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TABLE OF CONTENTS
SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIV
INTRODUCTION ....................................................................................................... XV
VEHICLE INFORMATION ........................................................................................... XVI
MANUAL INFORMATION ........................................................................................ XVIII
FASTENER INFORMATION ....................................................................................... XXII
01 MAINTENANCE
01 - BREAK-IN INSPECTION......................................................................................... 9
02- PERIODIC MAINTENANCE SCHEDULE (600 HO E-TEC) . .. . ... . . . . . . .. .. .. . . . . . . .. . . .. . .. . . . .. . . .. . . . . .. 11
03- PERIODIC MAINTENANCE SCHEDULE (600 ACE AND 1200 4-TEC).. .. . . .. . . . . . . .. .. .. . . . . . . .. . ... . . 13
04- PERIODIC MAINTENANCE PROCEDURES ................................................................. 15
GENERAL .................................................................................................... 15
PROCEDURES ............................................................................................... 15
ENGINE................................................................................................... 15
FUEL SYSTEM............................................................................................ 26
ELECTRICAL SYSTEM.................................................................................... 28
DRIVE SYSTEM AND BRAKE............................................................................. 31
CHASSIS .................................................................................................. 36
05- STORAGE PROCEDURE....................................................................................... 39
06- PRESEASON PREPARATION ................................................................................. 41
02 ENGINE (600 HO E-TECI
01- ENGINE REMOVAL AND INSTALLATION .................................................................. 43
GENERAL .................................................................................................... 45
PROCEDURES ............................................................................................... 45
ENGINE ................................................................................................... 45
ENGINE STOPPER........................................................................................ 50
ENGINE SUPPORT ........................................................................................ 51
ENGINE RUBBER MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
02 - ENGINE LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
TROUBLESHOOTING...................................................................................... 56
PROCEDURES ............................................................................................... 57
ENGINE ................................................................................................... 57
PUMP SHAFT OIL GEAR RESERVOIR . .. .. . . .. . . .. . ... . . .. . . .. . ... . . ... . .. . . .. . .. . . . .. . . .. . . .. . . .. . . .. . . 58
03- ENGINE MEASUREMENT.................................................................................... 61
PROCEDURES ............................................................................................... 61
CYLINDER HEAD WARPAGE............................................................................. 61
CYLINDER TAPER .. . . .. . .. . . ... . . . . . . .. . . .. . . . . . . .. . . .. . . . .. . ... . .. . . .. . ... . . .. . . .. . .. . . . .. . . .. . . . . . . .. .. 61
CYLINDER OUT OF ROUND.............................................................................. 61
CYLINDER/PISTON CLEARANCE......................................................................... 62
RING/PISTON GROOVE CLEARANCE.................................................................... 63
RING END GAP ........................................................................................... 64
CRANKSHAFT DEFLECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
CONNECTING ROD BIG END AXIAL PLAY ............................................................... 65
CRANKSHAFT ALIGNMENT.............................................................................. 65
PISTON PROJECTION MEASUREMENT................................................................. 66
04- AIR INTAKE SYSTEM.......................................................................................... 69
GENERAL .................................................................................................... 70
PROCEDURES ............................................................................................... 70
AIR FILTER................................................................................................ 70
PRIMARY AIR INTAKE SILENCER........................................................................ 70
SECONDARY AIR INTAKE SILENCER.................................................................... 71
TABLE OF CONTENTS
02 ENGINE (600 HO E-TECI (cont'd)
II
05 - EXHAUST SYSTEM................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
GENERAL .................................................................................................... 76
PROCEDURES ............................................................................................... 76
MUFFLER ................................................................................................. 76
EGTS SENSOR............................................................................................ 76
TUNED PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
06- LUBRICATION SYSTEM....................................................................................... 79
GENERAL .................................................................................................... 81
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
RECOMMENDED INJECTION OIL ....................................................................... 82
INSPECTION ................................................................................................. 82
OIL SYSTEM LEAK TEST ................................................................................. 82
TROUBLESHOOTING...................................................................................... 83
PROCEDURES ............................................................................................... 83
OIL PUMP ................................................................................................ 83
OIL TANK ................................................................................................. 86
OIL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
INJECTION NOZZLE...................................................................................... 90
07 - COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
GENERAL .................................................................................................... 95
INSPECTION ................................................................................................. 95
COOLING SYSTEM LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
TROUBLESHOOTING...................................................................................... 95
PROCEDURES ......................................................................................... : ..... 96
WATER PUMP ............................................................................................ 96
THERMOSTAT............................................................................................ 96
COOLANT TANK CAP ..................................................................................... 97
