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SNOW-HAWK
800 HO
2007
MANUEL DE RÉPARATION
Incluant :
- Conseils de sécurité
- Fonctionnement du véhicule
- Entretien du véhicule
- Manuel de pièces
SHOP MANUAL
Include:
- Safety
- Vehicle information
- Maintenance information
- Parts catalog
PART #: SH-MAN-2007
AD Boivin Design
700 Jean-Marchand Street
Lévis (Québec)
G6V 9G6
Tel : (418) 838-3783
Fax : (418) 838-3957 www.adboivin.com
Warranty Policies
SNOW HAWK 800HO MY2007
June 6, 2007
AD BOIVIN WARRANTY POLICIES
__________________________________________________________
TABLE OF CONTENTS
1.
AD BOIVIN LIMITED WARRANTY .................................................................................................. 3
2.
SNOW HAWK 2007................................................................................................................................ 3
2.1.
SCOPE OF THE LIMITED WARRANTY ....................................................................................... 3
2.2.
WARRANTY COVERAGE PERIOD .............................................................................................. 3
2.3.
CONDITIONS TO HAVE WARRANTY COVERAGE................................................................... 4
2.4.
WHAT TO DO TO OBTAIN WARRANTY COVERAGE .............................................................. 4
2.5.
WHAT AD BOIVIN WILL DO......................................................................................................... 4
2.6.
EXCLUSIONS .................................................................................................................................. 5
2.7.
LIMITATIONS OF LIABILITY ....................................................................................................... 5
2.8.
TRANSFER....................................................................................................................................... 6
2.9.
CONSUMER ASSISTANCE ............................................................................................................ 6
3.
WARRANTY INFORMATION ............................................................................................................ 7
3.1.
WEAR ITEMS .................................................................................................................................. 7
3.2.
LABOUR TIME ................................................................................................................................ 7
3.3.
VEHICLE TESTING AFTER REPAIR ............................................................................................ 7
3.4.
STUDDED TRACK .......................................................................................................................... 7
3.5.
DAMAGE IN TRANSIT................................................................................................................... 8
3.5.1.
Visible crate damage ................................................................................................................. 8
3.5.2.
Concealed crate damage ........................................................................................................... 8
4.
WARRANTY PARTS MANAGEMENT .............................................................................................. 9
4.1.
PARTS IDENTIFICATION .............................................................................................................. 9
4.2.
PARTS KEPT AT THE DEALER’S FACILITY .............................................................................. 9
4.3.
DEFECTIVE PARTS TO BE RETURNED ...................................................................................... 9
4.4.
ADDRESS FOR WARRANTY PARTS RETURN......................................................................... 10
APPENDIX 1 ................................................................................................................................................. 11
June 2007 AD Boivin Design Inc.
Page 2 of 12
AD BOIVIN WARRANTY POLICIES
__________________________________________________________
1.
AD BOIVIN LIMITED WARRANTY
• Warranty coverage only becomes available upon proper registration of the product by an authorized Snow Hawk dealer. Moreover, this warranty coverage is only available if the vehicle is purchased in the country in which the purchaser resides .
For Cross Border procedure please call AD Boivin.
• All genuine AD Boivin parts and accessories , installed by an authorized Snow
Hawk dealer at the time of delivery of the vehicle, carry the same warranty as that of the vehicle.
• Please note that parts that are changed under the limited warranty by the manufacturer do not extend the limited warranty over the original coverage.
• Use of the product for racing or any other competitive activity, at any point, even by a previous owner, will render this warranty null and void.
• Routine maintenance outlined in the Snow Hawk Manual’s must be timely performed in order to maintain warranty coverage. AD Boivin reserves the right to make warranty coverage contingent upon proof of proper maintenance.
• AD Boivin reserves the right to improve or modify products from time to time without assuming any obligation to modify products previously manufactured.
2.
SNOW HAWK 2007
2.1.
SCOPE OF THE LIMITED WARRANTY
AD Boivin Inc. warrants its 2007 Snow Hawk from defects in material or workmanship for the period and under the conditions below.
2.2.
WARRANTY COVERAGE PERIOD
This warranty will be in effect from the date of delivery to the first retail consumer or the date the product is first put into use, whichever occurs first and for a period of:
TWELVE (12) CONSECUTIVE MONTHS, for private or commercial use owners. However, the warranty coverage period on a Snow Hawk delivered between
June 1 st and December 1 st of a given year will expire December 1 st of the following year.
The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration dates.
June 2007 AD Boivin Design Inc.
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AD BOIVIN WARRANTY POLICIES
__________________________________________________________
2.3.
CONDITIONS TO HAVE WARRANTY COVERAGE
This warranty coverage is available only on 2007 Snow Hawk purchased as new and unused by its first owner from Snow Hawk dealer authorized to distribute
Snow Hawk products in the country in which the sale occurred and then only after the AD Boivin pre-delivery inspection process is completed and documented.
Warranty coverage only becomes available upon proper registration of the product by an autorized Snow Hawk dealer. Moreover, this warranty coverage is only available if the Snow Hawk snowbike is purchased in the country in which the purchaser resides.
AD Boivin will not honor this limited warranty to any private use owner or commercial use owner if the preceding conditions have not been met. Such limitations are necessary in order to allow AD Boivin to preserve both the safety of its products, and also that of its consumers and the general public.
Routine maintenance outlined in the Snow Hawk Manual must be timely performed in order to maintain the warranty coverage. AD Boivin reserves the right to make warranty coverage contingent upon proof of proper maintenance.
2.4.
WHAT TO DO TO OBTAIN WARRANTY COVERAGE
The customer must notify a servicing Snow Hawk dealer within two (2) days of the appearance of a defect, and provide it with reasonable access to the product and reasonable opportunity to repair it. The customer must also present to the authorized Snow Hawk dealer, proof of purchase of the product and must sign the repair/work order prior to starting the repair in order to validate the warranty repair.
All parts replaced under this limited warranty become the property of AD Boivin.
2.5.
WHAT AD BOIVIN WILL DO
AD Boivin’s obligations under this warranty are limited to, at its sole discretion, repairing parts found defective under normal use, maintenance and service, or replacing such parts with new genuine Snow Hawk parts without charge for parts and labor, at any authorized Snow Hawk dealer during the warranty coverage period.
June 2007 AD Boivin Design Inc.
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AD BOIVIN WARRANTY POLICIES
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2.6.
EXCLUSIONS
The following are not warranted under any circumstances:
• Normal wear and tear;
• Routine maintenance items, tune ups, adjustments;
• Damage caused by failure to provide proper maintenance and/or storage, as described in the Snow Hawk Manual;
• Damage resulting from removal of parts, improper repairs, service, maintenance, modifications or use of parts not manufactured or approved by
AD Boivin or resulting from repairs done by a person that is not an authorized servicing dealer;
• Damage caused by abuse, abnormal use, neglect, use of the product on surfaces other than snow, or operation described in the Snow Hawk Manual;
• Damage resulting from accident, submersion, fire, theft, vandalism or any act of god;
• Operation with fuel, oils or lubricants which are not suitable for use with the product (see Snow Hawk Manual);
• Snow or water ingestion;
• Incidental or consequential damages, or damages of any kind including without limitation towing, storage, telephone, rental, taxi, inconvenience, insurance coverage, loan payments, loss time, loss income; and
• Damage resulting from studs installed on tracks.
2.7.
LIMITATIONS OF LIABILITY
THIS WARRANTY IS EXPRESSELY GIVEN AND ACCEPTED IN LIEU
OF ANY AND ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED,
INCLUDING WITHOUT LIMITATION ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. TO THE
EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED
WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS
WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE
EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES /
PROVINCES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITAIONS AND
EXCLUSIONS IDENTIFIED ABOVE, AS A RESULT, THEY MAY NOT APPLY
TO YOU. THIS WARRANTY GIVES YOU SPECIFIC RIGHTS, AND YOU MAY
ALSO HAVE LEGAL RIGHTS WHICH MAY VARY FROM STATE TO STATE,
OR PROVINCE TO PROVINCE.
Neither the distributor, any Snow Hawk dealer nor any other person has been authorized to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against AD Boivin.
June 2007 AD Boivin Design Inc.
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AD BOIVIN WARRANTY POLICIES
__________________________________________________________
AD Boivin reserves the right to modify this warranty at any time, being understood that such modification will not alter the warranty conditions applicable to the products sold while this warranty is in effect.
2.8.
TRANSFER
If the ownership of a product is transferred during the warranty coverage period, this warranty shall also be transferred and be valid for the remaining coverage period provided that AD Boivin is notified of such transfer of ownership in the following way: a) The former owner contacts AD Boivin (at the phone number below) or an authorized Snow Hawk dealer gives the coordinates of the new owner; or b) AD Boivin or an authorized Snow Hawk dealer receives a proof that the former owner agreed to the transfer of ownership, in addition to the coordinates of the new owner.
2.9.
CONSUMER ASSISTANCE
In the event of a controversy or a dispute in connection with this limited warranty, AD Boivin suggests that you try to resolve the issue at the dealership level.
We recommend discussing issue with the authorized dealer’s service manager or owner.
If the issue has not yet been solved, please submit your complaint in writing or call at the following number:
AD Boivin
Customer service
700 Jean-Marchand Street
Lévis, Qc (G6V 9G6)
Tel : (418) 838-3783 ext 245
June 2007 AD Boivin Design Inc.
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AD BOIVIN WARRANTY POLICIES
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3.
WARRANTY INFORMATION
3.1.
WEAR ITEMS
The following items are what we consider Wear items and they are not covered under the warranty unless failure is a direct result of a defect in material or workmanship.
Brake components
Carburetor components
Clutches
Hydraulic components
Light bulbs / Sealed
Beam lamps
Slide rails
Snow-Tracker wear
Spark plugs
Drive belts Lubricants Steering components
Filters Sealants
Finished and unfinished surfaces Seat components Track
Fuses Ski wear rods
Hoses Skis
3.2.
LABOUR TIME
The time taken to complete the repair and the hourly rate must be submitted to
AD Boivin via form AD-CLAIM available in appendix 1. You can also request an electronic copy ( [email protected]
) and return it to us by email or fax. While reviewing your claim, AD Boivin reserves the right to adjust hours claimed according to the usual time needed to complete the repair.
3.3.
VEHICLE TESTING AFTER REPAIR
AD Boivin recognizes the importance of verifying certain repairs by testing the products in real conditions. Because each authorized dealership has differences in local conditions, AD Boivin will allow you to claim up to 0.5 hour of extra labor for vehicle testing, if the situation should warrant it. Any request for vehicle testing must be appropriate and explained in detail. If certain conditions exist which require additional testing time, prior authorization from AD Boivin must be acquired.
3.4.
STUDDED TRACK track.
Install studs on a Snow Hawk track automatically void the warranty on the
June 2007 AD Boivin Design Inc.
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AD BOIVIN WARRANTY POLICIES
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3.5.
DAMAGE IN TRANSIT
3.5.1.
Visible crate damage
Every precaution is taken to ensure that new products leave the factory in proper condition. However, a product may be received with damages incurred during transit. The carrier is insured and is responsible for the products during the transportation from the factory to its destination.
Dealer must make all claims for shortage and/or damaged products time of delivery and to notify AD Boivin by describing the shortages and/or damages on the Bill of Lading or delivery receipt and agrees to forward this notification to AD Boivin within 7 days after receipt of shipment. AD Boivin will not cover these claims under warranty but will make sure your request is properly processed by the carrier.
Please call AD Boivin (Ask for vehicle shipping)
.1-418-838-3783
*** TAKE THE TIME TO
INSPECT
THE COMPLETE
LOAD AND SIGN THE BILL OF LADING ***
9 Load must be inspected in the presence of the carrier (crate damages number of vehicle included in the load, etc.);
9 When damages to a crate is noticed, the carrier’s bill of lading must be marked ‘ ’temporarily accepted, subject to a further inspection ’’ and signed by you and the carrier !
3.5.2.
Concealed crate damage
In case of concealed damage discovery at the time of unpacking, call the warranty department. Please note that pictures may be required:
• Picture of the crate;
• Picture of vehicle damage while in the crate;
• Picture of vehicle damaged area (we should be able to clearly identify it)
June 2007 AD Boivin Design Inc.
Page 8 of 12
AD BOIVIN WARRANTY POLICIES
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4.
WARRANTY PARTS MANAGEMENT
As we find ways to ensure continued improvement in product quality, durability and reliability, we need as much evidence as possible to correctly identify, diagnose and find solutions to actual, ‘’in-field’’ defects or failures. As a vital link between the customer and our Quality Assurance department, dealer co-operation in parts handling procedures is valuable for everyone involved.
4.1.
PARTS IDENTIFICATION
Each part returned to AD Boivin / Warranty Department or kept at your dealership must be identified with a tag containing your dealer name and claim number.
4.2.
PARTS KEPT AT THE DEALER’S FACILITY
Under AD Boivin policies, you are required to keep at your place of business all parts for a minimum of
90 days
from the claim credit date. Any / or all parts can be requested for further analysis by the manufacturer within this period. Failure to provide these parts upon request will automatically result in a debit of the complete claim.
4.3.
DEFECTIVE PARTS TO BE RETURNED
When we request that defective parts be returned to AD Boivin they must be received with a copy of the AD Boivin claim within
21 days
from the claim credit date. If they are not returned, we will debit the repairs automatically from the dealer’s parts account.
If you are required, or requested to return certain parts with your warranty claim, it is imperative to package the parts appropriately . Improperly packaged and subsequently damaged parts may result in a rejection of the claim, should the damage render the component useless or impossible to diagnose. Since rejected warranty parts could be returned to you, per your request , you want to be sure they arrive in good condition. Our warranty parts inspection staff always makes sure to package parts appropriately.
June 2007 AD Boivin Design Inc.
Page 9 of 12
AD BOIVIN WARRANTY POLICIES
__________________________________________________________
Identified parts will be returned at the expense of AD Boivin after an authorization.
Here is a partial list of parts to be returned:
1.
Short Block
2.
Engine assembly
3.
Piston
4.
Crankshaft (new or rebuilt)
5.
Cylinder (new or rebuilt)
6.
Crankcase
7.
Track: i.
A minimum of 24 inch portion (at least 12 rods) showing both serial number as well as the defect. In this case, you should keep the rest of the track properly tagged for 90 days since we might need to examine it. ii.
If the track is replaced for shrinkage, stretching and/or excessive vibration the complete track assembly must be returned with a copy of the warranty claim.
8.
Electronic Module (MPEM)
9.
Hoods ( A minimum of one square foot (12’’ x 12’’) of the damaged portion.
10.
Or and any other part that is identified for return or requested by AD
Boivin departments.
4.4.
ADDRESS FOR WARRANTY PARTS RETURN
Send the parts at the following address:
Ad Boivin Design
(Warranty Department)
700 Jean-Marchand Street
Lévis (Québec), G6V 9G6
Tel : (418) 838-3783
Fax : (418) 838-3957
June 2007 AD Boivin Design Inc.
Page 10 of 12
AD BOIVIN WARRANTY POLICIES
__________________________________________________________
APPENDIX 1
Warranty Claim Sheet
June 2007 AD Boivin Design Inc.
Page 11 of 12
P/N
Snow Hawk Warranty Claim Sheet
General Information
Dealer Name: Client Name:
Contact Person: Client Signature:
VIN:
Engine No.:
Date Damaged:
Description
Year:
Model:
Qty Dealer Unit Cost Total
Time
Notes:
LABOUR
Description
Parts Subtotal:
Flat rate Total
Total Claim Cost
Labour Subtotal:
US or CAN
A
VERTISSEMENT /
A
VIS LÉGAL
AD Boivin Design Inc. ne sera tenu responsable d’aucune blessure – ou décès – pouvant survenir lors de l’utilisation du Snow Hawk. Comme tout autre véhicule récréatif, le
Snow Hawk peut potentiellement être dangereux si les précautions suivantes ne sont pas prises :
• Faire une lecture approfondie du guide d’utilisateur avant de conduire le véhicule;
• Apprendre comment manier adéquatement le véhicule de façon progressive avant d’en faire la conduite dans les sentiers publics;
• Conduire le véhicule en tenant compte de ses capacités personnelles et des conditions du terrain;
• Toujours porter un casque protecteur et tout autre équipement de protection adéquat;
• Ne jamais conduire en état d’ébriété ou suite à la consommation de drogues;
• Éviter toute manœuvre pouvant être dangereuse;
• Ne pas permettre l’utilisation du véhicule à un individu qui n’a pas préalablement pris connaissance des précautions à prendre;
• N’utiliser le véhicule que sur la neige (Ne pas utiliser le véhicule sur l’eau, la terre ou toute autre condition du terrain n’étant pas la neige);
• Le Snow Hawk est conçu pour un seul utilisateur et aucun passager n’est permis.
Afin d’assurer la validité de votre garantie, vous devez nous faire parvenir ce formulaire dûment signé ainsi que la carte de garantie complétée.
Veuillez s’il vous plaît nous faire parvenir ces deux documents (Avertissement/Avis légal et Carte de garantie) dans l’enveloppe pré-adressée ci-incluse.
Je reconnais avoir lu et bien compris le contenu de ce document.
_____________________________________
Nom du propriétaire du véhicule (imprimé)
______________________________________ _________________
Nom du propriétaire du véhicule (signature) Date
_________________________________________________________________
VIN
( An English copy is on the reverse )
W
ARNING /
L
EGAL
N
OTICE
AD Boivin Design Inc. will not be held responsible for any physical injury – or death – occurred while riding a Snow Hawk. Like any other recreational vehicle, the Snow
Hawk can be potentially dangerous if the following precautions are not taken:
• Read the owner’s manual carefully before operating the vehicle;
• Learn how to handle the vehicle progressively before riding on public trails;
• Drive according to your personal capabilities and terrain conditions;
• Always wear a helmet and other protective gear;
• Never drive under the influence of alcohol or any other drugs;
• Avoid any hazardous maneuvers;
• Do not let anyone else drive your vehicle unless they are aware of the precautions to take;
• Do not operate the vehicle on water, dirt or any other terrain conditions except snow;
• The Snow Hawk is designed for a single operator only, therefore no passengers are allowed;
In order to validate your warranty coverage, we must receive a signed copy of this form and the warranty card filled out. Please return both documents (Warning/Legal
Notice and Warranty Card) signed and completed in the enclosed self-addressed envelope.
I attest that I have read this form and understand it clearly.
______________________________
Vehicle Owner Name (printed)
______________________________
Vehicle Owner Name (signature)
_________________
Date
___________________________________________________________
VIN
( Une version en français se situe au verso )
o
F
SNOW HAWK 800HO 2007
High altitude adjustment recommendations
(For information only) o
C
Pilot
-22
-4
14
32
50
68
Main
-30
-20
-10
0
10
20 m
0
20
20
20
20
20
20
Ft
0
500
490
480
470
460
450
305
20
20
20
20
20
20
1000
500
490
480
470
460
450
610
20
20
20
17,5
17,5
17,5
2000
490
480
470
460
450
440
914
20
20
17,5
17,5
17,5
17,5
3000
480
470
460
450
440
430
1219
20
17,5
17,5
17,5
17,5
17,5
4000
470
460
450
440
430
420
1524
17,5
17,5
17,5
17,5
17,5
17,5
5000
460
450
440
430
420
410
1829
17,5
17,5
17,5
17,5
17,5
17,5
6000
450
440
430
420
410
400
2134
17,5
17,5
17,5
17,5
17,5
15
7000
440
430
420
410
400
390
2438
17,5
17,5
17,5
17,5
15
15
8000
430
420
410
400
390
380
2743
17,5
17,5
17,5
15
15
15
9000
420
410
400
390
380
370
3048
17,5
17,5
15
15
15
15
86
30
20
440
17,5
440
17,5
430
17,5
420
17,5
410
17,5
400
15
390
15
380
15
370
15
360
15
NOTICE :
1. In place of changing the pilot jet, the correction can be made through the airscrew adjustement.
2. Airscrew range of adjustement varies from 1 to 3 turns outwards. 1 to 2 turns outwards is optimal.
3. These jetting are only a suggested guide. Spark plug electrode color and piston wash are always your best reference.
4. In all cases, the needle clip must remain at position #3.
5. The stock airscrew setting with a 20 pilot jet is 1.6 turns out from full tight.
*** AD Boivin is not responsible for any damage after utilisation of this chart. Many facteurs can influence the calibration of a vehicle like atmospheric pressure and humidity.
10000
410
400
390
380
370
360
350
WIRE, CABLE AND HOSE ROUTING 16-1
CHAPTER 16
WIRE, CABLE AND HOSE ROUTING
WIRE, CABLE AND HOSE ROUTING 16-2
WIRE, CABLE AND HOSE ROUTING
◆ WARNING
Make sure that all the wires are well set in the terminals and that the connector holders are well installed. Keep the wires away from any rotating, moving, heating or vibrating part. If necessary, use good retaining devices.
When reassembling, it is important to always re-install the wires to the stock positions.
SPARK PLUG WIRES AND MPEM
When changing the ignition coil or either of the ignition wires, it is important that the wires are re-installed in exactly the same position. o The two ignition wires must be installed as shown at right. o The ignition coil power connector connects to the MPEM in the first 2-pin connector from the front of the vehicle as shown at right.
◆ WARNING
The MPEM has a built in key guide at each socket to ensure that the correct connectioins find their place. If there is difficulty to make a connection with one of the housings, check the wiring diagram to make sure the location is correct.
MPEM
1. 2-circuit housing (BL and WT/BL wires)
2. 6-circuit housing
3. 2-circuit housing (BK and WT/BL wires)
4. 12-circuit housing
MAIN CHASSIS GROUND CONNECTION
Raccourci vers Extranet.lnk
The main chassis ground of the entire electrical system is located on the MAG side chassis rail just above the ignition coil, as indicated at right.
◆ WARNING
It is of utmost importance that the bolt AND locknut securing the ground connection’s ring lug to the chassis is well tightened in in full contact with the chassis. A bad ground connection can cause other component failures.
The main wiring harness is divided into several segments immediately after the MPEM. The following three sections go vertically up the steering plate and towards the steering column.
Temperature Warning Light
1. Two 1-circuit connectors (BK and BK/WT wires)
Fuse
2. Fuse and fuse housing, installed with one rivet on the choke cable bracket.
Relay
3. Relay and connector, installed with one rivet on the vertical steering plate.
WIRE, CABLE AND HOSE ROUTING 16-3
2
3
3
1 2 3
Ground
1
1
2
4
WIRE, CABLE AND HOSE ROUTING 16-4
Near the base of the engine, close to the magneto, there are two cables. One is covered by a grey sheath and has a 2-circuit connector at its end (BL and WT/YL wires)
This is the wire from the Crankshaft Position Sensor (CPS),
The grey-sheathed wire then travels upward between the MAG side intake socket and the MAG side chassis as shown at right.
The 2-circuit housing from the CPS (BL and WT/YL wires) is connected to the main wiring harness as shown at right.
At the upper end of the cable, near where the ignition coil is mounted, a nylon tie-wrap is used to connect the CPS cable and the ignition coil wires together with the main wiring harness to avoid striking any moving parts when the vehicle is in operation, as shown at right.
Tie-wrap
Grey sheath
Ignition coil wire
CPS (grey wire
Temperature Sensors
There are two temperature sensors on the Snow Hawk 800HO.
The first temperature sensor is blue (Bosch), is located on the
MAG side of the head and uses a special 2-circuit connector
(GR and BK wires) it is shown as Sensor No. 1 at right.
Once the connector is connected to the main wiring harness, use a nylon tie-wrap to secure the sensor wire, the CPS wire and the main wiring harness to the rigid oil tube running from the small water-pump oil reservoir to the rear of the engine, as shown at right. This connection MUST NOT obstruct the flow of oil from the reservoir to the engine!
The second temperature sensor is black (Indebras), is located on the PTO side of the head and uses the two 1-circuit connectors (YL and BK/WT wires). This cable is routed under the MAG side intake socket, around the vertical coolant tube and then under the PTO side intake socket and then directly to the temperature sensor.
◆ WARNING
It is very important that all wires and cables be installed in exactly the same positions as from the factory. There are many moving parts in the compact engine bay of the
Snow Hawk 800HO and the wires must clear all of these.
Voltage Regulator
1. The voltage regulator uses a special female, grey 4circuit connector (YL, YL and YL wires) to directly connect to the magneto through a special male, grey 4circuit connector (YL, GR and YL)
2. The 2-circuit female connector from the voltage regulator (RD/BL and BK wires) connects to the 2circuit male connector (RD/BL and BK) on the main wiring harness.
3. The 2-circuit connector (GR and BK wires) from the magneto connects to the main wiring harness via the 2circuit connector (GR/WT and BK/RD wires).
WIRE, CABLE AND HOSE ROUTING 16-5
Sensor 2 Sensor 1
Tie-wrap
2
3
1
WIRE, CABLE AND HOSE ROUTING 16-6
Once the connectors are all well connected, group all of the cables from the voltage regulator, the magneto and parts of the main wiring harness and tie them together with one nylon tie wrap for compactness as shown at right.
From here, the tail lamp wire (WT, BK and RD wires) must pass under the engine impulse hose and along the MAG side chassis towards the rear as shown at right.
The end of the tail lamp wire should be secured with two tie wraps – one near the end of the heat exchangers where the cable must change direction, one at the very end of the tunnel cover using the two holes supplied - as shown at right.
Tie-wrap
Handlebar-Mounted Devices/Switchgears
The 2-circuit connector from the brake switch (YL and
YL/WT wires) connects to the 2-circuit connector on the main wiring harness (YL and WT wires).
WIRE, CABLE AND HOSE ROUTING 16-7
3 2 1
The 3-circuit connector from the dimmer switch (GY, RD/YL and GY/BK wires) connects to the 3-circuit connector on the main wiring harness (GY, YL and VI/WT).
The 2-circuit connector from the tether switch (BK and
BK/YL wires) connects to the 2-circuit connector on the main wiring harness (BK and BK/YL wires).
4. Emergency stop switch
The 2-circuit connector from the emergency stop switch (BK and BK/YL wires) connects to the 2-circuit connector on the main wiring harness (BK and BK/YL wires).
5. Headlamp Connector
Once all of the connectors are seated, group the handlebar accessory, headlamp and throttle cable together with a nylon tie wrap. MAKE SURE that this grouping does not affect the cycling of the throttle cable or the steering of the vehicle in any way.
Place the emergency stop switch, the dimmer switch and the brake switch wires underneath the crashpad as shown at right.
4
2
3
5
1
Tie-wrap
WIRE, CABLE AND HOSE ROUTING 16-8
RPM Output Signal and Accessory Connector
1. Single-circuit connector (YL wire) for accessories (i.e. handwarmers, visor outlet, etc.).
2. 2-circuit connector (GR/WT and BK/RD wires) for an optional tachometer.
Using a nylon tie-wrap, attach the two wires to the main wiring harness as shown at right.
Hood
The headlamp cable underneath the hood is attached to the hood in three places:
1. On the PTO side installation screw.
2. On the PTO vent grill.
3. On a cable tie block fixed to the rear grill.
CABLE ROUTING
Throttle Cable
1. The upper end of the throttle cable is attached to the twist throttle itself. The cable then passes in front of the handlebar and steering column.
2. Connect the throttle cable to the bundle of handlebar accessory wires with a nylon tie wrap. The cable then passes over the MPEM and then downward to the carburetors and the throttle slide actuator rack as shown on the following page.
Tie-wrap
3
1
1
2
1
2
2
3. Throttle Cable
Choke Cable
The choke cable is attached to a racked system on the carburetors and is then routed vertically upwards, under the main wiring harness and is then attached to the small oil reservoir with a nylon tie wrap as shown at right.
The cable then passes completely under the steering plate and up to the angled choke support bracket as shown at right.
● NOTICE:
For installation or adjustment of either the choke cable or the throttle cable, see Chapter 3 – Fuel System .
WIRE, CABLE AND HOSE ROUTING 16-9
4
3
WIRE, CABLE AND HOSE ROUTING 16-10
Rewind Starter Cord
(503 shown, 800HO identical)
1. Pass the rewind starter cord over the forward pulley.
2. Then under the rearward pulley.
3. Then, slide the rewind starter rode through the eyebolt.
Install the D-ring starter handle immediately and tie a secure knot.
HOSE ROUTING
◆ WARNING
Always ensure that all hoses are well attached at both ends, that they are in good physical condition, that they are well away from any moving part or heat source. If
ANY surface cracks are present, replace the hose immediately.
