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Formula 583 DL 1998
Ski-Doo Formula 583 DL 1998 User Manual
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Section 04
ENGINE
Subsection 10
(REW
IND STARTER)
04-10-
2
All Fan Coole
d Engines
A21C08S
10 N•m
(89 lbf•
in
)
Molykote G-n
paste or
equivalent
Silicone
compound
grease
Silicone
compound
grease
8 N•m
(71 lbf•
in
)
15
6
7
5
4
1
3
8
9
10
12
11
FLAT RATE
PARTS
149
151
Table of Contents
Table of Contents
4
Safety Notice
6
What's New
7
Introduction
8
01 Service Tools and Service Products
10
Service Tools
20
Service Products
33
Lubrication and Maintenance Chart
40
Troubleshooting
45
Table of Contents
45
Engine
46
Engine Leak Verification Flow Chart
55
Fuel and Oil Systems
56
Transmission
59
Transmission and Brake Systems
59
Brake System
65
Hydraulic Brake
65
Mechanical Brake
65
Mechanical and Hydraulic Brakes
66
Electrical System
67
Suspension and Track
76
Suspension System and Track
76
Engine
79
Table of Contents
79
443 And 503 Engine Types
82
Engine Removal and Installation
82
Engine Removal and Installation
83
Tuned Pipe Identification
83
Top End
86
Cleaning
87
Disassembly
87
Assembly
88
Inspection
88
Bottom End
92
Assembly
93
Cleaning
93
Disassembly
93
Inspection
93
494, 583 and 670 Engine Types
95
Engine Support and Muffler
95
Engine Support and Muffler Disassembly and Assembly
96
Installation on Vehicle
96
Removal from Vehicle
96
Top End
98
Cleaning
99
Disassembly
99
Inspection
99
Assembly
100
Bottom End
104
Assembly
105
Cleaning
105
Disassembly
105
Inspection
105
Leak Test
108
Leak Test and Engine Dimension Measurement
108
Preparation
108
Procedure
108
Cooling System Leak Test
111
Finalizing Reassembly
111
Engine Leak Verification Flow Chart
112
Combustion Chamber Volume Measurement
113
Cylinder Head Warpage
113
Cylinder out of Round
113
Cylinder Taper
113
Engine Dimension Measurement
113
Cylinder/Piston Clearance
115
Used Piston Measurement
115
Ring End Gap
116
Ring/Piston Groove Clearance
116
Connecting Rod Big End Axial Play
117
Crankshaft Deflection
117
Connecting Rod/Crankpin Clearance
118
Connecting Rod/Piston Pin Clearance
118
Crankcase/Rotary Valve Gap
118
Crankshaft End-Play
118
Checking Surface Flatness
119
Rectifying Surfaces
119
Checking Crankshaft Alignment
120
CDI System
121
Nippondenso Trigger Coil Ignition System
121
Cleaning
122
Disassembly
122
Assembly
124
Ducati Ignition System
125
Cleaning
126
Disassembly
126
Repair
126
Assembly
127
Oil Injection Pump
128
Oil Injection System
128
Adjustment
130
Assembly
130
Cleaning
130
Disassembly
130
Oil Pump Identification
130
Checking Operation
132
Axial Fan Cooling System
133
Cleaning
134
Disassembly and Assembly
134
Removal
134
Liquid Cooling System
136
Disassembly and Assembly
138
Draining the System
138
Inspection
138
Cooling System Refilling Procedure
139
Rotary Valve, Coolant Pump and Reservoir
141
Cleaning
142
Disassembly
142
General
142
Assembly
143
Inspection
143
Rewind Starter
149
Assembly
151
Disassembly
151
Removal
151
Installation
152
Carburetor and Fuel Pump
154
Cleaning and Inspection
155
Identification
155
Removal
155
Carburetor Float Level Adjustment
156
Disassembly and Assembly
156
Installation
158
Carburetor Adjustments
159
Preliminary Idle Speed Adjustment
160
Choke
161
Idle Speed Final Adjustment
161
Fuel Pump
165
Cleaning and Inspection
166
Installation
166
Pump Verification
166
Removal
166
Fuel Tank and Throttle Cable
167
Transmission
169
Table of Contents
169
1998 Application Chart
171
Drive Belt
171
Rotation Direction
171
Drive Belt Deflection Measurement
172
Deflection Adjustment
173
Drive Pulley
174
Tra
174
General
175
Removal
175
Disassembly
176
Cleaning
177
Inspection
177
Assembly
178
Installation
181
Drive Pulley Adjustment
182
Driven Pulley
184
Cleaning
186
Disassembly
186
Inspection
186
Removal
186
Assembly
188
Installation
188
Adjustment
189
General
191
General Procedure
191
Pulley Distance and Alignment
191
Pulley Alignment and Distance Specifications Chart
192
Brake
194
Hydraulic Disc Brake
194
Removal
195
Cleaning
196
Disassembly
196
Inspection
