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BRP ski-doo MACH Z 1000 SDI User Manual

BRP ski-doo MACH Z 1000 SDI
493 pages
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Mmc-2005-001 Racing.FH8 Wed Sep 15 15:27:01 2004 Page 1
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Table of Contents

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BRP ski-doo MACH Z 1000 SDI Specifications

General IconGeneral
BrandBRP
Modelski-doo MACH Z 1000 SDI
CategoryOffroad Vehicle
LanguageEnglish

Summary

SECTION 01 - CONTACTING THE RACE DEPARTMENT

RACE DEPARTMENT CONTACTS

Lists contacts for U.S./CDN racers and services provided by the race department.

CDN RACERS (FRENCH SPEAKING RACERS ONLY)

Lists contacts for French-speaking racers and services provided.

SECTION 02 - 2005 MODELS TECHNICAL DATA

TIGHTENING TORQUE (engine cold)

Specifies torque values for engine fasteners.

SECTION 03 - CHASSIS PREPARATION

SUSPENSION OPERATION/ WEIGHT TRANSFER

Explains how suspension affects weight transfer and track tension.

CORNERING DYNAMICS

Discusses factors affecting handling in turns, including sway bars and limiter straps.

SHOCKS

Explains shock absorber valving and dampening, including effect of bleed slits.

SECTION 04 - SUSPENSION SC-3 SC-4 - RAS

FRONT SUSPENSION

General inspection, disassembly, inspection, and installation of the front suspension.

CHASSIS SET-UP

Procedures for checking drive axle alignment, sprockets, and countershaft alignment.

BRAKES

Information on brake fluid type, extreme brake use, and bleeding the system.

CHASSIS TUNING GUIDELINES

Guidelines for addressing handling problems like pushing, loose conditions, and ski lift.

SECTION 05 - ENGINE PREPARATION

ENGINE TUNING CAUTIONS

General advice on engine tuning, legal adjustments, RPM, and carburetor jetting.

FUEL TANK AND FUEL PUMP

Covers fuel filter, tank, impulse/fuel lines, float type gauge, electric sensor, pressurization, and pump verification.

ENGINE SYSTEM

Procedures for engine removal, inspection, installation, and troubleshooting.

ENGINE LEAK TEST AND DIMENSION MEASUREMENT

Procedures for verifying engine airtightness and measuring dimensions.

DETONATION

Describes detonation, its effects on the engine, and causes like low octane fuel or lean mixture.

PRE-IGNITION

Explains pre-ignition, its sources (overheated spark plug, carbon deposits), and piston damage.

CAUSES OF DETONATION

Lists causes of detonation: low fuel octane, lean mixture, incorrect timing, high compression, exhaust restrictions, overheating.

OPERATION OF THE RAVE VALVE

Explains the Rotax Adjustable Variable Exhaust (RAVE) valve system.

CARBURETION

Chart for correcting main jet size based on altitude and temperature.

CARBURETOR FLOAT LEVEL ADJUSTMENT

Importance of correct float level for engine efficiency and checking procedure.

TUNING THE MAIN JET SYSTEM

Procedures for tuning the main jet system based on exhaust manifold and spark plug condition.

Troubleshooting

Common carburetor setting issues and their causes (rich/lean mixture).

SPARK PLUGS

Procedures for spark plug removal, installation, and tightening torque.

CHECKING IGNITION TIMING

How to check ignition timing using a timing light and tachometer.

CHECKING CALIBRATION PROGRAM

Procedures for checking calibration using VCK or MPEM Programmer.

SYSTEM TESTING

Sequence for testing ignition and lighting systems for problems.

REMOVAL FROM VEHICLE

Initial preparation steps for engine removal, including removing windshield and side panels.

COOLING SYSTEM LEAK TEST

Procedure for testing the cooling system for leaks using a radiator cap and pump.

DISASSEMBLY AND ASSEMBLY

Procedures for disassembling and assembling the coolant pump, sender, pressure cap, coolant tank, and front radiator.

REWIND STARTER

Procedures for inspecting, removing, replacing rope, and disassembling/assembling the rewind starter.

SECTION 06 - DRIVE SYSTEM

EFFECTS OF THE DRIVE PULLEY LEVER ARM, ROLLER AND ROLLER PIN WEIGHT

Discusses how component weight affects centrifugal force and shift RPM.

