C M Y CM MY CY CMY K

2005
Shop Manual

TUNDRA
SKANDIC LT/LT E/WT/SWT/WT LC/SUV 550/SUV 600
EXPEDITION TUV 600 HO SDI/TUV V-1000

BOMBARDIER RECREATIONAL PRODUCTS INC.

Legal deposit:
National Library of Quebec
National Library of Canada 2004
All rights reserved. No parts of this manual may be reproduced in any form without the prior written
permission of Bombardier Recreational Products Inc.
© Bombardier Recreational Products Inc. 2004

Technical Publications
Bombardier Recreational Products Inc.
Valcourt (Quebec) Canada

Printed in Canada
®™ Trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates.

† Bombardier and sprocket design are trademarks of Bombardier Inc., used under license.

This document contains the trademarks of the following companies:

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
 TABLE OF CONTENTS

SAFETY NOTICE .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. . XIII

INTRODUCTION .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. XIV
VEHICLE DESCRIPTION DECAL . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . XV
VEHICLE IDENTIFICATION NUMBER (VIN). .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . XVI
ENGINE SERIAL NUMBER .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . XVI
LIST OF ABBREVIATIONS USED IN THIS MANUAL. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. XVII
ARRANGEMENT OF THIS MANUAL .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . XVIII
GENERAL INFORMATION. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . XX
ILLUSTRATIONS AND PROCEDURES . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . XX
SELF-LOCKING FASTENERS PROCEDURE .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . XX
LOCTITE APPLICATION PROCEDURE. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . XXI
THREADLOCKER . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . XXI
STRIPPED THREAD REPAIR . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. XXII
GASKET COMPOUND . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . XXIII
MOUNTING ON SHAFT . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . XXIII
CASE-IN COMPONENTS . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . XXIV
TIGHTENING TORQUE .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. XXV

01 MAINTENANCE
01 – MAINTENANCE CHART. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 1
02 – STORAGE . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 3
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
VEHICLE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUEL STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE OIL CHANGE AND FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
COUNTERSHAFT LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PULLEY PROTECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
VEHICLE PROTECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RAGS IN AIR INTAKE AND EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
03 – PRESEASON PREPARATION . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 7
FUEL FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
THROTTLE BODY CLEANING (ON SO EQUIPPED MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CARBURETOR CLEANING (ON SO EQUIPPED MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
RAGS IN AIR INTAKE AND EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CLEANING OF DRIVE AND DRIVEN PULLEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CLEANING OF BRAKE DISK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DRIVE BELT CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPARK PLUGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

02 TROUBLESHOOTING GUIDE
01 – ENGINE (2-STROKE). .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 9
02 – ENGINE (4-TEC) . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 17
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

I
TABLE OF CONTENTS

CYLINDER AND CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ELECTRIC STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ENGINE GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
03 – FUEL AND OIL SYSTEMS (2-STROKE ENGINES) . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 25
04 – TRANSMISSION AND BRAKE SYSTEMS .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 29
TRANSMISSION . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 29
BRAKE SYSTEM. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 33
MECHANICAL BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
HYDRAULIC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
MECHANICAL AND HYDRAULIC BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
05 – ELECTRICAL SYSTEM . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 35
06 – SUSPENSION AND TRACK. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 43

03 ENGINES (2-STROKE)
01 – 277 ENGINE TYPE.. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 47
ENGINE REMOVAL AND INSTALLATION .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 48
REMOVAL FROM VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
ENGINE SUPPORT AND MUFFLER DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION ON VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
TOP END. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 50
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
TOP END REMOVAL (WITHOUT REMOVING ENGINE FROM CHASSIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
BOTTOM END .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 57
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
02 – 443 AND 552 ENGINES . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 61
ENGINE REMOVAL AND INSTALLATION .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 62
ENGINE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
TOP END. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 65
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
BOTTOM END .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 75
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
BREAK-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
03 – 593 AND 593 HO SDI ENGINES.. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 85
REMOVAL FROM VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
INSTALLATION ON VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
TOP END. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 87

II
 TABLE OF CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
RAVE VALVE BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
BOTTOM END .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 100
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
DISASSEMBLY .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . 102
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 103
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
BREAK-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
04 – LEAK TEST AND ENGINE DIMENSION MEASUREMENT. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 109
LEAK TEST .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 109
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
FINALIZING REASSEMBLY. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . . . . . . . . . . . . . . . . 112
ENGINE LEAK VERIFICATION FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
ENGINE DIMENSION MEASUREMENT . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 114
CYLINDER HEAD WARPAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
CYLINDER TAPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
CYLINDER OUT OF ROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
COMBUSTION CHAMBER VOLUME MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
USED PISTON MEASUREMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
CYLINDER/PISTON CLEARANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
RING/PISTON GROOVE CLEARANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . 118
RING END GAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
CRANKSHAFT DEFLECTION .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . . . . . . . . . . . . . . . . 118
CONNECTING ROD BIG END AXIAL PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
CRANKSHAFT END-PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
CHECKING SURFACE FLATNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
RECTIFYING SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
CHECKING CRANKSHAFT ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
05 – MAGNETO SYSTEM. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 123
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
DISASSEMBLY .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . 128
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
06 – OIL INJECTION SYSTEM . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 131
OIL INJECTION PUMP. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 132
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
OIL TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
OIL SYSTEM LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
OIL PUMP IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
DISASSEMBLY .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . 137
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
BLEEDING OIL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
CHECKING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

III
TABLE OF CONTENTS

07 – AXIAL FAN COOLING SYSTEM.. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 141

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
FAN BELT REPLACEMENT AND DEFLECTION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
08 – LIQUID COOLING SYSTEM. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 147
COOLING SYSTEM LEAK TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 149
DRAINING THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
COOLING SYSTEM REFILLING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
09 – REWIND STARTER . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 153
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 156
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
ROPE REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
DISASSEMBLY .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 157
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
10 – FUEL SYSTEM .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 161
CARBURETOR .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 162
IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
CARBURETOR ADJUSTMENTS . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . 166
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
IDLE SPEED FINAL ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
CHOKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
FUEL PUMP . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 172
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
PUMP VERIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
FUEL TANK.. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 173

04 ENGINE (4-TEC)
01 – LEAK TEST .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 175
VERIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
LEAK TEST PROCEDURE . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 175
PREPARATION AND TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
02 – REMOVAL AND INSTALLATION. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 177
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
03 – COOLING SYSTEM . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 183
COOLING SYSTEM LEAK TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 186
COOLANT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
COOLANT HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
WATER PUMP HOUSING/THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

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WATER PUMP IMPELLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

IGNITION COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
WATER PUMP SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
PRESSURE CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
RADIATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
04 – LUBRICATION SYSTEM . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 195
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
ENGINE OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
OIL FILTER HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
ENGINE OIL PRESSURE REGULATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
OIL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
PRESSURE OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
SUCTION OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
OIL NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
OIL SIEVES . . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 206
REED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
05 – CYLINDER AND CYLINDER HEAD. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 209
CYLINDER/CYLINDER HEAD 1 (FRONT-SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
CYLINDER/CYLINDER HEAD 2 (REAR-SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
VALVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
ROCKER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
CHAIN TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
BREATHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
DECOMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
CAMSHAFT TIMING GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
VALVE SPRINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
PISTON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
06 – CRANKSHAFT/DRIVE GEARS . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 231
TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
DRIVE GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
TRIGGER WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
CRANKSHAFT LOCKING TOOL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . 241
PISTON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
07 – CRANKCASE . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 247
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
PTO COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
CRANKCASE. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . 251

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TABLE OF CONTENTS

05 ENGINE MANAGEMENT (2-TEC)

01 – OVERVIEW .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 257
OPERATING PRINCIPLE . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 258
AIR INDUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
FUEL DELIVERY SYSTEM. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 258
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
ENGINE MANAGEMENT SYSTEM (EMS) . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 259
EMS — GENERAL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
EMS — ENGINE MANAGEMENT SYSTEM FUNCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
ELECTRONIC FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
ELECTRONICALLY CONTROLLED RAVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
KNOCK SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
ENGINE MODES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
FLOODED ENGINE (DROWNED MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
MONITORING SYSTEM .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 263
LIMP HOME MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
DIAGNOSTIC MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
CHARGING SYSTEM .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 264
IGNITION SYSTEM . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 264
DOUBLE IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
TRIGGER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
02 – DIAGNOSTIC PROCEDURE. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 265
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
VCK (VEHICLE COMMUNICATION KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
2-TEC SYSTEM FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
03 – COMPONENT INSPECTION AND ADJUSTMENT . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 269
GENERAL . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 269
FUEL SYSTEM .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 269
ELECTRICAL SYSTEM . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 270
RESISTANCE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
ENGINE CONNECTOR PIN-OUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
AIR INDUCTION SYSTEM . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 274
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 274
FUEL DELIVERY . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 277
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
FUEL RAILS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
ELECTRONIC MANAGEMENT . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 285
ECM REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
ENGINE WIRING HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
THROTTLE POSITION SENSOR (TPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
CRANKSHAFT POSITION SENSOR (CPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
AIR TEMPERATURE SENSOR (ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
COOLANT TEMPERATURE SENSOR (CTS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
AIR PRESSURE SENSOR (APS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
EXHAUST GAS TEMPERATURE SENSOR (EGTS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
KNOCK SENSOR (KS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
E-RAVE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
DOUBLE IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

VI
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IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

ENGINE START/RER BUTTON VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
DESS SWITCH VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
SPARK PLUGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
CRANKING SYSTEM . .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . 296

06 ENGINE MANAGEMENT (4-TEC)

01 – OVERVIEW .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 297
OPERATING PRINCIPLE OF ENGINE MANAGEMENT .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 298
AIR INDUCTION . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 298
FUEL DELIVERY SYSTEM . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 298
BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
ELECTRONIC MANAGEMENT .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 300
EMS (ENGINE MANAGEMENT SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
EMS — GENERAL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
EMS — ENGINE MANAGEMENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
02 – DIAGNOSTIC PROCEDURE. .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 305
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
MONITORING BEEPER CODED SIGNALS . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 306
VCK (VEHICLE COMMUNICATION KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
4-TEC SYSTEM FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
4-TEC TPS FAULT TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
03 – COMPONENT INSPECTION AND ADJUSTMENT . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 311
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
ENGINE CONNECTOR PIN-OUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
CONNECTORS ON ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
AIR INDUCTION SYSTEM . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 315
THROTTLE BODY . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . . . . . . . . . . . . . . . . 315
FUEL DELIVERY . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 318
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
FUEL RAILS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
ELECTRONIC MANAGEMENT . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 325
ECM REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
ENGINE WIRING HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
THROTTLE POSITION SENSOR (TPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
IDLE BYPASS VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
CRANKSHAFT POSITION SENSOR (CPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
CAMSHAFT POSITION SENSOR (CAPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
AIR TEMPERATURE SENSOR (ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
COOLANT TEMPERATURE SENSOR (CTS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
MANIFOLD AIR PRESSURE SENSOR (MAPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
OIL PRESSURE SWITCH (OPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
IGNITION COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
ENGINE START SWITCH VERIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
DESS SWITCH VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
SPARK PLUGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

VII
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CRANKING SYSTEM . .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 340

07 TRANSMISSION
01 – DRIVE BELT . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 341
APPLICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
CHECKING NEUTRAL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 341
ROTATION DIRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
DRIVE BELT HEIGHT MEASUREMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
DRIVE BELT DEFLECTION MEASUREMENT (REFERENCE ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
02 – DRIVE PULLEY.. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 345
BOMBARDIER LITE . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 346
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
DISASSEMBLY .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 347
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 348
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
COMET® 102C .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 350
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
DISASSEMBLY .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 352
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 353
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
TRA III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
TRA IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
DISASSEMBLY .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 358
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 360
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
DRIVE PULLEY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
03 – DRIVEN PULLEY . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 369
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
DISASSEMBLY .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 371
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 372
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
DISASSEMBLY .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 375
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 375
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379

VIII
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DISASSEMBLY .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . 379
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 379
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
04 – PULLEY DISTANCE AND ALIGNMENT . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 381
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
GENERAL PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
05 – BRAKE . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 387
MECHANICAL BRAKE . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 388
HYDRAULIC BRAKE . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 390
BRAKE FLUID TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
BRAKE PADS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
DISASSEMBLY .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . 392
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 393
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
06 – CHAINCASE . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 397
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
DISASSEMBLY .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . 399
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 399
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 402
GEAR RATIO MODIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
DRIVE CHAIN ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
07 – GEARBOX . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 405
3-SPEED GEARBOX. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 406
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
DISASSEMBLY .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . 407
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 414
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
08 – DRIVE CHAIN . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 419
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
SILENT CHAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
CHAIN ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
CHAIN SEPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419

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08 ELECTRICAL
01 – IGNITION TIMING .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 421
....................................................................................................................... 421
02 – SPARK PLUGS .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 433
NGK SPARK PLUG . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 433
NGK SPARK PLUG NUMBERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
DESIGN SYMBOLS USED IN NGK SPARK PLUGS . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 434
DISASSEMBLY .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 435
HEAT RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
FOULING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
SPARK PLUG ANALYSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
SPARK PLUG INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
SPARK PLUG TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
03 – ALTERNATOR . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 437
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 437
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
04 – BATTERY . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 439
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 440
BATTERY CHARGE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
BATTERY STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
ACTIVATION OF NEW BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
INSTALLATION OF BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
CABLE TERMINAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
05 – ELECTRIC STARTER . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 449
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
DISASSEMBLY .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 453
CLEANING AND INSPECTION . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 456
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 456
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
06 – TESTING PROCEDURE . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 463
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
IGNITION SYSTEM TESTING SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
LIGHTING SYSTEM TESTING SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
1. SPARKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
2. ELECTRICAL CONNECTOR TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
3. IGNITION SWITCH, DESS SWITCH OR TETHER CORD CUT-OUT SWITCH AND ENGINE CUT-OUT
SWITCH TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
4. IGNITION GENERATOR COIL TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
5. TRIGGER COIL TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
6. MPEM VOLTAGE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
7. HIGH VOLTAGE COIL TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
8. BUZZER TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
LIGHTING GENERATOR COIL VOLTAGE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
CONCLUSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473

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INSPECTION OF AC CIRCUIT ISOLATION . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 479

INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 479
INSPECTION OF HEATING ELEMENTS . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 479

09 REAR SUSPENSION
01 – TORQUE REACTION SUSPENSION. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 481
COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
SUSPENSION ASS'Y REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 484
SUSPENSION ASS'Y INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
RIDE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
02 – ARTICULATING SLIDE SUSPENSION .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 489
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
SHOCK ABSORBER SERVICING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
RIDE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
03 – SUV SUSPENSION . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 493
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
SHOCK ABSORBER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
RIDE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
04 – DRIVE AXLE. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 499
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
DISASSEMBLY .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . 504
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
05 – TRACK . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 511
TRACK TYPE APPLICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 511
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512

10 STEERING / FRONT SUSPENSION

01 – STEERING SYSTEM . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 515
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 520
DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
HANDLEBAR POSITION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
STEERING ADJUSTMENT (SKIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
02 – SUSPENSION AND SKI SYSTEM . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 529
ON-VEHICLE COMPONENT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
DISASSEMBLY .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . 531
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 532
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532

XI
TABLE OF CONTENTS

ON-VEHICLE COMPONENT VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535

DISASSEMBLY .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 536
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 536
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
DISASSEMBLY .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 539
INSPECTION. .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . 539
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540

11 BODY/FRAME
01 – BODY. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 541
INSTALLATION AND ADJUSTMENT . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 541
HEADLAMP BEAM AIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541
BULB REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541
DECAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
BELT GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
WIRING HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543
CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543
TUBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543
PLASTIC MAINTENANCE AND REPAIR . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 543
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543
REPAIR PROCEDURE FOR R.I.M. URETHANE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
02 – FRAME . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 547
FRAME CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547
FRAME WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547

12 TECHNICAL DATA
01 – ENGINES . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 549
02 – VEHICLES . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 559
03 – TECHNICAL DATA LEGENDS . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 567
ENGINE TECHNICAL DATA LEGEND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567
VEHICLE TECHNICAL DATA LEGEND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568

13 WRING DIAGRAMS
01 – WIRING DIAGRAMS . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 569
WIRE COLORS AND CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569

XII
 SAFETY NOTICE

SAFETY NOTICE
This manual has been prepared as a guide to correctly service and repair some 2005 Ski-Doo® snowmo-
biles. See model list in introduction.
This edition was primarily published to be used by snowmobile mechanic technicians who are already
familiar with all service procedures relating to BRP made snowmobiles. Mechanic technicians should
attend continuous training courses given by BRP 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 discrepan-
cy, the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Ser-
vice and Warranty Bulletins may be published to update the content of this manual. Make sure to read
and understand them.
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 BRP parts is most strongly recommended when considering replacement of any component.
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 pos-
sibility 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 Recreational Products Inc. (BRP) 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.

 WARNING
Torque wrench tightening specifications must strictly be adhered to. Locking devices (ex.: lock-
ing 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. Unless otherwise specified, engine should
be turned OFF and cold for all maintenance and repair procedures.

mmr2005-001 http://ReadManuals.com XIII

INTRODUCTION

INTRODUCTION
This Shop Manual covers the following BRP made 2005 snowmobiles:

MODEL ENGINE COLOR MARKET MODEL NUMBER

TUNDRA 280F (R) YELLOW CANADA USA FK5A
TUNDRA 280F (R) BLACK CANADA USA FK5B
SKANDIC LT 440F (R) YELLOW CANADA FH5B
SKANDIC LT 440F (R) YELLOW USA FH5A
SKANDIC LT (E) 440F (R) YELLOW CANADA FH5D
SKANDIC LT (E) 440F (R) YELLOW USA FH5C
SKANDIC WT 550F (R) YELLOW CANADA FG5B
SKANDIC WT 550F (R) YELLOW USA FG5A
SKANDIC SWT 550F (R) YELLOW CANADA FE5B
SKANDIC SWT 550F (R) YELLOW USA FE5A
SKANDIC WT LC 600 (R) YELLOW CANADA FF5B
SKANDIC WT LC 600 (R) YELLOW USA FF5A
SKANDIC SUV 550F (R) YELLOW CANADA FD5B
SKANDIC SUV 550F (R) YELLOW USA FD5A
SKANDIC SUV 600 (R) YELLOW CANADA FC5B
SKANDIC SUV 600 (R) YELLOW USA FC5A
SKANDIC SUV 600 (R) BLACK CANADA FC5D
SKANDIC SUV 600 (R) BLACK USA FC5C
SKANDIC SUV 550F (R) BLACK CANADA FD5C
SKANDIC SUV 550F (R) BLACK USA FD5D
EXPEDITION TUV 600 HO SDI (R) BLACK CANADA USA FB5B
SEASHORE
EXPEDITION TUV 600 HO SDI (R) CANADA USA FB5A
METALLIC
EXPEDITION TUV V-1000 (R) BLACK CANADA USA FA5B
SEASHORE
EXPEDITION TUV V-1000 (R) CANADA USA FA5A
METALLIC

(E) = Electric start

(R) = Reverse

XIV
http://ReadManuals.com mmr2005-001
 INTRODUCTION

Tundra Expedition TUV 600 HO SDI

Expedition TUV V-1000

A05A0EA

TYPICAL — TUNDRA

Skandic LT
A29H1AC
Skandic LT E
Skandic WT TYPICAL — EXPEDITION SERIES
Skandic SWT
Skandic WT LC
Skandic SUV 550 VEHICLE DESCRIPTION DECAL
Skandic SUV 600
Location
Vehicle description decal is located on right hand
side of tunnel.
1

A29A03A

TYPICAL — SKANDIC SERIES

A29H0SA

TYPICAL
1. Vehicle description decal

mmr2005-001 http://ReadManuals.com XV
INTRODUCTION

Description ENGINE SERIAL NUMBER

1 3 2 Location
1

A00A6HB 5 4 6 8 7
VEHICLE DESCRIPTION DECAL
1. Manufacturer name and address
2. Manufacturing date
3. Vehicle identification number (VIN)
4. Model name
5. Option package
6. Engine type A03A0BA
7. Model year
8. Color codes
TYPICAL — 2–STROKE FAN-COOLED ENGINES
1. Engine serial number

VEHICLE IDENTIFICATION
NUMBER (VIN)
Location
VIN is scribed on vehicle description decal. See
above. It is also embossed on tunnel near vehicle
description decal.

Description
2BPSBX5A9Y1000001
Model number Serial number
Model year: y = 2000 A32C01B 1
1 = 2001
2 = 2002 TYPICAL — 2–STROKE LIQUID-COOLED ENGINES
1. Engine serial number
A00A8HA etc.

A32A1XA 1
4-TEC ENGINE — RH OF ENGINE
1. Engine serial number

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 INTRODUCTION

LIST OF ABBREVIATIONS USED ABREVIATION MEANING

IN THIS MANUAL LO low
LT long track
ABREVIATION MEANING
m meter
A ampere
m. mile
amp ampere
MAG magneto
A•h ampere-hour
Max. maximum
AC alternate current
Min. minimum
ACM acceleration and control modulator
mL milliliter
ARM advance ride management
mm millimeter
BDC bottom dead center
MPEM multipurpose electronic module
BTDC before top dead center
MPH mile per hour
°C degree Celsius
N newton
cc cubic centimeter
N.A. not applicable
CDI capacitor discharge ignition
no. number
CTR center
00.0 continuity
cm centimeter
0.L overload (open circuit)
cm² square centimeter
O.D. outside diameter
cm³ cubic centimeter
OPT optional
DC direct current
oz ounce
DPM digital performance management
P/N part number
DSA direct shock action
PSI pound per square inch
°F degree Fahrenheit
PTO power take off
FC fan cooled
R rectangular
fl. oz fluid ounce
RH right hand
ft foot
RAVE rotax adjustable variable exhaust
GRD ground
RPM revolution per minute
H.A.C. high altitude compensator
RMS root mean square
hal. halogen
reinforced reaction injection
HI high RRIM
molding
imp. oz imperial ounce Sp. Gr. specific gravity
in inch ST semi-trapezoidal
in² square inch TDC top dead center
in³ cubic inch TRA total range adjustable
k kilo (thousand) U.S. oz ounce (United States)
kg kilogram V volt
km/h kilometer per hour Vac volt (alternative current)
kPa Kilopascal
L liter
lb pound
lbf pound (force)
LH left hand

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INTRODUCTION

ARRANGEMENT OF THIS MANUAL

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 (SUSPENSION SC-10 SPORT, TOURING AND MOUNTAIN) beginning of the
subsection.

SUSPENSION SC-10 SPORT,

Italic subtitle above TOURING AND MOUNTAIN
exploded view
A-Series and B-Series
indicates
pertaining models.
1
Low
temp.
Low grease
temp. Loctite 7
grease 271
6 2
4 Loctite
11 271
Exploded view
19
assists you in 12 16
6 Drop represents
Low
identifying parts and temp.
3 a service
18 N•m
related positions. (160 lbf•in) 9 grease product to be
13 5
14
8 applied to
Loctite
271 a surface.
15
In this case
11 Loctite 271 to
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 N•m
11
parts of a particular
(35 lbf•in)
process. model in this case
the short track
A03F24S models only.
Document
number for MMR2000_042_00-02A.FM 56
publishing
process.
Tightening torque nearby
fastener. In this case, nut
must be torqued to Page number
4 N•m or 35 lbf•in.

CAUTION: Pay attention to torque

specifications. Some of these are
in lbf•in instead of lbf•ft. Use appro-
priate torque wrench.
A00A7XS

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 INTRODUCTION

TYPICAL PAGE

Section 05 TRANSMISSION
Subsection 03 (DRIVEN PULLEY)

Title indicates
Turn puller handle and sliding half at once to extract INSTALLATION main procedure
the bushing.
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 then look for Brake Disc and Countershaft
529 031 200 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 N•m (18 lbf•ft). Call-outs for
it pertains. A03D1ZA
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
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 57

Bold face number following part

name refers to exploded view
at beginning of subsection.

A00A7YS

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INTRODUCTION

GENERAL INFORMATION
The information and component/system descrip-
tions contained in this manual are correct at time
of publication. BRP however, maintains a policy
of continuous improvement of its products with-
out imposing upon itself any obligation to install
them on products previously manufactured.
1 2
Due to late changes, it may have some differences
between the manufactured product and the de-
scription and/or specifications in this document.
BRP reserves the right at any time to discontinue
or change specifications, designs, features, mod-
els or equipment without incurring obligation.

ILLUSTRATIONS AND
PROCEDURES
Illustrations and photos show the typical construc-
A03A0CA
tion of the different assemblies and, in all cases,
may not reproduce the full detail or exact shape of TYPICAL
1. Left
the parts shown. However, they represent parts 2. Right
which have the same or a similar function.
CAUTION: Most components of those vehi-
cles are built with parts dimensioned in the SELF-LOCKING FASTENERS
metric system. Most fasteners are metric and PROCEDURE
must not be replaced by customary fasteners
or vice versa. Mismatched or incorrect fasten-
ers could cause damage to the vehicle or pos-
sible personal injury.
As many of the procedures in this manual are inter-
related, we suggest, that before undertaking any
task, you read and thoroughly understand the en-
tire section or subsection in which the procedure
is contained. A00A6LA

A number of procedures throughout the book re- TYPICAL — SELF-LOCKING FASTENER

quire the use of special tools. Before commenc-
ing any procedure, be sure that you have on hand The following describes the most common appli-
all the tools required, or approved equivalents. cation procedures when working with self-locking
fasteners.
The use of RIGHT and LEFT indications in the text,
always refers to driving position (when sitting on Use a metal brush or a screwtap to clean the hole
vehicle). properly then use a solvent (Methyl-Chloride), let
act during 30 minutes and wipe off. The solvent
utilization is to ensure the adhesive works proper-
ly.

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 INTRODUCTION

LOCTITE APPLICATION Blind Holes

PROCEDURE
The following describes the most common ap- 1
plication procedures when working with Loctite
products.
2
NOTE: Always use proper strength Loctite prod-
uct as recommended in this Shop Manual.

THREADLOCKER
Uncovered Holes (bolts and nuts)

A00A3MA

1. On threads
1 2. On threads and at the bottom of hole

– Clean threads (bolt and hole) with solvent.

– Apply Loctite Primer N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30
seconds.
– Choose proper strength Loctite threadlocker.
2
– Apply several drops along the threaded hole and
A00A3LA at the bottom of the hole.
1. Apply here – Apply several drops on bolt threads.
2. Do not apply – Tighten as required.

– Clean threads (bolt and nut) with solvent. Stud in Blind Holes
– Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
– Choose proper strength Loctite threadlocker.
1 3
– Fit bolt in the hole.
– Apply a few drops of threadlocker at proposed
tightened nut engagement area. 2
– Position nut and tighten as required.

A00A5RA

1. On threads
2. On threads and in the hole
3. Onto nut threads

– Clean threads (stud and hole) with solvent.

– Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
– Put several drops of proper strength Loctite
threadlocker on female threads and in hole.

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INTRODUCTION

– Apply several drops of proper strength Loctite Adjusting Screw

on stud threads.
– Install stud.
1 2
– Install cover, etc.
– Apply drops of proper strength Loctite on un-
covered threads.
– Tighten nuts as required.

Preassembled Parts

A00A3PA
1
1. Apply here
2. Plunger

– Adjust screw to proper setting.

– Apply drops of proper strength Loctite thread-
locker on screw/body contact surfaces.
– Avoid touching metal with tip of flask.
NOTE: If it is difficult to readjust, heat screw with
2 a soldering iron (232°C (450°F)).
A00A3OA

1. Apply here STRIPPED THREAD REPAIR

2. Do not apply
Stripped Threads
– Clean bolts and nuts with solvent.
– Assemble components. 5
– Tighten nuts. 1
6
– Apply drops of proper strength Loctite on
bolt/nut contact surfaces. 8
– Avoid touching metal with tip of flask. 2
NOTE: For preventive maintenance on exist-
ing equipment, retighten nuts and apply proper
strength Loctite on bolt/nut contact surfaces. 3

A00A3QA 4 7
1. Release agent
2. Stripped threads
3. Form-A-Thread
4. Tape
5. Cleaned bolt
6. Plate
7. New threads
8. Threadlocker

Standard Thread Repair

– Follow instructions on Loctite FORM-A-
THREAD (P/N 413 708 600) package.

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 INTRODUCTION

– If a plate is used to align bolt: – Spray Loctite Primer N on both mating surfaces
– Apply release agent on mating surfaces. and on both sides of gasket. Allow to dry 1 or
– Put waxed paper or similar film on the sur- 2 minutes.
faces. – Apply GASKET ELIMINATOR 515 (P/N 413 702
– Twist bolt when inserting it to improve thread 700) on both sides of gasket, using a clean ap-
conformation. plicator.
NOTE: NOT intended for engine stud repairs. – Place gasket on mating surfaces and assemble
immediately.
Repair of Small Holes/Fine Threads NOTE: If the cover is bolted to blind holes (above),
Option 1: Enlarge damaged hole, then follow apply proper strength Loctite in the hole and on
STANDARD THREAD REPAIR procedure. threads. Tighten.
Option 2: Apply FORM-A-THREAD on the screw If holes are sunken, apply proper strength Loctite
and insert in damaged hole. on bolt threads.
Permanent Stud Installation (light duty) – Tighten as usual.
– Use a stud or thread on desired length.
– DO NOT apply release agent on stud. MOUNTING ON SHAFT
– Do a STANDARD THREAD REPAIR. Mounting with a Press
– Allow to cure for 30 minutes.
– Assemble.

GASKET COMPOUND
All Parts 1

1 2 2

3
A00A3UA

1. Bearing
2. Proper strength Loctite
3. Shaft

1 Standard
– Clean shaft external part and element internal
part.
– Apply a strip of proper strength Loctite on shaft
circumference at insert or engagement point.
NOTE: Retaining compound is always forced out
when applied on shaft.
A00A3SA 1 3
– DO NOT use antiseize Loctite or any similar
1. Proper strength Loctite product.
2. Loctite Primer N (P/N 413 708 10) and Gasket Eliminator
515 (P/N 413 702 700) on both sides of gasket – No curing period is required.
3. Loctite Primer N only
Mounting in Tandem
– Remove old gasket and other contaminants – Apply retaining compound on internal element
with Loctite Chisel (P/N 413 708 500). Use a bore.
mechanical mean if necessary. – Continue to assemble as shown above.
NOTE: Avoid grinding.
– Clean both mating surfaces with solvent.

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INTRODUCTION

CASE-IN COMPONENTS
Metallic Gaskets

A00A3VA 1
1. Proper strength Loctite

– Clean inner housing diameter and outer gasket

diameter.
– Spray housing and gasket with Loctite Primer N
(P/N 293 800 041).
– 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.
– Install according to standard procedure.
– Wipe off surplus.
– 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.

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 INTRODUCTION

TIGHTENING TORQUE
Tighten fasteners to torque mentioned in exploded views and/or text, When they are not specified, refer
to following table. The table also gives the metric conversion.

 WARNING
Torque wrench tightening specifications must strictly be adhered to. Locking devices (ex.: lock-
ing tabs, elastic stop nuts, 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.

In order to avoid a poor assembling, tighten screws, bolts or nuts in accordance with the following pro-
cedure:
– Manually screw all screws, bolts and/or nuts.
– Apply the half of the recommended torque value.
CAUTION: Be sure to use proper tightening torque for the proper strength grade.

4.8 8.8 9.8 10.9 12.9

Property
class
and 4.8 8.8 9.8 10.9 12.9
head
markings 4.8 8.8 9.8 10.9 12.9 12.9

Property 5 10 10 12
class
and
10

10

12
5

nut
markings
A00A8BS

FASTENER FASTENER GRADE/TORQUE

SIZE 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade
1.5 – 2 N•m 2.5 – 3 N•m 3.5 – 4 N•m 4 – 5 N•m
M4
(13 – 18 lbf•in) (22 – 27 lbf•in) (31 – 35 lbf•in) (35 – 44 lbf•in)
3 – 3.5 N•m 4.5 – 5.5 N•m 7 – 8.5 N•m 8 – 10 N•m
M5
(27 – 31 lbf•in) (40 – 47 lbf•in) (62 – 75 lbf•in) (71 – 89 lbf•in)
6.5 – 8.5 N•m 8 – 12 N•m 10.5 – 15 N•m
M6 16 N•m (142 lbf•in)
(58 – 75 lbf•in) (71 – 106 lbf•in) (93 – 133 lbf•in)
M8 15 N•m (11 lbf•ft) 24.5 N•m (18 lbf•ft) 31.5 N•m (23 lbf•ft) 40 N•m (30 lbf•ft)
M10 29 N•m (21 lbf•ft) 48 N•m (35 lbf•ft) 61 N•m (45 lbf•ft) 72.5 N•m (53 lbf•ft)
M12 52 N•m (38 lbf•ft) 85 N•m (63 lbf•ft) 105 N•m (77 lbf•ft) 127.5 N•m (94 lbf•ft)
M14 85 N•m (63 lbf•ft) 135 N•m (100 lbf•ft) 170 N•m (125 lbf•ft) 200 N•m (148 lbf•ft)

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 INTRODUCTION

BRP SERVICE PUBLICATIONS REPORT

Publication title and year Page
Machine Report of error q Suggestion q
We would be pleased if you could
communicate to BRP any suggestions
you may have concerning our publi-
cations.

Name
Address
City and State/Prov. Date
Zip code/Postal code

BRP SERVICE PUBLICATIONS REPORT

Publication title and year Page
Machine Report of error q Suggestion q

Name
Address
City and State/Prov. Date
Zip code/Postal code

BRP SERVICE PUBLICATIONS REPORT

Publication title and year Page
Machine Report of error q Suggestion q

Name
Address
City and State/Prov. Date
!

Zip code/Postal code

A00A89

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INTRODUCTION

AFFIX
PROPER
POSTAGE

Technical Publications
After Sales Service
565 de la Montagne Street
Valcourt, Quebec, Canada J0E 2L0

AFFIX
PROPER
POSTAGE

Technical Publications
After Sales Service
565 de la Montagne Street
Valcourt, Quebec, Canada J0E 2L0

AFFIX
PROPER
POSTAGE

Technical Publications
After Sales Service
565 de la Montagne Street
Valcourt, Quebec, Canada J0E 2L0
A00A8A

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 Section 01 MAINTENANCE
Subsection 01 (MAINTENANCE CHART)

MAINTENANCE CHART
10-HOUR OR 500 KM (300 mi) INSPECTION (to be performed by dealer)
A: ADJUST WEEKLY OR EVERY 240 KM (150 mi)
I: INSPECT (clean, inspect, repair, adjust, lubricate) MONTHLY OR EVERY 800 KM (500 mi)
L: LUBRICATE ONCE A YEAR OR EVERY 3200 KM (2000 mi)
R: REPLACE 6000 KM (3700 mi)
C: CLEAN STORAGE (to be performed by dealer)
PRESEASON PREPARATION
(to be performed by dealer)
REFER TO SECTION(S) AND
PART/TASK
SUBSECTION(S)
ENGINE
Rewind starter and rope I,L,C I 03-09
Section 03 or 04, see the
Engine nuts and screws I I I
appropriate subsection
Section 03 or 04, see the
Exhaust system I I I
appropriate subsection
Engine lubrication L 01-02
Cooling system I I I 03-08 or 04-03
Coolant I R 03-08 or 04-03
Condition of seals (4) I I 03-01, 03-02, 03-03 or 04-02 to 04–07
RAVE valves (4) C 03-03
LUBRICATION

Oil and filter replacement (4-TEC) R 04-04

Injection oil filter I R 03-06
Oil injection pump A A A 03-06
FUEL

Fuel stabilizer R 01-02

Fuel filter R 01-03
Fuel lines and connections I I I 03-10, 06-03 or 05-03
Carburetor A A A,C 03-10
Throttle cable I I I I 03-10
Air filter C C 01-03
Fuel injection system (visual inspection) I 05-03 or 06-03
Throttle body bores and throttle plates (4) C 05-03 or 06-03
DRIVE

Drive belt I I I 07-01

Drive and driven pulley I I C I C 07-02 and 07-03
Tightening torque of drive pulley screw I I I 07-02
Driven pulley preload I I I 07-03
BRAKE

Brake fluid I I R I 07-05

Brake I I A I,A I 07-05

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Section 01 MAINTENANCE
Subsection 01 (MAINTENANCE CHART)

10-HOUR OR 500 KM (300 mi) INSPECTION (to be performed by dealer)

A: ADJUST WEEKLY OR EVERY 240 KM (150 mi)
I: INSPECT (clean, inspect, repair, adjust, lubricate) MONTHLY OR EVERY 800 KM (500 mi)
L: LUBRICATE ONCE A YEAR OR EVERY 3200 KM (2000 mi)
R: REPLACE 6000 KM (3700 mi)
C: CLEAN STORAGE (to be performed by dealer)
PRESEASON PREPARATION
(to be performed by dealer)
REFER TO SECTION(S) AND
PART/TASK
SUBSECTION(S)
TRANSMISSION

Drive chain tension A A A 07-06

Chaincase and gearbox oil R I R(3) R I 07-06
Drive axle end bearing (2) L L L 09-04
Countershaft L L L 09-04
STEERING/FRONT SUSPENSION

Steering and front suspension mechanism lubrication (2) A,I,L A,I L A,I,L 10-01 and 10-02
Wear and condition of skis and runners I I I 10-02
SUSPENSION

Suspension adjustments A AS REQUIRED

09-01, 09-02 or 09-03
Suspension (2) I I,L I,L
Suspension stopper strap I I 09-01, 09-02 or 09-03
Track I I I 09-05
Track tension and alignment A AS REQUIRED 09-05
ELECTRICAL

EMS fault codes (4) I I 05-03 or 06-03

Spark plugs (1) (4) I I R 08-02
Battery (if so equipped) I I I I 08-04
Headlamp beam aiming A A 11-01
Wiring harnesses, cables and lines (4) I I I 11-01
Operation of lighting system (HI/LO beam, brake light, etc.)
test operation of engine cut-out switch and tether cut-out I I I Operator’s Guide
switch
VEHICLE
Rags in air intake and exhaust system R C 01-02 and 01-03
Engine compartment C C C 01-02
Vehicle cleaning and protection C C C 01-02

(1) 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.
(2) Lubricate whenever the vehicle is used in wet conditions (wet snow, rain, puddles).
(3) Change oil every 3200 km (2000 mi).
(4) Emission-related

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 Section 01 MAINTENANCE
Subsection 02 (STORAGE)

STORAGE
SERVICE PRODUCTS
Description Part Number Page
anti-seize lubricant ................................................................ 293 800 070 ............................................. 5
BOMBARDIER LUBE ........................................................... 293 600 016 ......................................... 3, 5
BOMBARDIER premixed coolant ......................................... 293 600 038 ............................................. 5
BOMBARDIER Scratch Remover Kit.................................... 861 774 800 ............................................. 3
fuel stabilizer (250 mL) ......................................................... 413 408 600 ............................................. 4
Heavy duty cleaner (4 L) ....................................................... 293 110 002 ............................................. 3
Heavy duty cleaner (spray can 400 g)................................... 293 110 001 ............................................. 3
storage oil (Canada) .............................................................. 413 711 600 ............................................. 4
storage oil (United States) .................................................... 413 711 900 ............................................. 4
Vinyl & Plastic Cleaner (6 x 1 L) ............................................ 413 711 200 ............................................. 3

GENERAL To clean the entire vehicle, including bottom pan

and metallic parts use Heavy duty cleaner (spray
Proper snowmobile storage is a necessity during can 400 g) (P/N 293 110 001) and Heavy duty
the summer months or when a vehicle is not being cleaner (4 L) (P/N 293 110 002).
used for more than one month.
CAUTION: Do not use Heavy duty cleaner on
Refer to storage column from MAINTENANCE decals or vinyl.
CHART jointly with the present storage proce-
dure in order to cover each and every aspect of For vinyl and plastic parts, use Vinyl & Plastic
the snowmobile storage procedure. Any worn, Cleaner (6 x 1 L) (P/N 413 711 200).
broken or damaged parts should be replaced. To remove scratches on windshield or hood use
BOMBARDIER Scratch Remover Kit (P/N 861 774
 WARNING 800).
Unless otherwise specified, engine should be CAUTION: Never clean plastic parts or hood
turned off for storage procedure. with strong detergent, degreasing agent, paint
thinner, acetone, products containing chlorine,
etc.
VEHICLE CLEANING Inspect the hood and repair any damage.
To facilitate the inspection and ensure adequate Touch up all metal spots with touch-up paint
lubrication of components, it is recommended to where paint has been scratched off.
clean the entire vehicle. Spray all bare metal parts including shock chromed
Remove any dirt or rust. rods with BOMBARDIER LUBE (P/N 293 600 016).
To clean the entire vehicle, use only flannel cloths Wax the hood and the painted portion of the frame
or equivalent. for better protection.
CAUTION: It is necessary to use flannel cloths NOTE: Apply a non-abrasive wax on glossy finish
or equivalent on windshield and hood to avoid only.
damaging further surfaces to clean.
ENGINE COMPARTMENT
Keep clean of grass, twigs, cloth, etc. These are
combustible under certain conditions.

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Section 01 MAINTENANCE
Subsection 02 (STORAGE)

BATTERY Engine internal parts must be lubricated to protect

them from possible rust formation during the stor-
Remove battery, clean its tray and its exterior sur- age period. To protect appropriately the engine
face. Charge battery as explained in BATTERY use storage oil (Canada) (P/N 413 711 600) or stor-
section. age oil (United States) (P/N 413 711 900).
Proceed as follows:
FUEL STABILIZER
Start the engine and allow it to run at idle speed
With the new fuel additives, it is critical to use until the engine reaches its operating tempera-
the fuel stabilizer (250 mL) (P/N 413 408 600) to ture.
prevent fuel deterioration, gum formation and fuel
system components corrosion. Follow manufac-  WARNING
turer’s instructions for proper use. Ensure the track is free of all particles which
Pour fuel stabilizer in fuel tank prior to starting could be thrown out while it is rotating. Keep
engine so that stabilizer lubricate all fuel system hands, tools, feet and clothing clear of track.
components. Fill up fuel tank completely. Ensure Ensure no one is standing in close proximity
there is no water inside fuel tank. to the vehicle.
CAUTION: Should any water be trapped inside
fuel tank, severe internal damage will occur to Stop the engine.
the fuel injection system (if so equipped). Models with a Primer
On so equipped models, after engine starting, use To prevent fuel from draining, primer button
primer several times so that stabilizer flows inside should be pushed all the way in.
it.
Disconnect the outlet primer hose from the primer
Do not drain fuel system. valve (straight coupling).
CAUTION: Fuel stabilizer should be added prior
to engine lubrication to ensure carburetor pro-
tection against varnish deposit.

 WARNING
Fuel is flammable and explosive under cer-
tain conditions. Always work in a well ven- 1
tilated area. Do not smoke or allow open 2
flames or sparks in the vicinity. Fuel tank
A17C0EA
may be pressurized, slowly turn cap when
opening. Never use an open flame to check 1. Straight coupling
fuel level. When fueling, keep vehicle level. 2. To intake manifold

Do not overfill or top off the fuel tank and

Insert storage oil nozzle into primer outlet hose.
leave vehicle in the sun. As temperature
increases, fuel expands and might overflow. Models with a Choke
Always wipe off any fuel spillage from the Remove air silencers to spray storage oil into each
vehicle. Periodically inspect fuel system. carburetor bore.
All Models
ENGINE LUBRICATION Restart engine and run at idle speed.
Inject storage oil until the engine stalls or until a
NOTE: Be sure to add fuel stabilizer before start-
sufficient quantity of oil has entered the engine
ing the engine.
(approximately half a can).
With the engine stopped, remove the spark plug
and spray storage oil into each cylinder.

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 Section 01 MAINTENANCE
Subsection 02 (STORAGE)

Crank slowly 2 or 3 revolutions to lubricate cylin- VEHICLE PROTECTION

ders.
Protect the vehicle with a cover to prevent dust
Reinstall the spark plugs and the outlet primer accumulation during storage.
hose or air silencers.
CAUTION: The snowmobile has to be stored
 WARNING in a cool and dry place and covered with an
opaque but ventilated tarpaulin. This will pre-
This procedure must only be performed in a vent sun rays and grime from affecting plastic
well-ventilated area. Do not run engine dur- components and vehicle finish.
ing storage period.
Lift rear of vehicle until track is clear of the ground.
Install on a snowmobile mechanical stand.
COOLING SYSTEM NOTE: Do not release track tension.

4-Stroke Models RAGS IN AIR INTAKE AND

Antifreeze should be replaced for the storage pe- EXHAUST SYSTEM
riod to prevent antifreeze deterioration.
Block air intake hole and exhaust system hole us-
Make sure to perform an antifreeze density test.
ing clean rags.
Cooling system must be filled with BOMBARDIER
premixed coolant (P/N 293 600 038) or with dis-
tilled water antifreeze solution (50% distilled wa-
ter, 50% antifreeze).
CAUTION: Improper antifreeze mixture might
allow freezing of the liquid in the cooling sys-
tem if vehicle is stored in area where freezing
point is reached. This would seriously damage
the engine. Failure to replace the antifreeze
for storage may allow its degradation that
could result in poor cooling when engine will
be used.
Refer to COOLING SYSTEM section.

ENGINE OIL CHANGE AND FILTER

4-Stroke Models
Change engine oil and filter. Refer to LUBRICA-
TION in ENGINE section.

COUNTERSHAFT LUBRICATION
Driven pulley and brake disc must be floating on
the countershaft for efficient operation. Lubricate
with anti-seize lubricant (P/N 293 800 070).
CAUTION: Do not lubricate excessively as
lubricant could contact and soil brake pads
and/or drive belt.

PULLEY PROTECTION
After inspection and interior cleaning of pulleys,
spray BOMBARDIER LUBE (P/N 293 600 016) on
sheaves. Do not reinstall drive belt.

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 Section 01 MAINTENANCE
Subsection 03 (PRESEASON PREPARATION)

PRESEASON PREPARATION
Proper vehicle preparation is necessary after the V-1000 and 593 SDI Engine Equipped
summer months or when a vehicle has not been Models Only
used for more than one month. Fuel filter, inlet and outlet hoses come as an as-
Refer to preseason preparation column from sembly.
MAINTENANCE CHART jointly with the present The fuel filter is located beside the steering col-
preseason preparation procedure in order to cover umn, next to coolant tank.
each and every aspect of the snowmobile presea-
son preparation procedure. Using B.U.D.S. release the fuel pressure. Refer to
COMPONENT INSPECTION AND ADJUSTMENT.
Any worn, broken or damaged parts found during
the storage procedure should have been replaced. Remove console to gain access to top of fuel
If not, proceed with the replacement. pump module.
Disconnect both ends of fuel filter line.
 WARNING Unfasten clip retaining fuel filter line to fuse box
Unless otherwise specified, engine should be support.
turned off for preparation procedure. Unscrew the fuel filter support nut then remove
the filter.
Reverse removal procedure for installation.
FUEL FILTER REPLACEMENT
All Models except V-1000 and 593 SDI THROTTLE BODY CLEANING (ON
Engine Equipped Models SO EQUIPPED MODELS)
Drain fuel tank.
Remove the throttle body from vehicle.
Remove fuel line grommet from fuel tank and pull
out inlet fuel line from tank. Using the pulley flange cleaner (P/N 413 711 809),
remove the dirt ejected by the drive belt from the
throttle plate and from both throttle body bores.
After throttle body installation, adjust throttle and
injection oil cables.

CARBURETOR CLEANING (ON

SO EQUIPPED MODELS)
Disassemble carburetor(s) in order to clean all in-
ternal parts. Do not hesitate to replace any jets
having gum or varnish on their surfaces.

AIR FILTER CLEANING

Check that inside of air silencer is clean and dry
A03I0GA 3 1 2
then properly reinstall the filter.
TYPICAL
1. Inlet fuel line CAUTION: These snowmobiles have been cal-
2. Position of grommet when installing ibrated with the filter installed. Operating the
3. Fuel filter snowmobile without it may cause engine dam-
age.
Replace fuel filter. To facilitate the fuel line instal-
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.

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Section 01 MAINTENANCE
Subsection 03 (PRESEASON PREPARATION)

RAGS IN AIR INTAKE AND

EXHAUST SYSTEM
Remove rags that were installed during STORAGE
preparation.

ENGINE LUBRICATION
All Models except 4-TEC
Add 500 mL (17 U.S. oz) of recommended injec-
tion oil to the first full filled fuel tank.

CLEANING OF DRIVE AND

DRIVEN PULLEYS
Clean drive and driven pulleys sheaves with pulley
flange cleaner (P/N 413 711 809).

CLEANING OF BRAKE DISK

Remove any rust built-up on braking surfaces.
Clean brake disk braking surfaces with pulley
flange cleaner (P/N 413 711 809).

DRIVE BELT CONDITION

Inspect belt for cracks, fraying or abnormal wear.
Replace if necessary. Make sure to install the
proper belt with arrow printed on belt pointing
front of vehicle.

SPARK PLUGS
Once preseason preparation is done, start engine
with the old spark plug(s) to burn excess stor-
age oil. Then, install new properly gapped spark
plug(s).

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 Section 02 TROUBLESHOOTING GUIDE
Subsection 01 (ENGINE (2-STROKE))

ENGINE (2-STROKE)
The following chart is provided to help diagnose 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.
1. Check spark plugs.
- Carbon accumulation caused by defective spark plug(s). Clean carbon accumulation from piston
and cylinder head and install dry properly gapped spark plug(s).
2. Check ignition timing.
- Timing is too advanced. Set timing according to specifications (refer to TECHNICAL DATA).
3. Check for erratic sparks.
- Poor electrical connections. Repair.
- Faulty stator. Replace defective parts.
4. Check carburetor.
- Fuel passages obstructed. Clean carburetor and install new filter(s).
- Fuel level too low. Adjust float level according to specifications.
5. Check cooling system.

Fan-Cooled Engines
- Loose fan belt. Adjust or replace fan belt (refer to AXIAL FAN COOLING SYSTEM).
- Dirty cooling fins or blocked air ducts. Clean.
Liquid-Cooled Engines
- Low antifreeze level. Adjust antifreeze level. Proceed with a leakage test (refer to LIQUID
COOLING SYSTEM) and repair as required.
- Defective tank cap. Replace cap.
- Defective thermostat. Replace thermostat.
- Air in system. Bleed system.

Symptom: ENGINE SUDDENLY TURNS OFF AT HIGH RPM AND/OR WITH LIGHT LOAD.
1. Check that all ground wires are well connected.

Symptom: ENGINE SUDDENLY TURNS OFF.

1. Perform engine leak test. Check possible piston seizure.
- Damaged gasket and/or seal. Replace defective parts.
2. “Four-corner” seizure of piston(s).
- High acceleration when engine is cold. Piston expands faster than cylinder. Replace piston(s).
Ask driver to refer to the warm-up procedure in the Operator's Guide.

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Section 02 TROUBLESHOOTING GUIDE
Subsection 01 (ENGINE (2-STROKE))

Symptom: ENGINE SUDDENLY TURNS OFF. (cont’d)

3. Piston(s) seizure on exhaust side (color on piston dome is correct).
- Kinked fuel tank vent tube. Relocate fuel tank vent tube.
- Leaks at fuel line connections or damaged fuel lines. Replace defective lines.
- 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).
- Spark plug heat range is too warm. Install spark plugs with appropriate heat range (refer to
TECHNICAL DATA).
- Improper ignition timing. Adjust according to specifications (refer to TECHNICAL DATA).
- Restriction in exhaust system. Replace.
- Compression ratio is too high. Install genuine parts.
- Too low fuel octane number. Use proper fuel octane number.
- Carburetor calibration is too lean. Adjust according to specifications (refer to TECHNICAL DATA).
- Improper reed valve adjustment or damage. Adjust according to specifications (refer to appro-
priate ENGINES TYPES) and/or install BRP's recommended reed valve.
- Poor quality oil. Use XP-S injection oil.
- Leaks at air intake silencer. Replace air intake silencer grommets.
4. Melted and/or perforated piston dome; melted section at ring end gap.
- When piston reaches TDC, mixture is ignited by heated areas in combustion chamber. This is
due to an incomplete combustion of a poor quality oil. Clean residue accumulation in combustion
chamber and replace piston(s). Use XP-S injection oil.
- Spark plug heat range is too high. Install recommended dry properly gapped spark plugs (refer
to TECHNICAL DATA).
- Ignition timing is too advanced. Adjust according to specifications (refer to TECHNICAL DATA).
- Inadequate fuel quality. Use appropriate fuel.
- Carburetion is too lean. Adjust according to specifications (refer to TECHNICAL DATA).
5. Seized piston all around the circumference (dry surface).
- Lack of oil, damaged oil line or defective injection pump. Replace defective part(s).
6. Grooves on intake side of piston only.
- Oil film eliminated by water (snow infiltration in engine). This can also be caused by running
engine on choke for too long. Excessive fuel will remove the oil film on the piston and make
marks. Replace piston(s) and check if intake system leaks.
7. Piston color is dark due to seizure on intake and exhaust sides.
- Broken or loose fan belt. Replace fan belt and/or adjust its tension (refer to TECHNICAL DATA).
- Cooling system leaks and lowers coolant level. Proceed with a leakage test (refer to LIQUID
COOLING SYSTEM) and repair as required. Add coolant in cooling system until appropriate level
is reached.
- Accumulation of foreign particles in needle valve and/or main jet area. Clean carburetor(s).
8. Cracked or broken piston(s).
- Cracked or broken piston(s) due to excessive piston/cylinder clearance or engine overreving. Re-
place 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.
9. DPM manifold air vent is obstructed.
- Carburetion is too lean. Ensure proper air vent.

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 Section 02 TROUBLESHOOTING GUIDE
Subsection 01 (ENGINE (2-STROKE))

Symptom: PISTON RING AND CYLINDER SURFACES ARE SCRATCHED.

1. Check oil quality.
- Poor quality oil. Use XP-S injection oil.
2. Check injection pump and its hoses.
- Inadequate injection pump adjustment and/or defective hoses. Adjust pump according to spec-
ifications (refer to ENGINE) and/or replace hoses.

Symptom: ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH
MAXIMUM OPERATING RPM.
1. Check spark plug condition and gap.
- fouled spark plugs or wrong spark plug gap. Replace or readjust gap.
2. Check if there is water in fuel.
- There is water in fuel. Drain fuel system, then fill with appropriate fuel.
3. Check proper operation of RAVE valves. (Refer to ENGINE EQUIPPED WITH RAVE VALVE
DOES NOT REACH ITS FULL OPERATING RPM (500 TO 1000 RPM LOWER).)
- Repair.
4. Check items listed in ENGINE RUNS OUT OF FUEL (refer to FUEL AND OIL SYSTEMS sub-
section).
5. Check carburetor adjustments and cleanliness.
- Inadequate carburetor adjustments or dirt accumulation. Adjust according to specifications (refer
to TECHNICAL DATA) or clean.
6. Check drive belt.
- Worn belt. Replace belt if width is 3 mm (1/8 in) less than nominal dimension (refer to TECHNI-
CAL DATA).
7. Check track adjustment.
- Too much tension and/or improper alignment. Align track and adjust its tension to specifications
(refer to TECHNICAL DATA).
8. Check drive pulley.
- Improper calibration screw adjustments (TRA pulley) and/or worn bushing(s). Adjust according
to specifications (refer to TECHNICAL DATA) and/or replace bushing(s).
9. Check driven pulley.
- Worn bushing and/or spring tension. Replace spring and/or adjust its tension according to spec-
ifications (refer to TECHNICAL DATA).
10. Check exhaust system.
- Restriction or exhaust system leakage. Replace or reseal with Ultra Copper.
11. Check ignition timing.
- Decrease in power due to delayed ignition. Adjust according to specifications (refer to TECHNI-
CAL DATA).
12. Check engine compression.
- Worn piston(s) and ring(s). Replace (refer to TECHNICAL DATA for specifications).
13. Check engine cooling system.
- Improper fan belt tension. Adjust fan belt (refer to TECHNICAL DATA).
- Coolant level is low, cap fails to pressurize system or air circulates through lines. Adjust level,
replace cap or bleed cooling system.

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Section 02 TROUBLESHOOTING GUIDE
Subsection 01 (ENGINE (2-STROKE))

Symptom: ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH
MAXIMUM OPERATING RPM. (cont’d)
14. Check reed valve.
- Improper tightness and/or opening. Replace or adjust. Refer to proper engine subsection.

Symptom: ENGINE DETONATION AT MAXIMUM RPM.

1. Check which type of fuel is used.
- Octane number is too low and/or alcohol level is too high. Use recommended fuel type.
2. Check spark plug type.
- Improper spark plug heat range. Install recommended spark plugs (refer to TECHNICAL DATA).
3. Check exhaust system.
- Too much restriction. Replace.
4. Check ignition timing.
- Timing is too advanced. Adjust according to specifications (refer to TECHNICAL DATA).
5. Check proper operation of RAVE valves. (Refer to ENGINE EQUIPPED WITH RAVE VALVE
DOES NOT REACH ITS FULL OPERATING RPM (500 TO 1000 RPM LOWER).)
- Repair.
6. Check if engine is overheating. (Refer to HIGH ENGINE OPERATING TEMPERATURE).
7. Check carburetion.
- Fouled and/or improper carburetor components. Clean or replace according to specifications
(refer to TECHNICAL DATA).
8. Check compression ratio and combustion chamber volume.
- Compression ratio is too high. Install genuine parts.

Symptom: ENGINE TURNS OVER BUT FAILS TO START (MANUAL START).

1. Check switches.
- Ignition switch, emergency cut-out switch or tether switch is OFF. 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.
- Fuel valve is OFF or not fully open. Fully open fuel valve.
3. Check fuel level.
- Mixture too lean to start cold engine. Check fuel tank level and use choke or primer.
4. Check spark plug.
- Defective spark plug (no spark) or wrong spark plug gap. Replace spark plugs or readjust gap.
5. Check amount of fuel on spark plug.
- 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 properly
gapped spark plugs. Start engine following usual starting procedure.
6. Check fuel lines.
- 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.

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 Section 02 TROUBLESHOOTING GUIDE
Subsection 01 (ENGINE (2-STROKE))

Symptom: ENGINE TURNS OVER BUT FAILS TO START (MANUAL START). (cont’d)
7. Check engine compression.
- Insufficient engine compression. Replace defective part(s) (ex.: piston(s), ring(s), etc.).

Symptom: IRREGULAR ENGINE IDLE (NORMAL USE AFTER ENGINE WARM UP).
1. Check choke.
- Choke plunger may be partially opened. Readjust.
2. Check carburetor adapter.
- Air enters through a crack. Replace.
3. Check air screw position.
- Inadequate fuel/air mixture. Adjust according to specifications (refer to TECHNICAL DATA).
4. Check dimension of pilot jet.
- Inadequate fuel/air mixture. Adjust according to specifications (refer to TECHNICAL DATA).
5. Check reed valve.
- Improper tightness and/or opening. Replace or adjust. Refer to proper engine subsection.
6. Perform engine leak test.
- Leaking gaskets allow air to enter in engine. Replace defective parts.
7. DPM manifold air vent is obstructed.
- Carburetion is too lean. Ensure proper air vent.
8. Check ignition system trigger coil air gap.
- Air gap is too large. Adjust according to specifications (refer to TECHNNICAL DATA).

Symptom: HIGH ENGINE OPERATING TEMPERATURE (FAN COOLED ENGINES).

1. Check cooling system.
- Loose fan belt. Adjust or replace fan belt (refer to AXIAL FAN COOLING SYSTEM).
- Dirty cooling fins or blocked air ducts. Clean.
2. Check carburetion.
- Improperly adjusted or inadequate carburetor components.
Adjust according to specifications (refer to TECHNICAL DATA) or replace inadequate compo-
nent(s).
3. Check cylinder O-rings.
- Worn O-rings. Replace.
4. Check ignition timing.
- Ignition timing is too advanced. Adjust according to specifications (refer to TECHNICAL DATA).
5. Check if there are leaks at air intake silencer and/or engine crankcase.
- Leak(s). Repair or replace.
6. Check condition and heat range of spark plugs.
- Melted spark plug tip or inadequate heat range. Replace.

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Section 02 TROUBLESHOOTING GUIDE
Subsection 01 (ENGINE (2-STROKE))

Symptom: HIGH ENGINE OPERATING TEMPERATURE (LIQUID COOLED ENGINES).

1. Check temperature gauge sensor.
- False reading. Check terminal connections. If problem persists, replace sensor.
2. Check if heat exchangers are clean.
- Dirty heat exchangers. Clean heat exchangers.
3. Check coolant level and check if there is air infiltration in the system or if there are leaks in
gasket areas.
- Low coolant level or air in system. Add coolant until recommended level is reached, bleed sys-
tem and/or tighten clamps.
4. Check if coolant flows through system properly.
- Foreign particles and/or broken coolant pump impeller. Clean cooling system and/or replace
coolant pump impeller.
5. Check thermostat.
- Thermostat reacts slowly or not at all. Replace.
6. Check antifreeze concentration.
- Antifreeze concentration is too high. Adjust concentration according to BRP recommendations.
7. Check tank cap.
- Cap does not hold pressure. Replace.
8. Check carburetion.
- Improperly adjusted or inadequate carburetor components. Adjust according to specifications
(refer to TECHNICAL DATA) or replace inadequate component(s).
9. Check cylinder head gaskets.
- Worn gaskets. Replace.
10. Check ignition timing.
- Ignition timing is too advanced. Adjust according to specifications (refer to TECHNICAL DATA).
11. Check if there are leaks at air intake silencer and/or engine crankcase.
- Leak(s). Repair or replace.
12. Check condition and heat range of spark plugs.
- Melted spark plug tip or inadequate heat range. Replace.

Symptom: ENGINE EQUIPPED WITH RAVE VALVE DOES NOT REACH ITS FULL OPERAT-
ING RPM (500 TO 1000 RPM SLOWER).
1. Check RAVE valve pistons.
- Valve piston(s) is (are) not screwed to the bottom. Screw valve piston(s) to bottom.
2. Check that valve moves freely.
- Valve stuck in closed position. Clean.
3. Check RAVE valve stems.
- Bent RAVE valve stem(s). Replace.
4. Check RAVE valves.
- Jammed valve(s). Clean.

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 Section 02 TROUBLESHOOTING GUIDE
Subsection 01 (ENGINE (2-STROKE))

Symptom: ENGINE EQUIPPED WITH RAVE VALVE DOES NOT REACH ITS FULL OPERAT-
ING RPM (500 TO 1000 RPM SLOWER). (cont’d)
5. Check tension of RAVE springs.
- Inadequate spring tension. Replace.
6. Check RAVE pressure holes.
- Clogged holes. Clean.
7. Check clamps or sleeves.
- Damaged clamp(s) or sleeve(s). Replace.
8. Check exhaust tightness.
- Exhaust system is leaking leading to a too low back pressure. Replaces parts and reseal.

Symptom: ENGINE EQUIPPED WITH RAVE. ENGINE HESITATES AT LOW OR MID-SPEED

AND REACHES MAXIMUM PERFORMANCE ONLY AFTER A WHILE.
1. Check RAVE valve spring(s).
- Spring tension is too low or spring(s) is (are) broken. Replace.
2. Check RAVE valve cover red adjustment screws.
- Adjustment screw(s) is (are) too loose. Adjust according to ASSEMBLY PROCEDURE in appro-
priate engine subsections.
3. Check RAVE valve movement (RAVE movement indicator (P/N 861 725 800).
- Valve(s) is (are) stuck in open position. Clean.

Symptom: REWIND STARTER ROPE DOES NOT REWIND.

1. Check rewind spring.
- Broken spring. Replace spring.

Symptom: REWIND STARTER PAWL DOES NOT ENGAGE.

1. Check stopper spring.
- Broken stopper spring. Replace.
2. Check pawl and pawl lock.
- Pawl and pawl lock have stuck together because of heat. Replace.
3. Check pawl and rope sheave.
- Pawl and rope sheave have stuck together because of heat. Replace.

Symptom: ENGINE PINGING.

1. Check for proper fuel octane number according to engine type.
- Too low fuel octane number. Use appropriate fuel octane number (refer to Operator's Guide).
2. Check fuel lines.
- Bent fuel lines (preventing fuel from flowing through). Relocate or replace fuel lines.
3. Check if carburetor(s) is (are) clean.
- Dirt prevents fuel from flowing through. Clean.
4. Check ignition timing.
- Timing is too advanced. Adjust according to specifications (refer to TECHNICAL DATA).

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Section 02 TROUBLESHOOTING GUIDE
Subsection 01 (ENGINE (2-STROKE))

Symptom: ENGINE PINGING. (cont’d)

5. Check compression ratio.
- Compression ratio is too high. Replace inadequate part(s) to obtain manufacturer's recommend-
ed compression ratio or use a higher grade fuel.

Symptom: ENGINE GENERATES A LOT OF VIBRATIONS.

1. Check engine supports and stopper.
- 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 ORIGINATING FROM DRIVE PULLEY).
3. Check carburetors synchronization.
- Throttle slide height is not the same on each carburetor and/or throttle slides opening is unsyn-
chronized. Adjust throttle slide heights and throttle cable.
4. Check crankshaft and bearings.
- Loose crankshaft bearings or uneven crankshaft. Replace parts.

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 Section 02 TROUBLESHOOTING GUIDE
Subsection 02 (ENGINE (4-TEC))

ENGINE (4-TEC)
COOLING SYSTEM
Symptom: HIGH ENGINE OPERATING TEMPERATURE.
1. Check coolant level.
- Coolant level lower than recommended. Check for leakage.
- Coolant leaking from control bore means a damaged water pump rotary seal. Replace rotary seal
(refer to COOLING SYSTEM and CRANKCASE).
- Cylinder head and/or cylinder base. Gasket(s) is(are) causing coolant leakage. Replace.
- Gasket on water pump housing leaks. Retighten screws and/or replace gasket.
- Hoses are brittle and/or hard. Replace.
- Hose clamps are loose. Retighten clamps.
2. Check temperature sensor for electrical/mechanical failure.
- Temperature sensor defective. Replace.
3. Check thermostat (located in the thermostat housing on the alternator side cover).
- Thermostat defective (does not open when engine gets hot). Replace water pump housing (refer
to COOLING SYSTEM).
4. Check condition of impeller located on the water pump shaft.
- Impeller fins broken and/or impeller threads are damaged. Replace.

ALTERNATOR
Symptom: NOT CHARGING AT ALL OR CHARGING VOLTAGE INADEQUATE.
1. Check the alternator and measure the charging voltage.
- Defective alternator. Replace the alternator (refer to alternator).
2. Inspect the alternator; check if it is turning along during starting.
- Generator gear damaged. Replace the generator gear (refer to CRANKSHAFT/DRIVE GEARS).
3. Check wiring harness for cracks or other damages.
- Harness shows electrical failure and/or other damages. Replace wire harness.
4. Check the alternator charging light on the dashboard for proper functioning.
- Alternator charging light defective. Replace the alternator charging light.

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Section 02 TROUBLESHOOTING GUIDE
Subsection 02 (ENGINE (4-TEC))

LUBRICATION
Symptom: LOW OR NO OIL PRESSURE.
1. Check oil level and search for leakage on crankcase and/or sealing parts.
- Oil drain plug on engine bottom is loosed and/or gasket ring is missing. Retighten the plug and/or
place gasket ring.
- Control bore if oil leaks (beside thermostat housing). Oil leaking from control bore means a dam-
aged oil seal on water pump shaft. Replace oil seal (refer to COOLING SYSTEM).
- Crankcase is leaking due to damage. Rebuild engine with new crankcase and gasket parts. Use
recommended oil (refer to TECHNICAL DATA).
- Crankcase is leaking due to loose screws. Retighten screws with recommended torque.
- Sealing rings, O-rings and/or gaskets are brittle and/or hard or damaged. Replace damaged parts.
- Piston rings worn out (blue coloured engine exhaust emission). Replace piston rings (refer to
CRANKSHAFT/DRIVE GEARS).
- Piston rings are broken (low compression). Replace piston rings (refer to CRANKSHAFT/DRIVE
GEARS).
- Valve stem seal damaged and/or sealing lip is hard and/or brittle. Replace all valve stem seals.
2. Check oil pressure switch function.
- Oil pressure switch damaged. Replace oil pressure switch.
3. Check oil orifice(s) on the oil pump suction side.
- Oil orifice(s) is(are) clogged. Clean from contamination. Replace oil and oil filter if necessary
(refer to MAINTENANCE or LUBRICATION SYSTEM).
4. Check oil pump function.
- Oil pump rotor is out of wear limit. Replace oil pump shaft (refer to LUBRICATION SYSTEM).
- Oil pump seized due to oil leakage and/or air inclusion. Replace oil pump (refer to LUBRICATION
SYSTEM).
- Gears driving oil pump are broken or otherwise damaged. Replace gears.
- Incorrect oil being used. Use recommend oil (refer to TECHNICAL DATA).
5. Check oil pressure regulator valve (spring) function.
- Valve spring damaged (valve always open). Replace spring.
- Valve piston is stuck in oil pump housing. Repair valve piston.
6. Check plain bearings in crankcase for heavy wear.
- Plain bearings out of specification (increased clearance). Replace plain bearings.

Symptom: OIL CONTAMINATION (WHITE APPEARANCE).

1. Check control bore (beside thermostat housing) if water and oil leaks.
- Leakage of oil/water mixture from bore means damaged water pump seal ring and rotary seal.
Replace sealing ring, rotary seal and change oil, oil filter and/or coolant (refer to LUBRICATION
SYSTEM, COOLING SYSTEM and CRANKCASE).
2. Check cylinder head and/or cylinder base gasket.
- Gasket damaged or leaking. Retighten cylinder head with recommended torque and/or replace
gasket.
3. Check tightening torque of cylinder head screws.
- Screws not properly tightened. Retighten screws to recommended torque and replace oil.

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Subsection 02 (ENGINE (4-TEC))

Symptom: OIL CONTAMINATION (WHITE APPEARANCE). (cont’d)

4. Check oil for particles (may indicate possible engine internal damages).
- Oil contamination due to metal or plastic particles. Replace possibly damaged part(s) including
oil and oil filter. Use recommended oil (refer to TECHNICAL DATA).

CYLINDER AND CYLINDER HEAD

Symptom: UNUSUAL ENGINE NOISE AND/OR VIBRATIONS.
1. Check noise coming from cylinder head area.
- Faulty chain tensioner. Replace spring and/or mechanism.
- Chain guide worn out. Replace chain guide.
- Stretched chain and/or worn out sprockets. Replace chain and sprockets.
- Sprocket screws got loose. Retighten screws with recommended torque.
- Hydraulic element inside rocker arm(s) is(are) worn out (valve adjustment). Replace rocker
arm(s).
- Rocker arm screws not tightened. Replace screws and perform the torque procedure (refer to
CYLINDER AND CYLINDER HEAD).

Symptom: OIL CONTAMINATION ON CYLINDER AND/OR CYLINDER HEAD.

1. Check screws for torque.
- Loose screws. Retighten screws with recommended torque.
- Gaskets are brittle, hard, worn out or otherwise damaged. Replace damaged gaskets, O-rings
or the V-ring on breather.
- Contact area between spark plug and stick coils fouled by oil. Clean spark plug area and replace
spark plug tube.

CRANKSHAFT
Symptom: UNUSUAL ENGINE NOISE AND/OR VIBRATIONS.
1. Check noise coming from crankshaft area.
- Crankshaft bushings are damaged. Replace the crankshaft bushings. (refer to CRANK-
SHAFT/DRIVE GEARS).
- Connecting rod bushings are damaged. Replace the connecting rod bushings. (refer to CRANK-
SHAFT/DRIVE GEARS).
2. Check if drive gears are loosen.
- Crankshaft nut retaining drive gear is loose. Retighten retaining nut with recommended torque.

ELECTRIC STARTER
Symptom: STARTER DOES NOT TURN.
1. Check the battery voltage.
- Battery discharged. Charge the battery.
2. Check wiring harness for cracks or other damages.
- Harness shows electrical failure and/or other damages. Replace wire harness.

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Section 02 TROUBLESHOOTING GUIDE
Subsection 02 (ENGINE (4-TEC))

Symptom: STARTER DOES NOT TURN. (cont’d)

3. Check 30 A and 5 A fuses.
- Burnt fuse. Check wiring condition and replace fuse.
4. Check continuity of starter switch contact points.
- Poor contact of starter switch contact points. Repair or replace switch.
5. Check continuity between starter switch and ECM.
- Open circuit. Repair.
6. Check continuity between ECM and solenoid switch.
- Open circuit. Repair.

Symptom: STARTER TURNS, BUT ENGINE DOES NOT CRANK.

1. Check the starter gear.
- Starter gear and/or intermediate gear is worn or damaged. Replace starter gear and/or interme-
diate gear (refer to CRANKSHAFT/DRIVE GEARS).
2. Check the sprag clutch.
- Sprag clutch is worn or otherwise damaged. Replace sprag clutch (refer to CRANKSHAFT/DRIVE
GEARS).

Symptom: STARTER TURNS SLOWLY

1. Check battery capacity.
- Shorted battery cell(s). Replace.
2. Check battery charge.
- Low battery. Recharge battery and check recharge system and wires.
3. Check wire connection.
- Inadequate connection (too much resistance). Clean and reconnect.
4. Check brushes.
- Poor contact of brushes. Replace starter.
5. Check commutator.
- Burnt commutator. Replace starter.
6. Check engine.
- Engine seized. Overhaul the engine.
7. Check field coil resistance.
- Shorted field coil. Replace starter.
8. Check armature resistance.
- Shorted armature. Replace starter.
9. Check tension of brush springs.
- Weak brush spring tension. Replace starter.
10. Check if bushings are worn.
- Worn bushings. Replace starter.

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 Section 02 TROUBLESHOOTING GUIDE
Subsection 02 (ENGINE (4-TEC))

ENGINE GENERAL
Symptom: ENGINE BACKFIRES.
1. Check spark plug.
- Carbon accumulation caused by defective spark plug. Clean carbon accumulation and replace
spark plug.
2. Check fault codes in B.U.D.S. system.
- Check if electrical actuator(s) is/are defective. Replace defective part(s) (refer to COMPONENT
INSPECTION AND ADJUSTMENT).
3. Check leakage on intake manifold.
- Air leak on intake system. Retighten screws and/or replace intake manifold gasket.
4. Check exhaust air leaking.
- Exhaust gasket is leaking. Retighten screws and/or replace exhaust gasket.
5. Check intake valve(s) for leaking.
- Intake valve(s) is(are) leaking. Repair or replace valve(s).
6. Check if fuel supply is sufficient at high RPM.
- Fuel line is contaminated and/or bent (engine gets lean). Clean and/or replace defective part(s).

Symptom: ENGINE SUDDENLY TURNS OFF.

1. Check spark plug condition and/or gap.
- Fouled spark plug or wrong spark plug gap. Readjust gap and clean spark plug or replaceplace
pistons. Ask driver to refer to warm-up procedure in Operator’s Guide.
2. Check fault codes in B.U.D.S. system.
- Check if electrical actuator(s) is/are defective. Replace defective part(s) (refer to COMPONENT
INSPECTION AND ADJUSTMENT).
3. Check if fuel supply is sufficient at high RPM.
- Fuel line is contaminated and/or bent. Clean and/or replace defective part(s).
4. Perform engine leak test. Refer to ENGINE LEAK TEST procedure. Check for possible pis-
ton seizure.
- Damaged head gasket and/or seal and/or leaking inlet/exhaust valve(s). Replace and/or repair
defective parts.
5. Piston seizure.
- Spark plug heat range is too hot. Install spark plug with appropriate heat range (refer to TECH-
NICAL DATA).
- Compression ratio is too high. Install genuine parts.
- Poor oil quality. Use BRP's XP-S recommended oil.
- Leaks at air intake manifold (engine gets too lean). Retighten screws or replace air intake mani-
fold gasket.
- Snow/water intrusion through intake system into combustion chamber. Clean intake system and
replace defective part(s).

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Section 02 TROUBLESHOOTING GUIDE
Subsection 02 (ENGINE (4-TEC))

Symptom: ENGINE SUDDENLY TURNS OFF. (cont’d)

6. Melted and/or perforated piston dome; melted section at ring end gap.
- Spark plug heat range is too hot. Install recommended spark plug (refer to TECHNICAL DATA).
- Coolant less than recommended level (engine gets too hot). Repair cooling circuit and/or refill
with recommended liquid.
- Poor quality and/or wrong fuel. Clean from contamination and use appropriate fuel (refer to
TECHNICAL DATA).
7. Piston color is dark due to seizure on intake and exhaust sides.
- Cooling system leaks and lowers coolant level. Tighten clamps or replace defective parts. Add
antifreeze in cooling system until appropriate level is reached. Replace damaged parts.
- Oil nozzle is clogged or bent. Clean or replace oil nozzle (refer to LUBRICATION SYSTEM).
8. Cracked or broken piston.
- Cracked or broken piston due to excessive piston/cylinder clearance or engine overreving. Re-
place piston. Check piston/cylinder clearance (refer to CRANKSHAFT/DRIVE GEARS).
9. Check piston rings and cylinder surface for grooves.
- Poor oil quality. Use recommended oil.
- Contamination through engine intake. Replace defective part(s) and use new air filter.
10. Check valve springs exhaust/intake.
- Broken valve spring damages the cylinder head, valve(s), rocker arm(s)/piston/ piston rings and
connecting rod. Replace defective part(s).
11. Check crankshaft, rocker arms movement.
- Oil pump failure due to leack of oil. Repair and replace defective parts and use recommended
oil.
- Oil contamination due to clogged oil filter/oil sieve. Replace oil and oil filter at the same time,re-
place defective part(s) (refer to MAINTENANCE CHART and LUBRICATION SYSTEM).

Symptom: ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH
MAXIMUM OPERATING RPM.
1. Check spark plug condition and/or gap.
- Fouled spark plug or wrong spark plug gap. Readjust gap or replace.
2. Check spark plug type.
- Improper spark plug heat range. Install recommended spark plug (refer to TECHNICAL DATA).
3. Check fault codes in B.U.D.S system.
- Check if electrical actuator(s) is/are defective. Replace defective part(s) (refer to COMPONENT
INSPECTION AND ADJUSTMENT).
4. Check for water in fuel (wrong fuel).
- There is water in fuel or wrong fuel. Drain fuel system, search for leakage and refill it with ap-
propriate fuel.
5. Check engine compression.
- Worn piston(s) and/or piston ring(s). Replace (refer to CYLINDER AND HEAD).
6. Check fuel pressure.
- Low fuel pressure. Perform fuel pressure test (refer to COMPONENT INSPECTION AND AD-
JUSTMENT).

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 Section 02 TROUBLESHOOTING GUIDE
Subsection 02 (ENGINE (4-TEC))

Symptom: ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH
MAXIMUM OPERATING RPM. (cont’d)
7. Perform engine leak test. Refer to ENGINE LEAK TEST procedure. Check for possible pis-
ton seizure.
- Damaged head gasket and/or seal and/or leaking intake/exhaust valve(s). Replace and/or repair
defective parts.

Symptom: ENGINE CRANKS BUT FAILS TO START.

1. Check fault codes in B.U.D.S. system.
- Check if electrical actuator(s) is/are defective. Replace defective part(s) (refer to COMPONENT
INSPECTION AND ADJUSTMENT).
2. Check if stick coil fits on spark plug (refer to spark plug).
3. Check spark plug.
- Define spark plug (no spark) or wrong spark plug gap. Readjust gap and clean spark plug or
replace.
4. Check for fuel on spark plug.
- Flooded engine (spark plug wet when removed). Activate engine drowned mode and crank en-
gine with rags over the spark plug holes (refer to OVERVIEW in EMS system).
5. Check battery voltage.
- Battery is discharged and starter works not properly. Charge battery.
6. Check engine compression.
- Insufficient engine compression. Replace defective part(s) (ex.: piston, ring(s), etc.).
7. In cold weathers, check engine decompressor (located on camshaft sprocket/timing gear).
- Centrifugal weight spring is not engaged and/or damaged. Readjust spring or replace centrifugal
weight if damaged.

Symptom: ENGINE DOES NOT START — NO SPARK AT SPARK PLUG (REFER TO ENGINE
MANAGEMENT SYSTEM).
1. Check fault codes in B.U.D.S. system.
- Check if electrical actuator(s) is/are defective. Replace defective part(s) (refer to COMPONENT
INSPECTION AND ADJUSTMENT).
2. Verify spark plug condition.
- Defective, improperly set, worn out, fouled. Identify source of problem and correct. Replace
spark plug.
3. Check stick coil (refer to COMPONENT INSPECTION AND ADJUSTMENT).
- Defective part. Replace stick coil.
4. Check crankshaft position sensor (refer to COMPONENT INSPECTION AND ADJUSTMENT).
- Defective crankshaft position sensor. Corroded connector terminals. Replace crankshaft posi-
tion sensor. Clean terminals and apply silicone dielectric grease.
5. Check condition of wiring harness and connectors.
- Cables and/or connectors are damaged and/or corroded. Replace connectors or complete wiring
harness (refer to COMPONENT INSPECTION AND ADJUSTMENT). Clean terminals and apply
silicone dielectric grease.

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 Section 02 TROUBLESHOOTING GUIDE
Subsection 03 (FUEL AND OIL SYSTEMS (2-STROKE ENGINES))

FUEL AND OIL SYSTEMS

(2-STROKE ENGINES)
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.
NOTE: For the SDI fuel and oil systems troubleshooting, also refer to appropriate ENGINE subsection.
Symptom: HIGH FUEL CONSUMPTION OR RICH MIXTURE.
1. Check fuel tank.
- Perforated fuel tank. Replace fuel tank.
2. Check fittings on fuel pump, fuel tank and carburetor(s).
- Leaking fittings. Replace defective part.
3. Check choke adjustment.
- Fuel flows through choke circuit while engine runs. Readjust choke.
4. Check float height in carburetor(s).
- Fuel level is too high in float bowl(s). Adjust according to specifications (refer to TECHNICAL
DATA).
5. Check needle valve of carburetor(s).
- 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.

1. Check items 3, 4 and 5 of HIGH FUEL CONSUMPTION.
2. Check fuel pump diaphragm.
- Cracked diaphragm. Replace.

Symptom: ENGINE LACKS POWER OR STALLS AT HIGH RPM.

1. Check fuel tank vent hose.
- Kinked or clogged vent hose. Relocate or replace.
2. Check fuel filter.
- Clogged filter. Replace.
3. Check fuel lines.
- Kinked or clogged lines. Relocate or replace.
4. Check fuel pump flow.
- Leaking impulse hose. Replace.
- Dried diaphragm. Replace.
5. Check if carburetor(s) is (are) clean.
- Varnish. Clean.

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Section 02 TROUBLESHOOTING GUIDE
Subsection 03 (FUEL AND OIL SYSTEMS (2-STROKE ENGINES))

Symptom: HIGH INJECTION OIL CONSUMPTION.

1. Check oil injection pump adjustment.
- Oil injection pump adjusted too rich. Adjust.
2. Check injection pump identification.
- Wrong pump installed. Replace with the appropriate pump. Refer to OIL INJECTION SYSTEM.
3. Check injection oil lines and their fitting.
- Leaking lines. Replace defective part(s).
4. Check injection pump cover gasket.
- Worn gasket. Replace.
5. Check pump check valve(s).
- Check valve(s) stuck open. Replace.
6. Check pump.
- Leaking pump. Replace.
7. Check oil pump cable.
- Cable stuck in open position. Replace cable.
8. On liquid-cooled models, test pump shaft gear reservoir for leaks.
- Leaking seals. Replace seals.

Symptom: ENGINE LACKS FUEL (OR LEAN MIXTURE).

1. Check fuel filter ball located in fuel tank. Ball must move freely.
- Corrosion due to oxidation at installation. Replace fuel filter.
2. Check if lines are perforated or kinked or if they leak at fittings.
- Lines are too big for their fittings or are improperly routed. Replace or properly relocate lines.
3. Check fuel pump outlet flow.
- Dirt clogging fuel pump lines or torn membrane. Clean or replace fuel pump.
4. Check needle valve of carburetor(s).
- Dirt (varnish, foreign particle) clogging fuel line inlets. Clean.
5. Check main jet.
- Dirt (varnish, foreign particle) accumulation at main jet. Clean.
6. Check float height in carburetor bowl(s).
- Running out of fuel at high speed because float height is too low. Adjust float height according
to specifications.

Symptom: DPM SEEMS TO BE DEFECTIVE.

1. Check electrical connections.
- Corroded terminals. Clean or replace.
2. Fuel mixture is too rich or too poor.
- Possible damage to DPM. If DPM does not operate properly, unplug compensation solenoid
connector while engine is running. The carburetion is now identical to that of carburetors without
a DPM, provided that all pipe fittings are tight and that solenoid is in good condition, (it must not
be half-open). If problem is resolved with this procedure, DPM is faulty.

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Subsection 03 (FUEL AND OIL SYSTEMS (2-STROKE ENGINES))

Symptom: DPM SEEMS TO BE DEFECTIVE. (cont’d)

3. Check for DPM manifold leaking.
- DPM manifold is leaking. Repair or replace.

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 Section 02 TROUBLESHOOTING GUIDE
Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS)

TRANSMISSION AND BRAKE SYSTEMS

The following charts are provided to help in diagnosing the probable source of troubles. It should be used
as a guideline. Some causes or corrections may not apply to a specific model.

TRANSMISSION
Symptom: THE SNOWMOBILE ACCELERATES SLOWLY, ESPECIALLY FROM A STANDING
START.
1. Check drive belt condition.
- 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.
- 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 speci-
fications (refer to TECHNICAL DATA).
3. Check driven pulley sliding half play.
- Jammed sliding half. Replace.
4. Check spring tension of driven pulley sliding half.
- Sliding half rotation is accelerated when spring tension is too weak. Adjust according to speci-
fications (refer to TECHNICAL DATA).
5. Refer to VIBRATIONS ORIGINATING FROM DRIVE PULLEY and VIBRATIONS ORIGINATING
FROM DRIVEN PULLEY and check items listed.
6. Check drive pulley spring tension.
- Spring tension is too weak. Replace.

Symptom: ENGINE MAXIMUM RPM IS TOO HIGH AND TOP SPEED IS NOT REACHED.
1. Check items 1, 2 and 3 of THE SNOWMOBILE ACCELERATES SLOWLY, ESPECIALLY WHEN
IT IS STOPPED.
2. Check driven pulley spring tension.
- Spring tension is too stiff. Adjust according to specifications (refer to TECHNICAL DATA).
3. Check position of the calibration screws (TRA drive pulley).
- Selected numbers are too high. Adjust according to specifications (refer to TECHNICAL DATA).
4. Refer to VIBRATIONS ORIGINATING FROM DRIVEN PULLEY and check items listed.
5. Check the driven pulley.
- Driven pulley does not open completely. Clean, readjust or replace driven pulley.
6. Check if levers of drive pulley move freely.
- Stuck levers. Replace lever bushings.

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Section 02 TROUBLESHOOTING GUIDE
Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS)

Symptom: LOOSENESS IS FELT IN DRIVE SYSTEM WHEN ACCELERATING/DECELERAT-

ING.
1. Check drive chain tension.
- Drive chain is too loose. Adjust.
2. Check radial play of driven pulley.
- Worn key, keyway or splines. Replace.

Symptom: VIBRATIONS ORIGINATING FROM DRIVE PULLEY.

1. Check drive belt.
- Belt width is uneven at many places. Replace.
2. Check tightening torque of drive pulley screw.
- Moving governor cup. Retighten screw.
3. Spring cover screws.
- Spring cover moves and restrains sliding half movement. Retighten screws.
4. Check spring cover (TRA TYPE) and/or sliding half bushings.
- Excessive gap between bushings and fixed half shaft, thus restraining sliding half movements.
Replace bushing(s).
5. Check governor cup splines.
- Excessive radial play. Replace governor cup.
6. Check lever assembly.
- Lever assembly is damaged (worn bushing, bent lever, etc.). Replace damaged part.

Symptom: VIBRATIONS ORIGINATING FROM DRIVEN PULLEY.

1. Check sliding half side play.
- Sliding half bushing worn out. Replace sliding half bushing.
2. Check sliding half and fixed half straightness.
- Sliding half/fixed half warped. Replace.
3. Check cam slider shoes.
- One or two slider shoes out of three are broken. Replace.

Symptom: PULLEYS DO NOT DOWN SHIFT PROPERLY.

1. Check driven pulley spring tension.
- Spring tension is too low. Adjust according to specifications (refer to TECHNICAL DATA).
2. Refer to VIBRATIONS COMING FROM DRIVEN PULLEY and check items listed.
3. Check drive pulley bushings (cleanliness, wear, etc.).
- Bushings stick to fixed half pulley shaft. Clean or replace.

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Symptom: IN REVERSE ENGINE FAILS AND DRIVEN PULLEY OPENS TOO FAST (DRIVE
BELT IS LOW IN DRIVEN PULLEY).
1. Check pulley distance and alignment.
- Improper adjustment. Adjust according to specifications (refer to PULLEY DISTANCE AND
ALIGNMENT) and make sure that torque rod is resting against engine. Check engine mounts.
2. Check for reverse sliding shoes.
- Sliding shoes are worn or missing. Replace sliding shoes.
3. Check spring.
- Spring is weak or insufficient tension. Replace spring.

Symptom: UNEVEN BELT WEAR ON ONE SIDE ONLY.

1. Check tightening torque of engine mount bolts.
- Loose engine mount. Tighten engine mount nuts/bolts equally.
2. Check pulley alignment.
- Pulley misalignment. Align pulleys.
3. Check drive belt contact area on pulleys.
- Rough or scratched pulley surfaces. Repair or replace pulley half.
4. Check driven pulley sliding half play.
- Driven pulley bushing worn. Replace bushing.

Symptom: BELT GLAZED EXCESSIVELY OR HAVING BAKED APPEARANCE.

1. Check if drive pulley bushings are worn.
- Slipping due to insufficient pressure on belt sides. Replace bushing.
2. Check condition of drive pulley fixed half shaft.
- Slipping due to rusted drive or driven pulley shafts. Clean shaft with fine steel wool.
3. Check if pulley halves are clean.
- Slipping due to oily pulley surfaces. Clean pulley halves.
4. Check pulley calibration.
- Slipping due to improper pulley calibration. Calibrate according to specifications.

Symptom: BELT WORN EXCESSIVELY IN TOP WIDTH.

1. Check drive pulley.
- Excessive slippage due to jammed of drive pulley. Inspect drive pulley.
2. Check drive belt identification number.
- Improper belt angle. (wrong type of belt). Replace belt with an appropriate drive belt.
3. Check drive belt width.
- Considerable use. Replace belt if width is less than specified in DRIVE BELT.

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Section 02 TROUBLESHOOTING GUIDE
Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS)

Symptom: BELT TOO NARROW ON ONE SECTION.

1. Check for frozen track.
- Frozen track. Free track from ice.
2. Check parking brake.
- Parking brake is engaged. Release parking brake.
3. Check track tension/alignment.
- Track too tight. Adjust track tension and alignment.
4. Check drive pulley.
- Drive pulley does not operate properly. Repair or replace drive pulley.
5. Check idle speed.
- Engine idle speed is too high. Adjust according to specifications.
6. Check drive belt length.
- Incorrect belt length. Replace with an appropriate drive belt (refer to TECHNICAL DATA).
7. Check distance between pulleys.
- Incorrect pulley distance. Readjust according to specifications.
8. Check belt height.
- Belt height is incorrect. Adjust according to specifications.

Symptom: BELT SIDES WORN CONCAVE.

1. Check pulley half surfaces.
- Rough or scratched pulley half surfaces. Repair or replace.
2. Check drive belt identification number.
- Wrong type of belt. Replace belt with an appropriate drive belt (refer to TECHNICAL DATA).

Symptom: BELT DISINTEGRATION.

1. Check drive belt identification number.
- Excessive belt speed. Wrong type of belt. Replace belt with proper type of belt. (refer to TECH-
NICAL DATA).
2. Check if pulley halves are clean.
- Oil on pulley surfaces. Clean pulley surfaces with fine emery cloth and wipe clean using Parts
Cleaner (P/N 413 711 809) and a cloth.

Symptom: BELTCORD POPPED OUT.

1. Check pulley alignment.
- Pulley misalignment. Align pulley according to specifications (refer to TECHNICAL DATA).

Symptom: FATIGUE CRACKS BETWEEN COGS.

1. Check drive belt condition.
- Belt considerably worn, worn out. Replace.
- Distortion of natural belt shape due to improper storage. Store properly.

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Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS)

Symptom: TOOTH CHUNK OUT.

