Ski-Doo 2005 ZX series Operator's Manual
  1. Manuals
  2. Brands
  3. Ski-Doo Manuals
  4. Offroad Vehicle
  5. 2005 ZX series
  6. Operator's manual
Ski-Doo 2005 ZX series Operator's Manual

Ski-Doo 2005 ZX series Operator's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 2005 ZX series and is the answer not in the manual?

Questions and answers

Related Manuals for Ski-Doo 2005 ZX series

Summary of Contents for Ski-Doo 2005 ZX series

  • 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. SKI-DOO ADRENALINE LEGEND ROTAX DESS ®...
  • Page 3 Whatever model you have chosen, it is backed by the Bombardier Recreational Products inc. (BRP) warranty and a network of autho- rized SKI-DOO snowmobile dealers ready to provide the parts, ser- vice or accessories you may require. The Operator's Guide has been prepared to acquaint the owner/op- erator and passenger with this new snowmobile and its various con- trols, maintenance and safe riding instructions.
  • Page 4 Your dealer is committed to your satisfaction. He has taken train- ing to perform the initial set-up and inspection of your snowmobile as well as completed the final adjustment required to suit your spe- cific weight and riding environment before you took possession. At delivery, your dealer would have explained the snowmobile controls and provided you with a brief explanation of the various suspension adjustments.

  • Page 5: Table Of Contents

    FREQUENTLY ASKED QUESTIONS ......32 AUTHORIZED SKI-DOO DEALERS ......34 HOW TO IDENTIFY YOUR SNOWMOBILE .
  • Page 6 19) Rewind Starter Handle........90 20) Choke Lever.
  • Page 7 Track ............FUEL AND OIL .
  • Page 8 ® BRP LIMITED WARRANTY NORTH AMERICA: 2005 SKI-DOO SNOWMOBILES ..........

  • Page 9: 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 snowmo- bile.
  • Page 10 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 11 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 au- thorized by BRP or its subsidiaries. Electronic reverse (RER™) models only: The shifting to reverse mode on these snowmobiles is done by the push of the RER button when the engine is running.
  • Page 12 _________________________...

  • 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 Snow- mobile Safety and Certification Committee (SSCC) of which BRP 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 underwear next to the skin also provides an important layer of insu- lation.

  • Page 17: A Word To All Snowmobilers

    A WORD TO ALL SNOWMOBILERS Everyone is a beginner the first time he sits behind the controls of a snowmobile regardless of previous experience in driving an automo- bile, a motorcycle or a motorboat. The safe use of your snowmobile is dependent on many conditions such as visibility, speed, weather, environment, traffic, vehicle condition and the condition of the driver.

  • Page 18: Traction Enhancing Products

    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 regu- lar and safety maintenance, as well as snowmobile accessories you may require.
  • Page 19 1- Oversteering In certain conditions, using more positive carbide ski runners without studding the track could make the snowmobile prone to oversteer- ing, see illustration. OVERSTEERING 2- Understeering In certain conditions, the use of studs could make the snowmobile prone to understeering if the skis are not equipped with more posi- tive carbide runners, see illustration.
  • Page 20 3- Controlled Driving A balanced combination of carbide ski runners and studs ensures adequate control and better handling, see illustration. CONTROLLED DRIVING Acceleration: Studding the track will allow your sled to accelerate better on packed snow and ice but will have no noticeable effect on soft snow. This can cause sudden variations in traction under certain conditions.
  • Page 21 Important Safety Rules: WARNING To prevent serious injury to individuals near the snowmobile: – NEVER stand behind or near a moving track. – Always use a wide-base snowmobile stand with a rear de- flector panel. – When the track is raised off the ground, only run it at the low- est possible speed.
  • Page 22 Installation of Studs: To ensure safe and proper installation, BRP recommends to have the studs installed by your dealer. – Use only studs, mounting plates, and bolts sold by BRP. – Never use studs that exceed the height of your snowmobile’s track profile by more than 9.5 mm (3/8 in).
  • Page 23 APPROVED TRACKS CAN BE IDENTIFIED BY THIS SYMBOL Maintenance/Replacement: PROCEED WITH A VISUAL INSPECTION OF YOUR TRACK BEFORE EACH USE. Look for any defects, such as: – perforations in the track – tears in the track (particularly around traction holes) –...

  • Page 24: Laws And Regulations

    LAWS AND REGULATIONS Federal, state, provincial and local government agencies have en- acted 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. Respect and observance will result in safer snowmobiling for all.

  • Page 25: Summary Of Accident Prevention Practices

    SUMMARY OF ACCIDENT PREVENTION PRACTICES Snowmobiling at night can be a delightful experience but because of reduced visibility, be extra cautious. Avoid unfamiliar terrain and be sure your lights are working. Always carry a flashlight and spare light bulbs. Do not leave your keys in the ignition switch, it presents an invita- tion to thieves and a danger to young children.
  • Page 26 Tailgating another snowmobile should be avoided. If the snowmo- bile in front of you slows for any reason, its driver and passenger could be harmed through your neglect. Maintain a safe stopping distance between you and the snowmobile in front of you. De- pending on the terrain condition, stopping may require a little more space than you think.
  • Page 27 Never have the engine running while the hood is open. Even at idle, a snowmobile engine is turning around 1,800 revolutions per minute. Always turn off the ignition before opening the hood for any reason. Never remove any original equipment from your snowmobile. Each vehicle has many safety features built in.
  • Page 28 A poorly maintained snowmobile itself can be a potential haz- ard. Excessively worn components could render the vehicle completely inoperative. Keep the snowmobile in good working condition at all times. Follow your pre-operation check, weekly, monthly and annually routine maintenance and lubrication proce- dures as detailed in this guide.

  • Page 29: Passenger Safety Basics

    PASSENGER SAFETY BASICS Never ride as a passenger unless the snowmobile is equipped with a passenger seat, and sit only on the designated passenger seat. Always wear an DOT approved helmet, and follow the same dressing guidelines as those recommended for the driver as described above.

  • Page 30: Environment

    ENVIRONMENT There is nothing more exhilarating than snowmobiling. Venturing onto snowmobile trails that criss-cross the wild areas of the U.S. and Canada is an exciting and healthy winter sport. However, as the number of people using these recreational parks increases, so does the potential for damage to the environment.
  • Page 31 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 32 _____ _____ SAFETY INFORMATION...

  • Page 33: Vehicle Information

    VEHICLE INFORMATION __________________________...

  • Page 34: Frequently Asked Questions

    I do have my original invoice as proof of when I pur- chased my snowmobile. A: Registration is very important and your SKI-DOO dealer must register your snowmobile with BRP. Make sure the registra- tion 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 35 If the problem already has been reviewed 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 36: 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 37: How To Identify Your Snowmobile

    HOW TO IDENTIFY YOUR SNOWMOBILE Vehicle Description Decal Vehicle description decal is located on right hand side of tunnel. TYPICAL 1. Vehicle description decal VEHICLE DESCRIPTION DECAL 1. Manufacturer name 2. Manufacturing date 3. Vehicle identification number (VIN) 4. Model name 5.

