Content .. 68 69 70 71 ..

Snowmobile Ski Doo REV SERIES (2006 year). Instruction - part 70

Section 06 ENGINE MANAGEMENT (SDI)
Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT)



WARNING

Always respect the polarity when connecting
the capacitor.

Wait 5 minutes, then measure capacitor voltage.
It must be within 1 V maximum of battery voltage.

If in doubt, proceed with the following residual
voltage test.

Residual Voltage Test

Connect a 12 V test lamp to capacitor terminals
during a complete minute to discharge capacitor.

Connect a switch (in OFF position) between a 12 V
battery positive post and the capacitor positive
post. Connect the battery negative post to the
capacitor negative post. Turn on the switch for 2
seconds. Disconnect the capacitor from the bat-
tery. Note battery voltage.



WARNING

Always respect the polarity when connecting
the capacitor.

Connect a switch (in OFF position) and a 300
5 W resistor to the capacitor. Turn on the switch
for 12 seconds ± 1 second of discharge.

Residual voltage after 12 seconds ± 1 second of
discharge must be above 5 volts.

Installation

Connect a 12 V test lamp to capacitor terminals
during a complete minute to discharge capacitor.

Make sure 30 A fuse is removed.

Install the capacitor.

Make sure to connect BLACK wire to negative ter-
minal and RED/WHITE to positive terminal.



WARNING

Always respect the polarity when connecting
the capacitor.

Install the 30 A fuse.

ENGINE START/RER SWITCH
VERIFICATION

All Models

A quick operation test can be done using the ve-
hicle communication kit (VCK) with the B.U.D.S.
software, using the Monitoring section. Press
the START/RER button and look at the START/RER
button LED. It should turn on, indicating the start-
ing system is working on the input side of the
starting system (START/RER button, ECM and
wiring). If so, you know now the problem is
on the output side of the starting system (ECM
output signal to starting solenoid, wiring harness
going to the solenoid and starter motor. Other-
wise, check the input side as follows.

Test corresponding fuse, relay and wiring.

Disconnect the two connectors of the steering
harness.

Measure the resistance of the two wires on the
small connector (BEIGE and BLACK/BROWN) for
0

. Depress start button and the reading should

change from 0

to infinitely high.

Release the start button and measure the resis-
tance between pin 2 (BEIGE wire) of the small
connector and pin 6 (RED/BROWN wire) on the
big connector for infinitely high resistance to 0
while the start button is depressed.



WARNING

Always respect the wire position when con-
necting the switch. Refer to the wiring dia-
gram.

Test continuity of circuit B-19. If it is good, try a
new ECM. Otherwise, repair harness/connectors.

RER Operation

When RER works erratically or if engine idle slow
down then engine stalls, do the following.

– Check engine compression. A low compres-

sion engine may result in RER working erratical-
ly making you think the problem is an electronic
problem.

276

mmr2005-081

Section 06 ENGINE MANAGEMENT (SDI)

Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT)

– Check piston condition. Remove exhaust sys-

tem and reed valves on intake side. Verify pis-
ton condition through the intake and exhaust
ports. Look for scoring on piston skirts. Scored
piston skirts may result in RER working errati-
cally making you think the problem is an elec-
tronic problem.

When it does not work at all, check wiring and
START/RER switch as explained above. If every-
thing is normal, try another ECM.

DESS POST VERIFICATION

If 2 short beeps are not heard when starting the
engine, refer to DIAGNOSTIC PROCEDURES.

The following continuity tests can also be per-
formed using an ohmmeter.

Disconnect DESS post wires.

Tether Cord Cap Removed

Connect test probes to post BLACK/GREEN and
BLACK/WHITE wires. Measure resistance, there
should be NO continuity (open circuit).

Connect one test probe to the WHITE/GREY wire
and the other test probe to the switch top termi-
nal. Measure resistance, it must be close to 0
ohm.

Connect one test probe to the BLACK/GREEN
wire and the other test probe to the post ring.
Measure resistance, it must be close to 0 ohm.

