BOMBARDIER 1980 User manual

SAFETY NOTICE
The Bombardier snowmobile Shop manual supplement has been prepared in order to as-
sist skill ed mechanic's in the efficient repair and maintenance of Bombardier snowmo-
biles.
Safe ty 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.
Never run engine in a
close~ area. Exhaust fumes contain poisonous'carbon monoxide.
Always wear protective clothing (h elmet, goggl es, boots etc...) when riding vehicle,
even for brief periods. '
This manual emphasizes particular information denoted by the wording and symbols;
•
~A RNING: Identifies and instruction which, if n ot followed, could cause personal
Injury. .
_ CAUTION: Denotes an instruction which, if not followed, could,severely damage
.. vehic le components. .
oNOTE: Indicates supplementary information need ed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your un-
derstanding
of the information will promote its correct us e.
@ *Trademarks of Bombardier Limitee
All rights reserved © Bombardier Limitee Litho'd in Canada
(1981 SUPPLEMENT)

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ONOTE: This supplement manual relates to
new
features and information applicable to 1981 models
and therefore not covered in the 1980 Bombardier
Snowmobile Shop Manual. Information that applies to
both
1980 and 1981 models is contained in the 1980
Bombardier Shop Manual and not repeated in the 1981
Supplement. It is necessary that both the 1981 Shop
Manual Supplement and the 1980 Bombardier Snow-
mobile Shop Manual be used for complete reference on
servicing the
1981 models.
ARRANGEME NT OF THE MANUAL
The manual is divided into 9 major 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 composed of various sub-sections, and
yet again, although
not in dicated in 'the table of con-
tent, each sub-section has one or more divisions.
(1981 SUPP LEM ENT )
INTRODUCTION
ILLUSTRATIONS & PROCEDURES
An exploded view is conveniently located at the beginn-
ing
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 repro-
duce 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 adjustment,...
etc.), the specific parts are circled and referred to
in the
text.
As many
of the procedures in this manual are interre-
lated, 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 indi-
cated, refer to section
01 . Before beginning any proce-
dure,
be sure that you have on hand all the tools re-
quired, or approved equivalents.
The use of "Right" and "Left" indications in the text,
always refers to driving position (when sitting on vehi-
cle) .
LEFT ~
~ RIGHT
(INTRODUCTION), PAGE 1

MODEL IDENTIFICATION
This shop manual covers the following Bombardier
made
1981 snowmobiles:
Elan -Spirit
Citation 3500 -Mirage I
Citation 4500/E -
Mir age IIIE
Nordik
Citation SS -Mirage Special
Everest 500/500E -Futura 500/500E
Eve r es t LIC -Futura LlC
Blizzard 5500 -Grand Prix Special
Blizzard
MX - Grand Prix MX
Blizzard 7500 -Super Sonic
Blizzard 9500 -Ultra Sonic
Alpine 640
Elite
Furthermore, each vehicle has its particular vehicle seri-
al number.
(INTRODUCTION ), PAGE 2
The engine also has a serial number.
ENGINE
SERIAL
NUMBER
Liquid cooled engin
es
ENGINE
SERIAL
NUMBER
Fan cooled engines
GENERAL
The information, illustrations and component/system
descriptions contained in this manual are correct at time
of publication. Bombardier Limitee, however, maintains
a policy
of continuous improvement of its products
without imposing upon itself any obligation to install
them on products previously manufactured.
Bombardier Limitee reserves the right at any time to dis-
continue or change specifications, designs, features,
mode ls or equipment without incurring obligation.
This manual is published by the
Technical Publications
Bombardier Limitee
Valcourt. Quebec, Canada
(1981 SUPPLEMENT)
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1981 SHOP MANUAL SUPPLEMENT
SECTION
TABLE OF CONTENTS
SUB-SECTION
01
TOOLS
02 TECH
NI CAL D ATA
03
ENGINE
01 -Engine tolerance measurements
02 -Engines
03 -Ignition timing
04 -Carburetor and fuel pump
05 -Air intake silencer, fuel tank, throttle cable
06 -Rewind starter
04
ELECTRICAL
01 -Electric charts
02 -Tests procedure
03 - El ectric starter
04 -Battery
05 -Alternator and regulator
06 -Spark plugs
05
TRANSM ISSION
01 -Pulley guard
02 -Drive belt
03 -Drive pulley
04 -Driven pulley
05 -Pulley alignment
06 -Brake
07 -Chaincase
08 -Gearbox and shifter mechanism
09 -Drive chain
06
SUSPENSION
01 -Bogie wheel
02 -Slide suspension, MX suspension
03 - Rear axle
04 -Drive axle
05 -Track
07 STEERING / SKI
01 -Steering system
02 -Ski system
08 HOOD AND FRAME
01 -Hood
02 -Frame
09 WARRA NTY

