Ski-Doo ZX SERIES Operator's Manual
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Ski-Doo ZX SERIES Operator's Manual

Ski-Doo ZX SERIES Operator's Manual

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  • Page 2: Safety Warning

    GRAND TOURING SUMMIT ® ROTAX ® MX-Z ® SKI-DOO ® LEGEND DESS Kleen-Flo* is a trademark of Kleen-Flo Tumbler Industries Ltd. Printed in Canada (Mmo2002-002a.fm GM) are trademarks of Bombardier Inc. and are trademarks of Bombardier Inc. or its subsidiaries.
  • Page 3 2002 SKI-DOO OPERATOR’S GUIDE This guide is applicable to the following ZX series models: Legend Grand Touring ® MX-Z Summit ®...
  • Page 4 FOREWORD Congratulations on your purchase of a new SKI-DOO snowmobile. Whatever model you have chosen, it is backed by the Bombardier warranty and a network of authorized SKI-DOO snowmobile dealers ready to provide the parts, service or accessories you may require.
  • Page 5 The illustrations show the typical construction of the different assem- blies and, in all cases, may not reproduce the full detail or exact shape of the parts shown, however, they represent parts which have the same or a similar function. It is understood that this guide may be translated into another lan- guage.

  • Page 6: Table Of Contents

    2002 SKI-DOO SNOWMOBILES..........BOMBARDIER LIMITED WARRANTY INTERNATIONAL: ® 2002 SKI-DOO SNOWMOBILES..........FREQUENTLY ASKED QUESTIONS ........AUTHORIZED SKI-DOO DEALERS ......... HOW TO IDENTIFY YOUR SNOWMOBILE ......Vehicle Description Decal............Serial Numbers ................ON-VEHICLE IMPORTANT INSTRUCTIONS......CONTROLS/INSTRUMENTS/EQUIPMENT ......1) Throttle Lever ..............
  • Page 7 29) Heated Throttle Lever Switch ..........30) Electric Visor Jack Connector ..........31) 12-Volt Power Outlet ............32) Electric Valving Shock Switch ..........33) Electric Valving Shock Pilot Lamp (Amber) ......34) Air Suspension Switch ............35) Air Suspension Gauge............36) Hood Latches ...............
  • Page 8 VEHICLE WARM-UP ..............101 POST-OPERATION CARE ............102 SPECIAL OPERATIONS ............102 Riding at High Altitudes ............. 102 Engine Overheating..............102 Fuel Flooded Engine ..............102 Rear Suspension Slider Shoe Sticking........103 PERIODIC MAINTENANCE CHART......... 104 FLUID LEVELS................106 Brake System ................106 Chaincase Oil Level ..............

  • Page 9: Safety Measures

    Use of Rotax ® snowmobile engines in other than SKI-DOO snowmobiles is not recommended or autho- rized by Bombardier Inc. Do not stud the track. Reverse models only: These snowmobiles are capable of a fast reverse.

  • Page 10: Bombardier Limited Warranty North America: 2002 Ski-Doo Snowmobiles

    This warranty coverage is available only on 2002 SKI-DOO snowmobile pur- chased as new and unused by its first owner from a BOMBARDIER dealer authorized to distribute SKI-DOO products in the country in which the sale occurred (hereinafter “BOMBARDIER dealer”), and then only after the BOM- BARDIER specified pre-delivery inspection process is completed and docu- mented.
  • Page 11 6. EXCLUSIONS - ARE NOT WARRANTED • Normal wear and tear; • Routine maintenance items, tune ups, adjustments; • Damage caused by failure to provide proper maintenance and/or storage, as described in the Operator’s Guide; • Damage resulting from removal of parts, improper repairs, service, mainte- nance, modifications or use of parts not manufactured or approved by BOM- BARDIER or resulting from repairs done by a person that is not an authorized servicing BOMBARDIER dealer;...
  • Page 12 If the issue has not yet been resolved, please submit your complaint in writing or call the appropriate number below: In Canada: In USA: BOMBARDIER INC. BOMBARDIER MOTOR RECREATIONAL PRODUCTS CORPORATION OF AMERICA SKI-DOO ® RECREATIONAL PRODUCTS CUSTOMER ASSISTANCE CENTER SKI-DOO ® VALCOURT QC J0E 2L0 CUSTOMER ASSISTANCE CENTER Tel: (819) 566-3366 P.O.

  • Page 13: Bombardier Limited Warranty International: 2002 Ski-Doo Snowmobiles

    All genuine BOMBARDIER parts and accessories, installed by an authorized BOMBARDIER distributor/dealer (as hereinafter defined) at the time of delivery of the 2002 SKI-DOO snowmobile, carry the same warranty as that of the snow- mobile. Use of the product for racing or any other competitive activity, at any point, even by a prior owner will render this warranty null and void.
  • Page 14 5. WHAT BOMBARDIER WILL DO BOMBARDIER’s obligations under this warranty are limited to, at its sole dis- cretion, repairing parts found defective under normal use, maintenance and service, or replacing such parts with new genuine BOMBARDIER parts without charge for parts and labor, at any authorized BOMBARDIER distributor/dealer. BOMBARDIER reserves the right to improve or modify products from time to time without assuming any obligation to modify products previously manufac- tured.
  • Page 15 8. TRANSFER If the ownership of a product is transferred during the warranty coverage peri- od, this warranty shall also be transferred and be valid for the remaining cover- age period provided that BOMBARDIER is notified of such transfer of owner- ship in the following way: a.

