Ski-Doo 1978 Blizzard User manual

"_rIfIII'®
1978
OPERATOR MANUAL
"""-""'ski-doa
snowmobll ••
Suggested retail price $2.50
(first copy fr. with unit purchaeed)
"Trademarks of Bomberchr limited
Utho'd in canada
414347&00

BLIZZARD
This vehicle has been designed for and should be used
on, oval racetrack only.
The performance of this snowmobile significantly ex-
ceeds that
of other snowmobiles you may have oper-
ated. Therefore, use of this vehicle should be restricted
to experienced snowmobile racers.
•WARNING: The design of this snowmobilediffers
considerably from most other snowmobiles. Main-
tenance and adjustment must be performed only by a
knowfedgeable mechanic. Always refer
to operator
manual.
All warranties on 1978 Blizzard Super Stock .either
expressed or implied including any implied warranty of
merchantability and any implied warranty of fitness for
aparticular purpose are hereby excluded and dis-
claimed.
september30th, 1m
BombarderUmited
Valcowt. Quebec. Canada
Recreational
Products
The following aretrademarksof Bombardier limited.
BOMBARDIER ELITE MOTO-SKI
SKI-DOO
EVEREST FUTURA
ALPINE MIRAGE SPIRIT
BLIZZARD NORDIC NUVIK
CARRY BOOSE OLYMPIQUE SONIC
ELAN SKI-BOOSE
RV
T'NT
Text By:
TECHNICAL INFORMATION CENTRE
AFTER SALES SERVICE OEPARTMENT
BOMBARDIER LlMITEO
VALCOURT, QUEBEC, CANADA
All nghts r8SQrvedCBombardier limited 1977
FOREWORD
CONGRATULAnONS
This tough. sleekand fast racing vehicle is the result of
incomparable teamwork between Bombardier design-
ers,engineers, technicians and
top racing drivers. Con-
sequently. this vehicle is designed and engineered with
safety, handling and comfort foremost. Realizing that
this vehicle has been purchased for racing only, this
manual has been prepared to acquaint the owner I
operator with the various vehicle controls and owner-
relatedmaintenance instructions.
This manual emphasizesparticular information denoted
by the wording and symbols:
•WARNING: Identifies an instruction which,
if not
followed, could causepersonal injury.
... CAUTION: Denotes an instruction which, if not
9' follovved, could severely damage vehicle compo-
nents.
ONOTE: Indicates
supplementary information
neededto fully complete an instruction.
All the information, illustrations and component/sys-
temdescriptionscontainedin this manual are correct
at
the time of publication. However, Bombardier limited
reserves the right to make changes in design and spe-
cifications, and /or to make additions to or improve-
ments in its products
without imposing any obligations
upon itself to install them on its products previously
manufactured.
1

SAFETY IN MAINTENANCE
OII •• rve the foIowII .. preceudonc
•Throttle mechanism should be checked for free
movement before starting engine.
• Engineshould be running only when pulley guard is
securedin place.
• Never run engine without drive belt installed. Run-
ning an unloadedengine can prove to be dangerous.
• Never run the engine at high R.P.M. when the track
of the vehicleis raised off the ground.
• It can be dangerous to run engine
with the cab re-
moved.
• Gasoline is flammable and explosive under certain
conditions. Always perform procedures in a well
ventilated area. Do not smoke or allow open flames
or sparksin the vicinity. If gasolinefumes arenoticed
while driving, the cause should be determined and
correctedwithout delay.
• Your snowmobile is not designed to be operated on
public streets,roador highways.
Maintain your vehicle in top mechanical condition at
alltimes.
• Your snowmobile is not designed to be driven or
operatedon black top, bare earth, or other abrasive
surfaces. On such surfaces abnormal and excessive
wearof critical parts isinevitable.
• Only perform such procedures as detailed in this
manual.It is recommended that dealer assistancebe
periodically obtained on other components / sys-
tems not covered in this manual. Unless otherwise
specified,engine should be turned OFF for alilubri-
cationandmaintenanceprocedures.
• Installation of other than
"stock" equipment, in-
cluding ski-spreaders bumpers, pack racks, etc.,
could
severely affect the stability and safety of your
vehicle.Avoid "adding
on" accessoriesthat alter the
basicvehicle configuration.
• Thesnowmobileengine can be stopped by activating
theemergency cut-out or tether switches.
• This
vehicle is not designed nor intended to be used
for otherthan oval racing. Operating it for other use
than competition isillegal.
Please read and understand all other warnings con-
tainedelsewhere inthis manual.
THIS MANUAL SHOULD REMAIN
WITH THE VEHICLE AT THE nME
OFREIALE.
2
INDEX
CONTROLS/INSTRUMENTS
Throttle control lever, brake control lever, emergency
cut-out switch, tether cut-out switch, rewind starter
handle, choke, tachometer, temperature gauge, fuel
gauche,cab removal 3
BREAK"'N PERIOD 4
FUELMIXING
Recommendedgasoline, recommended oil, fuel mixture
ratio, fuel mixing procedure 4
PRE-STARTCHECK
Checkpoints ................................•
STARnNG PROCEDURE Ii
LUBRICAnGN
Frequency, pulley guard removal, drive belt removal,
steeringmechanism, chaincase oil level,hydraulic brake
oil level,rotary valve system, driven pulley I
MAINTENANCE
Spark plug, suspension, track, suspensionadjustment,
track adjustment, drive chain tension, carburetor, drive
belt, drive pulley, steering mechanism. steering adjust-
ment, cooling system, engine head nuts, engine mount
nuts, exhaust system, vehicle general inspection
. 7
TROUBLE SHOOnNG GUIDE 11
STORAGE
Suspension,skis, fuel tank, carburetors, coolingsystem,
drive pulley, chaincase, controls, chassis, general in-
spection . . . . . . . . . . . 17
SPE~FlCAnG~ 1'

