TABLE OF CONTENTS 0 - HBCcustomers.hbci.com/~jbeebe/2002 MXZ Manual/Skidoo_a...Subsection 02 (IGNITION TIMING) MMR2002_093_06_02A.FM 06-02-1 IGNITION TIMING 0 377 and 503 Engine Types

Section 06 ELECTRICALSubsection 01 (TABLE OF CONTENTS)

MMR2002_109_06_01ATOC.FM 06-01-1

TABLE OF CONTENTS 0IGNITION TIMING ................................................................................................................. 06-02-1

SPARK PLUGS....................................................................................................................... 06-03-1

NGK SPARK PLUG............................................................................................................. 06-03-1

NGK SPARK PLUG NUMBERING SYSTEM ..................................................................... 06-03-1DESIGN SYMBOLS USED IN NGK SPARK PLUGS......................................................... 06-03-2

DISASSEMBLY................................................................................................................... 06-03-3HEAT RANGE..................................................................................................................... 06-03-3FOULING............................................................................................................................ 06-03-3SPARK PLUG ANALYSIS................................................................................................... 06-03-3SPARK PLUG INSTALLATION........................................................................................... 06-03-4SPARK PLUG TIGHTENING TORQUE.............................................................................. 06-03-4

BATTERY................................................................................................................................ 06-04-1

GENERAL ........................................................................................................................... 06-04-1REMOVAL........................................................................................................................... 06-04-1CLEANING ......................................................................................................................... 06-04-1INSPECTION ...................................................................................................................... 06-04-1BATTERY CHARGE TESTING ........................................................................................... 06-04-1BATTERY STORAGE.......................................................................................................... 06-04-2ACTIVATION OF NEW BATTERY ...................................................................................... 06-04-2TIPS FOR CHARGING A USED BATTERY ........................................................................ 06-04-3BATTERY CHARGING EQUIPMENT ................................................................................. 06-04-4INSTALLATION OF BATTERY ........................................................................................... 06-04-5

ELECTRIC STARTER.............................................................................................................. 06-05-1

REMOVAL........................................................................................................................... 06-05-3DISASSEMBLY................................................................................................................... 06-05-3CLEANING AND INSPECTION.......................................................................................... 06-05-6

CLEANING ......................................................................................................................... 06-05-6RELAY ................................................................................................................................ 06-05-8ASSEMBLY......................................................................................................................... 06-05-8INSTALLATION .................................................................................................................. 06-05-10

Section 06 ELECTRICALSubsection 01 (TABLE OF CONTENTS)

06-01-2 MMR2002_109_06_01ATOC.FM

TESTING PROCEDURE .......................................................................................................... 06-06-1

GENERAL............................................................................................................................ 06-06-1ACCESS TO MPEM CONNECTORS.................................................................................. 06-06-7

SYSTEM TESTING ............................................................................................................. 06-06-8

IGNITION SYSTEM TESTING SEQUENCE....................................................................... 06-06-8LIGHTING SYSTEM TESTING SEQUENCE ...................................................................... 06-06-8LIGHTING GENERATOR COIL VOLTAGE TESTING ........................................................ 06-06-12INSPECTION OF AC CIRCUIT INSULATION..................................................................... 06-06-19

INSPECTION....................................................................................................................... 06-06-19INSPECTION OF HEATING ELEMENTS............................................................................ 06-06-19

HEADLIGHT SYSTEM TESTING........................................................................................ 06-06-19

ACCESSORIES TESTING................................................................................................... 06-06-21

Section 06 ELECTRICALSubsection 02 (IGNITION TIMING)

MMR2002_093_06_02A.FM 06-02-1

IGNITION TIMING 0377 and 503 Engine Types

If for any reason, ignition timing accuracy is sus-pected, it can be verified as follows.IMPORTANT: For ZX fan models.

Verifying Magneto Flywheel Timing Mark PositionPrior to checking the timing, it may be necessaryto verify the position of the timing mark on themagneto flywheel, for the following reasons:1. To detect a missing or broken magneto flywheel

Woodruff key which would allow a change oftiming to occur, with eventual break down ofthe engine.

2. To correctly locate and mark a timing mark on anew service magneto flywheel.

3. To verify the correct location of the factory tim-ing mark.

4. To detect a wrong magneto flywheel corre-sponding to a different engine type.

To verify the position of the timing mark on themagneto flywheel, proceed as follows:1. Clean the area around the spark plugs, and re-

move them.2. Remove the rewind starter from the engine.3. Install the TDC gauge in the spark plug hole,

(magneto/generator side) and adjust as follows:a. Position the magneto flywheel at approximate-

ly TDC.

TYPICAL — INSTALLATION OF TDC GAUGE1. Gauge on MAG side cylinder2. Adaptor lock nut

b. Assemble the gauge to the adaptor and tight-en the roller lock nut. Do not tighten the adap-tor lock nut.

c. Screw the adaptor into the spark plug holeand tighten to prevent movement in the plughole.

d. Position the dial face toward the magneto/generator. Move the gauge down until theneedle just begins to move, then move downa further 5 or 6 mm (approximately 1/4 in).Tighten adaptor lock nut by hand.

4. Locate the piston TDC position as follows:a. Slowly rotate the magneto flywheel back and

forth across TDC while observing the needle.Note that the needle stops moving only asthe piston is changing direction.

b. Rotate the dial face so that “0” is in line withthe needle when it stops moving.

c. Again, slowly rotate the magneto flywheelback and forth across TDC and adjust the dialface to “0”, until the needle always stops ex-actly at “0” before changing direction.

d. “0” now indicates exact TDC.


06-02-2 MMR2002_093_06_02A.FM

5. Verify the position of the timing mark on the mag-neto flywheel as follows:

NOTE: When checking timing, certain proceduresrequire that the magneto flywheel be turned in aclockwise direction, viewed facing the magneto/generator. If it is necessary to turn back (counter-clockwise) for any reason, rotate the magneto fly-wheel at least one-quarter turn counterclockwise,and then rotate it clockwise. The last magneto fly-wheel movement when making a critical checkmust always be in a clockwise direction, to ensurethat the slack in engine moving parts is taken-up.

a. Rotate the magneto flywheel counterclock-wise, one-quarter turn then carefully rotate itclockwise until the needle indicates the spec-ified measurement. Refer to TECHNICALDATA.

b. Verify that the magneto flywheel mark per-fectly aligns with the mark on the trigger coil,refer to illustration.

c. If the marks do not align, check magneto fly-wheel and trigger coil part numbers andcheck Woodruff key condition. If all parts arethe appropriate ones and if Woodruff key isin good condition, continue the procedure.

TYPICAL1. Trigger coil mark2. Magneto flywheel mark

NOTE: These marks cannot be used to check dy-namic (with engine running) ignition timing with atiming light: a new mark must be scribed on mag-neto flywheel for this purpose.

6. Scribe a new mark on magneto flywheel as fol-lows.a. Remove the fan cover from the engine.b. Maintain magneto flywheel so that previous

marks remain aligned.c. Scribe or punch a mark on magneto flywheel

so that it perfectly aligns with the arrow oncrankcase, refer to illustration. This new tim-ing mark should be used for future timingchecks (dynamic timing).

d. Reinstall rewind starter.e. Check the timing with a timing light.

TYPICAL 1. Crankcase arrow2. Scribe a mark here3. Maintain verified timing marks aligned (static timing)

Checking Ignition TimingUse timing light (P/N 529 031 900) and digital in-duction type tachometer (P/N 529 014 500).

TIMING LIGHT (P/N 529 031 900)

A17E10A

2

1


MMR2002_093_06_02A.FM 06-02-3

TACHOMETER (P/N 529 014 500)

To check the ignition timing, refer to illustration andproceed as follows:

1. Connect the timing light pick-up to a spark plugcable.

NOTE: To avoid an incorrect reading due to paral-lax, view the magneto flywheel and the crankcasetiming marks in a straight line.2. Connect tachometer wire to spark plug wire or

aim tachometer toward spark plug wire withoutusing any connection wire.

3. Start the engine and raise the engine speed atleast to 3500 RPM (3000 to 4000 RPM) whileobserving the timing marks, refer to illustration.The magneto flywheel mark scribed previouslyand the crankcase arrow should be perfectlyaligned. If the marks do not align, a faulty triggercoil (check proper grounding of coil), a faulty fly-wheel, a faulty Woodruff key, a misaligned(twisted) crankshaft or a faulty CDI modulecould be the cause: substitute one part at a timeand recheck timing marks (check connectorscondition prior to substituting any part).

NOTE: Ignition timing may be verified when en-gine speed is anywhere within 3000 - 4000 RPM.

TYPICAL

4. Install parts which were removed.

493, 593, 693 and 793 Engines

Normally ignition timing adjustment should not berequired. It has been set at factory and it shouldremain correctly adjusted since every part is fixedand not adjustable. The only time the ignition tim-ing might have to be changed would be when re-moving and reinstalling the magneto housing, re-placing the crankshaft, the magneto flywheel, thetrigger coil or the MPEM. If the ignition timing isfound incorrect, first check for proper crankshaftalignment. Refer to LEAK TEST AND ENGINE DI-MENSION MEASUREMENT. This might be the in-dication of a twisted crankshaft.The ignition timing can be checked with either theengine hot or cold. Also, the ignition timing is tobe checked at 3500 RPM with a timing light.NOTE: All models, except Summit have 3° retardtiming during their first 8 hours of operation. Whereas Summit has 3° retard timing during their firstfour hours of operation.NOTE: Between 3000 and 4000 RPM, the sparkadvance does not change. So when checking igni-tion timing at 3500 RPM, a change in engine speedwithin ± 500 RPM will not affect the timing markwhen checked with the timing light.

WARNING

Place ski tips against a wall, raise rear of ve-hicle on a stand, so that track does not contactthe ground. Do not allow anyone in front ofor behind the vehicle while engine is running.Keep clear of track and do not wear looseclothing which can get caught in moving parts.


