Ski doo shop manual 1997
Give your content the digital home it deserves. Get it to any device in seconds. Ski doo complete workshop service manual all models 3, pages pdf, mb, searchable,. Publish for free today. Go explore. Worn slider shoes or lost retaining screws. Check slide suspension retaining bolts. Missing bolt s allowing movement of certain components which in turn interfere with track rotation.
Replace missing bolt s. Check condition of idler wheel s. Idle wheel rubber is damaged. Check guide cleats. Top portion of guide cleat s is bent. Check sprockets. One or various teeth of drive shaft sprockets are broken.
Replace sprocket s. Replace track. Track is too loose. Check if track and slider shoes are properly aligned. Improper alignment. Track is too tight. Check if axles are properly lubricated. Check rear spring preload. Insufficient preload.
Increase preload using shock adjustment cams. Check ski runner condition. Worn ski runners. Check tension of front spring adjustment cams.
Insufficient ski pressure on the ground. Increase spring preload. Check if front arm stopper strap is too long. Shorten stopper strap. Check front arm spring tension. Slacken spring tension. Check position of front spring adjustment cams. More pressure on the ground when cam increases spring preload. Reduce front spring preload. Check position of stopper strap. More weight when stopper strap is short. Lengthen front arm stopper strap. Check position of front arm shock adjustment cam s.
When spring tension is weak, more weight is transferred to the skis. Check condition of ball joints. Corrosion restrains movement. Lubricate or replace. Check swing arm camber liquid cooled models. Too much ski leg inclination. Worn or bent ski runners. Replace ski runners.
Check ski alignment. Improper ski alignment. Check if bushings are too loose in steering system. Bushings are too loose. Grease only. Clean all metal components in a non-ferrous met- al cleaner. Scrape off carbon formation from cylinder ex- haust port, cylinder head and piston dome using a 1 00 wooden spatula. Expansion sleeve Clean the piston ring grooves with a groove clean- er tool, or with a piece of broken ring. Remove cylinder heads. Then with a pointed A21C05A tool inserted in piston no.
Then push needle bear- ings along with thrust washers using a 21 mm. NOTE: 0. Pusher 21 mm. Then with a pointed tool inserted in piston notch, remove cir- clip from piston no. To remove piston pin no.
A21C03A 3 2 — Insert puller end into piston pin. Expansion sleeve — Screw LH threads extracting nut. Locating sleeve — Hold puller firmly and rotate puller handle coun- terclockwise to pull piston pin. Instead of expan- sion sleeve, needles are held in place by 2 inner plastic cage halves. Plastic halves should come off pis- ton. If not, pull them out using long nose pliers. Use piston circlip installer sleeve. At cylinder no. Place circlip in 2. Restrain 3. If so, replace them. NOTE: Be sure to restore the chamfer.
Before inserting piston in cylinder no. Install proper ring compressor on piston assem- 1 bly. Cross torque cylinder head nuts nos. For proper position of noise dampers nos. Install armature plate, fan housing and then air de- flector. Install a gasket on each side of the air deflector.
Loctite Remove stator plate. Remove all trace of Loctite from crankshaft taper. Feeler gauge 2. This will expand bearings and ease installation. In- stall bearings with groove as per exploded view. These radius maintain the gap use a protective cap and a special puller, as illus- needed for bearings lubrication. When installing crankshaft, position drive pins no. Drive pins. At seal no. For bearing lubrication purpose, a gap of 1. Crankcase halves nos. Prior to joining of crankcase halves, spray some new injection oil or equivalent on all moving 4 2 parts of the crankshaft.
Let it dry for A09C05A. All Engines. It increases fill- ing capacity and reduces curing time. Position the crankcase halves together and tight- en bolts by hand then install and tighten armature plate on magneto side to correctly align the crank- case halves. Loctite , and engines. These parts are identified on welded hook.
