Ski-Doo ZX series Operator's Manual
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  • Page 2: Safety Warning

    In USA, products are distributed by Bombardier Motor Corporation of America. In Canada, products are distributed by Bombardier Inc. The following are trademarks of Bombardier Inc or its subsidiaries. ® ® BOMBARDIER ROTAX SKANDIC ® SKI-DOO D.E.S.S. ® ® MX-Z SUMMIT LEGEND RENAGADE ADRENALINE HIGHMARK Printed in Canada (mmo2004-003a.fm GM)
  • Page 3 2004 SKI-DOO OPERATOR’S GUIDE This guide is applicable to the following ZX series models: ® ® Skandic , MX-Z , Summit Fan and Legend and to the following REV series models: ® MX Z - REV , Summit, GSX...
  • Page 4 Make sure you read and understand the content of this Operator’s Guide. For any questions pertaining to the warranty and its application, consult the WARRANTY section in this guide, and/or an authorized SKI-DOO dealer. This guide uses the following safety alert symbol in conjunction with signal words to indicate a potential personal injury hazard.
  • Page 5 At delivery, you were also informed of the warranty coverage and completed the Warranty Registration Form which is to be sent to us for processing. The information and components/system descriptions contained in this guide are correct at time of publication. Bombardier Inc., howev- er maintains a policy of continuous improvement of its products with- out imposing upon itself any obligation to install them on products previously manufactured.
  • Page 6: Table Of Contents

    LIST OF HOT PARTS..............LIST OF MOVING PARTS ............BOMBARDIER LIMITED WARRANTY NORTH AMERICA ..INTERNATIONAL BOMBARDIER LIMITED WARRANTY ..FREQUENTLY ASKED QUESTIONS ........AUTHORIZED SKI-DOO DEALERS ......... HOW TO IDENTIFY YOUR SNOWMOBILE ......Vehicle Description Decal............Serial Numbers................ON-VEHICLE IMPORTANT INSTRUCTIONS ......
  • Page 7 17) Low Battery Voltage Pilot Lamp .......... 18) Engine Management System (EMS) Pilot Lamp....19) Rewind Starter Handle ............20) Choke Lever ................. 21) Speedometer ............... 22) Mode Button ................ 23) Odometer................24) Trip Meter ................25) Resetable Hourmeter............26) Tachometer ................27) Fuel Tank Cap/Gauge ............
  • Page 8 FUEL AND OIL................149 Recommended Fuel ..............149 Recommended Oil ..............150 COLD WEATHER CARBURETION MODIFICATIONS ..... 151 BREAK-IN PERIOD ..............152 Engine ..................152 Belt .................... 152 10-Hour Inspection ..............152 PRE-OPERATION CHECK ............153 PRE-OPERATION CHECK LIST ..........155 OPERATING INSTRUCTIONS ..........
  • Page 9 Brake Condition................204 Brake Adjustment ..............204 Rear Suspension Condition............204 Suspension Stopper Strap Condition ......... 204 Track Condition ................205 Track Tension and Alignment............. 205 Steering and Front Suspension..........210 Wear and Condition of Skis and Runners ........210 Exhaust System .................
  • Page 10: Safety Measures

    SAFETY MEASURES Observe the Following Warnings: The performance of some snowmobiles may significantly exceed that of other snowmobiles you have operated. Therefore, use by novice or inexperienced operators is not recommended. Basic training is required for the safe operation of any snowmobile. Study your Operator’s Guide paying particular attention to cautions and warnings.
  • Page 11 Never ride after consuming drugs or alcohol or if you feel tired or ill. Operate your snowmobile prudently. Speeding can be fatal. In many cases, you cannot react or respond quickly enough to the unexpected. Always ride at a speed which is suitable to the trail, weather conditions and your own ability.
  • Page 12 The engine and components used in a particular model should not be used on other models. Use of Rotax snowmobile engines in other than SKI-DOO snowmobiles is not recommended or autho- rized by Bombardier Inc.or its subsidiaries. Electronic reverse (RER...
  • Page 13: Safety Information

    SAFETY INFORMATION SAFETY INFORMATION...
  • Page 14: Introduction

    If the snowmobile is resold, please give the guide to the new owner for his awareness. An extra copy of the Operator’s Guide is available from your SKI-DOO snowmobile dealer at no charge. This safety information section is dedicated to safer snowmobiling.
  • Page 15: Safety Labeling

    SAFETY LABELING Safety standards for snowmobiles have been adopted by the Snowmo- bile Safety and Certification Committee (SSCC) of which Bombardier is a proud participating member. Assurance that your snowmobile meets these standards is easily checked by locating the Certification Label on a right vertical portion of the vehicle.
  • Page 16 HOW TO DRESS Proper snowmobile clothing should be worn. It should be comfort- able and not too tight. Always check the weather forecast before you go on a ride. Dress for the coldest weather expected. Thermal under- wear next to the skin also provides an important layer of insulation. Approved helmets are recommended at all times.
  • Page 17: A Word To All Snowmobilers

    We encourage you to have an Annual Safety Inspection of your snowmobile. Please contact an authorized SKI-DOO dealer for further details. Finally, we urge you to visit an authorized SKI-DOO dealer periodically for regular and safety maintenance, as well as snowmobile accessories you may require.
  • Page 18: Laws And Regulations

    TRANSPORTING AND TOWING Follow transporting and towing instructions explained further in this guide. LAWS AND REGULATIONS Federal, state, provincial and local government agencies have enact- ed laws and regulations pertaining to the safe use and operation of snowmobiles. It is your responsibility as a snowmobiler to learn and obey these laws and regulations.
  • Page 19 Be aware of inherent risks associated with riding off trails, such as avalanche and other natural or man made hazards or obstacles. Avoid road traveling. If you must do so and it is permitted, reduce speed. The snowmobile is not designed to operate or turn on pav- ing.
  • Page 20 Always show a new operator how to start and stop the vehicle. Indicate the correct riding positions and, above all else, only allow him to operate the snowmobile in a restricted flat area — at least until he is completely familiar with its operation. If there is a local snowmobile operator’s training course existing, have him enroll.
  • Page 21 Meadows sometimes have low areas where waters accumulate and freeze over in winter. This ice is usually glare ice. Attempting to turn or brake on this surface could cause your vehicle to spin out of control. Never brake or attempt speeding or turning on glare ice.
  • Page 22: Environment

    Safaris are both fun and enjoyable but don’t show off or overtake others in the group. A less experienced operator might try to do the same as you and fail. When riding with others, limit your abil- ities to the experience of others. Always cover your snowmobile when leaving it overnight or during extended periods of inactivity.
  • Page 23 Light Treading refers to more than the thread of our tracks. It’s a statement of concern, respect and willingness to take the lead and take action. It applies to the environment in general, its proper care and maintenance, its natural inhabitants and all enthusiasts and the public at large who enjoy the great outdoors.
  • Page 24 Finally, Light Treading is the sign of a smart snowmobiler. You don’t have to leave big tracks or careen through a virgin forest to show you can ride. So whether you’re driving a high performance Ski-Doo, a sporty MX-Z snowmobile or any other make or model, show you know what you’re doing.
  • Page 25: Vehicle Information

    VEHICLE INFORMATION...
  • Page 26: List Of Hot Parts

    LIST OF HOT PARTS All power train components. LIST OF MOVING PARTS All transmission, suspension and steering parts.
  • Page 27: Bombardier Limited Warranty North America

    All genuine BOMBARDIER parts and accessories, installed by an autho- rized BOMBARDIER dealer (as hereinafter defined) at the time of delivery of the 2004 SKI-DOO snowmobile, carry the same warranty as that of the snowmobile. 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 28 5. WHAT BOMBARDIER WILL DO BOMBARDIER’s obligations under this warranty are limited to, at its sole discretion, 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 dealer.
  • Page 29 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...
  • Page 30: International Bombardier Limited Warranty

