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Ski-Doo 1997 Tundra II LT 3266, User Manual

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Ski-Doo 1997 Tundra II LT 3266 User Manual Download Page 67

Litho’d in Canada

(MBL-9707 PS)

®*Trademarks of Bombardier Inc.
©1997 Bombardier Inc. All rights reserved.

97-5

Page 1 of 2

SHIPPING STRAP REMOVAL

Cut shipping strap using one of these 2 following 
methods:

Method 1

Using a long flat chisel such as Snap-On

®

PPC820LA cut shipping strap that collapses front
portion of rear suspension, as shown on the next
photo.

Method 2

Using a special tool cut shipping strap as shown
on the next photo.

1. Insert tool tip onto strap and twist

How to build the special tool

Using 20 mm (3/4 in) steel tubing, cut the first
piece to 460 mm (18 in) and the second one to
410 mm (16 in).

NOTE:

 High forces will be apply on this special

tool, use strong tubing with a minimum wall thick-
ness of 2 mm (5/64 in).

On one end of the 460 mm (18 in) piece, cut a 1.2
mm (3/64 in) slot by 28.5 mm (1-1/8 in).

Make a chamfer of 30° X 10 mm (25/64 in), as
shown on the next photo.

No.

 97-5

Date: August 2, 1996

SUBJECT: Uncrating Procedure

YEAR

MODEL NAME

MODEL NUMBER

SERIAL NUMBER

1997

ALL except Skandic* WT/SWT

and Tundra* II LT

ALL

ALL

A03F15A

A01F2CA

Summary of Contents for 1997 Tundra II LT 3266

Page 1: ... install them on products previously manufactured Due to late changes it may have some differences between the manufactured product and the descriptions and or specifications in this document Bombardier Inc reserves the right at any time to discontinue or change specifications designs features models or equipment without incurring obligation The illustrations in this document show the typical cons...

Page 2: ... UNCRATING 3 PARTS INSTALLATION 5 STEERING COVER PARTS INSTALLATION 6 FRONT BUMPER PARTS INSTALLATION 7 SKI SUBJECT PAGE PARTS INSTALLATION 8 WINDSHIELD PARTS INSTALLATION 8 DRIVE BELT LIQUIDS 9 OIL INJECTION PUMP BLEEDING TECHNICAL DATA 10 ...

Page 3: ...specified If the efficiency of a locking device is impaired it must be renewed CAUTION Allowing the crate to drop may cause serious damage to the vehicle Using a screwdriver remove all screws retaining crate cover to base F02P04S Tip cover towards front of vehicle There is a notch in crate base at front A05H0XS 1 1 Notch Detach parts to be installed e g skis windshield from the vehicle and its bas...

Page 4: ...om crate Keep ski leg bolts to bolt skis to ski legs Discard nuts Remove vehicle from base Remove predelivery kit from engine compartment PREDELIVERY KIT P N MODELS 582 0609 00 All Tundra II LT ONOTE This rule can be helpful to identify fastener length size M5 M6 M8 M10 M12 M14 inches pouces mm cm 1 2 3 4 5 6 7 8 9 1 5 1 1 1 2 1 0 1 3 1 4 1 2 3 4 5 6 A99A0HS ...

Page 5: ...97 1 Page 5 of 10 PARTS INSTALLATION STEERING COVER A03G09S 1 A 2 1 Steering cover P N 572 0669 00 on handlebar 2 Equal gap all around A 26 N m 19 lbf ft ...

Page 6: ...ION FRONT BUMPER A05H0NS 1 2 3 4 A 1 Nut M8 x 1 25 4 P N 228 5810 45 Section no 2 Torque to 15 N m 133 lbf in 2 Bushing long 2 P N 517 2506 00 Section no 3 3 Bushing short 2 P N 517 2507 00 Section no 3 4 Groove on top A 55 mm 2 1 8 in ...

Page 7: ...TS INSTALLATION SKI A05G0GS 1 2 3 1 Nut 2 M10 x 1 5 P N 228 5010 45 Section no 1 Torque to 29 N m 21 lbf ft 2 Stopper 2 P N 570 0270 00 Section no 4 Thicker side toward front 3 Bolt 2 M10 x 1 5 x 90 P N 222 0090 65 on crate ...

Page 8: ...lleys and disc brake This protective coating must be removed at predelivery Clean pulleys and brake disc with a suitable cleaner such as Loctite Safety Solvent P N 413 7082 00 before installing drive belt Make sure the entire surface of the drive belt travel is clean open the driven pulley as required for cleaning CAUTION Do not install a new drive belt without properly cleaning the pulleys ...

Page 9: ...ng the bleeder screw until all air has es caped from the line A05C0UA 2 3 1 1 Main oil line 2 Bleeder screw 3 Small line Bleed the small line between pump and intake manifold by running engine at idle while holding the pump lever in fully open position A15C1QA 1 TYPICAL ENGINE AT IDLE 1 Fully open position ...

Page 10: ... 100 RPM 3100 Pulley Distance Z 0 1 mm 0 1 32 in 37 0 1 29 64 Offset X 0 4 mm 1 64 in 36 0 1 27 64 Y Dimension Y must exceed X by up to 1 5 mm 1 16 in Drive Belt Adjustment Deflection mm in 32 1 1 4 Force kg lbf 6 8 15 Driven Pulley Preload 1 kg 2 lbf 3 6 8 Drive Chain Tension Automatic Spring Loaded Track Adjustment Deflection mm in 35 to 45 1 3 8 to 1 3 4 Engine speed at which maximum power is a...

Page 11: ...esent parts that have the same or similar function The content of this bulletin is designed as a guideline only All mechanics performing predelivery proce dures should have attended the current model year service training Further information or inquires should be directed to your distributor service representative and or specific Shop Manual sections Please complete the Predelivery Check List for ...

Page 12: ...ION 6 BATTERY PARTS INSTALLATION 8 SKIS PARTS INSTALLATION 9 STEERING PAD PARTS INSTALLATION 11 WINDSHIELD PARTS INSTALLATION 12 BACKREST PARTS INSTALLATION 13 DRIVE BELT LIQUIDS 13 OIL INJECTION PUMP BLEEDING LIQUIDS 14 BRAKE FLUID LEVEL ADJUSTMENT 14 SUSPENSION ADJUSTMENT 14 TRACK ADJUSTMENT 14 DRIVEN PULLEY TECHNICAL DATA 15 ...

Page 13: ...m engine com partment Apply pressure on rear suspension and remove hook from rear portion of suspension as illustrat ed 1 Remove hook Using a long flat chisel such as Snap On PPC820LA cut shipping strap that collapses front portion of rear suspension WARNING Torque wrench tightening specifications must be strictly adhered to Locking devices e g Iock tabs elastic stop nuts must be in stalled or rep...

Page 14: ...G Shipping strap must be cut and hook re moved to have snowmobile suspension op erational PREDELIVERY KIT P N MODELS 580 6532 00 TOURING E 580 6529 00 TOURING ELT LE SLE 580 6533 00 SKANDIC 380 500 580 6388 00 FORMULA S SL M5 M6 M8 M10 M12 M14 inches pouces mm cm 1 2 3 4 5 6 7 8 9 1 5 1 1 1 2 1 0 1 3 1 4 1 2 3 4 5 6 A99A0HS ...

Page 15: ...spension with their adjusting ring if equipped at bottom NOTE Position screw heads toward front Properly position exhaust suppport on chassis making sure that its lug rests in chassis recess Hook up exhaust spring TYPICAL RIGHT SIDE SHOWN 1 Shock absorber 2 engine compartment adjusting ring if equipped at bottom 2 Screw M10 x 1 5 x 60 2 P N 222 0060 65 on suspension 3 Screw M10 x 1 5 x 55 2 P N 22...

Page 16: ...stall vent tube on battery Connect RED positive cable and RED wire to pos itive battery terminal Connect BLACK negative cable LAST Connect vent tube to vehicle fitting on front frame as shown BATTERY CONNECTION 1 Vent tube on fitting Apply silicone dielectric grease P N 413 7017 00 on battery posts and connectors Ensure vent tube is properly installed on battery elbow then install protective boot ...

Page 17: ...TALLATION BATTERY BATTERY PROTECTIVE BOOT INSTALLED Ensure that vent tube is not kinked or blocked Reinstall air silencer and ignition module Reinstall throttle cable and primer hose plastic clip to air silencer Fasten spark plug cables A03H1WA ...

Page 18: ... Make sure that slider cushions are still in ski leg Replace vehicle on ground TYPICAL RIGHT SIDE SHOWN 1 Nut M12 x 1 75 2 section no 1 or 3 torque to 40 N m 30 lbf ft 2 Slider cushion 4 ski leg 3 Bolt M12 2 ski leg 4 Twist ski to ease bolt installation A03G0ES 2 2 1 3 4 ...

Page 19: ...eering pad and torque nuts to 26 N m 19 lbf ft Reinstall steering pad adjust and tighten throttle and brake handle housings 1 Steering pad P N 572 0238 00 engine compartment 2 Keyway 2 P N 572 0239 00 section no 4 use liquid soap to ease installation 3 Screw M5 x 20 2 P N 222 8520 65 section no 4 4 Nut M5 2 P N 228 7510 45 section no 4 seat tighten only no deformation of rubber 5 Loosen allen scre...

Page 20: ...pad temporary and adjust for proper fit with console Remove steering pad and torque nuts to 26 N m 19 lbf ft Reinstall steering pad adjust and tighten throttle and brake handle housings 1 Torque to 26 N m 19 lbf ft 2 Equal gap each side 3 Loosen allen screw 4 Steering pad P N 572 0840 00 and 572 0841 00 engine compartment 5 Use liquid soap to ease installation 6 Keyway 2 P N 572 0724 00 section no...

Page 21: ...TS INSTALLATION WINDSHIELD Install windshield on dashboard 1 Dart 1 P N 414 6443 00 section no 2 or 5 2 Latch 6 P N 570 0238 00 section no 4 or 6 3 Temporary remove headlamp molding for windshield installation A03H17S 2 1 3 ...