1. Check drive belt rotational direction.
- Improper belt installation. Replace.
2. Check if drive belt rubs against components.
- Belt rubs against fixed components. Relocate components.
3. Check drive pulley.
- Violent engagement of drive pulley. Check drive pulley engagement speed, drive pulley bushings
and components.

Symptom: BELT “FLIP-OVER” AT HIGH SPEED.

1. Check pulley alignment.
- Pulley misalignment. Align pulley according to specifications (refer to TECHNICAL DATA).
2. Check drive belt identification number.
- Wrong type of belt. Replace with an appropriate drive belt.

BRAKE SYSTEM
MECHANICAL BRAKE
Symptom: BRAKE DOES NOT ADJUST AUTOMATICALLY.
1. Check ratchet wheel spring.
- Broken ratchet wheel spring tab. Replace.
2. Check mobile pad stud.
- Stud rotates in pad. Replace.

Symptom: BRAKE HANDLE DOES NOT RETURN COMPLETELY.

1. Check brake return spring.
- Broken return spring. Replace.
2. Check if brake cable moves freely in its housing.
- Brake cable movement is limited due to oxidation or dirt accumulation. Replace.
3. Check distance between brake lever and caliper.
- Distance is too wide. Adjust according to specifications (refer to TRANSMISSION).

HYDRAULIC BRAKE
Symptom: SPONGY BRAKE CONDITION.
1. Contaminated brake fluid.
- Replace brake fluid and bleed system. If the problem persists, replace master cylinder.
2. Check for damaged hose, master cylinder and caliper.
- Replace part(s) and check for proper mounting.

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Section 02 TROUBLESHOOTING GUIDE
Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS)

Symptom: BRAKE FLUID LEAKING.

1. Check for loosen hose connectors.
- Replace copper washers and retighten.

MECHANICAL AND HYDRAULIC BRAKES

Symptom: BRAKE SYSTEM IS NOISY.
1. Check brake pad thickness.
- Pads are worn up to wear warner. Replace.
2. Check key/keyway or splines.
- Key/keyway or splines are worn out. Replace parts.

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 Section 02 TROUBLESHOOTING GUIDE
Subsection 05 (ELECTRICAL SYSTEM)

ELECTRICAL SYSTEM
The following chart is provided to help in diagnosing the probable source of troubles. It should be used
as a guideline. Some causes or corrections may not apply to a specific model.
Symptom: STARTER DOES NOT TURN.
1. Check fuse.
- Burnt fuse. Check wiring condition and replace fuse.
2. Check continuity of starter switch contact points.
- Poor contact of starter switch contact points. Repair or replace switch.
3. Check continuity between starter switch and solenoid on fan-cooled models or between
starter switch and MPEM on liquid-cooled models.
- Open circuit. Repair.
4. On liquid-cooled models check continuity between MPEM and solenoid switch.
- Open circuit. Repair.

Symptom: STARTER TURNS BUT DOES NOT CRANK THE ENGINE.

1. Check engine.
- Engine seized. Rebuild engine.
2. Check wire connection.
- Inadequate connection (too much resistance). Clean and reconnect.
3. Check battery charge.
- Weak battery. Recharge battery and verify recharge system and wires.
4. Check battery capacity.
- Shorted battery cell(s). Replace.
5. Check starter relay contact disc.
- Burnt or poor contact of starter relay contact disc. Replace starter relay.
6. Check continuity of starter relay pull-in winding.
- Open circuit of starter relay pull-in winding. Replace starter relay.
7. Check continuity of starter relay hold-in winding.
- Open circuit of starter relay hold-in winding. Replace starter relay.
8. Check brushes.
- Poor contact of brushes or worn. Replace brushes.
9. Check commutator.
- Burnt commutator. Turn commutator on a lathe. Respect outer diameter wear limit. Refer to
ELECTRIC STARTER.
10. Check height of commutator mica.
- Commutator mica too high. Undercut mica.
11. Check field coil resistance.
- Shorted field coil. Repair or replace yoke.
12. Check armature resistance.
- Shorted armature. Repair or replace armature.

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Section 02 TROUBLESHOOTING GUIDE
Subsection 05 (ELECTRICAL SYSTEM)

Symptom: STARTER TURNS BUT DOES NOT CRANK THE ENGINE. (cont’d)
13. Check tension of brush springs.
- Weak brush spring tension. Replace springs.
14. Check yoke assembly magnets.
- Weak magnets. Replace yoke assembly.
15. Check if bushings are worn.
- Worn bushings. Replace bushings.

Symptom: STARTER TURNS, BUT OVERRUNNING CLUTCH PINION DOES NOT MESH
WITH RING GEAR.
1. Check clutch pinion gear and small return spring.
- Worn clutch pinion gear or damaged small return spring. Replace damaged part(s).
2. Check clutch.
- Defective clutch. Replace clutch.
3. Check brackets.
- Worn or broken brackets. Replace brackets.
4. Check movement of clutch on splines.
- Poor movement of clutch on splines. Clean and correct.
5. Check clutch bushing.
- Worn clutch bushing. Replace clutch.
6. Check starter bushings.
- Worn starter bushing(s). Replace bushing(s).
7. Check ring gear.
- Worn ring gear. Replace ring gear.
8. Check for proper starter rotation direction.
- Starter turns in wrong direction, incorrectly installed brushes, wrong polarity or wrong starter.
Replace starter or reconnect properly.

Symptom: ELECTRIC STARTER KEEPS TURNING WHEN ENGINE IS STARTED.

1. Check clutch.
- Jammed clutch pinion gear. Replace or clean.
2. Check movement of clutch on splines.
- Clutch is stuck on splines. Clean.
3. Check starter brackets.
- Broken bracket(s). Replace bracket(s).
4. Check ignition switch (fan-cooled models).
- Ignition switch does not return to its ON position or is short-circuited. Adjust retaining screw or
replace switch.
5. Check starter relay.
- Shorted starter relay winding(s). Replace starter relay.

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 Section 02 TROUBLESHOOTING GUIDE
Subsection 05 (ELECTRICAL SYSTEM)

Symptom: ELECTRIC STARTER KEEPS TURNING WHEN ENGINE IS STARTED. (cont’d)

6. Check starter relay contacts.
- Melted starter relay contacts. Replace starter relay.
7. Check starter switch.
- Starter switch returns poorly. Replace ignition switch.

Symptom: NOISE OCCURENCE WHEN STARTING ENGINE.

1. Check if ring gear is well-mounted to drive pulley fixed half.
- Loose and/or broken bolts. Retighten bolts using threadslocker or replace ring gear and drive
pulley fixed half.

Symptom: REGULATOR BLACK WIRE IS MELTED (HARNESS SIDE).

1. Check that big ground wire at battery is well connected to chassis.
- Corroded and/or loose connection(s). Clean and/or retighten.

Symptom: OPTIONAL ELECTRIC STARTER DOES NOT WORK WHEN TURNING IGNITION
SWITCH.
1. Check connection of BLACK wire (starter relay ground) in 3-wire housing coming from mag-
neto (white housing).
- Corroded and/or loose connection(s). Clean and/or retighten.

Symptom: ELECTRIC STARTER SOMETIMES DOES NOT WORK WHEN ACTIVATED.

1. Check battery cables and starter wires.
- Corroded and/or loose connection(s). Clean and/or retighten.
2. Check fuse(s).
- Oxidized or burnt fuse(s). Clean or replace.
3. Check wiring harness connections.
- Oxidized connections. Clean or replace defective terminals.
4. Check ignition switch.
- Defective contacts in ignition switch. Replace.
5. Check starter relay.
- Shorted starter relay wiring harness or eroded contact washer. Replace.

Symptom: ENGINE DOES NOT START — NO SPARK AT SPARK PLUG. (AT ENGINE CRANK-
ING.)
1. Verify spark plug condition.
- Defective, improperly set, worn-out, fouled. Identify source of problem and correct. Replace
spark plugs.
2. Verify spark plug cap resistance with an ohmmeter.
- Defective part. Replace cap.

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Section 02 TROUBLESHOOTING GUIDE
Subsection 05 (ELECTRICAL SYSTEM)

Symptom: ENGINE DOES NOT START — NO SPARK AT SPARK PLUG. (AT ENGINE CRANK-
ING.) (cont’d)
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.
- 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.
- Defective coil. Corroded connector terminals. Replace defective coil. Clean terminals and apply
silicone dielectric grease.
5. Verify condition of ignition coil.
- Mechanically damaged part. Vibration problem. Electrically damaged part. Tighten mounting
screws. Replace ignition coil.
6. Verify condition of ignition generator coils.
- Mechanically damaged part. Vibration problem. Electrically damaged part. Tighten mounting
screws. Replace coils.
7. Verify MPEM.
- Mechanically damaged part. Vibration problem. Electrically damaged part. Tighten mounting
screws. Replace MPEM, retest and verify ignition timing.

Symptom: CDI/MPEM MODULE DOES NOT WORK.

1. Check that high tension coil wires do not touch any metal parts.
- Short circuit. Isolate and reroute wires.

Symptom: ENGINE STALLS (AT LOW SPEED).

1. Verify items 4, 5 and 6 above.

Symptom: IRREGULAR ENGINE SPEED (AT HIGH SPEED).

1. Verify items 4, 5 and 6 above.

Symptom: IRREGULAR ENGINE SPEED (AT LOW SPEED).

1. Verify items 4 and 5 above and trigger coil/flywheel protrusion air gap.
- Air gap too large. Readjust air gap.

Symptom: ENGINE IS MISFIRING — ERRATIC SPARK AT SPARK PLUG. (RIDING ON WET

SNOW.)
1. Verify if spark plug wires and/or spark plug cap seals are sealing out moisture.
- Defective wires and/or seals. Replace defective part.
2. Verify if ignition system wiring harness connectors are in good condition and/or are sealing
out moisture.
- Loose connectors, corroded terminals or defective parts. Clean terminals and apply silicone di-
electric grease. Replace defective parts.

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 Section 02 TROUBLESHOOTING GUIDE
Subsection 05 (ELECTRICAL SYSTEM)

Symptom: ENGINE IS MISFIRING — ERRATIC SPARK AT SPARK PLUG (NORMAL USE).

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 con-
nectors.
- 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 switch(es). Clean terminals and apply
silicone dielectric grease.

Symptom: ENGINE IS MISFIRING — ERRATIC SPARK AT SPARK PLUG. (RIDING IN DEEP

AND THICK SNOW.)
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.
- Defective and/or worn spark plug(s) and/or cable(s) and/or cap(s). Replace defective part(s). Pro-
ceed with ignition system testing procedures. Perform engine analysis.

Symptom: FOULED (BLACK) SPARK PLUG TIP.

1. Check carburetor(s).
- Carburetion is too rich. Adjust according to specifications (refer to TECHNICAL DATA).
2. Check injection oil consumption.
- Injection pump flow is too high. Adjust according to specifications or replace.
3. Check oil quality.
- Poor quality oil. Use Bombardier injection oil.
4. Check engine compression.
- Leaking piston ring(s). Replace.

Symptom: SPARK PLUG TIP(S) IS (ARE) LIGHT GREY.

1. Refer to ENGINE SLOWS DOWN OR STOPS AT HIGH RPM and check items listed.
2. Check spark plug heat range.
- Spark plug heat range is too high. Replace by Bombardier's recommended spark plug (refer to
TECHNICAL DATA).
3. Check if air intake silencer leaks.
- Air surplus coming from opening(s) located between halves. Seal.
4. Check carburetor adapter collars.
- Loose collar(s). Tighten.
5. Check carburetor adapter(s).
- Cracked or deformed adapter(s). Replace.
6. Check if primary compression leaks.
- Primary compression leaks. Perform leak down test and repair as necessary.

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Section 02 TROUBLESHOOTING GUIDE
Subsection 05 (ELECTRICAL SYSTEM)

Symptom: RER (ROTAX ELECTRONIC REVERSE) DOES NOT WORK.

1. Check idle speed.
- Wrong idle speed. Adjust according to specification (refer to TECHNICAL DATA).
2. Check spark plug.
- Faulty spark plug. Replace.
3. Check drive belt deflection.
- Wrong deflection. Adjust according to specification (refer to TECHNICAL DATA).
4. Check carburetor synchronization and air screw adjustment.
- Wrong adjustment. Adjust according to specification (refer to TECHNICAL DATA) and read car-
buretor subsection.
5. Check electrical connections.
- Bad electrical connections or damaged wires. Clean or replace.
6. Check MPEM.
- Faulty MPEM. Replace.

Symptom: RER (ROTAX ELECTRONIC REVERSE) DOES NOT WORK (AT HIGH ALTITUDE).
1. Check high altitude cap continuity.
- Broken jumper inside high altitude cap. Replace high altitude cap.

Symptom: HEADLAMP NOT LIGHTING (WHITE BULB).

1. Check bulb.
- Gas leak. Replace bulb.

Symptom: HEADLAMP NOT LIGHTING (BROKEN ELEMENT).

1. Check for loose headlamp housing and bulb socket.
- Vibration problem. Tighten headlamp mounting screws. Lock bulb in socket. Replace bulb.

Symptom: HEADLAMP NOT LIGHTING. (MELTED FILAMENT (ENDS OF ELEMENT HOLD-

ER) AND BLACK BULB.)
1. Check voltage at headlamp at different speeds. It must not be above 15 Vac. (If quartz
halogen bulb is involved, ensure that proper voltage regulator is installed).
- Excessive voltage in lighting circuit. Replace voltage regulator and ensure proper grounding.
Retest.

Symptom: HEADLAMP DIMING.

1. Check voltage at headlamp at different speeds. It must not be below 11 Vac.
- 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.
- Heating, rotating or sharp part in contact with harness. Improper harness routing. Repair/replace
damaged wires and/or terminals. Reroute harness where necessary.
3. On manual start models: Verify regulator ground.
- Rusted or loose retaining screws. Clean, apply lithium grease (LMZ1) and firmly tighten screws.

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 Section 02 TROUBLESHOOTING GUIDE
Subsection 05 (ELECTRICAL SYSTEM)

Symptom: HEADLAMP DIMING. (cont’d)

4. Verify if there is an interconnection between AC and DC current (fan-cooled models).
- 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/BU). Disconnect and reconnect to AC
current (YL and YL/BK wires).
5. Verify if optional electric accessories are overloading the magneto/generator.
- Excessive electrical load to magneto/generator. Reduce the electrical load by removing excess
accessories. Reconnect as recommended by manufacturer.
6. Hot Grips brand: Verify if they were connected in parallel by mistake.
- Excessive electrical load to magneto/generator. Reconnect as recommended by manufacturer.
7. Bombardier heating grips: Verify if the return wires of the elements were grounded to the
chassis by mistake.
- Faulty installation of optional equipment. Reconnect as recommended by manufacturer.
8. Verify if heating grips installation overloads the magneto/generator capacity.
- Excessive electrical load to magneto/generator. Reduce the electrical load by removing acces-
sories.

Symptom: FALSE FUEL AND/OR TEMPERATURE GAUGE READINGS.

1. Verify if gauge was connected on DC current by mistake (in case of optional installation).
- Faulty installation of optional equipment. Find optional wires connected directly to DC ground
(BK wire to chassis) or to any DC hot wire (RD, RD/BU). Disconnect and reconnect to AC current
(YL and YL/BK wires).
2. Verify sender unit for resistance variation when moving float arm.
- Defective or damage part. Replace sender unit.
3. Verify sender unit for free movement and/or correct arm position.
- Defective or damaged part. Correct or replace sender unit.
4. Verify sender unit/gauge wiring harness condition.
- Heating, rotating or sharp part in contact with harness. Improper harness routing. Replace or
repair damaged wires. Reroute where necessary.

Symptom: WITH ENGINE IDLING NO ELECTRICAL ACCESSORIES WORK.

1. Check idle speed.
- Too low idle speed. Readjust to specifications.
2. Verify regulator.
- Faulty regulator. Replace.

Symptom: BRAKE LIGHT REMAINS ON.

1. Check if bulb is properly installed.
- Bulb is not installed correctly (contact elements are reversed). Install bulb correctly.
2. Check brake switch.
- Switch contact remains closed. On mechanical brake if brake switch is in good condition, adjust
brake cable or brake switch. On hydraulic brake, replace brake switch.
3. Check wiring harness.
- Shorted wiring harness. Replace or repair wiring harness.

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Section 02 TROUBLESHOOTING GUIDE
Subsection 05 (ELECTRICAL SYSTEM)

Symptom: REAR LIGHT BULB FLASHES.

1. Check bulb tightness in housing.
- Looseness at bulb contact elements. Install bulb correctly.
2. Check if rear light is properly connected.
- Connector housing is partially connected. Install connector housing properly.
3. Check continuity of wires.
- Corroded terminals and/or broken wires. Replace terminal(s) or crimp defective wires

Symptom: TACHOMETER DOES NOT WORK.

1. Check continuity of wires.
- Corroded terminals and/or broken wires. Replace terminal(s) or crimp defective wires.

Symptom: HIGH BEAM PILOT LAMP LIGHTS UP WHEN LOW BEAM IS SELECTED.
1. Check proper connections.
- 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.

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 Section 02 TROUBLESHOOTING GUIDE
Subsection 06 (SUSPENSION AND TRACK)

SUSPENSION AND TRACK

The following chart is provided to help diagnose the probable source of troubles. It should be used as a
guideline. Some causes or corrections may not apply to a specific model.
Symptom: SUSPENSION IS TOO LOW.
1. Check condition of springs.
- Springs are broken. Replace springs.
2. Check springs preload.
- Too low spring preload. Increase preload to the recommended position.
3. Check springs.
- Installed springs are too soft. Install optional stiffer springs, refer to Service Bulletin SPRING
REFERENCE ACCORDING TO LOAD.

Symptom: REAR SUSPENSION BOTTOMS OUT.

1. Check condition of springs.
- Springs are broken. Replace springs.
2. Check springs preload.
- Too low spring preload. Increase preload to the recommended position.
3. Check springs.
- Springs installed are too soft. Install optional stiffer springs, refer to Service Bulletin SPRING
REFERENCE ACCORDING TO LOAD.
4. Check the rear shock motion ratio position.
- It is adjusted in soft position. Adjust rear shock motion ratio to firm position.

Symptom: REAR SUSPENSION IS TOO STIFF.

1. Check rear spring preload.
- Too much preload. Adjust to a softer position.
2. Check springs.
- Springs installed are too stiff. Install optional softer springs, refer to Service Bulletin SPRING
REFERENCE ACCORDING TO LOAD.
3. Check the rear shock motion ratio position.
- It is adjusted in firm position. Adjust rear shock motion ratio to soft position.
4. Check track tension.
- Track is too tight. Adjust.
5. Check if axles are properly lubricated.
- Improper lubrication and/or contaminated grease (sticky oil sludge). Clean and/or lubricate.

Symptom: WHEN HANDLEBAR IS TURNED, SNOWMOBILE UNDERSTEERS.

1. Check ski runner condition.
- Worn ski runners. Replace.
2. Check ski spring preload.
- Insufficient ski pressure on the ground. Increase spring preload.

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Section 02 TROUBLESHOOTING GUIDE
Subsection 06 (SUSPENSION AND TRACK)

Symptom: WHEN HANDLEBAR IS TURNED, SNOWMOBILE UNDERSTEERS. (cont’d)

3. Check if front arm stopper strap is too long.
- Insufficient ski pressure on the ground. Shorten stopper strap.
4. Check front arm spring preload.
- Insufficient ski pressure on the ground. Loosen spring tension.

Symptom: HANDLEBAR IS DIFFICULT TO TURN.

1. Check if the handle bar turns freely when skis are off the ground.
- Ball joints corrosion restrains movement. Lubricate or replace the ball joint.
- Component need proper lubrication. Lubricate. Refer to MAINTENANCE.
- Bent parts. Replace parts.
2. Check ski spring preload.
- Too much preload. Reduce ski spring preload.
3. Check position of stopper strap.
- Too much weight when stopper strap is short. Lengthen front arm stopper strap.
4. Check position of front arm spring adjustment cam(s).
- When spring tension is weak, more weight is transferred to the skis. Increase spring preload.

Symptom: THE SNOWMOBILE ZIGZAGS.

1. Check ski runner condition.
- Worn or bent ski runners. Replace ski runners.
2. Check ski alignment.
- 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.
- Bushings are too loose. Replace.
4. Check ski pressure.
- Too much pressure on skis. Reduce ski spring preload and/or increase center spring preload.

Symptom: SLIDER SHOES WEAR OUT PREMATURELY/OR TRACK CLEATS BECOME BLUE.
1. Check track tension.
- Pressure is too great on slider shoes. Adjust according to specifications (refer to TECHNICAL
DATA). Replace defective parts.
2. Check idler wheel condition.
- Stuck bearing, flat spot on wheel or damaged wheel. Replace defective parts.
3. Check snow conditions or lack of snow.
- Lack of lubrication of slider shoes Ask driver to ride in appropriate snow conditions (see Opera-
tor's Guide).
4. Check slider shoes and/or suspension retaining screws.
- Twisted slider shoes or loose retaining screws. Replace defective parts and/or tighten loose
screws.

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 Section 02 TROUBLESHOOTING GUIDE
Subsection 06 (SUSPENSION AND TRACK)

Symptom: DERAILING TRACK.

1. Check track tension.
- Track is too loose. Adjust.
2. Check if track and slider shoes are properly aligned.
- Improper alignment. Adjust.

Symptom: NOISE OR VIBRATION COMING FROM THE TRACK.

1. Check slide suspension retaining bolts.
- Missing bolt(s) (some components interfere with track rotation). Replace missing bolt(s).
2. Check condition of idler wheel(s).
- Idler wheel rubber is damaged. Replace.
3. Check guide cleats.
- Top portion of guide cleat(s) is bent. Replace.
4. Check sprockets.
- One or several teeth of drive shaft sprockets are broken. Replace sprocket(s).
5. Check track tension.
- Track is too loose. Adjust to recommended tension.
6. Check track rods and/or internal traction teeth.
- One or several track rods and/or teeth are broken. Replace track.

mmr2005-009 http://ReadManuals.com 45
 Section 03 ENGINES (2-STROKE)
Subsection 01 (277 ENGINE TYPE)

277 ENGINE TYPE

SERVICE TOOLS
Description Part Number Page
18 mm sleeve kit .................................................................. 529 035 541 ........................................... 51
locating sleeve...................................................................... 529 023 800 ........................................... 51
piston circlip installer ............................................................ 529 035 561 ........................................... 54
piston pin puller .................................................................... 529 035 503 ........................................... 51
plate...................................................................................... 529 024 900 ........................................... 58
puller..................................................................................... 420 876 298 ........................................... 58
pusher................................................................................... 420 277 875 ........................................... 59
pusher................................................................................... 420 876 660 ........................................... 59
rubber pad ............................................................................ 529 023 400 ........................................... 51

SERVICE PRODUCTS
Description Part Number Page
anti-seize lubricant ................................................................ 293 800 070 ........................................... 58
Loctite 243............................................................................ 293 800 060 ........................................... 49
Loctite 30542........................................................................ 293 800 090 ........................................... 49

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Section 03 ENGINES (2-STROKE)
Subsection 01 (277 ENGINE TYPE)

ENGINE REMOVAL AND INSTALLATION

10 N•m
(89 lbf•in)

48 N•m 15 N•m
4 (133 lbf•in)
(35 lbf•ft)
10
Super Lube
grease

Super Lube
grease

Loctite 30542

21 N•m
2 (15 lbf•ft)
Loctite 243
Loctite 243
Super Lube
grease

16
25 N•m 48 N•m
(35 lbf•ft)
(18 lbf•ft)
10

1 48 N•m
(35 lbf•ft)
A05C1BS

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 Section 03 ENGINES (2-STROKE)
Subsection 01 (277 ENGINE TYPE)

REMOVAL FROM VEHICLE

Remove or disconnect the following then lift en-
gine from vehicle:
– guard
– drive belt
– muffler
– carburetor
– oil injection pump cable
– oil injection inlet line
– impulse line
– electrical connectors
– hood retaining cable
– engine mount nuts.

ENGINE SUPPORT AND MUFFLER

DISASSEMBLY AND ASSEMBLY
Torque the manifold screws no. 16 to 25 N•m
(18 lbf•ft).
Torque the support screws no. 4 to 15 N•m
(133 lbf•in) and nuts no. 1 to 48 N•m (35 lbf•ft).
Torque the engine support screws and nut no. 10
to 48 N•m (35 lbf•ft).
Apply Loctite 243 (P/N 293 800 060) on threads of
screw no. 2. Torque screws no. 2 retaining the
engine support to engine crankcase to 21 N•m
(15 lbf•ft).

INSTALLATION ON VEHICLE
To install engine on vehicle, reverse removal pro-
cedure. However, pay attention to the following:
– Check tightness of engine mount nuts, and
drive pulley screw.
– After throttle cable installation, check maximum
throttle slide opening.
– Check pulley alignment and drive belt tension.
– Seal exhaust ball joints with Loctite 30542
(P/N 293 800 090).

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Section 03 ENGINES (2-STROKE)
Subsection 01 (277 ENGINE TYPE)

TOP END

26 N•m
1 (19 lbf•ft)
2

22 N•m
(16 lbf•ft)

5
6

7
8

Molykote 111

A05C1CS

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 Section 03 ENGINES (2-STROKE)
Subsection 01 (277 ENGINE TYPE)

TROUBLESHOOTING Place a clean cloth or rubber pad (P/N 529 023

400) over crankcase to prevent circlips no. 8 from
Before completely disassembling the engine, falling into crankcase. Then with a pointed tool
check airtightness. Refer to LEAK TEST AND inserted in piston notch, remove both circlips from
ENGINE DIMENSION MEASUREMENT. piston no. 5.
NOTE: The following procedures can be done
without removing the engine from chassis.

TOP END REMOVAL (WITHOUT

REMOVING ENGINE FROM
CHASSIS)
Remove the following then lift cylinder head no. 3
and cylinder no. 4:
– belt guard
– carburetor
– exhaust system
– spark plug
– oil injection inlet
– fan cowl and hood cable
– cylinder head nuts no. 1 and washers no. 2. A02C29A

TYPICAL
CLEANING
Insert piston pin puller (P/N 529 035 503) making
Discard all gaskets. sure it sits squarely against piston.
Clean all metal components in a non-ferrous metal
cleaner.
Scrape off carbon formation from cylinder exhaust
port, cylinder head and piston dome using a wood-
en spatula.
NOTE: The letters “AUS” (over an arrow 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.

DISASSEMBLY
5, Piston
On this engine, piston pin needle bearing no. 6 is
mounted without a cage.
Use piston pin puller (P/N 529 035 503) along with A02C2AA 1
18 mm sleeve kit (P/N 529 035 541) and locating
TYPICAL
sleeve (P/N 529 023 800). 1. Properly seated all around
NOTE: The locating sleeve is the same that con-
tains new cageless bearing.

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Section 03 ENGINES (2-STROKE)
Subsection 01 (277 ENGINE TYPE)

Install sleeve then shouldered sleeve over puller 1 2 3

rod.
1 2

A02C2DA

TYPICAL
A02C2BA 1. Sleeve inside bearing
2. Thrust washer
TYPICAL — INSTALLATION OF SLEEVE KIT 3. Shouldered sleeve end
1. Sleeve
2. Shouldered sleeve
Remove puller. Pull out shouldered sleeve care-
Pull out piston pin no. 7 by unscrewing puller until fully.
shouldered sleeve end is flush with thrust washer
of piston pin bearing.

A02C2EA

TYPICAL
A02C2CA

Remove piston from connecting rod.

TYPICAL — PISTON PIN EXTRACTION

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 Section 03 ENGINES (2-STROKE)
Subsection 01 (277 ENGINE TYPE)

Install locating sleeve. Then push needle bearings

along with thrust washers and sleeve.

A02C2FA 1 2
TYPICAL
1. Locating sleeve
2. Sleeve
A02C2GA

NOTE: 0.25 and 0.5 mm oversize pistons and TYPICAL

1. Sleeve
rings are available if necessary.
Use a locking tie to fasten all needles and thrust Grease thrust washers and install them on each
washers along with locating sleeve. end of needles.
Insert cageless bearing into connecting rod.
INSPECTION
Refer to LEAK TEST AND ENGINE DIMENSIONS
MEASUREMENT.

ASSEMBLY
When reinstalling original needle bearings, make
sure that 31 needles are inserted between sleeve
and locating sleeve.
A02C2HA
When installing a new cageless bearing, replace
half plastic cages by sleeve. TYPICAL — CAGELESS BEARING AND SLEEVE INSTALLED

Mount piston over connecting rod with the letters

“AUS” (over an arrow on the piston dome) facing
in the direction of exhaust port.

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Section 03 ENGINES (2-STROKE)
Subsection 01 (277 ENGINE TYPE)

Install shouldered sleeve. Insert circlip in tool at an angle.

A02C2KA

1. Circlip

A02C2IA
Square it up using a finger.
TYPICAL — SHOULDERED SLEEVE INSTALLATION

1
Install piston pin puller and turn handle until piston
pin is correctly positioned in piston.

A02C2JA

TYPICAL

Remove piston pin puller and sleeve kit. A02C2LA

To minimize the effect of acceleration forces on 1. Circlip

circlip, install each circlip so the circlip break is at
6 o'clock as illustrated. Use piston circlip installer
(P/N 529 035 561).

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 Section 03 ENGINES (2-STROKE)
Subsection 01 (277 ENGINE TYPE)

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
1. Circlip break facing down
A02C2MA
Hold tool firmly against piston then strike on round
Using square end of tool, push circlip in until it end of tool. Circlip will move from tool groove to
rests in groove. piston groove.

A02C2PA

TYPICAL

A02C2NA

1. Circlip in groove

A01C02A 2
1. Piston notch
2. Circlip break

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Section 03 ENGINES (2-STROKE)
Subsection 01 (277 ENGINE TYPE)

CAUTION: Circlips must not move freely in the

groove after installation. If so, replace them.
Before inserting piston in the cylinder, lubricate
the cylinder with new injection oil or equivalent.
Position cylinder head on cylinder with fins in line
with crankshaft center line. Cross torque retaining
nuts to 26 N•m (19 lbf•ft).

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 Section 03 ENGINES (2-STROKE)
Subsection 01 (277 ENGINE TYPE)

BOTTOM END

Molykote 111

1 3
5

Molykote 111
Molykote 111

Loctite 76732

6
4

Loctite 648
2 7
22 N•m
(16 lbf•ft)

A05C1DS

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Section 03 ENGINES (2-STROKE)
Subsection 01 (277 ENGINE TYPE)

NOTE: Engine must be removed from chassis to

perform the following procedures. M8 x 110 mm
1
CLEANING
Discard all oil seals and gaskets.
Clean all metal components in a non-ferrous metal
cleaner.

DISASSEMBLY
General
To remove drive pulley, refer to DRIVE PULLEY.
To remove magneto, refer to MAGNETO.
2
2,6, Crankcase Half A05C0HA

Heat to 110 - 120°C (230 - 248°F) all around 1. Plate

2. Flat washers
bearing seat on PTO side. Install puller (P/N 420
876 298) to plate (P/N 529 024 900) with flat To remove seals no. 3 and 4, push from outside
washer under screw heads and extract PTO side the crankcase towards the inside.
crankcase half no. 1.
To remove bearings no. 5 and 6 from crankshaft
use a protective cap and special puller as illustrat-
ed.

M8 x 40 1
M8 x 30 2

2
A00B28A

1. Protective cap
2. Special puller

INSPECTION
A05C0GA
Refer to LEAK TEST AND ENGINE DIMENSION
1. Plate MEASUREMENT.
2. Flat washer

Heat to 110 - 120°C (230 - 248°F) all around bear-

ASSEMBLY
ing seat on MAG side. Install puller with plate, Install connecting rod with its lubrication slot on
long bolts M8 x 110 mm and flat washers. Extract big end facing exhaust side.
MAG side crankcase half no. 2. Smear anti-seize lubricant (P/N 293 800 070) on
part of crankshaft where bearing fits.

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 Section 03 ENGINES (2-STROKE)
Subsection 01 (277 ENGINE TYPE)

Prior to installation, place bearings into an oil con-

tainer and heat the oil to 75°C (167°F) for 5 to 10
min. This will expand bearings and ease installa-
tion.
Install bearings with groove outward.
NOTE: Crankshaft end play requires adjustment
only when crankshaft and/or crankcase is re-
placed. Prior to magneto side bearing installation,
determine crankshaft end play and install required
shim(s) on crankshaft extension. For the crank-
shaft end play adjustment procedure, refer to
LEAK TEST AND ENGINE DIMENSION MEA-
SUREMENT.
Prior to crankcase adjoining, install a protector
sleeve on each crankshaft extension to prevent oil
seal damage. Apply a light coat of lithium grease
on seal lip. Spray some new injection oil on all
moving parts of the crankshaft.
A05C0JA
Install crankshaft seals with pusher (P/N 420 277
875) for MAG side seal no. 4 and pusher (P/N 420
Torque the screws no. 7 to 22 N•m (16 lbf•ft) fol-
876 660) for PTO side seal no. 3.
lowing illustrated sequence.
CAUTION: To ensure appropriate crankshaft
bearing lubrication, seal outer surface must be
pressed against seal crankcase shoulder. 1
Using a press, install crankshaft into MAG side 3
crankcase half.

A02C04A
2

A05C0IA

Press down PTO side crankcase half onto crank-

shaft using appropriate spacer(s).

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 Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

443 AND 552 ENGINES

SERVICE TOOLS
Description Part Number Page
bearing heater....................................................................... 529 035 969 ..................................... 70, 79
circlip installer ....................................................................... 529 035 686 ........................................... 72
distance gauge ..................................................................... 420 876 822 ........................................... 79
distance gauge ..................................................................... 529 035 965 ........................................... 80
feeler gauge.......................................................................... 420 876 620 ........................................... 79
piston circlip installer ............................................................ 529 035 561 ........................................... 71
piston pin puller .................................................................... 529 035 503 ........................................... 67
protective cap ....................................................................... 420 876 552 ........................................... 77
protective cap ....................................................................... 420 876 557 ........................................... 78
rubber pad ............................................................................ 529 023 400 ........................................... 67
screws .................................................................................. 420 840 681 ........................................... 77
support plate......................................................................... 529 035 976 ........................................... 80
temperature indicator stick................................................... 529 035 970 ........................................... 79

SERVICE PRODUCTS
Description Part Number Page
anti-seize lubricant ................................................................ 413 701 000 ........................................... 78
Isoflex grease ....................................................................... 293 550 021 ........................................... 81
Loctite 518............................................................................ 293 800 038 ........................................... 73
Loctite 5910.......................................................................... 293 800 081 ........................................... 82
Loctite Chisel........................................................................ 413 708 500 ............................... 67, 73, 77
pulley flange cleaner............................................................. 413 711 809 ........................................... 78
RTV sealant........................................................................... 293 800 090 ........................................... 64
synthetic grease ................................................................... 413 711 500 ........................................... 77

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Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

ENGINE REMOVAL AND INSTALLATION

443 Engine

High temperature
RTV sealant

A29C2BS 39 N•m (29 lbf•ft)

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 Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

552 Engine

39 N•m
A29C2US (29 lbf•ft)

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Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

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.
Tighten fasteners to recommended torque in ap-
propriate exploded view.
Apply high temperature RTV sealant (P/N 293 800
090) on metal-to-metal exhaust joints.

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 Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

TOP END
443 Engine

22 N•m
(16 lbf•ft)

2 2
1

3
21 N•m
(15 lbf•ft)

Anti-seize
Loctite

5
6 21 N•m
(15 lbf•ft)

5
6

7
22 N•m
(16 lbf•ft)
8
9
10

Injection oil
A29C2VS

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Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

552 Engine

22 N•m
(16 lbf•ft)
2

3
21 N•m
(15 lbf•ft)

6 11
4

5 N•m
(44 lbf•in) 11

6
13

12
8
11
9
10

Injection oil

A32C67T

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 Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

GENERAL
CAUTION: While performing any engine relat-
ed procedure, always make sure that the work-
ing area is clean and free from dust or particles
to reduce the risk of damaging the engine.

TROUBLESHOOTING
Before completely disassemble engine, check air-
tightness. Refer to LEAK TEST AND ENGINE DI-
MENSION MEASUREMENT.
NOTE: The following procedures can be done
without removing the engine from chassis.

CLEANING
Discard all gaskets. Use Loctite Chisel (P/N 413 A02C29A

708 500) to clean mating surfaces. TYPICAL

Clean all metal components in a non-ferrous metal
cleaner. 443 and 552 Engines
Scrape off carbon formation from cylinder exhaust On these engines, piston pin needle bearing is
port, cylinder head and piston dome using a wood- mounted without a cage.
en spatula. NOTE: The PTO cylinder or fan housing have to be
NOTE: The letters “AUS” and arrow on the piston removed to give access to MAG piston pin with
dome must be visible after cleaning. Clean the the puller.
piston ring grooves with a groove cleaner tool, or Use piston pin puller along with sleeve kit and lo-
with a piece of broken ring. cating sleeve as per following table.

PULLER SLEEVE KIT LOCATING

DISASSEMBLY ENGINE
P/N P/N SLEEVE P/N
Remove top fan cowl, intake sockets and lower 529 035 541
443 529 035 503 529 023 800
fan cowl. (18 mm)
Remove cylinder heads. 529 035 542
552 529 035 503 529 023 800
(20 mm)
Remove cylinders.
Place a clean cloth or rubber pad (P/N 529 023 NOTE: The locating sleeve is the same that con-
400) over crankcase to prevent circlips no. 10 from tains new cageless bearing.
falling into crankcase. Then with a pointed tool Insert piston pin puller (P/N 529 035 503) making
inserted in piston notch, remove both circlips from sure it sits squarely against piston.
piston no. 8.

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Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

A02C2CA

TYPICAL — PISTON PIN EXTRACTION

A02C2AA 1 1 2 3

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

A02C2BA

TYPICAL — INSTALLATION OF SLEEVE KIT

1. Sleeve
2. Shouldered sleeve

Pull out piston pin no. 10 by unscrewing puller

until shouldered sleeve end is flush with thrust
washer of piston pin bearing.

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 Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

Remove puller. Pull out shouldered sleeve care- ASSEMBLY

fully.
443 and 552 Engines
When reinstalling original needle bearings, make
sure that 31 needles (in case of 443 engine) or
34 (in case of 552 engine) are inserted between
sleeve and locating sleeve.
When installing a new cageless bearing, replace
half plastic cages by sleeve.

A02C2EA

TYPICAL

Remove piston from connecting rod.

Install locating sleeve. Then push needle bearings 1
along with thrust washers and sleeve.

A02C2GA

TYPICAL
1. Sleeve

Grease thrust washers and install them on each

end of needles.
Insert cageless bearing into connecting rod.
A02C2FA 1 2
TYPICAL
1. Locating sleeve
2. Sleeve

NOTE: 0.25 and 0.5 mm oversized piston and

rings are available if necessary.
Use a locking tie to fasten all needles and thrust
washers along with locating sleeve.
A02C2HA

INSPECTION TYPICAL — CAGELESS BEARING AND SLEEVE INSTALLED

Refer to ENGINE DIMENSION MEASUREMENT.

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Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

Heat piston using bearing heater (P/N 529 035

969).

A02C2IA

TYPICAL — SHOULDERED SLEEVE INSTALLATION

A32CBHA

Install piston pin puller and turn handle until piston

CAUTION: Piston temperature must not exceed pin is correctly positioned in piston.
46°C (115°F). NEVER USE DIRECT FLAME to
heat the piston and never freeze the pin. In-
appropriate heating procedure(s) may damage
the piston.
Mount piston over connecting rod with the letters
“AUS” (over an arrow on the piston dome) facing
in the direction of exhaust port.

1
AUS
A02C2JA

TYPICAL

Remove piston pin puller and sleeve kit.

A01C01A

1. Exhaust

Install shouldered sleeve.

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 Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

443 Engine
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.

1
A02C2MA

Using square end of tool, push circlip in until it

rests in groove.

A02C2KA

1. Circlip 1

Square it up using a finger.

A02C2NA

1. Circlip in groove

A02C2LA

1. Circlip

Continue to square it up using round end of circlip

installer.

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Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

Mount tool in piston making sure that circlip break

is facing down.

A32B0AA

With round end of pusher, position circlip perpen-

dicular to the support axis.

A02C2OA 1
TYPICAL
1. Circlip break facing down

Hold tool firmly against piston then strike on round

end of tool with a plastic hammer. Circlip will
move from tool groove to piston groove.

A32B0BA

With the other end of the pusher, push circlip into

1 the support groove.

A32B0CA
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.
552 Engine
Use circlip installer (P/N 529 035 686) to install
new mono-hook circlips no. 10. 1
Insert circlip into support in such a way that when A32B0DA

installed in piston groove, the tab will face upward. 1. Groove

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 Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

CAUTION: Always install a gasket of the proper

thickness. Failure to do so may cause detona-
tion and severe engine damage.
All Engines
Before inserting piston in cylinder no. 4, lubricate
the cylinder with new injection oil or equivalent.
Install proper ring compressor on piston assembly.

RING COMPRESSOR
ENGINE
P/N
A32B0EA
443 420 876 090
CIRCLIP READY TO BE INSTALLED ON PISTON
552 420 876 972
Using a plastic hammer, tap pusher to insert circlip
in place. Take care to install new circlips with tab NOTE: The ring compressor will not fit on over
toward top as per following photo. size pistons.
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.

ENGINE ALIGNING TOOL P/N

443 and 552 420 876 171

A32C4BA

TAB TOWARD TOP

420 876 171
CAUTION: Always install new mono-hook cir-
clips. If circlip installation fails at the first at-
tempt, always retry with a new one as on a sec-
ond attempt circlip will lose its normal retain-
ing capabilities.
CAUTION: Circlips must not move freely after
installation; if so, replace them. A17C01A

Clean cylinders and crankcase mating surfaces

with Loctite Chisel (P/N 413 708 500).
Coat crankcase mating surface with Loctite 518
(P/N 293 800 038). Choose the right gasket thick-
ness according to combustion chamber volume.
Refer to LEAK TEST AND ENGINE DIMENSION
MEASUREMENT. Install it on crankcase. Coat
gasket with Loctite 518.

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Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

With blade stopper no. 13 removed, check reed

valve for proper tightness. There must be no play
between blade and valve body when exerting a
finger pressure on blade at blade stopper location.
In case of a play, turn blade upside down and
recheck. If there is still a play, replace blade and/or
valve body.

1 1
A17C02A

1. Or use exhaust manifold to align cylinders

Position distance nuts no. 2 as shown below.

A06C0FA

1. No play

Check distance from blade stopper inner edge and

distance from center of reed valve block.

A03C1XA 2 1 A A
1. Exhaust
2. Distance nuts

Cross torque cylinder head nuts no. 1 and no. 2

to 22 N•m (16 lbf•ft); torque each cylinder head
individually. A06C36A

Install armature plate, fan housing and then air de- TYPICAL
flector. A. 14.75 - 0, + 0.75 mm (.580 - 0, + .030 in)

Install a gasket on each side of the air deflector. Bent blade stopper as required to obtain the prop-
Torque intake socket bolts to 22 N•m (16 lbf•ft). er distance.
552 Engine Blade stoppers may slightly interfere with cylinder
during installation. Adjusted distance will be re-
12, Reed Valve duced automatically upon installation.
Blades have a curved shape. Install with their
curve facing reed block.

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 Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

BOTTOM END
443 Engine

1
2 Multi-purpose
grease

3
Anti-seize
lubricant
3
Anti-seize
lubricant

6 Anti-seize
lubricant
6

Loctite
Loctite 243
Anti-seize
5910 lubricant

12
4

22 N•m 5
(16 lbf•ft) 2

503: 22 N•m
(16 lbf•ft)
443: 10 N•m
(89 lbf•in)
22 N•m
A29C2WT (16 lbf•ft)

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Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

552 Engine

Isoflex

3
2
6 3
Anti-seize
lubricant

Loctite 243

6
Anti-seize
lubricant
Engine 4
oil 6 Anti-seize
lubricant 2

5 Loctite 243
Loctite 5910

Loctite 243

11 N•m
(97 lbf•in)

40 N•m
(30 lbf•ft)
27 N•m
A29C2XT
(20 lbf•ft)

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 Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

NOTE: Engine must be removed from chassis to

perform the following procedures.
Remove engine from chassis.
Remove fan guard, rewind starter, starting pulley,
trigger coil wire from 4-connector housing, mag-
neto flywheel then fan housing.
Remove stator plate.

CLEANING
Discard all seals, gaskets and O-rings.
Clean all metal components in a non-ferrous met-
al cleaner. Use Loctite Chisel (P/N 413 708 500)
accordingly. 1
Remove all trace of Loctite from crankshaft taper.
Remove old sealant from crankcase mating sur-
faces with Loctite Chisel (P/N 413 708 500).
A32CB1A
CAUTION: Never use a sharp object to scrape
away old sealant as score marks incurred are 1. Protective cap
detrimental to crankcase sealing.
Using screws (P/N 420 840 681), install bearing
DISASSEMBLY puller on the half rings.

To remove PTO side bearing no. 3 from crank-

shaft, install half rings on the bearing.
NOTE: Remove the bearing O-ring prior to instal-
lation of half ring.

A32CB2A

PULLER INSTALLED ON THE HALF RINGS

Secure the bearing puller in a vise by one of its rib.

A32CB0A

1. Half ring
2. Puller ring

Apply synthetic grease (P/N 413 711 500) on the

crankshaft end and install protective cap (P/N 420
876 552).

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Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

INSPECTION
Refer to ENGINE DIMENSIONS MEASUREMENT.

ASSEMBLY
Clean crankshaft end with sand paper no. 180
and remove all residue using pulley flange cleaner
(P/N 413 711 809).

A32CB3A

BEARING PULLER SECURED IN THE VISE

CAUTION: Never use any air impact tool to

tighten the puller bolt.
Lubricate the puller bolt and then proceed with
tightening the puller bolt until the bearing comes
out.
Follow the same procedure for the inner bearing.
NOTE: In the case of damaged bearing or less
clearance between crankshaft counterbalance and
the bearing, use bearing separator (Snap-On tool
(P/N CJ951)) or (SPX/OTC tool (P/N 1124)) to facil-
itate the removal.
A32CB5A

Smear anti-seize lubricant (P/N 413 701 000) on

part of crankshaft where bearing fits.

A32CB4A 1
1. Bearing separator

Procedure for MAG side bearings no. 4 is same as

of PTO side with the exception of protective cap
(P/N 420 876 557). A32CB6A

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 Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

443 Engine CAUTION: Bearing should not be heated to

To check proper clearance between bearing no. 3 more than 80°C (176°F). Do not heat bearing
with direct flame or heat gun or heated oil.
and crankshaft counterbalance, use feeler gauge Inappropriate heating procedure(s) may cause
(P/N 420 876 620). inner seal failure.
Mount second bearing with distance gauge Turn bearing(s) several times during heating
(P/N 420 876 822) for 443 for proper positioning. process for heating it/them properly.
1 2 NOTE: Normally it takes approximately 10 min-
utes to heat up a bearing. So in the event of re-
placing a bearing, it is recommended to start heat-
ing it prior to removal. Two bearings can be heat-
ed at the same time on one bearing heater.

A00C46A

1. Feeler gauge
2. Distance gauge

Prior to installation, heat the bearing as per the

procedure given further in this subsection.
This will expand bearings and ease installation. In-
A32CB8A
stall bearings with groove as per exploded view.
1. Bearings
552 Engine
Heat up the bearing(s) using bearing heater Touch the inner race of the bearing with the tem-
(P/N 529 035 969). This will expand bearings perature indicator stick (P/N 529 035 970). Stick
and ease installation. If required, put a suitable will liquefy when the bearing reaches the proper
plate or shim to avoid the direct contact between temperature.
integrated seal and the heating surface.

A32CB9A

A32CB7A

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Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

 WARNING
Do not touch heated bearing with bare hands.
Wear heat resisting gloves before handling
the heated bearing(s).

Slide in the inner PTO bearing with the integrated

seal facing crankshaft. Push bearing to end posi-
tion.

1
A32CBCA

1. Support plate
2. Distance gauge

Install bearing locator tool.

A32CBAA

A32CBBA

BEARING TO END POSITION

A32CBDA

Install the O-ring.

Make a bearing locator tool using support plate Slide in the heated outer PTO bearing onto the
(P/N 529 035 976) and distance gauge (P/N 529 crankshaft.
035 965).

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 Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

A03C1HA 1
TYPICAL
1. Drive pins

552 Engine
CAUTION: Use only the recommended Isoflex
grease (P/N 293 550 021). Make sure not to
A32CBEA push Isoflex grease between outside bearing
race and half crankcase.
Install the MAG side heated bearing. NOTE: The 50 g tube corresponds to 50 cc of
grease.
Put 27 to 32 mL of grease in a syringe.
With the syringe, fill the PTO side ball bearings
with 27 to 32 mL of Isoflex grease as shown be-
low.

A32CBFA

All Engines
Bearings are pressed on crankshaft until they rest
against radius. These radius maintain the gap A32CBGA

needed for bearings lubrication.

All Engines
When installing crankshaft, position drive pins
no. 6 as illustrated. At seal no. 2 assembly, apply a light coat of lithium
grease on seal lip.
For bearing lubrication purpose, a gap of 1.0 mm
(.040 in) must be maintained between seals and
bearings.

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Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

When installing plain oil seals (seal without locat- CAUTION: Do not use Loctite 515 or 518 to seal
ing ring or without spacing legs), ensure to main- crankcase. Do not use Loctite Primer N with
tain 1.0 mm (.040 in) gap. the Loctite 5910. Using these products or non
silicone-based sealant over a previously sealed
1 A
crankcase with Loctite 5910 will lead to poor
adhesion and possibly a leaking crankcase.
These products are chemically incompatibles.
Even after cleaning, the Loctite 5910 would
leave incompatible microscopic particles.
2 Use a plexiglass plate and apply some sealant on
it. Use a soft rubber roller (50 - 75 mm (2 - 3 in))
(available in arts products suppliers for printmak-
ing) and roll the sealant to get a thin uniform coat
3 on the plate (spread as necessary). When ready,
apply the sealant on crankcase mating surfaces.

A17C07A

1. Bearing
2. Feeler gauge
3. Plain oil seal
A. 1 mm (.040 in)

Crankcase halves no. 1 and no. 5 are factory

matched and therefore, are not interchangeable
as single halves.
Crankcase Assembly
IMPORTANT: The total assembly sequence, in-
cluding sealing compound spreading, screwing F12R17A

and torquing of bolts according to the proper

sequence 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 a Loctite 5910 (P/N 293 800 081).
NOTE: It is recommended to apply this specific
sealant as described here to get an uniform ap-
plication without lumps. If you do not use the
roller method, you may use your finger to uniform-
ly distribute the sealant (unlike the Dreibond seal-
ing compound, using a finger will not affect the
adhesion).
Use the silicone-based Loctite 5910 (P/N 293 800 F12R18A

081) on mating surfaces.

Do not apply in excess as it will spread out inside
NOTE: The sealant curing time is similar to the
crankcase.
Loctite 518 without using the Primer N.
CAUTION: If sealant spreads out inside air com-
pressor area, it could plug the compressor lu-
brication nipple and serious compressor dam-
age may occur.

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 Section 03 ENGINES (2-STROKE)
Subsection 02 (443 AND 552 ENGINES)

NOTE: Do not use Loctite Primer N with this BREAK-IN

sealant. The sealant curing time is similar to the
Loctite 518 without using the Primer N, which is After rebuilding an engine always observe a break-
4 to 24 hours. in period as described in Operator's Guide.
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 (13 N•m (115 lbf•in) for M8
bolts), then, tighten to the required torque (i.e.
22 N•m (16 lbf•ft)).
552 Engine

13 9 7 1 3 5 11

14 10 6 4 2 8 12
A17C08A

TIGHTENING SEQUENCE FOR 552 ENGINE TYPE

443 Engine

9 7 13 A 11 5
1 3

4 2
10 8 14 A 12 6
A09C05A

TIGHTENING SEQUENCE FOR 443 ENGINE TYPE

A. 10 N•m (89 lbf•in ). All the other screws are torqued
to 22 N•m (16 lbf•ft)

All Engines
To install magneto, refer to MAGNETO SYSTEM.

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 Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

593 AND 593 HO SDI ENGINES

SERVICE TOOLS
Description Part Number Page
20 mm sleeve kit .................................................................. 529 035 542 ........................................... 93
bearing heater....................................................................... 529 035 969 ................................... 96, 104
bearing puller ........................................................................ 529 036 004 ......................................... 102
circlip installer ....................................................................... 529 035 686 ........................................... 97
crankshaft protector ............................................................. 420 876 552 ......................................... 102
crankshaft protector ............................................................. 420 876 557 ................................. 102–103
half rings ............................................................................... 420 977 479 ......................................... 102
piston pin puller .................................................................... 529 035 503 ........................................... 93
puller ring.............................................................................. 420 977 494 ......................................... 102
rubber pad ............................................................................ 529 023 400 ........................................... 92
screws .................................................................................. 420 840 681 ......................................... 102
support plate......................................................................... 529 035 976 ......................................... 105
temperature indicator stick................................................... 529 035 970 ......................................... 104
vacuum/pressure pump........................................................ 529 021 800 ........................................... 90

SERVICE PRODUCTS
Description Part Number Page
anti-seize lubricant ................................................................ 413 701 000 ......................................... 103
BOMBARDIER LUBE ........................................................... 293 600 016 ......................................... 102
Dreibond sealing compound ................................................ 420 297 906 ........................................... 95
grease................................................................................... 413 711 500 ......................................... 102
Isoflex grease ....................................................................... 293 550 021 ................................. 105–106
Loctite 518............................................................................ 293 800 038 ........................................... 98
Loctite 5910.......................................................................... 293 800 081 ......................................... 107
Loctite Chisel........................................................................ 413 708 500 ................................... 98, 102
Petamo grease ..................................................................... 420 899 271 ......................................... 103
pulley flange cleaner............................................................. 413 711 809 ......................................... 103
Ultra Copper ......................................................................... 413 710 300 ........................................... 86

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Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

Skandic WT LC/SUV 600/Expedition – Seal exhaust ball joints with Ultra Copper
TUV 600 HO SDI (P/N 413 710 300).

REMOVAL FROM VEHICLE

Open hood.
Expedition TUV 600 HO SDI
Using B.U.D.S. software, remove the pressure
in the fuel system. Refer to ENGINE MANAGE-
MENT.
All Models
Remove tuned pipe and muffler.
Drain engine coolant.
Remove or unplug the following then lift off en-
gine from engine compartment.
NOTE: Use of a hoist is recommended.
– guard
– air silencer
– drive belt
– rewind starter handle
– drive pulley (not necessary if engine is not dis-
assembled)
– hood
– carburetors/throttle body (as applicable)
– 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 radi-
ator
– 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
carburetor/throttle body maximum throttle
opening and oil injection pump adjustment.
– Check pulley alignment and drive belt tension.

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 Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

TOP END
593 Engine
Sealing compound Dreibond
8 N•m
8 N•m (71 lbf•in)
(71 lbf•in)
30
29 N•m 24 29 N•m
(21 lbf•ft)
(21 lbf•ft)
24

5.5 N•m
2 (49 lbf•in)
5
3 N•m
(27 lbf•in)
Loctite 9 6
243
3 7
11 8
29 N•m 12 10
(21 lbf•ft) 13
26 Sealing
22 compound
Dreibond
4 15 14
Molykote G-N paste
7.5 N•m
(66 lbf•in) M8:
23 N•m
(17 lbf•ft)

1.5 N•m
(13 lbf•in)
5.5 N•m 21
(49 lbf•in)
16
1
17
19
18
Injection oil
20
Injection oil

A29C2ST

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Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

593 HO SDI Engine

Sealing 5.5 N•m 24 23 N•m
compound (49 lbf•in) (17 lbf•ft)
Dreibond 8 N•m
(71 lbf•in) Loctite
8 N•m
(71 lbf•in) 29 N•m 5910 20
30 (21 lbf•ft) 19
24 18
29 N•m 24
(21 lbf•ft) 20
23

2
Injection
oil

5.5 N•m
3 (49 lbf•in)
Sealing 5
compound
Dreibond

6
40 N•m 40 N•m 7
7.5 N•m (30 lbf•ft) (30 lbf•ft)
(66 lbf•in) 27 8
26
Multi-purpose 9 3 N•m
grease 12 (27 lbf•in)
11
22 10
25
13
5.5 N•m 14
(49 lbf•in) Engine oil
9 N•m
(80 lbf•in) 15

1.5 N•m
(13 lbf•in) 28
16
4

17 21
5.5 N•m 1
(49 lbf•in)
Loctite 518 M6:
11 N•m
5.5 N•m (97 lbf•in)
A33C3R S
(49 lbf•in) 21

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 Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

GENERAL
CAUTION: While performing any engine relat-
ed procedure, always make sure that the work-
ing area is clean and free from dust or particles
to reduce the risk of damaging the engine.

TROUBLESHOOTING
Before completely disassembling the engine,
check airtightness. Refer to LEAK TEST AND
ENGINE DIMENSION MEASUREMENT.

COMPONENT REMOVAL
Most engine components can be removed with
engine in vehicle such as:
– cylinder head A32C94A 1
– piston(s) 1. Pressure from solenoid
– cylinder(s)
2
– rewind starter
– oil pump
– water pump
– magneto flywheel
– RAVE valve(s)
– reed valve(s).

CLEANING
Discard all gaskets and O-rings.
Clean all metal components in a non-ferrous metal
cleaner.
Scrape off carbon formation from cylinder exhaust
port, cylinder head and piston dome using a wood-
en spatula. A32C95A 4 1 3
NOTE: The letters “AUS” (over an arrow on the 1. Solenoid
piston dome) must be visible after cleaning. 2. Pressure to RAVE valves
3. Vent to throttle body
Clean the piston ring groove with a groove cleaner 4. Pressure with check valve from crankcase
tool or with a piece of broken ring.
To close the RAVE valves, the ECM deactivates
the solenoid. In the closed position, the RAVE
RAVE VALVE BASIC OPERATION valves are vented through the intake manifold.
593 HO SDI Engine
The RAVE valves change the height of the exhaust
port. The RAVE valve solenoid, which is controlled
by the ECM, allows positive crankcase pressure to
inflate the bellows and open the RAVE valves.
To open the RAVE valves, the ECM activates a
solenoid which directs the pressure to the valves.

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Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

Maintenance
All Engines
There are no wear parts anywhere in the system
and there are no adjustments to be periodically
checked. The only possible maintenance required
would be cleaning of carbon deposits from the 2
guillotine slide. Cleaning intervals would depend
upon the user's riding style and the quality of the
oil used.
BRP suggests annual cleaning of the valve. If a
customer uses lower quality oil, than recommend- 1
ed, more frequent cleaning may be required.
No special solvents or cleaners are required when
cleaning the valve. 2

On SDI models, check if solenoid heating ele-

A32C96A
ment is still functional once a year, the element
should be warm after one minute of riding (mea- TYPICAL
1. RAVE valve cover
sure should be between 0.0 to 0.4 ohms). At 2. Screws
the same time, using a vacuum/pressure pump
(P/N 529 021 800), check if crankcase check valve Remove the compression spring no. 8.
is still functional.
NOTE: Make sure hoses are not kinked or dam-
aged.

Boring Precaution
All Engines
In its stock configuration, the RAVE valve guillo-
tine has a minimum of 0.5 mm (.020 in) clearance
to the cylinder bore measured at the center line
of the cylinder. This is the minimum production
clearance.

DISASSEMBLY
RAVE System
NOTE: RAVE stands for Rotax Adjustable Variable A32C97A
Exhaust.
Remove RAVE valve cover no. 7 by removing Unscrew the Allen socket screws no. 22 then re-
screws no. 5. move the RAVE valve base no. 13.

 WARNING
Firmly hold cover to valve base. The com-
pression spring inside the valve is applying
pressure against the cover.

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 Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

A32C98A 1
TYPICAL A32C9AA 1 2 3
1. Allen socket screws
2. RAVE valve base 1. Spring
2. Valve piston
3. Bellows
Unscrew and remove the guillotine no. 15 from
the valve piston no. 9 than remove the gasket Remove the valve piston.
no. 14.
1

A32C9BA

A32C99A 2 3 Remove the small spring no. 12 retaining bellows

1. Guillotine to valve base.
2. Gasket
3. Valve piston

Remove spring no. 10 retaining bellows no. 11 to

valve piston.

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Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

All Engines
Unplug coolant hose from upper thermostat hous-
ing no. 30.
Unscrew all cylinder head cover screws no. 24.

Cylinder Head
Remove the cylinder head cover no. 2.
Disconnect the temperature sensor connector.
Remove the cylinder head no. 3.

Cylinder
593 HO SDI Engine
A32C9CA 1 2 3
Release the fuel pressure of the system. Refer to
1. Bellows COMPONENT INSPECTION AND ADJUSTMENT.
2. Small spring
3. Valve base Unplug fuel injector connectors then remove the
fuel rail no. 25. Refer to COMPONENT INSPEC-
Remove bellows from valve base. TION AND ADJUSTMENT.
All Engines
Remove cylinder head no. 3.
Remove manifold and RAVE valves.
Unscrew cylinder screws no. 26 and no. 27 then
remove the cylinder(s) no. 4.

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 both circlips no. 20 from
piston no. 18.

A32C9DA

REED Valve
If applicable, remove intake resonator on top of
reed valves no. 1.
Unscrew reed valve screws no. 21 then remove
reed valve(s).

Cylinder Head Cover

Unplug spark plug cables.
593 HO SDI Engine
Disconnect the knock sensor no. 23.
A02C29A

TYPICAL

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 Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

This engine is equipped with cageless piston pin 1 2

bearings.

A02C2BA

A32C17A TYPICAL — INSTALLATION OF SLEEVE KIT

1. Sleeve
2. Shouldered sleeve
Use piston pin puller (P/N 529 035 503) along with
20 mm sleeve kit (P/N 529 035 542) and locating Screw (LH threads) extracting nut.
sleeve. Pull out piston pin no. 19 by unscrewing puller
NOTE: The locating sleeve is the same that con- until shouldered sleeve end is flush with thrust
tains new cageless bearing. washer of piston pin bearing.
Insert piston pin puller (P/N 529 035 503) making
sure it sits squarely against piston.

A02C2CA

TYPICAL — PISTON PIN EXTRACTION

A02C2AA 1
TYPICAL
1. Properly seated all around

Install sleeve then shouldered sleeve over puller

rod.

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Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

1 2 3

A02C2FA 1 2
TYPICAL
A02C2DA 1. Locating sleeve
2. Sleeve
TYPICAL
1. Sleeve inside bearing
2. Thrust washer
3. Shouldered sleeve end Exhaust Manifold
593 HO SDI Engine
Remove puller. Pull out shouldered sleeve care-
fully. Upon removal of the exhaust manifold no. 28, you
must heat M6 bolt heads for 30 seconds before
loosening.
NOTE: Heat one bolt at a time.

INSPECTION
Cylinder Head Cover, Cylinder
Head and Cylinder
NOTE: Refer to LEAK TEST AND ENGINE DIMEN-
SIONS MEASUREMENT.

RAVE System
A02C2EA
Check valve rod housing and cylinder for clogged
passages.
TYPICAL

Remove piston from connecting rod.

Install locating sleeve. Then push needle bearings
along with thrust washers and sleeve.

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 Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

2
1

A32CD0A
A32C16A 2 1
TYPICAL
1. Draining hole 1. Locking tie
2. Passages 2. Spring

NOTE: Oil dripping from draining hole indicates a Install RAVE valve with its mention “TOP” as illus-
loosen spring or damaged bellows. trated in the following photo.

Bellows
Check for cracked, dried or perforated bellows
no. 11.

Spring
Check if the compression springs no. 87 are in
specifications.

WIRE
FREE
SPRING DIA.
ENGINE COLOR LENGTH
P/N mm
mm (in)
(in)
1.0 38.0 A32C15A
593 420 239 948 GREY
(.039) (1.50) RAVE VALVE PARTIALLY INSERTED
593 HO 0.8 42.5
420 239 942 BLACK Tighten red cap no. 6 screw to bottom.
SDI (.031) (1.67)

Cylinder and Piston

ASSEMBLY Be sure to restore the chamfer around all cylinder
RAVE System sleeve port openings.
Apply Dreibond sealing compound (P/N 420 297 Before inserting piston no. 18 in cylinder no. 4, lu-
906) in the groove of valve base and in the piston bricate the cylinder with new injection oil or equiv-
valve groove, then install bellows. alent.
NOTE: To ease the installation of the spring no. 12 Cylinder Head Cover, Cylinder
retaining bellows no. 13 to valve piston, refer to Head and Cylinder
the following photo.
Check flatness of part sealing surfaces. Refer
to LEAK TEST AND ENGINE DIMENSION MEA-
SUREMENT and look for CHECKING SURFACE
FLATNESS.

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Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

When installing a new cageless bearing, replace

half plastic cages with sleeve.
NOTE: 593 engine cageless bearings have 28 nee-
dles.

A32CBHA

TYPICAL

CAUTION: Piston temperature must not exceed

46°C (115°F). NEVER USE DIRECT FLAME to
A02C2GA heat the piston and never freeze the pin. Inap-
propriate heating procedure/s may damage the
TYPICAL
1. Sleeve piston.
At assembly, place the pistons over the connect-
Lubricate needle bearings with injection oil. ing rods with the letters “AUS” (above the arrow
Grease thrust washers and install them on each on the piston dome) facing in direction of the ex-
end of needles. haust port.
Insert cageless bearing into connecting rod.

1
AUS

A01C01A

1. Exhaust
A02C2HA

TYPICAL — CAGELESS BEARING AND SLEEVE INSTALLED Install shouldered sleeve.

Heat piston using bearing heater (P/N 529 035
969).

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 Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

A32B0AA

With round end of pusher, position circlip perpen-

dicular to the support axis.

A02C2IA

TYPICAL — SHOULDERED SLEEVE INSTALLATION

Install piston pin puller and turn handle until piston

pin is correctly positioned in piston.

A32B0BA

With the other end of the pusher, push circlip into

the support groove.

A02C2JA

TYPICAL
A32B0CA
CAUTION: Always install new circlips.
To minimize the effect of acceleration forces on
circlip, install each circlip so the circlip break is
at 6 o’clock as illustrated. Use appropriate piston
circlip installer.

PISTON CIRCLIP
ENGINE
INSTALLER (P/N)
593, 593 HO SDI 529 035 686

Use circlip installer (P/N 529 035 686) to install 1

new mono-hook circlips no. 20. A32B0DA

Insert circlip into support in such a way that when 1. Groove

installed in piston groove, the tab will face upward.

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Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

CAUTION: Always install a gasket of the proper

thickness. Failure to do so may cause detona-
tion and severe engine damage.
Before inserting piston no. 18 in cylinder no. 4, lu-
bricate the cylinder with new injection oil or equiv-
alent.
Install cylinders. Do not tighten.
Install new rubber ring and round O-rings on each
cylinder.

A32B0EA

CIRCLIP READY TO BE INSTALLED ON PISTON

Using a plastic hammer, tap pusher to insert circlip

in place. Take care to install new circlips with tab
toward top as per following photo.

A32C4CA

TYPICAL

NOTE: Carefully clean screws before reinstalla-

tion, specifically under screw head.
Install exhaust manifold with gaskets. Do not
tighten yet.
At assembly, torque cylinder head screws using
the following table and as per the following illus-
trated sequence.
A32C4BA
ENGINE
TAB TOWARD TOP
593 593 HO SDI
CAUTION: Always install new mono-hook cir- 29 N•m (21 lbf•ft)
clips. If circlip installation fails at the first at- 29 N•m Cylinder head screw
tempt, always retry with a new one as on a sec- (21 lbf•ft) with knock sensor:
ond attempt circlip will lose its normal retain-
23 N•m (17 lbf•ft)
ing capabilities.
CAUTION: Circlips must not move freely after
installation; if so, replace them.
Clean cylinders no. 4 and crankcase mating sur-
faces with Loctite Chisel (P/N 413 708 500).
Coat crankcase mating surface with Loctite 518
(P/N 293 800 038). Choose the right gasket thick-
ness according to combustion chamber volume.
Refer to LEAK TEST AND ENGINE DIMENSION
MEASUREMENT. Install it on crankcase. Coat
gasket with Loctite 518.

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 Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

In case of a play, turn blade upside down and

recheck. If there is still a play, replace blade and/or
5 7 valve body.
11 1 3 9

12 4 2 10
6 8
1

A32C18A

TYPICAL

Tighten exhaust manifold bolts in a criss-cross se-

A06C0FA
quence as per the following table.
1. No play
ENGINE
593 593 HO SDI Check distance from blade stopper inner edge and
distance from center of reed valve block.
23 N•m (17 lbf•ft) 11 N•m (97 lbf•in)

Install outlet socket and tighten screws to 8 N•m

(71 lbf•in). Note position of longer screw.

A A

A06C36A

TYPICAL
A. 14.75 - 0, + 0.75 mm (.580 - 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
during installation. Adjusted distance will be re-
Reed Valve duced automatically upon installation.
Blades have a curved shape. Install with their
curve facing reed block.
With blade stopper no. 16 removed, check reed
valve for proper tightness. There must be no play
between blade and valve body when exerting a
finger pressure on blade at blade stopper location.

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Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

BOTTOM END
593 Engine

Petamo 9 N•m
(80 lbf•in)
2 Loctite 243
Anti-seize
lubricant

Anti-seize
lubricant
Isoflex

4
Isoflex
Loctite 243

2
Petamo
3 Loctite
243

Anti-seize Anti-seize
lubricant lubricant
125 N•m
(92 lbf•ft)
Petamo
Anti-seize 11 N•m
lubricant (97 lbf•in)
3
Injection oil Multi- 5.5 N•m
purpose (49 lbf•in)
grease
29 N•m
(21 lbf•ft) Loctite
5910 Loctite
Loctite
648 243
4.5 N•m
(40 lbf•in)
Petamo
grease
Loctite
648
29 N•m 9 N•m
A29C2TT (21 lbf•ft) (80 lbf•in)

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 Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

593 HO SDI Engine

2
Isoflex grease Isoflex grease
Petamo
grease

Petamo
grease 4 125 N•m
2 (92 lbf•ft)
Antiseize
Anti-seize lubricant
lubricant 2 3

Loctite 243
Anti-seize
lubricant
3
Antiseize
lubricant
Petamo 11 N•m (97 lbf•in)
grease
9 N•m (80 lbf•in) Loctite 243

4.5 N•m (40 lbf•in)

Multi-purpose Loctite 243

grease
5.5 N•m (49 lbf•in)

11 N•m
(97 lbf•in) Injection
oil

Petamo
1 grease

Loctite 5910
•

29 N•m
(21 lbf•ft)

11 N•m 9 N•m
A33C2UT
(97 lbf•in) (80 lbf•in)

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Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

NOTE: Engine must be removed from chassis to

perform the following procedures.

CLEANING 1
Discard all oil seals, gaskets, O-rings and sealing 2
rings.
Clean all metal components in a non-ferrous met-
al cleaner. Use Loctite Chisel (P/N 413 708 500)
accordingly.
Remove old paste gasket from crankcase mating
surfaces with Loctite Chisel (P/N 413 708 500).
CAUTION: Never use a sharp object to scrape
away old sealant as score marks incurred are
detrimental to crankcase sealing.

DISASSEMBLY A32CARA

General 1. Half ring

2. Puller ring
To remove drive pulley, refer to DRIVE PULLEY.
Remove rewind starter. NOTE: Apply grease (P/N 413 711 500) on crank-
shaft end in order to hold in place the crankshaft
To remove magneto, refer to MAGNETO SYS-
protector (P/N 420 876 552) on PTO side and
TEM.
crankshaft protector (P/N 420 876 557) on MAG
593 HO SDI Engine side.
Remove oil seal cover no. 1. Using screws (P/N 420 840 681), install bearing
puller (P/N 529 036 004) on the half rings.
Secure the bearing puller in a vise by one of its rib.

A32C07A

BEARING PULLER SECURED IN THE VISE

A33C2OA
CAUTION: Never use any air impact tool for
TYPICAL tightening the puller bolt. Lubricate the bolt
with BOMBARDIER LUBE (P/N 293 600 016) to
avoid damaging the threads.
Crankshaft Bearing
Lubricate the puller bolt and then proceed with
To remove PTO side bearings no. 2 and no. 3 from tightening the puller bolt until the bearing comes
crankshaft no. 4, install the following tools on the out.
bearing.
Follow the same procedure for the inner PTO side
– half rings (P/N 420 977 479)
bearing.
– puller ring (P/N 420 977 494).

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 Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

NOTE: In the case of damaged bearing or less

clearance between crankshaft counterbalance
and the bearing or on the MAG side bearing, use
bearing separator (Snap-On tool (P/N CJ951) or
(P/N SPX/OTC) tool (P/N 1124) to facilitate the
removal.

A32CATA

A32CB4A 1
1. Bearing separator

Procedure for MAG side bearings no. 2 and no. 3

is same as of PTO side with the exception of
crankshaft protector (P/N 420 876 557).

INSPECTION
NOTE: Refer to LEAK TEST AND ENGINE DIMEN-
SIONS MEASUREMENT.
A32CBWB

ASSEMBLY Remove all residue using pulley flange cleaner

Coat lip of all seals with Petamo grease (P/N 420 (P/N 413 711 809).
899 271). Smear anti-seize lubricant (P/N 413 701 000) on
part of crankshaft where bearing fits.
Crankshaft Bearing
CAUTION: Never reinstall a bearing that has
been removed.
Inspect crankshaft ends for damage.
Clean crankshaft end with sand paper no.180 and
remove all residue using pulley flange cleaner
(P/N 413 711 809).

A32CAUA

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Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

Heat up the bearing(s) using bearing heater Probe the inner race of the bearing with the tem-
(P/N 529 035 969). This will expand bearings perature indicator stick (P/N 529 035 970). Stick
and ease installation. If required, put a suitable will liquefy when the bearing reach the proper
plate or shim to avoid the direct contact between temperature.
integrated seal and the heating surface.

A32CB9A

 WARNING
A32CB7A Do not touch heated bearing with bare hands.
Wear heat resisting gloves before handling
CAUTION: Bearing should not be heated to the heated bearing(s).
more than 80°C (176°F). Do not heat bearing
with direct flame or heat gun or heated oil.
Inappropriate heating procedure(s) may cause Slide in the inner PTO bearing with the integrated
inner seal failure. seal facing crankshaft. Push bearing to end posi-
tion.
Turn bearing(s) several times during heating
process for heating it/them properly.
NOTE: Normally it takes approximately 10 min-
utes to heat up a bearing. So, in the event of re-
placing a bearing, it is recommended to start heat-
ing it prior to removal. Two bearings can be heat-
ed at the same time on one bearing heater.

A32CAVA

NOTE: Heated bearings will slide onto the crank-

shaft. If required, push with a steel tube on the
inner ring of the bearing. Pay special attention
to correct positioning of the drive pins and/or
retaining discs.
A32CB8A
Install retaining discs.
1. Bearings

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 Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

Install support plate (P/N 529 035 976) with appro-

priate distance gauge; refer to following table.

DISTANCE GAUGE P/N ENGINE APPLICATION

529 035 966 593
529 035 968 593 HO SDI

A32CC4B

Slide-in the second bearing until it contacts the

first one.
2

1
A32CBCA

1. Support plate
2. Distance gauge

Install bearing locator tool.

A32CAWA

Slide in the heated outer PTO bearing onto the A32CC5B

crankshaft until it contacts the distance gauge.

Slide-in the first MAG bearing with the integrated CAUTION: Use only the recommended Isoflex
grease (P/N 293 550 021). Make sure not to
seal facing crankshaft. Push bearing to the bot-
push Isoflex grease between outside bearing
tom with pusher, using a rubber hammer. race and half crankcase.
NOTE: The 50 g tube corresponds to 50 cc of
grease.

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Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

Put 50 to 55 mL of Isoflex grease (P/N 293 550

021) in a syringe.
CAUTION: Do not exceed the recommended
amount of grease.
Fill inner side of PTO side bearing with Isoflex
grease (P/N 293 550 021) (about 10 mL).

A33C17A

TYPICAL — FILL WITH GREASE AND SET IN PLACE

Apply 6 mL of Isoflex grease (P/N 293 550 021) to

MAG side outer bearing.
NOTE: If replaced with new bearing, do not apply
grease as new bearings come with grease already
A33C15A
applied.
PTO SIDE BEARING FILLED WITH ISOFLEX GREASE At crankshaft installation, position drive pins as il-
lustrated.
With the syringe, fill the outer ball bearing and in-
ner side of outer seal with 40 to 45 mL of Isoflex
grease (P/N 293 550 021).

A32C1CA 1
1. Position pins

Pour 50 mL (2 U.S. oz) of injection oil in the pan

under central gear to lubricate pump gearing as
per photo.

A33C16A

BALLS COATED WITH A SEAM OF GREASE

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 Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

Use a plexiglass plate and apply some sealant on

it. Use a soft rubber roller (50 - 75 mm (2 - 3 in))
(available in arts products suppliers for printmak-
ing) and roll the sealant to get a thin uniform coat
on the plate (spread as necessary). When ready,
apply the sealant on crankcase mating surfaces.

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
sequence must be performed within 10 minutes. F12R17A

Do not wait between each bolt torquing. All bolts

must be torqued in a row.
Before screwing both parts of crankcase, seal it
with a Loctite 5910 (P/N 293 800 081).
NOTE: It is recommended to apply this specific
sealant as described here to get an uniform ap-
plication without lumps. If you do not use the
roller method, you may use your finger to uniform-
ly distribute the sealant (unlike the Dreibond seal-
ing compound, using a finger will not affect the
adhesion).
Use the silicone-based Loctite 5910 (P/N 293 800
081) on mating surfaces.
F12R18A
NOTE: The sealant curing time is similar to the
Loctite 518 without using the Primer N. Do not apply in excess as it will spread out inside
CAUTION: Do not use Loctite 515 or 518 to seal crankcase.
crankcase. Do not use Loctite Primer N with CAUTION: If sealant spreads out inside air com-
the Loctite 5910. Using these products or non pressor area, it could plug the compressor lu-
silicone-based sealant over a previously sealed brication nipple and serious compressor dam-
crankcase with Loctite 5910 will lead to poor age may occur.
adhesion and possibly a leaking crankcase.
These products are chemically incompatibles. NOTE: Do not use Loctite Primer N with this
Even after cleaning, the Loctite 5910 would sealant. The sealant curing time is similar to the
leave incompatible microscopic particles. Loctite 518 without using the Primer N, which is
4 to 24 hours.

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Section 03 ENGINES (2-STROKE)
Subsection 03 (593 AND 593 HO SDI ENGINES)

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)).
B B
11 9 14 4 1 16 5 19 8 18

12 10 13 2 3 15 6 7 17
A B

20 21
A32C3FA B B
1. Torque bolts 1 through 16 to 29 N•m (21 lbf•ft)
2. Torque bolts 17 through 21 to 9 N•m (80 lbf•in )

593 HO SDI Engine

Install oil seal cover.

BREAK-IN
After rebuilding an engine always observe a break-
in period as described in Operator's Guide.

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 Section 03 ENGINES (2-STROKE)
Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT)

LEAK TEST AND ENGINE DIMENSION

MEASUREMENT
SERVICE TOOLS
Description Part Number Page
degree wheel........................................................................ 414 352 900 ......................................... 121
dial indicator.......................................................................... 414 104 700 ................................. 118, 121
hose pincher ......................................................................... 295 000 076 ......................................... 109
vacuum/pressure pump........................................................ 529 021 800 ................................. 110–111

LEAK TEST
The following gives verification procedures for liq-
uid cooled engines though it also applies to fan
cooled engines. For FC engines, do not consid-
er 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
– Remove tuned pipe.
– Install plug over exhaust manifold.
– Remove carburetors/throttle body assembly (as A32C1DA

applicable).
– Using a hose pincher (P/N 295 000 076), block
– Insert plugs in intake rubber boots. Tighten impulse hose.
with clamps already there.
– Using hose pincher (P/N 295 000 076), block
pump shaft oil hose and lubrication nipple on
PTO side.

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Section 03 ENGINES (2-STROKE)
Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT)

PROCEDURE
NOTE: A flow chart has been prepared as a visual
reference. See last page of this chapter.
Using flow chart and following text, pressurize
area to be tested and spray soapy solution at the
indicated location.

TEST PRESSURE: 34 KPA (5 PSI) FOR 3 MINUTES

– If there is a leak at the tested location, it is rec-

ommended to continue testing next items be-
fore overhauling engine. There is a possibility
A32C1EA
of more than one leak.
– If there is no leak at the tested location, contin-
– Install vacuum/pressure pump (P/N 529 021 ue pumping to maintain pressure and continue
800) on exhaust plug. with next items until leak is found.
NOTE: If necessary, lubricate vacuum/pressure
pump (P/N 529 021 800) piston with mild soap. Engine
CAUTION: Using hydrocarbon lubricant (such Check the following:
as engine oil) will damage rubber seal of pump – All jointed surfaces and screw/stud threads of
piston. engine:
• spark plug base, insulator
• 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
• crankcase grease reservoir fitting.
– Small injection oil lines coming from pump.

A32C1FA

– Activate pump and pressurize engine to 34 kPa

(5 PSI). Do not exceed this pressure.
– 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.
1 2 1
A32C1GA

1. Injection nipples
2. Small injection oil lines

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 Section 03 ENGINES (2-STROKE)
Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT)

Check for air bubbles or oil column going toward

pump. It indicates defective check valve in injec-
tion nipples.
– Remove cooling system cap.
Check for air bubbles in antifreeze. It indicates de-
fective cylinder head O-ring or cylinder base gas-
ket.
– Remove drive pulley then check crankshaft out-
er seal.
– Remove rewind starter and magneto system
then check crankshaft outer seal.
– Check pump shaft gear oil reservoir.
1 2
Pump Shaft Oil Gear Reservoir A32C1IA

Install vacuum/pressure pump (P/N 529 021 800) CRANKSHAFT INSTALLED IN UPPER HALF CRANKCASE
1. Crankshaft inner seal on PTO side
on adapter and pressurize as before. 2. Crankshaft inner seal on MAG side

– Check weep hole below coolant pump housing

with soapy water.

A32C1HA

If pressure drops, it indicates a defective crank-

shaft inner seal.
A32C1JA 1
1. Weep hole

If there is a leak, it indicates defective seal of

pump shaft (oil seal beside coolant ceramic seal).
– Leaks can be also on oil pump side. Check
mounting area for leaks.

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Section 03 ENGINES (2-STROKE)
Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT)

A32C1GB 1
1. Check mounting area

– 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
leakage.

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 Section 03 ENGINES (2-STROKE)
Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT)

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 INJECTION NIPPLE(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 HOSE OF PUMP SHAFT
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 PUMP SHAFT GEAR

RESERVOIR IN CRANKCASE

PRESSURIZE PUMP SHAFT 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
IS RESERVOIR LEAKING?

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

CAREFULLY INSPECT ENGINE CASTINGS,

PARTICULARLY THE THREAD HOLE AREAS

YES
ANY LEAK FOUND? REPLACE DEFECTIVE PARTS

NO

ENGINE IS PERFECTLY SEALED

INTERNALLY

A32C1KS

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Section 03 ENGINES (2-STROKE)
Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT)

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,
0.05 mm (.002 in) per 50 mm cylinder should be rebored and honed or should
(2 in) of surface be replaced. Nikasil cylinder can be honed using
All diamond hone but can not be rebored.
0.5 mm (.020 in) for total length
of cylinder head NOTE: Be sure to restore the chamfer around all
cylinder sleeve port openings.
Check gasketed surface of the cylinder head with
a straightedge and a feeler gauge.

CYLINDER TAPER 1

ENGINE TYPE MAXIMUM

All 0.10 mm (.004 in)

Compare cylinder diameter 16 mm (5/8 in) from

top of cylinder to just below its intake port area.
If the difference exceeds the specified dimension
the cylinder should be rebored and honed or 2
A
should be replaced. Nikasil cylinder can be honed
using diamond hone but can not be rebored.
NOTE: Be sure to restore the chamfer around all
cylinder sleeve port openings.
A33C1CA

1. Piston pin position

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

A33C1BA 1
1. Below the intake port
A. 16 mm (5/8 in) from top

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 Section 03 ENGINES (2-STROKE)
Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT)

F01D5VA

1. Combustion chamber

NOTE: When checking the combustion chamber

volume, engine must be cold, piston must be free
of carbon deposit and cylinder head must be lev-
eled.
– Remove both spark plugs and bring one piston F00B0BA

to Top Dead Center a using a TDC gauge. 1. Graduated burette (0-50 cc)

1
– Open burette valve to fill its tip. Add liquid in
burette until level reaches 0 cc.
– Inject the burette content through the spark
plug hole until liquid touches the top of the
spark plug hole.

A33C1DA
F00D0HA 1
1. Bring piston to TDC
1. Top of spark plug hole
– Obtain a graduated burette (capacity 0-50 cc)
and fill with an equal part (50/50) of gasoline and NOTE: The liquid level in cylinder must not drop
injection oil. for a few seconds after filling. If so, there is a
leak between piston and cylinder. The recorded
volume would be false.
– Let burette stand upward for about 10 minutes,
until liquid level is stabilized.
– Read the burette scale to obtain the quantity of
liquid injected in the combustion chamber.

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Section 03 ENGINES (2-STROKE)
Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT)

NOTE: When the combustion chamber is filled to

top of spark plug hole, it includes an amount of
2.25 cc corresponding to the spark plug well.
– Repeat the procedure for the other cylinder.
A
COMBUSTION
CHAMBER VOLUME (cc)
ENGINE TYPE
(up to top thread of spark
plug hole)
443 24.0 ± 1.0
552 34.43 ± 1.2
593 28.97 ± 1.2
1
593 HO SDI 26.4 ±1.2 F01D0NA

1. Measuring perpendicularly (90°) to piston pin axis

Install a thicker or thinner cylinder/crankcase gas- A. 15 mm (.590 in)
ket (refer to Parts Catalogs) in order to obtain the
specified combustion chamber volume. ENGINE MAXIMUM PISTON SKIRT WEAR
TYPE mm (in)
USED PISTON MEASUREMENT All 0.15 (.006)
Note the measurement on the piston dome.
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.

CYLINDER/PISTON CLEARANCE
Used and New Pistons
IMPORTANT: Make sure used piston is not worn
more than specified. See USED PISTON MEA-
SUREMENT above.
Take the measurement on the piston dome.

F00D0EA 2 1
1. Piston dome
2. Piston measurement

Using a micrometer, measure piston at A perpen-

dicularly (90°) to piston pin.

F00D0EA 2 1
1. Piston dome
2. Piston measurement

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 Section 03 ENGINES (2-STROKE)
Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT)

Adjust and lock a micrometer to the specified val-

ue on the piston dome.

F00B08A F00B0AA

1. Micrometer set to the piston dimension 1. Indicator set to 0 (zero)

With the micrometer set to the piston dimension, IMPORTANT: Always remove cylinders from
adjust a cylinder bore gauge to the micrometer crankcase before measuring.
dimension and set the indicator to 0. Position the dial bore gauge at 16 mm (5/8 in) be-
low cylinder top edge.

2 1

F00B09A

1. Use the micrometer to set the cylinder bore gauge F01D0KA

2. Dial bore gauge
1. Measuring perpendicularly (90°) to piston pin axis
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
tolerance, replace cylinder or rebore. Refer to
TECHNICAL DATA.
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.
IMPORTANT: The total piston/cylinder clearance
(actual cylinder diameter minus actual piston skirt
diameter) should be within 0.30 mm (.012 in).

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Section 03 ENGINES (2-STROKE)
Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT)

RING/PISTON GROOVE Measuring (in crankcase)

CLEARANCE First, check deflection with crankshaft in engine.
If deflection exceeds the specified tolerance,
Using a feeler gauge check clearance between up- recheck deflection using V-shaped blocks to de-
per compression ring and groove. Replace piston termine the defective part(s). See below.
if clearance exceeds specified tolerance. Refer to
TECHNICAL DATA. Measuring (on bench)
Once engine is disassembled, check crankshaft
deflection 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 determine the defective part(s). See
measurement A in following illustration.

A01C0PA

RING END GAP

Position ring halfway between transfer port and
intake port.
NOTE: In order to correctly position the ring in the
cylinder, use piston as a pusher.
A 1
Using a feeler gauge, check ring end gap. Replace
ring if gap exceeds specified tolerance. Refer to A01C0RD

TECHNICAL DATA. TYPICAL

1. Measure at mid point between the key and the first thread
1 A. 3 mm (1/8 in)

Crankshaft Deflection on PTO Side

MAXIMUM ON PTO SIDE
ENGINE TYPE
mm (in)
All 0.06 (.0024)
2

Crankshaft Deflection on MAG Side

A01C0QA
MAXIMUM ON MAG SIDE
ENGINE TYPE
1. Transfer port mm (in)
2. Intake port
277, 443 and
0.03 (.0012)
552
CRANKSHAFT DEFLECTION 593/593 HO SDI 0.05 (.0020)
Crankshaft deflection is measured with a dial indi-
cator (P/N 414 104 700).

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 Section 03 ENGINES (2-STROKE)
Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT)

Crankshaft Deflection in Center CRANKSHAFT END-PLAY

of Crankshaft 277 Engine Type
MAXIMUM IN CENTER
ENGINE TYPE MINIMUM MAXIMUM
ENGINE TYPE OF CRANKSHAFT
mm (in) 0.10 mm .030 mm
277
(.004 in) (.012 in)
All 0.08 (.0031)
Adjustment
NOTE: Crankshaft deflection cannot be correctly
measured between centers of a lathe. Crankshaft end-play is adjusted with shims locat-
ed between crankshaft and magneto side bearing.
NOTE: If the deflection exceeds the specified tol-
erance, crankshaft should be repaired or replaced.

CONNECTING ROD BIG END 2 3

AXIAL PLAY 1

NEW PARTS
ENGINE TYPE WEAR LIMIT
(min. - max.)
277, 443 and 0.20 - 0.53 mm 1.0 mm 4
552 (.008 - .021 in) (.039 in) 5
A01C1NA

0.39 - 0.74 mm 1.20 mm

593 1. Distance ring
(.015 - .029 in) (.047 in) 2. Shim location
3. Bearing
0.31 - 0.67 mm 1.20 mm 4. PTO
593 HO SDI
(.012 - .026 in) (.047 in) 5. MAG

CAUTION: Always install end-play adjustment

Using a feeler gauge, measure distance between shims on the magneto side between bearing
thrust washer and crankshaft counterweight. If and crankshaft counterweight.
the distance exceeds specified tolerance, repair or
replace the crankshaft. The following is required for the adjustment pro-
cedure:
– adjustment shims (refer to Parts Catalog)

THICKNESSES AVAILABLE
0.10 mm (.004 in)
0.20 mm (.008 in)
0.30 mm (.012 in)
0.50 mm (.020 in)
– micrometer
– caliper.
Total shim thickness needed for the end-play ad-
A01C0SA justment is determined with the following proce-
dure:
TYPICAL
• Measure crankcase halves as illustrated (M1
and M2).
A standard compressed crankcase gasket will
have a 0.30 mm (.012 in) thickness (M3). Add
these measurements to obtain dimension A.

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Section 03 ENGINES (2-STROKE)
Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT)

The result is the actual crankshaft end-play that

must be within specification.
1 If the result is over specification, add adjustment
shim(s) to reach this specification.
If the result is under specification, remove adjust-
ment shim(s) to reach this specification.
To Summarize

A = M1 + M 2 + M3
B = M 4 + M 5 + M 6 + M 7 + M8
Actual end-play that must be
A-B =
within specification.
A01C0TA

MEASURING M1 AND M2 M8 is the dimension that must be adjusted to ob-

1. Bearing seat
tain the specified crankshaft end-play.
• Measure the thickness of each bearing (M4 and A
M5). M3
1 M1 M2

A01C0UA

MEASURING M4 AND M5
1. Bearing thickness
2 3

• Measure distance between bearing shoulders

on crankshaft (M6).

M6
M4 M5
M7
M8
A01C0WA B
1. End-play is adjusted with shims
2. PTO
A02C0LA 3. MAG

MEASURING M6 443, 552 and 593 Engine Types

End-play is not adjustable but it should be be-
• Measure the distance ring (M7) and adjustment
tween 0.10 - 0.30 mm (.004 - .012 in).
shims thickness (M8). Add these measure-
ments to obtain dimension B.
• From dimension A, subtract dimension B. CHECKING SURFACE FLATNESS
Intake manifold, intake manifold cover can be
checked for perfectly mating surfaces.

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 Section 03 ENGINES (2-STROKE)
Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT)

Lay part on a surface plate (marble, mirror or thick

glass plate). 20
10
0

90
30

Holding down one end of part, try pushing down 40

50 60
70
80

the other end.

