Ski-Doo Legend Operator's Manual
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Ski-Doo Legend Operator's Manual

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Questions and answers

don g. friedrich
February 4, 2025

how to adjust float height on a 2004 500 Legend

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1 comments:
Mr. Anderson
May 14, 2025

To adjust the float height on a 2004 Ski-Doo 500 Legend with TMX-style carbs:

1. Remove the carburetor float bowl to access the float.
2. Hold the carburetor so the float arm just contacts the needle valve without compressing the spring inside the needle.
3. Check if the float is level with the carburetor body.
4. If adjustment is needed, carefully bend the small metal tab that contacts the needle valve.
5. Bend the tab slightly until the float sits level when the needle just closes.
6. Reassemble the carburetor after adjustment.

No need to run the engine during this process.

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Summary of Contents for Ski-Doo Legend

  • Page 2: Safety Warning

    ® BOMBARDIER GRAND TOURING SUMMIT ® ® ROTAX MX-Z SKANDIC SKI-DOO ® LEGEND DESS Printed in Canada (Mmo2003-003a.fm GM) ®TM are trademarks and ® are registered trademarks of Bombardier Inc. or its subsidiaries. © 2002 Bombardier Inc. All rights reserved.
  • Page 3 2003 SKI-DOO OPERATOR’S GUIDE This guide is applicable to the following ZX series models: Legend Grand Touring ® MX-Z ® Summit Skandic*...
  • 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 We also reserve the right at any time to discontinue or change spec- ifications, designs, features, models or equipment without incurring obligation. The illustrations show the typical construction of the different assem- blies and, in all cases, may not reproduce the full detail or exact shape of the parts shown, however, they represent parts which have the same or a similar function.

  • Page 6: Table Of Contents

    ® SNOWMOBILES ..........BOMBARDIER LIMITED WARRANTY INTERNATIONAL: 2003 SKI-DOO ® SNOWMOBILES ..........FREQUENTLY ASKED QUESTIONS ......... AUTHORIZED SKI-DOO DEALERS ........... HOW TO IDENTIFY YOUR SNOWMOBILE ......Vehicle Description Decal............Serial Numbers................ON-VEHICLE IMPORTANT INSTRUCTIONS......CONTROLS/INSTRUMENTS/EQUIPMENT ......1) Throttle Lever ................
  • Page 7 29) Engine Overheat Warning Lamp (Red) ......... 30) Fuel Tank Cap/Gauge ............31) Electric Fuel Level Gauge ............. 32) Heated Grip Switch............... 33) Heated Throttle Lever Switch..........34) Electric Visor Jack Connector ..........35) 12-Volt Power Outlet ............36) Air Suspension Switch............37) Air Suspension Gauge ............
  • Page 8 VEHICLE WARM-UP ..............110 POST-OPERATION CARE ............111 SPECIAL OPERATIONS ............. 111 Riding at High Altitudes............... 111 Engine Overheating..............111 Fuel Flooded Engine..............112 Rear Suspension Slider Shoe Sticking......... 112 PERIODIC MAINTENANCE CHART........... 113 FLUID LEVELS................115 Brake System ................115 Chaincase Oil Level ..............

  • Page 9: Safety Measures

    The engine and components used in a particular model should not ® be used on other models. Use of Rotax snowmobile engines in other than SKI-DOO snowmobiles is not recommended or autho- rized by Bombardier Inc.

  • Page 10: List Of Hot Parts

    Electronic reverse (RER ) models only: The shifting to reverse mode on these snowmobiles is done by the push of the RER but- ton when the engine is running. Wait until the reverse alarm sounds and the DESS /RER pilot lamp comes on in the dash be- fore operating throttle to proceed in reverse.

  • 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 oc- curred (hereinafter “BOMBARDIER dealer”), and then only after the BOMBARDIER specified pre-delivery inspection process is completed and doc- umented.
  • 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 2003 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 peri- od, this warranty shall also be transferred and be valid for the remaining cover- age period provided that BOMBARDIER is notified of such transfer of owner- ship in the following way: a.

  • Page 17: Frequently Asked Questions

    I do have my original invoice as proof of when I purchased my snowmobile. A: Registration is very important and your authorized SKI-DOO dealer must register your snowmobile with Bombardier. Make sure the registration form has been sent. All of this will allow...
  • Page 18 DOO dealership management. If the problem already has been reviewed with the Sales Manager or Service Manager, contact the General Manager or the owner of this authorized SKI-DOO dealership. We are always pleased to receive your comments on the SKI-DOO snowmobile.

  • Page 19: Authorized Ski-Doo Dealers

    AUTHORIZED SKI-DOO DEALERS For Canada and USA Only To find the nearest authorized SKI-DOO dealer, dial: 1-800-375-4366 or visit our web site at WWW.SKIDOO.COM. HOW TO IDENTIFY YOUR SNOWMOBILE Vehicle Description Decal Vehicle description decal is located on right hand side of tunnel.

  • Page 20: Serial Numbers

    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 21 Vehicle Identification Number (VIN) Location VIN is scribed on vehicle description decal. See above. It is also em- bossed on tunnel near vehicle description decal. Model Number Location Model number is part of vehicle identification number (VIN). X X X X X X X X X X X X X X X X X Model number Serial number A00A6IA...

