Ski-Doo MX Z 800 2145 2002 Operator'S Manual Download

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112

STORAGE AND PRESEASON PREPARATION

Storage

It is during summer, or when a snowmobile is not in use for more
than one month that proper storage is a necessity.

Refer to an authorized SKI-DOO dealer for vehicle preparation.

CAUTION:

Do not run engine during storage period.

Preseason Preparation

Refer to an authorized SKI-DOO dealer.

CAUTION:

Have carburetor(s) cleaned-up before restarting engine.



WARNING

Have an authorized SKI-DOO dealer inspect fuel and oil sys-
tems integrity as specified in

Periodic Maintenance Chart

Mmo2002-006b.book Page 112 Thursday, November 29, 2001 2:31 PM

Summary of Contents for MX Z 800 2145 2002

Page 1: ......

Page 2: ...2002 006a fm GM TM are trademarks and are registered trademarks of Bombardier Inc or its subsidiaries 2001 Bombardier Inc All rights reserved SAFETY WARNING Disregarding any of the safety precautions...

Page 3: ...1 2002 SKI DOO OPERATOR S GUIDE This guide is applicable to the following model MX Z 800 2145...

Page 4: ...the correct use of the vehicle Your dealer is committed to your satisfaction He has taken training to perform the initial set up and inspection of your snowmobile as well as completed the final adjust...

Page 5: ...parts which have the same or a similar function It is understood that this guide may be translated into another lan guage In the event of any discrepancy the English version shall pre vail Most compon...

Page 6: ...MPORTANT INSTRUCTIONS 20 CONTROLS INSTRUMENTS EQUIPMENT 25 1 Throttle Lever 26 2 Brake Lever 26 3 Parking Brake Locking Lever 26 4 Parking Brake Pilot Lamp Red 28 5 Handlebar 28 6 Start RER Button 33...

Page 7: ...umper 56 35 Adjustable Suspensions 56 General 56 Guidelines to Adjust Suspension 57 TROUBLESHOOTING CHART 73 In Deep Snow 73 FUEL AND OIL 74 Recommended Fuel 74 Recommended Oil 75 COLD WEATHER CARBURE...

Page 8: ...e Belt Condition 101 Brake Condition 102 Brake Adjustment 102 Rear Suspension Condition 102 Suspension Stopper Strap Condition 102 Track Condition 102 Track Tension and Alignment 103 Steering and Fron...

Page 9: ...streets roads or highways In most States and Provinces it is considered an illegal operation Electric start models only Never charge or boost a battery while installed on snowmobile Do not lubricate...

Page 10: ...ng throttle to proceed in reverse The reverse speed of these snowmobiles is not limited Always pro ceed with caution as fast reverse could result in loss of vehicle stability Come to complete stop bef...

Page 11: ...sed by its first owner from a BOMBARDIER dealer authorized to distribute SKI DOO products in the country in which the sale occurred hereinafter BOMBARDIER dealer and then only after the BOMBARDIER spe...

Page 12: ...OSE TO THE EXTENT THAT THEY CAN NOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DU RATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UN...

Page 13: ...f the issue has not yet been resolved please submit your complaint in writing or call the appropriate number below In Canada In USA BOMBARDIER INC BOMBARDIER MOTOR RECREATIONAL PRODUCTS CORPORATION OF...

Page 14: ...s warranty does not extend the life of this warranty beyond its original expiration date 3 CONDITIONS TO HAVE WARRANTY COVERAGE This warranty coverage is available only on 2002 SKI DOO snowmobile pur...

Page 15: ...t see the Operator s Guide Snow or water ingestion Incidental or consequential damages or damages of any kind including with out limitation towing storage telephone rental taxi inconvenience insur anc...

Page 16: ...distributor dealer receives a proof that the former owner agreed to the transfer of ownership in addition to the coordinates of the new owner 9 CONSUMER ASSISTANCE a In the event of a controversy ora...

Page 17: ...A Snowmobile registration has two purposes In many provinces or states it is mandatory to register a snowmobile in the same way as for a car It allows the state or province to maintain records of exi...

