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Summary of Contents for Mini Z 2000

Page 1: ......

Page 2: ...Shop Manual MINI Z...

Page 3: ...bec Canada Printed in Canada Registered trademarks of Bombardier Inc and or its subsidiaries This document contains the trademarks of the following companies Kimtowels is a trademark of Kimberly Clark...

Page 4: ...NE 01 Table of Contents 04 01 1 02 Engine Removal and Installation 04 02 1 03 Valve Adjustment 04 03 1 04 Disassembly Assembly 04 04 1 05 Compression Test and Engine Dimension Measurement 04 05 1 06 T...

Page 5: ...ion and Ski System 08 03 1 09 BODY AND FRAME 01 Table of Contents 09 01 1 02 Body 09 02 1 03 Frame 09 03 1 10 TECHNICAL DATA 01 SI Metric Information Guide 10 01 1 02 Engine 10 02 1 03 Vehicle 10 03 1...

Page 6: ...e and the corresponding components identified in this document should not be utilized on product s other than those mentioned in this document Torque wrench tightening specifications must be strictly...

Page 7: ...TION NUMBER Vehicle Identification Number Location TYPICAL 1 Vehicle identification number Vehicle Identification Number Meaning ENGINE SERIAL NUMBER Engine Serial Number Location 1 Engine serial numb...

Page 8: ...SERVICE PRODUCTS 02 LUBRICATION AND MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 TRANSMISSION 06 ELECTRICAL 07 REAR SUSPENSION 08 STEERING FRONT SUSPENSION 09 BODY FRAME 10 TECHNICAL DATA 11 WIRING DIA...

Page 9: ...c inch k kilo thousand kg kilogram km h kilometer per hour kPa kilopascal L liter lb pound lbf pound force lbf in pound per square inch LH left hand m meter MAG magneto Max maximum Min minimum mL mill...

Page 10: ...is case nut must be torqued to 4 N m or 35 lbf in This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog Exploded view assists you in identifying parts...

Page 11: ...be removed before small bushing installation Coat bushing outside diameter with Loctite 609 P N 413 703 100 Install bushing as following photo A03D1YA 529 031 300 529 031 200 A03D1ZA 529 031 300 529 0...

Page 12: ...pe of the parts shown however they represent parts which have the same or a similar function CAUTION Most components of those vehicles are built with parts dimensioned in the metric system Most fasten...

Page 13: ...eads bolt and nut and allow to dry for 30 seconds 3 Choose proper strength Loctite threadlocker 4 Apply several drops along the threaded hole and at the bottom of the hole 5 Apply several drops on bol...

Page 14: ...PAIR Stripped Threads 1 Release agent 2 Stripped threads 3 Form A Thread 4 Tape 5 Cleaned bolt 6 Plate 7 New threads 8 Threadlocker Standard Thread Repair 1 Follow instructions on Loctite FORM A THREA...

Page 15: ...sket on mating surfaces and assemble immediately NOTE If the cover is bolted to blind holes above apply proper strength Loctite in the hole and on threads Tighten If holes are sunken apply proper stre...

Page 16: ...ite on lead ing edge of outer metallic gasket diameter NOTE Any Loctite product can be used here A low strength liquid is recommended as normal strength and gap are required 4 Install according to sta...

Page 17: ...f ft 21 M8 15 22 M8 16 23 M8 17 24 M8 18 25 M8 18 43 M10 32 44 M10 32 45 M10 33 46 M10 34 47 M10 35 48 M10 35 49 M10 36 50 M10 37 51 M10 38 52 M10 38 53 M10 39 76 M12 56 77 M12 57 78 M12 58 79 M12 58...

Page 18: ..._____________________________________________________ ____________________________________________________________ ____________________________________________________________ ________________________...

Page 19: ...bec Canada J0E 2L0 AFFIX PROPER POSTAGE AFFIX PROPER POSTAGE AFFIX PROPER POSTAGE Technical Publications After Sales Service 565 de la Montagne Street Valcourt Qu bec Canada J0E 2L0 Technical Publicat...

Page 20: ...oo snowmobile models specified on cover page The list includes both the mandatory tools and the optional tools that are ordered separately The list of Service Products both mandatory and optional are...

Page 21: ...RVICE PRODUCTS Subsection 01 SERVICE TOOLS 01 01 2 MMR2000_114_01_01A FM ENGINE MANDATORY SERVICE TOOLS Hose pincher 2 P N 295 000 076 A01B2I4 APPLICATION All vehicles Fluke multimeter P N 529 022 000...

Page 22: ...time Circuit tester continuity light P N 414 012 200 A00C214 APPLICATION All models Digital induction type tachometer P N 529 014 500 F01B1G4 APPLICATION All engines Driver tool P N 529 035 521 A00B4...

