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Ski-Doo MACH 1 1997 User Manual

Ski-Doo MACH 1 1997
219 pages
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Table of Contents

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Ski-Doo MACH 1 1997 Specifications

General IconGeneral
BrandSki-Doo
ModelMACH 1 1997
CategorySnowmobiles
LanguageEnglish

Summary

1997 Ski-Doo Shop Manual Volume 3

Covered Models

Lists the snowmobile models covered in this manual.

Safety Notice

WARNING

Identifies instructions that could cause serious personal injury or death.

CAUTION

Denotes instructions that could severely damage vehicle components.

Tightening Torques Reference

Section 01 Lubrication and Maintenance

Lubrication and Maintenance Chart

A chart detailing lubrication and maintenance tasks and their schedules.

Engine Lubrication Procedures

Step-by-step guide for engine lubrication for storage.

Drive Belt Condition Inspection

How to inspect the drive belt for wear and damage.

Section 02 Troubleshooting

Engine Troubleshooting

Diagnosing and resolving engine-related issues.

Fuel and Oil Systems Troubleshooting

Diagnosing and resolving fuel and oil system issues.

Transmission and Brake Systems Troubleshooting

Diagnosing and resolving transmission and brake issues.

Electrical System Troubleshooting

Diagnosing and resolving electrical system issues.

Rear Suspension Troubleshooting

Diagnosing and resolving rear suspension issues.

Engine Backfires Troubleshooting

Engine Suddenly Turns Off Troubleshooting

Piston Damage Troubleshooting

Engine Power Loss Troubleshooting

Engine Detonation Troubleshooting

Engine Fails to Start Troubleshooting

Irregular Engine Idle Troubleshooting

High Engine Operating Temperature Troubleshooting

"RAVE" Valve Troubleshooting

RAVE Hesitation Troubleshooting

Rewind Starter Troubleshooting

Engine Pinging Troubleshooting

Engine Vibration Troubleshooting

High Fuel Consumption Troubleshooting

Fuel Leaks Troubleshooting

Engine Power Loss or Stalling Troubleshooting

High Injection Oil Consumption

Engine Runs Out of Fuel Troubleshooting

Slow Acceleration Troubleshooting

High RPM / Low Top Speed Troubleshooting

Drive System Looseness Troubleshooting

Driven Pulley Vibrations Troubleshooting

Uneven Belt Wear Troubleshooting

Mechanical Brake Adjustment Issues

Brake Handle Return Issues

Spongy Brake Condition Troubleshooting

Brake Fluid Leaking Troubleshooting

Starter Does Not Turn Troubleshooting

Starter Turns, Engine Not Cranking Troubleshooting

Starter/Ring Gear Mesh Issues

Electric Starter Continuous Operation Troubleshooting

Noise During Starting Engine Troubleshooting

Intermittent Electric Starter Operation

Headlamp Not Lighting Troubleshooting

Headlamp Dimming Troubleshooting

Engine No Spark Troubleshooting

Engine Stalls Troubleshooting

Irregular Engine Speed Troubleshooting

Engine Misfiring Troubleshooting

Fouled Spark Plug Tip Troubleshooting

Rear Suspension Bottoms Out Troubleshooting

Premature Slider Shoe Wear Troubleshooting

Track Noise or Vibrations Troubleshooting

Derailing Track Troubleshooting

Rear Suspension Low or Stiff Troubleshooting

Snowmobile Understeers Troubleshooting

Handlebar Difficult to Turn Troubleshooting

Snowmobile Instability Troubleshooting

Section 03 Engine

Engine Types (599, 699, 809)

Details on the different engine types used in the snowmobiles.

Engine Removal and Installation

Procedures for removing and installing the engine.

Top End Procedures

Procedures related to the top end of the engine.

Bottom End Procedures

Procedures related to the bottom end of the engine.

Leak Test and Engine Dimension Measurement

Procedures for leak testing and measuring engine dimensions.

