BOMBARDIER ELAN 3042 1985 Install guide

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Servic8
Legal deposit:
National Library of Quebec
4th trimester 1 984
National Library of Canada
All rights reserved. No parts of this manual may be
reproduced in any form without the prior written per-
mission of Bombardier Inc.
"'Bombardier Inc.
1984
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
already familiar
with all service procedures relating to Bombardier made snowmobiles.
Please note that the instructions will apply only if proper hand tools and special ser-
vice
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
include dealer modifications, whether authorized or not by Bombardier, after manufac-
turing the product.
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 interpreted as technical drawings or exact replicas 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 devi-
ces (ex.:
tab lock, nylon lock) must be installed or replaced by new ones, where spe-
cified. 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.
T
0
CAUTION: Denotes an instruction which, if not followed, could severely damage
vehicle
components.
NOTE: Indicates supplementary information needed to fully complete an instruc-
tion.
Although the mere reading of such information does not eliminate the hazard, your
understanding 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 ..
However, 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 unders-
tood that certain modifications may render use of the vehicle illegal under existing
federal, provincial and state regulations .
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Ill

1985 BOMBARDIER SNOWMOBILES
SHOP MANUAL
INTRODUCTION
This Sh op Manual covers the following Bombardier made
1985 snowmob i le s
MODELS MODEL NUMBER
ELAN 3042
CITATION
LS
3206
CITATION LSE 3207
TUNDRA
3208
TUNDRA LT 3209
SKANDIC 377
3198
SKANDIC
377 R
3199
SAFARI 377 3609
SAFARI 377 E
3610
SAFARI 447
3611
SAFARI GRAND LUXE
LC 3612
FORMULA SS
3613
FORMULASP
3614
FORMULA MX
3720
FORMULA PLUS 3721
ALPINE
503
3341
MIRAGE Ill
5147
Furthermore, each vehicle has its particular veh1cle s er i-
al n umb er.
Serial number:
0000
model number
A00000000 1
The eng1ne a ls o ha s a serial number.
IV
00001
vehicule serial
number
Liquid cooled engines
A 00000 20 17
Fan coo led engines
A000002018
DEFINITION OF NUMBERING SYSTEMS
Sections and sub-sections system
The manual makes u ses of a 2-part dig1t al num bering
system
(i e 01 - 01 l, in which the first digit represents
the section, the second digit the s
ub - se ction.
01-01
/~
Section Sub-section

------------- - ----- -- - ·-·-·-- --- -- - --- -
~
Pages system
The numerotation at the bottom of each page assists the
user
in page location.
01-01-01
/!~
Section Sub-section Page
ARRANGEMENT OF THE MANUAL
The manual IS d1vided into ten (10) major sections
01
Tools
02 Engine
03 Transmission
04
Electrical
05 Suspension
06
Steering and skis
07 Hood and frame
08 Fuel line, wiring harness and cable routing
09 Technical data
10 Warranty
Each section is div1ded in various sub-sections, and again,
each sub-section has one or more division.
EX.: 02 ENGINE
04 Engine type 44 7
- Cooling system
-Magneto
The use of "Right" and "Left" indications in the text,
always refers to driving position (when sitting on veh1clel
---,
1985 BOMBARDIER SNOWMOBILES
SHOP MANUAL
LEFT----
---il.,_._ RIGHT
4000000002
GENERAL
The information, illustrations and c omponent /system
descriptions contained
in this manual are correct at time
of publication. Bombardier Inc. however, maintains a
policy of continuous 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 view is conveniently located at the beginn-
ing of each section and
is meant to assist the user in iden-
tifying parts and components.
This Shop Manual uses technical terms
which may be
sligthly different from the ones of the parts catalogue.
When ordering parts always refer to the parts catalogue.
The illustrations
show the typical construction of the dif-
ferent assemblies and. in all cases. may
not reproduce
the full detail or exact shape of the parts s
hown, howe-
ver, they represent parts which have the same or a similar
function.
When something spec1al applies (such as adjust-
ment,etc.), bold numbers are used for specific parts and
referred to in the text.
v
' - j

1985 BOMBARDIER SNOWMOBILES
SHOP MANUAL
Pay attent1on to torque specifications. Some of these are
1n lbf•in instead of lbf•ft
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 sec-
tion
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 tool1s indicated, refer
to
sect1on 01. Before commencing any procedure, be sure
that you have on hand all the tools required, or approved
equivalents.
VI
This manual is published by the
Technical Publications
Bombardier Inc.
Valcourt, Quebec, Canada

