Ski-Doo EXPEDITION V-1000 User manual

Date: August 25, 2005 Subject: Skandic/Expedition No. 2006-1
YEAR MODEL PACKAGE MODEL NUMBER SERIAL NUMBER
2006 EXPEDITION V-1000 TUV FA6A, FA6B All
2006 EXPEDITION 600 HO SDI TUV FB6A, FB6B All
2006 SKANDIC 440 (E) Fan LT FH6B All
2006 SKANDIC 550 (E) Fan SUV FD6B, FD6D All
2006 SKANDIC 550 (E) Fan SWT FE6B All
2006 SKANDIC 550 (E) Fan WT FG6B All
2006 SKANDIC 600 (E) SUV FC6B, FC6D All
2006 SKANDIC 600 (E) WT FF6B All
TABLE OF CONTENTS
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2
IMPORTANT NOTICE .......................... 2
UNCRATING..................................... 3
Procedure .......................................... 3
SET-UP............................................ 4
Battery Preparation................................ 4
Battery Removal................................... 4
Battery Installation ................................ 5
Rear Suspension Rear Shock.................... 5
Front Suspension Shocks ........................ 6
Skis.................................................. 7
Instrument Panel .................................. 8
Handlebar........................................... 9
Steering Pad ....................................... 9
Holding Strap.......................................10
Windshield .........................................11
Aluminum Foil Heat Shield.......................13
Seat Belt............................................13
Backrest ............................................14
Drive Belt...........................................14
Air Intake Silencer.................................15
Snow Guard........................................16
FINAL PREPARATION..........................16
MPI (Connecting)..................................16
B.U.D.S. (Customer Name) ......................17
B.U.D.S. (Programing a DESS Key) .............18
Engine Oil Level ...................................18
Recommended Oil ................................18
Break-in Period.....................................19
Oil Injection Pump Bleeding .....................19
Brake Fluid Level ..................................20
Coolant Reservoir Level ..........................20
Track Adjustments ................................20
Brake Disk..........................................20
Driven Pulley.......................................20
DELIVERY TO CUSTOMER...................20
Predelivery Check List............................20
Speedometer ......................................21
Rear Suspension Adjustments ..................21
SPECIFICATIONS ...............................22
Printed in Canada. (mbl2006-002 AP) 1/24
©2005 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.
®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.
* Trademark of Bombardier Inc. used under license.

IMPORTANT NOTICE
IMPORTANT NOTICE
This bulletin must be used in conjunction with the check list enclosed in the bag with the OPERATOR’S
GUIDE. Make sure that PREDELIVERY CHECK LIST is completed and signed.
WARNING
To obtain limited warranty coverage, predelivery procedures must be performed by an authorized
Ski-Doo®snowmobile dealer/distributor. Apply all necessary torques as indicated.
N
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:The information and components/system descriptions contained in this document are correct
at the time of publication. Bombardier Recreational Products Inc. (BRP) however, maintains a policy
of continuous improvement of its products without imposing upon itself any obligation to install
them on products previously manufactured. Due to late changes, there might be some differences
between the manufactured product and the descriptions and/or specifications in this document. BRP
reserves the right at any time to discontinue or change specifications, designs, features, models
or equipment without incurring obligation. The illustrations in this document show the typical
construction of the different assemblies and may not reproduce the full detail or exact shape of
the parts. However, they represent parts that have the same or similar function.
The content of this bulletin is designed as a guideline only. All mechanics performing predelivery
procedures should have attended the current model year service training. Further information
or inquiries should be directed to your distributor service representative and/or specific SHOP
MANUAL sections. Please complete the PREDELIVERY CHECK LIST for each snowmobile and
retain a customer signed copy. Make sure the customer receives the OPERATOR’S GUIDE,
PREDELIVERY CHECK LIST signed copy and SAFETY VIDEOCASSETTE.
There is a tag attached to the ignition key, only the customer must remove it. This label
will remind the customer to ask dealer/distributor to perform suspension adjustments
according to riding style and vehicle load.
2 / 24 2006-1 Predelivery