XXXX wire — drain the cooling system and disconnect hoses from the engine. To install engine on vehicle, reverse removal pro- cedure. However, pay attention to the following: — Check tightness of engine rubber mount nuts. Match the marked carburetor to the side marked on the A06C1LA. Number sequence This is required because of the different jet- tings. Discard all gaskets and O-rings. Cut clamp no. Spread clamp no. Clean the piston ring groove with a groove cleaner tool, or with a piece of broken ring.
Exhaust valve extracting nut LH threads. Draining hole circlip, install each circlip so the circlip break is at 2. Use piston circlip installer. Check for cracked, dried or perforated bellows 1 no.
Place circlip in Restrain 1. Oil and Apply Loctite to screw threads. Circlip break torque cylinders screws. Install 4 screws in center holes. A00A1EA 2 1. Pins A00A1DA 2. Remove pins and install remaining screws.
Tighten all screws in recommended above se- on exhaust flanges to perform this procedure. Place a 0. Make sure to install O-rings around spark plug holes. For 1. O-rings and engines longer screws go on exhaust 2. Temperature sensor hole side.
Longer screws Only , and Only Install gasket with its larger holes on exhaust side. When reassembling the cylinders to the crank- case, it is important to have them properly aligned so that the cylinder head holes will match up with the studs. Cylinder head itself can be used to align the cylinders. Torque screws no. Install gasket and valve rod housing with their pas- sages toward bottom. Check free sliding action of valve. Torque cylinder head screws following illustrated Screw by hand valve piston on valve rod until it sequence.
On and engines longer bottoms. Secure bellows to valve piston with a clamp spring on engine. Install spring, cover and spring clip.
Turn adjust- ment screw by hand until it bottoms. Clean all metal components in a non-ferrous met- Prior to installation, place bearings into an oil con- al cleaner. This will expand bearing and ease instal- Remove all trace of Loctite from crankshaft taper. Install bearings and labyrinth sleeve with groove as per the following illustration. Keep a Remove old paste gasket from crankcase mating 0. A15C22A 2 1 1. Labyrinth sleeve 2,4,6,9, Crankshaft Bearing 2.
Outer bearing A. Install O-rings as illustrated. MAG side Install bearing drive pins no. Prior to joining of crankcase halves, spray some new injection oil or equivalent on all moving parts of the crankshaft. Let it dry for 10 to 20 minutes.
Drive pins cure on aluminum surfaces. Apply Loctite on screw. Torque screws as speci- bearings. When installing plain oil seals seal without locat- 1 ing ring or without spacing legs , ensure to main- tain a 1.
For seals with spacing 15 7 11 1 3 9 5 13 legs, install them against the bearing. NOTE: Torque the 2 smaller screws 15 and. Engine must stand this pressure during 3 min- uid cooled engines though it also applies to fan utes.
If pressure drops before 3 minutes, cooled engines. For FC engines, do not consider check tester kit by spraying a soapy solution information pertaining to coolant system and on pump piston, all plugs and fittings. Be- sides, on FC engines, leak will occur through lab- yrinth sleeve in center of crankshaft. See pages of this chapter. Install plug s over exhaust flange s.
Tighten with previously removed screws. Tighten — If there is a leak at the tested location, it is rec- with previously removed screws. Remove carburetor s. There is a possibility of 5.
Insert plug s in intake rubber boot s. Tighten more than one leak. Install air pump on any valve of exhaust plug. Rotate crankshaft so that piston goes to B. Bottom Dead Center on side where the pump is installed. This will open exhaust port. Activate pump and pressurize engine to 34 kPa 5 PSI. Do not exceed this pressure. Engine Check the following: 1. Small injection oil lines coming from pump.
Blocked intake flanges 2. Blocked impulse fitting 3. Open ends if applicable 4. Blocked RAVE valve flanges if applicable 5. Blocked exhaust flanges. When exhaust manifold is installed, use rubber A01B2XA 2 plug. In this case it is not necessary to move pis- 1.