HEAT EXCHANGER....................................................................................... 97
COOLANT TANK.......................................................................................... 97
COOLANT TEMPERATURE SENSOR ICTSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
FRONT RADIATOR........................................................................................ 97
COOLING FAN............................................................................................ 99
08- MAGNETO SYSTEM .......................................................................................... 101
GENERAL ................................................................................................... 103
PROCEDURES .............................................................................................. 103
MAGNETO FLYWHEEL.................................................................................. 103
STATOR ................................................................................................... 105
CRANKSHAFT POSITION SENSOR (CPS) ............................................................... 107
09- RAVE ............................................................................................................ 109
GENERAL ................................................................................................... 111
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
TROUBLESHOOTING..................................................................................... 112
DIAGNOSTIC TIPS ....................................................................................... 112
TROUBLESHOOTING GUIDELINES ..................................................................... 112
PROCEDURES .............................................................................................. 113
3D RAVE VALVES POSITION SENSOR . . . .. . . .. . . .. . ... . . . . . . .. . .. . . .. .. . ... . .. . . .. . . . . . . .. . . . . . . .. . . . .. 113
3D RAVE VALVES ........................................................................................ 114
CHECK VALVES (ACTUATOR CIRCUIT) .................................................................. 123
CHECK VALVES (LUBRICATION CIRCUIT) ............................................................... 123
SOLENOID............................................................................................... 124
10- TOP END ........................................................................................................ 127
GENERAL ................................................................................................... 129
ENGINE BREAK-IN....................................................................................... 129
02 ENGINE (600 HO E-TEC) (cont'd)
10 - TOP END (cont'd)
TABLE OF CONTENTS
INSPECTION ................................................................................................ 129
ENGINE COMPRESSION TEST.......................................................................... 129
PROCEDURES .............................................................................................. 130
REED VALVES ............................................................................................ 130
CYLINDER HEAD ........................................................................................ 130
CYLINDERS .............................................................................................. 131
CYLINDER BASE GASKET............................................................................... 131
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
11- BOTTOM END ................................................................................................. 135
GENERAL ................................................................................................... 137
ENGINE BREAK-IN ....................................................................................... 137
PROCEDURES .............................................................................................. 137
WATER PUMP ........................................................................................... 137
BEARING CARRIER AND PUMP SHAFT................................................................ 138
CRANKCASE ............................................................................................. 142
CRANKSHAFT ............................................................................................ 144
03 ENGINE (600 ACE)
01- ENGINE REMOVAL AND INSTALLATION ................................................................. 151
GENERAL ................................................................................................... 152
PROCEDURES .............................................................................................. 152
ENGINE .................................................................................................. 152
ENGINE SUPPORTS ..................................................................................... 157
ENGINE RUBBER MOUNTS ............................................................................. 159
02- AIR INTAKE SYSTEM......................................................................................... 161
GENERAL ................................................................................................... 163
PROCEDURES .............................................................................................. 163
AIR FILTER ............................................................................................... 163
AIR INTAKE SILENCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
INTAKE MANIFOLD ...................................................................................... 164
03 - EXHAUST SYSTEM........................................................................................... 167
GENERAL ................................................................................................... 168
PROCEDURES .............................................................................................. 168
EXHAUST PIPES ......................................................................................... 168
EXHAUST FLANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
MUFFLER................................................................................................ 169
04- LUBRICATION SYSTEM...................................................................................... 171
GENERAL ................................................................................................... 174
SYSTEM DESCRIPTION ................................................................................. 174
INSPECTION ................................................................................................ 174
ENGINE OIL PRESSURE ................................................................................. 174
TROUBLESHOOTING ..................................................................................... 175
PROCEDURES .............................................................................................. 176
OIL PRESSURE SWITCH (OPS) .......................................................................... 176
OIL FILLER TUBE ........................................................................................ 177
OIL TANK ................................................................................................ 178
OIL COOLER ............................................................................................. 179
ENGINE OIL PRESSURE REGULATOR .................................................................. 180
OIL PUMP DRIVE GEARS ............................................................................... 181
OIL PRESSURE PUMP ................................................................................... 182
OIL SUCTION PUMP MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
OIL SUMP COVER ....................................................................................... 187