EFFECTS OF THE RAMP PROFILE ON THE SHIFT FORCE

Explains how ramp profiles control shift force, axial force, and upshift/downshift behavior.

EFFECTS OF THE DRIVEN PULLEY SPRING

Explains the role of the driven pulley spring in controlling engine RPM and shift characteristics.

DRIVE BELT

Discusses changes in belt technology (Kevlar), width, and proper belt selection and installation.

TRANSMISSION CALIBRATION PROCEDURE

Step-by-step guide for fine-tuning transmission calibration for optimal performance.

BRAKE PADS REPLACEMENT

When to replace brake pads and the importance of replacing them in pairs.

Brake Pad

Information on when to replace brake pads and the requirement to replace them in pairs.

Brake

Procedure for bleeding the brake system.

REMOVAL AND DISASSEMBLY

Procedures for removing the chaincase, sprockets, chain, and drive axle.

DRIVE CHAIN ADJUSTMENT

Procedure for adjusting drive chain tension.

SECTION 07 - 2005 MX Z X 440 INFORMATION

2005 MX Z X 440 LC REV

Overview of the 2005 MX Z X 440 LC REV sled, including engine, ignition, drivetrain, and suspension.

ENGINE

Information on the 453 engine, its reliability, fuel requirements, and oil system.

HOLESHOT BUTTON

Explanation of the Holeshot button's function in determining ignition curves and performance.

DRIVETRAIN

Improvements in the drivetrain, including clutching, chaincase, and bottom gear.

SC-4 REAR SUSPENSION

Overview of the SC-4 rear suspension, designed for REV chassis.

SECTION 08 - 2005 MX Z 550 AND 380 FC

377 AND 552 ENGINE TYPES

Exploded view and procedures for engine removal and installation for 377 and 552 engines.

RAVE VALVE BASIC OPERATION

Maintenance and precautions for the RAVE valve system.

ENGINE DIMENSION MEASUREMENT

Covers cylinder head warpage, taper, out-of-round, and combustion chamber volume measurement.

CYLINDER/PISTON CLEARANCE

How to measure cylinder bore and piston skirt for clearance.

CRANKSHAFT DEFLECTION

Procedures for measuring crankshaft deflection both in and out of the crankcase.

CHECKING CRANKSHAFT ALIGNMENT

Procedures for checking crankshaft alignment using a degree wheel and TDC gauge.

OIL INJECTION SYSTEM

General information, oil types, and leak testing for the oil injection system.

OIL SYSTEM LEAK TEST

Procedure to test the oil system for leaks using a special cap and pump.

SECTION 09 - 2005 800 MOD ENGINE KIT

2005 OPEN MOD SNOCROSS ENGINE SPECIFICATIONS & PARTS 793 (ROTAX) 2 CYLINDERS

Engine specifications and parts list for 2005 Open Mod Snocross engines.

SECTION 10 - 2004 MX Z X 440

MX Z X 440 REV DRIVE SPROCKET REPLACEMENT

Procedure for replacing drive sprockets on the MX Z X 440 REV.

2004 SKI-DOO MX Z RACING TIP SHEET

Racing tips for 2004 MX Z models, including track tension and tether switch.

SECTION 11 - COMPETITION PREPARATION

SNO CROSS

Guidelines for preparing a stock REV chassis for Sno Cross racing.

Front Suspension

Advice on using adjustable shocks, spring preload, and anti-roll bars for front suspension.

Fuel and Carburetion

Fuel octane requirements and jetting guidelines for altitude.

HILLCROSS

Special rules for Hillcross, including stud rules and suspension setup.

Transmission

Advice on gearing, belt selection, and clutch maintenance for optimal performance.

HILL CLIMBING

Tuning guidelines for front, center, and rear suspension for hill climbing.

Traction

Recommendations for stud height, type, quantity, and carbide runners for ice and grass racing.

SUGGESTED SPARE PARTS

List of essential spare parts to have for self-contained racing.

SECTION 12 - SERVICE TOOLS

SERVICE TOOLS

Lists mandatory and recommended tools for servicing Ski-Doo snowmobiles.

ENGINE — MANDATORY TOOLS

Lists mandatory tools required for engine service.

TRANSMISSION — MANDATORY TOOLS

Lists mandatory tools for transmission service.

SUSPENSION — MANDATORY TOOLS

Lists mandatory tools for suspension service.

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