Ski-Doo 2000 ZX series Operator's Manual
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Ski-Doo 2000 ZX series Operator's Manual

Ski-Doo 2000 ZX series Operator's Manual

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  • Page 2: Safety Warning

    After Sales Service Valcourt (Quebec) Canada J0E 2L0 The following are trademarks of Bombardier Inc. BOMBARDIER ® SKANDIC* TUNDRA* FORMULA* SKI-DOO ® CK3* Printed in Canada (Mmo2000-003a.fm GM) ® *Trademarks of Bombardier Inc. © 1999 Bombardier Inc. All rights reserved.
  • Page 3 2000 SKI-DOO OPERATOR’S GUIDE This guide is applicable to the following ZX series models: Formula Z 600 Formula Z 700 Formula Deluxe 600 Formula Deluxe 700 Grand Touring 600 MX Z 500 MX Z 600 MX Z 700 MX Z 700 Millennium Edition...
  • 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 NOTICE The Operator’s Guide and the Snowmobiler’s Safety Handbook have been prepared to acquaint the owner/operator and passenger of a new snowmobile with the various snowmobile controls, mainte- nance and safe operating instructions. Each is indispensable for the proper use of the product. This guide uses the following symbols.

  • Page 6: Table Of Contents

    BOMBARDIER INTERNATIONAL LIMITED WARRANTY ® 2000 SKI-DOO SNOWMOBILE ..........OFTEN ASKED QUESTIONS ........... LIST OF CUSTOMER RELATIONS OFFICES ......AUTHORIZED SKI-DOO DEALERS ......... HOW TO IDENTIFY YOUR SNOWMOBILE ......Vehicle Identification Number Location........Engine Serial Number Location ..........ON-VEHICLE IMPORTANT INSTRUCTIONS......CONTROLS/INSTRUMENTS ..........
  • Page 7 24) Heated Throttle Lever Switch ..........25) Electric Visor Jack Connector ..........26) Hood Latches ............... 27) Adjustable Mirrors..............Hood Grills ................. Adjustable Backrest ..............Rear Passenger Heated Grip Switch.......... Storage Compartment ............... Tool Bag ..................Fuses ..................Spare Spark Plug Holder ............Spare Drive Belt Holder .............
  • Page 8 MAINTENANCE ............... Guard Removal and Installation ..........Drive Belt Removal/Installation ..........Drive Chain Tension ..............TRA Drive Pulley Adjustment ............ Drive Belt Condition ..............Brake Condition ................. Brake Adjustment..............Rear Suspension Condition ............Suspension Stopper Strap Condition......... Track Condition................Track Tension and Alignment ............ Steering and Front Suspension Mechanism ......

  • Page 9: Safety Measures

    Use of Rotax ® snowmobile engines in other than SKI-DOO snowmobiles is not recommended or autho- rized by Bombardier Inc. 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 10 Reverse models only: These snowmobiles are capable of a fast reverse. Always remain seated and apply the brake before shifting. Come to a complete stop before pressing the reverse button. En- sure the path behind is clear of obstacles or bystanders. Fast re- verse while turning could result in loss of stability.

  • Page 11: Bombardier Limited Warranty 2000 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 Cov- erage Period as for the SKI-DOO snowmobile. 2. WHAT BOMBARDIER WILL DO...
  • Page 12 WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR FIT- NESS FOR ANY PARTICULAR PURPOSE. Neither the distributor, any authorized SKI-DOO dealer nor any other person has been authorized to make any affirmation, representation or warranty other than those con- tained in this warranty, and if made, such affirmation, representation or warranty shall not be enforceable against BOMBARDIER or any other person.

  • Page 13: Bombardier International Limited Warranty 2000 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 ser-...
  • Page 14 BOMBARDIER or any other person. Every SKI-DOO snowmobile is sold with the English version of this warranty. A spe- cific SKI-DOO International Distributor may elect to translate this warranty into local language, it is then understood and agreed that in the event of any discrepancy among the two versions, the English version shall prevail.

  • Page 15: Often Asked Questions

    OFTEN ASKED QUESTIONS Q: Why must my snowmobile be registered at the factory? After all I do have my original invoice as proof of when I purchased my snowmobile. A: Registration is very important and your dealer must register your snowmobile with Bombardier. Make sure the card has been sent.
  • Page 16 If the problem already has been re- viewed with the Sales Manager or Service Manager, contact the Dealer himself or the General Manager. We are always pleased to receive your comments on the SKI-DOO snowmobile.

