Ski-Doo 2002 Mach Z STD Operator'S Manual Download

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Drive Belt Removal/Installation

NOTE:

Removal and installation of drive belt is easier when driven

pulley is held with brake so that it can not rotate. Apply parking brake,
for this purpose.

Turn off engine cut-out switch.

Open hood and remove belt guard.

Open the driven pulley with the drive belt installer/remover provided
in tool box.

DRIVE BELT INSTALLER/REMOVER

Screw drive belt installer/remover in the free threaded hole and tight-
en to open the pulley. Remove belt.

A03D2PA

Mmo2002-003a.book Page 84 Friday, February 2, 2001 1:47 PM

Summary of Contents for 2002 Mach Z STD

Page 1: ......

Page 2: ...Industries Ltd Printed in Canada Mmo2002 003a fm GM are registered trademarks and TM are trademarks of Bombardier Inc or its subsidiaries 2001 Bombardier Inc All rights reserved SAFETY WARNING Disrega...

Page 3: ...1 2002 SKI DOO OPERATOR S GUIDE This guide is applicable to CK3TM series Mach Z STD Mach Z Tech Plus...

Page 4: ...adjustment required to suit your specific weight and riding environment before you took possession At deliv ery your dealer would have explained the snowmobile controls and provided you with a brief...

Page 5: ...dimen sioned in the metric system Most fasteners are metric and must not be replaced by customary fasteners or vice versa We recommend genuine Bombardier products for replacement parts and accessories...

Page 6: ...Lever 25 2 Brake Lever 25 3 Parking Brake Button 25 4 Injection Oil Level Parking Brake Pilot Lamp Red 26 5 Handlebar 26 6 Reverse Button 27 7 Tether Cut Out Switch 28 8 DESS Pilot Lamp 30 9 Engine Cu...

Page 7: ...ART 63 In Deep Snow 63 FUEL AND OIL 64 Recommended Fuel 64 Recommended Oil 65 COLD WEATHER CARBURETION MODIFICATIONS 66 BREAK IN PERIOD 66 Engine 66 Belt 66 10 Hour Inspection 66 PRE OPERATION CHECK 6...

Page 8: ...rake Condition 91 Brake Adjustment 91 Rear Suspension Condition 91 Suspension Stopper Strap Condition 91 Track Condition 91 Track Tension and Alignment 92 Steering and Front Suspension Mechanism 96 We...

Page 9: ...not lubricate throttle and or brake cables and housings Only perform procedures as detailed in this guide Unless other wise specified engine should be turned OFF and cold for all lubri cation adjustm...

Page 10: ...sed by its first owner from a BOMBARDIER dealer authorized to distribute SKI DOO products in the country in which the sale occurred hereinafter BOMBARDIER dealer and then only after the BOM BARDIER sp...

Page 11: ...POSE TO THE EXTENT THAT THEY CAN NOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DU RATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE U...

Page 12: ...If the issue has not yet been resolved please submit your complaint in writing or call the appropriate number below In Canada In USA BOMBARDIER INC BOMBARDIER MOTOR RECREATIONAL PRODUCTS CORPORATION O...

Page 13: ...s warranty does not extend the life of this warranty beyond its original expiration date 3 CONDITIONS TO HAVE WARRANTY COVERAGE This warranty coverage is available only on 2002 SKI DOO snowmobile pur...

Page 14: ...t see the Operator s Guide Snow or water ingestion Incidental or consequential damages or damages of any kind including with out limitation towing storage telephone rental taxi inconvenience insur anc...

Page 15: ...distributor dealer receives a proof that the former owner agreed to the transfer of ownership in addition to the coordinates of the new owner 9 CONSUMER ASSISTANCE a In the event of a controversy or a...

Page 16: ...owmobile registration 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...

Page 17: ...ny Genuine Bombardier part used in warranty repairs assumes the remaining warranty that exists on the snowmobile Q If I sell my snowmobile within the warranty period will the new owner qualify for the...

Page 18: ...and USA Only To find the nearest authorized SKI DOO dealer dial 1 800 375 4366 HOW TO IDENTIFY YOUR SNOWMOBILE Vehicle Description Decal Vehicle description decal is located on right hand side of tunn...

Page 19: ...wmobile in the event of loss These numbers are required by the SKI DOO dealer to complete warranty claims properly No war ranty will be allowed by Bombardier Inc if the engine serial number or Vehicle...

