2003 Ski-Doo Legend Sport 500R Factory Service & Work Shop Manual

2004 Shop Manual REV SERIES

TABLE OF CONTENTS SAFETY NOTICE ................................................................................... IX INTRODUCTION .................................................................................... X VEHICLE IDENTIFICATION NUMBER........................................................................... XV ENGINE SERIAL NUMBER ....................................................................................... XV LIST OF ABBREVIATIONS USED IN THIS MANUAL ......................................................... XV ARRANGEMENT OF THIS MANUAL .......................................................................... XVII GENERAL INFORMATION........................................................................................ XIX ILLUSTRATIONS AND PROCEDURES ......................................................................... XIX SELF-LOCKING FASTENERS PROCEDURE ................................................................... XIX LOCTITE APPLICATION PROCEDURE .......................................................................... XIX THREADLOCKER .................................................................................................. XX STRIPPED THREAD REPAIR ..................................................................................... XXI GASKET COMPOUND ........................................................................................... XXII MOUNTING ON SHAFT ......................................................................................... XXII CASE-IN COMPONENTS ....................................................................................... XXIII TIGHTENING TORQUES ....................................................................................... XXIII 01 TOOLS AND SERVICE PRODUCTS 01 – SERVICE TOOLS ............................................................................................... 1 ENGINE — MANDATORY TOOLS ................................................................................... 2 ENGINE — RECOMMENDED TOOLS............................................................................... 4 TRANSMISSION — MANDATORY TOOLS ........................................................................ 10 TRANSMISSION — RECOMMENDED TOOLS .................................................................... 11 SUSPENSION — MANDATORY TOOLS ........................................................................... 15 SUSPENSION — RECOMMENDED TOOLS ....................................................................... 16 VEHICLE — RECOMMENDED TOOLS............................................................................. 19 02 – SERVICE PRODUCTS ........................................................................................ 21 02 MAINTENANCE 01 – MAINTENANCE CHART ..................................................................................... 29 02 – STORAGE ..................................................................................................... 33 GENERAL ............................................................................................................. 33 FUEL STABILIZER .................................................................................................... 33 ENGINE LUBRICATION .............................................................................................. 33 ENGINE COMPARTMENT ........................................................................................... 34 PULLEY PROTECTION............................................................................................... 34 COUNTERSHAFT LUBRICATION ................................................................................... 34 BATTERY .............................................................................................................. 34 VEHICLE CLEANING ................................................................................................. 34 RAGS IN AIR INTAKE AND EXHAUST SYSTEM ................................................................... 34 VEHICLE PROTECTION.............................................................................................. 34 03 – PRESEASON PREPARATION ............................................................................... 35 FUEL FILTER REPLACEMENT ...................................................................................... 35 THROTTLE BODY CLEANING(ON SO EQUIPPED MODELS) .................................................... 36 CARBURETOR CLEANING(ON SO EQUIPPED MODELS)........................................................ 36 AIR FILTER CLEANING .............................................................................................. 36 RAGS IN AIR INTAKE AND EXHAUST SYSTEM ................................................................... 36 CLEANING OF DRIVE AND DRIVEN PULLEYS .................................................................... 36 CLEANING OF BRAKE DISK ........................................................................................ 36 DRIVE BELT CONDITION ............................................................................................ 36 SPARK PLUGS ........................................................................................................ 36 I

