Ski-Doo MX Z X 440 Manual

Mmo-2005 MX Z X 440 suppl.FH8 Fri Aug 13 13:26:44 2004 Page 1
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SAFETY WARNING
Disregarding any of the safety precautions and instructions
contained in this Operator’s Guide Supplement,Safety Videocas-
sette or on-product warnings may result in injury, including the
possibility of death.
This Operator’s Guide Supplement 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 ADRENALINETM LEGENDTM
REV®ROTAX®DESSTM
GSXTM RERTM SUMMIT®
GTX†MX-Z®
† GTX is a trademark of Castrol Ltd. Used under license.
Printed in Canada. (MMO2005-006 SH)
©Bombardier RecreationalProductsInc.andBRPUSInc.Allrightsreserved.
®™Trademarks of Bombardier Recreational Products Inc. or its affiliates.
*Trademarkof Bombardier Inc.used underlicense.

Dear 2005 MX Z XTM 440 owner, informations in the 2005
ZXTM/REV®Series Operator's Guide (P/N 520 000 499) also
apply to your MX Z X 440 except for the following.
__________________________ 1

TABLE OF CONTENTS
4) Brake/Parking Brake Pilot Lamp (Red)...................... 5
11) Tether Cord Cut-Out System .............................. 6
13) Engine Cut-Out Switch .................................... 6
28) Fuel Level .................................................. 7
60) Adjustable Suspensions ................................... 7
61) Primer Button .............................................. 8
62) Pre-Heat Switch............................................ 9
Recommended Fuel ........................................... 10
Recommended Oil ............................................. 11
METRIC (SI) .................................................... 13
IMPERIAL ...................................................... 13
UNITED STATES ............................................... 13
Brake System .................................................. 15
Coolant Pump Shaft Oil Reservoir............................. 15
Coolant Reservoir .............................................. 15
Drive Belt Removal/Installation................................ 17
2__________________________

LIMITED WARRANTY VALIDATION
Because of its racing application, the 2005 MX Z X 440 is shipped
from the factory with high compression ratio (CR) combustion cham-
ber inserts installed.
To validate limited warranty coverage and to run engine with 91 oc-
tane number gasoline (R + M)/2 inside North America (95 RON out-
side North America), the following modifications must be done at
predelivery before using the vehicle.
1. Low CR combustion chamber inserts must be installed on en-
gine. The high CR combustion chamber inserts must be returned
to BOMBARDIER Warranty Department.
2. Replace the main jets with the ones recommended in the Prede-
livery bulletin.
3. Replace the needle jets with the ones recommended in the Pre-
delivery bulletin.
4. Disconnect the pre-heat switch as explained in the Predelivery
bulletin.
__________________________ 3

RACING APPLICATION
For racing application, the main jets have to be replaced according to
thechartfoundonbeltguard.
4__________________________

CONTROLS/INSTRUMENTS
40
A33A1RA
44
42
28
50
32
33
14
62
2 3 8 13
1
11
27
19
NOTE: See description of numbered items in 2005 ZX/REV Series
Operator’s Guide (P/N 520 000 499) except for the following.
4) Brake/Parking Brake Pilot Lamp (Red)
This pilot lamp is disabled (does not light up) on the MX Z X 440.
WARNING
Make sure parking brake is fully disengaged before operating
the snowmobile.
When you ride the vehicle, brake that are caused to drag by
a continuous pressure on the lever may cause damage to the
brake system and cause loss of braking capacity and/or fire.
__________________________ 5

11) Tether Cord Cut-Out System
General
The tether cord cut-out system prevents snowmobile to runaway, if
the operator accidently falls off, by shutting off the engine.
WARNING
Always disconnect tether cord when leaving vehicle unattend-
ed and keep in a secured location.
Operation
Attach tether cord to clothing eyelet then snap tether cord cap over
post before starting engine.
To stop engine, completely pull cap from post.
13) Engine Cut-Out Switch
Locatedonrightsideofhandlebarthisswitchisusedtostopthe
engine.
OFF
A33E0HB
ON
OFF
6__________________________

