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  The following are trademarks of Bombardier Inc or its subsidiaries. BOMBARDIER ® ® ® ® ROTAX MX-Z SKI-DOO DESS Printed in Canada (Mmo2002-006a.fm GM) TM ® are trademarks and ® are registered trademarks of Bombardier Inc. or its subsidiaries. ©…
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  2002 SKI-DOO OPERATOR’S GUIDE This guide is applicable to the following model: ® MX-Z 800 (2145)
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  FOREWORD Congratulations on your purchase of a new SKI-DOO snowmobile. Whatever model you have chosen, it is backed by the Bombardier warranty and a network of authorized SKI-DOO snowmobile dealers ready to provide the parts, service or accessories you may require.
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  The information and components/system descriptions contained in this guide are correct at time of publication. We also reserve the right at any time to discontinue or change spec- ifications, designs, features, models or equipment without incurring obligation. The illustrations show the typical construction of the different assem- blies 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.

• Page 6: Table Of Contents

  2002 SKI-DOO SNOWMOBILES……….BOMBARDIER LIMITED WARRANTY INTERNATIONAL: 2002 SKI-DOO ® SNOWMOBILES……….FREQUENTLY ASKED QUESTIONS ……..AUTHORIZED SKI-DOO DEALERS ……… HOW TO IDENTIFY YOUR SNOWMOBILE ……Vehicle Description Decal…………Serial Numbers…………….ON-VEHICLE IMPORTANT INSTRUCTIONS ……CONTROLS/INSTRUMENTS/EQUIPMENT ……1) Throttle Lever …………..

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  22) Fuel Tank Cap …………..23) Mechanical Fuel Level Gauge ……….24) Heated Grip Switch ………….. 25) Heated Throttle Lever Switch ……….26) Hood and Side Panel Latches ……….27) Adjustable Toeholds…………. 28) Heated Carburetor Valve …………29) Storage Compartment …………30) Tool Bag …………….
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  Engine Overheating…………..Fuel Flooded Engine…………..Rear Suspension Slider Shoe Sticking……..PERIODIC MAINTENANCE CHART……… FLUID LEVELS…………….Brake System …………….Chaincase Oil Level …………..Oil Injection System …………..Cooling System …………….. MAINTENANCE …………… Vehicle Cleaning and Protection……….Belt Guard Removal and Installation ……… Drive Belt Removal/Installation ……….

• Page 9: Safety Measures

  Use of Rotax ® snowmobile engines in other than SKI-DOO snowmobiles is not recommended or autho- rized by Bombardier Inc. Do not stud the track. At speed it may cause the track to tear and…

• Page 10: List Of Hot Parts

  Electronic reverse (RER ) models only: The shifting to reverse mode on these snowmobiles is done by the push of the START/RER button when the engine is running. Wait until the reverse alarm sounds and the DESS /RER indicator lamp comes on in the clus- ter gauge before operating throttle to proceed in reverse.

• Page 11: Bombardier Limited Warranty North America: 2002 Ski-Doo Snowmobiles

  This warranty coverage is available only on 2002 SKI-DOO snowmobile pur- chased as new and unused by its first owner from a BOMBARDIER dealer authorized to distribute SKI-DOO products in the country in which the sale occurred (hereinafter “BOMBARDIER dealer”), and then only after the BOMBARDIER specified pre-delivery inspection process is completed and documented.

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  6. EXCLUSIONS — ARE NOT WARRANTED • Normal wear and tear; • Routine maintenance items, tune ups, adjustments; • Damage caused by failure to provide proper maintenance and/or storage, as described in the Operator’s Guide; • Damage resulting from removal of parts, improper repairs, service, maintenance, modifications or use of parts not manufactured or approved by BOMBARDIER or resulting from repairs done by a person that is not an authorized servicing BOMBARDIER dealer;…
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  If the issue has not yet been resolved, please submit your complaint in writing or call the appropriate number below: In Canada: In USA: BOMBARDIER INC. BOMBARDIER MOTOR RECREATIONAL PRODUCTS CORPORATION OF AMERICA SKI-DOO ® RECREATIONAL PRODUCTS CUSTOMER ASSISTANCE CENTER SKI-DOO ® VALCOURT QC J0E 2L0 CUSTOMER ASSISTANCE CENTER Tel: (819) 566-3366 P.O.