Page 18: ...part used in warranty repairs assumes the remaining warranty that exists on the snowmobile Q If I sell my snowmobile within the warranty period will the new owner qualify for the balance of the warra...

Page 19: ...nearest authorized SKI DOO dealer dial 1 800 375 4366 or visit our web site at WWW SKIDOO COM HOW TO IDENTIFY YOUR SNOWMOBILE Vehicle Description Decal Vehicle description decal is located on right h...

Page 20: ...our snowmobile in the event of loss These numbers are required by the authorized SKI DOO dealer to complete warranty claims prop erly No warranty will be allowed by Bombardier Inc if the engine serial...

Page 21: ...ion Model number is part of vehicle identification number V I N V I N DESCRIPTION Engine Serial Number Location TYPICAL 1 Engine serial number X X X X X X X X X X X X X X X X X A00A6IA Model number Se...

Page 22: ...20 ON VEHICLE IMPORTANT INSTRUCTIONS Please read the following instructions carefully before operating snow mobile LOCATION OF IMPORTANT INSTRUCTIONS Instruction 1 6 A33A02A 5 4 3 2 1 A33H0NA...

Page 23: ...21 Instruction 2 A33H02A DO NOT SIT HERE NE PAS S ASSEOIR ICI...

Page 24: ...22 Instruction 3 A33A03A...

Page 25: ...23 Instruction 4 Instruction 5 A01A2EA A01A2FA...

Page 26: ...24 Instruction 6 TYPICAL ALL MODELS A01A24D...

Page 27: ...25 CONTROLS INSTRUMENTS EQUIPMENT TYPICAL TYPICAL 35 A33H01B 29 30 28 32 31 33 34 27 26 35 26 Callout A33A01A 12 13 7 1 9 23 22 5 6 10 24 2 3 25 27 27...

Page 28: ...ebar When squeezed the brake is applied When released it automatically returns to its original position Braking effect is proportional to the pressure applied on the lever and to the type of terrain a...

Page 29: ...ease mechanism squeeze brake lever Locking lever will auto matically return to its original position Brake lever now returns to rest position Always release parking brake before riding TYPICAL 1 Locki...

Page 30: ...right or left the skis are turned right or left to steer the snowmobile Steering column position is adjustable Proceed as follows There are 2 positions NOTE Following procedure describes how to chang...

Page 31: ...29 Remove steering cover and console cap 1 Steering cover 2 Console cap A33H05A 2 1...

Page 32: ...30 Unscrew 4 bolts retaining console 1 Bolts retaining console 1 1 A33H06A 1...

Page 33: ...connector housings Unplug the 2 large connector housings TYPICAL 1 Large connector housings Remove console Remove 2 bolts retaining top of steering column STEERING COLUMN IN LOWER POSITION 1 Two bolts...

Page 34: ...R POSITION Reinstall the2 bolts Usenew lock nuts Torquenuts to 24N m 18lbf ft Reinstall all removed parts Position of console cap will be inverted Instead of being above it will be beneath steering co...

Page 35: ...gnition timing to cause crankshaft rotation re versing Engine will automatically shift into forward when starting after stop ping or stalling Shifting procedure will take place only when the engine is...

Page 36: ...nd release the reverse button 1 Reverse button WARNING The shifting to reverse mode on these snowmobiles is done by the push of the START RER button when the engine is running Wait until the reverse a...

Page 37: ...s are equipped with a Digital Performance Management DPM system This system takes care of the altitude mode required by the RER No reverse button operation is needed to select a mode Just follow Shift...

Page 38: ...tether cord to clothing then snap tether cord cap over switch post before starting engine TYPICAL 1 Snap over switch post 2 Attach to eyelet To stop engine completely pull cap from post switch TYPICAL...

Page 39: ...tional Tether Cord Caps The MPEM of your snowmobile can be programmed by your autho rized SKI DOO dealer to accept 8 different key codes tether cord caps We recommend the purchase of additional tether...

Page 40: ...Red This lamp will light up to confirm DESS and RER status Refer to pre vious paragraphs for description 9 Engine Cut Out Switch A toggle type switch located on the right side of the handlebar To sto...

Page 41: ...and everytime to stop the engine there after Thereby this engine cut out procedure will become reflex preparing operators to emergency sit uations requiring its use WARNING If the switch has been use...

