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Ski-Doo
Offroad Vehicle
ELITE SERIES
Ski-Doo ELITE SERIES User Manual
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from
coolant
pump
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ousin
g
means
damaged
gasket(s)
and/or
loosened
screws
(refer
to
COOLING
SYSTEM).
NOTE:
For
all
t
he
chec
kpoi
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ap
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70
Te
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84
86
Table of Contents
Default Chapter
4
Table of Contents
4
Safety Notice
11
Introduction
12
Vehicle Identification Number
12
Vehicle Identification Number Location
12
Identification Number Meaning
12
Engine Serial Number
13
Engine Serial Number Location
13
List of Abbreviations Used in this Manual
13
Arrangement of this Manual
14
Illustrations and Procedures
15
Stripped Thread Repair
17
Gasket Compound
17
Mounting on Shaft
18
Case-In Components
18
Tightening Torque
19
Service Tools and Service Products
22
Service Tools
22
Engine - Mandatory Tools
22
Engine - Recommended Tools
25
Transmission - Mandatory Tools
30
Transmission - Recommended Tools
31
Suspension - Mandatory Tools
35
Suspension - Recommended Tools
36
Vehicle - Recommended Tools
39
Service Products
41
Maintenance
48
Maintenance Chart
48
Storage
51
General
51
Fuel Stabilizer
51
Cooling System
51
Engine Oil Change and Filter
51
Engine Lubrication
51
Engine Compartment
52
Pulley Protection
52
Battery
52
Vehicle Cleaning
52
Rags in Air Intake and Exhaust System
53
Vehicle Protection
53
Preseason Preparation
54
Air Filter Cleaning
54
Rags in Air Intake and Exhaust System
54
Cleaning of Drive and Driven Pulleys
54
Cleaning of Brake Disks
54
Drive Belt and Final Drive Belt Condition
54
Fuel System
54
Spark Plugs
54
Troubleshooting
55
Engine
55
Cooling System
55
Alternator
56
Lubrication
57
Cylinder and Cylinder Head
58
Crankshaft
59
Electrical Starter
59
Engine General
61
Transmission and Brake System
65
Transmission
65
Brake System
72
Hydraulic Brake
72
Electrical System
73
Suspension and Track
78
Engine
82
Leak Test
82
Leak Test Procedure
82
Preparation
82
Procedure
83
Installation
84
Intake System
86
Removal
87
Installation
91
Exhaust System
93
Muffler
93
Exhaust Manifold
94
Removal and Installation
95
Engine Removal
95
Engine Installation
100
Pto Housing
101
General
102
Pto Housing
102
Pto Seal
105
Adapter Sleeve and Flange Coupling
106
Coupling
107
Encoder Wheel
107
Ring Gear
108
Starter Drive Ass'y
108
Cooling System
110
General
111
Pressure Cap
111
Cooling System Leak Test
111
Inspection
111
Draining the System
112
Coolant Replacement
113
Coolant Pump Housing
114
Thermostat
115
Coolant Pump Impeller
115
Rotary Seal
116
Care
118
Lubrication System
119
General
121
Oil Level Verification
121
Engine Oil Pressure Test
122
Oil Change
122
Oil Type and System Capacity
123
Oil Filter
123
Oil Strainers
124
Engine Oil Pressure Regulator
126
Oil Pressure Pump
127
Oil Suction Pump
130
Oil Cooler
133
Oil Separator
134
Cylinder Head and Valves
136
General
137
Spark Plug
137
Valve Cover
137
Rocker Arm
138
Camshaft Timing Gear
142
Timing Chain
143
Cylinder Head
143
Camshaft
145
Valve Spring
146
Valve
147
Engine Block
153
General
155
Crankshaft Locking
155
Crankshaft
155
Timing Chain
159
Chain Tensioner
160
Balancer Shaft
160
Engine Block
163
Piston/Connecting Rod
168
Piston Rings
174
Engine Management
176
Overview
176
Complete Electrical System Overview
177
Alternator
178
Operating Principle of Engine Management
178
Air Induction
178
Fuel Delivery System
178
Basic Operation
178
Intake Manifold
179
Fuel Pump Module
179
Electronic Management
180
Ecm (Engine Control Module)
180
Ecm Ecu
180
Ecm - General Functions
180
Ems - Engine Management Functions
182
VCM - Vehicle Control Module
184
Component Inspection and Adjustment
185
General
185
Fuel System
185
Electrical System
186
Engine Connector Pin out
187
Connectors on Engine
188
Air Induction System
189
Throttle Body
189
Fuel Delivery
192
Fuel Pump
193
Fuel Rail
196
Fuel Injector
197
Electronic Management
