1994 Ski-Doo Formula Z Factory Service & Work Shop Manual

) TABLE OF CONTENTS SECTION SUB-SECTION PAGE SAFETY NOTICE..................................................................................................................................... Ill 1994 BOMBARDIER SNOWMOBILES SHOP MANUAL (INTRODUCTION) ....................................... IV 01 SERVICE TOOLS AND 01- Service tools .................................................................................... 01-01-1 SERVICE PRODUCTS 02- Service products ................ ............................................................. 01-02-1 02 LUBRICATION AND MAINTENANCE ............................................................................................. 02-00-1 03 TROUBLESHOOTING 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 track ......................................................... 03-05-1 04 ENGINE 01-247 and 277 Engine types .............................................................. 04-01-1 02 - 377 and 503 Engine types .............................................................. 04-02-1 03 - 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- Axial fan cooling system ................................................................. 04-08-1 09- Liquid cooling system ..................................................................... 04-09-1 10- Rotary valve, coolant pump and reservoir....................................... 04-10-1 11 - Rewind starter................................................................................. 04-11-1 12- Carburetor and fuel pump ............................................................... 04-12-1 13- Fuel tank and throttle cable............................................................. 04-13-1 05 TRANSMISSION 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 06 ELECTRICAL 01 -Wiring diagrams.............................................................................. 06-01-1 02- Ignition timing .................................. ............................................... 06-02-1 03 -Spark plugs...................................................................................... 06-03-1 04 - Battery............................................................................................. 06-04-1 05- Electric starter................................................................................. 06-05-1 06 -.Testing procedure ................................................................., ......... 06-06-1 ?''--- ~---__

TABLE OF CONTENTS SECTION SUB-SECTION PAGE 07 REAR SUSPENSION 01 · Bogie wheels .................................................................................. 07-01.1 02 ·Torque reaction suspension............................................................ 07-02-1 03 ·Safari suspension ............................................................................ 07-03-1 04 · C-7 suspension ............................................................................... 07-04-1 05 ·Improved C-7 suspension ............................................................... 07-05-1 06- Hinged suspension.......................................................................... 07-06-1 07- Rear axle ......................................................................................... 07-07-1 08 ·Drive axle .......................................................... .............................. 07-08-1 09- Track ............................................................................................... 07-09-1 08 STEERING I 01- Steering system .............................................................................. 08-01-1 FRONT SUSPENSION 02 • Supension and ski system .............................................................. 08-02-1 09 BODY I FRAME 01 -Body................................................................................................ 09-01-1 02 - Frame .......... .................................................................................... 09-02-1 10 TECHNICAL DATA ........................................................................................................................... 10-00-1 . II ~

SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair 1994 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 autho{lzed or not by Bombardier, after manufacturing the product. In addition, the sole purpose of the illustrations I photographs 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} must be installed or replaced with 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 ; • 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

1994 BOMBARDIER SNOWMOBILES SHOP MANUAL INTRODUCTION This Shop Manual covers the following Bombardier made 1994 snowmobiles : MODELS MODEL NUMBER ELAN® .................................................... 3051 ALPINE® 11.............................................. 3356 TUNDRA* II ........................................... 3258 TUNDRA* II LT ...................................... 3259 SKANDIC* II 377 ................................... 3685 SKANDIC* II 377 R ................................ 3686 SKANDIC* II 377 R (Sweden)............... 3690 SKANDIC* II 503 R ................................ 3687 SKANDIC* II 503 R (Sweden)............... 3691 SKANDIC* II 503 R SL T ........................ 3688 SKANDIC* II 503 R SL T (Sweden) ....... 3692 SAFARI* L .............................................. 3682 SAFARI* DELUXE ................................. 3683 SAFARI* DELUXE (Sweden) ................ 3694 SAFARI* RALLY E ................................. 3689 GRAND TOURING*............................... 3867 GRAND TOURING* (Sweden) ............. 3879 GRAND TOURING* XTC ...................... 3864 GRAND TOURING* XTC (Sweden) ..... 3878 GRAND TOURING* SE ......................... 3866 SUMMIT* 470 (Canada) ....................... 3871 SUMMIT* 470 (U.S.)............................. 3888 SUMMIT* 470 (2) (U.S.) ....................... 3887 SUMMIT* 470 (2) (Canada) .................. 3865 SUMMIT* 583 (Canada) ....................... 3876 SUMMIT* 583 (U.S.) ............................. 3891 SUMMIT* 583 (2) (Canada) .................. 3881 SUMMIT* 583 (2) (U.S.) ....................... 3882 SUMMIT* 583 (2) (Sweden) ................. 3890 *Trademarks of Bombardier Inc. IV MODELS MODEL NUMBER MX* (Canada) ....................................... 3868 MX"* (U.S.) ............................................. 3883 MX* (Sweden) ...................................... 3885 MX Z* (Canada).................................... 3870 MX Z* (U.S.).......................................... 3886 FORMULA* ST (Canada) ...................... 3872 FORMULA* ST (U.S.) ........................... 3889 FORMULA* STX (Canada) ................... 3873 FORMULA* STX (U.S.) ......................... 3893 FORMULA* STX (Sweden) .................. 3892 FORMULA* STX (2) (Canada) .............. 3874 FORMULA* STX (2) (U.S.) ................... 3894 FORMULA* Z (Canada) ........................ 3875 FORMULA* Z (U.S.) .............................. 3897 FORMULA* Z (Sweden) ....................... 3896 MACH 1 * .......... ...................................... 3863 MACH 1* (Sweden) .............................. 3880 MACH Z* (Canada) ............................... 3877 MACH Z* (U.S.)..................................... 3899 MACH Z* (Sweden) .............................. 3898

