Lynx Rave 440 User manual

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OPERATOR’S MANUAL LYNX 2005
Rave 440/800
Enduro Sport/600SDI/550/400
Adventure 800
Touring V-1000
Sport Touring 600 SDI
Ranger 600

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CONTENT
SAFETY MEASURES ............................................................ 5
WARRANTY ...................................................................... 6
HOW TO IDENTIFY YOUR SNOWMOBILE ................................... 9
Vehicle serial number .............................................................................................. 9
Engine serial number............................................................................................... 9
CONTROLS / INSTRUMENTS ................................................ 10
1. Throttle lever ................................................................................................ 11
2. Brake lever ................................................................................................... 11
3. Parking brake lever ...................................................................................... 11
4. Brake / parking brake / low oil level pilot lamp (Red) .................................. 12
5. Gear shift lever or RER button ..................................................................... 12
6. Reverse indicator lamp ................................................................................ 15
7. Handle bar.................................................................................................... 15
8. Ignition switch/START/RER button .............................................................. 15
9. Tether cut-out switch ................................................................................... 16
10. DESS pilot lamp ........................................................................................... 17
11. Emergency cut-out switch ........................................................................... 17
12. Headlamp dimmer switch ............................................................................ 18
13. High beam pilot lamp (Blue) ........................................................................ 20
14. Rewind starter handle .................................................................................. 20
15. Choke lever .................................................................................................. 20
16. Primer .......................................................................................................... 21
17. Speedometer ................................................................................................ 21
18. Odometer ..................................................................................................... 21
19. Trip meter..................................................................................................... 21
20. Trip meter reset button/mode button ........................................................... 21
21. Fuel tank cap/gauge ..................................................................................... 23
22. Engine overheating warning lamp (Red) ...................................................... 23
23. Heated grip and throttle lever switch ........................................................... 23
24. Heated throttle lever switch ......................................................................... 24
25.. Hood latches ................................................................................................ 24
26. Electric power outlet .................................................................................... 25
27. Fuse ............................................................................................................. 25
28. Front bumper ............................................................................................... 27
29. Storage compartment .................................................................................. 27
30. Rear rack...................................................................................................... 27
31. Tool kit ......................................................................................................... 27
32. Spark plug holder......................................................................................... 27
33. Seat strap..................................................................................................... 28

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34. Hitch ............................................................................................................ 28
35. Adjustable suspension ................................................................................. 28
36. Engine temperature warning light ................................................................ 28
Guidelines.............................................................................................................. 29
Suspension troubleshooting.................................................................................. 36
In deep snow ......................................................................................................... 36
FUEL AND OIL ................................................................. 36
Recommended fuel ............................................................................................... 36
Recommended oil .....................................................................................................
COLD WEATHER CARBURETION MODIFICATIONS....................... 38
BREAK-IN PERIOD ............................................................ 39
Engine ................................................................................................................... 39
Drive belt ............................................................................................................... 39
10 hour inspection ................................................................................................ 39
PRE-OPEARATION CHECK ................................................... 40
CHECK LIST.................................................................... 40
OPERATION INSTRUCTIONS ................................................ 40
Operations ............................................................................................................. 40
Starting the engine ................................................................................................ 41
Manual starting ..................................................................................................... 42
Shutting off the engine .......................................................................................... 44
VEHICLE WARM UP .......................................................... 45
POST-OPERATION CARE ..................................................... 45
SPECIAL OPERATIONS ....................................................... 45
Riding at high altitudes ......................................................................................... 45
Engine overheating ................................................................................................ 45
Fuel flooded engine ............................................................................................... 46
Rear suspension slider shoe sticking .................................................................... 46
FLUID LEVELS................................................................. 46
Brake system ......................................................................................................... 46
Chain case oil level/Gearbox oil level..................................................................... 47
Oil injection system ............................................................................................... 47