CDI System

Information and procedures related to the CDI system.

Oil Injection System

Oil Injection Pump

Exploded view of the oil injection pump components.

Liquid Cooling System

Rewind Starter

Carburetor and Fuel Pump

Fuel Tank and Throttle Cable

599, 699, 809 Engine Types Exploded View

Engine Removal From Vehicle

Engine Installation On Vehicle

Top End Exploded View

Component Removal

Disassembly Procedures

RAVE System Procedures

Assembly Procedures

Cylinder Head, Cylinder Head Cover, and Cylinder Procedures

Bottom End Exploded View

Reed Valve Inspection

Crankshaft Bearing Procedures

Crankshaft Bearing, Lubricant, and Sleeve Assembly

Crankcase Assembly

Water Pump Housing Installation

Leak Test and Engine Dimension Measurement

Leak Test Preparation

Steps to prepare the engine for leak testing.

Leak Test Procedure

Step-by-step procedure for performing an engine leak test.

Engine Leak Checks

Rotary Valve Gear Reservoir Leak Check

Cooling System Leak Test

Engine Leak Verification Flow Chart

Engine Dimension Measurement

Cylinder Taper Measurement

Procedure for measuring cylinder taper.

Cylinder Out of Round Measurement

Procedure for measuring cylinder out of round.

Cylinder/Piston Clearance Measurement

Procedure for measuring cylinder to piston clearance.

Ring/Piston Groove Clearance Measurement

Ring End Gap Measurement

Crankshaft Deflection Measurement

Connecting Rod Big End Axial Play Measurement

Connecting Rod/Piston Pin Clearance Measurement

Connecting Rod/Crankpin Clearance Measurement

Crankshaft End-Play Measurement

Checking Crankshaft Alignment

CDI System

Magneto and Flywheel Nut Removal

Trigger Coil and Screw Procedures

Trigger Coil Air-Gap Adjustment

Stator Replacement

Magneto Flywheel and Nut Installation

Oil Seal Installation

Oil Injection System

Gear Retaining Nut and Oil Pump Gear Procedures

Oil Pump Adjustment

Bleeding Oil Lines

Checking Oil Pump Operation

Liquid Cooling System

Cooling System Inspection

Draining the Cooling System

Thermostat Check

Cooling System Refilling Procedure

Rewind Starter

Rewind Starter Removal

Rewind Starter Disassembly

Rewind Starter Assembly

Rewind Starter Installation

Carburetor and Fuel Pump

Carburetor Removal

Carburetor Cleaning and Inspection

Filter Inspection

Carburetor Disassembly and Assembly

E-clip and Needle Procedures

Carburetor Float Level Adjustment

Carburetor Installation

Carburetor Adjustments

Air Screw Adjustment

Carburetor Synchronization

Throttle Slide Position Check

Full Throttle Adjustment

Throttle Slide Adjustment

Preliminary Idle Speed Adjustment

Idle Speed Final Adjustment

Choke Plunger Adjustment

Choke Plunger Adjustment Details

Choke Rod Procedures

Choke Cable Adjustment

Fuel Pump

Fuel Pump Removal

Fuel Pump Verification

Fuel Pump Cleaning and Inspection

Fuel Pump Installation

Fuel Tank and Throttle Cable

Fuel Level Sensor Inspection

Section 04 Transmission

Pulley Distance and Alignment

Procedures for adjusting pulley distance and alignment.