  • Page 22: 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. 3 4 5 A32A02E LOCATION OF IMPORTANT INSTRUCTIONS...
  • Page 23 Instruction 1 SINGLE SEAT MODELS DOUBLE SEAT MODELS A02A0HA...
  • Page 24 Instruction 2 A01A1ZD ALL MODELS Instruction 3 A01A2EA ALL MODELS...
  • Page 25 Instruction 4 A01A2FA ALL MODELS Instruction 5 A01A24D TYPICAL — ALL MODELS...
  • Page 26 Instruction 6 SUSPENSION ADJUSTMENT CHART/TABLEAU DES RÉGLAGES DE LA SUSPENSION FRONT SUSPENSION (SKI)/SUSPENSION AVANT (SKI) NOT APPLICABLE SANS OBJET REAR SUSPENSION/SUSPENSION ARRIÈRE ADJUST ACCORDING TO LOAD/RÉGLER SELON LA CHARGE LOAD REAR SPRING CHARGE RESSORT ARRIÈRE APPLICABLE SANS OBJET FOR LOADS EXCEEDING RANGE SHOWN ABOVE, CONSULT YOUR DEALER. SI LES CHARGES EXCÈDENT LES PLAGES MONTRÉES CI-HAUT, CONSULTEZ VOTRE CONCESSIONNAIRE.
  • Page 27 Instruction 7 A32A0MA SUMMIT WITHOUT RENAGADE PACKAGE...
  • Page 28 A32A0NA SUMMIT WITH RENEGADE PACKAGE...
  • Page 29 Instruction 8 A32F21A SUMMIT...

  • Page 30: Controls/Instruments/Equipment

    CONTROLS/INSTRUMENTS/EQUIPMENT NOTE: Some controls/instruments/equipment are optional on some models. 45 40 39 48 44 49 50 42 43 A32A0HB 47 42 41 51 46 52 53 44 45 A32A12A TYPICAL...
  • Page 31 3 31 32 34 40 12 33 29 18 40 A32A13A TYPICAL — LIQUID-COOLED MODELS 40 38 A32E1CB TYPICAL — FAN-COOLED MODELS...
  • Page 32 23 20 22 13 4-5 17 A32A14A TYPICAL — FAN-COOLED MODELS 22-23 25-36 A32A15A LIQUID-COOLED MODELS...

  • Page 33: Throttle Lever

    1) Throttle Lever Located on the right hand side of handlebar and designed to be thumb activated. When squeezed, it increases the engine speed and engages the transmission. When released, engine speed returns au- tomatically to idle. WARNING Throttle lever must operate easily and smoothly. It must return to idle position when released.
  • Page 34 MECHANICAL BRAKE To engage mechanism, squeeze brake lever and maintain while pull- ing button with the other hand. There are 2 retaining notches on but- ton lever; pull button until it locks on a notch then release brake lever. To release mechanism, squeeze brake lever then fully push parking brake button.

  • Page 35: Brake/Parking Brake Pilot Lamp (Red)

    HYDRAULIC BRAKE To engage mechanism, squeeze brake lever and maintain while pull- ing locking lever with a finger. When brake lever is held at half-way, the parking brake should be fully applied. To release mechanism, squeeze brake lever. Locking lever will auto- matically return to its original position.

  • Page 36: Low Injection Oil Level (Red)

    WARNING Fast reverse while turning, could result in loss of stability. Handlebar height is adjustable. See an authorized SKI-DOO dealer. WARNING Adjust with vehicle at rest in a safe place. Securely retighten all fasteners. Never rotate throttle lever to operate with fingers...

  • Page 37: Adjustable Handlebar

    7) Adjustable Handlebar Handlebar angle can be adjusted to suit driver’s preference. Lift lever, tilt handlebar to desired position then release lever. WARNING Adjust with vehicle at rest in a safe place. Securely tighten all adjustments. A32A0RA 1. Lever 8) Holding Strap Holding strap provides a grip for driver when side-hilling.

  • Page 38: Rer Button

    9) RER Button WARNING These snowmobiles are capable of a fast reverse. Always re- main seated and apply the brake before shifting. Come to a complete stop then push RER button. Ensure the path behind is clear of obstacles or bystanders. Fast reverse, could result in loss of stability.
  • Page 39 With the snowmobile completely stopped and engine running at idle, press and release the RER button. A32E1BA 1. RER button The RER pilot lamp will blink and a warning buzzer will sound when the snowmobile is engaged in reverse. Apply throttle slowly and evenly. Allow drive pulley to engage then accelerate carefully.

  • Page 40: Start/Rer Button

    At high altitude, the RER system needs a different engine timing curve to work properly. Operation Fan-Cooled Models Before using vehicle at high altitude see an authorized SKI-DOO deal- er for installation of a high altitude cap. Fan-cooled Summit models are already equipped with high altitude cap. 10) Start/RER Button General The START/RER button has two functions.
  • Page 41 Start Mode To start engine, push START/RER button and hold until engine has started. CAUTION: Do not hold START/RER button more than 15 seconds. A rest period should be observed between the cranking cycles to let starter cool down. Holding START/RER button when engine has started could damage starter mechanism.
  • Page 42 RER Modification at High Altitude General At high altitude, the RER system needs a different engine timing curve to work properly. Operation Non-DPM Liquid-Cooled Models Before using the reverse system, first select the altitude mode that changes engine timing curve. To do so, push and hold START/RER button with engine running.

