1991 SKI DOO SAFARI GLX Factory Service & Work Shop Manual

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1991 BOMBARDIER SNOWMOBILES SHOP MANUAL INTRODUCTION TI " SI'op ~ a'1Jal CO\IC", the foH(>,"'lrg 3oN'bil/di€ , '1'1.1& 1881 "n0Wmo"'l~s MODELS ~LAN"' ALPINE "' II 503 CITATION~ CITATION ~ E TUNDRA" TUNDRA" LT NORDIK' 50 NORDIK-' 60 SCOUT' SAFARI" L SAFARI" LE SAFARI'LX SAFARI'LXE SAFARI'LCE SAFARI' GLX CKEYENNE' FORMULA' '-IX FORMULA' MX E FORMULfI" MX XTC FORMULA" MX XTC E FORMULA' MX XTC SSiSR FORMULA" MX XTC E SSfSR FORMULA" PLUS FORMULA" PLUS E FORMULA' PLUS XTC FORMULA' PLUS XTC E FORMULA" PLUS XTC SSiSR FORMULA" PLUS XTC E SSfSR FORMULA" MACH 1 FORMULA" MACH 1 XTC FORMULA" MACH 1 XTC SSiSR "'"Trudo"",", 0' E. ,,:mb210iel 1,-,,: MODEL NUMBER 3048 3352 32'17 32'18 3249 32~0 3251 32~2 3649 3650 3651 36 52 3653 3656 36b4 36'18 3765 3756 3757 3758 376Q 3770 3759 3760 3761 3762 3771 3772 3763 3764 3773 F'''lhcr"nor~, C,J~c, ,'~'i:13 I",. I:> p'lic" ,J" ,.,,,,",,,, 1" """ei "cn'te, Serial Number Meaning: "" "" '" 0000 00000 ---,-- - --,--- Mod~1 M Vehicl~ "" LiqLJi<l-Cooled ln~ine. ,"" 'co 0<.'

SECTION 01 TOOLS 02 ENGINE 03 TRANSMISSION 04 ELECTRICAL o 5 REAR SUSPENSION 06 STEERING/ FRONT SUSPENSION o 7 BODY /FRAME 08 TECHNICAL DATA SUB-SECTION 01 - Basic tools 02 - Service tools 03 - Service products 01 - 247 Engine type 02 - 253 Engine type 03 - 377-477 Engine type 04 - 467 Engine type 05 - 503 Engine type 06 - 536 Engine type 07 - 643 Engine type 08 - Leak test 09 - Engine dimensions measurement 10 - CDI magneto 11 - Oil injection system 12 - Fan cooling system 13 - Liquid cooling system 14 - Rotary valve, coolant pump & reservoir 1 5 - Rewind starter 16 - Carburetor & fuel pump 17 - Air intake silencer & fuel tank 01 • Drive belt 02 - Drive pulley 03 -Driven pulley 04 - Pulley distance & ",Ii",nrrl,ant 05 - Brake 06 - Chaincase 07 - Gearbox 08 - Drive chain 01 -Wiring diagrams 02 - Ignition timing 03 - Sparkph,Igs 04 - Battery 05", ELectric starter 06 - Testing procedure 01,.. Bogie wheel 02 - Slide suspension 03 ~ SPsuspension 04 - Safari suspension O&'~·M(jAOshMk'·stJs'Pension 06 - Hinged suspension 07;-;~l\lof.GiR.~; 3' }~t" c!-:,[r,.!f;;'~~~~" " < V' <' • 08 - Nordik 60 10 - Drive axle TABLE OF CONTENTS PAGE ';:~01-0 1'-1 01-02-1 01 ;:03+1 02-01 .. 1 02-02-1 02-03~1 02-04-1 02 .. 05 .. 1 02-06-1 02"07~1 02-08-1 " \o2-09~1 02-10-1 : 02;.: 11 . .. 1 02-12-1 , 02~13-1 02-14-1 02~·15"1 02-16-1 02~ H·l D3"01'" 03-02-1 03-03-1 03-04-1 :03,;05-1 03-06-1 ·"103 .. 07-1 03-08-1 . ' 04-01 .. 1 04-02-1 04 .. 03·1 04-04-1 04-05 ·1 04-06-1 05.01-1 05-02-1 05 .. 03-1 05-04-1 05-05-1 05-06-1 ,05-07-1 05-08-1 ,,1;'t "'i~l' l'f ~~ '(i\'£:~t'~~i~'3.:~~~':1;,,·;f;;i',; (it,,·, P":""":;~"" 'i:~:"':~5::'/":,":\.;(!:"·./'.,.> ',:<"FiT 02 - Suspension & ski system 06-02-1 02 - Frame 07-02-1