    BOMBARDIER specified predelivery in- spection process is completed and documented. Moreover, this warranty coverage is only available if the SKI-DOO snowmobile is purchased in the country in which the purchaser resides. Bombardier will not honor this lim- ited warranty to any personal use owner or commercial use owner where the preceding conditions have not been met.
  • Page 31 5. WHAT BOMBARDIER WILL DO BOMBARDIER’s obligations under this warranty are limited to, at its sole discretion, 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.
  • Page 32 BOMBARDIER is notified of such trans- fer of ownership in the following way: BOMBARDIER or an authorized BOMBARDIER SKI-DOO distributor/dealer receives a proof that the former owner agreed to the transfer of ownership, in addition to the co-ordinates of the new owner. The distributor will then forward this information directly to Bombardier.
  • Page 33: 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 reg- istration 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 34 If the problem already has been re- viewed with the Sales Manager or Service Manager, contact the General Manager or the owner of this authorized SKI-DOO dealership. We are always pleased to receive your comments on the Ski-Doo snowmobile.
  • Page 35: 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 or visit our web site at WWW.SKIDOO.COM.
  • Page 36: How To Identify Your Snowmobile

    HOW TO IDENTIFY YOUR SNOWMOBILE Vehicle Description Decal Vehicle description decal is located on right hand side of tunnel. A33H01A TYPICAL 1. Vehicle description decal A00A6MA VEHICLE DESCRIPTION DECAL 1. Manufacturer name 2. Manufacturing date 3. Vehicle identification number (VIN) 4.
  • Page 37: Serial Numbers

    These numbers are required by the authorized SKI-DOO dealer to complete warranty claims properly. No warranty will be allowed by Bombardier if the engine serial number or vehicle identification number (VIN) is removed or mutilated in any way.
  • Page 38 A32C01B 2-STROKE LIQUID COOLED MODELS 1. Engine serial number A32A1XA 4-TEC MODELS 1. Engine serial number...
  • Page 39: On-Vehicle Important Instructions

    ON-VEHICLE IMPORTANT INSTRUCTIONS The following instructions are on your snowmobile. If missing or dam- aged, the decals can be replaced free of charge. See an authorized SKI-DOO dealer. Please read the following instructions carefully before operating this snowmobile. 2 11 A03A04J TYPICAL —...
  • Page 40 Instruction 1 A32A1YA ZX SERIES...
  • Page 41 Instruction 1 A32A24A REV SERIES...
  • Page 42 Instruction 2 A05H1CA SKANDIC FAN 550 Instruction 3 A01A2EA ALL MODELS...
  • Page 43 Instruction 4 A01A2FA ALL MODELS Instruction 5 A01A2GA TYPICAL — ALL MODELS Instruction 6 A32A08A 4-TEC MODELS...
  • Page 44 Instruction 7 A32A1GA ALL MODELS Instruction 8 A32A1HA LIQUID-COOLED MODELS Instruction 9 A32A1EA 2-TEC MODELS...
  • Page 45 Instruction 10 A32A1ZA 4-TEC MODELS Instruction 11 A01A1ZD SINGLE SEAT ZX SERIES...
  • Page 46 Instruction 12 A33H11A SOME MODELS...
  • Page 47 Instruction 13 A33A1HA NORTH AMERICA LIQUID-COOLED SUMMIT MODELS...
  • Page 48 Instruction 13 (cont’d) A33F3QA EUROPEAN LIQUID-COOLED SUMMIT MODELS...
  • Page 49 Instruction 14 A32F21A SUMMIT MODELS...
  • Page 50: Controls/Instruments/Equipment

    NOTE: Some controls/instruments/equipment do not apply or are op- tional on some models. In these cases their reference numbers are deliberately missing in the illustrations. 48 37 43 55 47 56 46 36 34 A32A28A TYPICAL — ZX SERIES A33H2AA TYPICAL — REV SERIES...
  • Page 51 11 27-28 32 33 A32H41A TYPICAL — FAN-COOLED ZX SERIES 8 29 A32H42A TYPICAL — LIQUID-COOLED ZX SERIES...
  • Page 52 20-39 A33A1FA TYPICAL — REV SERIES...
  • Page 53 7-12 23-24-25 A32A15C TYPICAL — LIQUID-COOLED MODELS 7-12 21-23-24-25 A33A1GA TYPICAL — SUMMIT X/H.M. X/H.M. XTREME...
  • Page 54: Throttle Lever

    1) Throttle Lever Located on the right hand side of handlebar and designed to be thumb activated. When squeezed, it increases the engine speed and engages the transmission. When released, engine speed returns au- tomatically to idle. WARNING Test the throttle lever operation each time before starting the engine.
  • Page 55 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; 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 56: Brake/Parking Brake (Red)

    HYDRAULIC BRAKE To engage mechanism, squeeze brake lever and maintain while pull- ing locking lever with a finger. When brake lever is held at half-way the parking brake should be fully applied. To release mechanism, squeeze brake lever. Locking lever will auto- matically return to its original position.
  • Page 57: Gear Shift Lever Or Rer Button

    5) Gear Shift Lever or RER Button Gear Shift Lever 4-TEC Models These models are equipped with a mechanical reverse controlled by a 2-position gear shift lever. A32D1TA 1. Forward 2. Reverse Shifting Procedure WARNING The reverse speed of these snowmobiles is not limited. Always proceed with caution as fast reverse could result in loss of ve- hicle stability and control.
  • Page 58 RER Button Fan-Cooled ZX Series General These models are equipped with a Rotax Electronic Reverse (RER controlled by a RER button. When the engine is running, depressing the RER button will com- mand the engine to reverse crankshaft rotation as driving the snow- mobile in reverse is achieved by changing the direction of rotation of the engine, not by shifting the chaincase in reverse gear.
  • Page 59 At high altitude, the RER system on fan-cooled models needs a dif- ferent engine timing curve to work properly. Before using vehicle at a 2300 m (8000 ft) altitude or higher see an authorized SKI-DOO dealer for installation of a high altitude cap.
  • Page 60: Start/Rer Button

    6) Start/RER Button General The START/RER button has two functions. When the engine is not running, depressing the START/RER button will engage the electric starter on vehicle so equipped and start the engine. When the engine is running, depressing the START/RER button will command the engine to reverse crankshaft rotation as driving the snowmobile in reverse is achieved by changing the direction of rota- tion of the engine, not by shifting the chaincase in reverse gear.
  • Page 61 Shifting in Reverse WARNING The shifting to reverse mode on these snowmobiles is done by the push of the START/RER button when the engine is running. Wait until the reverse alarm sounds and the DESS/RER pilot lamp comes on in the dash before operating throttle to pro- ceed in reverse.
  • Page 62: Reverse Pilot Lamp

    RER Modification at High Altitude General At high altitude, the RER system needs a different engine timing curve to work properly. Operation Non-DPM Liquid-Cooled Models Before using the reverse system, first select the altitude mode that changes engine timing curve. To do so, push and hold START/RER button with engine running.
  • Page 63: Handlebar