  • Page 43: Ignition Switch

    11) Ignition Switch Fan-Cooled Models Only A23H04A MANUAL START ELECTRIC START MODELS 1. OFF 1. OFF 2. ON 2. ON 3. START Manual Starting Key operated, 2-position switch. To start the engine, first turn the key to ON position then, pull rewind starter grip. To stop the engine, turn the key to OFF position.

  • Page 44: Tether Cut-Out Switch

    12) Tether Cut-Out Switch General Fan-Cooled Models The tether cut-out system shuts-off engine if the driver accidently falls off the vehicle. Liquid-Cooled Models Only The tether cut-out switch is part of tether cut-out system. This sys- tem serves 3 functions. It shuts off engine preventing snowmobile to runaway if the operator falls off the vehicle accidently.
  • Page 45 Operation All Models Attach tether cord to clothing eyelet then snap tether cord cap over switch post receptacle before starting engine. A32H0NA TYPICAL 1. Snap over switch post 2. Attach to eyelet To stop engine, completely pull cap from post switch. A32H0EA TYPICAL...
  • Page 46 See above for details. Additional Tether Cord Caps The MPEM of your snowmobile can be programmed by your autho- rized SKI-DOO dealer to accept 8 different key codes (tether cord caps). We recommend the purchase of additional tether cord caps from your authorized SKI-DOO dealer as an additional keys.

  • Page 47: Rer Pilot Lamp (Red)

    To check for bad connection, remove tether cord cap. Make sure the cap is free of dirt or snow. Reinstall tether cord cap and restart en- gine. If a blink per 1.5 seconds still occurs contact an authorized SKI- DOO dealer. A30H08A 1.

  • Page 48: Engine Cut-Out Switch

    16) Engine Cut-Out Switch A push-pull type switch located on the right side of the handlebar. To stop the engine, push the button to the lower OFF position and si- multaneously apply the brake. To restart, button must be at the upper ON position.

  • Page 49: 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 whenever stopping the engine there after. Thereby this engine cut- out procedure will become a reflex and will prepare operators in emergency situations requiring its use.

  • Page 50: Choke Lever

    20) Choke Lever This device features a 3-position lever to facilitate cold start. A32H01A 0. OFF 1. Position 1 2. Position 2 See OPERATING INSTRUCTIONS for more details.

  • Page 51: Speedometer

    21) Speedometer Fan-Cooled Models Direct-reading dial indicates the speed of the snowmobile in kilome- ters per hour (miles per hour for the USA). Liquid-Cooled Models A33E09A SPEEDOMETER This model is equipped with an electronic speedometer. It may show speed in km/h or MPH. NOTE: At vehicle speed of 90 km/h (55 MPH) and more the mode LCD screen will show speed only instead of the selected mode.

  • Page 52: Mode Button

    22) Mode Button Depress mode button to change display. Each time engine is started, display shows odometer. From that point depressing mode button will change display for the trip meter. Depressing mode button again will change display for the resetable hourmeter.

  • Page 53: Resetable Hourmeter

    25) Resetable Hourmeter Records engine running time in hours and minutes since it has been reset. NOTE: At vehicle speed of 90 km/h (55 MPH) and more the mode LCD screen will show speed only instead of the selected mode. Push and hold mode button for 2 seconds to reset the resetable hour- meter.

  • Page 54: Tachometer

    A32A16A TYPICAL 1. Normal 2. Overheat 29) Engine Overheat Warning Lamp (Red) If this lamp glows, stop engine immediately and allow to cool. If prob- lem repeats, see your authorized SKI-DOO dealer.

  • Page 55: Fuel Tank Cap/Gauge

    30) Fuel Tank Cap/Gauge On some models fuel level gauge is part of fuel tank cap. Unscrew to fill up tank then fully tighten. A32I01A WARNING Always stop engine before refueling. Fuel tank may be pressur- ized, open cap slowly. Fuel is flammable and explosive. Never use an open flame to check fuel level.

  • Page 56: Electric Fuel Level Gauge

    31) Electric Fuel Level Gauge Dash-mounted gauge to facilitate fuel level reading. This gauge func- tions when engine is running. A32A17A TYPICAL 1. Full 2. Empty 32) Heated Grip Switch Three-position toggle switch. Select the desired position to keep your hands at a comfortable temperature.

  • Page 57: Heated Throttle Lever Switch

    33) Heated Throttle Lever Switch Three-position toggle switch. Select the desired position to keep your right thumb at a comfortable temperature. Fan-Cooled Models A32H0FA HEATED GRIP SWITCH HEATED THROTTLE LEVER SWITCH 1. HOT 4. HOT 2. OFF 5. OFF 3. WARM 6.
  • Page 58 liquid-Cooled Models A32A18A 1. Heated grip switch 2. Heated throttle lever switch 3. Hot 4. Warm 5. Off...

  • Page 59: Electric Visor Jack Connector

    An electric visor can be connected to the 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 authorized SKI-DOO dealer for the extension. A32E0OA TYPICAL 1.

  • Page 60: 12-Volt Power Outlet

    35) 12-Volt Power Outlet A 12-volt electric appliance may be connected to that jack connector. Electric current is supplied when ever engine is running. See Fuses below for 12-volt power outlet fuse location. A32E16A TYPICAL 1. 12-volt power outlet...

  • Page 61: Air Suspension Switch

    Always completely stop vehicle in a safe place before attempt- ing any suspension adjustments. NOTE: Compressor will keep the minimum required pressure when engine is running. If the minimum required pressure can not be main- tained, see an authorized SKI-DOO dealer.

