BOMBARDIER 1980 Install guide

//'1\/
SAFETY NOTICE
The Bombardier snowmobile Shop manual has been prepared in order to assist skilled rnechanic's
in
the efficient repair and maintenance of Bombardier snowmobiles,
Safety features may be impaired if other than genuine Bombardier parts are installed,
Torque wrench tightening specifications must be strictly adhered by, Locking devices must be
installed or replaced by new ones, where specified, If the efficiency of a locking device is impaired,
it must be renewed,
This
manual emphasizes particular information denoted by the wording and symbols;
•
•
o
WARNING: Identifies an instruction which, if not followed, could cause personal injury,
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,

Ie
INTRODUCTION
This Shop Manual covers the following Bombardier made
1980 snowmobiles:
Elan -Spirit
Citation
3500 Mirage I
Citation 4500/E Mirage IIIE
Citation SS Mirage Special
Everest 5001500 E - Futura 500/500E
Everest LC -Futura LC
Blizzard 5500 -Grand Prix Special
Blizzard'
7500 -Super Sonic
Blizzard
9500 -Ultra Sonic
Alpine
640
Elite 450 LlC
DEFINITION OF NUMBERING
SYSTEMS
The manual makes uses of a 2-part digital numbering
system (i,e, 01-01), in which the first digit represents
the Section, the second
digit the Sub-section,
01-01
/~
section sub-section
The numerotation at the
bottom of each page assists
the user
in page location.
ARRANGEMENT OF THE MANUAL
The Manual IS diVided into nine (9) malar sections:
01 Tools
02 Technical data
03 Engine
04 Electrical
05 Transmission
06 Suspension
07 Steering and skis
08 Frame and hood
09 Warranty
Each section
is comprised of various sub-sections, and
again each sub-section has one more division.
Ex.:
05 TRANSMISSION
07 Chaincase
Steel chaincase
Aluminum chaincase
1980 BOMBARDIER SNOWMOBILES
SHOP MANUAL
ILLUSTRATIONS & PROCEDURES
An exploded view is conveniently located at the beginning
of each section. and is meant to assist the user in
identifying parts and
components.
The illustrations show the typical construction of the
different assemblies and, in all cases, may not reproduce
the full detail or exact shape
of the parts shown, however,
they represent parts
which have the same or a similar
function.
When something special applies (such
as adlustment"
etc), the specific parts are circled and referred to in the
text.
As many of the procedures In this manual are Interrelated,
we suggest, that before undertaking any task, you read
and thoroughly understand the entire section or sub-
section in which the procedure is contained.
A number of procedures throughout the book require the
use of special tools,
Where a special tool is indicated,
refer to section
01. Before commencing any procedure,
be sure that you have on hand all the tools required,
or approved equivalents.
GENERAL
The information, illustrations and component! system de-
scriptions contained in this manual are correct at time
of publication. Bombardier Limited, however, maintains
a policy of continuous
improvement ofits products without
Imposing upon itself any obligation to install them on
products previously
manufactured.
Bombardier Limited reserves the right at any time to
discontinue or change specifications, designs, features,
models or equipment
without incurring obligation.
This manual
IS published by the
Technical Publications
Bombardier Limited
Valcourt, Quebec, Canada.

1980 SHOP MANUAL
TABLE OF CONTENTS
SECTION
SUB-SECTION
01 TOOLS
02
TECHNICAL DATA
03
01 -Engine tolerance measurements
ENGINE
02 -Engines
03 -Timing
04 -Carburetor
05 -Air intake silencer and fuel tank
06 -Rewind starter
04-
01 -Electric charts
ELECTRICAL
02 -Tests procedure
03 -Electric starter
04 -Battery
05 -Alternator
06 -Spark plugs
05
01 -Pulley guard
TRANSMISSION
02 -Drive belt
03 -Drive pulley
04 -Driven pulley
05 -Pulley alignment
06 -Brake
07 -Chaincase
OB -Gearbox
09 -Drive chain
06
01 -Bogle wheel
SUSPENSION
02 -Slide suspension
03 -Rear hub
04 -Drive axle
05 -Track
01 Steenng system
07
STEERING / SKI
02 - Ski system
08
01 -Hood
HOOD AND FRAME
02 -Frame
09
WARRANTY

