Ski-Doo MXZ X 440 LC 1999 Factory Service & Work Shop Manual

Ski-Doo 1998 Shop Manual This manual is divided up into 3 volumes. Use the links below or the bookmarks to the left to get to the volume that covers your sled. Volume 1: Tundra II LT Touring E / LE Formula S / Electric / SL Skandic 380 / 500 Volume 2: MX Z 440 / 500 / 583 / 670 Formula 500 / 500 Deluxe / 583 Deluxe / Z 583 / Z 670 Summit 500 / 583 / 670 Grand Touring 500 / 583 Skandic WT / SWT / WT LC Volume 3: Grand Touring 700 / SE Formula III 600 / 600 R / 600 LT / 700 / 700 R Mach 1 / 1 R / Z / Z R / Z LT / Z LT R Supplement for MX Zx models Supplement for Summit X 670 models Supplement for Tundra R and Touring SLE models

1998 Shop Manual VOLUME 1 TUNDRA II LT TOURING E/LE FORMULA S/S ELECTRIC/SL SKANDIC 380/500 ®

I SECTION SUBSECTION PAGE SAFETY NOTICE .................................................................................................................................. III INTRODUCTION .................................................................................................................................. IV 01 SERVICE TOOLS AND SERVICE PRODUCTS 01 – Service tools ............................................................................. 01-01-1 02 – Service products....................................................................... 01-02-1 02 LUBRICATION AND MAINTENANCE 01 – Lubrication and maintenance chart .......................................... 02-01-1 03 TROUBLESHOOTING 01 – Table of contents...................................................................... 03-01-1 02 – Engine ...................................................................................... 03-02-1 03 – Fuel and oil systems................................................................. 03-03-1 04 – Transmission and brake systems ............................................. 03-04-1 05 – Electrical system ...................................................................... 03-05-1 06 – Suspension and track ............................................................... 03-06-1 04 ENGINE 01 – Table of contents...................................................................... 04-01-1 02 – 277 engine type........................................................................ 04-02-1 03 – 377, 443 and 503 engine types ................................................ 04-03-1 04 – Leak test and engine dimension measurement ....................... 04-04-1 05 – CDI system............................................................................... 04-05-1 06 – Oil injection system.................................................................. 04-06-1 07 – Axial fan cooling system........................................................... 04-07-1 08 – Rewind starter .......................................................................... 04-08-1 09 – Carburetor and fuel pump ........................................................ 04-09-1 10 – Fuel tank and throttle cable ...................................................... 04-10-1 05 TRANSMISSION 01 – Table of contents...................................................................... 05-01-1 02 – Drive belt .................................................................................. 05-02-1 03 – Drive pulley............................................................................... 05-03-1 04 – Driven pulley............................................................................. 05-04-1 05 – Pulley distance and alignment .................................................. 05-05-1 06 – Brake ........................................................................................ 05-06-1 07 – Chaincase ................................................................................. 05-07-1 08 – Gearbox .................................................................................... 05-08-1 09 – Drive chain................................................................................ 05-09-1 06 ELECTRICAL 01 – Table of contents...................................................................... 06-01-1 02 – Wiring diagrams (see annexes at the end of this manual) ....... 06-02-1 03 – Ignition timing........................................................................... 06-03-1 04 – Spark plugs ............................................................................... 06-04-1 05 – Battery ...................................................................................... 06-05-1 06 – Electric starter .......................................................................... 06-06-1 07 – Testing procedure .................................................................... 06-07-1 07 REAR SUSPENSION 01 – Table of contents...................................................................... 07-01-1 02 – Torque reaction suspension ..................................................... 07-02-1 03 – SC-10 Sport and Touring suspension ....................................... 07-03-1 04 – Drive axle.................................................................................. 07-04-1 05 – Track ......................................................................................... 07-05-1 TABLE OF CONTENTS

II 08 STEERING/ FRONT SUSPENSION 01 – Table of contents ..................................................................... 08-01-1 02 – Steering system....................................................................... 08-02-1 03 – Suspension and ski system ..................................................... 08-03-1 09 BODY/FRAME 01 – Table of contents ..................................................................... 09-01-1 02 – Body ......................................................................................... 09-02-1 03 – Frame ....................................................................................... 09-03-1 10 TECHNICAL DATA 01 – SI metric information guide...................................................... 10-01-1 02 – Engines .................................................................................... 10-02-1 03 – Vehicles.................................................................................... 10-03-1 04 – Technical data legends............................................................. 10-04-1 ANNEXES (wiring diagrams) SECTION SUBSECTION PAGE TABLE OF CONTENTS

III SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair some 1998 Ski-Doo snowmobiles. See model list on next page. 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. It is understood that this manual may be translated into another language. In the event of any discrepan- cy, the english version shall prevail. The content depicts parts and/or procedures applicable to the particular product at its time of manufac- ture. It does not include dealer modifications, whether authorized or not by Bombardier, after manufac- turing 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 com- ponent. Dealer and/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 impaired, it must be renewed. This manual emphasizes particular information denoted by the wording and symbols: 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/or injuries resulting from the improper use of the contents. We strongly recommend that any servic- es 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. ; WARNING Identifies an instruction which, if not followed, could cause serious personal injury including possibility of death. - CAUTION Denotes an instruction which, if not followed, could severely damage vehicle components. SAFETY NOTICE

