BOMBARDIER ski-doo Alpine 1972 User manual

4
f-----
5
~ 6
:-- 7
10. Console
11. Choke Knob
12. Tachometer
13. Brake Lever
14. Windshield
,..-------------------1
r---------- 2
f----3
6. Underseat Storage
Compartment
7. Bogie Wheel Set
8. Overload Leaf Spring
9. Drive Pulley
1. Throttfe Lever
2. Seat
3. Backrest
4. Side Handle
5. Suspension Spring
*
8 __ ~
9 _
14 ---..,
13 ---,
12 ---,
11 ----,
10 _
*Trademark Bombardier Limited

5
6
1--
7
......... 8
11. Pulley Guard
12. Ski Assembly
013. Front Bumper
14. Side Reflective Stripe
15. Light Switch
6. Side Reflector
7. AdjusterBolt
8. Link Plate
9. Track
10. Fuel Filter.
1. Handlebar
2. Ignition Switch
3. Gear Shift Lever
4. Carburetor
5. Taillight
*
9 _
14 _
13--- ....
12
11
10 .z:
15 --,
*Trademark Bombardier Limited

Bombardier Ltd. reserves the right to
make changes in design and specifica-
tions,
and/or to make additions to or im-
provements in its products without im-
posing any obligations upon itself to in-
stall them on its products previously
manufactured.
This manual has been published by the
Technical Information Centre, Bombar-
dier Ltd., 8600 Decarie Blvd., Montreal
307, Quebec.
'The following are trade marks of Bom-
bardier Limited
Ski-Doo
Ski-Boose
Nordic
Alpine
Valmont
T'NT
~~fz~ard ~
Skandic ,. ,.,. .
Carry-Boose
Bombardier andthecrest.

INDEX
CONTROLS &INSTRUMENTS 2Valmont
440R
Valmont 440ER Alpine 640ER
TWO TWO TWO
TOOL KIT AND USES .
..............
22 x 67.5mm 2 x 67.5mm 2
x76mm
FUEL MIXING .. 32 x 61mm 2 x 61mm 2 x 70mm
436.6 cc 436.6 cc 635.1 cc
PRE-START CHECK 428 H.P. 28 H.P. 35 H.P.
BREAK-IN PERIOD 49:1 9:1 9:1
Manual Electric Electric
TIPS 4104Y2"
104112"
113%"
35"
35"
35"
STARTING PROCEDURE. 5
39%"
39%" 39%"
LUBRICATION 6, 7 496 531 596
1756 sq. in. 1756 sq. in. 2160 sq. in.
MAINTENANCE 8,9,10
0.282 0.302 0.277
2 x
15"
2 x 15" 2 x 15"
EMERGENCY GUIDE .. 11
13/39
13/39 13/29
TROUBLE SHOOTING GUIDE .. 12,13
Standard Standard Standard
75 75 120
STORAGE. 14,15 M240T1 M240T1 M280T31
.020"
.020" .020"
HOW TO IDENTIFY YOUR
.014"- .018"
.014"- .018"
.014"- .018"
SKI-DOO SNOWMOBILE .. 15 5 gals. 5 gals. 5 gals.
WARRANTY .. 16 6.25 gals. 6.25 gals. 6.25 gals.
20:1 20:1 20:1
Disc
Disc Disc
Standard Standard Optional
• The above spark plug number is recommended when operating the vehicle at fuli throttle. However, when
prevailing
conditions do not permit such operation, a hotter plug (one heat range hotter) can be installed to
prevent
possible fouling. To prevent piston failure, always reinstall standard plug for high speed operation.

CONTROLS&INSTRUMENTS
B---
H---
J
E
(A) Throttle lever
(B) Brake lever
(C) Ignition switch
(D)
light switch
(E) Choke knob
2
---A
---D
---c
---G
F
(F) Manual starter
(G) Gear shift lever
(H) lighter (Valmont 440ER)
(J) Tachometer (Valmont only)
(K) Handlebar
TOOL KIT AND USES
As standard equipment, Bombardier
equips each new Ski-Doo snowmobile
with the fol!owing tools:
Screwdriver
Use for Carburetor Pivntirlfl
to pry off Taillight lens;
Case Access Covers: etc.
Box Wrench (22126mm)
Use 22mm end to remove and ror.l",,,·,,,
"W" type Spark Plug, 26mm end for
type Spark Plug.
Box Wrench (11/13mm)
Use 11mm end to remove Air S!l(~nCler
(Skandic* Mode!). Use 13mm end
gine Head Nuts. Transmission Gear Box
Nuts (Alpine/Vaimont only).
Pin (8 x 130mm)
Use as handle for Box Wrench.
Open End Wrench (11113mm)
Use 11mm end for Carburetor Studs
(Skandic* Model only). Use 13mm end
for left side Carburetor Flange Nut, left
side Muffler Flange Nut (single cylinder
models only).
Angular Wrench (10/13mm)
Use 10mm end for Rewind Starter Unit
bolts. Use 13mm end for right side Car-
buretor
and/or Muffler Flange Nuts.

