Ski-Doo CK3 Series 2002 Operator's Manual
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Ski-Doo CK3 Series 2002 Operator's Manual

Ski-Doo CK3 Series 2002 Operator's Manual

Ck3 series snowmobiles
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  • Page 2 America. In Canada, products are distributed by Bombardier Inc. The following are trademarks of Bombardier Inc. or its subsidiaries. BOMBARDIER ® MACH Z ® SKI-DOO ® ROTAX ® DESS Kleen-Flo* is a trademark of Kleen-Flo Tumbler Industries Ltd. Printed in Canada (Mmo2002-003a.fm GM) ®...
  • Page 3 2002 SKI-DOO OPERATOR’S GUIDE This guide is applicable to CK3 series: Mach Z ® Mach Z Tech Plus...
  • Page 4 FOREWORD Congratulations on your purchase of a new SKI-DOO snowmobile. Whatever model you have chosen, it is backed by the Bombardier warranty and a network of authorized SKI-DOO snowmobile dealers ready to provide the parts, service or accessories you may require.
  • Page 5 It is understood that this guide may be translated into another lan- guage. In the event of any discrepancy, the English version shall pre- vail. Most components of this snowmobile are built with parts dimen- sioned in the metric system. Most fasteners are metric and must not be replaced by customary fasteners or vice versa.

  • Page 6: Table Of Contents

    2002 SKI-DOO SNOWMOBILES..........BOMBARDIER LIMITED WARRANTY INTERNATIONAL: 2002 SKI-DOO ® SNOWMOBILES..........FREQUENTLY ASKED QUESTIONS ........AUTHORIZED SKI-DOO DEALERS ......... HOW TO IDENTIFY YOUR SNOWMOBILE ......Vehicle Description Decal............Serial Numbers ................ON-VEHICLE IMPORTANT INSTRUCTIONS......CONTROLS/INSTRUMENTS/EQUIPMENT ......1) Throttle Lever ..............
  • Page 7 26) Adjustable Handlebar ............27) Adjustable Windshield ............28) Hood Grills ................29) Fuel Shut-Off Valve .............. 30) Storage Compartment ............31) Tool Box ................32) Spark Plug Holder ..............33) Spare Drive Belt Holder ............34) Fuse ..................35) Front Grab Handles/Front Bumper ........36) Adjustable Suspensions ............
  • Page 8 PERIODIC MAINTENANCE CHART......... FLUID LEVELS................Brake System ................Chaincase Oil Level ..............Oil Injection System ..............Cooling System ................. MAINTENANCE ............... Vehicle Cleaning and Protection..........Belt Guard Removal and Installation ......... Drive Belt Removal/Installation ..........Drive Chain Tension ..............TRA Drive Pulley Adjustment ............ Drive Belt Condition ..............

  • Page 9: Safety Measures

    ® be used on other models. Use of Rotax snowmobile engines in other than SKI-DOO snowmobiles is not recommended or autho- rized by Bombardier Inc. Do not stud the track. Reverse models only: These snowmobiles are capable of a fast reverse.

  • Page 10: Bombardier Limited Warranty North America: 2002 Ski-Doo Snowmobiles

    This warranty coverage is available only on 2002 SKI-DOO snowmobile pur- chased as new and unused by its first owner from a BOMBARDIER dealer authorized to distribute SKI-DOO products in the country in which the sale occurred (hereinafter “BOMBARDIER dealer”), and then only after the BOM- BARDIER specified pre-delivery inspection process is completed and docu- mented.
  • Page 11 6. EXCLUSIONS - ARE NOT WARRANTED • Normal wear and tear; • Routine maintenance items, tune ups, adjustments; • Damage caused by failure to provide proper maintenance and/or storage, as described in the Operator’s Guide; • Damage resulting from removal of parts, improper repairs, service, mainte- nance, modifications or use of parts not manufactured or approved by BOM- BARDIER or resulting from repairs done by a person that is not an authorized servicing BOMBARDIER dealer;...
  • Page 12 If the issue has not yet been resolved, please submit your complaint in writing or call the appropriate number below: In Canada: In USA: BOMBARDIER INC. BOMBARDIER MOTOR RECREATIONAL PRODUCTS CORPORATION OF AMERICA SKI-DOO ® RECREATIONAL PRODUCTS CUSTOMER ASSISTANCE CENTER SKI-DOO ® VALCOURT QC J0E 2L0 CUSTOMER ASSISTANCE CENTER Tel: (819) 566-3366 P.O.

