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MMR2000_042_00_02A.FM

GENERAL INFORMATION

The information and component/system descrip-
tions contained in this manual are correct at time
of publication. Bombardier Inc. however, main-
tains a policy of continuous improvement of its
products without imposing upon itself any obliga-
tion to install them on products previously manu-
factured.

Due to late changes, it may have some differences
between the manufactured product and the de-
scription 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.

USEFUL PUBLICATIONS

Refer to 

Parts Catalogs to order the right parts.

Use 

Specification Booklet to find rapidly the right

specs.

1996-2000 SPECIFICATION BOOKLET (P/N 484
200 018).

ILLUSTRATIONS AND 
PROCEDURES

Illustrations and photos show the typical construc-
tion of the different assemblies and, in all cases,
may not reproduce the full detail or exact shape of
the parts shown. However, they represent parts
which have the same or a similar function.

CAUTION:

Most components of those vehicles

are built with parts dimensioned in the metric
system. Most fasteners are metric and must
not be replaced by customary fasteners or vice
versa. Mismatched or incorrect fasteners could
cause damage to the vehicle or possible per-
sonal injury.

As many of the procedures in this manual are in-
terrelated, we suggest, that before undertaking
any task, you read and thoroughly understand the
entire section or subsection in which the proce-
dure is contained.

A number of procedures throughout the book re-
quire the use of special tools. Before commencing
any procedure, be sure that you have on hand all
the tools required, or approved equivalents.

The use of RIGHT and LEFT indications in the text,
always refers to driving position (when sitting on
vehicle).

TYPICAL

1. Left
2. Right

PARTS CATALOG

MODELS

P/N

FORMULA III 700 R
FORMULA III 800

484 400 071

MACH 1 R

484 400 069

MACH Z
MACH Z R
MACH Z R M.E.

484 400 067

GRAND TOURING 700
GRAND TOURING SE
GRAND TOURING SE M.E.

484 400 073

1

A03A0CA

2

INTRODUCTION

Summary of Contents for 2000 Formula III 700 R

Page 1: ......

Page 2: ...2000 Shop Manual VOLUME 2 GRAND TOURING 700 SE GRAND TOURING SE MILLENNIUM EDITION FORMULA III 700 R 800 MACH 1 R Z Z R MACH Z R MILLENNIUM EDITION...

Page 3: ...nada Registered trademarks of Bombardier Inc This document contains the trademarks of the following companies Crest is a trademark of Crest Industries Inc Kimtowels is a trademark of Kimberly Clark Lo...

Page 4: ...and engine dimension measurement 04 03 1 04 CDI system 04 04 1 05 Oil injection system 04 05 1 06 Liquid cooling system 04 06 1 07 Rewind starter 04 07 1 08 Carburetor and fuel pump 04 08 1 09 Fuel t...

Page 5: ...ion and ski system 08 03 1 09 BODY FRAME 01 Table of contents 09 01 1 02 Body 09 02 1 03 Frame 09 03 1 10 TECHNICAL DATA 01 SI metric information guide 10 01 1 02 Engines 10 02 1 03 Vehicles 10 03 1 0...

Page 6: ...oubt The engines and the corresponding components identified in this document should not be utilized on product s other than those mentioned in this document Torque wrench tightening specifications mu...

Page 7: ...IV MMR2000_042_00_02A FM WHAT S NEW 0 STEERING SYSTEM 08 02 Ski alignment specifications WHAT S NEW...

Page 8: ...cation number Identification Number Meaning MODELS MODEL NUMBER FORMULA III 700 R Canada 1590 FORMULA III 700 R U S 1591 FORMULA III 800 Canada 1619 FORMULA III 800 U S 1620 MACH 1 R Canada 1617 MACH...

Page 9: ...r sections 01 SERVICE TOOLS AND SERVICE PRODUCTS 02 LUBRICATION AND MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 TRANSMISSION 06 ELECTRICAL 07 REAR SUSPENSION 08 STEERING FRONT SUSPENSION 09 BODY FRAME...

Page 10: ...c inch k kilo thousand kg kilogram km h kilometer per hour kPa Kilopascal L liter lb pound lbf pound force lbf in pound per square inch LH left hand LO low LT long track m meter MAG magneto Max maximu...

Page 11: ...er In this case nut must be torqued to 4 N m or 35 lbf in This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog Exploded view assists you in identifyi...

Page 12: ...efore small bushing installation Coat bushing outside diameter with Loctite 609 P N 413 703 100 Install bushing as following photo A03D1YA 529 031 300 529 031 200 A03D1ZA 529 031 300 529 031 200 Cam C...

Page 13: ...the full detail or exact shape of the parts shown However they represent parts which have the same or a similar function CAUTION Most components of those vehicles are built with parts dimensioned in...

Page 14: ...tite threadlocker 4 Fit bolt in the hole 5 Apply a few drops of threadlocker at proposed tightened nut engagement area 6 Position nut and tighten as required Blind Holes 1 On threads 2 On threads and...

Page 15: ...s 4 Apply drops of proper strength Loctite on bolt nut contact surfaces 5 Avoid touching metal with tip of flask NOTE For preventive maintenance on existing equipment retighten nuts and apply proper s...

Page 16: ...0 on both sides of gasket 3 Loctite Primer N only 1 Remove old gasket and other contaminants with Loctite Chisel remover P N 413 708 500 Use a mechanical mean if necessary NOTE Avoid grinding 2 Clean...

Page 17: ...housing and gasket with Loctite Primer N P N 293 800 041 3 Apply a strip of proper strength Loctite on lead ing edge of outer metallic gasket diameter NOTE Any Loctite product can be used here A low...

Page 18: ...8 18 43 M10 32 44 M10 32 45 M10 33 46 M10 34 47 M10 35 48 M10 35 49 M10 36 50 M10 37 51 M10 38 52 M10 38 53 M10 39 76 M12 56 77 M12 57 78 M12 58 79 M12 58 80 M12 59 81 M12 60 82 M12 60 83 M12 61 84 M1...

Page 19: ..._____________________________________________________ ____________________________________________________________ ____________________________________________________________ ________________________...

Page 20: ...ions After Sales Service 565 de la Montagne Street Valcourt Quebec Canada J0E 2L0 Technical Publications After Sales Service 565 de la Montagne Street Valcourt Quebec Canada J0E 2L0 Technical Publicat...

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