2003 Ski-Doo MXZ 800 Service & Repair Manual
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2003
Shop Manual
ZX SERIES
MMR2003_068_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 MAINTENANCE 01 – Table of contents...................................................................... 02-01-1
02 – 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 – 377, 503 and 552 engine types ................................................ 04-02-1
03 – 493, 593, 593 HO, 693, 793 and 793 HO 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 – Liquid cooling system............................................................... 04-08-1
09 – Rewind starter .......................................................................... 04-09-1
10 – Carburetor and fuel pump ........................................................ 04-10-1
11 – Fuel tank and throttle cable ...................................................... 04-11-1
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 – Drive chain................................................................................ 05-08-1
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 MMR2003_068_00_02A.FM
07 REAR SUSPENSION 01 – Table of contents ..................................................................... 07-01-1
02 – SC-10 suspension .................................................................... 07-02-1
03 – SC-10 III 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
MMR2003_068_00_02A.FM III
SAFETY NOTICE 0
This manual has been prepared as a guide to correctly service and repair some 2003 Ski-Doo snowmo-
biles. 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 strictly be 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 possi-
bility of death.
SAFETY NOTICE
IV MMR2003_068_00_02A.FM
WHAT’S NEW 0
CARBURETOR AND FUEL PUMP 04-10
• Revised leak test for float bowl ventilation.
• Revised test for DPM solenoid.
• Revised leak test for DPM manifold.
STEERING SYSTEM 08-02
• Added procedure for new heating grips.
• Revised alignment procedures.
WHAT’S NEW
MMR2003_068_00_02A.FM V
INTRODUCTION 0
This Shop Manual covers the following Bombardier made 2003 snowmobiles:
MODEL PACKAGE ENGINE COLOR COUNTRY MODEL NUMBER
GRAND TOURING (E) FAN 380F (R) Black (EUR) 2628
GRAND TOURING (E) FAN 380F (R) Black (U.S.) 2446
GRAND TOURING (E) FAN 380F (R) Black (CDN) 2445
GRAND TOURING (E) FAN 550F (R) Black (CDN) 2443
GRAND TOURING (E) FAN 550F (R) Black (U.S.) 2444
GRAND TOURING (E) FAN 550F (R) Black (EUR) 2627
GRAND TOURING (E) SE 600 (R) Black (U.S./CDN) 2433
GRAND TOURING (E) SE 600 (R) Autumn Red metallic (U.S./CDN) 2434