Page 22: ...installing headlamp molding make sure lip is behind headlamp 1 Headlamp 2 Lip of headlamp molding behind headlamp PARTS INSTALLATION BACKREST Except Touring E and Formula S SL 1 Slide backrest on mounting bracket and install with screws A03H1XA 1 2 A00H0CA 1 ...

Page 23: ... Oil P N 496 0133 00 should be added to fuel for the first full filling of fuel tank Always remove and clean spark plugs after en gine break in Bleed main oil line between tank and pump by loosening the bleeder screw until air has escaped from the line Add injection oil as required TYPICAL 1 Main oil line 2 Bleeder screw Bleed the small oil line between pump and intake manifold by running engine a...

Page 24: ...n pulley guard 1 Adjustment chart 2 Pulley guard ADJUSTMENT TRACK Refer to Shop Manual to adjust track tension and alignment See Technical Data section at the end of this bulletin ADJUSTMENT DRIVEN PULLEY It is usual to experience spring settings during break in period of a new spring The factory spring preload is slightly higher to compensate for springs settings Specifications in Technical Data ...

Page 25: ... Adjustment 1 mm 040 in 23 9 94 23 9 94 Air Screw Adjustment 1 32 turn 1 1 4 2 1 4 Idle Speed RPM 200 RPM 1650 1650 Gas Grade Octane Number R M 2 Regular Unleaded 87 Regular Unleaded 87 Gas Oil Ratio Oil Injection Oil Injection Ignition Timing BTDC mm in 1 68 066 1 68 066 Trigger Coil Air Gap mm in 0 45 0 55 018 022 0 45 0 55 018 022 Gear Ratio teeth 21 44 21 44 Engagement Speed 100 RPM Formula S ...

Page 26: ...Pilot Jet 40 Needle Identification clip position 6DH2 Slide Cut away 2 5 Float Adjustment 1 mm 040 in 23 9 94 Air Screw Adjustment 1 32 turn 1 5 8 Idle Speed RPM 200 RPM 1650 Gas Grade Octane Number R M 2 Regular Unleaded 87 Gas Oil Ratio Oil Injection Ignition Timing BTDC mm in 1 66 065 Trigger Coil Air Gap mm in 0 45 0 55 018 022 Gear Ratio teeth Touring SLE and Skandic 500 21 44 Formula SL 22 4...

Page 27: ...ed Bombardier Inc 1997 97 2 Page 1 of 1 Please update the predelivery bulletin 97 2 with the following page Replace existing page of your bulletin Year models has been changed from 1996 to 1997 No 97 2 REVISION 1 Date July 4 1996 SUBJECT Predelivery Procedures FOR APPROVAL ONLY ...

Page 28: ...hat have the same or similar function The content of this bulletin is designed as a guideline only All mechanics performing predelivery proce dures should have attended the current model year service training Further information or inquires should be directed to your distributor service representative and or specific Shop Manual sections Please complete the Predelivery Check List for each snowmobi...

Page 29: ...ION 6 BATTERY PARTS INSTALLATION 8 SKIS PARTS INSTALLATION 9 STEERING PAD PARTS INSTALLATION 11 WINDSHIELD PARTS INSTALLATION 12 BACKREST PARTS INSTALLATION 13 DRIVE BELT LIQUIDS 13 OIL INJECTION PUMP BLEEDING LIQUIDS 14 BRAKE FLUID LEVEL ADJUSTMENT 14 SUSPENSION ADJUSTMENT 14 TRACK ADJUSTMENT 14 DRIVEN PULLEY TECHNICAL DATA 15 ...

Page 30: ...resent parts that have the same or similar function The content of this bulletin is designed as a guideline only All mechanics performing predelivery proce dures should have attended the current model year service training Further information or inquires should be directed to your distributor service representative and or specific Shop Manual sections Please complete the Predelivery Check List for...

Page 31: ...ATION 6 BATTERY PARTS INSTALLATION 7 SKIS PARTS INSTALLATION 9 STEERING PAD PARTS INSTALLATION 11 WINDSHIELD PARTS INSTALLATION 12 DRIVE BELT LIQUIDS 12 OIL INJECTION PUMP BLEEDING ADJUSTMENT 13 DRIVE PULLEY LIQUIDS 13 BRAKE FLUID LEVEL ADJUSTMENT 13 SUSPENSION ADJUSTMENT 13 TRACK ADJUSTMENT 14 DRIVEN PULLEY TECHNICAL DATA 14 ...

Page 32: ...ard crating spacers and nuts Remove vehicle from base Remove steering pad drive belt predelivery kit and detach shock absorbers from engine com partment Apply pressure on rear suspension and remove hook from rear portion of suspension as illustrat ed 1 Remove hook Using a long flat chisel such as Snap On PPC820LA cut shipping strap that collapses front portion of rear suspension WARNING Torque wre...

Page 33: ...oval could result in personal injury A03F15A WARNING Shipping strap must be cut and hook re moved to have snowmobile suspension op erational PREDELIVERY KIT P N MODELS 580 6540 00 SUMMIT 500 583 670 FORMULA Z FORMULA 500 DE LUXE 580 6543 00 FORMULA 500 583 M5 M6 M8 M10 M12 M14 inches pouces mm cm 1 2 3 4 5 6 7 8 9 1 5 1 1 1 2 1 0 1 3 1 4 1 2 3 4 5 6 A99A0HS ...

Page 34: ...pt for Summit 500 and 583 bottom screw heads position screw heads toward front Properly position exhaust support on chassis making sure that its lug rests in chassis recess Hook up exhaust spring NOTE On models equipped with a 5 holes ex haust support hook up exhaust spring on mid hole TYPICAL RH SIDE SHOWN 1 Shock absorber 2 Engine compartment adjusting ring if equipped at bottom 2 Screw M10 x 1 ...

Page 35: ...al Connect BLACK negative cable LAST Connect vent tube to vehicle fitting on front frame as shown BATTERY CONNECTION 1 Vent tube on fitting Apply silicone dielectric grease P N 413 7017 00 on battery posts and connectors Ensure vent tube is properly installed on battery elbow then install protective boot over battery Close and fasten retaining strips as shown on the next photo BATTERY PROTECTIVE B...

Page 36: ...NOTE Make sure that slider cushions are still in ski leg Replace vehicle on ground LEFT SIDE SHOWN 1 Elastic flanged nut M12 x 1 75 2 P N 228 5210 45 Section no 1 Torque to 40 N m 30 lbf ft 2 Slider cushion 4 Ski leg 3 Bolt M12 2 Ski leg 4 Twist ski to ease bolt installation A03G0ES 2 2 1 3 4 ...

Page 37: ... 3 Elastic flanged nut M12 2 Ski leg Torque to 40 N m 30 lbf ft 4 Loosen then adjust against stop bounding Torque to 14 N m 124 lbf in 5 Bolt M12 2 Ski leg After ski installation adjust stopper against stop bounding then tighten nut to 14 N m 124 lbf in More preload on stop bounding will result in a more aggressive steering Adjust according to driver preferences A16G0CS 5 3 1 2 4 ...

Page 38: ...e handle housings Install steering pad temporary and adjust for proper fit with console Remove steering pad and torque nuts to 26 N m 19 lbf ft Reinstall steering pad adjust and tighten throttle and brake handle housings 1 Torque to 26 N m 19 lbf ft 2 Equal gap each side Both clamps 3 Keyway 2 P N 572 0724 00 Section no 3 or 5 4 Steering pad engine compartment 4 A06G1GT 3 2 1 ...

Page 39: ...Page 10 of 19 97 3 PARTS INSTALLATION STEERING PAD BRAKE HANDLE HOUSING 1 Tighten set screw to 2 N m 18 lbf in THROTTLE HANDLE HOUSING 1 Tighten set screw to 2 N m 18 lbf in A06G1HA 1 A06G1IA 1 ...

Page 40: ...d on dashboard NOTE Make sure that protective foam is properly positioned around headlamp before installing windshield 1 Protective foam 2 Install windshield on dashboard WINDSHIELD INSTALLED ON DASHBOARD 1 Latch 6 P N 570 0238 00 section no 4 or 6 A03H1YA 1 2 A03H1ZA 1 A03H20A ...

Page 41: ...Remove air silencer and move carburetors aside Bleed main oil line between tank and pump by loosening the bleeder screw until air has escaped from the line Add injection oil as required Check also for proper oil lever adjustment Marks must aligned when throttle lever is activated just enough to take all cable play 1 Small oil line 2 Marks aligned 3 Main oil line Reinstall all parts except air sile...

Page 42: ...ECHNICAL DATA ADJUSTMENT SUSPENSION Rear suspension is calibrated at factory At prede livery mechanics should perform suspension ad justments according to customer riding style and vehicle load as described on suspension adjust ment chart which is located on pulley guard 1 Adjustment chart 2 Pulley guard CAUTION Use only DOT 4 brake fluid from a sealed container Do not store or use a partial bottl...

Page 43: ...slightly higher to compensate for springs settings Specifications in TECHNICAL DATA are applicable after break in period about 10 hours of use TECHNICAL DATA TECHNICAL DATA The content of the TECHNICAL DATA pages should be used as necessary to fine tune and perform additional adjustments required on the snowmobile Vehicles used at high altitudes above 600 m 2000 ft should be fitted with a high alt...

Page 44: ...0 1800 Gas Grade Octane Number R M 2 Regular Unleaded 87 Regular Unleaded 87 Gas Oil Ratio Oil Injection Oil Injection Ignition Timing BTDC mm in 1 81 071 1 75 069 Trigger Coil Air Gap mm in 0 55 1 45 022 057 0 55 1 45 022 057 Gear Ratio teeth 23 44 25 44 Engagement Speed 100 RPM 4200 4100 Drive Pulley Calibration Screw Position 3 3 Pulley Distance Z 0 1 mm 0 1 32 in 16 5 21 32 Offset X 0 4 mm 1 6...

