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2005 Ski-Doo Tundra, Skandic, Expedition Shop Manual

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Original Ski-Doo Shop Manual covers the following models:
- TUNDRA
- SKANDIC - LT/LT E/WT/SWT/WT LC/SUV 550/SUV 600
- EXPEDITION - TUV 600 HO SDI/TUV V-1000

Manual Chapters:

TABLE OF CONTENTS
SAFETY NOTICE
INTRODUCTION
 - Vehicle description decal
 - Vehicle identification number (VIN)
 - Engine serial number
 - List of abbreviations used in this manual
 - Arrangement of this manual
 - General information
 - Illustrations and procedures
 - Self-locking fasteners procedure
 - Loctite application procedure
 - Threadlocker
 - Stripped thread repair
 - Gasket compound
 - Mounting on shaft
 - Case-in components
 - Tightening torque
SECTIONS
 - MAINTENANCE
   - MAINTENANCE CHART
   - STORAGE
     - General
     - Vehicle cleaning
     - Engine compartment
     - Battery
     - Fuel stabilizer
     - Engine lubrication
     - Cooling system
     - Engine oil change and filter
     - Countershaft lubrication
     - Pulley protection
     - Vehicle protection
     - Rags in air intake and exhaust system
   - PRESEASON PREPARATION
     - Fuel filter replacement
     - Throttle body cleaning (on so equipped models)
     - Carburetor cleaning (on so equipped models)
     - Air filter cleaning
     - Rags in air intake and exhaust system
     - Engine lubrication
     - Cleaning of drive and driven pulleys
     - Cleaning of brake disk
     - Drive belt condition
     - Spark plugs
 - TROUBLESHOOTING GUIDE
   - ENGINE (2-STROKE)
   - ENGINE (4-TEC)
     - Cooling system
     - Alternator
     - Lubrication
     - Cylinder and cylinder head
     - Crankshaft
     - Electric starter
     - Engine general
   - FUEL AND OIL SYSTEMS (2-STROKE ENGINES)
   - TRANSMISSION AND BRAKE SYSTEMS
     - Transmission
     - Brake system
     - Mechanical brake
     - Hydraulic brake
     - Mechanical and hydraulic brakes
   - ELECTRICAL SYSTEM
   - SUSPENSION AND TRACK
 - ENGINES (2-STROKE)
   - 277 ENGINE TYPE
     - Engine removal and installation
     - Removal from vehicle
     - Engine support and muffler disassembly and assembly
     - Installation on vehicle
     - Top end
     - Troubleshooting
     - Top end removal (without removing engine from chassis)
     - Cleaning
     - Disassembly
     - Inspection
     - Assembly
     - Bottom end
     - Cleaning
     - Disassembly
     - Inspection
     - Assembly
   - 443 AND 552 ENGINES
     - Engine removal and installation
     - Engine removal and installation
     - Top end
     - General
     - Troubleshooting
     - Cleaning
     - Disassembly
     - Inspection
     - Assembly
     - Bottom end
     - Cleaning
     - Disassembly
     - Inspection
     - Assembly
     - Break-in
   - 593 AND 593 HO SDI ENGINES
     - Removal from vehicle
     - Installation on vehicle
     - Top end
     - General
     - Troubleshooting
     - Component removal
     - Cleaning
     - RAVE valve basic operation
     - Disassembly
     - Inspection
     - Assembly
     - Bottom end
     - Cleaning
     - Disassembly
     - Inspection
     - Assembly
     - Break-in
   - LEAK TEST AND ENGINE DIMENSION MEASUREMENT
     - Leak test
     - Preparation
     - Procedure
     - Finalizing reassembly
     - Engine leak verification flow chart
     - Engine dimension measurement
     - Cylinder head warpage
     - Cylinder taper
     - Cylinder out of round
     - Combustion chamber volume measurement
     - Used piston measurement
     - Cylinder/piston clearance
     - Ring/piston groove clearance
     - Ring end gap
     - Crankshaft deflection
     - Connecting rod big end axial play
     - Crankshaft end-play
     - Checking surface flatness
     - Rectifying surfaces
     - Checking crankshaft alignment
   - MAGNETO SYSTEM
     - General
     - Cleaning
     - Disassembly
     - Assembly
   - INJECTION SYSTEM
     - Oil injection pump
     - General
     - Oil type
     - Oil system leak test
     - Oil pump identification
     - Cleaning
     - Disassembly
     - Assembly
     - Adjustment
     - Bleeding oil lines
     - Checking operation
   - AXIAL FAN COOLING SYSTEM
     - Removal
     - Cleaning
     - Disassembly and assembly
     - Installation
     - Fan belt replacement and deflection adjustment
   - LIQUID COOLING SYSTEM
     - Cooling system leak test
     - Inspection
     - Draining the system
     - Disassembly and assembly
     - Cooling system refilling procedure
   - REWIND STARTER
     - Inspection
     - Removal
     - Rope replacement
     - Disassembly