CONTROLS / INSTRUMENTS
AJ Throttle ControlLever
BJ Brake ControlLever
CJ Emergency Cut-OutSwitch
OJ Tether Cut-Out Switch
EJ RewindStarterHandle
FJ Tachometer
GJ Temperature Gauge
AI Throttle Control Lev ..
located on right side of handlebar. When compressed,
it controls the engine speed and the engagement of the
transmission. When released, engine speed returns au-
tomatically to idle.
BI Brake Control Lev ..
Mounted on left side of handlebar when applied acti-
vates the hydraulic disc brake system binding the vehi-
cle to a fast smooth stop.
C) Emergency Cut-Out SwItch
Apush button switch located on right sideof handlebar.
To stop the engine in an emergency, pressbutton down
into lowerposition.
Before re-starting engine always depress button into
released upper position. Thedriver 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 situation the source of malfunction
should be determined and corrected before restarting
engine.
D) Teth. Cut-Gut ~ch
A pull switch located on the right side of dash panel.
Attach tether cord to wrist or other convenient location
before starting engine then fully insert tether
cut -out
cap on receptacle.
·0NOTE: The cap must be used at all time in order
to operate the vehicle.
If emergency engine
"shut off" is required, "pull" com-
pletely the cap from switch and engine power will auto-
maticallybe
shut "off" .
•WARNING: If
the switch is used in an emergency
situation the source
of malfunction should be de-
"""'ined and correctedbeforerestartingengine.
ElRewincl .....
Auto rewind type located on the center of vehicle. To
engage mechanism, pull handle.
FlTac:hom8t.
The tachometer registers the impulses of magneto.
Direct-reading dial indicates the number of revolutions
per minute (RPM)
of the engine.
.. C.AUTION:The tachometeris protected by afuse,
• if tachometer stops operating check fuse condi-
tion and if necessary replace. The fuse is 0.1 amp. Do
not use a higher rated fuse as this can cause severe
damage to the tachometer.
G) Tem ............
The gauge.indicates engine coolant temperature, Nor-
mal operating temperature is 00° C(140° A ~ The
coolant temperature can vary depending on driving con-
dition however it should never exceed80° C080°
FL
•WARNING: Do
not remove coolant tank' cap un-
less pressure is released by pulling on
the top
lever, loss of fluid and possible severe bums could
occur.
Choke
The carburetor levers are located on the right side of
each carburetor. To engage choke depress each lever.
To disengagelift levers.
oNOTE: Do not operate vehicle with chokeon.
Fuel Gauge
To check fuel level, simply look through the translucent
tank.
•WARNING: Never use a lite match or open flame
to check fuel level.
C8bRemov"
For those procedures that require cab removal. unlock
side latches then remove cab from vehicle by sliding it
forward.
•WARNING: It is dangerous to run engine
with cab
removed. <
3

BREAK-IN PERIOD
With Bombardier-Rotax engines, abreak-in period of 6
to 10 operating hours is required before running the ve-
hicle at full throttle. During this period, brief full throttle
accelerations and constant speed variation
will contrib-
ute to a good break-in. Continued wide open throttle
accelerations can be detrimental. Never let your engine
overheat.
.. CAUTION: Incorrect or lack of abreak-in period
'9 will resultin enginehorsepowerloss.
FUEL MIXING
Oil must be added to the gasoline in pre-measured
amounts then
both oil and gasoline should be thorough-
ly mixed together before fueling the tank.
Recommended Guo'"
High octane gasoline must be used. Ex.: Aviation gaso-
line
light blue 100octane or light green 100-13:> octane.
... CAUTION: Never experiment with different fuel
.". or fuel· ratios. Never use low lead or non leaded
gasoline, naphtha, methanol
or similarproducts.
ReconwnendedOil
Use a 50 / 1 Blizzard snowmobile oil, this type of oil is
specially formulated to meet lubrication requirements
of
the high performance Bombardier-Rotax engine.
... CAUTION: Use of other than recommended oil
.". can resultin engine damage. .
Fuel Mixture Ratio
The importance of using the correct fuel mixture cannot
be overstressed. An incorrect fuel ratio results in serious
engine damage.
Recommended
fuel/oil ratio is 20/ 1.
Imperial Measures
2cans of 16oz Blizzard oil to 4Imp. gals =20to 1
U.S. Measures
2cans of 12 oz Blizzardoil to 4U.S. gals =20to 1
ONOTE: To facilitate fuel mixing, oil should be kept
at
room temperature. .
Fuel Mixing Procedure
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, either plastic or
metal.
Draw from one until empty then use the second
one.
•WARNING: Gasoline is flammable and explosive
under certain conditions.
Always perform proce-
dures in • well ventilated .... Do not smoke or allow
open flames or sparks in the vicinity. If gasoline fumes
4
are.noticed while driving, the cause should be deter-
mined and corrected without delay. Never add fuel
while engine is running. Avoid ski contact with fuel at
below freezing temperatures.
1. Pour approximately one gallon of gasoline into a
clean container,
2. Add full amountof oil.
3. Replace container gap and shake the container
thoroughly.
4. Add the remainder of the qasoline,
5. Once again thoroughly agitate the container. Then
using a funnel With a fine mesh
SCreen to prevent the
entry of water and foreign particles, transfer
mix-
ture from container into the snowmobile tenk,
O
NOTE: When using pre-mixed fuel, always shake
. the container thoroughly as the oil has a tendency
to settle.
•WARNING: Never -rap
up' gas tank before placing
the vehicle in a warm area. At certain tempera-
tures, gasolinewill expand and overflow.

