BOMBARDIER Ski-Doo Legend Sport 4-Tec Owner's manual

2003
Shop Manual Supplement
4-TECTM
LEGEND V-1000 SPORT
GRAND TOURING V-1000 SPORT
This supplement must be used in conjunction with the
2003 ZX Series Shop Manual (P/N 484 200 042).

Legal deposit:
National Library of Quebec
National Library of Canada 2003
All rights reserved. No parts of this manual may be reproduced in any
form without the prior written permission of Bombardier Inc.
©Bombardier Inc. 2003
Technical Publications
Bombardier Inc.
Valcourt (Quebec) Canada
Printed in Canada
®*Registered trademarks of Bombardier Inc.
This document contains the trademarks of the following companies:
Loctite®is a trademark of Loctite Corporation
Molykote®is a trademark of Dow Corning Corporation
Silastic®is a trademark of Dow Corning Corporation
Snap-on®is a trademark of Snap-on Tools Corporation
Versilube®is a trademark of General Electric Company
SupertaniumTM is a trademark of Premier Industrial Corporation
AMP® is a trademark of Tyco Electronics Corporation

MMR2003_018_00_02A.FM I
SECTION SUBSECTION PAGE
SAFETY NOTICE .................................................................................................................................. II
INTRODUCTION .................................................................................................................................. III
01 SERVICE TOOLS AND
SERVICE PRODUCTS
01 – Service tools ............................................................................ 01-01-1
02 – Service products ...................................................................... 01-02-1
02 MAINTENANCE 01 – Table of contents ..................................................................... 02-01-1
02 – Maintenance chart ................................................................... 02-02-1
03 – Storage..................................................................................... 02-03-1
04 – Preseason preparation ............................................................. 02-04-1
03 ENGINE 01 – Table of contents ..................................................................... 03-01-1
02 – Troubleshooting ....................................................................... 03-02-1
03 – Leak test .................................................................................. 03-03-1
04 – Removal and installation .......................................................... 03-04-1
05 – Cooling system ........................................................................ 03-05-1
06 – Lubrication system................................................................... 03-06-1
07 – Cylinder and cylinder head ....................................................... 03-07-1
08 – Crankshaft/Drive gears............................................................. 03-08-1
09 – Crankcase ................................................................................ 03-09-1
04 ENGINE
MANAGEMENT
01 – Table of contents ..................................................................... 04-01-1
02 – Overview.................................................................................. 04-02-1
03 – Component inspection and adjustment ................................... 04-03-1
04 – Diagnostic procedures ............................................................. 04-04-1
05 TRANSMISSION 01 – Table of contents ..................................................................... 05-01-1
02 – Drive belt.................................................................................. 05-02-1
03 – Drive pulley .............................................................................. 05-03-1
04 – Pulley distance and alignment ................................................. 05-04-1
05 – Gearbox.................................................................................... 05-05-1
06 ELECTRICAL 01 – Table of contents ..................................................................... 06-01-1
02 – Ignition timing .......................................................................... 06-02-1
03 – Spark plugs .............................................................................. 06-03-1
04 – Alternator ................................................................................. 06-04-1
05 – Battery ..................................................................................... 06-05-1
06 – Electric starter.......................................................................... 06-06-1
07 – Testing procedure .................................................................... 06-07-1
07 STEERING/FRONT
SUSPENSION
01 – Table of contents ..................................................................... 07-01-1
02 – Steering system ....................................................................... 07-02-1
08 TECHNICAL DATA 01 – SI metric information guide...................................................... 08-01-1
02 – Engine ...................................................................................... 08-02-1
03 – Vehicles.................................................................................... 08-03-1
04 – Technical data legends............................................................. 08-04-1
09 WIRING DIAGRAMS 01 – Wiring diagrams ....................................................................... 09-01-1
TABLE OF CONTENTS
ZX SERIES

