Table Of Content

Mmr-2004 REV ang.FH8 Thu Dec 04 15:16:23 2003 Page 1 C M Y CM MY CY CMY K 2004 Shop Manual REV SERIES Legal deposit: National Libraryof Quebec National Library of Canada 2003 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. ©Bombardier Inc. 2003 TechnicalPublications Bombardier Inc. Valcourt (Quebec) Canada Printed in Canada ®*Registered trademarks of Bombardier Inc. This document contains the trademarks of the following companies: Crest© is a trademark of Crest Industries Inc. 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 GeneralElectric Company Supertanium© is a trademark of Premier IndustrialCorporation AMP© is a trademark of Tyco Electronics Corporation TABLE OF CONTENTS SAFETY NOTICE................................................................................... IX INTRODUCTION .................................................................................... X VEHICLEIDENTIFICATIONNUMBER........................................................................... XV ENGINESERIALNUMBER....................................................................................... XV LISTOFABBREVIATIONSUSEDINTHIS MANUAL......................................................... XV ARRANGEMENTOFTHIS MANUAL.......................................................................... XVII GENERALINFORMATION........................................................................................ XIX ILLUSTRATIONS ANDPROCEDURES ......................................................................... XIX SELF-LOCKINGFASTENERS PROCEDURE ................................................................... XIX LOCTITEAPPLICATIONPROCEDURE.......................................................................... XIX THREADLOCKER .................................................................................................. XX STRIPPEDTHREADREPAIR ..................................................................................... XXI GASKETCOMPOUND........................................................................................... XXII MOUNTINGONSHAFT......................................................................................... XXII CASE-INCOMPONENTS....................................................................................... XXIII TIGHTENINGTORQUES ....................................................................................... XXIII 01 TOOLS AND SERVICE PRODUCTS 01– SERVICETOOLS ............................................................................................... 1 ENGINE—MANDATORYTOOLS................................................................................... 2 ENGINE—RECOMMENDEDTOOLS............................................................................... 4 TRANSMISSION—MANDATORYTOOLS........................................................................ 10 TRANSMISSION—RECOMMENDEDTOOLS.................................................................... 11 SUSPENSION—MANDATORYTOOLS........................................................................... 15 SUSPENSION—RECOMMENDEDTOOLS....................................................................... 16 VEHICLE—RECOMMENDEDTOOLS............................................................................. 19 02– SERVICEPRODUCTS........................................................................................ 21 02 MAINTENANCE 01– MAINTENANCECHART..................................................................................... 29 02– STORAGE ..................................................................................................... 33 GENERAL............................................................................................................. 33 FUELSTABILIZER.................................................................................................... 33 ENGINELUBRICATION.............................................................................................. 33 ENGINECOMPARTMENT........................................................................................... 34 PULLEYPROTECTION............................................................................................... 34 COUNTERSHAFTLUBRICATION................................................................................... 34 BATTERY.............................................................................................................. 34 VEHICLECLEANING................................................................................................. 34 RAGSINAIRINTAKEANDEXHAUSTSYSTEM................................................................... 34 VEHICLEPROTECTION.............................................................................................. 34 03– PRESEASONPREPARATION............................................................................... 35 FUELFILTERREPLACEMENT...................................................................................... 35 THROTTLEBODYCLEANING(ONSOEQUIPPEDMODELS).................................................... 36 CARBURETORCLEANING(ONSOEQUIPPEDMODELS)........................................................ 36 AIRFILTERCLEANING.............................................................................................. 36 RAGSINAIRINTAKEANDEXHAUSTSYSTEM................................................................... 36 CLEANINGOFDRIVEANDDRIVENPULLEYS.................................................................... 36 CLEANINGOFBRAKEDISK ........................................................................................ 36 DRIVEBELTCONDITION............................................................................................ 36 SPARKPLUGS........................................................................................................ 36 I TABLE OF CONTENTS 03 TROUBLESHOOTING 01– ENGINE........................................................................................................ 37 ENGINELEAKVERIFICATIONFLOWCHART..................................................................... 48 02– FUELANDOILSYSTEMS .................................................................................. 49 03– TRANSMISSIONANDBRAKESYSTEM.................................................................. 53 TRANSMISSION ............................................................................................. 53 BRAKESYSTEM.............................................................................................. 60 HYDRAULICBRAKE................................................................................................. 60 04– ELECTRICALSYSTEM....................................................................................... 61 05– SUSPENSIONANDTRACK................................................................................. 73 04 ENGINE 01– 593, 593HO,593HOSDIAND793HOENGINETYPES............................................... 77 EXHAUSTSYSTEM.......................................................................................... 77 TUNEDPIPE.......................................................................................................... 78 MANIFOLD........................................................................................................... 78 MUFFLER............................................................................................................. 78 ENGINESYSTEM ............................................................................................ 80 REMOVALFROMVEHICLE......................................................................................... 81 INSPECTION.......................................................................................................... 84 INSTALLATION....................................................................................................... 84 TOPEND....................................................................................................... 85 TROUBLESHOOTING................................................................................................ 89 COMPONENTREMOVALWITHTHEENGINEINSTALLED...................................................... 89 CLEANING............................................................................................................ 89 RAVEVALVEBASICOPERATION................................................................................... 89 DISASSEMBLY....................................................................................................... 90 INSPECTION.......................................................................................................... 94 ASSEMBLY........................................................................................................... 95 BOTTOMEND ............................................................................................... 100 CLEANING.......................................................................................................... 103 DISASSEMBLY..................................................................................................... 103 INSPECTION........................................................................................................ 104 ASSEMBLY......................................................................................................... 104 BREAK-IN........................................................................................................... 109 02– ENGINELEAKTESTANDDIMENSIONMEASUREMENT............................................ 111 LEAKTEST.......................................................................................................... 111 PREPARATION ..................................................................................................... 