Ski-Doo 2003 Mini Z Operator's Manual
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Ski-Doo 2003 Mini Z Operator's Manual

Ski-Doo 2003 Mini Z Operator's Manual

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Summary of Contents for Ski-Doo 2003 Mini Z

  • Page 2: Safety Warning

    SAFETY WARNING Disregarding any of the safety precautions and instructions con- tained in this Operator’s Guide or on-product warnings may result in injury, including the possibility of death. This Operator’s Guide should remain with the unit at time of resale. In USA, products are distributed by Bombardier Motor Corporation of America.

  • Page 3: Foreword

    We trust you have taken full advantage of this! If you need more com- plete servicing information, please ask your dealer about the Ski-Doo Mini Z Shop Manual. At delivery, you were also informed of the warranty coverage and completed the Warranty Registration Form which is to be sent to us for processing.

  • Page 4: Notice To Parents

    NOTICE TO PARENTS Review this guide with any user of this snowmobile. Please take time with the children to review the instructions on its safe and proper use, while paying attention to the on-product safety labeling before allowing them to ride snowmobile. Understand the controls and operation of the snowmobile, carefully read the Operator’s Guide, pay attention to the on-product safety labeling and review them with the children before allowing them to...

  • Page 5: Table Of Contents

    BOMBARDIER LIMITED WARRANTY NORTH AMERICA: ® 2003 SKI-DOO SNOWMOBILES ..........BOMBARDIER LIMITED WARRANTY INTERNATIONAL: ® 2003 SKI-DOO SNOWMOBILES ..........AUTHORIZED SKI-DOO DEALERS .......... CHILD’S SECTION ..............SNOWMOBILE DESCRIPTION..........CLOTHING ................SNOWMOBILE CONTROLS............. 1) Throttle Lever............... 2) Brake Lever ................3) Handlebar ................
  • Page 6 EMERGENCY STOP ..............FIRST RIDE ................HOW TO RIDE ................Sitting ..................Kneeling..................Standing ..................Passenger.................. People at Front ................SIGNALS .................. Stop ................... Left Turn..................Right Turn.................. AFTER USE................PARENT’S SECTION ..............HOW TO IDENTIFY YOUR SNOWMOBILE ......Vehicle Identification Number Location........Engine Serial Number Location ..........
  • Page 7 REPAIR AND MAINTENANCE ..........Vehicle Cleaning and Protection ..........Chain Guard Removal and Installation ........Clutch Axle and Drive Chain Lubrication ........Drive Chain Tension ..............Brake Condition................Brake Adjustment ..............Rear Suspension Condition............Suspension Stopper Straps Condition ........Track Condition ................Track Tension and Alignment.............

  • Page 8: Safety

    SAFETY This guide uses the following symbols. WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a potentially hazardous situation which, if not avoid- ed, may result in minor or moderate injury. When used without the safety alert symbol , potential hazard exists for property damage only.

  • Page 9: Safety Labeling

    SAFETY LABELING Safety standards for snowmobiles have been adopted by the Snow- mobile Safety and Certification Committee of which Bombardier 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 10 Maintain the snowmobile in top mechanical condition at all times. Do not lubricate throttle and/or brake cables and housings. Only perform procedures as detailed in this guide. Unless other- wise specified, engine should be turned OFF and cold for all lu- brication and maintenance procedures.

  • Page 11: Bombardier Limited Warranty North America: 2003 Ski-Doo Snowmobiles

    This warranty coverage is available only on 2003 SKI-DOO snowmobile pur- chased as new and unused by its first owner from a BOMBARDIER dealer au- thorized to distribute SKI-DOO products in the country in which the sale occurred (hereinafter “BOMBARDIER dealer”), and then only after the BOMBARDIER specified pre-delivery inspection process is completed and documented.
  • Page 12 5. WHAT BOMBARDIER WILL DO BOMBARDIER’s obligations under this warranty are limited to, at its sole dis- cretion, repairing parts found defective under normal use, maintenance and service, or replacing such parts with new genuine BOMBARDIER parts without charge for parts and labor, at any authorized BOMBARDIER dealer. BOMBARDIER reserves the right to improve or modify products from time to time without assuming any obligation to modify products previously manufac- tured.
  • Page 13 If the issue has not yet been resolved, please submit your complaint in writing or call the appropriate number below: In Canada: In USA: BOMBARDIER INC. BOMBARDIER MOTOR RECREATIONAL PRODUCTS CORPORATION OF AMERICA SKI-DOO ® RECREATIONAL PRODUCTS ® CUSTOMER ASSISTANCE CENTER SKI-DOO VALCOURT QC J0E 2L0 CUSTOMER ASSISTANCE CENTER...