28) Fuel Level
Open fabric door to see the fuel level through the translucent fuel
tank.
A33H1OA 1
1. Fabric door
60) Adjustable Suspensions
NOTE: There is no rear shock motion ratio adjustment on the
MX Z X 440.
In addition to all suspension adjustments described in ZX/REV Series
Operator’s Guide, take note of the 2 following points.
Shocks
All 4 shocks feature 2 adjustments.
Low Speed Compression Adjuster
The low speed adjuster modifies the damping force for small suspen-
sion velocities —less than 0.75 m/s (2.5 ft/s). It tunes the vehicle
for braking, cornering, hole shot and all the bumps that create low
speed movement in the suspension. This adjuster has 4 turns of
adjustment. Use a flat screwdriver to adjust it. Turning it clockwise
increases shock damping action (stiffer) for these low compression
speeds.
__________________________ 7

High Speed Compression Adjuster
The High speed adjuster modifies the damping force for high sus-
pension velocities —more than 0.5 m/s (1.6 ft/s). It tunes the ve-
hicle for hoops or bumps that create high speed movement in the
suspension. This adjuster has 3 turns of adjustment. Use a 17 mm
wrench to adjust it. Turning it clockwise increases shock damping
action (stiffer) for these high compression speeds.
A33F0DA 12
1. Low speed compression adjuster (flat screwdriver)
2. High speed compression adjuster (17 mm wrench)
Center and Front Springs
CAUTION: Make sure that center spring and both front springs
are still preloaded when front of vehicle is off the ground. Max-
imum spring preload is 25 mm (1 in). Otherwise, spring will be
coil bound when fully compressed.
61) Primer Button
Pull and push button. It is not necessary when engine is warm.
To prime, activate button until a pumping resistance is felt. From
this point, pump 2 or 3 times to inject fuel in intake manifold. After
priming, ensure that primer button is pushed back.
NOTE: In very cold temperature, it is recommended to rotate primer
button 3-4 turns prior to pull it. This will eliminate the possibility of
sticking.
8__________________________

62) Pre-Heat Switch
Racing Application Only
NOTE: This switch is disabled (not operative) on vehicles modified
forwarrantyvalidation. Torunenginewith91octanenumberfuel
(R + M)/2 inside North America (95 RON outside North America),
this switch must be disabled.
1
A33E0SA
2
1. Button depressed: Pre-heat timing curve
2. Button released: 108 (R + M)/2+ Octane timing curve for North America
version (98 RON + Octane timing curve for outside North America).
After starting the engine, push and hold the pre-heat switch button
in order to pre-heat the tuned pipe. Release pre-heat switch button
once the tuned is pre-heated.
__________________________ 9

FUEL AND OIL
Recommended Fuel
Vehicles with Valid Warranty (Pre-Heat Switch Disabled)
Use Premium unleaded gasoline or oxygenated gasoline containing
less than 10% of ethanol or 5% of methanol.
In North America, use gasoline with an octane number of 91 (R +
M)/2.
NOTE: In most service station pump in North America, octane num-
ber corresponds to (R + M)/2.
Outside North America, use gasoline with an octane number of 95
(RON).
Vehicles without Warranty (Pre-Heat Switch Enabled)
Use racing fuel with an octane number of 108 (R + M)/2 or higher
inside North America.
Outside North America, use racing fuel with an octane number of 98
(RON) or higher.
NOTE: The fuel tank cap specifies an octane number of 91 as a min-
imum. A higher octane number is required in racing application.
All Vehicles
CAUTION: Never experiment with other fuels or fuel ratios. The
use of unrecommended fuel can result in snowmobile perfor-
mance deterioration and damage to critical parts in the fuel sys-
tem and engine components.
WARNING
Always stop engine before refueling. Open cap slowly. If a dif-
ferential pressure condition is noticed (whistling sound heard
when loosening fuel tank cap) have vehicle inspected and/or
repaired before further operation. Fuel is flammable and ex-
plosive under certain conditions. Never use an open flame to
check fuel level. Never smoke or allow flame or spark in vicin-
ity. Always work in a well-ventilated area. Never top up the
fuel tank before placing the vehicle in a warm area. As tem-
perature increases, fuel expands and may overflow. Always
wipe off any fuel spillage from the vehicle.
10 _________________________

