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

Ski-Doo CK3 series Operator's Manual

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  • Page 2: Safety Warning

    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. 1997 (MMO-9802 GM)
  • Page 3 1998 SKI-DOO OPERATOR’S GUIDE This guide is applicable to: Grand Touring 700 Grand Touring SE Formula III 600 Formula III 600 R Formula III 600 LT Formula III 700 Formula III 700 R Mach 1 Mach 1 R Mach Z...
  • 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

    BOMBARDIER INTERNATIONAL LIMITED WARRANTY: ® 1998 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 (amber)........... 28) Heated Throttle Lever Switch ..........29) Heated Throttle Lever Pilot Lamp (amber) ......30) Electric Visor Jack Connector ..........31) Hood Latches ...............
  • Page 8 TROUBLESHOOTING CHART ..........In Deep Snow................LUBRICATION AND MAINTENANCE CHART ......FLUID LEVELS................Brake System ................Chaincase/Gearbox Oil Level............. Oil Injection System ..............Cooling System ................. Battery Electrolyte ..............MAINTENANCE ............... Belt Guard Removal and Installation ......... Drive Belt Removal/Installation ..........Drive Chain Tension ..............

  • 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...

  • 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 WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILI- TY OR FITNESS FOR ANY PARTICULAR PURPOSE. Neither the distributor, any authorized SKI-DOO dealer nor any other person has been authorized to make any affirmation, rep- resentation or warranty other than those contained in this war- ranty, 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 warranty. A specific SKI-DOO International Distributor may elect to...

  • 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

    54402-8035. USA Telephone: (715) 848-4957 Fax: (715): 848-4975 OTHER COUNTRIES For customer relations, contact your local distributor. Your local dealer can provide distributor contact information. AUTHORIZED SKI-DOO DEALERS For North-America 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. A30A01A TYPICAL — LOCATION OF IMPORTANT INSTRUCTIONS...
  • Page 20 A01A1ZB 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: THROTTLE LEVER MOVES FREELY AVANT DE DÉMARRER LE MOTEUR, S'ASSURER QUE:...
  • Page 22 A01A24B 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 CAUTION : Bring vehicle to a complete stop before changing gear. ATTENTION : Immobiliser le véhicule complètement avant de changer de vitesses. A30A06A 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. 22 27 21 29 24 31 33 25 28 13 33 31 A30A03A TYPICAL —...
  • Page 25 8 21 29 24 22 27 20 18 19 17 A30A09A TYPICAL — GRAND TOURING SE...

  • Page 26: Throttle Lever

    1) Throttle Lever Located on the right side of handlebar. When compressed, it controls the engine speed and the engagement of the transmission. When released, engine speed returns automatically to idle. 2) Brake Lever Located on the left side of handlebar. When compressed, the brake is applied.

  • Page 27: Injection Oil Level/Parking Brake Pilot Lamp (Red)

    A30D01A 1. Locking lever 2. OFF 3. ON 4) Injection Oil Level/Parking Brake Pilot Lamp (Red) Lights when injection oil level is low. Check oil level and replenish as soon as possible. Also lights when parking brake is applied (with en- gine running).
  • Page 28 A30D02A 1. Forward 2. Reverse Shifting Procedure With snowmobile completely stopped and engine at idle, move lever to engage in desired gear. Do not force lever. If unable to shift, apply throttle to move snowmo- bile and try again. WARNING These snowmobiles are capable of a fast reverse.

  • Page 29: Ignition Switch

    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. Not used 3. START Manual Starting Key operated, 3-position switch. To start the engine, first turn the key to ON position.

  • Page 30: Tether Cut-Out Switch

    NOTE: Engine may be manually started with rewind starter if neces- sary. If starter does not operate, check starting system fuse condition. Refer to Starting System Fuse below. 7) Tether Cut-out Switch General Tether cut-out switch features a double function. First it is a safety device to shut-off engine if the driver accidently falls off the vehicle.
  • Page 31 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. Dealer programmed, the tether cord provided with your snowmobile is the only one that al- lows engine to turn more than 2500 RPM.