111 PROCEDURE....................................................................................................... 111 FINALIZINGREASSEMBLY........................................................................................ 113 ENGINELEAKVERIFICATIONFLOWCHART................................................................... 114 ENGINEDIMENSIONMEASUREMENT.......................................................................... 115 CYLINDERHEADWARPAGE ..................................................................................... 115 CYLINDERTAPER.................................................................................................. 115 CYLINDEROUTOFROUND...................................................................................... 115 COMBUSTIONCHAMBERVOLUMEMEASUREMENT........................................................ 115 USEDPISTONMEASUREMENT.................................................................................. 117 CYLINDER/PISTONCLEARANCE................................................................................. 117 RING/PISTONGROOVECLEARANCE............................................................................ 119 RINGENDGAP..................................................................................................... 119 CRANKSHAFTDEFLECTION...................................................................................... 119 CONNECTINGRODBIGENDAXIALPLAY...................................................................... 120 II TABLE OF CONTENTS CRANKSHAFTEND-PLAY......................................................................................... 120 CHECKINGCRANKSHAFTALIGNMENT......................................................................... 120 03– MAGNETOSYSTEM........................................................................................ 121 GENERAL........................................................................................................... 123 CLEANING.......................................................................................................... 123 DISASSEMBLY..................................................................................................... 123 ASSEMBLY......................................................................................................... 124 04– OILINJECTIONSYSTEM .................................................................................. 127 GENERAL........................................................................................................... 128 OILTYPE............................................................................................................ 128 OILSYSTEMLEAKTEST.......................................................................................... 128 OILPUMPIDENTIFICATION...................................................................................... 129 CLEANING.......................................................................................................... 129 DISASSEMBLY..................................................................................................... 129 ASSEMBLY......................................................................................................... 130 ADJUSTMENT...................................................................................................... 131 CHECKINGOPERATION........................................................................................... 132 05– LIQUIDCOOLINGSYSTEM................................................................................ 133 COOLINGSYSTEMLEAKTEST................................................................................... 135 INSPECTION........................................................................................................ 135 DRAININGTHESYSTEM.......................................................................................... 135 DISASSEMBLYANDASSEMBLY................................................................................. 135 COOLINGSYSTEMREFILLINGPROCEDURE................................................................... 137 06– REWINDSTARTER.......................................................................................... 139 INSPECTION........................................................................................................ 140 REMOVAL .......................................................................................................... 140 ROPEREPLACEMENT............................................................................................. 140 DISASSEMBLY..................................................................................................... 140 ASSEMBLY......................................................................................................... 141 INSTALLATION..................................................................................................... 143 07– CARBURETORANDTHROTTLECABLE................................................................. 145 CARBURETORTMTYPE................................................................................... 145 IDENTIFICATION................................................................................................... 146 REMOVAL .......................................................................................................... 146 CLEANINGANDINSPECTION.................................................................................... 147 DISASSEMBLYANDASSEMBLY................................................................................. 148 CARBURETORADJUSTMENTS.................................................................................. 149 INSTALLATION..................................................................................................... 151 DPM........................................................................................................... 152 TESTING............................................................................................................ 152 PARTSREMOVALANDINSTALLATION.......................................................................... 152 DPMMANIFOLDTESTING........................................................................................ 153 THROTTLECABLE.......................................................................................... 155 THROTTLE/OILPUMPCABLEREMOVAL....................................................................... 155 THROTTLE/OILPUMPCABLEINSTALLATION.................................................................. 155 THROTTLECABLEADJUSTMENT............................................................................... 155 08– FUELTANK ANDFUELPUMP............................................................................ 157 FUELFILTER........................................................................................................ 159 FUELTANK......................................................................................................... 159 IMPULSE/FUELLINESSPRINGCLIPS(ALLMODELS)......................................................... 160 FLOAT-TYPEFUELLEVELGAUGE............................................................................... 161 ELECTRICFUELLEVELSENSOR................................................................................. 161 III TABLE OF CONTENTS FUELLEVELSENSORSCREWS.................................................................................. 161 FUELSYSTEMPRESSURIZATION................................................................................ 161 FUELPUMP.................................................................................................. 162 REMOVAL .......................................................................................................... 163 PUMPVERIFICATION.............................................................................................. 163 CLEANINGANDINSPECTION.................................................................................... 163 INSTALLATION..................................................................................................... 163 05 2–TEC ENGINE MANAGEMENT 01– OVERVIEW................................................................................................... 165 OPERATINGPRINCIPLE.................................................................................... 166 AIRINDUCTION.................................................................................................... 166 FUELDELIVERY SYSTEM.................................................................................. 166 GENERAL........................................................................................................... 166 COMPONENTDESCRIPTION..................................................................................... 166 ENGINEMANAGEMENTSYSTEM(EMS) .............................................................. 167 EMS—GENERALFUNCTIONS.................................................................................. 168 ECU—ENGINEMANAGEMENTFUNCTIONS.................................................................. 169 ELECTRONICFUELINJECTION.................................................................................. 170 IGNITIONTIMING.................................................................................................. 170 ELECTRONICALLYCONTROLLEDRAVE........................................................................ 170 KNOCKSENSOR................................................................................................... 170 ENGINEMODESOFOPERATION................................................................................ 170 FLOODEDENGINE(DROWNEDMODE)........................................................................ 170 MONITORINGSYSTEM........................................................................................... 