-_ . - .. [+]Bki-doo.l SHOP MANUAL

Section 01 TOOLS Sub-Section 01 (BASIC TOOLS) BASIC TOOLS A Screwdriver 8 , Socksr 10113 mm C Emergency sramng rope D, Sacker wrench ha ndle E Open end wrench 101 13 mm F. £margfJflc'( Slaning clip G Socker 2U26 mm H Spring cam adjus(ment kev (rear suspension) /, From spring Cllm adjus rmenl key (PRS rear 5u5f)ensionJ J Carry-boose adap rer K Tool bag L $pflng collar adjustment key (rear suspenSion/ M Rear sprmg cam adp.Js(menr key fPR$ real SUSpensiOn) N Fan hOld er H A (FAil) IP.'N 414 6424 00) C ::".-:;;"--;'- " ~ ;-- - .--=:::- .;;. '. ----. - - iP:N 412 5001 00 ) D Ii ) (P,N 414 6427 00 1 0) (PiN 414 8513 40l IP/I\ 529 002A 00) B Q IPn' .. 41 4 64 2600 1 cPiN 414 6428 001 /P IN 529 0053 am (PiN 4 14 542!) om (PIN 5 17 187 1 001 "" . - . 001 00' on !PiN 41 4 64 2 3001 1991 MODELS Elan Citat ion I E Tundra, Tundra LT Scoul All Safar iS Cheyenne All Formu las Alp ine II Nordik 50 Nordik 60 ~,.-_L __ ="') (PiN 529 0122 001 APPLICABLE TOOLS A. B. C, D. E. G, K. A. B, C, D. E. F. G, K. A, B, C, 0, E, G, H. K A, B, C. D, E, G, H, K. A, B. C, D, E, F, G, I, K, L. A, B. C, D, E, F, G, H, J, K A, B. C, D, E, F, G, I, K, M A, B. C, D, E, F, G, H, K A, B, C, D, E, G, M, N A, B, C, D, E, G, N N {PiN 420 8763 571 01-0 1·1

SERVICE TOOL Dia! indicator (TOe gauge ) PIN,414 10 4 70 0 Degree wheel PI N. 41 4352 900 ." . '/ : :: ' , .. "",001 '" CirCUlI teste, (continui ty li ght ) PIN : 414 0122 00 StroboscopiC timing light PIN: 52 9 0092 00 ~OO1 001 ali. Section 01 TOOLS Sub·Section 02 (SERVICE TOOLS) SERVICE TOOLS PURPOSE Engine l iming, to det er mine TOC To mark timing position of rOl ary va lve ~oo, 003 091 En gine timing Continui ty tests To verify engi ne timing ENGINE APP LICATI ON All en gin es 467 . 53 6 & 643 eng ines All engine s All engmes 01-02-1

Section 01 TOO LS Sub-Section 02 (SERVICE TOOLS) ENGINE SERVICE TOOL Bombard ier ign ition lester PiN 41 9003300 Nipoond er'1 so electronic ignition lester PI N . 4 19 DOell 00 6 """ "'" """ Hose pince r PIN 52 9009900 01·02·2 PURPOSE En gine elect ric al components l ests Engi ne ignition system componentS t es ts To a VOid leaks wh il e working on a vehicle APPLICATION All engines All Nippondenso elect ro nic ign ition syste ms All veh icl es

SERVICE TOOL Carburetor tool kit PIN 404 112000 " 000 001 0011 Engine leak tester kit PIN 861 725600 Parts included in the kit Exhaust outlet plug (21 PIN 529010900 2 Air valve (2) PIN 742060004 3 Intake manifold plug (21 PIN 529011000 4 Air pump (1 f PIN 529011100 5 RAVE system plug (21 PIN 529011200 O NOTE: Must maintain a pressure of 5 Ib during three minutes. Never pressurize over 5 Ib ,.,. CAUTION: Lubricate air pump .... piston seal using mild soap. Using hydrocarbon lubricant will destroy rubber seal. ,,00, 00, O~. , '-./ -;// // Section 01 TOOLS Sub-Section 02 (SERVICE TOOLS) PURPOSE To ease disassembly and assembly of carburetor To verify airtightness "001 001 o~a ENGINE APPLICATION All models 247, 377, 447, 467, 503. 536 & 643 engines 01-02-3

I Section 01 TOO LS Sub-Section 02 (SERVICE TOOLSI ENGINE SERVICE TOOL RAVE movemeni mdicator PIN - 86 1 725 800 Part5 included in the klt Ind ica t or gu ide 11) FIN 5290 104 00 2. Indicator (1 1 PI N : 4208766 40 Air pressu re gauge, 0-200 inch of w a ter Pi N 529010400 Adapter 114-1 18 NPT PIN· 5 290 1 0500 O N?TE : Fi ls on ai r pump from kit Pi N .861 725600 . A""'''''' <>OJ OH)2 ·4 PURPOSE To troubleshoot and / or ad just RAVE system To verify RAVE system valve opening pressure "1XI1oo,oee APPLICATION 643 engine 643 engi ne

SERVIC E TOOL Flywheel holder PIN: 420976550 Fan holder A) PI N : 420 8763 55 Bl PI N : 4 20 8763 57 PURP OS E To hOld flywhee l To hO ld Ian Section 01 TOOLS Sub-Section 02 ( SERV I CE TOOLS ) ENGINE APPL ICATI ON 247 engine Al 5 03 engine Bl 253 . 377 & 44 7 engines 01 · 02·5

1991 SKI DOO SAFARI GLX Factory Service & Work Shop Manual

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