BOMBARDIER 1983 Elan Install guide

SAFETY NOTICE
This Shop Manual has been prepared primarily for use by professional snowmobile mechanics,
who are already familiar with all service procedures relating to Bombardier made snowmobiles,
and secondly to assist the mechanically oriented snowmobiler
who has limited access to an au-
thorizeddealer, or prefers to perform his own servicing. '
In either case,special tools must be used, where required, and a good sense of safety
i~(ip.p.'mf:!rl
necessary. If in doubt, contact your dealer for assistance. '
This manuai emphasizes particular information denoted by the wording and symbols;
i+ WARNING: Identifies an lnstructlonwhich, if not followed; could cause personal....r_ .
1 .,'
i~ CAUTION: Denotes an instruc_~16~:which, if not followed, Cbl,J19 severely.damage velhiclle<·);,;;·}~S
components.
oNOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does
not eliminate the hazard, your understandinq
of the information will promote its correct use. /
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INTRODUCTION
This Shop Manual covers the following Bombardier
made 1978 snowmobiles:
Elan@ and Spirit"
Olympique* and Nuvik*
Citation"
Everest" and Futura"
TNT@ F/ A and F/C
RV* and Sonic*
Blizzard" 6500 Plus
Alpine@
Elite@
@*Trademarks of Bombardier Limited.
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.
/1-01
. ~b'
section su -section
The numerotation at the bottom of each page assists
the user in page location.
ARRANGEMENT OF THE MANUAL
1978 BOMBARDIER SNOWMOBILES
SHOP
MANUAL
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. 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 inter-
related, we suggest that before undertaking any task,
you read and thoroughly understand the entire section
or sub-section in which the procedure is contained.
Anumber of procedures
throughout the book require
the use of special tools. Where a special tool is indi-
:!'~,~i~)'cF;
cated, refer to section 07. Before commencing any pro-:,
cedure, be sure that you have on hand all of the tools re-
quired, or approved equivalents.
GENERAL
All of the information, illustrations and component/
system descriptions contained in this manual are correct
at time of publication. Bombardier Limited, however,
maintains apolicy of continuous improvement of its
products
without imposing upon itself any obligation to
install them on products previously manufactured.
The Manual is divided into nine (9) major sections:
01 Suspension
02 Transmission
03 Steering and skis
04 Engine
05 Electrical
06 Cab and chassis
07 Tools
08 Technical data
09 Warranty
Each section is comprised of various sub-sections, and
yet again each sub-section has one or more divisions.
Ex.: 02 TRANSMISSION
07 Chalncase
Steel chaincase
Aluminum chaincase This manual has been published by
the'
TECHNICAL INFORMATION CENTRE
SERVICEDEPARTEMENT
BOMBARDIER
VALCOURT,
QUls~~:t~,~qAr~A[)A

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SECTION
SHOP MANUAL
TABLE OF CONTENTS
SUB-SECTION
01
02
03
04
05
SUSPENSION
TRANSMISSION
STEERING/SKI
ENGINE
ELECTRICAL
01 - Bogie wheel
02 - Slide suspension
03 - Rear hub
04 - Drive axle
05 - Track
01 - Pulley guard
02 - Drive belt
03 - Drive pulley
04 - Driven pulley
05 - Pulley alignment
06 - Brake
07 - Chaincase
08 - Gearbox
09 - Drive chain
01 - Steering system
02 - Ski system
01 -Enginetdleranc;es measurement
02 - Engines .
03 - Rewind starter
04 - Timing
05 -
c:;arburetqrC .
06 _. Air intake silencer and fuel tank
01 Electrical charts
02 - Spark plugs
03- Test procedure
04 - Electric starter
05 •
-Battery
. 06-Alternator
06 CAB &FRAME
07 TOOLS
08 TECHNICAL DATA
09 WARRANTY

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4
4
t, Wheel support
2. Spring
3. Lock washer (cross shaft)
4. Bolt (cross shaft)
5. Cross shaft
6. Grease cap
7.
Nut (flange)
8. Inner flange
9. 13earing
10. Wheel tire
tt. Outer flange
12. Bolt (flange)
13. Grease fitting
SECTION 01
SUB-SECTION 01 (BOGIE WHEELS)
BOGIE WHEELS
4 WHEELS, SINGLE SPRING
4 WHEELS, 2 SPRINGS
4
(BOGIE WHEELS), PAGE 1