TABLE OF CONTENTS 03 TROUBLESHOOTING 01 – ENGINE ........................................................................................................ 37 ENGINE LEAK VERIFICATION FLOW CHART ..................................................................... 48 02 – FUEL AND OIL SYSTEMS .................................................................................. 49 03 – TRANSMISSION AND BRAKE SYSTEM.................................................................. 53 TRANSMISSION ............................................................................................. 53 BRAKE SYSTEM.............................................................................................. 60 HYDRAULIC BRAKE ................................................................................................. 60 04 – ELECTRICAL SYSTEM ....................................................................................... 61 05 – SUSPENSION AND TRACK................................................................................. 73 04 ENGINE 01 – 593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES ............................................... 77 EXHAUST SYSTEM.......................................................................................... 77 TUNED PIPE .......................................................................................................... 78 MANIFOLD ........................................................................................................... 78 MUFFLER ............................................................................................................. 78 ENGINE SYSTEM ............................................................................................ 80 REMOVAL FROM VEHICLE ......................................................................................... 81 INSPECTION.......................................................................................................... 84 INSTALLATION ....................................................................................................... 84 TOP END....................................................................................................... 85 TROUBLESHOOTING ................................................................................................ 89 COMPONENT REMOVAL WITH THE ENGINE INSTALLED ...................................................... 89 CLEANING ............................................................................................................ 89 RAVE VALVE BASIC OPERATION ................................................................................... 89 DISASSEMBLY ....................................................................................................... 90 INSPECTION.......................................................................................................... 94 ASSEMBLY ........................................................................................................... 95 BOTTOM END ............................................................................................... 100 CLEANING .......................................................................................................... 103 DISASSEMBLY ..................................................................................................... 103 INSPECTION........................................................................................................ 104 ASSEMBLY ......................................................................................................... 104 BREAK-IN ........................................................................................................... 109 02 – ENGINE LEAK TEST AND DIMENSION MEASUREMENT ............................................ 111 LEAK TEST .......................................................................................................... 111 PREPARATION ..................................................................................................... 111 PROCEDURE ....................................................................................................... 111 FINALIZING REASSEMBLY........................................................................................ 113 ENGINE LEAK VERIFICATION FLOW CHART ................................................................... 114 ENGINE DIMENSION MEASUREMENT.......................................................................... 115 CYLINDER HEAD WARPAGE ..................................................................................... 115 CYLINDER TAPER .................................................................................................. 115 CYLINDER OUT OF ROUND ...................................................................................... 115 COMBUSTION CHAMBER VOLUME MEASUREMENT ........................................................ 115 USED PISTON MEASUREMENT.................................................................................. 117 CYLINDER/PISTON CLEARANCE ................................................................................. 117 RING/PISTON GROOVE CLEARANCE............................................................................ 119 RING END GAP ..................................................................................................... 119 CRANKSHAFT DEFLECTION ...................................................................................... 119 CONNECTING ROD BIG END AXIAL PLAY ...................................................................... 120 II