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Cooling system...................................................................................................... 49
Battery ................................................................................................................... 50
MAINTENANCE ................................................................ 51
Vehicle cleaning and protection............................................................................. 51
Belt guard removal and installation ....................................................................... 52
Drive belt removal and installation ........................................................................ 52
Drive chain tension................................................................................................ 57
TRA drive pulley adjustment ................................................................................. 58
Drive belt condition ............................................................................................... 60
Brake condition ..................................................................................................... 60
Brake adjustment .................................................................................................. 60
Rear suspension condition .................................................................................... 60
Suspension stopper strap condition ...................................................................... 60
Track condition ...................................................................................................... 60
Track tension and alignment.................................................................................. 61
Steering and front suspension mechanism ........................................................... 62
Wear and condition of skis and runners ................................................................ 62
Exhaust system ..................................................................................................... 63
Air filter cleaning ................................................................................................... 63
Headlight ............................................................................................................... 64
STORAGE AND PRE-SEASON PREPARATION ............................. 66
Storage .................................................................................................................. 66
Pre-season preparation ......................................................................................... 66
TROUBLESHOOTING ......................................................... 67

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SAFETY MEASURES
* For vehicle with a parking brake, always engage brake when snowmobile is not in
use.
* Throttle mechanism should be checked for free movement before starting engi-
ne.
* The snowmobile can be stopped by activating the emergency cut-out switch, pul-
ling the tether cord or turning off the ignition key (if equipped).
* Engine should be running only when belt guard is secured in place. Never run the
engine without drive belt installed. Running an unloaded engine can prove to be
dangerous.
* Never run the engine when the track is raised off the ground or with the hood
opened or removed.
* Do not stud the track. At speed it may cause the track to tear and separate from
vehicle posing a risk of severe injury or death.
* Never start the engine in closed area or indoors.
* Maintain your snowmobile in top mechanical condition at all times.
* Snowmobile is not designed to be operated on public streets, roads or highways.
In most countries it is considered an illegal operation.
* Never charge or boost battery while installed on snowmobile.
* Do not lubricate throttle and/or brake cables and housings.

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BRP INTERNATIONAL LIMITED WARRANTY:
2005 LYNX®SNOWMOBILES
1. SCOPE OF THE LIMITED WARRANTY
Bombardier-Nordtrac Oy (“BRP”) warrants its 2005 LYNX snowmobiles from defects in ma-
terial or workmanship for the period and under the conditions described below.
All genuine LYNX parts and accessories, installed by an authorized BRP distributor/dealer (as
hereinafter defined) at the time of delivery of the 2005 LYNX snowmobile, carry the same
warranty as that of the snowmobile.
Use of the product for racing or any other competitive activity, at any point, even by a previo-
us owner, will render this warranty null and void.
2. WARRANTY COVERAGE PERIOD
This warranty will be in effect from the date of delivery to the first retail consumer or the date
the product is first put into use, whichever occurs first and for a period of:
A) TWELVE (12) CONSECUTIVE MONTHS, for private use owners
B) TWELVE (12) CONSECUTIVE MONTHS, for commercial use owners
C) TWENTY FOUR (24) CONSECUTIVE MONTHS, for private use owners when product was
sold in a member state of the European Union.
The repair or replacement of parts or the performance of service under this warranty does
not extend the life of this warranty beyond its original expiration date.
3. CONDITIONS TO HAVE WARRANTY COVERAGE
This warranty coverage is available only on 2005 LYNX snowmobile purchased as new and
unused by its first owner from a BRP distributor/dealer authorized to distribute LYNX pro-
ducts in the country in which the sale occurred ( “BRP distributor/dealer”), and then only
after the BRP specified pre-delivery inspection process is completed and documented. War-
ranty coverage only becomes available upon proper registration of the product by an autho-
rized BRP distributor/dealer. Moreover, this warranty coverage is only available if the LYNX
snowmobile is purchased in the country or union of countries in which the purchaser resides.
BRP will not honor this limited warranty to any private use owner or commercial use owner if
the preceding conditions have not been met. Such limitations are necessary in order to allow
BRP to preserve both the safety of its products, and also that of its consumers and the
general public.
Routine maintenance outlined in the Operator’s Guide must be timely performed in order to
maintain warranty coverage. BRP reserves the right to make warranty coverage contingent
upon proof of proper maintenance.