196
Assembly
197
Installation
197
Adjustment
198
Bleeding
198
Chaincase
199
Gear Ratio Modification
200
Inspection
200
Installation
200
Removal
200
Drive Chain Adjustment
201
Adjustment
202
3-Speed Gearbox
203
Gearbox
203
Disassembly
204
Removal
204
Assembly
211
Inspection
211
Installation
214
Oil Level
214
2-Speed Gearbox
215
Assembly
216
Disassembly
216
Inspection
216
Adjustment
218
Oil Change
219
Drive Chain
220
Silent Chain
220
Electrical
221
Table of Contents
221
Ducati CDI System
223
Ignition Timing
223
Nippondenso Trigger Coil System
226
Ngk Spark Plug
229
Ngk Spark Plug Numbering System
229
Reference Chart
229
Spark Plugs
229
Design Symbols Used in Ngk Spark Plugs
230
Disassembly
231
Fouling
231
Heat Range
231
Spark Plug Analysis
231
Spark Plug Installation
232
Spark Plug Tightening Torque
232
Battery
233
Cleaning
233
Removal
233
Hydrometer Test
234
Inspection
234
Activation of New Battery
235
Battery Storage
235
Servicing
238
Tips for Charging a Used Battery
238
Battery Charging Equipment
239
Installation of Battery
239
Electric Starter
241
Disassembly
242
Removal
242
Assembly
244
Cleaning and Inspection
244
Installation
245
Cleaning
246
Cleaning and Inspection
246
Inspection
246
Solenoid Switch
248
Starter Disassembly
250
Starter Removal
250
Cleaning
251
Parts Inspection
251
Starter Assembly
252
Starter Installation
253
General
254
Testing Procedure
254
Electrical Connector Testing
256
Ignition System Testing Sequence
256
Lighting System Testing Sequence
256
Nippondenso CDI System Testing
256
Sparking
256
Ignition Switch, Tether Cord Switch and Emergency Switch Testing
257
High Voltage Coil Voltage Testing
258
Ignition Generator Coil Voltage Testing
258
Ignition Module Voltage Testing
258
Conclusion
259
Lighting Generator Coil Voltage Testing
259
Ducati CDI System Testing
262
Electrical Connector Testing
262
Ignition System Testing Sequence
262
Lighting System Testing Sequence
262
Sparking
262
Ignition Switch, Tether Cord Switch and Emergency Switch Testing
263
High Voltage Coil Voltage Testing
264
Ignition Generator Coil Voltage Testing
264
Trigger Coil Voltage Testing
264
Conclusion
265
Lighting Generator Coil Voltage Testing
265
Inspection
268
Inspection of Ac Circuit Isolation
268
Inspection of Heating Elements
269
Rear Suspension
270
Table of Contents
270
Suspensions (All Versions)
271
Component Removal and Installation
275
Removal
277
Disassembly and Assembly
278
Shock Absorber Inspection
280
Installation
281
Lubrication
281
Ride Adjustment
281
Formula Z 670 Suspension
282
Component Removal and Installation
283
Inspection
290
Installation
291
Lubrication
292
Ride Adjustment
292
Skandic WT Suspension
293
Disassembly and Assembly
294
Removal
294
Shock Absorber Servicing
295
Installation
296
Drive Axle
297
Disassembly
299
Removal
299
Assembly
300
Axial Play
301
Installation
304
Adjustment
305
Lubrication
305
General
306
Inspection
306
Installation
306
Removal
306
Track
306
Track Type Application
306
Table of Contents
309
Steering System
310
Disassembly and Assembly
313
Inspection
313
Inspection
314
Adjustable Handlebar
316
Steering Adjustment (Skis)
317
Lubrication
319
Suspension and Ski System
321
Disassembly
322
Inspection
323
Installation
323
On-Vehicle Component Verification
325
Disassembly
326
Inspection
327
Installation
327
Body/Frame
329
Table of Contents
329
Body
330
Bulb Replacement
330
Headlamp Beam Aiming
330
Installation and Adjustment
330
Decal
331
Hood
331
Windshield Installation
331
Belt Guard
332
Cables
332
Piping
332
Wiring Harness
332
Maintenance
333
Plastic Maintenance and Repair
333
Repair
334
Material Repair Procedure
335
Repair Procedure for R.I.M. Urethane
335
Frame
337
Frame Cleaning
337
Frame Component Replacement
337
Frame Welding
337
Si* Metric Information Guide
339
Technical Data
339
Technical Data Legends
350
Wiring Diagrams
351
5
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Ski-Doo Formula 583 DL 1998 Specifications
General
Brand
Ski-Doo
Model
Formula 583 DL 1998
Category
Snowmobiles
Language
English
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