Ski-Doo Tundra R Skandic LT 2003 Owner's manual

2003
Shop Manual Supplement
TUNDRA R
SKANDIC LT/LT E/WT/SWT/WT LC/SUV
THIS SUPPLEMENT MUST BE USED IN CONJUNCTION WITH THE
SKI-DOO 2002 SHOP MANUAL VOLUME 1 (P/N 484 200 032).

Legal deposit:
National Library of Quebec
3rd trimester 2002
National Library of Canada 2002
All rights reserved. No parts of this manual may be reproduced in any
form without the prior written permission of Bombardier Inc.
©Bombardier Inc. 2002
Technical Publications
Bombardier Inc.
Valcourt (Quebec) Canada
Printed in Canada
®*Registered trademarks of Bombardier Inc.
This document contains the trademarks of the following companies:
Comet®is a trademark of Hoffco/Comet Industries Inc.
Kimtowels®is a trademark of Kimberly-Clark
Loctite®is a trademark of Loctite Corporation
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

MMR2003-050_00_02A.FM I
SECTION SUBSECTION PAGE MANUAL
TO BE USED
THIS
SUPPLEMENT
2002
VOLUME1
SAFETY NOTICE ...................................................................................................................... III ✔
WHAT’S NEW ........................................................................................................................... IV ✔
INTRODUCTION ....................................................................................................................... V✔
01 SERVICE TOOLS AND
SERVICE PRODUCTS
01 – Service tools ............................................................. 01-01-1
02 – Service products ....................................................... 01-02-1
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02 LUBRICATION
AND MAINTENANCE
01 – Table of contents ...................................................... 02-01-1
02 – Lubrication and maintenance chart........................... 02-02-1
03 – Storage ..................................................................... 02-03-1
04 – Preseason preparation .............................................. 02-04-1
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03 TROUBLESHOOTING 01 – Table of contents ...................................................... 03-01-1
02 – Engine....................................................................... 03-02-1
03 – Fuel and oil systems ................................................. 03-03-1
04 – Transmission and brake systems ............................. 03-04-1
05 – Electrical system....................................................... 03-05-1
06 – Suspension and track................................................ 03-06-1
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04 ENGINE 01 – Table of contents ......................................................... 04-01-1
02 – 277 engine type ........................................................... 04-02-1
03 – 443 and 503 engine types ........................................... 04-03-1
04 – 593 engine type .......................................................... 04-04-1
05 – Leak test and engine dimension measurement .......... 04-05-1
06 – CDI system .................................................................. 04-06-1
07 – Oil injection system ..................................................... 04-07-1
08 – Axial fan cooling system .............................................. 04-08-1
09 – Liquid cooling system .................................................. 04-09-1
10 – Rewind starter ............................................................. 04-10-1
11 – Carburetor and fuel pump............................................ 04-11-1
12 – Fuel tank and throttle cable ......................................... 04-12-1
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05 TRANSMISSION 01 – Table of contents ......................................................... 05-01-1
02 – Drive belt ..................................................................... 05-02-1
03 – Drive pulley .................................................................. 05-03-1
04 – Driven pulley ................................................................ 05-04-1
05 – Pulley distance and alignment ..................................... 05-05-1
06 – Brake............................................................................ 05-06-1
07 – Chaincase .................................................................... 05-07-1
08 – Gearbox ....................................................................... 05-08-1
09 – Drive chain ................................................................... 05-09-1
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TABLE OF CONTENTS
2002 VOLUME 1

