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MACH 1 1997
Ski-Doo MACH 1 1997 User Manual
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Section 03
ENGINE
Sub-Section 04
(CDI SYSTEM)
03-04-1
CDI SYSTEM
0
NIPPONDENSO TRIGGER COI
L IGNITION
SYSTEM
599, 699 and 809 Engines
A06E29S
Dielectric grease
(P/N 413 7017 00)
Dielectric grease
(P/N 413 7017 00)
Silastic 732
1
7
6
Loctite 242
4
22 N•m
(195 lbf•
in
)
Loctite 242
5
125 N•m
(92 lbf•ft)
Loctite
648
2
Loctite
242
Dielectric grease
(P/N 413 7017 00)
699 Only
FLAT RATE
PARTS
76
78
Table of Contents
Section 1
53
Default Chapter
53
Table of Contents
53
599, 699 and 809 Engine Types
55
Removal from Vehicle
56
Installation on Vehicle
56
Top End
57
Component Removal
58
Cleaning
58
Disassembly
58
Inspection
59
Assembly
59
Bottom End
63
Cleaning
64
Disassembly
64
Inspection
64
Assembly
65
Leak Test and Engine Dimension Measurement
67
Leak Test
67
Preparation
67
Procedure
67
Finalizing Reassembly
70
Cooling System Leak Test
70
Engine Leak Verification Flow Chart
71
Engine Dimension Measurement
72
Cylinder Taper
72
Cylinder out of Round
72
Cylinder/Piston Clearance
72
Ring/Piston Groove Clearance
73
Ring End Gap
73
Crankshaft Deflection
73
Connecting Rod Big End Axial Play
74
Connecting Rod/Piston Pin Clearance
74
Connecting Rod/Crankpin Clearance
75
Crankshaft End-Play
75
Checking Surface Flatness
75
Rectifying Surfaces
75
Checking Crankshaft Alignment
75
CDI System
77
Nippondenso Trigger Coil Ignition System
77
Disassembly
78
Assembly
80
Adjustment
82
Checking Operation
84
Liquid Cooling System
85
Inspection
86
Draining the System
86
Disassembly and Assembly
86
Cooling System Refilling Procedure
87
Rewind Starter
88
Removal
89
Disassembly
89
Assembly
89
Installation
91
Carburetor and Fuel Pump
92
Removal
94
Cleaning and Inspection
94
Identification
94
Disassembly and Assembly
95
Carburetor Float Level Adjustment
96
Installation
97
Carburetor Adjustments
98
Preliminary Idle Speed Adjustment
101
Idle Speed Final Adjustment
101
Choke
101
Fuel Pump
105
Removal
106
Pump Verification
106
Cleaning and Inspection
106
Installation
106
Fuel Tank and Throttle Cable
107
Section 2
109
Drive Belt
111
1997 Application Chart
111
Rotation Direction
111
Drive Belt Deflection Measurement
112
Deflection Adjustment
113
Drive Pulley
114
Tra
114
General
115
Removal
115
Disassembly
116
Cleaning
117
Inspection
118
Assembly
119
Installation
121
Drive Pulley Adjustment
122
Driven Pulley
124
Removal
125
Disassembly
125
Cleaning
125
Inspection
125
Assembly
127
Installation
127
Adjustment
128
Pulley Distance and Alignment
130
General
130
General Procedure
130
Pulley Alignment and Distance Specifications Chart
131
Brake
133
Hydraulic Disc Brake
133
Removal
134
Inspection
135
Gear Ratio Modification
139
Installation
139
Drive Chain Adjustment
140
Adjustment
141
Drive Chain
142
Silent Chain
142
Section 3
143
Wiring Diagrams
144
Chart Codes
144
Unpluging Connectors
146
Tab and Receptacle Connectors Removal
146
Tab and Receptacle Connectors Installation
146
Accessories Installation
147
Ignition Timing
148
Nippondenso Trigger Coil System
148
Spark Plugs
151
Ngk Spark Plug
151
Ngk Spark Plug Numbering System
151
1997 Reference Chart
151
Design Symbols Used in Ngk Spark Plugs
152
Disassembly
153
Heat Range
153
Fouling
153
Spark Plug Analysis
153
Spark Plug Installation
154
Spark Plug Tightening Torque
154
Testing Procedure
155
General
155
Use of Bombardier Ignition Tester
156
Nippondenso CDI Trigger Coil System Testing
157
Trigger Coil Output
157
Ignition Coil Output
157
Ignition Module
158
Magneto Output (Ignition Generator Coil)
159
Lighting Generator Coil Output
159
Summary Table
160
Resistance Measurements
161
Voltage Regulator Inspection
162
Testing Procedure
162
Inspection of Ac Circuit Isolation
163
Inspection
163
Inspection of Heating Elements
164
Section 4
165
Suspension (Hp Version)
166
Component Removal and Installation
167
Removal
169
Disassembly and Assembly
169
Shock Absorber Inspection
171
Installation
172
Ride Adjustment
172
Lubrication
172
Drive Axle
173
Removal
174
Disassembly
174
Assembly
174
Axial Play
176
Installation
179
Lubrication
179
Adjustment
180
Track
181
Track Type Application
181
General
181
Inspection
181
Removal
181
Installation
181
Section 5
184
Steering System
185
Inspection
186
Disassembly and Assembly
186
Inspection
187
Adjustable Handlebar
188
Steering Adjustment (Skis)
189
Lubrication
191
Suspension and Ski System
193
Disassembly
194
Inspection
195
Installation
195
,14, Tie Rod and Lever
197
Body
198
Installation and Adjustment
198
Headlamp Beam Aiming
198
Bulb Replacement
198
Decal
199
Windshield Installation
199
Hood
199
Belt Guard
199
Wiring Harness
199
Cables
200
Piping
200
Plastic Maintenance and Repair
201
Maintenance
201
Repair
202
Material Repair Procedure
203
Repair Procedure for R.I.M. Urethane
203
Frame
205
Frame Cleaning
205
Frame Welding
205
Frame Component Replacement
205
5
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Ski-Doo MACH 1 1997 Specifications
General
Brand
Ski-Doo
Model
MACH 1 1997
Category
Snowmobiles
Language
English
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