PRE-START CHECK
CheckPoiints
•Activate the throttle control lever several times to
check that it operates easily and smoothly. The
throttle control lever must return to idle position
when released.
• Check
that the skis and the track are not frozen to
the ground
or snow surface and that steering oper-
ates freely.
•Activate the brake control lever and make sure the
brake fully applies before the brake control lever
touches the handlebar grip.
• Check coolant level.
liquid should be up to the lower
portion at the top return hose. If additional coolant
is necessary, always use a 50/ 50 (50 parts of water
for 50parts of anti-freeze) solution. When entire sys-
tem hasto be refilled, usea solution of 3parts of anti-
freeze
for 2 parts of water. See coling system in
storage procedures.
•WARNING: Before removing
the cap always re-
leasethe pressure by lifting
the lever incorporated
on the cap, loss
of fluid and possibility of severe burns
could occur. .
Pressure release
and locking lever
Coolant
level
• Check fuel level.
• Verify that the path ahead of the vehicle is clear of
bystanders and obstacles.
•WARNING: Only start your snowmobile once all
components are checked and functioning
property.
STARTING PROCEDURE
1. Test operation of throttlecon1ro11ever.
2. Engage choke by depressing each lever. To disen-
gage choke simply
lift the levers. The chokes should
always be used far easier cold engine starts.
After
engine is warm, it is not necessaryto usechokewhen
starting. Do
not operate vehicle with choke on.
3. Make sure that the tether cut-out cap is in position
and thatthe cord isattached to your body.
4. Grasp manual starter handle firmly and pull slowly
until a resistance is felt then pull vigorously. Slowly
releaserewind starter handle.
•WARNING: Do
not apply throttlewhile starting.
5. Check operation of emergency
cut -out switch and
tether switch. Restartengine.
•WARNING:
If the switch is used in an emergency
situation
the source of malfunction should be de-
termined and corrected before restarting engine•
6. Allow the engine to warm before operating at full
throttle.
.. CAUTION: Since engine coolirig is in effect only
... when the vehicle is in motion, it is recommended
that you do not allow the engine to idle for more than
brief periods. Prolonged idling
may cause engine dam-
age.
LUBRICATION
Frequency
As with any mechanical product routine maintenance
isnecessary.
The steering system and suspension must be lubricated
on a weekly basisor more often if the vehicle isoperated
in wet snow.
•WARNING: Only perform such procedures as
detailed in this manual.
It is recommended that
dealer assistance be periodically obtained on other
components/ systems
not covered in this manual.
Unless otherwise specified, engine should be turned
OFF
for all lubrication and maintenanceprocedures.
PulleyGuard Remov"
•WARNING: Engine should be running only when
pulleyguard is securedin place.
5

Remove cab. Pull out locking clips and unlock latches,
slide the pulleyguard sideways.
locking
clips
J)riveBelt Remov"
•
WARNING: Never start or run engine without
drive belt installed. Running an unloaded engine
isdangerous.
1. Remove cab and pulley guard.
2. Open
the driven pulley by twisting and pushinq.the
sliding half.' Holdin fully open position.
3. Slip slackened belt over the top edge of the sliding
half.
4. Slip the belt out from the drive pulley and remove
completely from vehicle. To install drive belt, reverse
procedure.
6
Steering Mechanism
Lubricate all tie rod ends at grease fitting until new
greaseappears at joints. Oil ski leg Icouplerbolts.
Lubricate at the stabilizer bar retaining clamps until
new
greaseappears.
... CAUTION: Do not lubricate throttle and Ior
.... brake cable housings.
Chainca. Oil Level
Remove plug then using a rigid wire as "dipstick",
check oil level. The oil level on the "dipstick" should be
50 mm (2"), replenish as necessary. The chaincase oil
capacity is approximately 255 ml (9 fl oz).
Hydraulic Brake 011 Level
To check fluid level remove reservoir cover located on
handlebar. Fluid must reach
top lip of reservoir. If nec-
essary to replenish use only hydraulic brake fluid
meeting specification J-1703.
... CAUTION: The entry of dirt or foreign particles
.... into the brake fluid may constitute system flush-
ing.
Check brake hose for abrasion and signs
of leakage.
Check brake pad condition, iflessthan:
250model: 4.5
mm ( ~ ") thick
340-440models: 1.6 mm ( Ylt ") thick.
the pads must be replaced.

