Ski-Doo 2000 Mach 1 Operator'S Manual Download

Page: 103 / 123

101

TYPICAL

1. Adjustment screw
2. Loosen screw
3. Wheel cap removing

Alignment

NOTE:

Track tension and alignment are inter-related. Do not adjust

one without the other.



WARNING

Before checking track alignment, ensure that the track is free
of all particles which could be thrown out while track is rotat-
ing. Keep hands, tools, feet and clothing clear of track. Ensure
no one is standing in close proximity to the snowmobile.

A30F03A

Mmo2000-004b.book Page 101 Monday, May 10, 1999 9:13 AM

Summary of Contents for 2000 Mach 1

Page 1: ......

Page 2: ...l rights reserved SAFETY WARNING Disregarding any of the safety precautions and instructions con tained in this Operator s Guide Safety Handbook or on product labels could cause injury including the p...

Page 3: ...GUIDE This guide is applicable to CK3 series Grand Touring 700 Grand Touring SE Grand Touring SE Millennium Edition Formula III 700 Formula III 700 R Formula III 800 Mach 1 Mach 1 R Mach Z Mach Z R Ma...

Page 4: ...and provided you with a brief explanation of the various suspension ad justments We trust you have taken full advantage of this If you need more complete servicing information please ask your dealer a...

Page 5: ...mation needed to fully com plete an instruction The information and components system descriptions contained in this guide are correct at time of publication We also reserve the right at any time to d...

Page 6: ...OLS INSTRUMENTS 21 1 Throttle Lever 24 2 Brake Lever 24 3 Parking Brake Button 24 4 Injection Oil Level Parking Brake Pilot Lamp Red 25 5 Reverse Button 25 6 Ignition Switch 27 7 Tether Cut Out Switch...

Page 7: ...justable Rear Grab Handles 51 Hood Grills 52 Rear Passenger Heated Grip Switch 53 Fuel Shut Off Valve 54 Storage Compartment 54 Tool Box 55 Spark Plug Holder 56 Spare Drive Belt Holder 56 Fuses 57 Fro...

Page 8: ...5 TRA Drive Pulley Adjustment 95 Drive Belt Condition 98 Brake Condition 98 Brake Adjustment 98 Rear Suspension Condition 98 Suspension Stopper Strap Condition 98 Track Condition 99 Track Tension and...

Page 9: ...d housings Only perform procedures as detailed in this guide Unless other wise specified engine should be turned OFF and cold for all lubri cation adjustment and maintenance procedures Some snowmobile...

Page 10: ...enanceand service with a genuine BOMBARDIER part without charge for parts and labor at any authorized SKI DOO dealer during the Warranty Coverage Period 3 CONDITION TO HAVE WARRANTY WORK VALIDATED The...

Page 11: ...rranty lasts so the above limitation or exclusion may not apply BOMBARDIER reserves the right to modify this warranty at any time being under stood that such modification will not alter the warranty c...

Page 12: ...e BOMBARDIER part without charge for parts and labor at any local authorized SKI DOO dealer 3 CONDITION TO HAVE WARRANTY WORK VALIDATED The customer must notify a local authorized SKI DOO dealer withi...

Page 13: ...stributor may elect to translate this warranty into local language it is then understood and agreed that in the event of any discrepancy among the two versions the English version shall prevail It is...

Page 14: ...egistration has two purposes In many provinces or states it is mandatory to register a snowmobile in the same way as for a car It allows the state or province to maintain records of existing snowmobil...

Page 15: ...aler any Genuine Bombardier part used in warranty repairs assumes the remain ing warranty that exists on the snowmobile Q If I sell my snowmobile within the warranty period will the new owner qualify...

Page 16: ...eational Products 726 St Joseph Street Valcourt Quebec Canada J0E 2L0 Phone 450 532 5000 Fax 450 532 5077 USA BOMBARDIER MOTOR CORPORATION OF AMERICA 7575 Bombardier Court P O Box 8035 Wausau WI 54402...

Page 17: ...nt of loss These numbers are required by the dealer to complete warranty claims properly No warranty will be allowed by Bombardier Inc if the engine serial number or Vehicle Identification Number VIN...

Page 18: ...16 Engine Serial Number Location TYPICAL 1 Engine serial number A30C01A 1...

