES
1. Engine serial number
VI
INTRODUCTION
LIST OF ABBREVIATIONS lbf pound (force)

USED IN THIS MANUAL lbf/in² pound per square inch
A ampere LH left hand
amp ampere LO low
A•h ampere-hour LT long track
AC alternate current m meter
ACM acceleration and control modulator MAG magneto
ARM advance ride management Max. maximum
BDC bottom dead center Min. minimum
BTDC before top dead denter mL milliliter
°C degree Celsius mm millimeter
cc cubic centimeter MPEM multi-purpose electronic module
CDI capacitor discharge ignition MPH mile per hour
CTR center N newton
cm centimeter N.A. not applicable
cm² square centimeter no. number
cm³ cubic centimeter 00.0 continuity
DC direct current 0.L overload (open circuit)
DPM digital performance management O.D. outside diameter
DSA direct shock action OPT optional
°F degree Fahrenheit oz ounce
FC fan cooled P/N part number
fl. oz fluid ounce PSI pound per square inch
ft foot PTO power take off
GRD ground R rectangular
H.A.C. high altitude compensator RH right hand
hal. halogen RAVE rotax adjustable variable exhaust
HI high RPM revolution per minute
imp. oz imperial ounce RMS root mean square
in inch RRIM reinforced reaction injection molding
in² square inch Sp. Gr. specific gravity
in³ cubic inch ST semi-trapezoidal
k kilo (thousand) TDC top dead center
kg kilogram TRA total range adjustable
km/h kilometer per hour U.S. oz ounce (United States)
kPa Kilopascal V volt
L liter Vac volt (alternative current)
lb pound
VII
INTRODUCTION
ARRANGEMENT OF THE
MANUAL
The manual is divided into 11 major sections:
01 SERVICE TOOLS AND SERVICE PRODUCTS
02 LUBRICATION AND MAINTENANCE
03 TROUBLESHOOTING
04 ENGINE
05 TRANSMISSION
06 ELECTRICAL
07 REAR SUSPENSION
08 STEERING/FRONT SUSPENSION
09 BODY/FRAME
10 TECHNICAL DATA
11 WIRING DIAGRAMS
Each section is divided in various subsections, and
again, each subsection has one or more division.
VIII
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
Section 07 REAR SUSPENSION indicates
Subsection 01 (SUPENSION SC-10 SPORT, TOURING AND MOUNTAIN) beginning of the
subsection.
SUSPENSION SC-10 SPORT,

TOURING AND MOUNTAIN Italic subtitle above
Grand Touring 500/580, Formula 500/583 and Summit 500 exploded view
indicate pertaining
1
models.
Low
temp.
grease
Low
temp. Loctite 7
grease 271
6 2
4 Loctite
11 271
Exploded view
19 6
assists you in 12 16 Drop represents
Low
identifying parts and 18 Nm temp.
3
a liquid product
related positions. 13
(160 lbfin) 9 grease
5
to be applied to
8
14
Loctite
a surface.
15 271 In this case
Loctite 271 to
11 screw threads.
SLE
Only
11
Bold face number
10 indicates special
11 Loctite procedure concerning
271
this part.
Long Track 17
Models Only Loctite
271
16 18
20
Loctite
271
Loctite
271 Short Track Models Only
Loctite
Illustration number 271 Dotted box contains
for publishing 4 Nm
11
parts of a particular
(35 lbfin)
process. model in this case
the short track
A03F24S models only.
07-01-1
Tightening torque nearby

fastener. In this case, nut
must be torqued to
4 Nm or 35 lbfin. Page numbering system:
07: REAR SUSPENSION section
01: SUSPENSION SC-10 SPORT,
CAUTION: Pay attention to torque TOURING AND MOUNTAIN subsection
specifications. Some of these are 1: First page of this subsection
in lbfin instead of lbfft. Use appro-
priate torque wrench.
A01A28S
IX
INTRODUCTION
TYPICAL PAGE
Section 05 TRANSMISSION
Subsection 03 (DRIVEN PULLEY)
Title indicates
Turn puller handle and sliding half at once to extract
the bushing.
INSTALLATION main procedure
Countershaft to be carried-out.
CAUTION: Always apply anti-seize lubricant (P/N
413 701 000) on the countershaft before final pulley Italic bold face type
installation. setting indicates a
particular procedure
A-Series and B-Series Only
529 031 300 concerning a model.
Should installation procedure be required, refer
to BRAKE 05-05 then look for Brake Disc and
529 031 200 Countershaft Bearing Adjustment.
Reinstall the pulley on the countershaft by rever- Italic bold face setting
sing the removal procedure. in this case indicates
that particular
All Models
procedure for
A03D1YA
Check end play of driven pulley on countershaft by A and B-Series is
IMPORTANT: Large bushing retaining screws and
pushing pulley towards outer housing so that the inner
shims (P/N 504 108 200) contact it. Measure end play
finished, so from
washers must be removed before small bushing at the mounting screw end between shim(s) and puley. this point, all models
installation. See illustration. are concerned.
Coat bushing outside diameter with Loctite 609
(P/N 413 703 100). 1
Install bushing as following photo.
TYPICAL caption
2 indicates a general
view which does
not represent full
detail.
529 031 300
TOP VIEW
A
caption helps you
in understanding
1
529 031 200
A16D0IA
illustration.
TYPICAL TOP VIEW
1. Shim (P/N 504 108 200) (as required)
Illustration always 2. Contact
A. 0 to 1 mm (0 to 3/64 in)
follows text to which Torque retaining screw no. 13 to 25 Nm (18 lbfft). Call-outs for
it pertains. A03D1ZA
above illustration.
ADJUSTMENT
ASSEMBLY Refer to PULLEY DISTANCE AND ALIGNMENT 05-04
to adjust pulley distance. Adjust drive belt height
Came Slider Shoe between pulley halves to obtain specified belt
When replacing slider shoes no. 4, always install a new deflection.
set (3 shoes) to maintain equal pressure on the cam.
Assemble driven pulley components by reversing
the disassembly procedure. Reference to look
Subtitle indicates up a certain section
a particular procedure Cam and subsection.
for the named part. Coat cam no. 18 interior with anti-seize lubricant.
In this case it concerns
pulleys adjustment.
MMR2000_042_00-02A.FM 05-03-5
Bold face number following part

name refers to exploded view
at beginning of subsection.
A01A2BS
X
INTRODUCTION
GENERAL INFORMATION CAUTION: Most components of those vehicles

are built with parts dimensioned in the metric
The information and component/system descrip- system. Most fasteners are metric and must
tions contained in this manual are correct at time not be replaced by customary fasteners or vice
of publication. Bombardier Inc. however, main- versa. Mismatched or incorrect fasteners could
tains a policy of continuous improvement of its cause damage to the vehicle or possible per-
products without imposing upon itself any obliga- sonal injury.
tion to install them on products previously manu-
As many of the procedures in this manual are in-
factured.
terrelated, we suggest, that before undertaking
Due to late changes, it may have some differences any task, you read and thoroughly understand the
between the manufactured product and the de- entire section or subsection in which the proce-
scription and/or specifications in this document. dure is contained.
Bombardier Inc. reserves the right at any time to A number of procedures throughout the book re-
discontinue or change specifications, designs, quire the use of special tools. Before commencing
features, models or equipment without incurring any procedure, be sure that you have on hand all
obligation. the tools required, or approved equivalents.
The use of RIGHT and LEFT indications in the text,
USEFUL PUBLICATIONS always refers to driving position (when sitting on
Refer to Parts Catalogs to order the right parts. vehicle).
PARTS CATALOG
MODELS P/N
Skandic LT 484 400 153
Skandic WT/SWT/WT LC 484 400 093
Touring FAN 380/500
484 400 103
Touring CARGO 380/500
Formula DLX FAN 380 1 2
484 400 253
MX Z FAN 380
Formula DLX FAN 500
484 400 114
MX Z FAN 440/500
SUMMIT FAN 500 484 400 243
Use Specification Booklet to find rapidly the right

specs.
1997-2001 SPECIFICATION BOOKLET (P/N 484
300 198).
ILLUSTRATIONS AND A03A0CA
PROCEDURES TYPICAL
1. Left
Illustrations and photos show the typical construc- 2. Right
tion of the different assemblies and, in all cases,
may not reproduce the full detail or exact shape of
the parts shown. However, they represent parts
which have the same or a similar function.
XI
INTRODUCTION
SELF-LOCKING Blind Holes

FASTENERS PROCEDURE
The following describes the most common appli-
cation procedures when working with self-locking 1
fasteners.
Use a metal brush or a screwtap to clean the hole 2
properly then use a solvent (Methyl-Chloride), let
act during 30 minutes and wipe off. The solvent
utilization is to ensure the adhesive works properly.
LOCTITE
APPLICATION PROCEDURE
The following describes the most common appli- A00A3MA
cation procedures when working with Loctite 1. On threads

products. 2. On threads and at the bottom of hole
NOTE: Always use proper strength Loctite prod- 1. Clean threads (bolt and hole) with solvent.
uct as recommended in this Shop Manual. 2. Apply Loctite Primer N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30
THREADLOCKER seconds.
3. Choose proper strength Loctite threadlocker.
Uncovered Holes (bolts and nuts)
4. Apply several drops along the threaded hole and
at the bottom of the hole.
5. Apply several drops on bolt threads.
6. Tighten as required.
1
Stud in Blind Holes
1 3
2
2
A00A3LA
1. Apply here
2. Do not apply
A00A5RA
1. Clean threads (bolt and nut) with solvent.
2. Apply Loctite Primer N (P/N 293 800 041) on 1. On threads
2. On threads and in the hole
threads and allow to dry. 3. Onto nut threads
3. Choose proper strength Loctite threadlocker. 1. Clean threads (stud and hole) with solvent.
4. Fit bolt in the hole. 2. Apply Loctite Primer N (P/N 293 800 041) on
5. Apply a few drops of threadlocker at proposed threads and allow to dry.
tightened nut engagement area. 3. Put several drops of proper strength Loctite
6. Position nut and tighten as required. threadlocker on female threads and in hole.
4. Apply several drops of proper strength Loctite
on stud threads.
XII
INTRODUCTION
5. Install stud. 1. Adjust screw to proper setting.

6. Install cover, etc. 2. Apply drops of proper strength Loctite thread-
7. Apply drops of proper strength Loctite on un- locker on screw/body contact surfaces.
covered threads. 3. Avoid touching metal with tip of flask.
8. Tighten nuts as required. NOTE: If it is difficult to readjust, heat screw with
a soldering iron (232°C (450°F)).
Preassembled Parts
STRIPPED THREAD REPAIR
Stripped Threads
1 5
1
6
8
2
3
2
A00A3OA
A00A3QA 4 7
1. Apply here
2. Do not apply 1. Release agent
2. Stripped threads
3. Form-A-Thread
1. Clean bolts and nuts with solvent. 4. Tape
5. Cleaned bolt
2. Assemble components. 6. Plate
3. Tighten nuts. 7. New threads
8. Threadlocker
4. Apply drops of proper strength Loctite on bolt/nut
Standard Thread Repair
contact surfaces.
5. Avoid touching metal with tip of flask. 1. Follow instructions on Loctite FORM-A-THREAD
(P/N 413 708 600) package.
NOTE: For preventive maintenance on existing
equipment, retighten nuts and apply proper 2. If a plate is used to align bolt:
strength Loctite on bolt/nut contact surfaces. a. Apply release agent on mating surfaces.
b. Put waxed paper or similar film on the surfaces.
Adjusting Screw
3. Twist bolt when inserting it to improve thread
conformation.
2 NOTE: NOT intended for engine stud repairs.
1 Repair of Small Holes/Fine Threads
Option 1: Enlarge damaged hole, then follow
Standard Thread Repair procedure.
Option 2: Apply FORM-A-THREAD on the screw
and insert in damaged hole.
A00A3PA
1. Apply here
2. Plunger
XIII
INTRODUCTION
Permanent Stud Installation (light duty) NOTE: If the cover is bolted to blind holes (above),
1. Use a stud or thread on desired length. apply proper strength Loctite in the hole and on
threads. Tighten.
2. DO NOT apply release agent on stud.
If holes are sunken, apply proper strength Loctite
3. Do a Standard Thread Repair. on bolt threads.
4. Allow to cure for 30 minutes. 6. Tighten as usual.
5. Assemble.
MOUNTING ON SHAFT
GASKET COMPOUND
Mounting with a Press
All Parts
1 2
1 2
A00A3UA
1. Bearing
2. Proper strength Loctite
A00A3SA 1 3 3. Shaft
1. Proper strength Loctite Standard

2. Loctite Primer N (P/N 413 708 100) and Gasket Eliminator 515
(P/N 413 702 700) on both sides of gasket 1. Clean shaft external part and element internal
3. Loctite Primer N only part.
1. Remove old gasket and other contaminants 2. Apply a strip of proper strength Loctite on shaft
with Loctite Chisel remover (P/N 413 708 500). circumference at insert or engagement point.
Use a mechanical mean if necessary. NOTE: Retaining compound is always forced out
NOTE: Avoid grinding. when applied on shaft.
2. Clean both mating surfaces with solvent. 3. DO NOT use anti-seize Loctite or any similar
3. Spray Loctite Primer N on both mating surfaces product.
and on both sides of gasket. Allow to dry 1 or 2 4. No curing period is required.
minutes.
Mounting in Tandem
4. Apply GASKET ELIMINATOR 515 (P/N 413 702
1. Apply retaining compound on internal element
700) on both sides of gasket, using a clean ap-
bore.
plicator.
2. Continue to assemble as shown above.
5. Place gasket on mating surfaces and assemble
immediately.
XIV
INTRODUCTION
CASE-IN COMPONENTS
Metallic Gaskets
A00A3VA 1
1. Clean inner housing diameter and outer gasket

diameter.
2. Spray housing and gasket with Loctite Primer N
(P/N 293 800 041).
3. Apply a strip of proper strength Loctite on lead-
ing edge of outer metallic gasket diameter.
NOTE: Any Loctite product can be used here. A
low strength liquid is recommended as normal
strength and gap are required.
4. Install according to standard procedure.
5. Wipe off surplus.
6. Allow it to cure for 30 minutes.
NOTE: Normally used on worn-out housings to
prevent leaking or sliding.
It is generally not necessary to remove gasket
compound applied on outer gasket diameter.
XV
INTRODUCTION
TIGHTENING TORQUES N•m

FASTENER SIZE
Lbf•ft
(8.8 GRADE)
Tighten fasteners to torque mentioned in exploded
123 M14 91
views and text. When they are not specified refer
to following table. All torques apply to 8.8 grade 124 M14 91
fasteners. Bold face size (e.g. M4) indicates nomi- 125 M14 92
nal value (mean value). 126 M14 93
127 M14 94
FASTENER SIZE
N•m Lbf•in 128 M14 94
(8.8 GRADE)
2 M4 18 129 M14 95
3 M4 27 130 M14 96
4 M5 35 131 M14 97
8 M6 71 132 M14 97
9 M6 80 133 M14 98
10 M6 89 134 M14 99
11 M6 97 135 M14 100
12 M6 106 136 M14 100
137 M14 101
FASTENER SIZE 138 M14 102
N•m Lbf•ft
(8.8 GRADE)
139 M14 103
21 M8 15
140 M14 103
22 M8 16 141 M14 104
23 M8 17
142 M14 105
24 M8 18
143 M14 105
25 M8 18 144 M14 106
43 M10 32
145 M14 107
44 M10 32
146 M14 108
45 M10 33 147 M14 108
46 M10 34
148 M14 109
47 M10 35
149 M14 110
48 M10 35 150 M14 111
49 M10 36
TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS
50 M10 37
51 M10 38
52 M10 38
53 M10 39
76 M12 56
77 M12 57
78 M12 58
79 M12 58
80 M12 59
81 M12 60
82 M12 60
83 M12 61
84 M12 62
121 M14 89
122 M14 90
XVI
Bombardier SERVICE PUBLICATIONS REPORT
Publication title and year ________________________ Page______
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____________________________________________________________
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gestions you may have concerning
our publications. ____________________________________________________________
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✁

AFFIX
PROPER
POSTAGE
After Sales Service
565 de la Montagne Street
Valcourt, Quebec, Canada J0E 2L0
AFFIX
PROPER
POSTAGE
After Sales Service
AFFIX
PROPER
POSTAGE
After Sales Service
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 01 (SERVICE TOOLS)
SERVICE TOOLS 0
This is a list of tools to properly service Ski-Doo snowmobiles. The list includes both the mandatory tools
included in a kit (P/N 861 743 700) and the optional tools that are ordered separately. The list of Service
Products, both mandatory and optional, are not part of any kit and must all be ordered separately. If you
need to replace or add to your tool inventory these items can be ordered through the regular parts channel.
Following mention points out new tool and product: NEW
MMR2001_002_01_01A.FM 01-01-1
WORKSHOP — MANDATORY SERVICE TOOLS

Tool board
(P/N 529 034 000)
01
A00A3X4
APPLICATION
All models.
01-01-2 MMR2001_002_01_01A.FM
ENGINE — MANDATORY SERVICE TOOLS

Exhaust spring installer/remover Fan holder Aligning pin (4)
(P/N 529 035 400) (P/N 420 876 357) (P/N 529 018 900)
A00A1D4
APPLICATION
467, 494 and 582 engines.
Pusher
A01B584
A00C0Q4 (washer behind the impeller)
APPLICATION APPLICATION (P/N 529 020 700)
CK3 series. 377, 443 and 503 engines.
Degree wheel Magneto puller ring

(P/N 529 035 607) (P/N 420 876 080) A00C3H4
340
350360 10
20
30
APPLICATION
33
0 10 360 350 3
20 40 40
0 30 33
32
50
40 0
32
0
Rotary valve engines.
50
0
31
60
60
31
0
0
70
30
300
70
80
290
290
80
110 100 90
Rotary valve shaft pusher

280
280 270 26
90 100 11
270
(P/N 420 876 612)

260
A00C1R4
120
0
0
250
130
250
12
APPLICATION
0
0
24
14
24
13
0
0
2
30
30
15 2
1
40
All engines except 247.
0 22
210 0
16
22
0 0
15 A00C0F4
200 190 180 17 0 0
160 21
170 00
180 190 2
APPLICATION
A00B514
Magneto puller Rotary valve engines with a 10 mm
APPLICATION (P/N 529 035 547) impeller shaft.
All rotary valve engines.
NOTE: This tool replaces degree Rotary valve seal pusher
wheel (P/N 295 000 007). (valve side)
(P/N 420 876 607)
Hose pincher (2)
A00C1A4
(P/N 295 000 076)
APPLICATION
NOTE: The previous extractor A00C0Y4
(P/N 529 022 500) can be upgrad-

ed by replacing the screw with the APPLICATION
new one (P/N 529 035 549). Rotary valve engines.
A01B2I4
APPLICATION
All vehicles.
NOTE: Only the P/N has been
changed. This hose pincher is iden-
tical to the P/N 529 009 900.
MMR2001_002_01_01A.FM 01-01-3
ENGINE (continued) — MANDATORY SERVICE TOOLS

Rotary valve shaft seal pusher Ceramic seal pusher Choke plunger tool
(inner, water pump side) (P/N 420 877 820) A) (P/N 529 032 100)
(P/N 420 876 512)
NEW
B) (P/N 529 035 602)
A00B524
A00C374 APPLICATION
A01C5D4
APPLICATION 494 and 670 engines with ceramic
seal on water pump side. APPLICATION
Rotary valve engines, 1991 and
newer with a 10 mm impeller shaft. A) All models equipped with chokes
Engine leak tester kit except ZX series (small end for
(P/N 861 749 100) 34 mm carburetor and big end
Rotary valve shaft seal pusher for 38 mm carburetor).
(outer, water pump side)
B) ZX series.
(P/N 420 877 050)
A00C0X4
A01B2D5
APPLICATION APPLICATION
Rotary valve engines. All engines.
Bearing pusher Fuel and oil system leak tester kit

(rotary valve)
(P/N 529 033 100)
(P/N 420 876 500)
A00B2J4
APPLICATION
A01B5E4
APPLICATION
All models.
01-01-4 MMR2001_002_01_01A.FM

1) Piston pin puller Rubber pad Choke/DESS nut tool
(P/N 529 035 503) (P/N 529 023 400) (P/N 529 034 600)
A01B554
A01B4C4
APPLICATION
APPLICATION
All models equipped with a choke
A02B094 All cageless bearing engines.
and/or a DESS.
2) Sleeve kit 18 mm NOTE: This tool replaces choke
Rotary valve circlip tool nut tool (P/N 529 032 200).
(P/N 529 035 541)
A) (P/N 529 029 100)
3) Sleeve kit 20 mm
B) (P/N 529 020 800)
(P/N 529 035 542)
A00C3I4
APPLICATION
A) 1994 and on rotary valve engines.
A01B5A4
B) Up to 1993 rotary valve engines.
NOTE: 18 mm sleeve kit contains
1 shouldered sleeve and 3 sleeves. Multimeter
20 mm sleeve kit contains 1 shoul-
(P/N 529 022 000)
dered sleeve and 2 sleeves.
APPLICATION
1) All engines.
2) 277, 443, 503 and 809 engine.
3) 593, 670 and 693 engines.
NOTE: The previous piston pin
puller (P/N 529 029 000) can be up-
graded by adding protector (P/N
529 035 513) and replacing the ex-
pansion sleeve with appropriate
sleeve kit.
F01B1O4
APPLICATION
All models.
MMR2001_002_01_01A.FM 01-01-5

9-volt adaptor Homemade adaptor 1-2) Programmer kit
(P/N 529 035 675) NEW (P/N 529 035 718)
NEW 2) Communication cables
7 (P/N 529 001 052)
8 NEW
1
1
4
2 3
5 6
A00B5J4
A00B5G4
Required parts:
APPLICATION
All models equipped with a DESS. 1) Female housing
(P/N 515 175 245)
2
2) Female terminal (2)
A01B5B5
(P/N 409 015 100)
3) Female lock APPLICATION
(P/N 515 175 246) All models equipped with a DESS.
4) Male housing
(P/N 409 207 000)
5) Male terminal (2)
(P/N 278 000 631)
6) Male lock
(P/N 409 207 600)
7) RED wire in position 1
(4-wire connector) and B
(3-wire connector)
8) BLACK wire in position 2
(4-wire connector) and C
(3-wire connector)
APPLICATION
2001 Mach Z TECH PLUS.
01-01-6 MMR2001_002_01_01A.FM
ENGINE (continued) — RECOMMENDED SERVICE TOOLS

The following tools are highly recommended to optimize your basic tool kit and reduce repair time.
1-2) Crankshaft bearing 1) Screw M16 x 1.5 x 150 (P/N 420 940 755)
puller with screw
2) Screw M8 x 40 (4) (P/N 420 840 681)
(P/N 420 877 635)
3) Screw M8 x 70 (4) (P/N 420 841 201)
1
2,3 2,3
4) Crankshaft protector (P/N 420 976 890)
247 engine.
5) Crankshaft protector PTO (P/N 420 876 552)
6) Crankshaft protector MAG (P/N 420 876 557)
5 4,6 All engines except 247.
7) Puller ring (P/N 420 977 490)
7,10 Use with half rings
(P/N 420 977 475 or 420 276 025).
8,9,11 8) Half ring (2) (P/N 420 977 475)

For 72 mm O.D. bearings.
A01B547
9) Half ring (2) (P/N 420 276 025)
APPLICATION For 62 mm O.D. bearings.
All engines.
10) Puller ring (P/N 420 977 494)
For half rings (P/N 420 977 479).
11) Half ring (P/N 420 977 479)
MMR2001_002_01_01A.FM 01-01-7

Piston circlip installer Ring compressor Seal protector sleeve
A) (P/N 529 035 561) 18 mm A) (P/N 420 876 090) (P/N 420 276 900)
(62 mm) (MAG)
B) (P/N 529 035 562) 20 mm
B) (P/N 420 876 974)
(69.5 mm)
C) (P/N 420 876 970)
(72 mm)
D) (P/N 420 876 972)
A00C0D4
(76 mm)
E) (P/N 420 876 975) APPLICATION
A00B4Y4
(67.5 mm) 247 engine.
APPLICATION F) (P/N 529 030 800)
A) All engines except 593, 670 and (78 mm) Polyamid ring pusher
693. (P/N 420 276 930)
NOTE: This tool replaces circlip in-
staller (P/N 529 016 900).
B) 593, 670 and 693 engines.
staller (P/N 290 877 016). A00C0Z4
A01B1T4
APPLICATION
Piston pin/connecting APPLICATION 247 engine.
rod bearing centering tool
A) 377 engine.
(P/N 529 009 100)
B) 467 and 494 engines. Crankshaft feeler gauge
NOTE: New diameter is 9.65 mm
(0.380 in). C) 503, 253 and 536 engines. (P/N 420 876 620)
D) 582, 583 and 643 engines.
E) 443 and 447 engines.
F) 670 engine.
Magneto coil centering ring

A01B1R4
(P/N 420 876 922)
A00C114
APPLICATION
All engines except cageless and APPLICATION
670 engines. 377, 443, 447 and 503 engines.
A01B1V4
APPLICATION
All engines with Nippondenso CDI
(160 W).
01-01-8 MMR2001_002_01_01A.FM

Crankshaft distance gauge Driver tool Carburetor tool kit
(5.7 mm) (P/N 529 035 521) (P/N 404 112 000)
(P/N 420 876 822)
A00B4O4
APPLICATION
Mini Z.
A00B2F4
A00C294
Attachment APPLICATION
APPLICATION (P/N 529 035 522) All models.
Adaptor
Crankshaft distance gauge (P/N 529 033 800)
(12.7 mm) (TYPICAL)
(P/N 420 876 824)
A00B4P4
APPLICATION A00B4H4
Mini Z.
APPLICATION
1997 and 1998 Grand Touring SE
A00C3A4 Pilot 22 mm 1998 Summit x 670.
APPLICATION (P/N 529 035 523)
503 engine. Float level gauge
(P/N 529 035 520)
Cylinder aligning tool
A) (P/N 420 876 904)
(on exhaust side)
B) (P/N 420 876 171)
4
(on intake side)

3
A00B4Q4
2
APPLICATION
1
A00B084 Mini Z.
A00B4N4
APPLICATION
APPLICATION
A) 2-cylinder liquid cooled
engines. All models.
B) 2-cylinder fan cooled engines.
MMR2001_002_01_01A.FM 01-01-9

Circuit tester RAVE movement indicator Magneto puller
(continuity light) (P/N 861 725 800) (P/N 420 976 235)
(P/N 414 012 200)
A00C214
APPLICATION
F01B294
All vehicles.
APPLICATION
247 engine.
Stroboscopic timing light A18B014
(P/N 529 031 900) APPLICATION

Injection pump gear holder
All RAVE equipped engines.
(P/N 420 876 695)
Dial indicator
(TDC gauge)
(P/N 414 104 700)
A00B4F4
APPLICATION A00B314
All engines.
A00B4E4
APPLICATION
253, 377, 447 and 503 engines.
Bypass wires APPLICATION
(P/N 529 033 300) All engines.
(P/N 420 277 905)
Seal protector sleeve
A) (P/N 420 876 980)
B) (P/N 420 876 490)
A00I094
APPLICATION
360 W magneto
(Grand Touring 700/SE).
A00C164
A00C0D4
APPLICATION
APPLICATION All liquid cooled engines.
A) Rotary valve engines with 10 mm
shaft.
B) Rotary valve engines with 12 mm
shaft.
01-01-10 MMR2001_002_01_01A.FM
Digital/induction type tachometer Base puller plate kit Handle for insertion jig
(P/N 529 014 500) (P/N 529 024 900) (P/N 420 877 650)
A00C3V4
APPLICATION
454, 494, 599, 670, 699, 779 and
A05C0M4
809 engines.
F01B1G4
277 engine. Exhaust spring installer/remover
All engines.
(P/N 529 035 559)
MAG seal pusher Insertion jig

(magneto side seal)
(P/N 420 277 875)
(P/N 420 876 516)
A00C3S4
APPLICATION
A00C0V4 All models except CK3 series.
APPLICATION NOTE: This tool replaces exhaust
spring installer/remover (P/N 529
277 engine.
028 100).
PTO seal pusher A00C3T4 Rotary valve seal and

(P/N 420 876 660) shaft pusher
APPLICATION
(P/N 420 876 605)
779 engine.
Insertion jig
A00C0V4 (magneto seal)
A00C0Y4
277 engine.
APPLICATION
Rotary valve engines 1990 models
and older.
A00C3U4
APPLICATION
454, 494, 599, 670, 699 and 809
engines.
MMR2001_002_01_01A.FM 01-01-11
NGINE (continued) — RECOMMENDED SERVICE TOOLS

Seal pusher (rotary valve)
(P/N 420 876 510)
A00C374
APPLICATION
All rotary valve shaft seals with a
12 mm I.D.

(P/N 420 876 610)
A00C0F4
APPLICATION
All rotary valve engines with 12 mm
shaft.
Large hose pincher

(P/N 529 032 500)
(TYPICAL)
F01B234
APPLICATION
All vehicles.
01-01-12 MMR2001_002_01_01A.FM
TRANSMISSION — MANDATORY SERVICE TOOLS

Driven pulley opening tool Forks (3) Drive pulley puller
(P/N 529 017 200) (P/N 529 005 500) (P/N 529 002 100)
(standard threads)
A00C084
APPLICATION
Square shaft, standard
(SAE) threads.
A16B014
A00A1A4
APPLICATION APPLICATION Drive pulley puller

All non-RER models. All vehicles equipped with a TRA (P/N 860 414 200)
drive pulley. (square shaft metric)
Clutch holder Consists of:
Tool kit
(P/N 529 006 400) 529 003 000 529 002 800
(P/N 529 025 400)
NEW
A01B154
APPLICATION A00C095
All TRA drive pulleys. APPLICATION

Square shaft, metric threads drive
TRA drive pulley puller pulley.
(P/N 529 022 400)
A00B5N4
APPLICATION
A06B014 Comet® 102C drive pulley.
APPLICATION
TRA drive pulley for the 454, 494, Drive pulley puller
599, 670, 699, 779 and 809 engines. (P/N 529 025 000)
NEW
TRA drive pulley puller

(P/N 529 007 900) (25 mm)
A00B5M4
A18B044
APPLICATION
APPLICATION Comet® 102C drive pulley.
TRA drive pulley for 443, 467, 503,
536 and 537 engines.
MMR2001_002_01_01A.FM 01-01-13
TRANSMISSION (continued) — MANDATORY SERVICE TOOLS

Transmission alignment bar Drive belt tension adjuster tool Driven pulley spring compressor
A) (P/N 529 026 900) (P/N 529 008 700) (P/N 529 035 300)
B) (P/N 529 030 000)
2
C) (P/N 529 035 586)
D) (P/N 529 026 700)
1
E) (P/N 529 035 530)
F) (P/N 529 031 000)
G) (P/N 529 035 527) A15B044
H) (P/N 529 035 572)

I) (P/N 529 035 594) Parts included:
1) Hexagonal wrench
(P/N 420 876 730).
A01B4D4
2) Socket wrench A05B034
APPLICATION (P/N 529 015 000).
APPLICATION
A) Tundra II LT/R. APPLICATION
Tundra R.
B) S-Series with Bombardier Lite. All vehicles except Élan, Tundra II
C) S-Series with Bombardier Lite and Skandic WT.
and RER. Tension tester
(P/N 414 348 200)
D) F-Series, S-Series and ZX series Pulley spring compressor
with TRA. (P/N 529 035 524)
E) S-Series with TRA and RER. A00C074
F) Skandic WT LC/SWT.
APPLICATION
G) CK3 series except 1998 Mach Z
All models.
series.
H) 1998 Mach Z series.
Countershaft bearing installer
I) CK3 series with RER.
(P/N 529 030 200)
Spring scale hook (long)

A) (P/N 529 006 500)
B) (P/N 529 030 900)
C) (P/N 529 035 557)
A02D1P4
(TYPICAL)
APPLICATION
All models.
NOTE: This tool has Acme threads A00A194
and replaces spring compressor APPLICATION

(P/N 529 018 600).
S-Series and F-Series.
A00B4A4
APPLICATION
A) Tundra II LT.
B) F-Series and S-Series
(1995 and newer).
C) CK3 without RER.
01-01-14 MMR2001_002_01_01A.FM

Countershaft bearing remover Countershaft bearing
(P/N 529 030 100) remover/installer
(P/N 529 035 699)
NEW
A00A274
APPLICATION
A00B5K4
Countershaft bearing
remover/installer APPLICATION
(P/N 529 035 554) ZX and CK3 Series.
NOTE: This tool replaces CK3 se-
ries countershaft bearing remover/
installer (P/N 529 035 554).
Spring cover tool

(P/N 529 027 300)
A01B5C4 A01B4M4
CK3 Series. Bombardier Lite drive pulley.
MMR2001_002_01_01A.FM 01-01-15
TRANSMISSION (continued) — RECOMMENDED SERVICE TOOLS

Clutch holder Alignment tool
(P/N 529 027 600) (P/N 420 476 010)
A02B034
APPLICATION
Bombardier Lite drive pulley. A00C1D4
APPLICATION
Drive pulley puller Skandic WT and Alpine II gearbox.
(P/N 529 031 400)
(P/N 529 018 800)
A18B044
APPLICATION
Bombardier Lite drive pulley, ex-
cept Élan.
Driven pulley opening tool

(P/N 529 035 501)
A00A194
APPLICATION
PRS chassis.
A03D2P4
APPLICATION
S and CK3 series with RER.
NOTE: This tool replaces driven
pulley opening tool (P/N 529 019
500).

(P/N 529 034 200)
A05B044
APPLICATION
Tundra R.
01-01-16 MMR2001_002_01_01A.FM

Cam pusher Transmission ball mounting pin Alignment bar
(P/N 529 012 900) (P/N 420 476 020) A) (P/N 529 025 600)
B) (P/N 529 028 200)
C) (P/N 529 028 300)
D) (P/N 529 026 800)
A00C1C4
E) (P/N 529 031 000)
APPLICATION
A18B064
Alpine II 3-speed gearbox.
A01B4D4
APPLICATION
Transmission adjuster APPLICATION
Tundra II LT.
(P/N 529 028 500) A) PRS chassis.
B) Alpine II.
Countershaft bearing remover
C) Élan.
(P/N 529 018 700)
D) Safari L.
E) Skandic WT 1996.
A00D0X4
Burnishing bar
(P/N 529 026 402)
APPLICATION
F-Series equipped with “twist
shifter” reverse transmission.

(P/N 529 015 200)
A00A164 A00B464
PRS chassis. Tundra II LT, Safari L and Skandic.
Drive pulley puller A01B514
(P/N 529 023 100)

APPLICATION
1994 models and older except Al-
pine II.
A00C3J4
APPLICATION
Élan.
MMR2001_002_01_01A.FM 01-01-17

Large bushing extractor Large bushing extractor Chaincase seal pusher
(P/N 529 031 100) (P/N 529 035 575) (P/N 529 035 584)
NEW
A00B4I4 A02D1Q4
All models except Tundra/R, Skan- S-Series with RER. A00B504
dic WT/SWT/WT LC and S-Series NOTE: Use this tool only with
with RER. APPLICATION
new puller (P/N 529 035 524) that
NOTE: Use this tool only with has Acme threads and support S, F, CK3 and ZX Series.
former puller (P/N 529 018 600) plate included with extractor (P/N NOTE: This tool replaces chain-
that has regular threads. 529 031 100). case upper seal pusher (P/N 529
032 300).
Large bushing extractor Large bushing installer and small

(P/N 529 035 576) bushing extractor 3-speed transmission bearing
(P/N 529 031 200) extractor
1) Screw M8 x 25 (2)
(P/N 207 182 544)
2) Plate
3) Half ring (2)
(P/N 420 876 330)
4) Ring
(P/N 420 977 480)
A02D1Q4
A00B4J4 1
APPLICATION
All models except Tundra/R, Skan- APPLICATION
2
dic WT/SWT/WT LC and S-Series All models except Tundra/R, Skandic
with RER. WT/SWT/WT LC and S-Series with
NOTE: Use this tool only with RER.
new puller (P/N 529 035 524) that 3
has Acme threads and support
plate included with extractor (P/N
529 031 100).
4
A00C1B4
APPLICATION
Alpine II 3-speed transmission.
01-01-18 MMR2001_002_01_01A.FM

TRA drive pulley puller (27 mm) Drive axle sprocket adjuster Transmission adjuster
(P/N 529 010 100) (P/N 861 725 700) (P/N 529 030 300)
5
2
A18B044 3 A03D1T4
1
TRA drive pulley (27 mm) shaft ex- 4 Vehicles equipped with “push-pull
cept 454, 670 and 779 engines. shifter” reverse transmission.
6
A01B2O4
Parts included in the kit:

1) Block with threads
(P/N 529 010 700)
2) Block without threads
(P/N 529 010 800)
3) Plate
(P/N 529 010 600)
4) Bolt M10 (2)
(P/N 222 007 565)
5) Allen screw M8 (2)
(P/N 222 983 065)
6) Screw M8 (2)
(P/N 222 082 565)
NOTE: When the tool is to be used
between tunnel and sprocket use
screws M8.
APPLICATION
All vehicles except Élan.
MMR2001_002_01_01A.FM 01-01-19
SUSPENSION — MANDATORY SERVICE TOOLS

Shock spring removal kit
(P/N 529 035 504)
Replacement clevis pin:
(P/N 414 528 400)
A01B4O4
APPLICATION
All suspensions with coil spring.
NOTE: The previous shock spring
removal kit (P/N 529 027 100) can
be upgraded by replacing the stop-
per with a wider stopper (P/N 529
035 551).
01-01-20 MMR2001_002_01_01A.FM
SUSPENSION (continued) — RECOMMENDED SERVICE TOOLS

A) Track cleat remover Camber angle tool Track cleat installer
(P/N 529 008 200) (P/N 529 021 600) A) (P/N 529 008 500)
Pins NOTE: Angle finder with a mag- Narrow
(P/N 529 008 204) netic base must be used. B) (P/N 529 028 800)
NOTE: Pins can be rotated 180° de- Suggestion: K-D tool no. 2968 Narrow
pending on whether the tool is used C) (P/N 529 007 700)
by a left-hander or right-hander. Wide
A06B024
A01B1J4
APPLICATION
B) Track cleat remover All DSA front suspensions.
A01B1M4
(P/N 529 028 700)
Track tension gauge APPLICATION
(P/N 529 021 500) A) 1993 and older.
B) 1994 and newer.
C) 1992 and older with wide cleat
opening.
Dome guide
A01F224
(P/N 529 026 500
APPLICATION
A) 1993 and older.
B) 1994 and newer except Élan A00B3X4 A06F1B4
and Tundra II.
All models except Élan. T/A shocks.
MMR2001_002_01_01A.FM 01-01-21

Piston guide Drill bit Kayaba shock adjustment tool
A) (P/N 529 026 600) (P/N 529 031 800) (P/N 529 035 582)
B) (P/N 529 035 608)
A01B564
APPLICATION
A06F1C4 All 3/16 inch rivets. A00A1K4
A) Most T/A shocks. Spring installer (bar) C-7 suspension.
B) C-46 T/A shocks. (P/N 529 005 000)
Hexagonal wrench
Gas shock valve tool (P/N 529 014 700)
(P/N 529 035 570)
A19B024
A00C1I4
APPLICATION
All SC-10 suspensions, Safari and
APPLICATION Skandic prior to 1995.
Tundra II LT, Scout and all SC-10
A02F134
suspensions.
Suspension adjustment wrench
Drive axle holder
1999 and older T/A shocks.
(P/N 529 007 200)
Tool for shock A15B094
(P/N 529 035 614)

APPLICATION
1992 and old Formula C-7.

(P/N 529 032 900)
A01B1E4
A00B5I4
APPLICATION
APPLICATION All models.
2000 and up T/A shocks.
A02F114
APPLICATION
ARM and SC 10 II suspensions.
01-01-22 MMR2001_002_01_01A.FM

(P/N 529 034 100)
A02F124
APPLICATION
CK3 series.
Adjustment wrench
(P/N 861 743 900)
Consists of:
529 024 000
529 025 500
A00B4B4
APPLICATION
1998 and older models with T/A
shock.
Adjustment wrench
(P/N 520 000 126)
A00B5H4
APPLICATION
SC 10 II (coupling blocks).
MMR2001_002_01_01A.FM 01-01-23
VEHICLES — RECOMMENDED SERVICE TOOLS

Protective mat
(P/N 529 030 600)
A01B45W
APPLICATION
All vehicles.
Dolly Snowmobile jack

(P/N 529 029 900) (P/N 529 020 000)
A00B4CJ A01A1JJ
All models. All models.
01-01-24 MMR2001_002_01_01A.FM
VEHICLES (continued) — RECOMMENDED SERVICE TOOLS

Template for hood drilling Terminal (Packard) remover Hose clamp pliers
(P/N 529 034 400) Not sold by Bombardier (P/N 295 000 070)
Snap-on NEW
TT 600-4
NEW
A02H154
F01B1J4
APPLICATION
S-Series. APPLICATION F01D174
NOTE: To drill new hood prior to Models with Packard connectors. APPLICATION
install meters. Some models.
Crimping tool
Flexible spout for oil container (P/N 295 100 164)
(P/N 414 837 300) NEW
F04B044
APPLICATION
All models.
Adjustment wrench F00B0E4

Models with AMP connectors.
A32B044
APPLICATION
To remove and install fuel tank nut
on ZX series.
MMR2001_002_01_01A.FM 01-01-25
Subsection 02 (SERVICE PRODUCTS)
SERVICE PRODUCTS 0
MANDATORY SERVICE PRODUCTS
Retaining compound Paste gasket Medium-strength threadlocker
(P/N 413 703 100) (P/N 413 702 700) (P/N 293 800 060)
Loctite® RC/609: Loctite® 515: Loctite® 243:
Retaining compound (10 mL) Gasket eliminator (50 mL) Threadlocker (10 mL)
(green) (blue, medium strength)
NEW
A00B2T4
APPLICATION
Crankcase halves and gearbox mat-
ing surfaces.
A00B2S4
Paste gasket
(P/N 293 800 038)
APPLICATION F00A0O4
Loctite® 518:
Used for retaining bushings, bear-
ings in slightly worn housing or on Gasket eliminator (50 mL) APPLICATION
shaft. Flywheel nut, crankcase studs, etc.
NOTE: This product replaces Loc-
tite 242 (P/N 293 800 015).
Sealing compound
(P/N 420 297 906) F01B124
High strength threadlocker
Crankcase halves and gearbox Loctite® 271:
mating surfaces.
Threadlocker (10 mL)
(red, high strength)
A00B564
A00B2U4
To seal crankcase on all ZX series Fasteners and studs up to 25 mm
engines. (1 in) diameter.
NOTE: This product replaces the
larger tube (P/N 420 297 905).
MMR2001_002_01_02A.FM 01-02-1
MANDATORY SERVICE PRODUCTS (continued)

Gasket/paint remover Molykote PG 54 Petamo grease
(P/N 413 708 500) (P/N 420 899 763) (P/N 420 899 271)
Loctite® Chisel (10 g)
510 g (18 oz) NEW
A00B5F4
APPLICATION
Lubricate pawl and pawl lock of re-
wind starter.
Grease Isoflex
(P/N 293 550 021)
A00B584
(50 g)
APPLICATION
A00B574
To lubricate lip of all ZX series en-
APPLICATION gine crankshaft seals.
Clean mating surfaces of cylinders
and crankcase. Remove carbon in
combustion chambers.
Loctite® primer
(P/N 293 800 041)
Primer N
128 g (5 oz)
A00B554
APPLICATION
To lubricate some bearings on 3-
cylinder, 453, 493, 593 and 693 en-
gines.
A00B3N4
APPLICATION
To prepare mating surfaces before
applying paste gasket, retaining
compound or threadlockers.
changed. This product is identical
to the P/N 413 708 100.
01-02-2 MMR2001_002_01_02A.FM
RECOMMENDED SERVICE PRODUCTS

Premix oil BOMBARDIER-ROTAX Formula Storage oil
(P/N 413 803 100) XP-S synthetic injection oil (P/N 413 711 600)
(12 x 500 mL) (P/N 413 710 500) (350 g spray can) (12 x 350 g)
(12 x 1 liter)
(P/N 413 711 000)
(3 x 4 liter)
(P/N 413 710 700)
(205 liter)
A00B5L4 Two-stroke
Injection Oil
APPLICATION
F01B354
All pre-mix models.
A02B054
APPLICATION
All engines. APPLICATION
Injection oil
All models.
(P/N 413 802 900)
(12 x 1 liter) NOTE: Only the P/N has been
Premixed coolant - 52°C (- 62°F) changed. This product is identical
(P/N 413 803 000) (P/N 413 711 802) to the P/N 496 014 100.
(3 x 4 liter) (16 x 1 L)
(P/N 413 803 200)
(205 liter) Fuel stabilizer
(P/N 413 408 600)
(12 x 8 oz)
® ®
F01B2H4
APPLICATION
All engines. A00B5E4
A00B3V4
APPLICATION
All liquid cooled models. APPLICATION
All models.
MMR2001_002_01_02A.FM 01-02-3
RECOMMENDED SERVICE PRODUCTS (continued)

Chaincase oil Grease LMZ no. 1 BOMBARDIER LUBE
(P/N 413 801 900) (P/N 413 707 500) (P/N 293 600 016)
(16 x 250 mL) (400 g) (12 x 14 oz)
A00B1Y4
APPLICATION
Mainly used between regulators
or rectifiers and frame to transfer
the heat build-up and to assure a
good ground.
A00B2R4
Synthetic grease
APPLICATION (400 g)
Chaincase lubricant on all fan- (P/N 413 711 500)
cooled models except Skandic WT
A00B4W4
series.
APPLICATION
Synthetic chaincase oil Steering ball joints on all models.
(P/N 413 803 300)
A01B574
(12 x 355 mL) Shock oil
For front and rear suspension com- (32 oz)
ponents and drive axle bearing. (TYPICAL)
Super Lube (grease)

(P/N 293 550 014)
A06F0P4
APPLICATION
A01B4Q4
T/A shocks.
APPLICATION
Chaincase lubricant on all liquid-
cooled models and Skandic WT A00B474
series.
APPLICATION
Exhaust tail pipe grommet.
01-02-4 MMR2001_002_01_02A.FM

Anti-seize lubricant Silicone dielectric grease Bombardier cleaner
(P/N 293 800 070) (P/N 293 550 004) (P/N 293 110 001)
Loctite anti-seize (3 oz) (400 g)
lubricant 236 mL (8 oz) (P/N 293 110 002)
(4 L)
A00B1X4
APPLICATION
On all electric connections. High
tension coil and spark plug connec-
tions. Connector housings, etc.
to the P/N 413 701 700.
F01B2J4
Parts cleaner
APPLICATION
(P/N 413 711 809)
All models.
A00B594 (320 g)
APPLICATION
Mounting surfaces of driven pulley Plastic & vinyl cleaner
and brake disc on countershaft. (P/N 413 711 200)
(6 x 1 L)
Molykote 111
(P/N 413 707 000)
111
A00B3W4
APPLICATION
Crankshaft seals on all engines ex-
cept ZX series ones.
A00B4X4
APPLICATION
Engine crankcase joining surfaces,
pulleys and any greasy surfaces. A00B4V4
APPLICATION
Hood, bottom pan and seat.
MMR2001_002_01_02A.FM 01-02-5

High temperature threadlocker Clear silicone General purpose instant adhesive
(P/N 413 711 400) (P/N 293 800 033) (P/N 293 800 021)
Loctite 648 (green) (5 mL) Loctite 495 (3 g)
F01B1S4
APPLICATION
All models to seal bottom pan.
High temperature RTV sealant

(P/N 413 710 300)
A00B3D4 Ultra Copper
(80 mL)
APPLICATION
A00B2V4
To fasten oil injection nozzle to
crankcase. APPLICATION
NOTE: Only the P/N has been Rubber to metal bonding and most
changed. This product is identical hard plastic.
to the P/N 420 899 788. NOTE: Only the P/N has been
to the P/N 413 703 200.
Pipe sealant
(P/N 293 800 018)
Loctite 592 (50 mL) Gel instant adhesive
(P/N 413 708 300)
Loctite 454-40
20 g (.70 oz)
A00B2W4 A00B5A4
A00B3O4
Engine plugs and senders. All models.
NOTE: Only the P/N has been APPLICATION
changed. This product is identical Isolating foam and rubber strip.
to the P/N 413 702 300.
01-02-6 MMR2001_002_01_02A.FM

Tough adhesive Stripped threads repair kit Paint for frame touch-up
(P/N 413 408 300) (P/N 413 708 600) (P/N 413 401 000)
Loctite Black Max Form-A-thread 81668 Black semi-gloss
3 mL (.10 oz) (spray can)
A00A1J4
APPLICATION
Repair damaged threads of grade
5 (SAE) or 8.8 (metric) maximum. A00B3H4
Do not use in applications where
A00B3P4
temperatures will exceed 149°C APPLICATION
(300°F) or on critical assemblies. All models with a black frame.
APPLICATION
Shifter boot or grip.
MMR2001_002_01_02A.FM 01-02-7
Section 02 LUBRICATION AND MAINTENANCE
Subsection 01 (LUBRICATION AND MAINTENANCE CHART)
PERIODIC MAINTENANCE CHART 0
PRE-SEASON PREPARATION
10-HOUR OR 500 km (300 mi)
(to be performed by dealer)

EVERY 3200 km (2000 mi)
EVERY 240 km (150 mi)
ONCE A YEAR OR
SYSTEM PART/TASK REFER TO
MONTHLY OR
INSPECTION
WEEKLY OR
STORAGE
Rewind Starter Lubrication and Rope
✔ ✔ Subsection 04-09
Condition
Appropriate section:
Engine Head Nuts or Screws ✔ ✔ ✔ See Top End
Engine Mount Nuts ✔ ✔ ✔ Appropriate section:

See ENGINE REMOVAL
Exhaust System ✔ ✔ ✔ Appropriate section:

See ENGINE REMOVAL
Engine Lubrication ✔ ✔ This section no. 1
Cooling System Condition ✔ ✔ ✔ Subsections 04-07 and 04-08
Coolant Replacement
(except fan cooled) ✔ Subsection 04-08
Condition of Seals ✔ ✔ Subsections 04-02 and 04-03

Injection Oil Filter Condition ✔ Subsection 04-06
Injection Oil Filter Replacement ✔ Subsection 04-06
Oil Injection Pump Adjustment ✔ ✔ ✔ Subsection 04-06
Fuel Stabilizer ✔ This section no. 2
Fuel Filter Replacement ✔ This section no. 3
Fuel Lines and Connections ✔ ✔ ✔ Subsection 04-11
Carburetor Adjustment ✔ ✔ ✔ Subsection 04-10
Throttle Cable Inspection ✔ ✔ ✔ ✔ Subsection 04-11
Air Filter Cleaning ✔ ✔ This section no. 4
Drive Belt Condition ✔ ✔ ✔ Subsection 05-02
Condition of Drive and Driven Pulleys ✔ ✔ ✔ Subsections 05-03 and 05-04
Cleaning of Drive and Driven Pulleys ✔ Subsections 05-03 and 05-04
Retorquing of Drive Pulley Screw ✔ Subsection 05-03
Driven Pulley Preload ✔ ✔ ✔ Subsection 05-04
Brake Fluid Level ✔ ✔ ✔ Subsection 05-06
Brake Fluid Change (once a year) ✔ Subsection 05-06
Brake Condition ✔ ✔ ✔ ✔ Subsection 05-06
Brake Adjustment ✔ ✔ Subsection 05-06
Drive Chain Tension ✔ ✔ ✔ Subsections 05-07 and 05-08
Countershaft Lubrication ✔ ✔ ✔ Subsection 05-06
Chaincase/Gearbox Oil Level ✔ ✔ ✔ Subsections 05-07 and 05-08
Gearbox Oil Change
✔ ✔ ✔ Subsection 05-08
(Skandic WT/SWT/WT LC only)
Chaincase/Gearbox Oil Change ✔ ✔ Subsections 05-07 and 05-08
Lubrication of Drive Axle End Bearing** ✔ ✔ ✔ Subsection 07-04
MMR2001_003_02_01A.FM 02-01-1
10-HOUR OR 500 km (300 mi)

EVERY 3200 km (2000 mi)
ONCE A YEAR OR
MONTHLY OR
INSPECTION
WEEKLY OR
STORAGE
Handlebar Bolts. Retorque to 26 N•m
(19 Ibf•ft)
Steering and Front Suspension ✔ ✔ ✔ Subsections 08-02 and 08-03
Mechanism Lubrication**
Steering and Front Suspension ✔ ✔ ✔ Subsections 08-02 and 08-03
Mechanism Condition
Wear and Condition of Skis and Runners ✔ ✔ ✔ Subsection 08-03
Steering and Ski Leg Camber
Adjustment
Section 07:
Suspension Adjustments AS REQUIRED See appropriate subsection
and Operator’s Guide
Section 07:
Suspension Lubrication** ✔ ✔ See appropriate subsection
Suspension Condition ✔ ✔ ✔ Section 07:

See appropriate subsection
Suspension Stopper Strap Condition ✔ ✔ Section 07:

Track Condition ✔ ✔ ✔ Subsection 07-05
Track Tension and Alignment ✔ AS REQUIRED Subsection 07-05
Spark Plugs* ✔ ✔ ✔ Subsection 06-03
Engine Timing ✔ ✔ Subsection 06-02
Battery Condition ✔ ✔ ✔ ✔ Subsection 06-04
Headlight Beam Aiming ✔ ✔ Subsection 09-02
Wiring Harnesses, Cables and Lines ✔ ✔ ✔ Subsection 09-02
Operation of Lighting System
(HI/LO beam, brake light, etc.)
✔ ✔ ✔ Operator’s Guide
Test Operation of Emergency Cut-Out
Switch and Tether Cut-Out Switch
Rags in Air Intake and Exhaust System ✔ ✔ This section no. 5
Engine Compartment ✔ ✔ ✔ This section no. 6
Vehicle Cleaning and Protection ✔ ✔ ✔ This section no. 7
* Before installing new spark plugs at pre-season preparation, it is suggested to burn excess storage oil
by starting the engine with the old spark plugs. Only perform this operation in a well-ventilated area.
**Lubricate whenever the vehicle is used in wet conditions (wet snow, rain, puddles).
02-01-2 MMR2001_003_02_01A.FM
NO. 1 ENGINE LUBRICATION All Models

Restart engine and run at idle speed.
At Storage Inject storage oil until the engine stalls or until a
Engine internal parts must be lubricated to protect sufficient quantity of oil has entered the engine
them from possible rust formation during the stor- (approximately half a can).
age period. With the engine stopped, remove the spark plug
Proceed as follows: and spray storage oil (P/N 496 014 100) into each
Start the engine and allow it to run at idle speed cylinder.
until the engine reaches its operating tempera- Crank slowly 2 or 3 revolutions to lubricate cylin-
ture. ders.
Reinstall the spark plugs and the outlet primer
 WARNING hose or air silencers.
Ensure the track is free of all particles which
could be thrown out while it is rotating. Keep  WARNING
hands, tools, feet and clothing clear of track. This procedure must only be performed in a
Ensure no one is standing in close proximity well-ventilated area. Do not run engine dur-
to the vehicle. ing storage period.
Stop the engine.
At Pre-Season Preparation
Models with a Primer
Add 500 mL (17 U.S. oz) of recommended injec-
To prevent fuel from draining, primer button tion oil to the first full filled fuel tank.
should be pushed all the way in.
Disconnect the outlet primer hose from the primer NO. 2 FUEL STABILIZER
valve (straight coupling).
With the new fuel additives, it is critical to use the
fuel stabilizer (P/N 413 408 600) (250 mL) to pre-
vent fuel deterioration, gum formation and fuel
system components corrosion. Follow manufac-
turer’s instructions for proper use.
Pour fuel stabilizer in fuel tank prior to starting en-
1 gine for internal parts lubrication so that stabilizer
2
flows everywhere in fuel system.
After engine starting, use primer several times so
A17C0EA
that stabilizer flows inside it.
1. Straight coupling
2. To intake manifold Do not drain fuel system.
Insert storage oil (P/N 496 014 100) nozzle into CAUTION: Fuel stabilizer should be added pri-
primer outlet hose. or to engine lubrication to ensure carburetor(s)
protection against varnish deposit.
Models with a Choke
Remove air silencers to spray storage oil into each
carburetor bore.
MMR2001_003_02_01A.FM 02-01-3
NO. 3 FUEL FILTER REPLACEMENT S-Series

Lift hood and remove air filter from air intake si-
Drain fuel tank.
lencer.
Remove fuel line grommet from fuel tank and pull
out inlet fuel line from tank.
A03I0GA 3 1 2 A03H0LA
1
TYPICAL TYPICAL
1. Inlet fuel line 1. Filter
2. Position of grommet when installing
3. Fuel filter
To clean the filter, shake the snow out of it then,
Replace fuel filter. To facilitate the fuel line instal- dry it out.
lation, slide grommet on fuel line about 50 mm
(2 in) away from elbow then install grommet on NO. 5 RAGS IN AIR INTAKE AND
fuel tank and push elbow through grommet. EXHAUST SYSTEM
NO. 4 AIR FILTER CLEANING At storage preparation, block air intake hole and
exhaust system hole using clean rags.
Check that the air box is clean and dry then prop- Remove those rags at pre-season preparation.
erly reinstall the filter.
CAUTION: These snowmobiles have been cali- NO. 6 ENGINE COMPARTMENT
brated with the filter installed. Operating the
snowmobile without it may cause engine dam- Keep clean of grass, twigs, cloth, etc. These are
age. combustible under certain conditions.
NO. 7 VEHICLE CLEANING AND

PROTECTION
Remove any dirt or rust.
To clean the entire vehicle, use only flannel clothes
or Kimtowels® wipers no. 58-380 from Kimberly-
Clark.
CAUTION: It is necessary to use flannel cloths
or Kimtowels wipers on windshield and hood
to avoid damaging further surfaces to clean.
02-01-4 MMR2001_003_02_01A.FM
To clean the entire vehicle, including metallic parts

with a thick coat of grease, use Endust® imported
by Bristol Myers, available at hardware stores or
supermarkets.
For bottom pan cleaning, use Bombardier Cleaner
(P/N 293 110 001 (spray can 400 g) and 293 110
002 (4 L)).
CAUTION: Do not use Bombardier Cleaner on
decals or vinyl.
with a thin coat of grease, use Simple Green®
from Sunshine Makers Inc., available at hardware
stores or at automotive parts retailer.
For vinyl and plastic parts, use Vinyl & Plastic
Cleaner (P/N 413 711 200 (6 x 1 L)).
To remove scratches on windshield or hood: Start
with “Slip Streamer Motorcycle Windshield
Heavy Duty Scratch, Remover”. Finish with “Slip
Streamer Motorcycle Cleaner and Polish”.
NOTE: The latest product may be use alone if only
light scratches are noticeable.
CAUTION: Never clean plastic parts or hood
with strong detergent, degreasing agent, paint
thinner, acetone, products containing chlorine,
etc.
Inspect the hood and repair any damage.
Touch up all metal spots where paint has been
scratched off. Spray all metal parts including shock
chromed rods with BOMBARDIER LUBE (P/N 293
600 016).
Remove drive belt and spray BOMBARDIER
LUBE (P/N 293 600 016) on drive and driven pulley
sheaves.
Wax the hood and the painted portion of the frame
for better protection.
NOTE: Apply wax on glossy finish only. Protect
the vehicle with a cover to prevent dust accumu-
lation during storage.
CAUTION: The snowmobile has to be stored in
a cool and dry place and covered with an
opaque tarpaulin. This will prevent sun rays
and grime from affecting plastic components
and vehicle finish.
Lift rear of vehicle until track is clear of the ground.
Install on a snowmobile mechanical stand.
NOTE: Do not release track tension.
MMR2001_003_02_01A.FM 02-01-5
Section 03 TROUBLESHOOTING
Subsection 01 (ENGINE)
TABLE OF CONTENTS 0
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 ................................................................................................................ 03-04-8
MECHANICAL BRAKE ....................................................................................................... 03-04-8
HYDRAULIC BRAKE .......................................................................................................... 03-04-8
MECHANICAL AND HYDRAULIC BRAKES ...................................................................... 03-04-8
ELECTRICAL SYSTEM........................................................................................................... 03-05-1
SUSPENSION AND TRACK .................................................................................................. 03-06-1
MMR2001_038_03_01ATOC.FM 03-01-1
ENGINE 0
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.

CONDITION NORMAL USE.
Test/Inspection 1. Check spark plugs.
a. Carbon accumulation caused by defective spark plug(s).
Clean carbon accumulation and replace spark plugs.
2. Check ignition timing.
a. Timing is too advanced.
Set timing according to specifications (refer to TECHNICAL DATA).
3. Check carburetor.
a. Fuel passages obstruted.
Clean carburetor and install new filter(s).
b. Fuel level too low.
Adjust float level according to specifications.
4. Check cooling system.
a. Loose fan belt.
Adjust or replace fan belt (refer to TECHNICAL DATA).
b. Low antifreeze level.
Adjust antifreeze level. Then check clamps or hoses.
c. Defective tank cap.
Replace cap.
d. Air in system.
Bleed system.
SYMPTOM ENGINE SUDDENLY TURNS OFF AT HIGH RPM AND/OR WITH LIGHT LOAD.
Test/Inspection 1. Check that all ground wires are well connected.
MMR2001_004_03_02A.FM 03-02-1
SYMPTOM ENGINE SUDDENLY TURNS OFF.

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. Accelerating too fast when engine is cold. Piston expands faster than cylinder.
Replace piston(s). Ask driver to refer to warm-up procedure in Operator’s Guide.
3. Piston(s) seizure on exhaust side (color on piston dome is correct).
a. Kinked fuel tank vent tube.
Relocate fuel tank vent tube.
b. Leaks at fuel line connections or damaged fuel lines.
Replace defective lines.
c. Fuel does not flow through carburetor(s) (foreign particles in needle area and/or
varnish formation in carburetor(s)).
Clean carburetor(s) and install new filter(s).
d. Spark plug heat range is too warm.
Install spark plugs with appropriate heat range (refer to TECHNICAL DATA).
e. Improper ignition timing.
Adjust according to specifications (refer to TECHNICAL DATA).
f. Restriction in exhaust system.
Replace.
g. Compression ratio is too high.
Install genuine parts.
h. Carburetor calibration is too lean.
i. Reed valve improperly adjusted or damaged.
Adjust according to specifications (refer to 593 ENGINE TYPE) and/or install Bom-
bardier’s recommended reed valve.
j. Poor oil quality.
Use BOMBARDIER injection oil.
k. Leaks at air intake silencer.
Replace air intake silencer grommets.
4. Melted and/or perforated piston dome; melted section at ring end gap.
a. When piston reaches TDC, mixture is ignited by heated areas in combustion chamber.
This situation is due to an incomplete combustion of a poor oil quality.
Clean residue accumulation in combustion chamber and replace piston(s). Use
BOMBARDIER injection oil.
b. Spark plug heat range is too high.
Install recommended spark plugs (refer to TECHNICAL DATA).
c. Ignition timing is too advanced.
d. Inadequate fuel quality.
Use appropriate fuel.
e. Carburetion is too lean.
03-02-2 MMR2001_004_03_02A.FM
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.
7. Piston color is dark due to seizure on intake and exhaust sides.
a. Broken or loose fan belt.
Replace fan belt or adjust its tension (refer to TECHNICAL DATA).
b. Cooling system leaks and lowers coolant level.
Tighten clamps or replace defective parts. Add antifreeze in cooling system until
appropriate level is reached.
c. Accumulation of foreign particles in needle and/or main jet area.
Clean carburetor(s).
8. Cracked or broken piston(s).
a. Cracked or broken piston(s) due to excessive piston/cylinder clearance or engine
overreving.
Replace piston(s). Check piston/cylinder clearance (refer to TECHNICAL DATA).
Adjust drive pulley according to specifications (refer to TECHNICAL DATA)
and/or clean pulley sheaves if they are contaminated with greasy particles.
SYMPTOM PISTON RING AND CYLINDER SURFACES ARE GROOVED.

Test/Inspection 1. Check oil quality.
a. Poor oil quality.
2. Check injection pump and its hoses.
a. Inadequate injection pump adjustment and/or defective hoses.
Adjust pump according to specifications (refer to ENGINE) and/or replace hoses.
MMR2001_004_03_02A.FM 03-02-3
SYMPTOM ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH
MAXIMUM OPERATING RPM.
Test/Inspection 1. Check spark plug condition.
a. Fouled spark plugs.
Replace.
2. Check if there is water in fuel.
a. There is water in fuel.
Drain fuel system, then fill it with appropriate fuel.
3. Check items listed in ENGINE RUNS OUT OF FUEL
(refer to fuel and oil systems subsection).
4. Check carburetor adjustments and cleanliness.
a. Inadequate carburetor adjustments or dirt accumulation.
Adjust according to specifications (refer to TECHNICAL DATA) or clean.
5. Check drive belt.
a. Worn belt.
Replace belt if width is 3 mm (1/8”) less than nominal dimension
(refer to TECHNICAL DATA).
6. Check track adjustment.
a. Too much tension and/or improper alignment.
Align track and adjust its tension to specifications (refer to TECHNICAL DATA).
7. Check drive pulley.
a. Improper calibration screw adjustments (TRA pulley) and/or worn bushing(s).
Adjust according to specifications (refer to TECHNICAL DATA) and/or replace bush-
ing(s).
8. Check driven pulley.
a. Worn bushing and/or spring tension.
Replace spring and/or adjust its tension according to specifications
9. Check exhaust system.
a. Restriction.
Replace.
a. Decrease in power due to retarded ignition.
11. Check engine compression.
a. Worn piston(s) and ring(s).
Replace (refer to TECHNICAL DATA for specifications).
12. Check engine cooling system.
a. Engine overheats. Improper fan belt tension.
Adjust fan belt (refer to TECHNICAL DATA).
b. Antifreeze level is low, cap fails to pressurize system or air circulates through lines.
Adjust level, replace cap or bleed cooling system.
13. Check reed valve.
a. Improper tightness and/or opening.
Replace or adjust. Refer to proper ENGINE subsection.
03-02-4 MMR2001_004_03_02A.FM
SYMPTOM ENGINE DETONATION AT MAXIMUM RPM.

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. Check spark plug type.
a. Improper spark plug heat range.
a. Too much restriction.
Replace.
5. Check carburetion.
a. Fouled and/or improper carburetor components.
Clean or replace according to specifications (refer to TECHNICAL DATA).
6. Check compression ratio and combustion chamber volume.
a. Compression ratio is too high.
MMR2001_004_03_02A.FM 03-02-5
SYMPTOM ENGINE TURNS OVER BUT FAILS TO START.

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).
2. Check fuel valve.
a. Fully open fuel valve.
3. Check fuel level.
a. Mixture not rich enough to start cold engine.
Check fuel tank level and use primer.
4. Check spark plug.
a. Defective spark plug (no spark).
Replace spark plugs.
5. Check amount of fuel on spark plug.
a. Flooded engine (spark plug wet when removed).
Do not overprime or overchoke. Remove wet spark plugs, turn ignition switch to
OFF and crank engine several times. Install clean dry spark plugs. Start engine
following usual starting procedure.
6. Check fuel lines.
a. No fuel to the engine (spark plugs dry when removed).
Check fuel tank level; turn fuel valve on if applicable; check fuel filter, replace if
clogged; check condition of fuel and impulse lines and their connections.
a. Insufficient engine compression.
Replace defective part(s) (ex.: piston(s), ring(s), etc.).
03-02-6 MMR2001_004_03_02A.FM
SYMPTOM IRREGULAR ENGINE IDLE.

CONDITION NORMAL USE AFTER ENGINE WARM UP.
Test/Inspection 1. Check choke.
a. Choke plunger may be partially opened.
Readjust.
2. Check carburetor adapter.
a. Air enters through a crack.
Replace.
3. Check air screw position.
a. Inadequate fuel/air mixture.
4. Check ignition system trigger coil air gap.
a. Air gap is too large.
5. Check dimension of pilot jet.
7. Perform engine leak test.
a. Leaking gaskets allow air to enter in engine.
MMR2001_004_03_02A.FM 03-02-7
SYMPTOM HIGH ENGINE OPERATING TEMPERATURE.

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.
3. Verify antifreeze level and check if there is air infiltration in the system or if there
are leaks in gasket areas.
a. Low antifreeze level or air in system.
Add antifreeze until recommended level is reached, bleed system and/or tighten
clamps at fitting.
4. Check if antifreeze flows through system properly.
a. Foreign particles and/or broken coolant pump impeller.
Clean cooling system and/or replace coolant pump impeller.
5. Check thermostat.
a. Thermostat reacts slowly or not at all.
Replace.
6. Check antifreeze concentration.
a. Antifreeze concentration is too high.
Adjust concentration according to Bombardier’s recommendations.
7. Check tank cap.
a. Cap does not hold pressure.
Replace.
a. Improperly adjusted or inadequate carburetor components.
Adjust according to specifications (refer to TECHNICAL DATA) or replace
inadequate component(s).
9. Check cylinder head gaskets.
a. Worn gaskets.
Replace.
a. Ignition timing is too advanced.
11. Check if there are leaks at air intake silencer and/or engine crankcase.
a. Leak(s).
Repair or replace.
12. Check condition and heat range of spark plugs.
a. Melted spark plug tip or inadequate heat range.
Replace.
03-02-8 MMR2001_004_03_02A.FM
SYMPTOM ENGINE EQUIPPED WITH RAVE VALVE DOES NOT REACH ITS FULL
OPERATING RPM (500 TO 1000 RPM SLOWER).
Test/Inspection 1. Check RAVE valve pistons.
a. Valve piston(s) is (are) too far out.
Screw valve piston(s) to bottom.
2. Check RAVE valve stems.
a. Bent RAVE valve stem(s).
Replace.
3. Check RAVE valves.
a. Jammed valve(s).
Clean.
4. Check tension of RAVE springs.
a. Inadequate spring tension.
Replace.
5. Check RAVE pressure holes.
a. Clogged holes.
Clean.
6. Check clamps or sleeves.
a. Damaged clamp(s) or sleeve(s).
Replace.
7. Check exhaust tightness.
a. Exhaust system is leaking leading to a too low back pressure.
Replaces parts and reseal.
SYMPTOM ENGINE EQUIPPED WITH RAVE. ENGINE HESITATES AT MID-SPEED AND

REACHES MAXIMUM PERFORMANCE ONLY AFTER A WHILE.
Test/Inspection 1. Check RAVE valve spring(s).
a. Spring tension is too weak or spring(s) is (are) broken.
Replace.
2. Check RAVE valve cover red adjustment screws.
a. Adjustment screw(s) is (are) too loose.
Adjust according to ASSEMBLY PROCEDURE in appropriate ENGINE subsections.
3. Check RAVE valve movement (RAVE movement indicator P/N 861 725 800).
a. Valve(s) is (are) stuck in open position.
Clean.
SYMPTOM REWIND STARTER ROPE DOES NOT REWIND.

Test/Inspection 1. Check rewind spring.
a. Broken spring.
Replace spring.
MMR2001_004_03_02A.FM 03-02-9
SYMPTOM REWIND STARTER PAWL DOES NOT ENGAGE.

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.
3. Check pawl and rope sheave.
a. Pawl and rope sheave have stuck together because of heat.
Replace.
SYMPTOM ENGINE PINGING.

Test/Inspection 1. Check fuel lines.
a. Bent fuel lines (preventing fuel from flowing through).
Relocate or replace fuel lines.
2. Check if carburetor(s) is (are) clean.
a. Dirt prevents fuel from flowing through.
Clean.
4. Check compression ratio.
Replace inadequate part(s) to obtain manufacturer’s recommended compression
ratio or use a higher grade fuel.
SYMPTOM ENGINE GENERATES A LOT OF VIBRATIONS.

Test/Inspection 1. Check engine supports and stopper.
a. Loose and/or broken supports or interference between support(s) and chassis.
Retighten to specification (refer to TECHNICAL DATA) or replace.
2. Check drive pulley (refer to: vibrations coming from drive pulley).
3. Check carburetor synchronization.
a. Throttle slide heights are adjusted differently and/or throttle slide openings are
unsynchronized.
Adjust throttle slide heights and throttle cable.
03-02-10 MMR2001_004_03_02A.FM
ENGINE LEAK VERIFICATION FLOW CHART
ENGINE LEAK VERIFICATION

FLOW CHART
PRESSURIZE ENGINE
NO
IS ENGINE LEAKING?
YES
CHECK ALL JOINTED SURFACES,

SCREW/STUD THREADS. MOUNTING
FLANGES ETC.
YES REPLACE GASKET OR O-RING,

ANY LEAK FOUND? RE-SEAL LEAKING AREA
NO
CHECK SMALL OIL LINES OF

INJECTION PUMP
AIR BUBBLES FOUND YES

OR OIL MOVING REPLACE BANJO FITTING(S)/LINE(S)
TOWARD PUMP?
NO
REMOVE BLEED SCREW ON CYLINDER HEAD
YES REPLACE O-RING OF CYLINDER HEAD

ARE ANY AIR BUBBLES IN COOLANT?
AND/OR CYLINDER BASE GASKET
NO
BLOCK LARGE HOSES OF

ROTARY VALVE GEAR
LUBRICATION SYSTEM
NO
IS ENGINE STILL LEAKING?
YES
CHECK CRANKSHAFT OUTER

SEAL OF PTO AND
MAG SIDES
YES
ARE SEALS LEAKING? REPLACE DEFECTIVE SEAL(S)
NO
PRESSURIZE ROTARY VALVE GEAR

RESERVOIR IN CRANKCASE
PRESSURIZE ROTARY VALVE GEAR YES

RESERVOIR IN CRANKCASE IS RESERVOIR LEAKING?
NO
UNSEAL PTO CYLINDER AND MAG
CYLINDER SEPARATELY
YES REPLACE DEFECTIVE SEAL(S)

IS RESERVOIR LEAKING?
NO
CHECK LEAKAGE AT DRAIN HOLE

YES BELOW COOLANT PUMP HOUSING
YES REPLACE OIL SEAL OF ROTARY

NO ANY LEAK FOUND? VALVE SHAFT END, BESIDE
COOLANT SEAL
NO
REMOVE ROTARY VALVE COVER, CHECK

SEAL OF ROTARY VALVE SHAFT
YES
IS SEAL LEAKING? REPLACE DEFECTIVE SEAL
NO
CAREFULLY INSPECT ENGINE CASTINGS,

PARTICULARLY THE THREAD HOLE AREAS
YES
ANY LEAK FOUND? REPLACE DEFECTIVE PARTS
NO
ENGINE IS PERFECTLY SEALED

INTERNALLY
A00A23S
MMR2001_004_03_02A.FM 03-02-11
Subsection 03 (FUEL AND OIL SYSTEMS)
FUEL AND OIL SYSTEMS 0

SYMPTOM HIGH FUEL CONSUMPTION OR RICH MIXTURE.
Test/Inspection 1. Check fuel tank.
a. Perforated fuel tank.
Replace fuel tank.
2. Check fuel pump reservoir and carburetor fittings.
a. Leaking fittings.
Replace defective part.
3. Check choke adjustment.
a. Fuel flows through choke circuit while engine runs.
Readjust choke.
4. Check float height in carburetor(s).
a. Fuel level is too high in float bowl(s).
5. Check needle valve.
a. Foreign particles prevent needle valve(s) from closing and/or worn seating area.
Clean or replace needle valve(s), then clean seating area.
SYMPTOM FUEL LEAKS IN ENGINE BASE WHEN ENGINE IS STOPPED.

Test/Inspection 1. Check items 3, 4 and 5 of HIGH FUEL CONSUMPTION.
2. Check fuel pump diaphragm.
a. Cracked diaphragm.
Replace.
MMR2001_004_03_03A.FM 03-03-1
SYMPTOM ENGINE LACKS POWER OR STALLS AT HIGH RPM.

Test/Inspection 1. Check fuel tank vent hose.
a. Kinked or clogged hose.
Relocate or replace.
2. Check fuel filter.
a. Clogged filter.
Replace.
a. Kinked or clogged lines.
4. Check fuel pump flow.
a. Dried diaphragm.
Replace.
a. Varnish.
Clean.
SYMPTOM HIGH INJECTION OIL CONSUMPTION.

Test/Inspection 1. Check oil injection pump adjustment.
a. Oil injection pump adjusted too rich.
Adjust.
2. Check injection pump identification.
a. Wrong pump installed.
Replace with the appropriate pump. Refer to OIL INJECTION SYSTEM.
3. Check injection oil lines and their fitting.
a. Leaking lines and/or cover.
4. Check injection pump cover gasket.
a. Worn gasket.
Replace.
03-03-2 MMR2001_004_03_03A.FM
SYMPTOM ENGINE RUNS OUT OF FUEL (OR LEAN MIXTURE).

Test/Inspection 1. Check fuel filter ball located in fuel tank. Ball must move freely.
a. Corrosion due to oxidation at installation.
Replace fuel filter.
2. 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.
3. Check fuel pump outlet flow.
a. Dirt clogging fuel pump lines or torn membrane.
Clean or replace fuel pump.
4. Check carburetor needle valve(s).
a. Dirt (varnish, foreign particle) clogging fuel line inlets.
Clean.
5. Check main jet.
a. Dirt (varnish, foreign particle) accumulation at main jet.
Clean.
6. Check float height in carburetor bowl(s).
a. Running out of fuel at high speed because float height is too low.
Adjust float height according to specifications.
MMR2001_004_03_03A.FM 03-03-3
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
TRANSMISSION
SYMPTOM THE SNOWMOBILE ACCELERATES SLOWLY, ESPECIALLY WHEN IT IS STOPPED.
Test/Inspection 1. Check drive belt condition.
a. Belt is too narrow (drive belt engagement is higher in drive pulley).
Replace belt if width is less than specified in DRIVE BELT.
2. Check distance between pulleys and/or drive belt deflection.
a. Distance is too small between pulleys or deflection is too high
(drive belt engagement is higher in drive pulley).
Adjust distance between pulleys and/or drive belt deflection according
to specifications (refer to TECHNICAL DATA).
3. Check driven pulley sliding half play.
a. Jammed sliding half.
Replace.
4. Check spring tension of driven pulley sliding half.
a. Sliding half rotation is accelerated when spring tension is too weak.
5. Refer to VIBRATIONS ORIGINATING FROM DRIVEN PULLEY and check items
listed.
6. Check drive pulley spring tension.
a. Spring tension is too weak.
Replace.
SYMPTOM ENGINE MAXIMUM RPM IS TOO HIGH AND TOP SPEED IS NOT REACHED.
Test/Inspection 1. Check items 1, 2 and 3 of THE SNOWMOBILE ACCELERATES SLOWLY,
ESPECIALLY WHEN IT IS STOPPED.
2. Check driven pulley spring tension.
a. Spring tension is too stiff.
3. Check position of the calibration screws. (TRA drive pulley)
a. Selected numbers are too high.
listed.
MMR2001_004_03_04A.FM 03-04-1
SYMPTOM LOOSENESS IS FELT IN DRIVE SYSTEM WHEN ACCELERATING/DECELERATING.

Test/Inspection 1. Check drive chain tension.
a. Drive chain is too loose.
Adjust.
2. Check radial play of driven pulley.
a. Worn key, keyway or splines.
Replace.
SYMPTOM VIBRATIONS ORIGINATING FROM DRIVE PULLEY.

Test/Inspection 1. Check drive belt.
a. Belt width is uneven at many places.
Replace.
2. Check tightening torque of drive pulley screw.
a. Moving governor cup.
Retighten screw.
3. Spring cover screws.
a. Spring cover moves and restrains sliding half movement.
Retighten screws.
4. Check spring cover (TRA TYPE) and/or outer half bushings.
a. Excessive gap between bushings and inner half shaft, thus restraining sliding half
movements.
Replace bushing(s).
5. Check sliding half slider shoes.
a. Worn slider shoes.
Replace.
SYMPTOM VIBRATIONS ORIGINATING FROM DRIVEN PULLEY.

Test/Inspection 1. Check sliding half play.
a. Sliding half runout.
Replace sliding half bushing.
2. Check sliding half and fixed half straightness.
a. Sliding half/fixed half runout.
Replace.
3. Check cam slider shoes.
a. One or two slider shoes out of three are broken.
Replace.
03-04-2 MMR2001_004_03_04A.FM
SYMPTOM PULLEYS DO NOT DOWN SHIFT PROPERLY.

Test/Inspection 1. Check driven pulley spring tension.
2. Refer to VIBRATIONS COMING FROM DRIVEN PULLEY and check items listed.
3. Check drive pulley bushings (cleanliness, wear, etc.).
a. Bushings stick to fixed half pulley shaft.
Clean or replace.
Replace.
SYMPTOM UNEVEN BELT WEAR ON ONE SIDE ONLY.

Test/Inspection 1. Check tightening torque of engine mount bolts.
a. Loose engine mount.
Tighten engine mount nuts/bolts equally.
2. Check pulley alignment.
a. Pulley misalignment.
Align pulleys.
3. Check drive belt contact area on pulleys.
a. Rough or scratched pulley surfaces.
Repair or replace pulley half.
a. Driven pulley bushing worn.
A00D09Y Replace bushing.
MMR2001_004_03_04A.FM 03-04-3
SYMPTOM BELT GLAZED EXCESSIVELY OR HAVING BAKED APPEARANCE.

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. Rusted drive or driven pulley shafts.
Clean shaft with fine steel wool.
3. Check if pulley halves are clean.
a. Oil on pulley surfaces.
Clean pulley halves.
4. Check pulley calibration.
a. Improper pulley calibration.
A00D0AY Calibrate according to specifications.
SYMPTOM BELT WORN EXCESSIVELY IN TOP WIDTH.

Test/Inspection 1. Check drive pulley.
Considerable a. Excessive slippage due to irregular outward actuation movement of drive pulley.
use Carry out drive pulley inspection.
2. Check drive belt identification number.
a. Improper belt angle. (wrong type of belt).
Replace belt with an appropriate drive belt.
3. Check drive belt width.
a. Considerable use.
New belt
Replace belt if width is less than specified specified in DRIVE BELT.
A00D0BY
03-04-4 MMR2001_004_03_04A.FM
SYMPTOM BELT WORN NARROW IN ONE SECTION.

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.
a. Drive pulley not functioning properly.
Repair or replace drive pulley.
4. Check idle speed.
a. Engine idle speed too high.
Adjust according to specifications.
5. Check drive belt length.
a. Incorrect belt length.
Replace belt with an appropriate drive belt (refer to TECHNICAL DATA).
6. Check distance between pulleys.
a. Incorrect pulley distance.
Readjust according to specifications.
7. Check belt deflection.
a. Deflection is too small.
A00D0CY Adjust according to specifications.
SYMPTOM BELT SIDES WORN CONCAVE.

Test/Inspection 1. Check pulley half surfaces.
a. Rough or scratched pulley half surfaces.
Repair or replace.
a. Unspecified type of belt.
A00D0DY Replace belt with an appropriate drive belt (refer to TECHNICAL DATA).
MMR2001_004_03_04A.FM 03-04-5
SYMPTOM BELT DISINTEGRATION.

Test/Inspection 1. Check drive belt identification number.
a. Excessive belt speed.
Using unspecified type of belt. Replace belt with proper type of belt
Clean pulley surfaces with fine emery cloth and wipe clean using Parts Cleaner
A00DOEY (P/N 413 711 809) and a cloth.
SYMPTOM BELT EDGE CORD BREAKAGE.

Test/Inspection 1. Check pulley alignment.
Align pulley according to specifications (refer to TECHNICAL DATA).
A00DOFY
SYMPTOM FLEX CRACKS BETWEEN COGS.

a. Considerable use, belt wearing out.
Replace.
A00D0GY
SYMPTOM SHEARED COGS, COMPRESSION SECTION FRACTURED OR TORN.

Test/Inspection 1. Check drive belt rotational direction.

a. Improper belt installation.
Replace.
2. Check if drive belt rubs against components.
a. Belt rubbing on stationary object.
Relocate components.
a. Violent engagement of drive pulley.
A00D0HY Check drive pulley engagement speed, drive pulley bushings and components.
03-04-6 MMR2001_004_03_04A.FM
SYMPTOM BELT “FLIP-OVER” AT HIGH SPEED.


a. Using unspecified type of belt.
A00D0IY
MMR2001_004_03_04A.FM 03-04-7
BRAKE SYSTEM
MECHANICAL BRAKE
SYMPTOM BRAKE DOES NOT ADJUST AUTOMATICALLY.
Test/Inspection 1. Check ratchet wheel spring.
a. Broken ratchet wheel spring tab.
Replace.
2. Check mobile pad stud.
a. Stud rotates in pad.
Replace.
SYMPTOM BRAKE HANDLE DOES NOT RETURN COMPLETELY.

Test/Inspection 1. Check brake return spring.
a. Broken return spring.
Replace.
2. Check if brake cable moves freely in its housing.
a. Brake cable movement is limited due to oxidation or dirt accumulation.
Replace.
3. Check distance between brake lever and caliper.
a. Distance is too wide.
Adjust according to specifications (refer to TRANSMISSION).
HYDRAULIC BRAKE
SYMPTOM SPONGY BRAKE CONDITION.
Test/Inspection 1. Faulty brake fluid.
Replace brake fluid and bleed system. If problem still occurs, replace master cylinder.
SYMPTOM BRAKE FLUID LEAKING.

Test/Inspection 1. Check for loosen hose connectors.
Replace copper washers and retighten.
2. Check for damaged hose, master cylinder and caliper.
Replace part(s) and check for proper mounting.
MECHANICAL AND HYDRAULIC BRAKES

SYMPTOM BRAKE SYSTEM IS NOISY.
Test/Inspection 1. Check brake pad thickness.
a. Pads are worn up to wear warner.
Replace.
03-04-8 MMR2001_004_03_04A.FM
Subsection 05 (ELECTRICAL SYSTEM)
ELECTRICAL SYSTEM 0
SYMPTOM STARTER DOES NOT TURN.

Test/Inspection 1. Check 30 A fuse located near battery.
a. Burnt fuse.
Check wiring condition and replace 30 A fuse.
2. Check continuity of starter switch contact points.

a. Poor contact of starter switch contact points.
Repair or replace switch.
3. Check continuity between starter switch and solenoid.

a. Open circuit between starter switch and solenoid switch.
Repair.
MMR2001_004_03_05A.FM 03-05-1
SYMPTOM STARTER TURNS; BUT DOES NOT CRANK THE ENGINE.

Test/Inspection 1. Check engine.
a. Engine seized.
Rebuild engine.
2. Check wire connection.
a. Inadequate connection (too much resistance).
Clean and reconnect.
3. Check battery charge.
a. Weak battery.
Recharge battery and verify recharge system and wires.
4. Check battery capacity.
a. Shorted battery cell(s).
Replace.
5. Check solenoid switch contact disc.
a. Burnt or poor contact of solenoid switch contact disc.
Replace solenoid switch.
6. Check continuity of solenoid switch pull-in winding.
a. Open circuit of solenoid switch pull-in winding.
7. Check continuity of solenoid switch hold-in winding.
a. Open circuit of solenoid switch hold-in winding.
8. Check brushes.
a. Poor contact of brushes or worn.
Replace brushes.
9. Check commutator.
a. Burnt commutator.
Turn commutator on a lathe. Respect outer diameter wear limit.
Refer to ELECTRIC STARTER.
10. Check height of commutator mica.
a. Commutator mica too high.
Undercut mica.
11. Check field coil resistance.
a. Shorted field coil.
Repair or replace yoke.
12. Check armature resistance.
a. Shorted armature.
Repair or replace armature.
13. Check tension of brush springs.
a. Weak brush spring tension.
Replace springs.
14. Check yoke assembly magnets.
a. Weak magnets.
Replace yoke assembly.
15. Check if bushings are worn.
a. Worn bushings.
Replace bushings.
03-05-2 MMR2001_004_03_05A.FM
SYMPTOM STARTER TURNS, BUT OVERRUNNING CLUTCH PINION DOES NOT MESH WITH
RING GEAR.
Test/Inspection 1. Check clutch pinion gear.

a. Worn clutch pinion gear.
Replace clutch.
2. Check clutch.
a. Defective clutch.
Replace clutch.
3. Check brackets.
a. Worn or broken brackets.
Replace brackets.
4. Check movement of clutch on splines.

a. Poor movement of clutch on splines.
Clean and correct.
5. Check clutch bushing.

a. Worn clutch bushing.
Replace clutch.
6. Check starter bushings.

a. Worn starter bushing(s).
Replace bushing(s).
7. Check ring gear.

a. Worn ring gear.
Replace ring gear.
MMR2001_004_03_05A.FM 03-05-3
SYMPTOM ELECTRIC STARTER KEEPS TURNING WHEN ENGINE IS STARTED.

Test/Inspection 1. Check clutch.
a. Jammed clutch pinion gear.
Replace or clean.

a. Clutch is stuck on splines.
Clean.
3. Check starter brackets.

a. Broken bracket(s).
Replace bracket(s).
4. Check ignition switch.

a. Ignition switch does not return to its ON position or is short-circuited.
Adjust retaining screw or replace switch.
5. Check solenoid.
a. Shorted solenoid switch winding(s).
6. Check solenoid switch contacts.

a. Melted solenoid switch contacts.
7. Check starter switch.

a. Starter switch returns poorly.
Replace ignition switch.
SYMPTOM NOISE OCCURENCE WHEN STARTING ENGINE.

Test/Inspection 1. Check if ring gear is well-mounted to drive pulley inner half.
a. Loose and/or broken bolts.
Retighten bolts using thread locker or replace ring gear and drive pulley inner half.
SYMPTOM REGULATOR BLACK WIRE IS MELTED (HARNESS SIDE).

Test/Inspection 1. Check that big ground wire at battery is well connected to chassis.
a. Corroded and/or loose connection(s).
Clean and/or retighten.
03-05-4 MMR2001_004_03_05A.FM
SYMPTOM OPTIONAL ELECTRIC STARTER DOES NOT WORK WHEN TURNING IGNITION
SWITCH.
Test/Inspection 1. Check connection of BLACK wire (solenoid ground) in 3-wire housing coming
from magneto (white housing).
SYMPTOM ELECTRIC STARTER SOMETIMES DOES NOT WORK WHEN TURNING IGNITION
SWITCH.
Test/Inspection 1. Check battery cables and starter wires.

2. Check fuse.
a. Oxidized or burnt fuse.
Clean or replace.
3. Check wiring harness connections.

a. Oxidized connections.
Clean or replace defective terminals.

a. Defective contacts in ignition switch.
Replace.
5. Check solenoid of electric starter.

a. Shorted solenoid wiring harness or eroded contact washer.
Replace.
MMR2001_004_03_05A.FM 03-05-5
SYMPTOM ENGINE 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. Verify spark plug cap resistance with an ohmmeter.

a. Defective part.
Replace cap.
3. Verify if problem originated from electrical system wiring harness and/or

accessories and/or ignition cut-out switches by unplugging the 3-wire
connectors between the magneto/generator and the vehicle wiring harness.
Check condition of connectors.
a. Heating, rotating or sharp part in contact with harness. Improper harness routing.
Defective switch(es). Corroded connector terminals.
Replace or repair damaged wires. Reroute where necessary. Replace defective
switch(es). Clean terminals and apply silicone dielectric grease.
4. Verify trigger coil resistance with an ohmmeter and connector condition.

a. Defective coil. Corroded connector terminals.
Replace defective coil. Clean terminals and apply silicone dielectric grease.
5. Verify condition of ignition coil.

a. Mechanically damaged part. Vibration problem. Electrically damaged part.
Tighten mounting screws. Replace ignition coil.
6. Verify condition of ignition generator coils.

Tighten mounting screws. Replace coils.
7. Verify MPEM.
Tighten mounting screws. Replace MPEM, retest and verify ignition timing.
SYMPTOM CDI MODULE DOES NOT WORK.

Test/Inspection 1. Check that high tension coil wires do not touch any metal parts.
a. Short circuit.
Isolate and reroute wires.
SYMPTOM ENGINE STALLS.
CONDITION AT LOW SPEED.

Test/Inspection 1. Verify items 4, 5 and 6 above.
03-05-6 MMR2001_004_03_05A.FM
SYMPTOM IRREGULAR ENGINE SPEED.
CONDITION AT HIGH SPEED.

Test/Inspection 1. Verify items 4 and 5 above and trigger coil/flywheel protrusion air gap.
a. Air gap too large.
Readjust air gap.
SYMPTOM ENGINE IS MISFIRING — ERRATIC SPARK AT SPARK PLUG.
CONDITION RIDING ON WET SNOW.

Test/Inspection 1. Verify if spark plug wires and/or spark plug cap seals are sealing out moisture.
a. Defective wires and/or seals.
2. Verify if ignition system wiring harness connectors are in good condition

and/or are sealing out moisture.
a. Loose connectors, corroded terminals or defective parts.
Clean terminals and apply silicone dielectric grease. Replace defective parts.
Test/Inspection 1. Verify misfiring by observing flash of stroboscopic timing light; unplug

connectors between magneto/generator and vehicle wiring harness to isolate
problem. Check condition of connectors.
a. Defective spark plug(s) and/or cable(s)/cap(s). Defective electrical system wiring
harness and/or accessories and/ignition cut-out switches. Condition of connector
terminals.
Replace defective parts and/or repair damaged wires. Replace defective
CONDITION RIDING IN DEEP AND THICK SNOW.
Test/Inspection 1. Perform all verifications outlined under ENGINE DOES NOT START — NO
SPARK AT SPARK PLUG.
2. Verify spark plugs. Proceed with spark plug analysis in order to identify source
of problem.
a. Defective and/or worn spark plug(s) and/or cable(s) and/or cap(s).
Replace defective part(s). Proceed with ignition system testing procedures.
Perform engine analysis.
MMR2001_004_03_05A.FM 03-05-7
SYMPTOM FOULED (BLACK) SPARK PLUG TIP.

Test/Inspection 1. Check carburetor(s).
a. Carburetion is too rich.
2. Check injection oil consumption.

a. Injection pump flow is too high.
Adjust according to specifications or replace.
3. Check oil quality.

a. Poor oil quality that creates deposits.

a. Leaking piston ring(s).
Replace.
SYMPTOM SPARK PLUG TIP(S) IS (ARE) LIGHT GREY.

Test/Inspection 1. Refer to ENGINE SLOWS DOWN OR STOPS AT HIGH RPM and check items
listed.
2. Check spark plug heat range.

a. Spark plug heat range is too high.
Replace by Bombardier’s recommended spark plug
3. Check if air intake silencer leaks.

a. Air surplus coming from opening(s) located between halves.
Seal.
4. Check carburetor adapter collars.

a. Loose collar(s).
Tighten.
5. Check carburetor adapter(s).

a. Cracked or deformed adapter(s).
Replace.
03-05-8 MMR2001_004_03_05A.FM
SYMPTOM RER (ROTAX ELECTRONIC REVERSE) DOES NOT WORK.

Test/Inspection 1. Check idle speed.
a. Wrong idle speed.
Adjust according to specification (refer to TECHNICAL DATA).

a. Faulty spark plug.
Replace.
3. Check drive belt deflection.

a. Wrong deflection.
4. Check carburetor synchronization and air screw adjustment.

a. Wrong adjustment.
Adjust according to specification (refer to TECHNICAL DATA)
and read carburetor subsection.
5. Check electrical connections.

a. Bad electrical connections or damaged wires.
Clean or replace.
6. Check MPEM.
a. Faulty MPEM.
Replace.
CONDITION AT HIGH ALTITUDE.

Test/Inspection 1. Check high altitude cap continuity.
a. Broken jumper inside high altitude cap.
Replace high altitude cap.
SYMPTOM HEADLAMP NOT LIGHTING.
CONDITION WHITE BULB.

Test/Inspection 1. Check bulb.
a. Gas leak.
Replace bulb.
CONDITION BROKEN ELEMENT.
Test/Inspection 1. Check for loose headlamp housing and bulb socket.

a. Vibration problem.
Tighten headlamp mounting screws. Lock bulb in socket. Replace bulb.
CONDITION MELTED FILAMENT (ENDS OF ELEMENT HOLDER) AND BLACK BULB.
Test/Inspection 1. Check voltage at headlamp at different speeds. It must not be above 15 Vac.
NOTE: If quartz halogen bulb is involved, ensure that proper voltage regulator is
installed.
a. Excessive voltage in lighting circuit.
Replace voltage regulator and ensure proper grounding. Retest.
MMR2001_004_03_05A.FM 03-05-9
SYMPTOM HEADLAMP DIMING.

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. Visually inspect wiring harness for damaged and/or melted wires and/or bad
wire terminal crimping and/or connections.
Repair/replace damaged wires and/or terminals. Reroute harness where necessary.
3. Verify if there is an interconnection between AC and DC current.

a. Faulty installation of optional equipment.
Find optional equipment connected directly to DC ground (BK wire or chassis) or
to any DC hot wire (RD, RD/BL). Disconnect and reconnect to AC current
(YL and YL/BK wires).
4. Verify if optional electric accessories are overloading the magneto/generator.

a. Excessive electrical load to magneto/generator.
Reduce the electrical load by removing excess accessories. Reconnect as
recommended by manufacturer.
5. Hot Grips brand: Verify if they were connected in parallel by mistake.

Reconnect as recommended by manufacturer.
6. Bombardier heating grips: Verify if the return wires of the elements were
grounded to the chassis by mistake.
7. Verify if heating grips installation overloads the magneto/generator capacity.

Reduce the electrical load by removing accessories.
03-05-10 MMR2001_004_03_05A.FM
SYMPTOM FALSE FUEL AND/OR TEMPERATURE GAUGE READINGS.

Test/Inspection 1. Verify if gauge was connected on DC current by mistake (in case of optional
installation).
Find optional wires connected directly to DC ground (BK wire to chassis) or to any DC
hot wire (RD, RD/BL). Disconnect and reconnect to AC current (YL and YL/BK wires).
2. Verify sender unit for resistance variation when moving float arm.
a. Defective or damage part.
Replace sender unit.
3. Verify sender unit for free movement and/or correct arm position.
a. Defective or damaged part.
Correct or replace sender unit.
4. Verify sender unit/gauge wiring harness condition.

Replace or repair damaged wires. Reroute where necessary.
SYMPTOM WITH ENGINE IDLING NO ELECTRICAL ACCESSORIES WORK.

a. Too low idle speed.
Readjust to specifications.
2. Verify regulator.
a. Faulty regulator.
Replace.
SYMPTOM BRAKE LIGHT REMAINS ON.

Test/Inspection 1. Check if bulb is properly installed.
a. Bulb is not installed correctly (contact elements are reversed).
Install bulb correctly.
2. Check brake switch.

a. Switch contact remains closed.
On mechanical brake if brake switich is in good condition, adjust brake cable or
brake switch. On hydraulic brake, replace brake switch.
MMR2001_004_03_05A.FM 03-05-11
SYMPTOM REAR LIGHT BULB FLASHES.

Test/Inspection 1. Check bulb tightness in housing.
a. Looseness at bulb contact elements.
2. Check if rear light is properly connected.

a. Connector housing is partially connected.
Install connector housing properly.
3. Check continuity of wires.

a. Corroded terminals and/or broken wires.
Replace terminal(s) or crimp defective wires.
SYMPTOM TACHOMETER DOES NOT WORK.

Test/Inspection 1. Check continuity of wires.
SYMPTOM HIGH BEAM PILOT LAMP LIGHTS UP WHEN LOW BEAM IS SELECTED.

Test/Inspection 1. Check proper connections.
a. YELLOW wire connected to pilot lamp. Mixed-up connections with heating
element pilot lamps.
Reconnect a YELLOW/BLACK wire to pilot lamp. YELLOW wires are connected to
heating element pilot lamps.
03-05-12 MMR2001_004_03_05A.FM
Subsection 06 (SUSPENSION AND TRACK)
SUSPENSION AND TRACK 0

SYMPTOM SUSPENSION IS TOO LOW.
Test/Inspection 1. Check condition of spring.
a. Spring is weakened or broken.
Replace spring.
2. Check preload of spring.
a. Low spring preload.
Increase preload to the recommended position.
SYMPTOM REAR SUSPENSION BOTTOMS OUT.

Test/Inspection 1. Check rear spring preload or rear arm spring preload.
a. Spring tension is too low.
Increase rear arm spring preload.
SYMPTOM SLIDER SHOES WEAR OUT PREMATURELY.

Test/Inspection 1. Check track tension.
a. Pressure is too great on slider shoes.
SYMPTOM TRACK CLEATS BECOME BLUE.

a. Pressure is too great on cleats.
2. Check slider shoes and/or suspension retaining screws.
a. Worn slider shoes or lost retaining screws.
Replace defective parts and/or tighten loose screws.
MMR2001_004_03_06A.FM 03-06-1
SYMPTOM NOISE OR VIBRATIONS ORIGINATING FROM THE TRACK.

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).
2. Check condition of idler wheel(s).
a. Idler wheel rubber is damaged.
Replace.
3. Check guide cleats.
a. Top portion of guide cleat(s) is bent.
Replace.
4. Check sprockets.
a. One or various teeth of drive shaft sprockets are broken.
Replace sprocket(s).
5. Check track rods and/or internal traction teeth.
a. One or various track rods and/or teeth are broken.
Replace track.
SYMPTOM DERAILING TRACK.

a. Track is too loose.
Adjust.
2. Check if track and slider shoes are properly aligned.
a. Improper alignment.
Adjust.
3. Check for proper suspension fastening.
a. Loose or lost retaining screws.
Install new screws and tighten to recommended torque.
03-06-2 MMR2001_004_03_06A.FM
SYMPTOM REAR SUSPENSION IS TOO STIFF.

a. Track is too tight.
Adjust.
2. Check if axles are properly lubricated.
a. Improper lubrication and/or contaminated grease (sticky oil sludge).
Clean and/or lubricate.
3. Check rear spring preload.
a. Too much preload.
Adjust to recommended position.
SYMPTOM WHEN HANDLEBAR IS TURNED, SNOWMOBILE UNDERSTEERS.

Test/Inspection 1. Check ski runner condition.
a. Worn ski runners.
Replace.
2. Check tension of ski spring adjustment cams.
a. Insufficient ski pressure on the ground.
Increase spring preload.
3. Check if front arm stopper strap is too long.
Shorten stopper strap.
4. Check front arm spring tension.
Loosen spring tension.
5. On Skandic WT series only, check distance between shackle and stopper.
Install horse shoe washer(s) as described in Operator’s Guide.
MMR2001_004_03_06A.FM 03-06-3
SYMPTOM HANDLEBAR IS DIFFICULT TO TURN.

Test/Inspection 1. Check position of ski spring adjustment cams.
a. More pressure on the ground when cam increases spring preload.
Reduce ski spring preload.
2. Check position of stopper strap.
a. More weight when stopper strap is short.
Lengthen front arm stopper strap.
3. Check position of front arm shock adjustment cam(s).
a. When spring tension is weak, more weight is transferred to the skis.
4. Check condition of ball joints.
a. Corrosion restrains movement.
Lubricate or replace.
5. Check swing arm camber.
a. Too much ski leg inclination.
Adjust camber to specifications.
6. Check for proper lubrication.
a. Components need lubrication.
Lubricate. Refer to LUBRICATION AND MAINTENANCE.
SYMPTOM THE SNOWMOBILE IS UNSTABLE

(IT MOVES FROM LEFT TO RIGHT AND VICE VERSA).
a. Worn or bent ski runners.
Replace ski runners.
2. Check ski alignment.
a. Improper ski alignment.
Align skis in order to obtain proper toe-out (opening)
(to adjust, refer to STEERING SYSTEM).
3. Check if bushings are too loose in steering system.
a. Bushings are too loose.
Replace.
4. Check ski pressure.
NOTE: If all parts are in good condition and the customer still complains about an
unstable snowmobile, consider the installation of optional Proactive Control System.
03-06-4 MMR2001_004_03_06A.FM
Section 04 ENGINE
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS 0
377, 443 AND 503 ENGINE TYPES....................................................................................... 04-02-1
ENGINE REMOVAL AND INSTALLATION........................................................................ 04-02-1
ENGINE REMOVAL AND INSTALLATION ........................................................................ 04-02-3
TUNED PIPE IDENTIFICATION ......................................................................................... 04-02-3
TOP END ............................................................................................................................ 04-02-4
CLEANING ......................................................................................................................... 04-02-5
DISASSEMBLY................................................................................................................... 04-02-5
INSPECTION ...................................................................................................................... 04-02-7
ASSEMBLY......................................................................................................................... 04-02-7
BOTTOM END.................................................................................................................... 04-02-12
CLEANING ......................................................................................................................... 04-02-13
DISASSEMBLY................................................................................................................... 04-02-13
INSPECTION ...................................................................................................................... 04-02-13
ASSEMBLY......................................................................................................................... 04-02-13
593 ENGINE TYPE ................................................................................................................. 04-03-1

REMOVAL FROM VEHICLE ............................................................................................... 04-03-1
INSTALLATION ON VEHICLE............................................................................................ 04-03-1
TOP END ............................................................................................................................ 04-03-2
COMPONENT REMOVAL .................................................................................................. 04-03-3
CLEANING ......................................................................................................................... 04-03-3
DISASSEMBLY................................................................................................................... 04-03-3
INSPECTION ...................................................................................................................... 04-03-5
ASSEMBLY......................................................................................................................... 04-03-6
BOTTOM END.................................................................................................................... 04-03-11
CLEANING ......................................................................................................................... 04-03-12
DISASSEMBLY................................................................................................................... 04-03-12
INSPECTION ...................................................................................................................... 04-03-12
ASSEMBLY......................................................................................................................... 04-03-12
LEAK TEST AND ENGINE DIMENSION MEASUREMENT ................................................. 04-04-1

LEAK TEST ......................................................................................................................... 04-04-1
PREPARATION ................................................................................................................... 04-04-1
PROCEDURE ...................................................................................................................... 04-04-2
FINALIZING REASSEMBLY............................................................................................... 04-04-3
ENGINE DIMENSION MEASUREMENT........................................................................... 04-04-5
CYLINDER HEAD WARPAGE ............................................................................................ 04-04-5
CYLINDER TAPER .............................................................................................................. 04-04-5
CYLINDER OUT OF ROUND ............................................................................................. 04-04-5
COMBUSTION CHAMBER VOLUME MEASUREMENT .................................................. 04-04-5
USED PISTON MEASUREMENT ...................................................................................... 04-04-7
MMR2001_005_04_01ATOC.FM 04-01-1
Section 04 ENGINE
CYLINDER/PISTON CLEARANCE ...................................................................................... 04-04-7

RING/PISTON GROOVE CLEARANCE .............................................................................. 04-04-8
RING END GAP................................................................................................................... 04-04-8
CRANKSHAFT DEFLECTION ............................................................................................. 04-04-9
CONNECTING ROD BIG END AXIAL PLAY ...................................................................... 04-04-10
CONNECTING ROD/PISTON PIN CLEARANCE................................................................ 04-04-10
CONNECTING ROD/CRANKPIN CLEARANCE.................................................................. 04-04-10
CRANKSHAFT END-PLAY.................................................................................................. 04-04-11
CHECKING SURFACE FLATNESS ..................................................................................... 04-04-11
RECTIFYING SURFACES.................................................................................................... 04-04-11
CHECKING CRANKSHAFT ALIGNMENT .......................................................................... 04-04-11
CDI SYSTEM........................................................................................................................... 04-05-1

NIPPONDENSO TRIGGER COIL IGNITION SYSTEM....................................................... 04-05-1
DUCATI IGNITION SYSTEM .............................................................................................. 04-05-2
RER IGNITION SYSTEM .................................................................................................... 04-05-3
CLEANING .......................................................................................................................... 04-05-4
DISASSEMBLY ................................................................................................................... 04-05-4
ASSEMBLY ......................................................................................................................... 04-05-5
ADJUSTMENT.................................................................................................................... 04-05-6
OIL INJECTION SYSTEM....................................................................................................... 04-06-1

OIL INJECTION PUMP ....................................................................................................... 04-06-1
OIL SYSTEM LEAK TEST................................................................................................... 04-06-3
OIL PUMP IDENTIFICATION .............................................................................................. 04-06-3
CLEANING .......................................................................................................................... 04-06-3
DISASSEMBLY ................................................................................................................... 04-06-3
ASSEMBLY ......................................................................................................................... 04-06-4
ADJUSTMENT.................................................................................................................... 04-06-4
BLEEDING........................................................................................................................... 04-06-6
CHECKING OPERATION .................................................................................................... 04-06-6
AXIAL FAN COOLING SYSTEM ............................................................................................ 04-07-1

REMOVAL ........................................................................................................................... 04-07-2
CLEANING .......................................................................................................................... 04-07-2
DISASSEMBLY AND ASSEMBLY...................................................................................... 04-07-2
INSTALLATION .................................................................................................................. 04-07-3
FAN BELT REPLACEMENT AND DEFLECTION ADJUSTMENT ...................................... 04-07-3
LIQUID COOLING SYSTEM ................................................................................................... 04-08-1

INSPECTION ....................................................................................................................... 04-08-2
DRAINING THE SYSTEM................................................................................................... 04-08-2
COOLING SYSTEM REFILLING PROCEDURE .................................................................. 04-08-3
04-01-2 MMR2001_005_04_01ATOC.FM
Section 04 ENGINE
REWIND STARTER ................................................................................................................ 04-09-1

INSPECTION ...................................................................................................................... 04-09-2
REMOVAL........................................................................................................................... 04-09-2
ROPE REPLACEMENT ....................................................................................................... 04-09-2
DISASSEMBLY................................................................................................................... 04-09-2
ASSEMBLY......................................................................................................................... 04-09-3
INSTALLATION .................................................................................................................. 04-09-5
CARBURETOR AND FUEL PUMP......................................................................................... 04-10-1

CARBURETOR ................................................................................................................... 04-10-1
IDENTIFICATION ............................................................................................................... 04-10-2
CARBURETOR CIRCUIT OPERATION VERSUS THROTTLE OPENING.......................... 04-10-2
REMOVAL........................................................................................................................... 04-10-2
CLEANING AND INSPECTION.......................................................................................... 04-10-3
DISASSEMBLY AND ASSEMBLY ..................................................................................... 04-10-3
CARBURETOR FLOAT LEVEL ADJUSTMENT ................................................................. 04-10-4
CARBURETOR ADJUSTMENTS ....................................................................................... 04-10-5
INSTALLATION .................................................................................................................. 04-10-6
IDLE SPEED FINAL ADJUSTMENT .................................................................................. 04-10-8
CHOKE................................................................................................................................ 04-10-8
FUEL PUMP ....................................................................................................................... 04-10-9
REMOVAL........................................................................................................................... 04-10-9
PUMP VERIFICATION ........................................................................................................ 04-10-10
INSTALLATION .................................................................................................................. 04-10-10
FUEL TANK AND THROTTLE CABLE ................................................................................... 04-11-1
MMR2001_005_04_01ATOC.FM 04-01-3
Section 04 ENGINE
Subsection 02 (377, 443 AND 503 ENGINE TYPES)
377, 443 AND 503 ENGINE TYPES 0

ENGINE REMOVAL AND INSTALLATION
S-Series 377, 443 and 503 Engine Types
377 engine type Some engines
Super
Lube
Super
Lube
Ultra
Copper 28 Nm
(21 lbfft)
17 Nm
(150 lbfin)
Loctite Some engines
37 Nm 271
(27 lbfft)
37 Nm
(27 lbfft)
39 Nm
(29 lbfft)
Super
Lube
A03C3BS
MMR2001_005_04_02A.FM PARTS FLAT RATE 04-02-1

Section 04 ENGINE
Skandic LT 443 Engine Type and Skandic WT/SWT 503 Engine Type
21 Nm
(15 lbfft)
A29C0FS
04-02-2 PARTS FLAT RATE MMR2001_005_04_02A.FM

Section 04 ENGINE
ENGINE REMOVAL AND

INSTALLATION
Disconnect or remove the following:
 WARNING
Before disconnecting any electrical wire in
starter system always first disconnect the
BLACK negative battery cable (on electric
starting models).
– negative cable from battery

(on electric starting models)
– guard
– drive belt
– drive pulley using appropriate puller, refer to
DRIVE PULLEY
– air silencer and carburetors
– impulse line from engine crankcase
– electrical connector housings
– exhaust pipe
– oil pump inlet line and plug it
– oil pump cable
– rewind cable: tie a knot near rewind housing
and remove starting grip.
TUNED PIPE IDENTIFICATION

This part is identified on welded support.
Second number sequence of P/N is stamped on
part.
A03C1KA
1
1. Identification: 0467 for 514 046 700
MMR2001_005_04_02A.FM 04-02-3
Section 04 ENGINE
TOP END
22 Nm
(16 lbfft) 2 1 2 22 Nm
(16 lbfft)
1
1 2 22 Nm
(16 lbfft)
All except 443 engine
7 6
7 8
22 Nm
(16 lbfft)
9
10
Grease
443 and
503 engines
only
A23C08S

Section 04 ENGINE
NOTE: The following procedures can be done 377 Engine

without removing the engine from chassis. To remove piston pin no. 9, use piston pin puller
(P/N 529 035 503).
CLEANING Fully screw puller handle.
Discard all gaskets. Use Gasket Remover (P/N 413 Insert puller end into piston pin.
708 500) to clean mating surfaces.
Screw (LH threads) extracting nut.
Clean all metal components in a non-ferrous metal
Hold puller firmly and rotate puller handle counter-
cleaner.
clockwise to pull piston pin.
Scrape off carbon formation from cylinder exhaust
port, cylinder head and piston dome using a wood-
en spatula.
NOTE: The letters “AUS” and arrow on the pis-
ton dome must be visible after cleaning.
Clean the piston ring grooves with a groove clean-
er tool, or with a piece of broken ring.
DISASSEMBLY
Remove top fan cowl, intake sockets and lower
fan cowl.
A01B1AA
Remove cylinder heads.
Place a clean cloth or rubber pad (P/N 529 023 400) TYPICAL
over crankcase to prevent circlips no. 10 from fall- NOTE: The PTO cylinder or fan housing have to be
ing into crankcase. Then with a pointed tool insert- removed to give access to MAG piston pin with
ed in piston notch, remove both circlips from pis- the puller.
ton no. 8.
443 and 503 Engines
On these engines, piston pin needle bearing is
mounted without a cage.
Use piston pin puller (P/N 529 035 503) along with
18 mm sleeve kit (P/N 529 035 541) and locating
sleeve (P/N 529 023 800).
NOTE: The locating sleeve is the same that con-
tains new cageless bearing.
Place a clean cloth or rubber pad (P/N 529 023 400)
over crankcase to prevent circlips no. 10 from fall-
ing into crankcase. Then with a pointed tool insert-
ed in piston notch, remove both circlips from pis-
ton no. 8.
A02C29A
TYPICAL
MMR2001_005_04_02A.FM 04-02-5
Section 04 ENGINE
Insert piston pin puller (P/N 529 035 503) making

sure it sits squarely against piston.
A02C2CA
TYPICAL — PISTON PIN EXTRACTION
1 2 3
A02C2AA 1
TYPICAL
1. Properly seated all around
Install sleeve then shouldered sleeve over puller

rod.
1 2
A02C2DA
TYPICAL
1. Sleeve inside bearing
2. Thrust washer
3. Shouldered sleeve end
Remove puller. Pull out shouldered sleeve careful-

ly.
A02C2BA
TYPICAL — INSTALLATION OF SLEEVE KIT

1. Sleeve
2. Shouldered sleeve
Pull out piston pin no. 10 by unscrewing puller un-

til shouldered sleeve end is flush with thrust wash-
er of piston pin bearing.
A02C2EA
TYPICAL
04-02-6 MMR2001_005_04_02A.FM
Section 04 ENGINE
Remove piston from connecting rod.

Install locating sleeve. Then push needle bearings
along with thrust washers and sleeve.
A02C2FA 1 2
TYPICAL
1. Locating sleeve A02C2GA
2. Sleeve
TYPICAL
NOTE: 0.25 and 0.5 mm oversized piston and 1. Sleeve
rings are available if necessary. Grease thrust washers and install them on each
Use a locking tie to fasten all needles and thrust end of needles.
washers along with locating sleeve. Insert cageless bearing into connecting rod.
INSPECTION
Refer to ENGINE DIMENSIONS MEASUREMENT.
ASSEMBLY
443 and 503 Engines
When reinstalling original needle bearings, make
sure that 31 needles are inserted between sleeve
and locating sleeve.
When installing a new cageless bearing, replace
half plastic cages by sleeve. A02C2HA
TYPICAL — CAGELESS BEARING AND SLEEVE INSTALLED
MMR2001_005_04_02A.FM 04-02-7
Section 04 ENGINE
Mount piston over connecting rod with the letters 377 Engine
“AUS” (over an arrow on the piston dome) facing To center the piston pin with the connecting rod
in the direction of exhaust port. bearing, use centering tool (P/N 529 009 100).
1
AUS
529 009 100
A01C01A
1. Exhaust
Install shouldered sleeve.

A01B1SA
NOTE: The circlip on the opposite side can be in-

stalled before pin installation, the tool will easily
go out.
Use piston pin puller (P/N 529 035 503) to install a
piston pin that cannot be installed as described
above.
All Models
To minimize the effect of acceleration forces on
circlip, install each circlip so the circlip break is at
6 o’clock as illustrated. Use piston circlip installer
(P/N 529 035 561).
Insert circlip in tool at an angle.
A02C2IA
TYPICAL — SHOULDERED SLEEVE INSTALLATION
Install piston pin puller and turn handle until piston

pin is correctly positioned in piston.
A02C2KA
1. Circlip
A02C2JA
TYPICAL
– Remove piston pin puller and sleeve kit.
04-02-8 MMR2001_005_04_02A.FM
Section 04 ENGINE
Square it up using a finger. Using square end of tool, push circlip in until it
rests in groove.
1
A02C2NA
A02C2LA
1. Circlip in groove
1. Circlip
Mount tool in piston making sure that circlip break
Continue to square it up using round end of circlip is facing down.
installer.
A02C2OA 1
TYPICAL
1. Circlip break facing down
A02C2MA
MMR2001_005_04_02A.FM 04-02-9
Section 04 ENGINE
Hold tool firmly against piston then strike on round NOTE: The ring compressor will not fit on over
end of tool. Circlip will move from tool groove to size pistons.
piston groove. Check flatness of intake sockets no. 6. Refer to
ENGINE DIMENSION MEASUREMENT and look
for Checking Surface Flatness.
At cylinder no. 4 and/or cylinder head no. 3 instal-
lation, use aligning tool or exhaust manifold itself
to ensure sealing of intake manifold and exhaust
before tightening cylinder head nuts.
ALIGNING TOOL
ENGINE TYPE
P/N
377, 443 and 503 420 876 171
A02C2PA
TYPICAL
420 876 171
A17C01A
A01C02A 2
1. Piston notch
2. Circlip break at 6 o’clock
CAUTION: Circlips must not move freely in the

groove after installation. If so, replace them.
NOTE: Be sure to restore the chamfer around all
cylinder sleeve port openings.
Before inserting piston in cylinder no. 4, lubricate
the cylinder with new injection oil or equivalent.
Install proper ring compressor on piston assembly. 1
A17C02A
RING COMPRESSOR
ENGINE TYPE 1. Or use exhaust manifold to align cylinders
P/N
377 and 443 420 876 090
503 420 876 970
04-02-10 MMR2001_005_04_02A.FM
Section 04 ENGINE
Position distance nuts no. 2 as illustrated.
A03C1XA 2 1
1. Exhaust
2. Distance nuts
Cross torque cylinder head nuts nos. 1 and 2 to 22

N•m (16 lbf•ft); torque each cylinder head individ-
ually.
Install armature plate, fan housing and then air de-
flector.
Install a gasket on each side of the air deflector.
Torque intake socket bolts to 22 N•m (16 lbf•ft).
MMR2001_005_04_02A.FM 04-02-11
Section 04 ENGINE
BOTTOM END
2 1
3
Anti-seize
lubricant
3
Anti-seize
lubricant
Anti-seize
lubricant
10
22 Nm 9
(16 lbfft) 6 2
7
503: 22 Nm
(16 lbfft) 8
377 and 443: 10 Nm
(89 lbfin) 11
22 Nm
A03C1IU (16 lbfft)

Section 04 ENGINE
NOTE: Engine must be removed from chassis to ASSEMBLY

perform the following procedures.
Smear anti-seize lubricant (P/N 413 701 000) on
Remove engine from chassis.
part of crankshaft where bearing fits.
Remove fan guard, rewind starter, starting pulley,
To check proper clearance between bearing no. 3
trigger coil wire from 4-connector housing, mag-
and counterweight, use feeler gauge (P/N 420 876
neto flywheel then fan housing.
620).
Remove stator plate.
Mount second bearing with distance gauge (P/N
420 876 822) for 377 and 443 and (P/N 420 876
CLEANING 824) for 503 for proper positioning.
Discard all seals, gaskets and O-rings. 1 2
cleaner. Use gasket remover (P/N 413 708 500)
accordingly.
Remove all trace of Loctite 243 from crankshaft
taper.
Remove old sealant from crankcase mating sur-
faces with Bombardier gasket remover (P/N 413
708 500).
CAUTION: Never use a sharp object to scrape
away old sealant as score marks incurred are
A00C46A
detrimental to crankcase sealing.
1. Feeler gauge
2. Distance gauge
DISASSEMBLY
Prior to installation, place bearings into an oil con-
To remove bearings nos. 3 and 4 from crankshaft, tainer filled with oil heated to 75°C (167°F).
use a protective cap and a special puller, as illus-
trated. This will expand bearings and ease installation. In-
stall bearings with groove as per exploded view.
1 Bearings are pressed on crankshaft until they rest
against radius. These radius maintain the gap
needed for bearings lubrication.
When installing crankshaft, position drive pins
no. 10 as illustrated.
A00C38A
2
1. PTO side
2. MAG side
INSPECTION
Refer to ENGINE DIMENSIONS MEASUREMENT.
A03C1HA 1
TYPICAL
1. Drive pins
MMR2001_005_04_02A.FM 04-02-13
Section 04 ENGINE
At seal no. 2 assembly, apply a light coat of lithium 503 Engine Type
grease on seal lip. Torque screws nos. 6, 7, 8 and 11 to 10 N•m (89
For bearing lubrication purpose, a gap of 1.0 mm lbf•in) then to 22 N•m (16 lbf•ft) following illus-
(.040 in) must be maintained between seals and trated sequence.
bearings.
When installing plain oil seals (seal without locat- 13 9 7 1 3 5 11
ing ring or without spacing legs), ensure to main-
tain 1.0 mm (.040 in) gap.
1 A
2
14 10 6 4 2 8 12
A17C08A
3
377 and 443 Engines
Torque screws to proper torque in the following
sequence.
9 7 13 A 11 5
A17C07A
1 3
1. Bearing
2. Feeler gauge
3. Plain oil seal
A. 1 mm (.040 in)
Crankcase halves nos. 1 and 9 are factory matched

and therefore, are not interchangeable as single
halves.
Prior to joining of crankcase halves, spray some
new injection oil (or equivalent) on all moving parts
of the crankshaft. Spray Primer N (P/N 413 708 4 2
100) on one of mating surfaces. Let it dry for 10 to 10 8 14 A 12 6
20 minutes. A09C05A
Apply paste gasket (P/N 413 702 700) no. 5 on the A. 10 N•m (89 lbf•in)
All the other screws are torqued to 21 N•m (15 lbf•ft)
other mating surface.
NOTE: Primer N allows Loctite 515 to fully cure All Engines
on aluminum surfaces. It increases filling capacity To install magneto, refer to CDI MAGNETO.
and reduce curing time.
Position the crankcase halves together and tight-
en bolts by hand then install and tighten armature
plate on magneto side to correctly align the crank-
case halves.
04-02-14 MMR2001_005_04_02A.FM
Section 04 ENGINE
Subsection 03 (593 ENGINE TYPE)
593 ENGINE TYPE 0

Skandic WT LC
REMOVAL FROM VEHICLE

Open hood.
Remove tuned pipe and muffler.
Drain engine coolant.
Remove or unplug the following then lift off engine
from engine compartment.
NOTE: Use of a hoist is recommended.
– guard
– air silencer
– drive belt
– rewind starter handle
– drive pulley (not necessary if engine has not to
be disassemble)
– hood
– carburetors
– impulse hose and electrical connectors
– oil injection inlet line at oil injection pump, install
hose pincher
– oil pump cable
– coolant hoses between cylinder head and radiator
– coolant by-pass hose
– coolant hose at front of coolant reservoir
– engine support screws
– engine stopper (left rear of engine).
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:
– After throttle cable installation, check carbure-
tor maximum throttle opening and oil injection
pump adjustment.
– Check pulley alignment and drive belt tension.
– Seal exhaust ball joints with Ultra Copper (P/N
413 710 300).
MMR2001_006_04_03A.FM 04-03-1
Section 04 ENGINE
TOP END
12 Nm 5
29 Nm (106 lbfin)
1
(21 lbfft)
3
6
9
7
11 8
2 12
13
14 10
M8: 23 Nm
29 Nm 4 (17 lbfft)
15
(21 lbfft)
Loctite
518
16
17
18 19
20
Injection oil
21
A29C0HS

Section 04 ENGINE
COMPONENT REMOVAL
Most engine components can be removed with
engine on vehicle such as:
– cylinder head
– piston(s)
– cylinder(s)
– rewind starter
– oil pump
– water pump
– magneto flywheel
A32C15A
– RAVE valve(s)
RAVE VALVE PARTIALLY REMOVED
– reed valve(s).
2, Cylinder
CLEANING
Remove spark plugs, coolant outlet no. 30. Un-
Discard all gaskets and O-rings. screw cylinder head cover no. 2 then cylinder
Clean all metal components in a non-ferrous metal head no. 3.
cleaner.
18, Piston
port cylinder head and piston dome using a wood- Place a clean cloth or rubber pad (P/N 529 023 400)
en spatula. over crankcase. then with a pointed tool inserted
in piston notch, remove both circlips no. 20 from
NOTE: The letters “AUS” (over an arrow on the
piston no. 18.
piston dome) must be visible after cleaning.
Clean the piston ring groove with a groove cleaner
tool or with a piece of broken ring.
DISASSEMBLY
RAVE System
NOTE: RAVE stands for Rotax Adjustable Variable
Exhaust.
Remove spring clip no. 5, cover no. 7 and spring
no. 8.
Remove spring no. 10.
Unscrew valve piston no. 9.
Remove bellows no. 11 and spring no. 12.
Remove cylindrical screws. Remove valve hous-
A02C29A
ing no. 13.
TYPICAL
Pull out exhaust valve no. 15.
MMR2001_006_04_03A.FM 04-03-3
Section 04 ENGINE
This engine is equipped with cageless piston pin Install sleeve then shouldered sleeve over puller
bearings. rod.
1 2
A32C17A
A02C2BA
20 mm sleeve kit (P/N 529 035 542) and locating 1. Sleeve
sleeve. 2. Shouldered sleeve
NOTE: The locating sleeve is the same that con- Screw (LH threads) extracting nut.
Insert piston pin puller (P/N 529 035 503) making til shouldered sleeve end is flush with thrust wash-
sure it sits squarely against piston. er of piston pin bearing.
A02C2CA
A02C2AA 1
TYPICAL
04-03-4 MMR2001_006_04_03A.FM
Section 04 ENGINE

1 2 3
along with thrust washers and sleeve.
A02C2DA
A02C2FA 1 2
TYPICAL TYPICAL
1. Sleeve inside bearing 1. Locating sleeve
2. Thrust washer 2. Sleeve
Remove puller. Pull out shouldered sleeve carefully. INSPECTION

NOTE: Refer to LEAK TEST AND ENGINE DIMEN-
SIONS MEASUREMENT.
RAVE System
Check valve rod housing and cylinder for clogged
passages.
A02C2EA
TYPICAL
A32C16A 2 1
1. Draining hole
2. Passages
NOTE: Oil dripping from draining hole indicates a

loosen spring or damaged bellows.
MMR2001_006_04_03A.FM 04-03-5
Section 04 ENGINE
11, Bellows
Check for cracked, dried or perforated bellows.
8, Spring
Preload in
Wire Free N (lbf) at
Engine Spring dia. length compressed
type P/N mm mm length of
(in) (in) 14 mm
(.551 in) 1
0.9 48.5 15.9
593 420 239 944
(.031) (1.91) (3.56)
ASSEMBLY
RAVE System
A02C2GA
Install RAVE valve with its mention top as illustrated
in the removal photo. Tighten red cap no. 6 screw TYPICAL
to bottom. 1. Sleeve
Grease thrust washers and install them on each

4,18, Cylinder and Piston end of needles.
Be sure to restore the chamfer around all cylinder Insert cageless bearing into connecting rod.
sleeve port openings.
Before inserting piston in cylinder, lubricate the
cylinder with new injection oil or equivalent.
2,3,4, Cylinder Head Cover, Cylinder

Head and Cylinder
Check flatness of part sealing surfaces. Refer to
LEAK TEST AND ENGINE DIMENSION MEASURE-
MENT and look for Checking Surface Flatness.
When installing a new cageless bearing, replace
half plastic cages by sleeve.
NOTE: 593 engine cageless bearings have 28 A02C2HA
needles. TYPICAL — CAGELESS BEARING AND SLEEVE INSTALLED
At assembly, place the pistons over the connecting

rods with the letters “AUS” (over an arrow on the
piston dome) facing in direction of the exhaust port.
1
AUS
A01C01A
1. Exhaust
04-03-6 MMR2001_006_04_03A.FM
Section 04 ENGINE
Install shouldered sleeve. Insert circlip in tool at an angle.
A02C2KA
TYPICAL
1. Circlip
A02C2IA
Square it up using a finger.
Install piston pin puller and turn handle until piston 1

A02C2JA
TYPICAL
CAUTION: Always install new circlips.

To minimize the effect of acceleration forces on A02C2LA
circlip, install each circlip so the circlip break is at TYPICAL

6 o’clock as illustrated. Use appropriate piston cir- 1. Circlip
clip installer.
PISTON CIRCLIP
ENGINE TYPE
INSTALLER (P/N)
593 529 035 562
MMR2001_006_04_03A.FM 04-03-7
Section 04 ENGINE
Continue to square it up using round end of circlip Mount tool in piston making sure that circlip break
installer. is facing down.
A02C2OA 1
TYPICAL
A02C2MA
Hold tool firmly against piston then strike on round
TYPICAL end of tool. Circlip will move from tool groove to
piston groove.
Using square end of tool, push circlip in until it
rests in groove.
A02C2PA
TYPICAL
A02C2NA
TYPICAL
04-03-8 MMR2001_006_04_03A.FM
Section 04 ENGINE
Install outlet socket and tighten screws to 12 N•m

(106 Ibf•in). Note position of longer screw.
A01C02B 1
TYPICAL
A32C19A 1
1. Circlip break
1. Longer screw
CAUTION: Circlips must not move freely after
installation; if so, replace them. 17, Reed Valve
Coat both sides of a new cylinder gasket with Loc- Blades have a curved shape. Install with their
tite 518 then, install it on crankcase. curve facing reed block.
Loosely install cylinders. With blade stopper no. 16 removed, check reed
Install exhaust manifold then, tighten cylinder re- valve for proper tightness. There must be no play
taining screws to 29 N•m (21 lbf•ft) in a criss-cross between blade and valve body when exerting a
sequence. finger pressure on blade at blade stopper location.
At assembly, torque cylinder head screws to 29 In case of a play, turn blade upside down and re-
N•m (21 Ibf•ft) in the following illustrated sequence. check. If there is still a play, replace blade and/or
valve body.
5 7
11 1 3 9
12 4 2 10 1
6 8
A32C18A
TYPICAL A06C0FA
1. No play
MMR2001_006_04_03A.FM 04-03-9
Section 04 ENGINE
Check distance from blade stopper outer edge and

distance from center of reed valve block.
A A
A06C36A
TYPICAL
A. 17.0 - 0, + 0.75 mm (.669 - 0, + .030 in)
Bent blade stopper as required to obtain the prop-

er distance.
Blade stoppers may slightly interfere with cylinder
during installation. Adjusted distance will be re-
duced automatically upon installation.
04-03-10 MMR2001_006_04_03A.FM
Section 04 ENGINE
BOTTOM END
Isoflex
Anti-seize
lubricant
Petamo
2
3 Isoflex
Petamo
Anti-seize
Anti-seize lubricant
lubricant
Loctite
Petamo 243
Anti-seize
lubricant
Sealing compound
Molykote
111
29 Nm
(21 lbfft)
Loctite
648 Loctite
243
Petamo
Loctite
648
29 Nm
A32C1AT (21 lbfft)
MMR2001_006_04_03A.FM
PARTS FLAT RATE 04-03-11
Section 04 ENGINE
NOTE: Engine must be removed from chassis to 2, Crankshaft Bearing

CLEANING Prior to installation, place bearings into an oil con-
Discard all oil seals, gaskets, O-rings and sealing tainer filled with injection oil previously heated to
rings. 75°C (167°F). This will expand bearing and ease
Clean all metal components in a non-ferrous metal installation.
cleaner. Use Gasket remover (P/N 413 708 500) Some bearings must be lubricated with Isoflex
accordingly. grease (P/N 293 550 021).
Remove old paste gasket from crankcase mating CAUTION: Use only the recommended Isoflex
surfaces with Gasket remover (P/N 413 708 500). grease. Make sure not to push Isoflex grease be-
CAUTION: Never use a sharp object to scrape tween outside bearing race and half crankcase.
away old sealant as score marks incurred are det- NOTE: The 50 g tube corresponds to 50 cc of grease.
rimental to crankcase sealing. Fill PTO side inner seal with Isoflex grease.
DISASSEMBLY
General
To remove drive pulley, refer to DRIVE PULLEY.
To remove magneto, refer to CDI SYSTEM.
2,3, Crankshaft Bearing

To remove bearings from crankshaft, use a protec-
tive cap and special puller, as illustrated.
A32C1BA 1
1. PTO side inner seal filled with Isoflex grease
Put 35 to 40 mL of grease in a syringe.

2
With the syringe, fill the outer ball bearing with
grease.
A00C0HA
1. PTO side
2. MAG side
INSPECTION
SIONS MEASUREMENT.
ASSEMBLY
A32C0AA
Coat lip of all seals with Petamo grease (P/N 420
899 271). BALLS COATED WITH A SEAM OF GREASE
04-03-12 MMR2001_006_04_03A.FM
Section 04 ENGINE
Coat inner side of seal and set it in place. Drop 50 mL (2 U.S. oz) of injection oil in the pan
under central gear to lubricate pump gearing as
per photo.
A32C0BA 1
1. Fill with grease and set in place
A32C0DA 1
Use the remaining grease to coat the inner side of
1. Oil bath
the ball bearing.
Crankcase Assembly
IMPORTANT: The total assembly sequence, in-
cluding sealing compound spreading, screwing
and torquing of bolts according to the proper se-
quence must be performed within 10 minutes.
Before screwing both parts of crankcase, seal it
with a sealing compound (P/N 420 297 905). Make
sure surfaces are clean and degreased before ap-
plying sealing compound.
Spread a seam of 1.2 mm (1/16 in) maximum in
diameter on surface of lower crankcase half.
A32C0CA
Apply 20 mL of grease to MAG side outer bearing.

At crankshaft installation, position drive pins as il-
lustrated.
A32C0EA
A32C1CA 1
1. Position pins
MMR2001_006_04_03A.FM 04-03-13
Section 04 ENGINE
As far as possible, sealing compound must be ap-

plied in one run to avoid any risks of leaking through
the crankcase.
A32C0FA
SEAMING COMPLETED — CONTACT SURFACES COVERED

AND SCREW HOLES SURROUNDED
Screw the 4 central bolts to squeeze compound

between crankcase halves before it starts to dry.
NOTE: Sealing compound spreading plus screw-
ing of engine central four bolts must be performed
within 2 minutes to ensure a good sealing and
avoid linking.
Screw all crankcase bolts in place in the following
sequence and to the appropriate torque through a
two steps torquing: first, screw bolts up to 60%
of the final torque (18 N•m (13.5 lbf•ft) for most
of the bolts), then, tighten to the required torque
(i.e. 29 N•m (21 lbf•ft)).
11 9 14 4 1 16 5 8 18
12 10 13 2 3 15 6 7 17
A32C0GA A B
A. Torque bolts 1 through 16 to 29 N•m (21 lbf•ft)
B. Torque bolts 17 and 18 to 9 N•m (80 lbf•in)
04-03-14 MMR2001_006_04_03A.FM
Section 04 ENGINE
Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT)
LEAK TEST AND ENGINE DIMENSION

MEASUREMENT 0
LEAK TEST 6. Using hose pinchers (P/N 295 000 076), block
pump shaft oil hose and lubrication nipple on PTO
The following gives verification procedures for liq- side.
uid cooled engines though it also applies to fan
cooled engines. For FC engines, do not consider
information pertaining to coolant system and
pump shaft oil gear reservoir.
On FC twin-cylinder engines, each cylinder cannot
be verified individually due to leakage from one
cylinder to the other through labyrinth sleeve in
center of crankshaft.
PREPARATION
1. Remove tuned pipe.
2. Install plug over exhaust manifold.
3. Remove carburetors. A32C1EA
4. Insert plugs in intake rubber boots. Tighten with

7. Install air pump on exhaust plug.
clamps already there.
NOTE: If necessary, lubricate air pump piston with
mild soap.
CAUTION: Using hydrocarbon lubricant (such
as engine oil) will damage rubber seal of pump
piston.
A32C1DA
5. Using a hose pincher (P/N 295 000 076), block im-

A32C1FA
pulse hose.
MMR2001_007_04_04A.FM 04-04-1
Section 04 ENGINE
8. Activate pump and pressurize engine to 34 kPa 2. Small injection oil lines coming from pump.
(5 PSI). Do not exceed this pressure.
9. Engine must stand this pressure during 3 min-
utes. If pressure drops before 3 minutes, check
tester kit by spraying a soapy solution on pump
cylinder, all plugs and fittings.
– If tester kit is leaking, bubbles will indicate
where leak comes from.
– If tester kit is not leaking, check engine as per
following procedure.
PROCEDURE
NOTE: A flow chart has been prepared as a visual
reference. See last page of this chapter. 1 2 1
A32C1GA
Using flow chart and following text, pressurize
area to be tested and spray soapy solution at the 1. Injection nipples
2. Small injection oil lines
indicated location.
Check for air bubbles or oil column going toward
TEST PRESSURE: 34 KPA (5 PSI)
pump. It indicates defective check valve in injec-
FOR 3 MINUTES
tion nipples.
– If there is a leak at the tested location, it is rec- 3. Remove cooling system cap.
ommended to continue testing next items be- Check for air bubbles in antifreeze. It indicates de-
fore overhauling engine. There is a possibility of fective cylinder head O-ring or cylinder base gas-
more than one leak. ket.
– If there is no leak at the tested location, contin- 4. Remove drive pulley then check crankshaft out-
ue pumping to maintain pressure and continue er seal.
with next items until leak is found.
5. Remove rewind starter and magneto system
Engine then check crankshaft outer seal.
Check the following: 6. Check pump shaft gear oil reservoir.
1. All jointed surfaces and screw/stud threads of Pump Shaft Oil Gear Reservoir
engine:
Install air pump on adapter and pressurize as be-
– spark plug base, insulator fore.
– cylinder head
– RAVE valve bellows, piston and housing
– cylinder
– crankcase halves (joint)
– oil injection pump mounting flange
(O-ring, seal)
– coolant pump housing
– bleed screws/plugs.
A32C1HA
04-04-2 MMR2001_007_04_04A.FM
Section 04 ENGINE
If pressure drops, it indicates a defective crank- If there is a leak, it indicates defective seal of
shaft inner seal. pump shaft (oil seal beside coolant ceramic seal).
2. Leaks can be also on oil pump side. Check
mounting area for leaks.
A32C1IA
1 2
CRANKSHAFT INSTALLED IN UPPER HALF CRANKCASE
1. Crankshaft inner seal on PTO side A32C1GB 1
2. Crankshaft inner seal on MAG side
1. Check mounting area
1. Check drain hole below coolant pump housing
with soapy water. 3. If leak still persists, it indicates a defective cast-
ing somewhere in engine.
Disassemble engine and carefully check for de-
fects in castings. Pay attention to tapped holes
which may go through engine sealed area and
thus lead to leakage.
FINALIZING REASSEMBLY
After reassembling engine, always recheck for leak-
age.
A32C1JA 1
1. Drain hole
MMR2001_007_04_04A.FM 04-04-3
Section 04 ENGINE

FLOW CHART
PRESSURIZE ENGINE
NO
IS ENGINE LEAKING?
YES

FLANGES ETC.

