Ski-Doo 1997 Tundra II LT 3266 User Manual
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Ski-Doo 1997 Tundra II LT 3266 User Manual

Ski-Doo 1997 Tundra II LT 3266 User Manual

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Date : March 18, 1996
YEAR
MODEL NAME
1997
(Canada and United States)
1997
Tundra II LT (Europe)
This bulletin must be used in conjunction with the check list enclosed in Operator's Guide bag. Make sure
that predelivery check list is completed and signed.
WARNING : To obtain warranty coverage, predelivery procedures must be performed by an
authorized Bombardier snowmobile dealer. Apply all necessary torques as indicated.
O
NOTE : The Information and components / system descriptions contained in this document are
correct at the time of publication. Bombardier Inc. however, maintains a policy of continuous
improvement of its products without imposing upon itself any obligation to install them on products
previously manufactured. Due to late changes, it may have some differences between the manufactured
product and the descriptions and / or specifications in this document. Bombardier Inc. reserves the right
at any time to discontinue or change specifications, designs, features, models or equipment without
incurring obligation.
The illustrations in this document show the typical construction of the different assemblies and may not
reproduce the full detail or exact shape of the parts. However, they represent parts that have the same or
similar function.
The content of this bulletin is designed as a guideline only. All mechanics performing predelivery
procedures should have attended the current model year service training. Further information or
inquires should be directed to your distributor service representative and / or specific Shop
Manual sections.
Please complete the Predelivery Check List for each snowmobile and return a customer signed
copy. Make sure the customer receives the Operator's Guide , Safety Handbook and video.
Litho'd in Canada (MBL-9702 GM)
®* Trademarks of Bombardier Inc.
All rights reserved © Bombardier Inc. 1996
Tundra II LT
Campaign no. 00000
SUBJECT : Predelivery Procedures
MODEL NUMBER
3266
3267
97-1
97-1
No.
Revision 1
SERIAL NUMBER
All
All
Page 1 of 10

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  • Page 1 97-1 Campaign no. 00000 Revision 1 Date : March 18, 1996 SUBJECT : Predelivery Procedures YEAR MODEL NAME MODEL NUMBER SERIAL NUMBER Tundra II LT 1997 3266 (Canada and United States) 1997 Tundra II LT (Europe) 3267 This bulletin must be used in conjunction with the check list enclosed in Operator's Guide bag. Make sure that predelivery check list is completed and signed.

  • Page 2: Table Of Contents

    CONTENTS SUBJECT PAGE SUBJECT PAGE UNCRATING PARTS INSTALLATION WINDSHIELD PARTS INSTALLATION PARTS INSTALLATION STEERING COVER DRIVE BELT PARTS INSTALLATION LIQUIDS FRONT BUMPER OIL INJECTION PUMP BLEEDING PARTS INSTALLATION TECHNICAL DATA Page 2 of 10 97-1...

  • Page 3: Uncrating

    UNCRATING WARNING : Torque wrench tightening specifications must be strictly adhered to. Locking devices (e.g. lock tabs, elastic stop nuts) must be installed or replaced by new ones, where specified. If the efficiency of a locking device is impaired, it must be renewed. CAUTION : Allowing the crate to drop may cause serious damage to the vehicle.
  • Page 4 UNCRATING CAUTION : Make sure vehicle is properly supported before removing ski legs and rear suspension from crate brackets. Detach ski legs from crate. Keep ski leg bolts to bolt skis to ski legs. Discard nuts. Remove vehicle from base. Remove predelivery kit from engine compartment.

  • Page 5: Parts Installation Steering Cover

    PARTS INSTALLATION STEERING COVER A03G09S 1. Steering cover (P / N 572 0669 00) (on handlebar) 2. Equal gap all around A. 26 N•m (19 lbf•ft) 97-1 Page 5 of 10...

  • Page 6: Parts Installation Front Bumper

    PARTS INSTALLATION FRONT BUMPER A05H0NS 1. Nut M8 x 1.25 (4) (P / N 228 5810 45) (Section no. 2). Torque to 15 N•m (133 lbf•in) 2. Bushing (long) (2) (P / N 517 2506 00) (Section no. 3) 3. Bushing (short) (2) (P / N 517 2507 00) (Section no. 3) 4.

  • Page 7: Parts Installation Ski

    PARTS INSTALLATION A05G0GS 1. Nut (2) M10 x 1.5 (P / N 228 5010 45) (Section no. 1). Torque to 29 N•m (21 lbf•ft) 2. Stopper (2) (P / N 570 0270 00) (Section no. 4). Thicker side toward front 3.

  • Page 8: Parts Installation Windshield

    PARTS INSTALLATION WINDSHIELD A05H12S 1. Latch (9) (P / N 570 0238 00) (Section no. 3) PARTS INSTALLATION DRIVE BELT At factory a protective coating for the shipping is applied on pulleys and disc brake. This protective coating must be removed at predelivery. Clean pulleys and brake disc with a suitable cleaner such as Loctite Safety Solvent (P / N 413 7082 00) before installing drive belt.

  • Page 9: Liquids

    LIQUIDS OIL INJECTION PUMP BLEEDING Bleed main oil line (between tank and pump) by Bleed the small line between pump and intake loosening the bleeder screw until all air has es- manifold by running engine at idle while holding caped from the line. the pump lever in fully open position.

  • Page 10: Technical Data

    TECHNICAL DATA TUNDRA II LT Engine Type Maximum HP RPM ± 100 RPM 6900 Carburetor Type VM 34-443 Main Jet Needle Jet 159 O-8 Pilot Jet Needle Identification – Clip Position 6DH4-2 Slide Cut-away Float Adjustment ± 1 mm (± .04 in) (.94) Air Screw Adjustment ±...
  • Page 11 No. 97-2 SUBJECT: Predelivery Procedures Date: June 28, 1996 YEAR MODEL NAME MODEL NUMBER SERIAL NUMBER Canada and United states: 1115, 1116, 1113, 1112, Touring E/E LT/LE/SLE, 1110, 1111, 1120, 1121, 1996 Skandic 380/500 1117, 1118, 1108, 1106, Formula S/SL and 1107 Sweden: 1186, 1114, 1122, 1119...
  • Page 12 TABLE OF CONTENTS SUBJECT PAGE SUBJECT PAGE UNCRATING PARTS INSTALLATION DRIVE BELT PARTS INSTALLATION LIQUIDS FRONT SUSPENSION OIL INJECTION PUMP BLEEDING PARTS INSTALLATION LIQUIDS BATTERY BRAKE FLUID LEVEL PARTS INSTALLATION ADJUSTMENT SKIS SUSPENSION PARTS INSTALLATION ADJUSTMENT STEERING PAD TRACK ADJUSTMENT PARTS INSTALLATION DRIVEN PULLEY WINDSHIELD...

  • Page 13: Uncrating

    TECHNICAL DATA UNCRATING Cut locking ties retaining windshield. Slowly pull WARNING out metal strip, if equipped. Torque wrench tightening specifications CAUTION must be strictly adhered to. Locking devices (e.g. Iock tabs, elastic stop nuts) must be in- Make sure vehicle is properly supported be- stalled or replaced by new ones, where fore removing ski legs and rear suspension specified.
  • Page 14 TECHNICAL DATA UNCRATING WARNING Shipping strap must be cut and hook re- moved to have snowmobile suspension op- erational. A03F15A PREDELIVERY KIT P/N MODELS 580 6532 00 TOURING E 580 6529 00 TOURING ELT/LE/SLE 580 6533 00 SKANDIC 380/500 580 6388 00 FORMULA S/SL NOTE: This rule can be helpful to identify fastener length or size.

  • Page 15: Parts Installation Front Suspension

    PARTS INSTALLATION TECHNICAL DATA FRONT SUSPENSION Except Skandic 380/500 Lift front of vehicle and block safely. Cut locking tie retaining exhaust spring to exhaust Remove and discard shipping brackets from sus- support. pension. Discard spring clips, keep screws. Secure shock absorbers to suspension with their adjusting ring, if equipped, at bottom.
  • Page 16 PARTS INSTALLATION TECHNICAL DATA BATTERY Touring Models Only Connect RED positive cable and RED wire to pos- itive battery terminal. During vehicle preparation, the battery can be ac- tivated as described in Shop Manual. Connect BLACK negative cable LAST. CAUTION WARNING Prior to charging the battery, always remove Always connect the battery cables exactly in...

  • Page 17: Parts Installation

    PARTS INSTALLATION TECHNICAL DATA BATTERY A03H1WA BATTERY PROTECTIVE BOOT INSTALLED Ensure that vent tube is not kinked or blocked. Reinstall air silencer and ignition module. Reinstall throttle cable and primer hose plastic clip to air silencer. Fasten spark plug cables. 97-2 Page 7 of 16...

  • Page 18: Parts Installation Skis

    PARTS INSTALLATION SKIS Install skis on vehicle. NOTE: Make sure that slider cushions are still in ski leg. Replace vehicle on ground. A03G0ES TYPICAL—RIGHT SIDE SHOWN 1. Nut M12 x 1.75 (2) (section no. 1 or 3) torque to 40 N•m (30 lbf•ft) 2.