Page 45: ...1800 Gas Grade Pump Octane Number R M 2 Regular Unleaded 87 Gas Oil Ratio Oil Injection Ignition Timing BTDC mm in 1 81 071 Trigger Coil Air Gap mm in 0 55 1 45 022 057 Gear Ratio teeth 22 44 Engagement Speed 100 RPM 4800 Drive Pulley Calibration Screw Position 5 Pulley Distance Z 0 1 mm 0 1 32 in 16 5 21 32 Offset X 0 4 mm 1 64 in 35 0 1 3 8 Y Dimension Y must exceed X from 1 mm 1 32 in to 2 mm 5...

Page 46: ...M 1900 Gas Grade Pump Octane Number R M 2 Regular Unleaded 87 Gas Oil Ratio Oil Injection Ignition Timing BTDC mm in 1 75 069 Trigger Coil Air Gap mm in 0 55 1 45 022 057 Gear Ratio teeth 22 44 Engagement Speed 100 RPM 4500 Drive Pulley Calibration Screw Position 5 Pulley Distance Z 0 1 mm 0 1 32 in 16 5 21 32 Offset X 0 4 mm 1 64 in 35 0 1 3 8 Y Dimension Y must exceed X from 1 mm 1 32 in to 2 mm...

Page 47: ... 1900 Gas Grade Pump Octane Number R M 2 Regular Unleaded 87 Gas Oil Ratio Oil Injection Ignition Timing BTDC mm in 1 93 076 Trigger Coil Air Gap mm in 0 55 1 45 022 057 Gear Ratio teeth 23 44 Engagement Speed 100 RPM 4100 Drive Pulley Calibration Screw Position 5 Pulley Distance Z 0 1 mm 0 1 32 in 16 5 21 32 Offset X 0 4 mm 1 64 in 35 0 1 3 8 Y Dimension Y must exceed X from 1 mm 1 32 in to 2 mm ...

Page 48: ...on clip Position 7ECY1 Slide Cut away 2 5 Float Adjustment 1 mm in 18 1 71 Air Screw Adjustment 1 16 turn 2 Idle Speed RPM 200 RPM 1800 Gas Grade Pump Octane Number R M 2 Regular Unleaded 87 Gas Oil Ratio Oil Injection Ignition Timing BTDC mm in 1 75 069 Trigger Coil Air Gap mm in 0 55 1 45 022 057 Gear Ratio teeth 25 44 Engagement Speed 100 RPM 4100 Drive Pulley Calibration Screw Position 3 Pulle...

Page 49: ...show the typical construction of the different assemblies and may not reproduce the full detail or exact shape of the parts However they represent parts that have the same or similar function The contents of this bulletin is designed as a guideline only All mechanics performing predeliv ery procedures should have attended the current model year service training Further information or inquires shou...

Page 50: ...TS INSTALLATION 8 FRONT SUSPENSION PARTS INSTALLATION 9 SKIS PARTS INSTALLATION 11 STEERING PAD PARTS INSTALLATION 12 WINDSHIELD PARTS INSTALLATION 13 BACKREST AND SEAT STRAP PARTS INSTALLATION 14 DRIVE BELT LIQUIDS 14 OIL INJECTION PUMP BLEEDING LIQUIDS 15 BRAKE FLUID LEVEL LIQUIDS 15 ENGINE COOLANT LEVEL ADJUSTMENT 15 TRACK TECHNICAL DATA 16 ...

Page 51: ...G Torque wrench tightening specifications must be strictly adhere to Locking devices e g lock tabs nylon stop nuts must be installed or replaced by new one where specified If the efficiency of a locking device is impaired it must be renewed CAUTION Allowing the crate to drop may cause serious damage to the vehicle F02P04S ...

Page 52: ...ts base Remove predelivery kit and parts to be installed from under seat compartment NOTE This rule can be helpful to identify fastener length size CAUTION Make sure vehicle is properly supported before removing ski legs and rear suspension from crate brackets A29H07S 1 M5 M6 M8 M10 M12 M14 inches pouces mm cm 1 2 3 4 5 6 7 8 9 1 5 1 1 1 2 1 0 1 3 1 4 1 2 3 4 5 6 A99A0HS ...

Page 53: ...els During preparation the battery can be activated as described in 1997 Ski Doo Shop Manual On WT and SWT models a special vented rivet is fixed to the chassis in order to plug the vent tube from the battery On WT LC vent tube is connected to a special plastic reservoir CAUTION Make sure vehicle is properly supported A29G0AA A29F05A CAUTION Prior to charging the battery always remove it from the ...

Page 54: ...battery vent tube is properly installed from battery to the plug provided on the frame Reinstall air intake silencer Secure oil injection pump cable to air intake silenc er using a locking tie Install locking tie loosely as per following illustration 1 Locking tie Skandic SWT Battery removal Remove battery bracket and remove battery from vehicle A22C09A 1 A22C0AA 1 A22E0GA 1 WARNING Always connect...

Page 55: ...ttery from vehicle 1 Wing screw Battery installation Install battery in vehicle Connect battery cables Apply silicone dielectric grease P N 413 7017 00 on battery posts and connectors Install battery cover Install battery bracket with solenoid and secure with wing screw Ensure vent tube is properly installed from battery to the special reservoir provided WARNING Always connect the battery cables e...

Page 56: ... using previously removed screws Apply Loctite 242 on threads and torque screws to 58 N m 43 lbf ft TECHNICAL DATA PARTS INSTALLATION FRONT SUSPENSION Remove long bolts that compresses front suspen sion on both sides Install 2 plastic bushings into shock absorber eye let Stretch shock to its maximum Slide shock absorber onto bottom of ski leg until shock rod goes through cap hole Loosely install w...

Page 57: ...ings PARTS INSTALLATION SKIS Install stop bounding on skis with its highest por tion toward front 1 Stop bounding Instal skis on vehicle using bolts nuts washers and rubber bushings supplied in the predelivery kit A22G0IA 1 A29G0BA 1 ...

Page 58: ... 10 of 18 97 4 1 Stop bounding 2 Sleeve 3 Rubber bushing 2 4 Flat washer 2 5 Bolt M10 x 120 6 M10 lock nut tighten to 48 N m 35 lbf ft Tighten shock rod top nuts to 30 N m 22 lbf ft A22G0GS 1 3 4 5 2 3 4 6 ...

Page 59: ...E On Skandic SWT make sure to secure steering column cover with steering pad before tightening bolts Adjust both throttle and brake handle housings to match steering pad TYPICAL Step Torque to 26 N m 19 lbf ft 1 Steering pad 2 Keyway Use liquid soap to ease installation 3 Screw M5 x 0 80 x 20 2 4 Nut M5 x 0 80 x 20 2 Seat tighten only no deformation of rubber A Equal gap on each side Both clamps A...

Page 60: ...IELD Remove headlamp molding Install rubber support in predrilled holes on the hood Step Pry out headlamp molding Step Install support Apply soap on tips to ease installation Step Install windshield Step Install latches 10 A22H0OS 3 2 4 1 1 2 3 4 ...

Page 61: ...s tic molding under head lamp 1 Rubber Expansion Nut 2 hole in windshield PARTS INSTALLATION BACKREST AND SEAT STRAP WT and WT LC Remove screws retaining backrest to seat Remove backrest Install spacers included in shrink kit in rear seat holes of backrest 1 Spacer Reinstall backrest in its proper position Secure rear arm backrest using 2 M8 x 30 screws previously retaining backrest to seat Instal...

Page 62: ...jection oil as required 1 No air in main line 2 Bleeder screw Bleed the small oil lines between pump and intake manifold by running engine at idle while holding the pump lever in fully open position Skandic WT LC 1 Small oil line 2 Marks aligned 3 Main oil line Remove air silencer and move carburetors aside Bleed main oil line between tank and pump by loosening the bleeder screw until air has esca...

Page 63: ... then stop en gine Check hoses for leaks When engine has completely cooled down re check coolant level and top up if necessary ADJUSTMENT TRACK Refer to Shop Manual to adjust track tension and alignment See TECHNICAL DATA section at the end of this bulletin CAUTION Use only DOT 4 brake fluid from a sealed container Do not store or use a partial bottle of brake fluid A06G1OA 1 CAUTION To prevent ru...

Page 64: ...A pages should be used as necessary to fine tune and perform additional adjustments required on the snowmobile Vehicle used at high altitudes above 600 m 2000 ft should be fitted with a high altitude kit Further inquires should be directed to your distributor service representative ...

Page 65: ...ade Pump Octane Number R M 2 Regular Unleaded 87 Regular Unleaded 87 Gas Oil Ratio Oil Injection Oil Injection Ignition Timing BTDC mm in 1 66 065 1 66 065 Trigger Coil Air Gap mm in 0 45 0 55 018 022 0 45 0 55 018 022 Gear Ratio 1st gear 1 3 27 2nd gear 1 2 07 1st gear 1 4 41 2nd gear 1 3 19 Engagement Speed 100 RPM 3300 3300 Drive Pulley Calibration Screw Position 3 4 Pulley Distance Z 0 1 mm 0 ...

Page 66: ...t Adjustment 1 mm 040 in 23 9 15 16 Air Screw Adjustment 1 16 turn PTO 1 0 MAG 3 4 Idle Speed RPM RPM 1800 2000 Gas Grade Octane Number R M 2 Regular Unleaded 87 Gas Oil Ratio Oil Injection Ignition Timing BTDC mm in 1 81 071 Trigger Coil Air Gap mm in 0 55 1 45 022 057 Gear Ratio Low 1 3 38 High 1 1 86 Engagement Speed RPM 3400 Drive Pulley Calibration Screw Position 2 Pulley Distance Z 0 1 mm 0 ...

Page 67: ...next photo 1 Insert tool tip onto strap and twist How to build the special tool Using 20 mm 3 4 in steel tubing cut the first piece to 460 mm 18 in and the second one to 410 mm 16 in NOTE High forces will be apply on this special tool use strong tubing with a minimum wall thick ness of 2 mm 5 64 in On one end of the 460 mm 18 in piece cut a 1 2 mm 3 64 in slot by 28 5 mm 1 1 8 in Make a chamfer of...

Page 68: ...t front of vehicle to position bumper 35 to 40 inches upward Lean on vehicle seat to apply pressure on rear suspension and remove hook from rear portion of suspension as shown on the next photo 1 Remove hook on the rear portion of the suspension WARNING Failure to use one of these two methods of strap removal could result in personal injury A01F2DA D A C B A01F2EA A B 2 1 WARNING Shipping strap mu...

