Ski-Doo CK 3 Operator's Manual
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Ski-Doo CK 3 Operator's Manual

Ski-Doo CK 3 Operator's Manual

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  • Page 2: Safety Warning

    AFTER SALES SERVICE BOMBARDIER INC. VALCOURT, QUEBEC CANADA J0E 2L0 The following are trademarks of Bombardier Inc. ® BOMBARDIER SKANDIC* TUNDRA* ® FORMULA* SKI-DOO CK3* Litho’d in Canada ® *Trademarks of Bombardier Inc. All rights reserved © Bombardier Inc. 1998 (MMO-9903 GM)
  • Page 3 1999 SKI-DOO OPERATOR’S GUIDE This guide is applicable to CK3 series: Grand Touring 700 Grand Touring SE Formula III 600 Formula III 700 Formula III 800 Mach 1 Mach 1 R Mach Z Mach Z M.H. R Mach Z R...
  • 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. These guides use the following symbols.

  • Page 6: Table Of Contents

    ® 1999 SKI-DOO SNOWMOBILE..........OFTEN ASKED QUESTIONS ........... LIST OF CUSTOMER RELATIONS OFFICES ......AUTHORIZED SKI-DOO DEALERS ......... HOW TO IDENTIFY YOUR SNOWMOBILE ......Vehicle Serial Number Location ..........Engine Serial Number Location ..........ON-VEHICLE IMPORTANT INSTRUCTIONS ......CONTROLS/INSTRUMENTS ..........
  • Page 7 24) Electric Fuel Level Gauge ............ 25) Fuel Tank Cap ..............26) Heated Grip Switch .............. 27) Heated Grip Pilot Lamp (yellow) .......... 28) Heated Throttle Lever Switch ..........29) Heated Throttle Lever Pilot Lamp (yellow)......30) Electric Visor Jack Connector ..........31) Hood Latches ...............
  • Page 8 TROUBLESHOOTING CHART ..........In Deep Snow................LUBRICATION AND MAINTENANCE CHART ......FLUID LEVELS................Brake System ................Chaincase Oil Level ..............Oil Injection System ..............Cooling System ................. Battery Electrolyte..............MAINTENANCE ............... Guard Removal and Installation..........Drive Belt Removal/Installation ..........Drive Chain Tension ..............TRA Drive Pulley Adjustment ............

  • 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: Bombardier Limited Warranty

    All genuine Bombardier accessories, installed by an authorized SKI-DOO dealer at the time of delivery of the new and unused SKI-DOO, carry the same Warranty Coverage Period as for the SKI-DOO snowmobile. 2. WHAT BOMBARDIER WILL DO...
  • Page 11 WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTIC- ULAR PURPOSE. Neither the distributor, any authorized SKI-DOO dealer nor any other per- son has been authorized to make any affirmation, representation or war- ranty other than those contained in this warranty, and if made, such affirmation, representation or warranty shall not be enforceable against BOMBARDIER or any other person.

  • Page 12: Bombardier International Limited Warranty

    PERIOD of TWELVE (12) CONSECUTIVE MONTHS. All genuine Bombardier accessories, installed by an authorized SKI-DOO dealer at the time of delivery of the new and unused SKI-DOO snowmo- bile, carry the same Warranty Coverage Period as for the SKI-DOO snow- mobile.
  • Page 13 BOMBARDIER or any other person. Every SKI-DOO snowmobile is sold with the English version of this war- ranty. A specific SKI-DOO International Distributor may elect to translate...

