Ski-Doo CK3 series Operator's Manual
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Ski-Doo CK3 series Operator's Manual

Ski-Doo CK3 series Operator's Manual

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  • Page 2: Safety Warning

    This Operator’s Guide , Safety Handbook and Safety Video should remain with the unit at time of resale. The following are trademarks of Bombardier Inc. BOMBARDIER ® MACH* GRAND TOURING* SKI-DOO ® CK3* Printed in Canada (Mmo2001-003a.fm GM) ® *Trademarks of Bombardier Inc. and/or its subsidiaries. ©...
  • Page 3 2001 SKI-DOO OPERATOR’S GUIDE This guide is applicable to CK3 series: Grand Touring SE Mach Z STD Mach Z Tech Plus...
  • 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 It is understood that this guide may be translated into another lan- guage. In the event of any discrepancy, the English version shall pre- vail. Most components of this snowmobile are built with parts dimen- sioned in the metric system. Most fasteners are metric and must not be replaced by customary fasteners or vice versa.

  • Page 6: Table Of Contents

    2001 SKI-DOO ® SNOWMOBILE ..........FREQUENTLY 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 27) Heated Grip Switch .............. 28) Heated Grip Pilot Lamp (Yellow) .......... 29) Heated Throttle Lever Switch ..........30) Heated Throttle Lever Pilot Lamp (Yellow) ......31) Electric Visor Jack Connector ..........32) Hood Latches ............... 33) Adjustable Mirrors..............34) Adjustable Toeholds............. 35) Adjustable Handlebar ............
  • Page 8 POST-OPERATION CARE ............SPECIAL OPERATIONS ............Riding at High Altitudes ............. Engine Overheating..............Fuel Flooded Engine ..............Rear Suspension Slider Shoe Starts Sticking ......PERIODIC MAINTENANCE CHART......... FLUID LEVELS................Brake System ................Chaincase Oil Level ..............Oil Injection System ..............Cooling System .................

  • Page 9: Safety Measures

    ® 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. 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 Warranty Coverage Period as for the SKI-DOO snowmobile. 2. WHAT BOMBARDIER WILL DO...
  • Page 11 IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. Neither the distributor, any authorized SKI-DOO dealer nor any other per- son has been authorized to make any affirmation, representation or war- ranty other than those contained in this warranty, and if made, such affir- mation, representation or warranty shall not be enforceable against BOMBARDIER or any other person.

  • 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: Frequently Asked Questions

    I do have my original invoice as proof of when I purchased my snow- mobile. 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 15 Bombardier. Normally, any problems that arise in connection with the sales transaction or the operation of your snowmobile will be handled by your SKI-DOO dealers Sales or Service De- partments. It is recognized, however, that despite the best in- tentions 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 infor- mation. 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: Engine Serial Number Location

    Engine Serial Number Location A30C01A TYPICAL 1. Engine serial number...

  • Page 19: On-Vehicle Important Instructions

    ON-VEHICLE IMPORTANT INSTRUCTIONS Please read the following instructions carefully before operating snow- mobile. TYPICAL — LOCATION OF IMPORTANT INSTRUCTIONS Instruction 1 SINGLE SEAT MODELS...
  • Page 20 Instruction 2...
  • Page 21 Instruction 3 ALL MODELS Instruction 4 ALL MODELS Instruction 5 ALL MODELS WITH A REVERSE...
  • Page 22 Instruction 6 TYPICAL — ALL MODELS Instruction 7 TYPICAL — ALL MODELS...

  • Page 23: Controls/Instruments/Equipment

    CONTROLS/INSTRUMENTS/EQUIPMENT NOTE: Some controls/instruments/equipment do not apply to some models. In these cases their reference numbers are deliberately missing in the illustrations. Some controls/instruments/equipment are optional on some models. TYPICAL...
  • Page 24 TYPICAL — MACH Z STD/TECH PLUS...
  • Page 25 TYPICAL — GRAND TOURING SE...

  • 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)

    1. Locking lever 2. OFF 3. ON 4) Injection Oil Level/Parking Brake Pilot Lamp (Red) Mach Z STD/Tech Plus Lights when injection oil level is low or when parking brake is applied (with engine running). Check oil level and replenish as soon as pos- sible.

  • Page 28: Handlebar

    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 di- rection of intented travel. Handlebar height is adjustable. See an authorized SKI-DOO dealer. 6) Reverse Button WARNING These snowmobiles are capable of a fast reverse.

