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

    The following are trademarks of Bombardier Inc. ® BOMBARDIER GRAND TOURING ® FORMULA* SKI-DOO Printed in Canada (Mmo2001-002a.fm GM) ® *Trademarks of Bombardier Inc. and/or its subsidiaries. © 2000 Bombardier Inc. All rights reserved.
  • Page 3 2001 SKI-DOO OPERATOR’S GUIDE This guide is applicable to the following ZX series models: Formula Deluxe STD 500 Formula Deluxe STD 600 Formula Deluxe GS 700 Formula Deluxe GSE 600/700 Grand Touring STD 500/600 Grand Touring GS 700 MX Z STD 500/600/700...
  • 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

    ® WARRANTY 2001 SKI-DOO SNOWMOBILE ......OFTEN ASKED QUESTIONS........... LIST OF CUSTOMER RELATIONS OFFICES ......AUTHORIZED SKI-DOO DEALERS ......... HOW TO IDENTIFY YOUR SNOWMOBILE ......Vehicle Identification Number Location........Model Number ................Engine Serial Number Location ..........ON-VEHICLE IMPORTANT INSTRUCTIONS ......
  • Page 7 24) Electric Fuel Level Gauge ............ 25) Heated Grip Switch .............. 26) Heated Throttle Lever Switch ..........27) Electric Visor Jack Connector ..........28) Electric Valving Shock Switch ..........29) Electric Valving Shock Pilot Lamp (Amber) ......30) Hood Latches ............... 31) Adjustable Mirrors..............
  • Page 8 POST-OPERATION CARE ............SPECIAL OPERATIONS ............Riding at High Altitudes............. Engine Overheating..............Gas Flooded Engine ..............Rear Suspension Slider Shoe Sticking........PERIODIC MAINTENANCE CHART......... FLUID LEVELS................Brake System ................Chaincase/Gearbox Oil Level............. Oil Injection System ..............Cooling System ................. MAINTENANCE ............... Belt Guard Removal and Installation .........

  • 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 2001 Ski-Doo Snowmobile

    All genuine Bombardier accessories, installed by an authorized SKI-DOO dealer at the time of delivery of the new and unused SKI-DOO, carry the same War- ranty Coverage Period as for the SKI-DOO snowmobile. 2. WHAT BOMBARDIER WILL DO...
  • Page 11 BOMBARDIER reserves the right to modify this warranty at any time, being understood that such modification will not alter the warranty conditions appli- cable to the SKI-DOO snowmobile sold while this warranty is in effect. 6. CONSUMER ASSISTANCE a. In the event of a controversy or a dispute arising in connection with this BOMBARDIER LIMITED WARRANTY, BOMBARDIER suggests that you try to resolve the issue at the dealership level.

  • Page 12: Bombardier International Limited Warranty 2001 Ski-Doo Snowmobile

    SKI-DOO dealer. 3. CONDITION TO HAVE WARRANTY WORK VALIDATED The customer must notify a local authorized SKI-DOO dealer within two (2) days of the appearance of a defect in material and/or workmanship and present to the servicing authorized SKI-DOO dealer the SKI-DOO Warran-...
  • Page 13 BOMBARDIER or any other person. Every SKI-DOO snowmobile is sold with the English version of this war- ranty. A specific SKI-DOO International Distributor may elect to translate...

  • Page 14: Often 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 15 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 16: List Of Customer Relations Offices

    Telephone: (715) 848-5957 Fax: (715) 848-6879 OTHER COUNTRIES For customer relations, contact your local distributor. Your local SKI-DOO dealer can provide distributor contact informa- tion. AUTHORIZED SKI-DOO DEALERS For Canada and USA Only To find the nearest authorized SKI-DOO dealer, dial: 1-800-375-4366.

  • Page 17: How To Identify Your Snowmobile

    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 18: Model Number

    Model Number Model number is part of vehicle identification number. 2 B P S 1 5 9 2 9 Y 1 0 0 0 0 0 1 Model number Serial number Model year: y = 2000 1 = 2001 2 = 2002 etc.

  • Page 19: On-Vehicle Important Instructions

    ON-VEHICLE IMPORTANT INSTRUCTIONS Please read the following instructions carefully before operating snowmobile. 5 6 7 A32A02C LOCATION OF IMPORTANT INSTRUCTIONS Instruction 1 A01A1XB TYPICAL — SUMMIT MODELS...
  • Page 20 Instruction 2 A01A1ZD ALL MODELS Instruction 3 A32A08A TYPICAL — ALL MODELS WITH REVERSE...
  • Page 21 Instruction 4 SINGLE SEAT MODELS DOUBLE SEAT MODELS A02A0EA...
  • Page 22 Instruction 5 A02A07C ALL MODELS Instruction 6 A02A06C ALL MODELS...
  • Page 23 Instruction 7 A01A24D TYPICAL — ALL MODELS Instruction 8 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 24: Controls/Instruments/Equipment

    Instruction 9 CAUTION: In order to avoid severe engine damage, use the “sea level” calibration kit when operating this vehicle below 4000 feet (1200 meters) in altitude. Please see your local dealer for more information. ATTENTION: Afin d’éviter des dommages importants au moteur, l’utilisation de ce véhicule à...
  • Page 25 A32A0IA TYPICAL 19 18 16 17 22 13 10 20 24 A32A0JA TYPICAL...

