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FORMULA 500 1997
Ski-Doo FORMULA 500 1997 - User Manual
352 pages
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2
Table of Contents
Main Page
Table of Contents
4
Safety Notice
6
1997 Bombardier Snowmobiles Shop Manual Volume 2 (Introduction)
7
General Information
12
Tightening Torques
13
Lubrication and Maintenance Chart
16
Troubleshooting
21
Table of Contents
21
Engine
22
Fuel and Oil Systems
32
Transmission and Brake Systems
35
Transmission
35
Brake System
42
Mechanical Brake
42
Hydraulic Brake
43
Mechanical and Hydraulic Brakes
43
Electrical System
44
Suspension System and Track
53
Engine
56
Default Chapter
56
Table of Contents
56
443 And 503 Engine Types
59
Engine Removal and Installation
59
Engine Removal and Installation
60
Tuned Pipe Identification
60
Top End
63
Cleaning
64
Disassembly
64
Assembly
65
Inspection
65
Bottom End
69
Assembly
70
Cleaning
70
Disassembly
70
Inspection
70
Engine Support and Muffler
72
Engine Support and Muffler Disassembly and Assembly
73
Installation on Vehicle
73
Removal from Vehicle
73
494, 583 and 670 Engine Types
75
Top End
75
Cleaning
76
Disassembly
76
Inspection
76
Assembly
77
Bottom End
81
Assembly
82
Cleaning
82
Disassembly
82
Inspection
82
Leak Test and Engine Dimension Measurement
85
Leak Test
85
Preparation
85
Procedure
85
Finalizing Reassembly
88
Cooling System Leak Test
88
Engine Leak Verification Flow Chart
89
Engine Dimension Measurement
90
Cylinder Taper
90
Cylinder out of Round
90
Cylinder/Piston Clearance
90
Ring/Piston Groove Clearance
91
Ring End Gap
91
Crankshaft Deflection
91
Connecting Rod Big End Axial Play
92
Connecting Rod/Piston Pin Clearance
92
Connecting Rod/Crankpin Clearance
93
Crankshaft End-Play
93
Crankcase/Rotary Valve Gap
93
Checking Surface Flatness
94
Rectifying Surfaces
94
Checking Crankshaft Alignment
94
Nippondenso Trigger Coil Ignition System
95
Cleaning
96
Disassembly
96
Assembly
98
CDI System
95
Ducati Ignition System
99
Cleaning
100
Disassembly
100
Repair
100
Assembly
101
Oil Injection Pump
102
Oil Pump Identification
104
Cleaning
104
Assembly
104
Adjustment
104
Checking Operation
106
Oil Injection System
102
Axial Fan Cooling System
107
Removal
109
Cleaning
109
Disassembly and Assembly
109
Liquid Cooling System
111
Inspection
113
Disassembly and Assembly
113
Draining the System
113
Cooling System Refilling Procedure
114
Rotary Valve, Coolant Pump and Reservoir
116
General
117
Cleaning
117
Disassembly
117
Assembly
118
Inspection
118
Rewind Starter
124
Removal
125
Assembly
125
Disassembly
125
Installation
126
Carburetor and Fuel Pump
128
Removal
129
Cleaning and Inspection
129
Identification
129
Carburetor Float Level Adjustment
130
Disassembly and Assembly
130
Installation
132
Carburetor Adjustments
133
Preliminary Idle Speed Adjustment
134
Choke
135
Idle Speed Final Adjustment
135
Hac System
136
Fuel Pump
137
Cleaning and Inspection
138
Installation
138
Pump Verification
138
Removal
138
Fuel Tank and Throttle Cable
139
Transmission
141
Default Chapter
141
Table of Contents
141
1997 Application Chart
143
Rotation Direction
143
Drive Belt Deflection Measurement
144
Deflection Adjustment
145
Drive Belt
143
Tra
146
General
147
Removal
147
Disassembly
148
Cleaning
149
Inspection
150
Assembly
151
Installation
153
Drive Pulley Adjustment
154
Drive Pulley
146
Driven Pulley
156
Removal
158
Cleaning
158
Disassembly
158
Inspection
158
Bushing Replacement
159
Assembly
160
Installation
160
Adjustment
161
Pulley Distance and Alignment
163
General
163
General Procedure
163
Pulley Alignment and Distance Specifications Chart
164
Hydraulic Disc Brake
166
Removal
167
Disassembly
168
Cleaning
168
Inspection
168
Assembly
169
Installation
169
Adjustment
170
Bleeding
170
Brake
166
Chaincase
172
Removal
173