FUEL MIXING
With Ski-Doo snowmobiles, the OIL must
be added to the GASOLINE in pre-meas-
ured amounts then both oil and gasoline
should be thoroughly mixed together,
BEFORE fueiing the tank.
The importance of using the correct fuel
mixture cannot be over-stressed. Prior
experience has shown that the largest
cause of engine damage is from incor-
rect fuel mixtures.
Which Gasoline to Use
The correct gasoline for your Ski-Doo
snowmobile is regular gasoline, (not
less than 88 octane) available from all
service stations.
Which Oil to Use
Use only Ski-Doo Oil* available in REG-
ULAR or CONCENTRATED form. Both
types have especially tormutated oil
bases to meet the lubrication require-
ments of the Bombardier-Rotax engine.
CAUTION: Unless absolutely necessary
(in case of emergency) do not use out-
board or straight mineral oil. Never use
multi-viscosity oils.
Fuel Mixing Ratio
When using REGULAR SKI-DOO OIL,
the correct mixture is
20/1.
5 GALLONS, REGULAR GASOLINE plus
1 QUART, REGULAR SKI-DOO OIL
CORRECT FUEL MIXTURE.
'Trademark Bombardier Limited
When using CONCENTRATED SKI-DOO
OIL, the correct mixture is
40/1.
5 U.S. GALLONS or 4 IMPERIAL GAL-
LONS,REGULAR GASOLINE plus 1 PINT
CONCENTRATED SKI-DOO OIL =COR-
RECT FUEL MIXTURE.
Note: To facilitate fuel mixing, concen-
trated Ski-Doo oil should be kept at room
temperature.
Fuel Consumption Table
Throttle R.P.M.
H.P.
Time II
0Full 6500 28 1h.48m.
"'"
"'"
Qj %6500 21 2h.12m.
'U
0
V2
5500 14 3h.18m.
::as
V4
5500 7
6h.36m.
Throttle R.P.M. H.P.
Time II
0Full 5500 35
1h.15m.
"'"
CD
Qj %5500 26
1h.30m.
'U
0
V2
4500 14 3h.15m.
::as
1J4
4500 7
5h.45m.
II Running Time (in hours and minutes)
The Fuel Consumption table must be
construed as approximate only. Results
have been obtained by running static
tests under full load, but cannot take into
account such factors as snow conditions,
carburetor adjustments, etc.
Fuel Mixing Procedure
To mix the gasoline and oil always use a
separate clean container. Never mix
directly in your snowmobile tank.
Note: For best results, acquire two con-
tainers, either plastic or metal. Draw from
one until empty then use the second one.
Meanwhile, refill the first as soon as
con-
venient.
WARNING: Gasoline is flammable and
explosive under certain conditions,
Store in awell ventilated area. Always
stop the engine and do not smoke 01'
allow open flames or sparks neal' the
vehicle when refueling. If gasoline
fumes are noticed while driving, the
cause should be determined and cor-
rected without delay.
1. Pour the full amount of Ski-Doo oil
required for the total mixture into the
container.
2. Add approximately half the amount of
gasoline to be mixed.
3. Shake the container thoroughly.
4. Add the remainder of the gasoline.
5.
Once again thoroughly agitate the
container.
6. Using a funnel with a fine mesh screen
to prevent the entry of water and foreign
particles, transfer the mixture from the
container into the snowmobile tank.
3

