Ski-Doo 2005 Rt series Manual

Mmo-2005 BRP RT ANG_520000501.FH8 Thu Aug 26 15:33:37 2004 Page 1
Composite
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SAFETY WARNING
Disregarding any of the safety precautions and instructions
contained in this Operator’s Guide,Safety Videocassette or on-
product warnings may result in injury, including the possibility of
death.
This Operator’s Guide and Safety Videocassette should remain
with the unit at time of resale.
In USA, products are distributed by BRP US Inc.
In Canada, products are distributed by Bombardier Recreational Prod-
ucts Inc.
The following are trademarks of Bombardier Recreational Products
Inc. or its subsidiaries.
SKI-DOO ROTAX®RERTM
DESSTM MACH Z®SUMMIT®
Printed in Canada. (mmo2005-008 DR)
©2004 Bombardier Recreational Products Inc and BRP US Inc. All rights reserved.
®™Trademarks of Bombardier Recreational Products Inc. or its affiliates.
* Trademark of Bombardier Inc., used under license.

FOREWORD
Congratulations on your purchase of a new SKI-DOO snowmobile.
Whatever model you have chosen, it is backed by the Bombardier
Recreational Products Inc. (BRP) warranty and a network of autho-
rized SKI-DOO snowmobile dealers ready to provide the parts, ser-
vice or accessories you may require.
The Operator's Guide has been prepared to acquaint the owner/
operator and passenger with this new snowmobile and its various
controls, maintenance and safe riding instructions. This guide is
indispensable for the proper use of the product and should be kept
with this snowmobile at all times.
Make sure you read and understand the content of this Operator's
Guide.
For any questions pertaining to the warranty and its application, con-
sult the WARRANTY section in this guide, and/or an authorized SKI-
DOO dealer.
This guide uses the following safety alert symbol in conjunction with
signal words to indicate a potential personal injury hazard.
WARNING
Indicates a potentially hazardous situation which, if not avoid-
ed, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoid-
ed, may result in minor or moderate injury. When used with-
outthesafetyalertsymbol, potential hazard exists for prop-
erty damage only.
CAUTION: Denotes an instruction which, if not followed, could
severely damage vehicle components.
NOTE: Indicates supplementary information needed to fully com-
plete an instruction.
Although the mere reading of such information does not eliminate
the hazard, the understanding and application of the information will
promote the correct use of the vehicle.
__________________________ 1

Your dealer is committed to your satisfaction. He has taken train-
ing to perform the initial set-up and inspection of your snowmobile
as well as completed the final adjustment required to suit your spe-
cific weight and riding environment before you took possession. At
delivery, your dealer would have explained the snowmobile controls
and provided you with a brief explanation of the various suspension
adjustments. We trust you have taken full advantage of this!
At delivery, you were also informed of the warranty coverage and
completed the Warranty Registration Form which is to be sent to us
for processing.
The information and components/system descriptions contained in
this guide are correct at time of publication. BRP, however maintains
a policy of continuous improvement of its products without impos-
ing upon itself any obligation to install them on products previously
manufactured.
Because of its ongoing commitment to product quality and innova-
tion, BRP reserves the right at any time to discontinue or change
specifications, designs, features, models or equipment without in-
curring obligation.
The illustrations in this document show the typical construction 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.
It is understood that this guide may be translated into another lan-
guage. In the event of any discrepancy, the English version shall
prevail.
Specifications are given in the SI metric system with the SAE U.S.
equivalent in parentheses. Where precise accuracy is not required,
some conversions are rounded off for easier use.
Most components of this snowmobile are built with parts dimen-
sioned in the metric system. Most fasteners are metric and must
not be replaced by customary fasteners or vice versa.
We recommend genuine BRP products for replacement parts and
accessories. They've been specially designed for your vehicle and
manufactured to meet BRP's demanding standards.
AShop Manual can be obtained for complete service, maintenance
and more repair information.
2__________________________