Page 69: ...hey represent parts that have the same or similar function The content of this bulletin is designed as a guideline only All mechanics performing predelivery proce dures should have attended the current model year service training Further information or inquires should be directed to your distributor service representative and or specific Shop Manual sections Please complete the Predelivery Check L...

Page 70: ...TS INSTALLATION 7 SKIS PARTS INSTALLATION 8 STEERING PAD PARTS INSTALLATION 10 WINDSHIELD PARTS INSTALLATION 11 DRIVE BELT LIQUIDS 11 OIL INJECTION PUMP BLEEDING LIQUIDS 12 BRAKE FLUID LEVEL ADJUSTMENT 13 SUSPENSION ADJUSTMENT 13 TRACK ADJUSTMENT 13 DRIVEN PULLEY TECHNICAL DATA 13 M5 M6 M8 M10 M12 M14 inches pouces mm cm 1 2 3 4 5 6 7 8 9 1 5 1 1 1 2 1 0 1 3 1 4 1 2 3 4 5 6 A99A0HS ...

Page 71: ...ve vehicle from base Remove steering pad drive belt predelivery kit and detach shock absorbers from engine com partment SHIPPING STRAP REMOVAL Cut shipping strap using one of these 2 following methods Method 1 Using a long flat chisel such as Snap On PPC820LA cut shipping strap that collapses front portion of rear suspension as shown on the next photo PREDELIVERY KIT P N MODELS 580 6543 00 MX Z 44...

Page 72: ...d of the 460 mm 18 in piece cut a 1 2 mm 3 64 in slot by 28 5 mm 1 1 8 in Make a chamfer of 30 X 10 mm 25 64 in as shown on the next photo A 1 2 mm 3 64 in B 10 mm 25 64 in C 28 5 mm 1 1 8 in D 30 Remove all sharp edges Assemble the two pieces and weld them togeth er as shown on the following photo 1 20 mm 3 4 in steel tubing 2 Welded joint A 410 mm 16 in B 460 mm 18 in HOOK REMOVAL 1 Hook to be r...

Page 73: ... apply pressure on rear sus pension and remove hook from rear portion of suspension as shown on the next photo 1 Remove hook on the rear portion of the suspension WARNING Shipping strap must be cut and hook re moved to have snowmobile suspension op erational A01F2FA 1 ...

Page 74: ...ng ring at bottom NOTE Except for MX Z 440 F bottom screw heads position screw heads toward front Properly position exhaust support on chassis making sure that its lug rests in chassis recess Hook up exhaust spring TYPICAL RH SIDE SHOWN 1 Shock absorber 2 Engine compartment adjusting ring if equipped at bottom 2 Screw M10 x 1 5 x 60 2 P N 222 0060 65 On suspension 3 Screw M10 x 1 5 x 55 2 P N 222 ...

Page 75: ...ke sure that slider cushions are still in ski leg Replace vehicle on ground LEFT SIDE SHOWN 1 Elastic flanged nut M12 x 1 75 2 P N 228 5210 45 Section no 1 Torque to 40 N m 30 lbf ft 2 Slider cushion 4 Ski leg 3 Bolt M12 2 Ski leg 4 Twist ski to ease bolt installation A03G0ES 2 2 1 3 4 ...

Page 76: ...rake handle housings Install steering pad temporarily and adjust for proper fit with console Remove steering pad and torque nuts to 26 N m 19 lbf ft Reinstall steering pad adjust and tighten throttle and brake handle housings 1 Torque to 26 N m 19 lbf ft 2 Equal gap each side Both clamps 3 Keyway 2 P N 572 0724 00 Section no 3 4 Steering pad Engine compartment 4 A06G1GT 3 2 1 ...

Page 77: ... Page 9 of 16 PARTS INSTALLATION STEERING PAD BRAKE HANDLE HOUSING 1 Tighten set screw to 2 N m 18 lbf in Except MX Z 440 F THROTTLE HANDLE HOUSING 1 Tighten set screw to 2 N m 18 lbf in A06G1HA 1 A06G1IA 1 ...

Page 78: ...d on dashboard NOTE Make sure that protective foam is properly positioned around headlamp before installing windshield 1 Protective foam 2 Install windshield on dashboard WINDSHIELD INSTALLED ON DASHBOARD 1 Latch 6 P N 570 0238 00 section no 4 or 6 A03H22A 1 2 A03H1ZA 1 A03H20A ...

Page 79: ...ING PROCEDURE Remove air silencer and move carburetors aside Bleed main oil line between tank and pump by loosening the bleeder screw until air has escaped from the line Add injection oil as required Check also for proper oil lever adjustment Marks must aligned when throttle lever is activated just enough to take all cable play 1 Small oil line 2 Marks aligned 3 Main oil line Reinstall all parts e...

Page 80: ...d pump by loosening the bleeder screw until air has escaped from the line Add injection oil as required TYPICAL 1 Main oil line 2 Bleeder screw Bleed the small oil line between pump and intake manifold by running engine at idle while holding the pump lever in fully open position TYPICAL 1 Fully open position 2 Small lines LIQUIDS BRAKE FLUID LEVEL Check brake fluid in reservoir for proper level Ad...

Page 81: ...s bulletin ADJUSTMENT DRIVEN PULLEY It is usual to experience spring settings during break in period of a new spring The factory spring preload is slightly higher to compensate for springs settings Specifications in TECHNICAL DATA are applicable after break in period about 10 hours of use TECHNICAL DATA TECHNICAL DATA The content of the TECHNICAL DATA pages should be used as necessary to fine tune...

Page 82: ...ade Octane Number R M 2 Regular Unleaded 87 Regular Unleaded 87 Gas Oil Ratio Oil Injection Oil Injection Ignition Timing BTDC mm in 1 48 058 1 75 069 Trigger Coil Air Gap mm in 0 55 1 45 022 057 0 55 1 45 022 057 Gear Ratio teeth 23 44 25 44 Engagement Speed 100 RPM 4400 4400 Drive Pulley Calibration Screw Position 3 3 Pulley Distance Z 0 1 mm 0 1 32 in 16 5 21 32 Offset X 0 4 mm 1 64 in 35 0 1 3...

Page 83: ...0 Gas Grade Pump Octane Number R M 2 Regular Unleaded 87 Gas Oil Ratio Oil Injection Ignition Timing BTDC mm in 1 75 069 Trigger Coil Air Gap mm in 0 55 1 45 022 057 Gear Ratio teeth 26 44 Engagement Speed 100 RPM 3800 Drive Pulley Calibration Screw Position 3 Pulley Distance Z 0 1 mm 0 1 32 in 16 5 21 32 Offset X 0 4 mm 1 64 in 35 0 1 3 8 Y Dimension Y must exceed X from 1 mm 1 32 in to 2 mm 5 64...

Page 84: ...H2 Slide Cutaway 2 5 Float Adjustment 1 mm in 23 9 94 Air Screw Adjustment 1 16 turn 1 1 2 Idle Speed RPM 200 RPM 1650 Gas Grade Pump Octane Number R M 2 Regular Unleaded 87 Gas Oil Ratio Oil Injection Ignition Timing BTDC mm in 1 68 066 Trigger Coil Air Gap mm in 0 45 0 55 018 022 Gear Ratio teeth 22 44 Engagement Speed 100 RPM 3800 Drive Pulley Calibration Screw Position 3 Pulley Distance Z 0 1 ...

Page 85: ... technical data sheet for the above mentioned models has been updated Refer to the Ski Doo Predelivery Bulletin no 97 6 Replace with the attached No 97 6 UPDATE Date December 6 1996 SUBJECT Technical Data YEAR MODEL MODEL NUMBER SERIAL NUMBER 1997 MX Z 670 Canada 1193 United States 1194 Sweden 1195 All FOR APPROVAL ONLY ...

Page 86: ...0 Gas Grade Pump Octane Number R M 2 Regular Unleaded 87 Gas Oil Ratio Oil Injection Ignition Timing BTDC mm in 1 93 076 Trigger Coil Air Gap mm in 0 55 1 45 022 057 Gear Ratio teeth 26 44 Engagement Speed 100 RPM 3800 Drive Pulley Calibration Screw Position 3 Pulley Distance Z 0 1 mm 0 1 32 in 16 5 21 32 Offset X 0 4 mm 1 64 in 35 0 1 3 8 Y Dimension Y must exceed X from 1 mm 1 32 in to 2 mm 5 64...

Page 87: ...H2 Slide Cutaway 2 5 Float Adjustment 1 mm in 23 9 94 Air Screw Adjustment 1 16 turn 1 1 2 Idle Speed RPM 200 RPM 1650 Gas Grade Pump Octane Number R M 2 Regular Unleaded 87 Gas Oil Ratio Oil Injection Ignition Timing BTDC mm in 1 68 066 Trigger Coil Air Gap mm in 0 45 0 55 018 022 Gear Ratio teeth 22 44 Engagement Speed 100 RPM 3800 Drive Pulley Calibration Screw Position 3 Pulley Distance Z 0 1 ...

Page 88: ...ct shape of the parts However they represent parts that have the same or similar function The content of this bulletin is designed as a guideline only All mechanics performing predelivery procedures should have attended the current model year service training Further information or inquires should be directed to your distributor service representative and or specific Shop Manual sections Please co...

Page 89: ...LATION 8 STEERING PAD PARTS INSTALLATION 10 WINDSHIELD PARTS INSTALLATION 11 SNOW GUARD PARTS INSTALLATION 11 REAR BUMPER PARTS INSTALLATION 12 DRIVE BELT LIQUIDS 12 OIL INJECTION PUMP BLEEDING LIQUIDS 13 BRAKE FLUID LEVEL ADJUSTMENTS 13 SUSPENSION ADJUSTMENTS 14 TRACK ADJUSTMENTS 14 DRIVEN PULLEY TECHNICAL DATA 14 M5 M6 M8 M10 M12 M14 inches pouces mm cm 1 2 3 4 5 6 7 8 9 1 5 1 1 1 2 1 0 1 3 1 4 ...