II MMR2003-050_00_02A.FM
06 ELECTRICAL 01 –Table of contents..........................................................06-01-1
02 –Ignition timing...............................................................06-02-1
03 –Spark plugs...................................................................06-03-1
04 –Battery..........................................................................06-04-1
05 –Electric starter ..............................................................06-05-1
06 –Testing procedure ........................................................06-06-1
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07 REAR SUSPENSION 01 –Table of contents..........................................................07-01-1
02 –Torque reaction suspension .........................................07-02-1
03 –Skandic WT suspension ...............................................07-03-1
04 –Drive axle......................................................................07-04-1
05 –Track.............................................................................07-05-1
06 –Skandic SUV suspension..............................................07-06-1 ✔
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08 STEERING/
FRONT SUSPENSION
01 –Table of contents..........................................................08-01-1
02 –Steering system ...........................................................08-02-1
03 –Suspension and ski system..........................................08-03-1
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09 BODY/FRAME 01 –Table of contents..........................................................09-01-1
02 –Body .............................................................................09-02-1
03 –Frame ...........................................................................09-03-1
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10 TECHNICAL DATA 01 –SI metric information guide ..........................................10-01-1
02 –Engines.........................................................................10-02-1
03 –Vehicles ........................................................................10-03-1
04 –Technical data legends .................................................10-04-1
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11 WIRING DIAGRAMS 01 –Wiring diagrams ...........................................................11-01-1 ✔
SECTION SUBSECTION PAGE MANUAL
TO BE USED
THIS
SUPPLEMENT
2002
VOLUME1
TABLE OF CONTENTS
2002 VOLUME 1

MMR2003-050_00_02A.FM III
SAFETY NOTICE 0
This manual has been prepared as a guide to correctly service and repair some 2003 Ski-Doo snowmo-
biles. See model list below.
This edition was primarily published to be used by snowmobile mechanic technicians who are already
familiar with all service procedures relating to Bombardier made snowmobiles. Mechanic technicians
should attend continuous training courses given by Bombardier Training Dept.
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 the Parts
Catalog.
It is understood that this manual may be translated into another language. In the event of any discrepancy,
the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Service
and Warranty Bulletins may be published to update the content of this manual. Make sure to read and
understand these.
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,
self-locking fasteners, etc.) must be installed or replaced with new ones. If the efficiency of a locking
device is impaired, it must be renewed.
This manual emphasizes particular information denoted by the wording and symbols:
CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle compo-
nents.
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.
Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the
contents. We strongly recommend that any services 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.
SAFETY NOTICE

IV MMR2003-050_00_02A.FM
WHAT’S NEW 0
SERVICE TOOLS 01-01
•New service tools, see NEW mention in the
subsection.
SERVICE PRODUCTS 01-02
•New service products, see NEW mention in the
subsection.
OIL INJECTION SYSTEM 04-07
•Installation procedure for injection nozzle on 593
engine type.
DRIVE BELT 05-02
•Procedure for checking neutral function.
DRIVE PULLEY 05-03
•Procedure for new Bombardier Lite drive pulley
installed on Tundra R.
•Ring gear added on Skandic LT E drive pulley.
DRIVEN PULLEY 05-04
•Procedure for Skandic WT/SWT/WT LC/SUV
driven pulley.
PULLEY DISTANCE AND
ALIGNEMENT 05-05
•New alignment bar for Skandic LT/LT E.
GEARBOX 05-08
•Procedure for shifter.
ELECTRIC STARTER 06-05
•Procedure for Skandic WT LC/SUV electric starter.
TESTING PROCEDURE 06-06
•Testing procedure for new heating elements.
SKANDIC SUV SUSPENSION 07-06
•Procedure for Skandic SUV suspension.
STEERING SYSTEM 08-02
•Procedure for Skandic SUV steering system.
SUSPENSION AND SKI SYSTEM
08-03
•Procedure for Skandic SUV front suspension
and ski system.
WHAT’S NEW