  • Page 19: Parts Installation Steering Pad

    PARTS INSTALLATION STEERING PAD Align handlebar with steering column axis and tighten nuts loosely for now. Loosen, at least 3 turns, Allen screw of throttle and brake handle housings. Install steering pad temporary, and adjust for proper fit with console. Remove steering pad and torque nuts to 26 N•m (19 lbf•ft).
  • Page 20 PARTS INSTALLATION STEERING PAD Formula S/SL Only Adjust handlebar temporary and tighten nuts loosely for now. Loosen, at least 3 turns, Allen screw of throttle and brake handle housings. Install steering pad temporary, and adjust for proper fit with console. Remove steering pad and torque nuts to 26 N•m (19 lbf•ft).

  • Page 21: Parts Installation Windshield

    PARTS INSTALLATION WINDSHIELD Install windshield on dashboard. A03H17S 1. Dart (1) (P/N 414 6443 00) (section no. 2 or 5) 2. Latch (6) (P/N 570 0238 00) (section no. 4 or 6) 3. Temporary remove headlamp molding for windshield installation 97-2 Page 11 of 16...

  • Page 22: Parts Installation Backrest

    PARTS INSTALLATION WINDSHIELD When reinstalling headlamp molding make sure lip is behind headlamp. A03H1XA 1. Headlamp 2. Lip of headlamp molding behind headlamp PARTS INSTALLATION BACKREST Except Touring E and Formula S/SL A00H0CA 1. Slide backrest on mounting bracket and install with screws Page 12 of 16 97-2...

  • Page 23: Parts Installation Drive Belt

    PARTS INSTALLATION DRIVE BELT Clean pulleys and disc brake with a suitable cleaner such as Loctite Cleaning Solvent (P/N 413 7082 00) before installing drive belt. LIQUIDS OIL INJECTION PUMP BLEEDING To assure additional protection during the initial Bleed the small oil line between pump and intake engine break-in, 500 mL (18 imp.

  • Page 24: Liquids Brake Fluid Level

    LIQUIDS BRAKE FLUID LEVEL Check brake fluid in reservoir for proper level. Add fluid (DOT 4) as required. CAUTION Use only (DOT 4) brake fluid from a sealed container. Do not store or use a partial bottle of brake fluid. ADJUSTMENT TECHNICAL DATA SUSPENSION...
  • Page 25 TECHNICAL DATA TECHNICAL DATA TOURING E/E LT MODELS FORMULA S TOURING LE SKANDIC 380 Engine Type Maximum HP RPM ±100 RPM 6900 7000 Rotary Valve Opening(BTDC)/ N.A. N.A. Closing (ATDC) Carburetor Type 2 x Mikuni VM 30 mm 2 x Mikuni VM 34 Main Jet Needle Jet P-0 (159)
  • Page 26 TECHNICAL DATA TECHNICAL DATA TOURING SLE MODELS FORMULA SL SKANDIC 500 Engine Type Maximum HP RPM ± 100 RPM 7100 Rotary Valve Opening(BTDC)/ N.A. Closing (ATDC) Carburetor Type PTO VM 34-481 MAG VM 34-482 Main Jet PTO 180 MAG 170 Needle Jet P-0 (159) Pilot Jet...
  • Page 27 No. 97-2 REVISION 1 Date: July 4, 1996 SUBJECT: Predelivery Procedures Please update the predelivery bulletin 97-2 with the following page. Replace existing page of your bulletin. Year models has been changed from 1996 to 1997. 97-2 Page 1 of 1 Litho’d in Canada (MBL-9706 PS) ®*Trademarks of Bombardier Inc.
  • Page 28 ANNEX FROM 97-2 REVISION 1 No. 97-2 SUBJECT: Predelivery Procedures Date: July 4, 1996 YEAR MODEL NAME MODEL NUMBER SERIAL NUMBER Canada and United states: 1115, 1116, 1113, 1112, Touring E/E LT/LE/SLE, 1110, 1111, 1120, 1121, 1997 Skandic 380/500 1117, 1118, 1108, 1106, Formula S/SL and 1107 Sweden:...
  • Page 29 TABLE OF CONTENTS SUBJECT PAGE SUBJECT PAGE UNCRATING PARTS INSTALLATION DRIVE BELT PARTS INSTALLATION LIQUIDS FRONT SUSPENSION OIL INJECTION PUMP BLEEDING PARTS INSTALLATION LIQUIDS BATTERY BRAKE FLUID LEVEL PARTS INSTALLATION ADJUSTMENT SKIS SUSPENSION PARTS INSTALLATION ADJUSTMENT STEERING PAD TRACK ADJUSTMENT PARTS INSTALLATION DRIVEN PULLEY WINDSHIELD...
  • Page 30 No. 97-3 Date: July 29, 1996 SUBJECT: Predelivery Procedures YEAR MODEL NAME MODEL NUMBER SERIAL NUMBER 1997 Canada and United States: 1157/1158/1159/1160/ Summit* 500/583/670 and Formula* 1162/1163/1138/1139/ 500/500 De Luxe/583/Z 1191/1192/1141/1142/ 1145/1146 1997 Sweden: 1161/1140 Summit 583 and Formula 500 This bulletin must be used in conjunction with the check list enclosed in the bag with the Operator's Guide .
  • Page 31 TABLE OF CONTENTS SUBJECT PAGE SUBJECT PAGE UNCRATING PARTS INSTALLATION DRIVE BELT PARTS INSTALLATION LIQUIDS FRONT SUSPENSION OIL INJECTION PUMP BLEEDING PARTS INSTALLATION ADJUSTMENT BATTERY DRIVE PULLEY LIQUIDS PARTS INSTALLATION BRAKE FLUID LEVEL SKIS PARTS INSTALLATION ADJUSTMENT STEERING PAD SUSPENSION ADJUSTMENT PARTS INSTALLATION TRACK...
  • Page 32 TECHNICAL DATA UNCRATING When this metal strip is under the seat loosen 2 WARNING or 4 nuts retaining the seat before pulling out the metal strip. Torque wrench tightening specifications must be strictly adhered to. Locking devices CAUTION (e.g. Iock tabs, elastic stop nuts) must be in- stalled or replaced by new ones, where Make sure vehicle is properly supported be- specified.
  • Page 33 TECHNICAL DATA UNCRATING WARNING WARNING Shipping strap must be cut and hook re- Failure to use this method of strap removal moved to have snowmobile suspension op- could result in personal injury. erational. PREDELIVERY KIT MODELS SUMMIT 500/583/670 580 6540 00 FORMULA Z FORMULA 500 DE LUXE 580 6543 00...

  • Page 34: Parts Installation Front Suspension

    PARTS INSTALLATION TECHNICAL DATA FRONT SUSPENSION Formula 500/500 De Luxe/583, Summit 583 All Models Cut locking tie retaining exhaust spring to exhaust Lift front of vehicle and block safely. support. Remove and discard shipping brackets from sus- pension. Discard spring clips, keep screws. Secure shock absorbers to suspension with their adjusting ring at bottom.

  • Page 35: Parts Installation

    PARTS INSTALLATION TECHNICAL DATA BATTERY Formula 500 De Luxe Only Connect vent tube to vehicle fitting on front frame, as shown. During vehicle preparation, the battery can be ac- tivated as described in Shop Manual . CAUTION Prior to charging the battery, always remove it from the vehicle to prevent electrolyte spillage.

  • Page 36: Parts Installation Skis

    PARTS INSTALLATION SKIS Formula 500 and 583 Only Install skis on vehicle. NOTE: Make sure that slider cushions are still in ski leg. Replace vehicle on ground. A03G0ES LEFT SIDE SHOWN 1. Elastic flanged nut M12 x 1.75 (2) (P/N 228 5210 45) (Section no. 1). Torque to 40 N•m (30 lbf•ft) 2.
  • Page 37 PARTS INSTALLATION SKIS Formula 500 De Luxe, Formula Z, Summit 500/583/670 A16G0CS LEFT SIDE SHOWN 1. Stop bounding (2) (P/N 570 0468 00) (Section no. 8) 2. Slider cushion (4) (Ski leg) 3. Elastic flanged nut M12 (2) (Ski leg). Torque to 40 N•m (30 lbf•ft) 4.

  • Page 38: Parts Installation Steering Pad

    PARTS INSTALLATION STEERING PAD All Models Adjust handlebar temporary and tighten nuts loosely for now. Loosen, at least 3 turns, Allen screw of throttle and brake handle housings. Install steering pad temporary, and adjust for proper fit with console. Remove steering pad and torque nuts to 26 N•m (19 lbf•ft). Reinstall steering pad, adjust and tighten throttle and brake handle housings.
  • Page 39 PARTS INSTALLATION STEERING PAD A06G1HA BRAKE HANDLE HOUSING A06G1IA 1. Tighten set screw to 2 N•m (18 lbf•in) THROTTLE HANDLE HOUSING 1. Tighten set screw to 2 N•m (18 lbf•in) Page 10 of 19 97-3...

