Ski-Doo 2005 REV series Operator'S Manual Download Page 7

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Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

167

FUEL AND OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

168

Recommended Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

168

Recommended Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

169

COLD WEATHER CARBURETION MODIFICATIONS . . . . . . . . .

172

BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173

Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173

10-Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173

PRE-OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

174

PRE-OPERATION CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

176

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

177

Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

177

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

178

Emergency Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

182

Shutting Off the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

185

VEHICLE WARM-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

186

RIDING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187

HOW TO RIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

188

TERRAIN/RIDING VARIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192

POST-OPERATION CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200

SPECIAL OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201

Riding at High Altitudes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201

Engine Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201

Fuel Flooded Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201

Rear Suspension Slider Shoe Sticking. . . . . . . . . . . . . . . . . . . . . . .

202

MAINTENANCE INFORMATION

PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . .

204

FLUID LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

207

Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

207

Chaincase/Gearbox Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

208

Oil Injection System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

209

Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

210

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

211

Battery Electrolyte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213

MAINTENANCE FOR EPA CERTIFIED ENGINES . . . . . . . . . . . . .

214

Engine Emissions Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214

__________________________

Summary of Contents for 2005 REV series

Page 1: ...Mmo 2005 ZX REV ang FH8 Tue Mar 30 09 28 26 2004 Page 1 Composite C M Y CM MY CY CMY K...

Page 2: ...mbardier Motor Corporation of America In Canada products are distributed by Bombardier Inc The following are trademarks of Bombardier Inc or its subsidiaries SKI DOO ADRENALINETM LEGENDTM REVTM ROTAXT...

Page 3: ...questions pertaining to the warranty and its application con sult the WARRANTY section in this guide and or an authorized SKI DOO dealer This guide uses the following safety alert symbol in conjunctio...

Page 4: ...the right at any time to discontinue or change specifications designs features models or equipment without in curring obligation The illustrations in this document show the typical construction of th...

Page 5: ...Numbers 36 ON VEHICLE IMPORTANT INSTRUCTIONS 39 CONTROLS INSTRUMENTS EQUIPMENT 58 1 Throttle Lever 62 2 Brake Lever 62 3 Parking Brake Lever 62 4 Brake Parking Brake Pilot Lamp Red 63 5 Gear Shift Le...

Page 6: ...ab Handles 103 37 Adjustable Backrest 104 38 Electric Visor Jack Connector 105 39 12 Volt Power Outlet 108 40 Windshield 108 41 Adjustable Mirrors 108 42 Adjustable Toeholds 108 43 Heated Carburetor V...

Page 7: ...LE WARM UP 186 RIDING THE VEHICLE 187 HOW TO RIDE 188 TERRAIN RIDING VARIATIONS 192 POST OPERATION CARE 200 SPECIAL OPERATIONS 201 Riding at High Altitudes 201 Engine Overheating 201 Fuel Flooded Engi...

Page 8: ...Wear and Condition of Skis and Runners 238 Exhaust System 238 Air Filter Cleaning 238 Headlamp Beam Aiming 242 Bulb Replacement 243 TOWING AN ACCESSORY 247 TOWING ANOTHER SNOWMOBILE 248 TRANSPORTING T...

Page 9: ...he respect and care due of any power driven machine Common sense proper handling and routine maintenance will result in safer and enjoyable use Check your machine before each ride Always make a pre st...

Page 10: ...nt and return to idle position before starting engine Always engage parking brake when vehicle is not in use Always stop the engine before refueling Fuel is inflammable and explosive under certain con...

Page 11: ...ctronic Reverse RER pilot lamp comes on in the dashboard before operating throttle to proceed in re verse The reverse speed of these snowmobiles is not limited Always proceed with caution as fast reve...

Page 12: ...10 _________________________...

Page 13: ...SAFETY INFORMATION ______SAFETY INFORMATION _____ 11...

Page 14: ...se give the guide to the new owner for his awareness An extra copy of the Operator s Guide is available from your SKI DOO snowmobile dealer at no charge This safety information section is dedicated to...

Page 15: ...LE A T VALU PAR UN LABORATOIRE D ESSAIS IND PENDANT ET SATISFAIT TOUTES LES NORMES DE S CURIT DU SSCC EN VIGUEUR LA DATE DE FABRICATION PARRAIN PAR LE COMIT DE S CURIT DE CERTIFICATION D E L A M O T O...

Page 16: ...humbs and fin gers for operation of controls Rubber bottom boots with either a nylon or a leather top with re movable felt liners are best suited for snowmobiling You should keep yourself as dry as po...

Page 17: ...ibility speed weather environment traffic vehicle condition and the condition of the driver A00A1NA Each operator has a responsibility to ensure the safety of his her pas senger if any and of other re...

Page 18: ...obile equipped with traction enhancing products studs car bide ski runners requires a certain adaptation period If your snow mobile is equipped with traction products be sure to take plenty of time to...

Page 19: ...he snowmobile prone to oversteer ing see illustration A33A31A OVERSTEERING 2 Understeering In certain conditions the use of studs could make the snowmobile prone to understeering if the skis are not e...

Page 20: ...e possibly resulting in serious injury or death Always go easy on the throttle NEVER try to spin the track to make the rear of the snowmo bile skid This could cause debris or ice to be thrown violentl...

Page 21: ...l This can cause premature wear on parts such as belts brake linings bearings chain and chaincase sprocket and shorten track life For this reason it is even more important to follow the detailed maint...

Page 22: ...e illustra tion molded into the track surface Studs should only be installed in the locations indicated by molded bulges in the track surface Never stud a track with a profile of 35 mm 1 375 in or mor...

Page 23: ...rods delamination of the rubber broken rods broken studs bent studs studs that are torn off the track missing track guide s Replace broken or damaged studs immediately If your track shows signs of det...

Page 24: ...have en acted laws and regulations pertaining to the safe use and operation of snowmobiles It is your responsibility as a snowmobiler to learn and obey these laws and regulations Respect and observanc...

Page 25: ...ntify hazardous wires near your trail Overhead branches can cause driver distraction cut faces and even cause eye damage Always wear an approved safety hel met eye protection and a face shield This al...

Page 26: ...witch pulling the tether cord cap or by turning off the ignition Correct the problem before the snowmobile is operated Be pre pared to immediately respond should a throttle malfunction occur Always sh...

Page 27: ...e to spin out of control Never brake or attempt speeding or turning on glare ice If you do happen to travel over such a condition reduce speed by carefully releasing the throttle Never jump your snowm...

Page 28: ...th of a following snowmobile In addition when gunning the throttle the vehicle digs into and leaves an irregular snow surface for others Safaris are both fun and enjoyable but don t show off or overta...

Page 29: ...essing guidelines as those recommended for the driver as described above Make sure that you are able to achieve a stable stance both feet resting positively on the footboards of footrests with good gr...

Page 30: ...heir share in preserving areas that make it possible to enjoy our sport BRP has developed the Light Treading Is Smart Sledding campaign for snowmobilers Light Treading refers to more than the thread o...

Page 31: ...mobilers know all too well the efforts that have been made throughout the sport s history to enjoy access to areas where people can snowmobile safely and responsibly This effort continues today as str...