NO

INJECTION PUMP

OR OIL MOVING REPLACE INJECTION NIPPLE(S)
TOWARD PUMP?
NO

NO
BLOCK HOSE OF PUMP SHAFT
GEAR
LUBRICATION SYSTEM
NO
YES

SEAL OF PTO AND
MAG SIDES
YES
NO
PRESSURIZE PUMP SHAFT GEAR

PRESSURIZE PUMP SHAFT GEAR YES

NO
CYLINDER SEPARATELY

NO

YES REPLACE OIL SEAL OF PUMP

NO ANY LEAK FOUND? SHAFT CERAMIC,, BESIDE
COOLANT SEAL
NO
CHECK OIL PUMP

MOUNTING AREA FOR LEAKS
YES
IS O-RING LEAKING? REPLACE DEFECTIVE O-RING
NO

YES
NO

INTERNALLY
A32C1KS
04-04-4 MMR2001_007_04_04A.FM
Section 04 ENGINE
ENGINE DIMENSION CYLINDER OUT OF ROUND

MEASUREMENT
ENGINE TYPE MAXIMUM
This section covers all engine types.
All 0.08 mm (.003 in)
CYLINDER HEAD WARPAGE Measuring 16 mm (5/8 in) from top of cylinder with
a cylinder gauge, check if the cylinder out of round
ENGINE TYPE MAXIMUM is more than the specified dimension. If larger, cyl-
0.05 mm (.002 in) per inder should be rebored and honed or should be
50 mm (2 in) of surface replaced.
All NOTE: Be sure to restore the chamfer around all
0.5 mm (.020 in) for total
length of cylinder head cylinder sleeve port openings.
Check gasketed surface of the cylinder head with

a straightedge and a feeler gauge. 1
CYLINDER TAPER
ENGINE TYPE MAXIMUM
All 0.10 mm (.004 in)
A
Compare cylinder diameter 16 mm (5/8 in) from
top of cylinder to just below its intake port area. 2
On rotary valve engines, measure just below aux-
iliary transfer port, facing exhaust port. If the dif-
ference exceeds the specified dimension the cyl- A01C54A
inder should be rebored and honed or should be

1. Piston pin position
replaced. 2. Measures to be compared
A. 16 mm (5/8 in)
COMBUSTION CHAMBER
VOLUME MEASUREMENT
The combustion chamber volume is the region in
the cylinder head above the piston at Top Dead
Center. It is measured with the cylinder head in-
stalled on the engine.
A
1
A01C53A 1
1. Below the intake port
A. 16 mm (5/8 in) from top F01D5VA
1. Combustion chamber
MMR2001_007_04_04A.FM 04-04-5
Section 04 ENGINE
NOTE: When checking the combustion chamber 3. Open burette valve to fill its tip. Add liquid in
volume, engine must be cold, piston must be free burette until level reaches 0 cc.
of carbon deposit and cylinder head must be lev- 4. Inject the burette content through the spark
eled. plug hole until liquid touches the top spark plug
1. Remove both spark plugs and bring one piston hole.
to Top Dead Center a using a TDC gauge.
F00D0HA 1
1. Top of spark plug hole
F01D2IA NOTE: The liquid level in cylinder must not drop

for a few seconds after filling. If so, there is a leak
1. Bring piston to TDC
between piston and cylinder. The recorded vol-
2. Obtain a graduated burette (capacity 0-50 cc) ume would be false.
and fill with an equal part (50/50) of gasoline and 5. Let burette stand upward for about 10 minutes,
injection oil. until liquid level is stabilized.
6. Read the burette scale to obtain the quantity of
liquid injected in the combustion chamber.
NOTE: When the combustion chamber is filled to
top of spark plug hole, it includes an amount of
1 2.25 cc corresponding to the spark plug tip.
7. Repeat the procedure for the other cylinder.
COMBUSTION CHAMBER VOLUME

ENGINE (CC)
TYPE (UP TO TOP THREAD OF
SPARK PLUG HOLE)
377 20.3 ± 0.8
443 24.0 ± 1.0
503 27.5 ± 1.2
F00B0BA
593 29.9 ± 1.2

1. Graduated burette (0-50 cc)
Install a thicker or thinner cylinder/crankcase gas-

ket (refer to Parts Catalogs) in order to obtain the
specified combustion chamber volume.
04-04-6 MMR2001_007_04_04A.FM
Section 04 ENGINE
USED PISTON MEASUREMENT

Using a micrometer, measure piston at A perpen-
dicularly (90°) to piston pin.
F00D0EA 2 1
1. Piston dome
2. Piston measurement
F01D0NA
1 Adjust and lock a micrometer to the specified value
on the piston dome.
1. Measuring perpendicularly (90°) to piston pin axis
A. See table below
1
DIMENSION A
ENGINE TYPE
mm (in)
377 and 443 20.8 (.819)
503 18.0 (.709)
593 25.57 (1.004)
The measured dimension should be the same as

the one scribed on piston dome. If not, install a F00B08A
new piston.
1. Micrometer set to the piston dimension
CYLINDER/PISTON CLEARANCE With the micrometer set to the piston dimension,

adjust a cylinder bore gauge to the micrometer di-
Used and New Pistons mension and set the indicator to 0.
NOTE: Make sure used piston is not worn. See
USED PISTON MEASUREMENT above.
Take the measurement on the piston dome.
1
2
F00B09A
1. Use the micrometer to set the cylinder bore gauge

2. Dial bore gauge
MMR2001_007_04_04A.FM 04-04-7
Section 04 ENGINE
RING/PISTON GROOVE
CLEARANCE
Using a feeler gauge check clearance between
rectangular ring and groove. Replace piston if clear-
ance exceeds specified tolerance. Refer to TECH-
NICAL DATA.
1
F00B0AA
1. Indicator set to 0 (zero)
Position the dial bore gauge at 16 mm (5/8 in) be-

low cylinder top edge.
A01C0PA
RING END GAP

Position ring half-way between transfer ports and
intake port. On rotary valve engines, position ring
just below transfer ports.
1 NOTE: In order to correctly position the ring in the
cylinder, use piston as a pusher.
A Using a feeler gauge, check ring end gap. Replace
ring if gap exceeds specified tolerance. Refer to
TECHNICAL DATA.
F01D0KA 1
A. 16 mm (5/8 in)
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.
2
NOTE: Make sure the cylinder bore gauge indica-
tor is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
A01C0QA
1. Transfer port
2. Intake port
04-04-8 MMR2001_007_04_04A.FM
Section 04 ENGINE
CRANKSHAFT DEFLECTION Crankshaft Deflection on PTO Side

Crankshaft deflection is measured with a dial indi- ENGINE MAXIMUM ON PTO SIDE
cator. TYPE mm (in)
Measuring (in engine) 377, 443 and 503 on

0.06 (.0024)
S-Series
First, check deflection with crankshaft in engine.
If deflection exceeds the specified tolerance, re- 443 on Skandic LT 0.08 (.0031)
check deflection using V-shaped blocks to deter- 503 on Skandic
mine the defective part(s). See below. 0.06 (.0024)
WT/SWT
Measuring (on bench) 593 0.08 (.0031)
Once engine is disassembled, check crankshaft

deflection on V-shaped blocks. If deflection ex- Crankshaft Deflection on MAG Side
ceeds the specified tolerance, it can be worn bear-
ings or a bent crankshaft. Remove crankshaft bear- MAXIMUM ON MAG SIDE
ENGINE TYPE
ings and check deflection again on V-shaped blocks mm (in)
to determine the defective part(s). See measure- 377, 443 and 503 on
ment A in following illustration. 0.03 (.0012)
S-Series
443 on Skandic LT 0.06 (.0024)
503 on Skandic
0.03 (.0012)
WT/SWT
593 0.06 (.0024)
Crankshaft Deflection in Center of

Crankshaft
MAXIMUM IN CENTER
ENGINE TYPE
OF CRANKSHAFT
A 1 377, 443 and 503 on
0.08 (.0031)
S-Series
A01C0RD
443 on Skandic LT 0.03 (.0012)

TYPICAL
1. Measure at mid point between the key and the first thread 503 on Skandic
A. 3 mm (1/8 in) 0.08 (.0031)
WT/SWT
593 0.05 (.002)
MMR2001_007_04_04A.FM 04-04-9
Section 04 ENGINE
NOTE: Crankshaft deflection cannot be correctly

measured between centers of a lathe.
If the deflection exceeds the specified tolerance,
crankshaft should be repaired or replaced.
CONNECTING ROD BIG END

AXIAL PLAY
ENGINE NEW PARTS WEAR
TYPE MIN. - MAX. LIMIT
377, 443 0.20 - 0.53 mm 1.0 mm
A01C3GA
and 503 (.008 - .021 in) (.039 in)
0.39 - 0.74 mm 1.20 mm
593
(.015 - .029 in) (.047 in)
Using a feeler gauge, measure distance between

thrust washer and crankshaft counterweight. If
the distance exceeds specified tolerance, repair or
replace the crankshaft.
A01C3HA

TYPE MIN. - MAX. LIMIT
0.003 - 0.012 mm 0.015 mm
All
(.0001 - .0005 in) (.0006 in)
A01C0SA
TYPICAL
CONNECTING ROD/CRANKPIN
CLEARANCE
CONNECTING ROD/PISTON PIN
CLEARANCE TYPE MIN. - MAX. LIMIT
Measure piston pin with its needle bearing. Com- 377, 443 and 0.020 - 0.033 mm 0.05 mm
pare to inside diameter of connecting rod. 503 (.0008 - .0013 in) (.0020 in)
0.038 - 0.050 mm 0.06 mm
593
(.0015 - .0020 in) (.0024 in)
04-04-10 MMR2001_007_04_04A.FM
Section 04 ENGINE
CRANKSHAFT END-PLAY CHECKING CRANKSHAFT

All Engine Types ALIGNMENT
End-play is not adjustable but it should be between Install a degree wheel (P/N 414 352 900) on crank-
0.10 - 0.30 mm (.004 - .012 in). shaft end.
Remove both spark plugs.
CHECKING SURFACE FLATNESS Install a TDC gauge (P/N 414 104 700) in spark plug
Intake manifold, intake manifold cover can be hole on MAG side.
checked for perfectly mating surfaces. Bring MAG piston at top dead center.
Lay part on a surface plate (marble, mirror or thick Rotate degree wheel (not crankshaft) so that 360°
glass plate). mark aligns with center of crankcase. Scribe a
Holding down one end of part, try pushing down mark on crankcase.
the other end. Remove TDC gauge and install it on PTO side cyl-
If any play is felt, part must be rectified. inder.
Bring PTO piston to top dead center. Degree wheel
RECTIFYING SURFACES must rotate with crankshaft.
Stick a fine sand paper sheet on the surface plate

then lightly oil the sand paper. 30
20
10
0
90
80
Rub part mating surface on sand paper using 8- 40
50 60
70
figure movements.
Sand until mating surface is perfectly straight.
180
A06C1TA 0
TYPICAL
A00A1LA
Interval between cylinders must be 180° ± 0.5.
Any other reading indicates a misaligned (twisted)
crankshaft.
MMR2001_007_04_04A.FM 04-04-11
Section 04 ENGINE
Subsection 05 (CDI SYSTEM)
CDI SYSTEM 0
NIPPONDENSO TRIGGER COIL IGNITION SYSTEM
290 W on Skandic WT LC
Loctite
243
5
4
1 125 Nm
(92 lbfft)
3
Loctite
243
2
22 Nm
Loctite (195 lbfin)
243
Dielectric
grease
Dielectric
grease
A29E0MS

Section 04 ENGINE
DUCATI IGNITION SYSTEM

Skandic WT/SWT
Dielectric grease
Loctite 243
105 Nm
(77 lbfft)
1
6
2
5
Loctite 243
4
22 Nm
A03E2YT (195 lbfin)

Section 04 ENGINE
RER IGNITION SYSTEM

S-Series and Skandic LT
Dielectric grease
To main harness
3
Loctite
243
105 Nm
(77 lbfft)
1
5
Loctite
4 243
A03E2ZT

Section 04 ENGINE
NOTE: The following procedures can be done CAUTION: Use only M8 x 20 mm screws to bolt
without removing the engine from chassis. To fa- puller to magneto.
cilitate magneto removal, hold drive pulley with
tool (P/N 529 027 600).
CDI means Capacitor Discharge System.
CLEANING
cleaner.
CAUTION: Clean stator and magneto using only
a clean cloth.
DISASSEMBLY
3, Magneto Flywheel A06E22B 1 2
To gain access to magneto assembly, remove the
TYPICAL
following parts as needed on different engines:
1. Tab in magneto housing opening
– tuned pipe and muffler 2. M8 x 20 mm screws
– rewind starter – Remove magneto flywheel nut, using a 30 mm

– starting pulley no. 2. socket machined to 40 mm (1.580 in) outside
diameter by 16 mm (5/8 in) long.
To remove magneto flywheel retaining nut no. 1:
NOTE: To correctly remove a threadlocked fasten-
– Use magneto puller ring (P/N 420 876 080). er it is first necessary to tap on the fastener to
Former puller has to be modified as shown. break threadlocker bond. This will eliminate the
possibility of thread breakage.
A 420 876 080
A06E23A 1
1. Cut by 25 mm (1 in)
A03C1JA
– Install puller with its tab in magneto housing
opening. TYPICAL
A. 30 mm socket
04-05-4 MMR2001_008_04_05A.FM
Section 04 ENGINE
To remove magneto flywheel, install the puller (P/N

2 1
529 022 500).
A32E0KA
1. Crankcase recess
A03C07A 420 876 080 529 022 500 2. Wire protectors
TYPICAL 3, Magneto Flywheel

– Tighten puller bolt and at the same time, tap on Clean crankshaft extension (taper) and apply Loc-
bolt head using a hammer to release magneto tite 243 (blue) on taper, then position Woodruff
flywheel from its taper. key, flywheel and lock washer on crankshaft.
Clean nut threads and apply Loctite 243 (blue) then
5, Trigger Coil tighten nut to 105 N•m (77 lbf•ft) for fan-cooled
Magneto and stator no. 6 must be removed be- engines and to 125 N•m (92 lbf•ft) for 593 engine.
fore trigger coil removal. At reassembly coat all electric connections except
To replace trigger coil: Deutsch housings (waterproof gray housing) with
– Disconnect trigger coil connector housing. silicone dielectric grease (P/N 293 550 004) to pre-
vent corrosion or moisture penetration.
– Remove grommet from crankcase where trig-
ger coil wire exits magneto housing. CAUTION: Do not use silicone “sealant”, this
product will corrode contacts. Do not apply sil-
– Remove retaining screws no. 4. icone dielectric grease on any Deutsch (gray)
– Remove trigger coil and carefully pull wires. housing otherwise housing seal will be dam-
– Install new trigger coil and other parts removed. aged.
ASSEMBLY Ignition Timing

Check as described in IGNITION TIMING.
6, Stator
Make sure to position stator in a way that its wire
protectors are over recess of crankcase.
MMR2001_008_04_05A.FM 04-05-5
Section 04 ENGINE
ADJUSTMENT
Skandic WT/SWT Only
Whenever the trigger coil or the magneto flywheel
is removed or replaced, the air-gap between the
trigger coil and the flywheel protrusion must be
checked and adjusted. The purpose of this adjust-
ment is to obtain the minimum clearance between
these parts — without touching at any RPM — so
that the trigger coil produces its proper electrical
output. Ignition timing must also be checked. Re-
fer to IGNITION SYSTEM.
Proceed as follows:
1. Rotate flywheel so that one protrusion aligns
with trigger coil.
2. Using a feeler gauge of 0.45 mm (.018 in) to
0.55 mm (.022 in) thick, check air-gap between
center pole of trigger coil and flywheel protru-
sion.
3. If necessary, adjust by slackening retaining
screws and moving trigger coil toward or away
of protrusion.
4. Retighten screws and recheck air-gap.
A25E0UB 1
ADJUSTING TRIGGER COIL AIR-GAP
1. Flywheel protrusion
2. Trigger coil
04-05-6 MMR2001_008_04_05A.FM
Section 04 ENGINE
Subsection 06 (OIL INJECTION SYSTEM)
OIL INJECTION SYSTEM 0

OIL INJECTION PUMP
377, 443 and 503 Engines on S-Series and Skandic LT/WT/SWT
Injection
oil
5
1 6
Loctite
5 Nm Loctite 243
(44 lbfin) 243
1 3 Grease
A03C2TT
TYPICAL

Section 04 ENGINE
593 Engine on Skandic WT LC
Injection oil
Loctite 648
2
4
5 Nm 3
(44 lbfin) Loctite 648
2
A32C0WT
TYPICAL

Section 04 ENGINE
 WARNING ENGINE TYPE

OIL PUMP
IDENTIFICATION
Wipe off any oil spills. Oil is highly flammable.
377 (S-Series) L13
OIL SYSTEM LEAK TEST 443 (S-Series) E8
All Models 443 (Skandic LT) L13

The following test will indicate any leak from oil 503 (S-Series) E8
reservoir to the banjo fitting(s).
503 (Skandic WT/SWT) E6
Install on oil reservoir special cap of leak testing kit
(P/N 529 033 100). 593 (Skandic WT LC) L7
Install hose pinchers (P/N 295 000 076) on outlet NOTE: The following procedures can be done with-
hoses. out removing the engine from chassis.
1 2
CLEANING
cleaner.
DISASSEMBLY
NOTE: Some oil pump components are not avail-
able as single parts.
5,6, Gear Retaining Nut and Oil Pump

Gear
To remove gear retaining nut, first extract the nee-
A03C2UA dle roller with pliers then lock gear in place using
TYPICAL
one of the following gear holder.
1. Special cap on reservoir
2. Hose pinchers on outlet hoses ENGINE TYPE TOOL P/N
Connect pump of leak testing kit to special cap. 377/443/503 420 876 695
Pressurize oil system to 21 kPa (3 PSI). That pres-
sure must not drop during 3 minutes.
If pressure drops, locate leak(s) and repair/replace
leaking component(s). To ease locating leak(s)
spray soapy water on components, bubbles will
indicate leak location(s).
OIL PUMP IDENTIFICATION

All Models
4, Pump Lever
Different engines need different pumps. See iden-
tification on lever no. 4.
CAUTION: Always mount proper pump on en- A10C01A 420 876 695
gine.
MMR2001_009_04_06A.FM 04-06-3
Section 04 ENGINE
ASSEMBLY
1
1, Spring Clip
Always check for spring clips tightness.
6, Oil Pump Gear 3

At gear assembly, apply a light coat of Molykote
111 (P/N 413 707 000) on gear teeth.
7, Needle Roller
(fan cooled engine only) 2
The needle roller must be engaged as deep as A13C0PA

possible in the pump mounting flange.
TYPICAL — S-SERIES AND SKANDIC WT/SWT
3, Screw 1. Adjuster nut
2. Bleeder screw
3. Marks
Torque to 5 N•m (44 lbf•in).
Cable plastic elbow must be fastened and fully in- CAUTION: Proper oil injection pump adjustment
serted. is very important. Any delay in the opening of
the pump can result in serious engine damage.
Make sure cable barrel is well seated in oil pump
lever. Pump Identified L7
Secure barrel with plastic washer and circlip. Do not touch throttle lever. The cable free-play has
Install cable lock washer on lever side. not to be eliminated on this model.
Verify cable and oil pump lever operation. Because the oil pump is mounted low on engine,
it is very difficult to avoid parallax problem and set
ADJUSTMENT a good adjustment.
Parallax Problem
All Models
When adjusting pump lever, since the mechanic can
Prior to adjusting the pump, make sure all carbu- not view the pump perpendicularly, the adjustment
retor adjustments are completed. will not be accurate. Following photos show three
Pumps Identified E6, E8 and L13 different views of the same properly adjusted pump.
Eliminate the throttle cable free-play by pressing
the throttle lever until a light resistance is felt, then
hold in place.
The mark on the pump casting and on the lever
must align. Width of lever mark is the tolerance. PROTRUSION
Loosen the adjuster nut and adjust accordingly.
Retighten the adjuster nut.
A32C1MA
VIEW TOO HIGH — ADJUSTMENT SEEMS TO BE TOO RICH

WHEN TOP OF BODY’S PROTRUSION CAN BE SEEN
04-06-4 MMR2001_009_04_06A.FM
Section 04 ENGINE
Procedure for Oil Pump Adjustment

Ensure carburetors are synchronized according to
the technical specifications.
Remove air box. Carburetors may also be removed
to improve visibility and ease adjustment of oil
pump cable.
NOTE: Place carburetors on top of intake boots to
keep cable routing near original location.
Use a small round or oblong mirror to see the marks.
The second mark on pump lever must be aligned or
up to 1 mm (.039 in) below pump casting mark. If
not, loosen the adjuster nut and adjust accordingly.
A32C22A 1 2 Retighten the adjuster nut.
VIEW STRAIGHT AHEAD — BODY’S PROTRUSION LOOKS LIKE 1 4
A CIRCLE, MARK ON PUMP ALIGN WITH SECOND MARK ON
LEVER (MARK ON DOT SIDE)
1. Minimum setting
2. Maximum setting
A32C1PA 3 2
VIEW WITH AIR BOX, CARBURETORS AND FUEL PUMP
REMOVED
1. Oil pump
2. Mirror
3. Lever
4. Adjustment screw
PROTRUSION Make sure that view in mirror is straight ahead, with-

A32C1OA out parallax problem.
VIEW TOO LOW — ADJUSTMENT SEEMS TO BE TOO LEAN Protrusion with fixed mark on pump must look
WHEN BOTTOM OF BODY’S PROTRUSION CAN BE SEEN
like a full circle. See next photo.
To avoid a bad adjustment, follow below procedure.
MMR2001_009_04_06A.FM 04-06-5
Section 04 ENGINE
CAUTION: Proper oil injection pump adjust-

1 3
ment is very important. Any delay in the open-
ing of the pump can result in serious engine
damage.
BLEEDING
Bleed main oil line (between tank and pump) by
loosening the bleeder screw until air has escaped
from the line. Add injection oil as required.
Reinstall all parts.
2
Bleed the small oil line between pump and engine
by running engine at idle while holding the pump
lever in fully open position.
NOTE: Make a J hook out of mechanical wire to
lift the lever.
 WARNING
Ensure not to operate carburetor throttle mech-
anism. Secure the rear of the vehicle on a stand.
A32C1QA 4
VIEW FROM MIRROR SHOULD LOOK LIKE THIS
1. Mark on pump casting
CHECKING OPERATION
2. Second mark on lever
3. Dot Oil Pump
4. Pump protrusion as a circle, not a cylinder
On Vehicle
A 1 A NOTE: Main oil line must be full of oil. See bleed-
ing procedure above.
Lift rear of vehicle and support with a mechanical
stand. Unplug small oil lines from pump. Start en-
gine and stop it as soon as it fires.
Check that oil in small oil lines has been sucked up
(this will be indicated by a clear section of small oil
2 lines). Repeat the procedure until this condition is
attained.
6 Reconnect small oil lines, start engine and run at
idle while holding the pump lever in fully open po-
4 sition. Oil columns must advance into small oil
B lines.
If not, remove pump assembly and check the pump
3 gear and drive shaft (if applicable) for defects, replace
5 as necessary. Test pump as describes below.
A32C0XA
NOTE: Through normal use, oil level must not drop
1. Lock washer
2. Plastic elbow fastened and fully inserted in small tubes. If oil drops, verify check valve oper-
3. Pump casting mark ation in injection nozzle. Replace as necessary.
4. Second mark aligned or below
5. First mark
6. Bleeder screw
A. 5 N•m (44 lbf•in)
B. 0 to 1 mm (0 to .039 in)
04-06-6 MMR2001_009_04_06A.FM
Section 04 ENGINE
Test Bench
Connect a hose filled with injection oil to main line
fitting. Insert other hose end in an injection oil con-
tainer. Using a clockwise rotating drill rotate pump
shaft. Oil must drip from outer fittings while holding
lever in a fully open position. If not replace pump.
2, Check Valve
Check valve is part (built-in) of injection nozzle.
To verify this check valve, proceed the same as for
checking pump operation on vehicle. First unplug
oil line from injection nozzle. After restarting the
engine, check that a clear section in small oil line
is present. Reconnect oil line.
Run engine at idle. Oil column must advance. If
the check valve is faulty, oil column will go back
and forth. Replace if so.
MMR2001_009_04_06A.FM 04-06-7
Section 04 ENGINE
Subsection 07 (AXIAL FAN COOLING SYSTEM)
AXIAL FAN COOLING SYSTEM 0

377, 443 and 503 Engines
13 Nm
1 (115 lbfin)
5
18
4
10
11 12
13
14 443 and
15 503 engines
16 only
10
Loctite
20 48 Nm
243
(35 lbfft) 17
A03C0WV
MMR2001_010_04_07A.FM
Section 04 ENGINE
NOTE: The following procedures can be done with- To remove or install fan pulley retaining nut no. 17,
out removing engine from chassis. lock fan pulley with special holder wrench (P/N
420 876 357). At assembly, torque nut to 48 N•m
REMOVAL (35 lbf•ft).
NOTE: To facilitate further disassembly, fan nut may

be removed before removing fan housing.
Remove rewind starter, starting pulley, trigger coil
wire from 4-connector housing then fan housing
ass’y.
CLEANING
cleaner.
DISASSEMBLY AND ASSEMBLY

Using a flat screwdriver, lift fan protector tabs as 420 876 357
shown in the following photo, then remove fan pro- A09C08A
tector.
TYPICAL
Using a press, drive the fan shaft no. 9 out.
A03C1YA 1 A23C06A
1. Lift tab and remove fan protector
04-07-2 MMR2001_010_04_07A.FM
Section 04 ENGINE
Support fan housing no. 12 with a ring. With a punch, Using fan holder tool (P/N 420 876 357), remove fan
working all around bearing no. 10 inner race, drive nut.
bearing out of fan housing. Keep shims for instal- Remove fan with pulley half.
lation.
A23C07A
1. Ring supporting fan housing A03C22A 1
Remove circlip no. 11 then remaining bearing. 1. Remove fan with pulley half
To install, press one bearing in place then install Remove fan belt.
circlip and shims. Press the other bearing from op- Leave shims and second half pulley in place. Refer
posite side until it is flush with housing. Press fan to the following photo.
shaft from engine side of fan housing. Check for
free rolling action.
INSTALLATION
At assembly, apply a light coat of Loctite 243 (blue)
on screw no. 1 threads.
A gasket must be placed on both sides (inner and
outer) of intake and exhaust holes of cylinder cowl
nos. 4 and 5.
Reinstall fan protector no. 18 properly.
 WARNING
Always reinstall fan protector after servicing.
FAN BELT REPLACEMENT AND

DEFLECTION ADJUSTMENT
A03C23A 1 2
Remove muffler, rewind starter and on so equipped
1. Keep shims
models connecting flange. Following procedure de- 2. Leave second half pulley in place
scribed above.
MMR2001_010_04_07A.FM 04-07-3
Section 04 ENGINE
Reassembly 1
Install fan belt on bottom pulley first then position
onto fan shaft, as shown in the next photo.
1 2
A03C2AA 3
FAN BELT PROPERLY INSTALLED ON BOTTOM PULLEY AND
FAN SHAFT
1. Bottom pulley
2. Fan shaft
3. Starting pulley
Reinstall fan assembly on fan shaft. Temporarily

tighten fan nut.
CAUTION: When reinstalling fan assembly, en-
A03C2BA
sure that key is properly positioned into fan
shaft keyway. TYPICAL
1. Measure deflection here
2. Fish scale
Fan Belt Deflection Adjustment
Check fan belt deflection using a ruler and a fish Belt deflection must be according to the following
scale positioned midway between pulleys as per specifications:
following photo.
ENGINE BELT FORCE
TYPE DEFLECTION APPLIED
8.5 mm
377
(11/32 in) 5 kg
9.5 mm (11 lb)
443 and 503
(3/8 in)
04-07-4 MMR2001_010_04_07A.FM
Section 04 ENGINE
To adjust deflection tension, add or remove shim(s) Finalizing Reassembly

no. 15 between pulley halves nos. 14 and 16. In-
Reinstall rewind starter.
stall excess shim(s) between distance sleeve no. 13
and half pulley no. 14 (housing side). CAUTION: When installing rewind starter, en-
sure that oil pump shaft is properly positioned.
2 3 Do not force shaft insertion. Turn fan until oil
pump shaft slides in place, as shown in the fol-
1 lowing photo.
A09C0VA
1. Unused shim(s) here

2. Adjust here
3. Positioning noses
4. Some engines only
Some engines have a separate metal pulley half

instead of using back of fan as pulley half. On first
A03C25A
mentioned engines, select pulley halves so that
the one with 2 positioning noses will be on fan TURN FAN TO SLIDE OIL PUMP SHAFT IN PLACE
side. Ensure to insert these noses into fan notches.
Secure rewind starter with original screws.
Once fan belt is properly adjusted, torque fan nut
to 48 N•m (35 lbf•ft) using fan holder tool (P/N 420 Reinstall fan protector no. 18 properly.
876 357), as shown in the following photo.
NOTE: Apply Loctite 243 (blue) on fan nut threads.  WARNING
Always reinstall fan protector after servicing.
Reinstall muffler.
A03C24A
TORQUE FAN NUT USING FAN HOLDER TOOL
MMR2001_010_04_07A.FM 04-07-5
Section 04 ENGINE
Subsection 08 (LIQUID COOLING SYSTEM)
LIQUID COOLING SYSTEM 0

593 Engine
2
3
Loctite 592
4
A32C0YS
TYPICAL

Section 04 ENGINE
INSPECTION
Check general condition of hoses and clamp tight- 1
ness.
DRAINING THE SYSTEM

 WARNING
Never drain or refill the cooling system when
engine is hot.
To drain the cooling system, siphon the coolant

mixture from the coolant tank. Disconnect hose at
water pump.
A16C02A 2
DISASSEMBLY AND ASSEMBLY TYPICAL — CLOSED THERMOSTAT, COLD ENGINE

1. To reservoir
2. From cylinders
3,4, Sender and Plug
b. When the liquid is warmed enough, the thermo-
Apply Loctite 592 (P/N 413 702 300) thread sealant
stat opens progressively the circuit, water pump
on sender and plug to avoid leaks.
— engine — radiators — coolant tank to keep
the liquid at the desired temperature. (See the
1, Pressure Cap diagram of the exploded view).
Check if the cap pressurizes the system. If not,
install a new 90 kPa (13 PSI) cap (do not exceed this
pressure).
6,7, Radiator and Radiator Protector

1
Insert radiator protector into radiator C-rail and
crimp C-rail at rear end. Refer to FRAME for radi-
ator removal.
5, Thermostat
To check thermostat, put in water and heat water.
Thermostat should start to open when water tem-
perature reaches the following degree. It will be
almost fully open at 50°C (122°F). 2
A16C03A
ENGINE TEMPERATURE TYPICAL — OPEN THERMOSTAT, WARM ENGINE

1. To radiators
593 42°C (108°F) 2. From cylinders
Thermostat is a double action type. These 2 functions have the advantage of prevent-
ing a massive entry of cold water into the engine.
a. Its function is to give faster warm up of the en-
gine by controlling a circuit; water pump —
engine — coolant tank. This is done by bypass-
ing the radiator circuit.
04-08-2 MMR2001_011_04_08A.FM
Section 04 ENGINE
COOLING SYSTEM REFILLING

PROCEDURE
Recommended Coolant
Use Premixed coolant - 52°C (- 62°F) (P/N 413 711
802) (16 x 1L). Do not reinstall pressure cap.
CAUTION: To prevent rust formation or freezing
condition, always replenish the system with rec-
ommended premixed coolant.
System Capacity
Refer to TECHNICAL DATA.
Refilling Procedure
Lift front of vehicle until the tunnel is horizontal.
With engine cold, refill coolant tank no. 2 up to
cold level line. Wait a few minutes then refill to
line. Start engine. Refill up to line while engine is
idling until all air bubbles have escaped from sys-
tem (about 4 to 5 minutes). Install pressure cap.
To make sure coolant flows through radiators,
touch them by hand. They must feel warm.
Put back front of vehicle on the ground.
When engine has completely cooled down, re-
check coolant level in coolant tank and refill up to
line.
Check coolant concentration (freezing point) with
proper tester.
MMR2001_011_04_08A.FM 04-08-3
Section 04 ENGINE
Subsection 09 (REWIND STARTER)
REWIND STARTER 0
Plastic Rewind Starter on All Models
15
10 Nm
(89 lbfin)
13
12 6
11 10 7
9
8
Molykote PG 54 5
7 Nm
1 (62 lbfin)
4
2
Molykote PG 54
Molykote PG 54
A03C3CT

Section 04 ENGINE
INSPECTION 1 2
NOTE: Due to dust accumulation, rewind starter
must be periodically cleaned, inspected and relu-
bricated.
CAUTION: It is of the utmost importance that
the rewind starter spring be lubricated period-
ically using specific lubricant. Otherwise, re-
wind starter component life will be shortened
and/or rewind starter will not operate properly
under very cold temperatures.
Check if rope no. 6 is fraying, replace if so.
When pulling starter grip, mechanism must en-
gage within 30 cm (1 ft) of rope pulled. If not, dis- A03C3DA
assemble rewind starter, clean and check for dam-
aged plastic parts. Replace as required, lubricate, 1. Rope exit hole
2. Key to be removed
reassemble and recheck. Always replace O-ring
no. 11 every time rewind starter is disassemble. With a long thin pin punch inserted through rope
When releasing starter grip, it must return to its exit hole, push key no. 7. Remove key and rope.
stopper and stay against it. If not, check for proper Install a new rope and lock it using key no. 7.
spring preload or damages. Readjust or replace as NOTE: When rope is completely pulled out, spring
required. preload is 4-1/2 turns.
When pulling starter grip 10 times in a row, it must
return freely. If not, check for damaged parts or DISASSEMBLY
lack of lubrication. Replace parts or lubricate ac- Undo knot previously tied at removal. Let sheave
cordingly. get free to release spring preload.
Cut push nut no. 13 and discard. Remove locking
REMOVAL element no. 12, O-ring no. 11, step collar no. 10,
Using a small screwdriver, extract rope knot from pawl lock no. 9 and pawl no. 8.
starter grip no. 15. Cut rope close to knot. Tie a Remove sheave no. 5 from starter housing no. 1.
knot near starter. Hold spring with a screwdriver.
Remove screws no. 2 securing rewind starter no. 1
to engine then remove rewind starter.
Remove pump from rewind starter cover.
ROPE REPLACEMENT
Completely pull out rope. Hold rewind starter in a
vise.
A03C3EA
04-09-2 MMR2001_012_04_09A.FM
Section 04 ENGINE
– Disengage key no. 7 and pull out rope no. 6. CAUTION: It is of the utmost importance that
Lubricate spring assembly with Molykote PG 54
(P/N 420 899 763).
A01C12A
GENTLY TAP ON KEY
ASSEMBLY
At assembly, position spring no. 4 outer end into
spring guide notch then wind the spring counter- A01C14A
clockwise into guide.
TYPICAL
 WARNING 1. Grease inside spring guide
Since the spring is tightly wound inside the CAUTION: The use of standard multi-purpose
guide it may fly out when rewind is handled. grease could result in rewind starter malfunc-
Always handle with care. tion.
To install rope no. 6, insert rope into sheave no. 5
orifice and lock it with the key no. 7 as illustrated.
A01C15A
1. Push to lock
Lubricate housing post with silicone compound

grease. Install sheave.
A03C3FA 1
1. Outer end into guide notch
MMR2001_012_04_09A.FM 04-09-3
Section 04 ENGINE
To adjust rope tension: Lubricate pawl lock no. 9 with Molykote PG 54

Wind rope on sheave and place rope sheave into (P/N 420 899 763). Install over pawl.
starter housing making sure that the sheave hub
notch engages in the rewind spring hook.
Rotate the sheave counterclockwise until rope
end is accessible through rope exit hole. This will
give 1/2 turn of preload.
Pull the rope out of the starter housing and tem-
porarily make a knot to hold it.
A03C3HA
A01C0CA
Install step collar no. 10 with its sleeve first. Lubri-
TYPICAL cate a new O-ring no. 11 and locking element no. 9
with Molykote PG 54 (P/N 420 899 763). Install
Lubricate pawl no. 8 with Molykote PG 54 (P/N over pawl lock.
420 899 763) then install over rope sheave.
A03C3IA 3 1 2
1. Step collar
2. O-ring
A03C3GA
3. Locking element
Position a new push nut no. 13.
04-09-4 MMR2001_012_04_09A.FM
Section 04 ENGINE
INSTALLATION
Reinstall oil pump on rewind starter assembly.
Thread starter rope no. 6 through rope guide when
applicable.
A03C0VA
TYPICAL
Reinstall rewind starter assembly on engine.

Prior to installing starter grip no. 15 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. Fuse the knot with a lit match
then insert rope end down and pull the starter grip
over the knot.
A01C18A
TYPICAL
MMR2001_012_04_09A.FM 04-09-5
Section 04 ENGINE
Subsection 10 (CARBURETOR AND FUEL PUMP)
CARBURETOR AND FUEL PUMP 0

CARBURETOR
All Models
To other
carburetor
15
Choke
equipped
models only
1
7
10
13
2
3
8
4
5
9
11
14 12
A03C3LS
TYPICAL

Section 04 ENGINE
IDENTIFICATION NOTE: For proper calibration refer to TECHNICAL

DATA and to SPARK PLUG.
All carburetors are identified on their body.
NOTE: For high altitude regions, a Service Bulletin
will give information about calibration according to
altitude and temperature.
REMOVAL
Skandic LT/WT/SWT
Remove air silencer.
1 Skandic WT LC
Remove air silencer cover. Unscrew through bolt
then, remove air silencer.
1
A01C59A
1. Identification: 34-482
CARBURETOR CIRCUIT
OPERATION VERSUS THROTTLE
OPENING
The following illustration shows the part of the car-
buretor which begins and stops to function at dif-
ferent throttle slide openings.
A29C0GA
Note that the wider part of symbol corresponds to

1. Through bolt
the opening mostly affected. For instance, throttle
slide cut-away begins to function at closed posi- S-Series
tion but it is most effective at 1/4 opening and de- Remove air silencer. Refer to BATTERY.
creases up to 1/2 opening.
All Models
Throttle slide openings
Disconnect fuel inlet line.
Wide Disconnect primer line from carburetor on some
open
models.
3/4
Disconnect choke cable on some models.
1/2
Unscrew carburetor cover no. 1 then pull out
1/4 throttle slide no. 5 from carburetor.
1/8
Close
13,6, Pilot jet and air screw

 WARNING
5, Throttle slide cut-away Exercise care when handling throttle slide.
3, Needle taper and needle position Scratches incurred may cause throttle slide to
14, Needle jet stick open in operation.
8, Main jet
A00C04A
Disconnect throttle cable from throttle slide.
VIEW FROM AIR INTAKE OPENING Untighten rubber flange clamps then remove car-
buretor from engine.
04-10-2 MMR2001_013_04_10A.FM
Section 04 ENGINE
CLEANING AND INSPECTION 2,3, E-Clip and Needle

The entire carburetor should be cleaned with a Remove screws from needle retaining plate to
general solvent and dried with compressed air be- withdraw the needle.
fore disassembly. The position of the needle in the throttle slide is
CAUTION: Heavy duty carburetor cleaner may adjustable by means of an E-clip inserted into 1 of
be harmful to the float material and to the rub- 5 grooves located on the upper part of the needle.
ber parts, O-rings, etc. Therefore, it is recom- Position 1 (at top) is the leanest, 5 (at bottom) the
mended to remove those parts prior to clean- richest.
ing. NOTE: The last digit of the needle identification
Carburetor body and jets should be cleaned in a number gives the recommended position of the E-
carburetor cleaner following manufacturer’s in- clip from the top of the needle.
structions.
Example 6DH4-3
 WARNING Needle
Recommended
position.
Solvent with a low flash point such as gaso- identification
of the E-clip from top
line, naphtha, benzol, etc., should not be used
as they are flammable and explosive.
1 Lean
Check inlet needle tip condition. If worn, the inlet
needle and seat must be replaced as a matched
2
set.
NOTE: Install needle valve for snowmobile carbu-
retor only. It is designed to operate with a fuel 3
pump system.
Check throttle slide no. 5 for wear. Replace as
necessary. 4
Check that idle speed screw no. 7 is straight. Re-
place as necessary. 5 Rich
A00B2GA
Check for fuel soaked into float no. 12; replace as
necessary. CLIP POSITIONS
Check float no. 12 for cracks or other damages The size of the throttle slide cut-away affects the
affecting free movement; replace as necessary. fuel mixture between 1/8 to 1/2 throttle opening.
Inspect throttle cable and housing for any damag-
es. Replace as necessary.

NOTE: To ease the carburetor disassembly and 3
1
assembly procedures it is recommended to use
carburetor tool kit (P/N 404 112 000).
A00C01A 2 4
1. Low cut-away low
2. Rich mixture
3. High cut-away high
4. Lean mixture
A00B2FA
MMR2001_013_04_10A.FM 04-10-3
Section 04 ENGINE
8, Main Jet
The main jet installed in the carburetor has been
selected for a temperature of - 20°C (0°F) at sea 1
level. Different jetting can be installed to suit tem-
perature and/or altitude changes. Always check
spark plug tip and/or piston dome color to find out
correct jetting.
CARBURETOR FLOAT LEVEL

ADJUSTMENT
9,10, Float Arm and Float Arm Pin
Correct fuel level in float chamber is vital toward
maximum engine efficiency. To check for correct
A01C5BA
float level proceed as follows:
– Make sure that float arm is symmetrical — not 1. Ruler vertical and in line with main jet
distorted.
CARBURETOR FLOAT HEIGHT H
– Remove float bowl and gasket from carburetor.
MODEL ± 1 mm (± .040 in)
– With carburetor chamber upside-down on a lev-
el surface, measure height H between bowl Skandic LT/WT/SWT
seat and top edge of float arm. Keep ruler per- Formula DLX FAN 380/500
fectly vertical and in line with main jet hole. Touring FAN 380/500
23.9 (.941)
MX Z FAN 380/440/500
Summit FAN 500
Skandic LT/WT/SWT
Skandic WT LC 18.1 (.713)
To Adjust Height H
– Bend the contact tab of float arm until the spec-
ified height is reached.
1
A01C5AA H
TYPICAL
H: Float height
A00C03A
1. Contact tab
04-10-4 MMR2001_013_04_10A.FM
Section 04 ENGINE
CARBURETOR ADJUSTMENTS
Adjustments should be performed following this 1 2
sequence:
– air screw adjustment
– throttle slide height
(preliminary idle speed adjustment)
3
– throttle cable adjustment
– carburetor synchronization
(dual carburetor models)
– final idle speed adjustment (engine running)
– oil pump and carburetor synchronization.
A00C1TA
CENTER POST TYPE

1. Throttle cable
2. Needle retaining plate
3. Throttle slide
Make sure the nylon packing no. 4 is installed on

2 all applicable throttle slides.
1
CAUTION: Serious engine damage can occur if
this notice is disregarded.
2
A02C09A
1 3
1. Idle speed screw
2. Air screw
6, Air Screw
Completely close the air screw (until a slight seat-
ing resistance is felt) then back off as specified.
Turning screw in clockwise enrichners mixture
and conversely, turning it out counterclockwise 4
leans mixture. 5
Refer to TECHNICAL DATA for the specifications.
A00C3MA
7, Idle Speed Screw CENTER POST TYPE

1. E-clip
Throttle Slide Opening 2. Needle retaining plate
(preliminary idle speed adjustment) 3. Screw
4. Needle
Hook throttle cable into the needle retainer plate. 5. Nylon packing
NOTE: Do not obstruct hole in throttle slide when Adjust throttle slide height (see following table) by
installing needle retaining plate. This is important turning idle speed screw no. 7. Throttle slide
to allow air escaping through and thus allowing a height is measured on outlet side of carburetor
quick response. (engine side).
NOTE: Make sure that throttle cable does not hold
throttle slide. Loosen cable adjuster accordingly.
Throttle cable adjustment will be done during ad-
justment of throttle-slide-to-cover free play.
MMR2001_013_04_10A.FM 04-10-5
Section 04 ENGINE
Final idle speed adjustment (engine running at idle However, pay attention to the following:
speed) should be within 1/2 turn of idle speed On applicable models, make sure to align tab of
screw from preliminary adjustment. carburetor and air intake silencer (if applicable)
with notch of adaptor(s). On applicable models, in-
THROTTLE SLIDE
MODELS HEIGHT
stall adaptor with UP mark facing up.
mm (in) CAUTION: The rubber flange must be checked
for cracks and/or damage. At assembly, the
Skandic LT/WT/SWT/WT LC, flange must be perfectly matched with the air
Formula DLX FAN 500, intake manifold or severe engine damage will
Touring FAN 500 1.5 (.059)
MX Z FAN 440/500
occur.
Summit FAN 500 Install clamps in a way that their tightening bolts
are staggered — not aligned.
Touring FAN 380
Formula DLX FAN 380 1.3 (.051)
MX Z FAN 380
Throttle Cable Adjustment
 WARNING
Ensure the engine is turned OFF, prior to per-
forming the throttle cable adjustment.
For maximum performance, correct cable adjust-

ment is critical.
At full opening throttle slide must be flush or 1.0 mm
1 (.040 in) lower than the top of carburetor outlet bore
(engine side).
First loosen adjuster nut then turn throttle cable
adjuster accordingly.
1
2
A01C3NA
TYPICAL
1. Drill bit used as gauge for throttle slide height
INSTALLATION
CAUTION: Never allow throttle slide(s) to snap
shut.
Prior to install carburetor, adjust air screw and pre-
liminary idle speed as described above. A01C3MA
To install carburetor on engine, inverse removal FULL OPENING (THROTTLE LEVER AGAINST HANDLE GRIP)
procedure. 1. Throttle cable adjuster
2. Throttle slide flush or 1.0 mm (.040 in) lower than carburetor
outlet bore (engine side)
04-10-6 MMR2001_013_04_10A.FM
Section 04 ENGINE
Check that with the throttle lever fully depressed,

there is a free play between the carburetor cover
and top of throttle slide.
A03C2VA 1 2
TYPICAL
1. Screw or unscrew adjuster
2. Check that both slides start to open at the same time
Check throttle slide position at wide open throttle.

A00C3FA
Throttle slide must be flush or 1 mm (.040 in) low-
FULL OPENING (THROTTLE LEVER AGAINST HANDLE GRIP) er than carburetor outlet bore. At that same posi-
1. Cover tion, check that throttle slide does not contact car-
2. Free play buretor cover. Turn cable adjuster and recheck
3. Throttle slide
synchronization.
 WARNING CAUTION: If the throttle slide rests against the
carburetor cover at full throttle opening, this
This gap is very important. If the throttle slide will create too much strain and may damage
rests against the carburetor cover at full throt- the throttle cable or other components in throt-
tle opening, this will create too much strain tle mechanism.
and may damage the throttle cable or other
components in throttle mechanism. CAUTION: On dual carburetor models, make
sure both carburetors start to operate simulta-
neously. Beside do not interchange carbure-
Carburetor Synchronization tors, the jetting may be different on each side.
Dual Carburetor Models Only A red dot is printed on one carburetor and on
the engine. Match the carburetor and the en-
When depressing throttle lever, both carburetor gine dots when applicable.
slides must start to open at the same time.
CAUTION: The oil injection pump adjustment
Unlock cable adjustment lock nut on one carbure- must be checked each time carburetor is adjust-
tor. ed. Refer to OIL INJECTION SYSTEM.
Screw or unscrew cable adjuster until both carbu-
retor slides start to open at same time. Cable play
will be identical on both carburetors. Retighten
jam nut.
MMR2001_013_04_10A.FM 04-10-7
Section 04 ENGINE
IDLE SPEED FINAL ADJUSTMENT Skandic WT/LC

Use big diameter (for VM 38) of choke plunger tool
7, Idle Speed Screw (P/N 529 032 100).
CAUTION: Before starting engine for the final All Models
idle adjustment, make sure that oil pump is ad-
justed. The oil injection pump adjustment must Insert proper diameter of choke plunger tool into
be checked each time carburetor is adjusted. choke air inlet of each carburetor. Tool stopper may
Refer to OIL INJECTION SYSTEM. not lean against recess wall. Though it must be
within 1 mm (.040 in) of recess wall.
Start engine and allow it to warm then adjust idle
speed to specifications by turning idle speed
screw clockwise to increase engine speed or
counterclockwise to decrease it.
NOTE: On twin-carburetor models: Turn adjust-
ment screw the same amount to keep carburetors
synchronized.
CAUTION: Do not attempt to set the idle speed 1
by using the air screw. Severe engine damage
can occur.
CHOKE
S-Series and Skandic LT/WT/SWT/WT LC
Choke Plunger Adjustment
Set choke lever to fully open position.
A01C5EA
AIR SILENCER SIDE SHOWN

1. Tool stopper within 1 mm (.040 in) of recess wall
A01C5HA
CHOKE LEVER — FULLY OPEN POSITION
S-Series Models and Skandic LT/WT/SWT A01C5FA
Use small diameter (for VM 30, VM 32 and VM 34 CUT-AWAY (ENGINE SIDE SHOWN)
carburetors) of choke plunger tool (P/N 529 032 1. Choke plunger
2. Tool properly seated under choke plunger
100).
04-10-8 MMR2001_013_04_10A.FM
Section 04 ENGINE
If tool tip does not seat under choke plunger Tighten choke cable lock nut and reinstall protec-
no. 15, adjust as follows: tor cap.
Make sure choke lever is at fully open position. Set choke lever to close and open positions and
Lift up protector cap and loosen choke cable lock ensure that tool properly seats under plunger only
nut, as shown in the next photo. 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).
1
A01C5GA
A01C5JA
1. Lift up protector cap
2. Loosen lock nut
CHOKE LEVER — CLOSED POSITION
Turn choke cable adjustment nut by hand until tool
properly seats under choke plunger. FUEL PUMP
NOTE: A light pressure should be needed to posi- REMOVAL
tion tool under plunger.
Install a hose pincer (P/N 295 000 076) on fuel sup-
1 2 ply line close to pump inlet.
295 000 076
A01C5IA A01B2JA
1. Choke cable adjustment nut

2. Choke plunger tool Disconnect fuel outlet line(s).
Disconnect impulse line.
Remove screws securing fuel pump.
MMR2001_013_04_10A.FM 04-10-9
Section 04 ENGINE
PUMP VERIFICATION CLEANING AND INSPECTION

Check fuel pump valves operation as follows: The entire pump should be cleaned with general
Connect a clean plastic tubing to the inlet nipple purpose solvent before disassembly.
and alternately apply pressure and vacuum with Fuel pump components should be cleaned in gen-
pump of leak test kit. The inlet valve should re- eral purpose solvent and dried with compressed air.
lease with pressure and hold under vacuum.
Repeat the same procedure at the outlet nipple.  WARNING
This time the outlet valve should hold with pres- Solvent with a low flash point such as gaso-
sure and release under vacuum. line, naphtha, benzol, etc., should not be used
NOTE: On model fitted with 2 outlets, plug 1 out- as each is flammable and explosive.
let with finger while checking outlet valve.
Inspect diaphragm. The pumping area should be
Check impulse diaphragm and gasket on high-sup- free of holes, tears or imperfections. Replace as
ply fuel pump with twin outlets as follows: needed.
Connect a clean plastic tubing to the impulse nip- High-supply pump with twin outlets: Thoroughly
ple and plug vent hole on top cover. Either apply clean filter on top cover. Replace pump if too dirty.
pressure or vacuum. The diaphragm/gasket must
not leak.
INSTALLATION
To install, inverse removal procedure.
 WARNING
Pressure test to ensure there is no leak in fuel
system.
04-10-10 MMR2001_013_04_10A.FM
Section 04 ENGINE
Subsection 11 (FUEL TANK AND THROTTLE CABLE)
FUEL TANK AND THROTTLE CABLE 0

Fuel Tank Lines
2
 WARNING
When draining a fuel tank or whenever a fuel
line is disconnected, obstruct line with a hose
pincher (P/N 295 000 076) or equivalent device. 1
Fuel is flammable and explosive under cer-
tain conditions. Ensure work area is well ven-
tilated. Do not smoke or allow open flames or
sparks in the vicinity.
3
A02C0FA 4
295 000 076 TYPICAL
1. Throttle cable housing
2. Throttle handle housing
3. Throttle handle
4. Circlip
Adjust throttle cable as specified in CARBURE-

TOR AND FUEL PUMP.
A01B2JA
Throttle Cable Routing
CAUTION: Check that throttle cable is routed
away from sharp edges, hot or vibrating parts.
Impulse/Fuel Lines Spring Clips When turning steering while engine is running,
All Models idle speed must not vary.
Always reposition spring clips after any repair to
prevent possible leaks.
Throttle Cable Circlip at Handlebar

All Models
Put silicone grease (P/N 413 701 700) around cable
barrel. Locate circlip as per illustration.
 WARNING
If this procedure is disregarded, throttle might
be half-open at normally closed position and
the engine will speed up when starting.
MMR2001_014_04_11A.FM 04-11-1
TABLE OF CONTENTS 0
DRIVE BELT............................................................................................................................ 05-02-1
INSPECTION ...................................................................................................................... 05-02-1
ROTATION DIRECTION ..................................................................................................... 05-02-1
DRIVE BELT DEFLECTION MEASUREMENT ................................................................... 05-02-1
DEFLECTION ADJUSTMENT............................................................................................ 05-02-2
DRIVE PULLEY....................................................................................................................... 05-03-1

BOMBARDIER LITE ........................................................................................................... 05-03-1
GENERAL ........................................................................................................................... 05-03-2
REMOVAL........................................................................................................................... 05-03-2
DISASSEMBLY................................................................................................................... 05-03-2
CLEANING ......................................................................................................................... 05-03-3
INSPECTION ...................................................................................................................... 05-03-3
ASSEMBLY......................................................................................................................... 05-03-3
INSTALLATION .................................................................................................................. 05-03-3
COMET® 102C .................................................................................................................... 05-03-4
GENERAL ........................................................................................................................... 05-03-5
MAINTENANCE ................................................................................................................. 05-03-5
REMOVAL........................................................................................................................... 05-03-5
DISASSEMBLY................................................................................................................... 05-03-6
CLEANING ......................................................................................................................... 05-03-7
INSPECTION ...................................................................................................................... 05-03-7
ASSEMBLY......................................................................................................................... 05-03-7
INSTALLATION .................................................................................................................. 05-03-8
TRA ..................................................................................................................................... 05-03-9
GENERAL ........................................................................................................................... 05-03-10
REMOVAL........................................................................................................................... 05-03-10
DISASSEMBLY................................................................................................................... 05-03-10
CLEANING ......................................................................................................................... 05-03-11
INSPECTION ...................................................................................................................... 05-03-12
ASSEMBLY......................................................................................................................... 05-03-13
INSTALLATION .................................................................................................................. 05-03-15
DRIVE PULLEY ADJUSTMENT......................................................................................... 05-03-15
DRIVEN PULLEY .................................................................................................................... 05-04-1

THRUSTBUSHING............................................................................................................. 05-04-1
LPV27 ................................................................................................................................. 05-04-2
DISASSEMBLY................................................................................................................... 05-04-3
INSPECTION ...................................................................................................................... 05-04-3
ASSEMBLY......................................................................................................................... 05-04-4
INSTALLATION .................................................................................................................. 05-04-5
ADJUSTMENT ................................................................................................................... 05-04-5
MMR2001_038_05_01ATOC.FM 05-01-1
PULLEY DISTANCE AND ALIGNMENT ................................................................................ 05-05-1

GENERAL............................................................................................................................ 05-05-1
GENERAL PROCEDURE..................................................................................................... 05-05-1
PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART ................................. 05-05-2
BRAKE..................................................................................................................................... 05-06-1
MECHANICAL BRAKE ........................................................................................................ 05-06-1
HYDRAULIC BRAKE ........................................................................................................... 05-06-2
REMOVAL ........................................................................................................................... 05-06-4
DISASSEMBLY ................................................................................................................... 05-06-5
CLEANING .......................................................................................................................... 05-06-5
INSPECTION ....................................................................................................................... 05-06-5
ASSEMBLY ......................................................................................................................... 05-06-6
INSTALLATION ................................................................................................................... 05-06-6
ADJUSTMENT.................................................................................................................... 05-06-7
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

3-SPEED GEARBOX ........................................................................................................... 05-08-1
REMOVAL ........................................................................................................................... 05-08-2
DISASSEMBLY ................................................................................................................... 05-08-3
INSPECTION ....................................................................................................................... 05-08-8
ASSEMBLY ......................................................................................................................... 05-08-8
INSTALLATION ................................................................................................................... 05-08-11
OIL LEVEL ........................................................................................................................... 05-08-11
DRIVE CHAIN ......................................................................................................................... 05-09-1

SILENT CHAIN.................................................................................................................... 05-09-1
05-01-2 MMR2001_038_05_01ATOC.FM
Subsection 02 (DRIVE BELT)
DRIVE BELT 0
PART WIDTH (NEW) MINIMUM WIDTH
MODEL
NUMBER ± 0.25 mm (.010 in) (WEAR LIMIT)
S-Series
415 060 600 34.70 mm (1.366 in) 32.30 mm (1.272 in)
Skandic LT/WT/SWT/WT LC
INSPECTION
Inspect belt for cracks, fraying or abnormal wear
(uneven wear, wear on one side, missing cogs,
cracked fabric). If abnormal wear is noted, proba-
ble cause could be pulley misalignment, excessive
RPM with frozen track, fast starts without warm-
up period, burred or rusty sheave, oil on belt or
distorted spare belt.
Check the drive belt width. Replace the drive belt
if width is less than the minimum width recom-
mended (see table above).
ROTATION DIRECTION
The maximum drive belt life span is obtained when
the drive belt is installed as shown. This will en-
sure that correct direction of rotation is respected.
A01D2LA
INCORRECT
NOTE: For used drive belt, mark and reinstall in

the same position.
DRIVE BELT DEFLECTION

MEASUREMENT
NOTE: The drive belt deflection measurement must
be performed each time a new drive belt is in-
stalled.
NOTE: To obtain an accurate drive belt deflection
measurement, it is suggested to allow a break-in
period of 50 km (30 mi).
Before checking the belt deflection, ensure vehi-
cle has the proper belt (Refer to the application
chart).
A01D2KA
Adjust pulley distance and alignment. Refer to PUL-
CORRECT LEY DISTANCE AND ALIGNMENT.
MMR2001_015_05_02A.FM 05-02-1
To obtain maximum vehicle performance, the belt Or use the belt tension tester (P/N 414 348 200).
tension must be adjusted according to specifica-
tions shown in the accompanying chart. 1 2
DEFLECTION FORCE HEIGHT†

MODEL mm kg OVER DRIVEN
(in) (lb) PULLEY A00C07B 4 3
32 ± 5 11.3 0 - 1.5 mm 1. Lower O-ring
All models
(1-1/4 ± 13/64) (25) (0 - 1/16 in) 2. Upper O-ring
3. Force (read down)
† 4. Deflection (read up)
FOR REFERENCE ONLY
To Check Tension 1. Slide lower O-ring of tester to specified deflec-

tion.
Position a reference rule on drive belt.
2. Slide upper O-ring of tester until reaching mark
Wooden Stick and Spring Scale Method 0 (zero).
3. Apply pressure until lower O-ring is flush with
1 edge of rule and read force on the upper scale
at top edge of O-ring.
2
A00D05A
1. Mark specified deflection
Using spring scale and stick, apply specified force

on drive belt halfway between pulleys as shown.
1 3
4
1
5
2
A00D08A
1. Upper O-ring — force

2. Force applied
3 3. Lower O-ring — deflection
4. Reference rule
5. Deflection
A00D06A
Vary pulley distance — within tolerances — to ob-

1. Force
2. Read deflection here tain proper drive belt deflection.
3. Reference rule
05-02-2 MMR2001_015_05_02A.FM
Subsection 03 (DRIVE PULLEY)
DRIVE PULLEY 0
BOMBARDIER LITE
NOTE: This is a lubrication free drive pulley.
377 Engine S-Series
3
11
6 7
8
128 N•m
(95 lbf•ft)
9
95 N•m
(70 lbf•ft)
A03D2GT
MMR2001_016_05_03A.FM
GENERAL Insert drive pulley puller (P/N 529 031 400) then
remove drive pulley.
Some drive pulley components (return spring, cali-
bration disk) can be changed to improve vehicle
performance in high altitude regions. A Service Bul-
letin will give information about calibration accord-
ing to altitude.
CAUTION: Such modifications should only be
performed by experience mechanics since they
can greatly affect vehicle performance.
 WARNING
Any drive pulley repairs must be performed by
an authorized Bombardier snowmobile dealer,
or other such qualified person. Sub-component
installation and assembly tolerances require
strict adherence to procedures detailed.
A05D0KA 529 031 400
REMOVAL TYPICAL
NOTE: If disassembling drive pulley, first straight-
en tab washer no. 7 then untighten nut no. 8. DISASSEMBLY
 WARNING Unscrew nut. Remove tab washer.
Never use an impact wrench to remove or in- Check for alignment marks for proper indexing at
stall the drive pulley. reassembly.
Use holder (P/N 529 027 600).

Remove retaining screw no. 9.
529 027 600
A03D2IA 1
1. Alignment marks
A05D0JB
TYPICAL
05-03-2 MMR2001_016_05_03A.FM
Identify blocks no. 1 and their respective positive CLEANING

positions for reassembly.
Clean pulley faces and shaft with fine steel wool
and clean dry cloth. Clean sliding half bushing with
clean dry cloth.
1
INSPECTION
Check sliding half for excessive lateral play and
1
fixed half shaft for scratches. Replace as required.
ASSEMBLY
Install circlip no. 11 then washer no. 10.
A05D0LA
Make sure to install blocks at their original position
and with their curved end toward governor cup.
1. Identify See following illustration.
2, Cap, Washer and Disk Tighten nut no. 8 to 128 N•m (95 lbf•ft).
These are calibration parts. Refer to TECHNICAL INSTALLATION
DATA.
Install spring cover tool (P/N 529 027 300) with pull- Torque screw to 90 to 100 N•m (66 to 74 lbf•ft).
er (P/N 529 031 400) on spring cover. Install drive belt and belt guard.
Raise and block the rear of the vehicle and support
1 2
it with a mechanical stand.
 WARNING
Ensure that the track is free of particles which
could be thrown out while track is rotating.
Keep hands, tools, feet and clothing clear of
track. Ensure nobody is standing near the ve-
hicle.
Accelerate the vehicle at low speed (maximum 30

km/h (20 MPH)) and apply the brake, repeat 5
times.
A03D2HA
Recheck the torque of 90 to 100 N•m (66 to 74
lbf•ft).
1. Puller tool
2. Spring cover tool
 WARNING
Screw puller (hand tight) to hold spring cover and After 10 hours of operation the transmission
remove screws holding spring cover. system of the vehicle must be inspected to
Slowly unscrew puller to release spring pressure. ensure the retaining screw is properly torqued.
Remove spring cover no. 5, spring and washer
no. 11.
MMR2001_016_05_03A.FM 05-03-3
COMET® 102C
377 Engine Skandic LT
10
3
2 11
7
6
12 Nm
(110 lbfin)
6
1 13
9 12
4 14
68 Nm 8
(50 lbfft) 15
5 13
170 Nm
(125 lbfft)
Primer N
Loctite 271 16
Primer N
Loctite 271
A29D20S

GENERAL REMOVAL
Some drive pulley components can be changed to
improve vehicle performance in high altitude re-  WARNING
gions. A Service Bulletin will give information Never use an impact wrench to remove or in-
about calibration according to altitude. stall the drive pulley.
CAUTION: Such modifications should only be Unfasten center and rear bottom pan attachments
performed by experience mechanics since they on left hand side. Remove belt guard.
can greatly affect vehicle performance.
Open driven pulley using driven pulley opening
 WARNING tool (P/N 529 017 200). Remove drive belt.
Any drive pulley repairs must be performed by Use holder (P/N 529 006 400). Make sure holder
an authorized Bombardier snowmobile dealer, hook is positioned on top of tower.
or other such qualified person. Sub-component
installation and assembly tolerances require 529 006 400
strict adherence to procedures detailed.
MAINTENANCE
Cam Arm Pivot Nut
At first 10-hour (500 km) cam arm pivot nuts no. 15
have to be retighten.
To do so, loosen one turn all cover screws no. 2.
Retighten to 5.6 N•m (50 lbf•in) maximum all three
pivot nuts no. 15. Make sure cam arms no. 12 can
still move on their pivot bolts no. 11.
A29D21A
Retighten cover screws no. 2 to 12 N•m (110
lbf•in). Proceed with one screw per tower in a criss-
cross sequence then, remaining three screws.
Cam Arm Bushing

Cam arm bushings no. 14 have to be replaced ev-
ery 3000 km (2000 mi).
With drive pulley still installed on crankshaft, re-
move one cam arm no. 12 at a time. Install parts
included in Cam Arm Kit. Proceed with remaining
cam arms.
Loosen one turn all cover screws no. 2.
Retighten to 5.6 N•m (50 lbf•in) maximum all
three pivot nuts no. 15. Make sure cam arms A29D22A 1
no. 12 can still move on their pivot bolts no. 11.
1. Holder hook on top of tower
Retighten cover screws no. 2 to 12 N•m (110 lbf•in).
Proceed with one screw per tower in a criss-cross Remove retaining screw no. 1.
sequence then, remaining three screws.
MMR2001_016_05_03A.FM 05-03-5
Install holder (P/N 529 006 400) in a way to limit

pulley clockwise rotation.
Insert drive pulley puller (P/N 529 025 000) then
turn puller clockwise to free drive pulley from
crankshaft taper.
529 006 400
A29D23A 529 025 000
Remove driven pulley to make room for drive pul-

ley removal.
Remove drive pulley. A29D24A
1. Scribe marks
DISASSEMBLY
Remove cover screws no. 2.
Mount retainer from tool kit (P/N 529 025 400) in
a vise. Hold cover no. 3 by hand then, unscrew retaining
screw no. 1.
Install drive pulley over retainer then, fasten reta-
ing screw no. 1 and torque to 68 N•m (50 lbf•ft).
Now drive pulley is locked on retainer.
Scribe pen marks on fixed half no. 16, sliding half
no. 10, spider no. 5 and cover no. 3 for proper in-
dexing at reassembly.
A29D25A
Remove cover no. 3.
05-03-6 MMR2001_016_05_03A.FM
Heat spider no. 5 to melt threadlocker. CLEANING

Install spider wrench from tool kit (P/N 529 025
400) then, unscrew spider no. 5.
and clean dry cloth. Clean sliding half bushing
1 no. 9 and cover bushing with clean dry cloth.
Thoroughly clean spider threads and fixed half
post threads.
INSPECTION
Check sliding half for excessive lateral play and
fixed half post for scratches. Replace as required.
Check cover bushing interior. Replace cover if
bushing is completely bronze instead of the origi-
nal teflon coating.
Check that spider thrust buttons no. 6 for proper
sliding action. Replace as required.
A29D26A Check rollers no. 7 for free action. Replace as re-
1. Spider wrench quired.
Note shim no. 8 quantity. ASSEMBLY
1 Install shims no. 8 on fixed half post.
Apply Primer N (P/N 293 800 041) to both post and
spider threads, allow to dry for 10 minutes. Apply
Loctite 271 (P/N 293 800 005) to threads.
Using spider wrench from tool kit (P/N 529 025
400) torque spider no. 5 to 170 N•m (125 lbf•ft).
With square end facing sliding half install a washer
no. 13 on each side of cam arm no. 12.
A29D27A
1. Shims
Remove cam arms no. 12.
A29D28A 1
1. Square end facing sliding half
MMR2001_016_05_03A.FM 05-03-7
Tighten to 5.6 N•m (50 lbf•in) maximum all three INSTALLATION

pivot nuts no. 15. Make sure cam arms no. 12 can
still move on their pivot bolts no. 11. Install drive pulley on crankshaft.
Torque retaining screw to 68 N•m (50 lbf•ft).
Reinstall driven pulley, drive belt and belt guard.
Refasten bottom pan center and rear attachments
on left hand side.
 WARNING
track. Ensure nobody is standing near the vehi-
A29D29A
cle.
Install spring no. 4, cover no. 3. Accelerate the vehicle at low speed (maximum
30 km/h (20 MPH)) and apply the brake, repeat 5
Tighten cover screws no. 2 to 12 N•m (110 lbf•in). times.
Proceed with one screw per tower in a criss-cross
sequence then, remaining three screws. Recheck the torque of 68 N•m (50 lbf•ft).
Use puller (P/N 529 025 000) to unlock drive pulley
from retainer.
 WARNING
After 10 hours of operation the transmission
system of the vehicle must be inspected to
ensure the retaining screw is properly torqued.
529 025 000
A29D2AA
05-03-8 MMR2001_016_05_03A.FM
TRA
Touring Fan 500, Formula Deluxe Fan 500, MX Z Fan 440/500, Summit Fan 500
and Skandic WT/SWT/WT LC
Loctite 271
27 Nm
(20 lbfft)
12 Nm
(106 lbfin)
6 13
12
Loctite 12 11
609
Electric start models 14
7 17
5 15
16
13 Nm
(115 lbfin) Loctite
609 18
23
25
19
20
28 10 Nm
21 24 (89 lbfin)
22
Loctite
609
27 25
Repair kit 26
30
29 31
95 Nm
(70 lbfft)
A30D16S

GENERAL  WARNING
Some drive pulley components (return spring, Never use any type of impact wrench at drive
ramp) can be changed to improve vehicle perfor- pulley removal and installation.
mance in high altitude regions. A Service Bulletin
will give information about calibration according to Remove retaining screw.
altitude. To remove drive pulley ass’y and/or fixed half from
CAUTION: Such modifications should only be engine, use puller (P/N 529 022 400).
performed by experienced mechanics since CAUTION: These pulleys have metric threads.
they can greatly affect vehicle performance. Ver- Do not use imperial threads puller. Always tight-
ify spring specifications before installation. Do en puller by hand to ensure that the drive pulley
not only refer to the spring color code. has the same type of threads (metric vs imperi-
NOTE: TRA drive pulley stands for Total Range al) prior to fully tightening.
Adjustable drive pulley. To Remove Drive Pulley Ass’y:
 WARNING Retain drive pulley with clutch holder.
Any drive pulley repairs must be performed by Install puller in pulley shaft then tighten.
an authorized Bombardier snowmobile dealer,
or other such qualified person. Sub-component DISASSEMBLY
installation and assembly tolerances require
strict adherence to procedures detailed. 1,2, Screw and Ring Gear
CAUTION: Retaining screws must be heated be-
REMOVAL fore disassembly. Do not exceed 150°C (300°F).
30,31, Conical Spring Washer and 5,6, Fixed and Sliding Half
Screw CAUTION: Do not tap on governor cup.
Use holder (P/N 529 006 400). Screw puller into fixed half shaft about 13 mm (1/2
in). Raise drive pulley and hold it by the sliding half
while knocking on puller head to disengage fixed
half.
529 006 400
2
1
A20D06A
A16D01A
2
TYPICAL
1. Retaining screw 1. Puller
2. Insert in any slot 2. Holding sliding half
NOTE: No components marking is required be-

fore disassembling this drive pulley since it has
factory mark and arrows as indexing reference.
05-03-10 MMR2001_016_05_03A.FM
25,29, Slider Shoe and Governor Cup

Carefully lift governor cup until slider shoes come
at their highest position into guides.
Hold a slider shoe set then carefully lift its housing
and remove slider shoes. Proceed the same way for 1
other housings lifting one at a time.
A03D3EA
A16D02A
1. Support guide
1. Hold slider shoes
2. Lift one housing at a time Install sliding half then a second support guide. These
support guides will prevent bushing damages.
NOTE: To ease disassembly, forks (P/N 529 005
500) should be used to hold slider shoes prior to
removing governor cup.
529 005 500
A16B02A
A03D3FA
1. Support guide
19, Spring Cover Ass’y
Remove 3 Allen screws retaining spring cover then
It is pushed by clutch spring pressure. unscrew compressor.
 WARNING CLEANING
Clutch spring is very strong. Never attempt to
remove spring cover without the recommend- 5,6, Fixed and Sliding Half
ed tools.
Use spring compressor (P/N 529 035 524). and dry cloth.
Install support guide.
MMR2001_016_05_03A.FM 05-03-11
5, Fixed Half and Crankshaft End 24,25, O-Ring and Slider Shoe
Parts must be at room temperature before clean- Check if O-rings are cracked, cut or crushed. Re-
ing. place as required.
Using a paper towel with cleaning solvent, clean Check slider shoes for wear. Replace if groove is not
crankshaft tapered end and the taper inside the apparent on top.
fixed half of the drive pulley, crankshaft threads
and retaining screw threads. 5,29, Fixed Half and Governor Cup
 WARNING Inspect splines and free play between both parts.
Maximum free play is 0.5 mm (.020 in) measured
This procedure must be performed in a well- at calibration screw radius. Replace if required.
ventilated area.
7,20, Sliding Half and Spring Cover
CAUTION: Avoid contact between cleaner and Bushing
crankshaft seal because damage may occur.
Visually inspect coating. Replace if worn.
Remove all hardened oil deposits that have baked
on crankshaft and pulley tapered surfaces with Sliding Half Bushing Replacement
coarse or medium steel wool and/or sand paper This bushing is not replacable. If worn out, replace
no. 600. sliding half ass’y.
CAUTION: Do not use any other type of abrasive. Spring Cover Bushing Replacement
Reclean mounting surfaces with paper towel and Under normal use there is no need to replace this
cleaning solvent. bushing.
Wipe off the mounting surfaces with a clean, dry Mount compressor (P/N 529 035 524) in a vise.
paper towel.
Use tools (P/N 529 031 300 and 529 031 200) to
CAUTION: Mounting surfaces must be free of remove old bushing.
any oil, cleaner or towel residue.
7,20, Bushing
Only use petrol base cleaner when cleaning bush-
ings. 529 031 300
CAUTION: Do not use acetone to clean bushing.
529 031 200
INSPECTION
Drive pulley should be inspected annually.
16,17, Thrust Washer and Roller

Check roller for roundness of external diameter.
Check thrust washer for thickness wear. Replace
as required.
CAUTION: Ensure rollers are in good condition. A01D2MA
Replace as required.
CAUTION: Bushing must be bonded with retain-
9,12, Fitting Bolt Ass’y and Flanged ing compound.
Bushing Apply retaining compound Loctite 609 outside of
Check for wear, replace as required. bushing then press it down to counterbore from
outside end.
CAUTION: Insert bushing from sliding half side
(inner side) of spring cover.
05-03-12 MMR2001_016_05_03A.FM
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 413 702 900) on threads and
then torque to 27 N•m (20 lbf•ft).
26,27,28, Calibration Screw, Washer

and Locking Nut
When installing calibration screw, make sure to in-
stall washer as shown.
A16D2PA
A16D07A
1. Washer
Torque locking nut to 10 N•m (89 lbf•in). A16D09A 1 1

1. Equal distance
15, Pin
Always use the same type of pin as originally in- Torque screws to 10 N•m (89 lbf•in).
stalled when servicing. Different types have differ-
ent weights for calibration purpose. Refer to TECH- 9,11,13,14, Screw, Lever Ass’y, Nut and
NICAL DATA. Cotter Pin
Always install lever assemblies so that cotter pins
21,22,23, Screw, Dowel Tube and Ramp are on the shown side. Besides install cotter pin
Insert dowel tube from chamfered side. Make head on top when lever is sat at bottom of sliding
sure ramp is centered on dowel tube. half. Bend cotter pin ends to sit perfectly against
lever.
1
 WARNING
Whenever replacing centrifugal levers, always
replace all 3 at the same time. Otherwise, drive
pulley misbalancing will occur because of le-
A16D08A vers difference.
1. Chamfered side
MMR2001_016_05_03A.FM 05-03-13
1
6,25,29, Sliding Half, Slider Shoe and
Governor Cup
To install governor cup, use following tool:
2
529 005 500
A16B01A
A16D0BA
1. Head on top Insert spring and slider shoes into governor cup so
2. All on the same side that groove in each slider shoe is vertical to prop-
CAUTION: Lever assemblies must be installed so erly slide in guides.
that cotter pins are on the same side. CAUTION: Make sure O-rings are installed on
Torque nuts to 12 N•m (106 lbf•in). slider shoes and their grooves are positioned
vertically.
CAUTION: Lever ass’y and rollers must move
easily after installation. Install fork (P/N 529 005 500) into slider shoe grooves
to maintain them for governor cup installation. Pro-
5,6,18,19, Fixed Half, Sliding Half, Spring, ceed on 3 set of slider shoes.
Spring Cover and Screw
To install spring cover, use spring compressor (P/N
529 035 524).
Assemble fixed and sliding halves. Note that fixed 529 005 500
halves have different cone angle. Match cone an-
gle with crankshaft.
Lift sliding half against spring cover and align spring
cover arrow with sliding half mark.
1 A16B02A
Make sure to align governor cup arrow with sliding

half and fixed half mark.
NOTE: If fixed half has no mark, align governor
cup mark with segment no. 1 of inner half. Seg-
ments are identified on engine side.
A16D0DA
1. Align
Install and torque screws to 13 N•m (115 lbf•in).
05-03-14 MMR2001_016_05_03A.FM
Use holder. See removal procedure.

Torque screw to 90 to 100 N•m (66 to 74 lbf•ft).
1
Install drive belt and guard.
 WARNING
track. Ensure nobody is standing near the vehi-
cle.
A16D0EA
1. Align km/h (20 MPH) and apply the brake, repeat 5 times.
Carefully slide governor cup into sliding half. Align Recheck the torque of 90 to 100 N•m (66 to 74 lbf•ft).
mark of governor cup with mark of fixed half.
Remove forks and push governor cup so that its
 WARNING
splines engage with fixed half shaft splines. After 10 hours of operation the transmission
system of the vehicle must be inspected to en-
CAUTION: Make sure splines of both parts are sure the retaining screw is properly torqued.
fully engaged.
INSTALLATION DRIVE PULLEY ADJUSTMENT

The drive pulley is factory calibrated to transmit
 WARNING maximum engine power at a predefined RPM. Fac-
Do not apply anti-seize or any lubricant on tors such as ambient temperature, altitude or sur-
crankshaft and drive pulley tapers. face condition may vary this critical engine RPM
thus affecting snowmobile efficiency.
 WARNING This adjustable drive pulley allows setting maxi-
mum engine RPM in the vehicle to maintain max-
Never use any type of impact wrench at drive imum power.
pulley removal and installation.
Calibration screws should be adjusted so that actu-
Clean mounting surfaces as described in CLEAN- al maximum engine RPM in vehicle matches with
ING above. the maximum horsepower RPM given in TECHNI-
CAL DATA.
Drive Pulley Ass’y NOTE: Use precision digital tachometer for en-
The installation procedure must be strictly adhered gine RPM adjustment.
to as follows. NOTE: The adjustment has an effect on high RPM
Install drive pulley on crankshaft extension. only.
Install conical washer with its concave side to- To adjust, modify ramp end position by turning cal-
wards drive pulley then install screw. ibration screws.
 WARNING
Never substitute conical washer and/or screw
with jobber ones. Always use Bombardier gen-
uine parts for this particular case.
MMR2001_016_05_03A.FM 05-03-15
26,28,29, Calibration Screw, Locking Each number modifies maximum engine RPM by
Nut and Governor Cup about 200 RPM.
Calibration screw has a notch on top of its head. Lower numbers decrease engine RPM in steps of
200 RPM and higher numbers increase it in steps
of 200 RPM.
Example:
Calibration screw is set at position 3 and is changed
to position 5. So maximum engine RPM is increased
by about 400 RPM.
To Adjust:
Just loosen locking nut enough to pull calibration
screw partially out and adjust to desired position.
Do not completely remove the locking nut. Torque
1 locking nuts to 10 N•m (89 lbf•in).
A16D0FA
CAUTION: Do not completely remove calibra-
1. Notch tion screw otherwise its inside washer will fall
off.
Governor cup has 6 positions numbered 2 to 6.
Note that in position 1 there is no stamped num- CAUTION: Always adjust all 3 calibration screws
ber (due to its location on casting). and make sure they are all set at the same num-
ber.
See TECHNICAL DATA for original setting.
A16D0GA
1. Position 1 (not numbered) A16D0HA
1. Loosen just enough to permit rotating of calibration screw
05-03-16 MMR2001_016_05_03A.FM
DRIVEN PULLEY 0
THRUSTBUSHING
Skandic WT/SWT/WT LC
Anti-seize
lubricant
A22D11T

LPV27
Anti-seize
lubricant
1
2
3
4 5
6 Red 10
7 Black 11
Loctite
609
Loctite
609
8 9
12
14
A03D3PS

DISASSEMBLY
Use spring compressor (P/N 529 035 524).
2
529 035 524
A15D0OA
3
1. Measure thickness of slope base here

2. Sliding pulley side
3. Slope base
Bushing Replacement
Large Bushing
Remove Allen screws if applicable. Heat to break
Loctite bond.
Install support plate included in tool (P/N 529 031
100) inside sliding half.
Place extractor (P/N 529 035 575) below bushing.
A15D36B
TYPICAL
Remove half keys no. 3 and spacer no. 4 to disas-

semble the outer cam and the 2 pulley halves. 2
 WARNING
Driven pulley cam is spring loaded, use above
mentioned tool. 1
INSPECTION
Replace bushing(s) if worn more than specified.
DRIVEN PULLEY BUSHING WEAR LIMIT A03D1WB
mm (in) TYPICAL
Small bushing 38.30 (1.508) 1. Support plate
2. Extractor
Large bushing 108.2 (4.260) Mount screw head of new puller (P/N 529 035
524) in a vise.
10,11, Slider Shoe Turn pulley half by hand to extract old bushing.
Black slider shoe = forward Before bushing installation, file sliding half bore to
Red slider shoe = reverse remove burrs from crimping areas.
Check cam slider shoes for wear. Replace when Coat bushing outside diameter with Loctite 609
inside edge of cam slider shoe slope base is worn (P/N 413 703 100). Place new bushing on sliding
to 1 mm (.039 in) or less. half and slightly tap to engage squarely the bush-
ing in the sliding.
MMR2001_017_05_04A.FM 05-04-3
ASSEMBLY 5,6,7, Cam, Guard and Spring

Make sure to install proper cam. Refer to TECHNI-
10,11, Cam Slider Shoe CAL DATA.
When replacing slider shoes, always install a new Cam angle is identified on cam.
set (3 shoes) to maintain equal pressure on the
cam.
1
Install slider shoes as per following photo. Red 2
slider shoes are being used for reverse and black
3
ones for forward.
4
5
44°
6
2
BO
BA
M
RD
2 IER
A24D06A
1
Position guard no. 6 in cam no. 5 then insert spring
in adjusting hole no. 3 (mid-hole) into outer cam.
1
2 Compress outer cam using spring compressor
(P/N 529 035 524).
Install spacer no. 4 then secure outer cam with
A03D2SA
half keys no. 3, as shown in the next photo.
1. BLACK slider shoe CAUTION: Ensure that half keys are properly
2. RED slider shoe
inserted into shaft groove and that spacer re-
Assemble driven pulley components by reversing cess is facing half keys.
the disassembly procedure.
1
A03D3JA 2
1. Half keys inserted into shaft groove
2. Spacer recess facing half keys
05-04-4 MMR2001_017_05_04A.FM
INSTALLATION
1, Countershaft
CAUTION: Always apply anti-seize lubricant
(P/N 413 701 000) on the countershaft before
final pulley installation.
Make sure that spacer no. 2 is on countershaft be-
fore installing driven pulley. Note also that washer
shoulder is facing driven pulley.
1 2
A30D0HA
TYPICAL
1. Spacer
2. Shoulder on this side
Should installation procedure be required, refer to

BRAKE then look for Brake Disc and Counter-
shaft Bearing Adjustment.
Reinstall the pulley on the countershaft by revers-
ing the removal procedure.
14, Pulley Retaining Screw

Torque to 25 N•m (18 lbf•ft).
ADJUSTMENT
Pulley Alignment and Drive Belt
Deflection
Refer to PULLEY DISTANCE AND ALIGNMENT
and DRIVE BELT to perform adjustments.
CAUTION: Drive belt and pulley adjustments must
always be checked whenever pulleys have been
removed, replaced or disassembled.
MMR2001_017_05_04A.FM 05-04-5
Subsection 05 (PULLEY DISTANCE AND ALIGNMENT)
PULLEY DISTANCE AND ALIGNMENT 0

GENERAL GENERAL PROCEDURE
The pulley distance we will refer to in this section, Remove guard.
is the space separating the drive and driven pulley
outside diameters (Z measurement). S-Series and Skandic LT
This basic distance is provided as an assembly Use driven pulley opening tool (P/N 529 035 501).
guide and indicates the dimensions between which All Models
satisfactory belt deflection will be obtained.
Remove drive belt.
Both pulley distance adjustment and pulley align-
ment must be carried out to ensure the highest Insert a straight bar 9.5 mm (.375 in) square, 48 cm
efficiency of the transmission system. Further- (19 in) long or the proper alignment template into
more, optimum drive belt operation and minimal the opened driven pulley.
wear will be obtained only with proper pulley align-
ment. Measuring Procedure
CAUTION: Before checking pulley adjustment, Using Straight Bar:
the rear suspension must be mounted on the Always measure distances X and Y from the far-
vehicle and track tension/alignment must be ther straight bar side (including its thickness to the
done. Always check pulley adjustment after fixed half edge).
suspension is adjusted.
Y
 WARNING
Failure to correctly perform pulley alignment
may cause the vehicle to creep forward at idle.
All pulley alignment specifications refer to: X Z

X = Distance between straight bar and drive pul-
ley fixed half edge, measured between pul-
leys.
2
Y = Distance between straight bar and drive pul-
ley fixed half edge, measured at the end of
straight bar.
Z = Distance between outside diameter of pul- A00D0WA
1
leys.
1. Straight bar
2. Front of vehicle
The distance Y must exceed distance X to com-

pensate for the twist due to the engine torque.
Nominal Value Procedure and Quick

Alignment and Distance Check
Alignment template tabs must fully contact fixed
half of drive pulley.
Pulley distance is correct when tab contacts both
pulley halves.
MMR2001_018_05_05A.FM 05-05-1
Refer to chart below for proper alignment template. Drive Belt Deflection
NOTE: When pulley distance and alignment are
adjusted to specifications, refer to DRIVE BELT to
adjust drive belt deflection.
CAUTION: This section deals mainly with ad-
justment procedures. For complete assembly
1 requirements, refer to the proper ENGINE or
TRANSMISSION installation section.
A06D0LA
TYPICAL
1. Contact (alignment)
2. Contact (distance)
PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART

PULLEY
OFFSET ALIGNMENT
DISTANCE
TEMPLATE
MODEL Z X Y-X
➀
± 0.50 mm ± 0.50 mm ± 0.5 mm P/N
(.020 in) (.020 in) (.020 in)
Touring Fan 380,
26.0 33.4 1.0
Formula DLX 380, 529 035 586
(1.024) (1.315) (.039)
MX Z Fan 380
Touring Fan 500,
17.0 35.5 1.0
Formula DLX Fan 500, 529 035 530
(.669) (1.398) (.039)
MX Z Fan 440/500
34.2 ± 0.75 37.0 ± 0.75 0.75 to 2.25
Skandic LT
(1.346 ± .030) (1.457 ± .030) (.030 to .086)
32.3 ± 0.75 35.0 ± 0.75 0.75 to 2.25
Skandic WT/SWT/WT LC 529 035 545
(1.272 ± .030) (1.380 ± .030) (.030 to .086)
➀ Alignment templates have been made according to pulley alignment nominal values. However, they
do not take into account allowed tolerances for alignment specifications. They are used as GO/NO GO
gauges for quick alignment and pulley distance check and as templates to reach alignment nominal
values.
05-05-2 MMR2001_018_05_05A.FM
Pulley Distance Adjustment Method Engine Movement

S-Series The engine support has slotted mounting holes.
Move engine to obtain specified distance between
Y pulleys.
Pulley Alignment Method

1 Driven Pulley Movement
When engine slotted mounting holes do not allow
to set proper pulley offset X, adjust with shims
X Z (P/N 504 108 200) between pulley and counter-
shaft bearing support (pulley pushed toward brake
disc).
Engine Movement
Loosen the 4 bolts retaining engine support to the
frame. Position engine to obtain the specified align-
A15D02A 2 ment.
TYPICAL NOTE: After alignment, adjust torque rod so it
1. Engine movement slightly contacts stopper plate. Do not over tight-
2. Contact
en, it will disalign pulleys.
NOTE: Prior to performing pulley adjustment, loos-
en torque rod nut to allow engine movement. En- 1
gine supports have tendency to stick to frame, work
engine loose prior to aligning.
1
A06D07A
1. Retighten
A06D07B
1. Loosen
MMR2001_018_05_05A.FM 05-05-3
Subsection 06 (BRAKE)
BRAKE 0
MECHANICAL BRAKE
Formula DLX 380, Touring Fan 380, MX Z Fan 380 and Skandic LT
2 9
Dielectric
grease
7
12 Anti-seize
lubricant
11
1
14
15
16
Anti-seize
lubricant
20
19
A03D3US

HYDRAULIC BRAKE
17
A29D1XS

Formula DLX Fan 500, Touring Fan 440/500 and Summit Fan 500
Loctite
243
Loctite 271
17
Anti-seize
lubrifiant
19
20
A03D3VS

REMOVAL Countershaft Bearing Removal

Brake Disc Removal S-Series
Unbolt bearing support and triangular support. In-
stall screw from remover (P/N 529 030 100) and
– Remove caliper by unscrewing M10 Allen screws. some flat washers of 3 mm (1/8 in) total thickness.
– Unbolt disc.
– Remove caliper.
– Remove guard, belt and driven pulley.
– Remove air silencer.
– Unbolt bearing support no. 19 from chassis.
– Open chaincase and remove upper sprocket.
– Pull countershaft assembly toward driven pul-
ley side to gain access to clip no. 25.
– Remove clip no. 25 on countershaft.
A03D2ZA 1 2
1. Screw from tool
2. Washers use as a 3 mm (1/8 in) spacer
Install remover (P/N 529 030 100) on countershaft

and medium thickness spacer. Use M6 x 70 mm
screws instead of screws supplied with remover.
A03D11A
– Pull countershaft toward driven pulley side to

free from chaincase and disc.
– Remove disc.
Countershaft Removal
S-Series and Skandic LT with Mechanical
Brake A03D30A 529 030 100 2 1
Proceed the same as for brake disc removal. 1. Medium thickness spacer
2. M6 x 70 mm screws
05-06-4 MMR2001_019_05_06A.FM
Add the thin spacer to complete bearing removal. INSPECTION

7, Brake Pad
Models with Mechanical Brake
Brake pads must be replaced when fixed pad
projects only 1 mm (1/32 in) from caliper.
CAUTION: Brake pads must always be replaced
in pairs.
1
A03D31A 1 2
1. Thin spacer
2. Medium thickness spacer
DISASSEMBLY
7,15,16,23, Brake Pad, Brake Lever, Pin
and Screw
All Models with Mechanical Brake 2
Pull pin out of caliper and remove lever.
Fixed pad is riveted to chaincase on these models. A15D03A A
Caliper must be split to remove moving pad. To
removed fixed pad, drill out its rivet then pry disc TYPICAL
in order to free fixed pad. 1. Fixed pad
2. Inner caliper
A. 1 mm (1/32 in) minimum
All Models with Hydraulic Brake
Only brake pads are available as spare parts. If cal- Models with Hydraulic Brake
iper or master cylinder are damaged, replace each Brake pads must be replaced when lining is 1 mm
of them as an assembly. (1/32 in) thick.
CLEANING in pairs.
Clean all metal components in a general purpose
solvent. Thoroughly dry all components before as-
Brake Disc
sembling. All Models
CAUTION: Do not clean brake pads in solvent. Check for scoring, cracking or heat discoloration,
Soiled brake pads must be replaced by new ones. replace as required.
CAUTION: Brake disc should never be machined.
MMR2001_019_05_06A.FM 05-06-5
ASSEMBLY 7, Brake Pad

Models with Hydraulic Brake
14, Ratchet Wheel
After brake pads installation, brake disc must be
Apply synthetic grease (P/N 413 711 500) on threads centered in caliper. Apply brake then check for
and spring seat prior to installing. Fully tighten then proper brake disc positioning.
back off one turn.
Push on appropriate caliper piston in order to
16, Pin move pad inward allowing proper brake disc posi-
tioning.
Install so that it can only be removed upward. Lock
it in the caliper casting notch.
INSTALLATION
To install brake, reverse removal procedure paying
attention to the following.
 WARNING 1 2
Avoid getting oil on brake pads. Do not lubri-
cate or apply antirust or antifreeze solution in
brake cable.
3
17, Brake Disc
The brake disc must be floating on countershaft
for efficient operation of brake.
A03D2KA
Apply anti-seize lubricant (P/N 413 701 000) on
shaft and check that disc slides freely. 1. Brake disc not centered
2. Brake disc centered
The disc hub exceeds the disc more from one side 3. Apply brake before checking
than from the other. Install disc with the longer
Apply brake then recheck.
exceeding portion toward driven pulley.
Push O-rings inside disc hub. Countershaft Bearing Adjustment
S-Series
Insert countershaft (with brake disc) from chain-
case side through countershaft support (driven
pulley side), then insert into chaincase.
Install countershaft bearing no. 19 using proper tool.
A03D13A
05-06-6 MMR2001_019_05_06A.FM
To install bearing on countershaft, use remover 5,12, Brake Cable and Nut
(P/N 529 030 100) and some flat washers of 3 mm
Insert brake cable into upper hole in brake lever
(1/8 in) total thickness. Using original retaining
and caliper. Install nut and tighten until a few
screw and shouldered washer tighten until bearing
threads exceed.
rests against circlip.
 WARNING
At least 3 threads must exceed the elastic stop
nut.
ADJUSTMENT
Brake
Fully depress brake handle several times to obtain
13 mm (1/2 in) between brake handle and handle-
bar grip when brake is fully applied.
A
A03D32A 2 1 529 030 200 3
1. Washers use as a 3 mm (1/8 in) spacer
2. Original retaining screw and shouldered washer
3. Bearing against circlip
Ensure that countershaft is properly aligned, then

tighten 3 retaining screws.
A08G02A
NOTE: A misaligned countershaft will result in dif-
ficulty to center the bearing in its support. A. 13 mm (1/2 in)
Refer to DRIVE AXLE then look Chaincase Per- Should this adjustment be unattainable, retighten
pendicularity Adjustment. nut no. 12 as needed.
Torque castellated nut of upper sprocket to 53 N•m Models with Hydraulic Brake
(39 lbf•ft).
Change brake fluid once a year.
Close chaincase referring to CHAINCASE.
Bleed brake system as follows:
1,11,12, Locking Tab, Outer Caliper Keep sufficient DOT 4 brake fluid in reservoir at all
and Nut times.
S-Series and Skandic LT CAUTION: Use only DOT 4 brake fluid.
Install caliper retaining bolts. Install a hose on left side bleeder. Route this hose
to a container.
Assemble outer caliper. Install locking tab then
nuts. Torque nuts to 24 N•m (18 lbf•ft). Bend lock- Pump a few times brake lever and while holding
ing tab over a flat of each nut. brake lever depressed, open bleeder and check for
air to escape.
Repeat with the same bleeder until no air appears
in hose.
MMR2001_019_05_06A.FM 05-06-7
Proceed the same way with the right side bleeder.
A06D0JA 2
TYPICAL
1. Open bleeder
2. Clear hose to catch used brake fluid
Brake Light
Brake light should light up before brake pads touch
brake disc. To adjust, unscrew nut no. 12 until
brake light goes on.
 WARNING
At least one full thread must exceed the elas-
tic stop nut.
Check brake adjustment as described above.

NOTE: If brake light adjustment is unattainable
while respecting brake adjustment, ratchet wheel
may be too far out. If so, tighten ratchet wheel.
Models with Hydraulic Brake
There is no adjustment on these models. Check
that switch is securely installed.
05-06-8 MMR2001_019_05_06A.FM
Subsection 07 (CHAINCASE)
CHAINCASE 0
Chaincase oil
Touring fan 380,

2 Formula DLX 380
MX Z fan 380
Skandic LT
1 24
7 22
12
23
Loctite
271
7
25
27 11
Lithium
9 grease
8
Anti-seize
lubricant
6
5 10
Loctite
3 19 515 20
14
4
45 to 75 Nm 27
(33 to 55 lbfft) 26
17
Anti-seize
lubricant
16
Loctite
515
46 Nm 18 19
(34 lbfft) 15 14
21
SYNTHETIC CHAINCASE OIL
HUILE SYNTHÉTIQUE POUR CARTER
13
Loctite 271
A03D3WS

REMOVAL INSPECTION
To remove chaincase proceed as follows. Visually inspect the chain for cracked, damaged or
Remove tuned pipe and muffler. missing links. Check for worn or defective bear-
ings, sprockets and chain tensioner components.
 WARNING  WARNING
Never remove exhaust components when en-
gine is hot. If chain deflection is greater than 38 mm (1.5
in) (without chain tensioner), replace chain
Remove hair pin no. 8. Release drive chain ten- and check condition of sprockets.
sion by unscrewing tensioner adjustment screw.
Drain oil by removing chaincase cover no. 2. GEAR RATIO MODIFICATION
Apply brakes. For particular applications, the number of teeth of
Remove cotter pin no. 3, nut no. 4, washer no. 26 the sprockets can be increased or decreased on
retaining upper sprocket no. 5 and screw no. 15 lower and upper sprockets.
retaining lower sprocket no. 16. Pull sprockets Refer to TECHNICAL DATA for gear ratios.
and drive chain simultaneously. Remove shims
nos. 6 and 17. CAUTION: Gear ratio modifications should
only be performed by experienced mechanics
NOTE: Should countershaft removal be required, since they can greatly affect vehicle perfor-
refer to BRAKE then look for Brake Disc. mance.
Remove 5 nuts no. 14. Three nuts are behind the NOTE: For high altitude regions, a Service Bulletin
lower sprocket. will give information about calibration according to
Unfold locking tab no. 23, then remove caliper re- altitude.
taining screws no. 22.
Release track tension, use drive axle holder (P/N INSTALLATION
529 007 200).
Reverse removal procedure and pay attention to
the following. Replace oil seals, gaskets and O-rings.
1
Sealed side of bearing no. 27 must face chaincase
529 007 200 cover.
11, Oil Seal

Clean chaincase bore with cleaning solvent then
apply Loctite 609 to oil seal mounting surface (out-
side).
2 Using an appropriate pusher, press the oil seal into
chaincase hub. Oil seal must fit flush with the chain-
A01B1FA case edge.
TYPICAL NOTE: Should installation procedure for counter-
1. Drive axle shaft be required, refer to BRAKE then look for
2. Suspension cross shaft
Brake Disc and Countershaft Bearing Adjust-
Pry out drive axle oil seal no. 20 from chaincase. ment.
Pull chaincase from drive axle and countershaft.
5,16, Sprockets
Using 2 prybars inserted between chaincase no. 7
and frame, pry complete assembly from vehicle. Position the sprockets with the writing facing the
chaincase cover.
05-07-2 MMR2001_020_05_07A.FM
26, Conical Spring Washer 10, O-Ring

Install washer with its concave side towards drive Replace both O-rings no. 10 on tensioner adjust-
pulley. ment screw. Fully tighten tensioner adjustment
screw by hand, then back off only far enough for
hair pin to engage in locking hole.
This initial adjustment should provide 3 - 5 mm
(1/8 - 13/64 in) free-play when measured at the
outer circumference of the brake disc.
CAUTION: Free-play must not exceed 5 mm
(13/64 in), readjust if necessary.
 WARNING
If the specified free-play is not reached with
the tensioner screw fully tightened, replace
A03D14A
chain and check the condition of sprockets.
4, Upper Sprocket Castellated Nut 21, Chaincase Oil

Torque to 45 to 90 N•m (33 to 66 lbf•ft). S-Series Models
Install new cotter pin in the position shown. Pour 250 mL (8.5 fl. oz) of mineral chaincase oil
CAUTION: When removing a cotter pin always (P/N 413 801 900) into chaincase.
replace with a new one. Skandic LT
CAUTION: Cotter pin will rub on chaincase cover Pour 375 mL (12.7 fl. oz) of synthetic chaincase oil
if installed otherwise. (P/N 413 803 300) into chaincase.
All Models
Check oil level with the dipstick then add if re-
1 quired. Remove metal particles from magnet.
2
A02D08A
1. New
2. Fold cotter pin over castellated nut flats only
18, Circlip
CAUTION: It is of the utmost importance to in- 1
stall the circlip otherwise damage to the chain-
case components may occur.
DRIVE CHAIN ADJUSTMENT

NOTE: Brake disc key must be in good condition
before checking chain free play.
A03A03A
TYPICAL
1. Dipstick
MMR2001_020_05_07A.FM 05-07-3
NOTE: Chaincase must be in its proper position

when checking oil level.
ADJUSTMENT
Pulley Alignment
Refer to PULLEY DISTANCE AND ALIGNMENT.
Track Tension and Alignment

Refer to TRACK.
05-07-4 MMR2001_020_05_07A.FM
Subsection 08 (GEARBOX)
GEARBOX 0
3-SPEED GEARBOX
3
5
12 Loctite 242
6
11 10
8
7 9
9
15
16 14
8 18 16
Loctite 19 13
242 4
17 38
20
18 16 10
8 8
9
23
24
25
21
32 22
26
33 9
34
28 29
35
Loctite
648 36
9
30
27
10
28 31
30
10 9
37
A29D0KS

REMOVAL Remove rear suspension.

Remove angle drive and square pin from bottom
Drain gearbox oil.
of gearbox.
Remove muffler. Unbolt RH end bearing then pull
drive axle toward right side.
A29D0LA 1
1. Bottom pan drain hole nearby gearbox drain plug
A29D0NA 1
Remove belt guard, drive belt. Remove air silenc-
er, carburetor(s) then, driven pulley. 1. RH end bearing
Remove brake caliper, brake disc. Unfasten shift- Unbolt gearbox from chassis.
ing rod and unplug reverse switch.
A29D0OA
A29D0MA
05-08-2 MMR2001_021_05_08A.FM
DISASSEMBLY Unfasten sleeve nut no. 4, remove spring no. 7

then, partially pull shaft no. 5 and remove pin
For the following procedure, right hand side refers no. 6.
to driven pulley side and left hand side to brake
disc side.
2 1
A29D0RA
A29D0PA
1. RH side driven pulley side 1. Pin

2. LH side brake disc side
Completely remove shaft no. 5.
Remove dipstick no. 17. Unfasten cover no. 2 Drill a 10 mm (3/8 in) dia. hole through all plugs
from gearbox housing. no. 8.
Remove nut no. 3 retaining pin no. 6.
1
A29D0SA
A29D0QA 2 Remove all plugs no. 8 from gearbox.

1. Cover
2. Nut
MMR2001_021_05_08A.FM 05-08-3
Remove all circlips no. 9.
A29D0WA
A29D0TA
Remove sleeve no. 23.
IMPORTANT: Note all shims quantity and location. NOTE: Brake shaft gears remain in gearbox hous-
Remove brake shaft oil seal then, circlip. ing.
Remove bearing no. 27 from brake shaft no. 26
using a press.
A29D0UA 1
1. Brake shaft
Proceeding from right side, drive brake shaft out

of gearbox housing.
A29D0XA
Drive reverse shaft no. 38 out until its LH side

bearing is free.
A29D0VA
05-08-4 MMR2001_021_05_08A.FM
Make sure gears mesh. Use a puller to extract LH reverse shaft bearing.
A29D0YA 1 A29D10A
1
1. These gears must mesh as reverse shaft is driven out 1. Extract reverse shaft LH side bearing
Shift in reverse gear. To remove sliding sleeve from reverse shaft, first
Turn reverse shaft so its sliding sleeve dog will not remove circlip.
touch the RH gear of driven pulley shaft no. 15.
This will allow the driven pulley shaft to be pushed 1
out enough for bearing removal.
1 2
A29D11A
1. Circlip
2. Sliding sleeve
A29D0ZA 2
1. Sleeve dog not touching right gear
2. Brake shaft gears are still in gearbox
MMR2001_021_05_08A.FM 05-08-5
Use a puller to extract bearing no. 19. Use a puller to extract bearing no. 12.
A29D12A
A29D14A
Remove brake shaft gears.

Unbolt driven pulley shaft screw no. 11 and re- Remove circlip then, gear no. 14. Now driven pul-
move washer. ley shaft can be pulled out from gearbox.
Push driven pulley shaft no. 15 out of gearbox un- Remove sliding sleeve taking care not to lose balls
til its LH gear no. 14 is against gearbox inner wall. no. 18 and spring no. 16.
A29D13A
A29D16A 1 2-3
1. Sliding sleeve
2. Spring
3. Balls
05-08-6 MMR2001_021_05_08A.FM
1
A29D17A
DRIVEN PULLEY SHAFT COMPONENTS
Remove screws no. 16 from intermediate shafts

no. 30.
Fasten a long M8 x 1.25 screw in axle end then
drive it out, beginning with top one.
A29D1AA
1. Spacer
Do not disassemble bearings of intermediate

gears needlessly.
Pry out bottom seal no. 33 from gearbox housing.
Remove sleeve no. 32 then, circlip no. 9.
A29D18A
M8 x 1.25
Remove intermediate gears and spacers.
A29D1BA
A29D19A
1. Spacer
MMR2001_021_05_08A.FM 05-08-7
Drive out plug no. 37.
A29D1EA
A29D1CA
Remove circlip no. 9 from LH side. INSPECTION

Check bearing condition. There must be no discol-
oration, missing rollers or balls, broken cages, etc.
Check sprocket teeth.
ASSEMBLY
Install lower gear no. 34 with its shoulder facing
RH side.
A29D1DA
Using a press, drive out lower shaft no. 36 from

RH side.
CAUTION: Do not push against inner bearing
race.
A29D1FA
05-08-8 MMR2001_021_05_08A.FM
Install lower shaft no. 36 with its hollow side (no

splines) on RH side. Align key with lower gear
no. 34 keyway.
1 2
A29D1IA
1. Shoulder
A29D1GA
2. Recess
Install sleeve no. 23 on brake shaft no. 26 then,

Install intermediate gears no. 29 with their shoul- slide gears and sleeve until end of sleeve is flush
der towards LH side. Position spacers no. 28 as with shaft end.
illustrated in removal procedure. Beveled side of
spacers goes against gearbox wall.
Install RH side bearing of brake and reverse shafts.
A29D1JA 1
1. Flush
A29D1HA
Install brake shaft no. 26 into gearbox then, loose-
Partially assemble brake shaft gears nos. 24 and ly install gear no. 22 with its shoulder facing bear-
25 with shoulder facing recess. ing no. 21. Do not push brake shaft into bearing
no. 21 at this time.
MMR2001_021_05_08A.FM 05-08-9
Install reverse shaft ass’y no. 38 into its RH side Install driven pulley shaft no. 15 with the sliding
bearing no. 19. sleeve loosely inserted. Gear no. 14 must be at its
place.
A29D1MA 2 1
1. Sliding sleeve loosely inserted
2. Gear no. 14 in place
A29D1KA
Install balls no. 18 and spring no. 16 into driven
1. Reverse shaft installed in its RH bearing pulley shaft.
Position gear no. 22 against bearing RH side bear-
ing no. 19 then, finalize brake shaft no. 26 inser-
tion.
1
A29D1NA 1
1. Push on ball with a screwdriver then move sliding sleeve to the
right
A29D1LA
1. Finalizing brake shaft insertion
05-08-10 MMR2001_021_05_08A.FM
Finalize driven pulley shaft insertion. Make sure INSTALLATION

that gears mesh during insertion. Install circlip
no. 20. Reverse removal procedure. Check pulley align-
ment.
OIL LEVEL
To check, pull dipstick. Oil should reach level mark.
NOTE: After first outing, oil level will decrease as
the upper oil cavity fills with oil. Recheck oil level
and refill as required.
A29D1PA 1
1. Circlip
Install LH side bearings nos. 12, 19 and 21, shims

no. 8, circlip no. 9 then, plugs no. 8.
1
A29D0IA
1. Full level mark

2. Lower level mark
To fill, remove filler plug from top of transmission.

Refill as required using Bombardier synthetic
A29D1OA
chaincase oil (P/N 413 802 800 — 12 x 250 mL).
READY TO INSTALL BEARINGS, SHIMS, CIRCLIPS AND PLUGS
MMR2001_021_05_08A.FM 05-08-11
Subsection 09 (DRIVE CHAIN)
DRIVE CHAIN 0
SILENT CHAIN
There are 2 types of silent chains. One is 11-plates
wide and the other is 13-plates wide (stronger). Do
not interchange sprockets. Fit chain on sprockets
to make sure that you are using the right ones ac-
cording to width. Refer to TECHNICAL DATA.
NOTE: No work (separation, lengthening) can be
done on a silent chain.
MMR2001_022_05_09A.FM 05-09-1
Section 06 ELECTRICAL
TABLE OF CONTENTS 0
IGNITION TIMING ................................................................................................................. 06-02-1
TWIN CYLINDER RER CDI SYSTEM ................................................................................. 06-02-1
DUCATI CDI SYSTEM........................................................................................................ 06-02-3
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................................................................................................................... 06-03-3
HEAT RANGE ..................................................................................................................... 06-03-3
FOULING ............................................................................................................................ 06-03-3
SPARK PLUG ANALYSIS................................................................................................... 06-03-3
SPARK PLUG INSTALLATION........................................................................................... 06-03-4
SPARK PLUG TIGHTENING TORQUE .............................................................................. 06-03-4
BATTERY................................................................................................................................ 06-04-1
REMOVAL........................................................................................................................... 06-04-1
CLEANING ......................................................................................................................... 06-04-1
INSPECTION ...................................................................................................................... 06-04-2
HYDROMETER TEST ......................................................................................................... 06-04-2
BATTERY STORAGE.......................................................................................................... 06-04-3
ACTIVATION OF NEW BATTERY ...................................................................................... 06-04-3
SERVICING......................................................................................................................... 06-04-5
TIPS FOR CHARGING A USED BATTERY ........................................................................ 06-04-5
BATTERY CHARGING EQUIPMENT ................................................................................. 06-04-6
INSTALLATION OF BATTERY ........................................................................................... 06-04-7
ELECTRIC STARTER .............................................................................................................. 06-05-1

REMOVAL........................................................................................................................... 06-05-3
DISASSEMBLY................................................................................................................... 06-05-3
CLEANING ......................................................................................................................... 06-05-5
INSPECTION ...................................................................................................................... 06-05-5
SOLENOID SWITCH .......................................................................................................... 06-05-7
ASSEMBLY......................................................................................................................... 06-05-7
INSTALLATION .................................................................................................................. 06-05-8
MMR2001_038_06_01ATOC.FM 06-01-1
TESTING PROCEDURE .......................................................................................................... 06-06-1

GENERAL............................................................................................................................ 06-06-1
DUCATI TRIGGER COIL CDI SYSTEM TESTING .............................................................. 06-06-3
IGNITION SYSTEM TESTING SEQUENCE ....................................................................... 06-06-3
LIGHTING SYSTEM TESTING SEQUENCE ...................................................................... 06-06-3
1. SPARKING ...................................................................................................................... 06-06-4
2. ELECTRICAL CONNECTOR TESTING ........................................................................... 06-06-4
3. IGNITION SWITCH, TETHER CORD SWITCH AND EMERGENCY
SWITCH TESTING .......................................................................................................... 06-06-4
4. IGNITION GENERATOR COIL VOLTAGE TESTING ..................................................... 06-06-5
5. TRIGGER COIL VOLTAGE TESTING .............................................................................. 06-06-6
CONCLUSION..................................................................................................................... 06-06-6
LIGHTING GENERATOR COIL VOLTAGE TESTING ......................................................... 06-06-6
CONCLUSION..................................................................................................................... 06-06-6
RER DUAL TRIGGER COIL CDI SYSTEM TESTING ......................................................... 06-06-9
1. SPARKING ...................................................................................................................... 06-06-10
3. IGNITION SWITCH, TETHER CORD SWITCH AND EMERGENCY
SWITCH TESTING .......................................................................................................... 06-06-10
4. IGNITION GENERATOR COIL VOLTAGE TESTING ..................................................... 06-06-11
5. TRIGGER COIL VOLTAGE TESTING .............................................................................. 06-06-11
BUZZER TESTING .............................................................................................................. 06-06-12
MPEM CONNECTORS ....................................................................................................... 06-06-12
NIPPONDENSO CDI SYSTEM TESTING........................................................................... 06-06-15
INSPECTION OF AC CIRCUIT ISOLATION........................................................................ 06-06-17
INSPECTION ....................................................................................................................... 06-06-17
INSPECTION OF HEATING ELEMENTS ............................................................................ 06-06-17
06-01-2 MMR2001_038_06_01ATOC.FM
Subsection 02 (IGNITION TIMING)
IGNITION TIMING 0
TWIN CYLINDER RER CDI
SYSTEM 2
S-Series and Skandic LT 1
If for any reason, ignition timing accuracy is sus-

pected, it can be verified as follows.
Verifying Magneto Flywheel Timing

Mark Position
Prior to checking the timing, it may be necessary
to verify the position of the timing mark on the
magneto flywheel, for the following reasons:
1. To detect a missing or broken magneto flywheel
Woodruff key which would allow a change of
timing to occur, with eventual break down of
the engine.
2. To correctly locate and mark a timing mark on a A17E0YA
new service magneto flywheel.
TYPICAL — INSTALLATION OF TDC GAUGE
3. To verify the correct location of the factory tim- 1. Gauge on MAG side cylinder
ing mark. 2. Adaptor lock nut
4. To detect a wrong magneto flywheel corre- b. Assemble the gauge to the adaptor and tight-
sponding to a different engine type. en the roller lock nut. Do not tighten the adap-
To verify the position of the timing mark on the tor lock nut.
magneto flywheel, proceed as follows: c. Screw the adaptor into the spark plug hole
1. Clean the area around the spark plugs, and re- and tighten to prevent movement in the plug
move them. hole.
2. Remove the rewind starter from the engine. d. Position the dial face toward the magneto/
generator. Move the gauge down until the
3. Install the TDC gauge in the spark plug hole, needle just begins to move, then move down
(magneto/generator side) and adjust as follows: a further 5 or 6 mm (approximately 1/4 in).
a. Position the magneto flywheel at approxi- Tighten adaptor lock nut by hand.
mately TDC. 4. Locate the piston TDC position as follows:
a. Slowly rotate the magneto flywheel back and
forth across TDC while observing the needle.
Note that the needle stops moving only as
the piston is changing direction.
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” before changing direction.
d. “0” now indicates exact TDC.
MMR2001_023_06_02A.FM 06-02-1
5. Verify the position of the timing mark on the 6. Scribe a new mark on magneto flywheel as fol-
magneto flywheel as follows: lows.
NOTE: When checking timing, certain procedures a. Remove the fan cover from the engine.
require that the magneto flywheel be turned in a b. Maintain magneto flywheel so that previous
clockwise direction, viewed facing the magneto/ marks remain aligned.
generator. If it is necessary to turn back (counter-
clockwise) for any reason, rotate the magneto fly- c. Scribe or punch a mark on magneto flywheel
wheel at least one-quarter turn counterclockwise, so that it perfectly aligns with the arrow on
and then rotate it clockwise. The last magneto fly- crankcase, refer to illustration. This new tim-
wheel movement when making a critical check ing mark should be used for future timing
must always be in a clockwise direction, to ensure checks (dynamic timing).
that the slack in engine moving parts is taken-up. d. Reinstall rewind starter.
a. Rotate the magneto flywheel counterclock- e. Check the timing with a timing light.
wise, one-quarter turn then carefully rotate it
clockwise until the needle indicates the spec-
ified measurement. Refer to TECHNICAL 1
DATA.
b. Verify that the magneto flywheel mark per- 2
fectly aligns with the mark on the trigger coil,
refer to illustration.
c. If the marks do not align, check magneto fly-
wheel and trigger coil part numbers and
check Woodruff key condition. If all parts are
the appropriate ones and if Woodruff key is
in good condition, continue the procedure.
2
1
A17E0ZA 3
TYPICAL
1. Crankcase arrow
2. Scribe a mark here
3. Maintain verified timing marks aligned (static timing)
Checking Ignition Timing

Use timing light (P/N 529 031 900) and digital in-
duction type tachometer (P/N 529 014 500).
A17E10A
TYPICAL
1. Trigger coil mark
2. Magneto flywheel mark
NOTE: These marks cannot be used to check dy-

namic (with engine running) ignition timing with a
timing light: a new mark must be scribed on mag-
neto flywheel for this purpose.
A00B4FA
TIMING LIGHT (P/N 529 031 900)
06-02-2 MMR2001_023_06_02A.FM
F01B1GA
TACHOMETER (P/N 529 014 500)
To check the ignition timing, refer to illustration 2 1

and proceed as follows:
 WARNING
Place ski tips against a wall, raise rear of ve-
hicle on a stand, so that track does not contact
the ground. Do not allow anyone in front of
or behind the vehicle while engine is running.
Keep clear of track and do not wear loose
clothing which can get caught in moving parts. 3
A03E1EA
1. Connect the timing light pick-up to a spark plug
cable. S-SERIES
1. Timing light pick-up on MAG side
NOTE: To avoid an incorrect reading due to paral- 2. Crankcase arrow
lax, view the magneto flywheel and the crankcase 3. Magneto flywheel mark
timing marks in a straight line. 4. Install parts which were removed.
2. Connect tachometer wire to spark plug wire or
aim tachometer toward spark plug wire without DUCATI CDI SYSTEM
using any connection wire.
503 Engine Types on Skandic WT/SWT
3. Start the engine and raise the engine speed at
least to 3500 RPM (3000 to 4000 RPM) while Proper ignition timing is determined by trigger coil
observing the timing marks, refer to illustration. position.
The magneto flywheel mark scribed previously If for any reason, ignition timing accuracy is sus-
and the crankcase arrow should be perfectly pected, it can be checked as follows.
aligned. If the marks do not align, a faulty trigger
coil (check proper grounding of coil), a faulty fly- Verifying Magneto Flywheel Timing
wheel, a faulty Woodruff key, a misaligned Mark Position
(twisted) crankshaft or a faulty CDI module
Prior to checking the timing, it may be necessary
could be the cause: substitute one part at a time
to verify the position of the timing mark on the
and recheck timing marks (check connectors
magneto flywheel, for the following reasons:
condition prior to substituting any part).
1. To detect a missing or broken magneto flywheel
NOTE: Ignition timing may be verified when en-
Woodruff key which would allow a change of
gine speed is anywhere within 3000 - 4000 RPM.
timing to occur, with eventual break down of
the engine.
MMR2001_023_06_02A.FM 06-02-3
2. To correctly locate and mark a timing mark on a 4. Locate the piston TDC position as follows:
new service magneto flywheel. a. Slowly rotate the magneto flywheel back and
3. To verify the correct location of the factory tim- forth across TDC while observing the needle.
ing mark. Note that the needle stops moving only as
4. To detect a wrong magneto flywheel. the piston is changing direction.
To verify the position of the timing mark on the b. Rotate the dial face so that 0 (zero) is in line
magneto flywheel, proceed as follows: with the needle when it stops moving.
1. Clean the area around the spark plugs, and re- c. Again, slowly rotate the magneto flywheel
move them. back and forth across TDC and adjust the dial
face to 0 (zero), until the needle always stops
2. Remove the rewind starter from the engine. exactly at 0 (zero) before changing direction.
3. Install the TDC gauge in the spark plug hole, d. 0 (zero) now indicates exact TDC.
(magneto/generator side) and adjust as follows:
5. Verify the position of the timing mark on the
a. Position the magneto flywheel at approximate- magneto flywheel as follows:
ly TDC.
NOTE: When checking timing, certain procedures
require that the magneto flywheel be turned in a
2 clockwise direction, viewed facing the magneto/
1 generator. If it is necessary to turn back (counter-
clockwise) for any reason, rotate the magneto fly-
wheel at least 1/4 turn counterclockwise, and then
rotate it clockwise. The last magneto flywheel
movement when making a critical check must al-
ways be in a clockwise direction, to ensure that
the slack in engine moving parts is taken-up.
a. Rotate the magneto flywheel 1/4 turn coun-
terclockwise, 1/4 turn then carefully rotate it
clockwise until the needle indicates the spec-
ified measurement. Refer to TECHNICAL
DATA.
b. Verify that the magneto flywheel mark per-
fectly aligns with the mark on the trigger coil,
refer to illustration.
A17E0YA
c. If the marks do not align, check magneto fly-

INSTALLATION OF TDC GAUGE
wheel and trigger coil part numbers and
1. Adapter lock nut
2. Gauge on MAG side cylinder check Woodruff key condition. If all parts are
the appropriate ones and if Woodruff key is
b. Assemble the gauge to the adapter and tight- in good condition, continue the procedure.
en the roller lock nut. Do not tighten the adapt-
er lock nut.
c. Screw the adapter into the spark plug hole
and tighten to prevent movement in the plug
hole.
d. Position the dial face toward the magne-
to/generator. Move the gauge down until the
needle just begins to move, then move down
a further 5 or 6 mm (approximately 1/4 in).
Tighten adapter lock nut by hand.
06-02-4 MMR2001_023_06_02A.FM
2
1
1
A17E10A
1. Trigger coil mark

NOTE: These marks cannot be used to check dy- A17E0ZA 3

namic (with engine running) ignition timing with a 1. Crankcase arrow
timing light: a new mark must be scribed on mag- 2. Scribe a mark here
3. Maintain verified timing marks aligned (static timing)
neto flywheel for this purpose.
6. Scribe a new mark on magneto flywheel as fol- Checking Ignition Timing
lows: Use timing light (P/N 529 031 900).
a. Remove the fan cover from the engine. To check the ignition timing, refer to illustration
b. Maintain magneto flywheel so that previous and proceed as follows:
marks remain aligned. NOTE: Engine should be cold when checking tim-
c. Scribe or punch a mark on magneto flywheel ing. Do not idle engine for more than 20 seconds
so that it aligns perfectly with the arrow on and make checks quickly.
crankcase, refer to illustration. This new tim-
ing mark should be used for future timing  WARNING
checks (dynamic timing). Place ski tips against a wall, raise rear of ve-
d. Reinstall rewind starter. hicle on a stand, so that track does not contact
e. Check the timing with a timing light (P/N the ground. Do not allow anyone in front of
529 031 900). or behind the vehicle while engine is running.
Keep clear of track and do not wear loose
clothing which can get caught in moving parts.
MMR2001_023_06_02A.FM 06-02-5

cable and the power connections to the battery.
NOTE: To avoid an incorrect reading due to paral-
lax, view the magneto flywheel and the crankcase
timing marks in a straight line.
2. Start the engine and raise the engine speed to
6000 RPM while observing the timing marks,
refer to illustration. The magneto flywheel mark
scribed previously and the crankcase arrow
should be perfectly aligned. If the marks do not
align, move trigger coil accordingly.
NOTE: Ignition timing have to be verified when
engine speed is 6000 RPM.
2 1
3
A03E1EA
CHECKING IGNITION TIMING

1. Timing light pick-up on MAG side
2. Crankcase arrow
3. Install parts which were removed.
06-02-6 MMR2001_023_06_02A.FM
Subsection 03 (SPARK PLUGS)
SPARK PLUGS 0
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
NGK spark plugs used on Bombardier snowmo-
biles are covered in this manual:
– BR9ES.
MMR2001_024_06_03A.FM 06-03-1
DESIGN SYMBOLS USED IN NGK SPARK PLUGS

PREFIX SUFFIX WIDE GAP
10: 1.0 mm (.040")
B R 9 E S 15
11: 1.1 mm (.044")
13: 1.3 mm (.050")
14: 1.4 mm (.055")
15: 1.5 mm (.060")
20: 2.0 mm (.080")
Thread Heat rating Reach Firing end

diameter numbers construction
A: 18 mm E: 19 mm
(3/4") A: Special Design
2 Hot
B: 14 mm F: Taper B: Single Ground
Special Alloy
Seat
C: 10 mm 4
H: 12.7mm C: Dual Ground
D: 12 mm (1/2") Special Alloy
E: 8 mm 5 L: 11.2 mm
(7/16")
G: Racing Type
J: 12 mm x 19 mm
Reach Z: 21 mm GV: Racing Version
of V-Type
6 (53/54")
L: Half Heat Range
Construction 7
S: Standard
Electrode
Center
M: Compact Type Blank
P: Projected
Insulator Type
8 V: Fine Wire Center
Electrode
18 mm ø 12 mm
R: Resistor Type
(31/64") X: Booster Gap
9
U: Surface Discharge 14 mm ø 9.5 mm
(3/8")
Y: V-Grooved
Electrode
Center
Z: Inductive
Suppressor Type
10 Cold
A00E4NS
CROSSCUTS AND GAP STYLES OF SPARK PLUGS
Standard Projected Taper V-Type Surface

A01E1PS
Type Insulator Type Seat Type Discharge Type
06-03-2 MMR2001_024_06_03A.FM
DISASSEMBLY CAUTION: Severe engine damage might occur

if a wrong heat range plug is used.
First unscrew the spark plug 1 turn.
A too hot plug will result in overheating and pre-
Clean the spark plug and cylinder head with pres- ignition, etc.
surized air, then completely unscrew.
A too cold plug will result in fouling (shorting the
 WARNING spark plug) or may create carbon build up which
can heat up red-hot and cause pre-ignition or det-
Whenever using compressed air, always wear onation.
protective eye wear.
FOULING
HEAT RANGE Fouling of the spark plug is indicated by irregular
The proper operating temperature or heat range of running of the engine, decreased engine speed due
the spark plugs is determined by the spark plug to misfiring, reduced performance, and increased
ability to dissipate the heat generated by combus- fuel consumption. This is due to a loss of compres-
tion. sion. Other possible causes are: prolonged idling,
or running on a too rich mixture due to a faulty car-
The longer the heat path between the electrode buretor adjustment or incorrect fuel and/or fuel mix-
tip to the plug shell, the hotter the spark plug op- ing. The plug face of a fouled spark plug has either
erating temperature will be — and inversely, the a dry coating of soot or an oily, glossy coating given
shorter the heat path, the colder the operating by an excess either of oil or of oil with soot. Such
temperature will be. coatings form a conductive connection between
A cold type plug has a relatively short insulator the center electrode and ground.
nose and transfers heat very rapidly into the cylin-
der head. SPARK PLUG ANALYSIS
Such a plug is used in heavy duty or continuous
high speed operation to avoid overheating.
The hot type plug has a longer insulator nose and
transfers heat more slowly away from its firing
end. It runs hotter and burns off combustion de-
posits which might tend to foul the plug during
prolonged idle or low speed operation.
A00E0AA 1 2 3
1. Overheated (light grey)
2. Normal (brownish)
3. Fouled (black)
1 2 The plug electrode and piston dome reveal the
condition of the engine, operating condition, method
of driving and fuel mixture. For this reason it is
advisable to inspect the spark plug at regular inter-
vals, examining the plug electrode and the piston
dome.
A00E09A
1. Cold
2. Hot
MMR2001_024_06_03A.FM 06-03-3
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.
2. Apply anti-seize lubricant (P/N 413 701 000) over
the spark plug threads to prevent possible sei-
zure.
3. Hand screw spark plug into cylinder head and
tighten with a torque wrench and a proper socket.
1 2
A00E0BA
1. Proper socket
2. Improper socket
SPARK PLUG TIGHTENING

TORQUE
SPARK TORQUE
MODELS
PLUGS N•m (lbf•ft)
All models NGK 27 (20)
06-03-4 MMR2001_024_06_03A.FM
Subsection 04 (BATTERY)
BATTERY 0
REMOVAL S-Series
Unfasten retaining strips.
All Models
Open strips and lift battery protective boot.
 WARNING Remove vent tube.
Battery BLACK negative cable must always
be disconnected first and connected last.
 WARNING
Never charge or boost battery while installed 1
on vehicle.
S-Series
Remove belt guard.
Unfasten spark plug cables from fan housing. Un-
plug spark plug caps. 3 2
Remove throttle cable attachment from air silencer.
A06E1BA
Unplug CDI box harness connector.
Loosen collar on carburetor adaptors. Remove air Step 1 : Unfasten and open
silencer. CDI box will come along with. Step 2 : Lift protective boot
Step 3 : Remove vent tube
2 All Models
Withdraw battery from vehicle being careful not
lean it so that electrolyte flows out of vent tube.
CAUTION: Should any electrolyte spillage oc-
cur, immediately wash off with a solution of
1 baking soda and water to prevent damage to
vehicle components.
CLEANING
Clean the battery, battery casing, vent tube, caps,
cables and battery posts using a solution of baking
soda and water.
CAUTION: Do not allow cleaning solution to en-
ter battery interior since it will destroy the elec-
trolyte.
A03C18A
1. Attachment
2. CDI box harness connector
MMR2001_025_06_04A.FM 06-04-1
A hydrometer measures the charge of a battery in

terms of specific gravity of the electrolyte. Most
hydrometers give a true reading at 27°C (80°F).
1
In order to obtain correct readings, adjust the initial
reading by adding .004 points to the hydrometer
readings for each 5.5°C (10°F) above 27°C (80°F)
and by subtracting .004 point for every 5.5°C
(10°F) below 27°C (80°F).
This chart will be useful to find the correct reading.
A17E0LA
ELECTROLYTE
1. Baking soda TEMPERATURE OPERATION TO PERFORM
Remove corrosion from battery cable terminals °C °F
and battery posts using a firm wire brush.
38 100 .008 to the
add
INSPECTION 32 90 .004 reading
27 80 correct reading
Visually inspect battery casing for cracks or other
possible damage. If casting is damaged, replace 21 70 .004
battery and thoroughly clean battery tray and close 16 60 .008
area with water and baking soda. 10 50 .012
4 40 .016
 WARNING -1
-7
30
20
.020
.024 from the
Should the battery casing be damaged, wear subtract
- 12 10 .028 reading
a suitable pair of non-absorbent gloves when - 18 0 .032
removing the battery by hand. - 23 - 10 .036
- 29 - 20 .040
Inspect battery posts for security of mounting. - 34 - 30 .044
- 40 - 40 .048
Inspect for cracked or damaged battery caps, re-
place defective caps.
EXAMPLE NO. 1
 WARNING Temperature below 27°C (80°F):
Hydrometer Reading: 1.250
Battery caps do not have vent holes. Make Electrolyte temperature: - 7°C (20°F)
sure that vent tube is not obstructed. Subtract .024 Sp. Gr.
Corrected Sp. Gr. is 1.226
HYDROMETER TEST EXAMPLE NO. 2
Temperature above 27°C (80°F):
Hydrometer Reading: 1.235
Electrolyte temperature: 38°C (100°F)
Add .008 Sp. Gr.
1 Corrected Sp. Gr. is 1.243
CAUTION: Do not install a partially charged bat-
tery on a snowmobile since the casing might
crack at freezing temperature. The following
chart shows the freezing point of the electrolyte
in relation to the charge of the battery.
A17E0JA
1. Specific gravity 1.260
06-04-2 MMR2001_025_06_04A.FM
TEMPERATURE
A new battery is factory fresh dry charged. For
FREEZING storage purposes, it is fitted with a temporary seal-
CORRECTED BATTERY
POINT OF ing tube.
SPECIFIC CHARGE
ELECTROLYTE
GRAVITY Do not remove the sealing tube or loosen battery
1.260 Fully charged - 59°C (- 74°F)
caps unless activation is desired.
1.230 3/4 charged - 40°C (- 40°F) In case of accidental premature removal of caps or
1.200 1/2 charged - 27°C (- 16°F) sealing tube, battery should be given a full charge.
1.170 1/4 charged - 18°C (0°F)
1.110 Discharged - 7°C (+ 19°F)
Perform the following operations anytime a new
battery is to be installed.
1. Remove the sealing tube from the vent elbow.
BATTERY STORAGE Install vent tube, included in the battery kit, to
Disconnect and remove battery from the vehicle. battery elbow.
Check electrolyte level in each cell, add distilled
water up to upper level line.
 WARNING
Failure to remove the sealing tube could re-
CAUTION: Do not overfill. sult in an explosion.
The battery must always be stored in fully charged
condition. If required, charge until specific gravity
of 1.260 is obtained.
CAUTION: Battery electrolyte temperature must
not exceed 50°C (122°F). The casing should not 1
feel hot.
Clean battery terminals and cable connections us-
ing a wire brush. Apply a light coat of dielectric
grease (P/N 293 550 004) or petroleum jelly on ter-
minals.
Clean battery casing and caps using a solution of
baking soda and water. Do not allow cleaning so-
lution to enter battery, otherwise it will destroy the
electrolyte. Rinse battery with clear water and dry
well using a clean cloth. A17E0FA
Store battery on a wooden shelf in a cool dry place. 1. Battery electrolyte

Such conditions reduce self-discharging and keep
2. Remove caps and fill battery to UPPER LEVEL
fluid evaporation to a minimum.
line with electrolyte (specific gravity: 1.260 at
During the storage period, recheck electrolyte lev- 20°C (68°F)).
el and specific gravity readings at least every 40 3. Allow the battery to stand for 30 minutes MIN-
days. As necessary, keep the battery at its upper IMUM so that electrolyte soaks through battery
level line and near full charge as possible (trickle cells.
charge).
ACTIVATION OF NEW BATTERY

 WARNING
Never charge or boost battery while installed
on vehicle.
CAUTION: Prior to charging the battery, always 1

remove it from the vehicle to prevent electro- A17E0GA
lyte spillage.
1. 30 minutes
MMR2001_025_06_04A.FM 06-04-3
4. Allow gas bubbles to escape by lightly shaking CAUTION: If charging rate raises higher than
battery by hand. 2.4 A reduce it immediately. If cell temperature
rises higher than 50°C (122°F) (if the casing
feels hot) discontinue charging temporarily or
reduce the charging rate.
 WARNING
Gases given off by a battery being charged
are highly explosive. Always charge in a well
ventilated area. Keep battery away from cig-
arettes or open flames. Always turn battery
charger off prior to disconnecting cables.
Otherwise a spark will occur and battery
A17E0HA
might explode.
5. Readjust the electrolyte level to the UPPER 7. Disconnect battery charger.
LEVEL line.
1
1
2 - + 3
A17E0IB
8. Test battery state of charge. Use a hydrometer.
A17E0RA
1. Battery electrolyte
6. Connect a 2 A battery charger for 10 to 20 1

hours.
2 - + 1
A17E0JA
1. Specific gravity 1.260
A17E0IA
06-04-4 MMR2001_025_06_04A.FM
9. Let battery settle for 1 hour. 12. Reinstall caps and clean any electrolyte spill-
age using a solution of baking soda and water.
1
A17E0KA
A17E0LA
1. 60 minutes
1. Baking soda
10. Allow gas bubbles to escape by lightly shake bat-
tery. CAUTION: Do not allow cleaning solution to
enter battery interior since it will destroy the
electrolyte.
NOTE: It is recommended to verify the battery
charge once a month. If necessary, fully charge
battery.
SERVICING
Electrolyte Level
Since a battery has been activated (see above),
A17E0HA add distilled water to top up electrolyte.
11. Readjust electrolyte level. TIPS FOR CHARGING A USED

BATTERY
CAUTION: Prior to charging the battery, always
1 remove it from the vehicle to prevent electro-
lyte spillage.
For best results, battery should be charged when
the electrolyte and the plates are at room temper-
ature. A battery that is cold may not accept current
for several hours after charging begun.
Do not charge frozen battery. If the battery charge
is very low, the battery may freeze. If it is suspect-
ed to be frozen, keep it in a heated area for about
A17E0RA
2 hours before charging.
 WARNING
Do not place battery near open flame.
MMR2001_025_06_04A.FM 06-04-5
Time required to charge a battery will vary de- – Since the battery chargers vary in the amount
pending some factors such as: of voltage and current they provide, the time
– Battery temperature: Charging time is increased required for the battery to accept measurable
as the temperature goes down. The current ac- charger current might be up to approximately
cepted by a cold battery will remain low. As the 10 hours or more.
battery warms up, it will accept a higher rate of – If the charging current is not up to a measurable
charge. amount at the end of about 10 hours, the bat-
– State of charge: Because the electrolyte is near- tery should be replaced.
ly pure water in a completely discharged battery, – If the charging current is measurable before the
it cannot accept current as well as electrolyte. end or at the end of about 10 hours, the battery
This is the reason the battery will not accept cur- is good and charging should be completed in
rent when the charging cycle first begins. As the the normal manner as specified in Activation of
battery remains on the charger, the current from a new battery.
the charger causes the electrolytic acid content – It is recommended that any battery recharged
to rise which makes the electrolyte a better con- by this procedure be load tested prior to return-
ductor and then, the battery will accept a higher ing it to service.
charging rate.
– Type of charger: Battery chargers vary in the BATTERY CHARGING
amount of voltage and current that they can
supply. Therefore, time required for the battery
EQUIPMENT
to begin accepting measurable current will also The battery charger should have an adjustable
vary. charging rate. Variable adjustment is preferred,
but a unit which can be adjusted in small incre-
Charging a Very Flat or Completely ments is acceptable.
Discharged Battery The battery charger must be equipped with an am-
Unless this procedure is properly followed, a good meter capable of accurately measuring current of
battery may be needlessly replaced. less than one ampere.
– Measure the voltage at the battery posts with If the present charger is not adjustable to the prop-
an accurate voltmeter. If it is below 10 volts, the er current values, a rheostat can be connected in
battery will accept current at very low rate, in series with the battery to provide adjustment. 12
term of milliamperes, because electrolyte is ohm, 50 watt rheostat, such as OHMITE — 0314
nearly pure water as explained above. It could or MALLORY 50K 12P, are available from electron-
be some time before the charging rate increas- ic parts supply shops and they are suitable for use
es. Such low current flow may not be detect- with most chargers if the peak current is to be held
able on some charger ammeters and the bat- below 2 A.
tery will seem not to accept any charge. If you need an accurate ammeter, we recommend
– Only for this particular case, set the charger to the use of: SHURITE — 5202 (0 to 3 A) or — 5203
a high rate. (0 to 5 A) available from electronic parts supply
NOTE: Some chargers have a polarity protection shops.
feature which prevents charging unless the charg-
er leads are connected to the correct battery ter-
minals. A completely discharged battery may not
have enough voltage to activate this circuitry, even
though the leads are connected properly. This will
make it appear that the battery will not accept a
charge. Follow the charger manufacturer’s instruc-
tion telling how to bypass or override this circuitry
so that the charger will turn on and charge a low-
voltage battery.
06-04-6 MMR2001_025_06_04A.FM
INSTALLATION OF BATTERY
1 Ensure vent tube is properly installed on battery
elbow.
Connect vent tube to vehicle fitting on front frame.
Route RED positive cable behind retaining strip
and connect it to positive battery terminal. Con-
2 nect RED wire (coming from ignition switch).
Connect BLACK negative cable LAST.
3 4
CAUTION: Negative battery terminal should al-
ways be disconnected FIRST and reconnected
A00E0DA LAST.
1. Charger Apply silicone dielectric grease (P/N 293 550 004)
2. Rheostat 12 Ω 50 W
3. Ammeter on battery posts and connectors.
4. Battery
1
For a service application and a permanent installa-
tion, both ammeter and rheostat can be built into
a small box adjacent to your charger.
CAUTION: Adequate ventilation MUST be pro-
vided to cool the rheostat.
Charging 2 or More Batteries at a Time

Connect all positives together and use a charger
with a capacity (rated) equal to: number of batter-
ies to be charged multiply by 2 A.
For example: charging 5 batteries at a time re-
quires a 10 A rated charger (5 × 2 A = 10 A). A03H1SA
- 1 BATTERY CONNECTION
+ 1. Vent tube on fitting
Ensure that vent tube is not kinked or blocked then

install protective boot over battery.
Close and fasten retaining strips.
Reinstall air silencer.
Fasten spark plug cables to fan housing.
Reinstall throttle cable to air silencer. See removal
A17E0PA - + illustration.
TYPICAL
1. Two batteries = 4 A
MMR2001_025_06_04A.FM 06-04-7
Subsection 05 (ELECTRIC STARTER)
ELECTRIC STARTER 0
S-Series with Electric Starting and Skandic WT/SWT
2
3
5 7
6
8
11
12
13
12
17
10
15 18
19
A03E13S
16
MMR2001_026_06_05A.FM
Skandic WT LC
2
1 3
4
5 4 7
9
17 8
11
12
10 17
13
15 18
19
16
A32E0LT

REMOVAL Remove outer collar, circlip then inner collar.

