Page 2 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 modifications be carried out and/or ver- ified by a highly-skilled professional racing mechanic.
Page 3 • Race Resumes • Race Sleds Allocation • Marketing and Communication • Press Events • Dealer Programs Tom Lawrence Race Coordinator 7575 Bombardier Court Wausau WI. 54401 Phone: 715-848-4971 Fax: 715-847-6879 E-mail: tom.lawrence@recreation.bombardier.com • Technical Support • Race Schools • Race Manual •...
Page 4 CDN RACERS (FRENCH SPEAKING RACERS ONLY) Marcel Imbeault Race Manager 565, de la Montagne Valcourt, QC J0E 2L0 Phone: 450-532-2211 Ext. 5479 Fax: 450-532-6175 E-mail: marcel.imbeault@recreation.bombardier.com • Race Program • Race Resumes • Race Sleds Allocation Hélène Despaties Race Manager Assistant 565, de la Montagne Valcourt, QC J0E 2L0 Phone: 450-532-2211 Ext.
Page 5 Name: City: To receive the T.I.P. sheets by e-mail, send an e-mail to the following: helene.despaties@recreation.bombardier.com and mention to add your address on the tip sheet distribution list ******* To receive the T.I.P. sheets by fax, send a fax to the following: Fax to: Hélène Despaties at (450) 532-6175...
Page 6 SECTION 01 - CONTACTING THE RACE DEPARTMENT 25'(5 )250 9DOFRXUW 5DFH 'HSW '$7( 3DJH RI )D[ 5DFH 'HSW 3DUWV 2UGHU 'HVN ,I \RX DUH D GHDOHU 6+,3 72 QDPH FRPSOHWH DGGUHVV '($/(5 )(' ,' 86 GHDOHU RQO\ ,I \RX DUH D UDFHU 62&,$/ 6(&85,7<...
Page 7: Shipping Conditions
SECTION 01 - CONTACTING THE RACE DEPARTMENT Race Support Truck DATE: Page 1 of____ Fax: 320-251-3733 Phone : 320-251-2882 If you are a dealer: SHIP TO: (name & complete address) Name: Number: Signature: PHONE #: FAX #: PAYMENT: VISA ___ MASTER CARD ___ # __________________________ Exp. Date _______ SHIPPING CONDITIONS: RED: ______ BLUE: _______ GROUND: ______...
Page 8: Table Of Contents
SECTION 02 - 2004 MODELS TECHNICAL DATA TABLE OF CONTENTS ENGINE ............................02-2 MX Z X 440 RACING (CAN./U.S.) ..................... 02-2 MX Z 600 HO /E/R/X/ ADRENALINE/RENEGADE/X (CAN./U.S.) ..........02-2 MX Z 800 HO/E/R/X/ ADRENALINE/RENEGADE/X (CAN./U.S.) ..........02-2 SUMMIT 600 HO/R/ ADRENALINE/X (CAN./U.S.) ..............02-3 SUMMIT 800 HO /R/ HIGHMARK/X/XTREME (CAN./U.S.) .............
Page 9: Engine
SECTION 02 - 2004 MODELS TECHNICAL DATA ENGINE MX Z 600 HO /E/R/X/ MX Z 800 HO/E/R/X/ MX Z X 440 RACING ADRENALINE/ ADRENALINE/ VEHICLE MODEL (CAN./U.S.) RENEGADE/X RENEGADE/X (CAN./U.S.) (CAN./U.S.) ENGINE TYPE Number of Cylinders Bore mm (in) 65.0 (2.56) 72.0 (2.835) 82.0 (32.228) Stroke...
Page 10: Section 02 - 2004 Models Technical Data
SECTION 02 - 2004 MODELS TECHNICAL DATA SUMMIT 600 HO/R/ SUMMIT 800 HO /R/ SUMMIT 800 HO /R/ VEHICLE MODEL ADRENALINE/X HIGHMARK/X/Xtreme SPORT (CAN./U.S.) (CAN./U.S.) (CAN./U.S.) ENGINE TYPE Number of Cylinders Bore mm (in) 72.00 (2.835) 82.0 (3.228) 82.00 (32.228) Stroke mm (in) 73.0 (2.874)
Page 11: Vehicle
SECTION 02 - 2004 MODELS TECHNICAL DATA VEHICLE MX Z 600 HO R/X/ MX Z 600 HO E/R (CAN./ MX Z X 440 RACING VEHICLE MODEL ADRENALINE(CAN./ U.S.) (CAN./U.S.) U.S.) ENGINE TYPE Chain Drive Ratio 21/43 22/43 22/43 Pitch mm (in) 9.525 (.375) 9.525 (.375) 9.525 (.375)
Page 12: Mx Z 800 Ho R/X/ Adrenaline(Can./U.s.))
SECTION 02 - 2004 MODELS TECHNICAL DATA MX Z 600 E/R/ MX Z 800 HO R/X/ MX Z 800 E/R/ VEHICLE MODEL RENEGADE/X ADRENALINE(CAN./ RENEGADE/X (CAN./U.S.) U.S.)) (CAN./U.S.) ENGINE TYPE Chain Drive Ratio 22/43 26/45 23/43 Pitch mm (in) 9.525 (.375) 9.525 (.375) 9.525 (.375) Chain...
Page 13: Summit 600 Ho R/X/ Adrenaline (Can./U.s.)
SECTION 02 - 2004 MODELS TECHNICAL DATA SUMMIT 600 HO R/X/ SUMMIT 800 HO R/X/ SUMMIT 800 HO R VEHICLE MODEL ADRENALINE ADRENALINE HIGHMARK (CAN./U.S.) (CAN./U.S.) (CAN./U.S.) ENGINE TYPE Chain Drive Ratio 19/45 19/45 19/43 Pitch mm (in) 9.525 (.375) 9.525 (.375) 9.525 (.375) Chain...
Page 14: Summit 800 Ho R Highmark Xtreme (Can./U.s.)
SECTION 02 - 2004 MODELS TECHNICAL DATA SUMMIT 800 HO R SUMMIT 800 HO R SUMMIT 800 HO R VEHICLE MODEL HIGHMARK X HIGHMARK Xtreme SPORT (CAN./U.S.) (CAN./U.S.) (CAN./U.S.) ENGINE TYPE Chain Drive Ratio 19/43 19/43 19/43 Pitch mm (in) 9.525 (.375) 9.525 (.375) 9.525 (.375)
Page 15: Engine Legend
➀ The maximum horsepower RPM applicable on ➂ Force or downward pull applied to track to ob- the vehicle. It may be different under certain cir- cumstances and BOMBARDIER INC. reserves tain specified tension deflection. the right to modify it without obligation.
Page 16 SECTION 03 - CHASSIS PREPARATION TABLE OF CONTENTS SUSPENSION OPERATION/ WEIGHT TRANSFER ..............03-2 SPRINGS ............................ 03-3 SPRING DESCRIPTION ......................... 03-8 COIL SPRINGS (compression) ....................03-8 TORSION SPRINGS........................03-9 SPRING APPLICATIONS ....................... 03-10 SPRING SPECIFICATIONS ......................03-12 SHOCKS ............................. 03-17 INTERNAL FLOATING PISTON MEASUREMENT ..............
Page 17: Suspension Operation/ Weight Transfer
SECTION 03 - CHASSIS PREPARATION SUSPENSION OPERATION/ If we keep force “C” constant, we can then vary the size of the vertical and horizontal forces at the WEIGHT TRANSFER front arm by varying angle “A”. As angle “A” is made smaller, force “X” decreases, and force “Z” The purpose of any suspension system is to iso- increases.
Page 18: Springs
SECTION 03 - CHASSIS PREPARATION Contrary to popular belief, it is not necessary to have the skis 2 feet off the ground to achieve good weight transfer. In fact, the energy used to lift the Number front of the vehicle is not available to push the ve- of coils hicle forward.
Page 19: Spring Rate
SECTION 03 - CHASSIS PREPARATION Coil Springs Most springs are designed as a straight rate spring. This means that the spring requires the same The free length of a coil spring is the length with force to compress the last one inch of travel as the no load applied to the spring.
Page 20 SECTION 03 - CHASSIS PREPARATION In terms of your suspension, if a bump is encoun- tered that translates into a force at the spring of 450 pounds, the 100 lbf/in spring will want to com- press 4.5 inches while the 150 lbf/in spring will only compress 3 inches.
Page 21 SECTION 03 - CHASSIS PREPARATION 2" 2" 1" 3" 3" 1" FREE LENGTH STRAIGHT RATE = 100 lbf/in PROGRESSIVE RATE = 100/200 lbf/in A01F1LS An easy way to measure coil springs is to put a bathroom scale in a press with the spring resting on the scale.
Page 22 SECTION 03 - CHASSIS PREPARATION Dual Rate Spring Formula × Spring 1 Spring 2 ------------------------------------------------- - Spring Spring 2 A Dual Rate Spring will assume the rate of the heavier rate spring when the lighter spring bot- toms or coil binds. Example: Spring 1 100# Rate Free opening angle...
Page 23: Spring Description
SECTION 03 - CHASSIS PREPARATION SPRING DESCRIPTION Type T (barrel shape on both ends) COIL SPRINGS (Single Rate Spring) (compression) NOTE: Read color when spring is upright and stripes are down. Type R (straight on both ends) (Single Rate Spring) A06F02A 1.
Page 24: Torsion Springs
SECTION 03 - CHASSIS PREPARATION Type Y Type 4 (barrel shape on both ends with (barrel shape on both ends with positioning tab at the color code coils end) positioning tab at the color code coils end) (Single Rate Spring) (Dual Rate Spring) 1.
Page 25: Spring Applications
SECTION 03 - CHASSIS PREPARATION SPRING APPLICATIONS 2004 FRONT SPRINGS 2004 MODEL (P/N) SOFTER SPRING (P/N) STANDARD (P/N) HARDER SPRING MX Z SPORT 505 070 852 505 071 179 505 070 153 MX Z ADRENALINE Not Applicable 505 070 852 505 070 153 MX Z TRAIL 505 070 758...
Page 26 SECTION 03 - CHASSIS PREPARATION 2004 REAR SPRINGS 2004 MODEL (P/N) SOFTER SPRING (P/N) STANDARD (P/N) HARDER SPRING 503 189 948 LH 503 189 594 LH 503 189 904 LH MX Z SPORT 503 189 592 RH 503 189 902 RH 503 189 947 RH 503 189 904 LH 503 189 629 LH...
Page 27: Spring Specifications
SECTION 03 - CHASSIS PREPARATION SPRING SPECIFICATIONS Coil Springs Specifications-Steel SPRING FREE WIRE COLOR CODE COLOR OF TYPE RATE LENGTH DIAMETER STRIPES SPRING (lb/in) ± 10 (mm) ± 3 (mm) ± .05 486 130 023 8,25 BK/BK/BK/BK YELLOW 486 130 024 9,19 GN/GN/GN/GN YELLOW...
Page 28 SECTION 03 - CHASSIS PREPARATION SPRING FREE WIRE COLOR CODE COLOR OF TYPE RATE LENGTH DIAMETER STRIPES SPRING (lb/in) ± 10 (mm) ± 3 (mm) ± .05 505 070 760 8,25 BL/GD/BK YELLOW 505 070 762 8,71 GN/GD/BK YELLOW 505 070 852 40-85 7,49 RD/GN/RD...
Page 29 SECTION 03 - CHASSIS PREPARATION Torsion Spring Specification-Steel-Round Wire WIRE DIAMETER OPENING ANGLE LENGTH COLOR CODE (MM) + - 7 (MM) 486 071 100 RH 10,3 YL/YL 486 071 200 LH 486 071 300 RH 10,3 WH/WH 486 071 400 LH 486 078 500 RH 10.0 YL/RD...