  • Page 17: List Of Customer Relations Offices

    Telephone: (715) 848-4957 Fax: (715) 848-4978 OTHER COUNTRIES For customer relations, contact your local distributor. Your local dealer can provide distributor contact information. AUTHORIZED SKI-DOO DEALERS For Canada and USA Only To find the nearest authorized SKI-DOO dealer, dial: 1-800-375-4366.

  • Page 18: How To Identify Your Snowmobile

    HOW TO IDENTIFY YOUR SNOWMOBILE The main components of your snowmobile (engine and frame) are identified by different serial numbers. It may sometimes become necessary to locate these numbers for warranty purposes or to trace your snowmobile in the event of loss. These numbers are required by the dealer to complete warranty claims properly.

  • Page 19: Engine Serial Number Location

    Engine Serial Number Location A32C01B TYPICAL 1. Engine serial number...

  • Page 20: On-Vehicle Important Instructions

    ON-VEHICLE IMPORTANT INSTRUCTIONS Please read the following instructions carefully before operating snowmobile. 5 6 7 8 A32A02B LOCATION OF IMPORTANT INSTRUCTIONS Instruction 1 A01A1XB TYPICAL — SUMMIT MODELS...
  • Page 21 Instruction 2 A01A1ZD ALL MODELS Instruction 3 A32A08A TYPICAL — ALL MODELS WITH REVERSE Instruction 4 WARNING. WARNING. AVERTISSEMENT. AVERTISSEMENT. Read & follow all Warning Labels & Operators Guide/Safety Handbook before operation. Read & follow all Warning Labels & Operators Guide/Safety Handbook before operation. Lisez et respectez scrupuleusement tous les avertissements contenus dans le Lisez et respectez scrupuleusement tous les avertissements contenus dans le Severe injury or death can result from ignoring warnings or through improper use of snowmobile.
  • Page 22 Instruction 4 A01A29A DOUBLE SEAT MODELS Instruction 5 A02A07C ALL MODELS Instruction 6 A02A06C ALL MODELS...
  • Page 23 Instruction 7 A01A24D TYPICAL — ALL MODELS Instruction 8 SUSPENSION ADJUSTMENT CHART/TABLEAU DES RÉGLAGES DE LA SUSPENSION FRONT SUSPENSION (SKI)/SUSPENSION AVANT (SKI) NOT APPLICABLE SANS OBJET REAR SUSPENSION/SUSPENSION ARRIÈRE ADJUST ACCORDING TO LOAD/RÉGLER SELON LA CHARGE LOAD REAR SPRING CHARGE RESSORT ARRIÈRE APPLICABLE SANS OBJET...

  • Page 24: Controls/Instruments

    CONTROLS/INSTRUMENTS NOTE: Some controls/instruments are optional on some models. A32A09A TYPICAL 17 16 14 15 A32A0AA TYPICAL...

  • Page 25: 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. 2) Brake Lever Located on the left side of handlebar. When compressed, the brake is applied.

  • Page 26: Injection Oil Level/Parking Brake Pilot Lamp (Red)

    A30D01A 1. Locking lever 2. OFF 3. ON 4) Injection Oil Level/Parking Brake Pilot Lamp (Red) 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 27: Gear Shift Lever

    5) Gear Shift Lever With engine running, a warning buzzer will sound when the shift lever is in reverse gear position. A 2-position lever: Move lever toward left side: Forward gear. Move lever toward right side: Reverse gear. A32D0AA 1. Forward 2.

  • Page 28: Ignition Switch

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

  • Page 29: Tether Cut-Out Switch

    7) Tether Cut-Out Switch General Lights are automatically ON whenever the engine is running. There is no ignition key on certain models, the tether cut-out system shuts-off engine if the driver accidently falls off the vehicle and the DESS (Digitally Encoded Security System) performs the same function as a key.
  • Page 30 To stop engine, completely pull cap from safety switch. A32H0EA DESS (Digitally Encoded Security System) Description This system is a deterrent against theft. The tether cord provided with your snowmobile is dealer programmed and is the only one that allows engine to turn more than 3000 RPM. If an incorrectly pro- grammed tether cord is installed the engine can not reach engage- ment speed required to move vehicle.

