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2005 SUMMIT HIGHMARK
Ski-Doo 2005 SUMMIT HIGHMARK User Manual
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Mmr-2005
s
rie
RT
ang
.
FH8
Mon
Dec
20
08:16:36
2004
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Table of Contents
Default Chapter
5
Table of Contents
5
Safety Notice
13
Introduction
14
Vehicle Identification Number
14
Engine Serial Number
14
List of Abbreviations Used in this Manual
14
Arrangement of this Manual
16
General Information
18
Illustrations and Procedures
18
Self-Locking Fasteners Procedure
18
Loctite Application Procedure
19
Threadlocker
19
Stripped Thread Repair
20
Gasket Compound
21
Mounting on Shaft
21
Case-In Components
22
Tightening Torque
22
Maintenance
26
Maintenance Chart
26
Storage
28
General
28
Engine
28
Fuel System
29
Drive System
29
Steering/Front Suspension
30
Suspension
30
Electrical
30
Vehicle
30
Preseason Preparation
32
Engine
32
Fuel System
32
Drive System
33
Electrical System
33
Vehicle
33
Engine
34
Leak Test
34
Preparation
34
Procedure
36
Finalizing Reassembly
38
Engine Leak Verification Flow Chart
39
Air Intake System
40
Air Filter/Air Intake Silencer Removal (Body Side)
41
Air Filter/Air Intake Silencer Installation (Body Side)
41
Air Intake Silencer Removal (Engine Side)
41
Air Intake Silencer Installation (Engine Side)
42
Adaptor Plate Removal
42
Adaptor Plate Installation
42
Intake Deflector/Filter Removal
42
Exhaust System
44
Tuned Pipe
46
Manifold
47
Muffler
47
Engine Removal and Installation
49
Removal from Vehicle
51
Inspection
55
Installation
56
Magneto System
58
General
60
Magneto Flywheel
60
Stator
61
Cps
62
E-Rave System
63
General
65
E-Rave System Dynamic Test
65
E-Rave Cables
65
E-Rave Actuator
68
E-Rave Cover
69
E-Rave Shaft
69
E-Rave Housing
71
E-Rave Valves
71
Top End
72
Troubleshooting
74
General
74
Component Removal with the Engine Installed
74
Disassembly
74
Cleaning
75
Inspection
76
Assembly
77
Piston Circlip Installer
78
Bottom End
81
Service Products
81
Description Part Number Page
81
Loctite Chisel
81
Molykote 111
82
Troubleshooting
84
General
84
Preparation
84
Cleaning
84
Disassembly
84
Inspection
89
Assembly
89
Break-In
93
Engine Measurement
94
Cylinder Head Warpage
94
Cylinder Taper
94
Cylinder out of Round
94
Combustion Chamber Volume Measurement
95
Used Piston Measurement
96
Cylinder/Piston Clearance
97
Ring/Piston Groove Clearance
98
Ring End Gap
98
Crankshaft Deflection
98
Connecting Rod Big End Axial Play
99
Checking Crankshaft Alignment
99
Cooling System
101
Cooling System Leak Test
103
Inspection
103
Draining the System
103
Disassembly and Assembly
104
Cooling System Refilling Procedure
105
Rewind Starter
106
General
108
Inspection
108
Removal
108
Rope Replacement
108
Disassembly
108
Assembly
109
Installation
111
Oil Injection System
112
General
114
Oil Type
114
Oil System Leak Test
114
Oil Pump Identification
115
Cleaning
115
Removal
115
Checking Operation
116
Installation
116
Bleeding Procedure
117
Adjustment
118
Fuel System
119
Fuel Tank and Fuel Pumps
119
Fuel Tank
120
In-Tank Fuel Filter Removal
121
In-Tank Fuel Filter Installation
121
In-Line Fuel Filter Removal
122
In-Line Fuel Filter Installation
122
Fuel Tank Removal
122