  • Page 32: Dess Pilot Lamp

    To check for bad connection, remove tether cord make sure it is free of dirt or snow. Reinstall tether cord and restart engine. If a beep per 3 seconds still occurs contact an authorized dealer. A30H08A 1. Free of dirt or snow A continuous beep and DESS pilot lamp blinking rapidly mean that a wrong tether cord is installed.
  • Page 33 A30E03A TYPICAL 1. ON 2. OFF...

  • Page 34: Headlamp Dimmer Switch

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

  • Page 35: High Beam Pilot Lamp (Blue)

    A30H0CA MACH Z AND GT SERIES 11) High Beam Pilot Lamp (Blue) Lights when headlamp is on HIGH beam. 12) 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 36: 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 with the choke lever on. Move the choke lever to position 2 and start the engine. As soon as the engine starts move the lever to position 1.

  • Page 37: Air Suspension Switch

    14) Air Suspension Switch This switch controls pressure inside rear air shock absorber. Holding switch upward (big spring on decal) increases air pressure. Holding switch downward (small spring on decal) decreases air pres- sure. A30H0UA WARNING Always completely stop vehicle and engine in a safe place before attempting any suspension adjustments.

  • Page 38: Not Used

    15) Not used 16) Air Suspension Gauge Located at bottom of tachometer, this gauge indicates comfort level (pressure inside rear air shock absorber). 17) Speedometer These vehicles are equipped with a speedometer graduated in km or miles according to country of use. Direct-reading dial indicates the speed of the snowmobile in kilome- ters or miles per hour.

  • Page 39: Trip Meter Reset Button

    20) Trip Meter Reset Button To reset, push on button until all numbers read zero. 21) Tachometer Direct-reading dial indicates the number of thousand of revolutions per minute (RPM) of the engine. X1000 r /min A06H05A 1. Multiply the reading by 1000 22) Temperature Gauge The gauge indicates engine coolant temperature.

  • Page 40: Not Used

    A30H0GA 1. Normal 2. Overheat 23) Not used 24) Electric Fuel Level Gauge Dash-mounted gauge to facilitate fuel level reading. This gauge works only when engine is running.

  • Page 41: 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.

  • Page 42: 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 43: Heated Grip Pilot Lamp (Amber)

    A30H0IA TYPICAL — MACH Z AND GT SERIES 1. Holding + position for more than 1 second will increase heating to maximum 27) Heated Grip Pilot Lamp (amber) Lights when heated grip switch is on the high position. Light dimmed when switch is on the low position. 28) Heated Throttle Lever Switch All Models Except Mach Z and GT Series Three-position toggle switch.

  • Page 44: Heated Throttle Lever Pilot Lamp (Amber)

    29) Heated Throttle Lever Pilot Lamp (amber) Lights when heated throttle lever switch is on the high position. Light dimmed when switch is on the low position. 30) Electric Visor Jack Connector An electric visor may be connected to that jack connector. Electric current is supplied when ever engine is running.

  • Page 45: 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 46: 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 47: 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 48: 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 49: 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 50: 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 pulley guard. A30D03A 1. Tool box 2. Remove hair pin before opening 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.

  • Page 51: Spare Drive Belt Holder

    A30D04A 1. Spare spark plugs stored in tool box 2. Instructions for spare spark plugs removal Spare Drive Belt Holder A spare drive belt can be installed in drive belt holder clip. NOTE: Spare drive belt is not supplied with snowmobile. A30D03B 1.

  • Page 52: Fuses

    Fuses Fuse Location CAUTION Do not use a higher rated fuse as this can cause severe dam- age to electric components. Some fuses are located on top of right side footrest. To gain access open hood. Grand Touring 700 A30H0KA 1.
  • Page 53 Grand Touring SE A30H0LA 1. Main including starter 30 A 2. Compressor 20 A 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. To remove fuse from holder, pull fuse out.