  • Page 40: Parts Installation Windshield

    PARTS INSTALLATION WINDSHIELD All Models Install windshield on dashboard. NOTE: Make sure that protective foam is properly positioned around headlamp before installing windshield. A03H1YA A03H20A 1. Protective foam 1. Latch (6) (P/N 570 0238 00) (section no. 4 or 6) 2.

  • Page 41: Parts Installation Drive Belt

    PARTS INSTALLATION DRIVE BELT Clean pulleys and disc brake with a suitable cleaner such as Loctite Cleaning Solvent (P/N 413 7082 00) before installing drive belt. LIQUIDS OIL INJECTION PUMP BLEEDING SUPPLEMENTAL OIL Bleed the small oil line between pump and intake manifold by running engine at idle while holding To assure additional protection during the initial en- the pump lever in fully open position.

  • Page 42: Liquids Brake Fluid Level

    ADJUSTMENT DRIVE PULLEY Summit 500 and 583 Adjust TRA drive pulley screw according to decal on belt guard. LIQUIDS BRAKE FLUID LEVEL Check brake fluid in reservoir for proper level. Add CAUTION fluid (DOT) as required. Use only (DOT 4) brake fluid from a sealed container.

  • Page 43: Adjustment Track

    ADJUSTMENT TRACK Refer to Shop Manual to adjust track tension and alignment. See TECHNICAL DATA section at the end of this bulletin. ADJUSTMENT DRIVEN PULLEY It is usual to experience spring settings during break-in period of a new spring. The factory spring preload is slightly higher to compensate for springs settings.
  • Page 44 TECHNICAL DATA TECHNICAL DATA A dot (•) on right indicates changes from 1996 model. FORMULA 500/500 MODELS FORMULA 583 DE LUXE Engine Type • • Maximum HP RPM ±100 RPM 7750 7900 Rotary Valve 420 9245 09 420 9245 02 Opening (BTDC)/ 135°/64°...
  • Page 45 TECHNICAL DATA TECHNICAL DATA A dot (•) on right indicates changes from 1996 model. MODEL SUMMIT 500 Engine Type • Maximum HP RPM ±100 RPM 7750 Rotary Valve 420 9245 09 Opening (BTDC)/ 135°/64° Closing (ATDC) Carburetor Type PTO VM 38 - 363 MAG VM 38 - 364 •...
  • Page 46 TECHNICAL DATA TECHNICAL DATA A dot (•) on right indicates changes from 1996 model. MODEL SUMMIT 583 Engine Type • Maximum HP RPM ±100 RPM 7800 Rotary Valve 420 9245 09 Opening (BTDC)/ 135°/64° Closing (ATDC) • Carburetor Type PTO VM 38 - 365 MAG VM 38 - 366 •...
  • Page 47 TECHNICAL DATA TECHNICAL DATA A dot (•) on right indicates changes from 1996 model. MODEL SUMMIT 670 Engine Type • Maximum HP RPM ±100 RPM 7700 Rotary Valve 420 9245 00 • Opening (BTDC)/ 145°/71° Closing (ATDC) • Carburetor Type PTO VM 40 - 90 MAG VM 40 - 91 Main Jet...
  • Page 48 TECHNICAL DATA TECHNICAL DATA A dot (•) on right indicates changes from 1996 model. MODEL FORMULA Z Engine Type • Maximum HP RPM ±100 RPM 7900 Rotary Valve 420 9245 02 Opening (BTDC)/ 140°/71° Closing (ATDC) • Carburetor Type PTO VM 40 - 88 MAG VM 40 - 89 •...
  • Page 49 No. 97-4 Date: August 2, 1996 SUBJECT: Predelivery Procedures YEAR MODEL NAME MODEL NUMBER SERIAL NUMBER Skandic* WT 1997 1134/1135 (Canada and United States) Skandic* SWT 1997 1136/1137 (Canada and United States) Skandic* WT LC 1997 1132/1133 (Canada and United States) The contents of this bulletin is designed as a This bulletin must be used in conjunction with the check list enclosed in the Operator’s Guide bag.
  • Page 50 TABLE OF CONTENTS SUBJECT PAGE SUBJECT PAGE UNCRATING PARTS INSTALLATION BACKREST AND SEAT STRAP PARTS INSTALLATION PARTS INSTALLATION BATTERY DRIVE BELT LIQUIDS PARTS INSTALLATION OIL INJECTION REAR SUSPENSION PUMP BLEEDING PARTS INSTALLATION LIQUIDS FRONT SUSPENSION BRAKE FLUID LEVEL PARTS INSTALLATION LIQUIDS SKIS ENGINE COOLANT LEVEL...
  • Page 51 TECHNICAL DATA UNCRATING All Models WARNING Torque wrench tightening specifications must be strictly adhere to. Locking devices (e.g. lock tabs, nylon stop nuts) must be installed or replaced by new one, where specified. If the efficiency of a locking device is impaired, it must be renewed. CAUTION Allowing the crate to drop may cause serious damage to the vehicle.
  • Page 52 Tip cover towards rear of vehicle. There is a notch in crate base at front. A29H07S 1. Notch Detach parts to be installed (e.g. skis, windshield), from the vehicle and its base. CAUTION Make sure vehicle is properly supported before removing ski legs and rear suspension from crate brackets.
  • Page 53 PARTS INSTALLATION TECHNICAL DATA BATTERY All models During preparation, the battery can be activated as described in 1997 Ski-Doo Shop Manual. CAUTION Prior to charging the battery, always remove it from the vehicle to prevent electrolyte spillage. On WT and SWT models, a special vented rivet is fixed to the chassis in order to plug the vent tube from the battery.
  • Page 54 Skandic WT Battery installation Secure battery brackets. Battery removal Connect battery cables. Remove air intake silencer. WARNING Always connect the battery cables exactly in the specified order. Connect RED positive ca- ble first, then BLACK negative ground cable. Apply silicone dielectric grease (P/N 413 7017 00) on battery posts and connectors.
  • Page 55 Battery installation Battery installation Install battery in vehicle. Install battery in vehicle. Connect battery cables. Connect battery cables. WARNING WARNING Always connect the battery cables exactly in Always connect the battery cables exactly in the specified order. Connect RED positive ca- the specified order.

  • Page 56: Rear Suspension

    PARTS INSTALLATION REAR SUSPENSION Secure front arm upper axle of rear suspension Secure rear arm using previously removed using 2 M10 x 30 screws in plastic bag under the screws. seat. Apply Loctite 242 on threads and torque screws Apply Loctite 242 on threads and torque screws to 58 N•m (43 lbf•ft).

  • Page 57: Parts Installation Skis

    A22G0IA 1. Plastic Bushings PARTS INSTALLATION SKIS Install stop bounding on skis with its highest por- tion toward front. A29G0BA 1. Stop bounding Instal skis on vehicle using bolts, nuts, washers and rubber bushings supplied in the predelivery kit. 97-4 Page 9 of 18...
  • Page 58 A22G0GS 1. Stop bounding 2. Sleeve 3. Rubber bushing (2) 4. Flat washer (2) 5. Bolt M10 x 120 6. M10 lock nut, tighten to 48 N•m (35 lbf•ft) Tighten shock rod top nuts to 30 N•m (22 lbf•ft). Page 10 of 18 97-4...

  • Page 59: Parts Installation Steering Pad

    PARTS INSTALLATION STEERING PAD Adjust handle bar and set both clamps to have NOTE: On Skandic SWT, make sure to secure equal gap on each side. Torque nuts to 26 N•m steering column cover with steering pad before (19 lbf•ft). tightening bolts.

  • Page 60: Parts Installation Windshield

    PARTS INSTALLATION WINDSHIELD Remove headlamp molding. Install rubber support in predrilled holes on the hood. A22H0OS Step : Pry out headlamp molding Step : Install support. Apply soap on tips to ease installation Step : Install windshield Step : Install latches (10) Page 12 of 18 97-4...

  • Page 61: Parts Installation Backrest And Seat Strap

    Install windshield and secure with latches inside hood. Install rubber expansion nut in hole above head light. Line up hole in windshield with rubber expansion nut and install screw with cup. Tighten slightly so that rubber expands inside hood. Install rubber cap on screw and reinstall headlamp molding.

  • Page 62: Parts Installation Drive Belt

    PARTS INSTALLATION DRIVE BELT Clean pulleys and disk brake with a suitable cleaner such as Loctite Cleaning Solvent (P/N 413 7082 00) before installing drive belt. LIQUIDS OIL INJECTION PUMP BLEEDING All models Skandic WT LC To assure additional protection during the initial engine break-in, 500 ml (18 imp.

  • Page 63: Liquids Brake Fluid Level

    LIQUIDS BRAKE FLUID LEVEL All Models Check brake fluid in reservoir for proper level. Add recommended brake fluid as required. CAUTION Use only (DOT 4) brake fluid from a sealed container. Do not store or use a partial bottle of brake fluid. A06G1OA 1.