  • Page 14: Often Asked Questions

    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 Inc. Make sure the card has been sent.
  • Page 15 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 16: 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 17: 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 18: Engine Serial Number Location

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

  • Page 19: On-Vehicle Important Instructions

    ON-VEHICLE IMPORTANT INSTRUCTIONS Please read the following instructions carefully before operating snowmobile. A30A01B TYPICAL — LOCATION OF IMPORTANT INSTRUCTIONS Verify attachments frequently. Use rigid tow bar. Reduce speed when towing. Vérifier souvent les accouplements. Utiliser une barre rigide. Remorquer à vitesse réduite. A01A1WA GRAND TOURING SE...
  • Page 20 A01A1ZC SINGLE SEAT MODELS WARNING. AVERTISSEMENT. Read & follow all Warning Labels & Operators Guide/Safety Handbook before operation. 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. Manuel du conducteur, avant toute mise en route.
  • Page 21 WARNING. AVERTISSEMENT. Read & follow all Warning Labels & Operators Guide/Safety Handbook before operation. 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. Manuel du conducteur, avant toute mise en route. BEFORE STARTING ENGINE, CHECK: AVANT DE DÉMARRER LE MOTEUR, S'ASSURER QUE: THROTTLE LEVER MOVES FREELY...
  • Page 22 A01A24A A01A24A TYPICAL — ALL MODELS SUSPENSION ADJUSTMENT CHART/TABLEAU DES RÉGLAGES DE LA SUSPENSION FRONT SUSPENSION (SKI)/ SUSPENSION AVANT (SKI) ADJUST ACCORDING TO YOUR RIDING STYLE/ RÉGLER SELON VOTRE CONDUITE NOT APPLICABLE SANS OBJET REAR SUSPENSION/ SUSPENSION ARRIÈRE ADJUST ACCORDING TO LOAD/ RÉGLER SELON LA CHARGE LOAD REAR SPRING CENTER SPRING...
  • Page 23 lete éhi A30A0BA ALL MODELS WITH A REVERSE...

  • Page 24: Controls/Instruments

    CONTROLS/INSTRUMENTS NOTE: Some controls/instruments do not apply to some models. In these cases their reference numbers are deliberately missing in the illustrations. Some controls/instruments are optional on some models. 21 24 31 33 25 28 33 31 A30A0CA TYPICAL — FORMULA III AND MACH 1 SERIES...
  • Page 25 22 27 21 29 24 33 31 A30A0DA TYPICAL — MACH Z SERIES...
  • Page 26 27 11 29 4 17 20 18-19 A30A0JA TYPICAL — GRAND TOURING 700...
  • Page 27 7 14 27 11 29 4 17 20 18-19 A30A0KA TYPICAL — GRAND TOURING SE...

  • Page 28: 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 29: 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) All Models Except Grand Touring Series Lights when injection oil level is low. Check oil level and replenish as soon as possible. Also lights when parking brake is applied (with en- gine running).
  • Page 30 When depressing the reverse button, a signal will slow down the engine RPM enough to modify the ignition timing advance. This re- verses crankshaft rotation. No mechanical action and gear change is involved. No adjustment is needed except for high altitude. See RER Opera- tion at High Altitude below.
  • Page 31 Apply throttle slowly and evenly. Allow drive pulley to engage then accelerate carefully. CAUTION Do not rev the engine when driving in reverse. This may cause the clutch system to operate erratically. It is recommended to warm up the engine to its normal operating temperature before shifting.

  • Page 32: Ignition Switch

    No reverse button operation is needed to select a mode. Just follow Shifting Procedure above. 6) Ignition Switch The lights are automatically ON whenever the engine is running. A30H07A MANUAL START ELECTRIC START 1. OFF 1. OFF 2. ON 2. ON 3.

  • Page 33: Tether Cut-Out Switch

    Release key immediately when engine has started. Key returns to ON position as soon as it is released. If engine does not start on first try, turn key back to OFF position before restarting. To stop engine, turn key to OFF position. NOTE: Engine may be manually started with rewind starter if neces- sary.
  • Page 34 If emergency engine shut off is required, completely pull cap from safety switch. A30H0AA TYPICAL 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.