Page 32: ...30 _____SAFETY INFORMATION _____...

Page 33: ...VEHICLE INFORMATION __________________________ 31...

Page 34: ...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 snowmobiles and governmental...

Page 35: ...ranty 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 balance of the warranty A Yes provide...

Page 36: ...AUTHORIZED SKI DOO DEALERS For Canada and USA Only To find the nearest authorized SKI DOO dealer dial 1 800 375 4366 or visit our web site at WWW SKIDOO COM 34 _________________________...

Page 37: ...ight hand side of tunnel 1 A33H01A TYPICAL 1 Vehicle description decal 3 5 A00A6MA 2 4 6 8 7 1 VEHICLE DESCRIPTION DECAL 1 Manufacturer name 2 Manufacturing date 3 Vehicle identification number VIN 4...

Page 38: ...number or vehicle identification number VIN is removed or mutilated in any way We strongly recommend that you take note of all the serial numbers on your snowmobile and supply them to your insurance...

Page 39: ...Engine Serial Number Location 1 A25C0MA FAN COOLED MODELS 1 Engine serial number 1 A32C01B 2 STROKE LIQUID COOLED MODELS 1 Engine serial number __________________________ 37...

Page 40: ...A32A1XA 1 4 TEC MODELS RH OF ENGINE 1 Engine serial number 38 _________________________...

Page 41: ...ing or damaged the decals can be replaced free of charge See an autho rized SKI DOO dealer Please read the following instructions carefully before operating this snowmobile A32A02G 2 1 3 4 5 11 6 23 1...

Page 42: ...A33A1ZE 2 16 17 11 1 15 3 4 5 19 8 7 20 13 14 9 18 12 TYPICAL LOCATION OF IMPORTANT INSTRUCTIONS REV SERIES 40 _________________________...

Page 43: ...Instruction 1 A32A1YA ZX SERIES __________________________ 41...

Page 44: ...A33A2CA REV SERIES 42 _________________________...

Page 45: ...Instruction 2 A33A2DA EXPEDITION FAN 550 A33A2EA EUROPEAN MODELS __________________________ 43...

Page 46: ...Instruction 3 A01A2EA ALL MODELS 44 _________________________...

Page 47: ...ne Attention aux pi ces en rotation _ elles peuvent vous blesser ou capter vos v tements This guard must ALWAYS be in place when engine is running Beware of rotating parts _ they could cause injuries...

Page 48: ...ction 5 Ne pas d monter ni modifier cette poulie Do not disassemble or modify this pulley AVERTISSEMENT A01A2GA TYPICAL ALL FAN COOLED MODELS Instruction 6 A32A08A 4 TEC MODELS 46 ____________________...

Page 49: ...Instruction 7 A32A1GA 4 TEC MODELS Attention aux pi ces CHAUDES Beware of HOT parts 516002664 A33A2GA REV SERIES __________________________ 47...

Page 50: ...ED MODELS Instruction 9 Use XP S 2 Stroke Synthetic blend or XP S Synthetic 2 Stroke oil Utilisez de l huile semi synth tique 2 temps XP SMD ou synth tique 2 temps XP SMD 516 002 325A A33A2HA 2 TEC MO...

Page 51: ...Instruction 10 A32A1ZA 4 TEC MODELS Instruction 11 A01A1ZD SINGLE SEAT ZX SERIES __________________________ 49...

Page 52: ...A33H02A DO NOT SIT HERE NE PAS S ASSEOIR ICI SOME MODELS SINGLE SEAT REV SERIES 50 _________________________...

Page 53: ...A33A2IA DO NOT SIT HERE NE PAS S ASSEOIR ICI SOME MODELS SINGLE SEAT REV SERIES __________________________ 51...

Page 54: ...Instruction 12 A32F21A SUMMIT MODELS 52 _________________________...

Page 55: ...ements appropri s la motoneige Ne JAMAIS utiliser une motoneige sous l influence de drogues ou alcool m me en tant que passager ALWAYS wear a DOT approved HELMET and clothing appropriate for snowmobil...

Page 56: ...Instruction 14 A33A2KA SOME MODELS REV SERIES 54 _________________________...

Page 57: ...se et allouez plus d espace pour tourner ou freiner Respectez les lois sur l ge minimal du conducteur Le manufacturier recommande que le conducteur soit g d au moins 16 ans 516 002 671 Read and unders...

Page 58: ...ility MAXIMUM cargo load 15 8 Kg 35 Lbs NE JAMAIS S ASSEOIR LA PLACE DU CARGO Exc der le poids maximal du cargo peut affecter le contr le de la direction et la capacit de freinage Charge MAXIMALE carg...

Page 59: ...NE IS CERTIFIED TO OPERATE ON UNLEADED GASOLINE AND CONFORMS TO XXXX U S EPA REGULATIONS FOR SNOWMOBILE SI ENGINES EMISSION CONTROL INFORMATION ENGINE FAMILY FEL ENGINE DISPLACEMENT EXHAUST EMISSION C...

Page 60: ...ional on some models In these cases their reference numbers are deliberately missing in the illustrations 50 45 A32A28B 48 37 35 47 56 46 60 60 36 34 49 40 58 57 TYPICAL ZX SERIES 34 36 38 A33A2QA 60...

Page 61: ...A32H42B 27 42 42 38 44 44 39 6 14 33 32 41 2 3 30 21 26 8 29 13 41 1 5 11 TYPICAL ZX SERIES __________________________ 59...

Page 62: ...41 A33A36A 9 8 41 13 1 29 11 10 20 39 27 19 44 28 42 42 32 3 2 33 14 5 6 30 38 39 44 38 TYPICAL REV SERIES 60 _________________________...

Page 63: ...A32A15C 26 29 21 4 7 12 15 31 16 23 24 25 30 22 18 17 TYPICAL 7 12 A33A1GA 17 15 31 16 18 22 21 23 24 25 4 26 TYPICAL SUMMIT ADRENALINETM X __________________________ 61...

Page 64: ...ally returns to its orig inal position Braking effect is proportional to the pressure applied on the lever and to the type of terrain and its snow coverage 3 Parking Brake Lever Located on left hand s...

Page 65: ...ts original position Always release parking brake before riding NOTE On some models locking lever can be adjusted in two differ ent positions A06D11A 1 2 2 3 TYPICAL 1 Locking lever 2 OFF 3 ON 4 Brake...

Page 66: ...stability and control Come to complete stop before selecting reverse gear Wait until the reverse alarm sounds be fore operating throttle to proceed in reverse Always remain seated and apply the brake...

Page 67: ...r stop ping or stalling Shifting procedure will take place only when the engine is running If engine is running at a speed above 4300 RPM the reverse function of the START RER button is cancelled It i...

Page 68: ...gine running at idle press and release the START RER button The DESSTM RERTM pilot lamp will blink and a warning buzzer will sound once every second with a half a second duration when the snowmobile i...

Page 69: ...One beep then 2 beeps then one beep then 2 beeps and so on are heard with one second interval The mode to be selected corresponds to the last beep code heard NOTE The selected altitude mode is kept in...