Remove overrunning clutch no. 11.
– Disconnect BLACK ground cable from battery.
Check the wear on bushing no. 18 by measuring
– Disconnect RED positive cable from battery.
the amount of radial play between the armature
 WARNING shaft and the bushing.
The radial play should not exceed 0.20 mm (.008 in).
Always disconnect ground cable first and con-
If greater, replace the bushing. To replace, press
nect last.
out the old one toward bushing cover and press in
– Disconnect RED cable and RED/GREEN wire a new one with a bushing pusher. The correct size
from starter solenoid switch. of the bushing pusher to use is given on next illus-
tration.
– Remove starter from engine.
CAUTION: Support drive housing adequately
to prevent damage when pressing bushing.
DISASSEMBLY
Disconnect bare wire linking starter and solenoid. A
Remove nuts no. 16 then solenoid switch no. 10
by lifting and pulling to disengage from drive lever
no. 15. B
Unscrew starter screws (long) no. 1 then pull yoke

no. 8 with end frame no. 2 to separate from drive
housing no. 17.
C
Pull armature no. 9 with drive lever no. 15.
Remove insulator no. 4 then brush springs no. 7
being careful not to lose them since they will be A19E0AA
D
projected out.
BUSHING PUSHER
Pull brush holder no. 5 from yoke no. 8. A. 16 mm (5/8 in) diameter
B. 13 mm (1/2 in)
Insert blade of a small screwdriver between stop C. 11 mm (7/16 in)
collars. D. 11.0 mm (.433 in)
4
A19E0BA
A19E01A 1. Press-in
2. Bushing pusher
3. Bushing
Twist screwdriver to separate stop collars no. 12 4. Drive housing
thus giving access to circlip no. 13.
MMR2001_026_06_05A.FM 06-05-3
Install bushing cover no. 19 then, using a punch,

stake bushing cover in place.
A19E05A
1
1. Cut close to connector
Remove burrs with a file on the remaining welded

portion.
A19E02A
2 CAUTION: Be careful not to damage plastic por-
tion of yoke.
1. Stake bushing cover
2. Support Place spare brush plate edge against yoke connec-
tor edge (welded portion).
3, Bushing (end frame) Crimp plate over yoke connector with a pair of pliers.
shaft and the bushing.
If greater, replace bushing as follows: 1
Using a 12 mm tap, cut threads into bushing so

that the tap contacts the end frame. Continue to
rotate tap until the bushing comes free.
1
2 4
2 3
A19E06A
A19E03A 1. Plate edge

2. Yoke connector
1. Turn until bushing goes out 3. Crimp
2. 12 mm tap 4. Spare brush
To install new bushing, use the same bushing Solder the crimped portion.
pusher as for drive housing bushing installation. CAUTION: Do not overheat and quickly per-
form soldering to prevent solder from flowing
6, Brush to the brush through the wire. Preferably use a
To replace brush no. 6, proceed as follows: heat sink.
Cut brush wire close to connector at the welded
portion.
06-05-4 MMR2001_026_06_05A.FM
CLEANING AND INSPECTION Check the commutator out-of-round condition

with V Blocks and an indicator. If the commutator
out-of-round is more than 0.40 mm (.016 in), the
CLEANING commutator should be turned on a lathe.
CAUTION: Armature starter yoke ass’y and drive Check commutator outer diameter. If less than
unit assembly must not be immersed in cleaning specified value, replace.
solvent.
Clean brushes and holder with a clean cloth
soaked in solvent. Brushes must be dried thor-
oughly with a clean cloth.
Blow brush holder clean using compressed air.
 WARNING
Always wear safety goggles when using com-
pressed air.
Remove dirt, oil or grease from commutator using

a clean cloth soaked in suitable solvent. Dry well A03E06A
using a clean, dry cloth.

Clean engine starter gear teeth and drive unit MODEL WEAR LIMIT
(clutch).
All 27 mm (1.063 in)
NOTE: Bushings must not be cleaned with grease
dissolving agents.
Test for Ground Circuit in the Armature:
Immerse all metal components in cleaning solu-
tion. Dry using a clean, dry cloth. Use growler test probes. Check between arma-
ture core and the commutator bars. If growler
lamp turns on, bars are grounded. If so, replace
INSPECTION armature.
Armature
NOTE: An ohmmeter may be used for the follow- 1
ing testing procedures, except for the one con-
cerning the shorted windings in the armature.
Check the commutator for roughness, burnt or
scored surface. If necessary, turn the commutator
on a lathe, enough to remove grime only.
Check the commutator for mica depth. If the
depth is less than 0.20 mm (.008 in), undercut the
mica. Be sure that no burrs are left and no copper
dust remains between the segments after the un-
dercutting operation is completed.
2
A09E08A
1. Test probes
2. Commutator bars
F01H0RA
1. Commutator undercut 0.20 mm (.008 in)
MMR2001_026_06_05A.FM 06-05-5
Test Armature for Shorted Winding:

When the armature is rotated in the growler with
a steel strip (hacksaw blade) held above it, the
strip will vibrate over that area of the armature
which has short circuit. Replace armature if so. 1
A09E0AA
1. Test probes
Check the dynamic brake winding for open circuit

by placing one test probe on the positive brush
2 and the other probe on the negative brush.
A09E09A
If growler lamp does not turn on, the winding cir-
1. Steel strip (hack-saw blade) cuit is open-circuit and the yoke has to be repaired
2. Growler or replaced.
Test the Armature for Open Circuit:
Brush Holder
Use growler test probes. Place one test probe on
a commutator bar and the other test probe on the Check the brush holder for insulation using growl-
neighboring bar. Repeat this operation for all bars, er test probes. Place one test probe on the insu-
moving one test probe at a time. If the growler lated brush holder and the other test probe on the
lamp does not turn on, the armature circuit be- brush holder plate. If the growler lamp turns on,
tween these 2 bars is opened. The armature the brush holder has to be repaired or replaced.
should be replaced or repaired; open circuits most
often occur at the commutator riser where coils Brush Length
are soldered. (Burnt commutator bars are usually Measure brush length. If less than the specified
an indication of an open-circuit armature coil). value, replace them.
Field Windings and Brushes LENGTH
MODEL
Test the Field Winding for Open Circuit: NEW WEAR LIMIT
Use growler test probes. Place one test probe on 10 mm 6 mm
the negative brush and the other test probe on the All
(.400 in) (.236 in)
yoke. If growler lamp does not turn on, the field
winding has an open-circuit. The yoke has to be
repaired or replaced.
06-05-6 MMR2001_026_06_05A.FM
Install overrunning clutch onto armature shaft. In-

sert inner collar onto shaft. Install a new circlip.
CAUTION: Always install a new circlip when ser-
vicing.
1 2
Insert outer collar being careful to match protru-
sions with notches of collars.
Using a pair of pliers on each side of stop collars,
squeeze evenly until collars sit over circlip.
A03E05A
1
TYPICAL
1. New
2. Wear limit
Overrunning Clutch
The pinion of the overrunning clutch should turn
smoothly in a clockwise direction, and should not A19E07A
slip in a counterclockwise direction. If defective,
replace. 1. Squeeze evenly
Check the pinion teeth for wear and damage. If Install thrust washer against outer stop collar.
defective, replace. Place drive lever onto overrunning clutch then in-
sert into drive housing.
SOLENOID SWITCH
Inspect connections and clean as necessary. Sole-
noid switch condition can be checked with an
1
ohmmeter. Install test probes on large connectors
of solenoid when it is activated (+ on RED/GREEN
wire and – on solenoid body).
IMPORTANT: No current must be present on
large cables when using ohmmeter, otherwise
meter could be damaged.
ASSEMBLY
Prior to assembling, coat sliding surfaces and
moving parts on armature shaft splines, overrun- A19E08A 2
ning clutch, solenoid switch plunger, drive lever 1. Install on overrunning clutch
and bushings with grease. 2. Install thrust washer
Proceed as follows for assembling.

Secure drive housing in a vise.
CAUTION: Do not overtighten since housing
might be damaged.
MMR2001_026_06_05A.FM 06-05-7
Slide yoke over armature. INSTALLATION

Install brush holder then brushes in their housings.
Make sure that starter and engine mating surfaces
Insert springs as follows: place one end of spring
are free of grime. Serious trouble may arise if start-
against brush, compress, then push the other end
er is not properly aligned.
of spring onto its housing. Repeat for remaining
springs. Install starter.
NOTE: Check proper engaging depth of starter
pinion teeth to ring gear teeth (see illustration). In-
2 stall hardened washers (P/N 503 007 900) be-
1 tween engine and starter supports accordingly.
CAUTION: All starter bracket fasteners must be
secured with Loctite 271 (P/N 293 800 005).
2
A19E04A
3
1. This end first
2. Push this end to complete
Secure insulator over brushes and springs. Prop-

erly install end frame and tighten screws.
Insert solenoid plunger inside of drive lever fork
and secure to drive housing.
Connect starter bare wire to solenoid.
NOTE: Connect this wire on the shorter solenoid
stud. A09E0PA A
1. Screwdriver pulling starter pinion
2. Ring gear
3. No excessive backlash
A. 0.5 to 1.5 mm (.020 to .060 in)
1 Connect the RED battery cable and the RED wire

to the large terminal of the solenoid. Connect RED/
2
GREEN wire to small terminal of solenoid.
Connect BLACK cable to battery.
 WARNING
nect last.
A19E09A
1. Shorter stud
2. Bare wire
06-05-8 MMR2001_026_06_05A.FM
Subsection 06 (TESTING PROCEDURE)
TESTING PROCEDURE 0
GENERAL ➁RER Dual Trigger Coil CDI (twin cylinder)
The RER dual trigger coil CDI system has an igni-
The following chart gives the engine types with
tion coil integrated to the MPEM which is mount-
their implemented system.
ed on oil reservoir.
CHARGING MPEM is connected to a single ignition generator
ENGINE IGNITION
SYSTEM coil via a 3-connector housing (BLACK and RED
TYPE SYSTEM
OUTPUT wires).
503 on Skandic ➀ Ducati trigger coil MPEM is programmed to recognize a signal sent by
CDI 240
WT/SWT the switch located on snowmobile console.
377, 443 and 503 ➁ RER dual trigger When switch is activated, MPEM cuts off ignition
on Skandic LT coil CDI and engine rev drops at approximately 450 RPM.
(twin cylinder) 240
and S-Series MPEM fires a spark at a great advance creating a
with RER thrust which reverses engine rotation.
593 on Skandic ➂ Nippondenso Second trigger coil located on crankcase takes
trigger coil CDI 290
WT LC over to produce spark in reverse rotation.
A safety device is incorporated to MPEM prevent-
CDI System Identification ing it from reading any signal coming from reverse
switch at following engine revs.
➀Ducati Trigger Coil CDI
Below 1000 RPM and above 3500 RPM = No re-
The DUCATI trigger coil CDI system has a com-
verse signal.
bined ignition module/ignition coil which is mount-
ed on air silencer, below carburetors.
Ignition module is connected to the ignition gen-
erator coil via a 4-connector housing (GREEN and
WHITE wires).
2 1
A17E0TA
➀ DUCATI TRIGGER COIL CDI SYSTEM

1. Combined ignition module/ignition coil mounted on air silencer
below carburetors
2. 4-DA housing (GREEN and WHITE wires)
MMR2001_027_06_06A.FM 06-06-1
3
2
A03E2WS
➁ RER DUAL TRIGGER COIL CDI SYSTEM (TWIN CYLINDER)

1. MPEM
2. Trigger coils
3. 2-05 housing (BLACK and RED wires)

➂Nippondenso DUCATI TRIGGER COIL CDI

The NIPPONDENSO CDI system has a separate SYSTEM TESTING
ignition coil which is mounted on the reservoir
support. Skandic WT/SWT
1. Ignition module is connected to the ignition IGNITION SYSTEM TESTING
generator coil via a 3-wire connector (RED, SEQUENCE
BLACK/RED and BLACK wires).
In case of ignition problems, check the following
in the prescribed order until the problem can be
solved.
1. Sparking/spark plug condition.
2. Electrical connectors.
1 3. Ignition switches, tether cord cap and emergen-
cy switch.
4. Ignition coil output.
5. Trigger coil output.
LIGHTING SYSTEM TESTING

SEQUENCE
2. Magneto output (lighting generator coil).
Testing Conditions
Voltage measurements are always taken upon
starting the vehicle. Readings taken when the en-
gine is running will be higher than indicated range.
Part temperature must be approximately 20°C
(68°F) (room temperature), otherwise readings
2 could be distorted.
A27E02A
➂NIPPONDENSO TRIGGER COIL CDI SYSTEM Analysis of Readings

1. Separate ignition coil mounted on reservoir support Voltage Readings
2. Three-wire connector (RED, BLACK/RED and BLACK)
When testing the different magneto components,
it is important to take into consideration that read-
ings vary according to the force applied onto the
manual starter. It is therefore important to employ
enough force upon each trial.
The reading must be 3 times within or above the
range indicated in the corresponding table. If the
reading is too low, the part is considered to be de-
fective and it must be replaced.
MMR2001_027_06_06A.FM 06-06-3
Resistance Readings 3. IGNITION SWITCH, TETHER

Place multimeter selector switch to Ω in order to CORD SWITCH AND
measure resistance. Readings must be within the EMERGENCY SWITCH
indicated range. Otherwise, the part is considered
to be defective and must be replaced. TESTING
CAUTION: When taking measurements, it is use- Disconnect connector housing 2-01 from engine,
less to try to start the vehicle since readings and using a multimeter, check resistance as indi-
would then be distorted. cated in IGNITION table.
Intermittent Ignition Problems
It is difficult to make a diagnostic in the case of
intermittent ignition problems. Thus, problems oc-
curring only when the engine operating tempera-
ture is normal must be checked in similar condi-
tions.
In most cases when problems are caused by tem-
perature or vibrations, these can only be solved by
replacing parts. Most problems cannot be detect-
ed when the engine is stopped.
Multiple Problems
As a matter of fact, more that one component can A03E1IA
be defective. As a result, if the problem remains
although a part was replaced, start over the whole If readings are acceptable, go on to next step.
verification from the beginning in order to identify If readings are inadequate, individually check each
the other defective component. switch as follows.
1. SPARKING Ignition Switch (key)

During this operation, it is important to use the Disconnect switch housing. Using a multimeter,
snowmobile spark plug and not a new one. Bring check between MAG and GRD terminals if the cir-
the plug in contact with the engine. If no spark is cuit is open (0.L MΩ) in operating position and if the
produced, replace the spark plug with a new one circuit is closed (0 Ω) in off position.
and do the test again.
2. ELECTRICAL CONNECTOR
TESTING
Make sure that none of the connectors are discon-
nected.
A05E07A
TYPICAL
06-06-4 MMR2001_027_06_06A.FM
If readings do not correspond to the above-

mentioned indications, replace switch.
If readings are acceptable, check other switches.
Emergency Switch
Unplug switch block connected to main wiring har-
ness. Check using a multimeter. Connect probes
to 6-02-C-M and 6-02-D-M terminals. The multim-
eter should indicate an open circuit (0.L MΩ) in op-
erating position and a closed circuit (0 Ω) in off po-
sition.
A05E09A
TYPICAL

If none of these verifications are conclusive, the
problem finds its source in the main wiring har-
ness. Proceed as follows:
NOTE: For this next step, no stop switch must be
connected to the main wiring harness.
Disconnect all stop switches from the main wiring
A05E08A harness and check the continuity of each wire by
TYPICAL connecting probes to the end of wires of the same
color. Repeat with all other wires. It is important
If readings do not correspond to the above- to mention that all wires of the same color within
mentioned indications, replace switch. a given harness are connected together. These
If readings are acceptable, check other switches. wires should therefore have a closed circuit. On the
other hand, BLACK and BLACK/YELLOW wires
Tether Cord Switch must have an open circuit (0.L MΩ).
Unplug switch block connected to main wiring har- Repair or replace if necessary.
ness. Check using a multimeter by connecting
probes to 6-03-B-M and 6-03-A-M wires. The mul- 4. IGNITION GENERATOR COIL
timeter should indicate an open circuit (0.L MΩ) in VOLTAGE TESTING
operating position and a closed circuit (0 Ω) in off
position. General
When manually starting the engine while the
spark plug is installed, the engine will tend to ac-
celerate beyond the compression point. This will
result in higher magneto output power.
1. Disconnect the 4-wire housing between the ig-
nition module and the magneto wiring harness
(4-02).
MMR2001_027_06_06A.FM 06-06-5
2. Connect multimeter probes to GREEN and WHITE LIGHTING GENERATOR COIL

wires (female end), then bring selector to Ṽ and
scale to 00.0VAC.
VOLTAGE TESTING
3. Activate the manual starter and check values in- NOTE: The lighting generator coil is not part of the
dicated by the multimeter. ignition system. It is a self-contained system used
to supply current to the lighting system and to oth-
4. Repeat operation 3 times. er devices working on alternating current. Howev-
er, this system can be tested using a multimeter.
1. Disconnect housing from engine (2-01).
2. Connect multimeter wires to YELLOW and
YELLOW/BLACK wires (female side), then
place selector switch to Ṽ and scale to 0.00VAC.
3. Activate the manual starter and check values in-
dicated by the multimeter.
4. Repeat operation 3 times.
A03E1JA
5. Compare readings with those appearing in the

IGNITION table.
5. TRIGGER COIL VOLTAGE

TESTING
1. Disconnect 4-wire housing between the igni-
tion module and the engine (4-02).
A03E1LA
2. Connect multimeter probes to RED/WHITE
wire (female side) and to the engine, then bring 5. Compare readings with those appearing in the
selector switch to Ṽ and scale to 00.0VAC. LIGHTING table.
dicated by the multimeter. CONCLUSION
If none of the above testing operations produced
5. Compare readings with those appearing in the valid results, it is strongly recommended to keep
IGNITION table. on testing according to the list appearing in the
Resistance column of the LIGHTING table.
CONCLUSION Set the multimeter as indicated.
valid results, it is strongly recommended to keep
on testing according to the list appearing in the
Resistance column of the IGNITION table.
Set the multimeter as indicated.
06-06-6 MMR2001_027_06_06A.FM
IGNITION SYSTEM TESTING (Skandic WT/SWT)

RESISTANCE Ω VOLTAGE V
TEST TO BE WIRE
PART VALUE MULTIMETER VALUE MULTIMETER NOTE
PERFORMED COLOR
(OHMS) SCALE (VOLTS) SCALE
Running BK and All switches must be
0.L 00.0 MΩ — —
insulation BK/YL in run position.
Stop
switch At least one stop
Continuity in BK and 00.0 Ω
00.0 - 00.5 — — switch must be oper-
stop position BK/YL
ational.
WH and 230.0 - 30.0 - All switches must be
Ignition Output 00.0 Ω 00.0VAC
GN 330.0 60.0 in run position.
generator
coil Ground WH and 00.0 Ω
00.0 - 00.5 — — The term “engine” re-
continuity engine
fers to the engine met-
RD/WH al parts connected to
Trigger 140.0 - 00.0 Ω
Continuity and 2.0 - 9.0 00.0VAC the magneto housing.
coil 180.0
engine
Ignition
Secondary
module
winding 13.1 K - 00.0 KΩ CAUTION: Do not measure high voltage coil
and high — output voltage.
resistance 18.3 K
voltage
with caps
coil
Secondary Spark
winding plug cap 8.90 K - CAUTION: Do not measure high voltage coil
00.0 KΩ
resistance Spark 13.1 K output voltage.
with caps plug cap
Secondary
High
winding BK 0.90 K - CAUTION: Do not measure high voltage coil
voltage 00.0 KΩ
resistance BK 1.10 K output voltage.
coil
without caps
The measurement
Secondary
BK .100 - must be taken on the
winding — — 0.00VAC
engine .250 spark plug cable (with-
voltage
out the spark plug).
Spark Cap
— 4.0 K - 6.0 K 00.0 KΩ — — —
plug cap resistance
NOTE: Stop switches include the ignition switch, the tether cord switch and the emergency cut-out
switch.
It is important to take note that voltage measurements must be taken while starting the vehicle using the
manual starter.
Voltages obtained upon starting are proportional to the force applied onto the manual starter. A low voltage
is therefore normal under a low cranking force.
Perform testing in the prescribed order and replace any parts not performing according to specifications.
It is important to resume all tests when replacing a component.
If not specified, the probe connecting sequence is not important.
MMR2001_027_06_06A.FM 06-06-7
LIGHTING SYSTEM TESTING (Skandic WT/SWT)

TEST TO BE WIRE
PERFORMED COLOR
YL and
Power 0.05 - 0.6 00.0 Ω 2.5 - 7.0 00.0VAC —
YL/BK
Lighting
YL and 00.0 MΩ
generator Insulation 0.L — — —
engine
coil
Ground BK 00.0 -
00.0 MΩ — — —
continuity engine 00.5
switch.
manual starter.
06-06-8 MMR2001_027_06_06A.FM
RER DUAL TRIGGER COIL CDI Testing Conditions

SYSTEM TESTING Voltage measurements are always taken upon
starting the vehicle. Readings taken when the en-
Skandic LT and S-series with RER
gine is running will be higher than indicated range.
Part temperature must be approximately 21°C
(70°F) (room temperature), otherwise readings
3 could be distorted.
2
Analysis of Readings
1
Voltage Readings
A05E0KA range indicated in the corresponding table. If the
MPEM reading is too low, the part is considered to be de-
1. Reverse switch, reverse indicator and trigger coil fective and it must be replaced.
2. Trigger coil
3. Generator output and cut-off switches Resistance Readings
Place multimeter selector switch to Ω in order to
IGNITION SYSTEM TESTING measure resistance. Readings must be within the
SEQUENCE indicated range. Otherwise, the part is considered
to be defective and must be replaced.
In case of ignition problems, check the following
in the prescribed order until the problem can be CAUTION: When taking measurements, it is
solved. useless to try to start the vehicle since readings
would then be distorted.
3. Ignition switches, tether cord cap and emergen-
cy switch.
4. Ignition coil output. ture is normal must be checked in similar condi-
5. Trigger coil output. tions.
NOTE: Refer to DUCATI CDI SYSTEM TESTING In most cases when problems are caused by tem-
and appropriate model IGNITION SYSTEM TEST- perature or vibrations, these can only be solved by
ING TABLE at the end of this chapter for complete replacing parts. Most problems cannot be detect-
detailed testing procedure. ed when the engine is stopped.
Multiple Problems
LIGHTING SYSTEM TESTING As a matter of fact, more than one component can
SEQUENCE be defective. As a result, if the problem remains
1. Electrical connectors. although a part was replaced, start over the whole
verification from the beginning in order to identify
2. Magneto output (lighting generator coil). the other defective component.
NOTE: Refer to DUCATI CDI SYSTEM TESTING
and appropriate model LIGHTING SYSTEM TEST-
ING TABLE at the end of this chapter for complete
detailed testing procedure.
MMR2001_027_06_06A.FM 06-06-9
1. SPARKING
During this operation, it is important to use the
snowmobile spark plug and not a new one. Bring
the plug in contact with the engine. If no spark is
produced, replace the spark plug with a new one
TESTING
nected.
3. IGNITION SWITCH, TETHER

CORD SWITCH AND A05E07A
EMERGENCY SWITCH
TESTING TYPICAL

Disconnect connector housing 2-MO from engine,
and using a multimeter, check resistance as indi-
cated in IGNITION table. If readings are acceptable, check other switches.
Emergency Switch
Unplug switch block connected to main wiring har-
ness. Check using a multimeter. Connect probes
to 6-IU-C-M and 6-IU-D-M terminals. The multim-
eter should indicate an open circuit (0.L MΩ) in op-
erating position and a closed circuit (0 Ω) in off po-
sition.
A03E1IA
If readings are acceptable, go on to next step.

If readings are inadequate, individually check each
switch as follows.
Ignition Switch (key)

Disconnect switch housing. Using a multimeter,
A05E08A
check between MAG and GRD terminals if the cir-
cuit is open (0.L MΩ) in operating position and if the TYPICAL
circuit is closed (0 Ω) in off position.
06-06-10 MMR2001_027_06_06A.FM
Tether Cord Switch 4. IGNITION GENERATOR COIL

Unplug switch block connected to main wiring har- VOLTAGE TESTING
ness. Check using a multimeter by connecting General
probes to 6-BC-B-M and 6-BC-A-M wires. The mul-
timeter should indicate an open circuit (0.L MΩ) in When manually starting the engine while the
operating position and a closed circuit (0 Ω) in off spark plug is installed, the engine will tend to ac-
position. celerate beyond the compression point. This will
result in higher magneto output power.
1. Disconnect the 3-wire housing between the ig-
nition module and the magneto wiring harness
(2-DC).
2. Connect multimeter probes to RED and BLACK
wires (female end), then bring selector to Ṽ and
scale to 00.0VAC.
A05E09A
TYPICAL

If none of these verifications are conclusive, the
ness. Proceed as follows:
NOTE: For this next step, no stop switch must be
connected to the main wiring harness.
Disconnect all stop switches from the main wiring A03E1JA
harness and check the continuity of each wire by

connecting probes to the end of wires of the same 5. Compare readings with those appearing in the
color. Repeat with all other wires. It is important IGNITION table.
to mention that all wires of the same color within
a given harness are connected together. These 5. TRIGGER COIL VOLTAGE
wires should therefore have a closed circuit. On the TESTING
must have an open circuit (0.L MΩ). 1. Disconnect 4-wire housing between the igni-
Repair or replace if necessary. tion module and the engine (2-DA and 2-DB).
2. Connect multimeter probes to BLUE/YELLOW
wire and to WHITE/YELLOW wire, then bring
selector switch to Ṽ and scale to 00.0VAC.
IGNITION table.
MMR2001_027_06_06A.FM 06-06-11
BUZZER TESTING
Using jumper wires, connect battery positive post
to buzzer positive tab.
Connect battery negative post to buzzer negative
tab. See next photo.
CAUTION: To avoid buzzer damage, ensure that
polarity is respected.
A05E0GA
LIFT TABS TO REMOVE CAP
Insert multimeter probes into connector.
A03E21A
12-VOLT BATTERY PLUGGED TO BUZZER
MPEM CONNECTORS
To ease electrical readings on MPEM connectors,
connector cap must be removed.
Hold connector in hands then lift both tabs to re-
move connector cap.
A05E0LA
TEST USING MULTIMETER PROBES
06-06-12 MMR2001_027_06_06A.FM
IGNITION SYSTEM TESTING (S-Series and Skandic LT with RER 240 W)

TEST TO BE WIRE
PART PERFORMED COLOR VALUE MULTIMETER VALUE MULTIMETER NOTE
Running BK 00.0 MΩ All switches must
insulation BK/YL 0.L — — be in run position.
Stop Only one stop switch
switch Continuity in BK must be in stop posi-
00.0 - 00.5 00.0 Ω — —
STOP position BK/YL tion. Test them one
after the other.
RD 00.0 Ω
Output BK 4.5 - 6.5 7.0 - 15.0 00.0VAC —
Ignition The term “engine”
generator refers to the engine
coil Ground BK 00.0 Ω
00.0 - 00.5 — — metal parts connect-
continuity engine ed to the magneto
housing.
Front
trigger Resistance WH/YL 160 -180 00.0 Ω .150 - .350
and output BL/YL .000VAC —
coil
Rear Resistance WH/YL
trigger 160 -180 00.0 Ω .150 - .350 .000VAC —
coil and output BL/YL
Secondary Spark
winding plug cap 8.90 K - 00.0 KΩ CAUTION: Do not measure high voltage coil
resistance Spark 13.1 K output voltage.
with caps plug cap
MPEM Secondary
winding BK 0.90 K - 00.0 KΩ CAUTION: Do not measure high voltage coil
and high resistance BK 1.10 K output voltage.
voltage
coil without caps
The measurement
Secondary must be taken on
BK
winding engine — — .100 - .250 0.00VAC the spark plug cable
voltage (without the spark
plug).
Spark Cap 00.0 KΩ
— 4.0 K - 6.0 K — — —
plug cap resistance
switch.
manual starter.
Voltages obtained upon starting are proportional to the force applied onto the manual starter. A low
voltage is therefore normal under a low cranking force.
MMR2001_027_06_06A.FM 06-06-13
LIGHTING SYSTEM TESTING (S-Series and Skandic LT with RER 240 W)

TEST TO BE WIRE
PART PERFORMED COLOR VALUE MULTIMETER VALUE MULTIMETER NOTE
YL 00.0 - 00.0 Ω
Power YL/BK 00.6 3.0 - 7.0 00.0VAC —
Lighting YL The term “engine” re-
generator Insulation 0.L 00.0 MΩ — —
engine fers to the engine
coil metal parts connect-
Ground BK 00.0 - 00.0 Ω ed to the magneto
continuity engine 00.5 — —
housing.
NOTE: It is important to take note that voltage measurements must be taken while starting the vehicle
using the manual starter.
Voltages obtained upon starting are proportional to the force applied onto the manual starter. A low
voltage is therefore normal under a low cranking force.
06-06-14 MMR2001_027_06_06A.FM
NIPPONDENSO CDI SYSTEM TESTING

593 on Skandic WT LC
IGNITION SYSTEM TESTING (Skandic WT LC 290 W 2001)
TEST TO BE WIRE
PERFORMED COLOR
BK and 00.0 MΩ All switches must be in
Running insulation 0.L — —
BK/YL run position.
Only one stop switch
Continuity in stop BK and 00.0 - 00.0 Ω — — must be in stop posi-
position BK/YL 00.5
tion. Test one at a time.
Stop
switches BK/GN
Insulation in stop 00.0 MΩ Tether cord cap must
and 0.L — —
position be off.
BK/WH
BK/GN
Running continuity and 00.0 - 00.0 Ω Tether cord cap must
— —
00.5 be in place.
BK/WH
RD and 11.6 - 15.0 -
Output 00.0 Ω 00.0VAC —
BK/RD 21.6 30.0
Coil RD and 00.0 MΩ
Ignition 0.L — — —
insulation BK
generator
coil The term “engine” re-
Ground BK and 00.0 - 00.0 Ω fers to the engine metal
— —
continuity engine 00.5 parts connected to the
magneto housing.
WH/YL
Trigger Resistance and 00.0 Ω .200 -
and 190 - 300 .000VAC —
coil output .350
BL/YL
WH/BL 25.0 - All switches must be in
MPEM Output voltage
and BK
— —
100.0 00.0VAC run position.
Primary winding WH/BL 00.0 - 00.0 Ω — — —
resistance and BK 00.9
Spark
Secondary winding plug cap 19.5 K -
00.0 KΩ CAUTION: Do not measure high voltage coil out-
resistance (spark
Spark 26.5 K put voltage.
plug cap included) plug cap
Secondary winding
High resistance (without
BK and 9.6 K - 00.0 KΩ CAUTION: Do not measure high voltage coil out-
voltage spark plug cap)
BK 14.4 K put voltage.
coil
The measurement must
Secondary winding BK and — — 0.1 - 1.4
be taken on the spark
voltage engine 0.00VAC plug wire (without the
spark plug).
Spark
Insulation plug 0.L 00.0 MΩ — — —
cap BK
Spark plug 4.0 K - 00.0 KΩ
Cap resistance — — — —
cap 6.0 K
NOTE: Stop switches include the ignition switch and the emergency cut-out switch.
manual starter.
It is important to resume all test when replacing a component.
It not specified, the probe connecting sequence is not important.
MMR2001_027_06_06A.FM 06-06-15
LIGHTING SYSTEM TESTING (Skandic WT LC 290 W 2001)

TEST TO BE WIRE
PART NOTE
PERFORMED COLOR VALUE MULTIMETER VALUE MULTIMETER
Output YL 00.1 - 00.4 00.0 Ω 0.5 - 2.0 00.0VAC —
Lighting Coil YL and The term “engine” refers
generator 0.L 00.0 MΩ — —
insulation engine to the engine metal parts
coil connected to the magneto
Ground BK and 00.0 Ω
continuity engine 00.0 - 00.5 — — housing.
manual starter.
It is important to resume all test when replacing a component.
It not specified, the probe connecting sequence is not important.
06-06-16 MMR2001_027_06_06A.FM
INSPECTION OF AC CIRCUIT Current Measurement

ISOLATION HIGH 0.23 A
BROWN wire
All Electric Start Models INTENSITY minimum
If AC circuit is not isolated from frame, headlamp LOW 0.13 A
beam will weaken. BROWN /YELLOW wire
INTENSITY minimum
INSPECTION Handlebar Grip Heating Element

Disconnect regulator/rectifier. Resistance Measurement
Connect one digital ohmmeter probe (needle
ohmmeter will not offer enough precision) to HIGH YELLOW /BLACK wire 8.73 to ➀
frame and other probe to one of 2 YELLOW mag- INTENSITY ORANGE wire 10.67 ohms
neto wires. 17.7 to ➀
LOW YELLOW /BLACK wire
Measured resistance must be infinite. If such is INTENSITY ORANGE/VIOLET wire 20.7 ohms
not the case, it means there is a connection be-
tween AC circuit and DC circuit.
Disconnect one accessory at the time to identify
the faulty circuit. Throttle Lever Heating Element
Resistance Measurement
INSPECTION OF HEATING
ELEMENTS BLACK WIRE
48 ohms
BLACK WIRE
All Models Except Skandic LT/WT/SWT/WT LC
All measurements must be performed at 21°C
(70°F). Handlebar Grip Heating Element
Throttle Lever Heating Element
BLACK WIRE 9.6 ohms ➀
Resistance Measurement BLACK WIRE
HIGH YELLOW /BLACK wire 1.96 to
INTENSITY BROWN wire 3.64 ohms
➀ When measuring resistance at terminals the ac-
tual value will be half the measurement in table.
LOW YELLOW /BLACK wire 8.05 to The reason for that is the elements are connect-
INTENSITY BROWN /YELLOW wire 14.95 ohms ed in parallel. Therefore the total resistance is
half the resistance of one element.
MMR2001_027_06_06A.FM 06-06-17
Section 07 REAR SUSPENSION
TABLE OF CONTENTS 0
SC-10 SUSPENSIONS (ALL VERSIONS) ............................................................................. 07-02-1
COMPONENT REMOVAL AND INSTALLATION .............................................................. 07-02-3
SUSPENSION ASS’Y REMOVAL ...................................................................................... 07-02-4
SHOCK ABSORBER INSPECTION .................................................................................... 07-02-7
INSTALLATION .................................................................................................................. 07-02-7
RIDE ADJUSTMENT.......................................................................................................... 07-02-7
LUBRICATION .................................................................................................................... 07-02-7
SKANDIC WT SUSPENSION ................................................................................................ 07-03-1

REMOVAL........................................................................................................................... 07-03-2
SHOCK ABSORBER SERVICING....................................................................................... 07-03-3
INSTALLATION .................................................................................................................. 07-03-4
DRIVE AXLE........................................................................................................................... 07-04-1

REMOVAL........................................................................................................................... 07-04-3
DISASSEMBLY................................................................................................................... 07-04-3
ASSEMBLY......................................................................................................................... 07-04-4
INSTALLATION .................................................................................................................. 07-04-5
LUBRICATION .................................................................................................................... 07-04-6
ADJUSTMENT ................................................................................................................... 07-04-6
TRACK .................................................................................................................................... 07-05-1

TRACK TYPE APPLICATION.............................................................................................. 07-05-1
GENERAL ........................................................................................................................... 07-05-1
INSPECTION ...................................................................................................................... 07-05-1
REMOVAL........................................................................................................................... 07-05-1
INSTALLATION .................................................................................................................. 07-05-1
MMR2001_028_07_01ATOC.FM 07-01-1
Subsection 02 (SC-10 SUSPENSIONS (ALL VERSIONS))
SC-10 SUSPENSIONS (ALL VERSIONS)0

SC-10 Sport on Formula Deluxe Fan 380/500 and MX Z 380/440/500
SC-10 Touring on Touring Fan 380/500
1
Synthetic
grease
Synthetic 6
grease
6 2
11
12 19
16 7
Synthetic
19 Nm grease
(168 lbfin)
21
13 15
All
other
models
Some
models
11
10
11
Long track
models only 17
6
16
7 Nm 20 18
(62 lbfin)
6
6
Short track models only
11
4 Nm
(35 lbfin)
A03F44S
MMR2001_028_07_02A.FM
SC-10 Mountain on Summit Fan 500
7 Nm 2
(62 lbfin) 6
19
12 Low
temp.
grease
7
13 15
14
21
11
10
6
11
6
18
6
6
6 6
17
A03F43S

COMPONENT REMOVAL AND

INSTALLATION
Lift rear of vehicle and support it off the ground.
21, Rear Axle

Remove screw on rear axle on side of offset wheel.
Completely loosen track tension.
Pull out rear axle from opposite side of offset inner
wheel.
At assembly, align spacer hole with adjusting bolt.
Make sure to reinstall washer on each side of runner.
529 005 000
A03F2FA
Remove nut on top end of shock.

Remove nut on bottom end of shock. Pry up shock
bottom end to ease removing bolt (gas shock
only). See installation illustration below.
Installation is reverse of removal procedure. To
A03F1LA
easily compress gas shock absorber, use a pry bar
TYPICAL and locking pliers as a stopper.
15, Rear Shock CAUTION: Take care not to damage grease fit-
ting.
Lift rear of vehicle.
Slightly turn adjusting cam to expose spring end. 1 2
Using spring installer (P/N 529 005 000), remove
left spring from adjusting cam.
A03F1PA
1. Locking pliers
2. Pry bar
MMR2001_028_07_02A.FM 07-02-3
12, Front Shock 6,7, Self-Locking Screws

All Models CAUTION: These self-locking screws must al-
ways be replaced by new ones everytime they
Unfasten one end of stopper strap(s). are removed.
Unbolt shock and remove it. NOTE: To prevent axle from turning when un-
screwing self-locking screws, proceed as follows:
2, Rear Spring
– Knock on screw head and/or heat to break
All Models threadlocker bond.
Remove spring ends from adjusting cams. – Remove one self-locking screw then install a
Unbolt rear arm top axle from chassis. 10 mm shorter non-self-locking one in place.
– Remove the opposite self-locking screw.
All Liquid Cooled Models
– Remove the temporary installed non-self-locking
Unscrew set screws from locking ring at each end screw.
of top axle.
Unscrew center idler wheel axle from tunnel then
Remove spacers and top idler wheels. remove.
Remove springs. Lift rear of vehicle at least 1 m (3 ft).
A03F0WA
A03F1QA
1. At least 1 m (3 ft)
TYPICAL Remove both screws no. 6 retaining front arm to

tunnel.
At reassembly, respect THIS SIDE OUT inscription
on wheel. Remove suspension.
SUSPENSION ASS’Y REMOVAL

19, Cam
Decrease spring preload by turning cams accord-
ingly.
Loosen track tension.
Remove rear arm top axle screws no. 7 from chassis.
07-02-4 MMR2001_028_07_02A.FM
DISASSEMBLY AND ASSEMBLY 11, Axle

Inspect track thoroughly before reinstalling sus- Note position of axles at disassembly. Axles with
pension. Refer to TRACK. a paint stripe serve as idler wheel axles. These are
more precise than those used as pivot axles. Idler
1, Rear Arm wheel axles can be used as pivot axles but the
opposite is not true.
At installation, rear arm stroke limiter must be on
rear side. 12,13,14, Front Shock, Spring Stopper
and Cap
1
Use shock spring remover (P/N 529 035 504) and
put it in a vise. Mount shock in it and turn shock
so that spring coils matched spring compressor.
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.
1
A03F13A
1. Stroke limiter on rear side

2
10, Outer Bushing
At installation, hole must face adjustment screw.
A01B4LA
1. Clevis pin
2. Bar
A03F0XA
3. Handle horizontal
MMR2001_028_07_02A.FM 07-02-5
At installation, cap opening must be 180° from 17, Slider Shoe

spring stopper opening.
Molding line is the wear limit indicator.
1
2
A03F3SA 1 2
A03F12A TYPICAL
1. Slider shoe
1. Cap opening 2. Molding line (wear limit indicator)
2. Spring stopper opening
Replace slider shoes when wear limit is reached.
20, Stopper Strap CAUTION: Slider shoes must always be replaced
Inspect strap for wear or cracks, bolt and nut for in pairs.
tightness. If loose, inspect hole for deformation.
Replace as required. Make sure it is attached through 18, Spring Support
proper hole from the end. Refer to TECHNICAL DA- CAUTION: To avoid track damage, spring sup-
TA. Torque nut to 7 N•m (62 lbf•in). ports must be mounted upward.
A
1
2
A03F0VA 2
A03F0QA RIGHT SIDE SHOWN
1. Right position: upward
1. 1st hole 2. Wrong position
2. 2nd hole
07-02-6 MMR2001_028_07_02A.FM
SHOCK ABSORBER INSPECTION Completely push down the shock rod then release.
Rod must come out at a steady speed. If speed
All Models Equipped with Hydraulic Shock suddenly increases particularly at end of exten-
NOTE: Hydraulic shocks are black painted. sion, replace shock.
Secure the shock body end in a vise with its rod If suspecting a frozen gas shock proceed as follows:
upward. Place shock in a freezer (temperature below 0°C
1 (32°F)) for 4 hours.
Push down on rod and note its resistance, com-
pare to a new shock. If shock is frozen it will be
much more difficult to compress than for the new
one.
A14F0BA
INSTALLATION
1. Clamp
Install assembled suspension into track with front
CAUTION: Do not clamp directly on shock body. portion first.
Examine each shock for leaks. Extend and com- Insert rear portion of suspension into track.
press the piston several times over its entire
stroke. Check that it moves smoothly and with uni- Bolt front arm, rear arm then center top idler wheel
form resistance with its rod upward. axle.
Pay attention to the following conditions that will Adjust track tension.
denote a defective shock:
– A skip or a hang back when reversing stroke at RIDE ADJUSTMENT
mid travel. Refer to Operator’s Guide.
– Seizing or binding condition except at extreme
end of either stroke. LUBRICATION
– Oil leakage. Lubricate front and rear arms at grease fittings us-
– A gurgling noise, after completing one full coming synthetic grease (P/N 413 711 500).
pression and extension stroke.
Renew if any faults are present.
All Models Equipped with Gas Pressurized
Shock
NOTE: Gas pressurized shocks are light gray or pur-
ple painted, or bare aluminum.
Gas shock can be inspected as follows:
Because of gas pressure, strong resistance is felt
when compressing shock. When released, the
shock will extend unassisted. Renew as required.
If suspecting an internal gas leak between oil cham-
ber and gas chamber, check shock as follows: A03F10C
Install shock in a vise clamping on its bottom eye- SC-10 SPORT, MOUNTAIN AND TOURING: 5 GREASE FITTINGS
let with its rod upward.
Let it stand for 5 minutes.
MMR2001_028_07_02A.FM 07-02-7
Subsection 03 (SKANDIC WT SUSPENSION)
SKANDIC WT SUSPENSION 0
7
4
A22F18T
TYPICAL

REMOVAL
Release track tension.
Unbolt front arm then rear arm.
NOTE: To prevent cross shaft from turning when
unscrewing screws assembled with threadlocker,
proceed as follows:
– Knock on screw head to break threadlocker bond.
– Loosen one screw then retighten.
– Remove the opposite screw.
– Remove the first one.
Remove suspension assembly.
A22F19A 1
1. Support
2, Conical Washer
At installation, position conical washers as shown.
11 11 2 2 3 3 3 4
A22F1EA A22F1AA
WASHER QUANTITY AND MOUNTING POSITION

1, Extension
Remove nuts and conical washers from the eye
bolt adjuster. Remove bolt retaining eye bolt ad-
juster to support.
Remove rear idler wheel on appropriate side.
Remove idler wheel from support.
Unbolt extension from its support.
A22F1BA
Tighten nut 3/4 turn after contacting washers for

better deep snow performance. Maximum pre-
load is 3 turns after nut touching washers. This last
adjustment is for trail riding with or without a load
and for pulling a load.
07-03-2 MMR2001_029_07_03A.FM
4, Rear Spring Rivets can be substitued by M8 x 20 bolts and

nuts.
Remove top idler wheels.
Unscrew one end of shock. 3, Horse-Shoe Washer
Remove spring. For deep snow riding, do not install washer.
5, Front Spring For trail riding with passenger and/or weight, in-
stall 1 washer under each rubber stoppers.
Remove circlips retaining spring support to top
For trail riding with heavy load and/or pulling a load,
and bottom of front arm.
use 2 washers under each rubber stoppers.
Holding spring end, remove lock pin of top spring
support then bottom support lock pin. 7, Shock
Unbolt front idler wheel axle. Install shock with its rod upward.
Remove idler wheel on side where axle retaining
plate is not welded. SHOCK ABSORBER SERVICING
Remove springs. Secure the shock body end in a vise.
1
A14F0BA
TYPICAL
1. Clamp
CAUTION: Do not clamp directly on shock body.

Examine each shock for leaks. Extend and com-
stroke then check that it moves smoothly and with
A22F1CA 1 uniform resistance.
1. Circlips Pay attention to the following conditions that will
denote a faulty shock:
6, Support Plate
– A skip or a hang back when reversing stroke at
Drill rivets to remove support plate. Use a 8 mm mid travel.
(21/64 in) drill bit.
ends of stroke.
– Oil leakage.
– A gurgling noise, after completing one full com-
Renew if any fault is present.
A22F1DA
MMR2001_029_07_03A.FM 07-03-3
INSTALLATION
Use a tie-down between front arm and spring axle
to ease installation of front arm screws.
A22F1FA
07-03-4 MMR2001_029_07_03A.FM
Subsection 04 (DRIVE AXLE)
DRIVE AXLE 0
8
12 Lithium grease
13
9
9
13
11 3
5
3
2
10
Lithium
grease
A03D3NS
TYPICAL

6
13
A29D1TS

REMOVAL Remove 3 screws retaining end bearing then re-

move inner plate.
All Models Except Skandic WT/SWT/WT LC Remove drive axle.
Drain oil from chaincase or gearbox. Release drive
chain tension. Remove chaincase cover. DISASSEMBLY
Raise and block rear of vehicle off the ground.
Remove suspension. Refer to SUSPENSION. 4, Speedometer Drive Insert
Remove speedometer drive insert.
2,8, End Bearing Housing and Seal
Remove speedometer cable, cable protector, and 5,12, Bearing
plastic bearing cover. Remove circlip from drive axle. To remove bearings, use puller assembly, ring and
Remove chain and sprocket then circlip and bear- half rings as illustrated.
ing from drive axle.
Pry oil seals from chaincase and end bearing hous-
ing.
6,9,13, Drive Axle and Sprocket

Release drive axle sprocket from track and at the
same time, pulling the drive axle towards the end
bearing housing side.
Remove drive axle from vehicle.
Skandic WT/SWT/WT LC Only
A00C44A
Drain gearbox.
Remove suspension. Refer to SKANDIC WT SUS-
9,13, Sprocket and Half-Sprocket
PENSION. To remove press fit sprockets, use a press and a
Remove muffler. Unfasten screw from drive axle suitable support as illustrated.
end. Loosen both Allen screws from end bearing.
1
A00F06A
1
TYPICAL
1. Support sprocket near hub
A22D15A 2 NOTE: Two different types of sprocket press fit

can be found. Ensure to replace ring reinforced
1. Allen screws
2. Screw sprockets with the same type.
MMR2001_030_07_04A.FM 07-04-3
ASSEMBLY Skandic WT/WT LC

To assemble press fit sprockets, use a press and
a suitable pipe as illustrated. Sprockets must be
assembled according to the following dimensions.
A
1
B
C
1 A29D1VA
D
1. Gearbox side
A. 55.0 mm (2.165 in)
B. 157.0 mm (6.181 in)
C. 399.0 mm (15.709 in)
D. 501.0 mm (19.724 in)
Skandic SWT
A00F07A
1. Pipe
S-Series A
1
B
C
A29D1WA
D
1. Gearbox side
A. 105.0 mm (4.016 in)
B. 207.0 mm (8.150 in)
C. 449.0 mm (17.677 in)
D. 551.0 mm (21.693 in)
A
All Models
B
A03D3TA Ensure to align indexing marks of each sprocket
A. 151.2 mm (5.953 in)
when assembling.
B. 274.2 mm (10.795 in)
Skandic LT
1
B
C
D A24D05A
A29D1UA
TYPICAL
A. 47.0 mm (1.850 in)
B. 148.0 mm (5.827 in) 1. Indexing marks aligned
C. 271.0 mm (10.669 in)
D. 372.0 mm (14.646 in)
07-04-4 MMR2001_030_07_04A.FM
The maximum desynchronization for the sprockets 5,12, Bearing

is 1.5 mm (1/16 in).
Always push bearing by inner race.
To check this tolerance, place axle assembly on a
plane surface and measure the gap between sprock-
et tooth and surface.
A00F0DA
1 A
The bearing on the splined side of axle must be
A00F0AA pushed until it is seated on shaft shoulder. The end
1. Plane surface
bearing housing bearing must be flush with end of
A. 1.5 mm (1/16 in) MAXIMUM drive axle. Each bearing must have its shield facing
the sprocket.
CAUTION: The same sprocket must not be
pressed twice on the axle. If synchronization is 1 1
found to be defective, use a new sprocket.
6,8, Drive Axle and Seal

When assembling drive axle, always position a
new seal on each end of drive axle (if applicable).
Locate seal lip as illustrated.
2
1 2 A00F05A 3
1. Bearing shield on this side
2. Flush with drive axle
3. Seated on shaft shoulder
INSTALLATION
4, Speedometer Drive Insert
If the drive axle to be installed is a new part and
the vehicle is equipped with a speedometer, a cor-
A00F0CA
rect size speedometer drive insert must be in-
1. Grease seal type stalled into the axle end. Ensure that insert is flush
2. Oil seal type with end of axle.
11, Bearing Protector Position drive axle assembly into location. Install
end bearing housing. Install spacer (if applicable)
At assembly, flat side of bearing protector must be between bearing and lower chaincase sprocket.
against bearing.
MMR2001_030_07_04A.FM 07-04-5
Install chaincase and position seals (if applicable), LUBRICATION

making sure that a gap of approximately 2 mm
(1/16 in) exists between end of bearing housing 15, Grease Fitting
and each seal.
Lubricate end housing bearing with synthetic grease
(P/N 513 711 500).
3 A
ADJUSTMENT
4
1 2 Sprocket/Track Alignment
CAUTION: Do not tamper with sprocket/track
alignment if frame or suspension is damaged.
Sprockets might be repositioned to fit lugs with-
out removing drive axle.
Use drive axle sprocket adjuster kit (P/N 861 725
700).
A00F0GA
SIDE VIEW
1. Bearing
2. Seal
3. Housing
4. Seal lip
A. 2 mm (.080 in) approximately
3, Retainer Ring
Make sure that welded nuts are toward inside of
tunnel.
Lock drive axle sprocket with a circlip. A01B2PA
Reinstall the chaincase cover. TYPICAL

Refill with chaincase oil. Refer to TECHNICAL DATA.
Install the suspension. Refer to TRACK and adjust
track tension and carry out track alignment proce-
dure.
07-04-6 MMR2001_030_07_04A.FM
Subsection 05 (TRACK)
TRACK 0
TRACK TYPE APPLICATION Skandic WT/SWT/WT LC
Remove the following parts:
Refer to TECHNICAL DATA section.
– rear suspension
GENERAL – muffler.
This section gives guidelines for track removal. Drain gearbox.
Some components require more detailed disas- Remove drive axle then track.
sembly procedures. In these particular cases, re-
fer to the pertaining section in this manual. INSTALLATION
INSPECTION All Models
Reverse the removal procedure.
Visually inspect track for:
NOTE: When installing the track, respect rotation
– cuts and abnormal wear direction indicated by an arrow on track thread.
– broken rods Check sprocket/track alignment as described in
– broken or missing track cleats. DRIVE AXLE.
If track is damaged or rods are broken, replace
track. For damaged or missing cleats, replace by Track Tension and Alignment
new ones, using cleat remover (P/N 529 028 700). Track tension and alignment are inter-related. Do
Use small-cleat installer (P/N 529 008 500). not adjust one without checking the other. Track
tension procedure must be carried out prior to
 WARNING track alignment.
Do not operate a snowmobile with a cut, torn
or damaged track. Tension
Lift the rear of vehicle and support with a mechan-
REMOVAL ical stand. Allow the slide to extend normally.
Check the gap halfway between front and rear
S-Series and Skandic LT idler wheels. Measure between slider shoe and
bottom inside of track.
Remove the following parts:
When using the track tension gauge (P/N 529 021
– speedometer cable
500), slide U-shape extrusion to proper deflection.
– muffler Refer to TECHNICAL DATA.
– chaincase cover
– suspension
– drive axle seal
– end bearing housing 1
– sprockets and chain 40 2
– drive axle (toward end bearing housing) 45
– track. 50
A01B4JA
1. Example: 45 mm
2. Extrusion
MMR2001-031_07_05A.FM 07-05-1
Insert preset gauge between slider shoe and track. Alignment

Allow gauge to settle by forcing track up and
down. Track tension is as specified when edge of
gauge reaches line.
 WARNING
Before checking track tension, ensure that the
track is free of all particles which could be
thrown out while it is rotating. Keep hands,
tools, feet and clothing clear of track. Ensure
no one is standing in close proximity to the
vehicle.
All Models
With rear of vehicle supported off the ground, start
engine and allow the track to rotate slowly.
Check that the track is well centered; equal dis-
tance on both sides between edges of track
guides and slider shoes.
A01B4KA 1 2
TYPICAL
1. Line
NOTE: Lightly oil track tension gauge center pin

to avoid sticking.
CAUTION: Too much tension will result in pow-
er loss and excessive stress on suspension com- 3
A01F05A
ponents. If too loose, the track will have a ten-
dency to thump. 1. Guides
2. Slider shoes
To adjust, loosen the rear idler wheel retaining 3. Equal distance
screws then loosen or tighten the adjuster bolts
located on the inner side of the rear idler wheels.  WARNING
Before checking track alignment, ensure that
the track is free of all particles which could be
thrown out while track is rotating. Keep hands,
tools, feet and clothing clear of track.
To correct, stop engine then tighten the adjuster

bolt on side where guides are farthest to slide. Re-
check alignment.
1
1 2 1
2
A19F05A
TYPICAL
1. Retaining screw
3
A01F0BA
2. Adjuster bolt
1. Guides
2. Slider shoes
3. Tighten on this side
07-05-2 MMR2001-031_07_05A.FM
NOTE: Torque retaining screw to 48 N•m (35 lbf•ft) Track Cleat

after adjustment.
Removal
Tighten the idler wheel retaining screws.
– Raise rear of vehicle off the ground and lift snow
guard then rotate track to expose a cleat to be
replaced.
– Using track cleat remover (P/N 529 028 700) for
all models.
Installation
NOTE: Keep the same pitch between guide cleats.
1 – Place new cleat in position and using small track
cleat installer (P/N 529 028 800) bend cleat then
push tabs into rubber.
A19F05B
TYPICAL
1. Retighten
Restart engine, rotate track slowly and recheck 1

alignment.
A01B4UA
TYPICAL
1. First step
2. Second step (to push tabs into rubber)
MMR2001-031_07_05A.FM 07-05-3
Section 08 STEERING/FRONT SUSPENSION
TABLE OF CONTENTS 0
STEERING SYSTEM .............................................................................................................. 08-02-1
INSPECTION ...................................................................................................................... 08-02-3
HANDLEBAR POSITION ADJUSTMENT.......................................................................... 08-02-6
STEERING ADJUSTMENT (SKIS) .................................................................................... 08-02-6
LUBRICATION .................................................................................................................... 08-02-9
SUSPENSION AND SKI SYSTEM ........................................................................................ 08-03-1

DISASSEMBLY................................................................................................................... 08-03-2
INSPECTION ...................................................................................................................... 08-03-3
INSTALLATION .................................................................................................................. 08-03-3
ON-VEHICLE COMPONENT VERIFICATION .................................................................... 08-03-5
DISASSEMBLY................................................................................................................... 08-03-6
INSPECTION ...................................................................................................................... 08-03-6
INSTALLATION .................................................................................................................. 08-03-7
MMR2001-032_08_01ATOC.FM 08-01-1
Subsection 02 (STEERING SYSTEM)
STEERING SYSTEM 0
S-Series
5
4 7
2
25 Nm 6
(18 lbfft) 25
24
18
23
53 Nm 10 Nm
(39 lbfft) 1 (89 lbfin) 3
9 31
21
8
15 Nm 21
(133 lbfin)
18 Nm 16
(159 lbfin) 13
15 14 18 Nm
10 52 Nm (159 lbfin)
(38 lbfft)
21
9 53 Nm
22 (39 lbfft)
21 21
53 Nm 21
(39 lbfft) 9
16
13 18 Nm
(159 lbfin)
20 18 Nm
(159 lbfin)
15
10
12 21 25 Nm
17 11 (18 lbfft)
9 53 Nm
21 (39 lbfft)
A06G1XS
MMR2001-032_08_02A.FM PARTS FLAT RATE 08-02-1

25
23
5 24
8
2 31
24 Nm
20 Nm (18 lbfft)
(15 lbfft)
2
47 Nm
9 (35 lbfft)
10 21
20
15
18 Nm
(159 lbfin) 15 47 Nm
(35 lbfft) 9
16 21
15 20
18 Nm
(159 lbfin)
15 10
A29G0OS
TYPICAL
08-02-2 PARTS FLAT RATE MMR2001-032_08_02A.FM

INSPECTION The grips might be unremovable as explained

above, in this case, carefully proceed as follows to
Check skis and ski runner for wear, replace as nec- prevent damaging the heating elements.
essary. Refer to STEERING SYSTEM.
Start cutting and immediately peel it open to locate
the gap in the heating element, as shown.
17, Steering Arm and Ski Leg
Make sure steering arm and ski leg splines inter-
lock without excessive play.
 WARNING
Any parts having worn splines have to be re-
placed with new ones.
Check the general condition of the steering sys-

tem components for wear. Replace if necessary.
A19H04A 1
31, Heating Grip Element
TYPICAL
To test heating elements, refer to TESTING PRO- 1. Gap in the heating element opposite the wires
CEDURE.
Continue cutting along the gap and remove the grip.
10,16, Ball Joint If required, slowly peel heating element no. 31
(left hand and right hand threads) from handlebar and remove it.
Inspect ball joint ends for wear or looseness, if ex- To install, stick the heating element to the handle-
cessive, replace them. bar making sure the wires do not interfere with
operation of the accelerator or brake handle.
DISASSEMBLY AND ASSEMBLY Prior to install grips, position heating element pro-
tector no. 18.
8, 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.
Inject compressed air into the handlebar and twist
grip as pulling it out.
A30G0DA 1
1. Heating element protector
 WARNING
Never use lubricants (e.g. oil, grease, etc.) to
install the handlebar grip. Only use a mix of
soap and water. Mix 40 parts of water with
one part of dish washing soap (recommended:
Ultra Joy, Sunlight or Palmolive).
A30G0OA
MMR2001-032_08_02A.FM 08-02-3
Heat the grip with a heater gun or a spot light to 10,16, Ball Joint
ease installation. Insert new grip with compressed (left hand and right hand threads)
air.
Screw threaded end of the ball joint into the tie
rod. The maximum external threaded length not
engaged in the tie rod must not exceed 20 mm
(25/32 in).
A A
A02G0SA
A30G0NA TYPICAL
A. 20 mm (25/32 in) maximum
1, Steering Column The ball joint should be restrained when tightening

the tie rod end lock nut. Align it so the tie rod end
Remove steering pad then handlebar ass’y.
is parallel to the steering arm when assembled on
Detach the short tie rod (under the engine) from the vehicle, refer to the following illustration.
the steering column.
For proper torque specifications refer to the spe-
To gain access to lower U-clamp, remove the air cific exploded view for the vehicle being serviced.
intake silencer and carburetor(s). Remove U-clamps
then steering column. 1 2
17, Steering Arm

To maintain correct steering geometry for reas-
sembling, punch mark the steering arm and ski leg
before disassembly.
A02G0IA
TYPICAL
1. Parallel with steering arm
2. Steering arm
 WARNING
The cut off section of the ball joint must run
1 parallel with the steering arm. When tightening
lock nuts, restrain ball joint with appropriate
size wrench. The maximum external threaded
length not engaged in the tie rod must not ex-
ceed 20 mm (25/32 in).
A03G03A
TYPICAL
1. Punch marks
08-02-4 MMR2001-032_08_02A.FM
21, Hardened Washer on Ball Joint Stud S-Series

S-Series and Skandic LT 17, Steering Arm
Install a hardened washer on each side of the arm. Steering arm axis (from plastic cap center to a ball
center of ball joint) must run parallel to ski.
A30G0LB 1
A25G0MA
TYPICAL
TYPICAL 1. Parallel
1. Hardened washers
Tighten the steering arm nut no. 11 to the torque
Skandic WT/SWT/WT LC Only specified in the exploded view.
Install special washers (locking disks) with teeth Skandic LT/WT/SWT/WT LC Only
facing each others.
Install steering arm at mid-travel position when
handlebar and skis are facing straight ahead.
A22G0MA 1
A22G0LA
1. Large teeth
TYPICAL
9,13,15, Ball Joint Nut and Jam Nut

Tighten ball joint, nuts and jam nuts to specified
torque (see exploded view).
MMR2001-032_08_02A.FM 08-02-5
HANDLEBAR POSITION  WARNING

ADJUSTMENT Make sure that the steering pad and all controls
All Models are properly fixed to their normal location on
the handlebar.
Remove steering pad. Loosen 4 nuts on steering
clamps no. 2.
Adjust the steering handlebar to the desired posi-
tion.
Lock the handlebar in place by tightening the 4
nuts as specified in the illustrations.
CAUTION: Tighten the nuts equally in a criss-
cross sequence and ensure there is an equal
1
gap on each side of the clamps no. 2.
2
A09G05A
TYPICAL
A 1. Rubber attachment
2. Nut and bolt (where applicable)
1
STEERING ADJUSTMENT (SKIS)
Definitions
TOE-OUT:
A difference measured between the front edge of
A06G19A
the skis A and rear edge B as viewed from the top.
It is adjustable.
TYPICAL
1. Torque to 26 N•m (19 lbf•ft)
A. Equal gap all around
 WARNING
Avoid contact between the brake handle and
the windshield by NOT adjusting the handlebar A
too high.
B
 WARNING
Make sure that the steering pad and all controls
are properly fixed to their normal location on A01G04A
the handlebar.
CAMBER:
Properly fit the steering pad to the handlebar. As- A specific inward or outward tilt angle of ski leg
semble using the 2 rubber attachments, nuts and compared to a vertical line when viewing the ve-
bolts where applicable. hicle from front. This angle is not adjustable on
any models.
08-02-6 MMR2001-032_08_02A.FM
Adjustments
 WARNING 1
Maximum ball joint external threaded length
not engaged in the tie rod end must not exceed
20 mm (25/32 in). Torque lock nut to 18 N•m
(159 lbf•in).
A A
2 2
A A
A06G07A
A02G0SA
TYPICAL
A. 20 mm (25/32 in) maximum 1. Equal distance A on each side
2. Same reference point
S-Series
Adjustments should be performed following this With handlebar in that straight-ahead position, the
sequence: center of the pivot arm must be in line with the
end of the bolt. Loosen the jam nuts on tie rod
– Handlebar/pivot arm centering. no. 14 (LH threads on steering column end) and
– Toe-out adjustment. turn tie rod accordingly. Align and retighten the
jam nuts to 18 N•m (159 lbf•in).
HANDLEBAR/PIVOT ARM CENTERING
13,14,15,22, Jam Nut, Tie Rod and
Pivot Arm 1 2
Turn handlebar in a way that both grip ends are at
equal distance from reference point.
NOTE: The reference point must be the same rel-
ative to each side.
A06G04A
TYPICAL
1. Tie rod no. 14
2. Center of pivot arm in line with bolt end
MMR2001-032_08_02A.FM 08-02-7
This adjustment will provide same turning radius To adjust turn tie rods then retorque jam nuts.
for each side. To reduce tolerance when measuring, set one ski
After this adjustment, skis may not be in straight- to proper toe-out then measure from that ski to
ahead position. This situation will be corrected the opposite ski.
when adjusting toe-out.
 WARNING
Do not attempt to adjust skis straight-ahead
position by turning ball joint on tie rod no. 14.
TOE-OUT ADJUSTMENT
Make sure that handlebar is horizontal as ex- 2
plained above. 1
A06G03A
Toe-out adjustment is performed by adjusting TYPICAL

length of left and right tie rods no. 20. 1. Straight edge
2. Measure here
Procedure:
– Loosen jam nuts no. 13 and no. 15 of both tie Skandic LT/WT/SWT/WT LC
rods no. 20. Skis should have a toe-out of 10 mm (3/8 in) when
they are in a straight-ahead position and the vehi-
 WARNING cle is resting on the ground.
Never lengthen tie rod making threaded por- Proceed the same as S-Series above. Measure-
tion of ball joint exceed 20 mm (25/32 in). ments are taken 250 mm (10 in) at front and rear
of ski pivot bolt.
– Close front of skis manually to take all slack
NOTE: To make sure skis are in a straight-ahead
from steering mechanism.
position, place a straight edge against pre-adjusted
NOTE: A rubber cord must be hooked in front of track and measure the distance between front and
skis to keep them closed. rear of skis and straight edge. Distances should be
Toe-out is 0 mm (0 in) when skis are in a straight- equal. After the ski toe-out adjustment, distance
ahead position and the front of vehicle is lifted off at front of ski must be 5 mm (3/16 in) more than
the ground. at rear on both sides for a total toe-out of 10 mm
(3/8 in).
NOTE: To make sure skis are in a straight-ahead
position, place a straight edge against pre-adjusted
track and measure the distance between front and
rear of skis and straight edge. After the ski toe-out
adjustment, rear and front distances must be
equal.
08-02-8 MMR2001-032_08_02A.FM
LUBRICATION
 WARNING
Do not lubricate throttle and/or brake cable
nor their housing.
26, Grease Fittings

Only use synthetic grease (P/N 413 711 500).
The following symbols will be used to show what
type of lubricant should be used at the suitable
locations.
1 2
1
A00G01A
1. Synthetic grease
2. Penetrating lubricant (P/N 293 600 016)
Lubricate front suspension posts. Pump five
strokes of grease gun on each post.
NOTE: There are 2 grease fittings.
Oil ball joints and steering column bushings.
NOTE: There are 6 lubrication points.
A29G0PA
MMR2001-032_08_02A.FM 08-02-9
S-Series
Lubricate:
– Grease ski legs and ski pivots.
– Coat stabilizer sliders with grease, and oil their ball joints if so equipped.
If so
equipped
A06G08U
TYPICAL — S-SERIES
08-02-10 PARTS FLAT RATE MMR2001-032_08_02A.FM

Subsection 03 (SUSPENSION AND SKI SYSTEM)
SUSPENSION AND SKI SYSTEM 0

S-Series
10
9 4 29 Nm
5 (21 lbfft)
Some models 3
7
6
1 Loctite
40 Nm
(30 lbfft) 243
15 Nm
(133 lbfin)
2
Some models
32 Nm
(24 lbfft)
7 Nm 18 Nm
(62 lbfin) (159 lbfin)
9 Nm
(80 lbfin)
A03G13S

DISASSEMBLY
5, Shock
Lift front of vehicle and support it off the ground.
Reduce spring preload by turning adjusting ring ac-
cordingly with the adjustment wrench in vehicle
tool box.
1
2
A03F12A
1
1. Cap opening
1, Swing Arm
A06G0AA 2
Remove cap, circlip then loosen steering arm bolt
1. Shock cam and pull up steering arm. Note washer no. 2 posi-
2. Adjustment wrench tion. Ski leg may fall off from swing arm.
Remove lower bolt then upper bolt of shock. Unbolt lower end of shock from swing arm.
For shock spring disassembly use shock spring re- Unbolt both radius rods.
mover (P/N 529 035 504) in a vise. Mount shock
Unbolt swing arm from footrest.
in it and turn shock so that spring coils match
spring compressor. 1
Close and lock the bar. Adjust the handle horizon-
tal position by changing the position of the clevis 2
pin.
Push down on the handle until it locks. Remove
spring stopper and cap then release handle.
When installing the cap opening must be 180° 3
from the spring stopper opening.
A32G0EA
TYPICAL
1. Cap no. 4
2. Circlip no. 3
3. Washer no. 2
4. Bolt retaining lower end of shock no. 6
08-03-2 MMR2001_033_08_03A.FM
INSPECTION
Check all rubber cushions for crack and wear. Re-
place as required.
Check straightness of splines and proper inter-
locking with steering arm. Replace as required.
Check for straightness of swing arm. Replace as
required.
Check for clogged grease fittings. Clean or replace
as required.
Check for proper action of sliding blocks in swing
arm.
Check skis and runners for wear, replace as neces-
sary.
Check condition of ski stopper. Replace it when de-
teriorated.
To check condition of shock, refer to SC-10 SUS-
PENSION then look for Shock Absorber Inspec-
tion.
INSTALLATION
For assembly, reverse the disassembly procedure.
However, pay attention to the following.
Apply synthetic grease (P/N 413 711 500) to ski leg
components.
Tighten nuts and screws to proper torque as men-
tioned in exploded view.
7,8, Upper and Lower Radius Rods

Position radius rods and tie rods horizontally before
tightening nuts.
9,10, Rivet and Link Plate

Attach link plate to frame with rivets, if applicable.
MMR2001_033_08_03A.FM 08-03-3
1 13 Nm
(115 lbfin)
2
13
19
5
14
6
15 Except
Skandic
LT
7
16
17
10
8
9
9
11
12
A22G03T
TYPICAL

ON-VEHICLE COMPONENT
VERIFICATION
8, Shock
Lift front of vehicle and support off the ground.
Remove ski bolt and nut.
Remove steel bushing from ski using a pusher.
See pusher dimensions below.
A
B
C
1
A22G0IA
1. Bushings
A22G0OA F E D
A. 220 mm (8.66 in) 7, Spring
B. 180 mm (7.09 in)
C. 70 mm (2.75 in) Unscrew shock rod nut then remove washer. Un-
D. 25 mm (1.0 in) screw 3 Allen screws retaining cover no. 3, then
E. 15 mm (.59 in)
F. 9 mm (.35 in) remove stopper no. 5, washers no. 6, washer
no. 19.
A22G0PA
A05G0CA
Unfasten rod nut then pull out shock from bottom. 1. Allen screws
Check shock as described below in INSPECTION.
At installation, make sure bushings are in place. NOTE: These washers and stopper can be wedged
in cover.
MMR2001_033_08_03A.FM 08-03-5
13,14,16,17, Ski Leg, Bushing and Seal

1 Pull up ski leg. Steering arm will not interfere.
A05G0DA
A05G0EA
1. Washers and stopper wedged in cover
2. Spring 1. Pull up ski leg
2. Steering arm in place
Pull out spring.
Remove seal. Drive out bushing if worn out.
DISASSEMBLY
INSPECTION
Lift front of vehicle and support off the ground.
All Models
1,2,3,5,6,9,11,12, Bolt, Lock Washer, Suspension Free Operation
Cover, Stopper, Bushing and Nut
Remove cover and check for free movement of ski
Remove ski bolt, nut, bushings and ski. leg by lifting end of ski.
Unscrew shock rod nut then remove washer.
Shock will fall off the ski leg. 13, Ski Leg
Unscrew 3 Allen screws retaining cover, then re- Check straightness of ski leg. Check for scored or
move stopper and washers. scratched surface. Replace as required.
Check that splines on ski leg and steering arm in-
1 terlock properly with no excessive free play. Re-
new as necessary.
5, Stopper
Check condition of stopper. Replace it when dete-
riorated.
Grease Fitting
Ensure that grease fittings are not clogged.
10, Ski Stopper

Check stopper for crack or deterioration. Replace
A05G0CA
as required.
1. Allen screws
NOTE: These washers and stopper can be wedged

in cap.
08-03-6 MMR2001_033_08_03A.FM
8, Shock Absorber INSTALLATION

Secure the shock body end in a vise with its rod For assembly, reverse the disassembly procedure.
upward. However, pay attention to the following.
1 Apply synthetic grease (P/N 413 711 500) as illus-
trated in exploded view above.
Reinstall steering arm reinforcement when removed.
A14F0BA
1. Clamp

stroke with its rod upward. Check that it moves
smoothly and with uniform resistance.
Pay attention to the following conditions that will
mid travel.
end of either stroke. A22G0SA 1
– Oil leakage. 1. Reinforcement
– A gurgling noise, after completing one full com-
pression and extension stroke. 16,17, Seal
Renew if any faults are present. Install seal before reinstalling ski leg.
MMR2001_033_08_03A.FM 08-03-7
Section 09 BODY/FRAME
TABLE OF CONTENTS 0
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
BELT GUARD ..................................................................................................................... 09-02-2
WIRING HARNESS ............................................................................................................ 09-02-2
CABLES .............................................................................................................................. 09-02-3
PIPING ................................................................................................................................ 09-02-3
PLASTIC MAINTENANCE AND REPAIR........................................................................... 09-02-3
MAINTENANCE ................................................................................................................. 09-02-3
REPAIR................................................................................................................................ 09-02-4
MATERIAL REPAIR PROCEDURE ..................................................................................... 09-02-5
REPAIR PROCEDURE FOR R.I.M. URETHANE................................................................. 09-02-5
FRAME ................................................................................................................................... 09-03-1

FRAME CLEANING ............................................................................................................ 09-03-1
FRAME WELDING ............................................................................................................. 09-03-1
FRAME COMPONENT REPLACEMENT ........................................................................... 09-03-1
MMR2001_034_09_01ATOC.FM 09-01-1
Subsection 02 (BODY)
BODY 0
INSTALLATION AND Required Conditions
ADJUSTMENT Place the vehicle on a flat surface perpendicular to
test surface (wall or screen) and 381 cm (12 ft 6 in)
HEADLAMP BEAM AIMING away from it.
Rider or equivalent weight must be on the vehicle.
Beam aiming is correct when center of high beam
is 25 mm (1 in) below the headlamp horizontal cen- Select high beam.
ter line, scribed on a test surface, 381 cm (12 ft 6 in)
away. BULB REPLACEMENT
Measure headlamp center distance from ground. If headlamp bulb is burnt, tilt cab and unplug the
Scribe a line at this height on test surface (wall or connector from the headlamp. Remove the rubber
screen). Light beam center should be 25 mm (1 in) boot and unfasten the bulb retainer clips or locking
below scribed line. ring.
1 90°
A02E0AA B
1. Headlamp center line
A. 381 cm (12 ft 6 in) A25H0JA
1
B. 25 mm (1 in) below center line
TYPICAL
1 2 1. Locking ring
Replace bulb. If the taillight bulb is burnt, expose

the bulb by removing red plastic lens. To remove,
unscrew the 2 retaining screws. Verify all lights
3 after replacement.
A
A02E07A CAUTION: Never touch glass portion of an halo-
1. Headlamp horizontal gen bulb with bare fingers, as it shortens its op-
2. Light beam (high beam) (projected on the wall) erating life. If by mistake glass is touched, clean
3. Light beam center
A. 25 mm (1 in) it with isopropyl alcohol which will not leave a
film on the bulb.
MMR2001-034_09_02A.FM 09-02-1
DECAL
To remove a decal; heat old decal with a heat gun
and peel off slowly.
Using isopropyl alcohol, clean the surface and dry
thoroughly.
Apply liquid soap to new decal and carefully posi-
tion the decal. Using a sponge or a squeegee, re-
move the air bubbles and surplus water working
from the center toward the edges. Allow to air dry.
CAUTION: Do not apply isopropyl alcohol or sol-
vent directly on decals.
WINDSHIELD INSTALLATION A03H14A 1

Position the windshield on the hood then push it 1. Access hole
down until the tabs are fully inserted into the hood At installation, loosely install nuts, close hood then
slots. Lock the windshield tabs in position using adjust before tightening interior nuts through ac-
latches as shown. cess holes.
BELT GUARD
1 Disassembly and Assembly
NOTE: For additional information (ex.: exploded
view) refer to the corresponding Parts Catalog.
2  WARNING
Engine should be running only with belt guard
well-secured in place.
Inspection
All Models
Check belt guard mounting bosses, clips and re-
A03H17A
tainers for wear.
S-SERIES
1. Latch
2. Temporary remove headlamp molding for windshield installation
WIRING HARNESS
HOOD  WARNING
Ensure all terminals are properly crimped on
S-Series
the wires and that all connector housings are
Working from within engine compartment, re- properly fastened. Keep wires away from
move exterior nuts retaining both hinges. Then, any rotating, moving, heating and vibrating
close hood and remove interior nuts through the parts. Use proper fastening devices as re-
access holes. quired.
09-02-2 MMR2001-034_09_02A.FM
CABLES PLASTIC MAINTENANCE AND

REPAIR
 WARNING
Before installation, ensure that all cables are MAINTENANCE
in perfect condition. Properly install the ca-
ble ends and secure them in place. Pay atten- Clean the vehicle thoroughly, removing all dirt and
tion to route them properly, away from any grease accumulation.
rotating, moving, heating, or vibrating parts. To clean use a soft clean cloth and either soapy
water or isopropyl alcohol.
PIPING To remove grease, oil or glue use isopropyl alcohol.
CAUTION: Do not apply isopropyl alcohol or ac-
 WARNING etone directly on decals.
Always ensure that the fuel, vent, primer, im- CAUTION: The following products must not be
pulse, injection oil and rotary valve oil lines used to clean or wax any of the plastic compo-
are properly fixed to their connectors, that nents used on the vehicles:
they are not perforated or kinked and that – gasoline
they are properly routed away from any ro- – brake fluid
tating, moving, heating or vibrating parts.
Also check for leaks. Replace if required. – kerosene
– diesel fuel
NOTE: Refer to proper Parts Catalog to find suit-
able clip part numbers. – lighter fluid
– varsol
– naphtha
– acetone
– strong detergents
– abrasive cleaners
– waxes containing an abrasive or a cleaning agent
in their formula.
Apply wax on glossy finish only. Protect the vehi-
cle with a cover to prevent dust accumulation dur-
ing storage.
CAUTION: If for some reason the snowmobile
has to be stored outside it is preferable to cover
it with an opaque tarpaulin. This will prevent
the sun rays from affecting the plastic compo-
nents and the vehicle finish.
MMR2001-034_09_02A.FM 09-02-3
REPAIR
The very first step before repairing plastic materials is to find out exactly which type of material is involved.
Refer to following chart.
CAUTION: Consult chart and repair kit instructions carefully, some repair products are not compat-
ible with certain plastics.
 WARNING
Polycarbonate windshields must never be repaired by welding or otherwise.
IRREPAIRABLE REPAIRABLE
HIGH DENSITY R.I.M.

PART MODEL POLYPROPYLENE POLYETHYLENE
POLYETHYLENE URETHANE
HOOD Skandic
LT/WT SWT/
WT LC
S-Series
A06H194
BOTTOM PAN Skandic

LT/WT SWT/
WT LC
S-Series
A06H1A4
SIDE PANEL AND

REAR MOLDING
S-Series
A06H1B4
09-02-4 MMR2001-034_09_02A.FM
MATERIAL REPAIR PROCEDURE – Sand the surface using a smooth dry sand paper.
– Use the same product if a final finish is required.
R.I.M. Urethane – Clean surface with Crest Hi-Solv product.
R.I.M. urethane is light colored (tan) on the inside – Apply a flexible primer such as Crest Prima Flex
with a smooth surface. stock no. AP-F.
 WARNING – Wait 10 minutes.
Material should be repaired and repainted in – Repaint (air dry during 72 hours (approximately)).
a well-ventilated area only.
Large Crack
CAUTION: Clean R.I.M. with isopropyl alcohol or – Sand and scuff outside and inside area by ex-
Crest Hi-Solv product. Never use cleaners or ceeding it 31.7 mm (1-1/4 in) on each side and
products that contain chlorine. 12.7 mm (1/2 in) at each end.
CAUTION: R.I.M. should never be exposed to – Make a V groove (appr. 90°) on both sides of
temperatures exceeding 93°C (200°F). hood using a knife or a rough round file.
NOTE: When working on a R.I.M. surface, never – Enlarge the crack to 2.4 mm (3/32 in) – 3.2 mm
use a grinder or a high revolution tool such as an (1/8 in) using a sharp knife.
air or electric buffer. Use of such tools could over-
– Clean outside and inside surface with isopropyl
heat material and liberate agents in it thus causing
alcohol or Crest Hi-Solv product.
a bad adhesion.
– Repair inside surface first.
REPAIR PROCEDURE FOR R.I.M. – Cover inside area with Crest TP-E epoxy.
URETHANE – Apply a 50 mm × 30 mm (2 in × 1-1/4 in) patch.
If no room for the patch, use tape.
Small Scratches – Cover exterior surface with same product.
– Sand and scuff area. Damaged area should be slightly higher.
– Feather out edges. – Heat surface with a heater lamp placed at 38 mm
– Paint with a matching acrylic auto touch-up paint. (15 in) for a period of 15 minutes.
– Sand outside surface using a smooth dry sand
Deep Scratches paper.
– Sand and scuff area. – Use same product if a final finish is required.
– Make a V groove using a knife or a rough round – Apply a flexible primer.
file. – Wait 10 minutes.
– Clean surface with isopropyl alcohol or Crest Hi- – Repaint (air dry during 72 hours approximately).
Solv stock no. AH-S product.
NOTE: Both R.I.M. materials are high static plas-
– Cover with TP-E epoxy mixed in equal quantities. tics, painting must be done in a dust free area such
– Heat the surface with a heater lamp placed at as a paint booth.
38 cm (15 in) for a period of 15 minutes.
MMR2001-034_09_02A.FM 09-02-5
Crest products used in R.I.M. repair procedure are available from following locations:
CREST MAIN OFFICE AND MANUFACTURING PLANT

Phone: 734-283-4100
CREST INDUSTRIES, INC. Toll Free: 1-800-822-4100
3841 13th Street Fax: 1-800-344-4461
Wyandotte, Michigan Fax: 734-283-4461
48192 E-Mail: info@crestauto.com
www.crestauto.com
DISTRIBUTOR WAREHOUSE LOCATIONS

UNITED STATES CANADA
CREST EAST COAST, INC. CREST INDUSTRIES, INC. J2 PRODUCTS
P.O. Box 550 (CREST MID-WEST) A Division of Sawill Ltd.
1109 Industrial Parkway 231 Larkin Williams Ind. Court 54 Audia Court, Unit 2A
Brick, New Jersey 08723 St. Louis, Missouri 63026 Concord, Ontario, L4K 3N4
Phone: 732-458-9000 Phone: 314-349-4800 Phone:
Fax: 732-458-5753 Toll Free: 1-800-733-2737 Toronto: 416-665-1404
Fax: 314-349-4888 Concord: 905-669-9410
CREST PRODUCTS, INC.
Toll Free Fax: 1-800-776-2737
Shipping Address: Fax:
125 Production Drive CREST MID WEST Concord: 905-669-9419
Yorktown, Virginia 23693 Regional Branch Warehouses
WHEEL-IN AUTOMOTIVE
Phone: 757-599-6572 CREST INDUSTRIES, INC. SUPPLY
Virginia: 1-800-572-5025
Outstate: 1-800-368-5033 P.O. Box 635 Shipping Address:
Mountain Home, Arkansas 72653 No. 1, 3911A Brandon St. S.E.
Fax: 757-599-6630
Phone: 501-491-5583 Calgary, Alberta, T2G 4A7
Mailing Address: Toll Free: 1-800-733-2737 Phone: 403-287-0775
P.O. Box 2018
Grafton, Virginia 23692 CREST INDUSTRIES, INC. Mailing Address:
4200 Jackson Street, Unit 9 P.O. Box 40036
CREST INDUSTRIES 929-42nd Avenue S.E.
Denver, Colorado 80216
SOUTHEAST, INC. Calgary, Alberta, T2G 5G5
Phone: 303-320-3900
Shipping Address: Toll Free: 1-800-733-2737
1400-B Woodstock Rd. Fax: 303-320-6509
Roswell, Georgia 30075
REM-CO DISTRIBUTING, INC.
Mailing Address:
11530 Bowen Road 5625 S. Adams
Roswell, Georgia 30075 Tacoma, Washington 98409
Phone: 770-642-7670 Phone: 253-474-5414
Toll Free: 1-800-552-0876 Toll Free: 1-800-735-7224
Fax: 770-642-7679 Fax: 253-474-7339
09-02-6 MMR2001-034_09_02A.FM
Subsection 03 (FRAME)
FRAME 0
FRAME CLEANING
1
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.
scratched off. Spray all bare metal parts of vehicle
with metal protector.
Seat Cleaning
For all models, it is recommended to clean the
seat with a solution of warm soapy water, using
a soft clean cloth.
CAUTION: Avoid use of harsh detergents such
as strong soaps, degreasing solvents, abrasive
cleaners, paint thinners, etc. that may cause
damage to the seat cover. A03C18B
TYPICAL
FRAME WELDING 1. Unplug before electrical welding
Steel Frame: CAUTION: If welding is to be done near plastic

material, it is recommended to either remove
– electric welding the part from the area or to protect it with alu-
– amperage: 70-110 A minum foil to prevent damage.
– voltage: 20-24 V
– electrode: E-7014 (3/32 in). FRAME COMPONENT
REPLACEMENT
Aluminum Frame
(refer to specialized welding shop): S-Series
– electric welding: inert gas (argon) Drilling Procedure
– rod: ER-4043 (3/32 in). When drilling self-piercing rivets, use Supertanium™
CAUTION: Before performing electrical weld- drill bit (P/N 529 031 800), available in a 5 mm (3/16 in)
ing anywhere on the vehicle, unplug the multi- size and shipped in packs of 2.
ple connector at the electronic box. On models For proper drilling instructions and to prevent pre-
equipped with a battery, also unplug the nega- mature wear, follow the procedure below.
tive cable. This will protect the electronic box
and battery against damage caused by flowing Always use a variable speed electric drill.
current when welding. Partially drill rivet end — not the rivet head.
Maintain a slow to medium speed at all times
when drilling. The proper speed is attained when
a constant chip is ejected.
MMR2001_035_09_03A.FM 09-03-1
NOTE: To increase bit life, use Bombardier syn-

thetic chaincase oil (P/N 413 803 300) as a cutting
oil.
CAUTION: High speed drilling will cause exces-
sive heat which may destroy the cutting edge of
the bit, therefore avoid using pneumatic drills.
A03H2FA
Remove part riveted.

Punch out rivet head from drilled end.
If rivet is only accessible from head; ground rivet
head completely and punch out remaining part of
rivet.
09-03-2 MMR2001_035_09_03A.FM
Section 10 TECHNICAL DATA
Subsection 01 (SI METRIC INFORMATION GUIDE)
TECHNICAL DATA 0
SI* METRIC INFORMATION GUIDE
BASE UNITS
DESCRIPTION UNIT SYMBOL
length ............................................................... meter ................................................... m

mass ................................................................. kilogram ............................................... kg
force ................................................................. newton ................................................. N
liquid ................................................................. liter ....................................................... L
temperature ..................................................... Celsius ................................................. °C
pressure ........................................................... kilopascal .............................................. kPa
torque ............................................................... newton•meter ..................................... N•m
speed ............................................................... kilometer per hour ................................ km/h
PREFIXES
PREFIX SYMBOL MEANING VALUE
kilo .............................. k ............................ one thousand ....................................... 1 000

centi ........................... c ............................ one hundredth ...................................... 0.01
milli ............................. m ........................... one thousandth .................................... 0.001
micro .......................... µ ............................ one millionth ........................................ 0.000001
CONVERSION FACTORS
TO CONVERT TO † MULTIPLY BY
in ...................................................................... mm ....................................................... 25.4

in ...................................................................... cm ........................................................ 2.54
in2 ..................................................................... cm2 ....................................................... 6.45
in3 ..................................................................... cm3 ....................................................... 16.39
ft ....................................................................... m .......................................................... 0.3
oz ...................................................................... g ........................................................... 28.35
lb ...................................................................... kg ......................................................... 0.45
lbf ..................................................................... N .......................................................... 4.4
lbf•in ................................................................ N•m ..................................................... 0.11
lbf•ft ................................................................. N•m ..................................................... 1.36
lbf•ft ................................................................. lbf•in .................................................... 12
PSI (lbf/in2) ....................................................... kPa ....................................................... 6.89
imp. oz .............................................................. U.S. oz .................................................. 0.96
imp. oz .............................................................. mL ........................................................ 28.41
imp. gal ............................................................. U.S. gal ................................................. 1.2
imp. gal ............................................................. L ........................................................... 4.55
U.S. oz .............................................................. mL ........................................................ 29.57
U.S. gal ............................................................. L ........................................................... 3.79
MPH ................................................................. km/h .................................................... 1.61
Fahrenheit ........................................................ Celsius ................................................. (°F - 32) ÷ 1.8
Celsius .............................................................. Fahrenheit ............................................ (°C × 1.8) + 32
* The international system of units abbreviates SI in all languages.

† To obtain the inverse sequence, divide by the given factor. To convert mm to in, divide by 25.4.
NOTE: Conversion factors are rounded off to 2 decimals for easier use.
MMR2001_036_10_01A.FM 10-01-1
Subsection 02 (ENGINES)
TOURING FAN 380,

TOURING FAN 500,
TOURING CARGO 380
VEHICLE MODEL FORMULA DELUXE TOURING CARGO 500
FORMULA DELUXE 500 MX Z FAN 440
FAN 380
MX Z FAN 380 MX Z FAN 500
ENGINE TYPE 377 503 443

Number of Cylinders 2 2 2
Bore mm (in) 62.01 (2.441) 72.00 (2.835) 67.5 (2.6575)
Stroke mm (in) 61.00 (2.402) 61.00 (2.402) 61.0 (2.402)
Displacement cm3 (in3) 368.3 (22.48) 496.7 (30.31) 436.6 (26.64)
Compression Ratio (corrected) 6.7 6.4 6.4
Maximum Power Engine Speed ➀ ± 100 RPM 6900 7000 7000
Piston Ring Type 1st/2nd ST/R ST/R ST/R
(new) mm (in) 0.2 (.008) 0.25 (.010) 0.2 (.008)
Ring End Gap
(wear limit) mm (in) 1.0 (.039) 1.0 (.039) 1.0 (.039)
Ring/Piston Groove Clearance (new) mm (in) 0.04 (.0016) 0.04 (.0016) 0.04 (.0016)
(wear limit) mm (in) 0.2 (.008) 0.2 (.008) 0.2 (.0079)
(new) ± 0.016 mm (± .0006 in) 0.070 (.0028) 0.080 (.0031) 0.08 (.0031)
Piston/Cylinder Wall Clearance
(wear limit) mm (in) 0.2 (.008) 0.2 (.008) 0.2 (.008)
Connecting Rod Big End Axial (new) mm (in) 0.20 (.0079) 0.2 (.0079) 0.2 (.0079)
Play (wear limit) mm (in) 1.0 (.0394) 1.0 (.0394) 1.0 (.0394)
Maximum Crankshaft End-Play ➁ mm (in) 0.3 (.0118) 0.3 (.0118) 0.3 (.012)
Maximum Crankshaft Deflection
mm (in) 0.06 (.0024) 0.06 (.0024) 0.06 (.0024)
Measured at PTO
Magneto Generator Output W 240 240 240
Ignition Type CDI CDI CDI
Spark Plug Make and Type NGK BR9ES NGK BR9ES NGK BR9ES
Spark Plug Gap ± 0.05 mm (± .002 in) 0.45 (.018) 0.45 (.018) 0.45 (.018)
Ignition Timing BTDC ➃ ➇ mm (in) 2.79 (.110) 2.77 (.109) 2.79 (.110)
mm 0.50 – 0.70 0.50 – 0.70 0.50 – 0.70
Trigger Coil Air Gap
(in) (.020 – .028) (.020 – .028) (.020 – .028)
Trigger Coil ➄ Ω 160 – 180 160 – 180 160 – 180
Generating Coil ➄ Ω 5.1 – 6.2 5.1 – 6.2 5.1 – 6.2
Lighting Coil ➄ Ω 0.17 – 0.21 0.17 – 0.21 0.17 – 0.21
Primary Ω N.A. N.A. N.A.
High Tension Coil ➄
Secondary kΩ 0.9 – 1.1 0.9 – 1.1 0.9 – 1.1
Carburetor Type PTO/MAG 2 x VM 30-200 VM 34-549/550 VM 34 547/548
Main Jet PTO/MAG 140/140 180/170 205/195
Needle Jet 159 P-0 159 P-0 159 P-0
Pilot Jet 40 40 35
Needle Identification — Clip Position 6DP9-3 6DH2-3 6DH2-3
Slide Cut-Away 2.5 2.5 2.5
Float Adjustment ± 1 mm 23.9 23.9 23.9

(± .040 in) (.94) (.94) (.94)
Air Screw Adjustment ± 1/16 Turn 1-1/4 1-7/8 1-1/2
Idle Speed RPM ± 200 RPM 1650 1650 1650
Gas Type/Pump Octane Number Unleaded/87 Unleaded/87 Unleaded/87
Gas/Oil Ratio Injection Injection Injection
Type Axial fan Axial fan Axial fan
Deflection mm (in) 9 – 10 (.35 – .39) 9 – 10 (.35 – .39) 9 – 10 (.35 – .39)
Axial Fan Belt Adjustment
Force ➅ kg (lbf) 5 (11) 5 (11) 5 (11)
Thermostat Opening Temperature °C (°F) N.A. N.A. N.A.
Radiator Cap Opening Pressure kPa (PSI) N.A. N.A. N.A.
Drive Pulley Retaining Screw ➆ ➆ ➆
Exhaust Manifold Nuts or Bolts 22 (16) 22 (16) 22 (16)
Magneto Ring Nut 105 (77) 105 (77) 105 (77)
ENGINE COLD
N•m (lb•ft)
Crankcase Nuts or Screws M6 10 (7) — 10 (7)

M8 22 (16) 22 (16) 22 (16)
Crankcase/Engine Support Nuts or Screws 40 (29) 40 (29) 40 (29)
Cylinder Head Nuts 22 (16) 22 (16) 22 (16)
Crankcase/Cylinder Nuts or Screws N.A. N.A. N.A.
Axial Fan Shaft Nut 48 (35) 48 (35) 48 (35)
MMR2001_036_10_02A.FM 10-02-1
VEHICLE MODEL SUMMIT FAN 500 SKANDIC LT
ENGINE TYPE 503 443

Number of Cylinders 2 2
Bore mm (in) 72.00 (2.835) 67.5 (2.6575)
Stroke mm (in) 61.00 (2.402) 61.0 (2.402)
Displacement cm3 (in3) 496.7 (30.31) 436.6 (26.64)
Compression Ratio (corrected) 6.4 6.4
Maximum Power Engine Speed ➀ ± 100 RPM 7000 6750
Piston Ring Type 1st/2nd ST/R ST/R
(new) mm (in) 0.25 (.010) 0.2 (.008)
Ring End Gap
(wear limit) mm (in) 1.0 (.039) 1.0 (.039)
Ring/Piston Groove Clearance (new) mm (in) 0.04 (.0016) 0.04 (.0016)

(wear limit) mm (in) 0.2 (.008) 0.2 (.0079)
(new) ± 0.016 mm (± .0006 in) 0.080 (.0031) 0.080 (.0031) ➈
(wear limit) mm (in) 0.2 (.008) 0.2 (.008)
Connecting Rod Big End Axial (new) mm (in) 0.2 (.0079) 0.2 (.0079)
Play (wear limit) mm (in) 1.0 (.0394) 1.0 (.0394)
Maximum Crankshaft End-Play ➁ mm (in) 0.3 (.0118) 0.3 (.012)
mm (in) 0.06 (.0024) 0.08 (.0031)
Measured at PTO
Magneto Generator Output W 240 240
Ignition Type CDI CDI
Spark Plug Make and Type NGK BR9ES NGK BR9ES
Spark Plug Gap ± 0.05 mm (± .002 in) 0.45 (.018) 0.45 (.018)
Ignition Timing BTDC ➃ ➇ mm (in) 2.77 (.109) 2.79 (.110)
mm 0.50 – 0.70 0.45 – 0.55
(in) (.020 – .028) (.018 – .022)
Trigger Coil ➄ Ω 160 – 180 160 – 180
Generating Coil ➄ Ω 5.1 – 6.2 5.1 – 6.2
Lighting Coil ➄ Ω 0.17 – 0.21 0.17 – 0.21
Primary Ω N.A. N.A.
Secondary kΩ 0.9 – 1.1 0.9 – 1.1
Carburetor Type PTO/MAG VM 34 -565/566 VM 32-19110
Main Jet PTO/MAG 200/190 195
Needle Jet 159 P-2 159 O-6
Pilot Jet 70 45
Needle Identification — Clip Position 6DH2-4 6DGH10
Slide Cut-Away 2.5 2.5
Float Adjustment ± 1 mm
(± .040 in) 23.9 (.94) 23.9 (.94)
Air Screw Adjustment ± 1/16 Turn 2-1/4 1-1/2

Idle Speed RPM ± 200 RPM 1650 1650
Gas Type/Pump Octane Number Unleaded/87 Unleaded/87
Gas/Oil Ratio Injection Injection
Type Axial fan Axial fan
Deflection mm (in) 9 – 10 (.35 – .39) 9 – 10 (.35 – .39)
Force ➅ kg (lbf) 5 (11) 5 (11)
Thermostat Opening Temperature °C (°F) N.A. N.A.
Radiator Cap Opening Pressure kPa (PSI) N.A. N.A.
Drive Pulley Retaining Screw ➆ ➉
Exhaust Manifold Nuts or Bolts 22 (16) 22 (16)
Magneto Ring Nut 105 (77) 105 (77)
ENGINE COLD
N•m (lb•ft)
Crankcase Nuts or Screws M6 — —

M8 22 (16) 22 (16)
Crankcase/Engine Support Nuts or Screws 40 (29) 40 (29)
Cylinder Head Nuts 22 (16) 22 (16)
Crankcase/Cylinder Nuts or Screws N.A. N.A.
Axial Fan Shaft Nut 48 (35) 48 (35)
10-02-2 MMR2001_036_10_02A.FM
VEHICLE MODEL SKANDIC WT

SKANDIC SWT SKANDIC WT LC
ENGINE TYPE 503 593

Bore mm (in) 72.0 (2.835) 76.00 (2.992)
Stroke mm (in) 61.0 (2.402) 65.8 (2.591)
Piston Ring Type 1st/2nd ST/R ST
(new) mm (in) 0.2 (.0079) 0.4 (.016)
Ring End Gap
(wear limit) mm (in) 1.0 (.039) 1.0 (.039)
Ring/Piston Groove Clearance (new) mm (in) 0.04 (.0016) 0.04 (.0016)

(wear limit) mm (in) 0.2 (.0079) 0.2 (.0079)
(new) ± 0.016 mm (± .0006 in) 0.9 (.0035) 0.12 (.0047)
(wear limit) mm (in) 0.2 (.0079) 0.2 (.0079)
Connecting Rod Big End Axial (new) mm (in) 0.2 (.0079) 0.39 (.0154)
Play (wear limit) mm (in) 1.0 (.0394) 1.2 (.0472)
Maximum Crankshaft End-Play ➁ mm (in) 0.3 (.012) 0.3 (.012)
mm (in) 0.06 (.0024) 0.08 (.0031)
Measured at PTO
Ignition Timing BTDC ➃ ➇ mm (in) 1.66 (.065) 3.00 (.118)
mm 0.45 – 0.55 0.55 – 1.45
(in) (.018 – .021) (.022 – .057)
Trigger Coil ➄ Ω 140 – 180 190 – 300
Generating Coil ➄ Ω 230 – 330 11.6 – 21.6
Lighting Coil ➄ Ω 0.23 – 0.28 0.10 – 0.40
Primary Ω N.A. 0.0 – 0.9
Secondary kΩ 5.1 – 6.3 9.5 – 16.5
Carburetor Type PTO/MAG 2 x VM 34-19084 VM 38-19111/19112
Main Jet PTO/MAG 185 330/310
Needle Jet 159 P-1 480 Q-4
Pilot Jet 40 40
Needle Identification — Clip Position 6DH2-3 6FL14-4
Float Adjustment ± 1 mm
(± .040 in) 23.9 (.937) 18.1 (.710)
Air Screw Adjustment ± 1/16 Turn 1-1/4 1-1/2

Idle Speed RPM ± 200 RPM 1650 1900
Type Axial fan Liquid
Deflection mm (in) 9 – 10 (.35 – .39) N.A.
Force ➅ kg (lbf) 5 (11) N.A.
Thermostat Opening Temperature °C (°F) N.A. 42 (108)
Radiator Cap Opening Pressure kPa (PSI) N.A. 100 (14.5)
Drive Pulley Retaining Screw ➆ ➆
ENGINE COLD
N•m (lb•ft)
M6 — 9 (6.5)
Crankcase Nuts or Screws M8 29 (21)
22 (16)
Cylinder Head Nuts 22 (16) 29 (21)
Crankcase/Cylinder Nuts or Screws N.A. 29 (21)
Axial Fan Shaft Nut 48 (35) N.A.
MMR2001_036_10_02A.FM 10-02-3
Subsection 03 (VEHICLES)
VEHICLE MODEL TOURING FAN 380 TOURING FAN 500

TOURING CARGO 380 TOURING CARGO 500 FORMULA DELUXE FAN 380

Chain Drive Ratio 18/44 21/44 18/44
Pitch in 3/8 3/8 3/8
Chain
Type/Links Qty/Plates Qty Silent/70/11 Silent/72/11 Silent/70/11
Type of Drive Pulley Bombardier Lite TRA Bombardier Lite
Ramp Identification N.A. 292X ➄ N.A.
1181 1181
Calibration Screw Position or Calibration Part ➀ 3
Drive Pulley 1 x C, 1 x S21 1 x C, 1 x S21
Spring Color Green/Green Red/Red Red/Blue
Spring Length ± 1.5 mm (± .060 in) 72.0 (2.83) 97.2 (3.83) 96 (3.78)
Clutch Engagement ± 200 RPM 2500 2900 3500
Type of Driven Pulley LPV27 LPV27 LPV27
Driven Pulley Spring Preload ± 0.7 kg (± 1.5 lb) N.A. N.A. N.A.
Cam Angle degree 47 – 44 47 – 44 47 – 44
(+ 0, - 1) mm 26.0 ± 0.5 17.0 ± 0.5 26.0 ± 0.5
Pulley Distance Z
((+ 0, - 1/32) in) (1.024 ± .020) (.669 ± .020) (1.024 ± .020)
mm 33.4 ± 0.5 35.5 ± 0.5 33.4 ± 0.5
X (1.315 ± .020) (1.398 ± .020) (1.315 ± .020)
(in)
Offset
MIN. + 1 (+ .039) + 1 (+ .039) 1.0 – 2.0
Y–X
MAX. + 2 (+ .079) + 2 (+ .079) (.039 – .079)
Drive Belt Part Number (P/N) 415 060 600 415 060 600 415 060 600
Drive Belt Width (new) ➁ mm (in) 34.7 (1-3/8) 34.7 (1-3/8) 34.7 (1-3/8)
± 5 mm 32 32 32
Deflection
Drive Belt Adjustment (± 13/64 in) (1-1/4) (1-1/4) (1-1/4)
Force ➂ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width cm (in) 38.1 (15) 38.1 (15) 38.1 (15)
Length cm (in) 345 (136) 345 (136) 307 (121)
Profile Height mm (in) 18.4 (.724) 18.4 (.724) 18.4 (.724)
Track
Deflection mm 35 – 40 35 – 40 35 – 40
Adjustment (in) (1-3/8 – 1-9/16) (1-3/8 – 1-9/16) (1-3/8 – 1-9/16)
Force ➃ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Track SC-10 Touring SC-10 Touring SC-10 Sport
Suspension Type
Ski DSA DSA DSA
Length cm (in) 294 (115.7) 294 (115.7) 272.5 (107.3)
Width cm (in) 120.7 (47.5) 120.7 (47.5) 120.7 (47.5)
Height cm (in) 122 (48.0) 122 (48.0) 116.9 (46.0)
Ski Stance cm (in) 106.7 (42) 106.7 (42) 106.7 (42)
Toe-out and mm (in) 0 (0) 0 (0) 0 (0)
Camber degree 0 0 0
T. FAN 205 (452) T. FAN 224 (493)
Mass (dry) kg (lb) 202 (445)
T. CARGO 208 (458) T. CARGO 227 (499)
Ground Contact Area cm2 (in2) 7227 (1120) 7227 (1120) 6503 (1008)
Ground Contact Pressure kPa (PSI) T. FAN 2.84 (.412) T. FAN 3.04 (.441)
T. CARGO 2.82 (.409) T. CARGO 3.08 (.447) 3.05 (.442)
Frame Material Aluminum Aluminum Aluminum

Bottom Pan Material Impact copolymer Impact copolymer Impact copolymer
Hood Material RRIM polyurethane RRIM polyurethane RRIM polyurethane
Battery V (A•h) 12 (20) 12 (20) 12 (20)
Headlight W H4 60/55 H4 60/55 H4 60/55
Taillight and Stoplight W 8/27 8/27 8/27
Tachometer and Speedometer Bulb W 3 3 3
Fuel and Temperature Gauge Bulb W N.A. N.A. N.A.
Starter Solenoid A 30 30 30
Fuse
Tachometer A N.A. N.A. N.A.
Fuel Tank L (U.S. gal) 38 (10) 38 (10) 38 (10)
Chaincase Gearbox mL (U.S.oz) 250 (8.5) 250 (8.5) 250 (8.5)
Cooling System ➆ L (U.S. oz) N.A. N.A. N.A.
Injection Oil Reservoir L (U.S. oz) 2.55 (86) 2.55 (86) 2.55 (86)
MMR2001_036_10_03A.FM 10-03-1
VEHICLE MODEL FORMULA DELUXE FAN 500 MX Z FAN 440 MX Z FAN 380

Pitch in 3/8 3/8 3/8
Chain
Type/Links Qty/Plates Qty Silent 72/11 Silent 72/11 Silent 70/11
Type of Drive Pulley TRA TRA Bombardier Lite
Ramp Identification 291X ➄ 287 ➄ N.A.
1181
Calibration Screw Position or Calibration Part ➀ 3 3 1 x C, 1 x S21
Drive Pulley
Spring Color Yellow/Red Green/Violet Red/Blue
Spring Length ± 1.5 mm (± .060 in) 121 (4.77) 133.7 (5.26) 96 (3.78)
Cam Angle degree 47 – 44 47 – 44 47 – 44
(+ 0, - 1) mm 17.0 ± 0.5 16.5 ± 0.5 26.0 ± 0.5
Pulley Distance Z
((+ 0, - 1/32) in) (.669 ± .020) (.650 ± .020) (1.024 ± .020)
mm 35.5 ± 0.5 33.4
X 35.5 (1.398)
(in) (1.315 ± .020) (1.315)
Offset
MIN. 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
Y–X
MAX. (.039 – .079) (.039 – .079) (.039 – .079)
Drive Belt Width (new) ➁ mm (in) 34.7 (1-3/8) 34.7 (1.366) 34.7 (1.366)
± 5 mm 32 32 32
Deflection
Force ➂ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width cm (in) 38.1 (15) 38.1 (15.0) 38.1 (15.0)
Length cm (in) 307 (121) 307 (121) 307 (121)
Track
Deflection mm 35 – 40 35 – 40 35 – 40
Adjustment (in) (1-3/8 – 1-9/16) (1-3/8 – 1-3/4) (1-3/8 – 1-3/4)
Force ➃ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Track SC-10 Touring SC-10 Sport SC-10 Sport
Suspension Type
Ski DSA DSA DSA
Length cm (in) 272.5 (107.3) 272.5 (107.3) 272.5 (107.3)
Width cm (in) 120.7 (47.5) 120.7 (47.5) 120.7 (47.5)
Height cm (in) 116.9 (46.0) 116.9 (46.0) 116.9 (46.0)
Ski Stance cm (in) 106.7 (42) 106.7 (42) 106.7 (42)
Toe-out and mm (in) 0 (0) 0 (0) 0 (0)
Camber degree 0 0 0
Mass (dry) kg (lb) 211 (465) 201 (442) 193 (425)
Ground Contact Area cm2 (in2) 6503 (1008) 6503 (1008) 6503 (1008)
Ground Contact Pressure kPa (PSI) 3.18 (.461) 3.03 (.439) 2.91 (.422)
Bottom Pan Material Impact copolymer Impact copolymer Impact copolymer
Hood Material RRIM polyurethane RRIM polyurethane RRIM polyurethane
Battery V (A•h) 12 (20) N.A. N.A.
Headlight W H4 60/55 H4 60/55 H4 60/55
Starter Solenoid A 30 N.A. N.A.
Fuse
Fuel Tank L (U.S. gal) 38 (10) 38 (10) 38 (10)
Injection Oil Reservoir L (U.S. oz) 2.55 (86) 2.55 (86) 2.55 (86)
10-03-2 MMR2001_036_10_03A.FM
VEHICLE MODEL MX Z FAN 500 SUMMIT FAN 500 SKANDIC LT

Pitch in 3/8 3/8 3/8
Chain
Type of Drive Pulley TRA TRA Comet
Ramp Identification 287 ➄ 227 ➄ –
Calibration Screw Position or Calibration Part ➀ 3 3 –
Drive Pulley
Spring Color Green/Blue Green/Violet Silver/Black
Spring Length ± 1.5 mm (± .060 in) 147.4 (5.80) 133.7 (5.26)
Cam Angle degree 47 – 44 47 – 44 40
(+ 0, - 1) mm 16.5 ± 0.5 17.0 ± 0.5 34.2 ± 0.75
Pulley Distance Z
((+ 0, - 1/32) in) (.650 ± .020) (.669 ± .020) (1.346 ± .030)
mm
X 35.5 (1.398) 35.5 (1.398) 35.0 (1.380)
(in)
Offset
MIN. 1.0 – 2.0 1.0 – 2.0 0.75 – 2.25
Y–X (.039 – .079) (.039 – .079) (.030 – .086)
MAX.
Drive Belt Width (new) ➁ mm (in) 34.7 (1.366) 35.1 (1.382) 34.6 (1-3/8)
± 5 mm 32 38 32
Deflection
Force ➂ kg (lbf) 11.3 (25) 11.5 (25) 11.3 (25)
Width cm (in) 38.1 (15.0) 38.1 (15.0) 38.1 (15.0)
Length cm (in) 307 (121) 345.5 (136) 396.8 (156.2)
Profile Height mm (in) 18.4 (.724) 38.1 (1.5) 25 (1)
Track
Deflection mm 30 – 35 35 – 40 40 – 50
Adjustment (in) (1-3/16 – 1-3/8) (1-3/8 – 1-3/4) (1-9/16 – 1-31/32)
Force ➃ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Track SC-10 Sport SC-10 Mountain Skandic WT
Suspension Type
Ski DSA DSA Telescopic strut
Length cm (in) 272.5 (107.3) 293.9 (115.7) 302.0 (118.9)
Width cm (in) 120.0 (47.2) 120.7 (47.5) 96.0 (37.8)
Height cm (in) 116.9 (46.0) 122.0 (48) 129.5 (51)
Ski Stance cm (in) 106.7 (42) 106.7 (42) 82 (32.3)
Toe-out and mm (in) 0 (0) 0 (0) 5 (3/16)
Camber degree 0 0 -2
Mass (dry) kg (lb) 202 (445) 205 (450) 212 (467)
Ground Contact Area cm2 (in2) 6503 (1008) 7227.2 (1120.2) 8811.3 (1365.8)
Frame Material Aluminum Aluminum Steel
Bottom Pan Material Impact copolymer Impact copolymer HD polyethylene
Hood Material RRIM polyurethane RRIM polyurethane RRIM
Battery V (A•h) N.A. N.A. N.A.
Headlight W H4 60/55 H4 60/55 H4 60/55
Starter Solenoid A N.A. N.A. N.A.
Fuse
Fuel Tank L (U.S. gal) 38 (10) 38 (10) 37 (9.8)
Injection Oil Reservoir L (U.S. oz) 2.55 (86) 2.55 (86) 2.5 (84.5)
MMR2001_036_10_03A.FM 10-03-3
VEHICLE MODEL SKANDIC WT SKANDIC SWT SKANDIC WT LC

Chain Drive Ratio N.A. N.A. N.A.
Pitch in N.A. N.A. N.A.
Chain
Type/Links Qty/Plates Qty N.A. N.A. N.A.
Type of Drive Pulley TRA TRA TRA
Ramp Identification 290 ➄ 290 ➄ 290 ➅
Calibration Screw Position or Calibration Part ➀ 4 2 4
Drive Pulley
Spring Color Yellow/Orange Yellow/Orange Red/Red
Spring Length ± 1.5 mm (± .060 in) 105.7 (4.16) 105.7 (4.16) 96.3 (3.79)
Type of Driven Pulley Cam Cam Cam
Driven Pulley Spring Preload ± 0.7 kg (± 1.5 lb) 7.0 (15.4) 7.0 (15.4) 7 (15.4)
Cam Angle degree 40 40 40
(+ 0, - 1) mm 32.3 ± 0.75 32.3 ± 0.75 ± 0.75
Pulley Distance Z
((+ 0, - 1/32) in) (1.346 ± .030) (1.346 ± .030) (1.346 ± .030)
mm
X 35.0 (1.380) 35.0 (1.380) 35.0 (1.380)
(in)
Offset
MIN. 0.75 – 2.25 0.75 – 2.25 0.75 – 2.25
Y–X
MAX. (.030 – .086) (.030 – .086) (.030 – .086)
Drive Belt Width (new) ➁ mm (in) 34.6 (1-3/8) 34.6 (1-3/8) 34.6 (1-3/8)
± 5 mm 32 32 32
Deflection
Force ➂ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width cm (in) 50.0 (19.7) 60.0 (23.6) 50.0 (19.7)
Length cm (in) 396.8 (156.2) 396.8 (156.2) 396.8 (156.2)
Track Profile Height mm (in) 23.5 (.925) 23.5 (.925) 31.8 (1.250)
mm 40 – 50 40 – 50 40 – 50
Deflection
Adjustment (in) (1-9/16 – 1-31/32) (1-9/16 – 1-31/32) (1-9/16 – 1-31/32)
Force ➃ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Track Skandic WT Skandic WT Skandic WT
Suspension Type
Ski Telescopic strut Telescopic strut Telescopic strut
Length cm (in) 302.0 (118.9) 315.0 (124.0) 315.0 (124.0)
Width cm (in) 104.5 (41.1) 110.0 (43.3) 110.0 (43.3)
Height cm (in) 122 (48) 133 (52.4) 122 (48)
Ski Stance cm (in) 90.0 (35.4) 90.0 (35.4) 90.0 (35.4)
Toe-out and mm (in) 5 (3/16) 5 (3/16) 5 (3/16)
Camber degree -2 -2 -2
Mass (dry) kg (lb) 260 (573) 277 (611) 281 (620)
Ground Contact Area cm2 (in2) 10793 (1672.9) 13986 (2167.8) 12335 (1912)
Frame Material Steel Steel Steel
Bottom Pan Material HD polyethylene HD polyethylene HD polyethylene
Hood Material RRIM RRIM RRIM
Battery V (A•h) 12 (20) 12 (20) 12 (20)
Headlight W H4 60/55 H4 60/55 H4 60/55
Starter Solenoid A 15 15 15
Fuse
Fuel Tank L (U.S. gal) 42 (11.1) 42 (11.1) 42 (11.1)
Cooling System ➆ L (U.S. oz) N.A. N.A. 4.5 (152)
Injection Oil Reservoir L (U.S. oz) 2.5 (84.5) 2.5 (84.5) 2.5 (84.5)
10-03-4 MMR2001_036_10_03A.FM
Subsection 04 (TECHNICAL DATA LEGENDS)
ENGINE TECHNICAL DATA VEHICLE TECHNICAL DATA

LEGEND LEGEND
BTDC: Before Top Dead Center DSA: Direct Shock Action
CDI: Capacitor Discharge Ignition RRIM: Reinforced Reaction Injection Molding
K: Kilo (x 1000) TRA: Total Range Adjustable drive pulley
MAG: Magneto Side N.A.: Not Applicable
N.A.: Not Applicable
PTO: Power Take Off Side ➀ For Bombardier Lite drive pulleys:
R: Rectangular 1157 = Red block, push type 38 g
(P/N 417 115 700).
ST: Semi-Trapezoidal 1181 = Black block, screw type 39.6 g
(P/N 417 118 100).
➀ The maximum horsepower RPM is applicable 1143 = Red block, screw type 41.8 g
on the vehicle. It may be different under certain (P/N 417 114 300).
circumstances and BOMBARDIER INC. re- W = Washer 1.8 g (P/N 417 115 800).
serves the right to modify it without obligation. C = Cap 1.65 g (P/N 417 114 500).
➁ Crankshaft end-play is not adjustable on these S3.4 = Weight, screw type 3.4 g
models except Tundra R. Specification is given (P/N 417 114 400).
for verification purposes only. S21 = Weight, screw type 21 g
(P/N 417 120 400).
➂ Rotary valve to crankcase clearance: 0.27 – 0.48
mm (.011 – .019 in). ➁ Minimum allowable width may not be less than
3.0 mm (1/8 in) of a new drive belt.
➃ For all non-RER models timing is verified at
6000 RPM (engine cold) with headlamp turned ➂ Force applied midway between pulleys to ob-
on. tain specified deflection.
➄ All resistance measurements must be performed ➃ Force or downward pull applied to track to ob-
with parts at room temperature (approx. 20°C tain specified tension deflection.
(68°F)). Temperature greatly affects resistance ➄ Lever with roller pin (P/N 417 004 309) (hollow).
measurements. ➅ Lever with roller pin (P/N 417 004 308) (solid).
➅ Force applied midway between pulleys to ob- ➆ Ethylene-glycol antifreeze for aluminum en-
tain specified deflection. gines mixed with distilled water (3 parts of an-
➆ Drive pulley retaining screw: torque to 90 to 100 tifreeze for 2 parts of distilled water). Bombar-
N•m (66 to 74 lbf•ft), install drive belt, acceler- dier pre-mixed coolant - 52°C (- 62°F) (16 x 1 L)
ate the vehicle at low speed (maximum 30 km/h (P/N 413 711 802).
(20 MPH)) and apply the brake; repeat 5 times.
lbf•ft).
➇ For all RER models timing is verified at 3500
RPM (engine cold) with headlamp turned on.
➈ Piston/cylinder clearance with new parts on
Skandic LT is 0.080 ± 0.0067 mm (.0031 ±
.00026 in).
➉ Tightening torques for Skandic LT Comet drive
pulley.
Retaining screw: 60 to 68 N•m (44 to 50 lbf•ft).
Spider: 170 N•m (125 lbf•ft).
Cover screws: 12.5 N•m (110 lbf•in).
Pivot bolts and nuts: 5.6 N•m (50 lbf•in).
MMR2001_036_10_04A.FM 10-04-1
Section 11 WIRING DIAGRAMS
Subsection 01 (WIRING DIAGRAMS)
WIRING DIAGRAMS 0
ELECTRICAL
WIRING
HEADLIGHT TAILLIGHT SYSTEM
MODEL DIAGRAM
(WATT) (WATT) OUTPUT
PAGE
(WATT)
S-Series Annex 1 60 /55 hal. 8/27 240
Skandic LT Annex 2 60 /55 hal. 8/27 240
Skandic WT/SWT Annex 3 60 /55 hal. 8/27 240
Skandic WT LC Annex 4 60 /55 hal. 8/27 220
hal. = halogen
WIRING DIAGRAM LEGEND WIRE COLORS AND CIRCUIT

 WARNING
the wires and all connector housings are prop-
XX/XX
erly fastened. XX/XX
1- MC
A00I04F D
XX/XX
1 - MC The first color of a wire is the main color, second
D color is the stripe.
Example: YL/BK is a YELLOW wire with a BLACK
1 2 34 stripe.
A00I04E
1. Wire colors COLOR CODE

2. Housing area
3. Housing number per area BE – BEIGE OR – ORANGE
4. Wire connector location in housing
BK – BLACK RD – RED
BL – BLUE VI – VIOLET
BR – BROWN WH – WHITE
GN – GREEN YL – YELLOW
GY – GREY
MMR2001_037_11_01A.FM 11-01-1
Following table shows wire colors related to electrical circuits.

WIRE COLOR ELECTRICAL CIRCUIT ADDITIONAL INFORMATION
ENGINE SHUT OFF
– key switch
BLACK/YELLOW Must be grounded to stop engine.
– tether cord switch
– emergency switch
Ground for shut off, RER pilot lamp,
BLACK (small)
beeper and beeper switch
BLACK (big) Ground for starter (–)
BEIGE RER switch Must be grounded to activate RER.
BEIGE/BLACK Reverse alarm and pilot lamp Current returns by BLACK wire.
YELLOW
YELLOW/BLACK
If shorted, magneto stops producing
(S-Series) 12 volts (AC)
electricity.
YELLOW/GREEN
(Skandic Series)
12 volts (DC) (+)
RED
For starter motor
12 volts (DC) (+)
RED/GREEN
For starter solenoid
12 volts (DC) (+)
RED/BLUE
Rectifier output
12 volts (AC)
GREY
High beam Current returns by YELLOW/BLACK wire
12 volts (AC) connected to headlamp.
VIOLET/GREY
Low beam
12 volts (AC) Current returns by YELLOW/BLACK wire
WHITE
Brake light connected to taillight.
12 volts (AC) Current returns by YELLOW/BLACK wire
WHITE/RED
Low oil level connected to oil level sensor.
12 volts (AC) Current returns by YELLOW wire connected
BLUE
Fuel level indicator to fuel level sensor.
12 volts (AC)
ORANGE
Heated grips (max.)
12 volts (AC)
ORANGE/VIOLET
Heated grips (min.) Current returns by YELLOW/BLACK wire
12 volts (AC) connected to heating elements.
BROWN
Heated throttle lever (max.)
12 volts (AC)
BROWN/YELLOW
Heated throttle lever (min.)
12 volts (AC)
GREEN
Temperature gauge Current returns by YELLOW wire connected
12 volts (AC) to sensor.
VIOLET
Engine overheating light
11-01-2 MMR2001_037_11_01A.FM
CONNECTOR HOUSING AREA
XX/XX
1 - MC
A00I04G
1 D
7
6
11 3
9 8 4 2 1
5 10
A06H33C
AREA LOCATION
1 Front of engine compartment
2 Magneto
3 Carburetors
4 Near of intake silencer
5 Near driven pulley
6 Under console
7 Under hood
8 Near fuel tank
9 Rear of seat
10 Under engine
11 On injection oil reservoir
CONNECTOR LOCATION IN
HOUSING
XX/XX
1- MC
D
A00I04H
D
MMR2001_037_11_01A.FM 11-01-3
DEUTSCH
85
A A A 2 87
1
87a
B B B 1 86 30 2
2
1
A A
A A
A
B B
C C B B
B
C
A
B
C C A 3
A 1
B 21
A C B 2
A C 3
B B
A B A B
C B
D A C
C B D A C A
B
A B
A B
D C A
B A B 4
C D 1
2
3
1
4 2
3
PACKARD
A A
B B
C
6
5
1 4 1
2 2
3 6 3
5
4
A
A
B B
A C
B A
C 12
D CB 11
ED
1 10 1
2
F 2
3 12
9
8 3
4 11 7 4
5 10 5
6 9 6
8
A 7
A
B CB
D
V01G0EU D
C FE
11-01-4 MMR2001_037_11_01A.FM
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

ground ground
Frame
Bulb Pilot Analog sensor Solenoid valve
Magneto (Delta) 3 position switch Heating element Fuse
Trigger coil Battery Diode Partially illustrated

component
A00E55S
MMR2001_037_11_01A.FM 11-01-5
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.
A06E1PA
A00E1EA
TYPICAL
Step 1 : Insert screwdriver here

TAB AND RECEPTACLE Step 2 : Pull this side
CONNECTORS REMOVAL
Locking Receptacle Connector
Tab Connector To remove:
It is locked in its housing by a spring tab on its side. – Insert tool Snap-on TT 600-5 in access opening
Removal is done by squeezing this tab. then pull housing toward wire side.
A00E1DA
TAB CONNECTOR
1. Locking tab
A06E1QA
11-01-6 MMR2001_037_11_01A.FM
Waterproof Connector Housing

Female Connector Housing
To remove:
– Insert tool Snap-on TT 600-5 under lock and twist
to lift it.
A01E34A 1
1. Lock
– Pry tab to free connector then pull wire out of

housing.
A01E31A
A01E35A
housing. MALE CONNECTOR HOUSING — CUT-AWAY
TAB AND RECEPTACLE

CONNECTORS INSTALLATION
Prior to installing, make sure locking tab is suffi-
ciently lifted to properly lock.
A01E32A Insert tab and receptacle connectors in their re-
FEMALE CONNECTOR HOUSING — CUT-AWAY
spective housings as shown in following illustra-
tions. Push sufficiently so that they snap. Try pull-
Male Connector Housing ing wire to ensure they are properly locked.
To remove:
– Using a small hook, pull out the lock.
A00E1GA
2
1. Tab
2. Housing
A01E33A 1
1. Lock
MMR2001_037_11_01A.FM 11-01-7
2
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) consumers
(lights, heated grips, fuel gauge, etc.) utilize a sep-
arate ground wire.
Never interconnect AC and DC grounds as an AC
voltage drop will result. When installing accesso-
ries on any snowmobile, connect their wires di-
rectly to the YELLOW and YELLOW/BLACK light-
ing coil wires.
Even if manual start models have an AC ground
to the chassis (on voltage regulator), all accesso-
ries utilize a ground wire isolated from chassis.
When an electric starter kit is installed, the voltage
regulator and its ground wire are replaced by a
voltage rectifier/regulator unit permitting a com-
pletely isolated AC circuit.
 WARNING
Never secure electrical wires/cables with fuel
lines. Keep wires away from any rotating,
moving, heating, vibrating or sharp edge.
Use proper fastening devices as required.
11-01-8 MMR2001_037_11_01A.FM
S-SERIES
ANNEX 1
MMR2001_037_11_00A.FM
SKANDIC LT
ANNEX 2
MMR2001_037_11_00A.FM
2001 SKANDIC LT
BK/YL
YL
YL
YL
YL YL
BL/BK YL YL
BL/BK BK/YL BK/YL

GR/BL
GR/BK
YL YL YL
YL YL RD/BL
BK/YL BK/YL RD/BL
HEATED GRIPS
AND
LEVER SWITCH
1
TETHER EMERGENCY
REVERSE CUT-OUT KILL DIMMER BRAKE OIL LEVEL
KEY SWITCH SWITCH SWITCH
SWITCH SWITCH SWITCH SWITCH
OFF TACHO OR OR/GN
REGULATOR/
RECTIFIER ON METER FUEL LEVEL
MPEM 30A METER
START
L H BL
RD WH BR BR
WH/GR
GR PARKING
RD/GN BRAKE FUSE .25A
HEATED HEATED
GRIPS LEVER
TAIL
HEADLIGHT LIGHT
SOLENOID BK SPEEDO
METER
POWER BK BK
OUT REVERSE HIGH
BK YL/GN BK STARTER M OIL LEVEL
CONNECTOR BK BK LIGHT AND BEAM INDICATOR SENSOR
ALARM INDICATOR
YL/GN
BK BK
YL/GN YL/GN
YL/GN YL/GN YL/GN YL/GN YL/GN
YL/GN
YL/GN YL/GN
A29Z03
2001 SKANDIC LT
BK/YL
YL
YL
YL
YL YL
BL/BK YL YL
BL/BK BK/YL BK/YL

GR/BL
GR/BK
YL YL YL
YL YL RD/BL
BK/YL BK/YL RD/BL
HEATED GRIPS
AND
LEVER SWITCH
1
TETHER EMERGENCY
OFF TACHO OR OR/GN
REGULATOR/
MPEM 30A METER
START
L H BL
RD WH BR BR
WH/GR
GR PARKING
HEATED HEATED
GRIPS LEVER
TAIL
HEADLIGHT LIGHT
SOLENOID BK SPEEDO
METER
POWER BK BK
OUT REVERSE HIGH
ALARM INDICATOR
YL/GN
BK BK
YL/GN YL/GN
YL/GN
YL/GN YL/GN
A29Z03
2001 SKANDIC LT
BK/YL
YL
YL
YL
YL YL
BL/BK YL YL
BL/BK BK/YL BK/YL

GR/BL
GR/BK
YL YL YL
YL YL RD/BL
BK/YL BK/YL RD/BL
HEATED GRIPS
AND
LEVER SWITCH
1
TETHER EMERGENCY
OFF TACHO OR OR/GN
REGULATOR/
MPEM 30A METER
START
L H BL
RD WH BR BR
WH/GR
GR PARKING
HEATED HEATED
GRIPS LEVER
TAIL
HEADLIGHT LIGHT
SOLENOID BK SPEEDO
METER
POWER BK BK
OUT REVERSE HIGH
ALARM INDICATOR
YL/GN
BK BK
YL/GN YL/GN
YL/GN
YL/GN YL/GN
A29Z03
SKANDIC WT/SWT
ANNEX 3
MMR2001_037_11_00A.FM
2001 SKANDIC WT/ SWT
STOP
SWITCH
RD/GN
HEATED
START
RD
STOP
GRIP
RUN
FUSE SWITCH
20 A BK
STARTER RD/GN IGNITION
RD SWITCH
BK/YL BK
BK
RD/GN
RD/BL
RD
BATTERY
BACK-UP
ALARM
YL/GN
BK/YL BK
YL AC
BK/YL
YL
YL
BK/YL
GENERATING
YL
BK
BK
RD/WH RD/WH COIL
YL
BK/YL
GN GN YL
WH WH YL/BK YL BACK-UP
BK ALARM
YL
SWITCH
PLUGS
SPARK
YL/GN
IGNITION COIL
COIL SUPPLY
BK
HEATED
BK THROTTLE
BK/YL
YL/GN
LEVER
BK/YL
BK
BK
YL/GN
YL/GN
YL
YL
YL
RD/BL
REGULATOR
RECTIFIER GN BK BK
RD BK
YL/GN BK HEATED
BK BK GRIPS
BK
YL EMERGENCY
YL CUT-OUT
YL SWITCH
1 YL
TAILLIGHT YL/GN
YL
YL
2 YL/GN WH/GY
GY
WH GY
3
YL
YL RD/YL
RESISTOR
GY/VI
30 OHM
WH/RD WH/RD WH WH LIGHT
BR SWITCH
WH
WH/GY
YL
BR
GY
YL
BL
YL/GN
YL/GN
BRAKE
LIGHT
BL
YL/BK SWITCH
OIL LEVEL
SENSOR FUSE BL BR
FUEL LEVEL
SENSOR 0,25 A
YL/GN
BL
YL/GN
GY
GY
RD/YL
YL/BK
YL
WH/GY
YL
BL
RD/YL
YL/GN
HIGH BEAM
INDICATOR
YL/BK
HEADLAMP
BR
FUEL LEVEL SPEEDOMETER
GAUGE
OIL LEVEL
INDICATOR
A29Z04
MMR2001_037_11_00A.FM
SKANDIC WT LC
ANNEX 4
MMR2001_037_11_00A.FM
2001 SKANDIC WT LC
DESS
RD
BK HEATED
START
STOP
GRIP
RUN
BATTERY FUSE RD/GN ROM
20 A SWITCH
RD RD
STARTER
IGNITION
SWITCH BK/GN BK/GN
BK/YL BK/WH
BK
RD/GN
RD/BL
WH/GY
RD
BACK-UP
ALARM
YL/GN
WH/YL WH/GY
WH/OR
BK/WH
WH/YL
BK/GY
BK/YL
BL/YL
BL/YL
BK/WH YL AC
YL
YL
YL
YL BK/YL
BK
BK WH/BL YL
BK/YL
MPEM YL
BK BK
YL BACK-UP
YL ALARM
BK BK SWITCH
BK/GN
YL/GN
BK
VI HEATED
THROTTLE
YL/GN
BK/YL
BK
BK
YL/GN LEVER
TEMPERATURE YL/GN
SENSOR
YL
YL
YL
RD/BL
REGULATOR GN BK
RECTIFIER BK
RD BK HEATED
YL/GN BK
BK BK GRIPS
BK
YL EMERGENCY
YL CUT-OUT
YL SWITCH
1 YL
TAILLIGHT YL/GN WH/GY
YL
YL
2 YL/GN
WH GY GY
3
YL
RD/YL
RESISTOR
GY/VI
30 OHM WH
WH/RD WH/RD WH WH LIGHT
BR SWITCH
YL
BRAKE
YL/GN
LIGHT
YL SWITCH
YL/BK
YL
OIL LEVEL
SENSOR BL BL
FUEL LEVEL FUSE
SENSOR 0,25 A
YL/GN
YL
VI
BL
YL/GN
GY
WH/OR
BK
RD/YL
YL/BK
WH/GY
YL/GN
YL/GN
YL
BL
GY
RD/YL
ENGINE
DESS HIGH BEAM OVERHEATING
INDICATOR INDICATOR INDICATOR
YL/BK
BR
FUEL LEVEL SPEEDOMETER
A29Z05 GAUGE
HEADLAMP
OIL LEVEL
INDICATOR
MMR2001_037_11_00A.FM
2001
Shop Manual
VOLUME 2
GRAND TOURING SE
MACH Z STD/TECH PLUS

Legal deposit:
4th trimester 2000
Bombardier Inc.
Printed in Canada

TABLE OF CONTENTS
WHAT’S NEW ....................................................................................................................................... IV
INTRODUCTION .................................................................................................................................. V

02 LUBRICATION 01 – Periodic maintenance chart ...................................................... 02-01-1

AND MAINTENANCE

02 – Engine ...................................................................................... 03-02-1

02 – 809 engine type........................................................................ 04-02-1
04 – CDI system............................................................................... 04-04-1
07 – Rewind starter.......................................................................... 04-07-1

02 – Drive belt .................................................................................. 05-02-1
03 – Drive pulley............................................................................... 05-03-1
04 – Driven pulley............................................................................. 05-04-1
06 – Brake ........................................................................................ 05-06-1
07 – Chaincase ................................................................................. 05-07-1
08 – Drive chain................................................................................ 05-08-1

02 – Ignition timing........................................................................... 06-02-1
03 – Spark plugs............................................................................... 06-03-1
04 – Battery...................................................................................... 06-04-1
07 REAR SUSPENSION 01 – Table of contents...................................................................... 07-01-1

02 – SC-10 II suspension.................................................................. 07-02-1
03 – Drive axle.................................................................................. 07-03-1
04 – Track......................................................................................... 07-04-1
MMR2001_039_00_02A.FM I
TABLE OF CONTENTS


02 – Body......................................................................................... 09-02-1
03 – Frame....................................................................................... 09-03-1

02 – Engines .................................................................................... 10-02-1
03 – Vehicles.................................................................................... 10-03-1
II MMR2001_039_00_02A.FM
SAFETY NOTICE
SAFETY NOTICE 0
This edition was primarily published to be used by snowmobile mechanical technicians who are already
familiar with all service procedures relating to Bombardier made snowmobiles. Mechanical technicians
should attend continuous training courses given by Bombardier Training Dept.
Catalog.
The content depicts parts and/or procedures applicable to the particular product at time of writing Service
understand these.
of the parts.
 WARNING
nents.
MMR2001_039_00_02A.FM III
WHAT’S NEW
WHAT’S NEW 0
INTRODUCTION
• Procedure to change self-locking fasteners.
CARBURETOR AND FUEL PUMP

• Procedure to check DPM manifold for leaks.
• New pilot screw adjustment on GT SE.
STEERING SYSTEM
• Ski alignment specifications.
IV MMR2001_039_00_02A.FM
INTRODUCTION
INTRODUCTION 0
This Shop Manual Volume 2 covers the following Grand Touring SE and Mach Z STD/TECH PLUS
Bombardier made 2001 snowmobiles: These are CK3 Series models.
MODEL
MODELS
NUMBER
MACH* Z STD (BLACK)
(Canada).................................................1656
MACH* Z STD (BLACK)
(U.S.) ......................................................1657
MACH* Z STD (YELLOW)
(Canada).................................................1658
MACH* Z STD (YELLOW) A30A0PA
(U.S.) ......................................................1659
TYPICAL — CK3 SERIES
MACH* Z STD (YELLOW)
(Europe) .................................................1660 VEHICLE IDENTIFICATION
MACH* Z TECH PLUS (YELLOW) NUMBER
(Canada).................................................1661
MACH* Z TECH PLUS (YELLOW)
Vehicle Identification Number Location
(U.S.) ......................................................1662
MACH* Z TECH PLUS (BLACK)
(Canada).................................................1819
MACH* Z TECH PLUS (BLACK)
(U.S.) ......................................................1820
GRAND TOURING* SE (BLACK)
(Canada and U.S.) .................................1786
GRAND TOURING* SE (BLACK)
(Europe) .................................................1787 A30K01A 1
GRAND TOURING* SE (BLUE) TYPICAL
(Canada and U.S.) .................................1788 1. Vehicle identification number
*Trademarks of Bombardier Inc. Identification Number Meaning

2BPS15929Y1000001
Model year: y = 2000
1 = 2001
2 = 2002
A00A6EA etc.
MMR2001_039_00_02A.FM V
INTRODUCTION
ENGINE SERIAL NUMBER GRD ground

H.A.C. high altitude compensator
Engine Serial Number Location
hal. halogen
HI high
imp. oz imperial ounce
in inch
in² square inch
in³ cubic inch
1
k kilo (thousand)
kg kilogram
km/h kilometer per hour
kPa Kilopascal
A30C1IA L liter
1. Engine serial number lb pound
lbf pound (force)
LIST OF ABBREVIATIONS
lbf/in² pound per square inch
USED IN THIS MANUAL
LH left hand
A ampere LO low
amp ampere LT long track
A•h ampere-hour m meter
AC alternate current MAG magneto
ACM acceleration and control modulator Max. maximum
ADSA advanced direct shock action Min. minimum
BDC bottom dead center mL milliliter
BTDC before top dead center mm millimeter
°C degree Celsius M.E. millennium edition
cc cubic centimeter
MPEM multi-purpose electronic module
CDI capacitor discharge ignition
MPH mile per hour
CTR center
N newton
cm centimeter
N.A. not applicable
cm² square centimeter
no. number
cm³ cubic centimeter
00.0 continuity
DC direct current
0.L open line (open circuit)
DESS digitally encoded security system
O.D. outside diameter
DPM digital performance management
OPT optional
°F degree Fahrenheit
oz ounce
FC fan cooled
P/N part number
fl. oz fluid ounce
PSI pound per square inch
ft foot
VI MMR2001_039_00_02A.FM
INTRODUCTION
PTO power take off

R rectangular
RH right hand
RAVE Rotax adjustable variable exhaust
RER Rotax electronic reverse
RPM revolution per minute
RMS root mean square
RRIM reinforced reaction injection molding
Sp. Gr. specific gravity
ST semi-trapez
TDC top dead center
TRA total range adjustable
U.S. oz ounce (United States)
V volt
Vac volt (alternative current)
ARRANGEMENT OF THE
MANUAL
03 TROUBLESHOOTING
04 ENGINE
05 TRANSMISSION
06 ELECTRICAL
07 REAR SUSPENSION
09 BODY/FRAME
10 TECHNICAL DATA
11 WIRING DIAGRAMS
MMR2001_039_00_02A.FM VII
INTRODUCTION

TYPICAL PAGE
Page heading
indicates section
and subsection
detailed.
Subsection title
Subsection 01 (SUPENSION SC-10 SPORT, TOURING AND MOUNTAIN) beginning of the
subsection.

indicate pertaining
1
models.
Low
temp.
grease
Low
temp. Loctite 7
grease 271
6 2
4 Loctite
11 271
Exploded view
19 6
Low
3
a liquid product
5
to be applied to
8
14
Loctite
a surface.
15 271 In this case
Loctite 271 to
11 screw threads.
SLE
Only
11
Bold face number
271
this part.
Long Track 17
Models Only Loctite
271
16 18
20
Loctite
271
Loctite
271 Short Track Models Only
Loctite
for publishing 4 Nm
11
(35 lbfin)
the short track
07-01-1

must be torqued to
4 Nm or 35 lbfin. Page numbering system:
07: REAR SUSPENSION section
CAUTION: Pay attention to torque TOURING AND MOUNTAIN subsection
specifications. Some of these are 1: First page of this subsection
A01A28S
VIII MMR2001_039_00_02A.FM
INTRODUCTION
TYPICAL PAGE
Title indicates
the bushing.
that particular
All Models
procedure for
A03D1YA
finished, so from
(P/N 413 703 100). 1
TYPICAL caption
view which does
not represent full
detail.
529 031 300
TOP VIEW
A
caption helps you
in understanding
1
529 031 200
A16D0IA
illustration.
TYPICAL TOP VIEW
A. 0 to 1 mm (0 to 3/64 in)
above illustration.
ADJUSTMENT
pulleys adjustment.
MMR2000_042_00-02A.FM 05-03-5

A01A2BS
MMR2001_039_00_02A.FM IX
INTRODUCTION
GENERAL INFORMATION A number of procedures throughout the book re-

quire the use of special tools. Before commencing
The information and component/system descrip- any procedure, be sure that you have on hand all
tions contained in this manual are correct at time the tools required, or approved equivalents.
of publication. Bombardier Inc. however, main-
tains a policy of continuous improvement of its
always refers to driving position (when sitting on
products without imposing upon itself any obliga-
vehicle).
factured.
Due to late changes, it may have some differences
between the manufactured product and the de-
scription and/or specifications in this document.
Bombardier Inc. reserves the right at any time to
discontinue or change specifications, designs,
features, models or equipment without incurring
obligation. 1 2
USEFUL PUBLICATIONS
Refer to Parts Catalogs to order the right parts.
PARTS CATALOG
MODELS P/N
MACH Z 484 400 173
GRAND TOURING SE 484 400 183
Use Specification Booklet to find rapidly the right A03A0CA
specs. TYPICAL
1997-2001 SPECIFICATION BOOKLET (P/N 484 1. Left
2. Right
300 198).
ILLUSTRATIONS AND SELF-LOCKING FASTENERS

PROCEDURE
PROCEDURES
Illustrations and photos show the typical construc- cation procedures when working with self-locking
tion of the different assemblies and, in all cases, fasteners.
may not reproduce the full detail or exact shape of
the parts shown. However, they represent parts Use a metal brush or a screwtap to clean the hole
which have the same or a similar function. properly then use a solvent (Methyl-Chloride), let
act during 30 minutes and wipe off. The solvent
CAUTION: Most components of those vehicles utilization is to ensure the adhesive works properly.
are built with parts dimensioned in the metric
system. Most fasteners are metric and must
not be replaced by customary fasteners or vice LOCTITE APPLICATION
versa. Mismatched or incorrect fasteners could PROCEDURE
cause damage to the vehicle or possible per-
sonal injury.
cation procedures when working with Loctite
As many of the procedures in this manual are in- products.
NOTE: Always use proper strength Loctite prod-
any task, you read and thoroughly understand the
uct as recommended in this Shop Manual.
entire section or subsection in which the proce-
dure is contained.
X MMR2001_039_00_02A.FM
INTRODUCTION
THREADLOCKER 1. Clean threads (bolt and hole) with solvent.

