Ski-Doo Alpine 640ER User manual

.... - .. ski-doo
'76 OPERATOR MANUAL
No480-0131-00

Recreational
Products Group
This manual has been published by the:
TECHNICAL INFORMATION CENTRE
AFTER SALES SERVICE DEPARTMENT
BOMBARDIER LIMITED
VALCOURT,OUEBEC,
CANADA
Suggested Retail Price $1.00
(First copyfree
with unit purchased)
All rights reservedeshomberdier Limited 1975

\!Vithin the North America" Continent,
there exists avery special breed of peo-
ple,.. people who enjoy ice and snow,
and the unexcelled tralls rhat load to
virtually every corner at tne snowbelt,
They enjoy too, the
comfort of warm
clothing, the friendliness
of compan-
ions, and the recreational vehicle that
made it all
oossible.; the Ski-Doo
snowmobile
..
We, like millions of North American fa-
milies, have never torqotten our pio-
neer heritage, or our love
of nature and
the qreat outdoors, consequently, we
have designed and engineered all our
models with safety, comfort and quiet-
ness foremost in our minds. We do res-
poet your desires, and that of others,
This manual was prepared to acquaint
the owner /operator of a new '(976
snowmobile with the various vehicle
controls, owner-related maintenance,
and safe operating instructions.
This is accomplished via two manuals;
'The Snowmobile Safety Handbook'
and the 'Operator Manual'. Both are
inseparable toward proper use of the
product, and should be kept with the
vehicle at ail times.
Each manual emphasizes particular in
..
forrnation denoted by the Vyording and
symbols;
•;
WARNINd::(dentif),'i~g an ins-
.truction wHich, if n<;'t. followed,
.could cause personal Injury,
_CAUTION: Denotes 8f1 instruc-
... tion$iVhich, if not followed, could
severel~idamage vehicle compo-
nents. ~. ",'~" ,','. '
O
NOTE: Indicates supplementary
information needed to fully
com-
plete an instruction.
Although the mere reading of such in-
formation does not eliminate the haz-
ard, your understanding
of the infor ..
mation will promote its correct use,
Ride safe and have fun.
MICHEL CLOUTIF:R,
General Manager
Recreational Product Group

Observe the following
precautions:
.. Throttle mechanism should be
checked for tree movement before
starting engine.
o Engine should be running only when
pulley guard is secured in place.
eNever run engine without drive belt'
installed. Running an unloaded en
..
gine can prove to be dangerous.
iii> Never run the engine at high R.P.M.
when the tracks of the vehicle are
raised
off the ground.
• It can be dangerous to run engine
with the cab removed .
., Gasoline is flammable and explosive
under certain conditions. Always
perform procedures in awell ventila-
ted area. Do
not smoke or allow
open flames or sparks in the vicinity.
if gasoline fumes are noticed whiie
driving, the cause should be deter-
mined and corrected
without delay.
011> Your snowmobile is not designed to
be operated on public streets, roads
or highways. In most States and
Provinces, it is considered an ille-
gal operation.
iI!I Maintain your vehicle in top mecha-
nical condition at all times.
@Your snowmobile is not designed to
be driven or operated on black top,
bare earth, or other abrasive surfa-
ces. Abnormal and excessive wear
of critical parts is inevitable.
o Only perform such procedures as
detailed in this manual. Unless
otherwise specified, engine should
be turned OFF for all lubrication
and maintenance procedures.
Please read and understand all other
warnings contained elsewhere in this
manual.
2

CONTROLS / INSTRUMENTS 4
BREAK-IN /INSPECT!ON ,7
FUEl. MIXiNG 7
PRE··ST
ART CHECK 9
STARTING PROCEDURE , .. , 9
LUSHIGATION , 11
MAINTENANCE , , 14
TROUBLE SHOOTING GUIDE 20
STORAGE" , , , 22
PBE·::::a':;ASON PREPARATION , 25
SPECIFICATIONS , , . , 26
CONSUMER GUIDE , 27
SERVICE AREAS , 28
WARRl\NTY , , 29
"The followinQ are
Bombardier Limited.
BOMBARDIER
SKI-DOO
ALPINE
BUZZARD
CARBY BOOSE
ELAN
trademarks of
ELITE
EVEREST
MIRAGE
NORDIC
Ol.YMPIQUE
SKI BOOSE
TNT
3