     - Assembly
     - Installation
   - FUEL SYSTEM
     - Carburetor
     - Identification
     - Removal
     - Cleaning and inspection
     - Disassembly and assembly
     - Carburetor adjustments
     - Installation
     - Idle speed final adjustment
     - Choke
     - Fuel pump
     - Removal
     - Pump verification
     - Cleaning and inspection
     - Installation
     - Fuel tank
 - ENGINE (4-TEC)
   - LEAK TEST
     - Verification
     - Leak test procedure
     - Preparation and test
     - Preparation
     - Installation
   - REMOVAL AND INSTALLATION
     - Engine removal
     - Engine installation
   - COOLING SYSTEM
     - Cooling system leak test
     - Inspection
     - Coolant replacement
     - Coolant hoses
     - Water pump housing/thermostat
     - Water pump impeller
     - Ignition cover
     - Water pump shaft
     - Pressure cap
     - Radiators
   - LUBRICATION SYSTEM
     - General
     - Oil level check
     - Engine oil pressure test
     - Oil change
     - Oil filter
     - Oil tank
     - Oil filter housing
     - Engine oil pressure regulator
     - Oil pumps
     - Pressure oil pump
     - Suction oil pump
     - Oil nozzle
     - Oil sieves
     - Reed valve
   - CYLINDER AND CYLINDER HEAD
     - Cylinder/cylinder head 1 (front-side)
     - Cylinder/cylinder head 2 (rear-side)
     - General
     - Spark plug
     - Temperature sensor
     - Valve cover
     - Rocker arm
     - Chain tensioner
     - Breather
     - Decompressor
     - Camshaft timing gear
     - Timing chain
     - Cylinder head
     - Camshaft
     - Valve springs
     - Valve
     - Cylinder
     - Piston
   - CRANKSHAFT/DRIVE GEARS
     - Timing chain
     - Drive gears
     - Trigger wheel
     - Crankshaft
     - Crankshaft locking tool
     - Piston
     - Piston rings
   - CRANKCASE
     - General
     - PTO cover
     - Crankcase
 - ENGINE MANAGEMENT (2-TEC)
   - OVERVIEW
     - Operating principle
     - Air induction
     - Fuel delivery system
     - General
     - Component description
     - Engine management system (EMS)
     - EMS — General functions
     - EMS — Engine management system functions
     - Electronic fuel injection
     - Ignition timing
     - Electronically controlled RAVE
     - Knock sensor
     - Engine modes of operation
     - Flooded engine (drowned mode)
     - Monitoring system
     - Limp home modes
     - Diagnostic mode
     - Charging system
     - Ignition system
     - Double ignition coil
     - Trigger coil
   - DIAGNOSTIC PROCEDURE
     - General
     - Troubleshooting
     - VCK (vehicle communication kit)
     - 2-TEC system fault codes
   - COMPONENT INSPECTION AND ADJUSTMENT
     - General
     - Fuel system
     - Electrical system
     - Resistance measurement
     - Engine connector pin-outs
     - Air induction system
     - Throttle body
     - Fuel delivery
     - Fuel pump
     - Fuel rails
     - Fuel injectors
     - Electronic management
     - ECM replacement
     - Engine wiring harness
     - Throttle position sensor (TPS)
     - Crankshaft position sensor (CPS)
     - Air temperature sensor (ATS)
     - Coolant temperature sensor (CTS)
     - Air pressure sensor (APS)
     - Exhaust gas temperature sensor (EGTS)
     - Knock sensor (KS)
     - E-RAVE solenoid
     - Double ignition coil
     - Ignition timing
     - Engine START/RER button verification
     - DESS switch verification
     - Spark plugs
     - Cranking system
 - ENGINE MANAGEMENT (4-TEC)
   - OVERVIEW
     - Operating principle of engine management
     - Air induction
     - Fuel delivery system
     - Basic operation
     - Intake manifold
     - Fuel pump module
     - Electronic management
     - EMS (engine management system)
     - ECM
     - EMS — General functions
     - EMS — Engine management functions
   - DIAGNOSTIC PROCEDURE
     - General
     - Monitoring beeper coded signals
     - VCK (vehicle communication kit)
     - 4-TEC system fault codes
     - 4-TEC TPS fault tables
   - COMPONENT INSPECTION AND ADJUSTMENT
     - General
     - Fuel system
     - Electrical system
     - Engine connector pin-outs
     - Connectors on engine
     - Air induction system
     - Throttle body
     - Fuel delivery
     - Fuel pump
     - Fuel rails
     - Fuel injectors
     - Electronic management
     - ECM replacement
     - Engine wiring harness
     - Throttle position sensor (TPS)
     - Idle bypass valve
     - Crankshaft position sensor (CPS)
     - Camshaft position sensor (CAPS)
     - Air temperature sensor (ATS)
     - Coolant temperature sensor (CTS)
     - Manifold air pressures sensor (MAPS)