    WARNING Fast reverse while turning, could result in loss of stability and control. Handlebar height is adjustable. See an authorized SKI-DOO dealer. Some Models Handlebar angle can be adjusted to suit driver’s preference. Lift lever, tilt handlebar to desired position then release lever.
  • Page 64 Some REV Series Models Steering Column Position Adjustment Steering column position is adjustable. Proceed as follows. There are 2 positions. NOTE: Following procedure describes how to change steering col- umn position from rearward to forward position. Unscrew 4 bolts retaining windshield assembly to handlebar. Re- move windshield assembly.
  • Page 65 Remove steering cover and console cap. A33H05B 1. Steering cover 2. Console cap...
  • Page 66 Unscrew 4 bolts retaining console. A33H06A 1. Bolts retaining console...
  • Page 67 Slightly lift console to gain access to electrical connector housings. Unplug the 2 large connector housings and the separate 3 wire connector. A33H07A TYPICAL 1. Large connector housings Remove console. Remove 2 bolts retaining top of steering column. A33H08A STEERING COLUMN IN REARWARD POSITION 1.
  • Page 68 Move steering column to forward position. A33H09B STEERING COLUMN IN FORWARD POSITION 1. Longer bolt Reinstall the 2 bolts. Always install the longer bolt on thicker portion to be bolted. Use new lock nuts. Torque nuts to 24 N•m (18 lbf•ft). Reconnect the electrical connectors and reinstall all removed parts.
  • Page 69 Reinstall windshield assembly to handlebar. Refer to WINDSHIELD ADJUSTMENT below. A33H04A ONE SIDE SHOWN — FORWARD POSITION 1. Bolts retaining windshield assembly Readjust throttle lever housing and brake lever housing accordingly to optimal angle so that you will not need to release your grip to operate levers.
  • Page 70 Handlebar Position Adjustment The handlebar position can be adjusted to suit driver’s preferences. Loosen all 4 bolts retaining handlebar to steering column. A33H16A 1. Four bolts Move handlebar to the desired position. Torque all 4 bolts to 24 N•m (18 lbf•ft). Readjust windshield for proper fit with console.
  • Page 71 Windshield Adjustment The windshield can be adjusted to properly fit with console. Before adjusting windshield, make sure it is installed on the proper bracket slots according to steering column position. See above photos. Slots in brackets allow different windshield positions. Move wind- shield to fit with console.
  • Page 72: Holding Strap

    A33H18A PROPER FIT OF WINDSHIELD VERSUS CONSOLE 1. In line A. 8 to 12 mm (3/8 to 1/2 in) 9) 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.
  • Page 73: Ignition Switch

    10) Ignition Switch A23H04A MANUAL START ELECTRIC START MODELS 1. OFF 1. OFF 2. ON 2. ON 3. START Manual Starting To start the engine, first turn the key to ON position then, pull rewind starter grip. To stop the engine, turn the key to OFF position. Electric Starting To start engine, turn key to START position and hold until engine has started.
  • Page 74: Tether Cut-Out Switch

    11) Tether Cut-Out Switch All Models General It shuts off engine preventing snowmobile to runaway if the operator falls off the vehicle accidently. WARNING Always remove tether cord cap and key when vehicle is not in operation in order to prevent accidental engine starting or to avoid unauthorized use by children or others or theft.
  • Page 75 If emergency engine shut off is required, completely pull tether cord cap from post. A06H1XA TYPICAL Liquid-Cooled Models On these models tether cut-out switch is part of tether cut-out sys- tem. This system serves 3 functions. It shuts off engine preventing snowmobile to runaway if the operator falls off the vehicle accidently.
  • Page 76 Additional Tether Cord Caps The MPEM of your snowmobile can be programmed by your autho- rized SKI-DOO dealer to accept 8 different key codes (tether cord caps). We recommend the purchase of additional caps from your authorized SKI-DOO dealer as additional keys. If you have more than one DESS- equipped SKI-DOO snowmobile, each can be programmed by your authorized SKI-DOO dealer to accept the other vehicles’...
  • Page 77: Dess Pilot Lamp

    DESS Pilot Lamp Codes DESS pilot lamp blinking slowly (one time per 1.5 seconds) means that a bad connection has been detected. Vehicle can not be driven. To check for bad connection, remove tether cord cap. Make sure the tether cord cap is free of dirt or snow. Reinstall cap and restart engine. If a blink per 1.5 seconds still occurs contact an authorized dealer.
  • Page 78: Engine Cut-Out Switch

    13) Engine Cut-Out Switch All Models This push-pull type or toggle type switch (depending on models) is located on the right hand side of the handlebar. To stop the engine in an emergency, select OFF position and simultaneously apply the brake.
  • Page 79 WARNING If the switch has been used in an emergency caused by a sus- pected malfunction, the source of the malfunction should be determined and corrected before restarting engine. See an au- thorized SKI-DOO dealer for servicing.
  • Page 80: Headlamp Dimmer Switch

    14) Headlamp Dimmer Switch Located on left hand side of handlebar, allows selection of headlamp beam. Note that lights are automatically ON whenever the engine is running. A15G0XA TYPICAL — SOME MODELS A03H1IA TYPICAL — SOME MODELS...
  • Page 81: High Beam Pilot Lamp (Blue)

    17) Low Battery Voltage Pilot Lamp This lamp will light up to indicate a low battery voltage condition. See an authorized SKI-DOO dealer as soon as possible. 18) Engine Management System (EMS) Pilot Lamp This lamp will light up to indicate a trouble. Refer to TROUBLESHOOT-...
  • Page 82: Rewind Starter Handle

    19) Rewind Starter Handle Auto-rewind type located on right hand side of snowmobile. To en- gage mechanism, pull handle slowly until a resistance is felt then pull vigorously. Slowly release handle. 20) Choke Lever This device features a 3-position lever to facilitate cold start. A06H1KB 0.
  • Page 83: Speedometer

    Stop engine and open engine compartment. Cut locking ties. Plug connectors together to change units from miles to kilometers. Unplug to return to miles reading. Fasten connector to harness with locking ties. A32I0GA ZX SERIES — KILOMETERS READING — CONNECTORS PLUGGED...
  • Page 84 A33E05A REV SERIES — MILES READING — CONNECTORS UNPLUGGED 1. Locking ties 2. Connectors A32I0HA ZX SERIES — MILES READING — CONNECTORS UNPLUGGED...
  • Page 85: Mode Button

    A33E06A REV SERIES — KILOMETERS READING — CONNECTORS PLUGGED Summit X/H.M. X/H.M. Xtreme These models are equipped with a tachometer that includes a LCD screen on which speed is shown in km/h or MPH. NOTE: As soon as the vehicle is moving, the LCD screen will show speed only instead of the selected mode.
  • Page 86: Odometer

    23) Odometer Odometer records the total distance travelled and displays it either in miles or kilometers. Refer to SPEEDOMETER for changing units. All Models Except Summit X/H.M. X/H.M. Xtreme NOTE: At vehicle speed of 90 km/h (55 MPH) and more the mode LCD screen will show speed only instead of the selected mode.
  • Page 87: Tachometer

    Always wipe off any fuel spillage from the ve- hicle. Periodically verify fuel system. NOTE: Do not sit or lean on seat when fuel tank cap is not properly installed. Some ZX Series Models Fuel tank cap features a mechanical gauge.
  • Page 88: Mechanical Fuel Level Gauge

    28) Mechanical Fuel Level Gauge Located at rear of fuel tank cap the gauge facilitates fuel level reading. A32A25A TYPICAL 1. Full 2. Empty NEEDLE POSITION APPROXIMATE REMAINING OF FUEL LEVEL FUEL QUANTITY GAUGE L (U.S. gallon) 15 (4) 21 (5.5) 30 (8) 36 (9.5)
  • Page 89 Summit X/H.M. X/H.M. Xtreme Open fabric door to see the fuel level through the transparent fuel tank. A33H1OA 1. Fabric door...
  • Page 90: Electric Fuel Level Gauge

    29) Electric Fuel Level Gauge Dash-mounted gauge to facilitate fuel level reading. This gauge func- tions when engine is running. A32A26A TYPICAL 1. Full 2. Empty...
  • Page 91: Temperature Gauge

