Snowmobile Ski Doo REV SERIES (2004 year). Manual - part 14

Section 02 MAINTENANCE
Subsection 03 (PRESEASON PREPARATION)

THROTTLE BODY CLEANING
(ON SO EQUIPPED MODELS)

Remove the throttle body from vehicle.

Using the Pulley Flange Cleaner (P/N 413 711
809), remove the dirt ejected by the drive belt
from the throttle plate and from both throttle body
bores.

After throttle body installation, adjust

throttle and injection oil cables.

CARBURETOR CLEANING
(ON SO EQUIPPED MODELS)

Disassemble carburetor(s) in order to clean all in-
ternal parts. Do not hesitate to replace any jets
having gum or varnish on their surfaces.

AIR FILTER CLEANING

Check that inside of air silencer is clean and dry
then properly reinstall the filter.

CAUTION: These snowmobiles have been cal-
ibrated with the filter installed. Operating the
snowmobile without it, may cause engine dam-
age.

RAGS IN AIR INTAKE AND
EXHAUST SYSTEM

Remove rags that were installed during STORAGE
preparation.

CLEANING OF DRIVE AND
DRIVEN PULLEYS

Clean drive and driven pulleys sheaves with Pulley
Flange Cleaner (P/N 413 711 809).

CLEANING OF BRAKE DISK

Remove any rust built-up on braking surfaces.
Clean brake disk braking surfaces with Pulley
Flange Cleaner (P/N 413 711 809).

DRIVE BELT CONDITION

Inspect belt for cracks, fraying or abnormal wear.
Replace if necessary. Make sure to install the
proper belt with arrow printed on belt pointing
front of vehicle.

SPARK PLUGS

Once preseason preparation is done, start engine
with the old spark plug(s) to burn excess stor-
age oil. Then, install new properly gapped spark
plug(s).

mmr2004-Rev

Section 03 TROUBLESHOOTING

Subsection 01 (ENGINE)

ENGINE

The following chart is provided to help diagnose the probable source of troubles. It should be used as a
guideline. Some causes or corrections may not apply to a specific model.

NOTE: For engine management system troubleshooting, refer to appropriate subsection.

SYMPTOM

ENGINE BACKFIRES.

CONDITION

NORMAL USE.

1. Check spark plugs.

a. Carbon accumulation caused by defective spark plug(s).

Clean carbon accumulation from piston and cylinder head and install dry properly gapped spark plug(s).

2. Check ignition timing.

a. Timing is too advanced.

Set timing according to specifications (refer to TECHNICAL DATA).

3. Check for erratic sparks.

a. Poor electrical connections.

Repair.

b. Faulty stator.

Replace defective parts.

4. Check carburetor.

a. Fuel passages obstructed.

Clean carburetor and install new filter(s).

b. Fuel level too low.

Adjust float level according to specifications.

TEST/INSPECTION

5. Check cooling system.

a. Low antifreeze level.

Adjust antifreeze level. Proceed with a leakage test (refer to LIQUID COOLING SYSTEM) and repair as

required.

b. Defective tank cap.

Replace cap.

c. Defective thermostat.

Replace thermostat.

d. Air in system.

Bleed system.

SYMPTOM

ENGINE SUDDENLY TURNS OFF AT HIGH RPM AND/OR WITH LIGHT LOAD.

CONDITION

NORMAL USE.

TEST/INSPECTION

1. Check that all 3 ground wires are well connected.

mmr2004-Rev

Section 03 TROUBLESHOOTING
Subsection 01 (ENGINE)

SYMPTOM

ENGINE SUDDENLY TURNS OFF.

CONDITION

NORMAL USE.

1. Perform engine leak test. Refer to ENGINE LEAK VERIFICATION FLOW CHART. Check possible piston

seizure.

a. Damaged gasket and/or seal.

Replace defective parts.

2. “Four-corner” seizure of piston(s).

a. High acceleration when engine is cold. Piston expands faster than cylinder.