• Page 14: Bombardier Limited Warranty International: 2002 Ski-Doo Snowmobiles

  All genuine BOMBARDIER parts and accessories, installed by an authorized BOMBARDIER distributor/dealer (as hereinafter defined) at the time of delivery of the 2002 SKI-DOO snowmobile, carry the same warranty as that of the snow- mobile. Use of the product for racing or any other competitive activity, at any point, even by a prior owner will render this warranty null and void.

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  5. WHAT BOMBARDIER WILL DO BOMBARDIER’s obligations under this warranty are limited to, at its sole dis- cretion, repairing parts found defective under normal use, maintenance and service, or replacing such parts with new genuine BOMBARDIER parts without charge for parts and labor, at any authorized BOMBARDIER distributor/dealer. BOMBARDIER reserves the right to improve or modify products from time to time without assuming any obligation to modify products previously manufac- tured.
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  8. TRANSFER If the ownership of a product is transferred during the warranty coverage peri- od, this warranty shall also be transferred and be valid for the remaining cover- age period provided that BOMBARDIER is notified of such transfer of owner- ship in the following way: a.

• Page 17: Frequently Asked Questions

  I do have my original invoice as proof of when I purchased my snowmobile. A: Registration is very important and your SKI-DOO dealer must register your snowmobile with Bombardier. Make sure the registration form has been sent. All of this will allow you to: a) have warranty work performed at any authorized SKI-DOO dealer in North America.

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  DOO dealership management. If the problem already has been reviewed with the Sales Manager or Service Manager, contact the General Manager or the owner of this authorized SKI-DOO dealership. We are always pleased to receive your comments on the SKI-DOO snowmobile.

• Page 19: Authorized Ski-Doo Dealers

  AUTHORIZED SKI-DOO DEALERS For Canada and USA Only To find the nearest authorized SKI-DOO dealer, dial: 1-800-375-4366 or visit our web site at WWW.SKIDOO.COM. HOW TO IDENTIFY YOUR SNOWMOBILE Vehicle Description Decal Vehicle description decal is located on right hand side of tunnel.

• Page 20: Serial Numbers

  These numbers are required by the authorized SKI-DOO dealer to complete warranty claims prop- erly. No warranty will be allowed by Bombardier Inc. if the engine serial number or Vehicle Identification Number (V.I.N.) is removed or…

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  Model Number Location Model number is part of vehicle identification number (V.I.N.). X X X X X X X X X X X X X X X X X Model number Serial number A00A6IA V.I.N. DESCRIPTION Engine Serial Number Location A32C01B TYPICAL 1.

• Page 22: On-Vehicle Important Instructions

  ON-VEHICLE IMPORTANT INSTRUCTIONS Please read the following instructions carefully before operating snow- mobile. A33A02A LOCATION OF IMPORTANT INSTRUCTIONS Instruction 1 A33H0NA…

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  Instruction 2 DO NOT SIT HERE / NE PAS S’ASSEOIR ICI A33H02A…
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  Instruction 3 A33A03A…
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  Instruction 4 A01A2EA Instruction 5 A01A2FA…
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  Instruction 6 A01A24D TYPICAL — ALL MODELS…

• Page 27: Controls/Instruments/Equipment

  CONTROLS/INSTRUMENTS/EQUIPMENT 30 28 32 31 33 34 A33H01B TYPICAL Callout A33A01A TYPICAL…

• Page 28: Throttle Lever

  14 20 16-17-18 A33A05A TYPICAL 1) Throttle Lever Located on the right hand side of handlebar and designed to be thumb activated. When squeezed, it increases the engine speed and engages the transmission. When released, engine speed returns au- tomatically to idle. WARNING Throttle lever must operate easily and smoothly.

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  Whenever parking brake is applied and engine is running, brake/parking brake pilot lamp lights up to remind you that it is engaged. WARNING Make sure brake lever lock is fully disengaged before operat- ing the snowmobile. When you ride the vehicle, brake that are caused to drag by a continuous pressure on the lever may cause damage to the brake system and cause loss of braking capacity and/or fire.

• Page 30: Parking Brake Pilot Lamp (Red)

  4) Parking Brake Pilot Lamp (Red) Lights when brake or parking brake is applied (with engine running). 5) Handlebar The handlebar controls the steering of travel of the snowmobile. As the handlebar is rotated to right or left, the skis are turned right or left to steer the snowmobile.