GRAND TOURING (E) SE 600 (R) Black (U.S./CDN) 2435
GRAND TOURING (E) SE 600 (R) Autumn Red metallic (U.S./CDN) 2436
GRAND TOURING (E) SE 600 (R) Autumn Red metallic (EUR) 2624
GRAND TOURING (E) SE 700 (R) Autumn Red metallic (U.S./CDN) 2430
GRAND TOURING (E) SE 700 (R) Black (U.S./CDN) 2431
GRAND TOURING (E) SE 700 (R) Black (U.S./CDN) 2429
GRAND TOURING (E) SE 700 (R) Autumn Red metallic (U.S./CDN) 2432
GRAND TOURING (E) SPORT 500 (R) Autumn Red metallic (U.S./CDN) 2442
GRAND TOURING (E) SPORT 500 (R) Black (U.S./CDN) 2441
GRAND TOURING (E) SPORT 500 (R) Autumn Red metallic (EUR) 2626
GRAND TOURING (E) SPORT 600 (R) Black (U.S./CDN) 2439
GRAND TOURING (E) SPORT 600 (R) Autumn Red metallic (U.S./CDN) 2440
GRAND TOURING (E) SPORT 700 (R) Autumn Red metallic (U.S./CDN) 2438
GRAND TOURING (E) SPORT 700 (R) Black (U.S./CDN) 2437
LEGEND (E) FAN 380F (R) Black (CDN) 2370
LEGEND (E) FAN 380F (R) Black (U.S.) 2371
LEGEND (E) FAN 550F (R) Black (CDN) 2368
LEGEND (E) FAN 550F (R) Black (U.S.) 2369
LEGEND (E) SE 600 (R) 2 tone Moon - Blue (U.S./CDN) 2381
LEGEND (E) SE 600 (R) Black (U.S./CDN) 2382
LEGEND (E) SE 600 (R) 2 tone Moon - Blue (U.S./CDN) 2383
LEGEND (E) SE 600 (R) Black (U.S./CDN) 2380
LEGEND (E) SE 700 (R) Black (U.S./CDN) 2376
LEGEND (E) SE 700 (R) 2 tone Moon - Blue (U.S./CDN) 2377
LEGEND (E) SE 700 (R) Black (U.S./CDN) 2378
LEGEND (E) SE 700 (R) 2 tone Moon - Blue (U.S./CDN) 2379
LEGEND (E) SPORT 500 (R) Black (U.S./CDN) 2388
LEGEND (E) SPORT 500 (R) 2 tone Moon - Blue (U.S./CDN) 2389
LEGEND (E) SPORT 600 (R) 2 tone Moon - Blue (U.S./CDN) 2387
LEGEND (E) SPORT 600 (R) Black (U.S./CDN) 2386
LEGEND (E) SPORT 700 (R) 2 tone Moon - Blue (U.S./CDN) 2385
LEGEND (E) SPORT 700 (R) Black (U.S./CDN) 2384
MX Z ADRENALINE 500 Viper Red (U.S./CDN) 2346
MX Z ADRENALINE 500 Black (U.S./CDN) 2345
INTRODUCTION
VI MMR2003_068_00_02A.FM
MX Z ADRENALINE 500 (R) Viper Red (U.S./CDN) 2350
MX Z ADRENALINE 500 (R) 2 tone Yellow - Black (U.S./CDN) 2596
MX Z ADRENALINE 500 (R) 2 tone Yellow - Black (U.S./CDN) 2595
MX Z ADRENALINE 500 (R) Black (U.S./CDN) 2349
MX Z ADRENALINE 500 (R) 2 tone Yellow - Black (EUR) 2616
MX Z ADRENALINE 600 HO 2 tone Yellow - Black (U.S./CDN) 2587
MX Z ADRENALINE 600 HO Black (U.S./CDN) 2333
MX Z ADRENALINE 600 HO Viper Red (U.S./CDN) 2334
MX Z ADRENALINE 600 HO (R) Viper Red (U.S./CDN) 2340
MX Z ADRENALINE 600 HO (R) Black (U.S./CDN) 2339
MX Z ADRENALINE 600 HO (R) 2 tone Yellow - Black (U.S./CDN) 2590
MX Z ADRENALINE 600 HO (R) Black (U.S./CDN) 2337
MX Z ADRENALINE 600 HO (R) Viper Red (U.S./CDN) 2338
MX Z ADRENALINE 600 HO (R) 2 tone Yellow - Black (U.S./CDN) 2589