170 LIMPHOMEMODES.............................................................................................. 171 DIAGNOSTICMODE............................................................................................... 171 CHARGINGSYSTEM....................................................................................... 171 MAGNETOSYSTEM............................................................................................... 171 DOUBLEIGNITIONCOIL.......................................................................................... 171 TRIGGERCOIL..................................................................................................... 172 02– COMPONENTINSPECTIONANDADJUSTMENT..................................................... 173 GENERAL..................................................................................................... 173 FUELSYSTEM............................................................................................... 173 ELECTRICALSYSTEM...................................................................................... 174 RESISTANCEMEASUREMENT................................................................................... 175 ENGINECONNECTORPIN-OUTS................................................................................ 176 AIRINDUCTIONSYSTEM ................................................................................. 177 THROTTLEBODY.................................................................................................. 177 FUELDELIVERY ............................................................................................. 180 FUELPUMP........................................................................................................ 181 FUELRAIL.......................................................................................................... 185 FUELINJECTORS.................................................................................................. 186 ELECTRONIC MANAGEMENT............................................................................ 188 ECMREPLACEMENT.............................................................................................. 188 ENGINEWIRINGHARNESS....................................................................................... 189 THROTTLEPOSITIONSENSOR(TPS)............................................................................ 189 CRANKSHAFTPOSITIONSENSOR(CPS)........................................................................ 192 AIRTEMPERATURESENSOR(ATS).............................................................................. 193 COOLANTTEMPERATURESENSOR(CTS)...................................................................... 193 AIRPRESSURESENSOR(APS)................................................................................... 194 EXHAUSTGASTEMPERATURESENSOR(EGTS)............................................................... 195 IV TABLE OF CONTENTS KNOCKSENSOR(KS).............................................................................................. 196 E-RAVESOLENOID................................................................................................ 197 DOUBLEIGNITIONCOIL.......................................................................................... 197 TDCSETTING(TOPDEADCENTER)............................................................................. 199 CAPACITOR......................................................................................................... 199 ENGINESTART/RERBUTTONVERIFICATION .................................................................. 200 DESSSWITCHVERIFICATION.................................................................................... 200 SPARKPLUGS...................................................................................................... 200 CRANKINGSYSTEM............................................................................................... 201 03– DIAGNOSTICPROCEDURES.............................................................................. 203 GENERAL........................................................................................................... 203 TROUBLESHOOTING ............................................................................................. 203 VCK(VEHICLECOMMUNICATIONKIT)........................................................................... 206 2-TECSYSTEMFAULTCODES................................................................................... 207 06 TRANSMISSION 01– DRIVEBELT .................................................................................................. 209 APPLICATIONCHART............................................................................................. 209 INSPECTION........................................................................................................ 209 CHECKINGNEUTRALFUNCTION................................................................................ 209 ROTATIONDIRECTION............................................................................................ 209 DRIVEBELTHEIGHTMEASUREMENTANDADJUSTMENT.................................................. 210 DRIVEBELTDEFLECTIONMEASUREMENT(REFERENCEONLY)............................................ 212 02– DRIVEPULLEY............................................................................................... 215 TRAIII............................................................................................................... 215 GENERAL........................................................................................................... 216 REMOVAL .......................................................................................................... 216 DISASSEMBLY..................................................................................................... 216 CLEANING.......................................................................................................... 218 INSPECTION........................................................................................................ 218 ASSEMBLY......................................................................................................... 220 INSTALLATION..................................................................................................... 223 DRIVEPULLEYADJUSTMENT................................................................................... 224 03– DRIVENPULLEY ............................................................................................ 227 FORMULARER.................................................................................................... 227 REMOVAL .......................................................................................................... 228 DISASSEMBLY..................................................................................................... 228 CLEANING.......................................................................................................... 228 INSPECTION........................................................................................................ 228 BUSHINGREPLACEMENT........................................................................................ 229 ASSEMBLY......................................................................................................... 229 INSTALLATION..................................................................................................... 230 ADJUSTMENT...................................................................................................... 231 HPVVSA............................................................................................................ 232 REMOVAL .......................................................................................................... 233 DISASSEMBLY..................................................................................................... 233 CLEANING.......................................................................................................... 233 INSPECTION........................................................................................................ 233 ASSEMBLY......................................................................................................... 233 INSTALLATION..................................................................................................... 234 ADJUSTMENT...................................................................................................... 234 V TABLE OF CONTENTS 04– PULLEYDISTANCEANDALIGNMENT.................................................................. 235 GENERAL........................................................................................................... 235 GENERALPROCEDURE........................................................................................... 235 PULLEYALIGNMENTANDDISTANCESPECIFICATIONSCHART............................................. 236 05– BRAKE ........................................................................................................ 239 HYDRAULICBRAKE ........................................................................................ 239 BRAKEFLUID ...................................................................................................... 240 MASTERCYLINDER............................................................................................... 240 CALIPER............................................................................................................ 240 BRAKEPADS....................................................................................................... 241 BRAKEDISC........................................................................................................ 