Page 90: ...nd slider cushions to bolt skis to ski legs Discard crating spacers and elastic stop nuts PREDELIVERY KIT P N MODELS 580 6581 00 Mach 1 and Mach Z 580 6580 00 Formula III WARNING Torque wrench tightening specifications must be strictly adhered to Locking devices e g Iock tabs elastic stop nuts must be in stalled or replaced by new ones where specified If the efficiency of a locking device is impai...

Page 91: ...p as shown on the next photo INSERT TOOL TIP ONTO STRAP AND TWIST How to Build the Special Tool Using 20 mm 3 4 in steel tubing cut the first piece to 460 mm 18 in and the second one to 410 mm 16 in NOTE High forces will be applied on this special tool use strong tubing with a minimum 2 mm 5 64 in wall thickness On one end of the 460 mm 18 in piece cut a 1 2 mm 3 64 in slot by 28 5 mm 1 1 8 in Mak...

Page 92: ... Lean on vehicle seat to apply pressure on rear suspension and remove hook from rear portion of suspension as shown on the next photo 1 Remove hook on the rear portion of the suspension WARNING Failure to use one of these two methods of strap removal could result in personal injury A01F2EA A B 2 1 A03F14A 1 WARNING Shipping strap must be cut and hook re moved to have snowmobile suspension op erati...

Page 93: ... brackets from suspension Discard spring clips keep bolts Secure shock absorbers to suspension with their adjusting ring at bottom NOTE Position bolt heads toward front TYPICAL RIGHT SIDE SHOWN 1 Shock absorber 2 engine compartment 2 M10 x 1 5 x 55 bolt on suspension 3 M10 x 1 5 nut section no 4 Torque to 48 N m 35 lbf ft A06G1NS 2 3 1 ...

Page 94: ...2 2 section no 8 Torque to 40 N m 30 lbf ft 4 Loosen then adjust against ski stopper 14 N m 124 lbf in 5 Bolt M12 2 ski leg After ski installation adjust stopper against stop bounding then tighten nut to 14 N m 124 lbf in More preload on stop bounding will result in a more aggressive steering Adjust according to driver preferences A16G0CS 5 3 1 2 4 ...

Page 95: ...pad temporarily and adjust for proper fit with console Remove steering pad and torque nuts to 26 N m 19 lbf ft Reinstall steering pad adjust and tighten throttle and brake handle housings 1 Torque to 26 N m 19 lbf ft 2 Equal gap each side both clamps 3 Loosen Allen screw 4 Steering pad engine compartment 5 Use liquid soap to ease installation 6 Keyway 2 P N 572 0724 00 section no 5 6 A06G1CT 3 2 1...

Page 96: ...LLATION STEERING PAD Adjust then tighten throttle and brake handle housings BRAKE HANDLE HOUSING 1 Tighten set screw to 2 N m 18 lbf in Mach Z Only THROTTLE HANDLE HOUSING 1 Tighten set screw to 2 N m 18 lbf in A06G1HA 1 A06G1IA 1 ...

Page 97: ...Page 10 of 17 97 7 PARTS INSTALLATION WINDSHIELD Install windshield on hood NOTE To ease installation install windshield with darts first 1 Dart section no 6 2 Latch section no 6 A06H27S 2 1 ...

Page 98: ...Position washer inside tunnel VIEW FROM UNDER SNOW GUARD 1 Snow guard 2 Snow guard protector pad TECHNICAL DATA PARTS INSTALLATION REAR BUMPER NOTE Bolts located in section no 3 of shrink pack are not used Install rear bumper to chassis SLIDE BUMPER INSIDE REAR MOLDINGS 1 Rear bumper Secure bumper from inside of tunnel TYPICAL VIEW FROM INSIDE OF TUNNEL 1 Bolt M8 4 section no 1 Torque to 24 N m 18...

Page 99: ... N 496 0133 00 should be added to fuel for the first full filling of fuel tank Always remove and clean spark plugs after en gine break in Bleed main oil line between tank and pump by loosening the bleeder screw until all air has es caped from the line Add injection oil as required 1 Bleeder screw 2 Oil pump lever Bleed the small oil lines between pump and en gine crankcase by running engine at idl...

Page 100: ...on is calibrated at factory At prede livery mechanics should perform suspension ad justments according to customer riding style and vehicle load as described on suspension adjust ment chart which is located on pulley guard 1 Adjustment chart 2 Pulley guard CAUTION Use only DOT 4 brake fluid from a sealed container Do not store or use a partial bottle of brake fluid A06G1OA 1 A01H1HA 2 1 ...

Page 101: ... slightly higher to compensate for springs settings Specifications in TECHNICAL DATA are applicable after break in period about 10 hours of use TECHNICAL DATA TECHNICAL DATA The content of the TECHNICAL DATA pages should be used as necessary to fine tune and perform additional adjustments required on the snowmobile Vehicles used at high altitudes above 600 m 2000 ft should be fitted with a high al...

Page 102: ...DEY4 Slide Cutaway 2 5 Float Adjustment 1 mm in 18 1 71 Air Screw Adjustment 1 16 turn PTO 1 1 2 CRT 1 1 2 MAG 1 1 2 Idle Speed 200 RPM 1900 Gas Grade Octane Number R M 2 Super Unleaded 91 Gas Oil Ratio Oil Injection Ignition Timing BTDC mm in 2 18 086 Trigger Coil Air Gap mm in 0 55 1 45 022 057 Gear Ratio Teeth 25 44 Engagement Speed 100 RPM 4500 Drive Pulley Calibration Screw Position 4 Pulley ...

Page 103: ...DEY2 Slide Cutaway 2 5 Float Adjustment 1 mm in 18 1 71 Air Screw Adjustment 1 16 turn PTO 2 1 4 CRT 2 1 4 MAG 2 1 4 Idle Speed 200 RPM 1800 Gas Grade Octane Number R M 2 Super Unleaded 91 Gas Oil Ratio Oil Injection Ignition Timing BTDC mm in 2 18 086 Trigger Coil Air Gap mm in 0 55 1 45 022 057 Gear Ratio Teeth 26 44 Engagement Speed 100 RPM 4500 Drive Pulley Calibration Screw Position 4 Pulley ...

Page 104: ...n 8AGY1 41 Slide Cutaway 2 5 Float Adjustment 1 mm in 18 1 71 Air Screw Adjustment 1 16 turn PTO 4 CRT 4 MAG 4 Idle Speed 200 RPM 1800 Gas Grade Octane Number R M 2 Super Unleaded 91 Gas Oil Ratio Oil Injection Ignition Timing BTDC mm in 2 11 083 Trigger Coil Air Gap mm in 0 55 1 45 022 057 Gear Ratio Teeth 26 44 Engagement Speed 100 RPM 4100 Drive Pulley Calibration Screw Position 3 Pulley Distan...

Page 105: ...i Doo Predelivery Bulletin no 97 7 Replace with the attached Campaign no 36363 No 97 7 Replaces 95 12 UPDATE Date October 7 1996 SUBJECT Technical Data YEAR MODEL MODEL NUMBER SERIAL NUMBER 1997 Canada and United States Mach 1 1177 and 1178 ALL 1997 Sweden Mach 1 1179 ALL FOR APPROVAL ONLY Litho d in Canada MBL 9715 PS Trademarks of Bombardier Inc 1997 Bombardier Inc All rights reserved 97 7 Page ...

Page 106: ...DEY4 Slide Cutaway 2 5 Float Adjustment 1 mm in 18 1 71 Air Screw Adjustment 1 16 turn PTO 1 1 2 CRT 1 1 2 MAG 1 1 2 Idle Speed 200 RPM 1900 Gas Grade Octane Number R M 2 Super Unleaded 91 Gas Oil Ratio Oil Injection Ignition Timing BTDC mm in 2 18 086 Trigger Coil Air Gap mm in 0 55 1 45 022 057 Gear Ratio Teeth 25 44 Engagement Speed 100 RPM 4500 Drive Pulley Calibration Screw Position 4 Pulley ...

Page 107: ...Cutaway 2 5 Float Adjustment 1 mm in 18 1 71 Air Screw Adjustment 1 16 turn PTO 2 1 4 CRT 2 1 4 MAG 2 1 4 Idle Speed 200 RPM 1800 Gas Grade Octane Number R M 2 Super Unleaded 91 Gas Oil Ratio Oil Injection Ignition Timing BTDC mm in 2 18 086 Trigger Coil Air Gap mm in 0 55 1 45 022 057 Gear Ratio Teeth 26 44 Engagement Speed 100 RPM 4500 Drive Pulley Calibration Screw Position 4 Pulley Distance Z ...

Page 108: ...or exact shape of the parts However they represent parts that have the same or similar function The content of this bulletin is designed as a guideline only All mechanics performing predelivery proce dures should have attended the current model year service training Further information or inquires should be directed to your distributor service representative and or specific Shop Manual sections Pl...

Page 109: ...NG 3 PARTS INSTALLATION 6 FRONT SUSPENSION PARTS INSTALLATION 7 SKIS PARTS INSTALLATION 8 STEERING PAD PARTS INSTALLATION 10 WINDSHIELD PARTS INSTALLATION 11 DRIVE BELT LIQUIDS 11 OIL INJECTION PUMP BLEEDING LIQUIDS 12 BRAKE FLUID LEVEL ADJUSTMENTS 12 SUSPENSION ADJUSTMENTS 13 TRACK ADJUSTMENTS 13 DRIVEN PULLEY TECHNICAL DATA 13 A99A0HS ...

Page 110: ...s from crate Keep ski leg bolts slid er cushions to bolt skis to ski legs Discard crating spacers and nuts PREDELIVERY KIT P N MODELS 580 6472 00 FORMULA III LT MACH Z LT WARNING Torque wrench tightening specifications must be strictly adhered to Locking devices e g Iock tabs elastic stop nuts must be in stalled or replaced by new ones where specified If the efficiency of a locking device is impai...