If the reserve is low and / or air has entered the system
creating asoft, spongy braking action, the following
should be done:
Remove reservoir cover and 'top up' fluid level. Install
cover.
O
NOTE: Retain this reservoir level throughout the
following procedure.
Connect a bleeder drain to the valve and insert end of
bleederhose intoacontainer
of brake fluid.
Repeatedly depress the brake lever in quick succession
(pumping), to obtain pressure. Once obtained, hold
lever, open bleeder valve then quickly depress brake
lever. Close bleeder valve and allow brake lever to re-
turn slowly.
Continue pressing and releasing brake lever until the
fluid injected into the container isair free.
Disconnect bleederhose, recheck brake fluid.
O
NOTE: Brake fluid should be changed at leastonce
every snowmobilingseason.
Rm-y V.lve Sy_em
Check reservoir oillevet frequently. Level should not be
below level line of plastic reservoir. If necessary reple-
nish to oil level line using "Castrol Injector
Oil" or
equivalent.
~l
. level
DrIv .. Pulley
Remove the bolt locking the driven pulley to its shaft
and pull
off the driven pulley ass'v. Lubricate the shaft
using antiseize compound. Install pulley on shaft and
torque the
bolt to 0.5-1 kg-m (4-5 ft-lbsl,
MAINTENANCE
The following Maintenance Chart indicates regular ser-
vicing schedules to be performed by you or your ser-
vicing dealer. .
•.WARNING: Only perform such procedures as
detailed in this manual. It is recommended that
de8ler assistance be periodically obtained on other
components / systems not covered in this manual. Un-
leesotherwise specified, engine should be tumed OFF
for all lubrication and maintenanceprocedures.
Code
Weekly Page
Wl
Spark plugs 8
W2 Suspension condition 8
W3
Track condition 8
W4
Suspension 8
W5 Track adjustment 10
W6 Drive chain tension
11
W7 Carburetoradjustment 11
W8 Drive belt 11
W9
Drive pulley
11
W10 Drive belt tension 12
Code Monthly
Page
Ml Steering mechanism 13
M2 Steering adjustment 13
M3 Cooling system 14
M4 Engine head nuts 14
M5 Engine
mount nuts 14
M6 Exhaust system 14
M7 Vehicle general inspection 14
7

W1 Spark pIuga
Disconnect spark plug wires and remove spark plugs.
Checkcondition
of plugs.
• A brownish tip reflects ideal condition (correct car-
buretoradjustment, spark plug heat range,etc.I.
• A black insulator tip indicates fouling caused by: car-
buretor idle speed mixture and / or high speed mix-
ture
too rich, incorrect fuel mixing ratio, wrong type
of spark plug (heat range), or excessiveidling.
• A light grey insulator tip 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 sealor gasket.
ONOTE: This adjustment must
be performed with
the cab removed.
- Ensure that the front suspension is totally extended.
- With the angle finder and a straight edge (laid flat on
the ski feg
top portion) adjust the camber asrecom-
mended.
W3Track Condition
102.7 em (40~ It)
ski stance
Camber LH. 0°
Camber R.H. 5° negative
ONOTE: The camber is the tilting
of the ski leg /
ski from the vertical. To obtain anegative camber
the ski leg / ski must be tilt inward, so that the ski legs
are closer together at the
top then at the bottom. The
amount of tilt is measured in degrees from the vertical.
The measurement is called camber angle.
To adjust the camber:
Loosen the lock nuts of the upper and lower front arms.
Turn the arms manually until recommended camber
angle is reached. Firmly retighten lock nuts.
ONOTE: Always ensure to maintain the ski stanceof
102.8 cm (40%") while performing this adjust-
ment.
Fouled
(black)
Overheated
(light grey)
W2 Suspension Condition
... CAUTION: If spark plug condition is not ideal,
..". contact your dealer.
Check spark plug gap using a wire feeler gauge. Gap
must
be 0.40 mm L016"). Reinstall plugs and connect
wires. Correct spark plugs are Bosch W 340 S2S or
equivalent.
Visually inspect suspension springs. Replace any weak
or broken spring. Inspect shoe condition of slide sus-
pension and replace as necessary.
lift rear of the vehicle and support it off the ground so
that the track is free to turn. Rotate track by hand and
visually inspect the condition, pay attention to cross
links and rivets. Immediately replace cracked cross
links and loose or / and missing rivets.
•WARNING: Do not operate a snowmobile
with a
cut, torn or damaged track.
W4 Suspension Adjustment
FrontSuapension
Proceedas follows to adjust:
- Placethe vehicle on an horizontal surface.
- Lift the front of the vehicle (using
two wooden
blocks (approx.
6") installed under the bottom plate)
in order to obtain a gap of one inch under each ski
when the front suspension is totally extended.
8