A) Throttle ControlLever
B) Brake ControlLever
CJ Ignition I Light Switch
DJ Headlamp Dimmer Switch
EJ Emerqencv Cut-Out Switch
4
\\
FJ Manual Starter Hendle
GJ Choke
HJ Gear Shift lever
I) Access Door Latch

Located on right side of handlebar.
VVhen depressed, it controls the en-
gine speed and the engagement of the
transmission. When released, engine
speed returns automatically to idle.
Located on the left side of handlebar.
When depressed, the brake is applied.
When released, it automatically returns
to its original position. Brakin9 effect
is proportionate to the pressure applied
on the !ever.
OFF
Key operated, 4position switch. To
start enqine, turn key fully clockwise to
STArn position and hold. Return key
to ON position immediately engine has
started. To stop engine, turn key
counter-clockwise to OFF position. To
illuminate both headlamp and taillight,
turn key to LIGHTS position.
The dimmer
switch, located on leftside
of handlebar, allows correct selection
of headlarnp beam. To obtain high or
low beam simply depress switch.
Apush button switch located on right
side of handlebar. To stop the engine
in an emergency, press button down
into lower position.
Before re-starting engine always
de--
press button into released upper posi-
tion. The driver of this vehicle should
familiarize himself
with the function of
this device by using it several times on
first outing. Thereby being mentally
prepared for emergency situations
requiring its use.
WARNING: If the button has
been used in an emergency situa-
tion the source of malfunction
should be determined and correc-
ted before restarting engine.
Auto rewind type located on right hand
side
of vehicle. To engage mechanism,
pull handle.

Apush-pull button. Pull button to en-
gage choke, push to disengage, The
choke should always be used for easier
cold engine starts. After engine is
warm however, it is
not necessary to
use choke when starting.
A 2 position, (FORW/,RD! REVERSE)
gear shift lever. Push up for forward
and
down for reverse.
_CAUTION: Do not activate gear
" shift lever while snowmobile is in
motion.
ONOTE: When
towing a disabled
vehicle, its drive belt must be
removed from pulleys and the
gear shift lever positioned into
forward gear.
n bt4.C;4~Ql~~~
To gain access to the carburetor Of
spark plugs, lift pressure lock tap and
pull open access door.
To adjust locking device turn nut in
required direction.
6
Unlatch cab by turning both handles
toward front of vehicle, remove fuel
tank cap, gently lift cab then discon-
nect junction block at right side of en
gine. Hernove cab from vehicle.
WARNiNG: It is dangerous to run
engine with cab off. Personal
injury could result.
Remove backrest and
tilt seat ideal
location for spare plugs, bolt, rope,
etc.
Emergency materials should be wrap-
ped in foam or similar material. This
iNil1 prevent possible damage to break-
able items when traveiling over rough
or bumpy terrain.
Unscrew fuel tank cap and withdraw
dipstick to check fuel level.
WAHNING: Never use a lite
match or open flame to check
fuel level,

VVith Skf,,·[)OO snowmobile enqines, a
break-in period is required before run-
ning H18 vehicle at full throttle. Manu-
tacturers. recommendation for the
Bornbardier-Rotax engine is Wto 15
operating hours. Durinq this period, a
richer mixture is needed (i.e. 40 parts
of
g8S for J part of 50/'1 Ski-Doo oil).
Maximum throttle should not exceed
%, however. brief fuli acceleration
and speed variations contribute to a
900d break in, Continued wide open
throttle accelerations, prolonged cruis-
ing speeds, and lugging are dotrimen-
tal during the break-in period.
/\fter the break-in period. each Ski,
DOG snowmobile must have an insoec
tion chock. This inspection is at the ex,
panse of the vehicle owner,
Oii must be added to the gasoline in
pre-measured amounts then both oil
and qasoline should be
thorouqhlv
mixed together before fueling tho tank.
The correct gasoline is rogulargasoHna,
available from all service stations.
CAUTION: Never experiment
with different fuel or fuel ratios.
Never use low lead or non leaded
gasoline, naphta,
methanol or sl-
milar products.
Use concentrated Ski-Doo oil available
from your dealer. This type of oil has
specially formulated oil bases to meet
the lubrication requirements of the
Bcmbardier-Hotax enqine.
CAUTION: Never use outboard
or straight minerai oils,
The importance of using the correct ru-
el mixture cannot be overstressed. An
incorrect: fuel ratio results in serious en-
gine damage, liecornmended ruel ratio
is 50/ 'I.
bgaiions recommended gasoline pius 1
can of 50 / 1concentrated Ski-Doo olk
correct fuel mixture.
oNOTE: To facititate fuel mixing,
oil should be kept at room tempe-
rature,
7

