2007 Ski-Doo Tundra 300F Factory Service & Work Shop Manual
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Shop Manual
SKANDIC LT/SUV/WT/SWT
EXPEDITION TUV
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Legal deposit
National Library of Quebec
National Library of Canada 2006
All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission
of Bombardier Recreational Products Inc. (BRP)
© Bombardier Recreational Products Inc. (BRP) 2006
Printed in Canada
Technical Publications
Bombardier Recreational Products Inc. (B~P)
Valcourt (Quebec) Canada
®TM Trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates.
• Trademarks of Bombardier Inc., used under license.
DESS™ Rotax®
Expedition™ Ski-Doo®
HPG™ XP-S™
This document contains the trademarks of the following companies:
AMP® is a trademark of Tyco Electronics Corporation
Comet® is a trademark of Hoffco/Comet Industries Inc.
Crest® is a trademark of Crest Industries Inc.
Kimtowels® is a trademark of Kimberly-Clark
Loctite® is a trademark of Loctite Corporation
Molykote®. is a trademark of Dow Corning Corporation
Snap-on® is a trademark of Snap-on Tools Corporation
Supertanium® is a trademark of Premier Industrial Corporation
TABLE OF CONTENTS
SAFETY NOTICE . . . . . . . . • . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . • . . . . . . . . . • . • • . . . . • . . . . • . . . . . . . . . . . • . . . . . . . XV
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . XVI
GENERAL INFORMATIONS................. . ................................................................ ... . XVI
VEHICLE IDENTIFICATION NUMBER .......................................................................... XVII
ENGINE SERIAL NUMBER .................................................................................... .. XVII
ARRANGEMENT OF THIS MANUAL, ILLUSTRATIONS AND PROCEDURES .......................... XVII
ENGINE EMISSIONS INFORMATION ....... . ..................... . ......... .. ................................. XXI
SELF-LOCKING FASTENERS PROCEDURE ............... . ................................................... XXI
LOCTITE APPLICATION PROCEDURE.... .. .................................................................... XXI
TIGHTENING TORQUE .......................................................................................... XXV
01 MAINTENANCE
01- MAINTENANCE CHART (440F/550F/600) .................................................................. 1
02 - MAINTENANCE CHART (VSOOI .. .. . . . . .. . . .. .. .. . . .. . . .. .. .. . . .. . . .. . . .. . . .. . .. . . .. .. .. .. .. . .. .. . . . .. . .. . .. . 3
03- STORAGE PROCEDURE (440F/550F/600) ................................................................. 5
GENERAL .... ... . .... .... ... .... . ... .. ... .... ... .. ... ................... .. . ....... . ............. ... ...... . ........... .. 5
ENGINE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
LUBRICATION SYSTEM . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . .. .. . .. . . . . . . . . . . . 6
FUEL SYSTEM.. .... ... ............... .. ...... .............................. .. ... ..... ...... ..... ........ .......... ..... 6
DRIVE SYSTEM . . . . . . . . . . .. . . . . . . . . . .. . .. .. . . . . . . . . . . . . . . . . . . .. .. . . . .. . . . .. . . . . . .. . . . .. . .. .. .. . . . . . . .. .. . . . .. . .. .. . . . . 6
STEERING SYSTEM..................... ......... .. . .. . ...... . ........ . ....... .. ..... . ................ .. ... ..... ... ... 6
SUSPENSION.................. .... ... . ............. .......... ..... ....... ... .... .. ............................. .. ..... 7
ELECTRICAL SYSTEM...... ... ... .. .. .. . ... ........................ .. .......... ............ ............... .. ...... ... 7
VEHICLE .. ... ..................... .. .. . .. . . ....... .......................... ..... ............... ... ............ ...... .. 7
04- STORAGE PROCEDURE (VSOO) .............................................................................. 9
GENERAL ........................................................................................................ 9
PROCEDURES .. . . .. . . .. . . .. . . .. . . . . . . .. . . .. . . .. . . .. . . .. . . . . . . . . . . .. . . . . . . .. . . .. . . .. . . .. . . .. . . .. .. .. . . .. .. . . . . .. 9
ENGINE ............... .. . . .............................. .. .. . .................................. .... .................... 9
FUEL SYSTEM ... .. .. .... . ....... . .... . ...... . ...... . ....... .. ............. .. .. . .... ... .... ... .... ... ............. .... 10
ELECTRICAL SYSTEM..... .... ...... ...... ... ..... ... ... .. ............. . .. . . . .. .. . .. .. .. . .. .. . . . . . . .. . . . .. .. . .. . . . . . 10
DRIVE SYSTEM . . . . . . . . . . . . . . .. .. . .. . . . . . .. . .. . . . . . . . . . . . . . . . . ... . . . .. .. . . . . . . . .. .. . .. .. . .. .. .. . . .. . . . .. •. .. .. . .. . . . . . 10
SUSPENSION .. ............. .. ........ .. .... ..... ............ : .. .. .. . ... ........... ....................... ....... ..... 10
STEERING .... .... . ........ .. ... ........... .. .. .......................... .... .... . ............................ ........ 10
VEHICLE ...... ....................... . ... ............ .............. ...... ... ........... .................. .. .. ......... 11
05 - PRESEASON PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ENGINE ... .. .......... ....... .. ... ......... ...... ................. .................... ............................. .. . 13
LUBRICATION SYSTEM ... ....... .. . .. ............ . .............. . .... .... ....... .. . ......................... ..... .. 13
