Ski-Doo FORMULA III 1997 Install guide

I
1997
Shop Manual
VOLUME 3
FORMULA III/III LT
MACH 1/Z/Z LT
®

II
Legal deposit:
National Library of Quebec
3rd trimester 1996
National Library of Canada1996
All rights reserved. No parts of this manual may be reproduced in any
form without the prior written permission of Bombardier Inc.
©Bombardier Inc. 1996
Technical Publications
Bombardier Inc.
Valcourt (Quebec) Canada
Printed in Canada
®*Registered trademarks of Bombardier Inc.
This document contains the trademarks of the following companies:
Loctite®is a trademark of Loctite Corporation
Metton®is a trademark of Hercules Inc.
Molykote®is a trademark of Dow Corning Corporation
Silastic®is a trademark of Dow Corning Corporation
Snap-on®is a trademark of Snap-on Tools Corporation
Versilube®is a trademark of General Electric Company
SupertaniumTM is a trademark of Premier Industrial Corporation

III
SECTION SUB-SECTION PAGE
SAFETY NOTICE .................................................................................................................................. V
1997 BOMBARDIER SNOWMOBILES SHOP MANUAL VOLUME 3 (INTRODUCTION) ................. VI
01 LUBRICATION
AND MAINTENANCE 01 – Lubrication and maintenance chart..........................................01-01-1
02 TROUBLESHOOTING 01 – Table of contents......................................................................02-01-1
02 – Engine......................................................................................02-02-1
03 – Fuel and oil systems.................................................................02-03-1
04 – Transmission and brake systems.............................................02-04-1
05 – Electrical system......................................................................02-05-1
06 – Suspension system and track..................................................02-06-1
03 ENGINE 01 – Table of contents......................................................................03-01-1
02 – 599, 699 and 809 engine types................................................03-02-1
03 – Leak test and engine dimension measurement.......................03-03-1
04 – CDI system...............................................................................03-04-1
05 – Oil injection system..................................................................03-05-1
06 – Liquid cooling system...............................................................03-06-1
07 – Rewind starter..........................................................................03-07-1
08 – Carburetor and fuel pump........................................................03-08-1
09 – Fuel tank and throttle cable......................................................03-09-1
04 TRANSMISSION 01 – Table of contents......................................................................04-01-1
02 – Drive belt..................................................................................04-02-1
03 – Drive pulley...............................................................................04-03-1
04 – Driven pulley.............................................................................04-04-1
05 – Pulley distance and alignment..................................................04-05-1
06 – Brake........................................................................................04-06-1
07 – Chaincase.................................................................................04-07-1
08 – Drive chain................................................................................04-08-1
05 ELECTRICAL 01 – Table of contents......................................................................05-01-1
02 – Wiring diagrams (see Annexes at the end of this manual).......05-02-1
03 – Ignition timing...........................................................................05-03-1
04 – Spark plugs...............................................................................05-04-1
05 – Testing procedure....................................................................05-05-1
06 REAR SUSPENSION 01 – Table of contents......................................................................06-01-1
02 – SC-10 Suspension (HP)............................................................06-02-1
03 – Drive axle..................................................................................06-03-1
04 – Track.........................................................................................06-04-1
07 STEERING/
FRONT SUSPENSION 01 – Table of contents......................................................................07-01-1
02 – Steering system.......................................................................07-02-1
03 – Suspension and ski system......................................................07-03-1
08 BODY/FRAME 01 – Table of contents......................................................................08-01-1
02 – Body.........................................................................................08-02-1
03 – Frame.......................................................................................08-03-1
TABLE OF CONTENTS

IV
09 TECHNICAL DATA 01 – SI metric information guide...................................................... 09-01-1
02 – Engines .................................................................................... 09-02-1
03 – Vehicles.................................................................................... 09-03-1
04 – Technical data legends............................................................. 09-04-1
ANNEXES (wiring diagrams)
SECTION SUB-SECTION PAGE
TABLE OF CONTENTS