Page 20: ...mber Location Model number is part of vehicle identification number VIN Engine Serial Number Location TYPICAL 1 Engine serial number X X X X X X X X X X X X X X X X X A00A6IA Model number Serial numbe...

Page 21: ...ICLE IMPORTANT INSTRUCTIONS Please read the following instructions carefully before operating snow mobile TYPICAL LOCATION OF IMPORTANT INSTRUCTIONS Instruction 1 SINGLE SEAT MODELS A03A04D 5 4 6 3 2...

Page 22: ...20 Instruction 2 SINGLE SEAT MODELS A02A0GA...

Page 23: ...21 Instruction 3 ALL MODELS Instruction 4 ALL MODELS A01A2EA A01A2FA...

Page 24: ...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 25: ...trols instruments equipment do not apply to some models In these cases their reference numbers are deliberately missing in the illustrations Some controls instruments equipment are optional on some mo...

Page 26: ...24 TYPICAL MACH Z STD TECH PLUS A30A0RB 3 2 19 17 14 18 20 15 8 4 11 1 24 25 22 21 23 6 25 24 7 12 9 16 10 13 27 5 26 27...

Page 27: ...overheated condition could cause sudden loss of braking power and or fire 3 Parking Brake Button Located on left side of handlebar Parking brake should be used whenever snowmobile is parked Whenever p...

Page 28: ...Lights when injection oil level is low or when parking brake or brake is applied with engine running Check oil level and replenish as soon as possible Also lights when parking brake is applied with e...

Page 29: ...operating temperature before shifting Shifting in Reverse With the snowmobile completely stopped and engine running at idle press and release the reverse button The DESSTM indicator lamp will blink an...

Page 30: ...er accidently falls off the vehicle and the DESS Digitally Encoded Security Sys tem performs the same function as a key Operation Attach tether cord to clothing then snap tether cord cap over recep ta...

Page 31: ...the engine can not reach engagement speed required to move vehicle Additional Tether Cord Caps We recommend the purchase of additional tether cord caps from your authorized SKI DOO dealer Beep and Pil...

Page 32: ...seconds still occurs contact an authorized SKI DOO 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...

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: ...selection of headlamp beam Note that lights are automatically ON whenever the engine is run ning 11 High Beam Pilot Lamp Blue Lights when headlamp is on HIGH beam 12 Rewind Starter Handle Auto rewind...

Page 35: ...r more details 14 Speedometer These vehicles are equipped with a speedometer graduated in kilome ter per hour miles per hour for the USA Direct reading dial indicates the speed of the snowmobile in ki...

Page 36: ...relays for instance 1 Odometer 2 Trip meter 3 Reset button 17 Trip Meter Reset Button To reset push on button until all numbers read zero 18 Tachometer Direct reading dial indicates the number of thou...

Page 37: ...needle moves to the normal range as engine warms Under all riding conditions the needle should stay within this range If needle moves into the over heat range reduce snowmobile speed and run snowmobil...

Page 38: ...p with fuel tank cap Install cap that is identified OCTANE RATING OF 91 RECOM MENDED WARNING Fuel may be pressurized open cap slowly Fuel is flammable and explosive Never use an open flame to check fu...

Page 39: ...3 Heated Throttle Lever Switch Three position toggle switch Select the desired position to keep your right thumb at a comfortable temperature See illustration above 24 Hood Latches Stretch and unhook...

Page 40: ...ference 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 lbf in WARNING Adjust with vehicle at rest in a safe pla...

Page 41: ...n be adjusted to suit driver s preference Lift lever tilt handlebar to desired position then release lever Lever will locked on each position 1 Lever WARNING Adjust with vehicle at rest in a safe plac...

Page 42: ...gher windshield height Knobs are locked on each position To unlock first pull knobs then turn to adjust windshield height Both knobs must be set to same position Step Pull knob by about 3 mm 1 8 in St...

Page 43: ...hese hood grills must be closed at all times except when riding at high speeds and or when outside temperature is above 5 C 40 F Slightly unscrew wing nuts slide close grills then retighten wing nuts...

Page 44: ...er to operate the snowmobile CAUTION Always fully open the valve before riding Never allow the valve to remain half opened 30 Storage Compartment A storage compartment is provided inside rear portion...