TABLE OF CONTENTS CRANKSHAFT END-PLAY ......................................................................................... 120 CHECKING CRANKSHAFT ALIGNMENT ......................................................................... 120 03 – MAGNETO SYSTEM........................................................................................ 121 GENERAL ........................................................................................................... 123 CLEANING .......................................................................................................... 123 DISASSEMBLY ..................................................................................................... 123 ASSEMBLY ......................................................................................................... 124 04 – OIL INJECTION SYSTEM .................................................................................. 127 GENERAL ........................................................................................................... 128 OIL TYPE ............................................................................................................ 128 OIL SYSTEM LEAK TEST .......................................................................................... 128 OIL PUMP IDENTIFICATION ...................................................................................... 129 CLEANING .......................................................................................................... 129 DISASSEMBLY ..................................................................................................... 129 ASSEMBLY ......................................................................................................... 130 ADJUSTMENT ...................................................................................................... 131 CHECKING OPERATION ........................................................................................... 132 05 – LIQUID COOLING SYSTEM................................................................................ 133 COOLING SYSTEM LEAK TEST................................................................................... 135 INSPECTION........................................................................................................ 135 DRAINING THE SYSTEM .......................................................................................... 135 DISASSEMBLY AND ASSEMBLY ................................................................................. 135 COOLING SYSTEM REFILLING PROCEDURE................................................................... 137 06 – REWIND STARTER .......................................................................................... 139 INSPECTION........................................................................................................ 140 REMOVAL .......................................................................................................... 140 ROPE REPLACEMENT............................................................................................. 140 DISASSEMBLY ..................................................................................................... 140 ASSEMBLY ......................................................................................................... 141 INSTALLATION ..................................................................................................... 143 07 – CARBURETOR AND THROTTLE CABLE ................................................................. 145 CARBURETOR TM TYPE ................................................................................... 145 IDENTIFICATION ................................................................................................... 146 REMOVAL .......................................................................................................... 146 CLEANING AND INSPECTION .................................................................................... 147 DISASSEMBLY AND ASSEMBLY ................................................................................. 148 CARBURETOR ADJUSTMENTS .................................................................................. 149 INSTALLATION ..................................................................................................... 151 DPM ........................................................................................................... 152 TESTING ............................................................................................................ 152 PARTS REMOVAL AND INSTALLATION.......................................................................... 152 DPM MANIFOLD TESTING........................................................................................ 153 THROTTLE CABLE .......................................................................................... 155 THROTTLE/OIL PUMP CABLE REMOVAL ....................................................................... 155 THROTTLE/OIL PUMP CABLE INSTALLATION .................................................................. 155 THROTTLE CABLE ADJUSTMENT ............................................................................... 155 08 – FUEL TANK AND FUEL PUMP ............................................................................ 157 FUEL FILTER........................................................................................................ 159 FUEL TANK ......................................................................................................... 159 IMPULSE/FUEL LINES SPRING CLIPS (ALL MODELS) ......................................................... 160 FLOAT-TYPE FUEL LEVEL GAUGE ............................................................................... 161 ELECTRIC FUEL LEVEL SENSOR................................................................................. 161 III

TABLE OF CONTENTS FUEL LEVEL SENSOR SCREWS.................................................................................. 161 FUEL SYSTEM PRESSURIZATION................................................................................ 161 FUEL PUMP .................................................................................................. 162 REMOVAL .......................................................................................................... 163 PUMP VERIFICATION.............................................................................................. 163 CLEANING AND INSPECTION .................................................................................... 163 INSTALLATION ..................................................................................................... 163 05 2–TEC ENGINE MANAGEMENT 01 – OVERVIEW ................................................................................................... 165 OPERATING PRINCIPLE .................................................................................... 166 AIR INDUCTION .................................................................................................... 166 FUEL DELIVERY SYSTEM.................................................................................. 166 GENERAL ........................................................................................................... 166 COMPONENT DESCRIPTION ..................................................................................... 166 ENGINE MANAGEMENT SYSTEM (EMS) .............................................................. 167 EMS — GENERAL FUNCTIONS .................................................................................. 168 ECU — ENGINE MANAGEMENT FUNCTIONS .................................................................. 169 ELECTRONIC FUEL INJECTION .................................................................................. 170 IGNITION TIMING .................................................................................................. 170 ELECTRONICALLY CONTROLLED RAVE ........................................................................ 170 KNOCK SENSOR ................................................................................................... 170 ENGINE MODES OF OPERATION ................................................................................ 170 FLOODED ENGINE (DROWNED MODE) ........................................................................ 170 MONITORING SYSTEM ........................................................................................... 170 LIMP HOME MODES .............................................................................................. 171 DIAGNOSTIC MODE............................................................................................... 171 CHARGING SYSTEM ....................................................................................... 171 MAGNETO SYSTEM ............................................................................................... 171 DOUBLE IGNITION COIL .......................................................................................... 171 TRIGGER COIL ..................................................................................................... 172 02 – COMPONENT INSPECTION AND ADJUSTMENT ..................................................... 173 GENERAL ..................................................................................................... 173 FUEL SYSTEM ............................................................................................... 173 ELECTRICAL SYSTEM ...................................................................................... 174 RESISTANCE MEASUREMENT ................................................................................... 175 ENGINE CONNECTOR PIN-OUTS ................................................................................ 176 AIR INDUCTION SYSTEM ................................................................................. 177 THROTTLE BODY .................................................................................................. 177 FUEL DELIVERY ............................................................................................. 180 FUEL PUMP ........................................................................................................ 181 FUEL RAIL .......................................................................................................... 185 FUEL INJECTORS .................................................................................................. 186 ELECTRONIC MANAGEMENT ............................................................................ 188 ECM REPLACEMENT .............................................................................................. 188 ENGINE WIRING HARNESS....................................................................................... 189 THROTTLE POSITION SENSOR (TPS)............................................................................ 189 CRANKSHAFT POSITION SENSOR (CPS)........................................................................ 192 AIR TEMPERATURE SENSOR (ATS) .............................................................................. 193 COOLANT TEMPERATURE SENSOR (CTS) ...................................................................... 193 AIR PRESSURE SENSOR (APS) ................................................................................... 194 EXHAUST GAS TEMPERATURE SENSOR (EGTS) ............................................................... 195 IV