  • Page 16: Frequently Asked Questions

    I do have my original invoice as proof of when I purchased my snowmobile. A: Registration is very important and your SKI-DOO dealer must register your snowmobile with Bombardier. Make sure the registration form has been sent. All of this will allow you to: a) have warranty work performed at any authorized SKI-DOO dealer in North America.
  • Page 17 Bombardier. Normally, any problems that arise in connection with the sales transaction or the operation of your snowmo- bile will be handled by your SKI-DOO Dealers Sales or Service Departments. It is recognized, however, that despite the best intentions of everyone concerned, misunderstandings will sometimes occur.

  • Page 18: Authorized Ski-Doo Dealers

    AUTHORIZED SKI-DOO DEALERS For Canada and USA Only To find the nearest authorized SKI-DOO dealer, dial: 1-800-375-4366. HOW TO IDENTIFY YOUR SNOWMOBILE Vehicle Description Decal Vehicle description decal is located on right hand side of tunnel. A32H0DA TYPICAL 1. Vehicle description decal...

  • Page 19: Serial Numbers

    These numbers are required by the SKI-DOO dealer to complete warranty claims properly. No war- ranty will be allowed by Bombardier Inc. if the engine serial number or Vehicle Identification Number (VIN) is removed or mutilated in any way.

  • Page 20: Serial Number

    Model Number Location Model number is part of vehicle identification number (VIN). X X X X X X X X X X X X X X X X X Model number Serial number A00A6IA VIN DESCRIPTION Engine Serial Number Location A32C01B TYPICAL 1.

  • Page 21: On-Vehicle Important Instructions

    ON-VEHICLE IMPORTANT INSTRUCTIONS Please read the following instructions carefully before operating snow- mobile. 3 4 5 A32A02D LOCATION OF IMPORTANT INSTRUCTIONS Instruction 1 A01A1ZD ALL MODELS...
  • Page 22 Instruction 2 SINGLE SEAT MODELS DOUBLE SEAT MODELS A02A0HA...
  • Page 23 Instruction 3 A01A2EA ALL MODELS Instruction 4 A01A2FA ALL MODELS...
  • Page 24 Instruction 5 A01A24D TYPICAL — ALL MODELS Instruction 6 SUSPENSION ADJUSTMENT CHART/TABLEAU DES RÉGLAGES DE LA SUSPENSION FRONT SUSPENSION (SKI)/SUSPENSION AVANT (SKI) NOT APPLICABLE SANS OBJET REAR SUSPENSION/SUSPENSION ARRIÈRE ADJUST ACCORDING TO LOAD/RÉGLER SELON LA CHARGE LOAD REAR SPRING CHARGE RESSORT ARRIÈRE APPLICABLE SANS OBJET...
  • Page 25 Instruction 7 A32A0MA SUMMIT WITHOUT RENAGADE PACKAGE...
  • Page 26 A32A0NA SUMMIT WITH RENEGADE PACKAGE...
  • Page 27 Instruction 8 A32F21A SUMMIT...

  • Page 28: Controls/Instruments/Equipment

    CONTROLS/INSTRUMENTS/EQUIPMENT NOTE: Some controls/instruments/equipment are optional on some models. 45 40 39 48 44 49 50 42 43 A32A0HB TYPICAL 3 15 A32A0OA TYPICAL — LIQUID COOLED ELECTRIC START MODELS...
  • Page 29 3 15 5 A32A0PA TYPICAL — LIQUID COOLED MANUAL START MODELS 38 36 A32E1CA TYPICAL — FAN COOLED MODELS...
  • Page 30 22 21 19 20 25 16 12 23 27 A32A0JC TYPICAL — EXCEPT GRAND TOURING 800 SE 22 21 A32A0QA GRAND TOURING 800 SE...

  • Page 31: Throttle Lever

    1) Throttle Lever Located on the right side of handlebar. When compressed, it controls the engine speed and the engagement of the transmission. When released, engine speed returns automatically to idle. WARNING Throttle lever must operate easily and smoothly. It must return to idle position when released.
  • Page 32 MECHANICAL BRAKE To engage mechanism, squeeze brake lever and maintain while pull- ing button with the other hand. There are 2 retaining notches on but- ton lever; pull button until it locks on a notch then release brake lever. To release mechanism, squeeze brake lever then fully push parking brake button.

  • Page 33: Injection Oil Level/Parking Brake Pilot Lamp (Red)

    HYDRAULIC BRAKE To engage mechanism, squeeze brake lever and maintain while pull- ing locking lever with a finger. When brake lever is compressed half- way the brake should be fully applied. To release mechanism, squeeze brake lever. Locking lever will auto- matically return to its original position.

  • Page 34: Handlebar

    Handlebar height is adjustable. See an authorized SKI-DOO dealer. 6) Adjustable Handlebar Handlebar angle can be adjusted to suit driver’s preference. Lift lever, tilt handlebar to desired position then release lever.

  • Page 35: Holding Strap

    7) Holding Strap Holding strap provides a grip for driver when side-hilling. WARNING This strap is not for towing, lifting or other purpose than tem- porary use as a grab bar during side-hilling. Always keep at least one hand on handlebar. 8) Reverse Button WARNING These snowmobiles are capable of a fast reverse.
  • Page 36 Shifting in Reverse With the snowmobile completely stopped and engine running at idle, press and release the reverse button. A32E1BA 1. Reverse button The DESS (Digitally Encoded Security System) indicator lamp will blink and a warning buzzer will sound when the snowmobile is en- gaged in reverse.