  • Page 38: Serial Numbers

    These numbers are required by the authorized SKI-DOO dealer to complete warranty claims prop- erly. No warranty will be allowed by BRP if the engine serial number or vehicle identification number (VIN) is removed or mutilated in any way.

  • Page 39: Engine Serial Number Location

    Engine Serial Number Location A25C0MA FAN-COOLED MODELS 1. Engine serial number 2-STROKE LIQUID COOLED MODELS 1. Engine serial number __________________________...
  • Page 40 4-TEC MODELS — RH OF ENGINE 1. Engine serial number _________________________...

  • Page 41: On-Vehicle Important Instructions

    ON-VEHICLE IMPORTANT INSTRUCTIONS The following instructions are on your snowmobile. If missing or damaged, the decals can be replaced free of charge. See an autho- rized SKI-DOO dealer. Please read the following instructions carefully before operating this snowmobile. TYPICAL — LOCATION OF IMPORTANT INSTRUCTIONS — ZX SERIES...
  • Page 42 TYPICAL — LOCATION OF IMPORTANT INSTRUCTIONS — REV SERIES _________________________...
  • Page 43 Instruction 1 ZX SERIES __________________________...
  • Page 44 REV SERIES _________________________...
  • Page 45 Instruction 2 EXPEDITION FAN 550 EUROPEAN MODELS __________________________...
  • Page 46 Instruction 3 ALL MODELS _________________________...
  • Page 47 Instruction 4 4-TEC MODELS WARNING AVERTISSEMENT REV SERIES __________________________...
  • Page 48 Instruction 5 TYPICAL — ALL FAN-COOLED MODELS Instruction 6 4-TEC MODELS _________________________...
  • Page 49 Instruction 7 4-TEC MODELS REV SERIES __________________________...
  • Page 50 Instruction 8 LIQUID-COOLED MODELS Instruction 9 2-TEC MODELS _________________________...
  • Page 51 Instruction 10 4-TEC MODELS Instruction 11 SINGLE SEAT ZX SERIES __________________________...
  • Page 52 SOME MODELS — SINGLE SEAT REV SERIES _________________________...
  • Page 53 SOME MODELS — SINGLE SEAT REV SERIES __________________________...
  • Page 54 Instruction 12 SUMMIT MODELS _________________________...
  • Page 55 Instruction 13 REV SERIES __________________________...
  • Page 56 Instruction 14 SOME MODELS — REV SERIES _________________________...
  • Page 57 Instruction 15 • Read and understand all warning • Lire et comprendre toutes les labels and operator’s guide before étiquettes d’avertissements et le operation. guide du conducteur avant utilisation. • Get familiar with your snowmobile. • Familiarisez-vous avec votre motoneige. •...
  • Page 58 Instruction 17 NEVER SIT IN CARGO AREA. NE JAMAIS S'ASSEOIR À LA PLACE DU CARGO. Excéder le poids maximal du cargo peut Exceeding maximum cargo load affecter le contrôle de la may affect steering direction et la capacité de freinage. control and braking ability.
  • Page 59 Instruction 19 REV SDI MANUAL START MODELS Instruction 20 TYPICAL __________________________...

  • Page 60: Controls/Instruments/Equipment

    CONTROLS/INSTRUMENTS/EQUIPMENT NOTE: Some controls/instruments/equipment do not apply or are optional on some models. In these cases their reference numbers are deliberately missing in the illustrations. TYPICAL — ZX SERIES TYPICAL — REV SERIES _________________________...
  • Page 61 TYPICAL — ZX SERIES __________________________...
  • Page 62 TYPICAL — REV SERIES _________________________...
  • Page 63 TYPICAL TYPICAL — SUMMIT ADRENALINE __________________________...

  • Page 64: 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 automatically to idle. WARNING Test the throttle lever operation each time before starting the engine.

  • Page 65: Brake/Parking Brake Pilot Lamp (Red)

    To engage mechanism, squeeze brake lever and maintain while pulling locking lever with a finger. When brake lever is held at halfway the parking brake should be fully applied. To release mechanism, squeeze brake lever. Locking lever will auto- matically return to its original position. Always release parking brake before riding.

  • Page 66: Gear Shift Lever

    5) Gear Shift Lever ZX Series These models are equipped with a mechanical reverse controlled by a 2-position gear shift lever. 1. Forward 2. Reverse Shifting Procedure WARNING The reverse speed of these snowmobiles is not limited. Al- ways proceed with caution as fast reverse could result in loss of vehicle stability and control.

  • Page 67: Start/Rer Button

    6) START/RER Button General The START/RER button has two functions. All Liquid Cooled Models When the engine is not running, depressing the START/RER button will engage the electric starter on vehicle so equipped and start the engine. REV Series 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 68 Shifting in Reverse REV Series WARNING Shifting to reverse mode on these snowmobiles is done by depressing the START/RER button when the engine is run- ning. Wait until the reverse alarm sounds and the DESS/RER pilot lamp comes on in the dash before operating throttle to proceed in reverse.

  • Page 69: Reverse Pilot Lamp

    WARNING Fast reverse while turning, could result in loss of stability and control. Handlebar height is adjustable. See an authorized SKI-DOO dealer. __________________________...
  • Page 70 Some Models 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 71 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 72 Remove steering cover and console cap. 1. Steering cover 2. Console cap _________________________...
  • Page 73 Unscrew 4 bolts retaining console. 1. Bolts retaining console __________________________...
  • Page 74 Slightly lift console to gain access to electrical connector housings. Unplug the 2 large connector housings and the separate 3 wire con- nector. TYPICAL 1. Large connector housings _________________________...
  • Page 75 Remove console. Remove 2 bolts retaining top of steering column. STEERING COLUMN IN REARWARD POSITION 1. Two bolts retaining top of steering column __________________________...
  • Page 76 Move steering column to forward position. 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). NOTE: Should rearward position be selected, it is mandatory, while changing column position, to relocate fuel tank vent hose as per fol- lowing procedure.
  • Page 77 Locate blue check valve. 1. Check valve __________________________...
  • Page 78 Disconnect fuel tank vent hose from blue check valve. Reroute fuel tank vent hose under upper cross member. ROUTING WITH FORWARD POSITION STEERING COLUMN _________________________...
  • Page 79 ROUTING WITH REARWARD POSITION STEERING COLUMN Reconnect fuel tank vent hose to blue check valve. Reconnect the electrical connectors and reinstall all removed parts. Position of console cap will be inverted. Instead of being above it will be beneath steering column. CONSOLE CAP INSTALLED BENEATH STEERING COLUMN __________________________...
  • Page 80 Reinstall windshield assembly to handlebar. Refer to WINDSHIELD ADJUSTMENT below. 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 81 Handlebar Position Adjustment The handlebar position can be adjusted to suit driver's preferences. Loosen all 4 bolts retaining handlebar to steering column. 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 82 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 pho- tos. Slots in brackets allow different windshield positions. Move wind- shield to fit with console.