Page 111: ...mm 3 4 in steel tubing cut the first piece to 460 mm 18 in and the second one to 410 mm 16 in NOTE High forces will be applied on this special tool use strong tubing with a minimum 2 mm 5 64 in wall thickness On one end of the 460 mm 18 in piece cut a 1 2 mm 3 64 in slot by 28 5 mm 1 1 8 in Make a chamfer of 30 X 10 mm 25 64 in as shown on the next photo A 1 2 mm 3 64 in B 10 mm 25 64 in C 28 5 mm...

Page 112: ...s upward Lean on vehicle seat to apply pressure on rear suspension and remove hook from rear portion of suspension as shown on the next photo 1 Remove hook on the rear portion of the suspension WARNING Shipping strap must be cut and hook re moved to have snowmobile suspension op erational A03F14A 1 A01F2FA 1 ...

Page 113: ...g brackets from suspension Discard spring clips keep bolts Secure shock absorbers to suspension with their adjusting ring at bottom NOTE Position bolt heads toward front TYPICAL RIGHT SIDE SHOWN 1 Shock absorber 2 engine compartment 2 M10 x 1 5 x 55 bolt on suspension 3 M10 x 1 5 nut section 4 Torque to 48 N m 35 lbf ft A06G1NS 2 3 1 ...

Page 114: ...Section no 8 Torque to 40 N m 30 lbf ft 4 Loosen then adjust against ski stopper 14 N m 124 lbf in 5 Bolt M12 2 After ski installation adjust stopper against stop bounding then tighten nut to 14 N m 124 lbf in More preload on stop bounding will result in a more aggressive steering Adjust according to driver preferences A16G0CS 5 3 1 2 4 ...

Page 115: ...ing pad temporarily and adjust for proper fit with console Remove steering pad and torque nuts to 26 N m 19 lbf ft Reinstall steering pad adjust and tighten throttle and brake handle housings 1 Step Torque nuts to 26 N m 19 lbf ft 2 Equal gap each side both clamps 3 Loosen Allen screw 4 Steering pad engine compartment 5 Use liquid soap to ease installation 6 Keyway 2 section 5 6 A06G1CT 3 2 1 5 4 ...

Page 116: ...LATION STEERING PAD Adjust then tighten throttle and brake handle housings BRAKE HANDLE HOUSING 1 Tighten set screw to 2 N m 18 lbf in Mach Z LT Only THROTTLE HANDLE HOUSING 1 Tighten set screw to 2 N m 18 lbf in A06G1HA 1 A06G1IA 1 ...

Page 117: ...Page 10 of 15 97 8 PARTS INSTALLATION WINDSHIELD Install windshield on hood 1 Dart section 6 2 Latch section 6 A06H27S 2 1 ...

Page 118: ... N 496 0133 00 should be added to fuel for the first full filling of fuel tank Always remove and clean spark plugs after en gine break in Bleed main oil line between tank and pump by loosening the bleeder screw until all air has es caped from the line Add injection oil as required 1 Bleeder screw 2 Oil pump lever Bleed the small oil lines between pump and en gine crankcase by running engine at idl...

Page 119: ...on is calibrated at factory At prede livery mechanics should perform suspension ad justments according to customer riding style and vehicle load as described on suspension adjust ment chart which is located on pulley guard 1 Adjustment chart 2 Pulley guard CAUTION Use only DOT 4 brake fluid from a sealed container Do not store or use a partial bottle of brake fluid A06G1OA 1 A01H1HA 2 1 ...

Page 120: ... slightly higher to compensate for springs settings Specifications in TECHNICAL DATA are applicable after break in period about 10 hours of use TECHNICAL DATA TECHNICAL DATA The content of the TECHNICAL DATA pages should be used as necessary to fine tune and perform additional adjustments required on the snowmobile Vehicles used at high altitudes above 600 m 2000 ft should be fitted with a high al...

Page 121: ...ay 2 5 Float Adjustment 1 mm in 18 1 71 Air Screw Adjustment 1 16 turn PTO 1 5 CTR 1 5 MAG 1 5 Idle Speed RPM 200 RPM 1900 Gas Grade Octane Number R M 2 Regular Unleaded 87 or Super Unleaded 91 recommended Gas Oil Ratio Oil Injection Ignition Timing BTDC mm in 2 18 086 Trigger Coil Air Gap mm in 0 55 1 45 022 057 Gear Ratio Teeth 23 44 Engagement Speed 100 RPM 4500 Drive Pulley Calibration Screw P...

Page 122: ...Adjustment 1 mm in 20 0 787 Air Screw Adjustment 1 16 Turn PTO 4 CTR 4 MAG 4 Idle Speed RPM 200 RPM 1800 Gas Grade Octane Number R M 2 Regular Unleaded 87 or Super Unleaded 91 recommended Gas Oil Ratio Oil Injection Ignition Timing BTDC mm in 2 11 083 Trigger Coil Air Gap mm in 0 55 1 45 022 057 Gear Ratio Teeth 25 44 Engagement Speed 100 RPM 4100 Drive Pulley Calibration Screw Position 3 Pulley D...

Page 123: ...f the parts However they represent parts that have the same or similar function The content of this bulletin is designed as a guideline only All mechanics performing predelivery proce dures should have attended the current model year service training Further information or inquires should be directed to your distributor service representative and or specific Shop Manual sections Please complete th...

Page 124: ...T SUSPENSION PARTS INSTALLATION 7 BATTERY PARTS INSTALLATION 8 SKIS PARTS INSTALLATION 9 STEERING PAD PARTS INSTALLATION 11 WINDSHIELD PARTS INSTALLATION 12 BACKREST PARTS INSTALLATION 13 DRIVE BELT LIQUIDS 14 OIL INJECTION PUMP BLEEDING LIQUIDS 14 BRAKE FLUID LEVEL ADJUSTMENTS 15 SUSPENSION ADJUSTMENTS 15 TRACK ADJUSTMENTS 15 DRIVEN PULLEY TECHNICAL DATA 15 A99A0HS ...

Page 125: ...s Remove vehicle from base Remove parts to be installed and predelivery kit from engine compartment Detach shock absorb ers from engine compartment SHIPPING STRAP REMOVAL Cut shipping strap using one of these 2 following methods Method 1 Using a long flat chisel such as Snap On PPC820LA cut shipping strap that collapses front portion of rear suspension as shown on the next photo PREDELIVERY KIT P ...

Page 126: ... of the 460 mm 18 in piece cut a 1 2 mm 3 64 in slot by 28 5 mm 1 1 8 in Make a chamfer of 30 x 10 mm 25 64 in as shown on the next photo A 1 2 mm 3 64 in B 10 mm 25 64 in C 28 5 mm 1 1 8 in D 30 Remove all sharp edges Assemble the two pieces and weld them togeth er as shown on the following photo 1 20 mm 3 4 in steel tubing 2 Welded joint A 410 mm 16 in B 460 mm 18 in HOOK REMOVAL 1 Hook to be re...

Page 127: ... apply pressure on rear suspension and remove hook from rear portion of suspension as shown on the next photo 1 Remove hook on the rear portion of the suspension WARNING Shipping strap must be cut and hook re moved to have snowmobile suspension op erational A01F2FA 1 ...

Page 128: ...o suspension with their adjusting ring at bottom NOTE Position screw heads toward front Properly position exhaust support on chassis making sure that its lug rests in chassis recess Hook up exhaust spring NOTE On GT 500 model hook up exhaust spring on mid hole TYPICAL RH SIDE SHOWN 1 Shock absorber 2 engine compartment 2 Screw M10 x 1 5 x 60 2 P N 222 0060 65 on suspension 3 Screw M10 x 1 5 x 55 2...

Page 129: ... negative cable LAST Connect vent tube to vehicle fitting on front frame as shown BATTERY CONNECTION 1 Vent tube on fitting Apply silicone dielectric grease P N 413 7017 00 on battery posts and connectors Ensure vent tube is properly installed on battery elbow then install protective boot over battery Close and fasten retaining strips as shown on the next photo BATTERY PROTECTIVE BOOT INSTALLED En...

Page 130: ...leg Torque to 40 N m 30 lbf ft 4 Loosen then adjust against stop bounding Torque to 14 N m 124 lbf in 5 Bolt M12 2 ski leg After ski installation adjust stopper against stop bounding then tighten nut to 14 N m 124 lbf in More pre load on stop bounding will result in a more aggressive steering Adjust according to driver preferences A16G0CS 5 3 1 2 4 ...

Page 131: ... brake handle housings Install steering pad temporarily and adjust for proper fit with console Remove steering pad and torque nuts to 26 N m 19 lbf ft Reinstall steering pad adjust and tighten throttle and brake handle housings 1 Torque to 26 N m 19 lbf ft 2 Equal gap each side both clamps 3 Keyway 2 section no 3 4 Steering pad engine compartment 4 A06G1GT 3 2 1 ...

Page 132: ...Page 10 of 16 97 9 PARTS INSTALLATION STEERING PAD BRAKE HANDLE HOUSING 1 Tighten set screw to 2 N m 18 lbf in THROTTLE HANDLE HOUSING 1 Tighten set screw to 2 N m 18 lbf in A06G1HA 1 A06G1IA 1 ...

Page 133: ...dashboard NOTE Make sure that protective foam is properly positioned around headlamp before installing windshield 1 Protective foam 2 Install windshield on dashboard WINDSHIELD INSTALLED ON DASHBOARD 1 Latch 6 P N 570 0238 00 section no 4 or 6 A03H22A 1 2 A03H23A 1 A03H20A ...

Page 134: ...her 2 P N 732 9000 30 section no 6 4 Plastic washer 2 P N 414 8196 00 section no 6 5 Elastic nut 2 P N 228 5810 45 section no 6 Torque to 8 N m 73 lbf in 6 Lever assembly 2 P N 580 6110 00 section no 2 7 Guide 2 P N 517 2573 00 section no 2 8 Rubber shim 2 P N 570 0274 00 section no 6 9 Spacer 2 P N 517 2513 00 section no 2 10 Flanged washer 2 P N 414 8195 00 section no 6 11 Threaded plate 2 P N 5...