V
SAFETY NOTICE
This manual has been prepared as a guide to correctly service and repair some 1997 Ski-Doo snowmo-
biles. See model list on next page.
This edition was primarily published to be used by snowmobile mechanics who are already familiar with
all service procedures relating to Bombardier made snowmobiles.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
This
Shop Manual uses technical terms which may be slightly different from the ones used in Parts
Catalog
.
It is understood that this manual may be translated into another language. In the event of any discrepan-
cy, the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at its time of manufac-
ture. It does not include dealer modifications, whether authorized or not by Bombardier, after manufac-
turing the product.
In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the
general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas
of the parts.
The use of Bombardier parts is most strongly recommended when considering replacement of any com-
ponent. Dealer and/or distributor assistance should be sought in case of doubt.
The engines and the corresponding components identified in this document should not be utilized on
product(s) other than those mentioned in this document.
Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking tab,
elastic stop nut, etc.) must be installed or replaced with new ones, when damaged. If the efficiency of a
locking device is impaired, it must be renewed.
This manual emphasizes particular information denoted by the wording and symbols;
NOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
This information relates to the preparation and use of Bombardier snowmobiles and has been utilized
safely and effectively by Bombardier Inc. However, Bombardier Inc. disclaims liability for all damages
and/or injuries resulting from the improper use of the contents. We strongly recommend that any servic-
es be carried out and/or verified by a highly skilled professional mechanic. It is understood that certain
modifications may render use of the vehicle illegal under existing federal, provincial and state regulations.
◆WARNING
Identifies an instruction which, if not followed, could cause serious personal injury including
possibility of death.
-CAUTION
Denotes an instruction which, if not followed, could severely damage vehicle components.
SAFETY NOTICE

VI
INTRODUCTION
This Shop Manual VOLUME 3 covers the follow-
ing Bombardier made 1997 snowmobiles:
*Trademarks of Bombardier Inc.
LIST OF MODELS GROUPED BY
COMMUN CHASSIS
F-Series consists of:
FORMULA III/III LT
MACH 1/Z/Z LT
TYPICAL — F-SERIES
MODELS MODEL
NUMBER
FORMULA*III (CANADA)............... 1148
FORMULA*III (U.S.)....................... 1149
FORMULA*III (EUROPE)................ 1150
FORMULA*III LT (CANADA).......... 1151
FORMULA*III LT (U.S.).................. 1152
FORMULA*III LT (EUROPE)........... 1153
MACH*1 (CANADA)....................... 1177
MACH*1 (U.S.)............................... 1178
MACH*1 (EUROPE)........................ 1179
MACH*Z (CANADA)....................... 1180
MACH*Z (U.S.)............................... 1181
MACH*Z (EUROPE)........................ 1182
MACH*Z LT (CANADA).................. 1183
MACH*Z LT (U.S.).......................... 1184
MACH*Z LT (EUROPE)................... 1185
A06A09A
1997 BOMBARDIER SNOWMOBILES
SHOP MANUAL

VII
Each vehicle has its particular vehicle
serial number
Serial Number Meaning:
TYPICAL
1. Vehicle serial number
The engine also has a serial number.
Liquid-Cooled Engines
1. Engine serial number
ARRANGEMENT OF THE
MANUAL
The manual is divided into 09 major sections:
01 LUBRICATION AND MAINTENANCE
02 TROUBLESHOOTING
03 ENGINE
04 TRANSMISSION
05 ELECTRICAL
06 REAR SUSPENSION
07 STEERING/FRONT SUSPENSION
08 BODY/FRAME
09 TECHNICAL DATA
ANNEXES
Each section is divided in various sub-sections,
and again, each sub-section has one or more divi-
sion.
A00A0DA
Model no. Vehicle no.
0000 00000
A06H01A
1
A00C1QA
1
1997 BOMBARDIER SNOWMOBILES
SHOP MANUAL

