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Bombardier Ski Doo REV 2004 Service Manual
INTRODUCTION
VEHICLE IDENTIFICATION NUMBER
ENGINE SERIAL NUMBER
LIST OF ABBREVIATIONS USED IN THIS MANUAL
ARRANGEMENT OF THIS MANUAL
GENERAL INFORMATION
ILLUSTRATIONS AND PROCEDURES
SELF-LOCKING FASTENERS PROCEDURE
LOCTITE APPLICATION PROCEDURE
THREADLOCKER
STRIPPED THREAD REPAIR
GASKET COMPOUND
MOUNTING ON SHAFT
CASE-IN COMPONENTS
TIGHTENING TORQUES
01 TOOLS AND SERVICE PRODUCTS
01 ? SERVICE TOOLS
ENGINE ? MANDATORY TOOLS
ENGINE ? RECOMMENDED TOOLS
TRANSMISSION? MANDATORY TOOLS
TRANSMISSION? RECOMMENDED TOOLS
SUSPENSION ? MANDATORY TOOLS
SUSPENSION ? RECOMMENDED TOOLS
VEHICLE? RECOMMENDED TOOLS
02 ? SERVICE PRODUCTS
02 MAINTENANCE
01 ? MAINTENANCE CHART
02 ? STORAGE
GENERAL
FUEL STABILIZER
ENGINE LUBRICATION
ENGINE COMPARTMENT
PULLEY PROTECTION
COUNTERSHAFT LUBRICATION
BATTERY
VEHICLE CLEANING
RAGS IN AIR INTAKE AND EXHAUST SYSTEM
VEHICLE PROTECTION
03 ? PRESEASON PREPARATION
FUEL FILTER REPLACEMENT
THROTTLE BODY CLEANING(ON SO EQUIPPED MODELS)
CARBURETOR CLEANING(ON SO EQUIPPED MODELS)
AIR FILTER CLEANING
RAGS IN AIR INTAKE AND EXHAUST SYSTEM
CLEANING OF DRIVE AND DRIVEN PULLEYS
CLEANING OF BRAKE DISK
DRIVE BELT CONDITION
SPARK PLUGS
I
TABLE OF CONTENTS
03 TROUBLESHOOTING
01 ? ENGINE
ENGINE LEAK VERIFICATION FLOW CHART
02 ? FUEL AND OIL SYSTEMS
03 ? TRANSMISSION AND BRAKE SYSTEM
TRANSMISSION
BRAKE SYSTEM
HYDRAULIC BRAKE
04 ? ELECTRICAL SYSTEM
05 ? SUSPENSION AND TRACK
04 ENGINE
01 ? 593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES
EXHAUST SYSTEM
TUNED PIPE
MANIFOLD
MUFFLER
ENGINE SYSTEM
REMOVAL FROM VEHICLE
INSPECTION
INSTALLATION
TOP END
TROUBLESHOOTING
COMPONENT REMOVALWITH THE ENGINE INSTALLED
CLEANING
RAVE VALVE BASIC OPERATION
DISASSEMBLY
INSPECTION
ASSEMBLY
BOTTOM END
CLEANING
DISASSEMBLY
INSPECTION
ASSEMBLY
BREAK-IN
02 ? ENGINE LEAK TEST AND DIMENSION MEASUREMENT
LEAK TEST
PREPARATION
PROCEDURE
FINALIZING REASSEMBLY
ENGINE LEAK VERIFICATION FLOW CHART
ENGINE DIMENSION MEASUREMENT
CYLINDER HEADWARPAGE
CYLINDER TAPER
CYLINDER OUT OF ROUND
COMBUSTION CHAMBER VOLUME MEASUREMENT
USED PISTON MEASUREMENT
CYLINDER/PISTON CLEARANCE
RING/PISTON GROOVE CLEARANCE
RING END GAP
CRANKSHAFT DEFLECTION
CONNECTING ROD BIG END AXIAL PLAY
II
TABLE OF CONTENTS
CRANKSHAFT END-PLAY
CHECKING CRANKSHAFT ALIGNMENT
03 ? MAGNETO SYSTEM
GENERAL
CLEANING
DISASSEMBLY
ASSEMBLY
04 ? OIL INJECTION SYSTEM
GENERAL
OIL TYPE
OIL SYSTEM LEAK TEST
OIL PUMP IDENTIFICATION
CLEANING
DISASSEMBLY
ASSEMBLY
ADJUSTMENT
CHECKING OPERATION
05 ? LIQUID COOLING SYSTEM
COOLING SYSTEM LEAK TEST
