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BOMBARDIER 1996 Ski-doo MX Z440 Handbook

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Summary of Contents for BOMBARDIER 1996 Ski-doo MX Z440

  • Page 2 WARNING : This information relates to the preparation and use of snowmobiles in competitive events. Bombardier Inc. disclaims liability for all damages and / or injuries resulting from the improper use of the contents. We strongly recommend that these modifica- tions be carried out and / or verified by a highly-skilled professional racing mechanic.

  • Page 3: Competition Bulletins - Racing Parts

    Section 01 HOW TO COMMUNICATE If you have any suggestions on new information and ideas to improve next year’s handbook, including any errors or omissions, please mail or fax to; Ski Doo Race Department Bombardier Corp., PO B 8035 Wausau, Wise.
  • Page 4 Section 01 HOW TO COMMUNICATE RAGS, RADAR RUNS OVAL, II Rader FAX : 715-847-6869 Date : Driver Name : Driver Phone Dealership Name : Dealer Phone Number : Vehicle Type : Odometer Reading : Serial Number: Race Type : Class : Location : Finish Position : Temperature :...
  • Page 5 Section 01 HOW TO COMMUNICATE HILLCLIMB, MOUNTAIN FAX : 801-752-8249 Date : Driver Name : Driver Phone Number : Dealership Name : Dealer Phone Number : Vehicle Type : Odometer Reading : Serial Number : Race Type : Class : Location : Finish Position : Temperature :...
  • Page 6 Section 01 HOW TO COMMUNICATE CROSS-COUNTRY, SNO CROSS ATTN : Bill Rader FAX : 715-847-6869 Date : Driver Phone Number: Driver Name : Dealer Phone Number : Dealership Name : Vehicle Type : Odometer Reading : Serial Number: Race Type : Class : Location : Finish Position :...

  • Page 7: Table Of Contents

    Section 02 WHATS NEW FOR 1996 Table of Contents MX Z 440 m.. ,.. ,.. .,. ,., ,,, ,,. `,, .,. ,,. ,,m. .,, ,., .,, ,,..,. ,,. .., ,.., .,, .., ,,. .,, .,. .., ..
  • Page 8 Section 02 WHATS NEW FOR 1996 BTDC: Before Top Dead Center ATDC : After Top Dead Center PTO : Power Take OFF side MAG : Magneto side 02-3...
  • Page 9 Section 02 WHATS NEW FOR 1996 A dot (0) on right indicates changes from 1995 model. MODEL SUMMIT 670 Ermine Tv~e RPM I 7600-7800 Maximum HP RPM 0 Rotary Valve P / N 420924500 Opening (BTDC) / 144° J 72° Closing (ATDC) Carburetor Type Main Jet...
  • Page 10 Section 02 WHATS NEW FOR 1996 A dot (o) on right indicates changes from 1995 model. NOTE : See end of specifications for foot notes. 02-5...
  • Page 11 Section 02 WHATS NEW FOR 1996 A dot (0) on right indicates changes from 1995 model. NOTE : See end of specifications for foot notes. 02-6...
  • Page 12 Section 02 WHATS NEW FOR 1996 BTDC: Before Top Dead Center. ATDC: After Top Dead Center. PTO : Power Take Off side. CTR : Center. MAG : Magneto side. 02-7...
  • Page 13 Section 02 WHATS NEW FOR 1996 02-8...
  • Page 14 Section 02 WHATS NEW FOR 1996 02-9...
  • Page 15 Section 02 WHATS NEW FOR 1996 VEHICLE MODEL FORMULA GRAND SUMMIT GRAND TOURING TOURING ENGINE TYPE Chain Drive Ratio 25/44 23/44 Chain Pitch Type, Links - Plates CNy Silent 72-11 Silent 74-11 Type of Drwe Pulley Ramp Identlflcatlon 287 @ 228 = 287 G 228 C)
  • Page 16 Section 02 WHATS NEW FOR 1996 02-11...
  • Page 18 Section 03 CHASSIS PREPARATION SUSPENSION OPERATION / WEIGHT TRANSFER The purpose of any suspension system is to isolate the rider from the terrain while still allowing for complete control of the vehicle. A snowmobile rear suspension has the added requirements of providing weight transfer and maintaining correct track tension.
  • Page 19 Section 03 CHASSIS PREPARATION NOTE : A shorter nylon limiter strap is available for vehicles equipped with the strap and bolt style limiter. P / N 486056200. NOTE : Track tension must be checked whenever a major change is made to the limiter length.
  • Page 20 Section 03 CHASSIS PREPARATION SPRINGS Generally, 2 types of springs are used on our suspensions. Coil springs and torsional springs. Refer to following illustration. Number of coils Number of coils Torsional spring Coil spring AOOFOOS 1. Wire diameter 2. Free length 3.
  • Page 21 Section 03 CHASSIS PREPARATION Coil Springs The free length of a coil spring is the length with no load applied to the spring. The spring rate of a coil spring is defined as the amount of force required to compress the spring one inch.
  • Page 22 Section 03 CHASSIS PREPARATlON SPRING RATE = 100 Ibf / SPRING RATE = 150 Ibf / AOIFIJS In terms of your suspension, if a bump is encountered that translates into a force at the spring of 450 pounds, the 100 lb/ spring will want to compress 4.5 inches while the 150 lb/in spring will only compress 3 inches.
  • Page 23 Section 03 CHASSIS PREPARATION SPRING RATE = 100 Ibf / SPRING RATE = 150 Ibf / A spring can also be progressively wound. This means that the rate of the spring is increasing as it is compressed. A 100/ 200 lb/ progressive spring will require 100 pounds to compress the first one inch but will require 200 additional pounds to compress the last one inch (see following ill ustrati on).
  • Page 24 Section 03 CHASSIS PREPARATION STRAIGHT RATE = 100 Ibf / PROGRESSIVE RATE = 100/ 200 Ibf / AOIFILS An easy way to measure coil springs is to put a bathroom scale in a press with the spring resting on the sca-le. Measure the free Iength and then apply a load until the ‘spring compresses-l inch. The reading on the scale will approximate the rate of the spring.
  • Page 25 Section 03 CHASSIS PREPARATION 300 Ibf 100 Ibf SPRING RATE = 100 Ibf / in SPRING RATE = 100 Ibf / in 10 in FREE LENGTH 8 in FREE LENGTH AOIFIMS If we now apply a 200 pound load to the system, the 10 inch spring will not move because it has 300 pounds of preload.
  • Page 26 Section 03 CHASSIS PREPARATION If another 100 pounds is applied the 10 inch spring will still not move, but the 8 inch spring will compress another one inch (2 inches total). 300 Ibf, force --- .-., ~. ----- NO MOVEMENT 200 Ibf, available for compression (2”) 300 Ibf...
  • Page 27 Section 03 CHASSIS PREPARATION 400 Ibf, force 400 Ibf, force 100 Ibf, available for 300 Ibf, available for compression (1=) compression (3”) 300 Ibf SPRING RATE = 100 Ibf / in SPRING RATE = 100 Ibf / in 10 in FREE LENGTH 8 in FREE LENGTH , AOIFIPS Now let’s see what happens if we use a long, soft spring and a short, stiff spring.
  • Page 28 Section 03 CHASSIS PREPARATION 150 Ibf, force O Ibf, preload 150 Ibf, available for NO MOVEMENT compression (0.5”) 300 Ibf O Ibf SPRING RATE = 100 Ibf / in SPRING RATE = 300 Ibf / in 10 in FREE LENGTH 7 in FREE LENGTH At 300 pounds applied force the Ist spring will not yet move and the 2nd spring will compress 1 inch O Ibf, preload...
  • Page 29 Section 03 CHASSIS PREPARATION With a force of 500 pounds applied the 1s’ spring will compress 2 inches and the 2nd spring will compress 1.6 inches (following illustration). u IUI, — 500 Ibf, available for 200 Ibf, available for inn I 1 R*\ compression (2”) 1.6”...
  • Page 30 Section 03 CHASSIS PREPARATION 700 Ibf, force O Ibf, preload 400 Ibf, available for 700 Ibf, available for compression (4”) compression (2.3”) 4“ INSTALLED O Ibf SPRING RATE = 300 Ibf / in SPRING RATE = 100 Ibf / in 10 in FREE LENGTH 7 in FREE LENGTH AOIFITS...
  • Page 31 The preload on a torsional spring is controlled by the free opening angle and the installed opening angle. If a torsional spring must be “twisted” more to be installed, then it will have more preload (following illustration). Free opening Installed opening angle angle , A01F25S...
  • Page 32 Section 03 CHASSIS PREPARATION PRODUCTION SUSPENSION SPRINGS REAR FRONT CENTER MODEL RATE LENGTH P / N RATE LENGTH P / N RATE LENGTH N I mm N I mm N /mm (in) (in) (in) 28.0 414809100 21.9 1993 MX Z 414810100 414809300 (125)
  • Page 33 Section 03 CHASSIS PREPARATION PRODUCTION SUSPENSION SPRINGS FRONT REAR CENTER MODEL RATE LENGTH P / N RATE LENGTH P / N RATE LENGTH N J mm N /mm N /mm (in) (in) (in) 1995 FORMULA 414869000 414877800 28.0 414871300 21.9 (10.1 ) (125) (160)
  • Page 34 Section 03 CHASSIS PREPARATION B u l l e t i n Date: August 28, 1995 SUBJECT : Spring Application Chart YEAR MODEL NAME MODEL NUMBER SERIAL NUMBER 1996 All, except utility models on Both Ends) Shop Manual Type T (Barrel Shaped Please update your by indicating the number of this bulletin in the proper section of the...
  • Page 35 Section 03 CHASSIS PREPARATION REAR SUSPENSION SPRINGS FRONT SUSPENSION CENTER REAR REAR REAR HARD SPRINGS SOFT STANDARD I MACHZ IP/N (type) 223.1 7.14 7.92 7.77 +.05 I N / A N / A WH / WH MACH Z P / N (type) 4149565 00-(R) 4150137 00-(R) ( I Spring Rate (Ibs / in) +10 I 7.14...
  • Page 36 Section 03 CHASSIS PREPARATION MODELS FRONT REAR SUSPENSION SPRINGS SUSPENSION CENTER REAR REAR REAR SPRINGS SOFT STANDARD HARD FORMULA P / N (type) 4149761 K ] Spring Rate (Ibs / in) +10 L I Length (mm) +3 [Wire diameter (mm) +.05 ‘ Opening angle +7°...
  • Page 37 Section 03 CHASSIS PREPARATION MODELS FRONT REAR SUSPENSION SPRINGS SUSPENSION CENTER REAR REAR REAR SPRINGS SOFT STANDARD I HARD MX-Z583 P/ N(type) 4149563 00-(R) 4148951 00-(R) 414943500 RH K ISpring Rate (lbs/in) +10 N / A L I Length (mm) *3 N / A 7.14 7.14...
  • Page 38 Section 03 CHASSIS PREPARATION Spring Rate (Ibs / in) +10 Length (mm) *3 TOURING 4149560 00-(R) P I N (type) 4149440 00-(s) 414943500 RH , 414944200 R H Spring Rate (Ibs / in) *1O N / A N 1A Lenath (mm) *3 N 1A 7.49 7.49...
  • Page 39 Section 03 CHASSIS PREPARATION MODELS FRONT REAR SUSPENSION SPRINGS SUSPENSION CENTER REAR REAR REAR SPRINGS SOFT STANDARD HARD TOURING 4149560 00-(R) 4149744 00-(R) I P I N (type) I 414866300 LH I 414944300 LH K I %rina Rate (Ibs / in) +10 N / A N 1A L I Lenath (mm) +3...
  • Page 40 Section 03 CHASSIS PREPARATION MODEL FRONT REAR CENTER CENTER SOFT STANDARD I P I N (type) M548756 WIDE TRACK K ISrxinq Rate (lbs/in)t10 I N 1A N / A 410mm N 1A L lLenqth(mm)~3 N / A 10.5 10.0 9.0 mm 100°...
  • Page 41 Section 03 CHASSIS PREPARATION OPTIONAL SUSPENSION SPRING TYPE P / N COLORS SPRING RATE FREE LENGTH 414559100 BLUE / BLUE 45.5 (260) 241.3 (9.50) 414675700 YELLOW/ ORANGE 29.8 (170) 254.0 (10.00) 414677100 BLACK / WHITE 28.9(165) 302.0 (1 1.87) 414743300 GREEN / RED/ GREEN 30.6 (175) 301.0 (1 1.86)
  • Page 42 Section 03 CHASSIS PREPARATION OPTIONAL SUSPENSION SPRING P / N COLORS SPRING RATE FREE LENGTH TYPE 188.0 (7.40) 414536200 BROWN / RED 49.0 (280) 21.0 (120) 216.0 (8.50) 414558100 BROWN / PINK 414703400 YELLOW/ WHITE 24.5 (140) 311.2 (12.25) 248.0 (8.76) 414708000 GOLD /YELLOW 32.4 (185)