TABLE OF CONTENTS KNOCK SENSOR (KS) .............................................................................................. 196 E-RAVE SOLENOID ................................................................................................ 197 DOUBLE IGNITION COIL .......................................................................................... 197 TDC SETTING (TOP DEAD CENTER) ............................................................................. 199 CAPACITOR......................................................................................................... 199 ENGINE START/RER BUTTON VERIFICATION .................................................................. 200 DESS SWITCH VERIFICATION .................................................................................... 200 SPARK PLUGS ...................................................................................................... 200 CRANKING SYSTEM ............................................................................................... 201 03 – DIAGNOSTIC PROCEDURES .............................................................................. 203 GENERAL ........................................................................................................... 203 TROUBLESHOOTING ............................................................................................. 203 VCK(VEHICLE COMMUNICATION KIT) ........................................................................... 206 2-TEC SYSTEM FAULT CODES ................................................................................... 207 06 TRANSMISSION 01 – DRIVE BELT .................................................................................................. 209 APPLICATION CHART ............................................................................................. 209 INSPECTION........................................................................................................ 209 CHECKING NEUTRAL FUNCTION ................................................................................ 209 ROTATION DIRECTION ............................................................................................ 209 DRIVE BELT HEIGHT MEASUREMENT AND ADJUSTMENT .................................................. 210 DRIVE BELT DEFLECTION MEASUREMENT (REFERENCE ONLY) ............................................ 212 02 – DRIVE PULLEY............................................................................................... 215 TRA III ............................................................................................................... 215 GENERAL ........................................................................................................... 216 REMOVAL .......................................................................................................... 216 DISASSEMBLY ..................................................................................................... 216 CLEANING .......................................................................................................... 218 INSPECTION........................................................................................................ 218 ASSEMBLY ......................................................................................................... 220 INSTALLATION ..................................................................................................... 223 DRIVE PULLEY ADJUSTMENT ................................................................................... 224 03 – DRIVEN PULLEY ............................................................................................ 227 FORMULA RER .................................................................................................... 227 REMOVAL .......................................................................................................... 228 DISASSEMBLY ..................................................................................................... 228 CLEANING .......................................................................................................... 228 INSPECTION........................................................................................................ 228 BUSHING REPLACEMENT ........................................................................................ 229 ASSEMBLY ......................................................................................................... 229 INSTALLATION ..................................................................................................... 230 ADJUSTMENT ...................................................................................................... 231 HPV VSA ............................................................................................................ 232 REMOVAL .......................................................................................................... 233 DISASSEMBLY ..................................................................................................... 233 CLEANING .......................................................................................................... 233 INSPECTION........................................................................................................ 233 ASSEMBLY ......................................................................................................... 233 INSTALLATION ..................................................................................................... 234 ADJUSTMENT ...................................................................................................... 234 V