  • Page 29: Ignition Switch

    7) Ignition Switch The lights are automatically ON whenever the engine is running. ELECTRIC START 1. OFF 2. ON 3. START Electric Starting 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

    8) Tether Cut-Out Switch General The tether cut-out system shuts-off engine if the driver accidently falls off the vehicle and the DESS (Digitally Encoded Security Sys- tem) performs the same function as a key. Operation Attach tether cord to clothing then snap tether cut-out cap over re- ceptacle before starting engine.
  • 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

    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 beep per 3 seconds still occurs contact an authorized SKI-DOO dealer. 1. Free of dirt or snow A rapid beeping and DESS pilot lamp blinking at same rate mean that an incorrectly programmed tether cord is being used.

  • Page 33: Engine Cut-Out Switch

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

  • Page 34: Headlamp Dimmer Switch

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

  • Page 35: High Beam Pilot Lamp (Blue)

    Grand Touring SE NOTE: When holding switch for more than 1 second to dim light (from high to low beam), light will return to high beam position auto- matically after 10 seconds. GT SE 12) High Beam Pilot Lamp (Blue) Lights when headlamp is on HIGH beam.

  • Page 36: Choke Lever

    14) Choke Lever Mach Z STD/Tech Plus This device features a 3-position lever to facilitate cold start. 0. OFF 1. Position 1 2. Position 2 Refer to OPERATING INSTRUCTIONS for more details.

  • Page 37: Air Suspension Switch

    15) Air Suspension Switch Grand Touring SE Only This switch controls pressure inside rear air shock absorber. NOTE: Compressor can be activated only with the engine running. Holding switch upward (big spring on decal) increases air pressure. Holding switch downward (small spring on decal) decreases air pres- sure.

  • Page 38: Air Suspension Gauge

    17) Air Suspension Gauge Grand Touring SE Only This gauge indicates comfort level (pressure inside rear air shock ab- sorber). TYPICAL — AIR SUSPENSION GAUGE 1. Minimum required pressure before riding 18) Speedometer Mach Z STD/Tech Plus These vehicles are equipped with a speedometer graduated in kilome- ter per hour (miles per hour for the USA).

  • Page 39: Odometer

    GT SE This model is equipped with an electronic speedometer. It may show speed in km/h or MPH. Change from One Unit to the Other With engine running but vehicle at rest, depress button for 1 second max. until total shows. Display will not change before the button is released.

  • Page 40: Trip Meter

    20) Trip Meter Records distance travelled in kilometers (miles for the USA) until it is reset. It can be used to establish a fuel tank range or distance be- tween 2 relays for instance. MACH Z STD/TECH PLUS 1. Odometer 2.

  • Page 41: Trip Meter Reset Button

    21) Trip Meter Reset Button Mach Z STD/Tech Plus To reset, push on button until all numbers read zero. GT SE With engine running but vehicle at rest, depress button for 1 second max. until trip shows. Display will not change before the button is released.
  • Page 42 GRAND TOURING SE 1. Multiply the reading by 1000...

  • Page 43: Temperature Gauge

    23) Temperature Gauge Mach Z STD/Tech Plus 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 44: Electric Fuel Level Gauge

    25) Electric Fuel Level Gauge Dash-mounted gauge to facilitate fuel level reading. This gauge func- tions when engine is running. 1. Full 2. Empty 26) Fuel Tank Cap Unscrew to fill up tank then fully tighten. WARNING Fuel may be pressurized, open cap slowly. Fuel is flammable and explosive.

  • Page 45: Heated Grip Switch

    27) Heated Grip Switch Mach Z STD/Tech Plus Three-position toggle switch. Select the desired position to keep your hands at a comfortable temperature. A25H05A TYPICAL — MACH Z STD/TECH PLUS 1. HOT 2. OFF 3. WARM GT SE This toggle-type switch allows selecting 5 different intensity of han- dlebar grip heatings.

  • Page 46: Heated Grip Pilot Lamp (Yellow)

    Holding switch for more than about 1 second will increase to maxi- mum intensity or OFF position according selected position. 1. Holding + position for more than 1 second will increase heating to maximum 28) Heated Grip Pilot Lamp (Yellow) GT SE The pilot lamp in center of cluster lights up when heated grips are switched on.

  • Page 47: Heated Throttle Lever Switch

    29) Heated Throttle Lever Switch Mach Z STD/Tech Plus Three-position toggle switch. Select the desired position to keep your right thumb at a comfortable temperature. See illustration above. GT SE This toggle-type switch allows selecting 5 different intensity of throt- tle lever heatings.

  • Page 48: 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. TYPICAL 32) Hood Latches Unhook the latches to unlock the hood from its anchors.