  • Page 64: Technical Data

    TECHNICAL DATA TECHNICAL DATA The content of the TECHNICAL DATA pages should be used as necessary to fine-tune and perform additional adjustments required on the snowmobile. Vehicle used at high altitudes, above 600 m (2000 ft.) should be fitted with a high altitude kit. Further inquires should be directed to your distributor service representative.
  • Page 65 TECHNICAL DATA TECHNICAL DATA The dot (•) indicates changes from 1996 models. MODELS SKANDIC WT SKANDIC SWT Engine Type ROTAX 503 ROTAX 503 Maximum HP RPM ±100 RPM 6500 6500 Rotary Valve Opening (BTDC)/ N.A. N.A. Closing (ATDC) Carburetor Type VM 32 VM 32 Main Jet...
  • Page 66 TECHNICAL DATA TECHNICAL DATA MODELS SKANDIC WT LC Engine Type Maximum HP RPM 6800-6900 Rotary Valve 420 9245 09 Opening (BTDC)/ 148° Closing (ATDC) 52° Carburetor Type PTO VM 34 MAG VM 34 Main Jet PTO 260 MAG 260 Needle Jet PTO 159 P-0 MAG 159 P-0 Pilot Jet...
  • Page 67 No. 97-5 Date: August 2, 1996 SUBJECT: Uncrating Procedure YEAR MODEL NAME MODEL NUMBER SERIAL NUMBER ALL except Skandic* WT/SWT 1997 and Tundra* II LT SHIPPING STRAP REMOVAL Cut shipping strap using one of these 2 following methods: Method 1 Using a long flat chisel such as Snap-On ®...
  • Page 68 HOOK REMOVAL A01F2DA A. 1.2 mm (3/64 in) B. 10 mm (25/64 in) C. 28.5 mm (1-1/8 in) D. 30° Remove all sharp edges. A03F14A Assemble the two pieces and weld them togeth- er, as shown on the following photo. 1.
  • Page 69 No. 97-6 Date: August 14, 1996 SUBJECT: Predelivery Procedures YEAR MODEL NAME MODEL NUMBER SERIAL NUMBER Canada and United States: 1168, 1169, 1171, 1172, 1997 MX Z* 440, MX Z 440 F, 1174, 1175, 1193, 1194 MX Z 583 and MX Z 670 Sweden: 1997 MX Z 440, MX Z 440 F,...
  • Page 70 TABLE OF CONTENTS SUBJECT PAGE SUBJECT PAGE UNCRATING PARTS INSTALLATION DRIVE BELT PARTS INSTALLATION LIQUIDS FRONT SUSPENSION OIL INJECTION PUMP BLEEDING PARTS INSTALLATION LIQUIDS SKIS BRAKE FLUID LEVEL PARTS INSTALLATION ADJUSTMENT STEERING PAD SUSPENSION PARTS INSTALLATION ADJUSTMENT WINDSHIELD TRACK ADJUSTMENT DRIVEN PULLEY TECHNICAL DATA inches...
  • Page 71 TECHNICAL DATA UNCRATING Cut locking ties retaining windshield. Slowly pull PREDELIVERY KIT out metal strip, if equipped. MODELS When this metal strip is under the seat loosen 2 580 6543 00 MX Z 440/440 F/583/670 or 4 nuts retaining the seat before pulling out the metal strip.
  • Page 72 TECHNICAL DATA UNCRATING Method 2 Remove all sharp edges. Using a special tool cut shipping strap as shown Assemble the two pieces and weld them togeth- on the next photo. er, as shown on the following photo. A01F2EA 1. 20 mm (3/4 in) steel tubing 2.
  • Page 73 TECHNICAL DATA UNCRATING Lean on vehicle seat to apply pressure on rear sus- pension and remove hook from rear portion of suspension, as shown on the next photo. A01F2FA 1. Remove hook on the rear portion of the suspension WARNING Shipping strap must be cut and hook re- moved to have snowmobile suspension op- erational.

  • Page 74: Parts Installation

    PARTS INSTALLATION TECHNICAL DATA FRONT SUSPENSION Cut locking tie retaining exhaust spring to exhaust Lift front of vehicle and block safely. support. Remove and discard shipping brackets from sus- pension. Discard spring clips, keep screws. Secure shock absorbers to suspension with their adjusting ring at bottom.

  • Page 75: Parts Installation Skis

    PARTS INSTALLATION SKIS All Models Install skis on vehicle. NOTE: Make sure that slider cushions are still in ski leg. Replace vehicle on ground. A03G0ES LEFT SIDE SHOWN 1. Elastic flanged nut M12 x 1.75 (2) (P/N 228 5210 45) (Section no. 1). Torque to 40 N•m (30 lbf•ft) 2.

  • Page 76: Parts Installation Steering Pad

    PARTS INSTALLATION STEERING PAD All Models Adjust handlebar temporarily and tighten nuts loosely for now. Loosen, at least 3 turns, Allen screw of throttle and brake handle housings. Install steering pad temporarily, and adjust for proper fit with console. Remove steering pad and torque nuts to 26 N•m (19 lbf•ft). Reinstall steering pad, adjust and tighten throttle and brake handle housings.
  • Page 77 PARTS INSTALLATION STEERING PAD A06G1HA BRAKE HANDLE HOUSING 1. Tighten set screw to 2 N•m (18 lbf•in) Except MX Z 440 F A06G1IA THROTTLE HANDLE HOUSING 1. Tighten set screw to 2 N•m (18 lbf•in) 97-6 Page 9 of 16...

  • Page 78: Parts Installation Windshield

    PARTS INSTALLATION WINDSHIELD All Models Install windshield on dashboard. NOTE: Make sure that protective foam is properly positioned around headlamp before installing windshield. A03H22A A03H20A 1. Protective foam 1. Latch (6) (P/N 570 0238 00) (section no. 4 or 6) 2.

  • Page 79: Parts Installation Drive Belt

    PARTS INSTALLATION DRIVE BELT Clean pulleys and disc brake with a suitable cleaner such as Loctite Cleaning Solvent (P/N 413 7082 00) before installing drive belt. LIQUIDS OIL INJECTION PUMP BLEEDING All Models Except MX Z 440 F Reinstall all parts except air silencer. Bleed the small oil line between pump and intake SUPPLEMENTAL OIL manifold by running engine at idle while holding...

  • Page 80: Liquids

    LIQUIDS OIL INJECTION PUMP BLEEDING MX Z 440 F Only Bleed the small oil line between pump and intake manifold by running engine at idle while holding To assure additional protection during the initial the pump lever in fully open position. engine break-in, 500 mL (18 imp.

  • Page 81: Adjustment Track

    ADJUSTMENT TECHNICAL DATA SUSPENSION Rear suspension is calibrated at factory. At prede- livery, mechanics should perform suspension ad- justments according to customer riding style and vehicle load as described on suspension adjust- ment chart which is located on pulley guard. A01H1HA 1.
  • Page 82 TECHNICAL DATA TECHNICAL DATA A dot (•) on right indicates changes from 1996 model. MODELS MX Z 440 MX Z 583 Engine Type Maximum HP RPM ±100 RPM 8000 7900 Rotary Valve 420 9245 02 420 9245 02 Opening (BTDC)/ 146°/65°...
  • Page 83 TECHNICAL DATA TECHNICAL DATA A dot (•) on right indicates changes from 1996 model. MODEL MX Z 670 Engine Type Maximum HP RPM ±100 RPM 7700 Rotary Valve 420 9245 00 Opening (BTDC)/ 145°/71° Closing (ATDC) • Carburetor Type PTO VM 40 - 94 MAG VM 40 - 95 Main Jet PTO 300...
  • Page 84 TECHNICAL DATA TECHNICAL DATA A dot (•) on right indicates changes from 1996 model. MODEL MX Z 440 F Engine Type Maximum HP RPM ±100 RPM 7000 Rotary Valve N.A. Opening (BTDC)/ N.A. Closing (ATDC) Carburetor Type PTO VM 34 - 479 MAG VM 34 - 480 Main Jet PTO 205...
  • Page 85 MX Z 670 United States: 1194 Sweden: 1195 The technical data sheet for the above mentioned models has been updated. Refer to the Ski-Doo Predelivery Bulletin no. 97-6. Replace with the attached. 97-6 Page 1 of 1 Litho’d in Canada (MBL-9717 GA) ®*Trademarks of Bombardier Inc.
  • Page 86 TECHNICAL DATA TECHNICAL DATA A dot (•) on right indicates changes from 1996 model. MODEL MX Z 670 Engine Type Maximum HP RPM ± 100 RPM 7700 Rotary Valve 420 9245 00 145°/71° Opening (BTDC)/ Closing (ATDC) • Carburetor Type PTO VM 40 - 94 MAG VM 40 - 95 Main Jet...
  • Page 87 TECHNICAL DATA TECHNICAL DATA A dot (•) on right indicates changes from 1996 model. MODEL MX Z 440 F Engine Type Maximum HP RPM ±100 RPM 7000 Rotary Valve N.A. Opening (BTDC)/ N.A. Closing (ATDC) Carburetor Type PTO VM 34 - 479 MAG VM 34 - 480 Main Jet PTO 205...
  • Page 88 No. 97-7 Date: September 12, 1996 SUBJECT: Predelivery Procedure YEAR MODEL MODEL NUMBER SERIAL NUMBER Canada and United States: 1148, 1149, 1177, 1178, 1997 Formula*III, Mach*1 and Mach* Z 1180, 1181 Sweden: 1997 1150, 1179, 1182 Formula III, Mach 1 and Mach Z This bulletin must be used in conjunction with the check list enclosed in Operator's Guide bag.
  • Page 89 TABLE OF CONTENTS SUBJECT PAGE SUBJECT PAGE UNCRATING PARTS INSTALLATION DRIVE BELT PARTS INSTALLATION LIQUIDS FRONT SUSPENSION OIL INJECTION PUMP BLEEDING PARTS INSTALLATION LIQUIDS SKIS BRAKE FLUID LEVEL PARTS INSTALLATION ADJUSTMENTS STEERING PAD SUSPENSION PARTS INSTALLATION ADJUSTMENTS WINDSHIELD TRACK PARTS INSTALLATION ADJUSTMENTS SNOW GUARD DRIVEN PULLEY...
  • Page 90 TECHNICAL DATA UNCRATING PREDELIVERY KIT MODELS 580 6581 00 Mach 1 and Mach Z 580 6580 00 Formula III WARNING Torque wrench tightening specifications must be strictly adhered to. Locking devices (e.g. Iock tabs, elastic stop nuts) must be in- stalled or replaced by new ones, where specified.
  • Page 91 TECHNICAL DATA UNCRATING Remove vehicle from base. Remove steering pad, shock absorbers, snow guard, drive belt and predelivery kit from engine compartment. SHIPPING STRAP REMOVAL Cut shipping strap using one of these 2 following methods: Method 1 Using a long flat chisel such as Snap-On® PPC820LA cut shipping strap that collapses front portion of rear suspension, as shown on the next photo.
  • Page 92 TECHNICAL DATA UNCRATING A01F2EA 1. 20 mm (3/4 in) steel tubing 2. Welded joint A01F2FA A. 410 mm (16 in) B. 460 mm (18 in) 1. Remove hook on the rear portion of the suspension WARNING WARNING Failure to use one of these two methods of Shipping strap must be cut and hook re- strap removal could result in personal injury.