  • Page 35: Dess Pilot Lamp

    Beep and Pilot Lamp Codes NOTE: Only models with RER have a beeper. After engine is started 2 beeps and 2 DESS pilot lamp blinks confirm that the micro-processor has recognized the tether cord. The vehicle can be normally driven. A beep per 3 seconds and DESS pilot lamp blinking as same rate mean that a bad connection has been detected.

  • Page 36: Emergency Cut-Out Switch

    9) Emergency Cut-Out Switch A push-pull type switch located on the right side of the handlebar. To stop the engine in an emergency, push the button to the lower OFF position and simultaneously apply the brake. To restart, button must be at the upper ON position.

  • Page 37: 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 38: High Beam Pilot Lamp (Blue)

    Mach Z and Grand Touring Series NOTE: When holding switch for more than 1 second to dim light (from high to low beam), light will return to high beam position auto- matically after 10 seconds. A30H0CA MACH Z AND GT SERIES 11) High Beam Pilot Lamp (Blue) Lights when headlamp is on HIGH beam.

  • Page 39: Choke Lever

    13) Choke Lever This device features a 3-position lever to facilitate cold start. A30H0DA 0. OFF 1. Position 1 2. Position 2 Initial Cold Starting NOTE: Do not operate the throttle lever during starting. Set the choke lever to the second position. After the engine is started, close off choke.

  • Page 40: Air Suspension Switch

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

  • Page 41: Air Suspension Pilot Lamp

    15) Air Suspension Pilot Lamp This pilot lamp lights up each time the air suspension switch is used. This pilot lamp also lights up each time compressor runs because pressure has reached low level threshold. 16) Air Suspension Gauge This gauge indicates comfort level (pressure inside rear air shock ab- sorber).

  • Page 42: Odometer

    18) Odometer All Models Except GT Series Odometer records the total distance travelled in kilometers or miles. GT Series With engine running but vehicle at rest, depress button for 1 second max. until total shows. Display will not change before the button is released.

  • Page 43: Trip Meter Reset Button

    A30H0EA GT SERIES 1. Odometer 2. Trip meter 3. Reset button 20) Trip Meter Reset Button All Models Except GT Series To reset, push on button until all numbers read zero. GT Series With engine running but vehicle at rest, depress button for 1 second max.

  • Page 44: Tachometer

    trip A30H0WA DISPLAY AFTER RESETTING TRIP METER 21) Tachometer Direct-reading dial indicates the number of thousand of revolutions per minute (RPM) of the engine. X1000 r /min A06H05A ALL MODELS EXCEPT GT 700/SE 1. Multiply the reading by 1000...

  • Page 45: Temperature Gauge

    A30H0FA GRAND TOURING 700/SE 1. Multiply the reading by 1000 22) Temperature Gauge All Models Except Grand Touring SE 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.

  • Page 46: Engine Overheat Warning Lamp (Red)

    A30H0GA 1. Normal 2. Overheat 23) Engine Overheat Warning Lamp (Red) If this lamp glows, reduce snowmobile speed and run snowmobile in loose snow or stop engine immediately. 24) Electric Fuel Level Gauge Dash-mounted gauge to facilitate fuel level reading. This gauge works only when engine is running.

  • Page 47: Fuel Tank Cap

    A30H0HA 1. Full 2. Empty 25) Fuel Tank Cap Unscrew to fill up tank then fully tighten. WARNING Never use an open flame to check fuel level. CAUTION Do not mismatch oil reservoir cap with fuel tank cap. Install cap that is identified OCTANE RATING OF 91 RECOMMEND-...

  • Page 48: Heated Grip Switch

    26) Heated Grip Switch All Models Except Mach Z and GT Series Three-position toggle switch. Select the desired position to keep your hands at a comfortable temperature. A25H05A TYPICAL — ALL MODELS EXCEPT MACH Z AND GT SERIES 1. HOT 2.