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  Remove steering cover and console cap. A33H05A 1. Steering cover 2. Console cap…
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  Unscrew 4 bolts retaining console. A33H06A 1. Bolts retaining console…
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  Slightly lift console to gain access to electrical connector housings. Unplug the 2 large connector housings. A33H07A TYPICAL 1. Large connector housings Remove console. Remove 2 bolts retaining top of steering column. A33H08A STEERING COLUMN IN LOWER POSITION 1. Two bolts retaining top of steering column…
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  Move steering column to forward position. A33H09A STEERING COLUMN IN LOWER POSITION Reinstall the 2 bolts. Use new lock nuts. Torque nuts to 24 N•m (18 lbf•ft). Reinstall all removed parts. Position of console cap will be inverted. Instead of being above it will be beneath steering column.

• Page 35: Start/Rer Button

  Readjust throttle lever housing and brake lever housing accordingly to optimal angle so that you will not need to release your grip to operate levers. WARNING Adjust with vehicle at rest in a safe place. Securely retighten all fasteners. Never rotate throttle lever to operate with fingers instead of thumb.

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  Engine RPM needs to be increased above 1000 RPM at least once after starting engine to cancel the start function and allow the reverse function of the START/RER button. If engine is running at a speed above 3800 RPM, the reverse function of the START/RER button is cancelled.

• Page 37: Tether Cut-Out System

  The DESS/RER (Digitally Encoded Security System and Rotax Elec- tronic Reverse) pilot lamp will blink and a warning buzzer will sound once every second with a half a second duration when the snowmo- bile is engaged in reverse. Apply throttle slowly and evenly. Allow drive pulley to engage then accelerate carefully.

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  Operation Attach tether cord to clothing then snap tether cord cap over switch post before starting engine. A33A07A TYPICAL 1. Snap over switch post 2. Attach to eyelet To stop engine, completely pull cap from post switch. A33A08A TYPICAL…
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  We recommend the purchase of additional tether cord caps from your authorized SKI-DOO dealer as an additional key. If you have more than one SKI-DOO snowmobile, each can be programmed by your autho- rized SKI-DOO dealer to accept the other vehicles’ keys.

• Page 40: Dess/Rer Pilot Lamp (Red)

  A30H08A 1. Free of dirt or snow A rapid DESS/RER pilot lamp blinking 3 times per second means that an incorrectly programmed tether cord is being used. Vehicle can not be driven. DESS/RER Pilot Lamp (Red) This lamp will light up to confirm DESS and RER status. Refer to pre- vious paragraphs for description.

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  A33E03A TYPICAL 1. ON 2. OFF All drivers of the snowmobile should familiarize themselves with the function of this device by using it several times on first outing and everytime to stop the engine there after. Thereby this engine cut-out procedure will become reflex preparing operators to emergency sit- uations requiring its use.

• Page 42: Headlamp Dimmer Switch

  10) Headlamp Dimmer Switch Located on left hand side of handlebar, allows selection of headlamp beam. Note that lights are automatically ON whenever the engine is running. A33E04A 11) High Beam Pilot Lamp (Blue) Lights when headlamp is on HIGH beam. 12) Rewind Starter Handle Auto-rewind type located on right hand side of snowmobile.

• Page 43: Choke Lever

  13) Choke Lever This device features a 3-position lever to facilitate cold start. A32H01A 0. OFF 1. Position 1 2. Position 2 See OPERATING INSTRUCTIONS for more details. 14) Speedometer A33E09A SPEEDOMETER…

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  This model is equipped with an electronic speedometer. It may show speed in km/h or MPH. NOTE: Vehicle speed at 90 km/h (55 MPH) and more the display will show speed only instead of the selected mode. Change from One Unit to the Other NOTE: Speedometer, odometer and trip meter will have their units (kilometer or miles) changed all together.

• Page 45: Mode Button

  A33E06A 15) Mode Button Depress mode button to change display. Each time engine is started, display shows odometer. From that point depressing mode button will change display for the trip meter. Depressing mode button again will change display for the resetable hourmeter.

• Page 46: Resetable Hourmeter

  20) Engine Overheat Warning Lamp (Red) If this lamp glows, stop engine immediately and allow to cool. If prob- lem repeats, see your authorized SKI-DOO dealer. 21) Low Injection Oil Level (Red) Lights when injection oil level is low (with engine running). Check oil…

• Page 47: Fuel Tank Cap

  22) Fuel Tank Cap Unscrew to fill up tank then fully tighten. A33E0BA WARNING Always stop engine before refueling. Fuel may be pressurized, open cap slowly. Fuel is flammable and explosive. Never use an open flame to check fuel level. Never smoke or allow flame or spark in vicinity.