Page 19: ...e operating snowmobile TYPICAL LOCATION OF IMPORTANT INSTRUCTIONS Instruction 1 GRAND TOURING SE A30A01B 2 3 4 5 6 8 9 7 1 Verify attachments frequently Use rigid tow bar Reduce speed when towing V ri...

Page 20: ...ALL CONTROLS WORK NORMALLY DRIVE CAREFULLY Use of this vehicle by novice or inexperienced operator is not recommanded Seating on this vehicle is restricted to the operator only Do not carry passenger...

Page 21: ...19 Instruction 5 ALL MODELS Instruction 6 ALL MODELS Instruction 7 ALL MODELS WITH A REVERSE A02A07C A02A06C A30A0BB...

Page 22: ...SKI SUSPENSION AVANT SKI REAR SUSPENSION SUSPENSION ARRI RE ADJUST ACCORDING TO LOAD R GLER SELON LA CHARGE REAR SPRING RESSORT ARRI RE LOAD CHARGE NOT APPLICABLE SANS OBJET FOR LOADS EXCEEDING RANGE...

Page 23: ...me models In these cases their reference numbers are deliberately missing in the illustrations Some controls instruments are optional on some models TYPICAL FORMULA III MACH 1 AND MACH Z SERIES A30A0C...

Page 24: ...22 TYPICAL GRAND TOURING 700 P 26 9 22 15 3 2 32 10 6 28 31 33 A30A0JB 32 1 30 12 31 33 8 27 11 29 4 21 17 20 18 19 23 4 24 5 25 7 13...

Page 25: ...23 TYPICAL GRAND TOURING SE P 9 22 15 3 2 32 10 6 28 31 33 A30A0NA 32 1 30 12 31 33 8 27 11 29 4 21 17 20 18 19 23 4 24 5 25 7 14 34 34 35 13 26...

Page 26: ...arked Whenever parking brake is applied and engine is running injection oil level parking brake pilot lamp lights up to remind you that it is en gaged CAUTION Make sure parking brake is fully disengag...

Page 27: ...when parking brake is applied with engine running Grand Touring Series There are 2 pilot lamps One for injection oil level and one for parking brake See dashboard photo at beginning of this section 5...

Page 28: ...2 seconds one beep is heard meaning that the low altitude mode can be selected Releasing button just after hearing that one beep will select the low altitude mode The reverse system is now ready to o...

Page 29: ...ctric Starting Key operated 3 position switch To start engine turn key to START position and hold See illustration above CAUTION Do not hold key at START position more than 15 sec onds A rest period s...

Page 30: ...Tether Cut Out Switch General The tether cut out system shuts off engine if the driver accidently falls off the vehicle and the DESS Digitally Encoded Security Sys tem performs the same function as a...

Page 31: ...d the engine can not reach engage ment speed required to move vehicle Additional Tether Cords We recommend the purchase of additional tether cord from your au thorized dealer Beep and Pilot Lamp Codes...

Page 32: ...3 seconds still occurs contact an authorized dealer 1 Free of dirt or snow A rapid beeping and DESS pilot lamp blinking at same rate mean that an incorrectly programmed tether cord is being used Vehi...

Page 33: ...ll type switch located on the right side of the handlebar To stop the engine push the button to the lower OFF position and si multaneously apply the brake To restart button must be at the upper ON pos...

Page 34: ...re after Thereby being mentally prepared for emergency situations requiring its use 10 Headlamp Dimmer Switch Located on left side of handlebar allows selection of headlamp beam ALL MODELS EXCEPT GT S...

Page 35: ...high beam position auto matically after 10 seconds GT SERIES 11 High Beam Pilot Lamp Blue Lights when headlamp is on HIGH beam 12 Rewind Starter Handle Auto rewind type located on right hand side of s...

Page 36: ...evice features a 3 position lever to facilitate cold start 0 OFF 1 Position 1 2 Position 2 Grand Touring 700 SE These vehicles are equipped with an emergency choke located in engine compartment All Mo...

Page 37: ...es air pressure Holding switch downward small spring on decal decreases air pres sure 15 Air Suspension Pilot Lamp This pilot lamp lights up each time the air suspension switch is used This pilot lamp...

Page 38: ...L AIR SUSPENSION GAUGE 1 Minimum required pressure before riding 17 Speedometer All Models Except GT Series These vehicles are equipped with a speedometer graduated in km or miles according to country...

