1995 Ski-Doo Formula SS Factory Service & Work Shop Manual

• '' . .. , . •"' ,. , - .. ; • • •• 484 0618 00 1

il ski-doll 1995 Shop Manual

Legal deposit : National Library of Quebec 4t h trimester 1994 National Library of Canada All rights reserved. No pa rts of this manual may be reproduced in any form w ithout the prior written per- mission of Bombardier Inc. esombardier Inc. 1994 P ri nted in Canada ®*Registered trademarks of Bombardier Inc. This document contains the trademarks of the following companies : Loctite® is a trademark of Loctite Corporation Metton® is a trademark of Hercules Inc. Molykote® is a trademark of Dow Corning Corporation Silastic® is a trademark of Dow Corning Corporation Snap-on® is a trademark of Snap-on Tools Corporation Versilube® is a trademark of General Electric Company

TABLE OF CONTENTS SECTION SUB-SECTION PAGE SAFETY NOTICE ...................... ..................... ........ .............................................................................. ... Il l 1995 BOMBARDIER SNOWMOBILES SHOP MANUAL (INTRODUCTION)....................................... IV 01 SERVICE TOOLS AND 01 - Service tools ................................................... .. ........................... .. . 01 -01- 1 SERVICE PRODUCTS 02 - Servi ce products ......................................... .................................... 01 -02- 1 02 LUBRICATION AND MAINTENANCE .......... ............... ... ........ • ........ ................ ......................... ....... 02-01-1 03 TROUBLESHOOTING 04 ENGINE 05 TRANSMISSION 06 ELECT RI CAL 00- Table of contents ................................. .. ......................................... 03-00-1 01 - Engine ............. .. ................... ............ ............................................... 03-01 -1 02 - Fuel and oil systems ..... ............................ .................... ..... .. ........... 03-02-1 03 - Transmission and brake systems................................................... 03-03-1 04 - Electrical system ..... . :. ..................................................................... 03-04-1 05 - Suspension system and t rack ................ ... . .. .. .... ...... ..... ..... .... .. .. .... 03-05-1 00 - Tab le of contents .......... .... .............................................................. 04-00-1 01 - 247 and 277 Engine types ........................ ............. .. ...................... 04-01-1 02 - 377 and 503 Engine types ........... ... ..... ... ...... ........ .... .... . ... .. ......... .. 04-02-1 03 - 454, 467, 582, 583 and 670 Engine types ...................................... 04-03-1 04 - 779 Engine type .. .. .. ..... .... .. .... .. ... ......... .... ..... ..... ... .. .. .. .. ... .. ..... . .. .. ... 04-04-1 05 - Leak test and engine dimension measurement ............................. 04-05-1 06 - CDI system ....... .. .. .... ...... ........... .. . .. . .. ... . .. ...... ...... ... ........... ... ........ .. 04-06-1 07 - Oil injection system .. ................................... .. .. ... ............................ 04-07-1 08 - Axia l fan cooling system ..................................................... .. .. ........ 04-08-1 09 - Liquid cooling system .. .. .. .... ...... ............ ... .. .. ...... ..... ........ ... .... .... .... 04-09-1 1 0 - Rotary valve, coolant pump and reservoir .... ... .... ... .. .. .... ...... .... ...... 04-1 0-1 11 - Rewi nd starter ....... ..... .... .. .. ...... .. ... .... ... .. .... .. .. .. .. ..... .... .. . ... ... .......... 04-11-1 12 - Carb uretor and fu el pump ............................ ............ ........... ... ..... ... 04-12-1 13 - Fuel tank and throttle cable................ .. .......... ................ .. .... .......... 04-13-1 00 - Table of contents ... .. ... .. .. ...... . .... ... .. ... .. ...... ....... .. ... .. .. .. .. .. ... .... .. ... .. . 05-00-1 01 - Drive belt ... ................................ ........................................ ............. 05-01-1 02- Drive pulley .... ..... .. ... .. ... . .. .......... .. ......................... .. ....... .... ..... .. ...... 05-02-1 03 - Driven pulley ........... .. ... .......... ........... .. .. ............ .. ... .. .... ...... .. .... . .. .. .. 05-03-1 04 - Pulley distance and alignment.......................................... .. .. .. ..... ... 05-04-1 05- Brake ............................ ................................................................. .. 05-05-1 06- Chaincase ... .............................. .. ... ........ .. ... ... .. ................................ 05-06-1 07 - Gearbox .... ...... .. .... ........ ................................. ....... ........ ................ .. 05- 07-1 08 - Drive chain .... .. ... .... ..... .. . .. . .. .. .. .. .. .. ... .. .. .... .. . .. .. .... .. .... .. .. .. ..... .. . ... .... . 05- 08-1 00 - Table of contents .. .. .. .. . .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. . .. .. 06-00-1 01 -Wi ri ng diagrams (see Annexes at the end of this manual) ............. 06-01-1 02 - Ignition timing .......... .... .. ....... .. .... ... .. ... ...... .... .. ......... .. .... ...... ...... .. .. . 06-02-1 03 - Spark plugs ...................... .. .... ... ............. .... .... ............................ .. ... 06-03-1 04 - Battery ....... ..... .. .................. .. .. ..... .. ..... ... .. ........................ ... ....... ..... 06-04-1 05 - El ectric starter............................................. ....................... .. ........... 06-05-1 06- Testing procedure .. ....... .... ..... ... .............. .. .. .................................... 06-06-1