VIII
Section 07 REAR SUSPENSION
Sub-Section 01 (SUPENSION SC-10 SPORT, TOURING AND MOUNTAIN)
SUSPENSION SC-10 SPORT,
TOURING AND MOUNTAIN
Grand Touring 500/580, Formula 500/583 and Summit 500
07-01-1
A03F24S
Short Track Models Only
Long Track
Models Only
SLE
Only
Loctite
271
Loctite
271
Loctite
271
Loctite
271
Loctite
271
Loctite
271
Loctite
271
Loctite
271
Low
temp.
grease
6
5
6
7
4
3
2
1
6
19
Low
temp.
grease
8
9
16
Low
temp.
grease
11
12
13
14
15
11
11
11
16
20 18
10
17
11
18 N•m
(160 lbf•in)
4 N•m
(35 lbf•in)
Page heading
indicates section
and sub-section
detailed.
Bold face number
indicates special
procedure concerning
this part.
Tightening torque nearby
fastener. In this case, nut
must be torqued to
4 N•m or 35 lbf•in.
This
Shop Manual uses technical terms wich may be
slightly different from the ones in the parts catalog.
Exploded view
assists you in
identifying parts and
related positions.
TYPICAL PAGE
A01A1QS
Illustration number
for publishing
process.
Sub-section title
indicates
beginning of the
sub-section.
Drop represents
a liquid product
to be applied to
a surface.
In this case
Loctite 271 to
screw threads.
Dotted box contains
parts of a particular
model in this case
the short track
models only.
Page numbering system:
07: REAR SUSPENSION section
01: SUSPENSION SC-10 SPORT,
TOURING AND MOUNTAIN sub-section
1: First page of this sub-section
Italic sub-title
above exploded
view indicate
pertaining models.
Pay attention to torque specifi-
cations. Some of these are in
lbf•in instead of lbf•ft. Use appro-
priate torque wrench.
CAUTION
▼
1997 BOMBARDIER SNOWMOBILES
SHOP MANUAL

IX
05-03-5
A16D0IA
1
2
A
1
Turn puller handle and sliding half at once to extract
the bushing.
INSTALLATION
Countershaft
F-Series and S-Series Only
Should installation procedure be required, refer
to BRAKE 05-05 then look for Brake Disc and
Countershaft Bearing Adjustment.
IMPORTANT: Large bushing retaining screws and
washers must be removed before small bushing
installation.
Coat bushing outside diameter with Loctite 609
(P/N 413 7031 00).
Install bushing as following photo.
Always apply anti-seize lubricant (P/N 413 7010
00) on the countershaft before final pulley
installation.
All Models
Check end play of driven pulley on countershaft by
pushing pulley towards outer housing so that the inner
shims ( P/N 504 1082 00) contact it. Measure end play
at the mounting screw end between shim(s) and puley.
See illustration.
TYPICAL — TOP VIEW
1. Shim (P/N 504 1082 00) (as required)
2.Contact
A. 0 to 1 mm (0 to 3/64 in)
Torque retaining screw no. 13 to 25 N•m (18 lbf•ft).
ADJUSTMENT
Refer to PULLEY DISTANCE AND ALIGNMENT 05-04
to adjust pulley distance. Adjust drive belt height
between pulley halves to obtain specified belt
deflection.
Reinstall the pulley on the countershaft by rever-
sing the removal procedure.
A03D1YA
529 0313 00
529 0312 00
A03D1ZA
529 0313 00
529 0312 00
Cam
Coat cam no. 18 interior with anti-seize lubricant.
ASSEMBLY
Came Slider Shoe
Section 05 TRANSMISSION
Sub-Section 03 (DRIVEN PULLEY)
When replacing slider shoes no. 4, always install a new
set (3 shoes) to maintain equal pressure on the cam.
Assemble driven pulley components by reversing
the disassembly procedure.
TYPICAL PAGE
Title indicates
main procedure
to be carried-out.
Reference to look up
a certain section and
sub-section (PULLEY
DISTANCE AND
ALIGNMENT 05-04).
In this case it concerns
pulleys adjustment.
Italic bold face setting
in this case indicates
that particular
procedure for
F and S-series is
finished, so from
this point, all models
are concerned.
Illustration always
follows text to which
it pertains.
A01A1RS
Sub-title indicates
a particular procedure
for the named part.
Number: Following part name
refers to exploded view
at beginning of sub-section.
Call-outs for
above illustration.
Italic bold face type
setting indicates a
particular procedure
concerning a model.
"TYPICAL" caption
indicates a general
view which does
not represent full
detail.
"TOP VIEW"
caption helps you
in understanding
illustration.
CAUTION
▼
1997 BOMBARDIER SNOWMOBILES
SHOP MANUAL

