Ski-Doo ELITE SERIES User Manual

TABLE OF CONTENTS
FUEL SYSTEM.... . . .. .. . .. .. . .. .. . .... . .. .. . .. .. .. . .. . . ... .. . .. .. . .. .. ..... .. . .. .. . .. .. . .. . .... .. .. . .. .. . .. ..... .. . .. 37
SPARK PLUGS........................................................................................................ 37
03 TROUBLESHOOTING
01 – ENGINE ........................................................................................................ 39
COOLING SYSTEM .... . .. .. . .. .. . . . .. . .. .. . .. . . .. . .. .. . .. .. . .. .. . .. .. ..... .. . .. .. . .... . .. .. . .. .. . . . .. .. . .. .. . . . .. . .. 39
ALTERNATOR......................................................................................................... 40
LUBRICATION........................................................................................................ 41
CYLINDER AND CYLINDER HEAD ................................................................................. 42
CRANKSHAFT . .. . .. .. ..... .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .... . .. .. .. . . . .. . .. .. . .... . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. 43
ELECTRICAL STARTER.............................................................................................. 43
ENGINE GENERAL................................................................................................... 45
02 – TRANSMISSION AND BRAKE SYSTEM.................................................................. 49
TRANSMISSION ............................................................................................. 49
BRAKE SYSTEM.............................................................................................. 56
HYDRAULIC BRAKE ... . .. .. . .. .. . .. .. . .. .. . .. .. . . . .. .. . .. ... .. .. . .. .. . . . .. .. . .. ... .. .. . .. .. . . . .. .. . .. ... .. .. . .. .. . . . 56
03 – ELECTRICAL SYSTEM....................................................................................... 57
04 – SUSPENSION AND TRACK................................................................................. 63
04 ENGINE
01 – LEAK TEST .................................................................................................... 67
LEAK TEST PROCEDURE ................................................................................... 67
PREPARATION ....................................................................................................... 67
PROCEDURE ......................................................................................................... 68
INSTALLATION ....................................................................................................... 69
02 – INTAKE SYSTEM............................................................................................. 71
REMOVAL ............................................................................................................ 72
INSTALLATION ....................................................................................................... 76
03 – EXHAUST SYSTEM.......................................................................................... 79
MUFFLER. .. . .. .. . .. .. .. . .. .. . .. ....... ... .. . .. .. .. . .. .. . .. .. . .. .. . .. ... .... .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . ...... ... . .. 79
EXHAUST MANIFOLD............................................................................................... 80
04 – REMOVAL AND INSTALLATION........................................................................... 81
ENGINE REMOVAL .................................................................................................. 81
ENGINE INSTALLATION............................................................................................. 86
05 – PTO HOUSING................................................................................................ 87
GENERAL............................................................................................................. 88
PTO HOUSING ....................................................................................................... 88
PTO SEAL............................................................................................................. 91
ADAPTER SLEEVE AND FLANGE COUPLING.. . .. .. . .. .. . .. . . . .. .. .. . .... . .. .. . .. ... .. .. .. . .. . . . .. .. . .. ..... .. . .. 92
COUPLING............................................................................................................ 93
ENCODER WHEEL................................................................................................... 93
RING GEAR........................................................................................................... 94
STARTER DRIVE ASS'Y.............................................................................................. 94
06 – COOLING SYSTEM .......................................................................................... 97
GENERAL............................................................................................................. 98
PRESSURE CAP. . .. .. ... .. .. . .. .. . .. .. . .. .. . . . .. .. . .. ..... .. . .. .. . . . .. .. . .. ..... .. . .. .. . . . .. .. . .. ..... .. . .. .. . . . .. . .. 98
COOLING SYSTEM LEAK TEST.. .. .. . .... . .. .. .. . .. ..... .. . .. .. . .. . . .. . .. .. . .. ..... .. . .. .. .. . .... . .. .. . .. .. . . . .. . .. 98
INSPECTION. .. .. . .. .. ..... .. . .. .. . .. .. . .. ..... .. .. . .. .. . .. .. . .... . .. .. .. . .. .. . .. ..... .. . .. .. . .. .. .. . .... . .. .. . .. .. . .. 98
DRAINING THE SYSTEM............................................................................................ 99
COOLANT REPLACEMENT ....................................................................................... 100
COOLANT PUMP HOUSING...................................................................................... 101
THERMOSTAT...................................................................................................... 102
II

Ski-Doo ELITE SERIES Specifications

General

Brand	Ski-Doo
Model	ELITE SERIES
Category	Offroad Vehicle
Language	English