ITEM
Dial indicator (T.D.C. gauge).
414 1047 00
Tone timer.
414099000
Circuit tester (continuity light).
414 0122 00
~&e@)
Bombardier ignition tester.
419003300
~--§J ~ ••
KiNITIOIl TESTEn» '"
o ,,~. :
":~'-
USE
Engine timing, to determine T.D.C.
Engine timing (static).
Engine timing (static).
Continuity tests.
Engine electrical components tests.
SECTION 01
(TOOLS)
TOOLS
APPLI CABLE TO
All engine types.
All engine types.
All engine types.
All engine types.
(TOOLS). PAGE 1

SECTION 01
(TOOLS)
Track insert installer
Heavy duty
419 0027 00
0 !l
~:TI~D=!j
o !l
Insert block
529 0003 00
e
Cleat block
529 0026 00
1\ 1\ 1\
Link plate spring lever.
529 0006 00
Drive pulley retainer.
529 0017 00
(TOOLS). PAGE 2
!!J
cJ
.-/
i5'--
~Ma)eJlg
Track Insert . Female
JI9
-_ -.,,1
PES ~~:=~-
;;;J;:::-=::::;::p:::;;~p01061 .block
{Q \
For indexation of governor cup.
I
I
All types of track.
All types of track.
All models with
link plate springs.
Square shaft drive
pulley.

(
Drive pulley puller.
529 0021 00
c::c===c-----gg
8604142 00 (metric)
c:=!==::J)u ( utl@ID
Magneto hOUSing holder.
420 976 550
~
( 0 0)
To remove drive pulley from
crankshaft.
SECTION 01
(TOOLS)
Taper shaft engines
Single cylinder engine
types.
(TOOLS). PAGE 3

SECTION 01
(TOOLS)
Puller assembly.
420 876 296
With 145 mm screw.
~
~
~
~
g
~~
Screw M8 x 70 (2)
Screw
M8 X 40 (2)
Crankshaft protector PTO
Crankshaft protector Ma9
Distance ring
Puller ring
Half ring ass'y
Distance ring
Puller rin9
Half ring ass'y
(TOOLS). PAGE 4
420 841 200
420 840 680
420 876 550
420 876 555
420 876 560
420 977 480
420 276 020
420 876 565
420 977 490
420977 470
engine 377, 354, 454, 503
engine 247,277,444,464,640
All engines except 247, 640
377 engine only
all except 247 engine
all except 640 engine
all except 640 engine
377, 464 engines only
377, 464, 640 engines only
377, 464, 640 engines only
All engine types.

Oil seal sleeve
247 engines
PTO 420 977 910
MAG 420 276 900
Water pump oil
seal sleeve
354, 444, 454, 464
water pump 420 876 490
rotary valve 420 876 495
Rotary va Ive shaft pusher.
420876610
Ball bearing pusher.
420876 500
Bearing simulator.
640 engine
~
Q
420 B76 160
@
Belt tension tester.
414348200
( ! " ' [" • ! q:", (d :------4"[ Q
To avoid oil seal damage dunng
crankshaft Installation.
~~
Od seal sleeve (on crankshaft)
To Install water pump
ball bearing,
When adjusting crankshaft play.
Pressure
adjustment
Deflection
adjustment
32 mm
(11")
SECTION 01
(TOOLS)
Liquid cooled Rotary
valve engines
354, 444, 454, 464
engine types.
All models except
Mirage
I, Citation 3500
Mirage IIIE, Citation 4500/E
Mirage Special, Citation SS
(TOOLS), PAGE 5

SECTION 01
(TOOLS)
Cylinder aligning tool.
640 engine
503 engine
354-454 engines
420 876 170
420876171
420 876 575
[ .. - ... -I
f 503 engines 420240275
g '" '"""' '" "",0
Connecting rod holder.
420 977 gOO
Armature plate contact set pivot
pin remover (socket).
420 876 530
Fan holder
640 engine 420 977 880
503 engine 420 876 355
377 engine 420 876 357
@:::::::::::;;
(0)
(TOOLS). PAGE 6
Connecting rod
1M
To remove contact set pivot pin
from armature plate.
TWin cylinder engine
types.
All single cylinder
engines
All engine types
using breaker
pornt type Ignition.
Twin cylinder
fan-cooled engines