Page 70: ...adjusted to suit driver s preference Lift lever tilt handlebar to desired position then release lever WARNING Adjust with vehicle at rest in a safe place Securely tighten all adjustments 1 A32A0RA 1...

Page 71: ...are 2 positions NOTE Following procedure describes how to change steering col umn position from rearward to forward position Unscrew 4 bolts retaining windshield assembly to handlebar Re move windshie...

Page 72: ...Remove steering cover and console cap A33H05B 2 1 1 Steering cover 2 Console cap 70 _________________________...

Page 73: ...Unscrew 4 bolts retaining console 1 A33H06A 1 1 Bolts retaining console __________________________ 71...

Page 74: ...lift console to gain access to electrical connector housings Unplug the 2 large connector housings and the separate 3 wire con nector 1 A33H07A TYPICAL 1 Large connector housings 72 _________________...

Page 75: ...Remove console Remove 2 bolts retaining top of steering column 1 A33H08A STEERING COLUMN IN REARWARD POSITION 1 Two bolts retaining top of steering column __________________________ 73...

Page 76: ...all the 2 bolts Always install the longer bolt on thicker portion to be bolted Use new lock nuts Torque nuts to 24 N m 18 lbf ft NOTE Should rearward position be selected it is mandatory while changin...

Page 77: ...Locate blue check valve 1 A32I1CA 1 Check valve __________________________ 75...

Page 78: ...Disconnect fuel tank vent hose from blue check valve Reroute fuel tank vent hose under upper cross member A32I1DA ROUTING WITH FORWARD POSITION STEERING COLUMN 76 _________________________...

Page 79: ...t hose to blue check valve Reconnect the electrical connectors and reinstall all removed parts Position of console cap will be inverted Instead of being above it will be beneath steering column A33H0A...

Page 80: ...ield assembly Readjust throttle lever housing and brake lever housing accordingly to optimal angle so that you will not need to release your grip to operate levers WARNING Adjust with vehicle at rest...

Page 81: ...references Loosen all 4 bolts retaining handlebar to steering column 1 A33H16A 1 1 Four bolts Move handlebar to the desired position Torque all 4 bolts to 24 N m 18 lbf ft Readjust windshield for prop...

Page 82: ...on See above pho tos Slots in brackets allow different windshield positions Move wind shield to fit with console Retighten 4 nuts to 5 N m 44 lbf in Check that windshield does not touch console after...

Page 83: ...8 to 1 2 in 9 Holding Strap Holding strap provides a grip for driver when side hilling WARNING This strap is not for towing lifting or other purpose than tem porary use as a grab bar during side hill...

Page 84: ...than 10 seconds A rest period should be observed between the cranking cycles to let electric starter cool down Using electric starter when engine has started could damage electric starter mechanism Re...

Page 85: ...ways remove tether cord cap and key when vehicle is not in operation in order to prevent accidental engine starting or to avoid unauthorized use by children or others or theft Operation Attach to clot...

Page 86: ...ntly Through the DESS Digitally Encoded Security System it acts as a lock by preventing unauthorized use of your snowmobile thus de terring theft Finally it prevents unintentional electric starter ope...

Page 87: ...e 3000 RPM if and only if this unique code has been read after engine starting If a tether cord cap with different code is installed the engine will start but cannot reach drive pulley engagement spee...

Page 88: ...tall cap and restart engine If a blink per 1 5 seconds still occurs contact an authorized dealer A30H08A 1 1 Free of dirt or snow A DESS pilot lamp blinking 3 times per second means that you have inst...

Page 89: ...depending on models is located on the right hand side of the handlebar To stop the engine in an emergency select OFF position and simultaneously apply the brake To restart button must be at the ON pos...

Page 90: ...ng the engine thereafter This engine cut out procedure will become a reflex and will prepare operators for emer gency situations requiring its use WARNING If the switch has been used in an emergency c...

Page 91: ...then replenish injection oil reservoir 4 Stroke Models This pilot lamp will glow up when engine oil pressure is too low Stop vehicle in a safe place then check oil level and replenish as described in...

Page 92: ...ver This device features a 3 position lever to facilitate cold start 1 2 3 A06H1KA 1 OFF 2 Position 2 3 Position 3 Initial Cold Starting NOTE Do not operate the throttle lever with the choke lever on...

Page 93: ...dels are equipped with an electronic speedometer It may show speed in km h or MPH NOTE At vehicle speed of 90 km h 55 MPH and more the mode LCD screen will show speed only instead of the selected mode...

Page 94: ...A32I0GA ZX SERIES KILOMETERS READING CONNECTORS PLUGGED A32I0HA ZX SERIES MILES READING CONNECTORS UNPLUGGED 92 _________________________...

Page 95: ...A33E06A REV SERIES KILOMETERS READING CONNECTORS PLUGGED 1 A33E05A 2 REV SERIES MILES READING CONNECTORS UNPLUGGED 1 Locking ties 2 Connectors __________________________ 93...

Page 96: ...point depressing mode button will change display for the trip meter Depressing mode button again will change display for the resetable hourmeter Push mode button again to return to odometer Push and...

Page 97: ...cle is moving the LCD screen will show speed only instead of the selected mode 25 Resetable Hourmeter Records engine running time in hours and minutes since it has been reset All Models except Summit...

Page 98: ...t smoke or allow open flames or sparks in the vicinity Open cap slowly If a differential pressure con dition is noticed whistling sound heard when loosening fuel tank cap have vehicle inspected and or...

Page 99: ...uel Level Gauge Located at rear of fuel tank cap the gauge facilitates fuel level read ing A32A25B 1 2 TYPICAL 1 Full 2 Empty NEEDLE POSITION OF FUEL LEVEL GAUGE APPROXIMATE REMAINING FUEL QUANTITY L...

Page 100: ...Summit ADRENALINE X Open fabric door to see the fuel level through the transparent fuel tank A33H1OA 1 1 Fabric door 98 _________________________...

Page 101: ...29 Electric Fuel Level Gauge Dash mounted gauge to facilitate fuel level reading This gauge func tions when engine is running A32A26A 2 1 TYPICAL 1 Full 2 Empty __________________________ 99...

Page 102: ...hould stay within this range If needle moves into the overheat range reduce snowmobile speed and run snowmobile in loose snow or stop engine immediately A32A27A 2 1 TYPICAL 1 Normal 2 Overheat 31 Engi...

Page 103: ...ing throttle lever switch 3 Hot 4 Warm 5 Off 33 Heating Throttle Lever Switch Three position switch Select the desired position to keep your right thumb at a comfortable temperature See illustrations...

Page 104: ...IES RIGHT SIDE OF PASSENGER GRAB HANDLE 1 Rear passenger heating grab handles switch 1 A33H4RA REV SERIES LEFT SIDE OF PASSENGER GRAB HANDLE 1 Rear passenger heating grab handles switch 102 __________...

Page 105: ...eries Some Models Height of rear grab handles can be adjusted Lift adjustment lock move grab handle to desired position Secure adjustment lock Proceed the same with the other side WARNING Adjust with...