Page 39: ...ess button again for about 4 seconds and release it 18 Odometer All Models Except GT Series Odometer records the total distance travelled in kilometers or miles GT Series With engine running but vehic...

Page 40: ...can be used to establish a fuel tank range or distance between 2 relays for instance ALL MODELS EXCEPT GT SERIES 1 Odometer 2 Trip meter 3 Reset button GT SERIES 1 Odometer 2 Trip meter 3 Reset button...

Page 41: ...umbers read zero GT Series With engine running but vehicle at rest depress button for 1 second max until trip shows Display will not change before the button is released From that point depress button...

Page 42: ...t reading dial indicates the number of thousand of revolutions per minute RPM of the engine ALL MODELS EXCEPT GT 700 SE 1 Multiply the reading by 1000 GRAND TOURING 700 SE 1 Multiply the reading by 10...

Page 43: ...ng conditions the needle should stay within this range If needle moves into the over heat range reduce snowmobile speed and run snowmobile in loose snow or stop engine immediately 1 Normal 2 Overheat...

Page 44: ...unc tions when engine is running 1 Full 2 Empty 25 Fuel Tank Cap Unscrew to fill up tank then fully tighten CAUTION Do not mismatch oil reservoir cap with fuel tank cap Install cap that is identified...

Page 45: ...OT 2 OFF 3 WARM GT Series This toggle type switch allows selecting 5 different intensity of han dlebar grip heatings Each time engine is started low heating is selected Push switch according to desire...

Page 46: ...ferent heating level is selected the display changes to show heating elements settings for 2 seconds See photo of Heat ed Throttle Lever Pilot Lamp yellow below Each time engine is started low heating...

Page 47: ...about 1 second will increase to maxi mum intensity or OFF position according selected position 29 Heated Throttle Lever Pilot Lamp Yellow GT Series The pilot lamp in center of cluster lights up when h...

Page 48: ...s running An extension is sup plied with the vehicle It is included in the predelivery kit Ask your dealer for the extension 31 Hood Latches Unhook the latches to unlock the hood from its anchors Alwa...

Page 49: ...holds Each toehold can be adjusted to suit driver s preference Loosen bolts adjust then retighten bolts to 10 N m 89 lbf in RIGHT SIDE SHOWN 1 Toehold 2 After adjustment retighten bolts to 10 N m 89 l...

Page 50: ...48 34 Adjustable Handlebar Handlebar angle can be adjusted to suit driver s preference Lift lever tilt handlebar to desired position then release lever 1 Lever A30G16A 1...

Page 51: ...dshield height can be adjusted to suit driver s preference Turn both knobs at same position Position 1 corresponds to lower wind shield height Position 10 corresponds to higher windshield height 1 Kno...

Page 52: ...he backrest position and support angle may be adjusted to suit driv er or passenger convenience 1 Lift adjustment lock both sides 2 Turn adjustment knob Secure adjustment locks after desired position...

Page 53: ...ired position Secure adjustment lock Proceed the same with the other side 1 Lift adjustment lock WARNING Backrest should only be repositioned while the snowmobile is stopped Adjust to provide maximum...

Page 54: ...Grills These hood grills must be closed at all times except when riding at high speeds and or high outside temperature Slightly unscrew wing nuts slide close grills then retighten wing nuts 1 Grills A...

Page 55: ...Heated Grip Switch Three position switch Select the desired position to keep rear pas sager s hands at a comfortable temperature TYPICAL RIGHT SIDE OF PASSENGER GRAB HANDLE 1 Rear passenger heated gri...

Page 56: ...snowmobile 1 Opened 2 Closed Fully open the valve in order to operate the snowmobile CAUTION Always fully open the valve before riding Never allow the valve to remain half opened Storage Compartment...

Page 57: ...r basic maintenance is supplied with the vehicle Tool box is located in engine compartment in front of guard NOTE The plastic bag containing tools may be discarded to ease storing tools 1 Tool box 2 R...

Page 58: ...tool box 1 Spare spark plugs stored in tool box 2 Instructions for spare spark plugs removal Spare Drive Belt Holder A spare drive belt can be installed in drive belt holder clip Make sure to positio...

