1981 Blizzard 5500
model
serial number
purchase date
_
warranty expiry date
To be completed by dealer at time of sale
DEALER IMPRINT AREA
Text by:
The following are trademarks of Bombardier l.imitee.
TECHNICAL PUBLICATIONS
AFTER SALES SERVICE DEPARTMENT
BOMBARDIER L1MITEE
VALCOURT, QUEBEC
CANADA, JOE2LO
BOMBARDIER
EVEREST
SKI-DOD
CITATION
ALPINE
OLYMPIQUE
BLIZZARD
T'NT
CARRY-BOOSE
ELAN
ELITE
GRAND PRIX SPECIAL
MOTO-SKI
FUTURA
SPIRIT
NUVIK
MIRAGE
SUPER SONIC
ULTRA SONIC
INDEX
2
3
5
FOREWORD
THE 1981 uLIMITED WARRANTY"
OFTEN ASKED QUESTIONS
LISTING OF AREA DISTRIBUTORS
HOW TO IDENTIFY YOUR SNOWMOBILE
SAFETY IN MAINTENANCE . . . . . . . . ..
..
7
8
9
CONTROUINSTRUMENTS
Throttle lever, brake lever, ignition/light switch, headlamp dimmer switch,
emergency cut-out switch, manual starter handle, primer, speedometer, tether
10
cut-out switch, hood opening, tool box, fuel gauge, fuel tank cap
BREAK..IN PERIOD
Break-in, inspection. 10 hour inspection checklist
12
FUEL MIXING
Recommended gasoline, recommended oil, fuel mixture ratio, fuel mixing procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
14
PRE..START CHECK
Check points
15
STARTING PROCEDURE
Starting procedure, emergency starting .. .
1&
LUBRICATION
Frequency. belt guard removal, drive belt removal, steering mechanism. chain.. 17
case oil level
MAINTENANCE
Maintenance chart, spark plugs, suspension, track, track tension and alignment,
carburetor adjustment, drive belt. steering mechanism, drive pulley, brake, steering adjustment, engine head nuts, engine mount nuts, muffler attachment, fan
,
19
belt. bulb replacement. general inspection
STORAGE
Track, suspension, ski, controls, chaincase, fuel tank. carburetors. cylinder lubri24
cation, chassis. general inspection
PRE..SEASON PREPARATION
Pre-season preparation. chart. . . ..
.
TROUBLE SHOOTING
TOOLS
SPECIFICATIONS
,
.
WIRING DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . ..
SI METRIC INFORMATION GUIDE
CHANGE OF ADDRESS OR OWNERSHIP. . . . . . . . . . . . . . . . . . . . . . .. .
27
28
30
31
32
33
35
FOREWORD
The Operator Manual and the Snowmobile Safety handbook have been
prepared to acquaint the owner I operator of a new snowmobile with the various vehicle controls maintenance and
safe operating instructions.
Each is indispensable for the proper
use of the product, and should be kept
with the vehicle at all times.
Should you have any questions ~er­
taining to the warranty and Its application/ please consult the "0ften Asked
Question" section of this manual, or
your selling dealer.
2
This manual uses the following symbols.
•
WARNING: Identifies an instruc. . . tion which, if not followed, could
cause personal injury.
_
CAUTION: Denotes an instruc. . tion which, if not followed, could
severely damage vehicle components.
NOTE: Indicates supplementary
information needed to fully complete an instruction.
Although the mere re~di~g of such information does not eliminate the hazard/ your understandinq of the information will promote Its correct use.
O
LIMITED WARRANTY 1981
SKI-DOO~
SNOWMOBILES
1 - PERIOD
BOMBARDIER® LlMITEE as manufacturer, warrants FROM THE DATE OF
FIRST CONSUMER SALES, every 1981 SKI-DOO®snowmobile, sold as NEW
AND UNUSED, by an authorized SKI-DOO dealer, for periods of:
• 12 consecutive months for ELAN®, CITATION*, EVEREST®, ELlTE®,
ALPINE® models.
• 90 consecutive days for BLiZZARD® 5500, 7500 and 9500 models subject to
the following:
1. If delivery is made after the 31st day of March of a given year and before the 1st
day of December of the same year, the above 90 day warranty will start on December 1st.
2. If delivery is made on/or after the 2nd day of January of a given year but before
the 31st day of March of the same year, all the unused portion of the 90 day period will be carried over to the next winter and start again on the 1st day of December of the same year.
2· WHAT BOMBARDIER WILL DO
BOMBAR 01ER will repair and/or replace, at its option, components defective in
material and/or workmanship (under normal use and service,) with a genuine
BOMBARDIER component without charge for parts or labour, at any authorized
SKI-DOO dealer during said warranty period.
3 - CONDITION TO HAVE WARRANTY WORK PERFORMED
Present to the servicing dealer, the hard copy of the BOMBARDIER Customer Registration card received by the customer from the selling dealer at time of purchase.
4 • WARRANTY TRANSFER
This warranty is transferable to subsequent ownerts) for remainder of warranty period from original date of sale.
5 . EXCLUSIONS· ARE NOT WARRANTED
• Normal wear on all items such as, but not limited to:
- drive belts
slider shoes
- spark plugs
breaker points
- runners on skis
• A sulphated battery.
• Replacement parts and/or accessories which are not genuine BOMBARDIER
parts and/or accessories.
• Damage resulting from installation of parts other than genuine BOMBARDIER
parts.
• Damage caused by failure to provide proper maintenance as detailed in the
Operator Manual. The labour, parts and lubricants costs of all maintenance services, including tune-ups and adjustments will be charged to the owner.
3
• vehicles used for racing purposes.
• All optional accessories installed on the vehicle.
(The normal warranty policy for parts and accessories, if any, applies).
• Damage resulting from accident, fire or other casualty, misuse, abuse or neglect.
• Damage resulting from modification to the snowmobile not approved in writing
by BOMBARDIER.
• Losses incurred by the snowmobile owner other than parts and labour, such as,
but not limited to, transportation, towing, telephone calls, taxis, or any other
incidental or consequential damages.