Page 45: ...s may be discarded to ease stor ing tools 1 Tool box 2 Remove hair pin before opening 32 Spark Plug Holder To keep spare spark plugs dry and prevent shocks that might affect the adjustment or break th...

Page 46: ...ve Belt Holder A spare drive belt can be installed in drive belt holder clip Make sure to position spare drive belt as illustrated NOTE Spare drive belt is not supplied with the snowmobile 1 Spare dri...

Page 47: ...KI DOO dealer for fuse replacement 35 Front Grab Handles Front Bumper To be used whenever front of snowmobile requires manual lifting 1 Front grab handles CAUTION Do not use skis to pull or lift snowm...

Page 48: ...6 36 Adjustable Suspensions For factory recommended adjustments refer to decal on belt guard It describes settings for optimum comfort according to load for your SKI DOO model TYPICAL 1 Decal 1 A30F07...

Page 49: ...riding speed and field condition NOTE Some adjustments may not apply to your snowmobile Use special keys in tool box TYPICAL 1 Rear springs for comfort and ride height 2 Center spring for steering beh...

Page 50: ...ically until you are satisfied CAUTION Whenever adjusting rear suspension check track ten sion and adjust as necessary Slight suspension bottoming occurring under the worst riding condi tions indicate...

Page 51: ...Turn the left side adjustment cam in a clockwise direction the right side cam in acounterclockwisedirection Left and right adjustment cams may be set at different position TYPICAL 1 Increase spring p...

Page 52: ...T Turn the left side adjustment cam in a counterclockwise direction the right side cam in a clockwise direction Left and right adjustment cams may be at different position TYPICAL 1 Decrease spring pr...

Page 53: ...Spring Steering Behavior Ride at moderate speed on a trail If steering is too easy or too hard to turn adjust center spring accord ingly TYPICAL GOOD ADJUSTMENT AT MODERATE SPEED 1 Steering easy to tu...

Page 54: ...52 TYPICAL TOO SOFT OF ADJUSTMENT 1 Steering hard to turn TYPICAL 1 Use adjuster wrench provided in tool box to increase preload A32F0EA 1 A32F01A 1...

Page 55: ...53 TYPICAL TOO HARD OF ADJUSTMENT 1 Steering less aggressive TYPICAL 1 Use adjuster wrench provided in tool box to decrease preload A32F0EA 1 A32F01B 1...

Page 56: ...and right blocks by 90 There are only two adjustment positions Thicker part of block must be facing rearward or downward Use tool provided in tool box to adjust coupling blocks COUPLING BLOCK RIGHT SI...

Page 57: ...this direction to adjust to the other position 4 Stopper Strap Weight Transfer Ride at low speed then fully accelerate Note steering behavior Ad just stopper strap length accordingly At rest with dri...

Page 58: ...56 TYPICAL GOOD ADJUSTMENT AT FULL ACCELERATION 1 Comfortable steering 2 Good weight transfer to the track 3 Light pressure of skis on the ground A32F0EB 1 2 3...

Page 59: ...57 TYPICAL TOO LONG STRAP 1 Skis lift off the ground TYPICAL 1 Reduce strap length by bolting to a different hole A32F0EC 1 A03F0QB 1...

Page 60: ...58 TYPICAL TOO SHORT STRAP 1 Heavy steering TYPICAL 1 Increase strap length by bolting to a different hole A32F0EA 1 A03F0QB 1...

Page 61: ...ing Ride at moderate speed and check for proper handling Adjust front springs accordingly TYPICAL PROPER ADJUSTMENT 1 Good handling and comfortable steering WARNING Always adjust both front springs to...

Page 62: ...60 TOO SOFT OF ADJUSTMENT 1 Bad handling 1 Increase spring preload A32F0EA 1 A03F2IA 1...

Page 63: ...61 TOO HARD OF ADJUSTMENT 1 Steering hard to turn 1 Decrease spring preload A32F0EA 1 A03F2JA 1...

Page 64: ...shock motion ratio can be adjusted according to driver and pas senger weight and or trail condition There are two adjustment positions 1 Soft position 2 Firm position To adjust loosen nut move bolt t...

Page 65: ...uspension 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 Reduce cente...

Page 66: ...dditional gas line antifreeze or water absorbing additives are not required and should be not used When using non oxygenated fuel we highly recommend the use of isopropyl base gas line antifreeze in a...