II MMR2003_018_00_02A.FM
SAFETY NOTICE 0
This manual has been prepared as a guide to correctly service and repair some 2003 Ski-Doo snowmo-
biles. See model list below.
This edition was primarily published to be used by snowmobile mechanic technicians who are already
familiar with all service procedures relating to Bombardier made snowmobiles. Mechanic technicians
should attend continuous training courses given by Bombardier Training Dept.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
This Shop Manual uses technical terms which may be slightly different from the ones used in the Parts Catalog.
It is understood that this manual may be translated into another language. In the event of any discrepancy,
the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Service
and Warranty Bulletins may be published to update the content of this manual. Make sure to read and
understand them.
In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the
general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas
of the parts.
The use of Bombardier parts is most strongly recommended when considering replacement of any com-
ponent. Dealer and/or distributor assistance should be sought in case of doubt.
The engines and the corresponding components identified in this document should not be utilized on
product(s) other than those mentioned in this document.
Torque wrench tightening specifications must strictly be adhered to. Locking devices (ex.: locking tab,
self-locking fasteners, etc.) must be installed or replaced with new ones. If the efficiency of a locking
device is impaired, it must be renewed.
This manual emphasizes particular information denoted by the wording and symbols:
CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle components.
NOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the
contents. We strongly recommend that any services be carried out and/or verified by a highly skilled
professional mechanic. It is understood that certain modifications may render use of the vehicle illegal
under existing federal, provincial and state regulations.
WARNING
Identifies an instruction which, if not followed, could cause serious personal injury including possi-
bility of death.
SAFETY NOTICE

MMR2003_018_00_02A.FM III
INTRODUCTION 0
This Shop Manual covers the following Bombardier made 2003 snowmobiles:
VEHICLE IDENTIFICATION
NUMBER
Vehicle Identification Number Location
TYPICAL
1. Vehicle identification number
Identification Number Meaning
ENGINE SERIAL NUMBER
Engine Serial Number Location
TYPICAL
1. Engine serial number
LIST OF ABBREVIATIONS
USED IN THIS MANUAL
MODEL PACKAGE ENGINE COLOR COUNTRY MODEL NUMBER
GRAND TOURING (E) SPORT V-1000 2 tone Blue (U.S./CDN) 2638
GRAND TOURING (E) SPORT V-1000 2 tone Blue (EUR) 2644
LEGEND (E) SPORT V-1000 2 tone Blue (U.S./CDN) 2637
A32H0DA 1
2 B P S 1 5 9 2 9 Y 1 0 0 0 0 0 1
A00A6EA
Model number Serial number
Model year: y = 2000
1 = 2001
2 = 2002
e c.
A ampere
amp ampere
A•h ampere-hour
AC alternate current
ACM acceleration and control modulator
ADSA advanced direct shock action
ATS air temperature sensor
BDC bottom dead center
BTDC before top dead center
BV battery voltage
CAPS camshaft position sensor
CPS crankshaft position sensor
1
A32C8IA
INTRODUCTION

IV MMR2003_018_00_02A.FM
CTS coolant temperature sensor
°C degree Celsius
cc cubic centimeter
CDI capacitor discharge ignition
CTR center
cm centimeter
cm²square centimeter
cm³cubic centimeter
DC direct current
DESS digitally encoded security system
DPM digital performance management
ECM engine control module
EMS engine management system
°F degree Fahrenheit
FC fan cooled
fl. oz fluid ounce
ft foot
GRD ground
H.A.C. high altitude compensator
hal. halogen
HI high
IFP internal floating piston
imp. oz imperial ounce
in inch
in²square inch
in³cubic inch
k kilo (thousand)
kg kilogram
km/h kilometer per hour
kPa Kilopascal
Lliter
lb pound
lbf pound (force)
lb/in²pound per square inch
LH left hand
LO low
LT long track
m meter
MAPS manifold air pressure sensor
Max. maximum
Min. minimum
mL milliliter
mm millimeter
mn minute
MPH mile per hour
MPI multi protocol interface
N newton
N.A. not applicable
no. number
00.0 continuity
0.L open line (open circuit)
O.D. outside diameter
OPS oil pressure switch
OPT optional
oz ounce
P/N part number
PSI pound per square inch
PTO power take off
R rectangular
RH right hand
RAVE Rotax adjustable variable exhaust
RER Rotax electronic reverse
ROM read only memory
RPM revolution per minute
RMS root mean square
RRIM reinforced reaction injection molding
ssecond
Sp. Gr. specific gravity
ST semi-trapez
TDC top dead center
TPS throttle position sensor
TRA total range adjustable
U.S. oz ounce (United States)
Vvolt
Vac volt (alternative current)
VSA variable sheave angle
WOT wide open throttle
INTRODUCTION