    30) Temperature Gauge The gauge indicates engine coolant temperature. The needle moves to the normal range as engine warms. Under all riding conditions, the needle should stay within this range. If needle moves into the over- heat range, reduce snowmobile speed and run snowmobile in loose snow or stop engine immediately.
  • Page 92: Heating Grip Switch

    32) Heating Grip Switch It is a three-position switch. Select the desired position to keep your hands at a comfortable temperature. A25H05A TYPICAL — FAN-COOLED MODELS 1. HOT 2. OFF 3. WARM A33E04B LIQUID-COOLED MODELS 1. Heating grip switch 2. Heating throttle lever switch 3.
  • Page 93: Heating Throttle Lever Switch

    33) Heating Throttle Lever Switch Three-position switch. Select the desired position to keep your right thumb at a comfortable temperature. See illustrations above. 34) Rear Passenger Heating Grip Switch Three-position switch. Select the desired position to keep rear pas- sager’s hands at a comfortable temperature. A32H0QA TYPICAL —...
  • Page 94: Rear Grab Handles

    36) Rear Grab Handles Rear grab handles provides a grip for the passenger. Some Models 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.
  • Page 95: Adjustable Backrest

    37) 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. Some Models A03A0KA TYPICAL — BACKREST POSITION 1.
  • Page 96 A03A0KC TYPICAL — BACKREST SUPPORT ANGLE 1. Turn adjustment knob A03A0KB TYPICAL — BACKREST HEIGHT 1. Loosen center knobs (both sides) to adjust then retighten...
  • Page 97 Some Models A32H0PA 1. Turn adjustment knob 2. Lift adjustment lock (both sides) Secure adjustment locks after desired position is obtained.
  • Page 98: Electric Visor Jack Connector

    An electric visor can be connected to the jack connector. Electric current is supplied whenever engine is running. A stress relief exten- sion is supplied with the vehicle. It is included in the predelivery kit. Ask your authorized SKI-DOO dealer for the extension. A32E0OA TYPICAL — ZX SERIES 1.
  • Page 99: 12-Volt Power Outlet

    39) 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 electric power outlet fuse location. A29I04A 40) Windshield Windshield provides operator comfort, as well as protection by de- flecting wind and snow away from the operator.
  • Page 100: Adjustable Toeholds

    • When riding between - 5°C and 5°C (23°F and 41°F) in a high rel- ative humidity. • When riding in deep powder snow. • When following another snowmobile which makes dust snow. A32I0AA TYPICAL — ZX SERIES 1. ON 2. OFF...
  • Page 101 A33C01A TYPICAL — REV SERIES 1. ON 2. OFF CAUTION: When operating the snowmobile above 5°C (41°F), move the carburetor heating valve to the OFF position.
  • Page 102: Hood And Side Panel Latches

    44) Hood and Side Panel Latches ZX Series Stretch and unhook the latches to unlock the hood from its anchors. A32H02A TYPICAL — ZX SERIES 1. Latch 2. Recess provided to open hood Always lift hood gently until stopped by retaining device.
  • Page 103 REV Series To open hood, slightly widen (pull-out) its both sides top portion in order to unhook its anchors from their grommets. A33H0MA 1. Anchors 2. Grommets...
  • Page 104 To open a side panel, stretch and unhook the latches. A33H13A 1. Latch To remove a side panel remove by pulling up both locking devices from hinge. A33H0EA 1. Locking device...
  • Page 105 For left hand side panel removal, also unplug vent hose or sensor from air silencer. A33C02B NON-2-TEC MODELS 1. Vent hose...
  • Page 106: Fuses

    A33E0RA 2-TEC MODELS 1. Sensor Reverse opening procedure to close hood and side panels. Properly hook up latches. 45) Fuses To remove fuse from holder, pull fuse out. Check if filament is melted. A15E0KA 1. Fuse 2. Check if melted...
  • Page 107 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 deal- er for servicing. Ground Protection Fuse Electric Start Fan-Cooled Models Only Ground wire is protected with a 20 ampere rated fuse.
  • Page 108 Headlight Fuse Headlight is protected with 20 ampere rated fuse. See following il- lustration for fuse holder location. If headlight does not light up, check fuse condition and replace it if necessary. Electronic Module Fuse Electronic module is protected with 5 ampere rated fuse. See follow- ing illustration for fuse holder location.
  • Page 109 Headlight Fuse Headlight is protected with 20 ampere rated fuse. See following il- lustration for fuse holder location. If headlight does not light up, check fuse condition and replace it if necessary. A33E07A FUSE LOCATION — LEFT HAND SIDE OF ENGINE COMPARTMENT BEHIND HEADLIGHT 1.
  • Page 110 Electric-Start REV Series Except 2-TEC Models Charging System Fuse Charging system is protected with 30 ampere rated fuse. See follow- ing illustration for fuse holder location. If charging system or starter does not operate, check fuse condition and replace it if necessary. A33E0EA 1.
  • Page 111 MPEM Fuse MPEM is protected with 5 ampere rated fuse. See following illustra- tion for fuse holder location. If no voltage is present at MPEM or starter does not operate, check fuse condition and replace it if nec- essary. A33E0FA 1.
  • Page 112 2-TEC and 4-TEC Models To open fuse box push on cover tab and tilt cover. A32I0KA TYPICAL 1. Push tab...
  • Page 113 A32I0IA TYPICAL 1. Fuse description decal 2. Fuse remover/installer 3. Spare fuses...
  • Page 114: Front Grab Handle/Front Bumper

    A32I0JA 1. Fuse remover/installer Some Models Electric Fuel Level Gauge Fuse See an authorized SKI-DOO dealer for fuse replacement. 46) Front Grab Handle/Front Bumper All Models Except 4-TEC To be used whenever front of snowmobile requires manual lifting. WARNING Do not attempt to lift the vehicle by hand alone. Use appropriate lifting device or have assistance to share lifting stress in order to avoid risk of strain injuries.
  • Page 115 A32H05A ZX SERIES 1. Front grab handle A33H15A REV SERIES 1. Front grab handle...
  • Page 116 All 4-TEC Models To be used whenever snowmobile requires manual pulling. A32H05A 1. Front grab handle CAUTION: Do not lift snowmobile by the front bumper. All Models CAUTION: Do not use skis to pull or lift snowmobile.
  • Page 117: Hood Grills

    47) Hood Grills When riding on powdered snow, close plastic sliding hood grills from underneath hood. Otherwise always keep grills open. Squeeze tabs to close grills. A32H03A TO CLOSE, SQUEEZE CLOSING TABS BETWEEN THUMB AND INDEX...
  • Page 118: Storage Compartment

    A32H04A TO OPEN, SQUEEZE OPENING TABS BETWEEN THUMB AND INDEX 48) Storage Compartment WARNING All storage compartments must be properly latched and they must not contain any heavy or breakable objects.
  • Page 119 ZX Series and Some REV Series Models A33H1ZA 1. Storage compartment cover Some REV Series Models Pull latch slightly upward then, backward to unlock cover. A33H0LA 1. Latch...
  • Page 120: Rear Rack

    Avoid speed over bumps. 50) Tool Kit A tool kit containing tools for basic maintenance is supplied with the vehicle. Tool bag is located in engine compartment above left hand side toe- hold. A32B18A ZX SERIES 1. Tool kit...
  • Page 121 A33B0QA REV SERIES 1. Tool kit...
  • Page 122: Jerrican

    51) Jerrican Summit X/H.M. X/H.M. Xtreme Lift release lever to unfasten jerrican from vehicle. A33B0RA 1. Release lever Unhook holding strap from right and left side eyelets. A33B0KA LEFT HAND SIDE SHOWN 1. Eyelet...
  • Page 123 When putting back jerrican on vehicle, make sure filling neck is on left hand side of vehicle. Tighten holding strap with ratchet lever. A33B0LA FILLING NECK ON LEFT HAND SIDE OF VEHICLE 1. Ratchet lever...
  • Page 124: Shovel