  • Page 37: Reverse/Start Button

    Operation Fan Cooled Models Before using vehicle at high altitude see an authorized SKI-DOO deal- er for installation of a high altitude cap. Fan cooled Summit models are already equipped with high altitude cap. Non-DPM Liquid Cooled Models Before using the reverse system, first select the altitude mode that changes engine timing curve.

  • Page 38: Ignition Switch

    If engine does not start on first try, wait a few seconds then repeat procedure. To stop engine, turn off engine cut-out switch or pull off tether cord cap. NOTE: If necessary engine may be manually started with rewind starter. Reverse Mode Once engine is started, push reverse/start button to activate the Rotax Electronic Reverse (RER).

  • Page 39: Tether Cut-Out Switch

    If engine does not start on first try, turn key back to OFF position before restarting. To stop engine, turn key to OFF position. NOTE: Engine may be manually started with rewind starter if necessary. If starter does not operate, check starting system fuse condition. Refer to Starting System Fuse below.
  • Page 40 Liquid Cooled Models Only This system is a deterrent against theft. The tether cord cap provided with your snowmobile is SKI-DOO dealer programmed and is the only one that allows engine to turn more than 3000 RPM. If an incorrectly programmed tether cord cap is installed the engine can not reach engagement speed required to move vehicle.

  • Page 41: Dess Pilot Lamp (Red)

    To check for bad connection, remove tether cord. Make sure it is free of dirt or snow. Reinstall tether cord and restart engine. If a blink per 3 seconds still occurs contact an authorized SKI-DOO dealer. A30H08A 1. Free of dirt or snow A rapid DESS pilot lamp blinking means that an incorrectly pro- grammed tether cord is being used.

  • Page 42: Engine Cut-Out Switch

    14) Engine Cut-Out Switch A push-pull type switch located on the right side of the handlebar. To stop the engine, push the button to the lower OFF position and si- multaneously apply the brake. To restart, button must be at the upper ON position.

  • Page 43: Headlamp Dimmer Switch

    All drivers of the snowmobile should familiarize themselves with the function of this device by using it several times on first outing and to stop the engine there after. Thereby being mentally prepared for emergency situations requiring its use. WARNING If the switch has been used in a mechanical malfunction, the source of malfunction should be determined and corrected before restarting engine.

  • Page 44: Choke Lever

    18) Choke Lever This device features a 3-position lever to facilitate cold start. A32H01A 0. OFF 1. Position 1 2. Position 2 See OPERATING INSTRUCTIONS for more details. 19) Speedometer Direct-reading dial indicates the speed of the snowmobile in kilome- ters per hour (miles per hour for the USA).

  • Page 45: Trip Meter Reset Button

    22) Trip Meter Reset Button To reset, push on button until all numbers read zero. A32H08A ALL MODELS 1. Speedometer 2. Odometer 3. Trip meter 4. Reset button...

  • Page 46: Tachometer

    23) Tachometer Direct-reading dial indicates the number of thousand of revolutions per minute (RPM) of the engine. A32H09A MULTIPLY THE READING BY 1000...

  • Page 47: Temperature Gauge

    A30H0GA TYPICAL 1. Normal 2. Overheat 25) Engine Overheat Warning Lamp (Red) If this lamp glows, stop engine immediately and allow to cool. If prob- lem repeats, see your authorized SKI-DOO dealer.

  • Page 48: Fuel Tank Cap/Gauge

    26) Fuel Tank Cap/Gauge On some models fuel level gauge is part of fuel tank cap. Unscrew to fill up tank then fully tighten. A32I01A WARNING Fuel may be pressurized, open cap slowly. Fuel is flammable and explosive. Never use an open flame to check fuel level. Never smoke or allow flame or spark in vicinity.

  • Page 49: Electric Fuel Level Gauge

    27) Electric Fuel Level Gauge Dash-mounted gauge to facilitate fuel level reading. This gauge func- tions when engine is running. A30H0HA TYPICAL 1. Full 2. Empty 28) Heated Grip Switch Three-position toggle switch. Select the desired position to keep your hands at a comfortable temperature.

  • Page 50: Heated Throttle Lever Switch

    29) Heated Throttle Lever Switch Three-position toggle switch. Select the desired position to keep your right thumb at a comfortable temperature. A32H0FA HEATED GRIP SWITCH HEATED THROTTLE LEVER SWITCH 1. HOT 4. HOT 2. OFF 5. OFF 3. WARM 6. WARM...

  • Page 51: Electric Visor Jack Connector

    An electric visor can be connected to the jack connector. Electric current is supplied whenever engine is running. An extension is sup- plied with the vehicle. It is included in the predelivery kit. Ask your SKI-DOO dealer for the extension. A32E0OA 1. Electric visor jack connector...

  • Page 52: 12-Volt Power Outlet

    31) 12-Volt Power Outlet A 12-volt electric appliance may be connected to that jack connector. Electric current is supplied when ever engine is running. See Fuses below for 12-volt power outlet fuse location. A32E16A 1. 12-volt power outlet 32) Electric Valving Shock Switch This toggle type switch allows two different rear suspension rear shock valving: SPORT or COMFORT.

  • Page 53: Air Suspension Switch

    Always completely stop vehicle in a safe place before attempt- ing any suspension adjustments. NOTE: Compressor will keep the minimum required pressure when engine is running. If the minimum required pressure can not be main- tained, see an authorized SKI-DOO dealer.