Steel-Braided Brake Hose o The brake hose is attached at its upper end to the brake master cylinder. o The hose is then routed in front of the handlebars and steering column. o The brake hose must be free to move and slide if necessary and must not interfere with the movement of the steering of the vehicle in any way.
o The brake hose then passes behind the steering plate and is attached with one nylon tie wrap at the corner. o The second tie wrap is located in a hole just above the triangular cut-out in the PTO side of the chassis. o The hose is then routed out through this cut-out, under the belt guard towards the brake caliper and is connected there.
WIRE, CABLE AND HOSE ROUTING 16-11
WIRE, CABLE AND HOSE ROUTING 16-12
Fuel hoses
Fuel pump
The fuel pump uses 3 hoses to function properly:
1. Impulse (Vacuum) Hose
Once installed onto the pump, the impulse hose follows the
MAG side chassis and is then connected to the rear of the engine, as shown at right. Ensure that the spring clamps are well placed.
2. Fuel Hose from Fuel Tank
The black 5/16 in. fuel line follows the MAG side chassis towards the rear of the vehicle and is then connected via a reducer to the 1/4 in. clear fuel line that goes into the fuel tank.
.
The clear line must pass between the fuel tank and the airbox.
ENSURE that the fuel line does NOT become pinched.
3. Fuel supply line (to carburetors)
The carburetor fuel supply line is routed form the pump, between the engine plate and engine itself and then back up and into the black tee connection at the base of the rack of carburetors. Ensure that the spring clamps are well secured.
◆ WARNING
It is very im[portan that all of these hoses are installed exactly as shown in the photos at right.
3
1
2
Overflow/Vent hoses and Carburetor vent hoses
Coolant Reservoir
The coolant overflow/air bleeder line is attached to the reservoir with a black spring clamp. The overflow hose is then routed downwards along the length of the reservoir and through a guide to a position that is between the coolant hose and the engine.
Fuel Tank
The fuel tank overflow line is routed from the gas cap itself under the handlebar and through the top plate of the steering column.
The hose is then tied to the rest of the handlebar accessory wires with a nylon tie wrap to secure it in place. The hose is then routed to the MAG side of the MPEM.
At this point, the hose is routed between the two carburetors, under the PTO-most coolant hose, through the triangular PTO chassis cut-out and is then secured to the chassis with a nylon tie wrap near the brake system.
WIRE, CABLE AND HOSE ROUTING 16-13
WIRE, CABLE AND HOSE ROUTING 16-14
Carburetor Vent Hoses
The individual carburetor vent hoses are tee’d together at the top of the assembly, near the centre. The vent hose is then routed between the two carburetors, under the PTO-most coolant hose, through the triangular PTO chassis cut-out and is then secured to the chassis with a nylon tie wrap near the brake system. Ensure that the hose does not become pinched.
As was explained for both the fuel vent hose and the fuel tank vent/overflow hose, the ends of these two hoses must be attached to the outside of the PTO side chassis as shown at right.
DIMENSIONS AND TOLERANCES 15 - 1
CHAPTER 15
DIMENSIONS AND TOLERANCES
DIMENSIONS AND TOLERANCES 15 - 2
DIMENSIONS AND TOLERANCES
ENGINE
Engine type
Bore
Stroke
Displacement mm
(in) mm
(in) cm
3
(in
3
)
Compression Ratio
Max power engine speed
Piston ring type 1 st
Ring end gap (new)
2nd
Piston/ring groove clearance (new)
Piston/Cylinder wall clearance (new)
Connecting rod big edn axial play (new)
Maximum crankshaft end play
(wear limit)
(wear limit)
(wear limit)
(wear limit)
Maximum crankshaft deflection at PTO mm
(in) mm
(in) mm
(in) mm
(in) mm
(in) mm
(in) mm
(in) mm
(in) mm
(in) mm
(in)
ELECTRICAL
Magneto generator output
Ignition type
Spark plug make and type
Spark plug gap (Pre-gapped)
W
Ignition timing BTDC
(@ 3500 RPM w/headlamp turned on)
Trigger Coil
Generating Coil
Lighting Coil
High Tension Coil mm
(in) mm
(in)
W
W
W
W
Rotax 793 HO
82.0
(3.228)
75.7
(2.980)
799.5
(48.789)
12.00 ± 0,5
7850 ± 100 tr/mn
Semi-trapez ring
N.A.
0.40 to 0.55
(0.016 to 0,022)
1,00
(0.039)
0,05 to 0,1
(0.0020 to 0,0039)
0,2
(0.0079)
0.125 +/- 0.022
(0.049 +/- 0.0009)
0,2
(0.0079)
0.310 to 0.677
(0.0122 to 0,0267)
1.2
(0.0472)
0.3
(0.012)
0.06
(0.0024)
360
CDI
NGK BR9ECS
0.40 to 0.50
(0.016 to 0.020)
2.370
(0.0933)
190-300
N.A.
0.1-1.0
N.A.
DIMENSIONS AND TOLERANCES 15 - 3
CARBURETION
Carburator type
Main jet (MAG/PTO)
Needle Jet
Pilot jet
Needle Identification - Clip Position
Slide cutaway
Float adjustment
Airscrew position
Idle RPM
Fuel type
Fuel : Oil Ratio
COOLING SYSTEM
Type
Mixture ratio
Thermostat opening temperature
Radiator Cap Opening Pressure
TORQUES
Cylinder head bolts N-m (lbf-ft)
Exhaust manifold bolts
Crankcase/Cylinder Nuts or Bolts
Magneto Ring Nut
Axial fan nut
Primary clutch bolt
Secondary clutch bolt
Taper-Lock installation setscrews
Spark plugs
Handlebar mounting bolts
Fork leg bolts (in triple clamps)
Fork pivot bolts
Ski runner nuts
Lower clamp bolts
Ski saddle/fork adaptor nut
PRIMARY TRANSMISSION
Primary clutch
Engagement RPM
Primary spring colour
Ramp
Screw position
Secondary clutch
Secondary clutch spring pretension
Secondary spring colour
Helix type (progressive)
Primary transmission belt P/N
Width of primary trans. Belt (new)
(wear limit)
Drive belt adjustment Deflection
Force mm (in) o
C ( o
F) kPa (psi) kg
(lbf) mm
(in) mm
(in) mm
(in) kg
(lbf)
Mikuni TM40
490 / 490
P-0
20
9DGI7-58
2,0
N.A.
1.5 turns
1600
Unleaded 87
40 : 1
Liquid
50/50
42 (108)
90 (13)
TRA III
3400-3600
Blue/yellow
417
3
HPV VSA
0
0
50
Green o
- 40 o
144-4740U3
37,7
(1,484)
35,3
(1,390)
32
(1.25)
6,8
(15)
29 (21)
22 (16)
29 (21)
125 (92)
N.A.
90 (66)
31.7 (23)
14 (10.4)
27 (20)
36.5 (27)
6.8 (5)
45 (33)
22 (16)
23 (17)
85 (63)
DIMENSIONS AND TOLERANCES 15 - 4
SECONDARY TRANSMISSION
Drive sprocket number of teeth
Driven sprocket number of teeth
Secondary transmission belt P/N
Cog belt adjustment Deflection
Force
CHASSIS
Overall length
Overall width
Overall height
Dry weight
Track width
Track length (ST/LT)
Track adjustment Deflection
Force
FRONT SUSPENSION
Type
Travel
Oil level
Oil type
REAR SUSPENSION
Type
Travel
Sag (with rider)
Shock type
Oil Type
Hyfax P/N
FLUIDS
Fuel tank capacity mm
(in) kg
(lbf) mm
(in) mm
(in)
L
U.S. gal.
(lb) mm
(in) mm
(in) mm
(in) kg
(lbf) mm
(in) mm
(in) mm
(in) kg
30
56
1360PTH8M-60
7,3
(0.288)
6,44
(14.2)
2698
(105)
835
(32.5)
1233
(48)
170
(375)
308
(12)
3074 / 3495
(121 / 136)
40 -50
(1.5 - 2) freely hanging freely hanging mm
(in) mm
(in)
Inverted, 46mm Paioli
308
(12)
85
(3.3125)
SAE 15W
Expert Xtreme
405
(16)
100
(4)
KYB, rebuildable
KYB, No. snow
04-218-22
30
9,5
CHAPTER 14
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM 14-1
ELECTRICAL SYSTEM 14-2
CDI SYSTEM
13
12
20-23
14
15
16
17
27 N-m ( 20 lbf-ft
2.75 kg-m, 240 lbf-in)
11
18
19
21, 22, 23
243
4
Sikaflex Black, #221
(P/N 293530011)
22 N-m ( 16 lbf-ft
2.25 kg-m, 192 lbf-in)
648
243
Ref.
19
20-23
21
22
23
-
14
15
16
17
18
8
9
10
11
12
13
1-4
2
3
4
5
6
7
P/N
420 891 540
420 888 314
420 888 323
420 966 837
205 063 044
420 640 321
420 866 756
420 852 532
420 827 405
207 182 044
512 059 552
-
512 059 696
512 059 695
410 914 600
23162F
517 203 200
053.6.45
512 060 239
512 059 564
515 175 670
515 175 707
278 000 632
ELECTRICAL SYSTEM 14-3
Qty
1
1
2
1
1
2
1
1
1
2
2
1
2
2
3
2
1
1
1
1
1
1
1
Electrical System
Part Descriptions
Magneto (12V, 360W)
Stator Assy
Flywheel
Pick-up Assy
Socket Head Screw M6x30
Screw M6x16
Counter Weight
Starting Pulley
Washer 8mm
Hex Head Screw M8x20
BR9ECS Spark Plug
Spark plug cap
Spark plug wire (375mm) with cap
Spark plug wire (300mm) with cap
Plastic Clip
Locknut M6
Spacer
Hex Head Screw M6x45
MPEM Assembly
Ignition coil
Female terminal housing (2 circuit)
Female lock (2 circuit)
Female terminal
ELECTRICAL SYSTEM 14-4
WIRING DIAGRAM
Ref.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
P/N
278000632
515175670
515175673
409209900
410113200
561503100
515175588
278000998
278000999
278001673
278001671
515175567
515175665
409010400
409010100
515175684
410105500
515175571
515145900
515151500
410109700
278001016
512047000
AN-125
336772
515176100
512059923
515175704
278000631
ELECTRICAL SYSTEM 14-5
Electrical System - Wiring Harness
Qty Part Descriptions
2
4
4
1
2
2
1
1
2
1
4
10
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
Dimmer Switch
Emergency Stop Switch
Tether Switch
Tether Switch Nut
Tether Cap and Cord
Overheat Lamp
Bosch Temperature Sensor (Blue)
Indebras Temperature Sensor (Black)
Head Lamp Assy
Tail Lamp Assy
Voltage Regulator
MPEM
Female Terminal Housing (12-circuit) @ MPEM (Deutsch)
Male Terminal (used in P/N 515175665)
Female Terminal (used in Deutsch connectors)
Female Housing (2-circuit) @ MPEM (Deutsch)
Female Housing (6-circuit) @ MPEM (Deutsch)
Female Housing (5-circuit) @ Relay (Deutsch)
Relay
Female Relay Terminal
Housing @ Bosch Temp. Sensor
Female Terminal @ Bosch Temp. Sensor
White Rubber Gasket @ Bosch Temp. Sensor
Female Housing @ Voltage Regulator
Female Locking Wedge @ Voltage Regulator
Female Terminal @ Voltage Regulator (Big)
Male Housing
Female Housing (1-circuit)
Female Terminal (used in P/N 409010400)
ELECTRICAL SYSTEM 14-6
CDI SYSTEM
● NOTICE:
The following procedures can be carried out without removing the engine from the vehicle. Only the body panels must be removed.
For more details, see Chapter 1 – General Instructions .
CDI means Capacitor Discharge Ignition System
CLEANING
Clean all metal components in a non-ferrous metal cleaner.
▼ CAUTION
Clean stator and magneto using only a clean cloth.
DISASSEMBLY
3, Magneto Flywheel
To gain access to magneto assembly, remove the following parts: o All body panels o starter o starting pulley no. 8.
To remove magneto flywheel retaining nut on the end of the crankshaft (not shown in exploded view): o Use magneto puller ring (P/N 420 876 080). This puller must be modified as shown at right. (cut 25mm from the tab) o Install puller ring with its tab in magneto housing opening (No 1 at right).
▼ CAUTION
Use only M8 x 30 mm screws (No. 2 at right) to bolt puller to magneto.
o Remove magneto flywheel nut and lockwasher using a
30 mm socket machined to 40 mm (1.580 in) outside diameter by 16 mm (5/8 in) long.
● NOTICE:
To correctly remove a threadlocked fastener, first tap on the fastener to break the threadlocker bond. This will help avoid breakage.
o To remove magneto flywheel, install the crankshaft protector (P/N 420 876 557) onto the end of the crankshaft. o Screw puller (P/N 529 022 500) into puller ring. o Tighten puller bolt and at the same time, tap on bolt head using a hammer to release magneto flywheel from its taper.
4, Trigger Coil
Magneto and stator no. 2 must be removed before removing the trigger coil.
To replace the trigger coil no. 4: o Disconnect trigger coil connector housing. o Remove grommet from crankcase where trigger coil wire exits magneto housing. o Remove retaining screws no. 6. o Remove trigger coil and carefully pull wires. o Install new trigger coil and other parts removed.
ASSEMBLY
2, Stator o Position stator (No. 2 at right) so that its wire protectors are over crankcase recess (No 1 at right).
3, Magneto Flywheel o Clean crankshaft extension (taper) and apply Loctite
243 (blue) on taper, then position Woodruff key, flywheel and lock washer on crankshaft. o Clean nut threads and apply Loctite 243 (blue) then tighten magneto nut to 125 N-m (92 lbf-ft) . o At reassembly, coat all electric connections except
Deutsch housings (waterproof grey housing) with silicone dielectric grease (P/N 293 550 004) to prevent corrosion or moisture penetration.
▼ CAUTION
Do not use silicone “sealant”, this prodcut will corrode electrical contacts. Do not apply silcone dielectric grease on any Deutsch (grey) housing otherwise the housing seal will be damaged.
ELECTRICAL SYSTEM 14-7
ELECTRICAL SYSTEM 14-8
IGNITION TIMING
0
793 HO Engines
Normally ignition-timing adjustment should not be required. It has been set at the factory and it should remain correctly adjusted since every part is fixed and not adjustable. The only time the ignition timing might have to be changed would be when removing and reinstalling the magneto housing, replacing the crankshaft, the magneto flywheel, the trigger coil or the
MPEM. If the ignition timing is found incorrect, first check for proper crankshaft alignment. This might be the indication of a twisted crankshaft. Refer to Chapter 7 - Engine
(Cylinders/Head/Base) for more details. The ignition timing can be checked with either the engine hot or cold.
Also, the ignition timing is to be checked at 3500 RPM with a timing light.
Engine break-in retard timing for the Snow Hawk 600HO is as follows the first hour of operation.
TYPICAL
1. TDC gauge on MAG side
2. MAG side piston at TDC
● NOTICE:
Between 3000 and 4000 RPM, the spark advance does not change. So when checking ignition timing at 3500 RPM, a change in engine speed within ~ 500 RPM will not affect the timing mark when checked with the timing light.
Scribing a Timing Mark o Clean the area around the MAG side spark plug, and remove it. o Install the TDC gauge in the spark plug hole,
(magneto side) and adjust as follows: a. Position the MAG piston at approximately TDC. b. Assemble the gauge with the adaptor and tighten the roller lock nut. Do not tighten the adaptor lock nut. c. Screw the adaptor into the spark plug hole and tighten to prevent movement in the plug hole. d. Position the dial face toward the PTO. Move the gauge down until the needle just begins to move, then move down a further 5 or 6 mm (approximately 1/4 in). Tighten adaptor lock nut by hand.
o Locate the piston TDC position as follows: a. Slowly rotate the drive pulley back and forth across TDC while observing the needle. Note that the needle stops moving only as the piston is changing direction. b. Rotate the dial face so that “0” is in line with the needle when it stops moving. c. Again, slowly rotate the drive pulley back and forth across TDC and adjust the dial face to
“0”, until the needle always stops exactly at
“0” before changing direction. d. “0” now indicates exact TDC. o Rotate the drive pulley clockwise, one-quarter turn then carefully rotate it counterclockwise until the needle indicates the specified measurement, indicated in Chapter 15 – Dimensions and Tolerances . o Twist a wire as shown and use it as a pointer.
Install the wire on what would be the upper starter bolt.
Although there is no electric starter on any Snow Hawk, you can use the upper threaded hole in the crank case as a mounting position, indicated by the white arrow. o With the TDC gauge indicating specified timing (shown at right),scribe a mark on the primary clutch inner half in line with the pointer end (shown at lower right).
Checking Ignition Timing
Use timing light (P/N 529 031 900), shown at lower right.
To check the ignition timing, refer to the illustration and proceed as follows:
◆ WARNING
Place the tips of the ski against a wall. Lift the rear of the vehicle so that the track does not touch the ground and install it on a support.
Make sure that no one goes in front of or behind the vehicle while the engine is running.
Keep away from the track and do not wear loose-fitting clothing which could be caught up in the moving parts. o Connect the timing light pick-up to a spark plug cable. o Connect a digital induction type tachometer (P/N
529 014 500), as shown on the following page. o Start the engine and point the timing light on the timing mark. Bring the engine to 3500 RPM for a brief instant.
ELECTRICAL SYSTEM 14-9
ELECTRICAL SYSTEM 14-10 o The timing mark must be aligned with the pointer end.
If such is not the case, note if the timing is retarded or advanced. Tolerance is ± 0.5°.
Changing Timing
As a Snow Hawk dealer, there is no immediate way to alter the
MPEM’s internal timing settings other than to send the unit back to us and have us reset the unit for you or have your local
Bombardier dealer change the settings using his programmer.
SYSTEM TESTING
IGNITION SYSTEM TESTING SEQUENCE
In case of ignition problems, check the following in the prescribed order until the problem can be solved.
1. Sparking/spark plug condition.
2. Electrical connectors.
3. DESS switch and engine cut-out switch.
4. Generator coil.
5. Trigger coil(s).
6. MPEM voltage.
7. High voltage coil.
8. Buzzer testing.
LIGHTING SYSTEM TESTING SEQUENCE
1. Electrical connectors.
2. Magneto output (lighting generator coil).
Testing Conditions
Voltage measurements are always taken upon starting the vehicle. Readings when the engine is running will be higher than the indicated range. All part temperatures must be approximately
20°C (68°F) (room temperature), otherwise the readings could be distorted.
Analysis of Readings
Voltage Readings
When testing the different magneto components, it is important to take into consideration that readings vary according to the force applied onto the manual starter. It is therefore important to employ enough force upon each trial. The reading must be 3 times within or above the range indicated in the corresponding table. If the reading is too low, the part is considered to be defective and must be replaced.
Resistance Readings
Place multimeter selector switch to ohms in order to measure resistance. Readings must be within the indicated range.
Otherwise, the part is considered to be defective and must be replaced.
▼ CAUTION
When taking measurements, it is useless to try and start the vehicle since the readings would then be distorted.
ELECTRICAL SYSTEM 14-11
ELECTRICAL SYSTEM 14-12
Intermittent Ignition Problems
It is difficult to make an attempt at diagnostics in the case of intermittent ignition problems. Thus, problems occurring only when the engine operating temperature is normal must be checked in similar conditions. In most cases when problems are caused by temperature or vibrations, these can only be solved by replacing parts. Most problems cannot be detected when the engine is stopped.
Multiple Problems
As a matter of fact, more than one component can be defective at the same time. As a result, if the problem remains although a part was replaced, start the entire troubleshooting process over from the beginning in order to identify the other defective component.
1. SPARKING
During this operation, it is important to use the snowmobile spark plug and not a new one. Bring the plug in contact with the engine.
Pull rewind starter. If no spark is produced, replace the spark plug with a new one and do the test again.
2. ELECTRICAL CONNECTOR TESTING
Make sure that none of the connectors are disconnected.
3. ENGINE CUT-OFF SWITCH TESTING
Disconnect connector housings and check the resistance as indicated in IGNITION table. If the readings are acceptable, go on to the next step. If the readings are inadequate, individually check each switch as follows.
Tether Cord Switch
Using a multimeter check by connecting probes to BLACK and
BLACK/YELLOW wires. The multimeter should indicate a closed circuit (0 ) in the ‘operating’ position and an open circuit (0.L M ) in the ‘off’ position.
If the readings do not correspond to the above mentioned values, replace the switch. If none of these tests are conclusive, the problem finds its source in the main wiring harness.
Proceed as follows:
Engine Cut-Off Switch
Unplug the switch block connected to the main wiring harness.from the engine cut-off switch. Check using a multimeter by connecting probes to the appropriate wires. Refer to the corresponding IGNITION AND ELECTRICAL SYSTEM TESTING table values in this subsection. The multimeter should indicate an open circuit (0.L M ) in operating position and if the circuit is closed (0 ) in the off position.
● NOTICE:
For the next step, no switch must be connected to the main wiring harness.
Disconnect all switches from the main wiring harness and check the continuity of each wire by connecting probes to the end of wires of the same color. Repeat with all other wires. It is important to mention that all wires of the same color within a given harness are connected together. These wires should therefore have a closed circuit. On the other hand, BLACK and
BLACK/YELLOW wires must have an open circuit (0.L M ).
Repair or replace if necessary.
4. GENERATOR COIL TESTING
Resistance Testing o Disconnect the housing between the magneto and the MPEM. o Connect multimeter probes to appropriate wires and measure the resistance. Refer to the corresponding
IGNITION AND ELECTRICAL SYSTEM TESTING table in this subsection. o Compare readings with those appearing in the
IGNITION table.
Voltage Testing
When manually starting the engine while the spark plug is installed, the engine will tend to accelerate beyond the compression point. This will result in higher magneto output power. o Disconnect the housing between the magneto and the MPEM. o Connect the multimeter probes to the appropriate wires. Refer to the corresponding ignition and electrical system testing table in this subsection. Bring the selector switch to and the scale to 00.0 Vac. o Activate the manual starter and check the values indicated by the multimeter. o Repeat this operation 3 times. o Compare readings with those appearing in the IGNITION table.
ELECTRICAL SYSTEM 14-13
ELECTRICAL SYSTEM 14-14
5. TRIGGER COIL TESTING
Resistance Testing o Connect the probes to the appropriate wires from the trigger coil housing. Refer to the corresponding
IGNITION AND ELECTRICAL SYSTEM TESTING table in this subsection. o Compare these readings with those appearing in the
IGNITION table.
Voltage Testing o Connect the probes to the appropriate wires from the trigger coil housing. Refer to the corresponding
IGNITION AND ELECTRICAL SYSTEM TESTING table in this subsection. o Activate the manual starter and check the values indicated by the multimeter. o Repeat this operation 3 times. o Compare these readings with those appearing in the
IGNITION table.
6. MPEM VOLTAGE TESTING o Disconnect the housing between the module and the high voltage coil. o Connect the multimeter probes to the RED and the
BLACK wires coming out from the module. Place the selector switch and the scale to 00.0 Vac. o Activate the manual starter and check the values indicated by the multimeter. o Repeat this operation 3 times. o Compare these readings with those appearing in the
IGNITION table.
7. HIGH VOLTAGE COIL TESTING
Resistance Testing o Unplug housing between high tension coil and
MPEM. o Connect the multimeter probes to the WHITE/BLUE and the BLACK wires and measure the resistance. o Compare these readings with those appearing in the
IGNITION table.
Voltage Testing o Disconnect spark plug cap from spark plug. o Fasten alligator clip to spark plug cable, near the spark plug (position No. 1 at right). o Connect other multimeter wire to engine (ground), then place selector switch and scale to 0.00 Vac. o Activate the manual starter and check the values indicated by the multimeter. o Repeat this operation 3 times. o Compare these readings with those appearing in the
IGNITION table.
CONCLUSION
If none of the above testing operations produced valid results, it is strongly recommended to keep on testing according to the list appearing in the resistance column of the IGNITION table.
Set the multimeter as indicated.
LIGHTING GENERATOR COIL
VOLTAGE TESTING o Disconnect the housing from the engine (YELLOW and
GREEN wires). o Connect the multimeter probes to the YELLOW and
GREEN wires as described in the IGNITION AND
ELECTRICAL SYSTEM TESTING table. Place the selector switch and scale to 0.00 Vac. o Activate the manual starter and check the values indicated by the multimeter. o Repeat this operation 3 times. o Compare these readings with those appearing in the
IGNITION AND ELECTRICAL SYSTEM TESTING table.
CONCLUSION
If none of the above testing operations produced valid results, it is strongly recommended to keep on testing according to the list appearing in the Resistance column of the LIGHTING table.
Set the multimeter as indicated.
ELECTRICAL SYSTEM 14-15
ELECTRICAL SYSTEM 14-16
360W SNOW HAWK 800HO IGNITION AND ELECTRICAL SYSTEM TESTING TABLE
PART
TEST TO BE
PERFORMED
WIRE
COLOR
RESISTANCE
VALUE (OHMS)
VOLTAGE
(VOLTS, V)
NOTE
Engine stop
Running insulation
BL and
BL/YL
0.L -
Engine stop switches must be in run position.
switches Continuity in stop BL and Engine stop switches position BL/YL must be in stop position.
MPEM Ground connection
BL and body ground
00.0 to 00.5
-
MPEM Power
Power from regulator
RD and BK 3 to 5 Vdc While cranking engine.
Trigger coil No. 1
(STD)
Resistance and
Output
WT/BL and
BL
190 to 300
0.200-0.350
Vdc
While cranking engine.
MPEM Output
Voltage
Voltage to ignition coil
WT/BL and
BK
225-275 Vdc
With tether cap in place and with engine stop switches in run position.
While cranking engine.
Primary winding resistance
Secondary winding resistance spark plug wires and caps included
WT / BL and
BK
Between both spark plug caps
00.2 to 00.5
14.5 k to 23.5 k
-
-
Disconnect the ignition coil from the MPEM.
Do not attempt to remove spark plug caps from the wires.
High Voltage Coil Secondary winding resistance spark plug wires removed
Secondary winding
Male terminal to male terminal
9.6 k to 14.4 k -
With spark plug wires removed from high voltage coil.
voltage
BK and engine
1.5-2.5 Vdc
Do not probe in to spark plug cap with spark plug wires removed from spark
Output
YL, YL and
GR
00.0 - 00.5
3 times
3.5-5.5 Vac and B, A and C and B
3 times plug.
Do the test between A and C using the manual
Lighting generator coil
Coil insulation
YL and engine
0.L M starter.
The term engine refers to the metal parts connected to the magneto housing.
Relay
Coil
Contacts
-
-
-
-
10.5-13.6
Vdc
0.00-0.11
Vdc
Engine Idling (1500-1800
RPM)
Engine Idling (1500-1800
RPM)
● NOTICE:
If voltage is present at the coil and contact, replace the relay. An approved automotive spark plug tester is preferred for testing the secondary winding voltage. Ignition will not work if the engine stop switches are in the kill position.
CHASSIS, STEERING SYSTEM AND BODY 13-1
CHAPTER 13
CHASSIS, STEERING AND BODY
CHASSIS AND STEERING SYSTEM
CHASSIS, STEERING SYSTEM AND BODY 13-2
CHASSIS, STEERING SYSTEM AND BODY 13-3
CHASSIS AND STEERING SYSTEM
CHASSIS AND STEERING SYSTEM
CHASSIS, STEERING SYSTEM AND BODY 13-4
CHASSIS, STEERING SYSTEM AND BODY 13-5
CHASSIS AND STEERING SYSTEM
CHASSIS AND STEERING SYSTEM
67
58
66
61
62
63
65
91 (4x)
92 (4x)
94 (4x)
46
60
CHASSIS, STEERING SYSTEM AND BODY 13-6
64 (4x)
57
59
90 (4x)
92 (4x)
93 (4x)
95 (4x)
27
28
29
30
23
24
25
26
19
20
21
22
15
16
17
18
11
12
13
14
7
8
9
10
5
6
3
4
1
2
43
44
45
-
39
40
41
42
35
36
37
38
31
32
33
34
CHASSIS, STEERING SYSTEM AND BODY 13-7
Chassis
Ref.
