Ski-Doo EVEREST 500 1981 User manual

model
V.I.N.
purchase date _
warranty expiry date
To be completed by dealer at time of sale
DEALER IMPRINT AREA
MOTO-SKI
FUTURA
SPIRIT
NUVIK
MIRAGE
SUPER SONIC
ULTRA SONIC
TECHNICAL PUBLICATION
AFTER SALES SERVICE
BOMBARDIER
L1MITEE
VALCOURT, QUEBEC
CANADA, J02 2LO
The following are trademarks of Bom-
bardier Lirnitee.
BOMBARDIER EVEREST
SKI-DOO CITATION
ALPINE OLYMPIQUE
BLIZZARD
T'NT
CARRY-BOOSE
ELAN
ELITE
GRAND PRIX SPECIAL

.10
INDEX 0
THE 1981LIMITED WARRANTY. .. .2
FOREWORD 4
SAFETY IN MAINTENANCE , .. , , , 5
CONTROUINSTRUMENTS
Throttle lever, brake lever, ignition/light switch, headlamp dimmer switch,
emergency
cut-out switch, manual starter handle, primer, speedometer, tether
cut-out switch, adjustable steering handle, light switch, oil level indicator, hood
opening, tool box, fuel
gauge. .................................. 6
BREAK-IN PERIOD
Break-in, inspection, inspection checklist 8
FUEL
Recommended gasoline, recommended injection oil. .................... .10
PRE-START CHECK
Check points. . .
STARTING PROCEDURE
Manual starting.. ................................ . 11
EMERGENCY STARTING. . . . .. . . .. .. . 11
DRIVE BELT
AND GUARD REMOVAL ......................... . 12
LUBRICATION
Frequency, steering mechanism, chaincase oil level, oil injection system . . .13
MAINTENANCE
Maintenance chart, spark plugs, battery, suspension, track, track tension and
alignment, carburetor, drive belt, steering mechanism, drive pulley, brake, steer-
ing adjustment, engine head nuts, engine
mount nuts, muffler attachment, fan
belt, general inspection, bulb replacement . .
.. .14
STORAGE
Track, suspension, ski assembly, controls, chaincase. fuel tank, carburetor,
cylinder lubrication, chassis, general inspection. .20
PRE-SEASON PREPARATION
Pre-season preparation, chart, ,22
TROUBLE SHOOTING . 23
TOOLS.... .25
SPECIFICATIONS 26
WIRING
DIAGRAM. ....................... . 27
SI METRIC INFORMATION
GUIDE. ............. . 29
OFTEN ASKED
QUESTIONS.. .30
LISTING OFAREA DISTRIBUTORS. .................. . . 32
HOW TO IDENTIFY YOUR SNOWMOBILE ..................... . 33
CHANGE OFADDRESS OR OWNERSHIP ,35

LIMITED WARRANTY 1981 SKI .. DOO®SNOWMOBILES
1-PERIOD
BOMBARDIER Lirnitee as manufacturer, warrants FROM THE DATE OF FIRST
CONSUMER SALES, every
1981 Ski-Doo® snowmobile, sold as NEW AND UN-
USED, by an authorized Ski-Doo dealer,
for periods of:
• 12 months
for ELAN® , CITATION*, EVEREST®, ELlTE®, ALPINE®
models.
• 90 consecutive days for BLiZZARD® 5500,7500, 9500 models subjecs to the
following:
1. If delivery is made after the
31 st day of March of a given year and before the 1st
day of December of the same year, the above 90 day warranty will start on De-
cember 1st.
2. If delivery is made
on/or after the 2nd day of January of a given year but before
the 31st day of March of the same year, all the unused portion of the 90 day pe-
riod will be carried over to the next winter and start again on the 1st day of
December of the same year.
2- WHAT BOMBARDIER WILL DO
BOMBARDIER will repair and/or replace, at its option, components defective in
material
and/or workmanship (under normal use and service.) with a genuine
BOMBARDIER component
without charge for parts or labour, at any authorized
Ski-Doo dealer during said warranty period.
3· CONDITION TO HAVE WARRANTY WORK PERFORMED
Presentto the servicing dealer, the hard copy of the BOMBARDIER Customer Re-
gistration card received by the customer from the selling dealer at time of pur-
chase.
4-WARRANTY TRANSFER
This warranty istransferable to subsequent owner(s) for remainder of warranty pe-
riod from original date of sale.
5•EXCLUSIONS .. ARE NOT WARRANTED
• Normal wear on all items such as, but not limited to:
- drive belts
- slider shoes
- spark plugs
breaker points
- runners on skis
• A sulphated battery.
• Replacement parts
and/or accessorieswhich are not genuine Bombardier parts
and/or accessories.
• Damage resulting from installation of parts other than genuine BOMBARDIER
parts.
• Damage caused by failure to provide proper maintenance as detailed in the
Operator Manual. The labour, parts and lubricants costs of all maintenance ser-
vices, including tune-ups and adjustments will be charged to the owner.
2