  • Page 54: Air Suspension Gauge

    35) Air Suspension Gauge Grand Touring SE Only This gauge indicates comfort level (pressure inside rear air shock ab- sorber). A32E18A TYPICAL — AIR SUSPENSION GAUGE 1. Minimum required pressure before riding...

  • Page 55: Hood Latches

    36) Hood Latches Stretch and unhook the latches to unlock the hood from its anchors. A32H02A 1. Latch 2. Recess provided to open hood Always lift hood gently until stopped by retaining device. Close hood slowly then hook up latches. 37) Adjustable Mirrors Each mirror can be adjusted to suit driver’s preference.

  • Page 56: Adjustable Toeholds

    38) Adjustable Toeholds Each toehold can be adjusted to suit driver’s preference. Loosen bolts, adjust then, retighten bolts to 10 N•m (89 lbf•in). WARNING Adjust with vehicle at rest in a safe place. Do not adjust too snugly. Securely tighten all adjustments. A32H0VA RIGHT SIDE SHOWN 1.

  • Page 57: Heated Carburetor Valve

    39) Heated Carburetor Valve Turn valve on when riding at 5°C (41°F) or colder temperatures. A32I0AA 1. ON 2. OFF CAUTION: When operating the snowmobile above 5°C (41°F), move the carburetor heating valve to the OFF position.

  • Page 58: Adjustable Backrest

    40) Adjustable Backrest The backrest position and support angle may be adjusted to suit driv- er or passenger convenience. WARNING Adjust with vehicle at rest in a safe place. Securely tigthten all adjustments. Grand Touring 500 F A03A0KA TYPICAL — BACKREST POSITION 1.
  • Page 59 A03A0KC TYPICAL — BACKREST SUPPORT ANGLE 1. Loosen top knob to adjust then retighten A03A0KB TYPICAL — BACKREST HEIGHT 1. Loosen center knobs (both sides) to adjust then retighten...

  • Page 60: Seat Strap

    Liquid Cooled Grand Touring A32H0PA 1. Turn adjustment knob 2. Lift adjustment lock (both sides) Secure adjustment locks after desired position is obtained. 41) Seat Strap Seat strap provides a grip for the passenger.

  • Page 61: Rear Passenger Heated Grip Switch

    42) Rear Passenger Heated Grip Switch Three-position switch. Select the desired position to keep rear pas- sager’s hands at a comfortable temperature. A32H0QA TYPICAL — RIGHT SIDE OF PASSENGER GRAB HANDLE 1. Rear passenger heated grab handles switch...

  • Page 62: Adjustable Rear Grab Handles

    43) Adjustable Rear Grab Handles Height of rear grab handles can be adjusted. Lift adjustment lock, move grab handle to desired position. Secure adjustment lock. Proceed the same with the other side. WARNING Adjust with vehicle at rest in a safe place. Securely tighten all adjustments.
  • Page 63 A32H03A TO CLOSE, SQUEEZE CLOSING TABS BETWEEN THUMB AND INDEX A32H04A TO OPEN, SQUEEZE OPENING TABS BETWEEN THUMB AND INDEX...

  • Page 64: Storage Compartment

    45) Storage Compartment A storage compartment is provided inside rear portion of seat. WARNING All storage compartments must be properly latched and they must not contain any heavy or breakable objects. 46) Tool Bag A tool bag containing tools for basic maintenance is supplied with the vehicle.

  • Page 65: Fuses

    CAUTION: Do not use a higher rated fuse as this can cause se- vere damage to electric components and/or fire. WARNING If fuse has burnt out source of malfunction should be determined and corrected before restarting. See an authorized SKI-DOO dealer for servicing.
  • Page 66 3. 20 A accessories fuse 4. 5 A electronic module fuse To remove fuse from holder, pull fuse out. Check if filament is melted. A15E0KA 1. Fuse 2. Check if melted Electric Fuel Level Gauge Fuse See an authorized SKI-DOO dealer for fuse replacement.

  • Page 67: Spare Spark Plug Holder

    48) Spare Spark Plug Holder To keep spare spark plugs dry and prevent shocks that might affect the adjustment or break them, a holder is provided on the right side of oil tank. Firmly tighten them into the holder with spark plug socket (in tool kit) to ensure that they will not be loosened by vibrations.

  • Page 68: Spare Drive Belt Holder

    49) Spare Drive Belt Holder A spare drive belt can be stored in holder at front section of bottom pan. NOTE: Spare drive belt is not supplied with the snowmobile. A32H0TA TYPICAL — SPARE DRIVE BELT INSTALLED IN HOLDER 50) Front Grab Handles/Front Bumper To be used whenever front of snowmobile requires manual lifting.

  • Page 69: Convertible Ski Stance

    51) Convertible Ski Stance Summit Models Only Ski stance (distance between each skis) is adjustable. See an autho- rized SKI-DOO dealer. 52) Adjustable Suspensions For factory recommended adjustments refer to decal on belt guard. It describes settings for optimum comfort according to load for your SKI-DOO model.

  • Page 70: General

    General Snowmobile handling and comfort depend upon suspension adjust- ments. Choice of suspension adjustments vary with carrying load, driver’s weight, personal preference, riding speed and field condition. NOTE: Some adjustments may not apply to your snowmobile. Use special keys in tool bag. 6 7-8 A32F0FC TYPICAL...

