2002 Racing

0
2002 RACER HANDBOOK

TABLE OF CONTENTS
HOW TO COMMUNICATE ...................................................................................................... 01-1
2002 MODELS TECHNICAL DATA.......................................................................................... 02-1
CHASSIS PREPARATION ........................................................................................................ 03-1
ENGINE PREPARATION .......................................................................................................... 04-1
TRANSMISSION SYSTEM ...................................................................................................... 05-1
TECHNICAL PUBLICATIONS AND RACING PARTS .............................................................. 06-1
COMPETITION PREPARATION ............................................................................................... 07-1
SERVICE TOOLS...................................................................................................................... 08-1
 WARNING
This information relates to the preparation and use of snowmobiles in competitive events. Bom-
bardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of
the contents. We strongly recommend that these modifications be carried out and/or verified by
a highly-skilled professional racing mechanic. It is understood that racing or modifications of any
Bombardier-made snowmobile voids the vehicle warranty and that such modifications may ren-
der use of the vehicle illegal in other than sanctioned racing events under existing federal, pro-
vincial and state regulations.
KEEPING YOUR MACHINE LEGAL IS YOUR RESPONSIBILITY

Read and know your rule books.
MMC2002-001_00A.FM 1
SECTION 01 - HOW TO COMMUNICATE
GENERAL
If you have any suggestions on new information and ideas to improve next year’s handbook, including
any errors or omissions, please mail or fax to;
Ski-Doo Race Department

Bombardier Motor Corp of America
7575 Bombardier Court
Wausau, Wisconsin
54401.
For additional information or to pass on your feedback and suggestions please contact the following people
using the racer report format.
Your information is important to us.

Technical assistance for snocross, grass drag, oval, cross country hillclimb and asphalt racing
Contact Tom Lawrence: Phone 715-848-4971
Fax 715-847-6879
E-mail [email protected]
To order parts through Valcourt race department, use Parts order form.
Fax: 450-532-5076
A wide range of excellent publications and special tools are available to support your racing activities.
See Section 06-1, Competition bulletins-racing parts, useful publications.

Parts numbers with a 486 prefix must be ordered from the Valcourt Race Dept. All others must be ordered
from your local Ski-Doo dealer.
Race program, sponsorship, contingency programs

Contact Steve Cowing: Phone 651-452-3340
Fax 651-452-3341
E-mail [email protected]
MMC2002-001_01A.FM 01-1
PARTS ORDER
SKI-DOO RACING DEPT.
DATE: PAGE of
ORDER DESK: Robert Bourgeois Fax # (450) 532-5076
PARTS & CLOTHING Racing Parts Coordinator
FROM: if you are a dealer:
DEALER #:
FED. ID #: ( US dealers only)
PHONE #: FAX #:
FROM: if you are a racer:
SOCIAL SECURITY #:
(we need your SS # for custom regulations)
PHONE #: FAX #:
PAYMENT: VISA ___ MASTER CARD ___ # _______________________ Exp. Date ________
SHIPPING CONDITIONS: RED ______ GROUND ______ BLUE ______

(Shipping fees will be charged to you)
DESCRIPTION PART # OR CLOTHING PART # QUANTITY
Part numbers with a 486 prefix must be ordered from the Valcourt Race Dept. All others must be ordered from your local Ski-Doo dealer.
PHONE ORDERS WILL NOT BE ACCEPTED
MMC2002-001_01A.FM 01-3
T.I.P.
SHEET
APPLICATION
TECHNICAL INFORMATION POSTING
Dear Ski-Doo X-Team
Please add my name to your list of recipients for the T.I.P. sheets to be distributed
during the 2001-02 race season.
Name:
Address:
City: St./Prov: Zip/Code:
Phone: Day: Evening:
Please send my T.I.P. sheets to the following: Please print !

Priority (please circle one)
Fax: 1 2
Email: 1 2
Personal Information:
Race Circuits you compete in:
Number of years racing:
Type and class you currently race:
Model and year of race sled:
Please return this completed form by Fax to (715) 847-6869
MMC2002-001_01A.FM 01-5
SECTION 02 - 2002 MODELS TECHNICAL DATA
TABLE OF CONTENTS 0
ENGINES
MX Zx 440 RACING (CAN./U.S.) .............................................................................................. 02-3
MX Z 500 SPORT (CAN./U.S.)................................................................................................... 02-3
MX Z 500 R SPORT (CAN./U.S.) ............................................................................................... 02-3
MX Z 500 TRAIL (CAN./U.S.) .................................................................................................... 02-4
MX Z 600 SPORT (CAN./U.S.)................................................................................................... 02-4
MX Z 600 R SPORT (CAN./U.S.) ............................................................................................... 02-4
MX Z 600 TRAIL (CAN./U.S.) .................................................................................................... 02-5
MX Z 600 R ADRENALINE (CAN./U.S.) .................................................................................... 02-5
MX Z 600 R RENEGADE (CAN./U.S.) ....................................................................................... 02-5
MX Z 600 X (CAN./U.S.) ............................................................................................................ 02-6
MX Z 600 R X (CAN./U.S.) ........................................................................................................ 02-6
MX Z 700 SPORT (CAN./U.S.)................................................................................................... 02-6
MX Z 700 R SPORT (CAN./U.S.) ............................................................................................... 02-7
MX Z 700 TRAIL (CAN./U.S.) .................................................................................................... 02-7
MX Z 700 X (CAN./U.S.) ............................................................................................................ 02-8
MX Z 700 R X (CAN./U.S.) ........................................................................................................ 02-8
MX Z 800 SPORT (CAN./U.S.)................................................................................................... 02-9
MX Z 800 R SPORT (CAN./U.S.) ............................................................................................... 02-9
MX Z 800 TRAIL (CAN./U.S.) .................................................................................................... 02-9
MX Z 800 X (CAN./U.S.) ............................................................................................................ 02-10
MX Z 800 R X (CAN./U.S.) ........................................................................................................ 02-11
SUMMIT 600 SPORT (CAN./U.S.)............................................................................................. 02-11
SUMMIT 600 R SPORT (CAN./U.S.) ......................................................................................... 02-11
SUMMIT 800 X (CAN./U.S.) ...................................................................................................... 02-13
SUMMIT 800 R X (CAN./U.S.) .................................................................................................. 02-13
SUMMIT 800 HIGHMARK (CAN./U.S.)..................................................................................... 02-14
SUMMIT 800 R HIGHMARK (CAN./U.S.) ................................................................................. 02-14
SUMMIT 800 HIGHMARK X (CAN./U.S.) ................................................................................. 02-14
SUMMIT 800 R HIGHMARK X (CAN./U.S.).............................................................................. 02-15
MMC2002-001_02A.FM 02-1
VEHICLES
MX Zx 440 RACING (CAN./U.S.) ............................................................................................... 02-16
MX Z 500 SPORT (CAN./U.S.) ................................................................................................... 02-16
MX Z 500 R SPORT (CAN./U.S.) ................................................................................................ 02-16
MX Z 500 TRAIL (CAN./U.S.) ..................................................................................................... 02-17
MX Z 600 SPORT (CAN./U.S.) ................................................................................................... 02-17
MX Z 600 R SPORT (CAN./U.S.) ................................................................................................ 02-17
MX Z 600 TRAIL (CAN./U.S.) ..................................................................................................... 02-18
MX Z 600 R ADRENALINE (CAN./U.S.)..................................................................................... 02-18
MX Z 600 R RENEGADE (CAN./U.S.) ........................................................................................ 02-18
MX Z 600 X (CAN./U.S.)............................................................................................................. 02-19
MX Z 600 R X (CAN./U.S.) ......................................................................................................... 02-19
MX Z 700 SPORT (CAN./U.S.) ................................................................................................... 02-19
MX Z 700 R SPORT (CAN./U.S.) ................................................................................................ 02-20
MX Z 700 TRAIL (CAN./U.S.) ..................................................................................................... 02-20
MX Z 700 X (CAN./U.S.)............................................................................................................. 02-21
MX Z 700 R X (CAN./U.S.) ......................................................................................................... 02-21
MX Z 800 SPORT (CAN./U.S.) ................................................................................................... 02-22
MX Z 800 R SPORT (CAN./U.S.) ................................................................................................ 02-22
MX Z 800 TRAIL (CAN./U.S.) ..................................................................................................... 02-22
MX Z 800 X (CAN./U.S.)............................................................................................................. 02-23
MX Z 800 R X (CAN./U.S.) ......................................................................................................... 02-24
SUMMIT 600 SPORT (CAN./U.S.) ............................................................................................. 02-24
SUMMIT 600 R SPORT (CAN./U.S.) .......................................................................................... 02-24
SUMMIT 800 X (CAN./U.S.)....................................................................................................... 02-26
SUMMIT 800 R X (CAN./U.S.) ................................................................................................... 02-26
SUMMIT 800 HIGHMARK (CAN./U.S.) ..................................................................................... 02-27
SUMMIT 800 R HIGHMARK (CAN./U.S.) .................................................................................. 02-27
SUMMIT 800 HIGHMARK X (CAN./U.S.).................................................................................. 02-27
SUMMIT 800 R HIGHMARK X (CAN./U.S.) .............................................................................. 02-28
02-2 MMC2002-001_02A.FM
ENGINES 0
MX Zx 440 MX Z 500 MX Z 500 R
VEHICLE MODEL RACING SPORT SPORT
(CAN./U.S.) (CAN./U.S.) (CAN./U.S.)
ENGINE TYPE 453 493 493
Number of Cylinders 2 2 2
Bore mm (in) 65.00 (2.559) 69.50 (2.736) 69.50 (2.736)
Stroke mm (in) 65.80 (2.591) 65.80 (2.591) 65.80 (2.591)
Displacement cm3 (in3) 436.69 (26.65) 499.30 (30.47) 499.30 (30.47)
Compression Ratio (corrected) ± 0.5 14.8 ± 0.25 12.0 12.0
Maximum Power Engine Speed ➀ ± 100 RPM 8400 8000 8000
Piston Ring Type 1st /2nd ST/N.A. ST/N.A. ST/N.A.
New mm (in) 0.2 (.008) 0.4 (.016) 0.4 (.016)
Ring End Gap
Wear Limit mm (in) 1.0 (.039) 1.0 (.039) 1.0 (.039)
New mm (in) 0.04 (.0016) 0.04 (.0016) 0.04 (.0016)
Ring/Piston Groove Clearance
Wear Limit mm (in) 0.2 (.0079) 0.2 (.0079) 0.2 (.0079)
New mm (in) 0.113 ± 0.013 (.0044 ± .0005) 0.100 ± 0.016 (.0039 ± .0006) 0.100 ± 0.016 (.0039 ± .0006)
Piston/Cylinder Wall Clearance
Wear Limit mm (in) 0.18 (.0071) 0.20 (.0079) 0.20 (.0079)
New mm (in) 0.39 (.0154) 0.39 (.0154) 0.39 (.0154)
Connecting Rod Big End Axial Play
Wear Limit mm (in) 1.2 (.0472) 1.2 (.0472) 1.2 (.0472)
Maximum Crankshaft End-play ➁ mm (in) 0.3 (.012) 0.3 (.012) 0.3 (.012)
Maximum Crankshaft Deflection at PTO mm (in) 0.06 (.0024) 0.06 (.0024) 0.06 (.0024)
Magneto Generator Output W 290 290 290
Ignition Type CDI CDI CDI
Spark Plug Make and Type NGK BR9ES NGK BR9ECS NGK BR9ECS
Spark Plug Gap ± 0.05 mm (± .002 in) 0.45 (.018) 0.45 (.018) 0.45 (.018)
Ignition Timing BTDC ➂ mm (in) 3.14 (.124) 3.00 (.118) 3.00 (.118)
Trigger Coil ➃ Ω 190 – 300 190 – 300 190 – 300
Low Speed Ω 17.5 – 42.5 17.5 – 42.5 17.5 – 42.5
Generating Coil ➃
High Speed Ω 2.4 – 5.8 2.4 – 5.8 2.4 – 5.8
Lighting Coil ➃ Ω 0.1 – 0.4 0.1 – 0.4 0.1 – 0.4
Primary Ω 0.3 – 0.7 0.3 – 0.7 0.3 – 0.7
High Tension Coil ➃
Secondary kΩ 8.0 – 16.0 8.0 – 16.0 8.0 – 16.0
Carburetor Type PTO/MAG TMX 34-18 TM 40-B151 TM 40-B151
Main Jet PTO/MAG 260/260 500/500 500/500
Needle Jet P-0 ➄ P-0 ➄ P-0 ➄
Pilot Jet 25 17.5 17.5
Needle Identification — Clip Position 6FNY04/51 — 3 9HGY1/58 ➅ 9HGY1/58 ➅
Slide Cut-Away 4.0 2.0 2.0
Float Adjustment ± 1 mm (± .040 in) N.A. N.A. N.A.
Air or Pilot Screw Adjustment ± 1/16 Turn N.A. 1 1
Idle Speed ± 200 RPM 1600 1600 1600
Gas Type/Pump Octane Number Unleaded/87 Unleaded/87 Unleaded/87
Gas/Oil Ratio 33:1 Injection Injection
Type Liquid Liquid Liquid
Deflection mm (in) N.A. N.A. N.A.
Axial Fan Belt Adjustment
Force kg (lbf) N.A. N.A. N.A.
Thermostat Opening Temperature °C (°F) 42 (108) 42 (108) 42 (108)
Radiator Cap Opening Pressure kPa (PSI) 90 (13) 90 (13) 90 (13)
Drive Pulley Retaining Screw ➆ ➆ ➆
Exhaust Manifold Nuts or Bolts 22 (16) 22 (16) 22 (16)
Magneto Ring Nut 125 (92) 125 (92) 125 (92)
ENGINE COLD
N•m (lb•ft)
M6 9 (7) 9 (7) 9 (7)