MMR2003-050_00_02A.FM V
INTRODUCTION 0
This Supplement covers the following Bombardier
made 2003 snowmobiles:
*Trademarks of Bombardier Inc.
Tundra R
TYPICAL — TUNDRA R
Skandic LT
Skandic LT E
Skandic WT
Skandic SWT
Skandic WT LC
Skandic SUV
These are Skandic series models.
TYPICAL — SKANDIC SERIES
VEHICLE DESCRIPTION DECAL
Vehicle Description Decal Location
Vehicle description decal is located on right hand
side of tunnel.
TYPICAL
1. Vehicle description decal
MODELS MODEL
NUMBER
TUNDRA R (YELLOW)
(Canada and U.S.) .................................3279
TUNDRA R (BLACK)
(Canada and U.S.) .................................3280
SKANDIC* LT (Canada) ........................2573
SKANDIC* LT (U.S.) ..............................2574
SKANDIC* LT E (Canada) .....................2634
SKANDIC* LT E (U.S.)...........................2635
SKANDIC* WT (Canada).......................2571
SKANDIC* WT (U.S.) ............................2572
SKANDIC* SWT (Canada) ....................2567
SKANDIC* SWT (U.S.) ..........................2568
SKANDIC*WT LC (Canada) .................2569
SKANDIC*WT LC (U.S.) .......................2570
SKANDIC* SUV (Canada) .....................2565
SKANDIC*SUV (U.S.)...........................2566
A05A0EA
A29A03A
A29H0SA
1
INTRODUCTION

VI MMR2003-050_00_02A.FM
Vehicle Description Decal Meaning
VEHICLE DESCRIPTION DECAL
1. Manufacturer name and address
2. Manufacturing date
3. Vehicle identification number (VIN)
4. Model name
5. Option package
6. Engine type
7. Model year
8. Color codes
Vehicle Identification Number (VIN)
Location
VIN is scribed on vehicle description decal. See
above. It is also embossed on tunnel near vehicle
description decal.
Vehicle Identification Number Meaning
ENGINE SERIAL NUMBER
Engine Serial Number Location
Fan-Cooled Engines
TYPICAL —FAN-COOLED ENGINES
1. Engine serial number
Liquid-Cooled Engines
TYPICAL —LIQUID-COOLED ENGINES
1. Engine serial number
3
5
A00A6HB
2
4687
1
2 B P S 1 5 9 2 9 Y 1 0 0 0 0 0 1
A00A6EA
Model number Serial number
Model year y = 2000
1 = 2001
2 = 2002
etc.
A03A0BA
1
1
A32C01B
INTRODUCTION

MMR2003-050_00_02A.FM VII
LIST OF ABBREVIATIONS
USED IN THIS MANUAL
ARRANGEMENT OF THE
MANUAL
The supplement is divided into major sections.
Each section is divided in various subsections, and
again, each subsection has one or more division.
Aampere
amp ampere
A•h ampere-hour
AC alternate current
ACM acceleration and control modulator
ARM advance ride management
BDC bottom dead center
BTDC before top dead center
°C degree Celsius
cc cubic centimeter
CDI capacitor discharge ignition
CTR center
cm centimeter
cm²square centimeter
cm³cubic centimeter
DC direct current
DPM digital performance management
DSA direct shock action
°F degree Fahrenheit
FC fan cooled
fl. oz fluid ounce
ft foot
GRD ground
H.A.C. high altitude compensator
hal. halogen
HI high
imp. oz imperial ounce
in inch
in²square inch
in³cubic inch
k kilo (thousand)
kg kilogram
km/h kilometer per hour
kPa Kilopascal
L liter
lb pound
lbf pound (force)
lbf/in²pound per square inch
LH left hand
LO low
LT long track
m meter
m. mile
MAG magneto
Max. maximum
Min. minimum
mL milliliter
mm millimeter
MPEM multi-purpose electronic module
MPH mile per hour
N newton
N.A. not applicable
no. number
00.0 continuity
0.L overload (open circuit)
O.D. outside diameter
OPT optional
oz ounce
P/N part number
PSI pound per square inch
PTO power take off
R rectangular
RH right hand
RAVE rotax adjustable variable exhaust
RPM revolution per minute
RMS root mean square
RRIM reinforced reaction injection molding
Sp. Gr. specific gravity
ST semi-trapezoidal
TDC top dead center
TRA total range adjustable
U.S. oz ounce (United States)
Vvolt
Vac volt (alternative current)
INTRODUCTION