MX Z ADRENALINE 700 Viper Red (U.S./CDN) 2319
MX Z ADRENALINE 700 Black (U.S./CDN) 2318
MX Z ADRENALINE 700 R Viper Red (U.S./CDN) 2326
MX Z ADRENALINE 700 R 2 tone Yellow - Black (U.S./CDN) 2584
MX Z ADRENALINE 700 R Black (U.S./CDN) 2325
MX Z ADRENALINE 700 R 2 tone Yellow - Black (U.S./CDN) 2583
MX Z ADRENALINE 700 R Viper Red (U.S./CDN) 2328
MX Z ADRENALINE 800 Black (U.S./CDN) 2306
MX Z ADRENALINE 800 Viper Red (U.S./CDN) 2307
MX Z ADRENALINE 800 (R) Black (U.S./CDN) 2310
MX Z ADRENALINE 800 (R) Viper Red (U.S./CDN) 2311
MX Z ADRENALINE 800 (R) 2 tone Yellow - Black (U.S./CDN) 2577
MX Z ADRENALINE 800 (R) Black (U.S./CDN) 2312
MX Z ADRENALINE 800 (R) 2 tone Yellow - Black (U.S./CDN) 2578
MX Z FAN 380F (R) Black (U.S.) 2367
MX Z FAN 380F (R) Black (EUR) 2618
MX Z FAN 380F (R) Black (CDN) 2366
MX Z FAN 550F (R) Black (U.S.) 2639
MX Z FAN 550F (R) Black (EUR) 2617
MX Z FAN 550F (R) Black (CDN) 2364
MX Z RENEGADE 600 HO Viper Red (U.S./CDN) 2407
MX Z RENEGADE 600 HO 2 tone Yellow - Black (U.S./CDN) 2605
MX Z RENEGADE 600 HO Black (U.S./CDN) 2406
MX Z RENEGADE 600 HO (R) Black (U.S./CDN) 2419
MX Z RENEGADE 600 HO (R) 2 tone Yellow - Black (U.S./CDN) 2607
MX Z RENEGADE 600 HO (R) Viper Red (U.S./CDN) 2420
MX Z RENEGADE 600 HO (R) Black (U.S./CDN) 2417
MX Z RENEGADE 600 HO (R) Viper Red (EUR) 2620
MX Z RENEGADE 600 HO (R) Viper Red (U.S./CDN) 2418
MX Z RENEGADE 800 Black (U.S./CDN) 2390
MX Z RENEGADE 800 Viper Red (U.S./CDN) 2391
MODEL PACKAGE ENGINE COLOR COUNTRY MODEL NUMBER
INTRODUCTION
MMR2003_068_00_02A.FM VII
MX Z RENEGADE 800 (R) 2 tone Yellow - Black (EUR) 2619
MX Z RENEGADE 800 (R) Black (U.S./CDN) 2394
MX Z RENEGADE 800 (R) Viper Red (U.S./CDN) 2395
MX Z RENEGADE 800 (R) 2 tone Yellow - Black (U.S./CDN) 2601
MX Z RENEGADE 800 (R) 2 tone Yellow - Black (U.S./CDN) 2602
MX Z RENEGADE 800 (R) Viper Red (U.S./CDN) 2397
MX Z RENEGADE 800 (R) Black (U.S./CDN) 2396
MX Z TRAIL 500 Black (U.S./CDN) 2360
MX Z TRAIL 500 (R) Black (U.S./CDN) 2363
MX Z TRAIL 600 Black (U.S./CDN) 2358
MX Z TRAIL 600 (R) Black (U.S./CDN) 2359
MX Z (E) ADRENALINE 500 (R) 2 tone Yellow - Black (U.S./CDN) 2598
MX Z (E) ADRENALINE 500 (R) Viper Red (U.S./CDN) 2355
MX Z (E) ADRENALINE 500 (R) Black (U.S./CDN) 2354
MX Z (E) ADRENALINE 500 (R) 2 tone Yellow - Black (U.S./CDN) 2597
MX Z (E) ADRENALINE 600 HO (R) Black (U.S./CDN) 2341
MX Z (E) ADRENALINE 600 HO (R) Viper Red (U.S./CDN) 2342
MX Z (E) ADRENALINE 600 HO (R) 2 tone Yellow - Black (U.S./CDN) 2591
MX Z (E) ADRENALINE 600 HO (R) Black (U.S./CDN) 2343
MX Z (E) ADRENALINE 600 HO (R) 2 tone Yellow - Black (U.S./CDN) 2592