Page 23: ...bsection 01 SERVICE TOOLS 01 01 4 MMR2000_114_01_01A FM TRANSMISSION MANDATORY SERVICE TOOLS Clutch holder P N 529 006 400 A01B154 APPLICATION All TRA drive pulleys and Mini Z fly wheel Tension tester...

Page 24: ...c tool kit and reduce repair time Drive axle sprocket adjuster P N 861 725 700 A01B2O4 APPLICATION All vehicles Parts included in the kit 1 Block with threads P N 529 010 700 2 Block without threads P...

Page 25: ...PRODUCTS Subsection 01 SERVICE TOOLS 01 01 6 MMR2000_114_01_01A FM SUSPENSION RECOMMENDED SERVICE TOOLS Track tension gauge P N 529 021 500 A00B3X4 APPLICATION All models Drill bit P N 529 031 800 A0...

Page 26: ...VICE PRODUCTS Subsection 01 SERVICE TOOLS MMR2000_114_01_01A FM 01 01 7 VEHICLES RECOMMENDED SERVICE TOOLS Protective mat P N 529 030 600 A01B45W APPLICATION All models Snowmobile jack P N 529 020 000...

Page 27: ...ION To seal crankcase on all ZX series engines Paste gasket P N 413 702 700 Loctite 515 Gasket eliminator 50 mL A00B2T4 APPLICATION Crankcase halves and gearbox mating surfaces Paste gasket P N 293 80...

Page 28: ...ing surfaces before applying paste gasket retaining compound or threadlockers NOTE Only the P N has been changed This product is identical to the P N 413 708 100 Silicone compound P N 293 550 004 Dow...

Page 29: ...t build up and to assure a good ground Chaincase oil 16 x 250 mL P N 413 801 900 A00B2R4 APPLICATION Chaincase lubricant on all fan cooled models except Skandic WT series Synthetic chaincase oil 12 x...

Page 30: ...ankcase NOTE Only the P N has been changed This product is identical to the P N 420 899 788 Anti seize lubricant P N 293 800 023 Loctite anti seize lubricant 454 g 16 oz A00B594 APPLICATION Unpainted...

Page 31: ...N Isolating foam and rubber strip Tough adhesive P N 413 408 300 Loctite Black Max 3 mL 10 oz A00B3P4 APPLICATION Shifter boot or grip Stripped threads repair kit P N 413 708 600 Form A thread 81668 A...

Page 32: ...0 g P N 293 110 002 4 L F01B2J4 APPLICATION All models Clear silicone P N 293 800 033 F01B1S4 APPLICATION All models to seal bottom pan Fuel stabilizer 12 x 8 oz P N 413 408 600 A00B3V4 APPLICATION Al...

Page 33: ...VICE TOOLS AND SERVICE PRODUCTS Subsection 02 SERVICE PRODUCTS MMR2000_114_01_02A FM 01 02 7 RECOMMENDED SERVICE PRODUCTS continued Super Lube grease P N 293 550 014 A00B474 APPLICATION Exhaust tail p...

Page 34: ...06 Valve Clearance Subsection 04 03 Condition of Seals Subsection 04 04 Oil Level EACH USE This section no 1 Oil Change 6 MONTHS This section no 2 Fuel Filter Replacement This section no 5 Fuel Strain...

Page 35: ...dition Subsection 07 04 Track Tension and Alignment AS REQUIRED Subsection 07 04 Spark Plug Subsection 06 03 Headlight Beam Aiming Subsection 09 03 Wiring Harnesses Cables and Lines Subsection 09 03 O...

Page 36: ...ld pipe 2 Remove oil drain cap NO 3 ENGINE LUBRICATION Engine internal parts must be lubricated to protect them from possible rust formation during the stor age period Proceed as follows Start the eng...

Page 37: ...the engine lubrication to ensure carbure tor s protection against varnish deposit NO 5 FUEL FILTER REPLACEMENT Drain fuel tank Remove fuel line grommet from fuel tank and pull out inlet fuel line fro...

Page 38: ...aner P N 293 110 001 spray can 400 g and P N 293 110 002 4 L CAUTION Do not use Bombardier Cleaner on decals or vinyl To clean the entire vehicle including metallic parts with a thin coat of grease us...

Page 39: ...MMR2000_116_03_01ATOC FM 03 01 1 TABLE OF CONTENTS 0 ENGINE 03 02 1 FUEL AND OIL SYSTEMS 03 03 1 TRANSMISSION AND BRAKE SYSTEMS 03 04 1 TRANSMISSION 03 04 1 BRAKE SYSTEM 03 04 3 MECHANICAL BRAKE 03 0...

Page 40: ...MUM OPERATING RPM CONDITION NORMAL USE Test Inspection 1 Check spark plug condition a Fouled spark plug s Replace 2 Check if there is water in fuel a There is water in fuel Drain fuel system then fill...