P/N Qty
SH-062
SH-080
SH-036
SH-118R
SH-038
SH-020
SH-021
SH-120
SH11-SAG
SH11-SAD
SH-111
SH-110
SH-112
339-163P
12-0379
404-338AI
SH-001
SH-002
SH-116
SH-003L
SH-003R
SH-033L
SH-033R
SH-032L
SH-032R
SH-035
SH-030
SH-031
SH-117
SH-061
404-339AI
SH-039
SH-047
SH-046
SNC-26-03
29510P
BNO1-0618
S6-100P
SH-015
SH-251
S091C-2 001B
6206-2RSJEMC3
SH-250
SH-253
570 048 700
1
1
1
1
1
1
1
1
1
1
1
2
2
1
4
2
2
2
1
1
1
2
1
1
1
1
1
1
1
1
1
3
1
2
4
4
1
9
8
2
4
2
1
1
4
Part Descriptions
Frame right side (MAG)
Frame left side (PTO)
Handle bar plate support
Rear frame left side (PTO)
Rear frame right side (MAG)
Left front chassis extension (PTO)
Right front chassis extention (MAG)
Left front hood bungee hook (PTO)
Right front hood bungee hook (MAG)
Front belly pan bungee hook
Left side belly pan bungee hook (PTO)
Right side belly pan bungee hook (MAG)
Foot peg stiffener
Rear lateral protector
Front lateral protector
Belly pan side shield support
Rear module rear bungee hook
Rear module front bungee hook (RIGHT) MAG side
Front chassis spacer
Long chassis spacer
Short chassis spacer
Carburator support
Left Foot peg grip (PTO)
Right Foot peg grip (MAG)
Kickstand arm
Kickstand adaptor
Kickstans floater
1/2" shoulder screw socket screw
Kickstand spring
Button head socket cap screw 5/16" x 5/8" L
Button head socket cap screw 5/16" x 3/4" L
Side bumper and brake caliper pacer
Belt garde support
Belt garde cover
Rubber moulding
Hexagon head flange bolt M6 x 1.0 x 16MM (Grade 10.9)
Pop rivet 3/16" (medium)
Washer 3/16''
Bearing housing
Sprocket shaft
Sprocket 9 teeth
Bearing 6206
Steel jackshaft
Key 1.5" L
Bumper rubber
CHASSIS, STEERING SYSTEM AND BODY 13-8
P/N
SH-084
SH-034
SH-129
SH-058
6000LLEC
184-110
SH-057
MM9489T26
SH-042
20172CP
SNC-26-02
SH01-SA
SH-005
SH-013
SH-012
SH-043
SH-050
SH-066
21655P
23166P
503 183 300
20237P
18-95266HAWK
SH-016
SH-054
SH-049
SH-089
SH-008
SH-128
SH14-SA
BH67010.9P
20207P
23164P
23162P
SH-055
506 151 492
506 151 495
250 100 016
732 610 010
368.10.125
22204P
8461k133-2
SH-132
8461k133-1
SH-085
341-114P
Ref.
70
71
72
73
66
67
68
69
74
75
76
59
60
61
62
63
64
65
50
51
52
53
46
47
48
49
54
55
56
57
58
88
89
90
91
-
84
85
86
87
77
78
79
80
81
82
83
Chassis
Qty
1
1
4
4
1
1
4
1
4
6
2
2
2
4
4
2
8
2
2
1
2
2
1
2
1
1
2
2
2
1
1
4
4
1
1
1
2
11
1
4
33
21
1
1
1
1
Part Descriptions
Engine support
Choke support
Oil tank bracket
Hand starter wheel
Bearing 6000
Retaining ring
Hand starter wheel spacer
Eyebolt 5/16-18 x 1"
Belt tensioner block
Hexagon head cap screw M6 x 1.0 x 80MM (full threaded)
Rubber moulding
Fork tube support
Fork clamp support
Bottom clamp stiffener
Top clamp stiffener
Fork steel bushing
Fork MOS2 bushing
Fork bushing
Socket head screw M8 x 1.25 x 40MM
Nylon nut M10 x 1.5
Washer 10MM spécial
Hexagon head cap screw M10 x 1.5 x 55MM
Handle bar
Handle bar clamp
Rubber steering damper
Plastic half steering bushing
Lower handle bar stiffener
Upper handle bar stiffener
MPEM bracket
Steering colomn
Hexagon head cap screw M6 x 1.0 x 70MM (Grade 10.9)
Hexagon head cap screw M8 x 1.25 x 60MM
Nylon nut M8 x 1.25
Nylon nut M6 x 1.0
Threaded aluminum drive rod
RH ball joint
LH ball joint
LH hexagon jam nut M10
RH hexagon jam nut M10
Nylon nut M10 x 1.25
Button head socket cap screw M6 x 1,0 x 20MM
Adhesive rubber strip 1/8" thick x 2" wide x 16" L
Adhesive rubber strip (PTO) [modified #8461K133]
Adhesive rubber strip 1/8" thick x 2" wide (MAG)
Engine support adaptor
Washer 5/8
110
111
112
113
114
115
116
103
104
105
106
107
108
109
96
97
98
99
100
101
102
92
93
94
95
130
131
132
133
134
135
136
-
117
118
119
120
121
122
123
124
125
126
127
128
129
CHASSIS, STEERING SYSTEM AND BODY 13-9
Chassis
Ref.
P/N Qty
DDR6261
92140A118
21111P
20242P
061.6.25
20159P
23162F
22214P
22215P
22216P
336-103
2946P
22205P
22121P
22225P
29530
23164F
SNC-26-1
BS01 0622
053,8,40
21653P
057.8.30
21110P
442.12
20269P
21681P
SH-071
061.8.25
SH11-SAD
SH10-SA
SH-107
SH-106
195-105
SNB-384
SH11-SAG
SH-141
SH-118L
072.14.58
20198P
DP-02
DP-01
BN01-0618
SH-154
SH-153
22202P
3
8
4
8
8
2
2
2
2
1
2
4
16
1
2
2
2
2
2
4
1
4
2
8
2
4
23
2
3
1
16
4
4
4
1
2
1
1
4
2
2
1
1
2
1
Part Descriptions
Rubber damper
Washer M10 large
Lock washer M10
Hexagon head cap screw M10 x 1.5 x 80MM
Hexagon head flange bolt M6 x 1.0 x 25MM (Grade 10.9)
Hexagon head bolt M6 x 1.0 x 20MM (Grade 10.9)
Nylon flange nut M6 x 1.0
Button head socket cap screw M8 x 1.25 x 20MM
Button head socket cap screw M8 x 1.25 x 25MM
Button head socket cap screw M8 x 1.25 x 30MM
Hexagon flange stove nut 5/16"
Nylon flange nut 5/16-18
Button head socket cap screw M6 x 1.0 x 25MM
Flat head socket cap screw M8 x 1.25 x 30MM
Button head socket cap screw M10 x 1.5 x 25MM
Hexagon head flange bolt M8 x 1.25 x 30MM
Nylon flange nut M8 x 1.25
Rubber moulding
Aluminum pop rivet 3/16 (long)
Hexagon head cap screw M8 x 1.25 x 40MM
Socket head cap screw M8 x 1.25 x 30MM
Hexagon head cap screw M8 x 1.25 x 30MM
Lock washer M8
Lock washer 1/2"
Hexagon head cap screw M12 x 1.75 x 30MM
Socket head cap screw M10 x 1.5 x 30MM
Rear module rear bungee hook positioner
Hexagon head flange bolt M8 x 1.5 x 30MM
Foot peg grip (Right)
Foot peg yoke
Foot peg torsion spring
Foot peg plastic bushing
Cotter pin A3/32x3/4
Clevis pin A1 1/4x7/16
Foot peg grip (Left)
Tune pipe support
Rear module front bungee hook (LEFT) PTO side
A1/4x5/8 HHCS
Hexagonal head cap screw M8x20
Steering damper plate
Steering damper block
Pop rivet 3/16
Pipe support bracket
Tentionnor plate
Button head socket cap screw M6 x 1.25 x 16MM
BODY - HOOD
CHASSIS, STEERING SYSTEM AND BODY 13-10
CHASSIS, STEERING SYSTEM AND BODY 13-11
BODY – HOOD
CHASSIS, STEERING SYSTEM AND BODY 13-12
Ref.
10
11
12
19
20
21
22
23
24
25
26
27
28
-
13
14
15
16
17
18
7
8
9
4
5
6
@
1
2
3
Qty
21
1
2
1
1
1
1
1
1
1
1
4
2
2
2
1
1
1
2
1
1
1
6
6
2
1
1
21
2
P/N
SH-77A
ADB-083Y
1661-0619N
1641-0621N
5937
ADB-098Y
284118
AN-125
SH-069
SH-070L
SH-070R
SH-081
S6-100P
400-288
400-579A
402-637
SH-257
4204
SH-615
SH-075
SH-138
SH-139
SH-807-D01
SH-807-D02
SH-807-D07
SH-807-D08
SH-807-D09
ZZ-AD-HA-LU-AV
SH-161
Body - Hood
Parts description
Hood assy 800HO 2007
Yellow hood
A 3/16 Pop rivet (Alu,Black)
A 3/16 Pop rivet (Alu,large head,Black)
Head light spring
Hood guide yellow
Rubber hook bungee
Head lamp
Grill (rear of cab)
Grill (PTO side)
Grill (MAG side)
W earing plate
A 3/16 Flat washer
A 8-32 hex elastic nut
A 8-32 x 1 3/4 phillips
A 8-32 x 2 1/2 phillips
Grill (front cab)
Rubber button type
Decal "warning label"
Headlamp heat sheild
Hood heat sheild MAG
Hood heat sheild PTO
Decal top gun 800HO
Decal Tp
Decal Sponsor
Decal mag side
Decal PTO side
Headlight harness VR
Reflection shield
CHASSIS, STEERING SYSTEM AND BODY 13-13
BODY – BELLY PAN
CHASSIS, STEERING SYSTEM AND BODY 13-14
BODY – BELLY PAN
23
24
Ref.
-
-
-
-
-
-
-
-
-
-
-
CHASSIS, STEERING SYSTEM AND BODY 13-15
Ref.
P/N Qty
Body - Belly-pan
Parts descriptions
18
19
20
21
22
23
24
-
8
9
10
11
12
13
14
15
16
17
3
4
5
6
7
@
1
2
SH-76A
284118
1661-0619N
S6-100P
ADB-094
1641-0621N
SH-121
SH-065
SH-068
SH-081
SH-082
1661-0619
SH-115
SH-23A
SH-610
SH-611
SH-170
SH-121
SH-140
SH-137
SH-807-D03
SH-807-D04
SH-123
ADB-096
SH-077
1
1
1
1
1
1
1
10
1
1
1
1
6
1
1
1
1
1
8
14
23
1
10
1
1
Bellypan assy 800HO 2007
Rubber hook bungee
A 3/16 pop rivet (alu,black)
A 3/16 Flat washer
Black bellypan
A 3/16 pop rivet (alu, large head, black)
MAG side heat shield
PTO bellypan protector
PTO side grill
Wearing plate
Bellypan pipe protector
A 3/16 pop rivet (alu)
MAG side grill
Tool pocket assy
Reflector MAG side
Reflector PTO side
Clutch protecteur
Heat sheild
Heat sheild front PTO
Heat sheild front MAG
Bellypan decal PTO
Bellypan decal MAG
Heat sheild
Fork disc black
Fork disc heat sheild
P/N
204 630 050
204 630 051
529 017 500
529 035 582
529 019 400
529 035 501
SH-114
SH-133
1201-0293
1212-4580
Qty
1
1
1
1
1
1
1
1
1
1
SH-34A Tool pocket
Parts descriptions
Wrench socket
Bar steel
Rope starter
Wrench adjuster
Starter grip
Driven tool spacing
Universal key
Tool pocket
Seal
Therminal weather/pack f
CHASSIS, STEERING SYSTEM AND BODY 13-16
BODY – REAR MODULE
3 .
10
.
3
10
8
10
.
1
.
6
.
4
2
10
6
4
8
10
8
11 & 12
1
7
7
5
14 (MAG SIDE)
15 (PTO SIDE)
CHASSIS, STEERING SYSTEM AND BODY 13-17
Ref.
5
6
3
4
@
1
2
9
10
11
12
13
14
15
-
-
-
7
8
P/N
SH-78A
ADB-100Y
200281
22204P
1641-0621N
336772
284118
169-113
333-105P
S6-100P
341-103P
SH-612
SH-613
SH-618
SH-807-D05
SH-807-D06
ADB-099
200299R
Qty
1
4
2
4
1
1
1
4
1
1
1
1
1
4
1
1
2
4
Body - Rear module
Parts descriptions
Rear module assy 800HO 2007
Yellow rear module
Seat base
Button head cap screw M6 x 20
A 3/16 pop rivet (alu,large head, black)
Rear lamp
Rubber hook bungee
Push nut
A 1/4 hex elastic nut
A 3/16 Flat washer
W asher
Reflector MAG side
Reflector PTO side
Decal premix
Decal number plate MAG
Decal number plate PTO
Plastic seat base
Seat cover
CHASSIS, STEERING SYSTEM AND BODY 13-18
Ref.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
P/N
SH-263SA
SH-262
S6-100
BNO1-0618
SH-086
SN328-014
SN328-016
170-103
ADB-101-FRONT
ADB-101-REAR
513032979
513033022-1
403 901 811
420 874 370
BSO1-0622
SH-078
SH-260
SH-091
SH-092
Qty
Body - T unnel Cover
Part Descriptions
1
9
1
1
1
2
2
1
1
1
1
1
1
2
20
20
1
1
1
Radiator assembly
Side support
Falt washer
Pop rivet 3/16 (medium head )
Aluminium tunnel renforcement plate
Hex flange nut 1/4-20 X 3/4" (fuel pump)
Hex flange nut 1/4-20 X 1 1/4" (fuel pump)
T-screw
Front tunnel cover black
Rear tunnel cover black
Spring clamp (light green) (Pump-2-adaptor)
Rubber hose (Pump-2-adaptor)
Fuel pump
Fuel line adaptor (b/t fuel pump and tank)
Pop rivet 3/16 (long)
Tunnel cover heat sheild
UHMW tunnel protector
Long aluminium spacer
Short aluminium spacer
REAR SUSPENSION, SHOCKS AND TRACK 12 - 1
CHAPTER 12
REAR SUSPENSION, SHOCK AND TRACK
REAR SUSPENSION, SHOCKS AND TRACK 12 - 2
REAR SUSPENSION
REAR SHOCK
70
67
68
69
REAR SUSPENSION, SHOCKS AND TRACK 12 - 3
53
REAR SUSPENSION, SHOCKS AND TRACK 12 - 4
MIDDLE SHOCK
54
67
69
70
REAR SUSPENSION, SHOCKS AND TRACK 12 - 5
Ref.
3
4
5
1
2
8
9
6
7
10
11
12
13
33
34
35
36
37
29
30
31
32
38
39
40
41
42
24
25
26
27
28
20
21
22
23
14
15
16
17
18
19
SH-18A Suspension arrière
Qty Part descriptions
6
10
18
2
4
6
10
1
2
2
10
2
2
6
1
2
6
2
6
2
2
2
9
14
2
2
1
2
2
2
2
2
16
2
4
9
2
4
2
2
2
1
P/N
30628P
21111P
181-188P
SH-416
SF-2836-20
SH-43-SAG
21682P
20159P
23162P
SH-415
21681P
20272P
342-121P
SH-402
SH-421
SH-411
20144P
21084P
570 063 000
20200P
22205P
21085P
517 078 700
20165P
025-00
01-4931-1-01BLK
SH-401
250 000 019
503 183 300
503 189 809
BR16L
503 139 600
R0165K-1 001A
6205-2RS
371 907 700
SH-414
20246CP
23166P
23164P
23161P
057-00
SH-412
Hexagon head cap screw M10 x 1.5 x 45MM (Grade 10.9)
Lock washer M10
Washer 3/8 I.D
Front outside bushing
Oil lite bushing
Bushing housing (Left side)
Socket head cap screw M10 x 1.5 x 35MM
Hexagon head cap screw M6 x 1.0 x 20MM
Nylon nut M6 x 1.0
Front inside swinarm bushing
Socket head cap screw M10 x 1.5 x 30MM
Hexagon head cap screw M12 x 1.75 x 45MM
Lock washer 1/2
Swingarm
Swingarm press fit bushing
Swingarm spacer shaft
Hexagon head cap screw M5 x 0.80 x 40mm
Washer M5
Rubber stopper
Hexagon head cap screw M8 x 1.25 x 25MM
Button head socket cap screw M6 x 1.0 x 25MM
Washer M6
Limiter strap washer M8
Hexagon head cap screw M6 x 1.0 x 45mm
Rail cap
Slider shoe
Slide rail
Hexagon head cap screw M10 x 1.5 x 35MM
Washer M10 (spécial)
Rear axle outer spacer
Shim
Rear axle inner spacer
165mm idler wheel assy. (plastic)
Bearing 6205
Retaining ring
Rear axle shaft
Hexagon head cap screw M10 x 1.5 x 110MM
Nylon nut M10 x 1.5
Nylon nut M8 x 1.0
Nylon nut M5 x 0.80
Track tensioner block
Pivot shaft
REAR SUSPENSION, SHOCKS AND TRACK 12 - 6
SH-18A Suspension arrière
Ref.
P/N Qty Part desciptions
64
65
66
67
68
69
56
57
58
59
60
61
62
63
50
51
52
53
54
55
43
44
45
46
47
48
49
76
77
78
79
80
81
70
71
72
73
74
75
82
83
-
SH-63SA
023-00
BR14L
R3250C-1 001B
010-00
SH-424
SH-425
SH-428
503 163 700
414 942 300
No reference
No reference
014-00
SH-418
062-01
SH-419
018-00
R0100C-1 001A
SH-420
SH-426
SH-427
SH44-SA
SH43-SAD
013-00
503 188 930
C-375-2665-10375
11300-10362-5
181-190P
341-103P
30627P
SH-480
SH-447
SH-450
21652P
21663P
SH-446
23164P
23164F
SH-449
SH-48A
30633P
2
3
3
1
1
3
1
1
2
2
2
2
6
4
2
1
2
1
3
3
1
2
2
1
2
2
4
6
1
2
1
2
6
2
2
1
2
2
2
2
3
Lower shaft axle assy.
PVC spacer
Shim
83mm idler wheel assy. (plastic)
Wheel axle
Limiter strap
Aluminium shaft spacer
Upper limiter strap shaft
Lower shock eye steel bushing
Lower shock eye rubber bushing
Rear shock assy
Middle shock assy
Upper axle adaptor
Upper shaft spacer
Upper shock eye bushing
Spacer
Nylotron shim
100mm idler wheel assy. (plastic)
Upper shaft
Spacer
Spacer
Lower shock axle assy
Bushing housing (Right side)
Spring stopper
Spring cover
Spring 280 LB/IN
Rear shock KAYABA
Washer 1/2 (spécial)
Washer 3/16
Hexagon head cap screw M10X40
Wheel axe shaft
Extension plate angulé
Spacer (block tensionner track)
Socket head cap screw M8X25
Socket head cap screw M8X90
Aluminium adaptor
Hexagon elastic nut M8
Hexagon elastic flange nut M8
Spacer
Carburator assy
Hexagon head cap screw M10X70
SHOCK EXPLODED VIEW
1
11
10
11
REAR SUSPENSION, SHOCKS AND TRACK 12 - 7
9
2
7
6
8
12
4
3
5
13
REAR SUSPENSION, SHOCKS AND TRACK 12 - 8
Shock
Ref.
P/N Qty
6
7
8
9
1-13
1
2
3
4
5
10
11
12
13
11300-10362-5
11303-21209
11301-05056
11301-03303
11301-03006
11301-03805
11302-09919
11201-90604
11301-03021
11201-92151
11301-91030
11301-03207
11301-03922
11301-90513
1
1
1
1
1
1
1
1
3
1
1
2
1
1
Part descriptions
Shock assembly
Rod assembly
Shock body
Floating piston
O-ring
Piston bushing
Compressed air valve
Screw
O-ring
Label
Collar
Stop ring
Spring preload adjustment collar
Jam nut
REAR PAD
REAR SUSPENSION, SHOCKS AND TRACK 12 - 9
REAR SUSPENSION, SHOCKS AND TRACK 12 - 10
SH-24A Rear pad
Ref.
P/N Qty Part descriptions
5
6
7
8
9
10
11
12
13
14
15
16
-
3
4
1
2
SH-820
SH-821
SH-829
SH-830
284118
22205P
23162F
160-167P
SH-822B-L
SH-822B-R
23193P
23161P
S6-100P
K1610-40021
SH-144
165-176
2
3
3
3
1
1
16
16
25
11
2
7
2
1
1
1
UHMW Lower rear pad
UHMW Upper rear pad
Renforcement
Protector
Rubber hook ''Bungee''
Button Head cap screw M6 X 25
Hexagon elastic flange nut M6
Hexagon nut with free spinning washer M6
Rear pad bended plate left
Rear pad bended plate right
Button screw M5 X 16
Hexagon elastic nut M5
Flat washer 3/16''
3/16'' pop rivet large head aluminium black
Rear pad stopper block
Whell opening 4.2 X 13 black
REAR SUSPENSION, SHOCKS AND TRACK 12 - 11
Rear suspension adjustment
The rear suspension can be adjusted in two places
1- Rear spring preload adjustment.
2- Middle spring preload adjustment.
Spring tension
Loosen the jam nut # 1 .
Using the special tool # 3 , turn the spring preload adjustment collar # 2 , turning it CW to stiffen the rear suspension feeling and turning it CCW to soften the rear suspension feeling.
When the adjustment is finished, tighten the jam nut # 1 once more.
1- Jam nut
2- Spring adjustment ring
3- Special tool
Rear spring preload
The adjustment of the rear spring makes it possible to stiffen the suspension if it reaches the limit of its travel and to make it feel softer it the driver is the one absorbing the impacts instead of the suspension.
● NOTICE:
A properly set rear shock preload results in a 3-4” rear suspension sag with the rider on board.
Middle spring preload
Stiffen the middle spring : This puts less pressure on the front ski.
Softer the middle spring : This puts more pressure on the front ski.
3
1
2
REAR SUSPENSION, SHOCKS AND TRACK 12 - 12
Shock Maintenance
This type of shock absorber can be completely rebuilt. It can be calibred, the shims can be replaced, or the sealing rings can be replaced as need be. The driver can choose the precise adjustment that corresponds to his or her driving style.
DISASSEMBLY
Free nitrogen (N 2 ) pressure by removing the needle-type valve.
◆
WARNING
Nitrogen gas is under extreme pressure. Use caution when releasing this gas volume. Protective eye wear should be used.
Remove the shock absorber spring by unscrewing the pre-load collar and jam nut then by removing the spring retainer hat. To carry out these operations, use tool (P/N 861 7439 00).
Install the shock absorber in a vise then remove the shock body cap (complete) from the body of the shock absorber using a 32 mm (1.25 in) open-end wrench. Unscrew the cap in a counterclockwise direction.
● NOTICE:
Before unscrewing the pre-load collar and jam nut, mark their position so as to be able to reinstall them correctly. To find out their original adjustment, refer to the end of the present section.
Shock body cap (complete) has been removed, gently lift the rod of the shock absorber and remove it from the body.
REAR SUSPENSION, SHOCKS AND TRACK 12 - 13
● NOTICE:
Pull the rod of the shock absorber out gently to avoid spilling oil or damaging the top cap and seal with the threads on the body of the shock absorber. Wrap it in a cloth when removing the shock absorber piston to soak up any oil that might run down the sides.
Store the old oil in a container. Never re-use this old oil when rebuilding a shock.
Remove the needle-type valve. Using compressed air, carefully extract the floating piston from the body of the shock absorber.
Cover the opening of the shock absorber with a cloth to catch the floating piston. Make sure there is enough space in the cloth for the piston when it comes out.
◆ WARNING
Always wear safety glasses and use a compressed air gun approved by the O.H.S.A when working with compressed air.
Clean the body of the shock absorber thoroughly using an appropriate solvent. Dry it using compressed air and inspect it carefully to detect any imperfections or marks indicating wear in the bore. Replace the shock absorber in case of wear.
Put the shock absorber rod in a vise and then remove the piston and the shims.
REAR SUSPENSION, SHOCKS AND TRACK 12 - 14
After removing the parts, always lay them out in the order in which they were dismantled.
● NOTICE:
In general, it is recommended that the lock nut from the shock absorber rod be replaced after the absorber has been reassembled 4 times to ensure adequate locking friction.
● NOTICE:
If it is necessary to re-calibrate the valves, it is absolutely essential to identify the order in which the shims are stacked
(the number of shims and their thickness). The casing of the ring seal does not need to be removed if it is only an operation of re-calibration.
The shims can be measured using a sliding caliper or a micrometer.
The shock absorber rod is plated. It must be inspected in order to detect any visible marks of wear on the surface.
If there is a leak in the ring seal, it will be necessary to measure the camber of the rod which must not exceed 0.025 mm (.001 in).
Once the new shims or the replacement shims have been selected, reassemble everything by carrying out, in reverse order, the same operations as for dismantling. Tighten the piston nut between 11 and 13 N-m (1.1 and 1.3 kg-m, 8 and 9.5 lbf-ft)
▼ CAUTION
The nut for the rod of the shock absorber can only be used 4 times before it is replaced. Use only an original part to replace it; do not substitute any other kind of part for it.
Make sure that the number of washers between the nut of the shock absorber rod and the lock nut leave a sufficient number of threads for the nut of the shock absorber rod.
Install the lock nut with the rounded part facing down.
● NOTICE:
The stack of rebound shims must not touch the threads of the rod. The washer(s) under the nut on the rod prevent the nut from going to the end of the shoulder of the shock absorber rod.
REAR SUSPENSION, SHOCKS AND TRACK 12 - 15
REBOUND
Leave a play of about 0.203 mm (0.008 in) between the stack of shims and the lock nut.
When adjusting the shock absorber to increase the rebound damping, always use shims measuring 26 mm (1.02 in) against the piston to close the piston openings well. Even though the total thickness is the same, a large number of thin shims offer less damping effect than a small number of thick shims.
When adjusting the shock absorber to decrease the rebound damping, always use at least 3 shims measuring 26 mm (1.02 in) against the piston to prevent any breakage that could be caused by wear.
There are 4 kinds of pistons whose number of grooves varies between 0, 2, 4, and 6 according to the rapidity of the rebound.
These grooves offer variations in the damping in relation to the shims.
COMPRESSION
When adjusting the shock absorber to increase the compression damping, always use shims measuring 30 mm (1.18 in) against the piston to close the piston openings well. Even though the total thickness is the same, 2 thin shims offer less damping than one thick shim.
When adjusting the shock absorber to decrease the compression damping, always use at least 3 shims against the piston to prevent any breakage that could be caused by wear.
Always use at least one washer measuring 0.114 mm (the use of 2 or more is recommended) between the stack of shims and the lock nut washer so that the shims will have enough space to work.
During compression the grooves of the lock nut must face the stack of shims.
REAR SUSPENSION, SHOCKS AND TRACK 12 - 16
GENERAL INFORMATION
Calibrating the shock absorber so that there is too much damping is a frequent error. When this is done, the suspension has too much give. The suspension cannot carry out a complete extension after the compression caused by a bump.
After some time, the suspension becomes sluggish and no longer performs the movements of compression and extension efficiently.
Original Configuration
P/N Qty Rear Shocks
Shim Stack (Compression)
414 888 335 1 Damping shim Ø22 x 0.114
414 888 323 1 Damping shim Ø26 x 0.152
414 888 318 9 Damping shim Ø30 x 0.203
Calibrating the shock absorber so that there is not enough damping means the damping will either be insufficient or badly controlled.
P/N Qty
Original Configuration
Rear Shocks
Shim Stack (Rebound)
414 888 337 2 Damping shim Ø15 x 0.114
414 888 322 16 Damping shim Ø26 x 0.203
In such a case, the shock absorber moves up and down almost without any restriction. When going over a bump, the symptom most often noticed is that the snowmobile bounces.
REAR SUSPENSION, SHOCKS AND TRACK 12 - 17
● NOTICE:
Carry out a meticulous inspection of the shims and replace any bent shims in order to get perfect calibration.
Not having enough damping might lead to believe that bubbles have formed in the shock absorber because the gas pressure is not high enough. Although such a situation is rare, checking the gas pressure is recommended.
To replace the housing of the ring seal, use a ring seal guide
(P/N 529 0265 00) to guide the ring seal over the shock absorber rod. Lubricate the guide before using it.
▼ CAUTION
The ring seal will be damaged if the guide is not used.
Reassemble the shock absorber rod (complete) while taking care to correctly assemble the stack of shims according to the damping needed.
Install the floating piston in the body of the shock absorber. Use grease with a molybdenum bisulphide base (ex: G-N Molykote
Paste P/N 413 7037 00) to help the O-ring to pass more easily over the threads of the body of the shock absorber using the piston guide (P/N 529 0266 00).