199
Ecm Ecu and VCM Replacement
199
Engine Wiring Harness
201
Throttle Position Sensor (Tps)
202
Idle Bypass Valve
205
Crankshaft Position Sensor (Cps)
205
Camshaft Position Sensor (Caps)
207
Coolant Temperature Sensor (Cts)
208
Manifold Air Pressure Sensor (Maps)
209
Knock Sensor (Ks)
210
Oil Pressure Sensor (Ops)
211
Oil Separator Pressure Sensor (Osps)
211
Tops
212
Ignition Coils
213
Tdc Setting (Top Dead Center)
214
Engine Start Switch Verification
214
Dess Switch Verification
214
Spark Plugs
215
Cranking System
215
Diagnostic Procedures
216
General
216
Self-Diagnostic Mode
217
Vck (Vehicle Communication Kit)
218
4-Tec System Fault Codes
219
Transmission
221
Drive Belt
221
Application Chart
221
Inspection
221
Checking Neutral Function
221
Rotation Direction
221
Drive Belt Height Measurement and Adjustment
222
Drive Belt Deflection Measurement (Reference Only)
223
Drive Pulley
225
Tra IV Hd
225
General
226
Removal
226
Disassembly
226
Cleaning
228
Inspection
229
Assembly
229
Installation
231
Drive Pulley Adjustment
232
Driven Pulley
233
Hpv Vsa
233
Removal
234
Disassembly
234
Cleaning
234
Inspection
234
Assembly
234
Installation
235
Adjustment
236
Pulley Distance and Alignment
237
General
237
Procedure
237
Pulley Alignment and Distance Specifications Chart
238
Brake
239
Hydraulic Brake
239
General
240
Brake Fluid
240
Master Cylinder
240
Caliper
242
Brake Pads
242
Brake Disc
243
Brake Light Switch
245
Bleeding
246
Gearbox and Final Drive Belt
247
Gearbox
249
Oil Change
249
Shifter Adjustment
249
Reverse Switch Adjustment
250
Removal
250
Disassembly
250
Inspection
251
Assembly
251
Installation
251
Final Drive Belt
251
Deflection Adjustment
252
Removal
252
Installation
253
Electrical System
254
Alternator
254
Removal
255
Inspection
255
Installation
255
Belt Tension Adjustment
255
Battery
256
General
256
Removal
256
Cleaning
256
Inspection
256
Battery Charge Testing
256
Battery Charging
257
Battery Storage
257
Activation of New Battery
257
Installation of Battery
257
Cable Terminal Installation
257
Electric Starter
259
Removal
260
Disassembly
260
Cleaning
261
Parts Inspection
262
Assembly
262
Installation
263
Starter Specification
264
Testing Procedure
265
Inspection of Heating Elements
265
Headlight and Accessories Systems Testing
265
Rear Suspension
266
Sc-10 III Suspension
267
General
270
Component Removal and Installation
270
Suspension Assembly Removal
271
Disassembly and Assembly
272
Shock Absorber Inspection
275
Installation
275
Lubrication
275
Drive Axle
276
Removal
277
Assembly
277
Installation
278
Lubrication
278
Adjustment
278
Track
279
Track Type Application
279
General
279
Inspection
279
Removal
279
Installation
279
Adjustment
279
Steering/Front Suspension
282
Steering System
282
General
283
Steering Adjustment (Skis)
283
Grip
286
Steering Wheel
286
Lower Steering Column
288
Short and Long Tie-Rods
288
Steering Arm
289
Lubrication
290
Front Suspension
291
Disassembly
292
Inspection
292
Installation
292
Body/Frame
294
Body
294
Installation and Adjustment
294
Headlamp Beam Aiming
294
Bulb Replacement
294
Rearview Mirror
295
Decal
295
Windshield Installation
295
Guard
296
Body
296
Wiring Harness
298
Cables
298
Tubing
298
Plastic Maintenance and Repair
298
Maintenance
298
Windshield Repair
299
Body Repair
299
Tools and Materials List
301
Frame
303
Frame Cleaning
303
Frame Welding
303
Frame Component Replacement
303
Technical Data
304
Si Metric Information Guide
304
Engine
305
Vehicle
310
Technical Data Legends
312
Engine Legend
312
Vehicle Legend
312
1 Wiringdiagram
313
Wiring Diagram
313
Wiring Diagram Legend
313
Wire Colors
313
Connector Housing Area
313
Housing Reference Code Per Area
314
Wire Location in Connector Housing
314
Symbols Description
316
Unpluging Connectors
317
Tab and Receptacle Connectors Removal
317
Tab and Receptacle Connectors Installation
326
5
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Ski-Doo ELITE SERIES Specifications
General
Brand
Ski-Doo
Model
ELITE SERIES
Category
Offroad Vehicle
Language
English
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