Page 106: ...r or passenger convenience WARNING Adjust with vehicle at rest in a safe place Securely tighten all adjustments ZX Series Some Models A32H0PA 2 1 1 Turn adjustment knob 2 Lift adjustment lock both sid...

Page 107: ...lever to secure backrest in place 38 Electric Visor Jack Connector An electric visor can be connected to the jack connector Electric current is supplied whenever engine is running A stress relief ex t...

Page 108: ...1 A32E0OA 2 TYPICAL ZX SERIES 1 Electric visor jack connector 2 Stress relief extension 1 A33A0SA 2 TYPICAL REV SERIES 1 Electric visor jack connector 2 Stress relief extension 106 ___________________...

Page 109: ...Passenger A33H4TA 1 REV SERIES SOME MODELS 1 Electric visor jack connector _________________________ 107...

Page 110: ...n by de flecting wind and snow away from the operator 41 Adjustable Mirrors Each mirror can be adjusted to suit driver s preference WARNING Adjust with vehicle at rest in a safe place 42 Adjustable To...

Page 111: ...23 F and 41 F in a high rel ative humidity When riding in deep powder snow When following another snowmobile which makes snow dust 1 A33C01A 2 TYPICAL REV SERIES 1 ON 2 OFF CAUTION When operating the...

Page 112: ...s A32H02A 1 2 1 Latch 2 Recess provided to open hood Always lift hood gently until stopped by retaining device Close hood slowly then hook up latches REV Series To open hood slightly widen pull out it...

Page 113: ...1 A33H0MA 2 1 Anchors 2 Grommets To open a side panel stretch and unhook the latches 1 A33H13A 1 Latch _________________________ 111...

Page 114: ...To remove a side panel remove by pulling up both locking devices from hinge 1 A33H0EA 1 Locking device 112 _________________________...

Page 115: ...For left hand side panel removal also unplug vent hose or sensor from air silencer A33C02B 1 NON 2 TEC MODELS 1 Vent hose _________________________ 113...

Page 116: ...or Reverse opening procedure to close hood and side panels Properly hook up latches 45 Fuses To remove fuse from holder pull fuse out Check if filament is melted 1 2 A15E0KA 1 Fuse 2 Check if melted 1...

Page 117: ...ervicing Ground Protection Fuse Electric Start Fan Cooled Models Only Ground wire is protected with a 20 ampere rated fuse See following illustration for fuse holder location Check fuse condition and...

Page 118: ...r location If headlight does not light up check fuse condition and replace it if necessary 1 2 A33E07A FUSE LOCATION LEFT HAND SIDE OF ENGINE COMPARTMENT BEHIND HEADLIGHT 1 20 A headlight fuse RED ORA...

Page 119: ...N This fuse should always be disconnected before do ing any maintenance under the hood This is to prevent any un expected electrical activation 1 A33E0EA 1 Charging system fuse _______________________...

Page 120: ...ampere rated fuse See following illus tration for fuse holder location If no voltage is present at MPEM or starter does not operate check fuse condition and replace it if nec essary 1 A33E0FA 1 MPEM...

Page 121: ...2 TEC and 4 TEC Models To open fuse box push on cover tab and tilt cover 1 A32I0KA TYPICAL 1 Push tab _________________________ 119...

Page 122: ...2 A32I0IA 1 3 TYPICAL 1 Fuse description decal 2 Fuse remover installer 3 Spare fuses 120 _________________________...

Page 123: ...1 A32I0JA 1 Fuse remover installer Some Models Electric Fuel Level Gauge Fuse See an authorized SKI DOO dealer for fuse replacement _________________________ 121...

Page 124: ...of snowmobile requires manual lifting WARNING Do not attempt to lift the vehicle by hand alone Use appro priate lifting device or have assistance to share lifting stress in order to avoid risk of str...

Page 125: ...AUTION Do not lift snowmobile by the front bumper All Models CAUTION Do not use skis to pull or lift snowmobile 47 Hood Grills When riding on powdered snow close plastic sliding hood grills from under...

Page 126: ...A32H03A TO CLOSE SQUEEZE CLOSING TABS BETWEEN THUMB AND INDEX A32H04A TO OPEN SQUEEZE OPENING TABS BETWEEN THUMB AND INDEX 124 _________________________...

Page 127: ...t WARNING All storage compartments must be properly latched and they must not contain any heavy or breakable objects ZX Series and Some REV Series Models 1 A33H1ZA 1 Storage compartment cover ________...

Page 128: ...Some REV Series Models Pull latch slightly upward then backward to unlock cover 1 A33H0LA 1 Latch GTX Models A33H4UA 1 1 Storage compartment 126 _________________________...

Page 129: ...Always readjust suspension according to the load The capacity of this rack is limited Ride at very low speed when loaded Avoid speed over bumps 50 Tool Kit A tool kit containing tools for basic mainte...

Page 130: ...A33B0QA 1 REV SERIES 1 Tool kit 128 _________________________...

Page 131: ...its support by turning the upper button 90 clockwise NOTE If upper button cannot be turned unlock upper button using the suitcase locking device Push upper button downward and gently pull on the suit...

Page 132: ...A33A2UA 1 1 Locking device Lift suitcase to release it from its lower support A33A2TA 130 _________________________...

Page 133: ...cked using the safety locking device this will also prevent the upper button to turn A33A2UA 1 1 Locking device CAUTION Make sure suitcases are properly fixed and secured before using snowmobile _____...

Page 134: ...52 Integrated Bag GSX Lift release lever from plastic buckles to unfasten integrated bag from vehicle A33A2VA 132 _________________________...

Page 135: ...isual contact with the child and hold him if necessary In addition the child is best protected against the wind and cold temperature if seated in the center location WARNING Any passenger must be able...

Page 136: ...Transformation of the GTX Limited into a Snowmobile for 2 Occupants The GTX Limited can be converted into a snowmobile with 2 seats instead of 3 by removing the middle 2 1 seat and installing the pas...

Page 137: ...ng rear of seat A33A2YA 1 1 Strap Slightly pull passenger s seat rearward to release alignment tab from 2 1 seat CAUTION If passenger s seat needs to be removed from vehicle make sure to unplug passen...

Page 138: ...A33A2ZA Slightly pull 2 1 seat rearward to release alignment tab from driver seat Remove 2 1 seat A33A30A 136 _________________________...

Page 139: ...position Cargo placed in this hole would be unstable could fall and potentially injure someone A passenger sitting on the passenger s seat that is installed in the third position must not use the hol...

Page 140: ...A33A2XA 1 2 1 Driver seat 2 Passenger s seat WARNING Make sure the passenger s seat s that are installed are locked securely in place before using the snowmobile 138 _________________________...

Page 141: ...vided in engine com partment A33C02A 1 REV SERIES SPARK PLUG HOLDER ON LEFT HAND SIDE PANEL 1 Spare spark plugs installed in holder NOTE Spare spark plugs are not supplied with snowmobile NOTE Check s...

Page 142: ...OTE Spare drive belt is not supplied with the snowmobile A32H0TA ZX SERIES SPARE DRIVE BELT INSTALLED IN HOLDER A33H14A REV SERIES SPARE DRIVE BELT INSTALLED IN HOLDER 57 Hitch The hitch can be used t...