Ill
TABLE OF CONTENTS
03 ENGINE {600 ACE) (cont'd)
IV
05- COOLING SYSTEM ........................................................................................... 191
GENERAL ................................................................................................... 194
INSPECTION ................................................................................................ 194
COOLING SYSTEM LEAK TEST ......................................................................... 194
TROUBLESHOOTING ..................................................................................... 195
PROCEDURES .............................................................................................. 195
COOLANT RESERVOIR CAP ............................................................................. 195
COOLANT RESERVOIR.................................................................................. 195
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
WATER PUMP ........................................................................................... 197
WATER PUMP DRIVE GEARS ........................................................................... 202
HEAT EXCHANGER...................................................................................... 202
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
COOLING FAN ........................................................................................... 203
06- MAGNETO AND STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
GENERAL ................................................................................................... 209
PROCEDURES .............................................................................................. 209
MAGNETO COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
STATOR .................................................................................................. 212
ROTOR ................................................................................................... 213
SPRAG CLUTCH ......................................................................................... 215
SPRAG CLUTCH GEAR .................................................................................. 216
STARTER DRIVE GEARS ................................................................................. 217
STARTER ................................................................................................. 217
07- TIMING CHAIN ................................................................................................ 221
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
TROUBLESHOOTING ..................................................................................... 223
PROCEDURES .............................................................................................. 223
TIMING CHAIN TENSIONER ............................................................................. 223
CAMSHAFT TIMING GEARS ............................................................................ 224
TIMING CHAIN ........................................................................................... 229
CHAIN GUIDE (TENSIONER SIDEI ...................................................................... 233
08 - CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
INSPECTION ................................................................................................ 239
CYLINDER LEAK TEST ................................................................................... 239
TROUBLESHOOTING ..................................................................................... 240
PROCEDURES .............................................................................................. 241
VALVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
CAMSHAFTS ............................................................................................. 244
CAMSHAFT HOLDER .................................................................................... 246
HYDRAULIC VALVE LIFTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
CYLINDER HEAD ........................................................................................ 247
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
VALVES ................................................................................................... 250
09 -CYLINDER BLOCK............................................................................................. 255
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
TROUBLESHOOTING ..................................................................................... 258
PROCEDURES .............................................................................................. 258
PTO OIL SEAL ........................................................................................... 258
CYLINDER BLOCK....................................................................................... 260
CRANKSHAFT ............................................................................................ 267
PISTONS AND CONNECTING RODS .................................................................... 270
PISTON RINGS ........................................................................................... 276
TABLE OF CONTENTS
04 ENGINE (1200 4-TECJ
01- ENGINE REMOVAL AND INSTALLATION ................................................................. 279
GENERAL ................................................................................................... 281
PROCEDURES .............................................................................................. 281
ENGINE .................................................................................................. 281
ENGINE SUPPORTS ..................................................................................... 285
ENGINE RUBBER MOUNTS ............................................................................. 289
02- AIR INTAKE SYSTEM ......................................................................................... 291
GENERAL ................................................................................................... 292
PROCEDURES .............................................................................................. 292
AIR FILTER ............................................................................................... 292
INTAKE MANIFOLD ...................................................................................... 292
AIR INTAKE SILENCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
03 - EXHAUST SYSTEM........................................................................................... 299
GENERAL ................................................................................................... 301
PROCEDURES .............................................................................................. 301
EXHAUST PIPE .......................................................................................... 301
EXHAUST MANIFOLD ................................................................................... 302
MUFFLER................................................................................................ 303
04- LUBRICATION SYSTEM ...................................................................................... 305
GENERAL ................................................................................................... 309
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
INSPECTION ................................................................................................ 309
ENGINE OIL PRESSURE ................................................................................. 309
TROUBLESHOOTING ..................................................................................... 310
PROCEDURES .............................................................................................. 311