    52) Shovel Summit X/H.M. X/H.M. Xtreme Open hood to gain access to shovel. A33B0MA 1. Shovel tray 2. Telescopic handle and handsaw 3. Probe Assemble telescopic handle to shovel tray. A33B0NA SHOVEL ASSEMBLED...
  • Page 125: Probe

    53) Probe Shovel telescopic handle has to be removed first to gain access to probe. Assemble probe sections and slide locking device on last probe sec- tion end. A33B0OA LOCKING DEVICE ON LAST PROBE SECTION END 1. Locking device release disc Press on release disc to unlock then, disassemble probe section.
  • Page 126: Spark Plug Holder

    To keep spare spark plugs dry and prevent shocks that might affect the adjustment or break them, a holder is provided in engine com- partment. A32C0RA ZX SERIES — SPARK PLUG HOLDER ON INJECTION OIL RESERVOIR 1. Spare spark plugs installed in holder...
  • Page 127 A33C02A REV SERIES — SPARK PLUG HOLDER ON LEFT HAND SIDE PANEL 1. Spare spark plugs installed in holder NOTE: Spare spark plugs are not supplied with snowmobile. NOTE: Check spare spark plug gap according to SPECIFICATIONS be- fore installation. CAUTION: Do not attempt to adjust gap on spark plug BR9ECS.
  • Page 128: Spare Drive Belt Holder

    56) Spare Drive Belt Holder A spare drive belt can be stored in holder. NOTE: Spare drive belt is not supplied with the snowmobile. A32H0TA ZX SERIES — SPARE DRIVE BELT INSTALLED IN HOLDER A33H14A REV SERIES — SPARE DRIVE BELT INSTALLED IN HOLDER...
  • Page 129: Hitch

    Never attempt to make adjustments to any moving part while the engine is running. 59) Convertible Ski Stance Summit Models Only Ski stance (distance between each skis) is adjustable. See an autho- rized SKI-DOO dealer. 60) Adjustable Suspensions General All Models Snowmobile handling and comfort depend upon suspension adjust- ments.
  • Page 130: Guidelines To Adjust Suspension

    Slight suspension bottoming occurring under the worst riding condi- tions indicates a good choice of spring preload. NOTE: Some models may come from factory equipped with Take/Apart (T/A) shocks. These can be rebuilt or recalibrated. See an authorized SKI-DOO dealer.
  • Page 131 1. Rear Springs — Comfort IMPORTANT: Make sure that all objects to be transported are in place in storage compartment and rear rack. Grab 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 132 A32F0CA TYPICAL — TOO SOFT OF ADJUSTMENT (REAR SUSPENSION IS TOO LOW, IT HAS COLLAPSED MORE THAN 75 mm (3 in) CAUTION: To increase preload, always turn the left side adjust- ment cam in a clockwise direction, and the right side cam in a coun- terclockwise direction.
  • Page 133 A32F0DA TYPICAL — TOO HARD OF ADJUSTMENT (REAR SUSPENSION RUNS TOO HIGH, IT HAS COLLAPSED LESS THAN 50 mm (2 in) CAUTION: To decrease preload, always turn the left side adjust- ment cam in a counterclockwise direction, the right side cam in a clockwise direction.
  • Page 134 2. Center Spring — Steering Behavior Ride at moderate speed on a trail. If handlebar is felt too easy or too hard to turn, adjust center spring accordingly. WARNING Remove tether cord cap before performing any maintenance or adjustment, unless otherwise specified. Vehicle must be parked in a safe place, away from the trail.
  • Page 135 A03F2PA TYPICAL — TOO SOFT OF ADJUSTMENT 1. Handlebar harder to turn — oversteering altitude A32F01B TYPICAL 1. Use adjuster wrench provided in tool kit to increase preload...
  • Page 136 A32F0EA TYPICAL — TOO HARD OF ADJUSTMENT — TOO MUCH PRELOAD 1. Handlebar is very easy to turn — understeering attitude A32F01B TYPICAL 1. Use adjuster wrench provided in tool kit to decrease preload...
  • Page 137 3. Stopper Strap — Weight Transfer Ride at low speed then fully accelerate. Note steering behavior. Adjust stopper strap length accordingly. WARNING Remove tether cord cap before performing any maintenance or adjustment, unless otherwise specified. Vehicle must be parked in a safe place, away from the trail. CAUTION: Whenever stopper strap length is changed, track ten- sion must be readjusted.
  • Page 138 All Models Except Summit A32F0EC TYPICAL — TOO LONG STRAP 1. Skis lift off the ground A03F0QB TYPICAL 1. Reduce strap length by bolting to a different hole...
  • Page 139 A32F0EA TYPICAL — TOO SHORT STRAP 1. Heavy steering A03F0QB TYPICAL 1. Increase strap length by bolting to a different hole...
  • Page 140 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 141 A32F0EA TOO SHORT STRAP 1. Heavy steering A32E19B 1. Loosen lock nut, turn knob accordingly then retighten lock nut...
  • Page 142 4. Coupling Blocks — Handling All Models Except Summit Ride at moderate speed and check for desired handling. When driver and passenger (if applicable) are sitted on vehicle, 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 143 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 144 5. Front Springs — Handling Ride at moderate speed and check for proper handling. Adjust front springs accordingly. WARNING Remove tether cord cap before performing any maintenance or adjustment, unless otherwise specified. Vehicle must be parked in a safe place, away from the trail. WARNING Always adjust both front springs to same position.
  • Page 145 Some Models A32F0EA TYPICAL — TOO SOFT OF ADJUSTMENT 1. Bad handling A32F1CA 1. Increase spring preload 2. Position number...
  • Page 146 A32F0EA TYPICAL — TOO HARD OF ADJUSTMENT 1. Steering hard to turn A32F1CB 1. Decrease spring preload 2. Position number...
  • Page 147 CAUTION: Make sure that both front springs are still preloaded when front of vehicle is off the ground. Some Models A32F0EA TYPICAL — TOO SOFT OF ADJUSTMENT 1. Bad handling A03F2IA 1. Increase spring preload...
  • Page 148 A32F0EA TYPICAL — TOO HARD OF ADJUSTMENT 1. Steering hard to turn A03F2JA 1. Decrease spring preload...
  • Page 149 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. A32F30A 1. Soft position 2. Firm position WARNING Remove tether cord cap before performing any maintenance or adjustment, unless otherwise specified.
  • Page 150 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 151: Fuel And Oil

    FUEL AND OIL Recommended Fuel All Models Except Summit 800 HO and 600 HO SDI Engine Equipped Use regular unleaded gasoline, available from most service stations or oxygenated fuel containing less than 10% of ethanol or 5% of meth- anol. The gasoline used must have an octane number (R + M)/2 of 87 or higher.
  • Page 152: Recommended Oil

    CAUTION: Use only injection oil that flows at - 40°C (- 40°F). Do not mismatch oil reservoir cap with fuel tank cap. Oil reservoir cap is identified OIL. Oil is contained in the injection oil reservoir. Use only two-stroke engine injection oil sold by authorized SKI-DOO dealers. MODEL OIL TYPE ➀...
  • Page 153: Cold Weather Carburetion Modifications

    CAUTION: For colder temperatures than - 20°C (- 4°F), carbure- tor(s) must be recalibrated to avoid engine damage. Refer to an authorized SKI-DOO dealer. Refer also to RIDING AT HIGH ALTITUDES in following pages.
  • Page 154: Break-In Period

    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 also give you the opportunity to discuss the unanswered questions you may have encountered during the first hours of operation.
  • Page 155: Pre-Operation Check