Page 42: ...are automatically ON whenever the engine is running 11 High Beam Pilot Lamp Blue Lights when headlamp is on HIGH beam 12 Rewind Starter Handle Auto rewind type located on right hand side of snowmobile...

Page 43: ...3 Choke Lever This device features a 3 position lever to facilitate cold start 0 OFF 1 Position 1 2 Position 2 See OPERATING INSTRUCTIONS for more details 14 Speedometer SPEEDOMETER A32H01A 0 1 2 A33E...

Page 44: ...ed mode Change from One Unit to the Other NOTE Speedometer odometer and trip meter will have their units kilometer or miles changed all together Stop engine and open left hand side panel Cut locking t...

Page 45: ...e total distance travelled and displays it either in miles or kilometers Refer to Speedometer for changing units NOTE Vehicle speed at 90 km h 55 MPH and more the display will show speed only instead...

Page 46: ...resetable hour meter 19 Tachometer Direct reading dial indicates the number of thousand of revolutions per minute RPM of the engine MULTIPLY THE READING BY 1000 20 Engine Overheat Warning Lamp Red If...

Page 47: ...efueling Fuel may be pressurized open cap slowly Fuel is flammable and explosive Never use an open flame to check fuel level Never smoke or allow flame or spark in vicinity Always work in a well venti...

Page 48: ...Located at rear of fuel tank cap the gauge facilitate fuel level reading TYPICAL 1 Full 2 Empty 24 Heated Grip Switch Three position toggle switch Select the desired position to keep your hands at a c...

Page 49: ...ttle Lever Switch Three position toggle switch Select the desired position to keep your right thumb at a comfortable temperature 1 Heated grip switch 2 Heated throttle lever switch 3 Hot 4 Warm 5 Off...

Page 50: ...ortion in order to unhook its anchors from their grommets 1 Anchors 2 Grommets To open a side panel stretch and unhook the latches To remove a side panel remove by pulling up both locking devices from...

Page 51: ...49 1 Vent hose 1 Locking device removal Reverse opening procedure to close hood and side panels Properly hook up latches A33C02B 1 1 A33H0EA...

Page 52: ...oosen bolts adjust then retighten bolts to 10 N m 89 lbf in RIGHT SIDE SHOWN 1 Toehold 2 After adjustment retighten bolts to 10 N m 89 lbf in WARNING Adjust with vehicle at rest in a safe place Do not...

Page 53: ...rating the snowmobile above 5 C 41 F move the carburetor valve to the OFF position 29 Storage Compartment A storage compartment is provided at rear of seat Pull latch downward to unlock cover WARNING...

Page 54: ...ch 30 Tool Bag A tool bag containing tools for basic maintenance is supplied with the vehicle Tool bag is located in engine compartment in front of left hand side footrest TOOL BAG LOCATION 1 A33H0LA...

Page 55: ...for fuse holder location If headlight does not light up check fuse condition and replace it if necessary CAUTION Do not use a higher rated fuse as this can cause se vere damage to electric components...

Page 56: ...s melted 1 Fuse 2 Check if melted 32 Spare Spark Plug Holder To keep spare spark plugs dry and prevent shocks that might affect the adjustment or break them a holder is provided on the left side panel...

Page 57: ...NOTE Spare spark plugs are not supplied with the snowmobile 33 Spare Drive Belt Holder A spare drive belt can be stored in holder in engine compartment at front of headlight NOTE Spare drive belt is n...

Page 58: ...d adjustments refer to decal on belt guard It describes settings for optimum comfort according to load for your SKI DOO model General Snowmobile handling and comfort depend upon suspension adjust ment...

Page 59: ...ring 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 retest Proceed methodi cally un...

Page 60: ...until suspension is fully extended From this point rear of snowmobile should collapse by 50 to 75 mm 2 to 3 in when driver and passenger if so applicable take place Measure at end of tunnel as shown i...

Page 61: ...Turn the left side adjustment cam in a clockwise direction the right side cam in a counterclockwise direction Left and right adjustment cams may be set at different position TYPICAL 1 Increase spring...