X
GENERAL INFORMATION
The information and component/system descrip-
tions contained in this manual are correct at time
of publication. Bombardier Inc. however, main-
tains a policy of continuous improvement of its
products without imposing upon itself any obliga-
tion to install them on products previously manu-
factured.
Due to late changes, it may have some differences
between the manufactured product and the de-
scription and/or specifications in this document.
Bombardier Inc. reserves the right at any time to
discontinue or change specifications, designs,
features, models or equipment without incurring
obligation.
USEFUL PUBLICATIONS
Refer to Parts Catalogs to order the right parts.
Use
Tools and Accessories Catalog to order the
tools you need.
1994 TOOLS, SERVICE PRODUCTS, OPTION &
ACCESSORIES (P/N 480 1343 00).
Use
Specification Booklet to find rapidly the right
specs.
1990-1997 SPECIFICATION BOOKLET (P/N 480
1420 00).
ILLUSTRATIONS AND
PROCEDURES
Illustrations and photos show the typical con-
struction of the different assemblies and, in all
cases, may not reproduce the full detail or exact
shape of the parts shown, however, they repre-
sent parts which have the same or a similar func-
tion.
As many of the procedures in this manual are in-
terrelated, we suggest, that before undertaking
any task, you read and thoroughly understand the
entire section or sub-section in which the proce-
dure is contained.
A number of procedures throughout the book re-
quire the use of special tools. Before commenc-
ing any procedure, be sure that you have on hand
all the tools required, or approved equivalents.
The use of RIGHT and LEFT indications in the text,
always refers to driving position (when sitting on
vehicle).
TYPICAL
1. Left
2. Right
PARTS CATALOG
MODELS P/N
FORMULA III/III LT
MACH 1/Z/Z LT 480 1432 00
-CAUTION
Most components of those vehicles are built
with parts dimensioned in the metric sys-
tem. Most fasteners are metric and must not
be replaced by customary fasteners or vice
versa. Mismatched or incorrect fasteners
could cause damage to the vehicle or possi-
ble personal injury.
A06G07B
12
1997 BOMBARDIER SNOWMOBILES
SHOP MANUAL

XI
TIGHTENING TORQUES
Tighten fasteners to torque mentioned in explod-
ed views and text. When they are not specified
refer to following table.
N•m FASTENER SIZE (8.8) Lbf•in
19
2
M4 18
3M427
4M5 35
544
653
762
8M671
9M680
10 M6 89
11 M6 97
12 M6 106
13 115
14 124
15 133
16 142
17 150
18 159
19 168
N•m FASTENER SIZE (8.8) Lbf•ft
20 15
21 M8 15
22 M8 16
23 M8 17
24 M8 18
25 M8 18
26 19
27 20
28 21
29 21
30 22
31 23
32 24
33 24
34 25
35 26
36 27
37 27
38 28
N•m FASTENER SIZE (8.8) Lbf•ft
39 29
40 30
41 30
42 31
43 M10 32
44 M10 32
45 M10 33
46 M10 34
47 M10 35
48 M10 35
49 M10 36
50 M10 37
51 M10 38
52 M10 38
53 M10 39
54 40
55 41
56 41
57 42
58 43
59 44
60 44
61 45
62 46
63 46
64 47
65 48
66 49
67 49
68 50
69 51
70 52
71 52
72 53
73 54
74 55
75 55
76 M12 56
77 M12 57
78 M12 58
79 M12 58
80 M12 59
81 M12 60
82 M12 60
83 M12 61
1997 BOMBARDIER SNOWMOBILES
SHOP MANUAL