TABLE OF CONTENTS
SAFETY INFORMATION
INTRODUCTION ................................................... 8
SAFETY MEASURES .............................................. 9
SAFETY LABELING ............................................... 12
A WORD TO ALL SNOWMOBILERS ............................ 14
LAWS AND REGULATIONS...................................... 21
SUMMARY OF ACCIDENT PREVENTION PRACTICES .. ... .. . 22
PASSENGER SAFETY BASICS................................... 26
ENVIRONMENT................................................... 27
RIDING THE VEHICLE ............................................ 29
HOW TO RIDE..................................................... 30
TERRAIN/RIDING VARIATIONS ................................. 34
ON-VEHICLE IMPORTANT INSTRUCTIONS.................... 42
VEHICLE INFORMATION
HOW TO IDENTIFY YOUR SNOWMOBILE ..................... 54
Vehicle Description Decal...................................... 54
Serial Numbers................................................. 55
CONTROLS/INSTRUMENTS/EQUIPMENT .................... 57
1) Throttle Lever................................................ 59
2) Brake Lever.................................................. 59
3) Parking Brake Lever......................................... 59
4) Brake/Parking Brake Pilot Lamp (Red)...................... 60
5) START/RER Button.......................................... 61
6) Reverse Pilot Lamp.......................................... 62
7) Handlebar.................................................... 62
8) Holding Strap ................................................ 63
9) Tether Cut-Out Switch ...................................... 64
10) DESS Pilot Lamp........................................... 67
11) Engine Cut-Out Switch .................................... 67
12) Headlamp Dimmer Switch................................. 68
13) High Beam Pilot Lamp (Blue).............................. 69
14) Oil Pilot Lamp .............................................. 69
15) Low Battery Voltage Pilot Lamp........................... 69
16) Engine Management System (EMS) Pilot Lamp. . .. . .. . . . 69
17) Rewind Starter Handle..................................... 69
__________________________ 3

18) Speedometer............................................... 70
19) Mode Button ............................................... 71
20) Odometer .................................................. 71
21) Trip Meter .................................................. 71
22) Resetable Hourmeter...................................... 72
23) Tachometer................................................. 72
24) Fuel Tank Cap .............................................. 72
25) Mechanical Fuel Level Gauge ............................. 73
26) Electric Fuel Level Gauge.................................. 74
27) Temperature Gauge........................................ 75
28) Engine Overheat Warning Lamp (Red).................... 76
29) Heating Grip Switch........................................ 76
30) Heating Throttle Lever Switch............................. 77
31) Windshield ................................................. 77
32) Adjustable Toeholds........................................ 77
33) Hood and Side Panel Latches ............................. 78
34) Fuses....................................................... 80
35) Front Grab Handle/Front Bumper.......................... 82
36) Storage Compartment ..................................... 82
37) Rear Rack .................................................. 84
38) Tool Kit...................................................... 84
39) Spark Plug Holder.......................................... 84
40) Spare Drive Belt Holder.................................... 85
41) Shields and Guards ........................................ 86
42) Convertible Ski Stance..................................... 86
43) Adjustable Suspensions ................................... 87
Guidelines to Adjust Suspension .............................. 87
Track.......................................................... 103
FUEL AND OIL .................................................. 104
Recommended Fuel ......................................... 104
Recommended Oil ........................................... 105
BREAK-IN PERIOD.............................................. 106
Engine ........................................................ 106
Belt ........................................................... 106
10-Hour Inspection........................................... 106
PRE-OPERATION CHECK....................................... 107
PRE-OPERATION CHECK LIST................................. 109
OPERATING INSTRUCTIONS.................................. 110
Principle of Operation........................................ 110
Starting the Engine........................................... 111
Emergency Starting.......................................... 112
4__________________________