MX Z (E) ADRENALINE 700 R Black (U.S./CDN) 2331
MX Z (E) ADRENALINE 700 R Viper Red (U.S./CDN) 2330
MX Z (E) ADRENALINE 700 R 2 tone Yellow - Black (U.S./CDN) 2586
MX Z (E) ADRENALINE 700 R Black (U.S./CDN) 2329
MX Z (E) ADRENALINE 700 R 2 tone Yellow - Black (U.S./CDN) 2585
MX Z (E) ADRENALINE 800 (R) Black (U.S./CDN) 2316
MX Z (E) ADRENALINE 800 (R) Viper Red (U.S./CDN) 2317
MX Z (E) ADRENALINE 800 (R) 2 tone Yellow - Black (U.S./CDN) 2579
MX Z (E) ADRENALINE 800 (R) Viper Red (U.S./CDN) 2315
MX Z (E) ADRENALINE 800 (R) Black (U.S./CDN) 2314
MX Z (E) RENEGADE 600 HO (R) Black (U.S./CDN) 2421
MX Z (E) RENEGADE 600 HO (R) Viper Red (U.S./CDN) 2422
MX Z (E) RENEGADE 600 HO (R) 2 tone Yellow - Black (U.S./CDN) 2609
MX Z (E) RENEGADE 600 HO (R) Black (U.S./CDN) 2423
MX Z (E) RENEGADE 600 HO (R) Viper Red (U.S./CDN) 2424
MX Z (E) RENEGADE 600 HO (R) 2 tone Yellow - Black (U.S./CDN) 2610
MX Z (E) RENEGADE 800 (R) 2 tone Yellow - Black (U.S./CDN) 2604
MX Z (E) RENEGADE 800 (R) Black (U.S./CDN) 2400
MX Z (E) RENEGADE 800 (R) Black (U.S./CDN) 2398
MX Z (E) RENEGADE 800 (R) Viper Red (U.S./CDN) 2399
MX Z (E) RENEGADE 800 (R) 2 tone Yellow - Black (U.S./CDN) 2603
SKANDIC SPORT 500F (R) Black (CDN) 2447
SKANDIC SPORT 500F (R) Black (U.S.) 2448
SUMMIT ADRENALINE 600 HO Black (U.S./CDN) 2515
SUMMIT ADRENALINE 600 HO Voltage Blue (U.S./CDN) 2514
MODEL PACKAGE ENGINE COLOR COUNTRY MODEL NUMBER
INTRODUCTION
VIII MMR2003_068_00_02A.FM
SUMMIT ADRENALINE 600 HO (R) 2 tone Black - Orange (U.S./CDN) 2522
SUMMIT ADRENALINE 600 HO (R) Black (U.S./CDN) 2521
SUMMIT ADRENALINE 600 HO (R) Black (U.S./CDN) 2524
SUMMIT ADRENALINE 600 HO (R) Voltage Blue (U.S./CDN) 2520
SUMMIT ADRENALINE 600 HO (R) 2 tone Black - Orange (U.S./CDN) 2525
SUMMIT ADRENALINE 600 HO (R) 2 tone Black - Orange (EUR) 2630
SUMMIT ADRENALINE 600 HO (R) Voltage Blue (U.S./CDN) 2523
SUMMIT ADRENALINE 700 Black (U.S./CDN) 2496
SUMMIT ADRENALINE 700 Voltage Blue (U.S./CDN) 2495
SUMMIT ADRENALINE 700 (R) Voltage Blue (U.S./CDN) 2507
SUMMIT ADRENALINE 700 (R) Black (U.S./CDN) 2508
SUMMIT ADRENALINE 700 (R) 2 tone Black - Orange (U.S./CDN) 2509
SUMMIT ADRENALINE 800 HO Black (U.S./CDN) 2484
SUMMIT ADRENALINE 800 HO Voltage Blue (U.S./CDN) 2483
SUMMIT ADRENALINE 800 HO (R) Black (U.S./CDN) 2490
SUMMIT ADRENALINE 800 HO (R) 2 tone Black - Orange (U.S./CDN) 2491
SUMMIT ADRENALINE 800 HO (R) 2 tone Black - Orange (U.S./CDN) 2494
SUMMIT ADRENALINE 800 HO (R) Voltage Blue (U.S./CDN) 2489
SUMMIT FAN 550F (R) Black (U.S.) 2450
SUMMIT FAN 550F (R) 2 tone Black - Orange (U.S.) 2455
SUMMIT FAN 550F (R) 2 tone Black - Orange (EUR) 2640
SUMMIT FAN 550F (R) Black (CDN) 2449