Page 30 SECTION 03 - CHASSIS PREPARATION WIRE DIAMETER OPENING ANGLE LENGTH COLOR CODE (MM) + - 7 (MM) 503 189 902 RH 10.6 RD/RD/YL 503 189 904 LH 503 189 947 RH 10.3 GN/YL/YL 503 189 948 LH 503 189 992 RH 11.11 GN/RD/YL 503 189 994 LH...
Page 31 SECTION 03 - CHASSIS PREPARATION CORNERING DYNAMICS By having a sway bar in the suspension, softer springs can be used to achieve a good ride be- The ideal situation, while going through a turn, is cause the bar will help control roll in a corner. The to keep the snowmobile as flat as possible without bar has no affect on ride when traveling straight the skis or track losing contact with the driving sur-...
Page 32: Shocks
SECTION 03 - CHASSIS PREPARATION SHOCKS EFFECT OF BLEED SLITS Valving and Dampening bleeds Rebound 2 bleeds In the HPG shock, the piston passages are cov- 4 bleeds ered by a stack of thin metal shims of various 6 bleeds thicknesses and diameters.
Page 33 SECTION 03 - CHASSIS PREPARATION As mentioned earlier, the configuration of the shim stack will control most of the dampening of the shock. There are several methods to tuning shim stacks. The first and most commonly used is to increase or decrease the overall stiffness of the stack.
Page 34: Piston Speed
SECTION 03 - CHASSIS PREPARATION Shim Comparator Formula Thickness³ or cubed. Example: .152 x .152 x .152 COMPRESSION 16 mm diameter 15 mm diameter Dampening 12 mm force diameter PISTON SPEED REBOUND 16 mm diameter 15 mm diameter Dampening 12 mm force diameter The large shims are only able to deflect .203 mm...
Page 35 SECTION 03 - CHASSIS PREPARATION As you can see, low speed dampening remains – Bleed slit quantity will affect low speed damp- the same until the shim stack bottoms out against ening. the valve stopper. Then the dampening becomes – Under dampening may be due to an aerated significantly stiffer.
Page 36 SECTION 03 - CHASSIS PREPARATION 1. Schrader valve 1.5-2 N•m (13-17 lbf•in) 2. Schrader cap 5-6.5 N•m (44-57 lbf•in) NOTE: Before unscrewing pre-load rings, mea- sure the compressed length of the installed spring and mark position for reinstallation. For factory ad- justment refer to the end of this section.
Page 37 SECTION 03 - CHASSIS PREPARATION Holding damper assembly in bench vise with alumi- num jaw protectors, unthread seal assembly from damper body using a 32 mm (1.25 in) spanner wrench. This assembly uses a right hand thread. A27F06A TYPICAL WARNING Whenever using compressed air, use an O.S.H.A.
Page 38 SECTION 03 - CHASSIS PREPARATION Always arrange parts removed in the sequence of disassembly. A06F0WC MAXIMUM DEFLECTION 0.025 mm (.001 in) After the new or replacement shim pack has been selected, reassemble in the reverse order of dis- assembly. Torque piston nut 11-13 N•m (97-115 Ibf•in).
Page 39 SECTION 03 - CHASSIS PREPARATION NOTE: Rebound shim stack must not reach into Compression threads of damper shaft. Washer under damper Whenever tuning for more compression dampen- shaft nut is used to prevent damper shaft nut from ing always use 30 mm (1.18 in) shims against pis- bottoming on threads.
Page 40 SECTION 03 - CHASSIS PREPARATION On all HPG take apart shocks from 1996 on. The floating piston is installed hollow side up. 1. Damper nut torque 11-13 N•m (97-115 lbf•in) use Loctite 271 2. Rebound shim pack 3. Piston 4. Compression shim pack 5.
Page 41 SECTION 03 - CHASSIS PREPARATION Fill the shock with Bombardier HPG shock oil (P/N CAUTION: Use care when passing piston into 413 711 806) to approximately 10 mm (.393 in), damper body at damper body threads. from the base of seal carrier threads.
Page 42 SECTION 03 - CHASSIS PREPARATION Damper gas pressure cannot be confirmed by us- ing a pressure gauge. The volume of gas in the shock is very small, and the amount lost during gauge installation will lower the pressure too much and require refilling. After recharging is complete and before installing the spring the rebuilt shock should be bench-tested.
Page 43: Internal Floating Piston Measurement
SECTION 03 - CHASSIS PREPARATION 2004 MX Z X 440 HPG C-36 Shock INTERNAL FLOATING PISTON Part List MEASUREMENT DESCRIPTION MEASUREMENT SHOCK P/N 505 070 953 Shock ass’y left front 505 070 952 Shock ass’y right front 505 070 903 44.5 503 189 972 Shock ass’y center 505 070 904...
Page 44: 2004 Mx Z X 440 Hpg C-36 Shocks
SECTION 03 - CHASSIS PREPARATION 2004 MX Z X 440 HPG C-36 SHOCKS Low speed compression adjuster The 2004 MX ZX 440 REV will come equipped The low speed adjustment is used to change the with four C-36 HPG shocks. Each shock will be dampening force for relatively slow suspension equipped with high and low speed adjustable movement.
Page 45: Shock Rebuild Procedure
SECTION 03 - CHASSIS PREPARATION SHOCK REBUILD PROCEDURE 5. Push down the remote reservoir cover, remove the retaining clip. 1. Tightly secure the shock base in vise. DO NOT CLAMP ONTO SHOCK BODY. 2. Using a 12 mm wrench, slowly remove air valve, allowing the gas inside the reservoir to escape.
Page 46 13. Fill main shock body with shock oil (P/N 413 711 806) to a level of half full. 14. Fill remote reservoir with Bombardier shock oil to within 6.4 mm (1/4 inch) from the top. 15. Hold the remote reservoir as to have the oil level in it at the same height of the oil level in the shock.
Page 47 Using a small hammer 27. Install the safety screw into the air inlet valve or wrench, gently tap on the shaft mounting and clean your shock with Bombardier Sheave eyelet to help remove air. Cleaner. 03-32...
Page 48: Shock Valving
SECTION 03 - CHASSIS PREPARATION SHOCK VALVING C-36 HPG SHIMS Front Compression 7 x 30 x 0.152 SIZE (mm) (minimum 1 x 19 x 0.152 order quantity) 3 x 30 x 0.203 30 × .254 415 039 100 3 x 13 x 0.114 30 ×...
Page 49 SECTION 03 - CHASSIS PREPARATION C-46 REAR SHOCK SHIMS SIZE (mm) (minimum order quantity) 22 × .114 503 189 011 22 × .152 503 189 012 22 × .203 503 189 013 22 × .254 503 189 014 22 × .305 503 189 015 24 ×...
Page 50: Shock Calibration Work Sheet
SECTION 03 - CHASSIS PREPARATION SHOCK CALIBRATION WORK SHEET MODEL: ___________________________________________________ DATE:______________________________ RIDING CONDITIONS: _____________________________________________________________________________ FRONT CENTER REAR OPTION PISTON SLITS IFP HEIGHT COMPRESSION REBOUND SPRING PRELOAD NOTES: __________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ 03-35 MMC2004-001_03A.FM...
Page 51: Chassis Set-Up
SECTION 03 - CHASSIS PREPARATION CHASSIS SET-UP Now, reinstall the drive shaft. Using a large carpen- ters square, check to see that the drive axle is square (90°) with the tunnel. If not, slot the left end General bearing housing holes and reshim the chaincase Reducing rolling resistance of a snowmobile is to square up the drive axle and the countershaft.
Page 52 SECTION 03 - CHASSIS PREPARATION Shims can be placed between the left side bearing and the end bearing housing to move the axle to the right or between the right side bearing and the chaincase to move the axle to the left. NOTE: If shims are placed between the chaincase and the right side bearing, an equal thickness shim must be placed between the drive chain sprocket...
Page 53: Brakes
SECTION 03 - CHASSIS PREPARATION Finally, adjust the track tension and alignment. For straight line racing, top speed can sometimes Track tension and alignment are most critical to be increased by running the track a bit looser. top speed. Make certain the track is aligned so Ratcheting of the drive sprockets during hard ac- that you have equal clearance between the slider celeration can occur if the track is too loose.
Page 54: Adjusting Ride Height
SECTION 03 - CHASSIS PREPARATION ADJUSTING RIDE HEIGHT The threaded adjusters can be loosened to provide the desired amount of spring preload. A cross-country racer will want all the suspension travel you can for a rough snowcross-type event. Lowering the Rear Suspension But when racing a high speed event on a relatively Option 1: The rear suspension can be lowered by smooth lake, giving up some of the suspension...
Page 55: Track Guides
SECTION 03 - CHASSIS PREPARATION TRACK GUIDES SKIS AND RUNNERS Additional taller track guides (P/N 486 078 200) The skis on your Ski-Doo are not flat on their bot- should be installed when oval racing with a heavily toms, they are slightly convex. This is done to im- studded track.
Page 56: Bump Steer
SECTION 03 - CHASSIS PREPARATION A15F2IA A. 122 mm (5 in) 98 mm (4 in) 147 mm (6 in) 171 mm (7 in) The condition of the skis and runners, as well as their alignment, has an effect on top speed. The ski toe-out must be correct;...
Page 57: Ski Toe-Out
SECTION 03 - CHASSIS PREPARATION SKI TOE-OUT Most oval racers set the left ski leg at 0° camber and the right at - 3° to - 5° camber. Trail riders and Most oval racers use modified handlebars with drag racers should set both ski legs at 0° camber loops or angles on the left end.
Page 58: Chassis Tuning Guidelines
SECTION 03 - CHASSIS PREPARATION CHASSIS TUNING GUIDELINES c. Inside ski lifts. – Reduce the amount of negative camber on How to Deal with Handling Problems the ski legs. There is usually never one adjustment that will cor- – Check for free operation of stabilizer bar. rect a certain handling quirk.
Page 59 SECTION 03 - CHASSIS PREPARATION – Check steering linkages for binding and/or corrosion. – Rubber blocks between skis and ski legs have too much preload at the rear (causing rear of skis to be pushed down too much). – Lengthen limiter strap on center arm. –...
Page 60 SECTION 04 - ENGINE PREPARATION TABLE OF CONTENTS ENGINE TUNING CAUTIONS ....................04-3 BASIC ENGINE THEORY ......................04-3 OPERATION OF THE RAVE VALVE ................... 04-6 CARBURETION .......................... 04-9 MIKUNI VM AND TM TYPE CARBURETORS ................04-13 TM 40 CARBURETORS ......................04-13 IGNITION SYSTEMS, SPARK PLUGS ..................
Page 61 SECTION 04 - ENGINE PREPARATION DENSO TRIGGER COIL IGNITION SYSTEM ................04-56 CLEANING ..........................04-57 DISASSEMBLY ........................... 04-57 ASSEMBLY ..........................04-58 OIL TYPE ............................. 04-60 OIL SYSTEM LEAK TEST......................04-60 OIL PUMP IDENTIFICATION ...................... 04-60 CLEANING ..........................04-60 REMOVAL ........................... 04-60 INSTALLATION ..........................
Page 62: Engine Tuning Cautions
SECTION 04 - ENGINE PREPARATION ENGINE TUNING CAUTIONS BASIC ENGINE THEORY Here are a few items to keep in mind when work- Terminology ing with your engine. CYCLE In a combustion engine, a cycle is If you are in stock classes, know what adjust- accomplished when the four (4) ments are legal.
Page 63 SECTION 04 - ENGINE PREPARATION Combustion Process NORMAL COMBUSTION Since the beginning of this study we have spoken of air/fuel mixture combustion rather than explo- sion. This combustion is a slow then accelerated burning of the mixture within the combustion chamber.
