BOMBARDIER 1983 Install guide

SHOP
MANUAL
Bombardier
snowmobiles
. ,..
. \

Legal deposit:
National Library of Quebec
4th trimester 1982
National Library of Canada
All rights reserved.
No parts of this manual may be
reproduced in any form without the prior written
permission of Bombardier Inc.
©Bombardier Inc. 1982
Printed in Canada
® *Registered trademarks of Bombardier Inc.

SAFETY NOTICE
This manual has been prepared as a guide to correctly service and repair the Bombardier
snowmobiles.
This edition was primarily published
to be used by snowmobile mechanics who are al -
ready familiar
with all service procedures relating to Bombardier made snowmobiles.
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 parts catalogue.
The
content of Bombardier Inc. Recreational Product Shop Manual depicts parts and/or
procedures applicable to the particular product at its time of manufacture. It does not in-
clude dealer modifications,
whether authorized or not by Bombardier, after the products
manufacture.
In addition, the sole purpose of the illustrations/photographs throughout the manual, is
to assist identification of the general configuration of the parts. They are not to be inter-
preted
as technical drawings or exact replica's of the parts.
The use
of Bombardier parts is most strongly recommended when considering replace-
ment of any component. Dealer and/or distributor assistance should be sought in case
of doubt.
Torque wrench tightening specifications must be strictly adhered by. Locking devices
(ex.: tab lock, nylon lock)
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;
• ~ARNING: Identifies and instruction which, if not followed, could cause personal
Injury.
~
o 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 un-
derstanding
of the information will promote its correct use.
•
WARNING: This information relates to the preparation and use of Bombardier
snowmobiles and has been utilized safely and effectively
by Bombardier Inc.. How-
ever, 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.

1983 BOMBARDIER SNOWMOBILES
SHOP MANUAL
INTRODUCTION
This Shop Manual covers the following Bombardier made
1983 snowmobiles.
Elan
Citation 3500
Citation 4500/E
Citation SS
Nordik
Skandic 277/377
Everest 500/E
Everest LlC
Blizzard 5500 MX
Blizzard 9700
Alpine 503
Spirit
Mirage
II
Furthermore, each vehicle has its particular vehicle seri-
al number.
PAGE4
The engine also has a serial number.
Liquid cooled engines
Fan cooled engines
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 MANU AL
The manual is divided into ten (10) ma jor sections
01 Too ls
02 Engine
03 Transmission
04 El ectrical
05 Suspension
06 Steering and skis
07 Hood and frame
08 Fuel line, wi ring harness and cable routing
09 Technical data
10 Wa rranty
Each section
is comprised of various sub-sections, and
again, each sub-section has one or more division.
EX.: 02 ENGINE
04 Engine type 464 Everest
-Cooling system
-
Magneto
The use of " Right" and " L eft" indications in the text,
always refers to driving position (when sitting on vehi-
cle)
LEFT ...... f- --
-- 41.~ RIGHT
1983 BOM BARD I ER SNOWMOBILES
SHOP MAN UAL
GENERA L
The informat ion, illustrations and component/system
descriptions contained in this manual are correct at time
of publication. Bombardier Inc. however, maintains a
policy of contin uous improvement of its products with -
out imposing upon itself any obligation
to install them
on products previously manufactured.
Bombardier Inc. reserves the right at any time to discon-
tinue or change specifications, designs, features, mod -
els or equipment without incurring obligation.
ILLUSTRATIONS & PROCEDURES
An exploded vi ew is conveniently located at the beginn-
ing
of each section and is meant to ass ist the user in
identifying parts and components.
This Shop Manual uses technical terms
wh ich may be
sligthly different from the ones of the parts catalogue.
When ordering parts always·refer to the parts cata-
logue.
The il lustrations show the typ ical construct ion 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 wh ich have the same or a
similar funct ion.
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 thorough ly understand the entire section
or sub-section in
wh ich the procedure is contained.
A number
of procedures throughout the book require
the use
of special tools. Where a speci al tool is indi-
cated, refer
to section 01 . Before commencing any
procedure,
be sure that you have on hand all the tools
required, or approved equivalents.
This manual is published by the
Technical Publications
Bombardier Inc.
Valcourt, Quebec, Canada
PAGE5