FUEL SYSTEM ......... .. ............. . ........ .. ............................ ...... ... ..... . ... .. . .. .. .. . . ............ 13
DRIVE SYSTEM .... . ...................... ... ....... ....... ... .......................... . ....... .... ..... . .. . ...... .. 14
ELECTRICAL SYSTEM........... ... . ............... ............................................................. .. .. 14
02 TROUBLESHOOTING
01 - ENGINE (443/552/5931................................................ . ..................................... 15
ENGINE GENERAL ................. .......... .......................... ......... ......................... ............ 15
REWIND STARTER ...................... . ............................. .. ..... .. . .............................. .... ... 21
02- ENGINE (8101 ................................................................................................. 23
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
LUBRICATION SYSTEM ...... ....... . .... ........... ....... . .... ... ................... ... .. .. .. . .. ....... ... ... ..... 23
CYLINDER AND HEAD . . . .. . . . .. . .. . . . .. .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . .. .. .. . .. .. . .. .. .. . .. . . . .. . .. 25
CRANKSHAFT ... .. ... .... ....... . ..................... .... ..... .. ................ .... .......... .. .. . ....... ....... . .. 25
ENGINE GENERAL ..................... .. .. .. . ....... ....... . .... ..... .. ...... ................... , . .';· .............. ... 26
03 - FUEL AND OIL SYSTEMS (440F/550F/6001 .. . .. .. .. .. .. . .. .. . .. .. . .. . .. .. .. ... .. .. . .. .. .. .. .. .. .. .. .. .. 29
FUEL SYSTEM...................... ... .. .... .. ........ . ............... .. . ....... .. ........................... .. ...... 29
OIL INJECTION SYSTEM............. .. ............................. ..... ................................. ....... . .. 30
·-------·-··- .. ···· ·-· ---·----·
TABLE OF CONTENTS
04- DRIVE SYSTEM AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DRIVE AND DRIVEN PULLEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DRIVE BELT... .. ... . .............. .... ............. .. . .. ........... ... .... ........... ..... .. .............. ... . ........ 33
MECHANICAL BRAKE....... ....... .. ......... .. .... .. . ........... ... ... ........... .. . .... ...... ... .......... ....... 35
HYDRAULIC BRAKE ........ .... ....... ... ............. .... ............ .... ........... ... . .. .. ... .. . . ..... . .. . ... . .. . 35
TRACK ................. . ................. .. ..... ....... ..... . ... ... .... . .. .......... ..... .... .. ........ ... ... ... .. .... . 36
GEARBOX ... ........ ....... ... ...... ............ ....... .. .. ....... ..... ... .. .......... ........ ......... ..... ... .. ..... 36
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
05 - ELECTRICAL SYSTEM....................................................................................... 39
IGNITION SYSTEM ..... ..... ... .. ... ... .. ..... .. .. . ..... .. ..... .. . ........... ... ... .. .......... .... ........... .. ... .. 39
CHARGING SYSTEM ....... · . .......... ........ ......... .... .... ....... .. ... .. . .. .. . ... .. .. . . . ...... . .......... .. . .. .. 40
STARTING SYSTEM......... .. .... .. ............... .. .... . ....... .. . .... .......... . ............ .... .... .. .... ........ 40
ROT AX ELECTRONIC REVERSE (RER)....... ......... ....... ......... ........... ......... ............ ... ... .. ..... 42
LIGHTS, INSTRUMENTS AND ACCESSORIES ..... ............ .... ............... .. . .. .............. . .. .. ........ 43
06- STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SKI .. .. .. . .. .. . ...... .......... .......... ... .. ... .. .. . .. .. ... ..... .. .... ......... .. .. .. . ... .. ..... .......... ... .. ....... 47
07 - SUSPENSION................................................................................................. 49
03 ENGINE (443 AND 552)
II
01 - ENGINE REMOVAL AND INSTALLATION............... . ..... . .......................................... 51
GENERAL ... ..... . .... ....... ..... . ..... .... ... .. ........ .. . . . .. .. . ...... . .... . .. . ........... .. ...... ....... ... ... .... 54
PROCEDURES ...... ............ .. . .. ............... .... ........... .. .. ... ......... . .. ..... ............ ..... .. . ....... 54
· 02- ENGINE LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55
PROCEDURES .. ... ... ...... .. ..... . ... .... ....... . .......... ..... .......... ........... ....... ... ...... .......... ..... 55
ENGINE LEAK VERIFICATION FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
03 - AIR INTAKE SYSTEM............................................................ . ........................... 59
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
AIR FILTER.. .......... ........ ............ ... .. . .... .. ... ....... ......... . .. ......... ...... .. ........ .. . . . ..... ....... 61
AIR INTAKE SILENCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
04- EXHAUST SYSTEM........................... . .............................................................. 63
GENERAL ......................................................................... . ............................ 66
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
TUNED PIPE. .. .. ..... ........ .. ... .... .................... ..... ......... ........... ........ ............ ...... ........ 66
MANIFOLD .... ......... ...... .. .. . : .. ................................ .... .. .. ... ...... .... ..... .... ......... .... .. . .. . 66
05 - OIL INJECTION SYSTEM ..... . ·: .. .' "}~ .. ..................................... :!·. ...................... .. ...... 67
. . .