If any play is felt, part must be rectified.

RECTIFYING SURFACES
Stick a fine sand paper sheet on the surface plate
then lightly oil the sand paper.
Rub part mating surface on sand paper using 8-fig-
ure movements. 180

Sand until mating surface is perfectly straight.

A06C1TA 0

TYPICAL

Interval between cylinders must be 180° ± 0.5.

Any other reading indicates a misaligned (twisted)
crankshaft.

A00A1LA

CHECKING CRANKSHAFT
ALIGNMENT
Install a degree wheel (P/N 414 352 900) on crank-
shaft end.
Remove both spark plugs.
Install a dial indicator (P/N 414 104 700) in spark
plug hole on MAG side.
Bring MAG piston at top dead center.
Rotate degree wheel (P/N 414 352 900) (not
crankshaft) so that 360° mark aligns with center
of crankcase. Scribe a mark on crankcase.
Remove dial indicator (P/N 414 104 700) and install
it on PTO side cylinder.
Bring PTO piston to top dead center. degree
wheel (P/N 414 352 900) must rotate with crank-
shaft.

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 Section 03 ENGINES (2-STROKE)
Subsection 05 (MAGNETO SYSTEM)

MAGNETO SYSTEM
SERVICE TOOLS
Description Part Number Page
clutch holder ......................................................................... 529 027 600 ......................................... 128
crankshaft protector ............................................................. 420 876 557 ......................................... 129
magneto puller...................................................................... 529 035 547 ......................................... 129
magneto puller ring............................................................... 420 876 080 ......................................... 128

SERVICE PRODUCTS
Description Part Number Page
Loctite 243............................................................................ 293 800 060 ................................. 129–130
silicone dielectric grease ...................................................... 293 550 004 ......................................... 130

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Section 03 ENGINES (2-STROKE)
Subsection 05 (MAGNETO SYSTEM)

277 Engine

Dielectric
grease

Loctite
243 3

Reverse
5 2

22 N•m
Forward 4 (195 lbf•in)

105 N•m 1
(77 lbf•ft)
Loctite
A05E0XU
243

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 Section 03 ENGINES (2-STROKE)
Subsection 05 (MAGNETO SYSTEM)

443 and 552 Engines

Dielectric grease

To main harness

3
Loctite
243
105 N•m
(77 lbf•ft)
1

2
Reverse
(not functional 5
on 552 engine)
4
Loctite
Forward 243
22 N•m
(195 lbf•in)

A03E2ZV

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Section 03 ENGINES (2-STROKE)
Subsection 05 (MAGNETO SYSTEM)

593 Engine

Loctite
243
5

4
Sikaflex 1 125 N•m
(92 lbf•ft)
255 3
Loctite
243
2
22 N•m
Loctite (195 lbf•in)
243

Dielectric
grease

Dielectric
grease

A29E0MT

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 Section 03 ENGINES (2-STROKE)
Subsection 05 (MAGNETO SYSTEM)

593 SDI Engine

9 N•m
(80 lbf•in)
Loctite 243
3

Loctite 243
5 2

Loctite
5910
4 21 N•m
(15 lbf•ft)
8 N•m
(71 lbf•in)
1 125 N•m
(92 lbf•ft)
Frame harness

Loctite 243
Voltage regulator

A32C8JT

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Section 03 ENGINES (2-STROKE)
Subsection 05 (MAGNETO SYSTEM)

GENERAL
NOTE: The following procedures can be done
without removing the engine from chassis. To
facilitate magneto removal, hold drive pulley with
clutch holder (P/N 529 027 600).
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure. A06E23A 1

 WARNING 1. Cut by 25 mm (1 in)

Torque wrench tightening specifications

– Install magneto puller ring (P/N 420 876 080)
must strictly be adhered to.
with its tab in magneto housing opening.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, etc.) must CAUTION: Use only M8 x 20 mm screws to bolt
be installed or replaced with new ones where puller to magneto.
specified. If the efficiency of a locking device
is impaired, it must be renewed.

CLEANING
Clean all metal components in a non-ferrous metal
cleaner.
CAUTION: Clean stator and magneto using on-
ly a clean cloth.

DISASSEMBLY
Magneto Flywheel 2
A06E22B 1
To gain access to magneto flywheel no. 3 assem-
bly, remove the following parts as needed on dif- TYPICAL
1. Tab in magneto housing opening
ferent engines: 2. M8 x 20 mm screws
– tuned pipe and muffler
– rewind starter – Remove magneto flywheel nut, using a 30 mm
socket machined to 40 mm (1.580 in) outside
– starting pulley no. 2.
diameter by 16 mm (5/8 in) long.
To remove magneto flywheel nut no. 1:
NOTE: To correctly remove a threadlocked fasten-
– Use magneto puller ring (P/N 420 876 080). For- er, first tap on the fastener to break threadlocker
mer puller has to be modified as shown. bond. This will avoid thread breakage.

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 Section 03 ENGINES (2-STROKE)
Subsection 05 (MAGNETO SYSTEM)

1 420 876 080 – Remove grommet from crankcase where trig-

ger coil wire exits magneto housing.
– Remove retaining screws no. 4.
– Remove trigger coil and carefully pull wires.
– Install new trigger coil and other parts removed.

ASSEMBLY
Trigger Coil
For installation, reverse the removal procedure.
NOTE: It is important to remove the old silicon at
trigger coil location then apply new silicon. Screw
A03C1JB
trigger coil then stick the trigger coil wires in the
silicon.
TYPICAL
1. 30 mm socket
Stator
To remove magneto flywheel, install crankshaft Make sure to position stator no. 6 in a way that its
protector (P/N 420 876 557) on crankshaft end. wire protectors are over recess of crankcase.
Screw magneto puller (P/N 529 035 547) into
2 1
puller ring.
Tighten puller bolt and at the same time, tap on
bolt head using a hammer to release magneto fly-
wheel from its taper.

Stator
NOTE: Always check stator no. 6 before changing
it, refer to TESTING PROCEDURE.
Remove:
– magneto flywheel no. 3
– all Allen socket screws retaining stator to mag-
neto housing
A32E0KA
– grommet from crankcase where trigger coil and
stator wires exit magneto housing. 1. Crankcase recess
2. Wire protectors
Unplug the trigger coil connectors and pull the
wires through the grommet location. Apply Loctite 243 (P/N 293 800 060) on threads
NOTE: To pass the stator connector into the grom- of stator screws then torque them to 9 N•m
met location it is necessary to pass the trigger coil (80 lbf•in).
connector first. Reinstall all other removed parts.
Unplug the stator connector and remove the sta-
tor. Magneto Flywheel
Clean crankshaft extension (taper) and apply Loc-
Trigger Coil tite 243 (blue) on taper, then position Woodruff
Magneto and stator no. 6 must be removed be- key, magneto flywheel no. 3 and lock washer on
fore trigger coil removal. crankshaft.
To replace trigger coil no. 5:
– Disconnect trigger coil connector housing.

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Section 03 ENGINES (2-STROKE)
Subsection 05 (MAGNETO SYSTEM)

Clean nut threads and apply Loctite 243 (P/N 293

800 060) then tighten nut to 105 N•m (77 lbf•ft)
for fan-cooled engines and to 125 N•m (92 lbf•ft)
for liquid-cooled engines.
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
product will corrode contacts. Do not apply sil-
icone dielectric grease (P/N 293 550 004) on any
Deutsch (gray) housing otherwise housing seal
will be damaged.

Ignition Timing
Check as described in IGNITION TIMING.

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 Section 03 ENGINES (2-STROKE)
Subsection 06 (OIL INJECTION SYSTEM)

OIL INJECTION SYSTEM

SERVICE TOOLS
Description Part Number Page
gear holder............................................................................ 420 876 695 ......................................... 137
hose pinchers ....................................................................... 295 000 076 ......................................... 136
leak testing kit ...................................................................... 529 033 100 ......................................... 136

SERVICE PRODUCTS
Description Part Number Page
Loctite 648 (green) ............................................................... 413 711 400 ......................................... 138
Molykote 111........................................................................ 413 707 000 ......................................... 137
pulley flange cleaner............................................................. 413 711 809 ......................................... 138

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Section 03 ENGINES (2-STROKE)
Subsection 06 (OIL INJECTION SYSTEM)

OIL INJECTION PUMP

277 Engine

Injection oil

Loctite
243 1
5

Molykote 111

Loctite 243
A05C19S 3 4

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 Section 03 ENGINES (2-STROKE)
Subsection 06 (OIL INJECTION SYSTEM)

443 Engine

Injection oil

1 5
6

5 N•m Loctite Loctite

(44 lbf•in) 243 243
1 3 Grease

7
8

A21C0AS

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Section 03 ENGINES (2-STROKE)
Subsection 06 (OIL INJECTION SYSTEM)

552 Engine

Recommended
injection oil

Loctite
243

6 5
2
5 N•m
(44 lbf•in)

Molykote
7 111
1 8 3
1 4

1
2

A21C0BT

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 Section 03 ENGINES (2-STROKE)
Subsection 06 (OIL INJECTION SYSTEM)

593 and 593 HO SDI Engines

Injection oil

Loctite 648
2
4

5 N•m 3
(44 lbf•in) Loctite 648
2

8
A29C2OS

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Section 03 ENGINES (2-STROKE)
Subsection 06 (OIL INJECTION SYSTEM)

GENERAL OIL SYSTEM LEAK TEST

During assembly/installation, use the torque val- The following test will indicate any leak from oil
ues and service products as in the exploded reservoir to the banjo fitting(s).
views. Install on oil reservoir special cap of leak testing
Clean threads before applying a threadlocker. Re- kit (P/N 529 033 100).
fer to SELF-LOCKING FASTENERS and LOCTITE Install hose pinchers (P/N 295 000 076) on outlet
APPLICATION at the beginning of this manual for hoses.
complete procedure.
1 2
 WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, 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
Wipe off any oil spills. Oil is highly
flammable.
A03C2UA

NOTE: The following procedures can be done TYPICAL

without removing the engine from chassis. 1. Special cap on reservoir
2. Hose pinchers on outlet hoses

OIL TYPE Connect leak testing kit pump to special cap.

Pressurize oil system to 21 kPa (3 PSI). Pressure
ENGINE OIL TYPE must not drop during 3 minutes.
593 HO XP-S™ synthetic 2-stroke oil or XP-S™ If pressure drops, locate leak(s) and repair/replace
SDI(1) 2-stroke synthetic blend leaking component(s).
All others XP-S™ synthetic 2-stroke oil or XP-S™
2-stroke 2-stroke synthetic blend or XP-S™ OIL PUMP IDENTIFICATION
engines mineral injection oil (2) (3)
4, Pump Lever
(1) CAUTION: XP-S™ synthetic 2-stroke oil and Different engines need different pumps. See
XP-S™ 2-stroke synthetic blend oil are spe- identification on lever no. 4.
cially formulated and tested for the severe
requirement of these engines. Use of any oth- CAUTION: Always mount proper pump on en-
er brand two-stroke oil may void the limited gine.
warranty. Use only XP-S™ synthetic 2-stroke
oil and XP-S™ 2-stroke synthetic blend. There
is no known equivalent on the market for the
moment. If a high quality equivalent were
available, it could be used.
(2) If XP-S™ mineral injection oil is not available, API
TC high-quality low ash two-stroke injection oil
may be used.
(3) XP-S™ synthetic 2-stroke, XP-S™ 2-stroke syn-
thetic blend and XP-S™ mineral injection oil are
compatible, they can be mixed together.

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 Section 03 ENGINES (2-STROKE)
Subsection 06 (OIL INJECTION SYSTEM)

OIL PUMP 5,6, Gear Retaining Nut and Oil Pump

ENGINE TYPE
IDENTIFICATION Gear
277 132K 277, 443 and 552 Engines
443 E8 To remove gear retaining nut, first extract the nee-
dle roller with pliers then lock gear in place using
552 03 gear holder (P/N 420 876 695).
593 L7
593 HO SDI 02

NOTE: The following procedures can be done

without removing the engine from chassis.

CLEANING
Clean all metal components in a non-ferrous metal
cleaner.

DISASSEMBLY
NOTE: Some oil pump components are not avail-
A10C01A 420 876 695
able as single parts.

8, Injection Oil Pump ASSEMBLY

NOTE: Before removing the injection oil pump
no. 8, check its operation. Refer to the end of this 1, Spring Clip
section. Always check for spring clips tightness.
443 and 552 Engines
6, Oil Pump Gear
Remove:
At gear assembly, apply a light coat of
– air box
Molykote 111 (P/N 413 707 000) on gear teeth.
– carburetor
– pump mounting flange screws no. 3 8, Injection Oil Pump
Unplug all hoses connected to oil pump no. 8. For installation, reverse the removal procedure.
NOTE: Mark hose locations for installation. However, pay attention to the following.
Disconnect the oil pump cable. Torque the screws no. 3 to 5 N•m (44 lbf•in).
593, 593 HO SDI Engines Make sure cable barrel is well seated in oil pump
lever.
Remove:
Secure barrel with plastic washer and circlip.
– air box
Install cable lock washer on left side of support.
– carburetor or throttle body
– screw no. 3. Verify cable and oil pump lever operation then ad-
just cable.
Unplug all hoses connected to oil pump no. 8.
NOTE: Mark hose locations for installation. 7, Needle Roller
Disconnect the oil pump cable. (fan cooled engine only)
The needle roller must be engaged as deep as
possible in the pump mounting flange.

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Section 03 ENGINES (2-STROKE)
Subsection 06 (OIL INJECTION SYSTEM)

3, Screw
Torque to 5 N•m (44 lbf•in).
Cable plastic elbow must be fastened and fully
inserted.
B
Make sure cable barrel is well seated in oil pump
lever. A
Secure barrel with plastic washer and circlip.
Install cable lock washer on lever side.
Verify cable and oil pump lever operation.

2, Check Valve
A32C58A
593 and 593 HO SDI Engines
POSITION FOR 593 ENGINE
Apply Loctite 648 (green) (P/N 413 711 400) on A. PTO side: 30° ± 10° from cylinder axis to the bottom
B. MAG side: 0° from cylinder axis to the top
the outer diameter of the check valve (machined
section). Take care that Loctite is ONLY in this
area.
NOTE: Prior to coating it with Loctite, make sure
check valve body is clean and dry. Clean from dirt
or oil, if any, with pulley flange cleaner (P/N 413
711 809).
A B

A32C59A

TYPICAL — POSITION FOR 593 HO SDI ENGINE

A. PTO side 45° ± 5° from cylinder axis to the top
B. MAG side 20° ± 5° from cylinder axis to the bottom

Punch in the check valve carefully with a plastic

hammer.
Clean the crankcase from surplus of Loctite 648
with a rag.
A32C57A

APPLY LOCTITE ON THIS AREA ONLY ADJUSTMENT

Install the check valve in the correct position as Prior to adjusting the pump, make sure all car-
described on next photo into the crankcase lower buretor adjustments are completed and engine is
side. stopped.
277, 443 and 552 Engines
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.

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 Section 03 ENGINES (2-STROKE)
Subsection 06 (OIL INJECTION SYSTEM)

Loosen the adjuster nut and adjust accordingly. Depress the throttle lever lightly until the cable is
Retighten the adjuster nut. under tension but carburetors or throttle body are
not yet opened.
1 2 NOTE: Throttle cable visible distance “A” is mea-
sured between the throttle lever and the cable
housing end, using a feeler gauge.
Measure the visible distance “A” using the appro-
priate feeler gauge and note measurement.

3
A05C0YA 3
TYPICAL — TUNDRA R
1. Adjuster nuts
2. Bleeder screw
3. Marks 1

1 A33C3QA

TYPICAL
1. Feeler gauge
2. Throttle lever
3. Cable housing end
A. Measurement “A”
3
Next, add to measurement “A” the appropriate
specification “B”, using the chart below.

OIL PUMP ADJUSTMENT

2
Engine Type Specification “B”
A13C0PA 593 16.5 mm (0.650 in)
TYPICAL — SKANDIC LT/WT/SWT/SUV 550 593 HO SDI 18 mm (0.709 in)
1. Adjuster nut
2. Bleeder screw
3. Marks The correct specification for measurement “C” is
the sum of “A” plus the specification “B” found
CAUTION: Proper oil injection pump adjust- in the chart.
ment is very important. Any delay in the Stretch oil pump adjustment cable with a 32 N
opening of the pump can result in serious
engine damage. (7.2 lbf) force and measure the length of its visible
distance “C”.
593 and 593 HO SDI Engines
Before proceeding with the oil pump cable adjust-
ment, verify throttle cable adjustment and adjust
if needed. Refer to FUEL SYSTEM or COMPO-
NENT INSPECTION AND ADJUSTMENT, noting
that the throttle cable free play should be adjusted
just prior to the oil pump cable.

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Section 03 ENGINES (2-STROKE)
Subsection 06 (OIL INJECTION SYSTEM)

CHECKING OPERATION
Oil Pump
On Vehicle
NOTE: Main oil line must be full of oil. See bleed-
ing procedure above.
Lift rear of vehicle and support with a mechani-
cal stand. Disconnect small oil lines from pump.
Start engine and stop it as soon as it fires.
A32D1OB C 1 Check that oil in small oil lines has been sucked up
(this will be indicated by a clear section of small oil
TYPICAL
1. Lock nut lines). Repeat the procedure until this condition is
C. Oil pump adjustment (sum of “A” plus the specification “B”) attained.
Reconnect small oil lines, start engine and run at
If the visible distance is less or more than “A” + idle while holding the pump lever in fully open po-
“B”, adjust cable distance. To do so, loosen lock sition. Oil columns must advance into small oil
nut, turn adjusting screw in or out and retighten lines.
lock nut.
If not, remove pump assembly and check the
EXAMPLE: — The 593 HO SDI has a throttle pump gear and drive shaft (if applicable) for
lever measurement “A” of 1.5 mm (0.059 in); by defects, replace as necessary. Test pump as
adding the appropriate specification “B” found in describes below.
the chart (18 mm (0.709 in), you would determine
that the correct measurement “C” at the cable NOTE: Through normal use, oil level must not
would be 19.5 mm (0.768 in) as per equation drop in small oil lines. If oil drops, verify check
A + B = C. valve operation in injection nozzle. Replace as
necessary.
BLEEDING OIL LINES Test Bench
Bleed main oil line (between tank and pump) by Connect a hose filled with injection oil to supply
loosening the bleeder screw no. 8 until air has es- line fitting. Insert other hose end in an injection oil
caped from the line. Add injection oil as required. container. Using a clockwise rotating drill, rotate
pump shaft. Oil must drip from outer fittings while
Reinstall all parts. holding lever in a fully open position. If not replace
Bleed the small oil lines between pump and en- pump.
gine by running engine at idle while holding the
pump lever in fully open position. 2, Check Valve
NOTE: Make a J hook out of mechanical wire to For engine 593, check valve is part (built-in) of in-
lift the lever. jection nozzle.

 WARNING For engines 277, 443 and 552, check valve is part
(built-in) of banjo fitting.
Ensure not to operate carburetor throttle
To verify this check valve, proceed the same as for
mechanism. Secure the rear of the vehicle
checking pump operation on vehicle. First unplug
on a stand.
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.

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 Section 03 ENGINES (2-STROKE)
Subsection 07 (AXIAL FAN COOLING SYSTEM)

AXIAL FAN COOLING SYSTEM

SERVICE TOOLS
Description Part Number Page

holder wrench....................................................................... 420 876 357 ................................. 144, 146

SERVICE PRODUCTS
Description Part Number Page
holder wrench for the 443 engine ........................................ 420 876 357 ......................................... 143
holder wrench for the 5‘52 engine ...................................... 529 036 006 ......................................... 143
Loctite 243 (blue).................................................................. 293 800 060 ................................. 144, 146

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Section 03 ENGINES (2-STROKE)
Subsection 07 (AXIAL FAN COOLING SYSTEM)

443 and 552 Engines

NOTE: For 277 engine radial fan cooling system, refer to CDI SYSTEM.

7 N•m 13 N•m
1 (115 lbf•in)
(62 lbf•in)

5
18
4

7 N•m 10
(62 lbf•in) 12
11

13
14
15
16

10

17 Loctite
20 243
9 N•m 47 N•m
(80 lbf•in) (35 lbf•ft)

A29C2PS

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 Section 03 ENGINES (2-STROKE)
Subsection 07 (AXIAL FAN COOLING SYSTEM)

NOTE: The following procedures can be done

without removing engine from chassis.

REMOVAL
NOTE: To facilitate further disassembly, fan nut
may be removed before removing fan housing.
Remove rewind starter, starting pulley, trigger coil
wire from 4-connector housing then fan housing
ass'y.

CLEANING
Clean all metal components in a non-ferrous metal 420 876 357
cleaner.
A09C08A

DISASSEMBLY AND ASSEMBLY TYPICAL

Using a flat screwdriver, lift fan protector tabs as Using a press, drive the fan shaft no. 9 out.
shown in the following photo, then remove fan
protector.

A23C06A

Support fan housing no. 12 with a ring. With a

A03C1YA 1 punch, working all around bearing no. 10 inner
race, drive bearing out of fan housing. Keep shims
1. Lift tab and remove fan protector
for installation.
To remove or install fan pulley retaining nut no. 17,
lock fan pulley with holder wrench for the 443
engine (P/N 420 876 357) and holder wrench for
the 552 engine (P/N 529 036 006). At assembly,
torque nut to 48 N•m (35 lbf•ft).

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Section 03 ENGINES (2-STROKE)
Subsection 07 (AXIAL FAN COOLING SYSTEM)

552 Engine
Using holder wrench (P/N 529 036 006), remove
fan nut.
All Engines
Remove fan with pulley half.
1

A23C07A

1. Ring supporting fan housing

Remove circlip no. 11 then remaining bearing.

To install, press one bearing in place then install
circlip and shims. Press the other bearing from
opposite side until it is flush with housing. Press
fan shaft from engine side of fan housing. Check
for free rolling action. A03C22A 1
1. Remove fan with pulley half
INSTALLATION
Remove fan belt.
At assembly, apply a light coat of Loctite 243 (blue)
(P/N 293 800 060) on screw no. 1 threads. Leave shims and second half pulley in place. Re-
fer to the following photo.
A gasket must be placed on both sides (inner and
outer) of intake and exhaust holes of cylinder cowl
no. 4 and 5.
Reinstall fan protector no. 18 properly.

 WARNING
Always reinstall fan protector after servicing.

FAN BELT REPLACEMENT AND

DEFLECTION ADJUSTMENT
Remove muffler, rewind starter and on so
equipped models connecting flange. Follow-
ing procedure described above.
443 Engine
Using holder wrench (P/N 420 876 357), remove
fan nut. A03C23A 1 2
1. Keep shims
2. Leave second half pulley in place

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 Section 03 ENGINES (2-STROKE)
Subsection 07 (AXIAL FAN COOLING SYSTEM)

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.
BELT FORCE
ENGINE TYPE
DEFLECTION APPLIED
443 and 552 9.5 mm (3/8 in) 5 kg (11 lb)

To adjust deflection tension, add or re-

move shim(s) no. 15 between pulley halves
no. 14 and 16. Install excess shim(s) between
distance sleeve no. 13 and pulley half no. 14
(housing side).

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Section 03 ENGINES (2-STROKE)
Subsection 07 (AXIAL FAN COOLING SYSTEM)

Finalizing Reassembly
2 3
Reinstall rewind starter.
1
CAUTION: When installing rewind starter, en-
sure that oil pump shaft is properly positioned.
Do not force shaft insertion. Turn fan until oil
pump shaft slides in place, as shown in the fol-
lowing photo.

A09C0VA

1. Unused shim(s) here

2. Adjust here
3. Positioning noses
4. Some engines only

Select pulley halves so that the one with 2 posi-

tioning noses will be on fan side. Ensure to insert
these noses into fan notches.
Once fan belt is properly adjusted, torque fan nut
to 48 N•m (35 lbf•ft) using holder wrench (P/N 420
876 357), as shown in the following photo. A03C25A

NOTE: Apply Loctite 243 (blue) (P/N 293 800 060) TURN FAN TO SLIDE OIL PUMP SHAFT IN PLACE
on fan nut threads.
Secure rewind starter with original screws.
Reinstall fan protector no. 18 properly.

 WARNING
Always reinstall fan protector after servicing.

Reinstall muffler.

A03C24A

TORQUE FAN NUT USING HOLDER WRENCH

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 Section 03 ENGINES (2-STROKE)
Subsection 08 (LIQUID COOLING SYSTEM)

LIQUID COOLING SYSTEM

SERVICE TOOLS
Description Part Number Page
engine leak tester kit ............................................................ 861 749 100 ......................................... 149
hose pincher ......................................................................... 295 000 076 ......................................... 149
siphon tool ............................................................................ 529 035 880 ......................................... 149
special radiator cap ............................................................... 529 021 400 ......................................... 149
SupertaniumTM bit ................................................................ 529 031 800 ......................................... 149

SERVICE PRODUCTS
Description Part Number Page
50/50 PREMIXED COOLANT - 37°C ( - 35°F) ....................... 293 600 038 ......................................... 151
Loctite 592............................................................................ 293 800 018 ......................................... 149

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Section 03 ENGINES (2-STROKE)
Subsection 08 (LIQUID COOLING SYSTEM)

593 Engine

4 3

Loctite 592

A29C2QT

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 Section 03 ENGINES (2-STROKE)
Subsection 08 (LIQUID COOLING SYSTEM)

COOLING SYSTEM LEAK TEST 3,4 Sender and Plug or Elbow

Install special radiator cap (P/N 529 021 400) in- Apply Loctite 592 (P/N 293 800 018) thread sealant
cluded in engine leak tester kit (P/N 861 749 100) on sender no. 3 and plug or elbow no. 4 to avoid
on coolant tank. Install hose pincher (P/N 295 000 leaks.
076) on overflow hose. Using pump also included
in kit pressurize all system through coolant reser- 1, Pressure Cap
voir to 100 kPa (15 PSI). Check if the cap pressurizes the system. If not,
Check all hoses and cylinder/base for coolant install a new 90 kPa (13 PSI) cap (do not exceed
leaks. Spray a soap/water solution and look for this pressure).
air bubbles.
2, Coolant Tank
For removal, drain cooling system before remov-
ing coolant tank no. 2.
Remove all hoses from coolant tank.
Slide down the coolant tank to disengage it from
oil tank.
Check if the tank is cracked or melted. Replace if
necessary.
For installation, reverse the removal procedure.
NOTE: It may be necessary to move oil tank for
an easier installation of coolant tank.

A32C3AA 529 021 400 295 000 076 6, Radiators

Remove all debris between radiator fins. A clean
radiator is more efficient than a dirty one.
INSPECTION Check if radiator fins are damaged. Replace bro-
Check general condition of hoses and clamp tight- ken radiator if necessary.
ness. NOTE: A radiator with many broken fins does not
work properly.
DRAINING THE SYSTEM For disassembly, drain cooling system.
 WARNING Remove rear suspension (refer to REAR SUSPEN-
Never drain or refill the cooling system when SION).
engine is hot. Using SupertaniumTM bit (P/N 529 031 800), drill
all rivets retaining radiator to the frame or grind
To drain the cooling system, siphon the coolant the rivets with a grinding disk.
mixture from the coolant tank no. 2 using the Pull the radiator a little and remove the Oetiker
siphon tool (P/N 529 035 880). Disconnect hose clamps.
at water pump to drain coolant from engine.
For installation, reverse the removal procedure.
When the coolant level is low enough, lift the rear
of vehicle to drain the radiator. 5, Thermostat
For disassembly, drain the cooling system (see
DISASSEMBLY AND ASSEMBLY above).
Coolant Pump Unscrew clamp retaining hose to the water outlet
socket.
Refer to BOTTOM END section.

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Section 03 ENGINES (2-STROKE)
Subsection 08 (LIQUID COOLING SYSTEM)

3 1 A16C02A 2
TYPICAL — CLOSED THERMOSTAT, COLD ENGINE
1. To reservoir
2. From cylinders

A32C8UA
– When the liquid is warmed enough, the ther-
1. Hose
2. Clamp mostat opens progressively the circuit, water
3. Water outlet socket pump — engine — radiators — coolant tank
to keep the liquid at the desired temperature.
Remove: (See the diagram of the exploded view).
– water outlet
– socket screws
– gasket thermostat.
To check thermostat, put in water and heat water.
Thermostat should start to open when water tem- 1
perature reaches the following degree. It will be
almost fully open at 50°C (122°F).

ENGINE TEMPERATURE

593 42°C (108°F)

Thermostat is a double action type.

– Its function is to give faster warm up of the en- 2
A16C03A
gine by controlling a circuit; water pump — en-
gine — coolant tank. This is done by bypassing TYPICAL — OPEN THERMOSTAT, WARM ENGINE
1. To radiators
the radiator circuit. 2. From cylinders

These 2 functions have the advantage of prevent-

ing a massive entry of cold water into the engine.

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 Section 03 ENGINES (2-STROKE)
Subsection 08 (LIQUID COOLING SYSTEM)

COOLING SYSTEM REFILLING

PROCEDURE
CAUTION: To prevent rust formation or freez-
ing condition, always replenish the system
with the Bombardier premixed coolant or with
50% antifreeze and 50% water. Pure antifreeze
without water freezes (like slush ice). Always
use ethylene glycol antifreeze containing cor-
rosion inhibitors specifically recommended for
aluminum engines.

System Capacity
Refer to TECHNICAL DATA.

Refilling Procedure
IMPORTANT: USE THE 50/50 PREMIXED
COOLANT - 37°C ( - 35°F) (P/N 293 600 038).
Do not reinstall pressure cap.
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
system (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,
recheck coolant level in coolant tank and refill up
to line.
Check coolant concentration (freezing point) with
proper tester.

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 Section 03 ENGINES (2-STROKE)
Subsection 09 (REWIND STARTER)

REWIND STARTER
SERVICE PRODUCTS
Description Part Number Page

Molykote PG 54.................................................................... 420 899 763 ................................. 157, 159

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Section 03 ENGINES (2-STROKE)
Subsection 09 (REWIND STARTER)

Rewind Starter on Fan Cooled Models

15
10 N•m
(89 lbf•in)

13
12 6
11 10 7
9
8
Molykote PG 54 5

7 N•m
1 (62 lbf•in)
4
2
Molykote PG 54

Molykote PG 54

A03C3CT

TYPICAL

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 Section 03 ENGINES (2-STROKE)
Subsection 09 (REWIND STARTER)

Rewind Starter on Liquid Cooled Models

9 N•m
(80 lbf•in)

15

13 Molykote 6
PG 54
11 10
9
8
12

Molykote 7 N•m
PG 54 Molykote (62 lbf•in)
PG 54 2
1
4
Molykote
PG 54

Molykote
PG 54

A32C69S

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Section 03 ENGINES (2-STROKE)
Subsection 09 (REWIND STARTER)

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 peri-
odically using specific lubricant. Otherwise,
rewind starter component life will be short-
ened 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 Liquid Cooled Models Only
lack of lubrication. Replace parts or lubricate ac- Pull out rope. Hold rewind starter in a vise. Slide
cordingly. rope and untie the knot. Pull out the rope com-
pletely.
REMOVAL
Using a small screwdriver, extract rope knot from
starter grip no. 15. Cut rope close to knot. Tie a
knot near starter.
Remove screws no. 2 securing rewind starter
no. 1 to engine then remove rewind starter.
Fan Cooled Models Only
Remove pump from rewind starter cover.

ROPE REPLACEMENT
Fan Cooled Models Only
Completely pull out rope. Hold rewind starter in a
vise.

A32C6GA 1
1. Knot to be untied

NOTE: When rope is completely pulled out, spring

preload is 4-1/2 turns.

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 Section 03 ENGINES (2-STROKE)
Subsection 09 (REWIND STARTER)

DISASSEMBLY ASSEMBLY
Undo knot previously tied at removal. Let sheave At assembly, position spring no. 4 outer end into
get free to release spring preload. spring guide notch then wind the spring counter-
Cut push nut no. 13 and discard. Remove locking clockwise into guide.
element no. 12, O-ring no. 11, step collar no. 10,
pawl lock no. 9 and pawl no. 8.  WARNING
Remove sheave no. 5 from starter housing no. 1. Since the spring is tightly wound inside the
Hold spring with a screwdriver. guide it may fly out when rewind is handled.
Always handle with care.

A03C3EA
A03C3FA 1
Fan Cooled Models Only 1. Outer end into guide notch
Disengage key no. 7 and pull out rope no. 6.
CAUTION: It is of the utmost importance that
the rewind starter spring be lubricated period-
ically using Molykote PG 54 (P/N 420 899 763).
Otherwise, rewind starter component life will
be shortened and/or rewind starter will not op-
erate properly under very cold temperatures.
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

Liquid Cooled Models Only

Take out the knot and then rope no. 6.

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Section 03 ENGINES (2-STROKE)
Subsection 09 (REWIND STARTER)

1 1

A01C15A

1. Push to lock

A01C14A
Lubricate housing post with silicone compound
TYPICAL grease. Install sheave.
1. Molykote PG 54 inside spring guide
Liquid Cooled Models Only
1 To install rope no. 6, insert rope into sheave no. 5
orifice and lock it by making a knot, leaving behind
a free portion of about 25 mm in length. Fuse rope
end with a lit match and insert it into sheave.

25 mm

A32C2AA

1. Molykote PG 54 applied 1 cm (1/2 in) wide on bottom of housing

CAUTION: The use of standard multipurpose A32C6HA

grease could result in rewind starter malfunc-
tion. FREE PORTION

Fan Cooled Models Only

To install rope no. 6, insert rope into sheave no. 5
orifice and lock it with the key no. 7 as illustrated.

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 Section 03 ENGINES (2-STROKE)
Subsection 09 (REWIND STARTER)

Callout

A32C6IA
A32C6CA

FREE PORTION INSERTED INTO SHEAVE

Lubricate pawl lock no. 9 with Molykote PG 54
Lubricate housing post with silicone compound (P/N 420 899 763). Install over pawl.
grease. Install sheave.
To adjust rope tension:
Wind rope on sheave and place rope sheave into
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.

A32C6DA

Install step collar no. 10 with its sleeve first. Lu-

bricate a new O-ring no. 11 and locking element
no. 9 with Molykote PG 54 (P/N 420 899 763). In-
A01C0CA
stall over pawl lock.
TYPICAL

Lubricate pawl no. 8 with Molykote PG 54

(P/N 420 899 763) then install over rope sheave.

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Section 03 ENGINES (2-STROKE)
Subsection 09 (REWIND STARTER)

A32C6EA 3 1 2 A01C18A

1. Step collar
TYPICAL
2. O-ring
3. Locking element

Position a new push nut no. 13.

INSTALLATION
Fan Cooled Models Only
Reinstall oil pump on rewind starter assembly.
All Models
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.

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 Section 03 ENGINES (2-STROKE)
Subsection 10 (FUEL SYSTEM)

FUEL SYSTEM
SERVICE TOOLS
Description Part Number Page
carburetor tool kit ................................................................. 404 112 000 ......................................... 165
choke plunger tool ................................................................ 529 032 100 ......................................... 171
float level gauge ................................................................... 529 035 520 ......................................... 167
hose pincher ......................................................................... 295 000 076 ................................. 172–173
vacuum/pressure pump kit ................................................... 529 021 800 ......................................... 172

SERVICE PRODUCTS
Description Part Number Page

silicone grease...................................................................... 293 550 004 ......................................... 169

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Section 03 ENGINES (2-STROKE)
Subsection 10 (FUEL SYSTEM)

CARBURETOR
Tundra

14

13
10

8
9

12 11

A05C1AT

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 Section 03 ENGINES (2-STROKE)
Subsection 10 (FUEL SYSTEM)

Skandic LT/LT E

2 Choke equipped
model only
3

15
5
7

29
6

13
9
8
10
11
12

A29C01S

TYPICAL

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Section 03 ENGINES (2-STROKE)
Subsection 10 (FUEL SYSTEM)

Skandic WT/SUV/SWT

Choke equipped
2 model only
3

4
15
5
7

29
6

13
9
8

10
11
12

A21C0CT

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 Section 03 ENGINES (2-STROKE)
Subsection 10 (FUEL SYSTEM)

IDENTIFICATION CAUTION: Heavy duty carburetor cleaner may

be harmful to the float material and to the rub-
All carburetors are identified on their body. ber parts, O-rings, etc. Therefore, it is recom-
mended to remove those parts prior to clean-
ing.
Carburetor body and jets should be cleaned in
a carburetor cleaner following manufacturer's
instructions. Replace any jets having gum or
varnish on their surfaces.
 WARNING
1 Solvent with a low flash point such as gaso-
line, naphtha, benzol, etc., should not be used
as they are flammable and explosive.

Check inlet needle tip condition. If worn, the inlet

needle and seat must be replaced as a matched
set.
A01C59A
NOTE: Install needle valve for snowmobile carbu-
retor only. It is designed to operate with a fuel
1. Identification: 34-482 pump system.
Check throttle slide no. 5 for wear. Replace as
necessary.
REMOVAL
Check idle speed screw no. 7 for straightness.
Tundra and Skandic LT/WT/SWT Replace as necessary.
Remove air silencer. Check for fuel soaked into float no. 12; replace as
All Models necessary.
Disconnect fuel inlet line. Check float no. 12 for cracks or other damages
affecting free movement ; replace as necessary.
Disconnect primer line from carburetor on some
models. Inspect throttle cable and housing for any dam-
ages. Replace as necessary.
Disconnect choke cable on some models.
Unscrew carburetor cover no. 1 then pull out DISASSEMBLY AND ASSEMBLY
throttle slide no. 5 from carburetor.
NOTE: To ease the carburetor disassembly and
 WARNING 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.

Untighten rubber flange clamps then remove car-
buretor from engine.

CLEANING AND INSPECTION A00B2FA

The entire carburetor should be cleaned with a

general solvent and dried with compressed air be-
fore disassembly.

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Section 03 ENGINES (2-STROKE)
Subsection 10 (FUEL SYSTEM)

E-Clip and Needle – air screw no. 6 adjustment

Remove screws from needle retaining plate to re- – throttle slide no. 5 height (preliminary idle
move the needle no. 3. speed adjustment)
The position of the needle in the throttle slide is – throttle cable adjustment
adjustable by means of an E-clip no. 2 inserted – carburetor synchronization (dual carburetor
into 1 of 5 grooves located on the upper part of models)
the needle. Position 1 (at top) is the leanest, 5 (at – final idle speed adjustment (engine running)
bottom) the richest. – oil pump and carburetor synchronization.
NOTE: The last digit of the needle identification
number gives the recommended position of the Float Arm
E-clip from the top of the needle. CAUTION: Spark plugs will foul if float is ad-
justed too low. Engine may be damaged if float
EXAMPLE: 6DH4-3 is adjusted too high.
Recommended Correct fuel level in float chamber is vital toward
Needle
position of the E-clip maximum engine efficiency. To check for correct
identification
from top float level proceed as follows:
A00C6FA

– Make sure that float arm no. 9 is symmetrical

1 Lean — not distorted.
– Remove float bowl and gasket from carburetor.
– With carburetor chamber upside-down on a lev-
2 el surface, measure height A between bowl
seat and top edge of float arm. Keep ruler per-
fectly vertical and in line with main jet hole.
3

1
4

5 Rich
A00B2GA

CLIP POSITIONS

Main Jet
The main jet no. 8 installed in the carburetor has
been selected for a temperature of - 20°C (0°F)
at sea level. Different jetting can be installed to
suit temperature and/or altitude changes. A ser-
vice bulletin will give information about calibration
according to altitude and temperature. A01C5AC A
TYPICAL
1. Measure from top of float arm
CARBURETOR ADJUSTMENTS A. Float height (including float arm thickness)
NOTE: For high altitude regions, a Service Bulletin
will give information about calibration according to
altitude and temperature.
Adjustments should be performed following this
sequence:
– float arm

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 Section 03 ENGINES (2-STROKE)
Subsection 10 (FUEL SYSTEM)

A00C03A

1. Contact tab

A01C5BA

1. Ruler vertical and in line with main jet Air Screw Adjustment
Completely close the air screw no. 6 (until a slight
Float level height can be checked using float level seating resistance is felt) then back off as speci-
gauge (P/N 529 035 520). Keep tool in line with fied.
main jet as explained above.
Turning screw in clockwise enriches mixture and
529 035 520 conversely, turning it out counterclockwise leans
mixture.
Refer to TECHNICAL DATA for the specifications.

2
1

A30C1QA A02C09A

1. Idle speed screw

2. Air screw
FLOAT HEIGHT
MODELS
± 1 mm (± .040 in)
Tundra Throttle Slide Height
Skandic 440 LT 23.9 (.941)
Preliminary Idle Speed Adjustment
Skandic 550F WT/SWT/SUV
Hook throttle cable into the needle retainer plate.
Skandic 600 WT LC/SUV 18.1 (.713)
NOTE: Do not obstruct hole in throttle slide when
– Bend the contact tab of float arm until the spec- installing needle retaining plate. This is important
ified height is reached. to let air escape through and thus allow a quick
response.

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Section 03 ENGINES (2-STROKE)
Subsection 10 (FUEL SYSTEM)

Final idle speed adjustment (engine running at idle

1 2 speed) should be within 1/2 turn of idle speed
screw from preliminary adjustment.

THROTTLE
MODELS SLIDE HEIGHT
± 0.1 mm ( ± .004 in)
3 Tundra Skandic WT/
SWT/WT LC/ SUV 550/ 1.5 (. 059)
SUV 600
Skandic LT 1.3 ( .051)

A00C1TA

CENTER POST TYPE

1. Throttle cable
2. Needle retaining plate
3. Throttle slide

Make sure the nylon packing no. 4 is installed on 1

all applicable throttle slides.
CAUTION: Serious engine damage can occur if
this notice is disregarded.

1 3

A01C3NA

TYPICAL
1. Drill bit used as gauge for throttle slide height

INSTALLATION
4 CAUTION: Never allow throttle slide(s) to snap
5 shut.
A00C3MA
Prior to installing carburetor, adjust air screw and
preliminary idle speed as described above.
CENTER POST TYPE
1. E-clip To install carburetor on engine, inverse removal
2. Needle retaining plate procedure.
3. Screw
4. Needle However, pay attention to the following:
5. Nylon packing
On applicable models, make sure to align tab of
Using a drill bit as a gauge, adjust throttle slide carburetor and air intake silencer (if applicable)
height (see following table) by turning idle speed with notch of adaptor(s). On applicable models,
screw no. 7. Throttle slide height is measured on install adaptor with up mark facing up.
outlet side of carburetor (engine side).
CAUTION: The rubber flange must be checked
NOTE: Make sure that throttle cable does not hold for cracks and/or damage. At assembly, the
throttle slide. Loosen cable adjuster accordingly. flange must be perfectly matched with the air
Throttle cable adjustment will be done during ad- intake manifold or severe engine damage will
justment of throttle-slide-to-cover free play. occur.

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 Section 03 ENGINES (2-STROKE)
Subsection 10 (FUEL SYSTEM)

Install clamps in a way that their tightening bolts At full opening, throttle slide must be flush or
are staggered — not aligned. 1.0 mm (.040 in) lower than the top of carbure-
tor outlet bore (engine side). Use a mirror to look
Throttle Cable Circlip at Handlebar through inlet bore.
Put silicone grease (P/N 293 550 004) around cable First loosen adjuster nut then turn throttle cable
barrel. Locate circlip as per illustration. adjuster accordingly.

 WARNING
1
If this procedure is disregarded, throttle lever 2
might be half-open at normally closed posi-
tion and the engine will speed up when start-
ing.

A01C3MA

FULL OPENING (THROTTLE LEVER AGAINST HANDLE GRIP)

1. Throttle cable adjuster
2. Throttle slide flush or 1.0 mm (.040 in) lower than
carburetor outlet bore (engine side)

3 With the throttle lever fully depressed, check that

A02C0FA 4 there is a free play between the carburetor cover
and top of throttle slide.
TYPICAL
1. Throttle cable housing
2. Throttle lever housing 2
3. Throttle lever
4. Circlip
1

Throttle Cable Routing 3

CAUTION: Check that throttle cable is routed
away from sharp edges, hot or vibrating parts.
When turning handlebar while engine is run-
ning, idle speed must not vary.

Throttle Cable Adjustment

 WARNING
Ensure the engine is turned OFF, prior to per-
forming the throttle cable adjustment.
A00C3FA

Carburetors must be installed on engine and throt- FULL OPENING (THROTTLE LEVER AGAINST HANDLE GRIP)
1. Cover
tle cable properly routed. 2. Free play
3. Throttle slide
For maximum performance, correct cable adjust-
ment is critical.

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Section 03 ENGINES (2-STROKE)
Subsection 10 (FUEL SYSTEM)

 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
CAUTION: On dual carburetor models, make
components in throttle mechanism. sure both carburetors start to operate simulta-
neously. Do not interchange carburetors as the
After throttle cable adjustment, synchronized car- jetting may be different on each side. A red dot
buretors (refer to CARBURETOR SYNCHRONIZA- is printed on one carburetor and on the engine.
TION) and adjusted oil pump cable (refer to OIL Match the carburetor and the engine dots when
INJECTION PUMP). applicable.
CAUTION: The oil injection pump adjustment
Carburetor Synchronization must be checked each time carburetor is ad-
Dual Carburetor Models Only justed. Refer to OIL INJECTION SYSTEM.
When depressing throttle lever, both carburetor
slides must start to open at the same time. IDLE SPEED FINAL ADJUSTMENT
Unlock cable adjustment lock nut on one carbure- Idle Speed Screw
tor.
CAUTION: Before starting engine for the final
Screw or unscrew cable adjuster until both carbu- idle adjustment, make sure that oil pump is
retor slides start to open at same time. Cable play adjusted. The oil injection pump adjustment
will be identical on both carburetors. Retighten must be checked each time carburetor is ad-
jam nut. justed. Refer to OIL INJECTION SYSTEM.
Start engine and allow it to warm then adjust
idle speed no. 7 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.
NOTE: Refer to TECHNICAL DATA for the specifi-
cations.
CAUTION: Do not attempt to set the idle speed
by using the air screw. Severe engine damage
can occur.

A03C2VA 1 2 CHOKE
TYPICAL
1. Screw or unscrew adjuster Skandic LT/WT/SWT/WT LC
2. Check that both slides start to open at the same time
Choke Plunger Adjustment
Check throttle slide position at wide open throt-
tle. Throttle slide must be flush or 1 mm (.040 in) Set choke lever to fully open position.
lower than carburetor outlet bore. At that same
position, check that throttle slide does not contact
carburetor cover. Turn cable adjuster and recheck
synchronization.

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 Section 03 ENGINES (2-STROKE)
Subsection 10 (FUEL SYSTEM)

A01C5HA A01C5FA

CHOKE LEVER — FULLY OPEN POSITION CUT-AWAY (ENGINE SIDE SHOWN)

1. Choke plunger
2. Tool properly seated under choke plunger
Insert choke plunger tool (P/N 529 032 100) into
choke air inlet of each carburetor. Tool stopper If tool tip does not sit under choke plunger no. 15,
may not lean against recess wall. Though it must adjust as follows:
be within 1 mm (.040 in) of recess wall.
Make sure choke lever is at fully open position.
Lift up protector cap and loosen choke cable lock
nut, as shown in the next photo.

1
1

A01C5EA

AIR SILENCER SIDE SHOWN

1. Tool stopper within 1 mm (.040 in) of recess wall
A01C5GA

1. Lift up protector cap

2. Loosen lock nut

Turn choke cable adjustment nut by hand until tool

properly sits under choke plunger.
NOTE: A light pressure is be needed to position
tool under plunger.

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Section 03 ENGINES (2-STROKE)
Subsection 10 (FUEL SYSTEM)

1 2 FUEL PUMP
REMOVAL
Install a hose pincher (P/N 295 000 076) on fuel
supply line close to pump inlet.

295 000 076

A01C5IA

1. Choke cable adjustment nut

2. Choke plunger tool

Tighten choke cable lock nut and reinstall protector

A01B2JA
cap.
Set choke lever to close and open positions and Disconnect fuel outlet line(s).
ensure that tool properly seats under plunger only
Disconnect impulse line.
when lever is set to fully open position.
Remove screws securing fuel pump.
Set choke lever to close position and, by pulling
and pushing choke lever, make sure there is no
tension on cable (free play). PUMP VERIFICATION
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: On model fitted with 2 outlets, plug 1 out-
let with finger while checking outlet valve.
To check impulse diaphragm and gasket on high-
supply fuel pump equipped with twin outlets, pro-
ceed as follows:
Connect a clean plastic tubing to the impulse nip-
A01C5JA ple and plug vent hole on top cover. Either apply
pressure or vacuum using the vacuum/pressure
CHOKE LEVER — CLOSED POSITION pump kit (P/N 529 021 800). The diaphragm/gas-
ket must not leak.

CLEANING AND INSPECTION

The entire pump should be cleaned with general
purpose solvent before disassembly.

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 Section 03 ENGINES (2-STROKE)
Subsection 10 (FUEL SYSTEM)

Fuel pump components should be cleaned in gen- Impulse/Fuel Lines Spring Clips
eral purpose solvent and dried with compressed Always reposition spring clips after any repair to
air. prevent possible leaks.
 WARNING
Solvent with a low flash point such as gaso-
line, naphtha, benzol, etc., should not be used
as each is flammable and explosive.

Inspect diaphragm. The pumping area should be

free of holes, tears or imperfections. Replace as
needed.
High-supply pump with twin outlets: Thoroughly
clean filter on top cover. Replace pump if too dirty.

INSTALLATION
To install, inverse removal procedure.

 WARNING
Pressure test to ensure there is no leak in fuel
system.

FUEL TANK
Fuel Tank Lines
 WARNING
When draining a fuel tank or whenever a fu-
el line is disconnected, obstruct line with a
hose pincher (P/N 295 000 076) or equivalent
device. Fuel is flammable and explosive un-
der certain conditions. Ensure work area is
well ventilated. Do not smoke or allow open
flames or sparks in the vicinity.

295 000 076

A01B2JA

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 Section 04 ENGINE (4-TEC)
Subsection 01 (LEAK TEST)

LEAK TEST
VERIFICATION Remove:
Before performing the cylinder leak test, verify the – radiator cap.
following: Unplug and remove ignition coil.
– clamp(s) tightness Remove spark plug from cylinder head.
– radiator and hoses NOTE: Ignition coil can help removing spark plug.
– oily contamination on leak indicator hole means
a damaged oil seal on water pump shaft
– coolant out of leak indicator hole means a dam-
1
aged rotary seal on water pump shaft (refer to
COOLING SYSTEM)
2
– coolant escaping from water pump housing
means damaged gasket(s) and/or loosened
screws (refer to COOLING SYSTEM).
NOTE: For all the checkpoints mentioned above,
see the appropriate engine section to diagnose
and repair the engine.

LEAK TEST PROCEDURE

NOTE: The following instructions are valid for both
cylinders.
R1004motr28A
PREPARATION AND TEST
1. Ignition coil
NOTE: The following procedures should be done 2. Spark plug
with a cold engine.
Remove valve cover.
PREPARATION
Disconnect battery.

 WARNING 2 1
Always respect this order for disassembly;
disconnect BLACK (-) cable first. Electrolyte
or fuel vapors can be present in engine com-
partment and a spark may ignite them and
possibly cause personal injuries.

R1004motr34A

1. Ratchet wrench
2. Valve cover

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Section 04 ENGINE (4-TEC)
Subsection 01 (LEAK TEST)

Preparation Diagnose
Using a dial gauge set the crankshaft and the pis- Listen for air leaks.
ton to precisely ignition TDC. If a dial gauge is not – air escaping on intake port/carburetor means
available, use a screwdriver or another similarly leaking intake valve(s)
suitable tool. – air escaping on exhaust port means leaking ex-
NOTE: The engine must be set to precisely igni- haust valve(s)
tion TDC; if this is not ensured the engine will con- – air bubbles out of radiator means leaking cylin-
tinue to rotate when pressure builds up. der head gasket
1 – air/oil escaping from crankcase means dam-
aged gasket and/or loosened screws (refer to
CRANKCASE)
– air/coolant escaping from cylinder/head means
damaged gasket(s) and/or loosened screws (re-
fer to CYLINDER AND HEAD)
– air escaping into crankcase area means exces-
sively worn cylinder and/or broken piston rings.
NOTE: For all the checkpoints mentioned above
see the appropriate engine section to diagnose
and repair the engine.
R1004motr35A

1. Dial gauge
INSTALLATION
NOTE: Within the course of the assembly, always
Connect to adequate air supply. replace the valve cover gasket.
Set needle of measuring gauge to zero. Torque valve cover screws to 9 N•m (80 lbf•in).
NOTE: All testers have specific instructions on Torque spark plugs to 17 N•m (150 lbf•in).
gauge operation and required pressure.
Slightly oil the bottom outer part of the stick coil.
Install gauge adapter into previously cleaned spark This will simplify installation.
plug hole.
For installation, reverse the preparation proce-
Supply combustion chamber with air pressure. dure.
Note the amount or percentage of leakage (de-
pending on tester).

LEAKAGE ENGINE
PERCENTAGE CONDITION
0% to 7% Excellent condition
Fair condition; proceed
8% to 15% with tune-up or
adjustment
Poor condition; engine
will run but performance
16% to 30%
might be down in
some cases.
Very poor condition,
30% and higher diagnose and repair
engine.

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 Section 04 ENGINE (4-TEC)
Subsection 02 (REMOVAL AND INSTALLATION)

REMOVAL AND INSTALLATION

4 N•m
(35 lbf•in) 4 N•m
(35 lbf•in)
6 N•m
(53 lbf•in)
2
1

37 N•m
(27 lbf•ft)
4

7
37 N•m
(27 lbf•ft)
4
5
37 N•m 37 N•m
37 N•m (27 lbf•ft) (27 lbf•ft)
(27 lbf•ft)
4
6
5

37 N•m
(27 lbf•ft)

37 N•m
37 N•m (27 lbf•ft)
A32CCKS
(27 lbf•ft)

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Section 04 ENGINE (4-TEC)
Subsection 02 (REMOVAL AND INSTALLATION)

ENGINE REMOVAL
Use B.U.D.S. to release fuel pressure. Refer to
B.U.D.S. instructions.
Disconnect battery.
2
 WARNING
Battery BLACK (-) cable must always be dis-
connected first and connected last.

 WARNING
1
Never charge or boost battery while installed.
Battery contains sulfuric acid which is corro- A29I05A
sive and poisonous. In case of contact with
skin, flush with water and call a physician im- 1. Locking tie
2. Fuel supply line
mediately.
Lift front of vehicle by the front cross member.
 WARNING CAUTION: Never lift front of 4-TEC models by
Should the battery casing be damaged, wear the front bumper.
a suitable pair of non-absorbent gloves when
removing the battery by hand.

Unplug fuel supply line no. 1 by squeezing spring

lock of plastic female coupling.

A29C36A

NOTE: At this point, drain engine oil only if engine

needs repair.
A32C7IA 1 Working underneath bottom pan, remove oil drain
plug then lift oil filter cover.
1. Plastic female coupling

Cut locking tie retaining fuel supply line to engine

harness.

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 Section 04 ENGINE (4-TEC)
Subsection 02 (REMOVAL AND INSTALLATION)

A32C7LA 1
1. Oil drain plug
A29C3BA

Drain the engine oil. 1. ECM

2. Main harness
Put back vehicle on the ground.
Remove muffler and pipes. Loosen collar screw on air silencer grommet.
Remove coolant reservoir cap. Siphon as much Disconnect blow-by hose from air silencer.
coolant as possible.
Disconnect the following:
– bottom hose from thermostat housing
– side hose from thermostat housing
– air bleed hose from T-fitting no. 2
– alternator
– ground cable from engine. 1

2
A29C38A

1 1. Collar screw
2. Blow-by hose

Disconnect air temperature sensor at rear of air

silencer.

A29C37A

1. Ground cable

Disconnect engine harness connectors (top one)

from ECM (engine control module) and main har-
ness.

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Section 04 ENGINE (4-TEC)
Subsection 02 (REMOVAL AND INSTALLATION)

1
A29C3AA

A29C39A

1. Air temperature sensor ENGINE INSTALLATION

Remove air silencer. Before engine installation, make sure that the
Remove guard, drive belt, drive pulley. front deflectors no. 7 are positioned as per fol-
lowing illustration.
Disconnect the starter RED (+) cable from starter.
Disconnect throttle cable no. 3 from throttle body.

A32C7NA 1 A
1. Throttle cable attachment

Remove screws no. 4 of engine supports.

Hook up engine by lifting eye located on intake
manifold. Using appropriate lifting device, remove
engine from vehicle.
A32CCLA

A. 10 ± 1.5 mm (1/2 ± 1/16 in)

Before engine installation make sure a good con-

dition stopper no. 6 is in place.
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:

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 Section 04 ENGINE (4-TEC)
Subsection 02 (REMOVAL AND INSTALLATION)

Check pulley alignment and drive belt height.

Install doughnut shaped exhaust gasket with both
notches aligned with Y-manifold protrusions.
NOTE: No sealant required on doughnut shaped
exhaust gasket.
Torque screws no. 4 of engine supports to 37 N•m
(27 lbf•ft).
NOTE: Install washers no. 5 with the teeth toward
the support.

A32C8SA 1
1. Teeth

Do not forget to connect air temperature sensor

to air silencer otherwise a fault code will appear.

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 Section 04 ENGINE (4-TEC)
Subsection 03 (COOLING SYSTEM)

COOLING SYSTEM
SERVICE TOOLS
Description Part Number Page
engine leak tester kit ............................................................ 861 749 100 ......................................... 186
hand pump............................................................................ 529 021 800 ......................................... 186
hose pincher ......................................................................... 295 000 076 ......................................... 186
oil seal pusher....................................................................... 529 035 757 ......................................... 192
seal installer.......................................................................... 529 035 766 ......................................... 192
special radiator cap ............................................................... 529 021 400 ......................................... 186

SERVICE PRODUCTS
Description Part Number Page

50/50 PREMIXED COOLANT - 37°C (- 35°F) ........................ 293 600 038 ......................................... 186

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Section 04 ENGINE (4-TEC)
Subsection 03 (COOLING SYSTEM)

26

29
30

28

27

27

A29C34S

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 Section 04 ENGINE (4-TEC)
Subsection 03 (COOLING SYSTEM)

23 24

24 19
16

14 14
22 18

16

16
15
20 21
22
17
14

13
10
5
4
2
12

11 Engine oil
6 8
7 9

Engine oil

3
1

R1004motr130S

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Section 04 ENGINE (4-TEC)
Subsection 03 (COOLING SYSTEM)

COOLING SYSTEM LEAK TEST

 WARNING
To prevent burning yourself, do not work on
cooling system when the engine is hot.

Remove pressure cap no. 30.

Install special radiator cap (P/N 529 021 400) in-
cluded in engine leak tester kit (P/N 861 749 100)
on coolant tank no. 28.
Install hose pincher (P/N 295 000 076) on overflow
hose no. 26.
Using the hand pump (P/N 529 021 800) pressur-
ize all system through coolant tank to 120 kPa (17 A32CCDA 2 1 3
PSI).
1. Leak indicator hole
Check all hoses, radiators no. 27 and cylinder/base 2. Alternator
3. Water pump
for coolant leaks.
NOTE: Flowing coolant indicates a damaged ro-
tary seal no. 5. Oil out of the leak indicator hole
indicates a defective oil seal no. 4.

COOLANT REPLACEMENT
Recommended Coolant
IMPORTANT: USE THE 50/50 PREMIXED
COOLANT - 37°C (- 35°F) (P/N 293 600 038).
CAUTION: To prevent rust formation or freez-
ing condition, always replenish the system
with the recommended coolant.

System Capacity
A32C82A 529 021 400 295 000 076 Refer to TECHNICAL DATA.

Draining the System

INSPECTION
Check general condition of hoses and clamp tight-
 WARNING
ness. To prevent burning yourself do not work on
cooling system when the engine is hot.
Check leak indicator hole to see if there is oil or
coolant.
Remove pressure cap no. 30.
Siphon as much coolant through coolant tank
no. 28.
Empty the overflow coolant tank no. 29.
Disconnect side hose and bottom hose from ther-
mostat housing.

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 Section 04 ENGINE (4-TEC)
Subsection 03 (COOLING SYSTEM)

1 CAUTION: Never allow coolant tank to be emp-

ty during the filling procedure.
Let engine idling for about 10 minutes or until radi-
ators are warm — which means that the thermo-
stat is open.
Keep engine idling for an additional 5 minutes
maximum or until coolant temperature reaches
100°C (212°F). Always keep coolant tank half
filled but the bleed hose free.
CAUTION: Never allow coolant to exceed 100°C
(212°F). Put a thermometer in coolant tank to
monitor the temperature.
Stop engine. Fill up both coolant tank no. 28 and
overflow coolant tank no. 29. Install their respec-
tive caps.
A32C83A 2 Let vehicle cool down for at least 30 minutes.
1. Side hose location Check coolant level in overflow coolant tank
2. Bottom hose
no. 29. Some coolant should have been sucked
Let coolant drain. through the overflow hose up to the coolant tank.
If not repeat refilling procedure.
Refilling the System If some coolant have been siphoned from the
With vehicle on a flat surface, engine cold, slowly overflow coolant tank no. 29, remove pressure
half fill coolant tank no. 28. Coolant level must cap no. 30 and fill up the coolant tank no. 28.
not reach bleed hose nipple to allow air to escape Reinstall pressure cap no. 30.
from the system. Fill overflow coolant tank no. 29 to maximum level
line.
Recheck coolant level after vehicle has completely
cooled down. Coolant tank no. 28 must be full and
the level in overflow coolant tank no. 29 must be
between the minimum and maximum marks.

A32C84A

1. Bleed hose nipple

Coolant level will be stable once coolant tank is

half filled.
Do not install the pressure cap no. 30. A32C76A 2 1
Start engine. Check level in coolant tank. Refill 1. Minimum
with coolant to keep coolant tank half filled. 2. Maximum

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Section 04 ENGINE (4-TEC)
Subsection 03 (COOLING SYSTEM)

After the first few kilometers (miles) of running Inspection

recheck level. Check the water pump housing for cracks or other
damage.
COOLANT HOSES Replace water pump housing if damaged.
Any damaged/leaky or brittle coolant hose or com-
ponent must be replaced. When replacing a hose,
also replace the clamps.
At installation, do not twist or bend the hoses.

WATER PUMP
HOUSING/THERMOSTAT
The thermostat is a dual action type.

Removal
NOTE: The thermostat is located on the ignition
cover. Thermostat and water pump housing form
one unit and can only be replaced as one complete R1004motr132A
component.
WATER PUMP HOUSING WITH GASKET
Drain cooling system (refer to DRAINING THE
SYSTEM above).
Remove: Installation
– water pump housing screws no. 12 and no. 13 The installation is the opposite of the removal pro-
and pull water pump housing no. 11. cedure. Pay attention to the following details.
NOTE: At installation, replace the gasket of the
water pump housing.
Torque water pump housing screws to 9 N•m
(80 lbf•in).
CAUTION: To prevent leakage, make sure the
gasket is exactly in the groove when the water
pump housing is reinstalled.
Tightening sequence for screws on water pump
housing is as per following illustration.

R1004motr131A 1
1. Water pump housing with screws and thermostat inside

Test
To check thermostat, put in water and heat water.
Thermostat should open when water temperature
reaches 80°C (176°F).

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 Section 04 ENGINE (4-TEC)
Subsection 03 (COOLING SYSTEM)

Installation
The installation is the opposite of the removal pro-
7 8 cedure. Pay attention to the following details.

9
CAUTION: Be careful not to damage impeller
2 wings during installation. Tighten impeller to
6 7 N•m (62 lbf•in).
4 10
11
IGNITION COVER
5
Removal
1 12 Remove:
3
– drain lubrication system (refer to OIL CHANGE)
– alternator (refer to ALTERNATOR)
R1004motr133A
– water pump housing no. 11
– impeller no. 10
WATER PUMP IMPELLER – screws no. 3 and pull ignition cover no. 1.
Carefully remove the ignition cover using a screw-
Removal driver and a plastic hammer.
Remove:
– water pump housing no. 11
– impeller no. 10.
Using pliers, carefully turn the impeller anti-clock-
wise to remove it from the water pump shaft with-
out any damage. The thread of the water pump
shaft is right-hand.

R1004motr135A

Ball Bearing Removal Procedure

NOTE: Heat ignition cover up to 100°C (212°F) be-
fore removing ball bearings.

 WARNING
Clean oil, outside and inside ignition cover
before heating it.
R1004motr134A 1
1. Impeller NOTE: Using a suitable arbor, eject the ball bear-
ing with slight hammer blows towards the inside.
The ignition cover has to be supported from below
Inspection in order to prevent damage of the sealing surface.
Check impeller for cracks or other damage. Re-
place impeller if damaged.

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Section 04 ENGINE (4-TEC)
Subsection 03 (COOLING SYSTEM)

Inspection Place new ball bearing in freezer for 10 minutes

Check oil supply hole/support bearing for scorings before installation.
or other damages. There are no plain bearings in NOTE: Do not use any striking tool to insert the
the ignition cover. ball bearing. The bearing must be mounted man-
ually with moderate (thumb) pressure into the ig-
nition cover.
2
Replace gasket no. 2.
Torque ignition cover screws to 9 N•m (80 lbf•in).
Tighten screws in the following sequence.

7 8
9 2
6
23 4 10
5 11
1 1 12
22
3
13
A 21 14
R1004motr136A 16
15
1. Ignition cover
2. Ball bearing 20 17
A. Oil supply hole/support bearing diameter 19 18
R1004motr137A

NOTE: Measure oil supply hole/support bearing di-

ameter. Compare to crankshaft journal diameter
on alternator (refer to CRANKSHAFT). Replace the WATER PUMP SHAFT
ignition cover if the measurement is out of speci-
fication.
Removal
Remove:
DIAMETER OF OIL SUPPLY HOLE/ – water pump housing no. 11
SUPPORT BEARING – impeller no. 10
SERVICE LIMIT 20.040 mm (0.7889 in) – ignition cover

NOTE: Check ball bearing for excessive play and

smooth operation. Replace if necessary.

Installation
The installation is the opposite of the removal pro-
cedure. Pay attention to the following details.
Ball Bearing Installation Procedure
NOTE: Heat ignition cover up to 100°C (212°F) be-
fore installing ball bearing.

 WARNING
Clean oil, outside and inside housing before
heating it.

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 Section 04 ENGINE (4-TEC)
Subsection 03 (COOLING SYSTEM)

CAUTION: When removing water pump shaft,

1 always replace rotary seal with water pump
shaft no. 7 and oil seal no. 4 (behind rotary
seal).

R1004motr138A

1. Water pump gear R1004motr171A

2. Thrust washer behind water pump gear

WATER PUMP SHAFT WITH ROTARY SEAL

– water pump gear no. 9

NOTE: The water pump gear is held by a needle 2
1
pin on the water pump shaft.

R1004motr172A

1. Oil seal behind the rotary seal

R1004motr168A
2. Rotary seal bore

1. Water pump gear Extract the water pump shaft with rotary seal no. 5
together with oil seal no. 4 from inside ignition
– needle pin no. 8 and thrust washer no. 6. cover with a pusher.
1 2 CAUTION: Be careful not to damage the surface
of the rotary seal bore in ignition cover.

R1004motr170A

1. Needle pin
2. Thrust washer

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Section 04 ENGINE (4-TEC)
Subsection 03 (COOLING SYSTEM)

R1004motr139A R1004motr140A 1
1. Oil seal for the water pump shaft
Inspection 2. Oil seal pusher (P/N 529 035 757)
3. Handle for insertion jig (P/N 420 877 255)
Inspect water pump gear for wear and damage on
the snap mechanism to the needle pin. Replace Install the water pump shaft assembly using the
if damaged. water pump ceramic seal installer (P/N 529 035
Water pump shaft with rotary seal must rotate 766).
freely. Otherwise, replace it. CAUTION: Never use a hammer for the rotary
NOTE: When removing water pump shaft, al- seal installation. Only use a press to avoid
damaging the ceramic component.
ways replace together retaining ring, oil seal,
water pump shaft with rotary seal with new parts.

Installation 2
For installation, reverse the removal procedure.
Pay attention to the following details.
NOTE: Never use oil in the press fit area of the oil
seal and rotary seal.
Push water pump shaft oil seal in place by using
the oil seal pusher (P/N 529 035 757).

R1004motr141A

1. Water pump shaft with rotary seal

2. Water pump ceramic seal installer (P/N 529 035 766)

Mount thrust washer no. 6 and needle pin no. 8.

NOTE: The water pump shaft must be slightly pre-
loaded by the spring of the rotary seal.
Use multi-purpose grease in water pump shaft
bore.

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 Section 04 ENGINE (4-TEC)
Subsection 03 (COOLING SYSTEM)

PRESSURE CAP
Check if cap pressurizes the system. If not, install
a new 110 kPa (16 PSI) cap (do not exceed this
pressure).

RADIATORS
Refer to CHASSIS for radiators no. 27 removal and
installation.

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 Section 04 ENGINE (4-TEC)
Subsection 04 (LUBRICATION SYSTEM)

LUBRICATION SYSTEM
SERVICE TOOLS
Description Part Number Page
dial indicator.......................................................................... 414 104 700 ......................................... 203
fuel line remover................................................................... 529 035 714 ......................................... 198
oil pressure adapter .............................................................. 529 035 652 ......................................... 198
oil pressure gauge ................................................................ 529 035 709 ......................................... 198
oil seal pusher....................................................................... 529 035 911 ......................................... 204

SERVICE PRODUCTS
Description Part Number Page
Loctite 243............................................................................ 293 800 060 ......................................... 199
Molykote 111........................................................................ 413 707 000 ................................. 200, 207
XP-S 0W40 synthetic 4-stroke oil (12 x 1L) .......................... 293 600 054 ......................................... 198

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Section 04 ENGINE (4-TEC)
Subsection 04 (LUBRICATION SYSTEM)

18

8 7 19
6 Engine
oil
20
9 2
17

Molykote Molykote
111 5 10
4 111
16 12
14
3 15
1

Molykote
111

11
13

R1004motr173S

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 Section 04 ENGINE (4-TEC)
Subsection 04 (LUBRICATION SYSTEM)

46 Loctite
243

32
21 Engine
31
oil
22
30 23 24
Molykote
27 111

32 26 25
37
38
Molykote Engine 28
111 oil
29 36 34 38
35 Molykote
33 43 111
Engine
oil 42

Molykote
111
40
44
39
45 Molykote 41
111

R1004motr174S

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Section 04 ENGINE (4-TEC)
Subsection 04 (LUBRICATION SYSTEM)

GENERAL
Prior to changing the oil, ensure vehicle is on a
level surface.
Oil and oil filter must be replaced at the same
time. Oil change and oil filter replacement should
be done with a warm engine.

 WARNING
The engine oil can be very hot. Wait until en-
gine oil is warm.

At installation, use torque values and service

products from the exploded view. Clean threads
before using Loctite products when installing
screws. A32C75A 1 2
Dispose oil and filter as per your local environmen- 1. Maximum
2. Minimum
tal regulations.
Add XP-S 0W40 synthetic 4-stroke oil (12 x 1L)
OIL LEVEL CHECK (P/N 293 600 054)through dipstick hole as re-
quired.
Snowmobile must be on a level surface.
Reinstall dipstick.
Warm up the engine to 80°C (176°F).
Leave engine running at idle for at least 30 sec- ENGINE OIL PRESSURE TEST
onds.
Stop engine and wipe the dipstick. NOTE: The engine oil pressure test should be
done with a warm engine 80°C (176°F) and the
Dipstick must be completely screwed in before recommended oil.
checking oil level.
Remove the oil pressure switch no. 46 in the
Oil level must be between minimum and maxi- area of the cylinder head (intake side), mounted
mum marks on dipstick. on the ignition cover and install the oil pressure
There is a capacity of 500 mL (17 U.S. oz) between gauge (P/N 529 035 709) and oil pressure adapter
the two marks. (P/N 529 035 652). Use fuel line remover (P/N 529
035 714) to unplug oil pressure adapter from oil
pressure gauge.

R1004motr38A 1
1. Oil pressure switch

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 Section 04 ENGINE (4-TEC)
Subsection 04 (LUBRICATION SYSTEM)

NOTE: Oil pressure switch works between 20 kPa Inspection

(2.9 PSI) and 40 kPa (5.8 PSI). Oil condition gives information about the engine
The engine oil pressure should be within the fol- condition. See TROUBLESHOOTING section.
lowing values.
Installation
OIL PRESSURE 1300 RPM 7250 RPM The installation is the reverse of removal proce-
150 kPa 400 kPa dure. Pay attention to the following details.
MINIMAL
(22 PSI) (58 PSI) NOTE: At installation, remember to replace the
200 kPa 450 kPa gasket ring no. 44 of the drain plug.
NOMINAL
(29 PSI) (65 PSI) Torque drain plug to 55 N•m (40 lbf•ft).
250 kPa 550 KPa
MAXIMAL
(36 PSI) (80 PSI) System Capacity
Refer to TECHNICAL DATA.
If the engine oil pressure is out of specifications, NOTE: After filling, warm up the engine to 80°C
check the points described in troubleshooting sec- (176°F) and check the oil level with the dipstick.
tion. Refer to OIL LEVEL CHECK above.
To install oil pressure switch, reverse the removal
procedure. OIL FILTER
NOTE: Fit oil pressure switch with Loctite 243
(P/N 293 800 060). Removal
Remove:
OIL CHANGE – engine oil (refer to OIL CHANGE)
– oil filter screw no. 9
Removal – oil filter cover no. 7
Place a drain pan under the engine drain plug area. – oil filter no. 5.
Clean the drain plug area.
1 3 2 3 4
Unscrew drain plug no. 45 then remove dipstick
no. 16.

R1004motr40A
R1004motr39A 2 1
1. Oil filter screw
1. Drain plug 2. Oil filter cover
2. Gasket ring 3. Gaskets
4. Oil filter

– Unscrew retaining screw no. 9 to drain the oil

filter housing.
– Wait a while to allow oil to flow out of oil filter.

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Section 04 ENGINE (4-TEC)
Subsection 04 (LUBRICATION SYSTEM)

Inspection 3
Check and clean the oil filter inlet and outlet area
for dirt and other contaminations.

1
R1004motr41A 1 2
1. Inlet bore from the oil pump to the oil filter R1004motr55A 2 2
2. Outlet bore to the engine oil providing system
1. Oil tank
2. Six screws
3. Hoses
Installation
The installation is the opposite of the removal pro- CAUTION: Make sure that the O-rings no. 11
cedure. Pay attention to the following details. and no. 12 do not get stuck in the crankcase.
NOTE: Slightly oil the two gaskets at the top and Inspection
bottom sides of the oil filter before assembly. This
will ease assembly and prevent displacement of Inspect the oil tank for cracks/fractures or other
the gasket during installation. damage/leakage.
At assembly, remember to replace the two NOTE: If necessary, replace the oil tank.
O-rings no. 6 and no. 8 of the oil filter screw.
Installation
Slightly grease the O-ring no. 6 of the oil filter cov-
The installation is the opposite of the removal pro-
er before assembly using Molykote 111 (P/N 413
cedure. Pay attention to the following details.
707 000). This will ease assembly and prevent dis-
placement of the gasket during installation. NOTE: At assembly, replace both O-rings no. 11
and no. 12.
Torque oil filter screw to 9 N•m (80 lbf•in).
Before assembly, slightly grease the O-rings. This
OIL TANK will ease assembly and prevent displacement of
the gasket during installation.
Removal Torque oil tank screws to 9 N•m (80 lbf•in) as per
First drain the lubrication system (refer to OIL following sequence.
CHANGE).
Remove:
– hose clamps no. 17 and pull hoses
– oil tank screws no. 13 and no. 14 and pull oil
tank no. 10.

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 Section 04 ENGINE (4-TEC)
Subsection 04 (LUBRICATION SYSTEM)

1 Replace oil filter housing if damaged.

Installation
The installation is the opposite of the removal pro-
cedure. Pay attention to the following details.
NOTE: Always replace gasket no. 1.
Torque oil filter housing screws to 9 N•m
(80 lbf•in).
3

5
ENGINE OIL PRESSURE
REGULATOR
The oil pressure regulator is located on the engine
alternator side (behind ignition cover/pressure oil
pump cover).
R1004motr56A 2 4 6

OIL FILTER HOUSING

Removal
First drain the lubrication system (refer to OIL
CHANGE).
Remove:
– oil tank (refer to OIL TANK)
– oil filter (refer to OIL FILTER)
R1004motr43A 1
– oil filter housing screws no. 3 and no. 4 and pull
oil filter housing no. 2. 1. Engine oil pressure regulator

NOTE: The oil pressure regulator system works

between 240 kPa (35 PSI) and 430 kPa (62 PSI).

Removal
Remove:
– water pump housing (refer to COOLING SYS-
TEM)
– ignition cover (refer to COOLING SYSTEM)
– oil pump cover no. 25 (refer to PRESSURE OIL
PUMP)
– O-ring no. 36, valve seat no. 35, pressure reg-
ulating piston no. 34 and spring no. 33.
R1004motr42A 1 2 Put a suitable Allen wrench or another 90° an-
1. Oil filter housing
gle tool under the engine oil pressure regulator.
2. Three screws By slight hammer blows against the Allen wrench
carefully drive out the oil pressure regulator.

Inspection
Check the oil filter housing for cracks or other dam-
age.

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Section 04 ENGINE (4-TEC)
Subsection 04 (LUBRICATION SYSTEM)

Fit the engine oil pressure regulator by pushing it

carefully with an aluminum or brass rod. The en-
gine oil pressure regulator must be flush with the
crankcase. Following installation check the pres-
sure regulator piston for easy movement.
NOTE: At installation always replace the O-ring
no. 36, and fit it with grease.

OIL PUMPS
R1004motr44A 1
The oil pumps are located on the engine alternator
1. Allen wrench side (behind ignition cover).
The engine is equipped with two oil pumps, a pres-
sure oil pump and a suction oil pump.

R1004motr45A 1 2 3 4
1. O-ring
2. Valve seat
3. Pressure regulator piston
4. Spring

Inspection
Inspect pressure regulator piston and valve seat R1004motr46A 2 1
for scoring or other damages. 1. Pressure oil pump
2. Suction oil pump
Check spring for free length.

SPRING FREE LENGTH

PRESSURE OIL PUMP
NEW NOMINAL 46 mm (1.811 in)
SERVICE LIMIT 45 mm (1.771 in) Removal
Remove:
NOTE: Replace worn or damaged components. – water pump housing (refer to COOLING SYS-
Pressure regulator piston and valve seat may only TEM)
be replaced together. – ignition cover (refer to COOLING SYSTEM)
Clean bore and threads in the oil pump housing – oil pump gear no. 31
from metal shavings and other contaminations. – needle pin no. 30
– drive gear of crankshaft (refer to CRANKSHAFT)
Installation
– oil pump cover screws no. 32 and pull oil pump
For installation, reverse the removal procedure. cover no. 25
Pay attention to the following details.
– oil pump shaft with inner rotor no. 27 and outer
NOTE: Oil the pressure regulator piston before in- rotor no. 28
stallation. – intermediate plate no. 29.

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 Section 04 ENGINE (4-TEC)
Subsection 04 (LUBRICATION SYSTEM)

4 2 3 2 4 1

C
R1004motr49A 2
R1004motr47A 1 4 1 4
1. Outer rotor
1. Oil pump gear 2. Inner rotor
2. Needle pin
3. Drive gear of crankshaft
4. Oil pump cover screws OUTER AND INNER ROTORS
CLEARANCE MM (IN)
SERVICE LIMIT
Inspection
A
Inspect oil pump shaft assembly and the oil pump
cover for marks or other damages. B 0.25 mm (.009 in)
Check inner rotor for corrosion pin-holes or other C
damages. If so, replace oil pump shaft assembly.
Also check the oil pump cover. If damaged, re- If clearance between inner and outer rotors ex-
place the complete oil pump assembly. ceeds the tolerance, replace oil pump shaft as-
sembly. Ensure to also check oil pump cover. If
damaged, replace the complete oil pump assem-
bly.
If clearance between outer rotor and its bore in
oil pump exceeds the tolerance, replace the com-
plete oil pump assembly.
Using a dial indicator (P/N 414 104 700), measure
side wear as shown.
R1004motr48A 1
1. Pittings on the teeth

Using a feeler gauge, measure the clearance be-

tween inner and outer rotors.

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Section 04 ENGINE (4-TEC)
Subsection 04 (LUBRICATION SYSTEM)

2 Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
CAUTION: The outer rotor no. 28 and the oil
pump shaft with inner rotor no. 27 are marked
on the upper side. When installing, make sure
that the position of the outer rotor is not re-
versed.
1

R1004motr50A 1
1. Oil pump cover surface
2. Dial indicator

R1004motr51A 1
2
1. Marking

NOTE: At installation always replace the oil seal

no. 26 fitted in the oil pump cover.
Push oil seal in place by using the oil seal pusher
(P/N 529 035 911).

R1004motr62A 1
1. Oil pump outer rotor surface
2. Dial indicator

Difference between oil pump cover and outer ro-

tor should not exceed 0.1 mm (.004 in). If so, re-
place the complete oil pump assembly.
NOTE: When the axial clearance of the oil pump
shaft assembly increases, the oil pressure de- R1004motr52A 1 2
creases.
1. Oil seal
Check the inside of oil pump cover for scoring or 2. Oil seal pusher (P/N 529 035 911)
other damages. If so, change the complete oil
pump assembly. Torque oil pump housing screws to 9 N•m
(80 lbf•in) as per following sequence.

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 Section 04 ENGINE (4-TEC)
Subsection 04 (LUBRICATION SYSTEM)

1 5 1

R1004motr51A 1
1. Marking

Torque oil pump housing screws to 9 N•m

(80 lbf•in) as per following sequence.

4 1 3
R1004motr53A 4 2 3

Final Test
After engine is completely reassembled, start en-
gine and make sure oil pressure is within specifi-
cations.

SUCTION OIL PUMP

Removal
For information about disassembly of the suction
oil pump please refer to PRESSURE OIL PUMP.
Disassembly is the same for both pumps.
R1004motr54A 2
Inspection
For information about inspection of the suction oil Final Test
pump please refer to PRESSURE OIL PUMP. In- After engine is completely reassembled, start en-
spection is the same for both pumps. gine and make sure oil pressure is within specifi-
cations.
Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
CAUTION: The outer rotor no. 23 and the oil
pump shaft with inner rotor no. 22 are marked
on the upper side. When installing, make sure
that the position of the outer rotor is not re-
versed.

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Section 04 ENGINE (4-TEC)
Subsection 04 (LUBRICATION SYSTEM)

OIL NOZZLE
The oil nozzles no. 38 are located within the
crankcase. Each piston is equipped with a sepa-
rate oil nozzle.
3

R1004motr175A 1 2
R1004motr57A 1
1. Oil nozzle
1. Oil nozzle 2. Crankcase
3. Contact surface
NOTE: If the engine has to be disassembled with-
in the scope of repair work, take this opportunity NOTE: If the oil nozzles are damaged or bent dur-
to clean the oil nozzles. ing installation work in the crankcase, they must
be replaced immediately.
Cleaning and Inspection Torque oil nozzle screws to 19 N•m (168 lbf•in).
Clean oil nozzle with a part cleaner then use an air
gun to dry it. OIL SIEVES
 WARNING The engine is equipped with 3 oil sieves no. 37,
no. 39 and no. 42 for filtering dirt and abraded
Always wear eye protector. Chemicals can particles from the oil circuit. The sieves are fitted
cause a rash break out and injure your eyes. into the crankcase.

Installation
CAUTION: At assembly, make sure the contact
surfaces of the oil nozzle are well fitted onto the
crankcase. If this is not ensured, the spray di-
rection will change, causing potential damage R1004motr59A

to the engine.
3 OIL SIEVES

NOTE: Cleaning of the oil sieves is only possible

if the engine is disassembled. So, if the engine
has to be disassembled within the scope of repair
work, clean the sieves at the same time.

Cleaning and Inspection

Clean oil sieves with a part cleaner then use an air
gun to dry it.

 WARNING
Always wear eye protector. Chemicals can
cause a rash break out and injure your eyes.

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 Section 04 ENGINE (4-TEC)
Subsection 04 (LUBRICATION SYSTEM)

Check sieves for cracks or other damage. NOTE: If the engine has to be disassembled with-
NOTE: Replace sieves if damaged. in the scope of repair work, take this opportunity
to clean the reed valve, using a rag.
Installation
Inspection
NOTE: During assembly always replace both
O-rings no. 40 and no. 41. Check reed valve for cracks or other damage.
CAUTION: Take particular care with oil sieve NOTE: Replace reed valve if damaged.
no. 42 to ensure that it is re-installed in exactly
the same position. Installation
At installation, replace the rubber gasket of the
reed valve.
NOTE: Slightly grease the rubber gasket with
Molykote 111 (P/N 413 707 000). This will ease
assembly and prevent displacement of the gasket
during installation.

R1004motr60A 1
1. Correct installation position of oil sieve

NOTE: Before assembly, slightly oil the O-rings

and the sieves at the outside using Molykote 111
(P/N 413 707 000). This will ease assembly and
prevent displacement of the gasket during instal-
lation.

REED VALVE
The engine is equipped with a reed valve no. 43
which prevents accumulation of larger oil quanti-
ties in the crankcase. The reed valve is fitted into
the crankcase.

R1004motr61A

REED VALVE

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 Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

CYLINDER AND CYLINDER HEAD

SERVICE TOOLS
Description Part Number Page
camshaft locking tool............................................................ 529 035 839 ......................................... 220
................................ 213–214,
crankshaft locking tool.......................................................... 529 035 900 219–220, 222, 227–228
valve spring compressor clamp ............................................ 529 035 764 ......................................... 223
valve spring compressor cup................................................ 529 035 724 ......................................... 223
valve stem seal installer ....................................................... 529 035 687 ......................................... 227

SERVICE PRODUCTS
Description Part Number Page

Loctite 243............................................................................ 293 800 060 ................................. 217, 220

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Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

CYLINDER/CYLINDER HEAD 1 (FRONT-SIDE)

9 N•m 9 N•m
(80 lbf•in) (80 lbf•in)
Engine oil
51 56
53 48
Loctite 243
19 55
18 Multi-purpose
Multi-purpose grease
50 grease
49 46 17
54
Engine oil
40 9 N•m 10
39 9 N•m 47 16
52 (80 lbf•in) 26 15 (80 lbf•in)
9 N•m 35 7
(80 lbf•in) 33 25 17 N•m 9
(150 lbf•in) Loctite 243
9 N•m 41 31 27 8
(80 lbf•in) 37 60 50 N•m
28 24 (37 lbf•ft) + 90° 6
Loctite 38 36
243 6 N•m 34 20
5
(53 lbf•in) 13 11
32 4
Engine 29 30
oil Multi-purpose
20 N•m Loctite grease
(177 lbf•in) + 90° Engine 243 21
45 oil 44 22 9 N•m
Engine (80 lbf•in) 12
oil
23
42 14
16 15 Engine
19 17 3
18 oil
2
43 1
57 Engine
oil

58
59
9 N•m
(80 lbf•in)

R1004motr63U

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 Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

CYLINDER/CYLINDER HEAD 2 (REAR-SIDE)

48

53

50
58
49 51
9 N•m
52 (80 lbf•in)
Loctite 19
243
18
9 N•m Engine oil 57
(80 lbf•in) 23 17 19
56 18
50 N•m 16 9 N•m 59
17 (80 lbf•in)
(37 lbf•ft) 15
+ 90° 20 16
46 Engine oil 43
20 N•m
47 17 N•m 44 (177 lbf•in) + 90°
71
55 (150 lbf•in) 45
54 21
9 N•m
Super Lube (80 lbf•in) Engine
grease 42 Engine
66 oil oil
11 N•m
(97 lbf•in)
11 61
62
Engine oil 65 70
64 27
Super Lube 9 N•m Loctite
13 grease 63 (80 lbf•in) 243
14 9 N•m 29
(80 lbf•in) 33
5 6 8
3
34 Super Lube
Engine oil grease
Super Lube 3
grease 36
10 31
69 4 7 9 37
32
68 Super Lube Engine oil
grease Loctite 35
243 Engine oil
24
30 73
67 72 6 N•m 38
9 N•m (53 lbf•in)
(80 lbf•in) 26 Loctite
1 25 243
Loctite 243 9 N•m
R1004motr184S
(80 lbf•in)

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Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

GENERAL SPARK PLUG

NOTE: Components which are identical for both Removal
cylinders/cylinder heads are identified in the two
exploded views by the same number. Com- Unplug the stick coil connector.
ponents which are different or which are, for Remove the stick coil no. 48.
instance, present on one of the cylinders/cylinder Clean spark plug and stick coil area before disas-
heads but not on the other, have different num- sembly.
bers. The information given below always relates
to both cylinders/cylinder heads as a general rule. Unscrew spark plug no. 47 then use the stick coil
to take spark plug out of spark plug hole.
Special reference is made in the text to work in-
structions which are not the same for cylinder 1
and cylinder 2.
NOTE: For cylinder head, cylinder and piston re-
moval, it is not necessary to remove engine from
vehicle.
1
NOTE: When diagnosing an engine problem, al-
ways perform a cylinder leak test. This will help
pin-point the problem. Refer to the instructions
included with your leak tester and LEAK TEST sec- 2
tion for procedures.
Always place the vehicle on a level surface.
NOTE: For a better understanding, the following
illustrations are taken with engine out of vehicle.
However, it is not necessary to remove engine R1004motr65A
from vehicle to perform the following instructions.
1. Stick coil
Always disconnect the negative wire from the bat- 2. Spark plug
tery before working the engine.
Even though many parts do not need to be re-
moved to reach other parts, it is recommended
Inspection
to remove these parts anyway in order to check Check spark plug and stick coil condition (refer
them. to COMPONENT INSPECTION AND ADJUST-
MENT).
For installation, use the torque values and service
products from exploded views. Clean threads be- Installation
fore using Loctite product when installing screws.
For installation, reverse the removal procedure.
When disassembling parts that are duplicated in Pay attention to the following details.
the engine, (e.g.: valves), it is strongly recom-
mended to note their position (PTO, alternator Check spark plug gap (refer to TECHNICAL DATA).
side) and to keep them as a "group". If you find Slightly oil the bottom outer part of the stick coil.
a defective component, it will be much easier to This will ease installation.
find the cause of the failure among its group of Place spark plug into stick coil, screw spark plug
parts (e.g.: you found a worn valve guide. A bent then remove the stick coil. Torque spark plug to
spring could be the cause. It will be easy to know 17 N•m (150 lbf•in). Reinstall the stick coil.
which one among the springs is defective if you
grouped them at disassembly). Besides, since
used parts have matched together during the TEMPERATURE SENSOR
engine operation, they will keep their matched fit Temperature sensor no. 60 is located in the cylin-
when you reassemble them together within their der head 1 (front-side).
"group".

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 Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

Inspection Inspection
Check the temperature sensor for damage or leak- Check the profile sealing ring on the valve cover
age. For electrical inspection refer to COMPO- and the rubber bushing on the valve cover screws
NENT INSPECTION AND ADJUSTMENT. if they are brittle, cracked or hard. If so, replace
Torque temperature sensor to 17 N•m the profile sealing ring or the valve cover screw
(150 lbf•in). accordingly.

Installation
VALVE COVER
For installation, reverse the removal procedure.
Removal Pay attention to the following details.
Remove: NOTE: At installation, replace the profile sealing
ring no. 49.
– valve cover shield no. 53
– valve cover screws no. 51 NOTE: Install the valve cover screws in a criss-
cross sequence.
Torque valve cover screws to 9 N•m (80 lbf•in).

1 ROCKER ARM
When disassembling the rocker arms, the speci-
fied sequence must be followed. Start with cylin-
der 1, continue with cylinder 2.

Removal Cylinder 1 (front-side)

Lock crankshaft with crankshaft locking tool
(P/N 529 035 900), refer to CRANKSHAFT/DRIVE
GEARS.
Remove:
– spark plug (refer to SPARK PLUG)
R1004motr66A
– valve cover (refer to VALVE COVER)
1. Valve cover screws – spark plug tube no. 46

– valve cover no. 50 and profile sealing ring

no. 49.