  • Page 43 Section 03 CHASSIS PREPARATION CORNERING DYNAMICS The ideal situation, while going through a turn, is to keep the snowmobile as flat as possible without the skis or track losing contact with the driving surface. As you enter a corner and turn the skis, the rest of the vehicle will want to continue straight ahead. If the skis do not bite the surface, they will start slipping and the vehicle will not turn as tight as the skis are turned.
  • Page 44 Section 03 CHASSIS PREPARATION 1. Sway bar 2. End lever 3. Cornering force 4. Connector linkage 5. Pivot bushings By having a sway bar in the suspension, softer springs can be used to achieve a good ride because the bar will help control roll in a corner. The bar has no affect on ride when traveling straight ahead over bumps that are even from side to side.
  • Page 45 Section 03 CHASSIS PREPARATION The length of the lever arm also affects the “stiffness” of the sway bar. A shorter lever will ‘stiffen” the bar and a longer lever will “soften” the bar. Many lever arms will have 2 holes to mount the connector linkage.
  • Page 46 There are currently 5 sway bars used on the DSA (F2000 & S2000) chassis : 1 * 11/16” inch diameter bar with integral, non-adjustable end levers. Used on most F2000 & S2000 chassis. (While bar is a rather large diameter, it “acts” soft because the end levers are quite long this and the bar is also not mounted as rigidly.
  • Page 47 Section 03 CHASSIS PREPARATION NOTE : This kit is designed as a replacement for the 11/16 inch diameter, non-adjustable sway bar. The instructions for installation of this kit are on the following page. To fit vehicles that come with the 1/2 or 5/8 inch bar, slight modifications to the tube and end levers will be required.
  • Page 48 3/4” STABILIZER BAR KIT (P/ N 5806045 00) WARNING : For safety reasons, this kit must be installed by an authorized Bombardier snowmobile dealer. Should removal of a locking device be required when undergoing disassembly / assembly, always replace with a new one. This instruction sheet should be given to the purchaser.
  • Page 49 Section 03 CHASSIS PREPARATION 7. 222085065 Screw M8 x 1.25 50 (2) 1. 506115100 Stabilizer Bar 8. 224081201 Flat Washer M8 (4) 2. 506115200 Spacer (2) 9. 228581045 Nut M8 (2) 3. 506108100 Lever (2) 10. 371900900 Snap Ring (2) 4.
  • Page 50 The less resistance to oil flow through the piston, the less dampening the shock provides. Conversely, more resistance to oil flow equals more dampening. Bombardier uses a variety of shock absorber types which vary on the exact application and requirements for performance.
  • Page 51 Section 03 CHASSIS PREPARATION A06FOKS 1. Valved piston 2. Damper shaft 3. Oil volume 4. Highpressure gaschamber(300PSl N,) 5. Floating piston This shock absorber is standard on the 670 SE Grand Touring models and offers the benefit of a full gas (nitrogen) shock, with the addition of an external adjustment for rebound damping.
  • Page 52 Section 03 CHASSIS PREPARATION As mentioned, this calibration was used in the center shock of the 1994 MX Z (all HPG T/ A shocks since 1995 use an internal floating piston), this type of shock could suffer from fading however, the gas pressure assists to prevent this from occurring.
  • Page 53 dampening. By varying the number and thickness of shims the dampening characteristics can be very accurately obtained. There may also be orifices or “slits” in the piston that are not covered by the shims. These are referred to as bleed slits. The size and number of these slits will also affect dampening.
  • Page 54 Section 03 CHASSIS PREPARATION SOFTER STIFFER Dia. (mm) Tickness Dia. (mm) lickness .203 .203 — TOP OUT WASHER TOP OUT WASHER The overall stiffness of the stack has been increased by adding 7-30 mm x .203 mm shims. This will result in firmer dampening at both low and high piston speeds.
  • Page 55 Section 03 CHASSIS PREPARATION The diameter of the smaller shims that support the large shims will also affect the dampening. A larger support shim gives more support to the large shim thus making it act stiffer. Conversely, a smaller diameter support shim will allow the large shim to bend more easily thus softening the dampening.
  • Page 56 Section 03 CHASSIS PREPARATION The large shims are only able to deflect .203 mm instead of .610 mm thus reducing the flow area of the piston. This will result in the same low speed dampening, but the medium and high speed damping will be increased.
  • Page 57 —For faster weight transfer under acceleration and deceleration, use a piston with more bleed slits. Special Tools Special tools specific to the HPG T / A shock will be the seal pilot P / N 529026500 and piston guide P / N 529026600 from Bombardier. P / N 529026500 P / N...
  • Page 58 Section 03 CHASSIS PREPARATION Shock Oil P / N 413709400 (1 Liter) SHOCK P / N 413709400 1. Automotive type air pressure hose 2. 2 stage regulator, delivery pressure range 2070 KPa (300 PSI) 3. High pressure cylinderfilled with industrial grade nitrogen 4.
  • Page 59 Section 03 CHASSIS PREPARATION Disassembly and Assembly Release N (nitrogen) pressure from the damper Schrader valve on any HPG T / A with IFP. NOTE: When rebuilding a gas emulsion shock, such as the 1994 center MX Z, mount the shock vertically in a vice with the schrader valve up and let it sit for 5 minutes before releasing the gas.
  • Page 60 Section 03 CHASSIS PREPARATION , AZ7F04S With the seal assembly removed, slowly lift and remove damper rod assembly from the damper body. NOTE : Remove damper rod assembly slowly to reduce oil spillage and prevent piston seal damage by damper body threads. Wrap the damper body with a shop cloth to capture possible overflo-w oil while removi-ng the damper piston .
  • Page 61 Section 03 CHASSIS PREPARATION Discard old oil into storage container. Never reuse damper oil during shock rebuild. Remove Schrader valve core. Using compressed air pressure, carefully remove floating piston from damper body. Hold shop cloth over damper body opening to catch released floating piston. Allow room for floating piston to leave damper body.
  • Page 62 Section 03 CHASSIS PREPARATION Always arrange parts removed in the sequence of disassembly. ‘ A06FOVS NOTE : If revalving is to be done, it is imperative that you identify the original shim pack (size and number of shims). The seal carrier need not be removed if only revalving is to be done.
  • Page 63 Section 03 CHASSIS PREPARATION , A06FOWS Maximum deflection 0.025 mm (.001 in) After the new or replacement shim pack has been selected, reassemble in the reverse order of disassembly. Torque piston nut 11-13 Nom (96-108 Ibfoin). Use 271 Loctite. , A06FOXS CAUTION: The damper rod nut can only be reused 4 times, then, must be replaced.
  • Page 64 Section 03 CHASSIS PREPARATION Rebound A minimum of 0.203 mm (.008 in) clearance must be allowed between shim stack and rebound valve stopper. Use at least one shim of 12 x .203 mm. Whenever tuning for more rebound damping always use 26 mm (1.02 in) shims against piston to properly close piston orifice holes.
  • Page 65 Section 03 CHASSIS PREPARATION FACTORY HPG T/A SHOCK CALIBRATIONS A06FOZS FRONT / SKI SHOCK CENTER SHOCK REAR SHOCK 1994 Rebound 1994/95 Rebound 1994/95 Rebound 1. 2 x 15x 0.114 1. 1 12 xO.203 1. 2 x 15x 0.114 2. 8 0.203 2.
  • Page 66 Section 03 CHASSIS PREPARATION 1. Pilot (P/N 5290269 00) A06F13S 1. Damper nuttorque 11-13 N-m (96-108 Ibf*in) use Loctite 271. 2. Rebound shim pack. 3. Piston. 4. Compression shim pack. 5. O-ring visual inspection seal carrier assembly. 6. Damper rod. 7.
  • Page 67 Section 03 CHASSIS PREPARATION Kit includes : 2- 26 mm long spacer 1- 48 mm long spacer 2- 60 mm long spacer Reinstall floating piston into damper body (ensure that Schrader valve core has been removed). Use molybdenum disulfide grease (example : molykote paste (P/N 4137037 00) or silicone grease Dow Corning MS4 (P / N 420 897061) to ease O-ring past damper body threads with floating piston pilot (P/ N 5290266 00).
  • Page 68 CAUTION : Moisture laden compressed air will contaminate the gas chamber and rust floating piston. WARNING : Always wear protective eye wear whenever using compressed air. Fill the shock with Bombardier HPG shock oil (P/N 4137094 00) to approximately 10 mm (.393 in), from the base of seal carrier threads. 03-52...
  • Page 69 Section 03 CHASSIS PREPARATION A06F15S NOTE : Although we do not measure the exact amount of oil added to the damper, approximately 106 mL (3.58 oz. US) will be used. Carefully insert damper rod into the damper body. Install damper rod assembly into the damper body.
  • Page 70 Section 03 CHASSIS PREPARATION Slight oscillation of damper rod may be required to allow piston to enter damper body bore. Slowly push piston into damper body. Slight up and down movement maybe required to allow all air to pass through piston assembly. The gentle tapping of a small wrench, on the shock eye, may help dislodge air trapped in the submersed piston.
  • Page 71 Section 03 CHASSIS PREPARATION , A06F18S 1. Schrader valve 1.5-2 N*m (13-17 Ibf*in) 2. Schrader cap 5-6.5 N-m (44-57 Ibf=in) Adding Gas Pressure Nitrogen (N2) can now be added to damper body. NOTE ; Never substitute another gas for nitrogen. Nitrogen has been selected for its inert qualities and will not contaminate the gas chamber of the shock.
  • Page 72 Section 03 CHASSIS PREPARATION 1. Automotive type air pressure hose 2. 2 stage regulator, delivery pressure range 2070 KPa (300 PSI) 3. High pressure cylinder filled with industrial grade nitrogen 4. Valve tip Reinstall damper spring retainer, then your spring. Next, thread the spring pre-load rings up to the spring.
  • Page 73 Section 03 CHASSIS PREPARATION CALIBRATION WORK SHEET FRONT CENTER REAR OPTION PISTON-SLIT IFP HEIGHT SPRING PRELOAD COMPRESSION REBOUND Model Date : Riding conditions : Notes: 03-57...
  • Page 74 Section 03 CHASSIS PREPARATION HPG T / A Shocks SHOCK SHIMS PART NUMBER SIZE (mm) (minimum order quantity) 415039100 30X .254 414888318 30X .203 414888319 30X .152 414888320 28X .203 414888321 28X .152 415039000 26X .254 414888322 26X .203 414888323 26X .152 414888324 .203...
  • Page 75 Section 03 CHASSIS PREPARATION Shock Spare Parts P / N DESCRIPTION 414862102 Cylinder rod without bearing front Cylinder rod without bearing center 414861902 414861502 Cylinder rod without bearing rear 414862103 Cylinder bodywithout bearing front 414925702 Cylinder body without bearing center Cylinder body without bearing rear 414861503 414562900...
  • Page 76 Section 03 CHASSIS PREPARATION SHOCK ABSORBER CHART 1994 TABLEAU DES...