     - Oil pressure switch (OPS)
     - Ignition coils
     - Engine start switch verification
     - DESS switch verification
     - Spark plugs
     - Cranking system
 - TRANSMISSION
   - DRIVE BELT
     - Application chart
     - Checking neutral function
     - Cleaning
     - Inspection
     - Rotation direction
     - Drive belt height measurement and adjustment
     - Drive belt deflection measurement (reference only)
   - DRIVE PULLEY
     - Bombardier Lite
     - General
     - Removal
     - Disassembly
     - Cleaning
     - Inspection
     - Assembly
     - Installation
     - Comet® 102C
     - General
     - Maintenance
     - Removal
     - Disassembly
     - Cleaning
     - Inspection
     - Assembly
     - Installation
     - TRA III
     - TRA IV
     - General
     - Removal
     - Disassembly
     - Cleaning
     - Inspection
     - Assembly
     - Installation
     - Drive pulley adjustment
   - DRIVEN PULLEY
     - Removal
     - Disassembly
     - Inspection
     - Assembly
     - Installation
     - Adjustment
     - Disassembly
     - Inspection
     - Assembly
     - Installation
     - Adjustment
     - Removal
     - Disassembly
     - Cleaning
     - Inspection
     - Assembly
     - Installation
     - Adjustment
   - PULLEY DISTANCE AND ALIGNMENT
     - General
     - General procedure
     - Pulley alignment and distance specifications chart
   - BRAKE
     - Mechanical brake
     - Hydraulic brake
     - Brake fluid type
     - Brake pads replacement
     - Removal
     - Disassembly
     - Cleaning
     - Inspection
     - Assembly
     - Installation
     - Adjustment
     - Bleeding
   - CHAINCASE
     - Removal
     - Disassembly
     - Inspection
     - Assembly
     - Installation
     - Adjustment
     - Removal
     - Inspection
     - Gear ratio modification
     - Installation
     - Drive chain adjustment
     - Adjustment
   - GEARBOX
     - 3-Speed gearbox
     - Removal
     - Disassembly
     - Inspection
     - Assembly
     - Installation
     - Oil level
   - DRIVE CHAIN
     - General
     - Silent chain
     - Chain attachment
     - Chain separation
 - ELECTRICAL
   - IGNITION TIMING
     - Verifying magneto flywheel timing mark position
   - SPARK PLUGS
     - NGK spark plug
     - NGK spark plug numbering system
     - Design symbols used in NGK spark plugs
     - Disassembly
     - Heat range
     - Fouling
     - Spark plug analysis
     - Spark plug installation
     - Spark plug tightening torque
   - ALTERNATOR
     - Removal
     - Inspection
     - Installation
   - BATTERY
     - General
     - Removal
     - Cleaning
     - Inspection
     - Battery charge testing
     - Battery storage
     - Activation of new battery
     - Servicing
     - Battery charging
     - Installation of battery
     - Cable terminal installation
   - ELECTRIC STARTER
     - Removal
     - Disassembly
     - Cleaning and inspection
     - Cleaning
     - Inspection
     - Assembly
     - Installation
   - TESTING PROCEDURE
     - General
     - Ignition system testing sequence
     - Lighting system testing sequence
     - 1. Sparking
     - 2. Electrical connector testing
     - 3. Ignition switch, dess switch or tether cord cut-out switch and engine cut-out switch testing
     - 4. Ignition generator coil testing
     - 5. Trigger coil testing
     - 6. MPEM voltage testing
     - 7. High voltage coil testing
     - 8. Buzzer testing
     - Lighting generator coil voltage testing
     - Conclusion
     - Inspection of AC circuit isolation
     - Inspection
     - Inspection of heating elements
 - REAR SUSPENSION
   - TORQUE REACTION SUSPENSION
     - Component removal
     - Suspension ass'y removal
     - Disassembly and assembly
     - Inspection
     - Suspension ass'y installation
     - Ride adjustment
     - Lubrication
   - ARTICULATING SLIDE SUSPENSION
     - Removal
     - Disassembly and assembly
     - Shock absorber servicing
     - Installation
     - Ride adjustment
   - SUV SUSPENSION
     - Removal
     - Disassembly and assembly
     - Shock absorber inspection
     - Installation
     - Lubrication
     - Ride adjustment
   - DRIVE AXLE
     - Removal
     - Disassembly
     - Assembly
     - Installation
     - Lubrication
     - Adjustment
   - TRACK
     - Track type application
     - General
     - Inspection
     - Removal
     - Installation
 - STEERING / FRONT SUSPENSION
   - STEERING SYSTEM
     - Inspection
     - Disassembly and assembly
     - Handlebar position adjustment
     - Steering adjustment (skis)
     - Lubrication
   - SUSPENSION AND SKI SYSTEM