Some states or provinces do not allow the exclusion or limitation of incide....
tal or consequential damages, so the above limitation or exclusion may not
apply.
I · EXPRESSED OR IMPLIED WARRANTIES
This warranty gives you specific rights, and you may also have other legal
rights which may vary from state to state, or province to province. Where
applicable this warranty is expressly in lieu of all other expressed or implied
warranties of BOMBARDIER, its distributors and the .elling dealer, including
any wananty of merchantability of fitness for any particular purpose; otherwise the implied w.ranty is limited to the duration of this warranty. However, some states or provinces do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply.
Neither the distributor, the selling dealer, nor any other person has been
authorized to make any affirmation, representation or warranty other than
those contained in this warranty, and if made, such affirmation, representation or warranty shall not be enforceable against BOMBARDIER or any other
person.
BOMBARDIER LIMITEE reserves the right to modify its warranty policy at
any time, being understood that such modification will not alter the w.ranty
conditions applicable to vehicles sold while the above warranty is in effect.
7 • CONSUMER ASSISTANCE
If a servicing problem or other difficulty occurs, we suggest the following:
1. Try to resolve the problem at the dealership with the Service Manager or
Owner.
2. If this fails, contact your area distributor listed in the Operator Manual.
3. Then if your grievance still remains unsolved, you may write to us:
Bombardier Limitee
Customer Relations
Recreational Products
Valcourt, Quebec, Canada, JOE 2LO
January 1980
Bombardier Limitee
Valcourt, Quebec, Canada, JOE 2LO
@
*Trademarks of Bombardier Limitee
Copy of this text is available from your dealer on request.
4
OFTEN ASKED QUESTIONS
Q: Why must my snowmobile be registered? After aliI do have my original invoice
as proof of when I purchased my snowmobile.
A: Your warranty is valid at any authorized dealer of the product. Your registration is the key element in providinq the servicing dealer with the necessary
data to complete warranty claim forms. This information is also used to notify
owners in the event of a safety recall.
Q: How do I know my vehicle has been registered at the factory?
A: When you bought your snowmobile the dealer should have completed, and
forwarded us the manufacturer's copy of the Customer Warranty Registration. The hard copy of the card is your proof that the snowmobile is registered.
Q: I bought my snowmobile in 0' King County but I snowmobile in Washington
County. Can the dealer in Washington County accept to perform warranty work
on my snowmobile?
A: Yes, any authorized dealer in North America can perform warranty repairs,
providing the customer warranty registration card is presented.
Q: Where can I find information on the lubrication and maintenance of my snowmobile?
A: In this Operator Manual provided with the vehicle at the time of first sale.
Q: Will the entire warranty be void or cancelled, if I do not operate or maintain my
new snowmobile exactly as specified in the Operator's Manual?
A: The warranty of the new snowmobile cannot be "tvoided" or Cancelled".
However, if a particular failure is caused by operation or maintenance other
than is shown in the Operator Manual, that failure may not be covered under
warranty. This includes service work performed by the customer, especially
the critical adjustments to ignition, timing, carburetion and oil injection/or OJ!
mixture.
Q: Would you give some examples of abnormal use or strain, neglect or abuse?
A: These terms are general and overlap each other in areas. Some specific examples may include: running the machine out of oil, sustained high r.p.m. full
throttle use, chain failure caused by a lack of lubrication and/or adjustments,
operating the machine with a broken or damaged part which causes another
part to fail, and so on. If you have any specific questions on operation or maintenance, please contact your dealer for advice.
5
Q: What costs are my responsibility during the warranty period?
A: The customer's responsebilitv includes all costs of normal maintenance services, non-warranty repairs, accidents and collision damage, as well as oils,
and spark plugs, and incidental or consequential damages costs as explained
in the warranty.
Q: Are "Genuine" Bombardier replacement parts used in warranty repairs covered
by warranty?
A: Yes. When installed by an authorized dealer, any "genuine" Bombardier
part used in warranty repairs assumes the remaining warranty that exists on
the machine.
Q: If I sell my snowmobile within the warranty period, will the new owner qualify
for the balance of the warranty?
A: Yes, provided the unit has already been registered with the manufacturer.
Note that the change of ownership card in this manual should be completed
and sent to Valcourt
6
LISTING OF AREA DISTRIBUTORS
CANADIAN DISTRIBUTORS
.
AMERICAN DISTRIBUTORS
BOMBARDIER CORPORATION
4505 West Superior Street
PO. Box 6106
Duluth, Minnesota 55806
(218) 628-2881
DISTRIIBUTION DIVISION
North Dakota, Minnesota, Wisconsin. Illinois, Missouri,
Michigan. Indiana, Ohio Oess eastern half), Tennessee
Kentucky. West Virginia. Virginia. Northern Idaho,
Northern Wyoming, Montana, Iowa, Washington
ELLIOTT & HUTCHINS INC.
East Main Street Road
Malone, New York 12953
(518) 483-4411
New York. Massachusetts, Connecticut, Rhode Island.
Pennsylvania, New Jersey. Maryland, Delaware, District of
Columbia. Northern half of Ohio.
DIVISION
CrIlIlD"CI\'T
I
AND RECREATIONAL CENTER
"VIDcnL,",I~U MACHIf\IES INC.
DIVISION
03584
2V8
Franklin District & Keewatin
A2H 6G7
2Y8
Yukon, N.W.T.
7
I
HOW TO IDENTIFY YOUR SNOWMOBILE
The main components of your snowmobile (engine, track and frame) are
identified by different serial numbers. It
may sometimes become necessary to
locate these numbers for warranty purposes or to trace your snowmobile in
the event of theft.
O
ENGINE
SERIAL
NUMBER
NOTE: We strongly recommend that you take note of all the serial numbers
on your vehicle and supply them to your insurance company. It will surely
help in the event a snowmobile is stolen.
8
SAFETY IN MAINTENANCE
Observe the following
precautions:
• Throttle mechanism should be
checked for free movement before
starting engine.
• The snowmobile engine can be
stopped by activating the emergency cut-out switch, tether switch or
by turning off the key.
• Engine should be running only when
pulley guard is secured in place.