Protection cap.
247, 277, 640 engines
18 mm 420 976 890
354, 377, 444, 454, 464, 503
22 mm 420 876 402
Engine
Oil seal pusher.
247 engine 420 977 920
277 engine 420 277 865
420 876 660
J, @)
Oil seal pusher.
420876510
464 engine
420 876 500
Rotary valve oil
seal pusher
L
420 876 600 - 354, 454 engine
420876 605 - 464 engine
o
Protect crankshaft end, when
using bearing puller.
Protectlon cap
V
DJLL
011 seal pusher
Puller
To install water pump
oil seal.
To Install rotary valve
shaft
oil seal
SECTION 01
(TOOLS)
All engine types.
All single cylinder
engine type.
354, 444, 454, 464
engine types.
354, 454, 464 englOes
(TOOLS), PAGE 7

SECTION 01
(TOOLS)
Polyamld ring pusher
277 engine MAG 420 273 930
PTO 420 273 940
~-Ad1
Crankshaft feeler gauge.
503 engine
• MAG 420 876 625
PTO 420 876 620
ts2J
Crankshaft locking tool
420 876 640
Injection pump gear
holder
377 engine 420 876 690
464 engine 420 277 900
~ )
(TOOLS!. PAGE 8
To install
polyamld
ring
in crankcase.
To lock crankshaft
\ 277 engine
• Mag side:
All 503 engines up to
no.3 181 891
and engines
no. 3 181 921 to
3181937.
PTO: All 503 engines
277.
377
464 engines.
464. 377 engine
equipped with
oil injection

LOCTITE SEALANT KIT 413 7026 00 I
contains
PST Pipe Sealant with Teflon (50 mL) I
413 7023 00
Gasket Eliminator 515 (50 mL)
413 702700
Retaining Compound RC/601 (10 mL)
413 7031 00
Threadlocker 242 (10 mL)
413 703000
Threadlocker 271 (10 mL)
413 7029 00
SuperBonder 495 (3-gram tube)
413703200
LOCK'N SEAL
(242) BLUE,
MEDIUM STRENGTH 24 mL
413702500
~It:i.~-~
LOCK'N SEAL
(271) RED
HIGH STRENGTH 6 mL
747 020000
~ ";;"'~r=:J\
GASKET ELIMINATOR 515
50 mL
413 702700
For threadlocking, threadseallng,
gasketing, bonding and retaining
applications on engines, pulleys
and fasteners etc.
SECTION 01
(TOOLS)
A medium-strength adhesive for General purpose, nuts,
threadlocking and threadseallOg. bolts screws,
Vibration-proofs nuts, bolts
and Magneto ring nut, crank-
screws. case studs, etc.
High-strength threadlocklOg I Fastene~~ and studs
threadseallng adhesive for large under 1 d,a,
parts.
Seals instantly, For metal to metal I On all engine crankcases.
assembly. Replaces gaskets.
(TOOLS), PAGE 9

SECTION 01
(TOOLS)
RETAINING COMPOUND 601
10 mL
413703100
PRIMER CRANKCASE SEALANT
(SPRAY) 6 oz
413702400
STRIPPER NO 57
413 7021 00
ANTISEIZE
LUBRICANT
413701000
-;
ANTi
SeizE
lll6n.'"p,lIl
METAL PROTECTOR LPS.
NO 1 SPRAY
413 9022 00
(TOOLSI, PAGE 10
tiANoiE'..;:
~:~~
Restores fit between bearings and
worn crankcase.
Very fast cure
pnmer. Primer NF
provides hxturing In only 15-30
seconds with fuJI cure in 4 hours
or less.
On part life is 30 minutes
and parts should be assembled
as
soon as possible after adhesive is
applied.
For cleaning mating surfaces be-
fore assembly.
Protects moving and stationary
parts against high temperature
seizing. Prevents rust and corro-
sion
on parts exposed to high heat.
General service light lubricant.
Protects against rust. Displaces
moisture. Protects all electrical
systems and ignition systems.
All engines except 247,
277.
Mainly used when assem-
bling engine crankcase.
Used
to clean mating SUf-
faces before applying Loc-
lite 515 (Gasket Elimina-
tor).
Unpainted surfaces of
drive pulley countershaft.
For storage protection,
on
drive and driven pulleys,
High tension coil protec-
tion from moisture.