  • Page 31: Dess Pilot Lamp

    DESS Pilot Lamp Codes DESS pilot lamp blinking one time per three seconds means that a bad connection has been detected. Vehicle can not be driven. To check for bad connection, remove tether cord. Make sure it is free of dirt or snow. Reinstall tether cord and restart engine. If a blink per 3 seconds still occurs contact an authorized dealer.

  • Page 32: Engine Cut-Out Switch

    9) 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 33: 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 34: Choke Lever

    13) Choke Lever This device features a 3-position lever to facilitate cold start. A32H01A 0. OFF 1. Position 1 2. Position 2 See STARTING PROCEDURE for more details. 14) Speedometer These vehicles are equipped with a speedometer graduated in km or miles according to country of use.

  • Page 35: Trip Meter Reset Button

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

  • Page 36: Tachometer

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

  • Page 37: Temperature Gauge

    19) 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 38: Fuel Tank Cap/Gauge

    21) Fuel Tank Cap/Gauge On some models fuel level gauge is part of fuel tank cap. Unscrew to fill up tank then fully tighten. A32I01A WARNING Never use an open flame to check fuel level. CAUTION: Do not mismatch oil reservoir cap with fuel tank cap. Install cap that features fuel gauge.

  • Page 39: Electric Gauge

    22) Electric Gauge Dash-mounted gauge to facilitate fuel level reading. This gauge func- tions when engine is running. A30H0HA TYPICAL 1. Full 2. Empty 23) Heated Grip Switch Three-position toggle switch. Select the desired position to keep your hands at a comfortable temperature.

  • Page 40: Heated Throttle Lever Switch

    24) Heated Throttle Lever Switch Three-position toggle switch. Select the desired position to keep your right thumb at a comfortable temperature. A32H0FA HEATED GRIP SWITCH HEATED THROTTLE LEVER SWITCH 1. HOT 4. HOT 2. OFF 5. OFF 3. WARM 6. WARM 25) Electric Visor Jack Connector An electric visor can be connected to the jack connector.

  • Page 41: Hood Latches

    A30E09A TYPICAL 26) Hood Latches Stretch and unhook the latches to unlock the hood from its anchors. A32H02A 1. Latch 2. Recess provided to open hood Always lift hood gently until stopped by retaining device.

  • Page 42: Adjustable Mirrors

    27) Adjustable Mirrors Each mirror can be adjusted to suit driver’s preference. 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 43 A32H04A TO OPEN, SQUEEZE OPENING TABS BETWEEN THUMB AND INDEX...

  • Page 44: Adjustable Backrest

    Adjustable Backrest The backrest position and support angle may be adjusted to suit driv- er or passenger convenience. A32H0PA 1. Turn adjustment knob 2. Lift adjustment lock (both sides) Secure adjustment locks after desired position is obtained.

  • Page 45: Rear Passenger Heated Grip Switch

    Rear Passenger Heated Grip Switch Three-position switch. Select the desired position to keep rear pas- sager’s hands at a comfortable temperature. A32H0QA TYPICAL — RIGHT SIDE OF PASSENGER GRAB HANDLE 1. Rear passenger heated grip switch Storage Compartment A storage compartment is provided inside rear portion of seat.

  • Page 46: Tool Bag

    Tool Bag A tool bag containing tools for basic maintenance is supplied with the vehicle. Tool bag is located in engine compartment above right hand side toe-hold. A32B01A TYPICAL — TOOL BAG...

  • Page 47: Fuses

    Fuses Starting System Fuse Starting system is protected with a 30 ampere rated fuse. See fol- lowing illustration for fuse holder location. If starter does not operate, check fuse condition and replace if necessary. CAUTION: Do not use a higher rated fuse as this can cause se- vere damage to electric components.

  • Page 48: Spare Spark Plug Holder

    To remove fuse from holder, pull fuse out. Check if filament is melted. A15E0KA 1. Fuse 2. Check if melted Spare Spark Plug Holder To keep spare spark plugs dry and prevent shocks that might affect the adjustment or break them, a holder is provided on the right side of oil tank.