• Never run engine without drive belt
installed. Running an unloaded engine can prove to be dangerous.
• Never run engine when the track of
the vehicle is raised off the ground.
• Installation of other than standard
equipment, including ski-spreaders,
bumpers, pack racks, etc., could
severely affect the stability and safety of your vehicle. Avoid adding on
accessories that alter the basic vehicle configuration.
• Whenever the vehicle is parked outdoors, overnight or for a long
period, it is suggested to protect it
against the inclemency of the
wheather with a snowmobile cover.
• Do not lubricate throttle and/or
brake cables and housings.
• Please read and understand all warningsand cautions in this manualand
on the vehicle.
• It can be dangerous to run engine
with the cab removed.
• Gasoline is flammable and explosive
under certain conditions. Always
manipulate in a well ventilated area.
Do not smoke or allow open flames
or sparks in the vicinity. If gasoline
fumes are noticed while driving, the
cause should be determined and
corrected without delay.
• Maintain your vehicle in top mechanical condition at all times.
I
• Your snowmobile is not designed to
be driven or operated on black top,
bare earth, or other abrasive surfaces. On such surfaces abnormal
and excessive wear of critical parts
is inevitable.
THIS MANUAL SHOULD REMAIN WITH THE VEHICLE AT
THE TIME OF RESALE.
9
CONTROLS/INSTRUMENTS
A) Throttle Control Lever
B) Brake Control Lever
CJ Ignition/Light Switch
D) Headlamp Dimmer Switch
EJ Emergency Cut-Out Switch
A) Throttle Control Lever
Located on 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.
F) Manual Starter Handle
G) Primer
H) Speedometer
I) Tether Cut-Out Switch
C) Ignition/Light Switch
OFF
.......ON
B) Brake Control Lever
Located on the left side of handlebar.
When compressed, the brake is applied. When released, it autornaucallv
returns to its original position. Braking
effect is proportionate to the pressure
applied on the lever, and to the type of
terrain and its snow coverage.
Key operated, 2 position switch. To
start engine, first turn key clockwise to
ON position. To stop engine, turn key
counter-clockwise to OFF position.
The lights are automatically ON whenever the engine is running.
10
D) Headlamp Dimmer Switch
H) Speedometer
Located on left side of handlebar, flick
switch to high or low beam.
The speedometer is linked directly to
the drive axle. Direct-reading dial indicates the speed of the vehicle. Odometer records the total distance travelled.
E) Emergency Cut..Out Switch
A 3 position switch located on the right
side of the handlebar. To stop the engine in an emergency, flick the lever to
either upper or lower STOP" position. To start engine, lever must be in
middle "ON" position.
II
STOP
ON
I) Tether Cut-Out Switch
Attach tether cord to wrist or other
convenient location then snap tether
cut-out cap over receptacle before
starting engine.
If emergency engine "shut-off" is required completely pull cap from safety
switch and engine power will be automatically shut "off".
NOTE: The cap must be installed
on the safety switch at all times
in order to operate the vehicle .
O
The driver of this vehicle should
familiarize himself with the function of
this device by using it several times on
first outing. Thereby being mentally
prepared for emergency situations requiring its use.
...... WARNING: If the switch has
. . . been used in an emergency situation the source of malfunction should
be determined and corrected before restarting the engine.
F) Manual Starter Handle
Auto rewind type located on right hand
side of vehicle. To engage mechanism,
pull handle.
G) Primer
...... WARNING: If the switch is used
. . . in an emergency situation the
source of malfunction should be determined and corrected before restarting
engine.
Hood Opening
Pull down the latch to unhook the
hood from the anchor hole.
NOTE: Always lift hood gently up
until stopped by restraining device .
...... WARNING: It is dangerous to
. . . run an engine with the hood open
or removed. Personal injury could result.
_
CAUTION: Prior to re-securing
O
•
the hood latch, position the bot-
tom edge of the hood into the hood
guide located on each side of the
frame.
A push-pull button. Pull and push button (2-3 times) to activate primer. The
primer should always be used for cold
engine starts. After engine is warm
however, it is not necessary to use
primer when starting.
11
BREAK-IN PERIOD
ToolBox
Located under the hood. To gain access, tilt hood. Ideal location for spare
plugs, belt, rope, etc.
Fuel Gauge
The fuel gauge is located on the left
side of the fuel tank. The gauge functions on the principle of communicating vessels, so the fuel level inside the
tank is directly related with the level indicated on the gauge.
With Bombardier-Rotax snowmobile
engines, a break-in period is required
before running the vehicle at full throttle. Engine's manufacturer recommendation is 10 to 15 operating hours. During this period, a richer mixture is
needed (i.e. 40 parts of gas for 1 part of
50/1 Bombardier oil), Maximum throttle should not exceed 314, however,
brief full acceleration and speed variations contribute to a good break-in.
Continued wide open throttle accelerations, prolonged cruising speeds, and
lugging are detrimental during the
break-in period.
O
NOTE: A new drive belt requires
a break-in period of 15-25 km (1015 miles).
10-Hour Inspection
Fuel Tank Cap
Accessible under fuel tank cover. Lift
cover, unscrew cap. Plastic retainer
will stop cap from falling.
As with any precision piece of mechanical equipement, we suggest that alter
the first 10 hours of operation or 30
days after the purchase, whichever
comes first, that your vehicle be checked by your dealer. This inspection will
give you the opportunity to discuss the
unanswered questions you mat have
encountered during the first hours of
operation. Remember that it is easier
to remedy at this time than to allow the
snowmobile to operate until a possible
failure occurs.
The 10 hours inspection is at the expense of the vehicle owner.
12
10-HOUR INSPECTION CHECK LIST
Engine timing
Fan belt tension
"
Spark plug(s) condition
Carburetor adjustment
Engine head nuts
Engine mount nuts
Muffler attachment
Chaincase oil level
Suspension components
Brake operation and lining condition
Skis alignment (runners condition)
Pulley alignment and drive belt condition
Track condition, tension and alignment
Lubricate (steering, suspension)
!