  • Page 13: Bombardier Limited Warranty International: 2002 Ski-Doo Snowmobiles

    All genuine BOMBARDIER parts and accessories, installed by an authorized BOMBARDIER distributor/dealer (as hereinafter defined) at the time of delivery of the 2002 SKI-DOO snowmobile, carry the same warranty as that of the snow- mobile. Use of the product for racing or any other competitive activity, at any point, even by a prior owner will render this warranty null and void.
  • Page 14 5. WHAT BOMBARDIER WILL DO BOMBARDIER’s obligations under this warranty are limited to, at its sole dis- cretion, repairing parts found defective under normal use, maintenance and service, or replacing such parts with new genuine BOMBARDIER parts without charge for parts and labor, at any authorized BOMBARDIER distributor/dealer. BOMBARDIER reserves the right to improve or modify products from time to time without assuming any obligation to modify products previously manufac- tured.
  • Page 15 8. TRANSFER If the ownership of a product is transferred during the warranty coverage peri- od, this warranty shall also be transferred and be valid for the remaining cover- age period provided that BOMBARDIER is notified of such transfer of owner- ship in the following way: a.

  • Page 16: Frequently Asked Questions

    I do have my original invoice as proof of when I purchased my snow- mobile. A: Registration is very important and your SKI-DOO dealer must register your snowmobile with Bombardier. Make sure the reg- istration form has been sent. All of this will allow you to: a) have warranty work performed at any authorized SKI-DOO dealer in North America.
  • Page 17 Bombardier. Normally, any problems that arise in connection with the sales transaction or the operation of your snowmobile will be handled by your SKI-DOO dealers Sales or Service De- partments. It is recognized, however, that despite the best in- tentions of everyone concerned, misunderstandings will sometimes occur.

  • Page 18: Authorized Ski-Doo Dealers

    AUTHORIZED SKI-DOO DEALERS For Canada and USA Only To find the nearest authorized SKI-DOO dealer, dial: 1-800-375-4366. HOW TO IDENTIFY YOUR SNOWMOBILE Vehicle Description Decal Vehicle description decal is located on right hand side of tunnel. A03A04C 1. Vehicle description decal...

  • Page 19: Serial Numbers

    These numbers are required by the SKI-DOO dealer to complete warranty claims properly. No war- ranty will be allowed by Bombardier Inc. if the engine serial number or Vehicle Identification Number (VIN) is removed or mutilated in any way.
  • Page 20 Model Number Location Model number is part of vehicle identification number (VIN). X X X X X X X X X X X X X X X X X Model number Serial number A00A6IA Engine Serial Number Location A30C01A TYPICAL 1.

  • Page 21: On-Vehicle Important Instructions

    ON-VEHICLE IMPORTANT INSTRUCTIONS Please read the following instructions carefully before operating snow- mobile. A03A04D TYPICAL — LOCATION OF IMPORTANT INSTRUCTIONS Instruction 1 A01A1ZD SINGLE SEAT MODELS...
  • Page 22 Instruction 2 SINGLE SEAT MODELS A02A0GA...
  • Page 23 Instruction 3 A01A2EA ALL MODELS Instruction 4 A01A2FA ALL MODELS...
  • Page 24 Instruction 5 A01A24D TYPICAL — ALL MODELS Instruction 6 SUSPENSION ADJUSTMENT CHART/TABLEAU DES RÉGLAGES DE LA SUSPENSION FRONT SUSPENSION (SKI)/SUSPENSION AVANT (SKI) NOT APPLICABLE SANS OBJET REAR SUSPENSION/SUSPENSION ARRIÈRE ADJUST ACCORDING TO LOAD/RÉGLER SELON LA CHARGE LOAD REAR SPRING CHARGE RESSORT ARRIÈRE APPLICABLE SANS OBJET...