Tether Cord Cap on DESS Post

Connect test probes to switch BLACK/GREEN
and BLACK/WHITE wires. Measure resistance, it
must be close to 0 ohm.

mmr2005-081

277

Section 07 ELECTRICAL SYSTEM

Subsection 01 (IGNITION SYSTEM)

IGNITION SYSTEM

SERVICE TOOLS

Description

Part Number

Page

SERVICE PRODUCTS

Description

Part Number

Page

antiseize lubricant ................................................................. 293 800 070 ......................................... 291

GENERAL

Ignition System Testing Sequence

In the case of ignition problems, check the follow-
ing in the prescribed order until the problem can
be solved.

1) Spark testing.
2) Electrical connectors.
3) Ignition switch.
4) DESS post or tether cut-out switch.
5) Engine cut-out switch.
6) Ignition coil.
7) Trigger coil.
8) MPEM voltage (liquid cooled models only).
9) High voltage coil (liquid cooled models only).
10)Relay
11)Beeper.

Testing Conditions

Voltage measurements are always taken upon
vehicle starting. Readings when the engine is
running will be higher than indicated range. Part
temperature must be approximately 20 °C (68 °F)
(room temperature), otherwise readings could be
distorted.

Analysis of Readings

• Voltage Readings

When testing the different magneto components,
it is important to take into consideration that read-
ings vary according to the force applied onto the
manual starter. It is therefore important to employ
enough force upon each trial.

The reading must be 3 times within or above the
range indicated in the corresponding table. If the
reading is too low, the part is considered to be
defective and must be replaced.

• Resistance Readings

Place multimeter selector switch to

in order to

measure resistance. Readings must be within the
indicated range. Otherwise, the part is consid-
ered to be defective and must be replaced.

CAUTION: When taking measurements, it is
useless to try to start the vehicle since readings
would then be distorted.

• Intermittent Ignition Problems

It is difficult to make a diagnostic in the case of in-
termittent ignition problems. Thus, problems oc-
curring only when the engine operating tempera-
ture is normal must be checked in similar condi-
tions.

mmr2005-082

279

Section 07 ELECTRICAL SYSTEM
Subsection 01 (IGNITION SYSTEM)

In most cases when problems are caused by tem-
perature or vibrations, these can only be solved by
replacing parts. Most problems cannot be detect-
ed when the engine is stopped.

• Multiple Problems

As a matter of fact, more that one component can
be defective. As a result, if the problem remains
although a part was replaced, start over the whole
verification from the beginning in order to identify
the other defective component.

Spark Testing

During this operation, it is important to use the
snowmobile spark plug and not a new one. Bring
the plug in contact with the engine. Pull rewind
starter. If no spark is produced, replace the spark
plug with a new one and do the test again.

For more information on spark plug condition, re-
fer to SPARK PLUG further in this section.

Electrical Connector

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

Ignition Switch or Start/RER Button

Refer to STARTING SYSTEM.

DESS Post or Tether Cut-Out Switch

DESS Post
Liquid-Cooled Engines

DESS POST

TEST

Open circuit

Continuity

TEST

PROBES

BLACK/WHITE and

BLACK/GREEN wires

BLACK/WHITE and

BLACK/GREEN wires

RESISTANCE

O.L.

00.0 to 00.5

VOLTAGE

—

NOTE

DESS key removed

DESS key installed

If readings do not correspond to the above men-
tioned indications, replace post.

If none of these verifications are conclusive, the
problem finds its source in the main wiring har-
ness. Do the following.

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 same
color. Repeat with all other wires. It is impor-
tant to mention that all wires of the same color
within a given harness are connected together.
These wires should therefore have a closed cir-
cuit. On the other hand, BLACK and BLACK/YEL-
LOW wires must have an open circuit (0.L M ).

Repair or replace if necessary.

Tether Cut-Out Switch
Fan-Cooled Engines

TETHER CUT-OUT SWITCH

TEST

Open circuit

Continuity

TEST

PROBES

BLACK/YELLOW and

BLACK wires

BLACK/YELLOW and

BLACK wires

RESISTANCE

O.L.

00.0 to 00.5

VOLTAGE

—

NOTE

Engine cut-out switch must

be in RUN position

Engine cut-out switch must

be in STOP position

If readings do not correspond to the above men-
tioned indications, replace switch.

If none of these verifications are conclusive, the
problem finds its source in the main wiring har-
ness. Do the following.

NOTE: For the next step, no switch must be con-
nected to the main wiring harness.

Repair or replace if necessary.

Engine Cut-Out Switch

Check the condition of engine cut-out switch.

280

mmr2005-082

Content .. 68 69 70 71 ..