Page 143: ...vertible Ski Stance Summit Models Only Ski stance distance between each skis is adjustable See an autho rized SKI DOO dealer 60 Adjustable Suspensions General All Models Snowmobile handling and comfor...

Page 144: ...cessary to readjust center spring after adjusting front springs for instance Test run the snow mobile under the same conditions trail speed snow driver riding position etc Change one adjustment and re...

Page 145: ...t the suspension components CAUTION Whenever adjusting rear suspension check track ten sion and adjust as necessary Slight suspension bottoming occurring under the worst riding condi tions indicates a...

Page 146: ...50 to 75 mm 2 to 3 in when driver and passenger if so applicable take place Mea sure at rear bumper as shown in next photo WARNING Do not attempt to lift the vehicle by hand alone Use appro priate lif...

Page 147: ...3 IN CAUTION To increase preload always turn the left side adjust ment cam in a clockwise direction and the right side cam in a counterclockwise direction Left and right adjustment cams may be at dif...

Page 148: ...0 MM 2 IN CAUTION To decrease preload always turn the left side adjust ment cam in a counterclockwise direction the right side cam in a clockwise direction Left and right adjustment cams may be at dif...

Page 149: ...ding with any suspension adjustment remem ber park in a safe place remove DESS tether cord cap lift rear of vehicle off the ground with a wide base snowmo bile stand with a rear deflector panel make s...

Page 150: ...A32F0EA 1 TYPICAL TOO SOFT OF ADJUSTMENT 1 Handlebar harder to turn oversteering attitude A32F01A 1 TYPICAL 1 Use adjuster wrench provided in tool kit to increase preload 148 _________________________...

Page 151: ...PICAL TOO HARD OF ADJUSTMENT TOO MUCH PRELOAD 1 Handlebar is very easy to turn understeering attitude A32F01B 1 TYPICAL 1 Use adjuster wrench provided in tool kit to decrease preload _________________...

Page 152: ...e place remove DESS tether cord cap lift rear of vehicle off the ground with suitable lifting device make sure lifting device is stable and secure CAUTION Whenever stopper strap length is changed trac...

Page 153: ...All Models except Summit A32F0EC 1 TYPICAL TOO LONG STRAP 1 Skis lift off the ground A03F0QB 1 TYPICAL 1 Reduce strap length by bolting to a different hole _________________________ 151...

Page 154: ...A32F0EA 1 TYPICAL TOO SHORT STRAP 1 Heavy steering A03F0QB 1 TYPICAL 1 Increase strap length by bolting to a different hole 152 _________________________...

Page 155: ...Summit Models A32F0EC 1 TOO LONG STRAP 1 Skis lift off the ground A32E19A 1 1 Loosen lock nut turn knob accordingly then retighten lock nut _________________________ 153...

Page 156: ...A32F0EA 1 TOO SHORT STRAP 1 Heavy steering A32E19B 1 1 Loosen lock nut turn knob accordingly then retighten lock nut 154 _________________________...

Page 157: ...ar spring preload is done See above rear spring adjustment If handling requires adjustment turn both left and right blocks by 90 There are only two adjustment positions Thicker part of block must be f...

Page 158: ...IA 1 2 COUPLING BLOCK RIGHT SIDE VIEW R RIGHT EMBOSSED ON BLOCK 1 Thicker part of block facing rearward fully coupled suspension less track grip and more skis steering 2 Turn block in this direction t...

Page 159: ...Only Ride at moderate speed and check for desired handling If handling requires adjustment turn both left and right blocks by 90 to the desired position There are four possible adjustment positions Si...

Page 160: ...steering 2 Side of block marked 2 facing rearward partly coupled suspension reduce track grip and increase skis steering 3 Side of block marked 3 facing rearward partly coupled suspension reduce trac...

Page 161: ...remem ber park in a safe place remove DESS tether cord cap lift rear of vehicle off the ground with a wide base snowmo bile stand with a rear deflector panel make sure lifting device is stable and sec...

Page 162: ...Some Models A32F0EA 1 TYPICAL TOO SOFT OF ADJUSTMENT 1 Bad handling 2 A32F1CA 1 1 Increase spring preload 2 Position number 160 _________________________...

Page 163: ...OF ADJUSTMENT 1 Steering hard to turn 2 A32F1CB 1 1 Decrease spring preload 2 Position number CAUTION Make sure that both front springs are still pre loaded when front of vehicle is off the ground ___...

Page 164: ...Some Models A32F0EA 1 TYPICAL TOO SOFT OF ADJUSTMENT 1 Bad handling A03F2IA 1 1 Increase spring preload 162 _________________________...

Page 165: ...A32F0EA 1 TYPICAL TOO HARD OF ADJUSTMENT 1 Steering hard to turn A03F2JA 1 1 Decrease spring preload _________________________ 163...

Page 166: ...A32F30A 1 1 Soft position 2 Firm position WARNING Remove tether cord cap before performing any maintenance or adjustment unless otherwise specified Vehicle must be parked in a safe place away from the...

Page 167: ...ing it clockwise increases shock damp ing action stiffer for these low compression speeds High Speed Compression Adjuster The High speed adjuster modifies the damping force for high suspen sion veloci...

Page 168: ...Reduce front suspension spring preload Increase center spring preload Rear of snowmobile seems too stiff Reduce rear spring preload Rear of snowmobile seems too soft Increase rear spring preload Rear...

Page 169: ...section at the beginning of this guide This section also provides other important information that you must consider before having studs installed on a track A00A8KA 1 2 TRACK SYMBOLS 1 Approved 2 NOT...

Page 170: ...ded gasoline available from most service sta tions or oxygenated fuel containing less than 10 of ethanol or 5 of methanol The gasoline used must have the following recom mended minimum octane number L...

Page 171: ...hen using non oxygenated fuel we highly recommend the use of isopropyl base gas line antifreeze in a proportion of 150 mL 5 U S oz of gas line antifreeze added to 40 liters 10 1 2 U S gal of gas This...

Page 172: ...ing The XP STM 2 stroke synthetic blend and XP STM synthetic 2 stroke oilprovides superior lubrication reduced engine component wear and oil deposit thus maintaining maximum level performance and anti...

Page 173: ...4 stroke engine Use XP S 0W40 synthetic 4 stroke oil P N 293 600 054 12 x 1L NOTE There is no known equivalent for this oil on the market for the moment If a high quality equivalent were available it...

Page 174: ...r 20 C 4 F They can be oper ated at warmer winter temperatures without problems CAUTION For colder temperatures than 20 C 4 F carbure tor s must be recalibrated to avoid engine damage Refer to an auth...

Page 175: ...ecommended injection oil should be added to fuel for the first full filling of fuel tank Have spark plugs cleaned after engine break in Belt All Models A new drive belt requires a break in period of 5...

Page 176: ...ound Activate the brake control lever and make sure the brake fully ap plies before the brake control lever touches the handlebar grip It must fully return when released Check the parking device Apply...