  • Page 71: Guidelines To Adjust Suspension

    NOTE: Some models are equipped with Take/Apart (T/A) shocks. These can be rebuilt or recalibrated. See an authorized SKI-DOO dealer. 1. Rear Springs — Comfort and Ride Height Grasp rear bumper and lift until suspension is fully extended. From this point, rear of snowmobile should collapse by 50 to 75 mm (2 to 3 in) when driver and passenger (if so applicable) take place.
  • Page 72 A32F0CA TYPICAL — TOO SOFT OF ADJUSTMENT Turn the left side adjustment cam in a clockwise direction, the right side cam in a counterclockwise direction. Left and right adjustment cams may be set at different position. A30F04A TYPICAL 1. Increase spring preload...
  • Page 73 A32F0DA TYPICAL — TOO HARD OF ADJUSTMENT Turn the left side adjustment cam in a counterclockwise direction, the right side cam in a clockwise direction. Left and right adjustment cams may be at different position. A30F04B TYPICAL 1. Decrease spring preload...
  • Page 74 2. Center Spring — Steering Behavior Ride at moderate speed on a trail. If steering is too easy or too hard to turn, adjust center spring accord- ingly. A32F0EA TYPICAL — GOOD ADJUSTMENT AT MODERATE SPEED 1. Steering easy to turn...
  • Page 75 A32F0EA TYPICAL — TOO SOFT OF ADJUSTMENT 1. Steering hard to turn A32F01A TYPICAL 1. Use adjuster wrench provided in tool bag to increase preload...
  • Page 76 A32F0EA TYPICAL — TOO HARD OF ADJUSTMENT 1. Steering less aggressive A32F01B TYPICAL 1. Use adjuster wrench provided in tool bag to decrease preload...
  • Page 77 3. Coupling Blocks — Handling Ride at moderate speed and check for desired handling. All Models Except Summit When driver and passenger (if applicable) take place the coupling blocks should be centered between rubber stoppers. This condition is achieved when a proper rear spring preload is done. See above rear spring adjustment.
  • Page 78 A32F0JA COUPLING BLOCK — RIGHT SIDE VIEW (“R” — RIGHT EMBOSSED ON BLOCK) 1. Thicker part of block facing downward (partly coupled suspension) — more track grip and less skis steering 2. Turn block in this direction to adjust to the other position...
  • Page 79 4. Stopper Strap — Weight Transfer Ride at low speed then fully accelerate. Note steering behavior. Ad- just stopper strap length accordingly. At rest with driver and passenger (if applicable), stopper strap should have a free play of 12 mm (1/2 in). CAUTION: Whenever stopper strap length is changed, track ten- sion must be readjusted.
  • Page 80 All Models Except Summit Models A32F0EC TYPICAL — TOO LONG STRAP 1. Skis lift off the ground A03F0QB TYPICAL 1. Reduce strap length by bolting to a different hole...
  • Page 81 A32F0EA TYPICAL — TOO SHORT STRAP 1. Heavy steering A03F0QB TYPICAL 1. Increase strap length by bolting to a different hole...
  • Page 82 Summit Models A32F0EC TOO LONG STRAP 1. Skis lift off the ground A32E19A 1. Loosen lock nut, turn knob accordingly then retighten lock nut...
  • Page 83 A32F0EA TOO SHORT STRAP 1. Heavy steering A32E19B 1. Loosen lock nut, turn knob accordingly then retighten lock nut...
  • Page 84 5. Front Springs — Handling Ride at moderate speed and check for proper handling. Adjust front springs accordingly. WARNING Always adjust both front springs to same position. A32F0EA TYPICAL — PROPER ADJUSTMENT 1. Good handling and comfortable steering...
  • Page 85 Some Models A32F0EA TYPICAL — TOO SOFT OF ADJUSTMENT 1. Bad handling A32F1CA 1. Increase spring preload 2. Position number...
  • Page 86 A32F0EA TYPICAL — TOO HARD OF ADJUSTMENT 1. Steering hard to turn A32F1CB 1. Decrease spring preload 2. Position number CAUTION: Make sure that both front springs are still preloaded when front of vehicle is off the ground.
  • Page 87 Some Models A32F0EA TOO SOFT OF ADJUSTMENT 1. Bad handling A03F2IA 1. Increase spring preload...
  • Page 88 A32F0EA TOO HARD OF ADJUSTMENT 1. Steering hard to turn A03F2JA 1. Decrease spring preload...
  • Page 89 6. Rear Shock Motion Ratio — Damping Strength Some Models Only Rear shock motion ratio can be adjusted according to driver and pas- senger weight and/or trail condition. There are two adjustment positions. A32F0HA SC-10 AND SC-10 II SUSPENSIONS 1. Soft position 2.
  • Page 90 A32F22A SC-10 III SUSPENSION 1. Soft position 2. Firm position To adjust, loosen nut, move bolt to desired position then torque nut to 24 N•m (18 lbf•ft). 7. Rear Shock Valving — Damping Strength Legend SE Only Rear shock valving can be adjusted according to driver and passenger weight and/or trail condition.

  • Page 91: Troubleshooting Chart

    PROBLEM CORRECTIVE MEASURES Front suspension – Check ski alignment and camber angle wandering adjustment. See an authorized SKI-DOO dealer. – Reduce ski ground pressure. • Reduce front suspension spring preload. • Increase center spring preload. • Reduce rear spring preload.