Furthermore, each vehicle has its particular vehicle serial number. Serial Number Meaning : AOOO 000013 (TYPICAL) A006 007 001 0000 00000 ---, -r Model no. Vehicle no. Vehicle serial number The engine also has a serial number. Liquid-Cooled Engines AOOO 002062 Engine serial number 1994 BOMBARDIER SNOWMOBILES SHOP MANUAL Fan-Cooled Engines Engine serial number A007 002001 ARRANGEMENT OF THE MANUAL The manual is divided into 10 major sections : 01 SERVICE TOOLS ANO 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 TECHNICAL DATA Each section is divided in various sub-sections, and again, each sub-section has one or more division. v

1994 BOMBARDIER SNOWMOBilES SHOP MANUAl VI This Shop Manual uses technical terms wich may be slightly different the ones of the parts catalog. Explosed view assits you in identifying parts and related positions. TYPICAL PAGE Page heading indicates section and sub-section detailed. 1 - --- --- Sub-section title SUction 04 ENGINE indicates beginning ~ Sub-Section 06 (COr SYSTEM) of the sub-section . .................... ., .... .... ,,!!>~!!~.~~~:t: .. · · · Ill title. 277,.503 (Alpin. !II Engines~ LOC!•!O 242 /5/ _ll", ~~. ~7..="2.:"~on_~X _ _ _ _ Sub-title at top 1 right corner of I ~(&-............_ SXJ?IO~ed view I IJ ~ Doelewic 1nd1cates i ! 11 ''""'" pertaining models. 1 I Ill Dotted box 1 contains parts 1 II II( of a particular 1 ~ I Ill model, in this I ~ ~/& / case: the 277 : --.:; ~ 1 eng1ne only. I /''1-:.~ I I y I ! ________ _! tfo •r] ""' ~ J1j!11'" ents a ~ P" 7 Lo<::tLto242 Drop repres be I 1 2 . duct to ~ • //34 liqurddprtooasurface. •, / • Ire / ~I/ a 7'. • / '" app In this case I_., ' /• , . • .,. ,, '"'""'" r1( ' ~:... / ;. / '•. ·- """""'". c '21 ·,, ' 0;' ~ ,, 1 f~~t'-.....::_Nv / ,<)<R '"'m '(, I . . / I ,.,.y \'"'"''' (, ~-~~·. ' .. , '"""•~ ber .,, ' '•c -, ,, , '" "~'"' oom 1 ·~·""/ ', I i '• ';;! f( I indicates specla • I• •, - •, m~o" . b '""'"'' "'""""" ''<4J this part. number_ for publishmg ... -~ lightemng torque near by fastener. In this case, nut #22 must be torqued to 7 N•m or 62 lbf•in. .._,. CAUTION : Pay attention to torque specifica- y tions. Some of these are in lbf•in instead of lbfoft. Use appropriate torque wrench. Page numbering system : 04 : ENGINE section 06 :COl SYSTEM sub-section 1 First page of this sub-section \ )