Shutting Off the Engine...................................... 114
VEHICLE WARM-UP............................................ 115
POST-OPERATION CARE ...................................... 116
SPECIAL OPERATIONS......................................... 117
Riding at High Altitudes...................................... 117
Engine Overheating.......................................... 117
Fuel Flooded Engine ......................................... 117
Rear Suspension Slider Shoe Sticking....................... 117
MAINTENANCE INFORMATION
PERIODIC MAINTENANCE CHART............................ 120
FLUID LEVELS .................................................. 123
Brake System ................................................ 123
Chaincase/Gearbox Oil Level ................................ 124
Oil Injection System.......................................... 125
Cooling System .............................................. 125
Battery Electrolyte ........................................... 126
MAINTENANCE FOR EPA CERTIFIED ENGINES............. 128
Engine Emissions Information............................... 128
MAINTENANCE................................................. 130
Vehicle Cleaning and Protection............................. 130
Belt Guard Removal and Installation ........................ 131
Drive Belt Removal/Installation.............................. 133
Drive Pulley Adjustment ..................................... 136
Drive Belt Condition.......................................... 140
Brake Condition .............................................. 140
Brake Adjustment............................................ 140
Rear Suspension Condition.................................. 140
Suspension Stopper Strap Condition........................ 140
Track Condition............................................... 140
Track Tension and Alignment ................................ 141
Steering and Front Suspension.............................. 147
Wear and Condition of Skis and Runners ................... 147
Exhaust System.............................................. 147
Air Filter Cleaning ............................................ 148
Headlamp Beam Aiming..................................... 149
Bulb Replacement............................................ 149
__________________________ 5

TOWING AN ACCESSORY..................................... 152
TOWING ANOTHER SNOWMOBILE.......................... 153
TRANSPORTING THE VEHICLE ............................... 154
STORAGE AND PRESEASON PREPARATION................ 155
Storage ....................................................... 155
Preseason Preparation....................................... 155
TROUBLESHOOTING........................................... 156
Monitoring Beeper Coded Signals........................... 156
SPECIFICATIONS ............................................... 161
WARRANTY
BRP LIMITED WARRANTY NORTH AMERICA: 2005 SKI-DOO®
SNOWMOBILES ................................................ 166
BRP INTERNATIONAL LIMITED WARRANTY: 2005 SKI-DOO®
SNOWMOBILES ................................................ 171
PRIVACY OBLIGATIONS/DISCLAIMER ....................... 175
CHANGE OF ADDRESS OR OWNERSHIP .................... 176
6__________________________

SAFETY
INFORMATION
______SAFETY INFORMATION _____ 7

INTRODUCTION
This safety information section includes safety WARNINGS which if
not followed may result in serious personal injury including the pos-
sibility of death.
After reading, please keep this Operator's Guide with the snowmo-
bile. If the snowmobile is resold, please give the guide to the new
owner for his awareness. An extra copy of the Operator's Guide is
available from your SKI-DOO snowmobile dealer at no charge.
This safety information section is dedicated to safer snowmobiling.
If you have any question regarding any topic whether or not it is cov-
ered in this Operator's Guide, please call BRP at the number below
and we will be happy to assist you:
In USA:
[phone]
In Canada:
[phone]
8_____ SAFETY INFORMATION _____

SAFETY MEASURES
Observe the Following Warnings:
The performance of some snowmobiles may significantly exceed
that of other snowmobiles you have operated. Therefore, use by
novice or inexperienced operators is not recommended.
Basic training is required for the safe operation of any snowmo-
bile. Study your Operator's Guide paying particular attention to
cautions and warnings. Join your local snowmobile club: its so-
cial activities and trail systems are planned for both fun and safety.
Obtain basic instructions from your snowmobile dealer, friend, fel-
low club member or enroll in your state or provincial safety training
program.
Know the local laws regarding snowmobilesand be aware of the li-
ability, property damage and insurance laws relating to your equip-
ment.
Always keep right hand side of the trail.
Always keep a safe distance from other snowmobiles and by-
standers.
Jumping a snowmobile is an unsafe and dangerous practice.
Know your snowmobile and treat it with the respect and care due
of any power driven machine. Common sense, proper handling
and routine maintenance will result in safer and enjoyable use.
Check your machine before each ride.
Always make a pre-start inspection BEFORE you turn on the igni-
tion.
If you are a parent, you must be the judge of your child's capabil-
ity to understand, to operate and to control a snowmobile. Warn
against speeding, over confidence and carelessness. Never let
children snowmobile unsupervised.
Snowmobiles are used in many areas and in many snow condi-
tions. Not all models perform the same in similar conditions. Al-
ways consult your snowmobile dealer when selecting the snow-
mobile model for your particular needs and uses.
Injury or death may result to the snowmobile operator, passenger
or bystander if the snowmobile is used in risky conditions which
are beyond the driver's, passenger's or snowmobile's capabilities
or intended use.
Remember, promotional material may show risky maneuvers per-
formed by professional riders under ideal and/or controlled condi-
tions. You should never attempt any such risky maneuvers if they
are beyond your level of riding ability.
______SAFETY INFORMATION _____ 9