  • Page 77: Formula Ss

    Section 03 CHASSIS PREPARATION Shock Absorbers 1995 SPRING BUMPER P / N TYPE RETAINER STROKE LOCATION APPLICATION EXTENDED CONTACT CONTACT 414862100 T / A 187-279 FRONT 414925700 T / A 414861500 T / A 170-260 REAR 111.7 414855700 FRONT FORMULA GT 470,580, FORMULA SS 414869100...
  • Page 78 CHASSIS SET-UP Reducing rolling resistance of a snowmobile is also an important area to explore when you are searching for the ultimate top speed. The horsepower required to overcome rolling resistance or drag increases approximately with the square of velocity so small reductions here can provide measurable improvements in top speed.
  • Page 79 Section 03 CHASSIS PREPARATION TYPICAL NOTE : Shafts will have a tolerance in the bearing housings and the bearings them- selves. These tolerances can be felt by hand. The shafts should be mid-point in these tolerances when centered in the bearing mount holes. If not perfectly centered, the two upper as necessary to align the countershaft and drive axle in their bearing mount holes.
  • Page 80 Section 03 CHASSIS PREPARATION Reinstall the rear suspension and using a square check to see that the runners are square (90°) with the drive axle. If not, cut and shim the ends of the suspension cross tubes to perfectly align the runners and also remove any side-to-side movement.
  • Page 81 Section 03 CHASSIS PREPARATION , A01D04S TOP VIEW 1. Countershaft 2. Shim position on end bearing housing side 3. Shim position onchaincaseside 4. Drive axle 5. Axial play 6. Shim between sprocket and spacer If the axle must be shifted left or right, note the direction and distance, and shim the axle as necessary.
  • Page 82 Section 03 CHASSIS PREPARATION Rear Axle Modification Heavily studded tracks combined with hard cornering put enormous loads on the track. To reduce the chance of derailing the track and to help spread the tensile loads of the track, a fourth idler wheel should be installed.
  • Page 83 Section 03 CHASSIS PREPARATION , A15F1VS TYPICAL 1. Tension measured with7.3kg(161b) Slider shoes Equal distance For straight line racing, top speed can sometimes be increased by running the track a bit looser. Conversely, heavily studded tracks may need to be tighter to achieve top speed because the extra weight of the studs may cause the track to “baloon out”...
  • Page 84 Section 03 CHASSIS PREPARATION , A06DOJS 1. Hold bleeder adaptor while opening bleeder 2. Clear hose to catch used brake fluid Pump a few time brake lever and while holding brade lever depressed, open bleeder and check for air to escape. Repeat with the same bleeder until no air appears in hose.
  • Page 85 Section 03 CHASSIS PREPARATION Bombardier has spent many hours in the wind tunnel on the hood design, and has optimized the shape to fit the function. You cannot improve the shape of your snowmobile but you can reduce the frontal area of the snowmobile by lowering the ride height and by using the lowest windshield available.
  • Page 86 Section 03 CHASSIS PREPARATION Shorter springs should be used to avoid excessive preload. Option 2 On vehicles with rebuildable shocks (HPG T/A), a spacer can be installed internally on (P/N the shock shaft to limit the shock extension. 861 7442 00) is available that includes 60 mm long spacers.
  • Page 87 Section 03 CHASSIS PREPARATION Rear Install a limiter strap on the rear from shock bolt to shock bolt Long Travel (longer bolts may be required). The length of the strap can be S chassis adjusted to obtain the desired ride height Spring preload will be increased.
  • Page 88 / or verified by a highly-skilled profes- sional racing mechanic. [t is understood that racing or modifications of any Bombardier-made snowmobile voids the vehicle warranty and that such modifications may render use of the vehicle illegal in other than sanctioned racing events under existing federal, provincial and state regula- tions.
  • Page 89 TYPICAL 1. 6 stud row 2. 7 stud row Most race associations sanctioning oval, snow cross and cross-country events limit the length of the studs to 3/8 inch above the high point of the track, while most drag and speed run associations allow a 3/4 inch limit.
  • Page 90 Section 03 CHASSIS PREPARATION SLIDER SHOE LUBRICATION When running a vehicle on surfaces that do not provide adequate lubrication for the slider shoes, the plastic will start to melt and stick to the track guide clips. This not only reduces the life of the slider shoes but it also acts like a big brake that substantially reduces vehicle speed.
  • Page 91 Section 03 CHASSIS PREPARATION Parts list: Fuel pump Impulse Hose Hose Clamp (1/4 D) (4) (p/N 4088011 ()()) Fuel Line (1/4” D) Tee (1/4 x 1/4x 1/4) (3) (p/N 4141553 00) Spring Clamp (for fuel line) @ (P/N 4145548 00) Shutoff Valve Lube Tank (1 to 1 1/2 gallon) (1) N/A Roll Pin (1/4”...
  • Page 92 Section 03 CHASSIS PREPARATION BOTTOM VIEW For oval racing discharge on side SLIDER SHOE LUBRIFICATION 03-76...
  • Page 93 Section 03 CHASSIS PREPARATION SKIS AND RUNNERS The skis on your Formula are not flat on their bottoms, they are slightly convex. This is done to improve stability at high speed on straightaways. , A25GOFS 1. Measure here (Ski runner studs) A 2 mm (3/32 in) B.
  • Page 94 Section 03 CHASSIS PREPARATION Carbide inserted ski runners are necessary for all forms of racing except drag racing and radar runs. The type of racing you are involved in and the condition of the track will determine what style of carbide and how much carbide you will be using. For the ice race track, special flat-backed race runners with 60°...
  • Page 95 Section 03 CHASSIS PREPARATION A cross-country carbide does not need to be razor sharp. In fact, testing should be done with a slightly dulled edge, that way your set-up will be right for the majority of the race. If you test with sharp carbides, your chassis set-up will be off when the runners lose their edge after 5-10 miles.
  • Page 96 Section 03 CHASSIS PREPARATION Lift the ski up to its upper travel limit. Using a measuring tape, measure the distances from the front and rear edges of the ski to the concrete block reference. The front and rear measurements must be equal or no more than 1.6 mm (1/16 in) difference if the bump steer adjustment is correct. 03-80...
  • Page 97 SKI LEG CAMBER The camber angle of the ski legs changes how aggressively the ski runners hook up with the driving surface. Adding negative camber will have the most effect on handling. This is because the “weight shift” in a turn is always to the outside of the turn and the negative camber of the ski leg causes the wear bar to be presented to the driving surface in a more aggressive position.
  • Page 98 Section 03 CHASSIS PREPARATION A06G05S —Place the angle finder on the swing arm near the ski leg housing. CAUTION : Angle finder must sit square against swing arm. Positioning angle finder against a weld bead or decal may result in a false reading. —Loosen the lock nuts on the upper control arms.
  • Page 99 SKI TOE OUT Most oval racers use modified handlebars with loops or angles on the left end. Often a driver prefers a handlebar position that is not horizontal when the skis are in their straight ahead position. This allows a more comfortable driving position when in a corner. Whatever handlebar you prefer should be positioned as you prefer it when going down a straightaway before you begin your toe out adjustment.
  • Page 100 Section 03 CHASSIS PREPARATION With the aggressive setup of the front end necessary for competitive oval racing, it is important to keep all the steering system components tight and free of play. Worn ball joints and bushings should be replaced, bolts holding the skis to the ski leg must be tight and wear bars must be straight and bolted securely to the skis.
  • Page 101 Section 03 CHASSIS PREPARATION Il. Problems encountered while going around or exiting a corner. A. Front end pushes coming out of corner (steering is not precise). 1. Shorten limiter strap on center arm. 2. Decrease center spring preload. 3. Check condition of carbides. 4.
  • Page 102 Section 03 CHASSIS PREPARATION Again, measure from the floor to the bottom of the rear grab handle. This dimension should be 1“ to 2“ (25 mm to 50 mm) less than the fully extended dimension. A) If the vehicle settles more than 2“ (50 mm), increase the rear spring preload. B) If the vehicle settles less than 1“...
  • Page 103 Section 04 ENGINE PREPARATION Table of contents EQUIVALENT WEIGHTS AND MEASURES CHART 04-2 * 9 9 ..9 9 . . ENGINE TUNING CAUTIONS ............... 04-4 BASIC ENGINE THEORY .
  • Page 104 Section 04 ENGINE PREPARATION EQUIVALENT WEIGHTS AND MEASURES CHART LINEAR MEASURE 1 Inch = 25.4 Millimeters (mm) 1 Millimeter= .03937 Inch 1 Inch = 2.54 Centimeters (cm) 1 Centimeter = .3937 Inch 1 Foot= .3048 Meter (m) 1 Meter= 3.2808 Feet 1 Meter= 1.093 Yards 1 Statute Mile= 1.609 Kilometers (km) 1 Kilometer= .6214 Statute Mile...
  • Page 105 METRIC WEIGHTS AND MEASURE CHART AREA MEASURE LINEAR MEASURE 10 Millimeters (mm) = 1 Centimeter 100 Sq. mm = 1 Sq. Centimeter 10 Centimeters (cm) = 1 Decimeter 10000 Sq. Centimeters = 1 m 100 Sq. Meters = 1 Acre 10 Decimeters (din) = 1 Meter 10 Meters (m) = 1 Decameter (dcm) 100 Acres = 1 Hectare (h)
  • Page 106 ENGINE TUNING CAUTIONS Here are a few items to keep in mind when working with your engine. 1. If you are in stock classes, know what adjustments are legal. 2. Modifications to the power curve of an engine will require recalibration of the transmission. 3.
  • Page 107 BASIC ENGINE THEORY TERMINOLOGY Cycle : In a combustion engine, a cycle is accomplished when the four (4) phases; intake, compression, ignition and exhaust are complete. Top Dead Center: The position of the piston when it reaches the upper limit of its travel inside the cylinder.
  • Page 108 Section 04 ENGINE PREPARATION BASIC ENGINE COMPONENTS 04-6...
  • Page 109 Section 04 ENGINE PREPARATION Rings 9. Transfer port Cylinder 10. Wrist pin Cylinder head 11. Intake port Cylinder head cover 12. Oil pump 13. Crankcase Sparkplug 14. Crankshaft Sparkplug Combustion chamber 15. Connecting rod Exhaust port 16. Piston COMBUSTION PROCESS NORMAL COMBUSTION Since the beginning of this study we have spoken of air/fuel mixture combustion rather than explosion.
  • Page 110 Section 04 ENGINE PREPARATION Flame front begins... F01D5HS 04-8...
  • Page 111 Section 04 ENGINE PREPARATK)N — ...traverses combustion chamber rapidly..until mixture is completely burnt With all operating parameters correct, normal combustion will take place. However, if for some reason the temperature inside the cylinder is increased during combustion, abnormal combustion will occur and lead to serious engine damage.
  • Page 112 Section 04 ENGINE PREPARATION DETONATION rning and the air/fuel mixture starts to burn in the usual In detonation, the spark plug initiates b~ the heat generated affects the large portion of the yet manner but as combustion continues, unburnt air /fuel mixture. This unburnt mixture temperature becomes so high that it burns spontaneously creating high- velocity pressure waves within the combustion cha-mber.
  • Page 113 Section 04 ENGINE PREPARATION pressure rapidly build up... F01D5KS 04-11...
  • Page 114 Section 04 ENGINE PREPARATION ... remaining unburned mixture burns spontaneous ly... These shock waves can sometimes be heard as “pinging.” While these shock waves can be detrimental to the mechanical integrity of the engine, it is the excessive heat that causes most problems in 2-strokes.
  • Page 115 Section 04 ENGINE PREPARATION piston head. Since ignition occurs earlier than the timed spark, the hot gases stay longer in the combustion chamber, thus increasing cylinder head and piston temperatures to a dangerous level. Portion of the mixture is ignited by a hot spot before timed spark occurs...
  • Page 116 Section 04 ENGINE PREPARATION ...timed spark occurs... 04-14...
  • Page 117 Section 04 ENGINE PREPARATION ... flame front spreads and collides with pre-ignited portion of mixture . . . F01D50S 04-15...
  • Page 118 Section 04 ENGINE PREPARATION ... until all mixture is burned... , F01D5PS Usually the piston is subject to damage. It may seize or the aluminum on the exhaust side of the piston dome may melt. Pre-ignition is-always preceded by detonation. CAUSES OF DETONATION : Octane of the fuel is too low.
  • Page 119 Section 04 ENGINE PREPARATION 6. Exhaust system restrictions. a. Muffler plugged/ restricted b. Tailpipe diameter too small c. Incorrect design of expansion chamber 7. General overheating a. Broken fan belt b. Loss of coolant c. Lack of snow on heat exchangers 8.
  • Page 120 Section 04 ENGINE PREPARATlON The solder should be inserted above and in line with the wrist pin. 1. Solder 2. Flattened area CAUTION : Do not use acid core solder; the acid can damage the piston and cylinder. MEASURING A COMPRESSION RATlO the region in the head above the piston at T.D.C.
  • Page 121 Section ENGINE PREPARATION , F01D5VS 1. Combustion chamber(VJ 2. Liquid mixture 2threads NOTE : When the combustion chamber is filled to top of spark plug hole, subtrack 2.25 cc (19 mm reach head; i.e. BR9ES spark plug). Check if fluid level decreases, in that case there is a leak between piston/ cylinder.
  • Page 122 Section ENGINE PREPARATION The uncorrected compression ratio of an engine is the volume of the cylinder plus the minimum volume of the combustion chamber divided by the minimum volume of the combustion chamber. . .= Where : = compression ratio : 1 volume of a cylinder = v, = minimum combustion chamber volume...
  • Page 123 Section ENGINE PREPARATION MEASURING CORRECTED COMPRESSION RATlO C. C. R. ‘ V * Where : volume of a cylinder with piston just closing the exhaust port = = minimum combustion chamber volume , F01D60S 1. Exhaust portjust closed 3. T.D.C. 4.
  • Page 124 Section ENGINE PREPARATION HOW TO CALCULATE MACHINING CYLINDER HEAD HEIGHT VERSUS COMBUSTION CHAMBER VOLUME H = ‘ Where : = material to be machined from face of cylinder head (cm) “ = measured combustion chamber volume (cc) = Volume of cylinder B = bore of cylinder (cm) EXAMPLE : Desired compression ratio (CRJ = 14.0 : 1...
  • Page 125 Bombardier-Rotax has patented a remarkably simple system to automatically change the exhaust port height based on pressure in the exhaust system.
  • Page 126 To the outside of the return spring is a red plastic adjustment knob (item 5). Turning the adjustment in or out changes the preload on the return spring which, in turn, will change the RPM at which the RAVE valve opens and closes. The exhaust port height changes a total of 4 mm to 6 mm (depending on engine type) from the RAVE valve fully closed to fully open.
  • Page 127 Section ENGINE PREPARATION If the RAVE valve opens too late, the engine will bog or hesitate momentarily as the RPM increases. Full peak performance (item 6) is still available. From a functional Point of view~ it is be~er to have the valve open a bit early than a bit late.
  • Page 128 The 583 RAVE has, in effect, two ports. Let’s compare them separately. With the RAVE valve open, the exhaust port timing of the 583 and 537 are identical with a total open duration of 202°. The exhaust port of the 583, however, is 1 mm (.039 in) wider than on the 537. When the RAVE valve closes, the exhaust port timing of the 583 matches that of the 467 with a total open duration of 189°.
  • Page 129 Section 04 ENGINE PREPARATION E) BORING PRECAUTION In its stock configuration the RAVE valve guillotine has a minimum of 0.5 mm (.020 in) clearance to the cylinder bore measured at the center line of the cylinder. This is the minimum production clearance.
  • Page 130 OPERATION OF THE ROTARY VALVE Controlling the opening and closing of the intake port is also a critical factor in the volumetric efficiency of an engine. Best V.E.’S are obtained by asymmetrical intake timing (opening the intake Port at about 140° B.T.D.C. and closing the port at about 60° A.T.D.C.) while also allowing for an unobstructed intake tract to provide maximum airflow into the engine.
  • Page 131 Section ENGINE PREPARATION As the piston starts its upward stroke, the air/fuel mixture is sucked into the crankcase from the carburetor via the intake port (the rotary valve uncovers the intake port). As the piston continues upwards, it blocks the exhaust and transfer ports, and compresses the air/ fuel mixture in the combustion chamber (secondary compression).
  • Page 132 Section ENGINE PREPARATION EXHAUST AND PRIMARY COMPRESSION , F01D6VS 1. Fresh charge forthe other cylinder 2. Intake portcovered As the piston descends, the intake port is blocked by the rotary valve and pressure begins to build inside the crankcase (primary compression). The exhaust port is uncovered as the piston continues its course zdownward, and burnt gases are allowed to escape.
  • Page 133 Section ENGINE PREPARATION TRANSFER II Ill Ill 111A , F01D6WS 1. Fresh charge fortheother cylinder 2. Fresh charge 3. Intake port covered Near the bottom of the downward stroke, the transfer ports are uncovered by the piston, and the compressed air /fuel mixture in the crankcase rushes into the combustion chamber. Piston dome and combustion chamber configuration and muffler back pressures prevent fresh charge (air /fuel mixture) from escaping through the exhaust port.
  • Page 134 Section ENGINE PREPARATION , F01D6XS 1. Pinion (onrotaryvalve shaft) 2. Rotary valve 3. Gear(crankshaft) 4. Gear(on rotary valve shaft) Late closing Early closing 700. 85° 5000 6000 7000 8000 9000 Effect on power curve of changing rotary valve closing angle. ADVANTAGES OF THE ROTARY VALVE ENGINE The major differences between a piston port engine and a rotary valve engine are : 1 ) Intake port directly positioned in the crankcase.
  • Page 135 Section ENGINE PREPARATION The use of a rotary valve enables a very short inlet track. The design introduces the mixture in a very suitable position without obstruction to the gas flow that would impair the volumetric efficiency. This intake position also enhances the lubrication of the lower connecting rod bearings. With rotary valves, the opening duration of the intake port is specifically controlled by the disc.
  • Page 136 Section ENGINE PREPARATION ROTARY VALVE ADJUSTMENT The rotary valve controls the opening and the closing of the inlet ports. Therefore efficiency will depend on the precision of installation. ENGINE VALVE TIMING N P E S P / N opening, closing 1975 420924205 140°, 56°...
  • Page 137 Section ENGINE PREPARATION ENGINE VALVE TIMING TYPES P / N opening, closing 1986 420924200 132°, 52° 420924200 132°, 52° 420924200 132°, 52° 1987 354 (Competition) 420924207 130°, 73° 420924200 132°, 52° 420924200 132°, 52° 1988 354 (Competition) 420924207 140°, 69° 420924200 132°, 52°...
  • Page 138 Section ENGINE PREPARATION TIMING ENGINE VALVE opening N P E S closing 1995 420924502 146.8° 65.3° 420924504 132° 52° 420924509 129.5° 69.5° 583 (Summit) 420924509 134° 65° 583 (STX, FZ) 420924502 140° 670 (Summit, SS) 420924500 1 44° 72° 420924501 145°...
  • Page 139 Section ENGINE PREPARATION , AOOB2ES Dial indicator (P/ N 4141047 00) NOTE : Do not use crankshaft locking tool to find out MAGneto side top dead center. It will not give the right position on some engines. A degree wheel (P/N 4143529 00) is required to measure rotary valve opening and closing angles in relation with MAGneto side piston.
  • Page 140 Section 04 ENGINE PREPARATION , F01D2JS 1. Find 132° on degree wheel and mark here 2. Opening mark 3. Bottom of MAGneto inlet port 4. Align 360° line ofdegreewheel here — For closing mark, first align 360° line of degree wheel with TOP of MAGneto side inlet port. Then find 52°...
  • Page 141 Section ENGINE PREPARATION A13CONS MAGNETO SIDE PISTON MUST BEA TDC 1. ~ming mark 2. Timing mark NOTE : Rotary valve is asymmetrical. Therefore, try turning it inside out then reinstall on splines to determine best installation position. Apply injection oil on rotary valve before closing rotary valve cover. 04-39...
  • Page 142 Section ENGINE PREPARATION NOTE : Bombardier Corporation has running changes on rotary valves used in our snowmobile product line. The shape of the leading or trailing edge may not conform to the drawing shown in some technical materiel (example follows).
  • Page 143 Section ENGINE PREPARATION 420924202 actual size 420924207 actual size 04-41...
  • Page 144 Section ENGINE PREPARATION 420924220 actual size 420924502 actual size (substitute 4209242 09) 04-42...
  • Page 145 Section ENGINE PREPARATION 420924500 actual size 420924501 actual size 04-43...
  • Page 146 Section ENGINE PREPARATION 420924200 actual size 04-44...
  • Page 147 Section 04 ENGINE PREPARATION (substitute 4209245 02) 420924504 actual size (substitute 4209242 00)
  • Page 148 Section 04 ENGINE PREPARATION tolerance 04-46...
  • Page 149 BASE GASKET INFORMATION MODELS : All 1990 to 1992 SAFARI LC / LCE / GLX and all 1989 to 1993 FORMULA Series. Serial Nos : All Liquid Cooled Engines from 1989 to 1993. Subject : A) Cylinder Tightening Torque B) Cylinder/ Base Gasket C) Cylinder / Base Gasket on 1991 FORMULA PLUS and 1990 FORMULA MACH 1 Models A) On engines with screw-mounted cylinders, grease must be applied under screw head prior to...
  • Page 150 Section ENGINE PREPARATION CYLINDER / BASE GASKET CHART MODEL AND YEAR ENGINE PREVIOUS THICKNESS NEW P / N THICKNESS TYPE P / N LCE / GLX 1990 to 1992 420831835 Safari 420931187 0.5 mm Formula MX 1989 to 1992 420931180 0.6 mm 420931187 0.5 mm...