  • Page 62: Air Suspension Gauge

    37) Air Suspension Gauge Some Models Only This gauge indicates comfort level (pressure inside rear air shock ab- sorber). 38) Air Suspension Compressor Pilot Lamp Lights up each time compressor is activated. CAUTION: If air suspension compressor pilot lamp lights up more than 10 minutes, shut off the engine in a safe place to avoid compressor damage.

  • Page 63: Adjustable Mirrors

    40) Adjustable Mirrors Each mirror can be adjusted to suit driver’s preference. WARNING Adjust with vehicle at rest in a safe place. 41) 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). WARNING Adjust with vehicle at rest in a safe place.

  • Page 64: Heated Carburetor Valve

    42) Heated Carburetor Valve Turn valve on when riding at 5°C (41°F) or colder temperatures. A32I0AA 1. ON 2. OFF CAUTION: When operating the snowmobile above 5°C (41°F), move the carburetor heating valve to the OFF position.

  • Page 65: Adjustable Backrest

    43) Adjustable Backrest The backrest position and support angle may be adjusted to suit driv- er or passenger convenience. WARNING Adjust with vehicle at rest in a safe place. Securely tigthten all adjustments. Grand Touring 500 F A03A0KA TYPICAL — BACKREST POSITION 1.
  • Page 66 A03A0KC TYPICAL — BACKREST SUPPORT ANGLE 1. Loosen top knob to adjust then retighten A03A0KB TYPICAL — BACKREST HEIGHT 1. Loosen center knobs (both sides) to adjust then retighten...

  • Page 67: Seat Strap

    Liquid-Cooled Grand Touring A32H0PA 1. Turn adjustment knob 2. Lift adjustment lock (both sides) Secure adjustment locks after desired position is obtained. 44) Seat Strap Seat strap provides a grip for the passenger.

  • Page 68: Rear Passenger Heated Grip Switch

    45) Rear Passenger Heated Grip Switch Three-position switch. Select the desired position to keep rear pas- sager’s hands at a comfortable temperature. A32H0QA TYPICAL — RIGHT SIDE OF PASSENGER GRAB HANDLE 1. Rear passenger heated grab handles switch...

  • Page 69: Adjustable Rear Grab Handles

    46) 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. WARNING Adjust with vehicle at rest in a safe place. Securely tighten all adjustments.

  • Page 70: Hood Grills

    47) Hood Grills When riding on powdered snow, close plastic sliding hood grills from underneath hood. Otherwise always keep grills open. Squeeze tabs to close grills. A32H03A TO CLOSE, SQUEEZE CLOSING TABS BETWEEN THUMB AND INDEX...

  • Page 71: Storage Compartment

    A32H04A TO OPEN, SQUEEZE OPENING TABS BETWEEN THUMB AND INDEX 48) Storage Compartment A storage compartment is provided inside rear portion of seat. WARNING All storage compartments must be properly latched and they must not contain any heavy or breakable objects. 49) Rear Rack WARNING All objects in rear rack must be properly latched.

  • Page 72: Tool Bag

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

  • Page 73: Fuses

    51) Fuses Ground Protection Fuse Fan-Cooled Models Only Ground wire is protected with a 20 ampere rated fuse. See following illustration for fuse holder location. Check fuse condition and replace it if necessary. A32E2MA 1. Ground wire protection fuse Charging System Fuse Charging system is protected with 30 ampere rated fuse.
  • Page 74 Electronic Module Fuse Electronic module is protected with 5 ampere rated fuse. See follow- ing illustration for fuse holder location. If electronic module does not operate, check fuse condition and replace it if necessary. CAUTION: Do not use a higher rated fuse as this can cause se- vere damage to electric components and/or fire.

  • Page 75: Spare Spark Plug Holder

    1. Fuse 2. Check if melted Electric Fuel Level Gauge Fuse See an authorized SKI-DOO dealer for fuse replacement. 52) Spare Spark Plug Holder To keep spare spark plugs dry and prevent shocks that might affect the adjustment or break them, a holder is provided on the right side of oil tank.

  • Page 76: Spare Drive Belt Holder

    NOTE: Spare spark plugs are not supplied with the snowmobile. A32C0RA 1. Spare spark plugs installed in holder 53) Spare Drive Belt Holder A spare drive belt can be stored in holder at front section of bottom pan. NOTE: Spare drive belt is not supplied with the snowmobile. A32H0TA TYPICAL —...

  • Page 77: Front Grab Handles/Front Bumper

    To be used whenever front of snowmobile requires manual lifting. A32H05A 1. Front grab handles CAUTION: Do not use skis to pull or lift snowmobile. 55) Convertible Ski Stance Summit Models Only Ski stance (distance between each skis) is adjustable. See an autho- rized SKI-DOO dealer.

  • Page 78: Adjustable Suspensions

    56) Adjustable Suspensions For factory recommended adjustments refer to decal on belt guard. It describes settings for optimum comfort according to load for your SKI-DOO model. A32F0GA TYPICAL 1. Decal...

  • Page 79: General

    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. NOTE: Some adjustments may not apply to your snowmobile. Use special keys in tool bag. A32F0FB TYPICAL 1.