Never ride after consuming drugs or alcohol or if you feel tired or
ill. Operate your snowmobile prudently.
Speeding can be fatal. In many cases, you cannot react or respond
quickly enough to the unexpected. Always ride at a speed which
is suitable to the trail, weather conditions and your own ability.
Know your local rules. Speed limit may be in effect and meant to
be observed.
Snowmobile can carry a passenger only if it is equipped with a 2-up
or 3-up seat including a single hand grip (seat strap) or a double
hand grip (rear passenger grab handles).
The passenger (s) must be able to completely lean is feet on the
footrests and keep his hands on the grab handles or seat strap at
all times when he is seated on the snowmobile.
In an emergency, the snowmobile engine can be stopped by ac-
tivating the engine cut-out switch, pulling the tether cord cap or
turning off the key.
Your snowmobile is not designed to be operated on public streets,
roads or highways. In most States and Provinces, it is considered
an illegal operation.
Throttle mechanism should be checked for free movement and
return to idle position before starting engine.
Always engage parking brake when vehicle is not in use.
Always stop the engine before refueling. Fuel is flammable
and explosive under certain conditions. Always work in a well-
ventilated area. Do not smoke or allow open flames or sparks in
the vicinity. Open cap slowly. If a differential pressure condition
is noticed (whistling sound heard when loosening fuel tank cap)
have vehicle inspected and/or repaired before further operation.
Do not overfill or top off the fuel tank before placing the vehicle in
a warm area. As temperature increases, fuel expands and might
overflow. Always wipe off any fuel spillage from the vehicle.
Periodically verify fuel system.
Never run the engine in a non-ventilated area and/or if vehicle is
left unattended.
Never operate the engine without belt guard securely installed or,
with hood or access/side panels open or removed. Never run the
engine without drive belt installed. Running an unloaded engine
such as without drive belt or with track raised, can be dangerous.
Unless otherwise specified, never run the engine when the track
is raised off the ground or with the hood opened or removed.
Maintain your snowmobile in top mechanical condition at all times.
10 _____SAFETY INFORMATION _____

Do not lubricate throttle cable and housing.
Only perform procedures as detailed in this guide. Unless other-
wise specified, engine should be turned OFF and cold for all lubri-
cation, adjustment and maintenance procedures.
Electric start models only: Never charge or boost a battery while
installed on snowmobile.
The engine and components used in a particular model should not
be used on other models. Use of Rotax®snowmobile engines in
other than SKI-DOO snowmobiles is not recommended or autho-
rized by BRP or its subsidiaries.
Electronic reverse (RER™) models only: The shifting to reverse
mode on these snowmobiles is done by the push of the RER
button when the engine is running. Wait until the reverse alarm
sounds and the Rotax Electronic Reverse (RER) pilot lamp comes
on in the dashboard before operating throttle to proceed in re-
verse. The reverse speed of these snowmobiles is not limited.
Always proceed with caution as fast reverse could result in loss
of vehicle stability and control. Come to complete stop before de-
pressing RER button. Always remain seated and apply the brake
before shifting. Ensure the path behind is clear of obstacles or
bystanders before proceeding.
Models with mechanical reverse: The reverse speed of these
snowmobiles is not limited. Always proceed with caution as fast
reverse could result in loss of vehicle stability and control. Come
to complete stop before selecting reverse gear. Wait until the
reverse alarm sounds before operating throttle to proceed in re-
verse. Always remain seated and apply the brake before shifting.
Ensure the path behind is clear of obstacles or bystanders before
proceeding.
_____ SAFETY INFORMATION _____ 11

