Ski-Doo Legend Manual

In USA, products are distributed by Bombardier Motor Corporation
of America. In Canada, products are distributed by Bombardier Inc.
The following are trademarks of Bombardier Inc or its subsidiaries.
BOMBARDIER®GRAND TOURINGTM SUMMIT®
ROTAX®MX-Z®SKANDIC*
SKI-DOO®RERTM LEGENDTM
DESSTM DPMTM
Printed in Canada (Mmo2003-003a.fm GM)
®TM*are trademarks and ®are registered trademarks of Bombardier Inc. or its subsidiaries.
© 2002 Bombardier Inc. All rights reserved.
SAFETY WARNING
Disregarding any of the safety precautions and instructions con-
tained in this Operator’s Guide, Safety Handbook, Safety Video-
cassette or on-product warnings may result in injury, including the
possibility of death.
This Operator’s Guide, Safety Handbook and Safety Videocas-
sette should remain with the unit at time of resale.
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2003 SKI-DOO OPERATOR’S GUIDE
This guide is applicable to the following ZX series models:
LegendTM
Grand TouringTM
MX-Z®
Summit ®
Skandic*
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FOREWORD
Congratulations on your purchase of a new SKI-DOO snowmobile.
Whatever model you have chosen, it is backed by the Bombardier
warranty and a network of authorized SKI-DOO snowmobile dealers
ready to provide the parts, service or accessories you may require.
The Operator’s Guide and the Safety Handbook have been prepared
to acquaint the owner/operator and passenger of a new snowmobile
with the various snowmobile controls, maintenance and safe operat-
ing instructions. Each is indispensable for the proper use of the product.
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.
Your dealer is committed to your satisfaction. He has taken training
to perform the initial set-up and inspection of your snowmobile as
well as completed the final adjustment required to suit your specific
weight and riding environment before you took possession. At deliv-
ery, your dealer would have explained the snowmobile controls and
provided you with a brief explanation of the various suspension ad-
justments. We trust you have taken full advantage of this! If you need
more complete servicing information, please ask your dealer about
the proper model-year SKI-DOO Shop Manual.
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.
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 without
the safety alert symbol , potential hazard exists for property
damage only.
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We also reserve the right at any time to discontinue or change spec-
ifications, designs, features, models or equipment without incurring
obligation.
The illustrations show the typical construction of the different assem-
blies 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 pre-
vail.
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 Bombardier products for replacement parts
and accessories. They’ve been specially designed for your vehicle and
manufactured to meet Bombardier’s demanding standards.
A Shop Manual can be obtained for complete service, maintenance
and more repair information.
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TABLE OF CONTENTS
SAFETY MEASURES............................................................ 7
LIST OF HOT PARTS.................................................................. 8
LIST OF MOVING PARTS.......................................................... 8
BOMBARDIER LIMITED WARRANTY NORTH AMERICA:
2003 SKI-DOO®SNOWMOBILES ............................................. 9
BOMBARDIER LIMITED WARRANTY INTERNATIONAL:
2003 SKI-DOO®SNOWMOBILES ............................................. 12
FREQUENTLY ASKED QUESTIONS ......................................... 15
AUTHORIZED SKI-DOO DEALERS ........................................... 17
HOW TO IDENTIFY YOUR SNOWMOBILE .............................. 17
Vehicle Description Decal............................................................ 17
Serial Numbers............................................................................ 18
ON-VEHICLE IMPORTANT INSTRUCTIONS............................ 20
CONTROLS/INSTRUMENTS/EQUIPMENT ............................. 28
1) Throttle Lever........................................................................ 31
2) Brake Lever ........................................................................... 31
3) Parking Brake Locking Lever or Button................................. 31
4) Brake/Parking Brake Pilot Lamp (Red)................................... 33
5) Low Injection Oil Level (Red) ................................................ 34
6) Handlebar .............................................................................. 34
7) Adjustable Handlebar ............................................................ 35
8) Holding Strap......................................................................... 35
9) RER Button ........................................................................... 36
10) Start/RER Button................................................................... 38
11) Ignition Switch ...................................................................... 41
12) Tether Cut-Out Switch .......................................................... 42
13) RER Pilot Lamp (Red)............................................................ 45
14) DESS Pilot Lamp (Red).......................................................... 45
15) DESS/RER Pilot Lamp (Red).................................................. 45
16) Engine Cut-Out Switch.......................................................... 46
17) Headlamp Dimmer Switch .................................................... 47
18) High Beam Pilot Lamp (Blue) ................................................ 47
19) Rewind Starter Handle .......................................................... 47
20) Choke Lever .......................................................................... 48
21) Speedometer ........................................................................ 49
22) Mode Button ......................................................................... 50
23) Odometer.............................................................................. 50
24) Trip Meter ............................................................................. 50
25) Resetable Hourmeter............................................................ 51
26) Trip Meter Reset Button ....................................................... 51
27) Tachometer ........................................................................... 52
28) Temperature Gauge .............................................................. 52
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29) Engine Overheat Warning Lamp (Red) ................................. 52
30) Fuel Tank Cap/Gauge............................................................ 53
31) Electric Fuel Level Gauge ..................................................... 54
32) Heated Grip Switch............................................................... 54
33) Heated Throttle Lever Switch............................................... 55
34) Electric Visor Jack Connector ............................................... 57
35) 12-Volt Power Outlet ............................................................ 58
36) Air Suspension Switch.......................................................... 59
37) Air Suspension Gauge .......................................................... 60
38) Air Suspension Compressor Pilot Lamp ............................... 60
39) Hood Latches........................................................................ 60
40) Adjustable Mirrors ................................................................ 61
41) Adjustable Toeholds ............................................................. 61
42) Heated Carburetor Valve....................................................... 62
43) Adjustable Backrest .............................................................. 63
44) Seat Strap ............................................................................. 65
45) Rear Passenger Heated Grip Switch .................................... 66
46) Adjustable Rear Grab Handles .............................................. 67
47) Hood Grills ............................................................................ 68
48) Storage Compartment .......................................................... 69
49) Rear Rack ............................................................................. 69
50) Tool Bag................................................................................ 70