REAR SUSPENSION, SHOCKS AND TRACK 12 - 18
● NOTICE:
Using G-N Molykote Paste (P/N 413 7037 00) lubricate the inside of the piston guide.
Install the piston to a depth of A = 131.0 mm (5.16 in) . Measure this distance starting from the upper end of the shock absorber.
● NOTICE:
If the floating piston is installed too far down in the body of the shock absorber, a light pressure exerted through the hole in the needle valve will push the piston up
◆ WARNING
Be very careful when using compressed air. Cover the opening in the shock absorber with a cloth to reduce any risk of injury.
◆ WARNING
There is a risk that compressed air containing humidity will contaminate the gas chamber and cause the floating piston to rust.
◆ WARNING
Always wear safety glasses when working with compressed air.
Replace the shock absorber oil by HGP Bombardier shock absorber oil (P/N 413 7094 00). Fill up to about 10 mm (0.393 in) from the base of the threads of the ring seal housing.
REAR SUSPENSION, SHOCKS AND TRACK 12 - 19
Insert the shock absorber rod (complete) in the body of the shock absorber. Lightly lubricate the ring seal of the piston with shock absorber oil to make installation easier.
Install the ring seal housing near the piston. Check the shock absorber oil capacity to make sure there is no air in the body of the shock absorber when it is being reassembled.
● NOTICE:
Some oil will spill during the installation of the shock absorber so wrap it in a rag to absorb this oil.
◆ WARNING
Take care not to damage the threads of the body of the shock absorber when inserting the piston.
It might be necessary to jiggle the rod slightly to make it easier to place the piston in the bore of the body of the shock absorber.
Gently insert the piston into the body of the shock absorber. A slight up-and-down movement might be needed to allow the air to pass through the piston (complete).
● NOTICE:
When the shock absorber rod is installed hastily, there is risk that the floating piston will be moved out of its initial position.
This will have a negative effect on the way the shock absorber works.
Place the piston of the shock absorber rod in the oil and add a certain quantity of oil up as far as the base of the threads of the body of the shock absorber.
The ring seal housing can now be screwed into the body of the shock absorber. Proceed gently to allow for the oil flow of the shock absorber.
REAR SUSPENSION, SHOCKS AND TRACK 12 - 20
ADJUSTING THE NITROGEN PRESSURE
Nitrogen (N
2
) can now be added to the body of the shock absorber. Replace the needle valve.
Adjust the pressure regulator to 2070 KPa (300 lb/in pressure at its optimum level.
2
) of nitrogen. This pressure will re-establish the shock absorber
▼ CAUTION
Do not exceed the recommended pressure.
◆ WARNING
Always wear safety glasses when working with high pressure gas. Never point gas under pressure at anyone.
● NOTICE:
Make sure there are no gas or oil leaks. Carry out any necessary repairs before going on the next step.
1. Hose
2. Regulator
4. Charging tool (needle)
REAR SUSPENSION, SHOCKS AND TRACK 12 - 21
Replace the spring retainer hat, then the spring. Next, screw the pre-load rings up to the spring. Adjust the pre-load according to the length of the spring. The shock absorber can now be installed on the vehicle. L = Position # 2
MISCELLANEOUS INFORMATION o Never replace nitrogen by another gas. Nitrogen was chosen for its qualities as an inert gas: since it is dry (no humidity) it does not contaminate the gas chamber of the shock absorber. o When stacking shims, 2 thin shims stacked together are as thick as one thick shim, but offer less resistance than the latter. Refer to the table SHIM EQUIVALENCE FOR
THE SAME DIAMETER as illustrated in this section #. o When stacking shims for rebound, always use shims measuring 22 mm (0.87 in) in diameter against the piston. Use at least 3 shims for the stack to avoid bending or breaking. Leave a play of about 0.203 mm
(0.008 in) between the stacks of shims and the lock nut washer. o When stacking shims for compression, always use shims measuring 30 mm (1.181 in) in diameter against the piston. Use at least 3 shims for the stack to avoid bending or breaking. Install at least one washer measuring 0.114 mm (installing 2 or more of them is recommended) between the stack of shims and the lock nut washer.
REAR SUSPENSION, SHOCKS AND TRACK 12 - 22
TRACK ALIGNMENT
▼ CAUTION
The track of each SNOW HAWK
TM
was aligned and adjusted in the factory but it is recommended that the following be checked. o The alignment of the track
1. Guides
The track must have a free deflection of about 40 mm (1 ½”), just below the lower pivot of the swing arm (which is the midpoint of the rail), when the rear of the vehicle is supported and the track is hanging freely.
REAR PAD
The rear pad is essential to the Snow Hawk’s first-rate handling.
▼ CAUTION
Never take the rear pad off your vehicle.
Operating the Snow Hawk without its rear pad could cause the engine to overheat which could result in serious engine dammage.
Operating the vehicle without its rear pad could render nil the WARRANTY coverage of your vehicle.
REAR SUSPENSION, SHOCKS AND TRACK 12 - 23
REAR PAD ADJUSTMENT
Depending on snow conditions, the rear pad will need adjustments.
If snow conditions are as follows:
- Trail or hard surface;
- Icy surface;
Both rubber latches on the rear pad must be attached.
If snow conditions are as follows:
- Powdery trail or surface;
- Deep powdery snow;
The rear pad must be curved and attached.
▼ CAUTION
If the Snow Hawk’s rear pad is not curved and is not attached in deep snow conditions, it could be dammaged as a result.
▼ CAUTION
If the engine overheat indicator lights up, even while operating the vehicle in plenty of snow, immediately attach the rear pad’s rubber latches.
▼ CAUTION
If the rear pad is dammaged, it must immediately be repaired or replaced.
▼ CAUTION
It is crucial to follow all Snow Hawk rear pad adjustment guidelines.
PLEASE NOTE THAT OPERATING THE SNOW HAWK
WITHOUT ITS REAR PAD COULD RENDER NIL THE
WARRANTY COVERAGE OF YOUR VEHICLE.
REAR SUSPENSION, SHOCKS AND TRACK 12 - 24
EXTENSION PLATE ADJUSTMENT
There are two possible positions for the extension plate
The tilted position allow the snowhawk to improve its speed and its handling
The right position gives better performance on soft snow
CHAPTER 11
FRONT FORK AND TWIN-AXIS SKI
FRONT FORK AND SKI 11 – 1
FRONT FORK AND SKI 11 – 2
FORK LEG
7
6
4
3
8
1
3
1
9
2
5
2
Ref.
6
7
4
5
8
9
-
1-8
1
2
3
P/N
791 464 018
849 350 102
849 310 511
849 340 059
849 311 568
849 350 103
949 409 761
949 603 733
949 313 954
29516P
FRONT FORK AND SKI 11 – 3
Qty
1
1
1
1
1
2
1
1
1
1
Fork leg
Parts descriptions
Fork leg assembly
Cartridge
Inner tube
Fork seal and bushing kit
Top cap assembly
Compression valve assembly
Outer tube
Lower spring seat
Spring
Hexagone head flange bolt M6 x 30 mm
FRONT FORK AND SKI 11 – 4
FORK ASSEMBLY
2
19
7
6
8
8
19
2
7
1
7
6
8
1
7
8
16
17
16
17
13
14
15
5
18
21
12
4
12
20
20
10
18
9
10
9
11
3
Ref.
7
8
9
5
6
3
4
1
2
10
11
12
17
18
19
20
21
-
13
14
15
16
P/N
791 464 018
SH-028
SH-147
SH-019
SH-059
SH-066
29516P
23162F
SH-051
21623P
23162P
20171P
SH-060
342-121P
20280P
SH-044
236-306
P.64.12
SH-050
SH-135
SH-149
FRONT FORK AND SKI 11 – 5
8
8
2
1
2
1
1
2
2
4
2
2
2
2
1
2
2
1
2
1
1
SH-41A Fork assembly
Qty Parts descriptions
Front fork leg USD 46 mm PAIOLI
Triple clamp
Aluminum fork adaptor (Sport Trail)
Lower clamp
Aluminum fork shaft
Fork lower steering bushing
Hexagone head flange bolt M6 x 30 mm
Flanged locknut M6
Steel bushing
Socket head bolt M6 x 20 mm
Locknut M6
Hexagone head bolt M6 x 75 mm
End shaft bushing
1/2'' spring lock washer
Hexagone head bolt M12 x 85 mm
Fork collar
O-ring
Hardened bushing 3/4'' I.D. 1'' O.D. x 3/4''
Fork MOS2 bushing
Lower clamp collar
Shim
FRONT FORK AND SKI 11 – 6
ENSEMBLE DE SKI
10
1
5
13
2
6
12
11
8
7
9 13
13
12
8
11
4
13
9
3
6
12
5
15
16
14
15
16
14
FRONT FORK AND SKI 11 – 7
Ref.
13
14
15
16
-
9
10
11
12
5
6
7
8
3
4
1
2
P/N
RD0170
SH-31SA
SH-309
SH-310
ST-201
SH-831
SH-145
P05000050090A
P05000050095A
20279P
341-109P
23167F
12 462 100 001
22205P
23162P
SH-828
SH-25A Ski assembly
Qty Parts descriptions
2
2
4
2
2
3
2
1
2
2
1
2
1
1
1
1
Ski (black)
Base plate
Adaptor plate
Rubber ski cushion
Runner * Snow Tracker *
Carbide runner 60 o
Rubber positionner
Polyurethane bushing * RED *
Polyurethane bushing * GOLD *
Hexagone head bolt M12 x 80 mm
W asher
Flanged locknut M12
Flanged locknut M10
BHCS M6 x 25
Locknut M6
Spécial washer
FRONT FORK AND SKI 11 – 8
FRONT FORK
Removal o Loosen the fork leg top cap before removing the leg from its supports.
Disassembly o Clean the fork.
● NOTICE:
The Paioli tool kit (P/N 449 450 020) is needed to perform modifications such as seal replacements and complete fork disassembly. For smaller operations such as fluid changes and/or compression valving adjustments, the supplied special tool is sufficient.
▼ CAUTION
Scratches or other damage to inner tube surfaces or gasket edges may cause oil leaks.
Scratches and other damage must be avoided. Use a mild detergent or an automobile cleaning product to dislodge any dirt.
▼ CAUTION
An inadequate dismantling of the fork leg top cap may damage the rebound adjustment needle resulting in a malfunction of the system.
To prevent such a situation, set the rebound adjustment to its fastest position (by turning it counterclockwise) before taking the cap off.
Take note of the initial position of this adjustment by counting the number of "clicks" between the initial position and the point where a slight resistance is felt
(turning clockwise). o Unscrew the fork leg top cap completely while holding the outer tube. Lower the outer tube slowly until it comes into contact with the lower section of the inner tube. o Using your hand, push the top part of the spring down to provide enough space to insert the open end of a spanner wrench.
Coupling nut
Fork top cap
Swingarm bushing
(SH415) holder
Snow Hawk Special Tool
o Unscrew the lock nut (C) from the piston rod and remove the fork leg top cap (B). o Remove the upper spring retainer (R), the lock nut (C), the fork spring guide (G) and the O-ring (F).
● NOTICE:
When the fork leg is turned upside down, the push rod, the needle and the return spring will fall from the piston rod. It is possible to collect them by turning the strut over slowly and keeping a finger near the tip of the piston rod.
▼ CAUTION
A damaged piston rod, needle or return spring may affect performance on the rebound stroke.
Be careful not to lose or damage any of those parts. o Depress the piston rod (S) completely 8 to 10 times to force all the oil out.
FRONT FORK AND SKI 11 – 9
FRONT FORK AND SKI 11 – 10 o Install the lower part of the inner tube in a vise.
▼ CAUTION
Exerting too much pressure on the lower part of the inner tube can damage it and affect the stability of the ride.
Do not overtighten. o Remove the rubber cap (M) located under the lower part of the inner tube. o Remove the spring stop washer (S). o Unscrew and remove the cartridge, by inserting a 14 mm allen key in the compression adjustment, and by inserting the special "T" tool (T) (long tube, three prongs at one end) provided with the maintenance tool kit into the cartridge head.
● NOTICE:
Before unscrewing the cartridge, make sure the special tool (T) is well fitted into the socket in the cartridge head. o Empty the content of the cartridge (L) by pumping the piston rod (G) several times, until the cartridge is empty.
◆ WARNING
Never attempt to modify the cartridge!
Refer to authorized personnel to carry out this operation.
Modifications to the cartridge carried out by an unauthorized person can compromise the security of the operator and invalidate the warranty. o Move the outer tube slowly back and forth for a few complete strokes to make sure it is in good working order. o Remove the dust seal (M).
▼ CAUTION
Scratches on the outer tube will cause oil leaks.
Be careful not to scratch the outer tube while removing the dust seal. o Use a flat screwdriver to remove the dust seal. o Remove the stop ring. o With a few sharp blows, pull the outer tube (P) out to separate it from the inner tube (A). o The oil seal (T), the washer (Q), the dust seal (M) and the inner (R) and outer (S) bushings can be found on the inner tube. They must be removed and replaced with new parts.
FRONT FORK AND SKI 11 – 11
FRONT FORK AND SKI 11 – 12
Reassembly o Remove all the elements from the inner tube, one at a time, and clean the tube. o Replace the seals and bushings with new ones, following the prescribed sequence. (See the illustration)
● NOTICE:
While installing seals, wrap the end of the strut with a band of adhesive tape so that the seals will not be damaged by the sharp edge. o Make sure the bushings (S & R) are well inserted in their respective positions by using the special tool (W) designed for that purpose and included in the fork maintenance tool kit.
◆ WARNING
The oil and dust seals (T & M), contrary to the bushings
((S & R) and the washer (Q), must absolutely be installed on the inner tube in a specific direction for the fork to operate properly.
o Once the bushings (S & R) are correctly installed, use the other end of the special tool (W) to insert the washer
(Q), and then the oil seal (T). o Re-install the stop ring (O). o Re-install the dust seal (M). o Using a 14 mm allen key and the special tool (T), reinstall the cartridge (L) the compression adjustment (Z”) and the washer (A). o Use a torque wrench to tighten the cartridge to 25 N-m
(2.5 kg-m, 18.4 lbf-ft) .
FRONT FORK AND SKI 11 – 13
FRONT FORK AND SKI 11 – 14
● NOTICE:
Before adjusting the torque, make sure the special tool (T) is well fitted into the socket at the end of the cartridge. o Re-install the rubber cap (M). o Install the spring stop washer (S). o Make sure the O-ring (OR) is still in place. If not, reinstall it and push it against the stroke stop (F) to secure it. o Install the spring guide (G). o Install and screw the lock nut (C) up against the guide until a slight resistance can be felt. o Hold the fork leg in a vertical position, fully compressed, and fill it with fork fluid up to 50 mm (2 in) from the top of the outer tube.
Recommended fluid: Cartridge fork fluid, S.A.E. 15W o Move the piston rod in and out, in a series of complete alternating strokes, until a continual resistance can be felt during a complete stroke.
● NOTICE:
It is possible that fluid will have to be added a few times before reaching the point where a continuous resistance can be felt during a complete stroke.
◆ WARNING
Keep a finger pressed against the opening of the piston rod since the needle, if it has not been taken out, can be ejected during this operation. If this happens, re-install the needle after the operation has been completed.
o With the fork leg still in a vertical position and fully compressed, adjust the fluid level.
Recommended level: X = 85 mm (3-5/16 in)
● NOTICE:
It may be necessary to add or remove some fluid to reach the recommended level.
▼ CAUTION
The fluid level can be modified but must remain between
85 mm and 120 mm. o Insert the needle return spring, the needle and the push rod. o Install the spring (F) inside the strut (P).
● NOTICE:
When the coils are closer to one another at one end of the spring, this end must be placed facing the upper part of the fork leg (i.e. towards the top cap). o Install the upper spring retainer (R) and the top cap (B) of the strut.
FRONT FORK AND SKI 11 – 15
FRONT FORK AND SKI 11 – 16 o The top cap (B) must be screwed on until the piston rod
(G) touches the bottom of the cap (B) before the cap comes into contact with the lock nut (C). The space between the cap (B) and the nut (C) must be between 1
- 2 mm (0.040 – 0.080 in) . o Using your hand, push the top part of the spring down to provide enough space to reach the lock nut (C) with the open end of a 17 mm wrench. o Use a torque wrench and the special tool to adjust the torque to 18 – 20 N-m (1.8 – 2.0 kg-m, 13.2 –14.75 lbfin) .
o Screw the strut top cap onto o the outer tube. Again, use the torque wrench and the special tool to adjust the torque to 25 N-m (2.5 kg – m,
18.4 lbf-in) .
INSTALLATION
Follow the same procedure as for the removal but in the reverse order.
Adjustment of the front fork o Compression
Using a screwdriver, it is possible to choose a precise setting for the speed of compression from a range of 26 positions, depending on the conditions of the terrain and the purpose for which the vehicle is used.
+ Æ Stiffer (Slower)
- Æ Softer (Faster) o Rebound
Using a screwdriver, it is possible to choose a precise setting for the speed of rebound from a range of 28 positions, depending on the conditions of the terrain and the purpose for which the vehicle is used.
+ Æ Stiffer (Slower)
- Æ Softer (Faster)
FRONT FORK AND SKI 11 – 17
FRONT FORK AND SKI 11 – 18
TWIN AXIS SKI
The basic idea is that the ski can now stay flat when the vehicle is at a lean angle of up to approximately 12 o
. Its’s the gold and red polyurethane bushings that permits such movement and the adjustment of the two locknuts permits (No. 1 at right) can make a significant difference to the handling characteristics of the vehicle.
1
Tightening the nuts: o Tightening the nuts (No. 1 above right) will compress the polyurethane bushings and allow less lean angle.
The resulting stiffer front end will be more responsive and have a quicker turning feel. Recommended for deep powder snow condition.
o ALWAYS adjust the two locknuts together.
Loosening the nuts: o Loosening the nuts (No. 1 above right) will allow the polyurethane bushings to extend more and make the front end feel very forgiving. The stock settings have
1/4” (6.5mm) of thread protruding above the end of the locknuts, which is great for a novice rider and is near the minimum preload setting possible for the bushings. DO
NOT slacken the locknuts further than the stock settings. A large inclination angle is recommended for hard pack conditions and groomed trail riding.
o ALWAYS adjust the two locknuts together.
Inclination
(recommended)
8 - 10 o
Conditions
Groomed trail
Hard pack
4 - 8 o
Deep powder
0 - 4 o
Snow cross
Race track
1
Standard configuration
( Allow’s 8-10 degrees of inclination )
SNOW TRACKER
The * Snow Tracker * has bean designed to increase the responsiveness and steering accuracy of you vehicle when trail riding as well as act as an anti-darting mechanism. IF you use your vehicle off-trail or in powder snow conditions, you can use the Snow tracker device or you can remove it, we encourage to use whatever works best for you. In certain powder snow conditions, it may be preferable NOT to use this device.
For any hard pack, icy surface or well-groomed trail, we strongly recommended that you use the Snow Tracker device.
FRONT FORK AND SKI 11 – 19
HYDRAULIC BRAKE SYSTEM 10 - 1
CHAPTER 10
HYDRAULIC BRAKE SYSTEM
HYDRAULIC BRAKE SYSTEM 10 - 2
HYDRAULIC BRAKE SYSTEM
12
7
6
11
11
7
6
2
14
15 (5x)
4
13
8
3
8
25 N-m (220 lbf-in)
10 (5x)
9
17
16
5
1
14 N-m (125 lbf-in) 16
14 N-m (125 lbf-in)
Follow the suggested sequence
Chapter 9
Ref.
6
7
8
9
10
11
12
13
14
15
16
17
-
1
2
3
4
5
P/N
10.6707.81
20.6951.50
107.6949.11
SH 048
TDSH7-3116
SH 039
053.8.45
23164
1215X30
22204P
06.2196.13
06.2228.42
110.4671.91
70.3003A
24411
149-161
293 800 060
HYDRAULIC BRAKE SYSTEM 10 - 3
Hydraulic brake system
Qty Parts description
2
2
2
1
5
1
1
5
2
@
2
1
1
1
1
1
1
Master cylinder
Caliper
Replacement brake pad
Brake hub
Brake disc
Brake caliper spacer
Hexagon head cap screw M8 x 1.25 x 45MM
Nylon nut M8 x 1.25
* Taper lock *
Botton head cap screw M6 x 1.0 x 20MM
Copper washer
Banjo bolt
Microswitch
Steel braided brake line
Stove nut M6 x 1.0
Socket set screw 3/8-16 unc x 5/8''
Loctite 243, 10 ml
HYDRAULIC BRAKE SYSTEM 10 - 4
Removal/Installation of Brake Disc and/or Hub
To gain access to the brake system, the cab and belly pan must be completely removed. See Chapter 1 – General
Instructions for details.
To remove the brake disc and/or hub, the brake caliper must first be rotated up and out of the way. To do this, the lower M8 bolt that holds the caliper in place must be removed from inside the tunnel. The nut that holds this bolt in place is shown at the right.
Retainer
● NOTICE:
If the intent is to change brake pads only, the caliper must be completely detached from the chassis of the vehicle with the brake line remaining secure.
Holding this nut with an open-end wrench, remove the bolt from inside the tunnel with a socket and ratchet.
Loosen the other (upper) bolt holding the caliper tight to the chassis as well, then swing the caliper up and clear of the disc.
Re-tighten the upper bolt and nut enough to hold the caliper in this “swung up” position. Now completely clear from the brake disc itself, the disc can be removed either with or without the aluminum hub.
Brake Disc Only: Remove the five M6 x 16 button head bolts.
(Reference No. 10 in the exploded view at the beginning of this chapter)
Brake Disc and Hub: Follow the procedure outlined on page 9-3 of Chapter 9 – Secondary Transmission System that outlines the removal of the Taper-Lock bushing and hub.
Cleaning and Inspection
Clean the brake parts with an all-purpose cleaner. Dry the parts well with compressed air when finished.
▼ CAUTION
Do not clean the brake pads with the cleaner. Brake pads must be replaced with new ones.
Clip
Pin
Lower Bolt/Nut
Verify that the thickness of the pad material (as shown between the arrows in the photo at the right) is greater than 1 mm (1/32 in). If the thickness is found to be less than this, replace the pads.
▼ CAUTION
Always replace the brake pads as a set.
Brake Pad Replacement:
To replace the brake pads, proceed as follows: o Completely remove the caliper from the chassis of the vehicle by removing the two bolts that secure it. o Remove the clip at the end of the pin, shown in the picture on page 10-3 of this chapter. o Using a steel punch and a hammer, push the pin completely out of the brake caliper casting. Be sure to push the pin from the side shown in the picture at the right. o Remove the retainer clip shown in the picture on page
10-3 of this chapter. o Remove the pads and replace with a set of new ones.
Re-assemble the brake caliper and reinstall it on the chassis following the steps outlined above in the reverse order.
Brake Disc :
Verify whether the brake disc is scratched, cracked or discolored by heat and replace as required.
▼ CAUTION
Never machine the brake disc.
HYDRAULIC BRAKE SYSTEM 10 - 5
HYDRAULIC BRAKE SYSTEM 10 - 6
Re-/Installation of Brake Disc and/or Hub
Brake Disc Only: Install the five M6 x 16 button head bolts with
Loctite 243 and torque to 14 N-m (125 lbf-in) . (Reference No.
10 in the exploded view at the beginning of this chapter)
Brake Disc and Hub: Follow the procedure outlined on page 9-4 of Chapter 9 – Secondary Transmission System that outlines the installation of the Taper-Lock bushing and hub. As an alignment reference, the brake disc must ride approximately midway between the two brake pads.
Re-attach the caliper to the chassis by securing the two mounting bolts that hold it in place and torque each to 25 N-m
(220 lbf-in) .
Adjustment / Maintenance
Change the brake fluid each year.
It is very important to have a sufficient amount of brake fluid in the reservoir at all times to avoid the creation of air bubbles in the system. If air should become trapped in the system, follow the procedure outlined below.
Pump the brake lever several times to build pressure in the system. While holding the lever in the “brakes applied” position with force, slightly unscrew the bleeder valve with a wrench (see figure at right) to ensure that all air is purged from the system.
As the brake lever approaches the handlebar, re-tighten the bleeder valve.
Repeat several times or until the flow of fluid from the bleeder valve is completely free from air bubbles.
Ensure that the bleeder valve is tight and the rubber cover is placed over the fitting for protection when finished.
Brake Fluid
DOT 4 ( DOT 5 for intense use)
● NOTICE:
Never use DOT 4 brake fluid for intense or competition use.
Brake Fluid Level
Refer to Section 2.5 of Chapter 2 – Periodic Maintenance for details.
SECONDARY TRANSMISSION SYSTEM 9 - 1
CHAPTER 9
SECONDARY TRANSMISSION SYSTEM
SECONDARY TRANSMISSION SYSTEM 9 - 2
SECONDARY TRANSMISSION SYSTEM
12
1
3
13
19
14
11
14
10
17
4
14 N-m (125 lbf-in)
Follow the suggested sequence
5
6
6
9
4
2
5
6
6
19
11
14
14
16
7
18
14 N-m (125 lbf-in)
Follow the suggested sequence
13
15
7
8
9
13
Ref.
10
11
12
13
14
15
16
17
18
19
-
8
9
6
7
3
4
1
2
5
SECONDARY TRANSMISSION SYSTEM 9 - 3
P/N
SH-26A
SH-203R
SH-260
SH-204
184-153
6004-2RS KML
341-108P
441.1
30632P
90974 A116
1215X30
1360PTH8M-60
SH-202
149-163
23166P
SH-259
SH-266
414 348 200
293 800 060
Secondary transmission system
Qty Parts description
1
2
1
6
4
1
1
1
1
@
1
2
4
2
1
2
1
1
2
Torque limiter assembly
Tensioner sprocket 28T
Drive sprocket 30T
Tensioner sprocket shaf t
Retaining ring
Roller bearing, tensioner
Washer
Split spring lock washer
Hexagon head cap screw M10 x 1.5 x 65MM
Sliding T-nut
Taper lock
60MM Panther belt
Flange
Socket set screw 3/8-16 unc x 5/8''
Hexagon elastic nut M10
No-teeth pulley
Tentionning plate
Tensioning tool
Loctite 243, 10 ml
SECONDARY TRANSMISSION SYSTEM 9 - 4
TORQUE LIMITER SYSTEM
7 (6x)
4
9
8 (2x)
3
6 N-m (55 lbs-in)
6
5
10 N-m (89 lbs-in)
1
10 N-m (89 lbs-in)
8 (2x)
4
6
5
9
2
Ref.
7
8
9
-
5
6
1
2
3
4
SECONDARY TRANSMISSION SYSTEM 9 - 5
P/N
TL-003
TL-001
TL-002
TL-004
TL-005
6525K1 O.D. 5"
22320AI
22097P
293 800 060
SH-26A Torque limiter system
Qty Parts description
6
4
2
2
@
1
1
1
2
Drive sprocket 56T
Hub
Aluminum threaded disk
Outside pressure plate
Inside pressure plate
Wearing pad
Socket set screw M8 x 1.25 x 20MM
Flat head socket cap screw M6 x 1.0 x 8MM
Loctite 243, 10 ml
SECONDARY TRANSMISSION SYSTEM 9 - 6
Removal of cog belt
To gain access to the entire secondary transmission system, you must first completely remove the cab and belly pan. See
Chapter 1 – General Instructions for details. o Loosen the bolt that holds the tensioner sprocket in place. (See top picture at the right) o Remove the tension on the cog belt system by unscrewing the tensioning bolt shown in the top picture at the right. Continue until the belt is no longer tight against the teeth of the tensioner sprocket.
ALTERNATIVELY , if you wish to leave the belt tension as-is, you can simply remove the bolt that runs through the center of the tensioner sprocket and leave the tensioning bolt as-is.
• o Remove the tensioner sprocket completely. ( # 2 on secondary transmission system )
1 o Remove the two setscrews that hold the taper lock and the 28-tooth upper drive sprocket in place. (Position 1)
Using a punch, hit the taper lock 2-3 times in the shaded zone shown at right (Position 5) to loosen the grip between the taper lock and the sprocket.
2
● NOTICE:
If either of the installation holes (shown as ”Position 1“ in the picture in the sidebar at the right) becomes damaged, the taper lock can be rotated 45 o CCW in the sprocket bore and can then use the installation holes shown in “Position 3”. o Insert and thread in one of these two setscrews into the extraction hole (Position 2), at a maximum torque of 14
N-m (125 lbf-in).