  • Page 25: Controls/Instruments/Equipment

    CONTROLS/INSTRUMENTS/EQUIPMENT NOTE: Some controls/instruments/equipment do not apply to some models. In these cases their reference numbers are deliberately missing in the illustrations. Some controls/instruments/equipment are optional on some models. A03A04E TYPICAL...
  • Page 26 18 20 24 25 21 23 6 25 24 A30A0RB TYPICAL — MACH Z STD/TECH PLUS...

  • Page 27: Throttle Lever

    1) Throttle Lever Located on the right side of handlebar. When compressed, it controls the engine speed and the engagement of the transmission. When released, engine speed returns automatically to idle. WARNING Throttle lever must operate easily and smoothly. It must re- turn to idle position when released.

  • Page 28: Injection Oil Level/Parking Brake Pilot Lamp (Red)

    5) Handlebar The handlebar controls the direction of travel of the snowmobile. As the handlebar is rotated to right or left, the skis are turned in the di- rection of intented travel. Handlebar height is adjustable. See an authorized SKI-DOO dealer.

  • Page 29: Reverse Button

    6) Reverse Button WARNING These snowmobiles are capable of a fast reverse. Always remain seated and apply the brake before shifting. Come to a complete stop then push reverse button. Ensure the path behind is clear of obstacles or bystanders. Fast reverse could result in loss of stability.

  • Page 30: Tether Cut-Out Switch

    7) Tether Cut-Out Switch General The tether cut-out system shuts-off engine if the driver accidently falls off the vehicle and the DESS (Digitally Encoded Security Sys- tem) performs the same function as a key. Operation Attach tether cord to clothing then snap tether cord cap over recep- tacle before starting engine.
  • Page 31 DESS (Digitally Encoded Security System) Description This system is a deterrent against theft. The tether cord cap provided with your snowmobile is SKI-DOO dealer programmed and is the only one that allows engine to turn more than 3000 RPM. If an incorrectly programmed tether cord cap is installed the engine can not reach engagement speed required to move vehicle.

  • Page 32: Dess Pilot Lamp

    To check for bad connection, remove tether cord cap. Make sure it is free of dirt or snow. Reinstall tether cord and restart engine. If a beep per 3 seconds still occurs contact an authorized SKI-DOO dealer. A30H08A 1. Free of dirt or snow A rapid beeping and DESS pilot lamp blinking at same rate mean that an incorrectly programmed tether cord is being used.

  • Page 33: Engine Cut-Out Switch

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

  • Page 34: Headlamp Dimmer Switch

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

  • Page 35: Choke Lever

    13) Choke Lever This device features a 3-position lever to facilitate cold start. A30H0DA 0. OFF 1. Position 1 2. Position 2 Refer to OPERATING INSTRUCTIONS for more details. 14) Speedometer These vehicles are equipped with a speedometer graduated in kilome- ter per hour (miles per hour for the USA).

  • Page 36: Trip Meter

    16) Trip Meter Records distance travelled in kilometers (miles for the USA) until it is reset. It can be used to establish a fuel tank range or distance be- tween 2 relays for instance. 60 70 80 000000 0 0 0 0 A06H1FA 1.

  • Page 37: Temperature Gauge

    19) Temperature Gauge The gauge indicates engine coolant temperature. The needle moves to the normal range as engine warms. Under all riding conditions, the needle should stay within this range. If needle moves into the over- heat range, reduce snowmobile speed and run snowmobile in loose snow or stop engine immediately.

  • Page 38: Electric Fuel Level Gauge

    20) Electric Fuel Level Gauge Dash-mounted gauge to facilitate fuel level reading. This gauge func- tions when engine is running. A30H0HA 1. Full 2. Empty 21) Fuel Tank Cap Unscrew to fill up tank then fully tighten. WARNING Fuel may be pressurized, open cap slowly. Fuel is flammable and explosive.