  • Page 26: 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 re- turn to idle position when released.

  • Page 27: Injection Oil Level/Parking Brake Pilot Lamp (Red)

    The handlebar controls the direction of travel of the snowmobile. As the handlebar is rotated to right or left, the skis are turned in the direction of intented travel. Handlebar height is adjustable. See an authorized SKI-DOO dealer. 6) Holding Strap Holding strap provides a grip for driver when side-hilling.

  • Page 28: Gear Shift Lever

    7) Gear Shift Lever WARNING These snowmobiles are capable of a fast reverse. Always re- main seated and apply the brake before shifting. Come to a complete stop then change gear. Ensure the path behind is clear of obstacles or bystanders. Fast reverse while turning, could result in loss of stability.

  • Page 29: Ignition Switch

    8) Ignition Switch Electric Start Models Only The lights are automatically ON whenever the engine is running. A32H0MA 1. OFF 2. ON 3. START Key operated, 3-position switch. To start engine, turn key to START position and hold. See illustration above. CAUTION: Do not hold key at START position more than 15 sec- onds.

  • Page 30: Tether Cut-Out Switch

    9) Tether Cut-Out Switch General Lights are automatically ON whenever the engine is running. There is no ignition key on certain models, the tether cut-out system shuts-off engine if the driver accidently falls off the vehicle and the DESS (Digitally Encoded Security System) performs the same function as a key.
  • Page 31 DESS (Digitally Encoded Security System) Description This system is a deterrent against theft. The tether cord 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 is installed the engine can not reach engage- ment speed required to move vehicle.

  • Page 32: 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 33 A30E03A TYPICAL 1. ON 2. OFF 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.

  • Page 34: Headlamp Dimmer Switch

    WARNING If the switch has been used in a mechanical malfunction, the source of malfunction should be determined and corrected before restarting engine. 12) Headlamp Dimmer Switch Located on left side of handlebar, allows selection of headlamp beam. Note that lights are automatically ON whenever the engine is running.

  • Page 35: Choke Lever

    15) 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. 16) Speedometer Direct-reading dial indicates the speed of the snowmobile in kilome- ters per hour (miles per hour for the USA).

  • Page 36: Trip Meter Reset Button

    19) 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 37: Tachometer

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

  • Page 38: Temperature Gauge

    A30H0GA TYPICAL 1. Normal 2. Overheat 22) 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 39: Fuel Tank Cap/Gauge

    23) 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 40: Electric Fuel Level Gauge

    24) 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 25) Heated Grip Switch Three-position toggle switch. Select the desired position to keep your hands at a comfortable temperature.

  • Page 41: Heated Throttle Lever Switch

    26) 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 42: 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 2.

  • Page 43: Hood Latches

    30) 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. 31) Adjustable Mirrors Each mirror can be adjusted to suit driver’s preference. WARNING Adjust with vehicle at rest in a safe place.

  • Page 44: Adjustable Toeholds

    32) 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. A32H0VA RIGHT SIDE SHOWN 1. Toehold 2. After adjustment retighten bolts to 10 N•m (89 lbf•in)

  • Page 45: Heated Carburetor Valve

    33) Heated Carburetor Valve Turn valve on when riding at 5°C (41°F) or colder temperatures. A32I0AA 1. ON 2. OFF...

  • Page 46: Adjustable Backrest

    34) 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. A32H0PA 1. Turn adjustment knob 2. Lift adjustment lock (both sides) Secure adjustment locks after desired position is obtained.

  • Page 47: Rear Passenger Heated Grip Switch

    36) 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 grip switch 37) Hood Grills When riding on powdered snow, close plastic sliding hood grills from underneath hood.
  • Page 48 A32H03A TO CLOSE, SQUEEZE CLOSING TABS BETWEEN THUMB AND INDEX A32H04A TO OPEN, SQUEEZE OPENING TABS BETWEEN THUMB AND INDEX...

  • Page 49: Storage Compartment

    38) 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. 39) Tool Bag A tool bag containing tools for basic maintenance is supplied with the vehicle.