• Page 48: Mechanical Fuel Level Gauge

  23) Mechanical Fuel Level Gauge Located at rear of fuel tank cap the gauge facilitate fuel level reading. A33H0BA TYPICAL 1. Full 2. Empty 24) Heated Grip Switch Three-position toggle switch. Select the desired position to keep your hands at a comfortable temperature.

• Page 49: Heated Throttle Lever Switch

  25) Heated Throttle Lever Switch Three-position toggle switch. Select the desired position to keep your right thumb at a comfortable temperature. A33E04B 1. Heated grip switch 2. Heated throttle lever switch 3. Hot 4. Warm 5. Off…

• Page 50: Hood And Side Panel Latches

  26) Hood and Side Panel Latches To open hood, slightly widen (pull-out) its both sides top portion in order to unhook its anchors from their grommets. A33H0MA 1. Anchors 2. Grommets To open a side panel, stretch and unhook the latches.To remove a side panel remove by pulling up both locking devices from hinge.

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  A33C02B 1. Vent hose A33H0EA 1. Locking device removal Reverse opening procedure to close hood and side panels. Properly hook up latches.

• Page 52: Adjustable Toeholds

  27) Adjustable Toeholds Each toehold can be adjusted to suit driver’s preference. Loosen bolts, adjust, then retighten bolts to 10 N•m (89 lbf•in). WARNING Adjust with vehicle at rest in a safe place. Do not adjust too snugly to trap booted foot. Securely tighten all adjustments. A33H0GA RIGHT SIDE SHOWN 1.

• Page 53: Heated Carburetor Valve

  28) Heated Carburetor Valve Turn valve on when riding at 5°C (41°F) or colder temperatures. A33C01A 1. ON 2. OFF CAUTION: When operating the snowmobile above 5°C (41°F), move the carburetor valve to the OFF position. 29) Storage Compartment A storage compartment is provided at rear of seat. Pull latch downward to unlock cover.

• Page 54: Tool Bag

  A33H0LA 1. Latch 30) Tool Bag A tool bag containing tools for basic maintenance is supplied with the vehicle. Tool bag is located in engine compartment in front of left hand side footrest. A33B01A TOOL BAG LOCATION…

• Page 55: Fuses

  CAUTION: Do not use a higher rated fuse as this can cause se- vere damage to electric components and/or fire. WARNING If fuse has burnt out source of malfunction should be determined and corrected before restarting. See an authorized SKI-DOO dealer for servicing. A33E07A FUSE LOCATION — IN ENGINE COMPARTMENT BEHIND HEADLIGHT 1.

• Page 56: Spare Spark Plug Holder

  To remove fuse from holder, pull fuse out. Check if filament is melted. A15E0KA 1. Fuse 2. Check if melted 32) Spare Spark Plug Holder To keep spare spark plugs dry and prevent shocks that might affect the adjustment or break them, a holder is provided on the left side panel.

• Page 57: Spare Drive Belt Holder

  NOTE: Adjust spare spark plug gap according to SPECIFICATIONS be- fore installation. NOTE: Spare spark plugs are not supplied with the snowmobile. 33) Spare Drive Belt Holder A spare drive belt can be stored in holder in engine compartment at front of headlight.

• Page 58: Front Grab Handles/Front Bumper

  CAUTION: Do not use skis to pull or lift snowmobile. 35) Adjustable Suspensions For factory recommended adjustments refer to decal on belt guard. It describes settings for optimum comfort according to load for your SKI-DOO model. General Snowmobile handling and comfort depend upon suspension adjust- ments.

• Page 59: Guidelines To Adjust Suspension

  Slight suspension bottoming occurring under the worst riding condi- tions indicates a good choice of spring preload. NOTE: This model is equipped with Take/Apart (T/A) shocks. These can be rebuilt or recalibrated. See an authorized SKI-DOO dealer.