SUMMIT FAN 550F (R) 2 tone Black - Orange (CDN) 2454
SUMMIT HIGHMARK 700 Black (U.S./CDN) 2554
SUMMIT HIGHMARK 700 Voltage Blue (U.S./CDN) 2553
SUMMIT HIGHMARK 700 (R) 2 tone Black - Orange (U.S./CDN) 2561
SUMMIT HIGHMARK 700 (R) Black (U.S./CDN) 2560
SUMMIT HIGHMARK 700 (R) Voltage Blue (U.S./CDN) 2559
SUMMIT HIGHMARK 800 HO Voltage Blue (U.S./CDN) 2541
SUMMIT HIGHMARK 800 HO Black (U.S./CDN) 2542
SUMMIT HIGHMARK 800 HO (R) 2 tone Black - Orange (U.S./CDN) 2549
SUMMIT HIGHMARK 800 HO (R) Voltage Blue (U.S./CDN) 2550
SUMMIT HIGHMARK 800 HO (R) Black (U.S./CDN) 2548
SUMMIT HIGHMARK 800 HO (R) Voltage Blue (U.S./CDN) 2547
SUMMIT HIGHMARK X 800 HO Voltage Blue (U.S./CDN) 2526
SUMMIT HIGHMARK X 800 HO Black (U.S./CDN) 2527
SUMMIT HIGHMARK X 800 HO 2 tone Black - Orange (U.S./CDN) 2528
SUMMIT HIGHMARK X 800 HO (R) 2 tone Black - Orange (U.S./CDN) 2537
SUMMIT HIGHMARK X 800 HO (R) Black (U.S./CDN) 2536
SUMMIT HIGHMARK X 800 HO (R) Voltage Blue (U.S./CDN) 2535
SUMMIT HIGHMARK X 800 HO (R) 2 tone Black - Orange (U.S./CDN) 2534
SUMMIT HIGHMARK X 800 HO (R) Voltage Blue (U.S./CDN) 2532
SUMMIT HIGHMARK X 800 HO (R) Black (U.S./CDN) 2533
SUMMIT HIGHMARK Xtreme 800 HO (R) 2 tone Black - Orange (U.S./CDN) 2540
SUMMIT HIGHMARK Xtreme 800 HO (R) Black (U.S./CDN) 2539
MODEL PACKAGE ENGINE COLOR COUNTRY MODEL NUMBER
INTRODUCTION
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Upon purchasing this manual, you will receive a .PDF file containing an email contact. After contacting us, you will receive a reply with a link to access the manual for your Ski-Doo MXZ 800 2003.
This comprehensive manual covers every aspect of your machine, providing detailed guidance on every nut and bolt. With hundreds of pages, it equips you to address various issues, from routine maintenance like oil changes to more complex tasks such as transmission swaps. The manual includes numerous illustrations to assist you and features easy-to-understand text throughout.
Utilize the search function to navigate the manual efficiently and print the necessary pages as needed. This Factory Service Repair Manual serves as a thorough guide, walking you through the fundamentals of maintenance and repair in a step-by-step manner, imparting the knowledge that factory-trained technicians possess. By leveraging the insights within this service repair manual, any owner can confidently make informed decisions regarding the maintenance and repair of their machine.
Rest assured, in addition to providing a high-quality service manual, we are committed to delivering excellent customer service, ensuring your satisfaction.