Page 41: ...AT MAXIMUM RPM CONDITION NORMAL USE Test Inspection 1 Check which type of fuel is used a Octane number is too low and or alcohol level is too high Use recommended fuel type 2 Check spark plug type a I...

Page 42: ...aking care not to use choke If flooding is severe check carburetor float valve then change engine oil b Spark plug dry no fuel to the engine Check fuel tank level check if fuel valve is opened check f...

Page 43: ...Check engine compression a Insufficient engine compression Check valve clearance carbon accumulation defective cylinder head gasket valves or valve seats Check for worn piston rings piston or cylinder...

Page 44: ...st Inspection 1 Check ratchet and ratchet guide a Ratchet and ratchet guide have stuck together because of dirt or heat Clean or replace 2 Check ratchet and rope sheave a Ratchet and rope sheave have...

Page 45: ...etor fittings a Leaking fittings Replace defective part 3 Check float height in carburetor s a Fuel level is too high in float bowl Adjust according to specifications refer to TECHNICAL DATA 10 SYMPTO...

Page 46: ...ner Clean 2 Check if lines are perforated or kinked and make sure they do not leak at fittings a Lines are too big for their fittings or are improperly rooted Replace or properly relocate lines 3 Chec...

Page 47: ...Drive chain is worn out Replace drive chain with new one SYMPTOM VIBRATIONS ORIGINATING FROM DRIVEN SPROCKET CONDITION NORMAL USE Test Inspection 1 Check driven sprocket hub fit with drive axle a Dri...

Page 48: ...USE Test Inspection 1 Check drive chain lubrication a Drive chain is dry Lubricate drive chain 2 Check drive chain condition a Chain is cracked damaged or some link rollers are missing Replace drive...

Page 49: ...cable movement is limited due to oxidation or dirt accumulation Replace 3 Check distance between brake lever and caliper a Distance is too wide Adjust according to specifications refer to TRANSMISSION...

Page 50: ...ACK BULB Test Inspection 1 Check voltage at headlamp at different speeds It must not be above 15 Vac a Excessive voltage in lighting circuit Ensure proper wire connections and grounding Retest SYMPTOM...

Page 51: ...Replace defective switch es Clean terminals and apply silicone dielectric grease 4 Verify ignition coil resistance with an ohmmeter and connector condition a Defective coil Corroded connector terminal...

Page 52: ...oes not start no spark at spark plug 2 Verify spark plug Proceed with spark plug analysis in order to identify source of problem a Defective and or worn spark plug s and or cable s and or cap s Replac...

Page 53: ...REAR LIGHT BULB FLASHES CONDITION NORMAL USE Test Inspection 1 Check if rear light is properly connected a Connector housing is partially connected Install connector housing properly 2 Check continui...

Page 54: ...ion spring leg on each side SYMPTOM SLIDER SHOES WEAR OUT PREMATURELY CONDITION NORMAL USE Test Inspection 1 Check track tension a Pressure is too great on slider shoes Adjust according to specificati...

Page 55: ...ce 3 Check sprockets a One or various teeth of drive shaft sprockets are broken Replace sprocket s 4 Check track internal traction teeth a One or various track teeth are broken Replace track 5 Check s...

Page 56: ...SYMPTOM WHEN HANDLEBAR IS TURNED SNOWMOBILE UNDERSTEERS CONDITION NORMAL USE Test Inspection 1 Check ski runner condition a Worn ski runners Replace 2 Check if front arm stopper strap is too long a In...

Page 57: ...VICE VERSA CONDITION NORMAL USE Test Inspection 1 Check ski runner condition a Worn or bent ski runners Replace ski runners 2 Check ski alignment a Improper ski alignment Align skis in order to obtai...

Page 58: ...8 ASSEMBLY 04 04 8 COMPRESSION TEST AND ENGINE DIMENSION MEASUREMENT 04 05 1 COMPRESSION TEST 04 05 1 ENGINE DIMENSION MEASUREMENT 04 05 2 VALVE SPRING FREE LENGTH 04 05 2 VALVE SEAT WIDTH 04 05 2 VAL...

Page 59: ...TIFYING SURFACES 04 05 9 TRANSISTORIZED MAGNETO IGNITION 04 06 1 CLEANING 04 06 2 DISASSEMBLY 04 06 2 INSPECTION 04 06 2 ASSEMBLY 04 06 3 REWIND STARTER 04 07 1 REMOVAL 04 07 2 DISASSEMBLY 04 07 2 INS...