06-02-4 MMR2002_093_06_02A.FM

Scribing a Timing Mark1. Clean the area around the MAG spark plug, and

remove it.2. Install the TDC gauge in the spark plug hole,

(magneto side) and adjust as follows:a. Position the MAG piston at approximately TDC.

TYPICAL1. TDC gauge on MAG side2. MAG side piston at TDC

b. Assemble the gauge to the adaptor and tight-en the roller lock nut. Do not tighten the adap-tor lock nut.

c. Screw the adaptor into the spark plug holeand tighten to prevent movement in the plughole.

d. Position the dial face toward the PTO. Movethe gauge down until the needle just beginsto move, then move down a further 5 or 6 mm(approximately 1/4 in). Tighten adaptor lock nutby hand.

3. Locate the piston TDC position as follows:a. Slowly rotate the drive pulley back and forth

across TDC while observing the needle. Notethat the needle stops moving only as the pis-ton is changing direction.

b. Rotate the dial face so that “0” is in line withthe needle when it stops moving.

c. Again, slowly rotate the drive pulley back andforth across TDC and adjust the dial face to“0”, until the needle always stops exactly at“0” before changing direction.

d. “0” now indicates exact TDC.4. Rotate the drive pulley clockwise, one-quarter

turn then carefully rotate it counterclockwiseuntil the needle indicates the specified mea-surement, indicated in TECHNICAL DATA.

5. Twist a wire as shown and use it as a pointer.Install the wire on upper starter bolt.

1. Pointer

A06E2BA

1

2


MMR2002_093_06_02A.FM 06-02-5

6. With the TDC gauge indicating specified timing,scribe a mark on drive pulley inner half in linewith pointer end.

TYPICAL1. TDC gauge indicating specified timing

1. Timing mark in line with pointer end

Checking Ignition TimingUse timing light (P/N 529 031 900).

TIMING LIGHT (P/N 529 031 900)

To check the ignition timing, refer to illustration andproceed as follows:

1. Connect the timing light pick-up to a spark plugcable.

Connect a digital induction type tachometer (P/N529 014 500).

TACHOMETER (P/N 529 014 500)

WARNING

Place ski tips against a wall, raise rear of vehi-cle on a stand, so that track does not contactthe ground. Do not allow anyone in front of orbehind the vehicle while engine is running.Keep clear of track and do not wear loose cloth-ing which can get caught in moving parts.


06-02-6 MMR2002_093_06_02A.FM

2. Start the engine and point timing light on timingmark. Bring engine to 3500 RPM for a brief in-stant.

The timing mark must be aligned with pointer end.If such is not the case, note if timing is retarded oradvanced. Tolerance is ± 1°.

TIMING RETARDED BY ABOUT 2°

TIMING ADVANCED BY ABOUT 2°

Changing TimingTiming can only be changed using the programmer(P/N 529 035 718).Connect 9-volt adaptor (P/N 529 035 675) to MPEM.


MMR2002_093_06_02A.FM 06-02-7

Connect MPEM programmer to DESS post.Turn on programmer then enter password.From main menu select no. 3. INFO VEHICLE.

Vehicle information is transferred from MPEM toprogrammer.

NOTE: In fact the programmer takes a copy of allvehicle parameters scribed in MPEM. This copywill be modified within the programmer thentransferred to the MPEM.Select no. 4. ENGINE PARAMETER.

Select no. 1 TIMING ADJUSTMENT.

Press ENTER.

Now the display shows the engine timing correctionfactor that is programmed in the MPEM. In the fol-lowing example timing correction factor is no. 4.

Press any key.Select YES using the key .

Press ENTER.

Select a timing correction factor corresponding tocorrection needed.Example: Timing mark as verified with a timinglight at 3500 RPM was too early by 2°. The correc-tion factor programmed is no. 4.

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# ! # ! " & ! ! # % '

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! ! # ( ) * +

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! ! # ( ) * + ! ! # ( ) * +


06-02-8 MMR2002_093_06_02A.FM

Select correction factor no. 5. This will retard thetiming by 2° because the difference between cor-rection factor no. 4 and no. 5 is - 2° (passing from1° to - 1°).

Press ENTER.

Press ENTER.

The display confirms that correction factor hasbeen changed to no. 5.Press any key.

If the new correction factor selected above is thegood one select NO and press ENTER. Otherwiseselect YES to choose an other correction factor.

Press MENU.Scroll to no. 7 SAVE AND QUIT.

Press ENTER.

IGNITION CORRECTION FACTOR

CORRECTION FACTORPROGRAMMED IN MPEM

IGNITION TIMING CORRECTION

2 3°

3 2°

4 1°

1 0°

5 - 1°

6 - 2°

7 - 3°

8 - 4°

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MMR2002_093_06_02A.FM 06-02-9

Press ENTER.

During a very short period of time the followingmessage will appear.

After the programmer has verified, following mes-sage will appear.

Press any key.

Press any key.

Unplug 9-volt adaptor.

A00A42A

T R A N S F E RP G M R M P E M

!

!

O P E R A T I O NS U C C E S S F U L L

P R E S S A N Y K E Y. . .

A00A3EA

I F T E R M I N A T E DY O U C A N U N P L U G


A00A3FA

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Section 06 ELECTRICALSubsection 03 (SPARK PLUGS)

MMR2002-094_06_03A.FM 06-03-1

SPARK PLUGS 0NGK SPARK PLUGAll Models

NGK SPARK PLUG NUMBERING SYSTEMBombardier uses NGK brand spark plugs on all itssnowmobile models.The heat range identification system is:

Low number hot plug

High number cold plug


06-03-2 MMR2002-094_06_03A.FM

DESIGN SYMBOLS USED IN NGK SPARK PLUGS

%


MMR2002-094_06_03A.FM 06-03-3

DISASSEMBLYFirst unscrew the spark plug 1 turn.Clean the spark plug and cylinder head with pres-surized air, then completely unscrew.

HEAT RANGEThe proper operating temperature or heat range ofthe spark plugs is determined by the spark plugability to dissipate the heat generated by combus-tion.The longer the heat path between the electrodetip to the plug shell, the hotter the spark plug op-erating temperature will be — and inversely, theshorter the heat path, the colder the operatingtemperature will be.A cold type plug has a relatively short insulatornose and transfers heat very rapidly into the cylin-der head.Such a plug is used in heavy duty or continuoushigh speed operation to avoid overheating.The hot type plug has a longer insulator nose andtransfers heat more slowly away from its firingend. It runs hotter and burns off combustion de-posits which might tend to foul the plug duringprolonged idle or low speed operation.

1. Cold2. Hot

CAUTION: Severe engine damage might occur ifa wrong heat range plug is used.A too hot plug will result in overheating and pre-ignition, etc.A too cold plug will result in fouling (shorting thespark plug) or may create carbon build up whichcan heat up red-hot and cause pre-ignition or det-onation.

FOULINGFouling of the spark plug is indicated by irregularrunning of the engine, decreased engine speed dueto misfiring, reduced performance, and increasedfuel consumption. This is due to a loss of compres-sion. Other possible causes are: prolonged idling, orrunning on a too rich mixture due to a faulty carbure-tor adjustment or incorrect fuel and/or fuel mixing.The plug face of a fouled spark plug has either a drycoating of soot or an oily, glossy coating given by anexcess either of oil or of oil with soot. Such coatingsform a conductive connection between the centerelectrode and ground.

SPARK PLUG ANALYSIS

1. Overheated (light grey)2. Normal (brownish)3. Fouled (black)

The plug electrode and piston dome reveal the con-dition of the engine, operating condition, methodof driving and fuel mixture. For this reason it is ad-visable to inspect the spark plug at regular inter-vals, examining the plug electrode and the pistondome.

WARNING

Whenever using compressed air, always wearprotective eye wear.


06-03-4 MMR2002-094_06_03A.FM

SPARK PLUG INSTALLATIONPrior to installation make sure that contact surfac-es of the cylinder head and spark plug are free ofgrime.CAUTION: Do not adjust electrode gap of sparkplug BR9ECS.1. Using a wire feeler gauge, set electrode gap ac-

cording to TECHNICAL DATA.2. Apply anti-seize lubricant (P/N 293 800 070) over

the spark plug threads to prevent possible seizure.3. Hand screw spark plug into cylinder head and tight-

en with a torque wrench and a proper socket.

1. Proper socket2. Improper socket

SPARK PLUG TIGHTENING TORQUE

MODELS SPARKPLUGS

TORQUEN•m (lbf•ft)

All models NGK 27 (20)

Section 06 ELECTRICALSubsection 04 (BATTERY)

MMR2002_095_06_04A.FM 06-04-1

BATTERY 0GENERALAbsorbed Glass Mat (AGM) battery (YTX20L-BS,P/N 515 175 759) is used for the SKI-DOO snow-mobiles. AGM battery is sealed, non-spillable andmaintenance free.

REMOVALAll Models

Unfasten the strap and remove battery guard.Slide off the rubber boot from the RED cable.Disconnect the BLACK negative cable first fol-lowed by RED cable and remove battery.

1. Rubber boot for RED positive cable terminal2. Battery guard3. Strap

CAUTION: Should any electrolyte spillage oc-cur, immediately wash off with a solution ofbaking soda and water to prevent damage tovehicle components.

CLEANINGClean the battery, battery casing, cables and batteryposts using a solution of baking soda and water.Remove corrosion from battery cable terminalsand battery posts using a firm wire brush. Batterytop should be cleaned by soft brush and anygrease-cutting soap or baking soda solution.

INSPECTIONVisually inspect battery casing for cracks, leaks orother possible damage. Discoloration, warping orraised top, indicates that battery has overheatedor been overcharged. If casting is damaged, re-place battery and thoroughly clean battery tray andclose area with water and baking soda.

Inspect battery posts for security of mounting.