SECTION
01
02
03
04
05
06
07
08
- 09
10
TOOLS
ENGINE
TRANSMISSION
ELECTRICAL
SUSPENSION
STEERING/SKIS
HOOD /F RAME
FUEL LINE, WIRING HARN ESS
AND CABLE ROUTING
TECHNICAL
DATA (GENERAL)
WARRANTY
TABLE OF CONTENTS
SUB-SECTION PAGE
01 -Basic tools 9
02 -Service tools 11
03 -Service products
19
01 - 247 Engine type
23
02 - 277 Engine type
33
03 -377 Engine type 47
04 -464 Engine type
63
05 - 503 Engine type 87
06 -534 Engine type 109
07 -Engine tolerances measurement
131
08 -Carburetor and fuel pump
135
09 -Air intake silencer and fuel tank 143
10 -Rewind starter 145
01 -Pulley guard 149
02 -Drive belt
151
.'
03 -Drive pulley
159
04 -Driven pulley
175
..
,
05 -Pulley alignment 185 i
06 -Brake 189
07 -Chaincase 195
08 -Gear box
20 1
09 -Drive chain 209
01 -Electric charts
213
02 - Ignition timing 223
03 -Spark plugs
231
04 -Battery 235
05 -Electric starter 239
06 -Testing procedure 245
01 -Bogie wheel
261
02 -Slide & MX suspension 265
03 -Rear axle
28 1
04 -Drive axle 283
05 -Track 289
01 -Steering system 293
02 -Ski system
30 1
01 -Hood 313
02 -Frame 315
317
319
329

o

A. Screwdriver
8. Socket 10/13
mm
C. Open end wrench 10/13 mm
D. Socket wrench handle
E.
F.
G.
H.
I.
Starter rope
Socket 17/21
mm
Suspension adjustment key
Extension bar
Emergencv starter clip
(Citation 3500 & 4500 E onlv)
J. Suspension adjustment key
K. Socket 21126 mm
E
H
1983 MODELS
Elan, Spirit
Citation, Mirage (All)
Nordik, Skandic
Blizzard 5500 MX
Blizzard 9700,
Everest 500, E. L/C ,
Alpine
F
SECTION 01 TOOLS
SUB-SECTION
01 (BASIC TOOLS)
BASIC TOOLS
A
c
B
°
()
G
K
J
APPLICABLE TOOLS
A, B, C, 0, E, K.
A, B, C, 0, E, I, K.
A, B, C, D, E, K.
A, B, C, D, E, G, J, K.
A, B, C, D, E, G, K.
A, B, C, D, E, F, G.
A, B, C, D, E, H, K.
PAGE9

)

ITEM
Dial indicator (T.O. C. gauge).
414 104700
Circuit tester (continuity light).
414012200
Bombardier ignition tester.
419003300
Drive pulley retainer.
529001700
Belt tension tester
414348200
iPSJ]
SECTION 01 TOOLS
SUB-SECTION 02 (SERVICE TOOLS)
SERVICE TOOLS
USE
Engine timing, to determine T.O.C.
Engine timing (static).
Continuity tests.
Engine electrical
components tests.
For indexation
of governor cup.
To adjust belt deflection
and tension to specification
APPLICABLE TO
All engine types.
All engine types.
All engine types.
Square shaft drive
pulley.
All engines
PAGEll

SECTION 01 TOOLS
SUB-SECTION 02 (SERVICE TOOLS)
Drive pulley puller.
5290021 00
860 4142 00 (metric)
- __ oJIo( ...._ .... «m .... m
I ,
(529003000) (529002800)
Magneto housing holder.
420976550
Seal sleeve
247 engines
PTO 420 977 910
MAG 420276900
Water pump seal sleeve
464,534
water pump 420 876 490
rotary valve 420 876 495
Rotary valve shaft pusher.
420876610
PAGE 12
To remove drive pulley from
crankshaft.
To avoid
seal damage during
crankshaft installation
Seal sleeve (on crankshaft)
Taper shaft engines.
Single cylinder engine
types.
All engines types except
277, 377, 503.
Liquid cooled Rotary
valve engines.