Page 59: ...e located on top of right side footrest To gain access open hood Grand Touring 700 SE 1 Main including starter 30 A 2 Compressor 20 A Grand Touring SE only 3 All others accessories 20 A 4 Digital perf...

Page 60: ...k if filament is melted 1 Fuse 2 Check if melted Electric Fuel Level Gauge Fuse See your dealer for fuse replacement Front Grab Handles Front Bumper To be used whenever front of snowmobile requires li...

Page 61: ...to R M 2 octane number CAUTION Never experiment with other fuels The use of unrec ommended fuel can result in snowmobile performance deterio ration and damage to critical parts in the fuel system and...

Page 62: ...40 F If unavail able substitute with BOMBARDIER ROTAX pre mix oil P N 413 803 100 12 x 500 mL Always maintain a sufficient amount of recommended oil in the in jection oil reservoir CAUTION Check leve...

Page 63: ...N 413 802 900 12 x 1 L should be added to fuel for the first full filling of fuel tank Always remove and clean spark plugs after engine break in Belt A new drive belt requires a break in period of 50...

Page 64: ...ndlebar grip It must fully return when released Verify skis and steering operate freely Verify track and idler wheels are unfrozen and free to turn Check fuel and injection oil level Ensure fuel shut...

Page 65: ...riding CAUTION Operating the snowmobile without minimum re quired pressure in the air shock will cause premature wear of the rubber boot and failure of the component WARNING Only start your snowmobile...

Page 66: ...engine or use electric starter on so equipped models After the engine is started close off choke If speed is dropping below 1500 RPM set choke lever to first position for 2 seconds then close off cho...

Page 67: ...n Grasp manual starter handle firmly and crank engine Electric Starting some models only Insert key in ignition switch Turn key clockwise until starter engages Release key immediately when engine has...

Page 68: ...drive pulley unless it is a true emergency situation Have the snowmobile re paired as soon as possible Remove guard Attach emergency rope to rewind handle and to the starter clip sup plied in the tool...

Page 69: ...pulley and wind counter clockwise up to 3 turns 1 Clip Start engine as described in COLD ENGINE STARTING or WARM ENGINE STARTING according to engine temperature WARNING When starting the snowmobile i...

Page 70: ...g to load for your SKI DOO model 1 Decal General Snowmobile handling and comfort depend upon suspension adjust ments Choice of suspension adjustments vary with carrying load driver s weight personal p...

Page 71: ...ch adjustment one at a time Test run the snow mobile under the same conditions trail speed snow driver riding position etc Change one adjustment and retest Proceed methodi cally until you are satisfie...

Page 72: ...ir shock absorber can be adjusted as necessary Use the console mounted switch 1 Rear Springs Comfort When driver and passenger if so applicable take place rear of snow mobile should collapse by 50 to...

Page 73: ...urn the left side adjustment cam in a clockwise direction the right side cam in a counterclockwise direction Left and right adjustment cams may set be at different position 1 Increase spring preload A...

Page 74: ...urn the left side adjustment cam in a counterclockwise direction the right side cam in a clockwise direction Left and right adjustment cams may be set at different position 1 Decrease spring preload A...

Page 75: ...Spring Steering Behavior Ride at moderate speed on a trail with bumpy conditions If steering is easy to turn adjust center spring accordingly GOOD ADJUSTMENT AT MODERATE SPEED 1 Steering easy to turn...

Page 76: ...74 TOO SOFT OF ADJUSTMENT 1 Steering hard to turn 1 Adjuster wrench A03F2PA 1 A03F21A 1...

Page 77: ...75 TOO HARD OF ADJUSTMENT 1 Steering less aggressive 1 Adjuster wrench A03F2PA 1 A03F21B 1...

Page 78: ...rap length accordingly At rest stopper strap should have a free play of 12 mm 1 2 in CAUTION Whenever stopper strap length is changed track ten sion must be readjusted GOOD ADJUSTMENT AT FULL ACCELERA...

Page 79: ...77 TOO LONG STRAP 1 Skis lift off the ground 1 Reduce strap length by bolting to a different hole A03F2QA 1 A03F0QB 1...

Page 80: ...78 TOO SHORT STRAP 1 Heavy steering 1 Increase strap length by bolting to a different hole A03F2PA 1 A03F0QB 1...