Page 135: ...EST Turn adjustment knob left or right to adjust back rest cushion position PARTS INSTALLATION DRIVE BELT Clean pulleys and disc brake with a suitable cleaner such as Loctite Cleaning Solvent P N 413 7082 00 before installing drive belt A03H25A ...

Page 136: ...heck also for proper oil lever adjustment Marks must aligned when throttle lever is activated just enough to take all cable play 1 Small oil line 2 Marks aligned 3 Main oil line Reinstall all parts except air silencer Bleed the small oil line between pump and intake manifold by running engine at idle while holding the pump lever in fully open position NOTE If the air silencer has been rein stalled...

Page 137: ...is bulletin ADJUSTMENTS DRIVEN PULLEY It is usual to experience spring settings during break in period of a new spring The factory spring preload is slightly higher to compensate for springs settings Specifications in TECHNICAL DATA are applicable after break in period about 10 hours of use TECHNICAL DATA TECHNICAL DATA The content of the TECHNICAL DATA pages should be used as necessary to fine tu...

Page 138: ... in 1 81 071 1 75 069 Trigger Coil Air Gap mm in 0 55 1 45 022 057 0 55 1 45 022 057 Gear Ratio Teeth 23 44 23 44 Engagement Speed 100 RPM 3500 3800 Drive Pulley Calibration Screw Position 3 3 Pulley Distance Z 0 1 mm 0 1 32 in 16 5 21 32 Offset X 0 4 mm 1 64 in 35 0 1 3 8 Y Dimension Y must exceed X from 1 mm 1 32in to 2 mm 5 64 in Drive Belt Adjustment Deflection mm in 32 1 1 4 Force kg lbf 11 3...

Page 139: ...tion of the different assemblies and may not reproduce the full detail or exact shape of the parts However they represent parts that have the same or similar function The content of this bulletin is designed as a guideline only All mechanics performing predelivery proce dures should have attended the current model year service training Further information or inquires should be directed to your dis...

Page 140: ...helpful to identify fastener length or size UNCRATING 3 PARTS INSTALLATION 4 SKIS PARTS INSTALLATION 5 WINDSHIELD PARTS INSTALLATION 6 DRIVE BELT LIQUIDS 6 ROTARY VALVE OIL RESERVOIR LEVEL LIQUIDS 6 BRAKE FLUID LEVEL ADJUSTMENT 7 TRACK ADJUSTMENT 7 DRIVEN PULLEY TECHNICAL DATA 7 A99A0HS ...

Page 141: ...rating spacers and nuts Remove vehicle from base Remove drive belt and predelivery kit from engine compartment PREDELIVERY KIT P N MODELS 580 6564 00 MX Zx 440 LC WARNING Torque wrench tightening specifications must be strictly adhered to Locking devices e g Iock tabs elastic stop nuts must be in stalled or replaced by new ones where specified If the efficiency of a locking device is impaired it m...

Page 142: ... on ground LEFT SIDE SHOWN 1 Ski stopper 2 section no 8 AVANT toward front 2 Self locking nut M12 x 1 75 2 Section no 8 Torque to 24 N m 18 lbf ft 3 Slider cushion 4 Ski leg 4 Bolt M12 2 section no 8 Install bolt into mid hole 5 Washer 4 section no 8 6 Cotter pin 2 secion no 8 7 Twist ski to ease bolt installation A15G1MS 1 2 3 7 5 6 4 5 ...

Page 143: ...8 PARTS INSTALLATION WINDSHIELD Install windshield on dashboard 1 Dart 1 P N 414 6443 00 section no 6 2 Latch 6 P N 570 0238 00 section no 6 3 Temporary remove headlamp molding for windshield installation A15H46S 2 1 3 ...

Page 144: ...EVEL Check oil level in the rotary valve reservoir Add oil as required Refer to the following photo ROTARY VALVE OIL RESERVOIR LIQUIDS BRAKE FLUID LEVEL Check brake fluid in reservoir for proper level Add fluid DOT as required A15C2GA CAUTION Use only Bombardier Rotax injection oil P N 413 8029 00 12 x 1L CAUTION Use only DOT 4 brake fluid from a sealed container Do not store or use a partial bott...

Page 145: ...slightly higher to compensate for springs settings Specifications in TECHNICAL DATA are applicable after break in period about 10 hours of use TECHNICAL DATA TECHNICAL DATA The content of the TECHNICAL DATA pages should be used as necessary to fine tune and perform additional adjustments required on the snowmobile Vehicles used at high altitudes above 600 m 2000 ft should be fitted with a high alt...

Page 146: ...9 94 Air Screw Adjustment 1 16 turn 1 Idle Speed RPM 200 RPM 1700 Gas Grade Pump Octane Number R M 2 Regular Unleaded 87 Gas Oil Ratio Premix 40 1 with Bombardier synthetic injection oil Ignition Timing BTDC mm in 1 48 058 Trigger Coil Air Gap mm in 0 55 1 45 022 057 Gear Ratio teeth 23 43 Engagement Speed 100 RPM 4900 Drive Pulley Calibration Screw Position 3 Pulley Distance Z 0 1 mm 0 1 32 in 16...

Page 147: ...3 7105 00 Refer to the Ski Doo Predelivery Bulletin no 97 10 Replace with the attached Campaign no 36363 No 97 10 Replaces 95 12 UPDATE Date December 12 1996 SUBJECT Predelivery YEAR MODEL MODEL NUMBER SERIAL NUMBER 1997 Canada and United States MX Zx 440 LC 1214 and 1215 ALL 1997 Sweden MX Zx 440 LC 1216 ALL FOR APPROVAL ONLY Litho d in Canada MBL 9716 PS Trademarks of Bombardier Inc 1997 Bombard...

Page 148: ...97 10 Page 5 of 8 PARTS INSTALLATION WINDSHIELD Install windshield on dashboard 1 Dart 1 P N 414 6443 00 section no 6 2 Latch 6 P N 570 0238 00 section no 6 A15H46S 2 1 3 ...

Page 149: ...heck oil level in the rotary valve reservoir Add oil as required Refer to the following photo ROTARY VALVE OIL RESERVOIR LIQUIDS BRAKE FLUID LEVEL Check brake fluid in reservoir for proper level Add fluid DOT as required A15C2GA CAUTION Use only Bombardier Rotax synthetic injec tion oil P N 413 7105 00 12 x 1L CAUTION Use only DOT 4 brake fluid from a sealed container Do not store or use a partial...

Page 150: ...his bulletin is designed as a guideline only All mechanics performing predelivery proce dures should have attended the current model year service training Further information or inquires should be directed to your distributor service representative and or specific Shop Manual sections Please complete the Predelivery Check List for each snowmobile and return a customer signed copy Make sure the cus...

Page 151: ...T SUSPENSION PARTS INSTALLATION 7 SKIS PARTS INSTALLATION 8 BATTERY PARTS INSTALLATION 11 STEERING PAD PARTS INSTALLATION 12 WINDSHIELD PARTS INSTALLATION 13 BACKREST PARTS INSTALLATION 14 DRIVE BELT LIQUIDS 15 OIL INJECTION PUMP BLEEDING LIQUIDS 15 BRAKE FLUID LEVEL ADJUSTMENTS 16 SUSPENSION ADJUSTMENTS 16 TRACK ADJUSTMENTS 16 DRIVEN PULLEY TECHNICAL DATA 16 A99A0HS ...

Page 152: ...ve vehicle from base Remove parts to be installed and predelivery kit from engine compartment Detach shock absorb ers from engine compartment SHIPPING STRAP REMOVAL Cut shipping strap using one of these 2 following methods Method 1 Using a long flat chisel such as Snap On PPC820LA cut shipping strap that collapses front portion of rear suspension as shown on the next illustration PREDELIVERY KIT P...

Page 153: ... of the 460 mm 18 in piece cut a 1 2 mm 3 64 in slot by 28 5 mm 1 1 8 in Make a chamfer of 30 x 10 mm 25 64 in as shown on the next photo A 1 2 mm 3 64 in B 10 mm 25 64 in C 28 5 mm 1 1 8 in D 30 Remove all sharp edges Assemble the two pieces and weld them togeth er as shown on the following photo 1 20 mm 3 4 in steel tubing 2 Welded joint A 410 mm 16 in B 460 mm 18 in HOOK REMOVAL 1 Hook to be re...

Page 154: ...added Each tether cord has a small magnet as well as a small micro chip molded into the rubber cap The magnet will close a primary circuit in the electrical system This completes the circuit and allows the MPEM to read the electronic number in the tether cord when engine is started NOTE We do not program the tether cord we record the tether cord electronic number into the MPEM memory The MPEM also...

Page 155: ...lips keep screws Secure shock absorbers to suspension with their adjusting ring at bottom NOTE Position screw heads toward front TYPICAL RH SIDE SHOWN 1 Shock absorber 2 engine compartment 2 Screw M10 x 1 5 x 60 2 P N 222 0060 65 on suspension 3 Screw M10 x 1 5 x 55 2 P N 222 0055 65 on suspension 4 Nut M10 x 1 5 2 P N 228 5010 45 section no 3 Torque to 48 N m 35 lbf ft A06G0JS 1 2 4 3 4 ...

Page 156: ...leg Torque to 40 N m 30 lbf ft 4 Loosen then adjust against stop bounding Torque to 14 N m 124 lbf in 5 Bolt M12 2 ski leg After ski installation adjust stopper against stop bounding then tighten nut to 14 N m 124 lbf in More pre load on stop bounding will result in a more aggressive steering Adjust according to driver preferences A16G0CS 5 3 1 2 4 ...

Page 157: ...r temperature sensor 2 Remove left side screw 3 Twist DPM manifold and detach 4 Screw to be removed under heat shield deflector of air intake silencer Remove left side air intake silencer 1 Remove screw under heat shield deflector 2 Engine temperature sensor gauge connectors 3 Heat shield deflector of air intake silencer Remove screw retaining right side air intake si lencer as shown on the next p...

Page 158: ...tery cable and route ca ble behind air intake silencer support as shown on the following photo PULL OUT RED POSITIVE BATTERY CABLE 1 Air intake silencer support 2 Route RED positive battery cable behind air intake silencer support Battery Installation Position battery onto battery support on vehicle Ensure that vent tube is properly connected to ve hicle fitting on front frame Install vent tube on...