     - On-vehicle component removal
     - Disassembly
     - Inspection
     - Installation
     - On-vehicle component verification
     - Disassembly
     - Inspection
     - Installation
     - Disassembly
     - Inspection
     - Installation
 - BODY/FRAME
   - BODY
     - Installation and adjustment
     - Headlamp beam aiming
     - Bulb replacement
     - Decal
     - Belt guard
     - Wiring harness
     - Cables
     - Tubing
     - Plastic maintenance and repair
     - Maintenance
     - Repair
     - Repair procedure for R.I.M. urethane
   - FRAME
     - Frame cleaning
     - Frame welding
 - TECHNICAL DATA
   - ENGINES
   - VEHICLES
   - TECHNICAL DATA LEGENDS
     - Engine technical data legend
     - Vehicle technical data legend
 - WIRING DIAGRAMS
   - WIRING DIAGRAMS
     - Wire colors and circuit
   - ANNEXES
     - 2005 TUNDRA R
     - 2005 SKANDIC LT 440
     - 2005 SKANDIC WT, SKANDIC SWT, SKANDIC SUV 550
     - 2005 SKANDIC WT LC, SKANDIC SUV 600
     - 2005 EXPEDITION 600 TUV SDI
     - 2005 EXPEDITION V-1000 TUV

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Full list of manual chapters:

TABLE OF CONTENTS
SAFETY NOTICE
INTRODUCTION
    Vehicle description decal
    Vehicle identification number (VIN)
    Engine serial number
    List of abbreviations used in this manual
    Arrangement of this manual
    General information
    Illustrations and procedures
    Self-locking fasteners procedure
    Loctite application procedure
    Threadlocker
    Stripped thread repair
    Gasket compound
    Mounting on shaft
    Case-in components
    Tightening torque
SECTIONS
    MAINTENANCE
        MAINTENANCE CHART
        STORAGE
            General
            Vehicle cleaning
            Engine compartment
            Battery
            Fuel stabilizer
            Engine lubrication
            Cooling system
            Engine oil change and filter
            Countershaft lubrication
            Pulley protection
            Vehicle protection
            Rags in air intake and exhaust system
        PRESEASON PREPARATION
            Fuel filter replacement
            Throttle body cleaning (on so equipped models)
            Carburetor cleaning (on so equipped models)
            Air filter cleaning
            Rags in air intake and exhaust system
            Engine lubrication
            Cleaning of drive and driven pulleys
            Cleaning of brake disk
            Drive belt condition
            Spark plugs
    TROUBLESHOOTING GUIDE
        ENGINE (2-STROKE)
        ENGINE (4-TEC)
            Cooling system
            Alternator
            Lubrication
            Cylinder and cylinder head
            Crankshaft
            Electric starter
            Engine general
        FUEL AND OIL SYSTEMS (2-STROKE ENGINES)
        TRANSMISSION AND BRAKE SYSTEMS
            Transmission
            Brake system
            Mechanical brake
            Hydraulic brake
            Mechanical and hydraulic brakes
        ELECTRICAL SYSTEM
        SUSPENSION AND TRACK
    ENGINES (2-STROKE)
        277 ENGINE TYPE
            Engine removal and installation
            Removal from vehicle
            Engine support and muffler disassembly and assembly
            Installation on vehicle
            Top end
            Troubleshooting
            Top end removal (without removing engine from chassis)
            Cleaning
            Disassembly
            Inspection
            Assembly
            Bottom end
            Cleaning
            Disassembly
            Inspection
            Assembly
        443 AND 552 ENGINES
            Engine removal and installation
            Engine removal and installation
            Top end
            General
            Troubleshooting
            Cleaning
            Disassembly
            Inspection
            Assembly
            Bottom end
            Cleaning
            Disassembly
            Inspection
            Assembly
            Break-in
        593 AND 593 HO SDI ENGINES
            Removal from vehicle
            Installation on vehicle
            Top end
            General
            Troubleshooting
            Component removal
            Cleaning
            RAVE valve basic operation
            Disassembly
            Inspection
            Assembly
            Bottom end
            Cleaning
            Disassembly
            Inspection
            Assembly
            Break-in
        LEAK TEST AND ENGINE DIMENSION MEASUREMENT
            Leak test
            Preparation
            Procedure
            Finalizing reassembly
            Engine leak verification flow chart