Electrical wiring (loose connections, stripped wires, damaged insulatlonl, tighten all loose bolts, nuts and linkage
Operation of lighting system (HI / LO beam, brake light, etc.), test
operation of emergency cut-out switch and tether switch
We recommend that you have your dealer sign this inspection.
Date of 10 hour inspection
Dealer signature
13
FUEL MIXING
Oil rnust be added to the gasoline in
pre-measured amounts then both oil
and gasoline should be thoroughly
mixed together before fueling the tank.
Recommended Gasoline
Use regular leaded or unleaded gasoline available from all service stations.
_
CAUTION: Never experiment
... with different fuel or fuel ratios.
Never use naphtha, methanol or similar
products.
Recommended Oil
Use concentrated Bombardier snowmobile oil available from your dealer.
This type of oil has specially formulated oil bases to meet the lubrication
requirements of the Bombardier-Rotax
engine.
If Bombardier snowmobile oil is unavailable substitute with a high-quality
2 cycle snowmobile oil. The oil/gas
mix must meet the vehicle requirements. See oil manufacturer
recommendations on the container.
~ CAUTION: Never use outboard
•
or straight mineral oils.
Fuel Mixture Ratio
The importance of using the correct
fuel mixture cannot be overstressed.
An incorrect fuel ratio results in serious
engine damage. Recommended fuel
ratio is 50/1. (40/1 during break-in period).
S I Units
500 mL oil to 25 liters = 50/1.
Imperial Units
1 can 16 oz oil to 5 Imp. gals
50/1.
or
1 can 500 mL oil to 5 1/2 Imp. gals
50/1.
U.S. Units
1 can 12 oz oil to 5 U.S. gals
50/1.
NOTE: To facilitate fuel mixing,
oil should be kept at room temperature.
O
14
Fuel Mixing Procedure
To mix the gasoline and oil always use
a separate clean container. Never mix
directly in your snowmobile tank. For
best results, acquire two containers,
either plastic or metal. Draw from one
until empty then use the second one.
..... WARNING: Gasoline is flammaT· ble and explosive under certain
conditions. Always manipulate in a
well ventilated area. Do not smoke or
allow open flames or sparks in the vicinity. If gasoline fumes are noticed
while driving, the cause should be determined and corrected without delay.
Never add fuel while the engine is running. Avoid skin contact with fuel at
below freezing temperature.
1. Pour approximately one gallon of
gasoline into a clean container.
PRE-START CHECK
2. Add the full amount of oil.
Check Points
• Activate the throttle control lever
several times to check that it operates easily and smoothly. The throttle control lever must return to idle
position when released.
• Check fuel level.
• Check that the skis and the track are
not frozen to the ground or snow
surface and that the steering operates freely.
3. Replace the container cap and
shake the container thoroughly.
• Activate the brake control lever and
make sure the brake fully applies before the brake control lever touches
the handlebar grip.
• Verify that the path ahead of the vehicle is clear of bystanders and obstacles.
A. WARNING: Only start your snow..... mobile once all components are
checked and functioning properly.
4. Add the remainder of the gasoline.
5. Once again thoroughly
the
container. Then using a funnel with
a fine mesh screen to prevent the
entry of water and foreign particles,
pour the mixture into the snowmobile tank.
A. WARNING: To prevent fuel spill..... age in the engine compartment, a
funnel must always be used when filling the gas tank.
a
NOTE: When using pre-mixed
fuel, always shake the container
thoroughly as the oil has a tendency to
settle.
A. WARNING: Never 'top up' the
..... gas tank before placing vehicle
in a warm area. At certain temperatures, gasoline will expand and
overflow. Always wipe off any gasoline
spillage from the snowmobile.
15
STARTING PROCEDURE
Manual Starting
Emergency Starting
1. Insert the key in the ignition and
turn to ON position.
Should the rewind starter rope fray and
break, the engine can be started with
an emergency starter rope.
2. Test the throttle control lever.
3. Activate the primer (2 to 3 times).
O
NOTE: Primer is not necessary
when the engine is warm.
4. Ensure the tether cut-out cap is in
position and that the cord is attached to your clothing. Check that the
emergency cut-out switch is in the
center "ON" position.
5. Grasp manual starter handle firmly
and pull slowly until a resistance is
felt then pull vigorously. Slowly release the rewind starter handle.
..... WARNING: Do not apply throttle
~ while starting.
6. Check operation of the emergency
cut-out switch, and the tether
switch. Restart the engine .
..... WARNING: If engine does not
~ shut-off when applying the emergency cut-out switch and/or by pulling
the tether cut-out cap, stop the engine
by turning off the ignition key. Do not
operate the vehicle further, see your
dealer.
7. Allow the engine to warm before
operating at full throttle.
16
WARNING: Do not start the vehicle by the drive pulley unless it is
•
a true emergency situation, have the
vehicle repaired as soon as possible.
Remove the pulley guard from the
vehicle and wind the emergency rope
tiqht around the drive pulley between
the sliding half and the roller guard.
Start the engine as per usual manual
starting.
..... WARNING: When starting the
~ vehicle in an emergency situation
by the drive pulley, do not make a knot
at the end of the emergency rope and
do not reinstall the pulley guard.
\~~'J
~~
Sliding
half
I
\
\ "
LUBRICATION
Frequency
Drive Belt Removal
Routine maintenance is necessary for
all mechanized products, and the
snowmobile is no exception. A weekly
vehicle inspection contributes to the
life span of the snowmobile as well as
retains safe and dependable operation.
It is recommended that the steering
system, suspension and drive axle be
lubricated monthly or every 40 hours of
operation. If the vehicle is operated in
wet snow or in severe conditions/
these items should be lubricated more
frequently .
.... WARNING: Never start or run
T engine without the drive belt installed. Running an unloaded engine is
dangerous.
1. Tilt the hood and remove the belt
guard.
2. Open the driven pulley by twisting
and pushing the sliding half. Hold in
fully open position.
.... WARNING: Only perform such
T procedures as detailed in this
manual. It is recommended that dealer
assistance be periodically obtained on
other components!systems not covered in this manual. Unless otherwise
specified/ engine should be turned OFF
for all lubrication and maintenance procedures.
