BOMBARDIER Ski-Doo MX Z 600 Series User manual

Printed in Canada (mbs2001-001a.fm MD)
®*Trademarks of Bombardier Inc. and/or its subsidiaries.
©2000 Bombardier Inc. All rights reserved.
2001-7 Page 1 of 7
X package for above mentioned models gives a
sport calibrated ride as far as rear shock absorber
is concerned.
In order to obtain a softer dampening, similar to
what the adrenaline package gives, customer could,
at his own expense, change rear shock calibration
by removing five 36 x 0.203 and one 40 x 0.203
washers inside the shock absorber (P/N 503 189
609). Following table summarizes the operation.
Parts Required
The following 2000 Racing Manual revised pages
describe the entire procedure.
Valving and Dampening
In the HPG shock, the piston passages are covered
by a stack of thin metal shims of various thicknesses
and diameters. The shims provide dampening by
acting as spring loaded valves offering resistance
to the oil traveling through the piston. There is a
stack of shims on both sides of the piston. One
side controls compression dampening and the other
side controls rebound dampening. By varying the
number and thickness of shims the dampening
characteristics can be very accurately obtained.
Special Tools
Special tools specific to the HPG T/A shock will be
the seal pilot, shock wrench (P/N 529 035 727) and
piston guide from Bombardier for C-46 shock.
NOTE: Tools P/N 529 035 727 and 529 035 728
will be available in early December.
No. 2001-7
Date: November 3, 2000 SUBJECT: Rear Shock Absorber
Dampening
YEAR MODEL PKGE MODEL NUMBER SERIAL NUMBER
2001
MX* Z 600
X
1825/1826/1827/1828/1829/1830
AllMX* Z 700 1670/1671/1672/1673/1674/1675
MX* Z 800 1663/1664/1665/1666/1667/1668/1669
FUNCTION ORIGINAL
“X”VALVING
ACTION
TO BE
TAKEN
RECALIBRATED
DAMPENING
Piston
by-pass
hole
2.0 mm dia. none 2.0 mm dia.
COMPRESSION
4 x 40 x 0.203 Remove
1 washer 3 x 40 x 0.203
1 x 24 x 0.203 none 1 x 24 x 0.203
3 x 40 x 0.152 none 3 x 40 x 0.152
2 x 24 x 0.203 none 2 x 24 x 0.203
Rebound
9 x 36 x 0.203 Remove
5 washers 4 x 36 x 0.203
1 x 24 x 0.203 none 1 x 24 x 0.203
DESCRIPTION PART NUMBER QTY
Shock Absorber Oil 293 600 035 1 bottle
FOR
A
PPROV
A
L ONLY

Page 2 of 7 2001-7
SHOCK WRENCH (P/N 529 035 727)
NOTE: Do not attempt to rebuild the T/A damper
without the benefit of these assembly tools, dam-
age will occur without their use.
Shock Oil and Nitrogen
1. High pressure hose
2. 2 stage regulator, delivery pressure range 2070 kPa (300 PSI)
3. High pressure cylinder filled with industrial grade nitrogen
4. Schrader valve tip (P/N 529 035 570)
NOTE: Commercially available through compressed
gas dealers.
Disassembly and Assembly
Release N2(nitrogen) pressure from the damper
Schrader valve on any HPG T/A with IFP.
1. Schrader valve 1.5 - 2 N•m (13 - 17 lbf•in)
2. Schrader cap 5 - 6.5 N•m (44 - 57 lbf•in)
A06F0OB
529 035 728
529 035 608
A00F22A
A06F0PD
293 600 035
32 oz
WARNING
Nitrogen gas is under extreme pressure. Use
caution when releasing this gas volume. Pro-
tective eye wear should be used.
4
2
1
3
A06F0QA
A06F18B
21