TABLE OF CONTENTS 04 – PULLEY DISTANCE AND ALIGNMENT .................................................................. 235 GENERAL ........................................................................................................... 235 GENERAL PROCEDURE ........................................................................................... 235 PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART ............................................. 236 05 – BRAKE ........................................................................................................ 239 HYDRAULIC BRAKE ........................................................................................ 239 BRAKE FLUID ...................................................................................................... 240 MASTER CYLINDER ............................................................................................... 240 CALIPER ............................................................................................................ 240 BRAKE PADS ....................................................................................................... 241 BRAKE DISC ........................................................................................................ 242 COUNTERSHAFT BEARING....................................................................................... 242 COUNTERSHAFT................................................................................................... 243 BRAKE LIGHT SWITCH ............................................................................................ 243 BLEEDING .......................................................................................................... 244 06 – CHAINCASE .................................................................................................. 245 REMOVAL AND DISASSEMBLY .................................................................................. 246 INSPECTION........................................................................................................ 246 GEAR RATIO MODIFICATION..................................................................................... 246 INSTALLATION AND ASSEMBLY ................................................................................. 247 DRIVE CHAIN ADJUSTMENT ..................................................................................... 247 ADJUSTMENT ...................................................................................................... 248 07 – DRIVE CHAIN ................................................................................................ 249 SILENT CHAIN...................................................................................................... 249 07 ELECTRICAL SYSTEM 01 – IGNITION TIMING ........................................................................................... 251 SCRIBING A TIMING MARK....................................................................................... 251 CHECKING IGNITION TIMING .................................................................................... 252 CHANGING TIMING................................................................................................ 253 02 – SPARK PLUGS ............................................................................................... 257 DISASSEMBLY ..................................................................................................... 257 SPARK PLUG INSTALLATION ..................................................................................... 257 SPARK PLUG TIGHTENING TORQUE ............................................................................ 257 03 – BATTERY ..................................................................................................... 259 GENERAL ........................................................................................................... 259 REMOVAL .......................................................................................................... 259 CLEANING .......................................................................................................... 259 INSPECTION........................................................................................................ 259 BATTERY CHARGE TESTING ..................................................................................... 260 BATTERY STORAGE ............................................................................................... 260 ACTIVATION OF NEW BATTERY .................................................................................. 260 BATTERY CHARGING .............................................................................................. 260 INSTALLATION OF BATTERY ..................................................................................... 260 CABLE TERMINAL INSTALLATION ............................................................................... 261 04 – ELECTRIC STARTER ........................................................................................ 263 REMOVAL .......................................................................................................... 264 DISASSEMBLY ..................................................................................................... 264 CLEANING .......................................................................................................... 265 INSPECTION........................................................................................................ 265 ASSEMBLY ......................................................................................................... 267 INSTALLATION ..................................................................................................... 268 VI