PRE-START CHECK
Fuel Tank Quantity
Check that there is sufficient fuel in the
tank for your trip. A good habit to acquire
is to refill the tank before starting out
each day.
Since mixed fuel has a tendency to settle
overnight, agitate the fuel in the tank.by
standing on the footboards and rocking
the vehicle from side to side.
Steering Operation
Check operation of steering mechanism
by rotating the handlebars several.tirr:es
from side to side. If roughness or binding
is felt, check for ice or snow that may be
blocking the mechanism.
Throttle and Brake
Depress and release levers several times
to check that they operate easily and
smoothly. The throttle lever should return
to the idle position when released. The
brake lever should be fully applied when
it is
1" (minimum clearance) from the
handlebar grip. If the levers do not return
swiftly, remove cables
and/or housl~gs
and replace. Re-check lever operation.
Do not start the engine until levers re-
turn swiftly.
WARNING: Always check throttle and
brake operation before starting engine.
YOU MAY NOW START YOUR SKI-
DOO SNOWMOBilE.
4
BREAK-IN PERIOD
With Ski-Doo snowmobile engines,
a break-in period is required before
running the vehicle at full throttle.
Manufacturer's recommendation for
the Bombardier-Rotax engine is ten
(10) operating hours or the equivalent
fuel consumption. (Seepage 3 for the
equivalent fuel consumption of your
vehicle). During this period. maximum
throttle should not exceed %, except
momentarily to attain cruising speed
or avoid emergency. Before you took
delivery of your new Ski-Doo snow-
mobile the carburetor was adjusted
by your Dealer for a rich fuelrnlxture.
This permits better lubrication .and
cooling of the engme. Do not readjust.
regardless of excessive smoke in the
exhaust.
Inspection
As with any precision piece of me-
chanical equipment. we suggest that
after the first 10 hours of operation or
30 days after purchase whichever
comes first, that each Ski-Doo snow-
mobile has an inspection check. This
inspection, which should take approx-
imately 1
V2 hrs., is at the discretion
and expense of the vehicle owner.
IMPORTANT: After the first 2 hours of
operation, check drive .chain tension.
(See Maintenance Section).
TIPS
• By raising the outer attachment of the
bogie wheel sets vehicle manoeuvera-
bility
will increase.
You
will note that there are partially drill-
ed holes. located approx. 1 %" above the
original cross shaft holes of the frame.
(See Fig. 5). To reposition bogie
whe~)
sets, drill holes fully through usinq a ~6
dia. drill. Remove capscrews securing
bogie wheel cross shafts to frame and
reinstall in new position.
Note: Once holes have been drilled,
both positions are interc.hangeable
and
may be changed at any time.
• To start engine manually, when sta.rter
rope is broken. see Emergency GUide.
Page 11.

STARTING PROCEDURE
WARNING: Whenever practical, place
gear shift lever in NEUTRAL position
when starting engine.
The brake DOES NOT operate with
lever in NEUTRAL, so use caution on
inclined surfaces.
Never run the engine at HIGH R.P.M.
when gear shift lever is in NEUTRAL.
Electric Starting
For Models with electric starter:
1. Insert key in ignition switch (C).
2. Engage choke (E). (Choke is not ne-
cessary if engine is warmed up.)
3. Test throttle operation then apply
throttle lever (A) slightly.
4. Turn ignition key clockwise until start-
er engages.
CAUTION: Do not engage starter longer
than 30 seconds.
If engine does not start on first try, key
must be turned fully back to OFF each
time. Allow starter to cool for 2 minutes
before repeating procedure.
5. Release throttle and return key to ON
immediately engine has started.
6. Disengage choke (E).
CAUTION: Never operate the Ski-Doo
snowmobile with the battery removed or
disconnected.
7.
Allow the engine to warm up before
operating at full throttle.
Manual Starting
Every Ski-Doo snowmobile is equipped
with a manual starter (auto-rewind type)
located on the right hand side of the
engine. To start the engine manually:
1. Insert key in ignition (C) and turn to
ON position.
2. Engage choke (E). (Choke is not ne-
cessary if engine is warmed up).
3. Test throttle operation then apply
throttle lever (A) slightly.
4. Grasp manual starter handle (G) firmly
and pull slowly until a resistance is felt
then pull vigorously and engine will start.
Allow handle to return slowly to its origi-
nal position. If engine does not start, re-
peat the procedure.
Note: Do not pull starting rope to its full-
est extent or allow starting handle to
"fly
back" to its originalposition.
5. Release throttle (A), disengage choke
immediately engine has started.
6. Allow the engine to warm up before
operating at full throttle. 5

