1985-1989 Ski-Doo Tundra Service & Repair Manual

General Information Troubleshooting lubrication, Maintenance and Tune-up High-Altitude and Rear Suspension Adjustment Engine Fuel and Exhaust Systems Electrical System Oil Injection System Liquid Cooling System Recoil Starter Drive System Brake, Chaincase, [ackshaft and Drive Axle Front Suspension and Steering Track and Rear Suspension Off-Season Storage Index Wiring Diagrams

Contents QUICK REFERENCE DATA IX CHAPTER ONE GENERAL INFORMATION 1 Manual organization 1 Gasket remover 13 Notes, cautions and warnings 2 Basic hand tools 14 Safety first 2 Precision measuring tools 18 Service hints 3 Special tools 23 Engine and chassis serial numbers 5 Mechanic's tips 24 Engine operation 6 Ball bearing replacement 26 Torque specifications 7 Oil seals 31 Fasteners 7 Snowmobile operation 32 Lubricants 12 Snowmobile safety 34 RTV gasket sealant 13 Snowmobile code of ethics 34 Threadlock 13 CHAPTER TWO TROUBLESHOOTING 39 Operating requirements 40 Engine 54 Troubleshooting instruments 40 Two-stroke pressure testing 58 Testing electrical components 40 Power train 59 Engine electrical system troubleshooting 41 Skis and steering 60 Voltage regulator 51 Track assembly 61 Fuel system 51 CHAPTER THREE WBRICATION, MAINTENANCE AND TUNE-UP 62 Pre-ride checks 62 Monthly or every 500 miles (800 km) 70 Fluid checks 62 Once a year or every 2,000 miles (3,200 km) 76 Break-in procedure 62 General inspection and maintenance 82 lO-hour inspection 63 Engine tune-up 84 Lubrication 63 Weekly or every 150 miles (240 km) maintenance 69 CHAPTER FOUR HIGH-ALTITUDE AND REAR SUSPENSION ADJUSTMENT 98 High-altitude carburetor tuning 98 Gearing 108 High-altitude clutch tuning 108 Suspension adjustment 108

CHAPTER FIVE ENGINE 117 Engine number identification 117 Engine top end 127 Engine lubrication 118 Cylinder 135 Service precautions 118 Rotax Automatic Variable Exhaust Servicing engine in frame 119 (RAVE) (583 engines) 143 Engine removal 119 Piston, wrist pin and piston rings 146 Engine mounts 124 Crankcase, crankshaft and rotary valve 156 Engine installation 126 Rotary valve and shaft 169 CHAPTER SIX FUEL AND EXHAUST SYSTEMS 188 Air silencer 188 Fuel valve (if so equipped) 208 Carburetor 188 Throttle cable replacement 211 Carburetor operation 189 Exhaust system 211 Fuel pump 206 Exhaust system repair 214 Fuel tank 208 CHAPTER SEVEN ELECTRICAL SYSTEM 218 Capacitor discharge ignition (CDI) 218 Pilot lamps 231 Ignition coil 224 Switches 232 CDI box 226 Fuel level sensor 234 Voltage regulator 226 Oil level gauge 235 Lighting system 227 Wiring diagrams 235 Meter assembly 231 CHAPTER EIGHT OIL INJECTION SYSTEM 237 System components 237 Component replacement 238 Oil pump service 238 Oil pump 240 CHAPTER NINE LIQUID COOLING SYSTEM 246 Thermostat 246 Heat exchanger 251 Water pump 251 Hoses 252 CHAPTER TEN RECOIL STARTER. ............................................... .. 254 CHAPTER ELEVEN DRIVE SYSTEM 264 Drive unit 264 Primary sheave service (1985 and 1986 MX) 274 Primary sheave assembly 265 Primary sheave service (1986 Plus and Secondary sheave 266 all 1987 and later models) 279 Drive belt 268 Secondary sheave service 295 CHAPTER TWELVE BRAKE, CHAINCASE, JACKSHAFT AND DRIVE AXLE 303 Drive chain and sprockets 303 Drive axle 319 Chaincase, brake caliper and jackshaft 307 Drive axle axial play 322

CHAPTER THIRTEEN FRONT SUSPENSION AND STEERING 329 Skis 329 Steering assembly 338 Front suspension 332 Steering adjustment 342 Shock absorber 337 CHAPTER FOURTEEN TRACK AND REAR SUSPENSION 347 Rear suspension 347 Rear shackle and rear arm 360 Slide shoes 350 Rear axle 362 Runner protector 356 Suspension and guide wheels 363 Rear shock absorbers 356 Track 365 Front shackle, front swing arm and front arm 359 CHAPTER FIFTEEN OFF-SEASON STORAGE 371 INDEX 375 WIRING DIAGRAMS end of book