• Vehicles used for racing purposes.
• All optional accessories installed on the vehicle.
(The normal warranty policy
for parts and accessories, if any, applies).
• Damage resulting from accident, fire or other casualty, misuse, abuse or ne-
glect.
• Damage resulting from modification to the snowmobile
not approved in writing
by BOMBARDIER.
•Losses incurred by the snowmobile owner other than parts and labour,
such as, but not limited to, transportation, towing, telephone calls, taxis, or
any other incidental or consequential damages.
Some states or provinces do not allow the exclusion or limitation of inciden-
tal or consequential damages, so the above limitation or exclusion may not
apply.
I - EXPRESSED OR IMPLIED WARRANTIES
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. Where ap-
plicable this warranty is expressly in lieu of all other expressed or implied
warranties of BOMBARDIER, its distributors and the selling dealer, including
any warranty of merchantability of fitness for any particular purpose; other-
wise the implied warranty is limited to the duration of this warranty.
However, some states or provinces do not allow limitations on how long an
implied warranty lasts, so the above limitation may not apply.
Neither the distributor, the selling dealer, nor any other person has been
authorized to make any affirmation, representation or warranty other than
those contained in this warranty, and if made, such affirmation, representa-
tion or warranty shall not be enforceable against BOMBARDIER or any other
person.
7· CONSUMER ASSISTANCE
If a servicing problem or other difficulty occurs, we suggest the following:
1. Try to resolve the problem at the dealership with the Service Manager or
Owner.
2. If this fails, contact your area distributor listed in the Operator Manual.
3. Then if your grievance still remains unsolved, you may write to us:
BOMBARDIER llMITEE
Customer Relations
Recreational Products
Valcourt, Quebec, Canada, JOE 2LO
BOMBARDIER LIMITEE RESERVESTHE RIGHT TO MODIFY ITS WARRAN-
TY POLICY AT ANY TIME, BEING UNDERSTOOD THAT SUCH MODIFICA-
TION WILL NOT ALTER THE WARRANTY CONDITIONS APPLICABLE TO
VEHICLES SOLD WHILE THE
ABOVE WARRANTY IS IN EFFECT.
October 1979
Bombardier Limitae
Valcourt, Quebec, Canada, JOE 2LO
®"Trademarks of Bombardier Lirnitee
3

FOREWORD
The operator manual and the Snow-
mobile Safety handbook have been
prepared to acquaint the owner / oper-
ator of a new snowmobile with the var-
ious vehicle controls, maintenance and
safe operating instructions. Each is in-
dispensable for the proper use of the
product and should be kept with the
vehicle at all times.
Should you have any questions per-
taining to the warranty and its applica-
tion, please consult the
"Often Asked
Question" section of this manualIor
your selling dealer.
4
This manual uses the following sym-
bols.
.... WARNING: Identifies-en lnstruc-
~ tion which, if not followed, could
cause personal injury.
... CAUTION: Denotes an instruc-
• tion which, if not followed, could
severely damage vehicle components.
ONOTE: Indicates- supplementary
information needed to fu!ly 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.