  • Page 49: Heated Grip Pilot Lamp (Yellow)

    A30H0IA 1. Holding + position for more than 1 second will increase heating to maximum 27) Heated Grip Pilot Lamp (yellow) Mach Z Series Lights when heated grip switch is on the high position. Light dimmed when switch is on the low position. GT Series The pilot lamp in center of cluster lights up when heated grips are switched on.

  • Page 50: Heated Throttle Lever Pilot Lamp (Yellow)

    Push switch according to desired intensity. Holding + increases heat- ing and holding - decreases heating. Holding switch for more than about 1 second will increase to maxi- mum intensity or OFF position according selected position. 29) Heated Throttle Lever Pilot Lamp (yellow) Mach Z Series Lights when heated throttle lever switch is on the high position.

  • Page 51: Electric Visor Jack Connector

    30) Electric Visor Jack Connector An electric visor may be connected to that jack connector. Electric current is supplied whenever engine is running. An extension is sup- plied with the vehicle. It is included in the predelivery kit. Ask your dealer for the extension.

  • Page 52: Adjustable Toeholds

    33) Adjustable Toeholds Each toehold can be adjusted to suit driver's preference. Loosen bolts, adjust then, retighten bolts to 10 N•m (89 lbf•in). A30H0MA RIGHT SIDE SHOWN 1. Toehold 2. After adjustment retighten bolts to 10 N•m (89 lbf•in)

  • Page 53: Adjustable Backrest

    Adjustable Backrest The backrest position and support angle may be adjusted to suit driv- er or passenger convenience. A30H0OA 1. Lift adjustment lock (both sides) 2. Turn adjustment knob Secure adjustment locks after desired position is obtained.

  • Page 54: Adjustable Rear Grab Handles

    Adjustable Rear Grab Handles Height of rear grab handles can be adjusted. Lift adjustment lock, move grab handle to desired position. Secure adjustment lock. Proceed the same with the other side. A30H0PA 1. Lift adjustment lock WARNING Backrest should only be repositioned while the snowmobile is stopped.

  • Page 55: Hood Grills

    Hood Grills When riding on powdered snow, close hood grills. Slightly unscrew wing nuts, slide close grills then, retighten wing nuts. A30H0TA 1. Grills...

  • Page 56: Fuel Shut-Off Valve

    Fuel Shut-Off Valve Valve should be closed when transporting or storing snowmobile. A30I01A 1. Opened 2. Closed Fully open the valve in order to operate the snowmobile. CAUTION Always fully open the valve before riding. Never allow the valve to remain half opened. Storage Compartment A storage compartment is provided inside rear portion of seat.

  • Page 57: Tool Box

    Tool Box A tool box containing tools for basic maintenance is supplied with the vehicle. Tool box is located in engine compartment in front of guard. NOTE: The plastic bag containing tools may be discarded to ease storing tools. A30D0PA 1.

  • Page 58: Spark Plug Holder

    Spark Plug Holder To keep spare spark plugs dry and prevent shocks that might affect the adjustment or break them, a compartment is provided in tool box. NOTE: Spare spark plugs are not supplied with snowmobile. A30D04A 1. Spare spark plugs stored in tool box 2.

  • Page 59: Spare Drive Belt Holder

    Spare Drive Belt Holder A spare drive belt can be installed in drive belt holder clip. Make sure to position spare drive belt as illustrated. NOTE: Spare drive belt is not supplied with snowmobile. A30D0QA 1. Spare drive belt installed in holder clip 2.
  • Page 60 Grand Touring 700/SE A30E1CA 1. Main including starter 30 A 2. Compressor 20 A (Grand Touring SE only) 3. All others accessories 20 A 4. Digital performance management 1 A If any electrical device does not operate, check its fuse condition and replace if necessary.

  • Page 61: Front Grab Handles/Front Bumper

    Electric Fuel Level Gauge Fuse See your dealer for fuse replacement. Front Grab Handles/Front Bumper To be used whenever front of snowmobile requires lifting. A30H0NA 1. Front grab handles CAUTION Do not use skis to pull or lift snowmobile. Hitch The hook-type hitch can be used to pull most equipment.