Banjo fittings ton to B. Small injection oil lines. Check for air bubbles or oil column going toward pump. It indicates defective check valve in banjo fitting or lines. Remove cooling system cap. Check for air bubbles in antifreeze. It indicates de- fective cylinder head O-ring or cylinder base gas- ket.
Block both hoses of rotary valve gear lubrica- 1. Remove a spark plug or any plug of leak tester tion system with hose pinchers. If pressure drops, it indicates defective crank- shaft inner seal on PTO side. Remove a spark plug or any plug of leak tester kit on MAG side.
If pressure drops, it indicates defective crank- shaft inner seal on MAG side. Check drain hole below coolant pump housing with soapy water. If leakage stops, ignore remaining items and check crankcase rotary valve gear reservoir as per Crankcase Rotary Valve Gear Reservoir of this section.
Remove clutch then check crankshaft outer seal. Remove rewind starter and magneto system then check crankshaft outer seal. Check crankcase rotary valve gear reservoir. Drain hole Block one hose of rotary valve gear lubrication system with a hose pincher and install an adapter If there is a leak, it indicates defective seal of ro- in remaining hose. Install air pump on adapter and pressurize as be- fore.
Pressurize all system through coolant reser- voir to 15 PSI. 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 leading to leakage. A On rotary valve engines, measure just below aux- iliary transfer port, facing exhaust port. If the dif- 2 ference exceeds the specified dimension the cylinder should be rebored and honed or should be replaced. Piston pin position around all cylinder sleeve port openings. Measures to be compared A. Find the big- gest diameter. Find the smallest diameter.
A01C53A 1. If larger, cylinder should be rebored and honed or should be replaced. On rotary valve engines, position ring just below transfer ports. Using a feeler gauge, check ring end gap. Replace ring. The difference between these 2 measurements should be within specified tolerance.
Measurement fitting new parts With an inside micrometer, measure cylinder di- ameter above the exhaust port. The difference of both measurements is the clear- 1. Transfer port ance. Intake port. Replace piston. If clearance exceeds specified tolerance. First, check deflection with crankshaft in engine. If deflection exceeds the specified tolerance, re- check deflection using V-shaped blocks to deter- mine the defective part s.
See below. Measuring on bench ' rectly measured between centers of a lathe. NOTE: Crankshaft deflection can not be cor- Once engine is disassembled, check crankshaft deflection on V-shaped blocks. If deflection ex- If the deflection exceeds the specified tolerance, ceeds the specified tolerance, it can be worn crankshaft should be repaired or replaced.
LIMIT 0. Using a feeler gauge, measure distance between thrust washer and crankshaft counterweight. If the distance exceeds specified tolerance, repair or replace the crankshaft. Measure at mid point between the key and the first thread A.
See table below. First Method To measure this gap use a feeler gauge inserted between rotary valve and upper crankcase with the rotary valve cover in place without its O-ring.
Check the most surface as possible. Follow the A01C3GA same procedure with the lower crankcase. LIMIT be refaced to increase clearance. If gap is over tolerances, cover replacement may 0. Check if surfaces on crankcase and Apply grease to hold solder in position. Remove cover then clean and measure com- pressed solder thickness, it must be within the specified tolerance.
Remove both spark plugs. Bring MAG piston at top dead center. Bring PTO piston to top dead center. Lay part on a surface plate marble, mirror or thick glass plate. Holding down one end of part, try pushing down the other end. If any play is felt, part must be rectified. Rub manifold mating surface on sand paper using 8-figure movements.
A06C1TA 0. Sand until mating surface is perfectly straight. Any other reading indicates a misaligned twisted crankshaft. This will elimi- — rewind starter nate the possibility of thread breakage. Re- placed it in both cases. To replace trigger coil: — Disconnect trigger coil connector housing. A06E23A — Remove retaining screws. Cut by 25 mm 1 in — Remove trigger coil and carefully pull wires. Install puller with its tab in magneto housing open- ing.