  • Page 39: Heated Grip Switch

    22) Heated Grip Switch Three-position toggle switch. Select the desired position to keep your hands at a comfortable temperature. A25H05A TYPICAL 1. HOT 2. OFF 3. WARM 23) Heated Throttle Lever Switch Three-position toggle switch. Select the desired position to keep your right thumb at a comfortable temperature.

  • Page 40: Adjustable Toeholds

    25) Adjustable Toeholds Each toehold can be adjusted to suit driver’s preference. Loosen bolts, adjust then, retighten bolts to 10 N•m (89 lbf•in). WARNING Adjust with vehicle at rest in a safe place. Securely tighten all adjustments. Do not adjust too snugly. A30H0MA RIGHT SIDE SHOWN 1.

  • Page 41: Adjustable Handlebar

    26) Adjustable Handlebar Handlebar angle can be adjusted to suit driver’s preference. Lift lever, tilt handlebar to desired position then release lever. Lever will locked on each position. WARNING Adjust with vehicle at rest in a safe place. Securely tighten all adjustments.

  • Page 42: Adjustable Windshield

    27) Adjustable Windshield Windshield height can be adjusted to suit driver’s preference. Posi- tion 1 corresponds to lower windshield height. Position 10 corre- sponds to higher windshield height. Knobs are locked on each position. To unlock first pull knobs then, turn to adjust windshield height.

  • Page 43: Hood Grills

    28) Hood Grills These hood grills must be closed at all times except when riding at high speeds and/or when outside temperature is above 5°C (40°F). Slightly unscrew wing nuts, slide close grills then, retighten wing nuts. A30H0TA 1. Grills...

  • Page 44: Fuel Shut-Off Valve

    29) Fuel Shut-Off Valve Valve should be closed when transporting or storing snowmobile. A30I01A 1. Opened 2. Closed Fully open the valve in order to operate the snowmobile. CAUTION: Always fully open the valve before riding. Never allow the valve to remain half opened. 30) Storage Compartment A storage compartment is provided inside rear portion of seat.

  • Page 45: Tool Box

    31) Tool Box A tool box containing tools for basic maintenance is supplied with the vehicle. Tool box is located in engine compartment in front of belt guard. NOTE: The plastic bag containing tools may be discarded to ease stor- ing tools.

  • Page 46: Spare Drive Belt Holder

    A30D04A 1. Spare spark plugs stored in tool box 2. Instructions for spare spark plugs removal 33) Spare Drive Belt Holder A spare drive belt can be installed in drive belt holder clip. Make sure to position spare drive belt as illustrated. NOTE: Spare drive belt is not supplied with the snowmobile.

  • Page 47: Fuse

    See an authorized SKI-DOO dealer for servicing. Electric Fuel Level Gauge Fuse See an authorized SKI-DOO dealer for fuse replacement. 35) Front Grab Handles/Front Bumper To be used whenever front of snowmobile requires manual lifting.

  • Page 48: Adjustable Suspensions

    36) Adjustable Suspensions For factory recommended adjustments refer to decal on belt guard. It describes settings for optimum comfort according to load for your SKI-DOO model. A30F07A TYPICAL 1. Decal...

  • Page 49: General

    General Snowmobile handling and comfort depend upon suspension adjust- ments. Choice of suspension adjustments vary with carrying load, driver’s weight, personal preference, riding speed and field condition. NOTE: Some adjustments may not apply to your snowmobile. Use special keys in tool box. A32F0FA TYPICAL 1.