242 COUNTERSHAFTBEARING....................................................................................... 242 COUNTERSHAFT................................................................................................... 243 BRAKELIGHTSWITCH............................................................................................ 243 BLEEDING.......................................................................................................... 244 06– CHAINCASE.................................................................................................. 245 REMOVALANDDISASSEMBLY.................................................................................. 246 INSPECTION........................................................................................................ 246 GEARRATIOMODIFICATION..................................................................................... 246 INSTALLATIONANDASSEMBLY................................................................................. 247 DRIVECHAINADJUSTMENT..................................................................................... 247 ADJUSTMENT...................................................................................................... 248 07– DRIVECHAIN................................................................................................ 249 SILENTCHAIN...................................................................................................... 249 07 ELECTRICAL SYSTEM 01– IGNITIONTIMING........................................................................................... 251 SCRIBINGATIMINGMARK....................................................................................... 251 CHECKINGIGNITIONTIMING.................................................................................... 252 CHANGINGTIMING................................................................................................ 253 02– SPARKPLUGS............................................................................................... 257 DISASSEMBLY..................................................................................................... 257 SPARKPLUGINSTALLATION..................................................................................... 257 SPARKPLUGTIGHTENINGTORQUE............................................................................ 257 03– BATTERY ..................................................................................................... 259 GENERAL........................................................................................................... 259 REMOVAL .......................................................................................................... 259 CLEANING.......................................................................................................... 259 INSPECTION........................................................................................................ 259 BATTERYCHARGETESTING ..................................................................................... 260 BATTERYSTORAGE............................................................................................... 260 ACTIVATIONOFNEWBATTERY.................................................................................. 260 BATTERYCHARGING.............................................................................................. 260 INSTALLATIONOFBATTERY ..................................................................................... 260 CABLETERMINALINSTALLATION............................................................................... 261 04– ELECTRICSTARTER ........................................................................................ 263 REMOVAL .......................................................................................................... 264 DISASSEMBLY..................................................................................................... 264 CLEANING.......................................................................................................... 265 INSPECTION........................................................................................................ 265 ASSEMBLY......................................................................................................... 267 INSTALLATION..................................................................................................... 268 VI TABLE OF CONTENTS 05– TESTINGPROCEDURE..................................................................................... 269 GENERAL........................................................................................................... 269 CHECKINGCALIBRATIONPROGRAM........................................................................... 272 CHANGINGMPEMCALIBRATIONPROGRAM.................................................................. 275 SYSTEMTESTING ................................................................................................. 276 INSPECTIONOFHEATINGELEMENTS.......................................................................... 283 HEADLIGHTANDACCESSORIESSYSTEMTESTING.......................................................... 284 08 REAR SUSPENSION 01– SC-10SUSPENSION........................................................................................ 285 COMPONENTREMOVALANDINSTALLATION................................................................. 288 SUSPENSIONASSEMBLYREMOVAL............................................................................ 289 DISASSEMBLYANDASSEMBLY................................................................................. 289 SHOCKABSORBERINSPECTION................................................................................ 291 INSTALLATION..................................................................................................... 292 RIDEADJUSTMENT............................................................................................... 292 LUBRICATION...................................................................................................... 292 02– SC-10III SUSPENSION..................................................................................... 293 COMPONENTREMOVALANDINSTALLATION................................................................. 296 SUSPENSIONASSEMBLYREMOVAL............................................................................ 297 DISASSEMBLYANDASSEMBLY................................................................................. 298 SHOCKABSORBERINSPECTION................................................................................ 300 HPGT/ASHOCKSERVICING ..................................................................................... 301 INSTALLATION..................................................................................................... 309 RIDEADJUSTMENT............................................................................................... 309 LUBRICATION...................................................................................................... 309 03– DRIVEAXLE.................................................................................................. 311 REMOVAL .......................................................................................................... 312 ASSEMBLY......................................................................................................... 313 LUBRICATION...................................................................................................... 314 ADJUSTMENT...................................................................................................... 315 04– TRACK ........................................................................................................ 317 TRACKTYPEAPPLICATION....................................................................................... 317 GENERAL........................................................................................................... 317 INSPECTION........................................................................................................ 317 REMOVAL .......................................................................................................... 317 INSTALLATION..................................................................................................... 317 ADJUSTMENT...................................................................................................... 317 09 STEERING/FRONT SUSPENSION 01– STEERINGSYSTEM........................................................................................ 321 DISASSEMBLYANDASSEMBLY................................................................................. 323 INSPECTION........................................................................................................ 326 ADJUSTMENT...................................................................................................... 326 STEERINGADJUSTMENT(SKIS)................................................................................. 330 LUBRICATION...................................................................................................... 332 02– FRONTSUSPENSION...................................................................................... 333 GENERALINSPECTION........................................................................................... 334 DISASSEMBLY..................................................................................................... 334 INSPECTION........................................................................................................ 338 INSTALLATION..................................................................................................... 338 VII

