BOMBARDIER Ski-doo MX ZX 440 Manual

Printed in Canada (MMO2003-006_back coverA.fm GM)
TM®are trademarks and ® are registered trademarks of Bombardier Inc. or its subsidiaries.
©2002 Bombardier Inc. All rights reserved.
SAFETY WARNING
Disregarding any of the safety precautions and instructions con-
tained in this Operator’s Guide, Safety Handbook, Safety Video or
on-product warnings may result in injury, including the possibility
of death.
This Operator’s Guide, Safety Handbook and Safety Video should
remain with the unit at time of resale.
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1
Dear 2003 MX Z X 440 owner, informations in the 2003
REV Series Operator’s Guide (P/N 219 000 236) also apply
to your MX Z X 440 except for the following.
LIMITED WARRANTY VALIDATION
The 2003 MX Z X 440 is shipped from the factory with high compres-
sion ratio (CR) combustion chamber inserts installed.
To validate limited warranty coverage, low CR combustion chamber
inserts must be installed on engine at predelivery before using
the vehicle. The high CR combustion chamber inserts must be re-
turned to BOMBARDIER Warranty Department.
CONTROLS/INSTRUMENTS
NOTE: See description or numbered items in 2003 REV Series Op-
erator’s Guide (P/N 219 000 236) except for the following.
24-25
A33A0QA
23
22
26
36
12
7
1
9
23 37
10
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REV SERIES

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7) Tether Cord Cut-Out System
General
The tether cord cut-out system prevents snowmobile to runaway, if
the operator accidently falls off, by shutting off the engine.
Operation
Attach tether cord to clothing eyelet then snap tether cord cap over
post before starting engine.
To stop engine, completely pull cap from post.
9) Engine Cut-Out Switch
Located on right side of handlebar this switch is used to stop the
engine.
0. OFF
1. ON
WARNING
Always disconnect tether cord when leaving vehicle unattended
and keep in a secured location.
0
A33E0HA
1
0
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23) Fuel Level
Open fabric door to see the fuel level through the transparent fuel
tank.
1. Fabric door
35) Adjustable Suspensions
In addition to all suspension adjustments described in REV Series
Operator’s Guide, take note of the 2 following points.
Shocks
All 4 shocks feature 2 adjustments.
Low Speed Compression Adjuster
The low speed adjuster modifies the damping force for small suspen-
sion velocities — less than 0.75 m/s (2.5 ft/s). It tunes the vehicle for
braking, cornering, hole shot and all the bumps that create low speed
movement in the suspension. This adjuster has 4 turns of adjust-
ment. Use a flat screwdriver to adjust it. Turning it clockwise increas-
es shock damping action (stiffer) for these low compression speeds.
A33H1OA 1
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High Speed Compression Adjuster
The High speed adjuster modifies the damping force for high suspen-
sion velocities —more than 0.5 m/s (1.6 ft/s). It tunes the vehicle for
hoops or bumps that create high speed movement in the suspension.
This adjuster has 3 turns of adjustment. Use a 17 mm wrench to
adjust it. Turning it clockwise increases shock damping action (stiffer)
for these high compression speeds.
1. Low speed compression adjuster (flat screwdriver)
2. High speed compression adjuster (17 mm wrench)
Center and Front Springs
CAUTION: Make sure that center spring and both front springs
are still preloaded when front of vehicle is off the ground. Maxi-
mum spring preload is 25 mm (1 in). Otherwise, spring will be
coil bound when fully compressed.
36) Primer Button
Pull and push button. It is not necessary when engine is warm.
To prime, activate button until a pumping resistance is felt. From this
point, pump 2 or 3 times to inject fuel in intake manifold. After prim-
ing, ensure that primer button is pushed back.
NOTE: In very cold temperature, it is recommended to rotate primer
button 3-4 turns prior to pull it. This will eliminate the possibility of
sticking.
A33F0DA 12
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37) Timing Switch
Except European Model
NOTE: This switch is disabled (not operative) on vehicles modified for
warranty validation.
1. 91 Octane
2. 100 + Octane
Select octane level according to fuel octane number used.
CAUTION: Never use timing switch at position 100+ with 91 fuel
octane. Refer to MAIN JET - TIMING - FUEL CHART decal on belt
guard.
1
A33E0GA 2
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FUEL AND OIL
Recommended Fuel
Vehicles with Valid Warranty (Timing Switch Disabled)
Use super unleaded gasoline, available from most service stations or
oxygenated fuel containing less than 10% of ethanol or 5% of meth-
anol. The gasoline used must have an octane number (R + M)/2 of
91 or higher.