Fuel Tank Installation
123
Float-Type Fuel Level Gauge Removal/Installation
123
Electric Fuel Level Sensor Inspection
124
Fuel System Pressurization
124
Electric Fuel Pump
125
Diagnostic Flow Chart
125
Electric Fuel Pump Pressure Test
126
Electric Fuel Pump
127
Electric Fuel Pump Removal
128
Electric Fuel Pump Installation
129
Electric Fuel Pump Pressure Regulator Removal/Installation
129
Diaphragm Fuel Pump
130
Diaphragm Fuel Pump Removal
131
Diaphragm Fuel Pump Verification
131
Diaphragm Fuel Pump Cleaning and Inspection
132
Diaphragm Fuel Pump Installation
132
Engine Management (Sdi)
133
Overview
133
Operating Principle
134
Charging System
134
Ignition System
134
Air Induction
134
Fuel Delivery System
135
Engine Management System (Ems)
136
Ems - Engine Management System Functions
138
Power Distribution
138
Fuel Injection
139
Ignition System
139
Electronically Controlled Rave (E-Rave)
139
Digitally Encoded Security System (Dess)
139
Rotax Electronic Reverse (Rer)
140
Monitoring System
140
Diagnostic Mode
141
Diagnostic Procedure
142
General
142
Troubleshooting
143
Ems Fault Codes
143
Vck (Vehicle Communication Kit)
147
Component Inspection, Replacement and Adjustment
150
General
150
Fuel System
150
Electrical System
151
Testing Procedures
155
Electric Fuel Pump
155
Fuel Injectors
155
Engine Control Module (Ecm)
159
Engine Wiring Harness
160
Throttle Body
160
Throttle Position Sensor (Tps)
163
Crankshaft Position Sensor (Cps)
165
Air Temperature Sensor (Ats)
166
Coolant Temperature Sensor (Cts)
167
Air Pressure Sensor (Aps)
168
Knock Sensor (Ks)
169
E-Rave Actuator
169
Double Ignition Coil
170
Battery
172
Capacitor
172
Engine Start/Rer Switch Verification
173
Dess Post Verification
173
Electrical System
174
Ignition System
174
General
174
Ignition Timing
175
Spark Plug
177
Design Symbols Used in Ngk Spark Plugs
179
Charging System
180
General
180
Charging Generator Coil (Stator)
180
Voltage Regulator/Rectifier
181
Battery
181
Cable Terminal Installation
183
Starting System
185
General
185
Component Testing
185
Starter Removal
188
Starter Installation
188
Rotax Electronic Reverse (Rer)
189
Troubleshooting
189
Accessories and Lighting System
190
General
190
12-Volt Power Outlet (Cigarette-Lighter Type)
191
Beeper (Reverse Alarm)
191
Engine Temperature Gauge
192
Electric Fuel Gauge
192
Headlamp
193
Headlamp Beam Aiming
194
Heating Elements
194
Relay
194
Speedometer
195
Speed Sensor
196
Tachometer
196
Taillight
197
Visor Outlet
197
Drive System
198
Drive Belt
198
Application Chart
198
Inspection
198
Checking Neutral Function
198
Rotation Direction
198
Drive Belt Height Measurement and Adjustment
199
Drive Belt Deflection Measurement (Reference Only)
200
Drive Pulley
202
General
204
Removal
204
Disassembly
204
Cleaning
206
Inspection
206
Assembly
208
Installation
211
Drive Pulley Adjustment
212
Driven Pulley
214
Hpv Roller
215
General
216
Removal
216
Disassembly
216
Cleaning
217
Inspection
217
Assembly
218
Installation
218
Bushing Replacement
218
Hpv Vsa
221
General
222
Removal
222
Disassembly
222
Cleaning
222
Inspection
222
Assembly
223
Installation
223
Adjustment
223
Pulley Alignment
226
General
226
Measuring Procedure
226
Alignment Procedure
227
Brake
228
General
230
