BOMBARDIER 1982 Install guide

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SHOP MANUAL
1982
f i
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BOMBARDIER
snowmobiles .

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Legal deposit:
National Library of Quebec
4th trimester
National Library of Canada
All rights reserved. No parts of this manual maybe
reproduced in any form without the prior written
permission of Bombardier Inc.
©Bombardier Inc. 1981
Printed in Canada
@ *Registered trademarks of Bombardier Inc.
\ "

SAFETY NOTICE
The Bombardier snowmobile Shop manual has been prepared in order to assist skilled
mechanic's in the efficient repair and maintenance of Bombardier snowmobiles.
This Shop Manual covers only the procedures
as of the manufacturing date.
Safety 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.
This manual emphasizes particular information denoted by the wording and symbols;
•
~ARNING: Identifies and instruction which, if not followed, could cause personal
Injury.
_ CAUTION: Denotes
an instruction which, if not followed, could severely damage
.. vehicle components.
oNOTE: 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.

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1982 BOMBARDIER SNOWMOBILES
SHOP
MANUAL
INTRODUCTION
This Shop Manual covers the following Bombardier made
1982 snowmobiles.
Elan
Spirit
Citation 3500 Mirage I
Citation 4500/E Mirage
IIIE
Citation SS
Mirage Special
Nordik Futura 300
Skandic
Everest
500/E Futura 500IE
Everest LIC
Futura LIC
Blizzard 5500 MX
Sonic MX
Blizzard 9500 Ultra Sonic
Alpine 640
Elite 464 LC
.. Furthermore, each vehicle has its particular vehicle seri-
al number.
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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 wh ich 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.
'A
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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 comprised of various sub-sections, and
again, each sub-section
has one or more division.
EX.: 02 ENGINE
05 Engine type 464 Everest -Futura -Elite
-Cooling system
-Magneto
The
use of "Right" and "Left" indications in the text,
always refers to driving position (when sitting
on vehi-
clel.
.~
LEFT ....... f----
---I.~ RIGHT
1982 BOMBARDIER SNOWMOBILES
SHOP
MANUAL
GENERAL
The information, illustrations and component/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
identifying 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 cata-
logue.
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 commencing any
procedure,
be sure that you have on hand all the tools
required, or approved equivalents.
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This manual is published by the
Technical Publications
Bombardier Inc.
Valcourt, Quebec, Canada
.
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PAGE 5
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SECTION
01
02
03
04
05
08
07
08
09
10
TOOLS
ENGINE
TRANSMISSION
ELECTRICAL
SUSPENSION
."
-
STEERING/SKIS
HOOD/FRAME
. -
FUEL LINE, WIRING HARl\IESS
AND CABLE ROUTING
TECHNICAL DATA
WARRANTY
(
.-!t
TABLE OF CONTENTS
SUB-SECTION
01 -Basic tool kit '
02 -Service tools
03 -Service products
01 -Engine type 247
02 -Engine type 277
03 -Engine type 377
04 -Engine type 454
05 -Engine type 464
06 -Engine type 503
07 -Engine type 640
08 -
Eng i ne tolerance measurements
09 -Carburetor and fuel pump
10 -Air intake silenc!3r and fuel tank
11 -Rewind starter
01 -Pulley guard
02 -Drive belt
03 -Drive pulley
04 -Driven pulley
05 -Pulley alignment
06 -Brake
07 -Chaincase
08 -Gear box
09 -Drive chain
01 -Electrical charts
02 -Ignition timing
03 -Spark p lu gs
04 -Battery
05 -Alternator
06 -Electric starter
07 -Testing procedures
01 -Bog ie wheel
02 -Slide & MX suspension
03 - Rear axle
04 -Drive axle
05 -Track
01 -Steering system
02 -Ski system
01 -Hood
02 -Frame
01 -Engine
02 -Carburation
03 -Electrical
04 -Transmission
05 -Suspension
,~.
06 -Main snowmobile torgues
07 -General information
08 - SI metric info~mation chart
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PAGE
9
11
19
23
35
53
71
97
1 35
155
171
177
187
203
207
. 215
225
245
257
259
/
265
271
287
291
303
313
319
323
325
331
347
351
.369
371
377
381
391
405
425
445
453
455
457
461
467
469
477
481
483
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A. Screwdriver
B. Socket 70/73 mm
C. Open end wrench 70/73 mm
D. Socket wrench handle
E. Starter rope
F. Socket 77/27 mm
Suspension adjustment key
Oil gauge (gear box)
Starter rope handle
Extension
bar
Socket 77/73 mm
G.
H.
I.
J.
K.
L.
M. Emergency
starter rope handle
Emergency
starter clip
(Citation 3500 & Mirage I only)
N. Suspension adjustment key
O. Socket 27/26 mm
E
J K
q
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0
1982 MODELS
Elan, Spirit
Citation, Mirage (All)
Nordik, Skandic, Futura 300
Blizzard 5500 MX, Sonic
Blizzard 9500, Ultra Sonic
Everest 500, E, Lie, Futura 500, E, Lie
Eli te
Alpine
F
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SECTION 01 TOOLS
SUB-SECTION
01 (BASIC TOOLS)
BASIC TOOLS I
A
C
B
o
()
G H
0})
0
M 0
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APPLICABLE TOOLS
A, B, C, D, E, O.
A, B, C, D, E, L, M, O.
A, B, C, D, E, L. O.
A, B, C, D, E, G, N, O.
A, B, C, D, E, F, G.
A, B, e, D, E, F, G.
A, B, C, D, E, F, G, H, I.
A, B, e, D, E, F, J, K.
PAG" .J