To mix the gasoline and oil always use
a separate clean container. Never mix
directly in your snowmobile tank. For
best results, acquire
two containers, ei-
ther plastic or metal. Draw from one
until empty then use the second one.
WARNING: Gasoline is flamma-
ble and explosive under certain
conditions. Always perform pro-
cedures in a well ventilated area.
Do not smoke or allow open
flames or sparks in the vicinity. If
gasoline fumes are noticed while
driving. the cause should be de-
termined and corrected without
delay, Never add fuel while engi-
ne is running.
Avoid ski contact
with fuel at below freezing tem-
peratures.
1, Pour approximately one gallon of
n8solin8 into a clean container.
2. f-\dd triG amount of concentrated
Ski-Doo oil.
3. i~eplace container cap and snake
the containerthorouqhlv.
~I
4. Add the remainder of the gasoline.
5. Once again
thoroughly agitate the
container Then using a funnel with
a fine mesh screen to prevent the
entry of water and fmeign particles,
transfer mixture from container into
the snowmobile tank.
s
oNOTE:
When usin~] premixed fu-
el, always shake the container
thoroughly 8S the oil has a ten..
dencv to settle,
WARNING: NOVEll' 'top up' gas
tank before placing the vehicle in
a warm area. At certain tempera-
tures, gasoline wili expand and
overflow.

l@wer position
to stop engine.
Uppor position
before starting
engine.
1. Insert key in ignition switch.
2. Test throttle control lever and en-
gage choke.
3. Make sure the emergency cut-out
button is in the released UpPOI-
position.
4. Turn ignition key clockwise until
starter engages. If engine does
not
start on first try, key must be turned
fully back to OFF each time.
WARNING: Do
not apply throttle
whilestarting.
15. Helease key immediately enginG
has started then disengage choke.
CAUTION: Never operate your
snowmobile with the battery
removed or disconnected.
6. Check operation of the emergency
cut-out switch then restart enqine.
WARNING: tf engine does
not
cut-out, do not operate the vehi-
cle,seeyour dealer,
7. Allow the engine to warm before
operating at full throttle. If for some
reason,
the vehicle cannot be
sta rted electrically, place ignition
key to ON position and start enqine
manually.
Depress and release control levers S8--
veral times to check that they operate
easily and smoothly. The throttle lever
should return to the idle position when
released. The brake should fully apply
before the brake control lever touches
the handlebar grip. if the control levers
do not operate freely, do
not start your
vehicle, seeyour dealer.
WARNiNG: Throttle and brake
mechanisms should be chocked
for free movement before star-
ting engine, Once all compo-
nents are checked and func-
tloning properly, you can start
your Ski-Doo snowmobile,
Q!1mnttty
Check that there is sufficient fuel in
the tank for your trip. A good habit to
acquire is to refill the tank before star-
ting out each day.
$tooring Operation
Check operation of steering mecha-
nism by rnovinq ski by hand from side
to side
.. If roughness or binding is felt,
check for ice or
snow that may be
blocking the mechanism.

