Ski-Doo 2005 SUMMIT HIGHMARK - Subsection 04 (ENGINE REMOVAL AND INSTALLATION)

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Section02ENGINE

Subsection 04 (ENGINE REMOVAL AND INSTALLATION)

ENGINE REMOVAL AND INSTALLATION

SERVICE TOOLS

Description Part Number Page

engine removal hook ............................................................

529 035 829 ........................................... 30

hose pincher.........................................................................

295 000 076 ........................................... 31

spark plug lift ring .................................................................

529 035 830 ........................................... 30

SERVICE PRODUCTS

Description Part Number Page

Dielectric grease...................................................................

293 550 004 ........................................... 33

Molykote 111........................................................................

413 707 000 ........................................... 33

mmr2005-115 25

Main Page

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

Ski-Doo 2005 SUMMIT HIGHMARK - Subsection 04 (ENGINE REMOVAL AND INSTALLATION)

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