Using two (2) screwdrivers, remove the shock spring
collar, the spring, and the stopper.
Fully collapse the damper rod, ensure to align the top
collar mark
with the identification mark on the shock
body.
Top collar
mark
Stabilizer bar 3
adjusting positions
Front - light
Center -- medium
Rear hard
lower the vehicle at the floor and work the suspension
up and down so that all the suspension components
have a chance to move.
- It is recommended, to recheck the procedure, start-
ing at no. 2through4, stages.
- Recheck all bolts and locking nuts and ensure that
the ski stance remains at 102.8 cm
(40%") from
center to center
of skis.
- The stabilizer bar has three (3) interchangeable
attachment positions to suit the drivers preference,
however, it is also important that the stabilizer tie
rods be adjusted to a minimum height
of 8.2 cm
(3%") from center to center of each balljoint.
Adjust stabilizer
bar retaining
tie rods height to
8.2 em l3% ")
center to center
of the ball joints
Ski shock absorbers are adjustable to suit a driver's
particular preference. This adjustment includes, a
damping action adjustment as well as spring pre-
loading adjustment.
Damping Action Adjustment
The damping action has three possible variations,
regular, firm or extrafirm.
Remove the shock absorber from the vehicle and in-
stall the lower retaining eye in avise. Unscrew the upper
aluminium stopper retaining screw and lower the
stopper on the shaft.
Body
identification
Ta locate the existing adjustment, turn the damper rod
collar mark slowly, over the body identification marks
until engagement can be felt then turn in required di-
rection to attain desiredposition.
Preloading
- To adjust the spring preload, the cam collar can be
turned clockwise to increase, counter-clockwise to
decrease. A high spring preload will increase the ve-
hicle carrying capacity.
9

19mm(%")
-Adjust the front limiter until the front portion of the
track (at the rear
of the idler bracket) comes in con-
tact
with the ground.
25mm (1". gap
under skis
- Placethe vehicle on an horizontal surface.
Raise
the front of the vehicle (using two wooden
blocks installed under the
bottom plate) in order to
obtain a gap of one inch under each ski when the
front suspension istotally extended.
WI Track AcIjusb .. ent
Raisethe rear of vehicle and support with a mechanical
stand.
Allow slide to extend normally. A gap of 19 mm
(~") should exist between slider shoe and cross links.
If the track tension is too loose, the track will have a
tendency to thump.
•WARNING:
Too much tension will result in power
loss and excessive stresses on cross links and
suspension components.
If necessary to adjust simply loosen or tighten adjuster
bolts.
Reararm
c:=:t------- position -
/
Rear Arm Adjustment
Depending on the driver height and / or normal sitting
position, the suspension can be adjusted in order that
the driver can transfer his weight as desired toward the
front or the rear
of the vehicle. With the driver sitting on
the vehicle (normal driving position) place the rear arm
to the proper position to obtain the desired
"pivot
effect".
Short rider: Front position
Tall rider: Rearposition
Adjust the spring tension in such a way that when the
driver sits on the vehicle the rear end of the vehicle does
not lovvermore than 13 mm (Yz")'
................
Suspension Adjustment Driver's Weight
Front Umit. Adjustment O
NOTE: Track tension and alignment are inter-
related. Do not adjust one without the other.
Start the engine and accelerate slightly so that track
turns slowly. Check that track is well centered and turns
evenly. To correct, stop engine then tighten the adjuster
bolton side where track isclosest to the frame. Recheck
alignment.
•WARNING: Before checking track alignment,
en·
sure that the track is free of all particles which
could be thrown out whiletrack is rotating. Keep hands,
tools, feet and clothing clear of track. Ensure ~one is
standing in close proximity to the vehicle.
10