Page 60: ...MOVAL AND INSTALLATION MMR2000_117_04_02A FM 04 02 1 ENGINEREMOVALANDINSTALLATION0 A31C17T 3 Loctite 242 2 15 N m 133 lbf in 1 11 N m 97 lbf in Loctite 242 24 N m 18 lbf ft 4 Loctite 242 2 15 N m 133...

Page 61: ...no 2 brake support screws no 1 ENGINE AND MUFFLER DISASSEMBLY AND ASSEMBLY Torque the muffler nuts no 4 to 24 N m 18 lbf ft Torque both brake support screws no 1 to 11 N m 97 lbf in and 5 engine moun...

Page 62: ...Section 04 ENGINE Subsection 03 VALVE ADJUSTMENT MMR2000_118_04_03A FM 04 03 1 VALVE ADJUSTMENT 0 A31C1AT 10 N m 89 lbf in 9 8 5 3 7 4 6 2 1...

Page 63: ...t compression stroke both valves are fully closed Valve Clearance Inspection Insert a feeler gauge between rocker arm no 5 and valve no 6 Refer to the following table for valve clearance NOTE When ins...

Page 64: ...Section 04 ENGINE Subsection 04 DISASSEMBLY ASSEMBLY MMR2000_119_04_04A FM 04 04 1 DISASSEMBLY ASSEMBLY 0 TOP END A31C24U 16 15 3 1 2 11 4 10 6 17 12 7 13 14 9 8 5 24 N m 18 lbf ft...

Page 65: ...6 and piston dome using a wooden spatula NOTE The triangular mark on the piston dome must be visible after cleaning Clean the piston ring grooves with a groove clean er tool or with a piece of broken...

Page 66: ...NE DI MENSIONS MEASUREMENT 04 05 ASSEMBLY Slide exhaust valve small diameter into exhaust valve guide then slide intake valve large diame ter into intake guide See next photo Install springs and secur...

Page 67: ...as shown in the next photo 1 Cylinder head gasket 2 Locating pin Check push rods no 12 on both ends for wear Check also push rods for straightness Install push rod ends into lifters no 17 Reinstall cy...

Page 68: ...Subsection 04 DISASSEMBLY ASSEMBLY MMR2000_119_04_04A FM 04 04 5 BOTTOM END A31C2CS 24 7 6 6 5 4 3 2 9 8 12 27 10 25 1 28 11 24 13 26 25 28 15 16 17 19 18 20 21 14 23 22 12 N m 106 lbf in 12 N m 106 l...

Page 69: ...screws no 2 then remove connecting rod cap no 3 1 Connecting rod screws 2 Connecting rod cap Push on connecting rod no 4 and pull out piston no 5 Remove both piston pin circlips no 6 and push out pis...

Page 70: ...r rod 4 Governor arm Loosen governor arm screw then remove gover nor arm From inside crankcase rotate governor arm shaft no 14 then pull out governor slider no 15 and washer no 16 1 Rotate governor ar...

Page 71: ...rankcase flange Governor System Reinstall governor weights no 21 with pins no 20 Install governor weight holder washer no 19 then install governor weight holder no 18 on shaft Secure governor weight h...

Page 72: ...re not inter changed 1 Top ring chrome plated 2 Second ring 3 Oil ring Check that rings rotate smoothly after installation Space the piston ring end gaps 120 apart and do not align the gaps with the p...

Page 73: ...and ease crankcase cover installation apply grease on crankcase cover seal Slide down piston so that connecting rod properly seats on crankshaft Secure connecting rod with connecting rod cap Torque sc...

Page 74: ...in place Install gasket no 26 on crankcase Finalize crankcase assembling with crankcase cover no 1 Torque screws in a crisscross se quence to 12 N m 106 lbf in NOTE To protect seal and ease crankcase...

Page 75: ...ct spark plug cap then remove spark plug Plug compression testing gauge into spark plug hole Hold compression testing gauge in one hand then pull starter handle 3 or 4 times with the other hand as sho...

Page 76: ...lue replace cylinder head with new one VALVE STEM outside diameter Measure valve stem with a micrometer as shown in the next photo TYPICAL Inspect valve surface check for abnormal stem wear and bendin...

Page 77: ...e areas for cracks CYLINDER INSIDE DIAMETER Compare cylinder inside diameter 16 mm 5 8 in from top of cylinder halfway and 12 7 mm 1 2 in from bottom of cylinder Measure cylinder inside diameter in bo...

Page 78: ...e to the micrometer di mension and set the indicator to 0 zero 1 Use the micrometer to set the cylinder bore gauge 2 Dial bore gauge TYPICAL 1 Indicator set to 0 zero Position the dial bore gauge at 1...

Page 79: ...nder use piston as a pusher Using a feeler gauge check ring end gap Replace ring if gap exceeds specified tolerance See above table 1 Feeler gauge 2 Ring properly positioned in cylinder CONNECTING ROD...