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Mmr-2004 REV ang.FH8 Thu Dec 04 15:16:23 2003 Page 1 C M Y CM MY CY CMY K 2004 Shop Manual REV SERIES Legal deposit: National Libraryof Quebec National Library of Canada 2003 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. ©Bombardier Inc. 2003 TechnicalPublications Bombardier Inc. Valcourt (Quebec) Canada Printed in Canada ®*Registered trademarks of Bombardier Inc. This document contains the trademarks of the following companies: Crest© is a trademark of Crest Industries Inc. 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 GeneralElectric Company Supertanium© is a trademark of Premier IndustrialCorporation AMP© is a trademark of Tyco Electronics Corporation TABLE OF CONTENTS SAFETY NOTICE................................................................................... IX INTRODUCTION .................................................................................... X VEHICLEIDENTIFICATIONNUMBER........................................................................... XV ENGINESERIALNUMBER....................................................................................... XV LISTOFABBREVIATIONSUSEDINTHIS MANUAL......................................................... XV ARRANGEMENTOFTHIS MANUAL.......................................................................... XVII GENERALINFORMATION........................................................................................ XIX ILLUSTRATIONS ANDPROCEDURES ......................................................................... XIX SELF-LOCKINGFASTENERS PROCEDURE ................................................................... XIX LOCTITEAPPLICATIONPROCEDURE.......................................................................... XIX THREADLOCKER .................................................................................................. XX STRIPPEDTHREADREPAIR ..................................................................................... XXI GASKETCOMPOUND........................................................................................... XXII MOUNTINGONSHAFT......................................................................................... XXII CASE-INCOMPONENTS....................................................................................... XXIII TIGHTENINGTORQUES ....................................................................................... XXIII 01 TOOLS AND SERVICE PRODUCTS 01– SERVICETOOLS ............................................................................................... 1 ENGINE—MANDATORYTOOLS................................................................................... 2 ENGINE—RECOMMENDEDTOOLS............................................................................... 4 TRANSMISSION—MANDATORYTOOLS........................................................................ 10 TRANSMISSION—RECOMMENDEDTOOLS.................................................................... 11 SUSPENSION—MANDATORYTOOLS........................................................................... 15 SUSPENSION—RECOMMENDEDTOOLS....................................................................... 16 VEHICLE—RECOMMENDEDTOOLS............................................................................. 19 02– SERVICEPRODUCTS........................................................................................ 21 02 MAINTENANCE 01– MAINTENANCECHART..................................................................................... 29 02– STORAGE ..................................................................................................... 33 GENERAL............................................................................................................. 33 FUELSTABILIZER.................................................................................................... 33 ENGINELUBRICATION.............................................................................................. 33 ENGINECOMPARTMENT........................................................................................... 34 PULLEYPROTECTION............................................................................................... 34 COUNTERSHAFTLUBRICATION................................................................................... 34 BATTERY.............................................................................................................. 34 VEHICLECLEANING................................................................................................. 34 RAGSINAIRINTAKEANDEXHAUSTSYSTEM................................................................... 34 VEHICLEPROTECTION.............................................................................................. 34 03– PRESEASONPREPARATION............................................................................... 35 FUELFILTERREPLACEMENT...................................................................................... 35 THROTTLEBODYCLEANING(ONSOEQUIPPEDMODELS).................................................... 36 CARBURETORCLEANING(ONSOEQUIPPEDMODELS)........................................................ 36 AIRFILTERCLEANING.............................................................................................. 36 RAGSINAIRINTAKEANDEXHAUSTSYSTEM................................................................... 36 CLEANINGOFDRIVEANDDRIVENPULLEYS.................................................................... 36 CLEANINGOFBRAKEDISK ........................................................................................ 36 DRIVEBELTCONDITION............................................................................................ 36 SPARKPLUGS........................................................................................................ 36 I TABLE OF CONTENTS 03 TROUBLESHOOTING 01– ENGINE........................................................................................................ 37 ENGINELEAKVERIFICATIONFLOWCHART..................................................................... 48 02– FUELANDOILSYSTEMS .................................................................................. 49 03– TRANSMISSIONANDBRAKESYSTEM.................................................................. 53 TRANSMISSION ............................................................................................. 53 BRAKESYSTEM.............................................................................................. 60 HYDRAULICBRAKE................................................................................................. 60 04– ELECTRICALSYSTEM....................................................................................... 61 05– SUSPENSIONANDTRACK................................................................................. 73 04 ENGINE 01– 593, 593HO,593HOSDIAND793HOENGINETYPES............................................... 77 EXHAUSTSYSTEM.......................................................................................... 77 TUNEDPIPE.......................................................................................................... 78 MANIFOLD........................................................................................................... 78 MUFFLER............................................................................................................. 78 ENGINESYSTEM ............................................................................................ 80 REMOVALFROMVEHICLE......................................................................................... 81 INSPECTION.......................................................................................................... 84 INSTALLATION....................................................................................................... 84 TOPEND....................................................................................................... 85 TROUBLESHOOTING................................................................................................ 89 COMPONENTREMOVALWITHTHEENGINEINSTALLED...................................................... 89 CLEANING............................................................................................................ 89 RAVEVALVEBASICOPERATION................................................................................... 89 DISASSEMBLY....................................................................................................... 90 INSPECTION.......................................................................................................... 94 ASSEMBLY........................................................................................................... 95 BOTTOMEND ............................................................................................... 100 CLEANING.......................................................................................................... 103 DISASSEMBLY..................................................................................................... 103 INSPECTION........................................................................................................ 104 ASSEMBLY......................................................................................................... 104 BREAK-IN........................................................................................................... 109 02– ENGINELEAKTESTANDDIMENSIONMEASUREMENT............................................ 111 LEAKTEST.......................................................................................................... 111 PREPARATION ..................................................................................................... 111 PROCEDURE....................................................................................................... 