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For the following 1981 models:
Elan -Spirit
Citation 3500 -Mirage I
Citation
4500 / E-Mirage II/E
Citation SS -Mirage Special
Everest 500/E -Futura 500/E
Everest LC -Futura LC
Blizzard MX -Grand Prix MX
B li zza rd 5500 -Grand Prix Special
B
li zza rd 7500 -Super Sonic
Blizzard 9500 -Ultra Sonic
Elite
Alpine 640
ER
Nordik
SECTION 01
(TOOLS)
TOOLS
refer to the 1980 Bombardier Snowmobiles Shop Manual- section 01 (Tools)
For the following 1981 models:
Everest LC -Futura LC
Blizzard 7500 -Super Sonic
B
li zzard 9500 -Ultra Sonic
Elite
refer to this section for MAGNETO PULLER
For crankshaft fixation bolt, refer
to this section.
For suspension Uadjuster wrench"
on Blizzard MX and Grand Prix MX, refer to
this section.
(1981 SUPPLEMENT) (TOOLS), PAGE 1

SECTION 01
(TOOLS)
------------------ ---------------------------------------- ~ ~ ~
-The NIPPONDENSO magneto on models:
Everest LC -Futura LC
Blizzard 7500 -Super Sonic
Blizzard 9500 -Ultra Sonic
Elite
may be extracted using the following tool with four (4)
Allen screw M6 x 25 (PIN 420840860).
Puller ring
(P IN 420 876 6551
-The crankshaft on models:
Citation 3500 -Mirage I
Citation 4500 / E-Mirage II/E
Citati on SS -Mirage Special
Everest 500/E -Futura 500/E
Everest LC -Futura LC
Blizzard MX -Grand P rix MX
Blizzard 5500 -Gra nd Pr ix Special
B
li zza rd 7500 -Super Sonic
B
li zzard 9500 -Ultra Sonic
Elite
Nordik
(TOo.LS), PAGE 2
may be locked using the following tool:
(J
Crankshaft locking tool
(PIN 4208766401
-The front and r ea r spring suspension on models:
Blizzard MX -Grand Prix MX
may be adjusted using the following tool:
Adjuster wrench
(PIN 5290038001
(1 981 SUPPLEMENTI
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SECTION 02
TECHNICAL DATA LIST (PAGE)
TOLERANCE AND WEAR LIMIT -ENGINES 2
IGNITION TIMING SPECIFICATIONS 3
CARBURETOR SPECIFICATIONS 4-5
IGNITION GENERATING COIL, LIGHTING COIL, HIGH TENSION 6
COIL, RESISTANCE CHART
BOMBARDIER IGNITION TESTER DIAL POSITIONS 7
BOSCH SPARK PLUG CHART 8
VEHICLE MODEL/DR IVE BELT NUMBER 9
DRIVE PULLEY SPECIFICATIONS 10
DRIVEN PULLEY SPRING TENSION 11
PULLEY ALIGNMENT SPECIFICATIONS 12
SPROCKET AND CHAIN SPECIFICATIONS 13
TRACK TENSION SPECIFICATIONS (BOGIE WHEEL 14
SUSPENSION)
TRACK TENSION SPECIFICATIONS (SLIDE SUSPENSION) 14
TRACK SPECIFICATIONS 15
STEERING SYSTEM TORQUE SPECIFICATIONS 16
SKI SYSTEM TORQUE SPECIFICATIONS 17
GENERAL INFORMATION 18
METRIC INFORMATION CHART 19
(1981 SUPPLEMENT) (TECHNICAL
DATA LIST). PAGE 1

SECTION 02
SUB-SECTION 03-01, (ENGINE TOLERANCE MEASUREME
NT S)
TOLERANCE AND WEAR LIMIT - 1981 ENGINES
ENGINE CYLINDER BORE PISTON TO
WALL
MAXIMUM RING
CRANKSHAFT
TYPE (NOMINAL) CLEARANCE END CAP END PLAY
STD OVERSIZE
MIN.
MAX.
MIN . MAX .
247
69.50 mm
N.A . 0.065-0.200
mm 0. 20 -1.0 mm
0.20-0.40 mm
(27362")
( 0026-.008") (008-.039") (008-.016")
277
72.00 mm
72 . 25 mm
0.070-0.200 mm 0 .2 0-1.0 mm 0.20-0.40 mm
(2.8346")
(28445")
(.003-.008" ) (008-.039") (008-.016")
354
59 . 50 mm 59.75 mm 0.080-0.180 mm
0.15-1.0 mm
N.A.
(2.3425") (2.3524") (0031-.001" ) (006 -0.039")
377
62.00 mm
62 .2 5 mm
0.070-0.200 mm 0.20-1.0 mm
N.A.
(2.4409") (2.4508") (0028-.008") (008-0.039")
454
67.50 mm 67.75 mm
o 10-0 .2 0 mm 0.20-1.0 mm
N.A.
(2.6575") (2.6673") (004-.008")
(008- .039")
464
69.50 mm 69 . 75 mm
0.070-0.200 mm 0.20-1.0 mm
N.A.
(2.7362") (2.7461") (.0028-.008" ) (008-.039")
503
72.00 mm
72.25 mm
0.060-0.200 mm 0.20-1.0 mm
N.A.
(2.8346") (2.8445") (0024-.008") (.008-.039")
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") (0028-.009")
(010 -0.16") (008 -.016")
N. A.: not applicable
(TECHNICAL DATA LIST), PAGE2 (19
81 SU PP LEMENT)