Page 80: ...value replace piston pin or piston as needed CONNECTING ROD SMALL END inside diameter Measure connecting rod small end inside diame ter with a telescoping gauge and a micrometer as shown in the next...

Page 81: ...od cap and torque screws to 12 N m 109 lbf in See next photo NOTE Do not rotate crankshaft while plastigauge is in place 1 Connecting rod cap in place 2 Torque both screws Remove connecting rod cap an...

Page 82: ...th a micrometer as shown in the next photo 1 Exhaust valve cam 2 Intake valve cam CAMSHAFT outside diameter Measure camshaft outside diameter with a mi crometer as shown in the following photo MEASURE...

Page 83: ...rankcase cover can be checked for perfectly mat ing surfaces Lay part on a surface plate marble mirror or thick glass plate Holding down one end of part try pushing down the other end If any play is f...

Page 84: ...Section 04 ENGINE Subsection 06 TRANSISTORIZED MAGNETO IGNITION MMR2000_121_04_06A FM 04 06 1 TRANSISTORIZED MAGNETO IGNITION 0 A31E0JS Ground cable 1 2 3 5 4 75 N m 54 lbf ft Dielectric grease 6 7...

Page 85: ...ove magneto flywheel retaining nut no 1 use clutch holder tool P N 529 006 400 as shown in the next photo LOOSEN FLYWHEEL NUT 1 Hold flywheel using clutch holder tool P N 529 006 400 Remove starter pu...

Page 86: ...with silicone dielectric grease P N 413 701 700 to pre vent corrosion or moisture penetration CAUTION Do not use silicone sealant this product will corrode contacts Ignition Coil Air Gap Adjustment NO...

Page 87: ...Section 04 ENGINE Subsection 07 REWIND STARTER MMR2000_122_04_07A FM 04 07 1 REWIND STARTER 0 A31C1JS 5 7 6 8 9 10 11 4 3 2 1...

Page 88: ...n for re assembly Remove screws no 3 securing rewind starter housing no 4 to engine then remove rewind start er ass y DISASSEMBLY To remove rope from rewind starter mechanism Place rewind starter ass...

Page 89: ...hat the rewind starter spring be lubricated period ically using specific lubricants Otherwise re wind starter component life will be shortened and or rewind starter will not operate properly under ver...

Page 90: ...e end is accessible through starter housing orifice Pull the rope out of the starter housing and tem porarily make a knot to hold it Position both ratchets with springs as shown in the next photo 1 Ra...

Page 91: ...in 2 Turn clockwise CW ratchets out INSTALLATION Reinstall rewind starter ass y on engine Reinstall engine in snowmobile Prior to installing starter grip no 1 on new rope it is first necessary to fuse...

Page 92: ...Section 04 ENGINE Subsection 08 CARBURETOR MMR2000_123_04_08A FM 04 08 1 CARBURETOR 0 18 3 2 7 20 16 12 11 9 13 14 4 5 6 8 1 A31C0HS 19 17 10 21 15 4 N m 35 lbf in...

Page 93: ...the next photo REMOVE FUEL STRAINER CUP 1 O ring 2 Fuel strainer cup Disconnect fuel inlet line from carburetor and drain fuel from tank Remove fuel tank Remove carburetor cap Detach choke cable from...

Page 94: ...buretor choke lever Move carburetor choke lever to the left as shown in the next photo MOVE CARBURETOR CHOKE LEVER Unscrew carburetor protector screws then remove carburetor nuts Remove carburetor pro...

Page 95: ...air be fore disassembly CAUTION Heavy duty carburetor cleaner may be harmful to the float material and to the rub ber parts O rings etc Therefore it is recom mended to remove those parts prior to clea...

Page 96: ...h com pressed air Reinstall nozzle and main jet as shown in the next photo PROPER POSITION TO INSTALL NOZZLE AND MAIN JET 13 14 Pilot Jet Remove stop screw no 15 Using a flat screwdriver remove pilot...

Page 97: ...float level gauge tips are properly positioned on carburetor body and that L arm is leaning on float without compressing valve spring 1 Float level gauge tips properly leaned on carburetor body 2 Lea...

Page 98: ...sen governor arm nut Turn governor arm clockwise until carburetor throttle is fully opened Hold governor arm in this position Using pliers turn governor arm shaft clockwise until it stops At this poin...

Page 99: ...Section 04 ENGINE Subsection 09 FUEL TANK AND THROTTLE CABLE MMR2000_124_04_09A FM 04 09 1 FUEL TANK AND THROTTLE CABLE 0 A31I01T 2 3 1 6 7 5 Carburetor 4 4 8...

Page 100: ...o remove fuel filter no 1 from fuel tank no 2 first drain fuel tank Using a flat screwdriver carefully pull out fuel filter by removing grommet no 3 as shown in the next photo REMOVE GROMMET Ensure th...