  • Page 49: Spare Drive Belt Holder

    Spare Drive Belt Holder A spare drive belt can be placed in front section of bottom pan. A32H0TA TYPICAL — SPARE DRIVE BELT INSTALLED IN BOTTOM PAN Front Grab Handles/Front Bumper To be used whenever front of snowmobile requires manual lifting. A32H05A 1.

  • Page 50: Fuel And Oil

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

  • Page 51: Cold Weather Carburetion Modifications

    A32I03A 1. Fuel tank cap 2. Oil tank cap figures an oilcan and the words “HUILE - OIL” COLD WEATHER CARBURETION MODIFICATIONS All vehicles have been calibrated for - 20°C (- 4°F). They can be oper- ated at higher temperature without problems. CAUTION: For colder temperatures than - 20°C (- 4°F), carbure- tor(s) must be recalibrated to avoid engine damage.

  • Page 52: Break-In Period

    BREAK-IN PERIOD Engine A break-in period of 10 to 15 operating hours — 500 km (300 mi) — is required before running the snowmobile at full throttle. During this period, maximum throttle should not exceed 3/4. Howev- er, brief full acceleration and speed variations contribute to a good break-in.

  • Page 53: Pre-Start Check

    PRE-START CHECK Check Points • Activate the throttle control lever several times to check that it operates easily and smoothly. It must return to idle position when released. • Release parking brake then activate the brake control lever and make sure the brake fully applies before the brake control lever touches the handlebar grip.

  • Page 54: Starting Procedure

    STARTING PROCEDURE • 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. Initial Cold Starting NOTE: Do not operate the throttle lever during starting.

  • Page 55: Warm Engine Starting

    Warm Engine Starting Start the engine without using choke. Grasp manual starter handle firmly and crank engine or use electric starter on so equipped models. WARNING Do not apply throttle while starting. Emergency Starting The engine can be started with the emergency starter rope supplied with the tool kit.
  • Page 56 A17B01A Wind the rope tightly around drive pulley. When pulled, pulley must rotate counterclockwise. Tie a knot near clip. Hook up clip on drive pulley and wind counter- clockwise up to 3 turns. A19D13A 1. Clip...
  • Page 57 Start engine as described in COLD ENGINE STARTING or WARM ENGINE STARTING according to engine temperature. WARNING When starting the snowmobile in an emergency situation us- ing drive pulley, do not reinstall the guard and return slowly to have snowmobile repaired.

  • Page 58: Suspension Adjustments

    SUSPENSION ADJUSTMENTS For factory recommended adjustments refer to decal on guard. It describes settings for optimum comfort according to load for your SKI-DOO model. A32F0GA 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 59: Guidelines To Adjust Suspension