IV INTRODUCTION 0 This Shop Manual VOLUME 1 covers the follow- ing Bombardier made 1998 snowmobiles: Tundra II LT Touring E/LE Skandic 380/500 Formula S/SL These are S-Series models. TYPICAL — S-SERIES VEHICLE SERIAL NUMBER Vehicle Serial Number Location TYPICAL 1. Vehicle serial number Serial Number Meaning MODELS MODEL NUMBER TUNDRA* II LT ................................ 3270 SKANDIC* 380 (Canada) ................ 1240 SKANDIC* 380 (U.S.) ...................... 1241 SKANDIC* 380 (Europe) ................. 1242 SKANDIC* 500 (Canada) ................ 1237 SKANDIC* 500 (U.S.) ...................... 1238 SKANDIC* 500 (Europe) ................. 1239 TOURING* E (Canada) ................... 1234 TOURING* E (Europe) .................... 1236 TOURING* LE (Canada) ................. 1232 TOURING* LE (U.S.) ....................... 1233 FORMULA* S (Canada) .................. 1226 FORMULA* S (Europe) ................... 1227 FORMULA* S Electric ..................... 1228 FORMULA* SL (Canada) ................ 1224 FORMULA* SL (U.S.) ...................... 1225 *Trademark of Bombardier Inc. A03A09A A03A0AA A03H2AA 1 A00A0DA Model no. Vehicle no. 0000 00000 INTRODUCTION

V ENGINE SERIAL NUMBER Engine Serial Number Location TYPICAL — FAN-COOLED ENGINES 1. Engine serial number ARRANGEMENT OF THE MANUAL The manual is divided into 11 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/FRONT SUSPENSION 09 BODY/FRAME 10 TECHNICAL DATA ANNEXES Each section is divided in various subsections, and again, each subsection has one or more divi- sion. A03A0BA 1 INTRODUCTION

VI LIST OF ABBREVIATIONS USED IN THIS MANUAL A ampere amp ampere A•h ampere-hour AC alternate current BDC bottom dead center BTDC before top dead denter °C Celsius CDI capacitor discharge ignition cm centimeter cm² square centimeter cm³ cubic centimeter DC direct current DSA direct shock action °F Fahrenheit FC fan cooled fl. oz fluid ounce ft foot GRD ground H.A.C. high altitude compensator hal. halogen imp. oz imperial ounce in inch in² square inch in³ cubic inch k kilo (thousand) kg kilogram km/h kilometer per hour kPa Kilopascal L liter lb pound lbf pound (force) lbf/in² pound per square inch LH left hand m meter MAG magneto Max. maximum Min. minimum mL milliliter mm millimeter MPH mile per hour N newton N.A. not applicable no. number 00.0 continuity 0.L overload (open circuit) O.D. outside diameter OPT optional oz ounce P/N part number PSI pound per square inch PTO power take off R rectangular RAVE rotax adjustable variable exhaust RPM revolution per minute RRIM reinforced reaction injection molding Sp. Gr. specific gravity ST semi-trapez TDC top dead center TRA total range adjustable U.S. oz ounce (United States) V volt Vac volt (alternative current) INTRODUCTION

VII Section 07 REAR SUSPENSION Subsection 01 (SUPENSION SC-10 SPORT, TOURING AND MOUNTAIN) SUSPENSION SC-10 SPORT, TOURING AND MOUNTAIN Grand Touring 500/580, Formula 500/583 and Summit 500 07-01-1 A03F24S Short Track Models Only Long Track Models Only SLE Only Loctite 271 Loctite 271 Loctite 271 Loctite 271 Loctite 271 Loctite 271 Loctite 271 Loctite 271 Low temp. grease 6 5 6 7 4 3 2 1 6 19 Low temp. grease 8 9 16 Low temp. grease 11 12 13 14 15 11 11 11 16 20 18 10 17 11 18 N•m (160 lbf•in) 4 N•m (35 lbf•in) Page heading indicates section and subsection detailed. Bold face number indicates special procedure concerning this part. Tightening torque nearby fastener. In this case, nut must be torqued to 4 N•m or 35 lbf•in. This Shop Manual uses technical terms wich may be slightly different from the ones in the parts catalog. Exploded view assists you in identifying parts and related positions. TYPICAL PAGE A01A28S Illustration number for publishing process. Subsection title indicates beginning of the subsection. Drop represents a liquid product to be applied to a surface. In this case Loctite 271 to screw threads. Dotted box contains parts of a particular model in this case the short track models only. Page numbering system: 07: REAR SUSPENSION section 01: SUSPENSION SC-10 SPORT, TOURING AND MOUNTAIN subsection 1: First page of this subsection Italic subtitle above exploded view indicate pertaining models. Pay attention to torque specifications. Some of these are in lbf•in instead of lbf•ft. Use appro- priate torque wrench. CAUTION ▼ INTRODUCTION

Ski-Doo MXZ X 440 LC 1999 Factory Service & Work Shop Manual

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