SAFETY LABELING
Safety standards for snowmobiles have been adopted by the Snow-
mobile Safety and Certification Committee (SSCC) of which BRP
is a proud participating member. Assurance that your snowmobile
meets these standards is easily checked by locating the Certification
Label on a right vertical portion of the vehicle.
This label signifies that an independent testing laboratory has verified
compliance with the SSCC safety standards. Other important labels
on the vehicle are WARNING or CAUTION labels relating to safety,
maintenance and/or snowmobile operation. Ensure all such labeling
is retained on the vehicle and its content is followed by vehicle oper-
ator and passenger.
CE MODÈLE A ÉTÉ ÉVALUÉ
PAR UN LABORATOIRE
D'ESSAIS INDÉPENDANT
ET SATISFAIT TOUTES LES
NORMES DE SÉCURITÉ DU
SSCC EN VIGUEUR À LA
DATE DE FABRICATION.
PARRAINÉ PAR LE COMITÉ DE
SÉCURITÉ DE CERTIFICATION
DE LA MOTONEIGE, INC.
THIS MODEL HAS BEEN
EVALUATED BY AN INDE-
PENDENT TESTING LABOR-
ATORY AND IT MEETS ALL
SSCC SAFETY STANDARDS
IN EFFECT ON THE DATE OF
ITS MANUFACTURE.
SPONSORED BY THE SNOWMO-
BILE SAFETY AND CERTIFICA-
TION COMMITTEE, INC.
PRINTED IN U.S.A.
CERTIFIED
CERTIFIÉ
A00A1MA
OTHER SAFETY FEATURES
Read this Operator's Guide for other features that may be on your
particular snowmobile model. Do not operate your snowmobile un-
less all its safety features are in place and in good working order.
Lights —Head lamp, taillight and brake light are standard equipment.
Besurelightsareclearofdirt,slushorsnowandareingoodworking
order or condition.
HOW TO DRESS
Proper snowmobile clothing should be worn. It should be comfort-
able and not too tight. Always check the weather forecast before
you go on a ride. Dress for the coldest weather expected. Thermal
underwear next to the skin also provides an important layer of insu-
lation.
DOT approved helmets are recommended at all times. They provide
both warmth and reduce injury. A stocking type cap, balaclava and
face mask should always be carried or worn. Goggles ora face shield
which attach to the helmet are indispensable.
12 _____SAFETY INFORMATION _____

Hands should be protected by a pair of snowmobile gloves or mitts
which have sufficient insulation and permit use of thumbs and fin-
gers for operation of controls.
Rubber bottom boots with either a nylon or a leather top, with re-
movable felt liners are best suited for snowmobiling.
You should keep yourself as dry as possible when snowmobiling.
When you come indoors, take your snowmobile suit and boots off
and make certain they dry properly.
Do not wear long scarfs and loose apparels that could get caught in
moving parts.
WHAT TO BRING
Every snowmobiler should carry at least the following basic parts and
tools that can help him and others in an emergency:
•this Operator's Guide
•spare spark plugs and wrench
•friction tape
•spare drive belt
•spare starter rope
•spare Light bulbs
•tool kit (including at least pliers, screwdriver, adjustable wrench)
•knife
•flashlight.
Include other items depending on the length and time of your ride.
_____ SAFETY INFORMATION _____ 13

AWORDTOALLSNOWMOBILERS
Everyone is a beginner the first time he sits behind the controls of a
snowmobile regardless of previous experience in driving an automo-
bile, a motorcycle or a motorboat. The safe use of your snowmobile
is dependent on many conditions such as visibility, speed, weather,
environment, traffic, vehicle condition and the condition of the driver.
A00A1NA
Each operator has a responsibility to ensure the safety of his/her pas-
senger, if any, and of other recreationists or bystanders.
You are responsible for proper operation of your vehicle as well as
training those whom you allow to ride or drive. There may be notice-
able handling and performance differences from one snowmobile to
another one.
14 _____SAFETY INFORMATION _____