The sprocket and taper lock assembly should now be free to slide off the shaft. o At this point, begin to slide the belt off of the lower 56 tooth drive sprocket and simultaneously slide the entire
28 tooth driven sprocket assembly and belt off the jackshaft as shown in the picture at the right.
4
Tensionning screw
Tentioner sprocket screw
.
.
. .
.
. .
5
3
Installation of Cog Belt
Installation of a new cog belt is essentially the same as the steps outlined above, but in reverse order. One must pay special attention to the re-installation of the taper lock system:
SECONDARY TRANSMISSION SYSTEM 9 - 7
1. Thoroughly clean the jackshaft and sprocket bore.
2. Align the 28-tooth sprocket and taper lock flush with the end of the jackshaft.
3. Applying Loctite 243, install the two installation set screws into position 1 or 3.
4. Torque the two set screws to 14 N-m (125 lbf-in)
5. Tap the taper-lock face several times in the shaded region with a steel punch and re-tighten the setscrews.
6. Tap again and re-torque to 14 N-m (125 lbf-in) .
◆ WARNING
Loctite 243 must be used for both installation setscrews to prevent them from loosening under use. Failure to do so could result in personal injury.
Hand-tighten the tensioner sprocket bolt (Ref. No. 9 in the exploded view) and then proceed to re-apply tension to the system by tightening the tensioning bolt.
When tensioned properly, the secondary transmission system must have a deflection of 7.3 mm (0.288”) under a load of 6.44 kg (14.2 lbs) applied midspan between the upper most and lowest cog sprockets. This tension must be verified using special tensioning tool P/N 414348200. The picture at the right demonstrates how to use a straightedge as a reference when verifying this value and also where the measurement should be taken.
▼ CAUTION
Failure to provide or verify the correct tension in the secondary transmission system could lead to premature belt and/or component failure.
SECONDARY TRANSMISSION SYSTEM 9 - 8
Inspection of Secondary Transmission System o Check that the roller bearings in the tensioner sprocket bore are functioning properly. o Check for excessive dry surface cracking of the rubber in the cog belt. If excessive surface cracks are present, replace belt. o Check that the secondary transmission system is dry and free of dirt, grime or debris. If necessary, clean the belt and sprockets with a non-corrosive cleaner.
◆ WARNING
Never operate the vehicle with the cab and/or bellypan removed. Failure to do so could result in personal injury.
TORQUE LIMITER SYSTEM
DISASSEMBLY o Lightly loosen the 6 Allen bolts (part # 7 on the exploded view of the torque limiter) in a criss-cross pattern. o The threaded aluminum disc (part # 3 on the exploded view) can now be removed by hand.
SECONDARY TRANSMISSION SYSTEM 9 - 9 o After removing the threaded aluminum disc proceed to removing the core, the pressure plates and the friction plates. Next, remove the small Allen screws holding the final pressure plate to the cog sprocket and remove the pressure plates.
CLEANING o All of the torque limiter components should be clean before reassembly. The parts can be cleaned using brake cleaner.
INSPECTION
● NOTICE:
Because so much dirt and dust accumulates inside the torque limiter, it should be periodically cleaned and inspected.
◆ WARNING
After approximately 10 hours of use, it is necessary to verify the torque of the 6 allen head screw ( part # 7 ) of the torque limiter. The required torque for normal operation is 6 N-m ( 55 lbf-in ). o Verify the friction plates (part # 6 ) to ensure that they are not cracked or damaged. Replace if required. o Verify the pressure plates # 4 and # 5 to ensure they are not scratched. If so then they can be repaired using a fine sand paper or released.
o Verify that the cog sprocket is not damaged. If damaged, replace with a new one.
SECONDARY TRANSMISSION SYSTEM 9 - 10
REASSEMBLY o Install pressure plate # 5 inside the cog sprocket # 1 using the small Allen screws # 8 . Use loctite 243 on the
Allen screw and torque to 10 N-m (89 lbf-in).
o Reassemble the torque limiter as shown in the exploded view on page 9-3. o Once the pressure plates # 4 and the friction plates # 6 are properly installed, hand tighten the threaded aluminum disc # 3 until it stops; then loosen by a ½ turn. o To complete reassembly, tighten the 6 Allen bolts # 7 in a criss-cross pattern to a torque of 6 N-m (55 lbf-in).
INSTALLATION
Install the torque limiter as described in the previous section on installation of the secondary drive cog belt. o Lift up and immobilize the rear of the vehicle and place it on a mechanical support.
◆ WARNING
Make sure that the track is free of anything that could be projected out of its rotation field. Make sure that no one is near the vehicle. o Have the vehicle accelerate at low speed (maximum 30 km/h or 20 mi/h) and apply the brake. Repeat 5 times. o Ensure that the torque of the 6 Allen bolts # 7 is still at
6 N-m (55 lbf-in).
◆ WARNING
After approximately 10 hours of use, it is necessary to verify the torque of the 6 allen head screws ( part # 7 ) of the torque limiter. The required torque for normal operation is 6 N-m ( 55 lbf-in ).
PRIMARY TRANSMISSION SYSTEM 8-1
CHAPTER 8
PRIMARY TRANSMISSION SYSTEM
PRIMARY TRANSMISSION SYSTEM 8-2
PRIMARY TRANSMISSION SYSTEM / PRIMARY CLUTCH
2
21
5
4
3
23
Color 1
6
24
15
18
16
17
16
33 9
15
7
8
Color 2
32
11
10
1
33
26
27 26
25
31
30
22
29
28
19
20 21
14
13
12
P/N
XXX
417222167
417222171
417222758
293370037
417 222 312
414689500
417009205
417007500
417009204
250200009
205084044
250000059
417222552
250400009
417222362
732401030
417005700
417 222 213
417005500
417 005 600
233061414
234061410
250200006
417120000
732958001
417004302
417003900
417222594
232561414
417222671
417222633
417222028
413703100
Ref.
12
13
14
15
16
17
18
19
27
28
29
30
31
32
33
-
23
24
25
26
20
21
22
8
9
10
11
6
7
4
5
2
3
@
1
PRIMARY TRANSMISSION SYSTEM 8-3
Qty
Primary clutch
Part Descriptions
1
2
2
2
1
1
1
1
1
1
1
1
1
1
@
1
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
Drive pulley ass'y
Fixed flange
Sliding flange ass'Y
Bushing
Circlip
Spring seat
Spring blue/yellow
Protector
Spring cover ass'y
Bushing
Lock washer 8mm
Socket head cap screw M8x40
Hexagonal flange cap screw M6x18
Ramp
Rolled pin 10 x 32
Slider shoe
O-ring
Spring
Governor cup
Calibration screw
Washer
Hexagonal flange nut M6
Flat washer M6
Conical spring washer 14mm
Drive pulley bolt
Cotter pin
Stopper washer
Roller ass'y
Pin
Hexagonal nylon nut M6
Lever ass'y
Bushing
Screw ass'y
Locktite 609, 10ml
PRIMARY TRANSMISSION SYSTEM 8-4
PRIMARY TRANSMISSION SYSTEM / SECONDARY CLUTCH
26
27
6
5
4
25
26
14
13
7
10
9
8
19
18
15
3
17
16
12
11
28
21
20
13
22
24
23
Ref.
11
12
13
14
7
8
9
10
15
16
17
18
19
20
21
25
26
27
28
-
22
23
24
2
3
@
1
4
5
6
P/N
XXX
417 126 734
417 126 733
417 126 722
417 126 322
417 126 381
417 126 688
417 126 878
417 126 902
371 911 200
417 126 901
417 126 373
417 126 374
210 251 180
417 126 698
417 126 909
504 099 600
504 112 300
417 126 807
504 151 831
415 005 800
415 005 900
207 162 544
517 302 322
20207P
417 300 238
BR16L
138-4628U3
413 703 100
PRIMARY TRANSMISSION SYSTEM 8-5
Qty
Secondary clutch
Part Descriptions
2
1
3
3
1
1
1
1
1
1
1
1
1
1
3
1
2
1
@
3
1
1
1
1
1
1
1
1
1
Secondary clutch assembly
Half key
Spacer
Cam 50-40
Swivel abutment
Guard
Spring, green
Circlip
Bushing
Circlip
Bushing
Rear cam slider shoe
Front cam slider shoe
Hexagon forming screw M5x11
Cover
Sliding flange ass'y
Stopper washer
Shim
Fixed flange ass'y
Aerodynamic cover
Adjustment ring
Adjustment shim
Hexagonal cap screw M6x25
Strenght washer
Hexagonal cap screw M8x60
Protector
Shim
Drive belt
Loctite 609
PRIMARY TRANSMISSION SYSTEM 8-6
GENERAL INFORMATION (PRIMARY CLUTCH)
Some drive pulley components (return spring, ramp) can be changed to improve vehicle performance in high altitude regions. A service bulletin will give information about calibration according to altitude.
▼ CAUTION
Such modifications should only be performed by experienced mechanics since they can greatly affect vehicle performance. Verify spring specifications before installation. Do not only refer to the spring color code.
● NOTICE:
TRA drive pulley stands for Total Range Adjustable drive pulley.
◆ WARNING
Any drive pulley repairs must be performed by an authorized Snow Hawk dealer. Sub-component installation and assembly tolerances requires strict adherence to procedures detailed.
REMOVAL
23, 24, Conical Spring Washer and Screw o Use holder (P/N 529 035 674). o Insert the tool in sliding flange tower
◆ WARNING
Never use any type of impact wrench at drive pulley removal and installation o Remove screw. o To remove drive pulley ass’y and/or fixed half from engine, use puller (P/N 529 022 400) for liquid cooled models.
PRIMARY TRANSMISSION SYSTEM 8-7
▼ CAUTION
These pulleys have metric threads. Do not use imperial threads puller. Always tighten puller by hand to ensure that the drive pulley has the same type of threads (metric vs imperial) prior to fully tightening.
TO REMOVE DRIVE PULLEY ASS’Y o Retain drive pulley with clutch holder. o Install puller in pulley shaft then tighten
DISASSEMBLY
Screw and Ring Gear
▼ CAUTION
Retaining screws must be heated before disassembly. Do not exceed 150 ° C (300 ° F).
1, 2, Fixed and Sliding Half
▼ CAUTION
Do not tap on governor cup.
Screw puller into fixed half shaft about 13 mm (1/2 in). Raise drive pulley and hold it by the sliding half while knocking on puller head to disengage fixed half.
● NOTICE:
No components marking is required before disassembling this drive pulley since it has factory mark and arrows as indexing reference
1- Puller
2- Holding sliding half
PRIMARY TRANSMISSION SYSTEM 8-8
Cushion Drive
▼ CAUTION
Do not disassemble cushion drive. Governor cup and cushion drive are factory balanced as an assembly.
15, 18, Slider shoe and Governor Cup o Carefully lift governor cup until slider shoes come at their highest position into guides. o Hold a slider shoe set then carefully lift its housing and remove slider shoes. Proceed the same way for other housing lifting one at a time.
1- Hold slider shoes
2- Lift one housing at a time
● NOTICE:
To ease disassembly, forks (P/N 529 005 500) should be used to hold slider shoes prior to removing governor cup.
PRIMARY TRANSMISSION SYSTEM 8-9
8, Spring Cover Ass’y
It is pushed by clutch spring pressure.
◆ WARNING
Clutch spring is very strong. Never attempt to remove spring cover without the recommended tools. o Use spring compressor (P/N 529 035 524). o Install support guide. 1- Support guide o Install sliding half then a seconds support guide. These support guides will prevent bushing damages. o Remove 3 Allen screws retaining spring cover then unscrew compressor.
1- Support guide
CLEANING
1, 2, Fixed and Sliding Half
Clean pulley faces and shaft with fine steel wool and dry cloth.
1, Fixed Half and Crankshaft End
Parts must be at room temperature before cleaning.
Using a paper towel with cleaning solvent, clean crankshaft tapered end and the taper inside the fixed half of the drive pulley, crankshaft threads and retaining screw threads.
PRIMARY TRANSMISSION SYSTEM 8-10
◆ WARNING
This procedure must be performed in a well-ventilated area.
▼ CAUTION
Avoid contact between cleaner and crankshaft seal because damage may occur.
Remove all hardened oil deposits that have baked on crankshaft and pulley tapered surfaces with coarse or medium steel wool and/or sand paper no.600.
▼ CAUTION
Do not use any other type of abrasive.
Reclean mounting surfaces with paper towel and cleaning solvent.
Wipe off the mounting surfaces with a clean, dry paper towel.
▼ CAUTION
Mounting surfaces must be free of any oil, cleaner or towel residue.
3, 9, Bushing
Only use petrol base when cleaning bushings.
▼ CAUTION
Do not use acetone to clean bushing.
INSPECTION
Drive pulley should be inspected annually.
26, 27, Thrust Washer and Roller
Check roller for roundness of external diameter.
Check thrust washer for thickness wear. Replace as required.
▼ CAUTION
Ensure rollers are in good condition. Replace as required.
31, 32, Fitting Bolt Ass’y and Flanged Bushing
Check for wear, replace as required.
15, 16, O-Ring and Slider Shoe
Check if O-rings are cracked, cut or crushed. Replace as required.
Check slider shoes for wear. Replace if groove is not apparent on top.
1, 18, Fixed Half and Governor Cup
Inspect splines and free play between both parts. Maximum free play is 0.5 mm (0.020 in) measured at calibration screw radius.
Replace if required.
3, 9, Sliding Half and Spring Cover Bushing
Visually inspect coating. Replace if worn.
Sliding Half Bushing Replacement
This bushing is not replaceable. If worn out, replace sliding half ass’y.
PRIMARY TRANSMISSION SYSTEM 8-11
PRIMARY TRANSMISSION SYSTEM 8-12
Spring Cover Bushing Replacement
Under normal use there is no need to replace this bushing. o Mount compressor (P/N 529 035 524) in a vise. o Use tools (P/N 529 035 932 and 529 035 931) to remove old bushing.
▼ CAUTION
Bushing must be bonded with retaining compound. o Apply retaining compound Loctite 609 outside of bushing then press it down to counterbore from outside end.
▼ CAUTION
Insert bushing from sliding half side (inner side) of spring cover.
REASSEMBLING
● NOTICE:
This drive pulley is lubrication free. Do not lubricate any component.
Screw, Ring gear and Loctite 271 o Apply loctite 271 (P/N 412 702 900) on threads and torque to 27 N • m (20 lbf • ft).
PRIMARY TRANSMISSION SYSTEM 8-13
19, 20, 21 Calibration Screw, Washer and Lock Nut o When installing calibration screw, make sure to install washer as shown. o Torque locking nut to 10 N • m (89 lbf • in ).
28, Pin
Always use the same type of pin as originally installed when servicing. Different types have different weights for calibration purpose. Refer to TECHNICAL DATA.
1- Washer
12, 13, 14, Screw, Dowel Tube and Ramp o Insert dowel tube from chamfered side. Make sure ramp is centred on dowel tube
1- Chamfered side o Position dowel tube split at the angle A.
PRIMARY TRANSMISSION SYSTEM 8-14 o Torque screws to 10 N • m (89 lbf • in )
1- Equal distance
32, 30, 29, 25, Screw, Lever Ass’y, Nut Cotter Pin
● NOTICE:
While installing lever assemblies make sure that the curved sides of the levers are outwards as shown. o Always install lever assemblies so that cotter pins are on the shown side. Besides install cotter pin head on the top when lever is sat at bottom of sliding half. Bend cotter pin ends to sit perfectly against lever.
◆ WARNING
Whenever replacing centrifugal levers, always replace all
3 at the same time. Otherwise, drive pulley misbalancing will occur because of levers difference.
▼ CAUTION
Lever assemblies must be installed so that cotter pins are on the same side. o Torque nuts to 12 N • m (106 lbf • in )
1- Head on top
2- All on the same side
▼ CAUTION
Lever ass’y and rollers must move easily after installation.
1, 2, 6, 8, Fixed Half, Sliding Half, Spring, Spring Cover and
Screw o To install spring cover, use spring compressor
(P/N 529 035 524). o Assemble fixed and sliding halves. Note that fixed halves have different cone angle. Match cone angle with crankshaft. o Lift sliding half against spring cover and align spring cover arrow with sliding half mark. o Tighten screws to proper torque as mentioned in exploded view.
PRIMARY TRANSMISSION SYSTEM 8-15
1- Align
2, 15, 18, Sliding Half, Slider Shoe and Governor Cup o To install governor cup, use following tool: o Insert spring and slider shoes into governor cup so that groove in each slider shoe is vertical to properly slide in guides.
▼ CAUTION
Make sure O-rings are installed on slider shoes and that grooves are positioned vertically.
PRIMARY TRANSMISSION SYSTEM 8-16 o Install fork (P/N 529 005 500) into slider shoe grooves to maintain them for governor cup installation. Proceed on
3 sets of slider shoes. o Make sure to align governor cup arrow with sliding half and fixed half mark.
● NOTICE:
If fixed half has no mark, align governor cup mark with segment no.1 of inner half. Segments are identified on engine side. o Carefully slide governor cup into sliding half. Align mark of governor cup with mark of fixed half. o Remove forks and push governor cup so that its splines engage with fixed half shaft splines.
1- Align
▼ CAUTION
Make sure splines of both parts are fully engaged.
INSTALLATION
◆ WARNING
Do not apply anti-seize or any lubricant on crankshaft and drive pulley tapers.
◆ WARNING
Never use any type of impact wrench at drive pulley removal and installation. o Clean mounting surfaces as described in CLEANING above.
Drive Pulley Ass’y
The following installation procedure must be strictly adhered to. o Install drive pulley on crankshaft extension. o Install a new conical spring washer with its concave side towards drive pulley then install screw.
◆ WARNING
Never substitute conical spring washer and/or screw with jobber ones. Always use Snow hawk genuine parts for this particular case. o Use holder. See removal procedure. o Torque screws to 80 to 100 N • m (59 to 74 lbf • ft). o Install drive belt and guard. o Raise and block the rear of the vehicle and support it with a mechanical stand.
◆ WARNING
Ensure that the track is free of particles which could be thrown out while track is rotating. Keep hands, tools, feet and clothing clear of track. Ensure nobody is standing near the vehicule. o Accelerate the vehicle at low speed (maximum 30 km/h
(20 mph)) and apply the brake, repeat 5 times. o Retorque screws to 90 to 100 N • m (66 to 74 lbf • ft).
PRIMARY TRANSMISSION SYSTEM 8-17
PRIMARY TRANSMISSION SYSTEM 8-18
◆ WARNING
After 10 hours of operation, the transmission system of the vehicle must be inspected to ensure the retaining screw is properly torqued.
DRIVE PULLEY ADJUSTEMENT
The drive pulley is factory calibrated to transmit maximum engine power at a predefined RPM. Factors such as ambient temperature, altitude or surface condition may vary this critical engine RPM thus affecting Snow Hawk efficiency.
This adjustable drive pulley allows setting maximum engine
RPM in the vehicle to maintain maximum power.
Calibration screws should be adjusted so that actual maximum engine RPM in vehicle matches with the maximum horsepower
RPM given in TECHNICAL DATA.
● NOTICE:
Use precision digital tachometer for engine RPM adjustment.
● NOTICE:
The adjustment has an effect on high RPM only.
To adjust, modify ramp end position by turning calibration screws.
19, 21, 18, Calibration Screw, Locking Nut and Governor
Cup
Calibration screw has a notch on top of its head.
Governor cup has 6 positions numbered 2 to 6. Note that in position 1 there is no stamped number (due to its location on casting)
1-Notch
PRIMARY TRANSMISSION SYSTEM 8-19
See TECHNICAL DATA for original setting.
Each number modifies maximum engine RPM by about 200 RPM
Lower numbers decrease engine RPM in steps of 200 RPM and higher numbers increase it in steps of 200 RPM.
1- Position 1 (not numbered)
Example:
Calibration screw is set at position 3 and is changed to position
5. So maximum engine RPM is increased by about 400 RPM.
To adjust:
Just loosen locking nut enough to pull calibration screw partially out and adjust to desired position. Do not completely remove the locking nut. Torque locking nuts to 10 N • m (89 lbf • in ).
▼ CAUTION
Do not completely remove calibration screw otherwise its inside washer will fall off
▼ CAUTION
Always adjust all 3 calibration screws and make sure they are all set at the same number.
1- Loosen just enough to permit rotating of
calibration screw
PRIMARY TRANSMISSION SYSTEM 8-20
REMOVAL (SECONDARY CLUTCH) o Remove guard and drive belt from vehicle. o Remove cap screw no.24 shouldered washer no.20 then pull the driven pulley from the countershaft.
Note shouldered washer position for reinstallation.
Take care not to lose spacer no.26
1- Spacer
2- Shoulder on this side
3- Concave side facing driven pulley
Countershaft
Should countershaft removal be required, refer to BRAKE then look for COUNTERSHAFT AND BRAKE DISC REMOVAL.
DISASSEMBLY o Use spring compressor (P/N 529 035 524).
o Remove half key no.1 and washer no.2 to disassemble the cam and the 2 pulley halves.
◆ WARNING
Driven pulley cam is spring loaded, use above mentioned tool.
CLEANING
8, 10, Large Bushing and Small Bushing
During break-in period (about 10 hours of use), teflon from bushing moves to cam or shaft surface. A teflon over teflon running condition occurs, leading to low friction. So it is normal to see gray teflon deposit on cam or shaft. Do not remove that deposit, it is not dust.
When a dust deposit has to be removed from the cam or the shaft, use dry cloth to avoid removing transferred teflon.
PRIMARY TRANSMISSION SYSTEM 8-21
Pulley Half Cleaning o Use pulley flange cleaner (P/N 421 711 809)
INSPECTION
11, 12, Slider Shoe
Check cam slider shoes for wear. Replace when inside edge thickness of cam slider shoe slope base is worn to 1 mm
(0.039in) or less.
1- Measure thickness of slope base here
2- Sliding pulley side
3- Slope base
REASSEMBLING
11, 12, Cam Slider Shoe o When replacing slider shoes, always install a new set
(3 shoes) to maintain equal pressure on the cam. o Install slider shoes as per following photo. RED slider shoes are being used for reverse and BLACK ones for forward.
1- BLACK slider shoe
2- RED slider shoe
22, Screws
These screws are machined at their end. With the adjustment ring steel to position 0 (zero), screw ends are flush with inner side of fixed pulley half when tighten.
▼ CAUTION
If any of these screws is not flush with inner side of sliding pulley, bushings will worn unequally. o Assemble driven pulley components by reversing the disassembly procedure.
PRIMARY TRANSMISSION SYSTEM 8-22
3, Cam o Coat cam interior with anti-seize lubricant.
INSTALLATION
Countershaft
▼ CAUTION
Always apply anti-seize lubricant (P/N 293 800 070) on the countershaft before final pulley installation.
Should installation procedure be required, refer to BRAKE then look for BRAKE DISC and COUNTERSHAFT
BEARING ADJUSTMENT. o Reinstall the pulley on the countershaft by reversing the removal procedure. o Driven pulley end-play is 0 (zero).
24, Pulley Retaining Screw o Torque to 22 N • m (16 lbf • ft).
ADJUSTMENT
Pulley Alignment and Drive Belt Height o Refer to PULLEY DISTANCE AND ALIGNMENT and
DRIVE BELT to perform adjustments. o Loosen screws no.22 turn adjustment ring no.20 then retighten screws to adjust drive belt height.
▼ CAUTION
Drive belt and pulley adjustments must always be checked whenever pulleys have been removed, replaced or disassembled.
3, Cam o Make sure to install proper cam. Refer to TECHNICAL
DATA. o Cam angle is identified on cam
NOTE: For high altitude regions, a service bulletin will give information about calibration according to altitude.
PRIMARY TRANSMISSION SYSTEM 8-23
PRIMARY TRANSMISSION SYSTEM 8-24
DRIVE BELT
MODEL
SNOW HAWK
P/N
144-4740U3
WIDTH NEW
1.375 ± 0.030
MINIMUM WIDTH
(WEAR LIMIT)
1.250 ± 0.030
DIRECTION OF ROTATION
In order for the drive-belt to last as long as possible it must be installed as is shown in the illustration respecting the direction of rotation.
● NOTICE:
SNOW HAWK
SNOW HAWK
In the case of a belt that has already been used, mark it and reinstall it such that it will be used in the same direction.
DRIVE BELT HEIGHT MEASUREMENT AND ADJUSTMENT
M o d e l D e f l e c t i o n m m ( i n )
Measurement
NOTE: The drive belt height measurement must be performed each time a new drive belt is installed.
S n o w H a w k 3 2 ( 1 1 / 4 )
NOTE: To obtain an accurate drive belt height measurement, it is suggested to allow a break-in period of 50 km (30 m). o Before checking the belt height, ensure that a goodcondition proper belt (refer to the Application Chart) is installed. o Adjust pulley distance and alignment. Refer to PULLEY
DISTANCE AND ALIGNMENT. o To obtain maximum vehicle performance. The belt height must be adjusted according to specifications shown in the accompanying chart.
F o r c e k g ( l b )
6 . 8 ( 1 5 )
1- Flush
PRIMARY TRANSMISSION SYSTEM 8-25
ADJUSTMENT
Before adjusting the belt height, ensure that a good-condition proper belt (refer to the Application Chart) is installed. o Loosen screws and turn adjustment ring as follows: o To lower belt in driven pulley: turn adjustment ring counterclockwise and tighten the screws. o To raise belt in driven pulley: turn ring clockwise and tighten the adjustment screws.
1-Screws
2-Adjustment ring o Turn the adjustment ring up to one notch, tighten the screws, then rotate driven pulley to allow drive belt to settle in pulley. Check height, if required the adjustment ring can be turned up to ¼ or ½ the notch. Check height, repeat as required.
NOTE: Notches are there on the driven pulley for reference purpose only and the desired adjustment can be attained at any point.
Driven pulley notches
PRIMARY TRANSMISSION SYSTEM 8-26
CHECKING DRIVE BELT TENSION o Place a ruler on the drive belt. o Use the tension gauge (P/N 414 348 200) to verify the tension of the drive belt.
1. Lower ring
2. Upper ring
3. Force
4. Deflection o Slide the lower ring of the deflection scale to the required measurement. o Slide the upper ring of the deflection force scale to zero. o Exert pressure until the lower ring comes even with the ruler and note the force on the upper scale (above the ring).
1. Upper ring
2. Exert the required pressure
3. Lower ring
4. Reference ruler
5. Deflection
Emergency starting
It is possible to start the engine with an emergency starter cord and clip included in the toolkit stored in the bellypan of vehicle.
◆ WARNING
Do not wrap the cord around your hand. Pull only by the very end of the cord. Other than in a case of emergency, do not start your vehicle by the primary clutch. Have your vehicle repaired as soon as possible. o Attach the emergency starter cord to the starter grip and to the small plastic clip, as shown at right.
● NOTICE:
The spark plug socket can by used as on emergency starting handle, as shown at right. o Wrap the emergency starter cord around the primary clutch and use the groove between the cover and the sheave as a guide. Place the clip as shown at right and wrap the emergency starter cord in a counter-clockwise direction ( 2 full turns ).
PRIMARY TRANSMISSION SYSTEM 8-27
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 1
CHAPTER 7
ENGINE ( CYLINDERS / HEADS / BASE / EXHAUST )
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 2
ENGINE / BOTTOM END
Ref.
9
10
7
8
1-12
2
3
4
5
6
11
12
13
35
36
37
38
39
31
32
33
34
40-42
41
42
43
-
26
27
28
29
30
22
23
24
25
14
15
16
17-23
18
19
20
21
P/N
420 889 686
420 640 836
420 640 431
420 640 311
205 063 044
420 641 834
420 840 401
420 632 010
420 860 965
420 960 770
420 960 777
420 938 190
420 812 420
420 941 430
420 232 100
420 956 510
420 837 421
-
420 230 196
420 232 100
420 650 370
420 950 890
-
420 840 511
420 227 945
420 222 505
420 931 810
420 922 630
420 240 031
420 931 565
420 810 825
420 941 925
420 660 424
420 974 522
420 874 370
420 956 239
420 960 279
420 951 260
420 951 240
420 956 240
420 850 350
420 956 250
300 079 342
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 3
Engine bottom end
Qty Part descriptions
1
1
2
2
1
10
6
2
1
4
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
6
1
1
1
2
1
2
1
1
1
1
1
1
4
1
2
Crankcase assy.
Collar hexagone screw M8 x 75
Collar hexagone screw M8 x 45
Collar hexagone screw M6 x 45
Allen screw M6 x 30
Stud M10 x 29/17
Allen screw M6 x 22
Pin 8 x 12
Cable grommet 26 7/9
Closure cap for impulse joint
Protection cap
Clamp 8
Oil seal cover
Countersunk screw M6 x 20
Ball bearing 6000 10-26-8
Checkvalve assy.
