1983 SKI DOO CITATION 4500 Factory Service & Work Shop Manual

SHOP MANUAL Bombardier snowmobiles . ,.. . \

Legal deposit: National Library of Quebec 4th trimester 1982 National Library of Canada All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 1982 Printed in Canada ® * Registered trademarks of Bombardier Inc.

SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair the Bombardier snowmobiles. This edition was primarily published to be used by snowmobile mechanics who are al - ready familiar with all service procedures relating to Bombardier made snowmobiles. Please note that the instructions will apply only if proper hand tools and special service tools are used. This shop manual uses technical terms which may be slightly different from the ones used in parts catalogue. The content of Bombardier Inc. Recreational Product Shop Manual depicts parts and/or procedures applicable to the particular product at its time of manufacture. It does not in- clude dealer modifications, whether authorized or not by Bombardier, after the products manufacture. In addition, the sole purpose of the illustrations/photographs throughout the manual, is to assist identification of the general configuration of the parts. They are not to be inter- preted as technical drawings or exact replica's of the parts. The use of Bombardier parts is most strongly recommended when considering replace- ment of any component. Dealer and/or distributor assistance should be sought in case of doubt. Torque wrench tightening specifications must be strictly adhered by. Locking devices (ex.: tab lock, nylon lock) must be installed or replaced by new ones, where specified. If the efficiency of a locking device is impaired, it must be renewed. This manual emphasizes particular information denoted by the wording and symbols; • ~ARNING: Identifies and instruction which, if not followed, could cause personal Injury. ~ o CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle components. NOTE: Indicates supplementary information needed to fully complete an instruction. Although the mere reading of such information does not eliminate the hazard, your un- derstanding of the information will promote its correct use . • WARNING: This information relates to the preparation and use of Bombardier snowmobiles and has been utilized safely and effectively by Bombardier Inc .. How- ever, Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of the contents. We strongly recommend that any services be carried out and/or verified by a highly skilled professional mechanic. It is understood that certain modifications may render use of the vehicle illegal under existing federal, provincial and state regulations.

1983 BOMBARDIER SNOWMOBILES SHOP MANUAL INTRODUCTION This Shop Manual covers the following Bombardier made 1983 snowmobiles. Elan Citation 3500 Citation 4500/E Citation SS Nordik Skandic 277/377 Everest 500/E Everest LlC Blizzard 5500 MX Blizzard 9700 Alpine 503 Spirit Mirage II Furthermore, each vehicle has its particular vehicle serial number. PAGE4 The engine also has a serial number. Liquid cooled engines Fan cooled engines DEFINITION OF NUMBERING SYSTEMS The manual makes uses of a 2-part digital numbering system (i.e. 01 -01), in which the first digit represents the Section, the second digit the Sub-section. 01-01 / ~ section sub-section The numerotation at the bottom of each page assists the user in page location.

ARRANGEMENT OF THE MAN UAL The manual is divided into ten (10) ma jor sections 01 Too ls 02 Eng ine 03 Transmission 04 El ectrical 05 Suspension 06 Steering and skis 07 Hood and frame 08 Fuel line, wi ring harness and cable routing 09 Technical data 10 Wa rranty Each section is comprised of various sub-sections, and again , each sub-section has one or more division. EX.: 02 ENGINE 04 Engine type 464 Everest - Cooling system - Magneto The use of " Right" and " Left" indications in the text, always refers to driving position (when sitting on vehicle) LEFT ...... f--- --41.~ RIGHT 1983 BO M BARD I ER SNOWMOBILES SHOP MAN UAL GENERA L The informat ion, illustrations and component/system descriptions contained in this manual are correct at time of publication . Bombardier Inc. however, maintains a policy of contin uous improvement of its products with - out imposing upon itself any obligation to install them on products previously manufactured. Bombardier Inc. reserves the right at any time to discon- tinue or change specifications, designs, features, mod - els or equipment without incurring obligation. ILLUSTRATIONS & PROCEDURES An exploded view is conveniently located at the beginn- ing of each section and is meant to ass ist the user in identifying parts and components. This Shop Manual uses technical terms wh ich may be sligthly different from the ones of the parts catalogue. When ordering parts always · refer to the parts catalogue. The il lustrations show the typ ical construct ion of the different assemblies and, in all cases, may not repro- duce the full detail or exact shape of the parts shown , however, they represent parts wh ich have the same or a simi lar funct ion . When something special applies (such as adJustment, .. etc. ), the specific parts are circled and referred to in the text . As many of the procedures in this manual are interre- lated , we suggest, that before undertaking any task, you read and thorough ly understand the entire section or sub-section in wh ich the procedure is contained. A number of procedures throughout the book require the use of special tools. Where a speci al tool is indi- cated, refer to section 01 . Before commencing any procedure, be sure that you have on hand all the tools required, or approved equivalents. This manual is published by the Technical Publications Bombardier Inc. Valcourt, Quebec, Canada PAGE5

SECTION 01 02 03 04 05 06 07 08 - 09 10 TOOLS ENGINE TRANSMISSION ELECTRICAL SUSPENSION STEERING/SKIS HOOD /F RAME FUEL LINE, WIRING HARN ESS AND CABLE ROUTING TECHNICAL DATA (GENERAL) WARRANTY TABLE OF CONTENTS SUB-SECTION PAGE 01 - Basic tools 9 02 - Service tools 11 03 - Service products 19 01 - 247 Engine type 23 02 - 277 Engine type 33 03 - 377 Engine type 47 04 - 464 Engine type 63 05 - 503 Engine type 87 06 - 534 Engine type 109 07 - Engine tolerances measurement 131 08 - Carburetor and fuel pump 135 09 - Air intake silencer and fuel tank 143 10 - Rewind starter 145 01 - Pulley guard 149 02 - Drive belt 151 .' 03 - Drive pulley 159 04 - Driven pulley 175 .. , 05 - Pulley alignment 185 i 06 - Brake 189 07 - Chaincase 195 08 - Gear box 20 1 09 - Drive chain 209 01 - Electric charts 213 02 - Ignition timing 223 03 - Spark plugs 231 04 - Battery 235 05 - Electric starter 239 06 - Testing procedure 245 01 - Bogie wheel 261 02 - Slide & MX suspension 265 03 - Rear axle 28 1 04 - Drive axle 283 05 - Track 289 01 - Steering system 293 02 - Ski system 30 1 01 - Hood 313 02 - Frame 315 317 319 329

A. Screwdriver 8. Socket 10/13 mm C. Open end wrench 10/13 mm D. Socket wrench handle E. F. G. H. I. Starter rope Socket 17/21 mm Suspension adjustment key Extension bar Emergencv starter clip (Citation 3500 & 4500 E onlv) J. Suspension adjustment key K. Socket 21126 mm E H 1983 MODELS Elan, Spirit Citation, Mirage (All) Nordik, Skandic Blizzard 5500 MX Blizzard 9700, Everest 500, E. L/C , Alpine F SECTION 01 TOOLS SUB-SECTION 01 (BASIC TOOLS) BASIC TOOLS A c B ° () G K J APPLICABLE TOOLS A, B, C, 0, E, K. A, B, C, 0, E, I, K. A, B, C, D, E, K. A, B, C, D, E, G, J, K. A, B, C, D, E, G, K. A, B, C, D, E, F, G. A, B, C, D, E, H, K. PAGE9

1983 SKI DOO CITATION 4500 Factory Service & Work Shop Manual

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