  • Page 49: Adjustable Toeholds

    34) 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. Securely tighten all adjustments. Do not adjust too snugly. RIGHT SIDE SHOWN 1.

  • Page 50: Adjustable Handlebar

    35) Adjustable Handlebar Handlebar angle can be adjusted to suit driver’s preference. Lift lever, tilt handlebar to desired position then release lever. WARNING Adjust with vehicle at rest in a safe place. Securely tighten all adjustments. 1. Lever...

  • Page 51: Adjustable Windshield

    36) Adjustable Windshield Windshield height can be adjusted to suit driver’s preference. Posi- tion 1 corresponds to lower windshield height. Position 10 corre- sponds to higher windshield height. Knobs are locked on each position. To unlock first pull knobs then, turn to adjust windshield height.

  • Page 52: 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 tighten all adjustments. 1. Lift adjustment lock (both sides) 2. Turn adjustment knob Secure adjustment locks after desired position is obtained.

  • Page 53: Adjustable Rear Grab Handles

    39) Adjustable Rear Grab Handles Height of rear grab handles can be adjusted. Lift adjustment lock, move grab handle to desired position. Secure adjustment lock. Proceed the same with the other side. WARNING Adjust with vehicle at rest in a safe place. Securely tighten all adjustments.

  • Page 54: Hood Grills

    40) Hood Grills These hood grills must be closed at all times except when riding at high speeds and/or when outside temperature is above 5°C (40°F). Slightly unscrew wing nuts, slide close grills then, retighten wing nuts. 1. Grills...

  • Page 55: Rear Passenger Heated Grip Switch

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

  • Page 56: Fuel Shut-Off Valve

    42) Fuel Shut-Off Valve Valve should be closed when transporting or storing snowmobile. 1. Opened 2. Closed Fully open the valve in order to operate the snowmobile. CAUTION: Always fully open the valve before riding. Never allow the valve to remain half opened. 43) Storage Compartment A storage compartment is provided inside rear portion of seat.

  • Page 57: Tool Box

    44) Tool Box A tool box containing tools for basic maintenance is supplied with the vehicle. Tool box is located in engine compartment in front of belt guard. NOTE: The plastic bag containing tools may be discarded to ease storing tools. 1.

  • Page 58: Spark Plug Holder

    45) Spark Plug Holder To keep spare spark plugs dry and prevent shocks that might affect the adjustment or break them, a compartment is provided in tool box. NOTE: Always adjust spark plug gap according to SPECIFICATIONS section in this guide. 1.

  • Page 59: Fuses

    47) Fuses Fuse Location Some fuses are located on top of right side footrest. To gain access open hood. 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.

  • Page 60: Front Grab Handles/Front Bumper

    To remove fuse from holder, pull fuse out. Check if filament is melted. 1. Fuse 2. Check if melted Electric Fuel Level Gauge Fuse See an authorized SKI-DOO dealer for fuse replacement. 48) Front Grab Handles/Front Bumper To be used whenever front of snowmobile requires lifting. 1. Front grab handles...

  • Page 61: Adjustable Suspensions

    49) 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. TYPICAL 1. Decal 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.

  • Page 62: Guidelines To Adjust Suspension

    TYPICAL 1. Rear springs for comfort and ride height 2. Center spring for steering behavior 3. Coupling blocks — Handling 4. Stopper strap for snowmobile weight transfer 5. Front springs for handling 6. Rear shock motion ratio — Damping strength 7.
  • Page 63 1. Rear Springs — Comfort and Ride Height When driver and passenger (if so applicable) take place rear of snow- mobile should collapse by 50 to 75 mm (2 to 3 in). TYPICAL — PROPER ADJUSTMENT A. 50 to 75 mm (2 to 3 in)
  • Page 64 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. TYPICAL 1. Increase spring preload...
  • Page 65 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. TYPICAL 1. Decrease spring preload...
  • Page 66 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. TYPICAL — GOOD ADJUSTMENT AT MODERATE SPEED 1. Steering easy to turn...
  • Page 67 TYPICAL — TOO SOFT OF ADJUSTMENT 1. Steering hard to turn TYPICAL 1. Use adjuster wrench provided in tool box to increase preload...
  • Page 68 TYPICAL — TOO HARD OF ADJUSTMENT 1. Steering less aggressive TYPICAL 1. Use adjuster wrench provided in tool box to decrease preload...
  • Page 69 3. Coupling Blocks — Handling Ride at moderate speed and check for desired handling. 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 70 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 4.
  • Page 71 TYPICAL — GOOD ADJUSTMENT AT FULL ACCELERATION 1. Comfortable steering 2. Good weight transfer to the track 3. Light pressure of skis on the ground...
  • Page 72 TYPICAL — TOO LONG STRAP 1. Skis lift off the ground A03F0QB TYPICAL 1. Reduce strap length by bolting to a different hole...
  • Page 73 TYPICAL — TOO SHORT STRAP 1. Heavy steering A03F0QB TYPICAL 1. Increase strap length by bolting to a different hole...
  • Page 74 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. TYPICAL — PROPER ADJUSTMENT 1. Good handling and comfortable steering...
  • Page 75 TOO SOFT OF ADJUSTMENT 1. Bad handling 1. Increase spring preload...
  • Page 76 TOO HARD OF ADJUSTMENT 1. Steering hard to turn 1. Decrease spring preload...
  • Page 77 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. 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 78: 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 79: Fuel And Oil