Page 159: ...and connectors Ensure vent tube is properly installed on battery elbow then install protective boot over battery Close and fasten retaining strips and ensure that RED positive battery cable is routed into front re taining strip recess Reinstall air intake silencers Reinstall triangular air filter as shown on the next photo WARNING Always connect the battery cables exactly in the specified order Co...

Page 160: ... Remove steering pad and torque nuts to 26 N m 19 lbf ft Reinstall steering pad adjust and tighten throttle and brake handle housings 1 Torque to 26 N m 19 lbf ft 2 Equal gap each side both clamps 3 Keyway 2 section no 3 4 Steering pad engine compartment 5 Screw 2 P N 222 8520 65 section no 1 6 Nut 2 P N 228 7510 45 section no 1 tighten loosely do not deform rubber A06G0FS 2 1 4 3 5 6 ...

Page 161: ...of 17 97 11 PARTS INSTALLATION WINDSHIELD Install windshield on dashboard 1 Dart 8 section no 5 2 Latch 6 section no 5 3 Normal use position rotate mirror assy s half turn by hand 4 PDI position A06H24S 2 3 4 1 ...

Page 162: ...sher 2 P N 732 9000 30 section no 6 4 Plastic washer 2 P N 414 8196 00 section no 6 5 Elastic nut 2 P N 228 5810 45 section no 6 Torque to 8 N m 73 lbf in 6 Lever assembly 2 P N 580 6110 00 section no 2 7 Guide 2 P N 517 2573 00 section no 2 8 Rubber shim 2 P N 570 0274 00 section no 6 9 Spacer 2 P N 517 2513 00 section no 2 10 Flanged washer 2 P N 414 8195 00 section no 6 11 Threaded plate 2 P N ...

Page 163: ...REST Turn adjustment knob left or right to adjust back rest cushion position PARTS INSTALLATION DRIVE BELT Clean pulleys and disc brake with a suitable cleaner such as Loctite Cleaning Solvent P N 413 7082 00 before installing drive belt A03H25A ...

Page 164: ...der screw until air has escaped from the line Add injection oil as required 1 Bleeder screw 2 Oil pump lever Bleed the small oil lines between pump and en gine crankcase by running engine at idle while holding the pump lever in fully open position NOTE To ease pump lever holding make a J hook out of mechanical wire to lift the lever 1 Smal oil line 2 Engine at idle fully open position LIQUIDS BRAK...

Page 165: ...is bulletin ADJUSTMENTS DRIVEN PULLEY It is usual to experience spring settings during break in period of a new spring The factory spring preload is slightly higher to compensate for springs settings Specifications in TECHNICAL DATA are applicable after break in period about 10 hours of use TECHNICAL DATA TECHNICAL DATA The content of the TECHNICAL DATA pages should be used as necessary to fine tu...

Page 166: ... 022 057 Gear Ratio Teeth 25 44 Engagement Speed 100 RPM 3600 Drive Pulley Calibration Screw Position 3 Pulley Distance Z 0 1 mm 0 1 32 in 16 5 21 32 Offset X 0 4 mm 1 64 in 35 0 1 3 8 Y Dimension Y must exceed X from 1 mm 1 32in to 2 mm 5 64 in Drive Belt Adjustment Deflection mm in 32 1 1 4 Force kg lbf 11 34 25 Driven Pulley Preload 0 7 kg lbf 7 0 15 43 Drive Chain Tension Fully tighten adjusti...

Page 167: ...pment without incurring obligation The illustrations in this document show the typical construction of the different assemblies and may not reproduce the full detail or exact shape of the parts However they represent parts that have the same or similar function The contents of this bulletin is designed as a guideline only All mechanics performing predeliv ery procedures should have attended the cu...

Page 168: ...ION PARTS INSTALLATION 7 FRONT SUSPENSION PARTS INSTALLATION 8 SKIS PARTS INSTALLATION 10 STEERING PAD PARTS INSTALLATION 11 WINDSHIELD PARTS INSTALLATION 12 BACKREST PARTS INSTALLATION 13 WIRE CUTTER PARTS INSTALLATION 14 DRIVE BELT LIQUIDS 15 OIL INJECTION PUMP BLEEDING LIQUIDS 15 BRAKE FLUID LEVEL ADJUSTMENT 16 TRACK TECHNICAL DATA 16 ...

Page 169: ...que wrench tightening specifications must be strictly adhere to Locking devices e g lock tabs nylon stop nuts must be installed or replaced by new one where specified If the efficiency of a locking device is impaired it must be renewed CAUTION Allowing the crate to drop may cause serious damage to the vehicle F02P04S ...

Page 170: ...s to be installed e g skis windshield from the vehicle and its base Remove predelivery kit and parts to be installed from under seat compartment NOTE This rule can be helpful to identify fastener length size CAUTION Make sure vehicle is properly supported before removing ski legs and rear suspension from crate brackets A29H07S 1 A99A0HS ...

Page 171: ...from base TECHNICAL DATA PARTS INSTALLATION BATTERY During preparation the battery can be activated as described in 1997 Ski Doo Shop Manual NOTE A special vented rivet is fixed to the chas sis in order to plug the vent tube from the battery CAUTION Make sure vehicle is properly supported A29G0AA A29F05A CAUTION Prior to charging always remove the battery from the vehicle to prevent electrolyte sp...

Page 172: ...y cables Apply silicone dielectric grease P N 413 7017 00 on battery posts and connectors Install battery cover Secure battery with bracket and tighten wing screw Ensure vent tube is properly installed from battery to the plug provided on the frame WARNING Always connect the battery cables exactly in the specified order Connect RED positive ca ble first then BLACK negative ground cable A29E0DA ...

Page 173: ... removed screws Apply Loctite 242 on threads and torque screws to 58 N m 43 lbf ft TECHNICAL DATA PARTS INSTALLATION FRONT SUSPENSION Remove long bolts that compresses front suspen sion on both sides 1 Remove and discard long bolt Install 2 plastic bushings into shock absorber eye let Stretch shock to its maximum Slide shock absorber onto bottom of ski leg until shock rod goes through cap hole Loo...

Page 174: ... SUSPENSION 1 Plastic bushings PARTS INSTALLATION SKIS Install stop bounding on skis with its highest por tion toward front 1 Stop bounding Instal skis on vehicle using bolts nuts washers and rubber bushings supplied in the predelivery kit A22G0IA 1 A29G0BA 1 ...

Page 175: ...17 PARTS INSTALLATION SKIS 1 Stop bounding 2 Sleeve 3 Rubber bushing 2 4 Flat washer 2 5 Bolt M10 x 120 6 M10 lock nut tighten to 48 N m 35 lbf ft Tighten shock rod top nuts to 30 N m 22 lbf ft A22G0GS 1 3 4 5 2 3 4 6 ...

Page 176: ... steering pad Secure steering column cover with steering pad before tightening bolts Adjust both throttle and brake handle housings to match steering pad TYPICAL Step Torque to 26 N m 19 lbf ft 1 Steering pad 2 Keyway Use liquid soap to ease installation 3 Screw M5 x 0 80 x 20 2 4 Nut M5 x 0 80 x 20 2 Seat tighten only no deformation of rubber A Equal gap on each side both clamps A29G0CS 1 2 4 3 A...

Page 177: ...IELD Remove headlamp molding Install rubber support in predrilled holes on the hood Step Pry out headlamp molding Step Install support Apply soap on tips to ease installation Step Install windshield Step Install latches 10 A22H0OS 3 2 4 1 1 2 3 4 ...

Page 178: ...reinstall headlamp molding Make sure to properly position lower edge of plas tic molding under head lamp 1 Rubber expansion nut 2 Hole in windshield PARTS INSTALLATION BACKREST Install backrest on vehicle and secure with screws adjustment screws and washers Refer to the following photo for proper positioning TYPICAL LEFT SIDE SHOWN 1 Backrest frame 2 Screw M8 3 Washer 4 Adjustment screw 5 Washer A...

Page 179: ... on each side of hood Using holes in support plates as a template drill 8 mm 5 16 in holes through hood and install bolts M8 x 20 1 Drill 8 mm 5 16 in holes Open hood From inside hood install washers and lock nuts to secure side support plates Install backing support and secure with washers and lock nuts Torque to 20 N m 15 lbf ft Install cable and cable lock Adjust cable tight with hood in fully ...

Page 180: ...LLATION WIRE CUTTER 1 Backing support 2 Cable 3 Cable lock PARTS INSTALLATION DRIVE BELT Clean pulleys and disk brake with a suitable cleaner such as Loctite Cleaning Solvent P N 413 7082 00 before installing drive belt 1 A29H0GA 2 3 ...

Page 181: ...er screw until all air has escaped from the line Add injection oil as required 1 No air in main line 2 Bleeder screw Bleed the small oil lines between pump and intake manifold by running engine at idle while holding the pump lever in fully open position LIQUIDS BRAKE FLUID LEVEL Check brake fluid in reservoir for proper level Add recommended brake fluid as required 1 Fluid level window A22C0CA 1 2...

Page 182: ...NICAL DATA TECHNICAL DATA The content of the TECHNICAL DATA pages should be used as necessary to fine tune and perform additional adjustments required on the snowmobile Vehicle used at high altitudes above 600 m 2000 ft should be fitted with a high altitude kit P N 861 7581 00 Further inquires should be directed to your distributor service representative ...

Page 183: ...mp Octane Number R M 2 Regular Unleaded 87 Gas Oil Ratio Oil Injection Ignition Timing BTDC mm in 1 66 065 Trigger Coil Air Gap mm in 0 45 0 55 018 022 Gear Ratio 1st Gear 1 4 41 2nd Gear 1 3 19 Engagement Speed 100 RPM 2900 Drive Pulley Calibration Screw Position 4 Pulley Distance Z 0 1 mm 0 1 32 in 32 75 1 9 32 Offset X 0 4 mm 1 64 in 36 25 1 27 64 Y Dimension Y must exceed X from1 mm 1 32 in to...

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