Gear Ratio Modification
173
Inspection
173
Installation
173
Drive Chain Adjustment
174
Adjustment
175
3-Speed Gearbox (Shifter Mechanism)
176
Removal
177
Adjustment
177
Gearbox
176
3-Speed Gearbox
178
Removal
179
Disassembly
179
Inspection
181
Assembly
181
Installation
182
Oil Level
182
2-Speed Gearbox
183
Disassembly
184
Inspection
184
Assembly
184
Adjustment
186
Oil Change
187
Drive Chain
188
Silent Chain
188
Electrical
189
Default Chapter
189
Table of Contents
189
Tab and Receptacle Connectors Installation
193
Tab and Receptacle Connectors Removal
193
Unpluging Connectors
193
Accessories Installation
194
Ducati CDI System
195
Ignition Timing
195
Nippondenso Trigger Coil System
198
Spark Plugs
201
Ngk Spark Plug
201
Ngk Spark Plug Numbering System
201
1997 Reference Chart
201
Design Symbols Used in Ngk Spark Plugs
202
Disassembly
203
Heat Range
203
Fouling
203
Spark Plug Analysis
203
Spark Plug Installation
204
Spark Plug Tightening Torque
204
Battery
205
Removal
205
Cleaning
206
Hydrometer Test
207
Inspection
207
Activation of New Battery
208
Battery Storage
208
Servicing
211
Tips for Charging a Used Battery
211
Battery Charging Equipment
212
Installation of Battery
212
Electric Starter
214
Removal
215
Disassembly
215
Assembly
217
Cleaning and Inspection
217
Installation
218
Cleaning and Inspection
219
Cleaning
219
Inspection
219
Solenoid Switch
221
Starter Removal
223
Starter Disassembly
223
Cleaning
224
Parts Inspection
224
Starter Assembly
225
Starter Installation
226
Testing Procedure
227
General
227
Use of Bombardier Ignition Tester
228
Nippondenso CDI Trigger Coil System Testing
230
Trigger Coil Output
230
Ignition Coil Output
230
Ignition Module
231
Magneto Output (Ignition Generator Coil)
232
Lighting Generator Coil Output
232
Summary Table
234
Resistance Measurements
235
Ducati CDI System Testing
236
Trigger Coil Output
236
Magneto Output
236
Ignition Coil Output
237
Ignition Module
237
Lighting Generator Coil Output
237
Summary Table
238
Resistance Measurements
239
Voltage Regulator Inspection
240
Testing Procedure
240
Inspection of Ac Circuit Isolation
241
Inspection
241
Inspection of Heating Elements
242
Rear Suspension
243
Default Chapter
243
Table of Contents
243
Suspensions (All Versions)
244
SC-10 Suspensions (All Versions)
245
Component Removal and Installation
249
Removal
251
Disassembly and Assembly
252
Shock Absorber Inspection
253
Shock Absorber Servicing
254
Installation
262
Lubrication
262
Ride Adjustment
262
Skandic WT Suspension
263
Removal
264
Disassembly and Assembly
264
Shock Absorber Servicing
265
Drive Axle
267
Removal
269
Disassembly
269
Assembly
270
Axial Play
272
Installation
274
Adjustment
275
Lubrication
275
Track
276
Track Type Application
276
General
276
Inspection
276
Installation
276
Removal
276
Table of Contents
279
Steering System
280
Inspection
282
Disassembly and Assembly
282
Inspection
283
Adjustable Handlebar
284
Steering Adjustment (Skis)
285
Lubrication
288
Suspension and Ski System
290
Disassembly
291
Inspection
292
Installation
292
On-Vehicle Component Verification
295
Disassembly
296
Inspection
297
Installation
297
Table of Contents
299
Body
300
Installation and Adjustment
300
Headlamp Beam Aiming
300
Bulb Replacement
300
Decal
301
Windshield Installation
301
Hood
301
Belt Guard
302
Wiring Harness
302
Cables
302
Piping
302
Plastic Maintenance and Repair
303
Maintenance
303
Repair
304
Material Repair Procedure
305
Repair Procedure for R.I.M. Urethane
305
Frame
307
Frame Cleaning
307
Frame Welding
307
Frame Component Replacement
307
Technical Data
309
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Ski-Doo FORMULA 500 1997 Specifications
General
Brand
Ski-Doo
Model
FORMULA 500 1997
Category
Offroad Vehicle
Language
English
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