Water pump / oil pump shaft assy.
Step collar
Oil seal A 10x26x7 NBR
Ball bearing 6000 10-26-8
Rotary seal
O-ring 30x3
Waterpump / oil pump shaft
Allen screw M5 x 16
Thrust washer 8.1/15/0.5
Impeller
Gasket
Waterpump housing
Hexagone screw M6 x 25
Gasket
Cover plate
Taptite screw M5 x 16
Oil line 170 mm
Plastic line 120 mm
Reduction fitting
Oil tube 250 mm
Closure cap 10.32
Clamp 14
Clamp 12
Oil tank assy.
Rubber gasket 26.5 mm
Oil tank cap S 103/2D
Shortblock engine
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 4
ENGINE / CRANKSHAFT AND PISTONS
Ref.
7
8
5
6
1-10
2
3
4
9
10
11
12
13-14
18
19
20
21
14
15
16
17
22
22
-
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 5
P/N
420 889 675
420 832 638
420 832 575
420 931 792
420 945 759
420 842 230
420 832 608
420 926 190
420 832 700
420 931 285
420 246 015
420 832 428
420 889 456
420 815 360
420 916 371
420 845 106
420 832 575
420 931 455
420 834 355
420 819 032
420 819 061
420 684 653
420 684 654
Engine crankshaft and pistons
Qty Part descriptions
1
2
1
1
1
1
1
1
2
1
1
2
1
1
1
2
2
4
2
1
2
1
1
Crankshaft assembly
Ball bearing 6207 with oil seal assembly
Ball bearing 6207 with drive pin
Oil seal 30x42x7
Lock washer 22
Hexagone nut M22 x 1.5
Ball bearing 6208 with oil seal and drive pin
Retaining disk 72/83/2
Ball bearing 6208 with drive pin
Oil seal as 40x80x8 FPM
Woodruff key 3x5
Cageless needle bearing 20x25x23
Piston assembly 81,87 mm
Semi trapez ring is 2,5-82/75,4/2
Piston pin 20x12/15,5x65,7
Monohook circlip 20
Ball bearing 6207 with drive pin
Oil seal AD 34.5x76x2.6/10.2 NBR
Central gear 15T
Crankshaft PTO side
Crankshaft MAG side
Rod repair kit MAG side
Rod repair kit PTO side
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 6
ENGINE / TOP END
P/N
420 931 838
420 931 837
420 931 964
420 931 839
420 613 852
420 854 465
420 430 110
420 931 542
420 854 455
205 062 544
420 260 729
420 838 255
420 854 449
420 939 280
420 239 941
420 911 558
420 430 220
420 241 220
420 241 270
420 640 524
420 640 534
420 931 590
420 931 410
420 923 828
420 941 621
420 922 519
420 931 272
420 922 025
420 941 250
420 850 338
420 922 062
420 240 480
420 867 879
420 924 680
420 924 695
420 941 215
420 941 925
420 931 850
420 973 713
420 888 741
420 888 745
Ref.
4
5
6
2
3
7
8
9
10
34
35
36
37
38
-
30
31
32
33
26
27
28
29
19
20
21
22
23
24
25
15
16
17
18
11
12
13
14
1
1
1
1
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 7
Qty
Engine top end
Part descriptions
2
2
2
2
2
4
2
2
2
2
4
4
12
1
1
4
1
12
2
1
1
1
2
2
1
12
1
1
1
4
4
2
4
2
2
2
2
11
1
1
1
Gasket 0.5
Gasket 0.6
Gasket 0.7
Gasket 0.8
Cylinder ni si c plated
Exhaust valve
O-ring 10x2.7
Gasket
Valve rod housing
Allen screw M6 x 25 DIN 912
Bellows
Hose spring 70-1.7-0.3
Exhaust valve piston
Hose spring 134-3.0-0.65
Compression spring 52,5/0,8 mm
Valve cover
O-ring 15.9-2.3
Adjustment screw
Taptite screw M5 x 25
Collar hexagone screw M10 x 80
Collar hexagone screw M10 x 120
Square ring
O-ring 89x2
Cylinder head
Collar hexagone screw M8 x 56.5 SW 11
Thermostat 42 degr. with gasket
Thermostat gasket
Water outlet socket
Taptite screw M6 x 20
Gasket
Bent outlet socket
Plug screw 1/8-27NPT
Carburator socket with read valve assembly
Reed pedal
Pedal stop
Oval-head screw M3 x 5
Taptite screw M5x16
Gasket
Exhaust manifold assembly
Gasket set
Gasket set cylinder
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 8
ENGINE / EXHAUST SYSTEM
P/N
SH-75A
3060-30-013
3060-30-035
3060-30-014
3060-30-020
3060-30-036
3060-30-037
3060-30-029
3060-30-030
3060-30-027
3060-30-028
3060-30-033
3060-30-065
3060-30-032
3060-30-066
420 673 070
420 850 552
234 161 471
205 062 044
514 053 487
514 053 812
415 107 100
22216P
20231P
3060-30-077
181-137P
21110P
21008P
30602-30-022
23164P
21111P
3060-30-079
3060-30-080
3060-30-084
21650P
21653P
3060-30-067
3060-30-026
3060-30-068
3060-30-083
3060-30-045
3060-30-046
3060-30-047
3060-30-048
SH-159
Ref.
@
1
6
7
8
36
37
38
39
32
33
34
35
40
41
42
43
44
-
25
26
27
28
29
30
31
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
4
5
2
3
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 9
Qty
Exhaust system
Parts descriptions
1
1
1
1
1
6
7
16
16
1
1
1
1
1
1
1
1
1
2
1
2
2
1
2
1
11
1
2
1
1
2
8
8
1
1
1
2
1
1
1
1
1
1
1
1
Exhault system
Tuned pipe assy
Superior muffler assy
Lower muffler assy
Tail pipe assy
Upper rear half enveloppe
Lower rear half envloppe
Upper front haft enveloppe
Lower front haft enveloppe
Upper insulating wool
Lower insulating wool
R.H. heat sheild
L.H. heat sheild
R.H. insulating wool
L.H. insulating wool
Exhaust manifold
Gasket
Lock washer 6 mm
SHCS M6 x 20
Exhaust gasket
Exhaust gasket
Spring
BHCS M8 x 30
HHCS M10 x 25
Rubber mount
W asher
Lock washer
Nut M8
Rubber mount
Lock nut M8
Lock washer M10
Spring bracket
Bracket
Rubber bumper
SHCS M8 x 20
SHCS M8 x 30
Spring bracket
Spring
Pop rivet 3/16
Backing plate
Retaining strap
Retaining strap
Retaining strap
Retaining strap
Retaining strap
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 10
TOP END
● NOTICE:
The engine must be removed from the chassis to carry out the following operations. See Chapter 4 – Engine Removal for details.
TROUBLESHOOTING
Before completely disassembling the engine, check airtightness.
Refer to the section named LEAK TEST AND ENGINE
DIMENSION MEASUREMENT at the end of this chapter.
CLEANING o Discard all gaskets and O-rings. o Clean all metal components in a non-ferrous metal cleaner. o Scrape off carbon formation from cylinder exhaust port cylinder head and piston dome using a wooden spatula.
● NOTICE:
The letters “AUS” (over an arrow on the piston dome) must be visible after cleaning. o Clean the piston ring groove with a groove cleaner tool or with a piece of broken ring.
DISASSEMBLY
RAVE System
● NOTICE:
RAVE stands for Rotax Adjustable Variable Exhaust. o Remove spring clip or screws no. 16, cover no. 13 and spring no. 12. o Remove spring no. 11. o Unscrew valve piston no. 10. o Remove bellows no. 8 and spring no. 9. o Remove cylindrical screws. Remove valve housing no. 6. o Pull out exhaust valve no. 3. (see right)
2, Cylinder
Remove spark plugs, coolant outlet no. 32. Unscrew cylinder head no. 21.
13, Piston
Place a clean cloth or rubber pad (P/N 529 023 400) over crankcase. Then with a pointed tool inserted in piston notch, remove both circlips no. 16 from piston no. 13.
RAVE VALVE PARTIALLY REMOVED
TYPICAL
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 11
All engines are equipped with cageless piston pin
Bearings, as shown at right.
Once the head and cylinder(s) has been removed, Use piston pin puller (P/N 529 035 503) along with 20 mm sleeve kit (P/N 529
035 542). Use also a locating sleeve.
● NOTICE:
The locating sleeve is the same that contains new cageless bearing.
Insert piston pin puller (P/N 529 035 503) making sure it sits squarely against piston as shown at right.
Install sleeve (1) then shouldered sleeve (2) over puller rod as shown at right.
TYPICAL
1. Properly seated all around
1
1
TYPICAL – INSTALLATION OF SLEEVE KIT
1. Sleeve
2. Shouldered sleeve
2
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 12
Screw in (LH threads) extracting nut.
Pull out piston pin no. 15 by unscrewing puller until shouldered sleeve end is flush with thrust washer of piston pin bearing.
Remove puller. Pull out shouldered sleeve carefully.
Remove piston from connecting rod.
Install locating sleeve. Then push the needle bearings, thrust washers and sleeve into the upper connecting rod journal
TYPICAL – PISTON PIN EXTRACTION
1 2 3
TYPICAL
1. Sleeve inside bearing
2. Thrust washer
3. Shouldered sleeve end
TYPICAL
1. Locating sleeve
2. Sleeve
1 2
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 13
INSPECTION
● NOTICE:
For details , Refer to LEAK TEST AND ENGINE DIMENSIONS
MEASUREMENT AT THE END OF THIS CHAPTER.
RAVE System
Check valve rod housing and cylinder for clogged passages.
● NOTICE:
Oil dripping from draining hole (No. 1) indicates a loose spring or damaged bellows.
8, Bellows
Check for cracked, dried or perforated bellows.
12, Spring
TYPICAL
1. Draining hole
2. Passages
2 1
ASSEMBLY
RAVE System
Install RAVE valve (noting which is the top side when it was removed) Tighten red cap no. 15 screw to bottom.
2,13, Cylinder and Piston
Before inserting piston in cylinder, lubricate the cylinder with new injection oil or equivalent.
21,2, Cylinder Head and Cylinder
Make sure parts sealing surfaces are flat. Refer to LEAK TEST
AND ENGINE DIMENSION MEASUREMENT at the end of this chapter and look for CYLINDER HEAD WARPAGE.
When installing a new cageless bearing, replace half plastic cages with sleeve.
● NOTICE:
All 793 HO engine cageless bearings have 28 needles.
TYPICAL
1. Sleeve
1
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 14 o Oil needle bearing with injection oil. o Grease thrust washers and install them on each end of needles. The grease will help to hold them in place. o Insert cageless bearing into connecting rod. o Heat piston with a 100 W lamp or a heat gun before piston installation to make the insertion of the pin much easier.
▼ CAUTION
Piston temperature must not exceed 46°C (115°F). Never use direct flame to heat the piston and never freeze the pin.
At assembly, place the pistons over the connecting rods with the letters “AUS” (over an arrow on the piston dome) facing towards the exhaust port.
1. Exhaust
Install shouldered sleeve.
Install piston pin puller and turn handle until piston pin is correctly positioned in piston.
TYPICAL – SHOULDERED SLEEVE INSTALLATION
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 15
All Models
▼ CAUTION
Always install new circlips. To minimize the effect of acceleration forces on circlip, install each circlip so the circlip break is at 6 o’clock as illustrated. Use appropriate piston circlip installer.
Use circlip installer (P/N 529 035 686) to install new mono-hook circlips no. 16. Insert circlip into support so that, when installed in piston groove, the tab faces upward.
With round end of pusher, position circlip perpendicularly to the support axis.
With the other end of the pusher, push circlip into the support groove.
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 16
Using a plastic hammer, tap the pusher to put the circlip in place.
Make sure to install new circlips with the tab toward the top as per the following photos.
▼ CAUTION
Always install new mono-hook circlips. If circlip installation fails at the first attempt, always retry with a new one because, on a second attempt, the circlip will lose its normal retaining capabilities.
▼ CAUTION
Circlips must not move freely after installation; if so, replace them. Clean cylinders and crankcase mating surfaces with Loctite Chisel (P/N 413708500). Coat crankcase mating surface with Loctite 518 (P/N
293800038). Choose the right gasket thickness according to combustion chamber volume. Refer to LEAK TEST
AND ENGINE DIMENSION MEASUREMENT. Install it on the crankcase. Coat gasket with Loctite 518.
1. Groove
▼ CAUTION
Always install a gasket of the proper thickness. Failure to do so may cause detonation and severe engine damage.
Before inserting piston in cylinder, lubricate the cylinder with new injection oil or equivalent. Install cylinders. Do not tighten. Install new rubber ring and round O-rings on each cylinder.
CIRCLIP READY TO BE INSTALED ON PISTON
TAB TOWARD TOP
1
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 17
● NOTICE:
Carefully clean screws before reinstallation, specifically under screw head.
Install exhaust manifold with gaskets. Do not tighten yet.
Torque cylinder screws in a crisscross sequence as per the following table:
At assembly, torque cylinder head screws to 29 N-m
(21 Ibf-ft) in the illustrated sequence at right.
Tighten exhaust manifold bolts to 23 N-m (17 lbf-ft) in a crisscross sequence.
Apply Loctite 243 (P/N 293 800 060) on screws threads.
Install outlet socket and tighten screws to 12 N-m (106 Ibf-in).
Note position of longer screw.
1. Longer screw
30, Reed Valve
All Engines
Blades have a curved shape. Install with their curve facing reed block.
With blade stopper no. 32 removed, check reed valve for proper tightness. There must not be any play between blade and valve body when exerting a finger pressure on blade at blade stopper location.
In case of a play, turn blade upside down and recheck. If there is still a play, replace blade and/or valve body.
Check distance from blade stopper outer edge and distance from center of reed valve block.
TYPICAL
A. 18.7 - 0, + 0.75 mm (.736 - 0, + .030 in)
Bend blade stopper as required to obtain the proper distance.
1
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 18
Blade stoppers may slightly interfere with cylinder during installation. Adjusted distance will be reduced automatically upon installation.
BOTTOM END
● NOTICE:
The engine must be removed from the chassis to carry out the following operations. See Chapter 4 – Engine Removal for details.
CLEANING o Discard all gaskets and O-rings. o Clean all metal components in a non-ferrous metal cleaner. Use gasket remover (P/N 413 708 500) accordingly. o Remove old paste gasket material from crankcase mating surfaces with gasket remover (P/N 413 708 500)
▼ CAUTION
Never use a sharp object to scrape away old sealant as score marks incurred are harmful to crankcase sealing.
DISASSEMBLY
General
To remove drive pulley, refer to Chapter 8 – Primary
Transmission System . To remove magneto, refer to CDI
SYSTEM in Chapter 14 – Electrical System .
2,3,7,9 Crankshaft Bearings
To remove bearings from crankshaft, use a protective cap and special puller, as illustrated.
1. PTO side
2. MAG side
This includes the following parts:
P/N
PROTECTIVE CAP AND SPECIAL PULLER P/N
Description
420 940 755
420 840 681
420 841 201
420 876 552
420 876 557
M16 x 1.5 x 150 screw
M8 x 40 screw ( 4 )
M8 x 70 screw ( 4 )
Crankshaft protector PTO all engines except 247
Crankshaft protector MAG all engines except 247
420 977 490
420 977 475
420 276 025
420 977 480
420 977 494
420 977 479
420 876 330
Puller ring ( use with hafl rings 420 977 475 or 420 276 025 )
Half ring ( 2 ) for 72 mm O.D. bearings
Half ring ( 2 ) for 62 mm O.D. bearings
Puller ring
Puller ring ( use with hafl rings 420 977 479 )
Half ring ( 2 ) For 80 mm O.D. bearings
Half ring ( 2 ) For 52 mm O.D. bearings
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 19
INSPECTION
NOTE: Refer to LEAK TEST AND ENGINE DIMENSIONS
MEASUREMENT (End of this chapter)
ASSEMBLY
Coat lip of all seals with Petamo grease (P/N 420 899 271).
7, Crankshaft Bearing
Smear anti-seize lubricant (P/N 413 701 000) on part of crankshaft where bearing fits.
Prior to installation, place bearings into an oil container filled with injection oil previously heated to 75°C (167°F). This will expand the bearing and ease installation.
Some bearings must be lubricated with Isoflex grease (P/N 293
550 021).
▼ CAUTION
Use only the recommended Isoflex grease. Make sure not to push Isoflex grease between outside bearing race and half crankcase. Use a sharp object to scrape away old sealant as score marks incurred are harmful to crankcase sealing.
● NOTICE:
The 50 g tube corresponds to 50 cc of grease.
Put 50 to 55 mL of grease in a syringe.
▼ CAUTION
Do not exceed the recommended amount of grease.
Fill inner side of PTO side bearing with Isoflex grease (about 10 mL) as shown at right.
PTO SIDE BEARING FILLED WITH ISOFLEX GREASE
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 20
With the syringe, fill the outer ball bearing and inner side of outer seal with 40 to 45 mL of Isoflex grease as shown at right.
Apply 6 mL of grease to MAG side outer bearing.
● NOTICE:
If replaced with new bearing, do not apply grease as new bearings come with grease already applied.
At crankshaft installation, position drive pins as illustrated.
1. Position pins
For 50 mL (2 U.S. oz) of injection oil in the pan under central gear to lubricate pump gearing as per photo.
1. Oil bath
BALLS COATED WITH A SEAM OF GREASE
FILL WITH GREASE AND SET IN PLACE
1
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 21
Crankcase Assembly
IMPORTANT : The total assembly sequence, including sealing compound spreading, screwing and torquing of bolts according to the proper sequence, must be performed within 10 minutes. Do not wait between each bolt torquing. All bolts must be torqued in a row.
Before screwing together both parts of crankcase, seal it with sealing compound (P/N 420 297 906). Make sure surfaces are perfectly clean and degreased before applying sealing compound.
Spread a seam of 1.2 mm (1/16 in) maximum in diameter on the surface of lower crankcase half.
As far as possible, sealing compound must be applied in one run to avoid any risks of leakage through the crankcase.
SEAMING COMPLETED – CONTACT SURFACES COVERED
AND SCREW HOLES SURROUNDED
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 22
Screw all crankcase bolts in place in the following sequence and to the appropriate torque; this must be done in two steps, torquing: first, screw bolts up to 60% of the final torque (18 N-m
(13.5 lbf-ft) for most of the bolts), then, tighten to the required torque (i.e. 29 N-m (21 lbf-ft)).
A. Torque bolts 1 through 16 to 29 N-m (21 lbf-ft)
B. Torque bolts 17 through 21 to 9 N-m (80 lbf-in)
793 HO Engine Types
Install oil seal cover
BREAK-IN
After rebuilding an engine, always observe a break-in period as described in Chapter 1 – General Instructions .
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 23
LEAK TEST AND ENGINE MEASUREMENT
LEAK TEST
The following gives verification procedures for
593 HO engines.
PREPARATION
1. Remove tuned pipe.
2. Install plug over exhaust manifold.
3. Remove carburetors.
4.Unplug fuel inlet line from fuel rail
5. Insert plugs in intake rubber boots. Tighten with existing clamps.
6. Using a hose pincher (P/N 295 000 076), block impulse hose.
7. Install air pump on exhaust plug.
● NOTICE:
If necessary, lubricate air pump piston with mild soap.
▼ CAUTION
Using hydrocarbon lubricant (such as engine oil) will damage rubber seal of pump piston.
8. Activate pump and pressurize engine to 34 kPa
(5 PSI). Do not exceed this pressure.
9. Engine must stand this pressure during 3 minutes.
– If pressure drops before 3 minutes, check tester kit by spraying a soapy solution on pump cylinder, all plugs and fittings.
– If tester kit is leaking, bubbles will indicate where leak comes from.
– If tester kit is not leaking, check engine as per the following procedure.
PROCEDURE
● NOTICE:
A flow chart has been prepared as a visual reference. Page 7-25 and 7-26 of this chapter.
Using the flow chart and the following text, pressurize area to be tested and spray soapy solution at the indicated location.
– If there is a leak at the tested location, it is recommended to continue testing the next item before overhauling the engine.
There is a possibility of more than one leak.
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 24
– If there is no leak at the tested location, continue pumping to maintain pressure and continue with the next item until the leak is found.
Engine
Check the following:
1. All jointed surfaces and screw/stud threads of engine:
– spark plug base, insulator
– cylinder head
– RAVE valve bellows, piston and housing
– cylinder
– crankcase halves (joint)
– oil injection pump mounting flange (O-ring)
– coolant pump housing
– bleed screws/plugs.
– crankcase grease reservoir fitting
Check for air bubble or oil column going toward pump. It indicates defective check valve in injection nipples.
2. Remove cooling system cap.
Check for air bubbles in antifreeze. It indicates defective cylinder head O-ring or cylinder base gasket.
3. Remove drive pulley then check crankshaft outer seal.
4. Remove rewind starter and magneto system then check crankshaft outer seal.
5. Check pump shaft gear oil reservoir.
Pump Shaft Oil Gear Reservoir
Install air pump on adapter and pressurize as shown at right. If pressure drops, it indicates a defective crankshaft inner seal.
CRANKSHAFT INSTALLED IN UPPER HALF CRANKCASE
1. Crankshaft inner seal on PTO side
2. Crankshaft inner seal on MAG side
1 2
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 25
1. Check weep hole below coolant pump housing with soapy water.
1. Weep
If there is a leak, it indicates that a pump shaft is defective (oil seal beside coolant ceramic seal).
2. Leaks can be also on the oil pump side, which is blocked off on the Snow Hawk 600HO. Check this mounting area and the two mounting bolts for leaks.
3. If leak still persists, it indicates a defective casting somewhere in the engine.
Disassemble engine and carefully check for defects in castings.
Pay attention to tapped holes which may go through engine sealed area and thus lead to leakage.
FINALIZING REASSEMBLY
After reassembling engine, always recheck for leakage.
1
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 26
ENGINE DIMENSION MEASUREMENT
This section covers the 793HO engine type.
CYLINDER HEAD WARPAGE
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 27
Check gasketed surface of the cylinder head with a straightedge and a feeler gauge.
CYLINDER TAPER
Compare cylinder diameter 16 mm (5/8 in) from top of cylinder to just below its intake port area. If the difference exceeds the specified dimension the cylinder should be rebored and honed or should be replaced. Nikasil cylinder can be honed using diamond hone but cannot be rebored.
● NOTICE:
Be sure to restore the chamfer around all cylinder sleeve port openings.
1. Below the intake port
A. 16 mm (5/8 in) from top
CYLINDER OUT OF ROUND
1
A
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 28
Measuring 16 mm (5/8 in) from top of cylinder with a cylinder gauge, check if the cylinder out of round is more than the specified dimension. If larger, cylinder should be rebored and honed or should be replaced. Nikasil cylinder can be honed using diamond hone but cannot be rebored.
● NOTICE:
Be sure to restore the chamfer around all cylinder sleeve port openings.
1. Piston pin position
2. Measures to be compared
A. 16 mm (5/8 in)
COMBUSTION CHAMBER VOLUME MEASUREMENT
The combustion chamber volume is the region in the cylinder head above the piston at Top Dead Center. It is measured with the cylinder head installed on the engine.
1. Combustion chamber
● NOTICE:
When checking the combustion chamber volume, engine must be cold, piston must be free of carbon deposits and cylinder head must be leveled.
1. Remove both spark plugs and bring one piston to Top Dead Center a using a TDC gauge.
1. Bring piston to TDC
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 29
2. Remove cylinder head.
3. Seal piston ring gap with a small amount of grease.
4. Reinstall cylinder head.
5. Obtain a graduated burette (capacity 0 - 50 cc) and fill with an equal part (50/50) of gasoline and injection oil.
6. Open burette valve to fill its tip. Add liquid in burette until level reaches 0 cc.
7. Inject the burette content through the spark plug hole until liquid touches the top spark plug hole.
1. Graduated burette ( 0-50 cc )
● NOTICE:
The liquid level in cylinder must not drop for a few seconds after filling. If so, there is a leak between piston and cylinder. The recorded volume would be false. Reseal the piston ring gap and follow the instruction provided above.
8. Let burette stand upward for about 10 minutes, until liquid level is stabilized.
9. Read the burette scale to obtain the quantity of liquid injected in the combustion chamber.
● NOTICE:
When the combustion chamber is filled to top of spark plug hole, it includes an amount of 2.25cc corresponding to the spark plug well.
10. Repeat the procedure for the other cylinder.
1. Top of spack plug ho;e 1
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 30
11. Install a thicker or thinner cylinder/crankcase gasket (refer to
Parts Catalogs ) in order to obtain the specified combustion chamber volume or the nearest.
USED PISTON MEASUREMENT
Note the measurement on the piston dome.
1. Piston dome
2. Piston measurement
Using a micrometer, measure piston skirt at 15 mm (.590 in) perpendicularly (90°) to piston pin.
1. Measuring perpendicularly (90°) to piston pin axis
A. 15 mm (.590 in)
The measured dimension must not be less than 0.15 mm (.006 in) of the one scribed on piston dome. Otherwise, install a new piston.
2 1
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 31
CYLINDER/PISTON CLEARANCE
Used and New Pistons
IMPORTANT : Make sure used piston is not worn more than specified. See USED PISTON MEASUREMENT above.
Take the measurement on the piston dome.
1. Piston dome
2. Piston measurement
Adjust and lock a micrometer to the specified value on the piston dome.
1. Micrometer set to the piston dimension
With the micrometer set to the piston dimension, adjust a cylinder bore gauge to the micrometer dimension and set the indicator to
0.
1. Use the micrometer to set the cylinder bore gauge
2. Dial bore gauge
2 1
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 32
1. Indicator set to 0 (zero)
IMPORTANT : Always remove cylinders from crankcase before measuring.
Position the dial bore gauge at 16 mm (5/8 in) below cylinder top edge.
1. Measuring perpendicularly (90°) to piston pin axis
A. 16 mm (5/8 in)
Read the measurement on the cylinder bore gauge. The result is the exact piston/cylinder wall clearance. If clearance exceeds specified tolerance, replace cylinder.
● NOTICE:
Make sure the cylinder bore gauge indicator is set exactly at the same position as with the micrometer, otherwise the reading will be false.
IMPORTANT : The total piston/cylinder clearance (actual cylinder diameter minus actual piston skirt diameter) should be within 0.30 mm (.012 in).
1
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 33
RING/PISTON GROOVE CLEARANCE
Using a feeler gauge check clearance between rectangular ring and groove. Replace piston if clearance exceeds specified tolerance. Refer to Chapter 15 – Dimensions and Tolerances.
RING END GAP
Position ring half-way between transfer ports and intake port.
● NOTICE:
In order to correctly position the ring in the cylinder, use piston as a pusher.
Using a feeler gauge, check ring end gap. Replace ring if gap exceeds specified tolerance. Refer to Chapter 15 – Dimensions and Tolerances.
1. Transfer port
2. Intake port
CRANKSHAFT DEFLECTION
Crankshaft deflection is measured with a dial indicator.
Measuring (in crankcase)
First, check deflection with crankshaft in crankcase. If deflection exceeds the specified tolerance, recheck deflection using Vshaped blocks to determine the defective part(s). See below.
Measuring (on bench)
Once engine is disassembled, check crankshaft deflection on Vshaped blocks. If deflection exceeds the specified tolerance, it can be worn bearings or a bent crankshaft. Remove crankshaft bearings and check deflection again on V-shaped blocks to determine the defective part(s). See measurement A in following illustration.
1. Measure at mid point between the key and the first thread
A. 3 mm (1/8 in)
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 34
Crankshaft Deflection on PTO side
Crankshaft Deflection on MAG side
Crankshaft Deflection in Center of Crankshaft
● NOTICE:
Crankshaft deflection cannot be correctly measured between centers of a lathe.
If the deflection exceeds the specified tolerance, crankshaft should be repaired or replaced.
Connection Rod Big End Axial Play
Using a feeler gauge, measure distance between thrust washer and crankshaft counterweight. If the distance exceeds specified tolerance, repair or replace the crankshaft.
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST) 7 - 35
CRANKSHAFT END-PLAY
End-play is not adjustable but it should be between 0.10 - 0.30 mm (.004 - .012 in).