  • Page 83: Holding Strap

    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 84: Ignition Switch

    10) Ignition Switch Fan-Cooled Models MANUAL START ELECTRIC START MODELS 1. OFF 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 85: 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 86 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 87 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' keys.

  • Page 88: 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.

  • Page 89: 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 90 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 authorized SKI-DOO dealer for servicing. _________________________...

  • Page 91: Headlamp Dimmer Switch

    SKI-DOO dealer. 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. __________________________...

  • Page 92: Engine Management System (Ems) Pilot Lamp

    18) Engine Management System (EMS) Pilot Lamp This lamp will light up to indicate a trouble. Refer to TROU- BLESHOOTING for trouble code meaning and remedy. 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.

  • Page 93: Speedometer

    Warm Engine Starting Start the engine without any choke. If the engine will not start af- ter two pulls of the rope or two 5 second attempts with the electric starter move choke lever to position 2. Start the engine without ac- tivating the throttle lever.
  • Page 94 ZX SERIES — KILOMETERS READING — CONNECTORS PLUGGED ZX SERIES — MILES READING — CONNECTORS UNPLUGGED _________________________...
  • Page 95 REV SERIES — KILOMETERS READING — CONNECTORS PLUGGED REV SERIES — MILES READING — CONNECTORS UNPLUGGED 1. Locking ties 2. Connectors __________________________...

  • Page 96: Mode Button

    Summit ADRENALINE/X 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. Change from One Unit to the Other NOTE: Speedometer, odometer and trip meter will have their units (kilometer or miles) changed all together.

  • Page 97: Trip Meter

    24) Trip Meter Records distance travelled since it has been reset. Distance trav- elled is displayed either in miles or kilometers. Refer to SPEEDOME- TER for changing units. All Models except Summit ADRENALINE/X 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 98: Tachometer

    26) Tachometer Direct-reading dial indicates the number of thousand of revolutions per minute (RPM) of the engine. MULTIPLY THE READING BY 1000 27) Fuel Tank Cap/Gauge Unscrew to fill up tank then fully tighten. WARNING Always stop the engine before refueling. Fuel is inflammable and explosive under certain conditions.

  • Page 99: Mechanical Fuel Level Gauge

    Some ZX Series Models Fuel tank cap features a mechanical gauge. 28) Mechanical Fuel Level Gauge Located at rear of fuel tank cap the gauge facilitates fuel level read- ing. TYPICAL 1. Full 2. Empty APPROXIMATE REMAINING NEEDLE POSITION OF FUEL FUEL QUANTITY LEVEL GAUGE L ( U.S.
  • Page 100 Summit ADRENALINE/X Open fabric door to see the fuel level through the transparent fuel tank. 1. Fabric door _________________________...

  • Page 101: 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. TYPICAL 1. Full 2. Empty __________________________...

  • Page 102: 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 overheat range, reduce snowmobile speed and run snowmobile in loose snow or stop engine immediately.

  • Page 103: 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. TYPICAL 1. Heating grip switch 2. Heating throttle lever switch 3. Hot 4. Warm 5. Off 33) Heating Throttle Lever Switch Three-position switch.
  • Page 104 ZX SERIES— RIGHT SIDE OF PASSENGER GRAB HANDLE 1. Rear passenger heating grab handles switch REV SERIES — LEFT SIDE OF PASSENGER GRAB HANDLE 1. Rear passenger heating grab handles switch _________________________...

  • Page 105: Seat Strap

    35) Seat Strap Seat strap provides a grip for the passenger. 36) Rear Grab Handles Rear grab handles provides a grip for the passenger. ZX Series — Some Models Height of rear grab handles can be adjusted. Lift adjustment lock, move grab handle to desired position. Secure adjustment lock.

  • Page 106: Adjustable Backrest

    37) Adjustable Backrest The backrest position and support angle may be adjusted to suit driver or passenger convenience. WARNING Adjust with vehicle at rest in a safe place. Securely tighten all adjustments. ZX Series — Some Models 1. Turn adjustment knob 2.

  • Page 107: 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 ex- tension is supplied with the vehicle. It is included in the predelivery kit. Ask your authorized SKI-DOO dealer for the extension. _________________________...
  • Page 108 Driver TYPICAL — ZX SERIES 1. Electric visor jack connector 2. Stress relief extension TYPICAL — REV SERIES 1. Electric visor jack connector 2. Stress relief extension _________________________...
  • Page 109 Passenger REV SERIES — SOME MODELS 1. Electric visor jack connector _________________________...

  • Page 110: 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. 40) Windshield Windshield provides operator comfort, as well as protection by de- flecting wind and snow away from the operator.

  • Page 111: Heated Carburetor Valve

    43) Heated Carburetor Valve The heated carburetor valve should be closed except: • 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 snow dust. TYPICAL —...

  • Page 112: 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. 1. Latch 2. Recess provided to open hood Always lift hood gently until stopped by retaining device. Close hood slowly then hook up latches. REV Series To open hood, slightly widen (pull-out) its both sides top portion in order to unhook its anchors from their grommets.
  • Page 113 1. Anchors 2. Grommets To open a side panel, stretch and unhook the latches. 1. Latch _________________________...
  • Page 114 To remove a side panel remove by pulling up both locking devices from hinge. 1. Locking device _________________________...
  • Page 115 For left hand side panel removal, also unplug vent hose or sensor from air silencer. NON-2-TEC MODELS 1. Vent hose _________________________...

  • Page 116: Fuses

    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. 1. Fuse 2. Check if melted _________________________...
  • Page 117 WARNING If fuse has burnt out, source of malfunction should be de- termined and corrected before restarting. See an authorized SKI-DOO dealer for servicing. Ground Protection Fuse Electric Start Fan-Cooled Models Only Ground wire is protected with a 20 ampere rated fuse. See following illustration for fuse holder location.
  • Page 118 REV Series Models except 2-TEC Accessories Fuse Accessories are protected with 20 ampere rated fuse. See following illustration for fuse holder location. If any of the accessories stops functioning, check fuse condition and replace it if necessary. Headlight Fuse Headlight is protected with 20 ampere rated fuse. See following illustration for fuse holder location.
  • Page 119 CAUTION: This fuse should always be disconnected before do- ing any maintenance under the hood. This is to prevent any un- expected electrical activation. 1. Charging system fuse _________________________...
  • Page 120 MPEM Fuse MPEM is protected with 5 ampere rated fuse. See following illus- tration 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. 1. MPEM fuse _________________________...
  • Page 121 2-TEC and 4-TEC Models To open fuse box push on cover tab and tilt cover. TYPICAL 1. Push tab _________________________...
  • Page 122 TYPICAL 1. Fuse description decal 2. Fuse remover/installer 3. Spare fuses _________________________...
  • Page 123 1. Fuse remover/installer Some Models Electric Fuel Level Gauge Fuse See an authorized SKI-DOO dealer for fuse replacement. _________________________...