Crankcase Nuts or Screws
M8 29 (21) 29 (21) 29 (21)
Crankcase/Engine Support Nuts or Screws 35 (26) 35 (26) 35 (26)
Cylinder Head Screws 29 (21) 29 (21) 29 (21)
Crankcase/Cylinder Nuts or Screws 29 (21) 29 (21) 29 (21)
Axial Fan Shaft Nut N.A. N.A. N.A.
MMC2002-001_02A.FM 02-3
MX Z 500 TRAIL MX Z 600 MX Z 600 R

VEHICLE MODEL (CAN./U.S.) SPORT SPORT
(CAN./U.S.) (CAN./U.S.)
Bore mm (in) 69.50 (2.736) 76.00 (2.992) 76.00 (2.992)
Stroke mm (in) 65.80 (2.591) 65.80 (2.591) 65.80 (2.591)
Compression Ratio (corrected) ± 0.5 12.0 12.0 12.0
New mm (in) 0.4 (.016) 0.4 (.016) 0.4 (.016)
Ring End Gap
Wear Limit mm (in) 1.0 (.039) 1.0 (.039) 1.0 (.039)
New mm (in) 0.04 (.0016) 0.04 (.0016) 0.04 (.0016)
Wear Limit mm (in) 0.2 (.0079) 0.2 (.0079) 0.2 (.0079)
New mm (in) 0.100 ± 0.016 (.0039 ± .0006) 0.120 ± 0.016 (.0047 ± .0006) 0.120 ± 0.016 (.0047 ± .0006)
Piston/Cylinder Wall Clearance 0.20 (.0079)
Wear Limit mm (in) 0.20 (.0079) 0.20 (.0079)
New mm (in) 0.39 (.0154) 0.39 (.0154) 0.39 (.0154)
Wear Limit mm (in) 1.2 (.0472) 1.2 (.0472) 1.2 (.0472)
Spark Plug Make and Type NGK BR9ECS NGK BR9ECS NGK BR9ECS
Trigger Coil ➃ Ω 190 – 300 190 – 300 190 – 300
Low Speed Ω 17.5 – 42.5 17.5 – 42.5 17.5 – 42.5
Generating Coil ➃
High Speed Ω 2.4 – 5.8 2.4 – 5.8 2.4 – 5.8
Lighting Coil ➃ Ω 0.1 – 0.4 0.1 – 0.4 0.1 – 0.4
Primary Ω 0.3 – 0.7 0.3 – 0.7 0.3 – 0.7
Secondary kΩ 8.0 – 16.0 8.0 – 16.0 8.0 – 16.0
Carburetor Type PTO/MAG TM 40-B151 TM 40-B154 TM 40-B154
Main Jet PTO/MAG 500/500 500/500 500/500
Pilot Jet 17.5 20 20
Needle Identification — Clip Position 9HGY1/58 ➅ 9HGY1/58 ➅ 9HGY1/58 ➅
Air or Pilot Screw Adjustment ± 1/16 Turn 1.0 1-1/2 1-1/2
Idle Speed ± 200 RPM 1600 1600 1600
Gas/Oil Ratio Injection Injection Injection
Magneto Ring Nut 125 (92) 125 (92) 125 (92)
ENGINE COLD
N•m (lb•ft)
M6 9 (7) 9 (7) 9 (7)

M8 29 (21) 29 (21) 29 (21)
02-4 MMC2002-001_02A.FM
MX Z 600 TRAIL MX Z 600 R MX Z 600 R

VEHICLE MODEL (CAN./U.S.) ADRENALINE RENEGADE
Bore mm (in) 76.00 (2.992) 76.00 (2.992) 76.00 (2.992)
Stroke mm (in) 65.80 (2.591) 65.8 (2.591) 65.8 (2.591)
New mm (in) 0.4 (.016) 0.4 (.016) 0.4 (.016)
Ring End Gap
Wear Limit mm (in) 1.0 (.039) 1.0 (.039) 1.0 (.039)
New mm (in) 0.04 (.0016) 0.040 (.0016) 0.40 (.0157)
Wear Limit mm (in) 0.2 (.0079) 0.2 (.0079) 0.2 (.0079)
New mm (in) 0.120 ± 0.016 (.0047 ± .0006) 0.120 ± 0.016 (.0047 ± .0006) 0.120 ± 0.016 (.0047 ± .0006)
Piston/Cylinder Wall Clearance 0.20 (.0079) 0.20 (.0079)
Wear Limit mm (in) 0.20 (.0079)
New mm (in) 0.39 (.0154) 0.39 (.0154) 0.39 (.0154)
Connecting Rod Big End Axial Play 1.2 (.0472) 1.2 (.0472)
Trigger Coil ➃ Ω 190 – 300 190 – 300 190 – 300
Low Speed Ω 17.5 – 42.5 17.5 – 42.5 17.5 – 42.5
Generating Coil ➃
High Speed Ω 2.4 – 5.8 2.4 – 5.8 2.4 – 5.8
Lighting Coil ➃ Ω 0.1 – 0.4 0.1 – 0.4 0.1 – 0.4
Primary Ω 0.3 – 0.7 0.3 – 0.7 0.3 – 0.7
Secondary kΩ 8.0 – 16.0 8.0 – 16.0 8.0 – 16.0
Main Jet PTO/MAG 500/500 500/500 500/500
Pilot Jet 20 20 20
Needle Identification — Clip Position 9HGY1/58 ➅ 9HGY1/58 ➅ 9ZLY3/58 ➅
Air or Pilot Screw Adjustment ± 1/16 Turn 1.5 1-1/2 1-1/2
Idle Speed ± 200 RPM 1600 1600 1600
Magneto Ring Nut 125 (92) 125 (92) 125 (92)
ENGINE COLD
N•m (lb•ft)
M6 9 (7) 9 (7) 9 (7)

M8 29 (21) 29 (21) 29 (21)
MMC2002-001_02A.FM 02-5
MX Z 600 MX Z 600 R MX Z 700

VEHICLE MODEL X X SPORT
Bore mm (in) 76.00 (2.992) 76.00 (2.992) 78.00 (3.071)
Stroke mm (in) 65.80 (2.591) 65.80 (2.591) 73.00 (2.874)
New mm (in) 0.4 (.016) 0.4 (.016) 0.4 (.016)
Ring End Gap
Wear Limit mm (in) 1.0 (.039) 1.0 (.039) 1.0 (.039)
New mm (in) 0.04 (.0016) 0.04 (.0016) 0.04 (.0016)
Wear Limit mm (in) 0.2 (.0079) 0.2 (.0079) 0.2 (.0079)
New mm (in) 0.120 ± 0.016 (.0047 ± .0006) 0.120 ± 0.016 (.0047 ± .0006) 0.115 ± 0.013 (.0045 ± .0005)
Wear Limit mm (in) 0.20 (.0079) 0.20 (.0079) 0.20 (.0079)
New mm (in) 0.39 (.0154) 0.39 (.0154) 0.39 (.0154)
Wear Limit mm (in) 1.2 (.0472) 1.2 (.0472) 1.2 (.0472)
Trigger Coil ➃ Ω 190 – 300 190 – 300 190 – 300
Low Speed Ω 17.5 – 42.5 17.5 – 42.5 17.5 – 42.5
Generating Coil ➃
High Speed Ω 2.4 – 5.8 2.4 – 5.8 2.4 – 5.8
Lighting Coil ➃ Ω 0.1 – 0.4 0.1 – 0.4 0.1 – 0.4
Primary Ω 0.3 – 0.7 0.3 – 0.7 0.3 – 0.7
Secondary kΩ 8.0 – 16.0 8.0 – 16.0 8.0 – 16.0
Main Jet PTO/MAG 500/500 500/500 510N/510N
Pilot Jet 20 20 17.5
Needle Identification — Clip Position 9HGY1/58 ➅ 9HGY1/58 ➅ 9ZLY3/58 ➅
Air or Pilot Screw Adjustment ± 1/16 Turn 1-1/2 1-1/2 1-1/2
Idle Speed ± 200 RPM 1600 1600 1500
Magneto Ring Nut 125 (92) 125 (92) 125 (92)
ENGINE COLD
N•m (lb•ft)
M6 9 (7) 9 (7) 9 (7)

M8 29 (21) 29 (21) 29 (21)
02-6 MMC2002-001_02A.FM
MX Z 700 R MX Z 700 MX Z 700 R

VEHICLE MODEL SPORT TRAIL ADRENALINE
Bore mm (in) 78.00 (3.071) 78.00 (3.071) 78.00 (3.071)
Stroke mm (in) 73.00 (2.874) 73.00 (2.874) 73.00 (2.874)
New mm (in) 0.4 (.016) 0.4 (.016) 0.4 (.016)
Ring End Gap
Wear Limit mm (in) 1.0 (.039) 1.0 (.039) 1.0 (.039)
New mm (in) 0.04 (.0016) 0.04 (.0016) 0.04 (.0016)
Wear Limit mm (in) 0.2 (.0079) 0.2 (.0079) 0.2 (.0079)
New mm (in) 0.118 ± 0.016 (.0046 ± .0006) 0.115 ± 0.013 (.0045 ± .0005) 0.115 ± 0.013 (.0045 ± .0005)
Wear Limit mm (in) 0.20 (.0079) 0.20 (.0079) 0.20 (.0079)
New mm (in) 0.39 (.0154) 0.39 (.0154) 0.39 (.0154)
Wear Limit mm (in) 1.2 (.0472) 1.2 (.0472) 1.2 (.0472)
Trigger Coil ➃ Ω 190 – 300 190 – 300 190 – 300
Low Speed Ω 17.5 – 42.5 17.5 – 42.5 17.5 – 42.5
Generating Coil ➃
High Speed Ω 2.4 – 5.8 2.4 – 5.8 2.4 – 5.8
Lighting Coil ➃ Ω 0.1 – 0.4 0.1 – 0.4 0.1 – 0.4
Primary Ω 0.3 – 0.7 0.3 – 0.7 0.3 – 0.7
Secondary kΩ 8.0 – 16.0 8.0 – 16.0 8.0 – 16.0
Main Jet PTO/MAG 510N/510N 510N/510N 510N/510N
Pilot Jet 17.5 17.5 17.5
Needle Identification — Clip Position 9ZLY3/58 ➅ 9ZLY3/58 ➅ 9ZLY3/58 ➅
Idle Speed ± 200 RPM 1500 1500 1500
Magneto Ring Nut 125 (92) 125 (92) 125 (92)
ENGINE COLD
N•m (lb•ft)
M6 9 (7) 9 (7) 9 (7)