Page 64 SECTION 04 - ENGINE PREPARATION With all operating parameters correct, normal Spark plug heat range too high. combustion will take place. However, if for some Ignition timing too far advanced. reason the temperature inside the cylinder is in- a. Initial timing incorrect. creased during combustion, abnormal combustion b.
Page 65: Operation Of The Rave Valve
SECTION 04 - ENGINE PREPARATION If the squish clearance is increased, a loss in pow- BOMBARDIER-ROTAX has patented a remarkably er will occur while too small a squish clearance will simple system to automatically change the ex- lead to detonation.
Page 66 SECTION 04 - ENGINE PREPARATION Operation If the RAVE valve opens too late, the engine will bog or hesitate momentarily as the RPM increas- The RAVE valve does not allow an engine to make es. Full peak performance (item 6) is still available. higher peak horsepower than an engine not so From a functional point of view.
Page 67: Troubleshooting
SECTION 04 - ENGINE PREPARATION Bench Test for Checking RAVE Valve The movement indicator must be turned all the way in to provide maximum spring pre-load. As Operation you begin pressurizing the engine using engine The operation of the valve can be checked by pres- leak tester kit (P/N 861 749 100), you will find the surizing the engine as one would when checking RAVE valve beginning to move at 5 kPa (0.7 PSI or...
Page 68: Carburetion
SECTION 04 - ENGINE PREPARATION CARBURETION BASE GASKETS P/N 420 931 580 0.3 mm Carburetor Main Jet Correction Chart P/N 420 931 581 0.4 mm CARBURETOR MAIN JET CORRECTION CHART P/N 420 931 583 0.5 mm P/N 420 931 582 0.6 mm P/N 420 931 584 0.8 mm...
Page 69 SECTION 04 - ENGINE PREPARATION Jetting, horsepower, and B.S.F.C. data can be ob- Record the C.R.A.D. when correct jetting has tained with dyno testing but also confirmed with been established. This is the baseline for future field testing. The tried and true method of deter- use.
Page 70 SECTION 04 - ENGINE PREPARATION Most racers use an air density gauge. This gauge SATURATION PRESSURE (CHART 1) is fairly inexpensive. It basically establishes S.P. = SATURATION PRESSURE C.R.A.D. for you by combining the variables on any T = TEMP. (°F) (in-Hg) given day.
Page 71 SECTION 04 - ENGINE PREPARATION Exhaust Gas Temperature Probe Air entering the bell of the carburetor has a speed of V and pressure of P . As the air is forced into Location the smaller diameter of the venturi, speed increas- es (V ) but pressure drops (P Passages in the carburetor connect the venturi to...
Page 72: Mikuni Vm And Tm Type Carburetors
SECTION 04 - ENGINE PREPARATION TM 40 CARBURETORS A01C4BA The TM 40 carburetor “rack” system is used on all liquid cooled engine models except the 2004 1. Jet needle 2. Needle jet MX Z X 440 REV. While they are considerably dif- 3.
Page 73 SECTION 04 - ENGINE PREPARATION The inlet needle, seat and float are of integral con- The Needle Jet is cast into the body of the carbu- struction, and must be replaced as a set. The float retor and not removable. level is not adjustable.
Page 74 SECTION 04 - ENGINE PREPARATION There is no pilot air-screw used, as on VM carbu- The Jet Needle is specifically made for TM style retor. Instead there is a low speed fuel screw on carburetor and are calibrated for each specific en- the engine side of the throttle slide.
Page 75 SECTION 04 - ENGINE PREPARATION The float bowls are now vented to the air box. This gives us a much more precise calibration, espe- cially at higher speeds since the pressure in the float bowl remains the same as the pressure in the carburetors’...
Page 76 SECTION 04 - ENGINE PREPARATION 04-17 MMC2004-001_04A.FM...
Page 77 SECTION 04 - ENGINE PREPARATION Starting Device (enrichner) Selection of the Aperture of Carburetor Instead of a choke, the enrichner system is used One of the prerequisites for improving the output on some Mikuni carburetors. In the starter type, is to use a carburetor with as large an aperture as fuel and air for starting the engine are metered possible.
Page 78: Principles Of Operation
SECTION 04 - ENGINE PREPARATION Carburetor Test NOTE: This procedure may be performed for sin- gle and dual carburetors. Never adjust screws Once the aperture of the carburetor is determined, more than 1/4 turn at a time. a test to select the proper jet should be made. The 1.
Page 79 SECTION 04 - ENGINE PREPARATION b. To determinate the fully closed position of Pilot jets are numbered from no. 15 (the smallest) the air screw, turn the air screw slightly. Ex- to no. 80 (the largest). The number corresponds to cessive tightening of the air screw would fuel flow and not necessarily to drill size or damage the seat.
Page 80 SECTION 04 - ENGINE PREPARATION Jet Needle CHECKING AND SELECTING THROTTLE VALVE PRINCIPLES OF OPERATION Throttle valve opening (%) A01C2WA Throttle valve opening (%) A01C2YA 1. Operate engine at low throttle settings, accel- The jet needle works with the needle jet to in- erating from idle to 1/4 throttle.
Page 81 SECTION 04 - ENGINE PREPARATION LEAN RICH Number stamped here A01C2ZA Example: 6DH7 Basic length of needle. DH - A single letter would indicate a single taper 1. E-ring of the needle, double letter a double taper, 2. Needle jet and three letters mean there is a triple taper.
Page 82 SECTION 04 - ENGINE PREPARATION Needle Jet POSITIONING THE E-RING PRINCIPLES OF OPERATION 1 to 5 = E-ring position 1. 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 The needle jet works in combination with the jet brown or black color indicates a rich mixture.
Page 83 SECTION 04 - ENGINE PREPARATION Main Jet System PRINCIPLES OF OPERATION 1. Jet needle 2. Metered here 3. Fuel 4. Air 5. Needle jet The main jet system starts to function when the throttle is approximately 1/4 open. The mid range fuel is supplied by the main jet and regulated by the needle jet/jet needle combination.
Page 84 SECTION 04 - ENGINE PREPARATION Troubleshooting TUNING THE MAIN JET SYSTEM When the carburetor setting is not correct for the engine, various irregularities are noticed. These can be traced to two causes as a whole: 1. When the air/fuel mixture is too rich: a.
Page 85 SECTION 04 - ENGINE PREPARATION Functional Range Effectiveness in Relation to Throttle Opening THROTTLE VALVE OPENING Full open Closed Pilot jet and pilot air screw Throttle valve Needle jet Jet needle Main jet A01C2TS 04-26 MMC2004-001_04A.FM...
Page 86 SECTION 04 - ENGINE PREPARATION 04-27 MMC2004-001_04A.FM...
Page 87: Ignition Systems, Spark Plugs
SECTION 04 - ENGINE PREPARATION Mikuni TMX Carburetor (tuning parts) IGNITION SYSTEMS, SPARK PLUGS DESCRIPTION Two-stroke engines in snowmobiles rely on an 486 212 400 Pilot Jet, 15 electric spark to initiate combustion of the fuel/air charge which has been inducted into the cylinder. 486 212 500 Pilot Jet, 17.5 For the engine to operate efficiently, the spark...
Page 88 SECTION 04 - ENGINE PREPARATION Spark Plug Heat Range Flame speed is directly proportional to piston speed in an almost linear fashion. Though it is not Spark plug heat ranges are selected by measuring completely understood why this relationship ex- actual combustion chamber temperatures.
Page 89 SECTION 04 - ENGINE PREPARATION Design Symbols Used on NGK Spark Plugs B P 6 E 04-30 MMC2004-001_04A.FM...
Page 90: 593 Ho And 793 Ho Engine Types
SECTION 04 - ENGINE PREPARATION 593 HO AND 793 HO ENGINE TYPES REV Series TYPICAL 04-31 MMC2004-001_04A.FM...
Page 91: Maintenance
SECTION 04 - ENGINE PREPARATION MAINTENANCE NOTE: Replace with new ones any damaged clamps. Refer to appropriate Parts Catalogs to or- der new clamps. REMOVAL FROM VEHICLE Open hood and side panels, refer to BODY. Remove muffler, tuned pipe and exhaust mani- fold.
Page 92: Installation On Vehicle
SECTION 04 - ENGINE PREPARATION INSTALLATION ON VEHICLE To install engine on vehicle, reverse removal pro- cedure. However, pay attention, to all appropriate component/system reinstallation procedures de- scribed throughout this Shop Manual and to the following: – After throttle cable installation, check carbure- tor maximum throttle opening and oil injection pump adjustment.
Page 93: Top End
SECTION 04 - ENGINE PREPARATION TOP END 793 engine 04-34 MMC2004-001_04A.FM...
Page 94: Troubleshooting
SECTION 04 - ENGINE PREPARATION TROUBLESHOOTING Unscrew valve piston no. 9. Remove bellows no. 11 and spring no. 12. Before completely disassembling the engine, Remove cylindrical screws. Remove valve hous- check airtightness. Refer to LEAK TEST AND EN- ing no. 13. GINE DIMENSION MEASUREMENT.
Page 95 SECTION 04 - ENGINE PREPARATION All engines are equipped with cageless piston pin Install sleeve then shouldered sleeve over puller bearings. rod. A02C2BA Use piston pin puller (P/N 529 035 503) along with TYPICAL — INSTALLATION OF SLEEVE KIT 20 mm sleeve kit (P/N 529 035 542). Use also a 1.
Page 96: Inspection
SECTION 04 - ENGINE PREPARATION TYPICAL A02C2DA 1. Locating sleeve 2. Sleeve TYPICAL 1. Sleeve inside bearing INSPECTION 2. Thrust washer 3. Shouldered sleeve end NOTE: Refer to LEAK TEST AND ENGINE DIMEN- Remove puller. Pull out shouldered sleeve carefully. SIONS MEASUREMENT.
Page 97: Assembly
SECTION 04 - ENGINE PREPARATION 11, Bellows Check for cracked, dried or perforated bellows. 8, Spring PRELOAD IN WIRE FREE N (LBF) AT ENGINE SPRING COLOR DIA. LENGTH COMPRESSED TYPE mm (in) mm (in) LENGTH OF 14 mm (.551 in) 593 HO 420 239 944 Brown 0.9 (.035) 48.5 (1.91) 15.9 (3.56) 793 HO 420 239 940 Yellow 0.8 (.031) 48.5 (1.91)
Page 98: Engine Type
SECTION 04 - ENGINE PREPARATION At assembly, place the pistons over the connecting All Models rods with the letters “AUS” (over an arrow on the CAUTION: Always install new circlips. piston dome) facing towards the exhaust port. To minimize the effect of acceleration forces on circlip, install each circlip so the circlip break is at 6 o’clock as illustrated.
Page 99 SECTION 04 - ENGINE PREPARATION With the other end of the pusher, push circlip into the Using a plastic hammer, tap pusher to put circlip support groove. in place. Make sure to install new circlips with tab toward top as per following photo. TAB TOWARD TOP 1.
Page 100 SECTION 04 - ENGINE PREPARATION 17, Reed Valve NOTE: Carefully clean screws before reinstallation, specifically under screw head. All Engines Install exhaust manifold with gaskets. Do not tight- Blades have a curved shape. Install with their en yet. curve facing reed block. Torque cylinder screws in a crisscross sequence With blade stopper no.
Page 101: Bottom End
SECTION 04 - ENGINE PREPARATION BOTTOM END 04-42 MMC2004-001_04A.FM...
Page 102: Cleaning
SECTION 04 - ENGINE PREPARATION ASSEMBLY NOTE: Engine must be removed from chassis to perform the following procedures. Coat lip of all seals with Petamo grease (P/N 420 899 271). CLEANING 2, Crankshaft Bearing Discard all oil seals, gaskets, O-rings and sealing rings.