  • Page 80: Guidelines To Adjust Suspension

    NOTE: Some models are equipped with Take/Apart (T/A) shocks. These can be rebuilt or recalibrated. See an authorized SKI-DOO dealer. 1. Rear Springs — Comfort and Ride Height Grasp rear bumper and lift until suspension is fully extended. From this point, rear of snowmobile should collapse by 50 to 75 mm (2 to 3 in) when driver and passenger (if so applicable) take place.
  • Page 81 A32F0CA TYPICAL — TOO SOFT OF ADJUSTMENT Turn the left side adjustment cam in a clockwise direction, the right side cam in a counterclockwise direction. Left and right adjustment cams may be set at different position. A30F04A TYPICAL 1. Increase spring preload...
  • Page 82 A32F0DA TYPICAL — TOO HARD OF ADJUSTMENT Turn the left side adjustment cam in a counterclockwise direction, the right side cam in a clockwise direction. Left and right adjustment cams may be at different position. A30F04B TYPICAL 1. Decrease spring preload...
  • Page 83 2. Center Spring — Steering Behavior Ride at moderate speed on a trail. If steering is too easy or too hard to turn, adjust center spring accord- ingly. A32F0EA TYPICAL — GOOD ADJUSTMENT AT MODERATE SPEED 1. Steering easy to turn...
  • Page 84 A32F0EA TYPICAL — TOO SOFT OF ADJUSTMENT 1. Steering hard to turn A32F01A TYPICAL 1. Use adjuster wrench provided in tool bag to increase preload...
  • Page 85 A32F0EA TYPICAL — TOO HARD OF ADJUSTMENT 1. Steering less aggressive A32F01B TYPICAL 1. Use adjuster wrench provided in tool bag to decrease preload...
  • Page 86 3. Coupling Blocks — Handling Ride at moderate speed and check for desired handling. All Models Except Summit When driver and passenger (if applicable) take place the coupling blocks should be centered between rubber stoppers. This condition is achieved when a proper rear spring preload is done. See above rear spring adjustment.
  • Page 87 A32F0JA COUPLING BLOCK — RIGHT SIDE VIEW (“R” — RIGHT EMBOSSED ON BLOCK) 1. Thicker part of block facing downward (partly coupled suspension) — more track grip and less skis steering 2. Turn block in this direction to adjust to the other position...
  • Page 88 4. Stopper Strap — Weight Transfer Ride at low speed then fully accelerate. Note steering behavior. Ad- just stopper strap length accordingly. CAUTION: Whenever stopper strap length is changed, track ten- sion must be readjusted. A32F0EB TYPICAL — GOOD ADJUSTMENT AT FULL ACCELERATION 1.
  • Page 89 All Models Except Summit Models A32F0EC TYPICAL — TOO LONG STRAP 1. Skis lift off the ground A03F0QB TYPICAL 1. Reduce strap length by bolting to a different hole...
  • Page 90 A32F0EA TYPICAL — TOO SHORT STRAP 1. Heavy steering A03F0QB TYPICAL 1. Increase strap length by bolting to a different hole...
  • Page 91 Summit Models A32F0EC TOO LONG STRAP 1. Skis lift off the ground A32E19A 1. Loosen lock nut, turn knob accordingly then retighten lock nut...
  • Page 92 A32F0EA TOO SHORT STRAP 1. Heavy steering A32E19B 1. Loosen lock nut, turn knob accordingly then retighten lock nut...
  • Page 93 5. Front Springs — Handling Ride at moderate speed and check for proper handling. Adjust front springs accordingly. WARNING Always adjust both front springs to same position. A32F0EA TYPICAL — PROPER ADJUSTMENT 1. Good handling and comfortable steering...
  • Page 94 Some Models A32F0EA TYPICAL — TOO SOFT OF ADJUSTMENT 1. Bad handling A32F1CA 1. Increase spring preload 2. Position number...
  • Page 95 A32F0EA TYPICAL — TOO HARD OF ADJUSTMENT 1. Steering hard to turn A32F1CB 1. Decrease spring preload 2. Position number...
  • Page 96 CAUTION: Make sure that both front springs are still preloaded when front of vehicle is off the ground. Some Models A32F0EA TOO SOFT OF ADJUSTMENT 1. Bad handling A03F2IA 1. Increase spring preload...
  • Page 97 A32F0EA TOO HARD OF ADJUSTMENT 1. Steering hard to turn A03F2JA 1. Decrease spring preload...
  • Page 98 6. Rear Shock Motion Ratio — Damping Strength Some Models Only Rear shock motion ratio can be adjusted according to driver and pas- senger weight and/or trail condition. There are two adjustment positions. A32F30A 1. Soft position 2. Firm position To adjust, remove nut, move bolt to desired position.

  • Page 99: Troubleshooting Chart

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

  • Page 100: 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 87 or higher. NOTE: In most service station pump octane number corresponds to (R + M)/2 octane number.

  • Page 101: Recommended Oil

    CAUTION: Use only oil that flows at - 40°C (- 40°F). Do not mis- match oil reservoir cap with fuel tank cap. Oil reservoir cap is identified OIL. Oil is contained in the injection oil reservoir. Use only two-stroke engine injection oil sold by authorized SKI-DOO dealers. MODEL OIL TYPE...

  • Page 102: Cold Weather Carburetion Modifications

    10 hours of operation — 500 km (300 miles) — or 30 days after the purchase, whichever comes first, your snowmobile be checked by an authorized SKI-DOO dealer. This inspection will give you the opportunity to discuss the unanswered questions you may have encountered during the first hours of operation.