OIL PRESSURE SWITCH lOPS) .......................................................................... 311
OIL TANK ................................................................................................ 313
OIL COOLER ............................................................................................. 314
ENGINE OIL PRESSURE REGULATOR .................................................................. 316
OIL PUMP DRIVE GEARS ............................................................................... 317
OIL PRESSURE PUMP ................................................................................... 318
OIL SUCTION PUMP MODULE ......................................................................... 320
OIL SUMP COVER....................................................................................... 323
OIL SPRAY NOZZLES .................................................................................... 324
BREATHER ............................................................................................... 325
05- COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
GENERAL ................................................................................................... 330
INSPECTION ................................................................................................ 330
COOLING SYSTEM LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
TROUBLESHOOTING ..................................................................................... 331
PROCEDURES .............................................................................................. 331
COOLANT RESERVOIR CAP ............................................................................. 331
THERMOSTAT ........................................................................................... 331
WATER PUMP ........................................................................................... 333
WATER PUMP DRIVE GEARS ........................................................................... 338
HEAT EXCHANGER ........................................................... • .......................... 338
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
COOLING FAN........................................................................................... 340
06- MAGNETO AND STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
GENERAL ................................................................................................... 345
PROCEDURES .............................................................................................. 345
MAGNETO COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
STATOR .................................................................................................. 347
ROTOR ............................................................................................ • ...... 349
v
TABLE OF CONTENTS
04 ENGINE (1200 4-TECI (cont'd)
06- MAGNETO AND STARTER (cont'd)
PROCEDURES (cont'd)
SPRAG CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
SPRAG CLUTCH GEAR .................................................................................. 351
STARTER DRIVE GEARS ................................................................................. 352
STARTER................................................................................................. 353
07 -TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
GENERAL ................................................................................................... 357
TROUBLESHOOTING ..................................................................................... 357
PROCEDURES .............................................................................................. 357
TIMING CHAIN TENSIONER ............................................................................. 357
TIMING CHAIN GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
TIMING CHAIN ........................................................................................... 360
CHAIN GUIDE ITENSIONER SIDE! ...................................................................... 361
08 - CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
GENERAL ................................................................................................... 367
INSPECTION ................................................................................................ 367
CYLINDER LEAK TEST ................................................................................... 367
TROUBLESHOOTING ..................................................................................... 368
PROCEDURES .............................................................................................. 369
VALVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
CAMSHAFT TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
CAMSHAFTS ............................................................................................. 376
CAM FOLLOWERS ...................................................................................... 381
CYLINDER HEAD ........................................................................................ 381
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
VALVES ................................................................................................... 385
09- CYLINDER BLOCK............................................................................................. 389
GENERAL ................................................................................................... 392
TROUBLESHOOTING ..................................................................................... 392
PROCEDURES .............................................................................................. 392
PTO COVER.............................................................................................. 392
CYLINDER BLOCK....................................................................................... 395
CRANKSHAFT ............................................................................................ 401
BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
PISTONS AND CONNECTING RODS .................................................................... 405
PISTON RINGS ........................................................................................... 411
05 ENGINE MANAGEMENT SYSTEM
01- OVERVIEW (600 HO E-TEC) ................................................................................. 413
GENERAL ................................................................................................... 414
SYSTEM DESCRIPTION ................................................................................. 414
02- OVERVIEW (600 ACE AND 1200 4-TEC) .................... ............................................... 417
GENERAL ................................................................................................... 419
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
03- COMMUNICATION TOOLS AND B.U.D.S .. ............................................................... 421
GENERAL ................................................................................................... 421
REQUIRED TOOLS ...................................................................................... 421
TROUBLESHOOTING ..................................................................................... 421
DIAGNOSTIC TIPS ....................................................................................... 421
PROCEDURES .............................................................................................. 425
MULTI-PURPOSE INTERFACE-2 IMPI-2) ................................................................. 425
B.U.D.S. SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
VI
TABLE OF CONTENTS
05 ENGINE MANAGEMENT SYSTEM (cont'd)
04- DIAGNOSTIC AND FAULT CODES ......................................................................... 431
GENERAL ................................................................................................... 431