BATTERY CHARGE TESTING

Voltmeter TestThe sealed and maintenance free battery has tobe tested with a voltmeter.Battery testing requires a voltmeter that can mea-sure DC voltage. Connect a voltmeter parallel tothe circuit being tested, observing polarity; other-wise, wrong voltmeter reading will appear.There are two types of battery tests: unload andload.An unload test is made on a battery without dis-charging current. It‘s simplest and used mostcommonly.An load test is more accurate with precise reading.

WARNING

Battery BLACK negative cable must alwaysbe disconnected first and connected last.

WARNING

Never charge or boost battery while installedon vehicle.

WARNING

Should the battery casing be damaged, weara suitable pair of non-absorbent gloves whenremoving the battery by hand.


06-04-2 MMR2002_095_06_04A.FM

Unload TestCheck charge condition by using voltmeter. Volt-meter readings appear instantly to show the stateof charge.

Load TestThis is the best test of battery condition under astarting load. Use a load testing device that has anadjustable load.Apply a load of 3 times the ampere-hour rating ofthe battery. At 14 seconds into the test, check bat-tery voltage; if battery is in good condition, it willhave at least 10.5 Vdc.

BATTERY STORAGEDisconnect and remove battery from the vehicle.The battery must always be stored in fully chargedcondition.Clean battery terminals and cable connections us-ing a wire brush. Apply a light coat of dielectricgrease (P/N 293 550 004) or petroleum jelly on ter-minals.Clean battery casing using a solution of bakingsoda and water. Rinse battery with clear water anddry well using a clean cloth.Charge the battery every month if stored at tem-perature below 15°C (60°F).Charge the battery every two week if stored attemperature above 15°C (60°F).

ACTIVATION OF NEW BATTERY

Remove the aluminum sealing tape from the bat-tery. Remove the electrolyte container from theplastic bag and detach the strip of caps. Keep thestrip for battery plugs.

1. Electrolyte container2. Strip of caps3. Aluminum sealing tape

Fill the battery with electrolyte by placing the elec-trolyte container upside down, with the six sealedchambers in the battery‘s six filler pors.Push the container down firmly enough to breakthe seals. The electrolyte should start to emptyout.

WARNING

Connect the positive lead to the battery‘s pos-itive terminal, and the negative lead to thenegative terminal.

STATE OF CHARGE VOLTAGE READING

100%75% - 100%50% - 75%25% - 50%0% - 25%

12.8 - 13.0 V12.5 - 12.8 V12.0 - 12.5 V11.5 - 12.0 V11.5 V or less

WARNING


WARNING

Do not puncture or otherwise try to open thesealed chambers of the container.

WARNING

Do not lift or tilt the container while filling bat-tery.


MMR2002_095_06_04A.FM 06-04-3

Make sure air bubbles coming up should be seenfrom all six filler ports. If not, tap down on the con-tainer with hand two or three times.

The electrolyte should completely empty in to thebattery in about 20 minutes. If there is still somein the container, tap it again a few times. Removethe container. After adding electrolyte, a new bat-tery is approximately 80% charged.Seal filler ports with the strip of caps by pressingdown with both hands until flush with battery top.

1. Strip of caps

Allow battery to stand 30 minutes to one hourmaximum before charging.

Charging time of the battery is 15 hours using 1 A.charger (P/N 529 035 773) for first initial charge.Charging rate will vary depending on type of charg-er used. CAUTION: If battery gets hot to the touch, stopcharging and allow it to cool before continuing.Allow battery to rest 1 - 2 hours after charging be-fore checking voltage reading.Voltage reading should be a minimum of 12.8 - 13.0volts after charging. If open circuit voltage reading(with voltmeter) is not 12.8 volts or more - repeatcharging cycle.The following table shows the charging time of thebattery require.

TIPS FOR CHARGING A USED BATTERYCAUTION: Prior to charging the battery, alwaysremove it from the vehicle to prevent electro-lyte spillage.For best results, battery should be charged whenthe electrolyte and the plates are at room temper-ature. A battery that is cold may not accept currentfor several hours after charging begun.

WARNING

Do not squeeze the electrolyte container.

WARNING

Never topped off Absorbed Glass Mat (AGM)battery during its life. Never pry off sealingcaps.

*

WARNING

Do not open the sealed caps during charging.

CONSTANT CURRENT CHARGER (1.0 A)

STATE OF CHARGE CHARGING TIME (hours)

100%75% - 100%50% - 75%25% - 50%0% - 25%

None3 - 65 - 1113 - 15

20

BATTERY CHARGER 1.5 A(P/N 529 035 772)

STATE OF CHARGE CHARGING TIME (hours)

100%75% - 100%50% - 75%25% - 50%0% - 25%

None1 - 32 - 55 - 1010 - 15


06-04-4 MMR2002_095_06_04A.FM

Do not charge frozen battery. If the battery chargeis very low, the battery may freeze. If it is suspect-ed to be frozen, keep it in a heated area for about2 hours before charging.

Time required to charge a battery will vary depend-ing some factors such as:– Battery temperature: Charging time is increased

as the temperature goes down. The current ac-cepted by a cold battery will remain low. As thebattery warms up, it will accept a higher rate ofcharge.

– Type of charger: Battery chargers vary in theamount of voltage and current that they cansupply. Therefore, time required for the batteryto begin accepting measurable current will alsovary.

Charging a Very Flat or Completely Discharged BatteryUnless this procedure is properly followed, a goodbattery may be needlessly replaced.– Measure the voltage at the battery posts with

an accurate voltmeter. If it is below 10 volts, thebattery will accept current at very low rate, interm of milliamperes. It could be some time be-fore the charging rate increases. Such low cur-rent flow may not be detectable on some charg-er ammeters and the battery will seem not toaccept any charge.

– Only for this particular case, set the charger toa high rate.

NOTE: Some chargers have a polarity protectionfeature which prevents charging unless the charg-er leads are connected to the correct battery ter-minals. A completely discharged battery may nothave enough voltage to activate this circuitry, eventhough the leads are connected properly. This willmake it appear that the battery will not accept acharge. Follow the charger manufacturer’s instruc-tion telling how to bypass or override this circuitryso that the charger will turn on and charge a low-voltage battery.– Since the battery chargers vary in the amount

of voltage and current they provide, the timerequired for the battery to accept measurablecharger current might be up to approximately10 hours or more.

– If the charging current is not up to a measurableamount at the end of about 10 hours, the bat-tery should be replaced.

– If the charging current is measurable before theend or at the end of about 10 hours, the batteryis good and charging should be completed inthe normal manner as specified in Activation ofa new battery.

– It is recommended that any battery rechargedby this procedure be load tested prior to return-ing it to service.

BATTERY CHARGING EQUIPMENTThe battery charger should have an adjustablecharging rate. Variable adjustment is preferred,but a unit which can be adjusted in small incre-ments is acceptable.The battery charger must be equipped with an am-meter capable of accurately measuring current ofless than one ampere.If the present charger is not adjustable to the prop-er current values, a rheostat can be connected inseries with the battery to provide adjustment. 12ohm, 50 watt rheostat, such as OHMITE — 0314or MALLORY 50K 12P, are available from electron-ic parts supply shops and they are suitable for usewith most chargers if the peak current is to be heldbelow 2 A.If you need an accurate ammeter, we recommendthe use of: SHURITE — 5202 (0 to 3 A) or — 5203(0 to 5 A) available from electronic parts supplyshops.

1. Charger2. Rheostat 12 Ω 50 W3. Ammeter4. Battery

WARNING

Do not place battery near open flame.

A00E0DA

1

2

3 4


MMR2002_095_06_04A.FM 06-04-5

For a service application and a permanent installa-tion, both ammeter and rheostat can be built intoa small box adjacent to your charger.CAUTION: Adequate ventilation MUST be pro-vided to cool the rheostat.

INSTALLATION OF BATTERYAll Models

Connect RED positive cable it to positive batteryterminal. Connect RED wire (coming from 30 Afuse).Connect BLACK negative cable LAST.

Cover the RED positive terminal with rubber boot.Put the battery guard and fasten the strap.Apply silicone dielectric grease (P/N 293 550 004)on battery posts and connectors.

WARNING

Battery BLACK negative cable must alwaysbe disconnected first and connected last.

WARNING


Section 06 ELECTRICALSubsection 05 (ELECTRIC STARTER)

MMR2002_096_06_05A.FM 06-05-1

ELECTRIC STARTER 0Fan Cooled ZX Series with Electric Starting


06-05-2 MMR2002_096_06_05A.FM

Liquid Cooled ZX Series with Electric Starting

#./0123.4

#./0123.4

#./0123.4

567897:;<=9>?9


MMR2002_096_06_05A.FM 06-05-3

REMOVALFan Cooled ZX Series Starter

– Disconnect BLACK ground cable from battery.– Disconnect RED positive cable from battery.

– Remove tuned pipe.– Disconnect RED cable and RED/GREEN wire

from starter relay.– Disconnect ground cable from MAG side bracket.– Unbolt starter from PTO side bracket.– Unbolt MAG side bracket from engine.– Remove starter from engine.

TYPICAL

Liquid Cooled ZX Series

– Disconnect BLACK ground cable from battery.– Disconnect RED positive cable from battery.

– Remove tuned pipe.– Disconnect RED cable from starter.– Disconnect ground cable from starter.– Unbolt and remove starter from engine.

DISASSEMBLYFan Cooled ZX Series

Disconnect bare wire linking starter and relay.Remove nuts no. 16 then relay no. 10 by liftingand pulling to disengage from drive lever no. 15.Unscrew starter screws (long) no. 1 then pull yokeno. 8 with end frame no. 2 to separate from drivehousing no. 17.Pull armature no. 9 with drive lever no. 15.Remove insulator no. 4 then brush springs no. 7being careful not to lose them since they will beprojected out.Pull brush holder no. 5 from yoke no. 8.Insert blade of a small screwdriver between stopcollars.