  • Page 62: Fuel And Oil

    FUEL AND OIL Recommended Fuel Use super unleaded gasoline, available from most service stations or gasohol containing less than 10% of ethanol or methanol. The fuel used must have an octane number (R + M)/2 of 91 or higher. NOTE: In most service station pump octane number corresponds to (R + M)/2 octane number.

  • Page 63: Cold Weather Carburetion Modifications

    Oil is contained in the oil injection reservoir. Use BOMBARDIER-ROTAX INJECTION OIL (P/N 413 802 900 — 12 x 1 liter) available from authorized dealer. This type of oil will flow at temperatures as low as minus 40°C (-40°F). If unavailable, substitute with BOMBARDIER-ROTAX PRE-MIX OIL (P/N 413 803 100 —...

  • Page 64: 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. How- ever, brief full acceleration and speed variations contribute to a good break-in.

  • Page 65: 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. • Activate the brake control lever and make sure the brake fully ap- plies before the brake control lever touches the handlebar grip.
  • Page 66 A30F06A TYPICAL — AIR SUSPENSION GAUGE 1. Minimum required pressure before riding CAUTION Operating the snowmobile without minimum required pres- sure in the air shock will cause premature wear of the rubber boot and failure of the component. WARNING Only start your snowmobile once all components are checked and functioning properly.

  • Page 67: Starting Procedure

    STARTING PROCEDURE • Re-check throttle control lever operation. • Ensure that the emergency cut-out switch is in the ON position. • Ensure the tether cut-out cap is in position and that the cord is attached to your clothing. Initial Cold Starting All Models Except Grand Touring 700/SE NOTE: Do not operate the throttle lever during starting.

  • Page 68: Warm Engine Starting

    Warm Engine Starting All Models Except Grand Touring 700/SE Start the engine without any choke. Grand Touring 700/SE These vehicles are equipped with a DPM system. The only operation to be done is starting the engine. Manual Starting Insert the key in the ignition switch and turn to ON position. Grasp manual starter handle firmly and crank engine.
  • Page 69 A07D0UA Attach emergency rope to rewind handle and to the starter clip sup- plied in the tool box. NOTE: The spark plug socket can be used as an emergency handle. A17B01A Wind the rope tightly around drive pulley. When pulled, pulley must rotate counterclockwise.
  • Page 70 Tie a knot near clip. Hook up clip on drive pulley and wind counter- clockwise up to 3 turns. A30D06A 1. Clip Start engine as per usual manual starting. WARNING When starting the snowmobile in an emergency situation, using drive pulley, do not reinstall the guard and return slow- ly to have snowmobile repaired.

  • Page 71: Suspension Adjustments

    For factory recommended adjustments refer to decal on guard. A30F07A 1. Decal This decal describes settings for optimum comfort according to load for your SKI-DOO model. 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 72: Guidelines To Adjust Suspension