    A32F0FA TYPICAL 1. Rear springs for comfort and ride height 2. Center spring for steering behavior 3. Acceleration and control modulator (ACM) or coupling blocks — Handling 4. Stopper strap for snowmobile weight transfer 5. Front springs for handling 6. Rear shock motion ratio — Damping strength Guidelines to Adjust Suspension The best way to set up suspension, is to start from factory settings then customize each adjustment one at a time.
  • Page 60 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). A32F0BA TYPICAL — PROPER ADJUSTMENT A. 50 to 75 mm (2 to 3 in)
  • Page 61 A32F0CA TYPICAL — TOO SOFT OF ADJUSTMENT Turn the left side adjustment cam in a clockwise direction, the right side cam in a counterclockwise direction. Left and right adjustment cams may be set at different position. A03F3WA TYPICAL 1. Increase spring preload...
  • Page 62 A32F0DA TYPICAL — TOO HARD OF ADJUSTMENT Turn the left side adjustment cam in a counterclockwise direction, the right side cam in a clockwise direction. Left and right adjustment cams may be at different position. A30F04B TYPICAL 1. Decrease spring preload...
  • Page 63 2. Center Spring — Steering Behavior Ride at moderate speed on a trail. If steering is too easy or too hard to turn, adjust center spring accord- ingly. A32F0EA TYPICAL — GOOD ADJUSTMENT AT MODERATE SPEED 1. Steering easy to turn...
  • Page 64 A32F0EA TYPICAL — TOO SOFT OF ADJUSTMENT 1. Steering hard to turn A32F01A TYPICAL 1. Use adjuster wrench provided in tool bag to increase preload...
  • Page 65 A32F0EA TYPICAL — TOO HARD OF ADJUSTMENT 1. Steering less aggressive A32F01B TYPICAL 1. Use adjuster wrench provided in tool bag to decrease preload...
  • Page 66 3. ACM or Coupling Blocks — Handling Ride at moderate speed and check for desired handling. Grand Touring 600 Only If handling is not firm, turn the nut clockwise. Factory setting is fully tighten. A03F1EA SOME MODELS 1. Nut If handling is too aggressive, turn the nut counterclockwise. WARNING On the threaded rod there must be at least 2 threads exposed beyond the nut.
  • Page 67 All Models Except Grand Touring 600 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. If handling requires adjustment, turn both left and right blocks by 90°. There are only two adjustment positions.
  • Page 68 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 4.
  • Page 69 A32F0EB 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 70 All Models Except Summit Models A32F0EC TYPICAL — TOO LONG STRAP 1. Skis lift off the ground A03F0QB TYPICAL 1. Reduce strap length by bolting to a different hole...
  • Page 71 A32F0EA TYPICAL — TOO SHORT STRAP 1. Heavy steering A03F0QB TYPICAL 1. Increase strap length by bolting to a different hole...
  • Page 72 Summit Models A32F0EC TOO LONG STRAP 1. Skis lift off the ground A03F22A 1. Loosen lock nut, turn knob accordingly then retighten lock nut...
  • Page 73 A32F0EA TOO SHORT STRAP 1. Heavy steering A03F22B 1. Loosen lock nut, turn knob accordingly then retighten lock nut...
  • 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. A32F0EA TYPICAL — PROPER ADJUSTMENT 1. Good handling and comfortable steering...
  • Page 75 Some Models A32F0EA TYPICAL — TOO SOFT OF ADJUSTMENT 1. Bad handling A32F03A 1. Increase spring preload...
  • Page 76 A32F0EA TYPICAL — TOO HARD OF ADJUSTMENT 1. Steering hard to turn A32F03B 1. Decrease spring preload CAUTION: Make sure that both front springs are still preloaded when front of vehicle is off the ground.
  • Page 77 Some Models A32F0EA TOO SOFT OF ADJUSTMENT 1. Bad handling A03F2IA 1. Increase spring preload...
  • Page 78 A32F0EA TOO HARD OF ADJUSTMENT 1. Steering hard to turn A03F2JA 1. Decrease spring preload...
  • Page 79 6. Rear Shock Motion Ratio — Damping Strength Rear shock motion ratio can be adjusted according to driver and pas- senger weight and/or trail condition. There are two adjustment positions. A32F0HA 1. Soft position 2. Firm position To adjust, loosen nut, move bolt to desired position then torque nut to 24 N•m (18 lbf•ft).

  • Page 80: Troubleshooting Chart

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

  • Page 81: Lubrication And Maintenance Chart

    LUBRICATION AND MAINTENANCE CHART Some items may not apply to your particular model. Refer to LUBRI- CATION and MAINTENANCE section of Shop Manual for more details. 1 0-HOUR OR 500 km (300 mi) INSPECTION (To be performed by dealer) W EEKLY OR EVERY 240 km (150 mi) M ONTHLY OR EVERY 800 km (500 mi) O NCE A YEAR OR EVERY 3200 km (2000 mi) S TORAGE (To be performed by dealer)
  • Page 82 LUBRICATION AND MAINTENANCE CHART       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 83: Fluid Levels

    FLUID LEVELS Brake System Check brake fluid (DOT 4) in reservoir on handlebar for minimum lev- el. Add fluid (DOT 4) as required. CAUTION: Use only (DOT 4) brake fluid from a sealed container. A30D08A TYPICAL 1. Minimum Chaincase/Gearbox Oil Level With snowmobile on a level surface, check the oil level by removing dipstick.
  • Page 84 A32D02A TYPICAL 1. Dipstick 2. Oil level 3. Level between marks...