TABLE OF CONTENTS SECTION 07 REAR SUSPENSION SUB-SECTION PAGE 00- Table of contents ............................. ............................................... 07-00-1 01 -Bogie wheels ............. .. ..................................... .............................. 07-01-1 02- Torque reaction suspension.. ............... .... ...................................... 07-02-1 03- Touring suspension .. ........ ................................ ............................... 07-03-1 04- Skandic WT suspension .... .............. .. ............ .. .. .... .. ........................ 07-04-1 05 -I mproved C-7 suspens ion ............................... .. ............................. 07-05-1 06 - Hinged suspension ......... .. .......... .. .. ....................................... ......... 07-06-1 07- Rear axle .......... .. .. .... .. ..................................................................... 07-07-1 08- Drive axle .... .... ................ ... .... .... .. ........ .. ........... ........ .. ... ................. 07-08-1 09- Tra ck ................ .. .......... .. .................................................. .. ..... .. ...... 07-09-1 08 STEERING I 00- Table of contents .................... .. ................................................. .. ... 08-01-1 FRONT SUSPENSION 01 -Steering system ............................................... .. ............................. 08-02-1 02 - Suspension and ski system ............................................................ 08-02-1 09 BODY I FRAME 00- Table of contents ............................................ .. .......... .. ...... .. .......... 09-01-1 10 TECHNICAL DATA ANNEXES (Wiring diagrams) 01 - Body ................................................................................................ 09-02-1 02 - Frame............................................ .. ........................ .... ...... .. .......... .. 08-02-1 01 - Sl metric informati on guide .......................... .. ................................ 10-01-1 02 - Engines .. .. .. ..... .. .. .. ..... .. .. . .. .. ... .. .. .. .. .. .. ...... .. ..... .. ... . ... ...... .. .. . .. .. .. .. . .. . 1 0-02-1 03- Vehicles .............. .............. ....... ......... ...... ..... ......... ... ........... ... .... .. ... 1 0-03-1 04 - Techn ical data legends .. .. ...... .. .. .. .. .. .. .. ..... ... .... . .. .. .. .... .. .. ....... ..... .. .. . 1 0-04-1

SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair 1995 Ski-Doo snowmobiles. This edition was primarily published to be used by snowmobile mechanics who are already 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 catalog. The content depicts parts and I or procedures applicable to the particular product at its time of manufacture. It does not include dealer modifications, whether authorized or not by Bombardier, after manufacturing the product. In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas of the parts. The use of Bombardier parts is most strongly recommended when considering replacement of any component. Dealer and I or distributor assistance should be sought in case of doubt. The engines and the corresponding components identified in this document should not be utilized on product(s) other than those mentioned in this document. Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex. :locking tab, elastic stop nut, etc.) must be installed or replaced with new ones, where specified. If the efficiency of a locking device is imp-aired, it must be renewed. This manual emphasizes particular information denoted by the wording and symbols ; + WARNING : Identifies an instruction which, if not followed, could cause serious personal injury includ- ing possibility of death. T CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle components. Q NOTE : Indicates supplementary information needed to fully complete an instruction. Although the mere reading of such information does not eliminate the hazard, your understanding of the information will promote its correct use. Always use common shop safety practice. This information relates to the preparation and use of Bombardier snowmobiles and has been utilized safely and effectively by Bombardier Inc .. However, Bombardier Inc. disclaims liability for all damages and I or injuries resulting from the improper use of the contents. We strongly recommend that any services be carried out and I 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. Ill

