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MMR2003_018_00_02A.FM

SAFETY NOTICE

0

This manual has been prepared as a guide to correctly service and repair some 2003 Ski-Doo snowmo-
biles. See model list below.

This edition was primarily published to be used by snowmobile mechanic technicians who are already
familiar with all service procedures relating to Bombardier made snowmobiles. Mechanic technicians
should attend continuous training courses given by Bombardier Training Dept.

Please note that the instructions will apply only if proper hand tools and special service tools are used.

This 

Shop Manual

 uses technical terms which may be slightly different from the ones used in the 

Parts Catalog

.

It is understood that this manual may be translated into another language. In the event of any discrepancy,
the English version shall prevail.

The content depicts parts and/or procedures applicable to the particular product at time of writing. 

Service

and 

Warranty Bulletins

 may be published to update the content of this manual. Make sure to read and

understand them.

In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the
general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas
of the parts.

The use of Bombardier parts is most strongly recommended when considering replacement of any com-
ponent. Dealer and/or distributor assistance should be sought in case of doubt.

The engines 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 strictly be adhered to. Locking devices (ex.: locking tab,
self-locking fasteners, etc.) must be installed or replaced with new ones. If the efficiency of a locking
device is impaired, it must be renewed.

This manual emphasizes particular information denoted by the wording and symbols:

CAUTION:

Denotes an instruction which, if not followed, could severely damage vehicle components.

NOTE:

Indicates supplementary information needed to fully complete an instruction.

Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.

Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the
contents. We strongly recommend that any services be carried out and/or verified by a highly skilled
professional mechanic. It is understood that certain modifications may render use of the vehicle illegal
under existing federal, provincial and state regulations.

 WARNING

Identifies an instruction which, if not followed, could cause serious personal injury including possi-
bility of death.

SAFETY NOTICE

Содержание 2637

Страница 1: ......

Страница 2: ...2003 Shop Manual Supplement 4 TECTM LEGEND V 1000 SPORT GRAND TOURING V 1000 SPORT This supplement must be used in conjunction with the 2003 ZX Series Shop Manual P N 484 200 042...

Страница 3: ...nted in Canada Registered trademarks of Bombardier Inc This document contains the trademarks of the following companies Loctite is a trademark of Loctite Corporation Molykote is a trademark of Dow Cor...

Страница 4: ...GINE MANAGEMENT 01 Table of contents 04 01 1 02 Overview 04 02 1 03 Component inspection and adjustment 04 03 1 04 Diagnostic procedures 04 04 1 05 TRANSMISSION 01 Table of contents 05 01 1 02 Drive b...

Страница 5: ...t strongly recommended when considering replacement of any com ponent Dealer and or distributor assistance should be sought in case of doubt The engines and the corresponding components identified in...

Страница 6: ...R COUNTRY MODEL NUMBER GRAND TOURING E SPORT V 1000 2 tone Blue U S CDN 2638 GRAND TOURING E SPORT V 1000 2 tone Blue EUR 2644 LEGEND E SPORT V 1000 2 tone Blue U S CDN 2637 A32H0DA 1 2 B P S 1 5 9 2...

Страница 7: ...er square inch LH left hand LO low LT long track m meter MAPS manifold air pressure sensor Max maximum Min minimum mL milliliter mm millimeter mn minute MPH mile per hour MPI multi protocol interface...

Страница 8: ...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 a...

Страница 9: ...oved 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 529 031 300 529 031 200...

Страница 10: ...replaced by customary fasteners or vice versa Mismatched or incorrect fasteners could cause damage to the vehicle or possible personal injury As many of the procedures in this manual are in terrelate...

Страница 11: ...s 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 bolt t...

Страница 12: ...EAD REPAIR 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...

Страница 13: ...ket 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 stren...

Страница 14: ...trength Loctite 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 acco...

Страница 15: ...2 M4 18 3 M4 27 4 M5 35 8 M6 71 9 M6 80 10 M6 89 11 M6 97 12 M6 106 N m FASTENER SIZE 8 8 grade Lbf 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...

Страница 16: ..._____________________________________________________ ____________________________________________________________ ____________________________________________________________ ________________________...

Страница 17: ...ions After Sales Service 565 de la Montagne Street Valcourt Quebec Canada J0E 2L0 Technical Publications After Sales Service 565 de la Montagne Street Valcourt Quebec Canada J0E 2L0 Technical Publicat...

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