  • Page 85: Oil Injection System

    Oil Injection System Always maintain a sufficient amount of BOMBARDIER-ROTAX injec- tion oil (P/N 413 802 900 — 12 x 1 L) in the injection oil reservoir. CAUTION: Never allow oil level to drop more than 2/3. Do not mismatch oil reservoir cap with fuel tank cap. Install cap that is identified OIL.

  • Page 86: Cooling System

    Cooling System Check coolant level at room temperature. Liquid should be at level mark (engine cold) of coolant tank. NOTE: When checking level at low temperature it may be slight lower then mark. If additional coolant is necessary or if entire system has to be refilled, refer to an authorized dealer.

  • Page 87: Maintenance

    MAINTENANCE Guard Removal and Installation 1. Open hood. 2. Open retainer to release pin then pull guard toward center of ve- hicle. A32C05A TYPICAL 1. Pin retainer When reinstalling guard, position its cut-away toward front of snow- mobile. Refer to decal in guard.
  • Page 88 Place pulley guard in front tabs first, then snap rear part in retainer. A32C06A TYPICAL 1. Slots NOTE: Guard is purposely made slightly oversize to maintain tension on its pins and retainers preventing undue noise and vibration. It is important that this tension be maintained when reinstalling.

  • Page 89: Drive Belt Removal/Installation

    Drive Belt Removal/Installation 1. Remove tether cord cap. 2. Open hood and remove guard. 3. Open the driven pulley with the drive belt installer/remover provid- ed in tool bag. A03D2PA DRIVE BELT INSTALLER/REMOVER – Screw tool in the free threaded hole and tighten to open the pulley. Remove belt.
  • Page 90 A30D0BA TYPICAL 1. Tighten to open pulley Slip the belt over the top edge of the sliding half, as shown in previous photo. Remove access panel from bottom pan. A32H07A 1. Push tab down and remove panel out of bottom pan...
  • Page 91 A32H06A PULL PANEL OUT OF BOTTOM PAN Slip belt under drive pulley then, remove it from vehicle. A30D0CA TYPICAL...
  • Page 92 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. A30D0DA TYPICAL 1. Arrow pointing front of vehicle CAUTION: Do not force or use tools to pry the belt into place, as this could cut or break the cords in the belt.

  • Page 93: Drive Chain Tension

    Drive Chain Tension Remove hair pin. Fully tighten tensioner adjustment screw by hand, then back off only far enough for hair pin to engage in locking hole. A32D03A 1. Hair pin 2. Adjustment screw TRA Drive Pulley Adjustment The drive pulley is factory calibrated to transmit maximum engine power at a predefined RPM.
  • Page 94 NOTE: The adjustment has an effect on high RPM only. To adjust, modify ramp end position by turning calibration screws. Calibration screw has a notch on top of its head. A16D0FA 1. Notch Governor cup has 6 positions numbered 2 to 6. Note that in position 1 the number is substitued by a dot (due to its location on casting).
  • Page 95 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 of 400 RPM. CAUTION: Do not adjust TRA drive pulley so that engine turns over maximum power RPM.

  • Page 96: Drive Belt Condition

    Drive Belt Condition Inspect belt for cracks, fraying or abnormal wear (uneven wear, wear on one side, missing cogs, cracked fabric). If abnormal wear is noted, probable cause could be pulley misalignment, excessive RPM with frozen track, fast starts without warm-up period, burred or rusty sheave, oil on belt or distorted spare belt.

  • Page 97: Track Tension And Alignment

    Do not modify track, including by installing traction enhancing prod- ucts. This may weaken the track and cause it to break without warn- ing. WARNING Do not operate or rotate a track if torn, damaged or excessively worn (fibers showing). Track Tension and Alignment Tension NOTE: Ride the snowmobile in snow about 15 to 20 minutes prior...
  • Page 98 A06F1WA TYPICAL 1. 7.3 kg (16 lb) 2. Deflection 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. –...
  • Page 99 If correct tension is unattainable, contact an authorized dealer. A30F03A TYPICAL 1. Adjustment screw 2. Loosen screw 3. Wheel cap removing Alignment NOTE: Track tension and alignment are inter-related. Do not adjust one without the other. WARNING Before checking track alignment, ensure that the track is free of all particles which could be thrown out while track is rotat- ing.
  • Page 100 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 101: Steering And Front Suspension Mechanism

    Retighten wheel screws to 48 N•m (35 lbf•ft). WARNING Properly tighten wheel screws. A32F02A TYPICAL 1. Retighten to 48 N•m (35 lbf•ft) Restart engine and rotate track slowly to recheck alignment. Reposition snowmobile on ground. Steering and Front Suspension Mechanism Visually inspect steering and front suspension mechanism for tight- ness of components (steering arms, control arms and links, tie rods, ball joints, ski coupler bolts, etc.) If necessary, contact your dealer.