1995 BOMBARDIER SNOWMOBILES SHOP MANUAL INTRODUCTION This Shop Manual covers the following Bombardier made 1995 snowmobiles : MODELS MODEL NUMBER MODELS MODEL NUMBER ELAN ® .................. .. ................................ 3052 GRAND TOURING* SE 670 (Sweden) ALPINE ® II ........ .. .. ..... .......... .............. .... 3357 SUMMIT* 583 (Canada) .. ........ .. ........... TUNDRA* II LT .. .................................... 3262 SUMMIT* 583 (U.S.) ............................. TUNDRA* II L T {Sweden) ..................... 3263 SUMMIT* 583 (Sweden) ...................... SKANDIC* 380 {Canada) ...................... 1505 SUMMIT* 670 (Canada} ....................... SKANDIC* 380 (Sweden} ... .. ................ 1507 SUMMIT* 670 (U.S.) ............................. SKANDIC* 380 (U .S.) ............................ 1518 SUMMIT* 670 (Sweden) .. .................... SKANDIC* 500 (Canada) ................... ... 1504 MX* (Canada) ....................................... SKANDIC* 500 (Sweden) ..................... 1508 MX* (U .S.) ............................................. SKANDIC* 500 (U .S.) ...... ...................... 1517 MX Z* (Canada) .................................... SKANDIC* WT .................... .. ...... .. ........ 1515 MX Z* (U .S.) ........... ............................... tsKANDIC* MOUNTAIN SP ................ 1516 MX Z* (Sweden) ........ ........................... TOURING* E {Canada) ......................... 1503 FORMULA* STX (Canada) ................... TOURING* LE (Canada) ....................... 1502 FORMULA* STX (U.S.) ......................... TOURING* LE (Sweden) .... .. ................ 1510 FORMULA* STX LT (2) (Canada) ........ TOURING* LE (U.S) .............................. 1519 FORMULA* STX LT (2) {U.S.) .............. TOURING* SLE (Canada) .................. ... 1501 FORMULA* Z (Canada} ........................ TOURING* SLE (U.S.} .... ...................... 1511 FORMULA* Z {U.S.) .............................. TOURING* SLE {Sweden) .................... 1512 FORMULA* Z (Sweden} ......... .. ............ FORMULA* S (Canada} ........................ 1520 FORMULA* SS (Canada) ..................... FORMULA* SL (Canada) .. .............. ...... 1500 FORMULA* SS (U .S.} ........................... FORMULA* SL {U .S.) ...................... ... .. 1513 FORMULA* SS (Sweden) .................... GRAND TOURING* 470 (Canada) ..... . 1022 MACH 1* 670 (Canada) ........................ GRAND TOURING* 470 (U.S.) ............. 1023 MACH 1* 670 (U.S.) .............................. GRAND TOURING* 470 (Sweden) ..... 1046 MACH 1* {Sweden) .. .......... .................. GRAND TOURING* 580 (Canada) .... .. 1024 MACH Z* (Canada) ............................... GRAND TOURING* 580 (U .S.) ..... ........ 1025 MACH Z* (U .S.) .. ................................... GRAND TOURING* 580 {Sweden} ..... 1026 MACH Z* (Sweden) .............................. GRAND TOURING* SE 670 (Canada) . 1027 GRAND TOURING* SE 670 {U.S.} ...... 1028 *Tra demarks of Bombardier Inc. ts kan dic Mounta in SP may be identified in some sections of this manual as Ski Hill SP. IV 1029 1013 1014 1015 1016 1017 1018 1000 1001 1035 1036 1037 1003 1004 1007 1008 1030 1031 1032 1033 1034 1047 1043 1044 1045 1040 1041 1042

1995 BOMBARDIER SNOWMOBILES SHOP MANUAL LIST OF MODELS GROUPED BY COMMUN CHASSIS S-Series consists of: Touring E I LEI SLE Skandic 380 I 500 Formula S I SL (TYPICAL) S-SERIES AOOJ 000 002 F-Series consist of : MXIZ Grand Touring 470 I 580 I SE 670 Summit 583 I 670 Formu la STX I STX LT I SS I Z Mach 1 I Z (TYPICAL) F-SERIES A006 000 006 v