INSPECTION
DRAINING THE SYSTEM
DISASSEMBLY AND ASSEMBLY
COOLING SYSTEM REFILLING PROCEDURE
06 ? REWIND STARTER
INSPECTION
REMOVAL
ROPE REPLACEMENT
DISASSEMBLY
ASSEMBLY
INSTALLATION
07 ? CARBURETOR AND THROTTLE CABLE
CARBURETOR TM TYPE
IDENTIFICATION
REMOVAL
CLEANING AND INSPECTION
DISASSEMBLY AND ASSEMBLY
CARBURETOR ADJUSTMENTS
INSTALLATION
DPM
TESTING
PARTS REMOVAL AND INSTALLATION
DPM MANIFOLD TESTING
THROTTLE CABLE
THROTTLE/OIL PUMP CABLE REMOVAL
THROTTLE/OIL PUMP CABLE INSTALLATION
THROTTLE CABLE ADJUSTMENT
08 ? FUEL TANK AND FUEL PUMP
FUEL FILTER
FUEL TANK
IMPULSE/FUEL LINES SPRING CLIPS (ALL MODELS)
FLOAT-TYPE FUEL LEVEL GAUGE
ELECTRIC FUEL LEVEL SENSOR
III
TABLE OF CONTENTS
FUEL LEVEL SENSOR SCREWS
FUEL SYSTEM PRESSURIZATION
FUEL PUMP
REMOVAL
PUMP VERIFICATION
CLEANING AND INSPECTION
INSTALLATION
05 2?TEC ENGINE MANAGEMENT
01 ? OVERVIEW
OPERATING PRINCIPLE
AIR INDUCTION
FUEL DELIVERY SYSTEM
GENERAL
COMPONENT DESCRIPTION
ENGINE MANAGEMENT SYSTEM (EMS)
EMS ?GENERAL FUNCTIONS
ECU? ENGINE MANAGEMENT FUNCTIONS
ELECTRONIC FUEL INJECTION
IGNITION TIMING
ELECTRONICALLY CONTROLLED RAVE
KNOCK SENSOR
ENGINE MODES OF OPERATION
FLOODED ENGINE (DROWNED MODE)
MONITORING SYSTEM
LIMP HOME MODES
DIAGNOSTIC MODE
CHARGING SYSTEM
MAGNETO SYSTEM
DOUBLE IGNITION COIL
TRIGGER COIL
02 ? COMPONENT INSPECTION AND ADJUSTMENT
GENERAL
FUEL SYSTEM
ELECTRICAL SYSTEM
RESISTANCE MEASUREMENT
ENGINE CONNECTOR PIN-OUTS
AIR INDUCTION SYSTEM
THROTTLE BODY
FUEL DELIVERY
FUEL PUMP
FUEL RAIL
FUEL INJECTORS
ELECTRONIC MANAGEMENT
ECM REPLACEMENT
ENGINE WIRING HARNESS
THROTTLE POSITION SENSOR (TPS)
CRANKSHAFT POSITION SENSOR (CPS)
AIR TEMPERATURE SENSOR (ATS)
COOLANT TEMPERATURE SENSOR (CTS)
AIR PRESSURE SENSOR (APS)
EXHAUST GAS TEMPERATURE SENSOR (EGTS)
IV
TABLE OF CONTENTS
KNOCK SENSOR (KS)
E-RAVE SOLENOID
DOUBLE IGNITION COIL
TDC SETTING (TOP DEAD CENTER)
CAPACITOR
ENGINE START/RER BUTTON VERIFICATION
DESS SWITCH VERIFICATION
SPARK PLUGS
CRANKING SYSTEM
03 ? DIAGNOSTIC PROCEDURES
GENERAL
TROUBLESHOOTING
VCK(VEHICLE COMMUNICATION KIT)
2-TEC SYSTEM FAULT CODES
06 TRANSMISSION
01 ? DRIVE BELT
APPLICATION CHART
INSPECTION
CHECKING NEUTRAL FUNCTION
ROTATION DIRECTION
DRIVE BELT HEIGHT MEASUREMENT AND ADJUSTMENT
DRIVE BELT DEFLECTION MEASUREMENT (REFERENCE ONLY)
02 ? DRIVE PULLEY
TRA III
GENERAL
REMOVAL
DISASSEMBLY
CLEANING
INSPECTION
ASSEMBLY
INSTALLATION
DRIVE PULLEY ADJUSTMENT
03 ? DRIVEN PULLEY
FORMULA RER
REMOVAL
DISASSEMBLY
CLEANING
INSPECTION
BUSHING REPLACEMENT
ASSEMBLY
INSTALLATION
ADJUSTMENT
HPV VSA
REMOVAL
DISASSEMBLY
CLEANING
INSPECTION
ASSEMBLY
INSTALLATION
ADJUSTMENT
V
TABLE OF CONTENTS