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4. WHAT TO DO TO OBTAIN WARRANTY COVERAGE
The customer must notify a servicing BRP distributor/dealer within two (2) months of the
appearance of a defect, and provide it with reasonable access to the product and reasonable
opportunity to repair it. The customer must also present to the authorized BRP distributor/
dealer, proof of purchase of the product and must sign the repair/work order prior to starting
the repair in order to validate the warranty repair. All parts replaced under this limited war-
ranty become the property of BRP.
5. WHAT BRP WILL DO
BRP’s obligations under this warranty are limited to, at its sole discretion, repairing parts
found defective under normal use, maintenance and service, or replacing such parts with
new genuine LYNX parts without charge for parts and labor, at any authorized BRP distri-
butor/dealer during the warranty coverage period.
BRP reserves the right to improve or modify products from time to time without assuming
any obligation to modify products previously manufactured.
6. EXCLUSIONS
The following are not warranted under any circumstances:
• Normal wear and tear;
• Routine maintenance items, tune ups, adjustments;
• Damage caused by failure to provide proper maintenance and/or storage, as described in
the Operator’s Guide;
• Damage resulting from removal of parts, improper repairs, service, maintenance, modifi-
cations or use of parts not manufactured or approved by BRP or resulting from repairs
done by a person that is not an authorized servicing BRP distributor/dealer;
• Damage caused by abuse, abnormal use, neglect, use of the product on surfaces other
than snow, or operation of the product in a manner inconsistent with the recommended
operation described in the Operator’s Guide;
• Damage resulting from accident, submersion, fire, theft, vandalism or any act of God;
• Operation with fuels, oils or lubricants which are not suitable for use with the product (see
the Operator’s Guide);
• Snow or water ingestion;
• Incidental or consequential damages, or damages of any kind including without limitation
towing, storage, telephone, rental, taxi, inconvenience, insurance coverage, loan payments,
loss of time, loss of income; and
• Damage resulting from studs installed on tracks if the installation does not conform to
BRP’s instructions.

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7. LIMITATIONS OF LIABILITY
THIS WARRANTY IS EXPRESSLY GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER
WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WAR-
RANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. TO THE EX-
TENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN
DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL
DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/
PROVINCES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDEN-
TIFIED ABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU
SPECIFIC RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH MAY VARY
FROM STATE TO STATE, OR PROVINCE TO PROVINCE.
Neither the distributor, any BRP distributor/dealer nor any other person has been authorized
to make any affirmation, representation or warranty regarding the product, other than those
contained in this limited warranty, and if made, shall not be enforceable against BRP.
BRP reserves the right to modify this warranty at any time, being understood that such mo-
dification will not alter the warranty conditions applicable to the products sold while this
warranty is in effect.
8. TRANSFER
If the ownership of a product is transferred during the warranty coverage period, this warran-
ty shall also be transferred and be valid for the remaining coverage period provided BRP or
an authorised BRP distributor / dealer receives a proof that the former owner agreed to the
transfer of ownership, in addition to the co-ordinates of the new owner.
9. CONSUMER ASSISTANCE
(a) In the event of a controversy or a dispute in connection with this limited warranty, BRP
suggests that you try to resolve the issue at the dealership level. We recommend discus-
sing the issue with the authorized distributor/dealer’s service manager or owner.
(b) If further assistance is required, the distributor’s service department should be contacted
in order to resolve the matter.
(a) If the matter still remains unresolved then contact BRP by writing to us at the address
listed below.
BOMBARDIER-NORDTRAC OY
SERVICE DEPARTMENT
P.O. BOX 8040
FIN-96101 ROVANIEMI
FINLAND

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HOW TO IDENTIFY YOUR SNOWMOBILE
Serial numbers
The main components of your snowmobile (engine and frame) are identified by different
serial numbers. It may sometimes become necessary to locate these numbers for warranty
purposes or to trace your snowmobile in the event of loss.
These numbers are required by the Lynx dealers to complete warranty claims properly. No
warranty will be allowed by Bombardier if the engine serial number or VIN is removed or
mutilated in any way. We strongly recommend that you take all the serial numbers on your
snowmobile and supply them to your insurance company.
1. Engine serial number
1. Engine serial number

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4-tec models
1. Engine serial number
CONTROLS / INSTRUMENTS
NOTE! Some controls/instruments do not apply to some models.

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1. Engine Management System (EMS) pilot lamp
2. Air shock pilot lamp (not in use on Lynx)
3. Oil pressure pilot lamp
4. Cooling liquid pilot lamp
5. High beam pilot lamp
6. Low battery voltage pilot lamp
7. DESS pilot lamp
8. Brake pilot lamp
1. Throttle lever
Located on the right side of handlebar. When compressed, it controls the engine speed and
the engagement of the transmission. When released, engine speed returns automatically to
idle.
2. Brake lever
Located on the left side of handlebar. When compressed, the brake is applied. When re-
leased, it automatically returns to its original position. Braking effect is proportional to the
pressure applied on the lever and to the type of terrain and its snow coverage.
3. Parking brake button or lever
Located on left side of handlebar. Parking brake should be used whenever snowmobile is
parked.
Whenever parking brake is applied and engine is running, injection oil level/parking brake
pilot lamp lights up to remind you that it is engaged. Never leave your snowmobile on down-
hill only with parking brake engaged.