2. Apply Loctite Primer N (P/N 293 800 041) on
Uncovered Holes (bolts and nuts) threads (bolt and nut) and allow to dry for 30
seconds.
1 5. Apply several drops on bolt threads.
Stud in Blind Holes
1 3
2
A00A3LA
2
1. Apply here
2. Do not apply

threads and allow to dry. A00A3NA
3. Choose proper strength Loctite threadlocker. 1. On threads

4. Fit bolt in the hole. 2. On threads and in the hole
3. Onto nut threads
5. Apply a few drops of threadlocker at proposed
tightened nut engagement area. 1. Clean threads (stud and hole) with solvent.
6. Position nut and tighten as required. 2. Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
Blind Holes 3. Put several drops of proper strength Loctite
threadlocker on female threads and in hole.
1 on stud threads.
5. Install stud.
2 6. Install cover, etc.
7. Apply drops of proper strength Loctite on un-
covered threads.
8. Tighten nuts as required.
A00A3MA
1. On threads
2. On threads and at the bottom of hole
MMR2001_039_00_02A.FM XI
INTRODUCTION
Preassembled Parts NOTE: If it is difficult to readjust, heat screw with


1 Stripped Threads
5
1
6
8
2
2
3
A00A3OA
1. Apply here
2. Do not apply A00A3QA 4 7
1. Clean bolts and nuts with solvent. 1. Release agent
2. Stripped threads
2. Assemble components. 3. Form-A-Thread
4. Tape
3. Tighten nuts. 5. Cleaned bolt
6. Plate
4. Apply drops of proper strength Loctite on bolt/nut 7. New threads
contact surfaces. 8. Threadlocker
5. Avoid touching metal with tip of flask. Standard Thread Repair

NOTE: For preventive maintenance on existing 1. Follow instructions on Loctite FORM-A-THREAD
equipment, retighten nuts and apply proper 81668 package.
strength Loctite on bolt/nut contact surfaces. 2. If a plate is used to align bolt:
Adjusting Screw a. Apply release agent on mating surfaces.
b. Put waxed paper or similar film on the surfac-
es.
2 3. Twist bolt when inserting it to improve thread
1 conformation.
NOTE: NOT intended for engine stud repairs.
Repair of Small Holes/Fine Threads
Permanent Stud Installation (light duty)
A00A3PA 1. Use a stud or thread on desired length.
1. Apply here 2. DO NOT apply release agent on stud.
2. Plunger
3. Do a Standard Thread Repair.
1. Adjust screw to proper setting.
4. Allow to cure for 30 minutes.
2. Apply drops of proper strength Loctite thread-
5. Assemble.
locker on screw/body contact surfaces.
3. Avoid touching metal with tip of flask.
XII MMR2001_039_00_02A.FM
INTRODUCTION
GASKET COMPOUND MOUNTING ON SHAFT

All Parts Mounting with a Press
1 2
1
1
2
A00A3UA
1. Bearing
A00A3SA 1 3 2. Proper strength Loctite
3. Shaft
2. Loctite Primer N (P/N 413 708 100) and Gasket Eliminator 515 Standard
(P/N 413 702 700) on both sides of gasket
3. Loctite Primer N only 1. Clean shaft external part and element internal
1. Remove old gasket and other contaminants part.
with Loctite Chisel remover (P/N 413 708 500). 2. Apply a strip of proper strength Loctite on shaft
Use a mechanical mean if necessary. circumference at insert or engagement point.
NOTE: Avoid grinding. NOTE: Retaining compound is always forced out
2. Clean both mating surfaces with solvent. when applied on shaft.
3. Spray Loctite Primer N on both mating surfaces 3. DO NOT use anti-seize Loctite or any similar prod-
and on both sides of gasket. Allow to dry 1 or 2 uct.
minutes. 4. No curing period is required.
4. Apply GASKET ELIMINATOR 515 (P/N 413 702 Mounting in Tandem
plicator.
bore.
immediately.
NOTE: If the cover is bolted to blind holes (above),
apply proper strength Loctite in the hole and on
threads. Tighten.
on bolt threads.
6. Tighten as usual.
MMR2001_039_00_02A.FM XIII
INTRODUCTION
CASE-IN COMPONENTS TIGHTENING TORQUES

Metallic Gaskets Tighten fasteners to torque mentioned in explod-
ed views and text. When they are not specified
refer to following table. Bold face size (e.g. M4)
indicates nominal value (mean value).
FASTENER SIZE
N•m Lbf•in
(8.8 GRADE)
2 M4 18
3 M4 27
4 M5 35
8 M6 71
9 M6 80
10 M6 89
11 M6 97
12 M6 106
A00A3VA 1
FASTENER SIZE
1. Proper strength Loctite N•m Lbf•ft
(8.8 GRADE)
1. Clean inner housing diameter and outer gasket 21 M8 15
diameter. 22 M8 16
2. Spray housing and gasket with Loctite Primer N 23 M8 17
(P/N 293 800 041). 24 M8 18
3. Apply a strip of proper strength Loctite on lead- 25 M8 18
ing edge of outer metallic gasket diameter. 43 M10 32
NOTE: Any Loctite product can be used here. A 44 M10 32
low strength liquid is recommended as normal 45 M10 33
46 M10 34
4. Install according to standard procedure. 47 M10 35
5. Wipe off surplus. 48 M10 35
6. Allow it to cure for 30 minutes. 49 M10 36
NOTE: Normally used on worn-out housings to 50 M10 37
prevent leaking or sliding. 51 M10 38
It is generally not necessary to remove gasket 52 M10 38
compound applied on outer gasket diameter. 53 M10 39
76 M12 56
77 M12 57
78 M12 58
79 M12 58
80 M12 59
81 M12 60
82 M12 60
83 M12 61
84 M12 62
121 M14 89
122 M14 90
123 M14 91
XIV MMR2001_039_00_02A.FM
INTRODUCTION
FASTENER SIZE
N•m Lbf•ft
(8.8 GRADE)
124 M14 91
125 M14 92
126 M14 93
127 M14 94
128 M14 94
129 M14 95
130 M14 96
131 M14 97
132 M14 97
133 M14 98
134 M14 99
135 M14 100
136 M14 100
137 M14 101
138 M14 102
139 M14 103
140 M14 103
141 M14 104
142 M14 105
143 M14 105
144 M14 106
145 M14 107
146 M14 108
147 M14 108
148 M14 109
149 M14 110
150 M14 111
MMR2001_039_00_02A.FM XV
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
Name ______________________________________________________
Address ____________________________________________________

____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
Name ______________________________________________________
Address ____________________________________________________

____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
Name ______________________________________________________
Address ____________________________________________________
✁

AFFIX
PROPER
POSTAGE
After Sales Service
AFFIX
PROPER
POSTAGE
After Sales Service
AFFIX
PROPER
POSTAGE
After Sales Service
SERVICE TOOLS 0
MMR2001_040_01_01A.FM 01-01-1

Tool board
(P/N 529 034 000)
01
A00A3X4
APPLICATION
All models.
01-01-2 MMR2001_040_01_01A.FM

(P/N 529 035 400) (P/N 420 876 357) (P/N 529 018 900)
A00A1D4
APPLICATION
Pusher
A01B584

(P/N 529 035 607) (P/N 420 876 080) A00C3H4
360
33
0
340
20
350 10
10 360 350 3
20
40
30
APPLICATION
0 30 33 40
32 40 0
50
32
0 Rotary valve engines.
50
0
31
60
60
31
0
0
70
30
300
70
80
290
290
80
110 100 90

280
280 270 26
90 100 11
270
(P/N 420 876 612)

260
120
A00C1R4
0
0
250
130
250
12 0
APPLICATION
0
24
14
24
13
0
0
2
30
30
15 2
1
0 22 40
16
0 0
210
200 190 180 17
0
0
22 0
15 A00C0F4
160 2 1
170 00
180 190 2
APPLICATION
A00B514
(P/N 420 876 607)
Hose pincher (2)
A00C1A4
(P/N 295 000 076)
APPLICATION

A01B2I4
APPLICATION
All vehicles.
MMR2001_040_01_01A.FM 01-01-3

(P/N 420 876 512)
NEW
B) (P/N 529 035 602)
A00B524
A00C374 APPLICATION
A01C5D4
Rotary valve engines, 1991 and seal on water pump side. APPLICATION
(P/N 861 749 100) 30, 32 and 34 mm carburetor and
Rotary valve shaft seal pusher big end for 38 mm carburetor).
B) VM type carburetor on ZX series.
(P/N 420 877 050)
A00C0X4
A01B2D5

(rotary valve)
(P/N 529 033 100)
(P/N 420 876 500)
A00B2J4
APPLICATION
A01B5E4
APPLICATION
All models.
01-01-4 MMR2001_040_01_01A.FM

(P/N 529 035 503) (P/N 529 023 400) (P/N 529 034 600)
A01B554
A01B4C4
APPLICATION
APPLICATION
A02B094
All cageless bearing engines.
and/or a DESS.
(P/N 529 035 541)
A) (P/N 529 029 100)
3) Sleeve kit 20 mm
B) (P/N 529 020 800) 9-volt adaptor
(P/N 529 035 542)
(P/N 529 035 675)
NEW
A00C3I4
APPLICATION
A01B5A4
NOTE: 18 mm sleeve kit contains A00B5G4

20 mm sleeve kit contains 1 shoul- APPLICATION
APPLICATION
1) All engines.
2) 277, 443, 503 and 809 engine.
3) 593, 670 and 693 engines.
sleeve kit.
F01B1O4
APPLICATION
All models.
MMR2001_040_01_01A.FM 01-01-5

Homemade adaptor 1-2) Programmer kit
NEW (P/N 529 035 718)
2) Communication cables
7 (P/N 529 001 052)
8 NEW
1
1
4
2 3
5 6
A00B5J4
Required parts:
1) Female housing
(P/N 515 175 245)
2
A01B5B5
(P/N 409 015 100)
4) Male housing
(P/N 409 207 000)
(P/N 278 000 631)
6) Male lock
(P/N 409 207 600)
(3-wire connector)
(3-wire connector)
APPLICATION
01-01-6 MMR2001_040_01_01A.FM

puller with screw
2) Screw M8 x 40 (4) (P/N 420 840 681)
(P/N 420 877 635)
3) Screw M8 x 70 (4) (P/N 420 841 201)
1
2,3
2,3
247 engine.
7) Puller ring (P/N 420 977 490)
(P/N 420 977 475 or 420 276 025).
8,9,11 8) Half ring (2) (P/N 420 977 475)

A01B547
9) Half ring (2) (P/N 420 276 025)
All engines.
10) Puller ring (P/N 420 977 494)
11) Half ring (P/N 420 977 479)
MMR2001_040_01_01A.FM 01-01-7

A) (P/N 529 035 561) 18 mm A) (P/N 420 876 090) (P/N 420 276 900)
(62 mm) (MAG)
B) (P/N 529 035 562) 20 mm
B) (P/N 420 876 974)
(69.5 mm)
C) (P/N 420 876 970)
(72 mm)
D) (P/N 420 876 972) A00C0D4
(76 mm)
A00B4Y4
(67.5 mm) 247 engine.
693. (P/N 420 276 930)
staller (P/N 529 016 900).
B) 593, 670 and 693 engines.
staller (P/N 290 877 016). A00C0Z4
A01B1T4
APPLICATION
A) 377 engine.
(P/N 529 009 100)
D) 582, 583 and 643 engines.
F) 670 engine.

A01B1R4
(P/N 420 876 922)
A00C114
APPLICATION
A01B1V4
APPLICATION
(160 W).
01-01-8 MMR2001_040_01_01A.FM

(5.7 mm) (P/N 529 035 521) (P/N 404 112 000)
(P/N 420 876 822)
A00B4O4
APPLICATION
Mini Z.
A00B2F4
A00C294
Adaptor
(12.7 mm) (TYPICAL)
(P/N 420 876 824)
A00B4P4
APPLICATION A00B4H4
Mini Z.
APPLICATION
(P/N 529 035 520)
A) (P/N 420 876 904)
(on exhaust side)
B) (P/N 420 876 171)
4
(on intake side)

3
A00B4Q4
2
APPLICATION
1
A00B084 Mini Z.
A00B4N4
APPLICATION
APPLICATION
A) 2-cylinder liquid cooled engines.
All models.
MMR2001_040_01_01A.FM 01-01-9

(P/N 414 012 200)
A00C214
APPLICATION
F01B294
All vehicles.
APPLICATION
247 engine.

(P/N 420 876 695)
Dial indicator
(TDC gauge)
(P/N 414 104 700)
A00B4F4
APPLICATION A00B314
All engines.
A00B4E4
APPLICATION
253, 377, 447 and 503 engines.
(P/N 420 277 905)
A) (P/N 420 876 980)
B) (P/N 420 876 490)
A00I094
APPLICATION
360 W magneto
A00C164
A00C0D4
APPLICATION
shaft.
shaft.
01-01-10 MMR2001_040_01_01A.FM

(P/N 529 014 500) (P/N 529 024 900) (P/N 420 877 650)
A00C3V4
APPLICATION
454, 494, 599, 670, 699, 779 and
F01B1G4 A05C0M4
809 engines.
Exhaust spring installer/remover
All engines. 277 engine.
(P/N 529 035 559)

(P/N 420 277 875) (magneto side seal)
(P/N 420 876 516)
A00C3S4
APPLICATION
A00C0V4
All models except CK3 series.
277 engine. spring installer/remover (P/N 529
028 100).
PTO seal pusher

A00C3T4 Rotary valve seal and
APPLICATION
(P/N 420 876 605)
779 engine.
Insertion jig
A00C0V4
(magneto seal)
277 engine. A00C0Y4
APPLICATION
and older.
A00C3U4
APPLICATION
454, 494, 599, 670, 699 and 809
engines.
MMR2001_040_01_01A.FM 01-01-11

(P/N 420 876 510)
A00C374
APPLICATION
12 mm I.D.

(P/N 420 876 610)
A00C0F4
APPLICATION
shaft.
Large hose pincher

(P/N 529 032 500)
(TYPICAL)
F01B234
APPLICATION
All vehicles.
01-01-12 MMR2001_040_01_01A.FM

(P/N 529 017 200) (P/N 529 005 500) (P/N 529 002 100)
(standard threads)
A00C084
APPLICATION
Square shaft, standard (SAE) threads.
A16B014
A00A1A4
Drive pulley puller
(P/N 860 414 200)
All non-RER models. All vehicles equipped with a TRA (square shaft metric)
drive pulley.
Consists of:
Clutch holder 529 003 000 529 002 800
Tool kit
(P/N 529 006 400)
(P/N 529 025 400)
NEW
A01B154
A00C095
APPLICATION
APPLICATION
All TRA drive pulleys.
pulley.
(P/N 529 022 400)
A00B5N4
APPLICATION
APPLICATION
599, 670, 699, 779 and 809 engines. (P/N 529 025 000)
NEW

(P/N 529 007 900) (25 mm)
A00B5M4
A18B044
APPLICATION
MMR2001_040_01_01A.FM 01-01-13

A) (P/N 529 026 900) (P/N 529 008 700) (P/N 529 035 300)
B) (P/N 529 030 000)
2
C) (P/N 529 035 586)
D) (P/N 529 026 700)
1
E) (P/N 529 035 530)
F) (P/N 529 031 000)
G) (P/N 529 035 527) A15B044
H) (P/N 529 035 572)

1) Hexagonal wrench
(P/N 420 876 730).
A01B4D4
APPLICATION
Tundra R.
(P/N 414 348 200)
with TRA. (P/N 529 035 524)
APPLICATION
All models.
series.
(P/N 529 030 200)

A) (P/N 529 006 500)
B) (P/N 529 030 900)
C) (P/N 529 035 557)
A02D1P4
(TYPICAL)
APPLICATION
All models.

(P/N 529 018 600).
A00B4A4
APPLICATION
A) Tundra II LT.
(1995 and newer).
C) CK3 without RER.
01-01-14 MMR2001_040_01_01A.FM

(P/N 529 035 699)
NEW
A00A274
APPLICATION
A00B5K4
installer (P/N 529 035 554).
Spring cover tool

(P/N 529 027 300)
A01B5C4 A01B4M4
CK3 series. Bombardier Lite drive pulley.
MMR2001_040_01_01A.FM 01-01-15

Clutch holder Alignment tool
(P/N 529 027 600) (P/N 420 476 010)
A02B034
APPLICATION
APPLICATION
(P/N 529 031 400)
(P/N 529 018 800)
A18B044
APPLICATION
cept Élan.

(P/N 529 035 501)
A00A194
APPLICATION
PRS chassis.
A03D2P4
APPLICATION
S and CK3 series with RER.
500).

(P/N 529 034 200)
A05B044
APPLICATION
Tundra R.
01-01-16 MMR2001_040_01_01A.FM

Cam pusher Transmission ball mounting pin Alignment bar
(P/N 529 012 900) (P/N 420 476 020) A) (P/N 529 025 600)
B) (P/N 529 028 200)
C) (P/N 529 028 300)
D) (P/N 529 026 800)
A00C1C4
E) (P/N 529 031 000)
APPLICATION
A18B064
A01B4D4
APPLICATION
Transmission adjuster APPLICATION
Tundra II LT.
(P/N 529 028 500) A) PRS chassis.
B) Alpine II.
Countershaft bearing remover
C) Élan.
(P/N 529 018 700)
D) Safari L.
E) Skandic WT 1996.
A00D0X4
Burnishing bar
(P/N 529 026 402)
APPLICATION
F-Series equipped with “twist

(P/N 529 015 200)
A00A164 A00B464
PRS chassis. Tundra II LT, Safari L and Skandic.
Drive pulley puller A01B514
(P/N 529 023 100)

APPLICATION
pine II.
A00C3J4
APPLICATION
Élan.
MMR2001_040_01_01A.FM 01-01-17

Large bushing extractor Large bushing extractor Chaincase seal pusher
(P/N 529 031 100) (P/N 529 035 575) (P/N 529 035 584)
NEW
A00B4I4 A02D1Q4
Formula type driven pulley. LPV 27 driven pulley. A00B504
NOTE: Use this tool only with NOTE: Use this tool only with APPLICATION
former puller (P/N 529 018 600) new puller (P/N 529 035 524) that
that has regular threads. has Acme threads and support S, F, CK3 and ZX series.
plate included with extractor (P/N NOTE: This tool replaces chain-
529 031 100). case upper seal pusher (P/N 529
Large bushing extractor 032 300).
(P/N 529 035 576)
Large bushing installer and small
bushing extractor 3-speed transmission bearing
(P/N 529 031 200) extractor
1) Screw M8 x 25 (2)
(P/N 207 182 544)
2) Plate
3) Half ring (2)
(P/N 420 876 330)
A02D1Q4
4) Ring
(P/N 420 977 480)
APPLICATION
Formula type driven pulley. A00B4J4 1
NOTE: Use this tool only with
APPLICATION
new puller (P/N 529 035 524) that 2
has Acme threads and support All models except Tundra/R, Skandic
plate included with extractor (P/N WT/SWT/WT LC and S-Series with
529 031 100). RER.
3
A00C1B4
APPLICATION
01-01-18 MMR2001_040_01_01A.FM

TRA drive pulley puller (27 mm) Drive axle sprocket adjuster Transmission adjuster
(P/N 529 010 100) (P/N 861 725 700) (P/N 529 030 300)
5
2
A18B044 3 A03D1T4
1
TRA drive pulley (27 mm) shaft ex- 4 Vehicles equipped with “push-pull
cept 454, 670 and 779 engines. shifter” reverse transmission.
6
A01B2O4

(P/N 529 010 700)
(P/N 529 010 800)
3) Plate
(P/N 529 010 600)
4) Bolt M10 (2)
(P/N 222 007 565)
(P/N 222 983 065)
6) Screw M8 (2)
(P/N 222 082 565)
NOTE: When the tool is to be used
screws M8.
APPLICATION
All vehicles except Élan.
MMR2001_040_01_01A.FM 01-01-19

(P/N 529 035 504)
(P/N 414 528 400)
A01B4O4
APPLICATION
035 551).
01-01-20 MMR2001_040_01_01A.FM

(P/N 529 008 200) (P/N 529 021 600) A) (P/N 529 008 500)
Pins NOTE: Angle finder with a mag- Narrow
(P/N 529 008 204) netic base must be used. B) (P/N 529 028 800)
A06B024
A01B1J4
APPLICATION
A01B1M4
(P/N 529 028 700)
(P/N 529 021 500) A) 1993 and older.
B) 1994 and newer.
opening.
Dome guide
A01F224
(P/N 529 026 500)
APPLICATION
A) 1993 and older.
B) 1994 and newer except Élan A00B3X4
A06F1B4
and Tundra II.
All models except Élan. T/A shocks.
MMR2001_040_01_01A.FM 01-01-21

Piston guide Drill bit Kayaba shock adjustment tool
A) (P/N 529 026 600) (P/N 529 031 800) (P/N 529 035 582)
B) (P/N 529 035 608)
A01B564
APPLICATION
A06F1C4 All 3/16 inch rivets. A00A1K4
A) Most T/A shocks. Spring installer (bar) C-7 suspension.
B) C-46 T/A shocks. (P/N 529 005 000)
Hexagonal wrench
(tire valve type)
(P/N 529 035 570)
A19B024
A00C1I4
APPLICATION
All SC-10 suspensions, Safari and
APPLICATION Skandic prior to 1995.
Tundra II LT, Scout and all SC-10
suspensions.
A02F134
(P/N 529 017 100)
APPLICATION Drive axle holder
1999 and older T/A shocks and (P/N 529 007 200)
some 2000 and up T/A shocks.
A15B094
Tool for shock (needle type) APPLICATION

(P/N 529 035 614) 1992 and old Formula C-7.

(P/N 529 032 900)
A01B1E4
APPLICATION
A00B5I4
All models.
APPLICATION
A02F114
Most 2000 and up T/A shocks.
APPLICATION
01-01-22 MMR2001_040_01_01A.FM

(P/N 529 034 100)
A02F124
APPLICATION
CK3 series.
Adjustment wrench
(P/N 861 743 900)
Consists of:
529 024 000
529 025 500
A00B4B4
APPLICATION
shock.
Adjustment wrench
(P/N 520 000 126)
A00B5H4
APPLICATION
SC-10 II (coupling blocks).
MMR2001_040_01_01A.FM 01-01-23

Protective mat
(P/N 529 030 600)
A01B45W
APPLICATION
All vehicles.

(P/N 529 029 900) (P/N 529 020 000)
A00B4CJ A01A1JJ
01-01-24 MMR2001_040_01_01A.FM

Snap-on NEW
TT 600-4
NEW
A02H154
F01B1J4
APPLICATION
Crimping tool
(P/N 414 837 300) NEW
F04B044
APPLICATION
All models.

A32B044
APPLICATION
on ZX series.
MMR2001_040_01_01A.FM 01-01-25
SERVICE PRODUCTS 0
(P/N 413 703 100) (P/N 413 702 700) (P/N 293 800 060)
NEW
A00B2T4
APPLICATION
ing surfaces.
A00B2S4
Paste gasket
(P/N 293 800 038)
APPLICATION F00A0O4
Loctite® 518:
tite 242 (P/N 293 800 015).
Sealing compound
(P/N 420 297 906) F01B124
High strength threadlocker
APPLICATION
(P/N 293 800 005)
Crankcase halves and gearbox
Loctite® 271:
mating surfaces.
A00B564
A00B2U4
To seal crankcase on all ZX series Fasteners and studs up to 25 mm
engines. (1 in) diameter.
MMR2001_040_01_02A.FM 01-02-1

Gasket/paint remover Molykote PG 54 Petamo grease
(P/N 413 708 500) (P/N 420 899 763) (P/N 420 899 271)
Loctite® Chisel (10 g)
510 g (18 oz) NEW
A00B5F4
APPLICATION
wind starter.
Grease Isoflex
(P/N 293 550 021) A00B584
(50 g)
APPLICATION
A00B574
Loctite® primer
(P/N 293 800 041)
Primer N
128 g (5 oz)
A00B554
APPLICATION
To lubricate some crankshaft bear-
ings on some engines.
A00B3N4
APPLICATION
changed. This product is identical to
the P/N 413 708 100.
01-02-2 MMR2001_040_01_02A.FM

Premix oil BOMBARDIER Formula XP-S Storage oil
(P/N 413 803 100) synthetic injection oil (P/N 413 711 600)
(12 x 1 liter)
(P/N 413 711 000)
(3 x 4 liter)
(P/N 413 710 700)
(205 liter)
A00B5L4
APPLICATION
All pre-mix models.
A02B054
APPLICATION
BOMBARDIER injection oil
All models.
(P/N 413 802 900) A02F144

APPLICATION changed. This product is identical to
(P/N 413 803 000) All engines. the P/N 496 014 100.
(3 x 4 liter)
(P/N 413 803 200)
(205 liter) Premixed coolant - 52°C (- 62°F) Fuel stabilizer
(P/N 413 711 802) (P/N 413 408 600)
(16 x 1 L) (12 x 8 oz)
® ®
F01B2H4
APPLICATION
All engines.
A00B3V4
APPLICATION
A00B5E4
All models.
APPLICATION
All liquid cooled models.
MMR2001_040_01_02A.FM 01-02-3

(P/N 413 801 900) (P/N 413 707 500) (P/N 293 600 016)
(16 x 250 mL) (400 g) (12 x 14 oz)
A00B1Y4
APPLICATION
good ground.
A00B2R4
Synthetic grease
Chaincase lubricant on all fan- (400 g)
A00B4W4
series.
APPLICATION
(P/N 413 803 300)
A01B574
Super Lube (grease)

(P/N 293 550 014)
A02F154
APPLICATION
A01B4Q4
T/A shocks.
APPLICATION
series.
APPLICATION
01-02-4 MMR2001_040_01_02A.FM

(P/N 293 800 070) (P/N 293 550 004) (P/N 293 110 001)
(4 L)
A00B1X4
APPLICATION
the P/N 413 701 700.
F01B2J4
Parts cleaner
APPLICATION
(P/N 413 711 809)
All models.
A00B594 (320 g)
APPLICATION
Plastic & vinyl cleaner
Mounting surfaces of driven pulley
(6 x 1 L)
Molykote 111
(P/N 413 707 000)
111
A00B3W4
APPLICATION
A00B4X4
APPLICATION
APPLICATION
MMR2001_040_01_02A.FM 01-02-5

High temperature threadlocker High temperature RTV sealant Gel instant adhesive
(P/N 413 711 400) (P/N 413 710 300) (P/N 413 708 300)
Loctite 648 (green) (5 mL) Ultra Copper Loctite 454-40
(80 mL) 20 g (.70 oz)
A00B3O4
APPLICATION
Isolating foam and rubber strip.
Tough adhesive
A00B3D4
(P/N 413 408 300)
APPLICATION
Loctite Black Max
To fasten oil injection nozzle to 3 mL (.10 oz)
crankcase.
changed. This product is identical to A00B5A4
the P/N 420 899 788.
APPLICATION
All models.
Pipe sealant
(P/N 293 800 018)
General purpose instant adhesive
Loctite 592 (50 mL)
(P/N 293 800 021)
Loctite 495 (3 g)
A00B3P4
A00B2W4 APPLICATION
APPLICATION Shifter boot or grip.
Engine plugs and senders.
NOTE: Only the P/N has been Paint for frame touch-up
changed. This product is identical to (P/N 413 401 000)
the P/N 413 702 300.
Black semi-gloss
(spray can)
Clear silicone
(P/N 293 800 033) A00B2V4
APPLICATION
Rubber to metal bonding and most
F01B1S4
hard plastic.
All models to seal bottom pan. the P/N 413 703 200.
A00B3H4
APPLICATION
All models with a black frame.
01-02-6 MMR2001_040_01_02A.FM
Subsection 01 (PERIODIC MAINTENANCE CHART)
10-HOUR OR 500 km (300 mi)

EVERY 3200 km (2000 mi)
ONCE A YEAR OR
MONTHLY OR
INSPECTION
WEEKLY OR
STORAGE
Condition
Engine Head Nuts ✔ ✔ ✔
See Top End
Engine Mount Nuts ✔ ✔ ✔
See ENGINE REMOVAL
Exhaust System ✔ ✔ ✔
See ENGINE REMOVAL
Cooling System Condition ✔ ✔ ✔ Subsection 04-06
Coolant Replacement ✔ Subsection 04-06
Condition of Seals ✔ ✔ Subsection 04-02
Drive Belt Condition ✔ ✔ ✔ This section no. 5
Condition of Drive and Driven Pulleys ✔ ✔ ✔ Subsections 05-03 and 05-04
Brake Adjustment ✔ ✔ Subsection 05-06
Drive Chain Tension ✔ ✔ ✔ Subsection 05-07
Countershaft Lubrication** ✔ ✔ ✔ Subsection 05-06
Chaincase Oil Level ✔ ✔ ✔ Subsection 05-07
Chaincase Oil Change ✔ ✔ Subsection 05-07
Lubrication of Drive Axle Bearing** ✔ ✔ ✔ Subsection 07-03
MMR2001_041_02_01A.FM 02-01-1
10-HOUR OR 500 km (300 mi)

EVERY 3200 km (2000 mi)
ONCE A YEAR OR
MONTHLY OR
INSPECTION
WEEKLY OR
STORAGE
Handlebar Bolts. Retorque to 26 N•m
(19 Ibf•ft)
Steering and Front Suspension
✔ ✔ ✔ Subsections 08-02 and 08-03
Mechanism Condition
Steering and Front Suspension ✔
✔ ✔ Subsections 08-02 and 08-03
Wear and Condition of Skis and ✔
Runners
Adjustment
Subsection 07-02
Suspension Adjustments AS REQUIRED
Suspension Lubrication** ✔ ✔ Subsection 07-02
Suspension Condition ✔ ✔ ✔ Subsection 07-02
Suspension Stopper Strap Condition ✔ ✔ Subsection 07-02
✔ ✔ ✔ Operator’s Guide
Rags in Air Intake and Exhaust System ✔ ✔ This section no. 5
02-01-2 MMR2001_041_02_01A.FM
NO. 1 ENGINE LUBRICATION Pour fuel stabilizer in fuel tank prior to starting en-
gine for internal parts lubrication so that stabilizer
At Storage flows everywhere in fuel system.
Engine internal parts must be lubricated to protect After engine starting, use primer several times so
them from possible rust formation during the stor- that stabilizer flows inside it.
age period. Do not drain fuel system.
Proceed as follows: CAUTION: Fuel stabilizer should be added pri-
Start the engine and allow it to run at idle speed or engine lubrication to ensure carburetor(s)
until the engine reaches its operating temperature. protection against varnish deposit.
 WARNING NO. 3 FUEL FILTER

Ensure the track is free of all particles which REPLACEMENT
could be thrown out while it is rotating. Keep Drain fuel tank.
hands, tools, feet and clothing clear of track.
Ensure no one is standing in close proximity Remove fuel line grommet from fuel tank and pull
to the vehicle. out inlet fuel line from tank.
Stop the engine.

Remove air silencer to spray storage oil (P/N 496
014 100) into each carburetor bore.
Inject storage oil until the engine stalls or until a
sufficient quantity of oil has entered the engine
(approximately half a can).
With the engine stopped, remove the spark plug
and spray storage oil (P/N 496 014 100) into each
cylinder.
Crank slowly 2 or 3 revolutions to lubricate cylinders.
Reinstall the spark plugs and the outlet primer A03I0GA 3 1 2
hose or air silencer.
TYPICAL
 WARNING 1. Inlet fuel line

3. Fuel filter
This procedure must only be performed in a
well-ventilated area. Do not run engine dur- Replace fuel filter. To facilitate the fuel line instal-
ing storage period. lation, slide grommet on fuel line about 50 mm
(2 in) away from elbow then install grommet on
fuel tank and push elbow through grommet.
Add 500 mL (17 U.S. oz) of recommended injec- NO. 4 AIR FILTER CLEANING
tion oil to the first full filled fuel tank.
CAUTION: These snowmobiles have been cal-
NO. 2 FUEL STABILIZER ibrated with the filter installed. Operating the
snowmobile without it may cause engine dam-
With the new fuel additives, it is critical to use the age.
fuel stabilizer (P/N 413 408 600) (250 mL) to pre- Remove air filter from air deflector by pulling it.
system components corrosion. Follow manufac- Lift hood and remove air filter from air intake silencer.
turer’s instructions for proper use. To clean the filter, shake the snow out of it then,
dry it out.
MMR2001_041_02_01A.FM 02-01-3
Check that the air box is clean and dry then prop- Reinstall filter over dashboard sticking bottom
erly reinstall the filter. edge first.
A30H0XA
AIR FILTER INSTALLED A30H0SA
Insert air filter so its top edge is flush with air de- TYPICAL
flector. 1. Stick bottom edge first
Finalize filter top edge installation.

1
1
A30H0RA
TYPICAL
A30H0QA
1. Top edge of filter flush with air deflector
TYPICAL
1. Push top edge of filter under air deflector lip
02-01-4 MMR2001_041_02_01A.FM

decals or vinyl.
For vinyl and plastic parts, use Vinyl & Plastic Cleaner
(P/N 413 711 200 (6 x 1 L)).
To remove scratches on windshield or hood: Start
with “Slip Streamer Motorcycle Windshield Heavy
Duty Scratch, Remover”. Finish with “Slip Streamer
Motorcycle Cleaner and Polish”.
A30H0XA
NOTE: The latest product may be use alone if only
light scratches are noticeable.
NO. 5 RAGS IN AIR INTAKE AND CAUTION: Never clean plastic parts or hood with
EXHAUST SYSTEM strong detergent, degreasing agent, paint thin-
ner, acetone, products containing chlorine, etc.
At storage preparation, block air intake hole and Inspect the hood and repair any damage.
Remove those rags at pre-season preparation. scratched off. Spray all metal parts including shock
NO. 6 ENGINE COMPARTMENT 600 016).
Keep clean of grass, twigs, cloth, etc. These are Remove drive belt and spray BOMBARDIER LUBE
combustible under certain conditions. (P/N 293 600 016) on drive and driven pulley sheaves.
NO. 7 VEHICLE CLEANING AND for better protection.
PROTECTION NOTE: Apply wax on glossy finish only. Protect
Remove any dirt or rust. lation during storage.
To clean the entire vehicle, use only flannel clothes CAUTION: The snowmobile has to be stored in a
or Kimtowels® wipers no. 58-380 from Kimberly- cool and dry place and covered with an opaque
Clark. tarpaulin. This will prevent sun rays and grime
CAUTION: It is necessary to use flannel cloths from affecting plastic components and vehicle
or Kimtowels wipers on windshield and hood finish.
to avoid damaging further surfaces to clean. Lift rear of vehicle until track is clear of the ground.
To clean the entire vehicle, including metallic parts Install on a snowmobile mechanical stand.
with a thick coat of grease, use Endust® imported NOTE: Do not release track tension.
supermarkets.
(P/N 293 110 001 (spray can 400 g) and P/N 293 110
002 (4 L)).
MMR2001_041_02_01A.FM 02-01-5
TABLE OF CONTENTS 0
ENGINE .................................................................................................................................. 03-02-1
FUEL AND OIL SYSTEMS ..................................................................................................... 03-03-1

TRANSMISSION ................................................................................................................ 03-04-1
BRAKE SYSTEM ................................................................................................................ 03-04-7
HYDRAULIC BRAKE .......................................................................................................... 03-04-7
MMR2001_072_03_01ATOC.FM 03-01-1
ENGINE 0
a. Fuel passages obstructed.
a. Low antifreeze level.
b. Defective tank cap.
Replace cap.
c. Air in system.
Bleed system.
Test/Inspection 1. Check that all 3 ground wires are well connected.
MMR2001_042_03_02A.FM 03-02-1

Replace.
i. Improper reed valve adjustment or damage.
Adjust according to specifications (refer to 809 ENGINE TYPE) and/or install
Bombardier’s recommended reed valve.
Clean residue accumulation in combustion chamber and replace piston(s).
03-02-2 MMR2001_042_03_02A.FM

a. Cooling system leaks and lowers coolant level.
b. Accumulation of foreign particles in needle valve and/or main jet area.
overreving.
9. DPM manifold air vent is obstructed.
a. Carburetion is too lean.
Ensure proper air vent.

MMR2001_042_03_02A.FM 03-02-3
Test/Inspection 1. Check spark plug condition and gap.
a. Fouled spark plugs or wrong spark plug gap.
Replace or readjust gap.
3. Check items listed in ENGINE RUNS OUT OF FUEL (refer to fuel and oil system
subsection).
a. Worn belt.
Adjust according to specifications (refer to TECHNICAL DATA) and/or replace
bushing(s).
a. Restriction or exhaust system leaks.
Replace or reseal with Ultra Copper.
a. Antifreeze level is low, cap fails to pressurize system or air circulates through lines.
Replace or adjust. Refer to proper engine subsection.
03-02-4 MMR2001_042_03_02A.FM

Replace.
MMR2001_042_03_02A.FM 03-02-5

2. Check fuel valve.
a. Fully open fuel valve.
Check fuel tank level and use choke.
a. Defective spark plug (no spark) or wrong spark plug gap.
Replace spark plugs or readjust gap.
clogged ; check condition of fuel and impulse lines and their connections.
03-02-6 MMR2001_042_03_02A.FM

Readjust.
Replace.
MMR2001_042_03_02A.FM 03-02-7

a. False reading.
clamps at fitting.
5. Check tank cap.
Replace.
a. Worn gaskets.
Replace.
a. Leak(s).
Repair or replace.
Replace.
03-02-8 MMR2001_042_03_02A.FM
Replace.
a. Jammed valve(s).
Clean.
Replace.
a. Clogged holes.
Clean.
Replace.

Replace.
Adjust according to ASSEMBLY PROCEDURE in appropriate engine subsections.
Clean.

a. Broken spring.
Replace spring.
MMR2001_042_03_02A.FM 03-02-9

Replace.
Replace.
Replace.

Clean.

2. Check drive pulley (refer to: vibrations coming from drive pulley).
unsynchronized.
03-02-10 MMR2001_042_03_02A.FM

FLOW CHART
PRESSURIZE ENGINE
NO
IS ENGINE LEAKING?
YES

FLANGES ETC.

NO

INJECTION PUMP

OR OIL MOVING REPLACE BANJO FITTING(S)/LINE(S)
TOWARD PUMP?
NO

NO
BLOCK LARGE HOSES OF

ROTARY VALVE GEAR
LUBRICATION SYSTEM
NO
YES

SEAL OF PTO AND
MAG SIDES
YES
NO
PRESSURIZE ROTARY VALVE GEAR

PRESSURIZE ROTARY VALVE GEAR YES

RESERVOIR IN CRANKCASE IS RESERVOIR LEAKING?
NO
CYLINDER SEPARATELY

NO

YES REPLACE OIL SEAL OF ROTARY

NO ANY LEAK FOUND? VALVE SHAFT END, BESIDE
COOLANT SEAL
NO
REMOVE ROTARY VALVE COVER, CHECK

SEAL OF ROTARY VALVE SHAFT
YES
IS SEAL LEAKING? REPLACE DEFECTIVE SEAL
NO

YES
NO

INTERNALLY
A00A23S
MMR2001_042_03_02A.FM 03-02-11

Replace fuel tank.
2. Check fuel pump, reservoir and carburetor fittings.
Readjust choke.

Replace.
MMR2001_042_03_03A.FM 03-03-1

a. Clogged filter.
Replace.
a. Dried diaphragm.
Replace.
a. Varnish.
Clean.

Adjust.
a. Worn gasket.
Replace.
03-03-2 MMR2001_042_03_03A.FM

Clean.
5. Check main jet.
Clean.
SYMPTOM DPM SEEMS TO BE DEFECTIVE.

Test/Inspection 1. Check 1 A fuse.
a. Burnt fuse or corroded terminals.
Clean or replace fuse.
2. Fuel mixture is too rich or too poor.
a. Possible damage to DPM.
Unplug 1 A fuse while engine is running. The carburetion is now identical to that
of carburetors without a DPM provided, of course, that all pipe fittings are tight
and that solenoids are in good condition, None must be half-open. If problem is
resolved, DPM is faulty.
MMR2001_042_03_03A.FM 03-03-3

TRANSMISSION


Adjust distance between pulleys and/or drive belt deflection according to
specifications (refer to TECHNICAL DATA).

Replace.


listed.

Replace.




listed.
MMR2001_042_03_04A.FM 03-04-1

Adjust.
2. Check play of driven pulley splines.

a. Worn splines.
Replace.

Replace.

Retighten screw.

Retighten screws.
4. Check spring cover (TRA TYPE) and/or outer half bushings.

movements.
Replace bushing(s).

Replace.


Replace.

Replace.
03-04-2 MMR2001_042_03_04A.FM


Clean or replace.

Replace.
SYMPTOM IN REVERSE ENGINE BOGS AND DRIVEN PULLEY OPENS TOO FAST (DRIVE BELT
IS LOW IN DRIVEN PULLEY).
Test/Inspection 1. Check pulley distance and alignment.

a. Improper adjustment.
Adjust according to specifications (refer to PULLEY DISTANCE AND ALIGNMENT)
and make sure that engine stopper is resting against engine.

T ighten engine mount nuts/bolts equally.

Align pulleys.


A00D09Y Replace bushing.
MMR2001_042_03_04A.FM 03-04-3

Replace bushing.





a. Improper belt angle (wrong type of belt).

New belt a. Considerable use.
A00D0BY
Replace belt if less than specified in DRIVE BELT.
03-04-4 MMR2001_042_03_04A.FM








Repair or replace.

A00D0DY
MMR2001_042_03_04A.FM 03-04-5


Clean pulley surfaces with fine emery cloth and wipe clean using Loctite Safety
A00DOEY
Solvent (P/N 413 708 200) and a cloth.

A00DOFY

Replace.
A00D0GY

Replace.


A00D0HY
Check drive pulley engagement speed, drive pulley bushings and components.
03-04-6 MMR2001_042_03_04A.FM


A00D0IY
BRAKE SYSTEM
HYDRAULIC BRAKE
Replace brake fluid and bleed system. If problem still occurs,

Test/Inspection
replace master cylinder.
Test/Inspection 1. Check for loosen hose connectors.



Replace.
MMR2001_042_03_04A.FM 03-04-7
ELECTRICAL SYSTEM 0
Test/Inspection 1. Check fuse.

a. Burnt fuse.
Check wiring condition and replace fuse.


Repair.
Test/Inspection 1. Check battery capacity.

Replace.

a. Weak battery.



6. Check brushes.
a. Poor contact of brushes.
Replace brushes.
MMR2001_042_03_05A.FM 03-05-1

Undercut mica.



Replace springs.

a. Weak magnets.

a. Worn bushings.
Replace bushings.
RING GEAR.

Replace clutch.
2. Check clutch.
Replace clutch.

Clean and correct.

Replace clutch.

Replace bushing(s).
6. Check ring gear.

a. Worn ring gear.
Replace ring gear.
03-05-2 MMR2001_042_03_05A.FM

Replace or clean.

Clean.

Replace bracket(s).

Adjust switch position. Face nut is too far in.
5. Check starter relay.

a. Shorted starter relay winding(s).
Replace starter relay.
6. Check starter relay contacts.

a. Melted starter relay contacts.

a. Starter relay returns poorly.

SYMPTOM REGULATOR BLACK WIRE IS MELTED (HARNESS SIDE).
Test/Inspection 1. Check that big ground wire at battery is well connected to chassis.
MMR2001_042_03_05A.FM 03-05-3
SYMPTOM OPTIONAL ELECTRIC STARTER DOES NOT WORK WHEN TURNING IGNITION
SWITCH.
Test/Inspection 1. Check connection of BLACK wire (solenoid ground) in 3-wire housing coming
from magneto (white housing).
SWITCH.

2. Check fuse.
Clean or replace.


Replace.

Replace.
03-05-4 MMR2001_042_03_05A.FM


a. Defective part.
Replace cap.




7. Verify MPEM.
Tighten mounting screws. Replace MPEM, retest and verify ignition timing.
SYMPTOM CDI MODULE DOES NOT WORK.
a. Short circuit.
MMR2001_042_03_05A.FM 03-05-5
Readjust air gap.


terminals.
Test/Inspection 1. Perform all verifications outlined under ENGINE DOES NOT START —
NO SPARK AT SPARK PLUG.
of problem.
03-05-6 MMR2001_042_03_05A.FM




Replace.
Test/Inspection 1. Refer to ENGINE SLOWS DOWN OR STOPS AT HIGH RPM and check items
listed.


Seal.

a. Loose collar(s).
Tighten.

Replace.
MMR2001_042_03_05A.FM 03-05-7
SYMPTOM RER (ROTAX ELECTRONIC REVERSE) DOES NOT WORK.

a. Wrong idle speed.

a. Faulty spark plug.
Replace.
3. Check drive belt deflection.

a. Wrong deflection.
4. Check carburetor synchronization and air screw adjustment.

a. Wrong adjustment.
Adjust according to specification (refer to TECHNICAL DATA) and read
carburetor subsection.
5. Check electrical connections.

a. Bad electrical connections or damaged wires.
Clean or replace.
6. Check MPEM.
a. Faulty MPEM.
Replace.

a. Gas leak.
Replace bulb.

installed.
03-05-8 MMR2001_042_03_05A.FM
3. On manual start models: Verify regulator ground.

a. Rusted or loose retaining screws.
Clean, apply lithium grease (LMZ1) and firmly tighten screws.



8. Verify if heating grips installation overloads the magneto capacity.

MMR2001_042_03_05A.FM 03-05-9
Test/Inspection 1. Verify if gauge was connected on DC current by mistake (in case of optional
installation).
Find optional wires connected directly to DC ground (BK wire to chassis) or to any DC
hot wire (RD, RD/BL). Disconnect and reconnect to AC current (YL and YL/BK wires).
2. Verify sender unit for free movement and/or correct arm position.


Replace.


Replace brake switch.
03-05-10 MMR2001_042_03_05A.FM




2. Check tachometer part number.

a. Models with 360 W magneto have a different tachometer.
Replace with appropriate one.

a. YELLOW wire connected to pilot lamp. Mixed-up connections with heating
element pilot lamps.
Reconnect a YELLOW/BLACK wire to pilot lamp. YELLOW wires are connected to
heating element pilot lamps.
MMR2001_042_03_05A.FM 03-05-11


a. Spring is weaken or broken.
Replace spring.





MMR2001_042_03_06A.FM 03-06-1


Replace.

Replace.
4. Check sprockets.

Replace track.

Adjust.

Adjust.

Adjust.


03-06-2 MMR2001_042_03_06A.FM

Replace.









MMR2001_042_03_06A.FM 03-06-3




Replace.

a. NOTE: If all parts are in good condition and the customer still complains about an
unstable snowmobile, consider the installation of optional Proactive Control
System.
03-06-4 MMR2001_042_03_06A.FM
Section 04 ENGINE
TABLE OF CONTENTS 0
809 ENGINE TYPE ................................................................................................................. 04-02-1
INSTALLATION ON VEHICLE ............................................................................................ 04-02-4
TOP END ............................................................................................................................ 04-02-5
CLEANING ......................................................................................................................... 04-02-6
DISASSEMBLY................................................................................................................... 04-02-6
INSPECTION ...................................................................................................................... 04-02-7
ASSEMBLY......................................................................................................................... 04-02-8
BOTTOM END.................................................................................................................... 04-02-11
CLEANING ......................................................................................................................... 04-02-12
DISASSEMBLY................................................................................................................... 04-02-12
INSPECTION ...................................................................................................................... 04-02-12
ASSEMBLY......................................................................................................................... 04-02-13

LEAK TEST ......................................................................................................................... 04-03-1
PREPARATION ................................................................................................................... 04-03-1
PROCEDURE ...................................................................................................................... 04-03-1
CYLINDER TAPER .............................................................................................................. 04-03-4
CYLINDER/PISTON CLEARANCE ..................................................................................... 04-03-6
RING/PISTON GROOVE CLEARANCE.............................................................................. 04-03-7
RING END GAP .................................................................................................................. 04-03-7
CRANKSHAFT DEFLECTION............................................................................................. 04-03-7
CONNECTING ROD BIG END AXIAL PLAY ..................................................................... 04-03-8
CONNECTING ROD/PISTON PIN CLEARANCE ............................................................... 04-03-8
CONNECTING ROD/CRANKPIN CLEARANCE ................................................................. 04-03-9
CRANKSHAFT END-PLAY ................................................................................................. 04-03-9
CHECKING SURFACE FLATNESS..................................................................................... 04-03-9
RECTIFYING SURFACES ................................................................................................... 04-03-9
CHECKING CRANKSHAFT ALIGNMENT.......................................................................... 04-03-9
CDI SYSTEM .......................................................................................................................... 04-04-1

NIPPONDENSO TRIGGER COIL IGNITION SYSTEM ...................................................... 04-04-1
CLEANING ......................................................................................................................... 04-04-3
DISASSEMBLY................................................................................................................... 04-04-3
ASSEMBLY......................................................................................................................... 04-04-4
MMR2001_072_04_01ATOC.FM 04-01-1
Section 04 ENGINE

CLEANING .......................................................................................................................... 04-05-2
DISASSEMBLY ................................................................................................................... 04-05-2
ASSEMBLY ......................................................................................................................... 04-05-3
ADJUSTMENT.................................................................................................................... 04-05-3

COOLING SYSTEM LEAK TEST ........................................................................................ 04-06-2
INSPECTION ....................................................................................................................... 04-06-2
REWIND STARTER................................................................................................................. 04-07-1

INSPECTION ....................................................................................................................... 04-07-2
REMOVAL ........................................................................................................................... 04-07-2
DISASSEMBLY ................................................................................................................... 04-07-2
ASSEMBLY ......................................................................................................................... 04-07-2
INSTALLATION ................................................................................................................... 04-07-4
CARBURETOR AND FUEL PUMP ......................................................................................... 04-08-1

CARBURETOR .................................................................................................................... 04-08-1
CARBURETOR CIRCUIT OPERATION VERSUS THROTTLE OPENING .......................... 04-08-3
REMOVAL ........................................................................................................................... 04-08-3
CLEANING AND INSPECTION .......................................................................................... 04-08-3
CARBURETOR FLOAT LEVEL ADJUSTMENT .................................................................. 04-08-5
CARBURETOR ADJUSTMENTS........................................................................................ 04-08-6
INSTALLATION ................................................................................................................... 04-08-7
CHOKE ................................................................................................................................ 04-08-8
DPM..................................................................................................................................... 04-08-9
TESTING ............................................................................................................................. 04-08-9
PARTS REMOVAL AND INSTALLATION.......................................................................... 04-08-10
DPM MANIFOLD LEAK TESTING...................................................................................... 04-08-11
FUEL PUMP ........................................................................................................................ 04-08-12
REMOVAL ........................................................................................................................... 04-08-13
PUMP VERIFICATION......................................................................................................... 04-08-13
INSTALLATION ................................................................................................................... 04-08-13
FUEL TANK AND THROTTLE CABLE.................................................................................... 04-09-1
04-01-2 MMR2001_072_04_01ATOC.FM
Section 04 ENGINE
809 ENGINE TYPE 0

Mach Z STD/TECH PLUS
Ultra
Copper
9 Nm
(80 lbfin)
Ultra 28 Nm
Copper (21 lbfft)
ROT 15 Nm
Ultra (133 lbfin)
Copper
Loctite
271
35 Nm
(26 lbfft)
4 1
10 Nm
(89 lbfin) 37 Nm
(27 lbfft)
3
35 Nm
2 1 (26 lbfft)
29 Nm
A30C1GT (21 lbfft)
TYPICAL

Section 04 ENGINE
Grand Touring SE
Ultra
Copper
9 Nm
(80 lbfin)
9 Nm
(80 lbfin)
28 Nm
(21 lbfft)
ROT
Loctite
271
Ultra
Copper
35 Nm
10 Nm (26 lbfft)
4 (89 lbfin)
Ultra
Copper 35 Nm 3
(26 lbfft)
1 35 Nm
2
29 Nm (26 lbfft)
A30C1HT (21 lbfft)

Section 04 ENGINE
REMOVAL FROM VEHICLE – exhaust pipes using exhaust spring remover/

installer (P/N 529 035 400)
Open hood and close fuel shut-off valve.
Remove or unplug the following then lift off en-
gine from engine compartment.
NOTE: 3-cylinder engine is more heavy then a 2
cylinder engine. It weights about 45 kg (100 Ib).
Use of a hoist is recommended.
– guard
– air silencer
– drive belt
– driven pulley
– speedometer cable from angle drive
A30C0OA
529 035 400
TYPICAL
be disassemble) – tuned pipes
– hood, refer to BODY – after muffler
– carburetors – wiring connections
– impulse hose and high tension coil connector
housing
A30C0QA
A30C0PA 2 1
TYPICAL
1. Impulse hose
2. High tension coil connector housing
MMR2001_043_04_02A.FM 04-02-3
Section 04 ENGINE
– oil injection inlet line at oil injection pump, install 1,2,3,4, Engine Support Nut and
hose pincher Manifold Screw
– oil pump cable Torque the engine/support nuts no. 1 to 35 N•m
(26 lbf•ft).
Torque rubber mount no. 2 to support bracket to
29 N•m (21 lbf•ft).
Torque rubber mount/support screw to 37 N•m
(27 lbf•ft).
Torque manifold screws no. 4 to 10 N•m (89 lbf•in).
Torque removable side member screws to 7 N•m
(62 lbf•in).
Torque removable side member nut over counter-
shaft support to 15 N•m (133 lbf•in).
A30C0CB 2 1
1. Remove circlip cedure. However, pay attention, to all appropriate
2. Plastic washer
component/system reinstallation procedures de-
– coolant hoses at cylinder head and at front bot- scribed throughout this Shop Manual and to the
tom of engine following:
– engine support screws – It is easier to install oil pump cable before install-
ing engine on vehicle.
– engine stopper (left rear of engine)
– removable side member.
tor maximum throttle opening and oil injection
Turn steering left side. Remove engine from vehi- pump adjustment.
cle.
– Should a light exhaust leak be experienced at
muffler ball joint, Ultra Copper (P/N 413 710 300)
can be used.
04-02-4 MMR2001_043_04_02A.FM
Section 04 ENGINE
TOP END
Loctite 10 Nm
PST (89 lbfin)
3
30 Nm
(22 lbfft) 4
6
7
8
1 12 10
13
14 Grease
9
11
2 10 Nm
(89 lbfin)
16
Molykote 111
29 Nm (P/N 413 707 000)
(21 lbfft)
29 Nm
(21 lbfft)
17
19
20
18
21
A30C2NS

Section 04 ENGINE
COMPONENT REMOVAL
– cylinder head
– piston(s)
– cylinder(s)
– rewind starter
– oil pump
– water pump
– RAVE valve(s).
CLEANING
A02C29A
Discard all gaskets and O-rings.

TYPICAL
cleaner. To remove piston pin no. 19, use piston pin puller
(P/N 529 035 503) as follows:
port cylinder head and piston dome using a wood- Fully screw puller handle.
en spatula. Insert puller end into piston pin.
NOTE: The letters ’’AUS’’ (over an arrow on the Screw (LH threads) extracting nut.
piston dome) must be visible after cleaning. Hold puller firmly and rotate puller handle counter-
Clean the piston ring groove with a groove cleaner clockwise to pull piston pin.
DISASSEMBLY
18, Piston
Place a clean cloth or rubber pad (P/N 529 023 400)
over crankcase then with a pointed tool inserted
in piston notch, remove circlip no. 20 from piston
no. 18.
A01B1AA
TYPICAL
04-02-6 MMR2001_043_04_02A.FM
Section 04 ENGINE
RAVE System
Exhaust.
Remove screws no. 3, cover no. 6 and spring
no. 7.
Remove cylindrical screws no. 11 then valve rod
housing no. 13. Remove bellows no. 10 and
spring no. 12.
A06C3OA 2 1
1. Draining hole
2. Passages

10, Bellows
7, Spring
A06C3NA 1 PRELOAD IN
WIRE FREE N (LBF) AT
1. Exhaust valve ENGINE SPRING DIA. LENGTH COMPRESSED
TYPE P/N LENGTH OF
INSPECTION mm mm 14.7 mm
(in) (in) (.579 in)
SIONS MEASUREMENT. 809 on 420 1.0 48.5 0.0203
GT SE 239 945 (.039) (1.91) (.0045)
RAVE System 809 on 420 0.8 52.5 0.0110
Check valve rod housing and cylinder for clogged Mach Z 239 941 (.031) (2.07) (.0025)
passages.
MMR2001_043_04_02A.FM 04-02-7
Section 04 ENGINE
ASSEMBLY CAUTION: Always install new circlips.

RAVE System circlip, install each circlip so the circlip break is at
Install RAVE valve with its mention top as illustrat- 6 o’clock as illustrated. Use piston circlip installer
ed in the removal photo. Tighten red cap no. 4 (P/N 529 035 561).
screw to bottom. Insert circlip in tool at an angle.
17,18, Cylinder and Piston

cylinder with new injection oil or equivalent.

Head and Cylinder
Check flatness of part sealing surfaces. 1
Refer to LEAK TEST AND ENGINE DIMENSION
MEASUREMENT and look for Checking Surface
Flatness.
– Mount piston over connecting rod with the let-
A02C2KA
ters “AUS” (over an arrow on the piston dome)
facing in the direction of exhaust port (see illus- TYPICAL
tration below). 1. Circlip
1 1
AUS
A01C01A
1. Exhaust

A02C2LA
TYPICAL
1. Circlip
A02C2JA
TYPICAL
04-02-8 MMR2001_043_04_02A.FM
Section 04 ENGINE
Continue to square it up using round end of circlip Mount tool in piston making sure that circlip break
installer. is facing down.
A02C2OA 1
TYPICAL
A02C2MA
TYPICAL end of tool. Circlip will move from tool groove to
piston groove.
rests in groove.
A02C2PA
TYPICAL
A02C2NA
TYPICAL
MMR2001_043_04_02A.FM 04-02-9
Section 04 ENGINE
A01C02B 1
TYPICAL
A06C1QA
1. Circlip break
CAUTION: Circlips must not move freely after At assembly, torque cylinder head screws in the
installation; if so, replace them. following illustrated sequence. Tightening torques
Install cylinders and check for same height. are:
M6 screws: 12 N•m (106 Ibf•in)
M8 screws: 30 N•m (22 Ibf•ft)
16 14 18 5 2 3 9 8 12
A06C1PA
Also check for proper cylinder alignment.

17 13 19 20 1 6 11 7 10
A06C0GA
15 4
TYPICAL
04-02-10 MMR2001_043_04_02A.FM
Section 04 ENGINE
BOTTOM END
Loctite
515
Loctite
648 6
Loctite 10 Nm
243 Primer N (90 lbfin)
Loctite 515
Anti-seize
lubricant
(P/N 413 701 000) 2
3
5
Molykote 111
2 (P/N 413 707 000)
3 3 7
Primer N
Loctite 515
4
Loctite
243
Molykote
111
9
8
M8: 30 Nm
(22 lbfft) M6: 12 Nm
A30C2MS
TYPICAL

Section 04 ENGINE
NOTE: Engine must be removed from chassis to 1, Reed Valve

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-
Discard all oil seals, gaskets, O-rings and sealing sure on blade at blade stopper location.
rings. In case of a play, turn blade upside down and re-
Clean all metal components in a non-ferrous metal check. If there is still a play, replace blade and/or
cleaner. Use Gasket remover (P/N 413 708 500) valve body.
accordingly.
Remove old paste gasket from crankcase mating
surfaces with Gasket remover (P/N 413 708 500).
CAUTION: Never use a sharp object to scrape
away old sealant as score marks incurred are det-
1
rimental to crankcase sealing.
DISASSEMBLY
General
To remove drive pulley, refer to DRIVE PULLEY.
To remove magneto, refer to CDI SYSTEM.
A06C0FA
1. No play
tive cap and special puller, as illustrated. Check distance from blade stopper outer edge and
center of reed valve block.
1
A A
A00C0HA
1. PTO side
2. MAG side A06C36A
TYPICAL
INSPECTION A. 17.0 - 0, + 0.75 mm (.669 - 0, + .030 in)
NOTE: Refer to LEAK TEST AND ENGINE DIMEN- Bent blade stopper as required to obtain the prop-
SIONS MEASUREMENT. er distance.
Blade stoppers may slightly interfere with crank-
case during installation. Adjusted distance will be
reduced automatically upon installation.
04-02-12 MMR2001_043_04_02A.FM
Section 04 ENGINE
ASSEMBLY
2,3, Crankshaft Bearing and Anti-Seize
Lubricant
Prior to installation, place bearings into an oil con-
tainer filled with injection oil previously heated to
75°C (167°F). This will expand bearing and ease
installation.
Outer PTO bearing is 8 mm (5/16 in) from inner
bearing.
A30C1EA
A06C0HB
TYPICAL
A. 8 mm (5/16 in)
A30C1FA
Outer PTO Bearing Lubrication
Outer PTO bearing must be lubricated with Isoflex
grease (P/N 293 550 021).
CAUTION: Use only the recommended Isoflex
grease. Make sure not to push Isoflex grease be-
tween outside bearing race and half crankcase.
NOTE: The 50 g tube corresponds to 50 cc of
grease.
Total quantity of Isoflex grease to be applied is 21 to
26 cc.
Apply 21 to 26 cc of grease to outside bearing cage
and seal.
A30C1AA
MMR2001_043_04_02A.FM 04-02-13
Section 04 ENGINE
4, Crankcase
At crankshaft installation, position drive pins as il- 23 6 20 17 1 15 4 13 11 8 9
lustrated.
A30C1VA
24 5 22 21 3 19 18 2 16 14 12 7 10
TYPICAL — DRIVE PINS A06C3QA
Crankcase halves no. 4 and water pump housing TYPICAL

are factory matched and therefore, are not inter-
changeable as single halves. 5, Water Pump Housing
Prior to joining of crankcase halves, spray some Spray Primer N (P/N 413 708 100) on one of mat-
new injection oil (or equivalent) in bearings and on ing surfaces. Let it dry for 10 to 20 minutes.
all moving parts of the crankshaft. Spray Primer N
Apply Loctite 515 (P/N 413 702 700) on the other
(P/N 413 708 100) on one of mating surfaces. Let
mating surface.
it dry for 10 to 20 minutes.
Tighten water pump housing screws to 10 N•m
Apply Loctite 515 (P/N 413 702 700) on the other
(90 lbf•in) following sequence as illustrated.
mating surface.
NOTE: Primer N allows Loctite 515 to fully cure 6 4 8 10 12
on aluminum surfaces. It increases filling capacity
and reduce curing time.
Align both crankcase halves before tightening
screws.
Torque crankcase screws in the following illustrat-
ed sequence. Tightening torques are:
1
M6 screws: 12 N•m (106 Ibf•in)
M8 screws: 30 N•m (22 Ibf•ft)
2
A06C3RA 7 1 5 3 9 11
1. Oil level plug
04-02-14 MMR2001_043_04_02A.FM
Section 04 ENGINE
Add chaincase synthetic oil (P/N 413 802 800) into 8,9, Plastic Gear and Steel Gear
water pump housing until oil level reach bottom of
Apply Molykote 111 to needle bearing of each gear.
plug hole. See above illustration. Total capacity is
about 14 cc (.47 U.S. oz). Install plastic gear on oil pump side. Steel gear goes
on water side.
This oil addition is needed only when servicing wa-
ter pump. During normal engine operation, this oil
can flow through engine. After that fuel/oil mixture
will lubricate water pump bearings by scavenging.
6, Screw
Apply Loctite 243 on screw threads. Install the screw
retaining oil line clip first. If experiencing leaks at
carburetor adaptor, use primer N and Loctite 515
on sealing surfaces of crankcase and adaptor.
7, Seal
Install seal using pusher (P/N 420 876 516).
CAUTION: Make sure oil seal is fully pushed
against stator shoulder.
A30C0NB
1 2
TYPICAL
420 876 516 1. Plastic gear
2. Steel gear
A06C1RA
MMR2001_043_04_02A.FM 04-02-15
Section 04 ENGINE

MEASUREMENT 0
LEAK TEST 10. Activate pump and pressurize engine to 34 kPa
The following gives verification procedures for liq-
uid cooled engines.
utes. If pressure drops before 3 minutes,
check tester kit by spraying a soapy solution
PREPARATION on pump piston, all plugs and fittings.
IMPORTANT: All cylinders have to be checked in- – If tester kit is leaking, bubbles will indicate
dividually. where leak comes from.
1. Remove tuned pipe/muffler and exhaust mani- – If tester kit is not leaking, check engine as per
fold or exhaust sockets. following procedure.
2. Install plugs over exhaust flanges. Tighten with 12. Proceed the same for remaining cylinders.
previously removed screws.
3. Remove RAVE valves and install plugs over flang- PROCEDURE
es. Tighten with previously removed screws.
4. Remove carburetor(s). reference. See last page of this chapter.
5. Remove resonator and install a plug on intake Using flow chart and following text, pressurize
rubber boot resonator outlet. area to be tested and spray soapy solution at the
6. Insert plug(s) in intake rubber boot(s). Tighten indicated location.
with clamps already there.
TEST PRESSURE: 34 kPa (5 PSI)
7. Using a hose pincher(s) (P/N 295 000 076), block for 3 minutes
impulse hose(s).
8. Install air pump on any valve of exhaust plug. – If there is a leak at the tested location, it is rec-
ommended to continue testing next items be-
NOTE: If necessary, lubricate air pump piston with fore overhauling engine. There is a possibility of
mild soap. more than one leak.
CAUTION: Using hydrocarbon lubricant (such – If there is no leak at the tested location, contin-
as engine oil) will damage rubber seal of pump ue pumping to maintain pressure and continue
piston. with next items until leak is found.
9. Rotate crankshaft so that piston goes to BDC
(Bottom Dead Center) on side where the pump
is installed. This will open exhaust port.
MMR2001_044_04_03A.FM 04-03-1
Section 04 ENGINE
Engine 2. Small injection oil lines coming from pump.

1
1
2
A01B2XA 2
TYPICAL
1. Banjo fittings

pump. It indicates defective check valve in banjo
fitting (or lines).
3. Remove cooling system cap.
A01B4TA
5 Check for air bubbles in antifreeze. It indicates de-
fective cylinder head O-ring or cylinder base gas-
TYPICAL
1. Blocked intake flanges
ket.
2. Blocked impulse fitting 4. Remove drive pulley then check crankshaft out-
3. Open ends (if applicable)
4. Blocked RAVE valve flanges (if applicable) er seal.
5. Blocked exhaust flanges
Check the following: then check crankshaft outer seal.
1. All jointed surfaces and screw/stud threads of 6. If leak still persists, it indicates a defective cast-
engine: ing somewhere in engine.
– spark plug base, insulator Disassemble engine and carefully check for de-
– cylinder head fects in castings. Pay attention to tapped holes
– cylinder base thus lead to leakage.
– oil injection pump mounting flange (gasket) FINALIZING REASSEMBLY
– coolant pump housing After reassembling engine, always recheck for leak-
– bleed screws/plugs. age.
04-03-2 MMR2001_044_04_03A.FM
Section 04 ENGINE

FLOW CHART
PRESSURIZE ENGINE
NO
IS ENGINE LEAKING?
YES

FLANGES ETC.

NO

INJECTION PUMP

TOWARD PUMP?
NO

NO
GEAR
LUBRICATION SYSTEM
NO
YES

SEAL OF PTO AND
MAG SIDES
YES
NO


NO
CYLINDER SEPARATELY

NO


NO ANY LEAK FOUND? SHAFT CERAMIC,, BESIDE
COOLANT SEAL
NO
CHECK OIL PUMP

YES
NO

YES
NO

INTERNALLY
A32C1KS
MMR2001_044_04_03A.FM 04-03-3
Section 04 ENGINE

MEASUREMENT
ENGINE TYPE MAXIMUM
809 0.08 mm (.003 in)
50 mm (2 in) of surface replaced.
809
0.5 mm (.020 in) for total NOTE: Be sure to restore the chamfer around all
length of cylinder head cylinder sleeve port openings.

a straightedge and a feeler gauge. 1
CYLINDER TAPER
ENGINE TYPE MAXIMUM
809 0.10 mm (.004 in)
A
Compare cylinder diameter 16 mm (5/8 in) from
top of cylinder to just below its intake port area. 2
On rotary valve engines, measure just below aux-
iliary transfer port, facing exhaust port. If the dif-
ference exceeds the specified dimension the cyl- A01C54A
inder should be rebored and honed or should be

1. Piston pin position
replaced. 2. Measures to be compared
A. 16 mm (5/8 in)
COMBUSTION CHAMBER
VOLUME MEASUREMENT
A
1
A01C53A 1
A. 16 mm (5/8 in) from top F01D5VA
04-03-4 MMR2001_044_04_03A.FM
Section 04 ENGINE
NOTE: When checking the combustion chamber 3. Open burette valve to fill its tip. Add liquid in bu-
volume, engine must be cold, piston must be free rette until level reaches 0 cc.
F00D0HA 1

2. Obtain a graduated burette (capacity 0 - 50 cc) ume would be false.
1 2.25 cc corresponding to the spark plug tip.

ENGINE
(cc)
TYPE
(up to top thread of spark plug hole)
809 26.29 ± 1.1
F00B0BA
1. Graduated burette (0 - 50 cc)
MMR2001_044_04_03A.FM 04-03-5
Section 04 ENGINE
USED PISTON MEASUREMENT Adjust and lock a micrometer to the specified val-
ue on the piston dome.
Using a micrometer, measure piston at A perpen-
dicularly (90°) to piston pin. 1
F00B08A
With the micrometer set to the piston dimension,

1 adjust a cylinder bore gauge to the micrometer di-
F01D0NA
mension and set the indicator to 0.
A. See table below
DIMENSION A
ENGINE TYPE
mm (in)
809 28.7 (1.13) 1
The measured dimension should be the same as 2
the one scribed on piston dome. If not, install a
new piston.
CYLINDER/PISTON CLEARANCE
Used and New Pistons
NOTE: Make sure used piston is not worn. See
USED PISTON MEASUREMENT above. F00B09A
Take the measurement on the piston dome. 1. Use the micrometer to set the cylinder bore gauge
2. Dial bore gauge
1
F00D0EA 2 1
F00B0AA
1. Piston dome
2. Piston measurement 1. Indicator set to 0 (zero)
04-03-6 MMR2001_044_04_03A.FM
Section 04 ENGINE
Position the dial bore gauge at 16 mm (5/8 in) be- RING END GAP
low cylinder top edge.
intake port. On rotary valve engines, position ring
just below transfer ports.
NOTE: In order to correctly position the ring in the
Using a feeler gauge, check ring end gap. Replace
TECHNICAL DATA.
1
1
A
F01D0KA

A. 16 mm (5/8 in)
2
ance, replace cylinder or rebore. Refer to TECHNI- A01C0QA
CAL DATA. 1. Transfer port

2. Intake port
micrometer, otherwise the reading will be false. CRANKSHAFT DEFLECTION
Crankshaft deflection is measured with a dial indi-
RING/PISTON GROOVE cator.
CLEARANCE
Measuring (in engine)
rectangular ring and groove. Replace piston if First, check deflection with crankshaft in engine.
clearance exceeds specified tolerance. Refer to If deflection exceeds the specified tolerance, re-
TECHNICAL DATA. check deflection using V-shaped blocks to deter-
mine the defective part(s). See below.
Measuring (on bench)

Once engine is disassembled, check crankshaft de-
flection on V-shaped blocks. If deflection exceeds
the specified tolerance, it can be worn bearings or
a bent crankshaft. Remove crankshaft bearings and
check deflection again on V-shaped blocks to deter-
mine the defective part(s). See measurement A in
following illustration.
A01C0PA
MMR2001_044_04_03A.FM 04-03-7
Section 04 ENGINE

AXIAL PLAY
TYPE min. – max. LIMIT
2
0.31 - 0.68 1.20 mm
809
(.012 - .027 in) (.047 in)
Using a feeler gauge, measure distance between

the distance exceeds specified tolerance, repair or
replace the crankshaft.
A 1
A01C0RC
TYPICAL
1. Measure at mid point between the key and the first thread
2. Mid point of crankshaft bearing
A. See table below
Crankshaft Deflection on PTO Side

ENGINE DISTANCE A MAXIMUM ON PTO SIDE
TYPE mm (in) mm (in)
809 94.4 (3.717) 0.06 (.0024)
A01C0SA
Crankshaft Deflection on MAG Side
TYPICAL
MAXIMUM ON MAG SIDE
ENGINE TYPE
mm (in) CONNECTING ROD/PISTON PIN
809 0.05 (.002) CLEARANCE
Measure piston pin with its needle bearing. Com-
Crankshaft Deflection in Center of pare to inside diameter of connecting rod.
Crankshaft
MAXIMUM IN CENTER
ENGINE TYPE
OF CRANKSHAFT
809 0.08 mm (.0031 in)
NOTE: Crankshaft deflection cannot be correctly

If the deflection exceeds the specified tolerance,
A01C3GA
04-03-8 MMR2001_044_04_03A.FM
Section 04 ENGINE
A01C3HA A00A1LA

TYPE min. – max. LIMIT
CHECKING CRANKSHAFT
ALIGNMENT
0.003 - 0.012 mm 0.015 mm
809 Install a degree wheel (P/N 414 352 900) on crank-
(.0001 - .0005 in) (.0006 in)
shaft end.
Remove all spark plugs.
CONNECTING ROD/CRANKPIN
Install a TDC gauge (P/N 414 104 700) in spark plug
CLEARANCE hole on MAG side.
ENGINE NEW PARTS WEAR Bring MAG piston at top dead center.
TYPE min. – max. LIMIT Rotate degree wheel (not crankshaft) so that 360°
mark aligns with center of crankcase. Scribe a
0.024 - 0.038 mm 0.06 mm mark on crankcase.
809
(.0004 - .0015 in) (.0024 in)
Remove TDC gauge and install it on center cylinder.
Bring center piston to top dead center. Degree
CRANKSHAFT END-PLAY wheel must rotate with crankshaft.
End-play is not adjustable but it should be be-
tween 0.10 - 0.30 mm (.004 - .012 in). 20
10
0
90
30
80
40
CHECKING SURFACE FLATNESS

70
50 60
Intake manifold, intake manifold cover can be

checked for perfectly mating surfaces.
Lay part on a surface plate (marble, mirror or thick
glass plate).
Holding down one end of part, try pushing down
the other end.
If any play is felt, part must be rectified. 180
RECTIFYING SURFACES
Stick a fine sand paper sheet on the surface plate A06C1TA 0
then lightly oil the sand paper.

TYPICAL
Rub part mating surface on sand paper using 8-
figure movements. Interval between cylinders must be 120° ± 0.5.
Proceed the same with MAG side piston.
Any other reading indicates a misaligned (twisted)
crankshaft.
MMR2001_044_04_03A.FM 04-03-9
Section 04 ENGINE
CDI SYSTEM 0
290 W on Mach Z STD/TECH PLUS
Dielectric grease
RER models
equipped only
Clear Silicone 5
(P/N 293 800 033) 4
3 Loctite 243
2
6 1 125 Nm
(92 lbfft)
To wiring
harness 4 Loctite 243 Loctite 243
22 Nm
(195 lbfin)
A30E1QT
TYPICAL

Section 04 ENGINE
360 W on Grand Touring SE
Dielectric
Dielectric grease
grease
Silastic 732
Loctite 243
5 4
Loctite 243
125 Nm
6 (92 lbfft)
4
3
1
22 Nm
(195 lbfin)
Loctite 243
To voltage
regulator
A30E28T

Section 04 ENGINE
NOTE: The following procedures can be done with-

out removing the engine from chassis. To facilitate
magneto removal, hold drive pulley with tool (P/N
529 027 600).
CLEANING
cleaner.
a clean cloth.
DISASSEMBLY A06E22B 1 2
3, Magneto Flywheel TYPICAL

To gain access to magneto assembly, remove the 2. M8 x 20 mm screws
following parts as needed on different engines: – Remove magneto flywheel nut, using a 30 mm
– tuned pipe(s) and muffler socket machined to 40 mm (1.580 in) outside
– rewind starter diameter by 16 mm (5/8 in) long.
– starting pulley no. 2. NOTE: To correctly remove a threadlocked fasten-
er it is first necessary to tap on the fastener to break
To remove magneto flywheel retaining nut no. 1: threadlocker bond. This will eliminate the possibility
Use magneto puller ring (P/N 420 876 080). Former of thread breakage.
puller has to be modified as shown. To remove magneto flywheel, install the puller (P/N
529 022 500).
– Tighten puller bolt and at the same time, tap on
bolt head using a hammer to release magneto
flywheel from its taper.
5,6, Trigger Coil

NOTE: As spare parts only trigger coil with GN/BL
and GY/BL wires is available. This trigger coil can
replace any of both trigger coils installed on RER
models.
Magneto and stator plate must be removed before
trigger coil removal.
A06E23A 1
To replace trigger coil:
1. Cut by 25 mm (1 in)
– Disconnect trigger coil connector housing.
Install puller with its tab in magneto housing open- – Remove grommet from crankcase where trig-
ing. ger coil wire exits magneto housing.
CAUTION: Use only M8 x 20 mm screws to bolt – Remove retaining screws no. 4.
puller to magneto.
– Remove trigger coil and carefully pull wires.
– Install new trigger coil and other parts removed.
MMR2001_045_04_04A.FM 04-04-3
Section 04 ENGINE
ASSEMBLY
3, Magneto Flywheel
Clean crankshaft extension (taper) and apply Loc-
tite 243 (blue) on taper, then position Woodruff
key, flywheel and lock washer on crankshaft.
Clean nut threads and apply Loctite 243 (blue) then
tighten nut 125 N•m (92 lbf•ft).
At reassembly coat all electric connections except
Deutsch housings (waterproof gray housing) with
silicone dielectric grease (P/N 293 550 004) to pre-
vent corrosion or moisture penetration.
CAUTION: Do not use silicone sealant, this prod-
uct will corrode contacts. Do not apply silicone
dielectric grease on any Deutsch (gray) housing
otherwise housing seal will be damaged.
Ignition Timing
04-04-4 MMR2001_045_04_04A.FM
Section 04 ENGINE

OIL INJECTION PUMP
809 Engine
1 2
Loctite
648 6
6
4
5 6
5 Nm
3 (44 lbfin)
A30C1JT Loctite 243

Section 04 ENGINE
 WARNING OIL PUMP IDENTIFICATION

Wipe off any oil spills. Oil is highly flamma- 7, Pump Lever
ble.
tification on lever no. 7.
OIL SYSTEM LEAK TEST CAUTION: Always mount proper pump on en-
All Models gine.
The following test will indicate any leak from oil OIL PUMP
reservoir to the banjo fitting(s). ENGINE TYPE
IDENTIFICATION
Install on oil reservoir special cap of leak testing kit
809 15
(P/N 529 033 100).
Install hose pinchers (P/N 295 000 076) on outlet NOTE: The following procedures can be done with-
hoses. out removing the engine from chassis.
1 2
CLEANING
cleaner.
DISASSEMBLY
1,2, Gear Retaining Nut and Oil Pump

Gear
To remove gear retaining nut, first extract the nee-
A03C2UA dle roller with pliers then lock gear in place using
one of the following gear holder.
TYPICAL
2. Hose pinchers on outlet hoses ENGINE TYPE TOOL P/N
Connect pump of leak testing kit to special cap. 809 420 277 905
Pressurize oil system to 34 kPa (5 PSI). That pres-
sure must not drop during 3 minutes.
If pressure drops, locate leak(s) and repair/replace
leaking component(s). To ease locating leak(s) 420 277 905
indicate leak location(s).
A00C17A
TYPICAL
04-05-2 MMR2001_046_04_05A.FM
Section 04 ENGINE
ASSEMBLY ADJUSTMENT
2, Oil Pump Gear Prior to adjusting the pump, make sure all carbu-
retor adjustments are completed.
At gear assembly, apply a light coat of low temper-
ature grease (P/N 413 706 100) on gear teeth. Synchronizing Pump with Carburetor
5,6, Spring Clip and Clamp Eliminate the throttle cable free-play by pressing
the throttle lever until a light resistance is felt, then
Always check for spring clips tightness. hold in place. The aligning marks on the pump
casting and on the lever must align. If not, loosen
3, Screw the adjuster nut and adjust accordingly.
Torque to 5 N•m (44 lbf•in). Retighten the adjuster nut.
Make sure cable barrel is well seated in oil pump
lever.
Secure barrel with plastic washer and circlip.
Install cable lock washer above support.
1
2
1
A30C0CA
A06C3JA
1. Lock washer
1. Adjuster nut
Verify cable and oil pump lever operation. 2. Marks in line
CAUTION: Proper oil injection pump adjust-

ment is very important. Any delay in the open-
ing of the pump can result in serious engine
damage.
MMR2001_046_04_05A.FM 04-05-3
Section 04 ENGINE
To Bleed Oil Lines

A06C3KA
TYPICAL — ENGINE AT IDLE
 WARNING
A06C3JB Ensure not to operate carburetor throttle mech-
1. Small oil lines
2. Bleeder screw
3. Main oil line
Reinstall all parts.

CHECKING OPERATION
Bleed the small oil line between pump and intake Oil Pump
manifold by running engine at idle while holding On Vehicle
the pump lever in fully open position.
NOTE: Main oil line must be full of oil. See bleed-
NOTE: Make a J hook out of mechanical wire to ing procedure above.
lift the lever.
stand. Unplug oil lines from pump. Start engine
and stop it as soon as it fires.
04-05-4 MMR2001_046_04_05A.FM
Section 04 ENGINE
Check that oil in small oil lines has been sucked up Test Bench
(this will be indicated by a clear section of small oil Connect a hose filled with injection oil to main line
lines). Repeat the procedure until this condition is fitting. Insert other hose end in an injection oil con-
attained. tainer. Using a clockwise rotating drill rotate pump
Reconnect small oil lines, start engine and run at shaft. Oil must drip from outer fittings while hold-
idle while holding the pump lever in fully open po- ing lever in a fully open position. If not replace
sition. Oil columns must advance into small oil pump.
lines.
2 3 1
A06C3LA
2
TYPICAL
1. Fully open position
2. Clockwise rotating drill
3. Main line
4, Check Valve
A06C3KB To verify this check valve, proceed the same as for
TYPICAL — ENGINE AT IDLE
1. Oil columns advancing
oil line from check valve. After restarting the en-
2. Fully open position gine, check that a clear section in small oil line is
present. Reconnect oil line.
gear and drive shaft (if applicable) for defects, re- Run engine at idle. Oil column must advance. If
place as necessary. Test pump as describes below. the check valve is faulty, oil column will go back
and forth. Replace if so.
in small tubes. If oil drops, verify check valve oper-
ation in injection nozzle. Replace as necessary.
MMR2001_046_04_05A.FM 04-05-5
Section 04 ENGINE

809 Engine
6
Loctite
292
ROT
A30C2OS
TYPICAL

Section 04 ENGINE
COOLING SYSTEM LEAK TEST

Install special plug (radiator cap) (P/N 529 021 400)
and hose pincher (P/N 529 009 900) on overflow
hose. Pressurize coolant reservoir to 100 kPa (15 PSI).
Check all hoses and cylinder/base for coolant leaks.
Spray a soap/water solution and look for air bub-
bles.
A30C0DA
TYPICAL
When the coolant level is low enough, lift the rear

of vehicle to drain the radiators.

A01B4AA 529 009 900 Apply Loctite 592 (P/N 413 702 300) thread sealant
TYPICAL on sender and plug to avoid leaks.
INSPECTION 1, Pressure Cap

Check if the cap pressurizes the system. If not,
Check general condition of hoses and clamp tight-
install a new 90 kPa (13 PSI) cap (do not exceed this
ness.
pressure).
DRAINING THE SYSTEM 6,7, Radiator and Radiator Protector
 WARNING Insert radiator protector into radiator C-rail.
Never drain or refill the cooling system when COOLING SYSTEM REFILLING
engine is hot.
PROCEDURE
mixture from the coolant tank. Recommended Coolant
Disconnect hose from water pump housing to Use Premixed coolant - 52°C (- 62°F) (P/N 413 711
drain coolant from engine. 802) (16 x 1L). Do not reinstall pressure cap.
CAUTION: To prevent rust formation or freezing
condition, always replenish the system with rec-
ommended premixed coolant.
System Capacity
04-06-2 MMR2001_047_04_06A.FM
Section 04 ENGINE
Refilling Procedure
With engine cold, refill coolant tank up to cold level
line. Wait a few minutes then refill to line. Install
pressure cap. Start engine. Refill up to line while
engine is idling until all air bubbles have excaped
from system (about 4 to 5 minutes). Install pres-
sure cap.
To make sure coolant flows through radiators,
touch them by hand. They must feel warm.
line.
NIVEAU
FROID NIVEAU FROID
2
COLD COLD LEVEL
LEVEL
A30C0ZA
TYPICAL
1. Coolant tank
2. COLD LEVEL line

proper tester.
MMR2001_047_04_06A.FM 04-06-3
Section 04 ENGINE
REWIND STARTER 0
All Models
Molykote
PG 54 6
12 Molykote
PG 54
7
11 5
10
9
Molykote
PG 54
13
2
3
10 Nm
(89 lbfin)
A06C3GT

Section 04 ENGINE
INSPECTION
bricated.
the rewind starter springs be lubricated period-
gage within 30 cm (1 ft) of rope pulled. If not, dis- A01C12A
GENTLY TAP ON KEY
aged plastic parts. Replace as required, lubricate,
reassemble and recheck.
ASSEMBLY
When releasing starter grip, it must return to its
stopper and stay against it. If not, check for proper At assembly, position spring no. 4 outer end into
spring preload or damages. Readjust or replace as spring guide notch then wind the spring counter-
required. clockwise into guide.
return freely. If not, check for damaged parts or  WARNING
lack of lubrication. Replace parts or lubricate ac- Since the spring is tightly wound inside the
cordingly. guide it may fly out when rewind is handled.
Always handle with care.
REMOVAL
Using a small screwdriver, extract rope knot from
starter grip no. 13. Cut rope close to knot. Tie a knot
near starter. 1
Remove screws no. 3 and washers no. 2 secur-
ing rewind starter no. 1 to engine then remove re-
wind starter.
DISASSEMBLY
To remove rope from rewind starter mechanism:
– First remove locking ring no. 12, locking spring
no. 11, circlip no. 10, pawl lock no. 9 and pawl
no. 8.
– Let sheave get free to release spring preload.
– Remove sheave no. 5 from starter housing no. 1. A01C13A
– Disengage key no. 7 and pull out rope no. 6. 1. Outer end into guide notch

bricated.
04-07-2 MMR2001_048_04_07A.FM
Section 04 ENGINE
CAUTION: It is of the utmost importance that To adjust rope tension:

the rewind starter spring(s) be lubricated peri- Wind rope on sheave and place rope sheave into
odically using specific lubricant. Otherwise, re- starter housing making sure that the sheave hub
wind starter component life will be shortened notch engages in the rewind spring hook.
under very cold temperatures. Rotate the sheave counterclockwise until rope
end is accessible through starter housing orifice.
Lubricate spring assembly with Molykote PG 54
(P/N 420 899 763) and position into starter housing Pull the rope out of the starter housing and tem-
as illustrated. porarily make a knot to hold it. One turn preload
will give 7 turns of tension when fully extended.
A01C0CA
A01C14A Position pawl no. 8, pawl lock no. 9 and circlip

1. Grease inside spring guide
no. 10.
Install locking spring no. 11 and lubricate with
CAUTION: The use of standard multi-purpose
Molykote PG 54 (P/N 420 899 763).
grease could result in rewind starter malfunction.
To install a new rope no. 6: insert rope into sheave
no. 5 orifice and lock it with the key no. 7 as illus- 1
trated.
A01C17A
1. Spring coated with MOLYKOTE PG 54
Install locking ring.

A01C15A
1. Push to lock
MMR2001_048_04_07A.FM 04-07-3
Section 04 ENGINE
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
over the knot.
A01C18A
TYPICAL
04-07-4 MMR2001_048_04_07A.FM
Section 04 ENGINE

CARBURETOR
TM Type on Mach Z STD and TECH PLUS
2
4
7 5
14
10
13
12
9
6
8
A30C0FT

Section 04 ENGINE
TM Type on GT SE
PTO/Center
1
MAG
2
4
7
3
14
10
13
12
8 9 11
A30C2PS

Section 04 ENGINE
CARBURETOR CIRCUIT
OPERATION VERSUS THROTTLE
OPENING
The following illustration shows the part of the car-
buretor which begins and stops to function at dif-
ferent throttle slide openings.
Note that the wider part of symbol corresponds to
the opening mostly affected. For instance, throttle
slide cut-away begins to function at closed posi-
tion but it is most effective at 1/4 opening and de-
creases up to 1/2 opening.
Throttle slide openings

A30C08A 3 1 2
Wide TYPICAL
open
1. Air temperature sensor
3/4 2. Air intake silencer
3. MPEM
1/2
Twist DPM manifold and detach from air intake si-
1/4
1/8 lencer.
Close
All Models
13,11, Pilot jet and pilot screw
13,6, Pilot jet and air screw Unhook latches then, remove air intake silencer
5, Throttle slide cut-away from left hand side.On Grand Touring SE remove
3, Needle taper and needle position choke cable and lever from air silencer.
14, Needle jet
A00C04B 8, Main jet Disconnect fuel inlet lines. It is easier to discon-
nect MAG side carburetor fuel inlet lines when car-
VIEW FROM AIR INTAKE OPENING buretors are partially removed.
NOTE: For fine tuning refer to TECHNICAL DATA Grand Touring SE and Mach Z TECH PLUS
and to SPARK PLUG.
Unplug DPM solenoid connector and autoprimer
NOTE: For high altitude regions, a service bulletin solenoid connector on Grand Touring SE.
altitude and temperature. Disconnect throttle cable from throttle shaft.
Unfasten choke cable from choke rod.
REMOVAL Remove carburetors and DPM manifold as an as-
sembly from engine.
All Models
Close fuel shut-off valve. CLEANING AND INSPECTION
Grand Touring SE and Mach Z TECH PLUS The entire carburetor should be cleaned with a
Unplug air temperature sensor connector from air general solvent and dried with compressed air be-
intake silencer and remove MPEM, as shown in the fore disassembly.
next photo. CAUTION: Heavy duty carburetor cleaner may
be harmful to the float material and to the rubber
parts, O-rings, etc. Therefore, it is recommended
to remove those parts prior to cleaning.
MMR2001_049_04_08A.FM 04-08-3
Section 04 ENGINE
Carburetor body and jets should be cleaned in a For MAG side carburetor, raise throttle slide half
carburetor cleaner following manufacturer’s in- way then unscrew Allen screws.
structions.
2
 WARNING
Solvent with a low flash point such as gaso- 1
3
needle and seat must be replaced as a matched set.
retor only. It is designed to operate with a fuel
pump system.
Check throttle slide for wear. Replace as necessary.
Check idle speed screw straightness. Replace as
necessary.
Check for fuel soaked into float no. 12; replace as A06C0KA
necessary. 1. Allen screw

2. Arm moved aside
Check float for cracks or other damages affecting 3. Locking screw and adjusting nut removed
free movement; replace as necessary.
The position of the needle in the throttle slide is
Inspect throttle cable and housing for any damag- adjustable by means of an E-clip inserted into 1 of
es. Replace as necessary. 5 grooves located on the upper part of the needle.
Position 1 (at top) is the leanest, 5 (at bottom) the
DISASSEMBLY AND ASSEMBLY richest.
NOTE: To ease the carburetor disassembly and NOTE: The last digit of the needle identification
assembly procedures it is recommended to use number gives the recommended calibrated posi-
carburetor tool kit (P/N 404 112 000). tion of the E-clip from the top of the needle.
Example: 6DH4-3
Recommended
Needle
identification
calibrated position.
1 Lean
A00B2FA
2
2,3, E-Clip and Needle

3
To remove needle or to change its position or to
remove throttle slide, remove carburetor cover.
Except for MAG side carburetor, unscrew locking 4
screw and adjusting nut form throttle shaft.
Move arm aside just enough for unscrewing Allen
5 Rich
screw retaining throttle slide. At reassembly ap- A00B2GA
play Loctite 243 (P/N 293 800 060).

CLIP POSITIONS
04-08-4 MMR2001_049_04_08A.FM
Section 04 ENGINE
The size of the throttle slide cut-away affects the

fuel mixture between 1/8 to 1/2 throttle opening.
1 3
A00C01A 2 4
1. Low cut-away
2. Rich mixture
3. High cut-away
4. Lean mixture
A30C1KA
8, Main Jet TYPICAL — TM TYPE

1. Ruler vertical and in line with main jet
selected for a temperature of - 20°C (0°F) at sea Float level height can be check using tool (P/N 529
level. Different jetting can be installed to suit tem- 035 520). Keep tool in line with main jet as explained
perature and/or altitude changes. above.
529 035 520
ADJUSTMENT
CAUTION: Spark plugs will foul if float is adjust-
ed too low. Engine may be damaged if float is
adjusted too high.
9,10, Float Arm and Float Arm Pin

Correct fuel level in float chamber is vital toward
maximum engine efficiency. To check for correct
– Make sure that float arm is symmetrical — not
distorted.
– Remove float bowl and gasket from carburetor.
– With carburetor chamber upside-down on a lev- A30C1QA
el surface, measure height H between bowl

seat and top edge of float arm. Keep ruler per- CARBURETOR FLOAT HEIGHT H
fectly vertical and in line with main jet hole. TYPE ± 1 mm (± .040 in)
All TM 21.0 (.827)
MMR2001_049_04_08A.FM 04-08-5
Section 04 ENGINE
To Adjust Height H TM Type Carburetor

– Bend the contact tab of float arm until the spec-
ified height is reached. 1
A06C0YA
TYPICAL — MACH Z STD/TECH PLUS

A30C1LA 1 1. Idle speed screw
2. Air screw (on each carburetor)
TYPICAL — TM TYPE
1. Contact tab
Adjustments should be performed following this
sequence:
– air screw adjustment on Mach Z STD/TECH PLUS
– pilot screw adjustment on Grand Touring SE
2
(triple carburetor models)
1
A30C2TA
GRAND TOURING SE
1. Idle speed screw
2. Pilot screw (on each carburetor)
04-08-6 MMR2001_049_04_08A.FM
Section 04 ENGINE
6,11, Air Screw and Pilot Screw 1 4 3

Completely close the air screw or pilot screw de-
pending on model (until a slight seating resis-
tance is felt) then back off as specified.
Throttle Slide Height

Remove carburetor covers.
First proceed on MAG carburetor.
Using a drill bit to measure throttle slide height
(see following table) on outlet side of carburetor
(engine side).
Adjust by turning idle speed screw no. 7. A30C1PA 2
1. MAG carburetor adjusted first
1 3 2. Drill used as a gauge to measure throttle height
3. Locking screw
4. Adjusting nut
Tighten locking screws and recheck throttle height.

NOTE: By adjusting all throttle slides at same height
TM carburetors synchronization is done at same
time.
Final idle speed adjustment (engine running at idle
speed) should be within 1/2 turn of idle speed screw
from preliminary adjustment.
THROTTLE SLIDE
MODELS HEIGHT
mm (in)
All TM 1.3 (.051)
A30C1RA 2
1. Adjust MAG carburetor first
INSTALLATION
2. Drill used as a gauge to measure throttle height
3. Idle speed screw CAUTION: Never allow throttle slide(s) to snap
shut.
For center and PTO carburetors loosen locking
screws. Use same drill bit as for MAG carburetor Prior to install carburetor, adjust air screw and pre-
to measure throttle slide height. Turn adjusting nut liminary idle speed as described above.
to adjust. To install carburetor on engine, inverse removal
procedure.
However, pay attention to the following:
On applicable models, make sure to align tab of
carburetor and air intake silencer (if applicable)
with notch of adaptor(s). On applicable models, in-
MMR2001_049_04_08A.FM 04-08-7
Section 04 ENGINE
CAUTION: The rubber flange must be checked Remove plunger grommet from each carburetor.
for cracks and/or damage. At assembly, the Fill the grommet interior with dielectric grease
flange must be perfectly matched with the air (P/N 293 550 004). Reinstall the grommets.
intake manifold or severe engine damage will Apply dielectric grease (P/N 293 550 004) on choke
occur. Beside do not interchange carburetors, rod and reinstall it with its return spring and spacer on
the jetting may be different on each side. A red PTO side. Make sure that ferrule screws align with
dot is printed on MAG carburetor (blue on PTO each rod hole. Tighten screws to 2 N•m (18 lbf•in).
side) and on the high tension coil support.
Match the carburetor and the support dots. 1 2
Install clamps in a way that their tightening bolts
are staggered — not aligned.
Carburetor Synchronization
All 3 carburetor slides must start to open at the same
time.
Carburetor synchronization is done when adjust-
ing throttle slide height. See above.
Full Throttle Adjustment

To avoid stress on throttle cable when throttle le-
3
ver is against handlebar grip, stop screw must not A06C2IA
contact stopper. There must be slight free play (up

1. Spacer and spring on PTO side
to 0.5 mm (.020 in)) between stop screw and its 2. Ferrule screw aligned with rod hole
stopper. 3. Dielectric grease
Apply dielectric grease (P/N 293 550 004) on cable

housing end.
All 3 plungers must start to open at the same time.
Bend ferrule end as required. Do not change posi-
tion of ferrule on rod. Its screw must remain in line
with choke rod hole.
Choke Cable Adjustment

Choke cable barrel must be in left hole of sliding
rod lever.
A06C0LA 1
TYPICAL — FULL THROTTLE POSITION
1. Free play between stop screw and its stopper
CHOKE
Choke Rod
Check for free movement of choke rod. If hard to
slide, remove 3 plunger ferrules then choke rod. A06C2NA
Thoroughly clean choke rod and its mounting hole 1. Cable barrel in left hole
on each carburetor.
04-08-8 MMR2001_049_04_08A.FM
Section 04 ENGINE
Air intake silencer must be reinstalled and choke DPM

cable properly routed before finalizing adjustment.
Adjust choke cable to obtain a maximum gap of Mach Z Tech Plus and Grand Touring SE
approximately 0.3 mm (.012 in) between tab and TESTING
plunger when choke lever is not activated.
MPEM
Solenoids are supplied by the MPEM. If this MPEM
does not work, there will be no current on the com-
pensation solenoid RD/BU and BR/BU connectors
(6-VA housing); and on the RD/GN and BK connec-
tors (6-VA housing).
1
Unplug enrichment solenoid wire. Connect a good
solenoid to MPEM output connector.
Disconnect engine temperature sensor connector.
The MPEM now operates as though the engine
temperature was - 20°C (- 4°F) to simulate a big mix-
ture enrichment.
For the compensation solenoid, the air temperature
sensor must be at room temperature. Operate the
engine at 4000 RPM. The solenoid must vibrate.
A06C2MB
Start the engine and observe the solenoid. A vi-
1. 0.3 mm (.012 in) gap maximum brating solenoid indicates that the MPEM is in
good working order. If not, replace the MPEM and
NOTE: If there is no gap between tab and plunger,
repeat test.
a rich condition will occur and throttle response
will be affected; if the gap is too great, the plunger
stroke will be reduced causing poor cold engine Solenoid
starting. Static Test
If adjustment is required, loosen cable support on Unplug electric connector of solenoid and connect
middle carburetor to change choke cable position. it to a 12 V battery. The solenoid must sound when
it opens. Repeat test several times.
Dynamic Test
When checking the enrichment solenoid, discon-
nect engine temperature sensor connector. The
DPM system now operates as though the engine
temperature was - 20°C (- 4°F) to allow maximum
mixture enrichment.
Remove the solenoid, hold it in hand and start the
engine.
For the enrichment solenoid, check if it vibrates as
soon as the engine is started.
1
For the compensation solenoid, the air tempera-
A06C2OA
ture sensor must be at room temperature. Oper-
ate the engine at 3500 RPM. The solenoid must
1. Choke cable support vibrate.
After adjustment, retighten screw.
Temperature Sensor (air and engine)
At room temperature 20°C (68°F), the sensor resis-
tance must be 2500 Ω ± 300.
MMR2001_049_04_08A.FM 04-08-9
Section 04 ENGINE
PARTS REMOVAL AND Partially insert compensation solenoid into DPM

manifold.
INSTALLATION
1
Solenoid
At reassembly, ensure that solenoid seals are in
place.
A03I0SA
TYPICAL
A06E2OA 1 2 1. Embosses not engaged
1. Plastic seal Insert a 5/32 in drill bit with its round end first into
2. O-rings the transfer gallery.
Installation of compensation solenoid must be done Fully push solenoid into DPM manifold while main-
as follows: taining a pressure on drill bit. This will guide the
Remove transfer gallery plug by pushing 2 tabs. solenoid O-ring.
A03I0RA
1
TYPICAL — CUT-AWAY
1. Drill bit round end guiding solenoid O-ring
A03I0TA
TYPICAL
1. Transfer gallery plug
04-08-10 MMR2001_049_04_08A.FM
Section 04 ENGINE
DPM MANIFOLD LEAK TESTING

Disconnect all 3 carburetor venturi hoses from DPM.
Using a tubing, connect 2 carburetor venturi nip-
ples together as per following illustration and pro-
ceed with air tightness test by connecting tester
onto third nipple; must hold 35 kPa (5 PSI) vacuum
for 10 seconds.
DPM
BOMBARDIER
A30C2QA 1 2
TYPICAL
1. Tester
2. Tubing
Repair leaks (if any).

Reconnect carburetor venturi hoses to DPM.
MMR2001_049_04_08A.FM 04-08-11
Section 04 ENGINE
FUEL PUMP
All Models
From fuel
tank
To
carburetors
Engine impulse line
A30C0JS

Section 04 ENGINE
REMOVAL CLEANING AND INSPECTION

Install a hose pincer (P/N 295 000 076) on fuel sup- The entire pump should be cleaned with general
ply line close to pump inlet. purpose solvent before disassembly.
Fuel pump components should be cleaned in gen-
eral purpose solvent and dried with compressed
air.
295 000 076  WARNING
Solvent with a low flash point such as gaso-
as each is flammable and explosive.
Inspect diaphragm. The pumping area should be

free of holes, tears or imperfections. Replace as
needed.
A01B2JA
Disconnect fuel outlet line(s). INSTALLATION

Disconnect impulse line. To install, first insert a pick in bottom hole of pump
support to hold it in place.
Remove screws securing fuel pump support to
chassis. Fasten top screw using a long socket with grease
inside to restrain screw.
PUMP VERIFICATION 1 2
Check fuel pump valves operation as follows:
Connect a clean plastic tubing to the inlet nipple
and alternately apply pressure and vacuum with
pump of leak test kit. The inlet valve should re-
lease with pressure and hold under vacuum.
Repeat the same procedure at the outlet nipple.
This time the outlet valve should hold with pres-
sure and release under vacuum.
NOTE: Plug 2 outlets with finger while checking
outlet valve.
Check impulse diaphragm and gasket as follows:
Connect a clean plastic tubing to the impulse nip- A30C0IA
ple. Either apply pressure or vacuum max 35 kPa 1. Pick inserted in pump support bottom hole
2. Socket on top screw head to be fastened
(5 PSI). The diaphragm/gasket must not leak.
 WARNING
Pressure test to ensure there is no leak in fuel
system.
MMR2001_049_04_08A.FM 04-08-13
Section 04 ENGINE

Fuel Tank Lines
2
 WARNING
pincher (P/N 295 000 076) or equivalent de- 1
vice. Fuel is flammable and explosive under
certain conditions. Ensure work area is well
ventilated. Do not smoke or allow open flames
or sparks in the vicinity
3
A02C0FA 4
295 000 076 TYPICAL
1. Throttle cable housing
2. Throttle handle housing
3. Throttle handle
4. Circlip
Adjust throttle cable as specified in CARBURE-

TOR AND FUEL PUMP.
A01B2JA
Impulse/Fuel Lines Spring Clips When turning steering while engine is running,
(all models) idle speed must not vary.
prevent possible leaks. Fuel Level Sensor
Inspection
(all models) Visually inspect the condition of connectors and
wiring throughout the circuit. Connections must
Put silicone grease (P/N 293 550 004) around cable be clean and tight, and wiring free of damage. Re-
barrel. Locate circlip as per illustration. pair as necessary. Use silicone dielectric grease to
prevent corrosion at the connectors. Operate the
 WARNING engine to see if the problem has been corrected.
If this procedure is disregarded, throttle might Fuse Replacement
the engine will speed up when starting. A 0.25 ampere fuse protects fuel level sensor cir-
cuitry. Remove seat to gain access.
MMR2000_050_04_09A.FM 04-09-1
Section 04 ENGINE
Fuel Level Sensor Screws

Torque fuel level sensor retaining screws to 1 N•m
(8 lbf•in) in the sequence shown and then to 2.5 N•m
(22 lbf•in), using the same sequence.
4 3
2 5
A14C02A
04-09-2 MMR2000_050_04_09A.FM
TABLE OF CONTENTS 0
DRIVE BELT............................................................................................................................ 05-02-1
2001 APPLICATION CHART .............................................................................................. 05-02-1
DRIVE PULLEY....................................................................................................................... 05-03-1

TRA ..................................................................................................................................... 05-03-1
GENERAL ........................................................................................................................... 05-03-2
REMOVAL........................................................................................................................... 05-03-2
DISASSEMBLY................................................................................................................... 05-03-2
CLEANING ......................................................................................................................... 05-03-4
INSPECTION ...................................................................................................................... 05-03-4
ASSEMBLY......................................................................................................................... 05-03-5
INSTALLATION .................................................................................................................. 05-03-7
DRIVEN PULLEY .................................................................................................................... 05-04-1

REMOVAL........................................................................................................................... 05-04-2
DISASSEMBLY................................................................................................................... 05-04-2
CLEANING ......................................................................................................................... 05-04-2
INSPECTION ...................................................................................................................... 05-04-3
ASSEMBLY......................................................................................................................... 05-04-3
INSTALLATION .................................................................................................................. 05-04-3
ADJUSTMENT ................................................................................................................... 05-04-3
REMOVAL........................................................................................................................... 05-04-6
DISASSEMBLY................................................................................................................... 05-04-6
CLEANING ......................................................................................................................... 05-04-6
INSPECTION ...................................................................................................................... 05-04-6
ASSEMBLY......................................................................................................................... 05-04-6
INSTALLATION .................................................................................................................. 05-04-7
ADJUSTMENT ................................................................................................................... 05-04-7
PULLEY DISTANCE AND ALIGNMENT................................................................................ 05-05-1

GENERAL ........................................................................................................................... 05-05-1
GENERAL PROCEDURE .................................................................................................... 05-05-1
PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART................................. 05-05-2
MMR2001_051_05_01ATOC.FM 05-01-1
BRAKE..................................................................................................................................... 05-06-1
HYDRAULIC DISC BRAKE.................................................................................................. 05-06-1
REMOVAL ........................................................................................................................... 05-06-2
DISASSEMBLY ................................................................................................................... 05-06-2
CLEANING .......................................................................................................................... 05-06-2
INSPECTION ....................................................................................................................... 05-06-2
INSTALLATION ................................................................................................................... 05-06-2
ADJUSTMENT.................................................................................................................... 05-06-3
BLEEDING........................................................................................................................... 05-06-3
CHAINCASE............................................................................................................................ 05-07-1
REMOVAL ........................................................................................................................... 05-07-2
INSPECTION ....................................................................................................................... 05-07-2
INSTALLATION ................................................................................................................... 05-07-2
ADJUSTMENT.................................................................................................................... 05-07-3
DRIVE CHAIN ......................................................................................................................... 05-08-1

SILENT CHAIN.................................................................................................................... 05-08-1
05-01-2 MMR2001_051_05_01ATOC.FM
DRIVE BELT 0
2001 APPLICATION CHART
WIDTH (NEW) MINIMUM WIDTH (WEAR LIMIT)
MODEL PART NUMBER
± 0.25 mm (.010 in) mm (in)
CK3 Series 417 300 066 35.10 (1.382) 33.00 (1.299)
ROTATION DIRECTION
the drive belt is installed as shown. This will ensure
that correct direction of rotation is respected.
A01D2LA
INCORRECT
NOTE: For used drive belt, mark and reinstall in

the same position.
A01D2KA
CORRECT
MMR2001_051_05_02A.FM 05-02-1
DRIVE BELT DEFLECTION Using spring scale and stick, apply specified force
MEASUREMENT
NOTE: The drive belt deflection measurement
must be performed each time a new drive belt is 1
installed.
NOTE: To obtain an accurate drive belt deflection
period of 50 km (30 mi).
2
Before checking the belt deflection, ensure vehi-
cle has the proper belt (refer to the application
chart). 3
Adjust pulley distance and alignment. Refer to
PULLEY DISTANCE AND ALIGNMENT.
To obtain maximum vehicle performance, the belt
tension must be adjusted according to specifica- A00D06A
tions shown in the accompanying chart. 1. Force

2. Read deflection here
3. Reference rule
DEFLECTION FORCE HEIGHT†
MODEL mm kg OVER DRIVEN Or use the belt tension tester (P/N 414 348 200).
(in) (lb) PULLEY
1 2
38 ± 5 11.5 0 - 1.5 mm
All models
(1.496 ± .197) (25) (0 - 1/16 in)
† FOR REFERENCE ONLY
To Check Tension A00C07B 4 3

Position a reference rule on drive belt. 1. Lower O-ring
2. Upper O-ring
Wooden Stick and Spring Scale Method 3. Force (read down)
4. Deflection (read up)
1 1. Slide lower O-ring of deflection scale to speci-
fied measure.
2. Slide upper O-ring to 0 (zero) on the force scale.
A00D05A
edge of rule and read force on the upper scale
1. Mark specified deflection at top edge of O-ring.
05-02-2 MMR2001_051_05_02A.FM
1 3
4 - +
1
5
A00D08A A06D20A
1. Upper O-ring — force TYPICAL

2. Force 1. Allen screws with jam nuts
3. Lower O-ring — deflection
4. Reference rule
5. Deflection
Allen screws must be restrained while tightening
jam nut to prevent throwing adjustment out. Use
DEFLECTION ADJUSTMENT drive belt tension adjuster (P/N 529 008 700).
Adjust pulley distance according to specification,

refer to PULLEY DISTANCE AND ALIGNMENT.
Models Equipped with Formula Type Driven
Pulley
Adjust drive belt deflection using Allen screws, as
shown.
To increase deflection: turn Allen screws clock-
wise.
To decrease deflection: turn Allen screws counter-
clockwise.
NOTE: Turn Allen screws 1/4 turn at a time, then
rotate driven pulley to allow drive belt to settle in A06D21A 529 008 700
pulley. Check deflection, repeat as required.
TYPICAL
Models Equipped with HPV27 Type Driven

Pulley
Loosen screws and turn adjustment ring accord-
ingly. Retighten screws.
MMR2001_051_05_02A.FM 05-02-3
DRIVE PULLEY 0
TRA
All Models
Loctite 271
27 Nm
(20 lbfft)
12 Nm
(106 lbfin)
6 13
12
Loctite 12 11
609
Electric start models 14
7 17
5 15
16
13 Nm
(115 lbfin) Loctite
609 18
23
25
19
20
28 10 Nm
21 24 (89 lbfin)
22
Loctite
609
27 25
Repair kit 26
30
29 31
95 Nm
(70 lbfft)
A30D16S

GENERAL  WARNING
Some drive pulley components (return spring, Never use any type of impact wrench at drive
ramp) can be changed to improve vehicle perfor- pulley removal and installation.
mance in high altitude regions. A Service Bulletin
will give information about calibration according to Remove retaining screw.
altitude. To remove drive pulley ass’y and/or fixed half from
CAUTION: Such modifications should only be engine, use puller (P/N 529 022 400).
performed by experienced mechanics since they CAUTION: These pulleys have metric threads.
can greatly affect vehicle performance. Verify Do not use imperial threads puller. Always
spring specifications before installation. Do not tighten puller by hand to ensure that the drive
only refer to the spring color code. pulley has the same type of threads (metric vs
NOTE: TRA drive pulley stands for Total Range imperial) prior to fully tightening.
Adjustable drive pulley. To Remove Drive Pulley Ass’y:
 WARNING Retain drive pulley with clutch holder.
Any drive pulley repairs must be performed Install puller in pulley shaft then tighten.
by an authorized Bombardier snowmobile
dealer, or other such qualified person. Sub- DISASSEMBLY
component installation and assembly toler-
ances require strict adherence to procedures 1,2, Screw and Ring Gear
detailed. CAUTION: Retaining screws must be heated be-
fore disassembly. Do not exceed 150°C (300°F).
REMOVAL
5,6, Fixed and Sliding Half
30,31, Conical Spring Washer and CAUTION: Do not tap on governor cup.
Screw Screw puller into fixed half shaft about 13 mm
Use holder (P/N 529 006 400). (1/2 in). Raise drive pulley and hold it by the sliding
half while knocking on puller head to disengage
fixed half.
529 006 400

1
2
1
A20D06A A16D01A
2
TYPICAL 1. Puller
2. Holding sliding half
1. Retaining screw
2. Insert in any slot
factory mark and arrows as indexing reference.
05-03-2 MMR2001_052_05_03A.FM
25,29, Slider Shoe and Governor Cup Use spring compressor (P/N 529 035 524).
Carefully lift governor cup until slider shoes come Install support guide.
and remove slider shoes. Proceed the same way for
1
1
A16D02A
1. Hold slider shoes A03D3EA

2. Lift one housing at a time
1. Support guide
500) should be used to hold slider shoes prior to Install sliding half then a second support guide.
removing governor cup. These support guides will prevent bushing dam-
ages.
529 005 500

1
A16B02A

It is pushed by clutch spring pressure. A03D3FA
 WARNING
1. Support guide
Remove 3 Allen screws retaining spring cover

Clutch spring is very strong. Never attempt to then unscrew compressor.
remove spring cover without the recom-
mended tools.
MMR2001_052_05_03A.FM 05-03-3
CLEANING 9,12, Fitting Bolt Ass’y and Flanged

Bushing
5,6, Fixed and Sliding Half Check for wear, replace as required. When install-
Clean pulley faces and shaft with fine steel wool ing old style flanged bushing (made of black plas-
and dry cloth. tic), use a size “O” (letter) drill bit to ream inside
diameter.
5, Fixed Half and Crankshaft End
Parts must be at room temperature before clean-
24,25, O-Ring and Slider Shoe
ing. Check if O-rings are cracked, cut or crushed. Re-
Using a paper towel with cleaning solvent, clean place as required.
crankshaft tapered end and the taper inside the Check slider shoes for wear. Replace if groove is
fixed half of the drive pulley, crankshaft threads not apparent on top.
and retaining screw threads.
5,29, Fixed Half and Governor Cup
 WARNING Inspect splines and free play between both parts.
This procedure must be performed in a well- Maximum free play is 0.5 mm (.020 in) measured
ventilated area. at calibration screw radius. Replace if required.
CAUTION: Avoid contact between cleaner and 7,20, Sliding Half and Spring Cover
crankshaft seal because damage may occur. Bushing
Remove all hardened oil deposits that have baked Visually inspect coating. Replace if worn.
on crankshaft and pulley tapered surfaces with
coarse or medium steel wool and/or sand paper Sliding Half Bushing Replacement
no. 600. This bushing is not replacable. If worn out, replace
CAUTION: Do not use any other type of abra- sliding half ass’y.
sive. Spring Cover Bushing Replacement
Reclean mounting surfaces with paper towel and Under normal use there is no need to replace this
cleaning solvent. bushing.
Wipe off the mounting surfaces with a clean, dry Mount compressor (P/N 529 035 524) in a vise.
paper towel.
Use tools (P/N 529 031 300 and 529 031 200) to
CAUTION: Mounting surfaces must be free of remove old bushing.
7,20, Bushing
Only use petrol base cleaner when cleaning bush-
ings. 529 031 300
CAUTION: Do not use acetone to clean bush-
ing.
529 031 200
INSPECTION
Drive pulley should be inspected annually.
16,17, Thrust Washer and Roller

Check roller for roundness of external diameter.
Check thrust washer for thickness wear. Replace
as required.
A01D2MA
CAUTION: Ensure rollers are in good condition.
05-03-4 MMR2001_052_05_03A.FM
CAUTION: Bushing must be bonded with retain- 21,22,23, Ramp, Dowel Tube and Screw
ing compound.
Insert dowel tube from chamfered side. Make
Apply retaining compound Loctite 609 outside of sure ramp is centered on dowel tube.
bushing then press it down to counterbore from
outside end. 1
CAUTION: Insert bushing from sliding half side
(inner side) of spring cover.
ASSEMBLY A16D08A
NOTE: This drive pulley is lubrication free. Do not 1. Chamfered side

lubricate any component.
Position dowel tube split at the illustrated angle.
1,2,3, Screw, Ring Gear and Loctite 271
Apply Loctite 271 (P/N 413 702 900) on threads 30 ± 5°
and then torque to 27 N•m (20 lbf•ft).

and Locking Nut
A16D2PA
A16D07A
1. Washer
Torque locking nut to 10 N•m (89 lbf•in).
15, Pin
Always use the same type of pin as originally in- A16D09A 1 1
ent weights for calibration purpose. Refer to 1. Equal distance
TECHNICAL DATA. Torque screws to 10 N•m (89 lbf•in).
MMR2001_052_05_03A.FM 05-03-5
9,11,13,14, Screw, Lever Ass’y, Nut and 5,6,18,19, Fixed Half, Sliding Half, Spring,
Cotter Pin Spring Cover and Screw
Always install lever assemblies so that cotter pins To install spring cover, use spring compressor (P/N
are on the shown side. Besides install cotter pin 529 035 524).
head on top when lever is sat at bottom of sliding Assemble fixed and sliding halves. Note that fixed
half. Bend cotter pin ends to sit perfectly against halves have different cone angle. Match cone an-
lever. gle with crankshaft.
 WARNING Lift sliding half against spring cover and align spring
cover arrow with sliding half mark.
Whenever replacing centrifugal levers, al-
ways replace all 3 at the same time. Other-
wise, drive pulley misbalancing will occur be-
cause of levers difference. 1
A16D0DA
1. Align
Install and torque screws to 13 N•m (115 lbf•in).

A16D0BA
1. Head on top
2. All on the same side
Governor Cup
CAUTION: Lever assemblies must be installed
so that cotter pins are on the same side.
Torque nuts to 12 N•m (106 lbf•in). 529 005 500
easily after installation.
A16B01A
05-03-6 MMR2001_052_05_03A.FM
Insert spring and slider shoes into governor cup so INSTALLATION

that groove in each slider shoe is vertical to prop-
erly slide in guides.
 WARNING
CAUTION: Make sure O-rings are installed on Do not apply anti-seize or any lubricant on
slider shoes and their grooves are positioned crankshaft and drive pulley tapers.
vertically.
Install fork (P/N 529 005 500) into slider shoe
grooves to maintain them for governor cup instal-
 WARNING
lation. Proceed on 3 set of slider shoes. Never use any type of impact wrench at drive
Clean mounting surfaces as described in CLEAN-

ING above.
529 005 500
Drive Pulley Ass’y
The installation procedure must be strictly ad-
hered to as follows.
Install drive pulley on crankshaft extension.
Install conical washer with its concave side to-
wards drive pulley then install screw.
A16B02A
 WARNING
Make sure to align governor cup arrow with sliding Never substitute conical washer and/or screw
half and fixed half mark. with jobber ones. Always use Bombardier gen-
NOTE: If fixed half has no mark, align governor
cup mark with segment no. 1 of inner half. Seg- Use holder. See REMOVAL procedure.
1 Raise and block the rear of the vehicle and support
 WARNING
hicle.

km/h (20 MPH) and apply the brake, repeat 5 times.
A16D0EA
Recheck the torque of 80 to 100 N•m (59 to 74 lbf•ft).
1. Align
Carefully slide governor cup into sliding half. Align  WARNING

mark of governor cup with mark of fixed half. After 10 hours of operation the transmission
Remove forks and push governor cup so that its system of the vehicle must be inspected to en-
splines engage with fixed half shaft splines. sure the retaining screw is properly torqued.
CAUTION: Make sure splines of both parts are
fully engaged.
MMR2001_052_05_03A.FM 05-03-7
DRIVE PULLEY ADJUSTMENT 1

maximum engine power at a predefined RPM.
Factors such as ambient temperature, altitude or
surface condition may vary this critical engine
RPM thus affecting snowmobile efficiency.
This adjustable drive pulley allows setting maxi-
mum engine RPM in the vehicle to maintain max-
imum power.
Calibration screws should be adjusted so that ac-
tual maximum engine RPM in vehicle matches
A16D0GA
with the maximum horsepower RPM given in
TECHNICAL DATA. 1. Position 1 (not numbered)
NOTE: Use precision digital tachometer for en- Each number modifies maximum engine RPM by
gine RPM adjustment. about 200 RPM.
NOTE: The adjustment has an effect on high RPM Lower numbers decrease engine RPM in steps of
only. 200 RPM and higher numbers increase it in steps
To adjust, modify ramp end position by turning cal- of 200 RPM.
ibration screws. Example:
Calibration screw is set at position 3 and is changed
26,28,29, Calibration Screw, Locking to position 5. So maximum engine RPM is increased
Nut and Governor Cup by about 400 RPM.
Calibration screw has a notch on top of its head.
To Adjust:
Just loosen locking nut enough to pull calibration
Do not completely remove the locking nut. Torque
locking nuts to 10 N•m (89 lbf•in).
CAUTION: Do not completely remove calibration
screw otherwise its inside washer will fall off.
CAUTION: Always adjust all 3 calibration screws
and make sure they are all set at the same num-
ber.
1
A16D0FA
1. Notch

Note that in position 1 there is no stamped num-
ber (due to its location on casting).
See TECHNICAL DATA for original setting. 1
A16D0HA
05-03-8 MMR2001_052_05_03A.FM
DRIVEN PULLEY 0
Formula Type on Mach Z STD
1
Anti-seize
lubricant
Anti-seize
lubricant
Anti-seize
lubricant
Loctite
7 609 6
3
4
5
Loctite
9 609
Loctite
10 243
11
12 22 Nm
(16 lbfft)
A30D17S

REMOVAL 529 018 600

Remove guard and drive belt from vehicle.
Remove cap screw no. 12 and shouldered washer
no. 11 then pull the driven pulley from the coun-
tershaft.
Note shouldered washer position for reinstalla-
tion.
Take care not to loose spacer no. 2.
1 2
A30D0IA
Remove snap ring no. 3 and washer no. 4 to dis-

assemble the cam and the 2 pulley halves.
 WARNING
Driven pulley cam is spring loaded, use above
A30D0HA
mentioned tool.
TYPICAL
1. Spacer
2. Shoulder on this side CLEANING
1, Countershaft 9,10, Large Bushing and Small Bushing
Should countershaft no. 1 removal be required, During break-in period (about 10 hours of use), te-
refer to BRAKE then look for Countershaft and flon from bushing moves to cam or shaft surface.
Brake Disc Removal. A teflon over teflon running condition occurs, lead-
ing to low friction. So it is normal to see gray teflon
DISASSEMBLY deposit on cam or shaft. Do not remove that de-
posit, it is not dust.
When a dust deposit has to be removed from the
cam or the shaft, use dry cloth to avoid removing
transferred teflon.
Pulley Half Cleaning

Use Parts Cleaner (P/N 413 711 809).
05-04-2 MMR2001_053_05_04A.FM
INSPECTION ASSEMBLY
9,10, Bushings 6, Cam Slider Shoe
Check for cracks, scratch and for free movement When replacing slider shoes, always install a new
when assembled to fixed half. set (3 shoes) to maintain equal pressure on the
Using a dial bore gauge measure bushing diame- cam.
ter. Measuring point must be at least 5 mm (1/4 in) Assemble driven pulley components by reversing
from bushing edge. the disassembly procedure.
5, Cam
Coat cam interior with anti-seize lubricant.
INSTALLATION
1, Countershaft
A03D1OA
Driven pulley end-play is 0 (zero).
DRIVEN PULLEY BUSHING WEAR LIMIT
mm (in)
Small bushing 38.30 (1.508) ADJUSTMENT
Large bushing 89.15 (3.510) Refer to PULLEY DISTANCE AND ALIGNMENT to
adjust pulley distance. Adjust drive belt height in
6, Slider Shoe driven pulley to obtain specified belt deflection.
Turn Allen screws no. 10 equally accordingly.
Check cam slider shoes for wear. Replace when
inside edge of cam slider shoe slope base is worn 7, Spring
to 1 mm (.039 in) or less.
General
It is usual to experience spring setting during
breaking period of a new spring. The factory spring
2 preload is slightly higher (about 1 kg (2 lb)) to com-
pensate for spring setting. Specifications in TECH-
NICAL DATA are applicable after break-in period
1
(about 10 hours of use).
A15D0OA
3

3. Slope base
MMR2001_053_05_04A.FM 05-04-3
Spring Torsional Pre-Load

C
To check spring pre-load adjustment, use spring
A
scale hook (P/N 529 006 500) and a spring scale.
Remove drive belt.
Install the hook on the sliding half. Preventing
32
fixed half from turning, pull sliding half with the 54 1
6
spring scale perpendicularly with pulley axle.
Take 1st measurement when sliding half begins to
turn. Rotate sliding half to 10 mm (3/8 in) of rota-
tion. Hold fish scale at this position. Slowly release B
tension from fish scale and take 2nd measurement
when sliding half begins to return. Spring pre-load A18C0AA
is the average measurement between these 2. TYPICAL

Letters and numbers shown in illustration are actual letters and
1st 2nd numbers embossed on parts
measurement + measurement Spring
(when opening) (when closing) = pre-load NOTE: Always recheck torsional pre-load after ad-
justing.
2
3.6 kg
3.8 kg (8.4 lb) + 3.4 kg (7.5 lb) (8 lb)
Deflection
Example: (when opening) (when closing) = Actual Refer to PULLEY DISTANCE AND ALIGNMENT
spring and DRIVE BELT to perform adjustments.
2
pre-load
CAUTION: Drive belt and pulley adjustments
must always be checked whenever pulleys have
1 been removed, replaced or disassembled.
5, Cam
2 529 006 500
CAL DATA.
Cam angle is identified on cam.
1
2
3
4
5
A01B18A
44°
TYPICAL
6
Step 1 : 1st measurement

Step 2 : 2 nd measurement
BO
To adjust spring pre-load, relocate spring end in BA

M
cam, moving it clockwise to increase the pre-load RD

IER
and counterclockwise to decrease it. Refer to
A24D06A
TECHNICAL DATA.
NOTE: If spring pre-load can not be adjusted, try NOTE: For high altitude regions, a Service Bulletin
to relocate the other end of spring in sliding pulley will give information about calibration according to
(holes A, B and C). altitude.
05-04-4 MMR2001_053_05_04A.FM
HPV27 on Mach Z TECH PLUS and Grand Touring SE
5
Anti-seize
lubricant
Anti-seize
lubricant
4
6
7 11
Red 10
Black
9
8
3 Loctite
243
MACH Z TECH PLUS
only
12 1
22 Nm
(16 lbfft)
A30D18S

REMOVAL Remove half keys no. 6 and washer no. 7 to dis-

assemble the cam and the 2 pulley halves.
Remove cap screw no. 1 and shouldered washer  WARNING
no. 13 then pull the driven pulley from the coun- Driven pulley cam is spring loaded, use above
tershaft. mentioned tool.
tion.
CLEANING
1 3 2
8,9, Large Bushing and Small Bushing
During break-in period (about 10 hours of use), te-
flon from bushing moves to cam or shaft surface.
A teflon over teflon running condition occurs, lead-
deposit on cam or shaft. Do not remove that de-
transferred teflon.

A30D14A
1. Spacer INSPECTION
2. Shoulder on this side
3. Concave side facing driven pulley
10, Slider Shoe
5, Countershaft Check cam slider shoes for wear. Replace when
Should countershaft no. 5 removal be required, inside edge of cam slider shoe slope base is worn
refer to BRAKE then look for Countershaft and to 1 mm (.039 in) or less.
Brake Disc Removal.
DISASSEMBLY
2
529 035 524 1
A15D0OA
3

3. Slope base
ASSEMBLY
10, Cam Slider Shoe
When replacing slider shoes, always install a new
A30D0VA
05-04-6 MMR2001_053_05_04A.FM
Install slider shoes as per following photo. Red ADJUSTMENT

slider shoes are being used for reverse and black
ones for forward. Refer to PULLEY DISTANCE AND ALIGNMENT to
driven pulley to obtain specified belt deflection.
Loosen screws no. 12, turn adjustment ring then
retighten screws.
2 1
1 2 Deflection
Refer to PULLEY DISTANCE AND ALIGNMENT and
DRIVE BELT to perform adjustments.
CAUTION: Drive belt and pulley adjustments must
2 1 always be checked whenever pulleys have been
removed, replaced or disassembled.
A30D0WA
11, Cam
1. BLACK slider shoe
2. RED slider shoe Make sure to install proper cam. Refer to TECHNI-
CAL DATA.
12, Screws Cam angle is identified on cam.
These screws are machined at there end. With the
adjustment ring steel to position 0 (zero), screw
ends are flush with inner side of fixed pulley half
when tighten.
CAUTION: If any of these screws is not flush
with inner side of sliding pulley, bushings will
worn unequally.
the disassembly procedure.
11, Cam
INSTALLATION
5, Countershaft
BRAKE then look for Brake Disc and Counter- A30D0XA

Reinstall the pulley on the countershaft by revers- NOTE: For high altitude regions, a Service Bulletin
ing the removal procedure. will give information about calibration according to
altitude.

