1990 Ski-Doo Tundra LT Factory Service & Work Shop Manual

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Legal deposit: National Library of Quebec 4th trimester 1989 ' "National Library of Canada All rights reserved. No parts of this manual may be reproduced in any form without the prior written per- mission of Bombardier Inc. "Bombardier Inc. 1989 Printed in Canada ®*Registered trademarks of Bombardier Inc. Loctite® is a trademark of Loctite Corporation Metton TM is a trademark of Hercules Inc. Molykote® is a trademark of Dow Corning Corporation Posidriv® is a trademark of Phillips Screw Company Silastic® is a trademark of Dow Corning Corporation Snap-on® is a trademark of Snap-on Tools Corporation Versilube® is a trademark of General Electric Company

TABlE OF CONTENTS SECTION SUB-SECTION PAGE 01 TOOLS 01 - Basic tools 01-01 02 - Service tools 01-02 03 - Service products . 01-03 02 ENGINE 01 - 247 Engine type 02-01 02 - 253 Engine type 02-02 03 - 377 Engine type 02-03 04- 447 Engine type 02-04 05 - 467 Engine type 02-05 06 - 503 Engine type 02-06 07 - 508 Engine type 02-07 08 - 536 Engine type 02-08 09 - 583 Engine type 02-09 10 - Engine dimensions measurement 02-10 11 - CDI magneto 02-11 12 - Oil injection system 02-12 13- Two-cylinder fan cooling system 02,13 . 14 - Two-cylinder liquid cooling system 02-14 15 - Rotary valve, coolant pump & reservoir 02-15 16 - Rewind starter 02-16 17 - Carburetor and fuel pump 02-17 .. 18 - Air intake silencer and fuel tank 02-18 . 03 TRANSMISSION 01 - Drive belt 03-01 02 - Drive pulley 03-02 03 - Driven pulley 03-03 04 - Pulley alignment 03-04 . 05- Brake 03.:05 06 - Chaincase 03-06 07- Gearbox 03'07 08 - Drive chain 03-08 04 ELECTRICAL 01 -Wiring diagrams 04-01 02 - Ignition timing 04-02 03 - Spark plugs 04-03 04 - Battery 04-04 05 - Electric starter 04-05 06 -Testing procedure 04-06 05 SUSPENSION 01 - Bogie wheel . >'P•L Y< , )');{' 05-01 02 - Slide suspension 05-02 03 - TRS 6 suspension 05-03 04 - Safari suspension 05-04 05 - Monoshock suspension 05-05 06 - Hinged suspension 05-06 07 - Rear axle 05-07 08 - Drive axle 05-08 09- Track 05-09 06 STEERING /SKIS 01 -Steering system 06-01 02 - Ski system 06-02 07 BODY/FRAME 01 - Body . 07-01 02- Frame 07-02 08 TECHNICAL DATA 08-01

~------~------------------~ --~--~- SAFETY NOTICE This manual has been prepared as a guide to correctly service and repair 1990 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. 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/photographs 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. Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: lock tab, elastic stop nut) 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 including possibility of death. 'W'CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle V components. QNOTE: Indicates supplementary information needed to fully complete an instruction. Although the mere reading of such information does not eliminate the hazard, your under- standing of the information will promote its correct use. 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 I 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. Ill

1990 BOMBARDIER SNOWMOBILES SHOP MANUAL INTRODUCTION This Shop Manual covers the following Bombardier made 1990 snowmobiles. MODELS MODEL NUMBER ELAN® 3047 ALPINE® II 503 3350 ALPINE® IV 3351 SAFARI CITATION® 3239 SAFARI CITATION® E 3240 TUNDRA* 3241 TUNDRA* LT 3242 SAFARI SCOUT* 3644 SAFARI* L 3640 SAFARI* LE 3641 SAFARI* LX 3647 SAFARI* LXE 3642 SAFARI* LC 3646 FORMULA* GLX 3645 CHEYENNE* 3643 FORMULA* MX 3742 FORMULA* MX LT 3743 FORMULA* MX LT CD 3749 FORMULA* PLUS 3744 FORMULA* PLUS LT 3745 FORMULA* PLUS LT CD 3750 FORMULA* MACH 1 3746 FORMULA* MACH 1 XTC 3751 ®*Trademarks of Bombardier Inc. CD 2-passenger models Furthermore, each vehicle has its particular vehicle serial number. Serial number meaning: AOOO 000 013 IV 0000 00000 ---,----- ----,--- Model no Vehicle no (TYPICAL) Vehicle serial number A01S 007 023 The engine also has a serial number. Liquid-cooled engines AOOO 002 062 Fan-cooled engines Engine serial number A007 002 001 )