  • Page 151: Formula Ill

    1995 BASE GASKETS 1996 BASE GASKETS 454 MX Z - Base gasket set 420931365 - 494 Formula SLS / Grand Touring 500 Summit 500 Includes : P / N 931-360 (0,3) yellow con rod dot 1-420931360 .3 mm red con rod dot P/N 931-361 (0,4) 1-420931361 .4 mm...
  • Page 152 Section ENGINE PREPARATION CARBURETOR MAIN JET CORRECTION CHART “F J “C FT / METER -40 / +20 I +40 / +60 f +80 f -60 f -20 / -o I 111.10 107.40 103.70 ,Ofoo 92.60 88.90 85.20 96.30 2000 I 105.77 102.07 98.37 94.67 90.97...
  • Page 153 Section ENGINE PREPARATION Good Rich Lean The amount and color of carbon on the piston dome also indicate mixture ratio. Rich Lean Good , A01C49S Black and sooty indicate a rich mixture. Light tan and gray indicate too lean a mixture. The engine must be operated under load for at least one minute to obtain accurate readings.
  • Page 154 Section ENGINE PREPARATION USEFUL EQUATIONS : B - E 1737. 97x C. A. P. C. R. A. D. = 460 +T — 5252 1 Kw = 1.34102 Where : B = barometer reading (in-Hg) R. H. E = vapor pressure (in - Hg) = S.P. x — or use wet bulb/ dry bulb temperature and psychometric chart.
  • Page 155 Section ENGINE PREPARATION g = Grams Hr = Hour Lb = Pounds SATURATION PRESSURE (CHART 1) T = Temp. (°F~ .004 .008 .012 .020 .040 .055 .070 .090 .110 .140 .170 .208 .247 .314 .380 .450 .521 .630 .739 .884 1.030 1.225 1.420...
  • Page 156 Section ENGINE PREPARATION Exhaust Gas Temperature Probe Location 1. 100 mm from piston 1. 80 mm 1. 35 mm 2. Probe 2. Probe 2. Probe NOTE : Temperature at wide open throttle at maximum HP RPM. Carburetor Operation The operation of the carburetor is based on the physical principle that fluids (air is a fluid) under pressure gain speed but lose pressure when passing through a converging pipe (venturi).
  • Page 157 Section ENGINE PREPARATION Air entering the bell of the carburetor has a speed of VI and pressure of P1. As the air is forced into the smaller diameter of the venturi, speed increases (V2) but pressure drops (P2). Passages in the carburetor connect the venturi to a reservoir of fuel (float bowl). The float bowl is vented to the atmosphere (P1 ).
  • Page 158 Section 04 ENGINE PREPARATION m m m a m m a m m m m m m m m m m r 4 u m m m w 8 m m m m m m m m m : 04-59...
  • Page 159 Section 04 ENGINE PREPARATION 1. Jet needle 2. Needle Jet 3. Main Jet 4. Air Jet 04-56...
  • Page 160 Section ENGINE PREPARATION LARGE FUEL PUMP PARTS 70 Liter/ hour fuel pump P / N 403-9012-00 Filter, in-tank P / N 414-8721-00 Fuel line, in-tank P / N 414-9437-00 P / N 570-2739-00 Gromment, tank Connector, tank P / N 414-8727-00 Fuel line, tank to shut off valve P / N 414-9399-00 Shut off valve...
  • Page 161 Section ENGINE PREPARATION DUAL FUEL PUMP INSTALLATION With a heavily modified engine, especially when using large bore carburetors, the need for 580 or larger main jets may arise. The capacity of the fuel pump maybe exceeded when using these large jets.
  • Page 162 Section ENGINE PREPARATION STARTING DEVICE Instead of a choke, the enrichener system is used on some Mikuni carburetors. In the starter type, fuel and air for starting the engine are metered with entirely independent jets. The fuel metered in the starter jet is mixed with air and is broken into tiny particles inside the emulsion tube. The mixture then flows into the plunger area, mixes again with air coming from the air intake port for starting and is delivered to the engine in the optimum air/fuel ratio through the fuel discharge nozzle.
  • Page 163 Section 04 ENGINE PREPARATION SELECTION OF THE APERTURE OF CARBURETOR One of the prerequisites for improving the output is to use a carburetor with as large an aperture as possible. However, a large aperture alone does not necessarily improve the output. As shown in the following illustration, it is true that a large aperture improves the power output in the high speed range.
  • Page 164 Section ENGINE PREPARATION 2. Bend the actuating tab as required to make the float arm parallel to the base. Be careful not to bend the float arm. NOTE : Incorrect float adjustment can prevent proper tuning of a carburetor. Always make sure the float is properly adjusted before attempting adjustment of the other fuel metering system.
  • Page 165 Section 04 ENGINE PREPARATION -. . LOW FLOAT SETTING WILL RESULT IN HARD STARTING - LEAN RUNNING , A01C50S PILOT/ AIR SYSTEM PRINCIPLES OF OPERATION The pilot / air system controls the fuel mixture between idle and approximately the 1/4 throttle position.
  • Page 166 Section 04 ENGINE PREPARATION ADJUSTING AIR SCREW A01C4FS 1. Pilot bypass 2. Pilot outlet 3. Pilot jet 4. Air intake 5. Air screw NOTE: This procedure may be performed for single and dual carburetors. Never adjust screws more than 1/4 turn at a time. 1.
  • Page 167 Section ENGINE PREPARATION 7. Turn the air screw left and right (between 1/4 and 1/2 turn) and select the position where the engine revolution reaches the maximum. Adjust the throttle stop screw to bring down the engine revolution to your target speed for idling. After this adjustment of the throttle stop screw is made, select once more the position where the engine revolution reaches the maximum, by turning the air screw left and right (between 1 / 4 and 1 / 2 alternately).
  • Page 168 Section ENGINE PREPARATION REPLACING PILOT JET 1. Pilot jet Throttle valve opening (%) A01C4HS 1. Total amount of fuel flow 2. Main fuel system 3. Pilot fuel system 04-66...
  • Page 169 Pilot jets are numbered from No. 15 (the smallest) to No. 80 (the largest). The number corresponds to fuel flow and not necessarily to drill size or through-hole diameter. After changing the pilot jet, check and adjust air screw as described above. NOTE : Since the pilot/ air system provides some fuel up to wide open throttle, changes in this system will affect the throttle valve, jet needle/ needle jet, and main jet metering systems.
  • Page 170 Section ENGINE PREPARATION CHECKING AND SELECTING THROTTLE VALVE Throttle valve opening (%) , A01C2WS Operate engine at low throttle settings, accelerating from idle to 1/4 throttle. If engine bogs during acceleration, there is probably insufficient fuel. Turn in air screw about 1/ 4 turn at a time.
  • Page 171 Section ENGINE PREPARATION JET NEEDLE PRINCIPLES OF OPERATION Throttle valve opening , A01C2YS The jet needle works with the needle jet to increase the amount of fuel as the throttle valve is raised. Although the jet needle and needle jet function in the 1/4 to 3/4 throttle range, they also affect the amount of fuel present at wide open...
  • Page 172 Section ENGINE PREPARATION A01C2XS 1. E-ring 2. Needle jet 3. Fuel 4. Air 5. Metered here 6. Jet needle 7. Throttle valve The jet needle raises and lowers with the throttle valve which changes jet needle position in the needle jet. Because the jet needle is tapered from top to bottom, an increasing amount of fuel is delivered through the needle jet whenever the throttle valve is raised.
  • Page 173 Section ENGINE PREPARATION LEAN Number stamped RICH here , AOICZZS Example : 6DH7 Basic length of needle. DH -A single letter would indicate a single taper of the needle, double letter a double taper, and three letters mean there is a triple taper. D - Amount of taper at top of needle.
  • Page 174 Section 04 ENGINE PREPARATION POSITIONING THE E-RING Lean E-Ring Washer Rich , A01C58S Check for a rich or lean setting by examining exhaust manifold. A very light brown or white color indicates a lean mixture. A very dark brown or black color indicates-a rich mixture. The proper color is tan.
  • Page 175 Section 04 ENGINE PREPARATION NEEDLE JET PRINCIPLES OF OPERATION , A01C41S The needle jet works in combination with the jet needle to meter the fuel flow in the mid range. Changes to the needle jet should be made only if the results of changing the jet needle position are unsatisfactory.
  • Page 176 Section 04 ENGINE PREPARATION 15 25 Throttle valve opening c .- Increasing needle jet size ~ A01C4KS Needle jets are stamped with an alphanumeric code. The letter indicates a major change in fuel flow. P-2, for example, indicates low flow; P-4, greater flow, and so on. The number indicates minor adjustments in fuel flow.
  • Page 177 Section ENGINE PREPARATION NOTE : Needle jets carrying the numbers 166, 159 or 169 in addition to the P-2 or P-4 and are not interchangeable. Be sure correct needles are used as specified for your snowmobile. MAIN JET SYSTEM PRINCIPLES OF OPERATION , A01C30S 1.
  • Page 178 Section ENGINE PREPARATION TUNING THE MAIN JET SYSTEM 8-10 20-22 100 Throttle valve opening , A01C4LS Before operating the snowmobile, make sure all parts, including clutch and drive belt, are in good operating condition. 1. Operate snowmobile at wide open throttle for several minutes on a flat, well packed surface. Change main jet if snowmobile fails to achieve maximum rpm or labors at high rpm.
  • Page 179 Section ENGINE PREPARATION A01C2C N“ N“ N“ N“ BOMBARDIER BOMBARDIER LEAN LEAN 404133100 404101200 #300 404133000 #310 404107800 404132900 404101300 #320 404132800 #330 404101400 # l o o 404132000 #340 404104900 # l o 5 404132100 #350 404106000 #110 404124100...
  • Page 180 Section 04 ENGINE PREPARATION AOIC2D N“ N“ BOMBARDIER LEAN PAUVRE 159 N-2 404147700 159 N-4 404147300 159 N-6 404154300 1590-0 404130200 1590-6 404131000 1590-8 404116900 159 P-o 404107000 159 P-2 404100700 159 P-4 404103600 159 P-6 404110600 159 P-8 404120800...
  • Page 181 Section ENGINE PREPARATION A01C2E N“ N“ BOMBARDIER LEAN PAUVRE 404108600 404110300 404107700 404102700 404109100 404109400 404109500 404113900 404148100 RICH N“ N“ N“ N“ BOMBARDIER BOMBARDIER 404110400 6FJ6 404131100 404126900 404109200 404101900 404114100 404111300 404113200 404124400 404133300 6DP1 404118000 404127700 6EJ1...
  • Page 182 Section ENGINE PREPARATION , A01C2G SIZE CARBURETOR N“ BOMBARDIER NO. 404117700 1.2 (v) 404147500 34-434 404112600 40-49 404131400 1.5 (v) 404147400 1.5 (v) 404152300 40-71 2.0 (v) 404131400 ALL OTHERS 404103200 TOUS LES AUTRES Viton 04-80...
  • Page 183 Section ENGINE PREPARATION WITH LATERAL RESTRAINING DEVICE CARBURETOR CUT-AWAY N“ BOMBARDIER NO. 404118300 404109900 4 0 4 1 1 7 3 0 0 0 404117200 4 0 4 1 1 7 4 0 0 0 404130300 404109900 404119600 4 0 4 1 1 7 4 0 0 0...
  • Page 184 Section 04 ENGINE PREPARATION WITH CENTER RESTRAINING DEVICE AVEC DISPOSITIF DE RETENUE CENTRAL CUT-AWAY CARBURETOR N“ BOMBARDIER NO. CAR BURATEUR 404128400 404128600 404128400 404131300 404113400 404132300 04-82...
  • Page 185 Section ENGINE PREPARATION ENGINE TROUBLESHOOTING When the carburetor setting is not correct for the engine, various irregularities are noticed. These — — can be traced to two causes as a whole: When the air/ fuel mixture is too rich : The engine noise is full and intermittent.
  • Page 186 Section ENGINE PREPARATION FUEL / OIL RATlO CHARTS METRIC (S.1.) METRIC (S. L)/METRIQUE (S.1.) of fuel of oil + 25 L = 50/1 500 mL de carburant IMPERIAL /imperial of oil of fuel 5 Imp. gal = 50/1 de carburant Liters of oil of fuel...
  • Page 187 Section 04 ENGINE PREPARATION METRIC (S.1.)/METRIQUE (S.1.) METRIC (S.1.) of oil of fuel 500 mL + 20 L = 40/1 de carburant Liters of fuel IMPERIAL/ lMPERIAL of oil of fuel Milliliters of oil needed 4.0 Imp. gal = 40/1 250300 de carburant of oil...
  • Page 188 Section ENGINE PREPARATION METRIC (S. L)/MkTRIQUE (S.1.) METRIC (S.1.) of oil of fuel 500 mL + 15 L = 30/1 de carburant IMPERIAL/ lMPERIAL of oil of fuel 3 Imp. gal = 30/1 de carburant of oil of fuel 500 mL + 3.3 Imp.
  • Page 189 Section ENGINE PREPARATION METRIC (S. L)/METRIQUE (S.1.) METRIC (S.1.) of oil of fuel 500 mL + 12.5 L = 25/1 de carburant IMPERIAL/ lMPERIAL of oil of fuel 2.5 Imp. gal = 25/1 de carburant of fuel Liters of fuel Litres de carburant 500 mL + 2,7 Imp.
  • Page 190 Section ENGINE PREPARATION METRIC (S. L)/METRIQUE (S.1.) METRIC (S.1.) of oil of fuel 500 mL + 10 L = 20/1 de carburant Liters of fuel IMPERIAL/ lMPERIAL of oil of fuel Milliliters of oil needed 2 Imp. gal = 20/1 900 I de carburant (1 liter)