  • Page 124: Front Grab Handle/Front Bumper

    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 appro- priate lifting device or have assistance to share lifting stress in order to avoid risk of strain injuries.

  • Page 125: Hood Grills

    All 4-TEC Models To be used whenever snowmobile requires manual pulling. 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. 47) Hood Grills When riding on powdered snow, close plastic sliding hood grills from underneath hood.
  • Page 126 TO CLOSE, SQUEEZE CLOSING TABS BETWEEN THUMB AND INDEX TO OPEN, SQUEEZE OPENING TABS BETWEEN THUMB AND INDEX _________________________...

  • Page 127: Storage Compartment

    48) Storage Compartment WARNING All storage compartments must be properly latched and they must not contain any heavy or breakable objects. ZX Series and Some REV Series Models 1. Storage compartment cover _________________________...
  • Page 128 Some REV Series Models Pull latch slightly upward then, backward to unlock cover. 1. Latch GTX Models 1. Storage compartment _________________________...

  • Page 129: Rear Rack

    49) Rear Rack WARNING All objects in rear rack must be properly latched. Do not carry any breakable objects. Excessive weight in rack may reduce steering ability. CAUTION: Always readjust suspension according to the load. The capacity of this rack is limited. Ride at very low speed when loaded.
  • Page 130 REV SERIES 1. Tool kit _________________________...

  • Page 131: Suitcase

    51) Suitcase GTX Limited CAUTION: MAXIMUM load for each suitcase is 4 kg (9 lb). Unlock the suitcase from its support by turning the upper button 90° clockwise. NOTE: If upper button cannot be turned, unlock upper button using the suitcase locking device. Push upper button downward and gently pull on the suitcase to re- lease it from its locking support.
  • Page 132 1. Locking device Lift suitcase to release it from its lower support. _________________________...
  • Page 133 Suitcases can also be locked using the safety locking device, this will also prevent the upper button to turn. 1. Locking device CAUTION: Make sure suitcases are properly fixed and secured before using snowmobile. _________________________...

  • Page 134: Integrated Bag

    52) Integrated Bag Lift release lever from plastic buckles to unfasten integrated bag from vehicle. _________________________...

  • Page 135: Seat

    53) 2 + 1 Seat GTX Limited The GTX Limited has 3 seats. 1. Driver seat 2. 2+1 seat 3. Passenger's seat If you have an adult and a child for passenger, BRP recommends that the child sits in the center location. This allows an adult sitting in the rear seat to keep a visual contact with the child and hold him if necessary.
  • Page 136 WARNING – NEVER place any cargo on either of the 2 passenger seats, as cargo could collide with occupants. – If you ride with the 2 passenger seats installed, your cargo must be placed only in the suitcases. – If you want to ride with 1 passenger and some cargo, do not put the cargo on the passenger’s seat left unused.
  • Page 137 Pull on passenger's seat strap while gently lifting rear of seat. 1. Strap Slightly pull passenger's seat rearward to release alignment tab from 2 + 1 seat. CAUTION: If passenger's seat needs to be removed from vehicle, make sure to unplug passenger's seat harness. _________________________...
  • Page 138 Slightly pull 2 + 1 seat rearward to release alignment tab from driver seat. Remove 2 + 1 seat. _________________________...
  • Page 139 NOTE: When the “2 + 1” seat is removed, you must always proceed to the reinstallation of the passenger’s seat (the one with a backrest) immediately behind the operator’s seat before riding. Failure to do so leaves the snowmobile with a hole between the operator’s seat and the passenger’s seat.
  • Page 140 1. Driver seat 2. Passenger's seat WARNING Make sure the passenger’s seat(s) that are installed are locked securely in place before using the snowmobile. _________________________...

  • Page 141: Spark Plug Holder

    55) Spark Plug Holder All Models except 4-TEC 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. REV SERIES — SPARK PLUG HOLDER ON LEFT HAND SIDE PANEL 1.

  • Page 142: 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. ZX SERIES — SPARE DRIVE BELT INSTALLED IN HOLDER REV SERIES — SPARE DRIVE BELT INSTALLED IN HOLDER 57) Hitch The hitch can be used to pull most equipment.

  • Page 143: Shields And Guards

    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 144: Guidelines To Adjust Suspension