M8 29 (21) 29 (21) 29 (21)
MMC2002-001_02A.FM 02-7
MX Z 700 R MX Z 700 MX Z 700 R

VEHICLE MODEL RENEGADE X X
Bore mm (in) 78.00 (3.071) 78.00 (3.071) 78.00 (3.071)
Stroke mm (in) 73.00 (2.874) 73.00 (2.874) 73.00 (2.874)
New mm (in) 0.4 (.016) 0.4 (.016) 0.4 (.016)
Ring End Gap
Wear Limit mm (in) 1.0 (.039) 1.0 (.039) 1.0 (.039)
New mm (in) 0.04 (.0016) 0.04 (.0016) 0.04 (.0016)
Wear Limit mm (in) 0.2 (.0079) 0.2 (.0079) 0.2 (.0079)
New mm (in) 0.115 ± 0.013 (.0045 ± .0005) 0.115 ± 0.013 (.0045 ± .0005) 0.115 ± 0.013 (.0045 ± .0005)
Wear Limit mm (in) 0.20 (.0079) 0.20 (.0079) 0.20 (.0079)
New mm (in) 0.39 (.0154) 0.39 (.0154) 0.39 (.0154)
Wear Limit mm (in) 1.2 (.0472) 1.2 (.0472) 1.2 (.0472)
Trigger Coil ➃ Ω 190 – 300 190 – 300 190 – 300
Low Speed Ω 17.5 – 42.5 17.5 – 42.5 17.5 – 42.5
Generating Coil ➃
High Speed Ω 2.4 – 5.8 2.4 – 5.8 2.4 – 5.8
Lighting Coil ➃ Ω 0.1 – 0.4 0.1 – 0.4 0.1 – 0.4
Primary Ω 0.3 – 0.7 0.3 – 0.7 0.3 – 0.7
Secondary kΩ 8.0 – 16.0 8.0 – 16.0 8.0 – 16.0
Pilot Jet 17.5 17.5 17.5
Idle Speed ± 200 RPM 1500 1500 1500
Magneto Ring Nut 125 (92) 125 (92) 125 (92)
ENGINE COLD
N•m (lb•ft)
M6 9 (7) 9 (7) 9 (7)

M8 29 (21) 29 (21) 29 (21)
02-8 MMC2002-001_02A.FM
MX Z 800 MX Z 800 R MX Z 800

VEHICLE MODEL SPORT SPORT TRAIL
Bore mm (in) 82.00 (3.228) 82.00 (3.228) 82.00 (3.228)
Stroke mm (in) 75.70 (2.980) 75.70 (2.980) 75.70 (2.980)
New mm (in) 0.4 (.016) 0.4 (.016) 0.4 (.016)
Ring End Gap
Wear Limit mm (in) 1.0 (.039) 1.0 (.039) 1.0 (.039)
New mm (in) 0.05 (.0020) 0.05 (.0020) 0.05 (.0020)
Wear Limit mm (in) 0.2 (.0079) 0.2 (.0079) 0.2 (.0079)
New mm (in) 0.125 ± 0.013 (.0049 ± .0005) 0.125 ± 0.013 (.0049 ± .0005) 0.125 ± 0.013 (.0049 ± .0005)
Wear Limit mm (in) 0.20 (.0079) 0.20 (.0079) 0.20 (.0079)
New mm (in) 0.39 (.0154) 0.39 (.0154) 0.39 (.0154)
Wear Limit mm (in) 1.2 (.0472) 1.2 (.0472) 1.2 (.0472)
Trigger Coil ➃ Ω 190 – 300 190 – 300 190 – 300
Low Speed Ω 17.5 – 42.5 17.5 – 42.5 17.5 – 42.5
Generating Coil ➃
High Speed Ω 2.4 – 5.8 2.4 – 5.8 2.4 – 5.8
Lighting Coil ➃ Ω 0.1 – 0.4 0.1 – 0.4 0.1 – 0.4
Primary Ω 0.3 – 0.7 0.3 – 0.7 0.3 – 0.7
Secondary kΩ 8.0 – 16.0 8.0 – 16.0 8.0 – 16.0
Pilot Jet 17.5 17.5 17.5
Idle Speed ± 200 RPM 1500 1500 1500
Magneto Ring Nut 125 (92) 125 (92) 125 (92)
ENGINE COLD
N•m (lb•ft)
M6 9 (7) 9 (7) 9 (7)

M8 29 (21) 29 (21) 29 (21)
MMC2002-001_02A.FM 02-9
MX Z 800 R MX Z 800 R MX Z 800

VEHICLE MODEL ADRENALINE RENEGADE X
Bore mm (in) 82.00 (3.228) 82.00 (3.228) 82.00 (32.228)
Stroke mm (in) 75.70 (2.980) 75.7 (2.980) 75.70 (2.980)
New mm (in) 0.4 (.016) 0.4 (.016) 0.4 (.016)
Ring End Gap
Wear Limit mm (in) 1.0 (.039) 1.0 (.039) 1.0 (.039)
New mm (in) 0.05 (.0020) 0.05 (.0020) 0.05 (.0020)
Wear Limit mm (in) 0.2 (.0079) 0.2 (.0079) 0.2 (.0079)
New mm (in) 0.125 ± 0.013 (.0049 ± .0005) 0.125 ± 0.013 (.0049 ± .0005) 0.125 ± 0.013 (.0049 ± .0005)
Piston/Cylinder Wall Clearance 0.20 (.0079)
Wear Limit mm (in) 0.20 (.0079) 0.20 (.0079)
New mm (in) 0.39 (.0154) 0.39 (.0154) 0.39 (.0154)
Connecting Rod Big End Axial Play 1.2 (.0472)
Wear Limit mm (in) 1.2 (.0472) 1.2 (.0472)
Trigger Coil ➃ Ω 190 – 300 190 – 300 190 – 300
Low Speed Ω 17.5 – 42.5 17.5 – 42.5 17.5 – 42.5
Generating Coil ➃
High Speed Ω 2.4 – 5.8 2.4 – 5.8 2.4 – 5.8
Lighting Coil ➃ Ω 0.1 – 0.4 0.1 – 0.4 0.1 – 0.4
Primary Ω 0.3 – 0.7 0.3 – 0.7 0.3 – 0.7
Secondary kΩ 8.0 – 16.0 8.0 – 16.0 8.0 – 16.0
Pilot Jet 17.5 17.5 17.5

9ZLY3/58 ➅
Idle Speed ± 200 RPM 1500 1500 1500
Magneto Ring Nut 125 (92) 125 (92) 125 (92)
ENGINE COLD
N•m (lb•ft)
M6 9 (7) 9 (7) 9 (7)

M8 29 (21) 29 (21) 29 (21)
02-10 MMC2002-001_02A.FM
MX Z 800 R SUMMIT 600 SUMMIT 600 R

VEHICLE MODEL X SPORT SPORT
Bore mm (in) 82.00 (32.228) 76.00 (2.992) 76.00 (2.992)
Stroke mm (in) 75.70 (2.980) 65.80 (2.591) 65.80 (2.591)
New mm (in) 0.4 (.016) 0.4 (.016) 0.4 (.016)
Ring End Gap
Wear Limit mm (in) 1.0 (.039) 1.0 (.039) 1.0 (.039)
New mm (in) 0.05 (.0020) 0.045 (.0016) 0.045 (.0016)
Wear Limit mm (in) 0.2 (.0079) 0.2 (.0079) 0.2 (.0079)
New mm (in) 0.125 ± 0.013 (.0049 ± .0005) 0.120 ± 0.016(.0047 ± .0006) 0.120 ± 0.016 (.0047 ± .0006)
Wear Limit mm (in) 0.20 (.0079) 0.20 (.0079) 0.20 (.0079)
New mm (in) 0.39 (.0154) 0.39 (.0154) 0.39 (.0154)
Wear Limit mm (in) 1.2 (.0472) 1.2 (.0472) 1.2 (.0472)
Trigger Coil ➃ Ω 190 – 300 190 – 300 190 – 300
Low Speed Ω 17.5 – 42.5 17.5 – 42.5 17.5 – 42.5
Generating Coil ➃
High Speed Ω 2.4 – 5.8 2.4 – 5.8 2.4 – 5.8
Lighting Coil ➃ Ω 0.1 – 0.4 0.1 – 0.4 0.1 – 0.4
Primary Ω 0.3 – 0.7 0.3 – 0.7 0.3 – 0.7
Secondary kΩ 8.0 – 16.0 8.0 – 16.0 8.0 – 16.0
Main Jet PTO/MAG 520N/520N 500/500 500/500
Pilot Jet 17.5 20 20
Needle Identification — Clip Position 9ZLY2/58 ➅ 9HGY1/58 ➅ 9HGY1/58 ➅

9ZLY3/58 ➅
Idle Speed ± 200 RPM 1500 1500 1500
Magneto Ring Nut 125 (92) 125 (92) 125 (92)
ENGINE COLD
N•m (lb•ft)
M6 9 (7) 9 (7) 9 (7)

M8 29 (21) 29 (21) 29 (21)
MMC2002-001_02A.FM 02-11
SUMMIT 700 SUMMIT 700 R SUMMIT 800

VEHICLE MODEL SPORT SPORT SPORT
Bore mm (in) 78.00 (3.071) 78.00 (3.071) 82.00 (3.228)
Stroke mm (in) 73.0 (2.874) 73.0 (2.874) 75.70 (2.980)
New mm (in) 0.4 (.016) 0.4 (.016) 0.4 (.016)
Ring End Gap
Wear Limit mm (in) 1.0 (.039) 1.0 (.039) 1.0 (.039)
New mm (in) 0.04 (.0016) 0.04 (.0016) 0.05 (.0020)
Wear Limit mm (in) 0.2 (.0079) 0.2 (.0079) 0.2 (.0079)
New mm (in) 0.115 ± 0.013 (.0045 ± .0005) 0.115 ± 0.013 (.0045 ± .0005) 0.125 ± 0.013 (.0049 ± .0005)
Piston/Cylinder Wall Clearance 0.20 (.0079) 0.20 (.0079)
New mm (in) 0.39 (.0154) 0.39 (.0154) 0.39 (.0154)
Connecting Rod Big End Axial Play 1.2 (.0472) 1.2 (.0472)
Trigger Coil ➃ Ω 190 – 300 190 – 300 190 – 300
Low Speed Ω 17.5 – 42.5 17.5 – 42.5 17.5 – 42.5
Generating Coil ➃
High Speed Ω 2.4 – 5.8 2.4 – 5.8 2.4 – 5.8
Lighting Coil ➃ Ω 0.1 – 0.4 0.1 – 0.4 0.1 – 0.4
Primary Ω 0.3 – 0.7 0.3 – 0.7 0.3 – 0.7
Secondary kΩ 8.0 – 16.0 8.0 – 16.0 8.0 – 16.0
Pilot Jet 17.5 17.5 17.5
Idle Speed ± 200 RPM 1500 1500 1500
Magneto Ring Nut 125 (92) 125 (92) 125 (92)
ENGINE COLD
N•m (lb•ft)
M6 9 (7) 9 (7) 9 (7)