    FUEL AND OIL Recommended Fuel Use super 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 91 or higher. NOTE: In most service station pump octane number corresponds to (R + M)/2 octane number.

  • Page 80: 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 81: 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 82: 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 authorized SKI-DOO dealer in case of any leaks.
  • Page 83 • Verify that air filter(s) is free of snow and ice, 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.

  • Page 84: Pre-Operation Check List

    PRE-OPERATION CHECK LIST ITEM OPERATION Track and idler wheels Check for free movement. Brake lever Check proper action. Parking device Check proper action. Throttle lever Check proper action. Switches and lights Check proper action. Skis and steering Check proper action. Check for proper level and Fuel and oil leaks.

  • Page 85: 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 86: Starting The Engine

    Starting the Engine WARNING Operator and passenger (if applicable) must be properly seated 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 87 When Temperature is Above - 10°C (above + 15°F) Set the choke lever to the first position. Grasp starter handle firmly and crank engine. After the engine is started, close off choke to ensure proper air-fuel mix. Warm Engine Starting Start the engine without any choke.

  • Page 88: Emergency Starting

    Manual Starting All Models Insert the key if so equipped in the ignition switch and turn to ON posi- tion. Grasp manual starter handle firmly and crank engine. WARNING Do not apply throttle while starting. Electric Starting (some models only) Insert key in ignition switch.
  • Page 89 Use the spark plug socket as an emergency handle. WARNING Do not wind starting rope around your hand. Hold rope by the han- dle only. 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.

  • Page 90: Shutting Off The Engine

    Start engine as described in COLD ENGINE STARTING or WARM ENGINE STARTING according to engine temperature. Pull the rope using a sharp, crisp pull so the rope comes free of the drive pulley. WARNING When starting the snowmobile in an emergency situation us- ing drive pulley, do not reinstall the belt guard and return slowly to have snowmobile repaired.

  • Page 91: Special Operations

    600 m (2000 ft). Engine Overheating Reduce snowmobile speed and run snowmobile in loose snow or stop engine immediately. Check for adequate coolant level. See an authorized SKI-DOO dealer. Fuel Flooded Engine All Models WARNING Do not hold throttle partially or fully open when starting a fuel flooded engine.

  • Page 92: Periodic Maintenance Chart

    MONTHLY OR EVERY 800 km (500 miles) ONCE A YEAR OR EVERY 3200 km (2000 miles) STORAGE (To be performed by SKI-DOO dealer) PRE-SEASON PREPARATION (To be performed by SKI-DOO dealer) PERIODIC MAINTENANCE CHART Starting Rope Condition Engine Head Screws...
  • Page 93 PERIODIC MAINTENANCE CHART Brake Fluid Level Brake Fluid (change once a year) Brake Condition Drive Chain Tension Countershaft Lubrication** Chaincase Oil Level Chaincase Oil Change Lubrication of Drive Axle End Bearing** Handlebar Bolts, Retorque to 26 N•m (19 lbf•ft) Steering and Front Suspension Mechanism Lubrication** Steering and Front Suspension Mechanism Condition...

  • Page 94: Fluid Levels

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

  • Page 95: Chaincase 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 BOMBARDIER synthetic chaincase oil (P/N 413 803 300 —...

  • Page 96: Oil Injection System

    Oil Injection System Always maintain a sufficient amount of recommended BOMBARDIER 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 97: Cooling System

    (engine cold) of coolant tank. 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. NIVEAU FROID NIVEAU FROID...

  • Page 98: 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 re- moved for all maintenance procedures.
  • Page 99 1. Slots 1. Rear of belt guard properly installed Push down front portion of belt guard in retainer. NOTE: Belt guard is purposely made slightly oversize to maintain ten- sion on its pins and retainers preventing undue noise and vibration. It is important that this tension be maintained when reinstalling.