MONITORING SYSTEM ................................................................................. 431
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
SPECIFIC FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
06 FUEL SYSTEM
01 -FUEL TANK AND FUEL PUMP .............................................................................. 437
GENERAL ................................................................................................... 440
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
INSPECTION ................................................................................................ 443
FUEL SYSTEM PRESSURIZATION AND LEAK TEST .................................................... 443
FUEL TANK LEAK TEST .................................................................................. 444
FUEL PUMP PRESSURE TEST (600 HO E-TEC) ......................................................... 446
FUEL PUMP PRESSURE TEST 1600 ACE AND 1200 4-TECI ............................................ 447
PROCEDURES .............................................................................................. 449
FUEL TANK .............................................................................................. 449
FUEL PUMP ............................................................................................. 451
FUEL PRESSURE REGULATOR (600 ACE AND 1200 4-TEC) ........................................... 454
FUEL PRESSURE REGULATOR (600 HO E-TECI ........................................................ 454
FUEL PUMP INLET FILTER .............................................................................. 455
STEEL MESH FILTER .................................................................................... 457
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
02- E-TEC DIRECT FUEL INJECTION ........................................................................... 461
GENERAL ................................................................................................... 461
SYSTEM DESCRIPTION ................................................................................. 461
ADJUSTMENT ............................................................................................. 464
IDLE SPEED . . .. .. . . . . . . . . . . . . . .. . . .. . .. . . .. . . .. . . .. . . . . . . .. . . .. . . .. . . .. .. . . . . .. . .. . . . .. . . .. . . . . .. .. . . .. . 464
CLOSED THROTILE RESET (TPS) ....................................................................... 464
TROUBLESHOOTING ..................................................................................... 465
DIAGNOSTIC TIPS ....................................................................................... 465
PROCEDURES .............................................................................................. 466
THROTILE CABLE ....................................................................................... 466
FUEL INJECTOR......................................................................................... 468
ECM (ENGINE CONTROL MODULE) .................................................................... 481
THROTILE BODY ........................................................................................ 490
THROTILE POSITION SENSOR ITPSI ................................................................... 492
CPS (CRANKSHAFT POSITION SENSOR) ............................................................... 495
AIR TEMPERATURE SENSOR (ATS) ..................................................................... 497
COOLANT TEMPERATURE SENSOR ICTS) ............................................................. 499
AIR PRESSURE SENSOR lAPS) ......................................................................... 501
EXHAUST GAS TEMPERATURE SENSOR IEGTS) ....................................................... 502
KNOCK SENSOR IKSI .................................................................................... 503
03 - ELECTRONIC FUEL INJECTION (600 ACE) .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 505
GENERAL ................................................................................................... 505
SYSTEM DESCRIPTION . .. .. . . . . . . .. . .. . . .. .. . . . . .. .. .. . . . . . . .. . . .. . . . . . . .. . .. . . . .. . . . . . . .. . . .. . . .. . . . . . 505
ADJUSTMENT ............................................................................................. 507
IDLE SPEED .. .. . . .. . . .. . . .. . . .. . . .. . . .. .. .. . . . . . . .. . . . . . . .. . . .. . . .. . . .. . . .. . . .. .. .. . . .. . . .. . . . . . . .. . . .. . 507
TROUBLESHOOTING ..................................................................................... 508
DIAGNOSTIC TIPS....................................................................................... 508
PROCEDURES .............................................................................................. 508
ENGINE CONTROL MODULE IECMI .................................................................... 508
FUEL INJECTOR ......................................................................................... 515
THROTILE CABLE ....................................................................................... 523
VII
TABLE OF CONTENTS
06 FUEL SYSTEM (cont'd)
03 -ELECTRONIC FUEL INJECTION (600 ACE) (cent' d)
PROCEDURES (cont'd)
THROTTLE BODY ........................................................................................ 526
THROTTLE POSITION SENSOR ITPS) ................................................................... 528
IDLE AIR CONTROL VALVE IIACV) ...................................................................... 531
CRANKSHAFT POSITION SENSOR (CPS) ............................................................... 534
MANIFOLD ABSOLUTE PRESSURE AND TEMPERATURE SENSOR IMAPTS) ......................... 536
COOLANT TEMPERATURE SENSOR (CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
04- ELECTRONIC FUEL INJECTION (1200 4-TEC) ............................................................ 541
GENERAL ................................................................................................... 541
SYSTEM DESCRIPTION . . .. . . .. . . .. . . . .. . .. . .. . . . .. . . .. . . .. . . . . . . . . . . .. . . .. . . .. . . .. . . . . . . .. . . .. . . . . . . .. . 541
ADJUSTMENT ............................................................................................. 543
IDLE SPEED . . .. . . .. . . .. . . .. . . . . . . .. . . .. . . .. . . .. . .. . . . .. . . .. . . .. . . . . . . .. . . .. . . .. . . . . . . . . . . .. . . .. . . .. . . . . . 543
TROUBLESHOOTING ..................................................................................... 544
DIAGNOSTIC TIPS....................................................................................... 544
PROCEDURES .............................................................................................. 544
ENGINE CONTROL MODULE IECM) .................................................................... 544
FUEL RAIL .............................................................................................. 551
FUEL INJECTOR......................................................................................... 554
THROTTLE CABLE ....................................................................................... 560
THROTTLE BODY ........................................................................................ 563
THROTTLE POSITION SENSOR ITPS) ................................................................... 565
IDLE AIR CONTROL VALVE IIACV) .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 568
CRANKSHAFT POSITION SENSOR (CPS) ............................................................... 571
CAMSHAFT POSITION SENSOR (CAPS) ................................................................ 573
MANIFOLD ABSOLUTE PRESSURE AND TEMPERATURE SENSOR IMAPTS) ......................... 575