M8 29 (21) 29 (21) 29 (21)
02-12 MMC2002-001_02A.FM
SUMMIT 800 R SUMMIT 800 SUMMIT 800 R

VEHICLE MODEL SPORT X X
Bore mm (in) 82.00 (3.228) 82.00 (3.228) 82.00 (3.228)
Stroke mm (in) 75.70 (2.980) 75.70 (2.980) 75.70 (2.980)
New mm (in) 0.4 (.016) 0.4 (.016) 0.4 (.016)
Ring End Gap
Wear Limit mm (in) 1.0 (.039) 1.0 (.039) 1.0 (.039)
New mm (in) 0.05 (.0020) 0.05 (.0020) 0.05 (.0020)
Wear Limit mm (in) 0.2 (.0079 0.2 (.0079) 0.2 (.0079
New mm (in) 0.125 ± 0.013 (.0049 ± .0005) 0.125 ± 0.013 (.0049 ± .0005) 0.125 ± 0.013 (.0049 ± .0005)
Wear Limit mm (in) 0.20 (.0079) 0.20 (.0079) 0.20 (.0079)
New mm (in) 0.39 (.0154) 0.39 (.0154) 0.39 (.0154)
Wear Limit mm (in) 1.2 (.0472) 1.2 (.0472) 1.2 (.0472)
Trigger Coil ➃ Ω 190 – 300 190 – 300 190 – 300
Low Speed Ω 17.5 – 42.5 17.5 – 42.5 17.5 – 42.5
Generating Coil ➃
High Speed Ω 2.4 – 5.8 2.4 – 5.8 2.4 – 5.8
Lighting Coil ➃ Ω 0.1 – 0.4 0.1 – 0.4 0.1 – 0.4
Primary Ω 0.3 – 0.7 0.3 – 0.7 0.3 – 0.7
Secondary kΩ 8.0 – 16.0 8.0 – 16.0 8.0 – 16.0
Pilot Jet 17.5 17.5 17.5
Idle Speed ± 200 RPM 1500 1500 1500
Magneto Ring Nut 125 (92) 125 (92) 125 (92)
ENGINE COLD
N•m (lb•ft)
M6 9 (7) 9 (7) 9 (7)

M8 29 (21) 29 (21) 29 (21)
MMC2002-001_02A.FM 02-13

VEHICLE MODEL HIGHMARK HIGHMARK HIGHMARK X
Bore mm (in) 82.00 (3.228) 82.00 (3.228) 82.00 (3.228)
Stroke mm (in) 75.70 (2.980) 75.70 (2.980) 75.70 (2.980)
New mm (in) 0.4 (.016) 0.4 (.016) 0.4 (.016)
Ring End Gap
Wear Limit mm (in) 1.0 (.039) 1.0 (.039) 1.0 (.039)
New mm (in) 0.05 (.0020) 0.04 (.0016) 0.05 (.0020)
Wear Limit mm (in) 0.2 (.0079) 0.2 (.0079) 0.2 (.0079)
New mm (in) 0.125 ± 0.013 (.0049 ± .0005) 0.115 ± 0.013 (.0045 ± .0005) 0.125 ± 0.013 (.0049 ± .0005)
Wear Limit mm (in) 0.20 (.0079) 0.20 (.0079) 0.20 (.0079)
New mm (in) 0.39 (.0154) 0.39 (.0154) 0.39 (.0154)
Wear Limit mm (in) 1.2 (.0472) 1.2 (.0472) 1.2 (.0472)
Trigger Coil ➃ Ω 190 – 300 190 – 300 190 – 300
Low Speed Ω 17.5 – 42.5 17.5 – 42.5 17.5 – 42.5
Generating Coil ➃
High Speed Ω 2.4 – 5.8 2.4 – 5.8 2.4 – 5.8
Lighting Coil ➃ Ω 0.1 – 0.4 0.1 – 0.4 0.1 – 0.4
Primary Ω 0.3 – 0.7 0.3 – 0.7 0.3 – 0.7
Secondary kΩ 8.0 – 16.0 8.0 – 16.0 8.0 – 16.0
Pilot Jet 17.5 17.5 17.5
Idle Speed ± 200 RPM 1500 1500 1500
Magneto Ring Nut 125 (92) 125 (92) 125 (92)
ENGINE COLD
N•m (lb•ft)
M6 9 (7) 9 (7) 9 (7)

M8 29 (21) 29 (21) 29 (21)
02-14 MMC2002-001_02A.FM
SUMMIT 800 R
VEHICLE MODEL HIGHMARK X
(CAN./U.S.)
ENGINE TYPE 793
Number of Cylinders 2
Bore mm (in) 82.00 (3.228)
Stroke mm (in) 75.70 (2.980)
Displacement cm3 (in3) 799.20 (48.77)
Compression Ratio (corrected) ± 0.5 12.0
Maximum Power Engine Speed ➀ ± 100 RPM 7900
Piston Ring Type 1st /2nd ST/N.A.
New mm (in) 0.4 (.016)
Ring End Gap
New mm (in) 0.05 (.0020)
New mm (in) 0.125 ± 0.013 (.0049 ± .0005)
New mm (in) 0.39 (.0154)
Maximum Crankshaft End-play ➁ mm (in) 0.3 (.012)
Maximum Crankshaft Deflection at PTO mm (in) 0.06 (.0024)
Magneto Generator Output W 290
Ignition Type CDI
Spark Plug Make and Type NGK BR9ECS
Spark Plug Gap ± 0.05 mm (± .002 in) 0.45 (.018)
Ignition Timing BTDC ➂ mm (in) 3.51 (.138)
Trigger Coil ➃ Ω 190 – 300
Low Speed Ω 17.5 – 42.5
Generating Coil ➃
High Speed Ω 2.4 – 5.8
Lighting Coil ➃ Ω 0.1 – 0.4
Primary Ω 0.3 – 0.7
Secondary kΩ 8.0 – 16.0
Carburetor Type PTO/MAG TM 40-B175
Main Jet PTO/MAG 520N/520N
Needle Jet P-0 ➄
Pilot Jet 17.5
Needle Identification — Clip Position 9ZLY2/58 ➅
Slide Cut-Away 2.0
Float Adjustment ± 1 mm (± .040 in) N.A.
Air or Pilot Screw Adjustment ± 1/16 Turn 1-1/2
Idle Speed ± 200 RPM 1500
Gas Type/Pump Octane Number Unleaded/87
Gas/Oil Ratio Injection
Type Liquid
Deflection mm (in) N.A.
Force kg (lbf) N.A.
Thermostat Opening Temperature °C (°F) 42 (108)
Radiator Cap Opening Pressure kPa (PSI) 90 (13)
Drive Pulley Retaining Screw ➆
Exhaust Manifold Nuts or Bolts 22 (16)
Magneto Ring Nut 125 (92)
ENGINE COLD
N•m (lb•ft)
M6 9 (7)
M8 29 (21)
Crankcase/Engine Support Nuts or Screws 35 (26)
Cylinder Head Screws 29 (21)
Crankcase/Cylinder Nuts or Screws 40 (29)
Axial Fan Shaft Nut N.A.
MMC2002-001_02A.FM 02-15
VEHICLES 0
MX Zx 440 MX Z 500 MX Z 500 R
VEHICLE MODEL RACING SPORT SPORT
Chain Drive Ratio 21/43 22/43 22/43
Pitch in 3/8 3/8 3/8
Chain
Type/Links Qty/Plates Qty Silent 74/15 Silent 74/11 Silent 74/11
Type of Drive Pulley TRA TRA TRA
Ramp Identification and Roller Pin Type 296 ➇ 283 ➄ 283 ➄
Calibration Screw Position or Calibration Disc Quantity 4 4 3
Drive Pulley Spring Color Pink/White Green/White Green/Pink
mm 124.5 110.7 118.0
Spring Length ( in) (4.902) (4.36) (4.65)
Clutch Engagement ± 100 RPM 5000 4400 4400
Type FORMULA FORMULA HPV27
Driven Pulley Spring Preload ± 0.7 kg (± 1.5 lb) 7.0 (15.43) 7.0 (15.4) N.A.
Cam Angle Degree 48/44 42 44
± 0.5 mm 16.5 16.5 16.5
Pulley Distance Z (± .020 in) (.650) (.650) (.650)
± 0.5 mm 35.5 35.5 35.5
X (± .020 in) (1.398) (1.398) (1.398)
Offset
mm 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
Y–X MIN. – MAX. (in) (.040 – .080) (.040 – .080) (.040 – .080)
Drive Belt Part Number (P/N) 414 860 700 414 860 700 414 860 700
Drive Belt Width (new) ➀ mm (in) 35.3 (1.390) 35.30 (1.390) 35.30 (1.390)
± 5 mm 32 32 32
Deflection
Drive Belt Adjustment (± .197 in) (1.260) (1.260) (1.260)
Force ➁ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width mm (in) 381 (15.0) 381 (15.0) 381 (15.0)
Length mm (in) 3074 (121) 3074 (121) 3074 (121)
Track Profile Height mm (in) 36.8 (1.45) 22.3 (0.9) 22.3 (0.9)
mm 30 – 35 30 – 35 30 – 35
Deflection (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Adjustment
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Track SC-10 III SC-10 III SC-10 III
Suspension Type
Ski ADSA ADSA ADSA
Length mm (in) 2801 (110) 2725 (107.3) 2725 (107.3)
Width mm (in) 1213 (48) 1329 (52.3) 1329 (52.3)
Height mm (in) 1130 (44) 1130 (44.5) 1130 (44.5)
Ski Stance (carbide to carbide) mm (in) 1080 (43) 1195 (47.0) 1195 (47.0)
Toe-out and mm (in) 0 (0) 0 (0) 0 (0)
Camber degree 0 0 0
Mass (dry) kg (lb) 210 (463) 213 (468) 213 (468)
Ground Contact Area cm2 (in2) 6671 (1034) 6836 (1060) 6836 (1060)
Ground Contact Pressure kPa (PSI) 3.09 (.448) 3.06 (.444) 3.06 (.444)
Frame Material Aluminum Aluminum Aluminum
Bottom Pan Material Impact Copolymer Impact Copolymer Impact Copolymer
Hood Material RRIM Polyurethane RRIM Polyurethane RRIM Polyurethane
Battery V/A•h N.A. N.A. N.A.
Headlight W H4 60/55 H4 60/55 H4 60/55
Taillight and Stoplight W 8/27 8/27 8/27
Tachometer and Speedometer Bulbs W 3 3 3
Fuel and Temperature Gauge Bulbs W N.A. N.A. N.A.
Starter Solenoid A N.A. N.A. N.A.
Fuse
Fuel Level Sensor A N.A. N.A. N.A.
Fuel Tank L (U.S. gal) 37.3 (9.9) 37.3 (9.9) 37.3 (9.9)
Chaincase/Gearbox mL (U.S. oz) 250 (8.5) 250 (8.5) 250 (8.5)
Cooling System ➃ L (U.S. oz) 3.8 (128.5) 3.8 (128.5) 3.8 (128.5)
Injection Oil Reservoir L (U.S. oz) N.A. 3.5 (118.4) 3.5 (118.4)
02-16 MMC2002-001_02A.FM
MX Z 500 TRAIL MX Z 600 MX Z 600 R

VEHICLE MODEL (CAN./U.S.) SPORT SPORT
Pitch in 3/8 3/8 3/8
Chain
Ramp Identification and Roller Pin Type 283 ➄ 299 ➄ 299 ➄
Drive Pulley Spring Color Green/White Green/White Green/Violet
mm 110.7 110.7 133.5
Spring Length
( in) (4.35) (4.36) (5.26)
Type FORMULA FORMULA HPV27
Driven Pulley Spring Preload ± 0.7 kg (± 1.5 lb) 7.0 (15.4) 7.5 (16.54) N.A.
Cam Angle Degree 42 47 47
Pulley Distance Z ± 0.5 mm 16.5 16.5 16.5