Countershaft Bearing
230
Countershaft
230
Brake Fluid
230
Draining
230
Bleeding
230
Master Cylinder
230
Brake Pads
231
Caliper
232
Brake Disc
233
Brake Light Switch
234
Chaincase
235
General
237
Chaincase Oil Level
237
Oil Change
237
Drive Chain Adjustment
237
Chaincase Cover
237
Tensioner
238
Tensioner Roller Bearing
238
Drive Chain and Sprockets
239
Chaincase Housing
240
Chaincase Housing Bearings
241
Countershaft
241
Countershaft Bearing
241
Drive Axle
244
Removal
247
Assembly
247
Lubrication
249
Adjustment
249
Track
250
Track Type Application
250
General
250
Inspection
250
Removal
250
Installation
250
Adjustment
250
Track Cleat
252
Traction Enhancing Products (Studs)
252
Rear Suspension
254
Sc Suspension
254
Axle Self-Locking Screws Removal
258
Rear Axle Removal
258
Rear Axle Installation
258
Rear Shock Absorber Removal
258
Rear Shock Absorber Installation
259
Front Shock Absorber Removal
259
Front Shock Absorber Installation
259
Rear Spring Removal
260
Rear Spring Installation
260
Slider Shoe Verification
261
Slider Shoe Removal
261
Slider Shoe Installation
262
Front Arm Removal
262
Front Arm Installation
263
Rear Arm/Pivot Arm Removal
263
Rear Arm Installation
263
Stopper Strap
264
Suspension Removal
264
Suspension Installation
265
Ride Adjustment
265
Lubrication
265
Sc 4 Suspension
266
Axle Self-Locking Screw Removal
270
Rear Axle Removal
270
Rear Axle Installation
270
Rear Shock Absorber Removal
270
Rear Shock Absorber Installation
271
Front Shock Absorber Removal
271
Front Shock Absorber Installation
272
Rear Spring Removal
272
Rear Spring Installation
273
Slider Shoe Verification
273
Slider Shoe Removal
274
Slider Shoe Installation
275
Front Arm Removal
275
Front Arm Installation
275
Rear Arm/Pivot Arm Removal
275
Rear Arm/Pivot Arm Installation
276
Block Installation
276
Idler Wheels Installation
276
Stopper Strap
276
Suspension Removal
277
Suspension Installation
277
Ride Adjustment
277
Lubrication
278
Shock Absorber Inspection and Servicing
279
Spring Removal
279
Shock Absorber Inspection
279
Disassembly and Assembly
280
Steering/Front Suspension
288
Steering System
288
Disassembly and Assembly
291
Steering Column
293
Inspection
295
Adjustment
295
Steering Adjustment (Skis)
297
Lubrication
298
Front Suspension
299
General Inspection
303
Disassembly
303
Inspection
308
Installation
308
Body/Frame
313
Body
313
Decal
313
Hood
313
Front Bumper
313
Bottom Pan
314
Windshield
314
Access Panel
314
Indicator Panel
314
Console
315
Seat
315
Plastic Maintenance and Repair
316
Frame
318
Frame Cleaning
318
Frame Component Replacement
318
Frame Welding
318
Technical Data
323
Mach Z/Summit 1000 Sdi
323
Technical Data Legend
327
1 Wiring Diagrams
328
Wiring Diagrams
328
Wiring Diagram Legend
328
Wire Colors
328
Connector Housing Area
328
Housing Reference Per Area
329
Wire Location in Connector Housing
329
Symbols Description
331
Unplugging Connectors
332
Tab and Receptacle Connectors Removal
332
Tab and Receptacle Connectors Installation
338
4
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Ski-Doo 2005 SUMMIT HIGHMARK Specifications
General
Brand
Ski-Doo
Model
2005 SUMMIT HIGHMARK
Category
Offroad Vehicle
Language
English
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