GENERAL ........................ : ....... :
1
•••••••• • ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 72
RECOMMENDED OIL TYPE .. ..... ...... : . .. .. ... ... ............ ...... ............... . ............... .... .......... 72
INSPECTION ............................ ;!.................................................................... 72
OIL SYSTEM LEAK TEST ... ... ... .. ... ..· .... ... .. . .. . . . .. . ...... ........ ........... .......... ...... ...... ... ... .... . 72
PROCEDURES ............. . .............................................. :. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
OIL RESERVOIR ...... ....... . .. .. . .... ........ .. .......... .. . ..... ...... ........... ....... .. ..... .. ... ..... .. . ....... 73
OIL LEVEL SENSOR . .. . .. .. . .. .. . .. .. . .. .. . .. . . .. . .. .. . .. .. . .. .. . .. . . .. . . . .. . .. .. . .. . . . .. .. . .. .. .. . .. . . . .. .. . .. .. . .. 73
OIL FILTER... .... .................. .. .. . ......... .. ... .. ........... ....... ............ ..... .............. .. . .. ........ 74
OIL PUMP .. ... . ........ ... .. ... .. ... .. ... ... ......... ... .. ...... ........... ....... . .. ..... ....... .... .... ..... ..... .. 74
CHECK VALVE . . . . . . .. .. . .. . . . . . .. . .. . . . .. . . . . . .. . . . .. . . . .. . . . . . . . . .. . . .. . . . . . . .. . . . .. . . .. . . . . .. . . .. . .. . . . . . . . .. . .. . .. 79
INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
06- REWIND STARTER........................................................................................... 81
. GENERAL.......................................................... . ........................................... 83
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
STARTER HANDLE. .... ... ... ....... . .. .. .. . . . ..... ..... ......................... . ........... ...... ... .. ... .. . .. ..... 83
REWIND STARTER.......... . .......... . .... .. ................. .... ..... . .... . .. .. .. . .. .. . .. ....... . .. ... ...... ... ... 83
ROPE .......... ........ ....... .................... ........ ............ .. ................. . .. .. .......... .. . .... ........ 86
07 - AXIAL FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
GENERAL ...................................................................................................... 90
------·-- - -·-- - -- . ----
TABLE OF CONTENTS
PROCEDURES .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . 90
CYLINDER COWL.................... .............. ...................... ..... .................................. .. . .. 90
AXIAL FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
FAN BELT ...... .................... ..... ... ......... .................. ... . .......... .......... .. ............... ...... . 91
AXIAL FAN BEARING .. . .. .. . .. . . . .. .. . .. .. . . . . . . . . . . . . . .. .. . . . .. . .. . . . . . . . . . . .. .. . .. .. . . . .. .. . .. .. . .. .. . .. .. . . . .. . . . 93
08 - MAGNETO SYSTEM......................................................................................... 95
GENERAL . ..................................................................................................... 97
PROCEDURES ................................................................................................ 97
MAGNETO FLYWHEEL ............... ....... .............................. .. ................................. ... .... 97
STATOR .. ........... ................... ... . .... .... ... ................. ... .... . ......... ..... ... ......... ... .. ... . .... 99
TRIGGER COIL . . . .. . . .. . .. .. . . . . . . . . .. . .. . . . .. . . . . . .. .. . . . .. . .. .. . .. .. .. . . . .. . .. . . . . . .. . .. . . . .. . . .. . .. .. . .. . .. .. .. . .. 99
09- TOP END...................................................................................................... 101
GENERAL ..................................................................................................... 105
PROCEDURES ............................................................................................... 105
CYLINDER COWL ................................................................................................. . 105
CYLINDER HEAD .. ............... .......... ......................... .. ........ .. ............... . ................ .. . 105
CYLINDER .... . ........ ...... ....... ..... ....... .. ............................. . ............................. ...... . 106
PISTON .... ... ..... .. ........................................ ... ..... ... .. . ...... ............ ... ...... .. ... . ..... . .. . 107
REEDVALVE ........................... .... . .... ... ......... .. ... . ...... . ...... .... ..... .. ..... . ..... ...... ........ . 111
10 - BOTTOM END ............................................................ . ................................. . 113
GENERAL .................................................................................................... . 116
PROCEDURES .............................................................................................. . 116
CRANKCASE ............................... .. .. . ........................... .. . ..... ........................... ..... . 116
CRANKSHAFT ............................ ... ...................................................................... . 117
CRANKSHAFT BEARINGS ............ .... ........ ....................... ............ ...................... ....... . 118
11 - ENGINE MEASUREMENT ................................................................................ . 123
CYLINDER HEAD WARPAGE .............. ....... .. ..... ........ ..... .... ....... ... ... .. ..... .... ...... . .. .. ..... . 123
COMBUSTION CHAMBER VOLUME MEASUREMENT .. ......... .... ... . .................. .... .... .. ... ..... . 123
CYLINDER TAPER ...... ........... ............ .... .. .. .. .. .. .... ........ .. ..... . ..... .... ... .. .. ...... ... ...... ... . 124
CYLINDER OUT OF ROUND .......... .. ..... ... ............................. .. .................................. . 124
CYLINDER/PISTON CLEARANCE ... . .......... ............................. ... ...... .. ............... . .... .. .... . 125
RING/PISTON GROOVE CLEARANCE .. ..... ......................... . ...... . ................................... . 126
RING END GAP ........................... ....... ............................. .. ... ..... .................... .'~ ... ... . 127
CRANKSHAFT DEFLECTION .............. ..... ............................. ..... ............................ ... . . 127
CONNECTING ROD BIG END AXIAL PLAY .. ............................ ..... ... . ............................ . . . 127
CRANKSHAFT ALIGNMENT .......... . .. ....... ...................... ............... ... ...................... .... . 127
CHECKING SURFACE FLATNESS . ..... ... ...... .. .... ............. .... .. ..... ..... .......... . ............ .. ..... . 128
04 ENGINE (593)
01 - ENGINE REMOVAL AND INSTALLATION ............................................................. .. 129
GENERAL ............................ .. ...... ......... ... .. ....... .... .. ... . ....... . .................. . ...... ...... . 132
PROCEDURES ... .................... ................. .................... ................. .............. .... . .... . . 132
02 - ENGINE LEAK TEST ....................................................................................... . 137
GENERAL .......................................................................................................... . 137
PROCEDURES ............................. ... ........................................ . ... . .. . .......... .. .... .... . . 137
ENGINE LEAK VERIFICATION FLOW CHART .................................................................. . 140
03 - AIR INTAKE SYSTEM ...................................................................................... . 141
PROCEDURES ................................ <.· ·· ........................................................... . 143
AIR FILTER ... . .... . ........ .. .... .... .. .......... : ~ .. . : .. ... . ;• ... .. ........ . .... ... ... .................. .... .. .... ..... . . 143
··~· :, .