TYPICAL

Twist screwdriver to separate stop collars no. 12thus giving access to circlip no. 13.Remove outer collar, circlip then inner collar.Remove overrunning clutch no. 11.Check the wear on bushing no. 18 by measuringthe amount of radial play between the armatureshaft and the bushing.The radial play should not exceed 0.20 mm (.008 in).If greater, replace the bushing. To replace, pressout the old one toward bushing cover and press ina new one with a bushing pusher. The correct sizeof the bushing pusher to use is given on next illus-tration.

WARNING

Always disconnect ground cable first and con-nect last.

WARNING


A19E01A


06-05-4 MMR2002_096_06_05A.FM

CAUTION: Support drive housing adequatelyto prevent damage when pressing bushing.

BUSHING PUSHERA. 16 mm (5/8 in) diameterB. 13 mm (1/2 in)C. 11 mm (7/16 in)D. 11.0 mm (.433 in)

1. Press-in2. Bushing pusher3. Bushing4. Drive housing

Install bushing cover no. 19 then, using a punch,stake bushing cover in place.

1. Stake bushing cover2. Support

3, Bushing (end frame)Check the wear on bushing no. 3 by measuringthe amount of radial play between the armatureshaft and the bushing.The radial play should not exceed 0.20 mm (.008 in).If greater, replace bushing as follows:Using a 12 mm tap, cut threads into bushing sothat the tap contacts the end frame. Continue torotate tap until the bushing comes free.

1. Turn until bushing goes out2. 12 mm tap

To install new bushing, use the same bushingpusher as for drive housing bushing installation.

%

%

A19E02A

1

2


MMR2002_096_06_05A.FM 06-05-5

6, BrushTo replace brush no. 6, proceed as follows:Cut brush wire close to connector at the weldedportion.

1. Cut close to connector

Remove burrs with a file on the remaining weldedportion.CAUTION: Be careful not to damage plasticportion of yoke.Place spare brush plate edge against yoke connec-tor edge (welded portion).Crimp plate over yoke connector with a pair of pliers.

1. Plate edge2. Yoke connector3. Crimp4. Spare brush

Solder the crimped portion.CAUTION: Do not overheat and quickly per-form soldering to prevent solder from flowingto the brush through the wire. Preferably use aheat sink.


Before disassembling, trace index marks on start-er housing no. 10 and starter housing assemblyno. 8 to ease further assembly.Remove starter through bolts no. 17. Separateend frame housing no. 14 from starter housingno. 10. Withdraw starter housing from armatureno. 11.Brush holder no. 13 can be removed from end framehousing no. 14 by disconnecting the end frame at-tached brush from brush holder no. 13.Check the radial play between the armatureshaft and end frame bearing. Replace the endframe bearing or replace starter. If parts are ingood condition then coat with 10W30 engine oilbefore reinstalling them.Push back the collar no. 3 using a screwdriver.Remove snap ring no. 2. Remove collar no. 3 andspring no. 4.

1. Collar2. Snap ring

Turn starter clutch no. 6 clockwise to remove itfrom armature assembly no. 11.Pull housing from armature.

A19E06A

1

2

3

4


06-05-6 MMR2002_096_06_05A.FM

CLEANING AND INSPECTIONAll Models

CLEANINGCAUTION: Yoke ass’y and drive unit assemblymust not be immersed in cleaning solvent.Clean brushes and holders with a clean clothsoaked in solvent. Brushes must be dried thor-oughly with a clean cloth.Blow brush holders clean using compressed air.

Remove dirt, oil or grease from commutator usinga clean cloth soaked in suitable solvent. Dry wellusing a clean, dry cloth.Clean engine ring gear teeth and drive unit (clutch).NOTE: Bushings or bearings must not be cleanedwith grease dissolving agents.Immerse all metal components in cleaning solu-tion. Dry using a clean, dry cloth.

INSPECTIONAll Models

ArmatureNOTE: An ohmmeter may be used for the follow-ing testing procedures, except for the one con-cerning the shorted windings in the armature.Check the commutator for roughness, burnt orscored surface. If necessary, turn the commutatoron a lathe, enough to remove grime only.Check the commutator for mica depth. If thedepth is less than 0.20 mm (.008 in), undercut themica. Be sure that no burrs are left and no copperdust remains between the segments after the un-dercutting operation is completed.

1. Commutator undercut 0.20 mm (.008 in)

Check the commutator out-of-round conditionwith V Blocks and an indicator. If the commutatorout-of-round is more than 0.40 mm (.016 in), thecommutator should be turned on a lathe.Check commutator outer diameter. If less thanspecified value, replace.

Test for Ground Circuit in the Armature:Use growler test probes. Check between arma-ture core and the commutator bars. If growlerlamp turns on, bars are grounded. If so, replacearmature.

1. Test probes2. Commutator bars

WARNING

Always wear safety glasses when using com-pressed air.

MODEL WEAR LIMIT

ZX SERIES 27 mm (1.063 in)

*


MMR2002_096_06_05A.FM 06-05-7

Test Armature for Shorted Winding:When the armature is rotated in the growler witha steel strip (hacksaw blade) held above it, thestrip will vibrate over that area of the armaturewhich has short circuit. Replace armature if so.

1. Steel strip (hack-saw blade)2. Growler

Test the Armature for Open Circuit:Use growler test probes. Place one test probe ona commutator bar and the other test probe on theneighboring bar. Repeat this operation for all bars,moving one test probe at a time. If the growlerlamp does not turn on, the armature circuit be-tween these 2 bars is opened. The armature shouldbe replaced or repaired; open circuits most oftenoccur at the commutator riser where coils are sol-dered. (Burnt commutator bars are usually an indi-cation of an open-circuit armature coil).

Field Windings and Brushes

Fan Cooled ZX Series

Test the Field Winding for Open Circuit:Use growler test probes. Place one test probe onthe negative brush and the other test probe on theyoke. If growler lamp does not turn on, the fieldwinding has an open-circuit. The yoke has to berepaired or replaced.

1. Test probes

Check the dynamic brake winding for open circuitby placing one test probe on the positive brushand the other probe on the negative brush.If growler lamp does not turn on, the winding cir-cuit is open-circuit and the yoke has to be repairedor replaced.

Brush Holder

All Models

Check the brush holder for insulation using growl-er test probes. Place one test probe on the insu-lated brush holder and the other test probe on thebrush holder plate. If the growler lamp turns on,the brush holder has to be repaired or replaced.

Brush LengthMeasure brush length. If less than the specifiedvalue, replace them.

MODEL

LENGTH

NEW WEARLIMIT

ZX SERIES 10 mm(.400 in)

6 mm(.236 in)


06-05-8 MMR2002_096_06_05A.FM

TYPICAL1. New2. Wear limit

End Housing BearingLiquid Cooled ZX Series

Check the mica insulation of the positive brushand also the roller bearing condition.

1. Roller bearing2. Positive brush

Overrunning Clutch

All Models

The pinion of the overrunning clutch should turnsmoothly in a clockwise direction, and should notslip in a counterclockwise direction. If defective,replace.Check the pinion teeth for wear and damage. Ifdefective, replace.

RELAYInspect connections and clean as necessary. Relaycondition can be checked with an ohmmeter. Installtest probes on large connectors of relay when it isactivated (+ on RED/GREEN wire and – on relaybody).IMPORTANT: No current must be present on largecables when using ohmmeter, otherwise metercould be damaged.

ASSEMBLYFan Cooled ZX Series

Prior to assembling, coat sliding surfaces andmoving parts on armature shaft splines, overrun-ning clutch, relay plunger, drive lever and bushingswith 10W30 engine oil.Proceed as follows for assembling.Secure drive housing in a vise.CAUTION: Do not overtighten since housingmight be damaged.Install overrunning clutch onto armature shaft. In-sert inner collar onto shaft. Install a new circlip.CAUTION: Always install a new circlip when ser-vicing.Insert outer collar being careful to match protru-sions with notches of collars.Using a pair of pliers on each side of stop collars,squeeze evenly until collars sit over circlip.

1. Squeeze evenly


MMR2002_096_06_05A.FM 06-05-9

Install thrust washer against outer stop collar.Place drive lever onto overrunning clutch then in-sert into drive housing.

1. Install on overrunning clutch2. Install thrust washer

Slide yoke over armature.Install brush holder then brushes in their housings.Insert springs as follows: place one end of springagainst brush, compress, then push the other endof spring onto its housing. Repeat for remainingsprings.

1. This end first2. Push this end to complete

Secure insulator over brushes and springs. Prop-erly install end frame and tighten screws.Insert relay plunger inside of drive lever fork andsecure to drive housing.Connect starter bare wire to relay.NOTE: Connect this wire on the shorter relaystud.

TYPICAL1. Shorter stud2. Bare wire


Reverse the order of disassembly to reassemblestarter. However, attention should be paid to thefollowing operations.Prior to assembling, coat sliding surfaces on arma-ture shaft splines, overrunning clutch and bushingwith 10W30 engine oil.After placing collar no. 3 on armature shaft no. 11,fit new snap ring no. 2 on armature shaft, thenmake sure that it is properly secured.Slide collar no. 3 over snap ring no. 2 and securein place by punching it at two or three places.

1. Armature shaft2. Snap ring3. Collar4. Punch

*

A19E09A

12


06-05-10 MMR2002_096_06_05A.FM

Starter Housing Assembly and Starter HousingAlign previously traced indexing marks.

TYPICAL1. Aligned indexing marks

Open brushes and slide over commutator.Align end frame locating notch with yoke locatingprotrusion and properly sit brush holder no. 13into housing no. 14.

1. Brush holder

To ease end frame installation, retain brush holderwith a small screwdriver while installing armatureassembly.CAUTION: Make sure to place two end housingson a flat surface before tightening the throughbolts.CAUTION: Make sure end frame fits perfectlyon yoke.

INSTALLATIONFan Cooled ZX Series

Install carriage bolt in MAG side bracket before in-stalling starter.