            Engine dimension measurement
            Cylinder head warpage
            Cylinder taper
            Cylinder out of round
            Combustion chamber volume measurement
            Used piston measurement
            Cylinder/piston clearance
            Ring/piston groove clearance
            Ring end gap
            Crankshaft deflection
            Connecting rod big end axial play
            Crankshaft end-play
            Checking surface flatness
            Rectifying surfaces
            Checking crankshaft alignment
        MAGNETO SYSTEM
            General
            Cleaning
            Disassembly
            Assembly
        INJECTION SYSTEM
            Oil injection pump
            General
            Oil type
            Oil system leak test
            Oil pump identification
            Cleaning
            Disassembly
            Assembly
            Adjustment
            Bleeding oil lines
            Checking operation
        AXIAL FAN COOLING SYSTEM
            Removal
            Cleaning
            Disassembly and assembly
            Installation
            Fan belt replacement and deflection adjustment
        LIQUID COOLING SYSTEM
            Cooling system leak test
            Inspection
            Draining the system
            Disassembly and assembly
            Cooling system refilling procedure
        REWIND STARTER
            Inspection
            Removal
            Rope replacement
            Disassembly
            Assembly
            Installation
        FUEL SYSTEM
            Carburetor
            Identification
            Removal
            Cleaning and inspection
            Disassembly and assembly
            Carburetor adjustments
            Installation
            Idle speed final adjustment
            Choke
            Fuel pump
            Removal
            Pump verification
            Cleaning and inspection
            Installation
            Fuel tank
    ENGINE (4-TEC)
        LEAK TEST
            Verification
            Leak test procedure
            Preparation and test
            Preparation
            Installation
        REMOVAL AND INSTALLATION
            Engine removal
            Engine installation
        COOLING SYSTEM
            Cooling system leak test
            Inspection
            Coolant replacement
            Coolant hoses
            Water pump housing/thermostat
            Water pump impeller
            Ignition cover
            Water pump shaft
            Pressure cap
            Radiators
        LUBRICATION SYSTEM
            General
            Oil level check
            Engine oil pressure test
            Oil change
            Oil filter
            Oil tank
            Oil filter housing
            Engine oil pressure regulator
            Oil pumps
            Pressure oil pump
            Suction oil pump
            Oil nozzle
            Oil sieves
            Reed valve
        CYLINDER AND CYLINDER HEAD
            Cylinder/cylinder head 1 (front-side)
            Cylinder/cylinder head 2 (rear-side)
            General
            Spark plug
            Temperature sensor
            Valve cover
            Rocker arm
            Chain tensioner
            Breather
            Decompressor
            Camshaft timing gear
            Timing chain
            Cylinder head
            Camshaft
            Valve springs
            Valve
            Cylinder
            Piston
        CRANKSHAFT/DRIVE GEARS
            Timing chain
            Drive gears
            Trigger wheel
            Crankshaft
            Crankshaft locking tool
            Piston
            Piston rings
        CRANKCASE
            General
            PTO cover
            Crankcase
    ENGINE MANAGEMENT (2-TEC)
        OVERVIEW
            Operating principle
            Air induction
            Fuel delivery system
            General
            Component description
            Engine management system (EMS)
            EMS — General functions
            EMS — Engine management system functions
            Electronic fuel injection
            Ignition timing
            Electronically controlled RAVE
            Knock sensor
            Engine modes of operation
            Flooded engine (drowned mode)
            Monitoring system
            Limp home modes
            Diagnostic mode
            Charging system
            Ignition system
            Double ignition coil
            Trigger coil
        DIAGNOSTIC PROCEDURE
            General
            Troubleshooting