    PRE-OPERATION CHECK WARNING The pre-operation check is very important prior to operating the vehicle. Always check the proper operation of critical controls, safety features and mechanical components before starting. If not done as specified here, severe injury or death might occur. •...
  • Page 156 • Check fuel and injection oil for levels and leaks. Replenish as nec- essary and see an authorized SKI-DOO dealer in case of any leaks. • Verify that air filter(s) is free of snow, if so equipped.
  • Page 157: Pre-Operation Check List

    PRE-OPERATION CHECK LIST ✔ ITEM OPERATION Body including seat, footrests, lights, Check that there is no snow or ice. controls and instruments Track and idler wheels Check for free movement. Brake lever Check proper action. Parking device Check proper action. Throttle lever Check proper action.
  • Page 158: 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. Depending on models engine RPM must be be- tween 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 159: Starting The Engine

    Stopping Before riding your snowmobile, you should understand how to stop it. This is done by releasing the throttle and gradually depressing the brake lever on the left side of the handlebar. In an emergency, you may stop your vehicle by pressing the engine cut-out switch located near the throttle control and applying the brake.
  • Page 160 Choke Equipped Models Initial Cold Starting NOTE: Do not operate the throttle lever with the choke lever on. When Temperature is Below - 10°C (+ 15°F) Set the choke lever to the second position. Grab starter handle firmly and crank engine or use electric starter on so equipped models.
  • Page 161 2-TEC Models Initial Cold Starting and Warm Engine Starting Grab starter handle firmly and crank engine or use electric starter on so equipped models. IMPORTANT: On 2-TEC battery equipped models if the low battery voltage pilot lamp is on, battery would not have enough power to start the engine.
  • Page 162: Emergency Starting

    CAUTION: Do not use electric starter for more than 10 seconds. A rest period should be observed between the cranking cycles to let electric starter cool down. Using electric starter when engine has started could damage electric starter mechanism. NOTE: If for any reason, the engine cannot be cranked electrically, place ignition key to ON position and start engine manually using the rewind starter.
  • Page 163 A07D0UA Attach one end of emergency rope to rewind handle. NOTE: The spark plug socket can be used as an emergency handle. A17B01A TYPICAL Attach the other end of emergency rope to the starter clip supplied in the tool kit. Hook up clip on drive pulley.
  • Page 164 Wind the rope tightly around drive pulley. When pulled, pulley must rotate counterclockwise. A03D25A TYPICAL — FAN-COOLED MODELS 1. Knot on this side...
  • Page 165: Shutting Off The Engine

    A19D13A TYPICAL — LIQUID-COOLED MODELS 1. Clip Pull the rope using a sharp, crisp pull so the rope comes free of the drive pulley. Start engine as per usual manual starting. WARNING When starting the snowmobile in an emergency situation, us- ing drive pulley, do not reinstall the belt guard and return slow- ly to have snowmobile repaired.
  • Page 166: Vehicle Warm-Up

    VEHICLE WARM-UP Before every ride, vehicle has to be warmed up as follows. Snowmobile must be securely supported by the rear bumper using a wide-base snowmobile mechanical stand. Track must be 100 mm (4 in) off the ground. Attach tether cord to operator’s clothing eyelet. Start engine and allow it to warm up two or three minutes at idle speed.
  • Page 167: How To Ride

    HOW TO RIDE Your riding position and balance are the two basic principles of mak- ing your snowmobile go where you want it to. When turning on the side of a hill, you and your passenger must be ready to shift body weight to help it turn in the desired direction.
  • Page 168 Posting A semi-sitting position with the body off the seat and the feet under the body in a sort of squatting posture, thus allowing the legs to absorb the shocks when traveling over uneven terrain. Avoid abrupt stops. A30H03A Kneeling This position is achieved by placing one foot firmly on the running board and the opposite knee on the seat.
  • Page 169 Standing Place both feet on the running boards. Knees should be flexed to absorb the shock from surface bumps. This is an effective position to see better and to shift weight as conditions dictate. Avoid abrupt stop. A30H05A...
  • Page 170: Terrain/Riding Variations

    TERRAIN/RIDING VARIATIONS Groomed Trail On a maintained trail, sitting is the most preferred riding position. Do not race and, above all, keep to the right hand side of the trail. Be prepared for the unexpected. Observe all trail signs. Do not zigzag from one side of the trail to the other.
  • Page 171 Frozen Water Traveling frozen lakes and rivers can be fatal. Avoid waterways. If you are in a unfamiliar area, ask the local authorities or residents about the ice condition, inlets, outlets, springs, fast moving currents or oth- er hazards. Never attempt to operate your snowmobile on ice that may be too weak to support you and the vehicle.
  • Page 172 Downhill Downhill driving requires that you have full control of your vehicle at all times. On steeper hills, keep your center of gravity low and both hands on the handlebar. Maintain slight throttle pressure and allow the machine to run downhill with the engine operating. If a higher than safe speed is reached, slow down by braking but apply the brake with frequent light pressure.
  • Page 173 Bright Sunshine Bright sunny days can considerably reduce your vision. The glare from sun and snow may blind you to the extent that you cannot easily distinguish ravines, ditches or other obstacles. Goggles with colored lenses should always be worn under these conditions. Unseen Obstruction There may be obstructions hidden beneath the snow.
  • Page 174 Turning Depending on terrain conditions, there are two preferred ways to turn or corner a snowmobile. For most snow surfaces, “body english” is the key to turning. Leaning towards the inside of the turn and position- ing body weight on the inside foot will create a “banking” condition beneath the track.
  • Page 175 Railroad Crossing Never ride on railroad tracks. It is illegal. Railroad tracks and railroad rights-of-way are private property. A snowmobile is no match for a train. When crossing a railroad track, stop, look and listen. Night Rides The amount of natural and artificial light at a given time can effect your ability to see or to be seen.
  • Page 176 Carrying a Passenger Each operator has a responsability to ensure the safety of his pas- senger. If your snowmobile is so designed and you are carrying a passenger (if snowmobile is specifically designed or equipped), you should inform him of snowmobiling basics. Make sure that you in- struct your passenger to maintain a firm grab of the passenger strap or grips.
  • Page 177: Post-Operation Care

    Trail Stops Whenever possible, pull off the trail when you stop. This will reduce the hazard to other snowmobilers using the trail. Trails and Signs Trail signs are used to control, direct or regulate the use of snowmo- biles on trails. Become familiar with all signs used in the area where you are snowmobiling.
  • Page 178: Special Operations

    Engine overheating pilot lamp 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...
  • Page 179: Maintenance Information

    MAINTENANCE INFORMATION...
  • Page 180: Periodic Maintenance Chart

    ➃ ONCE A YEAR OR EVERY 3200 km (2000 m.) ➄ ONCE A YEAR OR EVERY 6000 km (3700 m.) ➅ STORAGE (to be performed by an authorized SKI-DOO dealer) ➆ PRESEASON PREPARATION (to be performed by an authorized SKI-DOO dealer).
  • Page 181 ➀ ➁ ➂ ➃ ➄ ➅ PERIODIC MAINTENANCE CHART Drive Belt Drive and Driven Pulleys Tightening Torque of Drive Pulley Screw Driven Pulley Preload Brake Fluid Brake Drive Chain Tension Countershaft Lubrication** Chaincase or Gearbox Oil I R,*** Drive Axle End Bearing** Steering and Front Suspension A,I,L A,I,L...
  • Page 182: 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. Remove tether cord cap before performing any maintenance or adjustment, unless otherwise specified.
  • Page 183: Chaincase/Gearbox Oil Level

    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. Remove metal particles from magnet. Refill up to upper mark using recommended oil, refer to SPECIFICA- TIONS.
  • Page 184: Oil Injection System