AIR INTAKE SILENCER . .. ....... ... ... .. .......... . ...... . : .. .... ... .. .. .. . .... ... . .............................. . 144
04 - EXHAUST SYSTEM ........................................................................................ . 145
GENERAL . ................................................................................................... . 147
PROCEDURES .............................................................................................. . 147
TUNED PIPE ................................ .... ... . ............................................................ . .. . 147
MANIFOLD ... .. .............. . ........ ......... ...................... . ..... ... .... ... ........................ ..... . 148
MUFFLER ..... . .. ............... ..... .. ...... ............................. ... .. .... ....... . ........... . ....... ..... . 148
Ill
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TABLE OF CONTENTS
IV
EXHAUST GAS TEMPERATURE SENSOR (EGTS). .. . .. . . . .. . . . . . . . . . . .. . . . .. . . . .. . . . . . .. . . . . . .. . .. . . . .. .. . .. . . . 149
05- COOLING SYSTEM ......................................................................................... 151
GENERAL ..................................................................................................... 154
INSPECTION ............ . ................................ ... ................................................. 154
COOLING SYSTEM LEAK TEST.... . .............. ...................... ............... ........ ........ ..... ...... 154
MAINTENANCE ............................................................................................. 154
COOLANT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
PROCEDURES .............................................. . ................................................ 155
THERMOSTAT ............................ ... ... . ...... . ..... .. .. ...... ..... .... . .............. .... .... ........ ..... 155
RADIATOR CAP ... .... . ........ ........................ .. ........ .. ...... . .......... ..... ....... .. ... . ............. 156
FRONT RADIATOR. ... . .......... ....................... ................ . .. ....... .... ... ... .. ..................... 156
REAR RADIATOR.. ............. ... . ................ ... . ................. .................. .. . ........ ..... ... ...... 157
COOLANT TANK . . . .. . . . .. .. . .. . . . .. .. . .. . . . .. . .. . . .. .. . . . .. . . . .. . .. .. . . . .. . . . . . .. .. . . . .. . . . . . . .. . . . . . .. . . .. . . . . .. . 157
WATER PUMP.... ................... ............. ... ... .... . ...... .................. .... .... ...... ...... ... ........ 157
COOLANT TEMPERATURE SENSOR (CTS) ...................................................................... 157
06- OIL INJECTION SYSTEM .................................................................................. 159
GENERAL ..................................................................................................... 163
RECOMMENDED OIL TYPE.................... ........................ ....... .. .... ... . ......................... 163
INSPECTION . . .. . . . . . . .. . . .. . . .. . . . . . . . .. . .. . . .. . . . . . . . . . . . . . . .. . . .. . . .. . . . . . . .. . . . . . ... .. .. . . .. . . .. . . .. .. .. . 163
OIL SYSTEM LEAK TEST ........... . ............ .. ... .. ............ ... ......................................... . .. 163
PROCEDURES ............................................................................................... 164
OIL RESERVOIR. ............... ... ....... ....... ...................... .................................. ........... 164
OIL LEVEL SENSOR . .. . .. .. . .. . . . .. .. . .. . . . .. . . .. . . . .. . . . . . . . . .. . . . . . .. . .. .. . .. .. . .. . . . . . .. . .. . . .. . .. . . .. . .. . .. .. . 165
OIL FILTER......... .... . .... .................... . ......... ... .... . ........ . ..................... ...... .............. 165
OIL PUMP .. . . . .. . .. . . .. . .. . . . . . .. . . . .. . . . . . . . . .. . . . . . . . . .. . . . .. . . . . . . . .. . .. .. . .. . . . . . .. . .. .. . .. .. .. . .. .. . .. . . . .. . . . 165
INJECTION NOZZLE.... ......... .......... ...... .. ...................... ............... ......... ... ..... .......... 168
07 - REWIND STARTER.......................................................................................... 171
GENERAL................................................. . ................................................... 173
PROCEDURES .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . . . . .. . . .. . . . . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 173
STARTER HANDLE... . . ........... .................... ......... . ................................................... 173
REWIND STARTER......... .. ....... ............ .......... ...... ..... ................ .......... ..... ... .... .. ...... 173
ROPE............. ...... ... ................................. .. ...... . .................... .......................... .. 176
08- MAGNETO SYSTEM ........................................................................................ 179
GENERAL................................................. . ................................................... 182
PROCEDURES .. . . .. . . .. . . .. . . .. .. .. .. .. . . .. .. .. . . .. . . .. . . .. . . .. . . .. .. .. . . .. . . .. . . .. .. .. . . .. . . .. . . .. .. .. .. .. . 182
,MAGNETO FLYWHEEL ............... ................. .......... .. .. .................... ......... .... ............. 182
STATOR....... ... . ........................ ......... . .. ............. .. .... .......... ............................ ..... 184
TRIGGER COIL .. . . . . . .. . . . .. . .. .. . .. .. . .. . . . . . . . .. . . . .. . .. .. . .. . . . . . .. .. . . . .. . .. .. . .. . . . .. .. . .. . . .. . . . .. . .. .. . .. .. . 185
CRANKSHAFT POSITION SENSOR (CPS) ... ....... ................... ..... .. .... ... .. ......... .... ....... ....... 185
09- TOP END ...................................................................................................... 187
GENERAL ..................................................................................................... 190
PROCEDURES ............................................................................................... 190
REED VALVE....... ..... . ...... ..... ............... ................ ......................... .......... .............. 190
RAVE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
CYLINDER HEAD.................... ....... . .................. . ............................. ... .................... 195