R1004motr67A

1. Valve cover
2. Profile sealing ring

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Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

2 3

R1004motr68A 1 R1004motr70A 2
1. Cylinder head 1. Rocker arm shaft
2. Spark plug tube 2. Rocker arms (exhaust side)
3. Rocker arm (intake side)

– rocker arm shaft screws no. 45 (discard screws)

1

R1004motr69A 2 R1004motr71A 1
1. Rocker arm shaft screws 1. Oil supply from the camshaft to the rocker arm shaft, then to
2. Rocker arms the rocker arms and finally to the valve adjustment

– rocker arm shaft no. 42 with rocker arm assem- Removal Cylinder 2 (rear-side)
bly (exhaust side no. 43 and intake side no. 44) Remove:
– spark plug (refer to SPARK PLUG)
– valve cover (refer to VALVE COVER)
– spark plug tube no. 46
Remove the crankshaft locking tool (P/N 529 035
900).
Crank the engine further until the second cylinder
is positioned at ignition TDC.
– rocker arm shaft screws no. 45 (discard screws)

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 Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

– rocker arm shaft no. 42 with rocker arm assem-

bly (exhaust side no. 43 and intake side no. 44).

Inspection
Spark Plug Tube
Check seals on spark plug tube. If seals are brittle,
cracked or hard, replace spark plug tube.
A
R1004motr74A 2 1
1. Rocker arm (exhaust side)
2. Roller
A. Bore for rocker arm shaft

Measure rocker arm bore diameter. If diameter is

R1004motr72A 2 1 3 out of specification, change the rocker arm assem-
bly.
1. Spark plug tube
2. Seal to the valve cover
3. Seal to the cylinder head ROCKER ARM BORE DIAMETER

Rocker Arm MINIMUM (NEW) 20.007 mm (.7877 in)

Inspect each rocker arm for cracks and scored fric- MAXIMUM (NEW) 20.020 mm (.7881 in)
tion surfaces. If so, replace rocker arm assembly. SERVICE LIMIT 20.035 mm (.7887 in)
Check the rocker arm rollers for free movement,
wear and excessive radial play. Replace rocker Press the hydraulic lifter with your thumb. If the
arm assembly if necessary. hydraulic lifter groove disappears inside rocker
arm casting, replace rocker arm assembly. Lifter
must turn freely in rocker arm bore. Otherwise,
replace.

A
2

R1004motr73A 1
1. Rocker arm (intake side)
2. Roller
R1004motr75A
A. Bore for rocker arm shaft
1. Hydraulic lifter groove

Rocker Arm Shaft

Check for scored friction surfaces, if so, replace
parts.
Measure rocker arm shaft diameter.

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Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

ROCKER ARM SHAFT DIAMETER CAUTION: For this assembly, stretch screws
are used. As the screws have been stretched
MINIMUM (NEW) 19.980 mm (.7866 in) from the previous installation, it is very im-
MAXIMUM (NEW) 19.993 mm (.7871 in)
portant to use new screws at assembly. Fail-
ure to replace screws and to strictly follow the
SERVICE LIMIT 19.965 mm (.7860 in) torque procedure may cause screws to loosen
and lead to engine damage.
A – Torque rocker arm shaft screws to 10 N•m
(88 lbf•in).
– Torque rocker arm shaft screws to 20 N•m
(177 lbf•in).
R1004motr76A – Finish tightening screws turning an additional
A. Measure rocker arm shaft diameter here
90° rotation with a torque angle gauge.

Replace any part that shows excessive wear.

Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
CAUTION: Make sure to observe the correct
matching of rocker arm shaft and rocker arm.
When installing the components, make sure
they are fitted exactly in their original position
on their respective cylinder head. Any inver-
sion of the components may cause damage to
the engine.
NOTE: At assembly, position the cylinder to igni- R1004motr78A 1 2
tion TDC. This will ensure stress-free installation
1. Rocker arm shaft screw
of the rocker arm shaft. 2. Torque angle gauge
Apply engine oil on rocker arm shaft.
Position the rocker arm shaft with the notches on CHAIN TENSIONER
top.
Removal
 WARNING
Chain tensioner is spring loaded. Take that
into account when removing chain tensioner
plug.

Remove:
– air silencer, guard and driven pulley to gain ac-
cess to cylinder 2 chain tensioner
– chain tensioner plug no. 10

R1004motr77A 2 1
1. Rocker arm shaft
2. Rocker arm shaft notches

Install NEW rocker arm shaft screws no. 45.

Torque as per following procedure:

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 Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

R1004motr79A 1 R1004motr81A

1. Chain tensioner plug

Check chain tension guides no. 24 for wear. Re-
 WARNING place as necessary.
Never perform this operation immediately af- Check spring condition. Replace if broken or
ter the engine has been run because the ex- worn.
haust system can be very hot. Wait until ex-
haust system is warm or cold.
Installation
NOTE: At installation, replace the O-rings no. 4
and no. 9. Slightly grease the O-rings before as-
– spring no. 8 sembly using super lube grease.
– screws no. 7
For installation, reverse the removal procedure.
Pay attention to the following details.
Torque chain tensioner housing screws to 9 N•m
(80 lbf•in). Apply Loctite 243 (P/N 293 800 060)
on threads.
NOTE: Slightly screw the plunger until it touch-
es the chain tension guide. Use only two fingers
to hold the screwdriver, in order to recognize the
gentle contact with the chain tension guide.
CAUTION: Improper adjustment of the chain
tension will lead to severe engine damage.
Install a spring end in plunger groove and the other
in the plug screw groove.
R1004motr80A 1
Screw in plug screw no. 10 by hand. There must
1. Chain tensioner screws be no distortion of the spring during installation.
Torque plug screw to 5 N•m (44 lbf•in).
– chain tensioner housing no. 5.

Inspection BREATHER
Using a flat screwdriver, unscrew chain tensioner
Removal
plunger no. 6. Check chain tensioner plunger for
free movement in the threads of chain tensioner Remove:
housing. – exhaust pipe and muffler

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Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

– air silencer then move vehicle harness away – thrust washer no. 34
from engine – cover no. 33
– remove breather hose then unscrew breather – centrifugal weight no. 32
screws no. 38 – decompressor shaft no. 31.
– pull out the breather no. 37 and gasket rings
no. 70. Inspection
NOTE: Pull out the breather with utmost care. Check decompressor shaft for service limit, re-
Thrust washer no. 34 may get caught on the place if it out of specifications.
breather and drop into the crankcase.

Inspection
Inspect the breather for cracks/fractures or other
damage/leakage.
If necessary, replace the breather. A B A
R1004motr82A

Installation DECOMPRESSOR SHAFT

A. Measure here
For installation, reverse the removal procedure. B. Measurement area
Pay attention to the following details.
DECOMPRESSOR SHAFT MEASUREMENT A
NOTE: At installation, replace the O-ring no. 36,
and fit it with grease. MINIMUM (NEW) 5.978 mm (.235 in)
Take care during installation that the flat surface of MAXIMUM (NEW) 5.990 mm (.236 in)
thrust washer precisely fits in the cover no. 33.
SERVICE LIMIT 5.850 mm (.230 in)
NOTE: Make sure to reinstall the two gasket rings
no. 70 between breather and cylinder head sur- Check torsion spring and edge of the centrifugal
face. weight for visible wear. If so, replace them to-
gether.

2
2

R1004motr185A

1. Breather
2. Gasket rings
R1004motr83A 1
Torque breather screws to 6 N•m (53 lbf•in). 1. Centrifugal weight with torsion spring
2. Edge of centrifugal weight
DECOMPRESSOR
Removal Installation
The installation is essentially the reverse of the re-
Remove:
moval procedure but, pay attention to the follow-
– breather (refer to BREATHER) ing details.
– valve cover (refer to VALVE COVER)

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 Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

NOTE: Engage the edge of centrifugal weight into

the decompressor shaft groove then put the parts
in place. 1

2 1

R1004motr176A

1. Hole in cover fits to pin of timing gear

R1004motr84A

1. Decompressor shaft groove CAUTION: Before and after cover installation,

2. Centrifugal weight make sure the centrifugal system works prop-
erly.
Place the torsion spring end under socket screw
head. CAMSHAFT TIMING GEAR
The engine is equipped with two camshaft timing
gears no. 28 and no. 70. The timing gear provides
the signals for the camshaft position sensor and is
located in the cylinder head of the cylinder 2.
NOTE: Although it is not necessary to position
crankshaft to TDC for disassembly, it is a good
practice to do it, as a troubleshooting step, to
know before disassembly if valve timing was ap-
propriate.

Removal
The procedure for disassembly of the two
camshaft timing gears no. 28 and no. 70, is
the same.
R1004motr85A 1
Lock crankshaft with crankshaft locking tool
1. Position of torsion spring end (P/N 529 035 900), refer to CRANKSHAFT AND
DRIVE GEARS.
Install the cover no. 33. Position the cover on the
timing gear so that the holes fits to the pin of tim- Remove:
ing gear. – valve cover (refer to VALVE COVER)
– breather (refer to BREATHER)
– chain tensioner (refer to CHAIN TENSIONER)
– decompressor (refer to DECOMPRESSOR)
– chain guide no. 30
– screws no. 29
– camshaft timing gear no. 70.

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Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

NOTE: Secure camshaft chain no. 27 with a re- CYLINDER HEAD

taining wire.
Removal
Inspection The removal procedure is the same for both cylin-
Check camshaft timing gear for wear or deteriora- der heads no. 12 and no. 71.
tion. Lock crankshaft with crankshaft locking tool
If gear is worn or damaged, replace it as a set (P/N 529 035 900), refer to CRANKSHAFT/DRIVE
(camshaft timing gear and timing chain). GEARS.
For crankshaft timing gear, refer to CRANKSHAFT Drain coolant (refer to COOLING SYSTEM).
AND DRIVE GEARS. Disconnect temperature sensor and/or camshaft
position sensor.
Installation
Remove:
For installation, reverse the removal procedure.
Pay attention to the following details. – RH side cover
Using the camshaft locking tool (P/N 529 035 839), – seat support
lock camshaft on TDC position. – exhaust pipe and upper engine support (refer to
REMOVAL AND INSTALLATION)
– engine outlet hose
– air intake manifold (refer to COMPONENT IN-
SPECTION AND ADJUSTMENT)
– chain tensioner (refer to CHAIN TENSIONER)
– valve cover (refer to VALVE COVER)
– valve cover and profile sealing ring (see VALVE
COVER above)
– breather (refer to BREATHER)
– decompressor (refer to DECOMPRESSOR)
– camshaft timing gear (refer to CAMSHAFT TIM-
ING GEAR)
– cylinder head screws M6 no. 21
R1004motr88A 2 1
1. Camshaft locking tool
2. Camshaft on TDC position

Install the camshaft timing gear with the writing

visible.
IMPORTANT: Make sure that tensioner is in place
and properly preloaded before tightening sprocket
screws.
Fit the screws with Loctite 243 (P/N 293 800 060).
Torque screws to 9 N•m (80 lbf•in).
CAUTION: Crankshaft and camshaft must be
locked on ignition TDC position of cylinder 1
(front-side) to place camshaft timing gear and R1004motr89A 1
timing chain in the proper position. 1. Cylinder head screws M6

TIMING CHAIN – cylinder head screws M11 no. 20 retaining

cylinder head and cylinder to cylinder base.
Refer to CRANKSHAFT/DRIVE GEARS.

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 Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

1 Installation
NOTE: The cylinder heads are not identical in de-
sign. Do not invert the cylinder heads at assem-
bly.
For installation, reverse the removal procedure.
Pay attention to the following details.
NOTE: At installation, replace gasket no. 11.
Ensure dowel pins are in place.
Install cylinder head screws M6 and M11.
Torque screws as per following procedure.
CAUTION: This assembly uses stretch screws.
R1004motr90A As the screws have been stretched from the
1. Cylinder head screws M11
previous installation, it is very important to
measure each screw at assembly. If screws
Pull up cylinder head no. 71. are out of specification, replace by a new ones.
Failure to replace screws and to strictly follow
Remove gasket no. 11. the torque procedure may cause screws to
loosen and lead to engine damage.
Inspection
Check for cracks between valve seats, if so, re- CYLINDER HEAD SCREW M11
place cylinder head. SERVICE LIMIT 216.5 mm (8.524 in)
Check gasket for cracks or other damages.
– Torque cylinder head screws M11 in criss-cross
Check mating surface between cylinder and cylin- sequence to 25 N•m (18 lbf•ft).
der head for contamination. If so, clean both sur-
faces. – Torque cylinder head screws M11 in criss-cross
sequence to 50 N•m (37 lbf•ft).
Check oil supply hole in cylinder head for contam- – Finish tightening screws turning an additional
ination. 90° rotation with a torque angle gauge then,
torque cylinder head screws M6 to 9 N•m
(80 lbf•in).

1 2

R1004motr91A 1 2
R1004motr177A
1. Cylinder screws M11
2. Angle torque wrench
1. Oil supply to camshaft bearing journal- big end
2. Oil supply to camshaft bearing journal- small end
3. Oil back flow through chain compartment to engine bottom

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Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

Remove crankshaft locking tool (P/N 529 035 900) 1

then install plug with sealing ring.

CAMSHAFT
NOTE: The engine is equipped with two different
camshafts no. 22 and no. 66.
2

R1004motr93A 2
1. Camshaft lock
2. Camshaft
R1004motr92A

1. Camshaft of cylinder 1
2. Camshaft of cylinder 2
Cleaning
Remove carbon deposits from combustion cham-
ber, exhaust port and piston top.
Removal
The removal procedure is the same for both Inspection
camshafts. Check each lobe and bearing journal of camshaft
Each camshaft is different in design. Thus, it is for scoring, scuffing, cracks or other signs of wear.
important not to mix up any parts of the camshaft Measure camshaft bearing journal diameter and
assembly with that of the other cylinder. Keep lobe height using a micrometer.
parts as a “group”. Measure clearance between both ends of
Remove: camshaft and cylinder head.
– valve cover (refer to VALVE COVER) NOTE: The data in the following tables are valid
– chain tensioner (refer to CHAIN TENSIONER) for both camshafts.
– breather (refer to BREATHER) D A B A C
– decompressor (refer to DECOMPRESSOR)
– rocker arms (refer to ROCKER ARMS)
– camshaft timing gear (refer to CAMSHAFT TIM-
ING GEAR)
– camshaft lock no. 23
– camshaft no. 22 and/or no. 66.

R1004motr94A

A. Camshaft lobe (exhaust valves)

B. Camshaft lobe (intake valves)
C. Camshaft bearing journal (big end)
D. Camshaft bearing journal (small end)

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 Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

CAMSHAFT LOBE - EXHAUST VALVE

MINIMUM (NEW) 31.435 mm (1.237 in)
MAXIMUM (NEW) 31.635 mm (1.245 in)
SERVICE LIMIT 31.400 mm (1.236 in)
CAMSHAFT LOBE - INTAKE VALVE
MINIMUM (NEW) 31.654 mm (1.246 in)

MAXIMUM (NEW) 31.854 mm (1.254 in)

SERVICE LIMIT 31.600 mm (1.244 in)
CAMSHAFT BEARING JOURNAL - BIG END
MINIMUM (NEW) 39.927 mm (1.5719 in)
R1004motr95A 1
MAXIMUM (NEW) 39.935 mm (1.5722 in)
1. Camshaft lock
SERVICE LIMIT 39.920 mm (1.5716 in)
CAMSHAFT BEARING JOURNAL - SMALL END For other parts, refer to proper installation proce-
dure.
MINIMUM (NEW) 24.967 mm (.9829 in)
MAXIMUM (NEW) 24.980 mm (.9835 in) VALVE SPRINGS
SERVICE LIMIT 24.960 mm (.9827 in) NOTE: The engine is equipped with two different
CAMSHAFT BORE - BIG END MEASURED valve springs no. 16 (inner) and no. 17 (outer) for
IN DIAMETER every valve.
MINIMUM (NEW) 39.984 mm (1.5742 in) Removal
MAXIMUM (NEW) 40.000 mm (1.5748 in) Remove:
SERVICE LIMIT 40.020 mm (1.5756 in) – rocker arms (refer to ROCKER ARMS)
– cylinder head (refer to CYLINDER HEAD).
CAMSHAFT BORE - SMALL END MEASURED
IN DIAMETER Compress valve springs no. 16 and no. 17, use
valve spring compressor clamp (P/N 529 035 764)
MINIMUM (NEW) 24.987 mm (.9837 in) and valve spring compressor cup (P/N 529 035
MAXIMUM (NEW) 25.000 mm (.9842 in) 724).
SERVICE LIMIT 25.020 mm (.9850 in)  WARNING
Always wear safety glasses when disassem-
Replace parts that are not within specifications. bling valve springs. Be careful when unlock-
ing valves. Components could be expelled
Installation under pressure from preloaded spring.
For installation, reverse the removal procedure.
Pay attention to the following details.
CAUTION: The camshafts are not identical in
design. Do not invert the camshafts during as-
sembly. Any mix-up of the components will
lead to engine damage.
Install camshaft then place the camshaft lock in
the slot.

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Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

A
R1004motr98A

A. Valve spring length

R1004motr96A VALVE SPRING FREE LENGTH

1. Valve spring compressor clamp (P/N 529 035 764) OUTER VALVE SPRING
2. Valve spring compressor cup (P/N 529 035 724)
NOMINAL (NEW) 45.45 mm (1.789 in)
SERVICE LIMIT 43 mm (1.693 in)
INNER VALVE SPRING
NOMINAL (NEW) 41.02 mm (1.615 in)
SERVICE LIMIT 38.80 mm (1.528 in)

Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
NOTE: Colored area of the valve spring must be
placed on top.
If the color cannot be identified any more, orienta-
R1004motr97A tion is possible, based on the shape of the spring.
LOCATE VALVE SPRING COMPRESSOR CLAMP IN The spacing of the coils is smaller at one end. At
CENTER OF THE VALVE installation, this end must be directed towards the
cylinder head.
Remove valve cotters no. 19.
NOTE: Valve cotters must be properly engaged in
Withdraw valve spring compressor, valve spring valve stem grooves.
retainer no. 18 and valve springs.

Inspection
Check valve springs for rust, corrosion or other
visible damages. If so, replace valve springs.
Check valve springs for free length and straight-
ness.
Replace valve springs if not within specifications.

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 Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

2 1

R1004motr99A

R1004motr101A
1. Position of the valve spring
2. Valve cotters

Inspection
VALVE Valve Stem Seal
NOTE: Inspection of valve stem seals is not need-
Removal ed because new seals should always be installed
Remove valve springs. whenever cylinder head is removed.
Push valve stem then pull valves no. 13 and no. 14 Valve
out of valve guide.
Inspect valve surface, check for abnormal stem
wear and bending. If so, replace by a new one.
Valve Stem and Valve Guide Clearance
2
Measure valve stem and valve guide in three
1
places, using a micrometer and a small bore
gauge.
NOTE: Clean valve guide to remove carbon de-
posits before measuring.
Change valve if valve stem is out of specification
or has other damages such as wear or traces of
friction.

R1004motr100A

1. Intake valve 38 mm
2. Exhaust valve 31 mm

Remove valve stem seal no. 15 with special pliers

such as Snap-ON YA 8230.

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Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

Valve Face and Seat

3 2

R1004motr102A

A. Valve stem diameter

R1004motr103A 1
VALVE STEM DIAMETER 1. Valve seat
2. Exhaust valve contaminated area
MINIMUM (NEW) 3. Valve face (contact surface to valve seat)

Exhaust 5.946 mm (.2341 in) Check valve face and seat for burning or pittings
Intake 5.961 mm (.2347 in) and replace valve or cylinder head if there are signs
of damage.
MAXIMUM (NEW)
Ensure to seat valves properly. Apply some lap-
Exhaust 5.960 mm (.2346 in) ping compound to valve face and work valve on
Intake 5.975 mm (.2352 in)
its seat with a lapping tool.
Measure valve face contact width.
SERVICE LIMIT
NOTE: The location of contact area should be in
Exhaust center of valve seat.
5.93 mm (.233 in)
Intake Measure valve seat width, using a caliper.

Replace cylinder head if valve guide is out of spec- VALVE SEAT CONTACT WIDTH
ification or has other damages such as wear or
NEW
traces of friction.
1.25 to 1.55 mm
Exhaust
VALVE GUIDE DIAMETER (.049 to .061 in)
SERVICE LIMIT 1.10 to 1.30 mm
Intake
(.043 to .051 in)
Exhaust
6.060 mm (.2386 in) SERVICE LIMIT
Intake
Exhaust 1.8 mm (.071 in)
Intake 1.6 mm (.063 in)

If valve seat contact width is too wide or has dark

spots, replace the cylinder head.

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 Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

A B

R1004motr105A

1. Sealing lips of valve stem seal

To ease installation of cotters, apply oil or grease

on them so that they remain in place while releas-
V01C1HA
ing the spring.
A. Valve face contact width After spring is installed, ensure it is properly
B. Valve seat contact width
locked by tapping on valve stem end with a soft
hammer so that valve opens and closes a few
Installation times.
For installation, reverse the removal procedure. CAUTION: An improperly locked valve spring
Pay attention to the following details. will cause engine damage.
NOTE: At installation, replace the valve stem seal
no. 15, use valve stem seal installer (P/N 529 035 CYLINDER
687). NOTE: The engine is equipped with two different
cylinders no. 2 and no. 72.

2 Removal
Lock crankshaft with crankshaft locking tool
(P/N 529 035 900), refer to CRANKSHAFT/DRIVE
GEARS.
Remove:
1 – cylinder heads (refer to CYLINDER HEAD).
Pull cylinder no. 2 and no. 72.
Discard cylinder gaskets no. 1.

Inspection
Cylinder
R1004motr178A
Check cylinder for cracks, scoring and wear ridges
1. Valve stem seal
2. Valve stem seal installer (P/N 529 035 687) on the top and bottom of the cylinder. If so, re-
place cylinder.
Apply engine oil on valve stem and install it.
Cylinder Taper
CAUTION: Be careful when valve stem is Measure cylinder bore at 3 recommended posi-
passed through sealing lips of valve stem seal.
tions. See the following illustration.

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Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

CYLINDER OUT OF ROUND

2 MAXIMUM (NEW) 0.01 mm (.0002 in)
A SERVICE LIMIT 0.02 mm (.0008 in)

1 CAUTION: Always replace gasket no. 1 before

B installing the cylinder.
3 Installation
R1004motr106A
For installation, reverse the removal procedure.
1. First measuring diameter in line with cylinder bottom Pay attention to the following details.
2. Second measuring diameter
3. Third measuring diameter NOTE: The cylinders are not identical in design.
A. 60 mm (2.362 in) Do not invert the cylinders during assembly.
B. 50 mm (1.968 in)
First mount cylinder 1. Then remove the crank-
CYLINDER TAPER shaft locking tool (P/N 529 035 900). Crank the
MAXIMUM (NEW) 0.038 mm (.001 in) engine further and position piston 2 at TDC. Mount
cylinder 2. The cylinder cannot be pushed fully
SERVICE LIMIT 0.090 mm (.004 in) over the piston unless the piston is located at TDC.
Apply engine oil in the bottom area of the cylinder
Difference between measurements should not bore and also on the band of the piston ring com-
exceed the service limit mentioned above. pressor tool.
Cylinder Out of Round Using a piston ring compressor plier, such Snap-
Measure cylinder diameter in piston axis direction On RC-980, slide piston into cylinder.
from top of cylinder. Take another measurement
90° from first one and compare.
NOTE: Take the same measuring points like de-
scribed in CYLINDER TAPER above.

R1004motr108A

R1004motr107A

A. Parallel to piston axis

B. Perpendicular to piston axis

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 Section 04 ENGINE (4-TEC)
Subsection 05 (CYLINDER AND CYLINDER HEAD)

R1004motr109A

1. Timing chain

NOTE: Put timing chain through the chain pit then

put the cylinder in place.
Install cylinder head and the other parts in accor-
dance with the proper installation procedures.

PISTON
Refer to CRANKSHAFT/DRIVE GEARS.

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 Section 04 ENGINE (4-TEC)
Subsection 06 (CRANKSHAFT/DRIVE GEARS)

CRANKSHAFT/DRIVE GEARS
SERVICE TOOLS
Description Part Number Page
crankshaft locking tool.......................................................... 529 035 900 ................................. 235, 241
piston circlip installer ............................................................ 529 035 765 ......................................... 244
protection mushroom ........................................................... 420 876 552 ......................................... 235

SERVICE PRODUCTS
Description Part Number Page
Loctite 243............................................................................ 293 800 060 ......................................... 241
Molykote 111........................................................................ 413 707 000 ......................................... 241

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Section 04 ENGINE (4-TEC)
Subsection 06 (CRANKSHAFT/DRIVE GEARS)

11

10

12
13

13 Engine 80 N•m Engine

oil (59 lbf•ft) 13
12 oil
45 N•m 9
(33 lbf•ft) + 90° 2
8
4 45 N•m
13 (33 lbf•ft) + 90° 3
2 4

Engine
oil

3 Engine 1
Engine oil
oil

11

5
6
7 N•m
(62 lbf•in)

R1004motr01S

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 Section 04 ENGINE (4-TEC)
Subsection 06 (CRANKSHAFT/DRIVE GEARS)

Multi-purpose
grease
27 14 15

16
18
19
20
21 Engine
oil
22
23
17
29
Engine oil

26 24
3 N•m
(27 lbf•in) Loctite 243

8 N•m 25 28
(71 lbf•in)

R1004motr02S

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Section 04 ENGINE (4-TEC)
Subsection 06 (CRANKSHAFT/DRIVE GEARS)

TIMING CHAIN
The engine is equipped with two timing chains
no. 28 and no. 29. One of the timing chains is
located on the engine alternator side behind the
ignition cover. The second is located on the PTO
side behind the PTO cover. R610motr201A 1

Removal of Alternator Side 1. Timing chain

Timing Chain If chain is excessively worn or damaged, replace it

Remove: as a set (camshaft sprocket/timing gear and timing
– ignition cover (refer to COOLING SYSTEM) chain).
– chain tensioner and chain guide (refer to CYLIN-
DER AND CYLINDER HEAD) Installation
– camshaft sprocket (refer to CYLINDER AND Installation is the same for both timing chains
CYLINDER HEAD) no. 28 and no. 29.
– oil pump gears no. 24 (refer to LUBRICATION The installation is essentially the reverse of the re-
SYSTEM) moval procedure but, pay attention to the follow-
– crankshaft drive gear no. 7 (refer to DRIVE ing details.
GEARS). NOTE: Ensure to perform proper valve timing.
Carefully pull the timing chain sideward and down Lock crankshaft and camshaft at TDC (refer to
from the crankcase. CYLINDER AND CYLINDER HEAD).
Install chain then, adjust chain tension (refer to
Removal of PTO Side Timing Chain CYLINDER AND CYLINDER HEAD).
Remove: CAUTION: Improper valve timing will damage
– engine from vehicle (refer to REMOVAL AND engine components.
INSTALLATION)
– oil tank (refer to LUBRICATION SYSTEM) DRIVE GEARS
– chain tensioner and chain guide (refer to CYLIN-
The drive gears are located on the engine alterna-
DER AND CYLINDER HEAD)
tor side behind the ignition cover.
– camshaft timing gear (refer to CYLINDER AND
CYLINDER HEAD)
– PTO cover (refer to CRANKCASE)
– trigger wheel no. 6 (refer to TRIGGER WHEEL).
Carefully pull the timing chain sideward and down
from the crankcase.

Inspection
Inspection is the same for both timing chains
no. 28 and no. 29. Pay attention to the following
details.
NOTE: Check timing chain on camshaft sprock-
et/timing gear for excessive radial play.
Check chain condition for wear and rollers condi-
tion.

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 Section 04 ENGINE (4-TEC)
Subsection 06 (CRANKSHAFT/DRIVE GEARS)

5 4 3
2

R1004motr04A 1 3
R1004motr03A 6 2 1 2
1. Crankshaft drive gear
1. Crankshaft drive gear 2. Gear puller
2. Oil pump gears 3. Protection mushroom (P/N 420 876 552)
3. Generator gear
4. Double gear
5. Intermediate gear – generator gear no. 18 and thrust washer no. 23
6. Starter gear
– double gear no. 16
Removal – intermediate gear no. 14.
Lock crankshaft with crankshaft locking tool Inspection
(P/N 529 035 900) (refer to CRANKSHAFT LOCK-
ING TOOL). Double Gear/Intermediate Gear/Crankshaft
Drive Gear
Remove:
NOTE: Inspect the gears for wear and damage.
– ignition cover (refer to COOLING SYSTEM)
– oil pump gears no. 24 (refer to LUBRICATION Oil Pump Gears
SYSTEM) Refer to LUBRICATION SYSTEM.
– crankshaft nut no. 9
Generator Gear
– crankshaft drive gear no. 7.
Completely disassemble the generator gear.
Remove crankshaft drive gear with gear puller (af-
termarket tool). Also use the protection mush-
room (P/N 420 876 552) to avoid damage of the
crankshaft.
 WARNING
The gear puller and the crankshaft drive gear
are highly tensioned. When the crankshaft
drive gear is loosened, the puller may force- R1004motr05A 1 2
fully swing up.
1. Sprag clutch
2. Needle bearing

NOTE: Inspect all components, especially the

needle bearing, for wear and damage. Perform a
function test of the sprag clutch.

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Section 04 ENGINE (4-TEC)
Subsection 06 (CRANKSHAFT/DRIVE GEARS)

Location Pins

R1004motr07A 1
1. Trigger wheel

R1004motr06A 1
Removal
Remove:
1. Location pins
– oil tank (refer to LUBRICATION SYSTEM)
NOTE: Inspect all pins for wear and damage. The – PTO cover (refer to CRANKCASE)
pins are firmly pressed into the crankcase but may – trigger wheel screws no. 6 and pull trigger
work loose during the course of time. If the pins wheel no. 5.
can be rotated, there is no need for repair work.
Inspection
Installation
NOTE: Refer to COMPONENT INSPECTION AND
The installation is essentially the reverse of the re- ADJUSTMENT in ENGINE MANAGEMENT sec-
moval procedure, but pay attention to the follow- tion.
ing details.
NOTE: Adequately oil all components prior to in- Installation
stallation. The oil pump gears and the crankshaft For installation, reverse the removal procedure.
drive gear do not need to be oiled.
Torque trigger wheel screws to 7 N•m (62 lbf•in).
The generator gear and the double gear must be
installed at the same time on their respective lo- CRANKSHAFT
cation pin.
Torque crankshaft nut no. 9 to 80 N•m (59 lbf•ft). Removal
Remove:
TRIGGER WHEEL – drive gears (refer to DRIVE GEARS above)
The trigger wheel is located on the engine PTO – crankcase (refer to CRANKCASE)
side behind the PTO cover. – crankshaft no. 1

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 Section 04 ENGINE (4-TEC)
Subsection 06 (CRANKSHAFT/DRIVE GEARS)

Connecting Rod Big End Axial Play

Using a feeler gauge, measure distance between
butting face of connecting rods and crankshaft
counterweight. If the distance exceeds specified
tolerance, replace the crankshaft.

R1004motr08A 1 2
1. Crankshaft

– connecting rods no. 2.

NOTE: Mark the connecting rods prior to disman-
tling. The connecting rods must be reinstalled in
exactly the same position and running direction.
R1004motr10A 1 3
Inspection 1. Crankshaft
NOTE: Check each bearing journal of crankshaft 2. Connecting rods
3. Feeler gauge
for scoring, scuffing, cracks or other signs of wear.
NOTE: Replace crankshaft if the gears are worn CONNECTING ROD BIG END
or otherwise damaged.
NEW MINIMUM 0.150 mm (.006 in)
CAUTION: Components with less than the ser-
vice limit always have to be replaced. If this is NEW MAXIMUM 0.450 mm (.017 in)
not observed, severe damage may be caused SERVICE LIMIT 0.5 mm (.020 in)
to the engine.
Connecting Rod/Piston Pin Clearance
Measure piston pin. Compare to inside diameter
of connecting rod no. 2.

2 1

R1004motr09A 1
1. Crankshaft timing gear
R1004motr11A

1. Bore gauge
2. Connecting rod

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Section 04 ENGINE (4-TEC)
Subsection 06 (CRANKSHAFT/DRIVE GEARS)

R1004motr12A

A. Piston pin diameter in the area of the bushing

CONNECTING ROD SMALL END DIAMETER 2

NEW MINIMUM 23.01 mm (.9059 in)
NEW MAXIMUM 23.02 mm (.9063 in)
SERVICE LIMIT 23.07 mm (.908 in)

PISTON PIN DIAMETER R1004motr14A

NEW MINIMUM 22.996 mm (.9053 in) 1. Micrometer

2. Crankpin area for bushings
NEW MAXIMUM 23.000 mm (.9055 in)
SERVICE LIMIT 22.990 mm (.904 in)
To measure the connecting rod big end diameter,
use the OLD screws no. 4.
Install the OLD bushings no. 3 as they were
PISTON PIN BORE CLEARANCE
mounted initially.
SERVICE LIMIT 0.080 mm (.0035 in) Do the torque procedure as described further.

NOTE: If the connecting rod small end diameter is

out of specification, replace connecting rod.
Connecting Rod Big End Radial Play
Remove connecting rod no. 2 from crankshaft
no. 1. A
CAUTION: Always replace connecting rod
screws no. 4 if removing the connecting rod.
It is recommended to replace bushings no. 3,
in case of installing the connecting rod.

R1004motr15A

A. Connecting rod big end bushing

CRANKSHAFT PIN DIAMETER

NEW MINIMUM 45.017 mm (1.7723 in)

1 NEW MAXIMUM 45.033 mm (1.7729 in)

R1004motr13A
SERVICE LIMIT 45.000 mm (1.772 in)
1. Connecting rod screw

Measure crankpin. Compare to inside diameter of CONNECTING ROD BIG END DIAMETER
connecting rod big end. SERVICE LIMIT 45.090 mm (1.775 in)

CONNECTING ROD BIG END CLEARANCE

SERVICE LIMIT 0.09 mm (.0035 in)

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 Section 04 ENGINE (4-TEC)
Subsection 06 (CRANKSHAFT/DRIVE GEARS)

Crankshaft Radial Play Alternator Side 2

Measure crankshaft on alternator side. Compare 1
to inside diameter of alternator bushing (refer to
CRANKCASE).

R1004motr17A

1. Micrometer
2. Crankshaft area for PTO bushing
R1004motr16A 1
1. Micrometer CRANKSHAFT JOURNAL PTO DIAMETER
2. Crankshaft area for alternator bushing
NEW MINIMUM 54.961 mm (2.1638 in)
CRANKSHAFT ALTERNATOR SIDE DIAMETER
NEW MAXIMUM 54.980 mm (2.1645 in)
NEW MINIMUM 54.961 mm (2.1638 in)
SERVICE LIMIT 54.940 mm (2.1629 in)
NEW MAXIMUM 54.980 mm (2.1645 in)
SERVICE LIMIT 54.940 mm (2.1629 in) CRANKSHAFT ALTERNATOR SIDE
RADIAL CLEARANCE
CRANKSHAFT ALTERNATOR SIDE SERVICE LIMIT 0.08 mm (.0031 in)
RADIAL CLEARANCE
SERVICE LIMIT 0.08 mm (.0031 in) Crankshaft Radial Play (PTO side
support bearing)
Crankshaft Radial Play (PTO side) Measure crankshaft on PTO side journal for sup-
Measure crankshaft on PTO side. Compare port bearing. Compare to inside diameter of
to inside diameter of PTO bushing (refer to PTO support bearing (refer to PTO COVER in
CRANKCASE). CRANKCASE section).

1 2

R1004motr18A

1. Micrometer
2. Crankshaft area (PTO support bearing)

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Section 04 ENGINE (4-TEC)
Subsection 06 (CRANKSHAFT/DRIVE GEARS)

CRANKSHAFT JOURNAL DIAMETER NOTE: Use NEW bushings no. 3, when connect-
(PTO SUPPORT BEARING) ing rod big end diameter is out of specification.
NEW MINIMUM 37.984 mm (1.4954 in) Put bushings correctly in place and clean the split
surface on both sides (cracked area) carefully.
NEW MAXIMUM 38.000 mm (1.4960 in)
SERVICE LIMIT 37.960 mm (1.4945 in)

CRANKSHAFT PTO SUPPORT BEARING

1
RADIAL CLEARANCE
SERVICE LIMIT 0.08 mm (.0031 in) 3
2
Crankshaft Radial Play (alternator side
— oil supply hole)
Measure crankshaft on alternator side journal for
oil supply hole. Compare to inside diameter of oil
supply hole in ignition cover (refer to IGNITION
COVER in COOLING SYSTEM).

R1004motr20A

1. Half bushing of connecting rod big end

2. Split surface of the connecting rod
3. Nose of bushing in line with connecting rod groove

2 NOTE: Oil the plain bearing of the connecting rod

before installation.
1 Torque NEW connecting rod screws no. 4 as per
following procedure:
– Torque connecting rod screws to 20 N•m
(177 lbf•in). Do not apply any thread locker
R1004motr19A
product.
1. Micrometer
2. Crankshaft area (journal for oil supply hole) – Torque connecting rod screws to 45 N•m
(33 lbf•ft).
CRANKSHAFT JOURNAL DIAMETER – Finish tightening the screws with an additional
(OIL SUPPLY HOLE) 90° turn using an angle torque wrench.
NEW MINIMUM 19.987 mm (0.7869 in) CAUTION: Failure to strictly follow this proce-
NEW MAXIMUM 20.00 mm (0.7874 in) dure may cause screw to loosen and lead to en-
gine damage. The bushing tapered end must
SERVICE LIMIT 0.08 mm (.0031 in) be against the counterweight. Besides, as the
"crankpin" screw has been stretched from the
previous installation, it is very important to use
CRANKSHAFT PTO SUPPORT BEARING a new screw at assembly.
RADIAL CLEARANCE
Take care during installation that the connect-
SERVICE LIMIT 0.08 mm (.0031 in)
ing rods are not installed with a twist. The run-
ning direction of the big end bearings and of
Installation the piston pins must not change.
For installation, reverse the removal procedure. Do not mix up the connecting rods of cylinders 1
Pay attention to following details. and 2 during installation.

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 Section 04 ENGINE (4-TEC)
Subsection 06 (CRANKSHAFT/DRIVE GEARS)

CAUTION: Install crankshaft locking tool

(P/N 529 035 900) (refer to CRANKSHAFT
2 LOCKING TOOL) right away to put crankshaft
in TDC position before installing the camshaft
and rockers (refer to CYLINDER AND CYLIN-
DER HEAD).

CRANKSHAFT LOCKING TOOL

1
The engine must be locked for removal and in-
stallation work on crankshaft and camshaft. The
opening for the crankshaft locking tool is located in
the ignition cover and in crankcase alternator side.

R1004motr21A

1. Connecting rod screws

2. Angle torque wrench

CAUTION: Observe the correct installation

position when fitting the crankshaft with the
connecting rods. The connecting rod alterna-
tor side has to face to cylinder 1. R1004motr23A 1
1. Crankshaft locking tool (P/N 529 035 900)
2 3
Removal
Remove:
– plug screw no. 26
– plug screw no. 25.
CAUTION: Pull out the plug screw with utmost
care to prevent it from being dropped into the
crankcase during dismantling.

Installation
Fit the plug screw no. 25 with Loctite 243 (P/N 293
800 060).
Torque plug screw no. 25 to 8 N•m (71 lbf•in).
Replace O-ring no. 27 during installation and
grease it with Molykote 111 (P/N 413 707 000).
R1004motr22A 1
Torque plug screw no. 26 to 3 N•m (26 lbf•in).
1. Crankcase alternator side
2. Connecting rod cylinder 1
3. Connecting rod cylinder 2 PISTON
Removal
Remove:
– cylinder head (refer to CYLINDER AND CYLIN-
DER HEAD)

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Section 04 ENGINE (4-TEC)
Subsection 06 (CRANKSHAFT/DRIVE GEARS)

– cylinder (refer to CYLINDER AND CYLINDER

HEAD).
Place a rag under piston.
Remove one piston circlip no. 13 and discard it.

R1004motr26A 1
1. Measuring perpendicularly (90°) to piston pin
A. 18 mm (.709 in)

1 The measurement should be as in the following

R1004motr24A
table. If not, replace piston.
1. Piston circlip
PISTON MEASUREMENT
NOTE: The removal of both piston circlips is not 99.951 to 99.969 mm
necessary to remove piston pin. NEW NOMINAL
(3.935 to 3.936 in)
Push piston pin no. 12 out of piston. 99.80 mm (3.929 in)
SERVICE LIMIT

Piston/Cylinder Clearance
Adjust and lock a micrometer to the piston dimen-
sion.

R1004motr25A 2 1
1. Piston
2. Piston pin
R1004motr27A 1
Detach piston no. 10 from connecting rod. 1. Micrometer set to the piston dimension

Inspection With the micrometer set to the dimension, adjust

Piston a cylinder bore gauge to the micrometer dimen-
NOTE: Inspect piston for scoring, cracking or oth- sion and set the indicator to 0 (zero).
er damages. Replace piston and piston rings if
necessary.
Using a micrometer, measure piston at 18 mm
(.709 in) perpendicularly (90°) to piston pin.

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 Section 04 ENGINE (4-TEC)
Subsection 06 (CRANKSHAFT/DRIVE GEARS)

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.
Piston Pin
2 1 Using synthetic abrasive woven, clean piston pin
from deposits.
Inspect piston pin for scoring, cracking or other
damages.
Measure piston pin. See the following illustration
for the proper measurement position.

F00B09A
A
1. Use the micrometer to set the cylinder bore gauge
2. Dial bore gauge R1004motr12A

A. Piston pin diameter

PISTON PIN
NEW MINIMUM 22.996 mm (.9053 in)
NEW MAXIMUM 23.000 mm (.9055 in)
SERVICE LIMIT 22.990 mm (.9051 in)

NOTE: Replace piston pin if diameter is out of

specifications.
Piston Pin/Connecting Rod Bushing Clearance
1 Measure inside diameter of connecting rod.

F00B0AA CONNECTING ROD SMALL END DIAMETER

TYPICAL NEW MINIMUM 23.01 mm (.9059 in)

1. Indicator set to 0 (zero)
NEW MAXIMUM 23.02 mm (.9063 in)
Position the dial bore gauge 50 mm (2 in) above SERVICE LIMIT 23.07 mm (.908 in)
cylinder base, measuring perpendicularly (90°) to
piston pin axis. 2 1
Read the measurement on the cylinder bore
gauge. The result is the exact piston/cylinder wall
clearance.

PISTON/CYLINDER CLEARANCE
0.024 to 0.056 mm
NEW NOMINAL
(.001 to .002 in)
SERVICE LIMIT 0.090 mm (.004 in)

NOTE: Make sure used piston is not worn. See

PISTON MEASUREMENT above. R1004motr29A

If clearance exceeds specified tolerance, replace 1. Bushing of the connecting rod

cylinder. 2. Bore gauge

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Section 04 ENGINE (4-TEC)
Subsection 06 (CRANKSHAFT/DRIVE GEARS)

NOTE: Replace connecting rod if diameter of con-

necting rod small end is out of specifications.
Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
NOTE: Apply engine oil on the piston pin.
Insert piston pin into piston and connecting rod.
CAUTION: Take care that piston will be installed
with the punched arrow on piston top to the
exhaust side.

R1004motr31A 1 2
1. Sleeve with piston circlip inside
2. Assembly jig from piston clip installer

PISTON RINGS
Removal
Remove:
– cylinder head (refer to CYLINDER AND CYLIN-
DER HEAD)
– cylinder (refer to CYLINDER AND CYLINDER
R1004motr30A 1 HEAD)
1. Arrow should indicate to the exhaust side – piston pin no. 12 (refer to PISTON above)
– piston no. 10.
Use the piston circlip installer (P/N 529 035 765)
to assemble the piston circlip. Inspection
CAUTION: Secure piston pin with new piston Ring/Piston Groove Clearance
circlips.
NOTE: Using a feeler gauge measure each
NOTE: Take care that the hook of the piston circlip ring/piston groove clearance. If the clearance is
is positioned properly. too large, the piston and the piston rings should
be replaced.

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 Section 04 ENGINE (4-TEC)
Subsection 06 (CRANKSHAFT/DRIVE GEARS)

RING/PISTON GROOVE CLEARANCE MM (IN) Ring End Gap

NEW MINIMUM
RING END GAP
UPPER COMPRESSION
0.025 mm (.001 in) NEW MINIMUM
RING (rectangular)
UPPER COMPRESSION
LOWER COMPRESSION 0.30 mm (.012 in)
0.015 mm (.0006 in) RING (rectangular)
RING (taper-face)
LOWER COMPRESSION
OIL SCRAPER RING 0.020 mm (.0008 in) 0.35 mm (.014 in)
RING (taper-face)
NEW MAXIMUM
OIL SCRAPER RING 0.35 mm (.014 in)
UPPER COMPRESSION
0.070 mm (.0028 in) NEW MAXIMUM
RING (rectangular)
UPPER COMPRESSION
LOWER COMPRESSION 0.50 mm (.020 in)
0.060 mm (.0024 in) RING (rectangular)
RING (taper-face)
LOWER COMPRESSION
OIL SCRAPER RING 0.055 mm (.0021 in) 0.55 mm (.022 in)
RING (taper-face)
SERVICE LIMIT
OIL SCRAPER RING 0.50 mm (.020 in)
ALL 0.15 mm (.006 in)
SERVICE LIMIT
ALL 1.5 mm (.059 in)
1

Measure position for ring end gap in the area of 8

to 16 mm (.315 to .630 in) from top of cylinder.
NOTE: In order to correctly position the ring in the
cylinder, use piston as a pusher.
Using a feeler gauge, check ring end gap. Replace
ring if gap exceeds above described specified tol-
erance.

Installation
R1004motr33A 2 For installation, reverse the removal procedure.
1. Piston Pay attention to the following details.
2. Feeler gauge
NOTE: Install the oil scraper ring first with "O" fac-
ing up, then the lower compression (taper-face)
ring with the word "TOP" facing up, then the up-
per compression (rectangular) ring with the word
"TOP" facing up.

3
A31C2NA

1. Rectangular ring
2. Taper-face ring
3. Oil scraper ring

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Section 04 ENGINE (4-TEC)
Subsection 06 (CRANKSHAFT/DRIVE GEARS)

CAUTION: Ensure that top and second rings are

not interchanged.
NOTE: Use a ring expander to prevent breakage
during installation. The oil ring must be installed
by hand.
Check that rings rotate smoothly after installation.
Space the piston ring end gaps 120° apart and do
not align the gaps with the piston pin bore or the
thrust side axis.

A
A A

A31C2OA

1. DO NOT align ring gap with piston thrust side axis

2. DO NOT align ring gap with piston pin bore axis
A. 120°

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 Section 04 ENGINE (4-TEC)
Subsection 07 (CRANKCASE)

CRANKCASE
SERVICE TOOLS
Description Part Number Page
bearing installer/remover ...................................................... 529 035 913 ......................................... 253
bearing installer/remover ...................................................... 529 035 914 ......................................... 250
PTO cover oil seal installer ................................................... 529 035 910 ......................................... 250
support sleeve ...................................................................... 529 035 944 ................................. 253–254

SERVICE PRODUCTS
Description Part Number Page
Loctite 243............................................................................ 293 800 060 ......................................... 251
Molykote 111........................................................................ 413 707 000 ......................................... 255
Petamo grease ..................................................................... 420 899 271 ................................. 250, 253

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Section 04 ENGINE (4-TEC)
Subsection 07 (CRANKCASE)

10

Engine oil

8
6
11
9 N•m Petamo grease
(80 lbf•in)
12 Engine oil

5
9 N•m 14
(80 lbf•in) 2
15 13 24 N•m 5 N•m
Molykote (18 lbf•ft) (44 lbf•in)
111 3 22
23 Molykote
6 111
9 N•m
Petamo grease (80 lbf•in)
24 17A
Loctite
7 243

18 Engine oil
Engine
oil

4 Petamo
9 N•m 21 grease 19
(80 lbf•in) 16 20
17 Molykote
9 N•m 111
(80 lbf•in)

R1004motr110T

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 Section 04 ENGINE (4-TEC)
Subsection 07 (CRANKCASE)

GENERAL 1 2
To remove crankcase, the engine removal is nec-
essary.
For installation, use the torque values and Loctite
products indicated in the exploded view. Clean
threads before using Loctite when installing A
screws.

PTO COVER
R1004motr112A
Removal
1. Plain bearing
Remove: 2. Oil bore
A. Plain bearing inside diameter to be measured in area of oil bore
– engine from the vehicle (refer to REMOVAL
AND INSTALLATION) PLAIN BEARING INSIDE DIAMETER
– oil tank (refer to LUBRICATION SYSTEM) (PTO SIDE SUPPORT BEARING)
– disconnect crankshaft position sensor no. 23
Service limit 38.040 mm (1.4976 in)
– PTO cover screws no. 17 and no. 17A and pull
PTO cover no. 16. Bearing Removal Procedure
Carefully remove the oil seal no. 20 with a screw-
driver, without inflicting damage to the PTO cover.

TOOLS P/N TO REMOVE PTO SIDE

3 PLAIN BEARING
PTO side plain bearing
529 035 914
2 remover

NOTE: Carefully push-out the plain bearings

no. 18 and no. 19 from the outside towards the
1 inside. The PTO cover has to be supported from
below with suitable support with straight surface,
in order to prevent damage of the sealing surface.
R1004motr111A 2
1. PTO cover
2. PTO cover screws
3. Crankshaft position sensor

Inspection
Check the PTO cover for cracks or other damage.
Replace PTO cover if damaged.
Check plain bearings no. 18 and no. 19 for scor-
ings or other damages.
1
NOTE: Measure plain bearing inside diameter
and compare to crankshaft journal diameter (PTO R1004motr113A

support bearing). Refer to CRANKSHAFT/DRIVE 1. PTO cover

GEARS. Replace if the measurement is out of 2. Plain bearing remover (P/N 529 035 914)
specification.

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Section 04 ENGINE (4-TEC)
Subsection 07 (CRANKCASE)

Bearing Installation Procedure

NOTE: Unless otherwise instructed, never use
hammer to install plain bearings. Use press ma-
chine only.
Install plain bearings with the proper plain bearing
installer/remover (P/N 529 035 914).
Fit the plain bearings with Petamo grease (P/N 420 2
899 271).
NOTE: Carefully press-in the plain bearings no. 18
and no. 19 in the same direction as during disas-
sembly, from the outside towards the inside. Sup-
port PTO cover with suitable support with straight
surface, in order to prevent damage of the sealing
R1004motr115A 3 1
surface.
1. PTO cover
CAUTION: Mark position of oil bore in plain 2. Partition
bearing on crankcase half. Align mark on 3. Oil return holes
plain bearing installer/remover with mark on
crankcase half. Wrong oil bore position will Oil Seal Installation Procedure
stop oil supply to plain bearing and will dam- NOTE: At installation, replace PTO cover oil seal
age the engine. no. 20.
1 Push PTO cover oil seal in place by using the PTO
cover oil seal installer (P/N 529 035 910).

R1004motr114A 2 1

1. PTO cover
2. Oil bore

CAUTION: The partition of the plain bearings

must be positioned between the oil return
holes (refer to no. 3 in next illustration) in the R1004motr116A
PTO cover.
1. Oil seal for the PTO cover
2. Oil seal pusher (P/N 529 035 910)

Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
NOTE: At installation, replace gasket no. 21.
Torque PTO cover screws to 9 N•m (80 lbf•in).

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 Section 04 ENGINE (4-TEC)
Subsection 07 (CRANKCASE)

Tightening sequence for screws on PTO cover is 1 1

as per following illustration. Fit the screw no. 17A
with Loctite 243 (P/N 293 800 060).
1
1 2 3A

13
4

12
5
11
6 2
10 2
R1004motr117A

1. Six screws M8 x 90
R1004motr111B 9 8 7 2. Eight screws M6 x 65

A. Screw 17A with Loctite 243 Place the crankcase on a wood stand, PTO side
upwards.
CRANKCASE Carefully separate crankcase halves by using a
screwdriver and a plastic hammer.
Disassembly NOTE: During disassembly, do not damage the
Remove: sealing surfaces of the crankcase halves.
– engine from vehicle (refer to REMOVAL AND
INSTALLATION)
– oil tank and oil filter housing (refer to LUBRICA-
TION SYSTEM)
– PTO cover (refer to PTO COVER above)
– trigger wheel (refer to CRANKSHAFT/DRIVE
GEARS)
– electric starter (refer to ELECTRIC STARTER)
– alternator side cover (refer to COOLING SYS-
TEM)
– drive gears (refer to CRANKSHAFT/DRIVE
GEARS)
– cylinder head and cylinder (refer to CYLINDER
AND CYLINDER HEAD)
– timing chains (refer to CRANKSHAFT/DRIVE R1004motr118A

GEARS) POSITION FOR SCREWDRIVER

– cover no. 13
– screws no. 3 and no. 4 retaining crankcase
halves.

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Section 04 ENGINE (4-TEC)
Subsection 07 (CRANKCASE)

2 1
5

R1004motr120A

1. Plain bearing
2. Oil bore
A. Plain bearing inside diameter to be measured in area of oil bore

PLAIN BEARING INSIDE DIAMETER

(ALTERNATOR SIDE)
R1004motr119A
Service limit 55.020 mm (2.1661 in)
POSITION FOR PLASTIC HAMMER
PLAIN BEARING INSIDE DIAMETER (PTO side)
Service limit 55.020 mm (2.1661 in)
Inspection
NOTE: Remove all remaining parts from the Bearing Removal Procedure
crankcase halves; they could get damaged during
Always heat crankcase half up to 100°C (212°F)
the repair work.
before removing ball bearings.
Clean crankcase halves from contaminations and
blow the oil supply lines with compressed air.  WARNING
 WARNING Clean oil, outside and inside of crankcase half
before heating it.
Use safety goggles to avoid eye injuries.
CAUTION: Always support crankcase halves
Check bearing no. 8, for excessive play and properly when ball bearings or plain bearings
smooth operation. Replace if necessary. are removed. Damages to crankcase halves
may occur if this procedure is not performed
Check plain bearings no. 6 and no. 7 for scorings
correctly.
or other damages.
The generator gear ball bearing no. 8 in alterna-
NOTE: Measure plain bearing inside diameter and tor side crankcase half is removed with a suitable
compare to PTO/alternator side journal diameters bearing puller (not sold by BRP).
(refer to CRANKSHAFT/DRIVE GEARS). Replace if
the measurement is out of specification.

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 Section 04 ENGINE (4-TEC)
Subsection 07 (CRANKCASE)

PLAIN BEARING REMOVER

1 Alternator side
529 035 913
PTO side
SUPPORT SLEEVE
PTO side 529 035 944

R1004motr121A 2
1. Ball bearing
2. Bearing puller

Remove plain bearings no. 6, no. 7, no. 18 and

no. 19 with the proper plain bearing installer/re-
mover (P/N 529 035 913).
3
NOTE: Carefully push the plain bearings out, from
the crankcase half inside towards the outside. R1004motr123A 1
NOTE: Place the proper support sleeve (P/N 529 PUSH PLAIN BEARINGS OUTSIDE
1. Crankcase half PTO side
035 944) under PTO crankcase half before remov- 2. Plain bearing remover
ing plain bearings. There is no support sleeve 3. Support sleeve (P/N 529 035 944)
for alternator side crankcase half. To brace the
crankcase half, use a suitable wooden block or Bearing Installation Procedure
other support. Unless otherwise instructed, never use hammer
to install ball bearings or plain bearings. Use press
CAUTION: Suitable support sleeve must have
straight surface. machine only.
During disassembly, make sure not to damage the Always heat crankcase half up to 100°C (212°F)
sealing surfaces of the crankcase halves. before installing ball bearing.

1  WARNING
Clean oil, outside and inside of crankcase half
2 before heating it.

NOTE: Place new ball bearing in freezer for 10

minutes before installation.
NOTE: No striking tools are to be used to insert
the ball bearing. With moderate (thumb) pressure
the bearing has to be mounted manually into the
alternator side cover.
3 Install plain bearings no. 6, no. 7, no. 18 and
R1004motr122A no. 19 with the proper plain bearing installer/re-
mover (P/N 529 035 913).
PUSH PLAIN BEARINGS OUTSIDE
1. Crankcase half alternator side Fit the plain bearings with Petamo grease (P/N 420
2. Plain bearing remover
3. Wooden block 899 271).

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Section 04 ENGINE (4-TEC)
Subsection 07 (CRANKCASE)

NOTE: Carefully press-in the plain bearings in the 1 3 2

same direction as during disassembly, from the
case inside towards the outside.
NOTE: Place the proper support sleeve (P/N 529
035 944) under PTO crankcase half before in-
stalling the plain bearings. There is no support
sleeve for alternator side crankcase half. For
bracing of the crankcase half use a suitable wood-
en block or other support (refer to BEARING
REMOVAL PROCEDURE above).
CAUTION: Suitable support sleeve must have
straight surface.
R1004motr125A
During reassembly, make sure not to damage the
sealing surfaces of the crankcase halves. 1. Crankcase
2. Partition
3. Groove
PLAIN BEARING INSTALLER/REMOVER
NOTE: Use an O-ring (∅ 55 x 1 to 1.5 mm (.04
Alternator side
529 035 913 to .06 in) thickness) to hold plain bearings in place
PTO side during installation. The O-ring will disappear in the
groove of the plain bearing installer/remover.
SUPPORT SLEEVE
PTO side 529 035 944 Assembly
The assembly of crankcase is essentially the re-
CAUTION: Mark position of oil bore in plain verse of removal procedure. However, pay atten-
bearing on crankcase half. Align mark on tion to the following details.
plain bearing installer/remover with mark on
crankcase half. Wrong oil bore position will NOTE: Clean oil passages and make sure they are
stop oil supply to plain bearing and will dam- not clogged.
age the engine. Clean all metal components in a solvent.
1 NOTE: At installation, replace gasket no. 5.
NOTE: Oil the plain bearings before mounting the
crankshaft.
Reinstall all other parts (refer to LUBRICATION
SYSTEM).
Torque screws no. 4 M6 x 65 to 9 N•m (80 lbf•in).
2 Torque screws no. 3 M8 x 90 to 24 N•m (18 lbf•ft).
Tightening sequence for screws on crankcase is
as per following illustration.

R1004motr124A

1. Crankcase
2. Oil bore

CAUTION: The partition of the plain bearings

must be positioned near the groove (refer to
no. 3 in next illustration) of the crankcase.

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 Section 04 ENGINE (4-TEC)
Subsection 07 (CRANKCASE)

5 6 4

1
3
14

13
7

8
12

R1004motr117B 9 10 11

NOTE: At installation, replace gasket rings no. 15.

Slightly grease the gasket rings no. 15 before as-
sembly using Molykote 111 (P/N 413 707 000).
Torque cover screws no. 14 to 9 N•m (80 lbf•in).

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 Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 01 (OVERVIEW)

OVERVIEW
ENGINE MANAGEMENT SYSTEM OVERVIEW
FUEL
TANK
ELECTRIC MUFFLER
FUEL PUMP

EGTS

IGNITION
COIL

ECM
KS WTS APS

e-RAVE ATS
FR
RS
FI
TPS
+ -
BATTERY

LEGEND
APS – Air pressure sensor
ATS – Air temperature sensor
CPS – Crankshaft position sensor
ECM – Engine control module
EGTS – Exhaust gas temperature sensor
CPS FI – Fuel injector
FR – Fuel rail
KS – Knock sensor
RS – RAVE solenoid
TPS – Throttle position sensor
WTS – Water temperature sensor
IN OUT
A32A1RT

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Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 01 (OVERVIEW)

OPERATING PRINCIPLE The fuel pump module is located inside the fuel
tank. The module includes the fuel pump and the
For this SDI 2-stroke engine, a highly advanced en- fuel level sensor.
gine management system (EMS) has been used to
ensure a high power output combined with clean-
est combustion. An ECM (Engine Control Mod-
ule) calculates the proper air/fuel mixture and igni-
tion timing for each cylinder separately. The fuel
is injected into the transfer port of each cylinder.

AIR INDUCTION
Through air filters mounted on dash, air goes into
air silencer. The ECM measures at this point air
pressure and temperature. Then, air for combus-
tion is drawn through two throttle bodies. The air A32I18A
flow is controlled by two throttle plates. The air
continues through the reed valves into the cylin- The fuel pressure regulator controls the pressure
der base then the crankcase. in the system and allows the excess of fuel to
return to the fuel tank. The fuel pressure regu-
lator regulates the fuel pressure at approximately
400 kPa (58 PSI).

Fuel Rail
The fuel rail is a small tube on which the four in-
jectors are mounted. It ensures at all times that
enough fuel at the right pressure can be delivered
to the fuel injectors. The fuel rail is fed by the
fuel pump with a fuel pressure of approximately
400 kPa (58 PSI).

Fuel Injectors
Fuel injectors (two per cylinder) are used to inject
A32C8PA 1 fuel into the transfer port of cylinder.
THROTTLE BODY ASSEMBLY
1. Coolant-heated line Throttle Body
It is a dual throttle body mounted on the engine in-
take side. Fitted on this dual throttle body, there
FUEL DELIVERY SYSTEM is a TPS (Throttle Position Sensor) that sends in-
formation to the ECM.
GENERAL
When the piston reaches the correct position, Fuel Pickups
the ECM opens the fuel injectors and fuel is dis- The two fuel pickups come with 70 micron filter.
charged into the transfer ports of cylinders. This One is located at the front right side of the fuel
air/fuel mixture is then ignited by the spark plug. tank and the other at the rear left side.

COMPONENT DESCRIPTION
Fuel Pump and Fuel Pressure Regulator
They provide fuel pressure and flow rate to the
system.

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 Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 01 (OVERVIEW)

A32C8QA 2
1. Fuel tank
2. Fuel pickups

A32E3AA

In-Line Fuel Filter TYPICAL — ECM

The in-line 10 micron fuel filter is fastened under
the steering console. It comes as a complete as- The ECM is directly powered by the battery. It
sembly. is responsible for the following engine manage-
ment/electrical functions:
– interpreting information
– distributing information
– start/stop function
– DESS (Digitally Encoded Security System)
– ignition control
– injection control
NOTE: The ECM applies the proper maps (injec-
tion and ignition) for optimum engine operation in
all conditions.
– engine RPM limiter
– RER (Rotax Electronic Reverse)
A32C8RA
– etc.
The ECM features a permanent memory that will
keep the programmed tether cord cap(s) active,
ENGINE MANAGEMENT fault codes and other vehicle information, even
SYSTEM (EMS) when the battery is removed from the vehicle.
The EMS (Engine Management System) is
equipped with an ECM which controls the ig-
nition system, the vehicle electrical system, the
fuel injection system and the electronically con-
trolled RAVE.

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Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 01 (OVERVIEW)

EMS — GENERAL FUNCTIONS The memory of the ECM features two self-diag-
nostic modes for the DESS operation. Refer to
Automatic Power Shut-Down DIAGNOSTIC PROCEDURES section for more in-
The ECM is equipped with an automatic power formation.
shut-down. This feature prevents the battery The memory of the ECM is permanent. If the bat-
from losing its charge if the tether cord cap is tery is disconnected, no information is lost.
left on the post when the engine is not running Note that the DESS anti-drive circuitry is already
for more then 30 seconds. The ECM will remain activated on all new ECMs.
offline until the electric starter or the rewind
starter is activated. The ECM will shut down all Gauges Current Supply
outputs after 5 seconds when the tether cord cap
is removed. The purpose of this function is to allow reading
of gauges without the engine running. It will give
Antidrive Feature access to most functions of the information center
gauge without starting the engine.
This system allows the engine to reach pulley en-
gagement speed only if a programmed tether cord Gauges are supplied with current for 30 seconds
cap is installed on DESS post. See below for de- when connecting the tether cord cap on its post
tails. and pressing the START/RER switch.
NOTE: Each time the tether cord cap is connect-
Digitally Encoded Security ed to the post, the fuel pump is activated for 2
System (DESS) seconds to build up pressure in the fuel injection
The following components are specially designed system.
for this system: ECM, tether cord cap and DESS
post. Engine Starting
The tether cord cap contains a magnet and a ROM If the ECM recognizes a valid tether cord cap, it
chip. The magnet actually closes the reed switch allows engine to rev above 3000 RPM.
inside the post which is the equivalent of a me- If the tether cord cap is left on the DESS post for
chanical ON/OFF switch. The chip has a unique more than 30 seconds after stopping the engine,
digital code. the ECM will shut down. The current supply to
NOTE: Actually, it is the memory of the ECM gauges will be stopped as explained in the AN-
which is programmed to recognize the digital TIDRIVE FEATURE section.
code of the tether cord cap. This is achieved
with the VCK (Vehicle Communication Kit P/N 529
Engine RPM Limiter
035 981). Refer to the HELP menu to program a The ECM will limit the maximum engine speed.
tether cord cap.
Low-Oil Level Warning Device
The system is quite flexible. Up to 8 tether cord
caps may be programmed in the memory of the When the oil falls under a certain level, the low oil
vehicle ECM. They can also be erased individually. level LED will be illuminated. The buzzer will also
be activated intermittently.
NOTE: If desired, a tether cord cap can be used
on other vehicle equipped with the DESS. It only High Coolant Temperature Warning
needs to be programmed for that vehicle. Device
When waking up the ECM with a tether cord cap When the coolant temperature is getting to high,
on the post, the DESS is activated and will emit the ECM sends out signals to the buzzer, the high
audible signals: temperature LED and to the check engine LED.
– 2 short beeps indicate a working tether cord
cap. Engine starting can take place.
– 1 short beep indicates a wrong tether cord cap
is being used or that something is defective.
Engine starting is not allowed.

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 Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 01 (OVERVIEW)

High Muffler Temperature

Warning Device
When the muffler temperature is getting to high,
the ECM will extend the injection period temporar-
ily, until the temperature of the muffler will de-
crease.
If the temperature still increases, the high tem-
perature LED will be illuminated and further the
ECM will limit the engine speed to maximum 5250
RPM.

Power Distribution
The ECM distributes power from battery to all ac-
cessories. Accessories are protected by fuses lo-
cated in the fuse holder. Fuses are identified be-
sides their holder.
IMPORTANT: The sensors and injectors are con-
tinuously powered with the supply from the bat-
tery. The ECM switches the ground to com-
plete the electrical circuits it controls. Take this
into account when troubleshooting the electrical
system.
The system uses 3 relays: a main relay, a second
for the headlights and a third for the accessories.
If a problem occurs with the magneto system, the
ECM will turn off the accessories relay to distrib-
ute the remaining voltage to the main systems.

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Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 01 (OVERVIEW)

EMS — ENGINE MANAGEMENT SYSTEM FUNCTIONS

SDI SYSTEM
INPUTS OUTPUTS
Air pressure sensor (APS) Fuel pump

Air temperature sensor (ATS) Fuel injector (4)

Crankshaft position sensor (CPS) RAVE solenoid

Exhaust gas temperature sensor (EGTS) Ignition coil

Knock sensor (KS) Buzzer

Throttle position sensor (TPS)

ENGINE Speedometer
CONTROL
Water temperature sensor (WTS)
MODULE Communication port
(ECM)
Battery voltage

Digitally encoded security system (DESS)

START/RER button

Oil tank low-level

Communication port
A32A1SS

This engine management system controls the fuel ELECTRONIC FUEL INJECTION
injection, the ignition timing and the electronically
controlled RAVE. The ECM receives the signals from different sen-
sors which indicate engine operating conditions at
As shown in the ENGINE MANAGEMENT SYS- milli-second intervals.
TEM FUNCTIONS illustration, the ECM is the cen-
tral point of the fuel injection system. It reads Signals from sensors are used by the ECM to de-
the inputs, makes computations, uses pre-deter- termine the injection parameters (fuel maps) re-
mined parameters and sends the proper signals quired for optimum air-fuel ratio.
to the outputs for proper engine management. The CPS and TPS are the primary sensors used
The ECM also stores the fault codes and general to control the injection and ignition timing. Other
information such as: operating conditions, vehicle sensors are used for secondary input.
hours, serial numbers, customer and maintenance
information.

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 Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 01 (OVERVIEW)

IGNITION TIMING FLOODED ENGINE

The ECM is programmed with data (it contains ig- (DROWNED MODE)
nition mappings) for optimum ignition timing un- If the engine does not start and it is fuel-flooded,
der all operating conditions. Using engine operat- this special mode can be activated to prevent fuel
ing conditions provided by the sensors, the ECM injection and ignition while cranking. Proceed as
controls the ignition timing for optimum engine op- follows:
eration.
With tether cord cap on its post while engine
is stopped, press completely and HOLD throttle
ELECTRONICALLY CONTROLLED lever.
RAVE Press the START/RER button. The mode is now
The electronically controlled RAVE (e-RAVE) offers on.
two performance enhancements to conventional The engine should be cranked for 20 seconds.
RAVE system.
NOTE: No spark occurs on drowned mode.
– The opening of the valve is now activated elec-
tronically. A solenoid holds the valve closed. Release START/RER button and throttle lever. Try
The ECM monitors altitude, engine tempera- to start the engine normally.
ture, throttle position and RPM, and operates If the engine does not start, it may be necessary
the solenoid in optimal conditions. to remove the spark plugs and crank the engine
– The valve is now opened by crankcase pres- with rags over spark plug holes. Refer to COM-
sure, as opposed to exhaust pressure. The PONENT INSPECTION AND ADJUSTMENT.
greater and more constant pressure from the
crankcase opens the valve more crisply. MONITORING SYSTEM
NOTE: An electric heating element has been The ECM monitors the electronic components of
added to the RAVE solenoid to ensure proper the fuel injection system and some components
function in very cold weather. of the electrical system.
When a fault occurs, it sends visual messages
KNOCK SENSOR through the referring LED and/or audible signals
A knock sensor is mounted on top of the cylinder through a buzzer to inform you of a particular con-
head. It detects specific vibration that would be dition. Refer to the DIAGNOSTIC PROCEDURES
typically generated by engine detonation. If deto- section for the referring LED and the buzzer coded
nation occurs, the knock sensor detects it and the signals chart.
ECMs retards the ignition advance and extend the
injection period temporarily (it goes in a specific LIMP HOME MODES
mode) until detonation stops.
Besides the signals as seen above, the ECM may
automatically set default parameters to the engine
ENGINE MODES OF OPERATION management to ensure the adequate operation of
The ECM controls different operation modes of the vehicle if a component of the fuel injection
the engine to allow proper operation for all pos- system is not operating properly.
sible conditions: Cranking, start up, idle, warm NOTE: Sensor failures will not lead to a limp home
up, normal operation, engine speed limiter, flood- mode, warning will follow by the check engine
ed engine and limp home (see below). LED and the buzzer.
When minor fault occurs, the fault and mes-
sage/buzzer will disappear automatically, when
the condition disappears.
Depending on the severity of the malfunction, the
vehicle speed may be reduced and not allowed to
reach its usual top speed.

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Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 01 (OVERVIEW)

The engine RPM may be limited if some critical Two separate windings receive input from the
components fail. In this case, releasing throttle ECM. Each winding provides high voltage to its
and letting the engine returning to idle speed may corresponding spark plug.
allow normal operation to come back. If does not This ignition system allows spark plugs to spark
work, try removing and reinstalling the tether cord independently.
cap on DESS post.
CAUTION: Do not interchange spark plug ca-
These performance-reduced modes allow the rid- bles. Match reference (PTO or MAG printed
er to go back home which would not be possible on high tension cable yellow tag) with corre-
without this advanced system. Refer to the DIAG- sponding cylinder spark plug.
NOSTIC PROCEDURES for a complete chart.
Double ignition coil is located underneath air si-
If a fault occurs and involves a limp home mode lencer.
operation, the engine management system will re-
duce engine RPM gradually to the proper level. TRIGGER COIL
DIAGNOSTIC MODE Trigger coil is used for:
1) Forward engine rotation.
The malfunctions are recorded in the memory
of the ECM. The memory of the ECM can be 2) Reverse engine rotation.
checked using the VCK (Vehicle Communication 3) As a crankshaft position sensor (CPS). This in-
Kit) (P/N 529 035 981) to see the fault codes. Re- formation is sent to the ECM.
fer to the DIAGNOSTIC PROCEDURES section.
The B.U.D.S. software must be used for this sys-
tem (always use the latest software version).

CHARGING SYSTEM
The magneto is the primary source of electrical
energy. It transforms magnetic field into electric
current (AC).
The magneto has a 3 phases, delta wound stator
on 18 poles. Capacity is 480 watts.
Unregulated AC current is rectified and regulated
between 13.4 and 15 volts for the vehicle electri-
cal system.
Vehicle 12-volt battery supplies the ECM with DC
current.
Refer to MAGNETO SYSTEM.

IGNITION SYSTEM
The following type of ignition system is used:
– Digital Inductive System.

DOUBLE IGNITION COIL

Double ignition coil has two separate windings,
one for each spark plug.
Ignition coil induces voltage to a high level in the
secondary windings to produce a spark at the
spark plug.

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 Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 02 (DIAGNOSTIC PROCEDURE)

DIAGNOSTIC PROCEDURE
SERVICE TOOLS
Description Part Number Page
GRAY diagnostic key ............................................................ 529 035 896 ......................................... 267
supply cable.......................................................................... 529 035 869 ......................................... 267
VCK (Vehicle Communication Kit) ......................................... 529 035 981 ......................................... 266

GENERAL
Here is the basic order suggested to diagnose a suspected engine management or fuel injection related
problem:
– Check the chart in TROUBLESHOOTING section to have an overview of problems and suggested so-
lutions.
– Check if the engine management system (EMS) pilot lamp lights up. If so, use the VCK (Vehicle Com-
munication Kit) and look for fault codes to diagnose the trouble.
– Check all fuses.
– Check fuel pressure.
– Check spark plugs condition.
– Check all connections of the wiring harness.
Refer to COMPONENT INSPECTION AND ADJUSTMENT section for procedures.

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Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 02 (DIAGNOSTIC PROCEDURE)

TROUBLESHOOTING
The following chart is provided to help in diagnosing the probable source of simple troubles.

Monitoring Beeper Coded Signals

CODED SIGNALS POSSIBLE CAUSE REMEDY

2 short beeps (when engine is started). Confirms that proper tether cord cap is installed. No problem detected. Good ride.
DESS/RER pilot lamp also blinks. Engine can rev above clutch engagement.

1 short beep every 1.5 seconds (when Bad DESS system connection. Reinstall tether cord cap correctly over
engine is started). DESS/RER pilot lamp post.
also blinks. Engine cannot reach pulley Defective tether cord cap. Use another programmed tether cord
engagement speed. Vehicle cannot be cap.
driven. Dirt or snow in tether cord cap. Clean tether cord cap.
Defective DESS post. Replace DESS post.

1 long beep per second. Reverse is selected. Vehicle can be driven in reverse.

3 short beeps per second. DESS/RER pilot Wrong tether cord cap is installed. Install proper tether cord cap. Program
lamp also blinks. Engine cannot reach pulley key into ECM.
engagement speed. Vehicle cannot be
driven.

3 short beeps per second. Engine Engine is overheating. Stop engine immediately and allow to
overheating pilot lamp also blinks. cool. Check cooling system.

3 short beeps per second. Low battery voltage. Check battery and charging system.

4 short beeps every 2 minutes. Oil pilot Low oil level on 2-TEC models. Check oil level and replenish as soon as
lamp also lights up. possible.

Battery pilot lamp lights up. No charging. Check battery and charging system.

Many other codes use the engine pilot lamp and the buzzer to indicate a problem. A complete list of
codes is available in B.U.D.S.

VCK (VEHICLE COMMUNICATION  WARNING

KIT) If the computer you are using is connected to
the power outlet, there is a potential risk of
The VCK (Vehicle Communication Kit) (P/N 529 electrocution when working in contact with
035 981) is the primary tool to diagnose engine water. Be careful not to touch water while
management and fuel injection related problems. working with the VCK.
NOTE: The MPEM programmer does not work on
SDI models. IMPORTANT: When using the software B.U.D.S.,
The SDI models require B.U.D.S. version G2.1 or with the SDI engine, ensure that the protocol
P2.1 or above. “kW2000” is properly selected in “MPI” (multi
B.U.D.S. (Bombardier Utility and Diagnostic Soft- protocol interface) under “CHOOSE PROTO-
ware) is designed to allow actuators, sensors and COL”.
electronic equipments inspection, diagnostic op- When B.U.D.S. is connected to the vehicle, the
tions and reset such as the closed throttle and idle status bar shows the protocol (kW2000) and the
actuator. number 1 to the right. To communicate with the
For more information pertaining to the use of the ECM, number 1 must be displayed.
software B.U.D.S., use its help which contains de- Number 1 means that one module is connected.
tailed information on its functions.

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 Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 02 (DIAGNOSTIC PROCEDURE)

2-TEC SYSTEM FAULT CODES

kW2000 General
The faults registered in the ECM (engine control
F18H0WA
module) are kept when the battery is disconnect-
ed.
ONE MODULE IS CONNECTED
IMPORTANT: After a problem has been solved,
If an “X” is shown, this means that no communi- ensure to clear the fault(s) in the ECM using
cation between the MPI and the ECM is possible. the VCK. This will properly reset the appropriate
In this case possible causes are: counter(s). This will also record that the problem
– ECM is not powered-up has been fixed in the ECM memory.
– wrong protocol is used Many fault codes at the same time is likely to be
– bad connection between MPI and module. burnt fuse(s).
For more information pertaining to the code faults
ECM Supply (state, count, first, etc.) and report, refer to
To power-up the ECM, push the START button B.U.D.S. online help.
shortly while the engine cut-out switch is de-
pressed and the tether cord cap installed on Supplemental Information
DESS post. If your intention is to program the – Electrical noise is picked up by the ECM. Ensure
vehicle key, use GRAY diagnostic key (P/N 529 that all connections are in good condition, also
035 896) on DESS post. grounds (battery, ECM, engine and ignition sys-
The supply cable (P/N 529 035 869) may also be tem), they are clean and well tightened and that
used. Just the fact to connect it between MPI and all electronic components are genuine — partic-
vehicle will power-up the ECM. ularly in the ignition system. Installing non-re-
sistive spark plugs may lead to generate fault
VCK Supply code.
The VCK (MPI box) can use the vehicle power for – Electrical noise might also lead engine to occa-
its supply. Four AA batteries or an AC/DC power sional cutout without generating a fault code.
supply can also be used. Make sure to respect – If everything is in good condition, try a new
MPI specification if a power supply is used. ECM.
When using the service action suggested in the
Writing in ECM FAULT section of B.U.D.S., the system circuits are
When writing in ECM through B.U.D.S., there referred to as DA-41, which means connector “A”
will be an “EMS Tracking” message that will say on the ECM and the circuit D41.
“Remove key from vehicle“. When this occurs,
remove the tether cord cap from its post and wait
until the message disappears (it lasts approxi-
mately 15 seconds after tether cord cap removal).

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Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 02 (DIAGNOSTIC PROCEDURE)

TPS (Throttle Position Sensor) Faults

Faults which are reported in B.U.D.S. fall into two groups TPS faults and adaption faults. These are dis-
played on the B.U.D.S. system as TPS OUT OF RANGE and TPS ADAPTION FAILURE.

TPS “Out of Range” Fault

It is caused by the sensor reading going out of its allowable range. This fault can occur during the whole
range of movement of the throttle.
To diagnose this fully, it is recommended to operate the throttle through its full range. It is also recom-
mended to release the throttle quickly as this may also reveal a fault that is intermittent.

POSSIBLE CAUSES ACTION

Check if connector is disconnected from TPS Reconnect.
Check if sensor is loose Tighten sensor and reset Closed Throttle.
Inspect sensor for damage or corrosion Replace sensor and reset Closed Throttle.
Inspect wiring (voltage test) Repair.
Inspect wiring and sensor (resistance test) If bad wiring, repair.
If bad TPS, replace and reset Closed Throttle.
Test sensor operation (wear test) Replace sensor and reset Closed Throttle.

TPS “Adaptation Failure” Fault

It is caused by the idle position moving out of an acceptable range.
Following failures can be effected by a TPS “Adaption Failure“:
– Idle speed is out of range.
– Engine stops, when throttle is released quickly.
– Engine runs inconsistent in low partload or low RPM.

POSSIBLE CAUSES ACTION

Sensor has been replaced and TPS closed position not Reset Closed Throttle.
reset
Throttle body has been replaced and TPS closed Reset Closed Throttle.
position not reset
EMS has been replaced and TPS closed position not Reset Closed Throttle.
reset
Throttle cable too tight Adjust cable and reset Closed Throttle.
Sensor is loose Tighten sensor and reset Closed Throttle.
Throttle bracket is loose Fix and reset Closed Throttle.
Adjustment screw worn or loose Adjust idle speed screw using B.U.D.S.

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 Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

COMPONENT INSPECTION AND

ADJUSTMENT
SERVICE TOOLS
Description Part Number Page
Fluke 111 .............................................................................. 529 035 868 ......................................... 271
fuel pressure gauge ............................................................. 529 035 868 ......................................... 278
supply cable.......................................................................... 529 035 869 ......................................... 271
VCK (Vehicle Communication Kit) ......................................... 529 035 981 ................................. 269, 279
wrench.................................................................................. 529 035 603 ......................................... 279
wrench.................................................................................. 529 035 899 ................................. 279, 281

SERVICE PRODUCTS
Description Part Number Page
anti-seize lubricant ................................................................ 293 800 070 ......................................... 292
dielectric grease ................................................................... 293 550 004 ......................................... 282
Loctite 5910.......................................................................... 293 800 081 ................................. 289, 292
pulley flange cleaner............................................................. 413 711 809 ......................................... 275

GENERAL FUEL SYSTEM

Engine problems are not necessarily related to the  WARNING
electronic fuel injection system.
The fuel system of a fuel injection system
It is important to ensure that the mechanical in- holds much more pressure than that of a car-
tegrity of the engine/propulsion system is present: bureted snowmobile. Prior to disconnecting
– good transmission system operation a hose or to removing a component from
– good engine compression and properly operat- the fuel system, follow the recommenda-
ing mechanical components, no leaks etc. tion described here. Pay attention that some
– fuel pump connection and fuel lines without hoses may have more than one clamp at their
leaks. ends. Ensure to reinstall the same quantity
of clamps at assembly.
Check the chart in TROUBLESHOOTING section
to have an overview of problems and suggested
solutions. – Use the VCK (Vehicle Communication Kit)
(P/N 529 035 981) to release the fuel pressure
When replacing a component, always check its in the system. Look in the Activation section
operation after installation. of the software B.U.D.S. (ensure to use the
latest version available on BOSSWeb).

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Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

 WARNING
Ensure to verify fuel line connections for
damage and that NO fuel line is disconnect-
ed prior to installing the tether cord cap on
the DESS post. Always perform the high
529 035 981 pressure test if any component has been
removed. A pressure test must be done
before connecting the tether cord cap. The
fuel pump is started and pressure quickly
builds-up each time the tether cord cap is
installed and the START/RER button is de-
pressed (or rewind starter is pulled).

 WARNING To check fuel rail for leaks, first pressurize the sys-
tem then spray soapy water on all hose connec-
Fuel lines remain under pressure at all times. tions, regulators and injectors. Air bubbles will
Always proceed with care and use appro- show the leaking area. Check also for leaking fuel
priate safety equipment when working on or fuel odor.
pressurized fuel system. Wear safety glasses
and work in a well ventilated area. Do not  WARNING
allow fuel to spill on hot engine parts and/or Never use a hose pincher on injection system
on electrical connectors. Proceed with care high pressure hoses.
when removing/installing high pressure test
equipment or disconnecting fuel line connec-
tions. Use the VCK to release fuel pressure
prior to removing a hose. Cover the fuel ELECTRICAL SYSTEM
line connection with an absorbent shop rag. It is important to check that the electrical system
Slowly disconnect the fuel hose to minimize is functioning properly:
spilling. Wipe off any fuel spillage in the
engine compartment. Fuel is flammable and – battery
explosive under certain conditions. Always – fuses
work in a well ventilated area. Always dis- – DESS
connect battery prior to working on the fuel – ignition (spark)
system. After performing a pressure test, – ground connections
release the pressure.
– wiring connectors.
It is possible that a component seems to operate
– Always disconnect battery properly prior to in static condition but in fact, it is defective. In
working on the fuel system. Refer to BATTERY this case, the best way to solve this problem is
section. to remove the original part and replace it with one
When the job is done, ensure that hoses from fu- which is in good condition.
el rail going to fuel pump are properly secured in Never use a battery charger to substitute tem-
their supports. Then, pressurize the fuel system. porarily the battery, as it may cause the ECM
Perform the fuel pressure test as explained in this (engine control module) to work erratically or not
section. to work at all. Check related-circuit fuse solidity
Properly reconnect the battery. and condition with an ohmmeter. Visual inspec-
tion could lead to false results.

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 Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

 WARNING Before replacing a ECM, always check electrical

connections. Make sure that they are very tight
All electrical actuators (injectors, fuel pump, and they make good contact and that they are cor-
ignition coils and starter solenoid) may be rosion-free. Check if wiring harness shows any
suddenly supplied by the battery when the signs of scoring. Particularly check ECM ground
tether cord cap is installed and the start connections. Ensure that contacts are good and
button is depressed or if engine is rotated clean. A “defective module” could possibly be
(manually or with the rewind starter). Even repaired simply by unplugging and replugging the
a small movement of the crankshaft or the ECM. The voltage and current might be too weak
usage of the supply cable (P/N 529 035 869) to go through dirty wire pins. Check carefully if
will automatically activate the actuators. Al- pins show signs of moisture, corrosion or if they
ways disconnect the tether cord cap and the look dull. Clean pins properly and then coat them
battery prior to disconnecting any electric or with a silicon-based dielectric grease or equiva-
electronic parts. lent.
NOTE: Do not apply dielectric grease or other lu-
bricant on the ECM connectors.
If the newly replaced ECM works, try the old one
and recheck if it works.
Ensure that all electronic components are genuine
529 035 869 – any modification on the wiring harness may lead
to generate fault codes or bad operation.
NOTE: For diagnostics purposes, use Vehicle
Communication Kit (VCK). See DIAGNOSTIC
PROCEDURES subsection.
After a problem has been solved, ensure to clear
the fault(s) in the ECM using the VCK. Refer to
To perform verifications, a good quality multimeter DIAGNOSTIC PROCEDURES subsection.
such as Fluke 111 (P/N 529 035 868) should be
used. RESISTANCE MEASUREMENT
When measuring the resistance with an ohmme-
ter, all values are given for a temperature of 20°C
(68°F). The resistance value of a resistance varies
with the temperature. The resistance value for
usual resistor or windings (such as injectors) in-
529 035 868
creases as the temperature increases. However,
some of our temperature sensors are NTC types
(Negative Temperature Coefficient) and work the
opposite which means that the resistance value
decreases as the temperature increases. Take it
into account when measuring at temperatures dif-
Pay particular attention to ensure that pins are ferent from 20°C (68°F). Use this table for resis-
not out of their connectors or out of shape. The tance variation relative to temperature for temper-
troubleshooting procedures cover problems not ature sensors.
resulting from one of these causes.
CAUTION: Ensure all terminals are properly
crimped on wires and connector housings are
properly fastened.

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Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

TEMPERATURE SENSOR TABLE TEMPERATURE SENSOR TABLE

TEMPERATURE RESISTANCE (OHMS) TEMPERATURE RESISTANCE (OHMS)
CTS FOR CTS FOR
°C °F ATS EGTS °C °F ATS EGTS
GAUGE ECM GAUGE ECM
- 40 - 40 169.7 72412 120 248 111.5
- 35 - 31 52637 125 257 99.02
- 30 - 22 28000 38681 130 266 90 88.26
- 25 - 13 28718 135 275 78.93
- 20 - 4 14500 185.1 733.8 21529 140 284 70.81
- 15 5 587.7 16288 145 293 63.71
- 10 14 474 12431 150 302 312.7 57.49
- 5 23 384.8 9565 200 392 349.0
0 32 5500 200.5 314.3 7418 250 482 384.6
5 41 258.4 5807 300 572 419.7
10 50 213.7 4582 350 662 454.2
15 59 177.7 3644 400 752 488.1
20 68 2500 148.7 2919 450 842 521.4
25 77 219.6 125 2355 500 932 554.1
30 86 105.6 1912 600 1112 617.8
35 95 98.69 1562 700 1292 679.2
40 104 1200 76.5 1284 800 1472 738.2
45 113 65.54 1062 900 1652 794.9
50 122 238.5 56.38 882.6 1000 1832 849.2
55 131 48.72 738.9
The resistance value of a temperature sensor may
60 140 600 42.28 622 test good at a certain temperature but it might be
65 149 36.82 526.3 defective at other temperatures. If in doubt, try a
new sensor.
70 158 32.19 447.5
Also remember this validates the operation of the
75 167 28.24 382.3 sensor at room temperature. It does not validate
80 176 320 24.86 328.1 the over temperature functionality. To test it, the
sensor could be removed from the engine/air si-
85 185 21.95 282.8
lencer and heated with a heat gun while it is still
90 194 19.45 244.8 connected to the harness to see if the ECM will
95 203 17.28 212.8
detect the high temperature condition and gener-
ate a fault code.
100 212 180 275.9 15.4 185.6
105 221 162.4
110 230 142.7
115 239 125.9

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 Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

ENGINE CONNECTOR PIN-OUTS

Connector Position
3

A32CCPA

PROBE ONLY ON THE PIN NOZZLE OF FEMALE CONNECTOR

CAUTION: Do not disconnect the ECM connec-

2 1 tor needlessly. They are not designed to be dis-
connected/reconnected repeatedly.
A32C9HB
Engine Connector
1. ECM connectorA
2. ECM connector B Use this illustration to locate the pin numbers on
3. Engine connector the engine connector of the wiring harness when
performing tests.
ECM Connector 4 3 2 1
Use this diagram to locate the pin numbers on
the ECM connector of the wiring harness when
performing tests.

13 1

28
14

41 29
R1503motr176A

ECM CONNECTOR PIN-OUT (WIRING HARNESS SIDE)

CAUTION: Probe on top of terminal only. Do 5 6 7 8

A32C9IA
not try to probe inside terminal or to use a pa-
per clip to probe inside terminal, it will dam- ENGINE CONNECTOR PIN-OUT (WIRING HARNESS SIDE)
age the square-shaped terminal and this could
lead to improper function of the engine man-
agement system.

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Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

AIR INDUCTION SYSTEM Electrical Inspection

Refer to THROTTLE POSITION SENSOR (TPS) in
THROTTLE BODY ELECTRONIC MANAGEMENT below.
2 5 Replacement
Removal
To remove the throttle body from engine, proceed
as follows:
– Disconnect connectors from ATS (Air Tempera-
ture Sensor) and APS (Air Pressure Sensor).
– Disconnect air intake silencer from throttle
body. Move boot away.
– Drain cooling system.
– Remove clamps and hoses for throttle body
heating from nipples.
– Disconnect connectors and hoses from E-RAVE
solenoid and TPS.
A32C9JA 1 3 4 – Disconnect throttle cable.
1. Throttle body – Unscrew retaining clamps of throttle body.
2. Throttle cable attachment
3. Throttle plate
4. TPS
5. E-RAVE solenoid

Mechanical Inspection
Check that the throttle plate moves freely and
smoothly when depressing throttle lever. Take
this opportunity to lubricate the throttle cable.
IMPORTANT: The throttle body is designed to be
tamper proof. Changing the zero position stop
screw or synchronization screw or modifying
them in any way will not increase performance
but may cause poor startability and erratic idling.
Before replacing any part, check the following as
these could be causing the fault. Perform the test A32C9KA 2 1
while the engine is not running.
1. Throttle body
– Throttle cable adjustment too tight. Not return- 2. Clamp
ing fully to idle stop.
– Throttle body idle set screw is loose or worn. – Slightly pull throttle body out.
– Throttle linkage between the two throttles has Installation
moved.
Installation of the new throttle body is the reverse
– TPS is loose.
of the removal procedure. Pay attention to the
– Corroded or damaged wiring or connectors. following details.
– Throttle body has been replaced and the Closed
Refill and bleed the cooling system, refer to LIQ-
Throttle reset has not been performed.
UID COOLING SYSTEM.
– ECM has been replaced and the Closed Throt-
tle reset has not been performed.

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 Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

For TPS and E-RAVE solenoid replacement proce-

dures, refer to the respective paragraph in ELEC-
TRONIC MANAGEMENT below.

Adjustment
Throttle Body Synchronization
1
CAUTION: It is not allowed to perform any 2
change on the synchronization screw.
Before installation, clean throttle plates and bores
with pulley flange cleaner (P/N 413 711 809).
NOTE: The throttle body is designed as a single
part for both cylinders. No synchronization is re-
quired as it has already been done at the factory.
However, proceed with throttle cable and closed
TPS adjustments as described below.