Make sure that starter and engine mating surfacesare free of grime. Serious trouble may arise if start-er is not properly aligned.CAUTION: Make sure that both starter bracketsare well seated against engine crankcase andstarter before torquing all retaining bolts.Torque all M8 bolts to 24 ± 4 N•m (17 ± 3 lbf•ft).Torque all M5 bolts to 5 ± 0.5 N•m (44 ± 5 lbf•in).CAUTION: Before checking engaging depth ofstarter pinon teeth, make sure that battery ca-bles are disconnected.NOTE: Check proper engaging depth of starterpinion teeth to ring gear teeth (see illustration). In-stall hardened washers (P/N 503 007 900) be-tween engine and starter supports accordingly.CAUTION: Always install new self-locking fas-teners.


MMR2002_096_06_05A.FM 06-05-11

1. Screwdriver pulling starter pinion2. Ring gear3. No excessive backlashA. 0.5 to 1.5 mm (.020 to .060 in)

Connect the RED battery cable and the RED wireto the large terminal of the relay. Connect RED/GREEN wire to small terminal of relay.


– Use new teflon washers on the 3 bolts retainingstarter to engine.

– Torque the bolts to 28 ± 1N•m (20 ± 1 lbf•ft).– Make sure that starter and engine mating sur-

faces are free of grime. Serious trouble mayarise if starter is not properly aligned.

– Connect the RED battery cable and the REDwire to the large terminal of the starter.

– Torque large terminal nut to 7 N•m (62 lbf•in).

– Connect ground cable to the starter with starwasher in between.

– Torque ground cable connecting bolt to 11 N•m(97 lbf•in).

WARNING


Section 06 ELECTRICALSubsection 06 (TESTING PROCEDURE)

MMR2002_097_06_06A.FM 06-06-1

TESTING PROCEDURE 0GENERALThe following chart gives the engine types with theirimplemented system.

➀ RER Dual Trigger Coil CDI (twin cylinder)The RER dual trigger coil CDI system has an igni-tion coil integrated to the MPEM which is mount-ed on oil reservoir.MPEM is connected to a single ignition generatorcoil via a 3-connector housing (BLACK and REDwires).MPEM is programmed to recognize a signal sent bythe switch located on snowmobile console.When switch is activated, MPEM cuts off ignitionand engine rev drops at approximately 450 RPM.MPEM fires a spark at a great advance creating athrust which reverses engine rotation.Second trigger coil located on crankcase takesover to produce spark in reverse rotation.A safety device is incorporated to MPEM prevent-ing it from reading any signal coming from reverseswitch at following engine revs.Below 1000 RPM and above 3500 RPM = No re-verse signal.

MODELS IGNITIONSYSTEM

CHARGINGSYSTEMOUTPUT

ZX Fan Cooled ➀ RER dual

trigger coil CDI (twin cylinder)

300

ZX Manual Start Liquid Cooled

➁ BOMBARDIER 290 W 290

ZX Electric Start Liquid Cooled

➂ BOMBARDIER DC 360 W 360


06-06-2 MMR2002_097_06_06A.FM

➀ RER DUAL TRIGGER COIL CDI SYSTEM (TWIN CYLINDER)1. MPEM2. Trigger coils3. 11-DC housing (BLACK and RED wires)

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MMR2002_097_06_06A.FM 06-06-3

Multi-Purpose Electronic Module (MPEM) Connections

➁ BOMBARDIER 290 W MPEM 1. Generating coil and ground,6-DB housing2. Trigger coil, 6-DC housing3. DPM solenoid, 6-DG housing4. Atmospheric pressure nipple5. High tension coil, 6-DD housing6. Air temperature sensor, 6-DE housing7. DESS, ignition and kill switches, DESS pilot lamp, 6-DA housing

➂ BOMBARDIER 360 W MPEM 1. Trigger coil, 11-DE housing2. DPM solenoid, 11-DD housing3. Atmospheric pressure nipple4. High tension coil, 11-DC housing5. Air temperature sensor, 11-DB housing6. DESS, ignition and kill switches, DESS pilot lamp, 11-DA housing

Liquid Cooled Models

Checking Calibration ProgramCAUTION: Do not interchange MPEM from amodel to an other. Even if the P/N stamped onthe MPEM is the same, calibration programmay be different. When ordering a new MPEMalways refer to appropriate model parts cata-log. The service P/N published in parts catalogsare the ones with the good calibration programaccording to model.

With Engine RunningIf the below mentioned tool is not available startengine. Turn on programmer then enter password.Increase engine speed to 2000 - 2500 RPM then fol-low the same procedure as With Engine Stopped.CAUTION: Engine must run till the end of theprocedure.When data are being transferred, you must revthe engine at 2000 - 2500 RPM and make sureconnection between programmer and vehicleis good.IMPORTANT: In following procedure each time

Trs symbol appears, make sure to rev enginebetween 2000 and 2500 RPM.Engine will misfire while vehicle information is be-ing transferred from MPEM to programmer. If en-gine stalls, restart it, keep engine speed at 2000 -2500 RPM and select no. 3 VEHICLE INFO again.

With Engine Stopped

290 W Models

Connect 9-volt adaptor (P/N 529 035 675) to MPEM.


06-06-4 MMR2002_097_06_06A.FM

360 W Models

Ensure the switch on the bypass wire is in the OFFposition. Refer to decal on switch.

1. OFF

Remove both 20 A fuses.

1. 20 A fuses

Connect the flat terminal of bypass wire in one ofthe 20 A fuse holders where a RED/BROWN wirecomes in. Look at the back on one of 20 A fuse hold-ers for a RED/BROWN wire.NOTE: Both 20 A fuse holders have a RED/BROWN.Either one may be used.

TYPICAL — WIRES AND FUSE HOLDERS MAY BE INVERTED1. 20 A fuse holders2. RED/BROWN wires

TYPICAL — FLAT TERMINAL CONNECTED TO A RED/BROWN WIRE

Connect the bypass wire alligator clip to the posi-tive post of vehicle battery.Once bypass wire is properly in place, put the by-pass switch to the ON position.As switch gets turned on a beeping signal fromthe reverse buzzer will be heard. This indicates thatthe MPEM is now ready to transfer programmingoperations.

!

'


MMR2002_097_06_06A.FM 06-06-5

If no beeping signal is heard when switch is turnedon, check if either the headlight or the taillight ison. If this is the case, then the bypass wire wasincorrectly installed. Turn switch off and re-verifythat the flat terminal of bypass wire is connectedto a RED/BROWN wire.Once MPEM calibration program checking isdone, turn switch off. Remove alligator clip frombattery positive post. Remove flat terminal fromfuse holder. Reinstall 20 A fuses.Turn on programmer then enter password.From main menu select no. 3. VEHICLE INFO; Trs.

Vehicle information is transferred from MPEM toprogrammer.

NOTE: In fact the programmer takes a copy of allvehicle parameters scribed in MPEM. This copywill be modified within the programmer then trans-ferred to the MPEM.Select no. 4. ENGINE PARAMETER.

Select no. 3 CALIBRATION.

Press ENTER Trs.Following screen appears temporarily:

And then following screen showing the actual cal-ibration number in the MPEM.

Check for proper calibration number. See table be-low.Select NO and press ENTER.Press MENU twice; Trs then turn off program-mer, unplug it from MPEM. Remove 9-volt adaptor.Stop engine when using With Engine Running pro-cedure.

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06-06-6 MMR2002_097_06_06A.FM

Changing MPEM Calibration ProgramProceed the same as for checking MPEM calibra-tion but select YES to MODIFY? and press ENTERfollowing screen appears:

Enter new calibration number and press ENTER,following screen appears:

Simultaneously with the following operation atransfer will occur; Trs. At this point, be ready torev the engine so it won’t fall below the 2000 RPMmark when not using 9-volt adaptor.Plug-in the desired calibration cartridge (specialred key) onto the programmer post, the followingscreens will appear temporarily:

MODEL

CALIBRATEDMPEM P/N

(HARDWARE AND

SOFTWARE)

CALIBRATIONPROGRAMNUMBER

(SOFTWARE)

MPEM P/N(HARDWARE)

MX Z 500 Sport/Trail 512 059 448 512 059 449 512 059 410

MX Z 500 Sport R 512 059 450 512 059 559 512 059 412

MX Z 600 Sport/Trail 512 059 451 512 059 606 512 059 410

MX Z 600 Sport R 512 059 453 512 059 452 512 059 412

MX Z 600 Adrenaline R/ Renegade R 512 059 455 512 059 452 512 059 413

MX Z 700 Sport/Trail 512 059 456 512 059 608 512 059 410

MX Z 700 Sport R 512 059 458 512 059 457 512 059 412

Legend 700 GS, Grand Touring 700 GS 512 059 459 512 059 457 512 059 415

MX Z 700 Adrenaline R/Renegade R 512 059 460 512 059 457 512 059 413

MX Z 800 Sport/Trail 512 059 461 512 059 462 512 059 410

MX Z 800 Sport R 512 059 463 512 059 605 512 059 412

Summit Sport 700 512 059 464 512 059 609 512 059 411

MX Z 800 Adrenaline R/ Renegade R 512 059 466 512 059 605 512 059 412

Legend 500 Sport, Grand Touring 500 Sport 512 059 467 512 059 559 512 059 414


Legend 600 GS/SE, Grand Touring 600 GS/SE

512 059 469 512 059 452 512 059 415


Legend 800 SE, Grand Touring 800 SE 512 059 471 512 059 618 512 059 415

Summit 800 Sport/X/ H.M./H.M. X 512 059 474 512 059 604 512 059 411

MX Z 380 F, Legend 380 F, Grand Touring 380 F

512 059 518 512 059 521 512 059 941

MX Z 500 F, Legend 500 F, Grand Touring 500 F

512 059 519 512 059 522 512 059 941

Summit 500 F 512 059 520 512 059 522 512 059 337

Summit 800 Sport R 512 059 530 512 059 475 512 059 413

Summit 600 Sport 512 059 542 512 059 607 512 059 411

Summit 600 Sport R 512 059 543 512 059 544 512 059 413

Summit 700 Sport R 512 059 531 512 059 465 512 059 413

MX Z 600 512 059 593 512 059 606 512 059 591

MX Z 600 R 512 059 594 512 059 452 512 059 592

MX Z 700 512 059 595 512 059 608 512 059 591

MX Z 700 R 512 059 596 512 059 457 512 059 592

MX Z 800 512 059 597 512 059 462 512 059 591

MX Z 800 R 512 059 598 512 059 618 512 059 592

Summit 800 X R/ H.M. R/ H.M. X R 512 059 616 512 059 617 512 059 413

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MMR2002_097_06_06A.FM 06-06-7

Press any key, display will show followed by nextscreen:

Press MENU twice, following screen will show:

After procedure is completed, ensure engine idlespeed with engine hot is 1800 - 2000 RPM.Stop the engine.

