1996 Ski-Doo MXZ 583 Service & Repair Manual

Ski-Doo 1996 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: Elan Tundra II LT Touring E / E LT / LE / SLE Formula S / SL Skandic 380 / 500 Volume 2: Grand Touring 500 / 580 / SE Formula SLS / STX / STX LT (2) Summit 500 Mach 1 Volume 3: MX Z 440 / 583 / 670 Summit 583 / 670 Formula Z / SS / III / III LT Mach Z / Z LT Skandic Wide Track

1996 Shop Manual VOLUME 1 ELAN TUNDRA II LT TOURING E / LE / LE LT / SLE FORMULA S / SL SKANDIC 380/ 500

TABLE OF CONTENTS SECTION SUB-SECTION PAGE SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... Ill 1996 BOMBARDIER SNOWMOBILES SHOP MANUAL VOLUME 1 (INTRODUCTION) . . . . . . . . . . . . . . . . . . . IV 01 SERVICE TOOLS AND 01- Service tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-01-1 SERVICE PRODUCTS 02. Sewice products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-02-1 02 LUBRICATION 01- Lubrication and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-01-1 AND MAINTENANCE 03 TROUBLESHOOTING OO. Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-00-1 01 -Engineti.~.~~~~ti.~~~~~~. ~~~.~ti~~~~~~~~~.~~~~~~~ . . . . . . . 03-01-1 02 -Fuel and oil systems ti~~~..~.~..~~~~~..~.~..~.~.-. . . . . . . . . . . . . . . . . . 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 00 -Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 -247 and 277 engine types.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-377, 443and 503 engine types . . . . . . . . . . . . . . . . . . . . . . . . . 03- Leaktest and engine dimension measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04 -CDl system . . . . . . . . . ................~ . . . . . . . . . . . . . . . . 05 -Oil injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06 -Axial fan cooling system ~--~..t~.~..~.~~~~~~..~.~.~.~ . . . . . . . . . . . . . 07 -Rewind starter ~=~.~..~.fi~~~~-..~.~..~.~~~ ~~~..~~..ti..ti.t~~~.~~~ 08 -Carburetor and fuel pump ..............ti... . . . . . . . . . . . . 09 -Fuel tank and throttle cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-00-1 04-01-1 04-02-1 04-03-1 04-04-1 04-05-1 04-06-1 04-07-1 04-08-1 04-09-1 05 TRANSMISSION 00 -Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01 -Drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02 -Dtivepufley . . . . . . . . . . ......~ . . . . . . . . . . . . . . . . . . . . . . . . .. 03 -Driven pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04 -Pulley distance and alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06- Chaincase .,,..,,., . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07 - Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08 -Drive chain . . . . . . . . . . . . ~..~=~~.~..ti~.-.-~~~..~~..~~ . . . . . . . . . . . . . . . . . 05-00-1 05-01-1 05-02-1 05-03-1 05-04-1 05-05-1 05-06-1 05-07-1 05-08-1 06 ELECTRICAL 00 -Table of contents .................ti..ti.. . . . . . . . . . . . . . . 06-00-1 01 -Wiring diagrams (see Annexes at the end of this manual) . . . . . . . 06-01-1 02 -ignition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06-02-1 03-Sparkplugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06-03-1 04 -Batte~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06-04-1 05 -Electric starter . . . . . . ~~~~~~~--~tititi~~ti~~~~~~~ . . . . . . . . . . . 06-05-1 06 -Testing procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06-06-1 I

TABLE OF CONTENTS SECTION SUB-SECTION PAGE 07 IEAR SUSPENSION 00- Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01- Bogie wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02 -Torque reaction suspe nsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03 -SC-10 Sport and Touring suspension . . . . . . . . =..~.~.~~~.~.~~~..~.~ 04 -Rear axle . . . . . . . . . . . .~ti~~~.fi~~~.~.~.~~~~~~~ . . . . . . . . . . . 05 -Drive axle . . . . . . . . . . . . . ~.~ti~~~..~.~.ti~~ti~..~.~..~.~ . . . . . . . . . . . . . . . . 06-Track~~=~.ti~~ti~~~titi ti.~~~~~~titi.~q~~~~~~p~q. . . . . . . . . . . . 07-00-1 07-01-1 07-02-1 07-03-1 07-04-1 07-05-1 07-06-1 08 STEERING/ 00 -Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-01-1 FRONT SUSPENSION 01 -Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-02-1 02 -Suspension and ski systemti.ti....ti . . . . . . . . . . . . . . . . . . . . . 08-02-1 09 BODY/FRAME 00 -Table of contents .~..~.~~~..~.~,~~~~~~~~~~~~.~ . . . . . . . . . . . . . . . . . . . . 09-01-1 01 - Body . . . . . . . . . . . . . . . . ..ti. . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-02-1 02 - Frame . . . . . . . . . . . . . . ......................~ . . . . . . . . . 08-02-1 ANNEXES (Wiring diagrams) II

SAFETY NOTICE SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair 1996 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. 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 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 /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 ; + WARNING : Identifies an instruction which, if not followed, could cause serious personal injury includ- ing possibility of death. v CAUTION : Denotes an instruction which, if not followed, could severely damage vehicle components. o 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 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.