CHECKING CRANKSHAFT ALIGNMENT o Install a degree wheel (P/N 529 035 607) on crankshaft end. o Remove both spark plugs. o Install a TDC gauge (P/N 414 104 700) in spark plug hole on MAG side. o Bring MAG piston to top dead center. o Rotate degree wheel (not crankshaft) so that 360° mark aligns with center of crankcase. Scribe a mark on crankcase. o Remove TDC gauge and install it on center cylinder. o Bring PTO piston to top dead center. Degree wheel must rotate with crankshaft.
Interval between cylinders must be 180° ± 0.5
. Any other reading indicates a misaligned (twisted) crankshaft.
CHAPTER 6
COOLING SYSTEM
COOLING SYSTEM 6 - 1
COOLING SYSTEM 6 - 2
COOLING SYSTEM
Ref.
7
8
9
5
6
10
11
3
4
1
2
12
13
14
15
16
-
-
-
-
P/N
509000323
509000187
SH-263SA
SH-264
SH-093
SH-094
SH-095
SH-096
SH-097
415080200-S
414554800
408800400
BN01-0618
SH-262
SH-165
SH-064
278001016
512047000
420922517
420931272
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
12
17
2
1
1
COOLING SYSTEM 6 - 3
Qty
Cooling System
Part descriptions
Coolant reservoir
Closure cap
Heat exchanger
Protector
Coolant tube #4
Coolant tube #3
Coolant tube #1
Coolant tube #5
Coolant tube #2
Overflow tube
Spring clamp (black)
Hose clamp (geared)
3/16'' Medium pop rivet
Slide support
Wear pad
Wear pad
Temperature sensor (Bosch, Blue, MAG side)
Temperature sensor (Indebras, Black, PTO side)
Thermostat (42 o
)
Thermostat sealing ring
COOLING SYSTEM 6 - 4
◆ WARNING
This vehicle is equipped with a liquid cooling system.
ALWAYS ride with the rear deflector pad installed and in conditions where there is enough snow to properly cool the engine. If the red temperature light on the steering column should ever illuminate, stop immediately and let the vehicle cool down, and then find some snow. NEVER continue to operate the vehicle with the temperature light illuminated as severe engine damage will occur.
COOLING SYSTEM LEAK TEST o Install special radiator cap (P/N 529021400) included in engine leak tester kit (P/N 861749100) on coolant tank. o Install hose pincher (P/N 295000076) on the overflow hose. Using pump also included in the kit and pressurize the entire system through the coolant reservoir to 100 kPa (15 PSI). o Check all hoses and cylinder/base for coolant leaks.
Spray all connections with a soapy water solution and look for air bubbles.
INSPECTION
Check the general condition of hoses and clamp tightness.
DRAINING THE SYSTEM
To drain the cooling system: o Siphon the coolant mixture from the coolant tank. o Disconnect the hose at the water pump inlet housing to drain coolant from engine. o When the coolant level is low enough, lift the rear of the vehicle to drain the heat exchangers.
◆
WARNING
Never drain or refill the cooling system when the engine is hot.
DISASSEMBLY AND ASSEMBLY
Temperature sensors: o Apply Loctite 592 (P/N 413 702 300) thread sealant to temperature sensor threads to avoid leakage.
Pressure Cap (No. 2): o Check if the cap pressurizes the system. If not, install a new 90 kPa (13 PSI) cap (do not exceed this pressure).
Thermostat:
To check the thermostat, put it in a basin of water and gradually heat it. The thermostat should start to open when water temperature nears 42°C (108°F). It will be almost fully open at
50°C (122°F).
(2)
The thermostat is a double action type:
(1) Its function is to give faster warm up of the engine by controlling a circuit; water pump — engine — coolant tank. This is done by bypassing the heat exchanger radiator circuit and using what it called a short circuit during warm up, i.e. before the coolant temperature reaches 42°C (108°F).
When the liquid is warmed enough, the thermostat progressively opens the circuit; water pump
— engine — heat exchangers — coolant tank to keep the liquid at the desired temperature. (See the diagram of the exploded view on page 6-1).
These 2 functions have the advantage of preventing a massive entry of cold water into the engine.
COOLING SYSTEM 6 - 5
COOLING SYSTEM 6 - 6
COOLING SYSTEM REFILLING PROCEDURE
▼ CAUTION
To prevent the formation of corrosion or freezing, always re-fill the system with the recommended premixed coolant.
REFILLING PROCEDURE
● NOTICE:
Use the 50/50 premixed coolant rated for -37°C (- 35°F) (P/N 293
600 038). o Do not reinstall pressure cap. o With engine cold, refill coolant tank up to COLD LEVEL line. o Start engine. Refill up to line while engine is idling until rear heat exchangers are warm to the touch (about 4 to 5 minutes). o Always monitor coolant level while filling tank to avoid emptying. o Install pressure cap. o Lift rear of vehicle and support it safely. o Blip the throttle 3 - 4 times to bring engine speed to 7000
RPM. o Apply the brake to stop the track. o Lower vehicle back on ground and add coolant up to 15 mm (1/2 in) above the COLD LEVEL line, as shown at right. o Lift front of vehicle approximately 60 cm (24 in) and support it safely. Let the vehicle idle for two minutes like this o Put the vehicle back on the ground and add coolant up to
15 mm (1/2 in) above the COLD LEVEL line. o When the engine has completely cooled down, recheck coolant level in coolant tank and refill up to the line if needed. o Check for coolant mixture freezing point. The specification is - 37°C (- 35°F). Adjust as necessary.
CHAPTER 5
REWIND STARTER
REWIND STARTER 5 - 1
REWIND STARTER 5 - 2
REWIND STARTER
Ref.
1
2
3-12
3
4
7
8
5
6
9
10
11
12
13
14
15
16
17
-
P/N
420810868
420241236
420889765
420811404
420939115
420852286
412500200
420852297
420852305
420847925
420250400
420852520
420845560
-
420941256
420899763
293530011
572084400
REWIND STARTER 5 - 3
REWIND STARTER
Qty Part descriptions
1
1
1
1
4
1
1
1
1
1
1
1
1
1
4
@
@
1
Connecting flange
Socket head screw M6 x 16
Rewind starter
Starter housing
Rewind spring
Rope sheave
Starter rope (2200mm)
Pawl
Pawl lock
Stage sleeve
O-ring
Lock ring
Locking element
Positioning pin
Hex collar screw M6 x 20
Molykote PG 54, 10g
Sealant, Sikaflex black # 221
Starter grip
REWIND STARTER 5 - 4
INSPECTION
● NOTICE:
Due to dust accumulation, rewind starter must be periodically cleaned, inspected and re-lubricated.
◆ CAUTION
It is of the utmost importance that the rewind starter spring be lubricated periodically using Molykote PG 54 (P/N 420 899
763). Otherwise, rewind starter component life will be shortened and/or rewind starter will not operate properly under very cold temperatures. o Check if rope # 6 is fraying, replace if so. o When pulling starter grip, mechanism must engage within 30 cm (1 ft) of rope pulled. If not, disassemble rewind starter, clean and check for damaged plastic parts. Replace as required, lubricate, reassemble and recheck. Always replace O-ring # 10 every time rewind starter is disassemble. o When releasing starter grip, it must return to its stopper and stay against it. If not, check for proper spring preload or damages. Readjust or replace as required.
O When pulling starter grip 10 times in a row, it must return freely. If not, check for damaged parts or lack of lubrication. Replace parts or lubricate accordingly.
REMOVAL o Using a small screwdriver, extract rope knot from starter grip # 17 . Cut rope close to knot. Tie a knot near starter. o Remove # 14 securing rewind starter to engine then remove rewind starter.
ROPE REPLACEMENT o Pull out rope. Hold rewind starter in a vise. Slide rope and untie the knot. Pull out the rope completely.
1) Knot to be untied.
● NOTICE:
When rope is completely pulled out, spring preload is 4 ½ turns.
DISASSEMBLY o Undo knot previously tied at removal. Let sheave get free to release spring preload. o Cut locking element # 12 and discard. Remove lock ring
# 11 , O-ring # 10 , stepped sleeve # 9 , Pawl lock # 8 and
Pawl # 7 . o Remove # 5 from starter housing # 3 . Hold the spring with a screwdriver. o Pull out knot and then pull out rope # 6 .
ASSEMBLY
At assembly, position spring # 4 outer end into spring guide notch then wind the spring counter clockwise into guide.
▼ WARNING
Since the spring is tightly wound inside the guide it may fly out when rewind is handled. Always handle with care.
1) Outer end into guide notch
REWIND STARTER 5 - 5
REWIND STARTER 5 - 6
◆ CAUTION
It is of the utmost importance that the rewind starter spring be lubricated periodically using Molykote PG 54 (P/N 420 899
763). Otherwise, rewind starter component life will be shortened and/or rewind starter will not operate properly under very cold temperatures. o Lubricate spring assembly and 1cm (1/2 in) wide on bottom of housing with Molykote PG 54.
1) Molykote PG 54
◆ CAUTION
The use of standard multi-purpose grease could result in rewing starter malfunction. o To install rope # 6 , insert rope into sheave # 5 orifice and lock it by making a knot, leaving behind a free portion of about 25 mm in length. Fuse rope end with a lit match and insert it into sheave. o Free portion inserted into the sheave. o Lubricate housing post with silicone compound grease.
Install sheave.
To adjust cord tension: o Wind rope on the sheave and place the rope sheave into the starter housing making sure that the sheave hub notch engages in the rewind spring hook. o Rotate the sheave counter-clockwise until rope end is accessible through rope exit hole. This will give ½ turn of preload. o Pull the rope out of the starter housing and temporarily make a knot to hold it.
o Lubricate # 7 with Molykote PG 54 (P/N 420 899
763) then install over rope sheave. o Lubricate pawl lock # 8 with Molykote PG 54. Install over pawl. o Instal stepped sleeve # 9 with its sleeve first. Lubricate a new O-ring # 10 and lock ring # 11 whit Molykote PG
54. Install over pawl lock.
1) Stepped sleeve
2) O-ring
3) Lock ring o Install the locking element nut # 12 .
INSTALLATION o Fuse rope end with a lit match. o Thread starter rope # 6 over guide pulleys and through eye bolt. o Reinstall rewind starter assembly on engine. o Pass rope through starter grip # 17 and tie a knot in the rope end. Insert rope end down and pull the starter grip over the knot.
REWIND STARTER 5 - 7
ENGINE REMOVAL 4-1
CHAPTER 4
ENGINE REMOVAL
ENGINE REMOVAL
Remove the hood, bellypan and rear module from vehicle. Refer to Chapter 1, GENERAL INSTRUCTIONS .
Remove the two forward brackets (P/N SH-032 L/R )
Remove tuned pipe, primary muffler and secondary muffler.
Refer to chapter 7, ENGINE .
Front fork
Use a crate or box to support the vehicle just under the drive sprockets when removing the fork.
ENGINE REMOVAL 42
ENGINE REMOVAL 4-3
Front fork
Unfasten the tie rod end which connects the steering columb to the upper triple clamp.
Unfasten the two fork bolts that retain the fork to the vehicle.
1. Tie rod nut
2. Upper fork bolt (other fork bolt is directly below it)
Carburators
Remove the rubber latch retaining the fuel tank and place it as shown on the right to have free access to air box and carburators.
Remove the air box.
Remove the carburators to the engine boots. Refer to chapter 3,
FUEL SYSTEM .
Water pump oil tank
Using a drill and a 3/16 in. Bit, drill out the two rivets that secure the water pump oil tank to mag side chassis.
Cut the tie-wrap that secure the choke cable to the oil tank hose.
1
2
Recoil Starter o Using a flat-head screwdriver, push the knot out of the recess in the starter handle. Since it is often easier, cut the cord just before the knot while holding the cord securely such that it does not slip and go into the recoil housing. Make a new knot in the cord once the starter handle has been removed to prevent this from happening. o Make a knot as shown at right.
Secondary Clutch o Open the secondary clutch using the the spacer tool
(P/N 529 008 700). For more details, see Chapter 8 –
Primary Transmission System. o Remove the bolt retaining the secondary clutch to the jackshaft and then slide the secondary off the jackshaft at the same time removing the drive belt. o Using the primary clutch holder tool (P/N 529 027 600), remove the primary clutch bolt. o Using the primary clutch puller (P/N 529 022 400) remove the primay clutch from the engine.
ENGINE REMOVAL 44
ENGINE REMOVAL 4-5
Engine Connector o Cut the tie-wrap and disconnect the two-place housing that connects the Crank Position Sensor (CPS) to the wiring harness (blue and white/yellow wires). This connector is located just above the jackshaft, near the ignition coil and the water pump oil reservoir. o The engine-side of the Crank Position Sensor (CPS) wire then passes down the height of the chassis – towards the magneto – and is attached to the tube that goes from the water pump oil reservoir to the water pump itself via a tie-wrap. Cut this tie-wrap as well. o Cut the tie-wraps that secure the wires from the engine to the voltage regulator. Then disconnect the four-place housing (yellow, yellow and yellow wires) and the twoplace housing (green and black wires) that is next to the four-place housing. o Unplug the two wires from the two temperature sensors located at the rear of the head of the engine.
Impulse Hose o Disconnect the impulse hose from the crankcase of the engine.
Cooling System o Loosen the hose clamp that holds the forward cooling hose to the water pump housing inlet at the front of the engine. With a bucket below this point, let the coolant drain from the system completely . o Loosen the hose clamp on the reservoir end of the short hose that runs from the head to the reservoir and disconnect the hose from the reservoir, as shown at right.
ENGINE REMOVAL 46
ENGINE REMOVAL 4-7 o Loosen the hose clamp farthest towards the PTO side on the PTO side heat exchanger and disconnect the hose there. This hose runs from the head of the engine to the inlet of the tunnel-mounted heat exchangers and should remain connected to the engine when removing. o Now that all of the peripheral equipment has been disconnected, unscrew and remove the 4 bolts (per side) that secure the engine plate to each side of the chassis. o PTO side bolts (x 4) o MAG side bolts (x 4) o Now the engine can be completely removed from the vehicle.
Re-Installating Engine
To re-install the engine, follow the instructions above in the reverse order. However, pay close attention to the following details : o Ensure that the 4 (per side) engine plate bolts are well torqued to 37 N-m (27lbf-ft, 325 lbf-in). Loctite 243 is recommended here. o Ensure the correct alignment of the clutches and the preload/deflection of the drive belt. o Ensure that each cable, wire and hose is properly connected and its original routing is used. ( See Chapter
17 – Wire, Cable and Hose Routing for more details.) o Ensure that each coolant line is re-installed using the original routing and that each hose clamp is well tightened. o Re-fill the coolant reservoir to the Cold Level line before attempting to start the vehicle. It is recommended to elevate the front of the vehicle about 12 in. off the ground when adding coolant to the system to ensure that all of the air bubbles will escape. See Chapter 6 –
Cooling System for more details.
ENGINE REMOVAL 48
CHAPTER 3
FUEL SYSTEM
FUEL SYSTEM 3 - 1
FUEL SYSTEM 3 - 2
FUEL SYSTEM
27
25
24
35
37
11
26
39
25
31
36
37
28
9
38
11
25
25
32
12
8
31
33
7
34
13
4
10
7
6
30
23
22
18
29
14
15
6
16
21
20
1
19
40
5
2
17
3
P/N
ADB-SH1
322111-BLK
907301-01
95-S21TQ
SH-166
508 000 132
508 000 346
3060-20-003
3060-20-005
415 128 729
512 059 835
07-0411
512 059 110
394 103 300
512 059 094
01-0053
24-1101
570 135 100
414 580 700
415 080 200-01
404 162 001-01
572 045 500
404 162 001-02
403 901 811
414 415 200
14-349-01
415 080 200-2
415 079 800-1
07-241
415 050 200-03
513 032 979
513 033 022-1
420 874 370
414 420 700
SH-092
SH-091
170-103
SN328-016
SN328-014
570 045 500
Ref.
10
11
12
13-15
33
34
35
36
29
30
31
32
37
38
39
40
-
25
26
27
28
21
22
23
24
17
18
19
20
14
15
16
8
9
6
7
3
4
5
1
2
Qty
Fuel system
Parts descripsions
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
2
1
1
1
1
1
Fuel tank 31L
Gaz tank cap
7/32" gaz tank (overflow)
Rubber rope 21"
Air box
Intake adaptor
Gemi clamp
Air filter
O-ring
Carburator kit TM-40
Gemi clamp
Throttle cable
Choke cable
Lock washer (interior teeth)
Plstic nut
Twist throttle
Handle grip (set)
Grommet
Male connector
Hose
Hose
T-fitting
Hose
Fuel pump
Spring clamp
Tubing
Hose
Impulse hose
In-tank filter
Hose
Spring clamp
Hose
Male connector
Spring clamp
Short spacer
Long spacer
T-nut
Hex head flange screw 1/4-20 x 1 1/4
Hex head flange screw 1/4-20 x 3/4
Grommet
FUEL SYSTEM 3 - 3
FUEL SYSTEM 3 - 4
CARBURET0RS (TM 40)
P/N
403 138 740
404 162 017
404 161 955
404 161 945
404 107 900
404 161 887
404 162 019
404 162 020
404 137 600
404 152 200
404 161 940
404 161 939
404 162 006
-XXX-
-XXX-
404 161 935
404 161 961
404 161 933
404 161 932
404 161 960
707 200 027
404 162 007
404 162 008
404 161 928
404 162 009
404 161 926
404 161 925
404 161 924
404 161 923
404 138 300
404 162 010
404 162 011
404 161 920
404 161 919
404 162 012
404 161 918
404 161 917
404 162 022
404 162 014
404 162 015
404 137 500
404 161 913
Ref.
1
8
9
6
7
4
5
2
3
10
11
12
13
34
35
36
37
30
31
32
33
38
39
40
41
42
26
27
28
29
22
23
24
25
18
19
20
21
14
15
16
17
Carburetors (TM 40)
Qty Part Descriptions
1
2
2
2
2
2
2
1
2
2
1
1
1
2
1
1
2
2
2
1
1
1
1
1
2
1
2
4
2
2
4
2
2
1
4
2
2
2
1
1
2
2
Carburator kit TM-40
Funnel (PTO)
Screw
O-ring
Main jet 490
Pilot jet 20
Needle 9DHI12-58-3
Piston Valve 2.0
Packing
E-ring
Gasket
Cover
Throttle shaft
Screw
Adjustment spring
O-ring
O-ring
Screw
Float
Float Body
E-ring
Plate
Holder
Screw
Lever
Ring
Ring
Ring
Screw
E-ring
Spring
Spring
Screw
Plate
Funnel (MAG)
Spring (PTO)
Screw (PTO)
Bracket (PTO)
Spring
Throttle shaft
Adjustment screw
Spring
FUEL SYSTEM 3 - 5
FUEL SYSTEM 3 - 6
Ref.
P/N
66
67
68
69
62
63
64
65
70
71
72
73
55
56
57
58
51
52
53
54
59
60
61
47
48
49
50
43
44
45
46
404 161 912
404 136 100
404 161 911
404 161 910
404 161 909
404 140 000
404 136 900
404 161 908
404 161 907
404 161 906
404 161 905
404 162 001
404 161 903
404 162 000
404 161 901
404 161 899
404 161 898
404 161 897
404 161 896
404 161 895
404 153 400
404 154 900
404 161 894
404 103 500
404 161 981
404 161 956
404 161 957
404 138 800
-XXX-
270 500 118
270 500 095
Carburetors (TM 40)
Qty Part Descriptions
1
2
1
1
2
3
2
2
8
1
2
2
1
2
2
1
2
2
2
1
2
2
2
2
2
2
2
2
3
1
1
Screw
Screw
Screw
Screw
Lever
Cap
Holder guide
Spring
Plunger ass'y
Screw
Nipple
Hose
Screw
Bracket
Starter lever
Cap
Adjuster
Spring
W asher
Packing
Nipple
Cap
Packing
Spring
Shaft ass'y
Hose
Clip
Screw
Spring
Packing
Closure cap
FUEL SYSTEM 3 - 7
REMOVAL
Loosen clamps # 7 retaining air box # 5 to carburetor assembly and remove air box.
Disconnect the carburetor support block that is located at the middle-bottom of the carburetor assembly. Pull rearwards on the upper portion of the block to disconnect it completely.
Loosen clamps # 11 retaining dual carburetor assembly to carburetor sockets.
Disconnect throttle and choke cables.
▼ CAUTION
Always loosen the LOWER nut when removing the throttle or choke cable as to avoid disturbing the settings of either.
Remove dual carburetor assembly, pinch and disconnect fuel line. Take care to recuperate fuel.
Clamp
Carburetor support
◆ WARNING
Fuel is flammable and explosive under certain conditions.
Always wipe off any fuel or oil spillage from the vehicle.
Ensure work area is ventilated. Do not smoke or allow open flames or sparks in the vicinity.
Fuel line
Lower nut
CLEANING AND INSPECTION
The entire carburetor should be cleaned with an all-purpose cleaner and dried with compressed air before disassembly.
Lower nut
▼ CAUTION
Heavy duty carburetor cleaner may be harmful to the float material and to the rubber parts, O-ring, seats, etc.
Therefore, it is recommended to remove those parts prior to cleaning.
FUEL SYSTEM 3 - 8
▼ CAUTION
Carburetor body and jets should be cleaned with carburetor cleaner following manufacturer’s instructions.
When jets are very dirty or coated with varnish and gum, replace them.
◆ WARNING
Solvents with a low flash point such as gasoline, naphtha, benzol, etc., should not be used as they are flammable and explosive.
Inspect the condition of the tip of the fuel inlet valve. If the tip is worn, replace both the valve and its seat.
● NOTICE:
Install only a snowmobile carburetor inlet valve as it is designed to function with a fuel pump.
Check to see if the throttle slide is worn and replace it if required.
Check for fuel that may have soaked into float; replace as necessary.
Check float for cracks or other damage affecting free movement; replace as necessary.
Inspect throttle and choke cables and housings for any damage.
Replace as necessary.
DISASSEMBLY AND RE-ASSEMBLY
● NOTICE:
To ease the carburetor disassembly and assembly procedure, it is recommended to use carburetor tool kit (P/N 404 112 000)
# 20 FLOAT BOWL
Unscrew drain screw # 3 and screw # 52. Remove float bowl.
# 19 FLOAT AND NEEDLE VALVE ASS’Y
Unfasten both screws # 18 then, pull out float and needle valve assembly # 19.
Upon re-assembly, apply Loctite 243 on screw threads.
# 5 MAIN JET
The main jet installed in the carburetor has been selected for a temperature of - 20°C (0°F) at sea level. Different jetting can be installed to suit temperature and/or altitude changes. A service bulletin will give information about calibration according to altitude and temperature.
Main jet # 5 may be removed without removing float bowl # 20 by first removing drain screw # 3.
# 6 PILOT JET
Use narrow screwdriver from carburetor tool kit (P/N 404 112
000) to unfasten pilot jet # 6.
◆ WARNING
It is critical to the free operation of the throttle slide that the 2 connecting plates as assembled in one carburetor be of the exact same length. Always replace the connecting plates by a pair of new ones that were matched at the factory for length and discard the old ones. Simultaneously replace all the plates of the carburetors of a same rack.
● NOTICE:
Do not disassemble throttle slide needlessly.
FUEL SYSTEM 3 - 9
FUEL SYSTEM 3 - 10
▼ CAUTION
After throttle slide reassembly, proceed with a leak test.
See below for procedure.
# 7 NEEDLE
Remove carburetor cover # 12 .
Loosen needle retainer screw # 33 .
Fully open throttle and hold in this position for the following step.
Move aside needle retainer # 34 .
1. Needle retainer moved aside.
Turn dual carburetor assembly upside down to free needle # 7.
Take care not to loose plastic washer # 9 under needle circlip #
10.
# 2 INTAKE SPICKET
Unscrew throttle slide cover screws # 70 .
Open throttle 3/4 wide and hold it there.
Lift throttle slide covers bottom first until they are free from carburetor bodies. Then, slide them out.
1. Lift bottom first
2. Slide out
After inserting throttle slide cover in place and be-fore installing screws, ensure O-ring gasket is properly seated in its groove especially in the area around vent nipple. See illustration at right.
2. Ensure O-ring gasket is properly seated in nipple area.
FUEL SYSTEM 3 - 11
CARBURETOR ADJUSTMENTS
Adjustments should be performed following this sequence:
-
-
Pilot screw adjustment
Carburetor synchronization and throttle slide height
(preliminary idle speed adjustment)
Throttle cable adjustment
Choke adjustment
Mikuni TM 40
Pilot jet
Air screw
Slide cutaway
Needle
Main jet
Fuel level
-
Final idle speed adjustment (engine running).
PILOT SCREW ADJUSTMENT
Completely close the pilot screw (until a slight seating resistance is felt) then back off as specified.
Turning screw clockwise leans mixture and conversely, turning it counter-clockwise enriches mixture.
Refer to “DIMENSIONS AND TOLERANCES” for the exact specifications.
1- Idle speed screw
2- Pilot screw (one on each carburetor)
Setting
MAG
20
1.5 turns
2.0
9DHI12-58-3
490
N/A
-
PTO
20
1.5 turns
2.0
9DHI12-58-3
490
N/A
-
FUEL SYSTEM 3 - 12
CARBURETOR SYNCHRONIZATION AND THROTTLE SLIDE
HEIGHT (PRELIMINARY IDLE SPEED ADJUSTMENT)
First proceed on PTO carburetor.
Use a drill bit to measure the throttle slide height (see table at right) on outlet side of carburetor (engine side).
1- Adjust PTO carburetor first
2- Drill bit used as a gauge to measure throttle height
3- Idle speed screw
Adjust by turning idle speed screw # 41 .
For MAG carburetor, proceed using the synchronization screw.
Use the same drill bit used for the PTO carburetor to measure throttle slide height. Turn synchronization screw to adjust.
1- PTO carburetor adjusted first
2- Drill bit used as a gauge to measure throttle height.
3- Synchronization screw
● NOTICE:
Make sure that throttle cable does not hold the throttle slide.
Loosen cable adjuster accordingly
Final idle speed adjustment (engine running at idle speed) should be within 1/2 turn of idle speed screw from preliminary adjustment.
Model
Snow hawk 800 HO 2007
-
Throttle slide height
(drill bit size)
± 0.1 mm (±0.004'')
1.6 mm ( 0,063'')
-
INSTALLATION
▼ CAUTION
Never allow throttle slide(s) to snap shut.
To re-install the carburetor, carry out the removal operations in the reverse order.
Be sure that the carburetor assembly is properly inserted into the engine intake sockets before tightening the two hose clamps. (A small amount of white grease can help here) After this, be sure to reconnect the black plastic carburetor support block to the lower shaft at the middle-bottom of the carburetor assembly.
THROTTLE CABLE ADJUSTMENT
Adjust throttle cable as per following procedure:
Loosen throttle cable housing adjusting and locking nuts.
Connect throttle cable barrel to carburetor cam lever # 40.
While holding throttle lever to wide open throttle position, pull on the throttle cable until mechanism touches the stopper. In this position, turn cable housing adjusting nut and tighten lock nut.
Also ensure that, when throttle is released to idle position, the idle adjusting screw end touches its stopper.
3- Locking nut
FUEL SYSTEM 3 - 13
FUEL SYSTEM 3 - 14
CHOKE CABLE ADJUSTMENT
Adjust choke cable as per following procedure:
Loosen choke cable housing adjusting and locking nuts.
Connect choke cable on starter lever # 57.
While choke lever is fully open, pull choke cable until starter lever reaches the stopper. Tighten cable housing adjusting and locking nuts in this position.
As a confirmation, the gap between the stopper and the bracket should be within 0 and 0.5 mm (0 and 1/64 in).
A - Within 0 and 0.5 mm (0 and 1/64 in)
Idle Speed Final Adjustment
Start engine and allow it to warm then adjust idle speed to specifications by turning idle speed screw clockwise to increase engine speed or counterclockwise to decrease it.
Refer to Chapter 15 – Dimensions and Tolerances for the specifications.
● NOTICE:
Do not attempt to set the idle speed by using the pilot screw.
Severe engine dam-age can occur.
FUEL PUMP
REMOVAL
Install a hose pincer (P/N 295 000 076) on fuel supply line close to pump inlet.
Disconnect fuel outlet line(s).
Disconnect impulse line.
Remove screws securing fuel pump to chassis.
PUMP VERIFICATION
Check fuel pump valves operation as follows:
Connect clean plastic tubing to the inlet nipple and alternately apply pressure and vacuum with pump of leak test kit. The inlet valve should re-lease with pressure and hold under vacuum.
Repeat the same procedure at the outlet nipple. This time the outlet valve should hold with pres-sure and also under vacuum.