XII
TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTS
N•m FASTENER SIZE (8.8) Lbf•ft
84 M12 62
85 63
86 63
87 64
88 65
89 66
90 66
91 67
92 68
93 69
94 69
95 70
96 71
97 72
98 72
99 73
100 74
101 74
102 75
103 76
104 77
105 77
106 78
107 79
108 80
109 80
110 81
111 82
112 83
113 83
114 84
115 85
116 86
117 86
118 87
119 88
120 89
121 M14 89
122 M14 90
123 M14 91
124 M14 91
125 M14 92
126 M14 93
127 M14 94
128 M14 94
N•m FASTENER SIZE (8.8) Lbf•ft
129 M14 95
130 M14 96
131 M14 97
132 M14 97
133 M14 98
134 M14 99
135 M14 100
136 M14 100
137 M14 101
138 M14 102
139 M14 103
140 M14 103
141 M14 104
142 M14 105
143 M14 105
144 M14 106
145 M14 107
146 M14 108
147 M14 108
148 M14 109
149 M14 110
150 M14 111
1997 BOMBARDIER SNOWMOBILES
SHOP MANUAL

Section 01 LUBRIFICATION AND MAINTENANCE
Sub-Section 01 (LUBRIFICATION AND MAINTENANCE CHART)
01-01-1
LUBRIFICATION AND MAINTENANCE
CHART 0
➀➁➂➃➄➅
REFER TO
Starting Rope Condition ✔—
Engine Head Nuts ✔✔ Appropriate section: See Top End
Engine Mount Nuts ✔✔
Appropriate section: See ENGINE
REMOVAL
Exhaust System ✔✔ Appropriate section: See ENGINE
REMOVAL
Engine Lubrication ✔This section no. 1
Cooling System Condition ✔✔ Sub-section 03-06
Coolant Replacement (Except Fan Cooled) ✔Sub-section 03-06
Condition of Seals ✔Sub-section 03-02
Injection Oil Filter Condition ✔Sub-section 03-05
Injection Oil Filter Replacement ✔Sub-section 03-05
Oil Injection Pump Adjustment ✔✔
Sub-section 03-05
Fuel Stabilizer ✔This section no. 2
Fuel Filter Replacement ✔This section no. 3
Fuel Lines and Connections ✔✔ Sub-section 03-09
Carburetor Adjustment ✔✔ Sub-section 03-08
Throttle Cable Inspection ✔✔✔ Sub-section 03-09
Air Filter Cleaning ✔This section no. 4
Drive Belt Condition ✔✔ This section no. 5
Condition of Drive and Driven Pulleys ✔✔✔ Sub-sections 04-03 and 04-04
Cleaning of Drive and Driven Pulleys ✔Sub-sections 04-03 and 04-04
Retorquing of Drive Pulley Screw ✔Sub-section 04-03
Driven Pulley Preload ✔✔ Sub-section 04-04
Brake Condition ✔✔ Sub-section 04-06
Brake Adjustment ✔Sub-section 04-06
Lubrication of Ratchet Wheel or Fluid Change ✔Sub-section 04-06
Drive Chain Tension ✔✔ Sub-section 04-07
Countershaft Lubrication (S and F Series) ✔✔✔ Sub-section 04-06
Chaincase/Gearbox Oil Level ✔✔✔ Sub-section 04-07
Chaincase/Gearbox Oil Change ✔1✔Sub-section 04-07
Lubrication of drive axle bearing ✔✔✔ Sub-section 06-04
Handlebar Bolts. Retorque to
26 N•m (19 Ibf•ft) ✔Sub-section 07-02
Steering and Front Suspension Mechanism ✔✔✔ Sub-sections 07-02 and 07-03
Wear and Condition of Skis and Runners ✔✔ Sub-section 07-03
Steering and Ski Leg Camber Adjustment ✔✔ Sub-section 07-02

