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