  • Page 50: Guidelines To Adjust Suspension

    Guidelines to Adjust Suspension The best way to set up suspension, is to start from factory settings then customize each adjustment one at a time. Adjustments 2 through 6 are interrelated. It may be necessary to readjust center spring after adjusting front springs for instance.
  • Page 51 A32F0CA TYPICAL — TOO SOFT OF ADJUSTMENT Turn the left side adjustment cam in a clockwise direction, the right side cam in a counterclockwise direction. Left and right adjustment cams may be set at different position. A30F04A TYPICAL 1. Increase spring preload...
  • Page 52 A32F0DA TYPICAL — TOO HARD OF ADJUSTMENT Turn the left side adjustment cam in a counterclockwise direction, the right side cam in a clockwise direction. Left and right adjustment cams may be at different position. A30F04B TYPICAL 1. Decrease spring preload...
  • Page 53 2. Center Spring — Steering Behavior Ride at moderate speed on a trail. If steering is too easy or too hard to turn, adjust center spring accord- ingly. A32F0EA TYPICAL — GOOD ADJUSTMENT AT MODERATE SPEED 1. Steering easy to turn...
  • Page 54 A32F0EA TYPICAL — TOO SOFT OF ADJUSTMENT 1. Steering hard to turn A32F01A TYPICAL 1. Use adjuster wrench provided in tool box to increase preload...
  • Page 55 A32F0EA TYPICAL — TOO HARD OF ADJUSTMENT 1. Steering less aggressive A32F01B TYPICAL 1. Use adjuster wrench provided in tool box to decrease preload...
  • Page 56 3. Coupling Blocks — Handling Ride at moderate speed and check for desired handling. When driver and passenger (if applicable) take place the coupling blocks should be centered between rubber stoppers.This condition is achieved when a proper rear spring preload is done. See above rear spring adjustment.
  • Page 57 A32F0JA COUPLING BLOCK — RIGHT SIDE VIEW (“R” — RIGHT EMBOSSED ON BLOCK) 1. Thicker part of block facing downward (partly coupled suspension) — more track grip and less skis steering 2. Turn block in this direction to adjust to the other position 4.
  • Page 58 A32F0EB TYPICAL — GOOD ADJUSTMENT AT FULL ACCELERATION 1. Comfortable steering 2. Good weight transfer to the track 3. Light pressure of skis on the ground...
  • Page 59 A32F0EC TYPICAL — TOO LONG STRAP 1. Skis lift off the ground A03F0QB TYPICAL 1. Reduce strap length by bolting to a different hole...
  • Page 60 A32F0EA TYPICAL — TOO SHORT STRAP 1. Heavy steering A03F0QB TYPICAL 1. Increase strap length by bolting to a different hole...
  • Page 61 5. Front Springs — Handling Ride at moderate speed and check for proper handling. Adjust front springs accordingly. WARNING Always adjust both front springs to same position. A32F0EA TYPICAL — PROPER ADJUSTMENT 1. Good handling and comfortable steering...
  • Page 62 A32F0EA TOO SOFT OF ADJUSTMENT 1. Bad handling A03F2IA 1. Increase spring preload...
  • Page 63 A32F0EA TOO HARD OF ADJUSTMENT 1. Steering hard to turn A03F2JA 1. Decrease spring preload...
  • Page 64 6. Rear Shock Motion Ratio — Damping Strength Some Models Only Rear shock motion ratio can be adjusted according to driver and pas- senger weight and/or trail condition. There are two adjustment positions. A32F0HA 1. Soft position 2. Firm position To adjust, loosen nut, move bolt to desired position then torque nut to 24 N•m (18 lbf•ft).

  • Page 65: Troubleshooting Chart

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

  • Page 66: Fuel And Oil

    FUEL AND OIL Recommended Fuel Use super unleaded gasoline, available from most service stations or oxygenated fuel containing less than 10% of ethanol or 5% of meth- anol. The fuel used must have an octane number (R + M)/2 of 91 or higher.

  • Page 67: Recommended Oil

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

  • Page 68: Cold Weather Carburetion Modifications

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

  • Page 69: Pre-Operation Check

    • Check fuel and injection oil for levels and leaks. Replenish as nec- essary and see an authorized SKI-DOO dealer in case of any leaks. • Verify that air filter(s) is free of snow and ice, if so equipped.