6-8mm
(% "- III.")
Throttle slide
adjustment
Aepleaceable
ramps
WI Drive Pulley
•
WARNING: The d..wepulley maintenanceand / or
calibration should
be performed only by a profes-
sional mechanic
who is familiar with this type of drive
pulley.
Thedrive pulley is
of the replaceable ramp type. Depen-
ding on the terraincondition, driver'sweight and engine
torque, the calibration
of the drive pulley can be slightly
compensated.
WI Drive Belt
Inspect belt for cracks, fraying or abnormal wear (un-
even wear, wear on one side, etcJ. If abnormal wear is
noted, probable cause is pulley misalignment. Contact
your dealer.Checkdrive belt width. The drive belt width
should not be less than 31.7 mm (1
y.. ") wide. Atoo
narrow belt will resultin a loss of performance.
ONOTE: When installing a new drive belt, a break-in
period of 15-25 km (10-15 miles) is strongly re-
commended.
The clutch calibration kit supplied with the vehicle per-
mits different calibration.
C)Idle ....... Ad ........ i8IIt
Turn idle speed screw clockwise until it contacts the
throttle slide then continue turning
two (2) additional
turns. This will provide a preliminary idle speedsetting.
Start engine and allow it to warm then adjust idle speed
to
2500-3CXX> RPM by turning idle speed screw clock-
wise or counter-elockwise.
... CAUTION: Do not attempt to set the idle speed by
" using the air screw. Severe engine damage can
occur.
W7CarbwetorAdjustment
Thecarburetor adjustmentsare: Air Screw Adjustment,
Throttle Slide Adjustment and Idle Speed Adjustment.
... CAUTION: Do not overtighten the chain sprocket
". adjustment screw.
WI DriveCIuIinT .... n
The tension is correct when there is a deflection of 6-8
mm (y.. "- ~.") towards the exterior. Tension isadjusted
by slightly tightening the tensioner sprocket against
the chain and by locking it in position.
AI AIr SCre. Adlwblilent
Completely close the air screw (until a slight seating
resistance is felt), then back
off screw to specification.
•• ThIO •• "Ad)uIItment
Completely open (counter-clockwise) the idle speed
screw, unlock cable adjuster lock nut then adjust the
throttle cable to remove all slack when operating
throttle control lever. Lock cable adjuster in position
by tightening the adjusterlock nut.
When recalibrating the vehicle should be running at the
constant specified R.P.M.; 250 model: 9700 to 9900
R.P.M.
340-440 model: 9EKX) to 10.000R.P.M. Under no
circumstance should it be loaded or have hesitation.
poor acceleration,etc.
11

If excessive free-play is noticed replace the roller. The
flyweight assemblies should not have any excessive
horizontal play. If excessive play is noticed replace the
hub / shouldered pin bushings.
Using shims. adjust the driven pulley in order to have a
free-playof 1.6mm ( Yl.") on eachside.
Deflection
32mm (1% ")
Adjusting
screws
A ....... ent
Unlock the locking nuts and equally tighten or slacken
the adjusting screws in order to obtain the recom-
mended belt deflection.
... CAUTION: Ensure that the pulley width between
Yeach halves is the same all around then tighten
the locking
nut securely.
To obtain the proper belt deflection the driven pulley is
equiped with three adjusting screws which increasesor
decreasesthe distance between pulley halves while at
the sametime attainingexact belt tension.
A Vertical
play
BHorizontal
play
t
Distance
between pulleys A
Afree floating 1.6mm I YII")
W10 DriveBeltTension
Dimension Yand X (offset); 33-35mm (1 SA. "-1 % "l,
~ CAUTION: Dimension "X" must never exceed
.." dimension "V", Dimension "Y" can exceed di-
mension
"X" by 1.6mm ( YUI "l,
The distance between pulleys should be 35 mm (1 0/.''),
however, maximum vehicle performance is obtained
when the drive belt deflects by 32 mm
(1 %") when a
pressureof 6.8 kg (15Ibs) is applied on the drive belt.
12
TOIq" Speca.
51._" bolts retaining ramps on cup 2-2.5 kg-m (15-19
ft-jbs).
%" bolts retaining ramps on cup 1-1.4 kg-m (8-10
tt-losl.
Shouldered pin lock nuts 1.2-1.5kg-m (9-11 ft-Ibs).
Drivepulley retaining bolt8-9.4kg-m
(58-68 ft-lbsL
•WARNING: Loctite
00. 242 (medium strength) or
equivalent must be applied on the threads of each
bolt and nut before installation and where applicable,
the tab locks must be bent against the bolt heads. Tab
locks should neverbe usedmore than twice. .
...........
The drive pulley rollers are made of an internal teflon
sleeve(bonded) and a steel roller. The roller assemblies
should not have any excessive vertical play on the re-
taining pins.

ONOTE: The ski attachment position in inter-
changeable.
Steering
arm
o
Steering arm
"
.
Steering
transfer shaft
Tie rod
20° angle __ ....
Steering
shaft
•WARNING: Always ensurethatthe steering trans-
fer shaft ball jointattachment brackets arevertical
when the skisarepointed forward, and that
the steering
arm is positioned
at a 20° angle with the attachement
brackets.
'.... ..----Toe out of %" to Y:! .. ----.-.""""
To adjust:
loosen the lock nuts of each tie rod. Equally turn the tie
rods manually until skis are properly aligned. Firmly
retighten lock nuts.
•WARNING: The ball joint socket must run parallel
with the steering arm. The socket must be re-
strained when tightening the tie rod end lock nuts. The
handlebar should form a 90° angle
with the skis, when
the skisarepointed forward.
To adjust:
Ensure that the steering transfer shaft ball joint attach-
ment brackets are vertical and that the skis are pointed
directly forward.
• 2 St_ring Adjuatment
Skis should have a toe out of 9.5mm ( o/i ") minimumto
12.7 mm (Y:z") maximum. To check, measure distance
between skis at front and rearof outside edge.
·1 Steering Mech8nism
Inspect steering mechanism for tightness of compo-
nents (steering arms, tie rods, ball joints, spring coupler
bolts, ete.). If necessary, replace or retighten. Check
condition
of skis and ski runners. Replaceif worn .
To adjust:
loosen the lock nuts of the tie rod. (located at front of
track tunnel), Turn tie rod manually until the handlebar
forms a 90° angle
with the skis. Firmly retighten lock
nuts.
13