A32C9TA

1. Idle speed screw

2. Zero position stopper screw

CAUTION: Do not alter or tamper with throttle

cable adjustment or routing. It may cause poor
startability and erratic idling.
The only screw that has to be adjusted is the idle
speed screw and it has to be adjusted only with
the closed throttle reset procedure or for high al-
A32C9LA
titude application. This has to be done only if the
THROTTLE BODY ECM or throttle body are replaced or if screw has
1. Zero position stopper screw been tampered with by mistake. Refer to THROT-
TLE POSITION SENSOR (TPS) in ELECTRONIC
CAUTION: It is not allowed to perform any
change on the zero position stopper screw. MANAGEMENT below.
The adjustment of the zero position stopper screw Throttle Cable Adjustment
is optimized by the throttle body manufacturer and If closed throttle reset is required, then do it before
locked to prevent any modification. throttle cable adjustment.
CAUTION: Never attempt to adjust the zero po- Mechanically adjust the throttle cable.
sition stopper screw (the capped one) or the
idle speed adjustment would be impaired. Be- Handlebar and throttle cable must be at their nor-
sides, no adjustment could be performed by mal position.
the dealer nor the factory to correct the zero po- Adjust top nut to have a small free play at idle
sition stopper screw. The throttle body would position.
need to be replaced.
Tighten bottom nut to 4.5 N•m (40 lbf•in).

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Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

1 7

2
3
4

A32C7RA

1. Cable sheath
2. Upper nut
3. Lock washer
4. Lower nut
5. Throttle lever
6. Adjusting screw
7. Pull in this direction

Activate the throttle lever a few times. Make

sure throttle cam of throttle body rests against
idle speed screw without any tension on the
cable.
Using the VCK with B.U.D.S., perform the wide
open verification. In monitoring tab check if throt-
tle opening is within 82° to 86° when in wide open
position on throttle lever.
Closed Throttle Reset
Perform the Closed Throttle reset as described
in THROTTLE POSITION SENSOR (TPS) in ELEC-
TRONIC MANAGEMENT below.

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 Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

FUEL DELIVERY

Fuel delivery system diagnostic flow chart - SDI models

Connect tether cord, activate cut-out
Fuel pump does not run switch, push START/RER Fuel pump runs for 2 sec.
button momentarily then stops

Install fuel pressure gauge on fuel

pressure line

Check fuses and relays Connect tether cord, activate cut-out Replace fuel pump
Check tether cord cap connection switch, push START/RER module
Check fuel pump operation button momentarily
Repair or replace if necessary
Fuel pump runs

Fuel pressure under Fuel pressure at Fuel pressure over

400 kPa (58 PSI) 400 kPa (58 PSI) 400 kPa (58 PSI)

Repair or Fails
replace Check fuel line/rail for leaks

OK
Fails Perform fuel pump test
OK Crank or start Fuel pressure at
engine 400 kPa (58 PSI)

Fuel pressure under Fuel pressure over

400 kPa (58 PSI) 400 kPa (58 PSI)

Fast pressure No
drop Check fuel line/rail for leaks
Fuel system
Yes Fails OK OK

Fails Perform fuel

Repair or pump test
Verify fuel replace
pump check OK Fails OK
valve
Fails Check fuel
injectors
OK

Replace fuel pump

module

A32I1GS
Retest

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Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

FUEL PUMP Crank or start engine and observe fuel pressure.

The fuel pressure should be the same as above.
Fuel Pressure Test If pressure is within limits, fuel pump and pressure
Before proceeding to the pressure test, ensure regulator are working adequately.
the battery is fully charged. Battery voltage must A rapid pressure drop indicates leakage either
be over 12 volts. from the fuel rail or from the fuel pump check
Release the fuel pressure in the system using valve. Check fuel rail for leaks. If it is not leaking
B.U.D.S. Refer to the Activation tab. then replace fuel pump.
 WARNING A slow pressure drop indicates leakage either
from the fuel injector or from the fuel pump check
The fuel hose may be under pressure. Cov- valve. Check fuel injector for leaks (see below).
er the fuel line connection with an absorbent If it is not leaking then replace fuel pump module.
shop rag. Slowly disconnect the fuel hose
to release the pressure. Wipe off any fuel Release fuel pressure in the system using
spillage inside engine compartment. B.U.D.S. Look in the Activation tab.
Remove pressure gauge and plastic clip from inlet
The pressure test will show the available pressure hose. Reinstall fuel hose.
at the fuel pump outlet. It validates the pressure
regulator, the fuel pump and leaks in the system.
 WARNING
Wipe off any fuel spillage in the engine com-
Ensure there is no leak from hoses and fittings.
partment. Fuel is flammable and explosive
Repair any leak.
under certain conditions. Always work in a
Ensure there is enough gas in fuel tank. well ventilated area.
Disconnect outlet hose from fuel pump.
Reinstall removed parts.
Install fuel pressure gauge (P/N 529 035 591) be-
tween disconnected hose (inline installation). Electrical Test
When depressing the START/RER button, the fuel
pump should run for 2 seconds to build up the
pressure in the system.
If the pump does not work, disconnect the plug
connector from the fuel pump.
529 035 591
Install a temporary connector to the fuel pump
connector. Apply 12 V (+ on PINK wire and – on
PINK/BLACK wire) to this test harness.
If pump does not run, replace the fuel pump mod-
ule.
Otherwise, probe PINK wire and battery ground
of fuel pump connector on vehicle harness side.
Remove tether cord cap. Depress START/RER When depressing the START/RER button, you
button and observe fuel pressure. Do not crank should read battery voltage for approximately 2
engine. Repeat twice. Release pressure using seconds (then, the voltage will drop). If battery
B.U.D.S. between tests so that the gauge is “re- voltage does not appear, the problem can be
set” to zero (0). infuse, relay, harness or in fuel pump connector.
Repair or replace appropriate part (fuel pump may
FUEL PRESSURE be blown).
(WHEN DEPRESSING START BUTTON)
400 kPa (58 PSI)

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 Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Check continuity between PINK/BLACK wire of

the fuel pump connector on the vehicle harness
side and terminal 29 of the ECM connector B. If
there is no continuity the problem is in the har-
ness. Otherwise, try a new ECM.

Fuel Pump Module Replacement

Removal
Open hood. Connect VCK (Vehicle Communica-
tion Kit) (P/N 529 035 981). Use B.U.D.S. to re-
lease fuel pressure.
Drain fuel tank as much as possible.
Remove steering pad. Unbolt handlebar and
move it forward.
A32I10A 2 1
Unscrew fuel tank nut using wrench (P/N 529 035
1. Fuel supply hose
603). 2. Vent tube

Remove seat. Unbolt fuel tank.

529 035 603

A32I15A 1
1. Fuel tank retaining screws

Move fuel tank rearward, then unplug the fuel

pump module electric connector.
With two screwdrivers or a bent rod holding the
A32I0ZB
flange, unscrew fuel pump nut using fuel pump
TYPICAL nut wrench (P/N 529 035 899).
Unbolt console, then move it forward. 529 035 899
Disconnect fuel supply hose from fuel pump mod-
ule.
Disconnect vent tube from vent elbow.

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Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

A32I11A A32I13A

Installation
For installation, reverse the removal process but
pay attention to the following.
Install a new gasket.
Make sure that rear pickup hose is positioned as
following illustration.

1
A32I19A

1. Bent rod

Pull fuel pump module out of fuel tank to expose

sensor body.
Remove fuel pump module. Guide fuel pickups
when pulling out fuel pickup hoses.
A32I1AA

Align the arrow on fuel pump module with the

one on fuel tank. Keep arrows aligned during fuel
pump module nut tightening.

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 Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Put the vehicle back on the ground.

Do the above procedure three times.
Stop the engine. The rear fuel pickup hose is now
bled.

Fuel Hose Kit

Remove fuel pump module as explained above.
Unfasten blue hose clamp retaining old fuel hose
ass’y to pump inlet nipple. Remove old fuel hose
ass’y.
Install fuel hose ass’y to pump at an angle of 46 ±
3° from retaining rods axis.
1
A32I14A 1
1. Arrows

Install a torque wrench perpendicularly (90°) to fu-

el pump nut wrench (P/N 529 035 899). Torque
fuel pump nut to 30 N•m (22 lbf•ft).
A

A
A32I0VA 2
1
1. Retaining rods axis
2. Fuel hose ass’y
2 A. 30° ± 3

Install a new blue hose clamp on fuel hose ass’y.

Install a new gasket, then reinstall fuel pump mod-
ule as explained above.
A32I1BA

1. Arrows Pump Ass’y Kit

2. Torque wrench
Remove fuel pump module as explained above.
A. 90°
Disconnect fuel hose from pump inlet nipple.
Bleed the fuel system as following procedure. Disconnect pump electric connector.
Fuel Bleeding Procedure Disconnect pump outlet hose from pump module
The rear fuel pickup hose has to be bled. flange nipple.
Pour 12 L (3.17 U.S. gal.) of recommended fuel in Remove E-clips. Slide pump ass’y out of retaining
the fuel tank. rods.
Apply parking brake. Start the engine. Let it run
at idle speed.
Lift the front of vehicle at a 45° angle.

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Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

3 2 1
1
4

A32I0YA

TYPICAL
1. Pump inlet nipple
2. Pump electric connector
3. Pump module flange nipple
4. E-clips

Reverse removal procedure for installation. A32C9MA

Install a new gasket, then reinstall fuel pump mod- 1. Fuel injectors
ule as explained above.
Disconnect wiring harness from the four fuel in-
Regulator Kit jectors.
Remove fuel pump module as explained above. Cut tie raps and remove the wiring harness from
Remove 2 screws retaining regulator to pump the fuel rail.
module flange. Unscrew rail retaining nuts.
Replace O-rings with new ones. Install them in Gently pull rail up by hand, working each side
pump module flange bore. slightly at a time.
CAUTION: Regulator O-rings must be installed Pull rail out with fuel injectors.
in pump module flange bore. If necessary remove fuel injectors as described
Reverse removal procedure for installation. below.
Install a new gasket, then reinstall fuel pump mod- Installation
ule as explained above.
For installation, reverse the removal process but
pay attention to the following.
FUEL RAILS
Replace O-rings with new ones.
Pressure at fuel rails is supplied and controlled by A thin film of injection oil should be applied to
the fuel pump module. Refer to FUEL PUMP for O-rings of fuel injectors to ease installation in cylin-
pressure test. der.
Fuel Rail Replacement Torque rail retaining nuts to 10 N•m (89 lbf•in).
Removal Make sure that injector clips are well in place.
Release the fuel pressure in the system using Add dielectric grease (P/N 293 550 004) to injector
B.U.D.S. Look in the Activation tab. electrical connector.
Disconnect fuel hose at the connector. When installing fuel line connector to the fuel rail,
put some oil on the O-ring to ease installation.
Wrap a rag around the hose end to prevent rail
draining.  WARNING
Perform a fuel pressure test and ensure that
there is no leak. Refer to FUEL PUMP above.
Run engine and check for leaks.

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 Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

FUEL INJECTORS CIRCUIT NUMBER

INJECTOR NUMBER
(ECM CONNECTOR «A»)
Leakage Test
A-15 1/1 (MAG external)
To perform a leakage test, the injectors and fuel
rail have to be removed from the engine. Refer to A-33 2/1 (PTO external)
REMOVAL in FUEL RAIL REPLACEMENT for the A-14 1/2 (MAG internal)
procedure.
A-30 2/2 (PTO internal)
NOTE: Do not detach injectors from the fuel rail.
Reconnect the fuel line and the wiring harness. – If it does not read 12 V, check the corresponding
Place each injector in a clean bowl. fuse(s), relay and continuity of circuit. If continuity
Install the tether cord cap on the DESS post and is faulty, repair wiring harness.
press the engine START/RER button to activate Resistance Test
the fuel pump.
Disconnect the injector from the wiring harness
Check for fuel leakage from the injector nozzle. and check the resistance of the injector itself.
There should be less than 1 drop per minute. Per-
The resistance should be around 14.5 .
form the test for 2 minutes.
If resistance value is incorrect, replace the injector.
If not within specification, replace the fuel injec-
tor(s). Reconnect the injector and disconnect the con-
nector A from the ECM as well as the engine con-
The leakage test is validated when performing the
nector.
FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW
CHART elsewhere in this section. Using a multimeter, check resistance value be-
tween terminals as shown in the table below.
Electrical Test
4 3 2 1
Voltage Test
Tether cord cap must be on DESS post.
Using the vehicle communication kit (VCK) with
the B.U.D.S. software, energize the fuel injector
from the Activation section.
If the injector does not work, disconnect the plug
connector from the injector.
Install a temporary connector to the injector with
wires long enough to make the connection outside
the engine compartment and apply voltage (12 V)
to this test harness.
This will validate the injector mechanical and elec-
trical operation.
If it does not work, replace it. If it works, continue
procedure. A32C9IA 5 6 7 8
Wake up ECM using START button and measure ENGINE CONNECTOR
voltage between pin 1 (of injector on harness side)
and battery ground.
- If 12 V is read, disconnect connector A from the
ECM and check continuity of circuit as per follow-
ing table. If it is good, try a new ECM.

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Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

30 33

A32C9OA 3 1 2
FUEL RAIL ASS’Y
1. Fuel injector
A32C9NA
14 15 2. Injector clip
3. O-ring
ECM CONNECTOR
Then remove the injector clip. Now the fuel injec-
COMPONENT CONTACT LOCATION tor can be easily pulled out of the fuel rail.
4 (Engine Connector) Installation
Cylinder 1 fuel injector 1 and A-15
(ECM connector)
For the installation, reverse the removal proce-
dure. Pay attention to the following details.
3 (Engine Connector) Insert injectors with your hand. Do not use any
Cylinder 1 fuel injector 2 and A-14
(ECM connector)
tool. Ensure clip and injector are properly in-
stalled.
4 (Engine Connector) Replace O-rings with new ones.
Cylinderr 2 fuel injector 1 and A-33
(ECM connector) NOTE: A thin film of engine oil should be applied
to O-rings to ease insertion in rail.
3 (Engine Connector)
Cylinder 2 fuel injector 2 and A-30 Torque rail retaining nuts to 10 N•m (89 lbf•in).
(ECM connector) Attach injector wires with locking ties as shown in
following photo.
The resistance should be around 14.5 .
If resistance value is correct, check wiring of cor-
responding relay. If good, try a new ECM. Refer
to ECM REPLACEMENT procedures elsewhere in
this section.
If resistance value is incorrect, repair the wiring
harness/connectors or replace the wiring harness
1
between ECM connector and fuel injector .

Fuel Injector Replacement

Removal
A32CCSA
Before removing the injectors, the fuel rail has to
be removed from the engine. Refer to REMOVAL 1. Locking ties
in FUEL RAIL REPLACEMENT for the procedure.
 WARNING
Perform a fuel pressure test and ensure that
there is no leak. Refer to FUEL PUMP above.
Run engine and check for leaks.

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 Section 05 ENGINE MANAGEMENT (2-TEC)
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ELECTRONIC MANAGEMENT Unscrew all retaining screws and remove the en-
gine ECM from its support.
ECM REPLACEMENT Install the new ECM to the support.
Reconnect ECM connectors to ECM, and then bat-
General tery cables.
Prior to replacing a suspected ECM, ensure that all Transfer the data from the previous ECM to the
the recommendations in the general introduction new one using B.U.D.S. then proceed with the
of this section have been followed. required resets and reprogram tether cord cap(s),
IMPORTANT: When the ECM is replaced, the if you were unable to transfer the data.
tether cord cap(s) and the Closed Throttle must NOTE: If data cannot be transferred, manually en-
be reprogrammed/reset. Refer to their specific ter information in Vehicle tab.
section for adjustment.
After performing the required resets, ensure to
To allow transferring the previous recorded infor- clear all faults from the newly replaced ECM.
mation from the old ECM to the new one, use the
vehicle communication kit (VCK) with the B.U.D.S. Start the engine and increase engine speed above
software. Use Replace ECM in the ECM menu. 5000 RPM to be sure no fault appears.
Follow instructions provided by the help system.
NOTE: If the old ECM can still communicate, it ENGINE WIRING HARNESS
must be read inside B.U.D.S. prior to removing it 8
from the vehicle to carry vehicle information and 10 5
history to the new ECM. 2
1
ECM Replacement
3 11
Disconnect battery cables.
9
 WARNING
7
6

Battery BLACK (-) cable must always be dis- 4

connected first and connected last. A32CCQA
12

1. ECM
Disconnect both connectors from ECM. 2. CTS connector
3. EGTS connector
2 4. Fuel injector connector (cylinder MAG side)
5. Ignition coil connector
6. Fuel injector connector (cylinder PTO side)
7. TPS connector
8. ATS connector
9. Engine connector
10. APS connector
11. KS connector
12. CPS connector

Resistance Test
Check continuity of the circuits according to the
wiring diagram in the WIRING DIAGRAMS section
of this manual.
If wiring harness is good, check the respective
sensor/actuator as described in this section.
Otherwise, repair the connectors, replace the
A32C9PA 1
wiring harness or the ECM as diagnosed.
1. ECM
2. Retaining screws

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Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Removal The ECM may generate several fault codes per-

Remove air intake silencer. taining to the TPS. Refer to SYSTEM FAULT
CODES in DIAGNOSTIC PROCEDURES section
Disconnect the wiring harness from all sensors/ for more information.
actuators.
Disconnect the connector from the ECM. Wear Test
Cut all locking tie which are holding the wiring har- While engine is not running, activate throttle and
ness in position. pay attention for smooth operation without physi-
Remove complete wiring harness. cal stops of the cable.
Using the vehicle communication kit (VCK) with
Installation the B.U.D.S. software, use the Throttle Opening
First connect the connector A to the ECM and the display under Monitoring.
engine connector to the vehicle wiring harness. Slowly and regularly depress the throttle. Ob-
Reconnect the wiring harness to all sensors/actu- serve the needle movement. It must change
ators and reinstall all locking tie that have been re- gradually and regularly as you move the throttle.
moved. If the needle “sticks”, bounces, suddenly drops
or if any discrepancy between the throttle move-
Install all remaining parts, which have been re- ment and the needle movement is noticed, it
moved. indicates a worn TPS that needs to be replaced.

THROTTLE POSITION SENSOR Voltage Test

(TPS) Check the voltage output from ECM to the desired
throttle position sensor.
General
The throttle position sensor (TPS) is a potentiome- 1 2 3
ter that sends a signal to the ECM which is propor-
tional to the throttle shaft angle.

A32C9SA

TPS

Disconnect plug connector from throttle position

sensor. To unlock connector, insert a small screw-
driver between the folded tab. To see the con-
A32C9RA
nector pin-out and its pin numbers, temporarily re-
THROTTLE POSITION SENSOR (TPS) move the connector shield joining the harness.
IMPORTANT: Prior to testing the TPS, ensure Install the tether cord cap, turn OFF engine cut-out
that mechanical components/adjustments are switch and push START/RER button momentarily
adequate according to THROTTLE BODY in AIR to activate the ECM.
INDUCTION SYSTEM above. Connect a voltmeter between pin 1 and 2 in the
wiring harness.
Voltage should be 5 V.

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 Section 05 ENGINE MANAGEMENT (2-TEC)
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Check the continuity between pin 3 on wiring har- NOTE: When measuring between pins A-24 and
ness TPS connector and pin 24 on wiring harness A-39, resistance value increases while depress-
ECM connector. ing throttle lever. When measuring between pins
If tests are good, replace the TPS. A-24 and A-25, resistance value decreases while
depressing throttle lever. The resistance value
If voltage tests are not good, continue to check should change smoothly and proportionally to the
the resistance of the rest of the TPS circuit. throttle movement. Otherwise, replace TPS.
Resistance Test If resistance values are correct, try a new ECM.
Refer to ECM REPLACEMENT procedures else-
Reconnect the TPS. where in this section.
Disconnect the connector A from the ECM. If resistance values are incorrect, repair connector
or replace the wiring harness between ECM con-
25 24
nector and the TPS.

Replacement
Remove the throttle body as described above.
Loosen two screws retaining the TPS.
Remove TPS.

R1503motr191A
39

Using a multimeter, check resistance value be-

tween terminal A-25 and A-39.
The resistance should be 1600 - 2400 in any
throttle position.
1
Check the resistance between terminal A-24 and
terminal A-39 with the throttle plate in idle posi-
tion.
The resistance should be approximately 1000 . 2
Check the resistance between terminal A-24 and A32C9RB
terminal A-39 with the throttle plate in wide open
THROTTLE BODY
position. 1. Throttle position sensor (TPS)
2. Screws
The resistance should be 2500 .
Check the resistance between terminal A-24 and Install the new TPS.
A-25 with throttle plate in idle position. Apply Loctite 243 on the TPS retaining screws,
The resistance should be 2500 . then torque to 3 N•m (27 lbf•in).
Now check the resistance with the throttle plate Reinstall remaining removed parts.
in wide open position. Proceed with the Closed Throttle Reset. See be-
The resistance should be approximately 1000 . low.

Closed Throttle Reset

NOTE: This operation performs a reset of the val-
ues in the ECM.

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Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

This reset is very important. The setting of the If throttle cable has been loosen during the proce-
TPS will determine the basic parameters for all dure, adjust a throttle cable.
fuel mapping and several ECM calculations in idle Start engine and make sure it operates normally
speed control of the engine. through its full engine RPM range. If fault codes
NOTE: Reset must be done each time the throttle appear, refer to SYSTEM FAULT CODES in the DI-
position sensor (TPS) is loosened or removed or AGNOSTIC PROCEDURES section for more infor-
throttle body or ECM is replaced. mation.
CAUTION: An improperly set TPS may lead to
poor engine performance. CRANKSHAFT POSITION
Use the vehicle communication kit (VCK) with the SENSOR (CPS)
B.U.D.S. software to perform this adjustment. NOTE: The CPS is the trigger coil used for forward
Unscrew idle speed screw until the throttle body and reverse.
plate stop lever rest against its zero position stop-
per screw (capped screw). If necessary, loosen
the throttle cable. Open throttle approximately
one quarter then quickly release. Repeat 2 - 3
times to settle throttle plate.
Push the Reset button in the Setting section of
B.U.D.S.
The following message will be displayed:
Make sure the idle screw is not in contact with the
throttle stopper. Click OK to continue.
Follow instructions and click OK.
Another message will appear to ask you to per-
form a ECU tracking shut down to save the A32C9UA 1
changes into the ECU permanent memory.
1. CPS connector
Remove the tether cord cap from the DESS post
and wait until the message disappears before rein- NOTE: Take into account that a CPS fault can be
serting the tether cord cap. triggered by missing encoder wheel teeth. First
Re-power up the ECM by pushing the START/RER check fault codes then check the teeth condition
button momentarily. if necessary. See below.
The throttle opening displayed in B.U.D.S. should Disconnect CPS wiring harness connector. Probe
be 0.00 (0.1 maximum). terminals coming from CPS while cranking engine.
Voltage should be within 1-2 Vac. Otherwise, in-
If TPS is not within the allowed range while reset- spect wiring and replace CPS if wiring is good.
ting the Closed Throttle, the ECM will generate a
fault code and will not accept the setting. Resistance Test
Now, the idle speed screw has to be adjusted. Disconnect the CPS plug connector from the
To do this, screw in the idle speed screw until wiring harness and check the resistance of the
B.U.D.S. throttle opening displays value as per fol- sensor itself.
lowing table.
The resistance should be between 190 and
VALUE 300 .
ENGINE Otherwise, replace the CPS.
TYPE ABOVE
AT SEA LEVEL If resistance tests good, reconnect the CPS and
1800 m (6000 ft)
disconnect the connector A on the ECM.
593 SDI 3.9° ±0.1 4.9° ±0.1

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 Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

5
AIR TEMPERATURE SENSOR
(ATS)
1

R1503motr182A
19

Using a multimeter, recheck resistance value be-

tween terminals 5 and 19.
If resistance value is correct, try a new ECM. Refer
to ECM REPLACEMENT procedures elsewhere in
this section. A32CA3A

If resistance value is incorrect, repair the connec- 1. Air temperature sensor (ATS)
tors or replace the wiring harness between ECM
connector and the CPS.
Resistance Test
Replacement
Disconnect the plug connector from the ATS and
Disconnect connectors and remove the rewind check the resistance of the sensor itself.
starter, then the magneto flywheel. Refer to
Refer to TEMPERATURE SENSOR TABLE at the
MAGNETO SYSTEM.
beginning of this section to find the corresponding
Remove CPS. resistance value for this sensor temperature.
1 If out of specification, replace the sensor.
If resistance tests good, reconnect the ATS and
disconnect the connector A on the ECM.

A32C9VA
R1503motr186A
21
1. CPS inside crankcase
Using a multimeter, recheck resistance value be-
When installing new CPS apply Loctite 5910 tween terminals 7 and 21.
(P/N 293 800 081) between CPS and crankcase.
If resistance value is correct, try a new ECM. Refer
Torque to 8 N•m (71 lbf•in). to ECM REPLACEMENT procedures elsewhere in
Reinstall remaining removed parts. this section.

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Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

If resistance value is incorrect, repair the connec-

tors or replace the wiring harness between ECM
connector and the ATS.

Replacement
Disconnect the connector of the ATS.
Pull the ATS out of the air intake silencer.
Follow this procedure to install the ATS.
First, install the ATS rubber ring.
NOTE: If the rubber ring is installed on ATS sensor,
remove it before ATS installing.
Spray soapy water on ring. Install ring on air intake
silencer then push the sensor in place. Reconnect
it.
A32C9IC 5 6
COOLANT TEMPERATURE ENGINE CONNECTOR
SENSOR (CTS)
11
Resistance Test
Disconnect the plug connector from the CTS and
check the resistance of the sensor itself.

1 4
R1503motr187A
27
2 3
ECM CONNECTOR A

A32C9WA
Using a multimeter, recheck resistance value
between terminals 5 and 6 on engine connector.
The resistance between pin 1 and 2 is used for This resistance is used for temperature gauge.
temperature gauge. Refer to TEMPERATURE SENSOR TABLE at the
Refer to TEMPERATURE SENSOR TABLE at the beginning of this section to find the corresponding
beginning of this section to find the corresponding resistance value for this sensor temperature.
resistance value for this sensor temperature. Recheck also resistance value between terminals
If out of specification, replace the sensor. 11 and 27 on ECM connector A. This resistance is
used for ECM.
The resistance between pin 3 and 4 is used for
ECM. Refer to TEMPERATURE SENSOR TABLE at the
beginning of this section to find the corresponding
Refer to TEMPERATURE SENSOR TABLE at the resistance value for this sensor temperature.
beginning of this section to find the corresponding
resistance value for this sensor temperature. If resistance value is correct, try a new ECM. Refer
to ECM REPLACEMENT procedures elsewhere in
If out of specification, replace the sensor. this section.
If resistance tests good, reconnect the CTS and
disconnect the connector A on the ECM as well
as the engine connector.

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 Section 05 ENGINE MANAGEMENT (2-TEC)
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If resistance value is incorrect, repair the connec- If tests are good, replace the APS.
tors or replace the wiring harness between ECM If tests are not good, continue to check the conti-
connector and the CTS. nuity of the rest of the APS circuit on the harness.
Replacement Disconnect the connector A from the ECM.
Drain cooling system. Using a multimeter, check continuity of circuits as
per following table.
Disconnect CTS connector and remove CTS.
Install the new CTS and torque to 12 N•m CIRCUIT NUMBER
(106 lbf•in). APS CONNECTOR
(ECM CONNECTOR A)
Reinstall remaining removed parts.
A-3 PIN 1
Refill engine coolant and bleed cooling system.
Refer to LIQUID COOLING SYSTEM section. A-4 PIN 2
A-18 PIN 3
AIR PRESSURE SENSOR (APS)
If wiring harness is good, try a new ECM. Refer
1 to ECM REPLACEMENT procedures elsewhere in
this section.
Otherwise, repair the connectors or replace the
wiring harness between ECM connector and the
APS.

Replacement
Disconnect APS connector and remove the APS.
The ATS is retained with a screw.
Install the new APS.

EXHAUST GAS TEMPERATURE

SENSOR (EGTS)
A32CA3B

1. Air pressure sensor (APS)

Ensure sensor is correctly installed on air intake si-

lencer. Otherwise, the APS could generate a fault
code. Remove sensor and check for oil or dirt on
its end and if problem persists, check the wiring
harness. Perform the following tests.

Voltage Test
Check the voltage output from ECM to the APS.
Install the tether cord cap, turn OFF engine cut-out
switch and push START/RER button momentarily
to activate the ECM.
Disconnect plug connector from APS and connect A32C9YA 2 1
a voltmeter between pin 1 and 2 of wiring harness.
1. Muffler
Voltage should be 5 V. 2. Exhaust gas temperature sensor (EGTS)

Check the continuity between pin 3 on APS con-

nector and pin 18 on ECM connector.

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Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Resistance Test Using the vehicle communication kit (VCK) with

Disconnect the plug connector from the EGTS and the B.U.D.S. software, monitor the knock sensor
check sensor resistance. using the Faults section.
Refer to TEMPERATURE SENSOR TABLE at the Start the engine and bring engine RPM above
beginning of this section to find the corresponding 6000 RPM. If no fault code occurs, the knock
resistance value for this sensor temperature. sensor is good.
If out of specification, replace the sensor. Otherwise, do the following.
If resistance tests good, reconnect the EGTS and Ensure sensor and head contact surfaces are
disconnect the connector A on the ECM. clean and mounting bolt and washer are correct
and properly torqued down.
Using a multimeter, recheck resistance value be-
tween terminals 10 and 26. Check the knock sensor circuit on wiring harness.
If resistance value is correct, try a new ECM. Refer Disconnect the connector from knock sensor har-
to ECM REPLACEMENT procedures elsewhere in ness.
this section. Disconnect connector A from the ECM and check
If resistance value is incorrect, repair the connec- continuity of circuit as per following table.
tor or replace the wiring harness between ECM
connector and the EGTS.

Replacement
Disconnect EGTS connector and remove EGTS.
Apply anti-seize lubricant (P/N 293 800 070) over
EGTS threads to prevent possible seizure.
Torque the new EGTS to 45 N•m (33 lbf•ft).
Replug connector.

KNOCK SENSOR (KS)

A32C9NB
8 22

CIRCUIT NUMBER
KS CONNECTOR
(ECM CONNECTOR A)
A-22 PIN 1
A-8 PIN 2

If test is not good, repair the connector or replace

the wiring harness between ECM connector and
knock sensor.

Replacement
Unscrew and remove knock sensor from cylinder
A32C9ZA 1 head.
1. Knock sensor (KS) Clean contact surface, apply Loctite 5910 (P/N 293
800 081) on both contact surfaces on the knock
sensor then install the new sensor.
Dynamic Test
Lift rear of vehicle off the ground and support it
with a wide-base mechanical stand.

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 Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

CAUTION: Install screw and torque it within If test fail, repair connector or replace wiring har-
10 minutes to prevent the sealant to dry be- ness between ECM connector and solenoid.
fore torquing. A dried sealant before torquing
would impair the knock sensor operation. Replacement
Torque screw to 24 N•m (18 lbf•ft). Remove the air intake silencer. Unplug the sole-
CAUTION: Improper torque might prevent sen- noid connector and all hoses.
sor to work properly and lead engine to severe NOTE: Mark hose locations for installation.
damage of internal components.
Remove solenoid screws then the solenoid.
Replug connector.
For installation, reverse the removal procedure.
E-RAVE SOLENOID DOUBLE IGNITION COIL
1

A32CA1A A32CA2A 1
1. E-RAVE solenoid 1. Ignition coil

NOTE: The ECM energizes the primary side of

Resistance Test each ignition coil individually. It can detect if the
Disconnect the solenoid connector. double ignition coil is connected otherwise a trou-
ble code will appear upon starting..
Check resistance value between both terminals of
the solenoid. Using the vehicle communication kit (VCK) with
the B.U.D.S. software, energize the ignition coil
The resistance value should be approximately from the Activation section.
30 .
You should hear the spark occurring. In doubt, use
Voltage Test an inductive spark tester or a sealed tester – avail-
able from after-market tool/equipment suppliers –
Install the tether cord cap and push the to prevent spark occurring in the engine compart-
START/RER button momentarily to activate ECM. ment. Otherwise, perform the following checks.
Battery voltage should be present on An ignition coil with good resistance measure-
WHITE/GREEN wire. If test fail, fuse or re- ment can still be faulty. Voltage leak can occur
lay may be faulty. at high voltage level which is not detectable with
an ohmmeter. Replacing the ignition coil may be
Continuity Test necessary as a test.
WHITE/BROWN wire must show continuity be-
tween solenoid connector and pin 15 on ECM con-
nector.

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Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Voltage Test
 WARNING
When disconnecting coil from spark plug, al-
ways disconnect coil from main harness first.
Never check for engine ignition spark from
an open coil and/or spark plug in the engine
compartment as spark may cause fuel vapor
to ignite.

Disconnect the plug connector from the ignition

coil and check the voltage supplied by the battery.
A32C9NC 1 41
ECM CONNECTOR

If wiring harness is defective, repair the connector

or replace the wiring harness between ECM con-
nector and the ignition coil.
If wiring harness is good, test resistance of prima-
ry winding of ignition coil.

Resistance Test
Remove spark plug cables from ignition coil.
Using a multimeter, check the resistance of prima-
1 2 3 ry winding.
A32CA5A
NOTE: The secondary winding can not be mea-
Install tether cord cap on the DESS post and push sured with an ohmmeter. Try a new double igni-
the START/RER button momentarily to activate tion coil if necessary.
the ECM.
1 3
Check voltage between terminal 2 of ignition
coil connector on the wiring harness and battery
ground.
2
Battery voltage should be present (approx. 12 V).
If 12 V is NOT read, check continuity between ter-
minal 2 of ignition coil and the corresponding fuse.
Otherwise repair wiring harness.
If 12 V is read, disconnect the connector A from
the ECM and check the continuity of appropriate
circuit 41 (cylinder 1) or 1 (cylinder 2) and of ignition
coil connector, pin 3 and pin 1 respectively.

A32CCRA

1. Terminal 1a
2. Terminal 15
3. Terminal 1b

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 Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

For primary winding, check the resistance be- DESS SWITCH VERIFICATION
tween terminal 15 and terminal 1a (cylinder 1)
of the ignition coil and between terminal 15 and If 2 short beeps are not heard when starting the
terminal 1b (cylinder 2) respectively. engine, refer to DIAGNOSTIC PROCEDURES.
The resistance should be between 0.40 and The following continuity tests can also be per-
1.15 at 20°C (68°F). formed using an ohmmeter.
If the resistance of one of both windings is not Disconnect switch wires.
good, replace the ignition coil.
Tether Cord Cap Removed
If the windings test good, check corresponding
fuse, relay and wiring. If good, try a new ECM. Connect test probes to switch GREY/GREEN and
WHITE/BLACK wires. Measure resistance, there
 WARNING should be NO continuity (open circuit).
Always reconnect ignition coil cables at the Connect one test probe to the WHITE/GREY wire
same spark plugs where they come from. and the other test probe to the switch top termi-
Otherwise, severe backfire may occur with nal. Measure resistance, it must be close to 0
possible damage to exhaust system compo- ohm.
nents. Connect one test probe to the GREY/GREEN wire
and the other test probe to the switch ring. Mea-
sure resistance, it must be close to 0 ohm.
IGNITION TIMING
Tether Cord Cap on DESS Post
Refer to IGNITION TIMING section. Connect test probes to switch GREY/GREEN and
WHITE/BLACK wires. Measure resistance, it
ENGINE START/RER BUTTON must be close to 0 ohm.
VERIFICATION
A quick operation test can be done using the ve- SPARK PLUGS
hicle communication kit (VCK) with the B.U.D.S.
software, using the Monitoring section. Press
Disassembly
the START/RER button and look at the START/RER Disconnect the spark plug cable from the spark
button LED. It should turn on, indicating the start- plug.
ing system is working on the input side of the First unscrew the spark plug one turn.
starting system (START/RER button, ECM and
Clean the spark plug and cylinder head with pres-
wiring). If so, you know now the problem is
surize air then completely unscrew.
on the output side of the starting system (ECM
output signal to starting solenoid, wiring harness Spark Plug Installation
going to the solenoid and starter motor. Other-
wise, check the input side as follows. Prior to installation make sure that contact sur-
faces of the cylinder head and spark plug are free
Disconnect the connector of the steering harness. of grime.
Measure the resistance of the GREEN/RED and 1) Using a wire feeler gauge, set electrode gap
LIGHT BROWN wires for 0 . Depress start but- according to the following chart.
ton and the reading should change from 0 to in-
2) Apply anti-seize lubricant over the spark plug
finitely high.
threads to prevent possible seizure.
Release the start button and measure the resis- 3) Hand screw spark plug into cylinder head.
tor between LIGHT BROWN and BLACK wires. It Then, tighten the spark plug clockwise an
should be 50 . additional 1/4 turn with a proper socket.
Test continuity of circuit B-19. If it is good, try a
new ECM. Otherwise, repair harness/connectors.

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Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

1 2

A00E0BA

1. Proper socket
2. Improper socket

SPARK GAP
ENGINE TORQUE
PLUG mm (in)
Hand tighten
NGK 0.8
593 SDI + 1/4 turn
BR 9 ECS (.031)
with a socket

CRANKING SYSTEM
See above for start/stop switch and the DESS post
testing.

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 01 (OVERVIEW)

OVERVIEW
ENGINE MANAGEMENT SYSTEM - OVERVIEW
ROTAX 4-TEC 1004

Air silencer

Cyl.2

Cyl.1

BUZZER

CTS

MAPS
CAPS
ATS
OPS
ECM IDLE BYBASS VALVE

INJECTOR 1,2 TPS

CPS
IGNITION COIL 1,2

INSTRUMENT PANEL
- tachometer
- EMS pilot lamp
- low battery voltage pilot lamp
- + - DESS pilot lamp
BATTERY RELAY - engine overheating warning lamp.

A32I0LS

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 01 (OVERVIEW)

OPERATING PRINCIPLE OF 1 2
ENGINE MANAGEMENT
A highly advanced engine management system
(EMS) has been used to ensure a high power out-
put with cleaner combustion. The EMS calculates
the proper air/fuel mixture and ignition timing for
each cylinder separately. The fuel is injected into
the intake port of each cylinder.
NOTE: On the 1004, the cylinders are referenced
as 1 (front) and 2 (rear) instead of PTO and MAG.

2 1 R1004motr143A

52 MM THROTTLE BODY
1. Idle bypass valve
2. Throttle position sensor (TPS)

FUEL DELIVERY SYSTEM

BASIC OPERATION
When the intake valve reaches the correct posi-
tion, the ECM (engine control module) opens the
fuel injector and fuel is discharged into the intake
R1004motr142A port at the air intake manifold by the high fuel pres-
1. Cylinder 1 sure inside the fuel rail. The air/fuel mixture enters
2. Cylinder 2 then the combustion chamber through the open
intake valve. This mixture is then ignited by the
NOTE: “EMS” stands for engine management spark plug.
system. “EMS” includes an ECM (engine control
module), sensors and injectors.

AIR INDUCTION
Through air filters, air goes into the air silencer.
ECM measures at this point air temperature. Air
pressure is measured directly in the intake man-
ifold. Then, air for combustion is drawn through
one 52 mm throttle body. The air flow is controlled
by a throttle plate and an idle bypass valve respec-
tively. The air continues through the intake mani-
fold and goes into the cylinder head.

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 01 (OVERVIEW)

INTAKE MANIFOLD FUEL PUMP MODULE

2 2

A32I18A
4
The fuel pump module is located inside the fuel
4 tank. The module includes fuel pump, fuel pres-
6 sure regulator and fuel level sensor.
3
R1004motr144A 5 Fuel Pump
INTAKE MANIFOLD
1. Fuel rail It provides fuel pressure and flow rate to the sys-
2. Injector tem.
3. Throttle body
4. Ignition coil
5. Manifold air pressure sensor (MAPS) Fuel Pressure Regulator
6. Intake manifold
A fuel pressure regulator controls the pressure in
The intake manifold is mounted on the top of the the system and allows excess fuel to return to
engine on both cylinder heads. It provides support the fuel tank. The fuel pressure regulator regu-
for the fuel injectors, the fuel rails, MAPS (man- lates the fuel pressure at approximately 400 kPa
ifold air pressure sensor) and the throttle body. (58 PSI).
The air intake manifold is a resonator between
the throttle body and the air intake at the cylinder Fuel Pickups
heads. Two fuel pickups come with 70 micron filter. One
is located at the front right side of the fuel tank
Fuel Rail and the other at the rear left side.
Two fuel rails, one for each injector, are mounted
on the intake manifold. The fuel rails ensure all In-Line Fuel Filter
the time, that enough fuel at the right pressure
can be delivered to the fuel injectors. The fuel rails
are fed by the fuel pump with a fuel pressure of
approximately 400 kPa (58 PSI).

Fuel Injector
Two fuel injectors (one per cylinder) are used to
inject fuel into the intake port of the cylinder head.

Throttle Body
It is a 52 mm heated throttle body mounted on
intake manifold. Fitted on the throttle body, there
is the TPS and the idle bypass valve which allows
A32I0QA
the ECM to control the RPM while the throttle
plate is closed.

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 01 (OVERVIEW)

The in-line fuel filter is fastened under the steering

console. It comes as a complete assembly.

ELECTRONIC MANAGEMENT
EMS (ENGINE MANAGEMENT
SYSTEM)
The engine management system is controlled by
the ECM.
1

A32I1FA

The ECM (engine control module) is directly pow-

ered by the battery. It is responsible for the fol-
lowing engine management/electrical functions:
– analysis of information
– distribution of information
R1503motr215A – start/stop function
TYPICAL
– timer
1. ECM – DESS (Digitally Encoded Security System)
– ignition timing control
– injection control
ECM – proper mapping (injection and ignition) for opti-
The ECM is located between the engine and the mum engine operation in all conditions.
fuel tank, under the fuse box. – engine RPM limiter
It controls all engine management functions, by – etc.
processing the information given by various sen- The ECM features a permanent memory that will
sors. keep the programmed tether cord cap (s) active,
fault codes and other engine information, even
when the battery is removed from the vehicle.

EMS — GENERAL FUNCTIONS

Anti-Drive Feature
This system allows the engine to reach pulley en-
gagement speed only if a programmed tether cord
cap is installed on DESS post. See below for de-
tails.

Digitally Encoded Security

A32I0OA
System (DESS)
The ECM is designed to work with the DESS.

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 01 (OVERVIEW)

The tether cord cap contains a magnet and a ROM High Coolant Temperature
chip. The magnet actually closes the reed switch Warning Device
inside the post which is the equivalent of a me- When the coolant temperature is getting to high,
chanical ON/OFF switch. The chip has a unique the ECM sends out signals to the buzzer, the en-
digital code. gine overheating warning lamp and to the EMS pi-
NOTE: Actually, it is the memory of the ECM lot lamp.
which is programmed to recognize the digital
code of the tether cord cap. This is achieved with
the VCK (Vehicle Communication Kit) (P/N 529 035
981). Refer to B.U.D.S. help system to program
a tether cord cap.

529 035 981

The system is quite flexible. Up to 8 tether cord

caps may be programmed in the memory of the
vehicle ECM. They can also be erased individually.
NOTE: If desired, a tether cord cap can be used
on other vehicles equipped with the DESS. It only
needs to be programmed for that vehicle.
The memory of the ECM features a self-diagnos-
tic mode for the DESS operation. Refer to DIAG-
NOSTIC PROCEDURES section for more informa-
tion.
The memory of the ECM is permanent. If the bat-
tery is disconnected, no information is lost.
Note that the DESS anti-drive circuitry is already
activated on all new ECM.

Engine RPM Limiter

The ECM will limit the maximum engine speed.

Low Oil Pressure Warning Device

When the oil pressure falls under a certain level,
the ECM sends out signals to the buzzer, the low
oil pressure warning lamp and to the EMS pilot
lamp.

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 01 (OVERVIEW)

EMS — ENGINE MANAGEMENT FUNCTIONS

1004 4-TEC CONTROL SYSTEM

INPUTS OUTPUTS

Throttle position (TPS) Fuel pump

Crankshaft position (CPS) Starter solenoid

ENGINE
MANAGEMENT
Camshaft position (CAPS) SYSTEM (EMS) Fuel injectors (2)

Coolant temperature (CTS) Ignition coils (2)

Manifold air pressure (MAPS) Idle bypass valve

Air temperature sensor (ATS)

Oil pressure (OPS)

Battery voltage

Digitally Encoded
Security System (DESS)

Start switch

Stop switch
A32I17S

This engine management system controls both the fuel injection and the ignition timing.
As shown in the 1004 4-TEC CONTROL SYSTEM illustration, the ECM is the central point of the fuel
injection system. It reads the inputs, makes computations, uses pre-determined parameters and sends
the proper signals to the outputs for proper engine management.
The ECM also stores the fault codes and general information such as: operating conditions, vehicle hours,
serial numbers, customer and maintenance information.

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 01 (OVERVIEW)

Electronic Fuel Injection Ignition Timing

The ECM reads the signals from different sensors The ECM is programmed with data (it contains ig-
which indicate engine operating conditions at milli- nition mappings) for optimum ignition timing un-
second intervals. der all operating conditions. Using engine operat-
Signals from sensors are used by the ECM to de- ing conditions provided by the sensors, the ECM
termine the injection parameters (fuel maps) re- controls the ignition timing for optimum engine op-
quired for optimum air-fuel ratio. eration.There is no mechanical adjustment to per-
form.
The CPS, the ATS, the MAPS and the TPS are the
primary sensors used to control the injection and Engine Modes of Operation
ignition timing. Other sensors (like temperature
sensors, etc.) are used for secondary input. The ECM controls different operation modes of
the engine to allow proper operation for all possi-
Ignition System ble conditions: Cranking, start-up, idle, warm up,
part load, full load, engine speed limiter, drowned
The ignition system is fully managed by the ECM engine and limp home (see below).
which controls the ignition system parameters,
such as spark timing, duration and firing order to Flooded Engine (drowned mode)
achieve the proper engine requirements.
If engine is fuel-flooded and does not start, this
Ignition Coils special mode can be activated to prevent fuel in-
jection and ignition while cranking. Proceed as fol-
Two separate ignition coils induce voltage to a high lows to activate it.
level in the secondary windings to produce a spark
at the spark plug. With tether cord cap on its post while engine is
stopped, press and HOLD throttle lever at WOT
The ignition coils receive input from the ECM. position.
Each coil provides high voltage to its correspond-
ing spark plug. Press the start button. The mode is now on.
This ignition system allows spark plugs to spark Releasing throttle lever will bring back the normal
independently. mode.
NOTE: Ignition coil wires are not interchangeable If engine does not start, it may be necessary to re-
due to different lengths of the wiring harness. move spark plugs and crank engine with rags over
spark plug holes. Refer to COMPONENT INSPEC-
Both ignition coils are located on the cylinder TION AND ADJUSTMENT subsection.
heads directly on the spark plugs.
1
 WARNING
When disconnecting coil from spark plug, al-
ways disconnect coil from main harness first.
Never check for engine ignition spark from
an open coil and/or spark plug in the engine
compartment as spark may cause fuel vapor
to ignite.

Limp Home Mode

Besides the signals as seen above, the ECM may
automatically set default parameters to the engine
management to ensure the adequate operation of
the vehicle if a component of the fuel injection
R1004motr145A
system is not operating properly.
1. Ignition coils

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 01 (OVERVIEW)

Sensor failures will not lead to a limp home mode,

warning will follow through the EMS pilot lamp
and the buzzer.
When minor fault occurs, the fault and mes-
sage/buzzer disappear automatically when the
condition no longer exists.
Releasing throttle and letting the engine returning
at idle speed may allow normal operation to come
back. If it does not work, try removing and rein-
stalling the tether cord cap on its post.
These performance-reduced modes allow the rid-
er to go back home which would not be possible
without this advanced system. Refer to the DIAG-
NOSTIC PROCEDURES for a complete chart.

Shutdown Mode
ECM will shut down all outputs 5 seconds after
the tether cord cap is removed.
If the tether cord cap is still on DESS post but the
engine is turned off using engine cut-out switch,
the ECM will shut down all outputs after 15 sec-
onds.

Diagnostic Mode
The malfunctions are recorded in the memory
of the ECM. The memory of the ECM can be
checked using the VCK (Vehicle Communication
Kit) (P/N 529 035 981) to see the fault codes.
The ECM and the VCK are able to communicate
through a connector on the vehicle. Refer to the
DIAGNOSTIC PROCEDURES section. B.U.D.S.
Version G2.10 or P2.10 and up must be used for
this system.

Monitoring System
The ECM monitors the electronic components of
the fuel injection system and also the electrical
system. When a fault occurs, it sends visual mes-
sages through the referring LED and/or audible
signals through a buzzer to inform you of a particu-
lar condition. Refer to the DIAGNOSTIC PROCE-
DURES section for the LED and the buzzer coded
signals chart.

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 02 (DIAGNOSTIC PROCEDURE)

DIAGNOSTIC PROCEDURE
SERVICE TOOLS
Description Part Number Page
gray key ............................................................................... 529 035 896 ......................................... 307
supply cable ......................................................................... 529 035 869 ......................................... 307
VCK (Vehicle Communication Kit) ......................................... 529 035 981 ......................................... 306

GENERAL TERMS USED IN

TERMS USED IN OTHER
DOCUMENTS OR
THIS MANUAL
Here is the basic order suggested to diagnose a SOFTWARES
suspected engine management or fuel injection
Camshaft Cam
related problem:
– Check the chart in the TROUBLESHOOTING Crankshaft Crank
section to have an overview of problems and ECM – ECU
suggested solutions. – Module
– Check if the engine management system (EMS)
Idle bypass valve – DLA
pilot lamp lights up. If so, use the VCK (Vehicle (Digital Linear Actuator)
Communication Kit) and look for fault codes to – Idle actuator
diagnose the trouble. – Idle valve
– Check all fuses. – Idle control air valve
– Check fuel pressure. MAPS APS
– Check spark plugs condition. (Manifold Air Pressure (Air Pressure Sensor)
– Check all connections of the wiring harness. Sensor) or
(Atmospheric Pressure
– Refer to COMPONENT INSPECTION AND AD-
Sensor)
JUSTMENT section for procedures.
DESS tether cord – DESS key
Terminology – key
Some documents or softwares use technical
terms that may be different from the one used in
this manual. The following table will help to find
the equivalence.

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 02 (DIAGNOSTIC PROCEDURE)

MONITORING BEEPER CODED SIGNALS

CODED SIGNALS POSSIBLE CAUSE REMEDY
2 short beeps (when engine is started). Confirms that proper tether cord Normal condition.
DESS/RER pilot lamp also blinks. cap is installed. Engine can rev
above pulley engagement.

1 short beep every 1.5 seconds (when Bad DESS system connection. Reinstall tether cord cap correctly
engine is started). DESS/RER pilot over post.
lamp also blinks.
Defective tether cord cap. Use another programmed tether
Engine cannot reach pulley cord cap.
engagement speed. Vehicle cannot be Dirt or snow in tether cord cap. Clean tether cord cap.
driven.
Defective DESS post. Replace DESS post.
1 long beep per second. Reverse is selected. Vehicle can be driven in reverse.
3 short beeps per second. DESS/RER Wrong tether cord cap is Install proper tether cord cap.
pilot lamp also blinks. installed. Program key into electronic module.

Engine cannot reach pulley

engagement speed. Vehicle cannot be
driven.
3 short beeps per second. Engine is overheating. Stop engine immediately and allow
to cool. Check cooling system.
Engine overheating pilot lamp also
blinks.
3 short beeps per second. Low oil pressure on 4-TEC Stop engine immediately and check
models. oil level and top it. Check lubrication
Oil pilot lamp also lights up. system.
3 short beeps per second. Low battery voltage. No Check battery and charging system.
charging.
Battery pilot lamps lights up.
4 short beeps every 2 minutes. Low oil level on 2-TEC models. Check oil level and replenish as
soon as possible.
Oil pilot lamp also lights up.

VCK
(VEHICLE COMMUNICATION KIT)
The VCK (Vehicle Communication Kit) (P/N 529
035 981) is the primary tool to diagnose engine
management and fuel injection related problems. 529 035 981

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 02 (DIAGNOSTIC PROCEDURE)

NOTE: The MPEM programmer does not work on ECM Supply

4-TEC models. To power-up the ECM, push the START button
Ensure to use the latest B.U.D.S. version available shortly while the engine cut-out switch is OFF and
on BOSSWeb. the tether cord cap installed on DESS post. If your
B.U.D.S. (Bombardier Utility and Diagnostic Soft- intent is to program the vehicle key, use gray key
ware) is designed to allow actuators, sensors and (P/N 529 035 896) on DESS post.
electronic equipments inspection, diagnostic op- The supply cable (P/N 529 035 869) may also be
tions and reset such as the closed throttle and idle used. Connecting it between MPI and vehicle will
actuator. power-up the ECM.
For more information pertaining to the use of the
software B.U.D.S., use its help which contains de-
tailed information on its functions.
 WARNING
If the computer you are using is connected to
529 035 869
the power outlet, there is a potential risk of
electrocution when working in contact with
water. Be careful not to touch water while
working with the VCK.

IMPORTANT: When using the software B.U.D.S.,

with the 4-TEC engine, ensure that the protocol
“kW2000” is properly selected in “MPI” (multi-
protocol interface) under “Choose protocol”.
VCK Supply
The VCK (MPI box) can use the vehicle power for
When B.U.D.S. is connected to the vehicle, the
its supply. Four AA batteries or an AC/DC power
status bar shows the protocol (kW2000) and the
supply can also be used. Make sure to respect
number 1 to the right. To communicate with the
MPI specification if a power supply is used.
ECM (Engine Control Module), number 1 must be
displayed. Writing in ECM
Number 1 means that one module is connected. When writing in ECM through B.U.D.S., there will
be an “EMS Tracking” message that will say “Re-
move key from vehicle“. When this occurs, re-
kW2000 move the tether cord cap from its post and wait
until the message disappears (approximately 15
seconds after tether cord cap removal).
F18H0WA

ONE MODULE IS CONNECTED

4-TEC SYSTEM FAULT CODES
If an “X” is shown, this means that no communi-
cation between the MPI and the ECM is possible.
General
Possible causes are: The faults saved in the ECM (Engine Control Mod-
– ECM is not powered-up ule) are kept even if the battery is disconnected.
– wrong protocol is used IMPORTANT: After a problem has been solved,
– bad connection between MPI and module. ensure to clear the fault(s) in the ECM using
the VCK. This will properly reset the appropriate
counter(s) and will also record that the problem
has been fixed in the ECM memory.
Many fault codes at the same time is likely to be
burnt fuse(s).

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 02 (DIAGNOSTIC PROCEDURE)

For more information pertaining to the code faults – If everything is in good condition, try a new
(state, count, first, etc.) and report, refer to ECM.
B.U.D.S. online help. When using the service action suggested in the
Fault section of B.U.D.S., the system circuits are
Supplemental Information referred to as DA-41, which means connector
– Electrical noise is picked up by the ECM. Ensure “DA” on the ECM and the circuit 41.
that all connections are in good condition, also
grounds (battery, ECM, engine and ignition sys- TPS (Throttle Position Sensor) Faults
tem), they are clean and well tightened and that Faults which are reported in B.U.D.S. fall into two
all electronic components are genuine — partic- groups TPS faults and adaption faults. These are
ularly in the ignition system. Installing non-re- displayed on the B.U.D.S. system as TPS OUT OF
sistive spark plugs may lead to generate fault RANGE and TPS ADAPTION FAILURE.
code.
– Electrical noise might also lead engine to oc-
casional cutout without generating a fault code
when engine is restarted.

4-TEC TPS FAULT TABLES

TPS “OUT OF RANGE” Fault
It is caused by the sensor reading going out of its allowable range. This fault can occur during the whole
range of movement of the throttle.
To diagnose this fully, it is recommended to operate the throttle through its full range. It is also recom-
mended to release the throttle quickly as this may also reveal a fault that is intermittent.

POSSIBLE CAUSES ACTION

Check if connector is disconnected from TPS Fix.
Check if sensor is loose Fix and reset Closed Throttle and Idle Actuator.
Inspect sensor for damage or corrosion Replace and reset Closed Throttle and Idle Actuator.
Inspect wiring (voltage test) Repair.
If bad wiring, repair.
Inspect wiring and sensor (resistance test) If bad TPS, replace and reset Closed
Throttle and Idle Actuator.
Test sensor operation (wear test) Replace and reset Closed Throttle and Idle Actuator.

TPS “ADAPTATION FAILURE” Fault

It is caused by the idle position moving out of an acceptable range.
Following problems can be caused by a TPS “Adaption Failure“:
– Idle speed is out of range.
– Engine stops, when throttle is released quickly.
– Engine runs inconsistent in low partload or low RPM.

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 02 (DIAGNOSTIC PROCEDURE)

POSSIBLE CAUSES ACTION

Sensor has been replaced and TPS closed position not reset Reset Closed Throttle and Idle Actuator.
Throttle body has been replaced and TPS closed
Reset Closed Throttle and Idle Actuator.
position not reset
ECM has been replaced and TPS closed position not reset Reset Closed Throttle and Idle Actuator.
Throttle cable too tight Fix and reset Closed Throttle and Idle Actuator.
Sensor is loose Fix and reset Closed Throttle and Idle Actuator.
Throttle bracket is loose Fix and reset Closed Throttle and Idle Actuator.
Adjustment screw worn or loose Change throttle body.
Idle bypass valve replaced but not reset Reset Closed Throttle and Idle Actuator using B.U.D.S.

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

COMPONENT INSPECTION AND

ADJUSTMENT
SERVICE TOOLS
Description Part Number Page
Fluke 111 .............................................................................. 529 035 868 ......................................... 313
fuel pump wrench ................................................................ 529 035 899 ................................. 321–322
pressure gauge..................................................................... 529 035 591 ......................................... 319
supply cable.......................................................................... 529 035 869 ......................................... 338
tachometer ........................................................................... 529 014 500 ......................................... 315
VCK (vehicle communication Kit).......................................... 529 035 981 ................................. 311, 320
wrench.................................................................................. 529 035 603 ......................................... 320

SERVICE PRODUCTS
Description Part Number Page

silicone lubricant ................................................................... 293 600 041 ......................................... 338

GENERAL FUEL SYSTEM

Engine problems are not necessarily related to the  WARNING
electronic fuel injection system.
The fuel system of a fuel injection system
It is important to ensure that the mechanical in- holds much more pressure than on a carbu-
tegrity of the engine/propulsion system is present: reted snowmobile. Prior to disconnecting
– good transmission system operation a hose or to removing a component from
– good engine compression and properly operat- the fuel system, follow the recommenda-
ing mechanical components, no leaks etc. tion described here. Pay attention that some
– fuel pump connection and fuel lines without hoses may have more than one clamp at their
leaks. ends. Ensure to reinstall the same quantity
of clamps at assembly.
Check the chart in TROUBLESHOOTING section
to have an overview of problems and suggested
solutions. – Use the VCK (vehicle communication Kit)
(P/N 529 035 981) to release the fuel pressure
When replacing a component, always check its in the system. Look in the Activation section
operation after installation. of the software B.U.D.S.

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

 WARNING
Ensure to verify fuel line connections for
damage and that NO fuel line is disconnected
prior to installing the tether cord cap on the
DESS post. Always perform the pressure
529 035 981 test if any component has been removed.
A pressure test must be done before con-
necting the tether cord cap. The fuel pump
is started each time the tether cord cap is
installed and it builds pressure very quickly.

To check fuel rails for leaks, first pressurize the

system then spray soapy water on all hose con-
 WARNING nections, regulators and injectors. Air bubbles will
show the leaking area. Check also for leaking fuel
Fuel lines remain under pressure at all times. or fuel odor.
Always proceed with care and use appro-
priate safety equipment when working on  WARNING
pressurized fuel system. Wear safety glass- Never use a hose pincher on injection system
es and work in a well ventilated area. Do high pressure hoses.
not allow fuel to spill on hot engine parts
and/or on electrical connectors. Proceed
with care when removing/installing pressure
test equipment or disconnecting fuel line ELECTRICAL SYSTEM
connections. Use the VCK (Vehicle Commu- It is important to check that the electrical system
nication Kit) to release fuel pressure prior to is functioning properly:
removing a hose. Cover the fuel line con-
nection with an absorbent shop rag. Slowly – battery
disconnect the fuel hose to minimize spilling. – fuses
Wipe off any fuel spillage in the engine com- – DESS
partment. Fuel is flammable and explosive – ignition (spark)
under certain conditions. Always work in – ground connections
a well ventilated area. Always disconnect
– wiring connectors.
battery prior to working on the fuel system.
After performing a pressure test, use the It is possible that a component seems to operate
valve on the fuel pressure gauge to release in static condition but in fact, it is defective. In
the pressure (if so equipped). this case, the best way to solve this problem is
to remove the original part and replace it with one
which is in good condition.
– Always disconnect battery properly prior to
working on the fuel system. Refer to BATTERY Never use a battery charger to substitute tem-
section. porarily the battery, as it may cause the ECM
(engine control module) to work erratically or not
When the job is done, ensure that hoses from fu- to work at all. Check related-circuit fuse solidity
el rail going to fuel pump are properly secured in and condition with an ohmmeter. Visual inspec-
their supports. Then, pressurize the fuel system. tion could lead to false results.
Perform the pressure test as explained in this sec-
tion and pressurize the fuel tank and fuel lines as
explained in FUEL SYSTEM section.
Properly reconnect the battery.

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

 WARNING NOTE: Do not apply an other lubricant on the ECM

connectors.
All electrical actuators (idle bypass valve, in-
jectors, fuel pump, ignition coils and starter Ensure that all electronic components are genuine
solenoid) are permanently supplied by the — any modification on the wiring harness may
battery when the VCK (Vehicle Communi- lead to generate fault codes or bad operation.
cation Kit) is connected to the diagnostic NOTE: For diagnostics purposes, use Vehicle
connector of the engine wiring harness and Communication Kit (VCK). See DIAGNOSTIC
the tether cord cap is installed. Always dis- PROCEDURES subsection.
connect the battery prior to disconnecting After a problem has been solved, ensure to clear
any electric or electronic parts. the fault(s) in the ECM using the VCK. Refer to
DIAGNOSTIC PROCEDURES subsection.
To perform verifications, a good quality multimeter
such as Fluke 111 (P/N 529 035 868) should be Resistance Measurement
used.
When measuring the resistance with an ohmme-
ter, all values are given for a temperature of 20°C
(68°F). The resistance value of a resistance varies
with the temperature. The resistance value for
usual resistor or windings (such as injectors) in-
creases as the temperature increases. However,
529 035 868 our temperature sensors are NTC types (Negative
Temperature Coefficient) and work the opposite
which means that the resistance value decreases
as the temperature increases. Take it into account
when measuring at temperatures different from
20°C (68°F). Use this table for resistance variation
relative to temperature for temperature sensors.
Pay particular attention to ensure that pins are
not out of their connectors or out of shape. The TEMPERATURE SENSOR TABLE
troubleshooting procedures cover problems not
resulting from one of these causes. TEMPERATURE RESISTANCE (ohms)

 WARNING
°C °F ATS CTS
- 40 - 40 — 45000
Ensure all terminals are properly crimped on
wires and connector housings are properly - 30 - 22 28000 28000
fastened.
- 20 - 4 14500 15000
Before replacing an ECM, always check electrical 0 32 5500 5750
connections. Make sure connectors are properly
20 68 2500 2600
crimped on wires and fastened in housing, and
that they are free of corrosion. Check if wiring 40 104 1200 1200
harness shows any signs of scoring. Ensure 60 140 600 600
proper electrical connection. Particularly check
ECM ground connections. Ensure that contacts 80 176 320 320
are good and clean. A «defective module» could 100 212 180 180
possibly be repaired simply by unplugging and
replugging the ECM. The voltage and current 130 266 90 90
might be too weak to go through dirty wire pins. CONVERSION CHART FOR TEMPERATURE SENSORS
Check carefully if pins show signs of moisture,
corrosion or if they look dull. Clean pins properly
and then coat them prior to assembling with a
silicon-based dielectric grease.

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

The resistance value of a temperature sensor may ECM Connector

test good at a certain temperature but it might be CAUTION: Probe on top of terminal only. Do
defective at other temperatures. If in doubt, try a not try to probe inside terminal or to use a pa-
new sensor. per clip to probe inside terminal, it will dam-
Also remember this validates the operation of the age the square-shaped terminal and this may
sensor at room temperature. It does not validate lead to improper function of the engine man-
the over temperature functionality. To test it, the agement system.
sensor could be removed from the engine and
heated with a heat gun while it is still connected to
the harness to see if the ECM will detect the high
temperature condition and generate a fault code.

ENGINE CONNECTOR PIN-OUTS

Connector Position
R1004motr179A

PROBE ONLY ON THE PIN NOZZLE OF FEMALE CONNECTOR

CAUTION: Do not disconnect the ECM connec-

tor needlessly. They are not designed to be dis-
connected/reconnected repeatedly.

Engine Connector
Use this diagram to locate the pin numbers on
the Engine connector of the wiring harness when
performing tests.
A32E39A 1
1. ECM connector A

Use this diagram to locate the pin numbers on

the ECM connector A of the wiring harness when
performing tests. 4 1
3 2
13 1

28 R1004motr146A
14
ENGINE CONNECTOR PIN-OUT (WIRING HARNESS SIDE)

41 29 CONNECTORS ON ENGINE
R1503motr176A
Removal
ECM CONNECTOR PIN-OUT (WIRING HARNESS SIDE)
To disengage both connectors, press the release
button and disconnect them.

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

IMPORTANT: The throttle body is designed to be

tamper proof. Changing the idle stop or modify-
ing it in any way will not increase performance or
change the idle speed but may cause poor starta-
bility and erratic idling.
Before replacing any part, check the following as
these could be causing the fault. Perform the test
while the engine is off.
– Throttle cable adjustment too tight. Not return-
ing fully to idle stop.
– Throttle body idle set screw is loose or worn.
– TPS is loose.
F18Z0NA 2 1 – Idle bypass valve is loose.
– Corroded or damaged wiring or connectors.
TYPICAL
1. Connector – Throttle body has been replaced and the Closed
2. Press release button Throttle and Idle Actuator reset has not been
performed.
– ECM has been replaced and the Closed Throt-
AIR INDUCTION SYSTEM tle and Idle Actuator reset has not been per-
formed.
THROTTLE BODY
6
Electrical Inspection
Refer to THROTTLE POSITION SENSOR (TPS)
5 and IDLE BYPASS VALVE in ELECTRONIC MAN-
7
AGEMENT below.
To verify the engine RPM with the tachometer
(P/N 529 014 500), use the following procedure.

4 529 014 500

7
2

R1004motr147A 3 1 The inductive tachometer works on these ignition

1. Throttle body coils (stick coils) as well as on regular high tension
2. Throttle cable attachment coil. Simply wrap the tachometer's wire a few
3. Throttle plate
4. TPS turns around the protruding part of ignition coil.
5. Idle bypass channel
6. Idle bypass valve
7. Nipples for throttle body heating

Mechanical Inspection
Check that the throttle plate moves freely and
smoothly when depressing throttle lever.

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

– Disconnect connectors from idle bypass valve,

and TPS.
– Disconnect throttle cable.
Installation
Installation of the new throttle body is the reverse
of the removal procedure. Pay attention for the
following details.
Refill and bleed the cooling system, refer to
COOLING SYSTEM subsection.
For TPS and idle bypass valve replacement proce-
dures, refer to the respective paragraph in ELEC-
TRONIC MANAGEMENT below.

A32CCIA
Adjustment
TYPICAL 1

Replacement
Removal
To remove the throttle body from engine, proceed
as follows:
– Disconnect air intake silencer from throttle
body.
– Drain cooling system.
– Remove clamps and hoses for throttle body
heating from nipples.
– Remove retaining screws of throttle body.

R1503motr161A

THROTTLE BODY
1. Idle stop screw

CAUTION: It is not allowed to perform any

change on the idle stop screw.
The adjustment of the idle stop screw is optimized
by the throttle body manufacturer and locked to
prevent any modification.
CAUTION: Never attempt to adjust the idle
speed through the throttle body tamper proof
screw. If so, it would impair the idle speed
stability. Besides, no adjustment could be per-
formed by the dealer nor the factory to correct
the idle speed. The throttle body would need
R1004motr148A 1 3 2 to be replaced.
1. Throttle body CAUTION: Do not alter or tamper with throttle
2. Hoses
3. Screws cable adjustment or routing. It may cause poor
startability and erratic idling.
– Slightly pull throttle body out.

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

The only thing that has to be performed when Closed Throttle and Idle Actuator Reset
the throttle body has been replaced is the Closed Perform the Closed Throttle and Idle Actuator
Throttle and Idle Actuator reset. Refer to reset as described in THROTTLE POSITION SEN-
THROTTLE POSITION SENSOR (TPS) in ELEC- SOR (TPS) in ELECTRONIC MANAGEMENT be-
TRONIC MANAGEMENT below. low.
Throttle Cable Adjustment
Mechanically adjust the throttle cable.
Handlebar and throttle cable must be at their nor-
mal position.
Apply full throttle.
Pull on throttle cable housing with a force of 50 N
(11 lbf). Tighten top nut to 1 N•m (9 lbf•in).
Tighten bottom nut to 4.5 N•m (40 lbf•in).

A32I0SA 1 2
WIDE OPEN THROTTLE POSITION
1. Top nut torqued to 1 N•m (9 lbf•in)
2. Bottom nut torqued to 4.5 N•m (40 lbf•in )
A. 50 N (11 lbf)

Activate throttle lever a few times. Make sure

throttle cam of throttle body rests against idle
speed screw without any tension in the cable.
CAUTION: If there is no free-play at idle posi-
tion, it may cause poor idling and startability.
Improper cable adjustment will cause strain on
cable and/or damage cable bracket or throttle
lever at handlebar.

 WARNING
Make sure idle speed stopper contacts throt-
tle cam when throttle lever is fully released at
handlebar.

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

FUEL DELIVERY

4-TEC FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW CHART

Fuel pump does not run Connect tether cord, activate Fuel pump runs
cut-out switch, press START/RER for 2 sec. then stops
button momentarily
Check fuses and relays.
Check tether cord cap connection. Install fuel pressure gauge
Check fuel pump operation. on fuel pressure line
Repair or replace if necessary.
Connect tether cord, activate
cut-out switch, push START/RER Replace fuel
pump module
button momentarily

Fuel pump runs

Repair or Fuel pressure less Fuel pressure is Fuel pressure more

replace than 400 kPa (58 PSI) 400 kPa (58 PSI) than 400 kPa (58 PSI)

Fails Check fuel line/

rail for leaks
OK
Fails Crank or Start engine
Perform fuel pump test

OK

Fast No Fuel pressure less Fuel pressure more Fuel pressure is

pressure drop than 400 kPa (58 PSI) than 400 kPa (58 PSI) 400 kPa (58 PSI)
Yes
OK Check
Verify fuel
pump check fuel line/ Repair or
valve rail for leaks Fails FUEL SYSTEM OK
replace

Fails OK
Fails

OK
Check fuel Perform fuel Replace fuel
injectors pump test pump module Retest
Fails
OK

A29C3CS

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

FUEL PUMP
Fuel Pressure Test
Before proceeding to the pressure test ensure the
battery is fully charged. Battery voltage must be
over 12 volts.
Release the fuel pressure in the system using
B.U.D.S. Look in the Activation tab.
 WARNING
The fuel hose may be under pressure. Cov-
er the fuel line connection with an absorbent
shop rag. Slowly disconnect the fuel hose
to release the pressure. Wipe off any fuel
spillage inside engine compartment. A32I0TA 1
1. Clip installed on male fitting of fuel rail inlet hose
The pressure test will show the available pressure
at the fuel pump outlet. It validates the pressure Install fuel pressure gauge (P/N 529 035 591) be-
regulator, the fuel pump and leaks in the system. tween disconnected hoses (in-line installation).
Ensure there is no leak from hoses and fittings.
Repair any leak.
Ensure there is enough gas in fuel tank.
Disconnect outlet hose.
Remove plastic clip (P/N 275 500 429) from male
fitting of pressure gauge (P/N 529 035 591).

529 035 591

A32I0UA 1
1. In-line installation of fuel pressure gauge

Install the tether cord cap. Activate the cut-out

switch so the engine will not crank. Depress start
button and observe fuel pressure. Release pres-
Install the clip on male fitting of fuel rail inlet hose. sure using B.U.D.S. so that the gauge is «reset»
to zero (0). Remove the tether cord cap and install
it again. Repeat the test.

FUEL PRESSURE
(when depressing start button)
400 kPa (58 PSI)

Crank or start engine and observe fuel pressure.

The fuel pressure should be the same as above.

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

If pressure is within limits, fuel pump and pressure Drain fuel tank as much as possible.
regulator are working adequately. Remove steering pad. Unbolt handlebar and
A rapid pressure drop indicates leakage either move it forward.
from the fuel rail or from the fuel pump check Unscrew fuel tank nut using wrench (P/N 529 035
valve. Check fuel rail for leaks. If it is not leaking 603).
then replace fuel pump.
A slow pressure drop indicates leakage either
from the fuel injector or from the fuel pressure
regulator. Check fuel injector for leaks (see be- 529 035 603
low). If it is not leaking then replace fuel pump
module.
Release fuel pressure in the system using
B.U.D.S. Look in the Activation tab.
Remove pressure gauge and plastic clip from inlet
hose. Reconnect inlet hose.

 WARNING
Wipe off any fuel spillage in the engine com-
partment. Fuel is flammable and explosive
under certain conditions. Always work in a
well ventilated area.

Reinstall removed parts.

Electrical Test
When depressing start button, the fuel pump
should run for 2 seconds to build up the pressure
in the system. A32I0ZA 529 035 603
If the pump does not work, disconnect the plug TYPICAL
connector from the fuel pump.
Install a temporary connector to the fuel pump Unbolt console, then move it forward.
connector. Apply 12 V (+ on PINK wire and – on Disconnect fuel supply hose from fuel pump mod-
PINK/BLACK wire) to this test harness. ule.
If pump does not run, replace the fuel pump mod- Disconnect vent tube from vent elbow.
ule.
Otherwise, probe terminalsof fuel pump connec-
tor on vehicle harness side. When depressing
start button, you should read battery voltage for
approximately 2 seconds (then voltage will drop
to approximately 11 V). If battery voltage is read,
the problem can be in harness or in fuel pump
connector. Repair or replace appropriate part.

Fuel Pump Module Replacement

Removal
Open hood. Connect VCK (vehicle communica-
tion Kit) (P/N 529 035 981). Use B.U.D.S. to re-
lease fuel pressure.

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 Section 06 ENGINE MANAGEMENT (4-TEC)
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529 035 899

A32I10A 2 1
TYPICAL
1. Fuel supply hose
2. Vent tube

Remove seat. Unbolt fuel tank.

A32I11A

TYPICAL

A32I15A 1
TYPICAL
1. Fuel tank retaining screws

Move fuel tank rearward, then unplug the fuel

pump module electric connector. 1
With two screwdrivers or a bent rod holding the
A32I19A
flange, unscrew fuel pump nut using fuel pump
nut fuel pump wrench (P/N 529 035 899). TYPICAL
1. Bent rod

Pull fuel pump module out of fuel tank to expose

sensor body.
Remove fuel pump module. Guide fuel pickups
when pulling out fuel pickup hoses.

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

A
1

A32I13A

A32I1BA
TYPICAL
1. Arrows aligned
Installation 2. Torque wrench
A. 90°
For installation, reverse the removal process but
pay attention to the following. Bleed the fuel system as per following procedure.
Install a new gasket. Fuel Bleeding Procedure
Make sure that rear pickup hose is positioned as The rear fuel pickup hose has to be bled.
following illustration.
Pour 12 L (3.17 U.S. gal.) of recommended fuel in
the fuel tank.
Apply parking brake. Start the engine. Let it run
at idle speed.
Lift the front of vehicle at a 45° angle.
Put the vehicle back on the ground.
Repeat the operation twice.
Stop the engine. The rear fuel pickup hose is now
bled.

Fuel Hose Kit

Remove fuel pump module as explained above.
Unfasten blue hose clamp retaining old fuel hose
ass’y to pump inlet nipple. Remove old fuel hose
A32I1AA
ass’y.
Align the arrow on fuel pump module with the Install fuel hose ass’y to pump at an angle of 30 ±
one on fuel tank. Keep arrows aligned during fuel 3° from retaining rods axis.
pump module nut tightening.
Install a torque wrench perpendicularly (90°) to fu-
el pump nut fuel pump wrench (P/N 529 035 899).
Torque fuel pump nut to 30 N•m (22 lbf•ft).

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

1 Regulator Kit
Remove fuel pump module as explained above.
Remove 2 screws retaining regulator to pump
module flange.
Remove regulator from pump module flange.
Replace O-rings with new ones. Install them in
A pump module flange bore.
CAUTION: Regulator O-rings must be installed
in pump module flange bore.
Reverse removal procedure for installation.
Install a new gasket, then reinstall fuel pump mod-
ule as explained above.

A32I0VA 2 FUEL RAILS

1. Retaining rods axis
2. Fuel hose ass’y Pressure at fuel rails is supplied and controlled by
A. 30 ± 3° the fuel pump module. Refer to FUEL PUMP for
pressure test.
Install a new blue hose clamp on fuel hose ass’y.
Install a new gasket, then reinstall fuel pump mod- Fuel Rail Replacement
ule as explained above. Removal
Pump Ass’y Kit Release the fuel pressure in the system using
B.U.D.S. Look in the Activation tab.
Remove fuel pump module as explained above.
Wrap a rag around the hose end to prevent rail
Disconnect fuel hose from pump inlet nipple. draining.
Disconnect pump electric connector.
Disconnect pump outlet hose from pump module 2 1
flange nipple.
Remove circlips. Slide pump ass’y out of retaining
rods.
3 2
1
4

A32I0YA

TYPICAL
R1004motr180A
1. Pump inlet nipple
2. Pump electric connector 1. Fuel injector connectors
3. Pump module flange nipple 2. Fuel hose
4. Circlips

Reverse removal procedure for installation. Remove clamps and fuel hose from the fuel rails.
Install a new gasket, then reinstall fuel pump mod- Disconnect wiring harness from the two fuel in-
ule as explained above. jectors.

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Unscrew rail retaining screws. Using the vehicle communication kit (VCK) with
Gently pull rail up by hand. the B.U.D.S. software, energize the fuel injector
from the Activation section.
Pull rail out with fuel injector.
If the injector does not work, disconnect the plug
If necessary remove fuel injector as described be- connector from the injector.
low.
Install a temporary connector to the injector with
Installation wires long enough to make the connection outside
For installation, reverse the removal process but the engine compartment and apply voltage (12 V)
pay attention to the following. to this test harness.
A thin film of injection oil should be applied to This will validate the injector mechanical and elec-
O-rings of fuel injectors to ease installation in in- trical operation.
take manifold. If it does not work, replace it. If it works, continue
Tightening torque of the rail retaining screws is procedure.
10 N•m (89 lbf•in). Using B.U.D.S., activate injector while probing pin
corresponding to the power (VIOLET/BLUE for in-
 WARNING jector 1 and VIOLET/GREEN for injector 2) and bat-
Perform a fuel pressure test and ensure that tery ground.
there is no leak. Refer to FUEL PUMP above. – If 12 V is read, check continuity of circuit as per
Run engine and check for leaks. following table. If it is good, try a new ECM.

CIRCUIT NUMBER INJECTOR

FUEL INJECTORS (ECM connector “A”) NUMBER
A-15 1
Leakage Test
A-33 2
To perform a leakage test, the injectors and fuel
rails have to be removed from the engine. – If it does not read 12 V, check the corresponding
NOTE: Do not detach injectors and fuel rails from fuse(s), relay and continuity of circuit. If conti-
the intake manifold. Remove complete intake nuity is faulty, repair wiring harness.
manifold with installed fuel rails and injectors to Resistance Test
perform this test.
Reconnect the injector and disconnect the con-
Reconnect the fuel line and the wiring harness. nector A from the ECM.
Place each injector in a clean bowl. Using a multimeter, check resistance value be-
Install the tether cord cap on the DESS post and tween terminals as follows.
push start button, without cranking the engine, to
activate the fuel pump.
Check for fuel leakage from the injector nozzle.
There should be less than 1 drop per minute. Per-
form the test for 2 minutes.
4 1
If not within specification, replace the fuel injec-
tor(s). 3 2
The leakage test is validated when performing the
FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW
CHART elsewhere in this section. R1004motr146A

ENGINE CONNECTOR
Electrical Test
Voltage Test
Tether cord cap must be on DESS post.

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

A-33

R1004motr150A
A-15 1
1
ECM CONNECTOR

2
COMPONENT CONTACT LOCATION
1 (engine connector) 2
Fuel injector cylinder 1 and A-15
(ECM connector) 3
2 (engine connector)
Fuel injector cylinder 2 and A-33
R1004motr151A
(ECM connector)
FUEL RAIL ASS’Y
1. Fuel rail
The resistance should be between 13.8 and 2. Fuel injector
15.2 . 3. O-ring

If resistance value is correct, check wiring of cor-

The fuel injector can be easily pulled out of the fuel
responding relay. If good, try a new ECM. Refer
rail.
to ECM REPLACEMENT procedures elsewhere in
this section. Installation
If resistance value is incorrect, repair the wiring For the installation, reverse the removal proce-
harness/connectors or replace the wiring harness dure. Pay attention to the following details.
between ECM plug connector and fuel injector. Install new O-rings, if you reinstall a used injec-
tor then insert the fuel injector in place with your
Fuel Injector Replacement hand. Do not use any tool.
Removal NOTE: A thin film of engine oil should be applied
Before removing the injector, the fuel rail has to to O-rings to ease insertion in rail.
be removed from the engine. Refer to REMOVAL Tightening torque of the rail retaining screws is
in FUEL RAIL REPLACEMENT for the procedure. 10 N•m (89 lbf•in).

 WARNING
Perform a fuel pressure test and ensure that
there is no leak. Refer to FUEL PUMP above.
Run engine and check for leaks.

ELECTRONIC MANAGEMENT
ECM REPLACEMENT
General
Prior to replacing a possibly faulty ECM, ensure
that all the recommendations in the general intro-
duction of this section have been carried out.

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

IMPORTANT: When the ECM is replaced, the ENGINE WIRING HARNESS

tether cord cap(s) and the Closed Throttle and
Idle Actuator must be reprogrammed/reset. Re-
13 6 7 1 11
fer to their specific section for adjustment.
To allow transferring the previous recorded infor- 12
mation from the old ECM to the new one, use the
vehicle communication kit (VCK) with the B.U.D.S.
software. Use Replace ECM in the ECM menu. 2
Follow instructions in its help system.
4 10
NOTE: If the old ECM still works, its information
must be read by B.U.D.S. before being removed 5
from the vehicle in order to transfer vehicle infor- 3
mation and history to the new ECM.
8
ECM Replacement
Disconnect battery cables.
14
 WARNING R1004motr152A 9
1. ECM connector A
Battery BLACK negative cable must always be 2. CTS connector
disconnected first and connected last. 3. CAPS connector
4. Fuel injector connector (cylinder 1)
5. Ignition coil connector (cylinder 1)
Disconnect both connectors from ECM. 6. Fuel injector connector (cylinder 2)
7. Ignition coil connector (cylinder 2)
Unscrew all retaining screws and remove the 8. TPS connector
9. Idle bypass valve connector
ECM from vehicle. 10. ATS connector
11. Engine connector
Install the new ECM to the vehicle. 12. MAPS connector
13. OPS connector
Reconnect connectors to ECM, and then battery 14. CPS connector
cables.
Transfer the data from the previous ECM to the
new one using B.U.D.S. then proceed with the Resistance Test
required resets and reprogram tether cord cap(s), Check continuity of the circuits according to the
if you were unable to transfer the data. wiring diagram in the WIRING DIAGRAMS section
NOTE: If data cannot be transferred, manually en- of this manual.
ter information in Vehicle tab. If wiring harness is good, check the respective
After performing the required resets, ensure to sensor/actuator as described in this section.
clear all faults from the newly replaced ECM. Otherwise, repair the connectors, replace the
Start the engine and increase engine speed above wiring harness or the ECM as diagnosed.
5000 RPM to be sure no fault appears. Removal
Cut the locking ties retaining vehicle harness to
engine. Move the vehicle harness away from en-
gine.

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

A32C7OA 1
1. Vehicle harness

Disconnect the wiring harness from all sensors/

actuators. 2
Disconnect the connector A from the ECM.
Cut all locking ties which are holding the wiring
R1004motr181A
harness in position.
1. Position of locking tie
2. Green mark (tape) on wiring harness

1 Then connect CAPS. Ensure the cable is above the

breather hose, then fasten it with a locking tie.
Connect injector and ignition coil of cylinder 2 to
the wiring harness. Ensure that cables are under-
neath the fuel line.
Also connect the TPS, MAPS (grey connector) and
the idle bypass valve to the wiring harness.
Then connect injector and ignition coil of cylinder 1
to the wiring harness. Attach the cable with lock-
ing tie on the throttle cable bracket.

R1004motr153A

1. Wiring harness

Remove complete wiring harness.

Installation
First connect the connector A to the ECM and the
engine connector to the vehicle wiring harness.
Now attach the engine wiring harness with a lock-
ing tie to the breather hose.
NOTE: Wiring harness is marked with a green
tape, where locking tie has to be installed.
R1004motr155A 1
1. Locking tie

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Connect the CPS, CTS and OPS to the wiring har-

ness.
NOTE: Routing of the harness for CAPS, CTS and
OPS has to be between the intake manifold and
cylinder 1, underneath the water hoses.
Use locking ties to attach the cables for the CTS
on the water hose and on the sensor itself then for
the OPS on the T-fitting and on the sensor itself.

R1004motr157A 1
1. Throttle position sensor (TPS)

IMPORTANT: Prior to testing the TPS, ensure

that mechanical components/adjustments are
1
adequate according to THROTTLE BODY in AIR
INDUCTION SYSTEM above.
The EMS may generate several fault codes per-
taining to the TPS. Refer to SYSTEM FAULT
CODES in DIAGNOSTIC PROCEDURES section
for more information.

Wear Test
While engine is not running, activate throttle and
R1004motr182A pay attention for smooth operation without physi-
1. Locking ties
cal stops of the cable.
Using the vehicle communication kit (VCK) with
Install all remaining parts, which have been re- the B.U.D.S. software, use the Throttle Opening
moved. display under Monitoring.
Do not forget to connect ATS connector to the ATS Slowly and regularly depress the throttle. Ob-
on the air intake silencer. serve the needle movement. It must change
gradually and regularly as you move the throttle.
THROTTLE POSITION SENSOR If the needle «sticks», bounces, suddenly drops
(TPS) or if any discrepancy between the throttle move-
ment and the needle movement is noticed, it
General indicates that the TPS needs to be replaced.
The throttle position sensor (TPS) is a potentiome- Voltage Test
ter that sends a signal to the ECM which is propor-
tional to the throttle shaft angle. Check the voltage output from ECM to the desired
throttle position sensor.

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

25 24

1
R1503motr191A
39

Using a multimeter, check resistance value be-

R1503motr167A
tween terminal A-25 and A-39.
The resistance should be 1600 - 2400 .
TPS
Check the resistance between terminal A-24 and
Disconnect plug connector from throttle position terminal A-39 with the throttle plate in idle posi-
sensor. To unlock connector, press the release tion.
tab. To see the connector pin-out, temporarily re- The resistance should be approximately 2500 .
move the connector shield joining the harness, to
expose the pin numbers. Connect a voltmeter be- Check the resistance between terminal A-24 and
tween pin 1 and 3 and also between pin 1 and 2 terminal A-39 with the throttle plate in wide open
in the wiring harness. position.
Install the tether cord cap, then depress the cut- The resistance should be 1000 - 1100 .
out switch and push start button momentarily to Check the resistance between terminal A-24 and
activate the ECM. A-25 with throttle plate in idle position.
Check the voltage readings as follows. The resistance should be 1000 - 1100 .
Now check the resistance with the throttle plate
CONNECTION VOLTAGE in wide open position.
Pin 1 with engine ground 0 V The resistance should be 2600 - 2700 .
Pin 2 with engine ground 5 V NOTE: When measuring between pins A-24 and
Pin 3 with engine ground 4.75 - 5 V
A-39, resistance value decreases while depress-
ing throttle lever. when measuring between pins
A-24 and A-25, resistance value increases while
NOTE: Make sure the engine is properly ground- depressing throttle lever. The resistance value
ed. should change smoothly and proportionally to
If voltage test is good, replace the TPS. throttle movement. Otherwise, replace TPS.
If voltage test is not good, check the resistance of If resistance values are correct, try a new ECM.
the TPS circuit. Refer to ECM REPLACEMENT procedures else-
where in this section.
Resistance Test If resistance values are incorrect, repair connector
Reconnect the TPS. or replace the wiring harness between ECM con-
Disconnect the connector A from the ECM. nector and the TPS.

Replacement
Remove the throttle body as described above.
Loosen two screws retaining the TPS.

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Remove TPS. Click on the Reset button in the Setting section of

B.U.D.S.
NOTE: No message will be displayed if operation
is successful. If operation is wrong, an error mes-
sage will be displayed.
NOTE: There is no idle speed adjustment to
perform. The ECM takes care of that. If TPS is
not within the allowed range while resetting the
1 Closed Throttle and Idle Actuator, the ECM
will generate a fault code and will not accept the
setting.
Start engine and make sure it operates normally
through its full engine RPM range. If fault codes
R1004motr158A 2
appear, refer to SYSTEM FAULT CODES in the DI-
THROTTLE BODY AGNOSTIC PROCEDURES section for more infor-
1. Throttle position sensor (TPS)
2. Screws mation.

Install the new TPS. IDLE BYPASS VALVE

Apply Loctite 243 on the TPS retaining screws, An idle bypass valve with good resistance mea-
then torque to 3 N•m (27 lbf•in). surement can still be faulty. It is also possible
Reinstall remaining removed parts. that a mechanical failure occurs which is not de-
Proceed with the CLOSED THROTTLE AND IDLE tectable without measuring the air flow. Replac-
ACTUATOR RESET. See below. ing the idle bypass valve may be necessary as a
test.
Closed Throttle and Idle Actuator Reset
Resistance Test
NOTE: This operation performs a reset of the val-
ues in the ECM. Disconnect idle bypass valve from the wiring har-
ness.
This reset is very important. The setting of the
TPS will determine the basic parameters for all Using a multimeter, check the resistance in both
fuel mapping and several ECM calculations and windings.
the setting of the idle bypass valve will determine
the basic parameters for the idle speed control of
the engine.
NOTE: Reset must be done each time the throttle
position sensor (TPS) is loosened or removed or
throttle body is replaced or ECM is replaced.
CAUTION: An improperly set TPS or idle
bypass valve may lead to poor engine perfor-
mance.
Use the vehicle communication kit (VCK) with the
B.U.D.S. software to perform this adjustment.
Ensure the throttle body plate stop lever rest
against its stopper. Open throttle approximately
one quarter then quickly release. Repeat 2 - 3 R1004motr159A 1
times to settle throttle plate. If stopper does not 1. Idle bypass valve
rest against its stop lever, perform throttle cable
adjustment. Refer to THROTTLE BODY in AIR
INDUCTION SYSTEM above.

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Check the resistance between pin 1 and pin 4 and Clean all remaining parts and install the idle bypass
also between pin 3 and pin 2 of the idle bypass valve on the throttle body.
valve. Proceed with the CLOSED THROTTLE AND IDLE
The resistance in each winding should be approx- ACTUATOR RESET. See above.
imately 50 at 23°C (73°F).
If the resistance of one or both windings is not CRANKSHAFT POSITION
good, replace the idle bypass valve. SENSOR (CPS)
If resistance test of valve windings is good, check
continuity of circuits A-35, A-36, A-37, A-38.

Visual Inspection
NOTE: Make sure the tether cord cap is removed
during the following procedure.
Remove idle bypass valve from throttle body.
Check the piston and bypass channel for dirt/de-
posits which can cause a sticking piston.
CAUTION: Always keep the tether cord cap dis-
connected, while the idle bypass valve is re-
moved.
CAUTION: Do not try to operate the piston of
the idle bypass valve when it is dismounted.
Also do not move the piston by hand. The R1004motr160A 1
drive screw is very sensitive and may be de-
1. CPS connector
stroyed.
Using a part cleaner, clean idle bypass in throttle NOTE: Take into account that a CPS fault can be
body from contamination then use an air gun to triggered by bent or missing encoder wheel teeth.
dry it. First check fault codes then check the teeth con-
dition if necessary. See below.
 WARNING
Disconnect CPS wiring harness connector. Probe
Always wear eye protector. Chemicals can terminals 1 and 2 coming from CPS while cranking
cause a rash break out and injure your eyes. engine. Voltage should be within 1-2 Vac. Other-
wise, inspect wiring and replace CPS if wiring is
1 good.