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Make sure parking brake is fully disengaged before operating the snowmobile.
Hydraulic brake
To engage mechanism, squeeze brake lever and maintain while pulling locking lever with a
finger. Brake lever is now compressed halfway applying brakes.
To release mechanism, squeeze brake lever. Locking lever will automatically return to its
original position. Brake lever now returns to rest position. Always release parking brake befo-
re riding.
Locking keeps brake lever engaged and keeps pressure against brake disc.
Anyhow, this pressure may decrease so low, that it will not keep vehicle in place.
Never leave the snowmobile on hill only with parking brake applied.
1. Locking lever
2. OFF
3. ON
4. Brake/Parking brake/Low oil level pilot lamp (Red)
Lights when brake or parking brake is applied (with engine running).
This pilot lamp also lights up when injection oil level is low (with engine running). Check oil
level and replenish as soon as possible.
5. Gear shift lever or RER button
Touring V-1000: This model is equipped with a mechanical reverse controlled by a 2-position
gear shift lever.
WARNING!
WARNING!

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1. Forward
2. Reverse
NOTE: These models: Whenever shifting the gear the snowmobile has to be comple-
tely stopped, otherwise the gear system may get damaged.
Electric reverse
Some models: These models are equipped with an electronic reverse (RER), which is cont-
rolled by a RER button.
Reverse shift can be used when the snowmobile is stopped and engine is running at idle.
Engine is running automatically forward when the snowmobile is started after stalling or
stopping.
Shifting in reverse
With the snowmobile completely stopped and engine running at idle, press and release the
RER button.
1. RER button
The reverse pilot lamp blink and a reverse alarm will sound once every second with a half a
second duration when the snowmobile is engaged in reverse.

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Apply throttle slowly and evenly. Allow drive pulley to engage then accelerate carefully.
Shifting in forward
With the snowmobile completely stopped and engine running at idle, press and release the
RER button.
Reverse pilot lamp and reverse alarm will stop.
Apply throttle slowly and evenly. Allow drive pulley to engage then accelerate carefully
RER Modification at high altitude
At high altitude, the RER system needs a different engine timing curve to work properly.
Non DPMTM Liquid-Cooled Models
Before using the reverse system, first select the altitude mode that changes engine timing
curve.
To do so, push and hold START/RER button with engine running. After 2 seconds, one beep
is heard meaning that the low altitude mode is can be selected. Releasing START/RER button
just after hearing that one beep will select the low altitude mode. The reverse system is now
ready to operate in high altitude regions. Shifting in reverse is achieved as described above in
Shifting in Reverse.
To select high altitude mode, push and hold START/RER button until 2 beeps are heard.
Release button within one second. The reverse system is now ready to operate in hig (n)
altitudes. Shifting in reverse is achieved as described above in Shifting in Reverse.
As long as the START/RER button is pushed and held the RER system switches from one
mode to the other. One beep then 2 beeps the one beep then 2 beeps and so on are heard with
one second interval. The mode to be selected corresponds to the last beep code heard.
The selected altitude mode is kept in memory until a new one is chosen — whether the
engine is stopped or not.
DPM Liquid-Cooled Models
These vehicles are equipped with a Digital Performance Management (DPM) system. This
system takes care of the altitude mode required by the RER.
No START/RER button operation is needed to select a mode. Just follow Shifting in Reverse
above.

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6. Reverse pilot lamp
This pilot lamp will light up when reverse is selected.
1. Reverse pilot lamp
7. Handlebar
The handlebar controls the steering of the snowmobile. As the handlebar is rotated to right or
left, the skis are turned right or left to steer the snowmobile. Handlebar height is adjustable.
See an authorized Lynx dealer.
8. Ignition switch / START/RER button
Manual start Electric start models
1. OFF 1. OFF
2. ON 2. ON
3. START
Manual Starting
To start the engine, turn the key to ON position, then pull rewind starter grip, To stop the
engine, turn the key to OFF position.
Electric Starting
To start engine, turn key to START position and hold until engine has started. See illustration
above.