METAL PROTECTOR L.P.S.
NO 3 SPRAY
413 9008 00
SILICONE DIELECTRIC GREASE
3 oz
747018002
GREASE TUBE
14 oz
498 0281 00
CLUTCH LUBE
413800700
INJECTOR OIL
413801500
CHAINCASE OIL
413 8012 00
BOMBARDIER OIL
50/1
496013200
I~
II
~
-::
ImYJII
Heavy Duty Rust preventIVe lubri-
cant. Protects bare metal parts
against
rust and corrosion.
Special dielectric grease that pre-
vents mOisture and corrosion
build-up in electnc connections.
Multi purpose Lithium based
grease for use over a wide temper-
ature range.
Special Jow temperature metallic
lubricant for clutch shafts only.
High quality lubricant with good
resistance to high operat'lng tem-
peratures. Low foaming action.
Specially formulated all for chain
and roller lubrication. Assures
proper lubrication at low tempera-
tures.
SECTION 01
(TOOLS)
For storage protection. on
bare metal parts.
On all electric connec-
tions. High tension call.
Spark plug connections.
Connector housings, etc.
For Idler bearings. skllegs.
leaf spring cushion pads.
oil seal interior lips, etc,
Citation 3500. Citation
4500/E. Mirage I.
Mirage II/E. Elan and
Spirit drive pulleys.
Rotary valve lubncant on
354-444-454 and 464
engines.
Chaincase lubricant on all
models.
Specially formulated oil that meets I All models.
lubrication requirements of the
Bombardier-Rotax engine.
(TOOLS). PAGE 11

SECTION 02
TECHNICAL DATA LIST
TOLERANCE AND WEAR LIMIT -ENGINES
IGNITION TIMING SPECIFICATIONS
CARBURETOR SPECIFICATIONS
IGNITION GENERATING COIL, TRIGGER COIL AND LIGHTING
COIL RESISTANCE CHART
BOMBARDIER IGNITION TESTER DIAL POSITIONS
BOSCH
SPARK PLUG CHART
VEHICLE
MODEL/DRIVE BELT NUMBER
DRIVE PULLEY SPECIFICATIONS
DRIVEN PULLEY SPRING
TENSION
PULLEY ALIGNMENT SPECIFICATIONS
SPROCKET
AND CHAIN SPECIFICATIONS
TRACK
TENSION SPECIFICATIONS (BOGIE WHEEL SUSPENSION)
TRACK TENSION SPECIFICATIONS (SLIDE SUSPENSION)
TRACK SPECIFICATIONS
STEERING SYSTEM TORQUE SPECIFICATIONS
SKI SYSTEM TORQUE SPECIFICATIONS
METRIC
INFORMATION CHART
(TECHNICAL DATA LIST). PAGE 1

SECTION 02
SUB-SECTION 03-01, (ENGINE TOLERANCES MEASUREMENT)
TOLERANCES AND WEAR LIMIT - 1980 ENGINES
ENGINE CYLINDER BORE
PISTON TO WALL
MAXIMUM RING CRANKSHAFT
TYPE
(NOMINAL) CLEARANCE
END CAP
END PLAY
STD OVERSIZE
MIN. -MAX.
MIN. -MAX.
247
69.00 mm 69.50 mm 0.065-0.200 mm 0.20-0.35 mm 020-0.40 mm
(2.7165") (2.7362") (0026-.00B") (00B-.014")
(.00B-.016")
277
72.00 mm
72.25 mm 0.060-0.200 mm
0.20-0.35 mm
0.20-0.40 mm
(2.B346") (2.B445")
(0024-.00B")
(00B-014") (.00B-.016")
354 59.50 mm 59.75 mm 0.OBO-0.1BO mm
0.15-0.30 mm N.A.
(2.3425") (2.3524")
(0031-.007") (006-.012")
377 62.00 mm
62.25 mm
0070-0.200 mm
0.20-0.35 mm
NA
(2.4409")
(2.450B")
(0028-.00B") (00B-.014")
444 69.50 mm 69.75mm 0.070-0200 mm
0.20-0.35 mm
NA
(27362") (2.7461")
(002B-.00B")
(00B-014")
454 67.50 mm 67.75mm 0.090-0.200 mm 0.20-0.35 mm
NA
(2.6575")
(2.6673") (0035-.00B") (OOB-O 14")
464 69.50 mm
69.75 mm
0.070-0200 mm
0.20-0.35 mm N.A.
(2.7362")
(2.7461")
(0028-.00B")
(008-014")
503 72.00 mm
72.25 mm 0.060-0.200 mm
0.20-0.35 mm NA
(28346")
(2.B445") (0024-.00B")
(00B-014")
640 76.00 mm
76.50 mm 0.070-0.220 mm
0.25-0.40 mm 0.20-0.40 mm
(2.9921 ") (3.0118")
(.002B-.OOB") (010-016")
(008-016")
N A: not applicable
(TECHNICAL DATA LIST). PAGE 2