LUBRICATION
Code Weekly Page
L1
Ski Assembly 6
L2 Steering Mechanism 6
L3 Gear Box Oil Level 6
-
L4 Suspension 7
Code Monthly Page
L5 Driven Pulley 7
L6 Drive Pulley 7
Cab and Console Removal
To remove cab, unlock latches (2), dis-
connect electrical connectors (2), re-
move fuel tank cap and lift cab. (Valmont
only), to remove console unlock latches
(2) at base of console then remove.
WARNING: Always stop engine before
removing cab and do not start it
until
cab is closed and latches are fastened.
Pulley Guard Removal
1. Remove cab and console (Valmont
only).
2.
Pullout retaining clip and pullan
spring bolt to disengage pin from
bracket.
3. Move pulley guard toward front of ve-
hicle to disengage it from chain case
bracket.
6
WARNING: Never start the engine or
operate the vehicle when the pulley
guard is not installed.
Drive Belt Removal
To remove drive belt:
1. Remove cab, console (Valmont mod-
els) and pulley guard.
2. Disconnect brake cable at disc brake
unit.
3. Remove the two (2) bolts holding the
lower disc brake bracket to the frame.
Pivot the brake bracket assembly half
aturn.
4. Open the driven pulley (larger pulley).
Twist and push the sliding half then hold
in open position.
5. Slip the belt out from the drive pulley
(centrifugal governor) and remove from
vehicle by passing it under the driven
pulley and disc brake assembly. (See
Fig. 2).
6. To install drive belt, follow reverse
procedure. Check brake adjustment (See
BRAKE, page 10).
WARNING: Never start or run the en-
gine without drive belt installed.
(l1) Ski Assembly
Lubricate spring coupler bolt with 011.
(l2) Steering Mechanism
Using light machine oil, lubricate the
spring located on top of steering column
housing, allowing oil to run in. Oil the
mobile contact point at bottom end of
steering arm. Using a small brush,
dip-
ped in low temp-grease, lubricate steer-
ing arm ball joint. Grease the ski leg at
grease fitting until new grease appears
at the joint. (See Fig. 3).
(l3) Gear Box Oil level
All 440R and 440ER models have an oil
capacity of 12 ozs, The 640ER model has
an oil capacity of 16 ozs, To check:
1. Remove rubber inspection cover
lo-
cated on bottom right side of gear box.
2. Using a rigid piece of wire as dipstick,
check oil level (See Fig. 4). On 440R and
440ER models, oil level must reach
21/4 n
on dipstick. On 640ER model, oil level
must reach
3114".

To fill, remove filler cap (red cap) from
top of gear box. Refill as required using
Ski-Doo' chain case oil.
(l4) Suspension
Grease the suspension bogie wheels
with low-temp grease, using a low pres-
sure grease gun. Pump through the
grease fitting at the centre of each wheel
until new grease appears at the joints of
inner side of shaft. (See Fig. 5).
To grease the inner side bogie wheels,
tilt vehicle on its side and apply pres-
sure on track to expose grease fittings.
Also, grease rear axles at grease fittings.
(L5) Driven Pulley
With cab removed, grease the driven
pulley shaft, as follows:
1. Remove pulley guard and slip off
drive belt. Open the driven pulley, (push
and twist sliding half).
2. Thoroughly clean the driven pulley
shaft.
3 Apply a light coat of Ski-Doo' clutch
lube on the shaft.
Note: Activate the sliding half several
times to distribute lubricant over full
length at shaft. Be careful that lubricant
does not get on inner halves ot pulley.
CAUTION: Excess lubricant on pulley
shaft can penetrate drive belt causing
slippage and deterioration. Always lu-
bricate lightly
and wipe off sutptus.
(L6) Drive Pulley (or each 40 hours)
1. Remove cab and pulley guard then
slip off drive belt.
2. Remove centrifugal governor as fol-
lows:
• Remove spark plugs and position
the left side (P.T.O.)piston %" to 1%"
BEFOREtop dead center, making sure
that the piston closes the exhaust port.
• Accede by the spark plug hole and
pack the cylinder with
3/16" dia. rope.
(See Fig. 7).
• Pull manual starter to rotate crank-
shaft until piston bears against "cush-
ioning".
"Trademark Bombardier Limited
•Unscrew centrifugal bait, remove
centrifugal governor then pull out rope
from spark plug hole.
3. Thoroughly clean the inner pulley
shaft
using fine steel wool and a clean
cloth.
4.
Apply a light coat of Ski .. Doo* clutch
lube to
the four (4) flyweights of the cen-
trifugal governor.
5.
Making sure that the aligning mark on
inner pulley half coincides with the aliqn-
ing
mark of the outer pulley half, pack
inside
of pulley shaft with Ski-Doo"
clutch lube. (See Fig. 7).
6. Using light machine oil, lubricate the
governor bait threads and install gover"
nor.
Note: Installation procedure is reversed
insuring that the rope is inserted into
same
cylinder when piston is '%/I approx.
AFTER
top dead center.
wFig. 6
7