1996 BOMBARDIER SNOWMOBILES SHOP MANUAL Each vehicle has its particular vehicle serial number Serial Number Meaning : 0000 00000 l_T MOdel no. Vehicle no, 1 A06H01A TYPICAL 1, Vehicle serial number The engine also has a serial number. Fan-Cooled Engines Engine serial number AO07 002001 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/ FRONT SUSPENSION 09 BODY/ FRAME 10 TECHNICAL DATA ANNEXES Each section is divided in various sub-sections, again, each sub-section has one or more division. and v

1996 BOMBARDIER SNOWMOBILES SHOP MANUAL This Shop Manua/ uses technical terms wich may be slightly different from the ones in the parts catalog. TYPICAL PAGE Exploded viet assits you in identifying par and related positions. \ Illustration number for publishing process. L Page heading indicates section and I 13- % 9( Low temp. , \ :~m. greese ~ ‘\&@? Loctite I / """""""""'""'""'"""""'""'""""""""''""""''"'""'`"''"''"''"'`"'"'''"'"""""""""'"""""""""'""'"""""""-?w3l*m**ti-w:: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . :.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:,:,:.:.:,:.:.:,:.:.:.:.:.:.:.:.:.:.: $3@m@:&$$$8:&$@~m$m~~%’mB~mm# :.:.:.:.:...:.........:.:.....:...:.....:.:...:.....:...:...:.::::::..:...:.....:::...:...:::...:...:::...:.....:...::..::....:.......::::..:.:...:.....:.:.......:...:...:::.....:...:.....:.:::.......:.:...:...:...:...:.:..::. .:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.: ##MK%M$MMwHw#%RwIx#w:mMMEH;HsM*HsfaHi+ ::::::::::::::::::::::::::::::: ::::::::::::::::::::::::::::::: ::::::::::::::::::::::::::::::: ::::::::::::::::::::::::::::::: :::::::::::::::::::::::::::::::: :::::; ;:;:::::::::::::::::::::: ::::::::::::::::::::::::::::::: ::::::::::::::::::::::::::::::: ::::::::::::::::::::::::::;;::::: ;:;::::;:::::::::::::::::::::::: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................................... % ~ 1: . . ~: :: :: :: \ . . . . . . . . . . . . . ., / #$#l$a: ‘\ / /’ /’ /“ . . . . . . . . . . . . . . . + %@ , ~octite @ . . ‘ 0<27’ “L X**, \ *.-..*..- .-. W...-..-...A , . . . . . . . . . . ... , +..,..,.,.. . . . . . . . . . . ,.. , \ Tghtening torque nearby (’ fastener. In this case, nut Page numbering system : must be torqued to 4 N-m or 35 Ibf-in. 07 : REAR SUSPENSION section 03 : SC-1 O SPORT AND TOURING sub-section detailed. Sub-sectIon title indicates beginning of the sub-section. Sub-title at top right corner of exploded view indicates pertaining models. Drop represents a liquid product to be applied to a surface. In this case Loctite 271 to screw threads. Bold face number indicates special procedure concerning this part. Dotted box contains parts of a particular model, in this case the short track models only. v CAUTION : Pay attention to torque specifica- SUSPENSION sub-section tions. Some of these are in lbf*in instead of 1: First page of this sub-section Ibf+. Use appropriate torque wrench. AOIAIQS

1996 BOMBARDIER SNOWMOBILES SHOP MANUAL “Side view” caption at top helps you in understanding illustration, Sub-title beginning w lart reference numbe of sub-section explod view followed by part name(s). Italic bold face type setting indicates a particular procedure concerning a model. Illustration always follows text to whic it pertains. /’ Italic bold face settir in this case indicate that particular procedure for B-series is finishec so from this point, all models are concerned. TYPICAL PAGE Detailed view of illustration. / Sesstion 07 REAR SUSPENSION Sub-Section 08 (DRIVE AXLE) Make sure that welded nuts are toward mslde of tun- nel . . . . . . . . . . . . . =;:#M&<ti< . . . . . . . . . . . . . . . T r When matalllng end bearing housing, enaure to posi- tion grease fitww on top. This is required to have proper ahgnmant with accesa hole. Lock drive axle sprocket with a clrclip (use new cottar pin on Elan) Remstell the chaincaae cover (if applicable). Refill with chamcase 011. Refer to TECHNICAL DATA 10 Install the s.~ens!on.;~fug:~;~~g~~~ and ad- . . . . . just track tension and cairy out track”~qnment procedure \ ‘##gq!!~~~<— 15, Grease Fitting Lubricate end housing baaring with low temperature grease (P/ N 4137061 00). ADJUSTMENT Sprockat / Track Alignment v CAUTION: Do nottampar with sprocket/track alignmant if frame or auapension is damagad. . . . . . . . . . . . . . ~Hm~mim’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : Sprocka!a might ba repoaitwmed to flt track holes Wge on hqu)d cooled models and Skandlc II 503 R SLT) without removing drive ade Use drive axla sprocket adjuster kit (P/N 861 7257 001. ~gfJ<:K . . . . . . . . . . . . . Mo, mlm 07.08-9 \ Ttle indicates — main procedure to be carried-out. “Typical” caption 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. Reference to look up a certain section and sub-section (TRACK 07-09). In this case it concerns track adjustment. AOIAIRS Vll

1996 Ski-Doo MXZ 583 Service & Repair Manual

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