Page 177: ...must not contain any heavy or breakable objects Hood must be also properly latched WARNING All adjustable features should be positioned at optimal setting Securely tighten all adjustment locks Make c...

Page 178: ...thing eyelet Skis and steering Check for free movement and proper action Fuel and oil Check for proper level and leaks Air filter Check that there is no snow or ice Adjustable features Check for optim...

Page 179: ...and limits the belt movement The result is an optimized speed ratio between engine RPM and the speed of the vehicle at anytime WARNING Never operate engine without belt guard securely installed or wit...

Page 180: ...g the Engine IMPORTANT On 2 TEC electrical starter equipped models if the low battery voltage pilot lamp is on battery would not have enough power to start the engine In this case use the manual rewin...

Page 181: ...3 1 OFF 2 Position 1 3 Position 2 When Temperature is Above 10 C above 15 F Set the choke lever to position 1 Grab starter handle firmly and crank engine or use electric starter on so equipped models...

Page 182: ...NT If the low battery voltage pilot lamp is on battery would not have enough power to start the engine In this case use the manual rewind starter If the battery is dead engine cannot be started Have t...

Page 183: ...ing electric starter when engine has started could damage electric starter mechanism NOTE If for any reason the engine cannot be cranked electrically place ignition key to ON position and start engine...

Page 184: ...supplied with the tool kit Remove belt guard WARNING Do not wind starting rope around your hand Hold rope by the handle only Do not start the snowmobile by the drive pulley unless it is a true emerge...

Page 185: ...rewind handle NOTE The spark plug socket can be used as an emergency handle A17B01A TYPICAL Attach the other end of emergency rope to the starter clip supplied in the tool kit Hook up clip on drive p...

Page 186: ...Wind the rope tightly around drive pulley When pulled pulley must rotate counterclockwise A03D25A 1 TYPICAL FAN COOLED MODELS 1 Knot on this side 184 _________________________...

Page 187: ...ard and return slowly to have snowmobile repaired Shutting Off the Engine Release throttle lever and wait until engine has returned to idle speed Shut off the engine using either ignition switch fan c...

Page 188: ...nutes Release parking brake WARNING Make sure wide base snowmobile mechanical stand is stable Stay clear of the front of vehicle and the track Do not use too much throttle during warm up or when track...

Page 189: ...about the safe op erating practices Although the mere reading of such information does not eliminate the hazard its understanding and heeding of all of the warnings and cautions will promote the safe...

Page 190: ...o lean into a slope to maintain proper balance Generally the riding position for best balance and control is sitting However the posting kneeling or standing positions are also used under certain cond...

Page 191: ...tion with the body off the seat and the feet under the body in a sort of squatting posture thus allowing the legs to absorb the shocks when traveling over uneven terrain Avoid abrupt stops A30H03A ___...

Page 192: ...Kneeling This position is achieved by placing one foot firmly on the running board and the opposite knee on the seat Avoid abrupt stops A30H04A 190 _________________________...

Page 193: ...on the running boards Knees should be flexed to absorb the shock from surface bumps This is an effective position to see better and to shift weight as conditions dictate Avoid abrupt stop A30H05A ____...

Page 194: ...ware of hidden rocks or tree stumps partially hidden by a recent snowfall Deep Snow In deep powder snow your vehicle could begin to bog down If this occurs turn in as wide an arc as possible and look...

Page 195: ...do not have as much traction Best advice is to slow down and avoid rapid acceleration turning or braking Uphill There are two types of hills you can encounter the open hill on which there are few tre...

Page 196: ...should be avoided at all times Always check for slush before starting across any lake or river If dark spots appear in your tracks get off the ice immediately Ice and water can be thrown rearward into...

Page 197: ...in the fields guy wires next to poles and roads and into chains and wires used as road closures Slow speeds are a must Obstacles and Jumping Unplanned jumps of snowdrifts snowplow ridges culverts or...

Page 198: ...speed needed to crest the bank Stop completely at the top of the bank and wait for all traffic to clear Judge the drop to the roadway Cross the road at a 90 angle If you encounter another snowbank on...

Page 199: ...rtake the trail boss or for that matter any other snowmo bile Use down the line hand signals to indicate hazards or intent of direction change Assist others whenever necessary It is always IMPORTANT t...

Page 200: ...ssengers and operators must always wear DOT approved helmets and warm clothing appropriate for snowmobiling Make sure that no skin is exposed Once underway if a passenger feels uncomfortable or unsecu...

Page 201: ...on the belt guard Use extra caution and go even more slowly with young passengers Check frequently to make certain the child has a firm grip and is prop erly positioned with his feet on the running b...

Page 202: ...gine Install rear of vehicle on a wide base snowmo bile mechanical stand Remove snow and ice from rear suspension track front suspension steering mechanism and skis Protect vehicle with a snowmobile c...

Page 203: ...ing Fan Cooled Models Shut off the engine Check for clogged air duct passages Remove any foreign materials Check for proper fan belt condition and tension See an authorized SKI DOO dealer Liquid Coole...

Page 204: ...w When riding at mod erate or high speed on a thin snow covered surface slider shoes may stick on metallic track guides Run snowmobile on a surface covered by snow or drive snowmobile at very slow spe...

Page 205: ...MAINTENANCE INFORMATION _________________________ 203...

Page 206: ...uthorized SKI DOO dealer 2 WEEKLY OR EVERY 240 km 150 m 3 MONTHLY OR EVERY 800 km 500 m 4 ONCE A YEAR OR EVERY 3200 km 2000 m 5 EVERY 6000 km 3700 m 6 STORAGE to be performed by an authorized SKI DOO...

Page 207: ...ening Torque of Drive Pulley Screw I I I Driven Pulley Preload I I I BRAKE Brake Fluid I I R I Brake I I I I TRANSMISSION Drive Chain Tension A A A Countershaft Lubrication L L L Chaincase Oil I I R I...

Page 208: ...Rags in Air Intake and Exhaust System R C Engine Compartment C C C Vehicle Cleaning and Protection C C C A ADJUST I INSPECT CLEAN INSPECT REPAIR ADJUST AND LUBRICATE L LUBRICATE R REPLACE C CLEAN Befo...

Page 209: ...orming any maintenance or adjust ment unless otherwise specified Vehicle must be parked in a safe place away from the trail CAUTION Vehicle must be on a level surface before checking any fluid levels...

Page 210: ...ick mag net If bigger pieces of metal are found see an authorized SKI DOO dealer Remove metal particles from magnet Refill up to upper mark using recommended oil refer to SPECIFICA TIONS CAUTION Do no...

Page 211: ...empty Do not mismatch oil reservoir cap with fuel tank cap Install cap that is identified OIL WARNING Check level and refill every time you refuel Be careful not to overfill Wipe off any spillage Oil...

Page 212: ...and wipe the dipstick Dipstick must be completely screwed in before checking oil level Oil level must be between minimum and maximum marks on dip stick There is a capacity of 500 mL 17 U S oz between...

Page 213: ...ine engine cold of coolant tank NOTE When checking level at low temperature it may be slightly lower then the mark If additional coolant is necessary or if entire system has to be refilled refer to an...