(W1) Spark Plugs
1. Remove console. (Valmont models
only). Disconnect spark plug wires.
8
ground. Place gear shift lever in neu-
tral. With engine OFF, rotate tracks by
hand and inspect condition. If bad cuts
or missing track inserts are noted, see
your dealer.
(WS) Track Tension
Lift the rear of vehicle and support it off
the ground. Using a rule, check track
tension. On Valmont models, take mea-
sure at the middle set of bogie wheels.
On Alpine model, check measure at the
second set of bogie wheels from rear.
The track tension (distance from the
top
inside edge of the track to the lower edge
of the body) should be 2% inches plus
or minus Va inch (See Fig. 9). If neces-
sary to adjust:
1. Unscrew the lock nuts situated on the
inner side of the suspension springs of
one track (See Fig. 10).
2. Adjust to proper tension by turning
adjuster bolts clockwise to tighten track,
counter-clockwise to slacken. Adjust
both sides equally.
3. Repeat procedure for other track and
proceed with track alignment.
BurntNormal
Carbonized
(W2) Battery
(Electric Model only)
Remove battery caps then check elec-
trolyte level in each cell. Electrolyte level
must touch bottom of filler hole. If ne-
cessary, add Distilled Water up to this
level.
(W3) Suspension Springs
With engine OFF, visually inspect sus-
pension springs. Replace any weak or
broken spring.
(W4) Tracks
Lift rear of vehicle and support it off the
2. Check condition of plug.
Normal color is "brownish" (See Fig. 8).
If spark plug color is abnormal (black or
light grey) the engine is not running
under ideal conditions, due to either;
• Use of incorrect fuel mixture. (See
Fuel Mixing, page 3).
• Carburetor incorrectly set. (See Car-
buretor Adjustment, page 9 ).
• Wrong type of spark plug. (See Spe-
cifications, page 1 for correct spark
plug heat range.
Fig. 8
9
8
9
9
8
8
8
8
10
Page
W5 Track Tension
W9 Drive Chain Tension
W4 Tracks
W8 Drive Belt Condition
W6 Track Alignment
W2 Battery
Wi Spark Plugs
W3 Suspension Springs
W7 Carburetor Adjustment
Code Monthly Page
M1 Carburetor Flange Nuts 10
M2 Muffler Attachment 10
M3 Brake 10
M4 Steering Adjustment 10
M5 Engine Head Nuts 10
M6 Engine Mount Nuts 10
M7 Vehicle General Inspection 10
Code Weekly
MAINTENANCE

(W6) Track Alignment
After track tension has been corrected,
start the engine and accelerate slightly
so that tracks turn slowly. Check that
tracks are well centered and turn evenly
on rear sprockets.
The distance between the edges of
tracks and the link plates should be the
same on both sides. Misalignment can
cause excessive wear of track edges
and sprocket teeth.
To adjust:
1. Using wrench, turn track adjuster
screw clockwise on the side where the
track is closest to the link plate until track
aligns. (See Fig. 10).
2. Firmly retighten adjuster lock nuts.
3. Rotatetrack slowly and recheck align-
ment.
(W7) Carburetor Adjustment
Maximum Throttle Opening
With engine OFF,unscrew the Idle Speed
Adjusting screw until a gap exists be-
tween screw end and carburetor shaft
lever. Depress the
throttle lever at
handlebar and hold. Throttle butterfly
should be horizontal when the lever gent-
ly touches the handlebar grip.
To adjust for maximum opening, loosen
screw at point where cable joins carbu-
retor lever.
With finger, hold carburetor throttle lever
in fully open position (UP), pull cable
downward until taut. Retighten screw,
ensuringthrottle isfully depressed.
WARNING: Before starting engine,
make sure carburetor throttle lever
returns to idle positionwhen handlebar
throttle lever is released.
Idle Mixture Adjustment
A primary adjustment (with engine OFF)
should be made by first turning idle mix-
ture screw fully clockwise until closed.
Back off screw
3f4 of a turn counter-
clockwise. (See Fig.
11 or 12).
Note: Do not close too tightly as needle
and/or needle seat can be damaged.
For final adjustment, start engine and
allow it to warm up. Turn idle mixture
screw until engine reaches maximum
R.P.M.and obtain a steady idle and a fast
response of the engine to the throttle.
Idle Speed Adjustment
Turn the idle speed adjusting screw
clockwise to increase idling speed, coun-
ter-clockwise to decrease. ( Fig. 11or 12).
High Speed Mixture Adjustment
WARNING: High Speed Mixture adjust-
ment must be carried out only by an
authorized Ski-Doo dealer.
For primary adjustment however, with
engine OFF,turn high speed mixture ad-
justing screw fully clockwise until it
closes. (Do not close too tightly as screw
and/or screw seat can be damaged).
Then
back off screw 1 V4 turns counter-
clockwise. (See Fig.
11 or12).
(W8) Drive Belt Condition
To check the condition of the drive belt:
1. Remove cab and pulley guard.
2. With engine OFF and gear shift lever
in NEUTRAL position, rotate drive belt.
If belt is less than %/I wide or if it shows
abnormal or uneven wear it should be
replaced. To replace, see Drive Belt
Removal, Page 6.
Note: Probable cause of abnormal wear
is pulley misalignment. Contact your
dealer. 9