UNCRATING
UNCRATING
Procedure
3
2
1
A00A2F6
Carefully lay the crate on its bottom.
CAUTION: Allowing the crate to drop may
cause serious damage to the vehicle.
Using a drill or a screwdriver, remove all screws
[
[[
[1]
]]
] retaining crate cover to crate base.
Tilt [
[[
[3]
]]
] the crate cover toward the front
or the rear of the vehicle.
N
NN
NO
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::
:There is a notch at the front of the crate
that indicates the front of the vehicle [
[[
[2]
]]
].
Lift the crate cover slowly to avoid
damaging the vehicle.
Remove the predelivery kit and parts to be
installed from part box or from under the seat
compartment according to the model.
Detach skis from crate base.
Discard screws and washers.
Remove polyethylene foam protective sheets.
If applicable, detach windshield from seat.
CAUTION: Make sure vehicle is properly
supported before removing ski legs and rear
suspension from crate brackets.
Detach the ski legs from the crate base.
Discard screws.
A29G12A
Model(s): TUV and SUV
Model(s): All Models except TUV and SUV
A29F166
Remove the rear retaining strap.
Predelivery 2006-1 3 / 24

UNCRATING
A06F2Q6
Cut locking tie retaining hook.
Lay on seat and ask another person to apply
pressure onto rear bumper.
Remove hook from suspension.
WARNING
Before removing hook always verify that
vehicle is properly supported and that
parking brake is applied.
WARNING
Hook must be removed to have snowmobile
suspension operational.
Remove the vehicle from the crate base.
SET-UP
Battery Preparation
Model(s): All except LT
All electric starting equipped vehicles using a
YTX20L-BS or YTX24L-BS type battery require
a specific charging procedure at predelivery.
Follow the appropriate procedure as
described below.
WARNING
Always wear safety glasses and charge in
a ventilated area. Never charge or boost
battery while installed on vehicle. Do not
open the sealed caps during charging. Do
not place battery near open flame.
CAUTION: If battery becomes hot, stop charging
and allow it to cool before continuing.
N
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::
:Sealed VRLA batteries have an internal
safety valve. If battery pressure increases due to
overcharging, the valve opens to release excess
pressure, preventing battery damage.
An automatic charger is the fastest and most
convenient way for error-proof charging.
N
NN
NO
OO
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::
:If battery cannot be recharged using the
following charging chart, replace battery.
Battery Voltage below 12.8 V
STANDARD CHARGING
(recommended)
BATTERY TYPE TIME CHARGE
YTX20L-BS 4–9 hours
YTX24HL-BS 5–10 hours 2A
QUICK CHARGING
BATTERY TYPE TIME CHARGE
YTX20L-BS 50 minutes
YTX24HL-BS 1 hour 10 A
Model(s): LT Only
During preparation, the battery can be
activated as described in last year appropriate
SKI-DOO SHOP MANUAL.
CAUTION: Prior to charging the battery,
always remove it from the vehicle to
prevent electrolyte spillage.
Battery Removal
A29E136
1
2
Model(s): TUV
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::
:Battery is located under the seat.
Unhook battery cover strap [
[[
[1]
]]
] from its support.
Open battery cover [
[[
[2]
]]
].
Remove battery.
4 / 24 2006-1 Predelivery