ACCESS TO MPEM CONNECTORSFan Cooled Models

To ease electrical readings on MPEM connectors,connector cap must be removed.Hold connector in hands then lift both tabs to re-move connector cap.

LIFT TABS TO REMOVE CAP

Insert multimeter probes into connector.

TEST USING MULTIMETER PROBES

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06-06-8 MMR2002_097_06_06A.FM

SYSTEM TESTING

IGNITION SYSTEM TESTING SEQUENCEIn the case of ignition problems, check the follow-ing in the prescribed order until the problem canbe solved.1. Sparking/spark plug condition.2. Electrical connectors.3. Ignition switch, DESS switch or tether cut-out

switch and emergency switch.4. Ignition generator coil.5. Trigger coil.6. MPEM voltage (liquid cooled models only).7. High voltage coil (liquid cooled models only).8. Buzzer testing.

LIGHTING SYSTEM TESTING SEQUENCE1. Electrical connectors.2. Magneto output (lighting generator coil).

Testing ConditionsVoltage measurements are always taken upon vehi-cle starting. Readings when the engine is runningwill be higher than indicated range. Part tempera-ture must be approximately 20°C (68°F) (room tem-perature), otherwise readings could be distorted.

Analysis of ReadingsVoltage ReadingsWhen testing the different magneto components,it is important to take into consideration that read-ings vary according to the force applied onto themanual starter. It is therefore important to employenough force upon each trial.The reading must be 3 times within or above therange indicated in the corresponding table. If thereading is too low, the part is considered to be de-fective and must be replaced.

Resistance ReadingsPlace multimeter selector switch to Ω in order tomeasure resistance. Readings must be within theindicated range. Otherwise, the part is consideredto be defective and must be replaced. CAUTION: When taking measurements, it isuseless to try to start the vehicle since readingswould then be distorted.

Intermittent Ignition ProblemsIt is difficult to make a diagnostic in the case of in-termittent ignition problems. Thus, problems occur-ring only when the engine operating temperature isnormal must be checked in similar conditions.In most cases when problems are caused by tem-perature or vibrations, these can only be solved byreplacing parts. Most problems cannot be detect-ed when the engine is stopped.

Multiple ProblemsAs a matter of fact, more that one component canbe defective. As a result, if the problem remainsalthough a part was replaced, start over the wholeverification from the beginning in order to identifythe other defective component.

1. SPARKINGDuring this operation, it is important to use thesnowmobile spark plug and not a new one. Bringthe plug in contact with the engine. Pull rewindstarter. If no spark is produced, replace the sparkplug with a new one and do the test again.

2. ELECTRICAL CONNECTORTESTING

Make sure that none of the connectors are discon-nected.


MMR2002_097_06_06A.FM 06-06-9

3. IGNITION SWITCH, TETHERCORD SWITCH ANDEMERGENCY SWITCH TESTING

Disconnect connector housings and check resis-tance as indicated in IGNITION table.

If readings are acceptable, go on to next step.If readings are inadequate, individually check eachswitch as follows.

Ignition Switch (key, if equipped)Disconnect switch housing. Using a multimeter,check between MAG and GRD terminals if the cir-cuit is open (0.L MΩ) in operating position and if thecircuit is closed (0 Ω) in off position.

DESS Switch

Liquid Cooled Models Only

Tether Cord SwitchCheck using a multimeter by connecting probes toBLACK/GREEN and BLACK/WHITE wires. Themultimeter should indicate a closed circuit (0 Ω) inoperating position and a open circuit (0.L MΩ) in offposition.

DESS Switch WireCheck continuity (null resistance) between switchcenter terminal and WHITE/GRAY wire connector.Check continuity (null resistance) between switchside ring and BLACK/GREEN wire connector.If readings do not correspond to the above men-tioned indications, replace switch.If none of these verifications are conclusive, theproblem finds its source in the main wiring har-ness. Proceed as follows:

Fan Cooled Models Only

Tether Cord SwitchUnplug switch block connected to main wiring har-ness. Check using a multimeter by connectingprobes to 6-BC-2-M and 6-BC-1-M wires.The mul-timeter should indicate an open circuit (0.L MΩ ) inoperating position and if the circuit is closed (0 Ω )in off position.

Emergency Switch

All Models

Unplug switch block connected to main wiring har-ness. Check using a multimeter by connectingprobes to 6-HG-7-M and 6-HG-13-M wires.Themultimeter should indicate an open circuit (0.L MΩ)in operating position and if the circuit is closed(0 Ω) in off position.NOTE: For the next step, no switch must be con-nected to the main wiring harness. Disconnect all switches from the main wiring har-ness and check the continuity of each wire by con-necting probes to the end of wires of the samecolor. Repeat with all other wires. It is importantto mention that all wires of the same color withina given harness are connected together. Thesewires should therefore have a closed circuit. Onthe other hand, BLACK and BLACK/YELLOWwires must have an open circuit (0.L MΩ).Repair or replace if necessary.


06-06-10 MMR2002_097_06_06A.FM

4. IGNITION GENERATOR COILTESTING

Resistance Testing1. Disconnect housing between the magneto and

the MPEM.2. Connect multimeter probes to BLACK (or BLACK/

RED) and RED wires and measure resistance.

3. Compare readings with those appearing in theIGNITION table.

Voltage TestingWhen manually starting the engine while thespark plug is installed, the engine will tend to ac-celerate beyond the compression point. This willresult in higher magneto output power.1. Disconnect housing between the magneto and

the MPEM.2. Connect multimeter probes to BLACK (or BLACK/

RED) and RED wires and bring the selector switchto and the scale to 00.0VAC.

3. Activate the manual starter and check values in-dicated by the multimeter.

4. Repeat operation 3 times.5. Compare readings with those appearing in the

IGNITION table.

5. TRIGGER COIL TESTING

Resistance Testing1. Connect probes to WHITE/YELLOW and BLUE/

YELLOW wires from trigger coil housing.


Voltage Testing1. Connect probes to WHITE/YELLOW and BLUE/

YELLOW wires from trigger coil housing.2. Activate the manual starter and check values in-

dicated by the multimeter.3. Repeat operation 3 times.4. Compare readings with those appearing in the

IGNITION table.

V


MMR2002_097_06_06A.FM 06-06-11

6. MPEM VOLTAGE TESTINGLiquid Cooled Models Only

1. Disconnect the housing between module andhigh voltage coil.

2. Connect multimeter probes to WHITE/BLUE andBLACK wires coming out from module. Placethe selector switch to and the scale to 00.0Vac.

TYPICAL



IGNITION table.

7. HIGH VOLTAGE COIL TESTINGLiquid Cooled Models Only

Resistance Testing1. Unplug housing between high tension coil and

MPEM.2. Connect multimeter probes to WHITE/BLUE and

BLACK wires and measure resistance.


Voltage Testing1. Disconnect spark plug cap from spark plug.2. Fasten alligator clip to spark plug cable, near the

spark plug.3. Connect other multimeter wire to engine (ground),

then place selector switch to and scale to0.00Vac.

1. MAG side spark plug cable2. Connected to ground



IGNITION table.

V

V


06-06-12 MMR2002_097_06_06A.FM

8. BUZZER TESTINGUsing jumper wires, connect battery positive postto buzzer positive tab.Connect battery negative post to buzzer negativetab. See next photo.CAUTION: To avoid buzzer damage, ensure thatpolarity is respected.

TYPICAL — 12-VOLT BATTERY PLUGGED TO BUZZER

CONCLUSION If none of the above testing operations producedvalid results, it is strongly recommended to keepon testing according to the list appearing in theResistance column of the IGNITION table.Set the multimeter as indicated.

LIGHTING GENERATOR COIL VOLTAGE TESTINGNOTE: For 290 W system, the lighting generatorcoil is not part of the ignition system. It is a self-contained system used to supply current to thelighting system and to other devices working onalternating current. However, this system can betested using a multimeter.1. Disconnect round housing from engine (YEL-

LOW, YELLOW wires).2. Connect multimeter probes to YELLOW wires,

then place selector switch to and scale to0.00Vac.


4. Repeat operation 3 times.

TYPICAL

5. Compare readings with those appearing in theLIGHTING table.

CONCLUSION If none of the above testing operations producedvalid results, it is strongly recommended to keepon testing according to the list appearing in theResistance column of the LIGHTING table.Set the multimeter as indicated.

A03E21A

V


MMR2002_097_06_06A.FM 06-06-13

M: Male F: Female

NOTE: Stop switches include the ignition switch and the emergency cut-out switch.It is important to take note that voltage measurements must be taken while starting the vehicle using themanual starter.Voltages obtained upon starting are proportional to the force applied onto the manual starter. A low voltageis therefore normal under a low cranking force.Perform testing in the prescribed order and replace any parts not performing according to specifications.It is important to resume all tests when replacing a component.If not specified, the probe connecting sequence is not important.