SAFETY IN MAINTENANCE
Observe the following
pr~.,;tions:
•Throttle mechanism should be
checked
'f'or treernovement before
startinq engine..
• Engine should be running only when
pUII~y guard is secured in .pla?~.
!_ ~,el'e_r!u,nengine without drive belt
installed_.Running an unloaded en-
gine can prove to be dangerous.
- • Never run engine when the track of
- - .the.vehicle is raised off the ground.
• It can be dangerous to run engine
withthe cab" removed.
• Gasoline is flammable and explosive
'under certain conditions. Always
manipulate in a well ventilated area.
Do not smoke or allow open flames
or sparks in the vicinity. If gasoline
fumes are noticed while drivinq.rths
cause should be determined and
corrected without'delay.
•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 oiher abrasive sur-
faces. On such surfaces abnormal
and excessive wear of critical parts
is inevitable.
.,
•Installation of other than standard
equipment, including ski-spreaders,
bumpers, pack racks,
etc" could
severely affect the stability arid safe-
ty of your vehicle. Avoid adding on
accessories that alter the basic ve-
hicle configuration.
• The snowmobile engine can be
stopped by activating the emergen-
cy cut-out switch, tether switch or
~y turning off the key.
•Whenever the vehicle is parked out-
doors, overnight or for a long
period, it is suggested to protect it
against the inclemency of the
wheather with a
snowmobilecover.
• Do not lubricate throttle and/or
brake cables and housings.
Please read and understand all other
warnings contained elsewhere.
THIS MANUAL SHOULD REMAIN WITH THE VEHICLE AT
TltE ,TIME,OF,RESALE. '-,
5

CONTROLS/INSTRUMENTS
AJ Throttle Control Lever
B) Brake Control Lever
CJ Ignition/Light Switch
DJ Head/amp Dimmer Switch
EJ High Beam Indicator
F) Emergency Cut-Out
Switch
G) Manual Starter Handle
HJ Primer
/) Speedometer
J) Tether Cut-Out Switch
KJ Adjustable steering handle
U Light switch (Electric Model)
MJ Oil Level Indicator
A) Throttle Lever
Located on right side of handlebar,
When compressed, it controls the en-
gine speed and the engagement of the
transmission. When released,
returns to idle.
B) Brake Control Lever
Located on the left side of handlebar.
When compressedIthe brake is
plied. When it
returns to its original
"',,",C"T,r\Y,
effect is proportionate to the pressure
applied on the lever.
ONOTE: On electric start models
('tllrYlnrnC:Clrlf1 the brake lever
will light up the oil indicator bulb.
If bulb does
not up, replace with a
new one.
6
C) Ignition/Light Switch
(Manual Start Models)
OFF
f1i':\--ON
~-"TEST"
3switch. To
turn key clockwise to
ON . To stop engine, turn key
counter-clockwise to OFF
The lights are automatically ON when-
ever the engine is running.
To test oil level indicator bulb,
with en-
gine running, turn key to test position.
If bulb does not
(Electric Start Models)
OFF
f1i':\_ON
\..9- START
Key operated, 3position switch. To
start engine, turn key fully clockwise to
START position and hold. Return
to ON position immediately when en-
gine has started. To stop engine, turn
key counter-clockwise to OFF position.

D) Headlamp Dimmer Switch
Located on left side of handlebar, flick
switch to high or low beam.
E) High Beam Indicator
Lights up when headlamp is on high
beam.
AEmergency Cut-Out Switch
A3position switch located on the right
side of the handlebar. To stop the en-
gine in an emergency, flick the lever to
either upper or lower
"OFF' position.
To start engine, lever must be in mid-
dle
"ON" position.
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 re-
quiring its use.
•
WARNING: If the switch has
been used in an emergency situa-
tion the source of malfunction should
be determined and corrected before re-
starting the engine.
G) Manual Starter Handle
Auto rewind type located on right hand
side of vehicle. To engage mechanism,
pull handle.
H) Primer
Apush-pull button. Pull and push but-
ton (2-3 times) to activate primer. The
primer should always be used for cold
engine starts.
After engine is warm
however, it is not necessary to use
primer when starting.
I) Speedometer
The speedometer is linked directly to
the drive axle. Direct-reading dial indi-
cates the speed of the vehicle. Odom-
eter records the total number of dis-
tance travelled.
J) Tether Cut-Out Switch
Attach tether cord to wrist or other
convenient location then snap tether
cut-out cap over receptacle before
starting engine.
If emergency engine "shut-off" is re-
quired completely pull cap from safety
switch and engine power will be auto-
rnaticaIly shut
fI off" .
ONOTE: The cap must be installed
on the safety switch at all times
in order to the vehicle.
... WARNING: If the switch is used
"y in an emergency situation the
source of malfunction should be deter-
mined and corrected before restarting
engine.
K) Adjustable steering handle
Loosen the four retainer screws.
Adjust the steering handle to the de-
sired position.
Lock the steering handle in place by
tightening the four (4) screws to 26
N.m (19ft-lbs).
•
WARNING: Do not adjust the
handlebar to high to avoid inter-
ference when turning, between the
brake lever and windshield.
L) Light Switch
A push purl switch type, to illuminate
headlamp and taillight, pull switch
knob. (Ignition switch must be turned
to ON position).
M} Oil Level Indicator
Will light up when injection oil level is
low. Check level and replenish as soon
as possible.
~ CAUTION: Do not run engine out
Yof oil. Serious engine damage will
occur.
To test oil level indicator bulb: on man-
ual start models, turn ignition key (en-
gine running) to "test" position. On
electric start models, indicator light will
glow each time brake lever is used. If
light does not glow, replace bulb.
7