111 FINALIZINGREASSEMBLY........................................................................................ 113 ENGINELEAKVERIFICATIONFLOWCHART................................................................... 114 ENGINEDIMENSIONMEASUREMENT.......................................................................... 115 CYLINDERHEADWARPAGE ..................................................................................... 115 CYLINDERTAPER.................................................................................................. 115 CYLINDEROUTOFROUND...................................................................................... 115 COMBUSTIONCHAMBERVOLUMEMEASUREMENT........................................................ 115 USEDPISTONMEASUREMENT.................................................................................. 117 CYLINDER/PISTONCLEARANCE................................................................................. 117 RING/PISTONGROOVECLEARANCE............................................................................ 119 RINGENDGAP..................................................................................................... 119 CRANKSHAFTDEFLECTION...................................................................................... 119 CONNECTINGRODBIGENDAXIALPLAY...................................................................... 120 II TABLE OF CONTENTS CRANKSHAFTEND-PLAY......................................................................................... 120 CHECKINGCRANKSHAFTALIGNMENT......................................................................... 120 03– MAGNETOSYSTEM........................................................................................ 121 GENERAL........................................................................................................... 123 CLEANING.......................................................................................................... 123 DISASSEMBLY..................................................................................................... 123 ASSEMBLY......................................................................................................... 124 04– OILINJECTIONSYSTEM .................................................................................. 127 GENERAL........................................................................................................... 128 OILTYPE............................................................................................................ 128 OILSYSTEMLEAKTEST.......................................................................................... 128 OILPUMPIDENTIFICATION...................................................................................... 129 CLEANING.......................................................................................................... 129 DISASSEMBLY..................................................................................................... 129 ASSEMBLY......................................................................................................... 130 ADJUSTMENT...................................................................................................... 131 CHECKINGOPERATION........................................................................................... 132 05– LIQUIDCOOLINGSYSTEM................................................................................ 133 COOLINGSYSTEMLEAKTEST................................................................................... 135 INSPECTION........................................................................................................ 135 DRAININGTHESYSTEM.......................................................................................... 135 DISASSEMBLYANDASSEMBLY................................................................................. 135 COOLINGSYSTEMREFILLINGPROCEDURE................................................................... 137 06– REWINDSTARTER.......................................................................................... 139 INSPECTION........................................................................................................ 140 REMOVAL .......................................................................................................... 140 ROPEREPLACEMENT............................................................................................. 140 DISASSEMBLY..................................................................................................... 140 ASSEMBLY......................................................................................................... 141 INSTALLATION..................................................................................................... 143 07– CARBURETORANDTHROTTLECABLE................................................................. 145 CARBURETORTMTYPE................................................................................... 145 IDENTIFICATION................................................................................................... 146 REMOVAL .......................................................................................................... 146 CLEANINGANDINSPECTION.................................................................................... 147 DISASSEMBLYANDASSEMBLY................................................................................. 148 CARBURETORADJUSTMENTS.................................................................................. 149 INSTALLATION..................................................................................................... 151 DPM........................................................................................................... 152 TESTING............................................................................................................ 152 PARTSREMOVALANDINSTALLATION.......................................................................... 152 DPMMANIFOLDTESTING........................................................................................ 153 THROTTLECABLE.......................................................................................... 155 THROTTLE/OILPUMPCABLEREMOVAL....................................................................... 155 THROTTLE/OILPUMPCABLEINSTALLATION.................................................................. 155 THROTTLECABLEADJUSTMENT............................................................................... 155 08– FUELTANK ANDFUELPUMP............................................................................ 157 FUELFILTER........................................................................................................ 159 FUELTANK......................................................................................................... 159 IMPULSE/FUELLINESSPRINGCLIPS(ALLMODELS)......................................................... 160 FLOAT-TYPEFUELLEVELGAUGE............................................................................... 161 ELECTRICFUELLEVELSENSOR................................................................................. 161 III TABLE OF CONTENTS FUELLEVELSENSORSCREWS.................................................................................. 161 FUELSYSTEMPRESSURIZATION................................................................................ 161 FUELPUMP.................................................................................................. 162 REMOVAL .......................................................................................................... 163 PUMPVERIFICATION.............................................................................................. 163 CLEANINGANDINSPECTION.................................................................................... 163 INSTALLATION..................................................................................................... 163 05 2–TEC ENGINE MANAGEMENT 01– OVERVIEW................................................................................................... 165 OPERATINGPRINCIPLE.................................................................................... 166 AIRINDUCTION.................................................................................................... 166 FUELDELIVERY SYSTEM.................................................................................. 166 GENERAL........................................................................................................... 166 COMPONENTDESCRIPTION..................................................................................... 166 ENGINEMANAGEMENTSYSTEM(EMS) .............................................................. 167 EMS—GENERALFUNCTIONS.................................................................................. 168 ECU—ENGINEMANAGEMENTFUNCTIONS.................................................................. 169 ELECTRONICFUELINJECTION.................................................................................. 170 IGNITIONTIMING.................................................................................................. 170 ELECTRONICALLYCONTROLLEDRAVE........................................................................ 170 KNOCKSENSOR................................................................................................... 170 ENGINEMODESOFOPERATION................................................................................ 170 FLOODEDENGINE(DROWNEDMODE)........................................................................ 170 MONITORINGSYSTEM........................................................................................... 