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  1. Rear Springs — Comfort and Ride Height Grasp side of tunnel and lift until suspension is fully extended. From this point, rear of snowmobile should collapse by 50 to 75 mm (2 to 3 in) when driver and passenger (if so applicable) take place. Measure at end of tunnel as shown in next photo.
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  A33F05A TYPICAL — TOO SOFT OF ADJUSTMENT Turn the left side adjustment cam in a clockwise direction, the right side cam in a counterclockwise direction. Left and right adjustment cams may be set at different position. A30F04A TYPICAL 1. Increase spring preload…
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  A33F06A TYPICAL — TOO HARD OF ADJUSTMENT Turn the left side adjustment cam in a counterclockwise direction, the right side cam in a clockwise direction. Left and right adjustment cams may be at different position. A30F04B TYPICAL 1. Decrease spring preload…
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  2. Center Spring — Steering Behavior Ride at moderate speed on a trail. If steering is too easy or too hard to turn, adjust center spring accord- ingly. A33F07D TYPICAL — GOOD ADJUSTMENT AT MODERATE SPEED 1. Steering easy to turn…
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  A33F07D TYPICAL — TOO SOFT OF ADJUSTMENT 1. Steering hard to turn A32F01A TYPICAL 1. Use adjuster wrench provided in tool bag to increase preload…
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  A33F07D TYPICAL — TOO HARD OF ADJUSTMENT 1. Steering less aggressive A32F01B TYPICAL 1. Use adjuster wrench provided in tool bag to decrease preload…
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  3. Stopper Strap — Weight Transfer Ride at low speed then fully accelerate. Note steering behavior. Ad- just stopper strap length accordingly. CAUTION: Whenever stopper strap length is changed, track ten- sion must be readjusted. A33F07B TYPICAL — GOOD ADJUSTMENT AT FULL ACCELERATION 1.
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  A33F07C TYPICAL — TOO LONG STRAP 1. Skis lift off the ground A03F0QB TYPICAL 1. Reduce strap length by bolting to a different hole…
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  A33F07D TYPICAL — TOO SHORT STRAP 1. Heavy steering A03F0QB TYPICAL 1. Increase strap length by bolting to a different hole…
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  4. Coupling Blocks — Handling Ride at moderate speed and check for desired handling. When driver and passenger (if applicable) take place the coupling blocks should be centered between rubber stoppers. This condition is achieved when a proper rear spring preload is done. See above rear spring adjustment.
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  A32F0JA COUPLING BLOCK — RIGHT SIDE VIEW (“R” — RIGHT EMBOSSED ON BLOCK) 1. Thicker part of block facing downward (partly coupled suspension) — more track grip and less skis steering 2. Turn block in this direction to adjust to the other position 5.
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  A33F07D TYPICAL — PROPER ADJUSTMENT 1. Good handling and comfortable steering…
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  A33F07D TYPICAL — TOO SOFT OF ADJUSTMENT 1. Bad handling A33F01A 1. Increase spring preload 2. Position number…
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  A33F07D TYPICAL — TOO HARD OF ADJUSTMENT 1. Steering hard to turn A33F01B 1. Decrease spring preload 2. Position number CAUTION: Make sure that both front springs are still preloaded when front of vehicle is off the ground.
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  6. Rear Shock Motion Ratio — Damping Strength Rear shock motion ratio can be adjusted according to driver and pas- senger weight and/or trail condition. There are two adjustment positions. A32F22A SC-10 III SUSPENSION 1. Soft position 2. Firm position To adjust, loosen nut, move bolt to desired position then torque nut to 24 N•m (18 lbf•ft).

• Page 75: Troubleshooting Chart

  PROBLEM CORRECTIVE MEASURES Front suspension – Check ski alignment and camber angle wandering adjustment. See an authorized SKI-DOO dealer. – Reduce ski ground pressure. • Reduce front suspension spring preload. • Increase center spring preload. • Reduce rear spring preload.

• Page 76: Fuel And Oil

  FUEL AND OIL Recommended Fuel Use regular unleaded gasoline, available from most service stations or oxygenated fuel containing less than 10% of ethanol or 5% of methanol. The gasoline used must have an octane number (R + M)/2 of 87 or higher. NOTE: In most service station pump octane number corresponds to (R + M)/2 octane number.

• Page 77: Recommended Oil

  CAUTION: Use only oil that flows at — 40°C (- 40°F). Do not mis- match oil reservoir cap with fuel tank cap. Oil reservoir cap is identified OIL. Oil is contained in the injection oil reservoir. Use only two-stroke engine injection oil sold by authorized SKI-DOO dealers. MODEL OIL TYPE…

• Page 78: Cold Weather Carburetion Modifications

  10 hours of operation — 500 km (300 miles) — or 30 days after the purchase, whichever comes first, your snowmobile be checked by an authorized SKI-DOO dealer. This inspection will give you the opportunity to discuss the unanswered questions you may have encountered during the first hours of operation.