  • Page 14: Bombardier Limited Warranty International: 2003 Ski-Doo Snowmobiles

    All genuine BOMBARDIER parts and accessories, installed by an authorized BOMBARDIER distributor/dealer (as hereinafter defined) at the time of delivery of the 2002 SKI-DOO snowmobile, carry the same warranty as that of the snow- mobile. Use of the product for racing or any other competitive activity, at any point, even by a prior owner will render this warranty null and void.
  • Page 15 5. WHAT BOMBARDIER WILL DO BOMBARDIER’s obligations under this warranty are limited to, at its sole dis- cretion, repairing parts found defective under normal use, maintenance and service, or replacing such parts with new genuine BOMBARDIER parts without charge for parts and labor, at any authorized BOMBARDIER distributor/dealer. BOMBARDIER reserves the right to improve or modify products from time to time without assuming any obligation to modify products previously manufac- tured.
  • Page 16 8. TRANSFER If the ownership of a product is transferred during the warranty coverage period, this warranty shall also be transferred and be valid for the remaining coverage period provided that BOMBARDIER is notified of such transfer of ownership in the following way: a.

  • Page 17: Authorized Ski-Doo Dealers

    AUTHORIZED SKI-DOO DEALERS For Canada and USA To find the nearest authorized SKI-DOO dealer, dial: 1-800-375-4366 or visit our web site at WWW.SKIDOO.COM.

  • Page 18: Child's Section

    CHILD’S SECTION...

  • Page 19: Snowmobile Description

    SNOWMOBILE DESCRIPTION A31H11A 1. Windshield 2. Hood 3. Front bumper 4. Skis 5. Track 6. Snow guard 7. Rear bumper 8. Seat...

  • Page 20: Clothing

    CLOTHING Always wear all appropriate protective clothing including an approved safety helmet. User(s) should be adequately clothed. Do not permit loose clothing which could be entangled in moving parts or get snagged on tree branches. A31A0IA 1. Safety helmet 2. Goggles 3.

  • Page 21: Snowmobile Controls

    SNOWMOBILE CONTROLS A31H12A 1. Throttle lever 2. Brake lever 3. Handlebar 4. Ignition switch 5. Tether cut-out switch 6. Engine cut-out switch 7. Rewind starter handle 8. Choke button 9. Hood latches...

  • Page 22: Throttle Lever

    1) Throttle Lever Squeezing the lever with your thumb will make the snowmobile go faster. Releasing the lever slows the snowmobile. WARNING Test the throttle lever operation each time you want to start the engine. This must be done before starting. The lever must return to its original position once released.

  • Page 23: Ignition Switch

    4) Ignition Switch The lights come ON automatically whenever the engine is running. Manual Starting Key operated, 2-position switch. To start the engine, first turn the key to ON position, then follow STARTING PROCEDURE. To stop the en- gine, turn the key to OFF position. A31E09A 1.

  • Page 24: Tether Cut-Out Switch

    5) Tether Cut-Out Switch When the tether cord is pulled off its switch post, the engine stops and prevents the snowmobile from running away if a throttle problem occurs or you fall off while riding. Always clip the tether cord to your clothing eyelet and the tether cut-out switch post before starting the engine.

  • Page 25: Engine Cut-Out Switch

    6) Engine Cut-Out Switch All drivers of the snowmobile should familiarize themselves with the function of this device by using it several times on first outing and everytime to stop the engine there after. Thereby this engine cut-out procedure will become reflex preparing operators to emergency sit- uations requiring its use.

  • Page 26: Choke Button

    8) Choke Button This device features a multi-position button to facilitate cold start. A31C32A 1. Cold start 2. Warm start 9) Hood Latches Hood latches are used to lock hood to its anchors.

  • Page 27: Before You Start

    BEFORE YOU START Always do a pre-start inspection with your parents or an adult before you turn on the ignition. Refer to PRE-OPERATION CHECK. Throttle Operate the throttle 2 or 3 times before you turn on the ignition. It must return freely to the idle or closed position, as shown. WARNING Throttle lever must operate easily and smoothly.