  • Page 54: 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 55: Fuel And Oil

    FUEL AND OIL Recommended Fuel Use super unleaded gasoline, available from most service stations. The gasoline 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. CAUTION Never experiment with other fuels.

  • Page 56: Cold Weather Carburetion Modifications

    Oil is contained in the oil injection reservoir. Use BOMBARDIER ROTAX INJECTION OIL (P/N 413 8029 00 — 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 8031 00 —...

  • Page 57: 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 58: 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 59 A06H35A TYPICAL — AIR SUSPENSION GAUGE 1. Minimum required pressure before riding WARNING Only start your snowmobile once all components are checked and functioning properly.

  • Page 60: 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 NOTE: Do not operate the throttle lever with the choke lever on.

  • Page 61: Manual Starting

    Warm Engine Starting Start the engine without any choke. If the engine will not start after two pulls of the rope or two 5 second attempts with the electric starter move choke lever to position 1. Start the engine without acti- vating the throttle lever.
  • Page 62 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 63 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 belt guard and return slowly to have snowmobile repaired.

  • Page 64: Suspension Adjustments

    For factory recommended adjustments refer to decal on pulley guard. A30D07A 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 65: 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 66 Grand Touring SE Only After all adjustments are performed, rear air shock absorber can be adjusted as necessary. Use the console mounted switch. NOTE: Compressor can be activated with the engine shut-off and ignition key at run position. CAUTION Do not use compressor needlessly when engine is not run- ning.
  • Page 67 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 68 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 69 2. Center Spring — Steering Behavior Ride at moderate speed on a trail with bumpy conditions. Note if steering is easy to turn. Adjust center spring accordingly. A03F2PA GOOD ADJUSTMENT AT MODERATE SPEED 1. Steering easy to turn...
  • Page 70 A03F2PA TOO SOFT OF ADJUSTMENT 1. Steering hard to turn A03F21A 1. Adjuster wrench...
  • Page 71 A03F2PA TOO HARD OF ADJUSTMENT 1. Steering less aggressive A03F21B 1. Adjuster wrench...
  • Page 72 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 73 A03F2QA TOO LONG STRAP 1. Skis lift off the ground A03F0QB 1. Vary strap length by bolting to a different hole...
  • Page 74 A03F2PA TOO SHORT STRAP 1. Heavy steering A03F0QB 1. Vary strap length by bolting to a different hole...
  • Page 75 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. WARNING Nut must be in good condition to avoid unexpected loosen- ing.
  • Page 76 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 77 A03F2PA TOO SOFT OF ADJUSTMENT 1. Bad handling A03F2IA 1. Increase spring preload...
  • Page 78 A03F2PA TOO HARD OF ADJUSTMENT 1. Steering hard to turn A03F2JA 1. Decrease spring preload...
  • Page 79 6. Ski Stopper Stability When riding check for darting (unwanted side to side ski movement). A03A07A PROPER ADJUSTMENT 1. No darting...
  • Page 80 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 81: 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 82: 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 83 LUBRICATION AND MAINTENANCE CHART Drive Chain Tension Chaincase/Gearbox Oil Level Chaincase/Gearbox Oil Change Lubrication of Drive Axle 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 Suspension Adjustments AS REQUIRED Suspension Lubrication...

  • Page 84: 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. Min. Chaincase/Gearbox Oil Level With snowmobile on a level surface, check the oil level by removing dipstick.
  • Page 85 A30D0AA TYPICAL 1. Dipstick 2. Oil level 3. Level between marks...

  • Page 86: Oil Injection System

    Oil Injection System Always maintain a sufficient amount of BOMBARDIER ROTAX IN- JECTION OIL (P/N 413 8029 00 — 12 x 1 liter) in the injection oil reservoir. CAUTION Never allow oil level to drop more than 2/3. WARNING Check level and refill every time you refuel. Do not overfill. Wipe off any spillage.

