Ski-Doo FORMULA SL 1997 User Manual

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Section 04 TRANSMISSION

Sub-Section 03 (DRIVE PULLEY)

04-03-1

DRIVE PULLEY 0

TRA

All Models

NOTE:

This is a lubrication free drive pulley.

12 N•m

(106 lbf•in)

13 N•m

(115 lbf•in)

95 N•m

(70 lbf•ft)

10 N•m

(89 lbf•in)

Repair kit

A06D1ZS

5

6

7

9

12

11

12

13

14

15

16

17

16

Loctite

648

18

Loctite

648

19

20

21

22

23

25

24

27

26

25

29

32

30

31

95 N•m

(70 lbf•pi)

28

Loctite

648

FLAT RATE

PARTS

Table of Contents

Table of Contents4
- Safety Notice6
Table of Contents19
- Engine20
- Fuel and Oil Systems30
- Transmission and Brake Systems33
- Electrical System41
- Suspension System and Track50
Table of Contents53
- Engine Removal and Installation56
- 277 Engine Type56
- Top End58
- Bottom End62
- 377, 443 and 503 Engine Types66
- Engine Removal and Installation66
  - Engine Removal and Installation68
- Leak Test and Engine Dimension Measurement78
- Leak Test78
- Engine Dimension Measurement82
- Nippondenso Ignition System with Single Generating Coil88
- CDI System88
- Ducati Ignition System92
- Oil Injection System95
- Oil Injection Pump95
- Axial Fan Cooling System100
- Rewind Starter103
- Carburetor and Fuel Pump108
- Fuel Pump116
- Fuel Tank and Throttle Cable119
Table of Contents121
- 1997 Application Chart123
- Drive Belt123
- Drive Pulley127
- Bombardier Lite127
- Tra130
- Driven Pulley140
- Pulley Distance and Alignment151
- Brake155
- Mechanical Disc Brake155
- Hydraulic Disc Brake157
- Chaincase163
- 2-Speed Gearbox171
- Gearbox171
- Drive Chain176
Table of Contents178
- Default Chapter182
  - Tab and Receptacle Connectors Installation182
  - Accessories Installation183
- Ignition Timing184
- Nippondenso CDI System (Without Trigger Coil)184
- Ducati CDI System188
- Ngk Spark Plug191
  - Ngk Spark Plug Numbering System191
  - 1997 Reference Chart191
- Spark Plugs191
- Design Symbols Used in Ngk Spark Plugs192
- Battery195
- Electric Starter202
- Cleaning and Inspection207
- Testing Procedure210
  - General210
  - Use of Bombardier Ignition Tester211
- Nippondenso CDI System Testing213
- Ducati CDI System Testing218
- Voltage Regulator Inspection222
- Inspection of Ac Circuit Isolation223
  - Inspection223
- Inspection of Heating Elements224
Table of Contents225
- Torque Reaction Suspension226
- Lubrication231
- Sport and Touring Suspension232
- Drive Axle239
- Track247
Table of Contents251
- Steering System252
- Suspension and Ski System262
Table of Contents269
- Installation and Adjustment270
- Body270
- Plastic Maintenance and Repair272
- Frame275
Troubleshooting313
- Table of Contents313
Table of Contents348
- 443 And 503 Engine Types351
- Engine Removal and Installation351
  - Engine Removal and Installation352
  - Tuned Pipe Identification352
  - Engine Removal and Installation354
- Top End355
  - Cleaning356
  - Disassembly356
  - Inspection357
  - Assembly357
- Bottom End361
  - Cleaning362
  - Disassembly362
  - Inspection362
  - Assembly362
- Engine Support and Muffler364
  - Removal from Vehicle365
  - Engine Support and Muffler Disassembly and Assembly365
  - Installation on Vehicle365
- Top End367
  - Cleaning368
  - Disassembly368
  - Inspection368
  - Assembly369
- Bottom End373
  - Cleaning374
  - Disassembly374
  - Inspection374
  - Assembly374
- Leak Test377
  - Preparation377
  - Procedure377
  - Finalizing Reassembly380
  - Cooling System Leak Test380
  - Engine Leak Verification Flow Chart381
- Leak Test and Engine Dimension Measurement377
- Engine Dimension Measurement382
  - Cylinder Taper382
  - Cylinder out of Round382
  - Cylinder/Piston Clearance382
  - Ring/Piston Groove Clearance383
  - Ring End Gap383
  - Crankshaft Deflection383
  - Connecting Rod Big End Axial Play384
  - Connecting Rod/Piston Pin Clearance384
  - Connecting Rod/Crankpin Clearance385
  - Crankshaft End-Play385
  - Crankcase/Rotary Valve Gap385
  - Checking Surface Flatness386
  - Rectifying Surfaces386
  - Checking Crankshaft Alignment386
- CDI System387
- Nippondenso Trigger Coil Ignition System387
  - Cleaning388
  - Disassembly388
  - Assembly390
- Ducati Ignition System391
  - Cleaning392
  - Disassembly392
  - Repair392
  - Assembly393
- Oil Injection Pump394
  - Oil Pump Identification396
- Oil Injection System394
- Axial Fan Cooling System399