Belt Guard Removal
3. Slip the belt over the top edge of the
sliding half.
.... WARNING: Engine should be
T running only when belt guard is
secured in place.
1. Tilt the hood remove both belt guard
retaining clips {AL
2. Pullout both B & C retaining pins.
4. Slip the belt out from the drive pulley and remove completely from the
vehicle. To install the drive belt,
reverse the procedure .
.... WARNING: At the removal or inT stallation of the belt guard front
retaining pin be careful not to burn
yourself on the exhaust system.
3. Lift and remove the belt guard assembly.
17
Steering Mechanism
. . .WARNING: Do not lubricate
" . . throttle and/or brake cables and
housings.
Lubricate the ski legs at grease fittings
until grease appears at joints. Oil spring
coupler bolts.
Chaincase Oil Level
Check the oil level by removing the oil
level cap plug.
The oil should be level with the bottom
of the oil level orifice.
O
18
NOTE: The chaincase oil capacity
is approximately 200 mL (7 oz.).
Drive Axle and Suspension
Idler Wheels
Lubricate at grease fitting until grease
appears at joints. Use low temperature
grease only.
MAINTENANCE
+
The following Maintenance Chart indicates regular servicing schedules to be
performed by you or your servicing
dealer. If these services are performed
as suggested, your snowmobile will
give you many years of low-cost use.
SERVICE AND
MAINTENANCE
CHART
WARNING: Only perform such
procedures as detailed in this
manual. It is recommended that dealer
assistance be periodically obtained on
other components/systems not covered in this manual. Unless otherwise
specified, engine should be turned OFF
for all lubrication and maintenance procedures.
E
E
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....
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oro
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~
•
•
•
•
Spark plugs
Suspension (lubricate idler
wheels)
Track
Track tension and alignment
Carburetor adjustment
Drive belt
•
Steering mechanism, chaincase
Brake
Steering adjustment
•
•
•
•
Engine mount nuts
General inspection
O
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20
20
20
20
•
21
22
•
23
22
22
Engine head nuts
Muffler attachment
0
0
0
22
Fan belt
Drive pulley
E
....
•
•
22
•
•
23
23
23
24
NO.TE: The ten hour inspection is a very important part of proper service and
maintenance.
19
Spark Plugs
Track
Disconnect the spark plug wires and
remove the spark plugs.
Check the condition of the plugs.
• A brownish tip reflects ideal conditions. (Correct carburetor, spark
plug heat range; etc.).
• A black insulator tip indicates fouling
caused by: carburetor idle speed
mixture and/or high speed mixture
too rich, incorrect fuel mixture ratio,
wrong type of spark plug (heat
range), or excessive idling.
Lift the rear of the vehicle and support
it off the ground. With the engine off,
rotate the track by hand, and inspect
condition. If worn, cut or track fibers
are exposed or missing or defective inserts or guides are noted, contact your
dealer.
• A light grey insulator tip indicates a
lean mixture caused by; carburetor
high speed mixture adjusted too
lean, wrong spark plug heat range,
incorrect fuel mixture ratio, or a
leaking seal or gasket.
Overheated
(light grey)
..&. WARNING:
?' snowmobile
Do not operate a
with a cut, torn or
damaged track.
Track Tension and Alignment
The suspension is adjustable, the front
adjustment for surface condition, the
rear for driver's weight.
When the front adjuster blocks are at
the lowest elevation more weight is
distributed on the skis. At the highest
position the weight is transferred to the
track. The rear adjuster blocks should
be adjusted to suit the driver's preference.
Fouled
(black)
Normal (brownish)
. . CAUTION: If spark plug condi. . tion is not ideal, contact your authorized dealer.
Check spark plug gap using a wire
feeler gauge.
Reinstall plugs and connect wires.
Suspension
Visually inspect all suspension components including slider shoes, springs,
wheels, etc ...
O
NOTE: During normal driving,
snow will act as a lubricant and
coolant for the slider shoes. Extensive
riding on ice or sanded snow, (not to
mention dirt, asphalt, etc. never recommended) will create excessive heat
build-up and cause premature slider
shoe wear.
20
Adjuster blocks
. . CAUTION: Always turn the left
. . side adjuster blocks in a clockwise direction, the right side blocks in a
counter-clockwise direction. Left and
right adjuster blocks of each adjustment must always be set at the same
elevation.
Lift the rear of vehicle and support with
a mechanical stand. Allow the slide to
extend normally. Check the gap 13 mm
(1/2") between the slider shoe and the
bottom inside of the track. If the track
tension is too loose, the track will have
a tendency to thump.
•
WARNING: Before checking
track alignment, ensure that the
track is free of all particles which could
be thrown out while track is rotating.
Keep hands, tools, feet and clothing
clear of track. Ensure no-one is standing in close proximity to the vehicle.
T
_
CAUTION: Too much tension
... will result in power loss and excessive stresses on suspension components.
If necessary to adjust, loosen the rear
idler wheel retaining screw and then
loosen or tighten the adjuster bolts located on the inner side of the rear idler
wheels. If correct tension is unattainable. Contact your dealer.
To correct, stop the engine, loosen the
rear idler wheels retaining screws then
loosen the lock nuts and tighten the
adjuster bolt on the side where the
slider shoe is the furthest to the track
insert guides.
Tighten the lock nuts and recheck the
alignment. Ensure to retighten the idler
wheel retaining screws.
-,
"
Idler wheel
-."" retaining screw
O
NOTE: Track tension and alignment are inter-related. Do not adjust one without the other.
Start the engine and accelerate slightly
so that the track turns slowly. Check
that the track is well centered; equal
distance on both sides between edges
of track guides and slider shoes.
Adjuster
bolt
Carburetor Adjustment
_
CAUTION: Never operate your
... snowmobile with the air intake
silencer disconnected. Serious engine
damage will occur if this notice is disregarded.
Carburetor adjustment should be performed by your dealer.
21
Drive Belt
Brake
Inspect the belt for cracks, fraying or
abnormal wear (uneven wear, wear on
one side, etc.) If abnormal wear is noted, probable cause is pulley misalignment. Contact your dealer.