2001-7 Page 3 of 7
With the seal assembly removed, slowly lift and re-
move damper rod assembly from the damper body.
NOTE: Remove damper rod assembly slowly to re-
duce oil spillage and prevent piston seal damage by
damper body threads. Wrap the damper body with a
shop cloth to capture possible overflow oil while re-
moving the damper piston.
1. Oil flows
Discard old oil into storage container. Never reuse
damper oil during shock rebuild.
Remove Schrader valve core. Using compressed
air pressure, carefully remove floating piston from
damper body. Hold shop cloth over damper body
opening to catch released floating piston. Allow
room for floating piston to leave damper body.
TYPICAL
Thoroughly clean, with a typical cleaning solution,
and blow dry using low pressure air. Carefully in-
spect the damper body for any imperfections or
signs of wear in the damper bore.
Replace damper body if wear is identified.
Holding the damper rod assembly in a bench vise,
begin piston and valve removal.
A. Remove damper nut
529 035 727
A32F1NA
1
A27F0AA
WARNING
Whenever using compressed air, use an
O.S.H.A. approved air gun and wear protec-
tive eye wear.
A27F06A
A06F0UA
A

Page 4 of 7 2001-7
Always arrange parts removed in the sequence of
disassembly.
NOTE: As a general rule we suggest replacing the
damper rod lock-nut after 4 rebuilds to ensure
good Iocking friction and use Loctite†271 each
time.
NOTE: If revalving is to be done, it is imperative
that you identify the original shim pack (size and
number of shims). The seal carrier need not be
removed if only revalving is to be done.
Shims can be measured by using a vernier caliper
or a micrometer.
NOTE: All shims should be carefully inspected
and any bent or broken shims must be replaced
for the shock to function properly.
After the new or replacement shim pack has been
selected, reassemble in the reverse order of disas-
sembly. Torque piston nut 27 - 29 N•m (20 - 21 Ibf•ft).
1. Damper nut
2. Spacer
3. Washer
4. Shim pack
CAUTION: The damper rod nut can only be re-
used 4 times, then, must be replaced. Do not
substitute this part for non –O.E.M. use Loctite
271 on nut each time.
This (these) spacer washer(s) (P/N 414 888 309)
must be used as shown to ensure damper rod nut
does not contact shaft threads.
Rebound valve stopper with round edge facing
shim stack.
NOTE: Rebound shim stack must not reach into
threads of damper shaft. Washer under damper
shaft nut is used to prevent damper shaft nut from
bottoming on threads.
1. Rebound dampening shim pack
2. Rebound dampening shim pack
3. Piston
4. Compression dampening shim pack
5. Compression dampening shim pack
6. Stopper
†Loctite is a registered trademark of Loctite Corporation.
A06F0VA
A06F0XA
4
1
2
3
A06F0YA
1
2
3
4
5
6

2001-7 Page 5 of 7
If the seal carrier assembly is replaced, use seal
pilot to guide seal over damper shaft. Lubricate
seal carrier guide pilot before use.
CAUTION: Failure to use seal pilot will result in
seal damage.
Reassemble damper rod assembly, taking care to
properly assemble shim packs as required for your
dampening needs. Ensure that the shaft piston is
installed with the slits/larger intake holes facing
the rebound shim stack.
1. Pilot (P/N 529 035 728)
If floating piston has been removed, reinstall float-
ing piston into damper body (ensure that Schrader
valve core has been removed). Use Molykote G-n
paste (P/N 711 297 433) to ease O-ring past damper
body threads with floating piston guide (P/N 529
035 608).
CAUTION: Failure to install IFP correctly could
result in shock damage.
1. Push (slowly) by hand
2. Floating piston guide (P/N 529 035 608)
NOTE: Lubricate inside of piston guide with
Molykote G-n paste (P/N 711 297 433).
Install floating piston to the proper depth (190 mm
(7.5 in)).
On all HPG take apart shocks from 1996 on, the
floating piston is installed hollow side up.
A. Required distance for floating piston installation (190 mm (7.5 in))
NOTE: If the floating piston is installed too far into
the damper body, light air pressure through
Schrader valve (with core removed) will move pis-
ton outward.
NOTE: Reinstall Schrader valve core after IFP has
been installed at correct height and before adding
oil.
CAUTION: Moisture laden compressed air will
contaminate the gas chamber and rust floating
piston.
A06F12C
1
1
2
A06F14C
WARNING
Whenever using compressed air exercise ex-
treme caution, cover damper opening with
shop cloth to reduce chance of possible injury.
WARNING
Always wear protective eye wear whenever
using compressed air.
A27F0FD
A