Should the rewind starter rope fray and
break, remove starter unit using tool
supplied
with the vehicle. Transfer rope
handle to your emergency rope. Make
aknot at the end of emergency starter
rope and wind rope around rewind
starting pulley. Pull vigorously as per
usual manual starting.
By raising the outer attachment of
the bogie wheel sets vehicle maneu-
verability in deep snow will increase.
You will note that there are partially
dril!ed holes located approx.
1-< 3/8"
above the original cross shaft holes
of the frame. To reposition bogie wheel
sets, drill holes fully through a
5/ 16" dia, drill. Remove capscrews
securing bogie wheel cross shafts
to
frame and reinstall bogie wheels in new
position.
ONOTE: Once holes have been
drilled, the bogie whee! set po-
sition isinter-changeable.

Houtine meintenance is necessary for
ali mechanized products, and the
snowrnoblie is no exception. A weekly
vehicle inspection contributes to the
life span
of the snowmobile as well as
safe and trouble-free operation.
It is recommended that the steering
system and suspension, be lubricated
monthly or every 40 hours of oceration.
If the vehicle isoperated in wet snow or
in severe conditions these items should
be lubricated more frequently.
WARNING: Only perform such
procedures as detailed in this
manual. Unless otherwise spe-
cified, engine should be turned
OFF for all lubrication and main-
tenance procedures.
Pu~i~ev ~~.~311M'~ Renwv~1
•WARNING: Engine should be
running only when pulley guard
is secured in place.
1. Hernove cab. Pullout retaining clip
(A) and tilt driven pulley guard
toward front of vehicle
2.
Pullout retaining clip (D) to dison-
qaqe pin from bracket.
3. Move pullev guard toward front
of
vehicle to disengage it from front
bracket.

Grease the ski leg at grease tittinq until
new grease appears' at the join't, Lu-
bricate spring coupler bolt with oi!.
~
' '11/
1. __,
\:.~~~~':-
J~"-"""
""
The gearbox oil capacity is 1fi OlS. To
checkievei:
1. Remove rubber inspection cover
located on bottom right side of
gearbox.
2, Using a rigid piece of wire as dip-
stick, check oil loveI Oil klVOI must
roach 3% r s Oil dipstick.
Using light machine oil, lubricate ths
spring located on top of steering col-
umn housing.
Allow oil to run in. Oi!the
mobile contact point at bottom end of
steering arm. Usinn a smal' brush,
dipped in low temp grease, lubricate
steering arm ball joint,
Drhw$ID ~It a.,noval
•WARNING: Never
start or run
engine without drive belt in-
stalled. Running an unloaded en-
gine is dangerous.
Remove cab and pulley guard. Remove
the
two bolts (A) holding disc brake to
the frame. Loosen
nut (8) to separate
brake caliper from disc brake bracket.
Pivot the brake bracket assembly half
aturn. Open the driven pulley, Twist
and push the sliding half then hold in
open position. Slip the belt
out from
the drive pulley and remove from vehi
cia by passing it under the driven puliey
and disc brake assembly. To instal!
drive belt follow reverse procedure.

To fill, remove filler cap from top of
qoarbox. Refill as required using Ski-
Doc chaincass oil.
Grease the suspension booie wheels
with low-temperature grease. Pump
th!ou~Jh the grease fitting at the center
(,f each wheel until new qroa.sc~ appears
at the joint of inner side of shaft.
To crease the inns side boqie wheels
j
·. i. I · ~ ~;"'I~-i;;I;' "iJ::~ 'ij~' ';'idr.: "n~cj '''::Jlv ;;re~:'
,_ 'J.;;" ( .... 'J .... ' .! . ,,-,,) '-"'''' 'v" (.ll,Jr·, t'
SUfe on track to expose grease fittings.
Lubricate the real axles with tow-tern-
perature qrease. Pump grease throu(jh
the rear axle fittings
CAUTION: Always use a low-
pressure grea$(~ gUI1.
Drill#e~l P~diey
With cab removed, grease the driven
pulley shaft as follows:
1. Rernove pulley guard and slip off
drive belt. Open the driven pulley,
(push and
twist sliding half).
2. Thoroughly clean the driven pulley
shaft.
3. Apply alight coat of
low-temp
grease on the shaft. Always lubri-
cate lightly and wipe off surplus.
ONOTE; Activate) the slidin9 half
- several times to distribute lubri-
cant over full length of shaft.
Be careful that lubricant does not
get on inner halves of pulley.
13