• Page 79: Pre-Operation Check

  • Check fuel and injection oil for levels and leaks. Replenish as nec- essary and see an SKI-DOO authorized dealer in case of any leaks. • Open or close heated carburetor valve according to outside tem- perature.

• Page 80: Pre-Operation Check List

  WARNING All adjustable features should be positioned at optimal setting. Securely tighten all adjustment locks. • All storage compartments must be properly latched and they must not contain any heavy or breakable objects. PRE-OPERATION CHECK LIST ✔ ITEM OPERATION Body including seat, Check for free of snow and footrests, lights, controls ice.

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  ✔ ITEM OPERATION Check for proper latching and Storage compartment no heavy or breakable objects. Snowmobile must be pointed away from people or objects. Vehicle vinicity No one is to be standing in front of or in back of the snowmobile.

• Page 82: Operating Instructions

  OPERATING INSTRUCTIONS WARNING Proceed with pre-operation check list before riding. Principle of Operation Propulsion Depressing throttle lever increases engine RPM causing the drive pulley to engage. For most models engine RPM must be between 2500 and 4200 before drive pulley engagement will occur. Outer sheave of drive pulley moves toward inner sheave, forcing drive belt to move upward on the drive pulley and simultaneously forcing the sheaves apart on the driven pulley.

• Page 83: Starting The Engine

  Starting the Engine WARNING Operator and passenger (if applicable) must be properly seat- ed before starting engine. • Re-check throttle control lever operation. • Ensure that engine cut-out switch is in the ON position. • Ensure that tether cut-out cap is set in place and that cord is at- tached to your clothing.

• Page 84: Emergency Starting

  Warm Engine Starting Start the engine without any choke. If the engine will not start after two pulls of the rope or two 5 second attempts with the electric starter move choke lever to position 1. Start the engine without acti- vating the throttle lever.

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  A17B01A TYPICAL Attach the other end of emergency rope to the starter clip supplied in the tool kit. Hook up clip on drive pulley. Wind the rope tightly around drive pulley. When pulled, pulley must rotate counterclockwise. A33D02A TYPICAL — TRA TYPE DRIVE PULLEY 1.

• Page 86: Shutting Off The Engine

  Start engine as described in COLD ENGINE STARTING or WARM ENGINE STARTING according to engine temperature. Pull the rope using a sharp, crisp pull so the rope comes free of the drive pulley. WARNING When starting the snowmobile in an emergency situation us- ing drive pulley, do not reinstall the belt guard and return slowly to have snowmobile repaired.

• Page 87: Vehicle Warm-Up

  VEHICLE WARM-UP Before every ride, vehicle has to be warmed up as follows. Snowmobile must be securely supported by the rear bumper using a wide base mechanical snowmobile stand (P/N 529 020 000). Track must be 100 mm (4 in) off the ground. A33F08A A.

• Page 88: Post-Operation Care

  Engine overheating indicator will light up if engine is too hot. Reduce snowmobile speed and run snowmobile in loose snow or stop engine immediately. Check for adequate coolant level. See an authorized SKI-DOO dealer. Fuel Flooded Engine All Models WARNING Do not hold throttle partially or fully open when starting a fuel flooded engine.

• Page 89: Periodic Maintenance Chart

  ➁ WEEKLY OR EVERY 240 km (150 miles) ➂ MONTHLY OR EVERY 800 km (500 miles) ➃ ONCE A YEAR OR EVERY 3200 km (2000 miles) ➄ STORAGE (To be performed by an authorized SKI-DOO dealer) ➅ PRESEASON PREPARATION (To be performed by an authorized SKI-DOO dealer) ➀…

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  ➀ ➁ ➂ ➃ ➄ ➅ PERIODIC MAINTENANCE CHART Drive Belt Condition Condition of Drive and Driven Pulleys Cleaning of Drive and Driven Pulleys Retorquing of Drive Pulley Screw Driven Pulley Preload Brake Fluid Level Brake Fluid (change once a year) Brake Condition Drive Chain Tension Chaincase Oil Level…

• Page 91: Fluid Levels

  FLUID LEVELS WARNING It is recommended that the assistance of an authorized SKI- DOO dealer be periodically obtained on other components/ systems not covered in this guide. Unless otherwise specified, engine must be cold and not running. The tether cord cap must be removed for all maintenance procedures.