  • Page 191 Section ENGINE PREPARATION THEORY The high altitude compensator is a mechanical device designed to vary the pressure in the float bowl chamber relative to air density. Air density is affected by variations in elevation and air temperature. As the elevation goes up from sea level, the air density decreases and as temperatures increase air density also decreases.
  • Page 192 Section 04 ENGINE PREPARATION APPLICATION The carburetors must be adapted for use with the H.A.C. There must be a connection to provide venturi pressure and the air jet main opening is plugged. A small hole is drilled into the top of the air jet passageway.
  • Page 193 Section 04 ENGINE PREPARATION ‘ b\ 04-91...
  • Page 194 Section 04 ENGINE PREPARATION 3.4 HAC Operation VACUUM HOSE VACUUM HOSE FROM THE HAC CONNECTED TO CARBURETOR TO WHAT IS USUALLY CONSIDERED AS “AIR VENTS” A01C32S 1. Carburetor vacuum hoses manifold 2. Choke jets manifold 3. Vacuum generated by the engine induction 4.
  • Page 195 Section 04 ENGINE PREPARATION IGNITION SYSTEMS, SPARK PLUGS Two-stroke engines in snowmobiles rely on an electric spark to initiate combustion of the fuel/ air charge which has been inducted into the cylinder. For the engine to operate efficiently, the spark must be delivered at precisely the right moment in relation to the position of the piston in the cylinder and the rotational speed of the crankshaft.
  • Page 196 Starting with most 1990 Ski-Doo models, a Nippondenso CDI system with only one generating coil was introduced. This system is identified by having only two wires running from the stator plate to the CD box. The two generating coil system has three wires. This system functions the same as the dual generating coil system but has the following differences : 1.
  • Page 197 Section 04 ENGINE PREPARATION TACHOMETER SELECTION A different tachometer type is needed for different ignition types. The number of poles on the stator and flywheel determine the number of pulses generated per revolution. The tach must be matched to the ignition type. Two types of tachometers are used on Ski-doo models. Tachometers with no labeling are usually 4 pulse tachometers.
  • Page 198 Section ENGINE PREPARATION ROTAX CONNECTING RODS F01D5TS 1. Rod Length Center to Center A. All 22 mm (0.866”) except 670 24 mmm (0.945”) & 59918 mm (0.708”) ENGINE TYPE STROKE LENGTH mm (in) mm (in) - 253 61 (2.402) 115 (4.527) 61 (2.402) 115 (4.527) 61 (2.402)
  • Page 199 Section 04 ENGINE PREPARATION SPARK PLUG HEAT RANGE Spark plug heat ranges are selected by measuring actual combustion chamber temperatures. A colder spark plug, one that dissipates heat more rapidly, is often required when engines are modified to produce more horsepower. The proper operating temperature or heat range of the spark plugs is determined by the spark plug’s ability to dissipate the heat generated by combustion.
  • Page 200 Section 04 ENGINE PREPARATION DESIGN SYMBOLS USED ON NGK SPARK PLUGS First letter suffix for thread: Second letter suffix for con- Second and third letter prefix Heat rating number First letter prefix for thread reach and hexagon size for construction feature, except single prefix Hotter type...
  • Page 201 STOCK CLASS PREPARATION NOTE : Any machining and/or grinding is illegal in stock class racing. Keep your machine legal ! 1. Remove and disassemble the engine according to correct Shop A4anua/ procedures. 2. With the crankshaft resting in the lower half of the crankcase, set up a dial indicator and check the run out of the crankshaft at both ends.
  • Page 202 Section ENGINE PREPARATION Rotary valve timing should be set with the closing edge as close to specs as possible or slightly higher. NOTE : Refer to chart page. 7. The engine should be pressure-tested for air leaks. It should hold 6 PSI for 6 minutes with no more than a 1 PSI / min.
  • Page 203 Section ENGINE PREPARATION NOTES REGARDING ENGINE MODIFICATION 1. Tunnel porting This procedure refers to the grinding out of the crankcase from the rotary valve inlet towards the transfer ports at the cylinder base. The effort here streamlines the flow from the rotary valve inlet to the cylinders.
  • Page 204 Section ENGINE PREPARATION J - 1 J_l A-1 < < - - - 04-102...
  • Page 205 CHAINCASE GEARING ................. 05-39 BOMBARDIER SKI-DOO—1995 MODELS 05-44 m..
  • Page 206 Section 05 TRANSMISSION SYSTEM BASIC FUNCTIONS OF THE SYSTEM THE TRA CLUTCH We call it “a clutch” but that set of pulleys is a lot more than simply a clutch. Once the system reaches its low ratio speed, the clutch function ends and the pulleys become a completely automatic transmission searching for the highest gear ratio that can be pulled at the engine’s given output.
  • Page 207 Section 05 TRANSMISSION SYSTEM As the formula illustrates, we can control the size of the centrifugal force by varying the size of the weight we are rotating and by varying the radius of the circle we rotate the weight around. The largest influence on the force, however, is the rotational speed because the force increases with square of this speed.
  • Page 208 Section 05 TRANSMISSION SYSTEM POWER CURVES MILDLY TUNED VS. RACE TUNED 1 0 0 - - Race Turned 9 0 - - 8 0 – - 7 0 - - 6 0 - - 5 0 - - Mildly Turned ~ 4 0 –...
  • Page 209 Section 05 TRANSMISSION SYSTEM SPEED DIAGRAM ENGINE SPEED VS. VEHICLE SPEED Ratio High Ratio 1 0 , 0 0 0 - E n g a g e m e n t 9,000 7,000 4,000- - 2,000- - 1,000- 05-5...
  • Page 210 Section 05 TRANSMISSION SYSTEM EFFECTS OF THE DRIVE PULLEY LEVER ARM, ROLLER AND ROLLER PIN WEIGHT As you have seen in the formula defining centrifugal force, the force increases directly with the weight of the components involved. If you want to increase the centrifugal force, therefore, the shift force, it is a simple matter to increase the weight of the pressure levers.
  • Page 211 Section 05 TRANSMISSION SYSTEM DRIVE CLUTCH ROLLER PINS 10,000 9,000 8,000 7,000 6,000 5,000 4,000 3,000 2,000 1,000 — MPH gram roller pins A: 10- gram roler pins B : 14- gram roller pins AOIDOXS 05-7...
  • Page 212 The solid steel roller pins can be drilled axially (lengthwise) with various size holes to vary the weight from 16.5 grams down to 10.3 grams (about a 1/4 inch diameter hole), which is the weight of the hollow steel pin. A 1/8 inch diameter hole drilled in the solid steel pin will give you about 14.5 grams.
  • Page 213 Section 05 TRANSMISSION SYSTEM Light aluminum lever arm 37.9 grams 420448455 Heavy aluminum arm 39.1 486037800 27.3 Magnesium lever arm 16.4 (black) 504259600 Solid steel roller pin 16.8 (white) 420429140 10.3 Hollow steel roller pin 504260600 10.3 Threaded steel roller pin xxx Xxxx xx Solid aluminum roller pin 504260300...
  • Page 214 Section 05 TRANSMISSION SYSTEM COMBINATION WEIGHT Alum. Lever Steel Roller Solid steel pin 66.8 grams Alum. Lever Steel Roller Threaded steel + 4 set screws 64.2 Alum. Lever Steel Roller Threaded steel + 3 sets 63.3 Alum. Lever Steel Roller Threaded steel + 2 sets 62.4...
  • Page 215 Section 05 TRANSMISSION SYSTEM Alum. Lever Alum. Roller Threaded alum. pin Alum. Roller Threaded steel + 4 sets Alum. Roller Threaded steel + 3 sets Steel Roller Threaded alum. + 4 sets + 2 sets Steel Roller Threaded alum. + 3 sets Steel Roller Solid alum.
  • Page 216 Section 05 TRANSMISSION SYSTEM EFFECTS OF THE RAMP PROFILE ON THE SHIFT FORCE The shift force is the component or part of the centrifugal force that is used to actually move the sliding half of the drive pulley. This force is applied to the sliding half at the three lever arm pivot points (following illustration item 49).
  • Page 217 Section 05 TRANSMISSION SYSTEM In clinical condition such as on a dynamometer, moving the adjusters up will result in a 150 to 200 RPM increase with each position change. Lowering the adjuster positions will result in a decrease of 150 to 200 RPM with each number. On the snowmobile, however, depending on the operating conditions, a change of one adjuster position may not show up on the tachometer, but the shift speed of the pulley will have changed.
  • Page 218 Section 05 TRANSMISSION SYSTEM II I I I I I I l~& AOIDOYS For drag racing and radar running, it is usually better to try to go as low as possible on the adjusters without dropping the engine peak RPM too much as this will give the vehicle its fastest acceleration and top speed.
  • Page 219 Section 05 TRANSMISSION SYSTEM RAMP CHARACTERISTICS Taller ramp = Higher engagement Steeper angle = Higher shift RPM Shallower angle = More RPM at lower MPH (slower shift) 05-15...
  • Page 220 Section TRANSMISSION SYSTEM TRA RAMP PROFILES 4 2 0 4 8 0 1 4 0 5 0 4 0 6 9 9 0 0 AOIDIDA AOIDIGA 5 0 4 0 6 9 3 0 0 4 2 0 4 8 0 1 4 4 AOIDISA A03D1UA AOIDIEA...
  • Page 221 Section 05 TRANSMISSION SYSTEM 4 1 4 7 5 4 3 0 0 A01D20A 4 1 4 7 9 6 0 0 0 AOIDILA 4 2 0 4 8 0 1 4 3 4 2 0 4 8 0 1 4 2 5 0 4 2 5 9 4 0 0 A01D21A 05-17...
  • Page 222 Section 05 TRANSMISSION SYSTEM TRA RAMP PROFILES 4 2 0 4 8 0 2 8 4 4 2 0 4 8 0 2 2 7 A01D22A 4 2 0 4 8 0 2 8 0 4 2 0 4 8 0 2 8 5 5 0 4 1 4 0 8 0 0 4 2 0 4 8 0 2 8 6 A01D24A...
  • Page 223 Section 05 TRANSMISSION SYSTEM TRA RAMP PROFILES 4 1 5 0 2 3 5 0 0 4 1 5 0 2 3 8 0 0 A01D2AA A01D2CA 4 1 5 0 2 3 6 0 0 5 0 4 0 9 6 4 0 0 A01D29A A01D2BA 05-19...
  • Page 224 Section 05 TRANSMISSION SYSTEM EFFECTS OF THE DRIVE PULLEY SPRING The purpose of the clutch release spring is to return the sliding half of the engine pulley and the associated moving parts to the disengaged or neutral position at low engine RPM. The spring tension is calibrated to work with the pressure levers and ramp angles to allow clutch engagement at the desired RPM.
  • Page 225 Section 05 TRANSMISSION SYSTEM DRIVE CLUTCH SPRING (effect at engagement) CHART 1 10,000 9,000 8,000 7,000 6,000 5,000 4,000 3,000 2,000 1,000 Load at Load at 41 mm (1.6 in) 74 mm (2.9 in) 1157 N (2601 lb) 311 N (70 lb) 1201 N (270 lb) 712 N (160 lb) 05-21...
  • Page 226 Section 05 TRANSMISSION SYSTEM DRIVE CLUTCH SPRING (effect at top speed) CHART 1 10,000 9,000 8,000 7,000 6,000 5,000 4,000 3,000 2,000 1,000 AOIDIVS Load at Load at 41 mm (1.6in) 74 mm (2.9in) 311 N (70 lb) 756 N (170 lb) 1157 N (260 lb) 05-22...
  • Page 227 Section 05 TRANSMISSION SYSTEM FREE LENGHT NO OF FORCE @(Newton) PART NO. COLOR WIRE DIA. COILS 74 mm -41 mm 74 mm -41 mm BOMBARDIER (mm) CODE (mm) 70-170 311-756 414689800 RED-RED 96,3 70-230 414817500 RED-YELLOW 87,9 311-1023 414689200 I...
  • Page 228 Section 05 TRANSMISSION SYSTEM TRA SPRING CHART PART # Load at 74 mm Load at 41 mm Color Code (2.9 in) (1.6 in) N (lb)t5% N (lb)t5% 1824 415019500 BLACK (185) (410) 1023 1557 NEW PINK-PINK 486054700 (350) (230) OLD RED-BLUE 1023 1690 NEW PINK-WHITE...
  • Page 229 Section 05 TRANSMISSION SYSTEM TRA CLUTCH SPRING FORCE 200’ Force at Force at engagement full shift 05-25...
  • Page 230 Section 05 TRANSMISSION SYSTEM EFFECTS OF THE DRIVEN PULLEY SPRING The driven pulley spring is needed to keep the plastic slider buttons in contact with the cam and to provide enough side force on the belt in the low gear position to allow initial acceleration while the torque rises to a point where the torque sensing cam begins to take over.
  • Page 231 Section 05 TRANSMISSION SYSTEM To change the spring tension, relocate the spring end in the sliding pulley half or reposition the spring end in the cam. There are six holes available on a Formula cam. They are numbered 1-6. Most Formula driven pulleys have three adjustment holes in the sliding half.
  • Page 232 Section 05 TRANSMISSION SYSTEM EFFECTS OF THE DRIVEN PULLEY CAM The purpose of the driven pulley cam is to sense the torque requirements of the drive axle and feed a portion of the engine torque, which has been applied to the driven pulley, back to the sliding half of the pulley.
  • Page 233 Section TRANSMISSION SYSTEM 05-29...
  • Page 234 Section 05 TRANSMISSION SYSTEM Driven pulley cams are helices. A helix is measured in “ lead” . Lead is the distance a point moves along the axis of rotation in one revolution of the helix. (Screw threads are a helix. ) The helix angle is computed from the lead and the circumference of the helix.
  • Page 235 Section 05 TRANSMISSION SYSTEM Measuring a cam on the outside diameter will produce a different angle than on the mean diameter. A cam angle measured on the outside diameter can be converted to the “Ski-Doo spec” mean diameter angle as follows : L = C x Tan A Where : L = Lead...