  • Page 102: 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 103 A32H0RA REMOVAL OF RIGHT SIDE PRIMARY FILTER GRILL A32H0SA REMOVAL OF FILTER FROM ITS GRILL...

  • Page 104: High Altitude Kit

    A32H0OA SECONDARY FILTER INSTALLED ON AIR SILENCER Check that the air silencer is clean and dry and properly reinstall the filter. CAUTION: Snowmobile engines have been calibrated with the filter installed. Operating the snowmobile without it may cause engine damage. High Altitude Kit If you reside or ride at altitudes above 1200 m (4000 ft), your snow- mobile should have a high altitude kit installed.

  • Page 105: Headlight Beam Aiming

    Headlight Beam Aiming Turn knob to adjust beam height. A32E01A TYPICAL 1. Knob Bulb Replacement Always check light operation after bulb replacement. Headlight CAUTION: Never touch glass portion of an halogen bulb with bare fingers, it shortens its operating life. If glass is touched, clean it with isopropyl alcohol which will not leave a film on the bulb.
  • Page 106 A32E02A 1. Bulb connector 2. Rubber boot Unfasten bulb retainer ring. Detach the bulb and replace. Properly reinstall parts. A30E05A 1. Locking ring...
  • Page 107 Instrument(s) All Models Remove air duct from underneath hood. A32E03A TYPICAL 1. Remove these screws...

  • Page 108: Chromed Parts On Millennium Edition Models

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

  • Page 109: Troubleshooting

    TROUBLESHOOTING SYMPTOM: Engine turns over but fails to start. POSSIBLE CAUSES WHAT TO DO 1. Emergency cut-out switch or tether Place all switches in the ON position. switch is in the OFF position. 2. Mixture not rich enough to start Check fuel tank level and check cold engine.
  • Page 110 SYMPTOM: Engine lacks acceleration or power. POSSIBLE CAUSES WHAT TO DO 1. DESS has not read tether cord. DESS pilot lamp blinks once every 3 Engine can not exceed 3000 RPM. seconds. Properly install tether cord. 2. DESS is activated. DESS pilot lamp blinks rapidly.
  • Page 111 SYMPTOM: Engine misfires. POSSIBLE CAUSES WHAT TO DO 1. DESS has not read tether cord. DESS pilot lamp blinks once every 3 Engine can not exceed 3000 RPM. seconds. Properly install tether cord. 2. DESS is activated. DESS pilot lamp blinks rapidly. Install Engine can not exceed 3000 RPM.

  • Page 112: Specifications

    SPECIFICATIONS MX Z 500 Summit 600 MX Z 600 GENERAL Formula Z 600 Grand Touring Formula Deluxe Engine – Maximum Power 8000 8000 Engine Speed Drive belt – Part Number 414 860 700 414 860 700 – Width of a New Belt mm (in) 34.9 (1.374) 34.9 (1.374)

  • Page 113: Formula Z

    MX Z 700 Summit 700 MX Z 700 Summit 700 Millennium H.M. GENERAL Edition Summit 700 Formula Z 700 Millennium Formula Deluxe Edition Engine – Maximum Power 8000 8000 Engine Speed Drive belt – Part Number 417 300 067 417 300 128 –...
  • Page 114 Measure gap between slider shoe and bottom inside of track when exerting a downward pull of 7.3 kg (16 lbf) to the track. Equal distance between edges of track guides and slider shoes. Regular unleaded gasoline with a minimum octane number of 87 (R + M)/2.

  • Page 115: Other Publications Available

    High Altitude Technical Data 484 200 019 (loose sheets) Binder 484 054 500 1996 - 2000 Specification Booklet 484 200 018 2000 Racing Handbook 484 200 020 Order from your SKI-DOO dealer. Ask your dealer for the appropriate volume you need.

  • Page 116: 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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