MMR2001_053_05_04A.FM 05-04-7

The pulley distance we will refer to in this section, Remove 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). driven pulley. Insert a straight bar 9.5 mm (.375 in)
This basic distance is provided as an assembly square, 48 cm (19 in) long or the proper alignment
guide and indicates the dimensions between template into the opened driven pulley.
which satisfactory belt deflection will be obtained.
Both pulley distance adjustment and pulley align- Measuring Procedure
ment must be carried out to ensure the highest Using Straight Bar
efficiency of the transmission system. Further-
Always measure distances X and Y from the far-
more, optimum drive belt operation and minimal
ther straight bar side (including its thickness to the
fixed half edge).
ment.
CAUTION: Before checking pulley adjustment, Y
the rear suspension must be mounted on the ve-
hicle and track tension/alignment must be done.
Always check pulley adjustment after suspen-
sion is adjusted.
 WARNING X Z

may cause the vehicle to creep forward at
idle. 2
All Pulley Alignment Specifications Refer to:

X = Distance between straight bar and drive pul-
1
ley fixed half edge, measured between pul- A00D0WA
leys. TYPICAL
Y = Distance between straight bar and drive pul- 1. Straight bar
2. Front of vehicle
straight bar. The distance Y must exceed distance X to com-
Z = Distance between outside diameter of pul- pensate for the twist due to the engine torque.
leys.
Drive Belt Deflection
requirements, refer to the proper ENGINE or
MMR2001_054_05_05A.FM 05-05-1

PULLEY
OFFSET
DISTANCE
MODELS Z X Y-X
± 0.50 mm ± 0.50 mm ± 0.5 mm
(± .020 in) (± .020 in) (± .020 in)
121.0 35.5 1.5
(4.764) (1.398) (.060)
121.0 35.5 1.0
Grand Touring SE
(4.764) (1.398) (.039)
Y
Pulley Distance Adjustment Method
Engine Movement
The engine support has slotted mounting holes.
1 Move engine to obtain specified distance be-
tween pulleys.
X Z Pulley Alignment Method

Engine Movement
frame. Position engine to obtain the specified
alignment.
NOTE: After alignment, adjust torque rod so it
A15D02A 2 slightly contacts stopper plate. Do not over tight-
TYPICAL en, it will disalign pulleys.
1. Engine movement
2. Contact 1
NOTE: Prior to performing pulley adjustment,
loosen torque rod nut to allow engine movement.
Engine supports have tendency to stick to frame,
work engine loose prior to aligning.
1
A30D0KB
1. Retighten
A30D0KA
1. Loosen
05-05-2 MMR2001_054_05_05A.FM
BRAKE 0
HYDRAULIC DISC BRAKE
10
37 Nm
(27 lbfft)
7
3
2
1
Anti-seize
lubricant
Anti-seize 4
lubricant
Loctite 243
22 Nm
A30D10T (16 lbfft)

REMOVAL 1
BRAKE DISC REMOVAL
Brake disc can be withdraw without removing cal-
iper. Proceed as follows:
– Remove belt guard, belt and driven pulley.
– Unbolt bearing support no. 4 from chassis.
– Unbolt caliper from chaincase.
– Pull countershaft no. 3 toward driven pulley
side to free from chaincase and disc.
– Remove disc. 2
DISASSEMBLY
A15D03A A
Only brake pads are available as spare parts. If cal-
TYPICAL
iper or master cylinder are damaged, replace each
1. Fixed pad
of them as an assembly. 2. Inner caliper
CLEANING 2, Brake Disc

Clean all metal components in a general purpose Check for scoring, cracking or bending, replace as
solvent. Thoroughly dry all components before as- required.
sembling.
CAUTION: Do not clean brake pads in solvent.
Soiled brake pads must be replaced by new ones.  WARNING
Always install a new nut when servicing.
INSPECTION
1, Brake Pad INSTALLATION
Brake pads must be replaced when lining is 1 mm To install brake, reverse removal procedure paying
(1/32 in) thick or less. attention to the following.
in pairs.  WARNING
Avoid getting oil on brake pads.
05-06-2 MMR2001_055_05_06A.FM
10, Upper Clamp ADJUSTMENT

Install upper clamp with its arrow pointing at front
of vehicle. Tighten to 8 N•m (71 lbf•in) front screw Countershaft Bearing
before rear one. Insert countershaft (with brake disc) from chain-
2 1
Install countershaft bearing no. 4 and ensure that
countershaft is properly aligned, then tighten 3 re-
taining screws.
Torque castellated nut of upper sprocket to 60 N•m
(44 lbf•ft).
CAUTION: Upper sprocket castellated nut must
be tightened before bolting bearing support.
Close chaincase.
5, Brake Light
A03D3QB
BLEEDING
TYPICAL
1. Arrow on upper clamp pointing at front of vehicle Change brake fluid once a year.
2. Tighten front screw first
2, Brake Disc Keep sufficient DOT 4 brake fluid in reservoir at all
Apply anti-seize lubricant (P/N 413 701 000) on shaft. times.
The disc hub exceeds the disc more from one side CAUTION: Use only DOT 4 brake fluid.
than from the other. Install disc with the longer Install a hose on left side bleeder. Route this hose
exceeding portion toward driven pulley. to a container.
Pump a few times brake lever and while holding
1,7, Brake Pads and Caliper brake lever depressed, open left side bleeder and
Each time a new caliper or new brake pads are check for air to escape.
installed, proceed with the following: Repeat with the same bleeder until no air appears
– With caliper not bolted to chaincase, apply brake in hose.
few times until both new pads are touching each Proceed the same way with the right side bleeder.
other.
– Push back pads and repeat above step. 1
– Push back pads then fasten caliper to chain-
case.
– Proceed with bleeding as described below.
A06D0JA 2
TYPICAL
1. Open bleeder
2. Clear hose to catch used brake fluid
MMR2001_055_05_06A.FM 05-06-3
CHAINCASE 0
2
Synthetic
chaincase 1
oil
7 Nm
(62 lbfin)
7
22 Lithium
9 grease 42 Nm
23 (31 lbfft)
8
Stamped end 11
facing cover 24
6 10 Loctite
14
243
3
Seal facing
cover 19
45 to 75 Nm 5
(33 to 55 lbfft) 4
Frame
Anti-seize
13 lubricant
12 beetween
Loctite frame
Loctite 243
271 14 and nut
24
18 42 Nm
17 (31 lbfft) Synthetic
44 Nm chaincase
(32 lbfft) 15 oil
Sprocket shoulder
facing chaincase 21
Loctite
SYNTHETIC CHAINCASE OIL
HUILE SYNTHÉTIQUE POUR CARTER
A30D19S 271 16 housing 20

REMOVAL INSPECTION
To remove chaincase proceed as follows. Visually inspect the chain for cracked, damaged or
Remove tuned pipes and muffler. missing links. Check for worn or defective bear-
ings, sprockets and chain tensioner components.
 WARNING  WARNING
gine is hot. If chain deflection is greater than 38 mm (1.5 in)
(without chain tensioner), replace chain and
Remove hair pin no. 8. Release drive chain tension check condition of sprockets.
by unscrewing tensioner adjustment screw.
Drain oil by removing chaincase cover no. 2. GEAR RATIO MODIFICATION
3,4,5,6,13,16,17, Cotter Pin, Nut, For particular applications, the number of teeth of
Sprocket, Shim and Drive Chain the sprockets can be increased or decreased on
lower and upper sprockets.
Apply parking brake.
Refer to TECHNICAL DATA for gear ratios.
Remove cotter pin no. 3 and nut no. 4 retaining
upper sprocket no. 5 and screw no. 15 retaining CAUTION: Gear ratio modifications should only
lower sprocket no. 16. Pull sprockets and drive be performed by experienced mechanics since
chain simultaneously. Remove shims nos. 6 and 17. they can greatly affect vehicle performance.
NOTE: Should countershaft removal be required, re- NOTE: For high altitude regions, a Service Bulletin
fer to BRAKE then look for Countershaft Removal. will give information about calibration according to
altitude.
Remove 3 nuts no. 14. INSTALLATION
Unfold locking tab no. 23 then remove caliper re- Reverse removal procedure and pay attention to
taining screws no. 22. the following. Replace oil seals, gaskets and O-rings.
Release track tension, use drive axle holder no. 20
(P/N 529 007 200). 11, Oil Seal
Using an appropriate pusher, press the oil seal into
1 chaincase hub. Oil seal must fit flush with the
529 007 200 chaincase edge.
NOTE: Should installation procedure for counter-
shaft be required, refer to BRAKE.
24, Bearings
Bearing seal must face chaincase cover.
2
5,16, Sprockets
A01B1FA Position the sprockets with the writing facing the
TYPICAL chaincase cover. Sprocket hub faces toward chain-
1. Drive axle case.
2. Suspension cross shaft
Pry out drive axle oil seal no. 19 from chaincase. 4, Upper Sprocket Castellated Nut
Pull chaincase from drive axle and countershaft. Torque to 45 to 75 N•m (33 to 55 lbf•ft).
Using 2 large screwdrivers inserted between chain- Install new cotter pin in the position shown.
case no. 7 and frame, pry complete assembly from CAUTION: When removing a cotter pin always
vehicle. replace with a new one.
05-07-2 MMR2001_056_05_07A.FM
CAUTION: Cotter pin will rub on chaincase cover 21, Chaincase Oil
if installed otherwise.
Pour 250 mL (8.5 U.S. oz) of synthetic chaincase
oil (P/N 413 803 300) into chaincase.
NOTE: Chaincase oil capacity is 250 mL (8.5 U.S. oz).
1 Check oil level with the dipstick then add if re-
2
quired. Remove metal particles from magnet.
A02D08A
1. New
18, Circlip
CAUTION: It is of the utmost importance to in-
DRIVE CHAIN ADJUSTMENT

NOTE: Brake disc key must be in good condition 2 1
3
10, O-Ring
Replace O-ring no. 10 on tensioner adjustment
screw. Fully tighten tensioner adjustment screw A30D0AA
by hand, then back off only far enough for hair pin
TYPICAL
to engage in locking hole.
1. Dipstick
This initial adjustment should provide 3-5 mm (1/8- 2. Oil level
3. Level between marks
13/64 in) free-play when measured at the outer
circumference of the brake disc. NOTE: Chaincase must be in its proper position
CAUTION: Free-play must not exceed 5 mm when checking oil level.
(13/64 in), readjust if necessary.
ADJUSTMENT
 WARNING
If the specified free-play is not reached with Pulley Alignment
the tensioner screw fully tightened, replace Refer to PULLEY DISTANCE AND ALIGNMENT.
Refer to TRACK.
MMR2001_056_05_07A.FM 05-07-3
DRIVE CHAIN 0
SILENT CHAIN
All CK3 models are equipped with a 13-plates wide
silent chain. Fit chain on sprockets to make sure
that you are using right ones according to width.
done on the silent chain type.
MMR2001_057_05_08A.FM 05-08-1
TABLE OF CONTENTS 0
IGNITION TIMING ................................................................................................................. 06-02-1
NIPPONDENSO TRIGGER COIL SYSTEM........................................................................ 06-02-1
SPARK PLUGS....................................................................................................................... 06-03-1

NGK SPARK PLUG............................................................................................................. 06-03-1
DISASSEMBLY................................................................................................................... 06-03-3
HEAT RANGE ..................................................................................................................... 06-03-3
FOULING ............................................................................................................................ 06-03-3
BATTERY................................................................................................................................ 06-04-1
REMOVAL........................................................................................................................... 06-04-1
CLEANING ......................................................................................................................... 06-04-1
INSPECTION ...................................................................................................................... 06-04-1
HYDROMETER TEST ......................................................................................................... 06-04-2
BATTERY STORAGE.......................................................................................................... 06-04-2
SERVICING......................................................................................................................... 06-04-5
TIPS FOR CHARGING A USED BATTERY ........................................................................ 06-04-5
BATTERY CHARGING EQUIPMENT ................................................................................. 06-04-6
INSTALLATION OF BATTERY ........................................................................................... 06-04-7

REMOVAL........................................................................................................................... 06-05-2
INSTALLATION .................................................................................................................. 06-05-2
SOLENOID SWITCH .......................................................................................................... 06-05-2
TESTING PROCEDURE ......................................................................................................... 06-06-1

GENERAL ........................................................................................................................... 06-06-1
SYSTEM TESTING ............................................................................................................ 06-06-5
IGNITION SYSTEM TESTING SEQUENCE ...................................................................... 06-06-5
LIGHTING SYSTEM TESTING SEQUENCE...................................................................... 06-06-5
1. SPARKING ..................................................................................................................... 06-06-5
2. ELECTRICAL CONNECTOR TESTING .......................................................................... 06-06-5
3. IGNITION SWITCH, TETHER CORD SWITCH AND EMERGENCY SWITCH TESTING. 06-06-6
4. IGNITION GENERATOR COIL VOLTAGE TESTING..................................................... 06-06-7
5. TRIGGER COIL TESTING .............................................................................................. 06-06-7
6. MPEM VOLTAGE TESTING .......................................................................................... 06-06-7
MMR2001_072_06_01ATOC.FM 06-01-1
7. HIGH VOLTAGE COIL VOLTAGE TESTING .................................................................. 06-06-8

8. MPEM SUPPLY VOLTAGE TESTING ............................................................................ 06-06-8
9. MPEM TESTING ............................................................................................................. 06-06-8
CONCLUSION..................................................................................................................... 06-06-8
LIGHTING GENERATOR COIL VOLTAGE TESTING ........................................................ 06-06-8
CONCLUSION..................................................................................................................... 06-06-8
ELECTRIC ACCESSORIES TESTING ................................................................................. 06-06-9
INSPECTION OF AC CIRCUIT ISOLATION........................................................................ 06-06-15
INSPECTION ....................................................................................................................... 06-06-15
06-01-2 MMR2001_072_06_01ATOC.FM
IGNITION TIMING 0
NIPPONDENSO TRIGGER COIL
SYSTEM
Normally ignition timing adjustment should not be
required. It has been set at factory and it should
remain correctly adjusted since every part is fixed
1
and not adjustable. The only time the ignition tim-
ing might have to be changed would be when re-
moving and reinstalling the magneto housing, re-
placing the crankshaft, the magneto flywheel, the
trigger coil or the MPEM. If the ignition timing is
found incorrect, first check for proper crankshaft 2
alignment. This might be the indication of a twist-
ed crankshaft.
The ignition timing can be checked with either the
engine hot or cold. Also, the ignition timing is to
be checked at 3500 RPM with a timing light.
NOTE: Between 3000 and 4000 RPM, the spark
advance does not change. So when checking igni-
tion timing at 3500 RPM, a change in engine
speed within ± 500 RPM will not affect the timing
mark when checked with the timing light.
IMPORTANT: During the first 8 hours the timing
curve is retarded by 2° between 4500 RPM and
maximum RPM. Because checking ignition timing A06E2BA
is done at a lower RPM, this will not affect the TYPICAL

3500 RPM timing specification. There will be no 1. TDC gauge on MAG side
further timing adjustment required before and af- 2. MAG side piston at TDC
ter these hours.
b. Assemble the gauge to the adaptor and tight-
en the roller lock nut. Do not tighten the adap-
Scribing a Timing Mark tor lock nut.
1. Clean the area around the MAG spark plug, and c. Screw the adaptor into the spark plug hole
remove it. and tighten to prevent movement in the plug
2. Install the TDC gauge in the spark plug hole, hole.
(magneto side) and adjust as follows: d. Position the dial face toward the PTO. Move
a. Position the MAG piston at approximately TDC. the gauge down until the needle just begins
to move, then move down a further 5 or 6 mm
(approximately 1/4 in). Tighten adaptor lock nut
by hand.
MMR2001_058_06_02A.FM 06-02-1
3. Locate the piston TDC position as follows:

1
a. Slowly rotate the drive pulley back and forth
across TDC while observing the needle. Note
that the needle stops moving only as the pis-
ton is changing direction.
b. Rotate the dial face so that “0” is in line with
the needle when it stops moving.
c. Again, slowly rotate the drive pulley back and
forth across TDC and adjust the dial face to
“0”, until the needle always stops exactly at
“0” before changing direction.
d. “0” now indicates exact TDC.
4. Rotate the drive pulley clockwise, one-quarter
turn then carefully rotate it counterclockwise
A30E1TA 2
until the needle indicates the specified mea-
surement, indicated in TECHNICAL DATA. 1. Marks on side member used as reference point
2. Timing mark in line with both marks on side member
5. Scribe one mark on removable side member up-
per ridge and one on lower ridge just above Checking Ignition Timing
drive pulley center line. These both marks will
Use timing light (P/N 529 031 900).
be used as a reference point.
6. With the TDC gauge indicating specified timing,
scribe a mark on drive pulley inner half in line
with both marks previously scribed on remov-
able side member.
1
A00B4FA
TIMING LIGHT (P/N 529 031 900)
To check the ignition timing, refer to illustration

and proceed as follows:
 WARNING
Place ski tips against a wall, raise rear of vehi-
A30E1SA cle on a stand, so that track does not contact
the ground. Do not allow anyone in front of or
1. TDC gauge indicating specified timing
behind the vehicle while engine is running.
Keep clear of track and do not wear loose cloth-
ing which can get caught in moving parts.
06-02-2 MMR2001_058_06_02A.FM

cable.
NOTE: To avoid an incorrect reading due to paral-
lax, view both marks scribed on removable side
member and the timing mark in a straight line.
Connect a digital induction type tachometer (P/N
529 014 500).
A30E1VA
TIMING RETARDED BY ABOUT 2°
F01B1GA
TACHOMETER (P/N 529 014 500)
2. Start the engine and point timing light on timing

mark. Bring engine to 3500 RPM for a brief in-
stant.
A30E1WA
TIMING ADVANCED BY ABOUT 2°
Changing Timing
Timing can only be changed using the programmer
(P/N 529 035 718).
With Engine Running

A30E1UA All Models
If the below mentioned tools are not available start
The timing mark must be aligned with both marks engine. Turn on programmer then enter password.
on side member. If not, note if timing is retarded
or advanced. Tolerance is ± 1°. Increase engine speed to 2000 - 2500 RPM then fol-
low the same procedure as With Engine Stopped.
When data are being transferred, you must rev
the engine at 2000 - 2500 RPM and make sure
connection between programmer and vehicle
is good.
Engine will misfire during vehicle information is trans-
ferred from MPEM to programmer. If engine stalls,
restart it, keep engine speed at 2000 - 2500 RPM
and select no. 3 VEHICLE INFO again.
MMR2001_058_06_02A.FM 06-02-3
With Engine Stopped All Models

Mach Z STD Turn on programmer then enter password.
Connect 9-volt adaptor (P/N 529 035 675) to MPEM. From main menu select no. 3. INFO VEHICLE.
Mach Z TECH PLUS

On this model MPEM can be supplied with exter-
nal power using the 9-volt adaptor (P/N 529 035 1. CHECK KEYS
675) and a homemade adaptor, refer to TOOL for 2. PROGRAM KEY
details. >3. VEHICLE INFO
4+ S TA RT V E H .
1
A30E1XA
Vehicle information is transferred from MPEM to

programmer.
TRANSFER
PGMR MPEM
A30E1YA
A30E2EA 529 035 675
1. Homemade adaptor
NOTE: In fact the programmer takes a copy of all
vehicle parameters scribed in MPEM. This copy
Grand Touring SE will be modified within the programmer then
Connect bypass wire (P/N 529 033 300) and turn it transferred to the MPEM.
on. Select no. 4. ENGINE PARAMETER.
1. CUSTOMER NAME
2. D E L I V E R Y D AT E
3. VEH. SERIAL#
>4+ E N G I N E PA R A M .
A30E1ZA
Select no. 1 TIMING ADJUSTMENT.
A30E2FA
>1. TIMING ADJUST
2. ENGINE SERIAL#
3 . C A L I B R AT I O N
A30E2GA
Press ENTER.
06-02-4 MMR2001_058_06_02A.FM
Now the display shows the engine timing correction

factor that is programmed in the MPEM. In the fol-
lowing example timing correction factor is 4.
TIMING<1-8>:5
TIMING<1-8>:4
A30E2HA
P R E S S A N Y K E Y. . .
IGNITION CORRECTION FACTOR
A30E21A
CORRECTION FACTOR IGNITION TIMING
PROGRAMMED IN MPEM CORRECTION
Press any key.
Select YES using the key . 2 3°
3 2°
4 1°
MODIFY? 1 0°
5 - 1°
YES NO
6 - 2°
A00A3DA
7 - 3°
8 - 4°
Press ENTER.
Press ENTER.
TIMING<1-8>:
>1. TIMING ADJUST
2. ENGINE SERIAL#
A30E23A
A30E2GA
Select a timing correction factor corresponding to
correction needed. Press ENTER.
Example: Timing mark as verified with a timing
light at 3500 RPM was too early by 2°. The correc-
tion factor programmed is no. 4.
TIMING<1-8>:5
Select correction factor no. 5. This will retard the
timing by 2° because the difference between cor-
rection factor no. 4 and no. 5 is - 2° (passing from
1° to - 1°).
A30E24A
The display confirms that correction factor has

been changed to no. 5.
Press any key.
MMR2001_058_06_02A.FM 06-02-5
MODIFY? TRANSFER
PGMR MPEM
YES NO
A30E27A
A00A42A
If the new correction factor selected above is the During a very short period of time the following
good one select NO and press ENTER. Otherwise message will appear.
select YES to choose an other correction factor.
VERIFY
>1. TIMING ADJUST PGMR MPEM
2. ENGINE SERIAL#
A30E2BA
A30E2GA
After the programmer has verified, following mes-

Press MENU. sage will appear.
Scroll to no. 7 SAVE AND QUIT.
O P E R AT I O N
4. E N G I N E PA R A M . SUCCESSFULL
5. HOUR INFO.
6. MPEM INFO. P R E S S A N Y K E Y. . .
>7. S AV E + Q U I T
A00A3EA
A30E29A
Press any key.
Press ENTER.
I F T E R M I N AT E D
S AV E YOU CAN UNPLUG
M O D I F I C AT I O N S ?
YES NO
A00A3FA
A30E2AA
Press any key.
Press ENTER.
06-02-6 MMR2001_058_06_02A.FM
1. CHECK KEYS
2. PROGRAM KEY
>3. VEHICLE INFO
4+ S TA RT V E H .
A30E1XA
Unplug bypass wire or 9-volt adaptor. Stop engine

when using the With Engine Running procedure.
MMR2001_058_06_02A.FM 06-02-7
SPARK PLUGS 0
NGK SPARK PLUG
All Models

SYSTEM
snowmobile models.
Low number hot plug

MMR2001_059_06_03A.FM 06-03-1

10: 1.0 mm (.040")
B R 9 E S 15
11: 1.1 mm (.044")
13: 1.3 mm (.050")
14: 1.4 mm (.055")
15: 1.5 mm (.060")
20: 2.0 mm (.080")

A: 18 mm E: 19 mm
2 Hot
Special Alloy
Seat
C: 10 mm 4
E: 8 mm 5 L: 11.2 mm
(7/16")
G: Racing Type
J: 12 mm x 19 mm
of V-Type
6 (53/54")
L: Half Heat Range
Construction 7
S: Standard
Electrode
Center
P: Projected
Insulator Type
Electrode
18 mm ø 12 mm
R: Resistor Type
9
(3/8")
Y: V-Grooved
Electrode
Center
Z: Inductive
Suppressor Type
10 Cold
A00E4NS

A01E1PS
06-03-2 MMR2001_059_06_03A.FM
DISASSEMBLY CAUTION: Severe engine damage might occur if

a wrong heat range plug is used.
A too hot plug will result in overheating and pre-
FOULING
The proper operating temperature or heat range of running of the engine, decreased engine speed due
the spark plugs is determined by the spark plug to misfiring, reduced performance, and increased
ability to dissipate the heat generated by combus- fuel consumption. This is due to a loss of compres-
tion. sion. Other possible causes are: prolonged idling, or
running on a too rich mixture due to a faulty carbure-
The longer the heat path between the electrode tor adjustment or incorrect fuel and/or fuel mixing.
tip to the plug shell, the hotter the spark plug op- The plug face of a fouled spark plug has either a dry
erating temperature will be — and inversely, the coating of soot or an oily, glossy coating given by an
shorter the heat path, the colder the operating excess either of oil or of oil with soot. Such coatings
temperature will be. form a conductive connection between the center
A cold type plug has a relatively short insulator electrode and ground.
der head. SPARK PLUG ANALYSIS
A00E0AA 1 2 3
3. Fouled (black)
1 2 The plug electrode and piston dome reveal the
condition of the engine, operating condition,
method of driving and fuel mixture. For this reason
it is advisable to inspect the spark plug at regular
intervals, examining the plug electrode and the
piston dome.
A00E09A
1. Cold
2. Hot
MMR2001_059_06_03A.FM 06-03-3

grime.
cording to TECHNICAL DATA.
2. Apply anti-seize lubricant (P/N 293 800 070) over
the spark plug threads to prevent possible seizure.
3. Hand screw spark plug into cylinder head and tight-
en with a torque wrench and a proper socket.
1 2
A00E0BA
1. Proper socket
2. Improper socket

TORQUE
SPARK TORQUE
MODELS
06-03-4 MMR2001_059_06_03A.FM
BATTERY 0
REMOVAL CLEANING
Clean the battery, battery casing, vent tube, caps,
 WARNING cables and battery posts using a solution of baking
Battery BLACK negative cable must always soda and water.
be disconnected first and connected last. CAUTION: Do not allow cleaning solution to en-
ter battery interior since it will destroy the elec-
 WARNING trolyte.
on vehicle.
1
Air Intake Silencer Removal
Unplug air temperature sensor connector from air
intake silencer and remove MPEM, as shown in
the next photo.
A17E0LA
1. Baking soda
Remove corrosion from battery cable terminals

and battery posts using a firm wire brush.
INSPECTION
Visually inspect battery case for cracks or other
possible damage. If case is damaged, replace bat-
tery and thoroughly clean battery tray and close
area with water and baking soda.
A30C08A 3 1 2  WARNING
TYPICAL Should the battery casing be damaged, wear
1. Air temperature sensor a suitable pair of non-absorbent gloves when
2. Air intake silencer
3. MPEM removing the battery by hand.
Then twist DPM manifold and detach from air in- Inspect battery posts for security of mounting.
take silencer.
Inspect for cracked or damaged battery caps, re-
Remove air intake silencer. place defective caps.
Unfasten battery retaining strips.
Open strips.  WARNING
Remove vent tube. Battery caps do not have vent holes. Make
sure that vent tube is not obstructed.
Withdraw battery from vehicle being careful not
lean it so that electrolyte flows out of vent tube.
CAUTION: Should any electrolyte spillage occur,
immediately wash off with a solution of baking
soda and water to prevent damage to vehicle
components.
MMR2001_060_06_04A.FM 06-04-1
HYDROMETER TEST EXAMPLE NO. 2

Temperature above 27°C (80°F):
Hydrometer reading: 1.235
Electrolyte temperature: 38°C (100°F)
Add .008 Sp. Gr.
1 Corrected Sp. Gr. is 1.243
CAUTION: Do not install a partially charged bat-
tery on a snowmobile since the casing might
crack at freezing temperature 0°C (32°F). The
following chart shows the freezing point of the
electrolyte in relation to the charge of the bat-
tery.
TEMPERATURE
A17E0JA FREEZING
CORRECTED BATTERY
POINT OF
1. Specific gravity 1.260 SPECIFIC CHARGE
ELECTROLYTE
GRAVITY
A hydrometer measures the charge of a battery in
terms of specific gravity of the electrolyte. Most Fully
1.260 - 59°C (- 74°F)
hydrometers give a true reading at 27°C (80°F). charged
1.230 - 40°C (- 40°F)
3 /4 charged
In order to obtain correct readings, adjust the initial 1.200 - 27°C (- 16°F)
1 /2 charged
reading by adding .004 points to the hydrometer 1.170 - 18°C (0°F)
1 /4 charged
1.110 - 7°C (+ 19°F)
readings for each 5.5°C (10°F) above 27°C (80°F) Discharged
and by subtracting .004 point for every 5.5°C
(10°F) below 27°C (80°F).
This chart will be useful to find the correct reading.
BATTERY STORAGE
Disconnect and remove battery from the vehicle.
ELECTROLYTE
TEMPERATURE
Check electrolyte level in each cell, add distilled
OPERATION TO PERFORM water up to upper level line.
°C °F CAUTION: Do not overfill.
38 100 .008 to the The battery must always be stored in fully charged
add
32 90 .004 reading condition. If required, charge until specific gravity
27 80 CORRECT READING of 1.260 is obtained.
CAUTION: Battery electrolyte temperature must
21 70 .004
16 60 .008
not exceed 50°C (122°F). The casing should not
10 50 .012 feel hot.
4 40 .016 Clean battery terminals and cable connections using
-1 30 .020 a wire brush. Apply a light coat of dielectric grease
-7 20 .024 from the (P/N 413 701 700) or petroleum jelly on terminals.
subtract
- 12 10 .028 reading
- 18 0 .032 Clean battery casing and caps using a solution of
- 23 - 10 .036 baking soda and water. Do not allow cleaning so-
- 29 - 20 .040 lution to enter battery, otherwise it will destroy the
- 34 - 30 .044 electrolyte. Rinse battery with clear water and dry
- 40 - 40 .048 well using a clean cloth.
Store battery on a wooden shelf in a cool dry place.
EXAMPLE NO. 1
Such conditions reduce self-discharging and keep
Temperature below 27°C (80°F):
fluid evaporation to a minimum.
Hydrometer reading: 1.250
Electrolyte temperature: - 7°C (20°F)
Subtract .024 Sp. Gr.
Corrected Sp. Gr. is 1.226
06-04-2 MMR2001_060_06_04A.FM
ACTIVATION OF NEW BATTERY 3. Allow the battery to stand for 30 minutes MIN-
IMUM so that electrolyte soaks through battery
 WARNING cells.
on vehicle.
CAUTION: Prior to charging the battery, always

remove it from the vehicle to prevent electro-
lyte spillage.
A new battery is factory fresh dry charged. For
storage purposes, it is fitted with a temporary seal- 1
ing tube.
A17E0GA
Do not remove the sealing tube or loosen battery
1. 30 minutes
caps unless activation is desired.
In case of accidental premature removal of caps 4. Allow gas bubbles to escape by lightly shaking
or sealing tube, battery should be given a full charge. battery by hand.
Perform the following operations anytime a new
battery is to be installed.
1. Remove the sealing tube from the vent elbow.
Install vent tube, included in the battery kit, to
battery elbow.
 WARNING
Failure to remove the sealing tube could re-
sult in an explosion.
A17E0HA
5. Readjust the electrolyte level to the UPPER LEVEL

line.
1
A17E0FA
2. Remove caps and fill battery to UPPER LEVEL A17E0RA
line with electrolyte (specific gravity: 1.260 at 1. Battery electrolyte

20°C (68°F)).
MMR2001_060_06_04A.FM 06-04-3
6. Connect a 2 A battery charger for 10 to 20 hours. 8. Test battery state of charge. Use a hydrometer.
3
1
2 - + 1
A17E0IA
CAUTION: If charging rate raises higher than A17E0JA

2.4 A reduce it immediately. If cell temperature
rises higher than 50°C (122°F) (if the casing 1. Specific gravity 1.260
feels hot) discontinue charging temporarily or 9. Let battery settle for 1 hour.
reduce the charging rate.
1
 WARNING
Gases given off by a battery being charged
are highly explosive. Always charge in a well
ventilated area. Keep battery away from cig-
arettes or open flames. Always turn battery
charger off prior to disconnecting cables.
Otherwise a spark will occur and battery
might explode.
A17E0KA
7. Disconnect battery charger.
1. 60 minutes
10. Allow gas bubbles to escape by lightly shake

1 battery.
2 - + 3
A17E0IB
A17E0HA
06-04-4 MMR2001_060_06_04A.FM
11. Readjust electrolyte level. For best results, battery should be charged when
the electrolyte and the plates are at room temper-
ature. A battery that is cold may not accept current
for several hours after charging began.
1 Do not charge frozen battery. If the battery charge
is very low, the battery may freeze. If it is suspect-
ed to be frozen, keep it in a heated area for about
2 hours before charging.
 WARNING
Time required to charge a battery will vary depend-

ing some factors such as:
A17E0RA
– Battery temperature: Charging time is increased
as the temperature goes down. The current ac-
12. Reinstall caps and clean any electrolyte spill- cepted by a cold battery will remain low. As the
age using a solution of baking soda and water. battery warms up, it will accept a higher rate of
charge.
– State of charge: Because the electrolyte is
nearly pure water in a completely discharged
1 battery, it cannot accept current as well as elec-
trolyte. This is the reason the battery will not
accept current when the charging cycle first be-
gins. As the battery remains on the charger, the
current from the charger causes the electrolytic
acid content to rise which makes the electrolyte
a better conductor and then, the battery will ac-
A17E0LA
cept a higher charging rate.
1. Baking soda – Type of charger: Battery chargers vary in the
CAUTION: Do not allow cleaning solution to en- amount of voltage and current that they can
ter battery interior since it will destroy the elec- supply. Therefore, time required for the battery
trolyte. to begin accepting measurable current will also
vary.
NOTE: It is recommended to verify the battery
charge once a month. If necessary, fully charge Charging a Very Flat or Completely
battery. Discharged Battery
SERVICING Unless this procedure is properly followed, a good
battery may be needlessly replaced.
Electrolyte Level – Measure the voltage at the battery posts with
an accurate voltmeter. If it is below 10 volts, the
Since a battery has been activated (see above),
battery will accept current at very low rate, in
add distilled water to top up electrolyte.
term of milliamperes, because electrolyte is
nearly pure water as explained above. It could
TIPS FOR CHARGING A USED be some time before the charging rate increas-
BATTERY es. Such low current flow may not be detect-
able on some charger ammeters and the battery
CAUTION: Prior to charging the battery, always will seem not to accept any charge.
remove it from the vehicle to prevent electro-
lyte spillage. – Only for this particular case, set the charger to
a high rate.
MMR2001_060_06_04A.FM 06-04-5
NOTE: Some chargers have a polarity protection

feature which prevents charging unless the charg-
1
er leads are connected to the correct battery ter-
minals. A completely discharged battery may not
have enough voltage to activate this circuitry,
even though the leads are connected properly.
This will make it appear that the battery will not
accept a charge. Follow the charger manufactur-
2
er’s instruction telling how to bypass or override
this circuitry so that the charger will turn on and 4
charge a low-voltage battery. 3
– Since the battery chargers vary in the amount

of voltage and current they provide, the time A00E0DA
required for the battery to accept measurable 1. Charger

charger current might be up to approximately 2. Rheostat 12 Ω 50 W
3. Ammeter
10 hours or more. 4. 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. a small box adjacent to your charger.
– If the charging current is measurable before the CAUTION: Adequate ventilation MUST be pro-
end or at the end of about 10 hours, the battery vided to cool the rheostat.
is good and charging should be completed in
the normal manner as specified in Activation of Charging 2 or More Batteries at a Time
a new battery.
Connect all positives together and use a charger
– It is recommended that any battery recharged with a capacity (rated) equal to: number of batteries
by this procedure be load tested prior to return- to be charged multiply by 2 A.
ing it to service.
For example: Charging 5 batteries at a time re-
quires a 10 A rated charger (5 × 2 A = 10 A).
BATTERY CHARGING
EQUIPMENT - 1
+
The battery charger should have an adjustable
charging rate. Variable adjustment is preferred,
but a unit which can be adjusted in small incre-
ments is acceptable.
The battery charger must be equipped with an am-
meter capable of accurately measuring current of
less than one ampere.
If the present charger is not adjustable to the prop- - +
A17E0PA
er current values, a rheostat can be connected in
series with the battery to provide adjustment. TYPICAL
12 ohm, 50 watt rheostat, such as OHMITE — 1. Two batteries = 4 A
0314 or MALLORY 50K 12P, are available from
electronic parts supply shops and they are suitable
for use with most chargers if the peak current is
to be held below 2 A.
If you need an accurate ammeter, we recommend
the use of: SHURITE — 5202 (0 to 3 A) or — 5203
(0 to 5 A) available from electronic parts supply
shops.
06-04-6 MMR2001_060_06_04A.FM
INSTALLATION OF BATTERY Connect RED positive cable and RED wire to pos-
itive battery terminal. Refer to the following photo
Make sure that harness of oil reservoir low level for proper cable positioning.
sensor is positioned between fuel tank and battery
strip.
1
A30I04A
REAR VIEW — FUEL TANK REMOVED FOR CLARITY A30E0BA
1. Harness of oil reservoir low level sensor RED POSITIVE (+) BATTERY CABLE AND WIRE POSITIONING
Position battery onto battery support on vehicle.
Black Negative Cable and Wires
NOTE: To ease battery insertion, use soap with wa-
ter. Connect BLACK negative cable and BLACK wire
LAST. Refer to the following photo for proper ca-
Install vent tube on battery. ble positioning.
NOTE: Ensure that vent tube is not kinked or
blocked. Cut vent tube if necessary.
Red Positive Cable and Wire 2

Move RED positive cable and wire from right side
of engine compartment to battery positive post,
as shown in the next photo. 1
A30E0AA
A30I03A
1. Move RED positive cable and wire

1. BLACK negative (-) battery cable
2. BLACK wire
MMR2001_060_06_04A.FM 06-04-7
 WARNING
Always connect the battery cables exactly in
the specified order. Connect RED positive ca-
ble first, then BLACK negative ground cable.
Apply silicone dielectric grease (P/N 413 701 700)

on battery posts and connectors.
Ensure vent tube is properly installed on battery
elbow and chassis fitting.
Close and fasten retaining strips and ensure that
RED positive battery cable and oil injection supply
hose are routed into front retaining strip recess.
Reinstall air intake silencer with hose. Install DPM
manifold, MPEM and air temperature sensor.
LAST.
06-04-8 MMR2001_060_06_04A.FM
ELECTRIC STARTER 0
Loctite
271
A30E22S

REMOVAL Connect RED cable to starter solenoid switch.

Connect the RED positive cable to battery.
– Disconnect RED cable from starter solenoid  WARNING
switch.
– Remove starter from engine. nect last.
SOLENOID SWITCH
INSTALLATION Inspect connections and clean as necessary. Sole-
noid switch condition can be checked with an
Make sure that starter and engine mating surfaces ohmmeter.
er is not properly aligned. Disconnect large cables from solenoid making
sure that red positive from battery does not touch
Install starter. chassis.
NOTE: Check proper engaging depth of starter Install test probes on larges connectors of sole-
pinion teeth to ring gear teeth (see illustration). In- noid.
stall hardened washers (P/N 503 007 900) be-
tween engine and starter supports accordingly. Turn ignition key to start position. Reading should
be under 1 ohm.
CAUTION: All starter bracket fasteners must be
secured with Loctite 271 (P/N 413 707 400).
2
A09E0PA A
TYPICAL
2. Ring gear
A. 0.5 to 1.5 mm (.020 to .060 in)
06-05-2 MMR2001_061_06_05A.FM
TESTING PROCEDURE 0
GENERAL
The following chart gives the engine types with their
implemented system.
CHARGING
ENGINE IGNITION
SYSTEM
TYPE SYSTEM
OUTPUT
809 on Mach Z BOMBARDIER
290
STD/TECH PLUS 290 W
809 on BOMBARDIER
360 A30E2KA 2 4 5 1 3 7 6
GT SE 360 W
TYPICAL — BOMBARDIER 290 W MPEM — RER MODELS
1. High tension coils, 6-DD housing
Multi-Purpose Electronic Module 2. Generating coils (low and high speed) and trigger coil, 6-DB
(MPEM) Identification housing
3. Air temperature sensor, 6-DF housing
The BOMBARDIER 290 W MPEM receives elec- 4. Trigger coils, 6-DC housing
5. DPM solenoid, 4-DF housing
tricity produced by 2 generating coils (low and high 6. Reverse switch and alarm, DESS pilot lamp and ignition/kill
speed). It is smaller than the 360 W MPEM. switches, 6-DA housing
7. Atmospheric pressure nipple
5 6 4 The Bombardier 360 W MPEM receives DC elec-

tricity produced by the unique coil.
6
3
1
2
A30E2DA
TYPICAL — BOMBARDIER 290 W MPEM — NON-RER MODELS

1. High tension coils, 4-DC housing
2. Generating coils (low and high speed), 4-DD housing
3. Trigger coil, 4-DF housing
4. DESS switch, 4-DB housing
5. DESS pilot lamp and ignition/kill switches, 4-DA housing
6. External power supply 4-DE housing A30E2LA 1 2 3 4 5
TYPICAL — BOMBARDIER 360 W MPEM
1. Air temperature sensor, 6-TA housing
2. Power supply, ground, DESS switch, reverse switch and alarm,
high tension coils, kill switch, 6-DC housing
3. Trigger coils, 6-DB housing
4. DPM engine temperature sensor and solenoids, 6-VA housing
5. Battery/regulator connection, 6-DA housing
MMR2001_062_06_06A.FM 06-06-1
Checking Calibration Program 1

CAUTION: Do not interchange MPEM from a
model to an other. Even if the P/N stamped on
the MPEM is the same, calibration program
may be different. When ordering a new MPEM
always refer to appropriate model parts cata-
log. The service P/N published in parts catalogs
are the ones with the good calibration program
according to model.
With Engine Running
All Models
If the belowmentionned tools are not available
start engine. Turn on programmer then enter pass-
word. A30E2EA 529 035 675
Increase engine speed to 2000-2500 RPM then fol- 1. Homemade adaptor
Grand Touring SE
CAUTION: Engine must run till the end of the
procedure. Connect bypass wire (P/N 529 033 300) and turn it
on.
the engine at 2000-2500 RPM and make sure
connection between programmer and vehicle is
good.
Engine will misfire while vehicle information is be-
ing transferred from MPEM to programmer. If en-
gine stalls, restart it, keep engine speed at 2000-
2500 RPM and select no. 3 VEHICLE INFO again.
With Engine Stopped
Mach Z STD
Connect 9-volt adaptor (P/N 529 035 675) to MPEM.
Mach Z TECH PLUS
A30E2FA
On this model MPEM can be supplied with exter-
nal power using the 9-volt adaptor (P/N 529 035
675) and a homemade adaptor, refer to TOOL for All Models
details. Turn on programmer then enter password.
From main menu select no. 3. INFO VEHICLE.
1. CHECK KEYS
2. PROGRAM KEY
>3. VEHICLE INFO
4+ S TA RT V E H .
A30E1XA
06-06-2 MMR2001_062_06_06A.FM
Vehicle information is transferred from MPEM to And then following screen showing the actual cal-
programmer. ibration number in the MPEM.
TRANSFER C A L I B R AT I O N N U M B E R
PGMR MPEM XXX XXX XXX
MODIFY?
YES >NO
A30E1YA A30E2JA
NOTE: In fact the programmer takes a copy of all Check for proper calibration number. See table be-
vehicle parameters scribed in MPEM. This copy low.
will be modified within the programmer then trans- Select NO and press ENTER.
ferred to the MPEM.
Press MENU twice then turn off programmer, un-
Select no. 4. ENGINE PARAMETER. plug it from MPEM. Remove bypass wire or 9-volt
adaptor.
Stop engine when using With Engine Running pro-
1. CUSTOMER NAME cedure.
2. D E L I V E R Y D AT E
MODEL
3. VEH. SERIAL#
Mach Z Mach Z Grand
>4+ E N G I N E PA R A M .
STD TECH PLUS Touring SE
CALIBRATION
A30E1ZA
PROGRAM
515 175 431 512 059 293 512 059 289
NUMBER
Select no. 3 CALIBRATION. (SOFTWARE)
MPEM N/P
515 175 432 512 059 294 512 059 290
(HARDWARE)
1. TIMING ADJUST CALIBRATED
MPEM N/P
2. ENGINE SERIAL# (HARDWARE
515 175 430 512 059 292 512 059 288
> 3 . C A L I B R AT I O N AND SOFTWARE)
A30E2IA
Changing MPEM Calibration Program
Proceed the same as for checking MPEM calibra-
Press ENTER. tion but select YES to MODIFY? and press ENTER
Trs appears and following screen temporarily: following screen appears:
ENTER
VERIFY
C A L I B R AT I O N N U M B E R
PGMR MPEM
XXX XXX XXX
PRESS ENTER
A00A5NA
A30E2BA
MMR2001_062_06_06A.FM 06-06-3
Enter new calibration number and press ENTER,

following screen appears:
O P E R AT I O N
SUCCESSFULL
PLUG-IN KEY
TO END: P R E S S A N Y K E Y. . .
PRESS ANY KEY A00A3EA
A00A5OA
Press any key, Trs will show followed by next
screen:
Simultaneously with the following operation a
transfer will occur: Trs. At this point, be ready to
rev the engine so it won’t fall below the 2000 RPM 1. TIMING ADJUST
mark when not using bypass wire or 9-volt adap- 2. ENGINE SERIAL #
tor. 3 . C A L I B R AT I O N
Plug-in the desired calibration cartridge (special
red key) onto the programmer post, the following A00A5YA
screens will appear temporarily:

Press MENU twice, following screen will show:
TRANSFER 1. CHECK KEYS

+ 2. PROGRAM KEY
VERIFY >3. VEHICLE INFO
4+ S TA RT V E H .
A00A41A
A30E1XA
After procedure is completed, ensure engine idle

speed with engine hot is 1800-2000 RPM.
TRANSFER Stop the engine.
PGMR MPEM
RER Equipped Models
After changing calibration, start engine with vehi-
cle lanyard and verify the reverse (RER) function;
A00A42A this test will confirm that MPEM is correct. If re-
verse (RER) function does not operate, you must
redo the calibration download.
VERIFY
PGMR MPEM
A30E2BA
06-06-4 MMR2001_062_06_06A.FM
SYSTEM TESTING Resistance Readings

In the case of ignition problems, check the follow- CAUTION: When taking measurements, it is
ing in the prescribed order until the problem can useless to try to start the vehicle since readings
be solved. would then be distorted.
3. Ignition switches, DESS switch and emergency intermittent ignition problems. Thus, problems oc-
switch. curring only when the engine operating tempera-
4. Ignition generator coil voltage. ture is normal must be checked in similar condi-
tions.
5. Trigger coil.
6. Ignition module voltage.
7. High voltage coil output. replacing parts. Most problems cannot be detect-
8. MPEM voltage supply. ed when the engine is stopped.
9. MPEM. Multiple Problems
As a matter of fact, more that one component can
LIGHTING SYSTEM TESTING be defective. As a result, if the problem remains
SEQUENCE although a part was replaced, start over the whole
1. Electrical connectors. the other defective component.
2. Magneto output (lighting generator coil).
1. SPARKING
Testing Conditions
During this operation, it is important to use the
Voltage measurements are always taken upon ve- snowmobile spark plug and not a new one. Bring
hicle starting. Readings when the engine is run- the plug in contact with the engine. If no spark is
ning will be higher than indicated range. Part tem- produced, replace the spark plug with a new one
perature must be approximately 20°C (68°F) (room and do the test again.
temperature), otherwise readings could be distort-
ed.
Analysis of Readings TESTING
Voltage Readings Make sure that none of the connectors are discon-
When testing the different magneto components, nected.
fective and must be replaced.
MMR2001_062_06_06A.FM 06-06-5
3. IGNITION SWITCH, TETHER 1 2

CORD SWITCH AND
EMERGENCY SWITCH TESTING
Disconnect connector housing from engine and
check resistance as indicated in IGNITION table.
1 2
A30E0MA
TYPICAL — HARNESS REMOVED FOR CLARITY

1. Housing disconnected
2. DESS cap in place
1 2
A30E0LA
TYPICAL — 290 W
1. BK/YL wire, 4-DA-A-M housing (harness side)
2. BK wire, 4-DD-2-F housing (harness side)

switch as follows.
DESS Switch
Tether Cord Switch
Unplug 4-DB housing (6-DC on 360 W models) A30E0NA
connected to main wiring harness. Check using a
TYPICAL — HARNESS REMOVED FOR CLARITY
multimeter by connecting probes to BLACK/
1. Housing disconnected
GREEN and BLACK/WHITE wires. The multimeter 2. DESS cap removed
should indicate a closed circuit (0 Ω) in operating
position and a open circuit (0.L MΩ) in off position.
06-06-6 MMR2001_062_06_06A.FM
DESS Switch Wire 5. TRIGGER COIL TESTING

Check continuity (null resistance) between switch
center terminal and WHITE/GRAY wire connector. All Models
Check continuity (null resistance) between switch Resistance Testing
side ring and BLACK/GREEN wire connector. 1. Connect probes to WHITE/YELLOW and BLUE/
If readings do not correspond to the above men- YELLOW wires from trigger coil housing.
tioned indications, replace switch. 2. Activate the manual starter and check values in-
If none of these verifications are conclusive, the dicated by the multimeter.
problem finds its source in the main wiring har- 3. Repeat operation 3 times.
ness. Proceed as follows: 4. Compare readings with those appearing in the
NOTE: For the next step, no switch must be con- IGNITION table.
nected to the main wiring harness.
Disconnect all switches from the main wiring har-
ness and check the continuity of each wire by con-
necting probes to the end of wires of the same
color. Repeat with all other wires. It is important
to mention that all wires of the same color within
a given harness are connected together. These
wires should therefore have a closed circuit. On the
must have an open circuit (0.L MΩ).
Repair or replace if necessary.
4. IGNITION GENERATOR COIL

VOLTAGE TESTING A30E0PA 1
290 W Models Only 1. 10-04 housing
General
6. MPEM VOLTAGE TESTING
When manually starting the engine while the
spark plug is installed, the engine will tend to ac- All Models
celerate beyond the compression point. This will 1. Disconnect the housing between module and
result in higher magneto output power. high voltage coils.
1. Disconnect 4-DD housing (6-DB on Mach Z Tech 2. Connect multimeter probes to WHITE/BLUE and
Plus) between the magneto and the MPEM. BLACK wires coming out from module. Place
2. Connect multimeter probes to WHITE and RED the selector switch to Ṽ and the scale to 00.0Vac.
wires and bring the selector switch to Ṽ and 3. Activate the manual starter and check values in-
the scale to 00.0VAC. dicated by the multimeter.
3. Activate the manual starter and check values in- 4. Repeat operation 3 times.
4. Repeat operation 3 times. IGNITION table.
IGNITION table.
MMR2001_062_06_06A.FM 06-06-7
7. HIGH VOLTAGE COIL VOLTAGE LIGHTING GENERATOR COIL

TESTING VOLTAGE TESTING
1. Disconnect spark plug cap from spark plug. NOTE: For 290 W system, the lighting generator
2. Fasten alligator clip to spark plug cable, near the coil is not part of the ignition system. It is a self-
spark plug. contained system used to supply current to the
lighting system and to other devices working on
3. Connect other multimeter wire to engine (ground), alternating current. However, this system can be
then place selector switch to Ṽ and scale to tested using a multimeter.
0.00Vac.
1. Disconnect round 2-MO housing from engine
4. Activate the manual starter and check values in- (YELLOW, YELLOW wires).
2. Connect multimeter probes to YELLOW wires,
5. Repeat operation 3 times. then place selector switch to Ṽ and scale to
6. Compare readings with those appearing in the 0.00Vac.
IGNITION table. 3. Activate the manual starter and check values in-
8. MPEM SUPPLY VOLTAGE 4. Repeat operation 3 times.
TESTING
Grand Touring SE Only
1. Disconnect the 6-DA and 6-DC housings be-
tween module and main harness.
2. Connect multimeter probes to RED/BLUE and
BLACK wires coming out from harness. Place
the selector switch to Ṽ and the scale to 00.0Vdc.
IGNITION table. A05E0EA
TYPICAL
9. MPEM TESTING
Grand Touring SE Only LIGHTING table.
1. Disconnect the MPEM.
2. Install a known-good MPEM. CONCLUSION
3. Activate the manual starter and check values in- If none of the above testing operations produced
dicated by the multimeter. valid results, it is strongly recommended to keep
CONCLUSION Resistance column of the LIGHTING table.
All Models
Resistance column of the IGNITION table.
06-06-8 MMR2001_062_06_06A.FM
ELECTRIC ACCESSORIES
TESTING
Grand Touring SE Only
All accessories are supplied with electricity only
when engine is running at 800 RPM or faster.
The MPEM controls the electricity supply to ac-
cessories. To short-circuit this feature, avoiding to
let engine idling during testing, connect the by-
pass wires (P/N 529 033 300).
1. Disconnect the 6-DA housing.
2. Connect bypass wires (P/N 529 033 300) to the
harness housing in series into the 6-DA housing.
3. Turn bypass switch on. All accessories receive
the battery voltage.
MMR2001_062_06_06A.FM 06-06-9
IGNITION SYSTEM TESTING (CK3 SERIES — 290 W NON-RER)

Multimeter Resistance Ω Voltage V
Test to be Wire
Part probe Value Multimeter Value Multimeter Note
performed color connection (Ohms) scale (Volts) scale
BK and 4-DD-2-F 00.0
Running insulation 0.L MΩ — — No stop switch must be operational.
Ignition and BK/YL 4-DA-A-M
kill switches Continuity in stop BK and 4-DD-2-F Only one stop switch must be
00.0 - 00.5 00.0 Ω — —
position BK/YL 4-DA-A-M operational. Test one at a time.
Insulation in stop BK/GN 4-DB-B-M
and 0.L 00.0 MΩ — — Tether cord cap should be off.
position BK/WH 4-DB-C-M
DESS switch
BK/GN
4-DB-B-M 00.0 Ω
Running continuity and 4-DB-C-M 00.0 - 00.5 — — Tether cord cap should be in place.
BK/WH
WH 4-DD-3-F 25.0 - 56.0 00.0 Ω 30.0 - 50.0 —
and RD 4-DD-1-F 00.0Vac
Output
WH and 4-DD-3-F 00.0 Ω
BK/RD 4-DD-4-F 3.5 - 8.1 4.0 - 10.0 00.0Vac —
Ignition
generator BK 4-DD-2-F
coil Coil insulation 0.L 00.0 ΜΩ — — —
and RD 4-DD-1-F
4-DD-2-F The term “engine” refers to the
BK and 00.0 Ω
Ground continuity engine and 00.0 - 00.5 — — engine metal parts connected to the
engine magneto housing.
Resistance and WH/YL 4-DF-2-F
Trigger coil and 190 - 300 00.0 Ω .200 - .350 .000Vac —
output BL/YL 4-DF-1-F
Output WH/BL 4-DC-(1,2,3)-M 10.0 - 20.0 No switch must be operational and
MPEM — — 00.0Vac
voltage and BK 4-DC-(6,5,4)-M 3 times tether cord cap must be in place.
Primary winding WH/BL 4-DC-(1,2,3)-F 00.2 - 00.5 00.0 Ω — — —
resistance and BK 4-DC-(6,5.4)-F 3 times
Secondary Spark
winding resistance plug cap In spark plug cap 10.5 K - 19 K 00.0 KΩ
(spark plug cap and and on engine 3 times CAUTION: Do not measure high voltage coil output voltage.
included) engine
High voltage
coil Secondary
In spark plug
winding resistance BK and wire and on 6 K - 13 K 00.0 KΩ
(without spark plug engine 3 times CAUTION: Do not measure high voltage coil output voltage.
cap) engine
On spark The measurement must be taken on
Secondary BK and 1.5 - 2.5
winding voltage engine plug wire — — 3 times 0.00Vac the spark plug wire (without the
and on engine spark plug).
Spark plug Cap Spark plug 4.0 K - 6.0 K
— side and 00.0 KΩ — — —
cap resistance wire side 3 times
M: Male F: Female
06-06-10 MMR2001_062_06_06A.FM
IGNITION SYSTEM TESTING (CK3 SERIES — 290 W RER)

Part Test to be Wire probe Note
performed color Value Multimeter Value Multimeter
connection (Ohms) scale (Volts) scale
Running BK and 6-DB-2-F 0.L 00.0 MΩ — — No stop switch must be operational.
Ignition and insulation BK/YL 6-DA-3-F
kill switches Continuity in BK and 6-DB-2-F Only one stop switch must be
00.0 - 00.5 00.0 Ω — —
stop position BK/YL 6-DA-3-F operational. Test one at a time.
BK/GN
Insulation in and 6-DA-2-F 0.L 00.0 Ω — — Tether cord cap should be off.
stop position 6-DA-1-F
BK/WH
DESS switch
Running BK/GN 6-DA-2-F
and 00.0 - 00.5 00.0 Ω — — Tether cord cap should be in place.
continuity BK/WH 6-DA-1-F
WH 6-DB-3-F 00.0 Ω
and RD 6-DB-1-F 25.0 - 56.0 30.0 - 50.0 00.0Vac —
Output
WH and 6-DB-3-F 00.0 Ω
3.5 - 8.1 4.0 - 10.0 00.0Vac —
Ignition BK/RD 6-DB-4-F
generator BK 6-DB-2-F
coil Coil insulation 0.L 00.0 ΜΩ — — —
and RD 6-DB-1-F
Ground BK and 6-DB-2-F The term “engine” refers to the
and 00.0 - 00.5 00.0 Ω — — engine metal parts connected to the
continuity engine engine magneto housing.
WH/YL
Trigger coil Resistance and and 6-DC-1-F 190 - 300 00.0 Ω .200 - .350 —
no. 1 output 6-DC-4-F .000Vac
BL/YL
Trigger coil Resistance and GY/YL 6-DC-2-F
and 190 - 300 00.0 Ω .200 - .350 .000Vac —
no. 2 output GN/YL 6-DC-3-F
Output WH/BL 2-BA-(1,2,3)-M 10.0 - 20.0 No switch must be operational and
MPEM voltage and BK 2-BA-(6,5,4)-M — — 3 times 00.0Vac tether cord cap must be in place.
Primary
WH/BL 4-DC-(1,2,3)-F 00.2 - 00.5 00.0 Ω
winding and BK 4-DC-(6,5.4)-F 3 times — — —
resistance
Secondary Spark
winding In spark plug
resistance plug cap cap and on 10.5 K - 19 K 00.0 KΩ CAUTION: Do not measure high voltage coil output voltage.
and 3 times
(spark plug cap engine engine
High voltage included)
coil Secondary
BK and 6 K - 13 K 00.0 KΩ
resistance engine wire and on 3 times CAUTION: Do not measure high voltage coil output voltage.
(without spark engine
plug cap)
Secondary On spark The measurement must be taken
winding BK and plug wire — — 1.5 - 2.5 on the spark plug wire
engine 3 times 0.00Vac
voltage and on engine (without the spark plug).
— side and 00.0 KΩ — — —
M: Male F: Female
manual starter.
MMR2001_062_06_06A.FM 06-06-11
LIGHTING SYSTEM TESTING (CK3 SERIES — 290 W)

Test to be Wire
Part performed color probe Value Multimeter Value Multimeter Note
YL and 2-MO-B-F 00.15 -

Output and 00.0 Ω 3.0 - 7.0 00.0Vac —
YL 2-MO-C-F 00.35
Lighting Coil YL and 2-MO-(B,C)-F

generator and 0.L 00.0 MΩ — —
coil insulation engine engine The term “engine” refers to the engine
metal parts connected to the magneto
2-MO-A-F housing.
continuity engine and 00.0 - 00.5 — —
engine
M: Male F: Female
06-06-12 MMR2001_062_06_06A.FM
IGNITION SYSTEM TESTING (CK3 SERIES — 360 W)

Part Test to be Wire probe Note
performed color Value Multimeter Value Multimeter
Running BK and 6-DC-9-F 00.0 MΩ
insulation BK/YL 6-DC-3-F 0.L — — No stop switch must be operational.
Ignition and
kill switches Continuity in BK and 6-DC-9-F Only one stop switch must be operational.
00.0 - 00.5 00.0 Ω — —
stop position BK/YL 6-DC-3-F Test one at a time.
Insulation in BK/GN 6-DC-2-F

and 0.L 00.0 MΩ — — Tether cord cap must be off.
stop position BK/WH 6-DC-1-F
DESS
switch BK/GN
Running 6-DC-2-F 00.0 Ω
continuity and 6-DC-1-F 00.0 - 00.5 — — Tether cord cap must be in place.
BK/WH
Battery
Supply from RD/GY 6-DC-10-F — — voltage —
GY wire and BK 6-DC-9-F 00.0Vdc
within 0.5
Supply from RD/BL 6-DA-A-M — — 2.00 - 3.50 —
RD/BL wire and BK 6-DC-9-F 00.0Vdc
MPEM
Battery
Supply from RD/WH 6-DA-B-M — — voltage —
RD/WH wire and BK 6-DC-9-F 00.0Vdc
within 0.5
Ground BK and 6-DC-9-F 00.0 - 00.5 00.0 Ω — — The term “engine” refers to the engine metal
continuity engine and engine parts connected to the magneto housing.
WH/YL
Trigger coil Resistance and 6-DB-1-F 190 - 300 00.0 Ω .200 - .350 The test can be done on 2-BE housing, but this
no. 1 and output 6-DB-4-F .000Vac would not validate the harness.
BL/YL
Trigger coil Resistance GY/YL 6-DB-3-F The test can be done on 2-BE housing, but this
and 190 - 300 00.0 Ω .200 - .350 .000Vac
no. 2 and output GN/YL 6-DB-2-F would not validate the harness.
Ignition Output WH/BL 2-DG-(1,2,3)-M 10.0 - 20.0 No switch must be operational and tether cord
— — 00.0Vac
module voltage and BK 2-DG-(6,5,4)-M 3 times cap must be in place.
Primary WH/BL 2-DG-(1,2,3)-F 00.2 - 00.5
winding 00.0 Ω — — —
resistance and BK 2-DG-(6,5.4)-F 3 times
Secondary
Spark
winding plug cap In spark plug 10.5 K -
resistance cap and on 19 K 00.0 KΩ CAUTION: Do not measure high voltage coil output voltage.
(spark plug and engine 3 times
engine
High voltage cap included)
coil Secondary
resistance BK and wire and on 6 K - 13 K 00.0 KΩ CAUTION: Do not measure high voltage coil output voltage.
engine 3 times
(without spark engine
plug cap)
Secondary On spark
winding BK and plug wire — — 1.5 - 2.5 The measurement must be taken on the spark
engine 3 times 0.00Vac plug wire (without the spark plug).
voltage and on engine

— side and 00.0 KΩ — — —
M: Male F: Female
NOTE: Stop switches include the ignition switch, and the emergency cut-out switch.
manual starter.
MMR2001_062_06_06A.FM 06-06-13
LIGHTING SYSTEM TESTING (CK3 SERIES — 360 W)

Test to be Wire
Part probe Note
performed color connection Value Multimeter Value Multimeter
(Ohms) scale (Volts) scale
2-MO-(A,B,C)-F
00.0 - 00.5 00.0 Ω 3.5 - 5.5 Do the test between A and B, A and C and B
Lighting Output YL and YL and 3 times 3 times 00.0Vac and C.
generator 2-MO-(A,B,C)-F
coil YL and 2-MO-(A,B,C)-F The term “engine” refers to the engine metal
Coil insulation 0.L 00.0 MΩ — —
engine and engine parts connected to the magneto housing.
M: Male F: Female
06-06-14 MMR2001_062_06_06A.FM
INSPECTION OF AC CIRCUIT Grand Touring SE

ISOLATION YELLOW/BLACK wire
65 to 80 ohms
290 W Models BROWN wire
If AC circuit is not isolated from frame, headlamp

beam will weaken. Current Measurement
INSPECTION
HIGH 0.23 A
Disconnect regulator/rectifier. BROWN wire
INTENSITY minimum
Connect one digital ohmmeter probe (needle ohm- LOW 0.13 A
meter will not offer enough precision) to frame and BROWN /YELLOW wire
INTENSITY minimum
other probe to YELLOW wire (2-RE-A).
Measured resistance must be infinite. If such is
not the case, it means there is a connection be- Handlebar Grip Heating Element
tween AC circuit and frame. Resistance Measurement
Disconnect one accessory at the time to identify Mach Z STD/TECH PLUS
the faulty circuit.
LOW YELLOW /BLACK wire 17.7 to ➀
INSPECTION OF HEATING INTENSITY ORANGE/VIOLET wire 20.7 ohms
ELEMENTS HIGH YELLOW /BLACK wire 8.73 to ➀
All measurements must be performed at 21°C INTENSITY ORANGE wire 10.67 ohms
(70°F).
Grand Touring SE
RED/YELLOW wire
Resistance Measurement 6.5 to 8 ohms ➀
ORANGE wire
➀ When measuring resistance at terminals the
HIGH YELLOW /BLACK wire 1.96 to actual value will be half the measurement in ta-
INTENSITY BROWN wire 3.64 ohms ble. The reason for that is the elements are con-
nected in parallel. Therefore the total resistance
LOW YELLOW /BLACK wire 8.05 to
is half the resistance of one element.
INTENSITY BROWN /YELLOW wire 14.95 ohms
MMR2001_062_06_06A.FM 06-06-15
TABLE OF CONTENTS 0
SC-10 II SUSPENSION .......................................................................................................... 07-02-1
SUSPENSION ASSEMBLY REMOVAL ............................................................................. 07-02-4
INSTALLATION .................................................................................................................. 07-02-7
RIDE ADJUSTMENT.......................................................................................................... 07-02-7
LUBRICATION .................................................................................................................... 07-02-7
DRIVE AXLE ........................................................................................................................... 07-03-1

REMOVAL........................................................................................................................... 07-03-2
DISASSEMBLY................................................................................................................... 07-03-2
ASSEMBLY......................................................................................................................... 07-03-2
LUBRICATION .................................................................................................................... 07-03-3
ADJUSTMENT ................................................................................................................... 07-03-4
TRACK .................................................................................................................................... 07-04-1

GENERAL ........................................................................................................................... 07-04-1
INSPECTION ...................................................................................................................... 07-04-1
REMOVAL........................................................................................................................... 07-04-1
INSTALLATION .................................................................................................................. 07-04-1
MMR2001_072_07_01ATOC.FM 07-01-1
Subsection 02 (SC-10 II SUSPENSION)
SC-10 II SUSPENSION 0
SC-10 II
13
24 Nm
(18 lbfft) 7
48 Nm
(35 lbfft)
10 Nm
(89 lbfin)
2.5 Nm 4 Nm

11
A32F0XT

3 Nm (27 lbfin)
14
14
12
24 Nm
(18 lbfft)
12
80 Nm
(59 lbfft)
Synthetic
grease 5
6
16
17
24 Nm
(18 lbfft) 15
Synthetic
grease 17
15
80 Nm
Synthetic 16 (59 lbfft)
grease 6
A32F1HS

48 Nm (35 lbfft)
Synthetic grease 48 Nm

(35 lbfft)
48 Nm
(35 lbfft)
1
9
1
8
Europe
only
Synthetic
grease
3 2 48 Nm
(35 lbfft)
Synthetic
4 grease
3
80 Nm
10 (59 lbfft)
4
A32F1IS

SUSPENSION ASSEMBLY – Remove the opposite self-locking screw.

REMOVAL – Remove the temporary installed non-self-locking
screw.
19, Cam – If it doesn’t work, heat bolt head to melt thread-
Decrease spring preload by turning cams accord- locker.
ingly. Remove rear arm top axle self-locking screws no. 5
Slightly turn adjusting cam to expose spring end. from chassis.
Using spring installer (P/N 529 005 000), remove Lift rear of vehicle at least 1 m (3 ft).
both springs from adjusting cams.
A32F10A
TYPICAL
A. At least 1 m (3 ft)
Remove both self-locking screws no. 2 retaining

529 005 000 front arm to tunnel.
Remove suspension.
A03F2FB
TYPICAL

1,2,3,4,5,6, Self-Locking Screws

CAUTION: These self-locking screws must al-
are removed.
NOTE: To prevent axle from turning when un-
A32F11A
– Remove one self-locking screw then install a
10 mm shorter non-self-locking one in place.
Torque as specified in exploded view.
07-02-4 MMR2001_63_07_02A.FM
DISASSEMBLY AND ASSEMBLY 17, Block

Inspect track thoroughly before reinstalling sus- Both blocks are identified R or L (right or left), see
pension. Refer to TRACK. second following photo. At installation, make sure
to install proper block on proper side.
7, Outer Bushing Also, note that protrusion must be positioned above
At installation, hole must face adjustment screw. stoppers.
A32F15A 1 2
A32F12A
1. Protrusion
2. Stoppers
13,14, Center Rear Wheel and Top Idler 15,16, Dowel Pin and Block Guide
Wheels
Dowel pin must exceed block guide by 2 to 2.3 mm
At installation, circlip must face inner side. (.079 to .091 in).
1 At installation, insert dowel pin into pivot arm hole.
A32F13A
1. Circlip facing inner side A32F14A 2 1 3

LEFT SIDE SHOWN
1. Dowel pin
2. Pivot arm hole
3. L identification for left side
MMR2001_63_07_02A.FM 07-02-5
8,9, Front Shock and Spring Stopper 11, Slider Shoe

Use shock spring remover (P/N 529 035 504) and Molding line is the wear limit indicator.
stopper then release handle.
2
A03F3SA 1 2
TYPICAL
1. Slider shoe
2. Molding line (wear limit indicator)

CAUTION: Slider shoes must always be replaced
in pairs.
3
12, Spring Support
CAUTION: To avoid track damage, spring sup-
ports must be mounted upward.
A01B4LA
1. Clevis pin 1
2. Bar
10, Stopper Strap

Inspect strap for wear or cracks, bolt and nut for
Replace as required. Make sure it is attached through
proper holes. Torque nut to 7 N•m (62 lbf•in).
A03F0VA 2
TYPICAL — RIGHT SIDE SHOWN
A32F17A A 2. Wrong position
07-02-6 MMR2001_63_07_02A.FM
SHOCK ABSORBER INSPECTION Let it stand for 5 minutes.

Completely push down the shock rod then re-
All Models Equipped with Hydraulic Shock lease.
NOTE: Hydraulic shocks are painted black or dark Rod must come out at a steady speed. If speed
gray. suddenly increases particularly at end of exten-
Secure the shock body end in a vise with its rod sion, replace shock.
upward.
All Types of Shock
1 If suspecting a frozen shock proceed as follows:
Place shock in a freezer (temperature below 0°C
(32°F)) for 4 hours.
Push down on rod and note its resistance. If shock
is frozen it will be impossible or almost impossible
A14F0BA
to compress it.
1. Clamp
CAUTION: Do not clamp directly on shock body. INSTALLATION

Examine each shock for leaks. Extend and com- Install assembled suspension into track with front
press the piston several times over its entire stroke. portion first.
Check that it moves smoothly and with uniform Insert rear portion of suspension into track.
resistance with its rod upward.
Bolt front arm and rear arm.
denote a defective shock: Adjust track tension.
mid travel. RIDE ADJUSTMENT
– Seizing or binding condition except at extreme Refer to Operator’s Guide.
end of either stroke.
– Oil leakage. LUBRICATION
– A gurgling noise, after completing one full com- Lubricate front and rear arms at grease fittings us-
pression and extension stroke. ing synthetic grease (P/N 413 711 500).
Renew if any faults are present.
All Models Equipped with Gas Pressurized
Shock
ple painted, or bare aluminum.
ber and gas chamber, check shock as follows:
Install shock in a vise clamping on its bottom eye-
A32F16A
SC-10 II: 5 GREASE FITTINGS
MMR2001_63_07_02A.FM 07-02-7
DRIVE AXLE 0
8
Lithium
grease
13
13
3
11
5
10
Synthetic
grease
A30D0MS

REMOVAL 9,13, Sprocket and Half-Sprocket

Drain oil from chaincase. Release drive chain ten- To remove press fit sprockets, use a press and a
sion. Remove chaincase cover. suitable support as illustrated.
Remove suspension. Refer to SC-10 SUSPENSION.
2,8, End Bearing Housing and Seal

Remove outer flange cover of bearing housing.
Remove chain and sprocket then circlip and bear-
ing from drive axle.
Pry oil seal from chaincase.

1
Release drive axle sprocket from track and at the A00F06A
same time, pull the drive axle toward the end bear- TYPICAL
ing housing side. 1. Support sprocket near hub
Remove drive axle from vehicle. NOTE: Two different types of sprocket press fit
can be found. Ensure to replace ring reinforced
DISASSEMBLY sprockets with the same type.
4, Speedometer Drive Insert ASSEMBLY

Remove speedometer drive insert.
5,12, Bearing To assemble press fit sprockets, use a press and
To remove bearings, use puller assembly, ring and a suitable pipe as illustrated. Sprockets must be
half rings as illustrated. assembled according to the following dimensions.
A00C44A
A00F07A
TYPICAL
1. Pipe
07-03-2 MMR2001_064_07_03A.FM
CK3 Series
1
1 A
A00F0AA
A
B 1. Plane surface
A. 1.5 mm (1/16 in) MAXIMUM
C
D CAUTION: The same sprocket must not be
A06D1XC
pressed twice on the axle. If synchronization is
1. Measure from end of drive axle found to be defective, use a new sprocket.
A. 49 mm (1.929 in)
B. 151.2 mm (5.953 in)
C.
D.
274.2 mm (10.795 in)
376.3 mm (14.815 in)
11, Bearing Protector
At assembly, flat side of bearing protector must be
Ensure to align indexing marks of each sprocket against bearing.
when assembling.
5,12, Bearing
1
A00F0DA
A24D05A
The bearing on the splined side of axle must be
TYPICAL pushed until it is seated on shaft shoulder. Each
1. Indexing marks aligned bearing must have its shield facing the sprocket.
The maximum desynchronization for the sprock-
ets is 1.5 mm (1/16 in). LUBRICATION
plane surface and measure the gap between sprock- 15, Grease Fitting
et tooth and surface. Lubricate end housing bearing with synthetic grease
(P/N 413 711 500).
MMR2001_064_07_03A.FM 07-03-3
ADJUSTMENT
Sprocket/Track Alignment
CAUTION: Do not temper with sprocket/track
Sprockets might be repositioned to fit lugs with-
Use drive axle sprocket adjuster kit (P/N 861 725
700).
A01B2PA
TYPICAL
07-03-4 MMR2001_064_07_03A.FM
TRACK 0
TRACK TYPE APPLICATION INSTALLATION
Refer to TECHNICAL DATA. Reverse the removal procedure.
GENERAL direction indicated by an arrow on track thread.
This section gives guidelines for track removal. Check sprocket/track alignment as described in
Some components require more detailed disas- DRIVE AXLE.
fer to the pertaining section in this manual. Track Tension and Alignment
Track tension and alignment are inter-related. Do
INSPECTION not adjust one without checking the other. Track
Visually inspect track for: track alignment.
– cuts and abnormal wear
– broken rods Tension
– broken or missing track cleats. Lift the rear of vehicle and support with a mechan-
ical stand. Allow the slide to extend normally.
Check the gap half-way between front and rear
track. For damaged or missing cleats, replace by
idler wheels. Measure between slider shoe and
new ones, using cleat remover (P/N 529 028 700).
Use narrow-cleat installer (P/N 529 008 500).
 WARNING 500), slide U-shape extrusion to proper deflection.
or damaged track.
REMOVAL 1
Remove the following parts: 40 2
– speedometer cable 45
50
– muffler
– chaincase cover
– suspension
– drive axle seal A01B4JA
– end bearing housing 1. Example: 45 mm

2. Extrusion
– sprockets and chain
Insert pre-setted gauge between slider shoe and
– drive axle (toward end bearing housing) track. Allow gauge to settle by forcing track up and
– track. down. Track tension is as specified when edge of
gauge reaches line.
MMR2001_065_07_04A.FM 07-04-1
Alignment
 WARNING
tools, feet and clothing clear of track. Ensure no
one is standing in close proximity to the vehicle.
All Models
tance on both sides between edges of track
A01B4KA 1
TYPICAL 1
1. Line
2
NOTE: Lightly oil track tension gauge center pin
to avoid sticking.
All Models
Refer to TECHNICAL DATA for proper tension val-
ues.
CAUTION: Too much tension will result in ex- 3
cessive stress on suspension components. If A01F05A
too loose, the track will have a tendency to 1. Guides

thump. 2. Slider shoes
3. Equal distance
To adjust, loosen the rear idler wheel retaining
screws then loosen or tighten the adjuster bolts  WARNING
located on the inner side of the rear idler wheels.
thrown out while track is rotating. Keep

check alignment.
1 1 2 1
2
A19F05A
TYPICAL 3
A01F0BA
1. Retaining screw
2. Adjuster bolt
1. Guides
2. Slider shoes
3. Tighten on this side
07-04-2 MMR2001_065_07_04A.FM
NOTE: Torque retaining screw to 48 N•m (35 lbf•ft) Track Cleat

after adjustment.
Removal
– Raise rear of vehicle off the ground and lift snow-
replaced.
all models.
Installation
NOTE: Keep the same pitch between guide cleats.
1 – Place new cleat in position and using narrow
track cleat installer (P/N 529 008 500) bend cleat
then push tabs into rubber.
A19F05B
TYPICAL
1. Retighten
Restart engine, rotate track slowly and recheck 1

alignment.
A01B4UA
TYPICAL
1. First step
2. Second step (to push tabs into rubber)
MMR2001_065_07_04A.FM 07-04-3
TABLE OF CONTENTS 0
STEERING SYSTEM .............................................................................................................. 08-02-1
INSPECTION ...................................................................................................................... 08-02-8
STEERING ADJUSTMENT (SKIS) .................................................................................... 08-02-9
LUBRICATION .................................................................................................................... 08-02-12

DISASSEMBLY................................................................................................................... 08-03-2
INSPECTION ...................................................................................................................... 08-03-3
INSTALLATION .................................................................................................................. 08-03-3
MMR2001_072_08_01ATOC.FM 08-01-1
STEERING SYSTEM 0
CK3 Series
3
19
20 2
14 13
4 5
23 Nm
(17 lbfft)
16 Synthetic grease
39
10 Nm
48 Nm (89 lbfin) 1
(35 lbfft)
15 Synthetic
Loctite grease
271 5 53 Nm
4 6 (39 lbfft)
6
15 Nm 7
53 Nm (133 lbfin)
(39 lbfft)
17
7 8
18 Nm
(159 lbfin)
7
Loctite
271 18 Nm
52 Nm (159 lbfin)
(38 lbfft) 18
9
52 Nm 10
(38 lbfft)
21 53 Nm
48 Nm (39 lbfft)
7
(35 lbfft)
25 Nm
7 (18 lbfft) 18 Nm 7
(159 lbfin) 12
53 Nm Loctite
(39 lbfft) 271 25 Nm
17 (18 lbfft)
7
11
18
A30G08V
TYPICAL

 WARNING
On Grand Touring SE do not lift vehicle by steer-
ing column.

13, Grip
Grips must be carefully removed to prevent dam-
aging the heating elements. A19H04A 1
Heat grip with a heat gun. TYPICAL
Apply tape to handlebar near the grip to protect 1. Gap in the heating element opposite the wires
paint.
Continue cutting along the gap and remove the
Inject compressed air into the handlebar and twist grip.
If required, slowly peel heating element no. 15
from handlebar and remove it.
To install, stick the heating element to the handle-
bar making sure the wires do not interfere with
Prior to install grips, position heating element pro-
tector no. 14.
A30G0OA A30G0DA 1
The grips might be unremovable as explained
above, in this case, carefully proceed as follows to
prevent damaging the heating elements.
 WARNING
Locate the element wires inside the handlebar;
install the handlebar grip, use a mix of soap
look through end of grip. Start cutting the grip ex-
and water. Mix 40 parts of water with one part
actly opposite the element wires and immediately
of dish washing soap (recommended: Ultra
peel it open to locate the gap in the heating ele-
Joy, Sunlight or Palmolive).
ment, as shown.
08-02-2 MMR2001_066_08_02A.FM
Heat the grip with a heater gun or a spot light to Unbolt 4 nuts and bolts retaining clamp, front and
ease installation. Insert new grip with compressed rear arms.
air.
1 2
A30G0NA
A30G18A 3
Tilt Handlebar Mechanism 1. Clamp
2. Front arm
Grand Touring SE and Mach Z TECH PLUS Only 3. Rear arm
Move handlebar to its higher position. Remove plate, circlip on left side then, plastic wash-
Remove Allen screw retaining locking lever. Pull er on right side.
out locking lever.
1 3
Remove steering pad. Unhook throttle cable from
throttle lever.
Unscrew all 4 nuts and bolts securing handlebar.
NOTE: Do not unbolt master cylinder needlessly.
Move handlebar apart, keeping master cylinder
reservoir in upward position.
A30G19A 2
1. Plate removed
2. Circlip to be removed
3. Plastic washer on right side
A30G17A
HANDLEBAR READY TO BE MOVED
MMR2001_066_08_02A.FM 08-02-3
Using a hook, pull spring right side end to allow

removing welded lock.
 WARNING
Spring will be ejected upon welded lock re-
moval.
A30G1CA 1 2
1. Punch
2. Hook to pull spring end
Proceed the same with left side spring end.
A30G1AA
WELDED LOCK REMOVAL
To reassemble tilt handlebar mechanism, reverse

disassembly procedure. However, pay attention to
the following:
Install spring with its locking tab facing bottom and
rear.
A30G0DA
Temporary install locking lever. Push it forward in

order to maintain locking rod fully engaged. Tight-
en screws retaining plate while keeping locking
rod fully engaged.
A30G1BA
1
1. Spring tab
Hold left side portion of spring with a punch insert-

ed in lower bracket. Pull right side spring end with
a hook during welded lock insertion.
A30G1JA 1
1. Locking rod fully engaged
08-02-4 MMR2001_066_08_02A.FM
Install a new plastic washer on each end of spring.

1
A30G1GA 2 3
A30G1EA 1
1. Wiring harnesses
1. Plastic washers 2. Throttle cable
3. Nuts on right side
A30G1FA
WELDED LOCK INSTALLED

A30G1HA
Throttle cable must be under handlebar and wiring
harnesses above. HANDLEBAR IN UPPER POSITION
All 4 nuts retaining front and rear arms must be on

right side.
A30G1IA
HANDLEBAR IN LOWER POSITION
MMR2001_066_08_02A.FM 08-02-5
1, Steering Column Detach the short tie rod (under the engine) from the
steering column. Note that a hardened flat washer
Remove steering pad, remove master cylinder
no. 7 goes on each side of steering column lever.
from handlebar and put it aside. Remove circlip
retaining throttle cable to throttle housing. Unplug Unfasten steering column from vehicle.
all connector housings of handlebar switches. Re-
move handlebar assembly. 12, Steering Arm
sembling, scribe mark the steering arm and ski leg
before disassembly.
A30G0JA
HANDLEBAR ASSEMBLY
Cut locking tie retaining brake line and throttle ca-

ble to steering column.
1
A30G0BA
1. Marks
10, Bushing
Unscrew ball joint no. 18 from steering arm.
Unscrew sliding rod no. 9.
A30G0EA 1 Detach rubber boot from frame. Pull out sliding rod.
1. Cut this locking tie
Working from engine compartment, drive out
Remove the air intake silencer then center and bushing no. 10.
magneto side carburetors. Install a new bushing proceeding from front sus-
Unbolt console at center and sides. pension pit.
A30G0CA 1
A30G09A
1. Unbolt console
BUSHING INSTALLATION
08-02-6 MMR2001_066_08_02A.FM
21, Bracket
Bracket must be installed at 90° from top of center
ball joint.
2
90°
1 1
A30G1LA
FRONT VIEW AND SIDE VIEW

1. Bracket
2. Top of center ball joint
17,18, Ball Joint A30G1RA
(left hand and right hand threads) TYPICAL

1. Parallel
The maximum external threaded length not engaged
in the tie rod must not exceed 20 mm (25/32 in).
A A
A02G0SA
TYPICAL
A30G1KA
A. 20 mm (25/32 in) max.
TIE ROD BALL JOINT PARALLEL TO BRACKET BEFORE
The ball joint should be restrained when tightening TIGHTENING
the tie rod end lock nut. Align it so the tie rod end
cut-off section is parallel to the steering arm when  WARNING
assembled on the vehicle, refer to the following
The cut off section of the ball joint must run
illustration.
parallel with the steering arm. When tighten-
For proper torque specifications refer to the spe- ing lock nuts, restrain ball joint with appropri-
cific exploded view for the vehicle being serviced. ate size wrench. The maximum external
threaded length not engaged in the tie rod
must not exceed 20 mm (25/32 in).
MMR2001_066_08_02A.FM 08-02-7
7, Hardened Washer 12, Steering Arm

Install a hardened washer on each side of the arm. Make sure steering arm and ski leg splines inter-
lock.
 WARNING
Any parts having worn splines have to be re-
places with new ones.
Check the general condition of the steering sys-

15, Heating Grip Element

1 Refer to TESTING PROCEDURE.
17,18, Ball Joint

(left hand and right hand threads)
Inspect ball joint ends for wear or looseness, if ex-
A30G0KA
cessive, replace them.
1. Hardened washers
HANDLEBAR ADJUSTMENT
12, Steering Arm
Mach Z STD
Steering arm axis (from plastic cap center to ball
center of ball joint) must run parallel to ski. Loosen all 4 nuts no. 4 retaining steering clamps
no. 2.
tion.
Grand Touring SE and Mach Z TECH PLUS
With tilt handlebar mechanism is upper position,
install handlebar at 121° from steering column.
A30G0LB 1
1. Parallel
Tighten the steering arm pinch bolt and nut to the

torque specified in the exploded view.
121°
INSPECTION
Check skis and runner shoes for wear, replace as
necessary. Refer to FRONT SUSPENSION.
A30G1MA
08-02-8 MMR2001_066_08_02A.FM
All Models STEERING ADJUSTMENT (skis)

nuts as specified in the illustrations. Definitions
CAUTION: Tighten the nuts equally in a criss- TOE-OUT:
cross sequence and ensure there is an equal A difference measured between the front edge of
gap on each side of the clamps. 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.
1
220 mm 220 mm
A
B
1
A01G04D
A30G0HA TYPICAL
1. Ski pivot bolt axis
TYPICAL
1. Torque to 23 N•m (17 lbf•ft) CAMBER:
A specific inward or outward tilt angle of ski leg
 WARNING compared to a vertical line when viewing the ve-
hicle from front.
Avoid contact between the brake handle and
the windshield by NOT adjusting the handle-
bar too high.
Adjustments
 WARNING sequence:
– Pivot arm centering.
Make sure that the steering pad and all con-
trols are properly fixed to their normal loca- – Set camber angle.
tion on the handlebar. – Set toe-out.
PIVOT ARM CENTERING
19,20, Steering Pad and Rubber
Attachment  WARNING
CAUTION: Prior to installation, perform handle- Do not attempt to adjust straight ahead ski
bar adjustment. position by turning the ball joint on tie rod
Properly fit the steering pad to the handlebar. As- no. 8.
semble using the 2 rubber attachments.
 WARNING
trols are properly fixed to their normal loca-
tion on the handlebar.
MMR2001_066_08_02A.FM 08-02-9
8,17,18,21, Tie Rod, Ball Joint and Loosen the jam nuts on tie rod no. 8 (LH threads
Bracket on steering column end) and turn tie rod accord-
ingly. Align and retighten the jam nuts to 18 N•m
Remove steering pad. (159 lbf•in).
Turn handlebar all the way to the right. Check that
the right side bracket no. 21 is against the bushing  WARNING
no. 10. Never lengthen this tie rod so that threaded por-
tion of ball joint exceeds 20 mm (25/32 in).
A30G0UA
A30G0QA 1
1. Tie rod no. 8
1. Bracket against the bushing
CAMBER
Keeping the handlebar in that position, check that
the stopper on the steering column is almost touch- NOTE: Identical adjustments are required on both
ing the plate. sides of the vehicle.
– Make sure the vehicle is leveled by placing an
1 angle finder under the main frame member as
shown on the following illustration.
– Vehicle skis must be off the ground.
A06G05A 1
A30G0PA
TYPICAL
1. Stopper almost touching the plate 1. Angle finder
08-02-10 MMR2001_066_08_02A.FM
Using special tool (P/N 529 021 600) 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 1
available is the outside of the ski leg housing.
CAUTION: Angle finder must sit square against
swing arm. Positioning angle finder against weld
bead or decal may result in false reading.
A A
529 021 600 2 2
K-D Tools
ANGLE FINDER
Lancaster, PA
K-D Tools
17004
No. 2968
A06G1KA
TYPICAL — CAMBER ADJUSTMENT SET-UP
Adjusting A06G07A
– Loosen lock nut on both upper control arms. TYPICAL

1. Equal distance A on each side
– Unbolt both upper control arms at ski leg hous- 2. Same reference point
ing. Turn tie rod half turn at a time to obtain the
specified value when skis are not touching
ground. Bolt upper control arms.
 WARNING
Do not attempt to adjust skis straight ahead
CAMBER position by turning ball joint on tie rod no. 8.
MODEL
± 0.5°
Loosen jam nuts of both tie rods no. 11.
GT SE Not Adjustable NOTE: Hook a rubber cord in front of skis to keep
Mach Z STD/TECH PLUS - 0.5 them closed and to eliminate all free play.
Toe-out must be as specified when skis are in a
NOTE: Because of a negative camber, skis will lean straight-ahead position and the front of vehicle is
toward center of vehicle. lifted off the ground.
Tighten lock nut on both upper control arms.
TOTAL TOE-OUT
SKI TOE-OUT MODEL + 3 mm (+ 1/8 in)
- 0 mm (- 0 in)
Lift front of vehicle off the ground.
Make sure that handlebar is in straight ahead po- GT SE 12 (1/2)
sition by measuring from the extremities of the
Mach Z STD/TECH PLUS 8 (5/16)
grips to the rearmost edge of the tunnel, as
shown.
Place a straight edge against pre-adjusted track and
NOTE: The reference point must be the same rel- measure the distance between front and rear of
ative to each side. skis and straight edge. Measuring points are 220
mm (8-21/32 in) at front and rear of ski pivot axis.
MMR2001_066_08_02A.FM 08-02-11
To reduce tolerance when measuring, set one ski Lubricate:

to proper toe-out (half the total toe-out) then mea- – steering column bushings
sure from that ski to the opposite ski.
– short tie rod ends
– ball stud lever
– upper arm ball joint on Mach Z STD/TECH PLUS
only
– ski legs
– stabilizer ball joints.
A30G0SA
1 2
1. Straight edge
2. Measure at 220 mm (8-21/32 in) from ski pivot axis
LUBRICATION
 WARNING A30G0RA
Do not lubricate throttle cable or housing.
26, Grease Fittings

Only use synthetic grease (P/N 413 711 500).
The following symbols will be used to show what
type of lubricant should be used at the suitable
locations.
1 2
A30G1NA 1
1
A00G01A TYPICAL
1. Upper arm ball joint on Mach Z STD/TECH PLUS only
1. Synthetic grease (P/N 413 711 500)
2. BOMBARDIER LUBE (P/N 293 600 016)
08-02-12 MMR2001_066_08_02A.FM

CK3 Series
48 Nm
(35 lbfft)
7 Nm
(62 lbfin)
48 Nm
(35 lbfft)
Super
Loctite Lube
8 271 48 Nm
35 Nm 29 Nm 14 (35 lbfft)
(26 lbfft) (21 lbfft) 13
48 Nm
(35 lbfft)
7
Synthetic grease
4
12
5
Synthetic
grease
9 5
18 Nm
Mach STD (160 lbfin)
32 Nm
Mach Z TECH PLUS (24 lbfft)
GT SE
7 Nm
(62 lbfin)
GT SE
only
10
1.8 Nm 9 Nm

A30G1SS

DISASSEMBLY
5, Shock
Lift front of vehicle and support it off the ground. 1
cordingly with the adjustment wrench in vehicle
2
tool box.
A01B4LA
1. Clevis pin
A30G05A 2 1 2. Bar
TYPICAL
1. Shock cam Push down on the handle until it locks. Remove
2. Adjustment wrench spring stopper then release handle.
Remove lower bolt then upper bolt of shock.
1, Swing Arm
For shock spring disassembly use shock spring re-
mover (P/N 529 027 100) in a vise. Mount shock Lift front of vehicle and support it off the ground.
in it and turn shock so that spring coils matched Remove cap no. 4, circlip no. 3 then loosen steer-
spring compressor. ing arm bolt and pull up steering arm. Ski leg may
Close and lock the bar. Adjust the handle horizon- fall off from swing arm. Note washer no. 2 posi-
tal position by changing the position of the clevis tion.
pin. Unbolt lower end of shock from swing arm.
Unbolt arms.
Unbolt tie rod no. 13 ball joint from swing arm.
Unbolt rear of swing arm from frame.
Pull swing arm off the vehicle.
08-03-2 MMR2000_067_08_03A.FM
INSPECTION 7,8, Upper and Lower Half Arms

Check all rubber cushions for crack and wear. Re- Position half arms and tie rods horizontally before
place as required. tightening nuts.
Check straightness of ski leg no. 12 and make 8, Adjustable Arm
sure that splines are properly interlocking with
steering arm. Replace as required. Refer to STEERING SYSTEM for proper camber
adjustment using these arms.
required. 13,14, Tie Rod and Lever
Check for clogged grease fittings. Clean or replace as
Install levers pointing downward on both sides at
required.
same angle, see following photo.
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 II SUS-
PENSION then look for Shock Absorber Inspec-
tion.
INSTALLATION
For assembly, reverse the disassembly proce-
dure. However, pay attention to the following.
Apply synthetic grease (P/N 413 711 500) to ski
leg components.
A30G07A 1
tioned in exploded view. 1. Lever pointing downward
MMR2000_067_08_03A.FM 08-03-3
TABLE OF CONTENTS 0
BODY ...................................................................................................................................... 09-02-1
DECAL ................................................................................................................................ 09-02-2
HOOD ................................................................................................................................. 09-02-2
HALF BOTTOM PAN.......................................................................................................... 09-02-2
GUARD ............................................................................................................................... 09-02-3
WIRING HARNESS ............................................................................................................ 09-02-3
CABLES .............................................................................................................................. 09-02-4
PIPING ................................................................................................................................ 09-02-4
MAINTENANCE ................................................................................................................. 09-02-4
REPAIR................................................................................................................................ 09-02-4
REPAIR PROCEDURE FOR HOOD (MADE OF TPO) ........................................................ 09-02-4
FRAME ................................................................................................................................... 09-03-1

FRAME CLEANING ............................................................................................................ 09-03-1
FRAME WELDING ............................................................................................................. 09-03-1
MMR2001_072_09_01ATOC.FM 09-01-1
BODY 0
INSTALLATION AND BULB REPLACEMENT
ADJUSTMENT
Headlamp
HEADLAMP BEAM AIMING If any headlight bulb is burnt, remove windshield,
air filter then, air deflector.
Beam aiming is correct when center of high beam
is 25 mm (1 in) below the headlamp horizontal cen-
ter line, scribed on a test surface, 381 cm (12 ft 6 in)
away.
Measure headlamp center distance from ground.
Scribe a line at this height on test surface (wall or
screen). Light beam center should be 25 mm (1 in)
below scribed line.
1 90°
1
A A30E04A
1. Air deflector
Unplug burnt bulb connector. Remove the rubber

boot.
Unfasten bulb retainer ring. Detach the bulb and
A02E0AA B
replace. Properly reinstall parts including air filter.
TYPICAL
A. 381 cm (12 ft 6 in)
1 2
3 A
A02E07A
1. Headlamp horizontal
2. Light beam (high beam) (projected on the wall)
A. 25 mm (1 in) A30E05A 1
Required Conditions 1. Locking ring
Place the vehicle on a flat surface perpendicular to CAUTION: Never touch glass portion of an
test surface (wall or screen) and 381 cm (12 ft 6 in) halogen bulb with bare fingers, as it shortens
away from it. its operating life. If by mistake glass is touched,
Rider or equivalent weight must be on the vehicle. clean it with isopropyl alcohol which will not
Select high beam. leave a film on the bulb.
MMR2001_068_09_02A.FM 09-02-1
Taillight All Models

If the taillight bulb is burnt, expose the bulb by re- Remove hinge pin push nuts.
moving red plastic lens. To remove, unscrew the
2 retaining screws. Verify all lights after replace-
ment.
DECAL
thoroughly.
from the center toward the edges. Allow to air dry. A30H17A
CAUTION: Do not apply isopropyl alcohol or Unplug wiring harnesses then retaining cables.
solvent directly on decals. Use only in a well
ventilated area. Remove hinge pins, cables, spring and hood.
WINDSHIELD INSTALLATION HALF BOTTOM PAN

Remove protective film. Remove hood.
Remove tuned pipes and tail pipes. Remove muf-
Position the windshield on the hood then push it
fler when RH side half bottom pan has to be re-
down until the tabs are fully inserted into the hood
moved.
slots. Lock the windshield tabs in position.
Unbolt suspension tower bracket on appropriate
HOOD side.
Remove 4 screws, 1 nut and 1 rivet retaining front
All Models Except Grand Touring SE bumper.
Unfasten speedometer cable from angle drive.
Remove clips holding speedometer cable to bot-
tom pan.
2
2
A30H18A 1 1
1. Suspension tower bracket
2. Bottom pan screws, nut and rivet
A30H16A 1 Unfasten swing arm at rear pivot.
1. Clips Drill all rivets retaining half bottom pan to be re-
moved.
09-02-2 MMR2001_068_09_02A.FM
At installation, insert bottom pan protector between

1
tunnel and footrest.
A30H1BA
FRONT — SEEN FROM UNDERNEATH

A30H1AA 1 2 3 1. Bumper
1. Bottom pan protector

2. Footrest
3. Tunnel
GUARD
Disassembly and Assembly
NOTE: For additional information (ex.: exploded
view) refer to the correspondent parts catalog.
 WARNING
Engine should be running only with guard
well secured in place.
Inspection
Check guard mounting bosses, clips and retainers
for wear.
A30H19A
VEHICLE READY TO RECEIVE LH SIDE HALF BOTTOM PAN

WIRING HARNESS
When riveting bottom pan, do not install front riv-  WARNING
et. That rivet is installed with the bumper. Ensure all terminals are properly crimped on
properly fastened. Keep wires away from any
rotating, moving, heating and vibrating parts.
MMR2001_068_09_02A.FM 09-02-3
CABLES – abrasive cleaners

– waxes containing an abrasive or a cleaning
 WARNING agent in their formula.
Before installation, ensure that all cables are Apply wax on glossy finish only. Protect the vehicle
in perfect condition. Properly install the cable with a cover to prevent dust accumulation during
ends and secure them in place. Pay attention storage.
to route them properly, away from any rotat- CAUTION: If for some reason the snowmobile
ing, moving, heating, or vibrating parts. has to be stored outside it is preferable to cover
PIPING the sun rays from affecting the plastic compo-
 WARNING REPAIR
Always ensure that the fuel, vent, primer, im-
pulse, injection oil and rotary valve oil lines
are properly fixed to their connectors, that  WARNING
they are not perforated or kinked and that Polycarbonate windshields must never be re-
they are properly routed away from any rotat- paired by welding or otherwise.
ing, moving, heating or vibrating parts. Also
check for leaks. Replace if required.  WARNING
NOTE: Refer to proper Parts Catalog to find suitable Material should be repaired and repainted in
clip part numbers. a well-ventilated area only.
NOTE: When working on a Thermo Plastic Olefin

PLASTIC MAINTENANCE AND (TPO) surface, never use a grinder or a high revo-
REPAIR lution tool such as an air or electric buffer. Use of
such tools could overheat material and liberate
MAINTENANCE agents in it thus causing a bad adhesion.
Clean the vehicle thoroughly, removing all dirt and
grease accumulation.
REPAIR PROCEDURE FOR HOOD
To clean use a soft clean cloth and either soapy wa-
(MADE OF TPO)
ter or isopropyl alcohol. Small Scratches
To remove grease, oil or glue use isopropyl alcohol.
– Sand and scuff area.
CAUTION: Do not apply isopropyl alcohol or
– Feather out edges.
acetone directly on decals.
– Paint with a matching acrylic auto touch-up paint.
CAUTION: The following products must not be
used to clean or wax any of the plastic compo-
nents used on the vehicles:
Deep Scratches
– gasoline Preparation
– brake fluid – Sand and scuff area.
– kerosene – Make a V groove using a knife or a rough round
file.
– diesel fuel
– Clean surface with isopropyl alcohol or Crest®
– lighter fluid AS-X or BS-X Super Solv. Allow to dry thoroughly.
– varsol – Apply a light coat of Crest AF-S Flex Stik Adhe-
– naphtha sion Promoter. Allow 10 minutes to dry.
– acetone – Apply Crest Formula 21 CF-PR Universal Plastic
– strong detergents Repair directly to the repair area. Allow 30 min-
utes cure time before sanding.
09-02-4 MMR2001_068_09_02A.FM
Finishing – Apply a light coat of Crest AF-S Flex Stik Adhe-

– Carefully hand or machine sand with 80 grit pa- sion Promoter. Allow 10 minutes to dry.
per. – Install 50 mm (2 in) paper tape Crest no. RPT on
– Cover with TP-E epoxy mixed in equal quantities. rear of repair.
Never use polyester fillers over formula 21. 1
– After 30 minutes, sand with fine 220 or 320 grit
paper. Wipe or blow-off area.
A30H27A
– Prep for paint. Apply Crest AF-S Flex Stik to aid
in paint adhesion. 1. Paper tape
– Prime and paint, following manufacturer’s rec- – Apply Crest Formula 21 CF-PR Universal Plastic
ommendations or use Crest Prima Flex and one Repair directly to the repair area (to just beyond
of Crest’s Flexible Bumper Coats AF1-18. pinning holes). Allow 30 minutes cure time be-
fore sanding.
Large Crack
1
Preparation
– Clean repair area with Crest AS-X or BS-X Super
Solv. Allow to dry thoroughly. A30H28A
1. Fill area between tape and pinning holes
A30H24A
1
CROSS SECTION OF TORN HOOD
– Restore shape of plastic with heat gun, avoid

overheating, let cool. A30H29A
– Enlarge area to be repaired, bevel, soften edges 1. Fill just above pinning holes to form structural base
on both sides. Avoid smearing or melting the Finishing
plastic.
– Carefully hand or machine sand with 80 grit pa-
per.
– Cover with TP-E epoxy mixed in equal quantities.
A30H25A A Never use polyester fillers over formula 21.
A. 10 mm (3/8 in)
– After 30 minutes, sand with fine 220 or 320 grit
paper. Wipe or blow-off area.
– Drill 3 mm (1/8 in) diameter holes, 10 mm (3/8 in)
– Prep for paint. Apply Crest AF-S Flex Stik to aid
apart, around beveled edge of repair area.
in paint adhesion.
1 – Prime and paint, following manufacturer’s rec-
ommendations or use Crest Prima Flex and one
of Crest’s Flexible Bumper Coats AF1-18.
A30H26A
1. Holes A30H2AA
– Scuff the repair area with coarse sandpaper. NOTE: Painting must be done in a dust free area
Clean scuffed area with a clean, dry rag or clean, such as a paint booth.
oil-free compressed air.
MMR2001_068_09_02A.FM 09-02-5
Crest products are available from following locations:
CREST MAIN OFFICE AND MANUFACTURING PLANT

CREST INDUSTRIES, INC. Phone: 734-283-4100
3841 13th Street Toll Free: 1-800-822-4100
Wyandotte, Michigan Fax: 1-800-344-4461
48192 Fax: 734-283-4461
E-Mail: info@crestauto.com
www.crestauto.com
DISTRIBUTOR WAREHOUSE LOCATIONS

UNITED STATES CANADA
CREST EAST COAST, INC. CREST INDUSTRIES, INC. J2 PRODUCTS
P.O. Box 550 (CREST MID-WEST) A DIVISION OF SAWILL LTD.
1109 Industrial Parkway 231 Larkin Williams Ind. Court 54 Audia Court, Unit 2A
Brick, New Jersey 08723 St. Louis, Missouri 63026 Concord, Ontario, L4K 3N4
Phone: 732-458-9000 Phone: 314-349-4800 Phone:
Fax: 732-458-5753 Toll Free: 1-800-733-2737 Toronto: 416-665-1404
Fax: 314-349-4888 Concord: 905-669-9410
CREST PRODUCTS, INC. Toll Free Fax: 1-800-776-2737 Fax:
Shipping Address: Concord: 905-669-9419
125 Production Drive CREST MIDWEST
Yorktown, Virginia 23693 REGIONAL BRANCH WAREHOUSES WHEEL-IN AUTOMOTIVE
Phone: 757-599-6572 CREST INDUSTRIES, INC. SUPPLY
Virginia: 1-800-572-5025 P.O. Box 635 Shipping Address:
Outstate: 1-800-368-5033 Mountain Home, Arkansas 72653 No. 1, 3911A Brandon St. S.E.
Fax: 757-599-6630 Phone: 501-491-5583 Calgary, Alberta, T2G 4A7
Mailing Address: Toll Free: 1-800-733-2737 Phone: 403-287-0775
P.O. Box 2018 Mailing Address:
Grafton, Virginia 23692 CREST INDUSTRIES, INC. P.O. Box 40036
4200 Jackson Street, Unit 9 929-42nd Avenue S.E.
CREST INDUSTRIES Denver, Colorado 80216 Calgary, Alberta, T2G 5G5
SOUTHEAST, INC. Phone: 303-320-3900
Shipping Address: Toll Free: 1-800-733-2737
1400-B Woodstock Rd. Fax: 303-320-6509
Roswell, Georgia 30075
Mailing Address: REM-CO DISTRIBUTING, INC.
11530 Bowen Road 5625 S. Adams
Roswell, Georgia 30075 Tacoma, Washington 98409
Phone: 770-642-7670 Phone: 253-474-5414
Toll Free: 1-800-552-0876 Toll Free: 1-800-735-7224
Fax: 770-642-7679 Fax: 253-474-7339
09-02-6 MMR2001_068_09_02A.FM
FRAME 0
FRAME CLEANING CAUTION: If welding is to be done near plastic
NOTE: For aluminum frames use only aluminum the part from the area or to protect it with alu-
cleaner and follow instructions on container. (Dur- minum foil to prevent damage.
sol cleaner or equivalent).
Clean frame and tunnel with appropriate cleaners FRAME COMPONENT
and rinse with high pressure hose. REPLACEMENT
scratched off. Spray all bare metal parts of vehicle Drilling Procedure
with metal protector. When drilling self-piercing rivets, use Supertanium™
drill bit (P/N 529 031 800), available in a 5 mm
Seat Cleaning (3/16 in) size and shipped in packs of 2.
For all models, it is recommend to clean the seat For proper drilling instructions and to prevent pre-
with a solution of warm soapy water, using a soft mature wear, follow the procedure below.
clean cloth.
Always use a variable speed electric drill.
as strong soaps, degreasing solvents, abrasive Partially drill rivet end — not the rivet head.
cleaners, paint thinners, etc. that may cause Maintain a slow to medium speed at all times when
damage to the seat cover. drilling. The proper speed is attained when a con-
stant chip is ejected.
FRAME WELDING NOTE: To increase bit life, use Bombardier syn-
Aluminum Frame
oil.
(refer to specialized welding shop)
– argon-oxygen/acetylene welding
– rod: ER-4043 (3/32 in). the bit, therefore avoid using pneumatic drills.
CAUTION: Before performing electrical weld-
ing anywhere on the vehicle, unplug MPEM.
On models equipped with a battery, also un-
plug the negative cable. This will protect the elec-
tronic box and battery against damage caused by
flowing current when welding.
1
A03H2FA

Punch out rivet head from drilled end.
If rivet is only accessible from head; ground rivet
head completely and punch out remaining part of
A01H0MA rivet.
TYPICAL
1. Unplug before electrical welding
MMR2001_069_09_03A.FM 09-03-1
Grinding Procedure
Rear Cap
Grind rivet heads from top of rear cap and under-
neath for side retaining rivets.
A06H0XA
1. Rivets heads ground

2. Rivets to be ground from underneath
To remove rivet, strike with a punch from rivet

head side.
Make a chamfer from underneath on all 4 corner
holes.
09-03-2 MMR2001_069_09_03A.FM
TECHNICAL DATA 0
BASE UNITS
length .................................................................. meter ..................................................... m

mass .................................................................... kilogram ................................................. kg
force .................................................................... newton ................................................... N
liquid .................................................................... liter ......................................................... L
temperature ........................................................ Celsius ................................................... °C
pressure .............................................................. kilopascal ................................................ kPa
torque .................................................................. newton•meter ....................................... N•m
speed .................................................................. kilometer per hour .................................. km/h
PREFIXES
kilo ................................ k ............................... one thousand ......................................... 1 000

centi ............................. c ............................... one hundredth ........................................ 0.01
milli ............................... m .............................. one thousandth ...................................... 0.001
micro ............................ µ ............................... one millionth .......................................... 0.000001
CONVERSION FACTORS
in ......................................................................... mm ......................................................... 25.4

in ......................................................................... cm .......................................................... 2.54
in2 ........................................................................ cm2 ......................................................... 6.45
in3 ........................................................................ cm3 ......................................................... 16.39
ft .......................................................................... m ............................................................ 0.3
oz ......................................................................... g ............................................................. 28.35
lb ......................................................................... kg ........................................................... 0.45
lbf ........................................................................ N ............................................................ 4.4
lbf•in ................................................................... N•m ....................................................... 0.11
lbf•ft .................................................................... N•m ....................................................... 1.36
lbf•ft .................................................................... lbf•in ...................................................... 12
PSI (lbf/in2) .......................................................... kPa ......................................................... 6.89
imp. oz ................................................................. U.S. oz .................................................... 0.96
imp. oz ................................................................. mL .......................................................... 28.41
imp. gal ................................................................ U.S. gal ................................................... 1.2
imp. gal ................................................................ L ............................................................. 4.55
U.S. oz ................................................................. mL .......................................................... 29.57
U.S. gal ................................................................ L ............................................................. 3.79
MPH .................................................................... km/h ...................................................... 1.61
Fahrenheit ........................................................... Celsius ................................................... (°F - 32) ÷ 1.8
Celsius ................................................................. Fahrenheit .............................................. (°C x 1.8) + 32

MMR2001_070_10_01A.FM 10-01-1
VEHICLE MODEL GRAND TOURING SE MACH Z STD MACH Z TECH PLUS

Bore mm (in) 70.5 (2.776) 70.50 (2.776) 70.50 (2.776)
Stroke mm (in) 68.0 (2.677) 68.0 (2.677) 68.0 (2.677)
Piston Ring Type 1st /2nd ST/R ST/R ST/R
New mm (in) 0.2 (.008) 0.2 (.008) 0.2 (.008)
Ring End Gap
Wear Limit mm (in) 1.0 (.039) 1.0 (.039) 1.0 (.039)
New mm (in) 0.03 (.0012) 0.03 (.0012) 0.03 (.0012)
Ring/Piston Groove Clearance
Wear Limit mm (in) 0.2 (.0079) 0.2 (.0079) 0.2 (.0079)
± 0.016 mm
New (± .0006 in) 0.095 (.0037) 0.095 (.0037) 0.095 (.0037)
Wear Limit mm (in) 0.20 (.0079) 0.20 (.0079) 0.20 (.0079)
New mm (in) 0.39 (.0154) 0.39 (.0154) 0.39 (.0154)

Connecting Rod Big End Axial Play
Wear Limit mm (in) 1.2 (.0472) 1.2 (.0472) 1.2 (.0472)
Maximum Crankshaft End-play ➁ mm (in) 0.3 (.012) 0.3 (.012) 0.3 (.012)
Maximum Crankshaft Deflection at PTO mm (in) 0.06 (.0024) 0.06 (.0024) 0.06 (.0024)
Spark Plug Gap mm (in) 0.45 (.018) 0.45 (.018) 0.45 (.018)
Ignition Timing BTDC ➂ mm (in) 2.59 (.102) 1.94 (.076) 2.59 (.102)
Trigger Coil ➃ Ω 190 – 300 190 – 300 190 – 300
Low Speed Ω N.A. 25 – 56 25 – 56
Generating Coil ➃
High Speed Ω N.A. 3.5 – 8.1 3.5 – 8.1
Lighting Coil ➃ Ω 0.0 – 0.05 0.15 – 0.35 0.15 – 0.35
Primary Ω 0.2 – 0.5 0.2 – 0.5 0.2 – 0.5
High Tension Coil ➃
Secondary kΩ 6 – 13 6 – 13 6 – 13
Carburetor Type PTO/CTR/MAG TM 38 C321 TM 38 C317 TM 38 C317
Main Jet PTO/CTR/MAG 450/470/470 290 290
Needle Jet 876 O-2 327 O-2 327 O-2
Pilot Jet 15 50 50
Needle Identification 8BCY01-42-4 8ADY1-41-3 8ADY1-41-3
— clip position
Float Adjustment ± 1 mm (± .040 in) 21.0 (.83) 21.0 (.83) 21.0 (.83)
Air Screw Adjustment ± 1/16 Turn Closed 4-1/2 4-1/2
Idle Speed ± 200 RPM 2000 2000 2000
Gas Type/Pump Octane Number Super Unleaded/91 Super Unleaded/91 Super Unleaded/91
Type Liquid Liquid Liquid
Deflection mm (in) N.A. N.A. N.A.
Force kg (lbf) N.A. N.A. N.A.
Thermostat Opening Temperature °C (°F) N.A. N.A. N.A.
Radiator Cap Opening Pressure kPa (PSI) N.A. N.A. N.A.
Drive Pulley Retaining Screw ➄ ➄ ➄
Magneto Ring Nut 125 (92) 125 (92) 125 (92)
ENGINE COLD
N•m (lb•ft)
M6 11 (8) 11 (8) 11 (8)

Crankcase Nuts or Screws
M8 29 (21) 29 (21) 29 (21)
Cylinder Head Nuts 29 (21) 29 (21) 29 (21)
Crankcase/Cylinder Nuts or Screws 29 (21) 29 (21) 29 (21)
Axial Fan Shaft Nut N.A. N.A. N.A.
MMR2001_070_10_02A.FM 10-02-1
VEHICLE MODEL GRAND TOURING SE MACH Z STD MACH Z TECH PLUS

Pitch in 3/8 3/8 3/8
Chain
Ramp Identification and Roller Pin Type 299 ➄ 295 ➄ 295 ➄
Calibration Screw Position or Calibration Disc Quantity 3 3 3
Drive Pulley Spring Color Violet/Yellow Green/Blue Green/Blue
± 1.5 mm 157.9 147.4 147.4
Spring Length
(± .060 in) (6.22) (5.80) (5.80)
Type HPV27 Formula HPV27
Spring Preload ± 0.7 kg (± 1.5 lb) N.A. 7.0 (15.4) N.A.
Driven Pulley
Cam Angle 47 – 44 53 – 44 47 – 44
Degree
± 0.5 mm 121.0 121.0 121.0
Pulley Distance Z (± .020 in) (4.764) (4.764) (4.764)
± 0.5 mm 35.5 35.5 35.5
X (± .020 in) (1.398) (1.398) (1.398)
Offset
mm 0.5 – 1.5 1.0 – 2.0 1.0 – 2.0
Y–X MIN. – MAX. (in) (.020 – .060) (.039 – .079) (.039 – .079)
Drive Belt Width (new) ➀ mm (in) 35.1 (1.382) 35.1 (1.382) 35.1 (1.382)
Deflection ± 5 mm 38 38 38
Drive Belt Adjustment (± .197 in) (1.496) (1.496) (1.496)
Force ➁ kg (lbf) 11.5 (25) 11.5 (25) 11.5 (25)
Width cm (in) 38.1 (15.0) 38.1 (15.0) 38.1 (15.0)
Length cm (in) 345.5 (136) 307.4 (121) 307.4 (121)
Track
mm 30 – 35 30 – 35 30 – 35
Deflection (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Adjustment
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Track SC-10 II SC-10 II SC-10 II
Suspension Type
Ski ADSA ADSA ADSA
Length cm (in) 303.5 (119.5) 277.5 (109.3) 277.5 (109.3)
Width cm (in) 117.4 (46.2) 117.4 (46.2) 117.4 (46.2)
Height cm (in) 130.0 (51.2) 114.3 (45.0) 114.3 (45.0)
Ski Stance cm (in) 104.1 (41) 104.1 (41) 104.1 (41)
Toe-out and mm (in) 12 (1/2) 16 (5/8) 16 (5/8)
Camber degree - 4.5 - 2.5 - 2.5
Mass (dry) kg (lb) 279 (614) 254 (559) 254 (559)
Ground Contact Area cm2 (in2) 7356.7 (1140.3) 6670.9 (1034) 6670.9 (1034)
Bottom Pan Material Impact Copolymer Impact Copolymer Impact Copolymer
Hood Material TPO TPO TPO
Battery V (A•h) 12/20 N.A. N.A.
Headlight W H4 60/55 H4 60/55 H4 60/55
Tachometer and Speedometer Bulbs W 3 3 3
Fuel and Temperature Gauge Bulbs W 3 3 3
Fuse
Fuel Level Sensor A 0.25 0.25 0.25
Fuel Tank L (U.S. gal) 42 (11.1) 42 (11.1) 42 (11.1)
Chaincase/Gearbox mL (U.S. oz) 250 (8.5) 250 (8.5) 250 (8.5)
Cooling System ➃ L (U.S. oz) 5.1 (172.5) 5.0 (169) 5.0 (169)
MMR2001_070_10_03A.FM 10-03-1
ENGINE LEGEND VEHICLE LEGEND

BTDC: Before Top Dead Center ADSA: Advanced Direct Shock Action
CDI: Capacitor Discharge Ignition TPO: Thermo Plastic Olefin
CTR: Center TRA: Total Range Adjustable
K: Kilo (x 1000) N.A.: Not Applicable
MAG: Magneto Side ➀ Minimum allowable width may not be less than
N.A.: Not Applicable 3.0 mm (1/8 in) of new drive belt.
PTO: Power Take Off Side ➁ Force applied midway between pulleys to ob-
tain specified tension deflection.
R: Rectangular
➂ Force or downward pull applied to track to ob-
ST: Semi-Trapezoidal tain specified tension deflection.
➀ The maximum horsepower RPM applicable on ➃ Coolant mixture: 60% antifreeze/40% water.
the vehicle. It may be different under certain cir-
cumstances and BOMBARDIER INC. reserves ➄ Lever with roller pin (P/N 417 004 308) (solid).
the right to modify it without obligation.
➁ Crankshaft end-play is not adjustable on these
models. Specification is given for verification
purposes only.
➂ At 3500 RPM with headlamp turned on.
➃ All resistance measurements must be per-
formed with parts at room temperature (approx.
20°C (68°F)). Temperature greatly affects resis-
tance measurements.
➄ Drive pulley retaining screw: torque to 90 to 100
N•m (66 to 74 lbf•ft), install drive belt, acceler-
ate the vehicle at low speed (maximum 30 km/h
lbf•ft).
MMR2001_070_10_04A.FM 10-04-1
WIRING DIAGRAMS 0
ELECTRICAL
WIRING
MODELS DIAGRAM
(watt) (watt) OUTPUT
PAGE
(watt)
Mach Z Annex 1 60 /55 hal. 8/27 290
Mach Z Tech Plus Annex 2 60 /55 hal. 8/27 290
GT SE Annex 3 60 /55 hal. 8/27 360
hal. = halogen
WIRING DIAGRAM LEGEND WIRE COLORS
 WARNING
Ensure all terminals are properly crimped on XX/XX
the wires and all connector housings are prop-
erly fastened. XX/XX
1- MC
A00I04F D
XX/XX
1 - MC The first color of a wire is the main color, second
color is the stripe.
D
2 34
stripe.
A00I04E
1
1. Wire colors COLOR CODE
2. Connector housing area
3. Housing code per area BE – BEIGE OR – ORANGE
4. Wire connector location in housing BK – BLACK RD – RED
BU – BLUE VI – VIOLET
BR – BROWN WH – WHITE
GN – GREEN YL – YELLOW
GY – GREY
MMR2001_071_11_01A.FM 11-01-1
CONNECTOR HOUSING AREA CONNECTOR LOCATION IN

HOUSING
XX/XX
1 - MC XX/XX
1 D 1- MC
D
A00I04G
A00I04H
D
7
6
11 3
9 8 4 2 1
5 10
A06H33C
AREA LOCATION
2 Magneto
3 Carburetors
6 Under console
7 Under hood
8 Near fuel tank
9 Rear of seat
10 Under engine
11-01-2 MMR2001_071_11_01A.FM
DEUTSCH
85
A A A 2 87
1
87a
B B B 1 86 30 2
2
1
A A
A A
A
B B
C C B B
B
C
A
B
C C A 3
A 1
B 21
A C B 2
A C 3
B B
A B A B
C B
D A C
C B D A C A
B
A B
A B
D C A
B A B 4
C D 1
2
3
1
4 2
3
PACKARD
A A
B B
C
6
5
1 4 1
2 2
3 6 3
5
4
A
A
B B
A C
B A
C 12
D CB 11
ED
1 10 1
2
F 2
3 12
9
8 3
4 11 7 4
5 10 5
6 9 6
8
A 7
A
B CB
D
V01G0EU D
C FE
MMR2001_071_11_01A.FM 11-01-3
SYMBOLS DESCRIPTION


ground ground
Frame

component
A00E9PS
11-01-4 MMR2001_071_11_01A.FM

not on wire.
toward wire side.
A06E1PA
A00E1EA
TYPICAL

CONNECTORS REMOVAL
A00E1DA
TAB CONNECTOR
1. Locking tab
A06E1QA
MMR2001_071_11_01A.FM 11-01-5

To remove:
– Insert tool Snap-on TT 600-5 under lock and
twist to lift it.
A01E34A 1
1. Lock

housing.
A01E31A
A01E35A
Round Connector Housing

A01E32A
Male Connector Housing

To remove:
A00E56A
A01E33A 1
1. Lock
11-01-6 MMR2001_071_11_01A.FM
2
A00E1FA
TYPICAL
A00E57A 1. Receptacle
2. Housing
TAB AND RECEPTACLE ACCESSORIES INSTALLATION

CONNECTORS INSTALLATION On all electric start models: The direct current
Prior to installing, make sure locking tab is suffi- (DC) utilizes the snowmobile frame as ground
ciently lifted to properly lock. “wire” while all alternating current (AC) consum-
ers (lights, heated grips, fuel gauge, etc.) utilize a
Insert tab and receptacle connectors in their re- separate ground wire.
tions. Push sufficiently so that they snap. Try pull- Never interconnect AC and DC grounds as an AC
ing wire to ensure they are properly locked. voltage drop will result. When installing accesso-
ing coil wires.
1 When an electric starter kit is installed, the voltage
A00E1GA
2  WARNING
Keep wires away from any rotating, moving,
1. Tab
2. Housing heating, vibrating or sharp edge. Use proper
fastening devices as required.
MMR2001_071_11_01A.FM 11-01-7
ANNEX 1 MACH Z
ANNEX 2 MACH Z TECH PLUS
ANNEX 3 GT SE
2001
Shop Manual
VOLUME 3
GRAND TOURING STD 500/STD 600/GS 700

FORMULA DELUXE STD 500/600
FORMULA DELUXE GS 700
FORMULA DELUXE GSE 600/700
MX Z STD 500/600/700/800
MX Z TRAIL 500/600/700
MX Z ADRENALINE 600/700
MX Z X 600/700/800
SUMMIT STD 600/700
SUMMIT X 700/800
SUMMIT H.M. 700
SUMMIT H.M. X 800
Legal deposit:
4th trimester 2000
Bombardier Inc.
Printed in Canada

TABLE OF CONTENTS
WHAT’S NEW ....................................................................................................................................... IV
INTRODUCTION .................................................................................................................................. V

02 LUBRICATION 01 – Periodic maintenance chart ...................................................... 02-01-1

AND MAINTENANCE

02 – Engine ...................................................................................... 03-02-1

02 – 493, 593, 693 and 793 engine types ........................................ 04-02-1
04 – CDI system............................................................................... 04-04-1
07 – Rewind starter.......................................................................... 04-07-1

02 – Drive belt .................................................................................. 05-02-1
03 – Drive pulley............................................................................... 05-03-1
04 – Driven pulley............................................................................. 05-04-1
06 – Brake ........................................................................................ 05-06-1
07 – Chaincase ................................................................................. 05-07-1
08 – Gearbox .................................................................................... 05-08-1
09 – Drive chain................................................................................ 05-09-1

02 – Ignition timing........................................................................... 06-02-1
03 – Spark plugs............................................................................... 06-03-1
04 – Battery...................................................................................... 06-04-1
07 REAR SUSPENSION 01 – Table of contents...................................................................... 07-01-1

02 – SC-10 II suspension.................................................................. 07-02-1
03 – SC-10 Mountain suspension .................................................... 07-03-1
04 – Drive axle.................................................................................. 07-04-1
05 – Track......................................................................................... 07-05-1
MMR2001_073_00_02A.FM I
TABLE OF CONTENTS


02 – Body......................................................................................... 09-02-1
03 – Frame....................................................................................... 09-03-1

02 – Engines .................................................................................... 10-02-1
03 – Vehicles.................................................................................... 10-03-1
II MMR2001_073_00_02A.FM
SAFETY NOTICE
SAFETY NOTICE 0
This edition was primarily published to be used by snowmobile mechanic technicians who are already
familiar with all service procedures relating to Bombardier made snowmobiles. Mechanic technicians
should attend continuous training courses given by Bombardier Training Dept.
Catalog.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Service
understand these.
of the parts.
 WARNING
nents.
MMR2001_073_00_02A.FM III
WHAT’S NEW
WHAT’S NEW 0
SERVICE TOOLS AND SERVICE PRODUCTS
• New 21 mm circlip installer.
• New C-36 and C-46 service tools.
• Reintroduction of Molykote G-n paste for RAVE valve stem.
493, 593, 693 AND 793 ENGINES TYPES

• New oil seal on RAVE valve stem.
• New Isoflex grease application.
• New tightening sequence for crankcase screws.
OIL INJECTION SYSTEM

• Adjustment procedure.
REWIND STARTER
• New type of lubricant is used on all moving parts.
CARBURETOR AND FUEL PUMP

• TM carburetor repair procedure.
SC-10 II SUSPENSION
• New BOSS shock servicing procedure.
• New T/A HPG shock repair procedure.
SC-10 MOUNTAIN SUSPENSION

• New subsection.
IV MMR2001_073_00_02A.FM
INTRODUCTION
INTRODUCTION 0
This Shop Manual Volume 3 covers the following Bombardier made 2001 snowmobiles:
MODEL MODEL
MODELS MODELS
NUMBER NUMBER
GRAND TOURING* STD 500 (BLACK) FORMULA DELUXE GSE 600 (CLOUD)
(Canada) ............................................................. 1799 (U.S.) .................................................................. 1834
GRAND TOURING STD 500 (BLACK) (U.S.) ...... 1800 FORMULA DELUXE GSE 700 (RED)
GRAND TOURING STD 500 (BLACK) (Canada) ............................................................. 1764
(Europe) ............................................................. 1801 FORMULA DELUXE GSE 700 (RED) (U.S.) ....... 1765
GRAND TOURING STD 500 (CLOUD) FORMULA DELUXE GSE 700 (CLOUD)
(Canada) ............................................................. 1802 (Canada) ............................................................. 1766
GRAND TOURING STD 500 (CLOUD) (U.S.) ..... 1803 FORMULA DELUXE GSE 700 (CLOUD)
GRAND TOURING STD 600 (BLACK) (U.S.) .................................................................. 1767
(Canada) ............................................................. 1794 MX Z TRAIL 500 (YELLOW) (Canada)................ 1706
GRAND TOURING STD 600 (BLACK) (U.S.) ...... 1795 MX Z TRAIL 500 (YELLOW) (U.S.)..................... 1707
GRAND TOURING STD 600 (BLACK) MX Z TRAIL 500 (BLACK) (Canada) ................... 1708
(Europe) ............................................................. 1796 MX Z TRAIL 500 (BLACK) (U.S.) ........................ 1709
GRAND TOURING STD 600 (CLOUD) MX Z TRAIL 600 (YELLOW) (Canada)................ 1691
(Canada) ............................................................. 1797
MX Z TRAIL 600 (YELLOW) (U.S.)..................... 1692
GRAND TOURING STD 600 (CLOUD) (U.S.) ..... 1798
MX Z TRAIL 600 (BLACK) (Canada) ................... 1693
GRAND TOURING GS 700 (BLACK)(Canada) .... 1789
MX Z TRAIL 600 (BLACK) (U.S.) ........................ 1694
GRAND TOURING GS 700 (BLACK) (U.S.) ........ 1790
MX Z TRAIL 700 (YELLOW) (Canada)................ 1676
GRAND TOURING GS 700 (BLACK) (Europe) ... 1791
MX Z TRAIL 700 (YELLOW) (U.S.)..................... 1677
GRAND TOURING GS 700 (CLOUD)(Canada) ... 1792
MX Z TRAIL 700 (BLACK) (Canada) ................... 1678
GRAND TOURING GS 700 (CLOUD) (U.S.) ....... 1793
MX Z TRAIL 700 (BLACK) (U.S.) ........................ 1679
FORMULA* DELUXE STD 500 (RED)
(Canada) ............................................................. 1778 MX Z STD 500 (YELLOW) (Canada)................... 1710
FORMULA DELUXE STD 500 (RED) (U.S.) ....... 1779 MX Z STD 500 (YELLOW) (U.S.)........................ 1711
MX Z STD 500 (YELLOW) (Europe) ................... 1712
FORMULA DELUXE STD 500 (CLOUD)
(Canada) ............................................................. 1780 MX Z STD 500 (BLACK) (Canada) ...................... 1713
FORMULA DELUXE STD 500 (CLOUD) MX Z STD 500 (BLACK) (U.S.) ........................... 1714
(U.S.) .................................................................. 1781 MX Z STD 600 (YELLOW) (Canada)................... 1701
FORMULA DELUXE STD 600 (RED) MX Z STD 600 (YELLOW) (U.S.)........................ 1702
(Canada) ............................................................. 1773 MX Z STD 600 (YELLOW) (Europe) ................... 1703
FORMULA DELUXE STD 600 (RED) (U.S.) ....... 1774 MX Z STD 600 (BLACK) (Canada) ...................... 1704
FORMULA DELUXE STD 600 (CLOUD) MX Z STD 600 (BLACK) (U.S.) ........................... 1705
(Canada) ............................................................. 1775 MX Z STD 700 (YELLOW) (Canada)................... 1686
FORMULA DELUXE STD 600 (CLOUD) MX Z STD 700 (YELLOW) (U.S.)........................ 1687
(U.S.) .................................................................. 1776
MX Z STD 700 (BLACK) (Canada) ...................... 1688
FORMULA DELUXE STD 600 (CLOUD)
(Europe) ............................................................. 1777 MX Z STD 700 (BLACK) (U.S.) ........................... 1689
FORMULA DELUXE GS 700 (RED) (Canada) .... 1768 MX Z STD 700 (BLACK) (Europe)....................... 1690
FORMULA DELUXE GS 700 (RED) (U.S.) ......... 1769 MX Z STD 700 (YELLOW) (Europe) ................... 1703
FORMULA DELUXE GS 700 (CLOUD) MX Z STD 800 (YELLOW) (Canada)................... 1870
(Canada) ............................................................. 1770 MX Z STD 800 (YELLOW) (U.S.)........................ 1871
FORMULA DELUXE GS 700 (CLOUD) (U.S.) .... 1771 MX Z STD 800 (BLACK) (Canada) ...................... 1872
FORMULA DELUXE GS 700 (CLOUD) MX Z STD 800 (BLACK) (U.S.) ........................... 1873
(Europe) ............................................................. 1772 MX Z ADRENALINE 600 (YELLOW) (Canada) ... 1695
FORMULA DELUXE GSE 600 (RED) MX Z ADRENALINE 600 (YELLOW) (U.S.) ........ 1696
(Canada) ............................................................. 1831 MX Z ADRENALINE 600 (BLACK) (Canada)....... 1697
FORMULA DELUXE GSE 600 (RED) (U.S.) ....... 1832 MX Z ADRENALINE 600 (BLACK) (U.S.)............ 1698
FORMULA DELUXE GSE 600 (CLOUD) MX Z ADRENALINE 600 (RED) (Canada)........... 1689
(Canada) ............................................................. 1833
MX Z ADRENALINE 600 (RED) (U.S.)................ 1700
MMR2001_073_00_02A.FM V
INTRODUCTION
MODEL MODEL
MODELS MODELS
NUMBER NUMBER
MX Z ADRENALINE 700 (YELLOW) (Canada) ... 1680 SUMMIT X 700 (YELLOW) (Canada) ................. 1747
MX Z ADRENALINE 700 (YELLOW) (U.S.) ........ 1681 SUMMIT X 700 (YELLOW) (U.S.) ...................... 1748
MX Z ADRENALINE 700 (BLACK) (Canada)....... 1682 SUMMIT X 700 (BLACK) (Canada)..................... 1749
MX Z ADRENALINE 700 (BLACK) (U.S.)............ 1683 SUMMIT X 700 (BLACK) (U.S.).......................... 1750
MX Z ADRENALINE 700 (RED) (Canada)........... 1684 SUMMIT X 700 (RED) (Canada) ......................... 1751
MX Z ADRENALINE 700 (RED) (U.S.)................ 1685 SUMMIT X 700 (RED) (U.S.) .............................. 1752
MX Z ADRENALINE 800 (YELLOW) (Canada) ... 1856 SUMMIT X 800 (YELLOW) (Canada) ................. 1740
MX Z ADRENALINE 800 (YELLOW) (U.S.) ........ 1857 SUMMIT X 800 (YELLOW) (U.S.) ...................... 1741
MX Z ADRENALINE 800 (BLACK) (Canada)....... 1858 SUMMIT X 800 (YELLOW) (Europe).................. 1746
MX Z ADRENALINE 800 (BLACK) (U.S.)............ 1859 SUMMIT X 800 (BLACK) (Canada)..................... 1742
MX Z ADRENALINE 800 (RED) (Canada)........... 1860 SUMMIT X 800 (BLACK) (U.S.).......................... 1743
MX Z ADRENALINE 800 (RED) (U.S.)................ 1861 SUMMIT X 800 (RED) (Canada) ......................... 1744
MX Z X 600 (YELLOW) (Canada) ....................... 1825 SUMMIT X 800 (RED) (U.S.) .............................. 1745
MX Z X 600 (YELLOW) (U.S.) ............................ 1826 SUMMIT H.M. X 800 (YELLOW) (Canada) ........ 1723
MX Z X 600 (BLACK) (Canada)........................... 1827 SUMMIT H.M. X 800 (YELLOW) (U.S.) ............. 1724
MX Z X 600 (BLACK) (U.S.)................................ 1828 SUMMIT H.M. X 800 (BLACK) (Canada)............ 1725
MX Z X 600 (RED) (Canada) ............................... 1829 SUMMIT H.M. X 800 (BLACK) (U.S.)................. 1726
MX Z X 600 (RED) (U.S.) .................................... 1830 SUMMIT H.M. X 800 (RED) (Canada) ................ 1727
MX Z X 700 (YELLOW) (Canada) ....................... 1670 SUMMIT H.M. X 800 (RED) (U.S.) ..................... 1728
MX Z X 700 (YELLOW) (U.S.) ............................ 1671 SUMMIT H.M. X 800 (RED) (Europe) ................ 1824
MX Z X 700 (BLACK) (Canada)........................... 1672
*Trademarks of Bombardier Inc.
MX Z X 700 (BLACK) (U.S.)................................ 1673
MX Z X 700 (RED) (Canada) ............................... 1674
MX Z X 700 (RED) (U.S.) .................................... 1675 All the above listed models are ZX Series models.
MX Z X 800 (YELLOW) (Canada) ....................... 1663
MX Z X 800 (YELLOW) (U.S.) ............................ 1664
MX Z X 800 (BLACK) (Canada)........................... 1665
MX Z X 800 (BLACK) (U.S.)................................ 1666
MX Z X 800 (BLACK) (Europe) ........................... 1667
MX Z X 800 (RED) (Canada) ............................... 1668
MX Z X 800 (RED) (U.S.) .................................... 1669
SUMMIT STD 600 (YELLOW) (Canada)............. 1758
SUMMIT STD 600 (YELLOW) (U.S.).................. 1759
SUMMIT STD 600 (BLACK) (Canada) ................ 1760
SUMMIT STD 600 (BLACK) (U.S.) ..................... 1761 A32A0FA
SUMMIT STD 700 (YELLOW) (Canada)............. 1753

TYPICAL — ZX SERIES
SUMMIT STD 700 (YELLOW) (U.S.).................. 1754
SUMMIT STD 700 (YELLOW) (Europe) ............. 1757
SUMMIT STD 700 (BLACK) (Canada) ................ 1755
SUMMIT STD 700 (BLACK) (U.S.) ..................... 1756
SUMMIT H.M. 700 (YELLOW) (Canada)............ 1735
SUMMIT H.M. 700 (YELLOW) (U.S.)................. 1736
SUMMIT H.M. 700 (BLACK) (Canada) ............... 1737
SUMMIT H.M. 700 (BLACK) (U.S.) .................... 1738
SUMMIT H.M. 800 (YELLOW) (Canada)............ 1862
SUMMIT H.M. 800 (YELLOW) (U.S.)................. 1863
SUMMIT H.M. 800 (BLACK) (Canada) ............... 1864
SUMMIT H.M. 800 (BLACK) (U.S.) .................... 1865
VI MMR2001_073_00_02A.FM
INTRODUCTION
VEHICLE IDENTIFICATION LIST OF ABBREVIATIONS

NUMBER USED IN THIS MANUAL
Vehicle Identification Number Location A ampere
amp ampere
A•h ampere-hour
AC alternate current
ACM acceleration and control modulator
ADSA advanced direct shock action
BDC bottom dead center
BTDC before top dead center
°C degree Celsius
cc cubic centimeter
CDI capacitor discharge ignition
A32H0DA 1
CTR center
TYPICAL
1. Vehicle identification number cm centimeter
cm² square centimeter
Identification Number Meaning
cm³ cubic centimeter
2BPS15929Y1000001 DC direct current
Model number Serial number DESS digitally encoded security system
Model year: y = 2000 DPM digital performance management
1 = 2001 °F degree Fahrenheit
2 = 2002
A00A6EA etc. FC fan cooled
fl. oz fluid ounce
ENGINE SERIAL NUMBER ft foot
GRD ground
Engine Serial Number Location H.A.C. high altitude compensator
hal. halogen
HI high
IFP internal floating piston
imp. oz imperial ounce
in inch
in² square inch
in³ cubic inch
k kilo (thousand)
kg kilogram
A32C01B 1 kPa Kilopascal
TYPICAL
L liter
1. Engine serial number lb pound
lbf pound (force)
MMR2001_073_00_02A.FM VII
INTRODUCTION
lbf/in² pound per square inch ARRANGEMENT OF THE

LH left hand MANUAL
LO low The manual is divided into 11 major sections:
LT long track 01 SERVICE TOOLS AND SERVICE PRODUCTS
m meter 02 LUBRICATION AND MAINTENANCE
MAG magneto 03 TROUBLESHOOTING
Max. maximum 04 ENGINE
Min. minimum 05 TRANSMISSION
mL milliliter 06 ELECTRICAL
mm millimeter 07 REAR SUSPENSION
M.E. millennium edition 08 STEERING/FRONT SUSPENSION
MPEM multi-purpose electronic module 09 BODY/FRAME
MPH mile per hour 10 TECHNICAL DATA
N newton 11 WIRING DIAGRAMS
N.A. not applicable Each section is divided in various subsections, and
no. number again, each subsection has one or more division.
00.0 continuity
0.L open line (open circuit)
O.D. outside diameter
OPT optional
oz ounce
P/N part number
PSI pound per square inch
PTO power take off
R rectangular
RH right hand
RAVE Rotax adjustable variable exhaust
RER Rotax electronic reverse
RPM revolution per minute
RMS root mean square
RRIM reinforced reaction injection molding
Sp. Gr. specific gravity
ST semi-trapez
TDC top dead center
TRA total range adjustable
U.S. oz ounce (United States)
V volt
Vac volt (alternative current)
VIII MMR2001_073_00_02A.FM
INTRODUCTION

TYPICAL PAGE
Page heading
indicates section
and subsection
detailed.
Subsection title
Subsection 01 (SUSPENSION SC-10 SPORT, TOURING AND MOUNTAIN) beginning of the
subsection.

indicate pertaining
1
models.
Low
temp.
grease
Low
temp. Loctite 7
grease 271
6 2
4 Loctite
11 271
Exploded view
19 6
Low
3
a liquid product
5
to be applied to
8
14
Loctite
a surface.
15 271 In this case
Loctite 271 to
11 screw threads.
SLE
only
11
Bold face number
271
this part.
Long track 17
models only Loctite
271
16 18
20
Loctite
271
Loctite
271 Short track models only
Loctite
for publishing 4 Nm
11
(35 lbfin)
the short track
Document
number for MMR2000_042_00-02A.FM 07-01-1
publishing
process.
must be torqued to Page numbering system:
4 Nm or 35 lbfin. 07: REAR SUSPENSION section
TOURING AND MOUNTAIN subsection
CAUTION: Pay attention to torque 1: First page of this subsection
specifications. Some of these are
A01A2AS
MMR2001_073_00_02A.FM IX
INTRODUCTION
TYPICAL PAGE
Title indicates
Turn puller handle and sliding half at once to extract INSTALLATION main procedure
the bushing.
to BRAKE then look for Brake Disc and Countershaft
529 031 200 Bearing Adjustment.
that particular
All Models
procedure for
A03D1YA
finished, so from
(P/N 413 703 100). 1
TYPICAL caption
view which does
not represent full
detail.
529 031 300
TOP VIEW
A
caption helps you
in understanding
1
529 031 200
A16D0IA
illustration.
TYPICAL TOP VIEW
A. 0 to 1 mm (0 to 3/64 in)
above illustration.
ADJUSTMENT
ASSEMBLY Refer to PULLEY DISTANCE AND ALIGNMENT to adjust
pulley distance. Adjust drive belt height be-
Came Slider Shoe tween pulley halves to obtain specified belt
pulleys adjustment.
MMR2000_042_00-02A.FM 05-03-5

A01A2BS
X MMR2001_073_00_02A.FM
INTRODUCTION
GENERAL INFORMATION As many of the procedures in this manual are in-

The information and component/system descrip- any task, you read and thoroughly understand the
tions contained in this manual are correct at time entire section or subsection in which the proce-
of publication. Bombardier Inc. however, main- dure is contained.
A number of procedures throughout the book re-
any procedure, be sure that you have on hand all
factured.
the tools required, or approved equivalents.
vehicle).
obligation.
USEFUL PUBLICATIONS
PARTS CATALOG 1 2
MODELS P/N
Grand Touring 500/600/GS 700 484 400 163
Formula 500/600/700 484 400 143
MX Z 500/600700 484 400 123
MX Z X 800 484 400 213
Summit 600/700/800 484 400 133

specs. A03A0CA
1997-2001 SPECIFICATION BOOKLET (P/N 484 TYPICAL

300 198). 1. Left
2. Right
ILLUSTRATIONS AND
PROCEDURES SELF-LOCKING FASTENERS
PROCEDURE
Illustrations and photos show the typical construc-
tion of the different assemblies and, in all cases, The following describes the most common appli-
may not reproduce the full detail or exact shape of cation procedures when working with self-locking
the parts shown. However, they represent parts fasteners.
which have the same or a similar function. Use a metal brush or a tap to clean the hole prop-
CAUTION: Most components of those vehicles erly then use a solvent (Methyl-Chloride), let act
are built with parts dimensioned in the metric sys- during 30 minutes and wipe off. The solvent utili-
tem. Most fasteners are metric and must not be zation is to ensure the adhesive works properly.
replaced by customary fasteners or vice-versa.
Mismatched or incorrect fasteners could cause
damage to the vehicle or possible personal injury.
MMR2001_073_00_02A.FM XI
INTRODUCTION
LOCTITE APPLICATION Blind Holes

PROCEDURE
cation procedures when working with Loctite 1
products.
NOTE: Always use proper strength Loctite prod- 2
THREADLOCKER
Uncovered Holes (bolts and nuts)
A00A3MA
1. On threads
1
1. Clean threads (bolt and hole) with solvent.
threads (bolt and nut) and allow to dry for 30
seconds.
A00A3LA
1. Apply here
2. Do not apply
Stud in Blind Holes
1 3
4. Fit bolt in the hole.
2
tightened nut engagement area.
6. Position nut and tighten as required.
A00A3NA
1. On threads
2. On threads and in the hole
3. Onto nut threads
XII MMR2001_073_00_02A.FM
INTRODUCTION
1. Clean threads (stud and hole) with solvent. Adjusting Screw

3. Put several drops of proper strength Loctite 2
threadlocker on female threads and in hole. 1
on stud threads.
5. Install stud.
6. Install cover, etc.
covered threads.
A00A3PA
Preassembled Parts
1. Apply here
2. Plunger

1 locker on screw/body contact surfaces.
NOTE: If it is difficult to readjust, heat screw with

Stripped Threads
2
A00A3OA 5
1. Apply here 1
2. Do not apply 6
8
1. Clean bolts and nuts with solvent.
2
2. Assemble components.
3. Tighten nuts.
4. Apply drops of proper strength Loctite on bolt/nut 3
contact surfaces.
5. Avoid touching metal with tip of flask. 4
A00A3QA 7
NOTE: For preventive maintenance on existing
1. Release agent
equipment, retighten nuts and apply proper strength 2. Stripped threads
Loctite on bolt/nut contact surfaces. 3. Form-A-Thread
4. Tape
5. Cleaned bolt
6. Plate
7. New threads
8. Threadlocker
MMR2001_073_00_02A.FM XIII
INTRODUCTION
Standard Thread Repair 1. Remove old gasket and other contaminants

1. Follow instructions on Loctite FORM-A-THREAD with Loctite Chisel remover (P/N 413 708 500).
81668 package. Use a mechanical mean if necessary.
2. If a plate is used to align bolt: NOTE: Avoid grinding.
a. Apply release agent on mating surfaces. 2. Clean both mating surfaces with solvent.
b. Put waxed paper or similar film on the surfaces. 3. Spray Loctite Primer N on both mating surfaces
and on both sides of gasket. Allow to dry 1 or 2
3. Twist bolt when inserting it to improve thread minutes.
conformation.
4. Apply GASKET ELIMINATOR 515 (P/N 413 702
NOTE: NOT intended for engine stud repairs. 700) on both sides of gasket, using a clean ap-
Repair of Small Holes/Fine Threads plicator.
Option 1: Enlarge damaged hole, then follow 5. Place gasket on mating surfaces and assemble
Standard Thread Repair procedure. immediately.
Option 2: Apply FORM-A-THREAD on the screw NOTE: If the cover is bolted to blind holes (above),
and insert in damaged hole. apply proper strength Loctite in the hole and on
threads. Tighten.
1. Use a stud or thread on desired length. on bolt threads.
2. DO NOT apply release agent on stud. 6. Tighten as usual.
4. Allow to cure for 30 minutes. MOUNTING ON SHAFT
5. Assemble.
Mounting with a Press
GASKET COMPOUND
All Parts
1 2
1 3
A00A3UA
1. Bearing
3. Shaft
A00A3SA 1 3
2. Loctite Primer N (P/N 413 708 100) and Gasket Eliminator 515
3. Loctite Primer N only
XIV MMR2001_073_00_02A.FM
INTRODUCTION
Standard 1. Clean inner housing diameter and outer gasket

1. Clean shaft external part and element internal diameter.
part. 2. Spray housing and gasket with Loctite Primer N
2. Apply a strip of proper strength Loctite on shaft (P/N 293 800 041).
circumference at insert or engagement point. 3. Apply a strip of proper strength Loctite on lead-
NOTE: Retaining compound is always forced out ing edge of outer metallic gasket diameter.
when applied on shaft. NOTE: Any Loctite product can be used here. A
3. DO NOT use anti-seize Loctite or any similar low strength liquid is recommended as normal
product. strength and gap are required.
4. No curing period is required. 4. Install according to standard procedure.
Mounting in Tandem
bore. NOTE: Normally used on worn-out housings to
CASE-IN COMPONENTS compound applied on outer gasket diameter.
Metallic Gaskets
A00A3VA 1
MMR2001_073_00_02A.FM XV
INTRODUCTION

FASTENER SIZE
Lbf•ft
(8.8 GRADE)
Tighten fasteners to torque mentioned in explod-
123 M14 91
ed views and text. When they are not specified
refer to following table. Bold face size (e.g. M4) 124 M14 91
indicates nominal value (mean value). 125 M14 92
126 M14 93
FASTENER SIZE
N•m Lbf•in 127 M14 94
(8.8 GRADE)
128 M14 94
2 M4 18
129 M14 95
3 M4 27
4 M5 35 130 M14 96
8 M6 71 131 M14 97
132 M14 97
9 M6 80
133 M14 98
10 M6 89
11 M6 97 134 M14 99
135 M14 100
12 M6 106
136 M14 100
137 M14 101
FASTENER SIZE
N•m Lbf•ft 138 M14 102
(8.8 GRADE)
21 M8 15 139 M14 103
22 M8 16 140 M14 103
23 M8 17 141 M14 104
24 M8 18 142 M14 105
25 M8 18 143 M14 105
43 M10 32 144 M14 106
44 M10 32 145 M14 107
45 M10 33 146 M14 108
46 M10 34 147 M14 108
47 M10 35 148 M14 109
48 M10 35 149 M14 110
49 M10 36 150 M14 111
50 M10 37
51 M10 38
52 M10 38
53 M10 39
76 M12 56
77 M12 57
78 M12 58
79 M12 58
80 M12 59
81 M12 60
82 M12 60
83 M12 61
84 M12 62
121 M14 89
122 M14 90
XVI MMR2001_073_00_02A.FM
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
Name ______________________________________________________
Address ____________________________________________________

____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
Name ______________________________________________________
Address ____________________________________________________

____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
Name ______________________________________________________
Address ____________________________________________________
✁

AFFIX
PROPER
POSTAGE
After Sales Service
AFFIX
PROPER
POSTAGE
After Sales Service
AFFIX
PROPER
POSTAGE
After Sales Service
SERVICE TOOLS 0
MMR2001_074_01_01A.FM 01-01-1

Tool board
(P/N 529 034 000)
01
A00A3X4
APPLICATION
All models.
01-01-2 MMR2001_074_01_01A.FM

(P/N 529 035 400) (P/N 420 876 357) (P/N 529 018 900)
A00A1D4
APPLICATION
Pusher
A01B584

(P/N 529 035 607) (P/N 420 876 080) A00C3H4
360
33
0
340
20
350 10
10 360 350 3
20
40
30
APPLICATION
0 30 33 40
32 40 0
50
32
0 Rotary valve engines.
50
0
31
60
60
31
0
0
70
30
300
70
80
290
290
80
110 100 90

280
280 270 26
90 100 11
270
(P/N 420 876 612)

260
120
A00C1R4
0
0
250
130
250
12 0
APPLICATION
0
24
14
24
13
0
0
2
30
30
15 2
1
0 22 40
16 0
210
160
200 190 180 17
170 00
0
2 1 0
22
0
0
15
All engines except 247. A00C0F4
180 190 2
APPLICATION
A00B514
(P/N 420 876 607)
Hose pincher (2)
A00C1A4
(P/N 295 000 076)
APPLICATION

A01B2I4
APPLICATION
All vehicles.
MMR2001_074_01_01A.FM 01-01-3

(P/N 420 876 512)
NEW
B) (P/N 529 035 602)
A00B524
A00C374 APPLICATION
A01C5D4
seal on water pump side. APPLICATION
Rotary valve engines, 1991 and
(P/N 861 749 100) 30, 32 and 34 mm carburetor and
Rotary valve shaft seal pusher big end for 38 mm carburetor).
B) VM type carburetor on ZX series.
(P/N 420 877 050)
Piston circlip installer

(P/N 529 035 563) 21 mm
NEW
PA
UD
S
OU HA
V RIR A C
A00C0X4
A01B5F4

(rotary valve) A00B4Y4
(P/N 529 033 100)
793 Engine.
A00B2J4
APPLICATION
A01B5E4
APPLICATION
All models.
01-01-4 MMR2001_074_01_01A.FM

(P/N 529 035 503) (P/N 529 023 400) (P/N 529 034 600)
A01B554
A01B4C4
APPLICATION
APPLICATION
A02B094 All cageless bearing engines.
and/or a DESS.
(P/N 529 035 541)
A) (P/N 529 029 100)
3) Sleeve kit 20 mm
B) (P/N 529 020 800) 9-volt adaptor
(P/N 529 035 542)
(P/N 529 035 675)
NEW
A00C3I4
APPLICATION
A01B5A4
NOTE: 18 mm sleeve kit contains A00B5G4

20 mm sleeve kit contains 1 shoul- APPLICATION
APPLICATION
1) All engines.
2) 277, 443, 503 and 809 engine.
3) 593, 670 and 693 engines.
sleeve kit.
F01B1O4
APPLICATION
All models.
MMR2001_074_01_01A.FM 01-01-5

Homemade adaptor 1-2) Programmer kit
NEW (P/N 529 035 718)
2) Communication cables
7 (P/N 529 001 052)
8 NEW
1
1
4
2 3
5 6
A00B5J4
Required parts:
1) Female housing
(P/N 515 175 245)
2
(P/N 409 015 100) A01B5B5

4) Male housing
(P/N 409 207 000)
(P/N 278 000 631)
6) Male lock
(P/N 409 207 600)
(3-wire connector)
(3-wire connector)
APPLICATION
01-01-6 MMR2001_074_01_01A.FM

puller with screw
2) Screw M8 x 40 (4) (P/N 420 840 681)
(P/N 420 877 635)
3) Screw M8 x 70 (4) (P/N 420 841 201)
1
2,3 2,3
247 engine.
7) Puller ring (P/N 420 977 490)
(P/N 420 977 475 or 420 276 025).
8,9,11 8) Half ring (2) (P/N 420 977 475)

A01B547
9) Half ring (2) (P/N 420 276 025)
All engines.
10) Puller ring (P/N 420 977 494)
11) Half ring (P/N 420 977 479)
MMR2001_074_01_01A.FM 01-01-7

A) (P/N 529 035 561) 18 mm A) (P/N 420 876 090) (P/N 420 276 900)
(62 mm) (MAG)
B) (P/N 529 035 562) 20 mm
B) (P/N 420 876 974)
(69.5 mm)
C) (P/N 420 876 970)
(72 mm)
D) (P/N 420 876 972)
A00C0D4
(76 mm)
A00B4Y4
(67.5 mm) 247 engine.
693. (P/N 420 276 930)
staller (P/N 529 016 900).
B) 593, 670 and 693 engines.
staller (P/N 290 877 016). A00C0Z4
A01B1T4
APPLICATION
A) 377 engine.
(P/N 529 009 100)
D) 582, 583 and 643 engines.
F) 670 engine.