TABLE OF CONTENTS
SECTION SUB-SECTION PAGE
01 TOOLS
01 -Basic tools 01-01-1
02 -Service tools
01 -02-1
03 -Serv1ce products
01-03-1
02
ENGINE
01 -247 Engine type
02-01-1
02 -253 Engine type 02-02-1
03 -377 Engine type
02-03-1
04 - 447 Engine type
02-04-1
05 - 462 Eng1n e typ e 02-05-1
06 - 467 Engine type 02-06-1
07 - 503 Engine typ e 02-07-1
08 -532 Engine type 02-08-1
09 -537 Engine type 02-09-1
10 - Eng1ne dimensions measurement
02-10-1
11 -Carburetor and fuel pump
02-11-1
12 -Air intake silencer and fuel tank 02-12-1
13 -Rewind starter 02-13-1
03
TRANSMISSION
01 -Pulley guard
03-01-1
02 -Drive belt 03-02-1
03 -Drive pulley 03-03-1
04 -Driven pulley
03 -04-1
05 -Pulley a lignment
03-05-1
06 -Brake 03-06-1
07 -Chaincase 03-07-1
08 -Gearbox 03-08-1
09 -Drive cha1n
03-09-1
04
'•
ELECTRICAL 01 -Electric c hart s 04-01 -1
02 -Ignition t1ming 04-02-1
03 -Spark plugs 04-03-1
04- Battery
04 .- 04 -1
05 -Electric starter
04 -05-1
06 -Testing proce dur e 04-06-1
05 SUSPENSION 01 -Bogie wheel 05-0
1-1
02 -Slide suspension 05-02-1
03 - TRS 6 suspens1on 05-03-1
04 -MX suspension 05-04-1
05 - PRS suspension 05-05-1
06 -Rear ax le
05-06-1
07 -Drive axle 05-07-1
08 -Track
05 -08-1
06 STEERING/SKIS 01 -Steering system 06-01-1
02 -Ski system 06-02-1
07 HOOD/FRAME 01 -Hood 07-01-1
02- Frame 07-02-1
08
FUEL LINE, WIRING HARNESS 08-00-1
AND CABLE ROUTING
09
TECHNICAL DATA !GENERALI 09-00-1
e
10 WARRANTY 10-00-1
VII
~----__:__ -~-- ------ ~ -- -- --·· - - ·- -
-- ___J

,.----- --
e
A. Screwdriver
B. Sockel 70173 mm
S1ar1er rope
Socket
wrench handle
c
D.
E
F.
G.
H
I
J
K
L.
M
N
Open end wrench I0173 mm
Angular wrench 70173 mm
Starter gnp
Socket 2 71 26 mm (l ong /
Extension bar
Suspension adjustment key
Extension
sockel
Suspension adjustment key
Socket 11113 mm
Socket 27 ! 26 mm (s hort )
H
E
lrt G
K
~
(
A001001016
1985 MODELS
Elan
C1 tat1on LS /E
Tu ndra/LT, Skandic 377/R
Safari 377/E,
447, Mirage Ill
Safan GL, Formula
SS
Formula SP
Formula MX, Plus
Alpine
,_
L
Section 01 TOOLS
Sub-section 01 (BASIC TOOLS}
BASIC TOOLS
A
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c
B
0 eL
D
J
N
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M
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APPLICABLE TOOLS
A, B. C, D, F, H.
A, B. C. D, E. G. H.
A, B,
C, 0, E, G, H, J.
A, B. C, D. E. G. H, J.
A, B, C. D, E, G, J, N.
A, B, C, 0, E. G. J, L, N.
A, B. C, D. E, H.
A, B. C, D, E. H. I, K, M.
01 -01 -1
,

- ~~ - - -------'

ITEM
Dial indicator (T D.C. gaugel
414 1047 00
A000002001
Circuit tester (continuity lightl
414 0122 00
A 000002003
Bombardier ignition tester
419 0033 00
A000004004
Drive pulley re tamer
529 0017 00
A000002005
Be lt tension t es ter
414
3482 00
A000002007
•:JJD
Section 01 TOOLS
Sub-section 02 (SERVICE TOOLS)
SERVICE TOOLS
USE
Engine timing, to determtne T D.C
4000001001
Engine timing (static)
Continuity tests
Engine electrical components tests
For indexat1on of governor cup
A000002006
To adjust belt deflection and
tens1on to specifications
APPLICABLE TO
All engine types
All engine types
All engine types
Square shaft drive
pulley
Ail models
01 -02-1