Section 01 LUBRIFICATION AND MAINTENANCE
Sub-Section 01 (LUBRIFICATION AND MAINTENANCE CHART)
01-01-2
* Before installing new spark plugs at pre-season preparation, it is suggested to burn excess storage oil by starting
the engine with the old spark plugs. Only perform this operation in a well ventilated area.
➀10-HOUR OR 500 km (300 mi) INSPECTION (To be performed by dealer)
➁WEEKLY OR EVERY 240 km (150 mi)
➂MONTHLY OR EVERY 800 km (500 mi)
➃ONCE A YEAR OR EVERY 3200 km (2000 mi)
➄STORAGE (To be performed by dealer)
➅PRE-SEASON PREPARATION (To be performed by dealer)
1. Change oil at 10-hour inspection for Skandic WT/SWT/WT LC
2. Apply anti-seize lubricant (P/N 413 7010 00) on ACM rod every 10 hours or 500 km (300 mi).
Suspension Adjustments AS REQUIRED Section 06: See appropriate
sub-section and Operator’s Guide
Suspension Lubrication ✔2✔Section 06: See appropriate
sub-section
Suspension Condition ✔✔
Section 06: See appropriate
sub-section
Suspension Stopper Strap Condition ✔Section 06: See appropriate
sub-section
Track Condition ✔✔ Sub-section 06-04
Track Tension and Alignment ✔AS REQUIRED Sub-section 06-04
Spark Plugs* ✔Sub-section 05-04
Engine Timing ✔✔ Sub-section 05-03
Battery Condition ✔✔✔ Not applicable
Headlight Beam Aiming ✔Sub-section 08-02
Wiring Harnesses, Cables and Lines ✔✔ Sub-section 08-02
Operation of Lighting System
(HI/LO Beam, Brake Light, etc.)
Test Operation of Emergency Cut-Out Switch
and Tether Cut-Out Switch
✔✔ ✔
Operator’s Guide
Rags in Air Intake and Exhaust System ✔✔ This section no. 6
Engine Compartment ✔✔ This section no. 7
General Inspection ✔✔✔ This section no. 8
➀➁➂➃➄➅
REFER TO