  • Page 50: 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 deter- mined and corrected before restarting. See an SKI-DOO autho- rized dealer for servicing. A32E0PA 1. 30 A starting system fuse...
  • Page 51 A32E0QA 1. 20 A starting system 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 52: Spare Spark Plug Holder

    41) 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. A32C0RA 1. Spare spark plugs installed in holder...

  • Page 53: Spare Drive Belt Holder

    42) Spare Drive Belt Holder A spare drive belt can be placed in front section of bottom pan. A32H0TA TYPICAL — SPARE DRIVE BELT INSTALLED IN BOTTOM PAN NOTE: Spare drive belt is not supplied with the snowmobile. 43) Front Grab Handles/Front Bumper To be used whenever front of snowmobile requires manual lifting.

  • Page 54: Adjustable Suspensions

    CAUTION: Do not use skis to pull or lift snowmobile. 44) 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. A32F0GA TYPICAL 1. Decal...

  • Page 55: 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. A32F0FB TYPICAL 1.

  • Page 56: Guidelines To Adjust Suspension

    Guidelines to Adjust Suspension The best way to set up suspension, is to start from factory settings then customize each adjustment one at a time. Adjustments 2 through 7 are interrelated. It may be necessary to readjust center spring after adjusting front springs for instance. Test run the snow- mobile under the same conditions;...
  • Page 57 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 58 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 59 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 60 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 61 A32F0EA TYPICAL — TOO HARD OF ADJUSTMENT 1. Steering less aggressive A32F01B TYPICAL 1. Use adjuster wrench provided in tool bag to decrease preload...
  • Page 62 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 63 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 64 4. Stopper Strap — Weight Transfer Ride at low speed then fully accelerate. Note steering behavior. Ad- just stopper strap length accordingly. At rest 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 65 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 66 A32F0EA TYPICAL — TOO SHORT STRAP 1. Heavy steering A03F0QB TYPICAL 1. Increase strap length by bolting to a different hole...
  • Page 67 Summit Models A32F0EC TOO LONG STRAP 1. Skis lift off the ground A32F1BA 1. Loosen lock nut, turn knob accordingly then retighten lock nut...
  • Page 68 A32F0EA TOO SHORT STRAP 1. Heavy steering A32F1BB 1. Loosen lock nut, turn knob accordingly then retighten lock nut...
  • Page 69 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 70 Some Models A32F0EA TYPICAL — TOO SOFT OF ADJUSTMENT 1. Bad handling A32F1CA 1. Increase spring preload 2. Position number...
  • Page 71 A32F0EA TYPICAL — TOO HARD OF ADJUSTMENT 1. Steering hard to turn A32F1CB 1. Decrease spring preload 2. Position number...
  • Page 72 CAUTION: Make sure that both front springs are still preloaded when front of vehicle is off the ground. Some Models A32F0EA TOO SOFT OF ADJUSTMENT 1. Bad handling A03F2IA 1. Increase spring preload...
  • Page 73 A32F0EA TOO HARD OF ADJUSTMENT 1. Steering hard to turn A03F2JA 1. Decrease spring preload...
  • Page 74 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 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).

  • Page 75: 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 76: Fuel And Oil

    FUEL AND OIL Recommended Fuel Use regular unleaded gasoline, available from most service stations or gasohol containing less than 10% of ethanol or methanol. The fuel 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 77: 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 78: 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 79: Pre-Operation Check

    • Verify that skis and steering operate freely. Check corresponding action skis versus handlebar. • 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.

  • Page 80: 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 81: 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 82: 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 emergency 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 83 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 84: Emergency Starting

    Emergency Starting The engine can be started with the emergency starter rope supplied with the tool kit. Do not start the snowmobile by the drive pulley unless it is a true emergency situation. Have the snowmobile re- paired as soon as possible. Remove belt guard.
  • Page 85 Wind the rope tightly around drive pulley. When pulled, pulley must rotate counterclockwise. Tie a knot near clip. Hook up clip on drive pulley and wind counter- clockwise up to 3 turns. A19D13A 1. Clip Start engine as described in COLD ENGINE STARTING or WARM ENGINE STARTING according to engine temperature.

  • Page 86: 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, emergency cut-out switch or tether cut-out switch. WARNING Never leave key and tether cord on vehicle when not in oper- ation.

  • Page 87: Special Operations

    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. Gas Flooded Engine All Models WARNING Do not hold throttle partially or fully open when starting a gas flooded engine.

  • Page 88: 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 PRE-SEASON PREPARATION (To be performed by SKI-DOO dealer) ➀ ➁ ➂ ➃ ➄ ➅ PERIODIC MAINTENANCE CHART...
  • Page 89 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 or Gearbox Oil Level Chaincase or Gearbox Oil Change Lubrication of Drive Axle End Bearing** Handlebar Bolts, Retorque to 26 N•m (19 lbf•ft) Steering and Front Suspension Mechanism...