Hood Opening
Pull down the latch to unhook the hood
from the anchor.
ONOTE: Always lift hood gently up
until stopped by restraining de-
vice.
•WARNING: It is dangerous to
run an engine
with the hood open
or removed. Personal injury could re-
sult.
... CAUTION: Prior to re-securing
.. the hood latch, position the bot-
tom edge of the hood into the hood
guide located on each side of the
frame.
ToolBox
Located under the hood. To gain ac-
cess, tilt hood. Ideal location for spare
plugs, belt, rope, etc.
Fuel Gauge
The fuel gauge is located on the left
side of the fuel tank. The gauge func-
tions on the principle of communicat-
ing vessels, so the fuel level inside the
tank is directly related with the level in-
dicated on the gauge.
+WARNING: Never use a lite
match or open flame to check
fuel level.
8
BREAK-IN PERIOD
With Bombardier-Rotax snowmobile
engines, a break-in period is required
before running the vehicle at full throt-
tle. Engine's manufacturer recommen-
dation is 10 to 15 operating hours. Dur-
ing this period, a richer mixture is
needed (i.e. 40 parts
of gas for 1part of
50/1 Bombardier oil). Maximum throt-
tle should not exceed
3/4, however,
brief full acceleration and speed varia-
tions contribute to a good break-in.
Continued wide open throttle accelera-
tions, prolonged cruising speeds, and
lugging are detrimental during the
break-in period.
ONOTE: A new drive belt requires
a break-in period of 15-25 km (10-
15 miles).
1O-Hour Inspection
As with any precision piece of mechan-
ical equipement, we suggest that after
the first 10hours of operation or 30days
after the purchase, whichever comes
first,' your vehicle
be' checked by your
dealer. This inspection will give you the
opportunity.to .discuss the unanswered
questions you may have encountered
during the first hours
of operation.
Remember that it is to remedy at
this time than
to allow the snowmobile
to operate until a possible failure oc-
curs.
The 10 hours inspection is at the ex-
pense of the vehicle owner.

10·HOUR INSPECTION CHECK LIST ./
Engine timing
Fan belt tension
Spark plugs condition .
Carburetor adjustment
Oil injection
pump adjustment
Engine
head nuts
Engine
mount nuts
Muffler attachment
Chaincase oil level
Brake operation and lining condition
--~/
Ski alignment (runner condition)
Pulley alignment and drive belt condition
Track condition, tension and alignment
Lubrication (steering, suspension)
Electrical wiring (loose connections, stripped wires, damaged insula-
tionl, tighten all loose bolts, nuts and linkage
Operation of lighting system (HI / LO beam, brake light, etc.I, test-
operation of emergency
cut-out switch, tether switch
We recommend that you have your dealer sign this inspection.
Date of 10 hourinspection
Dealer signature
9

FUEL PRE-START CHECK
Recommended Gasoline
Use regular leaded gasoline available
from ali service stations.
.., CAUTION: Never experiment
• with different fuel or fuel ratios.
Never use naphtha, methanol or similar
products.
ONOTE: For the break-in period
only, 1 (16 oz) can of Bombardier
snowmobile oil should be added to the
first full fuel tank filling, at a 70/1 ratio.
This will assure additional protection
during the initial break-in.
•
WARNING: Never "top up" the
gas tank before placing the vehi-
cle in a warm area. At certain temper-
tures, gasoline will expand and ove-
flow.
Recommended Injection Oil
Use concentrated Bombardier snow-
mobile oil available from your dealer.
10
Check Points
• Activate the throttle control lever
several times to
check that it
ates and
smoothly. The
tie lever
must return to idle
position
when released.
• Check fuel level.
• Check
that the skis and the track are
not frozen to the ground or snow
surface and that the oper-
ates freely.
•
Activate the brake control lever and
make sure the brake
fully be-
fore the brake
control lever touches
the handlebar grip.
•Verify
that thepath ahead of the ve-
hicle is clear of and ob-
stacles.
..... WARNING: Onlystartyoursnow-
Tmobile once all components are
checked and functioning properly.