  • Page 103: Pre-Operation Check

    PRE-OPERATION CHECK WARNING The pre-operation check is very important prior to operating the vehicle. Always check the proper operation of critical con- trols, safety features and mechanical components before start- ing. If not done as specified here, severe injury or death might occur.
  • Page 104 • Check fuel and injection oil for levels and leaks. Replenish as nec- essary and see an SKI-DOO authorized dealer in case of any leaks. • Open or close heated carburetor valve according to outside tem- perature.

  • Page 105: Pre-Operation Check List

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

  • Page 106: Operating Instructions

    OPERATING INSTRUCTIONS WARNING Proceed with pre-operation check list before riding. WARNING Operator and passenger (if applicable) must be properly seated before riding. Principle of Operation Propulsion Depressing throttle lever increases engine RPM causing the drive pulley to engage. Depending on models engine RPM must be be- tween 2500 and 4200 before drive pulley engagement will occur.

  • Page 107: Starting The Engine

    Turning Handlebar controls the steering of the vehicle. As the handlebar is rotated to right or left, the skis are turned right or left to steer the snowmobile. WARNING Fast reverse while turning, could result in loss of stability. Starting the Engine •...
  • Page 108 When Temperature i s above - 10°C (above + 15°F) Set the choke lever to the first position. Grasp starter handle, pull handle slowly until a resistance is felt then, hold handle firmly and pull vigorously to start engine or use electric starter on so equipped models.

  • Page 109: Emergency Starting

    Emergency Starting The engine can be started with the emergency starter rope supplied with the tool kit. Remove belt guard. WARNING Do not wind starting rope around your hand. Hold rope by the handle only. Do not start the snowmobile by the drive pulley unless it is a true emergency situation.
  • Page 110 Attach the other end of emergency rope to the starter clip supplied in the tool kit. Hook up clip on drive pulley. Wind the rope tightly around drive pulley. When pulled, pulley must rotate counterclockwise. A19D13A TYPICAL — TRA TYPE DRIVE PULLEY 1.
  • Page 111 A03D25A TYPICAL — BOMBARDIER LITE DRIVE PULLEY TYPE 1. Knot on this side Start engine as described in COLD ENGINE STARTING or WARM ENGINE STARTING according to engine temperature. Pull the rope using a sharp, crisp pull so the rope comes free of the drive pulley.

  • Page 112: Shutting Off The Engine

    Shutting Off the Engine Release throttle lever and wait until engine has returned to idle speed. Shut off the engine using either ignition switch (fan-cooled models only), engine cut-out switch or tether cut-out switch. WARNING Never leave key and tether cord on vehicle when not in oper- ation in order to prevent accidental engine starting.

  • Page 113: Post-Operation Care

    600 m (2000 ft) (except Summit models). Engine Overheating Engine overheating pilot lamp will light up if engine is too hot. Reduce snowmobile speed and run snowmobile in loose snow or stop engine immediately. Check for adequate coolant level. See an authorized SKI-DOO dealer.

  • Page 114: Fuel Flooded Engine

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

  • Page 115: Periodic Maintenance Chart

    ➁ WEEKLY OR EVERY 240 km (150 miles) ➂ MONTHLY OR EVERY 800 km (500 miles) ➃ ONCE A YEAR OR EVERY 3200 km (2000 miles) ➄ STORAGE (To be performed by an authorized SKI-DOO dealer) ➅ PRESEASON PREPARATION (To be performed by an authorized SKI-DOO dealer) ➀...
  • Page 116 ➀ ➁ ➂ ➃ ➄ ➅ PERIODIC MAINTENANCE CHART Drive Belt Condition Condition of Drive and Driven Pulleys Cleaning of Drive and Driven Pulleys Retorquing of Drive Pulley Screw Driven Pulley Preload Brake Fluid Level Brake Fluid (change once a year) Brake Condition Drive Chain Tension Countershaft Lubrication**...

  • Page 117: Fluid Levels

    FLUID LEVELS WARNING It is recommended that the assistance of an authorized SKI- DOO dealer be periodically obtained on other components/ systems not covered in this guide. Unless otherwise specified, engine must be cold and not running. The tether cord cap must be removed for all maintenance procedures.

  • Page 118: Chaincase Oil Level

    Oil level must be between lower and upper marks. NOTE: It is normal to find metallic particles stuck to dipstick magnet. If bigger pieces of metal are found, see an authorized SKI-DOO dealer. Remove metal particles from magnet. Refill up to upper mark using BOMBARDIER synthetic chaincase oil (P/N 413 803 300 —...

  • Page 119: Oil Injection System

    Oil Injection System Always maintain a sufficient amount of recommended oil in the injec- tion oil reservoir. CAUTION: Never allow oil reservoir to be almost empty. Do not mismatch oil reservoir cap with fuel tank cap. Install cap that is identified OIL.

  • Page 120: Cooling System

    NOTE: When checking level at low temperature it may be slightly lower then mark. If additional coolant is necessary or if entire system has to be refilled, refer to an authorized SKI-DOO dealer. A32C29A 1. Coolant tank 2. COLD LEVEL line...

  • Page 121: Maintenance

    MAINTENANCE WARNING It is recommended that the assistance of an authorized SKI- DOO dealer be periodically obtained on other components/ systems not covered in this guide. Unless otherwise specified, engine must be cold and not running. The tether cord cap must be removed for all maintenance procedures.