Page 6 of 7 2001-7
Fill the shock with Bombardier HPG shock oil (P/N
293 600 035) to approximately 10 mm (.393 in),
from the base of seal carrier threads.
1. Fill to 10 mm (.393 in)
NOTE: Although we do not measure the exact
amount of oil added to the damper, approximately
252 mL (8.52 oz. U.S.) will be used.
Carefully insert damper rod into the damper body.
Lightly oil damper piston seal ring with shock oil
to ease installation.
NOTE: Some shock oil will overflow when install-
ing damper. Wrap damper with shop cloth to catch
possible overflow oil.
CAUTION: Use care when passing piston into
damper body at damper body threads.
Slight oscillation of damper rod may be required to
allow piston to enter damper body bore.
Slowly push piston into damper body. Slight up
and down movement may be required to allow all
air to pass through piston assembly. The gentle
tapping of a small wrench, on the shock eye, may
help dislodge air trapped in the submersed piston.
Be careful not to drive the shaft any deeper into
the oil than is necessary to just cover the shim
stack.
NOTE: Fast installation of the damper rod may dis-
place the floating piston from its original position.
This must not occur if the damper is expected to
perform as designed.
With damper rod piston into oil, TOP OFF damper
oil volume. Oil level should be to damper body
thread base.
Seal carrier assembly can now be threaded into
damper body. This should be done slowly to allow
weapage of oil and to minimize IFP displacement.
After the seal carrier is fully in place avoid pushing
the shaft into the body until the nitrogen charge is
added.
Torque seal carrier to 90 - 100 N•m (66 - 74 lbf•ft).
1
A06F15B
A06F16A
529 035 727
A32F1NA

2001-7 Page 7 of 7
1. Schrader valve 1.5 - 2 N•m (13 - 17 lbf•in)
2. Schrader cap 5 - 6.5 N•m (44 - 57 lbf•in)
Adding Gas Pressure
Nitrogen (N2) can now be added to damper body.
NOTE: Never substitute another gas for nitrogen.
Nitrogen has been selected for its inert qualities
and will not contaminate the gas chamber of the
shock.
Preset your pressure regulator to 2070 kPa (300 PSI)
nitrogen (N2), this gas pressure will restore the
correct pressure for your damper.
CAUTION: Do not exceed the recommended
pressure values.
When removing and retightening the Schrader
valve acorn nut use minimal torque. When the cap
is over tightened and subsequently removed it
may prematurely break the seal of the Schrader
valve to the shock body and cause a loss of nitro-
gen charge without being noticed. If you suspect
this has happened then recharge the shock as a
precaution. Inspect the acorn cap before installa-
tion to ensure that the internal rubber gasket is in
its proper position.
NOTE: Carefully inspect damper for gas or oil leaks.
Any leaks must be corrected before continuing.
Damper gas pressure cannot be confirmed by us-
ing a pressure gauge. The volume of gas in the
shock is very small, and the amount lost during
gauge installation will lower the pressure too
much and require refilling.
After recharging is complete the rebuilt shock
should be bench-tested. Stroke the shock to en-
sure full travel and smooth compression and re-
bound action. If the shaft moves in or out erratical-
ly this could indicate too much air is trapped inside.
If the shaft will not move or has partial travel then
it may be hydraulically locked. In either event the
shock must be rebuilt again. Pay particular attention
to the placement of the IFP, quantity of oil and shim
stack/piston assembly.
1. High pressure hose
2. 2 stage regulator, delivery pressure range 2070 kPa (300 PSI)
3. High pressure cylinder filled with industrial grade nitrogen
4. Valve tip (P/N 529 035 570)
WARNING
Whenever working with high pressure gas,
use eye wear protection. Never direct gas
pressure toward anybody.
A06F18B
21
4
2
1
3
A06F0QA