IGNITION SYSTEM TESTING (ZX SERIES — 290 W)

PART TEST TO BE PERFORMED

WIRECOLOR

MULTIMETERPROBE

CONNECTION

RESISTANCE Ω VOLTAGE VNOTEVALUE

(OHMS)MULTIMETER

SCALEVALUE

(VOLTS)MULTIMETER

SCALE

Ignition and kill switches

Running insulation BK and BK/YL

6-DB-C-F6-DA-3-F 0.L 00.0 MΩ — — No stop switch must be in run posi-

tion.

Continuity in stop position BK and BK/YL

6-DB-C-F6-DA-3-F 00.0 - 00.5 00.0 Ω — — Only one stop switch must be in run

position. Test one at a time.

DESS switch

Insulation in stop position BK/GNand BK/WH

6-DA-2-F6-DA-1-F 0.L 00.0 MΩ — — Tether cord cap should be off.

Running continuity BK/GNand BK/WH

6-DA-2-F6-DA-1-F 00.0 - 00.5 00.0 Ω — — Tether cord cap should be in place.

Ignition generator coil

Output RDand BK/RD

6-DB-A-F6-DB-B-F 11.6 - 21.6 00.0 Ω 15.0 - 30.0 00.0Vac —

Coil insulation BKand RD

6-DB-A-F6-DB-C-F 0.L 00.0 ΜΩ — — —

Ground continuity BK and engine

6-DB-C-Fand engine 00.0 - 00.5 00.0 Ω — —

The term “engine” refers to the en-gine metal parts connected to themagneto housing.

Trigger coil Resistance and output WH/YL

and BL/YL6-DC-2-F6-DC-1-F 190 - 300 00.0 Ω .200 - .350 .000Vac —

MPEM Output voltage WH/BLand BK

6-DD-1-F6-DD-2-F — — 25.0 -

100.0 00.0Vac No switch must be in run position andtether cord cap must be in place.

High voltage coil

Primary winding resistance WH/BLand BK

6-DD-1-F6-DD-2-F 00.0 - 00.9 00.0 Ω — — —

All 493 and 593 engines and 693 on DLX and GT:

Secondary winding resistance (spark plug

wires and caps included)

PTO spark plug cap andMAG spark

plug cap

In spark plug caps

17.6 K - 26.4 K 00.0 KΩ

CAUTION: Do not measure high voltage coil output voltageotherwise multimeter will be damaged.

793 engine and 693 on Summit and MX Z:Secondary winding

resistance (spark plug wires and caps included)

PTO spark plug cap andMAG spark

plug cap

In spark plug caps

14.5 K - 23.5 K 00.0 KΩ


Secondary winding resistance

(without spark plug cap)

BK andBK

In spark plugwires 9.6 K - 14.4 K 00.0 KΩ

793 engine and 693 on Summit and MX Z:Secondary winding

resistance (without spark plug wire and cap)

— On high voltage coil 9.6 K - 14.4 K 00.0 KΩ

Secondary winding voltage BK andengine

On sparkplug wire

and on engine— — 0.2 - 2.0 0.00Vac

The measurement must be taken onthe MAG spark plug wire, MAG sparkplug cap disconnected but PTO sparkplug cap installed on its spark plug.

Insulation Spark plug cap and BK

In spark plug cap

6-DD-2-F0.L 00.0 MΩ — — —

Spark plug cap


Cap resistance—

Spark plugside andwire side

4.0 K - 6.0 K 00.0 KΩ — — —


06-06-14 MMR2002_097_06_06A.FM

M: Male F: Female

NOTE: It is important to take note that voltage measurements must be taken while starting the vehicleusing the manual starter.Voltages obtained upon starting are proportional to the force applied onto the manual starter. A low voltageis therefore normal under a low cranking force.Perform testing in the prescribed order and replace any parts not performing according to specifications.It is important to resume all tests when replacing a component.If not specified, the probe connecting sequence is not important.

LIGHTING SYSTEM TESTING (ZX SERIES — 290 W)


WIRECOLOR

MULTIMETERPROBE

CONNECTION


(OHMS)MULTIMETER

SCALEVALUE

(VOLTS)MULTIMETER

SCALE

Lighting generator coil

Output YL and YL

2-MO-B-Fand

2-MO-C-F 00.1 - 00.4 00.0 Ω 1.0-5.0 00.0Vac —

Coilinsulation

YL and engine

2-MO-(B,C)-Fand

engine0.L 00.0 MΩ — —

The term “engine” refers to theengine metal parts connected tothe magneto housing.Ground

continuityBK andengine

2-MO-A-Fand

engine00.0 - 00.5 00.0 Ω — —


MMR2002_097_06_06A.FM 06-06-15

NOTE: Stop switches include the ignition switch, the tether cord switch and the emergency cut-outswitch.It is important to take note that voltage measurements must be taken while starting the vehicle using themanual starter.Voltages obtained upon starting are proportional to the force applied onto the manual starter. A lowvoltage is therefore normal under a low cranking force.Perform testing in the prescribed order and replace any parts not performing according to specifications.It is important to resume all tests when replacing a component.If not specified, the probe connecting sequence is not important.

IGNITION SYSTEM TESTING (ZX FAN-Series with RER 300 W)


WIRECOLOR


(ohms)MULTIMETER

SCALEVALUE(volts)

MULTIMETER SCALE

Stop switch

Running insulation BKBK/YL 0.L 00.0 MΩ — — All switches must be in run po-

sition.

Continuity in STOP position

BKBK/YL 00.0 - 00.5 00.0 Ω — —

Only one stop switch must be instop position. Test them one af-ter the other.

Ignition generator coil

Output RDBK 4.5 - 6.5 00.0 Ω 7.0 - 15.0 00.0VAC —

Groundcontinuity

BKengine 00.0 - 00.5 00.0 Ω — —

The term “engine” refers to theengine metal parts connectedto the magneto housing.

Front trigger coil

Resistanceand output

WH/YLBL/YL 160 -180 00.0 Ω .150 - .350 .000VAC —

Rear trigger coil

Resistanceand output

WH/YLBL/YL 160 -180 00.0 Ω .150 - .350 .000VAC —

MPEM and high voltage coil

Secondary winding resistancewith caps

Spark plug cap

Spark plug cap

8.90 K - 13.1 K 00.0 KΩ

CAUTION: Do not measure high voltage coil output voltage.Secondary winding resistance without

caps

BKBK 0.90 K - 1.10 K 00.0 KΩ

Secondary winding voltage

BKengine — — .100 - .250 0.00VAC

The measurement must be tak-en on the spark plug cable (with-out the spark plug).

Spark plug cap Capresistance — 4.0 K - 6.0 K 00.0 KΩ — — —


06-06-16 MMR2002_097_06_06A.FM

NOTE: It is important to take note that voltage measurements must be taken while starting the vehicleusing the manual starter.Voltages obtained upon starting are proportional to the force applied onto the manual starter. A lowvoltage is therefore normal under a low cranking force.Perform testing in the prescribed order and replace any parts not performing according to specifications.It is important to resume all tests when replacing a component.If not specified, the probe connecting sequence is not important.

LIGHTING SYSTEM TESTING (ZX FAN-Series with RER 300 W)


WIRECOLOR


(ohms) MULTIMETER SCALE VALUE(volts) MULTIMETER SCALE


Power YL YL/BK 00.0 - 00.6 00.0 Ω 3.0 - 7.0 00.0VAC —

Insulation YL engine 0.L 00.0 MΩ — — The term “engine” refers to the

engine metal parts connected tothe magneto housing.Ground

continuityBK

engine 00.0 - 00.5 00.0 Ω — —


MMR2002_097_06_06A.FM 06-06-17

M: Male F: Female

NOTE: An approved automotive spark tester is preferred for testing the secondary winding voltage.All cranking tests are performed with the manual starter. Faster cranking speeds may produce highervoltage.Vehicle will not crank if cut-out switch is engaged or shorted or if DESS key is not in place.If no spark condition is encountered on vehicle because of discharged battery, perform the chargingsystem tests after recharging battery with battery charger.

IGNITION SYSTEM TESTING (ZX SERIES — 360 W)


WIRECOLOR

MULTIMETERPROBE

CONNECTION


(ohms)MULTIMETER

SCALEVALUE(volts)

MULTIMETERSCALE

Cut-out switch

Running insulation BK and BK/YL 11-DA-3-F11-DA-6-F 0.L 00.0 Ω

or auto range — — Stop switch must not be in run posi-tion.

Continuity in stop position BK and BK/YL 11-DB-3-F

11-DA-6-F 00.0 - 00.5 00.0 Ωor auto range — — Stop switch must be in run position.

DESS switch

Insulation in stop position

BK/GNand BK/WH

11-DA-5-F11-DA-4-F 0.L 00.0 Ω

or auto range — — Tether cord cap must be off.

Running continuity BK/GNand BK/WH

11-DA-5-F11-DA-4-F 00.0 - 00.5 00.0 Ω

or auto range — — Tether cord cap must be in place.

Start/RERswitch

Battery voltage to switch from 5 AMP

fuseRD/GY 6-HC-12-F — — Battery

voltage 00.0Vdc —

Continuity from switch to MPEM

BEand BE

6-IR-B-F11-DA-7-F 00.0 - 1.0 00.0 Ω

or auto range — — —

Voltage to MPEM from switch

BK and negative battery

terminal

11-DA-7-Fand negative

battery terminal— — Battery

voltage 00.0Vdc Start button activated.

MPEM

Groundcontinuity

BK and negative battery

terminal


battery terminal00.0 - 00.5 00.0 Ω

or auto range — — —

Battery voltage to MPEM from 5 AMP

fuse

RD/GY and negative battery

terminal


battery terminal— — Battery

voltage 00.0Vdc —

Voltage to MPEM from regulator

RD/BU and negative battery

terminal


battery terminal— — 1.00-3.00 00.0Vdc While cranking engine.