Puller assembly.
420876296
With 145 mm screw.
Screw M8 x 70 (2)
Screw M8 x 40 (2)
Crankshaft protector PTO
Crankshaft protector Mag
Distance ring
Puller ring
Half ring ass'y
Distance ring
Puller ring
Half ring ass'y
420841 200
420840680
420876550
420876555
420876560
420977 480
420276020
420876565
420876567
420977 490
420977 470
SECTION 01 TOOLS
SUB-SECTION 02 (SERVICE TOOLS)
engine 377, 464, 534, 503
engine 247, 277, 534, 464
engine 277, 377, 464, 503, 534
engine 277, 377, 503, 534
engine 377, 464, 503, 534
all engines
all engines
377, 503 engines only
534 engine only
engine
277, 377, 503, 534
engine 277, 377, 503, 534
All engine types.
PAGE 13

SECTION 01 TOOLS
SUB-SECTION 02 (
SE RVICE TOOLS)
Cylinder aligning tool.
377,503 engines
464 engine
534 engine
420876 1
71
420876575
420876570
-
r 377, 503 engines 420240275
Connecting rod holder.
420977 900
Degree wheel
414352900
Fan holder
503 engine
377 engine
PAGE 14
420876355
420876357
Connecting rod
To mark timing position
of rotary
va l ve
Cylinder
aligning
tool
Fan holder
Tw in cylinder engines
247 and 277 engi nes
464 and 534 engines
Twin cylinder
fan-cooled engi
nes

Protection cap.
247, 277 engines
18 mm 420 976 890
377, 464, 503
22 mm 420876402
Engine seal pusher
247 engine 420 977 920
277 engine 420 277 865
420876660
Seal pusher
420876510
I! ~
Bearing pusher
420876500
Rotary valve seal
pusher
420 876 600 - 534 engine
420876605 -464 engine
SECTION 01 TOOLS
SUB-SECTION 02 (SERVICE TOOLS)
Protect crankshaft end, when
using bearing puller.
Protection cap
,
WLII
To install water pump bearing
and seal.
To install rotary valve
shaft seal.
All engine types.
247, 277
engine types
464,534
engine types.
534, 464 engines.
PAGE 15

SECTION 01 TOOLS
SUB-SECTION 02 (SERVI
CE TOOLS)
Polyamid ring pusher
engine
277 MAG 420276930
PTO 420 276 940
Crankshaft feeler gauge.
377 & 503 engine
PTO 420 876 620
Crankshaft locking tool
420876640
Injection pump gear
holder
277, 377, 503
Engine 420 876 690
464 engine 420 277 900
PAGE 16
To install
polyamid ring
in crankcase.
To lock crankshaft
277 engine
PTO. all 377 & 503
engines
277, 377, 534, 464, 503
engines
A ll injection
engines.
)

Magneto puller ring.
420876655
°0
°eYO
~ 0
Magneto puller
247 engine 420976235
277,377,464, 503,
534 engines 420876065
a)~~I!m't )
3 speeds transmission
bearings extractor.
i 1 i
(
:.~-:
l2
@~
3
~" ~4
To remove magneto.
To remove magneto.
SECTION 01 TOOLS
SUB-SECTION 02 (SERVICE TOOLS)
277, 377, 464, 503
and 534 engines.
247,
277, 377, 464, 503
and 534 engines.
To remove the bearings from Alpine 3 speeds
the drive shaft and the transmission
lay shaft.
1- screw M8 x 25 (2)
420240275
2- plate
420977
700
3- half ring (2)
420876330
4- ring
420977
480
PAGE 17