CYLINDER .. . . . .. . . . . . . . . . . .. . .. .. . .. . . . .. . . . . . . . . . . .. .. . .. .. . . . .. . .. . . . . . .. .. . .. .. . .. .. . . . .. . .. .. .. . .. . . . .. .. . .. . . . 195
PISTON. ....... . .. .. ............... . ............... .. ......... ... .. ...... ............... ...... ...................... . 196
10- BOTTOM END ................................. .' ............................................................. 201
GENERAL ..................................................................................................... 204
PROCEDURES ............................................................................................... 204
WATER PUMP. . .. ...... .. .. . .. .......................... ..... ........................... ... ........................ 204
BEARING HOUSING .......... ............. . ........... ............ ..... . ............. .................. ........... 204
WATER/OIL PUMP SHAFT. .. ...................... .... . .......... ................................................ 208
CRANKCASE............. ....... ............... . ............ .. .... ..... ..... ............. ............ ............ ... 208
CRANKSHAFT....... .. . ............ ........... . ......... .. ... ..... ................... .... ................. .... . .... 209
TABLE OF CONTENTS
CRANKSHAFT BEARINGS ......... ...... ......... ... ............. .... .... ... ........ ................ ... ... ....... . 211
11 - ENGINE MEASUREMENT ................................................................................ . 215
CYLINDER HEAD WARPAGE ... .. ...... . ........ .................... ....... .. ...... . .................... ...... . . . 215
COMBUSTION CHAMBER VOLUME MEASUREMENT ............. . . . . .. .. ..... ......................... ... . . 215
CYLINDER TAPER ................. . .... .. . .............. ....... . ...... . .. .. . ........... ..... ......... . ..... .... . .. . 216
CYLINDER OUT OF ROUND .. . .. . .. ......... .. ... .... ... . .... . ..... .... . ......... . .... .. .. ......... . .. ... . ...... . 216
PISTON/CYLINDER CLEARANCE .. ......... ................ .... .. . . ......... ...................... .... ..... .. .. . . 217
RING/PISTON GROOVE CLEARANCE ... ....... . ... .. .. . .... ..... ......... ..... .... . ..... .... .......... . ........ . 218
RING END GAP .. .... ... ... ... . .......................... . .... . ........ . ..... . ........... ........ ...... ... ......... . 219
CRANKSHAFT DEFLECTION ........ . .............. ....... ..... ..... .... ..................... ..... ..... . ......... . 219
CONNECTING ROD BIG END AXIAL PLAY .... .. . ... . ......... .. .. . ...... .. ... . .... ..... ........ . ....... . ... ... . 219
CRANKSHAFT ALIGNMENT. ...... .. . ...... ...... .... . ........... ...... ......... .. .... ............. . ....... ... .. . . 219
05 ENGINE (810)
01 - ENGINE REMOVAL AND INSTALLATION ........................... . .................................. . 221
GENERAL ................................ .. .................................................................. . 222
PROCEDURES ............... . .................................................... . ......................... . 222
ENGINE REMOVAL ...... .............. ............... ...... . ..... . ............ . .... ......... ... .. . .. . .. . . . .. .. . .. . 222
ENGINE INSTALLATION ..... .. ....... .. ................. .. ..... .. ....... . ....... .. ...... . .. . . .. .... ... ........... . 224
02 - ENGINE LEAK TEST ....................................................................................... . 227
GENERAL ......... . ....................... . ............................... . .................................. . 227
PROCEDURES .............................................................................................. . 227
PREPARATION ................. . .... .. .. .. . .. . ............... . ......... ..... ..... .... . ........................ .... . 227
LEAKTEST ..... ............. . .... .... .. .... ... ... ...... . ...... . .... .. .... ........... ......................... ...... . 229
REASSEMBLY .. .......... ... ........ ............. .. ............. .... .. . .. . ... ............ ................ .. ..... . . . 229
03 - AIR INTAKE SYSTEM ...................................................................................... . 231
GENERAL .................................................................................................... . 233
PROCEDURES ........................... . ................................ . ................ . ... . ........... . . 233
AIR INTAKE SILENCER . .. ....... ...... ............. .... .... . .................................... .. ..... ... .. ..... . 233
INTAKE MANIFOLD .. ..... ........ .... .. ..................... .. ... . .... . . .. .... . .. . ..... . .... ..... .. .. ... ..... .... . 233
04 - EXHAUST SYSTEM ..................................................... . .................................. . 235
GENERAL ................................. .... ....................... . ..................................... .. . 237
PROCEDURES .......................................... : ........... . ............................... ......... . 237
EXHAUST PIPE ..... ... ............. ........ .. ..... .... . ................ .... ... .. ..... ..................... ... .... . . 237
MUFFLER ...... .................... . . .. . .. . ... . ..... ................ ...... ........... .................... .. . .... . .. . 237
05 - LUBRICATION SYSTEM ..................................................................... •..• ........... 239
ENGINE LUBRICATION ................. . .................................................................. . 241
GENERAL ................................................................... . ............................... . . 242
MAINTENANCE ........................................ . ................. . ................ . ................ . 242
OIL LEVEL VERIFICATION ..... .... .................. .. ...... ...... ...... .. ........... . ...... .... ....... ..... .... . . 242
OIL CHANGE ......... ..... .. ...... .. .. ......................... . ........ . ...... ............. ........ .. . .. ......... . 242
OIL FILTER .... ................ . .. . .. . .. .. . ........ .... .... . .. . .. . .... .... . ...... ... ... .. ................. .......... . 242
INSPECTION ............................. . .................................................................. . 243
ENGINE OIL PRESSURE ....... .... .............. ..................... .. .. .. .... .. ..... ... ................ .... ... . . 243
PROCEDURES .......................... .. .................................................................. . 244
OIL PRESSURE SWITCH ...... ........ ..... . .. . . . .. .. . ............. ............... ..... . .............. ... ...... . . . 244
