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ski-doo MACH Z 1000 SDI
BRP ski-doo MACH Z 1000 SDI User Manual
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Mmc-2005-001 Racing.FH8 Wed Sep 15 15:27:01 2004 Page 1
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2
Table of Contents
2005 Racing Handbook
2
Table of Contents
2
Contacting the Race Department
3
MX Z X 440 Racing/MX Z 600 Ho/800Ho
8
Models Technical Data
9
MX Z X 440 Racing
9
MX Z 600 Ho/800Ho
12
MX Z 380F/550F
17
Summit 600 Ho/800Ho
21
Mach Z 1000 Sdi/Summit 1000 Sdi
26
Technical Data Legend
30
Table of Contents
31
Default Chapter
32
Suspension Operation/ Weight Transfer
32
Springs
33
Spring Description
36
COIL SPRINGS (Compression)
36
Torsion Springs
37
Spring Applications
38
Spring Specifications
41
Cornering Dynamics
45
Shocks
46
Chassis Set-Up
57
Brakes
59
Adjusting Ride Height
60
Track Guides
61
Skis and Runners
61
Bump Steer
62
Ski Leg Camber
62
Ski Toe-Out
63
Chassis Tuning Guidelines
64
Steering System
66
Disassembly and Assembly
68
Inspection
71
Adjustment
71
Steering Adjustment (Skis)
75
Lubrication
77
Body
78
Headlamp Beam Aiming
78
Bulb Replacement
78
Decal
79
Windshield
79
Guard
80
Wiring Harness
80
Cables
80
Tubing
80
Maintenance
80
Repair
81
Frame
82
Frame Cleaning
82
Frame Welding
82
Frame Replacement
82
Suspension Sc-3 Sc-4 - Ras
83
Front Suspension
84
General Inspection
85
Disassembly
85
Inspection
89
Installation
89
Sc-10 III Suspension
94
Component Removal and Installation
97
Suspension Assembly Removal
98
Disassembly and Assembly
99
Shock Absorber Inspection
101
Hpg T/A Shock Servicing
102
Installation
110
Ride Adjustment
110
Lubrication
110
Internal Floating Piston Measurement
111
Shock Rebuild Procedure
113
C-36 Hpg
116
Shock Calibration Work Sheet
117
Sc IV Rear Suspension
118
On Rider Forward Vehicle
120
Construction
121
Engine Preparation
125
Default Chapter
126
Accessories
126
Engine Tuning Cautions
128
Basic Engine Theory
128
Operation of the Rave Valve
131
Carburetion
135
Mikuni VM and Tm Type Carburetors
139
Ignition Systems, Spark Plugs
151
Carburetor - VM Type
154
Identification
155
Removal
155
Cleaning and Inspection
155
Disassembly and Assembly
155
Carburetor Float Level Adjustment
156
Carburetor Adjustment
157
Installation
158
Choke
159
Carburetor Tm Type
161
Identification
162
Removal
162
Cleaning and Inspection
163
Disassembly and Assembly
164
Carburetor Adjustment
165
Installation
167
Dpm
168
Testing
168
Parts Removal and Installation
168
Dpm Manifold Testing
169
Throttle Cable
171
Throttle/Oil Pump Cable Removal
171
Throttle/Oil Pump Cable Installation
171
Throttle/Oil Pump Cable Adjustment
171
Spark Plugs
173
Disassembly
173
Spark Plugs Installation
173
Spark Plugs Tightening
173
Ignition Timing
174
Checking Ignition Timing
175
Changing Timing
176
Testing Procedure
180
Checking Calibration Program
183
Changing Mpem Calibration Program
186
System Testing
187
Inspection of Heating Elements
194
Mmc2005-001_05A.fm
194
Fuel Tank and Fuel Pump
196
Fuel Filter
197
Fuel Tank
197
Impulse/Fuel Lines Spring Clips (All Models)
198
Float Type Fuel Level Gauge
199
Electric Fuel Level Sensor
199
Fuel Level Sensor Screws
199
Fuel System Pressurization
199
Fuel Pump
200
Pump Verification
201
Cleaning and Inspection
201
Exhaust System
202
Tuned Pipe
203
Manifold
203
Muffler
203
Engine System
205
Removal from Vehicle
206
Inspection
209
Installation
209
Troubleshooting
212
Component Removal with the Engine Installed
212
Cleaning
212
Rave Valve Basic Operation
213
Disassembly
213
Inspection
217
Assembly
218
Cleaning
225
Disassembly
225
Inspection
226
Assembly
226
Break-In
231
Engine Leak Test and Dimension Measurement
232
Leak Test
232
Preparation
232
Procedure
232
Finalizing Reassembly
234
Engine Leak Verification Flow Chart
235
Engine Dimension Measurement
236
Cylinder Head Warpage
236
Cylinder out of Round
236
Combustion Chamber Volume Mesurement
236
Used Piston Mesurement
238
Cylinder/Piston Clearance
238
Ring/Piston Grove Clearance
240
Ring End Gap
240
Crankshaft Deflection
240
Connecting Rod Big End Axial Play
241
Crankshaft End Play
241
Checking Crankshaft Alignment
241
Magneto System
242
General
244
Cleaning
244
Disassembly
244
Assembly
245
Oil Injection System
247
General
248
Oil Type
248
Oil System Leak Test