Page 62: ...T Turn the left side adjustment cam in a counterclockwise direction the right side cam in a clockwise direction Left and right adjustment cams may be at different position TYPICAL 1 Decrease spring pr...

Page 63: ...Spring Steering Behavior Ride at moderate speed on a trail If steering is too easy or too hard to turn adjust center spring accord ingly TYPICAL GOOD ADJUSTMENT AT MODERATE SPEED 1 Steering easy to tu...

Page 64: ...62 TYPICAL TOO SOFT OF ADJUSTMENT 1 Steering hard to turn TYPICAL 1 Use adjuster wrench provided in tool bag to increase preload A33F07D 1 A32F01A 1...

Page 65: ...63 TYPICAL TOO HARD OF ADJUSTMENT 1 Steering less aggressive TYPICAL 1 Use adjuster wrench provided in tool bag to decrease preload A33F07D 1 A32F01B 1...

Page 66: ...behavior Ad just stopper strap length accordingly CAUTION Whenever stopper strap length is changed track ten sion must be readjusted TYPICAL GOOD ADJUSTMENT AT FULL ACCELERATION 1 Comfortable steering...

Page 67: ...65 TYPICAL TOO LONG STRAP 1 Skis lift off the ground TYPICAL 1 Reduce strap length by bolting to a different hole A33F07C 1 A03F0QB 1...

Page 68: ...66 TYPICAL TOO SHORT STRAP 1 Heavy steering TYPICAL 1 Increase strap length by bolting to a different hole A33F07D 1 A03F0QB 1...

Page 69: ...and right blocks by 90 There are only two adjustment positions Thicker part of block must be facing rearward or downward Use tool provided in tool bag to adjust coupling blocks COUPLING BLOCK RIGHT SI...

Page 70: ...ly coupled suspension more track grip and less skis steering 2 Turn block in this direction to adjust to the other position 5 Front Springs Handling Ride at moderate speed and check for proper handlin...

Page 71: ...69 TYPICAL PROPER ADJUSTMENT 1 Good handling and comfortable steering A33F07D 1...

Page 72: ...70 TYPICAL TOO SOFT OF ADJUSTMENT 1 Bad handling 1 Increase spring preload 2 Position number A33F07D 1 1 A33F01A 2...

Page 73: ...O HARD OF ADJUSTMENT 1 Steering hard to turn 1 Decrease spring preload 2 Position number CAUTION Make sure that both front springs are still preloaded when front of vehicle is off the ground A33F07D 1...

Page 74: ...can be adjusted according to driver and pas senger weight and or trail condition There are two adjustment positions SC 10 III SUSPENSION 1 Soft position 2 Firm position To adjust loosen nut move bolt...

Page 75: ...suspension spring preload Increase center spring preload Reduce rear spring preload Snowmobile seems unstable and seems to pivot around its center Reduce rear suspension front arm pressure Reduce cent...

Page 76: ...or water absorbing additives are not required and should not be used When using non oxygenated fuel we highly recommend the use of iso propyl base gas line antifreeze in a proportion of 150 mL 5 U S o...

Page 77: ...t wear and oil deposit thus maintaining maximum level performance and antifriction properties This synthetic injection oil meets the latest ASTM and JASO standards by ensuring high bio degradability a...

Page 78: ...speeds and engine overheating are detrimental during the break in period To assure additional protection during the initial engine break in 500 mL 18 imp oz of recommended injection oil should be adde...

Page 79: ...eck corresponding action of skis versus handlebar Check fuel and injection oil for levels and leaks Replenish as nec essary and see an SKI DOO authorized dealer in case of any leaks Open or close heat...

Page 80: ...e Track and idler wheels Check for free movement Brake lever Check proper action Parking device Check proper action Throttle lever Check proper action Switches and lights Check proper action Tether co...

Page 81: ...r proper latching and no heavy or breakable objects Vehicle vinicity Snowmobile must be pointed away from people or objects No one is to be standing in front of or in back of the snowmobile Clothing B...

Page 82: ...ratio of the two pulleys which maximizes acceleration and forward movement of the vehicle Power is transferred to the track through the chaincase and drive axle Turning Handlebar controls the steering...