Page 81: ...lly tighten 1 Nut If handling is too aggressive turn the nut counterclockwise Nut must be in good condition to avoid unexpected loosening On the threaded rod there must be at least 2 threads exposed b...

Page 82: ...andling Ride at moderate speed and check for proper handling Adjust front springs accordingly CAUTION Always adjust both front springs to same position PROPER ADJUSTMENT 1 Good handling and comfortabl...

Page 83: ...81 TOO SOFT OF ADJUSTMENT 1 Bad handling 1 Increase spring preload A03F2PA 1 A03F2IA 1...

Page 84: ...82 TOO HARD OF ADJUSTMENT 1 Steering hard to turn 1 Decrease spring preload A03F2PA 1 A03F2JA 1...

Page 85: ...front suspension spring preload Increase center spring preload Reduce rear spring preload Snowmobile seems unstable and seems to pivot around its center Reduce rear suspension front arm pressure Reduc...

Page 86: ...D MAINTENANCE CHART Starting Rope Condition Engine Head Nuts Engine Mount Nuts Exhaust System Engine Lubrication Cooling System Condition Coolant Replacement Condition of Seals Injection Oil Filter Co...

Page 87: ...N m 19 lbf ft Steering and Front Suspension Mechanism Lubrication Steering and Front Suspension Mechanism Condition Wear and Condition of Skis and Runners Steering and Ski Leg Camber Adjustment Suspe...

Page 88: ...by removing dipstick Oil level must be between lower and upper marks NOTE It is normal to find metallic particles stuck to dipstick magnet If bigger pieces of metal are found see an authorized dealer...

Page 89: ...87 TYPICAL 1 Dipstick 2 Oil level 3 Level between marks A30D0AA 1 3 1 2...

Page 90: ...r allow oil level to drop more than 2 3 Do not mismatch oil reservoir cap with fuel tank cap Install cap that is identified OIL TYPICAL 1 Maximum level 13 mm 1 2 in from top 2 Injection oil reservoir...

Page 91: ...OTE When checking level at low temperature it may be slight lower then mark If additional coolant is necessary or if entire system has to be refilled refer to an authorized dealer 1 Coolant tank 2 COL...

Page 92: ...hood 2 Open retainer to release pin then pull guard toward center of ve hicle then toward front 1 Pin retainer When reinstalling guard position its cut away toward front of snow mobile Refer to decal...

Page 93: ...wn front portion of guard in retainer NOTE Guard is purposely made slightly oversize to maintain tension on its pins and retainers preventing undue noise and vibration It is important that this tensio...

Page 94: ...the driven pulley with the drive belt installer remover provid ed in tool box Screw tool in the free threaded hole and tighten to open the pulley Remove belt 1 Tighten to open pulley Slip the belt ove...

Page 95: ...93 Remove access panel from bottom pan 1 Push top of panel out of bottom pan 1 Pull panel tab out of bottom pan A30C04A 1 A30C05A 1...

Page 96: ...To install the drive belt reverse the removal procedure however pay attention to the following The maximum drive belt life span is obtained when the belt has the proper rotation direction See arrow o...

Page 97: ...calibrated to transmit maximum engine power at a predefined RPM Refer to SPECIFICATIONS at the end of this guide Factors such as ambient temperature altitude or surface condition may vary this critic...

Page 98: ...cup has 6 positions numbered 2 to 6 Note that in position 1 the number is substitued by a dot due to its location on casting 1 Position 1 not numbered Each number modifies maximum engine RPM by about...

Page 99: ...calibration screw or its in side washer will fall off Always adjust all 3 calibration screws and make sure they are all set at the same number 1 Loosen just enough to permit rotating of calibrate scr...

Page 100: ...if any problems Rear Suspension Condition Visually inspect all suspension components including slider shoes springs wheels etc NOTE During normal driving snow will act as a lubricant and coolant for t...

Page 101: ...to 20 minutes prior to adjusting track tension Lift rear of snowmobile and support it with a snowmobile mechan ical stand Allow the suspension to extend normally and check gap half way along slider s...

Page 102: ...sult in power loss and exces sive stresses on suspension components To adjust tension On some models remove wheel cap Loosen the rear idler wheel retaining screws Turn adjustment screws to adjust If c...