Page 101: ...g CAUTION Check that throttle cable is routed away from sharp edges hot or vibrating parts When turning steering while engine is running idle speed must not vary Throttle Cable Adjustment Loosen throt...

Page 102: ...02 1 REMOVAL 05 02 2 DISASSEMBLY 05 02 3 CLEANING 05 02 3 INSPECTION 05 02 3 INSTALLATION 05 02 4 BRAKE 05 03 1 REMOVAL 05 03 2 DISASSEMBLY 05 03 2 CLEANING 05 03 2 INSPECTION 05 03 3 INSTALLATION 05...

Page 103: ...Section 05 TRANSMISSION Subsection 02 CLUTCH MMR2000_125_05_02A FM 05 02 1 CLUTCH 0 A31D0GS 7 6 1 3 4 2 5 9 8 10 25 N m 19 lbf ft Loctite 242...

Page 104: ...the following photo and lift off guard 1 Using a screwdriver remove 3 screws Brake Pad Removal Using Allen key unlock brake cable from brake pad as shown in the next photo UNLOCK BRAKE CABLE FROM BRA...

Page 105: ...chain and driven sprocket no 8 removal and installation it may be useful to remove footrest Remove drive chain from driven sprocket Loosen driven sprocket locking nut no 9 then re move driven sprocke...

Page 106: ...tch axle only Do not spill oil into clutch mechanism or on clutch cover braking surface DRIP A FEW DROPS OF OIL ON CLUTCH AXLE To ease sprocket and clutch installation first install drive chain on bot...

Page 107: ...Section 05 TRANSMISSION Subsection 03 BRAKE MMR2000_126_05_03A FM 05 03 1 BRAKE 0 A31D0IS 2 4 5 3 1 6 Loctite 242 Loctite 242 11 N m 100 lbf in...

Page 108: ...AD 1 Pivot screw Brake Cable Replacement Remove circlip no 5 from brake cable at brake le ver location as shown in the next photo 1 Circlip 2 Detach brake cable from brake lever Detach brake cable fro...

Page 109: ...bly with new one INSTALLATION To install brake pad reverse removal procedure paying attention to the following When securing brake pad with elastic nut no 3 Stop tightening when nut leans against brak...

Page 110: ...t within 15 mm 19 32 in to 20 mm 25 32 in of the handlebar readjust brake Refer to the fol lowing photo 1 Brake lever A If measurement is not within 15 mm 19 32 in to 20 mm 25 32 in readjust brake To...

Page 111: ...re wear For that reason a stretched chain must never be shortened Visually inspect chain for cracked damaged or missing links Check for worn or defective bearings sprockets and chain tensioner compone...

Page 112: ...NGK SPARK PLUGS 06 02 2 DISASSEMBLY 06 02 3 HEAT RANGE 06 02 3 FOULING 06 02 3 SPARK PLUG ANALYSIS 06 02 3 SPARK PLUG INSTALLATION 06 02 4 SPARK PLUG TIGHTENING TORQUE 06 02 4 TESTING PROCEDURE 06 03...

Page 113: ...PARK PLUG NGK SPARK PLUG NUMBERING SYSTEM Bombardier uses the NGK spark plug brand on all its snowmobile models The heat range identification system is Low number hot plug High number cold plug REFERE...

Page 114: ...ion 02 SPARK PLUGS 06 02 2 MMR2000_128_06_02A FM DESIGN SYMBOLS USED IN NGK SPARK PLUGS A31E0ES A01E1PS Standard Type CROSSCUTS AND GAP STYLES OF SPARK PLUGS Surface Discharge Type Projected Insulator...

Page 115: ...a wrong heat range plug is used A too hot plug will result in overheating and pre ignition etc A too cold plug will result in fouling shorting the spark plug or may create carbon build up which can h...

Page 116: ...e 1 Using a wire feeler gauge set electrode gap ac cording to TECHNICAL DATA 10 2 Apply anti seize lubricant P N 413 701 000 over the spark plug threads to prevent possible seizure 3 Hand screw spark...

Page 117: ...lar condi tions In most cases when problems are caused by tem perature or vibrations these can only be solved by replacing parts Most problems cannot be detect ed when the engine is stopped Multiple P...

Page 118: ...iron core The measured resistance should be according to the following table If not replace ignition coil 4 SPARK PLUG CAP TESTING Remove spark plug cap by unscrewing cap from cable NOTE A false resis...

Page 119: ...ltimeter selector switch to position Connect first multimeter probe to pink wire then second probe to lamp coil iron core as shown in the next photo LAMP COIL TESTING 1 Multimeter to position 2 Pink w...