Page 67: ...superior lubrication reduced en gine component wear and oil deposit thus maintaining maximum level performance and antifriction properties This synthetic injection oil meets the latest ASTM and JASO s...

Page 68: ...speeds and engine overheating are detrimental during the break in period To assure additional protection during the initial engine break in 500 mL 18 imp oz of recommended injection oil should be adde...

Page 69: ...ssary and see an authorized SKI DOO dealer in case of any leaks Verify that air filter s is free of snow and ice if so equipped All storage compartments must be properly latched and they must not cont...

Page 70: ...e lever Check proper action Switches and lights Check proper action Skis and steering Check proper action Fuel and oil Check for proper level and leaks Air filter Check for free of snow and ice Adjust...

Page 71: ...ge in the ratio of the two pulleys which maximizes acceleration and forward movement of the vehicle Power is transferred to the track through the chaincase and drive axle Turning Handlebar controls th...

Page 72: ...ond position Grasp starter handle firmly and crank engine or use electric starter on so equipped models After the engine is started close off choke to ensure proper air fuel mix when speed drops below...

Page 73: ...witch Grasp manual starter handle firmly and crank engine Emergency Starting The engine can be started with the emergency starter rope supplied with the tool kit Remove belt guard Attach emergency rop...

Page 74: ...the rope tightly around drive pulley When pulled pulley must rotate counterclockwise 1 Clip Start engine as described in COLD ENGINE STARTING or WARM ENGINE STARTING according to engine temperature P...

Page 75: ...ehicle temperature is the longer vehicle warm up should be Shut off the engine and remove the snowmobile mechanical stand Skis may be frozen on the ground Grasp both skis by their loops and lift them...

Page 76: ...Engine Overheating Reduce snowmobile speed and run snowmobile in loose snow or stop engine immediately Check for adequate coolant level See an authorized SKI DOO dealer Fuel Flooded Engine All Models...

Page 77: ...em being checked When component conditions seem less than satisfactory replace with genuine BOMBARDIER parts or approved equivalents PERIODIC MAINTENANCE CHART Starting Rope Condition Engine Head Scre...

Page 78: ...que to 26 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 Adjustm...

Page 79: ...brake fluid from a sealed container Never use any other types of fluid TYPICAL BRAKE FLUID RESERVOIR 1 Minimum WARNING It is recommended that the assistance of an authorized SKI DOO dealer be periodi...

Page 80: ...magnet If bigger pieces of metal are found see an authorized SKI DOO dealer Remove metal particles from magnet Refill up to upper mark using BOMBARDIER synthetic chaincase oil P N 413 803 300 12 x 35...

Page 81: ...l reservoir to be almost empty 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 WARNING C...

Page 82: ...d of coolant tank NOTE When checking level at low temperature it may be slightly lower then mark If additional coolant is necessary or if entire system has to be refilled refer to an authorized SKI DO...

Page 83: ...RDIER Parts Cleaner P N 413 711 809 Inspect the hood and repair any damage Touch up all metal spots where paint has been scratched off Spray all metal parts including shock chromed rods with BOMBARDIE...

Page 84: ...ut out switch Open hood Open retainer to release pin then pull belt guard toward front 1 Pin retainer When reinstalling belt guard position its cut away toward front of snowmobile Refer to decal on be...

Page 85: ...front portion of belt guard in retainer NOTE Belt guard is purposely made slightly oversize to maintain ten sion on its pins and retainers preventing undue noise and vibration It is important that thi...

Page 86: ...can not rotate Apply parking brake for this purpose Turn off engine cut out switch Open hood and remove belt guard Open the driven pulley with the drive belt installer remover provided in tool box DRI...

Page 87: ...ten to open pulley Slip the belt over the top edge of the sliding half of driven pulley as shown in previous photo Remove access panel from bottom pan 1 Push top of panel out of bottom pan A30D0BA 1 A...

Page 88: ...86 1 Pull panel tab out of bottom pan Slip belt under drive pulley then remove it from vehicle Clean sheaves of both pulleys using BOMBARDIER Parts Cleaner P N 413 711 809 A30C05A 1 A30D0CA...

Page 89: ...rection See arrow on belt 1 Arrow pointing front of vehicle CAUTION Do not force or use tools to pry the belt into place as this could cut or break the cords in the belt To install the drive belt firs...