  • Page 87: 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 88: Maintenance

    MAINTENANCE Belt Guard Removal and Installation 1. Open hood. 2. Open retainer to release pin then pull belt guard toward front. A30C03A 1. Pin retainer When reinstalling belt guard, position its cutaway toward front of snowmobile. Refer to decal on belt guard. Insert pulley guard slots at rear first.
  • Page 89 A30C06A 1. Slots A30C07A 1. Rear of pulley guard properly installed Push down front portion of pulley guard in retainer.

  • Page 90: Drive Belt Removal/Installation

    NOTE: Belt guard is purposely made slightly oversize to maintain tension on its pins and retainers preventing undue noise and vibra- tion. It is important that this tension be maintained when reinstalling. Drive Belt Removal/Installation 1. Open hood and remove belt guard. 2.
  • Page 91 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 92 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 93: 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 belt guard. Drive Chain Tension Remove hair pin. Fully tighten tensioner adjustment screw by hand, then back off only far enough for hair pin to engage in locking hole.

  • Page 94: 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 95 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 96: Drive Belt Condition

    A16D0HA 1. Loosen just enough to permit rotating of calibrate screw WARNING Always reinstall drive belt guard. Do not operate engine with hood open or drive belt guard removed. Improper servicing, modification or poor adjustment may affect drive pulley per- formance and belt life.

  • Page 97: Brake Condition

    Brake Condition The brake mechanism on your snowmobile is an essential safety de- vice. Keep this mechanism in proper working condition. Above all, do not operate the snowmobile without an effective brake system. Pe- riodically verify the condition/wear of the brake pads. Brake Adjustment No adjustment is provided for hydraulic brake.

  • Page 98: 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 99 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 100 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 101 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 102: 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 103: 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 104 Reinstall filter over dashboard sticking bottom edge first. A30H0SA TYPICAL 1. Stick bottom edge first...
  • Page 105 Finalize filter top edge installation. A30H0QA TYPICAL 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 106: 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 107: 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 108 A30E05A 1. Locking ring Instrument(s) All Models Remove air duct from underneath hood. A30E06A 1. Remove these screws...
  • Page 109 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 1. Instruments sockets Taillight If taillight bulb is burnt, expose the bulb by removing the red plastic lens.

  • Page 110: 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 111: 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 RUN or ON switch or tether switch is in the position. OFF position. 2. Mixture not rich enough to start Check fuel tank level and check cold engine.
  • Page 112 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 113 SYMPTOM: Engine backfire Possible causes What to do 1. DESS has not read tether cord. DESS pilot lamp blinks once every 3 Engine can not exceed 2500 RPM. seconds, beeper sounds every 3 seconds as well. Properly install tether cord. 2.
  • Page 114 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 2500 RPM. seconds, beeper sounds every 3 seconds as well. Properly install tether cord.

  • Page 115: Specifications

    SPECIFICATIONS FORMULA III 600 FORMULA III 700 GENERAL FORMULA III 600 LT FORMULA III 700 LT GT SE GT 700 Engine – Maximum Power 8500 7900 Engine Speed Drive belt – Number 414 0450 00 415 0450 00 – New Belt Width mm (in) 35.0 (1-3/8) 35.0 (1-3/8)
  • Page 116 MACH Z/Z R/Z LT/ GENERAL MACH 1/1 R Z LT R Engine – Maximum Power 8300 8300 Engine Speed Drive belt – Number 414 0450 00 415 0450 00 – New Belt Width mm (in) 35.0 (1-3/8) 35.0 (1-3/8) – Wear Limit Width mm (in) 32.0 (1-1/4) 32.0 (1-1/4)

  • Page 117: Other Publications Available

    High Altitude Technical Data 484 0686 00 (Loose Sheets) Binder 484 0545 00 1995 - 1998 Specification Booklet 484 0685 00 1998 Racing Handbook 484 0687 00 Order from your SKI-DOO dealer. Ask your dealer for the appropriate volume you need.

  • Page 118: 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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