A01B1R4
(P/N 420 876 922)
A00C114
APPLICATION
A01B1V4
APPLICATION
(160 W).
01-01-8 MMR2001_074_01_01A.FM

(5.7 mm) (P/N 529 035 521) (P/N 404 112 000)
(P/N 420 876 822)
A00B4O4
APPLICATION
Mini Z.
A00B2F4
A00C294
Adaptor
(12.7 mm) (TYPICAL)
(P/N 420 876 824)
A00B4P4
APPLICATION A00B4H4
Mini Z.
APPLICATION
(P/N 529 035 520)
A) (P/N 420 876 904)
(on exhaust side)
B) (P/N 420 876 171)
4
(on intake side)

3
A00B4Q4
2
APPLICATION
1
A00B084 Mini Z.
A00B4N4
APPLICATION
APPLICATION
A) 2-cylinder liquid cooled engines.
All models.
MMR2001_074_01_01A.FM 01-01-9

(P/N 414 012 200)
A00C214
APPLICATION
F01B294
All vehicles.
APPLICATION
247 engine.

(P/N 420 876 695)
Dial indicator
(TDC gauge)
(P/N 414 104 700)
A00B4F4
APPLICATION A00B314
All engines.
A00B4E4
APPLICATION
253, 377, 447 and 503 engines.
(P/N 420 277 905)
A) (P/N 420 876 980)
B) (P/N 420 876 490)
A00I094
APPLICATION
360 W magneto
A00C164
A00C0D4
APPLICATION
shaft.
shaft.
01-01-10 MMR2001_074_01_01A.FM

(P/N 529 014 500) (P/N 529 024 900) (P/N 420 877 650)
A00C3V4
APPLICATION
454, 494, 599, 670, 699, 779 and
F01B1G4 A05C0M4
809 engines.
277 engine. Exhaust spring installer/remover
All engines.
(P/N 529 035 559)

(P/N 420 277 875) (magneto side seal)
(P/N 420 876 516)
A00C3S4
APPLICATION
A00C0V4 All models except CK3 series.
277 engine. spring installer/remover (P/N 529
028 100).
PTO seal pusher

A00C3T4 Rotary valve seal and
APPLICATION
(P/N 420 876 605)
779 engine.
Insertion jig
A00C0V4
(magneto seal)
277 engine. A00C0Y4
APPLICATION
and older.
A00C3U4
APPLICATION
454, 494, 599, 670, 699 and 809
engines.
MMR2001_074_01_01A.FM 01-01-11

(P/N 420 876 510)
A00C374
APPLICATION
12 mm I.D.

(P/N 420 876 610)
A00C0F4
APPLICATION
shaft.
Large hose pincher

(P/N 529 032 500)
(TYPICAL)
F01B234
APPLICATION
All vehicles.
01-01-12 MMR2001_074_01_01A.FM

(P/N 529 017 200) (P/N 529 005 500) (P/N 529 002 100)
(standard threads)
A00C084
APPLICATION
Square shaft, standard (SAE) threads.
A16B014
A00A1A4
Drive pulley puller
(P/N 860 414 200)
All non-RER models. All vehicles equipped with a TRA (square shaft metric)
drive pulley.
Consists of:
Clutch holder 529 003 000 529 002 800
Tool kit
(P/N 529 006 400)
(P/N 529 025 400)
NEW
A01B154
A00C095
APPLICATION
APPLICATION
All TRA drive pulleys.
pulley.
(P/N 529 022 400)
A00B5N4
APPLICATION
APPLICATION
599, 670, 699, 779 and 809 engines. (P/N 529 025 000)
NEW

(P/N 529 007 900) (25 mm)
A00B5M4
A18B044
APPLICATION
MMR2001_074_01_01A.FM 01-01-13

A) (P/N 529 026 900) (P/N 529 008 700) (P/N 529 035 300)
B) (P/N 529 030 000)
2
C) (P/N 529 035 586)
D) (P/N 529 026 700)
1
E) (P/N 529 035 530)
F) (P/N 529 031 000)
G) (P/N 529 035 527) A15B044
H) (P/N 529 035 572)

1) Hexagonal wrench
(P/N 420 876 730).
A01B4D4
APPLICATION
Tundra R.
(P/N 414 348 200)
with TRA. (P/N 529 035 524)
APPLICATION
All models.
series.
(P/N 529 030 200)

A) (P/N 529 006 500)
B) (P/N 529 030 900)
C) (P/N 529 035 557)
A02D1P4
(TYPICAL)
APPLICATION
All models.

(P/N 529 018 600).
A00B4A4
APPLICATION
A) Tundra II LT.
(1995 and newer).
C) CK3 without RER.
01-01-14 MMR2001_074_01_01A.FM

(P/N 529 035 699)
NEW
A00A274
APPLICATION
A00B5K4
installer (P/N 529 035 554).
Spring cover tool

(P/N 529 027 300)
A01B5C4 A01B4M4
CK3 series. Bombardier Lite drive pulley.
MMR2001_074_01_01A.FM 01-01-15

Clutch holder Alignment tool Countershaft bearing remover
(P/N 529 027 600) (P/N 420 476 010) (P/N 529 018 700)
A02B034
APPLICATION
APPLICATION
(P/N 529 031 400)
(P/N 529 018 800)
A18B044
A00A164
APPLICATION
APPLICATION
cept Élan. PRS chassis.
Driven pulley opening tool Drive pulley puller

(P/N 529 035 501) (P/N 529 023 100)
A00A194
APPLICATION
PRS chassis.
Cam pusher
A03D2P4 (P/N 529 012 900)
A00C3J4
S and CK3 series with RER. Élan.
500). Transmission ball mounting pin
(P/N 420 476 020)
A18B064

APPLICATION
(P/N 529 034 200)
Tundra II LT.
A00C1C4
APPLICATION
A05B044
APPLICATION
Tundra R.
01-01-16 MMR2001_074_01_01A.FM

Transmission adjuster Burnishing bar Large bushing extractor
(P/N 529 028 500) (P/N 529 026 402) (P/N 529 035 576)
A00D0X4
APPLICATION A00B464
A02D1Q4
F-Series equipped with “twist shifter” APPLICATION

reverse transmission. APPLICATION
Tundra II LT, Safari L and Skandic. Formula type driven pulley.
NOTE: Use this tool only with
Large bushing extractor new puller (P/N 529 035 524) that
(P/N 529 015 200) (P/N 529 031 100) has Acme threads and support
529 031 100).
Large bushing extractor

(P/N 529 035 575)
A01B514
APPLICATION
A00B4I4
pine II. APPLICATION
Formula type driven pulley.
Alignment bar NOTE: Use this tool only with
former puller (P/N 529 018 600)
A) (P/N 529 025 600) that has regular threads.
A02D1Q4
B) (P/N 529 028 200) APPLICATION

C) (P/N 529 028 300) LPV 27 driven pulley.
D) (P/N 529 026 800) NOTE: Use this tool only with
new puller (P/N 529 035 524) that
E) (P/N 529 031 000)
has Acme threads and support
529 031 100).
A01B4D4
APPLICATION
A) PRS chassis.
B) Alpine II.
C) Élan.
D) Safari L.
E) Skandic WT 1996.
MMR2001_074_01_01A.FM 01-01-17

Large bushing installer and small 3-speed transmission bearing Drive axle sprocket adjuster
bushing extractor extractor (P/N 861 725 700)
(P/N 529 031 200) 1) Screw M8 x 25 (2)
5
(P/N 207 182 544) 2
2) Plate 3
1
3) Half ring (2)
(P/N 420 876 330) 4
4) Ring
(P/N 420 977 480)
1 6
A00B4J4 A01B2O4
APPLICATION 2
All models except Tundra/R, Skandic
WT/SWT/WT LC and S-Series with 1) Block with threads
RER. (P/N 529 010 700)
3
(P/N 529 010 800)
Chaincase seal pusher
3) Plate
(P/N 529 035 584) (P/N 529 010 600)
4
4) Bolt M10 (2)
A00C1B4 (P/N 222 007 565)
APPLICATION 5) Allen screw M8 (2)
(P/N 222 983 065)
6) Screw M8 (2)
(P/N 222 082 565)
TRA drive pulley puller (27 mm) NOTE: When the tool is to be used
(P/N 529 010 100) between tunnel and sprocket use
A00B504
screws M8.
A18B044
S, F, CK3 and ZX series. All vehicles except Élan.

APPLICATION
NOTE: This tool replaces chain-
case upper seal pusher (P/N 529 TRA drive pulley (27 mm) shaft ex-
cept 454, 670 and 779 engines. Transmission adjuster
032 300).
(P/N 529 030 300)
A03D1T4
APPLICATION
Vehicles equipped with “push-pull
01-01-18 MMR2001_074_01_01A.FM

(P/N 529 035 504)
(P/N 414 528 400)
A01B4O4
APPLICATION
035 551).
MMR2001_074_01_01A.FM 01-01-19

(P/N 529 008 200) (P/N 529 021 600) A) (P/N 529 008 500)
Pins NOTE: Angle finder with a magnetic Narrow
(P/N 529 008 204) base must be used. B) (P/N 529 028 800)
A06B024
A01B1J4
APPLICATION
(P/N 529 028 700) A01B1M4

(P/N 529 021 500) A) 1993 and older.
B) 1994 and newer.
opening.
Dome guide
A01F224
A) (P/N 529 026 500)
APPLICATION
NEW
A) 1993 and older.
B) 1994 and newer except Élan and B) (P/N 529 035 728)
A00B3X4
Tundra II.
APPLICATION
All models except Élan.
A06F1B4
APPLICATION
A) C-36 T/A shocks.
B) C-46 T/A shocks.
01-01-20 MMR2001_074_01_01A.FM

Shock wrench Tool for shock (needle type) Drive axle holder
(P/N 529 035 727) (P/N 529 035 614) (P/N 529 007 200)
NEW
A00B5I4
APPLICATION A01B1E4
A00F224
Most 2000 and up T/A shocks.
APPLICATION
All T/A shocks All models.
Drill bit
(P/N 529 031 800)
Piston guide Kayaba shock adjustment tool
A) (P/N 529 026 600) (P/N 529 035 582)
B) (P/N 529 035 608)
A01B564
APPLICATION
All 3/16 inch rivets.
A06F1C4
A00A1K4
Spring installer (bar)
(P/N 529 005 000)
A) C-36 T/A shocks. C-7 suspension.
B) C-46 T/A shocks.
Hexagonal wrench
(tire valve type)
(P/N 529 035 570)
A00C1I4 A19B024
Tundra II LT, Scout and all SC-10 All SC-10 suspensions, Safari and
suspensions. Skandic prior to 1995.

A02F134
(P/N 529 017 100)
APPLICATION
1999 and older T/A shocks and
some 2000 and up T/A shocks.
A15B094
APPLICATION
1992 and old Formula C-7.
MMR2001_074_01_01A.FM 01-01-21

Suspension adjustment wrench Adjustment wrench
(P/N 529 032 900) (P/N 861 743 900)
Consists of:
529 024 000

A02F114
APPLICATION
529 025 500

(P/N 529 034 100) A00B4B4
APPLICATION
shock.
A02F124
Adjustment wrench
CK3 series.
A00B5H4
APPLICATION
SC-10 II (coupling blocks).
01-01-22 MMR2001_074_01_01A.FM

Protective mat
(P/N 529 030 600)
A01B45W
APPLICATION
All vehicles.

(P/N 529 029 900) (P/N 529 020 000)
A00B4CJ A01A1JJ
MMR2001_074_01_01A.FM 01-01-23

Snap-on NEW
TT 600-4
NEW
A02H154
F01B1J4
APPLICATION
Crimping tool
(P/N 414 837 300) NEW
F04B044
APPLICATION
All models.

A32B044
APPLICATION
on ZX series.
01-01-24 MMR2001_074_01_01A.FM
SERVICE PRODUCTS 0
(P/N 413 703 100) (P/N 413 702 700) (P/N 293 800 060)
NEW
A00B2T4
APPLICATION
ing surfaces.
A00B2S4
Paste gasket
(P/N 293 800 038)
APPLICATION F00A0O4
Loctite® 518:
tite 242 (P/N 293 800 015).
Sealing compound
(P/N 420 297 906) F01B124
(30 mL) High strength threadlocker

Crankcase halves and gearbox Loctite® 271:
mating surfaces.
A00B2U4
A00B564
APPLICATION
APPLICATION Fasteners and studs up to 25 mm
To seal crankcase on all ZX series (1 in) diameter.
engines.
MMR2001_074_01_02A.FM 01-02-1

Gasket/paint remover Molykote PG 54 Grease Isoflex
(P/N 413 708 500) (P/N 420 899 763) (P/N 293 550 021)
Loctite® Chisel (10 g) (50 g)
510 g (18 oz) NEW
A00B5F4
APPLICATION
To lubricate pawl and pawl lock of
rewind starter.
Molykote G-n paste

(P/N 711 297 433) A00B554
(50 g)
APPLICATION
A00B574 NEW
To lubricate some crankshaft bear-
APPLICATION ings on some engines.
and crankcase. Remove carbon in Petamo grease
(P/N 420 899 271)
Loctite® primer A00B5P4
(P/N 293 800 041)

APPLICATION
Primer N
128 g (5 oz) To lubricate RAVE valve stem on
engine with oil seal in RAVE hous-
ing.
A00B3N4
A00B584
APPLICATION
To prepare mating surfaces before APPLICATION
applying paste gasket, retaining To lubricate lip of all ZX series en-
compound or threadlockers. gine crankshaft seals.
to the P/N 413 708 100.
01-02-2 MMR2001_074_01_02A.FM

Premix oil BOMBARDIER Formula XP-S Storage oil
(P/N 413 803 100) synthetic injection oil (P/N 413 711 600)
(12 x 1 liter)
(P/N 413 711 000)
(3 x 4 liter)
(P/N 413 710 700)
(205 liter)
A00B5L4
APPLICATION
All pre-mix models.
A02B054
APPLICATION
BOMBARDIER injection oil
All models.
(P/N 413 802 900) A02F144

(P/N 413 803 000) All engines. the P/N 496 014 100.
(3 x 4 liter)
(P/N 413 803 200)
(205 liter) Premixed coolant - 52°C (- 62°F) Fuel stabilizer
(P/N 413 711 802) (P/N 413 408 600)
(16 x 1 L) (12 x 8 oz)
® ®
F01B2H4
APPLICATION
All engines.
A00B3V4
APPLICATION
A00B5E4
All models.
APPLICATION
All liquid cooled models.
MMR2001_074_01_02A.FM 01-02-3

(P/N 413 801 900) (P/N 413 707 500) (P/N 293 600 016)
(16 x 250 mL) (400 g) (12 x 14 oz)
A00B1Y4
APPLICATION
good ground.
A00B2R4
Synthetic grease
Chaincase lubricant on all fan- (400 g)
A00B4W4
series.
APPLICATION
(P/N 413 803 300)
A01B574
Super Lube (grease)

(P/N 293 550 014)
A02F154
APPLICATION
A01B4Q4
T/A shocks.
APPLICATION
series.
APPLICATION
01-02-4 MMR2001_074_01_02A.FM

(P/N 293 800 070) (P/N 293 550 004) (P/N 293 110 001)
(4 L)
A00B1X4
APPLICATION
the P/N 413 701 700.
F01B2J4
Parts cleaner
APPLICATION
(P/N 413 711 809)
All models.
A00B594 (320 g)
APPLICATION
Mounting surfaces of driven pulley Plastic & vinyl cleaner
(6 x 1 L)
Molykote 111
(P/N 413 707 000)
111
A00B3W4
APPLICATION
A00B4X4
APPLICATION
APPLICATION
MMR2001_074_01_02A.FM 01-02-5

High temperature threadlocker High temperature RTV sealant Gel instant adhesive
(P/N 413 711 400) (P/N 413 710 300) (P/N 413 708 300)
Loctite 648 (5 mL) Ultra Copper Loctite 454-40
(green) (80 mL) 20 g (.70 oz)
A00B3O4
APPLICATION
Tough adhesive
A00B3D4
(P/N 413 408 300)
Loctite Black Max
APPLICATION
3 mL (.10 oz)
crankcase.
NOTE: Only the P/N has been A00B5A4
the P/N 420 899 788. APPLICATION
All models.
Pipe sealant
(P/N 293 800 018) General purpose instant adhesive
Loctite 592 (50 mL) (P/N 293 800 021)
Loctite 495 (3 g)
A00B3P4
APPLICATION
A00B2W4
Shifter boot or grip.
APPLICATION
Engine plugs and senders. Paint for frame touch-up
NOTE: Only the P/N has been (P/N 413 401 000)
Black semi-gloss
the P/N 413 702 300.
(spray can)
Clear silicone
A00B2V4
(P/N 293 800 033)
APPLICATION
hard plastic.
F01B1S4 NOTE: Only the P/N has been
APPLICATION the P/N 413 703 200.
A00B3H4
APPLICATION
01-02-6 MMR2001_074_01_02A.FM
10-HOUR OR 500 km (300 mi)

EVERY 3200 km (2000 mi)
ONCE A YEAR OR
MONTHLY OR
INSPECTION
WEEKLY OR
STORAGE
Rewind Starter Lubrication and
Rope Condition
Engine Head Screws ✔ ✔ ✔
See TOP END
Engine Mount Nuts ✔ ✔ ✔
See ENGINE REMOVAL
Exhaust System ✔ ✔ ✔
See ENGINE REMOVAL
Cooling System Condition ✔ ✔ ✔ Subsection 04-06
Coolant Replacement ✔ Subsection 04-06
Condition of Seals ✔ ✔ Subsection 04-02
Drive Belt Condition ✔ ✔ ✔ This section no. 5
Condition of Drive and Driven
Pulleys
Drive Chain Tension ✔ ✔ ✔ Subsection 05-07
Countershaft Lubrication** ✔ ✔ ✔ Subsection 05-06
Chaincase or Gearbox Oil Level ✔ ✔ ✔ Subsections 05-07 and 05-08
Chaincase or Gearbox Oil Change ✔ ✔ Subsections 05-07 and 05-08
Lubrication of Drive Axle Bearing** ✔ ✔ ✔ Subsection 07-03
MMR2001_075_02_01A.FM 02-01-1
10-HOUR OR 500 km (300 mi)

EVERY 3200 km (2000 mi)
ONCE A YEAR OR
MONTHLY OR
INSPECTION
WEEKLY OR
STORAGE
Handlebar Bolts. Retorque to
26 N•m (19 Ibf•ft)
Mechanism Condition
Wear and Condition of Skis and
Runners
Adjustment
Subsection 07-02
Suspension Adjustments AS REQUIRED
Suspension Lubrication** ✔ ✔ Subsection 07-02
Suspension Condition ✔ ✔ ✔ Subsection 07-02
Suspension Stopper Strap Condition ✔ ✔ Subsection 07-02
Test Operation of Emergency ✔ ✔ ✔ Operator’s Guide
Cut-Out Switch and Tether Cut-Out
Switch
Rags in Air Intake and Exhaust
✔ ✔ This section no. 5
System
02-01-2 MMR2001_075_02_01A.FM
NO. 1 ENGINE LUBRICATION Pour fuel stabilizer in fuel tank prior to starting en-
gine for internal parts lubrication so that stabilizer
At Storage flows everywhere in fuel system.
Engine internal parts must be lubricated to protect After engine starting, use primer several times so
them from possible rust formation during the stor- that stabilizer flows inside it.
age period. Do not drain fuel system.
Proceed as follows: CAUTION: Fuel stabilizer should be added prior
Start the engine and allow it to run at idle speed engine lubrication to ensure carburetor(s) pro-
until the engine reaches its operating tempera- tection against varnish deposit.
ture.
NO. 3 FUEL FILTER
 WARNING REPLACEMENT
Ensure the track is free of all particles which Drain fuel tank.
could be thrown out while it is rotating. Keep
hands, tools, feet and clothing clear of track. Remove fuel line grommet from fuel tank and pull
Ensure no one is standing in close proximity to out inlet fuel line from tank.
the vehicle.
Stop the engine.

Remove air silencer to spray storage oil (P/N 496
014 100) into each carburetor bore.
Inject storage oil until the engine stalls or until a
sufficient quantity of oil has entered the engine
(approximately half a can).
With the engine stopped, remove the spark plug
and spray storage oil (P/N 496 014 100) into each
cylinder.
Crank slowly 2 or 3 revolutions to lubricate cylinders. A03I0GA 3 1 2
Reinstall the spark plugs and air silencer.
TYPICAL
 WARNING 1. Inlet fuel line

3. Fuel filter
well-ventilated area. Do not run engine dur- Replace fuel filter. To facilitate the fuel line instal-
ing storage period. lation, slide grommet on fuel line about 50 mm
(2 in) away from elbow then install grommet on
fuel tank and push elbow through grommet.
Add 500 mL (17 U.S. oz) of recommended injec- NO. 4 AIR FILTER CLEANING
tion oil to the first full filled fuel tank.
CAUTION: These snowmobiles have been cali-
NO. 2 FUEL STABILIZER brated with the filters installed. Operating the
snowmobile without them may cause engine
With the new fuel additives, it is critical to use the damage.
fuel stabilizer (P/N 413 408 600) (250 mL) to pre- Remove primary air filters.
system components corrosion. Follow manufac-
MMR2001_075_02_01A.FM 02-01-3
Lift hood and remove primary filter from air duct.

Remove secondary filter from air intake silencer.
To clean the filters, shake the snow out of them
then, dry it out.
Check that the air box is clean and dry then prop-
erly reinstall the filter.
A32H0LA
PRIMARY FILTER LOCATION
A32H0OA
SECONDARY FILTER INSTALLED ON AIR SILENCER
NO. 5 RAGS IN AIR INTAKE AND

EXHAUST SYSTEM
At storage preparation, block air intake hole and
A32H0RA Remove those rags at pre-season preparation.
REMOVAL OF RIGHT SIDE PRIMARY FILTER GRILL
NO. 6 ENGINE COMPARTMENT
Keep clean of grass, twigs, cloth, etc. These are
combustible under certain conditions.
NO. 7 VEHICLE CLEANING AND

PROTECTION
Remove any dirt or rust.
To clean the entire vehicle, use only flannel clothes
or Kimtowels® wipers no. 58-380 from Kimberly-
Clark.
CAUTION: It is necessary to use flannel cloths
or Kimtowels wipers on windshield and hood
to avoid damaging further surfaces to clean.
A32H0SA
REMOVAL OF FILTER FROM ITS GRILL
02-01-4 MMR2001_075_02_01A.FM

supermarkets.
(P/N 293 110 001 (spray can 400 g) and P/N 293
110 002 (4 L)). Then, finish with Vinyl & Plastic
Cleaner (P/N 413 711 200 (6 x 1L)).
decals or vinyl.
For vinyl and plastic parts, use Vinyl & Plastic Clean-
er (P/N 413 711 200 (6 x 1 L)).
CAUTION: Never clean plastic parts or hood with
strong detergent, degreasing agent, paint thin-
ner, acetone, products containing chlorine, etc.
Inspect the hood and repair any damage.
scratched off. Spray all metal parts including shock
600 016).
Remove drive belt and spray BOMBARDIER
LUBE (P/N 293 600 016) on drive and driven pulley
sheaves.
for better protection.
NOTE: Apply wax on glossy finish only. Protect
lation during storage.
CAUTION: The snowmobile has to be stored in
a cool and dry place and covered with an opaque
tarpaulin. This will prevent sun rays and grime
from affecting plastic components and vehicle
finish.
Lift rear of vehicle until track is clear of the ground.
Install on a snowmobile mechanical stand.
MMR2001_075_02_01A.FM 02-01-5
TABLE OF CONTENTS 0
ENGINE .................................................................................................................................. 03-02-1
FUEL AND OIL SYSTEMS..................................................................................................... 03-03-1

TRANSMISSION ................................................................................................................ 03-04-1
BRAKE SYSTEM ................................................................................................................ 03-04-7
HYDRAULIC BRAKE .......................................................................................................... 03-04-7
MMR2001_108_03_01ATOC.FM 03-01-1
ENGINE 0
a. Fuel passages obstructed.
a. Low antifreeze level.
b. Defective tank cap.
Replace cap.
c. Air in system.
Bleed system.
Test/Inspection 1. Check that all ground wires are well connected.
MMR2001_076_03_02A.FM 03-02-1

Replace.
i. Improper reed valve adjustment or damage.
Adjust according to specifications (refer to 493, 593, 693 AND 793 ENGINES
TYPES) and/or install Bombardier’s recommended reed valve.
Use BOMBARDIER oil.
Clean residue accumulation in combustion chamber and replace piston(s). Use
BOMBARDIER injection oil.
03-02-2 MMR2001_076_03_02A.FM

a. Cooling system leaks and lowers coolant level.
b. Accumulation of foreign particles in needle and/or main jet area.
overreving.

MMR2001_076_03_02A.FM 03-02-3
Test/Inspection 1. Check spark plug condition and gap.
a. Fouled spark plugs or wrong spark plug gap.
Replace or readjust gap.
3. Check items listed in ENGINE RUNS OUT OF FUEL
(refer to Fuel and Oil System subsection).
a. Worn belt.
Adjust according to specifications (refer to TECHNICAL DATA) and/or replace
bushing(s).
a. Restriction or exhaust system leaks.
Replace or reseal with Ultra Copper.
a. Antifreeze level is low, cap fails to pressurize system or air circulates through lines.
03-02-4 MMR2001_076_03_02A.FM

Replace.
MMR2001_076_03_02A.FM 03-02-5

a. Defective spark plug (no spark) or wrong spark plug gap.
Replace spark plugs or readjust gap.
clogged; check condition of fuel and impulse lines and their connections.
03-02-6 MMR2001_076_03_02A.FM

Readjust.
Replace.
MMR2001_076_03_02A.FM 03-02-7

a. False reading.
clamps at fitting.
5. Check thermostat.
a. Thermostat reacts slowly or not at all.
Replace.
6. Check tank cap.
Replace.
a. Worn gaskets.
Replace.
a. Leak(s).
Repair or replace.
Replace.
03-02-8 MMR2001_076_03_02A.FM
Replace.
a. Jammed valve(s).
Clean.
Replace.
a. Clogged holes.
Clean.
Replace.

Replace.
Adjust according to ASSEMBLY procedure in appropriate ENGINE subsections.
Clean.

a. Broken spring.
Replace spring.
MMR2001_076_03_02A.FM 03-02-9

Replace.
Replace.
Replace.

Clean.

2. Check drive pulley (refer to: VIBRATIONS COMING FROM DRIVE PULLEY).
unsynchronized.
03-02-10 MMR2001_076_03_02A.FM

FLOW CHART
PRESSURIZE ENGINE
NO
IS ENGINE LEAKING?
YES

FLANGES ETC.

NO

INJECTION PUMP

TOWARD PUMP?
NO

NO
GEAR
LUBRICATION SYSTEM
NO
YES

SEAL OF PTO AND
MAG SIDES
YES
NO


NO
CYLINDER SEPARATELY

NO


NO ANY LEAK FOUND? SHAFT CERAMIC, BESIDE
COOLANT SEAL
NO
CHECK OIL PUMP

YES
NO

YES
NO

INTERNALLY
A32C1KS
MMR2001_076_03_02A.FM 03-02-11

Replace fuel tank.
2. Check fuel pump reservoir and carburetor fittings.
Readjust choke.

Replace.
MMR2001_076_03_03A.FM 03-03-1

a. Clogged filter.
Replace.
a. Dried diaphragm.
Replace.
a. Varnish.
Clean.

Adjust.
a. Worn gasket.
Replace.
5. Pressurize pump shaft gear reservoir.
a. Leaking seal(s).
Replace seal(s).
03-03-2 MMR2001_076_03_03A.FM

Clean.
5. Check main jet.
Clean.
MMR2001_076_03_03A.FM 03-03-3

TRANSMISSION
Adjust distance between pulleys and/or drive belt deflection according to
specifications (refer to TECHNICAL DATA).
Replace.
listed.
Replace.
listed.
MMR2001_076_03_04A.FM 03-04-1

Adjust.
2. Check play of driven pulley splines.
a. Worn splines.
Replace.

Replace.
Retighten screw.
Retighten screws.
4. Check spring cover (TRA type) and/or outer half bushings.
movements.
Replace bushing(s).
Replace.

Replace.
Replace.
03-04-2 MMR2001_076_03_04A.FM

Clean or replace.
Replace.
IN REVERSE ENGINE BOGS AND DRIVEN PULLEY OPENS TOO FAST

SYMPTOM
(DRIVE BELT IS LOW IN DRIVEN PULLEY).
Test/Inspection 1. Check pulley distance and alignment.
a. Improper adjustment.
Adjust according to specifications (refer to PULLEY DISTANCE AND ALIGNMENT)
and make sure that engine stopper is resting against engine.

Tighten engine mount nuts/bolts equally.
Align pulleys.
A00D09Y
Replace bushing.
MMR2001_076_03_04A.FM 03-04-3

Replace bushing.


a. Improper belt angle (wrong type of belt).

New belt a. Considerable use.
A00D0BY Replace belt if less than specified in DRIVE BELT.
03-04-4 MMR2001_076_03_04A.FM


Repair or replace.
A00D0DY Replace belt with an appropriate drive belt (refer to TECHNICAL DATA).
MMR2001_076_03_04A.FM 03-04-5

Clean pulley surfaces with fine emery cloth and wipe clean using Parts Cleaner
A00DOEY (P/N 413 711 809) and a cloth.

A00DOFY

Replace.
A00D0GY

Replace.
A00D0HY Check drive pulley engagement speed, drive pulley bushings and components.
03-04-6 MMR2001_076_03_04A.FM


A00D0IY
BRAKE SYSTEM
HYDRAULIC BRAKE
Test/Inspection Replace brake fluid and bleed system. If problem still occurs, replace master cylinder.

Test/Inspection 1. Check for loosened hose connectors.

Replace.
MMR2001_076_03_04A.FM 03-04-7
ELECTRICAL SYSTEM 0
Test/Inspection 1. Check fuse.
a. Burnt fuse.
Check wiring condition and replace fuse.
Repair.

Test/Inspection 1. Check battery capacity.
Replace.
a. Weak battery.
6. Check brushes.
a. Poor contact of brushes.
Replace brushes.
MMR2001_076_03_05A.FM 03-05-1

Undercut mica.
Replace springs.
a. Weak magnets.
a. Worn bushings.
Replace bushings.
RING GEAR.
Replace clutch.
2. Check clutch.
Replace clutch.
Clean and correct.
Replace clutch.
Replace bushing(s).
6. Check ring gear.
a. Worn ring gear.
Replace ring gear.
03-05-2 MMR2001_076_03_05A.FM

Replace or clean.
Clean.
Replace bracket(s).
Adjust switch position. Face nut is too far in.
a. Shorted starter relay winding(s).
6. Check starter relay contacts.
a. Melted starter relay contacts.
a. Starter relay returns poorly.

SYMPTOM 20 A FUSE LOCATED IN LEFT FRONT CORNER OF ENGINE COMPARTMENT IS

BURNT.
Test/Inspection 1. 20 A fuse burns when electric starter is activated with a faulty starter ground.
Check that ground cable between chassis and starter bracket is well connected.
a. Broken, corroded and/or loose connection(s).
Replace, clean and/or retighten. Replace 20 A fuse.
MMR2001_076_03_05A.FM 03-05-3
SWITCH.
2. Check fuse.
Clean or replace.
Replace.
Replace.
03-05-4 MMR2001_076_03_05A.FM

2. Verify spark plug wire and cap resistance with an ohmmeter.
a. Defective part.
Replace.
7. Verify MPEM.
Check that MPEM is properly mounted and secured. Replace MPEM, retest and
verify ignition timing.
SYMPTOM MPEM DOES NOT WORK.

a. Short circuit.

MMR2001_076_03_05A.FM 03-05-5

Readjust air gap.

Clean terminals and apply silicone dielectric grease as specified
(refer to CDI MAGNETO). Replace defective parts.
terminals.
switch(es). Clean terminals and apply silicone dielectric grease as specified
(refer to CDI MAGNETO).
Test/Inspection 1. Perform all verifications outlined under ENGINE DOES NOT START — NO
SPARK AT SPARK PLUG.
of problem.
03-05-6 MMR2001_076_03_05A.FM

Replace.

Test/Inspection 1. Refer to IRREGULAR ENGINE SPEED AT HIGH SPEED and check items
listed.
Replace by Bombardier’s recommended spark plug (refer to TECHNICAL DATA).
Seal.
a. Loose collar(s).
Tighten.
Replace.
MMR2001_076_03_05A.FM 03-05-7

a. Gas leak.
Replace bulb.
installed.
03-05-8 MMR2001_076_03_05A.FM

3. On manual start models: Verify regulator ground.
a. Rusted contact surfaces or loose retaining screws.
Clean, apply lithium grease (LMZ1) and firmly tighten screws.
8. Verify if heating grips installation overloads the magneto/generator capacity.

Test/Inspection 1. Verify sender unit for free movement and/or correct arm position.
MMR2001_076_03_05A.FM 03-05-9

Replace.

Replace brake switch.

03-05-10 MMR2001_076_03_05A.FM

a. Other wire connected to pilot lamp. Mixed-up connections.
Reconnect YELLOW/BLACK and GRAY wires to pilot lamp. YELLOW wires are
connected to heating element pilot lamps.
MMR2001_076_03_05A.FM 03-05-11

a. Spring is weakened or broken.
Replace spring.



MMR2001_076_03_06A.FM 03-06-1

Replace.
Replace.
4. Check sprockets.
Replace track.

Adjust.
Adjust.
3. Check for proper suspension fastening.
a. Loose or lost retaining screws.
Install new screws and tighten to recommended torque.
03-06-2 MMR2001_076_03_06A.FM

Adjust.

Replace.
MMR2001_076_03_06A.FM 03-06-3


Replace.
a. NOTE: If all parts are in good condition and the customer still complains about an
unstable snowmobile, consider the installation of optional Proactive Control Sys-
tem.
03-06-4 MMR2001_076_03_06A.FM
Section 04 ENGINE
TABLE OF CONTENTS 0
493, 593, 693 AND 793 ENGINE TYPES............................................................................... 04-02-1
MAINTENANCE ................................................................................................................. 04-02-2
INSTALLATION ON VEHICLE............................................................................................ 04-02-2
TOP END ............................................................................................................................ 04-02-3
CLEANING ......................................................................................................................... 04-02-4
DISASSEMBLY................................................................................................................... 04-02-4
INSPECTION ...................................................................................................................... 04-02-6
ASSEMBLY......................................................................................................................... 04-02-7
BOTTOM END.................................................................................................................... 04-02-11
CLEANING ......................................................................................................................... 04-02-12
DISASSEMBLY................................................................................................................... 04-02-12
INSPECTION ...................................................................................................................... 04-02-12
ASSEMBLY......................................................................................................................... 04-02-12

LEAK TEST ......................................................................................................................... 04-03-1
PREPARATION ................................................................................................................... 04-03-1
PROCEDURE ...................................................................................................................... 04-03-2
CYLINDER TAPER .............................................................................................................. 04-03-5
RING END GAP .................................................................................................................. 04-03-9
CRANKSHAFT DEFLECTION............................................................................................. 04-03-9
CONNECTING ROD BIG END AXIAL PLAY ..................................................................... 04-03-10
CRANKSHAFT END-PLAY ................................................................................................. 04-03-10
CHECKING SURFACE FLATNESS..................................................................................... 04-03-10
RECTIFYING SURFACES ................................................................................................... 04-03-11
CHECKING CRANKSHAFT ALIGNMENT.......................................................................... 04-03-11
MMR2001_108_04_01ATOC.FM 04-01-1
Section 04 ENGINE
CDI SYSTEM........................................................................................................................... 04-04-1

NIPPONDENSO TRIGGER COIL IGNITION SYSTEM....................................................... 04-04-1
CLEANING .......................................................................................................................... 04-04-2
DISASSEMBLY ................................................................................................................... 04-04-2
ASSEMBLY ......................................................................................................................... 04-04-3

CLEANING .......................................................................................................................... 04-05-2
DISASSEMBLY ................................................................................................................... 04-05-2
ASSEMBLY ......................................................................................................................... 04-05-2
ADJUSTMENT.................................................................................................................... 04-05-2

COOLING SYSTEM LEAK TEST ........................................................................................ 04-06-2
INSPECTION ....................................................................................................................... 04-06-2
REWIND STARTER................................................................................................................. 04-07-1

INSPECTION ....................................................................................................................... 04-07-2
REMOVAL ........................................................................................................................... 04-07-2
ROPE REPLACEMENT........................................................................................................ 04-07-2
DISASSEMBLY ................................................................................................................... 04-07-2
ASSEMBLY ......................................................................................................................... 04-07-3
INSTALLATION ................................................................................................................... 04-07-5
04-01-2 MMR2001_108_04_01ATOC.FM
Section 04 ENGINE
CARBURETOR AND FUEL PUMP......................................................................................... 04-08-1

CARBURETOR ................................................................................................................... 04-08-1
IDENTIFICATION ............................................................................................................... 04-08-2
REMOVAL........................................................................................................................... 04-08-2
CARBURETOR FLOAT LEVEL ADJUSTMENT ................................................................. 04-08-3
INSTALLATION .................................................................................................................. 04-08-5
IDENTIFICATION ............................................................................................................... 04-08-9
REMOVAL........................................................................................................................... 04-08-9
INSTALLATION .................................................................................................................. 04-08-14
DPM .................................................................................................................................... 04-08-16
TESTING ............................................................................................................................ 04-08-16
PARTS REMOVAL AND INSTALLATION ......................................................................... 04-08-17
DPM MANIFOLD LEAK TESTING ..................................................................................... 04-08-17
FUEL PUMP ....................................................................................................................... 04-08-18
REMOVAL........................................................................................................................... 04-08-19
PUMP VERIFICATION ........................................................................................................ 04-08-19
INSTALLATION .................................................................................................................. 04-08-19
FUEL TANK AND THROTTLE CABLE ................................................................................... 04-09-1
MMR2001_108_04_01ATOC.FM 04-01-3
Section 04 ENGINE
Subsection 02 (493, 593, 693 AND 793 ENGINE TYPES)
493, 593, 693 AND 793 ENGINE TYPES0

ZX Series
9 Nm
(80 lbfin)
Ultra
Copper
M6: 10 Nm (89 lbfin)

M8: 23 Nm (17 lbfft)
28 Nm
(21 lbfft)
37 Nm
3 (27 lbfft)
37 Nm
(27 lbfft)
3
29 Nm
2 (21 lbfft)
37 Nm
(27 lbfft)
35 Nm 1 35 Nm
A32C3IS (26 lbfft) 1 (26 lbfft)
TYPICAL

Section 04 ENGINE
MAINTENANCE
Tuned pipe gear clamps must be retightened to
3.5 N•m (31 lbf•in) after the first 10 hours of use,
then every 3200 km (2000 mi).
CAUTION: Do not over tighten.
NOTE: Replace with new ones any damaged gear
clamps. Refer to appropriate Parts Catalogs to or-
der new gear clamps.

Open hood.
A32C13A
Remove tuned pipe and muffler.
TYPICAL — ENGINE REMOVAL
Remove or unplug the following then lift off en- 1,2,3,4, Engine Support Nut and
gine from engine compartment. Manifold Screw
NOTE: Use of a hoist is recommended. Torque the engine/support nuts no. 1 to 35 N•m
– guard (26 lbf•ft).
– air silencer Torque rubber mounts no. 2 to support bracket to
29 N•m (21 lbf•ft).
– drive belt
Torque rubber mount/support nuts to 37 N•m (27
lbf•ft).
Torque support brackets/chassis screws no. 3 to
be disassemble)
37 N•m (27 lbf•ft).
– hood, refer to BODY
Torque manifold screws no. 4 to:
– carburetors
M6 = 10 N•m (89 lbf•in)
– impulse hose and electrical connectors M8 = 23 N•m (17 lbf•ft)
– oil injection inlet line at oil injection pump, install
hose pincher INSTALLATION ON VEHICLE
– oil pump cable To install engine on vehicle, reverse removal pro-
– coolant hoses between cylinder head and radi- cedure. However, pay attention, to all appropriate
ator component/system reinstallation procedures de-
– coolant by-pass hose scribed throughout this Shop Manual and to the
following:
– coolant hose at front of coolant reservoir
– engine support screws tor maximum throttle opening and oil injection
– engine stopper (left rear of engine). pump adjustment.
– Seal exhaust ball joints with Ultra Copper (P/N
413 710 300).
04-02-2 MMR2001-077_04_02A.FM
Section 04 ENGINE
TOP END
12 Nm
(106 lbfin)
1 Some models
29 Nm
(21 lbfft)
5
6 Some models
2 9
7 5
12 11 8
13 6
3
10
9 7
15 11 8
14 12
13
G-n
29 Nm paste 14
(21 lbfft) 10
4
15
Loctite
518
M6: 10 Nm
(89 lbfin)
M8: 23 Nm
(17 lbfft)
16
17
19
793 engine 18 493 and 593
engines only
20
Injection
oil
21
A32C3BS

Section 04 ENGINE
COMPONENT REMOVAL
– cylinder head
– piston(s)
– cylinder(s)
– rewind starter
– oil pump
– water pump
A32C15A
– RAVE valve(s)
RAVE VALVE PARTIALLY REMOVED
– reed valve(s).
2, Cylinder
CLEANING
Remove spark plugs, coolant outlet no. 30. Un-
Discard all gaskets and O-rings. screw cylinder head cover no. 2 then cylinder
Clean all metal components in a non-ferrous metal head no. 3.
cleaner.
18, Piston
port cylinder head and piston dome using a wood- Place a clean cloth or rubber pad (P/N 529 023 400)
en spatula. over crankcase. then with a pointed tool inserted
in piston notch, remove both circlips no. 20 from
NOTE: The letters “AUS” (over an arrow on the
piston no. 18.
piston dome) must be visible after cleaning.
Clean the piston ring groove with a groove cleaner
DISASSEMBLY
RAVE System
Exhaust.
Remove spring clip or screws no. 5, cover no. 7
and spring no. 8.
Remove spring no. 10.
Remove bellows no. 11 and spring no. 12.
Remove cylindrical screws. Remove valve hous-
A02C29A
ing no. 13.
TYPICAL
04-02-4 MMR2001-077_04_02A.FM
Section 04 ENGINE
All engines are equipped with cageless piston pin Install sleeve then shouldered sleeve over puller
bearings. rod.
1 2
A32C17A
A02C2BA
20 mm sleeve kit (P/N 529 035 542) and locating 1. Sleeve
sleeve. 2. Shouldered sleeve
NOTE: The locating sleeve is the same that con- Screw (LH threads) extracting nut.
Insert piston pin puller (P/N 529 035 503) making til shouldered sleeve end is flush with thrust wash-
sure it sits squarely against piston. er of piston pin bearing.
A02C2CA
A02C2AA 1
TYPICAL
MMR2001-077_04_02A.FM 04-02-5
Section 04 ENGINE
1 2 3
A02C2FA 1 2
TYPICAL
A02C2DA
1. Locating sleeve
2. Sleeve
TYPICAL
1. Sleeve inside bearing
2. Thrust washer
INSPECTION
Remove puller. Pull out shouldered sleeve carefully.
SIONS MEASUREMENT.
RAVE System
Check valve rod housing and cylinder for clogged
passages.
A02C2EA
TYPICAL

along with thrust washers and sleeve. A32C16A 2 1
1. Draining hole
2. Passages

04-02-6 MMR2001-077_04_02A.FM
Section 04 ENGINE
11, Bellows
8, Spring
PRELOAD IN
WIRE FREE N (LBF) AT
ENGINE SPRING DIA. LENGTH COMPRESSED
TYPE P/N mm mm LENGTH OF
(in) (in) 14 mm
(.551 in) 1
1.0 38.0 19.5
493 420 239 948
(.039) (1.50) (4.37)
593
0.9 48.5 15.9
and 420 239 944
(.035) (1.91) (3.56)
693
793 on all 0.8 42.5 7.3
420 239 942
Summit (.031) (1.67) (1.64)
A02C2GA
793 on all 0.8 52.5 10.5
420 239 941 TYPICAL
MX Z (.031) (2.07) (2.36)
1. Sleeve
ASSEMBLY Grease thrust washers and install them on each

end of needles.
RAVE System Insert cageless bearing into connecting rod.
Install RAVE valve with its mention top as illustrat-
ed in the removal photo. Tighten red cap no. 6
screw to bottom.
4,18, Cylinder and Piston

493 and 593 Engines Only
Be sure to restore the chamfer around all cylinder
sleeve port openings.
All Engines
cylinder with new injection oil or equivalent. A02C2HA
TYPICAL — CAGELESS BEARING AND SLEEVE INSTALLED

Head and Cylinder At assembly, place the pistons over the connecting
rods with the letters “AUS” (over an arrow on the
Check flatness of part sealing surfaces. Refer to piston dome) facing in direction of the exhaust port.
LEAK TEST AND ENGINE DIMENSION MEASURE-
MENT and look for Checking Surface Flatness.
When installing a new cageless bearing, replace 1
half plastic cages by sleeve.
AUS
NOTE: 493 engine cageless bearings have 31
needles. 593, 693 and 793 engine cageless bear-
ings have 28 needles.
A01C01A
1. Exhaust
MMR2001-077_04_02A.FM 04-02-7
Section 04 ENGINE
Install shouldered sleeve. PISTON CIRCLIP

ENGINE TYPE
INSTALLER (P/N)
493 529 035 561
593 and 693 529 035 562
793 529 035 563
Insert circlip in tool at an angle.
1
A02C2IA

pin is correctly positioned in piston. A02C2KA
TYPICAL
1. Circlip
A02C2JA
TYPICAL
All Models
CAUTION: Always install new circlips.
circlip, install each circlip so the circlip break is at
6 o’clock as illustrated. Use appropriate piston cir-
clip installer.
A02C2LA
TYPICAL
1. Circlip
04-02-8 MMR2001-077_04_02A.FM
Section 04 ENGINE
Continue to square it up using round end of circlip

installer.
A02C2OA 1
TYPICAL

end of tool. Circlip will move from tool groove to
A02C2MA piston groove.
TYPICAL

rests in groove.
A02C2PA
TYPICAL
A02C2NA
TYPICAL
Mount tool in piston making sure that circlip break

is facing down.
A01C02B 1
TYPICAL
1. Circlip break
MMR2001-077_04_02A.FM 04-02-9
Section 04 ENGINE
CAUTION: Circlips must not move freely after With blade stopper no. 16 removed, check reed
installation; if so, replace them. valve for proper tightness. There must be no play
Coat both sides of a new cylinder gasket with Loc- between blade and valve body when exerting a
tite 518 then, install it on crankcase. finger pressure on blade at blade stopper location.
Loosely install cylinders. In case of a play, turn blade upside down and re-
check. If there is still a play, replace blade and/or
Install exhaust manifold then, tighten cylinder re- valve body.
taining screws to 29 N•m (21 lbf•ft) in a criss-
cross sequence.
At assembly, torque cylinder head screws to 29 N•m
(21 Ibf•ft) in the following illustrated sequence.
1
5 7
11 1 3 9
12 4 2 10
6 8
A06C0FA
1. No play
Check distance from blade stopper outer edge and

A32C18A
distance from center of reed valve block.
TYPICAL
Install outlet socket and tighten screws to 12 N•m

(106 Ibf•in). Note position of longer screw.
A A
A06C36A
TYPICAL
A. 17.0 - 0, + 0.75 mm (.669 - 0, + .030 in)
A32C19A 1 Bent blade stopper as required to obtain the prop-

er distance.
1. Longer screw
Blade stoppers may slightly interfere with cylinder
17, Reed Valve during installation. Adjusted distance will be re-
Blades have a curved shape. Install with their duced automatically upon installation.
curve facing reed block.
04-02-10 MMR2001-077_04_02A.FM
Section 04 ENGINE
BOTTOM END
Isoflex
Anti-seize
lubricant
Petamo
2
3 Isoflex
Petamo
Anti-seize
Anti-seize lubricant
lubricant
Loctite
Petamo 242
Anti-seize
lubricant
Molykote
111
29 Nm
(21 lbfft) Sealing
Loctite compound
648 Loctite
242
Petamo
Loctite
648
29 Nm
A32C3CS (21 lbfft)

Section 04 ENGINE
NOTE: Engine must be removed from chassis to ASSEMBLY

Coat lip of all seals with Petamo grease (P/N 420
CLEANING 899 271).
Discard all oil seals, gaskets, O-rings and sealing 2, Crankshaft Bearing
rings. Smear anti-seize lubricant (P/N 413 701 000) on
Clean all metal components in a non-ferrous metal part of crankshaft where bearing fits.
cleaner. Use Gasket remover (P/N 413 708 500) Prior to installation, place bearings into an oil con-
accordingly. tainer filled with injection oil previously heated to
Remove old paste gasket from crankcase mating 75°C (167°F). This will expand bearing and ease
surfaces with Gasket remover (P/N 413 708 500). installation.
CAUTION: Never use a sharp object to scrape Some bearings must be lubricated with Isoflex
away old sealant as score marks incurred are det- grease (P/N 293 550 021).
rimental to crankcase sealing. CAUTION: Use only the recommended Isoflex
grease. Make sure not to push Isoflex grease be-
DISASSEMBLY tween outside bearing race and half crankcase.
NOTE: The 50 g tube corresponds to 50 cc of
General grease.
To remove drive pulley, refer to DRIVE PULLEY. Put 45 to 50 mL of grease in a syringe.
To remove magneto, refer to CDI SYSTEM. Fill PTO side inner seal with Isoflex grease (about
10 mL).
tive cap and special puller, as illustrated.
A32C1BA 1
A00C0HA TYPICAL
1. PTO side inner seal filled with Isoflex grease
1. PTO side
2. MAG side
Put 35 to 40 mL of grease in a syringe.
INSPECTION With the syringe, fill the outer ball bearing with
grease.
NOTE: Refer to LEAK TEST AND ENGINE DI-
MENSIONS MEASUREMENT.
04-02-12 MMR2001-077_04_02A.FM
Section 04 ENGINE
693 and 793 Engines

Apply 6 mL of grease to MAG side outer bearing.
All Engines
At crankshaft installation, position drive pins as il-
lustrated.
A32C0AA
BALLS COATED WITH A SEAM OF GREASE
Coat inner side of outer seal (about 35 mL for 493

and 593 engine types and 40 mL for 693 and 793
engine types) and set it in place. A32C1CA 1
1. Position pins
Drop 50 mL (2 U.S. oz) of injection oil in the pan

under central gear to lubricate pump gearing as
per photo.
A32C0BA 1
1. Fill with grease and set in place
Use the remaining grease to coat the inner side of

the ball bearing.
A32C0DA 1
1. Oil bath
Crankcase Assembly
IMPORTANT: The total assembly sequence, in-
cluding sealing compound spreading, screwing
and torquing of bolts according to the proper se-
quence must be performed within 10 minutes. Do
not wait between each bolt torquing. All bolts
must be torqued in a row.
Before screwing both parts of crankcase, seal it
with sealing compound (P/N 420 297 905). Make
sure surfaces are clean and degreased before ap-
A32C0CA
plying sealing compound.
MMR2001-077_04_02A.FM 04-02-13
Section 04 ENGINE
Spread a seam of 2 to 3 mm (1/16 to 1/8 in) max- Screw all crankcase bolts in place in the following
imum in diameter on surface of lower crankcase sequence and to the appropriate torque through a
half. two steps torquing: first, screw bolts up to 60%
of the final torque (18 N•m (13.5 lbf•ft) for most
of the bolts), then, tighten to the required torque
(i.e. 29 N•m (21 lbf•ft)).
B B
A 11 9 14 4 1 16 5 19 8 18
A32C3GA
A. 2 to 3 mm (1/16 to 1/8 in) max.
As far as possible, sealing compound must be ap-

plied in one run to avoid any risks of leaking through
the crankcase.
12 10 13 2 3 15 6 7 17
A B
A32C3HA
SEAMING COMPLETED — CONTACT SURFACES COVERED

AND SCREW HOLES SURROUNDED
20 21
A32C3FA B B
A. Torque bolts 1 through 16 to 29 N•m (21 lbf•ft)
B. Torque bolts 17 through 21 to 9 N•m (80 lbf•in)
04-02-14 MMR2001-077_04_02A.FM
Section 04 ENGINE

MEASUREMENT 0
LEAK TEST
The following gives verification procedures for 2-
cylinder reed valve liquid cooled engines.
PREPARATION
1. Remove tuned pipe.
2. Install plug over exhaust manifold.
3. Remove carburetors.
4. Insert plugs in intake rubber boots. Tighten with
clamps already there.
A32C1EA
7. Install air pump on exhaust plug.

NOTE: If necessary, lubricate air pump piston with
mild soap.
CAUTION: Using hydrocarbon lubricant (such
as engine oil) will damage rubber seal of pump
piston.
A32C1DA
5. Using a hose pincher (P/N 295 000 076), block im-

pulse hose.
6. Using hose pinchers (P/N 295 000 076), block
pump shaft oil hose and lubrication nipple on PTO
side.
A32C1FA
MMR2001-078_04_03A.FM 04-03-1
Section 04 ENGINE
8. Activate pump and pressurize engine to 34 kPa 2. Small injection oil lines coming from pump.
utes. If pressure drops before 3 minutes, check
tester kit by spraying a soapy solution on pump
cylinder, all plugs and fittings.
– If tester kit is leaking, bubbles will indicate
where leak comes from.
– If tester kit is not leaking, check engine as per
PROCEDURE
reference. See last page of this chapter. 1 2 1
A32C1GA
Using flow chart and following text, pressurize
area to be tested and spray soapy solution at the 1. Injection nipples
indicated location.
TEST PRESSURE: 34 kPa (5 PSI)
pump. It indicates defective check valve in injec-
for 3 minutes
tion nipples.
– If there is a leak at the tested location, it is rec- 3. Remove cooling system cap.
ommended to continue testing next items be- Check for air bubbles in antifreeze. It indicates de-
fore overhauling engine. There is a possibility of fective cylinder head O-ring or cylinder base gas-
more than one leak. ket.
– If there is no leak at the tested location, contin- 4. Remove drive pulley then check crankshaft out-
ue pumping to maintain pressure and continue er seal.
with next items until leak is found.
Engine then check crankshaft outer seal.
Check the following: 6. Check pump shaft gear oil reservoir.
1. All jointed surfaces and screw/stud threads of Pump Shaft Oil Gear Reservoir
engine:
Install air pump on adapter and pressurize as be-
– spark plug base, insulator fore.
– cylinder head
– RAVE valve bellows, piston and housing
– cylinder
– oil injection pump mounting flange
(O-ring, seal)
– coolant pump housing
– bleed screws/plugs.
A32C1HA
04-03-2 MMR2001-078_04_03A.FM
Section 04 ENGINE
If pressure drops, it indicates a defective crank- If there is a leak, it indicates defective seal of
shaft inner seal. pump shaft (oil seal beside coolant ceramic seal).
2. Leaks can be also on oil pump side. Check
mounting area for leaks.
A32C1IA
1 2
CRANKSHAFT INSTALLED IN UPPER HALF CRANKCASE
1. Crankshaft inner seal on PTO side A32C1GB 1
2. Crankshaft inner seal on MAG side
1. Check mounting area
1. Check drain hole below coolant pump housing
with soapy water. 3. If leak still persists, it indicates a defective cast-
ing somewhere in engine.
Disassemble engine and carefully check for de-
fects in castings. Pay attention to tapped holes
thus lead to leakage.
FINALIZING REASSEMBLY
After reassembling engine, always recheck for leak-
age.
A32C1JA 1
1. Drain hole
MMR2001-078_04_03A.FM 04-03-3
Section 04 ENGINE

FLOW CHART
PRESSURIZE ENGINE
NO
IS ENGINE LEAKING?
YES

FLANGES ETC.

NO

INJECTION PUMP

TOWARD PUMP?
NO

NO
GEAR
LUBRICATION SYSTEM
NO
YES

SEAL OF PTO AND
MAG SIDES
YES
NO


NO
CYLINDER SEPARATELY

NO


NO ANY LEAK FOUND? SHAFT CERAMIC, BESIDE
COOLANT SEAL
NO
CHECK OIL PUMP

YES
NO

YES
NO

INTERNALLY
A32C1KS
04-03-4 MMR2001-078_04_03A.FM
Section 04 ENGINE

MEASUREMENT
ENGINE TYPE MAXIMUM
All 0.08 mm (.003 in)
50 mm (2 in) of surface replaced. Nikasil cylinder can be honed using dia-
All mond hone and can not be rebored.
0.5 mm (.020 in) for total
length of cylinder head NOTE: Be sure to restore the chamfer around all
a straightedge and a feeler gauge.
1
CYLINDER TAPER
ENGINE TYPE MAXIMUM
All 0.10 mm (.004 in)
Compare cylinder diameter 16 mm (5/8 in) from A

top of cylinder to just below its intake port area.
If the difference exceeds the specified dimension 2
the cylinder should be rebored and honed or
should be replaced. Nikasil cylinder can be honed
using diamond hone and can not be rebored. A01C54A
NOTE: Be sure to restore the chamfer around all 1. Piston pin position
cylinder sleeve port openings. 2. Measures to be compared
A. 16 mm (5/8 in)
COMBUSTION CHAMBER
VOLUME MEASUREMENT
A
A01C53A 1
A. 16 mm (5/8 in) from top
F01D5VA
MMR2001-078_04_03A.FM 04-03-5
Section 04 ENGINE
NOTE: When checking the combustion chamber 3. Open burette valve to fill its tip. Add liquid in
volume, engine must be cold, piston must be free burette until level reaches 0 cc.
F00D0HA 1

2. Obtain a graduated burette (capacity 0 - 50 cc) ume would be false.
1 2.25 cc corresponding to the spark plug well.

ENGINE (CC)
TYPE (up to top thread of
spark plug hole)
493 24.88 ± 1.00
28.86 + 1.30
593
- 1.20
F00B0BA
33.90 + 1.51
693
1. Graduated burette (0-50 cc) - 1.38
36.34 + 1.73
793
- 1.58
04-03-6 MMR2001-078_04_03A.FM
Section 04 ENGINE
8. Install a thicker or thinner cylinder/crankcase

gasket (refer to Parts Catalogs) in order to ob-
tain the specified combustion chamber volume
or the nearest.
A
CHANGE IN COMBUSTION CHAMBER
ENGINE
VOLUME (CC) FOR EVERY 0.1 mm
TYPE
(.004 in) OF GASKET THICKNESS
493 0.38
593 0.45
693 0.48
793 0.53
1
F01D0NA
USED PISTON MEASUREMENT 1. Measuring perpendicularly (90°) to piston pin axis

A. 15 mm (.590 in)
Note the measurement on the piston dome.
MAXIMUM PISTON SKIRT
ENGINE TYPE WEAR
mm (in)
All 0.15 (.006)
The measured dimension must not be less than

0.15 mm (.006 in) of the one scribed on piston
dome. Otherwise, install a new piston.
IMPORTANT: Make sure used piston is not worn
more than specified. See USED PISTON MEA-
F00D0EA 2 1 SUREMENT above.
1. Piston dome Take the measurement on the piston dome.
Using a micrometer, measure piston skirt at 15 mm

(.590 in) perpendicularly (90°) to piston pin.
F00D0EA 2 1
1. Piston dome
MMR2001-078_04_03A.FM 04-03-7
Section 04 ENGINE
Adjust and lock a micrometer to the specified val- IMPORTANT: Always remove cylinders from crank-
ue on the piston dome. case before measuring.
Position the dial bore gauge at 16 mm (5/8 in) be-
1 low cylinder top edge.
1
F00B08A
1. Micrometer set to the piston dimension A

mension and set the indicator to 0. F01D0KA

A. 16 mm (5/8 in)

1 clearance. If clearance exceeds specified toler-
ance, replace cylinder or rebore and install oversize
2
piston depending on engine type. Refer to TECH-
NICAL DATA.
IMPORTANT: The total piston/cylinder clearance
(actual cylinder diameter minus actual piston skirt
F00B09A diameter) should be within 0.30 mm (.012 in).
1. Use the micrometer to set the cylinder bore gauge
2. Dial bore gauge
1
F00B0AA
04-03-8 MMR2001-078_04_03A.FM
Section 04 ENGINE
RING/PISTON GROOVE CRANKSHAFT DEFLECTION

CLEARANCE Crankshaft deflection is measured with a dial indi-
Using a feeler gauge check clearance between cator.
rectangular ring and groove. Replace piston if clear-
ance exceeds specified tolerance. Refer to TECH- Measuring (in crankcase)
NICAL DATA. First, check deflection with crankshaft in crank-
case. If deflection exceeds the specified toler-
ance, recheck deflection using V-shaped blocks to
determine the defective part(s). See below.
Measuring (on bench)

Once engine is disassembled, check crankshaft
deflection on V-shaped blocks. If deflection ex-
ceeds the specified tolerance, it can be worn bear-
ings or a bent crankshaft. Remove crankshaft bear-
ings and check deflection again on V-shaped blocks
to determine the defective part(s). See measure-
ment A in following illustration.
A01C0PA
RING END GAP

intake port.
TECHNICAL DATA.
1 A 1
A01C0RD
TYPICAL
1. Measure at mid point between the key and the first thread
A. 3 mm (1/8 in)
A01C0QA
1. Transfer port
2. Intake port
MMR2001-078_04_03A.FM 04-03-9
Section 04 ENGINE
Crankshaft Deflection on PTO Side Using a feeler gauge, measure distance between
ENGINE MAXIMUM ON PTO SIDE the distance exceeds specified tolerance, repair or
TYPE mm (in) replace the crankshaft.
All 0.06 (.0024)
Crankshaft Deflection on MAG Side

MAXIMUM ON MAG SIDE
ENGINE TYPE
mm (in)
All 0.05 (.002)
Crankshaft Deflection in Center of

Crankshaft
MAXIMUM IN CENTER OF A01C0SA
ENGINE
CRANKSHAFT
TYPE TYPICAL
mm (in)
All 0.08 (.0031) CRANKSHAFT END-PLAY
NOTE: Crankshaft deflection cannot be correctly All Engine Types
End-play is not adjustable but it should be between
If the deflection exceeds the specified tolerance, 0.10 - 0.30 mm (.004 - .012 in).
Intake manifold, intake manifold cover can be
AXIAL PLAY checked for perfectly mating surfaces.
ENGINE NEW PARTS WEAR Lay part on a surface plate (marble, mirror or thick
TYPE MIN. - MAX. LIMIT glass plate).
0.39 - 0.74 mm 1.20 mm Holding down one end of part, try pushing down
All the other end.
(.015 - .029 in) (.047 in)
If any play is felt, part must be rectified.
04-03-10 MMR2001-078_04_03A.FM
Section 04 ENGINE
RECTIFYING SURFACES Bring MAG piston at top dead center.

Rotate degree wheel (not crankshaft) so that 360°
Stick a fine sand paper sheet on the surface plate
mark aligns with center of crankcase. Scribe a
mark on crankcase.
Rub part mating surface on sand paper using 8-
Remove TDC gauge and install it on center cylin-
figure movements.
der.
Bring PTO piston to top dead center. Degree wheel
must rotate with crankshaft.
10
0
20
90
30
80
40
70
50 60
A00A1LA
TYPICAL
180
CHECKING CRANKSHAFT
ALIGNMENT
A06C1TA 0
Install a degree wheel (P/N 414 352 900) on crank-

TYPICAL
shaft end.
Remove both spark plugs. Interval between cylinders must be 180° ± 0.5.
Install a TDC gauge (P/N 414 104 700) in spark plug Any other reading indicates a misaligned (twisted)
hole on MAG side. crankshaft.
MMR2001-078_04_03A.FM 04-03-11
Section 04 ENGINE
CDI SYSTEM 0
290 W on ZX Series
6
Loctite
243
5 Loctite
648
7
4 2
3 125 Nm
1 (92 lbfft)
Some
models
Loctite
243
Loctite
243
Air
sensor
Dielectric grease DPM

except for cable
with integrated cap Some
models
only
Dielectric grease
except for cable
with integrated cap
A32E0TS

Section 04 ENGINE
NOTE: The following procedures can be done

without removing the engine from chassis. To fa-
cilitate magneto removal, hold drive pulley with
tool (P/N 529 027 600).
CLEANING
cleaner.
a clean cloth.
DISASSEMBLY A06E22B 1 2
3, Magneto Flywheel TYPICAL

To gain access to magneto assembly, remove the 2. M8 screws
following parts as needed on different engines: – Remove magneto flywheel nut, using a 30 mm
– tuned pipe and muffler socket machined to 40 mm (1.580 in) outside
– rewind starter diameter by 16 mm (5/8 in) long.
– starting pulley no. 2. NOTE: To correctly remove a threadlocked fasten-
er it is first necessary to tap on the fastener to
To remove magneto flywheel retaining nut no. 1: break threadlocker bond. This will eliminate the
– Use magneto puller ring (P/N 420 876 080). possibility of thread breakage.
Former puller has to be modified as shown.
A 420 876 080
A06E23A 1 A03C1JA
1. Cut by 25 mm (1 in) TYPICAL

A. 30 mm socket
– Install puller ring with its tab in magneto hous-
ing opening. To remove magneto flywheel, screw puller (P/N 529
CAUTION: Use only M8 x 20 mm screws to bolt 022 500) into puller ring.
puller to magneto. When a flywheel no. 7 is in- – Tighten puller bolt and at the same time, tap on
stalled on magneto flywheel use M8 x 30 mm bolt head using a hammer to release magneto
screws. flywheel from its taper.
04-04-2 MMR2001-079_04_04A.FM
Section 04 ENGINE
5, Trigger Coil 3, Magneto Flywheel

Magneto and stator no. 6 must be removed be- Clean crankshaft extension (taper) and apply Loc-
fore trigger coil removal. tite 243 (blue) on taper, then position Woodruff
To replace trigger coil: key, flywheel and lock washer on crankshaft.
– Disconnect trigger coil connector housing. Clean nut threads and apply Loctite 243 (blue) then
tighten nut 125 N•m (92 lbf•ft).
– Remove grommet from crankcase where trig-
ger coil wire exits magneto housing. At reassembly coat all electric connections except
Deutsch housings (waterproof gray housing) with
– Remove retaining screws no. 4. silicone dielectric grease (P/N 293 550 004) to pre-
– Remove trigger coil and carefully pull wires. vent corrosion or moisture penetration.
– Install new trigger coil and other parts removed. CAUTION: Do not use silicone “sealant”, this
product will corrode contacts. Do not apply sil-
ASSEMBLY icone dielectric grease on any Deutsch (gray)
housing otherwise housing seal will be dam-
7, Stator Plate aged.
Make sure to position stator plate in a way that its Ignition Timing
wire protectors are over recess of crankcase.
2 1
A32E0KA
1. Crankcase recess
2. Wire protectors
MMR2001-079_04_04A.FM 04-04-3
Section 04 ENGINE

OIL INJECTION PUMP
493, 593, 693 and 793 Engines
Injection oil
Loctite 648
2
4
5 Nm 3
2
A32C0WT

Section 04 ENGINE
OIL SYSTEM LEAK TEST OIL PUMP

ENGINE TYPE
IDENTIFICATION
All Models
The following test will indicate any leak from oil res- 493 L7
ervoir to the banjo fitting(s). 593 L9
Install on oil reservoir special cap of leak testing kit 693 L14
(P/N 529 033 100).
Install hose pinchers (P/N 295 000 076) on outlet 793 L14
hoses.
NOTE: The following procedures can be done with-
1 2 out removing the engine from chassis.
CLEANING
cleaner.
DISASSEMBLY
ASSEMBLY
A03C2UA 1, Spring Clip
TYPICAL Always check for spring clips tightness.
2. Hose pinchers on outlet hoses
3, Screw
Connect pump of leak testing kit to special cap. Torque to 5 N•m (44 lbf•in).
Pressurize oil system to 34 kPa (5 PSI). That pres- Cable plastic elbow must be fastened and fully in-
sure must not drop during 3 minutes. serted.
If pressure drops, locate leak(s) and repair/replace Make sure cable barrel is well seated in oil pump
leaking component(s). To ease locating leak(s) lever.
indicate leak location(s). Secure barrel with plastic washer and circlip.
Install cable lock washer on left side of support.
OIL PUMP IDENTIFICATION Verify cable and oil pump lever operation.
4, Pump Lever ADJUSTMENT

tification on lever no. 4. Prior to adjusting the pump, make sure all carbu-
retor adjustments are completed.
CAUTION: Always mount proper pump on en-
gine. Synchronizing Pump with Carburetor
Because the oil pump is mounted low on engine,
it is very difficult to avoid parallax problem and set
a good adjustment.
04-05-2 MMR2001-080_04_05A.FM
Section 04 ENGINE
Parallax Problem
When adjusting pump lever, since the mechanic can
not view the pump perpendicularly, the adjustment
will not be accurate. Following photos show three
different views of the same properly adjusted pump.
PROTRUSION
PROTRUSION
A32C1OA
VIEW TOO LOW — ADJUSTMENT SEEMS TO BE TOO LEAN

WHEN BOTTOM OF BODY’S PROTRUSION CAN BE SEEN
To avoid a bad adjustment, follow procedure be-

low.
A32C1MA
Procedure for Oil Pump Adjustment
VIEW TOO HIGH — ADJUSTMENT SEEMS TO BE TOO RICH
WHEN TOP OF BODY’S PROTRUSION CAN BE SEEN Ensure carburetors are synchronized according to
the technical specifications.
Remove air box. Carburetors may also be removed
to improve visibility and ease adjustment of oil pump
cable.
NOTE: Place carburetors on top of intake boots to
keep cable routing near original location.
Lightly depress throttle lever to remove free play
from cable.
Use a small round or oblong mirror to see the marks.
The second mark on pump lever must be aligned or
up to 1 mm (.039 in) below pump casting mark. If
not, loosen the adjuster nut and adjust accordingly.
Retighten the adjuster nut.
A32C22A 1 2
VIEW STRAIGHT AHEAD — BODY’S PROTRUSION LOOKS LIKE
A CIRCLE, MARK ON PUMP ALIGN WITH SECOND MARK ON
LEVER (MARK ON DOT SIDE)
1. Minimum setting
2. Maximum setting
MMR2001-080_04_05A.FM 04-05-3
Section 04 ENGINE
1 4 A 1 A
A32C1PA 3 2
VIEW WITH AIR BOX, CARBURETORS AND FUEL PUMP 3 MIN. 4 MAX.
REMOVED
B
1. Oil pump
2. Mirror
3. Lever
4. Adjustment screw 5
A32C2HA
Make sure that view in mirror is straight ahead, with-
out parallax problem. 1. Lock washer
2. Plastic elbow fastened and fully inserted
Protrusion with fixed mark on pump must look 3. Pump casting mark
4. Second mark aligned or below
like a full circle. See next photo. 5. First mark
6. Bleeder screw
1 3 A. 5 N•m (44 lbf•in)
B. Up to 1 mm (.039 in)
CAUTION: Proper oil injection pump adjustment

is very important. Any delay in the opening of
the pump can result in serious engine damage.
To Bleed Oil Lines

2 Reinstall all parts.
Bleed the small oil line between pump and engine
by running engine at idle while holding the pump
lever in fully open position.
NOTE: Make a J hook out of mechanical wire to lift
the lever.
 WARNING
Ensure not to operate carburetor throttle mech-
A32C1QA 4
VIEW FROM MIRROR SHOULD LOOK LIKE THIS
1. Mark on pump casting
2. Second mark on lever
3. Dot
4. Pump protrusion as a circle, not a cylinder
04-05-4 MMR2001-080_04_05A.FM
Section 04 ENGINE
CHECKING OPERATION
Oil Pump
On Vehicle
NOTE: Main oil line must be full of oil. See bleed-
ing procedure above.
stand. Unplug small oil lines from pump. Start en-
gine and stop it as soon as it fires.
Check that oil in small oil lines has been sucked up
(this will be indicated by a clear section of small oil
lines). Repeat the procedure until this condition is
attained.
Reconnect small oil lines, start engine and run at
idle while holding the pump lever in fully open po-
sition. Oil columns must advance into small oil lines.
gear and drive shaft (if applicable) for defects, re-
place as necessary. Test pump as describes below.
in small tubes. If oil drops, verify check valve op-
eration in injection nozzle. Replace as necessary.
Test Bench
Connect a hose filled with injection oil to main line
fitting. Insert other hose end in an injection oil con-
tainer. Using a clockwise rotating drill rotate pump
shaft. Oil must drip from outer fittings while hold-
ing lever in a fully open position. If not replace pump.
2, Check Valve
To verify this check valve, proceed the same as for
oil line from check valve. After restarting the en-
gine, check that a clear section in small oil line is
present. Reconnect oil line.
Run engine at idle. Oil column must advance. If the
check valve is faulty, oil column will go back and
forth. Replace if so.
MMR2001-080_04_05A.FM 04-05-5
Section 04 ENGINE

493, 593, 693 and 793 Engines
Loctite 592
1
2
2
8
Loctite 592
7
A32C39S

Section 04 ENGINE
COOLING SYSTEM LEAK TEST 1, Pressure Cap

Install special radiator cap (P/N 529 021 400) in- Check if the cap pressurizes the system. If not,
cluded in engine leak tester kit (P/N 861 749 100) install a new 90 kPa (13 PSI) cap (do not exceed this
on coolant tank. Install hose pincher (P/N 295 000 pressure).
076) on overflow hose. Using pump also included
in kit pressurize all system through coolant reser- 6,7, Radiator and Radiator Protector
voir to 100 kPa (15 PSI). Insert radiator protector into radiator C-rail and
Check all hoses and cylinder/base for coolant crimp C-rail at rear end. Refer to FRAME for radi-
leaks. Spray a soap/water solution and look for air ator removal.
bubbles.
5, Thermostat
To check thermostat, put in water and heat water.
Thermostat should start to open when water tem-
perature reaches the following degree. It will be
almost fully open at 50°C (122°F).
ENGINE TEMPERATURE
493, 593, 693 and 793 42°C (108°F)
Thermostat is a double action type.

a. Its function is to give faster warm up of the en-
gine by controlling a circuit; water pump —
engine — coolant tank. This is done by bypass-
A32C3AA 529 021 400 295 000 076 ing the radiator circuit.
INSPECTION 1
Check general condition of hoses and clamp tight-
ness.
DRAINING THE SYSTEM

 WARNING
Never drain or refill the cooling system when
engine is hot.

mixture from the coolant tank. Disconnect hose at A16C02A 2
water pump.
TYPICAL — CLOSED THERMOSTAT, COLD ENGINE
1. To reservoir
DISASSEMBLY AND ASSEMBLY 2. From cylinders

Apply Loctite 592 (P/N 413 702 300) thread sealant
on sender and plug to avoid leaks.
04-06-2 MMR2001-081_04_06A.FM
Section 04 ENGINE
b. When the liquid is warmed enough, the thermo- System Capacity

stat opens progressively the circuit, water pump
— engine — radiators — coolant tank to keep
the liquid at the desired temperature. (See the
diagram of the exploded view).
Refilling Procedure
Open heated carburetor valve no. 8 on so equipped
models.
1 2
2
A16C03A
TYPICAL — OPEN THERMOSTAT, WARM ENGINE

1. To radiators A32I0AA
2. From cylinders
HEATED CARBURETOR VALVE
These 2 functions have the advantage of prevent- 1. ON
ing a massive entry of cold water into the engine. 2. OFF

COOLING SYSTEM REFILLING With engine cold, refill coolant tank no. 2 up to
PROCEDURE COLD LEVEL line. Wait a few minutes then refill
to line. Start engine. Refill up to line while engine
Recommended Coolant is idling until all air bubbles have escaped from sys-
Use premixed coolant - 52°C (- 62°F) (P/N 413 711 tem (about 4 to 5 minutes). Install pressure cap.
802) (16 x 1 L). Do not reinstall pressure cap.
CAUTION: To prevent rust formation or freez-
ing condition, always replenish the system
with recommended premixed coolant.
MMR2001-081_04_06A.FM 04-06-3
Section 04 ENGINE
To make sure coolant flows through radiators, touch

them by hand. They must feel warm.
line.
A32C29A
1. Coolant tank
2. COLD LEVEL line

proper tester.
04-06-4 MMR2001-081_04_06A.FM
Section 04 ENGINE
REWIND STARTER 0
Plastic Rewind Starter on All Models
9 Nm
(80 lbfin)
15
Molykote
13 PG 54 6
7
11 10
9
8
12
Molykote 2
PG 54 Molykote 7 Nm
PG 54 (62 lbfin)
1
4
Molykote
PG 54
Molykote
PG 54
A32C28S

Section 04 ENGINE
INSPECTION 1 2
bricated.
gage within 30 cm (1 ft) of rope pulled. If not, dis- A03C3DA
aged plastic parts. Replace as required, lubricate, 1. Rope exit hole
2. Key to be removed
reassemble and recheck. Always replace O-ring
no. 11 every time rewind starter is disassemble. With a long thin pin punch inserted through rope
When releasing starter grip, it must return to its exit hole, push key no. 7. Remove key and rope.
stopper and stay against it. If not, check for proper Install a new rope and lock it using key no. 7.
spring preload or damages. Readjust or replace as NOTE: When rope is completely pulled out, spring
required. preload is 4-1/2 turns.
return freely. If not, check for damaged parts or DISASSEMBLY
lack of lubrication. Replace parts or lubricate ac- Undo knot previously tied at removal. Let sheave
cordingly. get free to release spring preload.
Cut push nut no. 13 and discard. Remove locking
REMOVAL element no. 12, O-ring no. 11, step collar no. 10,
Using a small screwdriver, extract rope knot from pawl lock no. 9 and pawl no. 8.
starter grip no. 15. Cut rope close to knot. Tie a Remove sheave no. 5 from starter housing no. 1.
knot near starter. Hold spring with a screwdriver.
Remove screws no. 2 securing rewind starter no. 1
to engine then remove rewind starter.
Fan Cooled Engines Only
Remove pump from rewind starter cover.
ROPE REPLACEMENT
Completely pull out rope. Hold rewind starter in a
vise.
A03C3EA
04-07-2 MMR2001-082_04_07A.FM
Section 04 ENGINE
Disengage key no. 7 and pull out rope no. 6. CAUTION: It is of the utmost importance that
Lubricate spring assembly and 1 cm (1/2 in) wide
on bottom of housing with Molykote PG 54 (P/N
420 899 763).
A01C12A
GENTLY TAP ON KEY
ASSEMBLY
spring guide notch then wind the spring counter-
clockwise into guide. A01C14A
 WARNING TYPICAL
1. Molykote PG 54 inside spring guide
Since the spring is tightly wound inside the
guide it may fly out when rewind is handled. 1
Always handle with care.
A32C2AA
A03C3FA 1
1. Molykote PG 54 applied 1 cm (1/2 in) wide on bottom of housing
grease could result in rewind starter malfunc-
tion.
MMR2001-082_04_07A.FM 04-07-3
Section 04 ENGINE
To install rope no. 6, insert rope into sheave no. 5 Lubricate pawl no. 8 with Molykote PG 54 (P/N 420
orifice and lock it with the key no. 7 as illustrated. 899 763) then install over rope sheave.
A01C15A
1. Push to lock
Lubricate housing post with silicone compound

grease. Install sheave.
To adjust rope tension:
A03C3GA
Wind rope on sheave and place rope sheave into
starter housing making sure that the sheave hub Lubricate pawl lock no. 9 with Molykote PG 54
notch engages in the rewind spring hook. (P/N 420 899 763). Install over pawl.
end is accessible through rope exit hole. This will
give 1/2 turn of preload.
Pull the rope out of the starter housing and tem-
A01C0CA
TYPICAL A03C3HA
04-07-4 MMR2001-082_04_07A.FM
Section 04 ENGINE
Install step collar no. 10 with its sleeve first. Lubri- Reinstall rewind starter assembly on engine.
cate a new O-ring no. 11 and locking element no. 9 Prior to installing starter grip no. 15 on new rope,
with Molykote PG 54 (P/N 420 899 763). Install it is first necessary to fuse the rope end with a lit
over pawl lock. match. Pass rope through starter grip and tie a
over the knot.
A03C3IA 3 1 2
1. Step collar
2. O-ring
3. Locking element
A01C18A
Position a new push nut no. 13.
TYPICAL
INSTALLATION
Fan Cooled Engines Only
Reinstall oil pump on rewind starter assembly.
All Models
Thread starter rope no. 6 through rope guide when
applicable.
A03C0VA
TYPICAL
MMR2001-082_04_07A.FM 04-07-5
Section 04 ENGINE

CARBURETOR
VM Type
To other
carburetor
1
7
10
13
2
3
8
4
5
9
11
14 12
A30C1XT
TYPICAL
MMR2001_083_04-08A.FM PARTS FLAT RATE 04-08-1

Section 04 ENGINE
IDENTIFICATION CLEANING AND INSPECTION

All carburetors are identified on their body. The entire carburetor should be cleaned with a
general solvent and dried with compressed air be-
fore disassembly.
CAUTION: Heavy duty carburetor cleaner may
parts, O-rings, etc. Therefore, it is recommended
to remove those parts prior to cleaning.
Carburetor body and jets should be cleaned in a
carburetor cleaner following manufacturer’s in-
1 structions.
 WARNING
A01C59A
needle and seat must be replaced as a matched
TYPICAL set.
1. Identification: 34-482
retor only. It is designed to operate with a fuel
REMOVAL pump system.
Unfasten clamps then, remove air intake silencer Check throttle slide for wear. Replace as neces-
from left hand side. sary.
Disconnect fuel inlet lines. Check idle speed screw straightness. Replace as
necessary.
 WARNING Check for fuel soaked into float no. 12; replace as
Fuel is flammable and explosive under cer- necessary.
tain conditions. Always wipe off any fuel or
Check float for cracks or other damages affecting
oil spillage from the vehicle. Ensure work
area is well ventilated. Do not smoke or allow
open flames or sparks in the vicinity. Inspect throttle cable and housing for any damag-
es. Replace as necessary.
Unscrew carburetor cover no. 1 then pull out
throttle slide no. 5 from carburetor. DISASSEMBLY AND ASSEMBLY
 WARNING NOTE: To ease the carburetor disassembly and
assembly procedures it is recommended to use
Exercise care when handling throttle slide.
carburetor tool kit (P/N 404 112 000).
Scratches incurred may cause throttle slide to
stick open in operation.
Disconnect throttle cable from throttle slide.

Remove carburetors from engine.
Unscrew choke plunger from each carburetor.
A00B2FA
04-08-2 MMR2001_083_04-08A.FM
Section 04 ENGINE
2,3, E-Clip and Needle 9,10, Float Arm and Float Arm Pin
Remove screws from needle retaining plate to Correct fuel level in float chamber is vital toward
withdraw the needle. maximum engine efficiency. To check for correct
The position of the needle in the throttle slide is float level proceed as follows:
adjustable by means of an E-clip inserted into 1 of – Make sure that float arm is symmetrical — not
5 grooves located on the upper part of the needle. distorted.
Position 1 (at top) is the leanest, 5 (at bottom) the – Remove float bowl and gasket from carburetor.
richest.
– With carburetor chamber upside-down on a lev-
NOTE: The last digit of the needle identification el surface, measure height H between bowl
number gives the recommended calibrated posi- seat and top edge of float arm. Keep ruler per-
tion of the E-clip from the top of the needle. fectly vertical and in line with main jet hole.
Example 6DH4-3 1
Recommended
Needle
position.
identification
1 Lean
5 Rich A01C5AB H
A00B2GA
CLIP POSITIONS TYPICAL — VM TYPE

1. Measure from top of float arm
H: Float height (including float arm thickness)
8, Main Jet
selected for a temperature of - 20°C (0°F) at sea
level. Different jetting can be installed to suit tem- 1
perature and/or altitude changes. A Service Bulle-
tin will give information about calibration accord-
ing to altitude and temperature.

ADJUSTMENT
CAUTION: Spark plugs will foul if float is ad-
justed too low. Engine may be damaged if float
is adjusted too high.
A01C5BA
TYPICAL — VM TYPE
1. Ruler vertical and in line with main jet
MMR2001_083_04-08A.FM 04-08-3
Section 04 ENGINE
Float level height can be check using tool (P/N 529 CARBURETOR ADJUSTMENTS
035 520). Keep tool in line with main jet as ex-
plained above. NOTE: For high altitude regions, a Service Bulletin
529 035 520 altitude and temperature.
sequence:
– air screw adjustment
A30C1QA
CARBURETOR FLOAT HEIGHT H

2
IDENTIFICATION ± 1 mm (± .040 in) 1
VM 38-429 22.9 (.902)
To Adjust Height H
– Bend the contact tab of float arm until the spec- A02C09A
ified height is reached. 1. Idle speed screw

2. Air screw
1
6, Air Screw Adjustment
Completely close the air screw (until a slight seat-
ing resistance is felt) then back off as specified.
Turning screw in clockwise enrichners mixture
and conversely, turning it out counterclockwise
leans mixture.
A00C03A
TYPICAL
1. Contact tab
04-08-4 MMR2001_083_04-08A.FM
Section 04 ENGINE
Throttle Slide Height Using a drill bit adjust throttle slide height (see fol-
(preliminary idle speed adjustment) lowing table) by turning idle speed screw no. 7.
Hook throttle cable into the needle retainer plate. Throttle slide height is measured on outlet side of
carburetor (engine side).
NOTE: Do not obstruct hole in throttle slide when
installing needle retaining plate. This is important NOTE: Make sure that throttle cable does not hold
to allow air escaping through and thus allowing a throttle slide. Loosen cable adjuster accordingly.
quick response. Final idle speed adjustment (engine running at idle
speed) should be within 1/2 turn of idle speed
screw from preliminary adjustment.
1 2
THROTTLE SLIDE
MODELS HEIGHT
± 0.2 mm (± .008 in)
MX Z 500
3 Formula DLX 500 1.4 (.055)
Grand Touring 500
A00C1TA
CENTER POST TYPE

1. Throttle cable
2. Needle retaining plate 1
3. Throttle slide
Make sure the nylon packing no. 4 is installed on

all applicable throttle slides.
CAUTION: Serious engine damage can occur if
this notice is disregarded.
2
A01C3NA
1 3
TYPICAL
1. Drill bit used as gauge for throttle slide height
INSTALLATION
shut.
Prior to install carburetor, adjust air screw and pre-
4 liminary idle speed as described above.
5
To install carburetor on engine, inverse removal
A00C3MA procedure.
CENTER POST TYPE However, pay attention to the following:
1. E-clip On applicable models, make sure to align tab of
2. Needle retaining plate
3. Screw carburetor and air intake silencer (if applicable)
4. Needle with notch of adaptor(s). On applicable models, in-
5. Nylon packing
MMR2001_083_04-08A.FM 04-08-5
Section 04 ENGINE
CAUTION: The rubber flange must be checked Check that with the throttle lever fully depressed,
for cracks and/or damage. At assembly, the there is a free play between the carburetor cover
flange must be perfectly matched with the air and top of throttle slide.
intake manifold or severe engine damage will
occur. 2
Install clamps in a way that their tightening bolts
are staggered — not aligned. 1
Throttle Cable Adjustment 3
 WARNING
Ensure the engine is turned OFF, prior to per-
forming the throttle cable adjustment.
Carburetors must be installed on engine and throt-

tle cable properly routed.
For maximum performance, correct cable adjust-
ment is critical.
At full opening throttle slide must be flush or 1.0 mm A00C3FA
(.040 in) lower than the top of carburetor outlet

FULL OPENING (THROTTLE LEVER AGAINST HANDLE GRIP)
bore (engine side). Use a mirror and look through
1. Cover
air silencer. 2. Free play
3. Throttle slide
First loosen adjuster nut then turn throttle cable
adjuster accordingly.
 WARNING
This gap is very important. If the throttle slide
1 rests against the carburetor cover at full throttle
2 opening, this will create too much strain and
may damage the throttle cable or other compo-
nents in throttle mechanism.
Carburetor Synchronization
When depressing throttle lever, both carburetor
slides must start to open at same time.
Unlock cable adjustment lock nut on one carbure-
tor.
Screw or unscrew cable adjuster until all carbure-
A01C3MA tor slides start to open at same time. Cable play
FULL OPENING (THROTTLE LEVER AGAINST HANDLE GRIP) will be identical on all carburetors. Retighten jam
1. Throttle cable adjuster nut.
2. Throttle slide flush or 1.0 mm (.040 in) lower than carburetor
outlet bore (engine side)
04-08-6 MMR2001_083_04-08A.FM
Section 04 ENGINE
A03C2VA 1 2
TYPICAL
1. Screw or unscrew adjuster
2. Check that all slides start to open at the same time
Check throttle slide position at wide open throttle.

Throttle slide must be flush or 1.0 mm (.040 in)
lower than carburetor outlet bore. At that same
position, check that throttle slide does not contact
carburetor cover. Turn cable adjuster and recheck
synchronization.
CAUTION: If the throttle slide rests against the
carburetor cover at full throttle opening, this
will create too much strain and may damage
the throttle cable or other components in throt-
tle mechanism.
CAUTION: Make sure all carburetors start to
operate simultaneously.
Idle Speed Final Adjustment

CAUTION: Before starting engine for the final
justed. The oil injection pump adjustment must
be checked after each time carburetor idle is
adjusted. Refer to OIL INJECTION SYSTEM.
NOTE: Turn adjustment screw the same amount
to keep carburetors synchronized.
CAUTION: Do not attempt to set the idle speed
by using the air screw. Severe engine damage
can occur.
MMR2001_083_04-08A.FM 04-08-7
Section 04 ENGINE
TM Type
PTO MAG
5
4
12
3
6
7
10
8
Loctite 243
11
9 12
13 (Press fit)
Loctite
243 PTO
14
15
16
MAG
18
17
19 22
23
21
24 26
Some
models 25
20
27 Loctite
243
28
29
A32C3JS
31 30
04-08-8 PARTS FLAT RATE MMR2001_083_04-08A.FM

Section 04 ENGINE
IDENTIFICATION 1 2
TM type dual carburetor ass’y is identified on PTO
side carburetor body.
A32C3LA
DPM EQUIPPED MODELS

1. Air temperature sensor
2. DPM air vent hose nipple
1 Non-DPM Models
Disconnect carburetor float bowl vent hose nipple
from air silencer.
A32C3KA
DPM Models
TYPICAL
1. Identification: TM 40-B112
Unhook DPM manifold from its supports.
Remove DPM supports from air silencer.
REMOVAL All Models
All Models Loosen clamps retaining air silencer adapter to
Lift hood. carburetor assembly and remove air silencer.
DPM Models Heated Carburetor Models

Disconnect air temperature sensor connector at Close valve at heated carburetor coolant inlet line.
air silencer.
1 2
Disconnect DPM air vent hose nipple from air sli-
lencer.
A32C2WA
1. Valve
2. Inlet line
MMR2001_083_04-08A.FM 04-08-9
Section 04 ENGINE
Pinch heated carburetor coolant outlet line. Remove dual carburetor assembly, pinch and dis-
connect fuel line. Take care to recuperate fuel.
1 2
 WARNING
Fuel is flammable and explosive under cer-
tain conditions. Always wipe off any fuel or
oil spillage from the vehicle. Ensure work
area is well ventilated. Do not smoke or allow
open flames or sparks in the vicinity.
CLEANING AND INSPECTION

All Models
The entire carburetor should be cleaned with a
A32C2XA
fore disassembly.
1. Pincher (P/N 295 000 076)
2. Outlet line CAUTION: Heavy duty carburetor cleaner may
Disconnect both lines from carburetor assembly parts, O-rings, etc. Therefore, it is recommended
taking care to recuperate coolant. to remove those parts prior to cleaning.
All Models Carburetor body and jets should be cleaned in a
carburetor cleaner following manufacturer’s in-
Disconnect throttle and choke cables.
structions. When jets are very dirty or coated with
Loosen clamps retaining dual carburetor assembly varnish and gum, replace them.
to carburetor sockets.
Gently slid out securing strap.  WARNING
CAUTION: Securing strap between 2 carbure- Solvent with a low flash point such as gaso-
tors has to be gently slid out to avoid breakage. line, naphtha, benzol, etc., should not be used
1
Check throttle slide for wear. Replace as neces-
sary.
Check for fuel soaked into float no. 27; replace as
necessary.
Check float for cracks or other damages affecting
Inspect throttle and choke cables and housings for
any damages. Replace as necessary.
A32C2YA
1. Securing strap
04-08-10 MMR2001_083_04-08A.FM
Section 04 ENGINE
DISASSEMBLY AND ASSEMBLY 24, Starter Jet

NOTE: To ease the carburetor disassembly and Starter jet is part of choke system. Use a wide flat
assembly procedures it is recommended to use screwdriver for disassembly and assembly.
carburetor tool kit (P/N 404 112 000). On some models there is no starter jet no. 24; in-
stead, a hole in float bowl no. 29 acts as a starter
jet.
1 2
A00B2FA
29, Float Bowl

Unscrew drain screw no. 31 and screw no. 30.
Remove float bowl.
Some float bowls have an integrated starter jet
no. 24. In these cases do not mismatch float bowl.
27, Float and Needle Valve Ass’y

Unfasten both screws then, pull out float and nee-
dle valve ass’y no. 27. A32C3MA 4 3
At assembly, apply Loctite 243 on screw threads. 1. Float and needle valve ass’y screws
2. Main jet
3. Pilot jet
23, Main Jet 4. Starter jet located on carburetor body
The main jet installed in the carburetor has been 12, Throttle Slide
selected for a temperature of - 20°C (0°F) at sea
level. Different jetting can be installed to suit tem- Do not disassemble throttle slide needlessly.
perature and/or altitude changes. A Service Bulle- CAUTION: After throttle slide reassembly, pro-
tin will give information about calibration accord- ceed with a leak test. See below for procedure.
ing to altitude and temperature.
Heated Carburetor Models
Main jet no. 23 may be removed without remov-
ing float bowl no. 29 by first removing drain screw Disassemble both carburetors at the same time.
no. 31. At installation, make sure to install brass Coolant hose between carburetor throttle slide
washer no. 22 underneath main jet. covers must remain in place during the complete
disassembly and assembly.
25, Pilot Jet
Use narrow screwdriver from carburetor tool kit
(P/N 404 112 000) to unfasten pilot jet no. 25.
MMR2001_083_04-08A.FM 04-08-11
Section 04 ENGINE
All Models Lift throttle slide covers bottom first until there are
Remove carburetor cover. free from carburetor bodies. Then, slide them out.
Loosen needle retainer screw no. 10.
Move aside needle retainer no. 11. 2
1 1
A32C2OA
Step 1 : Lift bottom first

A32C3NA Step 2 : Slide out
1. Needle retainer moved aside Remove both circlips no. 1 retaining throttle slide.
Turn dual carburetor ass’y upside down to free Take care not to loose plastic washers nos. 2 and 9.
needle no. 8. Take care not to loose plastic washer
1
no. 7 under needle circlip no. 6.
A32C3RA
A32C3PA 2
1. Plastic washer 1. Circlips
2. Plastic washers
Unscrew throttle slide cover no. 19 screws.
Open throttle 3/4 wide and keep that opening.
04-08-12 MMR2001_083_04-08A.FM
Section 04 ENGINE
At throttle slide assembly, needle retainer must

face carburetor body. 1
A32C3SA
A32C3QA
1. Needle retainer 1. Idle speed screw

2. Pilot screw (one on each carburetor)
Float Bowl Ventilation Leak Test Pilot Screw Adjustment

Plug fuel inlet line. Plug other carburetor ventila- Completely close the pilot screw (until a slight
tion nipple. seating resistance is felt) then back off as speci-
Connect a long tube to ventilation nipple on top fied.
side of throttle slide cover. Turning screw in clockwise leans mixture and con-
Float bowl ventilation circuit must hold a vaccum versely, turning it out counterclockwise enrich-
of 600 mm (24 in) of water. ners mixture.
Adjustments should be performed following this Carburetor Synchronization and
sequence: Throttle Slide Height
– pilot screw adjustment
Remove MAG side carburetor cover.
– carburetor synchronization and throttle slide
height (preliminary idle speed adjustment) First proceed on PTO carburetor.
– throttle cable adjustment Using a drill bit to measure throttle slide height
(see following table) on outlet side of carburetor
– choke cable adjustment
(engine side).
– oil pump and carburetor synchronization
– final idle speed adjustment (engine running).
MMR2001_083_04-08A.FM 04-08-13
Section 04 ENGINE
Adjust by turning idle speed screw no. 15. Tighten locking screw and recheck throttle height.
NOTE: By adjusting both throttle slides at same
3 1
height TM carburetors synchronization is done at
same time.
NOTE: Make sure that throttle cable does not hold
throttle slide. Loosen cable adjuster accordingly.
Final idle speed adjustment (engine running at idle
speed) should be within 1/2 turn of idle speed
screw from preliminary adjustment.
THROTTLE SLIDE
MODELS HEIGHT
± 0.2 mm (± .008 in)
MX Z 600
1.8 (.071)
Summit 700
A32C3TA 2 Grand Touring 600
1.8 (.071)
1. Adjust PTO carburetor first
Formula DLX 600/GSE
2. Drill used as a gauge to measure throttle height
3. Idle speed screw Summit 600/800 2.2 (.087)
For MAG carburetor loosen locking screw. Use Formula DLX 700
same drill bit as for PTO carburetor to measure GS/GSE
1.5 (.059)
throttle slide height. Turn adjusting nut to adjust. MX Z 700
Grand Touring 700 GS
3 4 1
MX Z 800 1.7 (.067)
INSTALLATION
shut.
Install dual carburetor assembly making sure to
align securing strap in its bracket.
Make sure dual carburetor assembly is proper-
ly inserted into carburetor sockets, hold it in
place and tighten retaining clamps.
Secure heated carburetor inlet and outlet lines
with clamps, tighten to 1.5 to 2.0 N•m (13 to 18
lbf•in) and remove pincher on outlet line.
A32C3UA 2
Allow coolant to flow from coolant tank to carbu-
1. PTO carburetor adjusted first
2. Drill used as a gauge to measure throttle height retor before opening valve.
3. Locking screw
4. Adjusting nut Connect all hoses to dual carburetor assembly and
to DPM, making sure there is no kinked hoses af-
ter reconnection.
04-08-14 MMR2001_083_04-08A.FM
Section 04 ENGINE
NOTE: Left side DPM hose must be routed under

A
heated carburetor coolant inlet hose.
A32C30A 2 1
1. Left side DPM hose
2. Heated carburetor coolant inlet hose

Adjust throttle cable as per following procedure:
Loosen throttle cable housing adjusting and lock-
A32C33A
ing nuts.
A. Between 0.5 and 1 mm (1/64 and 1/32 in)
Connect throttle cable barrel to carburetor cam le-
ver no. 17. Choke Cable Adjustment
While holding throttle lever to wide open throttle Adjust choke cable as per following procedure:
position, pull on the throttle cable until cam lever
touches the stopper no. 16. In this position, tight- Loosen choke cable housing adjusting and locking
en cable housing adjusting and locking nuts. As a nuts.
confirmation, the gap should be in between 0.5 Connect choke cable on starter lever no. 20.
and 1 mm (1/64 and 1/32 in). While choke lever is fully open, adjust choke cable
until starter lever reaches the stopper. Tighten ca-
ble housing adjusting and locking nuts in this po-
sition.
MMR2001_083_04-08A.FM 04-08-15
Section 04 ENGINE
As a confirmation, the gap between the stopper Idle Speed Final Adjustment
and the bracket should be in between 0 and 0.5 mm
CAUTION: Before starting engine for the final
(0 and 1/64 in).
justed. The oil injection pump adjustment must
be checked after each time carburetor idle is
adjusted. Refer to OIL INJECTION SYSTEM.
CAUTION: Do not attempt to set the idle speed
by using the pilot screw. Severe engine dam-
age can occur.
DPM
A
Some Models
A32C32A
TESTING
A. Between 0 and 0.5 mm (0 and 1/64 in) MPEM
Reinstall air silencer and DPM. Solenoid is supplied by the MPEM. If this MPEM
Reconnect DPM air vent hose at air silencer. does not work, there will be no current on the com-
pensation solenoid.
Make sure dual carburetor assembly properly
slides into air silencer adapters; hold it in place Air temperature sensor must be at room tempera-
and tighten clamps. ture. Operate the engine at 4000 RPM. The sole-
noid must vibrate.
NOTE: DPM must be installed with its protrusion
in higher support slot. Start the engine and observe the solenoid. A vi-
brating solenoid indicates that the MPEM is in
good working order. If not, replace the MPEM and
repeat test.
Solenoid
Static Test
1
Unplug electric connector of solenoid and connect
it to a 12 V battery. The solenoid must sound when
it opens. Repeat test several times.
Dynamic Test
Air temperature sensor must be at room temper-
ature. Operate the engine at 3500 RPM. The sole-
noid must vibrate.
Air Temperature Sensor

A32C31A At room temperature 20°C (68°F), the sensor resis-
1. Protrusion in higher support slot tance must be 2500 Ω ± 300.
Reconnect DPM air vent hose nipple to air silencer.
Reconnect air temperature sensor connector to air
silencer.
04-08-16 MMR2001_083_04-08A.FM
Section 04 ENGINE
PARTS REMOVAL AND Partially insert compensation solenoid into DPM

manifold.
INSTALLATION
1
Solenoid
At reassembly, ensure that solenoid seals are in
place.
A03I0SA
TYPICAL
A06E2OA 1 2 1. Embosses not engaged
1. Plastic seal Insert a 5/32 in drill bit with its round end first into
2. O-rings the transfer gallery.
Installation of compensation solenoid must be done Fully push solenoid into DPM manifold while main-
as follows: taining a pressure on drill bit. This will guide the
Remove transfer gallery plug by pushing 2 tabs. solenoid O-ring.
A03I0RA
1
TYPICAL — CUT-AWAY
1. Drill bit round end guiding solenoid O-ring
A03I0TA
TYPICAL DPM MANIFOLD LEAK TESTING

1. Transfer gallery plug
Disconnect all carburetor venturi hoses from DPM.
Plug one venturi inlet nipple.
Proceed with air tightness test by connecting
tester onto the other nipple; must hold 35 kPa (5 PSI)
vacuum for 10 seconds.
Repair leaks (if any).
Reconnect carburetor venturi hoses to DPM.
MMR2001_083_04-08A.FM 04-08-17
Section 04 ENGINE
FUEL PUMP
All Models
From fuel tank
To
carburetors
Engine impulse
A32C1LS
04-08-18 PARTS FLAT RATE MMR2001_083_04-08A.FM

Section 04 ENGINE
REMOVAL NOTE: Plug remaining outlet with finger while

checking outlet valve.
Install a hose pincer (P/N 295 000 076) on fuel sup-
Check impulse diaphragm and gasket on high-supply
ply line close to pump inlet.
fuel pump with twin outlets as follows:
Connect a clean plastic tubing to the impulse nip-
ple and plug vent hole on top cover on so equipped
models. Either apply pressure or vacuum. The
295 000 076 diaphragm/gasket must not leak.
CLEANING AND INSPECTION

The entire pump should be cleaned with general
purpose solvent before disassembly.
Fuel pump components should be cleaned in gen-
eral purpose solvent and dried with compressed
A01B2JA
air.
Disconnect fuel outlet line(s).  WARNING

Disconnect impulse line. Solvent with a low flash point such as gaso-
Remove screws securing fuel pump to chassis. as each is flammable and explosive.
PUMP VERIFICATION Inspect diaphragm. The pumping area should be
free of holes, tears or imperfections. Replace as
Check fuel pump valves operation as follows:
needed.
Connect a clean plastic tubing to the inlet nipple
and alternately apply pressure and vacuum with INSTALLATION
pump of leak test kit. The inlet valve should re-
lease with pressure and hold under vacuum. Inverse removal procedure.
Repeat the same procedure at the outlet nipple.
This time the outlet valve should hold with pres-  WARNING
sure and also under vacuum. Pressure test to ensure there is no leak in fuel
system.
MMR2001_083_04-08A.FM 04-08-19
Section 04 ENGINE

Fuel Tank 1
After draining fuel tank, unplug fuel line.
1 2
A32I06A
1. Remove these screws

A32I04A
Open storage compartment at rear of seat.
1. Steering column
2. Fuel line Remove nuts and washers retaining rear of seat
then move seat rearward.
Remove console nut using console nut key (P/N
529 035 603). Disconnect taillight connector housing located be-
tween seat and fuel tank.
Remove seat then unbolt rear of fuel tank. Unplug
electric fuel level gauge on so equipped models.
A32I05A 529 035 603
Unscrew console and move it toward front.
A32I07A 2 3
1. Nuts retaining rear of fuel tank removed
2. Connector housing of electric fuel level gauge
3. Connector housing of taillight
MMR2001-084_04_09A.FM 04-09-1
Section 04 ENGINE
Move fuel tank rearward then, unplug vent tube Throttle Cable Circlip at Handlebar
from vent fitting at top front of fuel tank. (all models)
1 Put silicone grease (P/N 293 550 004) around cable
barrel. Locate circlip as per illustration.
 WARNING
If this procedure is disregarded, throttle might
the engine will speed up when starting.
Models with Easy Action Throttle Lever
A32I08A
1. Vent fitting
Fuel Tank Lines

 WARNING
Whenever a fuel line is disconnected, obstruct A20H0BA
line with a hose pincher (P/N 295 000 076) or
TYPICAL
equivalent device. Fuel is flammable and ex-
1. Circlip
plosive under certain conditions. Ensure work
area is well ventilated. Do not smoke or allow Other Models
open flames or sparks in the vicinity.
2
295 000 076 1
3
A01B2JA
A02C0FA 4
TYPICAL
Impulse/Fuel Lines Spring Clips 1. Throttle cable housing
(all models) 2. Throttle handle housing
3. Throttle handle
4. Circlip
prevent possible leaks. Adjust throttle cable as specified in CARBURE-
TOR AND FUEL PUMP.
04-09-2 MMR2001-084_04_09A.FM
Section 04 ENGINE

When turning steering while engine is running,
idle speed must not vary.
Fuel Level Sensor

Inspection
Visually inspect the condition of connectors and
wiring throughout the circuit. Connections must
be clean and tight, and wiring free of damage. Re-
pair as necessary. Use silicone dielectric grease to
prevent corrosion at the connectors. Operate the
engine to see if the problem has been corrected.
Fuse Replacement
A 0.25 ampere fuse protects fuel level sensor cir-
cuitry. Remove seat to gain access.
Fuel Level Sensor Screws

Torque fuel level sensor retaining screws to 1 N•m
(8 lbf•in) in the sequence shown and then to 2.5
N•m (22 lbf•in), using the same sequence.
4 3
2 5
A14C02A
MMR2001-084_04_09A.FM 04-09-3
TABLE OF CONTENTS 0
DRIVE BELT............................................................................................................................ 05-02-1
2001 APPLICATION CHART .............................................................................................. 05-02-1
INSPECTION ...................................................................................................................... 05-02-1
DRIVE PULLEY....................................................................................................................... 05-03-1

TRA ..................................................................................................................................... 05-03-1
GENERAL ........................................................................................................................... 05-03-2
REMOVAL........................................................................................................................... 05-03-2
DISASSEMBLY................................................................................................................... 05-03-2
CLEANING ......................................................................................................................... 05-03-3
INSPECTION ...................................................................................................................... 05-03-4
ASSEMBLY......................................................................................................................... 05-03-4
INSTALLATION .................................................................................................................. 05-03-7
DRIVEN PULLEY.................................................................................................................... 05-04-1

REMOVAL........................................................................................................................... 05-04-2
DISASSEMBLY................................................................................................................... 05-04-2
CLEANING ......................................................................................................................... 05-04-2
INSPECTION ...................................................................................................................... 05-04-3
ASSEMBLY......................................................................................................................... 05-04-3
INSTALLATION .................................................................................................................. 05-04-3
ADJUSTMENT ................................................................................................................... 05-04-3
PULLEY DISTANCE AND ALIGNMENT................................................................................ 05-05-1

GENERAL ........................................................................................................................... 05-05-1
GENERAL PROCEDURE .................................................................................................... 05-05-1
PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART................................. 05-05-2
BRAKE .................................................................................................................................... 05-06-1

HYDRAULIC DISC BRAKE ................................................................................................. 05-06-1
REMOVAL........................................................................................................................... 05-06-2
DISASSEMBLY................................................................................................................... 05-06-2
CLEANING ......................................................................................................................... 05-06-2
INSPECTION ...................................................................................................................... 05-06-2
INSTALLATION .................................................................................................................. 05-06-2
ADJUSTMENT ................................................................................................................... 05-06-3
BLEEDING .......................................................................................................................... 05-06-3
MMR2001_108_05_01ATOC.FM 05-01-1
CHAINCASE............................................................................................................................ 05-07-1
REMOVAL AND DISASSEMBLY ....................................................................................... 05-07-2
INSPECTION ....................................................................................................................... 05-07-2
INSTALLATION AND ASSEMBLY ..................................................................................... 05-07-3
ADJUSTMENT.................................................................................................................... 05-07-4
GEARBOX ............................................................................................................................... 05-08-1

DISASSEMBLY ................................................................................................................... 05-08-2
INSPECTION ....................................................................................................................... 05-08-3
ASSEMBLY ......................................................................................................................... 05-08-3
ADJUSTMENT.................................................................................................................... 05-08-5
OIL CHANGE....................................................................................................................... 05-08-5
DRIVE CHAIN ......................................................................................................................... 05-09-1

SILENT CHAIN.................................................................................................................... 05-09-1
05-01-2 MMR2001_108_05_01ATOC.FM
DRIVE BELT 0
2001 APPLICATION CHART
WIDTH (NEW) MINIMUM WIDTH (WEAR LIMIT)
MODEL PART NUMBER
± 0.25 mm (.010 in) mm (in)
All 493 and 593 engine
equipped models 414 860 700 35.30 (1.390) 32.30 (1.272)
except Summit 600
All 693 and 793 engine
equipped models and 417 300 127 36.35 (1.431) 33.35 (1.313)
Summit 600
INSPECTION
Inspect belt for cracks, fraying or abnormal wear
(uneven wear, wear on one side, missing cogs,
cracked fabric). If abnormal wear is noted, proba-
ble cause could be pulley misalignment, excessive
RPM with frozen track, fast starts without warm-
up period, burred or rusty sheave, oil on belt or
distorted spare belt.
Check the drive belt width. Replace the drive belt
if width is less than the minimum width recom-
mended (see table above).
ROTATION DIRECTION
the drive belt is installed as shown. This will ensure
that correct direction of rotation is respected.
A01D2KA
CORRECT
MMR2001_085_05_02A.FM 05-02-1
To Check Tension
Position a reference rule on drive belt.
Wooden Stick and Spring Scale Method
A00D05A
1. Mark specified deflection
Using spring scale and stick, apply specified force

1
A01D2LA
INCORRECT
NOTE: For used drive belt, mark and reinstall in the 2

same position.
DRIVE BELT DEFLECTION 3

MEASUREMENT
NOTE: The drive belt deflection measurement
must be performed each time a new drive belt is A00D06A
installed.
1. Force
NOTE: To obtain an accurate drive belt deflection 2. Read deflection here
3. Reference rule
period of 50 km (30 mi). Or use the belt tension tester (P/N 414 348 200).
Before checking the belt deflection, ensure vehi- 1 2
cle has the proper belt (refer to the Application
Chart).
Adjust pulley distance and alignment. Refer to
PULLEY DISTANCE AND ALIGNMENT.
A00C07B 4 3
To obtain maximum vehicle performance, the belt
tension must be adjusted according to specifica- 1. Lower O-ring
2. Upper O-ring
tions shown in the accompanying chart. 3. Force (read down)
4. Deflection (read up)
DEFLECTION FORCE HEIGHT† 1. Slide lower O-ring of deflection scale to speci-
MODEL mm kg OVER DRIVEN fied measure.
(in) (lb) PULLEY
2. Slide upper O-ring to 0 (zero) on the force scale.
32 ± 5 11.5 0 - 1.5 mm
All models
(1.260 ± .197) (25) (0 - 1/16 in)
† FOR REFERENCE ONLY
05-02-2 MMR2001_085_05_02A.FM

edge of rule and read force on the upper scale
at top edge of O-ring.
1
- +
3
4 1
A06D20A
TYPICAL
5 1. Allen screw with jam nut
A00D08A
Allen screws must be restrained while tightening
1. Upper O-ring — force jam nut to prevent throwing adjustment out. Use
2. Force
3. Lower O-ring — deflection drive belt tension adjuster (P/N 529 008 700).
4. Reference rule
5. Deflection
Adjust pulley distance according to specification,
refer to PULLEY DISTANCE AND ALIGNMENT.
Adjust drive belt deflection using Allen screws, as
shown.
To increase deflection: turn Allen screws clock-
wise.
To decrease deflection: turn Allen screws counter-
clockwise.
NOTE: Turn Allen screws 1/4 turn at a time, then
rotate driven pulley to allow drive belt to settle in A06D21A 529 008 700
pulley. Check deflection, repeat as required. TYPICAL
MMR2001_085_05_02A.FM 05-02-3
DRIVE PULLEY 0
TRA
All Models
Loctite 271
27 Nm 5
(20 lbfft)
12 Nm
(106 lbfin)
13
14
6 12
11
12
15
Electric start
models only
7 16
9
Loctite
609
Loctite
609 18
33 16 Nm
(142 lbfin)
for 693 ou 793
engine equipped
models
13 Nm
(115 lbfin) 23
Some models
only
25
19
20
28 10 Nm
21 (89 lbfin)
Loctite 22
24
609
Repair kit 30
95 Nm
(70 lbfft)
31
27 25
26
32
29
A32D1AS

GENERAL Remove retaining screw.

To remove drive pulley ass’y and/or fixed half from
Some drive pulley components (return spring,
engine, use puller (P/N 529 022 400).
ramp) can be changed to improve vehicle perfor-
mance in high altitude regions. A service bulletin CAUTION: These pulleys have metric threads.
will give information about calibration according to Do not use imperial threads puller. Always
altitude. tighten puller by hand to ensure that the drive
pulley has the same type of threads (metric vs
CAUTION: Such modifications should only be
imperial) prior to fully tightening.
performed by experienced mechanics since
they can greatly affect vehicle performance. Ver- To Remove Drive Pulley Ass’y:
ify spring specifications before installation. Do Retain drive pulley with clutch holder.
not only refer to the spring color code.
Install puller in pulley shaft then tighten.
NOTE: TRA drive pulley stands for Total Range
Adjustable drive pulley.
DISASSEMBLY
 WARNING 1,2, Screw and Ring Gear
Any drive pulley repairs must be performed by
an authorized Bombardier snowmobile dealer, CAUTION: Retaining screws must be heated be-
or other such qualified person. Subcompo- fore disassembly. Do not exceed 150°C (300°F).
nent installation and assembly tolerances re-
quire strict adherence to procedures detailed. 5,6, Fixed and Sliding Half
CAUTION: Do not tap on governor cup.
REMOVAL Screw puller into fixed half shaft about 13 mm
(1/2 in). Raise drive pulley and hold it by the sliding
30,31, Conical Spring Washer and Screw half while knocking on puller head to disengage
fixed half.
Use holder (P/N 529 006 400).
529 006 400
2
1 2
A16D01A
1. Puller
2. Holding sliding half
A20D06A

TYPICAL
1. Retaining screw
2. Insert in any slot factory mark and arrows as indexing reference.
 WARNING
Never use any type of impact wrench at drive
05-03-2 MMR2001-086_05_03A.FM
32, Cushion Drive Use spring compressor (P/N 529 035 524).
CAUTION: Do not disassemble cushion drive. Install support guide.
Governor cup and cushion drive are factory bal-
anced as an assembly.
25,29, Slider Shoe and Governor Cup

Carefully lift governor cup until slider shoes come 1
and remove slider shoes. Proceed the same way for
A03D3EA
1. Support guide
Install sliding half then a second support guide.

A16D02A These support guides will prevent bushing damages.
1. Hold slider shoes
2. Lift one housing at a time

500) should be used to hold slider shoes prior to 1
removing governor cup.
529 005 500
A03D3FA
1. Support guide
A16B02A
Remove 3 Allen screws retaining spring cover
then unscrew compressor.
It is pushed by clutch spring pressure. CLEANING
 WARNING 5,6, Fixed and Sliding Half

Clutch spring is very strong. Never attempt to Clean pulley faces and shaft with fine steel wool
remove spring cover without the recommend- and dry cloth.
ed tools.
MMR2001-086_05_03A.FM 05-03-3
5, Fixed Half and Crankshaft End CAUTION: Ensure rollers are in good condition.
Parts must be at room temperature before cleaning.
Using a paper towel with cleaning solvent, clean 9,12, Fitting Bolt Ass’y and Flanged
crankshaft tapered end and the taper inside the Bushing
fixed half of the drive pulley, crankshaft threads
and retaining screw threads. Check for wear, replace as required.
 WARNING 24,25, O-Ring and Slider Shoe

This procedure must be performed in a well- Check if O-rings are cracked, cut or crushed. Re-
ventilated area. place as required.
Check slider shoes for wear. Replace if groove is
CAUTION: Avoid contact between cleaner and not apparent on top.
crankshaft seal because damage may occur.
Remove all hardened oil deposits that have baked 5,29, Fixed Half and Governor Cup
on crankshaft and pulley tapered surfaces with Inspect splines and free play between both parts.
coarse or medium steel wool and/or sand paper Maximum free play is 0.5 mm (.020 in) measured
no. 600. at calibration screw radius. Replace if required.
CAUTION: Do not use any other type of abra-
sive. 7,20, Sliding Half and Spring Cover
Reclean mounting surfaces with paper towel and Bushing
cleaning solvent. Visually inspect coating. Replace if worn.
Wipe off the mounting surfaces with a clean, dry Sliding Half Bushing Replacement
paper towel.
This bushing is not replacable. If worn out, replace
CAUTION: Mounting surfaces must be free of sliding half ass’y.
Spring Cover Bushing Replacement
7,20, Bushing Under normal use there is no need to replace this
Only use petrol base cleaner when cleaning bush- bushing.
ings. This bushing is not replacable. If worn out, replace
CAUTION: Do not use acetone to clean bush- spring cover ass’y.
ing.
ASSEMBLY
INSPECTION NOTE: This drive pulley is lubrication free. Do not
Drive pulley should be inspected annually. lubricate any component.
16,17, Thrust Washer and Roller 1,2,3, Screw, Ring Gear and Loctite 271
Check roller for roundness of external diameter. Apply Loctite 271 (P/N 413 702 900) on threads
Check thrust washer for thickness wear. Replace and then torque to 27 N•m (20 lbf•ft).
as required.
05-03-4 MMR2001-086_05_03A.FM

and Locking Nut 30 ± 5°
A16D2PA
A16D07A
1. Washer
Torque locking nut to 10 N•m (89 lbf•in).
15, Pin
Always use the same type of pin as originally in-
ent weights for calibration purpose. Refer to
TECHNICAL DATA.
1 1
21,22,23, Ramp, Dowel Tube and Screw A16D09A
Insert dowel tube from chamfered side. Make 1. Equal distance

sure ramp is centered on dowel tube. Torque screws to 10 N•m (89 lbf•in).
1
9,11,13,14, Screw, Lever Ass’y, Nut and
Cotter Pin
Always install lever assemblies so that cotter pins
are on the shown side. Besides install cotter pin
A16D08A
head on top when lever is sat at bottom of sliding
half. Bend cotter pin ends to sit perfectly against
1. Chamfered side
lever.
Position dowel tube split at the illustrated angle.
 WARNING
Whenever replacing centrifugal levers, al-
ways replace all 3 at the same time. Other-
wise, drive pulley misbalancing will occur be-
cause of levers difference.
MMR2001-086_05_03A.FM 05-03-5
1
5,6,18,19, Fixed Half, Sliding Half,
Spring, Spring Cover and Screw
All Models
2
To install spring cover, use spring compressor (P/N
529 035 524). Align indexing arrows.
Assemble fixed and sliding halves.
A16D0BA
1. Head on top
2. All on the same side
CAUTION: Lever assemblies must be installed

so that cotter pins are on the same side.
Torque nuts to 12 N•m (106 lbf•in).
easily after installation.
A16D0DA
33, Guard 1. Align
Some Models Only Install and torque screws to 13 N•m (115 lbf•in)
for 593 engine equipped models and to 16 N•m
Install guard with its reinforcements in line with le- (142 lbf•in) for 693 and 793 engine equipped
vers. models.
1
Governor Cup
529 005 500
A16B01A
A32D0IA
Insert spring and slider shoes into governor cup so
1. Reinforcements that groove in each slider shoe is vertical to prop-
erly slide in guides.
CAUTION: Make sure O-rings are installed on
slider shoes and their grooves are positioned
vertically.
05-03-6 MMR2001-086_05_03A.FM
Install fork (P/N 529 005 500) into slider shoe INSTALLATION
grooves to maintain them for governor cup instal-
lation. Proceed on 3 set of slider shoes.
 WARNING
Do not apply anti-seize or any lubricant on
crankshaft and drive pulley tapers.
529 005 500  WARNING

Never use any type of impact wrench at drive
Clean mounting surfaces as described in CLEAN-

ING above.
Drive Pulley Ass’y

A16B02A
The installation procedure must be strictly ad-
hered to as follows.
Make sure to align governor cup arrow with sliding
half and fixed half mark. Install drive pulley on crankshaft extension.
NOTE: If fixed half has no mark, align governor Install conical washer with its concave side to-
cup mark with segment no. 1 of inner half. Seg- wards drive pulley then install screw.
 WARNING
Never substitute conical washer and/or screw
1 with jobber ones. Always use Bombardier gen-
Use holder. See removal procedure.

 WARNING
A16D0EA could be thrown out while track is rotating.
1. Align
Carefully slide governor cup into sliding half. Align hicle.
mark of governor cup with mark of fixed half.
Remove forks and push governor cup so that its Accelerate the vehicle at low speed (maximum 30
splines engage with fixed half shaft splines. km/h (20 MPH) and apply the brake, repeat 5 times.
CAUTION: Make sure splines of both parts are Recheck the torque of 90 to 100 N•m (66 to 74
fully engaged. lbf•ft).
MMR2001-086_05_03A.FM 05-03-7
 WARNING 1
After 10 hours of operation the transmission
system of the vehicle must be inspected to en-
sure the retaining screw is properly torqued.
DRIVE PULLEY ADJUSTMENT

maximum engine power at a predefined RPM.
Factors such as ambient temperature, altitude or
surface condition may vary this critical engine
RPM thus affecting snowmobile efficiency. A16D0GA
This adjustable drive pulley allows setting maxi- 1. Position 1 (not numbered)
mum engine RPM in the vehicle to maintain maxi-
Each number modifies maximum engine RPM by
mum power.
about 200 RPM.
Calibration screws should be adjusted so that ac-
Lower numbers decrease engine RPM in steps of
tual maximum engine RPM in vehicle matches
200 RPM and higher numbers increase it in steps
with the maximum horsepower RPM given in
of 200 RPM.
TECHNICAL DATA.
Example:
NOTE: Use precision digital tachometer for en-
gine RPM adjustment. Calibration screw is set at position 3 and is changed
to position 5. So maximum engine RPM is increased
NOTE: The adjustment has an effect on high RPM
by about 400 RPM.
only.
To adjust, modify ramp end position by turning cal- To Adjust:
ibration screws. Just loosen locking nut enough to pull calibration
26,28,29, Calibration Screw, Locking Do not completely remove the locking nut. Torque
Nut and Governor Cup locking nuts to 10 N•m (89 lbf•in).
Calibration screw has a notch on top of its head. CAUTION: Do not completely remove calibration
screw otherwise its inside washer will fall off.
CAUTION: Always adjust all 3 calibration screws
and make sure they are all set at the same num-
ber.
1
A16D0FA
1
1. Notch

Note that in position 1 there is no stamped num-
ber (due to its location on casting).
See TECHNICAL DATA for original setting. A16D0HA
05-03-8 MMR2001-086_05_03A.FM
DRIVEN PULLEY 0
All Models
2
31
1
1
Anti-seize Anti-seize
30 lubricant 1
lubricant
9
10
4
5
6
7
8
2
3
4
5
7 Loctite 6
609
Some models only
Anti-seize
lubricant
9 Loctite
609 18
10 Loctite
21 243
28
29
22
Some models only
A32D16S
24 23

REMOVAL 529 018 600

Remove cap screw no. 12 and shouldered washer
no. 11 then pull the driven pulley from the coun-
tershaft.
tion.
1 2
A30D0IA
Remove snap ring no. 3 and washer no. 4 to dis-

assemble the cam and the two pulley halves.
 WARNING
Driven pulley cam is spring loaded, use above-
A30D0HA
mentioned tool.
TYPICAL
1. Spacer
2. Shoulder on this side CLEANING
1, Countershaft 9,10, Large Bushing and Small Bushing
Should countershaft no. 1 removal be required, During break-in period (about 10 hours of use), te-
refer to BRAKE then look for Countershaft and flon from bushing moves to cam or shaft surface.
Brake Disc Removal. A teflon over teflon running condition occurs, lead-
DISASSEMBLY deposit on cam or shaft. Do not remove that de-
transferred teflon.

05-04-2 MMR2001-087_05_04A.FM
INSPECTION ASSEMBLY
9,10, Bushings 6, Cam Slider Shoe
Check for cracks, scratch and for free movement When replacing slider shoes, always install a new
when assembled to fixed half. set (three shoes) to maintain equal pressure on
Using a dial bore gauge measure bushing diame- the cam.
ter. Measuring point must be at least 5 mm (1/4 in) Assemble driven pulley components by reversing
from bushing edge. the disassembly procedure.
5, Cam
INSTALLATION
1, Countershaft
A03D1OA
DRIVEN PULLEY BUSHING WEAR LIMIT
mm (in)
Small bushing 38.30 (1.508) ADJUSTMENT
Large bushing 89.15 (3.510) Refer to PULLEY DISTANCE AND ALIGNMENT to
6, Slider Shoe driven pulley to obtain specified belt deflection.
Turn Allen screws no. 10 equally accordingly.
Check cam slider shoes for wear. Replace when
inside edge of cam slider shoe slope base is worn 7, Spring
to 1 mm (.039 in) or less.
General
It is usual to experience spring setting during
break-in period of a new spring. The factory spring
2 preload is slightly higher (about 1 kg (2 lb)) to com-
pensate for spring setting. Specifications in TECH-
NICAL DATA are applicable after break-in period
1
(about 10 hours of use).
3
Spring Torsional Pre-Load
A15D0OA
To check spring pre-load adjustment, use spring
1. Measure thickness of slope base here scale hook (P/N 529 006 500) and a spring scale.
3. Slope base Remove drive belt.
MMR2001-087_05_04A.FM 05-04-3
Install the hook on the sliding half. Preventing

C
fixed half from turning, pull sliding half with the
spring scale perpendicularly with pulley axle. A
Take 1st measurement when sliding half begins to
turn. Rotate sliding half to 10 mm (3/8 in) of rota-
tion. Hold fish scale at this position. Slowly release 32
54 1
tension from fish scale and take 2nd measurement 6
when sliding half begins to return. Spring pre-load
is the average measurement between these
two.
1st
2nd B
measurement
+ measurement Spring A18C0AA
(when
(when closing) = pre-load
opening) TYPICAL
2 Letters and numbers shown in illustration are actual letters and
numbers embossed on parts
3.8 kg 3.4 kg 3.6 kg NOTE: Always recheck torsional pre-load after ad-
(8.4 lb) (7.5 lb) (8 lb) justing.
+
Example: (when (when = Actual
opening) closing) spring Pulley Alignment and Drive Belt
2 pre-load Deflection
Refer to PULLEY DISTANCE AND ALIGNMENT
and DRIVE BELT to perform adjustments.
1
CAUTION: Drive belt and pulley adjustments
must always be checked whenever pulleys
2 529 006 500 have been removed, replaced or disassembled.
5, Cam
CAL DATA.
Cam angle is identified on cam.
1
2
3
A01B18A
4
TYPICAL
Step 1 : 1st measurement
5
Step 2 : 2 nd measurement 44°
To adjust spring pre-load, relocate spring end in

6
cam, moving it clockwise to increase the pre-load

and counterclockwise to decrease it. Refer to
BO
TECHNICAL DATA. BA
M
RD
NOTE: If spring pre-load can not be adjusted, try IER
to relocate the other end of spring in sliding pulley A24D06A
(holes A, B and C).
NOTE: For high altitude regions, a service bulletin
altitude.
05-04-4 MMR2001-087_05_04A.FM

The pulley distance we will refer to in this section, Remove 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). driven pulley. Insert a straight bar 9.5 mm (.375 in)
This basic distance is provided as an assembly square, 48 cm (19 in) long or the proper alignment
guide and indicates the dimensions between template into the opened driven pulley.
which satisfactory belt deflection will be obtained.
Both pulley distance adjustment and pulley align- Measuring Procedure
ment must be carried out to ensure the highest Using Straight Bar
efficiency of the transmission system. Further-
Always measure distances X and Y from the far-
more, optimum drive belt operation and minimal
ther straight bar side (including its thickness to the
fixed half edge).
ment.
CAUTION: Before checking pulley adjustment, Y
the rear suspension must be mounted on the ve-
hicle and track tension/alignment must be done.
Always check pulley adjustment after suspen-
sion is adjusted.
 WARNING X Z

may cause the vehicle to creep forward at
idle. 2
All Pulley Alignment Specifications Refer to:

X = Distance between straight bar and drive pul- A00D0WA
1
ley fixed half edge, measured between pul-
leys. TYPICAL
1. Straight bar
Y = Distance between straight bar and drive pul- 2. Front of vehicle
The distance Y must exceed distance X to com-
straight bar.
pensate for the twist due to the engine torque.
Z = Distance between outside diameter of pul-
leys. Drive Belt Deflection
requirements, refer to the proper ENGINE or
MMR2001_088_05_05A.FM 05-05-1

PULLEY
OFFSET ALIGNMENT
DISTANCE
TEMPLATE
MODEL Z X Y-X
➀
± 0.50 mm ± 0.50 mm ± 0.5 mm P/N
(.020 in) (.020 in) (.020 in)
16.5 35.50 1.5
All 529 026 700
(.650) (1.398) (.060)
➀ Alignment templates have been made according to pulley alignment nominal values. However, they
do not take into account allowed tolerances for alignment specifications. They are used as GO/NO GO
gauges for quick alignment and pulley distance check and as templates to reach alignment nominal
values.
NOTE: Prior to performing pulley adjustment,
Y loosen torque rod nut to allow engine movement.
Engine supports have tendency to stick to frame,
work engine loose prior to aligning.
1
X Z
A15D02A 2
TYPICAL
1. Engine movement
2. Contact
A32D12A 2 1
1. Loosen lock nut first
2. Loosen
Pulley Distance Adjustment Method

Engine Movement
The engine support has slotted mounting holes.
Move engine to obtain specified distance be-
tween pulleys.
A32D11A
ALIGNMENT BAR IN PULLEYS
05-05-2 MMR2001_088_05_05A.FM
Pulley Alignment Method

Engine Movement
frame. Position engine to obtain the specified
alignment.
NOTE: After alignment, adjust torque rod so it
slightly contacts stopper plate. Do not over tight-
en, it will disalign pulleys.
A32D12B 1 2
1. Slightly tighten
2. Retighten
MMR2001_088_05_05A.FM 05-05-3
BRAKE 0
HYDRAULIC DISC BRAKE
DOT 4
37 Nm 10
(27 lbfft)
7
5
Except 493 engine
type equipped models
Except 493
engine type
equipped
8 models
9
1 493 engine
type equipped
models only
2 Anti-seize 3
lubrifiant
493 engine
type equipped
models only
6
Anti-seize 4
lubrifiant
Loctite
243
22 Nm
A32D1BS (16 lbfft)

REMOVAL CAUTION: Do not clean brake pads in solvent.