            VCK (vehicle communication kit)
            2-TEC system fault codes
        COMPONENT INSPECTION AND ADJUSTMENT
            General
            Fuel system
            Electrical system
            Resistance measurement
            Engine connector pin-outs
            Air induction system
            Throttle body
            Fuel delivery
            Fuel pump
            Fuel rails
            Fuel injectors
            Electronic management
            ECM replacement
            Engine wiring harness
            Throttle position sensor (TPS)
            Crankshaft position sensor (CPS)
            Air temperature sensor (ATS)
            Coolant temperature sensor (CTS)
            Air pressure sensor (APS)
            Exhaust gas temperature sensor (EGTS)
            Knock sensor (KS)
            E-RAVE solenoid
            Double ignition coil
            Ignition timing
            Engine START/RER button verification
            DESS switch verification
            Spark plugs
            Cranking system
    ENGINE MANAGEMENT (4-TEC)
        OVERVIEW
            Operating principle of engine management
            Air induction
            Fuel delivery system
            Basic operation
            Intake manifold
            Fuel pump module
            Electronic management
            EMS (engine management system)
            ECM
            EMS — General functions
            EMS — Engine management functions
        DIAGNOSTIC PROCEDURE
            General
            Monitoring beeper coded signals
            VCK (vehicle communication kit)
            4-TEC system fault codes
            4-TEC TPS fault tables
        COMPONENT INSPECTION AND ADJUSTMENT
            General
            Fuel system
            Electrical system
            Engine connector pin-outs
            Connectors on engine
            Air induction system
            Throttle body
            Fuel delivery
            Fuel pump
            Fuel rails
            Fuel injectors
            Electronic management
            ECM replacement
            Engine wiring harness
            Throttle position sensor (TPS)
            Idle bypass valve
            Crankshaft position sensor (CPS)
            Camshaft position sensor (CAPS)
            Air temperature sensor (ATS)
            Coolant temperature sensor (CTS)
            Manifold air pressures sensor (MAPS)
            Oil pressure switch (OPS)
            Ignition coils
            Engine start switch verification
            DESS switch verification
            Spark plugs
            Cranking system
    TRANSMISSION
        DRIVE BELT
            Application chart
            Checking neutral function
            Cleaning
            Inspection
            Rotation direction
            Drive belt height measurement and adjustment
            Drive belt deflection measurement (reference only)
        DRIVE PULLEY
            Bombardier Lite
            General
            Removal
            Disassembly
            Cleaning
            Inspection
            Assembly
            Installation
            Comet 102C
            General
            Maintenance
            Removal
            Disassembly
            Cleaning
            Inspection
            Assembly
            Installation
            TRA III
            TRA IV
            General
            Removal
            Disassembly
            Cleaning
            Inspection
            Assembly
            Installation
            Drive pulley adjustment
        DRIVEN PULLEY
            Removal
            Disassembly
            Inspection
            Assembly
            Installation
            Adjustment
            Disassembly
            Inspection
            Assembly
            Installation
            Adjustment
            Removal
            Disassembly
            Cleaning
            Inspection
            Assembly
            Installation
            Adjustment
        PULLEY DISTANCE AND ALIGNMENT
            General
            General procedure
            Pulley alignment and distance specifications chart
        BRAKE
            Mechanical brake
            Hydraulic brake
            Brake fluid type
            Brake pads replacement
            Removal
            Disassembly
            Cleaning
            Inspection
            Assembly
            Installation
            Adjustment
            Bleeding
        CHAINCASE
            Removal
            Disassembly
            Inspection
            Assembly
            Installation
            Adjustment
            Removal
            Inspection