  • Page 236: Mach

    Section 05 TRANSMISSION SYSTEM DRIVEN PULLEY CAMS 87.8 mm diameter 1/4 inch keyway P / N CAM ANGLE USED ON (sea-level) 44° 1986 PLUS; 1987-88 MX, PLUS 504128200 1989-1993 EXCEPT 93 MACH Z 87.8 mm DIAMETER 8 mm KEYWAY 1994 ALL PRS CHASSIS P / N CAM ANGLE USED ON...
  • Page 237 Section 05 TRANSMISSION SYSTEM 8 mm KEYWAY P / N MULTI-ANGLE CAM ANGLE I P / N CAM ANGLE 44°-400 415021100 415022800 30° 415021200 46°-420 415022900 32° 415021300 48°-400 415023000 34° 48°-440 415021400 415023100 36° 38° 415021500 50°-360 415022700 415021600 50°-400 504092100 40°...
  • Page 238 BALANCING OF PULLEYS Each half of Ski-Doo driven pulley is individually balanced. This means that parts can be interchanged and that no alignment marks are needed for assembling for the complete assembly to be in balance. The TRA clutch is similar to our driven pulleys in the sense that each major component is balanced separately.
  • Page 239 Install drive pulley on crankshaft extension. Install lock washer and screw. WARNING : Never substitute lock washer and/or screw with “jobber” ones. Always use Bombardier genuine parts for this particular case. 105 Nom (77 Ibf”ft). Torque screw to Install drive belt and pulley guard.

  • Page 240: Drive Belts

    Kevlar cords in the tensile layer for strength with today’s high output sleds. Use only the specific Bombardier drive belt listed for your application. The drive belt is a calibrated part of the transmission system. Different belts with different compounds or angles will change how your transmission shifts.
  • Page 241 Section 05 TRANSMISSION SYSTEM PROPER ALIGNMENT OF THE TRA CLUTCH ON A FORMULA MODEL 1. Sleeve (Note: noclearancetithis side of driven pulley) 6. PRS = 268.3 (10-9/16 in) 2. 2 shims (504-1082-00) 3. Use straight bar (.375 in x 19 in) 7.
  • Page 242 Section 05 TRANSMISSION SYSTEM Proper belt deflection and alignment are extremely important. Included is a page on proper alignment procedures and deflection measurement methods for your use. Do not forget about the torque limiter rod on Formula models. This bolt is located between the after the proper alignment and center to center distances have been set.
  • Page 243 Section 05 TRANSMISSION SYSTEM Contrary to popular belief, small gear changes do not directly affect top speed as long as the clutches are functioning properly. Gearing one or two teeth taller on the top will not generally make the vehicle any faster on top end unless the clutches are fully shifted out and the engine is starting to overrev.
  • Page 244 The following chart illustrates the effects of increased R.P.M. on delivered horsepower. As motor R.P. M. is raised to attain higher maximum horsepower, efficiency of both the drive and driven clutch drop considerably. This loss will often exceed the horsepower gained from the installation of aftermarket exhausts or engine modifications.
  • Page 245 Section 05 TRANSMISSION SYSTEM You can easily check your gearing selection by marking your drive clutch with a black marker with straight lines from bottom to top on the belt surfaces of the clutch. Go out and ride your sled under your normal conditions and stop to see how far the belt has rubbed the marker off the clutch surfaces.
  • Page 246 Section 05 TRANSMISSION SYSTEM There are many dynamic considerations that affect this figure in the field. Drastic tem-perature changes under the hood, pressure changes both under the hood and near the air box inlet, exhaust system temperature changes, and even rotating parts such as clutches, jackshafts, and brake discs causing air turbulence under the hood all affect where the engine peak power is when the engine is doing its work under the hood.