(± .020 in) (.650) (.650) (.650)
X ± 0.5 mm 35.5 35.5 35.5

(± .020 in) (1.398) (1.398) (1.398)
Offset
Y–X MIN. – MAX. mm 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
(in) (.040 – .080) (.040 – .080) (.040 – .080)
Deflection ± 5 mm 32 32 32
Force ➁ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width mm (in) 381 (15.0) 381 (15.0) 381 (15.0)
Length mm (in) 3074 (121) 3074 (121) 3074 (121)
Profile Height mm (in) 22.3 (.880) 22.3 (.880) 22.3 (.880)
Track
Deflection mm 30 – 35 30 – 35 30 – 35
Adjustment (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Suspension Type
Ski ADSA ADSA ADSA
Length mm (in) 2725 (107.3) 2725 (107) 2725 (107)
Width mm (in) 1213 (47.7) 1329 (52) 1329 (52)
Height mm (in) 1130 (44.5) 1130 (44) 1130 (44)
Ski Stance (carbide to carbide) mm (in) 1080 (42.5) 1195 1195

(47) (47)
Toe-out and mm (in) 0 (0) 0 (0) 0 (0)
Camber degree 0 0 0
Mass (dry) kg (lb) 213 (468) 215 (472) 215 (472)
Ground Contact Area cm2 (in2) 6670.9 (1034) 6836 (1060) 6836 (1060)
Headlight W H4 60/55 H4 60/55 H4 60/55
Fuse
Fuel Tank L (U.S. gal) 37.3 (9.9) 37.3 (9.9) 37.3 (9.9)
Injection Oil Reservoir L (U.S. oz) 3.5 (118.4) 3.5 (118.4) 3.5 (118.4)
MMC2002-001_02A.FM 02-17
MX Z 600 TRAIL MX Z 600 R MX Z 600 R

VEHICLE MODEL (CAN./U.S.) ADRENALINE RENEGADE
Pitch in 3/8 3/8 3/8
Chain
Drive Pulley Spring Color Green/White Green/Violet Violet/Violet
mm 110.7 133.7 107.0
Spring Length
( in) (4.35) (5.26) (4.21)
Type FORMULA HPV27 HPV27
Driven Pulley Spring Preload ± 0.7 kg (± 1.5 lb) 7.0 (15.4) N.A. N.A.

(± .020 in) (.650) (.650) (.650)
X ± 0.5 mm 35.5 35.5 35.5

(± .020 in) (1.398) (1.398) (1.398)
Offset
Y–X MIN. – MAX. mm 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
(in) (.040 – .080) (.040 – .080) (.040 – .080)
Force ➁ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width mm (in) 381 (15.0) 381 (15.0) 381 (15.0)
Length mm (in) 3074 (121) 3074 (121) 3455 (136)
Profile Height mm (in) 22.3 (.880) 22.3 (.9) 31.8 (1.3)
Track
Deflection mm 30 – 35 30 – 35 30 – 35
Adjustment (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Track SC-10 III SC-10 III SC-10 II 136
Suspension Type
Ski ADSA ADSA ADSA
Length mm (in) 2725 (107.3) 2725 (107.3) 3005 (118.3)
Width mm (in) 1213 (47.7) 1218 (48.0) 1172 (46.1)
Height mm (in) 1130 (44.5) 1130 (44.5) 1136 (44.7)
Ski Stance (carbide to carbide) mm (in) 1080 (42.5) 1195 (47) 1092 or 1156 (43 or 45.5)
Toe-out and mm (in) 0 (0) 0 (0) 0 (0)
Camber degree 0 0 0
Mass (dry) kg (lb) 213 (469) 215 (472) 221 (486)
Ground Contact Area cm2 (in2) 6670.9 (1034) 6836 (1060) 7522 (1166)
Headlight W H4 60/55 H4 60/55 H4 60/55
Fuse
Fuel Tank L (U.S. gal) 37.3 (9.9) 37.3 (9.9) 37.3 (9.9)
02-18 MMC2002-001_02A.FM
MX Z 600 MX Z 600 R MX Z 700

VEHICLE MODEL X X SPORT
Pitch in 3/8 3/8 3/8
Chain
Drive Pulley Spring Color Green/White Green/Violet Violet/Yellow
mm 110.7 133.7 157.9
Spring Length
( in) (4.36) (5.26) (6.22)
Type FORMULA HPV27 FORMULA
Driven Pulley Spring Preload ± 0.7 kg (± 1.5 lb) 7.0 (15.43) N.A. 8 (17.6)
Cam Angle Degree 47 47 48/44

(± .020 in) (.650) (.650) (.650)
X ± 0.5 mm 35.5 35.5 35.5

(± .020 in) (1.398) (1.398) (1.398)
Offset
Y–X MIN. – MAX. mm 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
(in) (.040 – .080) (.040 – .080) (.040 – .080)
Force ➁ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width mm (in) 381 (15.0) 381 (15.0) 381 (15.0)
Length mm (in) 3074 (121) 3074 (121) 3074 (121)
Profile Height mm (in) 25.4 (1.0) 25.4 (1.0) 22.34 (.880)
Track
Deflection mm 30 – 35 30 – 35 30 – 35
Adjustment (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Suspension Type
Ski ADSA ADSA ADSA
Length mm (in) 2801 (110) 2801 (110) 2725 (107)
Width mm (in) 1217 (48) 1217 (48) 1329 (52)
Height mm (in) 1085 (43) 1085 (43) 1130 (44)
Ski Stance (carbide to carbide) mm (in) 1195 1195 (47) 1195 (47)
(47)
Toe-out and mm (in) 0 (0) 0 (0) 0 (0)
Camber degree 0 0 0
Mass (dry) kg (lb) 215 (472) 215 (472) 215 (472)
Headlight W H4 60/55 H4 60/55 H4 60/55
Fuse
Fuel Tank L (U.S. gal) 37.3 (9.9) 37.3 (9.9) 37.3 (9.9)
MMC2002-001_02A.FM 02-19
MX Z 700 R MX Z 700 MX Z 700 R

VEHICLE MODEL SPORT TRAIL ADRENALINE
Pitch in 3/8 3/8 3/8
Chain
Drive Pulley Spring Color Green/Violet Green/Violet Green/Violet
mm 133.7 133.7 133.7
Spring Length
( in) (5.26) (5.26) (5.26)
Type HPV 27 FORMULA HPV 27
Driven Pulley Spring Preload ± 0.7 kg (± 1.5 lb) N.A. 8 (17.6) 0 (0)
Cam Angle Degree 50/47 48/44 50/47

(± .020 in) (.650) (.650) (.650)
X ± 0.5 mm 35.5 35.5 35.5

(± .020 in) (1.398) (1.398) (1.398)
Offset
Y–X MIN. – MAX. mm 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
(in) (.040 – .080) (.040 – .080) (.040 – .080)
Force ➁ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width mm (in) 381 (15.0) 381 (15.0) 381 (15.0)
Length mm (in) 3074 (121) 3074 (121) 3074 (121)
Profile Height mm (in) 22.34 (.880) 22.3 (.880) 25.4 (1.0)
Track
Deflection mm 30 – 35 30 – 35 30 – 35
Adjustment (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Track SC-10 III SC-10 III SC-10 II 136
Suspension Type
Ski ADSA ADSA ADSA
Length mm (in) 2725 (107) 2725 (107) 2725 (107)
Width mm (in) 1329 (52) 1213 (48) 1329 (52)
Height mm (in) 1130 (44) 1130 (44) 1130 (44)
Ski Stance (carbide to carbide) mm (in) 1195 (47) 1080 (42.5) 1195 (47)
Toe-out and mm (in) 0 (0) 0 (0) 0 (0)
Camber degree 0 0 0
Mass (dry) kg (lb) 215 (472) 215 (472) 215 (472)
Headlight W H4 60/55 H4 60/55 H4 60/55
Fuse
Fuel Tank L (U.S. gal) 37.3 (9.9) 37.3 (9.9) 37.3 (9.9)
02-20 MMC2002-001_02A.FM
MX Z 700 R MX Z 700 MX Z 700 R

VEHICLE MODEL RENEGADE X X
Pitch in 3/8 3/8 3/8
Chain
Drive Pulley Spring Color Violet/Yellow Green/Violet Green/Violet
mm 157.9 133.7 133.7
Spring Length
( in) (6.22) (5.26) (5.26)
Type HPV 27 FORMULA HPV27
Driven Pulley Spring Preload ± 0.7 kg (± 1.5 lb) 0 (0) 8.0 (17.64) N.A.
Cam Angle Degree 47 48/44 50/47

(± .020 in) (.650) (.650) (.650)
X ± 0.5 mm 35.5 35.5 35.5

(± .020 in) (1.398) (1.398) (1.398)
Offset
Y–X MIN. – MAX. mm 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
(in) (.040 – .080) (.040 – .080) (.040 – .080)
Force ➁ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width mm (in) 381 (15.0) 381 (15.0) 381 (15.0)
Length mm (in) 3455 (136) 3074 (121) 3074 (121)
Profile Height mm (in) 31.8 (1.25) 25.4 (1.0) 25.4 (1.0)
Track
Deflection mm 30 – 35 30 – 35 30 – 35
Adjustment (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Track SC-10 II 136 SC-10 III SC-10 III
Suspension Type
Ski ADSA ADSA ADSA
Length mm (in) 3005 (118) 2801 (110) 2801 (110)
Width mm (in) 1172 (46) 1217 (48) 1217 (48)
Height mm (in) 1136 (45) 1085 (43) 1085 (43)
Ski Stance (carbide to carbide) mm (in) 1156 or 1192 1195 (47) 1195 (47)
(45.5 or 47)
Toe-out and mm (in) 0 (0) 0 (0) 0 (0)
Camber degree 0 0 0
Mass (dry) kg (lb) 221 (487) 215 (472) 215 (472)
Headlight W H4 60/55 H4 60/55 H4 60/55
Fuse
Fuel Tank L (U.S. gal) 37.3 (9.9) 37.3 (9.9) 37.3 (9.9)
Cooling System ➃ L (U.S. oz) 4 (135.3) 3.8 (128.5) 3.8 (128.5)
MMC2002-001_02A.FM 02-21
MX Z 800 MX Z 800 R MX Z 800

VEHICLE MODEL SPORT SPORT TRAIL
Pitch in 3/8 3/8 3/8
Chain
Drive Pulley Spring Color Violet/Yellow Violet/Yellow Violet/Yellow
mm 157.9 157.9 157.9
Spring Length
( in) (6.22) (6.22) (6.22)
Type HPV 27 HPV 27 HPV 27
Driven Pulley Spring Preload ± 0.7 kg (± 1.5 lb) N.A. N.A. N.A.