Printed in Canada (mbs2001-002a.fm SG)
®*Trademarks of Bombardier Inc. and/or its subsidiaries.
©2000 Bombardier Inc. All rights reserved.
2001-3 Page 1 of 7
This bulletin is divided into 2 main sections.
Section 1: Spring Applications
It is a quick reference chart which provides autho-
rized spring application for each Ski-Doo model. It
contains the standard spring part number (in gray
shading) as installed at the factory, as well as 1 softer
spring and 1 harder spring recommendation.
Section 2: Spring Specifications
Refers to spring specifications.
The informations in this bulletin supersede all in-
formations previously published.
Please update your Shop Manual by indicating the
number of this bulletin in the proper section of the
manual.
COIL SPRINGS
(compression)
NOTE: Read color when spring is upright and stripes
are down.
Type R
(straight on both ends)
(Single Rate Spring)
1. Color code stripes
2. Wire diameter
3. Free length
Type S
(barrel shape on one end)
(Single Rate Spring)
1. Color code stripes
2. Wire diameter
3. Free length
Type T
(barrel shape on both ends)
(Single Rate Spring)
1. Color code stripes
2. Wire diameter
3. Free length
No. 2001-3
Date: September 1, 2000 SUBJECT: Spring Chart
YEAR MODEL MODEL NUMBER SERIAL NUMBER
2001 All (except utility models) All All
A00F0PA
1
2
23
1
3
A00F19A
2
A06F02A
1
2
33

Page 2 of 7 2001-3
Type U
(barrel shape on one end with
positioning tab at the other end)
(Single Rate Spring)
1. Color code stripes
2. Wire diameter
3. Free length
4. Positioning tab
Type Y
(barrel shape on both ends with
positioning tab at the color code coils end)
(Single Rate Spring)
1. Color code stripes
2. Wire diameter
3. Free length
4. Positioning tab
Type 2
(barrel shape on both ends)
(Dual Rate Spring)
1. Color code stripes
2. Wire diameter
3. Free length
Type 4
(barrel shape on both ends with
positioning tab at the color code coils end)
(Dual Rate Spring)
1. Color code stripes
2. Wire diameter
3. Free length
4. Positioning tab
TORSION SPRINGS
1. Color code stripes
2. Wire diameter
3. Opening angle (°)
4. Left hand (LH)
5. Right hand (RH)
1
3
A00F12A
24
1
3
A06F2VA
2
4
3
A00F20A
2 1
3
A00F21A
1
4
2
A00F0SA
2
3
4
5
1

2001-3 Page 3 of 7
SECTION 1
SPRING APPLICATIONS
2001 FRONT SPRINGS 2001
MODEL (P/N) SOFTER SPRING (P/N) STANDARD (P/N) HARDER SPRING
MACH Z 414 956 300 415 075 900 415 039 700
MACH Z TECH PLUS 414 956 300 415 075 900 415 039 700
FORMULA DELUXE
STANDARD Not Applicable 505 070 686 Not Applicable
FORMULA DELUXE GS Not Applicable 505 070 686 Not Applicable
FORMULA DELUXE GSE Not Applicable 505 070 686 Not Applicable
FORMULA DELUXE 500 414 956 300 415 070 685 415 039 700
FORMULA DELUXE 380 414 956 300 415 070 685 415 039 700
MX Z STANDARD Not Applicable 505 070 181 Not Applicable
MX Z ADRENALINE Not Applicable 505 070 181 Not Applicable
MX Z TRAIL Not Applicable 505 070 393 Not Applicable
MX Z X Not Applicable 505 070 692 Not Applicable
MX Z 500 F 414 956 300 415 075 900 415 039 700
MX Z 380 F 414 956 300 415 075 900 415 039 700
SUMMIT STANDARD Not Applicable 505 070 020 505 070 305
SUMMIT X Not Applicable 505 070 573 505 070 305
SUMMIT STANDARD HM Not Applicable 505 070 020 505 070 305
SUMMIT X HM Not Applicable 505 070 573 505 070 305
SUMMIT 500 F 414 859 300 505 070 698 414 968 600
GRAND TOURING SE Not Applicable 505 070 684 505 070 298
GRAND TOURING
STANDARD Not Applicable 505 070 686 Not Applicable
GRAND TOURING GS Not Applicable 505 070 686 Not Applicable
TOURING 500 F 414 956 300 505 070 685 415 039 700
TOURING 380 F 414 956 300 505 070 685 415 039 700