(W9) Drive Chain Tension
Before checking, be sure that vehicle
has been run forward so that true free-
play will be on side exposed by inspec-
tion port. (See Fig. 13).
Check tension then turn driven pulley
Y2 turn counter-clockwise and recheck.
Starting from maximum reading adjust
chain tension to
1f4!1 free-play. '
1. Remove capscrew locking chain ten-
sioner in place. (See Fig. 13). Tensioner
is located at bottom left of gear box.
2. Rotate the tensioner as required to
obtain correct chain tension.
3. Replace capscrew to lock chain ten-
sioner in place.
(Mi) Carburetor flange Nuts
After the first 2 hours of operation check
tightness of carburetor flange nuts. Use
the 13mm open end wrench provided in
the tool kit, and tighten.
(M2) Muffler Attachment
With cab removed, tighten nuts and
bolts attaching muffler to flanges and
10
brackets. Loose muffler attaching parts
Will greatly reduce muffler life.
(MS) Brake
Brake should be fully applied when lever
is
1" from handlebar (See Fig. 14). To
adjust:
1. With cab removed, slacken cable lock
nut located at cable end nearest frame
(See Fig. 14).
2. If brake lever is too low, grasp free
end of cable with pliers and pull evenly.
Retighten nut.
3. If brake lever is too high, depress
brake lever slowly to position desired.
Retighten nut.
(M4) Steering Adjustment
Ski should be perpendicular to handle-
bar.
To align:
1. Remove bolt securing handlebar to
steering column.
2. Remove handlebar to expose splined
end of steering column.
3. Reposition handlebar on splines so
that it is perpendicular with ski. Install
and
fully tighten bolt.
(M5) Engine Head Nuts
With cab removed, check that engine
head nuts are tight and equally torqued.
(16 to 18
fUlbs when COLD). '
(MS) Engine Mount Nuts
With cab and console removed, check
engine mount nuts. Retighten if neces-
sary.
(M?) Vehicle General Inspection
With cab tilted, check electrical wiring
and. components, retighten loose con-
nections. Check for stripped wires or
damaged insulations. Thoroughly inspect
the vehicle and tighten loose bolts nuts
and linkages, Close cab and clea'n thf)
chassis throughout. Wax the cab for
greater protection. Special Ski-Doo*
pair:ts, for necessary touch ups, are
available at your dealer.
"Trademark of Bombardier limited

EMERGENCY GUIDE The following charts list the "most likely to
occur" problems, their possible causes
and remedies. Should you encounter trouble on the trail, first identify the symptoms
then rectify, using your manual to assist you.
What To Do
If headlamp is burnt, stop engine, unlock cab latches (2) and tilt cab. Unfasten bulb
retainer clips. Detach bulb and replace. If
taillight bulb is burnt, expose bulb by
removing red plastic lens. To remove, pry off red plastic lens using flat bladed
screwdriver.
Remove throttle cable and replace. Check lever operation. If necessary replace
housing. Do not start the engine until levers return
SWiftly.
If rope is broken Inside starter unit, remove starter unit, using 10mm wrench sup-
plied in Tool KIt. Make a knot at end of remaining rope at end opposite handle.
Wind remainder of rope around pulley. Pull vigorously, as per usual manual start.
(SeeFig. 1, page 4).
Travel with friends or in company with other snowmobiles. When exploring new
areas, always use the
"buddy" system. Even then, don't be foolhardy. Plan your
trips and carry at least some sort of rough gUide showing fuel stops and shelter.
Always know where you are. Unless you do, stay on known trails and familiar
terrain.
If both headlamp and taillight go out at same time, most possible cause is burnt
fuse. Check light fuse filament, if broken, replace. Light fuse is in fuse holder on
red wire going from starter to rectifier.
In emergency, fuel can be siphoned from companion or passing vehicle. To
siphon, disconnect both fuel lines of vehicle with fuel, at carburetor. Position
vehicle with fuel higher than vehicle with empty fuel tank. Run longer line into
empty fuel tank, (or container, if available). Placing hand over open filler neck of
tank with fuel, to form a sea! and build pressure, blow into open end of shorter
fuel line until flow starts.
11