SET-UP
Model(s): All Models except TUV
Remove air silencer.
Unhook the battery strap or undo steel strips
nut and screw holding battery.
Remove the battery.
Battery Installation
Properly position the battery on its rack.
WARNING
Always connect the battery cables exactly in
the specified order. Connect RED ( + ) cable
first, then BLACK ( –) ground cable.
Connect RED ( + ) cable to battery positive post.
Apply silicone dielectric grease (P/N 293 550 004)
on battery positive connection.
Cover the RED ( + ) connection with rubber boot.
Connect BLACK ( –) cable to battery negative post.
Apply silicone dielectric grease (P/N 293 550 004)
on battery negative connection.
N
NN
NO
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::
:Place the BLACK ( –) cable under
the battery strap.
Close battery cover (if applicable)
Secure battery with steel strips or rubber strap.
Reinstall previously removed parts if applicable.
Rear Suspension Rear Shock
1
2
A29F126
Model(s): TUV and SUV Only
Lift up rear side of snowmobile.
Install shock absorber bearing bushings
in place [
[[
[1]
]]
].
Install shock absorber in place (with
protector upward and adjustments handle
towards the rear) [
[[
[2]
]]
].
Secure shock to upper arm using:
–one hexagonal bolt M10 x 50
–one nut M10.
Secure shock to rear arm using:
–two hexagonal bolts M10 x 40
–two lock washers
–two shims
–two circlips
–one rear shock shaft.
Torque to 45 N•m(33 lbf•ft).
1
Model(s): SWT/WT Only
Secure front arm upper axle of rear suspension
usingtwoM10x30screws[
[[
[1]
]]
] in plastic
bag under the seat.
Apply Loctite 243 (blue) (P/N 293 800 060)
on threads.
N
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NO
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::
:Use a tie-down between the front
arm and spring axle to ease the installation
of the front arm screws.
Torque screws to 58 N•m(43 lbf•ft).
Predelivery 2006-1 5 / 24

SET-UP
Secure rear arm using previously removed screws.
Apply Loctite 243 (blue) (P/N 293 800 060)
on threads.
Torque screws to 58 N•m(43 lbf•ft).
Model(s): WT Only
N
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::
:For single driving condition use upper
hole and for two person driving condition or
load in rack, use lower hole.
Apply Loctite 243 (blue) (P/N 293 800 060)
on threads.
Torque screws to 58 N•m(43 lbf•ft).
Model(s): All except TUV and SUV
N
NN
NO
OO
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E:
::
:Also in shrink pack are 4 horse shoe type
washers that are used to adjust rear suspension
for trail riding according to load (refer to the
appropriate SHOP MANUAL for proper procedure);
they are to be put in the tool box for further use.
Front Suspension Shocks
A29F176
1
23
23
Model(s): TUV and SUV Only
Lift front of vehicle and block safely.
Remove and discard shipping brackets
from suspension.
Discard spring clips, keep screws.
Remove air intake silencer.
Install shock absorbers to suspension with
their adjusting ring at bottom.
Secure with hexagonal bolts and nuts
provided in predelivery kit.
1
Model(s): WT/SWT Only
Remove long bolts [
[[
[1]
]]
] that compress front
suspension on both sides.
1
Install 2 plastic bushings [
[[
[1]
]]
]intoshock
absorber eyelets.
Stretch shock to its maximum.
Slide shock absorber into bottom of ski leg
until shock rod goes through cap hole.
Loosely install conical spring washer, concave
surface inside, and M10 nut on shock rods,
keeping at least 1/4 in (5 mm) of free play.
Install stop bounding on ski with its highest
portion toward front.
6 / 24 2006-1 Predelivery

SET-UP
Install skis on snowmobile using bolts,
nuts, washers and rubber bushings supplied
in the predelivery kit.
Skis
A29F186
4
56
1
3
2
7
7
Model(s): TUV and SUV Only
N
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::
:Ensure the ski leg bushing [
[[
[5]
]]
]is
still on the ski leg [
[[
[6]
]]
].
Insert the ski stopper [
[[
[1]
]]
] from the predelivery
kit with the higher side toward the front
[
[[
[3]
]]
] into the ski.
Install the ski [
[[
[7]
]]
] to ski leg [
[[
[6]
]]
].
Secure the ski to ski leg with:
–the existing M10 hexagonal bolt [
[[
[2]
]]
].
N
NN
NO
OO
OT
TT
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E:
::
:Make sure that the hexagonal bolt head
is toward the outside of the vehicle.
–M10 elastic flanged nut [
[[
[4]
]]
] from the
predelivery kit.
Torque to 45 N•m(33 lbf•ft).
N
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NO
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::
:Repeat the same procedure on
the opposite ski.
Put the vehicle back on the ground.
1
A29G1GA
Model(s): All except TUV and SUV
Install stop bounding [
[[
[1]
]]
] on skis with its
highest portion toward front.
On some models, a support plate should
be installed as per photo.
Install a washer on both side of ski leg.
3
4
6
1
4
2
5
3
Install skis on vehicle using the following
parts from the predelivery kit:
–[
[[
[1]
]]
] stop bounding (already installed)
–[
[[
[2]
]]
]sleeve
–[
[[
[3]
]]
] rubber bushings
–[
[[
[4]
]]
] conical spring washers (concave surface
inside) (SWT only)
–[
[[
[5]
]]
]bolts
–[
[[
[6]
]]
]nuts.
Predelivery 2006-1 7 / 24