  • Page 92: Fuel And Oil

    FUEL AND OIL Recommended Fuel Use regular unleaded gasoline, available from most service stations or oxygenated fuel containing less than 10% of ethanol or 5% of methanol. The gasoline used must have an octane number (R + M)/2 of 87 or higher. NOTE: In most service station pump octane number corresponds to (R + M)/2 octane number.

  • Page 93: Recommended Oil

    CAUTION: Use only oil that flows at - 40°C (- 40°F). Do not mis- match oil reservoir cap with fuel tank cap. Oil reservoir cap is identified OIL. Oil is contained in the oil injection reservoir. Use only two-stroke engine injection oil sold by authorized SKI-DOO dealers. MODEL OIL TYPE...

  • Page 94: Cold Weather Carburetion Modifications

    10 hours of operation — 500 km (300 miles) — or 30 days after the purchase, whichever comes first, your snowmobile be checked by an authorized SKI-DOO dealer. This inspection will give you the opportunity to discuss the unanswered questions you may have encountered during the first hours of operation.

  • Page 95: Pre-Operation Check

    • Check fuel and injection oil for levels and leaks. Replenish as nec- essary and see an SKI-DOO authorized dealer in case of any leaks. • Open or close heated carburetor valve according to outside tem-...

  • Page 96: Pre-Operation Check List

    • Verify that air filter(s) is free of snow, if so equipped. WARNING All adjustable features should be positioned at optimal setting. Securely tighten all adjustment locks. • All storage compartments must be properly latched and they must not contain any heavy or breakable objects. PRE-OPERATION CHECK LIST ✔...

  • Page 97: Operating Instructions

    OPERATING INSTRUCTIONS WARNING Proceed with pre-operation check list before riding. Principle of Operation Propulsion Depressing throttle lever increases engine RPM causing the drive pulley to engage. For most models engine RPM must be between 2500 and 4200 before drive pulley engagement will occur. Outer sheave of drive pulley moves toward inner sheave, forcing drive belt to move upward on the drive pulley and simultaneously forcing the sheaves apart on the driven pulley.

  • Page 98: Starting The Engine

    Starting the Engine WARNING Operator and passenger (if applicable) must be properly seat- ed before starting engine. • Re-check throttle control lever operation. • Ensure that engine cut-out switch is in the ON position. • Ensure that tether cut-out cap is set in place and that cord is at- tached to your clothing.
  • Page 99 Warm Engine Starting Start the engine without any choke. If the engine will not start after two pulls of the rope or two 5 second attempts with the electric starter move choke lever to position 1. Start the engine without acti- vating the throttle lever.

  • Page 100: Emergency Starting

    Emergency Starting The engine can be started with the emergency starter rope supplied with the tool kit. Remove belt guard. WARNING Do not wind starting rope around your hand. Hold rope by the handle only. Do not start the snowmobile by the drive pulley unless it is a true emergency situation.
  • Page 101 Attach the other end of emergency rope to the starter clip supplied in the tool kit. Hook up clip on drive pulley. Wind the rope tightly around drive pulley. When pulled, pulley must rotate counterclockwise. A19D13A TYPICAL — TRA TYPE DRIVE PULLEY 1.
  • Page 102 A03D25A TYPICAL — BOMBARDIER LITE DRIVE PULLEY TYPE 1. Knot on this side Start engine as described in COLD ENGINE STARTING or WARM ENGINE STARTING according to engine temperature. Pull the rope using a sharp, crisp pull so the rope comes free of the drive pulley.

  • Page 103: Shutting Off The Engine

    Shutting Off the Engine Release throttle lever and wait until engine has returned to idle speed. Shut off the engine using either ignition switch (fan cooled models only), engine cut-out switch or tether cut-out switch. WARNING Never leave key and tether cord on vehicle when not in oper- ation.

  • Page 104: Post-Operation Care

    Engine overheating indicator will light up if engine is too hot. Reduce snowmobile speed and run snowmobile in loose snow or stop engine immediately. Check for adequate coolant level. See an authorized SKI-DOO dealer. Fuel Flooded Engine All Models WARNING Do not hold throttle partially or fully open when starting a fuel flooded engine.

  • Page 105: Rear Suspension Slider Shoe Sticking

    Run snowmobile on a surface covered by snow or drive snowmobile at very slow speed. Have slider shoes inspected by an authorized SKI-DOO dealer.

  • Page 106: Periodic Maintenance Chart

    ➂ MONTHLY OR EVERY 800 km (500 miles) ➃ ONCE A YEAR OR EVERY 3200 km (2000 miles) ➄ STORAGE (To be performed by SKI-DOO dealer) ➅ PRESEASON PREPARATION (To be performed by SKI-DOO dealer) ➀ ➁ ➂ ➃ ➄ ➅ PERIODIC MAINTENANCE CHART...
  • Page 107 ➀ ➁ ➂ ➃ ➄ ➅ PERIODIC MAINTENANCE CHART Brake Fluid Level Brake Fluid (change once a year) Brake Condition Drive Chain Tension Countershaft Lubrication** Chaincase Oil Level Chaincase Oil Change Lubrication of Drive Axle End Bearing** Handlebar Bolts. Retorque to 26 N•m (19 lbf•ft) Steering and Front Suspension Mechanism Lubrication**...