The following Maintenance Chart
indicates reqular sorvicing schedules
to be performed by you or your ser,
vicing dealer. If these services are per-
formed as suggested, voursnowrnobile
will give you many years of low-cost
use. WARNING: Only perform suet!
procedures as detailed in this
manual. Unless otherwise sped-
fied, engine should be turned
OFF for all lubrication and main-
tenance procedures.
Iy
W1 Spark
PI~gs '14
W2 Battery 15
W3 Suspension 15
W4 Tracks 15
W5 Track
tension and alif!nrnent
15
V..;6
Carburetor adjustment 16
W7 Drive bolt 17
WS Steering mechanism 17
WS Drive chain tension 17
Code
Monthly
P
----
foAl
Brake 18
M2 Steering adjustment 18
/',13
Engine head nuts \9
M4 Engine
mount nuts 19
~/H)
Muffler attachment lB
M6 Fan belt 19
M7 Vehicle general inspection 19
Headlarnp adjustment i9
14
Open access dOOL Disconnect snark
plug wires and remove plugs, Check
condition of plugs.
oAbrownish til) reflects ideal condi-
tions. (Correct carburetor
trnent. spark plug heat ranqo, etc.l.
@A black insulator tip indicates feu-
ling caused by; carburetor idle
mixture and / or high speed mixture
too rich, incorrect fuel rnix!n~J ratio,
wrong type of spark piup (neat
ranOtJ), or excessiveidlin[J.
@Alight grey insulator tip indicates a
lean mixture caused try; carburetor
high speed mixture adjusted too
lean, wrong spark plug heat range,
Incorrect fuel mixture ratio. or a
leaking seal or gaskElt. .
Ov~rhs.ated
OiilhY!lf"")
Norm"l (I',lrownishl
Check spark plu~J gap using a wire
feeler gauge. Gap 1'(lUSt be ,020"
(0,50 rnm). .
Reinstall plugs and connect wires.

NOTE: Without these inserts
continual abrasion would wear
and cut the track therefore, 81
ways replace amissing or dam-
aged insert as soon as possible,
The tension of each track should be
214" ±1/
a" between top inside edge
of track and bottom of footboard.
lift the rearof vehicle and support it otf
the ground, Using a rule, check track
tension at the second set of bogie
wheels from real',
Lift rear of vehicle and support it
off the
ground. Place gear shift lever in for-
ward position, With engine off, rotate
tracks by hand and inspect condition. If
bad cuts or missing track inserts are
noted, see your dealer.
Visually inspect suspension springs.
Replace any weak or broken spring.
o
CAUTION: Do not allow cleaning
solution to enter battery. It will
destroy the chemical properties
of the electrolyte.
WARNING: Overflow tube must
be freo and open. A kinked or
bent tube wi!! restrict ventilation
and create gas accumulation
that Gould result in an explosion.
Avoid skin contact with electro-
lyte.
,A Iter reconnecting battery,coat battery
terminals and connectors with petro-
leum jeliy to prevent corrosion, Check
that battery is well secured and that
battery overflow tube is not blocked or
kinked.
Check electrolyte level. Electrolyte
level must be at upper level line on
battery casing,
if necessary add distilled water. Battery
'connections must also be free of cerro
sian, Ij cleaning is necessary, remove
corrosion using a stiff brush then clean
with asolution of baking soda and
water. Rinseand dry well.
15

To adjust track use the following pro-
cedure:
Loosen link plate spring lock nuts (4)
located on inner side
of link plate
springs.
Turn adjuster bolts clockwise to tight-
en tracks, counter-clockwise to slack-
en.
To correct:
Turn inner side adjuster boltts) COW1-
tor-clockwise to bring track closer to
center link olatsts), turn clockwise to
withdraw trackts) from link platets).
Tighten link plate spring lock nuts.
Rotate tracks Slowly and recheck
alignment.
WARNING: Before
track alignment, ensure that
track is free of ali particles which
Gould be thrown out while track
is Keep
tools and clothing clear
The carburetor mixture
are:
Low Speed Mlxture,
Speed Mixture.
Start engine and allow tracks to rotate
slowly. Check if tracks are well cen-
tered and turn evenly on the rear
sprockets. The distance between track
edges and link plates should be equal.
Turn
Low Speed Mixture Screw
clockwise until closed. Back off screw
1-1/8 turn (ot- % ~O) counter-clockwise.
ONOTE: Do
not close screw too
tightly as screw and / or seat can
be damaged.
16