  • Page 247: Formula Sls

    Section 05 TRANSMISSION SYSTEM SPROCKET / CHAIN CHART S / L S / L 1993 1994 “L 1996 SPROCKETS SPROCKETS MACH 1 26X 44 22 x 44 23X 44 MX II 22 x 44 FORMULA ST* 23X 44 SUMMIT 500 22x 44 25X 44 MX XTC R...
  • Page 248 Section 05 TRANSMISSION SYSTEM 05-44...
  • Page 249 Section 05 TRANSMISSION SYSTEM SPROCKET / CHAIN CHART (cent’d) RATIOS AND CHAIN LENGTHS CHAINS L I N K S I N A R R O W I WIDE 1.73 1.65 1.58 1.52 1.46 412106000 — 1.90 1.82 1.74 1.67 1.60 1.54 72 I 4 1 2 1 0 5 5 0 0 I 4 1 2 1 0 6 7 0 0 74 I 4 1 2 1 0 5 8 0 0 I 4 1 2 1 0 6 9 0 0 2.10 2.00 1.91...
  • Page 250 Section 05 TRANSMISSION SYSTEM 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 05-46...
  • Page 251 Section TRANSMISSION SYSTEM 05-47...
  • Page 252 Section 05 TRANSMISSION SYSTEM 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0...
  • Page 253 Section 05 TRANSMISSION SYSTEM 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 05-49...
  • Page 254 Section 05 TRANSMISSION SYSTEM TRANSMISSION CALIBRATION PROCEDURE A new vehicle should be broken-in before fine tuning the transmission. 200-300 miles will allow things like bearings and the track to loosen-up. This will allow the sled to roll much freer which may slightly change the clutch calibration.
  • Page 255 Section 05 TRANSMISSION SYSTEM 9. For drag racers, try running the engine down to several hundred RPM below the stated power peak. When the exhaust is cold, the peak power RPM drops. How much lower depends on the engine type, exhaust type, jetting and underhood temperature. Summer and fall grass draggers should especially try lower RPM.
  • Page 256 Section 05 TRANSMISSION SYSTEM TRANSMISSION TUNING TEST SHEET DATE : VEHICLE : SHEET NO. : TEST SITE : TEMPERATURE : SURFACE COND. : Test 1 Test 2 Test 3 Test 4 Test 5 Cam Angle Spring Color Code Spring Preload, lb Spring Position ex.
  • Page 257 Section 05 TRANSMISSION SYSTEM RACERS LOG Sheet Date : Number: Surface Conditions : Barometric Pressure : Humidity : C. R.A.D. : Fuel : MAG. n o t e s : Main Jet Needle Jet Jet Needle E-Clip Position Slide Cutaway Pilot Jet Drive Pulley LeverArm/PinType...
  • Page 258 Section 06 COMPETITION BULLETINS AND RACING PARTS Table of Contents HIGH PERFORMANCE PARTS ............... 06-2 HIGH PERFORMANCE CENTERS .
  • Page 259 Section 06 COMPETITION BULLETINS AND RACING PARTS HIGH PERFORMANCE PARTS PART NUMBER DESCRIPTION 420448452 (3) Magnesium Clutch Lever Driven Pulley Windage Plate 504136700 (OUTER) 504137000 (INNER) 732601067 (12) Screw for Windage Plate 486019700 Extension Bushing (Formula 1) (For double driven pulley large bushings) 486037100 (4 PULSES) High Revolution Tachometer 486052100 (6 PULSES)
  • Page 260 Section 06 COMPETITION BULLETINS AND RACING PARTS DESCRIPTION Formula 1 Ski (Aluminum) Small Fuel Tank Mechanical Temperature Gauge 486037300 Fiberglass Gas or Lube Tank 486049500 15” X 121” High Profile Track Stabilizing Bar Assembly 3/4” 486056200 Shorter Limiter Strap Skid-Plate 1996 S-2000 -1996 861749700 Black Skid-Plate 1996 S-2000 -1996 Skid-Plate 1996 S-2000 -1996...
  • Page 261 Section 06 COMPETITION BULLETINS AND RACING PARTS HIGH PERFORMANCE CENTERS FAST INC Larry’s Small Engine Bombardier Corp. 1040 South Hwy 53 RR 4 7575 Bombard er Court Eveleth, MN 8035 55734-9604 L9W 2ZI Wausau, Wisconsin Tel : 218-744-2101 Tel : 715-842-8886...
  • Page 262 Section 06 COMPETITION BULLETINS AND RACING PARTS A03F1JS COMPLETE ASSEMBLY FOR 1996 MXZ - FORMULA FORMULA SS Attache courroie solide Axe de goupille 06-5...

  • Page 263: Technical Data

    Angle 8607 Part number Drive belt 25° Calibration done at temperature of The maximum horsepower RPM is applicable on the vehicle. It may be different under certain circumstances and BOMBARDIER INC. reserves the right to modify it without obligation. 06-6...
  • Page 264 Angle 54° Angle Drive belt 15° c Calibration done at temperature of The maximum horsepower RPM is applicable on the vehicle. It may be different under certain circumstances and BOMBARDIER INC. reserves the right to modify it without obligation. 06-7...
  • Page 265 Lever *Std. aluminum — Beige Spring Color Driven pulley 17 Ibs (504 Angle 54-44 degrees Part number 9182 Drive belt Calibration done at temperature of degrees C circumstance and BOMBARDIER INC. reserves the right to modify it without obligation. 06-8...
  • Page 266 9182 - . . 30 degrees Calibration done at temperature of * The maximum horsepower RPM is applicable on the vehicle. It may be different under certain circumstances and BOMBARDIER INC. reserves the right to modify it without obligation. 06-9...
  • Page 267 Driven pulley (lb) Angle 54-46 deg. Part number 414860700 Drive belt * The maximum horsepower RPM is applicable on the vehicle. It may be different under certain circumstance and BOMBARDIER INC. reserves the right to modify it without obligation. 06-10...