Page 103 SECTION 04 - ENGINE PREPARATION With the syringe, fill the outer ball bearing and inner At crankshaft installation, position drive pins as il- side of outer seal with 40 to 45 mL of Isoflex lustrated. grease. TYPICAL 1. Position pins Pour 50 mL (2 U.S.
Page 104: Break-In
SECTION 04 - ENGINE PREPARATION Spread a seam of 1.2 mm (1/16 in) maximum in diameter on surface of lower crankcase half. As far as possible, sealing compound must be ap- plied in one run to avoid any risks of leakage through the crankcase.
Page 105: Preparation
SECTION 04 - ENGINE PREPARATION LEAK TEST AND ENGINE DIMENSION MEASUREMENT The following gives verification procedures for 593 HO and 793 types of engines. PREPARATION 1. Remove tuned pipe. 2. Install plug over exhaust manifold. 3. Remove carburetors. 4. Insert plugs in intake rubber boots. Tighten with existing clamps.
Page 106 SECTION 04 - ENGINE PREPARATION Engine Pump Shaft Oil Gear Reservoir Check the following: Install air pump on adapter and pressurize as above. 1. All jointed surfaces and screw/stud threads of engine: – spark plug base, insulator – cylinder head –...
Page 107: Finalizing Reassembly
SECTION 04 - ENGINE PREPARATION 1. Check weep hole below coolant pump housing with soapy water. 1. Weep hole If there is a leak, it indicates that a pump shaft is defective (oil seal beside coolant ceramic seal). 2. Leaks can be also on oil pump side. Check mount- ing area for leaks.
Page 108: Engine Leak Verification Flow Chart
SECTION 04 - ENGINE PREPARATION ENGINE LEAK VERIFICATION FLOW CHART ENGINE LEAK VERIFICATION FLOW CHART PRESSURIZE ENGINE IS ENGINE LEAKING? CHECK ALL JOINTED SURFACES, SCREW/STUD THREADS. MOUNTING FLANGES ETC. REPLACE GASKET OR O-RING, ANY LEAK FOUND? RE-SEAL LEAKING AREA CHECK SMALL OIL LINES OF INJECTION PUMP AIR BUBBLES FOUND REPLACE INJECTION NIPPLE(S)
Page 109: Engine Dimension Measurement
SECTION 04 - ENGINE PREPARATION ENGINE DIMENSION CYLINDER OUT OF ROUND MEASUREMENT ENGINE TYPE MAXIMUM This section covers all engine types. 0.08 mm (.003 in) CYLINDER HEAD WARPAGE Measuring 16 mm (5/8 in) from top of cylinder with a cylinder gauge, check if the cylinder out of round ENGINE TYPE MAXIMUM is more than the specified dimension.
Page 110: Combustion Chamber Volume Measurement
SECTION 04 - ENGINE PREPARATION COMBUSTION CHAMBER VOLUME MEASUREMENT The combustion chamber volume is the region in the cylinder head above the piston at Top Dead Center. It is measured with the cylinder head in- stalled on the engine. 1. Combustion chamber 1.
Page 111: Used Piston Measurement
SECTION 04 - ENGINE PREPARATION 10. Repeat the procedure for the other cylinder. Using a micrometer, measure piston skirt at 15 mm (.590 in) perpendicularly (90°) to piston pin. COMBUSTION CHAMBER VOLUME ENGINE (cc) TYPE (up to top thread of spark plug hole) 593 HO 28.65 ±1.2 793 HO...
Page 112 SECTION 04 - ENGINE PREPARATION Adjust and lock a micrometer to the specified val- IMPORTANT: Always remove cylinders from crank- ue on the piston dome. case before measuring. Position the dial bore gauge at 16 mm (5/8 in) be- low cylinder top edge. 1.
Page 113: Ring/Piston Groove Clearance
SECTION 04 - ENGINE PREPARATION RING/PISTON GROOVE CRANKSHAFT DEFLECTION CLEARANCE Crankshaft deflection is measured with a dial indi- cator. Using a feeler gauge check clearance between rectangular ring and groove. Replace piston if clear- Measuring (in crankcase) ance exceeds specified tolerance. Refer to TECH- NICAL DATA.
Page 114: Connecting Rod Big End Axial Play
SECTION 04 - ENGINE PREPARATION Crankshaft Deflection in Center of CRANKSHAFT END-PLAY Crankshaft All Engine Types MAXIMUM IN CENTER OF End-play is not adjustable but it should be between ENGINE CRANKSHAFT 0.10 - 0.30 mm (.004 - .012 in). TYPE mm (in) CHECKING CRANKSHAFT 0.08 (.0031)
Page 115: Denso Trigger Coil Ignition System
SECTION 04 - ENGINE PREPARATION CDI SYSTEM DENSO TRIGGER COIL IGNITION SYSTEM 360 W on REV Series models 04-56 MMC2004-001_04A.FM...
Page 116: Cleaning
SECTION 04 - ENGINE PREPARATION NOTE: The following procedures can be done without removing the engine. CDI means Capacitor Discharge Ignition System. CLEANING Clean all metal components in a non-ferrous metal cleaner. CAUTION: Clean stator and magneto using only a clean cloth. DISASSEMBLY 3, Magneto Flywheel To gain access to magneto assembly, remove the...
Page 117: Assembly
SECTION 04 - ENGINE PREPARATION 5, Trigger Coil 3, Magneto Flywheel Magneto and stator no. 6 must be removed be- Clean crankshaft extension (taper) and apply Loc- fore removing the trigger coil. tite 243 (blue) on taper, then position Woodruff key, flywheel and lock washer on crankshaft.
Page 118: Oil Injection System
SECTION 04 - ENGINE PREPARATION OIL INJECTION SYSTEM 04-59 MMC2004-001_04A.FM...
Page 119: Oil Type
SECTION 04 - ENGINE PREPARATION Connect leak testing kit pump to special cap. WARNING Pressurize oil system to 21 kPa (3 PSI). That pres- Wipe off any oil spills. Oil is highly flammable. sure must not drop during 3 minutes. If pressure drops, locate leak(s) and repair/replace OIL TYPE leaking component(s).
Page 120: Adjustment
SECTION 04 - ENGINE PREPARATION 3, Screw NOTE: Prior to coating it with Loctite, make sure check valve body is clean and dry. Clean from dirt Torque to 5 N•m (44 lbf•in). or oil, if any, with Pulley flange cleaner (P/N 413 Cable plastic elbow must be fastened and fully in- 711 809).
Page 121: Checking Operation
SECTION 04 - ENGINE PREPARATION The visible stretched distance of the cable should Check that oil in small oil lines has been sucked up be 18.0 ± 0.3 mm (0.708 ± 0.012 in). (this will be indicated by a clear section of small oil lines).
Page 122: Liquid Cooling System
SECTION 04 - ENGINE PREPARATION LIQUID COOLING SYSTEM 04-63 MMC2004-001_04A.FM...
Page 123: Cooling System Leak Test
SECTION 04 - ENGINE PREPARATION COOLING SYSTEM LEAK TEST DISASSEMBLY AND ASSEMBLY Install special radiator cap (P/N 529 021 400) in- 3,4, Sender and Plug cluded in engine leak tester kit (P/N 861 749 100) Apply Loctite 592 (P/N 413 702 300) thread sealant on coolant tank.
Page 124: Cooling System Refilling Procedure
SECTION 04 - ENGINE PREPARATION Refilling Procedure b. When the liquid is warmed enough, the thermo- stat opens progressively the circuit, water pump IMPORTANT: USE THE 50/50 PREMIXED COOL- — engine — radiators — coolant tank to keep ANT - 37°C (- 35°F) (P/N 293 600 038). the liquid at the desired temperature.
Page 125 SECTION 04 - ENGINE PREPARATION Lower vehicle back on ground and add coolant up to 15 mm (1/2 in) above the COLD LEVEL line. 1. Cold level line A. 15 mm (1/2 in) Lift front of vehicle of 60 cm (24 in) and support it safely.
Page 126: Rewind Starter
SECTION 04 - ENGINE PREPARATION REWIND STARTER Plastic Rewind Starter on REV Series Models 04-67 MMC2004-001_04A.FM...
Page 127: Inspection
SECTION 04 - ENGINE PREPARATION INSPECTION NOTE: Due to dust accumulation, rewind starter must be periodically cleaned, inspected and relu- bricated. CAUTION: It is of the utmost importance that the rewind starter spring be lubricated period- ically using Molykote PG 54 (P/N 420 899 763). Otherwise, rewind starter component life will be shortened and/or rewind starter will not op- erate properly under very cold temperatures.
Page 128: Assembly
SECTION 04 - ENGINE PREPARATION ASSEMBLY At assembly, position spring no. 4 outer end into spring guide notch then wind the spring counter- clockwise into guide. WARNING Since the spring is tightly wound inside the guide it may fly out when rewind is handled. Always handle with care.
Page 129 SECTION 04 - ENGINE PREPARATION To install rope no. 6, insert rope into sheave no. 5 To adjust rope tension: orifice and lock it by making a knot, leaving behind Wind rope on sheave and place rope sheave into a free portion of about 25 mm in length. Fuse rope starter housing making sure that the sheave hub end with a lit match and insert it into sheave.
Page 130: Installation
SECTION 04 - ENGINE PREPARATION INSTALLATION Lubricate pawl lock no. 9 with Molykote PG 54 (P/N 420 899 763). Install over pawl. Fuse rope end with a lit match. Thread starter rope no. 6 through rope guide when applicable. A03C0VA TYPICAL Reinstall rewind starter assembly on engine.
Page 131 SECTION 05 - DRIVE SYSTEM TABLE OF CONTENTS BASIC FUNCTIONS OF THE SYSTEM ..................05-3 EFFECTS OF THE DRIVE PULLEY LEVER ARM, ROLLER AND ROLLER PIN WEIGHT ..05-4 EFFECTS OF THE RAMP PROFILE ON THE SHIFT FORCE ............. 05-7 RAMP CHARACTERISTICS .......................
Page 132 SECTION 05 - DRIVE SYSTEM INSTALLATION .......................... 05-47 TROUBLESHOOTING ......................... 05-47 GENERAL............................ 05-51 GENERAL PROCEDURE......................05-51 PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART ......... 05-52 APPLICATION CHART ........................05-55 DRIVE BELTS ..........................05-55 INSPECTION ..........................05-55 CHECKING NEUTRAL FUNCTION .................... 05-55 ROTATION DIRECTION ......................
Page 133: Basic Functions Of The System
SECTION 05 - DRIVE SYSTEM BASIC FUNCTIONS OF THE In the speed diagram, the inclined line labelled low ratio indicates the vehicle speed at each RPM SYSTEM when locked into the 3.8:1, low gear ratio. At 8000 RPM, the vehicle speed would be just under 20 The TRA Clutch MPH if held in this ratio.
Page 134: Effects Of The Drive Pulley Lever Arm, Roller And Roller Pin Weight
SECTION 05 - DRIVE SYSTEM EFFECTS OF THE DRIVE PULLEY POWER CURVES MILDLY TUNED VS. RACE TUNED LEVER ARM, ROLLER AND ROLLER PIN WEIGHT As you have seen in the formula defining centrifu- gal force, the force increases directly with the weight of the components involved.
Page 135 SECTION 05 - DRIVE SYSTEM Curve A shows a clutch set up with three 10-gram type roller pins. This amount of weight will govern the engine to 7200 RPM and allow engagement of the clutch at 4000 RPM. Curve B illustrates the effect of exchanging the three 10-gram pins for three 14-gram roller pins.