Soiled brake pads must be replaced by new ones.
All Models
BRAKE DISC REMOVAL INSPECTION
Brake disc can be withdraw without removing
chaincase. Proceed as follows:
1, Brake Pad
– Remove belt guard, belt and driven pulley. Brake pads must be replaced when lining is 1 mm
(1/32 in) thick or less.
– Unbolt bearing support no. 4 from chassis. in pairs.
– Unbolt caliper from chaincase.
493 Engine Type Equipped Models
– Pull countershaft ass’y no. 3 toward driven pul-
ley side to get access to clip no. 6 on counter-
shaft. A
A32D1CA
TYPICAL
2, Brake Disc
Check for scoring, cracking or bending, replace as
required.
A03D11A
TYPICAL
INSTALLATION
All Models
To install brake, reverse removal procedure paying
– Pull countershaft no. 3 toward driven pulley attention to the following.
side to free from chaincase and disc.
– Remove disc.  WARNING
Avoid getting oil on brake pads.
DISASSEMBLY
Only brake pads are available as spare parts. If cal- 10, Upper Clamp
iper or master cylinder are damaged, replace each Install upper clamp with its arrow pointing at front
of them as an assembly. of vehicle. Tighten to 8 N•m (71 lbf•in) front screw
before rear one.
CLEANING
sembling.
05-06-2 MMR2001-089_05_06A.FM
Torque castellated nut of upper sprocket to 60 N•m

2 1
(44 lbf•ft).
CAUTION: Upper sprocket castellated nut must
be tightened before bolting bearing support.
Close chaincase.
Install countershaft bearing no. 4 and ensure that
countershaft is properly aligned, then tighten 3 re-
taining screws.
BLEEDING
Change brake fluid once a year.
Keep sufficient DOT 4 brake fluid in reservoir at all
times.
A03D3QB
CAUTION: Use only DOT 4 brake fluid.
1. Arrow on upper clamp pointing at front of vehicle
2. Tighten front screw first Install a hose on left side bleeder. Route this hose
to a container.
8,9, O-Ring and Spacer Pump a few times brake lever and while holding
All Models except 493 Engine Type Equipped brake lever depressed, open left side bleeder and
Models check for air to escape.
Make sure that O-ring and spacer are inserted into Repeat with the same bleeder until no air appears
chaincase upper oil seal before reinstalling coun- in hose.
tershaft. Proceed the same way with the right side bleeder.
2, Brake Disc 1
Apply anti-seize lubricant (P/N 413 701 000) on shaft.
The disc hub exceeds the disc more from one side
than from the other. Install disc with the longer
exceeding portion toward driven pulley.
1,7, Brake Pads and Caliper

Each time a new caliper or new brake pads are
installed, proceed with the following:
– With caliper not bolted to chaincase, apply brake A06D0JA 2
few times until both new pads are touching each
TYPICAL
other.
1. Open bleeder
– Push back pads and repeat above step. 2. Clear hose to catch used brake fluid
– Push back pads then fasten caliper to chaincase. 5, Brake Light

– Proceed with bleeding as described below.
ADJUSTMENT
Countershaft Bearing
Insert countershaft (with brake disc) from chain-
MMR2001-089_05_06A.FM 05-06-3
CHAINCASE 0
Stamped end this side
2 12
Loctite 271
17 Nm
(150 lbfin)
7 Nm 1
(62 lbfin)
793 engine
type equipped
models
Synthetic
grease Synthetic
chaincase Anti-seize lubricant
oil Except between frame
42 Nm 493 engine and nuts
(31 lbfft) type
22 equipped 25 Nm
Synthetic grease models
23 (18 lbfft)
10
8 9 7 Loctite
271 25 Nm Loctite
Synthetic (18 lbfft) 271
grease 11
13 Sealed 19 25 Nm
side (18 lbfft)
493 5 6
engine
type 42 Nm 14
equipped (31 lbfft)
models 18 17 20
Synthetic
chaincase oil
4 Sealed
3 Loctite
side
271 14
4 Nm 42 Nm 21
15 44 Nm (35 lbfin) 24 (31 lbfft)
(32 lbfft) 16
A32D18S

REMOVAL AND DISASSEMBLY Pry out drive axle oil seal no. 19 from chaincase.
Pull chaincase from drive axle and countershaft.
To remove chaincase proceed as follows.
Using 2 large prybars inserted between chaincase
Remove tuned pipes and muffler.
housing no. 7 and frame, pry complete assembly
 WARNING from vehicle.
gine is hot.
Remove hair pin no. 8. Release drive chain ten-

sion by unscrewing tensioner adjustment screw.
Drain oil by removing drain plug no. 24.
3,4,5,6,13,16,17, Cotter Pin, Nut,

Sprocket, Shim and Drive Chain
Apply parking brake.
Remove cotter pin no. 3 and nut no. 4 retaining
upper sprocket no. 5 and screw no. 15 retaining
A32D0KA
lower sprocket no. 16. Pull sprockets and drive
chain simultaneously. Remove shims nos. 6 and 17. CHAINCASE HOUSING REMOVAL
NOTE: Should countershaft removal be required,

refer to BRAKE then look for Countershaft Re- INSPECTION
moval. Visually inspect the chain for cracked, damaged or
Release parking brake. missing links. Check for worn or defective bear-
Remove 3 nuts no. 14. ings, sprockets and chain tensioner components.
Unfold locking tab no. 23 then remove caliper re-
taining screws no. 22.
 WARNING
If chain deflection is greater than 38 mm (1.5 in)
Release track tension, use drive axle holder no. 20 (without chain tensioner), replace chain and
(P/N 529 007 200). check condition of sprockets.
GEAR RATIO MODIFICATION

For particular applications, the number of teeth of
the sprockets can be increased or decreased on
lower and upper sprockets.
Refer to TECHNICAL DATA for gear ratios.
529 007 200
2 CAUTION: Gear ratio modifications should
only be performed by experienced mechanics
since they can greatly affect vehicle perfor-
mance.
NOTE: For high altitude regions, a Service Bulletin
1 altitude.
A32D0LA
1. Drive axle
2. Suspension front arm upper axle
05-07-2 MMR2001-090_05_07A.FM
INSTALLATION AND ASSEMBLY 4, Upper Sprocket Castellated Nut

Reverse removal and disassembly procedure and Torque to 45 to 75 N•m (33 to 55 lbf•ft).
pay attention to the following. Replace oil seals, gas- Install new cotter pin in the position shown.
kets O-rings and drain plug. CAUTION: When removing a cotter pin always
replace with a new one.
25, Hardened Washer
CAUTION: Cotter pin will rub on chaincase cov-
793 Engine Equipped Models Only er if installed otherwise.
Make sure to install a hardened washer on each
end of spring.
1
2
A02D08A
1. New
18, Circlip
CAUTION: It is of the utmost importance to in-
A32D19A 1
1. Hardened washers DRIVE CHAIN ADJUSTMENT
All Models NOTE: Brake disc key must be in good condition
11, Oil Seal
Using an appropriate pusher, press the oil seal into 10, O-Ring
chaincase hub. Oil seal must fit flush with the chain- Replace O-ring no. 10 on tensioner adjustment
case edge. screw. Fully tighten tensioner adjustment screw
NOTE: Should installation procedure for counter- by hand, then back off only far enough for hair pin
shaft be required, refer to BRAKE. to engage in locking hole.
This initial adjustment should provide 3 - 5 mm
5,16, Sprockets (1/8 - 13/64 in) free-play when measured at the
Position the sprockets with the writing facing the outer circumference of the brake disc.
chaincase cover. Sprocket hub faces toward chain- CAUTION: Free-play must not exceed 5 mm
case. (13/64 in), readjust if necessary.
 WARNING
If the specified free-play is not reached with
the tensioner screw fully tightened, replace
MMR2001-090_05_07A.FM 05-07-3
21, Chaincase Oil

Pour 250 mL (8.5 U.S. oz) of synthetic chaincase
oil (P/N 413 803 300) into chaincase.
NOTE: Chaincase oil capacity is 250 mL (8.5 U.S. oz).
Check oil level with the dipstick then add if re-
quired. Remove metal particles from magnet.
2 3
4
A32D02A
TYPICAL
1. Dipstick
2. Oil level
4. Magnet
NOTE: Chaincase must be in its proper position

when checking oil level.
ADJUSTMENT
Pulley Alignment
Refer to PULLEY DISTANCE AND ALIGNMENT.

Refer to TRACK.
05-07-4 MMR2001-090_05_07A.FM
GEARBOX 0
Grand Touring 500/600/700 and Formula Deluxe 500/600/700
29
3 15 21
19
23
20
4 5
Synthetic
chaincase 18
oil 22
3 24
16
Lithium
grease
17
493 engine type
equipped models
15 Nm 39
8 Except
(133 lbfin) 7 6 25 493 engine type
equipped models
493
engine type 11 Lithium
equipped models 27 grease
Anti-seize
13 lubricant
12 30 between
frame
26 14 and nuts
9 Seal on
Stamped this side
10 25 Nm
end this side (18 lbfft)
45 to 75 Nm
(33 to 55 lbfft) 34 35 36 Loctite
Loctite 271 2 271
17 Nm(150 lbfin) 38
33 1 42 Nm
32 (31 lbfft)
4 Nm
28 (35 lbfin)
40
37
31 5 Nm
(44 lbfin)
A32D17S Loctite 271

DISASSEMBLY Unscrew cover screws no. 5 as well as reverse

axle screw no. 7.
Disconnect negative cable from battery if so equipped.
Separate cover no. 6 from housing and move it
Drain gearbox oil by removing drain plug no. 1. toward the front in order to disengage fork from
Remove tuned pipe, muffler and muffler grommet. sliding gear.
Remove battery then, battery rack if so equipped.
1
A32D0QA 1
1. Battery rack
Unfasten tie rod from shifter.

A15D1VA 2
TYPICAL
1. Fork
2. Sliding gear
A32D0RA 1
1. Tie rod
A32D0SA
GEARBOX COVER REMOVED
05-08-2 MMR2001-091_05_08A.FM
Loosen chain tension, unscrew sliding gear retain- INSPECTION

ing screw no. 31, then remove sliding gear no. 32.
14, Chain Slider
Replace slider if maximum wear is 1.0 mm (.039 in)
at contact point.
Bearings
Check bearing condition. There must be no discol-
oration, missing rollers, broken cages, etc.
Sprockets and Gears

Check teeth.
ASSEMBLY
A32D0TA 1 2 3 Reinstall gearbox housing.
1. Retaining screw Sealed side of bearings nos. 2 and 27 must face
2. Sliding gear
3. Reverse axle gearbox cover.
Remove 19-tooth reverse gear no. 18 then remove Do not reuse removed oil seals. Replace them
reverse axle no. 20. with new ones.
Remove coupling shaft no. 33, 44-tooth sprocket Install bearing no. 2 and circlip in chaincase bore.
no. 34, spacer no. 38 and chain no. 28. Temporary install spacer no. 38 with its large outer
First unscrew castellated nut no. 10, then remove diameter against sprocket, 44-tooth sprocket
22-tooth sprocket no. 12. no. 34, coupling shaft no. 33, cap no. 40 and
screw no. 31.
Force 2 spring pins no. 16 out to disengage fork
no. 17 from its axle. Place a 25 cm (10 in) rule against sprockets. Max-
imum allowable offset is 1 mm (.040 in).
Install drive axle holder (P/N 529 007 200) before
removing gearbox housing. a. If upper sprocket is too far in, possible causes
are:
1. Countershaft bearing on driven pulley side
may be too far in. To check, pull out bearing
then recheck sprocket alignment. Reposition
bearing. Bearing housing (triangle) must be
against frame without preload.
2. Add shim(s) between chaincase and frame
529 007 200 and reposition bearing on driven pulley side
2 accordingly.
b. If upper sprocket is too far out, check:
If there are too many shims between chaincase
and frame. Remove shims accordingly and re-
position bearing on driven pulley side.
Press needle bearing in 44-tooth sprocket. As-
1
semble drive pins no. 35 and their spring no. 36
on 44-tooth sprocket. Tighten nut no. 37 to 5 N•m
(44 lbf•in) in a criss-cross sequence.
A32D0LA
1. Drive axle
2. Suspension front arm upper axle
MMR2001-091_05_08A.FM 05-08-3
Insert spring pin no. 21 in reverse axle up to inside

diameter. Press needle bearing in 19-tooth sprock- 1
et. Install ring no. 24 and 19-tooth sprocket on re-
verse axle.
A15D1WA
1. Reverse axle ass’y

2. Sliding gear ass’y
Install shim no. 13 and 22-tooth sprocket (drive)

A15D1VB 2
no. 12 then tighten castellated nut no. 10 and
conical spring washer. Secure with a new cotter 1. Fork tabs
pin. 2. Thrust washer
Install chain no. 28, 44-tooth sprocket no. 34 and CAUTION: Gearbox cover must lay completely
its spacer no. 38. Spacer’s large outer diameter against housing.
must be against sprocket. Insert coupling shaft
no. 32 in 44-tooth sprocket. 5,7,8,39, Screws, Locking Tab and
Install needle bearing no. 15 (wider one) in re- Copper Washer
verse gear no. 18. Tighten screws in a criss-cross sequence starting
Install reverse axle no. 20 (assembly) making sure with the one above reverse axle. Install reverse
to properly position spring pin in housing slot. In- axle screw, copper washer and bend locking tab
stall alignment rod no. 19, reverse gear no. 18 and against screw head flat.
spacer no. 24. Drive sprocket hole and driven gear
hole must be aligned to insert alignment rod.
Mount chain tensioner (assembly) to adjustment
screw already fixed to gearbox. Assemble fork
no. 17 to axle using spring pins no. 16. Apply
grease on O-rings.
6, Cover
Join cover (assembly) to housing. Make sure fork
tabs are behind sliding sprocket thrust washer.
A32D0UA 1 2
1. Reverse axle screw
2. Copper washer
05-08-4 MMR2001-091_05_08A.FM
Bolt tie rod to shifter. 6. Hold linkage and tighten ball joint jam nut.
29, Alarm Switch

Adjust backup alarm switch so that buzzer sounds
when transmission is in reverse gear while engine
is running.
OIL CHANGE
Place a container under bottom pan (gearbox side).
Remove drain plug.
NOTE: It is normal to find metallic particles stuck
to dipstick magnet. If bigger pieces of metal are
A32D0VA
found, disassemble and check all parts.
Fill gearbox with Bombardier synthetic chaincase
oil (P/N 413 802 800 — 12 x 250 mL). Oil capacity
ADJUSTMENT is 250 mL (8.5 oz).
Check oil level with dipstick. With dipstick un-
28, Chain screwed, oil level must be between MIN. and
Fully tighten adjustment screw by hand, then back MAX. marks.
off only far enough for hair pin to engage in locking
hole.
4, Gear Shift Linkage

1. Check proper fit of handle in console.
2. Shift into forward gear.
3. Loosen ball joint lock nuts on the tie-rod.
4. Lengthen tie-rod until distance between upper
ball joint screw head and stopper is 0 to 0.3 mm
(0 to .012 in).
2 3
A
4
A32D0WA
A32D02A
A. 0 to 0.3 mm (0 to .012 in)
TYPICAL
NOTE: It is normal to feel a light friction when 1. Dipstick
shifting into gear. 2. Oil level
5. Statically test transmission operation in forward 4. Magnet
and reverse positions.
MMR2001-091_05_08A.FM 05-08-5
DRIVE CHAIN 0
SILENT CHAIN
There are 2 types of silent chains. One is 11-plates
wide and the other is 13-plates wide (stronger). Do
not interchange chains. Fit chain on sprockets to
make sure that you are using right one according
to width. Refer to TECHNICAL DATA.
done on the silent chain type.
MMR2001-092_05_09A.FM 05-09-1
TABLE OF CONTENTS 0
IGNITION TIMING ................................................................................................................. 06-02-1
NIPPONDENSO TRIGGER COIL SYSTEM........................................................................ 06-02-1
SPARK PLUGS....................................................................................................................... 06-03-1

NGK SPARK PLUG............................................................................................................. 06-03-1
DISASSEMBLY................................................................................................................... 06-03-3
HEAT RANGE ..................................................................................................................... 06-03-3
FOULING ............................................................................................................................ 06-03-3
BATTERY................................................................................................................................ 06-04-1
BATTERY TESTING ........................................................................................................... 06-04-1
REMOVAL........................................................................................................................... 06-04-1
CLEANING ......................................................................................................................... 06-04-1
INSPECTION ...................................................................................................................... 06-04-1
BATTERY STORAGE ......................................................................................................... 06-04-1
INSTALLATION .................................................................................................................. 06-04-2

REMOVAL........................................................................................................................... 06-05-2
DISASSEMBLY................................................................................................................... 06-05-2
CLEANING ......................................................................................................................... 06-05-4
INSPECTION ...................................................................................................................... 06-05-4
RELAY ................................................................................................................................ 06-05-6
ASSEMBLY......................................................................................................................... 06-05-6
INSTALLATION .................................................................................................................. 06-05-7
MMR2001_108_06_01ATOC.FM 06-01-1
TESTING PROCEDURE .......................................................................................................... 06-06-1

GENERAL............................................................................................................................ 06-06-1
SYSTEM TESTING ............................................................................................................. 06-06-4
1. SPARKING ...................................................................................................................... 06-06-4
3. IGNITION SWITCH, TETHER CORD SWITCH AND EMERGENCY SWITCH TESTING 06-06-5
4. IGNITION GENERATOR COIL TESTING ....................................................................... 06-06-5
5. TRIGGER COIL TESTING ............................................................................................... 06-06-6
6. MPEM VOLTAGE TESTING ........................................................................................... 06-06-6
7. HIGH VOLTAGE COIL TESTING .................................................................................... 06-06-6
CONCLUSION..................................................................................................................... 06-06-7
LIGHTING GENERATOR COIL VOLTAGE TESTING ........................................................ 06-06-7
CONCLUSION..................................................................................................................... 06-06-7
INSPECTION OF AC CIRCUIT INSULATION ..................................................................... 06-06-10
INSPECTION ....................................................................................................................... 06-06-10
06-01-2 MMR2001_108_06_01ATOC.FM
IGNITION TIMING 0
NIPPONDENSO TRIGGER COIL
SYSTEM
Normally ignition timing adjustment should not be
required. It has been set at factory and it should
remain correctly adjusted since every part is fixed
and not adjustable. The only time the ignition tim-
ing might have to be changed would be when re-
placing the crankshaft, the magneto flywheel, the
trigger coil or the MPEM. If the ignition timing is
found incorrect, first check for proper crankshaft
alignment. This might be the indication of a twist-
ed crankshaft.
The ignition timing can be checked with either the
engine hot or cold. Also, the ignition timing is to
be checked at 3500 RPM with a timing light.
NOTE: Between 3000 and 4000 RPM, the spark
advance does not change. So when checking igni-
tion timing at 3500 RPM, a change in engine
speed within ± 500 RPM will not affect the timing
mark when checked with the timing light.
IMPORTANT: During the first 8 hours (4 hours on
Summit models) the timing curve is retarded by 3°
between 4500 RPM and maximum RPM. Be-
cause checking ignition timing is done at a lower
RPM, this will not affect the 3500 RPM timing
specification. There will be no further timing ad-
justment required before and after these hours.
No tools were available at printing time for timing
procedure.
MMR2001-093_06_02A.FM 06-02-1
SPARK PLUGS 0
NGK SPARK PLUG
All Models

SYSTEM
snowmobile models.
Low number hot plug

MMR2001-094_06_03A.FM 06-03-1

10: 1.0 mm (.040")
B R 9 E S 15
11: 1.1 mm (.044")
13: 1.3 mm (.050")
14: 1.4 mm (.055")
15: 1.5 mm (.060")
20: 2.0 mm (.080")

A: 18 mm E: 19 mm
2 Hot
Special Alloy
Seat
C: 10 mm 4
E: 8 mm 5 L: 11.2 mm
(7/16")
G: Racing Type
J: 12 mm x 19 mm
of V-Type
6 (53/54")
L: Half Heat Range
Construction 7
S: Standard
Electrode
Center
P: Projected
Insulator Type
Electrode
18 mm ø 12 mm
R: Resistor Type
9
(3/8")
Y: V-Grooved
Electrode
Center
Z: Inductive
Suppressor Type
10 Cold
A00E4NS

A01E1PS
06-03-2 MMR2001-094_06_03A.FM
DISASSEMBLY A too hot plug will result in overheating and pre-

ignition, etc.
Clean the spark plug and cylinder head with pres- spark plug) or may create carbon build up which
surized air, then completely unscrew. can heat up red-hot and cause pre-ignition or det-
onation.
 WARNING
Whenever using compressed air, always wear FOULING
Fouling of the spark plug is indicated by irregular
running of the engine, decreased engine speed due
HEAT RANGE to misfiring, reduced performance, and increased
fuel consumption. This is due to a loss of compres-
The proper operating temperature or heat range of sion. Other possible causes are: prolonged idling, or
the spark plugs is determined by the spark plug running on a too rich mixture due to a faulty carbure-
ability to dissipate the heat generated by combus- tor adjustment or incorrect fuel and/or fuel mixing.
tion. The plug face of a fouled spark plug has either a dry
The longer the heat path between the electrode coating of soot or an oily, glossy coating given by an
tip to the plug shell, the hotter the spark plug op- excess either of oil or of oil with soot. Such coatings
erating temperature will be — and inversely, the form a conductive connection between the center
shorter the heat path, the colder the operating electrode and ground.
temperature will be.
A cold type plug has a relatively short insulator SPARK PLUG ANALYSIS
der head.
prolonged idle or low speed operation. A00E0AA 1 2 3
3. Fouled (black)
The plug electrode and piston dome reveal the con-

dition of the engine, operating condition, method
1 2 of driving and fuel mixture. For this reason it is ad-
visable to inspect the spark plug at regular inter-
vals, examining the plug electrode and the piston
dome.

A00E09A
1. Cold grime.
2. Hot
CAUTION: Severe engine damage might occur if cording to TECHNICAL DATA.
a wrong heat range plug is used. 2. Apply anti-seize lubricant (P/N 293 800 070) over
the spark plug threads to prevent possible seizure.
MMR2001-094_06_03A.FM 06-03-3
3. Hand screw spark plug into cylinder head and tight-

en with a torque wrench and a proper socket.
1 2
A00E0BA
1. Proper socket
2. Improper socket

TORQUE
SPARK TORQUE
MODELS
06-03-4 MMR2001-094_06_03A.FM
BATTERY 0
BATTERY TESTING INSPECTION
There are 2 types of battery tests: unloaded and Visually inspect battery case for cracks or other
loaded. An unloaded test is made on a battery possible damage. If case is damaged, replace bat-
without discharging current. It is the simplest and tery and thoroughly clean battery support and
commonly used. However, be aware that the volt- close area with water and baking soda.
age test can be good while the battery has not
enough power to start the engine. A load test  WARNING
gives more accuracy of the battery condition. Should the battery casing be damaged, wear
a suitable pair of non-absorbent gloves when
Unload Test removing the battery by hand.
Check charge condition using a multimeter.
Inspect battery posts for security of mounting.
With a multimeter, voltage readings appear in-
stantly to show the state of charge. Always re-
spect polarity. A fully charged battery will have a BATTERY STORAGE
reading of 12.6 Vdc. Disconnect and remove battery from the vehicle.
Load Test The battery must always be stored in fully charged
condition.
This is the best test of battery condition under a
starting load. Use a load testing device that has an Clean battery terminals and cable connections us-
adjustable load. ing a wire brush. Apply a light coat of dielectric
grease (P/N 413 701 700) or petroleum jelly on ter-
Apply a load of 3 times the ampere-hour rating of minals.
the battery. After 14 seconds check battery volt-
age; if battery is in good condition, it will have at Clean battery casing and caps using a solution of
least 10.5 Vdc. baking soda and water. Rinse battery with clear
water and dry well using a clean cloth.
REMOVAL Store battery on a wooden shelf in a cool dry place.
Such conditions reduce self-discharging to a mini-
 WARNING mum.
Check for full charge condition every 40 days. Re-
Battery BLACK negative cable must always
charge battery as required.
be disconnected first and connected last.
ACTIVATION OF NEW BATTERY
 WARNING
Never charge or boost battery while installed  WARNING
on vehicle.
Unfasten battery retaining strap. on vehicle.
Withdraw battery from vehicle. CAUTION: Prior to charging the battery, always
remove it from the vehicle.
CLEANING Connect a 10 A battery charger for a few hours.
Clean the battery, battery casing, cables and bat- NOTE: It is recommended to verify the battery
tery posts using a solution of baking soda and wa- charge once a month. If necessary, fully charge
ter. battery.
Remove corrosion from battery cable terminals
and battery posts using a firm wire brush.  WARNING
MMR2001-095_06_04A.FM 06-04-1
INSTALLATION
Position battery onto battery support on vehicle.
Fasten battery retaining strap making sure that
negative cable is positioned as illustrated.
A32E09A
1. Negative cable under battery strap
 WARNING
Always connect the battery cables exactly in
the specified order. Connect RED positive ca-
ble first, then BLACK negative ground cable.
Apply silicone dielectric grease (P/N 413 701 700)

on battery posts and connectors.
LAST.
06-04-2 MMR2001-095_06_04A.FM
ELECTRIC STARTER 0
ZX Series with Electric Starting
2
1 3
4
5 4 7
9
17 8
11
12
10 17
13
15 18
19
16
19
A32E0LS
MMR-2001-096_06_05A.FM PARTS FLAT RATE 06-05-1

REMOVAL
 WARNING
nect last.
– Remove tuned pipe.

– Disconnect RED cable and RED/GREEN wire
from starter relay.
– Disconnect ground cable from MAG side bracket.
A19E01A
– Unbolt starter from PTO side bracket.
– Unbolt MAG side bracket from engine. TYPICAL
– Remove starter from engine. Twist screwdriver to separate stop collars no. 12
thus giving access to circlip no. 13.
Remove outer collar, circlip then inner collar.
Remove overrunning clutch no. 11.
shaft and the bushing.
If greater, replace the bushing. To replace, press
out the old one toward bushing cover and press in
a new one with a bushing pusher. The correct size
of the bushing pusher to use is given on next illus-
tration.
A32E0MA
DISASSEMBLY
A
Disconnect bare wire linking starter and relay.
Remove nuts no. 16 then relay no. 10 by lifting
and pulling to disengage from drive lever no. 15. B
Unscrew starter screws (long) no. 1 then pull yoke
no. 8 with end frame no. 2 to separate from drive
housing no. 17.
C
Pull armature no. 9 with drive lever no. 15.
Remove insulator no. 4 then brush springs no. 7
being careful not to lose them since they will be A19E0AA
D
projected out.
BUSHING PUSHER
Pull brush holder no. 5 from yoke no. 8. A. 16 mm (5/8 in) diameter
B. 13 mm (1/2 in)
Insert blade of a small screwdriver between stop C. 11 mm (7/16 in)
collars. D. 11.0 mm (.433 in)
06-05-2 MMR-2001-096_06_05A.FM

1 If greater, replace bushing as follows:
Using a 12 mm tap, cut threads into bushing so
that the tap contacts the end frame. Continue to
rotate tap until the bushing comes free.
2
1
2
4
A19E03A
A19E0BA
1. Turn until bushing goes out

1. Press-in
2. Bushing pusher 2. 12 mm tap
3. Bushing
4. Drive housing To install new bushing, use the same bushing
pusher as for drive housing bushing installation.
Install bushing cover no. 19 then, using a punch,
stake bushing cover in place. 6, Brush
To replace brush no. 6, proceed as follows:
Cut brush wire close to connector at the welded
portion.
A19E02A
2
A19E05A
1. Stake bushing cover
2. Support 1. Cut close to connector
3, Bushing (end frame) Remove burrs with a file on the remaining welded
portion.
the amount of radial play between the armature CAUTION: Be careful not to damage plastic por-
shaft and the bushing. tion of yoke.
Place spare brush plate edge against yoke connec-
tor edge (welded portion).
Crimp plate over yoke connector with a pair of pliers.
MMR-2001-096_06_05A.FM 06-05-3
INSPECTION
Armature
1 NOTE: An ohmmeter may be used for the follow-
ing testing procedures, except for the one con-
cerning the shorted windings in the armature.
Check the commutator for roughness, burnt or
scored surface. If necessary, turn the commutator
on a lathe, enough to remove grime only.
2 4 Check the commutator for mica depth. If the
depth is less than 0.20 mm (.008 in), undercut the
mica. Be sure that no burrs are left and no copper
3 dust remains between the segments after the un-
A19E06A
dercutting operation is completed.
1. Plate edge
2. Yoke connector
3. Crimp
4. Spare brush
Solder the crimped portion. 1

CAUTION: Do not overheat and quickly per-
form soldering to prevent solder from flowing
to the brush through the wire. Preferably use a F01H0RA
heat sink.
1. Commutator undercut 0.20 mm (.008 in)
CLEANING AND INSPECTION Check the commutator out-of-round condition

with V Blocks and an indicator. If the commutator
CLEANING out-of-round is more than 0.40 mm (.016 in), the
commutator should be turned on a lathe.
CAUTION: Armature starter yoke ass’y and drive Check commutator outer diameter. If less than
unit assembly must not be immersed in cleaning specified value, replace.
solvent.
Clean brushes and holder with a clean cloth soaked
in solvent. Brushes must be dried thoroughly with
a clean cloth.
Blow brush holder clean using compressed air.
 WARNING
Always wear safety goggles when using com-
pressed air.
Remove dirt, oil or grease from commutator using

a clean cloth soaked in suitable solvent. Dry well A03E06A
using a clean, dry cloth.

Clean engine starter gear teeth and drive unit MODEL WEAR LIMIT
(clutch).
ZX SERIES 27 mm (1.063 in)
NOTE: Bushings must not be cleaned with grease
dissolving agents.
Immerse all metal components in cleaning solu-
tion. Dry using a clean, dry cloth.
06-05-4 MMR-2001-096_06_05A.FM
Test for Ground Circuit in the Armature: Test the Armature for Open Circuit:
Use growler test probes. Check between arma- Use growler test probes. Place one test probe on
ture core and the commutator bars. If growler a commutator bar and the other test probe on the
lamp turns on, bars are grounded. If so, replace neighboring bar. Repeat this operation for all bars,
armature. moving one test probe at a time. If the growler
lamp does not turn on, the armature circuit be-
tween these 2 bars is opened. The armature should
1 be replaced or repaired; open circuits most often
occur at the commutator riser where coils are sol-
dered. (Burnt commutator bars are usually an indi-
cation of an open-circuit armature coil).
Field Windings and Brushes

Test the Field Winding for Open Circuit:
Use growler test probes. Place one test probe on
the negative brush and the other test probe on the
yoke. If growler lamp does not turn on, the field
winding has an open-circuit. The yoke has to be
2 repaired or replaced.
A09E08A
1. Test probes
2. Commutator bars
Test Armature for Shorted Winding:

When the armature is rotated in the growler with 1
a steel strip (hacksaw blade) held above it, the
strip will vibrate over that area of the armature
which has short circuit. Replace armature if so.
A09E0AA
1. Test probes
Check the dynamic brake winding for open circuit

by placing one test probe on the positive brush
and the other probe on the negative brush.
If growler lamp does not turn on, the winding cir-
2 cuit is open-circuit and the yoke has to be repaired
or replaced.
A09E09A
1. Steel strip (hack-saw blade)

2. Growler
Brush Holder
Check the brush holder for insulation using growl-
er test probes. Place one test probe on the insu-
lated brush holder and the other test probe on the
brush holder plate. If the growler lamp turns on,
the brush holder has to be repaired or replaced.
MMR-2001-096_06_05A.FM 06-05-5
Brush Length ASSEMBLY

Measure brush length. If less than the specified Prior to assembling, coat sliding surfaces and
value, replace them. moving parts on armature shaft splines, overrun-
ning clutch, relay plunger, drive lever and bushings
LENGTH
with 10W30 engine oil.
MODEL WEAR
NEW Proceed as follows for assembling.
LIMIT
Secure drive housing in a vise.
10 mm 6 mm
ZX SERIES
(.400 in) ( .236 in)
CAUTION: Do not overtighten since housing
might be damaged.
Install overrunning clutch onto armature shaft. In-
sert inner collar onto shaft. Install a new circlip.
CAUTION: Always install a new circlip when ser-
vicing.
1 2 Insert outer collar being careful to match protru-
sions with notches of collars.
Using a pair of pliers on each side of stop collars,
squeeze evenly until collars sit over circlip.
A03E05A
1
TYPICAL
1. New
2. Wear limit
Overrunning Clutch
The pinion of the overrunning clutch should turn
smoothly in a clockwise direction, and should not A19E07A
slip in a counterclockwise direction. If defective,
replace. 1. Squeeze evenly
Check the pinion teeth for wear and damage. If Install thrust washer against outer stop collar.
defective, replace. Place drive lever onto overrunning clutch then in-
sert into drive housing.
RELAY
Inspect connections and clean as necessary. Re-
lay condition can be checked with an ohmmeter.
1
Install test probes on large connectors of relay
when it is activated (+ on RED/GREEN wire and –
on relay body).
IMPORTANT: No current must be present on
large cables when using ohmmeter, otherwise
meter could be damaged.
A19E08A 2
1. Install on overrunning clutch
2. Install thrust washer
06-05-6 MMR-2001-096_06_05A.FM
Slide yoke over armature. INSTALLATION

Install brush holder then brushes in their housings.
Install carriage bolt in MAG side bracket before in-
Insert springs as follows: place one end of spring
stalling starter.
against brush, compress, then push the other end
of spring onto its housing. Repeat for remaining
springs.
2
1
A32E0NA 1
1. Carriage bolt must be in place before starter installation
A19E04A Make sure that starter and engine mating surfaces

1. This end first
2. Push this end to complete er is not properly aligned.
Secure insulator over brushes and springs. Prop- CAUTION: Make sure that both starter brackets
erly install end frame and tighten screws. are well seated against engine crankcase and
starter before torquing all retaining bolts.
Insert relay plunger inside of drive lever fork and
secure to drive housing. Torque all M8 bolts to 29 N•m (21 lbf•ft).
Connect starter bare wire to relay. Torque all M6 bolts to 11 N•m (97 lbf•in).
NOTE: Connect this wire on the shorter relay NOTE: Check proper engaging depth of starter
stud. pinion teeth to ring gear teeth (see illustration). In-
stall hardened washers (P/N 503 007 900) be-
tween engine and starter supports accordingly.
CAUTION: Always install new self-locking fas-
teners.
1
2
A19E09A
TYPICAL
1. Shorter stud
2. Bare wire
MMR-2001-096_06_05A.FM 06-05-7
A09E0PA A
2. Ring gear
A. 0.5 to 1.5 mm (.020 to .060 in)
Connect the RED battery cable and the RED wire

to the large terminal of the relay. Connect RED/
GREEN wire to small terminal of relay.
Connect BLACK cable to MAG side bracket.
 WARNING
nect last.
06-05-8 MMR-2001-096_06_05A.FM
TESTING PROCEDURE 0
GENERAL CAUTION: Engine must run till the end of the pro-
cedure.
The following chart gives the engine types with their
implemented system.
the engine at 2000 - 2500 RPM and make sure
CHARGING connection between programmer and vehicle is
ENGINE IGNITION good.
SYSTEM
TYPE SYSTEM
OUTPUT IMPORTANT: In following procedure each time
493, 593, 693 BOMBARDIER Trs symbol appears, make sure to rev engine
290 between 2000 and 2500 RPM.
and 793 290 W
Engine will misfire while vehicle information is be-
ing transferred from MPEM to programmer. If en-
Multi-Purpose Electronic Module gine stalls, restart it, keep engine speed at 2000 -
(MPEM) Connections 2500 RPM and select no. 3 VEHICLE INFO again.
With Engine Stopped
All Models
Connect 9-volt adaptor (P/N 529 035 675) to MPEM.
A32E0WA 1 2 3 4 5 6 7
TYPICAL — BOMBARDIER 290 W MPEM
1. Generating coil and ground, 11-DB housing
2. Trigger coil, 11-DC housing
3. DPM solenoid, 11-DG housing
5. High tension coil, 11-DD housing
6. Air temperature sensor, 11-DF housing
7. DESS, ignition and kill switches, DESS pilot lamp, 11-DA housing
Checking Calibration Program

A32E13A 529 035 675
CAUTION: Do not interchange MPEM from a
model to an other. Even if the P/N stamped on Turn on programmer then enter password.
the MPEM is the same, calibration program
may be different. When ordering a new MPEM From main menu select no. 3. VEHICLE INFO;
always refer to appropriate model parts cata- Trs.
log. The service P/N published in parts catalogs
are the ones with the good calibration program
according to model.
1. CHECK KEYS
With Engine Running 2. PROGRAM KEY
All Models >3. VEHICLE INFO
4+ S TA RT V E H .
If the below mentionned tool is not available start
engine. Turn on programmer then enter password.
A30E1XA
Increase engine speed to 2000 - 2500 RPM then fol-
MMR2001_097_06_06A.FM 06-06-1
Vehicle information is transferred from MPEM to And then following screen showing the actual cal-
programmer. ibration number in the MPEM.
TRANSFER C A L I B R AT I O N N U M B E R
PGMR MPEM XXX XXX XXX
MODIFY?
YES >NO
A30E1YA A30E2JA
NOTE: In fact the programmer takes a copy of all Check for proper calibration number. See table be-
vehicle parameters scribed in MPEM. This copy low.
will be modified within the programmer then trans- Select NO and press ENTER.
ferred to the MPEM.
Press MENU twice; Trs then turn off program-
Select no. 4. ENGINE PARAMETER. mer, unplug it from MPEM. Remove 9-volt adaptor.
Stop engine when using With Engine Running pro-
cedure.
1. CUSTOMER NAME
CALIBRATED
2. D E L I V E R Y D AT E MPEM P/N CALIBRATION
PROGRAM MPEM P/N
3. VEH. SERIAL# MODEL (HARDWARE NUMBER (HARDWARE)
AND
>4+ E N G I N E PA R A M . SOFTWARE) (SOFTWARE)
Grand Touring 500
A30E1ZA Formula DLX 500 515 175 380 512 059 137 512 059 201
MX Z 500 STD/TRAIL
Select no. 3 CALIBRATION. Grand Touring 600
MX Z 600 STD/TRAIL 512 059 300 512 059 299 512 059 201
Formula DLX 600
MX Z 600
ADRENALINE/X 512 059 298 512 059 299 512 059 202
1. TIMING ADJUST Summit 600 512 059 296 512 059 297 512 059 353
2. ENGINE SERIAL# Formula DLX 600 GSE 512 059 298 512 059 299 512 059 202
> 3 . C A L I B R AT I O N MX Z 700 STD/TRAIL 512 059 383 512 059 384 512 059 201
Grand Touring 700 GS
Formula DLX 700
A30E2IA
GS/GSE 512 059 385 512 059 384 512 059 202
MX Z 700
ADRENALINE/X
Press ENTER Trs. Summit 700
STD/X/H.M./H.M X 512 059 380 512 059 381 512 059 382
Following screen appears temporarily:
MX Z 800 STD 512 059 387 512 059 432 512 059 201
MX Z 800
ADRENALINE/X 512 059 431 512 059 432 512 059 202
Summit 800
VERIFY STD/X/H.M. X
512 059 360 512 059 361 512 059 382
PGMR MPEM
A30E2BA
06-06-2 MMR2001_097_06_06A.FM
Changing MPEM Calibration Program

Proceed the same as for checking MPEM calibra-
tion but select YES to MODIFY? and press ENTER VERIFY
following screen appears: PGMR MPEM
ENTER
C A L I B R AT I O N N U M B E R A30E2BA
XXX XXX XXX

PRESS ENTER
A00A5NA O P E R AT I O N
SUCCESSFULL
Enter new calibration number and press ENTER,
following screen appears: P R E S S A N Y K E Y. . .
A00A3EA
PLUG-IN KEY Press any key, display will show followed by next
TO END: screen:
PRESS ANY KEY
1. TIMING ADJUST
A00A5OA 2. ENGINE SERIAL #
Simultaneously with the following operation a
transfer will occur; Trs. At this point, be ready A00A5YA
to rev the engine so it won’t fall below the 2000
RPM mark when not using 9-volt adaptor. Press MENU twice, following screen will show:
Plug-in the desired calibration cartridge (special
red key) onto the programmer post, the following
screens will appear temporarily:
1. CHECK KEYS
2. PROGRAM KEY
>3. VEHICLE INFO
TRANSFER 4+ S TA RT V E H .
+
VERIFY A30E1XA
After procedure is completed, ensure engine idle

A00A41A
speed with engine hot is 1800 - 2000 RPM.
Stop the engine.
TRANSFER
PGMR MPEM
A00A42A
MMR2001_097_06_06A.FM 06-06-3
SYSTEM TESTING Resistance Readings

In the case of ignition problems, check the follow- CAUTION: When taking measurements, it is
ing in the prescribed order until the problem can useless to try to start the vehicle since readings
be solved. would then be distorted.
3. Ignition switches, DESS switch and emergency intermittent ignition problems. Thus, problems oc-
switch. curring only when the engine operating tempera-
4. Ignition generator coil. ture is normal must be checked in similar condi-
tions.
5. Trigger coil.
6. MPEM voltage.
7. High voltage coil. replacing parts. Most problems cannot be detect-
ed when the engine is stopped.
LIGHTING SYSTEM TESTING Multiple Problems
SEQUENCE As a matter of fact, more that one component can
1. Electrical connectors. be defective. As a result, if the problem remains
2. Magneto output (lighting generator coil). although a part was replaced, start over the whole
Testing Conditions the other defective component.
Voltage measurements are always taken upon ve- 1. SPARKING

hicle starting. Readings when the engine is running
will be higher than indicated range. Part tempera- During this operation, it is important to use the
ture must be approximately 20°C (68°F) (room tem- snowmobile spark plug and not a new one. Bring
perature), otherwise readings could be distorted. the plug in contact with the engine. Pull rewind
starter. If no spark is produced, replace the spark
Analysis of Readings plug with a new one and do the test again.
Voltage Readings
it is important to take into consideration that read- TESTING
ings vary according to the force applied onto the Make sure that none of the connectors are discon-
manual starter. It is therefore important to employ nected.
fective and must be replaced.
06-06-4 MMR2001_097_06_06A.FM
3. IGNITION SWITCH, TETHER Disconnect all switches from the main wiring har-
ness and check the continuity of each wire by con-
CORD SWITCH AND necting probes to the end of wires of the same
EMERGENCY SWITCH TESTING color. Repeat with all other wires. It is important
Disconnect connector housings from MPEM and to mention that all wires of the same color within
check resistance as indicated in IGNITION table. a given harness are connected together. These
wires should therefore have a closed circuit. On
the other hand, BLACK and BLACK/YELLOW
wires must have an open circuit (0.L MΩ).
Repair or replace if necessary.
4. IGNITION GENERATOR COIL

TESTING
Resistance Testing
1. Disconnect housing between the magneto and
the MPEM.
2. Connect multimeter probes to WHITE and RED
wires and measure resistance.
A32E0XA

switch as follows.
DESS Switch
Tether Cord Switch
Check using a multimeter by connecting probes to
BLACK/GREEN and BLACK/WHITE wires. The
multimeter should indicate a closed circuit (0 Ω) in
operating position and a open circuit (0.L MΩ) in off
position.
A32E0YA
DESS Switch Wire
Check continuity (null resistance) between switch 3. Compare readings with those appearing in the
center terminal and WHITE/GRAY wire connector. IGNITION table.
Check continuity (null resistance) between switch
side ring and BLACK/GREEN wire connector. Voltage Testing
If readings do not correspond to the above men- When manually starting the engine while the
tioned indications, replace switch. spark plug is installed, the engine will tend to ac-
celerate beyond the compression point. This will
If none of these verifications are conclusive, the result in higher magneto output power.
ness. Proceed as follows: 1. Disconnect housing between the magneto and
the MPEM.
NOTE: For the next step, no switch must be con-
nected to the main wiring harness. 2. Connect multimeter probes to BLACK/RED and
RED wires and bring the selector switch to Ṽ and
the scale to 00.0VAC.
MMR2001_097_06_06A.FM 06-06-5

IGNITION table.
5. TRIGGER COIL TESTING

Resistance Testing
1. Connect probes to WHITE/YELLOW and BLUE/
YELLOW wires from trigger coil housing.
A32E0ZA
TYPICAL

IGNITION table.
7. HIGH VOLTAGE COIL TESTING

Resistance Testing
A32E10A
1. Unplug housing between high tension coil and
2. Compare readings with those appearing in the MPEM.
IGNITION table. 2. Connect multimeter probes to WHITE/BLUE and
BLACK wires and measure resistance.
Voltage Testing
1. Connect probes to WHITE/YELLOW and BLUE/
YELLOW wires from trigger coil housing.
IGNITION table.
6. MPEM VOLTAGE TESTING

1. Disconnect the housing between module and
high voltage coil. A32E12A
2. Connect multimeter probes to WHITE/BLUE and

BLACK wires coming out from module. Place 3. Compare readings with those appearing in the
the selector switch to Ṽ and the scale to 00.0Vac. IGNITION table.
06-06-6 MMR2001_097_06_06A.FM
Voltage Testing LIGHTING GENERATOR COIL

1. Disconnect spark plug cap from spark plug. VOLTAGE TESTING
2. Fasten alligator clip to spark plug cable, near the NOTE: For 290 W system, the lighting generator
spark plug. coil is not part of the ignition system. It is a self-
3. Connect other multimeter wire to engine (ground), contained system used to supply current to the
then place selector switch to Ṽ and scale to lighting system and to other devices working on
0.00Vac. alternating current. However, this system can be
tested using a multimeter.
1 2
1. Disconnect round housing from engine (YEL-
LOW, YELLOW wires).
2. Connect multimeter probes to YELLOW wires,
then place selector switch to Ṽ and scale to
0.00Vac.
A32E11A
1. MAG side spark plug cable

2. Connected to ground

IGNITION table.
A05E0EA
CONCLUSION TYPICAL
If none of the above testing operations produced 5. Compare readings with those appearing in the
valid results, it is strongly recommended to keep LIGHTING table.
Resistance column of the IGNITION table. CONCLUSION
Set the multimeter as indicated. If none of the above testing operations produced
Resistance column of the LIGHTING table.
MMR2001_097_06_06A.FM 06-06-7
IGNITION SYSTEM TESTING (ZX SERIES — 290 W)

MULTIMETER RESISTANCE Ω VOLTAGE V
TEST TO BE WIRE
PART PERFORMED COLOR PROBE VALUE MULTIMETER VALUE MULTIMETER NOTE
CONNECTION (OHMS) SCALE (VOLTS) SCALE
BK and 11-DB-C-F 00.0 MΩ No stop switch must be in run
Running insulation BK/YL 11-DA-3-F 0.L — — position.
Ignition and
kill switches Continuity in stop BK and 11-DB-C-F Only one stop switch must be in run
00.0 - 00.5 00.0 Ω — —
position BK/YL 11-DA-3-F position. Test one at a time.
BK/GN
Insulation in stop and 11-DA-2-F 0.L 00.0 MΩ — — Tether cord cap should be off.
position 11-DA-1-F
BK/WH
DESS switch
BK/GN 11-DA-2-F
Running continuity and 00.0 - 00.5 00.0 Ω — — Tether cord cap should be in place.
BK/WH 11-DA-1-F
RD 11-DB-A-F 00.0 Ω
Output 11.6 - 21.6 15.0 - 30.0 00.0Vac —
and BK/RD 11-DB-B-F
Ignition BK 11-DB-A-F 00.0 ΜΩ
generator Coil insulation and RD 11-DB-C-F 0.L — — —
coil 11-DB-C-F The term “engine” refers to the
BK and 00.0 Ω
Ground continuity engine and 00.0 - 00.5 — — engine metal parts connected to the
engine magneto housing.
WH/YL
Trigger coil Resistance and and 11-DC-2-F 190 - 300 00.0 Ω .200 - .350 —
output 11-DC-1-F .000Vac
BL/YL
MPEM Output WH/BL 11-DD-1-F — — 25.0 - 100.0 No switch must be in run position and
voltage and BK 11-DD-2-F 00.0Vac tether cord cap must be in place.
Primary winding WH/BL 11-DD-1-F 00.0 Ω
00.0 - 00.9 — — —
resistance and BK 11-DD-2-F
All 493 and 593
engines and 693 on PTO spark
DLX and GT: plug cap
17.6 K - 00.0 KΩ
Secondary and In spark plug caps 26.4 K
winding resistance MAG spark
(spark plug wires and plug cap
caps included)
793 engine and 693 PTO spark
on Summit and MX Z:
Secondary plug cap 14.5 K -
and In spark plug caps 00.0 KΩ
winding resistance MAG spark 23.5 K
(spark plug wires and
caps included) plug cap CAUTION: Do not measure high voltage coil output voltage oth-
erwise multimeter will be damaged.
All 493 and 593
High voltage
coil engines and 693 on
DLX and GT: BK and In spark plug 00.0 KΩ
Secondary winding BK wires 9.6 K - 14.4 K
resistance (without
spark plug cap)
793 engine and 693
on Summit and MX Z:
Secondary winding On high voltage 00.0 KΩ
resistance (without — coil 9.6 K - 14.4 K
spark plug wire
and cap)
The measurement must be taken on
Secondary winding BK and On spark the MAG spark plug wire, MAG spark
plug wire — — 0.2 - 2.0 0.00Vac
voltage engine and on engine plug cap disconnected but PTO spark
plug cap installed on its spark plug.
Spark plug In spark plug cap 00.0 MΩ
Insulation cap and BK 11-DD-2-F 0.L — — —
All 493 and 593
engines and 693 on Spark plug
Spark plug DLX and GT: — side and 4.0 K - 6.0 K 00.0 KΩ — — —
cap
Cap wire side
resistance
M: Male F: Female
manual starter.
06-06-8 MMR2001_097_06_06A.FM
LIGHTING SYSTEM TESTING (ZX SERIES — 290 W)
MULTIMETER RESISTANCE Ω VOLTAGE V
TEST TO BE WIRE
PART PERFORMED COLOR PROBE VALUE MULTIMETER VALUE MULTIMETER NOTE
CONNECTION (OHMS) SCALE (VOLTS) SCALE
YL and 2-MO-B-F
Output and 00.1 - 00.4 00.0 Ω 0.5 - 2.0 00.0Vac —
YL 2-MO-C-F
Lighting 2-MO-(B,C)-F
Coil YL and 00.0 MΩ
generator insulation engine and 0.L — —
coil engine The term “engine” refers to the
engine metal parts connected to
2-MO-A-F the magneto housing.
continuity engine and 00.0 - 00.5 — —
engine
M: Male F: Female
MMR2001_097_06_06A.FM 06-06-9
INSPECTION OF AC CIRCUIT
INSULATION
If AC circuit is not insulated from frame, headlamp
beam will weaken.
INSPECTION
Disconnect regulator/rectifier.
Connect one digital ohmmeter probe (needle ohm-
meter will not offer enough precision) to frame and
other probe to YELLOW wire (2-MO).
Measured resistance must be infinite. If such is
not the case, it means there is a connection be-
tween AC circuit and frame.
Disconnect one accessory at the time to identify
the faulty circuit.
INSPECTION OF HEATING
ELEMENTS
All measurements must be performed at 21°C
(70°F).

Current Measurement
HIGH 0.23 A
BROWN wire
INTENSITY minimum
LOW 0.13 A
BROWN /YELLOW wire
INTENSITY minimum
Handlebar Grip Heating Element

LOW YELLOW /BLACK wire 17.7 to

INTENSITY ORANGE/VIOLET wire 20.7 ohms
HIGH YELLOW /BLACK wire 8.73 to
INTENSITY ORANGE wire 10.67 ohms
06-06-10 MMR2001_097_06_06A.FM
TABLE OF CONTENTS 0
SC-10 II SUSPENSION .......................................................................................................... 07-02-1
SUSPENSION ASSEMBLY REMOVAL ............................................................................. 07-02-4
BOSS SHOCK ABSORBER SERVICING ........................................................................... 07-02-7
HPG T/A SHOCK SERVICING............................................................................................ 07-02-8
INSTALLATION .................................................................................................................. 07-02-15
RIDE ADJUSTMENT.......................................................................................................... 07-02-15
LUBRICATION .................................................................................................................... 07-02-15
SC-10 MOUNTAIN SUSPENSION ........................................................................................ 07-03-1

COMPONENT REMOVAL AND INSTALLATION .............................................................. 07-03-4
SUSPENSION ASS’Y REMOVAL ...................................................................................... 07-03-5
HPG T/A SHOCK SERVICING............................................................................................ 07-03-8
INSTALLATION .................................................................................................................. 07-03-8
RIDE ADJUSTMENT.......................................................................................................... 07-03-8
LUBRICATION .................................................................................................................... 07-03-8
DRIVE AXLE........................................................................................................................... 07-04-1

REMOVAL........................................................................................................................... 07-04-2
ASSEMBLY......................................................................................................................... 07-04-3
LUBRICATION .................................................................................................................... 07-04-4
ADJUSTMENT ................................................................................................................... 07-04-4
TRACK .................................................................................................................................... 07-05-1

GENERAL ........................................................................................................................... 07-05-1
INSPECTION ...................................................................................................................... 07-05-1
REMOVAL........................................................................................................................... 07-05-1
INSTALLATION .................................................................................................................. 07-05-1
MMR2001_108_07_01ATOC.FM 07-01-1
SC-10 II SUSPENSION 0
SC-10 II
13
24 Nm
(18 lbfft) 7
48 Nm
(35 lbfft)
10 Nm
(89 lbfin)
2.5 Nm 4 Nm

11
A32F1US

3 Nm (27 lbfin)
14
14
12
24 Nm
(18 lbfft)
12
85 Nm
(63 lbfft)
Synthetic
grease 5
6
16
15
17
24 Nm
(18 lbfft)
Synthetic
grease 17
85 Nm
Synthetic 16 (63 lbfft)
grease 6
A32F1VS

Formula DLX 600 GSE/700 GSE
24 Nm
(18 lbfft)
48 Nm
(35 lbfft)
Synthetic grease 24 Nm 18
(18 lbfft)
48 Nm
(35 lbfft)
1
80 Nm
(59 lbfft)
1
8
Europe
80 Nm only
(59 lbfft)
2
Synthetic
grease
3 2 48 Nm
(35 lbfft)
48 Nm
(35 lbfft) Synthetic
4 grease
7 Nm
(62 lbfin)
7 Nm
(62 lbfin) 3
85 Nm
10 (63 lbfft)
4
48 Nm
A32F1MS (35 lbfft)

SUSPENSION ASSEMBLY – Remove the opposite self-locking screw.

REMOVAL – Remove the temporary installed non-self-locking
screw.
19, Cam – If it doesn’t work, heat bolt head to melt thread-
Decrease spring preload by turning cams accord- locker.
ingly. Remove rear arm top axle self-locking screws no. 5
Slightly turn adjusting cam to expose spring end. from chassis.
Using spring installer (P/N 529 005 000), remove Lift rear of vehicle at least 1 m (3 ft).
both springs from adjusting cams.
A32F10A
TYPICAL

529 005 000 front arm to tunnel.
Remove suspension.
A03F2FB
TYPICAL

1,2,3,4,5,6, Self-Locking Screws

CAUTION: These self-locking screws must al-
are removed.
NOTE: To prevent axle from turning when un-
A32F11A
– Remove one self-locking screw then install a
Torque as specified in exploded view.
07-02-4 MMR2001_98_07_02A.FM
DISASSEMBLY AND ASSEMBLY 17, Block

Inspect track thoroughly before reinstalling sus- Both blocks are identified R or L (right or left), see
pension. Refer to TRACK. second following photo. At installation, make sure
to install proper block on proper side.
7, Outer Bushing Also, note that protrusion must be positioned above
At installation, hole must face adjustment screw. stoppers.
A32F15A 1 2
A32F12A
1. Protrusion
2. Stoppers
13,14, Center Rear Wheel and Top Idler 15,16, Dowel Pin and Block Guide
Wheels
Dowel pin must exceed block guide by 2 to 2.3 mm
At installation, circlip must face inner side. (.079 to .091 in).
1 At installation, insert dowel pin into pivot arm hole.
A32F13A
1. Circlip facing inner side A32F14A 2 1 3

LEFT SIDE SHOWN
1. Dowel pin
2. Pivot arm hole
3. “L” identification for left side
MMR2001_98_07_02A.FM 07-02-5
8,9, Front Shock and Spring Stopper 11, Slider Shoe

Use shock spring remover (P/N 529 035 504) and Molding line is the wear limit indicator.
2
A03F3SA 1 2
TYPICAL
1. Slider shoe
2. Molding line (wear limit indicator)

in pairs.
3
12, Spring Support
CAUTION: To avoid track damage, spring sup-
ports must be mounted upward.
A01B4LA
1. Clevis pin 1
2. Bar
10, Stopper Strap

Inspect strap for wear or cracks, bolt and nut for
Replace as required. Make sure it is attached through
proper holes. Torque nut to 7 N•m (62 lbf•in).
A03F0VA 2
TYPICAL — RIGHT SIDE SHOWN
A32F17A A 2. Wrong position
07-02-6 MMR2001_98_07_02A.FM
BOSS SHOCK ABSORBER

SERVICING
Formula DLX 600 GSE and 700 GSE
Only the actuator can be replaced.
Remove actuator retaining screws.
Connect actuator black wire (connector no. 3) to a
12-volt battery negative post.
To select COMFORT position apply positive to yel-
low wire (connector no. 2) for one second. Actua-
tor shaft must be in following position.
A32F1TA
SHOCK ABSORBER INSPECTION

All Models Equipped with Hydraulic Shock
NOTE: Hydraulic shocks are painted black or dark
gray.
Secure the shock body end in a vise with its rod
upward.
A32F1QA 2 1
COMFORT POSITION — SHAFT SLOT IN LINE WITH WIRE 1
HARNESS
1. Shaft
2. Wire harness
To select SPORT position apply positive to blue

wire (connector no. 1) for one second. Actuator
A14F0BA
shaft must be in following position.
1. Clamp

press the piston several times over its entire stroke.
Check that it moves smoothly and with uniform
resistance with its rod upward.
A32F1RA 2 1 mid travel.
SPORT POSITION — SHAFT SLOT ABOUT 45° FROM WIRE – Seizing or binding condition except at extreme
HARNESS
1. Shaft
2. Wire harness – Oil leakage.
Replace actuator otherwise. – A gurgling noise, after completing one full com-
When reassembling actuator to shock body align pression and extension stroke.
shaft slot with valve tip. Wire harness must face Renew if any faults are present.
shock body end.
MMR2001_98_07_02A.FM 07-02-7
All Models Equipped with Gas Pressurized SHOCK SIZE SERVICING TOOL
Shock
NOTE: Gas pressurized shocks are light gray or pur- Piston guide
ple painted, or bare aluminum. 529 026 600
Gas shock can be inspected as follows: Seal guide

C-36
529 026 500
when compressing shock. When released, the Shock wrench
shock will extend unassisted. Renew as required. 529 035 727
If suspecting an internal gas leak between oil cham- Piston guide
ber and gas chamber, check shock as follows: 529 035 608
Install shock in a vise clamping on its bottom eye- Seal guide
let with its rod upward. C-46
529 035 728
Shock wrench
Completely push down the shock rod then re- 529 035 727
lease.
Rod must come out at a steady speed. If speed Release N2 (nitrogen) pressure on any HPG T/A
suddenly increases particularly at end of exten- shock with internal floating piston (IFP).
sion, replace shock.
 WARNING
All Types of Shock Nitrogen gas is under extreme pressure. Use
If suspecting a frozen shock proceed as follows: caution when releasing this gas volume. Pro-
Place shock in a freezer (temperature below 0°C tective eye wear should be used.
Push down on rod and note its resistance. If shock All T/A Shock Types
is frozen it will be impossible or almost impossible Mount shock in a vise.
to compress it.
Tire Valve Type Shock
HPG T/A SHOCK SERVICING Remove tire valve cap and push on center rod of
valve to release gas pressure.
Disassembly and Assembly
There are two types of high pressure gas take 1 2
apart (HPG T/A) shock. One type has a tire valve
and the other has a needle valve.
SHOCK TYPE INFLATION TOOL

Tire valve type 529 035 570
Needle valve type 529 035 614
T/A shocks come in two sizes. C-36 shock is 36 mm

(1.417 in) in diameter and C-46 shock is 46 mm
(1.811 in). A06F18B
1. Tire valve
2. Tire valve cap
07-02-8 MMR2001_98_07_02A.FM
Needle Valve Type Shock With the seal carrier removed, slowly lift and re-
Remove screw on top of valve. Insert needle type move damper rod assembly from the damper
shock tool (P/N 529 035 614) very slowly into rub- body.
ber of needle valve. Push on shock tool valve cen- NOTE: Remove damper rod assembly slowly to re-
ter rod to release gas pressure. duce oil spillage and prevent piston seal damage by
damper body threads. Wrap the damper body with a
shop cloth to capture possible overflow oil while re-
moving the damper piston.
529 035 614
A27F0AA
A32F1OA 1. Oil flows
Remove tool from shock. Discard old oil into storage container. Never reuse
damper oil during shock rebuild.
All Types of Shock Remove valve core. Using compressed air pres-
Using appropriate size of shock wrench (P/N 529 sure, carefully remove floating piston from damp-
035 727) unscrew seal carrier. er body. Hold shop cloth over damper body open-
ing to catch released floating piston. Allow room
for floating piston to leave damper body.
529 035 727
A27F06A
TYPICAL
A32F1NA
 WARNING
Whenever using compressed air, use an
TYPICAL
O.S.H.A. approved air gun and wear protec-
tive eye wear.
MMR2001_98_07_02A.FM 07-02-9
Thoroughly clean, with a typical cleaning solution,

and blow dry using low pressure air. Carefully in-
spect the damper body for any imperfections or
signs of wear in the damper bore.
Replace damper body if wear is identified.
Holding the damper rod assembly in a bench vise,
begin piston and valve removal.
A06F0VA
NOTE: As a general rule we suggest replacing the

damper rod lock-nut after 4 rebuilds to ensure good
Iocking friction and use Loctite† 271 each time.
NOTE: If revalving is to be done, it is imperative
that you identify the original shim pack (size and
number of shims). The seal carrier need not be
A06F0UA
removed if only revalving is to be done.
A. Remove damper nut Shims can be measured by using a vernier caliper
Always arrange parts removed in the sequence of or a micrometer.
disassembly. NOTE: All shims should be carefully inspected
and any bent or broken shims must be replaced
for the shock to function properly.
After the new or replacement shim pack has been
selected, reassemble in the reverse order of disas-
sembly. Torque piston nut 27 - 29 N•m (20 - 21 Ibf•ft).
07-02-10 MMR2001_98_07_02A.FM
If the seal carrier assembly is replaced, use seal

1 pilot to guide seal over damper shaft. Lubricate
seal carrier guide pilot before use.
2
3 CAUTION: Failure to use seal pilot will result in
seal damage.
Reassemble damper rod assembly, taking care to
properly assemble shim packs as required for your
4 dampening needs. Ensure that the shaft piston is
installed with the slits/larger intake holes facing
the rebound shim stack.
A32F1WA
1. Damper nut
2. Spacer
3. Stopper with its round edge facing nut
4. Shim pack
CAUTION: The damper rod nut can only be re- 1

used 4 times, then, must be replaced. Do not sub-
stitute this part for non – O.E.M. use Loctite 271
on nut each time.
This (these) spacer washer(s) must be used as
shown to ensure damper rod nut does not bottom
A06F12C
out or contact shaft threads.
Rebound valve stopper with round edge facing 1. Seal guide (P/N 529 035 728)
nut. If floating piston has been removed, reinstall float-
NOTE: Rebound shim stack must not reach into ing piston into damper body (ensure that valve
threads of damper shaft. Spacer under damper core has been removed). Use Molykote G-n paste
shaft nut is used to prevent damper shaft nut from (P/N 711 297 433) to ease O-ring past damper body
bottoming on threads. threads with floating piston guide.
CAUTION: Failure to install IFP correctly could
result in shock damage.
1 1
2
4 A06F14C
1. Push (slowly) by hand

2. Floating piston guide
5
NOTE: Lubricate inside of piston guide with
A32F1XA 6 Molykote G-n paste (P/N 711 297 433).
1. Rebound dampening shim pack Install floating piston to the proper depth (190 mm
2. Rebound dampening shim pack
3. Piston (7.5 in)).
4. Compression dampening shim pack
5. Compression dampening shim pack
6. Stopper
MMR2001_98_07_02A.FM 07-02-11
On all HPG take apart shocks, the floating piston NOTE: If the floating piston is installed too far into
is installed hollow side up. the damper body, light air pressure through valve
(with core removed) will move piston outward.
NOTE: Reinstall valve core after IFP has been in-
stalled at correct height and before adding oil.
A
 WARNING
Whenever using compressed air exercise ex-
treme caution, cover damper opening with
shop cloth to reduce chance of possible injury.
CAUTION: Moisture laden compressed air will

contaminate the gas chamber and rust floating
piston.
 WARNING
Always wear protective eye wear whenever
A27F0FD
using compressed air.
A. Installation distance for floating piston installation
Fill the shock with Bombardier HPG shock oil (P/N
INSTALLATION 293 600 035) to approximately 10 mm (.393 in),
DISTANCE OF from the base of seal carrier threads.
SHOCK P/N
FLOATING PISTON
mm
503 189 745 130
1
503 189 678 130
503 189 491 130
503 189 610 130
503 189 279 130
503 189 528 130
503 189 076 130
503 189 677 183
503 189 077 183
503 189 492 183
A06F15B
503 189 609 190
1. Fill to 10 mm (.393 in)
503 189 280 190
503 189 527 183 NOTE: Although we do not measure the exact
amount of oil added to the damper, approximately
252 mL (8.52 oz. U.S.) will be used.
07-02-12 MMR2001_98_07_02A.FM
Carefully insert damper rod into the damper body. Seal carrier assembly can now be threaded into
Lightly oil damper piston seal ring with shock oil damper body. This should be done slowly to allow
to ease installation. weapage of oil and to minimize IFP displacement.
Torque seal carrier to 90 to 100 N•m (66 to 74 lbf•ft).
After the seal carrier is fully in place avoid pushing
the shaft into the body until the nitrogen charge is
added.
529 035 727
A06F16A
NOTE: Some shock oil will overflow when install-

ing damper. Wrap damper with shop cloth to catch
possible overflow oil.
CAUTION: Use care when passing piston into
damper body at damper body threads.
Slight oscillation of damper rod may be required to
A32F1NA
allow piston to enter damper body bore.
Slowly push piston into damper body. Slight up and When removing and retightening the tire valve
down movement may be required to allow all air to acorn nut use minimal torque. When the cap is
pass through piston assembly. The gentle tapping over tightened and subsequently removed it may
of a small wrench, on the shock eye, may help dis- prematurely break the seal of the tire valve to the
lodge air trapped in the submersed piston. Be care- shock body and cause a loss of nitrogen charge
ful not to drive the shaft any deeper into the oil than without being noticed. If you suspect this has hap-
is necessary to just cover the shim stack. pened then recharge the shock as a precaution.
NOTE: Fast installation of the damper rod may dis- Inspect the valve cap before installation to ensure
place the floating piston from its original position. that the internal rubber gasket is in its proper po-
This must not occur if the damper is expected to sition.
perform as designed.
With damper rod piston into oil, TOP OFF damper
oil volume. Oil level should be to damper body
thread base.
MMR2001_98_07_02A.FM 07-02-13
Adding Gas Pressure

1
Nitrogen (N2) can now be added to damper body.
2
A32F1SA
1. Larger diameter
529 035 570

3
4
A06F0QA
1. High pressure hose

2. 2 stage regulator, delivery pressure range 2070 kPa (300 PSI)
3. High pressure cylinder filled with industrial grade nitrogen
4. Valve tip (P/N 529 035 570) permanently installed
NOTE: Never substitute another gas for nitrogen. A32F1PA 529 035 614
Nitrogen has been selected for its inert qualities BOTH INFLATION TOOLS ARE USED ON NEEDLE VALVE TYPE
and will not contaminate the gas chamber of the SHOCK
shock. All Shock Types
Preset your pressure regulator to 2070 kPa NOTE: Carefully inspect damper for gas or oil
(300 PSI) nitrogen (N2), this gas pressure will re- leaks. Any leaks must be corrected before con-
store the correct pressure for your damper. tinuing.
CAUTION: Do not exceed the recommended Damper gas pressure cannot be confirmed by us-
pressure values. ing a pressure gauge. The volume of gas in the
shock is very small, and the amount lost during
 WARNING gauge installation will lower the pressure too
Whenever working with high pressure gas, much and require refilling.
use eye wear protection. Never direct gas After recharging is complete the rebuilt shock
pressure toward anybody. should be bench-tested. Stroke the shock to en-
sure full travel and smooth compression and re-
Use appropriate inflation tool. bound action. If the shaft moves in or out erratical-
Needle Valve Type Shock ly this could indicate too much air is trapped inside.
If the shaft will not move or has partial travel then
Insert needle type shock tool (P/N 529 035 614) it may be hydraulically locked. In either event the
very slowly into rubber of needle valve. shock must be rebuilt again. Pay particular attention
Rubber may pop out of needle valve when insert- to the placement of the IFP, quantity of oil and shim
ing tool needle. If so, remove valve core and rub- stack/piston assembly.
ber then, reinstall rubber with its larger diameter
last.
07-02-14 MMR2001_98_07_02A.FM
INSTALLATION
portion first.
Insert rear portion of suspension into track.
Bolt front arm and rear arm.
Adjust track tension.
RIDE ADJUSTMENT
Refer to Operator’s Guide.
LUBRICATION
Lubricate front and rear arms at grease fittings us-
ing synthetic grease (P/N 413 711 500).
A32F16A
SC-10 II: 5 GREASE FITTINGS
MMR2001_98_07_02A.FM 07-02-15
Subsection 03 (SC-10 MOUNTAIN SUSPENSION)
SC-10 MOUNTAIN SUSPENSION 0

All Summit Models
48 Nm
(35 lbfft) 24 Nm
(18 lbfft)
6
24 Nm
(18 lbfft)
10 Nm
(89 lbfin)
17
2.5 Nm 4 Nm
17
A32F1YS

2
24 Nm
(18 lbfft)
18
2.5 Nm
(22 lbfin)
24 Nm
(18 lbfft)
18
7
48 Nm
24 Nm (35 lbfft)
(18 lbfft)
1
19
24 Nm 19
(18 lbfft)
3 Nm
(27 lbfin)
A32F1ZS

48 Nm
(35 lbfft)
48 Nm
(35 lbfft)
24 Nm
(18 lbfft)
12
13
12
80 Nm
(59 lbfft)
6 Nm
(53 lbfin)
7 Nm
(62 lbfin)
20 21 Nm
(15 lbfft)
11
7 Nm
(62 lbfin)
48 Nm
(35 lbfft) 25 Nm
A32F20S
48 Nm (35 lbfft) (18 lbfft)

COMPONENT REMOVAL AND

INSTALLATION
21, Rear Axle

Remove screw on rear axle on side of offset wheel.
Completely loosen track tension.
Pull out rear axle from opposite side of offset inner
wheel.
At assembly, align spacer hole with adjusting bolt.
Make sure to reinstall washer on each side of runner.
529 005 000
A03F2FA
TYPICAL
Remove nut on top end of shock.

Remove nut on bottom end of shock. Pry up shock
bottom end to ease removing bolt (gas shock only).
See installation illustration below.
A03F1LA
Installation is reverse of removal procedure. To
TYPICAL easily compress gas shock absorber, use a pry bar
and locking pliers as a stopper.
15, Rear Shock
CAUTION: Take care not to damage grease fit-
Lift rear of vehicle. ting.
Slightly turn adjusting cam to expose spring end.
Using spring installer (P/N 529 005 000), remove 1 2
left spring from adjusting cam.
A03F1PA
TYPICAL
1. Locking pliers
2. Pry bar
07-03-4 MMR2001_099_07_03A.FM
12, Front Shock 6,7, Self-Locking Screws

Unfasten one end of stopper strap(s). CAUTION: These self-locking screws must al-
Unbolt shock and remove it. ways be replaced by new ones everytime they
are removed.
2, Rear Spring NOTE: To prevent axle from turning when un-
Remove spring ends from adjusting cams. screwing self-locking screws, proceed as follows:
Unbolt rear arm top axle from chassis. – Remove one self-locking screw then install a
Unscrew set screws from locking ring at each end Torque as specified in exploded view.
of top axle.
– Remove the opposite self-locking screw.
Remove spacers and top idler wheels.
– Remove the temporary installed non-self-locking
Remove springs. screw.
– If it doesn’t work, heat bolt head to melt thread-
locker.
Unscrew center idler wheel axle from tunnel then
remove.
Lift rear of vehicle at least 1 m (3 ft).
A03F1QA
TYPICAL
At reassembly, respect THIS SIDE OUT inscription A32F10A

on wheel.
TYPICAL
SUSPENSION ASS’Y REMOVAL
19, Cam front arm to tunnel.
Decrease spring preload by turning cams accord- Remove suspension.
ingly.
Remove rear arm top axle screws no. 7 from chassis.
MMR2001_099_07_03A.FM 07-03-5
DISASSEMBLY AND ASSEMBLY 11, Axle

Inspect track thoroughly before reinstalling sus- Note position of axles at disassembly. Axles with
pension. Refer to TRACK. a paint stripe serve as idler wheel axles. These are
more precise than those used as pivot axles. Idler
1, Rear Arm wheel axles can be used as pivot axles but the
opposite is not true.
At installation, rear arm stroke limiter must be on
rear side. 12,13, Front Shock and Spring Stopper
Use shock spring remover (P/N 529 035 504) and
1 put it in a vise. Mount shock in it and turn shock
1
A03F13A
2
1. Stroke limiter on rear side
10, Outer Bushing

At installation, hole must face adjustment screw.
A01B4LA
1. Clevis pin
2. Bar
A03F0XA
07-03-6 MMR2001_099_07_03A.FM
20, Stopper Strap SHOCK ABSORBER INSPECTION

Inspect strap for wear or cracks, bolt and nut for All Models Equipped with Hydraulic Shock
Replace as required. Torque nuts as specified in ex- NOTE: Hydraulic shocks are black painted.
ploded view. Secure the shock body end in a vise with its rod
upward.
17, Slider Shoe
1
Molding line is the wear limit indicator.
A14F0BA
1. Clamp

stroke. Check that it moves smoothly and with uni-
form resistance with its rod upward.
A03F3SA 1 2
TYPICAL mid travel.
1. Slider shoe
2. Molding line (wear limit indicator) – Seizing or binding condition except at extreme
– Oil leakage.
in pairs. – A gurgling noise, after completing one full com-
18, Spring Support Renew if any faults are present.
CAUTION: To avoid track damage, spring sup- All Models Equipped with Gas Pressurized
ports must be mounted upward. Shock
1 ple painted, or bare aluminum.
ber and gas chamber, check shock as follows:
Install shock in a vise clamping on its bottom eye-
A03F0VA 2
RIGHT SIDE SHOWN
2. Wrong position
MMR2001_099_07_03A.FM 07-03-7
Completely push down the shock rod then release.

Rod must come out at a steady speed. If speed
suddenly increases particularly at end of exten-
sion, replace shock.
All Types of Shock
If suspecting a frozen shock proceed as follows:
Place shock in a freezer (temperature below 0°C
Push down on rod and note its resistance. If shock
is frozen it will be impossible or almost impossible
to compress it.
HPG T/A SHOCK SERVICING

Refer to SC-10 II SUSPENSION.
INSTALLATION
portion first.
Insert rear portion of suspension into track.
Bolt front arm, rear arm then center top idler wheel
axle.
Adjust track tension.
RIDE ADJUSTMENT
Refer to Operator’s Guide.
LUBRICATION
Lubricate front and rear arms at grease fittings us-
ing synthetic grease (P/N 413 711 500).
A03F10C
TYPICAL — 5 GREASE FITTINGS
07-03-8 MMR2001_099_07_03A.FM
DRIVE AXLE 0
1 2
Synthetic
grease
7
8
Synthetic
grease
15 Nm
(133 lbfin)
9
10
11 12
A32D0XS

REMOVAL Remove cable protector no. 12, plastic cover

no. 11, outer flange no. 10 and circlip no. 9 from
According to model, drain oil from chaincase or left side.
gearbox. Remove chaincase or gearbox cover. Re-
lease drive chain tension. 1
A32D10A
A32D0YA
1. Circlip
Raise and block rear of vehicle off the ground. Apply parking brake.
Remove suspension. Refer to proper subsection. Remove chain and sprockets then circlip from
Track can be held in tunnel using a rod in place of right side.
center idler wheel axle. Release drive axle sprocket from track and at the
same time, push the drive axle no. 3 toward the right
side. Drive axle bearing no. 1 in chaincase or gear-
box will fall off.
A32D0ZA 1
A00C44A
1. Rod
TYPICAL
07-04-2 MMR2001-100_07_04A.FM
5,6, Sprocket and Half-Sprocket ZX Series

To remove press fit sprockets, use a press and a 1
suitable support as illustrated.
A
B
C
D
A06D1XC
1. Measure from end of drive axle

A. 47.3 mm (1.862 in)
B. 149.8 mm (5.898 in)
A00F06A
1 C. 272.8 mm (10.740 in)
D. 375.3 mm (14.776 in)
TYPICAL
Ensure to align indexing marks of each sprocket
1. Support sprocket near hub
when assembling.
ASSEMBLY
3,5,6, Drive Axle and Sprocket 1
To assemble press fit sprockets, use a press and a
suitable pipe as illustrated. Sprockets must be as-
sembled according to the following dimensions.
A24D05A
TYPICAL
1. Indexing marks aligned
The maximum desynchronization for the sprock-

ets is 1.5 mm (1/16 in).
A00F07A
plane surface and measure the gap between sprock-
TYPICAL et tooth and surface.
1. Pipe
1 A
A00F0AA
TYPICAL
1. Plane surface
A. 1.5 mm (1/16 in) MAXIMUM
MMR2001-100_07_04A.FM 07-04-3
CAUTION: The same sprocket must not be ADJUSTMENT

pressed twice on the axle. If synchronization is
found to be defective, use a new sprocket. Sprocket/Track Alignment
7, Bearing Protector CAUTION: Do not temper with sprocket/track
At assembly, flat side of bearing protector must be
against bearing. Sprockets might be repositioned to fit lugs with-
8, Bearing Use drive axle sprocket adjuster kit (P/N 861 725
700).
A00F0DA
TYPICAL
The bearing no. 8 must have its shield facing the

sprocket. A01B2PA
The bearing no. 1 must have its shield facing right TYPICAL
side (cover).
LUBRICATION
Lubricate end housing bearing with synthetic grease
(P/N 413 711 500).
07-04-4 MMR2001-100_07_04A.FM
TRACK 0
TRACK TYPE APPLICATION INSTALLATION
Refer to TECHNICAL DATA. Reverse the removal procedure.
GENERAL direction indicated by an arrow on track thread.
This section gives guidelines for track removal. Check sprocket/track alignment as described in
Some components require more detailed disas- DRIVE AXLE.
fer to the pertaining section in this manual. Track Tension and Alignment
Track tension and alignment are inter-related. Do
INSPECTION not adjust one without checking the other. Track
Visually inspect track for: track alignment.
– broken rods Tension
– broken or missing track cleats. Lift the rear of vehicle and support with a mechan-
ical stand. Allow the slide to extend normally.
Check the gap half-way between front and rear
track. For damaged or missing cleats, replace by
idler wheels. Measure between slider shoe and
new ones, using cleat remover (P/N 529 028 700).
Use narrow-cleat installer (P/N 529 008 500).
 WARNING 500), slide U shape extrusion to proper deflection.
or damaged track.
REMOVAL 1
Remove the following parts: 40 2
– speedometer cable 45
50
– muffler
– chaincase or gearbox cover
– rear suspension
– drive axle seal A01B4JA
– end bearing housing 1. Example: 45 mm

2. Extrusion
– sprockets and chain
Insert pre-setted gauge between slider shoe and
– drive axle track. Allow gauge to settle by forcing track up and
– track. down. Track tension is as specified when edge of
gauge reaches line.
MMR2001-101_07_05A.FM 07-05-1
Alignment
 WARNING
vehicle.
All Models
A01B4KA 1 tance on both sides between edges of track guides
and slider shoes.
TYPICAL
1. Line 1
NOTE: Lightly oil track tension gauge center pin to 2
avoid sticking.
All Models
Refer to TECHNICAL DATA for proper tension val-
ues.
CAUTION: Too much tension will result in power
loss and excessive stress on suspension com- 3
ponents. If too loose, the track will have a ten- A01F05A
dency to thump. 1. Guides

2. Slider shoes
To adjust, loosen the rear idler wheel retaining 3. Equal distance
screws then loosen or tighten the adjuster bolts
located on the inner side of the rear idler wheels.  WARNING
thrown out while track is rotating. Keep hands,
tools, feet and clothing clear of track.

check alignment.
1
2
A19F05A
TYPICAL
1. Retaining screw
2. Adjuster bolt
07-05-2 MMR2001-101_07_05A.FM
1 2 1
Track Cleat
Removal
– Raise rear of vehicle off the ground and lift snow-
replaced.
all models.
3
A01F0BA Installation
1. Guides NOTE: Keep the same pitch between guide cleats.
2. Slider shoes
3. Tighten on this side – Place new cleat in position and using narrow
track cleat installer (P/N 529 008 500) bend cleat
NOTE: Torque retaining screw to 48 N•m (35 lbf•ft) then push tabs into rubber.
after adjustment.
A01B4UA
TYPICAL
1. First step
A32F1DA 1 2. Second step (to push tabs into rubber)
TYPICAL
1. Retighten to 48 N•m (35 lbf•ft)
Restart engine, rotate track slowly and recheck

alignment.
MMR2001-101_07_05A.FM 07-05-3
TABLE OF CONTENTS 0
STEERING SYSTEM .............................................................................................................. 08-02-1
INSPECTION ...................................................................................................................... 08-02-5
STEERING ADJUSTMENT (skis) ...................................................................................... 08-02-6
LUBRICATION .................................................................................................................... 08-02-8

DISASSEMBLY................................................................................................................... 08-03-2
INSPECTION ...................................................................................................................... 08-03-3
INSTALLATION .................................................................................................................. 08-03-3
MMR2001_108_08_01ATOC.FM 08-01-1
STEERING SYSTEM 0
ZX Series
Summit only
11 Nm 2 Loctite 495 MX Z X

16 and
(97 lbfin)
Summit
25 Nm 14
13
(18 lbfft) 4 2
53 Nm
4 (39 lbfft)
25 Nm 3
5 (18 lbfft)
18 Nm
(159 lbfin)
1 7
Synthetic
grease 18 17
7 8
25 Nm 6
(18 lbfft) Synthetic
18 Nm grease
(159 lbfin)
17 7
53 Nm
7 18 (39 lbfft)
25 Nm 11 41 Nm
(18 lbfft) (30 lbfft)
12
7 25 Nm
(18 lbfft)
53 Nm
(39 lbfft) 18
9 18 Nm
(159 lbfin)
50 Nm
(37 lbfft) 25 Nm
(18 lbfft)
7 17
11
12
25 Nm
7 (18 lbfft)
53 Nm
A32G0VS
(39 lbfft)

DISASSEMBLY AND ASSEMBLY Continue cutting along the gap and remove the
grip.
13, Grip If required, slowly peel heating element no. 15
Grips must be carefully removed to prevent dam- from handlebar and remove it.
aging the heating elements. To install, stick the heating element to the handle-
Heat grip with a heat gun. bar making sure the wires do not interfere with
Apply tape to handlebar near the grip to protect
paint. Prior to install grips, position heating element pro-
tector no. 14.
Inject compressed air into the handlebar and twist
A30G0DA 1
 WARNING
install the handlebar grip, use a mix of soap
and water. Mix 40 parts of water with one part
of dish washing soap (recommended: Ultra
A30G0OA Joy, Sunlight or Palmolive).
The grips might be unremovable as explained Heat the grip with a heater gun or a spot light to
above, in this case, carefully proceed as follows to ease installation. Insert new grip with compressed
prevent damaging the heating elements. air.
Locate the element wires inside the handlebar;
look through end of grip. Start cutting the grip ex-
actly opposite the element wires and immediately
peel it open to locate the gap in the heating ele-
ment, as shown.
A30G0NA
A19H04A 1
TYPICAL
TYPICAL
1. Gap in the heating element opposite the wires
08-02-2 MMR2001_102_08_02A.FM
MX Z X and Summit
After grip installation apply few drops of Loctite
495 (P/N 293 800 021) 10 mm (3/8 in) deep be-
tween grip and handlebar.
Locate former rivet hole in handlebar then, drill 4.8
mm (3/16 in) dia. hole through grip in this position.
Install rivet no. 3.
16, Cut-Out Switch

Push on switch to remove plastic cover.
1
A32G0NA
Disengage carriage bolts no. 6 from chassis.

Disengage carriage bolts no. 5 from steering sup-
port then, pull steering column from top.
Plastic U-clamps will come out along with steering
column.
12, Steering Arm

sembling, scribe mark the steering arm and ski leg
before disassembly.
A32G0QA
1. Plastic cover
1, Steering Column
Remove steering pad, remove master cylinder
from handlebar and put it aside. Remove circlip
retaining throttle cable to throttle housing. Unplug
all connector housings of handlebar switches. Re-
move handlebar ass’y.
Remove the air intake silencer.
Unbolt console.
A32G0MA
Detach the short tie rod no. 8 (engine has to be
removed) from the steering column. Note that a
hardened flat washer no. 7 goes on each side of
steering column lever.
MMR2001_102_08_02A.FM 08-02-3
17,18, Ball Joint

(left hand and right hand threads)
The maximum external threaded length not engaged
in the tie rod must not exceed 20 mm (25/32 in).
A A
A32G0KA
A02G0SA TIE ROD BALL JOINT PARALLEL TO SWIVEL BAR BEFORE

TIGHTENING
TYPICAL
A. 20 mm (25/32 in) max.  WARNING
The ball joint should be restrained when tightening The cut off section of the ball joint must run par-
the tie rod end lock nut. Align it so the tie rod end allel with the swivel bar no. 9. When tightening
is parallel to the steering arm when assembled on lock nuts, restrain ball joint with appropriate
the vehicle, refer to the following illustration. size wrench. The maximum external threaded
For proper torque specifications refer to the spe- length not engaged in the tie rod must not ex-
cific exploded view for the vehicle being serviced. ceed 20 mm (25/32 in).
1 2 7, Hardened Washer
Install a hardened washer on each side of the arm.
A02G0IA
TYPICAL
2. Steering arm
A32G0OA 1
TYPICAL
1. Hardened washers
08-02-4 MMR2001_102_08_02A.FM
12, Steering Arm 17,18, Ball Joint

The steering arm angles should be equal on both (left hand and right hand threads)
sides when skis are parallel with vehicle. Inspect ball joint ends for wear or looseness, if ex-
Steering arm axis (from plastic cap center to ball cessive, replace them.
center of ball joint) must run parallel to ski.
HANDLEBAR ADJUSTMENT
Loosen all 4 nuts no. 4 retaining steering clamps
no. 2.
tion.
nuts as specified in the illustrations.
CAUTION: Tighten the nuts equally in a criss-
cross sequence and ensure there is an equal
gap on each side of the clamps.
A32G0PA 1
TYPICAL
1. Parallel A
Tighten the steering arm pinch bolt and nut to the
torque specified in the exploded view.
INSPECTION
necessary. Refer to FRONT SUSPENSION. 1
12, Steering Arm A30G0HA
Make sure steering arm and ski leg splines inter- TYPICAL
lock. 1. Torque to 25 N•m (18 lbf•ft)
 WARNING
Any parts having worn splines have to be re-  WARNING
places with new ones. Avoid contact between the brake handle and
the windshield by NOT adjusting the handle-
Check the general condition of the steering sys- bar too high.
15, Heating Grip Element  WARNING

Refer to TESTING PROCEDURE. trols are properly fixed to their normal loca-
tion on the handlebar.
MMR2001_102_08_02A.FM 08-02-5
STEERING ADJUSTMENT (skis) 8,17,18, Tie Rod and Ball Joint

Definitions Turn handlebar until bolt center of left side swivel
arm is 11 mm (.443 in) from chassis hole center.
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 ZX series models,
toe-out is measured at 220 mm (8-21/32 in) from A
ski pivot bolt axis.
1
1
220 mm 220 mm
A
B A32G0LA
1. Left side swivel arm

A. 11 mm (.443 in)
A01G04D
Check that handlebar is horizontal by measuring
TYPICAL from the extremities of the grips to the rearmost
1. Ski pivot bolt axis edge of the tunnel, as shown.
CAMBER: NOTE: The reference point must be the same rel-
A specific inward or outward tilt angle of ski leg ative to each side.
compared to a vertical line when viewing the ve-
hicle from front.
Adjustments 1

sequence:
– Pivot arm centering.
– Set camber angle. A A
– Check for a horizontal handlebar. 2 2
– Set toe-out.
PIVOT ARM CENTERING
 WARNING
Do not attempt to adjust straight ahead ski
position by turning the ball joint on tie rod
no. 8. A06G07A
TYPICAL
1. Equal distance A on each side
Remove engine.
08-02-6 MMR2001_102_08_02A.FM
Loosen the jam nuts on tie rod no. 8 (LH threads Adjusting
on steering column end) and turn tie rod accord- – Loosen lock nut on both upper control arms.
ingly. Retighten the jam nuts to 18 N•m (159
lbf•in). – Unbolt both upper control arms at ski leg hous-
ing. Turn tie rod half turn at a time to obtain the
 WARNING specified value when skis are not touching
ground. Bolt upper control arms.
Never lengthen this tie rod so that threaded por-
tion of ball joint exceeds 20 mm (25/32 in). CAMBER
MODEL
± 1.0°
CAMBER MX Z Trail -1
NOTE: Identical adjustments are required on both
sides of the vehicle. MX Z STD/X/Adrenaline -2
– Make sure the vehicle is leveled by placing an Others Not adjustable

angle finder under the main frame member as
shown on the following illustration. NOTE: Because of a negative camber, skis will lean
– Vehicle skis must be off the ground. toward center of vehicle.
Tighten lock nut on both upper control arms.
HANDLEBAR AND SKI TOE-OUT
Check that handlebar is horizontal when skis are
in straight ahead position by measuring from the
extremities of the grips to the rearmost edge of
the tunnel, as shown.
NOTE: The reference point must be the same rel-
ative to each side.
A06G05A 1
TYPICAL
1. Angle finder 1
Using special tool (P/N 529 021 600) 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. A A
CAUTION: Angle finder must sit square against 2 2
swing arm. Positioning angle finder against weld
bead or decal may result in false reading.
529 021 600
K-D Tools
ANGLE FINDER
Lancaster, PA
K-D Tools
17004
No. 2968
A06G07A
A06G1KA TYPICAL
TYPICAL — CAMBER ADJUSTMENT SET-UP 1. Equal distance A on each side
MMR2001_102_08_02A.FM 08-02-7
Adjustment is performed by adjusting length of

left and right tie rods no. 11.
 WARNING
Do not attempt to adjust skis straight ahead
position by turning ball joint on tie rod no. 8.
Procedure:
– Loosen jam nuts of both tie rods no. 11.
– Turn the tie rod on one side to shorten its length.
– Lengthen the other one by turning it exactly the
same amount, so that toe-out is not changed. A30G0SA
1 2
 WARNING TYPICAL
1. Straight edge
Never lengthen tie rod so that threaded por- 2. Measure at 220 mm (8-21/32 in) from ski pivot axis
tion of ball joint exceeds 20 mm (25/32 in).
LUBRICATION
– Close front of skis manually to take all slack
from steering mechanism.  WARNING
NOTE: A rubber cord must be hooked in front of Do not lubricate throttle cable or housing.
skis to keep them closed.
Toe-out must be as specified when skis are in a 26, Grease Fittings
straight-ahead position and the front of vehicle is
lifted off the ground. Only use synthetic grease (P/N 413 711 500).
– Grease ski legs.
TOTAL TOE-OUT
MODEL + 3 mm (+ 1/8 in) – Grease LH and RH swivel arms.
- 0 mm (- 0 in) Grease stabilizer blocks in swing arm.
8.0 For all others lubrication points use BOMBAR-
MX Z STD/Adrenaline Summit DIER LUBE (P/N 293 600 016).
(5/16)
MX Z X 4.0 (5/32) Lubricate:

– Steering column bushings.
MX Z Trail
3.0 – Long tie rod ends.
Formula DLX
(1/8)
Grand Touring – Short tie rod ends.
– Upper arm ball joint on so equipped models.
NOTE: To make sure skis are in a straight-ahead po-
sition, place a straight edge against pre-adjusted
track and measure the distance between front and
rear of skis and straight edge. Measuring points
are 220 mm (8-21/32 in) at front and rear of ski
pivot axis.
To reduce tolerance when measuring, set one ski
to proper toe-out (half the total toe-out) then mea-
sure from that ski to the opposite ski.
08-02-8 MMR2001_102_08_02A.FM

ZX Series
50 Nm
(37 lbfft)
Some models
Some models
6
50 Nm
(37 lbfft)
5
Super Lube
grease
25 Nm
(18 lbfft)
Synthetic Loctite 243
50 Nm 50 Nm grease
(37 lbfft) (37 lbfft)
1 Some models
8
7 4
8
50 Nm 3
(37 lbfft)
Some models Bent position 2
toward front
Synthetic
32 Nm 12 grease
(24 lbfft)
9 18 Nm
(160 lbfin)
18 Nm 1.7 Nm
9 Nm
(80 lbfin)
7 Nm
(62 lbfin)
10
A32G0TS

DISASSEMBLY
5, Shock
cordingly.
Remove lower bolt then upper bolt of shock.
For shock spring disassembly use shock spring re- 1
mover (P/N 529 027 100) in a vise. Mount shock in 2
it and turn shock so that spring coils matched spring
compressor.
Close and lock the bar. Adjust the handle at hori-
zontal position by changing the position of the cle-
vis pin.
A03F12A
1. Cap opening
1 1, Swing Arm
2 Remove cap no. 4, circlip no. 3 then loosen steer-
ing arm bolt and pull up steering arm. Ski leg may
fall off from swing arm. Note shim no. 2 position.
A01B4LA
1. Clevis pin
2. Bar
3. Handle horizontal A32G0IA 1
Push down on the handle until it locks. Remove 1. Shim no. 2
spring stopper then release handle.
Unbolt lower end of shock from swing arm.
At installation, cap opening no. 6 must be 180°
from spring stopper no. 5 opening. Unbolt upper and lower arms.
Unbolt rear of swing arm from frame.
Pull swing arm off the vehicle.
08-03-2 MMR2001_103_08_03A.FM
INSPECTION
place as required.
Check straightness of ski leg no. 12 and make
sure that splines are properly interlocking with
steering arm. Replace as required.
required.
Check for clogged grease fittings. Clean or replace as
required.
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 MOUN-
TAIN SUSPENSION then look for Shock Absorber
Inspection.
INSTALLATION
For assembly, reverse the disassembly proce-
dure. However, pay attention to the following.
Apply synthetic grease (P/N 413 711 500) to ski leg
components.
7,8, Upper and Lower Arms

Position arms and tie rods horizontally before tight-
ening nuts.
8, Adjustable Arm
Some Models Only
Refer to STEERING SYSTEM for proper camber ad-
justment using these arms.
All Models
Proceed with toe-out adjustment, refer to STEER-
ING SYSTEM.
MMR2001_103_08_03A.FM 08-03-3
TABLE OF CONTENTS 0
BODY...................................................................................................................................... 09-02-1
DECAL ................................................................................................................................ 09-02-2
GUARD ............................................................................................................................... 09-02-2
WIRING HARNESS ............................................................................................................ 09-02-2
CABLES .............................................................................................................................. 09-02-2
PIPING ................................................................................................................................ 09-02-2
MAINTENANCE ................................................................................................................. 09-02-3
REPAIR................................................................................................................................ 09-02-3
FRAME ................................................................................................................................... 09-03-1

FRAME CLEANING ............................................................................................................ 09-03-1
FRAME WELDING ............................................................................................................. 09-03-1
MMR2001_108_09_01ATOC.FM 09-01-1
BODY 0
INSTALLATION AND BULB REPLACEMENT
ADJUSTMENT
Headlamp
HEADLAMP BEAM AIMING If any headlight bulb is burnt, remove windshield.
Beam aiming is correct when center of high beam Unplug burnt bulb connector. Remove the rubber
is 25 mm (1 in) below the headlamp horizontal cen- boot.
ter line, scribed on a test surface, 381 cm (12 ft 6 in) Unfasten bulb retainer ring. Detach the bulb and
away. replace. Properly reinstall parts.
Measure headlamp center distance from ground.
below scribed line.
1 90°
A30E05A 1
1. Locking ring
A02E0AA B CAUTION: Never touch glass portion of an halo-

TYPICAL gen bulb with bare fingers, as it shortens its op-
1. Headlamp center line erating life. If by mistake glass is touched, clean
A. 381 cm (12 ft 6 in) it with isopropyl alcohol which will not leave a
film on the bulb.
1 2
Taillight
If the taillight bulb is burnt, expose the bulb by re-
moving red plastic lens. To remove, unscrew the
2 retaining screws. Verify all lights after replace-
3 A ment.
A02E07A
1. Headlamp horizontal
A. 25 mm (1 in)
Required Conditions
Place the vehicle on a flat surface perpendicular to
away from it.
Rider or equivalent weight must be on the vehicle.
Select high beam.
MMR2001_104_09_02A.FM 09-02-1
DECAL WIRING HARNESS

and peel off slowly.  WARNING
Using isopropyl alcohol, clean the surface and dry Ensure all terminals are properly crimped on
thoroughly. the wires and that all connector housings are
Apply liquid soap to new decal and carefully posi- rotating, moving, heating and vibrating parts.
tion the decal. Using a sponge or a squeegee, re- Use proper fastening devices as required.
CAUTION: Do not apply isopropyl alcohol or sol-
CABLES
vent directly on decals. Use only in a well venti-
lated area.  WARNING
Before installation, ensure that all cables are
WINDSHIELD INSTALLATION in perfect condition. Properly install the cable
ends and secure them in place. Pay attention
Remove protective film. to route them properly, away from any rotat-
Position the windshield on the hood then push it ing, moving, heating or vibrating parts.
down until the tabs are fully inserted into the hood
slots. Lock the windshield tabs in position.
PIPING
GUARD  WARNING
Disassembly and Assembly Always ensure that the fuel, vent, primer, im-
pulse, injection oil and rotary valve oil lines are
NOTE: For additional information (ex.: exploded properly fixed to their connectors, that they
view) refer to the correspondent Parts Catalog. are not perforated or kinked and that they are
properly routed away from any rotating, mov-
 WARNING ing, heating or vibrating parts. Also check for
Engine should be running only with guard well leaks. Replace if required.
secured in place.
NOTE: Refer to proper Parts Catalog to find suitable
clip part numbers.
Inspection
Check guard mounting bosses, clips and retainers
for wear.
09-02-2 MMR2001_104_09_02A.FM
PLASTIC MAINTENANCE AND

REPAIR
MAINTENANCE
Clean the vehicle thoroughly, removing all dirt and
grease accumulation.
To clean use a soft clean cloth and either soapy wa-
ter or isopropyl alcohol.
To remove grease, oil or glue use isopropyl alcohol.
acetone directly on decals.
CAUTION: The following products must not be
used to clean or wax any of the plastic compo-
nents used on the vehicles:
– gasoline
– brake fluid
– kerosene
– diesel fuel
– lighter fluid
– varsol
– naphtha
– acetone
– strong detergents
– abrasive cleaners
– waxes containing an abrasive or a cleaning
agent in their formula.
Apply wax on glossy finish only. Protect the vehicle
with a cover to prevent dust accumulation during
storage.
CAUTION: If for some reason the snowmobile
has to be stored outside it is preferable to cover
the sun rays from affecting the plastic compo-
REPAIR
 WARNING
Polycarbonate windshields must never be re-
paired by welding or otherwise.
MMR2001_104_09_02A.FM 09-02-3
FRAME 0
FRAME CLEANING CAUTION: If welding is to be done near plastic
NOTE: For bare aluminum frames use only alumi- the part from the area or to protect it with alu-
num cleaner and follow instructions on container. minum foil to prevent damage.
(Dursol cleaner or equivalent).
Clean frame and tunnel with appropriate cleaners FRAME COMPONENT
and rinse with high pressure hose. REPLACEMENT
scratched off. Spray all bare metal parts of vehicle Drilling Procedure
with metal protector. When drilling self-piercing rivets, use Supertanium™
drill bit (P/N 529 031 800), available in a 5 mm (3/16 in)
Seat Cleaning size and shipped in packs of 2.
For all models, it is recommend to clean the seat For proper drilling instructions and to prevent pre-
with a solution of warm soapy water, using a soft mature wear, follow the procedure below.
clean cloth.
Always use a variable speed electric drill.
as strong soaps, degreasing solvents, abrasive Partially drill rivet end — not the rivet head.
cleaners, paint thinners, etc. that may cause Maintain a slow to medium speed at all times
damage to the seat cover. when drilling. The proper speed is attained when
a constant chip is ejected.
FRAME WELDING NOTE: To increase bit life, use Bombardier syn-
Aluminum Frame
oil.
(refer to specialized welding shop)
CAUTION: High speed drilling will cause ex-
– Use tungsten inert gas welding (TIG).
cessive heat which may destroy the cutting
– Rod: ER-4043 (3/32 in). edge of the bit, therefore avoid using pneumatic
CAUTION: Before performing electrical weld- drills.
ing anywhere on the vehicle, unplug MPEM.
On models equipped with a battery, also un-
plug the negative cable. This will protect the elec-
tronic box and battery against damage caused by
flowing current when welding.
1
A03H2FA
Cut rivet using a chisel.

Drive out remaining rivet head using a punch.
A01H0MA
TYPICAL
1. Unplug before electrical welding
MMR2001_105_09_03A.FM 09-03-1
TECHNICAL DATA 0
BASE UNITS
length .................................................................. meter ..................................................... m

mass .................................................................... kilogram ................................................. kg
force .................................................................... newton ................................................... N
liquid .................................................................... liter ......................................................... L
PREFIXES

CONVERSION FACTORS
in ......................................................................... mm ......................................................... 25.4

in ......................................................................... cm .......................................................... 2.54
in2 ........................................................................ cm2 ......................................................... 6.45
in3 ........................................................................ cm3 ......................................................... 16.39
ft .......................................................................... m ............................................................ 0.3
oz ......................................................................... g ............................................................. 28.35
lb ......................................................................... kg ........................................................... 0.45
lbf ........................................................................ N ............................................................ 4.4
lbf•in ................................................................... N•m ....................................................... 0.11
lbf•ft .................................................................... N•m ....................................................... 1.36
lbf•ft .................................................................... lbf•in ...................................................... 12
PSI (lbf/in2) .......................................................... kPa ......................................................... 6.89
imp. oz ................................................................. U.S. oz .................................................... 0.96
imp. oz ................................................................. mL .......................................................... 28.41
imp. gal ................................................................ U.S. gal ................................................... 1.2
imp. gal ................................................................ L ............................................................. 4.55
U.S. oz ................................................................. mL .......................................................... 29.57
U.S. gal ................................................................ L ............................................................. 3.79
MPH .................................................................... km/h ...................................................... 1.61
Celsius ................................................................. Fahrenheit .............................................. (°C × 1.8) + 32

MMR2001_106_10_01A.FM 10-01-1
MX Z 500 STD/TRAIL FORMULA DLX 600

VEHICLE MODEL FORMULA DLX 500 MX Z 600 STD/TRAIL/
ADRENALINE/X STD/GSE
GRAND TOURING 500 GRAND TOURING 600
Bore mm (in) 69.50 (2.736) 76.00 (2.992) 76.00 (2.992)
Stroke mm (in) 65.80 (2.591) 65.80 (2.591) 65.80 (2.591)
Piston Ring Type 1st/2nd ST/N.A. ST/N.A. ST/N.A.
New mm (in) 0.4 (.016) 0.4 (.016) 0.4 (.016)
Ring End Gap
Wear Limit mm (in) 1.0 (.039) 1.0 (.039) 1.0 (.039)
New mm (in) 0.04 (.0016) 0.04 (.0016) 0.04 (.0016)
Wear Limit mm (in) 0.2 (.0079) 0.2 (.0079) 0.2 (.0079)
New ± 0.016 mm (± .0006 in) 0.10 (.0039) 0.120 (.0047) 0.120 (.0047)
Wear Limit mm (in) 0.20 (.0079) 0.20 (.0079) 0.20 (.0079)
New mm (in) 0.39 (.0154) 0.39 (.0154) 0.39 (.0154)
Wear Limit mm (in) 1.2 (.0472) 1.2 (.0472) 1.2 (.0472)
Maximum Crankshaft End-play ➁ mm (in) 0.3 (.012) 0.3 (.012) 0.3 (.012)
Maximum Crankshaft Deflection at PTO mm (in) 0.06 (.0024) 0.06 (.0024) 0.06 (.0024)
Spark Plug Gap ± 0.05 mm (± .002 in) 0.45 (.018) 0.45 (.018) 0.45 (.018)
Ignition Timing BTDC ➂ mm (in) 3.00 (.118) 3.00 (.118) 3.00 (.118)
Trigger Coil ➃ Ω 190 – 300 190 – 300 190 – 300
Low Speed Ω 11.6 – 21.6 11.6 – 21.6 11.6 – 21.6
Generating Coil ➃
High Speed Ω N.A. N.A. N.A.
Lighting Coil ➃ Ω 0.1 – 0.4 0.1 – 0.4 0.1 – 0.4
Primary Ω 0.0 – 0.9 0.0 – 0.9 0.0 – 0.9
Secondary kΩ 9.5 – 16.5 9.5 – 16.5 9.5 – 16.5
Carburetor Type PTO/MAG VM 38 429/429 TM 40-B91 TM 40-B112
Main Jet PTO/MAG 280/280 500/500 500/500
Needle Jet 480-P-8 P-0 ➄ P-0 ➄
Pilot Jet 40 20 20
Needle Identification — Clip Position 6DEY10-4 9HFY2/53 ➅ 9HFY2/53 ➅
Float Adjustment ± 1 mm (± .040 in) 22.9 (.902) N.A. N.A.
Air or Pilot Screw Adjustment ± 1/16 Turn 1-1/4 1 1
Idle Speed ± 200 RPM 1700 1600 1600
Gas Type/Pump Octane Number Unleaded/87 Unleaded/87 Unleaded/87
Type Liquid Liquid Liquid
Deflection mm (in) N.A. N.A. N.A.
Force kg (lbf) N.A. N.A. N.A.
Thermostat Opening Temperature °C (°F) 42 (108) 42 (108) 42 (108)
Radiator Cap Opening Pressure kPa (PSI) 90 (13) 90 (13) 90 (13)
Drive Pulley Retaining Screw ➆ ➆ ➆
Magneto Ring Nut 125 (92) 125 (92) 125 (92)
ENGINE COLD
N•m (lbf•ft)
M6 9 (7) 9 (7) 9 (7)

M8 29 (21) 29 (21) 29 (21)
Cylinder Head Screws 29 (21) 29 (21) 29 (21)
Crankcase/Cylinder Nuts or Screws 29 (21) 29 (21) 29 (21)
Axial Fan Shaft Nut N.A. N.A. N.A.
MMR2001_106_10_02A.FM 10-02-1
VEHICLE MODEL SUMMIT 600 MX Z 700 STD/TRAIL/

ADRENALINE/X
ENGINE TYPE 593 693
Bore mm (in) 76.00 (2.992) 78.00 (3.071)
Stroke mm (in) 65.80 (2.591) 73.00 (2.874)
Piston Ring Type 1st/2nd ST/N.A. ST/N.A.
New mm (in) 0.4 (.016) 0.4 (.016)
Ring End Gap
Wear Limit mm (in) 1.0 (.039) 1.0 (.039)
New mm (in) 0.04 (.0016) 0.04 (.0016)
Wear Limit mm (in) 0.2 (.0079) 0.2 (.0079)
New ± 0.016 mm (± .0006 in) 0.120 (.0047) 0.118 (.0046)
Wear Limit mm (in) 0.20 (.0079) 0.20 (.0079)
New mm (in) 0.39 (.0154) 0.39 (.0154)
Wear Limit mm (in) 1.2 (.0472) 1.2 (.0472)
Maximum Crankshaft End-play ➁ mm (in) 0.3 (.012) 0.3 (.012)
Maximum Crankshaft Deflection at PTO mm (in) 0.06 (.0024) 0.06 (.0024)
Ignition Timing BTDC ➂ mm (in) 3.00 (.118) 3.36 (.132)
Trigger Coil ➃ Ω 190 – 300 190 – 300
Low Speed Ω 11.6 – 21.6 11.6 – 21.6
Generating Coil ➃
High Speed Ω N.A. N.A.
Lighting Coil ➃ Ω 0.1 – 0.4 0.1 – 0.4
Primary Ω 0.0 – 0.9 0.0 – 0.9
Secondary kΩ 9.5 – 16.5 9.5 – 16.5
Carburetor Type PTO/MAG TM 40-B94 TM 40-B97
Main Jet PTO/MAG 500/500 520/520
Needle Jet P-0 ➄ P-0 ➄
Pilot Jet 20 17.5
Needle Identification — Clip Position 9HFY2/53 ➅ 9ZLY3/58 ➅
Float Adjustment ± 1 mm (± .040 in) N.A. N.A.
Air or Pilot Screw Adjustment ± 1/16 Turn 1 1-1/2
Idle Speed ± 200 RPM 1500 1500
Type Liquid Liquid
Deflection mm (in) N.A. N.A.
Force kg (lbf) N.A. N.A.
Thermostat Opening Temperature °C (°F) 42 (108) 42 (108)
Radiator Cap Opening Pressure kPa (PSI) 90 (13) 90 (13)
ENGINE COLD
N•m (lbf•ft)
M6 9 (7) 9 (7)
M8 29 (21) 29 (21)
Cylinder Head Screws 29 (21) 29 (21)
Crankcase/Cylinder Nuts or Screws 29 (21) 29 (21)
Axial Fan Shaft Nut N.A. N.A.
10-02-2 MMR2001_106_10_02A.FM
VEHICLE MODEL FORMULA DLX 700 GS/GSE

GRAND TOURING 700 SUMMIT 700 STD/X/H.M./H.M. X
ENGINE TYPE 693 693

Bore mm (in) 78.00 (3.071) 78.00 (3.071)
Stroke mm (in) 73.00 (2.874) 73.00 (2.874)
New mm (in) 0.4 (.016) 0.4 (.016)
Ring End Gap
Wear Limit mm (in) 1.0 (.039) 1.0 (.039)
New mm (in) 0.04 (.0016) 0.04 (.0016)
Wear Limit mm (in) 0.2 (.0079) 0.2 (.0079)
New ± 0.016 mm (± .0006 in) 0.118 (.0046) 0.118 (.0046)
Wear Limit mm (in) 0.20 (.0079) 0.20 (.0079)
New mm (in) 0.39 (.0154) 0.39 (.0154)
Wear Limit mm (in) 1.2 (.0472) 1.2 (.0472)
Trigger Coil ➃ Ω 190 – 300 190 – 300
Low Speed Ω 11.6 – 21.6 11.6 – 21.6
Generating Coil ➃
Lighting Coil ➃ Ω 0.1 – 0.4 0.1 – 0.4
Primary Ω 0.0 – 0.9 0.0 – 0.9
Secondary kΩ 9.5 – 16.5 9.5 –16.5
Pilot Jet 17.5 17.5
Needle Identification — Clip Position 9ZLY3/58 ➅ 9ZLY3/58 ➅
Air or Pilot Screw Adjustment ± 1/16 Turn 1-1/2 1-1/2
Type Liquid Liquid
ENGINE COLD
N•m (lbf•ft)
M6 9 (7) 9 (7)
M8 29 (21) 29 (21)
MMR2001_106_10_02A.FM 10-02-3
VEHICLE MODEL MX Z 800 STD/X/ADRENALINE SUMMIT 800 STD/X/H.M./H.M. X
ENGINE TYPE 793 793

Bore mm (in) 82.00 (3.228) 82.00 (3.228)
Stroke mm (in) 75.7 (2.980) 75.7 (2.980)
New mm (in) 0.4 (.016) 0.4 (.016)
Ring End Gap
Wear Limit mm (in) 1.0 (.039) 1.0 (.039)
New mm (in) 0.04 (.0016) 0.04 (.0016)
Wear Limit mm (in) 0.2 (.0079) 0.2 (.0079)
New ± 0.013 mm (± .0005 in) 0.145 (.0057) 0.145 (.0057)
Wear Limit mm (in) 0.20 (.0079) 0.20 (.0079)
New mm (in) 0.39 (.0154) 0.39 (.0154)
Wear Limit mm (in) 1.2 (.0472) 1.2 (.0472)
Trigger Coil ➃ Ω 190 – 300 190 – 300
Low Speed Ω 11.6 – 21.6 11.6 – 21.6
Generating Coil ➃
Lighting Coil ➃ Ω 0.1 – 0.4 0.1 – 0.4
Primary Ω 0.0 – 0.9 0.0 – 0.9
Secondary kΩ 9.5 – 16.5 9.5 – 16.5
Pilot Jet 17.5 17.5
Needle Identification — Clip Position 9ZLY2/58 ➅ 9ZLY2/58 ➅
Air or Pilot Screw Adjustment ± 1/16 Turn 1-1/2 1-1/2
Type Liquid Liquid
ENGINE COLD
N•m (lbf•ft)
M6 9 (7) 9 (7)
M8 29 (21) 29 (21)
10-02-4 MMR2001_106_10_02A.FM
VEHICLE MODEL MX Z 500 STD MX Z 500 TRAIL FORMULA DLX 500 STD

Pitch in 3/8 3/8 3/8
Chain
Drive Pulley Spring Color Green/Blue Green/Blue Green/Blue
Spring Length ± 1.5 mm 147.4 147.4 147.4

(± .060 in) (5.80) (5.80) (5.80)
Type Formula Formula Formula
Driven Pulley Spring Preload ± 0.7 kg (± 1.5 lb) 7.0 (15.4) 7.0 (15.4) 7.0 (15.4)
Cam Angle Degree 44 44 44
± 0.5 mm 16.5 16.5 16.5
Pulley Distance Z
(± .020 in) (.650) (.650) (.650)
± 0.5 mm 35.5 35.5 35.5
X
(± .020 in) (1.398) (1.398) (1.398)
Offset
Y–X MIN. – MAX. mm 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
(in) (.040 – .080) (.040 – .080) (.040 – .080)
± 5 mm 32 32 32
Deflection (± .197 in) (1.260) (1.260) (1.260)
Drive Belt Adjustment
Force ➁ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width cm (in) 38.1 (15.0) 38.1 (15.0) 38.1 (15.0)
Length cm (in) 307.4 (121) 307.4 (121) 307.4 (121)
Track
mm 30 – 35 30 – 35 30 – 35
Deflection
Adjustment (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Suspension Type
Ski ADSA ADSA ADSA
Length cm (in) 272.5 (107.3) 272.5 (107.3) 272.5 (107.3)
Width cm (in) 121.3 (47.7) 121.3 (47.7) 121.3 (47.7)
Height cm (in) 113.0 (44.5) 113.0 (44.5) 113.0 (44.5)
Ski Stance cm (in) 108 (42.5) 108 (42.5) 108 (42.5)
Toe-out and mm (in) 8 (5/16) 3 (1/8) 3 (1/8)
Camber degree -2 -1 N.A.
Mass (dry) kg (lb) 213 (468) 213 (468) 225 (496)
Ground Contact Area cm2 (in2) 6670.9 (1034) 6670.9 (1034) 6670.9 (1034)
Hood Material RRIM Polyurethane RRIM Polyurethane RRIM Polyurethane
Battery V/A•h N.A. N.A. 12/13
Headlight W H4 60/55 H4 60/55 H4 60/55
Fuel and Temperature Gauge Bulbs W N.A. N.A. 3
Starter Solenoid A N.A. N.A. 30
Fuse
Fuel Level Sensor A N.A. N.A. 0.25
Fuel Tank L (U.S. gal) 37.3 (9.9) 37.3 (9.9) 37.3 (9.9)
Cooling System ➃ L (U.S. oz) 3.8 (128.5) 3.8 (128.5) 3.8 (128.5)
MMR2001_106_10_03A.FM 10-03-1
VEHICLE MODEL GRAND TOURING 500 MX Z 600 STD/

ADRENALINE MX Z 600 TRAIL

Pitch in 3/8 3/8 3/8
Chain
Ramp Identification and Roller Pin Type 292X ➄ 293X ➄ 293X ➄
Drive Pulley Spring Color Blue/Yellow Green/White Green/White
Spring Length ± 1.5 mm 115.1 110.7 110.7

(± .060 in) (4.53) (4.35) (4.35)
Pulley Distance Z ± 0.5 mm 16.5 16.5 16.5

(± .020 in) (.650) (.650) (.650)
± 0.5 mm 35.5 35.5 35.5
X
(± .020 in) (1.398) (1.398) (1.398)
Offset
Y–X MIN. – MAX. mm 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
(in) (.040 – .080) (.040 – .080) (.040 – .080))
± 5 mm 32 32 32
Deflection (± .197 in) (1.260) (1.260) (1.260)
Force ➁ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width cm (in) 38.1 (15.0) 38.1 (15.0) 38.1 (15.0)
Length cm (in) 345.5 (136) 307.4 (121) 307.4 (121)
Track
mm 30 – 35 30 – 35 30 – 35
Deflection
Adjustment (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Suspension Type
Ski ADSA ADSA ADSA
Length cm (in) 297.8 (117.2) 272.5 (107.3) 272.5 (107.3)
Width cm (in) 121.3 (47.7) 121.3 (47.7) 121.3 (47.7)
Height cm (in) 123.2 (48.5) 113.0 (44.5) 113.0 (44.5)
Ski Stance cm (in) 108 (42.5) 108 (42.5) 108 (42.5)
Toe-out and mm (in) 3 (1/8) 8 (5/16) 3 (1/8)
Camber degree N.A. -2 -1
Mass (dry) kg (lb) 252 (554) 213 (469) 213 (469)
Battery V/A•h 12/13 N.A. N.A.
Headlight W H4 60/55 H4 60/55 H4 60/55
Fuel and Temperature Gauge Bulbs W N.A. N.A. N.A.
Fuse
Fuel Level Sensor A N.A. N.A. N.A.
Fuel Tank L (U.S. gal) 37.3 (9.9) 37.3 (9.9) 37.3 (9.9)
10-03-2 MMR2001_106_10_03A.FM
VEHICLE MODEL MX Z 600 X GRAND TOURING 600 FORMULA DLX 600

STD/GSE

Pitch in 3/8 3/8 3/8
Chain
Ramp Identification and Roller Pin Type 293X ➄ 281 ➄ 281 ➄
Drive Pulley Spring Color Green/White Blue/Yellow Violet/Yellow
Spring Length ± 1.5 mm 110.7 115.1 157.9

(± .060 in) (4.35) (4.53) (6.22)
± 0.5 mm 16.5 16.5 16.5
Pulley Distance Z
(± .020 in) (.650) (.650) (.650)
± 0.5 mm 35.5 35.5 35.5
X
(± .020 in) (1.398) (1.398) (1.398)
Offset
Y–X MIN. – MAX. mm 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
(in) (.040 – .080) (.040 – .080) (.040 – .080)
± 5 mm 32 32 32
Deflection (± .197 in) (1.260) (1.260) (1.260)
Force ➁ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width cm (in) 38.1 (15.0) 38.1 (15.0) 38.1 (15.0)
Length cm (in) 307.4 (121) 345.5 (136) 307.4 (121)
Profile Height mm (in) 24.5 (1.0) 22.3 (.880) 22.3 (.880)
Track
mm 30 – 35 30 – 35 30 – 35
Deflection
Adjustment (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Suspension Type
Ski ADSA ADSA ADSA
Length cm (in) 272.5 (107.3) 297.8 (117.2) 272.5 (107.3)
Width cm (in) 121.3 (47.7) 121.3 (47.7) 121.3 (47.7)
Height cm (in) 113.0 (44.5) 123.2 (48.5) 113.0 (44.5)
Ski Stance cm (in) 108 (42.5) 108 (42.5) 108 (42.5)
Toe-out and mm (in) 4 (5/32) 3 (1/8) 3 (1/8)
Camber degree -2 N.A. N.A.
Mass (dry) kg (lb) 213 (469) 252 (555) 226 (497)
Battery V/A•h N.A. 12/13 12/13
Headlight W H4 60/55 H4 60/55 H4 60/55
Fuel and Temperature Gauge Bulbs W N.A. 3 N.A.
Starter Solenoid A N.A. 30 30
Fuse
Fuel Level Sensor A N.A. 0.25 0.25
Fuel Tank L (U.S. gal) 37.3 (9.9) 37.3 (9.9) 37.3 (9.9)
MMR2001_106_10_03A.FM 10-03-3
VEHICLE MODEL SUMMIT 600 MX Z 700 STD/

ADRENALINE MX Z 700 TRAIL

Pitch in 3/8 3/8 3/8
Chain
Ramp Identification and Roller Pin Type 287 ➅ 300 ➄ 300 ➄
Drive Pulley Spring Color Pink/White Green/Violet Green/Violet
Spring Length ± 1.5 mm 124.5 133.7 133.7

(± .060 in) (4.90) (5.26) (5.26)

(± .020 in) (.650) (.650) (.650)
± 0.5 mm 35.5 35.5 35.5
X
(± .020 in) (1.398) (1.398) (1.398)
Offset
Y–X MIN. – MAX. mm 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
(in) (.040 – .080) (.040 – .080) (.040 – .080)
± 5 mm 32 32 32
Deflection (± .197 in) (1.260) (1.260) (1.260)
Force ➁ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width cm (in) 38.1 (15.0) 38.1 (15.0) 38.1 (15.0)
Length cm (in) 345.5 (136) 3307.4 (121) 307.4 (121)
Profile Height mm (in) 50.8 (2.0) 22.3 (.880) 22.3 (.880)
Track
mm 30 – 35 30 – 35 30 – 35
Deflection
Adjustment (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Track SC-10 Mountain SC-10 II SC-10 II
Suspension Type
Ski ADSA ADSA ADSA
Length cm (in) 293.9 (115.7) 272.5 (107.3) 272.5 (107.3)
Width cm (in) 107.3 (42.2) 121.3 (47.7) 121.3 (47.7)
Height cm (in) 113.0 (44.5) 113.0 (44.5) 113.0 (44.5)
Ski Stance cm (in) 94.0 (37.0) 108 (42.5) 108 (42.5)
Toe-out and mm (in) 8 (5/16) 8 (5/16) 3 (1/8)
Camber degree N.A. -2 -1
Mass (dry) kg (lb) 222 (489) 215 (472) 215 (472)
Battery V/A•h N.A. N.A. N.A.
Headlight W H4 60/55 H4 60/55 H4 60/55
Fuse
Fuel Tank L (U.S. gal) 37.3 (9.9) 37.3 (9.9) 37.3 (9.9)
10-03-4 MMR2001_106_10_03A.FM
VEHICLE MODEL MX Z 700 X GRAND TOURING 700 GS FORMULA DLX 700

GS/GSE

Pitch in 3/8 3/8 3/8
Chain
Drive Pulley Spring Color Green/Violet Blue/Blue Blue/Blue
Spring Length ± 1.5 mm 133.7 99.8 99.8

(± .060 in) (5.26) (3.93) (3.93)
± 0.5 mm 16.5 16.5 16.5
Pulley Distance Z
(± .020 in) (.650) (.650) (.650)
± 0.5 mm 35.5 35.5 35.5
X
(± .020 in) (1.398) (1.398) (1.398)
Offset
Y–X MIN. – MAX. mm 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
(in) (.040 – .080) (.040 – .080) (.040 – .080))
± 5 mm 32 32 32
Deflection (± .197 in) (1.260) (1.260) (1.260)
Force ➁ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width cm (in) 38.1 (15.0) 38.1 (15.0) 38.1 (15.0)
Length cm (in) 307.4 (121) 345.5 (136) 307.4 (121)
Track
mm 30 – 35 30 – 35 30 – 35
Deflection
Adjustment (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Suspension Type
Ski ADSA ADSA ADSA
Length cm (in) 272.5 (107.3) 297.8 (117.2) 272.5 (107.3)
Width cm (in) 121.3 (47.7) 121.3 (47.7) 121.3 (47.7)
Height cm (in) 113.0 (44.5) 123.2 (48.5) 113.0 (44.5)
Ski Stance cm (in) 108 (42.5) 108 (42.5) 108 (42.5)
Toe-out and mm (in) 4 (5/32) 3 (1/8) 3 (1/8)
Camber degree -2 N.A. N.A.
Mass (dry) kg (lb) 215 (472) 255 (560) 228 (502)
Ground Contact Area cm2 (in2) 6670.9 (1034) 7357 (1140) 6670.9 (1034)
Battery V/A•h N.A. 12/16 12/16
Headlight W H4 60/55 H4 60/55 H4 60/55
Fuel and Temperature Gauge Bulbs W N.A. 3 3
Starter Solenoid A N.A. 30 30
Fuse
Fuel Level Sensor A N.A. 0.25 0.25
Fuel Tank L (U.S. gal) 37.3 (9.9) 37.3 (9.9) 37.3 (9.9)
MMR2001_106_10_03A.FM 10-03-5
VEHICLE MODEL SUMMIT 700 STD/X SUMMIT 700 STD

(CAN./U.S.) (EUROPE) SUMMIT 700 H.M.

Pitch in 3/8 3/8 3/8
Chain
Ramp Identification and Roller Pin Type 299 ➅ 299 ➄ 299 ➅
Drive Pulley Spring Color Violet/Yellow Violet/Yellow Violet/Yellow
Spring Length ± 1.5 mm 157.9 157.9 157.9

(± .060 in) (6.22) (6.22) (6.22)

(± .020 in) (.650) (.650) (.650)
± 0.5 mm 35.5 35.5 35.5
X
(± .020 in) (1.398) (1.398) (1.398)
Offset
Y–X MIN. – MAX. mm 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
(in) (.040 – .080)) (.040 – .080) (.040 – .080)
± 5 mm 32 32 32
Deflection (± .197 in) (1.260) (1.260) (1.260)
Force ➁ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width cm (in) 38.1 (15.0) 38.1 (15.0) 38.1 (15.0)
Length cm (in) 364.8 (144) 364.8 (144) 383.6 (151)
Profile Height mm (in) 50.8 (2.0) 50.8 (2.0) 50.8 (2.0)
Track
mm 30 – 35 30 – 35 30 – 35
Deflection
Adjustment (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Track SC-10 Mountain SC-10 Mountain SC-10 Mountain
Suspension Type
Ski ADSA ADSA ADSA
Length cm (in) 294.7 (116.0) 294.7 (116.0) 315.3 (124.1)
Width cm (in) 107.3 (42.2) 107.3 (42.2) 107.3 (42.2)
Height cm (in) 113.0 (44.5) 113.0 (44.5) 113.0 (44.5)
Ski Stance cm (in) 94.0 (37.0) 94.0 (37.0) 94.0 (37.0)
Toe-out and mm (in) 3 (1/8) 3 (1/8) 8 (5/16)
Camber degree N.A. N.A. N.A.
Mass (dry) kg (lb) 224 (492) 224 (492) 226 (497)
Ground Contact Area cm2 (in2) 7356.7 (1140.3) 7356.7 (1140.3) 8271.1 (1282)
Headlight W H4 60/55 H4 60/55 H4 60/55
Fuse
Fuel Tank L (U.S. gal) 37.3 (9.9) 37.3 (9.9) 37.3 (9.9)
10-03-6 MMR2001_106_10_03A.FM
VEHICLE MODEL MX Z 800 STD/ SUMMIT 800 STD/X

ADRENALINE MX Z 800 X
(CAN./U.S.)