M3 Cooling System
By lifting the radiator cap lever check that the cap
pressurizesthe system. If
not install a new 141bpressure
radiator cap.
Using an hydrometer check that the anti-freeze solution
is strong enough for the temperature in which the vehi-
cle is operated.
If coolant temperature is above recommended temper-
ature 00° C (140° F) 80° C (180° F) check that the
radiator is not obstructed
with grim or foreign material.
M4 Engine Head Nuts
After the first 5 hours of operation, check that engine
head nuts are tight and equally torqued to 1.5-1.8 kq-rn
(11-13ft-lbsl when cold.
M& Engine Mount Nuts
Check engine mount nuts for tightness. Retighten if
necessary.
M8 Exhaust System
The engine / exhaust system parts are vital toward
efficient muffler function. Check all attachments. Re-
place springs and / or tighten ifnecessary.
... CAUTION: Do not operate vehicle with muffler
.". disconnected otherwise serious engine damage
will occur.
M7 Vehicle General Inspection
Check electrical wiring and components, retighten loose
connections. Check for stripped wires or damaged insu-
lation. Thoroughly inspect the vehicle and tighten loose
bolts, nuts and linkage. Inspect skis and ski runners for
wear.
14

TROUBLE SHOOTING
SYMPTOMS
POSSIBLE CAUSES
WHAT TO DO
Engineturnsover but fails 1. No fuel to the engine Check the tank level and fill up
with correct
to start or starts
with
gas-oil mixture. Check for possible clogging or
difficulty fuel, item 5.
2. Spark plug Check for fouled or defective spark plug. Dis-
connect spark plug wire, unscrew plug and re-
move from cylinder head. Reconnect wire and
ground exposed plug on engine, being careful
to hold away from spark plug hole.
Followen-
gine starting procedure and check for spark. If
no sparks appear, replace spark plug.
3. Faulty ignition Check for fouled or defective spark plug. Dis-
connect spark plug wire, unscrew plug and re-
move from cylinder head. Reconnect wire and
ground exposed plug on engine, being careful
to hold away from spark plug hole.
Followen-
gine starting procedure and check for spark. If
no sparks appear, replace spark plug.
4. Aooded engine Remove
wet spark plugs, turn ignition to OFF
and crank engine several times. Install clean dry
spark plugs. Start engine following usual start-
ing procedure. If engine continues to flood, see
your dealer.
5. Clogged fuel line (water or dirt) Remove and clean the fuel filter. Change filter
cartridge if necessary. Check condition and
connections
of fuel lines. Check the cleanliness
of fuel tank.
6. Faulty carburetor First make primary adjustments on carburetor
(See Maintenance Section). If carburetor is still
faulty, contact your dealer for repair.
7. Too much oil in fuel Drain the fuel tank and refill with the correct
gas / oil mixture.
8. Enginetiming Engine timing may be defective or out of ad-
justment. Contact your dealer.
9. Poor engine compression Running
with a lean fuel mixture may produce
excessive engine wear resulting in poor engine
compression. If this occurs, contact your dealer
at once.
Enginewill not turn 1. Seized engine In the caseof seizedengine contact your dealer.
manually Seizure is adirect result of poor lubrication. Use
of incorrect gas / oil ratio may be the cause.
15

SYMPTOMS POSSIBLECAUSES WHAT TO DO
Enginelacks acceleration 1. Fouled or defectivespark plug Check item 2 of "Engine turns over
but fails to
or power
start or starts with difficulty".
2. Clogged fuel line (wateror dirt) Check fuel line condition. (See item 5
of "En-
gine turns over but fails to start or starts with
difficulty" J
3. Carburetor Readjust the carburetors. (See Maintenance
Section). If trouble persists, contact your deal-
er.
4. Faulty ignition First check item 2 anbd 3of "Engine turns over
but fails to start or starts with
difficulty". If the
ignition system still seems faulty, contact your
dealer.
5. Engine If unable to locate specific symptoms, contact
your dealer.
Enginecontinually 1. Faulty spark plug Check item 2
of "Engine turns over but fails to
backfires start or starts
with difficulty".
2. Overheated Carburetors set too lean. Contact your dealer.
Coolant level to
low (leaking hose or gasket,
restricted hose). Engine coolant pump inopera-
tive. Air in cooling system.
3. Enginetimingincorrectlyset Contact your dealer.
Snowmobilecannot 1. Drive belt Check for damaged or worn drive belt. Replace
reach fullspeed ifnecessary.
2. Incorrecttrack adjustment Check track tension and alignment. Readjust to
specifications. (See Maintenance section).
3. Faulty engine Check item 1
to 5"Engine lacks acceleration or
power".
4. Pulleymisaligned Contact your dealer.
16