Quick Reference Data GENERAL ENGINE SPECIFICATIONS Sore MX,. MX (H/A) and M~ LT Plo~and Plus LT Machi Stroke MX, MX (H/A) and MX LT Plus and Plus LT Mach I Displacement MX, MX (H/A) and MXLT Plus and Plus LT Mach I Compression ratio MX, MX (H/A) and MXLT Plus 1985·1988 Plus and Plus LT 1989 Mach I 69.5 mm (2.736 ln.) 72.0 mm (2.835 ln.) 76.0 mm (2.992 in.) 61.0 mm (2.402 ln.) 64.0 mm (2.520 in.) 64.0 mm (2.520 ln.) 462.8 cc (28.2 cu. in.) 521.2 cc (31.8 cu. ln.) 580.8 cc (35.4 cu. in.) 7.5:1 6.5:1 6.1:1 5.9:1 SPARK PLUGS Gap Model Plug type mm (In.) 1985 NGK SR9ES 0.40 (0.016) 1986 Formula MX NGK SR10ES 0.40 (0.016) Formula MX (H/A) NGK SR10ES 0.40 (0.016) Formula Plus NGK SR9ES 0.40 (0.016) 1987·1~88 All modele NGK SR9ES 0.40 (0.016) 1989 Formula Mach I NGK SR9ES 0.45 (0.018) All other models NGK SR9ES 0.40 (0.016) FUEL RECOMMENDATIONS 1985·1987 1988·. .. . M)('~nd MX LT Plus 1989 Regular-leaded or unleaded Regular:....!eaded or unleaded Super Regular unleaded IX

Rotary valve reservoir 1985·1988 1989 Chaincase 1985-1988 1989 Oil injection reservoir All models Cooling system All models Fuel tank All models APPROXIMATE REFILL CAPACITY 455 cc (16 oz.) N.A. 256 cc (9 oz.) 200 cc (7 oz.) 2.9 L (98 oz.) 4.2 L (142 oz.) 28.6 L(7.6gal.) RECOMMENDED LUBRICANTS Item Lubricant type Countershatt bearing, hub bearings, A bogie wheels, ski legs, idler bearings, leaf spring cushion pads, etc. Oil seal interior lips A Engine injection oil B Chaincase C Rotary valve lubricant (1985-1988) 0 Lubricant legend: A. Bombardier bearing grease or equivalent multi-purpose lithium base grease for use through a temperature range of -40 0 to 95 0 C("'40 0 to 200 0 F). This grease will be referred to asa 'low temperature grease' throughout this manual. B. Bombardier injection oil or equiValent. Injection oil must flow ·at...;40° C( _40 0 F). C. Bombardier chaincase oil or equivalent. Make sure equivalent oil ptovideslubricatlon at low temper- atures. D. Bombardier injection oil or equivalent. * WD-40 can be used as a general Iubrlcant. REPLACEMENT BULBS Watt Headlight MX, MX (H/A) and MX LT 60/60 Plus and Plus LT 60/55* Mach I 60/55* Taillight 5/21 Tachometer and speedometer 5 Fuel and temperature gauge 2 • Halogen bulb. x

ft ..lb. 74 77· 3,100-3,400 rpm 3,600-3,900 rpm 3,500-3,700 rpm 3,700-3,900 rpm 3,500-3,700 rpm 3,400-3,600 rpm 3,000-3,200 rpm 34.92 mm (1 3/8 ln.] 34.5 mm (1 23/64 In.) 30.2-38.1 mm (1 3/16-1 1/2 ln.) 25.4·32.0 mm (1-1 1/4 in.) 32.0 mm (1 1/4 in.) XII N'm 100 105 DRIVE SYSTEM SPECIFICATIONS FLYWHEEL NUT TIGHTENING TORQUE 1989 Engagement rpm 1985-1986 MX and MX (H/A) Plus 1987-1988 MX and MX LT Plus 1989 MX and MX LT Plus andd Plus LT Mach I Drive belt width 1985-1987 1988-on Drive belt deflection 1985 1986-1987 1988-on 1,985.,988

SKI-DOO SNOWMOBILE SHOP MANUAL 1985-1989

Chapter One General Information This shop manual covers the 1985-1989 Ski-Doo Formula MX, Formula MX (H/A), Formula MX LT, Formula Plus, Formula Plus LT and Formula Mach I models. Troubleshooting, tune-up, maintenance and repair are not difficult, if you know what tools and equipment to use and what to do. Step-by- step instructions guide you through jobs ranging from simple maintenance to complete engine and suspension overhaul. This manual can be used by anyone from a first time do-it-yourselfer to a professional mechanic. Detailed drawings and clear photographs give you all the information you need to do the work right. Some of the procedures in this manual require the use of special tools. The resourceful mechanic can, in many cases, think of acceptable substitutes for special tools. However, using a substitute for a special tool is not recommended as it may damage the part and can be dangerous. If you find that a tool can be designed and safely made, but will require some type of machine work, you may want to search out a local community college or high school that has a machine shop curriculum. Shop teachers sometimes welcome outside work that can be used as practical shop applications for advanced students. Table 1 lists model number coverage. General specifications are listed in Table 2. Table 3 lists vehicle weight. Metric and U.S. standards are used throughout this manual. U.S. to metric conversions are given in Table 4. Critical torque specifications are found in tables at the end of each chapter (as required). The general torque specifications listed in Table 5 can be used when a torque specification is not listed for a specific component or assembly. A list of general technical abbreviations are given in Table 6. Metric tap drill sizes can be found in Table 7. Table 8 lists wind chill factors. Tables 1-8 are found at the end of the chapter. MANUAL ORGANIZATION This chapter provides general information useful to snowmobile owners and mechanics. In addition, information in this chapter discusses the tools and techniques for preventive maintenance, troubleshooting and repair.

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1985-1989 Ski-Doo Tundra Service & Repair Manual

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