"Side view" mention at top helps you in understanding I Sub-title beginning with part number{s) of above exploded view following by part name(s). Sub-sub-title indicates a particular procedure concerning a model. Illustration always follows text it is pertained to. Sub-sub-title in this case indicates that particular procedure for Alpine II is finished, so from this point, all models are concerned. 1994 BOMBARDIER SNOWMOBILES SHOP MANUAL TYPICAL PAGE Illustration with an auxiliary view to show details. WhBn instalhng end bearing housing. ensure to pos1· tion grc~se filling on top. This is wquired to have proper alignment with access hole. (ir•u,~IM~ ~~,0~ lock drivo a)(le sprocket with a crrclip (use new cotter pin or~ i!l6nl Reinstall the chaincose cover (if opplicabte). Refill with choinc~se oil. Refer to TECHNICAL. DATA " Install the suspens•on. f\efor !Q. TRACK ll-7..09" and ~d- JUS\ track tens•on and carry out tracl ~ 'nment procedure Section 07 REAR SUSPENSION Sub-Section 08 (DRIVE AXLE) 15, Grease Fitting L.ubricaw ond hous•ng bearing with low temperature grease IP f N 413 7061 00). ADJUSTMENT Sprocket 1 Track Alignment "B'" CAUTION :Do not temper with sprocket f track V alignmBn\ if frame or suspension is damaged. All Models Except Elon Sprockets might bu repo~iliOned to fit track holes (lugs on liquid cooled models and Skand1c II 503 A SL n without removing drive axle Use drive axle sproc~et adjuster kit IP f N 861 1257 001 07.08·~ ~~' Track section 07 sub-section 09 must be read for proper adjustment of track tension and alignment. Title indicates main procedure to be carried-out. "Typical" mention at top left corner indicates a general view which does not represent full detail. In this case, track is not illustrated even if the adjustment can be made when installed. VII _

r 1994 BOMBARDIER SNOWMOBilES SHOP MANUAl GENERAL INFORMATION The information and component I system descriptions contained in this manual are correct at time of publica- tion. Bombardier Inc. however, maintains a policy of continuous improvement of its products without im- posing upon itself any obligation to install them on products previously manufactured. Bombardier Inc. reseNes the right at any time to dis- continue or change specifications, designs, features, models or equipment without incurring obligation. USEFUL PUBLICATIONS Refer to Parts Catalogs to order the right parts. PARTS CATALOG MODELS PIN ELAN 480 1332 00 ALPINE II 480 1333 00 SAFARI L SFARI DELUXE 480 1335 00 SAFARI RALLY E SKANDIC II 377 SKANDIC II 377 R 480 1336 00 SKANDIC II 503 R SKANDIC II 503 R SLT TUNDRA 480 1334 00 TUNDRA LT MACH 1 GRAND TOURING 480 1337 00 GRAND TOURING XTC GRAND TOURING SE MX MXZ 480 1340 00 MACHZ SUMMIT 467 480 1341 00 SUMMIT583 FORMULA ST FORMULA STX 480 1342 00 FORMULAZ Use Tools and Accessories Catalog to orther the tools you need. 1994 TOOLS AND ACCESSORIES (PIN 480 1343 00). VIII Use Specification Booklet to find rapidly the right specs. 1990-1994 SPECIFICATION BOOKLET (PIN 4801296 00). ILLUSTRATIONS AND PROCEDURES The illustrations show the typical construction 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 which have the same or a similar function. ._,CAUTION : Most components of those vehi- T cles are built with parts dimensioned in the metric system. Most fasteners are metric and must not be replaced by customary fasteners or vice versa. Mismatched or incorrect fasteners could cause damage to the vehicle or possible personal injury. As many of the procedures in this manual are interre- lated, we suggest, that before undertaking any task, you read and thoroughly understand the entire section or sub-section in which the procedure is contained. A number of procedures throughout the book require the use of special tools. Before commencing any procedure, be sure that you have on hand all the tools required, or approved equivalents. 1 )

The use of RIGHT and LEFT indications in the text, always refers to driving position (when sitting on vehicle). (TYPICAL) LEFT AOOO 000 002.1 RIGHT Technical Publications Bombardier Inc. Valcourt (Quebec) Canada 1994 BOMBARDIER SNOWMOBILES SHOP MANUAl IX

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1994 Ski-Doo Formula Z Factory Service & Work Shop Manual

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