STARTING PROCEDURE
Emergency Cut-Out Switch
Manual Starting
1. Insert the in the ignition and
turn to ON position.
2. Test the
throttle control lever.
3. Activate the primer (2 to 3times).
ONOTE: Primer is not necessary
when the engine is warm.
4. Ensure the tether
cut-out cap is in
position and that the cord is attach-
ed to your clothing. Check that the
emergency
cut-out switch is in the
on position.
5. Grasp manual starter handle firmly
and pull slowly until a resistance is
felt then pull vigorously. Slowly re-
lease the rewind starter handle.
OFF
... WARNING: Do not apply throttle
.... while starting.
6. Check of the emergency
cut-out switchIand the tether
switch. Restart the
... WARNING: If engine does not
.... shut-off when applying the emer-
gency
cut-out switch and/or by pulling
the tether
cut-out cap, stop the engine
by turning
off the ignition key. Do not
operate the vehicle further, see your
dealer.
7.
Allow the engine to warm before
operating at full throttle.
Emergency Starting
Should the rewind starter rope fray and
break, the engine can be started
with
an emergency starter rope.
... WARNING: Do not startthe vehi-
.... cle by the drive pulley unless it is
atrue emergency situation, have the
vehicle repaired as soon as possible.
Remove the belt guard form the vehi-
cle and wind the emergency rope tight
around the drive pulley between the
sliding half and the roller guard. Start
the engine as per usual manual start-
ing.
... WARNING: When starting the
.... vehicle in an emergency situation
by the drive pulley, do
not make a knot
at the end of the emergency rope and
do
not reinstall the belt guard.
/
11

DRIVE BELT AND GUARD REMOVAL .
Belt Guard Removal
..... WARNING: Engine- should be
~ running only when belt guard is
secured in place.
1. Tilt the hood Iremove both belt
guard retaining clips (A).
2.
Pullout both B &Cretaining pins.
..... WARNING: At the removal or in-
~ stallation of the belt guard front
retaining pin be careful not to burn
yourself on the exhaOstsystem.-
3. Lift and remove the belt guard
assembly.
Drive Belt Removal
..... WARNING: Never start or run
~ engine without the drive belt in-
stalled. Running an unloaded engine is
dangerous.
12
1. Tilt the hood and remove the belt
guard.
2. Open the driven pulley by twisting
and pushing the sliding half.
Hold in
fully open position.
3. Slip the belt over the top edge of the
sliding half.
4. Slip the belt out from the drive pul-
ley and remove completely from the
vehicle. To install the drive belt,
reverse the procedure.

LUBRICATION
Frequency
Routine maintenance is necessary for
all mechanized products, and the
snowmobile is no exception. Aweekly
vehicle inspection
contributes to the
life span of the snowmobile as well as
retains safe and dependable ooeration
It is recommended
that the steering
system and be lubricated
monthly or every 40 hours of opera-
tion. If the vehicle is operated in
wet
snow or in severe conditions these
items should be lubricated more fre-
quently.
.& WARNING: Only perform such
Tprocedures as detailed in this
manual. It is recommended that dealer
assistance be periodically obtained on
other components/systems not cov-
ered in this manual. Unless otherwise
specified, engine should be turned OFF
for atllubrication and maintenance pro-
cedures.
Steering Mechanism
.& WARNING: Do not lubricate
Tthrottle and/or brake cables and
housings.
Lubricate the ski legs at grease fittings
until new grease appears at joints. Oil
spring coupler bolts.
Chaincase Oil Level
Check the oil level by removing the oil
level cap plug.
The oil should be level
with the bottom
of the oil level orifice.
ONOTE: The chaincase oil capacity
is approximately 200 mL (7 oz).
Oil Injection System
Check reservoir frequently. Replenish
as required, using Bombardier
snow-
mobile oil, available from your dealer.
13