Page 136 SECTION 05 - DRIVE 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 A: 10 gram roller pins B: 14 gram roller pins C: 16 gram roller pins A01D0XS 05-6 MMC2004-001_05A.FM...
Page 137: Effects Of The Ramp Profile On The Shift Force
SECTION 05 - DRIVE SYSTEM The weight of the lever arms will have a similar Remember, it is the angle of the ramp at the point effect on the shift RPM. of roller contact that will help determine the shift force at any given ratio.
Page 138 SECTION 05 - DRIVE 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.
Page 139: Ramp Characteristics
SECTION 05 - DRIVE SYSTEM RAMP CHARACTERISTICS Taller ramp = Higher engagement RPM Steeper angle = Higher shift RPM Shallower angle = More RPM at lower MPH (slower shift) A01D2IS 05-9 MMC2004-001_05A.FM...
Page 140: Effects Of The Drive Pulley Spring
SECTION 05 - DRIVE SYSTEM EFFECTS OF THE DRIVE PULLEY As you look through the spring chart, you will see that springs are available with equal pressures at SPRING 74 mm (2.9 in), but very different pressures at 41 mm (1.6 in). You will also note varying pres- The purpose of the clutch release spring is to re- sures at 74 mm (2.9 in) and equal pressures at turn the sliding half of the engine pulley and the...
Page 141 SECTION 05 - DRIVE SYSTEM Drive Clutch Spring Effect at Engagement 10,000 9,000 8,000 7,000 6,000 5,000 4,000 3,000 2,000 1,000 A01D1US LOAD AT LOAD AT 74 mm (2.9 in) 41 mm (1.6 in) 311 N (70 lb) 1157 N (260 lb) 712 N (160 lb) 1201 N (270 lb) 05-11...
Page 142 SECTION 05 - DRIVE SYSTEM Drive Clutch Spring Effect at Top Speed 10,000 9,000 8,000 7,000 6,000 5,000 4,000 3,000 2,000 1,000 A01D1VS LOAD AT LOAD AT 74 mm (2.9 in) 41 mm (1.6 in) 311 N (70 lb) 756 N (170 lb) 311 N (70 lb) 1157 N (260 lb) 05-12...
Page 143: Vsa
SECTION 05 - DRIVE SYSTEM TRA III Some 2004 models come equipped with a TRA III style drive clutch. They include most models with the 600 and 800 cc engines. This style of clutch is the “next” generation of engineering develop- ment from Ski-Doo and will certainly be used in more models as years go on.
Page 144: Drive Pulley
SECTION 05 - DRIVE SYSTEM DRIVE PULLEY TRA III All REV Series Models NOTE: This is a lubrication free drive pulley. Always refer to appropriate parts catalog for replacement part. Most parts of TRA III are not interchangeable with those of the TRA. Electric start models only 593 HO only...
Page 145: General
1,2, Screw and Ring Gear Any drive pulley repairs must be performed by CAUTION: Retaining screws must be heated be- an authorized Bombardier snowmobile dealer. fore disassembly. Do not exceed 150°C (300°F). Sub-component installation and assembly tol- erances require strict adherence to procedures 5,6, Fixed and Sliding Half detailed.
Page 146 SECTION 05 - DRIVE SYSTEM 32, Cushion Drive Use spring compressor (P/N 529 035 524). Install support guide. CAUTION: Do not disassemble cushion drive. Governor cup and cushion drive are factory bal- anced as an assembly. 25,29, Slider Shoe and Governor Cup Carefully lift governor cup until slider shoes come at their highest position into guides.
Page 147: Cleaning
SECTION 05 - DRIVE SYSTEM CLEANING 9,12, Fitting Bolt Ass’y and Flanged Bushing 5,6, Fixed and Sliding Half Check for wear, replace as required. Clean pulley faces and shaft with fine steel wool 24,25, O-Ring and Slider Shoe and dry cloth. Check if O-rings are cracked, cut or crushed.
Page 148 SECTION 05 - DRIVE SYSTEM 26,27,28, Calibration Screw, Washer Position dowel tube split at the angle A. and Locking Nut When installing calibration screw, make sure to in- stall washer as shown. MODEL ANGLE (A) A16D07A With TRA III 45 ± 3° 1.
Page 149 SECTION 05 - DRIVE SYSTEM 593 HO Engine Equipped Models Only Always install lever assemblies so that cotter pins are on the shown side. Besides install cotter pin head on top when lever is sat at bottom of sliding half. Bend cotter pin ends to sit perfectly against lever.
Page 150 SECTION 05 - DRIVE SYSTEM 6,25,29, Sliding Half, Slider Shoe and 793 Engine Equipped Models Only Governor Cup To install governor cup, use following tool: Insert spring and slider shoes into governor cup so that groove in each slider shoe is vertical to prop- erly slide in guides.
Page 151: Installation
Install a new conical spring washer with its con- cave side towards drive pulley then install screw. WARNING Never substitute conical spring washer and/or screw with jobber ones. Always use Bombardier genuine parts for this particular case. 05-21 MMC2004-001_05A.FM...
Page 152 SECTION 05 - DRIVE SYSTEM 26,28,29, Calibration Screw, Locking Example: Nut and Governor Cup Calibration screw is set at position 3 and is changed to position 5. So maximum engine RPM is increased Calibration screw has a notch on top of its head. by about 400 RPM.
Page 153: Kit P/N 486 400 003 Tra Iii Weight Set-Up For Pin
SECTION 05 - DRIVE SYSTEM KIT P/N 486 400 003 TRA III WEIGHT SET-UP FOR PIN From 12.4 to 22.15 grams 16.21 GRAMS SET-UP PART PART WEIGHT PART PART WEIGHT DESCRIPTION NUMBER DESCRIPTION NUMBER Pin 35.75 mm 417 222 595 12.4 Pin 35.75 mm 417 222 595...
Page 154 SECTION 05 - DRIVE SYSTEM 15.42 GRAMS SET-UP 16.94 GRAMS SET-UP PART PART WEIGHT PART PART WEIGHT DESCRIPTION NUMBER DESCRIPTION NUMBER Pin 35.75 mm 417 222 595 12.4 Pin 35.75 mm 417 222 595 12.4 Set screw 20 mm 206 262 099 3.02 Set screw 25 mm 206 262 599 3.81...
Page 155 SECTION 05 - DRIVE SYSTEM 22.15 GRAMS SET-UP 19.85 GRAMS SET-UP PART PART WEIGHT PART PART WEIGH DESCRIPTION NUMBER DESCRIPTION NUMBER T (G) Pin 35.75 mm 417 222 595 12.4 Pin 35.75 mm 417 222 595 12.4 Set screw 6 mm 206 260 699 0.73 Set screw 6 mm 206 260 699...
Page 156 SECTION 05 - DRIVE SYSTEM TRA III RAMP PROFILES 05-26 MMC2004-001_05A.FM...
Page 157 SECTION 05 - DRIVE SYSTEM 05-27 MMC2004-001_05A.FM...
Page 158: Tra Springs Chart
SECTION 05 - DRIVE SYSTEM TRA SPRINGS CHART FORCE @ WIRE DIA. FREE LENGTH POUNDS ± 5% COLOR CODE 74 mm - 41 mm BOMBARDIER 2.9 in - 1.6 in 5.26 0.207 70 - 170 414 689 800 RED - RED 5.00 0.197...
Page 159 SECTION 05 - DRIVE SYSTEM FORCE @ WIRE DIA. FREE LENGTH POUNDS ± 5% COLOR CODE 74 mm - 41 mm BOMBARDIER 2.9 in - 1.6 in 5.72 0.225 160 - 320 414 817 900 PURPLE - PURPLE 5.94 0.234 5.94...
Page 160: Effects Of The Driven Pulley Spring
SECTION 05 - DRIVE 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 161: Hpv 27 Vsa Clutch Springs
SECTION 05 - DRIVE SYSTEM • Next add the two readings together and di- FORMULA DRIVEN CLUTCH PRELOAD vide by two. This is the number we use as our reference. WHITE SPRING/LBS • Recording only the pull reading and this will POSITION definitely allow the driven pulley tension to be too low.
Page 162: Effects Of The Driven Pulley Cam
SECTION 05 - DRIVE SYSTEM EFFECTS OF THE DRIVEN PULLEY Multi-angle cams are sometimes used by racers needing a good holeshot. They generally work best on vehicles where no track spin is encoun- tered. As a vehicle idles on the starting line, the The purpose of the driven pulley cam is to sense exhaust temperature cools thus slightly lowering the torque requirements of the drive axle and feed...
Page 163: Driven Clutch Cams
SECTION 05 - DRIVE SYSTEM DRIVEN CLUTCH CAMS FORMULA - STD FORMULA RER & VSA HPV 27 & VSA PART PART PART NUMBER ANGLE TYPE ANGLE TYPE ANGLE NUMBER NUMBER 860 424 800 417 126 715 44 Alu. 417 126 445 44 Anod.
Page 164 SECTION 05 - DRIVE SYSTEM FORMULA - STD FORMULA RER & VSA HPV 27 & VSA PART PART PART NUMBER ANGLE TYPE ANGLE TYPE ANGLE NUMBER NUMBER 860 425 900 44-40 860 425 800 44-37 860 425 600 42-37 860 425 500 40-44 860 425 400 40-37...
Page 165: Driven Pulley
SECTION 05 - DRIVE SYSTEM DRIVEN PULLEY FORMULA VSA 05-35 MMC2004-001_05A.FM...
Page 166: Removal
SECTION 05 - DRIVE SYSTEM REMOVAL DISASSEMBLY Remove guard and drive belt from vehicle. Use spring compressor (P/N 529 018 600). Remove cap screw no. 12 and shouldered washer no. 11 then pull the driven pulley from the coun- tershaft. Note shouldered washer position for reinstallation.
Page 167: Inspection
SECTION 05 - DRIVE SYSTEM INSPECTION ASSEMBLY 9,10, Bushings 6, Cam Slider Shoe Check for cracks, scratch and for free movement When replacing slider shoes, always install a new when assembled to fixed half. set (3 shoes) to maintain equal pressure on the cam. Using a dial bore gauge measure bushing diame- Assemble driven pulley components by reversing ter.
Page 168 SECTION 05 - DRIVE SYSTEM Take 1 measurement when sliding half begins to turn. Rotate sliding half to 10 mm (3/8 in) of rotation. Hold spring scale at this position. Slowly release ten- sion from spring scale and take 2 measurement when sliding half begins to return.
Page 169: Hpv27 Vsa
SECTION 05 - DRIVE SYSTEM HPV27 VSA 05-39 MMC2004-001_05A.FM...
Page 170: Removal
SECTION 05 - DRIVE SYSTEM REMOVAL Remove half keys no. 6 and washer no. 7 to dis- assemble the cam and the 2 pulley halves. Remove guard and drive belt from vehicle. WARNING Remove cap screw no. 1 and shouldered washer no.
Page 171: Assembly
SECTION 05 - DRIVE SYSTEM ASSEMBLY Driven pulley end-play is 0 (zero). 1, Pulley Retaining Screw 10, Cam Slider Shoe Torque to 22 N•m (16 lbf•ft). When replacing slider shoes, always install a new set (3 shoes) to maintain equal pressure on the cam. ADJUSTMENT Install slider shoes as per following photo.
Page 172 SECTION 05 - DRIVE SYSTEM TEAM PERFORMANCE DRIVEN CLUTCH (All TEAM Performance Clutch Parts must be ordered from the Valcourt Race Dept. or Ski Doo Parts Support Truck) ITEM NO. PART NUMBER QUANTITY DESCRIPTION SERVICEABLE 130032 Ring, Retaining Basic Ext. 1.500 285275 Spider, 38T 10.75 Mach.