  • Page 108: Fluid Levels

    FLUID LEVELS WARNING It is recommended that the assistance of an authorized SKI- DOO dealer be periodically obtained on other components/ systems not covered in this guide. Unless otherwise specified, engine must be cold and not running. The tether cord cap must be removed for all maintenance procedures.
  • Page 109 NOTE: It is normal to find metallic particles stuck to dipstick magnet. If bigger pieces of metal are found, see an authorized SKI-DOO dealer. Remove metal particles from magnet. Refill up to upper mark using BOMBARDIER synthetic chaincase oil (P/N 413 803 300 — 12 x 355 mL).

  • Page 110: Oil Injection System

    Oil Injection System Always maintain a sufficient amount of recommended oil in the injec- tion oil reservoir. CAUTION: Never allow oil reservoir to be almost empty. Do not mismatch oil reservoir cap with fuel tank cap. Install cap that is identified OIL.

  • Page 111: Cooling System

    NOTE: When checking level at low temperature it may be slightly lower then mark. If additional coolant is necessary or if entire system has to be refilled, refer to an authorized SKI-DOO dealer. A32C29A 1. Coolant tank 2. COLD LEVEL line...

  • Page 112: Maintenance

    MAINTENANCE WARNING It is recommended that the assistance of an authorized SKI- DOO dealer be periodically obtained on other components/ systems not covered in this guide. Unless otherwise specified, engine must be cold and not running. The tether cord cap must be removed for all maintenance procedures.

  • Page 113: Belt Guard Removal And Installation

    Lift rear of vehicle until track is clear of the ground. Install on a snow- mobile mechanical stand. NOTE: Do not release track tension. Belt Guard Removal and Installation 1. Turn off engine cut-out switch. Open hood. 2. Open retainer to release pin then pull belt guard out of vehicle. A32C05A TYPICAL 1.
  • Page 114 When reinstalling belt guard, position its cut-away toward front of snowmobile. Refer to decal in belt guard. Place belt guard in front tabs first, then snap rear part in retainer. A32C06A TYPICAL 1. Slots NOTE: Belt guard is purposely made slightly oversize to maintain ten- sion on its pins and retainers preventing undue noise and vibration.

  • Page 115: Drive Belt Removal/Installation

    Drive Belt Removal/Installation NOTE: Removal and installation of drive belt is easier when driven pulley is held with brake so that it can not rotate. Apply parking brake, for this purpose. Turn off engine cut-out switch. Open hood and remove belt guard. Open the driven pulley with the drive belt installer/remover provided in tool bag.
  • Page 116 A32D13A TYPICAL 1. Tighten to open pulley Slip the belt over the top edge of the sliding half of driven pulley, as shown in previous photo. Remove access panel from bottom pan. A32H07A 1. Push tab down and remove panel out of bottom pan...
  • Page 117 A32H06A PULL PANEL OUT OF BOTTOM PAN Slip belt under drive pulley then, remove it from vehicle. A32D14A TYPICAL...
  • Page 118 Clean sheaves of both pulleys using BOMBARDIER Parts Cleaner (P/N 413 711 809). To install the drive belt, reverse the removal procedure, however pay attention to the following: The maximum drive belt life span is obtained when the belt has the proper rotation direction.

  • Page 119: Drive Chain Tension

    Drive Chain Tension Remove hair pin. Fully tighten tensioner adjustment screw by hand, then back off only far enough for hair pin to engage in locking hole. A32D03A TYPICAL 1. Hair pin 2. Adjustment screw TRA Drive Pulley Adjustment The drive pulley is factory calibrated to transmit maximum engine power at a predefined RPM.
  • Page 120 NOTE: Use precision digital tachometer for engine RPM adjustment. NOTE: The adjustment has an effect on high RPM only. To adjust, turn calibration screws. Calibration screw has a notch on top of its head. A16D0FA 1. Notch Governor cup has 6 positions numbered 2 to 6. Note that in position 1 the number is substitued by a dot (due to its location on casting).
  • Page 121 Each number modifies maximum engine RPM by about 200 RPM. Lower numbers decrease engine RPM in steps of 200 RPM and higher numbers increase it in steps of 200 RPM. Example: Calibration screw is set at position 4 and is changed to position 6. So maximum engine RPM is increased by 400 RPM.

  • Page 122: Drive Belt Condition

    RPM with frozen track, fast starts without warm-up period, burred or rusty sheave, oil on belt or distorted spare belt. Contact an authorized SKI-DOO dealer. Check the drive belt width. Replace the drive belt if width is less than the minimum width recommended in SPECIFICATIONS section.

  • Page 123: Rear Suspension Condition

    If worn or cut, or if track fibers are exposed, or if missing or defective inserts or guides are noted; contact an authorized SKI-DOO dealer. CAUTION: Do not modify track, including by installing traction enhancing products.
  • Page 124 CAUTION: Too much tension will result in power loss and exces- sive stresses on suspension components. To adjust tension: – On some models, remove wheel cap. – Loosen the rear idler wheel retaining screws. – Turn adjustment screws to adjust. If correct tension is unattainable, contact an authorized SKI-DOO dealer.
  • Page 125 A30F03A TYPICAL 1. Adjustment screw 2. Loosen screw 3. Wheel cap removing Alignment NOTE: Track tension and alignment are inter-related. Do not adjust one without the other. WARNING Before checking track alignment, ensure that the track is free of all particles which could be thrown out while track is rotat- ing.
  • Page 126 Start the engine and accelerate slightly so that track barely turns. This must be done in a short period of time (1 to 2 minutes). Check that the track is well centered; equal distance on both sides between edges of track guides and slider shoes. A01F05A TYPICAL 1.