    A03H2AB TYPICAL 1. Rear springs for comfort 2. Center spring for steering behavior 3. Stopper strap for snowmobile weight transfer 4. Acceleration and control modulator (ACM) — Handling 5. Front spring for handling 6. Ski stopper for stability 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 in the right order (re- fer to next illustrations).
  • Page 73 Grand Touring SE Only After all adjustments are performed, rear air shock absorber can be adjusted as necessary. Use the console mounted switch. 1. Rear Springs — Comfort When driver and passenger (if so applicable) take place rear of snow- mobile should collapse by 50 to 75 mm (2 to 3 in).
  • Page 74 A03F2MA TOO SOFT OF ADJUSTMENT CAUTION Always turn the left side adjustment cam in a clockwise direc- tion, the right side cam in a counterclockwise direction. Left and right adjustment cams must always be set at the same position. A30F04A 1.
  • Page 75 A03F2OA TOO HARD OF ADJUSTMENT CAUTION Always turn the left side adjustment cam in a clockwise direc- tion, the right side cam in a counterclockwise direction. Left and right adjustment cams must always be set at the same position. A30F04A 1.
  • Page 76 2. Center Spring — Steering Behavior Ride at moderate speed on a trail with bumpy conditions. If steering is easy to turn adjust center spring accordingly. A03F2PA GOOD ADJUSTMENT AT MODERATE SPEED 1. Steering easy to turn...
  • Page 77 A03F2PA TOO SOFT OF ADJUSTMENT 1. Steering hard to turn A03F21A 1. Adjuster wrench...
  • Page 78 A03F2PA TOO HARD OF ADJUSTMENT 1. Steering less aggressive A03F21B 1. Adjuster wrench...
  • Page 79 3. Stopper Strap — Weight Transfer Ride at low speed then fully accelerate. Note steering behavior. Ad- just stopper strap length accordingly. At rest stopper strap should have a free play of 12 mm (1/2 in). CAUTION Whenever stopper strap length is changed, track tension must be readjusted.
  • Page 80 A03F2QA TOO LONG STRAP 1. Skis lift off the ground A03F0QB 1. Vary strap length by bolting to a different hole...
  • Page 81 A03F2PA TOO SHORT STRAP 1. Heavy steering A03F0QB 1. Vary strap length by bolting to a different hole...
  • Page 82 4. ACM — Handling Ride at moderate speed and check for desired handling. If handling is not satisfactory, turn the nut clockwise. Factory setting is fully tighten. A03F1EA 1. Nut If handling is too aggressive, turn the nut counterclockwise. Nut must be in good condition to avoid unexpected loosening. On the threaded rod there must be at least 2 threads exposed beyond the nut.
  • Page 83 5. Front Springs — Handling Ride at moderate speed and check for proper handling. Adjust front springs accordingly. CAUTION Always adjust both front springs to same position. A03F2PA PROPER ADJUSTMENT 1. Good handling and comfortable steering...
  • Page 84 A03F2PA TOO SOFT OF ADJUSTMENT 1. Bad handling A03F2IA 1. Increase spring preload...
  • Page 85 A03F2PA TOO HARD OF ADJUSTMENT 1. Steering hard to turn A03F2JA 1. Decrease spring preload...
  • Page 86 6. Ski Stopper — Stability When riding check for darting (unwanted side-to-side ski movement). A03A07A PROPER ADJUSTMENT 1. No darting...
  • Page 87 A03A08A NOT ENOUGH PRELOAD 1. Darting A16G0AC 1. Loosen nut, adjust against stop bounding then retighten nut to 14 N•m (124 lbf•in)

  • Page 88: 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 89: 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. 10-HOUR OR 500 km (300 mi) INSPECTION (To be performed by dealer) WEEKLY OR EVERY 240 km (150 mi) MONTHLY OR EVERY 800 km (500 mi) ONCE A YEAR OR EVERY 3200 km (2000 mi) STORAGE (To be performed by dealer)
  • Page 90 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 Wear and Condition of Skis and Runners Steering and Ski Leg Camber Adjustment AS REQUIRED Suspension Adjustments...

  • Page 91: Fluid Levels

    FLUID LEVELS Brake System Check brake fluid (DOT 4) in reservoir for proper level. Add fluid (DOT 4) as required. CAUTION Use only (DOT 4) brake fluid from a sealed container. A30D08A TYPICAL 1. Minimum Chaincase Oil Level With snowmobile on a level surface, check the oil level by removing dipstick.
  • Page 92 Refill up to upper mark using BOMBARDIER SYNTHETIC CHAIN- CASE OIL (P/N 413 803 300 — 12 x 355 mL). CAUTION Do not use unrecommended other types of oil when servic- ing. Do not mix synthetic oil with other types of oil. A30D0AA TYPICAL 1.