  • Page 28: Brake

    Brake Test your brake lever as you did the throttle. A31D05A CORRECT BRAKE LEVER POSITION BEFORE STARTING...

  • Page 29: Visual Inspection

    Visual Inspection Make certain hood is fastened with hood latches and remove any snow and ice buildup from lights, windshield and running boards. A31H13A LEFT SIDE SHOWN — HOOD LATCH IN FASTENING POSITION...

  • Page 30: Track

    Track Make sure the track is not frozen to the ground. To verify, lift rear of snowmobile or ask an adult to help. WARNING Do not attempt to lift the vehicle by hand alone. Use appropriate lifting device or have assistance to share lifting stress in order to avoid risk of strain injuries.

  • Page 31: How To Start

    HOW TO START Never attempt to start the engine unless the throttle returns to its normal or idle position. Verify this before starting. Keep hands off of throttle when actually starting. Put on your safety helmet and attach tether cord to your clothing eyelet. A31A0KA TETHER CORD ATTACHED TO CLOTHING EYELET...
  • Page 32 Connect tether cord cap to snowmobile switch. A31E0RB TETHER CORD CAP CONNECTED TO SWITCH Turn the ignition key to the ON position. A31E01A TYPICAL — IGNITION KEY TO THE ON POSITION...
  • Page 33 Set engine cut-out switch to middle position. A31E0SB ENGINE CUT-OUT SWITCH TO MIDDLE POSITION Engage choke only if the engine is cold. A31C30A CHOKE IS ENGAGED FOR COLD ENGINE STARTING...
  • Page 34 Pull starter handle to start engine. A31C33A STARTER HANDLE IS PULLED Allow engine to warm then disengage choke before operating at full throttle. While the engine is warming, check the headlight and the taillight, then set the engine cut-out switch to both extreme positions to be certain it will stop the engine.

  • Page 35: How To Stop

    HOW TO STOP Before riding your snowmobile, you should understand how to stop it. Release the throttle and gradually depress the brake lever on the left side of the handlebar and then turn the ignition key to the OFF posi- tion.

  • Page 36: Emergency Stop

    EMERGENCY STOP In an emergency, you may stop your vehicle by turning the engine cut- out switch located near the throttle control and applying the brake. A31E0VA BOTH OFF POSITIONS FOR EMERGENCY STOP Remember, a snowmobile cannot “stop on a dime”. Braking charac- teristics vary with deep snow, packed snow or ice.

  • Page 37: First Ride

    FIRST RIDE Under adult supervision, select an open snow covered area which is free of hazards. Push on throttle lever while holding on to handlebar. A31C34A TO ACCELERATE...
  • Page 38 Practice riding by using throttle lever to accelerate then brake lever to brake. A31D0XA TO BRAKE Go slowly and avoid all obstacles.

  • Page 39: How To Ride

    HOW TO RIDE Your riding position and balance are the 2 basic principles of making your snowmobile go where you want it to. These are 3 ways to position your body while riding the snowmobile; sitting, kneeling or standing. Sitting A31H14A FEET ON THE RUNNING BOARDS, KNEES AND HIPS FLEXIBLE...

  • Page 40: Kneeling

    A31H15A WRONG Kneeling A31H18A ONE FOOT ON THE RUNNING BOARD AND THE OPPOSITE KNEE ON THE SEAT...

  • Page 41: Standing

    Standing A31H16A BOTH FEET ON THE RUNNING BOARD WITH KNEES FLEXED WARNING Be watchful of any overhead branches or other hazards.

  • Page 42: Passenger

    Passenger This vehicle is intended for one operator only, no passenger. A31H17A WRONG...

  • Page 43: People At Front

    People at Front Make certain your snowmobile is pointed away from people or ob- jects before you start it. No one is to be standing in front of or in back of the snowmobile. A31A0LA...

  • Page 44: Signals

    SIGNALS WARNING Always be careful of other snowmobiles ahead or near you. Stop or steer away from others. If you intend to stop, raise either hand straight above your head. A left turn is indicated by extending your left hand straight out in the proper direction.

  • Page 45: Left Turn

    Left Turn A31H06A TYPICAL — TO INDICATE LEFT TURN...

