BOMBARDIER Skandic 377 IR Install guide

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BOl11bardier
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1984
SHOP
MANUAL
snovvmobiles
Bombardier

Legal deposit:
National Library of Quebec
4th trimester 1 983
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 . 1983
Printed in Canada
@* Registered trademarks of Bombardier In c.
1 1

c
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 too ls 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 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 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 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: Id entifies and instruction which, if not followed, could cause personal
Injury.
_ CAUTION: Denotes
an instruction which, if not followed, could severe ly damage
... vehicle components.
O
~OTE : Indicates supplementary information needed to fully complete an instruc-
tion.
Although the mere reading of such information does not eliminate the hazard, your
unde rstanding 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 understood
that certain modifications may render use of the vehicle illegal under existing federal,
provincial and state regulations.
'"

1984 BOMBARDIER SNOWMOBILES
SHOP MANUAL
INTRODUCTION
This Shop Manual covers the following Bombardier made
1984 snowmobi le s.
Elan
Citation
3500
Skandic 377 IR
Safari 377 IE
Safari 447
Safari Grand Luxe
S5 - 25
Blizzard 5500 MX
Blizzard 9700
Alpine 503
Sonic LlC
Furthermore, each vehicle has its particular vehicle seri-
al number.
IV
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 dig
it 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 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 divided in various sub-sections, and
again, each sub-section has one or more division.
EX.: 02 ENGINE
04 Engine type 447
- Cooling system
- Magneto
The use of "Right" and" Left" indications in the text,
always refers to driving pos ition (when sitting on vehicle).
1\
§8l
LEFT ..... 1----
---l~~ RIGHT
1984 BOMBARDIER SNOWMOBILES
SHOP
MANUAL
GENERAL
The information, illustrations and components/system
descriptions contained in this manual
are correct at time
of publication. Bombardier Inc. however, maintains a
policy of continuous improvement of its products wi th-
out imposing upon itself an y obligation to install them
on products previously manufactured.
Bombardi
er Inc. reserves the right at an y 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 typi ca l construction of the dif -
ferent assemblies and, in a
ll 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 adjustment,...
etc. ), bold numbers are used for specific parts and refer-
red 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 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 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.
This manual is published by the
Technical Publications
Bombardier Inc.
Valcourt, Quebec, Canada
v

.J
J)

S ECTION
01
02
03
04
05
06
01
08
09
10
TOOLS
EN GINE
TRANS
MI SS ION
ELE CTRICAL
SUSP
EN SION
STEERING/SKIS
HOOD/FRAM E
FU EL LINE, WIR IN G HARN ESS
AND CAB LE RO UTING
T
EC HNICAL DATA ( GE N ER Al)
WA RR ANTY
TA BLE OF CONTENTS
SUB-SEC TI ON
PA GE
01 - Basic tools 1
02 - Service tools 3
03 -Service products 13
01 - 247 Engine type 17
02 - 277 Engine type
29
03 - 377 Engine type
45
04 - 447 Engine type 65
05 - 462 Engine type 83
-
06 - 5 03 Engine type 109
07 - 534 Engine type 129
08 -Engine dimensions measurement
149
09 -Carburetor and fuel pump 155
10 -Air intake silencer and fuel tank
165
11 -Rewind starter 181
01 -Pulley guard 185
02 -Drive belt
187
03 -Drive pulley 197
04 -Driven pulley
215
05 - Pulley alignment 235
06 -Brake 239
07 -Chaincase 251
08 - Gear box 263
09 - Drive chain 275
01 - Electric charts
279
02 -Ignition timing 2 89
03 -Spark pl ugs 297
04 - Battery
305
05 -Electric starter 309
06 -Testing procedure
315
01 - Bogie wheel 331
02 - Slide, MX & TRS -6 suspension 335
03 -Rear axle 355
04 - Drive axle 359
05 - Track 367
01 - Steering system 371
02 - S ki system 381
01 -Hood 393
02 - Frame
399
401
403
413
VII

A. Screwdriver
B. Socket 10113 mm
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
N.
O.
Starter rope
Socket wrench handle
Open end wrench 10173 mm
Angular wrench 70173 mm
Starter grip
E
Socket 27126 mm (long)
Extension socket
Suspension adjustment key
Extension
bar
Emergency starter clip
Suspension adjustment key
Socket 11173 mm
Socket 21126 mm (short)
H
F G
K
~
L
1984 MODELS
Elan
Citation
Skandic, Skandic "R"
Safari 377IE, 447, Grand Luxe
Sonic LlC,
SS - 25
Blizzard 5500 MX
Blizzard 9700
Alpine
SECTION 01 TOOLS
SUB-SECTION 01 (BASIC TOOLS)
BASIC TOOLS
c
B
0_
D
()
J
o
N
r----..M 1': fi)
( ~
o
APPLICABLE TOOLS
A, B, C, D, F, H.
A,
B, C, D, E, G, H, J, L.
A, B, C, D, E, G, H, J, L.
A, B, C, D, E, G, H, J.
A, B, C, D, E, G, J, o.
A, B, C, D, E, H, J, M.
A,
B, C, D, E, J, O.
A, B, C, D, E, H, I, K, N.
PAGE 1

.-..,

ITEM
Dial indicator (T.D.C. gauge).
414 1047 00
Circuit tester (continuity light!.
414012200
Bombardier ignition tester.
419 0033 00
Drive pulley retainer.
529 0017 00
Be lt tension tester
414 3482 00
( I I ie::sD
SECTION 01 TOOLS
SUB-SECTION
02 (SERVICE TOOLS)
SERV ICE TOOLS
U SE
Engine timing, to determine T.D .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
PAGE 3