Fuel System Antifreeze
NOTE: Fuel antifreeze may add alcohol to fuel which may lead to
disqualification by technical inspection after the race.
When using oxygenated fuel, additional gas line antifreeze or water
absorbing additives are not required and should be not used.
When using non-oxygenated fuel, we highly recommend the use of
isopropyl base gas line antifreeze in a proportion of 150 mL (5 U.S.
oz) of gas line antifreeze added to 40 liters (10-1/2 U.S. gal) of gas.
This precaution is in order to reduce the risk of frozen carburetor(s)
which may lead, in certain cases, to high fuel consumption or severe
damage to engine.
IMPORTANT: Use only methyl hydrate free gas line antifreeze.
Recommended Oil
CAUTION: Use only oil that can flow at - 40°C (- 40°F).
Oil must be mixed with fuel in proper ratio in a jerrycan then, be
poured in the fuel tank.
Use only two-stroke engine injection oil, sold by authorized SKI-DOO
dealers.
MODEL OIL TYPE
MX Z X 440 XP-S synthetic 2-stroke oil (1)
P/N293600045(12x1L)
CAUTION: (1) The XP-S synthetic 2-stroke oil is specially formu-
lated and tested for the severe requirements of the 453 engine.
Use of any other brand two-stroke oil may void the limited war-
ranty. Use only XP-S synthetic 2-stroke oil. There is no known
equivalent on the market for the moment. If a high quality equiv-
alent were available, it could be used.
The XP-S synthetic 2-stroke oil provides superior lubrication,
reduced engine component wear and oil deposit, thus maintaining
maximum-level performance and antifriction properties. This syn-
thetic injection oil meets the latest ASTM and JASO standards by
ensuring high biodegradability and low exhaust smoke.
__________________________ 11

CAUTION: Never use four-stroke petroleum or synthetic motor
oil and never mix these with outboard motor oil. Do not use
NMMA TC-W, TC-W2 or TC-W3 outboard two-stroke engine oils
or ashless two-stroke engine oils. Avoid mixing different brands
of API TC oil as resulting chemical reactions may cause severe
engine damage.
WARNING
Wipe off any oil spills. Oil is highly flammable.
12 _________________________

OIL/FUEL 33/1
METRIC (SI)
1 L of oil + 33 L of fuel = 33/1
IMPERIAL
35 imp. oz of oil + 7.2 imp. gal of fuel = 33/1
1 L of oil + 7.2 imp. gal of fuel = 33/1
UNITED STATES
34 U.S. oz of oil + 8.8 U.S. gal of fuel = 33/1
1 L of oil + 8.8 U.S. of fuel = 33/1
__________________________ 13

STARTING PROCEDURE
•Re-check throttle control lever operation.
•Ensure that the emergency cut-out switch is in the ON position.
•Ensure the tether cut-out cap is in position and that the cord is
attached to your clothing.
•To prime, activate button until a pumping resistance is felt. From
this point, pump 2 or 3 times to inject fuel in intake manifold. After
priming, ensure that primer button is pushed back.
NOTE: In very cold temperature, it is recommended to rotate primer
button 3 - 4 turns prior to pull it. This will eliminate the possibility of
sticking.
NOTE: Priming is not necessary when engine is warm.
14 _________________________

FLUID LEVEL
CAUTION: Vehicle must be on a level surface before checking
any fluid levels.
Brake System
Check brake fluid (DOT 4) in reservoir on handlebar for minimum lev-
el. Add recommended fluid (DOT 4) as required. Refer to SPECIFI-
CATIONS for recommended fluid.
CAUTION: Use only (DOT 4) brake fluid from a sealed container.
Never use any other types of fluid.
1
A33D03A
TYPICAL — BRAKE FLUID RESERVOIR
1. Minimum
Coolant Pump Shaft Oil Reservoir
UseXP-Smineralinjectionoil(P/N413802900)(12x1L).
Fill up to mark.
Coolant Reservoir
Use a blend of 50/50 distilled water and ethylene-glycol. That blend
will protect the system from freezing as low as - 37°C(-35°F).
BRP sells premixed 50/50 water/antifreeze can (P/N 413 711 802 —
16 x 1 L).
Fill up to mark when engine is cold.
__________________________ 15

A33C20A
12
1. Coolant pump shaft oil filling mark
2. Coolant cold level mark
16 _________________________

MAINTENANCE
Drive Belt Removal/Installation
Follow the procedure described in 2005 ZX/REV Series Operator’s
Guide except for the following:
CAUTION: Two different drive belt installer/removers are includ-
ed in the tool kit. Use the one piece installer/remover as shown
in following photos.
A03D2PB
WRONG TOOL — DO NOT USE ON MX Z X 440
A33B0SA
PROPER TOOL TO BE USED ON MX Z X 440
__________________________ 17

A33D1AA
PROPER TOOL OPENING DRIVEN PULLEY OF MX Z X 440
18 _________________________