Page 120: ...1 TABLE OF CONTENTS 0 REAR SUSPENSION 07 02 1 REMOVAL 07 02 2 DISASSEMBLY AND ASSEMBLY 07 02 3 INSPECTION 07 02 5 DRIVE AXLE 07 03 1 REMOVAL 07 03 2 DISASSEMBLY AND ASSEMBLY 07 03 3 INSTALLATION 07 0...

Page 121: ...Section 07 REAR SUSPENSION Subsection 02 REAR SUSPENSION MMR2000_130_07_02A FM 07 02 1 REAR SUSPENSION 0 A31F04S 19 7 15 16 9 2 1 11 6 3 20 3 8 10 17 18 5 12 13 21 17 18 14 4...

Page 122: ...oval Completely release track tension by loosening ad justment screws no 2 Unscrew one rear idler wheel screw no 3 Pull out rear axle no 1 from opposite side of offset inner wheel PULL OUT REAR AXLE 1...

Page 123: ...EMBLY Inspect track thoroughly before reinstalling sus pension Refer to TRACK 07 04 7 Runner NOTE Runner no 7 can be removed without re moving suspension assembly as described in the following procedu...

Page 124: ...ass y as de scribed in the following procedure Lift rear of snowmobile Completely release track tension Remove rear axle no 1 with idler wheels Lower snowmobile Lean on snowmobile seat then unscrew up...

Page 125: ...in the next photo 1 Rubber stopper 2 Special tool Snap on A161B 3 Push nuts Remove retaining pins no 16 Lift rubber stopper tab and remove it REMOVE RUBBER STOPPER Reinstall rubber stopper no 14 with...

Page 126: ...HING WHEEL AND SHAFT CONDITION 21 Slider Shoe Inspect slider shoes no 21 for wear CAUTION Even if only one slider shoe needs to be replaced always replace both ones Slid er shoes must always be replac...

Page 127: ...Section 07 REAR SUSPENSION Subsection 03 DRIVE AXLE MMR2000_131_07_03A FM 07 03 1 DRIVE AXLE 0 A31D0NS 8 2 1 7 7 7 6 5 5 6 3 4 9 9 Loctite 242...

Page 128: ...shown REMOVE SPRING PIN Using a prybar and a piece of wood to protect tun nel slide right side sprocket no 2 38 mm 1 1 2 in See the next photo NOTE Apply BOMBARDIER LUBE P N 293 600 016 12 x 14 oz on...

Page 129: ...no 8 as shown in the next photo PULL OUT DRIVE AXLE ASS Y DISASSEMBLY AND ASSEMBLY Bearing and Sprocket To remove or to install bearings no 9 and sprock ets no 2 use a press CAUTION Ensure that bearin...

Page 130: ...axle spring pin hole is properly aligned with sprocket hole REINSTALL SPRING PIN Drive Axle Alignment To ensure that drive axle sprockets are properly aligned with track guides measure right side driv...

Page 131: ...When installing the track respect rotation direction indicated by shaped arrows on track thread TRACK ROTATION Track Tension and Alignment Track tension and alignment are interrelated Do not adjust on...

Page 132: ...e supported off the ground start engine and allow the track to rotate slowly Check that the track is well centered equal dis tance on both sides between edges of track guides and slider shoes 1 Guides...

Page 133: ...04 TRACK MMR2000_132_07_04A FM 07 04 3 Tighten lock nuts and the idler wheel retaining screws TYPICAL 1 Retighten lock nuts 2 Retighten rear idler wheel retaining screws Restart engine rotate track sl...

Page 134: ...8_01ATOC FM 08 01 1 TABLE OF CONTENTS 0 STEERING SYSTEM 08 02 1 INSPECTION 08 02 2 DISASSEMBLY AND ASSEMBLY 08 02 2 INSPECTION 08 02 3 STEERING ADJUSTMENT skis 08 02 3 LUBRICATION 08 02 5 SUSPENSION A...

Page 135: ...YSTEM 0 A31G0FS 15 N m 133 lbf in Lithium grease P N 413 706 100 10 N m 89 lbf in Loctite 609 Loctite 609 Loctite 609 Loctite 609 1 2 3 4 5 6 7 8 9 10 11 12 3 13 6 12 Lithium grease P N 413 706 100 12...

Page 136: ...ved and installed without any damage by injecting compressed air into the han dlebar or by heating them with a heat gun 11 Steering Column From underneath bottom pan remove tie rod clip Refer to STEER...

Page 137: ...OE OUT Difference in measurement between front edge A and rear edge B of skis as viewed from top side of suspension system It is adjustable CAMBER A specific inward or outward tilt angle of ski leg co...

Page 138: ...hile firmly retighten nuts so that ball joint sockets run parallel with steering arm and pivot arm Ensure that pivot arm no 13 is still centered and check ski toe out TOE OUT Loosen lock nuts of long...