Page 173 SECTION 05 - DRIVE SYSTEM The two pictures shown below are showing how the helix angles are called out and how they are mea- sured. The first picture shown is a full progressive stamped as "F" on a helix (example 54-40- F). The second picture refers to a partial or .46 as most of our helix’s are called out (example 58-44.46.
Page 174: Springs
SECTION 05 - DRIVE SYSTEM SPRINGS Relationship Between Drive Clutch Ramps, Weight, And Spring In The springs used in the TEAM Performance Driv- Maintaining Operating RPM en Clutch are measured differently because of the The drive clutch is a RPM sensing unit designed use of a compression spring instead of a torsion to transfer the maximum amount of horsepower spring.
Page 175: Belt Removal On Team Roller Secondary
SECTION 05 - DRIVE SYSTEM 3. Tighten the jam nut after the belt adjustment Too Much Belt Deflection has been made. See arrow. If the belt is too long or the center distance is too short, the initial starting ratio will be too high, re- sulting in performance loss.
Page 176: Team Secondary Clutch Maintenance/Adjustment
SECTION 05 - DRIVE SYSTEM 1. Measure belt deflection with both clutches at 2. Once you have tension on the spider assembly, rest and in their full neutral position. remove the snap ring. 2. Place a straight edge on the belt and apply 3.
Page 177: Installation
SECTION 05 - DRIVE SYSTEM INSTALLATION 3. Helix angle selection. Starting angle will effect how fast the clutch opens from a dead stop. Ex. 1. Install proper number of spacer washers on (70-44.46, a 70° starting angle will shift ex- jackshaft between clutch and jackshaft bearing.
Page 178 SECTION 05 - DRIVE SYSTEM 7. When inspecting the rest of the clutching components the primary clutch should be checked for four things: • "Worn out rollers and bushings • "Flat spots on ramps • "Worn out buttons in the clutch towers •...
Page 179 SECTION 05 - DRIVE SYSTEM TEAM PERFORMANCE DRIVEN CLUTCH PARTS (All TEAM Performance Clutch Parts must be ordered from the Valcourt Race Dept. or the Ski Doo Parts Support Truck) HELIX SPRINGS PART NUMBER TWIN TRAX ANGLE PART NUMBER RATE LBS 420427 62-44-46-E 210035...
Page 180 SECTION 05 - DRIVE SYSTEM HELIX HELIX PART NUMBER TWIN TRAX ANGLE PART NUMBER TWIN TRAX ANGLE 420514 54-40-46 54-38-46 420563 40 STRT 44 STRT 420515 58-40-46 58-38-46 420564 42 STRT 46 STRT 420516 54-44-46 54-42-46 420565 44 STRT 48 STRT 420517 58-44-46 58-42-46 420566...
Page 181: Pulley Distance And Alignment
SECTION 05 - DRIVE SYSTEM PULLEY DISTANCE AND ALIGNMENT GENERAL Untighten torque rod using a long hexagonal key. Both pulley distance and pulley alignment must be checked out to ensure the highest efficiency of the transmission system. Furthermore, optimum drive belt operation and minimal wear will be ob- tained only with proper pulley alignment.
Page 182: Pulley Alignment And Distance Specifications Chart
SECTION 05 - DRIVE SYSTEM Measuring Procedure The distance Y must exceed distance X to com- pensate for the twist due to the engine torque. Using Straight Bar Always measure distances X and Y from the far- Drive Belt Deflection ther straight bar side (including its thickness to the NOTE: When pulley distance and alignment are fixed half edge).
Page 183: Drive Belts
Pulley Alignment Method with today’s high output sleds. Remove pulley and add or remove spacer(s) as re- Use only the specific Bombardier drive belt listed quired to obtain the specified alignment. for your application. The drive belt is a calibrated part of the transmission system.
Page 184 SECTION 05 - DRIVE SYSTEM Always break in a new belt by running it easy for 10-15 miles. Vary the vehicle speed and throttle setting without going over 2/3 throttle. It is also a good idea to mark the direction of rotation on the belt.
Page 185: Drive Belt
SECTION 05 - DRIVE SYSTEM DRIVE BELT APPLICATION CHART MINIMUM WIDTH (wear limit) MODEL PART NUMBER mm (in) 2004 440 REV 417 300 253 34.70 (1.366) All 593 HO engine equipped models 417 300 197 33.35 (1.313) All 793 HO engine equipped models 417 300 166 34.70 (1.366) Drag Race Belt...
Page 186: Drive Belt Height Measurement And Adjustment
SECTION 05 - DRIVE SYSTEM 1. Flush Adjustment INCORRECT NOTE: For used drive belt, mark and reinstall in the Before adjusting the belt height, ensure that a same position. good-condition proper belt (refer to the Application Chart) is installed. DRIVE BELT HEIGHT Adjust pulley distance according to specification, MEASUREMENT AND refer to PULLEY DISTANCE AND ALIGNMENT.
Page 187 SECTION 05 - DRIVE SYSTEM Models Equipped with HPV27 VSA Type Driven Pulley A06D20A TYPICAL 1. Allen screws with jam nuts Allen screws must be restrained while tightening jam nut to prevent throwing adjustment out. Use drive belt tension adjuster (P/N 529 008 700). 1.
Page 188: Drive Belt Deflection Measurement (Reference Only)
SECTION 05 - DRIVE SYSTEM DRIVE BELT DEFLECTION MEASUREMENT (reference only) NOTE: The drive belt deflection measurement must be performed each time a new drive belt is installed. NOTE: To obtain an accurate drive belt deflection measurement, it is suggested to allow a break-in period of 50 km (30 m).
Page 189: Chaincase Gearing
SECTION 05 - DRIVE SYSTEM 1. Slide lower O-ring of deflection scale to speci- Most snowmobiles are geared on the high side fied measure. from the factory. They are usually geared for 8 -16 km/h (5-10 MPH) more than they would reach in 2.
Page 190 SECTION 05 - DRIVE SYSTEM For oval racing, the small benefit you may achieve in top end speed would probably be lost by the loss of acceleration on the start and out of the cor- ners on a tight oval circuit. This holds true for cross-country and snow cross- ers also.
Page 191: Mx Z X 440 Gear Ratio Vs Speed
SECTION 05 - DRIVE SYSTEM × engine RPM teeth, top sprocket (pitch of track No. of teeth on drive sprocket) × × × -------------------------------- - ------------------------------------------------------------ - --------------------------------------------------------------------------------------------------------------------------- - ------------ - top speed in MPH clutch ratio teeth, bottom sprocket 5280 A little known fact that can seriously impair a rac- Generally, this is not the case.
Page 192: Chaincase Gears And Chains
SECTION 05 - DRIVE SYSTEM CHAINCASE GEARS AND CHAINS 13 WIDE 15 WIDE # OF # OF STEEL POWDER ALUMINUM STEEL POWDER ALUMINUM TEETH TEETH 504 152 030 504 152 031 — 486 092 600 — — 504 151 912 504 152 328 —...
Page 193: Transmission Calibration Procedure
SECTION 05 - DRIVE SYSTEM TRANSMISSION CALIBRATION • Pin weight and ramp angle are interrelated, but can be varied to achieve certain results. PROCEDURE A 16.5 gram pin and the adjuster set in #5 may produce the same full throttle RPM as a 1.
Page 194: Transmission Tuning Test Sheet
SECTION 05 - DRIVE 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.: (A-4) Chaincase gearing Lever arm and pin type Weight each assembly...
Page 195: Racers Log
SECTION 05 - DRIVE SYSTEM RACERS LOG VEHICLE: DATE: SHEET NUMBER: LOCATION: SURFACE CONDITIONS: TEMPERATURE: BAROMETRIC PRESSURE: HUMIDITY: CARBURETOR SIZE: FUEL: C.R.A.D.: Carburetion notes: Main jet Needle jet Jet needle E-clip position Slide cut-away Pilot jet Drive pulley Clutching notes: Lever arm/pin type Pin weight Ramp identification...
Page 196: Hydraulic Brake
SECTION 05 - DRIVE SYSTEM BRAKE HYDRAULIC BRAKE 05-66 MMC2004-001_05A.FM...
Page 197: Brake Fluid Type
SECTION 05 - DRIVE SYSTEM BRAKE FLUID TYPE Removal Brake pads removal procedure is as follows: Use recommended brake fluid SRF (DOT 4) (P/N 293 600 063) or GTLMA (DOT 4) (P/N 293 600 062). – Remove 2 retainers from the pins. –...
Page 198: Removal
SECTION 05 - DRIVE SYSTEM Installation – Open chaincase and remove upper sprocket. – Pull countershaft no. 3 toward driven pulley side – Install new brake pads. to free from chaincase and disc. – Install spring and push 2 pins to lock the brake –...
Page 199: Disassembly
SECTION 05 - DRIVE SYSTEM DISASSEMBLY 7, Brake Pad Only brake pads are available as spare parts. If cal- iper or master cylinder are damaged, replace each of them as an assembly. CLEANING Clean all metal components in a general purpose solvent.
Page 200: Adjustment
SECTION 05 - DRIVE SYSTEM 5, Brake Light Switch Ensure that countershaft is properly aligned, then tighten 3 retaining screws. There is no adjustment on these models. Check that NOTE: A misaligned countershaft will result in dif- switch is securely installed. ficulty to center the bearing in its support.
Page 201 SECTION 05 - DRIVE SYSTEM CHAINCASE 05-71 MMC2004-001_05A.FM...
Page 202: Removal And Disassembly
SECTION 05 - DRIVE SYSTEM REMOVAL AND DISASSEMBLY Pry out drive axle oil seal no. 19 from chaincase. Pull chaincase from drive axle and countershaft. To remove chaincase proceed as follows. Using 2 large prybars inserted between chaincase Remove hair pin no. 8. Release drive chain ten- housing no.
Page 203: Installation And Assembly
SECTION 05 - DRIVE SYSTEM INSTALLATION AND ASSEMBLY Reverse removal and disassembly procedure and pay attention to the following. Replace oil seals, gas- kets O-rings and drain plug. 25, Hardened Washer 1. New Make sure to install a hardened washer on each 2.
Page 204: Adjustment
SECTION 05 - DRIVE SYSTEM TYPICAL 1. Dipstick 2. Oil level 3. Level between marks 4. Magnet NOTE: Chaincase must be in its proper position when checking oil level. ADJUSTMENT Pulley Alignment Refer to PULLEY DISTANCE AND ALIGNMENT. Track Tension and Alignment Refer to TRACK.
Page 205: Drive Axle
SECTION 05 - DRIVE SYSTEM DRIVE AXLE REV Series Models 05-75 MMC2004-001_05A.FM...
Page 206: Removal
SECTION 05 - DRIVE SYSTEM REMOVAL Remove battery (if so equipped) to gain access, refer to BATTERY section. Drain oil from chaincase. Remove chaincase cov- er. Release drive chain tension. 1. Circlip Apply parking brake. Remove chain and sprockets then circlip from right side.
Page 207: Assembly
SECTION 05 - DRIVE SYSTEM ASSEMBLY Ensure to align indexing marks of each sprocket when assembling. 3,5,6, Drive Axle and Sprocket To assemble press fit sprockets, use a press and a suitable pipe as illustrated. Sprockets must be as- sembled according to the following dimensions. TYPICAL 1.
Page 208: Lubrication
SECTION 05 - DRIVE SYSTEM 7, Bearing Protector LUBRICATION At assembly, flat side of bearing protector must be Lubricate end housing bearing with synthetic grease against bearing. (P/N 413 711 500). 8, Bearing ADJUSTMENT Always push bearing by inner race. Sprocket/Track Alignment CAUTION: Do not temper with sprocket/track alignment if frame or suspension is damaged.
