Ski-Doo MX Z 440 Install guide

Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Sub-Section 01 (SERVICE TOOLS)
SERVICE TOOLS
o
NOTE : The numbers outlined in black (example : ❑ ) are reference numbers to tools from other divisions
(Sea-Doo Watercraft and /or Sea-Doo Jet Boats). Matching reference numbers indicate the same tool is being
used even if the part numbers are differem.
E~GINE (Mandatory service TOOIS)
Degree wheel
❑
(P/ N 4143529 00)
AOOB334
APPLICATION
All rotary valve engines.
Hose pincher (2)
(p/ N 5290099 00)
H
A01B214
APPLICATION
All vehicles.
Fan holder
❑
(P/ N 4208763 57)
(a>
Q
c1
o
AOOCOQ4
APPLICATION
377, 443 and 503 engines.
Magneto puller ring
❑
A
(p/ N 4208760 80)
AOOC1R4
APPLICATION
All engines except 247.
Magneto puller
(p/ N 5290225
00)
H
AOOC1A4
APPLICATION
All engines except 247.
Aligning pin (4)
❑
9
(p/ N 5290189 00)
AOOA1D4
APPLICATION
467 and 582 engines.
Pusher
(washer behind the impeller)
H
(p/ N 5290207 00)
AOOC3H4
APPLICATION
Rotary valve engines.
01-01-1

Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Sub-Section 01 (SERVICE TOOLS)
ENGINE (Mandatory Service Tools)
Rotary valve shaft pusher :
(p/ N 4208766 12)
❑
)
AOOCOF4
APPLICATION
Rotary valve engines with a
10 mm impeller shaft.
Rotary valve seal pusher ●
❑
(valve side)
(p/ N 4208766 07)
f
AOOCOY4
APPLICATION
Rotary valve engines.
Rotary valve shaft seal
m
o
pusher
(inner, water pump side)
(p/ N 4208765 12)
D
AOOC374
APPLICATION
Rotary valve engines, 1991 and
newer with a 10 mm impeller
shaft.
Rotary valve shaft seal
m
pusher
(outer, water pump side)
(p/ N 4208770 50)
AOOCOX4
APPLICATION
Rotary valve engines.
Bearing pusher
(rotary valve)
m
(p/ N 4208765 00)
AOOB2J4
APPLICATION
Rotary valve engines.
Engine leak tester kit
m
A
(P/ N 86 I 7491 00)
@
“ ‘ \
Q
5
%
~ .$’ o & ~ ~ ~
b
o
/
@
1 ; “-e
*
3
Q@
Q
/52 ‘ ‘
Q
o
.-
4
A01B2D4
APPLICATION
All engines.
Parts included in the kit :
1) Exhaust oulet plug (2)
(p/ N 5290246
00)
2) Intake manifold plug (2)
(p/ N 5290110
00)
3) Air pump (1)
(P/ N 5290218 00)
4) RAVE system plug (2)
(P/ N 5290112 00)
5) Adapter (2)
(p/ N 5172349
00)
6) Intake manifold plug -779
(p/ N 5290305
00)
2-1/4 in plug (1)
(p/ N 5290211 ()())
2-3/4 in plug,(1)
(p/ N 5290212 00)
Plates (2)
(p/ N 5290213 00)
Radiator plug (1)
(p/ N 5290214 00)
Clamp (1)
(p/ N 4088035 00)
Adapter 3/1 6 ID x 1/8 NPT (2)
(P/ N 4082011 00)
o
NOTE : Must maintain a
pressure of 5 lb during 3
minutes. Never pressurize over
5 lb.
01-01-2

Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Sub-Section 01 (SERVICE TOOLS)
ENGINE (Mandatory Service Took)
Piston pin puller
m
●
(P/ N 5290290 00)
6
1
2
@’d
p
3
A01B4H4
APPLICATION
All engines.
Parts included :
1) Locating sleeve (3)
(P/ N 5290238 00)
2) Expansion sleeve (3)
(p/ N 5290237
00)
3) Adaptor
(p/ N 5290236
00)
4) U-bushing
(p/ N 5290277 03)
Rubber pad
(p/ N 5290234 00)
m
r
\
o
00
0
((
o000
\
J
A01B4C4
APPLICATION
All cageless bearing engines (277
and 503).
Rotary valve circlip tool
m
A) (p/N 5290291 00) g
B) (p / N 529020800
m
AOOC314
APPLICATION
A) 454 and 670 engines.
B) All rotary valve engines except
the 454 and 670.
01-01-3

Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Sub-Section 01 (SERVICE TOOLS)
ENGINE (Optional Service Tools)
The following tools are highly recommended to optimize your basic tool kit and reduce repair time.
1-2 Crankshaft bearing
~
puller with screw
(p/ N 4208762 98)
H
2
1+2
.——————————
5,6,7 —Q
3—
l?!
4—
8—
e
9—
e
10,11 —
GB
AOOC3L4
APPLICATION
247, 277,377,443, 503, 582
an
583 engines.
1-2 Crankshaft bearing ~
puller with screw
(p/ N 4208776 35)
NEW
H
4 4
1+2
.——————————
6—f ~ 5,7
Q
9,12
@
— 10,11,13
A01BW4
APPLICATION
All, including 454, 494, 670, 59
and 779 engines.
Tools to be used with crankshaft bearing pullers N (P/N 4208762 98) and
~ (p/N 4208776 35).
-.
u
2- Bolt (M16 X 1.5 X 150)
(p/ N 4209407 55)
m
:
Use with both ~ or ❑ pullers.
3- Screw M8 x 40 (4) (P/ N 420 840681)
m
●
❑ puller MAG side, ❑ puller MAG and PTO side.
4- Screw M8 x 70 (4) (P/ N 420 841201)
❑ Puller only, PTO side.
m
● C
5- Crankshaft protector (p/ N 4209768 90)
m
● 0
247 engine.
6- Crankshaft protector PTO
(P/ N 4208765 52)
m
●
~ or ❑ Puller; all engines except 247.
7- Crankshaft protector MAG
(p/ N 4208765 57)
m
A
~ or ❑ puller; all engines except 247,
8- Distance ring PTO
(p/ N 4208765 69)
m
~ puller; 377,443,503,582 and 583 engines,
9- Puller ring (P/ N 4209774 90)
m
Use with half rings (P/ N 420977475 or 4202760 25).
10- Half ring (2)
(p/ N 4209774 75)
m
●
~ or ❑ puller; for 72 mm O.D. bearings.
11- Half ring
(p/ N 4202760 25)
m
:
~ or ❑ Puller; for 62 mm O.D. bearings.
12- Puller ring
(p/ N 4209774 94)
m
For half rings (P/ N 4209774 79).
13- Half ring (P/ N 4209774 79)
m
~ puller only; 80 mm O.D. bearings,
01-01-4

Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Sub-Section 01 (SERVICE TOOLS)
I
Piston circlip installer
A) (P / N 5290169 00)
m
o
B) (p / N 2908770 16)
m
A:
Piston
circlip
A01B1P4
APPLICATION
I A) Allenginesexcept 670.
I B) 670 engines.
Piston pin / connecting
m
o
rod bearing centering tool
(P/ N 5290091 00)
o
NOTE : New diameter is
9.65 mm (0.380”).
IAOIBIRA
APPLICATION
All engines.
ENGINE (Optional Service Tools)
Ring compressor
A)(P/N4208760 90)
m
~A
(62 mm)
B)(p/N4208769 74)
m
o
(69.5 mm)
Q(p/N 4208769 70)
m
O*
(72 mm)
D) (p
/ N 420876972)
m
t
(76 mm)
E) (p/N 4208769 75)
m
8:
(67.5 mm)
m
F) (p/N 5290308 00) ●
(78 mm)
A01B1T4
APPLICATION
A) 377 engines.
B) 467 engines.
C) 503, 253 and 536 engines.
D) 582, 583 and 643 engines.
E) 447 engines.
F) 670 engines.
Magneto coil centering o ●
m
ring
(P/ N 4208769 22)
A01B1V4
APPLICATION
All engines with Nippondenso
CDI (160 W).
Seal protector sleeve
${~, 4209779 IO)
Rn
t
(p/ N 4202769 00)
m
(MAG)
D
AOOCOD4
APPLICATION
247 engine.
Engine seal pusher
m
(P/ N 4209779 20)
AOOCOV4
APPLICATION
247 engine.
Polyamid ring pusher
(p/ N 4202769 30)
Q“
AOOCOZ4
APPLICATION
247 engine.
01-01-5

Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
sub-section 01 (SERVICE TOOLS)
ENGINE (Optional Service Tools)
Magneto holder
L
4
(p/ N 4209765 50)
AOOC1V4
APPLICATION
247 engine.
Crankshaft feeler gauge .
m
(p/ N 4208766 20)
AOOC114
APPLICATION
377, 443, 447 and 503 engines.
Crankshaft distance
m
gauge (5.7 mm)
(p/ N 4208768 22)
AOOC294
APPLICATION
377, 443 and 447 engines.
Crankshaft distance
m
.
.
gauge (1 2.7 mm)
(P/ N 4208768 24)
AOOC3A4
APPLICATION
503 engine.
Cylinder aligning tool
A) (p / N 4208769 02)
m
o
(on exhaust side)
B) (p / N 4208761 71)
m
(on intake side)
AOOBOB4
APPLICATION
A) 467, 536, 537, 582, 583, 643
and 670 engines.
B) 377, 443, 447 and 503 en-
gines.
Mikuni carburetor tool kit ~
(p/ N 4041120 00)
AOOB2F4
APPLICATION
All models.
Circuit tester
(continuity light)
m
(p/ N 4140122 00)
G“
AOOC214
APPLICATION
All vehicles.
Piston ring expander
m
A
(p/ N 5290097 00)
A01B2G4
APPLICATION
All engines.
Stroboscopic timing light
~
(p/ N 5290092 00)
A01B2K4
APPLICATION
All engines.
01-01-6

Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Sub-Section 01 (SERVICE TOOLS)
RAVE movement
m
●
indicator
(p/ N 8617258 00)
A18B014
APPLICATION
All RAVE equipped engines.
Air pressure gauge,
0-200 inch of water
m
(p/ N 5290104 ()())
Q
80 ~ 120
60
0 e MO
/
40
160
mn
H20 180
200
=
. .
W
n]
A18B034
APPLICATION
For pressure testing gauge.
ENGINE (Optional Service Tools)
Dial indicator
m
I
(TDC gauge)
(p/ N 2950001 43)
AOOB2E4
APPLICATION
All engines.
Seal protector sleeve
A)(p/N4208769
80)
(for 10 mm shaft)
m
B) (p / N 4208764 90)
(for 12 mm shaft)
m
D
AOOCOD4
APPLICATION
467, 582, 583 and 670 engines.
Magneto puller
m
(p/ N 4209762 35)
AOOC1A4
APPLICATION
247 engine.
Injection pump gear
m
A
holder
(p/ N 4208766 95)
0)
AOOB314
APPLICATION
253, 377, 447 and 503
engines.
Injection pump gear
m
holder
(P/ N 4202779 05)
AOOC164
APPLICATION
467, 494, 536, 537, 582, 583,
643, 670 and 779 engines.
Bombardier magneto
m
●
tester
(p/ N419 0033
00)
@o
&
IGNITION TESTER ~ w ~
a
m
Reset
m
@ ‘“6°’ a“
10 90
0
@
10I
Low W+ I
&a y
AOOC1K4
APPLICATION
All engines.

Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Sub-Section 01 (SERVICE TOOLS)
ENGINE (Optional Service Tools)
Digital / induction type
m
tachometer
(p/ N 5290145
00)
F01B1G4
APPLICATION
All engines.
Connecting rod holder :
m
(p/ N 4209779 00)
AOOCON4
APPLICATION
247 engine.
Fluke
multimeter
m
A
(p/ N 5290220 ()())
FO1B1O4
APPLICATION
All models.
MAG seal pusher
m
A
(p/ N 4202778 75)
AOOCOV4
APPLICATION
277 engine.
PTO seal pusher
m
(P/ N 4208766 60)
K=A’
AOOCOV4
APPLICATION
277 engine.
Base puller plate kit
m
A
(p/ N 5290249 00)
0000
m;
!!
A05COM4
APPLICATION
277 engine.
Insertion jig
m
A
(Ma9neto side seal)
(P/ N 4208765 16)
NEW
AOOC3TA
APPLICATION
779 engine.
01-01-8

Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Sub-Section 01 (SERVICE TOOLS)
Insertion jig
m
4:
(Magneto seal)
(P/ N 4208765 14)
NEW
AOOC3UA
APPLICATION
454 and 670 engines.
Handle for insertion jig
(P/ N 4208776 50)
NEW
AOOC3V4
APPLICATION
454, 670 and 779 engines.
ENGINE (Optional Service Tools)
Exhaust spring installer/ ~
remover
(p/ N 5290281
00)
NEW
n
AOOC3S4
APPLICATION
All models.
Bearing simulator
m
c
(P/ N 4208761 55)
AOOC1H4
APPLICATION
253, 305, 343, 402 and 440 en-
gines.
Rotary valve seal and ●
m
shaft pusher
(p/ N 4208766 05)
/
AOOCOY4
APPLICATION
Rotary valve engines 1990 mod-
els and older.
Seal pusher (rotary valve) ~
(p/ N 4208765 10)
D
AOOC374
APPLICATION
All rotary valve shaft seals with a
12 mm I.D.
Rotary valve shaft pusher
~
(P/ N 4208766 10)
1
AOOCOF4
APPLICATION
All rotary valve engines with 12
mm shaft.
Self fuel control injection
~
(S. F. C. I.) system test kit
(p/ N 8617391 00)
A28E034
APPLICATION
1993 Formula Plus EFI.
01-01-9