Page 214: ...1 A32C76A 2 4 TEC OVERFLOW COOLANT TANK 1 MINIMUM LEVEL line 2 MAXIMUM LEVEL line A32C8HA 1 4 TEC CHECK COOLANT LEVEL IN COOLANT TANK 1 Fill to maximum line if necessary 212 _________________________...

Page 215: ...hile installed Battery elec trolyte contains sulfuric acid which is corrosive and poisonous In case of contact with skin flush with water and call a physi cian immediately WARNING Should the battery c...

Page 216: ...ing service on all 2004 and more recent certified SKI DOO snowmobiles that carry an emissions control information label adjustments must be kept within published factory specifications Replacement or...

Page 217: ...of the design The responsibilities listed above are general and in no way a com plete listing of the rules and regulations pertaining to the EPA require ments on exhaust emissions for snowmobile prod...

Page 218: ...vy duty cleaner P N 293 110 001 spray can 400 g and P N 293 110 002 4 L CAUTION Do not use Heavy duty cleaner on decals or vinyl For vinyl and plastic parts use Vinyl Plastic Cleaner P N 413 711 200 6...

Page 219: ...o priate lifting device or have assistance to share lifting stress in order to avoid risk of strain injuries NOTE Do not release track tension Belt Guard Removal and Installation WARNING NEVER operate...

Page 220: ...rd cap Open engine compartment 4 TEC Models Only Remove air silencer access panel 1 A32C77A 1 Access panel Loosen collar screw on air silencer grommet Disconnect engine vent hose from air silencer 218...

Page 221: ...ine vent hose Disconnect air temperature sensor from air silencer 1 A32C79A 1 Air temperature sensor At installation do not forget to connect air temperature sensor other wise a trouble code will appe...

Page 222: ...All Models Open retainer to release pin then pull belt guard out of vehicle 1 A32C05A TYPICAL 1 Pin retainer 220 _________________________...

Page 223: ...WARNING Remove tether cord cap before performing any maintenance or adjustment unless otherwise specified Vehicle must be parked in a safe place away from the trail Removal All Models NOTE Removal an...

Page 224: ...BELT INSTALLER REMOVER Screw drive belt installer remover in the free threaded hole and tighten to open the pulley Remove belt 1 A32D13A TYPICAL 1 Tighten to open pulley Slip the belt over the top edg...

Page 225: ...ZX Series Only Remove access panel from bottom pan 1 A32H07A 1 Push tab down and remove panel out of bottom pan A32H06A PULL PANEL OUT OF BOTTOM PAN _________________________ 223...

Page 226: ...th pulleys using Pulley flange cleaner P N 413 711 809 Installation To install the drive belt reverse the removal procedure however pay attention to the following The maximum drive belt life span is o...

Page 227: ...rds in the belt To install the drive belt first place belt between drive pulley sheaves Then between driven pulley sheaves finishing with bottom Remove drive belt installer remover Reinstall belt guar...

Page 228: ...l Models Remove hair pin Fully tighten tensioner adjustment screw by hand then back off only far enough for hair pin to engage in locking hole 2 1 A33D0BA TYPICAL 1 Hair pin 2 Adjustment screw 226 ___...

Page 229: ...such as ambient temperature altitude or surface condition may vary this critical engine RPM thus affecting snowmo bile efficiency This adjustable drive pulley allows setting maximum engine RPM in the...

Page 230: ...gher position numbers increase it in steps of 200 RPM Example Calibration screw is set at position 4 and is changed to position 6 So maximum engine RPM is increased by 400 RPM 4 TEC Models From factor...

Page 231: ...t to the same position A16D0HA 1 TYPICAL 1 Loosen just enough to permit rotating of calibrate screw WARNING NEVER disassemble or modify the drive pulley Improper assembly or modifications could cause...

Page 232: ...mechanism on your snowmobile is an essential safety de vice Keep this mechanism in proper working condition Above all do not operate the snowmobile without an effective brake system Periodically verif...

Page 233: ...E Look for any defects such as perforations in the track tears in the track particularly around traction holes lugs that are broken or torn off exposing portions of rods delamination of the rubber bro...

Page 234: ...track to be violently thrown backwards out of the tunnel with tremendous force possibly resulting in the loss of a leg or other serious injury Tension NOTE Ride the snowmobile in snow about 15 to 20...

Page 235: ...ea sure deflection as well as force applied A00C07C BELT TENSION TESTER 3 A32F39A 2 1 TYPICAL 1 Top tool O ring positioned at 7 3 kg 16 lb 2 Push on top portion of tool until it contacts the top O rin...

Page 236: ...r wheel retaining screws Loosen the lock nuts on so equipped models then turn adjust ment screws to adjust If correct tension is unattainable contact an authorized SKI DOO dealer 1 2 3 A05F0EA TYPICAL...

Page 237: ...ack at high speed Centrifugal force could cause debris damaged or loose studs pieces of torn track or an entire severed track to be violently thrown backwards out of the tunnel with tremendous force p...

Page 238: ...arked in a safe place away from the trail Remove the tether cord cap Loosen rear idler wheel retaining screws Loosen the lock nuts on so equipped models Tighten the adjustment screw on side where the...

Page 239: ...el retain ing screws otherwise wheel may come off and cause track to lock 1 2 A05F0EB TYPICAL 1 Retighten so equipped models 2 Retighten to 48 N m 35 lbf ft Restart engine and rotate track slowly to r...

Page 240: ...should be centered with the exit hole in the bottom pan Exhaust system must be free of rust or leaks Make sure that gear clamps are properly tightened The exhaust system is designed to reduce noise a...

Page 241: ...A32H0RA REMOVAL OF RIGHT SIDE PRIMARY FILTER GRILL A32H0SA REMOVAL OF FILTER FROM ITS GRILL _________________________ 239...

Page 242: ...1 A32H4AA 1 Secondary filter installed on air silencer REV Series A33H0JA AIR FILTER LOCATION 240 _________________________...

Page 243: ...ls Check that the air silencer is clean and dry and properly reinstall the filter CAUTION Snowmobile engines have been calibrated with the filters installed Operating the snowmobile without them may c...

Page 244: ...Headlamp Beam Aiming ZX Series Turn knob to adjust beam height A32E01A 1 TYPICAL ZX SERIES 1 Knob 242 _________________________...

Page 245: ...ulb Replacement Always check light operation after bulb replacement Headlamp CAUTION Never touch glass portion of an halogen bulb with bare fingers it shortens its operating life If glass is touched c...

Page 246: ...windshield and unplug burnt bulb connector Remove the rubber boot A32E02A 1 2 1 Bulb connector 2 Rubber boot Turn bulb locking ring counterclockwise to remove it Detach the bulb and replace Properly...

Page 247: ...A30E05A 1 1 Locking ring REV Series Unplug burnt bulb connector Remove the rubber boot 2 A33E0CA 1 1 Bulb connector 2 Rubber boot _________________________ 245...

Page 248: ...o remove it Detach the bulb and replace Properly reinstall parts 1 A33E0DA 1 Locking ring Taillight If taillight bulb is burnt expose the bulb by removing the red plastic lens To remove unscrew the 2...