Page 83: ...arter handle firmly and crank engine or use electric starter on so equipped models After the engine is started close off choke to ensure proper air fuel mix when speed drops below 2000 RPM 0 OFF 1 Pos...

Page 84: ...resistance is felt then hold handle firmly and pull vigorously to start engine Emergency Starting The engine can be started with the emergency starter rope supplied with the tool kit Remove belt guard...

Page 85: ...emergency rope to the starter clip supplied in the tool kit Hook up clip on drive pulley Wind the rope tightly around drive pulley When pulled pulley must rotate counterclockwise TYPICAL TRA TYPE DRI...

Page 86: ...se throttle lever and wait until engine has returned to idle speed Shut off the engine using either engine cut out switch or tether cut out switch WARNING When starting the snowmobile in an emergency...

Page 87: ...t track rotate at low speed for several turns The lower the vehicle temperature is the longer vehicle warm up should be Shut off the engine and remove the snowmobile mechanical stand Skis may be froze...

Page 88: ...ne overheating indicator will light up if engine is too hot Reduce snowmobile speed and run snowmobile in loose snow or stop engine immediately Check for adequate coolant level See an authorized SKI D...

Page 89: ...NING Observe WARNINGS and CAUTIONS mentioned throughout this guide which are pertinent to the item being checked When component conditions seem less than satisfactory replace with genuine BOMBARDIER p...

Page 90: ...ncase Oil Level Chaincase Oil Change Lubrication of Drive Axle End Bearing Steering and Front Suspension Mechanism Lubrication Steering and Front Suspension Mechanism Condition Wear and Condition of S...

Page 91: ...er types of fluid TYPICAL BRAKE FLUID RESERVOIR 1 Minimum Chaincase Oil Level With snowmobile on a level surface check the oil level by removing dipstick Oil level must be between lower and upper mark...

Page 92: ...metal particles from magnet Refill up to upper mark using BOMBARDIER synthetic chaincase oil P N 413 803 300 12 x 355 mL CAUTION Use BOMBARDIER synthetic chaincase oil or a suitable equivalent when s...

Page 93: ...o be almost empty Do not mismatch oil reservoir cap with fuel tank cap Install cap that is identified OIL 1 Injection oil reservoir 2 Maximum level indicator 13 mm 1 2 in from top 3 Level marks 1 4 1...

Page 94: ...t level mark engine cold of coolant tank NOTE When checking level at low temperature it may be slightly lower then mark If additional coolant is necessary or if entire system has to be refilled refer...

Page 95: ...containing chlorine etc Clean sheaves of both pulleys using Pulley flange cleaner P N 413 711 809 Inspect the hood and repair any damage Touch up all metal spots where paint has been scratched off Sp...

Page 96: ...stand NOTE Do not release track tension Belt Guard Removal and Installation 1 Turn off engine cut out switch Open hood 2 Open retainer to release pin then pull belt guard out of vehicle TYPICAL 1 Pin...

Page 97: ...y oversize to maintain ten sion on its pins and retainers preventing undue noise and vibration It is important that this tension be maintained when reinstalling Drive Belt Removal Installation NOTE Re...

Page 98: ...drive belt installer remover provided in tool bag DRIVE BELT INSTALLER REMOVER Screw drive belt installer remover in the free threaded hole and tight en to open the pulley Remove belt TYPICAL 1 Tighte...

Page 99: ...to the following The maximum drive belt life span is obtained when the belt has the proper rotation direction See arrow on belt TYPICAL 1 Arrow pointing front of vehicle CAUTION Do not force or use t...

Page 100: ...Drive Chain Tension Remove hair pin Fully tighten tensioner adjustment screw by hand then back off only far enough for hair pin to engage in locking hole TYPICAL 1 Hair pin 2 Adjustment screw 2 1 A33D...

Page 101: ...affecting snowmo bile efficiency This adjustable drive pulley allows setting maximum engine RPM in the vehicle to maintain maximum power Calibration screws should be adjusted so that actual maximum en...

Page 102: ...ion 4 and is changed to position 6 So maximum engine RPM is increased by 400 RPM CAUTION Do not adjust TRA drive pulley so that engine turns over maximum power RPM Refer to SPECIFICATIONS To adjust Ju...