Page 209: Track Type Application
SECTION 05 - DRIVE SYSTEM TRACK TRACK TYPE APPLICATION INSTALLATION Refer to TECHNICAL DATA. Reverse the removal procedure. NOTE: When installing the track, respect rotation GENERAL direction indicated by an arrow on track thread. Check sprocket/track alignment as described in This section gives guidelines for track removal.
Page 210 SECTION 05 - DRIVE SYSTEM A01F05A 1. Guides 2. Slider shoes 3. Equal distance To correct, stop engine, loosen rear wheel screws, then tighten the adjustment screw on side where the slider shoe is the farthest from the track insert guides.
Page 211 SECTION 05 - DRIVE SYSTEM – Re-open installer, then position cleat tabs on open end of tool and squeeze tabs until they are indented in rubber. TYPICAL 1. First step 2. Second step (to push tabs into rubber) 05-81 MMC2004-001_05A.FM...
Page 212 SECTION 06 - 2004 800 MOD ENGINE KIT TABLE OF CONTENTS 2004 OPEN MOD SNOCROSS ENGINE SPECIFICATIONS & PARTS 793 (ROTAX) 2 CYLINDERS ......................06-2 DRIVE CLUTCH PARTS LIST..................... 06-3 06-1 MMC2004-001_06A.FM...
Page 213 SECTION 06 - 2004 800 MOD ENGINE KIT 2004 OPEN MOD SNOCROSS ENGINE SPECIFICATIONS & PARTS 793 (ROTAX) 2 CYLINDERS PISTON PIN P/N 420 916 370 BORE 82 mm CIRCLIP P/N 420 845 106 STROKE 75.7 mm BASE GASKET AVAILABLE 799.2 cc .4 mm P/N 420 931 836...
Page 214: Drive Clutch
SECTION 06 - 2004 800 MOD ENGINE KIT DRIVE CLUTCH Clutch ass’y - forged P/N 417 222 706 Ramp 419 pos. 4 P/N 417 222 557 Arm, std. aluminum P/N 417 222 383 • Pin, metric P/N 417 222 595 WITH •...
Page 215 SECTION 06 - 2004 800 MOD ENGINE KIT Engine Type: Engine Type: Stroke: 75.7 Stroke: 75.7 C.R. Length: C.R. Length: PISTON POS. PISTON POS. PISTON POS. PISTON POS. DEGREE DEGREE (mm) (inch) (mm) (inch) 0.000 4.88 0.192 0.01 0.000 5.25 0.207 0.03 0,001...
Page 216 SECTION 06 - 2004 800 MOD ENGINE KIT WARNING: 06-5 MMC2004-001_06A.FM...
Page 217 SECTION 06 - 2004 800 MOD ENGINE KIT 06-6 MMC2004-001_06A.FM...
Page 218 SECTION 06 - 2004 800 MOD ENGINE KIT 06-7 MMC2004-001_06A.FM...
Page 219 SECTION 06 - 2004 800 MOD ENGINE KIT Tune Pipe Support Make a new hole of 5/16 in. in the support hull. Insert the fastener of the tune pipe in that 5/16 in. hole. Make an other hole of 3/16 in. the support of the hull and install a new pop rivet to hold the fasterner. Tune Pipe Fastener Installation Update tune pipe fastener installation.
Page 220 SECTION 07 - 2003 MX Zx 440 INFORMATION TABLE OF CONTENTS 2003 SKI-DOO MX Zx RACING TIP SHEET ..................07-9 SKI-DOO RACING, 7575 BOMBARDIER COURT, WAUSAU, WI 54401-8035 NUMBER: 01 NOVEMBER 11, 2002 ........................ 07-9 2003 SKI-DOO MX Zx RACING TIP SHEET ..................07-11 SKI-DOO RACING, 7575 BOMBARDIER COURT, WAUSAU, WI 54401 NUMBER: 02 NOVEMBER 22, 2002 ........................
Page 221 SECTION 07 - 2003 MX Zx 440 INFORMATION 2003 OPTION PACKAGE COLOR MX Zx 440 RACING BLACK - YELLOW CDN / U.S. : 2613 MODEL NUMBER EUR : 2614 ENGINE Engine manufacturer Rotax Engine type no. Lubrication type Premix Number of cylinders Bore 65.00 2.559...
Page 222 SECTION 07 - 2003 MX Zx 440 INFORMATION 2003 OPTION PACKAGE COLOR MX Zx 440 RACING BLACK - YELLOW CDN / U.S. : 2613 MODEL NUMBER EUR : 2614 Crankshaft balance factor 42.5 % Cr. deflection (MAG side) 0.050 0.0020 Cr.
Page 223 SECTION 07 - 2003 MX Zx 440 INFORMATION 2003 OPTION PACKAGE COLOR MX Zx 440 RACING BLACK - YELLOW CDN / U.S. : 2613 MODEL NUMBER EUR : 2614 ELECTRICAL SYSTEM Ignition system manufacturer Nippondenso Ignition system type C.D.I. Ig. timing BTDC (Dynamic) 3.140 0.1236 at 3500 RPM...
Page 224 SECTION 07 - 2003 MX Zx 440 INFORMATION 2003 OPTION PACKAGE COLOR MX Zx 440 RACING BLACK - YELLOW CDN / U.S. : 2613 MODEL NUMBER EUR : 2614 POWER TRAIN (DRIVE PULLEY) Drive pulley manufacturer IBC Canada Drive pulley type Cushion drive T.R.A.
Page 225: Front Suspension
SECTION 07 - 2003 MX Zx 440 INFORMATION 2003 OPTION PACKAGE COLOR MX Zx 440 RACING BLACK - YELLOW CDN / U.S. : 2613 MODEL NUMBER EUR : 2614 Drive sprocket pitch diameter mm in 181.5 7.146 Drive sprocket number of teeth FRONT SUSPENSION Front suspension type...
Page 226: General Specifications
(FORMULA XP-S II) Recommended mixing oil Chaincase oil capacity US oz Oil level height Maximum mark on dipstick Recommended chaincase oil Bombardier synthetic chaincase oil Cooling system capacity US oz 145.4 Ethylene-glycol concentration % vol. 50 / 50 Brake fluid reservoir...
Page 227 SECTION 07 - 2003 MX Zx 440 INFORMATION 2003 OPTION PACKAGE COLOR MX Zx 440 RACING BLACK - YELLOW CDN / U.S. : 2613 MODEL NUMBER EUR : 2614 STANDARD/OPTIONAL EQUIPMENT Electric starter kit Gauge (Tachometer (White facia)) Gauge (Speedometer (White facia)) Gauge (Fuel (electric) (White facia)) Gauge (Temp.
Page 228: Ski-Doo Racing, 7575 Bombardier Court, Wausau, Wi 54401-8035 Number
SECTION 07 - 2003 MX Zx 440 INFORMATION TIP SHEET 2003 SKI-DOO MX Zx RACING SKI-DOO RACING, 7575 BOMBARDIER COURT, WAUSAU, WI 54401-8035 NUMBER: 01 NOVEMBER 11, 2002 FUEL OCTANE SWITCH - 2003 440 REV WARNING The wires from the fuel octane switch were inad- This information relates to the preparation and vertently switched on some units during production.
Page 229 Racing Coordinator The rolling chassis is equipped with a jetting chart 7575 Bombardier Court located on the belt/clutch guard, this chart is for Wausau WI. 55401 the 440 cc engine and should not be used with the Phone: 715-848-4971 800 Mod engine kit.
Page 230: Ski-Doo Racing, 7575 Bombardier Court, Wausau, Wi 54401 Number
SECTION 07 - 2003 MX Zx 440 INFORMATION TIP SHEET 2003 SKI-DOO MX Zx RACING SKI-DOO RACING, 7575 BOMBARDIER COURT, WAUSAU, WI 54401 NUMBER: 02 NOVEMBER 22, 2002 CARBURATION CALIBRATION - 440 WARNING This information relates to the preparation and The 440 REV comes stock with very rich jetting, use of snowmobiles in compétitive events.
Page 231: August 01, 2003
SECTION 07 - 2003 MX Zx 440 INFORMATION TIP SHEET 2003 SKI-DOO MX Zx RACING SKI-DOO RACING, 7575 BOMBARDIER COURT, WAUSAU, WI 54401 NUMBER: 03 AUGUST 01, 2003 SHOCKS - 2003 440 REV AND ROLLING WARNING CHASSIS This information relates to the preparation and It is highly recommended to check the torque of use of snowmobiles in compétitive events.
Page 232: April 2, 2003
SECTION 07 - 2003 MX Zx 440 INFORMATION TIP SHEET 2003 SKI-DOO MX Zx RACING SKI-DOO RACING, 7575 BOMBARDIER COURT, WAUSAU, WI 54401 NUMBER: 04 APRIL 2, 2003 2004 MX Z X 440, ROLLING CHASSIS, WARNING 800 MOD ENGINE KIT APPLICATION...
Page 233 SECTION 08 - COMPETITION PREPARATION TABLE OF CONTENTS SNO CROSS..........................08-2 HILLCROSS ..........................08-2 HILL CLIMBING.......................... 08-3 DRAG RACING (ICE AND GRASS) ................... 08-3 SPEED RUNS ..........................08-5 OVAL RACING..........................08-5 SUGGESTED SPARE PARTS..................... 08-7 EQUIVALENT WEIGHTS AND MEASURES CHART ..............08-9 FUEL/OIL RATIO CHARTS ......................
Page 234: Sno Cross
SECTION 08 - COMPETITION PREPARATION These are general guide lines for preparing a stock • Adjust spring pressure, with the rider in place, REV chassis for various forms of competition. Re- so the ACM block is in the center of the cou- fer to the appropriate section of the book for more pling window.
Page 235: Hill Climbing
SECTION 08 - COMPETITION PREPARATION Track Track • Best performance and speed is achieved by in- • Use a “finger” type track with a 1.75” to 2.00” stalling a 136” x 15” with 1.75” lug height. lug height profile. Beginning of season or fresh snow, use a track with a 1.75”...
Page 236 SECTION 08 - COMPETITION PREPARATION Center NOTE: The installation of hooker plates will re- quire modification to the tunnel protection system • Use stock springs but limit suspension travel and should be approached with caution. with limiter straps or stops to 76 mm (3 in), •...
Page 237: Speed Runs
SECTION 08 - COMPETITION PREPARATION Cooling OVAL RACING • Install a pair of hydraulic quick couplers in the Special Rules coolant hoses at a convenient location on the sled. Make a cooling cart using a cooler filled • Rear of tunnel must be enclosed per specifica- with ice and several winds of copper tubing in- tions in the l.S.R.
Page 238 SECTION 08 - COMPETITION PREPARATION Traction Transmission • Most rules limit maximum stud height to 3/8” • You need aggressive shifting to get a good hole- over the tallest part of the track. Track cutting is shot but you also need good backshifting. Here illegal.
Page 239: Parts Support
SECTION 08 - COMPETITION PREPARATION SUGGESTED SPARE PARTS International 262-335-2401 PH Snowmobile Racing 262-335-9440 Fax You should have a self-contained parts supply. The World Snowmobile 651-209-7400 PH factory parts truck won’t always be there to back Association 651-209-7447 Fax you up. Canadian Snowcross 905-476-7182 PH –...
Page 240 SECTION 08 - COMPETITION PREPARATION – tail light assembly – hood latch rubber – synthetic chaincase oil. Things to DOO Between Heats: – carefully remove ice and snow build up front and rear suspension – inspect suspension components – check/replace studs –...
Page 241: Equivalent Weights And Measures Chart
SECTION 08 - COMPETITION 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 yard = .914 meter (m) 1 meter = 1.093 yards...