NOTE: In most service station pump octane number corresponds to
(R + M)/2 octane number.
Vehicles without Warranty (Timing Switch Enabled)
Use one of the two following fuels depending of the type of racing.
1. Super unleaded gasoline, available from most service stations or
oxygenated fuel containing less than 10% of ethanol or 5% of meth-
anol. The gasoline used must have an octane number (R + M)/2 of
91 or higher.
2. Racing fuel with motor octane number of 100 and more.
Use timing switch to select octane level corresponding to the fuel
octane number used.
CAUTION: Never use timing switch at position 100+ with 91 fuel
octane. It may cause low engine performance or may damage
the engine.
All Vehicles
CAUTION: Never experiment with other fuels or fuel ratios. The
use of unrecommended fuel can result in snowmobile perfor-
mance deterioration and damage to critical parts in the fuel sys-
tem and engine components.
WARNING
Always stop engine before refueling. Open cap slowly. If a dif-
ferential pressure condition is noticed (whistling sound heard
when loosening fuel tank cap) have vehicle inspected and/or
repaired before further operation. Fuel is flammable and ex-
plosive under certain conditions. Never use an open flame to
check fuel level. Never smoke or allow flame or spark in vicin-
ity. Always work in a well-ventilated area. Never top up the fuel
tank before placing the vehicle in a warm area. As temperature
increases, fuel expands and may overflow. Always wipe off
any fuel spillage from the vehicle.
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Fuel System Antifreeze
NOTE: Fuel antifreeze may add alcohol to fuel which may lead to
disqualification by technical inspection after the race.
When using oxygenated fuel, additional gas line antifreeze or water
absorbing additives are not required and should be not used.
When using non-oxygenated fuel, we highly recommend the use of iso-
propyl base gas line antifreeze in a proportion of 150 mL (5 U.S. oz)
of gas line antifreeze added to 40 liters (10-1/2 U.S. gal) of gas.
This precaution is in order to reduce the risk of frozen carburetor(s)
which may lead, in certain cases, to high fuel consumption or severe
damage to engine.
IMPORTANT: Use only methyl hydrate free gas line antifreeze.
Recommended Oil
CAUTION: Use only oil that flows at - 40°C (- 40°F).
Oil must be mixed with fuel in proper ratio in a jerrycan then, be
poured in the fuel tank.
Use only two-stroke engine injection oil, sold by authorized SKI-DOO
dealers.
➀CAUTION: The BOMBARDIER Formula XP-S II oil is specially
formulated and tested for the severe requirements of the 453
engine. Use of any other brand two-stroke oil may void the
limited warranty. Use only BOMBARDIER FORMULA XP-S II oil.
There is no known equivalent on the market for the moment. If
a high quality equivalent were available, it could be used.
MODEL OIL TYPE
MX Z X 440 BOMBARDIER FORMULA XP-S II
synthetic injection oil ➀
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BOMBARDIER injection oil is a special blend of basic oil and additives
especially selected to ensure unequalled lubrication, engine cleanliness
and minimum spark plug fouling.The BOMBARDIER FORMULA XP-S
II synthetic injection oil provides superior lubrication, reduced en-
gine component wear and oil deposit, thus maintaining maximum-
level performance and antifriction properties. This synthetic injection
oil meets the latest ASTM and JASO standards by ensuring high bio-
degradability and low exhaust smoke.
CAUTION: Never use four-stroke petroleum or synthetic motor
oil and never mix these with outboard motor oil. Do not use
NMMA TC-W, TC-W2 or TC-W3 outboard two-stroke engine oils
or ashless two-stroke engine oils. Avoid mixing different brands
of API TC oil as resulting chemical reactions may cause severe
engine damage.
WARNING
Wipe off any oil spills. Oil is highly flammable.
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OIL/FUEL 33/1
METRIC (SI)
1 L of oil + 33 L of fuel = 33/1
IMPERIAL
35 imp. oz of oil + 7.2 imp. gal of fuel = 33/1
1 L of oil + 7.2 imp. gal of fuel = 33/1
UNITED STATES
34 U.S. oz of oil + 8.8 U.S. gal of fuel = 33/1
1 L of oil + 8.8 U.S. of fuel = 33/1
A32I09A
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STARTING PROCEDURE
•Re-check throttle control lever operation.
•Ensure that the emergency cut-out switch is in the ON position.
•Ensure the tether cut-out cap is in position and that the cord is
attached to your clothing.
