Name: Ski-Doo 2005 SUMMIT HIGHMARK
Brand: Ski-Doo
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Section02ENGINE

Subsection 09 (ENGINE MEASUREMENT)

A35C32A

Remove TDC gauge and install it in spark plug hole

on PTO side.

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.

mmr2005-119 81

Default Chapter5
- Table of Contents5
Safety Notice13
Introduction14
- Vehicle Identification Number14
- Engine Serial Number14
- List of Abbreviations Used in this Manual14
- Arrangement of this Manual16
- General Information18
- Illustrations and Procedures18
- Self-Locking Fasteners Procedure18
- Loctite Application Procedure19
- Threadlocker19
- Stripped Thread Repair20
- Gasket Compound21
- Mounting on Shaft21
- Case-In Components22
- Tightening Torque22
Maintenance26
- Maintenance Chart26
- Storage28
- Preseason Preparation32
Engine34
- Leak Test34
- Air Intake System40
Engine Removal and Installation49
- Removal from Vehicle51
- Inspection55
- Installation56
Magneto System58
- General60
- Magneto Flywheel60
- Stator61
- Cps62
E-Rave System63
- General65
- E-Rave System Dynamic Test65
- E-Rave Cables65
- E-Rave Actuator68
- E-Rave Cover69
- E-Rave Shaft69
- E-Rave Housing71
- E-Rave Valves71
Top End72
- Troubleshooting74
- General74
- Component Removal with the Engine Installed74
- Disassembly74
- Cleaning75
- Inspection76
- Assembly77
- Piston Circlip Installer78
Bottom End81
- Service Products81
- Description Part Number Page81
- Loctite Chisel81
- Molykote 11182
- Troubleshooting84
- General84
- Preparation84
- Cleaning84
- Disassembly84
- Inspection89
- Assembly89
- Break-In93
Engine Measurement94
- Cylinder Head Warpage94
- Cylinder Taper94
- Cylinder out of Round94
- Combustion Chamber Volume Measurement95
- Used Piston Measurement96
- Cylinder/Piston Clearance97
- Ring/Piston Groove Clearance98
- Ring End Gap98
- Crankshaft Deflection98
- Connecting Rod Big End Axial Play99
- Checking Crankshaft Alignment99
Cooling System101
- Cooling System Leak Test103
- Rewind Starter106
- Oil Injection System112
Fuel System119
- Fuel Tank and Fuel Pumps119
- Fuel Tank120
- Electric Fuel Pump125
  - Diagnostic Flow Chart125
  - Electric Fuel Pump Pressure Test126
- Electric Fuel Pump127
- Diaphragm Fuel Pump130
Engine Management (Sdi)133
- Overview133
  - Operating Principle134
  - Engine Management System (Ems)136
- Diagnostic Procedure142
- Component Inspection, Replacement and Adjustment150
  - General150
    - Fuel System150
    - Electrical System151
  - Testing Procedures155
Electrical System174
- Ignition System174
- Charging System180
- Starting System185
- Rotax Electronic Reverse (Rer)189
  - Troubleshooting189
- Accessories and Lighting System190
Drive System198
- Drive Belt198
- Drive Pulley202
- Driven Pulley214
Pulley Alignment226
- General226
- Measuring Procedure226
- Alignment Procedure227
Brake228
- General230
- Countershaft Bearing230
- Countershaft230
- Brake Fluid230
- Draining230
- Bleeding230
- Master Cylinder230
- Brake Pads231
- Caliper232
- Brake Disc233
- Brake Light Switch234
Chaincase235
- General237
- Chaincase Oil Level237
- Oil Change237
- Drive Chain Adjustment237
- Chaincase Cover237
- Tensioner238
- Tensioner Roller Bearing238
- Drive Chain and Sprockets239
- Chaincase Housing240
- Chaincase Housing Bearings241
- Countershaft241
- Countershaft Bearing241
Drive Axle244
- Removal247
- Assembly247
- Lubrication249
- Adjustment249
Track250
- Track Type Application250
- General250
- Inspection250
- Removal250
- Installation250
- Adjustment250
- Track Cleat252
- Traction Enhancing Products (Studs)252
Rear Suspension254
- Sc Suspension254
- Sc 4 Suspension266
- Shock Absorber Inspection and Servicing279
Steering/Front Suspension288
- Steering System288
- Front Suspension299
Body/Frame313
- Body313
- Frame318
Technical Data323
- Mach Z/Summit 1000 Sdi323
  - Technical Data Legend327
- 1 Wiring Diagrams328
Wiring Diagrams328
- Wiring Diagram Legend328
- Wire Colors328
- Connector Housing Area328
- Housing Reference Per Area329
- Wire Location in Connector Housing329
- Symbols Description331
- Unplugging Connectors332
- Tab and Receptacle Connectors Removal332
- Tab and Receptacle Connectors Installation338

Brand	Ski-Doo
Model	2005 SUMMIT HIGHMARK
Category	Offroad Vehicle
Language	English

Ski-Doo 2005 SUMMIT HIGHMARK User Manual

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