170 LIMPHOMEMODES.............................................................................................. 171 DIAGNOSTICMODE............................................................................................... 171 CHARGINGSYSTEM....................................................................................... 171 MAGNETOSYSTEM............................................................................................... 171 DOUBLEIGNITIONCOIL.......................................................................................... 171 TRIGGERCOIL..................................................................................................... 172 02– COMPONENTINSPECTIONANDADJUSTMENT..................................................... 173 GENERAL..................................................................................................... 173 FUELSYSTEM............................................................................................... 173 ELECTRICALSYSTEM...................................................................................... 174 RESISTANCEMEASUREMENT................................................................................... 175 ENGINECONNECTORPIN-OUTS................................................................................ 176 AIRINDUCTIONSYSTEM ................................................................................. 177 THROTTLEBODY.................................................................................................. 177 FUELDELIVERY ............................................................................................. 180 FUELPUMP........................................................................................................ 181 FUELRAIL.......................................................................................................... 185 FUELINJECTORS.................................................................................................. 186 ELECTRONIC MANAGEMENT............................................................................ 188 ECMREPLACEMENT.............................................................................................. 188 ENGINEWIRINGHARNESS....................................................................................... 189 THROTTLEPOSITIONSENSOR(TPS)............................................................................ 189 CRANKSHAFTPOSITIONSENSOR(CPS)........................................................................ 192 AIRTEMPERATURESENSOR(ATS).............................................................................. 193 COOLANTTEMPERATURESENSOR(CTS)...................................................................... 193 AIRPRESSURESENSOR(APS)................................................................................... 194 EXHAUSTGASTEMPERATURESENSOR(EGTS)............................................................... 195 IV TABLE OF CONTENTS KNOCKSENSOR(KS).............................................................................................. 196 E-RAVESOLENOID................................................................................................ 197 DOUBLEIGNITIONCOIL.......................................................................................... 197 TDCSETTING(TOPDEADCENTER)............................................................................. 199 CAPACITOR......................................................................................................... 199 ENGINESTART/RERBUTTONVERIFICATION .................................................................. 200 DESSSWITCHVERIFICATION.................................................................................... 200 SPARKPLUGS...................................................................................................... 200 CRANKINGSYSTEM............................................................................................... 201 03– DIAGNOSTICPROCEDURES.............................................................................. 203 GENERAL........................................................................................................... 203 TROUBLESHOOTING ............................................................................................. 203 VCK(VEHICLECOMMUNICATIONKIT)........................................................................... 206 2-TECSYSTEMFAULTCODES................................................................................... 207 06 TRANSMISSION 01– DRIVEBELT .................................................................................................. 209 APPLICATIONCHART............................................................................................. 209 INSPECTION........................................................................................................ 209 CHECKINGNEUTRALFUNCTION................................................................................ 209 ROTATIONDIRECTION............................................................................................ 209 DRIVEBELTHEIGHTMEASUREMENTANDADJUSTMENT.................................................. 210 DRIVEBELTDEFLECTIONMEASUREMENT(REFERENCEONLY)............................................ 212 02– DRIVEPULLEY............................................................................................... 215 TRAIII............................................................................................................... 215 GENERAL........................................................................................................... 216 REMOVAL .......................................................................................................... 216 DISASSEMBLY..................................................................................................... 216 CLEANING.......................................................................................................... 218 INSPECTION........................................................................................................ 218 ASSEMBLY......................................................................................................... 220 INSTALLATION..................................................................................................... 223 DRIVEPULLEYADJUSTMENT................................................................................... 224 03– DRIVENPULLEY ............................................................................................ 227 FORMULARER.................................................................................................... 227 REMOVAL .......................................................................................................... 228 DISASSEMBLY..................................................................................................... 228 CLEANING.......................................................................................................... 228 INSPECTION........................................................................................................ 228 BUSHINGREPLACEMENT........................................................................................ 229 ASSEMBLY......................................................................................................... 229 INSTALLATION..................................................................................................... 230 ADJUSTMENT...................................................................................................... 231 HPVVSA............................................................................................................ 232 REMOVAL .......................................................................................................... 233 DISASSEMBLY..................................................................................................... 233 CLEANING.......................................................................................................... 233 INSPECTION........................................................................................................ 233 ASSEMBLY......................................................................................................... 233 INSTALLATION..................................................................................................... 234 ADJUSTMENT...................................................................................................... 234 V TABLE OF CONTENTS 04– PULLEYDISTANCEANDALIGNMENT.................................................................. 235 GENERAL........................................................................................................... 235 GENERALPROCEDURE........................................................................................... 235 PULLEYALIGNMENTANDDISTANCESPECIFICATIONSCHART............................................. 236 05– BRAKE ........................................................................................................ 239 HYDRAULICBRAKE ........................................................................................ 239 BRAKEFLUID ...................................................................................................... 240 MASTERCYLINDER............................................................................................... 240 CALIPER............................................................................................................ 240 BRAKEPADS....................................................................................................... 241 BRAKEDISC........................................................................................................ 