MMR2003_018_00_02A.FM V
Section 07 REAR SUSPENSION
Subsec ion 01 (SUSPENSION SC-10 SPORT, TOURING AND MOUNTAIN)
SUSPENSION SC-10 SPORT,
TOURING AND MOUNTAIN
Grand Touring 500/580, Formula 500/583 and Summit 500
07-01-1
MMR2000_042_00-02A.FM
A03F24S
Short track models only
Long track
models only
SLE
only
Loc i e
271
Loc i e
271
Loc i e
271
Loc i e
271
Loc i e
271
Loc i e
271
Loc i e
271
Loc i e
271
Low
emp.
grease
6
5
6
7
4
3
2
1
6
1
Low
emp.
grease
8
16
Low
emp.
grease
11
12
13
14
15
11
11
11
16
20 18
10
17
11
18 Nm
(160 lbfin)
4 Nm
(35 lbfin)
Page heading
indicates section
and subsection
detailed.
Bold face number
indicates special
procedure concerning
this part.
Tightening torque nearby
fastener. In this case, nut
must be torqued to
4 Nm or 3 lbfin.
This Shop Manual uses technical terms wich may be
slightly different from the ones in the parts catalog.
Exploded view
assists you in
identifying parts and
related positions.
TYPICAL PAGE
A01A2AS
Illustration number
for publishing
process.
Subsection title
indicates
beginning of the
subsection.
Drop represents
a service
product to be
applied to
a surface.
In this case
Loctite 271 to
screw threads.
Dotted box contains
parts of a particular
model in this case
the short track
models only.
Page numbering system:
07: REAR SUSPENSION section
01: SUSPENSION SC-10 SPORT,
TOURING AND MOUNTAIN subsection
1: First page of this subsection
Italic subtitle above
exploded view
indicates
pertaining models.
CAUTION: Pay a en ion o orque
specifi
ca ions. Some of hese are
in
lbf  in ins ead of lbf  f . Use appro-
pria e orque wrench.
Document
number for
publishing
process.
INTRODUCTION

VI MMR2003_018_00_02A.FM
MMR2000_042_00-02A.FM
A16D0IA
1
2
A
1
A-Series and B-Series Only
Should installation procedure be required, refer
to BRAKE then look for Brake Disc and Coun ershaf
Bearing Adjus men .
All Models
Check end play of driven pulley on countershaft by
pushing pulley towards outer housing so that the inner
shims (P/N 04 108 200) contact it. Measure end play
at the mounting screw end between shim(s) and puley.
See illustration.
TYPICAL  TOP VIEW
1. Shim (P/N 504 108 200) (as required)
2. Conta t
A. 0 to 1 mm (0 to 3/64 in)
Torque retaining screw no. 13 to 2 Nm (18 lbfft).
ADJUSTMENT
Refer to PULLEY DISTANCE AND ALIGNMENT to adjust
pulley distance. Adjust drive belt height be-
tween pulley halves to obtain specified belt
deflection.
Reinstall the pulley on the countershaft by rever-
sing the removal procedure.
CAUTION: Always apply an i-seize lubrican (P/N
413 701 000) on he coun ershaf before final pulley
ins alla ion.
05-03-5
Turn puller handle and sliding half at once to extract
the bushing. INSTALLATION
Coun ershaf
IMPORTANT: Large bushing retaining screws and
washers must be removed before small bushing
installation.
Coat bushing outside diameter with Loctite 609
(P/N 413 703 100).
Install bushing as following photo.
A03D1YA
529 031 300
529 031 200
A03D1ZA
529 031 300
529 031 200
Cam
Coat cam no. 18 interior with anti-seize lubricant.
ASSEMBLY
Came Slider Shoe
Section 05 TRANSMISSION
Subsec ion 03 (DRIVEN PULLEY)
When replacing slider shoes no. 4, always install a new
set (3 shoes) to maintain equal pressure on the cam.
Assemble driven pulley components by reversing
the disassembly procedure.
TYPICAL PAGE
Title indicates
main procedure
to be carried-out.
Reference to look
up a certain section
and subsection.
In this case it concerns
pulleys adjustment.
Italic bold face setting
in this case indicates
that particular
procedure for
A and B-Series is
finished, so from
this point, all models
are concerned.
Illustration always
follows text to which
it pertains.
Subtitle indicates
a particular procedure
for the named part.
Bold face number following part
name refers to exploded view
at beginning of subsection.
Call-outs for
above illustration.
Italic bold face type
setting indicates a
particular procedure
concerning a model.
TYPICAL caption
indicates a general
view which does
not represent full
detail.
TOP VIEW
caption helps you
in understanding
illustration.
A01A2BS
INTRODUCTION