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  NOTE: It is normal to find metallic particles stuck to dipstick magnet. If bigger pieces of metal are found, see an authorized SKI-DOO dealer. Remove metal particles from magnet. Refill up to upper mark using BOMBARDIER synthetic chaincase oil (P/N 413 803 300 — 12 x 355 mL).

• Page 93: Oil Injection System

  Oil Injection System Always maintain a sufficient amount of recommended oil in the injec- tion oil reservoir. CAUTION: Never allow oil reservoir to be almost empty. Do not mismatch oil reservoir cap with fuel tank cap. Install cap that is identified OIL.

• Page 94: Cooling System

  NOTE: When checking level at low temperature it may be slightly lower then mark. If additional coolant is necessary or if entire system has to be refilled, refer to an authorized SKI-DOO dealer. A33C03A 1. Coolant tank 2. COLD LEVEL line…

• Page 95: Maintenance

  MAINTENANCE WARNING It is recommended that the assistance of an authorized SKI- DOO dealer be periodically obtained on other components/ systems not covered in this guide. Unless otherwise specified, engine must be cold and not running. The tether cord cap must be removed for all maintenance procedures.

• Page 96: Belt Guard Removal And Installation

  Lift rear of vehicle until track is clear of the ground. Install on a snow- mobile mechanical stand. NOTE: Do not release track tension. Belt Guard Removal and Installation WARNING Engine should be running only when belt guard is secured in place.

• Page 97: Drive Belt Removal/Installation

  When reinstalling belt guard, position its cut-away toward front of snowmobile. Refer to decal in belt guard. Place belt guard in rear slots first, then snap front part in retainer. A33D0AA TYPICAL 1. Slots NOTE: Belt guard is purposely made slightly oversize to maintain ten- sion on its pins and retainers preventing undue noise and vibration.

• Page 98
  Open the driven pulley with the drive belt installer/remover provided in tool bag. A03D2PA DRIVE BELT INSTALLER/REMOVER Screw drive belt installer/remover in the free threaded hole and tight- en to open the pulley. Remove belt. A33D06A TYPICAL 1. Tighten to open pulley…
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  Slip the belt over the top edge of the sliding half of driven pulley, as shown in previous photo. Slip belt under drive pulley then, remove it from vehicle. Clean sheaves of both pulleys using Pulley Flange Cleaner (P/N 413 711 809).

• Page 100: Drive Chain Tension

  Drive Chain Tension Remove hair pin. Fully tighten tensioner adjustment screw by hand, then back off only far enough for hair pin to engage in locking hole. A33D0BA TYPICAL 1. Hair pin 2. Adjustment screw…

• Page 101: Tra Drive Pulley Adjustment

  TRA Drive Pulley Adjustment The drive pulley is factory calibrated to transmit maximum engine power at a predefined RPM. Refer to SPECIFICATIONS at the end of this guide. Factors such as ambient temperature, altitude or surface condition may vary this critical engine RPM thus affecting snowmo- bile efficiency.

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  Governor cup has 6 positions numbered 2 to 6. Note that in position 1 the number is substitued by a dot (due to its location on casting). A16D0GA 1. Position 1 (not numbered) Each number modifies maximum engine RPM by about 200 RPM. Lower numbers decrease engine RPM in steps of 200 RPM and higher numbers increase it in steps of 200 RPM.

• Page 103: Drive Belt Condition

  RPM with frozen track, fast starts without warm-up period, burred or rusty sheave, oil on belt or distorted spare belt. Contact an authorized SKI-DOO dealer. Check the drive belt width. Replace the drive belt if width is less than…

• Page 104: Brake Condition

  Periodically verify the condition/wear of the brake pads. Brake Adjustment Hydraulic Brake A hydraulic brake is not adjustable. See an authorized SKI-DOO dealer if any problems. Rear Suspension Condition Visually inspect all suspension components including slider shoes, springs, wheels, etc.

• Page 105: Track Tension And Alignment

  Track Tension and Alignment Tension NOTE: Ride the snowmobile in snow about 15 to 20 minutes prior to adjusting track tension. Lift snowmobile by a rope, chain or lift strap that has been secured into holes provided for that purpose, one on each side of tunnel rear. Refer to following photo.