  - Removal401
  - Cleaning401
  - Disassembly and Assembly401
- Liquid Cooling System403
  - Inspection405
  - Draining the System405
  - Disassembly and Assembly405
  - Cooling System Refilling Procedure406
- Rotary Valve, Coolant Pump and Reservoir408
  - General409
  - Cleaning409
  - Disassembly409
  - Inspection410
  - Assembly410
- Rewind Starter416
  - Removal417
  - Disassembly417
  - Assembly417
  - Installation418
- Carburetor and Fuel Pump420
  - Removal421
  - Cleaning and Inspection421
  - Identification421
  - Disassembly and Assembly422
  - Carburetor Float Level Adjustment422
  - Installation424
  - Carburetor Adjustments425
  - Preliminary Idle Speed Adjustment426
  - Hac System428
- Fuel Pump429
  - Removal430
  - Pump Verification430
  - Cleaning and Inspection430
  - Installation430
- Fuel Tank and Throttle Cable431
Table of Contents433
- 1997 Application Chart435
- Drive Belt435
- Drive Pulley438
- Driven Pulley448
- Pulley Distance and Alignment455
- Brake458
- Hydraulic Disc Brake458
- Chaincase464
- Gearbox468
- 3-Speed Gearbox (Shifter Mechanism)468
  - Removal469
  - Adjustment469
- 3-Speed Gearbox470
- Drive Chain480
  - Silent Chain480
Table of Contents481
- Default Chapter485
- Ducati CDI System487
- Ignition Timing487
- Nippondenso Trigger Coil System490
- Ngk Spark Plug493
  - Ngk Spark Plug Numbering System493
- Spark Plugs493
- Design Symbols Used in Ngk Spark Plugs494
- Battery497
- Electric Starter506
- Cleaning and Inspection511
- Nippondenso CDI Trigger Coil System Testing522
- Ducati CDI System Testing528
- Voltage Regulator Inspection532
  - Testing Procedure532
- Inspection of Ac Circuit Isolation533
  - Inspection533
- Inspection of Heating Elements534
Table of Contents535
- Suspensions (All Versions)536
- Skandic Wt Suspension555
- Drive Axle559
- Track568
Table of Contents571
- Steering System572
- Disassembly and Assembly574
- Adjustable Handlebar576
- Steering Adjustment (Skis)577
- Lubrication580
- Disassembly583
- Inspection584
- Installation584
- On-Vehicle Component Verification587
- Disassembly588
- Inspection589
- Installation589
Table of Contents591
- Installation and Adjustment592
- Plastic Maintenance and Repair595
- Frame599
  - Frame Cleaning599
  - Frame Component Replacement599
Table of Contents661
- Engine662
- Fuel and Oil Systems672
- Transmission and Brake Systems675
  - Brake System682
- Electrical System684
- Suspension System and Track693
Engine696
- Default Chapter696
  - Table of Contents696
- 599, 699 and 809 Engine Types698
  - Installation on Vehicle699
  - Removal from Vehicle699
- Top End700
  - Component Removal701
- Leak Test710
- Leak Test and Engine Dimension Measurement710
- Engine Dimension Measurement715
- CDI System720
- Nippondenso Trigger Coil Ignition System720
Transmission/Drive Belt752
- Transmission752
- Tra757
- Brake776
- Hydraulic Disc Brake776
Table of Contents786
- Electrical787
  - Wiring Diagrams (See Annexes at the End of this Manual)787
- Ignition Timing791
- Nippondenso Trigger Coil System791
- Ngk Spark Plug794
  - Ngk Spark Plug Numbering System794
- Spark Plugs794
- Design Symbols Used in Ngk Spark Plugs795
- Testing Procedure798
  - General798
    - Use of Bombardier Ignition Tester799
- Nippondenso CDI Trigger Coil System Testing800
- Voltage Regulator Inspection805
  - Testing Procedure805
- Inspection of Ac Circuit Isolation806
  - Inspection806
- Inspection of Heating Elements807
Rear Suspension808
- Default Chapter808
  - Table of Contents808
- Suspension (Hp Version)809
- Drive Axle816
  - Removal817
- Track824
  - General824
Steering System/Suspension and Ski System827
- Steering827
Table of Contents840
- Installation and Adjustment841
- Plastic Maintenance and Repair844
- Frame848
  - Frame Cleaning848
  - Frame Component Replacement848
Table of Contents907
- Default Chapter908
  - Safety Notice908
- 1 - Lubrication909
- 2 - Troubleshooting909
- 3 - Engine909
  - General909
  - Liquid Cooling System910
- 4 - Transmission911
  - Brake911
- 5 - Electrical912
- 6 - Rear Suspension912
- 7 - Steering/Front Suspension912
- 8 - Body/Frame921
- 9 - Technical Data921

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Ski-Doo FORMULA SL 1997 Specifications

General

Brand	Ski-Doo
Model	FORMULA SL 1997
Category	Snowmobiles
Language	English

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