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ITEM
Dial indicator (T.D.C. gauge).
414 104700
Circuit tester (continuity light).
414012200
Bombardier ignition tester.
419003300
Drive pulley retainer.
529001700
SECTION 01 TOOLS
SUB-SECTION 02 (SERVICE TOOLS)
SERVICE TOOLS
USE
Engine timing, to determine T.D.C.
...
Engine timing (static).
Continuity tests.
Engine electrical components tests.
For indexation of governor cup.
APPLICABLE TO
All engine types.
All engine types.
All engine types.
Square shaft drive
pulley.
PAGE 11

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SECTION 01 TOOLS
SUB-SECTION 02 (SERVICE TOOLS)
Drive pulley puller.
5290021
00
860 414200 (metric)
_____ 0 ("'_oIlOOi;,;.;.;ii!(Q
! "
(529003 (00) (529002800)
Magneto housing holder.
420976550
(
Seal sleeve
247 engines
PTO 420 977 910
MAG 420 276 900
Water pump seal sleeve
354, 444, 454, 464
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 and 640.
Liquid cooled Rotary
valve engines.
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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
420977 490
420977 470
SECTION 01 TOOLS
SUB-SECTION 02 (SERVICE TOOLS)
engine 377, 354, 454, 503
engine 247, 277, 444, 464, 640
All engines except 247, 640
377 engine only
all except 247 engine
all except 640 engine
all except 640 engine
377, 464 engines only
377, 464, 640 engines only
377, 464, 640 engines only
All engine types.
PAGE 13

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Protection cap.
247, 277, 640 engines
18 mm 420976890
354, 377,444 , 454, 464, 503
22 mm 420 876 402
Engine seal pusher
247 engine 420 977 920
277 engine 420 277 865
420876660
Seal pusher
420876510
464 engine
420876500
Rotary valve seal
pusher
420876 600 -354, 454 engine
420 876 605 -464 engine
SECTION 01 TOOLS
SUB-SECTION 02 (SERVICE TOOLS)
Protect crankshaft end, when
using bearing puller.
Protection cap
,
OJ II
To install water pump
seal
To install rotary valve
shaft seal.
All engine types.
247,277
engine types
354, 444, 454, 464
engine types.
354, 454, 464 engines.
PAGE 15

'..,
SECTION 01 TOOLS
SUB-SECTION 02 (SERVICE TOOLS)
Polyamid ring pusher
engine 277 MAG 420 273 930
PTa 420 273 940
Crankshaft feeler gauge.
503 engine
*MAG
420876625
PTa 420 876 620
Crankshaft locking tool
420876640
Injection pump gear
holder
277, 377, 454, 503
Engine 420 876 690
464 engine 420 277 900
PAGE 16
To install
polyamid ring
in crankcase.
To lock crankshaft
277 engine
*Mag side:
All 503 engine up to
no. 3
181 891
and engines
no. 3
181 921 to
3
181 937
PTa: all 503 engines
277, 377, 454, 464, 503
engines
All injection
engines.
)

Magneto puller ring.
420876655
°0
(-'~<.)
~ <>
Adjuster wrench.
529003800
(
"'--!J
3 speeds transmission
bearings extractor.
i 1 i
I :
.... :
:i
J2
~~3
~III
.4
I I
To remove magneto.
SECTION 01 TOOLS
SUB-SECTION 02 (SERVICE TOOLS)
277, 377, 454, 464, 503
engines.
Front & rear suspension Blizzard
5500 MX
springs adjustment. Sonic
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
( 13
Alignment tool
420476010
Nippondenso electronic
ignition tester
490084 000
Clip-O-Matic
529004500
4
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1
PAGE 18
3
6
Transmission cover index
rod ball installation
(Refer to section 03 - 08 -Gearbox)
Drive shaft and
layshaft sprocket
alignment.
(Refer to section
03-08 Gearbox)
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
529004100
bending block no. 2
529004200
bending block no. 3
529004300
6- male block
529004000
7- hexagonal nut (2)
389804 000
Alpine 3 speeds
transmission
Alpine 3 speeds
transmission
-All Nippondenso
electronic ignition
systems
-(All engine types
except
247, 640)
All types of track.
)

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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 (271) RED
HIGH STRENGTH 6 mL
747020000
GASKET ELIMINATOR 515
50 mL
413702700
SECTION 01 TOOLS
SUB-SECTION 03 (SERVICE 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.
General purpose, nuts,
bolts screws.
Magneto ring nut, crank-
case studs, etc.
Fasteners and studs
under
1" dia.
Seals instantly. For metal to metal On all engine crankcases.
assembly. Replaces gaskets.
PAGE 19

SECTION 01 TOOLS
SUB-SECTION 03 (SERVICE PRODUCTS)
RETAINING COMPOUND (601)
10 mL
4137031 00
PRIMER CRANKCASE SEALANT
(SPRAY)
60z
413702400
STRIPPER NO 57
4137021 00
ANTI SEIZE
LUBRICANT
413701000
SILICONE DIELECTRIC GREASE
3 oz.
747018002
GREASE TUBE
140z
4980281 00
PAGE20
Restores fit between bearings and All engines except 247,
worn crankcase. 277.
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.
For cleaning mating surfaces be-
fore assembly.
Protects moving and stationary
parts against high temperature
seizing. Prevents rust and corro-
sion on parts exposed
to high heat.
Special dielectric grease that pre-
vents moisture and corrosion
build-up in electric connections.
Mainly used when assem-
bling engine crankcase.
Used
to clean mating sur-
fAces before applying Loc-
tite
515 (Gasket Elimina-
tor).
Unpainted surfaces
of
drive pulley countershaft.
On all electric connec-
tions. High tension coil.
Spark plug connections.
Connector housings, etc.
Multi purpose Lithium based For idler bearings, ski legs,
grease for use over a wide temper- leaf spring cushion pads,
ature range. seal interior lips, etc.