SECTION 01
SUB-SECTION 01 (BOGIE WHEELS) (
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5
Torque sequence
6
INSTALLATION
Q)@ Bogie wheels are factory riveted. When separation
is necessary, remove rivets securing wheel tire
and:
flanges by using a 3/16" dia. Secure flanges and tire us-
ing bolts and nuts tighten in the following sequence to
38 Nem (28 ft-lbs).
With rear of vehicle supported off the ground, position
front bogie wheel set in location and secure to frame us-
ing lock washers and bolts. Secure rear set then re-
. maining setts) to frame.
a
NOTE: On a single bogie wheel set, position bogie
wheel set so that wider wheel support is toward
front of vehicle.
.® Clean, then lubricate cross shaft - with low'
temperature grease before installation.
®Always pull or push bearing by inner race. When in-
stalling bearing on wheel support, position bearing
shield towards inner flange, then press down until bear-
ing is sitting flush with support end.
Cross support
DISASSEMBLY &ASSEMBLY
Link plate
spring
:L..ink plate
'spring lever
---~-----_.
Remove bogie wheel set.
a NOTE: Since spring diameter may vary depending
upon actual installation location, it is important to
identify the installation of each bogie wheel set.
Observe this position when reinstalling sets.
Repeat operation for remaining bogie wheel sets.
Starting at center bogie wheel set, remove bolts and
lock washers securing cross shaft to frame.
aNOTE: To prevent the cross shaft from rotating
within the cross support, wedge a screwdriver
blade between the cross shaft and cross support.
Raiseand block rear of vehicle
off the ground.
Release track tension by unlocking the link plate springs
using link plate lever (See Tool Section).
REMOVAL
. CD Heat wheel support anchor before attempting to
open or close anchor.
Rear -<Ill
~ Front
(BOGIE WHEELS), PAGE 2

Using link plate spring lever, apply track tension by
hooking the link plate springs into anchors.
O
NOTE: If applicable, place spring ends in middle
position of the 3 position slotted anchor.
SECTION 01
SUB-SECTION 01 (BOGIE WHEELS)
Middle
position
Link plate
spring
Link plate
spring lever
Lubricate each bogie wheel until new grease appears at
joint. Wipe
off excess grease.
Check track tension and alignment.
IBOGIE WHEELS), PAGE 3

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SECTION 01
SUB-SECTION 02 (SLIDE SUSPENSION)
,UTORQUE REACTION" TYPE SUSPENSION
TYPE 1
-45
a-®
18-V~1
19-~@_49
20-'4 ~
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®
,
""'"
Everest and Futura
RV and Sonic
@
~53
30
@
t:
~53@
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»-
("TORQUE REACTION"), PAGE 1

SECTION 01
SUB-SECTION 02 (SLIDE SUSPENSION)' (
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-45
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@-58
~--59
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~511 0 -
40 52 . a~®
I 18-~~
19 -~@-49
20-.1a ~
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22 D@
D I~
12 I~
31
Elan 250 Deluxe
Olympique and Nuvik
TNT
TYPE 2
("TORQUE REACTION")•.PAGE 2

SECTION 01
iSUB-SECTION 02 (SLIDE SUSPENSION)
TYPE3
Citation 300
(jj 49
rp~J .
®18' i ~
19 ,
20 @
,
~~47 ,~67
~~
/' i'O
, 11 48 I
~ 51 00 ~ ..
~~2. I
45
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®12 I
13
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53
("TORQUE REACTION"), PAGE 3

SECTION 01
SUB-SECTION 02 (SLIDE SUSPENSION) (.
TYPE 4
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1
I
45
~~@
0-
18
~-19
@-g,%47
~-®
~I ir ~.~
52 51 CD -45
a-®
18 -V~) C
19-~@_49
20-Jll ~
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0-
1
Blizzard 6500 Plus
("TORQUE REACTION"), PAGE 4