MAINTENANCE
The following Maintenance Chart indi-
cates schedules to be
by you or
your servicing
If these services are performed
as
your snowmobile will
give you many years of
low-cost use.
.... WARNING: Only perform such
Tprocedures as detailed in this
manual.
It is recommended that dealer
assistance be periodically obtained on
other components/systems not cov-
ered in this manual. Unless otherwise
specified, engine should be turned OFF
for all lubrication and maintenance pro-
cedures.
SERVICE AND
NO
gs~:s:
WOO
Xl
4:::>-,
N-':::J
<D
°CD
°CD
O
8~@
~
MAINTENANCE
7"<
7"<3-
3 ~ 3~2:
7"CD ru 0
CHART --< -
-<-<
3-<-<
----' CJl N
CD D
CJl 0Q.l ru
000
to
338({)
3
-
Spark plugs •15
Battery •15
Suspension •15
Track •15
Track tension and alignment •16
Carburetor adjustment •17
Drive belt •17
Steering mechanism •17
Drive pulley •18
Brake •18
Steering adjustment •18
Engine head nuts •19
Engine mount nuts •19
Muffler attachment
•19
Fan belt •19
General inspection •19
o
14
NOTE: The ten hour msoectron is a very important pan of proper service and
maintenance.

~ CAUTION: If spark plug condi-
... tion is not ideal, contact your au-
thorized dealer.
Check spark plug gap using a wire
feeler gauge.
Reinstall plugs and connect wires.
Spark Plugs
Disconnect the spark plug wires and
remove the spark plugs.
Check the condition of the plugs.
• A brownish tip reflects ideal condi-
tions. (Correct carburetor/ spark
plug heat range; etc.).
• A black insulator
tip indicates fouling
caused by: carburetor idle speed
mixture
and/or high speed mixture
too rich/ incorrect fuel mixture ratio,
wrong type of spark plug (heat
range), or excessive idling.
• A light grey insulator indicates a
lean mixture caused by; carburetor
high speed mixture adjusted too
lean,
wrong spark plug heat range/
incorrect fuel mixture ratio, or a
leaking seal or gasket.
IiI
~ CAUTION: Do not allow cleaning
... solution to enter battery. It will
destroy the chemical properties of the
electrolyte.
After reconnecting coat "",..,'r ......... ·'J
terminals and connectors wi
petroleum jelly to prevent corrosion.
Check
that battery is well secured and
that battery overflow tube is not bloc-
ked or kinked.
£. WARNING: Overflow tube must
.... be free and open. A kinked or
bent tube will restrict ventilation and
create gas accumulation
that could
result in an explosion. Avoid skin con-
tact with electrolyte.
~ CAUTION: Prior to charging the
... battery, always remove it from
the vehicle to prevent electrolyte spill-
age.
Suspension
Visually inspect all suspension compo-
nents including slider shoes, springs,
wheels, etc...
ONOTE: During normal driving,
snow will act as a lubricant and
coolant for the slider shoes. Extensive
riding on ice or sanded snow, (not to
mention asphalt, etc. never re-
f"r\''Y'lrY;nn,rlr.rll will create excessive heat
build-up and cause premature slider
shoe wear.
Fouled
(black)
Overheated
(light grey)
Battery (Electric Start Models)
Check electrolyte level. Electrolyte le-
vel must be at upper level line on bat-
tery
If necessary add distilled water. Bat-
tery connections must also be free of
corrosion. If cleaning is necessary
remove corrosion using a stiff brush
then clean
with asolution of baking
soda and water. Rinse and well.
Track
Lift the rear of the vehicle and support
it
off the ground. With the engine
rotate the track by hand/ and inspect
condition. If
worn, cut or track fibers
are exposed or missing or defective in-
serts or guides are noted, contact your
dealer.
£. WARNING: Do not operate .a
.... snowmobile with acut, torn or
damaged track.
15