    TYPICAL 1. Rear springs for comfort and ride height 2. Center spring for steering behavior 3. Stopper strap for snowmobile weight transfer 4. Coupling blocks — Handling 5. Front springs for handling 6. Rear shock motion ratio — Damping strength Guidelines to Adjust Suspension Following are guidelines to fine-tune suspension.
  • Page 145 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 146 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 147 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 counterclockwise direction.
  • Page 148 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 149 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 Before proceeding with any suspension adjustment, remem- ber: – park in a safe place –...
  • Page 150 TYPICAL — TOO SOFT OF ADJUSTMENT 1. Handlebar harder to turn — oversteering attitude TYPICAL 1. Use adjuster wrench provided in tool kit to increase preload _________________________...
  • Page 151 TYPICAL — TOO HARD OF ADJUSTMENT — TOO MUCH PRELOAD 1. Handlebar is very easy to turn — understeering attitude TYPICAL 1. Use adjuster wrench provided in tool kit to decrease preload _________________________...
  • Page 152 3. Stopper Strap — Weight Transfer Ride at low speed then fully accelerate. Note steering behavior. Ad- just stopper strap length accordingly. WARNING Before proceeding with any suspension adjustment, remem- ber: – park in a safe place – remove DESS tether cord cap –...
  • Page 153 All Models except Summit TYPICAL — TOO LONG STRAP 1. Skis lift off the ground A03F0QB TYPICAL 1. Reduce strap length by bolting to a different hole _________________________...
  • Page 154 TYPICAL — TOO SHORT STRAP 1. Heavy steering A03F0QB TYPICAL 1. Increase strap length by bolting to a different hole _________________________...
  • Page 155 Summit Models TOO LONG STRAP 1. Skis lift off the ground 1. Loosen lock nut, turn knob accordingly then retighten lock nut _________________________...
  • Page 156 TOO SHORT STRAP 1. Heavy steering 1. Loosen lock nut, turn knob accordingly then retighten lock nut _________________________...
  • Page 157 4. Coupling Blocks — Handling All Models except Summit and X Package Ride at moderate speed and check for desired handling. When driver and passenger (if applicable) are seated on vehicle, the coupling blocks should be centered between rubber stoppers. This condition is achieved when a proper rear spring preload is done.
  • Page 158 Use tool provided in tool bag to adjust coupling blocks. COUPLING BLOCK — RIGHT SIDE VIEW (“R” — RIGHT EMBOSSED ON BLOCK) 1. Thicker part of block facing rearward (fully coupled suspension) — less track grip and more skis steering 2.
  • Page 159 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 X Package Only Ride at moderate speed and check for desired handling.
  • Page 160 COUPLING BLOCK — RIGHT SIDE VIEW (“R” — RIGHT EMBOSSED ON BLOCK) 1. Side of block marked “1” facing rearward (partly coupled suspension) — more track grip and less skis steering 2. Side of block marked “2” facing rearward (partly coupled suspension) —...
  • Page 161 5. Front Springs — Handling Ride at moderate speed and check for proper handling. Adjust front springs accordingly. WARNING Before proceeding with any suspension adjustment, remem- ber: – park in a safe place – remove DESS tether cord cap – lift rear of vehicle off the ground with a wide-base snowmo- bile stand with a rear deflector panel –...
  • Page 162 Some Models TYPICAL — TOO SOFT OF ADJUSTMENT 1. Bad handling 1. Increase spring preload 2. Position number _________________________...
  • Page 163 TYPICAL — TOO HARD OF ADJUSTMENT 1. Steering hard to turn 1. Decrease spring preload 2. Position number CAUTION: Make sure that both front springs are still pre loaded when front of vehicle is off the ground. _________________________...
  • Page 164 Some Models TYPICAL — TOO SOFT OF ADJUSTMENT 1. Bad handling 1. Increase spring preload _________________________...
  • Page 165 TYPICAL — TOO HARD OF ADJUSTMENT 1. Steering hard to turn 1. Decrease spring preload _________________________...
  • Page 166 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 WARNING Remove tether cord cap before performing any maintenance or adjustment, unless otherwise specified.
  • Page 167 X Package Only Rear shock on the above mentioned models feature 2 adjustments. Low Speed Compression Adjuster The low speed adjuster modifies the damping force for small suspen- sion velocities. This adjuster has 5 turns of adjustment. Use a flat screwdriver to adjust it.
  • Page 168 Problem Corrective measures Front suspension – Check ski alignment and camber angle adjustment. wandering See an authorized SKI-DOO dealer. – Reduce ski ground pressure. • Reduce front suspension spring preload. • Increase center spring preload. • Reduce rear spring preload.

  • Page 169: Track

    Track Depending on the model of snowmobile that you own, your vehicle may come with a track for which the manufacturer permits the in- stallation of studs, or a track for which the manufacturer forbids it. Tracks approved for the installation of studs have a stud symbol (see illustration) molded into the track surface, and tracks not approved bear a forbidden stud symbol (see illustration).

  • Page 170: Fuel And Oil

    FUEL AND OIL Recommended Fuel All Models except 800 HO Engine Equipped Use regular unleaded gasoline, available from most service stations or oxygenated fuel containing less than 10% of ethanol or 5% of methanol. The gasoline used must have the following recom- mended minimum octane number.

  • Page 171: 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...
  • Page 172 CAUTION: (1) XP-S synthetic 2-stroke oil and XP-S 2-stroke synthetic blend oil are specially formulated and tested for the severe requirements of these engines. Use of any other brand two-stroke oil may void the limited warranty. Use only XP-S synthetic 2-stroke oil or XP-S 2-stroke synthetic blend. There is no known equivalent on the market for the moment.
  • Page 173 4-TEC Models These models are equipped with a 4-stroke engine. Use XP-S 0W40 synthetic 4-stroke oil (P/N 293 600 054 ) — 12 x 1L). NOTE: There is no known equivalent for this oil on the market for the moment. If a high quality equivalent were available, it could be used.

  • Page 174: 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 175: 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 176: 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 con- trols, safety features and mechanical components before start- ing. If not done as specified here, severe injury or death might occur.
  • Page 177 • Check fuel and oil for levels and leaks. Replenish as necessary and see an authorized SKI-DOO dealer in case of any leaks. • Verify that air filter(s) is free of snow, if so equipped. • All storage compartments must be properly latched and they must not contain any heavy or breakable objects.

  • Page 178: Pre-Operation Check List

    PRE-OPERATION CHECK LIST ✔ ITEM OPERATION Body including Check that there is no snow or ice. seat, footrests, lights, controls and instruments Check for free movement. Track and idler wheels Brake lever Check proper action. Check proper action. Parking device Throttle lever Check proper action.

  • Page 179: 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 180: 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 181 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 position 2. Grab starter handle firmly and crank engine or use electric starter on so equipped models.
  • Page 182 2-TEC Models (Manual Starting) Initial Cold Starting and Warm Engine Starting Push on the START/RER button once to energize the ECM and gauges, this will ease the starting. NOTE: If the small battery is low or dead, the ECM and gauges can- not be energize before starting.
  • Page 183 Grab manual starter handle, pull handle slowly until a resistance is felt then, hold handle firmly and pull vigorously to start engine. WARNING Never depress throttle when starting engine. Electric Starting (for models so equipped) Electric Start Fan-Cooled Models Insert key in ignition switch. Activate the choke according to the temperature as explained above.

  • Page 184: Emergency Starting

    Emergency Starting All Models except 4-TEC The engine can be started with the emergency starter rope supplied with the tool kit. Remove belt guard. WARNING Do not wind starting rope around your hand. Hold rope by the handle only. Do not start the snowmobile by the drive pulley unless it is a true emergency situation.
  • Page 185 Attach one end of emergency rope to rewind handle. NOTE: The spark plug socket can be used as an emergency handle. TYPICAL Attach the other end of emergency rope to the starter clip supplied in the tool kit. Hook up clip on drive pulley. _________________________...
  • Page 186 Wind the rope tightly around drive pulley. When pulled, pulley must rotate counterclockwise. TYPICAL — FAN-COOLED MODELS 1. Knot on this side _________________________...

  • Page 187: Shutting Off The Engine

    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, using drive pulley, do not reinstall the belt guard and return slowly to have snowmobile repaired.

  • Page 188: 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 189: Riding The Vehicle

    RIDING THE VEHICLE At this point you are acquainted to the specifics of these models of snowmobile and you are instructed about the control locations and operation. Before starting out on your first ride with this vehicle, read the fol- lowing safety information as you will be informed about the safe op- erating practices.

  • Page 190: 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 191 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. _________________________...
  • Page 192 Kneeling This position is achieved by placing one foot firmly on the running board and the opposite knee on the seat. Avoid abrupt stops. _________________________...
  • Page 193 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. _________________________...