Resistance Test
Disconnect the CPS plug connector from the
wiring harness and check the resistance of the
sensor itself.
The resistance should be between 0.7 k and
1.1 k .
Otherwise, replace the CPS.
If resistance tests good, reconnect the CPS and
disconnect the connector A on the ECM.

R1004motr183A

1. Clean bore from contamination

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Trigger Wheel Inspection

5
Remove PTO cover. Refer to CRANKCASE sub-
section in ENGINE section.
Remove trigger wheel.
Perform visual inspection of the trigger wheel for
bent teeth and also check the mating surface for
straightness. If necessary, straighten the teeth or
replace the trigger wheel.

R1503motr182A
19

Using a multimeter, recheck resistance value be-

tween terminals 5 and 19.
If resistance value is correct, try a new ECM. Refer
to ECM REPLACEMENT procedures elsewhere in
this section.
If resistance value is incorrect, repair the connec-
2
tors or replace the wiring harness between ECM
connector and the CPS.

Replacement
R1004motr162A 1
Disconnect CPS connector and remove the PTO
cover. Refer to CRANKCASE subsection in EN- 1. Trigger wheel
2. Mating surface
GINE section.
Remove CPS. Properly reinstall trigger wheel and cover.

1 CAMSHAFT POSITION SENSOR

(CAPS)

R1004motr161A

1. CPS inside PTO cover

Install new CPS.

Tightening torque of the CPS retaining screws is
6 N•m (53 lbf•in).
Reinstall remaining removed parts. R1004motr163A 1
1. CAPS

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Voltage Test (harness) 3 2 1

Disconnect the connector from the CAPS.
Install the tether cord cap, then depress the cut-
out switch and push start button momentarily to
activate the ECM.
Probe pin 3 of CAPS connector (wiring harness
side) and battery ground.
– If 12 V is read, check continuity of circuits A-20
and A-34. If test is good, perform the CAPS
voltage test as explained below. If CAPS tests
good, try a new ECM.

20

R1503motr184A

CAPS PIN-OUT

1200 W Voltmeter
V
34
R1503motr183A +
3 2 1
ECM CONNECTOR

– If 12 V is not read, check continuity of circuit

12 V CAPS
between pin 3 of CAPS connector and the cor-
responding fuse. Otherwise, repair wiring har- -
ness.
R1503motr208A
Remove the CAPS from the cylinder head.
Set up the following electric circuit to perform the Touch the CAPS with a conductor (ex.: screwdriv-
voltage test. er) and look if the voltage at the multimeter switch-
es from 12 V to less than 1 V.

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

The resistance should be between 2280 and

2 V
2740 at 20°C (68°F).
Otherwise, replace the ATS.
If resistance tests good, reconnect the ATS and
disconnect the connector A from the ECM.

1 Pin 1 Pin 2 Pin 3

R1503motr207A 1200 W resistor R1503motr186A
21

1. CAPS
2. Conductor Using a multimeter, recheck resistance value be-
tween terminals 7 and 21.
If the voltage is not good, replace the CAPS. If resistance value is correct, try a new ECM. Refer
to ECM REPLACEMENT procedures elsewhere in
Replacement this section.
Unscrew the retaining screw and replace the If resistance value is incorrect, repair the connec-
CAPS. Ensure to reinstall O-ring. tors or replace the wiring harness between ECM
Apply Loctite 243 (blue) on thread and torque to connector and the ATS.
6 N•m (53 lbf•in).
Replacement
AIR TEMPERATURE SENSOR Disconnect the connector of the ATS.
(ATS) Pull ATS out and install the new one.

A32C79A 1
AIR SILENCER
1. Air temperature sensor (ATS)

Resistance Test R1004motr164A

Disconnect the plug connector from the ATS and

check the resistance of the sensor itself.

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

COOLANT TEMPERATURE If resistance value is incorrect, repair the connec-

SENSOR (CTS) tors or replace the wiring harness between ECM
connector and the CTS.

Replacement
Disconnect CTS connector and remove CTS.
Install the new CTS and torque to 18 N•m
(159 lbf•in).
Reinstall remaining removed parts.
Refill and bleed the cooling system, refer to
COOLING SYSTEM subsection.

MANIFOLD AIR PRESSURE

SENSOR (MAPS)

R1004motr165A 1 1
1. Coolant temperature sensor (CTS)

Resistance Test
Disconnect the plug connector from the CTS and
check the resistance of the sensor itself.
The resistance should be between 2280 and
2740 at 20°C (68°F).
Otherwise, replace the CTS.
If resistance tests good,reconnect the CTS and
R1004motr166A
disconnect the ECM connector A from the ECM.
1. Manifold air pressure sensor (MAPS)
11
NOTE: This sensor is a dual function device.
When engine is started and it runs at idle speed,
the sensor takes the atmospheric pressure and
stores it in the ECM. Thereafter, it takes the man-
ifold air pressure at operating RPMs.
Ensure sensor is correctly installed on intake
manifold. Otherwise, the MAPS could generate
a fault code for an unexpected sensor range at
idle when it reads the atmospheric pressure.
27 Remove sensor and check for oil or dirt on its
R1503motr187A
end and if problem persists, check throttle plate
condition/position and the wiring harness. Per-
Using a multimeter, recheck resistance value be-
form the following tests.
tween terminals 11 and 27.
If resistance value is correct, try a new ECM. Refer Voltage Test
to ECM REPLACEMENT procedures elsewhere in Check the voltage output from ECM to the mani-
this section. fold air pressure sensor (MAPS).

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Disconnect plug connector from MAPS and con- OIL PRESSURE SWITCH (OPS)
nect a voltmeter between pin 1 and 2.
Install the tether cord cap, then depress the cut-
out switch and push start button momentarily to
activate the ECM. The measure should be 5 Vdc
on the voltmeter.
If voltage test is good, replace the MAPS.
If voltage test is not good, check the continuity of
the MAPS circuit.

Resistance Test
Disconnect the connector A from the ECM.
1
Using a multimeter, check continuity of circuits 12,
28 and 40.
R1004motr167A
If wiring harness is good, try a new ECM. Refer
to ECM REPLACEMENT procedures elsewhere in 1. OPS
this section.
Otherwise, repair the connectors or replace the
wiring harness between ECM connector and the
Oil Pressure Test
MAPS. To check the function of the oil pressure switch,
an oil pressure test has to be performed. Refer to
Verification Test OIL PRESSURE TEST in LUBRICATION SYSTEM
Using VCK, energize the MAPS from the MONI- section.
TORING section and read out the proper pressure If the engine oil pressure is out of specifications,
value while engine is stopped. check the points described in troubleshooting sec-
Perform the same test with a new MAPS and tion.
compare both readings. If the engine oil pressure is good, check the re-
Values have to be within ± 3.4 kPa (0.5 PSI). sistance of the OPS while engine is off and while
engine is running.
If old MAPS's value is out of this range, replace it.
Resistance Test
Replacement
Disconnect the plug connector from the OPS
Disconnect MAPS connector and remove the and use a multimeter to check the resistance be-
MAPS. tween OPS pin and engine ground while engine
Install the new MAPS paying attention to index is stopped (without oil pressure) and while engine
its tab into the adaptor notch. Apply Loctite 243 is running (with oil pressure).
(blue) on screw then torque to 6 N•m (53 lbf•in). When engine is stopped the resistance is close to
0 (normally close switch).
When engine is running and the oil pressure reach-
es 20 - 40 kPa (2.9 - 5.8 PSI), the resistance of the
OPS is infinitely high.
If resistance values are incorrect, replace OPS.
If the values are correct, check the continuity of
the wiring harness.
Disconnect the connector A from the ECM and
check continuity of circuit 10.

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

 WARNING
Never make a spark test with spark plug re-
moved. Flammable vapors may be present
in the engine compartment and ignited which
could cause an explosion.
R1004motr150B 10
Voltage Test
If wiring harness is good, try a new ECM. Refer
to ECM REPLACEMENT procedures elsewhere in
this section.
 WARNING
When disconnecting coil from spark plug, al-
Otherwise, repair the connector or replace the ways disconnect coil from main harness first.
wiring harness between ECM connector and OPS. Never check for engine ignition spark from
an open coil and/or spark plug in the engine
IGNITION COILS compartment as spark may cause fuel vapor
to ignite.
1
Disconnect the plug connector from the ignition
coil and check the voltage supplied by the battery.

1
2

R1004motr169A R1503motr196A

1. Ignition coil
Install tether cord cap and connect the VCK (Vehi-
NOTE: The ECM energizes the primary side of cle Communication Kit) to activate the system.
each ignition coil individually. A trouble code will Check voltage between terminal 2 of ignition
appear if the ECM can not energize the ignition coil connector on the wiring harness and battery
coils. ground.
Using the vehicle communication kit (VCK) with The voltage should be 12 V.
the B.U.D.S. software, energize the ignition coil
from the Activation section. If 12 V is NOT read, check continuity between ter-
minal 2 of ignition coil and the corresponding fuse.
You should hear the spark occurring. In doubt, use Otherwise, repair wiring harness.
an inductive spark tester or a sealed tester - avail-
able from after-market tool/equipment suppliers - If 12 V is read, disconnect the connector A from
to prevent spark occurring in the engine compart- the ECM and check the continuity of appropriate
ment. Otherwise, perform the following checks. circuit 41 (cylinder 1) or 1 (cylinder 2).
An ignition coil with good resistance measure-
ment can still be faulty. Voltage leak can occur
at high voltage level which is not detectable with
an ohmmeter. Replacing the ignition coil may be
necessary as a test.

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

41 NOTE: Prior to inserting the ignition coil to its lo-

cation, apply some silicone lubricant (P/N 293 600
041) around the seal area that touches the spark
plug hole. After installation, ensure the seal seats
properly with engine top surface.

 WARNING
R1004motr150C
1 Always reconnect ignition coil cables at the
same spark plugs where they come from.
ECM CONNECTOR Otherwise, severe backfire may occur with
possible damage to exhaust system com-
If wiring harness is defective, repair the connector
ponents. The genuine wiring harness is
or replace the wiring harness between ECM con-
designed to prevent mixing up the cables
nector and the ignition coil.
since they are different in length.
If wiring harness is good, test resistance of prima-
ry and secondary winding of ignition coil.

Resistance Test ENGINE START SWITCH

CAUTION: Do not remove the ignition coil be-
VERIFICATION
fore disconnecting the connector, or the wires If the ECM fails to wake-up or engine fails to start
may be damaged. To avoid damage, do not while depressing start button check battery volt-
pry up ignition coil with a screwdriver. age and fuses F1 and F8. Connect supply cable
Remove ignition coil from spark plug. (P/N 529 035 869) to wake-up the ECM.
1 1

529 035 869

R1503motr197A
2
1. Spark plug terminal

Using a multimeter, check the resistance in both

primary and secondary windings.
For primary winding check the resistance be-
tween pin 1 and pin 2 of the ignition coil. NOTE: Make sure the engine cut-out switch is not
The resistance should be between 0.85 and 1.15 in operation.
at 20°C (68°F). A quick operation test can be done using the ve-
For secondary winding check the resistance be- hicle communication kit (VCK) with the B.U.D.S.
tween pin 1 and spark plug terminal. software, using the Monitoring section. Press
the start button and look at the start button LED.
The resistance should be between 9.2 and 13.8 k It should turn on, indicating the starting system
at 20°C (68°F). is working on the input side of the starting sys-
If the resistance of one of both windings is not tem (start button, ECM and wiring). If so, you
good, replace the defective ignition coil. know now the problem is on the output side of
If the windings test good, check corresponding the starting system (ECM output signal to start-
fuse, relay and wiring. If good, try a new engine ing solenoid, wiring harness going to the solenoid
ECM. and starter motor. Refer to STARTING SYSTEM
for testing procedures). Otherwise, check the in-
put side as follows.

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 Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

Test corresponding fuse, relay and wiring. SPARK PLUGS

Disconnect the connector of the steering harness.
Disassembly
Measure the resistance of the BLUE/RED and
LIGHT BROWN wires for 0 . Depress start
button and the reading should change from 0
 WARNING
to infinitely high. Never remove ignition coil from the spark
plug without disconnecting it from the wiring
Release the start button and measure the resis- harness. Flammable vapors may be present
tor between LIGHT BROWN and BLACK wires. It in the engine compartment and ignited by a
should be 50 . spark which could cause an explosion.
Test continuity of circuit B-17. If it is good, try a
new ECM. Otherwise, repair harness/connectors. Disconnect the wiring harness from the ignition
Test continuity of circuit B-19. If it is good, try a coil.
new ECM. Otherwise, repair harness/connectors. Remove the ignition coil.
First unscrew the spark plug one turn.
DESS SWITCH VERIFICATION Clean the spark plug and cylinder head with pres-
If 2 short beeps are not heard when engine is start- surize air then completely unscrew.
ed, refer to DIAGNOSTIC PROCEDURES.
The following continuity tests can also be per-
Spark Plug Installation
formed using an ohmmeter. Prior to installation make sure that contact sur-
faces of the cylinder head and spark plug are free
Disconnect DESS post wires.
of grime.
Tether Cord Cap Removed – Using a wire feeler gauge, set electrode gap
according to the following chart.
Connect test probes to DESS post GREY/GREEN
and WHITE/BLACK wires. Measure resistance, – Apply anti-seize lubricant over the spark plug
there should be NO continuity (open circuit). threads to prevent possible seizure.
– Hand screw spark plug into cylinder head.
Connect one test probe to the WHITE/GRAY wire
Then, tighten the spark plug clockwise an addi-
and the other test probe to the DESS post top
tional 1/4 turn with a proper socket.
terminal. Measure resistance, it must be close to
0 ohm.
Connect one test probe to the GREY/GREEN wire
and the other test probe to the DESS post ring.
Measure resistance, it must be close to 0 ohm.

Tether Cord Cap on DESS Post 1 2

Connect test probes to DESS post GREY/GREEN
and WHITE/BLACK wires. Measure resistance, it
must be close to 0 ohm.

A00E0BA

TYPICAL
1. Proper socket
2. Improper socket

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Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)

GAP
SPARK
ENGINE TORQUE ± 0.05 mm
PLUG
(± .002 in)
Hand tighten
1004 NGK 0.75
+ 1/4 turn
4-TEC DCPR8-E (.030)
with a socket

CRANKING SYSTEM
See above for start switch and the DESS post test-
ing.

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 Section 07 TRANSMISSION
Subsection 01 (DRIVE BELT)

DRIVE BELT
SERVICE TOOLS
Description Part Number Page
belt tension tester ................................................................ 414 348 200 ......................................... 344
drive belt tension adjuster .................................................... 529 008 700 ......................................... 343

SERVICE PRODUCTS
Description Part Number Page

Pulley flange cleaner............................................................. 413 711 809 ......................................... 341

APPLICATION CHART
MODEL PART NUMBER MINIMUM WIDTH (wear limit)
Tundra 414 827 600 30.0 mm (1.181 in)
Skandic LT/LT E/WT/SWT/SUV 550 414 633 800 32.0 mm (1.260 in)
Skandic WT LC/SUV 600 414 300 155 34.7 mm (1.366 in)
Expedition TUV 600 HO SDI 605 348 425 34.7 mm (1.366 in)
Expedition TUV V-1000 605 348 425 34.7 mm (1.366 in)

CHECKING NEUTRAL FUNCTION – pulley center-to-center is as specified

 WARNING
– belt deflection is as specified.

Always check neutral function when servic- CLEANING

ing.
Before drive belt installation, clean drive and
Apply parking brake. Vehicle must be on the driven pulley sheaves with Pulley flange cleaner
ground and on a plane level surface. No one (P/N 413 711 809).
should be in front of vehicle.
Attach vehicle tether cord to your clothing. Stand INSPECTION
aside of vehicle then, start engine. Inspect belt for cracks, fraying or abnormal wear
(uneven wear, wear on one side, missing cogs,
 WARNING cracked fabric). If abnormal wear is noted, prob-
Do not sit on vehicle. able cause could be pulley misalignment, exces-
sive RPM with frozen track, fast starts without
Release parking brake. Vehicle must not creep warm-up period, burred or rusty sheave, oil on belt
when engine is idling. Otherwise, make sure that: or distorted spare belt.
– idle speed is as specified
– proper belt is installed

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Section 07 TRANSMISSION
Subsection 01 (DRIVE BELT)

Check the drive belt width. Replace the drive belt DRIVE BELT HEIGHT
if width is less than the minimum width recom- MEASUREMENT AND
mended (see table above).
ADJUSTMENT
ROTATION DIRECTION NOTE: The drive belt height measurement and
adjustment must be performed each time a new
The maximum drive belt life span is obtained drive belt is installed.
when the drive belt is installed as shown. This
will ensure that correct direction of rotation is Measurement
respected.
Before checking the belt height, ensure that a
good-condition proper belt (refer to the APPLICA-
TION CHART) is installed.
Adjust pulley distance and alignment. Refer to
PULLEY DISTANCE AND ALIGNMENT.
To obtain maximum vehicle performance, the belt
height must be adjusted according to specifica-
tions shown in the accompanying chart.

BELT HEIGHT
MODEL
mm (in)
Top edge of drive belt cord should
All models
be flush with driven pulley edge

A01D2KA

CORRECT

A02D1UA 1
1. Flush

Models Equipped with Formula VSA

Type Driven Pulley
Adjust drive belt height using Allen screws, as
A01D2LA
shown.
INCORRECT To lower belt in driven pulley: turn Allen screws
clockwise.
NOTE: For used drive belt, mark and reinstall in
the same position. To raise belt in driven pulley: turn Allen screws
counterclockwise.

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 Section 07 TRANSMISSION
Subsection 01 (DRIVE BELT)

NOTE: Turn Allen screws 1/4 turn at a time, then DRIVE BELT DEFLECTION
rotate driven pulley to allow drive belt to settle in MEASUREMENT (REFERENCE
pulley. Check height, repeat as required.
ONLY)
IMPORTANT: The drive belt deflection will be
automatically set after performing the pulley dis-
tance and belt height adjustments. The following
procedure will confirm proper pulley distance and
belt height adjustment.
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 that a
good-condition proper belt (Refer to the APPLICA-
TION CHART) is installed.
1
Adjust pulley distance and alignment. Refer to
A06D20A PULLEY DISTANCE AND ALIGNMENT.
TYPICAL To obtain maximum vehicle performance, the belt
1. Allen screws with jam nuts tension must be adjusted according to specifica-
tions shown in the accompanying chart.
Allen screws must be restrained while tightening
jam nut to prevent throwing adjustment out. Use DEFLECTION† FORCE
drive belt tension adjuster (P/N 529 008 700). MODEL
mm (in) kg (lb)
32 ± 5
Tundra 6.8 (15)
(1.260 ± .197)
All models 32 ± 5
11.5 (25)
(except Tundra) (1.260 ± .197)
† FOR REFERENCE ONLY

To Check Tension
Position a reference rule on drive belt.
Wooden Stick and Spring Scale Method

A06D21A 529 008 700

TYPICAL
A00D05A

All Models
1. Mark specified deflection
Vary pulley distance — within tolerances — to ob-
tain proper drive belt height. Using spring scale and stick, apply specified force
on drive belt halfway between pulleys as shown.

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Section 07 TRANSMISSION
Subsection 01 (DRIVE BELT)

2
1

1 3
2

4
3

5
A00D06A A00D08A

1. Force 1. Upper O-ring — force

2. Read deflection here 2. Force applied
3. Reference rule 3. Lower O-ring — deflection
4. Reference rule
5. Deflection
Or use the belt tension tester (P/N 414 348 200).
1 2

A00C07B 4 3
1. Lower O-ring
2. Upper O-ring
3. Force (read down)
4. Deflection (read up)

1) Slide lower O-ring of tester to specified deflec-

tion.
2) Slide upper O-ring of tester until reaching mark
0 (zero).
3) Apply pressure until lower O-ring is flush with
edge of rule and read force on the upper scale
at top edge of O-ring.

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 Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

DRIVE PULLEY
SERVICE TOOLS
Description Part Number Page
COMET drive pulley puller.................................................... 529 025 000 ................................. 351, 354
drive pulley retainer .............................................................. 529 035 674 ......................................... 357
driven pulley opening tool..................................................... 529 017 200 ......................................... 351
fork ....................................................................................... 529 005 500 ................................. 359, 364
governor cup extractor ......................................................... 529 035 894 ......................................... 358
holder.................................................................................... 529 006 400 ......................................... 351
holder.................................................................................... 529 027 600 ......................................... 347
large bushing extractor tool .................................................. 529 035 931 ................................. 360–361
pulley spring compressor ..................................................... 529 035 524 ......................... 359–361, 364
short dial indicator ................................................................ 295 000 143 ......................................... 365
spider tool............................................................................. 529 025 200 ......................................... 352
spider wrench....................................................................... 529 025 400 ......................................... 353
spring cover tool ................................................................... 529 027 300 ......................................... 348
tapered tool .......................................................................... 529 035 826 ......................................... 352
TRA drive pulley puller.......................................................... 529 022 400 ......................... 347–348, 357
TRA IV drive pulley support tool ........................................... 529 035 942 ......................................... 365
vise mount tool..................................................................... 529 031 200 ......................................... 360

SERVICE PRODUCTS
Description Part Number Page

Loctite 271............................................................................ 293 800 005 ......................... 353–354, 362

Primer N ............................................................................... 293 800 041 ......................................... 353
pulley flange cleaner............................................................. 413 711 809 ................................. 359, 361

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Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

BOMBARDIER LITE
NOTE: This is a lubrication free drive pulley.
Tundra/Skandic WT 550/SWT/SUV 550

3
11

6 7
8
128 N•m
(94 lbf•ft) 9
95 N•m
(70 lbf•ft)

A03D2GT

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 Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

GENERAL 529 027 600

Some drive pulley components (return spring, cal-
ibration disk) can be changed to improve vehicle
performance in high altitude regions. A Service
Bulletin will give information about calibration ac-
cording to altitude.
CAUTION: Such modifications should only be
performed by experienced mechanics since
they can greatly affect vehicle performance.

 WARNING
Any drive pulley repairs must be performed
by an authorized BRP snowmobile dealer.
Subcomponent installation and assembly
tolerances require strict adherence to proce-
A05D0JB
dures detailed.
TYPICAL

REMOVAL Insert TRA drive pulley puller (P/N 529 022 400)
then remove drive pulley.
NOTE: If disassembling drive pulley, first straight-
en tab washer no. 7 then untighten nut no. 8.

 WARNING
Never use an impact wrench to remove or in-
stall the drive pulley.

 WARNING
The drive pulley assembly is a precisely bal-
anced unit. Never replace parts with used
parts from another drive pulley assembly.

Use holder (P/N 529 027 600).

Remove retaining screw no. 9.

A05D0KB 529 022 400

TYPICAL

DISASSEMBLY
Unscrew nut. Remove tab washer.
Check for alignment marks for proper indexing at
reassembly.

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Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

1 2

A03D2IA 1 A03D2HA

1. Alignment marks 1. Puller tool

2. Spring cover tool
Identify blocks no. 1 and their respective positive
positions for reassembly. Screw puller (hand tight) to hold spring cover and
remove screws holding spring cover.
Slowly unscrew puller to release spring pressure.
Remove spring cover no. 5, spring and spring seat
1 no. 11.

CLEANING
1
Clean pulley faces and shaft with fine steel wool
and clean dry cloth. Clean sliding half bushing
with clean dry cloth.

INSPECTION
A05D0LA
Check sliding half for excessive lateral play and
1. Identify
fixed half shaft for scratches. Replace as required.

2, Cap, Washer and Disk ASSEMBLY

These are calibration parts. Refer to TECHNICAL Install spring seat no. 11 then the spring and its
DATA. cover no. 5.
Install spring cover tool (P/N 529 027 300) with Make sure to install blocks in their original position
TRA drive pulley puller (P/N 529 022 400) on spring and with their curved end toward governor cup.
cover. See following illustration.

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 Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

A05D0LB

1. Curved end

Tighten nut no. 8 to 128 N•m (94 lbf•ft).

INSTALLATION
Torque screw to 80 to 100 N•m (59 to 74 lbf•ft).
Install drive belt and belt guard.
Raise and block the rear of the vehicle and support
it with a mechanical stand.
 WARNING
Make sure the track is free of particles that
could be thrown out while track is rotating.
Keep hands, tools, feet and clothing clear of
track. Ensure nobody is standing near the ve-
hicle.

Accelerate the vehicle at low speed (maximum

30 km/h (20 MPH)) and apply the brake, repeat
5 times.
Re-torque screw to 90 to 100 N•m (66 to 74 lbf•ft).

 WARNING
After 10 hours of operation the transmission
system of the vehicle must be inspected
to ensure the retaining screw is properly
torqued.

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Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

COMET® 102C
Skandic LT/LT E

10

3
11
2
7
6
12 N•m
(106 lbf•in)
6
1 13
9 12
4 14
68 N•m 8
(50 lbf•ft) 15
5 13

170 N•m
(125 lbf•ft)
Primer N
Loctite 271 16

Primer N
Loctite 271

27 N•m
18 17 (20 lbf•ft)
19
Loctite 271

Skandic LT E

A29D2OS

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 Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

GENERAL REMOVAL
Some drive pulley components can be changed  WARNING
to improve vehicle performance in high altitude
Never use an impact wrench to remove or in-
regions. A Service Bulletin will give information
stall the drive pulley.
about calibration according to altitude.
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 Use holder (P/N 529 006 400). Make sure holder
by an authorized BRP snowmobile dealer. hook is positioned on top of tower.
Subcomponent installation and assembly
tolerances require strict adherence to proce- 529 006 400
dures 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 2 to 12 N•m (106 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 2 to 12 N•m (106 lbf•in).
Proceed with one screw per tower in a criss-cross Remove retaining screw no. 1.
sequence then, remaining three screws. Install holder (P/N 529 006 400) in a way to limit
pulley clockwise rotation.
Insert COMET drive pulley puller (P/N 529 025
000) then turn puller clockwise to free drive pul-
ley from crankshaft taper.

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Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

529 006 400

A29D23A 529 025 000

Remove driven pulley to make room for drive pul-

ley removal.
Remove drive pulley.

DISASSEMBLY
Skandic LT E Only
Remove retaining screws no. 17 and washers
A29D24A
no. 18 from ring gear no. 19.
1. Scribe marks
CAUTION: Retaining screws must be heat-
ed before disassembly. Heating temperature
must not exceed 150°C (300°F). Remove cover screws no. 2.
Hold cover no. 3 by hand then, unscrew retaining
Skandic LT and Skandic LT E screw no. 1.
Mount tapered tool (P/N 529 035 826) in a vise.
Install drive pulley over retainer then, fasten retain-
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
indexing at reassembly.

A29D25A

Remove cover no. 3.

Heat spider no. 5 to melt threadlocker.
Install spider tool (P/N 529 025 200) then, unscrew
spider no. 5.

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 Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

1 Check cover bushing interior. Replace cover if

bushing is completely bronze instead of the origi-
nal teflon coating.
Check spider thrust buttons no. 6 for proper slid-
ing action. Replace as required.
Check rollers no. 7 for free action. Replace as
required.

ASSEMBLY
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
A29D26A
Loctite 271 (P/N 293 800 005) to threads.
1. Spider wrench Using spider wrench (P/N 529 025 400) from tool
kit, torque spider to 5 to 170 N•m (125 lbf•ft).
Note shim no. 8 quantity. With square end facing sliding half, install a wash-
er no. 13 on each side of cam arm no. 12.
1

A29D27A
A29D28A 1
1. Shims
1. Square end facing sliding half
Remove cam arms no. 12.
Tighten to 5.6 N•m (50 lbf•in) maximum all three
pivot nuts no. 15. Make sure cam arms no. 12
CLEANING can still move on their pivot bolts no. 11.
Clean pulley faces and shaft with fine steel wool
and clean dry cloth. Clean sliding half bushing
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.

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Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

Skandic LT E Only
Secure ring gear no. 19 on inner fixed half using
self-tapping screws no. 17 and thick M8 flat wash-
ers no. 18. Apply Loctite 271 (P/N 293 800 005)
on screw threads and between screw heads and
thick flat washers.
NOTE: It is of the utmost importance to use thick
flat washers no. 18 with self-tapping screws
no. 17 in order not to pierce inner fixed half with
the screws.
CAUTION: Loctite 271 (P/N 293 800 005) must
be applied to safely assemble ring gear.
A29D29A
Torque screws in a criss-cross sequence to
27 N•m (20 lbf•ft).
Install spring no. 4, cover no. 3.
Tighten cover screws no. 2 to 12 N•m (106 lbf•in). INSTALLATION
Proceed with one screw per tower in a criss-cross
sequence then, remaining three screws. Install drive pulley on crankshaft.
Use COMET drive pulley puller (P/N 529 025 000) Install a new lock washer.
to unlock drive pulley from retainer. 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.
Raise the rear of the vehicle and support it with a
mechanical stand.
529 025 000
 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.
Recheck the torque of 68 N•m (50 lbf•ft).

 WARNING
After 10 hours of operation the transmission
system of the vehicle must be inspected
to ensure the retaining screw is properly
torqued.
A29D2AA

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 Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

TRA III
All Liquid Cooled Models except 4-TEC Models
NOTE: These are lubrication free drive pulleys. Always refer to appropriate parts catalog for replacement
part. Most parts of TRA III are not interchangeable with those of the TRA.

593 HO/SDI only

6 12 15
11
Electric start models only

Loctite 271 10 N•m 9

(89 lbf•in)
14
14
27 N•m 5 16
(20 lbf•ft)
12 N•m
(106 lbf•in)
13
2 6 12 14
11
12
15

7 16
9
Loctite
609

16 N•m Loctite
33 (142 lbf•in) 609 18
Some models for 693 engine
only equipped models
13 N•m
(115 lbf•in)
23

25
19
25 N•m 20
(18 lbf•ft)
21 28 10 N•m
(89 lbf•in)
for 593 HO/SDI Loctite 22
24
Repair kit and 793 SDI engine 609 30 95 N•m
(70 lbf•ft)
31
27 25
26
32
29

A32D3VS

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Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

TRA IV
4-TEC Models
NOTE: This is a lubrication free drive pulleys. Always refer to appropriate parts catalog for replacement
part. Most parts of TRA IV are not interchangeable with those of the TRA/TRA III.

Loctite 609

16
17
13 16 10 18
15

9 10 N•m
(89 lbf•in)
11
Black Max
12

19
25 N•m
(18 lbf•ft) 25
14 24

24
25 29
Loctite 609
20
10 N•m
(89 lbf•in) 21 22
23 30
130 N•m
(96 lbf•ft)
10 N•m 31
(89 lbf•in) 26
28 27
A32D23T

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 Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

GENERAL
Some drive pulley components (return spring,
ramp) can be changed to improve vehicle perfor-
mance in high altitude regions. A service bulletin
will give information about calibration according
to altitude.
CAUTION: Such modifications should only be
performed by experienced mechanics since
they can greatly affect vehicle performance.
Verify spring specifications before installation.
Do not only refer to the spring color code.
NOTE: TRA drive pulley stands for Total Range
Adjustable drive pulley.

 WARNING 529 035 674

Any drive pulley repairs must be performed
by an authorized BRP snowmobile dealer.
Sub-component installation and assembly
tolerances require strict adherence to proce-
dures detailed.
1
A32D26A

1. TRA IV — Sliding half tower

REMOVAL
30,31, Conical Spring Washer  WARNING
and Screw Never use any type of impact wrench at drive
Secure drive pulley retainer (P/N 529 035 674) over pulley removal and installation.
a sliding half tower.
Remove retaining screw.
To remove drive pulley ass’y and/or fixed half from
engine, use TRA drive pulley puller (P/N 529 022
400).
CAUTION: These pulleys have metric threads.
Do not use imperial threads puller. Always
tighten puller by hand to ensure that the drive
pulley has the same type of threads (metric vs
imperial) prior to fully tightening.
To Remove Drive Pulley Ass’y:
Retain drive pulley with drive pulley retainer
(P/N 529 035 674).
Install puller in pulley shaft then tighten.

A32D1WA

TRA III — INSERT THE TOOL IN SLIDING FLANGE TOWER

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Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

DISASSEMBLY
Models with TRA III

1,2, Screw and Ring Gear

CAUTION: Retaining screws must be heated
before disassembly. Do not exceed 150°C
(300°F).

5,6, Fixed and Sliding Halves

CAUTION: Do not tap on governor cup.
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.

A32D27A

All Models
NOTE: No components marking is required before
1
disassembling this drive pulley since it has factory
mark and arrows as indexing reference.

32, Cushion Drive

CAUTION: Do not disassemble cushion drive.
Governor cup and cushion drive are factory
balanced as an assembly.
2
A16D01A
25,29, Slider Shoe and Governor Cup
TYPICAL Carefully lift governor cup until slider shoes come
1. Puller
2. Holding sliding half at their highest position into guides.
Hold a slider shoe set then carefully lift its housing
Models with TRA IV and remove slider shoes. Proceed the same way
Install governor cup extractor (P/N 529 035 894) for other housings lifting one at a time.
on governor cup. Tighten Allen screws in a criss-
cross sequence. 1
Mount governor cup extractor in a vise.
Tighten extractor screw. Hold fixed half and 2
slighty hammer on extractor screw head. Fixed
half will come off.

A16D02A

1. Hold slider shoes

2. Lift one housing at a time

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 Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

NOTE: To ease disassembly, fork (P/N 529 005 Install sliding half then a second support guide.
500) should be used to hold slider shoes prior to These support guides will prevent bushing dam-
removing governor cup. ages.

529 005 500 1

A16B02A

19, Spring Cover Ass’y

A03D3FA
It is pushed by clutch spring pressure.
1. Support guide

 WARNING
Remove 3 Allen screws retaining spring cover
Clutch spring is very strong. Never attempt then unscrew compressor.
to remove spring cover without the recom-
mended tools.
CLEANING
Use pulley spring compressor (P/N 529 035 524). 5,6, Fixed and Sliding Halves
Install support guide. Clean pulley halves and shaft with fine steel wool
and dry cloth.

5,29, Fixed Half/Crankshaft End and

Governor Cup/Fixed Half Post
1 Parts must be at room temperature before clean-
ing.
Using a paper towel with pulley flange cleaner
(P/N 413 711 809), clean crankshaft tapered end
and the taper inside the fixed half of the drive
pulley, crankshaft threads and retaining screw
threads.
Before installation of drive pulley, clean also crank-
shaft threads and retaining screw threads.

 WARNING
This procedure must be performed in a well-
ventilated area.
A03D3EA

1. Support guide CAUTION: Avoid contact between cleaner and

crankshaft seal because damage may occur.

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Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

Remove all hardened oil deposits that have baked Sliding Half Bushing Replacement
on crankshaft and pulley tapered surfaces with NOTE: In case of worn out bushing, it is advisable
coarse or medium steel wool and/or sand paper to replace whole sliding half ass’y as replacing just
no. 600. the bushing may reduce the drive pulley perfor-
CAUTION: Do not use any other type of abra- mance.
sive. Remove circlip from the sliding half.
Reclean mounting surfaces with paper towel and
cleaning solvent.
Wipe off the mounting surfaces with a clean, dry
paper towel. 1
CAUTION: Mounting surfaces must be free of
any oil, cleaner or towel residue.

7,20, Bushing
Only use petrol base cleaner when cleaning bush-
ings.
CAUTION: Do not use acetone to clean bush-
ing.
A32D2TA

INSPECTION 1. Circlip
Drive pulley should be inspected annually.
Secure the pulley spring compressor (P/N 529 035
16,17, Thrust Washer and Roller 524) in a vise mount tool (P/N 529 031 200) and the
sliding half ass’y on it.
Check roller for roundness of external diameter.
Check thrust washer for thickness wear. Replace
as required.
CAUTION: Ensure rollers are in good condition.
Replace as required.

9,12, Fitting Bolt Ass’y and

Flanged Bushing
Check for wear, replace as required.

24,25, O-Ring and Slider Shoe 529 031 200

Check if O-rings are cracked, cut or crushed. Re- 529 035 524
place as required.
Check slider shoes for wear. Replace if groove is
not apparent on top.

5,29, Fixed Half and Governor Cup A32D2UA

Inspect splines and free play between both parts.
Maximum free play is 0.5 mm (.020 in) measured Use the large bushing extractor tool (P/N 529 035
at calibration screw radius. Replace if required. 931) to press out old bushing.
7,20, Sliding Half and Spring NOTE: Make sure to use the large bushing extrac-
tor tool (P/N 529 035 931) as marked; to remove
Cover Bushing the bushing press using the side marked “OUT”,
Visually inspect coating. Replace if worn. as shown below in the picture.

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 Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

A32D2VA

A32D2XA

Use a soft sand paper to clean sliding half bushing

mounting surface. NOTE: Make sure that the bushing is well seated
on the sliding half ass’y.

1
A32D2WA
A32D2YA

Clean sliding half bushing mounting surface with 1. Bushing

pulley flange cleaner (P/N 413 711 809).
Install the circlip.
To install a new bushing, secure the pulley spring
compressor (P/N 529 035 524) in a vise and mount
the sliding half ass’y. Insert the bushing from in-
ner side of sliding half ass’y.
Mount the large bushing extractor tool (P/N 529
035 931) with side marked “IN” to press in a new
bushing.
1

A32D2ZA

1. Circlip

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Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

Spring Cover Bushing Replacement 1

Under normal use there is no need to replace this
bushing.
In case of replacement, it’s recommended to re-
place spring cover ass’y.
A16D08A

ASSEMBLY 1. Chamfered side

NOTE: This drive pulley is lubrication free. Do not Position dowel tube split at the angle A.
lubricate any component.
A
1,2,3, Screw, Ring Gear and Loctite 271
Apply Loctite 271 (P/N 293 800 005) 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
install washer as shown.
1
A16D2PB

MODEL ANGLE (A)

With TRA 30 ± 5°
With TRA III and IV 45 ± 3°

A16D07A

TYPICAL
1. Washer

Torque locking nut to 10 N•m (89 lbf•in).

15, Pin
Always use the same type of pin as originally in-
stalled when servicing. Different types have dif-
ferent weights for calibration purpose. Refer to
TECHNICAL DATA. 1 1
A16D09A

21,22,23, Screw, Dowel Tube and Ramp 1. Equal distance

Insert dowel tube from chamfered side. Make
sure ramp is centered on dowel tube. Torque screws to 10 N•m (89 lbf•in).

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 Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

9,11,13,14, Screw, Lever Ass’y,

Nut and Cotter Pin
TRA III and IV
NOTE: While installing lever assemblies make
sure that the curved sides of the levers are out-
wards as shown.

A32D1XA 1
A32D1ZA 1. Head on top
2. All on the same side

All Models CAUTION: Lever assemblies must be installed

Always install lever assemblies so that cotter pins so that cotter pins are on the same side.
are on the shown side. Besides install cotter pin Torque nuts no. 9 as per the exploded view.
head on top when lever is sat at bottom of sliding
half. Bend cotter pin ends to sit perfectly against CAUTION: Lever ass’y and rollers must move
lever. easily after installation.

 WARNING 33, Guard

Whenever replacing centrifugal levers, al- Some Models Only
ways replace all 3 at the same time. Other- Install guard with its reinforcements in line with
wise, drive pulley misbalancing will occur levers.
because of levers difference.
1

A32D0IA

1. Reinforcements

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Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

5,6,18,19, Fixed Half, Sliding Half, CAUTION: Make sure O-rings are installed on
Spring, Spring Cover and Screw slider shoes and that grooves are positioned
vertically.
To install spring cover, use pulley spring compres-
sor (P/N 529 035 524). Install fork (P/N 529 005 500) into slider shoe
grooves to maintain them for governor cup instal-
Assemble fixed and sliding halves. Note that fixed lation. Proceed on 3 set of slider shoes.
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.
529 005 500

A16B02A

TYPICAL

Make sure to align governor cup arrow with sliding

half and fixed half mark.
TRA III
NOTE: If fixed half has no mark, align governor cup
mark with segment no. 1 of inner half. Segments
are identified on engine side.
A32D1YA

1. Align
1
Tighten screws to proper torque as mentioned in
exploded view.

6,25,29, Sliding Half, Slider Shoe

and Governor Cup
To install governor cup, use following tool:
529 005 500

A16D0EA

TYPICAL
1. Align

A16B01A Carefully slide governor cup into sliding half. Align

mark of governor cup with mark of fixed half.
Insert spring and slider shoes into governor cup Remove forks and push governor cup so that its
so that groove in each slider shoe is vertical to splines engage with fixed half shaft splines.
properly slide in guides.

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 Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

TRA IV
Using a plastic hammer, strike hub firmly 2 or 3
times to ensure proper seating of cones.

2 A32D2NA 1
1. Dial support in hub
3
CAUTION: For following procedure, make sure
to take off the wheel from the extremity of the
A32D2MA dial indicator.
STRIKING HUB
1. Alignment mark (arrow)
2. Sliding flange alignment mark
3. Fixed flange alignment mark (reported from underneath)

Position TRA IV drive pulley support tool (P/N 529

035 942) in hole and align assembly on press, with
press shaft.

A32D2SA

SHOWS WHEEL REMOVED

Completely screw short dial indicator (P/N 295 000

143) in housing support tool and install it on pulley
assembly; set dial indicator to “0”. Make sure
the set-up is well mounted and the dial constantly
reads “0”.

A32D2OA 1
POSITIONING TRA IV DRIVE PULLEY SUPPORT
1. TRA IV drive pulley support

Position dial support tool in hub and make sure it

is well seated on fixed flange shaft.

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Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

A32D2PA

1. Indicator
2. Housing support A32D2RA

1. Absolute “0”
Cover indicator with dial housing tool. 2. .017 in displacement

CAUTION: Make sure to respect given specifi-

cation to ensure adequate reassembly of drive
pulley. Failure to do so could cause damage to
2 drive pulley assembly.
CAUTION: Make sure splines of both parts are
3 fully engaged.

INSTALLATION
1  WARNING
Do not apply anti-seize or any lubricant on
crankshaft and drive pulley tapers.

 WARNING
Never use any type of impact wrench at drive
pulley removal and installation.
A32D2QA
Clean mounting surfaces as described in CLEAN-
1. Dial housing
2. Press shaft (aligned) ING above.
3. Needle at absolute “0”
Drive Pulley Ass’y
Align press shaft just over and without touching
The following installation procedure must be
the very middle of dial housing; do not apply pres-
strictly adhered.
sure yet.
Install drive pulley on crankshaft extension.
Ensure indicator needle is still set at absolute “0”
and then start activating press until needle reads Install a new conical spring washer with its con-
a displacement of .017 ± .0005 in. cave side towards drive pulley then install screw.

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 Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

 WARNING This adjustable drive pulley allows setting maxi-

mum engine RPM in the vehicle to maintain max-
Never substitute conical spring washer imum power.
and/or screw with jobber ones. Always use
BRP genuine parts for this particular case. Calibration screws should be adjusted so that ac-
tual maximum engine RPM in vehicle matches the
Use holder. See removal procedure. maximum horsepower RPM given in TECHNICAL
DATA.
TRA III NOTE: Use precision digital tachometer for engine
Torque screw to 80 to 100 N•m (59 to 74 lbf•ft). RPM adjustment.
TRA IV NOTE: The adjustment has an effect on high RPM
Torque screw to 125 to 135 N•m (92 to 100 lbf•ft). only.
To adjust, modify ramp end position by turning cal-
All Models ibration screws.
Install drive belt and guard.
TRA IV
Raise and block the rear of the vehicle and support
it with a mechanical stand. From factory TRA drive pulley adjustment screws
are set to position 3. This position allows the best
 WARNING compromise between acceleration, top speed and
fuel economy.
Ensure that the track is free of particles which
could be thrown out while track is rotating. Position 1 or 2 would provide the best fuel econo-
Keep hands, tools, feet and clothing clear of my. Top speed would be reduced.
track. Ensure nobody is standing near the ve- Position 4 would give the best acceleration. Fuel
hicle. economy would be reduced.

Accelerate the vehicle at low speed (maximum 26,28,29, Calibration Screw, Locking
30 km/h (20 MPH)) and apply the brake, repeat 5 Nut and Governor Cup
times.
Calibration screw has a notch on top of its head.
TRA III
Retorque screw to 90 to 100 N•m (66 to 74 lbf•ft).
TRA IV
Retorque screw to 125 to 135 N•m (92 to
100 lbf•ft).

 WARNING
After 10 hours of operation the transmission
system of the vehicle must be inspected
to ensure the retaining screw is properly
torqued. 1
A16D0FA

1. Notch
DRIVE PULLEY ADJUSTMENT
Governor cup has 6 positions numbered 2 to 6.
TRA III Note that in position 1 there is no stamped number
The drive pulley is factory calibrated to transmit (due to its location on casting).
maximum engine power at a predefined RPM. See TECHNICAL DATA for original setting.
Factors such as ambient temperature, altitude
or surface condition may vary this critical engine
RPM thus affecting snowmobile efficiency.

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Section 07 TRANSMISSION
Subsection 02 (DRIVE PULLEY)

A16D0GA

1. Position 1 (not numbered)

A16D0HA

Each number modifies maximum engine RPM by TYPICAL

about 200 RPM. 1. Loosen just enough to permit rotating of calibration screw

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
locking nuts to 10 N•m (89 lbf•in).
CAUTION: Do not completely remove calibra-
tion 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 number.

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 Section 07 TRANSMISSION
Subsection 03 (DRIVEN PULLEY)

DRIVEN PULLEY
SERVICE TOOLS
Description Part Number Page
driven pulley spring compressor........................................... 529 035 300 ................................. 371, 373
extractor ............................................................................... 529 035 575 ......................................... 375
pulley spring compressor .................................................... 529 035 524 ......................................... 375
pulley spring compressor ..................................................... 529 035 524 ......................... 375–376, 379
spring scale hook.................................................................. 529 006 500 ......................................... 379
support plate......................................................................... 529 031 100 ......................................... 375

SERVICE PRODUCTS
Description Part Number Page

anti-seize lubricant ................................................................ 413 701 000 ......................... 373, 376, 379
Loctite 609............................................................................ 413 703 100 ......................................... 375
pulley flange cleaner............................................................. 413 711 809 ......................................... 379

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Section 07 TRANSMISSION
Subsection 03 (DRIVEN PULLEY)

Tundra

15 N•m
(133 lbf•in)

1
2

Anti-seize
lubricant 6
9
10
3

4
5

11 13
12

14

15

15 N•m
(133 lbf•in)

A05D1JS

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 Section 07 TRANSMISSION
Subsection 03 (DRIVEN PULLEY)

NOTE: Driven pulley components (support, cam,

shoes, etc.) can be serviced without removing the
whole driven pulley from chaincase. Refer to the
following procedures but neither remove brake
caliper nor open chaincase for those cases.
A
REMOVAL
To remove driven pulley from chaincase, follow
this procedure.
Remove guard and drive belt from vehicle.
Remove brake support from chaincase with brake
ass'y.
Free countershaft support from support clamp. A05D0WA

1. 13 mm (1/2 in)
Chaincase
Open chaincase and drain oil. Unlock and remove Install driven pulley spring compressor (P/N 529
upper sprocket. 035 300). Fully tighten the 13 mm (1/2 in) exposed
The following is required to have enough space to threads in driven pulley. Tighten stop nut. Tighten
remove driven pulley from chaincase: tool knob to compress spring then remove roll pin
no. 2.
Loosen steering column upper retaining screws.
Disconnect carburetor boots from intake manifold
and air intake silencer. 2
Disconnect impulse hose from engine.
Disconnect oil injection supply line at injection 1
pump and plug line to prevent draining.
Remove screws retaining rear engine support to
chassis.
Tip engine forward just enough to allow driven pul- 3
ley removal from chaincase. Block in this position.
NOTE: In some cases, chaincase retaining screws
might have to be loosened to allow pivoting of
chaincase. In this case, note position of alignment
shims. In addition, air intake silencer and oil injec-
tion reservoir might have to be slightly moved to
get enough space to pull driven pulley.
Remove bearing cone. A05D0XB

Knock driven pulley shaft with a plastic hammer Step 1: Tighten stop nut
and pull driven pulley out. Step 2: Tighten knob to compress spring
Step 3: Remove roll pin

DISASSEMBLY Once roll pin has been removed, loosen knob until
spring pressure is completely released.
To disassemble driven pulley, driven pulley spring
compressor (P/N 529 035 300)) must be used.
See following procedure.
 WARNING
To avoid injuries always hold stop nut with
Position stop nut 13 mm (1/2 in) from threaded rod a key when loosening knob, as shown in the
end, as shown in the next photo. next photo.

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Section 07 TRANSMISSION
Subsection 03 (DRIVEN PULLEY)

ASSEMBLY
Assemble driven pulley components by reversing
the disassembly procedure except for the follow-
ing.

1 2,9, Slider Shoe

2
When replacing slider shoes, always install a new
set (3 shoes) to maintain equal pressure on the
cam.
Install slider shoes as per following photo. Red
slider shoes are being used for reverse and black
ones for forward.

A05D0YA

1. When loosening knob

2. Hold stop nut with a key

Remove tool and cam no. 3. Remove spring no. 4

and sliding half no. 10.

5, Large Bushing
Remove 3 screws no. 6 with washers and pry
bushing no. 5 out.

INSPECTION A05D14A

2,9, Slider Shoe BLACK SLIDER SHOES ON CAM

Black slider shoe = forward

Red slider shoe = reverse
Check cam slider shoes for wear. Replace when
inside edge thickness of cam slider shoe slope
base is 1 mm (.039 in) or less.

1
A05D12B

A15D0OA
3
RED SLIDER SHOES ON PULLEY HALF
1. Measure thickness of slope base here
2. Sliding pulley side
3. Slop base
2,4,5, Roller Pin, Outer Cam and Spring
Insert spring in adjusting hole no. 3 into sliding
half, as illustrated.

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 Section 07 TRANSMISSION
Subsection 03 (DRIVEN PULLEY)

A07E0CA

TYPICAL
1. Belt flush with the top of the pulley halves
A05D12A
Shim(s) no. 11 and no. 12 provide belt height ad-
1. Adjusting hole
justment between pulley halves. Adding shims
Insert other spring end in cam. Mount driven pul- will lower the belt in driven pulley, while remov-
ley spring compressor (P/N 529 035 300) as in DIS- ing shims will raise the belt. Adjust properly.
ASSEMBLY procedure.
Pulley Alignment and Drive Belt
Push cam all the way in then install roll pin coated Deflection
with anti-seize lubricant (P/N 413 701 000).
Refer to PULLEY DISTANCE AND ALIGNMENT
13,14,15, Fixed Pulley Half, Brake and DRIVE BELT to perform adjustments.
Disc and Screw CAUTION: Drive belt and pulley adjustments
Install brake disc on fixed pulley half and torque must always be checked whenever pulleys
have been removed, replaced or disassem-
screws to 15 N•m (133 lbf•in). bled.

INSTALLATION
Follow INSTALLATION procedure for Tundra driv-
en pulley at beginning of this subsection.

ADJUSTMENT
11,12, Shim
NOTE: The following adjustment must be per-
formed with a new drive belt.
For best performance, particularly at starting, top
of drive belt should be flush with top of driven
pulley halves.

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Section 07 TRANSMISSION
Subsection 03 (DRIVEN PULLEY)

Skandic LT/LT E

Anti-seize
lubricant
1

2
3
4 5

6 Red 10

7 Black 11

Loctite
609

Loctite
609
8 9

12
14

A03D3PS

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 Section 07 TRANSMISSION
Subsection 03 (DRIVEN PULLEY)

DISASSEMBLY
Use pulley 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 (P/N 529 031 100) (included in
tool) inside sliding half.
A15D36B Place extractor (P/N 529 035 575) below bushing.
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 mm (in) A03D1WB

Small bushing 38.30 (1.508) TYPICAL

1. Support plate
2. Extractor
Large bushing 108.2 (4.260)
Mount screw head of pulley spring compressor
10,11, Slider Shoe (P/N 529 035 524) in a vise.
Black slider shoe = forward Turn pulley half by hand to extract old bushing.
Red slider shoe = reverse Before bushing installation, file sliding half bore to
Check cam slider shoes for wear. Replace when remove burrs from crimping areas.
inside edge thickness of cam slider shoe slope Coat bushing outside diameter with Loctite 609
base is 1 mm (.039 in) or less. (P/N 413 703 100). Place new bushing on sliding
half and slightly tap to engage squarely the bush-
ing in the sliding.

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Section 07 TRANSMISSION
Subsection 03 (DRIVEN PULLEY)

ASSEMBLY
1
2
10,11, Cam Slider Shoe

3
When replacing slider shoes, always install a new
set (3 shoes) to maintain equal pressure on the

4
cam.

5
Install slider shoes as per following photo. Red 44°
slider shoes are being used for reverse and black

6
ones for forward.

BO
BA

M
RD
IER
1
A24D06A
2

Position guard no. 6 in cam no. 5 then insert spring

in adjusting hole no. 3 (mid-hole) into outer cam.
2
Compress outer cam using pulley spring compres-
sor (P/N 529 035 524).
1
Install spacer no. 4 then secure outer cam with
half keys no. 3, as shown in the next photo.
1
2 CAUTION: Ensure that half keys are properly in-
serted into shaft groove and that spacer recess
is facing half keys.
A03D2SA
1
1. BLACK slider shoe
2. RED slider shoe

Assemble driven pulley components by reversing

the disassembly procedure.

5,6,7, Cam, Guard and Spring

Make sure to install proper cam. Refer to TECH-
NICAL DATA.
Cam angle is identified on cam.

A03D3JA 2
1. Half keys inserted into shaft groove
2. Spacer recess facing half keys

INSTALLATION
1, Countershaft
CAUTION: Always apply anti-seize lubricant
(P/N 413 701 000) on the countershaft before
final pulley installation.

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 Section 07 TRANSMISSION
Subsection 03 (DRIVEN PULLEY)

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 disassem-
bled.

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Section 07 TRANSMISSION
Subsection 03 (DRIVEN PULLEY)

Skandic WT/WT LC/SWT/SUV/Expedition TUV

Anti-seize
lubricant

10

19

A29D2LS 2

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 Section 07 TRANSMISSION
Subsection 03 (DRIVEN PULLEY)

REMOVAL
Remove guard and drive belt from vehicle.
Remove the screw, and washer then pull the driv- 2
en pulley from the shaft.
1
DISASSEMBLY
3
Use pulley spring compressor (P/N 529 035 524). A15D0OA

Remove snap ring no. 2 and washer no. 3 to dis- 1. Measure thickness of slope base here
2. Sliding pulley side
assemble the outer cam and the 2 pulley halves. 3. Slope base

 WARNING
Driven pulley cam is spring loaded, use ASSEMBLY
above-mentioned tool.
4, Cam Slider Shoe
When replacing slider shoes, always install a new
CLEANING set (3 shoes) to maintain equal pressure on the
cam.
6, Bushing
Assemble driven pulley components by reversing
During break-in period (about 10 hours of use), the disassembly procedure.
teflon from bushing moves to cam or shaft sur-
face. A teflon over teflon running condition oc- 19, Cam
curs, leading to low friction. So it is normal to see
Coat cam interior with anti-seize lubricant.
gray teflon deposit on cam or shaft. Do not re-
move that deposit, it is not dust.
When a dust deposit has to be removed from the
INSTALLATION
cam or the shaft, use dry cloth to avoid removing CAUTION: Always apply anti-seize lubricant
transferred teflon. (P/N 413 701 000) on the shaft before final
pulley installation.
Pulley Half Cleaning
Use pulley flange cleaner (P/N 413 711 809). ADJUSTMENT
Refer to PULLEY DISTANCE AND ALIGNMENT to
INSPECTION adjust pulley distance. Adjust drive belt height in
driven pulley. Turn screws no. 10 equally accord-
6, Bushing ingly.
Check for cracks, scratch and for free movement
when assembled to fixed half. 5, Spring
General
4, Slider Shoe
It is usual to experience spring setting during
Check cam slider shoes for wear. Replace when breaking period of a new spring. The factory
inside edge of cam slider shoe slope base is worn spring preload is slightly higher (about 1 kg (2 lb))
to 1 mm (.039 in) or less. to compensate for spring setting. Specifications
in TECHNICAL DATA are applicable after break-in
period (about 10 hours of use).
Spring Torsional Pre-Load
To check spring preload adjustment, use spring
scale hook (P/N 529 006 500) and a spring scale.

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Section 07 TRANSMISSION
Subsection 03 (DRIVEN PULLEY)

Remove drive belt. Pulley Alignment and Drive Belt

Install the hook on the sliding half. Preventing Deflection
fixed half from turning, pull sliding half with the Refer to PULLEY DISTANCE AND ALIGNMENT
spring scale perpendicularly with pulley axle. and DRIVE BELT to perform adjustments.
Take 1st measurement when sliding half begins CAUTION: Drive belt and pulley adjustments
to turn. Rotate sliding half to 10 mm (3/8 in) of must always be checked whenever pulleys
rotation. Hold fish scale at this position. Slow- have been removed, replaced or disassem-
ly release tension from fish scale and take 2nd bled.
measurement when sliding half begins to return.
Spring preload is the average measurement be- 19, Cam
tween these 2. Make sure to install proper cam. Refer to TECH-
NICAL DATA.
1ST 2ND
MEASUREMENT + MEASUREMENT Cam angle is identified on cam.
(when (when = SPRING
opening) closing) PRELOAD 1
2
2

3
3.8 KG 3.4 KG 3.6 KG
(8.4 LB) (7.5 LB) (8 LB) 4
+
EXAMPLE: (when (when = ACTUAL
5

opening) closing) SPRING 44°

PRELOAD
2
6
BO

1
BA
M

RD
IER
2 529 006 500
A24D06A

NOTE: For high altitude regions, a service bulletin

will give information about calibration according to
altitude.

A01B18A

TYPICAL
Step 1: 1st measurement
Step 2: 2nd measurement

To adjust spring preload, relocate spring end in

cam, moving it clockwise to increase the preload
and counterclockwise to decrease it. Refer to
TECHNICAL DATA.
NOTE: Always recheck torsional preload after ad-
justing.

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 Section 07 TRANSMISSION
Subsection 04 (PULLEY DISTANCE AND ALIGNMENT)

PULLEY DISTANCE AND ALIGNMENT

SERVICE TOOLS
Description Part Number Page
driven pulley opening tool..................................................... 529 034 200 ......................................... 381
driven pulley opening tool..................................................... 529 035 501 ......................................... 381

GENERAL Skandic LT/LT E

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

 WARNING
Failure to correctly perform pulley alignment X Z
may cause the vehicle to creep forward at
idle.

All pulley alignment specifications refer to: 2

X = Distance between straight bar and drive pulley
fixed half edge, measured between pulleys.
Y = Distance between straight bar and drive pulley A00D0WA
1
fixed half edge, measured at the end of straight
bar. 1. Straight bar
2. Front of vehicle
Z = Distance between outside diameter of pulleys.
The distance Y must exceed distance X to com-
GENERAL PROCEDURE pensate for the twist due to the engine torque.

Remove guard.
Tundra
Use driven pulley opening tool (P/N 529 034 200).

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Section 07 TRANSMISSION
Subsection 04 (PULLEY DISTANCE AND ALIGNMENT)

Mean Value Procedure and Quick

Alignment and Distance Check 1
Alignment bar tabs must fully contact fixed half of
drive pulley.
Pulley distance is correct when tab contacts both
pulley halves. 2
Refer to chart on next page for proper alignment
bar.

3
A25D0QA

1 TYPICAL
1. Shaft
2. Alignment bar
3. Fixed half shoulder and shim(s)

Drive Belt Height

2 NOTE: When pulley distance and alignment are
adjusted to specifications, refer to DRIVE BELT to
adjust drive belt height.
CAUTION: This section deals mainly with ad-
justment procedures. For complete assembly
requirements, refer to the proper ENGINE or
TRANSMISSION installation section.

A06D0LA

TYPICAL
1. Contact (alignment)
2. Contact (distance)

Tundra
Bottom of alignment bar must not seat on shaft
nor fixed half shoulder and shim(s).

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 Section 07 TRANSMISSION
Subsection 04 (PULLEY DISTANCE AND ALIGNMENT)

PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART

PULLEY
OFFSET ALIGNMENT BAR
MODELS DISTANCE
➀ P/N
Z X Y-X
37.0 + 0 - 1.5 mm 36.0 ± 1.0 mm 0 to 1.5 mm
Tundra 529 026 900
(1.457 + 0 - 0.3 in) (1.417 ± .040 in) (0 to .060 in)
39.0 + 0 - 1.0 mm 37.0 ± 0.75 mm 0.75 to 1.5 mm
Skandic LT/LT E 529 035 808
(1.535 + 0 - .039 in) (1.457 ± .030 in) (.030 to .060 in)
41.8 + 0 - 1.0 mm 35.0 ± 0.75 mm 0.75 to 2.25 mm
Skandic WT/SWT/SUV 550 529 035 974
(1.645 + 0 - .039 in) (1.380 ± .030 in) (.030 to .086 in)
35.5 + 0 - 1.0 mm 37.0 ± 0.50 mm 0.75 to 2.25 mm
Skandic WT LC/SUV 600 529 035 545
(1.400 + 0 - .039 in) (1.456 ± .020 in) (.030 to .086 in)
37.0 ± 0.50 mm 0.75 to 2.25 mm
Expedition TUV 600 HO SDI 61 + 0 - 1.0 mm
(1.456 ± .020 in) (.030 to .086 in) (Universal)
37.0 ± 0.50 mm 0.75 to 2.25 mm 529 035 831
Expedition TUV V-1000 61 + 0 - 1.0 mm
(1.456 ± .020 in) (.030 to .086 in)

➀ Alignment bars have been made according to pulley alignment mean values. However, they do not
take into account allowed tolerances for alignment specifications. They are used as GO/NOGO gauges
for quick alignment and pulley distance check and as reference to reach alignment nominal values.

Pulley Distance Adjustment Method Move chaincase to obtain specific adjustment and
Tundra adjust driven pulley support length accordingly
(light contact).

Y
A05D0CA 2
1. Driven pulley movement
2. Engine movement

CAUTION: The rear suspension must be

mounted on the vehicle and track tension
and alignment must be done to provide the
right frame width.
Loosen the 4 chaincase retaining bolts, unlock and
raise pulley support.

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Section 07 TRANSMISSION
Subsection 04 (PULLEY DISTANCE AND ALIGNMENT)

A06D07B

1. Loosen

Engine Movement
The engine support has slotted mounting holes.
1 Move engine to obtain specified distance be-
tween pulleys.
Skandic WT/SWT/WT LC/SUV/Expedition
2 TUV
Driven Pulley Movement
Loosen gearbox retaining screws and move gear-
A05D0PA box accordingly.
Step 1: Push and hold Retighten screws.
Step 2: Raise support
Pulley Alignment Method
Skandic LT/LT E
Tundra
Y
Engine Movement
Loosen the support retaining bolts.
1 Move the engine to obtain specified pulley align-
ment, torque engine support bolts to 55 N•m
(41 lbf•ft) and remove engine support positioner.
X Z Driven Pulley Movement
Shims can be mounted between chaincase and
frame. Use shim (P/N 504 039 800), 0.53 mm
(.021 in) thick.
Skandic LT/LT E
A15D02A 2 When engine slotted mounting holes do not allow
to set proper pulley offset X, adjust with shims
TYPICAL
1. Engine movement
(P/N 504 108 200) between pulley and counter-
2. Contact shaft bearing support (pulley pushed toward brake
disc).
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.

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 Section 07 TRANSMISSION
Subsection 04 (PULLEY DISTANCE AND ALIGNMENT)

Engine Movement
Loosen the 4 bolts retaining engine support to
the 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.
1

A06D07A

1. Retighten

Skandic WT/SWT/WT LC/SUV/Expedition

TUV
Driven Pulley Movement
Loosen gearbox retaining screws.
Install or remove shims accordingly.
Retighten screws.

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 Section 07 TRANSMISSION
Subsection 05 (BRAKE)

BRAKE
SERVICE PRODUCTS
Description Part Number Page
anti-seize lubricant ................................................................ 413 701 000 ......................................... 393
brake fluid GTLMA (DOT 4) .................................................. 293 600 062 ................................. 391, 395
brake fluid SRF (DOT 4) ........................................................ 293 600 063 ................................. 391, 395
synthetic grease ................................................................... 413 711 500 ......................................... 393

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Section 07 TRANSMISSION
Subsection 05 (BRAKE)

MECHANICAL BRAKE
Tundra

Synthetic grease

12

3 Dielectric
4 grease
8
6
12
14
7
15

11
1

Loctite 76732

16

A05D1LS

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 Section 07 TRANSMISSION
Subsection 05 (BRAKE)

Skandic LT

9
Dielectric grease
2 7 5

12
Loctite 767
11
1

14
15
16

Anti-seize
lubricant

20

19

A03D3ZS

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Section 07 TRANSMISSION
Subsection 05 (BRAKE)

HYDRAULIC BRAKE
Skandic WT/SWT/WT LC/SUV/Expedition TUV

17

Loctite 243

8 N•m
(71 lbf•in)

24

A29D2QS

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 Section 07 TRANSMISSION
Subsection 05 (BRAKE)

BRAKE FLUID TYPE CAUTION: Brake pads must always be replaced

in pairs.
Use recommended brake fluid SRF (DOT 4)
(P/N 293 600 063) or brake fluid GTLMA (DOT 4) A
(P/N 293 600 062).

BRAKE PADS REPLACEMENT

Models with Mechanical Brake A30D1BA

Brake pads must be replaced when fixed pad A. 1 mm (1/32 in) minimum
projects only 1 mm (1/32 in) from caliper.
CAUTION: Brake pads must always be replaced Removal
in pairs.
Brake pads removal procedure is as follows:
1 – Remove 2 retainers from the pins.
– Pull out 2 pins which releases the spring.
– Remove the brake pads.
1 2

A15D03A A
TYPICAL
1. Fixed pad A30D1DA 3
2. Inner caliper
TYPICAL
A. 1 mm (1/32 in) minimum 1. Retainer
2. Spring
3. Pin
Removal
Pull pin no. 16 out of caliper and remove lever
no. 15.
Fixed pad is riveted to chaincase on these models.
Caliper must be split to remove moving pad. To
remove fixed pad, drill out its rivet no. 2 then pry
disc in order to free fixed pad.

Installation
Reverse removal procedure.
All Models with Hydraulic Brake
Brake pads must be replaced when lining is 1 mm
(1/32 in) thick or less.

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Section 07 TRANSMISSION
Subsection 05 (BRAKE)

Skandic LT
– 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 pulley
side to gain access to clip no. 25.
– Remove clip no. 25 on countershaft.

A30D1EA 1
TYPICAL
1. Brake pad

Installation
– Install new brake pads.
– Install spring and push 2 pins to lock the brake
pads.
– Install 2 retainers in the pin holes.

 WARNING A03D11A

Avoid getting oil on brake pads. – Pull countershaft toward driven pulley side to
free from chaincase and disc.
Press the brake lever until both new pads are – Remove disc.
touching the brake disc.
DISASSEMBLY
REMOVAL
7,15,16,23, Brake Pad, Brake Lever,
Brake Disc Removal Pin and Screw
Tundra R All Models with Mechanical Brake
The split caliper type brake should be removed Pull pin no. 16 out of caliper and remove lever
from chaincase as an assembly. Proceed as fol- no. 15.
lows:
Fixed pad is riveted to chaincase on these models.
– Remove guard. Caliper must be split to remove moving pad. To
– Disconnect brake cable. removed fixed pad, drill out its rivet no. 2 then pry
– Remove bolts no. 8 securing brake support to disc in order to free fixed pad.
chaincase. All Models with Hydraulic Brake
– Slide brake caliper ass'y out of brake support.
Only brake pads are available as spare parts. If
– To remove brake disc, driven pulley has to be caliper or master cylinder are damaged, replace
removed first. Refer to DRIVEN PULLEY. each of them as an assembly.
Skandic WT/SWT/WT LC/SUV/Expedition
TUV
– Remove caliper by unscrewing M10 Allen
screws.
– Unbolt disc.

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 Section 07 TRANSMISSION
Subsection 05 (BRAKE)

CLEANING CAUTION: Brake pads must always be replaced

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 replace as required.
ones.
CAUTION: Brake disc should never be ma-
INSPECTION chined.

7, Brake Pad ASSEMBLY

Models with Mechanical Brake
14, Ratchet Wheel
Brake pads must be replaced when fixed pad
projects only 1 mm (1/32 in) from caliper. Apply synthetic grease (P/N 413 711 500) on
threads and spring seat prior to installing. Fully
CAUTION: Brake pads must always be replaced tighten then back off one turn.
in pairs.
1
16, Pin
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
Avoid getting oil on brake pads. Do not lubri-
cate or apply antirust or antifreeze solution in
brake cable.

2
17, Brake Disc
Skandic LT
A15D03A A The brake disc must be floating on countershaft
TYPICAL for efficient operation of brake.
1. Fixed pad
2. Inner caliper Apply anti-seize lubricant (P/N 413 701 000) on
A. 1 mm (1/32 in) minimum shaft and check that disc slides freely.
Models with Hydraulic Brake The disc hub exceeds the disc more from one side
than from the other. Install disc with the longer
Brake pads must be replaced when lining is 1 mm exceeding portion toward driven pulley.
(1/32 in) thick.
A

A30D1BA

A. 1 mm (1/32 in) minimum

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Section 07 TRANSMISSION
Subsection 05 (BRAKE)

Push O-rings inside disc hub. 1,11,12, Locking Tab, Outer Caliper
and Nut
Skandic LT
Install caliper retaining bolts.
Assemble outer caliper. Install locking tab then
nuts. Torque nuts to 24 N•m (18 lbf•ft). Bend
locking tab over a flat of each nut.

5,12, Brake Cable and Nut

Insert brake cable into upper hole in brake lever
and caliper. Install nut and tighten until a few
threads exceed.

 WARNING
A03D13A At least 3 threads must exceed the elastic stop
nut.
7, Brake Pad
Models with Hydraulic Brake 24, Upper Clamp
After brake pads installation, brake disc must be Models with Hydraulic Brake
centered in caliper. Apply brake then check for
proper brake disc positioning. Install upper clamp with its arrow pointing at front
of vehicle. Tighten to 8 N•m (71 lbf•in) front
Push on appropriate caliper piston in order to screw before rear one.
move pad inward allowing proper brake disc po-
sitioning. 2 1

1 2

A03D3QB

TYPICAL
1. Arrow on upper clamp pointing at front of vehicle
2. Tighten front screw first
A03D2KA

1. Brake disc not centered

2. Brake disc centered
3. Apply brake before checking

Apply brake then recheck.

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 Section 07 TRANSMISSION
Subsection 05 (BRAKE)

ADJUSTMENT BLEEDING
Brake Change brake fluid once a year.
Models with Mechanical Brake Bleed brake system as follows:
Fully depress brake handle several times to obtain Keep sufficient brake fluid SRF (DOT 4) (P/N 293
13 mm (1/2 in) between brake handle and handle- 600 063) or brake fluid GTLMA (DOT 4) (P/N 293
bar grip when brake is fully applied. 600 062) 4 brake fluid in reservoir at all times.
CAUTION: Use only SRF (DOT 4) (P/N 293 600
A 063) or GTLMA (DOT 4) (P/N 293 600 062) brake
fluid.
Install a clear hose on left side bleeder. Route this
hose to a container. Open bleeder.
Pump brake lever until no air escapes from hose.
Close bleeder.
A08G02A Proceed the same way with the right side bleeder.
A. 13 mm (1/2 in)
1
Should this adjustment be unattainable, retighten
nut no. 12 as needed.
Models with Hydraulic Brake
There is no adjustment on these models.
Change brake fluid once a year.
If brake handle feels spongy or if hydraulic system
has been opened, the system must be bled, refer
to BLEEDING PROCEDURE.
A06D0JA 2
Brake Light TYPICAL
Skandic LT and Tundra Models Only 1. Open bleeder
2. Clear hose to catch used brake fluid
Brake light should light up before brake pads touch
brake disc. To adjust, unscrew nut no. 12 until  WARNING
brake light goes on. Avoid getting oil on brake pads. Do not lubri-
 WARNING cate or apply antirust or antifreeze solution in
brake cable.
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.

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 Section 07 TRANSMISSION
Subsection 06 (CHAINCASE)

CHAINCASE
SERVICE TOOLS
Description Part Number Page

drive axle holder ................................................................... 529 007 200 ................................. 399, 402
pusher................................................................................... 529 035 584 ......................................... 402

SERVICE PRODUCTS
Description Part Number Page
Loctite 20166........................................................................ 293 800 066 ......................................... 400
Loctite 609............................................................................ 413 703 100 ......................................... 402
XP-S mineral chaincase oil.................................................... 413 801 900 ......................................... 400
XP-S synthetic chaincase oil ................................................. 413 803 300 ......................................... 403

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Section 07 TRANSMISSION
Subsection 06 (CHAINCASE)

Tundra

7 Synthetic grease
10
9
1 Chaincase oil
10
9
11
12
13
28
4 14 15
5

Chaincase
2 oil
3
6

Loctite
20166

27

17 18
25
22 30
26

19

23
A05D1KS

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 Section 07 TRANSMISSION
Subsection 06 (CHAINCASE)

REMOVAL Remove chaincase cover no. 20 and drain oil.

Chaincase and driven pulley can be removed from Remove right side drive axle bearing cover.
the vehicle as an assembly. Remove circlip no. 17.
Remove guard and drive belt. Move drive axle and track together to the right side
Unlock and raise driven pulley support. as far as possible.
Unscrew the nut no. 14 on the upper sprock-
et no. 12. Remove chain tensioner assembly
no. 2 to 6, then simultaneously remove chain
no. 18 and both sprockets.
Remove the 4 cap screws no. 26 securing chain-
case to frame.

Chaincase and Driven Pulley Assembly

Using 2 large prybars inserted between chaincase
and frame, pry complete assembly from vehicle.

DISASSEMBLY
Disassemble driven pulley from chaincase. Refer
to DRIVEN PULLEY.

INSPECTION
1
Visually inspect the chain for cracked, damaged or
missing link rollers. Check for defective bearings,
sprockets and worn chain tensioner components.
2
 WARNING
If chain deflection is greater than 38 mm
(1.5 in) (without chain tensioner), replace
A05D0PA
chain and check condition of sprockets.
Step 1: Push and hold
Step 2: Raise support

Release track tension. Install drive axle holder ASSEMBLY

(P/N 529 007 200). Position oil deflector ring no. 10 then sit bearing in
chaincase aperture. Install spacer then the other
1 bearing.
529 007 200

A01B1FA

1. Drive axle
2. Suspension cross shaft

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Section 07 TRANSMISSION
Subsection 06 (CHAINCASE)

Check the oil level by removing the chaincase oil

level plug.

1 1

2 3 2
A01D0FA

1. Toward chaincase
2. Oil deflector
A03D02A
3. Bearing
1. Filler cap
2. Oil level plug
1, Oil Seal
Using an appropriate pusher, press new oil seal The oil should be leveled with the bottom of the
no. 7 into chaincase hub. Oil seal must sit flush oil level orifice.
with case hub edge. Reinstall battery and connect cables on electric
starting models.
INSTALLATION CAUTION: Always connect positive RED cable
first to prevent sparks.
Reverse removal procedure. Pay particular atten-
tion to the following:
ADJUSTMENT
Torque castellated nut 14 to 14 N•m (124 lbf•in),
loosen then retorque to 0.5 - 2.5 N•m Pulley Alignment
(5 - 22 lbf•in).
Refer to PULLEY DISTANCE AND ALIGNMENT.
Apply Loctite 20166 (P/N 293 800 066) around
both threaded holes of cover screws. Track Tension and Alignment
Grease new gasket no. 19 with petroleum jelly, or Refer to TRACK.
other suitable product, and install it making sure
it does not shift from its correct position. Tighten
bolts evenly.
NOTE: Bottom pan has an emboss below chain-
case housing to ease installation.

Chaincase Oil
Remove filler cap and pour 250 mL (8.5 fl. oz) of
XP-S mineral chaincase oil (P/N 413 801 900) into
chaincase.
NOTE: Chaincase oil capacity is 250 mL (8.5 fl. oz).

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 Section 07 TRANSMISSION
Subsection 06 (CHAINCASE)

Skandic LT

Chaincase
oil

12 24
22
Loctite
271

7 23
11
25
Loctite 27
243

Loctite 243
8
10
9
Synthetic
grease

Loctite 243 20
19
14
3
60 N•m 4 6
(44 lbf•ft) 5 27
26 17

16 Loctite 271

Loctite 515
46 N•m 18 19
(34 lbf•ft) 15 14

13

A03D3YS
Loctite 271

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Section 07 TRANSMISSION
Subsection 06 (CHAINCASE)

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 and check condition of sprockets.
Remove hair pin no. 8. Release drive chain ten-
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
and drive chain simultaneously. Remove shims Refer to TECHNICAL DATA for gear ratios.
no. 6 and no. 17. CAUTION: Gear ratio modifications should
NOTE: Should countershaft removal be required, only be performed by experienced mechanics
refer to BRAKE then look for BRAKE DISC. since they can greatly affect vehicle perfor-
mance.
Remove 5 nuts no. 14. Three nuts are behind the
lower sprocket. NOTE: For high altitude regions, a Service Bulletin
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 INSTALLATION
(P/N 529 007 200).
Reverse removal procedure and pay attention
1 to the following. Replace oil seals, gaskets and
O-rings.
529 007 200
Sealed side of bearing no. 27 must face chaincase
cover.

11, Oil Seal

Clean chaincase bore with cleaning solvent then
apply Loctite 609 (P/N 413 703 100) to oil seal
2 mounting surface (outside).
Using pusher (P/N 529 035 584), press the oil seal
A01B1FA
into chaincase hub. Oil seal must fit flush with the
TYPICAL chaincase edge.
1. Drive axle
2. Suspension cross shaft NOTE: Should installation procedure for counter-
shaft be required, refer to BRAKE then look for
Pry out drive axle oil seal no. 20 from chaincase. BRAKE DISC AND COUNTERSHAFT BEARING
Pull chaincase from drive axle and countershaft. ADJUSTMENT.
Using 2 prybars inserted between chaincase no. 7 5,16, Sprockets
and frame, pry complete assembly from vehicle.
Position the sprockets with the writing facing the
chaincase cover.

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 Section 07 TRANSMISSION
Subsection 06 (CHAINCASE)

26, Conical Spring Washer CAUTION: Free-play must not exceed 5 mm

Install washer with its concave side towards (13/64 in), readjust if necessary.
sprocket.
 WARNING
If the specified free-play is not reached with
the tensioner screw fully tightened, replace
chain and check the condition of sprockets.

21, Chaincase Oil

Pour 250 mL (8.5 fl. oz) of XP-S synthetic chain-
A03D14A
case oil (P/N 413 803 300) into chaincase.
Check oil level with the dipstick then add if re-
4, Upper Sprocket Castellated Nut quired. Remove metal particles from magnet.
Torque to 60 N•m (44 lbf•ft).
Install new cotter pin in the position shown.
CAUTION: When removing a cotter pin always
replace with a new one.
CAUTION: Cotter pin will rub on chaincase cov-
er if installed otherwise.

1 1
2

A02D08A

1. New
2. Fold cotter pin over castellated nut flats only

18, Circlip
A03A03A
CAUTION: It is of the utmost importance to in-
stall the circlip otherwise damage to the chain- TYPICAL
case components may occur. 1. Dipstick

NOTE: Chaincase must be in its proper position

DRIVE CHAIN ADJUSTMENT when checking oil level.
NOTE: Brake disc key must be in good condition
before checking chain free play. ADJUSTMENT
10, O-Ring Pulley Alignment
Replace both O-rings no. 10 on tensioner adjust- Refer to PULLEY DISTANCE AND ALIGNMENT.
ment screw. Fully tighten tensioner adjustment
screw by hand, then back off only far enough for Track Tension and Alignment
hair pin to engage in locking hole. Refer to TRACK.
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.

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 Section 07 TRANSMISSION
Subsection 07 (GEARBOX)

GEARBOX
SERVICE PRODUCTS
Description Part Number Page
synthetic grease ................................................................... 413 711 500 ......................................... 415
XP-S synthetic chaincase oil ................................................. 413 802 800 ......................................... 418

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Section 07 TRANSMISSION
Subsection 07 (GEARBOX)

3-SPEED GEARBOX
Skandic WT/SWT/WT LC/SUV/Expedition TUV

Skandic WT/SWT 4

2
3
5

7
42
40-41
9
15
39
14
Loctite 18 16
243 10 13
12 Loctite 243
4 19
17
11 10
38 9
8
20
18 16 10
9
10 8

23
SWT/SUV only
21
22
26
24 27
Synthetic 25 10
33 grease 9
34
41

35 28
36 29
28
30
31
30
Synthetic
10 grease
9
37
A29D2MU

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 Section 07 TRANSMISSION
Subsection 07 (GEARBOX)

REMOVAL
Drain gearbox oil.

A29D0NA 1
1. RH end bearing

1
Unbolt gearbox from chassis.
A29D0LA

1. Bottom pan drain hole nearby gearbox drain plug

Remove belt guard, drive belt. Remove air si-

lencer and carburetor(s); then remove driven
pulley.
Remove brake caliper, brake disc. Unfasten shift-
ing rod and unplug reverse switch.

A29D0OA

DISASSEMBLY
General
For the following procedure, right hand side refers
to driven pulley side and left hand side to brake
A29D0MA disc side.

Remove rear suspension.

Remove angle drive and square pin from bottom
of gearbox.
Remove muffler. Unbolt RH end bearing then pull
drive axle toward right side.

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Section 07 TRANSMISSION
Subsection 07 (GEARBOX)

2 1

A29D0PA

1. RH side driven pulley side A29D0RA

2. LH side brake disc side
1. Pin

Shaft Completely remove shaft no. 5.

Remove dipstick no. 17. Unfasten cover no. 2
from gearbox housing.
Plug
Remove LH side rubber plugs no. 8 and oil seal
Remove nut no. 3 retaining pin no. 6.
no. 41.
1 Remove RH side oil seal no. 41.

A29D0QA 2
A29D2TA
1. Cover
2. Nut
Drill a 10 mm (3/8 in) diameter hole through RH
Unfasten sleeve nuts no. 4, remove spring no. 7 side plugs no. 40.
then, partially pull shaft no. 5 and remove pin
no. 6.

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 Section 07 TRANSMISSION
Subsection 07 (GEARBOX)

A29D2UA
1

2
Brake Shaft A29D2WA

Remove all circlips no. 9. 1. Driven shaft bolt

2. Washer

Proceeding from right side, drive brake shaft

no. 26 out of gearbox housing.

A29D0UB

IMPORTANT: Note all shims no. 10 quantity and

location.
A29D2UA

A29D2VA

1. Note shims location A29D0WA

Remove driven shaft bolt no. 11 and washer.

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Section 07 TRANSMISSION
Subsection 07 (GEARBOX)

NOTE: Brake shaft gears and sleeve remain in Drive reverse shaft no. 38 out until its LH side
gearbox housing. bearing is free.
Remove bearing no. 27 from brake shaft no. 26 CAUTION: Make sure loose gears do not inter-
using a press. fere.
1

A29D0ZA 2
1. Sleeve dog not touching right gear
2. Brake shaft gears are still in gearbox

Use a puller to extract LH reverse shaft bearing.

A29D0XA

Reverse Shaft
Make sure gears mesh.

A29D2YA

Remove reverse shaft no. 38 from gearbox.

Remove loose gears.
A29D0YA 1
To remove sliding sleeve from reverse shaft, first
1. These gears must mesh as reverse shaft is driven out remove circlip.
Push sleeve dog against gear to lock it in place NOTE: Take care not to loose balls no. 18 and
(reverse gear). spring no. 16 when removing sliding sleeve.
This will allow the driven pulley shaft to be pushed
out enough for bearing removal and sliding sleeve
dog will not touch the RH gear of driven pulley
shaft no. 15.

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 Section 07 TRANSMISSION
Subsection 07 (GEARBOX)

A29D11A
A29D2ZA

1. Circlip
2. Sliding sleeve PUSH DRIVEN PULLEY SHAFT OUT

Use a puller to extract bearing no. 19.

A29D30A

LH GEAR IS AGAINST GEARBOX INNER WALL

Use a puller and a puller retaining plate to extract

A29D12A bearing no. 12.

Remove brake shaft gears.

Pulley Shaft
Push driven pulley shaft no. 15 out of gearbox until
its LH gear no. 14 is against gearbox inner wall.

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Section 07 TRANSMISSION
Subsection 07 (GEARBOX)

Remove sealant around caps no. 40.

1
3

2
A29D31A

1. Puller
2. Puller retaining plate
3. Bearing A29D32A

Remove circlip then, gear no. 14. Now driven pul- Remove caps no. 40.
ley shaft can be pulled out from gearbox.
Remove sliding sleeve taking care not to lose balls
no. 18 and spring no. 16.

A29D33A

NOTE: Brake shaft bearing and shims will come

out with cap no. 40.
A29D16A 1 2-3
1. Sliding sleeve
2. Spring
3. Balls

A29D34A

A29D17A

DRIVEN PULLEY SHAFT COMPONENTS

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 Section 07 TRANSMISSION
Subsection 07 (GEARBOX)

Intermediate Shaft
Remove screws no. 39 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
A29D18A
M8 x 1.25
Do not disassemble bearings of intermediate
Remove intermediate gears and spacers. gears needlessly.
Pry out bottom seal no. 33 from gearbox housing.
Remove circlip no. 9.

A29D1BA

Drive out plug no. 37.

A29D19A

1. Spacer

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Section 07 TRANSMISSION
Subsection 07 (GEARBOX)

A29D1CA A29D1EA

Remove circlip no. 9 from LH side.

INSPECTION
Check bearing condition. There must be no dis-
coloration, 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

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 Section 07 TRANSMISSION
Subsection 07 (GEARBOX)

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
2. Recess
A29D1GA

Install sleeve no. 23 on brake shaft no. 26 then,

Apply synthetic grease (P/N 413 711 500) on inter- slide gears and sleeve until end of sleeve is flush
mediate shaft no. 30 O-rings. with shaft end.
Install intermediate gears no. 29 with their shoul-
der towards LH side. Position spacers no. 28 as
illustrated in removal procedure. Beveled side of
spacers goes against gearbox wall.
Install new caps no. 40.
Install the appropriate premarked shims no. 10.
Using a pusher, install RH side bearing of brake
and reverse shafts.

A29D1JA 1
1. Flush

1 Install brake shaft no. 26 into gearbox then, loose-

ly install gear no. 22 with its shoulder facing bear-
ing no. 21. Do not push brake shaft into bearing
no. 21 at this time.

A29D35A

1. Bearings installed

Partially assemble brake shaft gears no. 24 and

no. 25 with shoulder facing recess.

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Section 07 TRANSMISSION
Subsection 07 (GEARBOX)

1
A29D36A

1. Gear loosely installed

2. Brake shaft assembly A29D1LA

1. Finalizing brake shaft insertion

Install reverse shaft ass'y no. 38 into its RH side
bearing no. 19. Install driven pulley shaft no. 15 with the sliding
sleeve loosely inserted. Gear no. 14 must be at
its place.

A29D1MA 2 1
A29D1KA 1. Sliding sleeve loosely inserted
2. Gear no. 14 in place
1. Reverse shaft installed in its RH bearing
Install balls no. 18 and spring no. 16 into driven
Position gear no. 22 against RH side bearing pulley shaft.
no. 19 then, finalize brake shaft no. 26 insertion.
NOTE: If necessary, partly install bearing in gear-
box to ease installation of balls and spring.

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 Section 07 TRANSMISSION
Subsection 07 (GEARBOX)

A29D1NA 1 A29D1OA

1. Push on ball with a screwdriver then move sliding READY TO INSTALL BEARINGS, SHIMS, CIRCLIPS AND PLUGS
sleeve to the right
CAUTION: Make sure that gearbox is well
Finalize driven pulley shaft insertion. Make sure supported before inserting driven pulley shaft
that gears mesh during insertion. Install circlip bearing, see photo.
no. 20.

A29D1PA 1
1. Circlip A29D2XA

Install LH side bearings no. 42, 19 and 21, shims

no. 10, circlip no. 9 then, plugs no. 40 and oil seal INSTALLATION
no. 41.
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.

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Section 07 TRANSMISSION
Subsection 07 (GEARBOX)

1
A29D0IA

1. Full level mark

2. Lower level mark

To fill, remove filler plug from top of transmission.

Refill as required using XP-S synthetic chaincase
oil (P/N 413 802 800).

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 Section 07 TRANSMISSION
Subsection 08 (DRIVE CHAIN)

DRIVE CHAIN
GENERAL
Bombardier drive chains exist in 2 types, for prop-
er use refer to TECHNICAL DATA.

1
A00D0RA

1 TYPICAL
1. Rotation

CHAIN SEPARATION
When separating an endless chain, always use a
chain bearing pin extractor. Also, make sure to
remove one complete link.
A00D0QA 2
1. 1/2 in single
2. 3/8 in silent chain

SILENT CHAIN
There are 2 types of silent chain. One is 11-plates
wide and the other is 13-plates wide (stronger). A00D0MA

Do not interchange sprockets. Fit chain on

sprockets to make sure using right ones accord- NOTE: Chain connecting link should only be used
ing to width. Refer to TECHNICAL DATA. to lengthen or shorten a chain when changing the
NOTE: No work (separation, lengthening) can be sprocket(s) for one(s) with a different number of
done on the silent chain type. teeth. A stretched chain must never be shortened
because the chain pitch has changed (increased)
and will not properly match the sprocket pitch,
CHAIN ATTACHMENT causing premature wear.
When joining chain ends, the open end of the cir- NOTE: Refer to TECHNICAL DATA, for chain
clip must be on opposite side of chain rotation. length according to gear ratio of each specific
The circlip should also be facing the outer side of vehicle.
chaincase.

 WARNING
Always ensure that the connecting link circlip
is in good condition and is properly secured.

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Section 07 TRANSMISSION
Subsection 08 (DRIVE CHAIN)

A A

A B

C C

C
E D
D A00D0OA

F LENGTHENING 1 LINK
A. Connecting link
B. Inner link
C. Outer link
D. Circlip

A00D0NA

LENGTHENING 1/2 LINK

A. Connecting link
B. Link pin
C. Cranked link
D. Cotter pin
E. Outer link
F. Circlip

A
D D

B
C

E
F F

A00D0PS

LENGTHENING 1-1/2 LINKS

A. Connecting link
B. Outer link
C. Cranked link
D. Link pin
E. Circlip
F. Cotter pin

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 Section 08 ELECTRICAL
Subsection 01 (IGNITION TIMING)

IGNITION TIMING
SERVICE TOOLS
Description Part Number Page
9 volt adapter........................................................................ 529 035 675 ......................................... 428
digital induction type tachometer ......................................... 529 014 500 ......................... 422, 424, 427
MPEM programmer.............................................................. 529 035 878 ......................................... 428
supply cable.......................................................................... 529 035 869 ......................................... 428
TDC gauge ........................................................................... 414 104 700 ......................... 421, 423, 426
Vehicle Communication Kit (VCK) ......................................... 529 035 981 ................................. 428, 431

277 Engine Type

This 277 engine type is equipped with a Rotax
414 104 700
Electronic Reverse system (RER). It uses a single
coil ignition system and 2 trigger coils. Refer to
MAGNETO SYSTEM for more information.
This section is mainly divided in 2 parts, the first • Rotate magneto flywheel clockwise until pis-
one using a Top Dead Center gauge to VERIFY ton is just Before Top Dead Center.
THE MAGNETO FLYWHEEL TIMING MARK POSI-
TION. The second one using a stroboscopic timing 1

90

80
light to CHECK IGNITION TIMING. 70

0
10

60
2

50
20
Flywheel timing mark position verification is re-

30

40
quired to:
3
– To detect a missing or broken magneto flywheel
Woodruff key which change the timing, with
eventual break down of the engine. 4
– To correctly locate and mark a timing mark on a
new service magneto flywheel.
– To verify the correct location of the factory tim-
ing mark.
A03E01A
– To detect a wrong magneto flywheel corre-
sponding to a different engine type. 1. Outer ring
2. Adaptor lock nut
Always verify magneto flywheel timing mark posi- 3. Roller lock nut
4. Adaptor
tion before checking ignition timing.

Verifying Magneto Flywheel Timing • Loosen adaptor lock nut then holding gauge
Mark Position with dial face toward magneto, screw adap-
tor in spark plug hole.
– Disconnect spark plug wire and remove spark • Slide gauge far enough into adaptor to obtain
plug. a reading then finger tighten adaptor lock nut.
– Install and adjust TDC gauge (P/N 414 104 700) • Rotate magneto flywheel clockwise until pis-
on engine as follows: ton is at Top Dead Center.
• Unlock outer ring of dial and turn it until “0”
(zero) on dial aligns with pointer.