TABLE OF CONTENTS 05 – TESTING PROCEDURE ..................................................................................... 269 GENERAL ........................................................................................................... 269 CHECKING CALIBRATION PROGRAM ........................................................................... 272 CHANGING MPEM CALIBRATION PROGRAM.................................................................. 275 SYSTEM TESTING ................................................................................................. 276 INSPECTION OF HEATING ELEMENTS .......................................................................... 283 HEADLIGHT AND ACCESSORIES SYSTEM TESTING .......................................................... 284 08 REAR SUSPENSION 01 – SC-10 SUSPENSION........................................................................................ 285 COMPONENT REMOVAL AND INSTALLATION ................................................................. 288 SUSPENSION ASSEMBLY REMOVAL............................................................................ 289 DISASSEMBLY AND ASSEMBLY ................................................................................. 289 SHOCK ABSORBER INSPECTION ................................................................................ 291 INSTALLATION ..................................................................................................... 292 RIDE ADJUSTMENT ............................................................................................... 292 LUBRICATION ...................................................................................................... 292 02 – SC-10 III SUSPENSION..................................................................................... 293 COMPONENT REMOVAL AND INSTALLATION ................................................................. 296 SUSPENSION ASSEMBLY REMOVAL............................................................................ 297 DISASSEMBLY AND ASSEMBLY ................................................................................. 298 SHOCK ABSORBER INSPECTION ................................................................................ 300 HPG T/A SHOCK SERVICING ..................................................................................... 301 INSTALLATION ..................................................................................................... 309 RIDE ADJUSTMENT ............................................................................................... 309 LUBRICATION ...................................................................................................... 309 03 – DRIVE AXLE.................................................................................................. 311 REMOVAL .......................................................................................................... 312 ASSEMBLY ......................................................................................................... 313 LUBRICATION ...................................................................................................... 314 ADJUSTMENT ...................................................................................................... 315 04 – TRACK ........................................................................................................ 317 TRACK TYPE APPLICATION ....................................................................................... 317 GENERAL ........................................................................................................... 317 INSPECTION........................................................................................................ 317 REMOVAL .......................................................................................................... 317 INSTALLATION ..................................................................................................... 317 ADJUSTMENT ...................................................................................................... 317 09 STEERING/FRONT SUSPENSION 01 – STEERING SYSTEM ........................................................................................ 321 DISASSEMBLY AND ASSEMBLY ................................................................................. 323 INSPECTION........................................................................................................ 326 ADJUSTMENT ...................................................................................................... 326 STEERING ADJUSTMENT (SKIS) ................................................................................. 330 LUBRICATION ...................................................................................................... 332 02 – FRONT SUSPENSION ...................................................................................... 333 GENERAL INSPECTION ........................................................................................... 334 DISASSEMBLY ..................................................................................................... 334 INSPECTION........................................................................................................ 338 INSTALLATION ..................................................................................................... 338 VII

TABLE OF CONTENTS 10 BODY/FRAME 01 – BODY .......................................................................................................... 343 INSTALLATION AND ADJUSTMENT .................................................................... 343 HEADLAMP BEAM AIMING ...................................................................................... 343 BULB REPLACEMENT ............................................................................................. 343 DECAL .............................................................................................................. 344 WINDSHIELD ....................................................................................................... 344 GUARD.............................................................................................................. 345 WIRING HARNESS................................................................................................. 345 CABLES ............................................................................................................. 345 TUBING ............................................................................................................. 345 PLASTIC MAINTENANCE AND REPAIR ................................................................. 345 MAINTENANCE .................................................................................................... 345 REPAIR .............................................................................................................. 346 02 – FRAME ........................................................................................................ 347 FRAME CLEANING ................................................................................................ 347 FRAME WELDING ................................................................................................. 347 FRAME COMPONENT REPLACEMENT ......................................................................... 347 11 TECHNICAL DATA 01 – SI* METRIC INFORMATION GUIDE ...................................................................... 349 02 – ENGINES ..................................................................................................... 351 03 – VEHICLES .................................................................................................... 379 04 – TECHNICAL DATA LEGENDS ............................................................................. 407 ENGINE LEGEND .................................................................................................. 407 VEHICLE LEGEND ................................................................................................. 408 12 WIRING DIAGRAM 01 – WIRING DIAGRAMS ........................................................................................ 409 WIRING DIAGRAM LEGEND ...................................................................................... 409 WIRE COLORS ..................................................................................................... 409 CONNECTOR HOUSING AREA ................................................................................... 409 HOUSING REFERENCE PER AREA............................................................................... 409 WIRE LOCATION IN CONNECTOR HOUSING .................................................................. 410 SYMBOLS DESCRIPTION ......................................................................................... 412 UNPLUGING CONNECTORS ...................................................................................... 413 TAB AND RECEPTACLE CONNECTORS REMOVAL ............................................................ 413 TAB AND RECEPTACLE CONNECTORS INSTALLATION ....................................................... 419 VIII

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2003 Ski-Doo Legend Sport 500R Factory Service & Work Shop Manual

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