(± .020 in) (.650) (.650) (.650)
X ± 0.5 mm 35.5 35.5 35.5

(± .020 in) (1.398) (1.398) (1.398)
Offset
Y–X MIN. – MAX. mm 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
(in) (.040 – .080) (.040 – .080) (.040 – .080)
Force ➁ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width mm (in) 381 (15.0) 381 (15.0) 381 (15.0)
Length mm (in) 3074 (121) 3074 (121) 3074 (121)
Track
Deflection mm 30 – 35 30 – 35 30 – 35
Adjustment (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Suspension Type
Ski ADSA ADSA ADSA
Length mm (in) 2725 (107) 2725 (107) 2725 (107)
Width mm (in) 1218 (48) 1218 (48) 1213 (48)
Height mm (in) 1130 (44) 1130 (44) 1130 (44)
Ski Stance (carbide to carbide) mm (in) 1195 (47) 1195 (47) 1080 (43)
Toe-out and mm (in) 0 (0) 0 (0) 0 (0)
Camber degree 0 0 0
Mass (dry) kg (lb) 215 (474) 215 (474) 215 (474)
Headlight W H4 60/55 H4 60/55 H4 60/55
Fuse
Fuel Tank L (U.S. gal) 37.3 (9.9) 37.3 (9.9) 37.3 (9.9)
02-22 MMC2002-001_02A.FM
MX Z 800 R MX Z 800 R MX Z 800

VEHICLE MODEL ADRENALINE RENEGADE X
Pitch in 3/8 3/8 3/8
Chain
Drive Pulley Spring Color Violet/Yellow Violet/Yellow Violet/Yellow
mm 157.9 157.9 157.9
Spring Length
( in) (6.22) (6.22) (6.22)
Type HPV 27 HPV27 HPV27

(± .020 in) (.650) (.650) (.650)
X ± 0.5 mm 35.5 35.5 35.5

(± .020 in) (1.398) (1.398) (1.398)
Offset
Y–X MIN. – MAX. mm 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
(in) (.040 – .080) (.040 – .080) (.040 – .080)
Force ➁ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width mm (in) 381 (15.0) 381 (15.0) 381 (15.0)
Length mm (in) 3074 (121) 3455 (136) 3074 (121)
Track
Deflection mm 30 – 35 30 – 35 30 – 35
Adjustment (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Track SC-10 III SC-10 II 136 SC-10 III
Suspension Type
Ski ADSA ADSA ADSA
Length mm (in) 2725 (107) 3005 (118.3) 2801 (110)
Width mm (in) 1329 (52) 1172 (46.1) 1217 (48)
Height mm (in) 1086 (43) 1136 (44.7) 1085 (43)
Ski Stance (carbide to carbide) mm (in) 1195 (47) 1092 or 1156 (43 or 45.5) 1195 (47)
Toe-out and mm (in) 0 (0) 0 (0) 0 (0)
Camber degree 0 0 0
Mass (dry) kg (lb) 215 (474) 222 (489) 215 (472)
Headlight W H4 60/55 H4 60/55 H4 60/55
Fuse
Fuel Tank L (U.S. gal) 37.3 (9.9) 37.3 (9.9) 37.3 (9.9)
MMC2002-001_02A.FM 02-23
MX Z 800 R SUMMIT 600 SUMMIT 600 R

VEHICLE MODEL X SPORT SPORT
Pitch in 3/8 3/8 3/8
Chain
Ramp Identification and Roller Pin Type 301 ➄ 300 ➆ 299 ➆
Drive Pulley Spring Color Violet/Yellow Violet/Green Violet/Blue
mm 157.9 133.5 114.6
Spring Length
( in) (6.22) (5.26) (4.51)
Type HPV27 FORMULA HPV 27
Driven Pulley Spring Preload ± 0.7 kg (± 1.5 lb) N.A. 7.5 (16.54) N.A.
Cam Angle Degree 47/44 44 47/44

(± .020 in) (.650) (.650) (.650)
X ± 0.5 mm 35.5 35.5 35.5

(± .020 in) (1.398) (1.398) (1.398)
Offset
Y–X MIN. – MAX. mm 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
(in) (.040 – .080) (.040 – .080) (.040 – .080)
Force ➁ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width mm (in) 381 (15.0) 381 (15.0) 381 (15.0)
Length mm (in) 3074 (121) 3648 (144) 3648 (144)
Profile Height mm (in) 25.4(1.0) 50.8 (2.0) 50.8 (2.0)
Track
Deflection mm 30 – 35 30 – 35 30 – 35
Adjustment (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Track SC-10 III SC-10 144 SC-10 144
Suspension Type
Ski ADSA ADSA ADSA
Length mm (in) 2801 (110) 2947 (116) 2947 (116)
Width mm (in) 1217 (48) 1139 (45) 1139 (45)
Height mm (in) 1085 (43) 1130 (44) 1130 (44)
Ski Stance (carbide to carbide) mm (in) 1195 (47) 1025 or 1080 1025 or 1080
(40 or 43) (40 or 43)
Toe-out and mm (in) 0 (0) 0 (0) 0 (0)
Camber degree 0 0 0
Mass (dry) kg (lb) 215 (472) 222 (489) 222 (489)
Headlight W H4 60/55 H4 60/55 H4 60/55
Fuse
Fuel Tank L (U.S. gal) 37.3 (9.9) 37.3 (9.9) 37.3 (9.9)
Cooling System ➃ L (U.S. oz) 3.8 (128.5) 4 (135.3) 4 (135.3)
02-24 MMC2002-001_02A.FM

VEHICLE MODEL SPORT SPORT SPORT
Pitch in 3/8 3/8 3/8
Chain
Ramp Identification and Roller Pin Type 299 ➆ 300 ➆ 300 ➆
Drive Pulley Spring Color Violet/Yellow Violet/Yellow Blue/Orange
mm 157.9 157.9 135.5
Spring Length
( in) (6.22) (6.22) (5.36)
Type FORMULA HPV27 HPV 27
Driven Pulley Spring Preload ± 0.7 kg (± 1.5 lb) 7.5 (16.5) N.A. N.A.

(± .020 in) (.650) (.650) (.650)
X ± 0.5 mm 35.5 35.5 35.5

(± .020 in) (1.398) (1.398) (1.398)
Offset
Y–X MIN. – MAX. mm 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
(in) (.040 – .080) (.040 – .080) (.040 – .080)
Force ➁ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width mm (in) 381 (15.0) 381 (15.0) 381 (15.0)
Length mm (in) 3648 (144) 3648 (144) 3648 (144)
Track
Deflection mm 30 – 35 30 – 35 30 – 35
Adjustment (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Track SC-10 144 SC-10 144 SC-10 144
Suspension Type
Ski ADSA ADSA ADSA
Length mm (in) 2947 (116.0) 2947 (116.0) 3134 (123)
Width mm (in) 1310 (51.6) 1310 (51.6) 1310 (52)
Height mm (in) 1130 (44.5) 1130 (44.5) 1130 (44)
Ski Stance (carbide to carbide) mm (in) 1139 (44.8) 1139 (44.8) 1025 or 1080
(40.3 or 42.5)
Toe-out and mm (in) 0 (0) 0 (0) 0 (0)
Camber degree 0 0 0
Mass (dry) kg (lb) 224 (492) 224 (492) 225 (494)
Headlight W H4 60/55 H4 60/55 H4 60/55
Fuse
Fuel Tank L (U.S. gal) 37.3 (9.9) 37.3 (9.9) 37.3 (9.9)
Cooling System ➃ L (U.S. oz) 4.0 (135.3) 4.0 (135.3) 4 (135.3)
MMC2002-001_02A.FM 02-25
SUMMIT 800 R SUMMIT 800 SUMMIT 800 R

VEHICLE MODEL SPORT X X
Pitch in 3/8 3/8 3/8
Chain
Drive Pulley Spring Color Blue/Orange Blue/Orange Blue/Orange
mm 135.5 135.5 135.5
Spring Length
( in) (5.36) (5.36) (5.36)

(± .020 in) (.650) (.650) (.650)
X ± 0.5 mm 35.5 35.5 35.5

(± .020 in) (1.398) (1.398) (1.398)
Offset
Y–X MIN. – MAX. mm 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
(in) (.040 – .080) (.040 – .080) (.040 – .080)
Force ➁ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width mm (in) 381 (15.0) 381 (15.0) 381 (15.0)
Length mm (in) 3648 (144) 3648 (144) 3648 (144)
Track
Deflection mm 30 – 35 30 – 35 30 – 35
Adjustment (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Track SC-10 144 SC-10 144 SC-10 144
Suspension Type
Ski ADSA ADSA ADSA
Length mm (in) 3134 (123) 3134 (123) 3134 (123)
Width mm (in) 1310 (52) 1310 (52) 1310 (52)
Height mm (in) 1130 (44) 1130 (44) 1130 (44)
Ski Stance (carbide to carbide) mm (in) 1025 or 1080 1025 or 1080 1025 or 1080
(40.3 or 42.5) (40.3 or 42.5) (40.3 or 42.5)
Toe-out and mm (in) 0 (0) 0 (0) 0 (0)
Camber degree 0 0 0
Mass (dry) kg (lb) 225 (494) 225 (494) 225 (494)
Headlight W H4 60/55 H4 60/55 H4 60/55
Fuse
Fuel Tank L (U.S. gal) 37.3 (9.9) 37.3 (9.9) 37.3 (9.9)
Cooling System ➃ L (U.S. oz) 4 (135.3) 4 (135.3) 4 (135.3)
02-26 MMC2002-001_02A.FM

VEHICLE MODEL HIGHMARK HIGHMARK HIGHMARK X
Pitch in 3/8 3/8 3/8
Chain
Drive Pulley Spring Color Blue/Orange Blue/Orange Blue/Orange
mm 135.5 135.5 135.5
Spring Length
( in) (5.36) (5.36) (5.36)

(± .020 in) (.650) (.650) (.650)
X ± 0.5 mm 35.5 35.5 35.5

(± .020 in) (1.398) (1.398) (1.398)
Offset
Y–X MIN. – MAX. mm 1.0 – 2.0 1.0 – 2.0 1.0 – 2.0
(in) (.040 – .080) (.040 – .080) (.040 – .080)
Force ➁ kg (lbf) 11.3 (25) 11.3 (25) 11.3 (25)
Width mm (in) 381 (15.0) 381 (15.0) 381 (15.0)
Length mm (in) 3836 (151) 3648 (144) 3836 (151)
Track
Deflection mm 30 – 35 30 – 35 30 – 35
Adjustment (in) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8) (1-3/16 – 1-3/8)
Force ➂ kg (lbf) 7.3 (16) 7.3 (16) 7.3 (16)
Track SC-10 151 SC-10 151 SC-10 151
Suspension Type
Ski ADSA ADSA ADSA
Length mm (in) 3216 (127) 3216 (127) 3216 (127)
Width mm (in) 1139 (45) 1139 (49) 1139 (45)
Height mm (in) 1130 (44) 1130 (44) 1130 (44)
Ski Stance (carbide to carbide) mm (in) 1025 or 1080 1025 or 1080 1025 or 1080
(40.3 or 42.5) (40.3 or 42.5) (40.3 or 42.5)
Toe-out and mm (in) 0 (0) 0 (0) 0 (0)
Camber degree 0 0 0
Mass (dry) kg (lb) 227 (499) 227 (499) 227 (499)
Headlight W H4 60/55 H4 60/55 H4 60/55
Fuse
Fuel Tank L (U.S. gal) 37.3 (9.9) 37.3 (9.9) 37.3 (9.9)
MMC2002-001_02A.FM 02-27
SUMMIT 800 R
VEHICLE MODEL HIGHMARK X
(CAN./U.S.)
ENGINE TYPE 793
Chain Drive Ratio 19/43
Pitch in 3/8
Chain
Type/Links Qty/Plates Qty Silent 72/13
Type of Drive Pulley TRA
Ramp Identification and Roller Pin Type 300 ➆
Calibration Screw Position or Calibration Disc Quantity 1
Drive Pulley Spring Color Blue/Orange
Spring Length mm 135.5