  • Page 122: Belt Guard Removal And Installation

    NOTE: Apply wax on glossy finish only. Protect the vehicle with a cover to prevent dust accumulation during storage. CAUTION: The snowmobile has to be stored in a cool and dry place and covered with an opaque tarpaulin. This will prevent sun rays and grime from affecting plastic components and vehicle finish.
  • Page 123 When reinstalling belt guard, position its cut-away toward front of snowmobile. Refer to decal in belt guard. Place belt guard in front tabs first, then snap rear part in retainer. A32C06A TYPICAL 1. Slots NOTE: Belt guard is purposely made slightly oversize to maintain ten- sion on its pins and retainers preventing undue noise and vibration.

  • Page 124: Drive Belt Removal/Installation

    Drive Belt Removal/Installation NOTE: Removal and installation of drive belt is easier when driven pulley is held with brake so that it can not rotate. Apply parking brake, for this purpose. Turn off engine cut-out switch. Open hood and remove belt guard. Open the driven pulley with the drive belt installer/remover provided in tool bag.
  • Page 125 Screw drive belt installer/remover in the free threaded hole and tight- en to open the pulley. Remove belt. A32D13A TYPICAL 1. Tighten to open pulley Slip the belt over the top edge of the sliding half of driven pulley, as shown in previous photo.
  • Page 126 Remove access panel from bottom pan. A32H07A 1. Push tab down and remove panel out of bottom pan A32H06A PULL PANEL OUT OF BOTTOM PAN...
  • Page 127 Slip belt under drive pulley then, remove it from vehicle. A32D14A TYPICAL Clean sheaves of both pulleys using Pulley flange cleaner (P/N 413 711 809). To install the drive belt, reverse the removal procedure, however pay attention to the following:...
  • Page 128 The maximum drive belt life span is obtained when the belt has the proper rotation direction. See arrow on belt. A32D15A TYPICAL 1. Arrow pointing front of vehicle CAUTION: Do not force or use tools to pry the belt into place, as this could cut or break the cords in the belt.

  • Page 129: Drive Chain Tension

    Drive Chain Tension Remove hair pin. Fully tighten tensioner adjustment screw by hand, then back off only far enough for hair pin to engage in locking hole. A32D03A TYPICAL 1. Hair pin 2. Adjustment screw TRA Drive Pulley Adjustment The drive pulley is factory calibrated to transmit maximum engine power at a predefined RPM.
  • Page 130 NOTE: Use precision digital tachometer for engine RPM adjustment. NOTE: The adjustment has an effect on high RPM only. To adjust, turn calibration screws. Calibration screw has a notch on top of its head. A16D0FA 1. Notch Governor cup has 6 positions numbered 2 to 6. Note that in position 1 the number is substitued by a dot (due to its location on casting).
  • Page 131 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 by 400 RPM.

  • Page 132: Drive Belt Condition

    RPM with frozen track, fast starts without warm-up period, burred or rusty sheave, oil on belt or distorted spare belt. Contact an authorized SKI-DOO dealer. Check the drive belt width. Replace the drive belt if width is less than the minimum width recommended in SPECIFICATIONS.

  • Page 133: Rear Suspension Condition

    With the engine off, rotate the track by hand, and inspect condition. If worn or cut, or if track fibers are exposed, or if missing or defective inserts or guides are noted; contact an autho- rized SKI-DOO dealer. WARNING Do not modify track, including by installing traction enhancing products.
  • Page 134 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 A06F1WA TYPICAL 1. 7.3 kg (16 lb) 2. Deflection CAUTION: Too much tension will result in power loss and exces- sive stresses on suspension components.
  • Page 135 If correct tension is unattainable, contact an authorized SKI-DOO dealer. A30F03A TYPICAL 1. Adjustment screw 2. Loosen screw 3. Wheel cap removing Alignment NOTE: Track tension and alignment are inter-related. Do not adjust one without the other. WARNING Before checking track alignment, ensure that the track is free of all particles which could be thrown out while track is rotat- ing.
  • Page 136 Start the engine and accelerate slightly so that track barely turns. This must be done in a short period of time (1 to 2 minutes). Check that the track is well centered; equal distance on both sides between edges of track guides and slider shoes. A01F05A TYPICAL 1.

  • Page 137: Steering And Front Suspension Mechanism

    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 an authorized SKI-DOO dealer.

  • Page 138: Wear And Condition Of Skis And Runners

    Wear and Condition of Skis and Runners Check the condition of the skis, ski runners and ski runner carbides. If worn, contact an authorized SKI-DOO dealer for replacement. WARNING Excessively worn skis and/or ski runners will affect snowmobile control. Exhaust System The tail pipes of the muffler should be centered with the exit holes in the bottom pan.
  • Page 139 A32H0RA REMOVAL OF RIGHT SIDE PRIMARY FILTER GRILL A32H0SA REMOVAL OF FILTER FROM ITS GRILL...
  • Page 140 A32H0OA TYPCIAL — SECONDARY FILTER INSTALLED ON AIR SILENCER Check that the air silencer is clean and dry and properly reinstall the filter. CAUTION: Snowmobile engines have been calibrated with the filter installed. Operating the snowmobile without it may cause engine damage.