COOLANT TEMPERATURE SENSOR ICTS) .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 578
07 ELECTRICAL SYSTEM
01 -POWER DISTRIBUTION (600 HO E-TEC) .................................................................. 581
GENERAL ................................................................................................... 581
OVERVIEW ............................................................................................... 581
SYSTEM VOLTAGE 155 VDC) ............................................................................ 581
SYSTEM VOLTAGE 112 VDC) .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. . 582
POWER DISTRIBUTION SUMMARY .................................................................... 582
02- POWER DISTRIBUTION (600 ACE) ......................................................................... 583
GENERAL ................................................................................................... 583
OVERVIEW ............................................................................................... 583
FUSES ................................................................................................... 583
RELAYS .................................................................................................. 584
GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585
PROCEDURES .............................................................................................. 585
RELAYS .................................................................................................. 585
03- POWER DISTRIBUTION (1200 4-TEC) ..................................................................... 589
GENERAL ................................................................................................... 589
OVERVIEW ............................................................................................... 589
FUSES ................................................................................................... 589
RELAYS .................................................................................................. 590
GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590
PROCEDURES .............................................................................................. 591
RELAYS .................................................................................................. 591
04- COMMUNICATION PROTOCOLS........................................................................... 593
GENERAL ................................................................................................... 593
CONTROLLER AREA NETWORK (CAN) ................................................................. 593
VIII
07 ELECTRICAL SYSTEM (cont'd)
04- COMMUNICATION PROTOCOLS (cont'd)
GENERAL (cont'd)
TABLE OF CONTENTS
LOCAL INTERCONNECT NETWORK (LIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594
PROCEDURES .............................................................................................. 594
CAN Ll NE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594
LIN LINE TEST........................................................................................... 596
05- IGNITION SYSTEM (600 HO E-TEC) ....................................................................... 597
GENERAL ................................................................................................... 597
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597
ADJUSTMENT ............................................................................................. 599
IGNITION TIMING ....................................................................................... 599
TROUBLESHOOTING ..................................................................................... 603
IGNITION SYSTEM TESTING SEQUENCE ............................................................... 603
PROCEDURES .............................................................................................. 603
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
SPARK PLUG CABLES................................................................................... 604
EMERGENCY ENGINE STOP SWITCH .................................................................. 604
ENGINE CUT-OFF SWITCH .............................................................................. 605
IGNITION COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
06 -IGNITION SYSTEM (600 ACE AND 1200 4-TEC) .. ....................................................... 611
GENERAL ................................................................................................... 611
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
TROUBLESHOOTING ..................................................................................... 611
DIAGNOSTIC TIPS....................................................................................... 611
IGNITION SYSTEM TESTING ............................................................................ 611
PROCEDURES .............................................................................................. 612
IGNITION COILS......................................................................................... 612
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
EMERGENCY ENGINE STOP SWITCH .................................................................. 615
ENGINE CUT-OFF SWITCH.............................................................................. 615
07- CHARGING SYSTEM (600 HO E-TEC) ..................................................................... 619
GENERAL ................................................................................................... 619
SYSTEM DESCRIPTION ................................................................................. 619
TROUBLESHOOTING ..................................................................................... 619
TROUBLESHOOTING GUIDELINES .................................................................... 619
PROCEDURES .............................................................................................. 620
BATIERY CHARGING FUSE ............................................................................. 620
BATIERY CHARGING RELAY (Rl) ....................................................................... 620
VOLTAGE REGULATOR/RECTIFIER ..................................................................... 620
DC-DC CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622
CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
BATIERY ................................................................................................ 628
08- CHARGING SYSTEM (600 ACE AND 1200 4-TEC) ....................................................... 633
GENERAL ................................................................................................... 633
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633
INSPECTION ................................................................................................ 634
CHARGING SYSTEM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634
TROUBLESHOOTING ..................................................................................... 635
DIAGNOSTIC TIPS....................................................................................... 635
PROCEDURES .............................................................................................. 635
VOLTAGE REGULATOR .................................................................................. 635
BATIERY ................................................................................................. 638
IX
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The Ski-Doo REV-XU Snowmobile All Models 2010-2012 Full Service & Repair Manual is a comprehensive factory service repair workshop manual. It is instantly accessible on your computer, tablet, or smartphone without any extra fees or expiry dates.
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