SECTION 01 TOOLS
SUB-SECTION 02 (SERVICE TOOLS)
Transmission ball
mounting bolt.
420476020
( (3
Alignment tool
420476010
0:
Nippondenso electronic
ignition tester
419008400
Clip-O-Matic
529004500
PAGE 18
4
I
I
1
"--""'-'''''3
-6
7
- 2
Transmission cover index
rod ball installation
Drive shaft and
layshaft sprocket
alignment.
Engine ignition system
components tests.
For track inserts
installation.
1- screw 5/ 16 - 11 x 6"
529003900
2- pressure plate
529004400
3- washer (2)
391 302900
4- hexagonal screw (2)
1/2-20 x 6"
391 717200
5- bending block no. 1(wide cleats)
529004 100
bending block no. 2 (narrow cleats)
529004200
bending block no. 3 (Moto-Ski
529004300 cleats up to 1975)
6- male block
529004000
7- hexagonal nut (2)
389804000
Alpine 3 speeds
transmission
Alpine 3 speeds
transmission
-All Nippondenso
electronic ignition
systems
-(All engine types
except 247)
All types of track.

LOCTITE SEALANT KIT 413 7026 00
contains
PST Pipe Sealant
with Teflon (50 mU
413702300
Gasket Eliminator 515 (50 mU
413702700
Retaining Compound Rc/601 (10 mU
4137031 00
Threadlocker 242 (10 mU
413703000
Threadlocker 271 (10 mU
413702900
Super Bonder 495 (3-gram tube)
413703200
LOCK'N SEAL (242) BLUE
MEDIUM STRENGTH 24 ml
413702500
LOCK'N SEAL (27 1) RED
HIGH STRENGTH 6 ml
747020000
MOLYKOTE G-n paste
2.80z
413703700
SECTION 01 TOOLS
SUB-SECTION 03 (SERVI
CE PRODUCTS)
SERVICE PRODUCTS
For threadlocking, threadsealing,
gasketing, bonding and retaining
applications on engines, pulleys
and fasteners etc.
A medium-strength adhesive for
threadlocking and threadsealing.
Vibration-proofs nuts, bolts and
screws.
Hi-strength threadlocking
threadsealing adhesive for large
parts.
A balanced blend
of molybdenum
disulfide and other lubricating
solids to handle extreme pressure.
Reduces frictional force and
surface damage. Provides excellent
protection against fretting wear.
Temperature range from -100°F to
750°F (-73°C to 399°C).
General purpose, nuts,
bolts screws.
Magneto ring nut, crank-
case studs, etc.
Fasteners and studs
under
1" dia.
For rewind starter
locking spring. (Not
to be used on rewind
springs as it does
not stay on when
dried.)
PAGE 19

SECTION 01 TOOLS
SUB-SECTION 03 (
SER VI CE PRODUCTS)
G.E. VERSILUBE G341 M
80z
413704000
PRIMER CRANKCASE SEALANT
(SPRAY) 60z
413702400
CHISEL gasket remover
(spray) 300 g
413704500
ANTISEI ZE
LUBRICANT
413701000
i
.. /.", ... .
~ 410 11 llllE
IUM K AHf
,
.
SILICONE DIELECTRIC GREASE
3 oz.
413701700
GREASE TUBE LMZ No 1
400 g
4980281 00
PAGE 20
This General Electric silicone
lubricant
is highly resistant
to oxidation, shear and heat
decomposition -and will pro-
vide excellent lubrication over
long intervals of no maintenance
under such conditions. Lubricates
under temperatures from -73°C to
204°C (-100°F to 400°F).
Very fast cure primer. Primer NF
provides fixturing
in only 15-30
seconds with full 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.
Creates a foaming action that
lifts gaskets off in minutes.
Protects moving and stationary
parts against high temperature
seizing. Prevents rust and corro-
sion
on parts exposed to high heat.
Speci al dielectric grease that pre-
vents moisture and corrosion
build-up in electric connections.
Multi purpose Lithium based
grease containing zinc monoxide
which makes it a good conductor
for heat & electri city .
Used to lubricate
manual starter rewind
spring. (Not to be used
on rewind starter locking
spring as the vibration
makes
it run out).
Mainly used when assem-
bl ing engine crankcase.
Mainly used to remove
gasket residues from
any metal surface.
Unpainted surfaces
of
drive pulley countershaft.
On all electric connec-
tions. High tension coil.
Spark plug connections.
Connector housings, etc.
Mainly used between
regulators or recti-
fiers and upper co-
lumn to transfer the
hea t build-up and to
assure a good ground.