( in) (5.36)
Clutch Engagement ± 100 RPM 4000
Type HPV 27
Driven Pulley Spring Preload ± 0.7 kg (± 1.5 lb) N.A.
Cam Angle Degree 44
± 0.5 mm 16.5
Pulley Distance Z (± .020 in) (.650)
± 0.5 mm 35.5
X (± .020 in) (1.398)
Offset
mm 1.0 – 2.0
Y–X MIN. – MAX. (in) (.040 – .080)
Drive Belt Part Number (P/N) 417 300 127
Drive Belt Width (new) ➀ mm (in) 36.4 (1.431)
Deflection ± 5 mm 32
Drive Belt Adjustment (± .197 in) (1.260)
Force ➁ kg (lbf) 11.3 (25)
Width mm (in) 381 (15.0)
Length mm (in) 3648 (144)
Profile Height mm (in) 50.8 (2.0)
Track
mm 30 – 35
Deflection (in) (1-3/16 – 1-3/8)
Adjustment
Force ➂ kg (lbf) 7.3 (16)
Track SC-10 151
Suspension Type
Ski ADSA
Length mm (in) 3216 (127)
Width mm (in) 1139 (49)
Height mm (in) 1130 (44)
1025 or 1080
Ski Stance (carbide to carbide) mm (in) (40.3 or 42.5)
Toe-out and mm (in) 0 (0)
Camber degree 0
Mass (dry) kg (lb) 227 (499)
Ground Contact Area cm2 (in2) 9141 (1417)
Ground Contact Pressure kPa (PSI) 2.49 (.354)
Frame Material Aluminum
Bottom Pan Material Impact Copolymer
Hood Material RRIM Polyurethane
Battery V/A•h N.A.
Headlight W H4 60/55
Taillight and Stoplight W 8/27
Tachometer and Speedometer Bulbs W 3
Fuel and Temperature Gauge Bulbs W N.A.
Starter Solenoid A N.A.
Fuse
Fuel Level Sensor A N.A.
Fuel Tank L (U.S. gal) 37.3 (9.9)
Chaincase/Gearbox mL (U.S. oz) 250 (8.5)
Cooling System ➃ L (U.S. oz) 4.3 (143.7)
Injection Oil Reservoir L (U.S. oz) 3.5 (118.4)
02-28 MMC2002-001_02A.FM
ENGINE LEGEND VEHICLE LEGEND

BTDC: Before Top Dead Center ADSA: Advanced Direct Shock Action
CDI: Capacitor Discharge Ignition RRIM: Reinforced Reaction Injection Molding
K: Kilo (x 1000) TRA: Total Range Adjustable
ST: Semi-trapezoidal N.A.: Not Applicable
MAG: Magneto Side ➀ Minimum allowable width may not be less than
N.A.: Not Applicable 3.0 mm (1/8 in) of new drive belt.
PTO: Power Take Off Side ➁ Force applied midway between pulleys to ob-
tain specified tension deflection.
➀ The maximum horsepower RPM applicable on
the vehicle. It may be different under certain cir- ➂ Force or downward pull applied to track to ob-
cumstances and BOMBARDIER INC. reserves tain specified tension deflection.
the right to modify it without obligation. ➃ Coolant mixture: 50% antifreeze/50% water.
➁ Crankshaft end-play is not adjustable on these ➄ Lever with roller pin (P/N 417 004 308) (solid).
models. Specification is given for verification pur- ➅ Lever with roller pin (P/N 417 004 309) (hollow).
poses only.
➆ Lever with roller pin (P/N 417 222 478) (solid).
➂ At 3500 RPM with headlamp turned on.
➇ Lever with roller pin (P/N 417 222 491) 10.3 g
➃ All resistance measurements must be performed threaded.
with parts at room temperature (approx. 20°C
(68°F)). Temperature greatly affects resistance
measurements.
➄ Press fit type, not replaceable.
➅ Neelde with on groove, not adjustable.
➆ Drive pulley retaining screw: torque to 80 to
100 N•m (66 to 74 lbf•ft), install drive belt, ac-
celerate the vehicle at low speed (maximum
30 km/h (20 MPH)) and apply the brake; repeat
5 times. Recheck the torque of 90 to 100 N•m
(66 to 74 lbf•ft).
MMC2002-001_02A.FM 02-29
SECTION 03 - CHASSIS PREPARATION
TABLE OF CONTENTS 0
SUSPENSION OPERATION/WEIGHT TRANSFER ................................................................... 03-2
SPRINGS .................................................................................................................................... 03-3
SPRING DESCRIPTION ................................................................................................................. 03-8
COIL SPRINGS (compression) ................................................................................................. 03-8
TORSION SPRINGS................................................................................................................... 03-9
SPRING APPLICATIONS ............................................................................................................... 03-10
SPRING SPECIFICATIONS ............................................................................................................ 03-13
CORNERING DYNAMICS .............................................................................................................. 03-16
SHOCKS ..................................................................................................................................... 03-18
SHOCK CALIBRATION WORK SHEET...................................................................................... 03-35
CHASSIS SET-UP....................................................................................................................... 03-36
BRAKES...................................................................................................................................... 03-39
AERODYNAMIC CONSIDERATIONS........................................................................................ 03-40
ADJUSTING RIDE HEIGHT ....................................................................................................... 03-40
TRACK GUIDES ......................................................................................................................... 03-41
TRACK STUDDING .................................................................................................................... 03-42
SLIDER SHOE LUBRICATION ................................................................................................... 03-43
SKIS AND RUNNERS ................................................................................................................ 03-44
BUMP STEER ............................................................................................................................. 03-45
SKI LEG CAMBER ...................................................................................................................... 03-45
SKI TOE-OUT ............................................................................................................................. 03-47
CHASSIS TUNING GUIDELINES .............................................................................................. 03-47
MMC2002-001_03A.FM 03-1
SUSPENSION If we keep force “C” constant, we can then vary

the size of the vertical and horizontal forces at the
OPERATION/WEIGHT TRANSFER front arm by varying angle “A”. As angle “A” is
The purpose of any suspension system is to iso- made smaller, force “X” decreases, and force “Z”
late the rider from the terrain while still allowing increases. This reduces the amount of torque re-
for complete control of the vehicle. A snowmobile action and more weight stays on the skis. As angle
rear suspension has the added requirements of “A” is increased, force “X” increases. The skis
providing weight transfer and maintaining correct then tend to lift more during acceleration and more
track tension. weight is placed on the track.
Weight transfer is essentially the shifting of weight We can vary angle “A”, within limits, by adjusting
to the track for better traction during acceleration, the length of the limiter strap. The limiter strap is
and to the skis for positive handling during corner- just that, a strap to limit the extension of the front
ing. of the suspension. Shortening the strap decreases
The physics that apply to all rear suspensions are angle “A” and is what we would do to set up a
basically the same. As we apply torque from the machine for more ski pressure. For more track
engine to the drive axle, the torque is transferred pressure we would want to lengthen the strap to
to the track and pulls it for forward. That energy increase angle “A”. The limiter adjustment has
enters the suspension system at the rear axle and the largest affect on controlling the amount of
tries to pull it forward (force “C” in following illus- weight transfer.
tration). The rear arm is a pivoting or sliding linkage NOTE: Track tension must be checked whenever
that only provides vertical forces at the rear of the a major change is made to the limiter length.
chassis, therefore, none of force “C” enters the Front arm spring pressure will also affect weight
chassis at the rear arm. transfer. A stiffer spring and/or more preload will
transfer more weight to the track. A softer spring
1
and/or less preload will keep more weight on the
X skis. Springs must also be selected to provide ab-
sorption to the intended size of bumps to be en-
Z countered. A soft spring will increase ski pressure
A
C but may bottom out on large bumps, while a stiff
Y
spring will provide more track pressure but may
produce a harsh ride.
A01F1VA X NOTE: In this and other Ski-Doo texts, we refer to
1. Drive axel torque the front arm of the rear suspension and it’s spring
and shock absorber, as the center of the vehicle.
The front arm is mounted with a pivot to both the The ski suspension is considered the front of the
runners and the chassis. It is through this arm that vehicle and the rear arm of the rear suspension
the major reaction to the engine torque is applied. and it’s spring(s) and shock(s) are indicated as the
As the front arm begins to swivel from the load of rear of the vehicle.
force “C”, it pushes down on the front of the track
(force “X” in illustration). This reduces weight on Also, think of the center arm as a pivot point. Dur-
the skis and applies more weight on the track for ing acceleration the rear arm will want to com-
better traction. The rest of the force “C” enters press and the front suspension will want to extend
the chassis through the front arm and accelerates (possibly raising the skis off the ground). Because
the vehicle (force “Z”). of this pivoting affect, the rear spring and preload
will also affect weight transfer (to a lesser amount
than center arm changes). A softer rear spring
and/or less preload will allow more weight transfer
to the track and less ski pressure, while stiffer rear
springs and/or more preload will allow less weight
transfer to the track and more ski pressure.
03-2 MMC2002-001_03A.FM
Contrary to popular belief, it is not necessary to

have the skis 2 feet off the ground to achieve good
5
weight transfer. In fact, the energy used to lift the 4
front of the vehicle is not available to push the ve- Number 3
hicle forward. of coils 2
1
The main function of the rear arm is to support the
weight of the vehicle and rider, yet provide usable
travel to absorb bumps and jumps. The springs are
chosen depending on the linkage design of the
rear arm and the intended load to be applied. Stiffer
springs will be used on vehicles intended to carry 3
heavier loads and on vehicles that plan to encoun-
ter large bumps, while vehicles used for lighter
loads and on smaller bumps will use softer springs.
Springs for the front suspension are chosen in a 4 Torsional spring
similar fashion. A softer spring will provide less ski
pressure and will be used on lighter vehicles while 1
stiffer springs will provide more ski pressure and
be used on heavier vehicles. 1
NOTE: Shock absorber valving and the type of 2
shock used will also affect weight transfer. Refer
to the shock absorber section for details.
3
A.C.M. Number
of coils 2
4
The SC-10 High Performance and Cross Country
Rear Suspensions incorporates the use of A.C.M.
technology. Under hard acceleration, the A.C.M. 5
linkage couples the front and rear arms moving the
rails rearward, thus reducing ski lift. The A.C.M. 6
can be used to increase and decrease weight
transfer. Tightening the A.C.M. will decrease weight Coil spring
A00F0OA
transfer. Loosening the A.C.M. will increase weight
transfer. 1. Wire diameter
2. Free length
3. Wire diameter
SPRINGS 4. Opening angle
Several factors are used to determine the charac-

General teristics of a spring and they are similar for both
Generally, 2 types of springs are used on our sus- the coil and torsional spring types. Wire diameter,
pensions. Coil springs and torsional springs. Refer material type, the number of coils and the physical
to following illustration. shape of a spring all determine how a spring will
act. Once these characteristics are built into a
spring, they determine the spring rate and the free
length in a coil spring or the opening angle and
spring rate in a torsional spring.
MMC2002-001_03A.FM 03-3
Coil Springs Most springs are designed as a straight rate spring.

This means that the spring requires the same
The free length of a coil spring is the length with
force to compress the last one inch of travel as the
no load applied to the spring.
first one inch of travel. Example: A 100 lbf/in rate
The spring rate of a coil spring is defined as the spring will compress one inch for every 100 pounds
amount of force required to compress the spring applied. A force of 200 pounds will compress the
one inch. If a 100 pound force compresses a spring spring 2 inches. A 300 pound force will compress
1 inch it is referred to as having a rate of 100 lbf/in the spring 3 inches and so on. The 150 lbf/in rate
(pounds per inch). If 150 pounds of force is required spring will require 150 pounds to compress the
to compress a spring 1 inch then it would have a spring each one inch. To compress this spring
rate of 150 lbf/in (see following illustration). 3 inches it will require a force of 450 pounds (see
following illustration).
1" 1" 150

100
FREE
LENGTH
SPRING RATE SPRING RATE

A01F1IA = 100 lbf/in = 150 lbf/in
450
300 2" 2" 300

200 1" 3" 3" 1" 150
100
FREE
LENGTH
SPRING RATE = 100 lbf/in SPRING RATE = 150 lbf/in

A01F1JS
03-4 MMC2002-001_03A.FM
In terms of your suspension, if a bump is encoun-

tered that translates into a force at the spring of
450 pounds, the 100 lbf/in spring will want to com-
press 4.5 inches while the 150 lbf/in spring will
only compress 3 inches. If our suspension only has
4 inches of spring travel the unit with the 100 lbf/in
spring will bottom out while the 150 lbf/in unit still
has 1 inch of travel remaining (see following illus-
tration).
450
450
3"
4.5"
FREE
LENGTH
SPRING RATE = SPRING RATE =