  • Page 46: Right Turn

    Right Turn A31H07A TYPICAL — TO INDICATE RIGHT TURN AFTER USE When you return from your ride, stop the engine and remove the tether cord. Talk to your parents or the owner of the snowmobile about your ride. Remember, always drive carefully with your snowmobile.

  • Page 47: Parent's Section

    PARENT’S SECTION...

  • Page 48: How To Identify Your Snowmobile

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

  • Page 49: Engine Serial Number Location

    Engine Serial Number Location A31H0RA 1. Engine serial number...

  • Page 50: On-Vehicle Important Instructions

    ON-VEHICLE IMPORTANT INSTRUCTIONS Please read the following instructions carefully before operating snow- mobile. Have all damaged decals replaced by an authorized SKI-DOO dealer. A31H11C LOCATION OF IMPORTANT INSTRUCTIONS...
  • Page 51 Instruction 1 A31A0MA...
  • Page 52 Instruction 2 A31A0OA Instruction 3 A33H11A...

  • Page 53: Fuel And Oil

    FUEL AND OIL Recommended Fuel 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 an octane number (R + M)/2 of 86 or higher. NOTE: In most service stations pump octane number corresponds to (R + M)/2 octane number.
  • Page 54 WARNING Do not allow children to refuel the snowmobile. A31A0PA WRONG...

  • Page 55: Recommended Oil

    Recommended Oil Always maintain oil engine level with 4-stroke engine oil that meets or exceeds the requirements for API service classification SF or SG. Always check the API service label on the oil container to be sure it includes the letters SF or SG. SAE 5W30 is recommended for general, all temperature use.

  • Page 56: Engine Oil Level

    Engine Oil Level NOTE: This should only be done by an adult. With snowmobile on a level surface, check the oil level by removing dipstick at engine base. Oil level must be to the top of the oil filler neck. If not, refill up to oil filler neck using SAE 5W30 recommended for general use.
  • Page 57 A31C0CA 1. Proper oil level WARNING Check level and refill every time you refuel. Do not overfill. Wipe off any spillage.

  • Page 58: Break-In Period

    10 hours of operation or 30 days after the purchase, whichever comes first, your snowmobile be checked by an autho- rized SKI-DOO dealer. This inspection will give you the opportunity to discuss the unanswered questions you may have encountered during the first hours of operation.

  • Page 59: Pre-Operation Check

    • Check fuel and engine oil for levels and leaks. Replenish as neces- sary (to be done by an adult only). See an authorized SKI-DOO dealer in case of any leaks. • Check for drive chain excessive wear. Have vehicle repaired.

  • Page 60: Pre-Operation Check List

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

  • Page 61: Starting Procedure

    STARTING PROCEDURE Before Starting • Re-check throttle operation. • Ensure that the engine cut-out switch is in the ON position. • Ensure the tether cut-out cap is in position and that the cord is attached to child clothing. • Check that tether cord disk is in place and in good condition. This disk will unplug tether cord and stop engine if children try to open hood while engine is running.

  • Page 62: Repair And Maintenance

    REPAIR AND MAINTENANCE NOTE: All maintenance should be done by an adult or an authorized SKI-DOO dealer and according to these directions as well as the LU- BRICATION AND MAINTENANCE CHART. Do not allow children to lift hood to attempt repairs or maintenance.

  • Page 63: Vehicle Cleaning And Protection

    Vehicle Cleaning and Protection Remove any dirt or rust. To clean the entire vehicle, use only flannel cloths or equivalent. CAUTION: It is necessary to use flannel cloths or equivalent on windshield and hood to avoid damaging further surfaces to clean. To clean the entire vehicle, including bottom pan and metallic parts, use Heavy duty cleaner (P/N 293 110 001 (spray can 400 g) and P/N 293 110 002 (4 L)).

  • Page 64: Chain Guard Removal And Installation

    Chain Guard Removal and Installation Open hood. Remove chain guard retaining screws and lift off the guard. WARNING Engine should be running only when belt guard is secured in place. WARNING When removing chain guard, ensure that engine is not running. A31C35A CHAIN GUARD 1.

  • Page 65: Clutch Axle And Drive Chain Lubrication

    Clutch Axle and Drive Chain Lubrication Clutch Axle Lubrication Remove chain guard. Find connecting link (inner side of chain), then separate chain. Re- move chain from clutch sprocket. NOTE: Do not remove chain from driven sprocket. Chain may be dif- ficult to reinstall.