  • Page 268: Formula Stx

    Driven pulley Spring Color Beige Beige Preload (lb) 20 Ibs 20 Ibs Angle 50° 50° Drive belt Part number 414860700 414860700 Calibration dona at tamparatura of 30° 30° circumstance and BOMBARDIER INC. reserves the right to modify it without obligation. 06-11...
  • Page 269 Angle 48° - 40° .%, . ‘ J y Part number 414828700 Drive belt 30° Calibration maximum horsepower RPM is applicable on the vehicle. It may be different under certain INC. reserves the right to modify it without obligation. circumstance and BOMBARDIER 06-12...
  • Page 270 Calibration screw position 250-460 Pink Spring color 4900 Clutch engagement Solid Std. aluminum Lever Color Beige Driven pulley Spring Preload Angle 52° 414794800 Drive belt ‘ ‘ ‘ 30° INC. reserves the right to modify it without obligation. circumstance and BOMBARDIER 06-13...
  • Page 271 (P/N 4145312 00). be carried out and/ or verified by a highly skilled professional racing mechanic. It is understood that racing or modifications of any Bombardier made snowmobile voids the vehicle warranty and that such modifications may render use of...
  • Page 272 REAR PORTION OF SUSPENSION professional racing mechanic. It is understood that racing or modifications of any Bombardier Additional idler made snowmobile voids the vehicle warranty...
  • Page 273 Section 06 COMPETITION BULLETINS AND RACING PARTS FRONT PORTION OF SUSPENSION 141 mm idler wheel Additional idler wheel set A024 005032 FRONT SUSPENSION Collapse front suspension until lower and upper Ao06 005046 arms are horizontal. Tie suspension to limit travel (reduced to 75 mm (3 in) in that position using Adjust preload of original center spring to the straps on shock bolts.
  • Page 274 Section COMPETITION BULLETINS AND RACING PARTS CHAIN CASE Formula Z (40 mm Carburetors) Replace original top sprocket (25 th) and chain with the following : 23-tooth narrow sprocket (P/ N 5040784 00) 72-link chain (P/ N 4121055 00) JET NEEDLE DRIVE BELT M - o AA-o...
  • Page 275 It is understood that racing or modifications of any Bombardier made snowmobile voids the vehicle warranty and that such modifications may render use of...
  • Page 276 Section 06 COMPETITION BULLETINS AND RACING PARTS REAR PORTION OF SUSPENSION (2-1 1/1 6 in) FRONT SUSPENSION Bolt rear arm pivot to rearmost hole of runner. Collapse front suspension until shock is 222 mm Replace center spring with a Blue/ Blue (P/N 4145591 00).
  • Page 277 Maximum engine RPM is 7300. DRIVEN PULLEY Install a 50° cam (P/N 5041363 00). Adjust spring preload to 7.3 kg (16 lb). DRIVE BELT Replace original drive belt with a softer one (P/N 4146338 00). CHAIN CASE Replace original top sprocket (26 th) with a 25- tooth sprocket (P/ N 5040843 00).
  • Page 278 P / N 572043500 Idler Wheel Assy (2) be ca;ried out and/ or verified by a highly skilled REAR PORTION OF SUSPENSION professional racing mechanic. It is understood that racing or modifications of any Bombardier Additional idler made snowmobile voids the vehicle warranty wheel set...
  • Page 279 Section 06 COMPETITION BULLETINS AND RACING PARTS FRONT PORTION OF SUSPENSION 141 mm idler wheels Additional idler wheel set A024 005032 FRONT SUSPENSION Collapse front suspension until lower and upper AO06 005046 arms are horizontal. Tie suspension to limit travel (reduced to 75 mm (3 in) in that position using Adjust preload of original center spring to the straps on shock bolts.
  • Page 280 Section 06 COMPETITION BULLETINS AND RACING PARTS CHAIN CASE For MX Z 1993 only, replace original top sprocket (24 th) and chain with the following : 23-tooth narrow sprocket (P/ N 5040784 00) 72-link chain (P/ N 4121055 00) DRIVE BELT Use drive belt P / N 414828700.
  • Page 281 It is understood that racing or modifica- tions of any Bombardier made snowmobile voids the vehicle warranty and that such modifications may render use of the vehi- cle illegal in other than sanctioned racing events under existing federal, provincial and state regulations.
  • Page 282 Section 06 COMPETITION BULLETINS AND RACING PARTS DRIVE SYSTEM FRONT PORTION OF SUSPENSION DRIVE PULLEY 141 mm idler wheels FRONT + Replace original spring with a Violet (P/N 417 Additional idler wheel set 2057 20) 254 lb (Comet P / N 207758A). Install four large washers (P/ N 417 2057 08) between spider and sliding half.
  • Page 283 It is u-nderstood REAR PORTION OF SUSPENSION that racing or modifications of any Bombardier made snowmobile voids the vehicle warranty Additional idler and that such modifications may render use of...
  • Page 284 Section 06 COMPETITION BULLETINS AND RACING PARTS FRONT PORTION OF SUSPENSION 141 mm idler wheel A024 005032 FRONT SUSPENSION Collapse front suspension until lower and upper AO06 LW5 046 arms are horizontal. Tie suspension to limit travel (reduced to 75 mm (3 in) in that position using Adjust original center spring to stiffer position.
  • Page 285 Section 06 COMPETITION BULLETINS AND RACING PARTS ENGINE AIR SILENCER Remove foams from both air silencer inlets. CAUTION : Following carburetor calibration is for grass racing at 20°C (68°F). MAIN JET (p/ N 4041004 ()()) NEEDLE JET Y-3 (327) Y-3 (327) Y-3 (327) (P/ N 404149UOO) JET NEEDLE...
  • Page 286 Section 06 COMPETITION BULLETINS AND RACING PARTS SERVICE TOOLS service took) The numbers outlined in black (example : are reference numbers to tools from NOTE : Matching numbers are the same tool other divisions (Sea-Doo and /or Sea-Doo Jet Boats). even if the part numbers are different.
  • Page 287 Section 06 COMPETITION BULLETINS AND RACING PARTS ENGINE (Mandatory service tools) Rotary valve shaft seal Engine leak tester kit Rotary valve seal pusher pusher (coolant pump side) (P/ N 8617491 00) (p/ N 4208766 07) (p/ N 4208770 50) AOOCOY4 APPLICATION .
  • Page 288 Section 06 COMPETITION BULLETINS AND RACING PARTS ENGINE (Mandatory service tools) Rubber pad Rotary valve circlip tool Piston pin puller (p/N 5290291 (P/ N 5290234 00) P / N 5290290 00) 5290208 00) APPLICATION APPLICATION All cageless bearing engines (277 A) 454 and 670 engines.
  • Page 289 Section 06 COMPETITION BULLETINS AND RACING PARTS ENGINE (Optional service tools) The following tools are highly recommended to optimize your basic tool kit and reduce tear down time. 2- Screw M8 x 70 (4) P / N 420841201 1- Crankshaft puller assembly All engines except 247.
  • Page 290 Section COMPETITION BULLETiNS AND RACING PARTS ENGINE (Optional service tools) Piston circlip installer Ring compressor Seal protector sleeve A) (p/N 5290169 00) A)(P/N4208760 90) (p/ N 4209779 10) (62 mm) (P/N 2908770 B) (P/N 4208769 74) (p/ N 4202769 00) (69.5 mm) C) (P/N 4208769 70) (72 mm)
  • Page 291 Section 06 COMPETITION BULLETINS AND RACING PARTS ENGINE (Optional service tools) Magneto holder Crankshaft distance Circuit tester gauge (continuity light) (P/ N 4209765 50) (P/ N 4208768 24) (p/ N 4140122 00) AOOC1V4 APPLICATION APPLICATION 247 engine. All vehicles. AOOC3A4 APPLICATION Crankshaft feeler gauge .
  • Page 292 APPLICATION 467, 582, 583 and 670 engines. APPLICATION 467, 494, 536, 537, 582, 583, Magneto puller 643, 670 and 779 engines. (p/ N 4209762 35) Bombardier magneto tester (P/ N 4190033 00) APPLICATION For pressure testing gauge. AOOC1A4 APPLICATION I G N I T I O N T E S T E R 247 engine.
  • Page 293 Section 06 COMPETITION BULLETINS AND RACING PARTS ENGINE (Optional service tools) Fluke multimeter Base puller plate kit Digital / induction type tachometer (p/ N 5290249 00) (p/ N 5290220 00) (p/ N 5290145 00) APPLICATION APPLICATION 277 engine. All engines. Insertion jig Connecting holder...
  • Page 294 Section 06 COMPETITION BULLETINS AND RACING PARTS ENGINE (Optional service tools) Insertion jig Exhaust spring installer/ ~ Seal pusher (rotary valve) ~ (Magneto seal) remover (p/ N 4208765 10) (P/ N 5290281 00) (p/ N 4208765 14) AOOC3S4 AOOC374 APPLICATION APPLICATION All models.
  • Page 295 Section 06 COMPETITION BULLETINS AND RACING PARTS ENG NE (Optional service tools) Large hose pincher (P/ N 5290304 00) APPLICATION All vehicles. 06-38...
  • Page 296 Clutch holder Forks (3) A) F-Series and S-Series with 503. (p/ N 5290276 00) (p/ N 5290055 00) B) Tundra Il. C) S-Series with Bombardier Lite drive pulley. D) Safari L and Skandic. Spring scale hook A02B034 (p/ N 5290152 00) APPLICATION Bombardier Lite drive pulley.
  • Page 297 Section 06 COMPETITION BULLETINS AND RACING PARTS TRANSMISSION (Mandatory service tools) Spring scale hook Spring compressor / 2) TRA clutch spring cover bush- ing flare tool (p/ N 5290309 00) A) INTERIOR flare tool (f’ / N 5290186 00) (p/ N 5290180 00) Parts included in the kit: EXTERIOR flare tool 1) Spring compressor...
  • Page 298 (P/ N 5290264 02) (p/ N 5290273 00) (p/ N 5290302 00) A01B4M4 APPLICATION AOOA194 Bombardier Lite drive pulley. APPLICATION APPLICATION S-Series and F-Series. Safari L and Skandic. Transmission adjuster . (p/ N 5290285 00) Shock spring remover kit .
  • Page 299 Section 06 COMPETITION BULLETINS AND RACING PARTS TRANSMISSION (Optional service tools) Transmission ball Alignment tool mounting pin remover (p/ N 4204760 10) (P/ N 5290187 00) (p/ N 4204760 20) APPLICATION Alpine II 3-speed transmission. AOOC1D4 APPLICATION Alignment bar Skandic WT and Alpine II gear- box.
  • Page 300 Section 06 COMPETITION BULLETINS AND RACING PARTS TRANSMISSION (Optional service tools) Alignment template Spacer Drive pulley puller (p/ N 5290083 ()()) (p/ N 5290054 00) (p/ N 5290021 ()()) (Standard threads) A03B034 APPLICATION scout. APPLICATION Square shaft, standard A16B044 threads. Driven pulley support APPLICATION extractor...
  • Page 301 Section 06 COMPETITION BULLETINS AND RACING PARTS ‘TRANSMISSION (Optional service tools) Transmission adjuster Drive axle sprocket adjuster (P/ N 5290303 00) (p/ N 8617257 00) A03D1T4 APPLICATION vehicles equipped with “push- pull” reverse transmission. A01B204 APPLICATION All vehicles except Elan. Parts included in the kit : Block with threads (P/ N 5290107 00)
  • Page 302 Section 06 COMPETITION BULLETINS AND RACING PARTS SUSPENSION (Optional service tools) Track cleat installer Camber angle tool A) (p / N 5290085 00) (p/ N 5290216 00) (p/ N 5290082 00) Narrow NOTE : Angle finder with Pins B) (p/N 5290288 00) a magnetic base must be (p/ N 5290082 04) Narrow...
  • Page 303 Section 06 COMPETITION BULLETINS AND RACING PARTS SUSPENSION (Optional service tools) Piston guide Spring installer (bar) Bushing installer / remover (p/ N 5290266 ()()) (p/ N 5290050 00) (p/ N 5290119 00) AOOC114 APPLICATION APPLICATION Tundra II / LT and Scout. MX Z T / A shocks.
  • Page 304 Section 06 COMPETITION BULLETINS AND RACING PARTS SUSPENSION (Optional service tools) Drive axle holder S u s p e n s i o n a d j u s t m e n t . Adjustment wrench wrench (p/ N 5290072 00) (p/ N 8617439 00) (p/ N 5290122 Consists of :...
  • Page 305 RACING PARTS VEHICLES (Optional service tools) Protective mat APPLICATION All vehicles. Snowmobile jack (f’ / N 5290200 (XII , MIAtJJ APPLICATION ‘APPLICATION All models. All models. 06-48...
  • Page 306 Section 06 COMPETITION BULLETINS AND RACING PARTS SERVICE PRODUCTS MANDATORY SERVICE PRODUCTS NOTE : The numbers outlined in black (example : other divisions (Sea-Doo and / or Sea-Doo Jet Boats). Matching numbers are the same tool even if the part numbers are different. Dow Corning”...
  • Page 307 Section COMPETITION BULLETINS AND RACING PARTS MANDATORY SERVICE PRODUCTS G a s k e t / p a i n t r e m o v e r s (p/ N 4137081 ()()) (p/ N 4137085 00) Primer N 510 g (18 170 g (6 AOOB3L4 APPLICATION...
  • Page 308 Section 06 COMPETITION BULLETINS AND RACING PARTS OPTIONAL SERVICE PRODUCTS Silicone dielectric grease ~ Blizzard oil (3 Oz) (12 x 500 mL) (p/ N 4138019 ()()) (P/ N 4137017 00) (p/ N 4138031 00) AOOB1X4 APPLICATION On all electric connections. High tension coil and spark plug con- nections.
  • Page 309 Section 06 COMPETITION BULLETINS AND RACING PARTS OPTIONAL SERVICE PRODUCTS Pipe sealant Anti-seize lubricant Storage oil (350 g spray can) (p/ N 4137023 00) (p/ N 4137010 00) (p/ N 4960141 00) lubricant 454 g (16 OZ) ilmsoA8ntwm Tdlal” ~ APPLICATION Engine plugs and senders.
  • Page 310 Section 06 COMPETITION BULLETINS AND RACING PARTS OPTIONAL SERVICE PRODUCTS Sealant 736 Dow Corning ~ HYLOMAR sealant instant adhesive (100 g) 4137092 00) (P/ N (p/ N413 7083 00) (P/ N 4137071 00) 20 g (.70 Oz) - - - AOOB3F4 APPLICATION AOOB304...
  • Page 311 Super Lube (grease) Shock oil (1 liter) (P/ N 2935500 13) (P/ N413 7094 00) u er e“ A06FOP4 APPLICATION Bombardier Lube AOOB474 (P/ N 2936000 16) APPLICATION Tie rod bushings. A01B4P4 APPLICATION Steering ball joints on all models. 06-54...
  • Page 312 Section COMPETITION PREPARATION Table of Contents LL CLIMBING ....................07-2 07-4 DRAG RACING CE SPEED RUNS .
  • Page 313 These are general guide lines for preparing a stock DSA chassis for various forms of competition. Refer to the appropriate section of the book for more detailed information. HILL CLIMBING Front suspension Use soft springs. You want the skis to compress very easily and not transmit any upward force into the chassis.
  • Page 314 Section COMPETITION PREPARATION Transmission Use a one tooth smaller than stock top sprocket. Good backshifting is important. Use a few pounds more than normal preload on the driven pulley. Driving style Contrary to popular belief, constant full throttle is not always the fastest way to the top. Use your thumb to adjust for the conditions.
  • Page 315 Section COMPETITION PREPARATION GRASS) DRAG RACING (ICE AND Special Rules Snow flap must be retained by chains or 1/8 inch diameter cable. Double limiter straps are required by many organizations. Front suspension Lower the ride height as far as possible but maintain the legal travel requirement of two inches. Shorter springs are available.
  • Page 316 Section COMPETITION PREPARATION Ice : Stud quantity is directly related to horsepower on the ice. Up to about 80 HP, 4to 5 ice picks per pitch should be used for a total of 200-250 studs. 80 to 105 HP should need 6 to 7 picks per pitch for a total of 300-350 studs.
  • Page 317 Section COMPETITION PREPARATION SPEED RUNS Generally, a speed run sled will be set up very similar to an ice drag sled with the following differences. Some organizations do not allow lowering for stock class sleds. Check your rules. Shorter springs may be an option to try. Because holeshots are not important, engagement speed does not have to be set at RPM.
  • Page 318 Section COMPETITION PREPARATION OVAL RACING Special Rules Rear of tunnel must be enclosed per specifications in the I.S.R rulebook. Tail light AND brake light element must be on at all times! Add a jumper wire inside the taillight assembly. Any glass lenses must be taped over with clear tape. Front suspension Lower the ride height to the two inch minimum travel requirement.
  • Page 319 Section COMPETITION PREPARATION Remove non guide clips and install Fill style taller track guides (486 0616 00) on the right side of the track. Traction to an .875 inch stud with a backer plate on the 94-95 stock tracks. Always verify your stud heights! Use a thin profile, sharp tipped stud for hard ice conditions.
  • Page 320 Section 07 COMPETITION PREPARATION Physical conditioning While a well setup sled will be easier to drive than a poor one, it still takes good arm strength to turn a stocker with aggressive carbide. Train your upper body for strength and endurance. A good overall conditioning program that also works your legs and respiratory system is a smart idea.
  • Page 321 Section 07 COMPETITION PREPARATION DUTIES OF THE MECHANIC AND TEAM MANAGER MECHANIC(S) 1. PRE RACE PREPARATION — To ensure that they are familiar with all aspects of the Ski-Doo snowmobile and capable of doing the worst case scenarios, which are track changes and motor repairs.
  • Page 322 Section 07 COMPETITION PREPARATION DUTIES OF THE TEAM MANAGER 1. PRE RACE PREPARATION — The team manager has an important job to do and must pull everyone and everything together in an organized fashion. Time spent in preparation is seldom wasted.
  • Page 323 Section 07 COMPETITION PREPARATION Contact the following circuits for detailed race rules for Cross-Country and Sno-Cross competition; — International Racing Association — 414-335-2401 I s o c — International Series Of Champions —61 2-497-2222 428-8845 — Motorsports Racing Plus — 612-786-7338 —...
  • Page 324 Section 07 COMPETITION PREPARATION 6. HEALTH INSURANCE — Check your personal health insurance plan to see what coverage is in effect while in another country. You may want to supplement your existing policy with temporary Blue Cross or equivalent for the driver and all team members. TEAM PRESS COVERAGE AND SPONSOR RECOGNITION You should make sure that all current and future potential sponsors are looked after in a professional manner.
  • Page 325 Section 07 COMPETITION PREPARATION SWING ARM REINFORCEMENT - When high speed lake racing using full race carbides you may want to add additional strength to the production swingarms. Strap the swingarms as per attached sketch. Note 4130 chrome moly is used in the 1994/96 MX Z swingarm. For extra strength you may want to weld a solid washer over each of the radius rod attachment holes located on the front swingarm and strap the swing arm to the ski spindle tube.
  • Page 326 Section 07 COMPETITION PREPARATION CENTER For more ski pressure and more front end bite, use spring P/N 486066600 (180 lbs/inch, 7.5 inch free length). REAR Adjust the spring preload to get about 1.5 inches of sag from full extension to normal ride height with the driver on board.
  • Page 327 Section COMPETITION PREPARATION Transmission events put a premium on top speed. Snow cross events will require an excellent holeshot and also good back shifting while top speed is not important. Use a spring and ramp combination in the drive clutch to get 5000 RPM engagement.
  • Page 328 Section 07 COMPETITION PREPARATION SUGGESTED SPARE PARTS You should have a self-contained parts supply. The factory parts truck won’t always be there to back you up. TEAM SPARE PARTS : parts book shop manual/specification booklet piston assembly and circlips engine gaskets, seals and o-rings rotary valve disc rewind assembly and components tuned pipe...
  • Page 329 Section 07 COMPETITION PREPARATION SUGGESTED SPARE PARTS ON BOARD SLED Enough tools to perform all maintenance period requirements in the event that your crew is delayed en route to the impound. throttle cable and lever spark plugs drive belts windshield o-rings rear idler wheel and bolt safety wire, tie wraps and duct tape long rubber bungees...
  • Page 330 Section 07 COMPETITION PREPARATION MAINTENANCE CHECK LIST Driver : Mechanic(s) : Problems observed/reported : (Double check with driver) Parts needed for work period/pit area : (Fuel and lubes) Tools/Equipment needed for work period/pit area : cover and jackstand toboggan/cart for tools and parts pieces of carpet to lay on 1 tool set per mechanic 3 flashlights...
  • Page 331 Section 07 COMPETITION PREPARATION Things to “DOO” during work period or between heats : carefully remove ice and snow from inspect track for damage and front and rear suspension missing guide clips inspect suspension components check skis and carbides check/replace studs check ski toe out check camber check drive axle seal...
  • Page 332 Section COMPETITION PREPARATION U.S. Racers compete on ice ovals, three eighths to one mile in length, and travel 150 to 500 miles non stop. The races take approximately two to eight hours depending on the course and conditions. Driving is usually shared by two or more drivers but change is not mandatory and some racers prefer to run the distance unassisted, fuel and maintenance stops give the racers short breaks or time to switch drivers but many times the engines are never stopped during the entire event so the action never stops.
  • Page 333 Section 07 COMPETITION PREPARATION NUTRITION It is recommended that you consult a physician before designing your own nutrition and fitness program. No single food can make you healthy, fit, nor race ready! Eating the right combination of these 25 foods will improve your health and athletic performance;...
  • Page 334 Section 07 COMPETITION PREPARATION PHYSICAL TRAINING Start tomorrow and change the way you “DOO” business! Get into a daily routine that includes balanced nutrition, rest, exercise, riding and vehicle service. You can not change a week before the race and undo bad habits that may have taken many years to perfect! Personal discipline and sacrifice is required before achieving success on the track.
  • Page 335 Section COMPETITION PREPARATION As you start training, quality is more important than quantity therefore do 1 good chinup at a time if that is all you are capable of completing. The next day try 2 and so on until you are up to 8.

This manual is also suitable for:

1996 ski-doo formula iii1996 ski-doo formula sls1996 ski-doo grand touring1996 ski-doo summit 5001996 ski-doo grand touring 5801996 ski-doo formula stx ... Show all

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