ENGINE OIL PRESSURE REGULATOR . .. ..... .. .. ........... ......... . .............. ......... .. ...... . .. .. ... .. . 244
OIL PUMP .... .. ... ...... . ..... ... .... . .... . ,. .............. .. ............ ... . .......... ... . .. ................. ..... . 245
ENGINE OIL STRAINER ............... .. .. ........ ...... . .. , .. ........... . ........... .. .. .. ..... .. .. . ....... ..... . 247
REED VALVE ... ... . ...... ............... ...... ..... .. .. ... ...... ......... ......... . .... ..... .... .... .. .... .. ....... . 248
06 - COOLING SYSTEM ............................................................... • ....................... .. 249
GENERAL . ..................................... .. ........................................................... . . 252
INSPECTION ............................................................. . .................................. . 252
COOLING SYSTEM LEAK TEST .......... .. .. . .. .................... .. . ..... ... .. .... . ................. .. ........ . 252
MAINTENANCE ........................................................................................... .. 253
COOLANT REPLACEMENT ....... .......... . .......................... .... .... ... ............................... . 253
v
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-· __j
TABLE OF CONTENTS
PROCEDURES . . . . . . . . .. . . .. . . .. . . .. . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . . . . . .. . . .. . . .. . . .. . . . . . . . . . . .. . . .. . . .. . 255
COOLANT TANK CAP ... ..... .. . ............................. .......... .................... ........... ............. 255
FRONT RADIATOR....... . ........ ... ........... .. ... .... ..... .............................. . . . . . . . . . . . . . . . . . . . . . . . 255
RADIATOR FAN . . .. .. . . . .. .. . .. .. . . .. . . . . .. . . . . . . .. .. .. . .. .. . .. .. . .. . . .. . .. .. . . . .. . . .. . . . . . . . . . . . .. . .. . . . .. . . . .. .. . 255
RELAY R3........ ....... .... ... .... . .... . .......... . .... ..... ....................................................... 256
REAR RADIATOR. ............ ..... ..... .. ..... .. ..... .. ... .. ...... . ..... .. .. .............. ... ....... . .............. 257
COOLANT TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
COOLANT TEMPERATURE SENSOR (CTS) ............... . ................ .. ................ ......... . ......... . 258
THERMOSTAT ...... ...... . .............. .. ........ . ...... . .. . ........ ....................... .... ...... ........ .... . 258
WATER PUMP HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
WATER PUMP IMPELLER...... . ........ .. ....... ......... . ...... .......................... .. ... .. ................ 258
WATER PUMP SHAFT AND SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
07- MAGNETO SYSTEM ........................................................................................ 263
GENERAL..................................................................................................... 265
PROCEDURES .. . . .. . . .. . . .. . . .. . . .. .. .. . . .. . . . . . . .. . .. .. . .. . . .. . . .. . . .. .. .. . . .. .. .. . . .. . . .. . .. . . . .. . . .. . .. . . 265
MAGNETO COVER.. . .. ... . .... ............... ... .. .... . ....... ............. .......... ..... .. . .... . ......... . ...... 265
STATOR ... .. ..... .......... ..... ........ .. ... .... ... .... .. .... .. .. .... .. ..... .... .. ................... .............. 266
ROTOR ........................................... . .................................................................. 267
SPRAG CLUTCH . .... ... . .......... . ......... ... .... .. . . . ............... .. .... . ............. .. . .... .. ............ ... 268
SPRAG CLUTCH GEAR .... .. ..... .. . ..... .. . ..... .... ..... .... .. .... .. .............. .. .. .... ... ... ... .... ... .... .. 269
STARTER DRIVE GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
08- CYLINDER AND HEAD . . . . . . .. . . .. . . . . . . . . . . .. . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . .. . . . . . . . . . . .. . . .. . . .. . 271
GENERAL..................................................................................................... 275
MAINTENANCE ......... ... ................................................................................. 275
VALVE CLEARANCE ADJUSTMENT........................... ...... ..................... ............ ............ 275
PROCEDURES .. .. .. . . .. . . .. . . .. . . .. . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .. . . . .. . .. . . . .. . . .. . . .. .. .. . 276
VALVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
TIMING CHAIN TENS lONER ..... .... ... ... .... ... ...... . ................ ...... ................................... 276
CAMSHAFT TIMING GEAR ........... ... ... .. ..... . .... . ............ .. .... .... .. .. ....................... .. .... ... 278
ROCKER ARM..... ......... . .............. .. ..... .... ........... ...... ............................................. 279
TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
CYLINDER HEAD. ....... ....... ... ..... .. ..... .... . ........... .................................. ........ ... .... .... 281
CAMSHAFT......... ... .... . .............. . .................. .... .. . ................................................ 283
VALVE SPRING . . . . . . . .. . .. .. . .. . . . . . .. . . . . . . .. . . .. . .. .. . . . . . . . . .. . .. . . . . . . . .. . . . .. . . . .. . . . .. . .. . . .. ... . . . .. . . . .. . . . 287
VALVE ................. ........... ................... .. ... .... ... ....... .. ................... .. .. .. . ......... . ....... 288
VALVE GUIDE....... . ................ ... ......................... .. ................................................. 291
CYLINDER .. . .. . . . .. .. . . . .. .. . .. . . . . . . . . . . .. . . .. . . . .. . .. . .. .. . . . . . . .. .. .. . .. .. . .. .. . .. . . . .. .. . .. . . .. .. . . . . .. . . . . . .. . 292
PISTON ........... .... .. .... . ............. ..... ... . .... ..... ........ . ............. .. ......... ...... ......... . .... . .. . 293
PISTON RINGS .. :·:· ...... .... ..... .... ......... . ............................ . ..... . ........... . ........ ............ . 297
09 - BOTTOM END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
GENERAL ..... ~ ............................................................................................... 302
PROCEDURES .. . . .. . . .. . . .. . . . . . . .. . . . . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .. .. . . .. .. .. . . .. .. .. . . .. .. .. . 302
PTO COVER OIL SEAL...... ......................... ..... .... .............................. ...... ................. 302 .