DEFINITION OF NUMBERING SYSTEMS Sections and sub-sections system The manual makes uses of a 2-part digital numbering system (i.e. 01-011, in which the first digit represents the section, the second digit the sub-section. 01-01 /--~ Section Sub-section Pages system The numerotation at the bottom of each page assists the user in page location. 01-01-01 /-T-~ Section Sub-section Page ARRANGEMENT OF THE MANUAL The manual is divided into f) major sections: 01 Tools 02 Engine 03 Transmission 04 Electrical 05 Suspension 06 Steering and skis 07 Body /frame 08 Technical data Each section is divided in various sub-sections, and again, each sub-section has one or more division. EX.: 02 ENGINE 05 Engine type 467 - Engine removal & installation -Top end - Bottom end -Etc. ' 1990 BOMBARDIER SNOWMOBILES SHOP MANUAl.. The use of "Right" and "Left" indications in the text, always refers to driving position (when sitting on vehicle). LEFT ..... ~RIGHT AOOO 000 002 GENERAL The information and component/system descriptions contained in this manual are correct at time of publica- tion. Bombardier Inc. however, maintains a policy of con- tinuous improvement of its products without imposing upon itself any obligation to install them on products previously manufactured. Bombardier Inc. reserves the right at any time to discon- tinue or change specifications, designs, features, models or equipment without incurring obligation. ILLUSTRATIONS & PROCEDURES An exploded view is conveniently located at the begin- ning of each section and is meant to assist the user in identifying parts and components. This Shop Manual uses technical terms which may be sligthly different from the ones of the parts catalog. v

1990 BOMBARDIER SNOWMOBILES SHOP MANUAL When ordering parts always refer to the parts catalog. The illustrations show the typical construction of the different assemblies and, in all cases, may not reproduce the full detail or exact shape of the parts shown, however, they represent parts which have the same or a similar function. When something special applies (such as adjustment, inspection, etc.), boldface numbers in exploded views are used for specific parts and referred to in the text. 'W' CAUTION :Pay attention to torque specifica- T tions. Some of these are in lbf•in instead of lbf•ft. Use appropriate torque wrench. 'W' CAUTION : Most components of those vehicles T are built with parts dimensioned in the metric system. Most fasteners are metric and must not be replaced by customary fasteners or vice versa. Mis- matched or incorrect fasteners could cause damage to the vehicle or possible personal injury. As many of the procedures in this manual are interrelat- ed, we suggest, that before undertaking any task, you read and thoroughly understand the entire section or sub-section in which the procedure is contained. A number of procedures throughout the book require the use of special tools. Where a special tool is indicated, refer to section 01. Before commencing any procedure, be sure that you have on hand all the tools required, or approved equivalents. VI ~-·-- Technical Publications Bombardier Inc. Valcourt (Quebec) Canada

A. Screwdriver B. Socket 7 0113 mm C. Emergency starting rope D. Socket wrench handle E. Open end wrench 7 0113 mm F. Emergency starting clip G. Socket 2 7/26 mm H. Spring cam adjustment key (rear suspension) /. Spring collar adjustment key (front suspension) Section 01 TOOLS Sub-Section 01 (BASIC TOOLS) BASIC TOOLS A ef2±&1D~=== ... !PIN 414 6424 001 c B 0 !PIN 414 6426 001 J Front spring cam adjustment key (PRS rear suspension) !PIN 412 5001 001 D E K. Carry boose adapter L. Tool bag M. Spring collar adjustment key (rear suspension) N. Rear spring cam adjustment key (PRS rear suspension) 0. Socket 7 8 mm !PIN 414 6427 001 G !PIN 414 6428 001 H F ~ ([ID ~ J:: ~ I PIN 529 0122 001 M I PIN 529 0024 001 !PIN 414 8523 001 ( ~ ~ !PIN 414 6425 001 N L © ~ ~ !PIN 529 0098 001 !PIN 529 0038 001 !PIN 517 1871 001 J 0 "" (Ol ED !PIN 529 0053 001 !PIN 420 2762 851 !PIN 414 6423 001 A001 001 083 1990 MODELS APPLICABLE TOOLS Elan A, B, C, D, E, G, L. Safari Citation IE A, B, C, D, E, F, G, L. Tundra, Tundra LT A, B, C, D, E, G, H, L. Safari Scout A, B, C, D, E, G, H, L. Safari L/ LEI LX I LXE A, B, C, D, E, F, G, I, L, M. Safari GLXILC A, B, C, D, E, F, G, I, L, M. Cheyenne A, B, C, D, E, F, G, H, K, L. Formula MXIMX LTIPiusiPius LT A, B, C, D, E, F, G, J, L, N. Formula Mach 1 I Mach 1 XTC A. B, C, D, E, F, G, J, L, N. Alpine II A, B, C, D, E, F, G, H, L. Alpine IV A, B, C, D, E, F, H, L, 0. 01-01-1 tl

1990 Ski-Doo Tundra LT Factory Service & Work Shop Manual

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