    Oil Injection System All Models Except 4-TEC Always maintain a sufficient amount of recommended injection oil 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.
  • Page 185 A32C27A ZX SERIES 1. Injection oil reservoir 2. Maximum level indicator: 13 mm (1/2 in) from top 3. Level marks (1/4, 1/2, 3/4)
  • Page 186: Engine Oil Level

    A33A09A REV SERIES 1. Injection oil reservoir 2. Maximum level indicator: 13 mm (1/2 in) from top 3. Level marks (1/4, 1/2, 3/4) Engine Oil Level 4-TEC Models Make sure engine is at operating temperature. Snowmobile must be on a level surface. Leave engine running at idle for 30 seconds.
  • Page 187: Cooling System

    There is a capacity of 500 mL (17 U.S. oz) between the two marks. A32C75A 1. Maximum 2. Minimum Add BOMBARDIER synthetic oil 0W40 through dipstick hole as re- quired. Reinstall dipstick. Cooling System All Liquid-Cooled Models Check coolant level at room temperature. Liquid should be at COLD LEVEL line (engine cold) of coolant tank.
  • Page 188 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 189 A33C03A 1. Coolant tank 2. COLD LEVEL line...
  • Page 190: Battery Electrolyte

    Battery Electrolyte Electric Start Models Only These vehicles are equipped with a maintenance-free battery. Elec- trolyte level can not be checked. WARNING Battery BLACK negative cable must always be disconnected first and connected last. WARNING Never charge or boost battery while installed. Battery electro- lyte contains sulfuric acid which is corrosive and poisonous.
  • Page 191: 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 not be running and cold. Remove tether cord cap before performing any maintenance or adjustment, unless otherwise specified.
  • Page 192: Belt Guard Removal And Installation

    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 accumulation during storage. CAUTION: The snowmobile has to be stored in a cool and dry place and covered with an opaque tarpaulin.
  • Page 193 All Models 1. Remove tether cord cap. Open engine compartment. 4-TEC Models Only 2. Remove air silencer access panel. A32C77A 1. Access panel...
  • Page 194 3. Loosen collar screw on air silencer grommet. 4. Disconnect engine vent hose from air silencer. A32C78B 1. Collar screw 2. Engine vent hose 5. Disconnect air temperature sensor at rear of air silencer. A32C79A 1. Air temperature sensor...
  • Page 195 At installation do not forget to connect air temperature sensor other- wise a trouble code will appear. All Models 6. Open retainer to release pin then pull belt guard out of vehicle. A32C05A TYPICAL 1. Pin retainer When reinstalling belt guard, position its cut-away toward front of snowmobile.
  • Page 196: Drive Belt Removal/Installation

    Place belt guard slots over tabs first, then snap the other end in re- tainer. A32C06A TYPICAL 1. Slots Drive Belt Removal/Installation WARNING Remove tether cord cap before performing any maintenance or adjustment, unless otherwise specified. Vehicle must be parked in a safe place, away from the trail.
  • Page 197 Removal All Models 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. Remove tether cord cap. Open engine compartment and remove belt guard.
  • Page 198 Screw drive belt installer/remover in the free threaded hole and tight- en to open the pulley. Remove belt. 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.
  • Page 199 ZX Series Only 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 200 All Models Slip belt under drive pulley then, remove it from vehicle. A32D14A TYPICAL Clean sheaves of both pulleys using Pulley flange cleaner (P/N 413 711 809). Installation 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 201 To install the drive belt, first place belt between drive pulley sheaves. Then, between driven pulley sheaves, finishing with bottom. Remove drive belt installer/remover. Reinstall belt guard. ZX Series Only Reinstall access panel. 4-TEC Models Only Reinstall air silencer.
  • Page 202: Drive Chain Tension

    Drive Chain Tension All Models Remove hair pin. Fully tighten tensioner adjustment screw by hand, then back off only far enough for hair pin to engage in locking hole. A33D0BA TYPICAL 1. Hair pin 2. Adjustment screw...
  • Page 203: Drive Pulley Adjustment

    Drive Pulley Adjustment WARNING Remove tether cord cap before performing any maintenance or adjustment, unless otherwise specified. Vehicle must be parked in a safe place, away from the trail. General All Models Except 4-TEC The drive pulley is factory calibrated to transmit maximum engine power at a predefined RPM.
  • Page 204 There are 6 positions numbered 1 to 6. On TRA drive pulley, note that in position 1 the number is substitued by a dot (due to its location on casting). A16D0GA TRA DRIVE PULLEY 1. Position 1 (not numbered) Each position modifies maximum engine RPM by about 200 RPM. Lower position numbers decrease engine RPM in steps of 200 RPM and higher position numbers increase it in steps of 200 RPM.
  • Page 205 Improper servicing, modification or poor adjustment may affect drive pulley performance and belt life. Always refer to the Shop Manual or obtain SKI-DOO dealer advice before servicing or modifying the drive or driven pulleys. Always respect maintenance schedules.
  • Page 206: 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.
  • Page 207: Track Condition

    If worn or cut, or if track fibers are ex- posed, or if missing or defective inserts or guides are noted; contact an authorized SKI-DOO dealer. WARNING Do not modify track, including by the installation of traction enhancing products.
  • Page 208 NOTE: A belt tension tester (P/N 414 348 200) may be used to mea- sure deflection as well as force applied. A00C07C BELT TENSION TESTER A32F39A TYPICAL 1. Top tool O-ring positioned at 7.3 kg (16 lb) 2. Push on top portion of tool until it contacts the top O-ring 3.
  • Page 209 – On some models, remove wheel caps. – Loosen the rear idler wheel retaining screws. – Loosen the lock nuts (on so equipped models) then turn adjust- ment screws to adjust. If correct tension is unattainable, contact an authorized SKI-DOO dealer. A05F0EA TYPICAL 1. Adjustment screw 2.
  • Page 210 Alignment WARNING Before checking track alignment, ensure that the track is free of all particles which could be thrown out while track is rotat- ing. Keep hands, tools, feet and clothing clear of track. Ensure no one is standing in close proximity to the snowmobile. Never rotate track at high speed.
  • Page 211 A01F0BA 1. Guides 2. Slider shoes 3. Tighten on this side Tighten lock nuts (some models only) and retaining screws. WARNING If lock nuts are not tightened properly, the adjusting screws could loosen causing the track to become extremely loose and, under some operating conditions, allow the idler wheels to climb over the track lugs forcing the track against the tunnel causing the track to “lock”.
  • Page 212: Steering And Front Suspension

    Visually inspect steering and front suspension for tightness of com- ponents (steering arms, control arms and links, tie rods, ball joints, ski bolts, ski legs, etc.). If necessary, contact an authorized SKI-DOO dealer. Wear and Condition of Skis and Runners Check the condition of the skis, ski runners and ski runner carbides (if so equipped).
  • Page 213: Air Filter Cleaning

    Air Filter Cleaning ZX Series A32H0LA TYPICAL — PRIMARY FILTER LOCATION A32H0RA REMOVAL OF RIGHT SIDE PRIMARY FILTER GRILL...
  • Page 214 A32H0SA REMOVAL OF FILTER FROM ITS GRILL A32H0OA TYPICAL — SECONDARY FILTER INSTALLED ON AIR SILENCER...
  • Page 215 REV Series A33H0JA AIR FILTER LOCATION A33H0KA REMOVAL OF FILTER FROM ITS GRILL All Models Check that the air silencer is clean and dry and properly reinstall the filter. CAUTION: Snowmobile engines have been calibrated with the filters installed. Operating the snowmobile without them may cause engine damage.
  • Page 216: Headlamp Beam Aiming

    Headlamp Beam Aiming ZX Series Turn knob to adjust beam height. A32E01A TYPICAL — ZX SERIES 1. Knob...
  • Page 217 REV Series Open left side panel. Turn knob to adjust beam height. A33E08A TYPICAL — REV SERIES 1. Knob...
  • Page 218: Bulb Replacement