Oi MbrtuwifiI AtJ!jiW~»trtlifil!~lt
Turn High Speed Mixture Screw fully
clockwise until closed, Back off screw
one (1) turn (..% .. 0) counter-clock-
wise,
CAUTION: Observe temperature
changes and locate
plLlgS ac-
cordingly. Incorrect location of
plugs mav cause carburetor ice-
up or engine overheating.
Inspect steering mechanism for
tiqht-
ness of components (steerinq arm,
ball joint, etc.l. If necessary, replace or
retighten. Check condition
of ski and
ski runner. Replace if worn.
Inspect belt for cracks, fraying or abo.
normal wear (uneven wear, wear on
one side, etc.). If abnormal wear is
noted, probable cause is pulley rnis
alignrnent.
Contact your dealer. Check
drive belt
width, drive belt width should
not be less than 1- 3/'16" 13 em) wide.
ONOTE:
When installing a new
drive belt, abreak-in period of 10-
15 miles is strongly' recornrnen-
ded.
WARNING: A final High Speed
Mixture Adjustment must be car,
ried out only by an authorized
Ski-Doo dealer.
NOTE:Do not close screw too
tightly or screw and / or seat can
be damaged.
CAUTION: Never operate your
snowmobile with the tube of the
air silencer 00)( disconnected.
Serious engine damage will occur
ifthis notice is disregarded.
When operating the vehicle in tern
perature exceeding 32° F, (0° c.i. tho
rubber plu~l must biock the engine side
orifics and the rubber vent must be
positioned on
the side of the silencer
box to allow cold air circulation.
o
~,
-,--_.---_. -. __ ., ,- -- .. _" J';'
W
--''''''~" ..-._-" Above r
32°F(OOC)
;~;;~
,
Bun vehicle forward so that true free-
play can be taken. Check tension then
turn driven pulley % turn counter..
clockwise and recheck. Starting from
maximum reading, adjust chain tension
to %tr(6 rnrn) free-·play.
if temperatures below 32QF. (0° C.)
the rubber plug must block the entry of
fresh air and the rubber vent must al-
low tile warm air being emitted from
the engine to be directed over the car-
buretor.
17

Remove capscrew locking chain ten-
sioner in place. (Tensioner is located
at bottom left of gearbox).
notate the tensioner as required to
obtain correct chain tension.
Replace capscrew to lock chain ten-
sioner in place.
IMPORTANT: If the vehicle is used to
carry or pull heavy loads, it is advisable
to change the gear ratio. Contact your
dealer for optional gears.
The brake mechanism is self-adjusting,
therefore, periodic adjustment is
not re-
quired. However, the brake mechanism
can be checked by depressing brake
control lever. Brake should apply fully
when lever is Y2" approx. from handle-
bar grip. If it does not, do
not tamper
with the brake, contact your servicing
dealer. Check the stop light to see it it
functions. If necessary, readjust
switch
position.
18
WARNING: Brake pucks less
than 3/ 16'" must be replaced,
Replacement must be performed
by an authorized Ski-Doo dealer.
Alwavs check the stop light to
seeifit functions.
Ski should be perpendicular to handle-
bar. To align:
Remove bolt handlebar to
steering column.
Remove handlebar to expose
Qn!in""rl
end of steering column.
Reposition handlebar on so
that it is perpendicular with .install
and tighten bolt to 30-35 It / lbs.
ONOTE: if c.'orrect spline
is unobtainable at
h"."nri!""h,:~ r ,
move lower steering bracket to
obtain proper location.
steering bracket holes are
slotted),