  • Page 93: Parts Installation

    PARTS INSTALLATION TECHNICAL DATA FRONT SUSPENSION Lift front of vehicle and block safely. Remove and discard shipping brackets from suspension. Discard spring clips, keep bolts. Secure shock absorbers to suspension with their adjusting ring at bottom. NOTE: Position bolt heads toward front. A06G1NS TYPICAL —...

  • Page 94: Parts Installation Skis

    PARTS INSTALLATION SKIS A16G0CS LEFT SIDE SHOWN 1. Ski stopper (2) (section no. 8) “AVANT” toward front 2. Slider cushion (4) 3. Elastic flanged nut M12 (2) (section no. 8). Torque to 40 N•m (30 lbf•ft) 4. Loosen then adjust against ski stopper 14 N•m (124 lbf•in) 5.

  • Page 95: Parts Installation Steering Pad

    PARTS INSTALLATION STEERING PAD Adjust handlebar temporarily and tighten nuts loosely for now. Loosen, at least 3 turns, Allen screw of throttle and brake handle housings. Install steering pad temporarily, and adjust for proper fit with console. Remove steering pad and torque nuts to 26 N•m (19 lbf•ft). Reinstall steering pad, adjust and tighten throttle and brake handle housings.
  • Page 96 PARTS INSTALLATION STEERING PAD Adjust then tighten throttle and brake handle housings. A06G1HA BRAKE HANDLE HOUSING 1. Tighten set screw to 2 N•m (18 lbf•in) Mach Z Only A06G1IA THROTTLE HANDLE HOUSING 1. Tighten set screw to 2 N•m (18 lbf•in) 97-7 Page 9 of 17...

  • Page 97: Parts Installation Windshield

    PARTS INSTALLATION WINDSHIELD Install windshield on hood. NOTE: To ease installation, install windshield with darts first. A06H27S 1. Dart (section no. 6) 2. Latch (section no. 6) Page 10 of 17 97-7...

  • Page 98: Snow Guard

    PARTS INSTALLATION TECHNICAL DATA SNOW GUARD Position snow guard protector pad onto chassis. Install snow guard over protector pad and secure the two parts with rivets. NOTE: Place washers inside tunnel. A06H2PA VIEW FROM UNDER SNOW GUARD 1. Snow guard 2.

  • Page 99: Parts Installation Drive Belt

    PARTS INSTALLATION DRIVE BELT Clean pulleys and disc brake with a suitable cleaner such as Loctite Cleaning Solvent (P/N 413 7082 00) before installing drive belt. LIQUIDS OIL INJECTION PUMP BLEEDING To assure additional protection during the initial Bleed the small oil lines between pump and en- engine break-in, 500 mL (18 imp.

  • Page 100: Liquids Brake Fluid Level

    LIQUIDS BRAKE FLUID LEVEL Check brake fluid (DOT 4) in reservoir for proper level. Add fluid (DOT 4) as required. CAUTION Use only (DOT 4) brake fluid from a sealed container. Do not store or use a partial bottle of brake fluid. A06G1OA 1.

  • Page 101: Adjustments Track

    ADJUSTMENTS TRACK Refer to Shop Manual to adjust track tension and alignment. See Technical Data section at the end of this bulletin. ADJUSTMENTS DRIVEN PULLEY It is usual to experience spring settings during break-in period of a new spring. The factory spring preload is slightly higher to compensate for springs settings.
  • Page 102 TECHNICAL DATA TECHNICAL DATA A dot (•) on right indicates changes from 1996 model. MODEL FORMULA III Engine Type • Maximum HP RPM ± 100 RPM 8500 Rotary Valve Opening (BTDC)/ N.A. Closing (ATDC) • Carburetor Type PTO VM 36-176 CRT VM 36-177 MAG VM 36-178 •...
  • Page 103 TECHNICAL DATA TECHNICAL DATA A dot (•) on right indicates changes from 1996 model. MODEL MACH 1 • Engine Type • Maximum HP RPM ± 100 RPM 8500 Rotary Valve • Opening (BTDC)/ N.A. Closing (ATDC) • Carburetor Type PTO VM 38-356 CRT VM 38-357 MAG VM 38-358 •...
  • Page 104 TECHNICAL DATA TECHNICAL DATA A dot (•) on right indicates changes from 1996 model. MODEL MACH Z • Engine Type • Maximum HP RPM ± 100 RPM 8500 Rotary Valve Opening (BTDC)/ N.A. Closing (ATDC) • Carburetor Type PTO TM 38 C159 CRT TM 38 C159 MAG TM 38 C159 •...
  • Page 105 Sweden: 1997 1179 Mach 1 The technical data sheet for the above mentioned models has been updated. Refer to the Ski-Doo Predelivery Bulletin no. 97-7. Replace with the attached. 97-7 97-7 Page 1 of 2 Page 1 of 1 Litho’d in Canada (MBL-9715 PS) Litho’d in Canada (MBL-9715 PS)
  • Page 106 TECHNICAL DATA TECHNICAL DATA A dot (•) on right indicates changes from 1996 model. MODEL FORMULA III Engine Type • Maximum HP RPM ± 100 RPM 8500 Rotary Valve Opening (BTDC)/ N.A. Closing (ATDC) • Carburetor Type PTO VM 36-176 CRT VM 36-177 MAG VM 36-178 •...
  • Page 107 TECHNICAL DATA TECHNICAL DATA A dot (•) on right indicates changes from 1996 model. MODEL MACH 1 • Engine Type • Maximum HP RPM ± 100 RPM 8500 Rotary Valve • Opening (BTDC)/ N.A. Closing (ATDC) • Carburetor Type PTO VM 38-356 CRT VM 38-357 MAG VM 38-358 •...
  • Page 108 No. 97-8 Date: October 25, 1996 SUBJECT: Predelivery Procedure YEAR MODEL MODEL NUMBER SERIAL NUMBER Canada and United States: 1997 1151, 1152, 1183 and 1184 Formula* III LT and Mach* Z LT Sweden: 1997 1153 and 1185 Formula III LT and Mach Z LT This bulletin must be used in conjunction with the check list enclosed in Operator's Guide bag .
  • Page 109 TABLE OF CONTENTS SUBJECT PAGE SUBJECT PAGE UNCRATING LIQUIDS OIL INJECTION PUMP BLEEDING PARTS INSTALLATION LIQUIDS FRONT SUSPENSION BRAKE FLUID LEVEL ADJUSTMENTS PARTS INSTALLATION SUSPENSION SKIS ADJUSTMENTS PARTS INSTALLATION TRACK STEERING PAD PARTS INSTALLATION ADJUSTMENTS WINDSHIELD DRIVEN PULLEY PARTS INSTALLATION TECHNICAL DATA DRIVE BELT NOTE: This ruler can be helpful to identify fastener length or size.
  • Page 110 TECHNICAL DATA UNCRATING PREDELIVERY KIT MODELS FORMULA III LT 580 6472 00 MACH Z LT WARNING Torque wrench tightening specifications must be strictly adhered to. Locking devices (e.g. Iock tabs, elastic stop nuts) must be in- stalled or replaced by new ones, where specified.
  • Page 111 Remove vehicle from base. How to Build the Special Tool Remove steering pad, drive belt, predelivery kit Using 20 mm (3/4 in) steel tubing, cut the first and detach shock absorbers from engine com- piece to 460 mm (18 in) and the second one to partment.
  • Page 112 HOOK REMOVAL A03F14A 1. Hook to be removed Lift front of vehicle to position bumper 35 to 40 inches upward. Lean on vehicle seat to apply pressure on rear suspension and remove hook from rear portion of suspension, as shown on the next photo. A01F2FA 1.