The brake mechanism on your snowmobile is an essential safety device.
Keep this mechanism in proper working condition. Above all, do not operate your snowmobile without an effective brake system.
Check the drive belt width, if less than
3 cm (1 3/16") replace.
O
NOTE: When installing a new
drive belt, a break-in period of 1525 km (10-15 miles) is strongly recommended.
Steering Mechanism
Inspect the steering mechanism for
tightness of components (steering arms,
tie rods, ball joints, spring coupler bolts,
etc.). If necessary, replace or retighten.
Check the condition of the skis and the
ski runners. Replace if half worn.
Drive Pulley
Mark reference
point
on both halves
22
be replaced. Replacement must be performed by an authorized dealer.
The brake mechanism is self-adjusting,
therefore, periodic adjustment is not
required. However, check operation of
brake mechanism by depressing brake
control level. Brake should apply fully
when lever is 13 mm (1/2") approx.
from handlebar grip. If not, do not tamper with the brake, contact your servicing dealer.
Steering Adjustment
Skis should have a toe out of 3 mm
Inspect the Duralon bushing condition
by checking the free-play of the sliding
half pulley. This is achieved by restraining the inner half and checking if the
sliding half moves in the direction of
the arrows more than 3 mm (1/8"). If
so contact your dealer.
Maximum free-play
3 mm (118")
.....WARNING: Brake pad or pucks
...·Iess than 3 mm (1/8 11 ) thick must
(118"). To check, measure the distance
between each ski at the front and rear
of the leaf springs. The front distance
should be 3 mm (1/8") more than the
rear when the handlebar is horizontal.
IMPORTANT: Close the front of the
skis manually to eliminate all slack from
the steering mechanism.
If adjustment is required:
Loosen the lock nuts of the longer tie
rod. Turn the tie rod manually until the
skis are properly aligned. Firmly
retighten the lock nuts.
3 mm (1/8")
toe alit
The handlebar should also be horizontal when the skis are pointed toward the front.
To adjust:
Loosen the lock nuts of the shorter tie
rod. Turn the tie rod manually until the
handlebar is horizontal. Retighten the
lock nuts firmly .
. . . WARNING: The ball joint socket
..... must run parallel with the steering arm. The socket must be restrained
when tightening the tie rod end lock
nuts.
Ensure that the forced flow system is
well aligned and tightened.
Fan Belt
Engine Head Nuts
With the engine cold, check that the
engine head nuts are tight and equally
torqued to 20 N.m (15 ft-lbsl.
IMPORTANT: The engine head nut
torque should be checked after the first
5 hours of operation.
Engine Mount Nuts
Check the engine mount nuts for tightness. Retighten if necessary.
If the belt seems damaged or if tension
is incorrect, contact your dealer immediately.
. . . WARNING: If fan protector is re..... moved, always reinstall after servicing.
Muffler Attachment
The engine/muffler attaching parts.are
vital toward efficient muffler function.
Check all attachments. Replace the
springs and/or tighten if necessary.
23
STORAGE
Bulb Replacement
If the headlamp bulb is burnt, tilt hood,
unplug the connector from the headlamp. Remove the rubber boot and unfasten bulb retainer clips. Detach the
bulb and replace. If taillight bulb is
burnt, expose the bulb by removing
the red plastic lens. To remove, unscrew the two (2) Phillips head screws.
Verify all lights after replacement.
General Inspection
Check the electrical wiring and components, retighten loose connections.
Check for stripped wires or damaged
. insulation. Thoroughly inspect. the ve~
hicle and tighten loose bolts, nuts and
linkage. lnspectskis and·ski runners for
wear.
It is during summer, or when a vehicle
is not in use for any length of time that
proper storage is a necessity. Storage
of the snowmobile during long period
of inactivity consists of checking and
replacing missing, broken or worn
parts, proper lubrication and treatment
to insure that parts do not become
rusted; deaning items such as carburetorof oil mixtures, to prevent gum
varnish formation and in general, preparing the vehicle so that when the
time comes to use the snowmobile
again it will start and be in top condition.
.
.... WARNING:·,· Only .perform such
'Y procedures as . detailed in this
manua!.lt is recommended that dealer
assistance be. periodically obtained on
other components/systems' not covered in this manual. Unless otherwise
specified, engine should be turned OFF
for all lubrication and maintenance procedures.
Track
Inspect the track for wear, cuts, .missing track guides and' broken rods.
Make any necessary replacement .
.... WARNING: Do not operate a
'Y snowmobile' with a cut, torn or
.
damage track.
Lift the rear of vehicle until track is
clear ofthe ground then support with a
brace or trestle. The snowmobile
should be stored insuch a way that the
track does not stay in contact with the
ground.
NOT E::The track should be rotated periodicallv, (every 40 days).
Do not release track tension.
O.
~ CAUTION:
To prevent track
•
damage, temperature inthe storage area must not exceed 38°e
(100°F).
Suspension
Remove any dirt or rust. Grease idler
wheels atgreasefittings. Wipe off surplus. Replace worn slider shoes.
24
Ski
Wash or brush all dirt or rust accumulation from .the skis and springs.
Grease the ski legs at the grease fittings. Check the condition of the skis,
ski' runners and leaf springs. Replace if
worn or weak.
Controls
Lubricate the steering rnechanism.Tnspect all components . for , tightness,
(spring coupler bolts, steering arm
locking bolts; tie rods, ball joints, etc.).
Tighten if necessary. Oil moving joints
of the brake mechanism.
A WARNING: Do not lubricate the
. . .·throttle and/or brake cables and
housings. Avoid getting oil on the
brake, pads.
Coat all electrical connections and
switches with a greaseless metal protector. If unavailable, use petroleum
jelly.
Chaincase
Drain the chaincase and refill to proper
level, using fresh chaincase oil. To
drain, remove the chaincase cover.
Fuel Tank
Remove the cap then using a syphon,
remove the gasoline from tank.
Once the fuel tank is emptied, remove
the float cha.mber drain plug on each
carburetor. Drain carburetors.
Re-install. plug. and connect fuel. line.