SECTION 01 TOOLS
SUB-SECTION 02 (SERVICE TOOLS)
Drive pulley pull er
529 0021 00
860 4142 00 (metric)
_~ __ O( u[lD
I -.....,
(529 003 000) (529 002 800 )
Magneto housing holder.
420 976 550
(
Seal sleeve
247 engines
PTO 420 977 910
MAG 420 276 900
Water pump sea l slee ve
462, 534
water pump 420 876 490
rotary valve 420 876 495
Rotary valve shaft pusher.
420876 610
PAGE 4
To remove drive pulley from
crankshaft.
To avoid
sea l damage during
crankshaft installation
Sea l sl ee ve (o n crankshaft)
Taper shaft engines.
Single cylinder engine
ty
pes .
All engines types e xc ept
277, 377 , 447 , 503
Liquid cooled Rotary
valve engines.

Pu ll er assembly.
420 876 296
With 145 mm screw.
PULLER COMPONENTS
Sc rew 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
Distance ring
Puller ring
Half ring ass'y
Puller assembly
247 277
420841 200
420840680 x x
420876 550
x
420876 555 x
420876 560
420977 480
x x
420276020 x x
420876 565
420876 567
420977 490 x
420977 470 x
420876 296 x x
SECTION 01 TOOLS
SUB-SECTION
02 (S ER VICE TOOLS)
All engine types.
ENG IN E TYPES
377 447 462 503 534
x x x x x
x x
x x x x x
x x x x
x x x x x
x x x x x
x x x x x
x x x
x
x x x x
x x x x
x x x x x
PAGE 5

SECTION 01 TOOLS
SUB-SECTION 02 (SERVICE TOOLS)
Cylinder aligning tool.
377, 447, 503 engines
462 engine
534 engine
420876171
420 876 175
420 876 570
-
i 377, 503 engines 420 240 275
Connecting rod holder.
420 977 900
Degree wheel
414 352 900
Fan holder
503 engine
377, 447 engines
PAGE 6
420 876 355
420 876 357
Connecting rod
To mark timing position
of rotary valve
Cylinder
a li gning
tool
" __ l....- Fan holder
Twin cylinder engines
247 and
277 engines
462 and
534 engines
Twin cylinder
fan-cooled engines
r
r

-
Protection cap.
247, 277 engines
18 mm
420 976 890
377, 447 , 462, 503
22 mm 420 876 402
Engine seal pusher
247 engine 420 977 920
277 engine 420 277 865
420 876 660
Seal pusher
420876 510
Bearing pusher
420 876 500
Rotary valve seal
pusher
420 876 600 - 534 engine
420 876 605 - 462 engine
SECTION 01 TOOLS
SUB-SECTION
02 (SERVICE TOOLS)
Protect crankshaft end, when
using bearing puller.
Protection cap
drll
Sea l pusher
To install water pump bearing
and seal.
To install rotary valve
shaft
sea l.
Al l engine types.
247, 277
engine ty
pes
462 , 534
eng i ne types.
462, 534 engines.
PAGE 7

SECTION 01 TOOLS
SUB - SECTION 02 (SERVICE TOOLS)
Polyamid ring pusher
engine
277 MAG 420 276 930
PTO 420 276 940
Crankshaft feeler gauge.
377, 447 & 503 engines
PTO 420 876 620
Crankshaft locking tool
420 876 640
Injection pump gear
holder
277, 377, 447, 503 Engine
420 876 690
462 engine 420 277 900
6 '
PAGE 8
To install
polyamid ring
in crankcase.
To lock crankshaft
277 engine
PTO: all 377, 447 & 503
engines
277,377,447,462
503, 534 engines
All injection
engines.
I

Magneto puller ring.
462 engine with 140W (4- 4P)
magneto 420 876 655
277, 377, 447, 462, 503, 534
engines
420 876 080
Magneto puller.
247 engine 420 976 235
277, 377, 447, 420 876 065
462, 503, 534 engines
a)jjjllil!Dlj~
3 speeds transmission
bearings extractor
i 1 i
I :-..a-:
@j~
] 2
3
~4
To remove magneto
To remove magneto.
SECTION 01 TOOLS
S
UB -SECTION 02 (S ER VICE TOOLS)
277,377,447,462,
503 and 534 engines
247 , 277, 377, 447, 462,
503 and 534 engines
To remove the bearings from
the drive shaft and the Alpine 3 speeds
transmission
lay shaft.
1- screw M8 x 25 (2)
420 240 275
2- plate
420 977 700
3- half ring (2)
420876 330
4- ring
420 977 480
PAGE 9

SECTION 01 TOOLS
SUB - SECTION 02 (SERVICE TOOLS)
Transmission ball
mounting bolt.
420 476 020
( /7
Alignment tool
420 4760 10
Nippondenso electronic
ignition tester
419 008 400
Clip-O-Matic
529 004 500
4
I
PAGE 10
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"
529 003 900
2- pressure plate
529 004 400
3- washer (2)
391
302 900
4- hexagonal screw (2)
1/2-20 x 6"
391 717 200
5- bending block no. 1(wide cleats)
529 004 100
bending block no. 2 (narrow
529 004 200 cleats)
bending block no. 3 (Moto-Ski
529 004 300 cleats up to 1975)
6- male block
529 004 000
7- hexagonal nut (2)
389 804000
Alpine 3 speeds
transmission
Alpine 3 speeds
transmission
-All Nippondenso
electronic ignition
systems
-(All engine types
except
247)
All types of track.