  • Page 93: Oil Injection System

    Oil Injection System Always maintain a sufficient amount of BOMBARDIER-ROTAX IN- JECTION OIL (P/N 413 802 900 — 12 x 1 liter) 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.

  • Page 94: 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 95: Maintenance

    MAINTENANCE Guard Removal and Installation 1. Open hood. 2. Open retainer to release pin then pull guard toward center of ve- hicle then toward front. A30C10A 1. Pin retainer When reinstalling guard, position its cut-away toward front of snow- mobile. Refer to decal on guard.
  • Page 96 Insert guard slots at rear first. A30C06A 1. Slots A30C07A 1. Rear of guard properly installed Push down front portion of guard in retainer.

  • Page 97: Drive Belt Removal/Installation

    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. Drive Belt Removal/Installation 1. Open hood and remove guard. 2. Open the driven pulley with the drive belt installer/remover provid- ed in tool box.
  • Page 98 Slip the belt over the top edge of the sliding half, as shown in previ- ous photo. Remove access panel from bottom pan. A30C04A 1. Push top of panel out of bottom pan A30C05A 1. Pull panel tab out of bottom pan...
  • Page 99 Slip belt under drive pulley then, remove it from vehicle. A30D0CA 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 1.

  • Page 100: Drive Chain Tension

    CAUTION Do not force or use tools to pry the belt into place, as this could cut or break the cords in the belt. Remove belt installer. Reinstall access panel and guard. Drive Chain Tension Remove hair pin. Fully tighten tensioner adjustment screw by hand, then back off only far enough for hair pin to engage in locking hole.

  • Page 101: Tra Drive Pulley Adjustment

    TRA Drive Pulley Adjustment The drive pulley is factory calibrated to transmit maximum engine power at a predefined RPM. Refer to SPECIFICATIONS at the end of this guide. Factors such as ambient temperature, altitude or surface condition may vary this critical engine RPM thus affecting snowmo- bile efficiency.
  • Page 102 A16D0GA 1. Position 1 (not numbered) Each number modifies maximum engine RPM by about 200 RPM. Lower numbers decrease engine RPM in steps of 200 RPM and higher numbers increase it in steps of 200 RPM. Example: Calibration screw is set at position 4 and is changed to position 6. So maximum engine RPM is increased of 400 RPM.

  • Page 103: Drive Belt Condition

    A16D0HA 1. Loosen just enough to permit rotating of calibrate screw WARNING Always reinstall guard. Do not operate engine with hood open or guard removed. Improper servicing, modification or poor adjustment may affect drive pulley performance and belt life. Always refer to the Shop Manual or obtain dealer advice before servicing or modifying the drive or driven pul- leys.

  • Page 104: Brake Adjustment

    Brake Adjustment No adjustment is provided for hydraulic brake. See an authorized dealer if any problems. Rear Suspension Condition Visually inspect all suspension components including slider shoes, springs, wheels, etc. NOTE: During normal driving, snow will act as a lubricant and cool- ant for the slider shoes.

  • Page 105: Track Tension And Alignment

    Track Tension and Alignment Tension NOTE: Ride the snowmobile in snow about 15 to 20 minutes prior to adjusting track tension. Lift rear of snowmobile and support it with a snowmobile mechan- ical stand. Allow the suspension to extend normally and check gap half-way along slider shoe.
  • Page 106 A06F1WA TYPICAL 1. 7.3 kg (16 lb) 2. Deflection CAUTION Too much tension will result in power loss and excessive stresses on suspension components. To adjust tension: – On some models, remove wheel cap. – Loosen the rear idler wheel retaining screws. –...
  • Page 107 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 108 A01F05A TYPICAL 1. Guides 2. Slider shoes 3. Equal distance To correct, stop the engine: Loosen rear wheel screws tighten the adjustment screw on side where the slider shoe is the farthest from the track insert guides. A01F0BA TYPICAL 1. Guides 2.