Cylinder Lubrication
Engine internal parts must
lubricated to protect cylinder walls from possible rust formation during the storage
period.
NOTE: This operation should be
repeated every 40 days during
storage.
Remove the spark plugs. Operate the
rewind starter to bring the piston attop
position. Pou r the equivalent of one
spoonful of oil into spark plug hole.
O·
Slowly crank the engine several times
using the manual starter. Repeat above
steps for other cylinder. Install the
spark plugs.
~..CAUTION: To prevent ign,ition
..., system damage, make sure that
the cut-out switch is in the STOP position.
A WARNING: Gasolineisflamma. . . ble and explosive under certain
conditions. Always manipulate in a
well ventilated area. Donat smoke or
allow open.flames or sparks in the vicinity..
Carburetors
Carburetors must be dried out completely to prevent gum formation during
the storage period.
25
Chassis
Clean the vehicle thoroughly removing
all dirt and grease accumulation .
I
. . . CAUTION: Plastic alloy compo".. nents such as fuel tank, windshield, controls, etc., can be cleaned
using mild detergents or isopropyl alcohol. Do not use strong soaps, degreasing solvents, abrasive cleaners,
paint thinners, etc.
Inspect the hood and repair any damage. Repair kits are available at your
authorized dealer. Clean the frame. For
the aluminum portion use only Aluminum cleaner" and follow instructions
on the container.
Touch up all metal spots where paint
has been scratched off. Spray all bare
metal parts with metal protector. Wax
the hood for better protection.
NOTE: Apply wax on glossy finish of hood only. Protect the vehicle with a cover to prevent dust accumulation during storage .
/I
O
. . . CAUTION: If for some reason the
".. snowmobile has to be stored outside it is necessary to cover it with an
opaque tarpaulin. This caution will prevent the sun rays affecting the plastic
components and the vehicle finish.
General Inspection
Check the electrical wiring and components, retighten loose connections.
Check for stripped wires or damaged
insulation.
Thoroughly inspect the vehicle and
tighten loose bolts, nuts and linkage.
NOTE: Leave the drive belt off
the pulleys for the entire storage
period.
O
26
PRE-SEASON PREPARATION
To simplify the pre-season preparation
we have drawn up a small chart. The
chart indicates servicing points to be
performed by you and your servicing
dealer. If these services are performed
as suggested, your vehicle will give
you many hours of fun and low cost
use.
IMPORTANT: Observe all Warnings
and Cautions mentioned throughout
this manual which are pertinent to the
item being checked. When component
condition seems less than satisfactory,
replace with genuine Bombardier part
or suitable equivalent.
PRE-8EASON PREPARATION CHART
TO BE PERFORMED BY DEALER
•
TO BE PERFORMED BY OWNER
0
Change spark plugs
0
Check chaincase oil level
0
Check pulleys, verify components and clean
•
Check steering alignment and ski runner condition
Clean fuel filter (located in fuel tank)
0
Check suspension idler wheel bearings
•
Check track tension and alignment
0
Inspect drive belt and install
0
Check throttle cable for damage and free operation
0
Inspect brake condition and operation
•
Inspect oil seals for possible cuts or leaks
0
Set engine timing, if necessary replace breaker points
•
Check electrical wiring (broken wire, damaged insulation)
0
Inspect condition of starting rope
0
Check tightness of all bolts, nuts and linkage
0
Refill gas tank
0
Adjust carburetors
•
Check fan belt condition and tension
0
27
TROUBLE SHOOTING
,0
NOTE: The possible causes have been listed in an order of frequencv.
Therefore, items should be checked out in the same order as mentioned
in the trouble shooting guide.
SYMPTOMS
POSSIBLE CAUSES
WHAT TODD
Engine turns over but
fails to start or starts
with difficulty
1. No fuel to the engine
Check the tank level' and fill up with correct
gas-oil mixture. Check forpossible clogging of
fuel line, item 4.
2. Flooded engine
Remove wetspark plugs, turn ignition to OFF
and crank engine sElveral times. Install clean
dry spark plugs. Start engine following usual
starting procedure. It engine continues to
flood, see your dealer.
3. Spark plug/faulty ignition
Check for fouled or defective spark plug. Disconnect spark plug wire, unscrew plug and remove from cylinder head. Reconnect wire and
ground exposed plug on engine cowl, being
careful to hold away from spark plug hole.
Follow engine starting procedure and check
for spark. If no sparks appear, replace spark
plug. If trouble persists, contact your dealer.
4. Clogged fuel line (water or
Check condition and connections of fuel lines
Check the cleanliness of fuel tank.
dirt)
5. Incorrect carburetor
Contact your dealer for. repair.
adjustment
Engine will not turn
manually
28
6. Too much oil in fuel
Drain the fuel tank and refill with the correct
gas/oil mixture.
7. Engine timing
Engine timing may be defective or out of adjustment. Contact your dealer.
8. Poor engine compression
Running with a lean fuel mixture may produce
excessive engine wear resulting inpoor engine
compression. If this occurs, contact your
dealer at once.
1. Seized engine
In the case of a seized engine contact your
dealer.
SYMPTOMS
POSSIBLE CAUSES
WHAT TO DO
Engine lacks acceleration or power
1. Fouled or defective spark
Check item 3 of "Engine turns over but fails
to start or starts with difficulty"
plug
2. Clogged fuel line (water or
dirt)
Engine continually
backfires
Snowmobile cannot
reach full speed
Check fuel line condition. (See item 4 of "Engina turns over but fails to start or starts
with difficulty'l
3. Carburetor
Contact your dealer.
4. Ignition
First check item 3 of "Engine turns over but
fails to start or starts with difficulty". If the
ignition system still seems faulty, contact your
dealer.
5. Engine
If unable to locate specific symptoms, contact
your dealer.
1. Spark plug
Check item 3 of"Engine turns over but fails to
start orstarts with difficulty".
2. Overheated
Carburetor sat too lean. Contact your dealer.
3. Engine timing incorrectly set
Contact your dealer.
1. Drive Belt
Check for damaged or worn drive belt. Re·
place if necessary.