22 kΩ resistorRD/BU and

negative battery terminal


battery terminal20 k −24 k 00.0 Ω

or auto range — — Engine not running.

Trigger coil no. 1

Resistance and output

BU/YL and WH/YL

11-DE-4-F11-DE-1-F 190-300 00.0 Ω

or auto range .200-.350 00.0Vdc Voltage test: while cranking engine.

Trigger coil no. 2

Resistance and output

GN/YL and GY/YL

11-DE-3-F11-DE-2-F 190-300 00.0 Ω

or auto range .200-.350 00.0Vdc Voltage test: while cranking engine.

MPEM output voltage

Output to ignition coil WH/BU and BK 11-DC-2-F11-DC-1-F — — 25.0-

100.0 00.0Vdc

At high voltage coil with wires dis-connected. Tether cord cap must bein place. Stop switch must not be inoperation, while cranking engine.

High voltage coil

Primary winding resistance WH/BU and BK 11-DC-2-M

11-DC-1-M 00.0-00.9 00.0 Ωor auto range — — At high voltage coil with wires dis-

connected.Secondary winding

resistance spark plug wires and caps

included

Spark plug cap and spark plug

cap

Spark plug cap and spark plug cap 14.5 k-23.5 k 00.0 Ω — — Do not attempt to remove spark plug

caps.

Secondary winding resistance spark plug

wires removed

Male terminal to male terminal

On male terminals of high voltage

coil9.6 k-14.4 k 00.0 Ω — — With spark plug wires removed from

high voltage coil.

Secondary winding voltage BK and engine

On MAG spark plug wire

insulation and on engine

— — 1.5-2.5 00.0VacDo not put probe into spark plug cap.With MAG spark plug wires removedfrom spark plugs.


06-06-18 MMR2002_097_06_06A.FM

M: Male F: Female

NOTE: If no spark condition is encountered on vehicle because of discharged battery, perform the charg-ing system tests after recharging battery with battery charger.If the charging relay is not working the engine will run and the accessories will function until the batteryvoltage drops below the MPEM threshold voltage. Battery will not charge. If the accessories relay is not working the engine will run until battery voltage drops below the MPEMthreshold voltage and there will be no accessory operation, the battery will not charge.When testing with engine running idle must be set between 1500 to 1800 RPM.

LIGHTING SYSTEM TESTING (ZX SERIES — 360 W)


WIRECOLOR

MULTIMETERPROBE

CONNECTION


(OHMS)MULTIMETER

SCALEVALUE

(VOLTS)MULTIMETER

SCALE


Output YL and YLand GN

2-MO-(A,B,C)-F and 2-MO-(A,B,C)-F

00.0 - 00.53 times

00.0 Ω or auto range

3.5 - 5.5 3 times 00.0Vac

Do the test between A and B, A and C and B and C using manual starter.

Coilinsulation YL and engine 2-MO-(B,C)-F

and engine 0.L 00.0 ΜΩ or auto range — — The term “engine”

refers to the engine metal parts connected to the magneto housing.

Engine ground Groundcontinuity

Engineframe

Engine and Frame 00.0 - 00.5 00.0 Ω

or auto range — —

Charging relay

Ground connectionBK and


5-RR-86-F and negative battery

terminal00.0 - 00.5 00.0 Ω

or auto range — — Relay connected. Backprobe terminal.

Voltage supply from regulator

RD/BU and negative battery

terminal


terminal— —

Above battery voltage below

15 volts00.0Vdc

Engine running.Relay connected. Backprobe terminal.

Power contact relay continuity

RD/BR and negative battery

terminal


terminal— —


15 volts00.0Vdc

Voltage supply to coil relay from accessory

relay


terminal


terminal— —


15 volts00.0Vdc

Coil relay testRelay terminal

and relay terminal

5-RR-85-M and 5-RR-86-M 95.0-115.0 00.0 Ω or auto

range — — Relay connected. Backprobe terminal.

Accessory relay

Ground connectionBK and



terminal00.0 - 00.5 00.0 Ω

or auto range — — Relay connected. Backprobe terminal.

Voltage supply to coil relay from MPEM

OR/WH and negative battery

terminal

5-RC-85-F and negative battery

terminal— — Battery voltage

below 15 volts 00.0VdcEngine running.Relay connected. Backprobe terminal.

Voltage supply from battery

RD/WH and negative battery

terminal


terminal— — Battery voltage 00.0Vdc

Engine not running.Relay connected. Backprobe terminal.

Accessory side voltage


terminal


terminal— —


15 volts00.0Vdc

Engine running.Relay connected. Backprobe terminal.

Coil relay testRelay terminal

and relay terminal

5-RC-85-M and 5-RC-86-M 95.0-115.0 00.0 Ω

or auto range — — Relay disconnected.

Charging current Current to battery Negative

battery cableAMP probe on negative

battery cable — — 0.7 AMP-12 AMPS

AMP probe in millivolt position

Engine @ 5000 RPM.


MMR2002_097_06_06A.FM 06-06-19

INSPECTION OF AC CIRCUIT INSULATIONFan Cooled Electric Start Models

If AC circuit is not insulated from frame, headlampbeam will weaken.

INSPECTIONDisconnect regulator/rectifier.Connect one digital ohmmeter probe (needle ohm-meter will not offer enough precision) to frame andother probe to YELLOW wire (2-MO).Measured resistance must be infinite. If such isnot the case, it means there is a connection be-tween AC circuit and frame.Disconnect one accessory at the time to identifythe faulty circuit.

INSPECTION OF HEATING ELEMENTSAll Models

All measurements must be performed at 21°C(70°F).

Current Measurement

Handlebar Grip Heating ElementResistance Measurement

290 W Model

300 W and 360 W Models

➀ When measuring resistance at terminals the ac-tual value will be half the measurement in table.The reason for that is the elements are connect-ed in parallel. Therefore the total resistance ishalf the resistance of one element.

HEADLIGHT SYSTEM TESTING360 W Models Only

Ensure the switch on the bypass wire is in the OFFposition. Refer to decal on switch.

1. OFF

HIGHINTENSITY BROWN wire 0.23 A

minimum

LOWINTENSITY BROWN/YELLOW wire 0.13 A

minimum

LOWINTENSITY

YELLOW/BLACK wireORANGE/VIOLET wire

17.7 to ➀20.7 ohms

HIGHINTENSITY

YELLOW/BLACK wireORANGE wire

8.73 to ➀10.67 ohms

LOWINTENSITY

YELLOW/BLACK wireORANGE/VIOLET wire

10.9 to ➀13.4 ohms

HIGHINTENSITY

YELLOW/BLACK wireORANGE wire

5.5 to ➀6.8 ohms


06-06-20 MMR2002_097_06_06A.FM


1. 20 A fuses

Connect the flat terminal of bypass wire in one ofthe 20 A fuse holders where the RED/ORANGE wirecomes in. Look at the back on one of 20 A fuse hold-ers for the RED/ORANGE wire.

TYPICAL — WIRES AND FUSE HOLDERS MAY BE INVERTED1. 20 A fuse holders2. RED/ORANGE wire

TYPICAL — FLAT TERMINAL CONNECTED TO THE RED/ORANGE WIRE

Connect the bypass wire alligator clip to the posi-tive post of vehicle battery.Once bypass wire is properly in place, put the bypassswitch to the ON position.Now the headlight system is supplied with 12 volts.Refer to appropriate wiring diagram in wiring dia-gram section to troubleshoot headlight system.As switch gets turned on a beeping signal fromthe reverse buzzer must not be heard. Headlightsystem receives 12 volts and is ready to be tested.If a beeping signal is heard when switch is turnedon, or the taillight is on, then the bypass harnesswas incorrectly installed. Turn switch off and re-verify that the flat terminal of bypass wire is con-nected to a RED/ORANGE wire.Once headlight system testing is done, turn switchoff. Remove alligator clip from battery positive post.Remove flat terminal from fuse holder. Reinstall 20 Afuses.

!


MMR2002_097_06_06A.FM 06-06-21

ACCESSORIES TESTING360 W Models Only

NOTE: Accessories include taillight, brake light,dash instruments, heated grips and throttle lever,BOSS shock electronics and air ride suspensionwhen applicable.Ensure the switch on the bypass wire is in the OFFposition. Refer to decal on switch.

1. OFF


1. 20 A fuses

Connect the flat terminal of bypass wire in one of the20 A fuse holders where the RED/YELLOW wirecomes in. Look at the back on one of 20 A fuse hold-ers for the RED/YELLOW wire.

TYPICAL — WIRES AND FUSE HOLDERS MAY BE INVERTED1. 20 A fuse holders2. RED/YELLOW wire

TYPICAL — FLAT TERMINAL CONNECTED TO THE RED/YELLOW WIRE

!

"


06-06-22 MMR2002_097_06_06A.FM

Connect the bypass wire alligator clip to the posi-tive post of vehicle battery.Once bypass wire is properly in place, put the bypassswitch to the ON position.Now accessories are supplied with 12 volts. Referto appropriate wiring diagram in wiring diagramsection to troubleshoot a faulty accessory.As switch gets turned on a beeping signal from thereverse buzzer must not be heard. All accessories re-ceive 12 volts and are ready to be tested.If a beeping signal is heard when switch is turnedon, or if the headlight is on, then the bypass har-ness was incorrectly installed. Turn switch off andre-verify that the flat terminal of bypass wire isconnected to a RED/YELLOW wire.Once accessory testing is done, turn switch off.Remove alligator clip from battery positive post.Remove flat terminal from fuse holder. Reinstall20 A fuses.

TABLE OF CONTENTS 0 - HBCcustomers.hbci.com/~jbeebe/2002 MXZ Manual/Skidoo_a...Subsection 02 (IGNITION TIMING) MMR2002_093_06_02A.FM 06-02-1 IGNITION TIMING 0 377 and 503 Engine Types

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