MMR2003_018_00_02A.FM VII
GENERAL INFORMATION
The information and component/system descrip-
tions contained in this manual are correct at time
of publication. Bombardier Inc. however, main-
tains a policy of continuous improvement of its
products without imposing upon itself any obliga-
tion to install them on products previously manu-
factured.
Due to late changes, it may have some differences
between the manufactured product and the de-
scription and/or specifications in this document.
Bombardier Inc. reserves the right at any time to
discontinue or change specifications, designs,
features, models or equipment without incurring
obligation.
ILLUSTRATIONS AND
PROCEDURES
Illustrations and photos show the typical construc-
tion of the different assemblies and, in all cases,
may not reproduce the full detail or exact shape of
the parts shown. However, they represent parts
which have the same or a similar function.
CAUTION: Most components of those vehicles
are built with parts dimensioned in the metric sys-
tem. Most fasteners are metric and must not be
replaced by customary fasteners or vice-versa.
Mismatched or incorrect fasteners could cause
damage to the vehicle or possible personal injury.
As many of the procedures in this manual are in-
terrelated, we suggest, that before undertaking
any task, you read and thoroughly understand the
entire section or subsection in which the proce-
dure is contained.
A number of procedures throughout the book re-
quire the use of special tools. Before commencing
any procedure, be sure that you have on hand all
the tools required, or approved equivalents.
The use of RIGHT and LEFT indications in the text,
always refers to driving position (when sitting on
vehicle).
TYPICAL
1. Left
2. Right
SELF-LOCKING FASTENERS
PROCEDURE
The following describes the most common appli-
cation procedures when working with self-locking
fasteners.
Use a metal brush or a tap to clean the hole prop-
erly then use a solvent (Methyl-Chloride), let act
during 30 minutes and wipe off. The solvent utili-
zation is to ensure the adhesive works properly.
LOCTITE APPLICATION
PROCEDURE
The following describes the most common applica-
tion procedures when working with Loctite prod-
ucts.
NOTE: Always use proper strength Loctite prod-
uct as recommended in this Shop Manual.
1
A03A0CA
2
INTRODUCTION

VIII MMR2003_018_00_02A.FM
THREADLOCKER
Uncovered Holes (bolts and nuts)
1. Apply here
2. Do not apply
1. Clean threads (bolt and nut) with solvent.
2. Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
3. Choose proper strength Loctite threadlocker.
4. Fit bolt in the hole.
5. Apply a few drops of threadlocker at proposed
tightened nut engagement area.
6. Position nut and tighten as required.
Blind Holes
1. On threads
2. On threads and at the bottom of hole
1. Clean threads (bolt and hole) with solvent.
2. Apply Loctite Primer N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30
seconds.
3. Choose proper strength Loctite threadlocker.
4. Apply several drops along the threaded hole and
at the bottom of the hole.
5. Apply several drops on bolt threads.
6. Tighten as required.
Stud in Blind Holes
1. On threads
2. On threads and in the hole
3. Onto nut threads
1. Clean threads (stud and hole) with solvent.
2. Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
3. Put several drops of proper strength Loctite
threadlocker on female threads and in hole.
4. Apply several drops of proper strength Loctite
on stud threads.
5. Install stud.
6. Install cover, etc.
7. Apply drops of proper strength Loctite on un-
covered threads.
8. Tighten nuts as required.
A00A3LA
1
2
A00A3MA
1
2
A00A3NA
2
13
INTRODUCTION