  • Page 194: 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 195 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 other hazards. Never attempt to operate your snowmobile on ice that may be too weak to support you and the vehicle.
  • Page 196 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 197 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 198 On occasion, you will find that the only way to turn the vehicle about in deep snow is to pull the snowmobile around. Do not overexert yourself. Get assistance. Remember to always lift using your legs as opposed to your back. Road Crossing In some cases, you will be approaching the road from a ditch or snowbank.
  • Page 199 Night Rides The amount of natural and artificial light at a given time can effect your ability to see or to be seen. Nighttime snowmobiling is delight- ful. It can be a unique experience if you acknowledge your reduced visibility. Before you start, make certain your lights are clean and work properly.
  • Page 200 WARNING Any passenger must be able to firmly lay his feet on the footrests and keep his hands on the grab handles or seat strap at all times when seated. Respecting those physical criteria is important to ensure that the passenger is stable and to reduce the risks of ejection.
  • Page 201 WARNING When riding with a passenger: – Braking ability and steering control are reduced. Decrease speed and allow extra space to maneuver. – Adjust suspension according to weight. For complete information on how to adjust the suspension, please refer to the section of this Operator’s Guide entitled ADJUSTABLE SUSPENSIONS and to the relevant label on the belt guard.

  • Page 202: Post-Operation Care

    POST-OPERATION CARE Shut off the engine. Install rear of vehicle on a wide-base snowmo- bile mechanical stand. Remove snow and ice from rear suspension, track, front suspension, steering, mechanism and skis. Protect vehicle with a snowmobile cover. _________________________...

  • Page 203: Special Operations

    Riding at High Altitudes If you ride at altitudes above 600 m (2000 ft), your snowmobile should be modified. Refer to an authorized SKI-DOO dealer. Sum- mit models are factory calibrated for high altitude. These models must be converted for sea level utilization.

  • Page 204: Rear Suspension Slider Shoe Sticking

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

  • Page 205: Maintenance Information

    MAINTENANCE INFORMATION _________________________...

  • Page 206: Periodic Maintenance Chart

    (3) MONTHLY OR EVERY 800 km (500 m.) (4) ONCE A YEAR OR EVERY 3200 km (2000 m.) (5) EVERY 6000 km (3700 m.) (6) STORAGE (to be performed by an authorized SKI-DOO dealer) (7) PRESEASON PREPARATION (to be performed by an authorized SKI-DOO dealer).
  • Page 207 PERIODIC MAINTENANCE CHART (2) (3) (4) (5) (6) (7) FUEL SYSTEM Fuel Stabilizer Fuel Filter Fuel Lines and Connections Carburetor Throttle Cable Air Filter Fuel Injection System (visual inspection) Throttle Body Bores and Throttle Plates *** DRIVE Drive Belt Drive and Driven Pulleys Tightening Torque of Drive Pulley Screw Driven Pulley Preload BRAKE...
  • Page 208 PERIODIC MAINTENANCE CHART (2) (3) (4) (5) (6) (7) ELECTRICAL EMS Fault Codes *** Spark Plugs */*** Battery (if so equipped) Headlamp Beam Aiming Wiring Harnesses, Cables and Lines Operation of Lighting System (HI/LO beam, brake light, etc.), Test Operation of Engine Cut-Out Switch and Tether Cut-Out Switch BODY/FRAME Rags in Air Intake and Exhaust System...

  • Page 209: Fluid Levels

    FLUID LEVELS WARNING It is recommended that the assistance of an authorized SKI-DOO dealer be periodically obtained on other compo- nents/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 adjust- ment, unless otherwise specified.

  • Page 210: Chaincase/Gearbox Oil Level

    Oil level must be between lower and upper marks. NOTE: It is normal to find metallic particles stuck to dipstick mag- net. If bigger pieces of metal are found, see an authorized SKI-DOO dealer. Remove metal particles from magnet.

  • Page 211: 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 212: Engine Oil Level

    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. Stop engine and wipe the dipstick. Dipstick must be completely screwed in before checking oil level. Oil level must be between minimum and maximum marks on dip- stick.

  • Page 213: Cooling System

    NOTE: When checking level at low temperature it may be slightly lower then the mark. If additional coolant is necessary or if entire system has to be refilled, refer to an authorized SKI-DOO dealer. REV SERIES 1. Coolant tank 2. COLD LEVEL line...
  • Page 214 4-TEC — OVERFLOW COOLANT TANK 1. MINIMUM LEVEL line 2. MAXIMUM LEVEL line 4-TEC — CHECK COOLANT LEVEL IN COOLANT TANK 1. Fill to maximum line if necessary _________________________...

  • Page 215: 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 BLACK negative battery cable must always be disconnected first and connected last. WARNING Never charge or boost battery while installed. Battery elec- trolyte contains sulfuric acid which is corrosive and poisonous.

  • Page 216: Maintenance For Epa Certified Engines

    MAINTENANCE FOR EPA CERTIFIED ENGINES Maintenance, replacement, or repair of the emission control devices and systems may be performed by any snowmobile SI (spark igni- tion) engine repair establishments or individual. Engine Emissions Information Manufacturer's Responsibility Beginning with 2004 model year engines, snowmobile manufactur- ers of snowmobile engines may determine the exhaust emission levels for each engine horsepower family and certify these engines with the United States of America Environmental Protection Agency...
  • Page 217 EPA Emission Regulations All new 2004 and more recent certified SKI-DOO snowmobiles man- ufactured by BRP are certified to the EPA as conforming to the re- quirements of the regulations for the control of air pollution from new snowmobile engines. This certification is contingent on certain ad- justments being set to factory standards.

  • Page 218: Maintenance

    MAINTENANCE WARNING It is recommended that the assistance of an authorized SKI-DOO dealer be periodically obtained on other compo- nents/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 adjust- ment, unless otherwise specified.

  • Page 219: Belt Guard Removal And Installation

    CAUTION: The snowmobile has to be stored in a cool and dry place and covered with an opaque tarpaulin. This will prevent sun rays and grime from affecting plastic components and vehi- cle finish. Lift rear of vehicle until track is clear of the ground. Install on a wide- base snowmobile mechanical stand with a rear deflector panel.
  • Page 220 All Models – Remove tether cord cap. Open engine compartment. 4-TEC Models Only – Remove air silencer access panel. 1. Access panel – Loosen collar screw on air silencer grommet. – Disconnect engine vent hose from air silencer. _________________________...
  • Page 221 1. Collar screw 2. Engine vent hose – Disconnect air temperature sensor from air silencer. 1. Air temperature sensor At installation do not forget to connect air temperature sensor other- wise a trouble code will appear. _________________________...
  • Page 222 All Models – Open retainer to release pin then pull belt guard out of vehicle. TYPICAL 1. Pin retainer _________________________...