SECTION 01
SUB-SECTION 02 (SLIDE SUSPENSION)
. ; TYPES
Elite
45
,I 18
'~(lJ 1147 ®
1°{Q)ct I48
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@
52 ~ '1 Q,
1/1 I
~ ~1 CD
("TORQUE REACTION"), PAGE 5

SECTION 01
SUB-SECTION 02 (SLIDE SUSPENSION) (
1. Runner
2. Slider shoe
3. Screw
4.
Nut
5. Spiral pin
6. Front arm bracket
7. Rivet
8. Adjustment plate
9. Reinforcement bracket
10. Rivet
11. Swaged tube
12. Washer
13. Bolt
14. Nut
15. Cross shaft
16. Idler
17. Bearing
18. Retaininer ring
19. Cap
20. Grease fitting
21. Spacer tube
22. Spacer
23. Washer
24. Bolt
26. Front arm
26. Clevis pin
27. Cotterpin
28. Stop bonding
29. Rivet
30. Stopper strap
31. Bolt
32. Adjustment cam
33. Clevis
pin
34. Swaged tube
35. Bushing
36. Shock
37. Sltding
pad
38. Spiral pin
39. Sliding support
40. Reararm
41. Clevis pin
42. Clevis pin
43. Rear axle
44. Bearing
45. Idler
46. Grease fitting
47. Spacer tube (inner)
48. Spacer tube (outer)
49. Washer
50.
Bolt
51. Nut
52. Adjustment bolt
53. Spring bushing
54. Front spring
55. Rear spring
56. Cross shaft
57. vvesher .
58. Lock washer
59.
Bolt
60. Cross shaft
61. Idler
62. Spacer bushing
63. Washer
64. Lock washer
65.
Bolt
66. Retainer washer
67. Square
nut
68. Spacer tube
69. Idler
70. Bearing
71. Spacer tube
72. Wheel flange
73. Bolt
74. Nut
75. Side member (
REMOVAL
Release track tension by loosening adjuster bolts lo-
cated on inner side of rear idler wheels.
Adjuster bolt
Position the adjustment cams at the lowest elevation.
LOW POSITION
HIGH POSITION
Remove the four (4) bolts securing suspension to frame.
On Elite model, remove bolts securing side members to
chassis.
Lift rear of vehicle then withdraw suspension ass'y from
track area.
ONOTE: To prevent cross shaft from turning within
the suspension arm, wedge the blade of a small
screwdriver between the shaft and suspension
arm. (
("TORQUE REACTION"), PAGE 6

DISASSEMBLY &ASSEMBLY
0000To replace a worn slide shoe, remove nut
and bolt securing front of shoe to runner, and remove
rear spirol pin.
Slide shoe rearwards out of runner.
000To remove rivets securing adjustment plate or
front arm supports, cut rivet head using a chisel.
At assembly, rest rivet head on a suitable metal block
and hold ass'y firmly. Using a flat head punch and ham-
mer secure rivet.
Flat head punch
Metal block'
®@ To remove rivet use a 3/16" dia. drill. At assembly,
secure reinforcement bracket to runner with
two (2)
10-32 x 1/2" bolts and nuts.
0@Front idler cross shaft must be positioned in rear
hole of front arm bracket, except on Blizzard 6500 Plus,
RV and Sonic.
BIi,,,,, fHXJ~" "hi","
RV and Sonic C
Rear of vehicle
®@Bearing must be installed with shield facing the in-
side of idler wheel.
SECTION 01
SUB-SECTION 02 (SLIDE SUSPENSION)
Center ball bearing on rear axle has slightly larger inside
diameter, i.e. 25.37 mm (,999") instead of 24.99 mm
(,984").
@Front arm.
Elan,
Olympique and Nuvik
Elite
Citation 300
TNT
Everest and Futura
RV and Sonic
Blizzard 6500 Plus
@@@>@Clevis pin lengths are:
44 mm 1
3/4") for no. 26
76 mm (3") for no. 33
33 mm
(1 5/16") for no. 41
50 mm (2") for no. 42
®At assembly, discard used cotter pins and install new
ones.
@To remove rivet, use a 7/32" dia. drill.
("TORQUE REACTION"), PAGE 7