STORAGE
IMPORTANT: It is during summer, or when a vehicle is
not in use for any length of time that proper storage is a
necessity. Storage of the snowmobile during long pe-
riods of inactivity consists
of checking and replacing
missing broken or
YlIOrn parts; proper lubrication and
treatments to insure that parts do
not become rusted;
cleaning items such ascarburetor
of oil mixtures, to pre-
vent gum varnish formation within the carburetor; and
in general, preparing the vehicle so that when the time
comesto usethe snowmobile again it will start and be in
top condition.
•WARNING: Only perform such procedures as de-
tailed in this manual. It is recommended that
dealer assistance be periodically obtained on other
components / systems
not covered in this manual.
Unless otherwise specified, engine should be turned
OFFfor all lubrication and maintenance procedures.
Track
Inspect track for cuts, loose or broken cross links and
rivets. Make any necessary replacement. Lift rear of
vehicle until track is clear of ground then support with
brace or trestle. The snowmobile should be stored in
such a way that track does not stay in contact with
cement floor or bareground.
ONOTE: The track should be rotated periodically,
(every40days).Do not
release track tension.l
Suspension
Removeany grime or rust. Check slider shoe condition.
Replace asnecessary.
Skis
Wash or brush all grime or rust accumulation from skis
and springs.
Grease ski legs at grease fittings. Check
condition of skis and ski runners. Replace if worn or
weak.
FuelT.nk
Removecapthen using a syphon, remove gasoline from
tank.
•WARNING: Gasoline is flammable and explosive
under certain conditions. Always perform proce-
dures in a well ventilated area. Do not smoke or allow
open flamesor sparksin the vicinity.
Carburetors
The carburetors must be dried out completely to pre-
vent gum formation during the storage period.
Assure that inlet line is disconnected. Remove drain
plug
of the float chamber of each carburetor. Drain
carburetors.
Reinstallplug and connect fuel line.
C¥UnderLubrieation
Engine internal parts must be lubricated to protect cyl-
inder walls from possible rust formation during the
storage period.
ONOTE:This operation should be repeatedevery 40
daysduring storage.
Remove spark plugs. Operate rewind starter to bring
piston at top position. Pour the equivalent of one
spoonful of oil into spark plug hole.
Slowly crank engine severaltimes using manual starter.
Repeat above steps for other cylinder. Install spark
plugs.
~ CAUTION: To prevent ignition system damage,
'9 make sure that the cut-out button is in the lower
position.
17

Gen_alln.pection
Check electrical wiring and components, retighten loose
connections. Check for stripped wires or damaged
insulation.
Thoroughly inspect the vehicle and tighten loose bolts.
nuts and linkage.
ONOTE: Leave drive belt
off pulleys for the entire
. storage period.
Ch .....
Clean the vehicle thoroughly, removing all dirt and
greaseaccumulation.
... CAUTION: Plastic alloy components such as fuel
.. tank, etc., can be cleaned using mild detergentsor
isopropyl alcohol. Do
not use strong soaps, degreasing
solvents, abrasive cleaners. paint thinners, etc.
Inspect cab and repair damage. Repair kits are available
at your authorized dealer. Clean frame (Use only
"Alu-
minum cleaner" and follow instructions on container>.
Touch up metal spots where paint has been scratched
off. Spray all bare metal parts of vehicle
with metal
protector. Wax the cab for better protection.
ONOTE: Apply wax on glossy finish
of cab only.
Protect the vehicle with a cover to prevent dust
accumulation during storage.
... CAUTION: If for some reason the snowmobile has
.. to be stored outside it is necessary to cover it with
an opaque tarpaulin. This caution will prevent the sun
rays affecting the plastic components and the vehicle
finish.
Lubricate steering mechanism. Inspect components for
tightness, (spring coupler bolts, steering arm locking
bolts, tie rods. ball joints. etc.). Tighten if necessary.
•WARNING: Do
not lubricatethrottlehousing.
Coat electrical connections and switches
with a grease-
less metal protector. If unavailable. use petroleum jelly.
Contro"
Drain the chaincase completely and refill to proper level
using fresh chaincase oil. To drain, remove chaincase
cover.
Chalncue
Drive Pulley
Inspection and cleaning should be performed by the
dealerat the end of each season.
----------=--_/
Coolant
level
Remove the radiator cap from the tank. Once the sys-
tem has been drained, unblock the elbow.
ONOTE: To completely drain the system the elbow
has to be blocked, otherwise no syphoning effect
will be produced and a certain quantity of liquid will
remain in the system.
... CAUTION: To prevent rust formation in the cool-
.. ing system, always replenish the system with the
recommended solution. (60% antifreeze40% water).
Torettl the cooling.,.....
Closethe radiator drain valve, position the disconnected
end
of the by-pass hose higher than the engine head,
then pour in the liquid until it reaches the elbow fitting
on the engine head. Reconnect the hose. Continue to
slowly pour the liquid in the tank until the coolant level
reachesthe lower portion
of the upper return hose.
Coollint 8y8t ...
Drain the cooling system by disconnecting the by-pass
hose from the engine head elbow, then block off the
elbow and open the radiator drain valve. (Located on
the lower portion
of the radiator) then lower the by-
passhose to drain engine.
18