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NOTE: Do not use electric starter for more than 15 seconds. If start/rer button is
pressed when engine has started it could damage electric starter mechanism.
Release key as soon as the engine starts. Key returns to ON position as soon as it is released.
If engine does not start on first try, turn key back to OFF position and wait a few seconds
before restarting. To stop engine, turn key to OFF position.
NOTE: Engine may be manually started with rewind starter if necessary.
If starter does not operate, check starting system fuse condition. refer to FUSES.
START/RER button
START/RER button has two functions.
When the engine is not running, depressing the START/RER button and hold until engine has
started.
When the engine is running, depressing the START/RER button will command the engine to
reverse crankshaft rotation as driving the snowmobile is in reverse is achieved by changing
the direction of rotation of the engine, not by shifting the chain case in reverse gear.
When depressing the START/RER button, the MPEM will practically slow down the engine
RPM to a stop and advance the ignition timing to cause crankshaft rotation reversing.
Engine will automatically shift into forward when starting after stopping or stalling.
Shifting procedure will take place only when the engine is running.
If engine is running at a speed above 3800 RPM, the reverse function of the START/RER
button is cancelled.
It is recommended to warm up the engine to its normal operating temperature before shif-
ting.
Start Mode
To start engine, push START/RER button and hold until engine has started.
NOTE! Do not hold START/RER button more than 10 seconds. A rest period should be
observed between the cranking cycles to let starter cool down. Holding START/RER
button when engine has started could damage starter mechanism.
9. Tether cut-out switch
It shuts off engine preventing snowmobile to runaway if the operator falls off the vehicle
accidently.

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Operation
Attach to clothing eyelet than snap tether cord cap over post before starting engine.
1. Snap over post
2. Attach to eyelet
If emergency engine shut off is required, completely pull tether cord cap from post.
Typical
Some Liquid-Cooled Models
On these models tether cut-out switch is part of tether cut-out system. This system serves 3
functions. It shuts off engine preventing snowmobile to runaway if the operator falls off the
vehicle accidently.
Through the D.E.S.S.TM (Digitally Encoded Security System), it acts as a lock by preventing
unauthorized use of your snowmobile thus deterring theft.
Finally, it prevents unintentional electric starter operation in vehicles so equipped by disab-
ling the electric starter and ignition circuits in the MPEM or ECU.
DESS (Digitally Encoded Security System) Description
This system is digitally encoded to provide you and your snowmobile with the equivalent
security as a conventional lock key.
The tether cord cap provided with your snowmobile contains an electronic chip in which a

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unique digital code is permanently memorized. You authorized Lynx dealer programs this key
code in the MPEM or ECU of your snowmobile to allow engine operation above 3000 RPM if
and only if this unique code has been read after engine starting.
If a tether cord cap with different code is installed, the engine will start but cannot reach drive
pulley engagement speed to move vehicle.
Additional Tether Cord Caps
The MPEM/ECU of your snowmobile can be programmed by your authorized Lynx dealer to
accept 8 different key codes (tether cord caps).
DESS Pilot Lamp Codes
DESS pilot lamp blinking slowly (one time per 1,5 second) means that a bad connection has
been detected. Vehicle can not be driven.
To check for bad connection, remove tether cord cap. Make sure the tether cord cap is free of
dirt or snow. Reinstall cap and restart engine. If a blink still occurs, contact an authorized
dealer.
1.Free of dirt and snow
A DESS pilot lamp blinking 3 times per second means that you have installed a cap with a
code that MPEM of this snowmobile was not programmed to recognize (wrong key). Vehicle
can not be driven.
10. DESS pilot lamp
This lamp will light up to confirm DESS status. Refer to previous paragraphs for description.
11. Engine cut-out switch
This push-pull type or toggle type switch is located on the right side of the handlebar. To stop
the engine in an emergency, select OFF position and simultaneously apply the brake. To
restart, button must be at the ON position.

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1. ON
2. OFF
All operators of the snowmobile should familiarize themselves with the function of this devi-
ce by using it several times on first outing and whenever stopping the engine there-after. This
engine cut-out procedure will become a reflex and will prepare operators for emergency
situations requiring its use
12. Headlamp dimmer switch
Located on left hand side of handlebar, allows selection of headlamp beam. Note that lights
are automatically ON whenever the engine is running.