Section 01 LUBRIFICATION AND MAINTENANCE
Sub-Section 01 (LUBRIFICATION AND MAINTENANCE CHART)
01-01-3
NO. 1 ENGINE LUBRICATION
Engine internal parts must be lubricated to protect
them from possible rust formation during the stor-
age period.
To perform the storage procedures, proceed as
follows:
Start the engine and allow it to run at idle speed
until the engine reaches its operating tempera-
ture.
Stop the engine.
Remove air silencers to spray storage oil into each
carburetor bore.
Restart engine and run at idle speed.
Inject storage oil until the engine stalls or until a
sufficient quantity of oil has entered the engine
(approximately half a can).
With the engine stopped, remove the spark plug
and spray storage oil (P/N 496 0141 00) into each
cylinder.
Crank slowly 2 or 3 revolutions to lubricate cylin-
ders.
Reinstall the spark plugs and the outlet primer
hose or air silencers.
NO. 2 FUEL STABILIZER
A fuel stabilizer (P/N 413 4086 00) can be added in
fuel tank to prevent fuel deterioration and avoid
draining fuel system for storage. Follow manufac-
turer’s instructions for proper use.
If above fuel stabilizer is not used, drain fuel sys-
tem including fuel tank and carburetor(s).
NO. 3 FUEL FILTER
REPLACEMENT
Drain fuel tank.
Remove fuel line grommet from fuel tank and pull
out inlet fuel line from tank.
TYPICAL
1. Inlet fuel line
2. Position of grommet when installing
3. Fuel filter
Replace fuel filter. To facilitate the fuel line instal-
lation, slide grommet on fuel line about 50 mm (2
in) away from elbow then install grommet on fuel
tank and push elbow through grommet.
NO. 4 AIR FILTER CLEANING
Check that the air box is clean and dry then prop-
erly reinstall the filter.
◆WARNING
Ensure the track is free of all particles which
could be thrown out while it is rotating. Keep
hands, tools, feet and clothing clear of track.
Ensure no one is standing in close proximity
to the vehicle.
◆WARNING
This procedure must only be performed in a
well ventilated area. Do not run engine dur-
ing storage period.
-CAUTION
Fuel stabilizer should be added prior engine
lubrication to ensure carburetor(s) protec-
tion against varnish deposit.
-CAUTION
These snowmobiles have been calibrated
with the filter installed. Operating the snow-
mobile without it may cause engine dam-
age.
A17C0DA
3
1
2

Section 01 LUBRIFICATION AND MAINTENANCE
Sub-Section 01 (LUBRIFICATION AND MAINTENANCE CHART)
01-01-4
Lift hood and remove air filters from air intake si-
lencer.
TYPICAL
1. Air intake silencer
2. Air filters
To clean a filter, shake the snow out of it then, dry
it out.
NO. 5 DRIVE BELT CONDITION
Inspect belt for cracks, fraying or abnormal wear
(uneven wear, wear on one side, missing cogs,
cracked fabric). If abnormal wear is noted, proba-
ble cause could be pulley misalignment, exces-
sive RPM with frozen track, fast starts without
warm-up period, burred or rusty sheave, oil on
belt or distorted spare belt.
Check the drive belt width. Replace the drive belt
if width is less than the minimum width recom-
mended in DRIVE BELT 04-02.
NO. 6 RAGS IN AIR INTAKE AND
EXHAUST SYSTEM
At storage preparation, block air intake hole and
exhaust system hole using clean rags.
Remove those rags at pre-season preparation.
NO. 7 ENGINE COMPARTMENT
Keep clean of grass, twigs, cloth, etc. These are
combustible under certain conditions.
NO. 8 GENERAL INSPECTION
Remove any dirt or rust.
To clean the entire vehicle, use only flannel
clothes or Kimtowels®wipers no. 58-380 from
Kimberly-Clark.
To clean the entire vehicle, including metallic parts
with a thick coat of grease, use “Endust” import-
ed by Bristol Myers, available at hardware stores
or supermarkets.
To clean the entire vehicle, including metallic parts
with a thin coat of grease, use “Simple Green”
from Sunshine Makers Inc., available at hardware
stores or at automotive parts retailer.
To remove scratches on windshield or hood: Start
with “Slip Streamer Motorcycle Windshield
Heavy Duty Scratch, Remover”. Finish with “Slip
Streamer Motorcycle Cleaner and Polish”.
NOTE: The latest product may be use alone if
only light scratches are noticeable.
Inspect the hood and repair any damage. Touch up
all metal spots where paint has been scratched
off. Spray all metal parts including shock chromed
rods with Bombardier Lube (P/N 293 6000 06).
Wax the hood and the painted portion of the
frame for better protection.
NOTE: Apply wax on glossy finish only. Protect
the vehicle with a cover to prevent dust accumu-
lation during storage.
A06C04A
2
1-CAUTION
It is necessary to use flannel cloths or “Kim-
towels” wipers on windshield and hood to
avoid damaging further surfaces to clean.
-CAUTION
Never clean plastic parts or hood with
strong detergent, degreasing agent, paint
thinner, acetone, products containing chlo-
rine, etc.
-CAUTION
The snowmobile has to be stored in a cool
and dry place and covered with an opaque
tarpaulin This will prevent sun rays and
grime from affecting plastic components
and vehicle finish.