04 ? PULLEY DISTANCE AND ALIGNMENT
GENERAL
GENERAL PROCEDURE
PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART
05 ? BRAKE
HYDRAULIC BRAKE
BRAKE FLUID
MASTER CYLINDER
CALIPER
BRAKE PADS
BRAKE DISC
COUNTERSHAFT BEARING
COUNTERSHAFT
BRAKE LIGHT SWITCH
BLEEDING
06 ? CHAINCASE
REMOVAL AND DISASSEMBLY
INSPECTION
GEAR RATIO MODIFICATION
INSTALLATION AND ASSEMBLY
DRIVE CHAIN ADJUSTMENT
ADJUSTMENT
07 ? DRIVE CHAIN
SILENT CHAIN
07 ELECTRICAL SYSTEM
01 ? IGNITION TIMING
SCRIBING A TIMING MARK
CHECKING IGNITION TIMING
CHANGING TIMING
02 ? SPARK PLUGS
DISASSEMBLY
SPARK PLUG INSTALLATION
SPARK PLUG TIGHTENING TORQUE
03 ? BATTERY
GENERAL
REMOVAL
CLEANING
INSPECTION
BATTERY CHARGE TESTING
BATTERY STORAGE
ACTIVATION OF NEW BATTERY
BATTERY CHARGING
INSTALLATION OF BATTERY
CABLE TERMINAL INSTALLATION
04 ? ELECTRIC STARTER
REMOVAL
DISASSEMBLY
CLEANING
INSPECTION
ASSEMBLY
INSTALLATION
VI
TABLE OF CONTENTS
05 ? TESTING PROCEDURE
GENERAL
CHECKING CALIBRATION PROGRAM
CHANGING MPEM CALIBRATION PROGRAM
SYSTEM TESTING
INSPECTION OF HEATING ELEMENTS
HEADLIGHT AND ACCESSORIES SYSTEM TESTING
08 REAR SUSPENSION
01 ? SC-10 SUSPENSION
COMPONENT REMOVAL AND INSTALLATION
SUSPENSION ASSEMBLY REMOVAL
DISASSEMBLY AND ASSEMBLY
SHOCK ABSORBER INSPECTION
INSTALLATION
RIDE ADJUSTMENT
LUBRICATION
02 ? SC-10 III SUSPENSION
COMPONENT REMOVAL AND INSTALLATION
SUSPENSION ASSEMBLY REMOVAL
DISASSEMBLY AND ASSEMBLY
SHOCK ABSORBER INSPECTION
HPG T/A SHOCK SERVICING
INSTALLATION
RIDE ADJUSTMENT
LUBRICATION
03 ? DRIVE AXLE
REMOVAL
ASSEMBLY
LUBRICATION
ADJUSTMENT
04 ? TRACK
TRACK TYPE APPLICATION
GENERAL
INSPECTION
REMOVAL
INSTALLATION
ADJUSTMENT
09 STEERING/FRONT SUSPENSION
01 ? STEERING SYSTEM
DISASSEMBLY AND ASSEMBLY
INSPECTION
ADJUSTMENT
STEERING ADJUSTMENT (SKIS)
LUBRICATION
02 ? FRONT SUSPENSION
GENERAL INSPECTION
DISASSEMBLY
INSPECTION
INSTALLATION
VII
TABLE OF CONTENTS
10 BODY/FRAME
01 ? BODY
INSTALLATION AND ADJUSTMENT
HEADLAMP BEAM AIMING
BULB REPLACEMENT
DECAL
WINDSHIELD
GUARD
WIRING HARNESS
CABLES
TUBING
PLASTIC MAINTENANCE AND REPAIR
MAINTENANCE
REPAIR
02 ? FRAME
FRAME CLEANING
FRAMEWELDING
FRAME COMPONENT REPLACEMENT
11 TECHNICAL DATA
01 ? SI* METRIC INFORMATION GUIDE
02 ? ENGINES
03 ? VEHICLES
04 ? TECHNICAL DATA LEGENDS
ENGINE LEGEND
VEHICLE LEGEND
12 WIRING DIAGRAM
01 ? WIRING DIAGRAMS
WIRING DIAGRAM LEGEND
WIRE COLORS
CONNECTOR HOUSING AREA
HOUSING REFERENCE PER AREA
WIRE LOCATION IN CONNECTOR HOUSING
SYMBOLS DESCRIPTION
UNPLUGING CONNECTORS
TAB AND RECEPTACLE CONNECTORS REMOVAL
TAB AND RECEPTACLE CONNECTORS INSTALLATION
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