MMR2003_018_00_02A.FM IX
Preassembled Parts
1. Apply here
2. Do not apply
1. Clean bolts and nuts with solvent.
2. Assemble components.
3. Tighten nuts.
4. Apply drops of proper strength Loctite on bolt/nut
contact surfaces.
5. Avoid touching metal with tip of flask.
NOTE: For preventive maintenance on existing
equipment, retighten nuts and apply proper strength
Loctite on bolt/nut contact surfaces.
Adjusting Screw
1. Apply here
2. Plunger
1. Adjust screw to proper setting.
2. Apply drops of proper strength Loctite thread-
locker on screw/body contact surfaces.
3. Avoid touching metal with tip of flask.
NOTE: If it is difficult to readjust, heat screw with
a soldering iron (232°C (450°F)).
STRIPPED THREAD REPAIR
Stripped Threads
1. Release agent
2. Stripped threads
3. Form-A-Thread
4. Tape
5. Cleaned bolt
6. Plate
7. New threads
8. Threadlocker
Standard Thread Repair
1. Follow instructions on Loctite FORM-A-THREAD
81668 package.
2. If a plate is used to align bolt:
a. Apply release agent on mating surfaces.
b. Put waxed paper or similar film on the surfaces.
3. Twist bolt when inserting it to improve thread
conformation.
NOTE: NOT intended for engine stud repairs.
Repair of Small Holes/Fine Threads
Option 1: Enlarge damaged hole, then follow
Standard Thread Repair procedure.
Option 2: Apply FORM-A-THREAD on the screw
and insert in damaged hole.
Permanent Stud Installation (light duty)
1. Use a stud or thread on desired length.
2. DO NOT apply release agent on stud.
3. Do a Standard Thread Repair.
4. Allow to cure for 30 minutes.
5. Assemble.
A00A3OA
1
2
A00A3PA
1
2
A00A3QA
5
8
6
7
1
2
3
4
INTRODUCTION

XMMR2003_018_00_02A.FM
GASKET COMPOUND
All Parts
1. Proper strength Loctite
2. Loctite Primer N (P/N 413 708 100) and Gasket Eliminator 515
(P/N 413 702 700) on both sides of gasket
3. Loctite Primer N only
1. Remove old gasket and other contaminants
with Loctite Chisel remover (P/N 413 708 500).
Use a mechanical mean if necessary.
NOTE: Avoid grinding.
2. Clean both mating surfaces with solvent.
3. Spray Loctite Primer N on both mating surfaces
and on both sides of gasket. Allow to dry 1 or 2
minutes.
4. Apply GASKET ELIMINATOR 515 (P/N 413 702
700) on both sides of gasket, using a clean ap-
plicator.
5. Place gasket on mating surfaces and assemble
immediately.
NOTE: If the cover is bolted to blind holes (above),
apply proper strength Loctite in the hole and on
threads. Tighten.
If holes are sunken, apply proper strength Loctite
on bolt threads.
6. Tighten as usual.
MOUNTING ON SHAFT
Mounting with a Press
1. Bearing
2. Proper strength Loctite
3. Shaft
Standard
1. Clean shaft external part and element internal
part.
2. Apply a strip of proper strength Loctite on shaft
circumference at insert or engagement point.
NOTE: Retaining compound is always forced out
when applied on shaft.
3. DO NOT use anti-seize Loctite or any similar
product.
4. No curing period is required.
Mounting in Tandem
1. Apply retaining compound on internal element
bore.
2. Continue to assemble as shown above.
A00A3SA
2
1
13
1
A00A3UA
1
2
3
INTRODUCTION