02-01-1
Section 02 TROUBLESHOOTING
Sub-Section 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS
ENGINE .................................................................................................................................. 02-02-1
FUEL AND OIL SYSTEMS ..................................................................................................... 02-03-1
TRANSMISSION AND BRAKE SYSTEMS ........................................................................... 02-04-1
TRANSMISSION ................................................................................................................ 02-04-1
BRAKE SYSTEM ................................................................................................................ 02-04-8
MECHANICAL BRAKE ....................................................................................................... 02-04-8
HYDRAULIC BRAKE .......................................................................................................... 02-04-9
MECHANICAL AND HYDRAULIC BRAKES ...................................................................... 02-04-9
ELECTRICAL SYSTEM........................................................................................................... 02-05-1
SUSPENSION SYSTEM AND TRACK .................................................................................. 02-06-1

Section 02 TROUBLESHOOTING
Sub-Section 02 (ENGINE)
02-02-1
ENGINE 0
The following chart is provided to help in diagnosing the probable source of troubles. It should be used
as a guideline. Some causes or corrections may not apply to a specific model.
SYMPTOM ENGINE BACKFIRES
CONDITION NORMAL USE
Test/Inspection 1. Check spark plug(s).
a.Carbon accumulation caused by defective spark plug(s).
Clean carbon accumulation and replace spark plug(s).
2. Check cooling system.
a.Loose fan belt.
Adjust or replace fan belt (refer to TECHNICAL DATA 09).
b.Low antifreeze level.
Adjust antifreeze level. Then check clamps or hoses.
c.Defective tank cap or thermostat.
Replace.
d.Air in system.
Bleed system.
3. Check ignition timing.
a.Timing is too advanced.
Set timing according to specifications (refer to TECHNICAL DATA 09).

Section 02 TROUBLESHOOTING
Sub-Section 02 (ENGINE)
02-02-2
SYMPTOM ENGINE SUDDENLY TURNS OFF
CONDITION NORMAL USE
Test/Inspection 1. Perform engine leak test. Refer to engine leak verification flow chart.
Check possible piston seizure.
a.Damaged gasket and/or seal.
Replace defective parts.
2. “Four-corner” seizure of piston(s).
a.Accelerating too fast when engine is cold. Piston expands faster than cylinder.
Replace piston(s). Ask driver to refer to warm-up procedure in Operator’s Guide.
3. Piston(s) seizure on exhaust side (color on piston dome is correct).
a.Kinked fuel tank vent tube.
Relocate fuel tank vent tube.
b.Leaks at fuel line connections or damaged fuel lines.
Replace defective lines.
c.Fuel does not flow through carburetor(s) (plastic particles in needle area and/or
varnish formation in carburetor(s)).
Clean carburetor(s).
d.Spark plug heat range is too warm.
Install spark plug(s) with appropriate heat range (refer to TECHNICAL DATA 09).
e.Improper ignition timing.
Adjust according to specifications (refer to TECHNICAL DATA 09).
f.Restriction in exhaust system.
Replace.
g.Compression ratio is too high.
Install genuine parts.
h.Carburetor calibration is too lean.
Adjust according to specifications (refer to TECHNICAL DATA 09).
i.Improper rotary valve timing or improper valve.
Adjust according to specifications (refer to TECHNICAL DATA 09) and/or install
Bombardier’s recommended rotary valve.
j.Poor quality oil.
Use Bombardier Rotax oil.
k.Leaks at air intake silencer.
Replace air intake silencer grommets.