51) Fuses .................................................................................... 71
52) Spare Spark Plug Holder ....................................................... 73
53) Spare Drive Belt Holder ........................................................ 74
54) Front Grab Handles/Front Bumper........................................ 75
55) Convertible Ski Stance.......................................................... 75
56) Adjustable Suspensions........................................................ 76
General ....................................................................................... 77
Guidelines to Adjust Suspension ................................................ 78
TROUBLESHOOTING CHART .................................................. 97
In Deep Snow ............................................................................. 97
FUEL AND OIL ........................................................................... 98
Recommended Fuel ................................................................... 98
Recommended Oil...................................................................... 99
COLD WEATHER CARBURETION MODIFICATIONS .............. 100
BREAK-IN PERIOD..................................................................... 100
Engine......................................................................................... 100
Belt ............................................................................................. 100
10-Hour Inspection ..................................................................... 100
PRE-OPERATION CHECK .......................................................... 101
PRE-OPERATION CHECK LIST ................................................. 103
OPERATING INSTRUCTIONS................................................... 104
Principle of Operation ................................................................. 104
Starting the Engine ..................................................................... 105
Emergency Starting .................................................................... 107
Shutting Off the Engine.............................................................. 110
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VEHICLE WARM-UP .................................................................. 110
POST-OPERATION CARE .......................................................... 111
SPECIAL OPERATIONS ............................................................. 111
Riding at High Altitudes............................................................... 111
Engine Overheating..................................................................... 111
Fuel Flooded Engine.................................................................... 112
Rear Suspension Slider Shoe Sticking......................................... 112
PERIODIC MAINTENANCE CHART........................................... 113
FLUID LEVELS............................................................................ 115
Brake System.............................................................................. 115
Chaincase Oil Level..................................................................... 116
Oil Injection System .................................................................... 117
Cooling System ........................................................................... 118
MAINTENANCE ......................................................................... 119
Vehicle Cleaning and Protection.................................................. 119
Belt Guard Removal and Installation ........................................... 120
Drive Belt Removal/Installation ................................................... 122
Drive Chain Tension .................................................................... 127
TRA Drive Pulley Adjustment...................................................... 127
Drive Belt Condition .................................................................... 130
Brake Condition........................................................................... 130
Brake Adjustment........................................................................ 130
Rear Suspension Condition ......................................................... 131
Suspension Stopper Strap Condition........................................... 131
Track Condition............................................................................ 131
Track Tension and Alignment...................................................... 131
Steering and Front Suspension Mechanism ............................... 135
Wear and Condition of Skis and Runners.................................... 136
Exhaust System .......................................................................... 136
Air Filter Cleaning ........................................................................ 136
Headlight Beam Aiming............................................................... 139
Bulb Replacement....................................................................... 139
Battery Electrolyte....................................................................... 143
TOWING THE VEHICLE ............................................................. 144
TRANSPORTING THE VEHICLE................................................ 144
STORAGE AND PRESEASON PREPARATION......................... 144
Storage........................................................................................ 144
Preseason Preparation ................................................................ 144
TROUBLESHOOTING ................................................................ 145
SPECIFICATIONS ....................................................................... 148
CHANGE OF ADDRESS OR OWNERSHIP................................ 158
PRIVACY OBLIGATIONS/DISCLAIMER ................................... 158
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SAFETY MEASURES
Observe the Following Warnings:
For vehicles with a parking brake, always engage brake when ve-
hicle is not in use.
Throttle mechanism should be checked for free movement and
return to idle position before starting engine.
In an emergency, the snowmobile engine can be stopped by activat-
ing the engine cut-out button, pulling the tether cord or turning off
the key. Note that only the fan-cooled models have an ignition key.
Engine should be running only when belt guard is secured in place.
Never run the engine without drive belt installed. Running an un-
loaded engine such as without drive belt or with track raised, can
be dangerous.
Never run the engine when the track is raised off the ground or
with the hood or access panel opened or removed.
Do not stud the track. At speed it may cause the track to tear and
separate from vehicle posing a risk of severe injury or death.
Never run the engine in a non well-ventilated area and/or unattended.
Maintain your snowmobile in top mechanical condition at all times.
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.
Electric start models only: Never charge or boost a battery while
installed on snowmobile.
Do not lubricate throttle and/or brake cables and housings.
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.
Some snowmobiles are designed for the driver only and no provi-
sions have been made for a passenger.
The performance of this snowmobile may significantly exceed that
of other snowmobiles you have operated. Therefore, use by nov-
ice or inexperienced operators is not recommended.
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 Bombardier Inc.
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Electronic reverse (RERTM) models only: The shifting to reverse
mode on these snowmobiles is done by the push of the RER but-
ton when the engine is running. Wait until the reverse alarm
sounds and the DESSTM/RER pilot lamp comes on in the dash be-
fore operating throttle to proceed in reverse. The reverse speed of
these snowmobiles is not limited. Always proceed with caution as
fast reverse could result in loss of vehicle stability. Come to com-
plete stop before selecting reverse. 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. Come to complete
stop before selecting reverse gear. Wait until the reverse alarm
sounds before operating throttle to proceed in reverse. Always
remain seated and apply the brake before shifting. Ensure the path
behind is clear of obstacles or bystanders before proceeding.
LIST OF HOT PARTS
All power train components.
LIST OF MOVING PARTS
All transmission, suspension and steering parts.
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