  • Page 66: Drive Chain Tension

    Install circlip so that open end is positioned opposite side of drive chain rotation. See the following illustration. WARNING Always ensure that connecting link, outer link and circlip are in good condition. Ensure that circlip is properly secured. A31D0KC TYPICAL 1.

  • Page 67: Brake Adjustment

    Brake Adjustment Fully apply brake with brake lever. If brake lever is not within 15 to 20 mm (19/32 to 25/32 in) of the handlebar, readjust brake. A31D03A 1. Brake lever A. 15 to 20 mm (19/32 to 25/32 in)
  • Page 68 Always reinstall chain guard. Do not operate engine with hood opened or chain guard removed. Improper servicing, modifica- tion or poor adjustment may affect sprockets performance and life. Always obtain authorized SKI-DOO dealer advice before ser- vicing or modifying the drive or driven sprockets. Always respect maintenance schedules.

  • Page 69: Rear Suspension Condition

    If worn or cut, or if track fibers are exposed, or if missing or defective inserts or guides are noted; contact an authorized SKI-DOO dealer. WARNING Do not modify track, including by installing traction enhancing products.
  • Page 70 NOTE: A belt tension tester (P/N 414 348 200) may be used to mea- sure deflection as well as force applied. A00C07C BELT TENSION TESTER A31D0YA A. 7.3 kg (16 lb) B. 60 mm (2-3/8 in) C. 35 mm (1-3/8 in)
  • Page 71 To adjust tension: – Loosen the rear idler wheel retaining screws. – Loosen the lock nuts then turn adjustment screws to adjust. If correct tension is unattainable, contact an authorized SKI-DOO dealer. A31F0IA 1. Adjustment screw 2. Loosen lock nut 3.
  • Page 72 Start the engine and accelerate slightly so that track barely rotates. This must be done in a short period of time (15 to 20 seconds). Check that the track is well centered; equal distance on both sides between edges of track guides and slider shoes. A31F01A TYPICAL 1.

  • Page 73: Steering And Front Suspension Mechanism

    Reposition snowmobile on the 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 an authorized SKI-DOO dealer.

  • Page 74: Wear And Condition Of Skis And Runners

    Wear and Condition of Skis and Runners Check the condition of the skis and ski runners. If worn, contact an authorized SKI-DOO dealer. WARNING Excessively worn skis and/or ski runners will affect snowmobile control. Exhaust System The tail pipe of the muffler should be centered with the exit hole in the bottom pan.

  • Page 75: 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. CAUTION: Do not run engine during storage period.

  • Page 76: Troubleshooting

    Install clean dry properly gapped spark plug. Start engine following usual starting procedure. If engine continues to flood, see an authorized SKI-DOO dealer. 4. No fuel to the engine Check fuel tank level; turn fuel valve...
  • Page 77 2. Lack of fuel to engine. Check item 4 of “Engine turns over but fails to start”. 3. Carburetor adjustments. Contact an authorized SKI-DOO dealer. 4. Clutch requires servicing. Contact an authorized SKI-DOO dealer. 5. Engine is overheating.

  • Page 78: Specifications

    SPECIFICATIONS GENERAL MINI Z ENGINE – Maximum power engine speed 4000 DRIVE CHAIN 12.7 – Pitch (in) (.500) – Number of links SPARK PLUG – Type NGK BPR6 ES 0.7 - 0.8 – Gap (in) (.028 - .031) TRACK – Tension (1-3/8) ➀...

  • Page 79: Lubrication And Maintenance Chart

    LUBRICATION AND MAINTENANCE CHART Refer to LUBRICATION AND MAINTENANCE in Shop Manual for more details. ➀ 10-HOUR INSPECTION (to be performed by an authorized SKI-DOO dealer) ➁ WEEKLY ➂ MONTHLY ➃ ONCE A YEAR ➄ STORAGE (to be performed by an authorized dealer) ➅...
  • Page 80 LUBRICATION AND ➀ ➁ ➂ ➃ ➄ ➅ MAINTENANCE CHART Drive chain tension Lubrication of drive axle and bearing Steering and front suspension mechanism Wear and condition of skis and runners Suspension lubrication Suspension condition Suspension stopper straps condition Track condition Track tension and alignment AS REQUIRED Spark plug*...

  • Page 81: 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 82: 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 authorized SKI-DOO dealers on a monthly basis to aid in recovery of such units to their...

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