TROUBLE SHOOTING GUIDE
12
Check the tank level and fill up with correct gas-oil mixture. (Refer to Fuel Mixing,
Page3). Check for possible clogging of fuel line, item 5.
Check for fouled or defective spark plug. Disconnect spark plug wire, unscrew plug
and removefrom cylinder head. Reconnect wire and ground exposed plug to engine
head, being careful to hold away from spark plug hole. Follow engine starting pro-
cedure and check for spark. If no sparks appear, replace spark plug. If trouble
persists, check item 3.
Disconnect spark plug wire from plug, unscrew the spark plug cap then hold
wire about Ys" from the cylinder head. Follow engine starting procedure and if
no sparks appear, it means a faulty ignition system. 00 not attempt to repair.
Contact your dealer.
----------------------------~--
Turn choke knob to OFF, wait 60 seconds or more then depress throttle lever
fully and try to start engine. Release throttle lever immediately after engine starts.
Remove and clean the fuel filter. Change filter cartridge if necessary. Check the
cleanliness of thefuel tank. Cleantank if necessary. (SeeFuelTank,Storage Section).
Screw in the idle speed mixture adjusting screw and turn it back %of a turn.
Make final adjustment with engine running and warmed up.
First make primary adjustments on carburetor. (See Maintenance Section). If car-
buretor is still faulty, contact your dealer for repair.
Drain the fuel tank and refill with the correct
gas/oil mixture. (Refer to Fuel
Mixing).
Breaker points may be worn or out of adjustment. Contact your dealer.
Running with a lean fuel mixture may produce excessive engine wear reSUlting
in poor engine compression. If this occurs, contact your dealer at once.
the case of a seized engine, contact your dealer. Seizure is a direct result of
poor lubrication.

Check for loose or corroded battery and starter connections. Tighten and clean if
necessary, also check fuse located on red wire
leading from rectifier to starter. Try
to restart engine electrically. If engine still does
not start, check item 2.
Check condition of battery by turning lights ON,
if lights are dim or out, battery
may be discharged or defective. Contact your
dealer to charge or replace.
If wire connections are tight and' fuse and battery are all in working order, most
probable cause of trouble is defective starter.
Contact your dealer for repair.
Change your spark plug. Fouled spark plug may
be cleaned, regapped and tested
by your dealer. (See Spark Plug, Maintenance Section).
Remove and clean fuel filter. Change filter
cartridge if necessary. Check fuel line
condition and connections. Check cleanliness of
fuel tank. Clean if necessary.
Readjust the carburetor. If the trouble persists,
contact your dealer.
-~.-
First check items 2 and 3 of "Engine turns over but fails to start or starts with
difficulty". If the ignition system still seems defective, contact your dealer.
If unable to locate specific symptoms, contact
your dealer.
Check item 1 of "Engine lacks acceleration or
power".
Carburetor set to lean. Readjust.
Contact your dealer.
Check for defective or worn drive belt. Replace if necessary.
If the drive and driven pulleys are not aligned correctly, contact your dealer.
Check track tension and alignment. Readjust to specifications. (See Maintenance
Section).
Check items 1 to 5 of "Engine lacks acceleration or power".
13

STORING PROCEDURE
It is during Summer, or when avehicle
is not in use for a month or more, that
proper storage is a necessity.
IMPORTANT: The necessity of proper
storage cannot be overstressed. If you
lack the time or proper tools, be sure to
see your authorized Ski-Doo Dealer.
(51) Tracks
1. Inspect tracks for cuts, missing track
inserts or broken rods and make any
necessary replacements.
2. Lift rear of vehicle until tracks are
clear of ground then support with brace
or trestle. The Ski-Doo snowmobile
should be stored in such a waythat tracks
do not stay in contact with cement floor
or bare ground.
Note: Due to the material change of the
'72 track, we recommend to keep the
spring tension applied. However, the
tracks should be rotated periodically,
(every 40 days).
(52) Suspension
(bogie wheels)
1. Remove the bogie wheei sets from
the vehicle.
2. Remove cross shaft from bogie wheel
set. Clean bogie wheel assembly and
cross shaft of dirt or rust.
3. Grease each bogie wheel until all old
grease is flushed out.
14
4. Spray bogie wheel springs with Ski-
000* meta! protector. If unavailable, wipe
with cloth or rag soaked in oil. Check
condition of shaft and replace if bent or
worn. Apply a coat of low temp. grease
on cross shaft.
,.--
'Y ro_-
"
Fig. 15
5. Reassemble entire bogie wheel set,
making sure assembly moves freely.
6. Reinstall bogie wheel set.
7. Repeat above steps on remaining bo-
gie wheel sets.
8. Lubricate rear hub through grease
fittings.
(53) 5ki Assembly
1. Wash or brush all dirt or rust accumu-
lation from ski and spring.
2. Grease ski leg at grease fittinr:!.
3. Check condition of ski runner. Re-
place if worn.
4. Apply
Ski-Doo' metal protector on
ski assembly. If unavailable, Wipethe en-
tire ski with cloth soaked in oil to prevent
rust formation.
"Trademark Bombardier Limited
(S4) Fuel Tal1k
1. Disconnect fuel lines by pulling plas-
tic lines away from tank. (See Fig. 16).
2. Remove tank retainer straps bolts,
pull out fuel tank from vehicle and drain it.
3. Rinse inside of tank thoroughly with
fresh gasoline.
4. Reinstall fuel tank.
WARNING: Gasoline is flammable and
explosive under certain conditions..
AI~
ways perform this procedure in a well
ventilated area. Do not smokeor allow
open flames or sparks near the vehicle.
(55) Carburetor
The carburetor must be dried out com-
pletely to prevent gum formation during
the storage period.
1. Assure that fuel lines are disconnect-
ed then start the engine and run it out
of gas.
2. Engage choke, then pack the carbu-
retor throat with a clean piece of cloth
and turn the engine a few more times.
The suction should eliminate the re-
maining fuel.