  • Page 113: Parts Installation

    PARTS INSTALLATION TECHNICAL DATA FRONT SUSPENSION Lift front of vehicle and block safely. Remove and discard shipping brackets from suspension. Discard spring clips, keep bolts. Secure shock absorbers to suspension with their adjusting ring at bottom. NOTE: Position bolt heads toward front. A06G1NS TYPICAL —...

  • Page 114: Parts Installation Skis

    PARTS INSTALLATION SKIS A16G0CS LEFT SIDE SHOWN 1. Ski stopper (2) (Section no. 8), “AVANT” toward front 2. Slider cushion (4) 3. Nut M12 (2) (Section no. 8). Torque to 40 N•m (30 lbf•ft) 4. Loosen then adjust against ski stopper 14 N•m (124 lbf•in) 5.

  • Page 115: Parts Installation Steering Pad

    PARTS INSTALLATION STEERING PAD Adjust handlebar temporarily and tighten nuts loosely for now. Loosen Allen screw of throttle and brake handle housings, at least 3 turns. Install steering pad temporarily, and adjust for proper fit with console. Remove steering pad and torque nuts to 26 N•m (19 lbf•ft). Reinstall steering pad, adjust and tighten throttle and brake handle housings.
  • Page 116 PARTS INSTALLATION STEERING PAD Adjust then tighten throttle and brake handle housings. A06G1HA BRAKE HANDLE HOUSING 1. Tighten set screw to 2 N•m (18 lbf•in) Mach Z LT Only A06G1IA THROTTLE HANDLE HOUSING 1. Tighten set screw to 2 N•m (18 lbf•in) 97-8 Page 9 of 15...

  • Page 117: Parts Installation Windshield

    PARTS INSTALLATION WINDSHIELD Install windshield on hood. A06H27S 1. Dart (section 6) 2. Latch (section 6) Page 10 of 15 97-8...

  • Page 118: Parts Installation Drive Belt

    PARTS INSTALLATION DRIVE BELT Clean pulleys and disc brake with a suitable cleaner such as Loctite Cleaning Solvent (P/N 413 7082 00) before installing drive belt. LIQUIDS OIL INJECTION PUMP BLEEDING To assure additional protection during the initial Bleed the small oil lines between pump and en- engine break-in, 500 mL (18 imp.

  • Page 119: Liquids Brake Fluid Level

    LIQUIDS BRAKE FLUID LEVEL Check brake fluid (DOT 4) in reservoir for proper level. Add fluid (DOT 4) as required. CAUTION Use only (DOT 4) brake fluid from a sealed container. Do not store or use a partial bottle of brake fluid. A06G1OA 1.

  • Page 120: Adjustments Driven Pulley

    ADJUSTMENTS TRACK Refer to Shop Manual to adjust track tension and alignment. See Technical Data section at the end of this bulletin. ADJUSTMENTS DRIVEN PULLEY It is usual to experience spring settings during break-in period of a new spring. The factory spring preload is slightly higher to compensate for springs settings.
  • Page 121 TECHNICAL DATA TECHNICAL DATA A dot (•) on right indicates changes from 1996 model. MODEL FORMULA III LT Engine Type • Maximum HP RPM ± 100 RPM 8500 Rotary Valve Opening (BTDC)/ N.A. Closing (ATDC) • Carburetor Type PTO VM 36-176 CTR VM 36-177 MAG VM 36-178 •...
  • Page 122 A dot (•) on right indicates changes from 1996 model. MODEL MACH Z LT • Engine Type • Maximum HP RPM ±100 RPM 8500 Rotary Valve Opening (BTDC)/ N.A. Closing (ATDC) • Carburetor Type PTO TM 38-C159 CTR TM 38-C159 MAG TM 38-C159 •...
  • Page 123 Campaign no. 36363 No. 97-9 Replaces 95-12 UPDATE Date: October 11, 1996 SUBJECT: Predelivery Procedures YEAR MODEL NAME MODEL NUMBER SERIAL NUMBER Canada and United States: 1997 1123, 1124, 1126 and 1127 Grand Touring 500/583 Sweden: 1997 1125 and 1128 Grand Touring 500/583 This bulletin must be used in conjunction with the check list enclosed in Operator's Guide bag.
  • Page 124 TABLE OF CONTENTS SUBJECT PAGE SUBJECT PAGE UNCRATING PARTS INSTALLATION DRIVE BELT PARTS INSTALLATION LIQUIDS FRONT SUSPENSION OIL INJECTION PUMP BLEEDING PARTS INSTALLATION LIQUIDS BATTERY BRAKE FLUID LEVEL PARTS INSTALLATION ADJUSTMENTS SKIS SUSPENSION PARTS INSTALLATION ADJUSTMENTS STEERING PAD TRACK PARTS INSTALLATION ADJUSTMENTS WINDSHIELD DRIVEN PULLEY...
  • Page 125 TECHNICAL DATA UNCRATING Cut locking ties retaining windshield. Slowly pull PREDELIVERY KIT P/N MODELS out metal strip retaining windshield, if equipped. When this metal strip is under the seat loosen 2 580 6541 00 GT 500/583 or 4 nuts retaining the seat before pulling out the metal strip.
  • Page 126 TECHNICAL DATA UNCRATING Method 2 Remove all sharp edges. Assemble the two pieces and weld them togeth- Using a special tool cut shipping strap as shown er, as shown on the following photo. on the next photo. A01F2EA 1. 20 mm (3/4 in) steel tubing 2.
  • Page 127 TECHNICAL DATA UNCRATING Lean on vehicle seat to apply pressure on rear suspension and remove hook from rear portion of suspension, as shown on the next photo. A01F2FA 1. Remove hook on the rear portion of the suspension WARNING Shipping strap must be cut and hook re- moved to have snowmobile suspension op- erational.

  • Page 128: Parts Installation

    PARTS INSTALLATION TECHNICAL DATA FRONT SUSPENSION Cut locking tie retaining exhaust spring to exhaust All Models support. Lift front of vehicle and block safely. Remove and discard shipping brackets from sus- pension. Discard spring clips, keep screws. Secure shock absorbers to suspension with their adjusting ring at bottom.

  • Page 129: Parts Installation

    PARTS INSTALLATION TECHNICAL DATA BATTERY During vehicle preparation, the battery can be ac- Connect vent tube to vehicle fitting on front tivated as described in Shop Manual . frame, as shown. CAUTION Prior to charging the battery, always remove it from the vehicle to prevent electrolyte spillage.

  • Page 130: Parts Installation Skis

    PARTS INSTALLATION SKIS A16G0CS LEFT SIDE SHOWN 1. Stop bounding (2) (P/N 570 0468 00) (section no. 4) 2. Slider cushion (4) (ski leg) 3. Nut M12 (2) (ski leg). Torque to 40 N•m (30 lbf•ft) 4. Loosen then adjust against stop bounding. Torque to 14 N•m (124 lbf•in) 5.

  • Page 131: Parts Installation Steering Pad

    PARTS INSTALLATION STEERING PAD Adjust handlebar temporarily and tighten nuts loosely for now. Loosen, at least 3 turns, Allen screw of throttle and brake handle housings. Install steering pad temporarily, and adjust for proper fit with console. Remove steering pad and torque nuts to 26 N•m (19 lbf•ft). Reinstall steering pad, adjust and tighten throttle and brake handle housings.
  • Page 132 PARTS INSTALLATION STEERING PAD A06G1HA BRAKE HANDLE HOUSING 1. Tighten set screw to 2 N•m (18 lbf•in) A06G1IA THROTTLE HANDLE HOUSING 1. Tighten set screw to 2 N•m (18 lbf•in) Page 10 of 16 97-9...

  • Page 133: Parts Installation Windshield

    PARTS INSTALLATION WINDSHIELD Install windshield on dashboard. NOTE: Make sure that protective foam is properly positioned around headlamp before installing windshield. A03H22A 1. Protective foam A03H20A 2. Install windshield on dashboard 1. Latch (6) (P/N 570 0238 00) (section no. 4 or 6) A03H23A WINDSHIELD INSTALLED ON DASHBOARD 97-9...

  • Page 134: Parts Installation Backrest

    PARTS INSTALLATION BACKREST Secure backrest frame on tunnel then install lever assembly onto luggage rack rail. Install hand protectors with rivets onto luggage rack handle. A03H24S 1. Handle protector (2) (seat storage compartment). Secure with rivets 2. Screw (2) (P/N 732 6011 75) (section no. 6) 3.