  • Page 70: Pre-Operation Check List

    PRE-OPERATION CHECK LIST ✔ ITEM OPERATION Track and idler wheels Check for free movement. Brake lever Check proper action. Parking device Check proper action. Throttle lever Check proper action. Switches and lights Check proper action. Skis and steering Check proper action. Check for proper level and Fuel and oil leaks.

  • Page 71: Operating Instructions

    OPERATING INSTRUCTIONS WARNING Proceed with pre-operation check list before riding. Principle of Operation Propulsion Depressing throttle lever increases engine RPM causing the drive pulley to engage. For most models engine RPM must be between 2500 and 4200 before drive pulley engagement will occur. Outer sheave of drive pulley moves toward inner sheave, forcing drive belt to move upward on the drive pulley and simultaneously forcing the sheaves apart on the driven pulley.

  • Page 72: Starting The Engine

    Starting the Engine WARNING Operator and passenger (if applicable) must be properly seated before starting engine. • Re-check throttle control lever operation. • Ensure that engine cut-out switch is in the ON position. • Ensure that tether cord cap is set in place and that cord is attached to your clothing.

  • Page 73: Emergency Starting

    Warm Engine Starting Start the engine without any choke. If the engine will not start after two pulls of the rope or two 5 second attempts with the electric starter move choke lever to position 1. Start the engine without acti- vating the throttle lever.
  • Page 74 A07D0UA Tie a knot near clip. Hook up clip on drive pulley and wind counter- clockwise up to 3 turns. Wind the rope tightly around drive pulley. When pulled, pulley must rotate counterclockwise. A30D06A 1. Clip Start engine as described in COLD ENGINE STARTING or WARM ENGINE STARTING according to engine temperature.

  • Page 75: Shutting Off The Engine

    WARNING When starting the snowmobile in an emergency situation us- ing drive pulley, do not reinstall the belt guard and return slowly to have snowmobile repaired. Shutting Off the Engine Release throttle lever and wait until engine has returned to idle speed. Shut off the engine using either engine cut-out switch or tether cut- out switch.

  • Page 76: Post-Operation Care

    600 m (2000 ft). Engine Overheating Reduce snowmobile speed and run snowmobile in loose snow or stop engine immediately. Check for adequate coolant level. See an authorized SKI-DOO dealer. Fuel Flooded Engine All Models WARNING Do not hold throttle partially or fully open when starting a fuel flooded engine.

  • Page 77: Periodic Maintenance Chart

    ➂ MONTHLY OR EVERY 800 km (500 miles) ➃ ONCE A YEAR OR EVERY 3200 km (2000 miles) ➄ STORAGE (To be performed by SKI-DOO dealer) ➅ PRE-SEASON PREPARATION (To be performed by SKI-DOO dealer) ➀ ➁ ➂ ➃ ➄ ➅ PERIODIC MAINTENANCE CHART...
  • Page 78 ➀ ➁ ➂ ➃ ➄ ➅ PERIODIC MAINTENANCE CHART Brake Fluid Level Brake Fluid (change once a year) Brake Condition Drive Chain Tension Countershaft Lubrication** Chaincase Oil Level ✔ Chaincase Oil Change Lubrication of Drive Axle End Bearing** Handlebar Bolts, Retorque to 26 N•m (19 lbf•ft) Steering and Front Suspension Mechanism Lubrication**...

  • Page 79: Fluid Levels

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

  • Page 80: Chaincase Oil Level

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

  • Page 81: Oil Injection System

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

  • Page 82: Cooling System

    (engine cold) of coolant tank. NOTE: When checking level at low temperature it may be slightly lower then mark. If additional coolant is necessary or if entire system has to be refilled, refer to an authorized SKI-DOO dealer. NIVEAU FROID NIVEAU FROID...