Page 249: ...and at the rear Check local laws for brake lights requirements WARNING Never tow an accessory with a rope Always use a rigid tow bar Using a rope would result in a collision between the ob ject and th...

Page 250: ...only if a rigid towbar is not available a rope can be used provided you proceed with extra caution Remove the drive belt attach the rope to the ski legs spindles have someone sit on the towed snowmob...

Page 251: ...of trailer or vehicle Many serious accidents have resulted from driving up and over a trailer Anchor your vehicle securely front and rear even on short hauls Be certain all equipment is securely fast...

Page 252: ...ation The antifreeze replacement and a density test should be performed by an authorized SKI DOO dealer CAUTION Improper antifreeze mixture might allow freezing of the liquid in the cooling system if...

Page 253: ...every 1 5 seconds when engine is started DESS RER pilot lamp also blinks Engine cannot reach pulley engagement speed Vehicle cannot be driven 1 Bad DESS system connection Reinstall tether cord cap cor...

Page 254: ...ls Check oil level and replenish as soon as possible Battery pilot lamp lights up 1 No charging Check battery and charging system 4 short beeps every 2 minutes 1 Too high battery voltage Check battery...

Page 255: ...k plug hole If no spark appears replace spark plug If trouble persists contact an authorized SKI DOO dealer 6 Engine compression As the engine is pulled over with the rewind starter cycles of resistan...

Page 256: ...aler Engine backfires 1 DESS did not read tether cord cap code DESS RER pilot lamp blinks once every 1 5 seconds Engine can not exceed 3000 RPM Properly install 2 DESS has read a different code then t...

Page 257: ...em and refill with fresh fuel Snowmobile cannot reach full speed 1 DESS did not read tether cord cap code DESS RER pilot lamp blinks once every 1 5 seconds Engine can not exceed 3000 RPM Properly inst...

Page 258: ...apacity L U S oz 3 5 118 Chaincase Transmission Oil Type 8 Capacity mL U S oz 250 8 5 Coolant Type N A Capacity L U S oz N A Brake System Fluid Type DOT 4 12 1 to 12 and N A See at end of specificatio...

Page 259: ...8 Oil engine Type 6 6 Tank capacity L U S oz 3 5 118 3 5 118 Chaincase Transmission Oil Type 8 8 Capacity mL U S oz 250 8 5 250 8 5 Coolant Type N A N A Capacity L U S oz N A N A Brake System Fluid Ty...

Page 260: ...3 Oil engine Type 7 7 Tank capacity L U S oz 3 4 115 3 4 115 Chaincase Transmission Oil Type 9 9 Capacity mL U S oz 250 8 5 250 8 5 Coolant Type 10 10 Capacity L U S oz 3 8 128 4 0 135 Brake System Fl...

Page 261: ...engine Type 6 6 Tank capacity L U S oz 3 5 118 3 5 118 Chaincase Transmission Oil Type 9 9 Capacity mL U S oz 250 8 5 250 8 5 Coolant Type 10 10 Capacity L U S oz 4 3 145 GTX 4 9 166 4 5 152 Brake Sys...

Page 262: ...5 5 Tank capacity L U S oz 3 5 118 3 5 118 Chaincase Transmission Oil Type 9 9 Capacity mL U S oz 250 8 5 250 8 5 Coolant Type 10 10 Capacity L U S oz 121 4 9 166 136 5 17 175 121 4 9 166 136 5 17 175...

Page 263: ...5 118 Chaincase Transmission Oil Type 9 Capacity mL U S oz 250 8 5 Coolant Type 10 Capacity L U S oz 121 4 9 166 136 5 17 175 Brake System Fluid Type DOT 4 12 1 to 12 and N A See at end of specificati...

Page 264: ...5 118 Chaincase Transmission Oil Type 9 Capacity mL U S oz 250 8 5 Coolant Type 10 Capacity L U S oz 144 4 5 152 159 4 69 159 Brake System Fluid Type DOT 4 12 1 to 12 and N A See at end of specificati...

Page 265: ...rica or 95 RON Outside North Amer ica 5 XP STM synthetic 2 stroke oil OR XP STM 2 stroke synthetic blend 6 XP STM synthetic 2 stroke oil OR XP STM 2 stroke synthetic blend OR XP STM mineral injection...

Page 266: ...264 _________________________...

Page 267: ...WARRANTY _________________________ 265...

Page 268: ...der this warranty null and void 2 WARRANTY COVERAGE PERIOD This warranty will be in effect from the date of delivery to the first re tail consumer or the date the product is first put into use whichev...

Page 269: ...Cylinder Head Rubber Rings O Ring or Gasket X X Cylinder Base Gaskets X Throttle Body Shaft Seals X RAVE Hose System X Exhaust System Sealing Components X Knock Sensor X Muffler Temperature Sensor X C...

Page 270: ...be timely performed in order to maintain warranty coverage BRP reserves the right to make warranty coverage contingent upon proof of proper maintenance 4 WHAT TO DO TO OBTAIN WARRANTY COVERAGE The cus...

Page 271: ...of the prod uct on surfaces other than snow or operation of the product in a manner inconsistent with the recommended operation described in the Operator s Guide Damage resulting from accident submer...

Page 272: ...been authorized to make any affirmation representation or warranty re garding the product other than those contained in this limited war ranty and if made shall not be enforceable against BRP BRP rese...

Page 273: ...dealer s service manager or owner b If the issue has not yet been resolved please submit your com plaint in writing or call the appropriate number below In Canada BOMBARDIER RECREATIONAL PRODUCTS INC...

Page 274: ...year will expire December 1st of the following year The repair or replacement of parts or the performance of service un der this warranty does not extend the life of this warranty beyond its original...

Page 275: ...ormal use maintenance and service or replacing such parts with new genuine Ski Doo parts without charge for parts and labor at any authorized BRP distribu tor dealer during the warranty coverage perio...

Page 276: ...THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVER AGE UNDER THIS WARRANTY...

Page 277: ...ontroversy or a dispute in connection with this limited warranty BRP suggests that you try to resolve the issue at the dealership level We recommend discussing the issue with the authorized distributo...

Page 278: ...fers please let us know by writing to the address below Also note that from time to time carefully selected and trustworthy organizations may be permitted to use the coordinates of our clients to prom...

Page 279: ...ion to your snow mobile becomes necessary 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...

Page 280: ...278 _________________________...

Page 281: ...IP VEHICLE IDENTIFICATION NUMBER OLD ADDRESS OR PREVIOUS OWNER NEW ADDRESS OR NEW OWNER NO CITY NAME STREET STATE PROVINCE APT ZIP POSTAL CODE NO CITY NAME STREET STATE PROVINCE APT ZIP POSTAL CODE A0...

Page 282: ...A00A8J Bombardier Recreational Products Inc WARRANTY DEPARTMENT 75 J A Bombardier Sherbrooke QC Canada J1L 1W3 AFFIX PROPER POSTAGE 280 _________________________...

Page 283: ...Mmo 2005 ZX REV ang FH8 Tue Mar 30 09 28 26 2004 Page 1 Composite C M Y CM MY CY CMY K...

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