• Page 106
  Allow the suspension to extend normally and check gap half-way along slider shoe. The gap should be as given in SPECIFICATIONS. If the track tension is too loose, track will have a tendency to thump. NOTE: A belt tension tester (P/N 414 348 200) may be used to mea- sure deflection as well as force applied.
• Page 107
  If correct tension is unattainable, contact an authorized SKI-DOO dealer. A33F03A 1. Adjustment screw 2. Loosen screw Alignment NOTE: Track tension and alignment are inter-related. Do not adjust one without the other. WARNING Before checking track alignment, ensure that the track is free of all particles which could be thrown out while track is rotat- ing.
• Page 108
  A01F05A TYPICAL 1. Guides 2. Slider shoes 3. Equal distance To correct, stop the engine: Loosen rear wheel screws tighten the adjustment screw on side where the slider shoe is the farthest from the track insert guides. A01F0BA TYPICAL 1. Guides 2.

• Page 109: Steering And Front Suspension Mechanism

  SKI-DOO dealer. Wear and Condition of Skis and Runners Check the condition of the skis, ski runners and ski runner carbides. If worn, contact an authorized SKI-DOO dealer for replacement. WARNING Excessively worn skis and/or ski runners will affect snowmobile…

• Page 110: Exhaust System

  Exhaust System The tail pipes of the muffler should be centered with the exit holes in the bottom pan. Exhaust system must be free of rust or leaks. Make sure that gear clamps are properly tightened. The exhaust system is designed to reduce noise and to improve the total performance of the engine.

• Page 111: Headlight Beam Aiming

  A33H0KA REMOVAL OF FILTER FROM ITS GRILL CAUTION: Snowmobile engines have been calibrated with the filter installed. Operating the snowmobile without it may cause engine damage. Headlight Beam Aiming Open left side panel. Turn knob to adjust beam height. A33E08A TYPICAL 1.

• Page 112: Bulb Replacement

  Bulb Replacement Always check light operation after bulb replacement. Headlight CAUTION: Never touch glass portion of an halogen bulb with bare fingers, it shortens its operating life. If glass is touched, clean it with isopropyl alcohol which will not leave a film on the bulb.

• Page 113: Towing The Vehicle

  Turn bulb locking ring counterclockwise to remove it. Detach the bulb and replace. Properly reinstall parts. A33E0DA 1. Locking ring Taillight If taillight bulb is burnt, expose the bulb by removing the red plastic lens. To remove, unscrew the 2 lens screws. TOWING THE VEHICLE First remove drive belt from vehicle to be towed.

• Page 114: Storage And Preseason Preparation

  STORAGE AND PRESEASON PREPARATION WARNING Have an authorized SKI-DOO dealer inspect fuel and oil sys- tems integrity as specified in Periodic Maintenance Chart. Storage It is during summer, or when a snowmobile is not in use for more than one month that proper storage is a necessity.

• Page 115: Troubleshooting

  Start engine following usual starting procedure. If engine continues to flood, see an authorized SKI-DOO dealer. 4. No fuel to the engine Check fuel tank level; check fuel filter; (spark plug dry when removed).

• Page 116
  Check item 4 of “Engine turns over but fails to start”. 5. Carburetor adjustments. Contact an authorized SKI-DOO dealer. 6. Drive belt worn too thin. If the drive belt has lost more than 3 mm (1/8 in) of its original width, it will affect vehicle performance.
• Page 117
  Replace as required. 4. Too much oil supplied to engine. Improper oil pump adjustment, refer to an authorized SKI-DOO dealer. 5. Water in fuel. Drain fuel system and refill with fresh fuel. SYMPTOM: Snowmobile cannot reach full speed.

• Page 118: Specifications

  SPECIFICATIONS GENERAL MX-Z 800 Engine – Maximum Power 7850 ± 100 RPM Engine Speed Drive Belt – Part Number 417 300 127 – Width of a New Belt mm (in) 36.35 (1.431) – Wear Limit Width mm (in) 33.95 (1.337) Spark Plug –…

• Page 119: Change Of Address Or Ownership

  Please provide your name, address, phone number, vehicle serial number and date it was stolen. Bombardier will provide a list of stolen units to all authorized SKI-DOO dealers on a monthly basis to aid in recovery of such units to their…

• Page 120: Privacy Obligations/Disclaimer

  PRIVACY OBLIGATIONS/DISCLAIMER We wish to inform you that your coordinates will be used for safety and warranty purposes. Sometimes, we also use the coordinates of our clients to inform them about our products and to present them offers. Should you prefer not to receive information on our products, services and offers, please let us know by writing to the address below.