  • Page 83: Maintenance

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

  • Page 84: Belt Guard Removal And Installation

    Belt Guard Removal and Installation Turn off engine cut-out switch. Open hood. Open retainer to release pin then pull belt guard toward front. A30C10A 1. Pin retainer When reinstalling belt guard, position its cut-away toward front of snowmobile. Refer to decal on belt guard. Insert belt guard slots at rear first.
  • Page 85 A30C06A 1. Slots A30C07A 1. Rear of belt guard properly installed Push down front portion of belt guard in retainer. NOTE: Belt guard is purposely made slightly oversize to maintain ten- sion on its pins and retainers preventing undue noise and vibration. It is important that this tension be maintained when reinstalling.

  • Page 86: Drive Belt Removal/Installation

    Drive Belt Removal/Installation NOTE: Removal and installation of drive belt is easier when driven pulley is held with brake so that it can not rotate. Apply parking brake, for this purpose. Turn off engine cut-out switch. Open hood and remove belt guard. Open the driven pulley with the drive belt installer/remover provided in tool box.
  • Page 87 A30D0BA 1. Tighten to open pulley Slip the belt over the top edge of the sliding half of driven pulley, as shown in previous photo. Remove access panel from bottom pan. A30C04A 1. Push top of panel out of bottom pan...
  • Page 88 A30C05A 1. Pull panel tab out of bottom pan Slip belt under drive pulley then, remove it from vehicle. A30D0CA Clean sheaves of both pulleys using BOMBARDIER Parts Cleaner (P/N 413 711 809).
  • Page 89 To install the drive belt, reverse the removal procedure, however pay attention to the following: The maximum drive belt life span is obtained when the belt has the proper rotation direction. See arrow on belt. A30D0DA 1. Arrow pointing front of vehicle CAUTION: Do not force or use tools to pry the belt into place, as this could cut or break the cords in the belt.

  • Page 90: Drive Chain Tension

    Drive Chain Tension Remove hair pin. Fully tighten tensioner adjustment screw by hand, then back off only far enough for hair pin to engage in locking hole. A30D0EA 1. Hair pin 2. Adjustment screw TRA Drive Pulley Adjustment The drive pulley is factory calibrated to transmit maximum engine power at a predefined RPM.
  • Page 91 To adjust, turn calibration screws. Calibration screw has a notch on top of its head. A16D0FA 1. Notch Governor cup has 6 positions numbered 2 to 6. Note that in position 1 the number is substitued by a dot (due to its location on casting). A16D0GA 1.
  • Page 92 Improper servicing, modification or poor adjustment may affect drive pulley performance and belt life. Always refer to the Shop Manual or obtain SKI-DOO dealer advice before servicing or modifying the drive or driven pulleys. Always respect maintenance schedules.

  • Page 93: Drive Belt Condition

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

  • Page 94: Track Tension And Alignment

    Do not modify track, including by installing traction enhancing prod- ucts. This may weaken the track and cause it to break without warning. WARNING Do not operate or rotate a track if torn, damaged or excessively worn. Track Tension and Alignment Tension NOTE: Ride the snowmobile in snow about 15 to 20 minutes prior to adjusting track tension.
  • Page 95 CAUTION: Too much tension will result in power loss and exces- sive stresses on suspension components. To adjust tension: – Remove wheel cap. – Loosen the rear idler wheel retaining screws. – Turn adjustment screws to adjust. If correct tension is unattainable, contact an authorized SKI-DOO dealer.
  • Page 96 A30F03A TYPICAL 1. Adjustment screw 2. Loosen screw 3. Wheel cap removing Alignment NOTE: Track tension and alignment are inter-related. Do not adjust one without the other. WARNING Before checking track alignment, ensure that the track is free of all particles which could be thrown out while track is rotat- ing.
  • Page 97 Start the engine and accelerate slightly so that track barely turns. This must be done in a short period of time (1 to 2 minutes). Check that the track is well centered; equal distance on both sides between edges of track guides and slider shoes. A01F05A TYPICAL 1.

  • Page 98: Steering And Front Suspension Mechanism

    Steering and Front Suspension Mechanism Visually inspect steering and front suspension mechanism for tight- ness of components (steering arms, control arms and links, tie rods, ball joints, ski coupler bolts, etc.). If necessary, contact your SKI-DOO dealer. Wear and Condition of Skis and Runners Check the condition of the skis, ski runners and ski runner carbides.