Page 103: ...inter related Do not adjust one without the other WARNING Before checking track alignment ensure that the track is free of all particles which could be thrown out while track is rotat ing Keep hands t...

Page 104: ...ed equal distance on both sides between edges of track guides and slider shoes TYPICAL 1 Guides 2 Slider shoes 3 Equal distance To correct stop the engine Loosen rear wheel screws tighten the adjustme...

Page 105: ...suspension mechanism for tight ness of components steering arms control arms and links tie rods ball joints ski coupler bolts etc If necessary contact your dealer Wear and Condition of Skis and Runne...

Page 106: ...local laws CAUTION If any exhaust system component is removed modi fied or damaged severe engine damage may result Air Filter Cleaning Leaving the snowmobile uncovered during a snowfall or riding in...

Page 107: ...105 Reinstall filter over dashboard sticking bottom edge first 1 Stick bottom edge first Finalize filter top edge installation 1 Push top edge of filter under air deflector lip A30H0SA 1 A30H0QA 1...

Page 108: ...obile engines have been calibrated with the filter installed Operating the snowmobile without it may cause engine damage High Altitude Kit If you reside or ride at altitudes above 1200 m 4000 ft your...

Page 109: ...ter bulb replacement Headlight CAUTION Never touch glass portion of an halogen bulb with bare fingers it shortens its operating life If glass is touched clean it with isopropyl alcohol which will not...

Page 110: ...1 Air deflector Unplug burnt bulb connector Remove the rubber boot Unfasten bulb retainer ring Detach the bulb and replace Properly reinstall parts including air filter 1 Locking ring A30E04A 1 A30E05...

Page 111: ...1 Remove these screws All Models Except GT Series Bulb socket is always behind the instrument under a black rubber boot Pull rubber boot and socket to expose bulb Pull bulb out of socket TYPICAL ALL M...

Page 112: ...odels After each ride clean and dry out every chromed parts to avoid rust formation Clean and dry out particulary around welds on chromed parts Use aftermarket cleaning and polish products for automot...

Page 113: ...level turn fuel valve on if applicable check fuel filter replace if clogged check condition of fuel and impulse lines and their connections A failure of the fuel pump or carburetor has occurred Contac...

Page 114: ...Engine turns over but fails to start 4 Lack of fuel to engine Checkitem 4of Engine turns over but fails to start 5 Carburetor adjustments Contact an authorized dealer 6 Drive belt worn too thin If th...

Page 115: ...power 5 Ignition timing is incorrect or there is an ignition system failure Contact an authorized dealer SYMPTOM Engine misfires POSSIBLE CAUSES WHAT TO DO 1 DESS has not read tether cord Engine can...

Page 116: ...tether cord 2 DESS is activated Engine can not exceed 3000 RPM DESS pilot lamp blinks rapidly and beeps are heard Install appropriate tether cord 3 Drive belt Check item 6 of Engine lacks acceleration...

Page 117: ...er 417 300 066 417 300 066 Width of a New Belt mm in 35 1 1 382 35 1 1 382 Wear Limit Width mm in 33 0 1 299 33 0 1 299 Spark plug Type NGK BR 9 ES NGK BR 9 ES Gap mm in 0 45 018 0 45 018 Track Tensio...

Page 118: ...mber 417 300 066 417 300 066 New Belt Width mm in 35 1 1 382 35 1 1 382 Wear Limit Width mm in 33 0 1 299 33 0 1 299 Spark plug Type NGK BR 9 ES NGK BR 9 ES Gap mm in 0 45 018 0 45 018 Track Tension m...

Page 119: ...oil P N 413 803 300 12 x 355 mL Ethylene glycol antifreeze for aluminum engines mixed with water 3 parts of antifreeze for 2 parts of water N A Not applicable OTHER PUBLICATIONS AVAILABLE Order from...

Page 120: ...ICE TO ALL NEW OWNERS Make sure to receive the warranty registration card from the previous owner when the ownership is transferred as you are entitled to the unexpired portion of the warranty STOLEN...

Page 121: ...________ NO STREET APT _____________________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE NEW ADDRESS OR NEW OWNER ______________________________________...

Page 122: ...AFFIX BOMBARDIER Recreational Products Ski Doo Warranty Valcourt Quebec Canada J0E 2L0 PROPER POSTAGE...

Page 123: ......

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