(56) Cylinder lubrication
1. Remove spark plugs.
2. Connect ignition wires to spark plugs
and ground plugs to prevent magneto
damage.
3. Operate rewind starter to bring piston
to the top position.
4. Four about one spoonful Ski-Doo*
oil into spark hole (See 17).
crank engine 10 to 12 times
manual starter.
procedure for other cylinder.
7. Instal! spark plugs.
(S1) Gear Box
Drain transmission gear box and refill
with 12
02S. (440R and 440ER models)
or 16 ozs. (640ER mode!) of fresh Ski-
000* chain case oil.
"Trademark Bombardier Limited
(S8) Controls
1. Oil steering mechanism linkage (See
Fig. 3).
2. Oil rnovinq joints of brake mechanism.
Avoid getting oil on brake shoe.
3. Coat ali electrical connections and
switches with Ski-Doo* metal protector
(greaseless).
(S9) Pulleys
1. Remove cab, console and drive belt.
(See Maintenance Section).
2. Thoroughly clean the driven pulley
shaft. Apply alight coat of Ski-Doo"
clutch lube on shaft .
3. Activate the sliding half several times
to distribute lubricant.
4. Lubricate drive pulley following the
procedure detailed in Lubrication Section
5. Spray internal pulley surfaces with
Ski-Doo* metal protector,
Note: Leave drive belt OFF during entire
storage period.
(510) Battery
(Electric model)
1. Open seat, disconnect battery and
remove it from vehicle.
2. Clean outside surfaces of battery. Do
not allow cleaning solution to enter bat-
tery.
3. Fully charge battery (trickle charge)
and store in a cool dry place.
Note: Recharge battery at least every
40 days to prevent sulphation.
HOW TO IDENTIFY YOUR
SKI-DOO SNOWMOBilE
Vehicle Serial Number (Frame)
The serial plate is located on the right
side of frame, at rear.
Engine
The identification plate is located at the
right side of the engine, on the fan cowl,
above the manual starter handle.
Tracks
The serial number is stamped directly
into each track, at one of the recesses
formed by the track ribs. To locate,
turn
tracks slowly until number appears be-
tween the rear sprockets.
IMPORTANT: Your Dealer retains a We
copy of your registration. Should you lose
or misplace your Service Card, he will
be more than pleased to assist you,
15

WARRANTY 1972 SKI-DOO SNOWMOBILE - U.S.A. and CANADA
16
Bombardier Limited (Bombardier), as manufacturer, warrants every
1972 Ski-Doo snowmobile sold as a new vehicle, by an author-
ized Ski-Coo dealer, to be free from defects in material, and
workmanship under normal use and service, for a period of ninety
(90) days from the date of the original retail purchase, subject to
the following exceptions:
1. Should the date of said original retail purchase be within ninety.
(90) days immediately preceding March 31, the warranty period
shall be for a period of ninety (90) days, beginning on the date
of said retail purchase until March 31 and the balance of said
warranty period shall be carried over into the following winter
season beginning with the date of the first snowfall, but not
later than the next 15th day of December.
2. Should the date of said original retail purchasing be on or after
March 31, the said warranty period shall be for a period of
ninety (90) days, beginning on the date of the first snowfall
during the following winter season, but not later than the next
15th day of December.
3. This warranty does not apply to Ski-Doo snowmobiles used
for racing purposes nor to Blizzard Ski-Doo snowmobile models.
Bombardier's obligation under this warranty is strictly limited to the
repair or replacement at its option, of any part or parts thereof
which shall, within the specified warranty period, be returned to
an authorized Ski-Doo dealer at such dealer's place of business
and, which examination shall disclose to the satisfaction of Bom-
bardier to have been thus defective. The repair or replacement of
defective parts under this warranty will be made by such dealer,
without charge for parts or labour, under the following conditions
only:
1. That proof of ownership and warranty registration be submitted
to the dealer by means of the Ski-Doo Service Card.
2. That warranty repairs be effected at the Dealer's place of busi-
ness.