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I

7

1997

Shop Manual Supplement

GRAND TOURING SE

®

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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