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Section 03 ENGINES

Subsection 09 (REWIND STARTER)

Rewind Starter on Liquid Cooled Models

1

7 Nm

(62 lbfin)

4

5

6

9 Nm

(80 lbfin)

8

10

9

11

12

13

Molykote

PG 54

15

Molykote

PG 54

Molykote

PG 54

Molykote

PG 54

Molykote

PG 54

A32C69S

2

mmr2005-075 149

Table of Contents

Default Chapter2
- Table of Contents2
Safety Notice12
Introduction12
- Vehicle Identification Number13
- Engine Serial Number13
- Arrangement of this Manual15
- General Information17
- Illustrations and Procedures17
- Self-Locking Fasteners Procedure17
- Loctite Application Procedure18
- Threadlocker18
- Stripped Thread Repair19
- Gasket Compound20
- Mounting on Shaft20
- Case-In Components21
- Tightening Torque22
Maintenance23
- Maintenance Chart23
- Storage25
- Preseason Preparation29
Troubleshooting31
- Engine31
- Fuel and Oil Systems42
- Drive and Brake Systems45
  - Drive System45
  - Brake System52
- Electrical System53
- Steering and Suspension63
Engines66
- Leak Test66
- Preparation66
- Procedure67
- Finalizing Reassembly68
- Engine Leak Verification Flow Chart69
Exhaust System70
- 377 And 552 Engines71
- Ho, 593 Ho Sdi and 793 Ho Engines72
Engine Removal and Installation75
- Removal from Vehicle77
- Inspection81
- Installation81
- Removal from Vehicle83
- Inspection87
- Installation87
Magneto System88
- General93
- Magneto Flywheel93
- Stator95
- Cps/Trigger Coil95
Top End97
- Troubleshooting100
- Cleaning100
- Disassembly100
- Inspection102
- Assembly102
- Reed Valve107
- Troubleshooting114
- Component Removal with the Engine Installed114
- Cleaning114
- Rave Valve Basic Operation114
- Disassembly114
- Inspection119
- Assembly120
Bottom End125
- Cleaning128
- Disassembly128
- Inspection129
- Assembly129
- Break-In134
- Cleaning138
- Disassembly138
- Inspection139
- Assembly139
- Break-In144
Engine Measurement145
- Cylinder Head Warpage145
- Cylinder Taper145
- Cylinder out of Round145
- Combustion Chamber Volume Measurement146
- Used Piston Measurement147
- Cylinder/Piston Clearance147
- Ring/Piston Groove Clearance149
- Ring End Gap149
- Crankshaft Deflection149
- 8 Cooling System154
- Rewind Starter163
- Oil Injection System171
Fuel System180
- Fuel Tank and Fuel Pump180
- Carburetors, Throttle and Choke Cables190
  - Carburetor - VM Type191
  - Carburetor Tm Type199
- Dpm System208
Engine Management (Power Tek)214
- Overview214
  - Operating Principle215
- Diagnostic Procedures219
- Component Inspection, Replacement and Adjustment226
  - General226
    - Electrical System226
    - Fuel System228
  - Engine Management System229
Engine Management (Sdi)243
- Overview243
  - Operating Principle244
  - Engine Management System (Ems)246
- Diagnostic Procedures252
- Component Inspection, Replacement and Adjustment260
Electrical System289
- Ignition System289
- Charging System303
- Starting System309
  - Troubleshooting311
- Accessories317
Drive System326
- Drive Belt326
- Drive Pulley331
  - Bombardier Lite332
  - Tra III336
- Driven Pulley347
- Pulley Alignment357
- Brake360
  - Hydraulic Brake361
- Chaincase367
- Drive Axle372
- Track380
Rear Suspension385
- Sc Suspension385
- Sc 3 Suspension398
- Sc 4 Suspension411
- Shock Absorber Inspection and Servicing424
Steering/Front Suspension434
- Steering System434
- Front Suspension448
Body/Frame461
- Body461
  - Installation and Adjustment461
  - Plastic Maintenance and Repair462
    - Maintenance462
    - Repair462
- Frame463
Technical Data465
- Fan Cooled Models465
- Liquid Cooled Models470
- Liquid Cooled (Sdi) Models478
Wiring Diagram484
Wiring Diagrams484
- Wiring Diagram Legend484
- Wire Colors484
- Connector Housing Area484
- Housing Reference Per Area485
- Wire Location in Connector Housing485
- Symbols Description487
- Unpluging Connectors488
- Tab and Receptacle Connectors Removal488
- Tab and Receptacle Connectors Installation494

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