Page 90: ...ATIONS at the end of this guide Factors such as ambient temperature altitude or surface condition may vary this critical engine RPM thus affecting snowmo bile efficiency This adjustable drive pulley a...

Page 91: ...h on top of its head 1 Notch Governor 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...

Page 92: ...ly remove the locking nut Torque locking nuts to 10 N m 89 lbf in CAUTION Do not completely remove calibration screw or its in side washer will fall off Always adjust all 3 calibration screws and make...

Page 93: ...rmal driving snow will act as a lubricant and coolant for the slider shoes Extensive riding on ice or sanded snow will create excessive heat build up and cause premature slider shoe wear Suspension St...

Page 94: ...of snowmobile and support it with a snowmobile mechan ical stand Allow the suspension to extend normally and check gap half way along slider shoe The gap should be as given in SPECIFICATIONS If the t...

Page 95: ...result in power loss and exces sive stresses on suspension components To adjust tension Remove wheel cap Loosen the rear idler wheel retaining screws Turn adjustment screws to adjust If correct tensi...

Page 96: ...nter 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 to...

Page 97: ...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 adjustment...

Page 98: ...r tight ness of components steering arms control arms and links tie rods ball joints ski coupler bolts etc If necessary contact your SKI DOO dealer Wear and Condition of Skis and Runners Check the con...

Page 99: ...y be in violation of 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 sn...

Page 100: ...98 Reinstall filter over dashboard sticking bottom edge first TYPICAL 1 Stick bottom edge first Finalize filter top edge installation A30H0SA 1...

Page 101: ...ilter under air deflector lip Check air silencer filter for snow Remove filter and shake it as required AIR SILENCER FILTER INSTALLED Check that the air silencer is clean and dry and properly reinstal...

Page 102: ...beam height 1 Knob Bulb Replacement Always check light operation after bulb replacement Headlight CAUTION Never touch glass portion of an halogen bulb with bare fingers it shortens its operating life...

Page 103: ...tor Unplug burnt bulb connector Remove the rubber boot Turn bulb locking ring counterclockwise to remove it Detach the bulb and replace Properly reinstall parts including air filter 1 Locking ring A30...

Page 104: ...t from underneath hood 1 Remove these screws 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 1 Instrume...

Page 105: ...ting unit securely using suitable straps STORAGE AND PRE SEASON PREPARATION Storage It is during summer or when a snowmobile is not in use for more than one month that proper storage is a necessity To...

Page 106: ...on if applicable check fuel filter re place if clogged check condition of fuel and impulse lines and their con nections A failure of the fuel pump or carburetor has occurred Contact an authorized SKI...

Page 107: ...ine turns over but fails to start 4 Lack of fuel to engine Check item 4 of Engine turns over but fails to start 5 Carburetor adjustments Contactan authorized SKI DOOdealer 6 Drive belt worn too thin I...

Page 108: ...r 5 Ignition timing is incorrect orthere is an ignition system failure Contactan authorized SKI DOOdealer SYMPTOM Engine misfires POSSIBLE CAUSES WHAT TO DO 1 DESS has not read tether cord Engine can...

Page 109: ...er 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 acceler ation or...

Page 110: ...1 1 382 Wear Limit Width mm in 32 7 1 287 Spark Plug Type NGK BR 9 ES Gap 0 05 mm 002 in 0 45 018 Track Tension mm in 30 35 1 3 16 1 3 8 Alignment FLUIDS Fuel Type Super Unleaded Tank Capacity L U S...

Page 111: ...usly manufactured Measure gap between slider shoe and bottom inside of track when exerting a downward pull of 7 3 kg 16 lbf to the track Equal distance between edges of track guides and slider shoes S...

Page 112: ...nowmobile becomes nec essary NOTICE TO ALL NEW OWNERS Make sure to mail the Change of Ownership Card as you are entitled to the unexpired portion of the warranty STOLEN UNITS If the event that your sn...

Page 113: ...________ NO STREET APT _____________________________________________________________________________ CITY STATE PROVINCE ZIP POSTAL CODE NEW ADDRESS OR NEW OWNER ______________________________________...

Page 114: ...AFFIX BOMBARDIER RECREATIONAL PRODUCTS WARRANTY DEPARTMENT 75 J A BOMBARDIER ST SHERBROOKE QUEBEC CANADA J1L 1W3 PROPER POSTAGE...

Page 115: ......

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