SECTION 01
SUB-SECTION 02 (SLIDE SUSPENSION) I
®At assembly, adjustment cam must be installed so
that hexagonal projection on cam is located toward
front of vehicle.
HIGH POSITION
@Sliding support must be installed with offset toward
front.
@Center wheel grease fitting is angled at 45°.
@Clean all traces of plastic from threads. Prior to as-
sembly, apply a light coat
of "Loctite" thread locking
compound or equivalent, on threads.
@@ Prior to assembly, identify front and rear springs.
Front spring coil diameter is smaller than rear.
@@ @Idler wheels are factory riveted. If wheel tire has
to be changed, use a
7/32" dia. bit to separate wheel
flanges.
At assembly, use
7/32" x 3/4" bolts with self-locking
nut and torque to 3N-m (2 ft-Ibsl.
INSTALLATION
Detach front stopper strap and shock absorber of the
suspension. Lift the rear of vehicle
off the ground.
Place suspension within the track and align front arm of
suspension
with front holes of frame and secure using
bolts and washers. Torque to 43 N-m (32 ft-lbsl.
Raise the rear section of the suspension and track into
the tunnel and align rear arm with rear holes in frame.
Secure to frame using bolts and washers. Torque to 43
N-m (32 ft-lbsl.
Reposition vehicle on the ground. Position the adjust-
ment cams at the lowest elevation then apply down-
ward pressure on the seat of vehicle and connect the
shock absorber. Attach front stopper strap.
("TORQUE REACTION"I, PAGE B
Olympique and Nuvik
Everest and Futura
T'NT, Citation
Elite
~~iIlII---2nd hole
I
RV and Sonic
Blizzard 6500 Plus
ONOTE: There are many installation positions for
the stopper strap. The recommended position
provides maximum traction and steering efficien-
cy for almost every snow condition. However, for
very special purposes or snow condition, it may
become necessary to alter this setting. Lenght
ening the strap (lst hole) has the same effect as
shifting the weight toward rear of vehicle; as a
result, traction is increased but steering efficiency
is decreased. Inversely, by shortening the strap
'lenqth (last hole), traction is decreased while
steering efficiency and effort are increased.
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ADJUSTMENT
Track tension
Lift rear of vehicle and support it off the ground. Allow
track to extend normally. There must be agap of 13mm
(1/2") between slider shoe and bottom inside of track,
on each side.
a a
13mm
To adjust tension, loosen or tighten adjuster bolts lo-
cated on inner side of rear idler wheels.
Adjuster bolt
oNOTE: Track tension, track alignment and ride ad-
justment are interrelated adjustments. The mea-
surement given for ride adjustment is initial. When
ride adjustment is finalized for snow condition
and driver suitability, it may be necessaryto read-
just track tension and alignment to specifications.
SECTION 01
SUB-SECTION 02 (SLIDE SUSPENSION)
ITrack alignment
IAfter track tension has been corrected, start the engine
and accelerate slightly so that track turns slowly. Check
that track is well centered and turns evenly. To correct
stop the engine then loosen the lock nuts and tighten
the adjuster bolt on side where track is closest to the
frame. Tighten lock nut and recheck alignment.
WARNING: Before checking track alignment, en-
sure that the track is free of all particles which
could be thrown
out while track is rotating. Keep
hands, feet, tools and clothing clear of track.
Ride adjustment
The front adjustment cams are used for snow con-
dition, and the rear for driver's'weight. The front
adjustment cams should be positioned at the
lowest elevation for deep snow conditions. A
higher elevation is preferred when negociating icy
Isnow. The rear adjustment cams should be ad-
justed until a distance of 11-14cm (4.5-5.5") is ob-
tained between rear of footrest and ground when
driver is seated on the vehicle.
CAUTION: Always turn left side adjustment cams
in a clockwise direction, the right side cams in a
counter-clockwise direction. Left and right adjust-
ment cams of each adjustment (front and rear),
must always be set at the same elevation.
("TORQUE REACTION"), PAGE 9