•If applicable use the octane level switch to select proper octane
number according to fuel used.
•To prime, activate button until a pumping resistance is felt. From
this point, pump 2 or 3 times to inject fuel in intake manifold. After
priming, ensure that primer button is pushed back.
NOTE: In very cold temperature, it is recommended to rotate primer
button 3-4 turns prior to pull it. This will eliminate the possibility of
sticking.
NOTE: Priming is not necessary when engine is warm.
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FLUID LEVEL
CAUTION: Vehicle must be on a level surface before checking any
fluid levels.
Brake System
Check brake fluid (DOT 4) in reservoir on handlebar for minimum lev-
el. Add recommended fluid (DOT 4) as required. Refer to SPECIFICA-
TIONS for recommended fluid.
CAUTION: Use only (DOT 4) brake fluid from a sealed container.
Never use any other types of fluid.
TYPICAL — BRAKE FLUID RESERVOIR
1. Minimum
Coolant Pump Shaft Oil Reservoir
Use BOMBARDIER injection oil (P/N 413 802 900) (12 x 1 L).
Fill up to mark.
1
A33D03A
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Coolant Reservoir
Use a blend of 50/50 distilled water and ethylene-glycol (P/N 293 600
038). That blend will protect the system from freezing as low as - 37°C
(- 35°F).
Fill up to mark when engine is cold.
1. Coolant pump shaft oil filling mark
2. Coolant cold level mark
A32C10A
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MAINTENANCE
Track Tension and Alignment
Tension
NOTE: Ride the snowmobile in snow about 15 to 20 minutes prior to
adjusting track tension.
Turn off engine cut-out switch.
Lift rear of snowmobile by the bumper using a wide-base snowmo-
bile mechanical stand.
Allow the rear suspension to fully extend and check gap half-way
between front and rear idler wheels.
Measure between slider shoe and bottom inside of track. The gap
should be as given in SPECIFICATIONS. If the track tension is too
loose, track will have a tendency to thump.
NOTE: A belt tension tester (P/N 414 348 200) may be used to mea-
sure deflection as well as force applied.
BELT TENSION TESTER
TYPICAL
1. 7.3 kg (16 lb)
2. Deflection
A00C07C
1
2
A06F1WA
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CAUTION: Too much tension will result in power loss and exces-
sive stresses on suspension components.
Adjustment
Loosen one of the rear idler wheel retaining screws.
Loosen lock nut on both adjustment screws before adjusting track
tension and/or alignment. Retighten after adjustments are done.
LEFT SIDE SHOWN
1. Lock nut on adjustment screw
A32F0WA
1
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SPECIFICATIONS
➀Measure gap between slider shoe and bottom inside of track when
exerting a downward pull of 7.3 kg (16 lb) to the track.
➁Equal distance between edges of track guides and slider shoes.
➂Super unleaded gasoline with a minimum octane number of 91
(R + M)/2 or racing fuels depending of type of racing.
➃BOMBARDIER Formula XP-S II synthetic injection oil (P/N 293 600
245 —12 x 1 L) or BOMBARDIER injection oil (P/N 413 802 900
—12 x 1 L) (or equivalent).
➄BOMBARDIER synthetic chaincase oil (P/N 413 803 300) (12 x 355 mL).
GENERAL MX Z X 440
Engine
– Maximum power engine speed ± 100 RPM 8400
Drive belt
– Number 414 860 700
– New belt width mm (in) 34.9 (1-3/8)
– Wear limit width mm (in) 32.5 (1-1/4)
Spark plug
– Type NGK BR 9 ECS
– Gap mm (in) 0.45 (.018) ➆
Track
– Tension mm (in) 30 to 35 (1-3/16 to 1-3/8) ➀
– Alignment ➁
FLUIDS
Fuel
–Type ➂
– Tank capacity L (U.S. gal) 21 (5.55)
Oil (engine)
–Type ➃
– Premix ratio 33/1
Chaincase/Transmission Oil
–Type ➄
– Capacity mL (U.S. oz) 250 (8.5)
Cooling System
–Type ➅
– Capacity L (U.S. oz) 3.5 (118)
Brake System Fluid
–Type DOT4
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➅Blend of 50/50 distilled water and ethylene-glycol (P/N 293 600
038). That blend will protect the system from freezing as low as
-37°C (- 35°F).
➆CAUTION: Do not attempt to adjust gap on spark plug BR 9 ECS.
Bombardier reserves the right at any time to discontinue or change spec-
ifications, designs features, models, prices or equipment without incur-
ring obligation.
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