  • Page 223: Drive Belt Removal/Installation

    When reinstalling belt guard, position its cutaway toward front of snowmobile. Refer to decal in belt guard. Place belt guard slots over tabs first, then snap the other end in re- tainer. TYPICAL 1. Slots Drive Belt Removal/Installation WARNING Remove tether cord cap before performing any maintenance or adjustment, unless otherwise specified.
  • Page 224 Open the driven pulley with the drive belt installer/remover provided in tool bag. DRIVE BELT INSTALLER/REMOVER Screw drive belt installer/remover in the free threaded hole and tighten to open the pulley. Remove belt. 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 225 ZX Series Only Remove access panel from bottom pan. 1. Push tab down and remove panel out of bottom pan PULL PANEL OUT OF BOTTOM PAN _________________________...
  • Page 226 All Models Slip belt under drive pulley then, remove it from vehicle. 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 227 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. To install the drive belt, first place belt between drive pulley sheaves. Then, between driven pulley sheaves, finishing with bottom.

  • Page 228: 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. TYPICAL 1. Hair pin 2. Adjustment screw _________________________...

  • Page 229: 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 230 There are 6 positions numbered 1 to 6. On TRA drive pulley, note that in position 1 the number is substituted by a dot (due to its loca- tion on casting). 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 231 This could lead to serious injury including the possibility of death. See your SKI-DOO dealer to maintain or service the drive pulley. Improper servicing or maintenance may affect per- formance and reduce belt life. Always respect maintenance schedules.

  • Page 232: Drive Belt Condition

    Periodically verify the condition/wear of the brake pads. Brake Adjustment No adjustment is provided for hydraulic brake. See an authorized SKI-DOO dealer if any problems. Rear Suspension Condition Visually inspect all suspension components including slider shoes, springs, wheels, etc.

  • Page 233: 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. Studded Tracks If the track of your snowmobile is studded, PROCEED WITH A VI- SUAL INSPECTION OF YOUR TRACK BEFORE EACH USE.

  • Page 234: Track Tension And Alignment

    Track Tension and Alignment NOTE: Track tension and alignment are interrelated. Do not adjust one without the other. WARNING To prevent serious injury to individuals near the snowmobile: – NEVER stand behind or near a moving track – always use a wide-base snowmobile stand with a rear de- flector panel –...
  • Page 235 NOTE: A belt tension tester (P/N 414 348 200) may be used to mea- sure deflection as well as force applied. BELT TENSION TESTER 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 236 – On some models, remove rear 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.
  • Page 237 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. Al- ways lift the snowmobile on a wide-base stand with a rear de- flector panel.
  • Page 238 To Adjust Track Alignment: 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. – Remove the tether cord cap. – Loosen rear idler wheel retaining screws. –...

  • Page 239: Steering And Front Suspension

    Install rear wheel caps if so equipped. 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. _________________________...

  • Page 240: Wear And Condition Of Skis And Runners

    Wear and Condition of Skis and Runners Check the condition of the skis, ski runners and ski runner carbides (if so equipped). If worn, contact an authorized SKI-DOO dealer. WARNING Excessively worn skis and/or ski runners will adversely affect snowmobile control.
  • Page 241 REMOVAL OF RIGHT SIDE PRIMARY FILTER GRILL REMOVAL OF FILTER FROM ITS GRILL _________________________...
  • Page 242 1. Secondary filter installed on air silencer REV Series AIR FILTER LOCATION _________________________...
  • Page 243 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 244: Headlamp Beam Aiming

    Headlamp Beam Aiming ZX Series Turn knob to adjust beam height. TYPICAL — ZX SERIES 1. Knob _________________________...

  • Page 245: Bulb Replacement

    REV Series Open left side panel. Turn knob to adjust beam height. TYPICAL — REV SERIES 1. Knob Bulb Replacement Always check light operation after bulb replacement. Headlamp 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 246 ZX Series If any headlamp bulb is burnt, remove windshield and unplug burnt bulb connector. Remove the rubber boot. 1. Bulb connector 2. Rubber boot Turn bulb locking ring counterclockwise to remove it. Detach the bulb and replace. Properly reinstall parts. _________________________...
  • Page 247 1. Locking ring REV Series Unplug burnt bulb connector. Remove the rubber boot. 1. Bulb connector 2. Rubber boot _________________________...
  • Page 248 Turn bulb locking ring counterclockwise to remove it. Detach the bulb and replace. Properly reinstall parts. 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. _________________________...

  • Page 249: Towing An Accessory

    TOWING AN ACCESSORY Always use a rigid towbar to tow an accessory. Any towed acces- sory should have reflectors on both sides and at the rear. Check local laws for brake lights requirements. WARNING Never tow an accessory with a rope. Always use a rigid tow- bar.

  • Page 250: Towing Another Snowmobile

    TOWING ANOTHER SNOWMOBILE If a snowmobile is disabled and must be towed use a rigid towbar, remove the drive belt and tow at moderate speed. CAUTION: Always remove the drive belt of the snowmobile that is to be towed to prevent damage to its belt and drive system. In an emergency situation only, if a rigid towbar is not available, a rope can be used provided you proceed with extra caution.

  • Page 251: Transporting The Vehicle

    TRANSPORTING THE VEHICLE Make sure that oil reservoir and fuel tank caps are properly installed. Tilt bed trailers can easily be equipped with a winch mechanism to afford maximum safety in loading. Simple as it may seem, never drive your snowmobile onto a tilt bed trailer or any other kind of trailer or vehicle.

  • Page 252: Storage And Preseason Preparation

    It is during summer, or when a snowmobile is not in use for more than one month that proper storage is a necessity. To prepare your snowmobile, refer to an authorized SKI-DOO dealer. Engine Cooling System Antifreeze should be replaced for the storage period to prevent an- tifreeze deterioration.

  • Page 253: Troubleshooting

    TROUBLESHOOTING Monitoring Beeper Coded Signals 2 short beeps (when engine is started) then engine stops. 1. Engine stops automatically after four minutes of idling (without de- pressing the throttle handle) and engine temperature higher than 85°C (185°F). – Depressing throttle lever within four minutes will reset timer to four minutes.
  • Page 254 3 short beeps per second. Engine overheating pilot lamp also blinks. 1. Engine is overheating. – Stop engine immediately and allow to cool. Check cooling sys- tem. 3 short beeps per second. Oil pilot lamp also lights up. 1. Low oil pressure on 4-TEC models. –...
  • Page 255 – Start engine following usual starting procedure. If engine con- tinues to flood, see an authorized SKI-DOO dealer. 4. No fuel to the engine (spark plug dry when removed). – Check fuel tank level; turn fuel valve on if applicable; check fuel filter;...
  • Page 256 – Replace drive belt. 7. Drive and driven pulleys require servicing. – Contact an authorized SKI-DOO dealer. 8. Engine is overheating. – On liquid cooled engines, check coolant level, pressure cap, thermostat and for air locks in cooling system.
  • Page 257 Clean/verify spark plug gap and identification number. Replace as required. 4. Too much oil supplied to engine. – Improper oil pump adjustment, refer to an authorized SKI-DOO dealer. – On premixed models only, improper fuel/oil mixture. Drain fuel tank and refill with appropriate mixture ratio.

