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.