MMR2003_018_00_02A.FM XI
INTRODUCTION
CASE-IN COMPONENTS
Metallic Gaskets
1. Proper strength Loctite
1. Clean inner housing diameter and outer gasket
diameter.
2. Spray housing and gasket with Loctite Primer N
(P/N 293 800 041).
3. Apply a strip of proper strength Loctite on lead-
ing edge of outer metallic gasket diameter.
NOTE: Any Loctite product can be used here. A
low strength liquid is recommended as normal
strength and gap are required.
4. Install according to standard procedure.
5. Wipe off surplus.
6. Allow it to cure for 30 minutes.
NOTE: Normally used on worn-out housings to
prevent leaking or sliding.
It is generally not necessary to remove gasket
compound applied on outer gasket diameter.
A00A3VA 1

XII MMR2003_018_00_02A.FM
TIGHTENING TORQUES
Tighten fasteners to torque mentioned in explod-
ed views and text. When they are not specified
refer to following table. Bold face size (e.g. M4)
indicates nominal value (mean value).
WARNING
Torque wrench tightening specifications must
strictly be adhered to.
Locking devices (ex.: locking tabs, elastic stop
nuts, self-locking fasteners, etc.) must be in-
stalled or replaced with new ones where spec-
ified. If the efficiency of a locking device is im-
paired, it must be renewed.
N•m FASTENER SIZE
(8.8 grade) Lbf•in
2M4 18
3M427
4M5 35
8M671
9M680
10 M6 89
11 M6 97
12 M6 106
N•m FASTENER SIZE
(8.8 grade) Lbf•ft
21 M8 15
22 M8 16
23 M8 17
24 M8 18
25 M8 18
43 M10 32
44 M10 32
45 M10 33
46 M10 34
47 M10 35
48 M10 35
49 M10 36
50 M10 37
51 M10 38
52 M10 38
53 M10 39
76 M12 56
77 M12 57
78 M12 58
79 M12 58
80 M12 59
81 M12 60
82 M12 60
83 M12 61
84 M12 62
121 M14 89
122 M14 90
123 M14 91
124 M14 91
125 M14 92
126 M14 93
127 M14 94
128 M14 94
129 M14 95
130 M14 96
131 M14 97
132 M14 97
133 M14 98
134 M14 99
135 M14 100
136 M14 100
137 M14 101
138 M14 102
139 M14 103
140 M14 103
141 M14 104
142 M14 105
143 M14 105
144 M14 106
145 M14 107
146 M14 108
147 M14 108
148 M14 109
149 M14 110
150 M14 111
N•m FASTENER SIZE
(8.8 grade) Lbf•ft
INTRODUCTION

We would be pleased if you could
communicate to Bombardier any sug-
gestions you may have concerning
our publications.
✁
Bombardier SERVICE PUBLICATIONS REPORT
Publication title and year ________________________ Page______
Machine___________________ Report of error ❏Suggestion ❏
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
Name ______________________________________________________
Address ____________________________________________________
City and State/Prov. ________________________ Date___________
Zip code/Postal code ________________________________________
Bombardier SERVICE PUBLICATIONS REPORT
Publication title and year ________________________ Page______
Machine___________________ Report of error ❏Suggestion ❏
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
Name ______________________________________________________
Address ____________________________________________________
City and State/Prov. ________________________ Date___________
Zip code/Postal code ________________________________________
Bombardier SERVICE PUBLICATIONS REPORT
Publication title and year ________________________ Page______
Machine___________________ Report of error ❏Suggestion ❏
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
Name ______________________________________________________
Address ____________________________________________________
City and State/Prov. ________________________ Date___________
Zip code/Postal code ________________________________________

AFFIX
PROPER
POSTAGE
AFFIX
PROPER
POSTAGE
AFFIX
PROPER
POSTAGE
Technical Publications
After Sales Service
565 de la Montagne Street
Valcourt, Quebec, Canada J0E 2L0
Technical Publications
After Sales Service
565 de la Montagne Street
Valcourt, Quebec, Canada J0E 2L0
Technical Publications
After Sales Service
565 de la Montagne Street
Valcourt, Quebec, Canada J0E 2L0