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Section 08 ELECTRICAL
Subsection 01 (IGNITION TIMING)

• Lock outer ring in position.  WARNING

– From this point, rotate magneto flywheel back Place ski tips against a wall, raise rear of vehicle
1/4 turn then rotate it clockwise to reach the on a stand so that track does not contact the
specified position. Refer to TECHNICAL DATA. ground. Do not allow anyone in front or behind
Check if red fin aligns with mark on fan cowl. the vehicle while engine is running. Keep clear
of track and do not wear loose clothing which
1 2 can get caught in moving parts.

– Start the engine and point timing light straight

in line with the fan cowl timing mark. Bring
engine to 3500 RPM (3000 to 4000 RPM) for
a brief instant.

A05E0TA

1. Fan cowl timing mark

2. Red fin

If marks do not align, there is something wrong 1

with fan mounting. Check Woodruff key and fan. A05E03A 2
CAUTION: Always check the timing with a TYPICAL — TUNDRA
stroboscopic timing light at 3500 RPM after the 1. Fan cowl timing mark
2. Red fin
marks have been checked.

Checking Ignition Timing – Check if the red fin aligns with the fan cowl
timing mark. Tolerance is ± 1°.
NOTE: To perform this procedure we strongly rec-
ommend a stroboscopic timing light which is able If the red fin aligns with the fan cowl timing mark,
to exceed 3500 RPM. timing is correct. If not the case, check for proper
flywheel, trigger coil position or MPEM.
– Connect timing light pickup to the spark plug
lead. Use a digital induction type tachometer The RER ignition system is not adjustable. Only
(P/N 529 014 500). trigger coil air gap can be verified. Refer to MAG-
NETO SYSTEM.
443 and 552 Engine Types
529 014 500 If for any reason, ignition timing accuracy is sus-
pected, it can be verified as follows.
NOTE: Ignition timing can not be adjusted (trigger
coil is fixed). If ignition timing is not within spec-
ifications, a component is either defective or bro-
ken.
TACHOMETER

Connect tachometer wire to spark plug wire or aim

tachometer toward spark plug wire without using
any connection wire.

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 Section 08 ELECTRICAL
Subsection 01 (IGNITION TIMING)

Verifying Magneto Flywheel Timing

Mark Position 2
Prior to checking the timing, it may be necessary 1
to verify the position of the timing mark on the
magneto flywheel, for the following reasons:
– 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.
– To correctly locate and mark a timing mark on a
new service magneto flywheel.
– To verify the correct location of the factory tim-
ing mark.
– To detect a wrong magneto flywheel corre-
sponding to a different engine type.
To verify the position of the timing mark on the
A17E0YA
magneto flywheel, proceed as follows:
– Clean the area around the spark plugs, and re- TYPICAL — INSTALLATION OF TDC GAUGE
1. Gauge on MAG side cylinder
move them. 2. Adaptor lock nut
– Remove the rewind starter from the engine.
– Install the TDC gauge (P/N 414 104 700) in the • Assemble the gauge to the adaptor and tight-
spark plug hole (magneto side) and adjust as en the roller lock nut. Do not tighten the
follows: adaptor lock nut.
• Screw the adaptor into the spark plug hole
and tighten to prevent movement in the plug
414 104 700 hole.
• Position the dial face toward the magneto.
Move the gauge down until the needle just
begins to move, then move down a further
• Position the magneto flywheel at approxi- 5 or 6 mm (approximately 1/4 in). Tighten
mately TDC. adaptor lock nut by hand.
– Locate the piston TDC position as follows:
• Slowly rotate the magneto flywheel back and
forth across TDC while observing the needle.
Note that the needle stops moving only as
the piston changes direction.
• Rotate the dial face so that “0” is in line with
the needle when it stops moving.
• Again, slowly rotate the magneto flywheel
back and forth across TDC and adjust the dial
face to “0”, until the needle always stops
exactly at “0” before changing direction.
• “0” now indicates exact TDC.
• Verify the position of the timing mark on the
magneto flywheel as follows:

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Section 08 ELECTRICAL
Subsection 01 (IGNITION TIMING)

NOTE: When checking timing, certain procedures • Scribe or punch a mark on magneto flywheel
require that the magneto flywheel be turned in a so that it perfectly aligns with the arrow on
clockwise direction, viewed facing the magneto. crankcase, refer to illustration. This new tim-
If it is necessary to turn back (counterclockwise) ing mark should be used for future timing
for any reason, rotate the magneto flywheel at checks (dynamic timing).
least one-quarter turn counterclockwise, and then • Reinstall rewind starter.
rotate it clockwise. The last magneto flywheel • Check the timing with a timing light.
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. 1
a. Rotate the magneto flywheel counterclock-
wise, one-quarter turn then carefully rotate
2
it clockwise until the needle indicates the
specified measurement. Refer to TECHNICAL
DATA.
b. Verify that the magneto flywheel mark perfect-
ly 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 ap-
propriate ones and if Woodruff key is in good
condition, continue the procedure.
2 A17E0ZA 3
1 TYPICAL
1. Crankcase arrow
2. Scribe a mark here
3. Maintain verified timing marks aligned (static timing)

Checking Ignition Timing

Use a timing light and digital induction type
tachometer (P/N 529 014 500).

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 TACHOMETER
timing light: a new mark must be scribed on mag-
neto flywheel for this purpose. To check the ignition timing, refer to illustration
and proceed as follows:
– Scribe a new mark on magneto flywheel as fol-
lows.
• Remove the fan cover from the engine.
• Maintain magneto flywheel so that previous
marks remain aligned.

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 Section 08 ELECTRICAL
Subsection 01 (IGNITION TIMING)

 WARNING
Place ski tips against a wall, raise rear of vehicle
on a stand, so that track does not contact the
ground. Do not allow anyone in front of or be-
hind the vehicle while engine is running. Keep
clear of track and do not wear loose clothing
which can get caught in moving parts.

– Connect the timing light pickup to a spark plug

cable.
NOTE: To avoid an incorrect reading due to paral-
lax, view the magneto flywheel and the crankcase
timing marks in a straight line.
2 1
– Connect tachometer wire to spark plug wire or
aim tachometer toward spark plug wire without
using any connection wire.
– Start the engine and raise the engine speed to
3500 RPM while observing the timing marks,
refer to illustration.
NOTE: Ignition timing may be verified when en-
gine speed is anywhere within 3000 - 4000 RPM.
3
A03E1EA

1. Timing light pickup on MAG side

2. Crankcase arrow
3. Magneto flywheel mark

– The magneto flywheel mark scribed previous-

ly and the crankcase arrow should be perfect-
ly aligned. If the marks do not align, a faulty
trigger coil (check proper grounding of coil), a
faulty flywheel, a faulty Woodruff key, a mis-
aligned (twisted) crankshaft or a faulty CDI mod-
ule could be the cause: substitute one part at a
time and recheck timing marks (check connec-
tors condition prior to substituting any part).
– Install parts which were removed.

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Section 08 ELECTRICAL
Subsection 01 (IGNITION TIMING)

593 and 593 HO SDI Engine Types

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- 1
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
alignment. This might be the indication of a twist-
ed crankshaft. Refer to LEAK TEST AND ENGINE 2
DIMENSION MEASUREMENT. The ignition tim-
ing 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.

Scribing a Timing Mark

– Clean the area around the MAG spark plug, and
remove it. A06E2BA

– Install the TDC gauge (P/N 414 104 700) in the TYPICAL
spark plug hole, (magneto side) and adjust as 1. TDC gauge on MAG side
2. MAG side piston at TDC
follows:
• Position the MAG piston at approximately • Assemble the gauge to the adaptor and tight-
TDC. en the roller lock nut. Do not tighten the
adaptor lock nut.
• Screw the adaptor into the spark plug hole
and tighten to prevent movement in the plug
hole.
• Position the dial face toward the PTO. 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 adap-
tor lock nut by hand.
– Locate the piston TDC position as follows:
• Slowly rotate the drive pulley back and forth
across TDC while observing the needle.
Note that the needle stops moving only as
the piston is changing direction.
• Rotate the dial face so that “0” is in line with
the needle when it stops moving.
• 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.

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 Section 08 ELECTRICAL
Subsection 01 (IGNITION TIMING)

• “0” now indicates exact TDC.

– Rotate the drive pulley clockwise, one-quarter
turn then carefully rotate it counterclockwise
until the needle indicates the specified mea-
surement, indicated in TECHNICAL DATA.
– Twist a wire as shown and use it as a pointer.
Install the wire on upper starter bolt.

A29E0TA 1
TYPICAL
1. Timing mark in line with pointer end

Checking Ignition Timing

Use a timing light.
A29E0RA 1 To check the ignition timing, refer to illustration
and proceed as follows:
TYPICAL
1. Pointer
 WARNING
– With the TDC gauge indicating specified timing, Place ski tips against a wall, raise rear of vehicle
scribe a mark on drive pulley fixed half in line on a stand, so that track does not contact the
with pointer end. ground. Do not allow anyone in front of or be-
hind the vehicle while engine is running. Keep
clear of track and do not wear loose clothing
which can get caught in moving parts.

– Connect the timing light pickup to a spark plug

cable.
Connect a digital induction type tachometer
(P/N 529 014 500).

529 014 500

A29E0SA 1
TYPICAL
1. TDC gauge indicating specified timing
TACHOMETER

– Start the engine and point timing light on timing

mark. Bring engine to 3500 RPM.

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Section 08 ELECTRICAL
Subsection 01 (IGNITION TIMING)

A29E0UA A29E0WA

TIMING ADVANCED BY ABOUT 2°

The timing mark must be aligned with pointer end.
If such is not the case, note if timing is retarded or
advanced. Tolerance is ± 1°. Changing Ignition Timing
593 Engine
Timing can be changed using the MPEM program-
mer (P/N 529 035 878) or using the Vehicle Com-
munication Kit (VCK) (P/N 529 035 981). See 593
HO SDI engine for more information on the VCK
kit or follow the procedure below when using the
MPEM programmer.
Connect the 9 volt adapter (P/N 529 035 675) to
supply cable (P/N 529 035 869) and supply cable
to diagnostic connector.

529 035 675

A29E0VA

TIMING RETARDED BY ABOUT 2°

A32E2VA 529 035 869

Connect MPEM programmer to DESS post.

Turn on programmer then enter password.
From main menu select no. 3 INFO VEHICLE.

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 Section 08 ELECTRICAL
Subsection 01 (IGNITION TIMING)

Now the display shows the engine timing correc-

tion factor that is programmed in the MPEM. In
1. CHECK KEYS the following example timing correction factor is
2. PROGRAM KEY no. 4.
>3. VEHICLE INFO
4+ S TA RT V E H .
TIMING<1-8>:4
A30E1XA

Vehicle information is transferred from MPEM to P R E S S A N Y K E Y. . .

programmer.
A30E21A

Press any key.

TRANSFER
Select YES using the key
PGMR MPEM

A30E1YA

NOTE: In fact the programmer takes a copy of all

MODIFY?
vehicle parameters scribed in MPEM. This copy
will be modified within the programmer then
transferred to the MPEM. YES NO
Select no. 4 ENGINE PARAMETER.
A00A3DA

Press ENTER.
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 . TIMING<1-8>:

A30E1ZA

Select no. 1 TIMING ADJUSTMENT.

A30E23A

Select a timing correction factor corresponding to

>1. TIMING ADJUST correction needed.
2. ENGINE SERIAL#
Example: Timing mark as verified with a timing
3 . C A L I B R AT I O N
light at 3500 RPM was too early by 2°. The cor-
rection factor programmed is no. 4.
A30E2GA
Select correction factor no. 5. This will retard the
timing by 2° because the difference between cor-
Press ENTER. rection factor no. 4 and no. 5 is - 2° (passing from
1° to - 1°).

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Section 08 ELECTRICAL
Subsection 01 (IGNITION TIMING)

Press any key.

TIMING<1-8>:5

MODIFY?

YES NO
A30E2HA

A30E27A

IGNITION CORRECTION FACTOR

If the new correction factor selected above is the
CORRECTION FACTOR
PROGRAMMED IN
IGNITION TIMING good one select NO and press ENTER. Otherwise
CORRECTION select YES to choose an other correction factor.
MPEM
2 3°
3 2°
>1. TIMING ADJUST
4 1° 2. ENGINE SERIAL#
1 0° 3 . C A L I B R AT I O N

5 - 1°
6 - 2° A30E2GA

7 - 3°
Press MENU.
8 - 4° Scroll to no. 7 SAVE AND QUIT.

Press ENTER.

4. E N G I N E PA R A M .
5. HOUR INFO.
>1. TIMING ADJUST 6. MPEM INFO.
2. ENGINE SERIAL# >7. S AV E + Q U I T
3 . C A L I B R AT I O N
A30E29A

A30E2GA Press ENTER.

Press ENTER.

S AV E
M O D I F I C AT I O N S ?
TIMING<1-8>:5
YES NO

P R E S S A N Y K E Y. . .
A30E2AA

A30E24A
Press ENTER.
The display confirms that correction factor has
been changed to no. 5.

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 Section 08 ELECTRICAL
Subsection 01 (IGNITION TIMING)

TRANSFER 1. CHECK KEYS

PGMR MPEM 2. PROGRAM KEY
>3. VEHICLE INFO
4+ S TA RT V E H .

A00A42A A30E1XA

During a very short period of time the following Unplug supply cable and 9-volt adaptor.
message will appear.
593 HO SDI Engine
To change the ignition timing on the 593 HO SDI,
the Vehicle Communication Kit (VCK) (P/N 529 035
VERIFY 981) is mandatory. The MPEM programmer can
PGMR MPEM not be used.
Look under the Setting tab of the BUDS software
to change the ignition timing.

A30E2BA

After the programmer has verified, following mes-

sage will appear.

O P E R AT I O N
SUCCESSFULL

P R E S S A N Y K E Y. . .

A00A3EA

A32A1TA
Press any key.
Detailed information about the BUDS software
and its usage is available under the HELP tab.
I F T E R M I N AT E D
YOU CAN UNPLUG

P R E S S A N Y K E Y. . .

A00A3FA

Press any key.

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 Section 08 ELECTRICAL
Subsection 02 (SPARK PLUGS)

SPARK PLUGS
SERVICE PRODUCTS
Description Part Number Page

anti-seize lubricant ................................................................ 293 800 070 ......................................... 436

NGK SPARK PLUG

All Models

NGK SPARK PLUG NUMBERING

SYSTEM
BRP uses NGK brand spark plugs on all its snow-
mobile models.
The heat range identification system is:

Low number hot plug

High number cold plug

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Section 08 ELECTRICAL
Subsection 02 (SPARK PLUGS)

DESIGN SYMBOLS USED IN NGK SPARK PLUGS

A01E4DS

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 Section 08 ELECTRICAL
Subsection 02 (SPARK PLUGS)

DISASSEMBLY A too hot plug will result in overheating and pre-

ignition, etc.
First unscrew the spark plug 1 turn.
A too cold plug will result in fouling (shorting the
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-
 WARNING
onation.

Whenever using compressed air, always FOULING

wear protective eye wear.
Fouling of the spark plug is indicated by irregular
running of the engine, decreased engine speed
due to misfiring, reduced performance, and in-
HEAT RANGE creased fuel consumption. This is due to a loss
The proper operating temperature or heat range of compression. Other possible causes are: pro-
of the spark plugs is determined by the spark plug longed idling, or running on a too rich mixture due
ability to dissipate the heat generated by combus- to a faulty carburetor adjustment or incorrect fu-
tion. el and/or fuel mixing. The plug face of a fouled
The longer the heat path between the electrode spark plug has either a dry coating of soot or an
tip to the plug shell, the hotter the spark plug op- oily, glossy coating given by an excess either of
erating temperature will be — and inversely, the oil or of oil with soot. Such coatings form a con-
shorter the heat path, the colder the operating ductive connection between the center electrode
temperature will be. and ground.
A cold type plug has a relatively short insulator
nose and transfers heat very rapidly into the cylin-
SPARK PLUG ANALYSIS
der head.
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)

The plug electrode and piston dome reveal the

1 2
condition of the engine, operating condition,
method of driving and fuel mixture. For this rea-
son it is advisable to inspect the spark plug at
regular intervals, examining the plug electrode
and the piston dome.

A00E09A

1. Cold
2. Hot

CAUTION: Severe engine damage might occur

if a wrong heat range plug is used.

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Section 08 ELECTRICAL
Subsection 02 (SPARK PLUGS)

SPARK PLUG INSTALLATION

Prior to installation make sure that contact sur-
faces of the cylinder head and spark plug are free
of grime.
1) Using a wire feeler gauge, set electrode gap
according to TECHNICAL DATA.
2) Apply anti-seize lubricant (P/N 293 800 070)
over the spark plug threads to prevent possi-
ble 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

SPARK PLUG TIGHTENING

TORQUE
TORQUE
MODELS SPARK PLUGS
N•m ( lbf•ft)
All models NGK 27 (20)

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 Section 08 ELECTRICAL
Subsection 03 (ALTERNATOR)

ALTERNATOR
The alternator is located on the ignition cover on INSTALLATION
the engine right hand side (alternator side).
The installation is the reverse of removal proce-
dure. Pay attention to the following details.
REMOVAL
NOTE: At assembly replace the O-ring of the alter-
Remove: nator. Grease the drive gear splines and the O-ring
– alternator cable before assembly using multi purpose grease. This
– alternator plug will ease assembly and prevent displacement of
the gasket during installation.
– alternator screws and pull alternator.
If it is not possible to move the alternator into the
guide, this is due to the position of the drive gear.
Pull the alternator out once more, slightly rotate
the drive gear and try again.
Torque alternator screws to 23 N•m (17 lbf•ft).

R1004motr128A 2 1 2
1. Alternator
2. Three screws

INSPECTION
1 2

R1004motr129A

1. Drive gear splines

2. O-ring

NOTE: The alternator does not require any main-

tenance and must not be opened for repair work.
Inspect the housing, O-ring and the alternator
drive gear splines for damage or wear. In case
of damage, the alternator must be replaced. The
alternator can only be replaced as a complete
assembly.

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 Section 08 ELECTRICAL
Subsection 04 (BATTERY)

BATTERY
SERVICE TOOLS
Description Part Number Page
crimp pliers ........................................................................... 529 035 730 ......................................... 447

SERVICE PRODUCTS
Description Part Number Page
protective heat shrink rubber tube ....................................... 278 001 692 ......................................... 448
silicone dielectric grease ...................................................... 293 550 004 ................................. 442, 447

GENERAL All Models Except Expedition TUV

All Models Except Skandic LT E Before removing battery, remove air silencer to
get access to the battery.
Sealed valve regulated lead acid (VRLA) battery
are used. They are non-spillable and maintenance Unlock the spring lock and remove intake cover
reduced — no electrolyte level to be checked and and tube plate from the air silencer.
readjusted. No ventilation tube is attached to the Remove pulley guard to get access to air intake
battery. adaptor collars clamps of air silencer.
Loose clamps and remove air silencer.
MODEL SUPPLIER P/N BRP P/N
2-stroke 410 301 203 2 1
YTX20L-BS
4-stroke YTX24HL-BS 410 922 962

REMOVAL
 WARNING
Battery BLACK negative cable must always be
disconnected first and connected last.

 WARNING
Never charge or boost battery while installed
on vehicle.

Expedition TUV
NOTE: Battery is located under the seat.
A29C2HA
Unhook battery cover strap from its support.
TYPICAL
Open battery cover. 1. Air silencer (cover and tube plate removed)
2. Collars loosened
Remove battery.

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Section 08 ELECTRICAL
Subsection 04 (BATTERY)

Unbolt battery cover steel strip and remove bat- CLEANING

tery cover.
Clean the battery, battery casing, vent tube, caps,
1 cables and battery posts using a solution of baking
soda and water.
Remove corrosion from battery cable terminals
and battery posts using a firm wire brush. Bat-
tery top should be cleaned by soft brush and any
grease-cutting soap or baking soda solution.
Skandic LT E
CAUTION: Do not allow cleaning solution to en-
ter battery interior since it will destroy the elec-
trolyte.

INSPECTION
A29C2IA
All Models
TYPICAL
1. Battery cover Visually inspect battery casing for cracks or other
possible damage. Discoloration, warping or raised
Unplug vent tube (if applicable) from battery vent top, indicates that battery has overheated or been
nipple. overcharged. If casting is damaged, replace bat-
Disconnect the black negative cable first followed tery and thoroughly clean battery tray and close
by red cable and remove battery. area with water and baking soda.

1  WARNING
Should the battery casing be damaged, wear
a suitable pair of non-absorbent gloves when
removing the battery by hand.

Inspect battery posts for security of mounting.

Inspect for cracked or damaged battery caps, re-
place defective caps.

 WARNING
Battery caps do not have vent holes. Make
sure that vent tube is not obstructed.

A29C2JA 2 3
TYPICAL
1. Vent tube (if applicable)
2. Black negative cable
3. Red cable

Remove battery from vehicle.

NOTE: On some models, be careful not to lean the
battery so that electrolyte flows out of vent tube.
CAUTION: Should any electrolyte spillage oc-
cur, immediately wash off with a solution of
baking soda and water to prevent damage to
vehicle components.

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 Section 08 ELECTRICAL
Subsection 04 (BATTERY)

BATTERY CHARGE TESTING ELECTROLYTE

TEMPERATURE OPERATION TO PERFORM
Skandic LT E
°C °F
Hydrometer Test
38 100 .008 TO THE
ADD
32 90 .003 READING

25 77 correct reading
1 21 70 .002
16 60 005
10 50 009
4 40 012
- 1 30 016
- 7 20 019 from the
A17E0JA subtract
- 12 10 022 reading
1. Specific gravity 1.265
- 18 0 026
A hydrometer measures the charge of a battery in - 23 - 10 029
terms of specific gravity of the electrolyte. Most
hydrometers give a true reading at 25°C (77°F). - 29 - 20 032
In order to obtain correct readings, adjust the ini- - 34 - 30 036
tial reading by adding .001 to the hydrometer read- - 40 - 40 039
ings for each 2°C (3°F) above 25°C (77°F) and by
subtracting .001 for every 2°C (3°F) below 25°C
EXAMPLE no. 1 Temperature below 25°C (77°F):
(77°F).
Hydrometer Reading: 1.250 Electrolyte tempera-
This chart will be useful to find the correct reading. ture: - 7°C (20°F) Subtract .019 Sp. Gr. Corrected
Sp. Gr. is 1.231
EXAMPLE no. 2 Temperature above 25°C (77°F):
Hydrometer Reading: 1.235 Electrolyte tempera-
ture: 38°C (100°F) Add .008 Sp. Gr. Corrected Sp.
Gr. is 1.243

TEMPERATURE
CORRECTED SPECIFIC BATTERY CHARGE
GRAVITY
1.265 Fully charged
1.215 3/4 charged
1.165 1/2 charged
1.125 1/4 charged
1.110 Discharged

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Section 08 ELECTRICAL
Subsection 04 (BATTERY)

CAUTION: Do not install a partially charged Clean battery terminals and cable connections us-
battery on a snowmobile since the casing ing a wire brush. Apply a light coat of silicone di-
might crack at freezing temperature. The fol- electric grease (P/N 293 550 004) or petroleum jel-
lowing chart shows the freezing point of the ly on terminals.
electrolyte in relation to the temperature cor-
rected specific gravity. Clean battery casing and caps using a solution of
baking soda and water. Do not allow cleaning so-
TEMPERATURE lution to enter battery, otherwise it will destroy the
CORRECTED FREEZING POINT OF electrolyte. Rinse battery with clear water and dry
SPECIFIC ELECTROLYTE well using a clean cloth.
GRAVITY Store battery in a cool dry place. Such conditions
1.265 - 59°C (- 75°F) reduce self-discharging and keep fluid evaporation
to a minimum.
1.225 - 37°C (- 35°F)
During the storage period, recheck electrolyte lev-
1.200 - 27°C (- 17°F) el and specific gravity readings at least every 40
1.150 - 15°C (+ 5°F) days. As necessary, keep the battery at its upper
level line and near full charge as possible (trickle
1.110 - 3°C (+ 27°F) charge).
Skandic WT/SWT/SUV/Expedition TUV
Voltmeter Test
CAUTION: A discharged battery will freeze and
Skandic WT/SWT/SUV/Expedition TUV it may damage its casing. A damaged casing
NOTE: To determine the battery state of charge, will allow electrolyte spillage that may damage
these sealed batteries have to be tested with a surrounding parts.
voltmeter. They also need to be tested when their Disconnect and remove battery from the vehicle.
voltage is stabilized. Disconnect battery to have
The battery must always be stored in fully charged
open connectors and wait 1-2 hours prior to read-
condition.
ing the voltage. The same condition is required
after a battery has been charged. Clean battery terminals and cable connections us-
ing a wire brush. Apply a light coat of silicone di-
Batteries with a voltage above 12.8 V do not need
electric grease (P/N 293 550 004) or petroleum jel-
to be charged.
ly on terminals.
Batteries with a voltage of 12.8 V and below need
Clean battery casing using a solution of baking so-
to be charged. Refer to BATTERY CHARGING be-
da and water. Rinse battery with clear water and
low.
dry well using a clean cloth.
BATTERY STORAGE Charge the battery every month if stored at a tem-
perature below 15°C (60°F).
Skandic LT E Charge the battery every two weeks if stored at a
Disconnect and remove battery from the vehicle. temperature above 15°C (60°F).
Check electrolyte level in each cell, add distilled
water up to upper level line. ACTIVATION OF NEW BATTERY
CAUTION: Do not overfill. Skandic WT/SWT/SUV/Expedition TUV
The battery must always be stored in fully charged Refer to the instructions provided with the battery.
condition. If required, charge until specific gravity
of 1.265 is obtained. Skandic LT E

CAUTION: Battery electrolyte temperature  WARNING

must not exceed 50°C (122°F). The casing Never charge or boost battery while installed
should not feel hot. on vehicle.

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 Section 08 ELECTRICAL
Subsection 04 (BATTERY)

CAUTION: Prior to charging the battery, al-

ways remove it from the vehicle to prevent
electrolyte spillage.
A new battery is factory fresh dry charged. For
storage purposes, it is fitted with a temporary seal-
ing tube.
Do not remove the sealing tube or loosen battery
caps unless activation is desired. 1
In case of accidental premature removal of caps or A17E0GA

sealing tube, battery should be given a full charge.

1. 30 minutes
Perform the following operations anytime a new
battery is to be installed. – Allow gas bubbles to escape by lightly shaking
– Remove the sealing tube from the vent elbow. battery by hand.
Install vent tube, included in the battery kit, to
battery elbow.

 WARNING
Failure to remove the sealing tube could re-
sult in an explosion.

1 A17E0HA

– Readjust the electrolyte level to the UPPER

LEVEL line.

A17E0FA

1. Battery electrolyte

– Remove caps and fill battery to UPPER LEVEL

line with electrolyte (specific gravity : 1.265 at
20°C (68°F)).
– Allow the battery to stand for 30 minutes MIN- A17E0RA

IMUM (1 hour MAXIMUM) so that electrolyte 1. Battery electrolyte

soaks through battery cells.
– Connect a 2 A battery charger for 10 to 20
hours.

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Section 08 ELECTRICAL
Subsection 04 (BATTERY)

3
1
2 - + 1

A17E0IA

CAUTION: If charging rate raises higher than A17E0JA

2.4 A reduce it immediately. If cell tempera-
ture rises higher than 50°C (122°F) (if the casing 1. Specific gravity 1.265
feels hot) discontinue charging temporarily or
reduce the charging rate. – Let battery settle for 1 hour.
 WARNING 1
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
– Disconnect battery charger.
1. 60 minutes

1 – Allow gas bubbles to escape by lightly shake

battery.
2 - + 3

A17E0IB

– Test battery state of charge. Use a hydrometer.

A17E0HA

– Readjust electrolyte level.

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 Section 08 ELECTRICAL
Subsection 04 (BATTERY)

BATTERY CHARGING
Tips for Charging a Used Battery
1
Skandic LT E
CAUTION: Prior to charging the battery, al-
ways remove it from the vehicle to prevent
electrolyte spillage.
For best results, battery should be charged when
the electrolyte and the plates are at room tempera-
ture. A battery that is cold may not accept current
for several hours after charging begun.
Do not charge frozen battery. If the battery charge
A17E0RA
is very low, the battery may freeze. If it is suspect-
1. Battery electrolyte ed to be frozen, keep it in a heated area for about
2 hours before charging.
– Reinstall caps and clean any electrolyte spillage
using a solution of baking soda and water.  WARNING
Do not place battery near open flame.

1 Time required to charge a battery will vary depend-

ing some factors such as:
– Battery temperature: Charging time is in-
creased as the temperature goes down. The
current accepted by a cold battery will remain
low. As the battery warms up, it will accept a
higher rate of charge.
A17E0LA – State of charge: Because the electrolyte is near-
1. Baking soda
ly pure water in a completely discharged bat-
tery, it cannot accept current as well as elec-
CAUTION: Do not allow cleaning solution to en- trolyte. This is the reason the battery will not
ter battery interior since it will destroy the elec- accept current when the charging cycle first be-
trolyte. gins. As the battery remains on the charger, the
NOTE: It is recommended to verify the battery current from the charger causes the electrolytic
charge once a month. If necessary, fully charge acid content to rise which makes the electrolyte
battery. a better conductor and then, the battery will ac-
cept a higher charging rate.
SERVICING – Type of charger: Battery chargers vary in the
amount of voltage and current that they can
Electrolyte Level supply. Therefore, time required for the battery
to begin accepting measurable current will also
Skandic LT E vary.
Since a battery has been activated (see above),
add distilled water to top up electrolyte.

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Section 08 ELECTRICAL
Subsection 04 (BATTERY)

Charging a Very Flat or Completely All Except Skandic LT E

Discharged Battery
Skandic LT E  WARNING
Unless this procedure is properly followed, a good Always wear safety glasses and charge in
battery may be needlessly replaced. a ventilated area. Never charge or boost
battery while installed on vehicle. Do not
– Measure the voltage at the battery posts with open the sealed caps during charging. Do
an accurate voltmeter. If it is below 10 volts, not place battery near open flame.
the battery will accept current at very low rate,
in term of milliamperes, because electrolyte CAUTION: If battery becomes hot, stop charg-
is nearly pure water as explained above. It ing and allow it to cool before continuing.
could be some time before the charging rate
increases. Such low current flow may not be NOTE: Sealed VRLA batteries have an internal
detectable on some charger ammeters and the safety valve. If battery pressure increases due to
battery will seem not to accept any charge. overcharging, the valve opens to release excess
pressure, preventing battery damage.
– Only for this particular case, set the charger to
a high rate. Perform BATTERY CHARGE TESTING above then
proceed as described here.
NOTE: Some chargers have a polarity protection
feature which prevents charging unless the charg- An automatic charger is the fastest and most con-
er leads are connected to the correct battery ter- venient way for error-proof charging.
minals. A completely discharged battery may not NOTE: If battery cannot be recharged using the
have enough voltage to activate this circuitry, even following charging chart, replace battery.
though the leads are connected properly. This will
When using a constant current charger, charge
make it appear that the battery will not accept
battery according to the chart below.
a charge. Follow the charger manufacturer's in-
struction telling how to bypass or override this cir- Battery Voltage Below 12.8 V
cuitry so that the charger will turn on and charge
a low-voltage battery. STANDARD CHARGING
– Since the battery chargers vary in the amount (RECOMMENDED)
of voltage and current they provide, the time BATTERY
required for the battery to accept measurable TIME CHARGE
TYPE
charger current might be up to approximately
10 hours or more. YTX20L-BS 4 – 9 hours
2 A
– If the charging current is not up to a measurable YTX24HL-BS 5 – 10 hours
amount at the end of about 10 hours, the bat-
tery should be replaced.
QUICK CHARGING
– If the charging current is measurable before the
end or at the end of about 10 hours, the battery BATTERY
TIME CHARGE
is good and charging should be completed in the TYPE
normal manner as specified in Activation of a YTX20L-BS 50 minutes
new battery. 10 A
YTX24HL-BS 1 hour
– It is recommended that any battery recharged
by this procedure be load tested prior to return-
ing it to service. INSTALLATION OF BATTERY
Skandic LT E
Ensure vent tube is properly installed on battery
elbow.
Connect vent tube to vehicle fitting on front frame.

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 Section 08 ELECTRICAL
Subsection 04 (BATTERY)

All Except Skandic LT E

Route RED positive cable behind retaining strip
and connect it to positive battery terminal. Con-
nect RED wire (coming from ignition switch).
Connect BLACK negative cable LAST.

 WARNING
Battery BLACK negative cable must always be A
disconnected first and connected last.
A32E2QA

 WARNING A. 10 mm (1/2 in)

Never charge or boost battery while installed NOTE: Make sure not to cut wire strands while
on vehicle. stripping the wire.
Apply silicone dielectric grease (P/N 293 550 004) Install the appropriate terminal on the wire accord-
on battery posts and connectors. ing to the requirement. Refer to appropriate parts
catalog.
All Models Except Expedition TUV
1

A32E2RA

INSTALLATION OF TERMINAL

Follow the instructions provided with the crimp pli-

ers (P/N 529 035 730) to select the proper position
of the tool.
NOTE: Different wires require different crimp pli-
A03H1SA ers settings, so make sure to follow the instruction
supplied with the tool.
TYPICAL — BATTERY CONNECTION
1. Vent tube on fitting (if applicable)

Ensure that vent tube is not kinked or blocked then

install battery cover over battery (if applicable).
Close and fasten retaining strips.
Reinstall air silencer and pulley guard.
Expedition TUV
Properly position the battery on its rack.
Close battery cover.
Secure cover with rubber strap.

CABLE TERMINAL INSTALLATION

Carefully strip the wire approximately to 10 mm
(1/2 in) in length, using a wire stripping tool or
sharp blade/knife.

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Section 08 ELECTRICAL
Subsection 04 (BATTERY)

CAUTION: Never weld the wire to the terminal.

Welding can change the property of the wire
and it can become brittle and break.
1 Install the protective heat shrink rubber tube
(P/N 278 001 692) on the terminal. Heat the
shrink rubber tube using a heat gun so that it
grasps the wire and the terminal.
CAUTION: Make sure that the protective heat
shrink rubber tube has been properly installed
and no part of wire is exposed.

2
A32E2SA

POSITIONING THE CRIMP PLIERS

Step 1 : Press
Step 2 : Rotate

After positioning the crimp pliers, crimp the termi-

nal already installed on wire.

A32E2TA

CRIMPING OF WIRE

A32E2UA

PROPERLY CRIMPED WIRE

To verify, if the wire is properly crimped, apply

some pulling force on wire and the terminal at the
same time from both directions.

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 Section 08 ELECTRICAL
Subsection 05 (ELECTRIC STARTER)

ELECTRIC STARTER
SERVICE PRODUCTS
Description Part Number Page
Loctite 271............................................................................ 293 800 005 ......................................... 460
Super Lube grease ............................................................... 293 550 030 ......................................... 461
synthetic grease ................................................................... 413 711 500 ................................. 458–459

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Section 08 ELECTRICAL
Subsection 05 (ELECTRIC STARTER)

443 and 552 Engines

6
2 3

4
9 7
5

11
8
12
12
15
17

10
13

18
19

16

A03E31S

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 Section 08 ELECTRICAL
Subsection 05 (ELECTRIC STARTER)

593 and 593 HO SDI Engines

5 N•m
(44 lbf•in)

15
7
9

6 4.5 N•m
(40 lbf•in)

4 17

3 16
2
12
14

13

Synthetic 1
grease 10
11 N•m 28 N•m
(97 lbf•in) (20 lbf•ft)

11
7 N•m
(62 lbf•in)

A29E0ZS

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Section 08 ELECTRICAL
Subsection 05 (ELECTRIC STARTER)

V-1000 Engine

Super Lube grease

(P/N 293 550 030)

9 N•m
(80 lbf•in)
2

A32E40S

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 Section 08 ELECTRICAL
Subsection 05 (ELECTRIC STARTER)

REMOVAL
443 and 552 Engines
– Disconnect BLACK ground cable from battery.
– Disconnect RED positive cable from battery.

 WARNING
Always disconnect ground cable first and
connect last.

– Disconnect RED cable and RED/GREEN wire

from starter relay. R1004motr126A 2 1
– Unbolt starter from PTO side bracket.
1. Electric starter
– Unbolt MAG side bracket from engine. 2. Screws
– Remove starter from engine.
Remove:
593 and 593 HO SDI Engines – starter cable
– Disconnect BLACK ground cable from battery. – starter screws.
– Disconnect RED positive cable from battery.
Remove starter.
 WARNING
Always disconnect ground cable first and
DISASSEMBLY
connect last. 443 and 552 Engines
Disconnect bare wire linking starter and relay.
– Remove tuned pipe. Remove nuts no. 16 then relay no. 10 by lifting
– Disconnect RED cable from starter. and pulling to disengage from drive lever no. 15.
– Disconnect ground cable from starter. Unscrew starter screws (long) no. 1 then pull yoke
– Unbolt and remove starter from engine. no. 8 with end frame no. 2 to separate from drive
V-1000 Engine housing no. 17.
Disconnect BLACK (-) cable from battery. Pull armature no. 9 with drive lever no. 15.
Remove insulator no. 4 then brush springs no. 7
 WARNING being careful not to lose them since they will be
Always disconnect BLACK (-) cable first and projected out.
connect last. Pull brush holder no. 5 from yoke no. 8.
Insert blade of a small screwdriver between stop
The starter is located below the second cylinder in
collars.
the crankcase.

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Section 08 ELECTRICAL
Subsection 05 (ELECTRIC STARTER)

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.
Install bushing cover no. 19 then, using a punch,
Remove outer collar, circlip then inner collar. stake bushing cover in place.
Remove overrunning clutch no. 11.
Check the wear on bushing no. 18 by measuring
the amount of radial play between the armature
shaft and the bushing.
The radial play should not exceed 0.20 mm
(.008 in). If greater, replace the bushing. To re-
place, 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 1
given on next illustration.
CAUTION: Support drive housing adequately
to prevent damage when pressing bushing.

A A19E02A
2

1. Stake bushing cover

2. Support
B

3, Bushing (end frame)

Check the wear on bushing no. 3 by measuring
C the amount of radial play between the armature
shaft and the bushing.
The radial play should not exceed 0.20 mm
A19E0AA
D (.008 in). If greater, replace bushing as follows:
BUSHING PUSHER Using a 12 mm tap, cut threads into bushing so
A. 16 mm (5/8 in) diameter that the tap contacts the end frame. Continue to
B. 13 mm (1/2 in)
C. 11 mm (7/16 in) rotate tap until the bushing comes free.
D. 11.0 mm (.433 in)

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 Section 08 ELECTRICAL
Subsection 05 (ELECTRIC STARTER)

1
2

A19E03A

1. Turn until bushing goes out

2. 12 mm tap

To install new bushing, use the same bushing 2 4

pusher as for drive housing bushing installation.

6, Brush 3
A19E06A
To replace brush no. 6, proceed as follows:
1. Plate edge
Cut brush wire close to connector at the welded 2. Housing connector
portion. 3. Crimp
4. Spare brush

Solder the crimped portion.

CAUTION: Do not overheat and quickly per-
form soldering to prevent solder from flowing
to the brush through the wire. Preferably use
a heat sink.
593 and 593 HO SDI Engines
1
Before disassembling, trace index marks on
starter housing no. 10 and starter housing assem-
bly no. 8 to ease later assembly.
A19E05A
Remove starter through bolts no. 17. Separate
1. Cut close to connector end frame housing no. 14 from starter housing
no. 10. Withdraw starter housing from armature
Remove burrs with a file on the remaining welded
no. 11.
portion.
Brush holder no. 13 can be removed from end
CAUTION: Be careful not to damage plastic frame housing no. 14 by disconnecting the end
portion of starter housing.
frame attached brush from brush holder no. 13.
Place spare brush plate edge against housing con-
Check the radial play between the armature shaft
nector edge (welded portion).
and end frame bearing. Replace the end frame
Crimp plate over housing connector with a pair of bearing or replace starter. If parts are in good con-
pliers. dition then coat with synthetic grease (P/N 413
711 500) before reinstalling them.
Push back the collar no. 3 using a screwdriver.
Remove snap ring no. 2. Remove collar no. 3 and
spring no. 4.

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Section 08 ELECTRICAL
Subsection 05 (ELECTRIC STARTER)

INSPECTION
Armature
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 commuta-
tor 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
A32E20A 2 1 the undercutting operation is completed.
1. Collar
2. Snap ring

Turn starter clutch no. 6 clockwise to remove it

1
from armature assembly no. 11.
Pull housing from armature.
V-1000 Engine F01H0RA

The starter is not serviceable. If defective, replace 1. Commutator undercut 0.20 mm (.008 in)
with a new one.
Check the commutator out-of-round condition
CLEANING AND INSPECTION with V Blocks and an indicator. If the commutator
out-of-round is more than 0.40 mm (.016 in), the
commutator should be turned on a lathe.
CLEANING
Check commutator outer diameter. If less than
CAUTION: Armature starter yoke ass'y and specified value, replace.
drive unit assembly must not be immersed in
cleaning 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 A03E06A

a clean cloth soaked in suitable solvent. Dry well

using a clean and dry cloth. MODEL WEAR LIMIT
Clean engine ring gear teeth and drive unit (clutch).
All 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 and dry cloth.

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 Section 08 ELECTRICAL
Subsection 05 (ELECTRIC STARTER)

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
ture core and the commutator bars. If growler on a commutator bar and the other test probe
lamp turns on, bars are grounded. If so, replace on the neighboring bar. Repeat this operation for
armature. all bars, moving one test probe at a time. If the
growler lamp does not turn on, the armature cir-
cuit between these 2 bars is opened. The arma-
1 ture should be replaced or repaired; open circuits
most often occur at the commutator riser where
coils are soldered. (Burnt commutator bars are
usually an indication of an open-circuit armature
coil.)

Field Windings and Brushes

443 and 552 Engines
Test the Field Winding for Open Circuit
Use growler test probes. Place one test probe on
2 the negative brush and the other test probe on the
A09E08A yoke. If growler lamp does not turn on, the field
1. Test probes
winding has an open-circuit. The yoke has to be
2. Commutator bars repaired or replaced.
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 1
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.
2
A09E09A If growler lamp does not turn on, the winding cir-
1. Steel strip (hack-saw blade) cuit is open-circuit and the starter housing has to
2. Growler be repaired or replaced.

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Section 08 ELECTRICAL
Subsection 05 (ELECTRIC STARTER)

Brush Holder
Check the brush holder for insulation using
growler test probes. Place one test probe on the
insulated 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.

Brush Length
Measure brush length. If less than the specified
value, replace them.

LENGTH
MODEL
NEW WEAR LIMIT 1 2
A32E22A

All 10 mm (.400 in) 6 mm (.236 in) 1. Roller bearing

2. Positive brush

Overrunning Clutch
The pinion of the overrunning clutch should turn
1 2 smoothly in a clockwise direction, and should not
slip in a counterclockwise direction. If defective,
replace.
Check the pinion teeth for wear and damage. If
defective, replace.

Starter Relay
A03E05A Inspect connections and clean as necessary. Re-
TYPICAL
lay condition can be checked with an ohmmeter.
1. New Install test probes on large connectors of relay
2. Wear limit when it is activated ((+) on RED/GREEN wire and
(-) on relay body for the fan cooled models and (-)
on the BLACK wire for liquid cooled models).
End Housing
593 and 593 HO SDI Engines IMPORTANT: No current must be present on large
cables when using ohmmeter, otherwise meter
Check the mica insulation of the positive brush could be damaged.
and also the roller bearing condition. Replace, if
required.
ASSEMBLY
443 and 552 Engines
Prior to assembling, coat sliding surfaces and
moving parts on armature shaft splines, overrun-
ning clutch, relay plunger, drive lever and bushings
with synthetic grease (P/N 413 711 500).
Proceed as follows for assembly.
Install overrunning clutch onto armature shaft. In-
sert inner collar onto shaft. Install a new circlip.
CAUTION: Always install a new circlip when
servicing.

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 Section 08 ELECTRICAL
Subsection 05 (ELECTRIC STARTER)

Insert outer collar being careful to match protru-

sions with notches of collars.
2
Using a pair of pliers on each side of stop collars,
1
squeeze evenly until collars sit over circlip.

A19E04A
A19E07A
1. This end first
1. Squeeze evenly 2. Push this end to complete

Install thrust washer against outer stop collar. Secure insulator over brushes and springs. Prop-
Place drive lever onto overrunning clutch then erly install end frame and tighten screws.
insert into drive housing. Insert relay plunger inside of drive lever fork and
secure to drive housing.
Connect starter bare wire to relay.
1 NOTE: Connect this wire on the shorter relay stud.

1
2

A19E08A 2
1. Install on overrunning clutch
2. Install thrust washer

Slide starter housing over armature.

A19E09A

Install brush holder then brushes in their housings.

1. Shorter stud
Insert springs as follows: place one end of spring 2. Bare wire
against brush, compress, then push the other end
of spring onto its housing. Repeat for remaining 593 and 593 HO SDI Engines
springs. Reverse the order of disassembly to reassemble
starter. However, attention should be paid to the
following operations.
Prior to assembling, coat sliding surfaces on arma-
ture shaft splines, overrunning clutch, bushing and
roller bearing with synthetic grease (P/N 413 711
500).

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Section 08 ELECTRICAL
Subsection 05 (ELECTRIC STARTER)

After placing collar no. 3 on armature shaft no. 11,

fit new snap ring no. 2 on armature shaft, then
make sure that it is properly secured.
Slide collar no. 3 over snap ring no. 2 and secure
in place by punching it at two or three places.

2 3

A32E23A 1
1. Brush holder
A03E0EA

1. Armature shaft
To ease end frame installation, retain brush holder
2. Snap ring with a small screwdriver while installing armature
3. Collar assembly.
4. Punch
CAUTION: Make sure to place two end hous-
ings on a flat surface before tightening the
Starter Housing Assembly and through bolts.
Starter Housing CAUTION: Make sure end frame fits perfectly
Align previously traced indexing marks. on yoke.

INSTALLATION
443 and 552 Engines
Make sure that starter and engine mating surfaces
are free of grime. Serious trouble may arise if
starter is not properly aligned.
CAUTION: Make sure that both starter brackets
are well seated against engine crankcase and
starter before torquing all retaining bolts.
A32E21A
1
Torque all M8 bolts to 24 ± 4 N•m (18 ± 3 lbf•ft).
TYPICAL
1. Aligned indexing marks Torque all M5 bolts to 5 ± 0.5 N•m (44 ± 5 lbf•in).
CAUTION: Before checking engaging depth of
Open brushes and slide over commutator. starter pinon teeth, make sure that battery ca-
Align end frame locating notch with yoke locating bles are disconnected.
protrusion and properly sit brush holder no. 13 into Install starter.
housing no. 14.
NOTE: Check proper engaging depth of starter
pinion teeth to ring gear teeth (see illustration).
Install hardened washers (P/N 503 007 900) be-
tween engine and starter supports accordingly.
CAUTION: All starter bracket fasteners must be
secured with Loctite 271 (P/N 293 800 005).

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 Section 08 ELECTRICAL
Subsection 05 (ELECTRIC STARTER)

2 – Torque ground cable connecting bolt to 11 N•m

(97 lbf•in).
V-1000 Engine
The installation is the reverse of removal proce-
1 dure. Pay attention to the following details.
NOTE: During assembly replace the O-ring
no. 1of the starter. Grease the drive gear and the
3 O-ring before assembly using Super Lube grease
(P/N 293 550 030). This will simplify assembly
and prevent displacement of the O-ring during
installation.
If it is not possible to move the starter into the
guide, this is due to the position of the drive
gearno. 2. Pull the starter out once more, slightly
rotate the drive gear and try again.
2
A09E0PA A
1. Screwdriver pulling starter pinion 1
2. Ring gear
3. No excessive backlash
A. 0.5 to 1.5 mm (.020 to .060 in) R1004motr127A

Connect the RED battery cable and the RED 1. Drive gear
2. O-ring
wire to the large terminal of the relay. Connect
RED/GREEN wire to small terminal of relay. Torque starter screws to 9 N•m (80 lbf•in).
Connect BLACK cable to battery.

 WARNING
Always disconnect ground cable first and
connect last.

593 and 593 HO SDI Engines

– Use new teflon washers on the 3 bolts retaining
starter to engine.
– Torque the bolts to 28 ± 1 N•m (21 ± 1 lbf•ft).
– Make sure that starter and engine mating sur-
faces are free of grime. Serious trouble may
arise if starter is not properly aligned.
– Connect the RED battery cable and the RED
wire to the large terminal of the starter.
– Torque large terminal nut to 7 N•m (62 lbf•in).

 WARNING
Always disconnect ground cable first and
connect last.

– Connect ground cable to the starter with star

washer in between.

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 Section 08 ELECTRICAL
Subsection 06 (TESTING PROCEDURE)

TESTING PROCEDURE
277 Engine

Reverse

Forward

A05E0WT

1. MPEM
2. Trigger coils
3. 4-DB housing (BLACK and RED wires)

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Section 08 ELECTRICAL
Subsection 06 (TESTING PROCEDURE)

443 and 552 Engines

Reverse
(not functional
on 552 engine)

3
2
Forward

A03E2WT

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

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 Section 08 ELECTRICAL
Subsection 06 (TESTING PROCEDURE)

593 Engine

Loctite
243

3 125 N•m
(92 lbf•ft)
Sikaflex
255
Loctite 243

22 N•m
(195 lbf•in)
Loctite 243

Dielectric grease 2

Dielectric grease

A29E0MU

1. MPEM
2. Ignition coil
3. Trigger coils

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Section 08 ELECTRICAL
Subsection 06 (TESTING PROCEDURE)

593 HO SDI Engine

1 2

9 N•m
(80 lbf•in)

Loctite
243

3 8 N•m
(71 lbf•in) Loctite 243

21 N•m
Frame harness (16 lbf•ft)
Voltage regulator

A32E3OS

1. ECM
2. Ignition coil
3. Trigger coil

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 Section 08 ELECTRICAL
Subsection 06 (TESTING PROCEDURE)

GENERAL Multi-Purpose Electronic Module

(MPEM) Connections
NOTE: The 4-TEC engines are equipped with an
alternator, not with a magneto. Refer to ALTER- 593 Engine
NATOR subsection for the checking procedure. 4 3 2 1
277 and 443 Engines
The RER dual trigger coil CDI system has an igni-
tion coil integrated to the MPEM.
MPEM is connected to a single ignition generator
coil via a 3-connector housing (BLACK and RED
wires).
MPEM is programmed to recognize a signal sent
by the switch located on snowmobile console.
When switch is activated, MPEM cuts off ignition A32E3QA

and engine rev drops at approximately: 1. Trigger coil

2. Cooling temperature sensor
ENGINE RPM 3. High tension coil
4. DESS, ignition and engine stop switches, DESS pilot lamp
277 700
443 450 593 HO SDI Engine
For more informations concerning the Engine Con-
MPEM fires a spark at a great advance creating a trol Module (ECM) refer to OVERVIEW in ENGINE
thrust which reverses engine rotation. MANAGEMENT (2-TEC) section.
Second trigger coil located on crankcase takes
over to produce spark in reverse rotation.
A safety device is incorporated to MPEM prevent-
ing it from reading any signal coming from reverse
switch at following engine revs:

NO REVERSE SIGNAL
ENGINE
BELOW ABOVE
277 800 RPM 3500 RPM
443 1000 RPM 3500 RPM

A32E3AA

TYPICAL — ECM

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Section 08 ELECTRICAL
Subsection 06 (TESTING PROCEDURE)

277, 443 and 552 Engines

2
1

A05E0LA

TEST USING MULTIMETER PROBES

A05E0KA

MPEM
1. Reverse switch, reverse indicator and trigger coil
2. Trigger coil
IGNITION SYSTEM TESTING
3. Generator output and cut-off switches SEQUENCE
To ease electrical readings on MPEM connectors, All Models
connector cap must be removed. In case of ignition problems, check the following
Hold connector in hands then lift both tabs to re- in the prescribed order until the problem can be
move connector cap. solved.
1) Sparking/spark plug condition.
2) Electrical connectors.
3) Ignition switch, DESS switch or tether cut-out
switch and engine cut-out switch.
4) Ignition generator coil.
5) Trigger coil.
6) MPEM voltage (liquid cooled engines only).
7) High voltage coil (liquid cooled engines only).
8) Buzzer testing.

LIGHTING SYSTEM TESTING

SEQUENCE
1) Electrical connectors.
2) Magneto output (lighting generator coil).
A05E0GA

LIFT TABS TO REMOVE CAP

Testing Conditions
Voltage measurements are always taken upon
Insert multimeter probes into connector. starting the vehicle. Readings taken when the
engine is running will be higher than indicated
range.
Part temperature must be approximately 21°C
(70°F) (room temperature), otherwise readings
could be distorted.

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 Section 08 ELECTRICAL
Subsection 06 (TESTING PROCEDURE)

Analysis of Readings 2. ELECTRICAL CONNECTOR

Voltage Readings TESTING
When testing the different magneto components, Make sure that none of the connectors are discon-
it is important to take into consideration that read- nected.
ings vary according to the force applied onto the
manual starter. It is therefore important to employ 3. IGNITION SWITCH, DESS
enough force upon each trial.
SWITCH OR TETHER CORD
Doing 3 trials, the readings must each time be CUT-OUT SWITCH AND ENGINE
within or above the range indicated in the corre-
sponding table. If the reading is too low, the part CUT-OUT SWITCH TESTING
is considered to be defective and it must be re- Disconnect connector housing and check resis-
placed. tance as indicated in IGNITION table.
Resistance Readings
Place multimeter selector switch to in order to
measure resistance. Readings must be within the
indicated range. Otherwise, the part is consid-
ered to be defective and must be replaced.
CAUTION: When taking measurements, it is
useless to try to start the vehicle since readings
would then be distorted.
Intermittent Ignition Problems
It is difficult to make a diagnostic in the case of in-
termittent ignition problems. Thus, problems oc-
curring only when the engine operating tempera- A03E1IA
ture is normal must be checked in similar condi-
tions. If readings are acceptable, go on to next step.
In most cases when problems are caused by tem- If readings are inadequate, individually check each
perature or vibrations, these can only be solved by switch as follows.
replacing parts. Most problems cannot be detect-
ed when the engine is stopped. Ignition Switch (key, if equipped)
Multiple Problems Disconnect switch housing. Using a multimeter,
check between MAG and GRD terminals if the
As a matter of fact, more than one component can
circuit is open (0.L M ) in operating position and
be defective. As a result, if the problem remains
if the circuit is closed (0 Ω) in off position.
although a part was replaced, start over the whole
verification from the beginning in order to identify
the other defective component.

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
and do the test again.

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Section 08 ELECTRICAL
Subsection 06 (TESTING PROCEDURE)

A05E08A

TYPICAL

A05E07A
If readings do not correspond to the above-men-
TYPICAL tioned indications, replace switch.
If readings are acceptable, check other switches.
If readings do not correspond to the above-men-
tioned indications, replace switch. Tether Cord Switch
If readings are acceptable, check other switches. Fan Cooled Engines
Liquid Cooled Models Only Unplug switch block connected to main wiring
Check using a multimeter by connecting probes harness. Check using a multimeter by connecting
to BLACK/GREEN and BLACK/WHITE wires. The probes to wires. Refer to corresponding IGNI-
multimeter should indicate a closed circuit (0 ) in TION and ELECTRICAL SYSTEM TESTING table
operating position and a open circuit (0.L M ) in in this subsection. The multimeter should indi-
off position. cate an open circuit (0.L M ) in operating position
and a closed circuit (0 ) in off position.
If readings do not correspond to the above men-
tioned indications, replace switch.
If none of these verifications are conclusive, the
problem finds its source in the main wiring har-
ness. Proceed as follows:

Engine Cut-Out Switch

All Models
Unplug switch block connected to main wiring har-
ness. Check using a multimeter. Connect probes
to terminals. The multimeter should indicate an
open circuit (0.L M ) in operating position and a A05E09A

closed circuit (0 ) in off position. TYPICAL

If readings do not correspond to the above-men-

tioned indications, replace switch.
If readings are acceptable, check other switches.
If none of these verifications are conclusive, the
problem finds its source in the main wiring har-
ness. Proceed as follows:

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 Section 08 ELECTRICAL
Subsection 06 (TESTING PROCEDURE)

NOTE: For this next step, no stop switch must be – Connect multimeter probes to RED and BLACK
connected to the main wiring harness. wires (female end), then bring selector to Vac
Disconnect all stop switches from the main wiring and scale to 00.0.
harness and check the continuity of each wire by – Activate the manual starter and check values
connecting probes to the end of wires of the same indicated by the multimeter.
color. Repeat with all other wires. It is important – Repeat operation 3 times.
to mention that all wires of the same color within – Compare readings with those appearing in the
a given harness are connected together. These IGNITION table.
wires should therefore have a closed circuit. On
the other hand, BLACK and BLACK/YELLOW 5. TRIGGER COIL TESTING
wires must have an open circuit (0.L M ).
Repair or replace if necessary. Resistance Testing
– Connect probes to appropriate wires from trig-
4. IGNITION GENERATOR ger coil housing. Refer to corresponding IGNI-
COIL TESTING TION and ELECTRICAL SYSTEM TESTING ta-
ble in this subsection.
Resistance Testing
– Disconnect housing between the magneto and
the MPEM.
– Connect multimeter probes to appropriate
wires and measure resistance. Refer to corre-
sponding IGNITION and ELECTRICAL SYSTEM
TESTING table in this subsection.

A32E10A

– Compare readings with those appearing in the

IGNITION table.

Voltage Testing
– Connect probes to appropriate wires from trig-
ger coil housing. Refer to corresponding IGNI-
A32E0YA
TION and ELECTRICAL SYSTEM TESTING ta-
– Compare readings with those appearing in the ble in this subsection.
IGNITION table. – Activate the manual starter and check values
indicated by the multimeter.
Voltage Testing – Repeat operation 3 times.
When manually starting the engine while the spark – Compare readings with those appearing in the
plug is installed, the engine will tend to accelerate IGNITION table.
beyond the compression point. This will result in
higher magneto output power. 6. MPEM VOLTAGE TESTING
– Disconnect housing between the MPEM and Liquid Cooled Engines
the magneto.
– Disconnect the housing between module and
high voltage coil.

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Section 08 ELECTRICAL
Subsection 06 (TESTING PROCEDURE)

– Connect multimeter probes to WHITE/BLUE Voltage Testing

and BLACK wires coming out from module. – Disconnect spark plug cap from spark plug.
Place the selector switch to Vac and the scale – Fasten alligator clip to spark plug cable, near the
to 00.0. spark plug.
– Connect other multimeter wire to engine
(ground), then place selector switch to Vac and
scale to 0.00.
1 2

A32E0ZA

TYPICAL

– Activate the manual starter and check values

indicated by the multimeter. A32E11A
– Repeat operation 3 times.
1. MAG side spark plug cable
– Compare readings with those appearing in the 2. Connected to ground
IGNITION table.
– Activate the manual starter and check values
7. HIGH VOLTAGE COIL TESTING indicated by the multimeter.
Liquid Cooled Engines – Repeat operation 3 times.
– Compare readings with those appearing in the
Resistance Testing IGNITION table.
– Unplug housing between high tension coil and
MPEM. 8. BUZZER TESTING
– Connect multimeter probes to WHITE/BLUE
2-Stroke Engines
and BLACK wires and measure resistance.
Using jumper wires, connect battery positive post
to buzzer positive tab.
Connect battery negative post to buzzer negative
tab.
CAUTION: To avoid buzzer damage, ensure
that polarity is respected.

A32E12A

– Compare readings with those appearing in the

IGNITION table.

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 Section 08 ELECTRICAL
Subsection 06 (TESTING PROCEDURE)

LIGHTING GENERATOR COIL

VOLTAGE TESTING
– Disconnect housing from engine (YELLOW
wires).
1 – Connect multimeter probes to YELLOW wires,
then place selector switch to Vac and scale to
0.00.
2 – Activate the manual starter and check values
indicated by the multimeter.
– Repeat operation 3 times.

A32E3SA

TYPICAL — 12-VOLT BATTERY PLUGGED TO BUZZER

1. Buzzer positive tab
2. Buzzer negative tab

A continuous sound should be heard. if not, re-

place the buzzer with a new one.
4-Stroke Engines
Using jumper wires, connect battery positive post
to buzzer positive tab.
A05E0EA
Connect battery negative post to buzzer negative
tab. See next photo. TYPICAL

CAUTION: To avoid buzzer damage, ensure – Compare readings with those appearing in the
that polarity is respected.
LIGHTING table.

CONCLUSION
1
If none of the above testing operations produced
valid results, it is strongly recommended to keep
on testing according to the list appearing in the
RESISTANCE column of IGNITION or LIGHTING
2 table.
When using the tables, make sure to follow these
guidelines:
NOTE: Stop switches include the ignition switch,
the tether cord switch and the engine cut-out
switch.
It is important to take note that voltage measure-
ments must be taken while starting the vehicle us-
A32E3TA
ing the manual starter.
TYPICAL — 12-VOLT BATTERY PLUGGED TO BUZZER
1. Buzzer positive tab
Voltages obtained upon starting are proportional to
2. Buzzer negative tab the force applied onto the manual starter. A low
voltage is therefore normal under a low cranking
An intermittent sound should be heard. If not, re- force.
place the buzzer with a new one.

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Section 08 ELECTRICAL
Subsection 06 (TESTING PROCEDURE)

Perform testing in the prescribed order and re-

place any parts not performing according to spec-
ifications.
It is important to resume all tests when replacing
a component.
If not specified, the probe connecting sequence is
not important.
Set the multimeter as indicated.

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 Section 08 ELECTRICAL
Subsection 06 (TESTING PROCEDURE)

IGNITION SYSTEM TESTING — 277 ENGINE

MULTIMETER RESISTANCE VOLTAGE V
TEST TO BE WIRE
PART PROBE VALUE MULTIMETER VALUE MULTIMETER NOTE
PERFORMED COLOR
CONNECTION (ohms) SCALE (volts) SCALE
Running BK 4-MOC-M No stop switch must be
0.L 00.0 M — —
insulation BK/YL 4-MOA-M operational.
Stop Only one stop switch
switch Continuity in BK 4-MOC-M must be operational.
00.0 - 00.5 00.0 — —
STOP position BK/YL 4-MOA-M Test them one after the
other.
RD 4-DB-1-F
Output 4.5 - 6.5 00.0 7.0 - 15.0 00.0VAC —
BK 4-DB-2-F
Ignition
generator The term “engine”
Ground BK 4-DB-2-F refers to the engine
coil 00.0 - 00.5 00.0 — —
continuity engine engine metal parts connected
to the magneto housing.
WH/YL 4-DC-2-F
Forward 160 -180 00.0 .100 - .300 .000VAC —
BU/YL 4-DC-1-F
Trigger coil
WH/YL 4-DA-4-F
Reverse 160 -180 00.0 .100 - .300 .000VAC —
BU/YL 4-DA-3-F
Secondary
Spark
winding In spark plug cap CAUTION: Do not measure high voltage coil output
plug cap 4.90 K - 7.10 K 0.00 K
resistance and on the engine voltage.
engine
with caps
MPEM Secondary
Inside spark plug
and high winding BK CAUTION: Do not measure high voltage coil output
cable and on 0.90 K - 1.10 K 0.00 K
voltage resistance engine voltage.
the engine
coil without caps
The measurement must
Secondary On spark plug
BK be taken on the spark
winding cable housing — — .150 - .350 .000VAC
engine plug cable (without the
voltage and on the engine
spark plug).
Spark plug Spark plug side
Cap resistance — 4.0 K - 6.0 K 00.0 K — — —
cap and cable side

LIGHTING SYSTEM TESTING — 277 ENGINE

MULTIMETER RESISTANCE VOLTAGE V
TEST TO BE WIRE
PART PROBE VALUE MULTIMETER VALUE MULTIMETER NOTE
PERFORMED COLOR
CONNECTION (ohms) SCALE (volts) SCALE
YL 4-MOB-F
Power 00.0 - 00.6 00.0 3.0 - 7.0 00.0VAC —
YL 4-MOA-F
The term “engine”
Lighting refers to the engine
YL 4-MO (A,B)-F
generator Insulation 0.L 00.0 M — — metal parts connected
engine engine
coil to the magneto
housing.
BK 4-MOC-F
Ground continuity 00.0 - 00.5 00.0 — — —
engine engine

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Section 08 ELECTRICAL
Subsection 06 (TESTING PROCEDURE)

IGNITION SYSTEM TESTING — 443 AND 552 ENGINES

RESISTANCE VOLTAGE V
TEST TO BE WIRE
PART VALUE MULTIMETER MULTIMETER NOTE
PERFORMED COLOR VALUE (volts)
(ohms) SCALE SCALE
BK All switches must be in run
Running insulation 0.L 00.0 M — —
BK/YL position.
Stop switch Only one stop switch must be
Continuity in STOP BK
00.0 - 00.5 00.0 — — in stop position. Test them one
position BK/YL
after the other.
RD
Output 4.5 - 6.5 00.0 7.0 - 15.0 00.0VAC —
Ignition BK
generator The term “engine” refers to the
coil BK
Ground continuity 00.0 - 00.5 00.0 — — engine metal parts connected to
engine
the magneto housing.
Front Resistance and WH/YL
160 -180 00.0 .150 - .350 .000VAC —
trigger coil output BL/YL
Rear Resistance and WH/YL
160 -180 00.0 .150 - .350 .000VAC —
trigger coil output BL/YL
Spark plug
Secondary winding
cap
resistance with 8.90 K - 13.1 K 00.0 K CAUTION: Do not measure high voltage coil output voltage.
Spark
caps
plug cap
MPEM and
Secondary winding
high voltage BK
resistance without 0.90 K - 1.10 K 00.0 K CAUTION: Do not measure high voltage coil output voltage.
coil BK
caps
The measurement must be taken
Secondary winding BK
— — .100 - .250 0.00VAC on the spark plug cable (without
voltage engine
the spark plug).
Spark plug
Cap resistance — 4.0 K - 6.0 K 00.0 K — — —
cap

LIGHTING SYSTEM TESTING — 443 AND 552 ENGINES

RESISTANCE VOLTAGE V
TEST TO BE WIRE
PART VALUE MULTIMETER VALUE MULTIMETER NOTE
PERFORMED COLOR
(ohms) SCALE (volts) SCALE
Power YL YL/BK 00.0 - 00.6 00.0 3.0 - 7.0 00.0VAC —
Lighting
Insulation YL engine 0.L 00.0 M — — The term “engine” refers to the
generator
coil BK engine metal parts con nected to
Ground continuity 00.0 - 00.5 00.0 — — the magneto housing.
engine

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 Section 08 ELECTRICAL
Subsection 06 (TESTING PROCEDURE)

IGNITION SYSTEM TESTING — 593 ENGINE

RESISTANCE VOLTAGE V
TEST TO BE
PART WIRE COLOR VALUE MULTIMETER VALUE MULTIMETER NOTE
PERFORMED
(ohms) SCALE (volts) SCALE
All switches must be in
Running insulation BK and BK/YL 0.L 00.0 M — —
run position.
Only one stop switch must
Continuity in stop
BK and BK/YL 00.0 - 00.5 00.0 — — be in stop position. Test
Stop position
one at a time.
switches
Insulation in stop BK/GN and Tether cord cap must be
0.L 00.0 — —
position BK/WH off.
BK/GN and Tether cord cap must be in
Running continuity 00.0 - 00.5 00.0 — —
BK/WH place.
Output RD and BK/RD 11.6 - 21.6 00.0 15.0 - 30.0 00.0VAC —
Coil insulation RD and BK 0.L 00.0 M — — —
Ignition
generator The term “engine” refers
coil to the engine metal parts
Ground continuity BK and engine 00.0 - 00.5 00.0 — —
con nected to the magneto
housing.
WH/YL and
Trigger coil Resistance and output 190 - 300 00.0 .200 - .350 .000VAC —
BL/YL
All switches must be in
MPEM Output voltage WH/BL and BK — — 25.0 - 100.0 00.0VAC
run position.
Primary winding
WH/BL and BK 00.0 - 00.9 00.0 — — —
resistance
Secondary winding Spark plug cap
CAUTION: Do not measure high voltage coil output
resistance (spark plug and Spark plug 19.5 K - 26.5K 00.0 K
voltage.
cap included) cap
Secondary winding
High resistance (without BK and BK 9.6 K - 14.4K 00.0 K
CAUTION: Do not measure high voltage coil output
voltage.
voltage coil spark plug cap)
The measurement must be
Secondary winding taken on the spark plug
BK and engine — — 0.1 - 1.4 0.00VAC
voltage wire (without the spark
plug).
Spark plug cap
Insulation 0.L 00.0 M — — —
and BK
Spark plug
Cap resistance — 4.0 K - 6.0 K 00.0 K — — —
cap

LIGHTING SYSTEM TESTING — 593 ENGINE

RESISTANCE VOLTAGE V
TEST TO BE WIRE
PART VALUE MULTIMETER VALUE MULTIMETER NOTE
PERFORMED COLOR
(ohms) SCALE (volts) SCALE
Output YL and YL 00.1 - 00.4 00.0 0.5 - 2.0 00.0VAC —
Lighting YL and
Coil insulation 0.L 00.0 M — — The term “engine” refers to the
generator engine
coil engine metal parts connected to the
Ground BK and magneto housing.
00.0 - 00.5 00.0 — —
continuity engine

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Section 08 ELECTRICAL
Subsection 06 (TESTING PROCEDURE)

IGNITION SYSTEM TESTING — 593 HO SDI ENGINE

MULTIMETER RESISTANCE VOLTAGE V
TEST TO BE WIRE
PART PROBE MULTIMETER VALUE MULTIMETER VALUE NOTE
PERFORMED COLOR
CONNECTION SCALE (ohms) SCALE (volt)
Engine cut-out
B-21 00.0 or auto
Running insulation YL/BK and BK 0.L — — switches must be
ground range
Engine stop in run position.
switch Engine cut-out
Continuity in STOP B-21 00.0 or auto 00.0 -
YL/BK and BK — — switches must be
position ground range 00.5
in stop position.
Insulation with DESS WH/GR and B-38 00.0 or auto
0.L — — DESS key removed.
removed WH/BK B-26 range
DESS switch
Continuity with DESS WH/GR and B-38 00.0 or auto 00.0 - DESS key must be
— —
in run position WH/BK B-26 range 00.5 in place.
BK and negative
B-1, B-2, B-9, 00.0 or auto 00.0 -
ECM Ground connection battery terminal — — —
B-32 and B-41 range 00.5
or body
Same as
B-11 Voltage always
ECM power Power from battery PK — — 00.0 VDC battery
ground present.
(with voltage
battery) B-36 and 1 to 2 While cranking
Power from regulator GN/BL — — 00.0 VDC
ground volts engine.
A-5 00.0 or auto While cranking
CPS Resistance and output BU/YL and WH/YL 190 - 290 00.0 VAC 2.0
A-19 range engine.
Disconnect the
Primary winding Pin 1-2 00.0 or auto
— 0.3 to 0.6 — — ignition coil from
High voltage resistance Pin 2-3 range
the ECM
coil
Secondary winding
— — — — — — No test possible.
resistance
When start/RER
11–DA-7–F Battery
Start switch Start signal at ECM OR/BK and LBN — — 00.0 VDC switch is activated
11–DA-3–F voltage
in all conditions.

LIGHTING SYSTEM TESTING — 593 HO SDI ENGINE

MULTIMETER RESISTANCE VOLTAGE V
TEST TO BE WIRE
PART PROBE MULTIMETER VALUE MULTIMETER VALUE NOTE
PERFORMED COLOR
CONNECTION SCALE (ohms) SCALE (volt)
Charging
Refer to B.U.D.S. — — — — — — —
voltage
Do the test between
.145 to 3.5 to
00.0 or 1 and 2, 1 and 3
Output YL and YL and GN Pin 1, 2, 3 .185 00.0 VAC 5.5
autorange and 2 and 3 using
3 times 3 times
Lighting manual starter.
generator The term engine
coil refers to the metal
Pin 1, 2, 3 and 00.0 or
Coil insulation YL, GN and engine 0.L — — parts connected
engine autorange
to the magneto
housing.

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 Section 08 ELECTRICAL
Subsection 06 (TESTING PROCEDURE)

INSPECTION OF AC CIRCUIT When measuring resistance at terminals the ac-

ISOLATION tual value will be half the measurement in table.
The reason for that is the elements are connect-
All Electric Start Models ed in parallel. Therefore the total resistance is half
If AC circuit is not isolated from frame, headlamp the resistance of one element.
beam will weaken.

INSPECTION
Disconnect regulator/rectifier.
On models with hydraulic brake, pull off the rubber
boot from brake light microswitch assembly.
Connect one digital ohmmeter probe (needle ohm-
meter will not offer enough precision) to frame
and other probe to one of 2 YELLOW magneto
wires.
Measured resistance must be infinite. If such is
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.

INSPECTION OF HEATING
ELEMENTS
All Skandic Models
All measurements must be performed at 21°C
(70°F).

Throttle Lever Heating Element

Current Measurement

HIGH BROWN 0.23 A

INTENSITY wire minimum
LOW BROWN/YELLOW 0.13 A
INTENSITY wire minimum

Handlebar Grip Heating Element

Resistance Measurement

YELLOW/BLACK
LOW wire 17.7 to 20.7
INTENSITY ORANGE/VIOLET ohms
wire
HIGH YELLOW/BLACK 8.73 to 10.67
INTENSITY wire ORANGE wire ohms

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 Section 09 REAR SUSPENSION
Subsection 01 (TORQUE REACTION SUSPENSION)

TORQUE REACTION SUSPENSION

SERVICE PRODUCTS
Description Part Number Page

synthetic grease ................................................................... 293 550 033 ......................................... 487

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Section 09 REAR SUSPENSION
Subsection 01 (TORQUE REACTION SUSPENSION)

Tundra

24 N•m
1 (18 lbf•ft)

Synthetic
24 N•m grease
(18 lbf•ft)
5
Synthetic
grease
48 N•m
2 3 (35 lbf•ft)
Loctite 271
4
24 N•m
(18 lbf•ft)
Synthetic Loctite
grease 243

Synthetic
grease
45 N•m
(35 lbf•ft)

Loctite
6 271
7
11 N•m 8
(97 lbf•in)

11 N•m
(97 lbf•in)
2.5 N•m 7 8
(23 lbf•in)
9 3 N•m
(27 lbf•in) Loctite
271
11 24 N•m
10 (18 lbf•ft)
A05F12T

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 Section 09 REAR SUSPENSION
Subsection 01 (TORQUE REACTION SUSPENSION)

COMPONENT REMOVAL
Lift rear of vehicle and support it off the ground.
A
5, Rear Arm
Release track tension.
Release spring tension. Unfasten shock from rear
arm. Remove 3 screws retaining rear arm.

SUSPENSION ASS'Y REMOVAL

Release track tension.
NOTE: To prevent cross shaft from turning when A05F0CA 1 2
unscrewing screws assembled with threadlocker,
proceed as follows: 1. 1st hole
2. 3rd hole
– Loosen one screw then retighten. A. 11 N•m (97 lbf•in)
– Remove the other screw.
– Remove the first one.
9,10,11, Nut, Slotted Screw and
1,2,3,4, Cross Shaft, Idler Wheel, Slider Shoe
Spacer and Screw To replace a worn shoe, remove the front screw
Remove idler wheel ass'y. and stop nut, then slide the shoe rearward out of
the runner.
Suspension Ass'y 1
Lift rear of vehicle and support it off the ground.
Unscrew 4 screws retaining front arm and rear
arm to frame.
Remove suspension.

DISASSEMBLY AND ASSEMBLY

6, Stopper Strap
When assembling make sure it is attached
through the 3rd hole from the end. Torque nut to
11 N•m (97 lbf•in). A05F0IC

1. Front screw and nut

CAUTION: Slider shoes must always be re-

placed in pairs.

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Section 09 REAR SUSPENSION
Subsection 01 (TORQUE REACTION SUSPENSION)

7,8, Support and Front Arm Support

To remove rivets securing the supports, cut rivet
heads off using a cold chisel.
At assembly, position the rivet head toward the
outside of the assembly. Support the rivet head
against a metal block, as shown, and use a flat
head punch to secure the rivet in place.

1
2

A03F3SA 1 2
TYPICAL
1. Slider shoe
3 2. Molding line (wear limit indicator)

Replace slider shoes when wear limit is reached.

4 CAUTION: Slider shoes must always be re-
placed in pairs.
A07F02A

1. Flat head punch

SUSPENSION ASS'Y
2.
3.
Support
Runner
INSTALLATION
4. Metal block
Release rear spring tension then install assembled
NOTE: Rivets can be substituted with 3/16 in x suspension into track with front portion first.
3/4 in long screws and flanged elastic stop nuts. Insert rear portion of suspension into track.
Always position screw head outside the assembly. Bolt suspension to tunnel.
Pry rear spring end onto cam.
INSPECTION
6, Stopper Strap
Inspect strap for wear or cracks, bolt and nut for
tightness. If loose, inspect hole for deformation.
Replace as required.

Shock Absorber
Refer to SUSPENSION AND SKI SYSTEM for
shock inspection.

11, Slider Shoe

Molding line is the wear limit indicator.
1
A05F0JA

1. Spring end

Adjust track tension/alignment. Refer to TRACK.

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 Section 09 REAR SUSPENSION
Subsection 01 (TORQUE REACTION SUSPENSION)

RIDE ADJUSTMENT 2
1
The front portion of rear suspension is adjustable
for surface condition and steering effects.
The stopper strap is adjustable for vehicle weight
transfer control.
The rear portion of rear suspension is adjustable
for driver's weight.

A05F0MA

SOFTEST ADJUSTMENT
1. Supporting edge closest to hexagonal
2. Spring

The stiffest adjustment is reached when the sup-

A05F0AA 2 3 4 porting edge of cam is the farthest to hexagonal
portion of cam.
1. Driver's weight
2. Stopper strap for weight transfer
3. Steering effect/surface condition 1
4. Adjustment cams

Choice of suspension adjustments depends on

carrying load, driver's weight, personal prefer-
ence, riding speed and field condition.
Slight suspension bottoming occurring under the
worst riding conditions indicates a good choice of
spring preload.
To adjust rear suspension with the adjustment
cams, use special key supplied in vehicle tool box.
Turning adjustment cam moves edges of cam A05F0NA

supporting spring rod. The softest adjustment is STIFFEST ADJUSTMENT

reached when the supporting edge of cam is the 1. Supporting edge farthest to hexagonal
closest to hexagonal portion of cam.

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Section 09 REAR SUSPENSION
Subsection 01 (TORQUE REACTION SUSPENSION)

NOTE: To quickly change rear cam position with-  WARNING

out using any tool:
Always torque the nut to 11 N•m (97 lbf•in).
– Lay vehicle on its side. Replace strap if worn or torn.
– Unhook rear spring by hand from lower idler
wheel.

A05F0CA 1 2
1. 1st hole
A05F0FA 2 2. 3rd hole
A. 11 N•m (97 lbf•in)
– Turn adjustment cam by hand to the desired
position. NOTE: When towing a load, it is suggested to ad-
– Reinstall spring on its support making sure that just stopper strap to its shortest length, soften
it sits in the groove of support. front springs of rear suspension and stiffen rear
springs. These adjustment will improve steering
Stopper Strap ability.
The function of the stopper strap is to control the Deep Snow Operation
transfer of vehicle weight during acceleration and
to control track lead angle. When operating the vehicle in deep snow, it may
be necessary to change position of adjustment
The longer the belt, the more the weight will be cams, stopper strap and/or driver's riding position,
transferred to the track to provide a better trac- to change the angle at which the track rides on the
tion. The shorter the belt, the lesser the weight snow. Operator's familiarly with the various ad-
transferred to the track, thus maintaining a more justments as well as snow conditions will dictate
positive steering. the most efficient combination.
The longer the belt, the greater will be the track
lead angle. A shorter belt will reduce track lead
angle which may help when negotiating a particu-
lar snow condition.
Adjusting holes on the stopper strap allow to
adjust it according to driver's requirements, field
and/or snow conditions.
CAUTION: Whenever stopper strap length is
changed, track tension must be readjusted to
prevent any possibility of operating vehicle
with a too loose or too tight track tension.
For normal use, locate bolt through 3rd hole from
strap end.

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 Section 09 REAR SUSPENSION
Subsection 01 (TORQUE REACTION SUSPENSION)

LUBRICATION
Lubricate front and rear arms at grease fittings
using suspension synthetic grease (P/N 293 550
033).
NOTE: There are 4 grease fittings.

A05F0GA

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 Section 09 REAR SUSPENSION
Subsection 02 (ARTICULATING SLIDE SUSPENSION)

ARTICULATING SLIDE SUSPENSION

Skandic LT/WT/SWT/WT LC

SWT
only

3
Loctite
243

2
Loctite
243

Loctite
243

SWT 5
6
only

Loctite
Loctite 243
243

A22F1GS

TYPICAL

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Section 09 REAR SUSPENSION
Subsection 02 (ARTICULATING SLIDE SUSPENSION)

REMOVAL
Release track tension.
Lift rear of vehicle and support it off the ground.
Unbolt front arm then rear arm.

Self-Locking Screws
CAUTION: These self-locking screws must al-
ways be replaced by new ones every time they
are removed.
NOTE: To prevent axle from turning when un-
screwing self-locking screws, proceed as follows:
– Remove one self-locking screw then install a
10 mm shorter non-self-locking one in place. A22F19A 1
Torque as specified in exploded view. 1. Support
– Remove the opposite self-locking screw.
– Remove the temporary installed non-self-
locking screw.
2, Conical Washer
– If it doesn't work, heat bolt head to melt thread- At installation, position conical washers as shown.
locker. 11 11 2 2 3 3 3 4
Remove suspension assembly.

A22F1AA

WASHER QUANTITY AND MOUNTING POSITION

A22F1EA

DISASSEMBLY AND ASSEMBLY

1, Extension
Remove nuts and conical washers from the eye
bolt adjuster. Remove bolt retaining eye bolt ad-
juster to support. A22F1BA

Remove rear idler wheel on appropriate side. Tighten nut 3/4 turn after contacting washers for
Remove idler wheel from support. better deep snow performance. Maximum pre-
Unbolt extension from its support. 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.

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 Section 09 REAR SUSPENSION
Subsection 02 (ARTICULATING SLIDE SUSPENSION)

4, Rear Spring
Remove top idler wheels.
Unscrew one end of shock.
Remove spring.

5, Front Spring
Remove circlips retaining spring support to top
and bottom of front arm.
Holding spring end, remove lock pin of top spring
support then bottom support lock pin.
Unbolt front idler wheel axle.
Remove idler wheel on side where axle retaining
A22F1DA
plate is not welded.
Remove springs. Rivets can be substituted by M8 x 20 bolts and
nuts.

3, Horse-Shoe Washer
For deep snow riding, do not install washer.
For trail riding with passenger and/or weight, in-
stall 1 washer under each rubber stoppers.
For trail riding with heavy load and/or pulling a load,
use 2 washers under each rubber stoppers.

7, Shock
Install shock with its rod upward.

SHOCK ABSORBER SERVICING

A22F1CA 1 Secure the shock body end in a vise.
1. Circlips
1

6, Support Plate
Drill rivets to remove support plate. Use a 8 mm
(21/64 in) drill bit.
A14F0BA

TYPICAL
1. Clamp

CAUTION: Do not clamp directly on shock

body.
Examine each shock for leaks. Extend and com-
press the piston several times over its entire
stroke then check that it moves smoothly and
with uniform resistance.

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Section 09 REAR SUSPENSION
Subsection 02 (ARTICULATING SLIDE SUSPENSION)

Pay attention to the following conditions that will

denote a faulty shock:
– A skip or a hang back when reversing stroke at
mid travel.
– Seizing or binding condition except at extreme
ends of stroke.
– Oil leakage.
– A gurgling noise, after completing one full com-
pression and extension stroke.
Renew if any fault is present.

INSTALLATION
Threaded holes must be cleaned before a self-
locking screw is installed. Use a metal brush or a
screwtap to clean the hole properly then use a sol-
vent (Methyl-Chloride), let act during 30 minutes
and wipe off. The solvent utilization is to ensure
the adhesive works properly.
Use a tie-down between front arm and spring axle
to ease installation of front arm screws.

A22F1FA

RIDE ADJUSTMENT
Refer to Operator's Guide.

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 Section 09 REAR SUSPENSION
Subsection 03 (SUV SUSPENSION)

SUV SUSPENSION
SERVICE TOOLS
Description Part Number Page
shock spring removal kit....................................................... 529 035 504 ......................................... 496

SERVICE PRODUCTS
Description Part Number Page

synthetic grease ................................................................... 413 711 500 ......................................... 498

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Section 09 REAR SUSPENSION
Subsection 03 (SUV SUSPENSION)

Skandic SUV/Expedition TUV

Synthetic
grease

7
1

Synthetic
grease
2
5

Loctite 271
54 N•m
(40 lbf•ft)

Loctite 271
80 N•m
(59 lbf•ft)
A29F0GU

TYPICAL

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 Section 09 REAR SUSPENSION
Subsection 03 (SUV SUSPENSION)

REMOVAL
Release track tension.
Lift rear of vehicle and support it off the ground.
Unbolt front arm then rear arm.

Self-Locking Screws
CAUTION: These self-locking screws must al-
ways be replaced by new ones every time they
are removed.
NOTE: To prevent axle from turning when un-
screwing self-locking screws, proceed as follows:
– Remove one self-locking screw then install a
10 mm shorter non-self-locking one in place. A22F19A 1
Torque as specified in exploded view. TYPICAL
1. Support
– Remove the opposite self-locking screw.
– Remove the temporary installed non-self-lock-
ing screw. 2, Conical Washer
– If it doesn't work, heat bolt head to melt thread- At installation, position conical washers as shown.
locker.
Remove suspension assembly. 3 3 2 2 11 11 11 11 11 11 11 11

A29F0IA

WASHER QUANTITY AND MOUNTING POSITION

A29F0HA

DISASSEMBLY AND ASSEMBLY

1, Extension
Remove nuts and conical washers from the eye
bolt adjuster. Remove bolt retaining eye bolt ad- A29F0JA

juster to support.
Tighten nut 3/4 turn after contacting washers
Remove rear idler wheel on appropriate side. for better deep snow performance. Maximum
Remove idler wheel from support. preload is 3 turns after nut touching washers.
Unbolt extension from its support. This last adjustment is for trail riding with or with-
out a load and for pulling a load.

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Section 09 REAR SUSPENSION
Subsection 03 (SUV SUSPENSION)

8, Rear Spring
Unbolt top and bottom ends of shock.

7, Front Spring 1
Unbolt top end of shock.
Unbolt axle retaining bottom end of shock. 2
At assembly, make sure that notch on both axle
sleeves match rail rib.

2 3

1
A01B4LA

1. Clevis pin
2. Bar
3. Handle horizontal

A29F0KA
Push down on the handle until it locks. Remove
1. Notch spring stopper then release handle.
2. Rail rib

For shock spring disassembly use shock spring SHOCK ABSORBER INSPECTION
removal kit (P/N 529 035 504) in a vise. Mount Secure the shock body end in a vise.
shock in it and turn shock so that spring coils rests
against spring compressor jaw. 1
Close and lock the bar. Place handle horizontally
by changing the position of the clevis pin.

A14F0BA

TYPICAL
1. Clamp

CAUTION: Do not clamp directly on shock

body.
Examine each shock for leaks. Extend and com-
press the piston several times over its entire
stroke then check that it moves smoothly and
with uniform resistance.
Pay attention to the following conditions that will
denote a faulty shock:

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 Section 09 REAR SUSPENSION
Subsection 03 (SUV SUSPENSION)

– A skip or a hang back when reversing stroke at 5, Stopper Strap

mid travel. Fasten stopper strap to lower bracket hole.
– Seizing or binding condition except at extreme
ends of stroke.
– Oil leakage.
– A gurgling noise, after completing one full com-
pression and extension stroke.
Renew if any fault is present.

3, Spacer
At assembly, install spacer on outer side of top
idler wheel.

A29F0PA

INSTALLATION
Threaded holes must be cleaned before a self-
locking screw is installed. Use a metal brush or a
screwtap to clean the hole properly then use a sol-
vent (Methyl-Chloride), let act during 30 minutes
and wipe off. The solvent utilization is to ensure
the adhesive works properly.
A29F0NA 1
Install front portion of suspension first.
1. Spacers

4, Coupling Tube
At assembly, install coupling tube with its grease
fitting facing outward.

A29F0QA

A29F0OA 1
1. Grease fitting facing outward

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Section 09 REAR SUSPENSION
Subsection 03 (SUV SUSPENSION)

LUBRICATION
Lubricate front and rear arms at grease fittings us-
ing synthetic grease (P/N 413 711 500).
NOTE: There is 9 grease fittings.

A29F0RA

RIDE ADJUSTMENT
Refer to Operator's Guide.

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 Section 09 REAR SUSPENSION
Subsection 04 (DRIVE AXLE)

DRIVE AXLE
SERVICE TOOLS
Description Part Number Page
drive axle sprocket adjuster kit ............................................. 861 725 700 ......................................... 509

SERVICE PRODUCTS
Description Part Number Page

suspension synthetic grease ................................................ 293 550 033 ......................................... 508

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Section 09 REAR SUSPENSION
Subsection 04 (DRIVE AXLE)

Tundra

12 9
11

6
Synthetic
grease
9

8
5

A05D1BT

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 Section 09 REAR SUSPENSION
Subsection 04 (DRIVE AXLE)

Skandic LT/LT E

12

Synthetic grease

8 6

13

13

11

5 14
10
Synthetic
grease

1
A29D2GS

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Section 09 REAR SUSPENSION
Subsection 04 (DRIVE AXLE)

Skandic WT/SWT/WT LC/SUV

13

4
9

1
13

6
Loctite 271

A29D2HT

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 Section 09 REAR SUSPENSION
Subsection 04 (DRIVE AXLE)

Expedition TUV

10

Synthetic
Grease
8

14 5
15 16 11 3
17
3

13

13

A29D2SS

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Section 09 REAR SUSPENSION
Subsection 04 (DRIVE AXLE)

REMOVAL Remove 3 screws retaining ball bearing housing

then, remove inner plate no. 3.
Tundra R and Skandic LT/LT E
Remove drive axle.
Drain oil from chaincase. Release drive chain ten-
sion. Remove chaincase cover. Expedition TUV
Raise and block rear of vehicle off the ground. Drain gearbox.
Remove suspension. Refer to SUSPENSION. Remove the following parts:
– speedometer flange no. 15
2,8, End Bearing Housing and Seal – magnetic adaptor no. 16
Remove cable protector no. 7, and plastic bearing – washer no. 17
cover. Remove circlip no. 14 from drive axle. – bearing housing cover no. 3.
Remove chain and sprocket then circlip and bear- Raise and block rear of vehicle off the ground.
ing no. 12 from drive axle.
Remove suspension. Refer to ARTICULATING
Pry oil seals from chaincase and end bearing hous- SLIDE SUSPENSION.
ing.
Release drive axle sprocket from track and at the
6,9,13, Drive Axle and Sprocket same time, pulling the drive axle towards the end
bearing housing side.
Release drive axle sprocket from track and at the
same time, pulling the drive axle towards the end Remove drive axle.
bearing housing side.
Remove drive axle from vehicle. DISASSEMBLY
Skandic WT/SWT/WT LC/SUV 4, Speedometer Drive Insert
Drain gearbox. Remove speedometer drive insert.
Remove angle drive no. 1 and square pin no. 4.
5,12, Bearing
Raise and block rear of vehicle off the ground.
Tundra Only
Remove suspension. Refer to ARTICULATING
SLIDE SUSPENSION. To remove bearings, use puller assembly, ring and
half rings as illustrated.
Remove muffler. Unfasten screw from drive axle
end. Loosen Allen screw on bearing race.
1

A00C44A

9,13, Sprocket and Half-Sprocket

All Models
A22D15B 2 To remove press fit sprockets, use a press and a
1. Allen screw suitable support as illustrated.
2. Screw

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 Section 09 REAR SUSPENSION
Subsection 04 (DRIVE AXLE)

A00F06A
1 A00F07A

TYPICAL — TUNDRA TYPICAL — TUNDRA

1. Support sprocket near hub 1. Pipe

A33D0MA

A33D0LA
TYPICAL — ALL MODELS EXCEPT TUNDRA
1. Pipe
TYPICAL — ALL MODELS EXCEPT TUNDRA

NOTE: Two different types of sprocket press fit

can be found. Ensure to replace ring reinforced
sprockets with the same type.