  • Page 258: Specifications

    SPECIFICATIONS GSX/GTX/MX-Z MODEL FAN 380 F Engine 6800 Maximum power engine speed ± 100 RPM Drive Belt Part number 415 060 600 Wear limit width mm (in) 32.3 (1-9/32) Spark Plug Type NGK BR 9 ES ± 0.05 mm (± .002 in) 0.45 ( .018) (11) Track 35 - 40...
  • Page 259 EXPEDITION GSX/GTX/MX-Z MODEL FAN 550F FAN 550F Engine Maximum power 6950 6950 ± 100 RPM 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 Type NGK BR 9 ES NGK BR 9 ES ±...
  • Page 260 LEGEND LEGEND MODEL SPORT /SE SE GT/SPORT V-1000 GT V-1000 Engine Maximum power ± 100 RPM 7250 7250 engine speed Drive Belt 417 300 197 417 300 197 Part number Wear limit width mm (in) 34.2 (1-11/32) 34.2 (1-11/32) Spark Plug Type NGK DCPR8E NGK DCPR8E...
  • Page 261 SUMMIT GSX/GTX/MX-Z MODEL ADRENALINE 500 SS 600 HO Engine Maximum power ± 100 RPM 8000 8000 engine speed Drive Belt 417 300 197 417 300 197 Part number Wear limit width mm (in) 34.2 (1-11/32) 34.2 (1-11/32) Spark Plug Type NGK BR 9 ECS NGK BR 9 ECS ±...
  • Page 262 GSX/GTX/MX-Z GSX/GTX/MX-Z MODEL 600 HO SDI 600 HO Engine Maximum power 8000 8000 ± 100 RPM 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 Type NGK BR 9 ECS NGK BR 9 ECS ±...
  • Page 263 GSX/GTX/MX-Z MODEL 800 HO Engine Maximum power engine speed ± 100 RPM 7850 Drive Belt 417 300 166 Part number Wear limit width mm (in) 35.3 (1-3/8) Spark Plug Type NGK BR 9 ECS ± 0.05 mm (± .002 in) 0.45 ( .018) (11) Track 30 - 35...
  • Page 264 SUMMIT ADR./X MODEL 800 HO Engine Maximum power engine speed ± 100 RPM 7850 Drive Belt Part number 417 300 166 Wear limit width mm (in) 35.3 (1-3/8) Spark Plug Type NGK BR 9 ECS ± 0.05 mm (± .002 in) 0.45 ( .018) (11) Track 30 - 35...
  • Page 265 (1) Measure gap between slider shoe and bottom inside of track when exerting a downward pull of 7.3 kg (16 lb) to the track. (2) Equal distance between edges of track guides and slider shoes. (3) Regular unleaded gasoline with a minimum octane number of: (87 (R + M)/2 Inside North America) or (91 RON Outside North Amer- ica).
  • Page 266 _________________________...

  • Page 267: Warranty

    WARRANTY _________________________...

  • Page 268: Brp Limited Warranty North America: 2005 Ski-Doo

    All genuine Ski-Doo parts and accessories, installed by an authorized BRP dealer (as hereinafter defined) at the time of delivery of the 2005 Ski-Doo snowmobile, carry the same warranty as that of the snow- mobile. A GPS receiver may be supplied by BRP as standard equipment on certain 2005 Ski-Doo snowmobiles.
  • Page 269 EMISSION-RELATED 600 HO 4-TEC COMPONENTS V-1000 Throttle Position Sensor (TPS) Air Temperature Sensor (ATS) Air Pressure Sensor (APS) Fuel Pressure Regulator Fuel Injectors Engine Management System (EMS) Cylinder Head Rubber Rings/O-Ring or Gasket Cylinder/Base Gaskets Throttle Body Shaft Seals RAVE Hose System Exhaust System Sealing Components Knock Sensor Muffler Temperature Sensor...
  • Page 270 BRP’s obligations under this warranty are limited to, at its sole discre- tion, repairing parts found defective under normal use, maintenance and service, or replacing such parts with new genuine Ski-Doo parts without charge for parts and labor, at any authorized BRP dealer dur- ing the warranty coverage period.
  • Page 271 6. EXCLUSIONS The following are not warranted under any circumstances: • Normal wear and tear; • Routine maintenance items, tune ups, adjustments; • Damage caused by failure to provide proper maintenance and/or storage, as described in the Operator's Guide; • Damage resulting from removal of parts, improper repairs, service, maintenance, modifications or use of parts not manufactured or ap- proved by BRP or resulting from repairs done by a person that is not an authorized servicing BRP dealer;...
  • Page 272 7. LIMITATIONS OF LIABILITY THIS WARRANTY IS EXPRESSLY GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PUR- POSE. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY.
  • Page 273 (b) If the issue has not yet been resolved, please submit your com- plaint in writing or call the appropriate number below: In Canada: BOMBARDIER RECREATIONAL PRODUCTS INC. SKI-DOO CONSUMER SERVICES GROUP VALCOURT QC J0E 2L0 Tel: (819) 566-3366 In USA:...

  • Page 274: Brp International Limited Warranty: 2005 Ski-Doo

    All genuine Ski-Doo parts and accessories, installed by an authorized BRP distributor/dealer (as hereinafter defined) at the time of delivery of the 2005 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 previous owner, will render this warranty null and void.
  • Page 275 BRP’s obligations under this warranty are limited to, at its sole discre- tion, repairing parts found defective under normal use, maintenance and service, or replacing such parts with new genuine Ski-Doo parts without charge for parts and labor, at any authorized BRP distribu- tor/dealer during the warranty coverage period.
  • Page 276 • Damage resulting from accident, submersion, fire, theft, vandalism or any act of God; • Operation with fuels, oils or lubricants which are not suitable for use with the product (see the Operator’s Guide); • Snow or water ingestion; • Incidental or consequential damages, or damages of any kind in- cluding without limitation towing, storage, telephone, rental, taxi, in- convenience, insurance coverage, loan payments, loss of time, loss of income;...
  • Page 277 (c) If the matter still remains unresolved then contact BRP by writing to us at the address listed below. BOMBARDIER RECREATIONAL PRODUCTS INC. SKI-DOO CONSUMER SERVICES GROUP VALCOURT QC J0E 2L0 Tel: (819) 566-3366...

  • Page 278: 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 279: Change Of Address Or Ownership

    Please provide your name, address, phone number, vehicle serial number and date of theft. BRP will provide a list of stolen units to all authorized SKI-DOO deal- ers on a monthly basis to aid in recovery of such units to their owners.
  • Page 280 _________________________...
  • Page 281 _________________________...
  • Page 282 _________________________...

This manual is also suitable for:

2005 rev series

Table of Contents

Save PDF