PTO COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
DRIVE GEARS..... .. .... . .......... ........... . ....... ....... .. .. .... . ................ . ......... .... ............... 305
TIMING CHAIN ..... ....... .... . .. .. . .. .. . .. .. ......... .......... ................................................... 306
TIMING CHAIN GUIDE .......... ...................... ......... .................... ..... ..... ...... ... ... .. ........ 307
CRANKCASE. .. . .............. .... .. . ...... .... . .................. .. ... ..... .. . ..... ................ ....... .... .... . 307
CRANKSHAFT. .. .... . ........ . .... . .... . .... ... .... .......... .. ....... .... ... . .... .. ... ... .. .. .... ... .... . .... ..... 311
06 FUEL SYSTEM
VI
01 - FUEL TANK AND FUEL PUMP (440F, 550F AND 600) . .. .. . .. .. . .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. . .. .. .. . 319
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
FUEL SYSTEM LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
DIAPHRAGM FUEL PUMP ..... ....................... ....... .............................. ..... .... . ............. 322
TABLE OF CONTENTS
IN-TANK FUEL STRAINER ........... ..... ...... ........... . ........... .. . .... .. . .......... . ............... ... .... . 323
FUEL FILTER .. . ................... . ...... ........ .... .......... . .... ... ...... .. ..... ..... .......... . .... . ..... .... . . 323
FUEL TANK .............................. .... ................ ... .... . ...... ... .... . ............ ..... ........... .. .. . 324
02- FUEL TANK AND FUEL PUMP (600 HO SDI) .......................................................... . 325
INSPECTION ............................ . ................................................................... . 327
FUEL SYSTEM LEAK TEST ... .... .................... . .... ..... ..................... ... ....... .... . .. .... ... ..... . 327
FUEL PRESSURE TEST ........ ...... . ............. . ............ .. . . ....... ...... .. . .. .. . ...... .. . .. .......... ... . . 327
PROCEDURES .............................................................................................. . 328
OETIKER CLAMPS ..... ... ... . ...... . ................... ... ... ... .. .... ... .. .. ........... . .... ... .. .... ... ... .... . . 328
FUEL PUMP .... .. ........ ..... ........ ............... ................ ... .. ..... .. .... ... . ........ ... ...... .. .... . . . 329
IN-TANK FUEL STRAINER ......... ....... ......... . .............. .... .. . . .... .... ... .................. . .... .... .. . 332
FUEL FILTER ...................... .. .. .. .. ........ ................. . ....... ..... .... .................. .. ... ...... .. . 332
FUEL TANK .... ...................... .. ............ .. ............... . ...... .. .. .. . .. . . ..... . .................. ... .. . 332
TROUBLESHOOTING ..................................................................... .' ................ . 335
FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW CHART ........ .... ... . ... .. ........................... ... ... . 335
03 - FUEL TANK AND FUEL PUMP (V800) ............................... . .................................. . 337
INSPECTION ................................................................................................ . 339
FUEL SYSTEM LEAK TEST .... .. .... .... ... ............................. ... ........ . ....... . ............... ..... . . 339
FUEL PRESSURE TEST .. .... . ...... . ... .. ................... .. .. . . . . . ... .... ... ...... ..... ...................... . . 339
TROUBLESHOOTING ...................................................................................... . 341
FUEL SYSTEM DIAGNOSTIC FLOW CHART ........................ ..... . .. .. . .. ..... ................ ......... . 341
PROCEDURES .......................... .. .................................................................. . 342
FUEL FILTER . ......................... ...... . ..... ......................... .. .. ...... .......................... .... . 342
FUEL PUMP ......... . ........... . ......... . ...... .. . ........ . .... . .... ...... . ........................... . ..... .. .. . 342
FUEL TANK .. ........................ ... .......... ..................... ... ........... . ............................ . . 343
04- VM CARBURETORS (440F, 550F AND 600) ............................................................ . 345
CARBURETOR .......... .... ... .. ... . ........................ .... .... ....... .... . .. .. . .. .. ............. ............ . 348
THROTTLE CABLE .... ........ ........... ...... ..... .. .. ........ ...... ..... ... ...... .... .... ... .... .. ... .......... . 354
CHOKE CABLE ................ ............ . ........ . .. .. . .................. .. ..... ................ ......... ....... . 356
07 ENGINE MANAGEMENT (SDI)
01 - OVERVIEW .................................................................................................. . 359
GENERAL .................................................................................................... . 360
OPERATING PRINCIPLE ................................................................................... . 360
AIR INDUCTION ..................................................................................... .. .... : ... .. .. . 360
FUEL DELIVERY SYSTEM ........ ........ .. . .... .. .............. . .. .. ....... . .. .. . .... ............. .... ........ .. . 360
ELECTRICAL SYSTEM .... . .. . ........ . .. ...... . ...... .... ..... .. .... ..... ... . .................................... . 361
ENGINE MANAGEMENT SYSTEM (EMS) ............................................................. . 362
FUEL INJECTION .. ..... .. ..... .. ........... .................... .... .... ......... ..... ......................... ... . . 362
IGNITION SYSTEM .......................... .. . . ...................................... .. ~ ... ....................... . 362
E-RAVE . .. .. .. .. . . .................... .. ... ...... .. ........................................................ .... .. ... . 363
ENGINE MODES OF OPERATION ........ .... ... .................. ... ...... .... .......................... .. .. .. . . 363
MONITORING SYSTEM ................. ...... .......................... .. ................................... .... . 363
DIAGNOSTIC MODE .................... .. .. ..... ................................... ... .................. ..... .. .. . 363
ENGINE MANAGEMENT SYSTEM FUNCTIONS .................... .... ................................ .... ... . 364
02- EMS DIAGNOSTIC AND COMMUNICATION TOOLS ................................................ . 365
DIAGNOSTIC ................................................................................................ . 365
GENERAL .. ................................ ... .. ....... ........................ .. ................................. . . 365
EMS FAULT CODE TABLES ....... .... ......... .... ... ....... .......... ....... .. ...... .... ... ........ .. .......... . 366
EMS FAULT CODES SUPPLEMENTAL INFORMATION .... .... ........... ........ .... ....... .... ....... ....... . 367
COMMUNICATION TOOLS ............................................................................... . 368
MPI (MULTI-PURPOSE INTERFACE) .... ... .. .................. . ....... . .. . .. .. ................................. . 368
MPI-2 (MULTI-PURPOSE INTERFACE) ..... .. ..................... . ............................................. . 371
B.U.D.S . SOFTWARE ............. ............... ......................... .... .... . .......................... ..... . 373
03 - ADJUSTMENT AND REPAIR PROCEDURES .......................................................... . 375
GENERAL .................................................................................................... . 375