Chaincase

Drive Belt

Drive Belt Deflection Measurement

Deflection Adjustment

Drive Pulley

Drive Pulley Removal

Drive Pulley Disassembly

Spring Cover Assembly

Drive Pulley Inspection

Ramp, Dowel Tube, and Screw Procedures

Lever Assembly Procedures

Fixed/Sliding Halves, Spring, Cover, Screw Assembly

Sliding Half, Slider Shoe, and Governor Cup Procedures

Drive Pulley Assembly Installation

Drive Pulley Adjustment

Driven Pulley

Driven Pulley Removal

Countershaft Removal

Driven Pulley Disassembly

Bushing Inspection

Slider Shoe Replacement

Bushing Replacement Procedures

Countershaft and Lubricant Installation

Driven Pulley Adjustment

Spring Pre-Load Adjustment

Pulley Alignment and Drive Belt Deflection

Pulley Distance and Alignment

Pulley Alignment and Distance Specifications Chart

Pulley Alignment Method

Pulley Distance Adjustment Method

Brake System

Brake Disc Removal

Countershaft Removal

Brake System Disassembly

Brake Pad Inspection

Brake Disc Inspection

Brake System Installation

Brake Pad Installation

Brake Disc Installation

Countershaft Bearing Adjustment

Brake System Bleeding

Chaincase

Chaincase Removal

Chaincase Inspection

Chaincase Installation

Drive Chain Adjustment

Chaincase Oil Filling

Pulley Alignment and Track Tension/Alignment

Drive Chain

Section 05 Electrical

Ignition Timing

Procedures for setting and checking ignition timing.

Wiring Diagrams

Wire Colors and Electrical Circuits

Accessories Installation

Ignition Timing

Verifying Magneto Flywheel Timing Mark Position (Continued)

Checking Ignition Timing

Spark Plugs

NGK Spark Plug Design Symbols

Spark Plug Heat Range Explanation

Spark Plug Fouling Explanation

Spark Plug Analysis

Spark Plug Installation

Spark Plug Tightening Torque

Testing Procedure

Engine Stop/Tether Cut-Out Switches Verification

Magneto System Verification

Test Condition and Analysis of Results

Nippondenso CDI Trigger Coil System Testing

Trigger Coil Output Test

Ignition Coil Output Test

Ignition Module Testing

Magneto Output Test

Lighting Generator Coil Output Test

Summary Table of Electrical Tests

Resistance Measurements

Voltage Regulator Inspection

Voltage Regulator Testing Procedure

AC Circuit Isolation Inspection

Heating Elements Inspection

Section 06 Rear Suspension

SC-10 Suspension (HP Version)

Component Removal and Installation

Rear Shock Removal

Front Shock Removal

Rear Spring Removal

Cam Adjustment

Suspension Disassembly and Assembly

Front Shock Assembly

Stopper Strap Inspection

Shock Absorber Inspection

Suspension Installation

Drive Axle

Drive Axle Removal

End Bearing Housing and Seal Removal

Drive Axle and Sprocket Removal

Bearing Removal

Sprocket and Half-Sprocket Removal

Drive Axle and Sprocket Assembly

Drive Axle and Seal Assembly

Bearing Installation

Chaincase Perpendicularity Adjustment

Axial Play Adjustment

Installation Procedures

Sprocket/Track Alignment

Track

Track Tension and Alignment

Procedures for adjusting track tension and alignment.

Track Tension Adjustment

Track Alignment

Track Cleat Removal and Installation

Section 07 Steering/Front Suspension

Steering System

Steering System Inspection

Steering Arm and Ski Leg

Ball Joint Inspection

Steering Arm Alignment

Adjustable Handlebar Procedures

Steering Adjustment (Skis) Definitions and Procedures

Pivot Arm Centering

Camber Adjustment Procedure

Handlebar and Ski Toe-Out Adjustment

Suspension and Ski System

Shock Disassembly

Swing Arm Removal

Suspension Component Inspection

Suspension Component Installation

Section 08 Body/Frame

Body Installation and Adjustment

Belt Guard Disassembly, Assembly, and Inspection

Plastic Maintenance and Repair

R.I.M. Urethane Repair Procedures

Frame Cleaning

Frame Component Replacement

Vehicle Model Specifications

Vehicle Model Specifications (Continued)

Wiring Diagram Information

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