SECTION 02
SUB-SECTION 03-03, (IGNITION TIMING)
1980 IGNITION TIMING SPECIFICATIONS
ENGINE IGNITION DIRECT INDIRECT
EDGE CAP
TYPE
TYPE MEASUREMENT MEASUREMENT
B.T.D.C. B.T.D.C.
f~
~
.. '
..
'.,,!'
n
'hFl
~
~
~r
)11
0> ??
il
c
247
Breaker
3.98 mm ± 0.25
NA
7-10 mm
(.157" ± .010)
(.275-394")
277
Breaker
NA
2.60 mm ± 0.25 8·12 mm
(.102" ± .010) (.315-.4 72")
354
CD
• 1.39 mm ± 0.25
NA
NA
(.055" ± .010)
377
Breakers
2.07 mm ± 0.25
NA
8-12 mm
(.081" ±01O)
(.315-.4 72")
444
Breakers
2.35 mm ± 0.25
NA
8·12 mm
(.093" ±01O)
(.315·.4 72")
454
CD
• 1.39 mm ± 0.25
(.055" ± .010)
NA
NA
464
Breakers
2.07 mm ± 0.25
NA
8-12 mm
(.081" ±010)
(.315-.472")
Breakers
2.07 mm ± 0.25
N.A.
8·12 mm
503
(. 081" ± a 10)
(.315-.4 72")
640
Breakers
NA
3.62 mm ± 0.25
7·10 mm
(.143" ±01 0)
(275-.394")
NA not applicable
• StroboscopIc tlmln9
at 6000 R.P.M.
(TECHNICAL DATA LIST). PAGE 3

SECTION 02
SUB-SECTION (03-04)
CARBURETOR SPECIFICATIONS
MODEL
ENGINE CARBURETOR LOW SPEED
TYPE TYPE
ADJ
Mikuni ± Jr
ELAN & SPIRIT 247
VM28-242
1i turn
CITATION 3500,
MIRAGE I
277 VM 34-228
1i turn
CITATION 4500/E,
MIRAGE II I E
377
VM-34-229 1 turn
CITATION SS,
MIRAGE SPECIAL
377
2XVM30-111
11 turn
EVEREST 500/E
FUTURA 500/E
503
VM36-83
1 turn
EVEREST LC,
FUTURA LC 464 VM34-227
11 turn
BLIZZARD 5500
GRAND PRIX SPECIAL
503 2XVM34-203 11 turn
BLIZZARD 7500
MAG: VM34-230
SUPER SONIC
354 PTa: VM34-233 1i turn
BLIZZARD 9500 PTa: VM36-88
ULTRA SONIC
454
MAG: VM36-86 1 turn
ALPINE 640ER
640 VM34-215 1 -t turn
ELITE 450 LC
444
VM34-201 1 turn
- --
. -
L-
---- -- --
(TECHNICAL DATA LIST). PAGE ~
IDLE
SPEED
R.P.M.
1100-1300
1100-1300
I
,
2000
,
,
1800-2000
1800-2000
2000
1800-2000
1800-2000
1800-2000
1800-2000
1800-2000
---

SECTION 02
SUB-SECTION (03-04)
1980 MIKUNI CARBURETOR SPECIFICATIONS
c§"
!j
S
~
(f
VM28-242
160
VM30-111 150
VM34-201
370
VM34-203
220
VM34-215
280
VM34-227
380
VM34-228
220
VM34-229
280
VM34-230
290
VM34-233
260
VM36-83
310
VM36-86
320
VM36-88
300
o Jet needle last digit
indicates
"E" clip
position from top.
Ex.: 6HD2-3: 3rd
slot from top.
CD Turning clockwise will
enrich the mixture and
counterclockwise will
lean it.
0
0-
,,0
//
if
<i'
t
..,
<v
<v
q" q"
d9
r5j
<::'
<::'
6DPl-3
182-0-8
6DH7-3 159 P-O
6EJ 1-3
159 P-2
6DH2-3 159 P-4
6F9-3
159 P-2
6EJ 1-3 159 PA
6DH4-3 159 P-2
6DH4-3
159 P-O
6DH4-3 159 P-4
6DH4-3 159 PA
6F9-3 159 P-8
6DH4-3
159 P-2
6DH4-3 159 P-2
(TECHNICAL DATA LIST). PAGE 5