Page 242: Fuel/Oil Ratio Charts
SECTION 08 - COMPETITION PREPARATION FUEL/OIL RATIO CHARTS 50/1 METRIC (SI) 500 mL of oil + 25 L of fuel = 50/1 IMPERIAL 16 oz of oil + 5 Imp. gal of fuel = 50/1 500 mL of oil + 5.5 Imp. gal of fuel = 50/1 UNITED STATES 13 oz of oil + 5 U.S.
Page 243 SECTION 08 - COMPETITION PREPARATION 40/1 METRIC (SI) 500 mL of oil + 20 L of fuel = 40/1 IMPERIAL 16 oz of oil + 4.0 Imp. gal of fuel = 40/1 500 mL of oil + 4.8 Imp. gal of fuel = 40/1 35.2 UNITED STATES 10.2...
Page 244 SECTION 08 - COMPETITION PREPARATION 33/1 METRIC (SI) 500 mL of oil + 16.5 L of fuel = 33/1 16.5 1000 IMPERIAL 24 oz of oil + 5 Imp. gal of fuel = 33/1 500 mL of oil + 3.6 Imp. gal of fuel = 33/1 17.6 35.2 UNITED STATES...
Page 245 SECTION 08 - COMPETITION PREPARATION 25/1 METRIC (SI) 500 mL of oil + 12.5 L of fuel = 25/1 12.5 IMPERIAL 16 oz of oil + 2.5 Imp. gal of fuel = 25/1 500 mL of oil + 2.7 Imp. gal of fuel = 25/1 35.2 UNITED STATES 15 oz of oil + 2.8 U.S.
Page 246 SECTION 08 - COMPETITION PREPARATION 20/1 METRIC (SI) 500 mL of oil + 10 L of fuel = 20/1 IMPERIAL 16 oz of oil + 2 Imp. gal of fuel = 20/1 500 mL of oil + 2.2 Imp. gal of fuel = 20/1 35.2 UNITED STATES 16 oz of oil + 2.4 U.S.
Page 247: Stock Class Preparation
SECTION 08 - COMPETITION PREPARATION STOCK CLASS PREPARATION 4. Check piston to cylinder clearances, ring end gap, cylinder taper and out-of round. NOTE: Any machining and/or grinding is illegal in 5. Assemble the engine using the correct seal- stock class racing. Keep your machine legal! ants where needed.
Page 248: Technical Data
➀ 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. A) Ski Spring = 150 lb/in P/N 415 020 700 - 5 mm preload shock length = 360 mm B) Center Spring = std 2-1/4 in travel max.
Page 249 ➀ 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. A) Ski Spring = 150 lb/in P/N 415 020 700 - 5 mm preload shock length = 360 mm B) Center Spring = std 2-1/4 in travel max.
Page 250 ➀ 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. A) Ski Spring = 150 lb/in P/N 415 020 700 - 5 mm preload shock length = 360 mm B) Center Spring = std 2-1/4 in travel max.
Page 251 P/N 414 860 700 Calibration done at temperature of 25° Celcius ➀ 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. 08-19 MMC2004-001_08A.FM...
Page 252 SECTION 09 - SERVICE TOOLS TABLE OF CONTENTS ENGINE ............................09-2 TRANSMISSION ........................09-6 SUSPENSION ..........................09-10 VEHICLE ............................. 09-13 NEW TOOLS AND USAGE ....................... 09-14 09-1 MMC2004-001_09A (TOOLS).FM...
Page 253: Service Tools
SECTION 09 - SERVICE TOOLS SERVICE TOOLS ENGINE Hose pincher (2) Engine leak tester kit 1) Piston pin puller (P/N 295 000 076) (P/N 861 749 100) (P/N 529 035 503) 1) Hand pump (P/N 529 021 800) A01B2I4 A02B094 APPLICATION All vehicles.
Page 254 SECTION 09 - SERVICE TOOLS ENGINE (continued) Rubber pad Multimeter (P/N 529 023 400) (P/N 529 035 788) A01B4C4 APPLICATION All cageless bearing engines. F01B1O4 APPLICATION All models. The following tools are highly recommended to optimize your basic tool kit and reduce repair time. 1-2) Crankshaft bearing 1) Screw M16 x 1.5 x 150 (P/N 420 940 755)
Page 255 SECTION 09 - SERVICE TOOLS ENGINE (continued) Piston circlip installer Ring compressor Driver tool (P/N 529 035 521) A) (P/N 529 035 561) 18 mm A) (P/N 420 876 090) (62 mm) B) (P/N 529 035 562) 20 mm B) (P/N 420 876 974) (69.5 mm) C) (P/N 420 876 970) A00B4O4...
Page 256 SECTION 09 - SERVICE TOOLS ENGINE (continued) Carburetor tool kit Stroboscopic timing light Injection pump gear holder (P/N 404 112 000) (P/N 529 031 900) (P/N 420 277 905) A00B2F4 A00B4F4 A00C164 APPLICATION APPLICATION APPLICATION All models. All engines. All liquid cooled engines. Float level gauge RAVE movement indicator Digital/induction type tachometer...
Page 257: Transmission
SECTION 09 - SERVICE TOOLS ENGINE (continued) Large hose pincher (P/N 529 032 500) Spark plug lift ring (TYPICAL) (P/N 529 035 876) A33B064 APPLICATION REV. F01B234 APPLICATION All vehicles. TRANSMISSION Driven pulley opening tool TRA drive pulley puller Forks (3) (P/N 529 017 200) (P/N 529 022 400) (P/N 529 005 500)
Page 258 SECTION 09 - SERVICE TOOLS TRANSMISSION (continued) Drive belt tension adjuster tool Driven pulley spring compressor Countershaft bearing remover/installer (P/N 529 008 700) (P/N 529 035 300) (P/N 529 035 699) A15B044 Parts included: 1) Hexagonal wrench (P/N 420 876 730). 2) Socket wrench A05B034 (P/N 529 015 000).
Page 259 SECTION 09 - SERVICE TOOLS TRANSMISSION (continued) The following tools are highly recommended to optimize your basic tool kit and reduce repair time. Driven pulley opening tool Large bushing extractor Chaincase seal pusher (P/N 529 035 501) (P/N 529 035 576) (P/N 529 035 584) A03D2P4 APPLICATION...
Page 260 SECTION 09 - SERVICE TOOLS TRANSMISSION (continued) Drive axle sprocket adjuster (P/N 861 725 700) Clutch alignment bar (P/N 529 035 831) A01B2O4 Parts included in the kit: A33B034 1) Block with threads APPLICATION (P/N 529 010 700) REV. 2) Block without threads (P/N 529 010 800) 3) Plate (P/N 529 010 600)
Page 261: Suspension
SECTION 09 - SERVICE TOOLS SUSPENSION Shock spring removal kit Camber angle tool Track cleat installer (P/N 529 035 504) (P/N 529 021 600) (P/N 529 028 800) Replacement clevis pin: NOTE: Angle finder with a magnetic Narrow base must be used. (P/N 414 528 400) Suggestion: K-D tool no.
Page 262 SECTION 09 - SERVICE TOOLS SUSPENSION (continued) Shock wrench Gas shock valve tool (tire valve type) (P/N 529 035 727) (P/N 529 035 570) A-arms nut wrench (P/N 529 035 876) A00F224 All T/A shocks except 2003 A02F134 MX Zx 440. APPLICATION A33B024 1999 and older T/A shocks and...
Page 263 SECTION 09 - SERVICE TOOLS SUSPENSION (continued) Ball joint remover support Ball joint installer support (P/N 529 035 873) (P/N 529 035 875) V00B1L4 APPLICATION V00B1J4 REV. APPLICATION REV. Ball joint installer (P/N 529 035 874) V00B1K4 APPLICATION REV. 09-12 MMC2004-001_09A (TOOLS).FM...
Page 264: Vehicle
SECTION 09 - SERVICE TOOLS VEHICLE Protective mat Snowmobile jack (P/N 529 030 600) (P/N 529 020 000) A01B454 APPLICATION All vehicles. A01A1JJ Dolly APPLICATION (P/N 529 029 900) All models. Adjustment wrench (P/N 529 035 603) A32B044 APPLICATION To remove and install fuel tank nut on ZX series.
Page 265: New Tools And Usage
SECTION 09 - SERVICE TOOLS NEW TOOLS AND USAGE NEW TOOLS USAGE DESCRIPTION MODEL A-arms nut wrench 529 035 876 (SUSPENSION) Clutch alignment 529 035 831 (TRANSMISSION) Engine removal hook (use with 529 035 829 529 035 830) (ENGINE) Spark plug lift ring 529 035 830 (ENGINE) Ball joint remover...
Page 266 SECTION 09 - SERVICE TOOLS NEW TOOLS USAGE DESCRIPTION MODEL Ball joint remover support 529 035 873 (SUSPENSION) Ball joint installer 529 035 874 (SUSPENSION) Ball joint installer support 529 035 875 (SUSPENSION) Filler neck nut wrench 529 035 891 (VEHICLE) 09-15 MMC2004-001_09A (TOOLS).FM...
Page 267: Section 10 - Accessories
SECTION 10 - ACCESSORIES SECTION 10 - ACCESSORIES PART NUMBER DESCRIPTION 861 784 100 A arm protector Black for (REV) X A arm protector Orange for 860 508 100 (REV) 861 784 000 A arm protector Yellow for (REV) X 517 302 803 Body panel Black LH 517 302 802 Body panel Black RH 517 302 805 Body panel Yellow LH...
Page 268 SECTION 10 - ACCESSORIES PART NUMBER DESCRIPTION 506 151 503 J hook long 90 Red 506 151 505 J hook long 90 Yellow 506 151 520 J hook short 45 Black 506 151 502 J hook short 45 Red 506 151 504 J hook short 45 Yellow 506 151 596 J hook Ultra, short 90 Black 415 128 580 J hook Ultra, short 90 Yellow 506 151 593 J hook Ultra, long 90 Black...
Page 269 SECTION 10 - ACCESSORIES PART NUMBER DESCRIPTION Seat snowcross XPS II 415 128 670 (long seat) Ski Mountain 860 508 300 (Bridge & fasteners kit) R.H. Ski plastic 505 071 391 (Mountain), Black B-160 Ski plastic (Mountain), 505 071 392 Black B-160 R.H.
Page 270 SECTION 10 - ACCESSORIES PART NUMBER DESCRIPTION Ski plastic (PRECISION), 505 071 051 Mix Yellow/ viper Red Ski plastic (PRECISION), 505 071 052 Orange B-228 Ski PRECISION 860 507 700 (Bridge & fasteners kit) 505 070 863 Ski runner (Montain) Ski runner (Carbides 5") 860 508 400 Plastic ski ( Mountain)
Page 271 SECTION 10 - ACCESSORIES PART NUMBER DESCRIPTION 861 001 100 Sled dolly 2 wheels 861 000 800 Sled shop wheels, Yellow 520 000 343 Snowguard (REV) X, Black 520 000 412 Snowguard (REV) X, Yellow 860 306 500 Suspenssion quick ajustment kit X Track 15.0"...
Page 272 SECTION 10 - ACCESSORIES PART NUMBER DESCRIPTION Track, Challenger C9875M 15 X 144 X 2,000 Track, Challenger C6799871 15 X 144 X 2,250 Track, Challenger C6799876 15 X 151 X 2,000 Track, Challenger C6799872 15 X 151 X 2,250 Track, Challenger C9808M 15 X 156 X 2,000 Track, Challenger...
Page 273 SECTION 10 - ACCESSORIES PART NUMBER DESCRIPTION Wheel 165mm for 860 306 800 rear suspension kit Wheel 180mm for 860 306 900 rear suspension kit 517 303 020 Windshield low fix swift, Black Windshield low fix swift, 517 303 130 fire Bee Windshield low fix swift, 517 303 131...

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