Page 139: ...front of ski must be 0 to 3 0 mm 0 to 1 8 in more than at rear on both sides for a total toe out of 0 to 6 mm 0 to 1 4 in TYPICAL 1 Straight edge 2 0 to 3 0 mm 0 to 1 8 in more at front than at rear C...

Page 140: ...Section 08 STEERING FRONT SUSPENSION Subsection 03 SUSPENSION AND SKI SYSTEM MMR2000_133_08_03A FM 08 03 1 SUSPENSION AND SKI SYSTEM 0 A31G0GS Loctite 242 Loctite 242 1 2 3 4 5 6 7 8 9...

Page 141: ...cushions for crack and wear Re place as required Check for straightness of swing arm Replace as required Check skis and runners for wear replace as nec essary INSTALLATION For assembly reverse the di...

Page 142: ...ION AND ADJUSTMENT 09 02 2 HEADLAMP BEAM AIMING 09 02 2 BULB REPLACEMENT 09 02 2 DECAL 09 02 3 WINDSHIELD INSTALLATION 09 02 3 CHAIN GUARD 09 02 3 WIRING HARNESS 09 02 3 CABLES 09 02 3 PIPING 09 02 4...

Page 143: ...Section 09 BODY AND FRAME Subsection 02 BODY MMR2000_134_09_02A FM 09 02 1 BODY 0 2 3 1 A31H0LS Loctite 242...

Page 144: ...ght beam center A 25 mm 1 in Required Conditions Place the vehicle on a flat surface perpendicular to test surface wall or screen and 381 cm 12 ft 6 in away from it Rider or equivalent weight must be...

Page 145: ...s as shown INSERT WINDSHIELD TABS INTO HOOD SLOTS From inside hood lock the windshield tabs in po sition using latches no 3 as shown VIEW FROM INSIDE HOOD LOCK WINDSHIELD TABS CHAIN GUARD Disassembly...

Page 146: ...s Catalog to find suit able clip part numbers WARNING Always ensure that the fuel and vent lines are properly fixed to their connectors that they are not perforated or kinked and that they are properl...

Page 147: ...l are used on Mini Z model as described in the following table Both plastic materials are irreparable In the case that parts are broken or damaged re place with new one MATERIAL WINDSHIELD Polycarbona...

Page 148: ...Section 09 BODY FRAME Subsection 03 FRAME MMR2000_135_09_03A FM 09 03 1 FRAME 0 4 5 3 3 1 2 A31H0NS...

Page 149: ...nts such as strong soaps degreasing solvents abrasive cleaners paint thinners etc that may cause damage to the seat cover FRAME WELDING Steel Frame electric welding amperage 70 110 A voltage 20 24 V r...

Page 150: ...sure torque speed meter kilogram newton liter Celsius kilopascal newton meter kilometer per hour m kg N L C kPa N m km h PREFIXES PREFIX SYMBOL MEANING VALUE kilo centi milli micro k c m one thousand...

Page 151: ...mm in mm in 015 05 0006 002 12 005 Connecting Rod Big End Side Clearance standard wear limit mm in mm in 0 1 0 7 004 028 1 1 043 Ignition Type Transistorized Spark Plug Make and Type NGK BPR6 ES Spar...

Page 152: ...Deflection Automatic Tensioner Track Width mm in 254 0 10 Length mm in 1748 8 68 85 Profile Height mm in 15 97 63 Adjustment Deflection mm in 35 1 3 8 Force kg lbf 7 3 16 Suspension Type Track Mini Z...

Page 153: ...x 1000 MAG Magneto Side N A Not Applicable PTO Power Take Off Side R Rectangular All resistance measurements must be performed with parts at room temperature approx 20 C 68 F Temperature greatly affe...

Page 154: ...LACK stripe CONNECTOR HOUSING AREA WARNING Ensure all terminals are properly crimpedon the wires and all connector housings are properly fastened COLOR CODE BK BLACK BL BLUE BR BROWN GN GREEN GY GREY...

Page 155: ...Section 11 WIRING DIAGRAM Subsection 01 WIRING DIAGRAM 11 01 2 MMR2000_137_11_01A FM CONNECTOR LOCATION IN HOUSING A00I04D XX XX D D 1 02 A00E4WB B A B A B A C C B A B C D B C A A B C B C D A A...

Page 156: ...l Male terminal Electronic module Meter Electric motor Low level sensor Buzzer Ignition coil Normally close switch Male terminal on instrument Engine ground Spark plug Meter movement Bulb Pilot lamp A...

Page 157: ...ANNEX 1 MINI Z...

Page 158: ...MINI Z...

Page 159: ...0 7 03A 9 01 1 02...

Page 160: ......

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