Trigger coil tween the trigger coil and the flywheel protrusion 2. Flywheel protrusion must be checked and adjusted. The purpose of 3. Measure at center pole of trigger coil 0. Each time trigger coil air-gap is adjusted, ig- nition timing must be checked. Proceed as follows: — Install new parts and other parts removed tak- 1.
Rotate flywheel so that the protrusion aligns ing care not to squeeze trigger coil harness. Using a feeler gauge of 0. If necessary, adjust by slackening retaining screws and moving trigger coil toward or away of protrusion. Retighten screws and recheck air-gap. This will elimi- nate the possibility of thread breakage. To replace generator coil no. Adjustment Whenever the trigger coil or the magneto fly- wheel is removed or replaced, the air-gap be- tween the trigger coil and the flywheel protrusion must be checked and adjusted.
The purpose of this adjustment is to obtain the minimum clear- ance between these parts — without touching at any RPM — so that the trigger coil produces its proper electrical output.
Ignition timing must also be checked. Proceed as follows: 1. Rotate flywheel so that one protrusion aligns with trigger coil. A03C07A 80 00 2. If necessary, adjust by slackening retaining — Remove magneto flywheel nut, using a 30 mm screws and moving trigger coil toward or away socket machined to 40 mm 1. Apply Loctite blue on taper. Position Woodruff key, flywheel and lock washer on crankshaft.
Flywheel protrusion Ignition Timing 2. X mp Oil pu et X gaske ts. X X Loctite Molykote Loctite Loctite 2 1 3. See iden- tification on lever no. Always check for spring clips and clamps tight- ness. Make sure cable barrel is well seated in oil pump lever. The aligning marks on the pump casting and on the lever must align. If not, loosen the adjuster nut and adjust accordingly. Retighten the adjuster nut.
Adjuster nut 1. Small oil line 2. Bleeder screw 2. Marks aligned 3. Marks in line 3. Main oil line. Reinstall all parts except air silencer. Any delay in the opening of the the pump lever in fully open position. S-Series Only Remove air silencer and move carburetors aside. All Models Bleed main oil line between tank and pump by loosening the bleeder screw until air has escaped from the line.
Add injection oil as required. Check also for proper pump lever adjustment. Marks must aligned when throttle lever is activat- ed just enough to take all cable play. S-Series Only Reinstall air silencer. Secure the rear of the vehicle on a stand. Test pump as de- scribes below. NOTE: Main oil line must be full of oil. If oil drops, verify Lift rear of vehicle and support with a mechanical check valve operation in banjo fittings.
For en- stand. Unbolt banjo fittings from pump. Start en- gine check valve is integrated in injection nozzle. For check valve is in oil line. Replace as nec- Check that oil level in small oil lines is passed ban- essary. Repeat the procedure until Connect a hose filled with injection oil to main line this condition is attained.
Insert other hose end in an injection oil Reconnect banjo fittings with a washers on each container. Using a counterclockwise rotating drill side, start engine and run at idle while holding the rotate pump shaft. Oil must drip from outer holes pump lever in fully open position. Oil columns while holding lever in a fully open position.
If not must advance into small oil lines. Fully open position 2. Counterclockwise rotating drill A15C17A 3 2 3. Main line. Oil columns advancing 2. Washer on each side 3. Fully open position. NOTE: The following procedures can be. Install ex- Remove fan protector. Unused shim s here 2. Adjust here 3. Positioning noses A09C08A 4. On first plying the proper force midway between pulleys. Ensure to insert these noses into fan notches. Using a press, drive the fan shaft no. Remove circlip no. To install, press one bearing in place then install circlip and shims.
Press the other bearing from op- posite side until it is flush with housing. Press fan shaft from engine side of fan housing. Download Links. Ski-Doo Alpine Operator Manual. Among Canadian models of Ski-Doo snowmobiles , the Renegade and Freeride ranges are of great interest to extreme people.
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