Check impulse diaphragm and gasket as follows:
Connect clean plastic tubing to the impulse nipple and plug vent hole on top cover with a finger. Either applies pressure or vacuum using the pump (P/N 529 021 800) from the Engine leak tester kit. The diaphragm/gasket must not leak.
1- Pump
2- Plug vent hole
FUEL SYSTEM 3 - 15
FUEL SYSTEM 3 - 16
CLEANING AND INSPECTION
Check fuel pump valves operation as follows:
The entire pump should be cleaned with general-purpose solvent before disassembly.
Fuel pump components should be cleaned in general purpose solvent and dried with compressed air.
◆ WARNING
Solvent with a low flash point such as gasoline, naphtha, benzol, etc., should not be used as each is flammable and explosive.
Inspect diaphragm. The pumping area should be free of holes, tears or imperfections. Replace as needed.
INSTALLATION
Inverse removal procedure.
◆ WARNING
Perform a pressure test to ensure there is no leak in the fuel system.
Chapter 2
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE 2 - 1
PERIODIC MAINTENANCE 2 - 2
● NOTICE:
Regular inspection and maintenance of the Snow Hawk is of utmost importance. Follow the guidelines in the table below for optimum vehicle performance. Suggested intervals must be reduced if the vehicle is subjected to severe usage conditions.
Interval (Hrs)
Item
2.1 Carburetion
2.2 Motor
2.3 Primary transmission system
2.4 Secondary transmission system
2.5 Brake system
2.6 Front suspension and ski
2.7 Rear suspension and track
2.8 Chassis
2.9 Electrical system
Fuel lines and connections
Carburetor adjustment
Throttle cable
Air Intake Filter
Carburetor support bracket
Starter cord
Cylinder head bolts
Engine support bolts
Exhaust system
Coolant level
Oil level (water pump oil reservoir)
Cooling System (hose connections)
Primary drive belt
Primary and secondary clutch
Primary clutch bolt
Secondary clutch pre-tension
Secondary drive belt (cog belt)
Cog sprockets
Torque Limiter
Taper Locks
Brake fluid
Brake pads
Brake microswitch
Front Fork
Fork rubber cushion and bolt
Fork air bleeder screw
Twin axis ski bushings / nuts
Ski and runners
Suspension
Shocks
Track
Handlebar bolts
Steering components
Assembly bolts / nuts
Spark plugs
Spark plug gap
Fuse
Headlight projection/aim
Lighting system, stop lamp and emergency stop switch
● NOTICE:
V = Verify, A = Adjust, C = Clean, R = Replace one or several part(s), F = Replace fluid
Break-in
( ~ 10 Hrs. )
V
V
V
V
V
F
V
V - A
V - A
V
V
V
V - A
V
V
V
V - A - R
V - A
V
-
V
V
V - A
V
-
V
V
V
V
V - A
V - A
V
V
V
V
V - A
V
V
V
5 Hrs 15 Hrs
65 Hrs
(yearly)
-
V
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
V
V
V
-
-
V
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
V - A
-
-
-
-
V - R
-
F
V
V - A
V - A
V - R as needed
V
V
V - A
V - A
V
F
V - R
V
F
V
V - A
V - A
V - R
-
F
V - A
-
V
V
V
V - C
V - A - R V - A - R
-
-
-
V - A
V
V - A
V
V
V - A
V - C
V
V - F
V
V
V - R
V
V
V
V
V - C
V
V - A
V
V
V V
2.1. CARBURATION
Fuel lines and connections
Check all hoses and connections in order to find and fix leaks and/or to help prevent them.
Carburetor adjustment
For carburetor adjustment, refer to Chapter 3 Fuel system section.
Throttle cable
The throttle cable can be adjusted by setting the adjustment mechanism on the throttle end of the throttle cable.
Air intake filter
The air intake filter must be cleaned at least once a year, or more often under severe usage conditions. Clean the filter in a solution containing a non-flammable cleaning solvant (such as hot soapy water). Once dry, apply some light engine to the filters to prevent the infiltration of water and dust.
2.2. ENGINE
Recoil starter cord
Pull gently on the handle to unwind the full length of the cable.
Inspect the cable visually to detect any wear or other damage that could eventually cause the cord to break.
Cylinder head bolts
Refer to the appropriate procedure in Chapter 7 – Engine
(Cylinders/Head/Base).
Engine support bolts
To carry out this operation, refer to the appropriate procedure in
Chapter 7 – Engine (Cylinders/Head/Base).
PERIODIC MAINTENANCE 2 - 3
PERIODIC MAINTENANCE 2 - 4
Exhaust system
Using a torque wrench, check the torque of the retaining bolts of the exhaust manifold. Apply a torque of 10 N-m (1 kg-m, 7.4 lbfft) .
Then, proceed to a visual inspection of the system to detect any leak or abnormality in the gasket material.
Cooling system
Inspect the coolant level in the coolant reservoir located on the
MAG side of the vehicle. If the coolant level is below the “Cold” coolant mark when the vehicle is not warm or has not been ridden within 30mins or more, add coolant until this line. Check all of the hoses / hose connections and ensure that there are no fluid leaks in the system.
Cold
Level
2.3. PRIMARY TRANSMISSION
Primary and secondary clutches
Remove the belt and verify that the sliding half-pulleys of the two clutches is in good working condition.
To take the belt off, first use the special tool provided to open the secondary clutch (P/N 529 008 700). Then, slip the belt over the pulley from rear to front as illustrated. To reinstall the belt, proceed in the reverse order.
Primary clutch bolt
Check the torque on the primary clutch retaining bolt.
Recommended torque: 90 - 100 N-m (9–10 kg-m, 70 lbf-ft).
For more information, refer to Chapter 8 - Primary
Transmission System .
Pre-tension of the secondary clutch spring
For more information, refer to Chapter 8 - Primary
Transmission System .
Primary transmission belt
Examine the belt. Make sure it is not cracked, frayed or worn in an abnormal way (uneven wear, wear on one side only, missing cogs, or cracked material). Abnormal wear of the belt is often due to mis-alignment of the pulleys, excessive throttle when the track is frozen, quick acceleration without a preliminary warmup, a scratched or rusted pulley, oil on the belt, or a twisted replacement belt. If need be, ask an authorized SNOW
HAWK™ dealer for advice.
Measure the width of the belt. Replace if it is less than 31.6 mm
(1.245 in) wide .
PERIODIC MAINTENANCE 2 - 5
PERIODIC MAINTENANCE 2 - 6
For more information, refer to Chapter 8 - Primary
Transmission System .
Secondary transmission cog belt
Examine the cog belt. Make sure it is not cracked, frayed or worn in an abnormal way. If in doubt as to the condition of the belt, replace it with a new one.
Verify the tension of the secondary transmission belt according to the instructions found in Chapter 9 - Secondary
Transmission System .
Cog Sprockets
Check the appearance of the cog sprockets. Make sure all the sprockets are there and are free of any accumulated dirt. Clean if necessary.
Taper-locks
Refer to Chapter 9 - Secondary Transmission System .
Brake fluid
Check to see if the brake fluid level is above the "mimimum" mark (see illustration). If not, add fluid.
▼ CAUTION
Use only DOT 4 brake fluid from a sealed container. Do not use any other type of brake fluid.
MIN
Brake pads
Verify the thickness of the brake pad linings as illustrated. Brake pads must both be replaced if either one of them shows a clearance of less than 1 mm (1/32 in.).
● NOTICE:
For the replacement of brake fluid, refer to Chapter 10 –
Hydraulic Brake System .
2.6. FRONT SUSPENSION AND SKI
Front fork
The air pressure inside the fork legs must be as close as possible to atmospheric pressure. Therefore, it is advisable to remove the bleeder screws after every ride to re-establish the pressure. It should be done more frequently when temperature variations are greater and more frequent (such as when the vehicle is stored in a heated garage).
A visual inspection of the fork legs can reveal oil leaks that might indicate broken main seals. If excessive oil is presest on the lower fork leg, a seal replacement may be required.
It is recommended to replace the fork oil after the break-in period and, from then on, after every 15 hours of use. For details, refer to Chapter 11 – Front Fork and Twin-Axis Ski.
▼ CAUTION
It is advisable to change the fork fluid when preparing the vehicle for storage. The presence of condensation in the suspension fluid could cause corrosion during the storage period.
Twin-Axis Ski and Runners
Verify the torque of all the bolts holding the ski, as well as all the studs and nuts retaining the runners. Also inspect the appearance of the runners to detect any wear, distortion, or broken studs.
PERIODIC MAINTENANCE 2 - 7
PERIODIC MAINTENANCE 2 - 8
2.7. REAR SUSPENSION AND TRACK
Suspension
Verify that all suspension bolts and nuts are well tightened, especially the four that retain the suspension to the chassis (use
Loctite 243 here) Verify that none of the parts are damaged or missing.
Verify that the suspension wheel bearings are in good working order. Check the condition of the suspension limiter straps.
Check the condition of the hyfax.
For more information, refer to Chapter 12 - Rear suspension and Track .
Shock absorbers
Check around the shock guards for the presence of oil leaks.
Shock oil must be replaced once a year. Refer to Chapter 12 -
Rear suspension and Track.
▼ CAUTION
It is advisable to change the shock fluid when preparing the vehicle for storage. The presence of condensation in the suspension fluid could cause corrosion during the storage period.
Track
Check the condition, alignment and tension of the track.
With the engine turned off and the rear end of the machine raised from the ground, rotate the track manually and inspect it to make sure it is in good working condition. It must not be cracked and all the lugs must be intact.
● NOTICE:
For track alignment and tension, refer to Chapter 12 - Rear
Suspension, Shocks and Track.
CHASSIS AND STEERING
Handlebar mounting bolts
Verify and adjust the torque to 36.5 N-m (3.7 kg-m, 27 lbf-ft) , following a criss-cross order.
Steering mechanism
Verify the condition of the tie rod ends and check for excessive play in the pivots of the steering system. For alignment, refer to
Chapter 13 – Chassis and Steering.
Assembly
The chassis of the SNOW HAWK is different in that most of the assembly is done by bolting components rather than welding them. Therefore, bolts must be checked and tightened as need be. When doing this, refer to the Torque Table at the end of this section.
PERIODIC MAINTENANCE 2 - 9
PERIODIC MAINTENANCE 2 - 10
Spark plug
Check the general condition of the plug, the colour of its electrodes, carbon deposits, plug gap and possible damage to the gasket
A NGK BR9ECS spark plug is recommended.
Check the spark plug gap. The suggested gap is 0.45 mm
(0.018").
When tightening the spark plug, the torque must be between 25 and 30 N-m (18 and 21.5 lbf-ft; 2.5 and 3.0 kg-m) .
Porcelain Colour
Light Grey (Overheated)
Blackish (Fouled)
Probable Cause
- Plug Temperature rating is too high
- Plug gap too wide
- Air/Fuel mixture too lean
- Stale gasoline
- Plug temperature rating too low
- Plug gap is too small
- Air/Fuel mixture too rich
- Oil/Fuel mixture too rich
Lean
(light grey)
▼ CAUTION
The engine may be seriously damaged if the temperature rating of the spark plug is inadequate.
Refer to the NGK codification on the next page.
Normal
(brownish)
Rich
(black)
Symbols used on the NGK spark plugs
PERIODIC MAINTENANCE 2 - 11
PERIODIC MAINTENANCE 2 - 12
Spark plug gap
The suggested gap is 0.45 mm (0.018"). For more information, refer to Chapter 14 – Electrical System.
Wiring Harness
Electrical wires and connections should be inspected visually to quickly locate broken wires or faulty connections. For more information, refer to Chapter 14 – Electrical System.
Headlamp, stop lamp and engine cut-off switch
Before each ride or excursion, it is recommended to verify that the headlamp, the stop/tail lamp and the engine cut-off switch are in good working order.
TORQUE TABLE
ITEM
Torque Limiter bolts (6)
Rear Suspension mounting bolts (4)
Rear Suspension lower swingarm bolts (2)
Recoil starter housing bolt
Primary clutch bolt
Secondary clutch bolt
Taper-Lock installation setscrews
Spark plugs
Handlebar mounting bolts
Triple clamp bolts
Fork pivot bolts
Ski runner nuts (4)
Lower clamp nuts
Ski saddle/fork adaptor nut
14
25
36.5
6.8
45
19
23
85
N-m
6.2
51
90
7
90
31.7
1.4
2.5
3.65
0.68
4.5
1.9
2.3
8.5
kg-m
0.62
5.1
9
0.7
9
3.17
For any other bolt or screw that is not mentioned in the list, please refer to the following table.
10.4
18
27
5
33
14
17
63 lbf-ft
4.6
38
66
5
66
23
BOLT
DIAMETER
(MM)
6
8
10
12
N-m
10
25
49
85
GRADE " 8.8 " kg-m
1
2.5
4.9
8.5
lbf-ft
7
18
36
63 lbf-in
84
216
432
756
N-m
15
36
72
125
GRADE " 10.9 " kg-m
1.5
3.6
7.2
12.5
lbf-ft
11
27
53
92
125
216
324
60
396
168
204
756 lbf-in
55
450
792
62
792
276 lbf-in
132
324
636
1104
CHAPTER 1
GENERAL INSTRUCTION
GENERAL INSTRUCTIONS 1 - 1
GENERAL INSTRUCTIONS 1 - 2
FIRST CONTACT
The SNOW HAWK™ is a completely new type of vehicle.
Technically speaking, it is a cross between a snowmobile and a motorcycle. However, its behaviour depends on the conditions in which it is used. Sometimes, it will react more like a bike while at other times, it will react more like a snowmobile or a jetski.
Describing exactly how the SNOW HAWK™ behaves is difficult.
This is why we recommend that you take the time to become acquainted with your machine in an area free of any obstacle.
This first contact should take place at low speed, with a series of basic manoeuvres that will allow you to learn about the reactions of the vehicle.
A good exercise is to follow a "figure 8" trajectory because this will allow you to experiment with right- and left-hand turns followed by accelerating and braking.
Turning can be done by steering right or left, keeping in mind the speed of the vehicle, the snow conditions and how quickly you want to change direction.
◆ WARNING
Some people enter a turn by stretching out a leg on the inside of the turn and letting the foot slide over the ground (a technique used in motocross). We advise against this practice which could cause severe injuries if your foot should sink into the snow. We rather suggest keeping both feet on the footpegs as much as possible.
An upright position, with the knees clutching the gas tank and the elbows pointing away from the vehicle, will give a sense of security and provide greater freedom of movement while accelerating or slowing down.
◆ WARNING
The greatest danger in using this vehicle is the perception you may have of how competent you are. Overestimating how competent you are can result in hazardous situations both for yourself and for other trail users.
Do not forget to take all the time that is necessary for you to practice and feel comfortable at low speeds before attempting high-speed manoeuvres. You will then be able to fully appreciate the joy of driving.
GENERAL INSTRUCTIONS 1 - 3
LOCATION OF MECHANISMS AND CONTROLS (503 SHOWN, 800HO IDENTICAL)
6
3
4
5
2
8
1
9
7
1. Throttle control
2. Brake lever
3. Parking brake lever
4. Engine-cutoff (tether)
5. Gas tank cap
6. Dimmer switch
7. Choke control
8. Emergency-stop button
9. Temperature Light
14 10
15
11
13
10. Hood latches (4)
11. Rear module latches (4)
12. Bellypan latches (6)
13. Kick stand
14. Headlight
15. Stop and tail light
12
18 16
17
16. Recoil starter handle
17. Hood latches (4)
18. Rear module latches (4)
19. Bellypan latches (6)
19
GENERAL INSTRUCTIONS 1 - 4
FUEL
This vehicle is powered by a two-stroke engine that uses a premixed gasoline and oil mixture.
Gasoline: Regular unleaded gas with a minimum octane rating of 89 (R+M)/2
Motor oil: Bombardier / ROTAX Formula XPS Synthetic
Pre-mix oil (P/N 293 600 045)
Mixture ratio: 32 : 1
Fuel tank capacity: 30 L (9.5 gallons)
▼ CAUTION
A mixture in which the proportion of oil is too low will cause piston failure. On the other hand, a mixture in which the proportion of oil is too high will cause excessive carbon deposits that will result in fouled spark plugs and will affect performance.
Always mix in a proportion of 32 parts of gasoline for each part of oil.
● NOTICE: o The use of isop[ropyl alcohol (commonly known as “gasline antifreeze) is recommended in a ratio of 150 mL per fuel tank in very cold temperatures. o Avoid mixing oils of different brands.
Gasoline
( L )
5
10
15
20
25
30
Oil
( ml )
156
313
469
625
781
937,5
OPERATING INSTRUCTIONS
Pre-driving inspection
◆ WARNING
A pre-driving inspection is of the utmost importance before using the vehicle. Do not start the machine until you are sure all mechanisms and controls are functioning properly. Failing to proceed in the prescribed manner may result in severe injuries or even death. o Make sure the track and the idler wheels are not frozen and that they move freely. o Depress the brake lever and make sure the brake is fully engaged before the end of the lever touches the handlebar.
The lever must return to its original position as soon as it is released. o Turn the twist throttle control a few times to make sure it functions properly. The control must return automatically to the idle position as soon as it is released. o Make sure the engine cutoff switch, the stop light, the headlight (high and low beams) and the tail light are in good working order.
Starting the engine o Put the cap of the engine cutoff (tether) switch in place. The other end of the cord must be securely attached to the driver. o If the engine is cold, use the choke control.
0. Normal position (not activated)
1. Intermediate choke position
2. Full choke position o Start the engine by firmly pulling the handle of the rewind starter.
◆ WARNING
Do not touch the throttle control while starting the engine.
GENERAL INSTRUCTIONS 1 - 5
GENERAL INSTRUCTIONS 1 - 6
Stopping the engine o While the engine is idling, remove the engine cutoff cap
(tether) or press the emergency-stop button.
BREAK-IN PERIOD
Engine
▼ CAUTION
A cautious break-in period of 10 to 15 hours is essential before using the vehicle at full power. Failure to provide a sufficient break-in period could result in severe engine damage.
▼ CAUTION
The timing of all Snow Hawk 600HO’s is retarded by 3 o
for a period of 1-hour during the first stages of the break-in period.
You may notice a slight increase in performance and a reduction in fuel consumption after this time.
During the break-in period, the throttle control should not be turned more than ¾ of its range. However, occasional periods of brief, brisk acceleration and frequent speed variations contribute to a good break-in. On the other hand, periods of long, high acceleration, sustained high speed and engine overheating are harmful during the break-in period.
◆ WARNING
This vehicle is equipped with a liquid cooling system. ALWAYS ride with the rear deflector pad installed and in conditions where there is enough snow to properly cool the engine. If the red temperature light on the steering column should ever illuminate, stop immediately and let the vehicle cool down, and then find some snow. NEVER continue to operate the vehicle with the temperature light illuminated as severe engine damage will occur.
◆ WARNING
During the first hour of the break-in period the fluid levels in the coolant reservoir and the small water pump oil reservoir will go down slightly. This is perfectly normal. Be sure to top-up these fluids with proper coolant (P/N 293600038) and proper oil (P/N
293600045).
Drive Belt
A new drive belt must be submitted to a 5-hour break-in period.
Avoid high-speed driving and brisk accelerations during this period.
Inspection – 10 hours
A general inspection is recommended after the first 10 hours of use. This inspection must be carried out by an authorized
SNOW HAWK ™ dealer.
● NOTICE: o Most of the wear in this vehicle occurs during the break-in period. o Bolts and nuts can easily become loose in a new machine.
Make sure you check them regularly during this period.
REMOVAL OF THE BODY PANELS (HOOD, REAR
MODULE AND BELLYPAN)
In order to work on the vehicle more easily and to access the anchor ties, we suggest that you remove the rear module from the vehicle. To do so, you must first remove the hood. Proceed as follows: o Disconnect the front headlight. o Unhook the 4 rubber latches (2 / side). o Remove hood. o Remove the fuel tank cap. o Set the choke to the full position. o Unplug the tail light connector located under the light itself, underneath the rear fender. o Release the rear module from its four rubber latches, slip the rewind starter handle through the space provided and remove the rear module.
GENERAL INSTRUCTIONS 1 - 7
GENERAL INSTRUCTIONS 1 - 8
Roll the two O-rings down and pull the two white plastic collars down over the fork legs. To ensure that they will not interfere, let them hang loose at the base of the fork leg. o Remove the circular fork disc o De-latch the two rubber latches on the sides of the belly pan (towards the rear of the vehicle) o De-latch the four rubber latches on the bottom of the belly pan. o Descend the belly pan to floor level; most maintenance can be performed with the belly pan in this position.
However, if it is required to completely remove the belly pan, remove the single bolt attaching the ski to the fork.
At this point, a second person can lift the front of the vehicle slightly and the belly pan can be slid out from underneath.
TABLE OF CONTENTS
GENERAL INSTRUCTIONS
PERIODIC MAINTENANCE
FUEL SYSTEM
ENGINE REMOVAL
REWIND STARTER
COOLING SYSTEM
ENGINE (CYLINDERS / HEAD / BASE / EXHAUST)
PRIMARY TRANSMISSION SYSTEM
SECONDARY TRANSMISSION SYSTEM
HYDRAULIC BRAKE SYSTEM
FRONT FORK AND TWIN-AXIS SKI
REAR SUSPENSION, SHOCKS, TRACK AND REAR PAD
CHASSIS, STEERING AND BODY
ELECTRICAL SYSTEM
DIMENSIONS AND TOLERANCES
WIRE, CABLE AND HOSE ROUTING
12
13
14
15
16
9
10
11
7
8
5
6
3
4
1
2
FOREWORD
Congratulations and thank you for buying an
A.D. Boivin design inc.
Snow Hawk™ vehicle.
We appreciate the confidence in our product that you have demonstrated by making this purchase .
Several years of design, tests and improvements were necessary to produce this vehicle which combines performance, driving pleasure and safety.
Proper maintenance on a regularly-scheduled basis is essential in order to obtain the performance you have the right to expect from your machine. In this manual, you will find all the information needed for adjustments to and the maintenance of this vehicle.
We sincerely hope that you will have many years of enjoyment with your Snow Hawk™.
AD Boivin design Inc.
All the information, illustrations, photographs and specifications found in this manual are based on the latest available data at the time of publication. Due to improvements or other changes, it is possible that you will note a few differences. AD Boivin design Inc. reserves the right to make changes at any time.
WARNING /CAUTION / NOTICE
Please read this manual and follow the instructions carefully. Pay particular attention to the boxes entitled WARNING and CAUTION as well as to the paragraphs preceded by the word
NOTICE .
◆ WARNING
This symbol is designed to call attention to particular instructions and procedures, which, if not followed to the letter, could cause injury and even fatal accidents.
▼ CAUTION
This symbol is designed to call attention to particular instructions and procedures, which, if not followed to the letter, could cause damage to or even destruction of the vehicle.
● NOTICE: The information in the NOTICES is designed to explain maintenance procedures and to ensure the best possible use of the vehicle.
IMPORTANT REMARKS
Using this vehicle can be a very pleasurable experience and we wish you all the enjoyment that it can bring you. However, if certain rules are not respected, this sport can become a source of environmental problems and of interpersonal conflicts.
Adopting a responsible attitude and behaving in a responsible manner at all times will help avoid such problems and conflicts.
Protect the Future of your sport. Be responsible and respect local laws at all times. Demonstrate an awareness of the importance of the environment and respect the rights of others.
WARRANTY
Refer to A&D Boivin warranty policies section.
LOCATION OF THE V.I.N.
There are two emplacements for the V.I.N on right side of vehicle.
I
IMPORTANT MAINTENANCE
WARNINGS:
◆ WARNING
Never have the motor running inside a building.
The exhaust fumes contain carbon monoxide, a colourless, odourless gas which can cause death or severe injuries.
Allow the motor to run only in a well-ventilated area.
◆ WARNING
When hot, a motor, an exhaust system or a drive system can cause burns.
Wait until they have cooled before carrying out maintenance.
◆ WARNING
The gas tank can catch fire if it is not handled correctly. Gas vapours can burst into flames easily.
Do not smoke while carrying out vehicle maintenance.
Do not carry out maintenance anywhere near exposed flames or sparks.
◆ WARNING
Brake fluid can be dangerous for people and animals. These fluids are harmful or fatal if swallowed and must not come into contact with the skin or eyes.
◆ WARNING
Carrying out maintenance of this vehicle while the motor is running can be dangerous. Injuries could result from contact with moving parts.
Make sure you turn off the motor before working on the vehicle.
II
◆ WARNING
Working on this vehicle without wearing the appropriate clothing can be dangerous. Injuries could result if you are not adequately protected.
Always wear the necessary equipment when working on the vehicle: shoes, goggles, gloves and/or mask if necessary.
Important information maintenance o Replace any joints, brake shoes, pins and clips by new ones. o Use special tools when so indicated. o Use original parts as well as recommended products. o After reassembling the vehicle, inspect the parts and verify the torque on the nuts and bolts.
Replacement parts
Use only A D Boivin parts or their equivalent.
A&D Boivin’s original high-quality parts are designed and manufactured especially for your vehicle.
● NOTICE: Using replacement parts that are not equivalent or are of inferior quality could mean your vehicle will not be able to perform as it should and could damage your machine.
Carte de garantie
( An English copy is on the reverse )
NUMÉRO D'IDENTIFICATION DU VÉHICULE
MODÈLE
______________________
_____________________________________________
COURRIER ÉLECTRONIQUE
PROPRIÉTAIRE ENREGISTRÉ
_____________________________________________
_____________________________________________
ADRESSE
VILLE
ÉTAT/PROVINCE
ZIP/CODE POSTAL
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
NUMÉRO DE TÉLÉPHONE
LIEU D'ACHAT
DATE D'ACHAT
SIGNATURE DU PROPRIÉTAIRE
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
SIGNATURE DU CONCESSIONNAIRE ____________________________________
En signant cette carte, le propriétaire consent avoir pris connaissance de l'avis légal fournit avec le véhicule. La garantie du véhicule n'est pas valide si la carte de garantie n'est pas signée par le propriétaire.
Veuillez svp conserver cette copie de votre carte de garantie à l'intérieur de votre guide pour toute référence future.
( An English copy is on the reverse )
NUMÉRO D'IDENTIFICATION DU VÉHICULE
MODÈLE
COURRIER ÉLECTRONIQUE
______________________
_____________________________________________
_____________________________________________
PROPRIÉTAIRE ENREGISTRÉ
ADRESSE
_____________________________________________
_____________________________________________
VILLE
ÉTAT/PROVINCE
_____________________________________________
_____________________________________________
ZIP/CODE POSTAL
NUMÉRO DE TÉLÉPHONE
_____________________________________________
_____________________________________________
LIEU D'ACHAT
DATE D'ACHAT
_____________________________________________
_____________________________________________
SIGNATURE DU PROPRIÉTAIRE _____________________________________________
SIGNATURE DU CONCESSIONNAIRE ____________________________________
En signant cette carte, le propriétaire consent avoir pris connaissance de l'avis légal fournit avec le véhicule. La garantie du véhicule n'est pas valide si la carte de garantie n'est pas signée par le propriétaire.
Veuillez svp compléter cette copie de la carte de garantie et nous la retourner afin d'activer la garantie d'un an pour les pièces et la main d'oeuvre. Veuillez noter que les renseignements contenus sur cette carte de garantie ont la priorité sur tout autre document.
Warranty Card
( Une version en français se situe au verso )
VEHICLE SERIAL NUMBER
MODEL
EMAIL ADDRESS
REGISTERED OWNER
ADDRESS
CITY
STATE/PROVINCE
ZIP/POSTAL CODE
TELEPHONE NUMBER
PLACE OF PURCHASE
DATE OF PURCHASE
OWNER SIGNATURE
DEALER SIGNATURE
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
The owner certifies that he carefully read the legal notice joined with the vehicle. If the warranty card is not signed by the vehicle owner, the warranty is void.
Please complete and keep this copy of your warranty registration card in your service manual for future reference.
( Une version en français se situe au verso )
VEHICLE SERIAL NUMBER
MODEL
EMAIL ADDRESS
REGISTERED OWNER
ADDRESS
CITY
STATE/PROVINCE
ZIP/POSTAL CODE
TELEPHONE NUMBER
PLACE OF PURCHASE
DATE OF PURCHASE
OWNER SIGNATURE
DEALER SIGNATURE
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
The owner certifies that he carefully read the legal notice joined with the vehicle. If the warranty card is not signed by the vehicle owner, the warranty is void.
Please complete and mail this copy of your warranty registration card to us in order to activate the one year parts & labour warranty for your Snow Hawk. Please note that the information contained on this warranty card takes precedence over other documentation.

Public link updated
The public link to your chat has been updated.
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