Page 103: ...belt or distorted spare belt Contact an authorized SKI DOO dealer Check the drive belt width Replace the drive belt if width is less than the minimum width recommended in SPECIFICATIONS section WARNIN...

Page 104: ...9 N m 80 lbf in Track Condition Lift the rear of the snowmobile and support it off the ground With the engine off rotate the track by hand and inspect condition If worn or cut or if track fibers are...

Page 105: ...the snowmobile in snow about 15 to 20 minutes prior to adjusting track tension Lift snowmobile by a rope chain or lift strap that has been secured into holes provided for that purpose one on each sid...

Page 106: ...ea sure deflection as well as force applied BELT TENSION TESTER TYPICAL 1 7 3 kg 16 lb 2 Deflection CAUTION Too much tension will result in power loss and exces sive stresses on suspension components...

Page 107: ...track barely turns This must be done in a short period of time 1 to 2 minutes Check that the track is well centered equal distance on both sides between edges of track guides and slider shoes WARNING...

Page 108: ...tance To correct stop the engine Loosen rear wheel screws tighten the adjustment screw on side where the slider shoe is the farthest from the track insert guides TYPICAL 1 Guides 2 Slider shoes 3 Tigh...

Page 109: ...f components steering arms control arms and links tie rods ball joints ski coupler bolts etc If necessary contact an authorized SKI DOO dealer Wear and Condition of Skis and Runners Check the conditio...

Page 110: ...rformance of the engine Modification may be in violation of local laws CAUTION If any exhaust system component is removed modi fied or damaged severe engine damage may result Air Filter Cleaning Leavi...

Page 111: ...UTION Snowmobile engines have been calibrated with the filter installed Operating the snowmobile without it may cause engine damage Headlight Beam Aiming Open left side panel Turn knob to adjust beam...

Page 112: ...UTION Never touch glass portion of an halogen bulb with bare fingers it shortens its operating life If glass is touched clean it with isopropyl alcohol which will not leave a film on the bulb Unplug b...

Page 113: ...ose the bulb by removing the red plastic lens To remove unscrew the 2 lens screws TOWING THE VEHICLE First remove drive belt from vehicle to be towed Use a rigid bar and tow at very low speed TRANSPOR...

Page 114: ...y Refer to an authorized SKI DOO dealer for vehicle preparation CAUTION Do not run engine during storage period Preseason Preparation Refer to an authorized SKI DOO dealer CAUTION Have carburetor s cl...

Page 115: ...oved Check fuel tank level check fuel filter replace if clogged check condition of fuel and impulse lines and their con nections If a failure of the fuel pump or carburetor has occurred contact an aut...

Page 116: ...fits original width it will affect vehicle performance 7 Drive and driven pulleys require ser vicing Contact an authorized SKI DOO dealer 8 Engine is overheating Check coolant level pressure cap ther...

Page 117: ...DOO dealer 5 Water in fuel Drain fuel system and refill with fresh fuel SYMPTOM Snowmobile cannot reach full speed POSSIBLE CAUSE WHAT TO DO 1 DESS has not read code of the tether cord cap Engine can...

Page 118: ...Width mm in 33 95 1 337 Spark Plug Type NGK BR 9 ECS Gap 0 05 mm 002 in 0 50 020 Track Tension mm in 30 35 1 3 16 1 3 8 Alignment FLUIDS Fuel Type Regular Unleaded Tank Capacity L U S gal 39 10 3 Oil...

Page 119: ...50 50 distilled water and ethylene glycol P N 293 600 038 12 x 1 L That blend will protect the system from freezing as low as 37 C 35 F N A Not applicable CHANGE OF ADDRESS OR OWNERSHIP If your addre...

Page 120: ...s services and offers 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 ou...

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

Page 122: ...AFFIX BOMBARDIER RECREATIONAL PRODUCTS WARRANTY DEPARTMENT 75 J A BOMBARDIER ST SHERBROOKE QUEBEC CANADA J1L 1W3 PROPER POSTAGE...

Page 123: ......

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Ski-Doo MX Z 800 2145 2002, Operator'S Manual

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