2. Incorrect track adjustment
Check track tension and alignment. Readjust
to specifications. (Sea Maintenance Sectionl.
3. Engine
Check item 1 to 5 of "Engine lacks aecelaration or power.".
4. Pulley misaligned
Contact your dealer.
29
TOOLS
As standard equipment each new snowmobile is supplied with basic tools such
as screwdriver, wrenches, emergency
starter rope, etc ...
Standard Tools
G
A
e~
0
D
II
B
01[
8
A.
Screwdriver
E.
Starter rope
B.
Socket 10/13 mm
F.
Socket 21/26 mm
C. Open end wrench 10/13 mm
D. Socket wrench handle
30
C
G. Suspension adjustment key
SPECIFICATIONS
ENGINE
No. of cylinders
Bore
Stroke
Displacement
Compression ratio (corrected)
Carburetor type
Carburetor adjustment
- air screw
- idle speed
Engine head nuts (torque)
Fan belt free-play
CHASSIS
Overall length
Overall width
Overall height
Ski stance (center to center)
Ski alignment (toe out)
Mass (weight)
Bearing area
Ground pressure
POWER TRAIN
Track dimensions
Track tension
1 1/2 turn
± 118
1800-2000 R.P.M.
20 N.m (15 tt-lbsl
6 mm (1/4")
265 cm (104")
99 cm (39")
102 cm (4O")
85 cm (33 112")
3 mm (liS")
193 kg (425 Ibs)
7710 cm 2 (1195 in. 2 )
2.447 kPa (.335 Ibs/in2 )
13 mm (1f2") gap should exist between slide shoe and bottom
inside of track.
Equal distance between edges of track guides and slider
shoes.
Std. gear ratio
Chaincase oil capacity
Drive belt (minimum width)
ELECTRICAL
Lighting system (output)
Headlamp bulb
Tail/stop
Spark plug (Bosch) - normal use
Spark plug (gap)
-
61 mm (2.401'')
496.7 cm 3 {30.31 in.3}
6.2:1
2 x VM 34-203
38.1 cm (15") x 289.6 cm {114"}
Track alignment
FUEL
Tank capacity -
2
72 mm (2.834")
SI*
Imp.
U.S.
Gasoline
Gas/oil ratio
BRAKE
Brake type
Brake adjustment (control)
Brake lining (minimum thickness)
21/38
200 mL (7 oz]
3 cm (1 3/16")
12 volts, 140 watts
45/45 W
5/21 W
W 275 T2 (W3C)
0.4 mm (.016")
25.5 liters
5.6 gallons
6.7 gallons
Regular leaded or unleaded
50/1
Disc. self-adjusting
13 mm (112") minimum distance from handlebar grip when
fully applied
3 mm (1/8")
*International Standard
Bombardier Limitee reserves the right to make changes in design and specifications and/or to make additions to, or improvements in its product without imposing any obligation upon itself to install them on
its product previously manufactured.
31
W
1'0
KILL SWITCH
VI/WH
BI(
BK
......,(
~OFF
~
VI/WH
VI
VI
4
ON
OFF
r
RD/YL
GRIVI
_GR_ _ _
DIMMER SWITCH
GN/BK
CD LIGHTING Call ,110 WI
CD LIGHTING COIL 130 WI
® GENERATOR COIL
o HEAOlAMP 145/45 WI
® BULB 15 WI
® TAILLIGHT 15·21 WI
CD FUSE 1.1 AI .
® VOLTAGE REGULATOR
GY/VI
GY
5K
IGNITION SWITCH
:-r----I
HK
®
OFF
ON
YL
YL
RD/YL
BK
BI<
®
BRAKE LIGHT SWITCH
:;::Iii'i
SPEEDOMETER
®
...... WARNING: Ensure all terminals
. . . are properly crimped on the wires
and all connector housings are properly
fastened.
51* METRIC INFORMATION GUIDE
BASE UNITS
DESCRIPTION
UNIT
SYMBOL
length
mass
liquid
temperature
pressure
torque
speed
meter
kilogram
liter
celsius
kilopascal
Newton meter
kilometer per hour
m
kg
L
°C
kPa
N·m
km/h
PREFIXES
PREFIX
kilo
centi
milli
SYMBOL
MEANING
VALUE
k
c
m
one thousand
one hundredth of a
one thousandth of a
1,000
0.01
0.001
*THE INTERNATIONAL SYSTEM OF UNITS (SYSTEME INTERNATIONAL
ABREVIATES IISIII IN ALL LANGUAGES.
33
NOTES
NOTES
NOTES
CHANGE OF ADDRESS AND OWNERSHIP
Any change in address or ownership should AJe brought to the attention of the
manufacturer by completing and sending out the card supplied below. This will
help us to maintain our files up-to-date.
:..................................................... •......•..•....••....~
: CHANGE OF ADDRESS
····
: VEHICLE IDENTIFICATION NUMBER
: OLD ADDRESS:
NAME
NO
CITY
STREET
STATE
APT,
ZIP I POSTAL CODE
·: NEW ADDRESS:
NAME
NO
STREET
APT,
:.........................................•........... •..•.•...•..•.•.•.••.~
: CHANGE OF OWNERSHIP
···
:
CITY
ZIP I POSTAt CODE
8TATE
·.'
: VEHICLE IDENTIFICATION NUMBER
: The ownership of this vehicle is transferred
··
: FROM:
---.,.
_
NAME
NO
CITY
STREET
APT.
ZIP I POSTAL CODE
STATE
: TO:
···
··
·•·
!
NAME
NO
CITY
STREET
STATE
APT,
ZIP I POSTAL CODE
35
...........•........•....•...........•.......••........•••••....•..•.............
BOMBARDIER LIMITEE
ATT.: WARRANTY DEPARTMENT
VALCOURT, QUEBEC
CANADA, JOE 2LO
·
····
···
···
·
····
····
····
···
····
···
···
·
...........•.....................................................................··
··
··
BOMBARDIER LIMITEE
ATT.: WARRANTY DEPARTMENT
VALCOURT, QUEBEC
CANADA, JOE 2LO
.-
·
·
··
36
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