  • Page 100: 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 box. DRIVE BELT INSTALLER/REMOVER Screw drive belt installer/remover in the free threaded hole and tight- en to open the pulley.
  • Page 101 Slip the belt over the top edge of the sliding half, as shown in previous photo. Remove access panel from bottom pan. 1. Push top of panel out of bottom pan 1. Pull panel tab out of bottom pan...
  • Page 102 Slip belt under drive pulley then, remove it from vehicle. 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. See arrow on belt. 1.

  • Page 103: Drive Chain Tension

    CAUTION: Do not force or use tools to pry the belt into place, as this could cut or break the cords in the belt. Remove drive belt installer/remover. Reinstall access panel and belt guard. 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.
  • Page 104 To adjust, modify ramp end position by turning calibration screws. Calibration screw has a notch on top of its head. A16D0FA 1. Notch Governor cup has 6 positions numbered 2 to 6. Note that in position 1 the number is substitued by a dot (due to its location on casting). 1.
  • Page 105 Lower numbers decrease engine RPM in steps of 200 RPM and high- er 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. To adjust: Just loosen locking nut enough to pull calibration screw partially out and adjust to desired position.

  • Page 106: Drive Belt Condition

    RPM with frozen track, fast starts without warm-up period, burred or rusty sheave, oil on belt or distorted 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 107: Track 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. WARNING Do not operate or rotate a track if torn, damaged or excessively worn.
  • Page 108 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 109 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 110 Start the engine and accelerate slightly so that track barely turns. This must be done in a short period of time (1 to 2 minutes). Check that the track is well centered; equal distance on both sides between edges of track guides and slider shoes. A01F05A TYPICAL 1.

  • Page 111: Steering And Front Suspension Mechanism

    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 your SKI-DOO dealer. Wear and Condition of Skis and Runners Check the condition of the skis, ski runners and ski runner carbides.

  • Page 112: Exhaust System

    Exhaust System The tail pipes of the muffler should be centered with the exit holes in the bottom pan. Exhaust system must be free of rust or leaks. The exhaust system is designed to reduce noise and to improve the total performance of the engine.
  • Page 113 Reinstall filter over dashboard sticking bottom edge first. 1. Stick bottom edge first Finalize filter top edge installation. 1. Push top edge of filter under air deflector lip...
  • Page 114 Check air silencer filter for snow. Remove filter and shake it as re- quired. AIR SILENCER FILTER INSTALLED Check that the air silencer is clean and dry and properly reinstall the filter. CAUTION: Snowmobile engines have been calibrated with the filter installed.

  • Page 115: Headlight Beam Aiming

    Headlight Beam Aiming Turn knob to adjust beam height. 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 116 1. Air deflector Unplug burnt bulb connector. Remove the rubber boot. Turn bulb locking ring counterclockwise to remove it. Detach the bulb and replace. Properly reinstall parts including air filter. 1. Locking ring...
  • Page 117 Instrument(s) All Models Remove air duct from underneath hood. 1. Remove these screws Mach Z STD/Tech Plus 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. A06H1EA TYPICAL —...

  • Page 118: Storage And Pre-Season Preparation

    To remove, unscrew the 2 lens screws. STORAGE AND PRE-SEASON PREPARATION WARNING Have an authorized SKI-DOO dealer inspect 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 119: Troubleshooting

    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 120 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 121 4. Engine is running too hot. See item 8 of “Engine lacks accelera- tion or power”. 5. Ignition timing is incorrect or there Contact an authorized SKI-DOO dealer. is an ignition system failure. SYMPTOM: Engine misfires. POSSIBLE CAUSES WHAT TO DO 1.
  • Page 122 3. Drive belt. Check item 6 of “Engine lacks acceler- ation or power”. 4. Incorrect track adjustment. See MAINTENANCE section and/or SKI-DOO dealer for proper alignment and tension adjustments. 5. Pulleys misaligned. Contact an authorized SKI-DOO dealer. 6. Engine. See items 3 to 8 of “Engine lacks ac-...

  • Page 123: Specifications

    SPECIFICATIONS MACH Z STD GRAND GENERAL MACH Z TECH TOURING SE PLUS Engine – Maximum Power 8000 8300 Engine Speed Drive belt – Number 417 300 066 – Width of a New Belt mm (in) 35.1 (1.382) – Wear Limit Width mm (in) 32.7 (1.287) Spark plug...

  • 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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