242 COUNTERSHAFTBEARING....................................................................................... 242 COUNTERSHAFT................................................................................................... 243 BRAKELIGHTSWITCH............................................................................................ 243 BLEEDING.......................................................................................................... 244 06– CHAINCASE.................................................................................................. 245 REMOVALANDDISASSEMBLY.................................................................................. 246 INSPECTION........................................................................................................ 246 GEARRATIOMODIFICATION..................................................................................... 246 INSTALLATIONANDASSEMBLY................................................................................. 247 DRIVECHAINADJUSTMENT..................................................................................... 247 ADJUSTMENT...................................................................................................... 248 07– DRIVECHAIN................................................................................................ 249 SILENTCHAIN...................................................................................................... 249 07 ELECTRICAL SYSTEM 01– IGNITIONTIMING........................................................................................... 251 SCRIBINGATIMINGMARK....................................................................................... 251 CHECKINGIGNITIONTIMING.................................................................................... 252 CHANGINGTIMING................................................................................................ 253 02– SPARKPLUGS............................................................................................... 257 DISASSEMBLY..................................................................................................... 257 SPARKPLUGINSTALLATION..................................................................................... 257 SPARKPLUGTIGHTENINGTORQUE............................................................................ 257 03– BATTERY ..................................................................................................... 259 GENERAL........................................................................................................... 259 REMOVAL .......................................................................................................... 259 CLEANING.......................................................................................................... 259 INSPECTION........................................................................................................ 259 BATTERYCHARGETESTING ..................................................................................... 260 BATTERYSTORAGE............................................................................................... 260 ACTIVATIONOFNEWBATTERY.................................................................................. 260 BATTERYCHARGING.............................................................................................. 260 INSTALLATIONOFBATTERY ..................................................................................... 260 CABLETERMINALINSTALLATION............................................................................... 261 04– ELECTRICSTARTER ........................................................................................ 263 REMOVAL .......................................................................................................... 264 DISASSEMBLY..................................................................................................... 264 CLEANING.......................................................................................................... 265 INSPECTION........................................................................................................ 265 ASSEMBLY......................................................................................................... 267 INSTALLATION..................................................................................................... 268 VI TABLE OF CONTENTS 05– TESTINGPROCEDURE..................................................................................... 269 GENERAL........................................................................................................... 269 CHECKINGCALIBRATIONPROGRAM........................................................................... 272 CHANGINGMPEMCALIBRATIONPROGRAM.................................................................. 275 SYSTEMTESTING ................................................................................................. 276 INSPECTIONOFHEATINGELEMENTS.......................................................................... 283 HEADLIGHTANDACCESSORIESSYSTEMTESTING.......................................................... 284 08 REAR SUSPENSION 01– SC-10SUSPENSION........................................................................................ 285 COMPONENTREMOVALANDINSTALLATION................................................................. 288 SUSPENSIONASSEMBLYREMOVAL............................................................................ 289 DISASSEMBLYANDASSEMBLY................................................................................. 289 SHOCKABSORBERINSPECTION................................................................................ 291 INSTALLATION..................................................................................................... 292 RIDEADJUSTMENT............................................................................................... 292 LUBRICATION...................................................................................................... 292 02– SC-10III SUSPENSION..................................................................................... 293 COMPONENTREMOVALANDINSTALLATION................................................................. 296 SUSPENSIONASSEMBLYREMOVAL............................................................................ 297 DISASSEMBLYANDASSEMBLY................................................................................. 298 SHOCKABSORBERINSPECTION................................................................................ 300 HPGT/ASHOCKSERVICING ..................................................................................... 301 INSTALLATION..................................................................................................... 309 RIDEADJUSTMENT............................................................................................... 309 LUBRICATION...................................................................................................... 309 03– DRIVEAXLE.................................................................................................. 311 REMOVAL .......................................................................................................... 312 ASSEMBLY......................................................................................................... 313 LUBRICATION...................................................................................................... 314 ADJUSTMENT...................................................................................................... 315 04– TRACK ........................................................................................................ 317 TRACKTYPEAPPLICATION....................................................................................... 317 GENERAL........................................................................................................... 317 INSPECTION........................................................................................................ 317 REMOVAL .......................................................................................................... 317 INSTALLATION..................................................................................................... 317 ADJUSTMENT...................................................................................................... 317 09 STEERING/FRONT SUSPENSION 01– STEERINGSYSTEM........................................................................................ 321 DISASSEMBLYANDASSEMBLY................................................................................. 323 INSPECTION........................................................................................................ 326 ADJUSTMENT...................................................................................................... 326 STEERINGADJUSTMENT(SKIS)................................................................................. 330 LUBRICATION...................................................................................................... 332 02– FRONTSUSPENSION...................................................................................... 333 GENERALINSPECTION........................................................................................... 334 DISASSEMBLY..................................................................................................... 334 INSPECTION........................................................................................................ 338 INSTALLATION..................................................................................................... 338 VII

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