Replace piston(s). Ask driver to refer to the WARM-UP PROCEDURE in the Operator’s Guide.

TEST/INSPECTION

3. Piston(s) seizure on exhaust side (color on piston dome is correct).

a. Kinked fuel tank vent tube.

Relocate fuel tank vent tube.

b. Leaks at fuel line connections or damaged fuel lines.

Replace defective lines.

c. Fuel does not flow through carburetor(s) (foreign particles in needle area and/or varnish formation in

carburetor(s)).

Clean carburetor(s) and install new filter(s).

d. Spark plug heat range is too warm.

Install spark plugs with appropriate heat range (refer to TECHNICAL DATA).

e. Improper ignition timing.

Adjust according to specifications (refer to TECHNICAL DATA).

f. Restriction in exhaust system.

Replace.

g. Compression ratio is too high.

Install genuine parts.

h. Too low fuel octane number.

Use proper fuel octane number.

i. Carburetor calibration is too lean.

Adjust according to specifications (refer to TECHNICAL DATA).

j. Improper reed valve adjustment or damage.

Adjust according to specifications (refer to appropriate ENGINE subsection) and/or install Bombardier’s

recommended reed valve.

k. Poor quality oil.

Use BOMBARDIER injection oil.

l. Leaks at air intake silencer.

Replace air intake silencer grommets.

m. Excessive wear of piston rings.

Replace piston rings.

mmr2004-Rev

Section 03 TROUBLESHOOTING

Subsection 01 (ENGINE)

SYMPTOM

ENGINE SUDDENLY TURNS OFF.

CONDITION

NORMAL USE.

4. Melted and/or perforated piston dome; melted section at ring end gap.

a. When piston reaches TDC, mixture is ignited by heated areas in combustion chamber. This is due to an

incomplete combustion of a poor quality oil.

Clean residue accumulation in combustion chamber and replace piston(s). Use Bombardier injection oil.

b. Spark plug heat range is too high.

Install recommended dry properly gapped spark plugs (refer to TECHNICAL DATA).

c. Ignition timing is too advanced.

Adjust according to specifications (refer to TECHNICAL DATA).

d. Inadequate fuel quality.

Use appropriate fuel.

e. Carburetion is too lean.

Adjust according to specifications (refer to TECHNICAL DATA).

5. Seized piston all around the circumference (dry surface).

a. Lack of oil, damaged oil line or defective injection pump.

Replace defective part(s).

6. Grooves on intake side of piston only.

a. Oil film eliminated by water (snow infiltration in engine). This can also be caused by running engine on

choke for too long. Excessive fuel will remove the oil film on the piston and make marks.

Replace piston(s) and check if intake system leaks.

7. Piston color is dark due to seizure on intake and exhaust sides.

a. Cooling system leaks and lowers coolant level.

Proceed with a leakage test (refer to LIQUID COOLING SYSTEM) and repair as required. Add coolant in

cooling system until appropriate level is reached.

b. Accumulation of foreign particles in needle valve and/or main jet area.

Clean carburetor(s).

8. Cracked or broken piston(s).

a. Cracked or broken piston(s) due to excessive piston/cylinder clearance or engine overrevving.

Replace piston(s). Check piston/cylinder clearance (refer to TECHNICAL DATA). Adjust drive pulley according

to specifications (refer to TECHNICAL DATA) and/or clean pulley sheaves if they are contaminated with

greasy particles.

TEST/INSPECTION

9. DPM manifold air vent is obstructed.

a. Carburetion is too lean.

Ensure proper air vent.

SYMPTOM

PISTON RING AND CYLINDER SURFACES ARE SCRATCHED.

CONDITION

NORMAL USE.

1. Check oil quality.

a. Poor quality oil.

Use BOMBARDIER injection oil.

TEST/INSPECTION

2. Check injection pump and its hoses.

a. Inadequate injection pump adjustment and/or defective hoses.

Adjust pump according to specifications (refer to ENGINE) and/or replace hoses.

mmr2004-Rev

Content .. 12 13 14 15 ..