VII
..J
TABLE OF CONTENTS
FUEL SYSTEM.. .. . ............. .. ...... ............... .... ......... .... ..... .......... . .. .......... ... . ............ 375
ELECTRICAL SYSTEM .......... .............. . ....... .... ......... .................... .. . ...... . .................. 376
BASIC ADJUSTMENTS ............................... . .................................................... 380
IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
CLOSED THROTILE RESET . . .. . .. .. . . . . . . . . . . . . .. .. . . . . . .. .. . . . .. .. . . . .. .. . . . . .. . . . . . . . . . . . . . . . . .. . . . .. . . . . . .. . . 380
THROTILE CABLE . .. .... ... .... . .......... .... ........ .. ....... ...... .. ........... ......... .... .... .. ..... ....... . 381
IGNITION TIMING ....... .. .... .. ... ... . ..... .. .. . ...... ..... .... . .................. .... ............ . ....... ... ..... 382
REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
FUEL INJECTORS ... ................ .. ..... ......... . ....... . ........ . ........... .. ................ ... .... ..... .... 382
ENGINE CONTROL MODULE (ECM) . .. . . . .. .. .. . . . .. . .. . . . . . .. . . . .. . . . . . .. . . . .. . .. . . . .. . . . .. .. .. . . . .. . . . .. . . . .. . 385
THROTILE BODY ........... .. . ..................... ...... .... ... ... ... . .... .. .......... ....... .. ........ .. ... .. .. . 386
THROTILE POSITION SENSOR (TPS) ............ ............ ... . ........ .. ................ ......... ... . ......... 387
CRANKSHAFT POSITION SENSOR (CPS)........ ..... ............. . ...... . ........... ........ ...... .. ........... 388
AIR TEMPERATURE SENSOR (ATS) .............. .. .. .. .... ..... ................. . ..... .......... .... .. .... ...... 389
COOLANT TEMPERATURE SENSOR (CTS)...... ... . ...... .. . . . .. .. . . . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . 390
AIR PRESSURE SENSOR (APS) .......... ..... .. ..... . .................. ........... .................. .. ...... ..... 391
EXHAUST GAS TEMPERATURE SENSOR (EGTS) .... .. . . ...... . ....... . .......... ........ ............... .. ..... 391
KNOCK SENSOR (KS) .... . .... . .... ... .... . .............................. .. ... .. . ..... . ........................... . 392
E-RAVE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
08 ENGINE MANAGEMENT (V800)
VIII
01 - OVERVIEW................................................................................................... 395
OPERATING PRINCIPLE .................................................................................... 396
AIR INDUCTION..... .... ... ... .. ................... .. ..... .. ... .. . ......................... ............... ......... 396
FUEL SYSTEM. ..... ..................... .......... ..... .... . ......... ... . ................................ . ......... 396
ELECTRICAL SYSTEM. ......................... .. .... ...... ........... ...................... .. ....... .. ... ....... . 397
ENGINE MANAGEMENT SYSTEM ..... . .................................. . .............................. 399
ELECTRONIC FUEL INJECTION .. ... . .. .. ........... .......... . .... ... ... ..... .. .... ... . .......... . ....... .. .. . . . 399
IGNITION. ................................... . .......................................... . ................. .... ....... 399
ENG INE MODE~ _OF OPERATION...... . .... .. ... .. .... ... ... .... ... ... . ......... . .... .... ..... ........... ..... .. 400
MONITORING SYSTEM . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .. . . . . .. . . . . . . . . . . . . .. . . . .. . . . .. .. . . . .. . 400
02- EMS DIAGNOSTIC AND COMMUNICATION TOOLS .. .. .. .. . .. .. .. .. . .. .. .. .. .. .. . .. .. . .. .. .. .. .. .. . 403
GENERAL ................. . ................................................................................... 403
COMMUNICATION TOOLS ................................................................................ 403
MULTI-PURPOSE INTERFACE (MPI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
MULTI-PURPOSE INTERFACE-2 (MPI-2).... . ..... ...... . ..... ... ........ .. ........... ........... .... .......... .. 405
B. U.D.S. SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . 408
DIAGNOSTIC .......................................................................... : ...................... 410
MONITORING SYSTEM .. . ........................................... .. .............. .. . .... ....... ............... 410
FAULT CODES. ..... ... ............. ... .... .. ................ .. ..... ... . ..... .. .. .......... . ................ . ....... 410
FAULTCODETABLE .................. .. .... . .. . .. . . ...... . ....... ..... .... ...... ... ............... ........ .. ... ... 411
03- ADJUSTMENT AND REPAIR PROCEDURES ........................................................... 417
GENERAL ..................................................................................................... 417
FUEL SYSTEM ........................................ ............... ................ .. .............. ...... ......... 417
ELECTRICAL SYSTEM . ..................................... ....... ................................................ 418
BASIC ADJUSTMENTS .................................................................................... 420
IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
THROTILE CABLE . .................. . ..................... . ....... . ......... . ......... .. ........... . ........... .. . 420
CLOSED THROTILE AND IDLE ACTUATOR RESET ... .. .......................... .. ........... . ......... . .... . 421
IGNITION TIMING .. ............ ...................... ... .... .. .. .. .. ........ .. ............... ........ .. ....... . .... 422
REPAIR PROCEDURES . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . . . . .. . . .. . . . . . .. .. . .. .. .. .. .. . . .. . . .. . . . . . . . . . 422
ENGINE CONTROL MODULE (ECM) ...................... ..... ... .. ......................... .. ..... ... .......... 422
FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
FUEL RAIL........ ........ ... ...... ..... .... ............ ..... . ...... . .... ... ..... ... .... ........... . .... ..... . ...... 427
THROTILE BODY .. ... .. ....... ... ..................... .. ................. ................. ... .. .... ............... 428
THROTI~E POSITION SENSOR (TPS) ............ ... . ...... ..... .. .......................... ....... .............. 431
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Upon purchasing this manual, you will receive a .PDF file containing an email contact. After contacting us, you will receive a reply with a link to access the manual for your 2007 Ski-Doo Tundra 300F.
This comprehensive manual covers every aspect of your machine, providing detailed guidance on every nut and bolt. With hundreds of pages, it equips you to address various issues, from routine maintenance like oil changes to more complex tasks such as transmission swaps. The manual includes numerous illustrations to assist you and features easy-to-understand text throughout.
Utilize the search function to navigate the manual efficiently and print the necessary pages as needed. This Factory Service Repair Manual serves as a thorough guide, walking you through the fundamentals of maintenance and repair in a step-by-step manner, imparting the knowledge that factory-trained technicians possess. By leveraging the insights within this service repair manual, any owner can confidently make informed decisions regarding the maintenance and repair of their machine.
Rest assured, in addition to providing a high-quality service manual, we are committed to delivering excellent customer service, ensuring your satisfaction.