  • Page 109: Steering And Front Suspension Mechanism

    Retighten wheel screws to 48 N•m (35 lbf•ft). WARNING Properly tighten wheel screws. A05F0EC 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 110: 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 111 Reinstall filter over dashboard sticking bottom edge first. A30H0SA 1. Stick bottom edge first Finalize filter top edge installation.
  • Page 112 A30H0QA 1. Push top edge of filter under air deflector lip Check air silencer filter for snow. Remove filter and shake it as re- quired. A30H0XA AIR SILENCER FILTER INSTALLED...

  • Page 113: High Altitude Kit

    Check that the air silencer is clean and dry and properly reinstall the filter. CAUTION Snowmobile engines have been calibrated with the filter in- stalled. Operating the snowmobile without it may cause en- gine 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 114: Bulb Replacement

    Bulb Replacement Always check light operation after bulb replacement. Headlight CAUTION Never touch glass portion of an halogen bulb with bare fin- gers, it shortens its operating life. If glass is touched, clean it with isopropyl alcohol which will not leave a film on the bulb. If any headlight bulb is burnt, remove windshield, air filter then, air deflector.
  • Page 115 A30E05A 1. Locking ring Instrument(s) All Models Remove air duct from underneath hood. A30E06A 1. Remove these screws...
  • Page 116 All Models Except GT Series Bulb socket is always behind the instrument under a black rubber boot. Pull rubber boot and socket to expose bulb. Pull bulb out of socket. A06H1EA TYPICAL — ALL MODELS EXCEPT GT SERIES 1. Instruments sockets GT Series Pry out plastic plug to reach burnt bulb.

  • Page 117: Towing

    Towing Only tow snowmobile using a rope to pull ski legs. A30G01A STORAGE 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, follow the maintenance chart in MAIN- TENANCE section.

  • Page 118: Troubleshooting

    TROUBLESHOOTING SYMPTOM : Engine turns over but fails to start. Possible causes What to do 1. Ignition switch, emergency cut-out Place all switches in the ON position. switch or tether switch is in the OFF position. 2. Mixture not rich enough to start Check fuel tank level and check cold engine.
  • Page 119 SYMPTOM: Engine turns over but fails to start. Possible causes What to do 6. Engine compression. As the engine is pulled over with the rewind starter, “cycles” of resistance should be felt as piston goes past top dead center (each piston on twin- cylinder engines).
  • Page 120 SYMPTOM: Engine backfires. 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, beeper sounds every 3 seconds as well. Properly install tether cord. 2.
  • Page 121 SYMPTOM: Snowmobile cannot reach full speed. Possible cause What to do 1. DESS has not read tether cord. DESS pilot lamp blinks once every 3 Engine can not exceed 3000 RPM. seconds, beeper sounds every 3 seconds as well. Properly install tether cord.

  • Page 122: Specifications

    SPECIFICATIONS GRAND TOURING GRAND TOURING GENERAL Engine – Maximum Power 8000 8000 Engine Speed Drive belt – Number 417 300 066 417 300 066 – Width of a New Belt mm (in) 35.1 (1.382) 35.1 (1.382) – Wear Limit Width mm (in) 33.0 (1.299) 33.0 (1.299)
  • Page 123 MACH 1/1 R FORMULA III 600 MACH Z/ Z M.H. R/ GENERAL FORMULA III 700 MACH Z R FORMULA III 800 MACH Z LT/Z LT R Engine – Maximum Power F. III 600 : 8400 8300 F. III 700/800 : 8500 Engine Speed Drive belt –...
  • Page 124 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. Super unleaded gasoline with a minimum octane number of 91 (R + M)/2.

  • Page 125: Other Publications Available

    High Altitude Technical Data 484 300 003 (Loose Sheets) Binder 484 054 500 1995 - 1999 Specification Booklet 484 300 002 1999 Racing Handbook 484 300 004 Order from your SKI-DOO dealer. Ask your dealer for the appropriate volume you need.

  • Page 126: 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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