    If glass is touched, clean it with isopropyl alcohol which will not leave a film on the bulb. ZX Series If any headlamp bulb is burnt, remove windshield and unplug burnt bulb connector. Remove the rubber boot.
  • Page 219 A30E05A 1. Locking ring REV Series Unplug burnt bulb connector. Remove the rubber boot. A33E0CA 1. Bulb connector 2. Rubber boot...
  • Page 220: Towing The Vehicle

    Turn bulb locking ring counterclockwise to remove it. Detach the bulb and replace. Properly reinstall parts. A33E0DA 1. Locking ring Taillight If taillight bulb is burnt, expose the bulb by removing the red plastic lens. To remove, unscrew the 2 lens screws. TOWING THE VEHICLE First remove drive belt from vehicle to be towed.
  • Page 221: Transporting The Vehicle

    STORAGE AND PRESEASON PREPARATION WARNING Have an authorized SKI-DOO dealer inspect fuel and oil systems 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 222: Troubleshooting

    TROUBLESHOOTING Monitoring Beeper Coded Signals CODED SIGNALS POSSIBLE CAUSE REMEDY 2 short beeps Confirms that Normal condition. (when engine is proper tether cord started). cap is installed. DESS/RER pilot Engine can rev lamp also blinks. above pulley engagement. 1 short beep every Bad DESS system Reinstall tether cord 1.5 seconds (when...
  • Page 223 CODED SIGNALS POSSIBLE CAUSE REMEDY 3 short beeps per Low battery Check battery and second. voltage. charging system. 4 short beeps every Low oil level on 2- Check oil level and 2 minutes. Oil pilot TEC models. replenish as soon as lamp also lights up.
  • Page 224 Install clean dry spark plug. Start engine following usual start- ing procedure. If engine continues to flood, see an authorized SKI-DOO dealer. 4. No fuel to the engine Check fuel tank level; turn fuel valve on (spark plug dry when removed).
  • Page 225 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 226 Clean/verify spark plug gap and identifi- cation number. Replace as required. 4. Too much oil supplied to engine. Improper oil pump adjustment, refer to an authorized SKI-DOO dealer. On pre- mixed models only, improper fuel/oil mixture. Drain fuel tank and refill with appropriate mixture ratio.
  • Page 227 3. Drive belt. Check item 6 of ENGINE LACKS ACCEL- ERATION OR POWER. 4. Incorrect track adjustment. See MAINTENANCE and/or an authorized SKI-DOO dealer for proper alignment and tension adjustments. 5. Pulleys misaligned. Contact an authorized SKI-DOO dealer. 6. Engine.
  • Page 228: Specifications

    SPECIFICATIONS LEGEND FAN MODEL 380 F/G.T. MX-Z FAN 380 F Engine – Maximum power engine speed ± 100 RPM 6800 Drive Belt – Part number 415 060 600 – Wear limit width mm (in) 32.3 (1-9/32) Spark Plug – Type NGK BR 9 ES ±...
  • Page 229 MX-Z FAN 550 LEGEND SKANDIC MODEL FAN 550/G.T. SPORT 550 SUMMIT FAN 550 Engine – Maximum power ± 100 6950 6950 engine speed Drive Belt – Part number 415 060 600 415 060 600 – Wear limit width mm (in) 32.3 (1-3/8) 32.3 (1-3/8) Spark Plug...
  • Page 230 LEGEND SPORT LEGEND SPORT MODEL 600 R G.T. 600 R Engine – Maximum power ± 100 8000 8000 engine speed Drive Belt – Part number 417 860 700 417 860 700 – Wear limit width mm (in) 32.5 (1-9/32) 32.5 (1-9/32) Spark Plug –...
  • Page 231 LEGEND LEGEND SE G.T./ MODEL SE/SPORT 600 SPORT G.T. 600 HO SDI R HO SDI R Engine – Maximum power ± 100 8000 8000 engine speed Drive Belt – Part number 417 300 197 417 300 197 – Wear limit width mm (in) 34.2 (1-11/32) 34.2 (1-11/32)
  • Page 232 LEGEND SPORT/ LEGEND SPORT MODEL SE 700 R G.T./SE G.T. 700 R Engine – Maximum power ± 100 8000 8000 engine speed Drive Belt – Part number 417 300 127 417 300 127 – Wear limit width mm (in) 33.95 (1-11/32) 33.95 (1-11/32) Spark Plug –...
  • Page 233 LEGEND SE 800 LEGEND SE G.T MODEL SDI R 800 SDI R Engine – Maximum power ± 100 7850 7850 engine speed Drive Belt – Part number 417 300 166 417 300 166 – Wear limit width mm (in) 35.3 (1-3/8) 35.3 (1-3/8) Spark Plug –...
  • Page 234 LEGEND SE LEGEND SPORT MODEL G.T/SPORT G.T. V-1000 V-1000 Engine – Maximum power ± 100 7250 7250 engine speed Drive Belt – Part number 417 300 197 417 300 197 – Wear limit width mm (in) 34.2 (1-11/32) 34.2 (1-11/32) Spark Plug –...
  • Page 235 MX-Z TRAIL/ADR./X MX-Z 500 SS/R MODEL 600 HO R GSX 500 SS R GSX SPORT 600 HO R Engine – Maximum power ± 100 — — engine speed Drive Belt – Part number 417 300 197 417 300 197 – Wear limit width mm (in) 34.2 (1-11/32) 34.2 (1-11/32)
  • Page 236 MX-Z SUMMIT ADR./X MODEL RENEGADE 600 600 HO R HO SDI R Engine – Maximum power ± 100 — — engine speed Drive Belt – Part number 417 300 197 417 300 197 – Wear limit width mm (in) 34.2 (1-11/32) 34.2 (1-11/32) Spark Plug –...
  • Page 237 MX-Z X/ADR./REN./ SUMMIT X/H.M. MODEL REN. X 800 HO R X/ADR./ GSX LIMITED SPORT 800 HO R 800 HO R Engine – Maximum power ± 100 7850 7850 engine speed Drive Belt – Part number 417 300 166 417 300 166 –...
  • Page 238 ➀ Measure gap between slider shoe and bottom inside of track when exerting a downward pull of 7.3 kg (16 lb) 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 239: Privacy Obligations/Disclaimer

    PRIVACY OBLIGATIONS/DISCLAIMER We wish to inform you that your coordinates will be used for safety and warranty purposes. Sometimes, we also use the coordinates of our clients to inform them about our products and to present them offers. Should you prefer not to receive information on our products, services and offers, please let us know by writing to the address below.
  • Page 240: Change Of Address Or Ownership

    Please provide your name, address, phone number, vehicle serial num- ber and date of theft. Bombardier will provide a list of stolen units to all authorized SKI-DOO dealers on a monthly basis to aid in recovery of such units to their...
  • Page 241: Change Of Address

    ✁ CHANGE OF ADDRESS CHANGE OF OWNERSHIP VEHICLE IDENTIFICATION NUMBER OLD ADDRESS OR PREVIOUS OWNER: _____________________________________________________________________________ NAME _____________________________________________________________________________ STREET APT. _____________________________________________________________________________ CITY STATE/PROVINCE ZIP/POSTAL CODE NEW ADDRESS OR NEW OWNER: _____________________________________________________________________________ NAME _____________________________________________________________________________ STREET APT. _____________________________________________________________________________ CITY STATE/PROVINCE ZIP/POSTAL CODE...
  • Page 242 AFFIX PROPER POSTAGE BOMBARDIER RECREATIONAL PRODUCTS WARRANTY DEPARTMENT 75 J.A. BOMBARDIER ST. SHERBROOKE (QUEBEC) CANADA J1L 1W3...

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