Pitch in 3/8 3/8 3/8
Chain
Ramp Identification and Roller Pin Type 300 ➄ 300 ➄ 300 ➅
Spring Length ± 1.5 mm 157.9 157.9 157.9

(± .060 in) (6.22) (6.22) (6.22)
Cam Angle Degree 53/47 53/47 50/47

(± .020 in) (.650) (.650) (.650)
± 0.5 mm 35.5 35.5 35.5
X
(± .020 in) (1.398) (1.398) (1.398)
Offset
Y–X MIN. – MAX. mm 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
(in) (.040 – .080) (.040 – .080) (.040 – .080)
± 5 mm 32 32 32
Deflection (± .197 in) (1.260) (1.260) (1.260)
Force ➁ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width cm (in) 38.1 (15.0) 38.1 (15.0) 38.1 (15.0)
Length cm (in) 307.4 (121) 307.4 (121) 364.8 (144)
Track
mm 30 – 35 30 – 35 30 – 35
Deflection
Adjustment (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Track SC-10 II SC-10 II SC-10 Mountain
Suspension Type
Ski ADSA ADSA ADSA
Length cm (in) 272.5 (107.3) 272.5 (107.3) 293.9 (115.7)
Width cm (in) 121.2 (47.7) 121.2 (47.7) 107.3 (42.2)
Height cm (in) 113.0 (44.5) 113.0 (44.5) 113.0 (44.5)
Ski Stance cm (in) 108 (42.5) 108 (42.5) 94.0 (37.0)
Toe-out and mm (in) 8 (5/16) 4 (5/32) 8 (5/16)
Camber degree -2 -2 N.A.
Mass (dry) kg (lb) 215 (474) 215 (474) 225 (494)
Ground Contact Area cm2 (in2) 6671 (1034) 6671 (1034) 7356.7 (1140.3)
Headlight W H4 60/55 H4 60/55 H4 60/55
Fuse
Fuel Tank L (U.S. gal) 37.3 (9.9) 37.3 (9.9) 37.3 (9.9)
MMR2001_106_10_03A.FM 10-03-7
VEHICLE MODEL SUMMIT 800 X SUMMIT 800 H.M./H.M. X SUMMIT 800 H.M. X
(EUROPE) (CAN./U.S.) (EUROPE)

Pitch in 3/8 3/8 3/8
Chain
Ramp Identification and Roller Pin Type 300 ➄ 300 ➅ 300 ➄
Spring Length ± 1.5 mm 157.9 157.9 157.9

(± .060 in) (6.22) (6.22) (6.22)
Cam Angle Degree 50/47 50/47 50/47
± 0.5 mm 16.5 16.5 16.5
Pulley Distance Z
(± .020 in) (.650) (.650) (.650)
± 0.5 mm 35.5 35.5 35.5
X
(± .020 in) (1.398) (1.398) (1.398)
Offset
Y–X MIN. – MAX. mm 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
(in) (.040 – .080) (.040 – .080) (.040 – .080)
± 5 mm 32 32 32
Deflection (± .197 in) (1.260) (1.260) (1.260)
Force ➁ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width cm (in) 38.1 (15.0) 38.1 (15.0) 38.1 (15.0)
Length cm (in) 364.8 (144) 383.6 (151) 383.6 (151)
Track
mm 30 – 35 30 – 35 30 – 35
Deflection
Adjustment (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Track SC-10 Mountain SC-10 Mountain SC-10 Mountain
Suspension Type
Ski ADSA ADSA ADSA
Length cm (in) 293.9 (115.7) 315.3 (124.1) 315.3 (124.1)
Width cm (in) 107.3 (42.2) 107.3 (42.2) 107.3 (42.2)
Height cm (in) 113.0 (44.5) 113.0 (44.5) 113.0 (44.5)
Ski Stance cm (in) 94.0 (37.0) 94.0 (37.0) 94.0 (37.0)
Toe-out and mm (in) 8 (5/16) 8 (5/16) 8 (5/16)
Camber degree N.A. N.A. N.A.
Mass (dry) kg (lb) 225 (494) 227 (499) 227 (499)
Ground Contact Area cm2 (in2) 7356.7 (1140.3) 8271.1 (1282) 8271.1 (1282)
Headlight W H4 60/55 H4 60/55 H4 60/55
Fuse
Fuel Tank L (U.S. gal) 37.3 (9.9) 37.3 (9.9) 37.3 (9.9)
10-03-8 MMR2001_106_10_03A.FM
ENGINE LEGEND VEHICLE LEGEND

BTDC: Before Top Dead Center ADSA: Advanced Direct Shock Action
CDI: Capacitor Discharge Ignition RRIM: Reinforced Reaction Injection Molding
K: Kilo (x 1000) TRA: Total Range Adjustable
ST: Semi-Trapezoidal N.A.: Not Applicable
MAG: Magneto Side ➀ Minimum allowable width may not be less than
N.A.: Not Applicable 3.0 mm (1/8 in) of new drive belt.
PTO: Power Take Off Side ➁ Force applied midway between pulleys to ob-
tain specified tension deflection.
➀ The maximum horsepower RPM applicable on
the vehicle. It may be different under certain cir- ➂ Force or downward pull applied to track to ob-
cumstances and BOMBARDIER INC. reserves tain specified tension deflection.
the right to modify it without obligation. ➃ Coolant mixture: 60% antifreeze/40% water.
➁ Crankshaft end-play is not adjustable on these ➄ Lever with roller pin (P/N 417 004 308) (solid).
models. Specification is given for verification ➅ Lever with roller pin (P/N 417 004 309) (hollow).
purposes only.
➂ At 3500 RPM with headlamp turned on.
➃ All resistance measurements must be per-
formed with parts at room temperature (approx.
20°C (68°F)). Temperature greatly affects resis-
tance measurements.
➄ Press fit type, not replaceable.
➅ Needle with one groove, not adjustable.
➆ Drive pulley retaining screw: torque to 90 to 100
N•m (66 to 74 lbf•ft), install drive belt, acceler-
ate the vehicle at low speed (maximum 30 km/h
lbf•ft).
MMR2001_106_10_04A.FM 10-04-1
WIRING DIAGRAMS 0
ELECTRICAL
WIRING
MODELS DIAGRAM
(watt) (watt) OUTPUT
PAGE
(watt)
Grand Touring 500/600 Annex 1 60/55 hal. 8/27 290
Grand Touring 700 Annex 2 60/55 hal. 8/27 290
MX Z 500/600/700 STD/TRAIL Annex 3 60/55 hal. 8/27 290
MX Z X/Adrenaline/600/700/800 Annex 4 60/55 hal. 8/27 290
Formula DLX STD/GS/GSE 600/700 Annex 5 60/55 hal. 8/27 290
Formula DLX STD 500/600 Annex 6 60/55 hal. 8/27 290
Summit 600/700/800 Annex 7 60/55 hal. 8/27 290
hal. = halogen
WIRING DIAGRAM LEGEND The first color of a wire is the main color, second
color is the stripe.
 WARNING Example: YL/BK is a YELLOW wire with a BLACK
stripe.
the wires and all connector housings are prop- COLOR CODE
erly fastened.
BE – BEIGE OR – ORANGE
BK – BLACK RD – RED
BU – BLUE VI – VIOLET
XX/XX BR – BROWN WH – WHITE
1 - MC GN – GREEN YL – YELLOW
D GY – GREY
A00I04E
1 2 34 CONNECTOR HOUSING AREA
1. Wire colors
2. Connector housing area
3. Housing code per area
4. Wire connector location in housing XX/XX
1 - MC
1
WIRE COLORS D
A00I04G
XX/XX
XX/XX
1- MC
A00I04F D
MMR2001_107_11_01A.FM 11-01-1
7
6
11 3
9 8 4 2 1
5 10
A06H33C
AREA LOCATION
2 Magneto
3 Carburetors
6 Under console
7 Under hood
8 Near fuel tank
9 Rear of seat
10 Under engine
HOUSING
XX/XX
1- MC
D
A00I04H
D
11-01-2 MMR2001_107_11_01A.FM
DEUTSCH
85
A A B 2 87
1
87a
B B A 1 86 30 2
2
1
A A
A A
A
B B
C C B B
B
C
A
B
C C A 3
A 1
B 21
A C B 2
A C 3
B B
A B A B
C B
D A C
C B D A C A
B
A B
A B
D C A
B A B 4
C D 1
2
3
1
4 2
3
PACKARD
A A
B B
C
6
5
1 4 1
2 2
3 6 3
5
4
A
A
B B
D C
C A
B 12
A CB 11
ED
1 10 1
2
F 2
3 12
9
8 3
4 11 7 4
5 10 5
6 9 6
8
A 7
D
C CB
D
V01G0EV A
B FE
MMR2001_107_11_01A.FM 11-01-3
SYMBOLS DESCRIPTION


ground ground
Frame

component
A00E55S
11-01-4 MMR2001_107_11_01A.FM

not on wire.
toward wire side.
A06E1PA
A00E1EA
TYPICAL

CONNECTORS REMOVAL
A00E1DA
TAB CONNECTOR
1. Locking tab
A06E1QA
MMR2001_107_11_01A.FM 11-01-5

To remove:
– Insert tool Snap-on TT 600-5 under lock and
twist to lift it.
A01E34A 1
1. Lock

housing.
A01E31A
A01E35A
Round Connector Housing

A01E32A

To remove:
A00E56A
A01E33A 1
1. Lock
11-01-6 MMR2001_107_11_01A.FM
2
A00E1FA
TYPICAL
A00E57A 1. Receptacle
2. Housing
TAB AND RECEPTACLE ACCESSORIES INSTALLATION

CONNECTORS INSTALLATION On all electric start models: The direct current
Prior to installing, make sure locking tab is suffi- (DC) utilizes the snowmobile frame as ground
ciently lifted to properly lock. “wire” while all alternating current (AC) consum-
ers (lights, heated grips, fuel gauge, etc.) utilize a
Insert tab and receptacle connectors in their re- separate ground wire.
tions. Push sufficiently so that they snap. Try pull- Never interconnect AC and DC grounds as an AC
ing wire to ensure they are properly locked. voltage drop will result. When installing accesso-
ing coil wires.
1 When an electric starter kit is installed, the voltage
A00E1GA
2  WARNING
Keep wires away from any rotating, moving,
1. Tab
2. Housing heating, vibrating or sharp edge. Use proper
fastening devices as required.
MMR2001_107_11_01A.FM 11-01-7
ANNEX 1 GRAND TOURING 500/600
ANNEX 2 GRAND TOURING 700
MX Z 500/600/
ANNEX 3 700 STD/TRAIL
MX Z X/ADRENALINE/
ANNEX 4 600/700/800
FORMULA DLX/STD/
ANNEX 5 GS/GSE 600/700
FORMULA DLX STD 500/
ANNEX 6 600
ANNEX 7 SUMMIT 600/700/800
Shop Manual
MINI Z
Legal deposit:

1st trimester 2000

Bombardier Inc.
Printed in Canada
®*Registered trademarks of Bombardier Inc. and/or its subsidiaries

Metton® is a trademark of Hercules Inc.
TABLE OF CONTENTS
INTRODUCTION .................................................................................................................................. IV
01 SERVICE TOOLS AND 01 – Service Tools ............................................................................ 01-01-1

SERVICE PRODUCTS 02 – Service Products ...................................................................... 01-02-1
02 LUBRICATION 01 – Lubrication and Maintenance Chart.......................................... 02-01-1

AND MAINTENANCE
03 TROUBLESHOOTING 01 – Table of Contents ..................................................................... 03-01-1

02 – Engine ...................................................................................... 03-02-1
03 – Fuel and Oil Systems ............................................................... 03-03-1
04 – Transmission and Brake Systems ............................................ 03-04-1
05 – Electrical System...................................................................... 03-05-1
06 – Suspension and Track .............................................................. 03-06-1
04 ENGINE 01 – Table of Contents ..................................................................... 04-01-1

02 – Engine Removal and Installation .............................................. 04-02-1
03 – Valve Adjustment ..................................................................... 04-03-1
04 – Disassembly/Assembly ............................................................ 04-04-1
05 – Compression Test and Engine Dimension Measurement........ 04-05-1
06 – Transistorized Magneto Ignition ............................................... 04-06-1
07 – Rewind Starter ......................................................................... 04-07-1
08 – Carburetor ................................................................................ 04-08-1
09 – Fuel Tank and Throttle Cable.................................................... 04-09-1
05 TRANSMISSION 01 – Table of Contents ..................................................................... 05-01-1

02 – Clutch ....................................................................................... 05-02-1
03 – Brake ........................................................................................ 05-03-1
04 – Drive Chain ............................................................................... 05-04-1
06 ELECTRICAL 01 – Table of Contents ..................................................................... 06-01-1

02 – Spark Plugs............................................................................... 06-02-1
03 – Testing Procedure .................................................................... 06-03-1
07 REAR SUSPENSION 01 – Table of Contents ..................................................................... 07-01-1

02 – Rear Suspension ...................................................................... 07-02-1
03 – Drive Axle ................................................................................. 07-03-1
04 – Track......................................................................................... 07-04-1
MMR2000_113_00_02A.FM I
TABLE OF CONTENTS
08 STEERING/ 01 – Table of Contents..................................................................... 08-01-1

FRONT SUSPENSION 02 – Steering System ...................................................................... 08-02-1
03 – Suspension and Ski System..................................................... 08-03-1
09 BODY AND FRAME 01 – Table of Contents..................................................................... 09-01-1

02 – Body......................................................................................... 09-02-1
03 – Frame....................................................................................... 09-03-1
10 TECHNICAL DATA 01 – SI Metric Information Guide..................................................... 10-01-1

02 – Engine ...................................................................................... 10-02-1
03 – Vehicle ..................................................................................... 10-03-1
04 – Technical Data Legends........................................................... 10-04-1
11 WIRING DIAGRAM 01 – Wiring Diagram ........................................................................ 11-01-1
II MMR2000_113_00_02A.FM
SAFETY NOTICE
SAFETY NOTICE 0
This manual has been prepared as a guide to correctly service and repair Ski-Doo Mini Z snowmobile.
This edition was primarily published to be used by snowmobile mechanics who are already familiar with
all service procedures relating to Bombardier made snowmobiles.
This Shop Manual uses technical terms which may be slightly different from the ones used in Parts
Catalog.
the english version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at its time of manufacture.
It does not include dealer modifications, whether authorized or not by Bombardier, after manufacturing
the product.
of the parts.
The engine and the corresponding components identified in this document should not be utilized on
self-locking fasteners, etc.) must be installed or replaced with new ones, where specified. If the efficiency
of a locking device is impaired, it must be renewed.
 WARNING
nents.
This information relates to the preparation and use of Bombardier snowmobiles and has been utilized
safely and effectively by Bombardier Inc. However, Bombardier Inc. disclaims liability for all damages
and/or injuries resulting from the improper use of the contents. We strongly recommend that any services
be carried out and/or verified by a highly skilled professional mechanic. It is understood that certain mod-
ifications may render use of the vehicle illegal under existing federal, provincial and state regulations.
MMR2000_113_00_02A.FM III
INTRODUCTION
INTRODUCTION 0
This Shop Manual covers the Ski-Doo Mini Z* snow- ENGINE SERIAL NUMBER
mobile.
* Trademark of Bombardier Inc. Engine Serial Number Location
VEHICLE IDENTIFICATION
NUMBER
Vehicle Identification Number Location
A31H09A 1
TYPICAL
1. Vehicle identification number
Vehicle Identification Number Meaning 1

2BPS15929Y1000001
Model year: y = 2000
A31H0RA
1 = 2001
2 = 2002 1. Engine serial number
A00A6EA etc.
IV MMR2000_113_00_02A.FM
INTRODUCTION
ARRANGEMENT OF THE MANUAL

03 TROUBLESHOOTING
04 ENGINE
05 TRANSMISSION
06 ELECTRICAL
07 REAR SUSPENSION
09 BODY/FRAME
10 TECHNICAL DATA
11 WIRING DIAGRAM
MMR2000_113_00_02A.FM V
INTRODUCTION
LIST OF ABBREVIATIONS USED Max. maximum

IN THIS MANUAL
Min. minimum
A ampere mL milliliter
amp ampere mm millimeter
A•h ampere-hour MPH mile per hour
AC alternate current N newton
°C degree Celsius N.A. not applicable
CCW counterclockwise no. number
cm centimeter 00.0 continuity
cm² square centimeter 0.L overload (open circuit)
cm³ cubic centimeter O.D. outside diameter
DC direct current OPT optional
°F degree Fahrenheit oz ounce
FC fan cooled P/N part number
fl. oz fluid ounce PSI pound per square inch
ft foot PTO power take off
GRD ground R rectangular
imp. oz imperial ounce RPM revolution per minute
in inch TDC top dead center
in² square inch U.S. oz ounce (United States)
in³ cubic inch V volt
k kilo (thousand) Vac volt (alternative current)
kg kilogram
kPa kilopascal
L liter
lb pound
lbf pound (force)
lbf/in² pound per square inch
LH left hand
m meter
MAG magneto
VI MMR2000_113_00_02A.FM
INTRODUCTION

TYPICAL PAGE
Page heading
indicates section
and subsection
detailed.
Subsection title
Subsection 01 (SUSPENSION SC-10 SPORT, TOURING AND MOUNTAIN) beginning of the
subsection.

indicate pertaining
1
models.
Low
temp.
grease
Low
temp. Loctite 7
grease 271
6 2
4 Loctite
11 271
Exploded view
19 6
Low
3
a liquid product
5
to be applied to
8
14
Loctite
a surface.
15 271 In this case
Loctite 271 to
11 screw threads.
SLE
only
11
Bold face number
271
this part.
Long track 17
models only Loctite
271
16 18
20
Loctite
271
Loctite
271 Short track models only
Loctite
for publishing 4 Nm
11
(35 lbfin)
the short track
Document
number for MMR2000_042_00-02A.FM 07-01-1
publishing
process.
must be torqued to Page numbering system:
4 Nm or 35 lbfin. 07: REAR SUSPENSION section
TOURING AND MOUNTAIN subsection
CAUTION: Pay attention to torque 1: First page of this subsection
specifications. Some of these are
A01A2AS
MMR2000_113_00_02A.FM VII
INTRODUCTION
TYPICAL PAGE
Title indicates
the bushing.
that particular
All Models
procedure for
A03D1YA
finished, so from
(P/N 413 703 100). 1
TYPICAL caption
view which does
not represent full
detail.
529 031 300
TOP VIEW
A
caption helps you
in understanding
1
529 031 200
A16D0IA
illustration.
TYPICAL TOP VIEW
A. 0 to 1 mm (0 to 3/64 in)
above illustration.
ADJUSTMENT
pulleys adjustment.
MMR2000_042_00-02A.FM 05-03-5

A01A2BS
VIII MMR2000_113_00_02A.FM
INTRODUCTION
GENERAL INFORMATION A number of procedures throughout the book re-

The information and component/system descrip- any procedure, be sure that you have on hand all
tions contained in this manual are correct at time the tools required, or approved equivalents.
of publication. Bombardier Inc. however, main-
vehicle).
factured.
obligation. 1 2
USEFUL PUBLICATIONS
specs.
ILLUSTRATIONS AND
PROCEDURES
Illustrations and photos show the typical construc-
tion of the different assemblies and, in all cases, A03A0CA
may not reproduce the full detail or exact shape of TYPICAL

the parts shown, however, they represent parts 1. Left
which have the same or a similar function. 2. Right
CAUTION: Most components of those vehicles

are built with parts dimensioned in the metric LOCTITE APPLICATION
system. Most fasteners are metric and must PROCEDURE
not be replaced by customary fasteners or vice-
versa. Mismatched or incorrect fasteners could
cation procedures when working with Loctite
cause damage to the vehicle or possible per-
products.
sonal injury.
NOTE: Always use proper strength Loctite prod-
As many of the procedures in this manual are in-
any task, you read and thoroughly understand the
entire section or subsection in which the proce-
dure is contained.
MMR2000_113_00_02A.FM IX
INTRODUCTION
THREADLOCKER 1. Clean threads (bolt and hole) with solvent.

Uncovered Holes (bolts and nuts) threads (bolt and nut) and allow to dry for 30
seconds.
Blind Holes
1 3
2
A00A3LA
2
1. Apply here
2. Do not apply

threads and allow to dry. A00A3NA
3. Choose proper strength Loctite threadlocker. 1. On threads

4. Fit bolt in the hole. 2. On threads and in the hole
3. Onto nut threads
tightened nut engagement area. 1. Clean threads (bolt and hole) with solvent.
6. Position nut and tighten as required. 2. Apply Loctite Primer N (P/N 293 800 041) on
Blind Holes 3. Put several drops of proper strength Loctite
threadlocker on female threads and in hole.
1 on stud threads.
5. Install stud.
2 6. Install cover, etc.
covered threads.
A00A3MA
1. On threads
X MMR2000_113_00_02A.FM
INTRODUCTION
Preassembled Parts NOTE: If it is difficult to readjust, heat screw with


1 Stripped Threads
5
1
6
8
2
2
3
A00A3OA
1. Apply here
2. Do not apply A00A3QA 4 7
1. Clean bolts and nuts with solvent. 1. Release agent
2. Stripped threads
2. Assemble components. 3. Form-A-Thread
4. Tape
3. Tighten nuts. 5. Cleaned bolt
6. Plate
4. Apply drops of proper strength Loctite on 7. New threads
bolt/nut contact surfaces. 8. Threadlocker
5. Avoid touching metal with tip of flask. Standard Thread Repair

NOTE: For preventive maintenance on existing 1. Follow instructions on Loctite FORM-A-
equipment, retighten nuts and apply proper THREAD (P/N 413 708 600) package.
strength Loctite on bolt/nut contact surfaces. 2. If a plate is used to align bolt:
Adjusting Screw a. Apply release agent on mating surfaces.
b. Put waxed paper or similar film on the surfac-
es.
2 3. Twist bolt when inserting it to improve thread
1 conformation.
NOTE: NOT intended for engine stud repairs.
Repair of Small Holes/Fine Threads
A00A3PA 1. Use a stud or thread on desired length.
1. Apply here 2. DO NOT apply release agent on stud.
2. Plunger
4. Allow to cure for 30 minutes.
5. Assemble.
locker on screw/body contact surfaces.
MMR2000_113_00_02A.FM XI
INTRODUCTION
GASKET COMPOUND MOUNTING ON SHAFT

All Parts Mounting with a Press
1 2
1
1
2
A00A3UA
1. Bearing
A00A3SA 1 3 2. Proper strength Loctite
3. Shaft
2. Loctite Primer N (P/N 413 708 100) and Gasket Eliminator 515 Standard
3. Loctite Primer N only 1. Clean shaft external part and element internal
1. Remove old gasket and other contaminants part.
with Loctite Chisel remover (P/N 413 708 500). 2. Apply a strip of proper strength Loctite on shaft
Use a mechanical mean if necessary. circumference at insert or engagement point.
NOTE: Avoid grinding. NOTE: Retaining compound is always forced out
2. Clean both mating surfaces with solvent. when applied on shaft.
3. Spray Loctite Primer N on both mating surfaces 3. DO NOT use anti-seize Loctite or any similar
and on both sides of gasket. Allow to dry 1 or 2 product.
minutes. 4. No curing period is required.
4. Apply GASKET ELIMINATOR 515 (P/N 413 702 Mounting in Tandem
plicator.
bore.
immediately.
NOTE: If the cover is bolted to blind holes (above),
apply proper strength Loctite in the hole and on
threads. Tighten.
on bolt threads.
6. Tighten as usual.
XII MMR2000_113_00_02A.FM
INTRODUCTION
CASE-IN COMPONENTS
Metallic Gaskets
A00A3VA 1
1. Clean inner housing diameter and outer gasket

diameter.
2. Spray housing and gasket with Loctite Primer N
(P/N 293 800 041).
3. Apply a strip of proper strength Loctite on lead-
ing edge of outer metallic gasket diameter.
NOTE: Any Loctite product can be used here. A
low strength liquid is recommended as normal
4. Install according to standard procedure.
NOTE: Normally used on worn-out housings to
compound applied on outer gasket diameter.
MMR2000_113_00_02A.FM XIII
INTRODUCTION

FASTENER SIZE
Lbf•ft
(8.8 GRADE)
Tighten fasteners to torque mentioned in exploded
views and text. When they are not specified refer 83 M12 61
to following table. All torques apply to 8.8 grade 84 M12 62
fasteners. Bold face size (e.g. M4) indicates nomi- 121 M14 89
nal value (mean value).
122 M14 90
N•m Lbf•in
(8.8 GRADE)
124 M14 91
2 M4 18
125 M14 92
3 M4 27
126 M14 93
4 M5 35
127 M14 94
8 M6 71
128 M14 94
9 M6 80
129 M14 95
10 M6 89
130 M14 96
11 M6 97
131 M14 97
12 M6 106
132 M14 97
N•m Lbf•ft
(8.8 GRADE)
134 M14 99
21 M8 15
135 M14 100
22 M8 16
136 M14 100
23 M8 17
137 M14 101
24 M8 18
138 M14 102
25 M8 18
139 M14 103
43 M10 32
140 M14 103
44 M10 32
141 M14 104
45 M10 33
142 M14 105
46 M10 34
143 M14 105
47 M10 35
144 M14 106
48 M10 35
145 M14 107
49 M10 36
146 M14 108
50 M10 37
147 M14 108
51 M10 38
148 M14 109
52 M10 38
149 M14 110
53 M10 39
150 M14 111
76 M12 56
TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS
77 M12 57
78 M12 58
79 M12 58
80 M12 59
81 M12 60
82 M12 60
XIV MMR2000_113_00_02A.FM
Machine___________________ Report of error
Suggestion
____________________________________________________________
communicate to Bombardier any sug-
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
Name ______________________________________________________
Address ____________________________________________________

Suggestion
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
Name ______________________________________________________
Address ____________________________________________________

Suggestion
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
Name ______________________________________________________

Address ____________________________________________________
AFFIX
PROPER
POSTAGE
After Sales Service
Valcourt, Québec, Canada J0E 2L0
AFFIX
PROPER
POSTAGE
After Sales Service
AFFIX
PROPER
POSTAGE
After Sales Service
SERVICE TOOLS 0
This is a list of tools to properly service Ski-Doo snowmobile models specified on cover page. The list
includes both the mandatory tools and the optional tools that are ordered separately. The list of Service
MMR2000_114_01_01A.FM 01-01-1

Hose pincher (2)
(P/N 295 000 076)
A01B2I4
APPLICATION
All vehicles.
Fluke multimeter
(P/N 529 022 000)
F01B1O4
APPLICATION
All models.
01-01-2 MMR2000_114_01_01A.FM

Circuit tester Driver tool Pilot 22 mm
(P/N 414 012 200)
A00B4O4
APPLICATION
A00C214
Crankcase bearings.
APPLICATION
All models. Attachment
A00B4Q4

Digital/induction type Crankcase bearings.
tachometer
(P/N 529 014 500) Float level gauge
(P/N 529 035 520)
A00B4P4
4
APPLICATION
3
Crankcase bearings.
2
F01B1G4
1
APPLICATION
All engines. A00B4N4
APPLICATION
All models.
MMR2000_114_01_01A.FM 01-01-3

Clutch holder
(P/N 529 006 400)
A01B154
APPLICATION
All TRA drive pulleys and Mini Z fly-
wheel.
Tension tester
(P/N 414 348 200)
A03D1T4
APPLICATION
All models.
01-01-4 MMR2000_114_01_01A.FM

Drive axle sprocket adjuster

(P/N 861 725 700)
5
2
3
1
6
A01B2O4
APPLICATION
All vehicles.
(P/N 529 010 700)
(P/N 529 010 800)
3) Plate
(P/N 529 010 600)
4) Bolt M10 (2)
(P/N 222 007 565)
(P/N 222 983 065)
6) Screw M8 (2)
(P/N 222 082 565)
NOTE: When the tool is to be use
screw M8.
MMR2000_114_01_01A.FM 01-01-5
SUSPENSION — RECOMMENDED SERVICE TOOLS

Track tension gauge
(P/N 529 021 500)
A00B3X4
APPLICATION
All models.
Drill bit
(P/N 529 031 800)
A01B564
APPLICATION
All 3/16 in rivets.
01-01-6 MMR2000_114_01_01A.FM

Protective mat
(P/N 529 030 600)
A01B45W
APPLICATION
All models.
Snowmobile jack
(P/N 529 020 000)
A01A1JJ
APPLICATION
All models.
MMR2000_114_01_01A.FM 01-01-7
SERVICE PRODUCTS 0
Loctite® is a trademarks of Loctite Corporation.
Dow Corning® is a trademarks of Dow Corning Corporation.
(P/N 413 703 100) (P/N 413 702 700) (P/N 293 800 015)
A00B2T4
APPLICATION
Crankcase halves and gearbox
mating surfaces.
A00B2S4
Paste gasket A00B324
(P/N 293 800 038)
Loctite® 518:
Used for retaining bushings, bear- Flywheel nut, crankcase studs, etc.
ings in slightly worn housing or on Gasket eliminator (50 mL)
NOTE: Loctite 242 will be replaced
shaft. by Loctite 243 (P/N 293 800 060).
Sealing compound High strength threadlocker

(P/N 420 297 905)
F01B124 (P/N 293 800 005)
APPLICATION Loctite® 271:
Crankcase halves and gearbox Threadlocker (10 mL)
mating surfaces. (red, high strength)
A00B2U4
A00B564 APPLICATION
APPLICATION Fasteners and studs up to 25 mm
To seal crankcase on all ZX series (1 in) diameter.
engines.
MMR2000_114_01_02A.FM 01-02-1

Gasket/paint remover Silicone compound Petamo grease
(P/N 413 708 500) (P/N 293 550 004) (P/N 420 899 271)
Loctite® Chisel Dow Corning® MS4
510 g (18 oz)
A00B3R4
APPLICATION
wind starter.
to the P/N 420 897 061.
Grease Isoflex
(50 g) A00B584

A00B574
Loctite® primer
(P/N 293 800 041)
Primer N
170 g (6 oz)
A00B554
APPLICATION
To lubricate some bearings on 3-
cylinder, 453, 493, 593 and 693 en-
gines.
A00B3N4
APPLICATION
to the P/N 413 708 100.
01-02-2 MMR2000_114_01_02A.FM

Silicone dielectric grease Synthetic chaincase oil Injection oil
(3 oz) (12 x 355 mL) (P/N 413 802 900)
(P/N 293 550 004) (P/N 413 803 300) (12 x 1 liter)
(P/N 413 803 000)
(3 x 4 liter)
(P/N 413 803 200)
(205 liter)
A00B1X4
APPLICATION
® ®

changed. This product is identical ®
to the P/N 413 701 700.

F01B2H4
A01B4Q4
Grease LMZ no. 1 APPLICATION
(400 g) APPLICATION All engines.
(P/N 413 707 500) Chaincase lubricant on all liquid-
cooled models and Skandic WT
series. BOMBARDIER-ROTAX Formula
XP-S synthetic injection oil
(P/N 413 710 500)
A00B1Y4 Blizzard oil (12 x 1 liter)
(12 x 500 mL)
(P/N 413 803 100) (3 x 4 liter)
Mainly used between regulators TYPICAL
or rectifiers and upper column to (P/N 413 710 700)
transfer the heat build-up and to (205 liter)
assure a good ground.
Chaincase oil
(16 x 250 mL)
(P/N 413 801 900)
Two-stroke
Injection Oil
F01B354
A00B2Q4
APPLICATION
APPLICATION
All engines.
All pre-mix models.
A00B2R4
APPLICATION
Chaincase lubricant on all fan-
series.
MMR2000_114_01_02A.FM 01-02-3

Pipe sealant Anti-seize lubricant Storage oil
(P/N 293 800 018) (P/N 293 800 023) (350 g spray can)
(12 x 350 g)
Loctite 592 (50 mL) Loctite anti-seize
lubricant 454 g (16 oz) (P/N 413 711 600)
A00B2W4
APPLICATION
Engine plugs and senders.
to the P/N 413 702 300.
High temperature threadlocker

(P/N 413 711 400)
Loctite 648 (green) (5 mL)
A00B594 A02B054
Unpainted surfaces of driven pul- All models.
ley countershaft. NOTE: Only the P/N has been
to the P/N 496 014 100.
Synthetic grease
(400 g)
(P/N 413 711 500) Degreaser
(P/N 413 708 400)
A00B3D4
Permatex® 48 TA
APPLICATION 433 g (15 oz)
crankcase.
NOTE: Only the P/N has been A01B574

APPLICATION
to the P/N 420 899 788.
For front and rear suspension
components and drive axle bear-
ing.
A00B3K4
APPLICATION
Engine, chaincase and any greasy
surfaces.
01-02-4 MMR2000_114_01_02A.FM

Plastic & vinyl cleaner Gel instant adhesive Paint for frame touch-up
(P/N 413 711 200) (P/N 413 708 300) (P/N 413 401 000)
6x1L Loctite 454-40 Black semi-gloss
20 g (.70 oz) (spray can)
A00B3O4
APPLICATION
Tough adhesive
(P/N 413 408 300) A00B3H4
Loctite Black Max

3 mL (.10 oz) APPLICATION
A00B4V4
General purpose instant adhesive

APPLICATION
Loctite 495 (3 g)
Hood, bottom pan and seat. A00B3P4
(P/N 293 800 021)

APPLICATION
Parts cleaner Shifter boot or grip.
(P/N 413 711 809)
320 g Stripped threads repair kit A00B2V4
(P/N 413 708 600)

APPLICATION
Form-A-thread 81668
hard plastic.
to the P/N 413 703 200.
A00A1J4
APPLICATION
Repair damaged threads of grade
5 (SAE) or 8.8 (metric) maximum.
Do not use in applications where
temperatures will exceed 149°C
A00B4X4
(300°F) or on critical assemblies.
APPLICATION
pulleys and any greasy surfaces.
tite Safety solvent (P/N 413 708
200).
MMR2000_114_01_02A.FM 01-02-5

High temperature RTV sealant Clear silicone Shock oil
Ultra Copper (P/N 293 800 033) (32 oz)
(P/N 413 710 300) (P/N 413 711 806)
(80 mL)
F01B1S4
APPLICATION
Fuel stabilizer
(12 x 8 oz) A06F0P4
(P/N 413 408 600)

APPLICATION
T/A shocks.
Bombardier Lube
(12 x 14 oz)
A00B5A4 (P/N 293 600 016)
APPLICATION
All models.
Bombardier cleaner
A00B3V4
(P/N 293 110 001) (400 g)
(P/N 293 110 002) (4 L) APPLICATION
All models.
Molykote 111
(P/N 413 707 000)
111
A00B4W4
A00B3W4
APPLICATION
APPLICATION Steering ball joints on all models.
F01B2J4
APPLICATION cept ZX series ones.
All models.
01-02-6 MMR2000_114_01_02A.FM

Super Lube (grease)
(P/N 293 550 014)
A00B474
APPLICATION
MMR2000_114_01_02A.FM 01-02-7
LUBRICATION AND MAINTENANCE

CHART 0

10-HOUR INSPECTION
ONCE A YEAR
MONTHLY
STORAGE
WEEKLY
Condition
Subsection 04-07
Engine Head Nuts Appropriate section:

See TOP END
Engine Mount Nuts Appropriate section:

See ENGINE REMOVAL
Exhaust System Appropriate section:

See ENGINE REMOVAL
Engine Lubrication This section no. 3
Cooling System Condition Subsection 04-06
Valve Clearance Subsection 04-03
Condition of Seals Subsection 04-04
Oil Level EACH USE This section no. 1
Oil Change 6 MONTHS This section no. 2
Fuel Filter Replacement This section no. 5
Fuel Strainer Cleaning This section no. 6
Fuel Lines and Connections Subsection 04-09
Carburetor Adjustment Subsection 04-08
Throttle Cable Inspection Subsection 04-09

Condition of Drive and Driven Sprockets Subsections 05-03 and 05-04
Lubrication of Drive and Driven
Sprockets
Subsections 05-03 and 05-04
Retorquing of Clutch Screw Subsection 05-02

Brake Condition Subsection 05-03
Brake Adjustment Subsection 05-03
Drive Chain Tension and Lubrication Subsection 05-04
Lubrication of Drive Axle Bearing Subsection 07-03

Mechanism
Subsections 08-02 and 08-03
Wear and Condition of Skis and Runners Subsection 08-03
MMR2000_115_02_01A.FM 02-01-1

10-HOUR INSPECTION
ONCE A YEAR
MONTHLY
STORAGE
WEEKLY
Suspension Condition Section 07:
Suspension Stopper Straps Condition Section 07:

Track Condition Subsection 07-04
Track Tension and Alignment AS REQUIRED Subsection 07-04
Spark Plug * Subsection 06-03
Headlight Beam Aiming Subsection 09-03
Wiring Harnesses, Cables and Lines Subsection 09-03
(headlight and taillight)
Operator’s Guide
Rags in Air Intake and Exhaust System This section no. 8
Engine Compartment This section no. 9
Vehicle Cleaning and Protection This section no. 10
* Before installing new spark plug at pre-season preparation, it is suggested to burn excess storage oil by
starting the engine with the old spark plug. Only perform this operation in a well ventilated area.
02-01-2 MMR2000_115_02_01A.FM
NO. 1 – ENGINE OIL LEVEL

With snowmobile on a level surface, check the oil
level by removing dipstick at engine base.
Oil level must be to the top of the oil filler neck. If
not, refill up to oil filler neck using SAE 5W/30 rec-
ommended oil. Refer to TECHNICAL DATA.
1 2
A31C14A
1. Hold pipe
2. Remove oil drain cap
NO. 3 – ENGINE LUBRICATION

Engine internal parts must be lubricated to protect
them from possible rust formation during the stor-
age period.
Proceed as follows:
Start the engine and allow it to run at idle speed
until the engine reaches its operating temperature.
1
 WARNING
Ensure the track is free of all particles which
could be thrown out while it is rotating. Keep
Ensure no one is standing in close proximity
A31C2ZA
to the vehicle.
ADD OIL UNTIL IT REACHES THE TOP OF THE OIL FILLER NECK
1. Top of the oil filler neck Stop the engine.
Remove carburetor cap to spray storage oil into
NO. 2 – ENGINE OIL CHANGE carburetor bore.
Refer to LUBRICATION AND MAINTENANCE Restart engine and run at idle speed.
CHART 02-01. Inject storage oil until the engine stalls or until a
To drain oil from engine, hold pipe using a key sufficient quantity of oil has entered the engine
then unscrew cap from underneath front of snow- (approximately half a can).
mobile. See next photo. With the engine stopped, remove the spark plug
NOTE: To completely drain oil from engine, keep and spray storage oil (P/N 496 014 100) into cylin-
snowmobile leveled. der.
Crank slowly 2 or 3 revolutions to lubricate cylin-
der.
MMR2000_115_02_01A.FM 02-01-3
Reinstall the spark plug. NO. 6 – FUEL STRAINER

 WARNING Turn off fuel valve.
well ventilated area. Do not run engine during
storage period.
NO. 4 – FUEL STABILIZER

A fuel stabilizer (P/N 413 408 600) can be added in
fuel tank to prevent fuel deterioration and avoid
draining fuel system for storage. Follow manufac-
If above fuel stabilizer is not used, drain fuel sys-
tem including fuel tank and carburetor.
CAUTION: Fuel stabilizer should be added pri- A31C06A
or the engine lubrication to ensure carbure- FUEL VALVE TO “OFF” POSITION

tor(s) protection against varnish deposit.
Remove the strainer cup, as shown in the next
photo.
NO. 5 – FUEL FILTER
REPLACEMENT
Drain fuel tank.
Remove fuel line grommet from fuel tank and pull
out inlet fuel line from tank.
1 2
A31C0NA 1 2
REMOVE STRAINER CUP
A31I03A
1. O-ring
2. Strainer cup
1. Fuel filter
2. Fuel hose
Clean the strainer cup with cleaning solvent (P/N
Replace fuel filter. 413 708 200).
Reinstall strainer cup with O-ring and tighten to
4 N•m (36 lbf•in).
02-01-4 MMR2000_115_02_01A.FM
NO. 7 – DRIVE CHAIN CONDITION For bottom pan cleaning, use Bombardier Cleaner
(P/N 293 110 001 (spray can 400 g) and P/N 293
Visually inspect the chain for cracked, damaged or 110 002 (4 L)).
missing link rollers.
Check for defective bearings, sprockets and worn decals or vinyl.
chain tensioner components.
Lubricate drive chain as per lubrication chart. with a thin coat of grease, use Simple Green®
Use BOMBARDIER LUBE (P/N 293 600 000). from Sunshine Makers Inc., available at hardware
CAUTION: Always lubricate drive chain slight-
ly. Oil must not contact brake pad. For vinyl and plastic parts, use Vinyl & Plastic
Cleaner (P/N 413 711 200 (6 x 1 L)).
NO. 8 – RAGS IN AIR INTAKE AND To remove scratches on windshield or hood: Start
EXHAUST SYSTEM with “Slip Streamer Motorcycle Windshield
Heavy Duty Scratch, Remover”. Finish with “Slip
At storage preparation, block air intake hole and Streamer Motorcycle Cleaner and Polish”.
exhaust system hole using clean rags. NOTE: The latest product may be use alone if only
Remove those rags at pre-season preparation. light scratches are noticeable.
CAUTION: Never clean plastic parts or hood
NO. 9 – ENGINE COMPARTMENT with strong detergent, degreasing agent, paint
Keep clean of grass, twigs, cloth, etc. These are thinner, acetone, products containing chlorine,
combustible under certain conditions. etc.
Inspect the hood and repair any damage. Touch up
NO. 10 – VEHICLE CLEANING AND all metal spots where paint has been scratched
off. Spray all metal parts with BOMBARDIER
PROTECTION LUBE (P/N 293 600 016). Wax the hood and the
Remove any dirt or rust. painted portion of the frame for better protection.
To clean the entire vehicle, use only flannel clothes NOTE: Apply wax on glossy finish only. Protect
or Kimtowels® wipers no. 58-380 from Kimberly- the vehicle with a cover to prevent dust accumu-
Clark. lation during storage.
CAUTION: It is necessary to use flannel cloths CAUTION: The snowmobile has to be stored in
or Kimtowels wipers on windshield and hood a cool and dry place and covered with an
to avoid damaging further surfaces to clean. opaque tarpaulin. This will prevent sun rays
and grime from affecting plastic components
and vehicle finish.
by Bristol Myers, available at hardware stores or Lift rear of vehicle until track is clear of the ground.
supermarkets. Install on a snowmobile mechanical stand.
MMR2000_115_02_01A.FM 02-01-5
TABLE OF CONTENTS 0
ENGINE .................................................................................................................................. 03-02-1
FUEL AND OIL SYSTEMS ..................................................................................................... 03-03-1

TRANSMISSION ................................................................................................................ 03-04-1
BRAKE SYSTEM ................................................................................................................ 03-04-3
MECHANICAL BRAKE ....................................................................................................... 03-04-3
MMR2000_116_03_01ATOC.FM 03-01-1
ENGINE 0
as a guideline.
Test/Inspection 1. Check spark plug.

a. Carbon accumulation caused by defective spark plug.
Clean carbon accumulation and replace spark plug.
a. Timing is fixed but ensure that woodruff key holding flywheel is in place.
Test/Inspection 1. Check spark plug condition.

a. Fouled spark plug(s).
Replace.
3. Check governor adjustment.
a. Governor out of adjustment.
Readjust.

Adjust according to specifications (refer to TECHNICAL DATA 10) or clean.
5. Check valve clearance.
a. Valve clearance incorrect.
Readjust.
6. Check valve condition.
a. Valve or valve seat worn or damaged.
Inspect and correct.

Align track and adjust its tension to specifications (refer to TECHNICAL DATA 10).
MMR2000_116_03_02A.FM 03-02-1

a. Restriction.
Replace.
9. Check ignition system.
a. Decrease in power due to incorrect ignition.
Check spark plug and ignition coil operation.
Replace (refer to TECHNICAL DATA 10 for specification).

Install recommended spark plug(s) (refer to TECHNICAL DATA 10).

Replace.
4. Check ignition system.
a. Incorrect ignition.
Check spark plug and ignition coil operation.
Clean or replace according to specification (refer to TECHNICAL DATA 10).
03-02-2 MMR2000_116_03_02A.FM

Place all switches in the RUN or ON position.

a. Defective spark plug (no spark).
Replace spark plug.
a. Spark plug wet (flooded engine).
Clean and dry spark plug. Reinstall spark plug and start engine taking care not to
use choke. If flooding is severe, check carburetor float valve, then change engine
oil.
b. Spark plug dry (no fuel to the engine).
Check fuel tank level; check if fuel valve is opened: check fuel strainer, clean if
clogged ; check condition of fuel lines and their connections.
Check carburetor main jet and nozzle.
5. Check the ignition system.

a. No spark or weak spark.
Replace parts as indicated in section electrical system.
Check valve clearance; carbon accumulation; defective cylinder head gasket,
valves or valve seats; Check for worn piston rings, piston or cylinder. Replace
defective part(s) (ex. : piston(s), ring(s), etc.).
7. Verify check valve on top of fuel tank.

a. Improperly installed or obstructed.
Install with vented side toward atmosphere or replace.
MMR2000_116_03_02A.FM 03-02-3

a. Choke plate may be partially closed.
Readjust.
2. Check pilot screw position.
Adjust according to specifications (refer to TECHNICAL DATA 10).
3. Check ignition system coil air gap.

4. Check dimension of main jet.
Check valve clearance; carbon accumulation; defective cylinder head gasket,
valves or valve seats.
Check for worn piston rings, piston or cylinder. Replace defective part(s)
(ex.: piston(s), ring(s), etc.).
Test/Inspection 1. Check cooling fins of engine.

a. Dirt accumulation between engine fins.
Clean thoroughly.
Adjust according to specifications (refer to TECHNICAL DATA 10) or replace
3. Check cylinder head gasket.
a. Worn gasket.
Replace.
4. Check condition and heat range of spark plug.

Replace.
5. Check exhaust condition.
a. Carbon deposit.
Clean.
03-02-4 MMR2000_116_03_02A.FM

a. Broken spring.
Replace spring.
SYMPTOM REWIND STARTER RATCHET DOES NOT ENGAGE.
Test/Inspection 1. Check ratchet and ratchet guide.

a. Ratchet and ratchet guide have stuck together because of dirt or heat.
Clean or replace.
2. Check ratchet and rope sheave.
a. Ratchet and rope sheave have stuck together because of heat.
Replace.

2. Check if carburetor is clean.
Clean.
MMR2000_116_03_02A.FM 03-02-5

as a guideline.

Replace fuel tank.
2. Check carburetor fittings.
a. Fuel level is too high in float bowl.
Test/Inspection 1. Check fuel filter or strainer.

a. Clogged filter or strainer.
Clean.
3. Check if carburetor is clean.

a. Varnish.
Clean.
4. Verify check valve on top of fuel tank.
a. Improperly installed or obstructed.
Install with vented side toward atmosphere or replace.
MMR2000_116_03_03A.FM 03-03-1
Test/Inspection 1. Check fuel filter or strainer.

a. Clogged filter or strainer.
Clean.
a. Lines are too big for their fittings or are improperly rooted.
3. Check main jet.

Clean.
4. Check float height in carburetor bowl.
Adjust float lever height according to specification.
03-03-2 MMR2000_116_03_03A.FM

as a guideline.
TRANSMISSION

a. Drive chain automatic tensioner is too loose.
Replace tensioner.
b. Drive chain is worn out.
Replace drive chain with new one.
SYMPTOM VIBRATIONS ORIGINATING FROM DRIVEN SPROCKET.
Test/Inspection 1. Check driven sprocket hub fit with drive axle.

a. Driven sprocket is loosened on drive axle.
Replace driven sprocket or drive axle.
2. Check drive chain.
a. Drive chain is worn out. It rubs on frame.
Replace drive chain.
SYMPTOM VIBRATIONS ORIGINATING FROM DRIVE SPROCKET.
Test/Inspection 1. Check tightening torque of drive sprocket screw.

a. Moving drive sprocket.
Retighten screw.
b. Worn key way.
Replace parts.
SYMPTOM CLUTCH DO NOT OPERATE PROPERLY.
Test/Inspection 1. Replace clutch with new one.
MMR2000_116_03_04A.FM 03-04-1
SYMPTOM EXCESSIVE NOISE WITH DRIVE CHAIN.
Test/Inspection 1. Check drive chain lubrication.

a. Drive chain is dry.
Lubricate drive chain.
2. Check drive chain condition.
a. Chain is cracked, damaged or some link rollers are missing.
3. Check sprockets.
a. Excessive wear at sprocket teeth.
Replace sprockets.
4. Check drive chain.
a. Drive chain is worn out. It rubs on frame.
03-04-2 MMR2000_116_03_04A.FM
BRAKE SYSTEM
MECHANICAL BRAKE
SYMPTOM BRAKE HANDLE DOES NOT RETURN COMPLETELY.
Test/Inspection 1. Check brake return spring.

a. Broken return spring.
Replace.
2. Check if brake cable moves freely in its housing.
a. Brake cable movement is limited due to oxidation or dirt accumulation.
Replace.
3. Check distance between brake lever and caliper.
a. Distance is too wide.
Adjust according to specifications (refer to TRANSMISSION 05).

a. Pad is worn up to wear limit.
Replace.
2. Check brake attachment.

a. Attachment is loose or cracked.
Tighten or replace.
3. Check brake pad alignment.
a. Brake pad is not properly aligned with clutch.
Rotate brake pad 180° or replace with new one.
MMR2000_116_03_04A.FM 03-04-3
ELECTRICAL SYSTEM 0
as a guideline.

a. Burnt bulb.
Replace bulb.

Ensure proper wire connections and grounding. Retest.
b. Wires are worn or loose.
Ensure proper wire connections and grounding. Retest.
MMR2000_116_03_05A.FM 03-05-1
SYMPTOM ENGINES DOES NOT START — NO SPARK AT SPARK PLUG.

Identify source of problem and correct. Replace spark plug.
a. Defective part.
Replace cap.

accessories and/or ignition cut-out switches. Check condition of connectors.
4. Verify ignition coil resistance with an ohmmeter and connector condition.

Test/Inspection 1. Verify items 3, 4, 5 and 6 above.
Test/Inspection 1. Verify items 3, 4 and 5 above and ignition coil/flywheel protrusion air-gap.
a. Air-gap too large.
Readjust air-gap.
03-05-2 MMR2000_116_03_05A.FM
Test/Inspection 1. Verify if spark plug wires and/or spark plug cap seals are sealing-out moisture.
and/or are sealing-out moisture.
Test/Inspection 1. Perform all verifications outlined under “Engine does not start — no spark at
spark plug”.
2. Verify spark plug. Proceed with spark plug analysis in order to identify source
of problem.
Test/Inspection 1. Check carburetor.

a. Carburation is too rich.
Replace.
SYMPTOM SPARK PLUG TIP IS LIGHT GREY.
Test/Inspection 1. Refer to “Engine slows down or stops at high RPM” and check items listed.

(refer to ELECTRICAL 06).
3. Check carburetor gasket.
a. Cracked or deformed gasket.
Replace.
MMR2000_116_03_05A.FM 03-05-3
Test/Inspection 1. Check if rear light is properly connected.

03-05-4 MMR2000_116_03_05A.FM

as a guideline.
Test/Inspection 1. Check rear spring preload.

Replace spring or add a shim under torsion spring leg on each side.

Adjust according to specifications (refer to TECHNICAL DATA 10). Replace
defective parts.
SYMPTOM PREMATURE WEAR ON TRACK GUIDES.

a. Pressure is too great on guides.

MMR2000_116_03_06A.FM 03-06-1

Replace.
3. Check sprockets.
4. Check track internal traction teeth.
a. One or various track teeth are broken.
Replace track.
5. Check stopper strap.
a. Stopper strap is worn out.
Replace stopper strap.

Adjust.

Adjust.
3. Check slide suspension retaining bolts.
03-06-2 MMR2000_116_03_06A.FM
SYMPTOM REAR SUSPENSION IS LOW OR TOO STIFF.

Adjust.
2. Check condition of cushion between shaft and front arm.
a. Damaged cushion and shaft.
Replace cushion and shaft.

a. Insufficient preload.
Replace rear spring.

Replace.

Replace front arm stopper strap.
SYMPTOM HANDLE BAR IS DIFFICULT TO TURN.
Test/Inspection 1. Check condition of ball joints.

2. Check U-clamp and retaining support
a. Torque on screws are too high.
Refer to STEERING/FRONT SUSPENSION 08.
b. Grease missing.
Apply lithium grease on steering column bushings.
MMR2000_116_03_06A.FM 03-06-3
SYMPTOM THE SNOWMOBILE IS UNSTABLE (IT MOVES FROM LEFT TO RIGHT AND VICE
VERSA).

Align skis in order to obtain proper toe-out (opening) (to adjust, refer to
STEERING/FRONT SUSPENSION 08).
Replace.
03-06-4 MMR2000_116_03_06A.FM
Section 04 ENGINE
TABLE OF CONTENTS 0
ENGINE REMOVAL AND INSTALLATION............................................................................ 04-02-1
ENGINE AND MUFFLER DISASSEMBLY AND ASSEMBLY............................................ 04-02-2
INSTALLATION ON VEHICLE ............................................................................................ 04-02-2
VALVE ADJUSTMENT .......................................................................................................... 04-03-1

VALVE ADJUSTMENT ....................................................................................................... 04-03-2
DISASSEMBLY/ASSEMBLY ................................................................................................. 04-04-1

TOP END ............................................................................................................................ 04-04-1
TOP END REMOVAL .......................................................................................................... 04-04-2
CLEANING ......................................................................................................................... 04-04-2
DISASSEMBLY................................................................................................................... 04-04-2
INSPECTION ...................................................................................................................... 04-04-3
ASSEMBLY......................................................................................................................... 04-04-3
TOP END INSTALLATION ................................................................................................. 04-04-4
BOTTOM END.................................................................................................................... 04-04-5
CLEANING ......................................................................................................................... 04-04-6
DISASSEMBLY................................................................................................................... 04-04-6
INSPECTION ...................................................................................................................... 04-04-8
ASSEMBLY......................................................................................................................... 04-04-8
COMPRESSION TEST AND ENGINE DIMENSION MEASUREMENT ................................ 04-05-1

COMPRESSION TEST ....................................................................................................... 04-05-1
VALVE SPRING FREE LENGTH ........................................................................................ 04-05-2
VALVE SEAT WIDTH ......................................................................................................... 04-05-2
VALVE STEM (outside diameter) ..................................................................................... 04-05-2
VALVE GUIDE (inside diameter) ....................................................................................... 04-05-2
GUIDE-TO-STEM CLEARANCE......................................................................................... 04-05-3
CYLINDER HEAD SURFACE ............................................................................................. 04-05-3
CYLINDER INSIDE DIAMETER.......................................................................................... 04-05-3
RING END GAP .................................................................................................................. 04-05-5
CONNECTING ROD BIG END SIDE CLEARANCE............................................................ 04-05-5
PISTON PIN (outside diameter)........................................................................................ 04-05-6
PISTON PIN BORE (inside diameter) ............................................................................... 04-05-6
PISTON-TO-PISTON PIN BORE CLEARANCE.................................................................. 04-05-6
CONNECTING ROD SMALL END (inside diameter) ....................................................... 04-05-6
CONNECTING ROD BIG END (inside diameter).............................................................. 04-05-6
MMR2000_117_04_01ATOC.FM 04-01-1
Section 04 ENGINE
CONNECTING ROD BIG END OIL CLEARANCE............................................................... 04-05-7

CRANKPIN (outside diameter) .......................................................................................... 04-05-8
CAMSHAFT CAM HEIGHT ................................................................................................. 04-05-8
CAMSHAFT (outside diameter) ........................................................................................ 04-05-8
CAMSHAFT HOLDER (inside diameter) ........................................................................... 04-05-9
CHECKING SURFACE FLATNESS ..................................................................................... 04-05-9
RECTIFYING SURFACES.................................................................................................... 04-05-9
TRANSISTORIZED MAGNETO IGNITION ............................................................................ 04-06-1

CLEANING .......................................................................................................................... 04-06-2
DISASSEMBLY ................................................................................................................... 04-06-2
INSPECTION ....................................................................................................................... 04-06-2
ASSEMBLY ......................................................................................................................... 04-06-3
REWIND STARTER ................................................................................................................. 04-07-1

REMOVAL ........................................................................................................................... 04-07-2
DISASSEMBLY ................................................................................................................... 04-07-2
INSPECTION ....................................................................................................................... 04-07-3
ASSEMBLY ......................................................................................................................... 04-07-3
INSTALLATION ................................................................................................................... 04-07-5
CARBURETOR ........................................................................................................................ 04-08-1

REMOVAL ........................................................................................................................... 04-08-2
CARBURETOR FLOAT LEVEL ............................................................................................ 04-08-6
INSTALLATION ................................................................................................................... 04-08-6
CARBURETOR ADJUSTMENTS........................................................................................ 04-08-7
GOVERNOR ADJUSTMENT .............................................................................................. 04-08-7
FUEL TANK AND THROTTLE CABLE.................................................................................... 04-09-1
04-01-2 MMR2000_117_04_01ATOC.FM
Section 04 ENGINE
Subsection 02 (ENGINE REMOVAL AND INSTALLATION)
ENGINE REMOVAL AND INSTALLATION0

24 Nm
(18 lbfft)
4
10 Nm
(89 lbfin)
10 Nm
(89 lbfin)
Loctite
242 2 15 Nm
(133 lbfin)
Loctite
242
1 2
11 Nm 15 Nm
Loctite
242
A31C17T

Section 04 ENGINE
Subsection 02 (ENGINE REMOVAL AND INSTALLATION)

Remove or disconnect the following then lift en-
gine from vehicle:
– chain guard
– drive chain
– drive sprocket (clutch)
– muffler no. 3
– engine protector no. 5
– throttle cable
– choke cable
– fuel line
– electrical connectors
– engine mount screws no. 2
– brake support screws no. 1
ENGINE AND MUFFLER

Torque the muffler nuts no. 4 to 24 N•m (18 lbf•ft).
Torque both brake support screws no. 1 to 11 N•m
(97 lbf•in) and 5 engine mount screws no. 2 to
15 N•m (133 lbf•in).
cedure. However, pay attention to the following:
– Check tightness of engine mount screws, and
clutch screw.
– After throttle cable and choke installation, check
for proper operation.
– Check drive chain automatic tensioner for proper
operation.
04-02-2 MMR2000_117_04_02A.FM
Section 04 ENGINE
Subsection 03 (VALVE ADJUSTMENT)
VALVE ADJUSTMENT 0
2
1
4
6
10 Nm
(89 lbfin)
9
8
5
A31C1AT

Section 04 ENGINE
Subsection 03 (VALVE ADJUSTMENT)
VALVE ADJUSTMENT Valve Clearance Inspection

NOTE: Valve clearance inspection and adjustment Insert a feeler gauge between rocker arm no. 5
must be performed with the engine cold. and valve no. 6. Refer to the following table for
valve clearance.
Preparation STANDARD VALVE CLEARANCE
Remove cylinder head cover bolts no. 1, cylinder
head cover no. 2 and gasket no. 3. 0.15 ± 0.02 mm
Intake valve
(0.006 ± 0.001 in)
Set the piston at TDC (Top Dead Center) of the
compression stroke, as shown in the following 0.20 ± 0.02 mm
Exhaust valve
procedure. (0.008 ± 0.001 in)
COMPRESSION STROKE TDC POSITIONING NOTE: When inspecting clearance, ensure that
Remove spark plug no. 4. feeler gauge does not compress valve springs
Turn engine clockwise (PTO side) by hand so that no. 7. Valve springs have low compression rates.
triangular mark on starter pulley align with the top If valve clearance is not according to the above
hole on the fan cover. table, perform valve clearance adjustment as de-
scribed in the following procedure.
Valve Clearance Adjustment

Hold rocker arm pivot no. 8 and loosen rocker arm
pivot lock nut no. 9, as shown in the next photo.
3
1
2
A31C18A
REWIND STARTER HAS BEEN REMOVED

1. Triangular mark aligned with fan cover top hole
2. Rotate clockwise to position engine at TDC of compression
stroke A31C19A 2 1
1. Tool retaining rocker arm pivot
CAUTION: The triangular mark on the starter 2. Tool loosening lock nut of rocker arm pivot
pulley will align with the top hole on the fan 3. Feeler gauge
cover when the piston is at top dead center of Turn rocker arm pivot to obtain the specified clear-
the compression or exhaust stroke. Ensure that ance.
piston is at TDC of the compression stroke. At
compression stroke both valves are fully Retighten the rocker arm pivot lock nut while hold-
closed. ing the rocker arm pivot.
Recheck valve clearance after tightening the rock-
er arm pivot lock nut.
Reinstall cylinder head cover with gasket then se-
cure with cylinder head cover bolts tightened in a
crisscross sequence.
04-03-2 MMR2000_118_04_03A.FM
Section 04 ENGINE
Subsection 04 (DISASSEMBLY/ASSEMBLY)
DISASSEMBLY/ASSEMBLY 0
TOP END
24 Nm 11
(18 lbfft)
2
1
16
15
10
4
6
17
7
13
14
12
5
8
9
A31C24U

Section 04 ENGINE
TOP END REMOVAL DISASSEMBLY

Remove the following then lift cylinder head no. 10: NOTE: Before disassembling, mark valve springs
– carburetor no. 7, valves no. 6 and rocker arms no. 5. This will
ensure that parts will not be inverse at reassem-
– exhaust system bly.
– spark plug no. 4 Unscrew rocker arm pivot lock nuts no. 9 and rocker
– cylinder head cover no. 2 arm pivots no. 8. Remove them.
– cylinder head nuts no. 11 Remove both rocker arms no. 5.
NOTE: When removing cylinder head, mark both 3
push rods no. 12 for reassembly.
1
A31C26A 1 2
A31C25A 2
TYPICAL — MECHANIC REMOVING ROCKER ARM OF INTAKE
TYPICAL — MECHANIC REMOVING CYLINDER HEAD VALVE
1. Cylinder head 1. Rocker arm pivot
2. Mark both push rods for reassembly 2. Rocker arm pivot lock nut
3. Rocker arm
Pull out push rods.
Push down and slide the spring retainer no. 13 to
CLEANING the side, so the valve stem slips through the hole,
as shown in the next photo.
Discard all gaskets.
cleaner.
port, cylinder head, valves no. 6 and piston dome
using a wooden spatula.
NOTE: The triangular mark on the piston dome
must be visible after cleaning.
Clean the piston ring grooves with a groove clean-
er tool, or with a piece of broken ring.
A31C27A
TYPICAL — PUSH DOWN AND SLIDE RETAINER TO THE SIDE
04-04-2 MMR2000_119_04_04A.FM
Section 04 ENGINE
Put apart valve spring retainer and spring.

Repeat procedure for exhaust valve but ensure
that valve rotator no. 14 is removed first. Refer to
the following photo.
A31C29A
1 2
EXHAUST AND INTAKE VALVES SECURED IN PLACE
1. Exhaust valve (small diameter) location
2. Intake valve (large diameter) location
Install valve rotator on exhaust valve.

CAUTION: To avoid engine damage, ensure
A31C28A that exhaust valve rotator is properly installed
1. On exhaust valve only, remove valve rotator then remove valve on exhaust valve, as shown in the next photo.
spring retainer
Pull out both valves from cylinder head.
INSPECTION 1
Refer to COMPRESSION TEST AND ENGINE DI-
MENSIONS MEASUREMENT 04-05.
ASSEMBLY
Slide exhaust valve (small diameter) into exhaust
valve guide, then slide intake valve (large diame-
ter) into intake guide. See next photo.
Install springs and secure with valve spring retain-
ers.
A31C2AA
EXHAUST VALVE SHOWN

1. Exhaust valve rotator in place
MMR2000_119_04_04A.FM 04-04-3
Section 04 ENGINE
TOP END INSTALLATION

Install cylinder head gasket no. 15 and check that
both locating pins no. 16 are in place, as shown in
the next photo.
A31C2BA 2
1. Cylinder head gasket
2. Locating pin
Check push rods no. 12 on both ends for wear.

Check also push rods for straightness.
Install push rod ends into lifters no. 17.
Reinstall cylinder head.
CAUTION: Ensure that push rods are properly
inserted into push rod guides and firmly seated
in the lifters.
Secure cylinder head with screws.
Reinstall cylinder head cover.
04-04-4 MMR2000_119_04_04A.FM
Section 04 ENGINE
BOTTOM END
23
19 24
18 22
20
21 14
6
5 7
17 6
16
15
4
10
3
12 N•m
2 (106 lbf•in)
Loctite 242 12
27
25 1
13 28
25 11
26
12 N•m
A31C2CS 28 24 (106 lbf•in)

Section 04 ENGINE
NOTE: Engine must be removed from chassis to Push on connecting rod no. 4 and pull out piston
perform the following procedures. no. 5.
Remove both piston pin circlips no. 6 and push out
CLEANING piston pin no. 7.
Discard all oil seals and gaskets. Detach piston from connecting rod.
Clean all metal components in a non-ferrous metal Remove crankshaft no. 8 and camshaft ass‘y no. 9.
cleaner. Mark both valve lifters and remove them. This will
ensure that lifters will not be inverse at reassembly.
DISASSEMBLY
General
To remove clutch, refer to CLUTCH 05-02.
To remove magneto, refer to TRANSISTORIZED
MAGNETO IGNITION 04-06.
Crankcase
Drain all oil from engine base.
Remove crankcase cover no. 1 on PTO side.
From inside crankcase, loosen both connecting
rod screws no. 2 then remove connecting rod cap
no. 3.
A31C2EA 1
MARK BOTH VALVE LIFTERS FOR REASSEMBLY
1. Valve lifters
Seals and Bearings

To remove seals nos. 10 and 11, push from inside
crankcase towards the outside.
1 To remove bearings nos. 12 and 13, use a press
with all 3 following tools:
– driver (P/N 529 035 521)
2
– attachment (P/N 529 035 522)
– pilot (P/N 529 035 523)
A31C2DA
1. Connecting rod screws

2. Connecting rod cap
04-04-6 MMR2000_119_04_04A.FM
Section 04 ENGINE
To reinstall bearings, reverse housing and use From inside crankcase, rotate governor arm shaft
same tools as for bearings removal, as shown in no. 14 then pull out governor slider no. 15 and
the next photo. washer no. 16.
2 1
A31C2IA
A31C2GA
1. Rotate governor arm shaft

TO INSTALL BEARING 2. Remove governor slider with washer (not shown)
Governor System Using a small flat screwdriver, remove clip no. 17

Detach governor spring (black), throttle return from governor weight holder no. 18.
spring and governor rod from governor arm. See
next photo.
3 2 1
A31C2JA 1 2
GOVERNOR ASS‘Y HAS BEEN REMOVED TO SHOW CLIP
A31C2HA 4 1. Clip
2. Governor weight holder
1. Governor spring (black)
2. Throttle return spring Pull out governor weight holder and washer no. 19.
3. Governor rod
4. Governor arm Remove pins no. 20 from governor weights no. 21
then remove governor weights.
Loosen governor arm screw then remove gover-
nor arm.
MMR2000_119_04_04A.FM 04-04-7
Section 04 ENGINE
From outside crankcase, remove lock pin no. 22 Governor System

from governor arm shaft, as shown in the next
Reinstall governor weights no. 21 with pins no. 20.
photo. Remove governor arm shaft no. 14 with
washer no. 23. Install governor weight holder washer no. 19 then
install governor weight holder no. 18 on shaft.
2 1
Secure governor weight holder with clip no. 17.
CAUTION: Ensure that clip is properly inserted
into shaft groove.
Spread governor weights no. 21 then install gov-
ernor slider washer no. 16 and governor slider
no. 15.
Check that governor slider moves smoothly.
Reinstall governor arm shaft no. 14 with washer
no. 23 inside crankcase. Secure with lock pin
no. 22.
CAUTION: The lock pin must be installed on
the governor arm shaft with the straight side of
A31C2KA
the pin against the groove in the shaft.
REMOVE LOCK PIN
1. Lock pin
2. Governor arm shaft
Piston and Rings
Align piston mark with connecting rod long end
INSPECTION and install piston on connecting rod. See the next
illustration.
Piston, Crankshaft and Camshaft
Inspect camshaft decompressor. If there is any 1
problems, replace camshaft assembly with new
one.
Refer to COMPRESSION TEST AND ENGINE DI-
MENSION MEASUREMENT 04-05.
Governor System
Check for wear or damage on governor weight
holder.
Check that governor weights move freely inside 2
governor weight holder.
ASSEMBLY A31C2LA
1. Piston mark
2. Connecting rod long end
Seals and Bearings
Insert piston pin no. 7 into piston no. 5 and con-
Using a press, install bearings nos. 12 and 13 so
necting rod no. 4.
that they lean on crankcase flange.
04-04-8 MMR2000_119_04_04A.FM
Section 04 ENGINE
Secure piston pin with both piston pin circlips no. 6. Space the piston ring end gaps 120° apart and do
NOTE: Do not align the end gap of the piston pin not align the gaps with the piston pin bore or the
circlips with the cutout in the piston bore. thrust side axis.
A
A A
2
1
2
A31C2MA
1. Piston pin circlip

2. Cutout
A31C2OA
Install all rings no. 24 with the markings facing up- RING POSITIONING
ward. 1. DO NOT align ring gap with piston trust side axis
2. DO NOT align ring gap with piston pin bore axis
Ensure that top and second rings are not inter- A. 120°
changed.
Position piston ass‘y with piston mark toward
push rod hole, as shown in the following illustra-
tion.
A31C2NA
1
1. Top ring (chrome plated)
2. Second ring
3. Oil ring
A31C2PA 2
Check that rings rotate smoothly after installation.
1. Piston mark
2. Push rod hole
MMR2000_119_04_04A.FM 04-04-9
Section 04 ENGINE
Using a ring compressor, slide piston into cylinder

with a hammer handle, as shown in the next photo.
A31C2RA 2 1
1. Connecting rod cap
A31C2QA
2. Torque wrench
SLIDE PISTON INTO CYLINDER
1. Ring compressor Camshaft
2. Hammer handle
Install exhaust and intake valve lifters inside crank-
Crankshaft case.
Apply oil on crankshaft connecting rod location, With the crankshaft in place, align the timing punch
connecting rod cap and connecting rod before mark of the cam gear with the punch mark of the
starting assembly. crankshaft drive gear. Refer to the following photo.
Install crankshaft into crankcase.
NOTE: To protect seal and ease crankcase cover
installation, apply grease on crankcase cover seal.
Slide down piston so that connecting rod properly
seats on crankshaft.
Secure connecting rod with connecting rod cap.
Torque screws to 12 N•m (106 lbf•in).
CAUTION: Ensure that connecting rod cap is
properly positioned, as shown in the next pho-
to.
A31C2SA
ALIGN BOTH MARKS
04-04-10 MMR2000_119_04_04A.FM
Section 04 ENGINE
Crankcase
Verify that locating sleeves no. 25 are in place.
Install gasket no. 26 on crankcase.
Finalize crankcase assembling with crankcase
cover no. 1. Torque screws in a crisscross se-
quence to 12 N•m (106 lbf•in).
NOTE: To protect seal and ease crankcase cover
installation, apply grease on crankcase cover seal.
Verify that oil drain bolt no. 27 and both oil filler
caps no. 28 are in place.
MMR2000_119_04_04A.FM 04-04-11
Section 04 ENGINE
Subsection 05 (COMPRESSION TEST AND ENGINE DIMENSION MEASUREMENT)
COMPRESSION TEST AND ENGINE

DIMENSION MEASUREMENT 0
COMPRESSION TEST
Set ignition and emergency cut-out switches to
the OFF position.
Disconnect spark plug cap, then remove spark
plug.
Plug compression testing gauge into spark plug
hole.
Hold compression testing gauge in one hand then
pull starter handle 3 or 4 times with the other
hand, as shown in the next photo.
A31C1KA
PULL STARTER HANDLE 3 OR 4 TIMES
Engine compression must be as described in the

following table. If not, see subsection 04-03
VALVE ADJUSTMENT or subsection 04-04 DISAS-
SEMBLY/ASSEMBLY.
STANDARD SERVICE LIMIT

110 - 120 PSI 85 PSI
MMR2000_120_04_05A.FM 04-05-1
Section 04 ENGINE
ENGINE DIMENSION MEASUREMENT

VALVE SPRING FREE LENGTH If valve seat width is under the standard or over
the service limit value, replace cylinder head with
STANDARD SERVICE LIMIT new one.
30.5 mm (1.20 in) 29.5 mm (1.16 in) VALVE STEM (outside diameter)
Measure valve springs free length with a caliper,
NOTE: When measuring free length, ensure not 5.48 mm 5.318 mm
INTAKE
to apply pressure onto spring. (0.216 in) (0.2094 in)
5.44 mm 5.275 mm
EXHAUST
(0.214 in) (0.2077 in)
Measure valve stem with a micrometer, as shown

in the next photo.
A31C1LA
VALVE SPRING FREE LENGTH
If the springs are shorter than service limit value,

replace with new one.
VALVE SEAT WIDTH

A31C1NA
0.8 mm (0.03 in) 2.0 mm (0.08 in)
TYPICAL
Measure valve seat width using a caliper, as Inspect valve surface, check for abnormal stem
shown in the next photo. wear and bending. If so, replace valve with new
one.
VALVE GUIDE (inside diameter)

5.50 mm (0.217 in) 5.572 mm (0.2194 in)
Clean valve guides to remove carbon deposits be-

fore measuring.
Measure valve guide inside diameter using a small
hole telescoping gauge and a micrometer.
Replace cylinder head if valve guides are over ser-
A31C1MA
vice limit value.
VALVE SEAT WIDTH
04-05-2 MMR2000_120_04_05A.FM
Section 04 ENGINE
GUIDE-TO-STEM CLEARANCE CYLINDER INSIDE DIAMETER

Subtract each valve stem outside diameter from STANDARD SERVICE LIMIT
the corresponding valve guide inside diameter to
obtain the stem-to-guide clearance. 60.0 mm (2.36 in) 60.165 mm (2.3687 in)
STANDARD SERVICE LIMIT Compare cylinder inside diameter 16 mm (5/8 in)

from top of cylinder, halfway and 12.7 mm (1/2 in)
0.020 - 0.044 mm 0.10 mm
INTAKE
(0.0008 - 0.0017 in) (0.004 in)
from bottom of cylinder.
Measure cylinder inside diameter in both X (per-
0.006 - 0.087 mm 0.12 mm pendicular to crankshaft) and Y (parallel to crank-
EXHAUST
(0.0024 - 0.0034 in) (0.005 in) shaft) axis. Take the maximum reading to deter-
mine cylinder wear.
If the stem-to-guide clearance exceeds the ser-
vice limit value, replace valve or cylinder head as
needed.
CYLINDER HEAD SURFACE X
SERVICE LIMIT 0.10 mm (0.004 in) Y
Clean cylinder head surface.

Check cylinder head flatness with a straight edge
and a feeler gauge, as shown in the next photo.
1 2
A31C1PA
X: Axis (perpendicular to crankshaft axis)

Y: Axis (parallel to crankshaft axis)
If the difference exceeds the specified dimension

the cylinder should be rebored and honed or
should be replaced.
USED PISTON MEASUREMENT

59.985 mm (2.3616 in) 59.845 mm (2.3561 in)
A31C1OA
Using a micrometer, measure piston at 10 mm
(25/64 in) perpendicularly (90°) to piston pin.
1. Straight edge
2. Feeler gauge
If cylinder head flatness is over service limit value,

replace cylinder head.
Cylinder Head Inspection

Remove carbon deposits from combustion cham-
ber.
Check the spark plug hole and valve areas for
cracks.
MMR2000_120_04_05A.FM 04-05-3
Section 04 ENGINE
A
1
2
1
F01D0NA F00B09A
TYPICAL 1. Use the micrometer to set the cylinder bore gauge

1. Measuring perpendicularly (90º) to piston pin axis 2. Dial bore gauge
A. 10 mm (25/64 in)
The measured dimension should be as described

in the previous table. If not, install a new piston.
0.015 - 0.050 mm 0.12 mm
(0.0006 - 0.0020 in) (0.005 in)

NOTE: Make sure used piston is not worn. See 1
USED PISTON MEASUREMENT above.
F00B0AA
Adjust and lock a micrometer to the piston dimen-

TYPICAL
sion.
1 Position the dial bore gauge at 16 mm (5/8 in) be-

low cylinder top edge, measuring perpendicularly
(90°) to piston pin axis. See CYLINDER INSIDE DI-
AMETER above.
ance, replace cylinder or rebore. See previous ta-
ble.
F00B08A tor is set exactly at the same position as with the

mension and set the indicator to 0 (zero).
04-05-4 MMR2000_120_04_05A.FM
Section 04 ENGINE
RING/PISTON GROOVE 2
CLEARANCE
0.015 - 0.045 mm 0.15 mm
(0.0006 - 0.0018 in) (0.006 in)
NOTE: These clearances are applicable for 3 rings;

top, second and oil ring.
ring and groove. Replace piston if clearance ex-
ceeds specified tolerance. See above table.
A31C1RA 1
1. Feeler gauge
2. Ring properly positioned in cylinder
CONNECTING ROD BIG END SIDE

CLEARANCE
0.1 - 0.7 mm 1.1 mm
(0.004 - 0.028 in) (0.043 in)
A31C1QA Using a feeler gauge, measure distance between

RING/PISTON GROOVE CLEARANCE
connecting rod and crankshaft counterweight. If
the distance exceeds specified tolerance, replace
the crankshaft.
RING END GAP
TOP AND 0.2 - 0.4 mm 1.0 mm
SECOND (0.008 - 0.016 in) (0.04 in)
0.15 - 0.35 mm 1.0 mm
OIL
(0.006 - 0.014 in) (0.04 in)
Position ring 16 mm (5/8 in) from top of cylinder.

ring, if gap exceeds specified tolerance. See
above table.
A31C1SA
MEASURE SIDE CLEARANCE
MMR2000_120_04_05A.FM 04-05-5
Section 04 ENGINE
PISTON PIN (outside diameter) PISTON-TO-PISTON PIN BORE

CLEARANCE
13.0 mm (0.51 in) 12.954 mm (0.5100 in) STANDARD SERVICE LIMIT
0.002 - 0.014 mm 0.08 mm
Mesure piston pin with a micrometer, as shown in (0.0001 - 0.0006 in) (0.003 in)
the next photo.
Compare both previously measured piston pin
(outside diameter) and piston pin bore (inside di-
ameter).
If clearance is out of service limit value, replace
piston pin or piston as needed.
CONNECTING ROD SMALL END

(inside diameter)
A31C1TA
13.005 mm (0.5120 in) 13.07 mm (0.515 in)
MEASURE PISTON PIN Measure connecting rod small end (inside diame-
ter) with a telescoping gauge and a micrometer,
PISTON PIN BORE as shown in the next photo.
(inside diameter)
13.002 mm (0.5119 in) 13.048 mm (0.5137 in)
Measure piston pin bore with a telescoping gauge

and a micrometer, as shown in the next photo.
A31C1VA
MEASURE CONNECTING ROD SMALL END

(inside diameter)
26.02 mm (1.024 in) 26.066 mm (1.0262 in)
A31C1UA
1
1. Piston pin bore Measure connecting rod big end (inside diameter)
with a telescoping gauge and a micrometer, as
shown in the next photo.
04-05-6 MMR2000_120_04_05A.FM
Section 04 ENGINE
NOTE: Do not rotate crankshaft while plastigauge

is in place.
A31C1WA
MEASURE CONNECTING ROD BIG END

A31C1YA
1
CONNECTING ROD BIG END OIL 1. Connecting rod cap in place
CLEARANCE 2. Torque both screws
Remove connecting rod cap and measure the

STANDARD SERVICE LIMIT plastigauge, as shown in the next photo.
0.040 - 0.063 mm 0.12 mm
(0.0016 - 0.0025 in) (0.005 in)
Clean all oil from crankpin and connecting rod big

end surfaces.
Position a piece of plastigauge on the crankpin, as
shown on the next photo.
A31C1ZA
1. Plastigauge
If clearance exceeds the service limit, replace con-

necting rod and recheck clearance.
NOTE: Replacement connecting rods are avail-
A31C1XA 1 able with standard and 0.25 mm (0.010 in) under-
1. Plastigauge properly positioned size bearing surfaces.
Reinstall connecting rod cap and torque screws to
12 N•m (109 lbf•in). See next photo.
MMR2000_120_04_05A.FM 04-05-7
Section 04 ENGINE
CRANKPIN (outside diameter) 1 2

25.98 mm 25.92 mm
(1.023 in) (1.020 in)
Measure crankpin outside diameter with a micro-

meter, as shown in the next photo.
A31C21A
1. Exhaust valve cam

2. Intake valve cam
CAMSHAFT (outside diameter)

13.984 mm (0.5506 in) 13.916 mm (0.5479 in)
Measure camshaft outside diameter with a mi-

crometer, as shown in the following photo.
A31C20A
MEASURE CRANKPIN
CAMSHAFT CAM HEIGHT

SERVICE
STANDARD
LIMIT
27.7 mm 27.45 mm
INTAKE
(1.09 in) (1.081 in)
27.75 mm 27.50 mm
EXHAUST
(1.093 in) (1.083 in)
Measure both camshaft cams with a micrometer, A31C22A

MEASURE CAMSHAFT OUTSIDE DIAMETER
04-05-8 MMR2000_120_04_05A.FM
Section 04 ENGINE
CAMSHAFT HOLDER RECTIFYING SURFACES

(inside diameter) Stick a fine sand paper sheet on the surface plate
Rub manifold mating surface on sand paper using
14.0 mm (0.55 in) 14.048 mm (0.5531 in) 8-figure movements.
Measure camshaft holder inside diameter with a
telescoping gauge and a micrometer, as shown in
the next photo.
A00A1LA
A31C23A
MEASURE CAMSHAFT HOLDER INSIDE DIAMETER

Crankcase cover can be checked for perfectly mat-
ing surfaces.
Lay part on a surface plate (marble, mirror or thick
glass plate).
Holding down one end of part, try pushing down
the other end.
If any play is felt, part must be rectified.
MMR2000_120_04_05A.FM 04-05-9
Section 04 ENGINE
Subsection 06 (TRANSISTORIZED MAGNETO IGNITION)
TRANSISTORIZED MAGNETO IGNITION 0
Dielectric
grease
4 3
2 Ground
cable
1
7
75 Nm
(54 lbfft)
A31E0JS

Section 04 ENGINE
NOTE: Engine must be removed to perform the Remove starter pulley no. 2 and fan no. 3.
following procedures. Reinstall magneto flywheel nut then using puller,
detach flywheel no. 5, as shown in the next photo.
CLEANING CAUTION: Never hold flywheel using magnet
Clean all metal components in a non-ferrous metal section. Flywheel may be damaged.
cleaner.
CAUTION: Clean armature and magneto using
only with a clean cloth.
DISASSEMBLY
To gain access to magneto assembly, remove the
following parts:
– chain guard
– drive chain
– clutch
– muffler
– disconnect fuel line A31E0LA 1
– engine 1. Magnet section
– rewind starter NOTE: Tighten puller bolt and at same time, tap
Remove ignition coil no. 7. on bolt head using a hammer to release magneto
flywheel from its taper.
To remove magneto flywheel retaining nut no. 1,
use clutch holder tool (P/N 529 006 400), as shown
in the next photo. INSPECTION
Test ignition no. 7 and lamp no. 6 coils as de-
scribed in TESTING PROCEDURE 06-03.
2 1
A31E0MA
A31E0KA
1. Lamp coils
LOOSEN FLYWHEEL NUT 2. Ignition coil
1. Hold flywheel using clutch holder tool (P/N 529 006 400)
04-06-2 MMR2000_121_04_06A.FM
Section 04 ENGINE
ASSEMBLY Ignition Coil Air Gap Adjustment

Clean crankshaft extension (taper). NOTE: To perform ignition coil air gap adjustment,
flywheel must be tightened.
Position Woodruff key no. 4 then reinstall fly-
wheel with fan. Loosen ignition coil screws.
Install starter pulley, as shown in the next photo. Insert feeler gauge between flywheel and ignition
coil. Adjust both gaps at the same time as shown
CAUTION: When installing starter pulley, en- in the next photo and according to the following
sure that locating pin is properly aligned with table.
flywheel alignment hole.
SPECIFIED 0.4 ± 0.2 mm
CLEARANCE (0.016 ± 0.008 in)
Push the ignition coil firmly toward flywheel and

tighten screws.
A31E0NA
1. Starter pulley locating pin must be aligned with flywheel hole
Torque flywheel nut to 75 N•m (54 lbf•ft). A31E0OA
At reassembly coat all electric connections with 1. Ignition coil

silicone dielectric grease (P/N 413 701 700) to pre- 2. Feeler gauge filling both gaps
vent corrosion or moisture penetration. CAUTION: Do not adjust ignition coil air gap at
CAUTION: Do not use silicone “sealant”, this magnet section on flywheel.
product will corrode contacts.
MMR2000_121_04_06A.FM 04-06-3
Section 04 ENGINE
REWIND STARTER 0
1
5
6
9
8
10
11 4
A31C1JS

Section 04 ENGINE
REMOVAL
The following must be removed before rewind
starter removal: 1
– chain guard
– drive chain
– clutch
– muffler
– disconnect fuel hose
– engine
Using a small screwdriver, extract rope knot from
starter grip no. 1. Cut rope no. 2 close to knot. Tie
a knot near starter.
Mark rewind starter housing no. 4 position for re-
assembly.
Remove screws no. 3 securing rewind starter
housing no. 4 to engine then remove rewind start-
er ass‘y.
DISASSEMBLY
2
To remove rope from rewind starter mechanism:
A31C1BA
Place rewind starter ass‘y on a bench.
1. Sheave
– First remove screw no. 5, then ratchet guide 2. Rewind starter housing
no. 6.
– Remove friction spring no. 8 and both ratchets  WARNING
no. 9 with springs no. 10. Since the spring is tightly wound inside the
– Remove sheave no. 7 from starter housing, as guide it may fly out when rewind is handled.
shown in the next illustration. Always handle with care.
04-07-2 MMR2000_122_04_07A.FM
Section 04 ENGINE
INSPECTION
Check rope no. 2 for fraying. Replace if so.
ASSEMBLY
spring guide notch then wind the spring counter-
clockwise into guide.
1
1
A31C1CA
1. Grease inside spring guide and sheave hub

grease could result in rewind starter malfunc-
tion.
To install a new rope:
Insert rope into sheave orifice and lock it with a
knot as illustrated.
A01C13A
TYPICAL

bricated.
ically using specific lubricants. Otherwise, re-
under very cold temperatures. A31C1DA
Lubricate spring assembly with silicone com- ROPE KNOT INTO SHEAVE ORIFICE
pound grease (P/N 420 897 061) and position into
starter housing as in the next photo.
MMR2000_122_04_07A.FM 04-07-3
Section 04 ENGINE
To adjust rope tension:

Wind rope on sheave and place sheave into starter
housing making sure that the sheave hub notch
engages in the rewind spring hook. See the next
photo.
1
A31C1EA
1. Ratchet
Finalize rewind starter assembly with friction

spring no. 8, ratchet guide no. 6 and screw no. 5.
Attach rope to sheave notch then turn (2 turns)
sheave counterclockwise, as shown in the next
photo. One turn preload will give 7 turns of tension
1 when fully extended.
A31C1BB
1. Sheave hub notch

2. Rewind spring hook

end is accessible through starter housing orifice.
Pull the rope out of the starter housing and tem- A31C1FA 1
2 TURNS COUNTERCLOCKWISE
Position both ratchets (with springs), as shown in 1. Sheave notch
the next photo.
04-07-4 MMR2000_122_04_07A.FM
Section 04 ENGINE
Check ratchet operation: when turning ratchet INSTALLATION

guide counterclockwise, ratchets must move in.
When turning ratchet guide clockwise, ratchets Reinstall rewind starter ass‘y on engine.
must move out as shown in the next photo. Reinstall engine in snowmobile.
Prior to installing starter grip no. 1 on new rope, it
is first necessary to fuse the rope end with a lit
match.
Pass rope through snowmobile fitting and starter
grip and tie a knot in the rope end. Fuse the knot
with a lit match then insert rope end down and pull
the starter grip over the knot.
Reconnect fuel hose.
Reinstall clutch, drive chain, then chain guard.
A31C1IA 2
1. Turn counterclockwise (CCW) — ratchets in
2. Turn clockwise (CW) — ratchets out
MMR2000_122_04_07A.FM 04-07-5
Section 04 ENGINE
Subsection 08 (CARBURETOR)
CARBURETOR 0
13
14
19
18
15 4
6
5
21
3 7
2
4 Nm
(35 lbfin)
20
12
16
11
17
10
A31C0HS

Section 04 ENGINE
REMOVAL Loosen fuel strainer cup no. 2 and remove from

carburetor. Keep O-ring no. 3, as shown in the next
Remove engine protective plate. photo.
Obstruct fuel line with a hose pincher (P/N 295 000
076), as shown in the next photo.
A01B2JD
Drain fuel from carburetor by loosening screw

no. 1, as shown in the next photo. A31C0NA 1 2
REMOVE FUEL STRAINER CUP
1. O-ring
2. Fuel strainer cup
Disconnect fuel inlet line from carburetor and drain

fuel from tank.
 WARNING
pincher (P/N 295 000 076) or equivalent de-
vice. Fuel is flammable and explosive under
certain conditions. Ensure work area is well
ventilated. Do not smoke or allow open
flames or sparks in the vicinity.
A31C0MA
1
TO DRAIN CARBURETOR Remove fuel tank.
1. Loosen this screw Remove carburetor cap.
Detach choke cable from choke cable attachment
no. 4, located on carburetor choke lever no. 6.
04-08-2 MMR2000_123_04_08A.FM
Section 04 ENGINE
Remove circlip no. 5 then remove choke cable at- Remove carburetor protector, as shown in the next
tachment from carburetor choke lever, as shown photo.
in the next photo.
A31C0OA
1. Circlip
2. Choke cable attachment
3. Carburetor choke lever
A31C0QA
Move carburetor choke lever to the left, as shown REMOVE CARBURETOR PROTECTOR
in the next photo.
Lift up choke lever no. 6 and detach from choke
no. 7, as shown in the next photo.
A31C0PA
MOVE CARBURETOR CHOKE LEVER
Unscrew carburetor protector screws then remove

carburetor nuts.
A31C0RA
2
LIFT UP CHOKE LEVER
1. Choke lever
2. Choke
MMR2000_123_04_08A.FM 04-08-3
Section 04 ENGINE
Slide out carburetor and activate carburetor throt- Carburetor body and jets should be cleaned in a
tle lever so that groove aligns with governor rod, carburetor cleaner following manufacturer’s in-
as shown in the next photo. structions.
1
 WARNING
2
Check for fuel soaked into float no. 8. Replace as

necessary.
Check float no. 9 and float pin no. 10 for cracks or
other damages affecting free movement. Replace
3 as necessary.

11,12, Main Jet and Nozzle
Place carburetor on a clean surface, then unscrew
main jet no. 11 using a flat screwdriver, as shown
in the next photo.
A31C0SA
SLIDE OUT CARBURETOR AND ALIGN GROOVE

1. Carburetor throttle lever groove aligned with governor rod
2. Governor rod
3. Throttle return spring
Detach governor rod with throttle return spring.

Detach governor spring.
Remove carburetor.
NOTE: Carburetor can be removed without re-
moving engine from vehicle, in that case remove
left side stud.
CLEANING AND INSPECTION A31C0TA 1

The entire carburetor should be cleaned with a 1. Unscrew main jet using a flat screwdriver
fore disassembly.
CAUTION: Heavy duty carburetor cleaner may
be harmful to the float material and to the rub-
ber parts, O-rings, etc. Therefore, it is recom-
mended to remove those parts prior to clean-
ing.
04-08-4 MMR2000_123_04_08A.FM
Section 04 ENGINE
To remove nozzle no. 12 use a flat screwdriver 13,14, Pilot Jet

and push from inside carburetor, as shown in the
Remove stop screw no. 15.
following photo.
Using a flat screwdriver remove pilot jet no. 13, as
shown in the next photo.
A31C0UA 1
1. Push on nozzle to remove it
Clean main jet and nozzle thoroughly with com-

pressed air.
Reinstall nozzle and main jet as shown in the next
photo.
A31C0WA
1
TO REMOVE, LIFT PILOT JET
1. Pilot jet
Clean pilot jet using compressed air.

Ensure that O-ring no. 14 is not damaged. If so,
replace with new one. See next photo.
A31C16A A31C0XA 1 2
PROPER POSITION TO INSTALL NOZZLE AND MAIN JET 1. Pilot jet
2. O-ring
MMR2000_123_04_08A.FM 04-08-5
Section 04 ENGINE
16,17, Float Valve STANDARD FLOAT

13.7 mm (0.54 in)
Remove float pin no. 10 then remove float no. 9 HEIGHT
from carburetor.
If float height is not according to specifications on
Check for worn valve seat on float. Replace if so. above table, replace float and/or float valve.
Check for weak float valve spring no. 17 or worn Recheck float level height.
float valve, as shown in the next photo.
1 2
INSTALLATION
To install carburetor on engine, inverse removal
procedure.
A31C0YA
However, pay attention to the following:
1. Float valve tip OK
2. Replace float valve – Inspect throttle cable and housing prior to instal-
lation.
CARBURETOR FLOAT LEVEL – Ensure that both packings no. 18 and insulator
no. 19 are properly positioned between cylin-
Correct fuel level in float chamber is vital toward der head and carburetor, as shown in the next
maximum engine efficiency. To check for correct photo.
– Remove float bowl no. 8 and gasket from car- 1 2 3
buretor.
– With carburetor leaned on a clean surface, mea-
sure float level height A using float level gauge
(P/N 529 035 520), as shown in the next photo.
– Keep float level gauge perfectly vertical and in line
with main jet hole.
– Ensure that both float level gauge tips are properly
positioned on carburetor body and that “L” arm is
leaning on float without compressing valve spring.
2
A31C10A
1. Packing
2. Insulator
3. Note packing hole position
– Ensure that spacer no. 20 is properly positioned

between carburetor and air cleaner elbow ass‘y,
A as shown in the following photo.
A31C0ZA 1
1. Float level gauge tips properly leaned on carburetor body
2. Lean “L” arm to carburetor to measure float level height
A. Float level height
04-08-6 MMR2000_123_04_08A.FM
Section 04 ENGINE
3 1
A31C11A 1 2
1. Spacer A31C12A 2
2. Air cleaner elbow ass‘y
1. Governor arm nut
2. Turn governor arm to fully open throttle
CARBURETOR ADJUSTMENTS 3. Turn governor arm shaft
Lift rear of snowmobile.

Preliminary Idle Speed Adjustment Start engine and allow to warm up to normal tem-
21, Pilot Screw perature.
Start engine and allow it to warm. Activate throttle lever so that engine revs to max-
Adjust idle speed by turning pilot screw no. 21 imum standard speed.
clockwise or counterclockwise until highest idle Adjust throttle lever stop screw so that engine will
RPM is attained. not rev over maximum standard speed. Refer to
TECHNICAL DATA 10-02.
Idle Speed Final Adjustment
15, Throttle Stop Screw
After the pilot screw is correctly adjusted, turn
throttle stop screw no. 15 to obtain the standard
idle speed.
STANDARD
1400 ± 200 RPM
IDLE SPEED
GOVERNOR ADJUSTMENT
Loosen governor arm nut.
Turn governor arm clockwise until carburetor
throttle is fully opened. Hold governor arm in this
position.
Using pliers, turn governor arm shaft clockwise
until it stops. 1
A31C13A
At this point tighten governor arm nut. See the next
photo. 1. Adjust throttle lever stop screw
MMR2000_123_04_08A.FM 04-08-7
Section 04 ENGINE

3
4
Carburetor
A31I01T

Section 04 ENGINE
Fuel Tank Lines
 WARNING
pincher (P/N 295 000 076) or equivalent device.
Fuel is flammable and explosive under certain
conditions. Ensure work area is well ventilat-
ed. Do not smoke or allow open flames or
sparks in the vicinity.
A31I02A
REMOVE GROMMET
Ensure that fuel filter and fuel line are clean and
not damaged, as per following photo.
1 2
A01B2JD
8, Check Valve
Check valve no. 8 must be installed with its black
side (stamped VAC) facing toward fuel tank.
To check proper operation of check valve, apply
vacuum to nipple of black side (stamped VAC).
A31I03A
There must be no air flow restriction.
1. Fuel filter
With 35 kPa (5 PSI) applied to nipple of black side 2. Fuel line
(stamped VAC) the check valve should not lose
more than 2 bubbles per minute at either nipple or Reinstall fuel filter with grommet.
at the weld joint while submersed in water. Refuel tank and ensure there are no leaks.
Replace if check valve doesn’t meet above men-
tionned specifications. Fuel Line Spring Clips
Always reposition spring clips no. 4 after any re-
Fuel Filter pair to prevent possible leaks.
To remove fuel filter no. 1 from fuel tank no. 2,
first drain fuel tank.
Using a flat screwdriver, carefully pull out fuel filter
by removing grommet no. 3, as shown in the next
photo.
04-09-2 MMR2000_124_04_09A.FM
Section 04 ENGINE

Put silicone grease (P/N 413 701 700) around ca-
ble barrel of throttle cable no. 7. Locate circlip
no. 5 as per following photo.
 WARNING
If this procedure is disregarded, throttle lever
no. 6 might be half-open at normally closed
position and the engine will speed up when
starting.
A31D0HA 1 2
TYPICAL — BRAKE SIDE SHOWN, IDENTICAL FOR THROTTLE
SIDE
1. Circlip
2. Detach throttle cable from throttle lever

When turning steering while engine is running,
idle speed must not vary.

Loosen throttle cable at carburetor.
While holding handlebar throttle lever and carbu-
retor lever at full throttle, tighten throttle cable to
this position.
 WARNING
Ensure that engine is not running when ad-
justing throttle cable.
MMR2000_124_04_09A.FM 04-09-3
TABLE OF CONTENTS 0
CLUTCH.................................................................................................................................. 05-02-1
REMOVAL .......................................................................................................................... 05-02-2
DISASSEMBLY .................................................................................................................. 05-02-3
CLEANING ......................................................................................................................... 05-02-3
INSPECTION ...................................................................................................................... 05-02-3
INSTALLATION.................................................................................................................. 05-02-4
BRAKE .................................................................................................................................... 05-03-1

REMOVAL .......................................................................................................................... 05-03-2
DISASSEMBLY .................................................................................................................. 05-03-2
CLEANING ......................................................................................................................... 05-03-2
INSPECTION ...................................................................................................................... 05-03-3
INSTALLATION.................................................................................................................. 05-03-3
ADJUSTMENT ................................................................................................................... 05-03-4
DRIVE CHAIN ......................................................................................................................... 05-04-1

REMOVAL........................................................................................................................... 05-04-1
INSPECTION ...................................................................................................................... 05-04-1
INSTALLATION.................................................................................................................. 05-04-1
LUBRICATION.................................................................................................................... 05-04-1
MMR2000_125_05_01ATOC.FM 05-01-1
Subsection 02 (CLUTCH)
CLUTCH 0
8
10
5 2
7
6
1
3
25 Nm
Loctite (19 lbfft)
242
A31D0GS

NOTE: Parts are not available separately. If clutch

4 2 1
no. 1 is damaged, replace clutch assembly.
REMOVAL
NOTE: Clutch can be removed without removing
brake. In that case drive chain no. 2 must be sep-
arated and removed first.
Lift hood.
Remove chain guard retaining screws as shown in
the following photo and lift off guard.
 WARNING
When removing chain guard, ensure that en-
gine is not running. Serious injuries may oc-
cur. A31D07A 3
UNLOCK BRAKE CABLE FROM BRAKE PAD
1. Brake pad
2. Brake cable
3. Unlock brake cable using Allen key
4. Hold screw head
Pull out brake cable from brake pad.

Remove elastic nut from pivot screw, then pull out
brake pad.
A31C0DA
1. Using a screwdriver, remove 3 screws
Brake Pad Removal

Using Allen key, unlock brake cable from brake A31D08A 1
pad, as shown in the next photo.
REMOVE BRAKE PAD
1. Pivot screw
05-02-2 MMR2000_125_05_02A.FM
1, Clutch Removal Loosen driven sprocket locking nut no. 9, then re-
move driven sprocket screw no. 10.
Holding clutch with a wrench, loosen clutch retain-
ing screw no. 3. Pull out driven sprocket from drive axle.
1
1
A31D09A A31D0AA
LOOSEN CLUTCH SCREW REMOVE DRIVEN SPROCKET

1. Wrench 1. Loosen driven sprocket locking screw
2. Clutch retaining screw
Remove drive chain automatic tensioner ass‘y no. 4. DISASSEMBLY

Remove drive chain from drive sprocket. Parts are not available separately. If clutch is dam-
NOTE: To ease drive chain removal, chain can be aged, replace clutch assembly.
separated by removing connecting link no. 5, as
described in subsection 04 DRIVE CHAIN. CLEANING
Remove clutch with extension no. 6 and spacer Clean all metal components in a general purpose
no. 7. solvent. Thoroughly dry all components before as-
sembling.
8, Driven Sprocket Removal
NOTE: To ease drive chain and driven sprocket INSPECTION
no. 8 removal and installation, it may be useful to
remove footrest. Inspect drive sprocket for wear. If sprocket is
worn, replace clutch ass‘y with new one.
Remove drive chain from driven sprocket.
If so check if clutch components are loose. If so,
replace clutch ass‘y with new one.
MMR2000_125_05_02A.FM 05-02-3
INSTALLATION CAUTION: Ensure that keyway is properly po-

sitioned when sliding clutch on shaft.
To install clutch, reverse removal procedure pay-
ing attention to the following.
Pour a few drops of oil into clutch sleeves, as
shown in the next illustration.
CAUTION: Pour a few drops of oil on clutch
axle only. Do not spill oil into clutch mechanism
or on clutch cover (braking surface).
A31D0FA
SLIDE CLUTCH AND DRIVEN SPROCKET

A31D01A Secure clutch and driven sprocket.
DRIP A FEW DROPS OF OIL ON CLUTCH AXLE Reinstall automatic drive chain tensioner.
To ease sprocket and clutch installation, first install
drive chain on both sprockets. Slide clutch and
driven sprocket on shafts, as per following photo.
05-02-4 MMR2000_125_05_02A.FM
BRAKE 0
5 4
Loctite 242
1 Loctite 242
11 N•m
(100 lbf•in) 3
A31D0IS

REMOVAL Brake Cable Replacement

Remove circlip no. 5 from brake cable at brake le-
2, Brake Pad Removal ver location, as shown in the next photo.
Using Allen key, unlock brake cable no. 1 from ca-
ble lock no. 4, as shown in the next photo.
4 2 1
A31D07A 3
UNLOCK BRAKE CABLE FROM BRAKE PAD 1 2
A31D0HA
1. Brake pad
2. Brake cable 1. Circlip
3. Unlock brake cable using Allen key 2. Detach brake cable from brake lever
4. Hold screw head
Pull out brake cable from cable lock. Detach brake cable from brake lever.
Remove elastic nut no. 3 from pivot screw, then Remove cable and replace with new one.
pull out brake pad no. 2.
DISASSEMBLY
Only brake pad no. 2 is available as spare part. If
clutch cover braking surface is damaged or worn,
replace clutch ass‘y no. 6.
CLEANING
sembling.
CAUTION: Do not clean brake pad in solvent.
Soiled brake pad must be replaced by new one.
A31D08A 1
REMOVE BRAKE PAD
1. Pivot screw
05-03-2 MMR2000_126_05_03A.FM
INSPECTION Check that brake lever is set to normal position (no

play), as shown in the next photo.
2, Brake Pad
1
Brake pad must be replaced when lining is 1 mm
(1/32 in) thick or less.
A A31D05B
1. No play here
Using pliers, secure brake cable so that brake pad

slightly rests on clutch cover.
A31D0JA
6, Brake Drum (clutch cover)

Inspect brake drum surface in clutch cover for
scoring, wear or cracking.
If brake drum needs to be replaced, replace clutch
assembly with new one.
2
INSTALLATION
To install brake pad, reverse removal procedure
paying attention to the following.
When securing brake pad with elastic nut no. 3.
Stop tightening when nut leans against brake pad.
This will avoid brake pad damage.
 WARNING A31D04A 1
Avoid getting oil on brake pad. 1. Tighten Allen screw
2. Pull brake cable with pliers
MMR2000_126_05_03A.FM 05-03-3
ADJUSTMENT
Fully apply brake with brake lever. If brake lever is
not within 15 mm (19/32 in) to 20 mm (25/32 in)
of the handlebar, readjust brake. Refer to the fol-
lowing photo.
A31D03A
1. Brake lever
A. If measurement is not within 15 mm (19/32 in) to 20 mm (25/32 in),
readjust brake
To adjust brake, loosen Allen screw then pull or

push on brake cable.
Retighten cable lock Allen screw.
Finally check brake adjustment.
05-03-4 MMR2000_126_05_03A.FM
DRIVE CHAIN 0
REMOVAL INSPECTION
NOTE: To ease drive chain removal, remove drive Check that chain is not stretched.
chain automatic tensioner first. CAUTION: On a stretched chain, pitch has
Rotate drive chain to locate connecting link circlip. changed (increased) and will not properly
Using a flat screwdriver push on both ends of cir- match the sprockets pitch, causing premature
clip to remove it. wear. For that reason, a stretched chain must
never be shortened.
Visually inspect chain for cracked, damaged or
missing links.
Check for worn or defective bearings, sprockets
and chain tensioner components.
1
A31D0KA
INSTALLATION
REMOVE CIRCLIP
1. Using a screwdriver, push circlip here Reinstall drive chain on both sprockets.
Remove outer link. Join both drive chain ends using connecting link.
Detach drive chain by removing connecting link. Secure connecting link using outer link and circlip.
Install circlip so that open end is positioned oppo-
site side of drive chain rotation. See the following
1 illustration.
 WARNING
Always ensure that connecting link, outer link
and circlip are in good condition. Ensure that
circlip is properly secured.
3 A31D0KB 1
A31D0LA
TYPICAL
1. Connecting link 1. Rotation
2. Outer link
3. Circlip Reinstall drive chain automatic tensioner.
Keep circlip, outer link and connecting link.
LUBRICATION
Lubricate drive chain as per lubrication chart.
Use BOMBARDIER LUBE (P/N 293 600 016).
CAUTION: Always lubricate drive chain slight-
ly. Oil must not contact brake pad.
MMR2000_127_05_04A.FM 05-04-1
TABLE OF CONTENTS 0
SPARK PLUGS....................................................................................................................... 06-02-1
NGK SPARK PLUG............................................................................................................. 06-02-1
REFERENCE CHART .......................................................................................................... 06-02-1
DISASSEMBLY................................................................................................................... 06-02-3
HEAT RANGE ..................................................................................................................... 06-02-3
FOULING ............................................................................................................................ 06-02-3
TESTING PROCEDURE ......................................................................................................... 06-03-1

IGNITION SYSTEM TESTING SEQUENCE ...................................................................... 06-03-1
LIGHTING SYSTEM TESTING SEQUENCE...................................................................... 06-03-1
1. SPARKING ..................................................................................................................... 06-03-1
2. ELECTRICAL CONNECTOR TESTING .......................................................................... 06-03-1
3. IGNITION COIL TESTING .............................................................................................. 06-03-1
4. SPARK PLUG CAP TESTING......................................................................................... 06-03-2
5. LAMP COIL TESTING .................................................................................................... 06-03-3
MMR2000_128_06_01ATOC.FM 06-01-1
SPARK PLUGS 0
NGK SPARK PLUG
SYSTEM
Bombardier uses the NGK spark plug brand on all
its snowmobile models.
Low number hot plug
REFERENCE CHART
NGK spark plug used on Bombardier Mini Z snow-
mobile is covered in this manual:
– BPR6 ES
MMR2000_128_06_02A.FM 06-02-1
A31E0ES

A01E1PS
06-02-2 MMR2000_128_06_02A.FM
DISASSEMBLY CAUTION: Severe engine damage might occur

if a wrong heat range plug is used.
A too “hot” plug will result in overheating and pre-
A too “cold” plug will result in fouling (shorting the
FOULING
The proper operating temperature or heat range of running of the engine, decreased engine speed
the spark plugs is determined by the spark plug due to misfiring, reduced performance, and in-
ability to dissipate the heat generated by combus- creased fuel consumption. This is due to a loss of
tion. compression. Other possible causes are : pro-
longed idling, or running on a too rich mixture due
The longer the heat path between the electrode to a faulty carburetor adjustment or incorrect fuel
tip to the plug shell, the hotter the spark plug op- and/or fuel mixing. The plug face of a fouled spark
erating temperature will be — and inversely, the plug has either a dry coating of soot or an oily,
shorter the heat path, the colder the operating glossy coating given by an excess either of oil or
temperature will be. of oil with soot. Such coatings form a conductive
A “cold” type plug has a relatively short insulator connection between the center electrode and
nose and transfers heat very rapidly into the cylin- ground.
der head.
Such a plug is used in heavy duty or continuous SPARK PLUG ANALYSIS
The “hot” type plug has a longer insulator nose
and transfers heat more slowly away from its firing
A00E0AA 1 2 3
1 2 3. Fouled (black)
The plug electrode and piston dome reveal the

condition of the engine, operating condition,
method of driving and fuel mixture. For this reason
it is advisable to inspect the spark plug at regular
intervals, examining the plug electrode and the
piston dome.
A00E09A
1. Cold
2. Hot
MMR2000_128_06_02A.FM 06-02-3

grime.
cording to TECHNICAL DATA 10.
2. Apply anti-seize lubricant (P/N 413 701 000)
over the spark plug threads to prevent possible
seizure.
3. Hand screw spark plug into cylinder head and
tighten with a torque wrench and a proper socket.
1 2
A00E0BA
1. Proper socket
2. Improper socket

TORQUE
SPARK TORQUE
MODELS
06-02-4 MMR2000_128_06_02A.FM
TESTING PROCEDURE 0
IGNITION SYSTEM TESTING 1. SPARKING
SEQUENCE During this operation, it is important to use the
In the case of ignition problems, check the follow- snowmobile spark plug and not a new one. Bring
ing in the prescribed order until the problem can the plug in contact with the engine. If no spark is
be solved. produced, replace the spark plug with a new one
1. Sparking/spark plug condition
2. Electrical connectors 2. ELECTRICAL CONNECTOR
3. Ignition switches, tether cord cap switch and TESTING
emergency switch
4. Ignition coil resistance
nected.
LIGHTING SYSTEM TESTING 3. IGNITION COIL TESTING
SEQUENCE
1. Electrical connectors Primary Side
2. Lamp coil resistance Bring multimeter selector switch to Ω position.
Connect first multimeter probe to ignition coil pri-
Analysis of Readings mary black wire then second probe to ignition coil
Resistance Readings iron core, as shown in the next photo.
Place multimeter selector switch to Ω in order to 2 1
measure resistance. Readings must be within the
indicated range. Otherwise, the part is considered
CAUTION: When taking measurements, it is
useless to try to start the vehicle since readings
would then be distorted.
ture is normal must be checked in similar condi-
tions.
perature or vibrations, these can only be solved by A31E0FA 3
replacing parts. Most problems cannot be detect-
PRIMARY SIDE TESTING
ed when the engine is stopped. 1. Multimeter to Ω position
2. Ignition coil primary black wire
Multiple Problems 3. Ignition coil iron core
As a matter of fact, more than one component can The measured resistance should be according to
be defective. As a result, if the problem remains the following table. If not, replace ignition coil.
although a part was replaced, start over the whole
verification from the beginning in order to identify PRIMARY SIDE
the other defective component. 0.8 - 1.0 Ω
RESISTANCE VALUE
MMR2000_129_06_03A.FM 06-03-1
Secondary Side 4. SPARK PLUG CAP TESTING

Bring multimeter selector switch to Ω position. Remove spark plug cap by unscrewing cap from
Remove spark plug cap by unscrewing cap from cable.
cable. NOTE: A false resistance reading will result if
NOTE: A false resistance reading will result if spark plug cap is not removed.
spark plug cap is not removed. Bring multimeter selector switch to Ω position.
Connect first multimeter probe to spark plug lead Connect first multimeter probe to one end of the
wire then second probe to ignition coil iron core, spark plug cap then second probe to the other end
as shown in the next photo. as shown in the next photo.
2 1
1
2
A31E0HA
A31E0GA 3 SPARK PLUG CAP TESTING

1. Multimeter to Ω position
SECONDARY SIDE TESTING 2. Spark plug cap end
2. Spark plug lead wire The measured resistance should be according to
3. Ignition coil iron core the following table. If not, replace spark plug cap.
The measured resistance should be according to
RESISTANCE 7.5 - 12.5 kΩ
the following table. If not, replace ignition coil.
SECONDARY SIDE
5.9 - 7.1 kΩ
RESISTANCE VALUE
06-03-2 MMR2000_129_06_03A.FM
5. LAMP COIL TESTING

NOTE: Lamp coil is parallel 2 coils type.
Bring multimeter selector switch to Ω position.
Connect first multimeter probe to pink wire then
second probe to lamp coil iron core, as shown in
the next photo.
1 3 2
A31E0IA
LAMP COIL TESTING

2. Pink wire
3. Lamp coil iron core
The measured resistance should be according to

the following table. If not, replace lamp coil.
RESISTANCE 0.18 - 0.23 Ω
MMR2000_129_06_03A.FM 06-03-3
TABLE OF CONTENTS 0
REAR SUSPENSION.............................................................................................................. 07-02-1
REMOVAL .......................................................................................................................... 07-02-2
DISASSEMBLY AND ASSEMBLY..................................................................................... 07-02-3
INSPECTION ...................................................................................................................... 07-02-5
DRIVE AXLE ........................................................................................................................... 07-03-1

REMOVAL........................................................................................................................... 07-03-2
DISASSEMBLY AND ASSEMBLY..................................................................................... 07-03-3
INSTALLATION .................................................................................................................. 07-03-3
TRACK .................................................................................................................................... 07-04-1

GENERAL ........................................................................................................................... 07-04-1
INSPECTION ...................................................................................................................... 07-04-1
REMOVAL........................................................................................................................... 07-04-1
INSTALLATION .................................................................................................................. 07-04-1
MMR2000_138_07_01ATOC.FM 07-01-1
Subsection 02 (REAR SUSPENSION)
REAR SUSPENSION 0
3
19
4
20
1
5 17-18
12
13
10
2
9
15 14
17-18 3
7 16
21
11
A31F04S

NOTE: The following is the complete procedure Rear Suspension

to remove rear suspension ass‘y. However some
Position a small block below track.
suspension components can be removed without
removing suspension ass‘y. See DISASSEMBLY Lower snowmobile so that track sits on block.
AND ASSEMBLY procedure.
REMOVAL
Lift rear of snowmobile and support it off the
ground.
1, Rear Axle
NOTE: Removing rear axle first will ease rear sus-
pension ass‘y removal.
Completely release track tension by loosening ad- A31F06A
justment screws no. 2.

POSITION A SMALL BLOCK BELOW TRACK
Unscrew one rear idler wheel screw no. 3.
Lean on snowmobile seat then unscrew upper
Pull out rear axle no. 1 from opposite side of offset idler wheel axle no. 4 from tunnel.
inner wheel.
A31F07A 1
2
1. Unscrew upper idler wheel axle
Remove both screws no. 5 retaining front arm to

A31F05A
tunnel.
PULL OUT REAR AXLE
1. Loosen this adjustment screw on both sides to release track
tension
2. Idler wheel previously removed
07-02-2 MMR2000_130_07_02A.FM
Unscrew front retainer axle no. 6 (retaining front

strap) from tunnel. See the following photo.
3 2 1
A31F08A
1. Upper idler wheel screw

2. Front arm screw
3. Front retainer axle screw A31F09A
Lift rear of snowmobile. REMOVE SCREW
Pull out suspension ass‘y. Remove front axle screw no. 11, as shown in the
following photo.
Inspect track thoroughly before reinstalling sus-
pension. Refer to TRACK 07-04.
7, Runner
NOTE: Runner no. 7 can be removed without re-
moving suspension assembly, as described in the
Completely release track tension.
Remove rear axle no. 1 with idler wheels.
Remove screws no. 8 retaining runner support
no. 9 to front arm no. 10, as shown in the follow-
ing photo.
A31F0AA
REMOVE SCREW
MMR2000_130_07_02A.FM 07-02-3
Pull out runner from track, as shown in the next

photo.
A31F07A 1
A31F0BA
1. Unscrew upper idler wheel axle
PULL OUT RUNNER
Remove both screws no. 5 retaining front arm to
To reinstall runner, reverse removal procedure. tunnel.
Lift rear of snowmobile so that rear suspension
12, Torsion Spring ass‘y comes out of tunnel.
NOTE: Torsion springs can be replaced without Remove torsion spring no. 12, as shown in the
completely removing rear suspension ass‘y, as de- next photo.
scribed in the following procedure.
Completely release track tension.
Remove rear axle no. 1 with idler wheels.
Lower snowmobile.
Lean on snowmobile seat then unscrew upper
idler wheel axle no. 4 from tunnel.
A31F0CA
REMOVE TORSION SPRING
07-02-4 MMR2000_130_07_02A.FM
Remove bushing no. 13, as shown in the next

photo. Clean all surfaces and check for excessive
wear.
A31F0DA
REMOVE AND CLEAN BUSHING

A31F0FA
To reinstall, reverse removal procedure. REMOVE RUBBER STOPPER
14,15,16, Rubber Stopper Reinstall rubber stopper no. 14 with retaining pins
no. 16 and push nuts no. 15.
NOTE: Rubber stopper no. 14 can be replaced
with runner and suspension ass‘y in place. CAUTION: When reusing original push nuts,
ensure that they are in good condition. If not,
Using special tool Snap-on A161B, remove push replace with new push nuts.
nuts no. 15 as shown in the next photo.
3 2 INSPECTION
17,18, Stopper Straps
Inspect straps for wear or cracks, bolts and nuts
for tightness. If nuts are loose, inspect hole for
deformation. Replace as required.
1
A31F0EA 1
1. Rubber stopper
2. Special tool Snap-on A161B
3. Push nuts
Remove retaining pins no. 16.

A31F0GA
Lift rubber stopper tab and remove it.
TYPICAL — FRONT STRAP SHOWN
1. Inspect bolts and nuts for tightness
MMR2000_130_07_02A.FM 07-02-5
19,20, Upper Idler Wheels

Remove bushing no. 20 and idler wheel no. 19
from shaft no. 4, as shown in the next photo.
Clean parts and check for wear and bearing condi-
tion.
A31F0HA
CHECK BUSHING, WHEEL AND SHAFT CONDITION
21, Slider Shoe

Inspect slider shoes no. 21 for wear.
CAUTION: Even if only one slider shoe needs
to be replaced, always replace both ones. Slid-
er shoes must always be replace in pairs.
To replace slider shoes:
– Remove left side runner.
– Bend tabs from used slider shoe then remove it.
– Install new slider shoe on one end of the runner,
then clip second end.
– Secure slider shoe by bending tabs onto runner.
– Repeat procedure on right side.
07-02-6 MMR2000_130_07_02A.FM
DRIVE AXLE 0
5
7
4
9
6
Loctite
3 242
7 8
1
2
A31D0NS

REMOVAL
Remove chain guard.
Remove drive chain then remove driven sprocket.
NOTE: To ease driven sprocket and drive axle re-
moval, it may be useful to remove left side foot-
rest.
Remove rear suspension. Refer to REAR SUS-
PENSION 07-02 of this manual.
Sprocket
From inside tunnel, remove spring pin no. 1 from
right side sprocket using a hammer and a punch,
as shown.
A31D0PA
SLIDE RIGHT SIDE SPROCKET INSIDE
Bearing Holder
Using Allen key loosen set screw no. 3 from bear-
ing lock sleeve no. 4, as shown in the next photo.
A31D0OA
REMOVE SPRING PIN
Using a prybar and a piece of wood (to protect tun-

nel), slide right side sprocket no. 2 (38 mm (1-1/2 in)).
See the next photo.
NOTE: Apply BOMBARDIER LUBE (P/N 293 600
016 — 12 x 14 oz) on drive axle to ease sliding A31D0QA 1
sprocket.
RIGHT SIDE SHOWN
CAUTION: When using prybar, ensure not to 1. Loosen set screw
apply too much pressure on tunnel wall in or-
der to avoid damaging tunnel. Using a hammer and a punch, turn CCW to unlock
bearing lock sleeve as shown.
07-03-2 MMR2000_131_07_03A.FM
Drive Axle Ass‘y

Pull out drive axle ass‘y no. 8, as shown in the next
photo.
A31D0RA 2
1. Lock sleeve
2. Position punch in this hole
Remove 3 bearing holder nuts no. 5 and screws A31D0TA

no. 6 then detach both halves no. 7 using a flat
screwdriver. See the following photo. PULL OUT DRIVE AXLE ASS‘Y

Bearing and Sprocket
To remove or to install bearings no. 9 and sprock-
ets no. 2, use a press.
CAUTION: Ensure that bearings and sprockets
are properly supported near hub and that
spring pins have been removed from sprock-
ets, before removal.
INSTALLATION
Reverse the removal procedure and pay a special
attention to the following points.
Sprockets can be positioned with drive axle in
place. In that case use drive axle sprocket adjuster
(P/N 861 725 700), as shown in the following photo.
A31D0SA
DETACH BEARING HOLDER HALVES
Repeat procedure for left side bearing, except for

lock sleeve.
MMR2000_131_07_03A.FM 07-03-3
1 2
Drive Axle Alignment
To ensure that drive axle sprockets are properly
aligned with track guides, measure right side drive
axle end.
Drive axle must exceed bearing locking sleeve by
4 mm (5/32 in), as shown in the next photo. If not,
realign drive axle.
A
A31D0UA 3
1. Tighten tool on drive axle with these screws
2. Install plate to protect sprocket
3. Use these screws to move sprocket
Reinstall spring pins as shown in the next photo.

CAUTION: Ensure that drive axle spring pin
hole is properly aligned with sprocket hole.
A31D0VA
A. 4 mm (5/32 in)
Tighten (clockwise) bearing lock sleeve and secure

with set screw. Apply Loctite 242 on set screw
threads.
A31D0OA
REINSTALL SPRING PIN
07-03-4 MMR2000_131_07_03A.FM
TRACK 0
GENERAL
This section gives guidelines for track removal.
Some components require more detailed disas-
fer to the pertaining section in this manual.
INSPECTION
Visually inspect track for:
– missing or defective inserts or guides
If track is damaged, replace track. A31F03A
 WARNING TRACK ROTATION
Do not operate a snowmobile with a cut, torn Track Tension and Alignment
or damaged track.
Track tension and alignment are interrelated. Do
not adjust one without checking the other. Track
REMOVAL tension procedure must be carried out prior to
track alignment.
Remove the following items:
– chainguard Tension
– drive chain and driven sprocket Lift the rear of vehicle and support with a mechan-
– rear suspension ical stand. Allow the suspension to extend normal-
ly. Check the gap 60 mm (2-3/8 in) from rear idler
– end bearing housing
wheel bracket.
– drive axle
Deflection should be 35 mm (1-3/8 in) between
– track slider shoe and bottom inside of track, when ex-
erting a downward force of 7.3 kg (16 lb).
INSTALLATION Use tension tester (P/N 414 348 200) to measure
Reverse the removal procedure. deflection as well as force applied.
NOTE: When installing the track, respect rotation 1
direction indicated by shaped arrows on track
thread.
A00C07A
1. Belt tension tester
MMR2000_132_07_04A.FM 07-04-1
Alignment
 WARNING
1 track is free of all particles which could be
vehicle.

A tance on both sides between edges of track
B
1 2 1
A31D0MA
1. 7.3 kg (16 lb)

A. 60 mm (2-3/8 in)
B. 35 mm (1-3/8 in)
3
CAUTION: Too much tension will result in pow- A31F01A
er loss and excessive stress on suspension 1. Guides

components. If too loose, the track will have a 2. Slider shoes
3. Equal distance
tendency to thump.
To adjust, loosen the rear idler wheel retaining To correct, stop engine then loosen the lock nuts
screws and the adjustment screw lock nuts; then and tighten the adjustment screw on side where
loosen or tighten the adjustment screws located guides are farthest to runner. Tighten lock nuts
on the inner side of the rear idler wheels. and recheck alignment.
1 2 1
1 2
3
A31F02A
1. Guides
2. Slider shoes
3 3. Tighten on this side
A05F0EA
TYPICAL
1. Adjustment screw
2. Lock nut
3. Retaining screw
07-04-2 MMR2000_132_07_04A.FM
Tighten lock nuts and the idler wheel retaining

screws.
2
A05F0EB
TYPICAL
1. Retighten lock nuts
2. Retighten rear idler wheel retaining screws
Restart engine, rotate track slowly and recheck

alignment.
MMR2000_132_07_04A.FM 07-04-3
TABLE OF CONTENTS 0
STEERING SYSTEM .............................................................................................................. 08-02-1
INSPECTION ...................................................................................................................... 08-02-2
INSPECTION ...................................................................................................................... 08-02-3
STEERING ADJUSTMENT (skis) ...................................................................................... 08-02-3
LUBRICATION .................................................................................................................... 08-02-5

DISASSEMBLY................................................................................................................... 08-03-2
INSPECTION ...................................................................................................................... 08-03-2
INSTALLATION .................................................................................................................. 08-03-2
MMR2000_133_08_01ATOC.FM 08-01-1
STEERING SYSTEM 0
1
2
3
3
4 15 Nm
(133 lbfin)
Lithium grease
(P/N 413 706 100)
5
11
15 Nm
6 (133 lbfin)
Lithium grease 13 6
12 (P/N 413 706 100)
7
Loctite
609
15 Nm 10 Nm
12
8
10 Nm 15 Nm
Loctite Loctite
609 609 12
9
15 Nm Loctite 609 10

(133 lbfin)
15 Nm
(133 lbfin)
A31G0FS

INSPECTION Remove U-clamp no. 7 with both half bushings,

no. 6 as shown in the following photo.
necessary. Refer to SUSPENSION AND SKI SYS- 2 1
TEM 08-03.
Steering System
Check general condition of steering system.
Check general condition of steering system com-
ponents for wear and replace if necessary.

2, Grip
Grips can be removed and installed without any
damage by injecting compressed air into the han- A31G06A
dlebar or by heating them with a heat gun.

REMOVE U-CLAMP
1. U-clamp
11, Steering Column 2. Bushing
From underneath bottom pan, remove tie rod clip. Remove retaining support no. 4 with both half
Refer to STEERING ADJUSTMENT (skis) for clip bushings no. 3, as shown in the following photo.
removal.
Detach short tie rod no. 8 from steering column
no. 11, as shown in the next photo.
A31G07A
1. Retaining support
A31G05A
1
DETACH TIE ROD

1. Clip removed
08-02-2 MMR2000_133_08_02A.FM
INSPECTION  WARNING
12, Ball Joint The cut off section of the ball joint must run
parallel with the steering arm. When tighten-
Inspect ball joint ends for wear or looseness, if ex- ing lock nuts, restrain ball joint with appropri-
cessive, replace. ate size wrench. Ensure not too many threads
If stud loosened apply Loctite 609 in ball joint thread- are kept outside of the tie rod according to the
ed hole and torque stud to 15 N•m (133 lbf•in). thread length chart.
Mount lock nut on exposed portion of stud. Screw
exposed portion of stud into tie rod. Torque lock nut
to 10 N•m (89 lbf•in). The maximum length for ball
STEERING ADJUSTMENT (skis)
joint center to tie rod end must not exceed the value
A in the following chart: Definitions
TOE-OUT:
Difference in measurement between front edge A
and rear edge B of skis as viewed from top side of
suspension system. It is adjustable.
A
A17G0SB B
TYPICAL
A
MODEL A01G04A
MM (IN)
Mini Z 47 (1-27/32) CAMBER:
A specific inward or outward tilt angle of ski leg
The cut-off section of the tie rod end must run par- compared to a vertical line when viewing vehicle
allel with the horizontal line of the steering arm from front. This angle is not adjustable on Mini Z.
when assembled on vehicle. The ball joint should
be restrained when tightening tie rod end lock nut. Adjustments
For torque specifications see specific exploded
view. Adjustments should be performed following this
sequence:
1 2 – Pivot arm centering/horizontal handlebar.
– Set toe-out.
PIVOT ARM CENTERING/HORIZONTAL
HANDLEBAR
Turn handlebar no. 1 until pivot arm no. 13 is well
centered.
Check if handlebar is horizontal and skis aligned
A02G0IA with track. If not, adjust as per following procedure:
TYPICAL Loosen lock nut of short tie rod end.
2. Steering arm Using a flat screwdriver, remove clip on short tie
rod end, as shown in the next photo.
MMR2000_133_08_02A.FM 08-02-3
5
4 3 Loctite 242
Loctite 242
6
8
7
A31G0GS

A31G0AA
A. 47 mm (1-27/32 in) maximum

A31G08A Restrain tie rod while firmly retighten nuts so that
TO REMOVE CLIP — LIFT THEN PULL OUT ball joint sockets run parallel with steering arm and
pivot arm.
Detach short tie rod end from steering arm no. 10.
Check that handlebar is horizontal and that skis are  WARNING
aligned with track. Ball joint sockets must run parallel with steer-
Rotate tie rod end CW or CCW until proper aligning arm and pivot arm. Tie rod must be re-
ment with steering arm is attain. See next photo. strained when tightening lock nuts.
Ensure that pivot arm no. 13 is still centered and

check ski toe-out.
TOE-OUT
Loosen lock nuts of long tie rod end no. 9 and de-
tach tie rod end from steering arm no. 10.
Turn each tie rod end to adjust toe-out. See next
photo.
A31G09A
DETACH TIE ROD END AND ROTATE CW OR CCW TO ADJUST
Re-attach tie rod end to steering arm.
 WARNING
Maximum length for ball joint center to tie rod
end must not exceed 47 mm (1-27/32 in).
Torque lock nut to 15 N•m (133 lbf•in).
A31G0BA 1 2
TO ADJUST — ROTATE TIE ROD END
1. Loosen lock nut
2. Steering arm
08-02-4 MMR2000_133_08_02A.FM
Re-attach tie rod end to steering arm then secure

with clip.
NOTE: A rubber cord must be hooked in front of
skis to keep them closed.
NOTE: To measure toe-out, place a straight edge
against pre-adjusted track and measure distance
between front and rear of skis and straight edge.
Distances should be equal. After ski toe-out ad-
justment, distance at front of ski must be 0 to 3.0
mm (0 to 1/8 in) more than at rear on both sides
for a total toe-out of 0 to 6 mm (0 to 1/4 in).
A31G0CA
HOLD TIE ROD THEN TIGHTEN LOCK NUT
LUBRICATION
2  WARNING
1 Do not lubricate throttle and/or brake cable,
A06G03A
housing and spring coupler bolts.

TYPICAL
1. Straight edge
2. 0 to 3.0 mm (0 to 1/8 in) more at front than at rear
Steering Column
Check external threaded length not engaged and Use lithium grease (P/N 413 706 100) at U-clamp
firmly retighten lock nuts, as shown in the next and retaining support location on steering column.
photo.
Ball Joints
Lightly grease ball joints with bearing grease (P/N
413 706 100).
MMR2000_133_08_02A.FM 08-02-5
DISASSEMBLY
2, Rubber Mount
Note rubber mount position.
Remove lower nut then upper nut of rubber mount.
1, Swing Arm
Unbolt ski.
Unbolt lower end of rubber mount from swing arm
no. 1.
A31G01A 1
Remove nuts and washers then detach tie rod end
from steering arm no. 3. SLIDE SKI
1. Ski leg spacer
Remove swing arm front screw no. 4 from frame.
Secure ski with screw no. 6, washer no. 7, nut
Remove swing arm rear screw no. 5 from frame.
no. 8 and cotter pin no. 9, then ensure that ski pin
Pull swing arm off the vehicle. is properly centered into ski leg, as shown in the
following photo.
INSPECTION
2 1
Check both rubber mounts for looseness and wear.
If so, replace with new one.
place as required.
required.
Check skis and runners for wear, replace as nec-
essary.
INSTALLATION
For assembly, reverse the disassembly procedure.
However, pay attention to the following.
Tighten nuts and screws to proper torque and ap-
ply Loctite 242 where specified, as mentioned in
exploded view. A31G02A 3
1. Bolt head toward OUTSIDE of vehicle
Ski 2. Washer, nut and cotter pin (not shown) toward inside of vehicle
3. Ski pin centered into ski leg
Slide ski on ski leg as shown in the next photo.
 WARNING
Always use new cotter pin when reinstalling
skis.
Tie Rod
Position tie rods horizontally before tightening nuts.
08-03-2 MMR2000_133_08_03A.FM
Section 09 BODY AND FRAME
TABLE OF CONTENTS 0
BODY ...................................................................................................................................... 09-02-1
DECAL ................................................................................................................................ 09-02-3
CHAIN GUARD .................................................................................................................. 09-02-3
WIRING HARNESS ............................................................................................................ 09-02-3
CABLES .............................................................................................................................. 09-02-3
PIPING ................................................................................................................................ 09-02-4
PLASTIC REPAIR................................................................................................................ 09-02-5
REPAIR................................................................................................................................ 09-02-5
FRAME ................................................................................................................................... 09-03-1

FRAME CLEANING ............................................................................................................ 09-03-2
FRAME WELDING ............................................................................................................. 09-03-2
MMR2000_134_09_01ATOC.FM 09-01-1
BODY 0
3
2
Loctite 242
A31H0LS

INSTALLATION AND ADJUSTMENT

HEADLAMP BEAM AIMING BULB REPLACEMENT
Beam aiming is correct when center of high beam Headlight
is 25 mm (1 in) below the headlamp horizontal cen-
ter line, scribed on a test surface, 381 cm (12 ft 6 in) If headlamp bulb is burnt, tilt hood.
away. Remove the rubber boot and turn the bulb retainer
Measure headlamp center distance from ground. ring counterclockwise.
below scribed line.
90°
A31E0BA
REMOVE RUBBER BOOT AND BULB RETAINER RING
A31E0DA
B Pull off bulb retainer ring, detach the bulb and re-
place. Properly reinstall parts.
A. 381 cm (12 ft 6 in)
B. 25 mm (1 in) below headlamp center
1 2
3 A
A02E07A
1. Headlamp horizontal center line

A. 25 mm (1 in)
Required Conditions A31E03A
Place the vehicle on a flat surface perpendicular to

away from it.
Taillight
Rider or equivalent weight must be on the vehicle. Taillight is sealed, if it is burnt, replace taillight
ass‘y with new one.
Adjustment To remove, unscrew the 2 lens screws.
Remove headlamp screw caps. Turn screws ac- Pull out taillight ass‘y.
cordingly at upper headlamp attachment. Unplug connector.
Install new taillight ass‘y.
09-02-2 MMR2000_134_09_02A.FM
DECAL
thoroughly.
solvent directly on decals.
WINDSHIELD INSTALLATION
When peeling off the protective film some poly-
A31H0KA
ethylene particles may remain on the windshield
no. 1. A soft clean cloth moistened with naphtha VIEW FROM INSIDE HOOD — LOCK WINDSHIELD TABS
(camping equipment fuel) will easily remove the
remaining particles. CHAIN GUARD
 WARNING Disassembly and Assembly
Naphtha is flammable and explosive under
certain conditions. Always manipulate in a  WARNING
well ventilated area. Do not smoke or allow Engine should be running only with chain
open flames or sparks in the vicinity. guard well secured in place.
Position the windshield no. 1 on the hood no. 2

then push it down until the tabs are fully inserted Inspection
into the hood slots, as shown. Check chain guard mounting tabs and spring nuts
for wear.
WIRING HARNESS
 WARNING
rotating, moving, heating and vibrating parts.
CABLES
A31H0JA
 WARNING
INSERT WINDSHIELD TABS INTO HOOD SLOTS Before installation, ensure that all cables are
From inside hood, lock the windshield tabs in po- in perfect condition. Properly install the cable
sition using latches no. 3 as shown. ends and secure them in place. Pay attention
to route them properly, away from any rotat-
ing, moving, heating, or vibrating parts.
MMR2000_134_09_02A.FM 09-02-3
PIPING
 WARNING
Always ensure that the fuel and vent lines are
properly fixed to their connectors, that they
are not perforated or kinked and that they are
properly routed away from any rotating,
moving, heating or vibrating parts. Also
check for leaks. Replace if required.
NOTE: Refer to proper Parts Catalog to find suit-

able clip part numbers.
09-02-4 MMR2000_134_09_02A.FM
PLASTIC REPAIR
REPAIR
Two types of plastic material are used on Mini Z
model, as described in the following table.
MATERIAL
WINDSHIELD Polycarbonate
HOOD Polyethylene
BOTTOM PAN Polyethylene
Both plastic materials are irreparable.

In the case that parts are broken or damaged, re-
place with new one.
 WARNING
Polycarbonate windshields must never be
repaired by welding or otherwise.
MMR2000_134_09_02A.FM 09-02-5
FRAME 0
A31H0NS

FRAME CLEANING FRAME WELDING

Clean frame no. 1, tunnel no. 2 and bumpers Steel Frame:
no. 3 with appropriate cleaners and rinse with – electric welding
high pressure hose.
– amperage: 70-110 A
scratched off. Spray all bare metal parts of vehicle – voltage: 20-24 V
with metal protector. – rod: E-7014 (3/32 in)
CAUTION: If welding is to be done near plastic
Seat Removal/Replacement material, it is recommended to either remove
Seat no. 4 is retained to tunnel with 4 wood the part from the area or to protect it with alu-
screws no. 5. All screws must be removed from minum foil to prevent damage.
inside tunnel.
To remove both front wood screws no. 5, detach FRAME COMPONENT
rear suspension from tunnel, as described in sec- REPLACEMENT
tion 07 REAR SUSPENSION.
CAUTION: Ensure that 4 wood screws no. 5 Drilling Procedure
have been removed before removing seat. For proper drilling instructions and to prevent pre-
mature wear, follow the procedure below.
Seat Cleaning Always use a variable speed electric drill.
It is recommend to clean the seat no. 4 with a so- Center the drill bit on the rivet hole and drill.
lution of warm soapy water, using a soft clean
cloth. Maintain a slow to medium speed at all times
when drilling. The proper speed is attained when
CAUTION: Avoid use of harsh detergents such a constant breaking chip is ejected.
as strong soaps, degreasing solvents, abrasive
cleaners, paint thinners, etc. that may cause NOTE: To increase bit life, use Bombardier syn-
damage to the seat cover. thetic chaincase oil (P/N 413 803 300) as a cutting
oil.
the bit, therefore avoid using pneumatic drills.
09-03-2 MMR2000_135_09_03A.FM
TECHNICAL DATA 0
BASE UNITS
length .................................................................. meter ..................................................... m

mass .................................................................... kilogram ................................................. kg
force .................................................................... newton ................................................... N
liquid .................................................................... liter ......................................................... L
PREFIXES

CONVERSION FACTORS
in ......................................................................... mm ......................................................... 25.4

in ......................................................................... cm .......................................................... 2.54
in2 ........................................................................ cm2 ......................................................... 6.45
in3 ........................................................................ cm3 ......................................................... 16.39
ft .......................................................................... m ............................................................ 0.3
oz ......................................................................... g ............................................................. 28.35
lb ......................................................................... kg ........................................................... 0.45
lbf ........................................................................ N ............................................................ 4.4
lbf•in ................................................................... N•m ....................................................... 0.11
lbf•ft .................................................................... N•m ....................................................... 1.36
lbf•ft .................................................................... lbf•in ...................................................... 12
PSI (lbf/in2) .......................................................... kPa ......................................................... 6.89
imp. oz ................................................................. U.S. oz .................................................... 0.96
imp. oz ................................................................. mL .......................................................... 28.41
imp. gal ................................................................ U.S. gal ................................................... 1.2
imp. gal ................................................................ L ............................................................. 4.55
U.S. oz ................................................................. mL .......................................................... 29.57
U.S. gal ................................................................ L ............................................................. 3.79
MPH .................................................................... km/h ...................................................... 1.61
Celsius ................................................................. Fahrenheit .............................................. (°C x 1.8) + 32

† To obtain the inverse sequence, divide by the given factor. To convert ’’mm’’ to ’’in’’, divide by 25.4.
MMR2000_136_10_01A.FM 10-01-1
VEHICLE MODEL MINI Z
ENGINE TYPE 4 Stroke

Overhead Valves
Number of Cylinders 1
Bore mm (in) 60.00 (2.362)
Stroke mm (in) 42.00 (1.654)
Displacement cm3 (in3) 118.00 (7.20)
Compression Ratio (corrected) 8.5: 1
Maximum Power Engine Speed ± 100 RPM 4000
Top/Second 0.2 - 0.4 (.008 - .016)
Ring End Gap Oil mm (in) 0.15 - 0.35 (.006 - .014)
(wear limit) 1.0 (.04)
(standard) mm (in) .015 - .045 (.0006 - .0018)
(wear limit) mm (in) .15 (.006)
(standard) mm (in) .015 - .05 (.0006 - .002)
Piston/Cylinder Wall Clearance (wear limit) mm (in) .12 (.005)
Connecting Rod Big End Side Clearance (standard) mm (in) 0.1 - 0.7 (.004 - .028)
(wear limit) mm (in) 1.1 (.043)
Ignition Type Transistorized
Spark Plug Make and Type NGK BPR6 ES
Spark Plug Gap mm (in) 0.7 - 0.8 (.028 - .031)
Ignition Timing BTDC mm (in) 25° (fixed)
Lamp Coil 0.18 - 0.23
Primary Ω 0.8 - 1.0
Ignition Coil
Secondary Ω 5.9 - 7.1
Carburetor Type Horizontal

Butterfly Valve
Main Jet 60
Float Height Adjustment ± 1 mm 13.7 (.54)

(± .040 in)
Pilot Screw Opening ± 1/16 turn 2 Turns Out
Idle Speed RPM ± 200 RPM 1400
Gas Type/Pump Octane Number Unleaded/86
Oil SAE 5W/30
Type Radial Fan
Drive Sprocket Retaining Screw 25 (19)

ENGINE COLD
Exhaust Nuts 24 (18)

N•m (lb•ft)
Crankcase Screws M6 12 (9)

Cylinder Head Screws 24 (18)
Axial Fan/Flywheel Nut 75 (55)
MMR2000_136_10_02A.FM 10-02-1
Subsection 03 (VEHICLE)
VEHICLE MODEL MINI Z
ENGINE TYPE 4 Stroke

Overhead Valve
Drive Chain Ratio 10/48
Pitch mm (in) 12.7 (.500)
Drive Chain
Type/Links Qty Single 40/78
Drive Sprocket Clutch Engagement N.A.
Outside Diameter mm (in) 201.37 (7.93)
Driven Sprocket
Pitch Diameter mm (in) 194.18 (7.65)
Drive Chain Part Number (P/N) 412 107 500
Drive Chain Adjustment Deflection Automatic Tensioner
Width mm (in) 254.0 (10)
Length mm (in) 1748.8 (68.85)
Track Profile Height mm (in) 15.97 (.63)
Deflection mm (in) 35 (1-3/8)
Adjustment
Force kg (lbf) 7.3 (16)
Track Mini Z
Suspension Type
Ski Mini Z
Length mm (in) 1860.0 (73.2)
Width mm (in) 885.0 (34.8)
Height mm (in) 750.0 (29.5)
Ski Stance mm (in) 685.0 (27.0)
Mass (dry) kg (lb) 70 (154)
Ground Contact Area cm2 (in2) 2754.5 (426.9)
Ground Contact Pressure kPa (PSI) 2.49 (.361)
Frame Material Steel
Bottom Pan Material Polyethylene
Hood Material Polyethylene
Battery V (A•h) N.A.
Headlight W 35
Taillight W 4.5
Fuel Tank L (U.S. 1.8 (.5)

gal)
L (U.S.
Oil Capacity oz) 0.6 (20.3)
MMR2000_136_10_03A.FM 10-03-1
ENGINE TECHNICAL DATA VEHICLE TECHNICAL DATA

LEGEND LEGEND
BTDC: Before Top Dead Center N.A.: Not Applicable
K: Kilo (x 1000) Force or downward pull applied to track to ob-
MAG: Magneto Side tain specified tension deflection.
N.A.: Not Applicable
PTO: Power Take Off Side
R: Rectangular
All resistance measurements must be performed
with parts at room temperature (approx. 20°C
(68°F)). Temperature greatly affects resistance
measurements.
MMR2000_136_10_04A.FM 10-04-1
Section 11 WIRING DIAGRAM
Subsection 01 (WIRING DIAGRAM)
WIRING DIAGRAM 0
WIRING DIAGRAM LEGEND
CONNECTOR HOUSING AREA
 WARNING
Ensure all terminals are properly crimped on the XX/XX
wires and all connector housings are properly
1 -02D
1
fastened.
XX/XX A00I04C
1-02D
1
A00I04A 2 3 4
7
1. Wire colors
2. Housing area 6
3. Housing number per area 3
4. Wire connector location in housing
9 8 4 2 1
5 10
WIRE COLORS AND CIRCUIT
XX/XX A06H33B
XX/XX AREA LOCATION

A00I04B 1-02D 1 Front of engine compartment
The first color of a wire is the main color, second 2 Magneto

color is the stripe. 3 Carburetors
stripe. 4 Near intake silencer
COLOR CODE
6 Under console
BK – BLACK PK – PINK
BL – BLUE RD – RED 7 Under hood
BR – BROWN VI – VIOLET
GN – GREEN WH – WHITE 8 Near fuel tank
GY – GREY YL – YELLOW
9 Rear of seat
OR – ORANGE
10 Under engine
MMR2000_137_11_01A.FM 11-01-1
HOUSING
XX/XX
1-02 D
A00I04D
D
B
A
B
A
B B
A A
C C
B B
C C
A A
D D
A A
C C
A00E4WB B B
11-01-2 MMR2000_137_11_01A.FM
SYMBOLS DESCRIPTION


ground ground
Frame
Bulb Pilot lamp Analog sensor Solenoid valve
Trigger coil Battery Diode
A00E52S
MMR2000_137_11_01A.FM 11-01-3
ANNEX 1 MINI Z
MINI Z 0
7-03A
9-01
1-02
A31Z02 ANNEX 1
MINI Z 0
7-03A
9-01
1-02
A31Z02 ANNEX 1

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2001

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SECTION SUBSECTION PAGE

SAFETY NOTICE .................................................................................................................................. III

WHAT’S NEW ....................................................................................................................................... IV

01 SERVICE TOOLS AND 01 – Service tools............................................................................. 01-01-1

02 LUBRICATION 01 – Lubrication and maintenance chart .......................................... 02-01-1

03 TROUBLESHOOTING 01 – Table of contents...................................................................... 03-01-1

04 ENGINE 01 – Table of contents...................................................................... 04-01-1

05 TRANSMISSION 01 – Table of contents...................................................................... 05-01-1

06 ELECTRICAL 01 – Table of contents...................................................................... 06-01-1

SECTION SUBSECTION PAGE

07 REAR SUSPENSION 01 – Table of contents ..................................................................... 07-01-1

08 STEERING/ 01 – Table of contents ..................................................................... 08-01-1

09 BODY/FRAME 01 – Table of contents ..................................................................... 09-01-1

10 TECHNICAL DATA 01 – SI metric information guide...................................................... 10-01-1

11 WIRING DIAGRAMS 01 – Wiring diagrams ....................................................................... 11-01-1

OIL INJECTION SYSTEM 04-06

REWIND STARTER 04-09

TOURING* FAN 380 (Canada) ..............1807 TYPICAL — S-SERIES

TOURING* FAN 380 (U.S.) ...................1808 Skandic LT

FORMULA* DELUXE FAN 500 (U.S.) ..1783 TYPICAL — SKANDIC SERIES

*Trademarks of Bombardier Inc.

VEHICLE ENGINE SERIAL NUMBER

Vehicle Identification Number Meaning A03A0BA

2BPS15929Y1000001 TYPICAL — FAN-COOLED ENGINES

LIST OF ABBREVIATIONS lbf pound (force)

A ampere LH left hand

amp ampere LO low

A•h ampere-hour LT long track

AC alternate current m meter

ACM acceleration and control modulator MAG magneto

ARM advance ride management Max. maximum

BDC bottom dead center Min. minimum

BTDC before top dead denter mL milliliter

°C degree Celsius mm millimeter

cc cubic centimeter MPEM multi-purpose electronic module

CDI capacitor discharge ignition MPH mile per hour

CTR center N newton

cm centimeter N.A. not applicable

cm² square centimeter no. number

cm³ cubic centimeter 00.0 continuity

DC direct current 0.L overload (open circuit)

DPM digital performance management O.D. outside diameter

DSA direct shock action OPT optional

°F degree Fahrenheit oz ounce

FC fan cooled P/N part number

fl. oz fluid ounce PSI pound per square inch

ft foot PTO power take off

GRD ground R rectangular

H.A.C. high altitude compensator RH right hand

hal. halogen RAVE rotax adjustable variable exhaust

HI high RPM revolution per minute

imp. oz imperial ounce RMS root mean square

in inch RRIM reinforced reaction injection molding

in² square inch Sp. Gr. specific gravity

in³ cubic inch ST semi-trapezoidal

k kilo (thousand) TDC top dead center

kg kilogram TRA total range adjustable

km/h kilometer per hour U.S. oz ounce (United States)

kPa Kilopascal V volt

L liter Vac volt (alternative current)

This Shop Manual uses technical terms wich may be