Ski-Doo MXZ 500 Standard 2002 Factory Service & Work Shop Manual

Ski-Doo 2002 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 R Skandic Volume 2: Mach Z Volume 3: Grand Touring Legend MX Z Summit

2002 Shop Manual VOLUME 1 TUNDRA R SKANDIC LT/WT/SWT/WT LC

MMR2002_001_00_02A.FM I SECTION SUBSECTION PAGE SAFETY NOTICE .................................................................................................................................. III WHAT’S NEW ....................................................................................................................................... IV INTRODUCTION .................................................................................................................................. V 01 SERVICE TOOLS AND SERVICE PRODUCTS 01 – Service tools ............................................................................. 01-01-1 02 – Service products....................................................................... 01-02-1 02 LUBRICATION AND MAINTENANCE 01 – Table of contents...................................................................... 02-01-1 02 – Lubrication and maintenance chart .......................................... 02-02-1 03 – Storage ..................................................................................... 02-03-1 04 – Preseason preparation.............................................................. 02-04-1 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 – 443 and 503 engine types ........................................................ 04-03-1 04 – 593 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 – Rewind starter .......................................................................... 04-10-1 11 – Carburetor and fuel pump ........................................................ 04-11-1 12 – Fuel tank and throttle cable ...................................................... 04-12-1 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 – 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

II MMR2002_001_00_02A.FM 07 REAR SUSPENSION 01 – Table of contents ..................................................................... 07-01-1 02 – Torque reaction suspension ..................................................... 07-02-1 03 – Skandic WT suspension ........................................................... 07-03-1 04 – Drive axle ................................................................................. 07-04-1 05 – Track ........................................................................................ 07-05-1 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 11 WIRING DIAGRAMS 01 – Wiring diagrams ....................................................................... 11-01-1 SECTION SUBSECTION PAGE TABLE OF CONTENTS

MMR2002_001_00_02A.FM III SAFETY NOTICE 0 This manual has been prepared as a guide to correctly service and repair some 2002 Ski-Doo snowmobiles. See model list below. This edition was primarily published to be used by snowmobile mechanic technicians who are already familiar with all service procedures relating to Bombardier made snowmobiles. Mechanic technicians should attend continuous training courses given by Bombardier Training Dept. 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 the Parts Catalog. It is understood that this manual may be translated into another language. In the event of any discrepancy, the English version shall prevail. The content depicts parts and/or procedures applicable to the particular product at time of writing. Service and Warranty Bulletins may be published to update the content of this manual. Make sure to read and understand these. 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, self-locking fasteners, etc.) must be installed or replaced with new ones. If the efficiency of a locking device is impaired, it must be renewed. This manual emphasizes particular information denoted by the wording and symbols: 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 understanding of the information will promote its correct use. Always use common shop safety practice. 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.  WARNING Identifies an instruction which, if not followed, could cause serious personal injury including possibility of death. SAFETY NOTICE

IV MMR2002_001_00_02A.FM WHAT’S NEW 0 INTRODUCTION • Meaning of vehicle description decal. SERVICE TOOLS 01-01 • New countershaft bearing removal and installer tool for Skandic LT. 443 AND 503 ENGINE TYPES 04-03 • Crankcase is now sealed with new sealing compound P/N 420 297 906 instead of Loctite 515. 593 ENGINE TYPES 04-04 • New installation and removal procedure for piston pin tab type circlip. OIL INJECTION SYSTEM 04-07 • Different pump adjustments according to pump identification. REWIND STARTER 04-10 • New type of lubricant is used on all moving parts. CARBURETOR AND FUEL PUMP 04-11 • New installation and removal procedure for air silencer. DRIVE BELT 05-02 • New adjustment of drive belt. IGNITION TIMING 06-02 • New procedure for ignition timing. BATTERY 06-04 • New installaltion and removal procedure for battery. WHAT’S NEW

MMR2002_001_00_02A.FM V INTRODUCTION 0 This Shop Manual Volume 1 covers the following Bombardier made 2002 snowmobiles: *Trademarks of Bombardier Inc. Tundra R TYPICAL — TUNDRA R Skandic LT Skandic WT Skandic SWT Skandic WT LC These are Skandic series models. TYPICAL — SKANDIC SERIES VEHICLE DESCRIPTION DECAL Vehicle Description Decal Location Vehicle description decal is located on right hand side of tunnel. TYPICAL 1. Vehicle description decal Vehicle Description Decal Meaning VEHICLE DESCRIPTION DECAL 1. Manufacturer name and address 2. Manufacturing date 3. Vehicle identification number (VIN) 4. Model name 5. Option package 6. Engine type 7. Model year 8. Color codes MODELS MODEL NUMBER TUNDRA R (Canada and U.S.) ............. 3278 SKANDIC* LT (Canada) ........................ 2101 SKANDIC* LT (U.S.) .............................. 2102 SKANDIC* WT (Canada) ....................... 2099 SKANDIC* WT (U.S.) ............................ 2100 SKANDIC* SWT (Canada) .................... 2097 SKANDIC* SWT (U.S.) .......................... 2098 SKANDIC* WT LC (Canada) ................. 2095 SKANDIC* WT LC (U.S.) ....................... 2096 A05A0EA A29A03A           INTRODUCTION

VI MMR2002_001_00_02A.FM Vehicle Identification Number (VIN) Location VIN is scribed on vehicle description decal. See above. It is also embossed on tunnel near vehicle description decal. Vehicle Identification Number Meaning ENGINE SERIAL NUMBER Engine Serial Number Location Fan-Cooled Engines TYPICAL — FAN-COOLED ENGINES 1. Engine serial number Liquid-Cooled Engines TYPICAL — LIQUID-COOLED ENGINES 1. Engine serial number         A03A0BA 1   INTRODUCTION

MMR2002_001_00_02A.FM VII LIST OF ABBREVIATIONS USED IN THIS MANUAL A ampere amp ampere A•h ampere-hour AC alternate current ACM acceleration and control modulator ARM advance ride management BDC bottom dead center BTDC before top dead center °C degree Celsius cc cubic centimeter CDI capacitor discharge ignition CTR center cm centimeter cm² square centimeter cm³ cubic centimeter DC direct current DPM digital performance management DSA direct shock action °F degree Fahrenheit FC fan cooled fl. oz fluid ounce ft foot GRD ground H.A.C. high altitude compensator hal. halogen HI high 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 LO low LT long track m meter MAG magneto Max. maximum Min. minimum mL milliliter mm millimeter MPEM multi-purpose electronic module 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 RH right hand RAVE rotax adjustable variable exhaust RPM revolution per minute RMS root mean square RRIM reinforced reaction injection molding Sp. Gr. specific gravity ST semi-trapezoidal TDC top dead center TRA total range adjustable U.S. oz ounce (United States) V volt Vac volt (alternative current) INTRODUCTION

Ski-Doo MXZ 500 Standard 2002 Factory Service & Work Shop Manual

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