Track Tension and Alignment
The suspension is adjustable. The front
adjustment for surface condition; use
the suspension adjustment key. The
rear adjustment is for driver's weight
and should be adjusted using the
21
mm socket and handle.
When the front adjuster blocks are at
the lowest elevation more is
distributed on the skis. At the
nlnnnl:'T
position the weight is transferred to the
track. The rear adjuster blocks should
be adjusted to suit the driver's
Adjuster blocks
... CAUTION: Always turn the left
.. side adjuster blocks in a clock-
wise direction, the right side blocks in a
counter-clockwise direction. Left and
right adjuster blocks of each adjust-
ment must always be set at the same
elevation.
Lift the rear of vehicle and support with
a mechanical stand.
Allow the slide to
extend normally. Check the 13mm
(1/2") between the slider and the
bottom inside of the track. If the track
tension is too loose, the track will have
a to thump.
13 mm (i/z")
16
.. CAUTION: Too much tension
~ will result in power loss and ex-
cessive stresses on suspension com-
ponents.
If necessary to adjust, loosen the rear
idler wheel retaining screw and then
loosen or tighten the adjuster bolts
lcated on the inner side of the rear idler
wheels. If correct tension is unat-
tainable. Contact your dealer.
ONOTE: Track tension and align
ment are inter-related. Do not ad-
just one
without the other.
Start the engine and accelerate slightly
so that the track turns slowly, Check
that the track is well centered;
distance on both sides between
of track guides and slider shoes.
... WARNING: Before checking
Ttrack alignment, ensure that the
track is free of all particles which could
be thrown out while track is rotating.
Keep hands, tools, feet and clothing
clear of track. Ensure no-ons is stand-
ing in close proximity to the vehicle.

Steering Mechanism
Inspect the steering mechanism for
tightness of components (steering
arms, tie rods, ball joints, spring
coupler bolts, etc,
J. If necessary, re-
place or retighten.
Check the condition of the skisand the
ski runners. Replace if worn more than
half.
Front of
vehicle
Drive Belt
Inspect the belt for cracks, fraying or
abnormal wear (uneven wear fwear on
one side,
etc.) If abnormal wear is not-
ed, probable cause is pulley misalign-
ment.Contact your dealer.
Check the drive belt
width, if less than
3cm (1 3/16")
ONOTE: When installing a new
drive belt, a break-in period of 15-
25 km (10-15 miles) is strongly recom-
mended.
Air Silencer
The air intake silencer elbow must
always be turned to the front of the ve-
hicle when operated in cold or warm
temperature.
If the vehicle is to be operated in deep
powdered
snow it is recommended to
turn the elbow towards the rear of the
vehicle.
Carburetor Adjustment
... CAUTION: Never operate your
• snowmobile with the air intake
silencer disconnected. Serious engine
damage will occur if this notice is dis-
regarded.
Carburetor adjustment should be per-
formed by your dealer.
To
correct stop the engine, loosen the
rear idler wheels retaining screws then
loosen the lock nuts and tighten the
adjuster bolt on the side where the
slider shoe is the furthest to the track
insert guides.
Tighten the lock nuts and recheck the
alignment. Ensure to retighten the idler
wheel retaining screws.
17

Drive Pulley
Inspect the Duralon bushing condition
by checking the free-play of the sliding
half pulley. This is achieved by restrain-
ing the inner half and checking if the
sliding half moves in the direction of
the arrows more than 3 mm (118"). If
so contact your dealer.
IMPORTANT: Close the front of the
skis manually to eliminate all slack from
the steering mechanism.
If adjustment is required:
Loosen the lock nuts of the longer tie
rod. Turn the tie rod manually until the
skis are
properly aligned. Firmly
retighten the lock nuts.
Mark reference
point
on both halves 3 mm
(i/a")
toe out
+
Maximum
3mm
Brake
The brake mechanism on snow-
mobile is an essential device.
this mechanism in proper work-
ing condition. Above all, do not
ate your snowmobile
without an
tive brake system.
.A. WARNiNG: Brake pad or pucks
.... Iess than 3 mm (118") thick must
be replaced. Replacement must be per-
formed by an authorized dealer.
The brake mechanism is C<A!T-::lr1IIIISTIl
periodic adjustment is
required. However, check operation of
brake mechanism by depressing brake
control level. Brake should apply fully
when lever is 13 mm
(1/2") approx.
from handlebar grip. If not, do not tam-
per with the brake, contact your servic-
ing dealer.
Steering Adjustment
Skis should have a toe out of 3 mm
(118"). To check, measure the distance
between each ski at the front and rear
of the leaf springs. The front distance
should be 3 mm
(1/8") more than the
rear when the handlebar is horizontal.
18
The handlebar should also be hori-
zontal when the skis are pointed to-
ward the front.
To adjust:
Loosen the lock nuts of the shorter tie
rod. Turn the tie rod manually until the
handlebar is horizontal. Retighten the
lock nuts firmly.
•
WARNING: The ball joint socket
must run parallel with the steer-
ing arm. The socket must be restrained
when tightening the tie rod end lock
nuts.