  • Page 135: Parts Installation Drive Belt

    PARTS INSTALLATION BACKREST Turn adjustment knob left or right to adjust back- rest cushion position. A03H25A PARTS INSTALLATION DRIVE BELT Clean pulleys and disc brake with a suitable cleaner such as Loctite Cleaning Solvent (P/N 413 7082 00) before installing drive belt. 97-9 Page 13 of 16...

  • Page 136: Liquids

    LIQUIDS OIL INJECTION PUMP BLEEDING SUPPLEMENTAL OIL Reinstall all parts except air silencer. Bleed the small oil line between pump and intake To assure additional protection during the initial manifold by running engine at idle while holding engine break-in, 500 mL (18 imp. oz) of BOMBAR- the pump lever in fully open position.

  • Page 137: Adjustments Track

    ADJUSTMENTS TECHNICAL DATA SUSPENSION Rear suspension is calibrated at factory. At prede- livery, mechanics should perform suspension ad- justments according to customer riding style and vehicle load as described on suspension adjust- ment chart which is located on pulley guard. A01H1HA 1.
  • Page 138 TECHNICAL DATA TECHNICAL DATA A dot (•) on right indicates changes from 1996 model. GRAND TOURING GRAND TOURING MODELS • Engine Type • • Maximum HP RPM ± 100 RPM 7800 7900 • 420 9245 09 420 9245 02 Rotary valve Opening (BTDC)/ •...
  • Page 139 No. 97-10 Date: November 5, 1996 SUBJECT: Predelivery Procedures YEAR MODEL NAME MODEL NUMBER SERIAL NUMBER Canada and United States: 1997 1214 and 1215 MX Zx* 440 LC This bulletin must be used in conjunction with the check list enclosed in the bag with the Operator's Guide .
  • Page 140 TABLE OF CONTENTS SUBJECT PAGE SUBJECT PAGE UNCRATING LIQUIDS BRAKE FLUID LEVEL PARTS INSTALLATION ADJUSTMENT SKIS TRACK PARTS INSTALLATION ADJUSTMENT WINDSHIELD DRIVEN PULLEY PARTS INSTALLATION TECHNICAL DATA DRIVE BELT LIQUIDS ROTARY VALVE OIL RESERVOIR LEVEL A99A0HS NOTE: This ruler can be helpful to identify fastener length or size. Page 2 of 8 97-10...
  • Page 141 TECHNICAL DATA UNCRATING Detach parts to be installed (e.g. skis, windshield) PREDELIVERY from the vehicle and its base. MODELS KIT P/N CAUTION 580 6564 00 MX Zx 440 LC Make sure vehicle is properly supported be- fore removing ski legs and rear suspension WARNING from crate brackets.

  • Page 142: Parts Installation Skis

    PARTS INSTALLATION SKIS Install skis on vehicle. NOTE: Make sure that slider cushions are still in ski leg. Replace vehicle on ground. A15G1MS LEFT SIDE SHOWN 1. Ski stopper (2) (section no. 8) “AVANT” toward front 2. Self-locking nut M12 x 1.75 (2) (Section no. 8). Torque to 24 N•m (18 lbf•ft) 3.

  • Page 143: Parts Installation Windshield

    PARTS INSTALLATION WINDSHIELD Install windshield on dashboard. A15H46S 1. Dart (1) (P/N 414 6443 00) (section no. 6) 2. Latch (6) (P/N 570 0238 00) (section no. 6) 3. Temporary remove headlamp molding for windshield installation 97-10 Page 5 of 8...
  • Page 144 PARTS INSTALLATION DRIVE BELT Clean pulleys and disc brake with a suitable cleaner such as Loctite Cleaning Solvent (P/N 413 7082 00) before installing drive belt. LIQUIDS ROTARY VALVE OIL RESERVOIR LEVEL Check oil level in the rotary valve reservoir. Add oil CAUTION as required.
  • Page 145 ADJUSTMENTS TRACK Refer to Shop Manual to adjust track tension and alignment. See TECHNICAL DATA section at the end of this bulletin. ADJUSTMENTS DRIVEN PULLEY It is usual to experience spring settings during break-in period of a new spring. The factory spring preload is slightly higher to compensate for springs settings.
  • Page 146 TECHNICAL DATA TECHNICAL DATA MODEL MX Zx 440 LC Engine Type Maximum HP RPM ± 100 RPM 8450 Rotary Valve 420 924 502 Opening (BTDC)/ Closing (ATDC) Carburetor Type PTO VM 34 - 498 MAG VM 34 - 499 Main Jet PTO 260 MAG 250 Needle Jet...
  • Page 147 MX Zx 440 LC The page 6 for the above mentioned models have been updated. Bombardier-Rotax synthetic injec- tion oil (12 x 1L) part number is 413 7105 00. Refer to the Ski-Doo Predelivery Bulletin no. 97-10. Replace with the attached. 97-10 97-10...
  • Page 148 PARTS INSTALLATION WINDSHIELD Install windshield on dashboard. A15H46S 1. Dart (1) (P/N 414 6443 00) (section no. 6) 2. Latch (6) (P/N 570 0238 00) (section no. 6) 97-10 Page 5 of 8...

  • Page 149: Parts Installation Drive Belt

    PARTS INSTALLATION DRIVE BELT Clean pulleys and disc brake with a suitable cleaner such as Loctite Cleaning Solvent (P/N 413 7082 00) before installing drive belt. LIQUIDS ROTARY VALVE OIL RESERVOIR LEVEL Check oil level in the rotary valve reservoir. Add oil CAUTION as required.
  • Page 150 Campaign no. 36363 No. 97-11 Replaces 95-12UP Date: December 6, 1996 SUBJECT: Predelivery Procedures YEAR MODEL NAME MODEL NUMBER SERIAL NUMBER Canada and United States: 1997 1129 and 1130 Grand Touring SE Sweden: 1997 1131 Grand Touring SE This bulletin must be used in conjunction with the check list enclosed in Operator's Guide bag. Make sure that predelivery check list is completed and signed.
  • Page 151 TABLE OF CONTENTS SUBJECT PAGE SUBJECT PAGE UNCRATING PARTS INSTALLATION DRIVE BELT PARTS INSTALLATION LIQUIDS FRONT SUSPENSION OIL INJECTION PUMP BLEEDING PARTS INSTALLATION LIQUIDS SKIS BRAKE FLUID LEVEL PARTS INSTALLATION ADJUSTMENTS BATTERY SUSPENSION PARTS INSTALLATION ADJUSTMENTS STEERING PAD TRACK PARTS INSTALLATION ADJUSTMENTS WINDSHIELD DRIVEN PULLEY...
  • Page 152 TECHNICAL DATA UNCRATING Cut locking ties retaining windshield. Slowly pull PREDELIVERY KIT P/N MODEL out metal strip retaining windshield, if equipped. When this metal strip is under the seat loosen 2 580 6542 00 GRAND TOURING SE or 4 nuts retaining the seat before pulling out the metal strip.
  • Page 153 TECHNICAL DATA UNCRATING Method 2 Remove all sharp edges. Assemble the two pieces and weld them togeth- Using a special tool cut shipping strap as shown er, as shown on the following photo. on the next photo. A01F2EA 1. 20 mm (3/4 in) steel tubing 2.
  • Page 154 A beep every 3 seconds and DESS pilot lamp blinking as same rate mean that a bad connection has been detected. Vehicle can not be driven. Refer to SKI-DOO MPEM Programmer Guide (P/N 480 1436 00) for proper procedure. 97-11...
  • Page 155 PARTS INSTALLATION TECHNICAL DATA FRONT SUSPENSION All Models Lift front of vehicle and block safely. Remove and discard shipping brackets from suspension. Discard spring clips, keep screws. Secure shock absorbers to suspension with their adjusting ring at bottom. NOTE: Position screw heads toward front. A06G0JS TYPICAL —...
  • Page 156 PARTS INSTALLATION SKIS A16G0CS LEFT SIDE SHOWN 1. Stop bounding (2) (P/N 570 0468 00) (section no. 4) 2. Slider cushion (4) (ski leg) 3. Nut M12 (2) (ski leg). Torque to 40 N•m (30 lbf•ft) 4. Loosen then adjust against stop bounding. Torque to 14 N•m (124 lbf•in) 5.
  • Page 157 PARTS INSTALLATION TECHNICAL DATA BATTERY During vehicle preparation, the battery can be ac- Remove left side air intake silencer. tivated as described in Shop Manual . CAUTION CAUTION When removing left side air intake silencer, Prior to charging the battery, always remove ensure not to damage engine temperature it from the vehicle to prevent electrolyte sensor (gauge) connectors, as shown on the...
  • Page 158 PARTS INSTALLATION TECHNICAL DATA BATTERY Remove right side air intake silencer. Unfasten battery retaining strips. Open strips and lift battery protective boot. A06E2WA PULL OUT RED POSITIVE BATTERY CABLE 1. Air intake silencer support 2. Route RED positive battery cable behind air intake silencer support A06E1BB Battery Installation...
  • Page 159 PARTS INSTALLATION TECHNICAL DATA BATTERY Connect BLACK negative cable and BLACK wire Apply silicone dielectric grease (P/N 413 7017 00) LAST. Refer to the following photo for proper ca- on battery posts and connectors. ble positioning. Ensure vent tube is properly installed on battery elbow, then install protective boot over battery.
  • Page 160 PARTS INSTALLATION STEERING PAD Adjust handlebar temporarily and tighten nuts loosely for now. Install steering pad temporarily, and adjust for proper fit with console. Remove steering pad and torque nuts to 26 N•m (19 lbf•ft). Reinstall steering pad, adjust and tighten throttle and brake handle housings. A06G0FS 1.
  • Page 161 PARTS INSTALLATION WINDSHIELD Install windshield on dashboard. A06H24S 1. Dart (8) (section no. 5) 2. Latch (6) (section no. 5) 3. Normal use position: rotate mirror assy’s half turn by hand 4. PDI position Page 12 of 17 97-11...
  • Page 162 PARTS INSTALLATION BACKREST Secure backrest frame on tunnel then install lever assembly onto luggage rack rail. Install hand protectors with rivets onto luggage rack handle. A03H24S 1.Handle protector (2) (seat storage compartment). Secure with rivets 2.Screw (2) (P/N 732 6011 75) (section no. 6) 3.Washer (2) (P/N 732 9000 30) (section no.
  • Page 163 PARTS INSTALLATION BACKREST Turn adjustment knob left or right to adjust back- rest cushion position. A03H25A PARTS INSTALLATION DRIVE BELT Clean pulleys and disc brake with a suitable cleaner such as Loctite Cleaning Solvent (P/N 413 7082 00) before installing drive belt. Page 14 of 17 97-11...
  • Page 164 LIQUIDS OIL INJECTION PUMP BLEEDING SUPPLEMENTAL OIL Bleed the small oil lines between pump and en- gine crankcase by running engine at idle while To assure additional protection during the initial holding the pump lever in fully open position. engine break-in, 500 mL (18 imp. oz) of BOMBAR- NOTE: To ease pump lever holding, make a J DIER ROTAX Mineral Injection Oil (P/N 413 8030 hook out of mechanical wire to lift the lever.