  • Page 127: Steering And Front Suspension Mechanism

    SKI-DOO dealer. Wear and Condition of Skis and Runners Check the condition of the skis, ski runners and ski runner carbides. If worn, contact your authorized SKI-DOO dealer for replacement. WARNING Excessively worn skis and/or ski runners will affect snowmobile...

  • Page 128: Exhaust System

    Exhaust System The tail pipes of the muffler should be centered with the exit holes in the bottom pan. Exhaust system must be free of rust or leaks. Make sure that gear clamps are properly tightened. The exhaust system is designed to reduce noise and to improve the total performance of the engine.
  • Page 129 A32H0RA REMOVAL OF RIGHT SIDE PRIMARY FILTER GRILL A32H0SA REMOVAL OF FILTER FROM ITS GRILL...
  • Page 130 A32H0OA TYPCIAL — SECONDARY FILTER INSTALLED ON AIR SILENCER Check that the air silencer is clean and dry and properly reinstall the filter. CAUTION: Snowmobile engines have been calibrated with the filter installed. Operating the snowmobile without it may cause engine damage.

  • Page 131: Headlight Beam Aiming

    Headlight Beam Aiming Turn knob to adjust beam height. A32E01A TYPICAL 1. Knob Bulb Replacement Always check light operation after bulb replacement. Headlight CAUTION: Never touch glass portion of an halogen bulb with bare fingers, it shortens its operating life. If glass is touched, clean it with isopropyl alcohol which will not leave a film on the bulb.
  • Page 132 A32E02A 1. Bulb connector 2. Rubber boot Turn bulb locking ring counterclockwise to remove it. Detach the bulb and replace. Properly reinstall parts. A30E05A 1. Locking ring...
  • Page 133 Instrument(s) All Models Remove air duct from underneath hood. A32E03A TYPICAL 1. Remove these screws...

  • Page 134: Towing The Vehicle

    Bulb socket is always behind the instrument under a black rubber boot. Pull rubber boot and socket to expose bulb. Pull bulb out of socket. A32E04A TYPICAL — ALL MODELS 1. Instruments sockets Taillight If taillight bulb is burnt, expose the bulb by removing the red plastic lens. To remove, unscrew the 2 lens screws.

  • Page 135: Storage And Preseason Preparation

    STORAGE AND PRESEASON PREPARATION WARNING Have an authorized SKI-DOO dealer inspects fuel and oil sys- tems integrity as specified in Periodic Maintenance Chart. Storage It is during summer, or when a snowmobile is not in use for more than one month that proper storage is a necessity.

  • Page 136: Troubleshooting

    Start engine following usual starting procedure. If engine continues to flood, see an authorized SKI-DOO dealer. 4. No fuel to the engine Check fuel tank level; check fuel filter; (spark plug dry when removed).
  • Page 137 Check item 4 of “Engine turns over but fails to start”. 5. Carburetor adjustments. Contact an authorized SKI-DOO dealer. 6. Drive belt worn too thin. If the drive belt has lost more than 3 mm (1/8 in) of its original width, it will affect vehicle performance.
  • Page 138 Replace as required. 4. Too much oil supplied to engine. Improper oil pump adjustment, refer to an authorized SKI-DOO dealer. 5. Water in fuel. Drain fuel system and refill with fresh fuel. SYMPTOM: Snowmobile cannot reach full speed.

  • Page 139: Specifications

    SPECIFICATIONS MX-Z 380 F MX-Z 500 F LEGEND 380 F LEGEND 500 F GENERAL GRAND TOURING GRAND TOURING 380 F 500 F Engine – Maximum Power 6900 7000 Engine Speed Drive Belt – Part Number 415 060 600 415 060 600 –...
  • Page 140 MX-Z 500/600 GENERAL SUMMIT 500 F LEGEND 500/600 Engine – Maximum Power 7000 8000 Engine Speed Drive Belt – Part Number 415 060 600 414 860 700 – Width of a New mm (in) 34.7 (1.366) 34.9 (1.374) Belt – Wear Limit Width mm (in) 32.3 (1.272) 32.5 (1.280)
  • Page 141 SUMMIT 600/700 GRAND TOURING GENERAL GRAND TOURING 500/600 Engine – Maximum Power 8000 8000 Engine Speed Drive Belt – Part Number 414 860 700 417 300 127 – Width of a New mm (in) 34.9 (1.374) 36.35 (1.431) Belt – Wear Limit Width mm (in) 32.5 (1.280) 33.95 (1.337)
  • Page 142 MX-Z 700 MX-Z 800 GENERAL LEGEND 700 LEGEND 800 Engine – Maximum Power 8000 7850 Engine Speed Drive Belt – Part Number 417 300 127 417 300 127 – Width of a New mm (in) 36.35 (1.431) 36.35 (1.431) Belt –...
  • Page 143 SUMMIT 800 GENERAL GRAND TOURING 800 Engine – Maximum Power 7850 Engine Speed Drive Belt – Part Number 417 300 127 – Width of a New mm (in) 36.35 (1.431) Belt – Wear Limit Width mm (in) 33.95 (1.337) Spark Plug –...

  • Page 144: Change Of Address Or Ownership

    Please provide your name, address, phone number, vehicle serial number and date it was stolen. Bombardier will provide a list of stolen units to all SKI-DOO dealers on a monthly basis to aid in recovery of such units to their owners.

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