            Gear ratio modification
            Installation
            Drive chain adjustment
            Adjustment
        GEARBOX
            3-Speed gearbox
            Removal
            Disassembly
            Inspection
            Assembly
            Installation
            Oil level
        DRIVE CHAIN
            General
            Silent chain
            Chain attachment
            Chain separation
    ELECTRICAL
        IGNITION TIMING
            Verifying magneto flywheel timing mark position
        SPARK PLUGS
            NGK spark plug
            NGK spark plug numbering system
            Design symbols used in NGK spark plugs
            Disassembly
            Heat range
            Fouling
            Spark plug analysis
            Spark plug installation
            Spark plug tightening torque
        ALTERNATOR
            Removal
            Inspection
            Installation
        BATTERY
            General
            Removal
            Cleaning
            Inspection
            Battery charge testing
            Battery storage
            Activation of new battery
            Servicing
            Battery charging
            Installation of battery
            Cable terminal installation
        ELECTRIC STARTER
            Removal
            Disassembly
            Cleaning and inspection
            Cleaning
            Inspection
            Assembly
            Installation
        TESTING PROCEDURE
            General
            Ignition system testing sequence
            Lighting system testing sequence
            1. Sparking
            2. Electrical connector testing
            3. Ignition switch, dess switch or tether cord cut-out switch and engine cut-out switch testing
            4. Ignition generator coil testing
            5. Trigger coil testing
            6. MPEM voltage testing
            7. High voltage coil testing
            8. Buzzer testing
            Lighting generator coil voltage testing
            Conclusion
            Inspection of AC circuit isolation
            Inspection
            Inspection of heating elements
    REAR SUSPENSION
        TORQUE REACTION SUSPENSION
            Component removal
            Suspension ass'y removal
            Disassembly and assembly
            Inspection
            Suspension ass'y installation
            Ride adjustment
            Lubrication
        ARTICULATING SLIDE SUSPENSION
            Removal
            Disassembly and assembly
            Shock absorber servicing
            Installation
            Ride adjustment
        SUV SUSPENSION
            Removal
            Disassembly and assembly
            Shock absorber inspection
            Installation
            Lubrication
            Ride adjustment
        DRIVE AXLE
            Removal
            Disassembly
            Assembly
            Installation
            Lubrication
            Adjustment
        TRACK
            Track type application
            General
            Inspection
            Removal
            Installation
    STEERING / FRONT SUSPENSION
        STEERING SYSTEM
            Inspection
            Disassembly and assembly
            Handlebar position adjustment
            Steering adjustment (skis)
            Lubrication
        SUSPENSION AND SKI SYSTEM
            On-vehicle component removal
            Disassembly
            Inspection
            Installation
            On-vehicle component verification
            Disassembly
            Inspection
            Installation
            Disassembly
            Inspection
            Installation
    BODY/FRAME
        BODY
            Installation and adjustment
            Headlamp beam aiming
            Bulb replacement
            Decal
            Belt guard
            Wiring harness
            Cables
            Tubing
            Plastic maintenance and repair
            Maintenance
            Repair
            Repair procedure for R.I.M. urethane
        FRAME
            Frame cleaning
            Frame welding
    TECHNICAL DATA
        ENGINES
        VEHICLES
        TECHNICAL DATA LEGENDS
            Engine technical data legend
            Vehicle technical data legend
    WIRING DIAGRAMS
        WIRING DIAGRAMS
            Wire colors and circuit
        ANNEXES
            2005 TUNDRA R
            2005 SKANDIC LT 440
            2005 SKANDIC WT, SKANDIC SWT, SKANDIC SUV 550
            2005 SKANDIC WT LC, SKANDIC SUV 600
            2005 EXPEDITION 600 TUV SDI
            2005 EXPEDITION V-1000 TUV

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