Section 01 TOOLS
Sub-section 02 (SERVICE TOOLS)
Drive pulley puller
529 0021 00
A000002008
860 414 2 00 (metric)
--:;---oc 11!1(0
i '
1529 003 0001 1 529 002 800 )
A000002009
Magneto housing holder
420 976 550
A00000201 1
Seal sleeve
247 engines
PTO 420 977 910
MAG 420 276 900
Water pump seal sleeve
462, 46 7, 532, 537
wate r pump 420 876 490
rotary valve 420 876 495
A000002013
Rotary valve shaft pusher
420876610
01-02-2
To remove drive pull ey from
crankshaft
A000002010
A.()(X)001011
To avoid seal damage during
crankshaft installation
~
1
1 . 1. ~p . ~ -.·:.
l! il! I
W I
Seal sleeve ion crankshaft!
A000002014
A000002016
Taper shaft engines
247 eng1ne type
All engine t yp es
except 253, 377 ,
447 & 503
L1quid cooled rotary
valve engines

~-
e
l"
Puller assembly
420 876 296
With 145 mm screw
~
~
accessories
~
@]
g
~~
A000002017
A0000020t8
Section 01 TOOLS
Sub-section 02 (SERVICE TOOLS)
All engine types
•
01-02-3

Section 01 TOOLS
Sub-section 02 (SERVICE TOOLS)
PULLER ASSEMBLY APPLICABLE TO ENGINE TYPES
P/N
COMPONENT 247 253 377 447 462 467
503
532 537
Scre..v M 16 x ~ .45 420 940 755 X X X X X X X X X
PULLER ASSEMBLY P/N
ACCESSORIES
Screw M8 x 70 121 420 841 200 X X X X X X X X
Screw M8 x 40 12 1 420 840 680
X X X X X
Crankshaft proteciOr PTO 420 876 550
X X X X X X X X
Crankshaft protec iOr MAG 420 876 557 X X X X
Crank sraft :xotecto r MAG 420 876 555 X X X
Distance ring
420 876 560 X X X X X X X X
01stance ring 420 876 565 X X X
Distance ricg
420 876 567 X X X
Puller ring
420 977 480 X X X X X X X X X
Puller ring 420 977 490
X X X X X X
Half ring ass'y· 420 276 020 X X X X X X X X X
Half nng ass'y 420 977 470
X X X X X X
01-02-4

Cy li nder aligning tools
377.44 7,503 engines
462 engine
467,532,537 engines
A0000020 19
377.503 engines
A 00000 2020
Connecting rod holder
420 977 900
A. 00000 202 3
Degree wheel
414 352 900
A00000 2 025
420 876 171
420 876 175
420 876 570
•
420 240 275
Section 01 TOOLS
Sub-section 02 (SERVICE TOOLS)
A000002 0 11
Cylinder aligning
tools
A00000 4 042
A000002014
Connect1ng rod
To mark timing pos tt1on of
rotary valve
Twin cylinder engines
247 e ng1n e
462 , 467, 532 & 537
engmes
01 - 02 -5

Section 01 TOOLS
Sub-section 02 (SERVICE TOOLS)
Fan holder
503 engine
253, 377 & 447
engines
6.000002026
Protect io n cap
247 engine
18 mm
420 976 890
377, 447 , 462, 503
22 mm 420 876 402
A000002028
Eng ine seal pusher
420 977 920
A0000020J1
Seal pusher
420 876 510
Bearing pusher
420 876 500
A000002 033
01 - 02-6
420 876 355
420 876 357
Fan holder
Protect crankshaft end, when
using bearing puller
Protect•o[Oc
A000002029
AO<X)QQ20JO
Seal pusher
Crankcase half
A0000020J2
To install water pump bearing
and seal
Axial fan cooled
engine types
247 , 377, 447 , 462 &
503 engine types
247 engtne type
462, 467, 532 & 537
engine types

Rotary valve seal pusher
420 876 605
A000002 0 34
Polyamid ring pusher
420 276 930
A0000020 3S
Crankshaft feeler gauge
377, 447 & 503 engines
420 876 620
A$000002037
Crankshaft locking tool
420 876 640
A000002039
Section 01 TOOLS
Sub-section 02 (SERVICE TOOLS)
To install rotary valve shaft
seal
To install
polyamid ring
in crankcase
A0000020J6
On PTO side
A000002038
To lock crankshaft
462, 467, 532 and
537 engine types
247 engine
PTO . 377, 447 & 503
engines
253, 377, 447, 462.
467.
503, 532 & 537
engines
01-02-7

Section 01 TOOLS
Sub-section 02 (SERVICE TOOLS)
Injection pump gear holder
253, 377, 447 & 503 engines
420 876 690
A000002041
J
( \
i
'-.____ __ /
462 , 467, 532 & 537 engines
42 0 277 900
A000002042
M ag neto puller rtng
All engine types except 247
420
876 080
A000002044
Magneto puller
247 engine
253,377.447.462
46 7 ,503 , 532,537
eng in es
A. OCOOOl C46
01-02-8
4 20 976 235
420 876 065
A000001043
To remove magneto
All injection engines
All engine types
except
247
All engine typ es
-I
_ _ __ ___ _j