ASSEMBLY
6,9,13, Drive Axle and Sprocket
To assemble press fit sprockets, use a press and
a suitable pipe as illustrated. Sprockets must be
assembled according to the following dimensions.

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Section 09 REAR SUSPENSION
Subsection 04 (DRIVE AXLE)

Tundra Expedition TUV

A B
2

A
1
B
C
A29D1VA
D
3
1. Gearbox side
A00F08B 1 A. 46.0 mm (1.811 in)
B. 148.0 mm (5.827 in)
TYPICAL C. 390.0 mm (15.354 in)
1. Chaincase side D. 492.0 mm (19.370 in)
2. Center line of sprocket
3. Drive axle end
Skandic SWT
A. 83.0 mm (3-17/64 in)
B. 237 mm (9-21/64 in)

Skandic LT/LT E

A
1
B
C
D
A A29D1WA

1. Gearbox side
B A. 105.0 mm (4.016 in)
C B. 207.0 mm (8.150 in)
C. 449.0 mm (17.677 in)
D D. 551.0 mm (21.693 in)
A29D1UA

A. 47.0 mm (1.850 in) All Models

B. 148.0 mm (5.827 in)
C. 271.0 mm (10.669 in) Ensure to align indexing marks of each sprocket
D. 372.0 mm (14.646 in) when assembling.
Skandic WT/WT LC/SUV

A
1
B
C
A29D1VA
D

1. Gearbox side
A24D05A
A. 55.0 mm (2.165 in)
B. 157.0 mm (6.181 in)
C. 399.0 mm (15.709 in) TYPICAL
D. 501.0 mm (19.724 in) 1. Indexing marks aligned

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 Section 09 REAR SUSPENSION
Subsection 04 (DRIVE AXLE)

The maximum de-synchronization for the sprock- 1 2

ets is 1.5 mm (1/16 in).
To check this tolerance, place axle assembly on
a plane surface and measure the gap between
sprocket tooth and surface.

A00F0CA

1 A 1. Grease seal type

2. Oil seal type
A00F0AA
11, Bearing Protector
TYPICAL — TUNDRA
1. Plane surface At assembly, flat side of bearing protector must
A. 1.5 mm (1/16 in) MAXIMUM be against bearing.

5,12, Bearing
Always push bearing by inner race.

A00F0DA

TYPICAL — TUNDRA

A33D0NA

TYPICAL — ALL MODELS EXCEPT TUNDRA

A. 1.5 mm (1/16 in) MAXIMUM

CAUTION: The same sprocket must not be

pressed twice on the axle. If synchronization
is 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.

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Section 09 REAR SUSPENSION
Subsection 04 (DRIVE AXLE)

Install chaincase and position seals (if applicable),

making sure that a gap of approximately 2 mm
(1/16 in) exists between end of bearing housing
and each seal.

3 A

4
1 2

A00F0GA

SIDE VIEW
1. Bearing
2. Seal
A33D0OA 3. Housing
4. Seal lip
TYPICAL — ALL MODELS EXCEPT TUNDRA A. 2 mm (.080 in) approximately
The bearing on the splined side of axle must be
pushed until it is seated on shaft shoulder. The 3, Retainer Ring
end bearing housing bearing must be flush with Make sure that welded nuts are toward inside of
end of drive axle. Each bearing must have its tunnel.
shield facing the sprocket. Lock drive axle sprocket with a circlip.
1 1 Reinstall the chaincase cover.
Refill with chaincase oil. Refer to TECHNICAL DA-
TA.
Install the suspension. Refer to TRACK and adjust
track tension and carry out track alignment proce-
dure.
2
A00F05A 3 LUBRICATION
1. Bearing shield on this side
2. Flush with drive axle
10, Grease Fitting
3. Seated on shaft shoulder Lubricate end housing bearing with suspension
synthetic grease (P/N 293 550 033).
INSTALLATION
Position drive axle assembly into location. Install ADJUSTMENT
end bearing housing. Install spacer (if applicable)
between bearing and lower chaincase sprocket. Sprocket/Track Alignment
CAUTION: Do not tamper with sprocket/track
alignment if frame or suspension is damaged.

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 Section 09 REAR SUSPENSION
Subsection 04 (DRIVE AXLE)

Sprockets might be repositioned to fit lugs without

removing drive axle.
Use drive axle sprocket adjuster kit (P/N 861 725
700).

A01B2PA

TYPICAL — TUNDRA

A33D0PA

TYPICAL — ALL MODELS EXCEPT TUNDRA

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 Section 09 REAR SUSPENSION
Subsection 05 (TRACK)

TRACK
SERVICE TOOLS
Description Part Number Page
belt tension tester ................................................................ 414 348 200 ......................................... 512
narrow track cleat installer.................................................... 529 008 500 ......................................... 511
narrow track cleat installer.................................................... 529 028 800 ......................................... 514
snowmobile mechanical stand ............................................. 529 020 000 ......................................... 512
track cleat remover............................................................... 529 028 700 ................................. 511, 514

TRACK TYPE APPLICATION REMOVAL

Refer to TECHNICAL DATA section. Tundra
Remove the following items:
GENERAL – chaincase cover, sprockets, chain
This section gives guidelines for track removal. – muffler
Some components require more detailed disas- – upper center idler ass'y
sembly procedures. In these particular cases, re- – suspension
fer to the pertaining section in this manual. – end bearing housing
– drive axle seal
INSPECTION – drive axle (outwards from end bearing housing)
Visually inspect track for: – track.
– cuts and abnormal wear Skandic LT/LT E
– broken rods Remove the following parts:
– broken or missing track cleats.
– speedometer cable
If track is damaged or rods are broken, replace – muffler
track. For damaged or missing cleats, replace by
– chaincase cover
new ones, using track cleat remover (P/N 529 028
700). Use narrow track cleat installer (P/N 529 008 – suspension
500). – drive axle seal
– end bearing housing
 WARNING – sprockets and chain
Do not operate a snowmobile with a cut, torn – drive axle (toward end bearing housing)
or damaged track. – track.
Skandic WT/SWT/WT LC/SUV/Expedition
TUV
Remove the following parts:
– rear suspension
– muffler.
Drain gearbox.
Remove drive axle then track.

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Section 09 REAR SUSPENSION
Subsection 05 (TRACK)

INSTALLATION
All Models
Reverse the removal procedure.
NOTE: When installing the track, respect rotation 2
direction indicated by an arrow on track thread.
Check sprocket/track alignment as described in
DRIVE AXLE.

Track Tension and Alignment

Track tension and alignment are inter-related. Do
not adjust one without checking the other. Track
tension procedure must be carried out prior to
track alignment.

Tension
A32F39A 1 3
NOTE: Ride the snowmobile in snow about 15 to
TYPICAL
20 minutes prior to adjusting track tension. 1. Top tool O-ring positioned at 7.3 kg (16 lb)
2. Push on top portion of tool until it contacts the top O-ring
Remove the tether cord cap. 3. Measured track deflection
Lift rear of snowmobile and support it with a wide-
base snowmobile mechanical stand (P/N 529 020 CAUTION: Too much tension will result in pow-
000). er loss and excessive stresses on suspension
components.
Allow the suspension to extend normally and
check gap halfway between front and rear idler To adjust track tension:
wheels. Measure between slider shoe bottom – Remove the tether cord cap.
and inside of track. The gap should be as given – Loosen the rear idler wheel retaining screws.
in SPECIFICATIONS at the end of this guide. If – Loosen the lock nuts (on so equipped models)
the track tension is too loose, track will have a then turn adjustment screws to adjust.
tendency to thump.
NOTE: A belt tension tester (P/N 414 348 200)
may be used to measure deflection as well as
force applied.

A00C07C

BELT TENSION TESTER

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 Section 09 REAR SUSPENSION
Subsection 05 (TRACK)

1 2 1
2

3
A01F05A

1. Guides
2. Slider shoes
3. Equal distance

3 To adjust track alignment:

A29F14A
– Remove the tether cord cap.
TYPICAL
1. Adjustment screw – Loosen rear idler wheel retaining screws.
2. Loosen lock nut (on so equipped models)
3. Loosen screw – Loosen the lock nuts (on so equipped models).
– Tighten the adjustment screw on side where
– Retighten retaining screws and lock nuts (on so the slider shoe is the farthest from the track
equipped models). insert guides.
– Check track alignment as described below. 1 2 1
Alignment
 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. 3
A01F0BA
Ensure no one is standing in close proximity
to the snowmobile. Never rotate track at high 1. Guides
2. Slider shoes
speed. 3. Tighten on this side

Start the engine and accelerate slightly so that Tighten lock nuts (some models only) and retaining
track barely turns. This must be done in a short screws.
period of time (15 to 20 seconds).
 WARNING
Check that the track is well centered; equal
If lock nuts are not tightened properly, the ad-
distance on both sides between edges of track
justing screws could loosen causing the track
guides and slider shoes.
to become extremely loose and, under some
operating conditions, allow the idler wheels
to climb over the track lugs forcing the track
against the tunnel causing the track to “lock”.
Properly tighten wheel retaining screws, oth-
erwise wheel may come off and cause track
to “lock”.

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Section 09 REAR SUSPENSION
Subsection 05 (TRACK)

A01B4UA

A29F14B 2 TYPICAL
1. First step
2. Second step (to push tabs into rubber)
TYPICAL
1. Retighten (so equipped models)
2. Retighten to 48 N•m (35 lbf•ft)

Restart engine and rotate track slowly to recheck

alignment.
Reposition snowmobile on ground.

Track Cleat
Removal
– 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.
– Place new cleat in position and using narrow
track cleat installer (P/N 529 028 800) bend cleat
then push tabs into rubber.

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 Section 10 STEERING / FRONT SUSPENSION
Subsection 01 (STEERING SYSTEM)

STEERING SYSTEM
SERVICE PRODUCTS
Description Part Number Page
Bombardier Lube .................................................................. 293 600 016 ................................. 527–528
suspension synthetic grease ................................................ 293 550 033 ......................................... 527
synthetic grease ................................................................... 413 711 500 ......................................... 528

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Section 10 STEERING / FRONT SUSPENSION
Subsection 01 (STEERING SYSTEM)

Tundra

5
2
8 8

Synthetic grease 2

24 N•m 6
(18 lbf•ft)
6 24 N•m
(18 lbf•ft)
1

53 N•m
(39 lbf•ft)

9
8 N•m
(71 lbf•in)
9 Synthetic 18 N•m
grease 9 16 (159 lbf•in)
21 9
53 N•m
(39 lbf•ft) 21 14
15
9 22
10 20 21
13
21 13 10
26 Synthetic
18 N•m grease 53 N•m
(159 lbf•in) 48 N•m (39 lbf•ft)
15 9
(35 lbf•ft)
21
16
20 17
15

21
18 N•m
(159 lbf•in)
A05G0OU 13 10

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 Section 10 STEERING / FRONT SUSPENSION
Subsection 01 (STEERING SYSTEM)

Skandic LT/LT E

23 24 25

2
5
8
2
3 11

Synthetic 31
grease

20 N•m 6 24 N•m
(15 lbf•ft) (18 lbf•ft)
1

53 N•m
(39 lbf•ft)

9 Synthetic grease

10
13
9
20
17
15
16

15

20

A29G0RS 13 10

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Section 10 STEERING / FRONT SUSPENSION
Subsection 01 (STEERING SYSTEM)

Skandic WT/SWT/WT LC

3 8

2 11
Synthetic
grease
31

20 N•m
(15 lbf•ft) 6 24 N•m
(18 lbf•ft)

9 1
20 N•m
53 N•m (15 lbf•ft)
(39 lbf•ft) Suspension
synthetic
grease
17

10

13

20
9
15 53 N•m
(39 lbf•ft)
16
16
15 17

20
10
13
A29G16S

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 Section 10 STEERING / FRONT SUSPENSION
Subsection 01 (STEERING SYSTEM)

Skandic SUV/Expedition TUV

7
8

11

5 3
TUV: 35 N•m 2
(26 lbf•ft)
SUV: 24 N•m
(18 lbf•ft)
6 31

20 N•m Suspension
(15 lbf•ft) synthetic
grease
53 N•m
(39 lbf•ft) 53 N•m
(39 lbf•ft)
14

21
13
53 N•m
(39 lbf•ft)
16 16
27
Loctite 243 15
21
20
10
Loctite 243
10
Loctite
243

53 N•m
(39 lbf•ft)
A29G17T

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Section 10 STEERING / FRONT SUSPENSION
Subsection 01 (STEERING SYSTEM)

INSPECTION
Check skis and ski runner for wear, replace as nec-
essary. Refer to STEERING SYSTEM.

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 steering system components for wear. Re-

place if necessary.
A30G0OA

31, Heating Grip Element

The grips might not be removable as explained
To test heating elements, refer to TESTING PRO- above; in this case, carefully proceed as follows
CEDURE. to prevent damaging the heating elements.
10,16, Ball Joint (left hand and Start cutting and immediately peel it open to lo-
right hand threads) cate the gap in the heating element, as shown.
Inspect ball joint ends for wear or looseness, if
excessive, replace them.

DISASSEMBLY AND ASSEMBLY

8, Grip
Grips must be carefully removed to prevent dam-
aging the heating elements.
Remove rivet no. 11 if applicable.
Heat grip with a heat gun. A19H04A 1

Apply tape to handlebar near the grip to protect TYPICAL

1. Gap in the heating element opposite the wires
paint.
Inject compressed air into the handlebar and twist Continue cutting along the gap and remove the
grip while pulling it out. grip.
If required, slowly peel heating element no. 31
from handlebar and remove it.
To install, stick the heating element to the handle-
bar making sure the wires do not interfere with
operation of the accelerator or brake handle.

 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 (recommend-
ed: Ultra Joy, Sunlight or Palmolive).

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 Section 10 STEERING / FRONT SUSPENSION
Subsection 01 (STEERING SYSTEM)

Heat the grip with a heater gun or a spot light 1

to ease installation. Insert new grip with com-
pressed air.

A30G1VA

A30G0NA
TYPICAL
1. U-clamp

Install rivet no. 11 if applicable.

10,16, Ball Joint (left hand and
1, Steering Column right hand threads)
Remove steering pad then handlebar ass'y. Screw threaded end of the ball joint into the tie
Detach tie rod(s) from the steering column. rod. The maximum external threaded length not
Remove U-clamps or half bushings (as applicable) engaged in the tie rod must not exceed 20 mm
holding steering column. (25/32 in).
NOTE: It may be necessary to remove part(s) to
gain access to lower U-clamp or half bushing (as
applicable).
Remove steering column.
NOTE: To remove steering column on Skandic
models only, loosen rear engine fastening screws.
A A

A02G0SA

TYPICAL
A. 20 mm (25/32 in) maximum

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Section 10 STEERING / FRONT SUSPENSION
Subsection 01 (STEERING SYSTEM)

The ball joint should be restrained when tightening 17, Steering Arm
the tie rod end lock nut. Align it so the tie rod end Tundra
is parallel to the steering arm when assembled on
the vehicle, refer to the following illustration. Steering arm notch must face outside of vehicle.
For proper torque specifications refer to the spe-
cific exploded view for the vehicle being serviced.

1 2

A02G0IA

TYPICAL
1. Parallel with steering arm A05G0CB
2. Steering arm
1. Notch facing outside
 WARNING
Skandic LT/LT E/WT/SWT/WT LC
The cut off section of the ball joint must run
parallel with the steering arm. When tighten- Install steering arm at mid-travel position when
ing lock nuts, restrain ball joint with appro- handlebar and skis are facing straight ahead.
priate size wrench. The maximum external
threaded length not engaged in the tie rod
must not exceed 20 mm (25/32 in).

21, Hardened Washer on Ball Joint Stud

Tundra and Skandic SUV
Install a hardened washer on each side of the arm.

A22G0LA

TYPICAL

1 Skandic SUV/Expedition TUV

Steering arm must be installed parallel to ski.

A25G0MA

TYPICAL
1. Hardened washers

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 Section 10 STEERING / FRONT SUSPENSION
Subsection 01 (STEERING SYSTEM)

9,13,15, Ball Joint Nut and Jam Nut

Tighten ball joint nuts and jam nuts to specified
torque (see exploded view).

HANDLEBAR POSITION A
ADJUSTMENT
1
All Models
Remove steering cover and paddings. Loosen 4
nuts on steering clamps no. 2.

1 A06G19A

TYPICAL
1. Torque to 24 N•m (18 lbf•ft)
A. Equal gap all around

 WARNING
Avoid contact between the brake handle and
the windshield by NOT adjusting the handle-
bar too high.

Properly fit the steering pad to the handlebar. As-

1 semble using the 2 rubber attachments, nuts and
A29G18A bolts where applicable.
1. Nuts to be removed
 WARNING
Adjust the steering handlebar to the desired posi- Make sure that the steering pad and all con-
tion. trols are properly fixed to their normal loca-
Lock the handlebar in place by tightening the 4 tion on the handlebar.
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 no. 2.

2
A09G05A

TYPICAL
1. Rubber attachment
2. Nut and bolt (where applicable)

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Section 10 STEERING / FRONT SUSPENSION
Subsection 01 (STEERING SYSTEM)

STEERING ADJUSTMENT (SKIS) 1

Definitions
TOE-OUT:
A difference measured between the front edge of
the skis A and rear edge B as viewed from the top. 2
It is adjustable.
3

A
B

A01G04A
A05G0KA

CAMBER: 1. Pivot arm centered in slot

2. Slot
A specific inward or outward tilt angle of ski leg 3. Turn to adjust
compared to a vertical line when viewing the vehi-
cle from front. This angle is not adjustable on any  WARNING
models. Maximum ball joint external threaded length
not engaged in the tie rod end must not ex-
Adjustments ceed 20 mm (25/32 in). Torque lock nut to
Tundra 18 N•m (159 lbf•in).
Adjustments should be performed following this
sequence:
– Handlebar/pivot arm centering.
– Set toe-out adjustment.
HANDLEBAR/PIVOT ARM CENTERING
Turn handlebar until pivot arm is well centered in
slot of its bracket. A A
Check if handlebar is horizontal. To adjust, loosen
lock nuts of short tie rod and turn it accordingly.
A02G0SA

1. 20 mm (25/32 in) maximum

Restrain short tie rod while torquing nuts so that

ball joint sockets run parallel with steering arm and
pivot arm.
Ensure that pivot arm is still centered and check
ski toe-out.

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 Section 10 STEERING / FRONT SUSPENSION
Subsection 01 (STEERING SYSTEM)

TOE-OUT ADJUSTMENT NOTE: To make sure skis are in straight-ahead

Raise front of vehicle so that skis are off the position, place a straight edge against pre-adjust-
ground. ed track and measure distance between front and
rear of skis and straight edge. Measurements are
Loosen lock nuts of long tie rods and turn each taken 200 mm (8 in) at rear and front of ski piv-
tie rod so that skis are in a straight ahead position. ot bolt. Distances should be equal. After ski toe-
To adjust toe-out, slightly turn both tie rods exactly out adjustment, distance at front of ski must be
the same amount. 3.0 mm (1/8 in) more than at rear on both sides
Make sure external threaded length not engaged for a total toe-out of 6 mm (1/4 in).
is not too long and torque nuts as specified above.

1 2
A06G03A

TYPICAL
1. Straight edge
2. 3.0 mm (1/8 in) more at front than at rear

A05G08A 1 1
LONG TIE ROD SHOWN
1. Restrain tie rod to tighten lock nuts

 WARNING
Ball joint sockets must run parallel with steer-
ing arm and pivot arm. Tie rod must be re-
strained when tightening lock nuts.

A05G05A

1. Turn to adjust

 WARNING
Do not attempt to adjust skis straight-ahead
position by turning ball joint on tie rod no. 14.
A05G09B

LONG TIE ROD SHOWN

1. Ball joint parallel with arm

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Section 10 STEERING / FRONT SUSPENSION
Subsection 01 (STEERING SYSTEM)

Skandic SUV/Expedition TUV

Adjustments should be performed following this
sequence:
– Handlebar/pivot arm positioning.
– Idler arm positioning.
– Set toe-out adjustment.
HANDLEBAR/PIVOT ARM POSITIONING
Turn handlebar until pivot arm is pointing straight
forward.
Check if handlebar is horizontal. To adjust, loosen
lock nuts of short tie rod and turn it accordingly.

 WARNING
A29G11A 1 2
Maximum ball joint external threaded length
not engaged in the tie rod end must not ex- TYPICAL
1. Pivot arm pointing straight forward
ceed 20 mm (25/32 in). Torque lock nut to 2. Idler arm pointing straight forward too
18 N•m (159 lbf•in).
TOE-OUT ADJUSTMENT
With the handlebar in straight ahead position, turn
left and right tie rods no. 20 or tie rods adjuster to
obtain specified toe-out.
Procedure:
– Loosen jam nuts no. 13 and no. 15 of both tie
rods no. 20.
A A NOTE: On models with tie rod adjuster, only
loosen adjuster jam nut.
A02G0SA

A. 20 mm (25/32 in) maximum

Restrain short tie rod while torquing nuts so that

ball joint sockets run parallel with steering arm and
pivot arm.
Ensure that pivot arm is still pointing straight for-
ward and check ski toe-out.
IDLER ARM POSITIONING
With the pivot arm pointing straight forward,
loosen lock nuts of idler arm tie rod and turn tie
rod until idler arm is pointing straight forward
too. With this adjustment properly done, turning
A29G1EA
radius will be the same on both sides.
MODELS WITH TIE ROD ADJUSTER

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 Section 10 STEERING / FRONT SUSPENSION
Subsection 01 (STEERING SYSTEM)

 WARNING NOTE: To make sure skis are in a straight-ahead

position, place a straight edge against pre-ad-
Never lengthen tie rod making threaded por- justed track and measure the distance between
tion of ball joint exceed 20 mm (25/32 in). front and rear of skis and straight edge. Distances
should be equal. After the ski toe-out adjustment,
– Close front of skis manually to take all free-play distance at front of ski must be 2.5 mm (3/32 in)
from steering mechanism. more than at rear on both sides for a total toe-out
NOTE: A rubber cord must be hooked in front of of 5 mm (3/16 in).
skis to keep them closed.
Skis should have a toe-out of 5 mm (3/16 in) when LUBRICATION
they are in a straight-ahead position and the vehi-
cle is resting on the ground.
 WARNING
Do not lubricate throttle and/or brake cable
Measurements are taken 250 mm (10 in) at front nor their housing.
and rear of ski pivot bolt.
NOTE: To make sure skis are in a straight-ahead The following symbols will be used to show what
position, place a straight edge against pre-ad- type of lubricant should be used at the suitable
justed track and measure the distance between locations.
front and rear of skis and straight edge. Distances
should be equal. After the ski toe-out adjustment,
distance at front of ski must be 2.5 mm (3/32 in)
more than at rear on both sides for a total toe-out
of 5 mm (3/16 in).
Skandic LT/LT E/WT/SWT/WT LC A00G01A 1 2
Toe-out adjustment is performed by adjusting 1. Synthetic grease (P/N 413 711 500)
2. Penetrating lubricant (P/N 293 600 016)
length of left and right tie rods no. 20. Handlebar
centering is done at same time by turning tie rods Tundra
accordingly.
Lubricate front suspension posts and pivot arm at
Procedure: grease fittings. Pump five strokes of grease gun
– Loosen jam nuts no. 13 and no. 15 of both tie on each post. Use suspension synthetic grease
rods no. 20. (P/N 293 550 033).
– Close front of skis manually to take all free-play NOTE: There are 3 grease fittings.
from steering mechanism.
Apply Bombardier Lube (P/N 293 600 016) to ball
 WARNING joints.
Never lengthen tie rod making threaded por- NOTE: There are 6 lubrication points.
tion of ball joint exceed 20 mm (25/32 in). Apply suspension synthetic grease (P/N 293 550
033) to both steering column bushings.
NOTE: A rubber cord must be hooked in front of
skis to keep them closed.
Skis should have a toe-out of 5 mm (3/16 in) when
they are in a straight-ahead position and the vehi-
cle is resting on the ground.
Measurements are taken 250 mm (10 in) at front
and rear of ski pivot bolt.

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Section 10 STEERING / FRONT SUSPENSION
Subsection 01 (STEERING SYSTEM)

Skandic SUV
Lubricate ski legs. Pump five strokes of grease
gun on each ski leg. Use synthetic grease
(P/N 413 711 500).
NOTE: There are 2 grease fittings.
Apply Bombardier Lube (P/N 293 600 016) to all
ball joints.
Apply synthetic grease (P/N 413 711 500) to both
steering column bushings.

A05G05C

TUNDRA

Skandic LT/LT E/WT/SWT/WT LC

Lubricate front suspension posts. Pump five
strokes of grease gun on each post. Use synthet-
ic grease (P/N 413 711 500).
NOTE: There are 2 grease fittings.
Apply Bombardier Lube (P/N 293 600 016) to ball
joints.
NOTE: There are 4 lubrication points.
Apply synthetic grease (P/N 413 711 500) to both
steering column bushings.

A29G0PB

SKANDIC LT/LT E/WT/SWT/WT LC

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 Section 10 STEERING / FRONT SUSPENSION
Subsection 02 (SUSPENSION AND SKI SYSTEM)

SUSPENSION AND SKI SYSTEM

SERVICE TOOLS
Description Part Number Page
shock spring removal kit....................................................... 529 035 504 ......................................... 539

SERVICE PRODUCTS
Description Part Number Page

suspension synthetic grease ................................................ 293 550 033 ......................... 532, 537, 540

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Section 10 STEERING / FRONT SUSPENSION
Subsection 02 (SUSPENSION AND SKI SYSTEM)

Tundra

29 N•m
(21 lbf•ft)
1 13 N•m
(115 lbf•in)
2

13 Synthetic 4
grease
5

7 15 N•m
Synthetic
14 grease (133 lbf•in)

10

9
8

9
Synthetic
grease
16 15 N•m
(133 lbf•in)
17

12

29 N•m
11 (21 lbf•ft)

A05G0SS

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 Section 10 STEERING / FRONT SUSPENSION
Subsection 02 (SUSPENSION AND SKI SYSTEM)

ON-VEHICLE COMPONENT DISASSEMBLY

REMOVAL Lift front of vehicle and support off the ground.
8, Shock 1,2,3,5,6,7,9,11,12, Bolt, Lock
Lift front of vehicle and support off the ground. Washer, Cover, Stopper, Bushing,
Remove ski. Cushion and Nut
Unscrew shock rod piston pin nut then remove Remove ski bolt, nut, bushings and ski.
washer. Unscrew 3 Allen screws retaining cover Unscrew shock rod nut then remove washer.
no. 3, then remove stopper no. 5, washers no. 6, Shock will fall off the ski leg.
washer no. 7.
Unscrew 3 Allen screws retaining cover, then re-
move stopper and washers.
1
1

A05G0CA

1. Allen screws A05G0CA

NOTE: These washers and stopper can be 1. Allen screws

wedged in cover.
NOTE: These washers no. 6 and no. 7 and stop-
per no. 5 can be wedged in cover.
1

A05G0DA

1. Washers and stopper wedged in cover

2. Spring

Pull out spring then check shock as described be-

low in INSPECTION.

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Section 10 STEERING / FRONT SUSPENSION
Subsection 02 (SUSPENSION AND SKI SYSTEM)

4,13,14,16,17, O-Ring, Ski Leg, Upper 8, Shock Absorber

Cushion, Lower Cushion and Seal Secure the shock body end in a vise with its rod
Pull up ski leg. Steering arm will not interfere. upward.
1
1

A14F0BA

2 1. Clamp

CAUTION: Do not clamp directly on shock

body.
Examine each shock for leaks. Extend and com-
press the piston several times over its entire
stroke checking that it moves smoothly and with
A05G0EA
uniform resistance.
1. Pull up ski leg Pay attention to the following conditions that will
2. Steering arm in place
denote a defective shock:
Remove seal and O-rings. Drive out upper and – A skip or a hang back when reversing stroke at
lower cushions if worn out. mid travel.
– Seizing or binding condition except at extreme
INSPECTION end of either stroke.
– Oil leakage.
Suspension Free Operation – A gurgling noise, after completing one full com-
Remove cover and check for free movement of ski pression and extension stroke.
leg by lifting end of ski. Renew if any faults are present.
13, Ski Leg
INSTALLATION
Check straightness of ski leg. Check for scored
or scratched surface. Replace as required. Check For assembly, reverse the disassembly procedure.
that splines on ski leg and steering arm interlock However, pay attention to the following.
properly without excessive free play. Replace as Apply suspension synthetic grease (P/N 293 550
necessary. 033) as illustrated in exploded view above.
5, Stopper Tighten nuts and screws to proper torque as men-
tioned in exploded view.
Check condition of stopper. Replace it when de-
teriorated. Steering arm notch must face outside of vehicle.

Grease Fitting
Ensure that grease fittings are not clogged.

10, Stopper
Check stopper for crack or deterioration. Replace
as required.

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 Section 10 STEERING / FRONT SUSPENSION
Subsection 02 (SUSPENSION AND SKI SYSTEM)

A05G0CB

1. Recess facing outside

16,17, Seal
Install seal before reinstalling ski leg.

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Section 10 STEERING / FRONT SUSPENSION
Subsection 02 (SUSPENSION AND SKI SYSTEM)

Skandic LT/LT E/WT/SWT/WT LC

Except
Skandic LT
29 N•m
(21 lbf•ft)
LT only 13 N•m
1 (115 lbf•in)
2
3
7

13
19
5
6

8
14
Except
Skandic LT

9
10
15
9

16
WT LC only
17
12 11

11

11
12
A29G1CS

TYPICAL

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 Section 10 STEERING / FRONT SUSPENSION
Subsection 02 (SUSPENSION AND SKI SYSTEM)

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)
B. 180 mm (7.09 in) 7, Spring
C. 70 mm (2.75 in)
D. 25 mm (1.0 in) Unscrew shock rod nut then remove washer. Un-
E. 15 mm (0.59 in)
F. 9 mm (0.35 in) screw 3 Allen screws retaining cover no. 3, then
remove stopper no. 5, washers no. 6, washer
no. 19.

A22G0PA

A05G0CA
Unfasten rod nut then pull out shock from bottom.
Check shock as described below in INSPECTION. 1. Allen screws
At installation, make sure bushings are in place.
NOTE: These washers and stopper can be
wedged in cover.

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Section 10 STEERING / FRONT SUSPENSION
Subsection 02 (SUSPENSION AND SKI SYSTEM)

NOTE: These washers and stopper can be

1 wedged in cap.

13,14,16,17, Ski Leg, Bushing and Seal

Pull up ski leg. Steering arm will not interfere.

1
2

A05G0DA

1. Washers and stopper wedged in cover

2. Spring

Pull out spring. A05G0EA

1. Pull up ski leg

DISASSEMBLY 2. Steering arm in place

Lift front of vehicle and support off the ground. Remove seal. Drive out bushing if worn out.

1,2,3,5,6,9,11,12, Bolt, Lock Washer, INSPECTION

Cover, Stopper, Bushing and Nut
All Models
Remove ski bolt, nut, bushings and ski.
Unscrew shock rod nut then remove washer. Suspension Free Operation
Shock will fall off the ski leg. Remove cover and check for free movement of ski
Unscrew 3 Allen screws retaining cover, then re- leg by lifting end of ski.
move stopper and washers.
13, Ski Leg
Check straightness of ski leg. Check for scored or
1
scratched surface. Replace as required.
Check that splines on ski leg and steering arm in-
terlock properly with no excessive free play. Re-
new as necessary.

5, Stopper
Check condition of stopper. Replace it when de-
teriorated.

Grease Fitting
Ensure that grease fittings are not clogged.
A05G0CA

1. Allen screws

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 Section 10 STEERING / FRONT SUSPENSION
Subsection 02 (SUSPENSION AND SKI SYSTEM)

10, Ski Stopper

Check stopper for crack or deterioration. Replace
as required.

8, Shock Absorber
Secure the shock body end in a vise with its rod
upward.
1

A14F0BA A22G0SA 1
1. Clamp 1. Reinforcement

CAUTION: Do not clamp directly on shock

body. 16,17, Seal
Examine each shock for leaks. Extend and com- Install seal before reinstalling ski leg.
press the piston several times over its entire
stroke checking that it moves smoothly and with
uniform resistance.
Pay attention to the following conditions that will
denote a defective shock:
– A skip or a hang back when reversing stroke at
mid travel.
– Seizing or binding condition except at extreme
end of either stroke.
– Oil leakage.
– A gurgling noise, after completing one full com-
pression and extension stroke.
Renew if any faults are present.

INSTALLATION
For assembly, reverse the disassembly procedure.
However, pay attention to the following.
Apply suspension synthetic grease (P/N 293 550
033) as illustrated in exploded view above.
Tighten nuts and screws to proper torque as men-
tioned in exploded view.
Reinstall steering arm reinforcement when re-
moved.

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Section 10 STEERING / FRONT SUSPENSION
Subsection 02 (SUSPENSION AND SKI SYSTEM)

Skandic SUV/Expedition TUV

50 N•m
(37 lbf•ft)

Loctite
Synthetic 243
grease
7
50 N•m 50 N•m
(37 lbf•ft) (37 lbf•ft)
6 1 25 N•m
(18 lbf•ft)
8
Synthetic
grease

4
3

Synthetic
12 grease
32 N•m
(24 lbf•ft)
18 N•m
9 (160 lbf•in)
9 N•m
(80 lbf•in)

7 N•m
(62 lbf•in)

10
A29G19T

TYPICAL

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 Section 10 STEERING / FRONT SUSPENSION
Subsection 02 (SUSPENSION AND SKI SYSTEM)

DISASSEMBLY
5, Shock
Lift front of vehicle and support it off the ground.
Reduce spring preload by turning adjusting ring
accordingly.
Remove lower bolt then upper bolt of shock.
For shock spring disassembly use shock spring
removal kit (P/N 529 035 504) in a vise. Mount
shock in 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. A29G0WA

Then loosen steering arm bolt and pull up steering

arm. Ski leg may fall off from swing arm.
Unbolt lower end of shock from swing arm.
1 Unbolt upper and lower arms.
Unbolt rear of swing arm from frame.
2
Pull swing arm off the vehicle.

INSPECTION
Check all rubber cushions for crack and wear. Re-
place as required.
Check straightness of ski leg no. 12 and make
sure that splines are properly interlocking with
3
steering arm. Replace as required.
Check for straightness of swing arm. Replace as
required.
Check for clogged grease fittings. Clean or re-
A01B4LA
place as required.
1. Clevis pin
Check skis and runners no. 10 for wear, replace
2. Bar as necessary.
3. Handle horizontal
Check condition of ski stopper no. 9. Replace it
Push down on the handle until it locks. Remove when deteriorated.
spring stopper then release handle. To check condition of shock, refer to SHOCK AB-
SORBER in INSPECTION CHAPTER.
1, Swing Arm
Lift front of vehicle and support it off the ground.
Remove cap no. 4, circlip no. 3.
Scribe mark the steering arm and ski leg before
disassembly.

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Section 10 STEERING / FRONT SUSPENSION
Subsection 02 (SUSPENSION AND SKI SYSTEM)

INSTALLATION 7,8, Upper and Lower Arms

For assembly, reverse the disassembly procedure. Position arms and tie rods horizontally before tight-
However, pay attention to the following. ening nuts.
Apply suspension synthetic grease (P/N 293 550 Bent portion of lower arm no. 6 must face down.
033) to ski leg components. Steering arm must be installed parallel to ski.
Install steering stopper no. 6 as per following pho-
to.
1
1

A29G0ZA
A29G0YA

1. Parallel
TYPICAL
1. Steering stopper

Longer bolts for shock and swing arm go on upper

attachments.
Tighten nuts and screws to proper torque as men-
tioned in exploded view.

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 Section 11 BODY/FRAME
Subsection 01 (BODY)

BODY
INSTALLATION AND BULB REPLACEMENT
ADJUSTMENT Headlamp
Tundra
HEADLAMP BEAM AIMING If headlamp is burnt, tilt hood. Unplug connector
Beam aiming is correct when center of high beam from headlamp. Remove protector cap and unfas-
is 25 mm (1 in) below the headlamp horizontal cen- ten bulb retainer clips. Detach bulb and replace.
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 1
or screen). Light beam center should be 25 mm
(1 in) below scribed line.

1 90°

A
A02E09A

TYPICAL
1. Retainers clips

B Skandic LT/LT E
If headlamp bulb is burnt, tilt cab and unplug the
A02E0AA connector from the headlamp. Remove the rub-
1. Headlamp center line ber boot and unfasten the bulb retainer ring. De-
A. 381 cm (12 ft 6 in) tach the bulb and replace it with a new one. Prop-
B. 25 mm (1 in) below center line erly reinstall parts.

1 2

3 A
A02E07A

1. Headlamp horizontal
2. Light beam (high beam) (projected on the wall)
3. Light beam center
A. 25 mm (1 in)

Required Conditions
Place the vehicle on a flat surface perpendicular to
test surface (wall or screen) and 381 cm (12 ft 6 in) A25H0JA
1
away from it. TYPICAL
Rider or equivalent weight must be on the vehicle. 1. Locking ring

Select high beam.

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Section 11 BODY/FRAME
Subsection 01 (BODY)

Skandic LT/SWT/WT LC/SUV All Models

If headlamp bulb is burnt, tilt hood. CAUTION: Never touch glass portion of an
Remove latches retaining plastic cover. Tempo- halogen bulb with bare fingers, as it short-
rary reinstall the top two latches to retain wind- ens its operating life. If by mistake glass is
touched, clean it with isopropyl alcohol which
shield during bulb replacement. will not leave a film on the bulb.
1 2 4 3 1 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-
ment.

DECAL
To remove a decal; heat old decal with a heat gun
and peel off slowly.
Using isopropyl alcohol, clean the surface and dry
thoroughly.
Apply liquid soap to new decal and carefully po-
sition the decal. Using a sponge or a squeegee,
remove the air bubbles and surplus water work-
A29H16A 1 ing from the center toward the edges. Allow to
air dry.
SKANDIC LT/SWT/WT LC/SUV
1. Latches CAUTION: Do not apply isopropyl alcohol or
2. Plastic cover solvent directly on decals.
3. Retaining nut and screw
4. Headlamp height adjustment knob

Expedition TUV
BELT GUARD
To replace a burnt headlamp bulb, remove the fol- Disassembly and Assembly
lowing: NOTE: For additional information (ex.: exploded
– windshield assembly view) refer to the corresponding Parts Catalog.
– air intake dashboard cover.
Replace bulb.
 WARNING
Engine should be running only with belt
guard well-secured in place.

Inspection
All Models
Check belt guard mounting bosses, clips and re-
tainers for wear.

A29H1IA

EXPEDITION TUV

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 Section 11 BODY/FRAME
Subsection 01 (BODY)

WIRING HARNESS CAUTION: The following products must not be

used to clean or wax any of the plastic compo-
 WARNING nents used on the vehicles:
Ensure all terminals are properly crimped on – gasoline
the wires and that all connector housings are – brake fluid
properly fastened. Keep wires away from – kerosene
any rotating, moving, heating and vibrating – diesel fuel
parts. Use proper fastening devices as re-
quired. – lighter fluid
– varsol
– naphtha
CABLES – acetone
– strong detergents
 WARNING – abrasive cleaners
Before installation, ensure that all cables are – waxes containing an abrasive or a cleaning
in perfect condition. Properly install the cable agent in their formula.
ends and secure them in place. Pay attention Apply wax on glossy finish only. Protect the ve-
to route them properly, away from any rotat- hicle with a cover to prevent dust accumulation
ing, moving, heating, or vibrating parts. during storage.
CAUTION: If for some reason the snowmobile
has to be stored outside it is preferable to cov-
TUBING er it with an opaque tarpaulin. This will prevent
 WARNING
the sun rays from affecting the plastic compo-
nents and the vehicle finish.
Always ensure that the fuel, vent, primer, im-
pulse, injection oil and rotary valve oil lines REPAIR
are properly fixed to their connectors, that
they are not perforated or kinked and that The very first step before repairing plastic materi-
they are properly routed away from any rotat- als is to find out exactly which type of material is
ing, moving, heating or vibrating parts. Also involved. Refer to following chart.
check for leaks. Replace if required. CAUTION: Consult chart and repair kit instruc-
tions carefully, some repair products are not
NOTE: Refer to proper Parts Catalog to find suit- compatible with certain plastics.
able clip part numbers.
 WARNING
PLASTIC MAINTENANCE Polycarbonate windshields must never be re-
AND REPAIR paired by welding or otherwise.

MAINTENANCE
Clean the vehicle thoroughly, removing all dirt and
grease accumulation.
To clean use a soft clean cloth and either soapy
water or isopropyl alcohol.
To remove grease, oil or glue use isopropyl alco-
hol.
CAUTION: Do not apply isopropyl alcohol or
acetone directly on decals.

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Section 11 BODY/FRAME
Subsection 01 (BODY)

IRRE- RE- Deep Scratches

PAIRABLE PAIRABLE – Sand and scuff area.
High density R.I.M. – Make a V groove using a knife or a rough round
PART MODEL
polyethylene urethane file.
Tundra – Clean surface with isopropyl alcohol or Crest
Skandic LT/ Hi-Solv stock no. AH-S product.
HOOD WT/SWT/
– Cover with TP-E epoxy mixed in equal quanti-
WT LC/ SUV/
Expedition
ties.
TUV – Heat the surface with a heater lamp placed at
Tundra 38 cm (15 in) for a period of 15 minutes.
Skandic LT/
– Sand the surface using a smooth dry sand pa-
BOTTOM WT/SWT/ per.
PAN WT LC/ SUV/ – Use the same product if a final finish is required.
Expedition – Clean surface with Crest Hi-Solv product.
TUV
– Apply a flexible primer such as Crest Prima Flex
stock no. AP-F.
REPAIR PROCEDURE FOR – Wait 10 minutes.
R.I.M. URETHANE – Repaint (air dry during 72 hours (approximate-
ly)).
R.I.M. urethane is light colored (tan) on the inside
with a smooth surface. Large Crack
 WARNING – Sand and scuff outside and inside area by ex-
ceeding it 31.7 mm (1-1/4 in) on each side and
Material should be repaired and repainted in
12.7 mm (1/2 in) at each end.
a well-ventilated area only.
– Make a V groove (appr. 90°) on both sides of
hood using a knife or a rough round file.
CAUTION: Clean R.I.M. with isopropyl alcohol
or Crest Hi-Solv product. Never use cleaners – Enlarge the crack to 2.4 mm (3/32 in) – 3.2 mm
or products that contain chlorine. (1/8 in) using a sharp knife.
CAUTION: R.I.M. should never be exposed to – Clean outside and inside surface with isopropyl
temperatures exceeding 93°C (200°F). alcohol or Crest Hi-Solv product.
– Repair inside surface first.
NOTE: When working on a R.I.M. surface, never
use a grinder or a high revolution tool such as an – Cover inside area with Crest TP-E epoxy.
air or electric buffer. Use of such tools could over- – Apply a 50 mm x 30 mm (2 in x 1-1/4 in) patch.
heat material and liberate agents in it thus causing If no room for the patch, use tape.
a bad adhesion. – Cover exterior surface with same product.
Damaged area should be slightly higher.
Small Scratches – Heat surface with a heater lamp placed at
– Sand and scuff area. 38 mm (15 in) for a period of 15 minutes.
– Feather out edges. – Sand outside surface using a smooth dry sand
– Paint with a matching acrylic auto touch-up paper.
paint. – Use same product if a final finish is required.
– Apply a flexible primer.
– Wait 10 minutes.
– Repaint (air dry during 72 hours approximately).
NOTE: R.I.M. materials are high static plastics,
painting must be done in a dust free area such as
a paint booth.

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 Section 11 BODY/FRAME
Subsection 01 (BODY)

Crest products used in R.I.M. repair procedure are

available from following locations:

CREST MAIN OFFICE AND

MANUFACTURING PLANT
Phone: 734-479-4141
CREST INDUSTRIES INC. Toll free: 1 800 822-4100
1337 King Road Trenton, Fax: 734-479-4040
Michigan, U.S.A. 48183 E-Mail: [email protected]
www.crestauto.com

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 Section 11 BODY/FRAME
Subsection 02 (FRAME)

FRAME
FRAME CLEANING
1
NOTE: For bare aluminum frames use only alu-
minum cleaner and follow instructions on contain-
er. (Dursol cleaner or equivalent).
Clean frame and tunnel with appropriate cleaners
and rinse with high pressure hose.
CAUTION: Never direct high-pressure water jet
towards decals. They would peel off.
Touch up all metal spots where paint has been
scratched off. Spray all bare metal parts of vehicle
with metal protector.

Seat Cleaning
For all models, it is recommended to clean the
A03C18B
seat with a solution of warm soapy water, using
a soft clean cloth. TYPICAL — FAN COOLED MODELS
1. Unplug before electrical welding
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.

FRAME WELDING
Steel Frame:
– electric welding
– amperage: 70-110 A A32E0WB

– voltage: 20-24 V
TYPICAL — LIQUID COOLED MODELS MPEM UNPLUGGED
– electrode: E-7014 (3/32 in).
CAUTION: Before performing electrical weld- CAUTION: If welding is to be done near plastic
ing anywhere on the vehicle, unplug the multi- material, it is recommended to either remove
ple connector at the electronic box. On models the part from the area or to protect it with alu-
equipped with a battery, also unplug the nega- minum foil to prevent damage.
tive cable. This will protect the electronic box
and battery against damage caused by flowing
current when welding.

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 Section 12 TECHNICAL DATA
Subsection 01 (ENGINES)

ENGINES
TUNDRA
ENGINE TYPE 277
ENGINE
Number of cylinder 1
Bore Standard mm (in) 72.00 (2.835)
Stroke mm (in) 66.00 (2.598)
cm3
Displacement 268.7 (16.40)
(in3)
Compression ratio (corrected) 11.2
Maximum power engine speed (1) ± 100 RPM 6900
1st ST
Piston ring type
2nd R
ST ring 0.25 (.010)
New mm (in)
Ring end gap R ring 0.20 (.008)
Wear limit mm (in) 1.0 (.039)
New mm (in) 0.025 (.001)
Ring/piston groove clearance
Wear limit mm (in) 0.2 (.008)
New mm (in) 0.080 (.0031)
Piston/cylinder wall clearance
Wear limit mm (in) 0.2 (.008)
Maximum crankshaft end play (2) New mm (in) 0.3 (.012)
Maximum crankshaft deflection at PTO Wear limit mm (in) 0.06 (.00241)
New mm (in) 0.20 (.0079)
Connecting rod big end axial play
Wear limit mm (in) 1.2 (.0472)
ELECTRICAL
Magneto generator output W 240
Ignition type CDI
Make and type NGK BR9ES
Spark plug
Gap mm (in) 0.45 (.018)
Ignition timing BTDC (3) mm (in) 3.61 (.142)
Trigger coil (4) 160 - 180
Low speed N.A.
Generating coil (4)
High speed 5.1 - 6.2
Lighting coil (4) .17 - .21
Primary N.A.
High tension coil (4)
Secondary k .9 - 1.1

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Section 12 TECHNICAL DATA
Subsection 01 (ENGINES)

TUNDRA
ENGINE TYPE 277
FUEL SYSTEM
Carburetor type PTO/MAG 1 x VM 34-585
Main jet PTO/MAG 200
Needle jet 159 O-8
Pilot jet 40
Needle identification — clip position PTO/MAG 6DH4-3
Slide cut-away 2.5
Float adjustment mm (in) 23.9 (.94) ± 1 (.040)
Air or pilot screw adjustment ± 1/16 turn 1
Idle speed ± 200 RPM 1650
Type Regular unleaded gasoline
Gas North America: 87 (R+M)/2
Octane number
Elsewhere: 91 RON
Gas/oil ratio Injection
COOLING SYSTEM
Type Radial Fan
Deflection mm (in) N.A.
Axial fan belt adjustment Force kg (lbf) N.A.

Coolant N.A.

Thermostat opening temperature °C (°F) N.A.

kPa
Radiator cap opening pressure N.A.
(PSI)
TIGHTENING TORQUE (engine cold)
N•m
Drive pulley retaining screw (5)
(lbf•ft)
N•m
Exhaust manifold nuts or bolts 25 (18)
(lbf•ft)
N•m
Magneto ring nut 95 (70)
(lbf•ft)
N•m
M6 N.A.
(lbf•in )
Crankcase nuts or screws
N•m
M8 22 (16)
(lbf•ft)
N•m
Crankcase/engine support nuts or screws 21 (15)
(lbf•ft)
N•m
Cylinder head screws or nuts 27 (20)
(lbf•ft)
N•m
Crankcase/cylinder nuts or screws N.A.
(lbf•ft)
N•m
Axial fan shaft nut N.A.
(lbf•ft)

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 Section 12 TECHNICAL DATA
Subsection 01 (ENGINES)

SKANDIC LT WT/SWT/SUV SUV/WT LC

ENGINE TYPE 443 552 593
ENGINE
Number of cylinder 2 2 2
Bore Standard mm (in) 67.5 (2.6575) 76.00 (2.992) 76.00 (2.992)
Stroke mm (in) 61.0 (2.402) 61.0 (2.402) 65.8 (2.591)
cm3
Displacement 436.6 (26.64) 553.4 (33.78) 597.0 (36.43)
(in3)
Compression ratio (corrected) 9.6 9.6 12.0
Maximum power engine speed (1) ± 100 RPM 6900 6900 7000
1st ST ST ST
Piston ring type
2nd R R N.A.
New mm (in) 0.2 (.008) 0.4 (.0157) 0.4 (.0157)
Ring end gap
Wear limit mm (in) 1.0 (.039) 1.0 (.0394) 1.0 (.0394)
New mm (in) 0.04 (.0016) 0.037 (.0015) 0.04 (.0016)
Ring/piston groove clearance
Wear limit mm (in) 0.2 (.0079) 0.2 (.0079) 0.2 (.0079)
New mm (in) 0.070 (.0031) 0.147 (.0058) 0.12 (.0047)
Piston/cylinder wall clearance
Wear limit mm (in) 0.2 (.008) 0.2 (.0079) 0.2 (.0079)
Maximum crankshaft end play (2) New mm (in) 0.3 (.012) 0.3 (.012) 0.3 (.012)
Maximum crankshaft deflection at PTO Wear limit mm (in) 0.06 (.0024) 0.06 (.0024) 0.06 (.0024)
New mm (in) 0.20 (.0079) 0.2 (.0079) 0.39 (.0154)
Connecting rod big end axial play
Wear limit mm (in) 1.2 (.0472) 1.2 (.0472) 1.2 (.0472)
ELECTRICAL
Magneto generator output W 240 340 290
Ignition type CDI CDI CDI
Make and type NGK BR9ES NGK BR9ES NGK BR9ECS (7)
Spark plug
Gap mm (in) 0.45 (.018) 0.45 (.018) 0.45 (.018)
Ignition timing BTDC (3) mm (in) 2.79 (.110) 2.77 (.109) 3.00 (.118)

Trigger coil (4) 160 - 180 160 - 180 190 - 300

Low speed N.A. N.A. 17.5 - 42.5

Generating coil (4)
High speed 5.1 - 6.2 6.3 - 7.7 2.4 - 5.8
Lighting coil (4) .17 - .21 .145 - .175 .10 - .40
Primary N.A. N.A. .3 - .7
High tension coil (4)
Secondary k .9 - 1.1 .9 - 1.1 8 - 16

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Section 12 TECHNICAL DATA
Subsection 01 (ENGINES)

SKANDIC LT WT/SWT/SUV SUV/WT LC

ENGINE TYPE 443 552 593
FUEL SYSTEM
Carburetor type PTO/MAG 1 x VM 32-306 2 x VM 34-614 2 x VM 38-449
Main jet PTO/MAG 180 190 330
Needle jet 159 O-0 159 P-0 480 P-9
Pilot jet 50 40 40
Needle identification — clip position PTO/MAG 6DGY12-3 6DH4-2 6DGL24-3
Slide cut-away 3 2.5 2.5
23.9 (.941) 23.9 (.941) 18.1 (.710)
Float adjustment mm (in)
± 1 (.040) ± 1 (.040) ± 1 (.040)
Air or pilot screw adjustment ± 1/16 turn 1 1-1/2 2

Idle speed ± 200 RPM 1800 1650 1900

Type Regular unleaded Regular unleaded Regular unleaded

Gas North America: North America: North America:
Octane number 87 (R+M)/2 87 (R+M)/2 87 (R+M)/2
Elsewhere: 91 RON Elsewhere: 91 RON Elsewhere: 91 RON
Gas/oil ratio Injection Injection Injection
COOLING SYSTEM
Type Axial Fan Axial fan Liquid
Deflection mm (in) 9 - 10 (.35 - .39) 9 - 10 (.35 - .39) N.A.
Axial fan belt adjustment
Force kg (lbf) 5 (11) 5 (11) N.A.
Coolant N.A. N.A. (8)
Thermostat opening temperature °C (°F) N.A. N.A. 42 (108)
Radiator cap opening pressure kPa
N.A. N.A. 100 (14.5)
(PSI)
TIGHTENING TORQUE (engine cold)
N•m
Drive pulley retaining screw (5) (5) (5)
(lbf•ft)
N•m
Exhaust manifold nuts or bolts 22 (16) 22 (16) 23 (17)
(lbf•ft)
N•m
Magneto ring nut 105 (77) 105 (77) 125 (92)
(lbf•ft)
N•m
M6 9 (6.5) N.A. 9 (6.5)
(lbf•in )
Crankcase nuts or screws
N•m
M8 22 (16) 27 (20) 29 (21)
(lbf•ft)
N•m
Crankcase/engine support nuts or screws 39 (29) 40 (30) 35 (26)
(lbf•ft)
N•m
Cylinder head screws or nuts 22 (16) 22 (16) 29 (21)
(lbf•ft)
N•m
Crankcase/cylinder nuts or screws N.A. N.A. 29 (21)
(lbf•ft)
N•m
Axial fan shaft nut 48 (35) 48 (35) N.A.
(lbf•ft)

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 Section 12 TECHNICAL DATA
Subsection 01 (ENGINES)

SKANDIC EXPEDITION TUV 600 HO SDI

ENGINE TYPE 593
ENGINE
Number of cylinder 2

Bore Standard mm (in) 72 (2.835)

Stroke mm (in) 73.00 (2.874)

Displacement cm3 (in3) 594.40 (36.273)

Compression ratio (corrected) 12.25

± 100
Maximum power engine speed (1) 8000
RPM
1st ST
Piston ring type
2nd N.A.
New mm (in) 0.40 - 0.55 (.016 - .022)
Ring end gap
Wear limit mm (in) 1.0 (.039)
New mm (in) 0.05 - 0.10 (.0020 - .0039)
Ring/piston groove clearance
Wear limit mm (in) 0.2 (.0079)
New mm (in) 0.105 ± 0.013 (.0041 ± .0009)
Piston/cylinder wall clearance
Wear limit mm (in) 0.18 (.0071)
Maximum crankshaft end play (2) New mm (in) 0.3 (.012)
Maximum crankshaft deflection at PTO Wear limit mm (in) 0.06 (.0024)
New mm (in) 0.310 - 0.677 (.0122 - .0267)
Connecting rod big end axial play
Wear limit mm (in) 1.2 (.0472)
ELECTRICAL
Magneto generator output W 480
Ignition type Inductive
Make and type NGK BR9ECS
Spark plug
Gap mm (in) 0.75 - 0.85 (.030 -.033) (7)
Ignition timing BTDC (3) mm (in) 5.390 (.2122)
Trigger coil (4) 190 -300
Low speed N.A.
Generating coil (4)
High speed N.A.
Lighting coil (4) .175 - .180
Primary N.A.
High tension coil (4)
Secondary k N.A.

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Section 12 TECHNICAL DATA
Subsection 01 (ENGINES)

SKANDIC EXPEDITION TUV 600 HO SDI

ENGINE TYPE 593
FUEL SYSTEM
SDI with Dell'Orto 46 mm
Fuel injection type
throttle body (no IACV)
Fuel pressure kPa (PSI) 400 (58)

Idle speed RPM 1600 ± 200

Throttle Position Sensor (TPS) (4) k 1.6 - 2.4

Crankshaft Position Sensor (CPS) (4) 190 - 300
Air Pressure Sensor (APS) (4) V 5
Air Temperature Sensor (ATS) (4) k 2.28 - 2.74
Coolant Temperature Sensor (CTS) (4) k 2.6 - 3.2
Fuel injector 13.8 - 15.2
Type Regular unleaded
Gas North America: 87 (R+M)/2
Octane number
Elsewhere: 91 RON
Gas/oil ratio Injection
COOLING SYSTEM
Type Liquid
Deflection mm (in) N.A.
Axial fan belt adjustment
Force kg (lbf) N.A.
Coolant N.A.
Thermostat opening temperature °C(°F) 42 (108)
Radiator cap opening pressure kPa (PSI) 90 (13)

TIGHTENING TORQUE (engine cold)

N•m (5)
Drive pulley retaining screw
(lbf•ft)
N•m
Exhaust manifold nuts or bolts 11 (97)
(lbf•in )
N•m
Magneto ring nut 125 (92)
(lbf•ft)
N•m
M6 9 (80)
(lbf•in )
Crankcase nuts or screws
N•m
M8 29 (21)
(lbf•ft)
N•m
Crankcase/engine support nuts or screws 35 (26)
(lbf•ft)
N•m
Cylinder head screws or nuts 29 (21)
(lbf•ft)
N•m
Crankcase/cylinder nuts or screws 40 (29)
(lbf•ft)
N•m
Axial fan shaft nut N.A.
(lbf•ft)

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 Section 12 TECHNICAL DATA
Subsection 01 (ENGINES)

SKANDIC EXPEDITION TUV V-1000

ENGINE TYPE 1004
ENGINE
BOMBARDIER-ROTAX 1004 4-TEC, 4-stroke, Over Head
Engine type
Camshaft (OHC), liquid cooled
Cylinder arrangement and quantity V2
Valves per cylinder 4 valves with hydraulic lifters (no adjustment)
Bore Standard mm (in) 100 (3.937)
Stroke mm (in) 63.4 (2.496)
Displacement cm3 (in3) 995.90 (60.774)
Compression ratio 10.3
Decompressor type Automatic
Maximum power engine speed (1) RPM 7250 RPM
Lubrication Dry sump with replaceable oil filter
Intake valve opening BTDC 10°
Intake valve closing ATDC 45°
Exhaust valve opening BTDC 50°
Exhaust valve closing ATDC 5°
Starting system Electric start
New mm (in) 5.961 - 5.975 (.2347 - .2352)
Intake
Wear limit mm (in) 5.930 (.2330)
Valve stem diameter
New mm (in) 5.946 - 5.960 (.2341 - .2346)
Exhaust
Wear limit mm (in) 5.930 (.2330)
Valve guide diameter Wear limit mm (in) 6.060 (.2386)
New mm (in) 41.02 (1.615)
Inner
Wear limit mm (in) 38.8 (1.499)
Valve spring free length
New mm (in) 45.45 (1.789)
Outer
Wear limit mm (in) 43 (1.693)
New mm (in) 1.1 - 1.3 (.043 - .051)
Intake
Wear limit mm (in) 1.6 (.063)
Valve seat contact width
New mm (in) 1.25 - 1.55 (.049 - 061)
Exhaust
Wear limit mm (in) 1.8 (.071)
New mm (in) 20.007 - 20.020 (.7876 - .7881)
Rocker arm bore diameter
Wear limit mm (in) 20.035 (.7887)
New mm (in) 19.980 - 19.993 (.7866 - 7871)
Rocker arm shaft diameter
Wear limit mm (in) 19.965 (.7860)
Service
Cylinder head screw length mm (in) 216.5 (8.524)
limit

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Section 12 TECHNICAL DATA
Subsection 01 (ENGINES)

SKANDIC EXPEDITION TUV V-1000

ENGINE TYPE 1004
ENGINE (cont'd)
1st Rectangular
Piston ring type 2nd Taper-face
3rd Oil scraper ring
1st mm (in) 0.30 - 0.50 (.012 - .020)
2nd New mm (in) 0.35 - 0.55 (.014 - .022)
Ring end gap
3rd mm (in) 0.15 - 0.3 (.006 - .012)
All Wear limit mm (in) 1.5 (.059)
1st mm (in) 0.025 - 0.07 (.001 - .0028)
2nd New mm (in) 0.015 - 0.06 (.0006 - .0024)
Ring/piston groove clearance
3rd mm (in) 0.02 - 0.055 (.0008 - .0021)
All Wear limit mm (in) 0.15 (.006)
New mm (in) 0.024 - 0.056 (.001 - .0022)
Piston/cylinder wall clearance
Wear limit mm (in) 0.09 (.0035)
New
mm (in) 0.038 (.0015)
Cylinder taper (maximum) (maximum)
Wear limit mm (in) 0.09 (.0035)
New
mm (in) 0.01 (.0004)
Cylinder out of round (maximum)
Wear limit mm (in) 0.02 (.0008)
New mm (in) 24.967 - 24.980 (.9830 - .9835)
PTO side
Wear limit mm (in) 24.960 (.9827)
Camshaft bearing journal
New mm (in) 39.927 - 39.935 (1.5719 - 1.5722)
Alternator side
Wear limit mm (in) 39.920 (1.5716)
New mm (in) 25.000 - 25.013 (.9842 - .9848)
PTO side
Wear limit mm (in) 25.020 (.9850)
Camshaft bore
New mm (in) 40.000 - 40.016 (1.5748 - 1.5754)
Alternator side
Wear limit mm (in) 40.020 (1.5756)
New mm (in) 31.654 - 31.854 (1.2462 - 1.2541)
Intake
Wear limit mm (in) 31.600 (1.2441)
Cam lobe
New mm (in) 31.435 - 31.635 (1.2376 - 1.2455)
Exhaust
Wear limit mm (in) 31.400 (1.2362)
Crankshaft axial clearance New mm (in) 0.100 - 0.45 (.0039 - .0177)
New mm (in) 54.961 - 54.980 (2.1638 - 2.1646)
Crankshaft journal diameter
Wear limit mm (in) 54.940 (2.1630)
Crankshaft deflection Wear limit mm (in) 0.050 (.002)
Crankshaft radial clearance Wear limit mm (in) 0.080 (.0031)

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 Section 12 TECHNICAL DATA
Subsection 01 (ENGINES)

SKANDIC EXPEDITION TUV V-1000

ENGINE TYPE 1004
ENGINE (cont'd)
Connecting rod big end diameter Wear limit mm (in) 45.090 (1.7752)
Connecting rod big end clearance Wear limit mm (in) 0.09 (.0035)
New mm (in) 0.150 - 0.450 (.0059 - .0177)
Connecting rod big end axial play
Wear limit mm (in) 0.500 (.0197)
New mm (in) 23.010 - 23.020 (.9059 - 9063)
Connecting rod small end diameter
Wear limit mm (in) 23.070 (.9080)
New mm (in) 22.996 - 23.000 (.9053 - .9055)
Piston pin diameter
Wear limit mm (in) 22.990 (.9051)
Piston pin bore clearance Wear limit mm (in) 0.080 (.0031)
ELECTRICAL
Alternator output V, A 12, 40
Ignition system type DI (Digital Induction)
Ignition timing Not adjustable
Make and type NGK DCPR8E
Spark plug
Gap mm (in) 0.75 (.030)
Primary .85 - 1.15
Ignition coil
Secondary k 9.2 - 13.8
Engine RPM limiter setting RPM 8000
FUEL SYSTEM
ROTAX EMS (Engine Management System) Multipoint
Fuel injection type
Fuel Injection, Single throttle body (52 mm)
kPa
Fuel pressure 400 (58)
(PSI)
Idle speed RPM 1400 ± 100
Throttle Position Sensor (TPS) (4) k 1.6 - 2.4
Crankshaft Position Sensor (CPS) (4) .7 - 1.1
Camshaft Position Sensor (CAPS) V 12
Camshaft Position Sensor (CAPS) (4) k 1.2
Air Temperature Sensor (ATS) (4) k 2.28 - 2.74
Coolant Temperature Sensor (CTS) (4) k 2.28 - 2.74
Manifold Air Pressure Sensor (MAPS) V 5
Idle bypass valve (4) 50
Oil Pressure Switch (OPS) (4) 0 (continuity), if oil pressure is lower than 20 kPa (2.9 PSI)
Fuel injector 13.8 - 15.2
Type Regular unleaded
Fuel North America: 87 (R+M)/2
Octane
Elsewhere: 91 RON

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Section 12 TECHNICAL DATA
Subsection 01 (ENGINES)

SKANDIC EXPEDITION TUV V-1000

ENGINE TYPE 1004
COOLING SYSTEM
Type Liquid cooled
Coolant (8)

Thermostat °C (°F) 80 (176)

TIGHTENING TORQUE (engine cold)

Drive pulley retaining screw (6)

N•m
M11 50 (37) + 90° rotation
(lbf•ft)
Cylinder head screws or nuts
N•m
M6 9 (80)
(lbf•in )
N•m
Rocker arm shaft screws 20 (15) + 90° rotation
(lbf•ft)
N•m
Crankshaft nut 80 (59)
(lbf•ft)
N•m
Connecting rod screws 45 (33) + 90° rotation
(lbf•ft)
N•m
M6 9 (80)
(lbf•in )
Crankcase screws
N•m
M8 24 (18)
(lbf•ft)
N•m
Oil drain plug 55 (41)
(lbf•ft)
N•m
Alternator screws 23 (17)
(lbf•ft)
N•m
Oil filter cover screw 9 (80)
(lbf•in )
N•m
Manifold screws 22 (16)
(lbf•ft)

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 Section 12 TECHNICAL DATA
Subsection 02 (VEHICLES)

VEHICLES
TUNDRA/SKANDIC LT 277 443
DRIVE
Chain drive ratio 14/25 17/44
Pitch in 1/2 3/8
Chain
Type/links qty/plate qty Single/62 Silent 70/13
Type Bombardier Lite (1) Comet
Clutch engagement ±100 RPM 3000 3200
Spring color Red/Yellow Silver/Black
Spring length ± 1.5 mm (± .060 in) 87.9 (3.461) 78.99 (3.110)
Screw: 417 120 400 = 21 g
Weight 5 x 3.4 g
Drive pulley Screw: 417 114 400 = 3.4 g
Calibration Block 417 114 300 218311C
Cap 417 114 500 N.A.
Pin N.A. 417 003 900
Ramp N.A. N.A.
Screw position N.A. N.A.
Type Tundra Reverse LPV27
Driven pulley Spring preload ± 0.7 kg (± 1.5 lb) 0, pos. 3 0
Cam angle degree 37.8 40
37.0 +0, -0.75 39 ± 0.75
Pulley distance Z mm (in)
(1.457 +0, -.030) (1.535 ± .030
36.0 ± 1.0 37 ± 0.75
X mm (in)
Offset (1.417 ± .040) (1.457 ± .030)
Y–X MIN.-MAX. mm (in) 1.51 (.060) 0.75 - 2.25 (.030 .090)
Drive belt part number (P/N) 414 827 600 414 633 800
Drive belt width Wear limit mm (in) 30.3 (1-3/16) 32.0 (1-1/4)
Deflection ± 5 mm (13/64 in) 32 (1-1/4) 32 (1-1/4)
Drive belt adjustment
Force (2) kg (lbf) 6.8 (15) 11.3 (25)
Width mm (in) 381 (15.0) 381 (15.0)
Length mm (in) 3540 (139) 3968 (156.2)

Track Profile height mm (in) 18.4 (.724) 25 (1)

35 - 40 40 - 50
Deflection mm (in)
Adjustment (1-3/8 - 1-9/16) (1-9/16 - 1-31/32)
Force (3) kg (lbf) 7.3 (16) 7.3 (16)
Torque Reaction
Track Skandic WT
Suspension type Slide
Ski Telescopic Strut Telescopic Strut

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Section 12 TECHNICAL DATA
Subsection 02 (VEHICLES)

TUNDRA/SKANDIC LT 277 443

ELECTRICAL
Battery V (Ah) N.A. N.A.
Headlamp W H4 60/55 H4 60/55
Taillight and stoplight W 8/27 8/27
Tachometer and speedometer bulbs W N.A. 3
Fuel and temperature gauge bulbs W N.A. N.A.
Starter solenoid A N.A. N.A.
Fuse
Fuel level sensor A N.A. N.A.
CAPACITIES
Fuel tank L (U.S. gal) 26 (6.9) 40 (10.6)
Chaincase/gearbox mL (U.S. oz) 250 (8.5) 250 (8.5)
Cooling system (5) L (U.S. oz) N.A. N.A.
Injection oil reservoir L (U.S. oz) 1.9 (64) 2.5 (84.5)
VEHICLE INFORMATIONS
Mass (dry) kg (lb) 173 (380) 210 (462)
Length mm (in) 2845 (112) 3020 (118.9)
Width mm (in) 953 (37.5) 960 (37.8)
Height mm (in) 1120 (44.1) 1295 (51)
Ski stance (carbide to carbide) mm (in) 813 (32.0) 820 (32.3)
Toe-out mm (in) 6 (1/4) 5 (3/16)
Camber mm (in) N.A. N.A.
Ground contact area cm2 (in2) 7570 (1173) 8811.3 (1365.8)
Ground contact pressure kPa (PSI) 2.24 (.325) 2.46 (.357)
Frame material Steel Steel
Polyethylene High Polyethylene High
Bottom pan material
Density Density
Polyethylene High
Hood material RRIM
Density

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 Section 12 TECHNICAL DATA
Subsection 02 (VEHICLES)

WT SWT WT LC
SKANDIC 552 552 593
DRIVE
1 st 1:2.82 1:3.80 1:2.82

Gear ratio 2nd 1:1.89 1:2.29 1:1.7

R 1:3.44 1:4.63 1:3.44

Bombardier Bombardier
Type TRA III
Lite (1) Lite (1)
Clutch engagement ±100 RPM 2500 2500 2700
Spring color Yellow/Green Yellow/Green Yellow/Red
Spring length ± 1.5 mm (± .060 in) 94.61 (3.725) 94.61 (3.725) 128 (5.039)
Screw: 417 120 400 = 21 g 417 120 400 417 120 400
Weight N.A.
Drive pulley Screw: 417 114 400 = 3.4 g 4 x 417 114 400 4 x 417 114 400
Calibration Block N.A. N.A. N.A.
Cap 417 114 500 = 1.65 g 417 114 500 417 114 500 N.A.
Pin N.A. N.A. 417 222 594
Ramp N.A. N.A. 600 (4)
Screw position N.A. N.A. 3
Type Cvtech Cvtech Cvtech VSA
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 40/35 40/35 35/30
Pulley 41.8 ± 0.75 41.8 ± 0.75 35.5 ± 0.75
Z mm (in)
distance (1.647 ± .030) (1.647 ± .030) (1.398 ± .030)
35 ± 0.75 35 ± 0.75 37 ± 0.75
X mm (in)
(1.380 ± .030) (1.380 ± .030) (1.457 ± .030)
Offset
0.75 - 2.25 0.75 - 2.25 0.75 - 2.25
Y–X MIN.-MAX. mm (in)
(.030 - .089) (.030 - .089 (.030 - .089
Drive belt part number (P/N) 414 633 800 414 633 800 417 300 155
Drive belt width Wear limit mm (in) 32.0 (1-1/4) 32.0 (1-1/4) 34.3 (1-11/32)
Deflection mm (in) 32 (1-1/4) 32 (1-1/4) 32 (1-1/4)
Drive belt adjustment
Force (2) kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width mm (in) 500 (19.7) 600 (23.6) 500 (19.7)
Length mm (in) 3968 (156.2) 3968 (156.2) 3968 (156.2)

Track Profile height mm (in) 31.8 (1.250) 23.5 (.925) 31.8 (1.250)
40 - 50 40 - 50 40 - 50
Deflection mm (in)
Adjustment (1-9/16 - 1-31/32) (1-9/16 - 1-31/32) (1-9/16 - 1-31/32)
Force (3) 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

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Section 12 TECHNICAL DATA
Subsection 02 (VEHICLES)

WT SWT WT LC
SKANDIC 552 552 593
ELECTRICAL
Battery V (Ah) 12 (18) 12 (18) 12 (18)
Headlamp W H4 60/55 H4 60/55 H4 60/55
Taillight and stoplight W 8/27 8/27 8/27
Tachometer and speedometer bulbs W 3 3 3
Fuel and temperature gauge bulbs W N.A. N.A. N.A.
Starter solenoid A 20 20 15
Fuse
Fuel level sensor A N.A. N.A. N.A.
CAPACITIES
Fuel tank L (U.S. gal) 40 (10.6) 40 (10.6) 40 (10.6)
Chaincase/gearbox mL (U.S. oz) 400 (13.5) 400 (13.5) 400 (13.5)
Cooling system 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)
VEHICLE INFORMATIONS
Mass (dry) kg (lb) 258 (568) 277 (610) 275 (605)
Length mm (in) 3020 (118.9) 3150 (124.0) 3150 (124.0)
Width mm (in) 1045 (41.1) 1100 (43.3) 1100 (43.3)
Height mm (in) 1295 (50.98) 1330 (52.4) 1220 (48)
Ski stance (carbide to carbide) mm (in) 900 (35.4) 900 (35.4) 900 (35.4)
Toe-out mm (in) 5 (3/16) 5 (3/16) 5 (3/16)
Camber mm (in) N.A. N.A. N.A.
Ground contact area cm2 (in2) 10793 (1672.9) 13986 (2167.8) 12335 (1912)
Ground contact pressure kPa (PSI) 2.46 (.357) 2.04 (.296) 2.33 (.338)
Frame material Steel Steel Steel
Polyethylene Polyethylene Polyethylene
Bottom pan material
High Density High Density High Density
Hood material RRIM RRIM RRIM

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 Section 12 TECHNICAL DATA
Subsection 02 (VEHICLES)

SKANDIC SUV 552 593

DRIVE
1st 1:2.82 1:2.82
Gear ratio 2nd 1:1.89 1:1.7
R 1:3.44 1:3.44

Type Bombardier Lite (1) TRA III

Clutch engagement ±100 RPM 2500 2700

Spring color Yellow/Green Yellow/Red
Spring length ± 1.5 mm (± .060 in) 94.61 (3.725) 128 (5.039)
Screw: 417 120 400 = 21 g 417 120 400
Drive pulley Weight N.A.
Screw: 417 114 400 = 3.4 g 4 x 417 114 400
Calibration Block N.A. N.A.
Cap 417 114 500 = 1.65 g 417 114 500 N.A.
Pin 417 222 594 417 222 594
Ramp N.A. 600 (4)
Screw position N.A. 3
Type Cvtech Cvtech
Driven pulley Spring preload ± 0.7 kg (± 1.5 lb) 7.0 (15.4) 7.0 (15.4)
Cam angle degree 40/35 35/30
41.8 ± 0.75 35.5 ± 0.75
Pulley distance Z mm (in)
(1.647 ± .030) (1.398 ± .030)
35 ± 0.75 37 ± 0.75
X mm (in)
(1.380 ± .030) (1.457 ± .030)
Offset
0.75 - 2.25 0.75 - 2.25
Y–X MIN.-MAX. mm (in)
(.030 - .089) (.030 - .089)
Drive belt part number (P/N) 414 633 800 417 300 155
Drive belt width Wear limit mm (in) 32.0 (1-1/4) 32.0 (1-1/4)
Deflection mm (in) 32 (1-1/4) 32 (1-1/4)
Drive belt adjustment
Force (2) kg (lbf) 11.3 (25) 11.3 (25)
Width mm (in) 500 (19.7) 500 (19.7)
Length mm (in) 3968 (156.2) 3968 (156.2)

Track Profile height mm (in) 31.8 (1.25) 31.8 (1.25)

40 - 50 40 - 50
Deflection mm (in)
Adjustment (1-9/16 - 1-31/32) (1-9/16 - 1-31/32)
Force (3) kg (lbf) 7.3 (16) 7.3 (16)
Track Skandic SUV Skandic SUV
Suspension type
Ski SUV SUV

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Section 12 TECHNICAL DATA
Subsection 02 (VEHICLES)

SKANDIC SUV 552 593

ELECTRICAL
Battery V (Ah) 12 (18) 12 (20)
Headlamp W H4 60/55 H4 60/55
Taillight and stoplight W 8/27 8/27
Tachometer and speedometer bulbs W 3 3
Fuel and temperature gauge bulbs W N.A. N.A.
Starter solenoid A 20 15
Fuse
Fuel level sensor A N.A. N.A.
CAPACITIES
Fuel tank L (U.S. gal) 40 (10.6) 40 (10.6)
Chaincase/gearbox mL (U.S. oz) 400 (13.5) 400 (13.5)
Cooling system L (U.S. oz) N.A. 4.5 (152)
Injection oil reservoir L (U.S. oz) 2.5 (84.5) 2.5 (84.5)
VEHICLE INFORMATIONS
Mass (dry) kg (lb) 274 (603) 291 (640)
Length mm (in) 3150 (124) 3150 (124)
Width mm (in) 110 (43.3) 110 (43.3)
Height mm (in) 1220 (48) 1220 (48)
Ski stance (carbide to carbide) mm (in) 900 (35.4) 900 (35.4)
Toe-out mm (in) 5 (3/16) 5 (3/16)
Camber mm (in) N.A. N.A.
Ground contact area cm2 (in2) 12335 (1912) 12335 (1912)
Ground contact pressure kPa (PSI) 2.25 (.320) 2.36 (.342)
Frame material Steel Steel
Polyethylene High Polyethylene High
Bottom pan material
Density Density
Hood material RRIM RRIM

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 Section 12 TECHNICAL DATA
Subsection 02 (VEHICLES)

600 HO V-1000
SKANDIC EXPEDITION TUV SDI 4–TEC
DRIVE
1st 1: 2.82 1: 2.82
Gear ratio 2nd 1: 1.70 1: 1.89
R 1: 3.44 1: 3.44

Type TRA III TRA IV

Clutch engagement ±100 RPM 2700 2500

Spring color violet/blue Red/Yellow
Spring length ± 1.5 mm (± .060 in) 120 (4.724) 87.9 (3.46)
Weight N.A. N.A.
Drive pulley
Calibration Block N.A. N.A.
Cap N.A. N.A.
417 222 594
Pin Solid
(long)
Ramp 410 607
Screw position 3 3(5)
Type Cvtech VSA Cvtech VSA
Driven pulley Spring preload ± 0.7 kg (± 1.5 lb) 7.7 7.5 - 9.0
Cam angle degree 35-30 40-30
61 ± 0.75 61 ± 0.75
Pulley distance Z mm (in)
(2.402 ± 0.030) (2.402 ± 0.030)
X mm (in) 37 (1.457) 37 (1.457)
Offset 0.75 - 2.25 0.75 - 2.25
Y–X MIN.-MAX. mm (in)
(.03 - .09) (.03 - .09)
Drive belt part number (P/N) 605 348 425 605 348 425
Drive belt width Wear limit mm (in) 35.5 (1.398) 35.5 (1.398)
Deflection mm (in) 32 (1-1/4) 32 (1-1/4)
Drive belt adjustment
Force (2) kg (lbf) 11.3 (25) 11.3 (25)
Width mm (in) 508 (20) 508 (20)
Length mm (in) 3960 (156) 3960 (156)

Track Profile height mm (in) 31.8 (1.25) 31.8 (1.25)

40 - 50 40 - 50
Deflection mm (in)
Adjustment (1-9/16 - 1-31/32) (1-9/16 - 1-31/32)
Force (3) kg (lbf) 7.3 (16) 7.3 (16)
Track SUV SUV
Suspension type
Ski SUV SUV

mmr2005-057 http://ReadManuals.com 565

Section 12 TECHNICAL DATA
Subsection 02 (VEHICLES)

600 HO V-1000
SKANDIC EXPEDITION TUV SDI 4–TEC
ELECTRICAL
Battery V (Ah) 12 (18) 12 (18)
Headlamp W 60/55 60/55
Taillight and stoplight W 8/27 8/27
Tachometer and speedometer bulbs W N.A. N.A.
Fuel and temperature gauge bulbs W N.A. N.A.
Starter solenoid A 5 5
Fuse
Fuel level sensor A N.A. N.A.
CAPACITIES
Fuel tank L (U.S. gal) 42 (11) 42 (11)
Chaincase/gearbox mL (U.S. oz) 400 (13.5) 400 (13.5)
Cooling system L (U.S. oz) 4.5 (15.2) 4.5 (15.2)
Engine L (U.S. oz) N.A. 3.4 (115 )
Engine oil
Reservoir L (U.S. oz) 2.5 (84.5) N.A.
VEHICLE INFORMATIONS
Mass (dry) kg (lb) 325 (717) 345 (761)
Length mm (in) 3150 (124) 3060 (120.5)
Width mm (in) 1185 (46.7) 1185 (46.7)
Height mm (in) 1320 (52) 1320 (52)
Ski stance (carbide to carbide) mm (in) 985 (38.8) 985 (38.8)
Toe-out mm (in) 5 (3/16) 5 (3/16)
Camber mm (in) N.A. N.A.
Frame material Steel Steel
High density High density
Bottom pan material
polyethylene polyethylene
Hood material RRIM RRIM

566 http://ReadManuals.com mmr2005-057

 Section 12 TECHNICAL DATA
Subsection 03 (TECHNICAL DATA LEGENDS)

TECHNICAL DATA LEGENDS

ENGINE TECHNICAL DATA LEGEND
A: Ampere (6) Drive pulley retaining screw: torque to 125
ABDC: After Bottom Dead Center to 135 N•m (92 to 100 lbf•ft), install drive
belt, accelerate the vehicle at low speed
ATDC: After Top Dead Center (maximum 30 km/h (20 MPH)) and apply the
BBDC: Before Bottom Dead Center brake; repeat 5 times. Retorque screw to
125 to 135 N•m (92 to 100 lbf•ft).
BTDC: Before Top Dead Center
CDI: Capacitor Discharge Ignition (7) CAUTION: Do not attempt to adjust gap
on spark plug BR9ECS. The specification
IACV: Idle Air Control Valve is given for verification purpose only. If
k: Kilo (X 1000) found out of specification, replace with a
new one.
MAG: Magneto Side
N.A.: Not Applicable (8) Use Bombardier premixed coolant (P/N 293
600 038) or a solution of ethylene glycol an-
PSI: Pound per square inch tifreeze for aluminum engines with deminer-
PTO: Power Take Off Side alized water (50% antifreeze, 50% deminer-
alized water).
R: Rectangular
SDI: Semi-direct injection (9) At 4000 RPM with APS disconnected.
ST: Semi-Trapezoidal
V: Volt
W: Watt

(1) The maximum horsepower RPM applicable

on the vehicle. It may be different under cer-
tain cricumstances and BOMBARDIER re-
serves the right to modify it without obliga-
tion.
(2) Crankshaft end-play is not adjustable on
these models. Specification is given for
verification purposes only.
(3) At 3500 RPM with headlamp turned on.
(4) All resistance measurements must be per-
formed with parts at room temperature (ap-
prox. 20°C (68°F)). Temperature greatly af-
fects resistance measurements.
(5) Drive pulley retaining screw: torque to 80
to 100 N•m (59 to 74 lbf•ft), install drive
belt, accelerate the vehicle at low speed
(maximum 30 km/h (20 MPH)) and apply the
brake; repeat 5 times. Retorque screw to
90 to 100 N•m (66 to 74 lbf•ft).

mmr2005-057 http://ReadManuals.com 567

Section 12 TECHNICAL DATA
Subsection 03 (TECHNICAL DATA LEGENDS)

VEHICLE TECHNICAL DATA

LEGEND
RRIM: Reinforced Reaction Injection Molding
TRA: Total Range Adjustable drive pulley
N.A.: Not Applicable

(1) For Bombardier Lite drive pulleys:

1157 = Red block, push type 38 g
(P/N 417 115 700).
1181 = Black block, screw type 39.6 g
(P/N 417 118 100).
1143 = Red block, screw type 41.8 g
(P/N 417 114 300)
W= Washer 1.8 g (P/N 417 115 800)
(2) Force applied midway between pulleys to ob-
tain specified deflection.
(3) Force or downward pull applied to track to ob-
tain specified tension deflection.
(4) Lever with roller pin (P/N 417 222 594) (long
and solid).
(5) From factory TRA IV drive pulley adjustment
screws are set to position 3. This position al-
lows the best compromise between accelera-
tion, top speed and fuel economy.
Position 1 or 2 would provide the best fuel
economy. Top speed would be reduce.
Position 4 would give the best acceleration.
Fuel economy would be reduced.

568 http://ReadManuals.com mmr2005-057

 Section 13 WRING DIAGRAMS
Subsection 01 (WIRING DIAGRAMS)

WIRING DIAGRAMS
Wiring diagrams can be found at the end of this
subsection.

WIRE COLORS AND CIRCUIT

All Models except Expedition TUV 600
HO SDI and V-1000
The first color of a wire is the main color, second
color is the stripe.
Example: YL/BK is a YELLOW wire with a BLACK
stripe.

COLOR CODE

BE = BEIGE OR = ORANGE
BK = BLACK RD = RED
BL or BU = BLUE VI or VL = VIOLET
BR = BROWN WH = WHITE
GN = GREEN YL= YELLOW
GY or GN = GREY

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2005 TUNDRA R

A05Z03
A29Z0C8

BU/BK 0.75
1

GR/BK 0.75
2
3
2005 SKANDIC LT 440

MPEM
1

RD
2

WH
2

1
3
BU/YL
BU/YL

WH/YL
WH/YL

IGNITION SYSTEM
BK

RD

BK 2.5 BK
BK/YL 2.5
YL/GN 2.5 YL YL YL 2.5
YL/GN 2.5 YL 2.5
BK 2.5
RECTIFIER

RD/BU 2.5
POWER SUPPLY
REGULATOR/

STARTER
M
20A
ON
OFF

START

RD 1.5

RD/GN 1.5

BK 1.5
KEY SWITCH

BK/YL 2.5
RD/BU 2.5
REVERSE ALARM
BK 0.75
GR/BK 0.75
BK 0.75
REVERSE SWITCH
REVERSE PILOT LAMP
BK 0.75 BU/BK 0.75
STARTER AND IGNITION SWITCHES

TETHER CUT-OUT SWITCH

BK 1.5 BK/YL 1.5
ENGINE CUT-OUT SWITCH
BK 1.5 BK/YL 1.5
DIMMER SWITCH
L

HEADLAMP
H

WH/GR 1.5
YL/GN 1.5 YL 1.5
GR 1.5
YL/GN 0.75
GR 0.75
HIGH BEAM INDICATOR
LIGHTING

TAIL LIGHT
BREAK SWITCH YL 0.75
YL 0.75
YL/GN 0.75
WH 0.75
50 OHMS

OIL LEVEL INDICATOR OIL LEVEL SWITCH

YL 0.75
YL/GN 0.75 BR 0.75
SPEEDOMETER
YL/GN 0.75 YL 0.75
INSTRUMENTS
FUEL LEVEL SENSOR
BU 0.75
YL/GN 0.75
FUEL LEVEL INDICATOR
YL 0.75
FUSE 0.25A

YL/GN 0.75 YL 0.75

OR 1.5
OR/VL 1.5
HEATING GRIP SWITCH
YL/GN 1.5 YL/BK 1.5 0
1
2 YL 1.5
HEATING LEVER SWITCH
0

HEATING ELEMENTS
1
HEATED LEVER 2 YL 1.5
BR 1.5
YL/GN 1.5 YL/BK 1.5
BR/YL 1.5
A29Z0E8
MODULE
IGNITION

IGNITION SYSTEM

BK 2.5
BK/YL 2.5
2005 SKANDIC WT, SKANDIC SWT, SKANDIC SUV 550

YL/GN 2.5
YL 2.5
YL 2.5
YL/GN 2.5
RD/BU 2.5
BK 2.5
POWER SUPPLY
REGULATOR

STARTER
M
RD 2.5

20A

RD/GN 1.5
ON
OFF

START

WH/RD

BK 1.5
KEY SWITCH

2.5

TETHER CUT-OUT SWITCH

BK 1.5
STARTER AND IGNITION SWITCHES

BK/YL 1.5
ENGINE CUT-OUT SWITCH
BK 1.5 BK/YL 1.5
HEADLAMPS DIMMER SWITCH
GR/RD 1.5
L

GR 1.5
YL/GN 1.5
H

GR/RD 1.5
YL 1.5
GR 1.5
YL/GN 1.5
LIGHTING

YL/GN 0.75 HIGH BEAM INDICATOR GR 0.75

TAIL LIGHT
BRAKE SWITCH
YL 0.75
YL/GN 0.75
WH 0.75 YL 0.75
50 OHMS

OIL LEVEL INDICATOR OIL LEVEL SWITCH

YL/GN 0.75 WH/RD 0.75 YL 0.75
REVERSE SWITCH
REVERSE ALARM
RD/YL 0.75 YL 0.75
YL/GN 0.75
SPEEDOMETER
REVERSE LIGHT
YL/GN 0.75 YL 0.75
INSTRUMENTS

FUEL LEVEL SENSOR

YL/GN 0.75 BU 0.75
FUEL LEVEL INDICATOR
0.25A

YL 0.75
YL/GN 0.75 YL 0.75
OR 1.5
HEATING GRIP
OR/VL 1.5
HEATING GRIP SWITCH
YL/GN 1.5 YL/BK 1.5 0
1
2 YL 1.5
OR 1.5
OR/VL 1.5
HEATING GRIP
HEATING LEVER SWITCH

HEATING ELEMENTS
0
1
2 YL 1.5
HEATED LEVER BR 1.5
YL/GN 1.5
YL/BK 1.5 BR/YL 1.5
POWER OUTLET
RD/BU 1.5
BK 1.5
A29Z0D8

WH/OR 0.75
BK/WH 1.5
2005 SKANDIC WT LC, SKANDIC SUV 600

WH/GR 1.5
MPEM

BK/GN 1.5
IGNITION SYSTEM

BK/YL 1.5
BK
RD
BU/YL

BK/RD
WH/YL

BK 2.5
YL 1.5
YL/GN 2.5
YL 2.5
YL/GN 2.5
RD/BU 2.5
BK 2.5
RECTIFIER

POWER SUPPLY
REGULATOR/

STARTER
M
20A
RD 2.5

NO 1.5
ON
OFF

RD/GN 1.5
WH/RD 2.5
START

NO 1.5
KEY SWITCH

ENGINE CUT-OUT SWITCH

NO 1.5 BK/YL 1.5
DESS SWITCH
STARTER AND IGNITION SWITCHES

BK/GN 1.5
BK/WH 1.5
WH/GR 1.5
ROM
HEADLAMPS DIMMER SWITCH
GR/RD 1.5
YL/GN 1.5
L

GR 1.5
H

GR/RD 1.5
YL 1.5
YL/GN 1.5
GR 1.5
LIGHTING

HIGH BEAM INDICATOR

YL/GN 0.75 GR 0.75
TAIL LIGHT
BRAKE SWITCH
YL 0.75
YL/GN 0.75
WH 0.75 YL 0.75
OIL LEVEL SWITCH
50 OHMS

OIL LEVEL INDICATOR

YL/GN 0.75 WH/RD 0.75 YL 0.75
REVERSE SWITCH
REVERSE ALARM
YL/GN 0.75 RD/YL 0.75 YL 0.75
DESS INDICATOR
BK 1.5 WH/OR 0.75
SPEEDOMETER
YL/GN 0.75 YL 0.75
TACHOMETER
YL/GN 0.75 YL 0.75
YL/GN 0.75 YL 0.75
INSTRUMENTS

FUEL LEVEL SENSOR

YL/GN 0.75 BU 0.75
FUEL LEVEL INDICATOR
0.25A

YL 0.75
YL/GN 0.75 YL 0.75
TEMP. SENSOR
YL/GN 0.75 VI 0.75 VI 0.75 YL 0.75
ENGINE OVERHEATING
INDICATOR
YL 0.75
YL/GN 0.75 YL 0.75
TEMP GAUGE
OR 1.5
HEATING GRIP
OR/VL 1.5
HEATING GRIP SWITCH
YL/GN 1.5 YL/BK 1.5 0
1
2 YL 1.5
OR 1.5
OR/VL 1.5
HEATING GRIP
HEATING LEVER SWITCH
0
1

HEATING ELEMENTS
2 YL 1.5
BR 1.5
HEATED LEVER
YL/GN 1.5 YL/BK 1.5 BR/YL 1.5
POWER OUTLET
BK 1.5 RD/BU 1.5
2005 EXPEDITION 600 TUV SDI

A29Z0G
2005 EXPEDITION V-1000 TUV

A29Z0F
C M Y CM MY CY CMY K