1995 BOMBARDIER SNOWMOBILES SHOP MANUAL Each vehicle has its pa rticul ar vehicle serial number. Serial Number Meaning: ~ ~ Model no. Vehicle no. AOOO 000 013 A006 007 001 Vehicle sen a I number The engine also has a se ri al number. Li qu id- Cooled Engines A000002 062 VI Engine senal number Fan-Cooled Engines Engine ser ial num ber A007 002 001 ARRANGEMENT OF THE MANUAL The manual is divided into 10 major sections : 01 SERVICE TOOLS AND SERVICE PRODUCTS 02 LUBRICATION AND MAINTENANCE 03 TROUBLESHOOTING 04 ENGINE 05 TRANSMISSION 06 ELECTRICAL 07 REAR SUSPENSION 08 STEERING I FRONT SUSPENSION 09 BODY I FRAME 10 TECHNI CAL DATA ANNEXES Each section is divided in va rious sub-sections, and again, each sub-section has one or more division.

1995 BOMBARDIER SNOWMOBILES SHOP MANUAL This Shop Manual uses technical terms wich m ay be slightly different from the ones in the parts catalog. Explosed view assits you in identifying parts and related positions. Illustration number for publishing proce ss . TYPICAL PAGE Page heading 1 ndicates section and sub-section detailed . .......: · ...:; ,• :.. ·· -;.; • . .... .. · ..:· ·· ;;:;; •· ·.;: ••"'"" ·" . ,;;;; ·.c· ;...;... . . ... .. .._ ., -..;.;·"" "';....;.:~ ·•;... ·· ·ii~i ·liii:.i '·•··o:o ··'".:o "·oo:: ····:;.. ·· ;o;; ··;.; ·":·_. ·:::;;:;; .~· ...... ;...;..,~ "·•;...· ... ·;.;· •· .... .... ·• ;;;;"·.· ·===- ·: ..,i ... .. , .., ~. ? ' "' ., . .. .. ·~ "'·;...· · ·· ± '':·.,..; . , .. • :? ; Sub-section title S~n _. ENG1NE · indicates begmning • Suh-Secuon 06 !CDI S,V'SWEI\otl of the sub- sect1on. ·.• ' ~·A - ~·'>•.• Ill ~ '··--~<= -~- .. .. . ... ... ,., ~ - ~, :~PPOJIIOE~~'SY$TEI)Ii~· SUil~~COI~~ 1 Oov1 S10n . ... . ""·* ·' · .. .. ~. ... - """ ... • . ... ··- ·. ·-· ·· - ~ . ... - ""' ·~ II title. ~ ft 4 ~W~lii lt~~~~~ ~~ ~' 5 Loc:.,.m ~- , ,~ m ...... ... ""'"' Sub-title at top r --- -- -- -i right co rner of 1 ~ ~"' 1 indicates I r~........... I I explosed view ~ ) -f : li pertaining models. Dotted box :: ~ 1 1 1 contains parts of a partocular .. ----7-~-77-- model, in this I fL-• case the 277 ! · .!~"'a 1 engine only. I '-t' l ! ______ __ _ ~ 7 lcctrto242 l \f"Jt~J(•/, w D <OP"Pffi"' "' 1 Loetott 2• 2 / 1 , • 1 , _ "'::;' liquid product to be ,1: ~-, 277 applied to a surfa ce. ('~~~ \~~®~ :f / ra __ 2 ;,t~~,~ ........ ?!..... to~ ~::r~:!!t. ortv , ... (. J!~lt a - , I ~ ' ', (_. z'v_·~· u----- 22 '',, /' i '&: f l~(.' _l~ l) I Bold f ace number '0> ond;cates specia l to procedure li ghtening torque near by fastener. In this case, nut no. 22 must be torqued to 7 N• m or 62 lbf•in . Page numbenng system : 04 ENGI NE section 06 COl SYSTEM sub-section 1 First page of this sub-section ~ CAUTION : Pay attenti on to torque speci fi ca- T tions. Some of th es e are in l bf•in instead of lbf• ft. Use appropriate torque wrench. VII

1995 Ski-Doo Formula SS Factory Service & Work Shop Manual

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