  • Page 141: Headlight Beam Aiming

    Headlight Beam Aiming Turn knob to adjust beam height. A32E01A TYPICAL 1. Knob Bulb Replacement Always check light operation after bulb replacement. Headlight CAUTION: Never touch glass portion of an halogen bulb with bare fingers, it shortens its operating life. If glass is touched, clean it with isopropyl alcohol which will not leave a film on the bulb.
  • Page 142 A32E02A 1. Bulb connector 2. Rubber boot Turn bulb locking ring counterclockwise to remove it. Detach the bulb and replace. Properly reinstall parts. A30E05A 1. Locking ring...
  • Page 143 Instrument(s) Fan-Cooled Models Only Remove air duct from underneath hood. A32E03A TYPICAL 1. Remove these screws...
  • Page 144 Bulb socket is always behind the instrument under a black rubber boot. Pull rubber boot and socket to expose bulb. Pull bulb out of socket. A32E04A TYPICAL — ALL MODELS 1. Instruments sockets Taillight All Models If taillight bulb is burnt, expose the bulb by removing the red plastic lens. To remove, unscrew the 2 lens screws.

  • Page 145: Battery Electrolyte

    Battery Electrolyte Electric Start Models Only These vehicles are equipped with a maintenance-free battery. Elec- trolyte level can not be checked. WARNING Battery BLACK negative cable must always be disconnected first and connected last. WARNING Never charge or boost battery while installed. Battery electro- lyte contains sulfuric acid which is corrosive and poisonous.

  • Page 146: Towing The Vehicle

    Make sure that oil reservoir and fuel tank caps are properly installed. Tie vehicle to the transporting unit securely using suitable straps. STORAGE AND PRESEASON PREPARATION WARNING Have an authorized SKI-DOO dealer inspects fuel and oil sys- tems integrity as specified in PERIODIC MAINTENANCE CHART. Storage It is during summer, or when a snowmobile is not in use for more than one month that proper storage is a necessity.

  • Page 147: Troubleshooting

    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; check fuel filter; (spark plug dry when removed).
  • Page 148 Check item 4 of “Engine turns over but fails to start”. 5. Carburetor adjustments. Contact an authorized SKI-DOO dealer. 6. Drive belt worn too thin. If the drive belt has lost more than 3 mm (1/8 in) of its original width, it will affect vehicle performance.
  • Page 149 Replace as required. 4. Too much oil supplied to engine. Improper oil pump adjustment, refer to an authorized SKI-DOO dealer. 5. Water in fuel. Drain fuel system and refill with fresh fuel. SYMPTOM: Snowmobile cannot reach full speed.

  • Page 150: Specifications

    SPECIFICATIONS MX-Z 380 F MX-Z 550 F LEGEND 380 F LEGEND 550 F MODEL GRAND TOURING GRAND TOURING 380 F 550 F Engine – Maximum Power ± 100 6800 6950 Engine Speed Drive Belt – Part Number 415 060 600 415 060 600 –...
  • Page 151 MODEL SKANDIC 500 F SUMMIT 550 F Engine – Maximum Power ± 100 6700 6950 Engine Speed Drive Belt – Part Number 415 060 600 415 060 600 – Width of a New mm (in) 34.7 (1.366) 34.7 (1.366) Belt –...
  • Page 152 MX-Z 500/600 GT 500/600/600 MODEL LEGEND 500/600 Engine – Maximum Power ± 100 8000 8000 Engine Speed Drive Belt – Part Number 414 860 700 414 860 700 – Width of a New mm (in) 34.9 (1.374) 34.9 (1.374) Belt –...
  • Page 153 MODEL MX-Z 600 HO SUMMIT 600 HO Engine – Maximum Power ± 100 8000 8000 Engine Speed Drive Belt – Part Number 417 300 197 417 300 197 – Width of a New mm (in) 36.6 (1.441) 36.6 (1.441) Belt –...
  • Page 154 GRAND TOURING MX-Z 600 HO MODEL RENEGADE Engine – Maximum Power ± 100 8000 8000 Engine Speed Drive Belt – Part Number 417 300 127 417 300 127 – Width of a New mm (in) 36.35 (1.431) 36.35 (1.431) Belt –...
  • Page 155 MX-Z 700 MODEL MX-Z 800 LEGEND 700 Engine – Maximum Power ± 100 8000 7850 Engine Speed Drive Belt – Part Number 417 300 127 417 300 127 – Width of a New mm (in) 36.35 (1.431) 36.35 (1.431) Belt –...
  • Page 156 SUMMIT 700 SUMMIT 700 MODEL X/ADRENALINE HIGHMARK Engine – Maximum Power ± 100 8000 8000 Engine Speed Drive Belt – Part Number 417 300 127 417 300 127 – Width of a New mm (in) 36.35 (1.431) 36.35 (1.431) Belt –...
  • Page 157 SUMMIT 800 HO MODEL SUMMIT 800 HO HIGHMARK Engine – Maximum Power ± 100 7850 7850 Engine Speed Drive Belt – Part Number 417 300 166 417 300 166 – Width of a New mm (in) 37.67 (1.483) 37.67 (1.483) Belt –...
  • Page 158 MX-Z 800 MODEL RENEGADE Engine ± 100 – Maximum Power Engine Speed 7850 Drive Belt – Part Number 417 300 127 – Width of a New Belt mm (in) 36.35 (1.431) – Wear Limit Width mm (in) 33.95 (1.337) Spark Plug –...
  • Page 159 Because of its ongoing commitment to product quality and innova- tion, Bombardier reserves the right, at any time, to make changes in design and specifications and/or to make additions to, or improve- ments in its products without imposing any obligation upon itself to install them on its products previously manufactured.

  • Page 160: 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 owners.

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