248
Oil Pump Identification
249
Cleaning
249
Disassembly
249
Assembly
250
Adjustment
251
Checking Operation
252
Liquid Cooling System
253
Cooling System Leak Test
255
Inspection
255
Draining the System
255
Disassembly and Assembly
255
Cooling System Refilling Procedure
257
Rewind Starter
258
Inspection
259
Removal
259
Rope Replacement
259
Disassembly
259
Assembly
260
Installation
262
Drive System
263
Default Chapter
265
Basic Functions of the System
265
Effects of the Drive Pulley Lever Arm, Roller and Roller Pin Weight
266
Effects of the Ramp Profile on the Shift Force
269
Ramp Characteristics
271
Effects of the Drive Pulley Spring
272
Tuning Components
275
Vsa
275
Drive Pulley Tra III
276
General
277
Removal
277
Disassembly
277
Cleaning
279
Inspection
279
Assembly
279
Installation
283
Drive Pulley Adjustment
283
Kit P/N 486 400 003 Tra III Weight Set-Up for Pin
285
Tra Springs Chart
290
Effects of the Driven Pulley Spring
292
Hpv 27 Vsa Clutch Springs
293
Effects of the Driven Pulley Cam
294
Driven Clutch Cams
295
Formula Vsa
297
Removal
298
Disassembly
298
Cleaning
298
Inspection
299
Assembly
299
Installation
299
Adjustment
299
Hpv27 Vsa
301
Removal
302
Disassembly
302
Cleaning
302
Inspection
302
Assembly
303
Installation
303
Adjustment
303
Springs
306
Adjusting Belt Deflection on the Team Roller Secondary
306
Belt Removal on Team Roller Secondary
307
Measuring Belt Deflection
307
Team Secondary Clutch Maintenance/Adjustment
308
Installation
309
Troubleshooting
309
General
313
General Procedure
313
Pulley Alignment and Distance Specifications Chart
314
Drive Belts
315
Inspection
317
Checking Neutral Function
317
Rotation Direction
317
Drive Belt Height Measurement and Adjustment
318
DRIVE BELT DEFLECTION MEASUREMENT (Reference Only)
320
Chaincase Gearing
321
Chaincase Gears and Chains
324
Transmission Tuning Test Sheet
326
Racers Log
327
Hydraulic Brake
328
Brake Fluid Type
329
Caliper
329
Brake Pads Replacement
329
Removal
330
Disassembly
331
Cleaning
331
Inspection
331
Installation
331
Adjustment
332
Bleeding
332
Removal and Disassembly
334
Inspection
334
Gear Ratio Modification
334
Installation and Assembly
335
Drive Chain Adjustment
335
Adjustment
336
Removal
338
Assembly
339
Lubrication
340
Adjustment
340
Track Type Application
341
General
341
Inspection
341
Removal
341
Installation
341
Adjustment
341
2005 MX Z X 440 Lc Rev
344
2005 MX Z X 440 Lc Rev
345
Drivetrain
345
Engine
345
Holeshot Button
345
Ignition System
345
Sc-4 Rear Suspension
346
Track & Traction
346
2005 Option Package Color
347
Table of Contents
354
And 552 Engine Type
358
Engine Removal and Installation
358
Top End
360
General
362
Troubleshooting
362
Cleaning
362
Disassembly
362
Inspection
364
Assembly
364
Bottom End
371
Cleaning
373
Disassembly
373
Inspection
374
Assembly
374
Oil Injection System
380
General
381
Oil System Leak Test
381
Oil Pump Identification
382
Cleaning
382
Disassembly
382
Assembly
383
Adjustment
384
Checking Operation
385
Axial Fan Cooling System
386
Removal
387
Cleaning
387
Disassembly and Assembly
387
Installation
388
Fan Belt Replacement and Deflection Adjustment
388
Drive Pulley
392
Bombardier Lite
392
General
393
Removal
393
Disassembly
393
Cleaning
394
Inspection
394
Assembly
394
Installation
394
Ignition Timing
396
Verifying Magneto Flywheel Timing Mark Position
396
Checking Ignition Timing
397
Mod Engine Kit
399
Table of Contents
407
1010 MX Z X 440 Rev Drive Sprocket Replacement
420
Ski-Doo Racing, 7575 Bombardier Court, Wausau, Wi 54401-8035 Number
420
November 23, 2003
420
Ski-Doo Racing, 7575 Bombardier Court, Wausau, Wi 54401 Number
421
December 03, 2003
421
Ski-Doo Racing, 7575 Bombardier Court, Wausau, Wi 54401 Number
422
December 10, 2003
422
2004 Ski-Doo MX Z Racing Tip Sheet
420
Competition Preparation
423
Hillcross
424
Sno Cross
424
Drag Racing (Ice and Grass)
425
Hill Climbing
425
Oval Racing
427
Speed Runs
427
Suggested Spare Parts
429
Equivalent Weights and Measures Chart
431
Fuel/Oil Ratio Charts
432
Stock Class Preparation
437
Service Tools
445
4
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BRP ski-doo MACH Z 1000 SDI Specifications
General
Brand
BRP
Model
ski-doo MACH Z 1000 SDI
Category
Offroad Vehicle
Language
English
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