A snowmobile is relatively simple to operate but like any other vehicle
or mechanical equipment, it can be hazardous if you or a passenger
are the least bit reckless, thoughtless or inattentive. We encourage
you to have an Annual Safety Inspection of your snowmobile. Please
contact an authorized SKI-DOO dealer for further details. Finally, we
urge you to visit an authorized SKI-DOO dealer periodically for regu-
lar and safety maintenance, as well as snowmobile accessories you
may require.
TRANSPORTING AND TOWING
Follow transporting and towing instructions explained further in this
guide.
TRACTION ENHANCING PRODUCTS
Using more positive carbide ski runners and traction enhancing
products on your snowmobile will change its behavior, particularly
in terms of manoeuvrability, acceleration, and braking.
Studding the track gives a better grip on packed snow and ice, but
has no noticeable effect on soft snow. For this reason, driving a
snowmobile equipped with traction enhancing products (studs, car-
bide ski runners) requires a certain adaptation period. If your snow-
mobile is equipped with traction products, be sure to take plenty of
time to get used to the way it handles when turning, accelerating,
and braking.
Also, always check local regulations concerning the use of studs on
snowmobiles. Always drive your snowmobile in a responsible man-
ner, respecting the environment and other people’s property.
Manoeuvrability:
Studding the track makes the snowmobile grip the ground better at
the rear. The use of carbide runners is therefore required to give
the skis a better grip, so that the front and rear of the snowmobile
are in balance. While off-the-shelf carbide ski runners are adequate,
they don’t necessarily give you optimal control, since that depends
on your personal preferences, your riding style, and how your sus-
pension is set.
WARNING
If the front and rear of the snowmobile are out of balance due
to an incorrect combination of studs and runners, the snow-
mobile may tend to oversteer or understeer, which could lead
to a loss of control.
_____ SAFETY INFORMATION _____ 15

1- Oversteering
In certain conditions, using more positive carbide ski runners without
studding the track could make the snowmobile prone to oversteer-
ing, see illustration.
OVERSTEERING
2- Understeering
In certain conditions, the use of studs could make the snowmobile
prone to understeering if the skis are not equipped with more posi-
tive carbide runners, see illustration.
A33A33A
UNDERSTEERING
3- Controlled Driving
A balanced combination of carbide ski runners and studs ensures
adequate control and better handling, see illustration.
16 _____SAFETY INFORMATION _____

A33A34A
CONTROLLED DRIVING
Acceleration:
Studding the track will allow your sled to accelerate better on packed
snow and ice but will have no noticeable effect on soft snow. This
can cause sudden variations in traction under certain conditions.
WARNING
To prevent surprises that could lead to a loss of control of the
snowmobile, possibly resulting in serious injury or death:
–Always go easy on the throttle.
–NEVER try to spin the track to make the rear of the snow-
mobile skid.
This could cause debris or ice to be thrown violently back-
wards, possibly injuring others nearby or on snowmobiles be-
hind you.
Braking:
As is the case for acceleration, studding the track will give you better
brakingcapacityonpackedsnoworicebutwillhavenonoticeable
effect on soft snow. Braking may thus vary suddenly under certain
conditions. Be sure to use restraint in braking to keep from blocking
the track in order to avoid surprises that could lead to a loss of control.
_____ SAFETY INFORMATION _____ 17

Important Safety Rules:
WARNING
To prevent serious injury to individuals near the snowmobile:
–NEVER stand behind or near a moving track.
–Always use a wide-base snowmobile stand with a rear de-
flector panel.
–When the track is raised off the ground, only run it at the
lowest possible speed.
Centrifugal force could cause debris, damaged or loose studs,
pieces of torn track, or an entire severed track to be violently
thrown backwards out of the tunnel with tremendous force,
possibly resulting in the loss of a leg or other serious injury.
Effects of Studding on the Life of the Snowmobile:
The use of traction enhancing products can increase the load and the
stress on certain snowmobile components, as well as the vibration
level. This can cause premature wear on parts such as belts, brake
linings, bearings, chain, and chaincase sprocket, and shorten track
life. For this reason, it is even more important to follow the detailed
maintenance program given in the periodic inspection table.
Studs can also cause serious damage to your snowmobile if it is
not equipped with the tunnel protectors designed for your particular
model. Damage to the electrical wiring or perforation of the heat ex-
changers are potential hazards, that could cause the engine to over-
heat and be severely damaged.
WARNING
If tunnel protectors are excessively worn or not installed, the
gas tank could be punctured, causing a fire.
CAUTION: Ask your dealer for the appropriate tunnel protectors
model and kit number required for your snowmobile.
NOTE: Consult the BRP limited warranty to find out what warranty
limitations are related to the use of studs.
Installation of Studs:
To ensure safe and proper installation, BRP recommends to have the
studs installed by your dealer.
–Use only studs, mounting plates, and nuts sold by BRP.
18 _____SAFETY INFORMATION _____