  • Page 90: Fluid Levels

    With snowmobile on a level surface, check the oil level by removing dipstick. Oil level must be between lower and upper marks. 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.
  • Page 91 Remove metal particles from magnet. Refill up to upper mark using BOMBARDIER synthetic chaincase oil (P/N 413 803 300 — 12 x 355 mL). CAUTION: Use BOMBARDIER synthetic chaincase oil or a suit- able equivalent when servicing. Do not mix synthetic oil with other oils.

  • Page 92: Oil Injection System

    Oil Injection System Always maintain a sufficient amount of recommended BOMBARDIER in the injection 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. WARNING Check level and refill every time you refuel.

  • Page 93: 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 94: 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 95 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 96: Drive Belt Removal/Installation

    Drive Belt Removal/Installation Remove tether cord cap. Open hood and remove belt guard. Open the driven pulley with the drive belt installer/remover provided in tool bag. A03D2PA DRIVE BELT INSTALLER/REMOVER Screw drive belt installer/remover in the free threaded hole and tight- en to open the pulley.
  • Page 97 Slip the belt over the top edge of the sliding half, as shown in previous photo. Remove access panel from bottom pan. A32H07A 1. Push tab down and remove panel out of bottom pan A32H06A PULL PANEL OUT OF BOTTOM PAN...
  • Page 98 Slip belt under drive pulley then, remove it from vehicle. A32D14A TYPICAL To install the drive belt, reverse the removal procedure, however pay attention to the following:...
  • Page 99 The maximum drive belt life span is obtained when the belt has the proper rotation direction. See arrow on belt. A32D15A TYPICAL 1. Arrow pointing front of vehicle CAUTION: Do not force or use tools to pry the belt into place, as this could cut or break the cords in the belt.

  • Page 100: 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 101 NOTE: Use precision digital tachometer for engine RPM adjustment. NOTE: The adjustment has an effect on high RPM only. To adjust, modify ramp end position by turning calibration screws. Calibration screw has a notch on top of its head. A16D0FA 1.
  • Page 102 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 103: 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 104: Suspension Stopper Strap 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. Do not modify track, including by installing traction enhancing prod- ucts.
  • Page 105 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 106 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 107 A01F05A TYPICAL 1. Guides 2. Slider shoes 3. Equal distance To correct, stop the engine: Loosen rear wheel screws tighten the adjustment screw on side where the slider shoe is the farthest from the track insert guides. A01F0BA TYPICAL 1. Guides 2.

  • Page 108: Steering And Front Suspension Mechanism

    Reposition snowmobile on ground. Steering and Front Suspension Mechanism Visually inspect steering and front suspension mechanism for tight- ness of components (steering arms, control arms and links, tie rods, ball joints, ski coupler bolts, etc.) If necessary, contact an authorized SKI-DOO dealer.

  • Page 109: Wear And Condition Of Skis And Runners

    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 snowmo- bile control.
  • Page 110 A32H0RA REMOVAL OF RIGHT SIDE PRIMARY FILTER GRILL A32H0SA REMOVAL OF FILTER FROM ITS GRILL...
  • Page 111 A32H0OA 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 112: 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 113 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 114 Instrument(s) All Models Remove air duct from underneath hood. A32E03A TYPICAL 1. Remove these screws...
  • Page 115 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.

  • Page 116: Storage And Pre-Season Preparation

    STORAGE AND PRE-SEASON 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 117: Troubleshooting

    If a failure of the fuel pump or carburetor has occurred, contact an authorized SKI-DOO dealer. 5. Spark plug/ignition (no spark). Remove spark plug(s) then reconnect to spark cap. Check that emergency...
  • Page 118 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 119 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 120: Specifications

    SPECIFICATIONS MX Z 500 Summit 600 MX Z 600 GENERAL Grand Touring Formula Deluxe 500/600 500/600 Engine – Maximum Power 8000 8000 Engine Speed Drive Belt – Part Number 414 860 700 414 860 700 – Width of a New mm (in) 34.9 (1.374) 34.9 (1.374)
  • Page 121 MX Z 700 Summit 700 GENERAL Formula Deluxe Grand Touring Engine – Maximum Power 8000 8000 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 122 GENERAL MX Z 800 Summit 800 Engine – Maximum Power 7750 7750 Engine Speed Drive Belt – Part Number 417 300 150 417 300 150 – Width of a New mm (in) 37.3 (1.469) 417 300 150 Belt – Wear Limit Width mm (in) 34.9 (1.374) 34.9 (1.374)
  • Page 123 ➀ Measure gap between slider shoe and bottom inside of track when exerting a downward pull of 7.3 kg (16 lbf) to the track. ➁ Equal distance between edges of track guides and slider shoes. ➂ Regular unleaded gasoline with a minimum octane number of 87 (R + M)/2.

  • Page 124: 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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