SET-UP
1
A29G1D6
N
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::
:[
[[
[1]
]]
] Front of the vehicle.
Torque ski leg nuts to 45 N•m(33 lbf•ft).
Torque shock rod top nuts to
30 N•m(22 lbf•ft).
Instrument Panel
Model(s): Expedition 600 HO SDI
mbl2006-002-100
Take the instrument panel out from front
compartment (under hood). Remove
protective plastic.
Remove both screws on the top of hood and
both screws on lower corner of instrument
panel. Keep them for installation.
mbl2006-002-101
Open hood and remove the inner cover.
mbl2006-002-102
Using 2 kept screws, install the lower
side of instrument panel to hood. Install
removed inner cover.
mbl2006-002-103
Install the top side of instrument panel
with the 2 last kept screws.
8 / 24 2006-1 Predelivery

SET-UP
Handlebar
A29G0Q6
Model(s): Already Installed on Steering Column
Adjust handlebar and set both clamps to
have equal gap on each side.
N
NN
NO
OO
OT
TT
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E:
::
:Use handlebar wire hole as a
guide to center.
Master cylinder brake fluid reservoir
must be levelled.
Torque nuts from 24 N•m(18 lbf•ft).
2
A29G1B6
3
1
4
Model(s): To be Installed on Steering Column
Assemble handlebar with extension [
[[
[1]
]]
]and
clamps [
[[
[2]
]]
] on steering column.
Secure temporarily with:
–[
[[
[3]
]]
] 2 hexagonal bolts (predelivery kit)
–[
[[
[4]
]]
] 2 elastic nuts (predelivery kit).
Adjust handlebar and set both clamps to
have equal gap on each side.
N
NN
NO
OO
OT
TT
TE
EE
E:
::
:Use handlebar wire hole as a
guide to center.
Master cylinder brake fluid reservoir
must be levelled.
MODELS TORQUE
SKANDIC SUV 24 N•m(18lbf•ft)
EXPEDITION 29 N•m(21lbf•ft)
Torque nuts from 24 N•m(18 lbf•ft).
Steering Pad
3
1
2
4
A29G156
Model(s): Steering Pad with Keyway
Loosen throttle and brake handle housings.
Install steering pad.
Adjust both throttle and brake handle housings
to match steering pad.
Secure steering pad [
[[
[1]
]]
] to handlebar with:
–2 keyways [
[[
[2]
]]
]
N
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NO
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E:
::
:Useliquidsoaptoeaseinstallation
if necessary.
–2 screws M5 x 20 [
[[
[3]
]]
]
–2nutsM5[
[[
[4]
]]
].
N
NN
NO
OO
OT
TT
TE
EE
E:
::
:Item [
[[
[3]
]]
]and[
[[
[4]
]]
] seat tighten only,
no deformation of rubber.
Predelivery 2006-1 9 / 24

SET-UP
A29F156
Model(s): Steering Pad with Zipper
Properly position foam in place.
N
NN
NO
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::
:Steering foam can be secured in
place with a device such as filament tape
to ease the installation.
Fit steering padding and set in place with zippers.
mbl2006-002-001
Holding Strap
A29G146
Model(s): If so Equipped
Cut locking tie retaining right side strap end.
If applicable, insert strap through holes
provided in steering padding.
1
2
3
5
6
4
A03G0X6
Secure right side strap end with retaining clip [
[[
[3]
]]
].
Tighten firmly using:
–hexagonal bolts [
[[
[1]
]]
]
–nuts [
[[
[6]
]]
]
10 / 24 2006-1 Predelivery