  • Page 99: Exhaust System

    Exhaust System The tail pipes of the muffler should be centered with the exit holes in the bottom pan. Exhaust system must be free of rust or leaks. Make sure that gear clamps are properly tightened. The exhaust system is designed to reduce noise and to improve the total performance of the engine.
  • Page 100 Reinstall filter over dashboard sticking bottom edge first. A30H0SA TYPICAL 1. Stick bottom edge first Finalize filter top edge installation.
  • Page 101 A30H0QA TYPICAL 1. Push top edge of filter under air deflector lip Check air silencer filter for snow. Remove filter and shake it as required. A30H0XA AIR SILENCER FILTER INSTALLED Check that the air silencer is clean and dry and properly reinstall the filter.

  • Page 102: Headlight Beam Aiming

    CAUTION: Snowmobile engines have been calibrated with the filter installed. Operating the snowmobile without it may cause engine damage. Headlight Beam Aiming Turn knob to adjust beam height. A30E08A 1. Knob Bulb Replacement Always check light operation after bulb replacement. Headlight CAUTION: Never touch glass portion of an halogen bulb with bare fingers, it shortens its operating life.
  • Page 103 A30E04A 1. Air deflector Unplug burnt bulb connector. Remove the rubber boot. Turn bulb locking ring counterclockwise to remove it. Detach the bulb and replace. Properly reinstall parts including air filter. A30E05A 1. Locking ring...
  • Page 104 Instrument(s) Remove air duct from underneath hood. A30E06A 1. Remove these screws Bulb socket is always behind the instrument under a black rubber boot. Pull rubber boot and socket to expose bulb. Pull bulb out of socket. A06H1EA TYPICAL 1. Instruments sockets...

  • Page 105: Towing The Vehicle

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

  • Page 106: Troubleshooting

    Install clean dry properly gapped spark plug. Start engine following usual starting procedure. If engine continues to flood, see an authorized SKI-DOO dealer. 4. No fuel to the engine Check fuel tank level; turn fuel valve (spark plug dry when removed).
  • Page 107 Check item 4 of “Engine turns over but fails to start”. 5. Carburetor adjustments. Contact an authorized SKI-DOO dealer. 6. Drive belt worn too thin. If the drive belt width is less than min- imum specification it will affect vehi- cle performance.
  • Page 108 4. Engine is running too hot. See item 8 of “Engine lacks accelera- tion or power”. 5. Ignition timing is incorrect or there Contact an authorized SKI-DOO dealer. is an ignition system failure. SYMPTOM: Engine misfires. POSSIBLE CAUSES WHAT TO DO 1.
  • Page 109 4. Incorrect track adjustment. See MAINTENANCE and/or SKI-DOO dealer for proper alignment and ten- sion adjustments. 5. Pulleys misaligned. Contact an authorized SKI-DOO dealer. 6. Engine. See items 3 to 8 of “Engine lacks ac- celeration or power”.

  • Page 110: Specifications

    SPECIFICATIONS MACH Z STD GENERAL MACH Z TECH PLUS Engine – Maximum Power 8300 Engine Speed Drive Belt – Number 417 300 066 – Width of a New Belt mm (in) 35.1 (1.382) – Wear Limit Width mm (in) 32.7 (1.287) Spark Plug –...
  • Page 111 Because of our ongoing commitment to product quality and innova- tion, Bombardier reserves the right, at any time, to make changes in design and specifications and/or to make additions to, or improve- ments in its products without imposing any obligation upon itself to install them on its products previously manufactured.

  • Page 112: Change Of Address Or Ownership

    Please provide your name, address, phone number, vehicle serial number and date it was stolen. Bombardier will provide a list of stolen units to all SKI-DOO dealers on a monthly basis to aid in recovery of such units to their owners.

This manual is also suitable for:

2002 mach z std2002 mach z tech plus

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