  • Page 165: Driven Pulley

    ADJUSTMENTS TECHNICAL DATA SUSPENSION Rear suspension is calibrated at factory. At prede- livery, mechanics should perform suspension ad- justments according to customer riding style and vehicle load as described on suspension adjust- ment chart which is located on pulley guard. A01H1HA 1.
  • Page 166 TECHNICAL DATA TECHNICAL DATA A dot (•) on right indicates changes from 1996 model. MODELS GRAND TOURING SE • Engine Type • Maximum HP RPM ±100 RPM 8500 • Rotary valve N.A. Opening (BTDC)/ • N.A. Closing (ATDC) • Carburetor Type PTO VM 38 - 372 •...
  • Page 167 No. 97-12 Date: February 6, 1997 SUBJECT: Predelivery Procedures YEAR MODEL NAME MODEL NUMBER SERIAL NUMBER 1997 SKANDIC* SWT 1301 This bulletin must be used in conjunction with the Please complete the Predelivery Check List for check list enclosed in the Operator’s Guide bag. each snowmobile and return a customer signed Make sure that predelivery check list is complet- copy.
  • Page 168 TABLE OF CONTENTS SUBJECT PAGE SUBJECT PAGE UNCRATING PARTS INSTALLATION BACKREST PARTS INSTALLATION PARTS INSTALLATION BATTERY WIRE CUTTER PARTS INSTALLATION REAR SUSPENSION PARTS INSTALLATION DRIVE BELT PARTS INSTALLATION FRONT SUSPENSION LIQUIDS OIL INJECTION PUMP BLEEDING PARTS INSTALLATION SKIS LIQUIDS BRAKE FLUID LEVEL PARTS INSTALLATION STEERING PAD ADJUSTMENT...
  • Page 169 TECHNICAL DATA UNCRATING WARNING Torque wrench tightening specifications must be strictly adhere to. Locking devices (e.g. lock tabs, nylon stop nuts) must be installed or replaced by new one, where specified. If the efficiency of a locking device is impaired, it must be renewed. CAUTION Allowing the crate to drop may cause serious damage to the vehicle.
  • Page 170 TECHNICAL DATA UNCRATING Tip cover towards rear of vehicle. There is a notch in crate base at front. A29H07S 1. Notch Detach parts to be installed (e.g. skis, windshield), from the vehicle and its base. CAUTION Make sure vehicle is properly supported before removing ski legs and rear suspension from crate brackets.

  • Page 171: Parts Installation

    A29G0AA PARTS INSTALLATION TECHNICAL DATA BATTERY During preparation, the battery can be activated as described in 1997 Ski-Doo Shop Manual. CAUTION Prior to charging, always remove the battery from the vehicle to prevent electrolyte spill- age. NOTE: A special vented rivet is fixed to the chas- sis in order to plug the vent tube from the battery.
  • Page 172 PARTS INSTALLATION TECHNICAL DATA BATTERY Battery Removal Remove battery bracket and remove battery from vehicle. A29E0DA Battery Installation Install battery in vehicle. Connect battery cables. WARNING Always connect the battery cables exactly in the specified order. Connect RED positive ca- ble first, then BLACK negative ground cable.

  • Page 173: Parts Installation Rear Suspension

    PARTS INSTALLATION REAR SUSPENSION Secure front arm upper axle of rear suspension Secure rear arm using previously removed using 2 M10 x 30 screws in plastic bag under the screws. seat. Apply Loctite 242 on threads and torque screws Apply Loctite 242 on threads and torque screws to 58 N•m (43 lbf•ft).

  • Page 174: Parts Installation Skis

    PARTS INSTALLATION TECHNICAL DATA FRONT SUSPENSION A22G0IA 1. Plastic bushings PARTS INSTALLATION SKIS Install stop bounding on skis with its highest por- tion toward front. A29G0BA 1. Stop bounding Instal skis on vehicle using bolts, nuts, washers and rubber bushings supplied in the predelivery kit.
  • Page 175 PARTS INSTALLATION SKIS A22G0GS 1. Stop bounding 2. Sleeve 3. Rubber bushing (2) 4. Flat washer (2) 5. Bolt M10 x 120 6. M10 lock nut, tighten to 48 N•m (35 lbf•ft) Tighten shock rod top nuts to 30 N•m (22 lbf•ft). 97-12 Page 9 of 17...

  • Page 176: Parts Installation Steering Pad

    PARTS INSTALLATION STEERING PAD Adjust handle bar and set both clamps to have equal gap on each side. Torque nuts to 26 N•m (19 lbf•ft). Loosen throttle and brake handle housings. Install steering pad. Secure steering column cover with steering pad before tightening bolts. Adjust both throttle and brake handle housings to match steering pad.

  • Page 177: Parts Installation Windshield

    PARTS INSTALLATION WINDSHIELD Remove headlamp molding. Install rubber support in predrilled holes on the hood. A22H0OS Step : Pry out headlamp molding Step : Install support. Apply soap on tips to ease installation Step : Install windshield Step : Install latches (10) 97-12 Page 11 of 17...

  • Page 178: Parts Installation Backrest

    PARTS INSTALLATION WINDSHIELD Install windshield and secure with latches inside hood. Install rubber expansion nut in hole above head light. Line up hole in windshield with rubber expansion nut and install screw with cup. Tighten slightly so that rubber expands inside hood.

  • Page 179: Parts Installation Wire Cutter

    PARTS INSTALLATION WIRE CUTTER Position wire cutter on the hood. A29H0FA 1. Drill 8 mm (5/16 in) holes A29H0DA 1. Install M8 bolt in predrilled hole Open hood. Line up the center hole of the center support plate From inside hood, install washers and lock nuts to with hole already drilled in hood and install bolt secure side support plates.

  • Page 180: Parts Installation Drive Belt

    PARTS INSTALLATION WIRE CUTTER A29H0GA 1. Backing support 2. Cable 3. Cable lock PARTS INSTALLATION DRIVE BELT Clean pulleys and disk brake with a suitable cleaner such as Loctite Cleaning Solvent (P/N 413 7082 00) before installing drive belt. Page 14 of 17 97-12...

  • Page 181: Oil Injection Pump Bleeding

    LIQUIDS OIL INJECTION PUMP BLEEDING To assure additional protection during the initial engine break-in, 500 ml (18 imp. oz) of BOMBAR- DIER ROTAX injection oil (P/N 413 8029 00) should be added to fuel for the first full filling of fuel tank.

  • Page 182: Adjustment Track

    ADJUSTMENT TRACK Refer to Shop Manual to adjust track tension and alignment. See TECHNICAL DATA section at the end of this bulletin. TECHNICAL DATA TECHNICAL DATA The content of the TECHNICAL DATA pages should be used as necessary to fine-tune and perform additional adjustments required on the snowmobile.
  • Page 183 TECHNICAL DATA TECHNICAL DATA MODEL SKANDIC SWT Engine Type ROTAX 503 Maximum HP RPM ±100 RPM 6500 Rotary Valve N.A. Carburetor Type VM 32 Main Jet Needle Jet 159 O-0 Pilot Jet Needle Identification — Clip Position 6DH8-4 Slide Cutaway Float Adjustment mm (in) 23.9 (.94)

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