100 lbf/in 150 lbf/in
A01F1KA
A spring can also be progressively wound. This

means that the rate of the spring is increasing as it
is compressed. A 100/200 lbf/in progressive spring
will require 100 pounds to compress the first one
inch but will require 200 additional pounds to com-
press the last one inch (see following illustration).
MMC2002-001_03A.FM 03-5
450
300 300
2" 2" 150
200 1" 3" 3" 1"
100
FREE LENGTH
STRAIGHT RATE = 100 lbf/in PROGRESSIVE RATE = 100/200 lbf/in

A01F1LS
An easy way to measure coil springs is to put a bathroom scale in a press with the spring resting on the
scale. Measure the free length and then apply a load until the spring compresses 1 inch. The reading on
the scale will approximate the rate of the spring. Now compress the spring another 1 inch. If the spring
is a straight rate, the scale reading should be doubled. If the reading is more than doubled, then you have
a progressive spring. If you can compress the spring another 1 inch (3 inches total) (do not exceed max-
imum scale rating or damage may occur) the reading should be 3 times your first reading. In order to
maintain a reasonable cost on springs, the manufacturing tolerances are quite large. A 100 lbf/in rated
spring may test anywhere from 80 to 120 lbf/in.
Now, so far we have assumed that the 2 springs in our examples have the same free length and that they
are not preloaded at all. In the case of our suspensions, we mount the coil springs on a shock absorber.
The shock will have a certain length between the spring retainers which is called the installed length of
the spring. If the installed length is less than the free length (as is the case in most applications), then
there will be some preloading of the spring.
03-6 MMC2002-001_03A.FM
Dual Rate Spring Formula

Spring 1 × Spring 2-
-------------------------------------------------
Spring + Spring 2
A Dual Rate Spring will assume the rate of the
heavier rate spring when the lighter spring bot-
toms or coil binds.
Example:
Spring 1 100# Rate Free opening angle
Spring 2 150# Rate
100 × 150- = 1500
------------------------- ------------- = 60
100 + 150 250
Spring 1 was a 100# Rate separately, but when Load Load
stacked on the 150# spring (spring 2), it now has
a 60# rate. As the spring bottoms or coil binds, it
will assume the 150# rate of spring 2.
Torsional Springs Installed opening angle

A01F25A
A torsional spring acts just like a coil spring but it

is shaped differently. It is much more difficult to
measure the rate of a torsional spring because of Spring Identification
the lengths of the legs and where the load will be Our springs will have one, 2 or 3 stripes of color
applied. The rear torsional springs on the S chassis painted on the spring. This is the color code used
are rated in lb-ft/degree (pounds-feet per degree for identification. Refer to the applicable chart to
of rotation). Suffice it to say that there are stiffer find a cross reference between the part number,
and softer springs for most applications. model application, color code, spring rate, free
The preload on a torsional spring is controlled by length and spring type. The spring type denotes
the free opening angle and the installed opening physical characteristics of the spring like the inside
angle. If a torsional spring must be twisted more diameter of the ends which will determine the
to be installed, then it will have more preload (fol- type of retainer used to hold the spring. All spring
lowing illustration). types are not interchangeable.
CHECK THE SPRING TYPE AND FIT OF THE
SPRING RETAINER BEFORE INSTALLING DIF-
FERENT SPRINGS!
MMC2002-001_03A.FM 03-7
SPRING DESCRIPTION Type T

(barrel shape on both ends)
COIL SPRINGS (Single Rate Spring)
(compression)
2 1
NOTE: Read color when spring is upright and stripes
are down.
Type R
(straight on both ends)
(Single Rate Spring)
3
A06F02A
2 1
1. Color code stripes
2. Wire diameter
3. Free length
Type U
(barrel shape on one end with
positioning tab at the other end)
3
2
A00F0PA (Single Rate Spring)
2. Wire diameter
3. Free length
Type S
(barrel shape on one end)
4
(Single Rate Spring) 2 1
2 1
3
A00F12A
3 1. Color code stripes

A00F19A 2. Wire diameter
3. Free length
1. Color code stripes 4. Positioning tab
2. Wire diameter
3. Free length
03-8 MMC2002-001_03A.FM
Type Y Type 4
(barrel shape on both ends with (barrel shape on both ends with
positioning tab at the color code coils end) positioning tab at the color code coils end)
(Single Rate Spring) (Dual Rate Spring)
2 1
4 4
2 1
3
A00F21A

2. Wire diameter
3 3. Free length
A06F2VA
4. Positioning tab
2.
3.
Wire diameter
Free length
TORSION SPRINGS
4. Positioning tab
Type 2
(barrel shape on both ends)
(Dual Rate Spring)
2
2 1
4
3 5
A00F20A
3
1. Color code stripes 6
2. Wire diameter A00F0SB
3. Free length
2. Wire diameter
3. Opening angle (°)
4. Left hand (LH)
5. Right hand (RH)
6. Length
MMC2002-001_03A.FM 03-9
SPRING APPLICATIONS
2001 FRONT SPRINGS 2001
MODEL (P/N) SOFTER SPRING (P/N) STANDARD (P/N) HARDER SPRING
MACH Z 414 956 300 415 075 900 415 039 700
MACH Z TECH PLUS 414 956 300 415 075 900 415 039 700
MX Z STANDARD Not Applicable 505 070 181 Not Applicable
MX Z ADRENALINE Not Applicable 505 070 181 Not Applicable
MX Z TRAIL Not Applicable 505 070 393 Not Applicable
MX Zx Not Applicable 505 070 692 Not Applicable
MX Z 500 F 414 956 300 415 075 900 415 039 700
MX Z 380 F 414 956 300 415 075 900 415 039 700
SUMMIT STANDARD Not Applicable 505 070 020 505 070 305
SUMMIT X Not Applicable 505 070 573 505 070 305
SUMMIT STANDARD HM Not Applicable 505 070 020 505 070 305
SUMMIT X HM Not Applicable 505 070 573 505 070 305
SUMMIT 500 F 414 859 300 505 070 698 414 968 600
03-10 MMC2002-001_03A.FM
2001 CENTER SPRINGS 2001
415 090 500

MACH Z 415 070 400 415 103 600
415 090 600
415 090 500

MACH Z TECH PLUS 415 070 400 415 103 600
415 090 600
MX Z STANDARD 415 070 500 503 189 325 Not Applicable
MX Z ADRENALINE 415 070 500 503 189 325 Not Applicable
MX Z TRAIL 415 070 500 503 189 325 Not Applicable
MX Zx 415 070 500 503 189 325 Not Applicable
MX Z 500 F 414 974 400 415 069 900 414 771 300
MX Z 380 F 414 974 400 415 069 900 414 771 300
SUMMIT STANDARD 415 070 500 503 189 325 Not Applicable
SUMMIT X 415 070 500 503 189 325 Not Applicable
SUMMIT HM
415 070 500 503 189 325 Not Applicable
STANDARD
SUMMIT HM X 415 070 500 503 189 325 Not Applicable
SUMMIT 500 F 414 974 400 503 189 000 414 771 300
MMC2002-001_03A.FM 03-11
2001 REAR SPRINGS 2001
503 189 629 LH 503 189 616 LH 503 189 445 LH

MACH Z
503 189 627 RH 503 189 615 RH 503 189 443 RH
503 189 629 LH 503 189 616 LH 503 189 445 LH

MACH Z TECH PLUS
503 189 627 RH 503 189 615 RH 503 189 443 RH
503 189 629 LH 503 189 445 LH 503 189 524 LH

MX Z STANDARD
503 189 627 RH 503 189 443 RH 503 189 522 RH
503 189 629 LH 503 189 445 LH 503 189 524 LH

MX Z ADRENALINE
503 189 627 RH 503 189 443 RH 503 189 522 RH
503 189 629 LH 503 189 445 LH 503 189 524 LH

MX Z TRAIL
503 189 627 RH 503 189 443 RH 503 189 522 RH
503 189 629 LH 503 189 445 LH 503 189 524 LH

MX Zx
503 189 627 RH 503 189 443 RH 503 189 522 RH
503 189 594 LH 503 189 629 LH 503 189 445 LH

SUMMIT STANDARD
503 189 592 RH 503 189 627 RH 503 189 443 RH
503 189 594 LH 503 189 629 LH 503 189 445 LH

SUMMIT X
503 189 592 RH 503 189 627 RH 503 189 443 RH
503 189 594 LH 503 189 629 LH 503 189 445 LH

SUMMIT HM STANDARD
503 189 592 RH 503 189 627 RH 503 189 443 RH
503 189 594 LH 503 189 629 LH 503 189 445 LH

SUMMIT HM X
503 189 592 RH 503 189 627 RH 503 189 443 RH
503 189 347 LH 503 189 355 LH 503 189 343 LH

SUMMIT 500 F
503 189 346 RH 503 189 354 RH 503 189 342 RH
LH = Left Hand RH = Right Hand
03-12 MMC2002-001_03A.FM
SPRING SPECIFICATIONS
Coil Springs Specifications
SPRING FREE WIRE COLOR
COLOR OF
P/N TYPE RATE LENGTH DIAMETER CODE
SPRING
(lb/in) ± 10 (mm) ± 3 (mm) ± .05 STRIPES
414 771 300 R 135 272.5 8.41 BK/BK SAFARI RED
414 859 300 R 90 239 7.14 BK/WH YELLOW
414 956 300 R 100 265 7.14 PI/WH/BL YELLOW
414 968 600 R 125 235 7.49 RD NEON GREEN
415 039 700 R 150 258 8.71 PI BLACK
415 057 500 R 160 264 8.71 RD/GD BLACK
415 075 900 R 125 262 7.92 BL/RD/BK YELLOW
415 090 500 R 293 45 6.17 YL/BL/YL BLACK
505 070 685 R 125 262 7.92 YL/YL/BK FULL MOON
505 070 698 R 100 239 7.14 WH/BK/BK YELLOW
415 090 600 S 220 210 9.19 RD/BL/YL BLACK
415 069 900 T 115 265 7.49 SI/YL/YL BLACK
415 070 400 T 115 270 8.25 GN/YL/YL BLACK
415 070 500 T 135 242 8.41 BL/YL/YL BLACK
415 103 600 T 135 264 8.25 GN/GN/YL BLACK
503 189 000 T 115 265 7.92 YL/GD/YL BLACK
503 189 325 T 150 242 8.25 YL/SI/YL BLACK
503 189 659 T 180 242 8.71 BL/RD/YL BLACK
503 189 686 T 200 242 9.19 RD/SI/YL BLACK
505 070 305 T 105 250 8.25 RD/OR/BK YELLOW
SILVER
505 070 475 T 90 250 7.77 BK/YL/GN
REFLECTION
505 070 573 Y 90 250 7.77 RD/BL/GN YELLOW
505 070 298 2 70 - 100 340 8.25 BL/PI/BK YELLOW
505 070 393 2 55 - 85 320 7.77 RD/BL/RD YELLOW
505 070 684 2 65 - 95 340 8.25 BK/GD/BK FULL MOON
505 070 686 2 55 - 85 320 7.77 YL/WH/BK FULL MOON
505 070 181 4 55 - 85 320 7.77 PI/BK/BK YELLOW
505 070 692 4 55 - 85 320 7.77 BL/GN/RD YELLOW
706 000 172 R 45 345 6.91 GR/BKRD YELLOW
505 070 941 T 150 315 9.52 RD/SI/BK YELLOW
503 189 999 R 325 189 9.52 GD/SI/YL BLACK
503 189 990 R 275 189 9.19 GD/WH/YL BLACK
SPRING COLOR CODES

BK = BLACK BL = BLUE GD = GOLD GN = GREEN OR = ORANGE PI = PINK RD = RED
SI = SILVER WH = WHITE YL = YELLOW
MMC2002-001_03A.FM 03-13
SPRING FREE WIRE COLOR

COLOR OF
P/N TYPE RATE LENGTH DIAMETER CODE
SPRING
(lb/in) ± 10 (mm) ± 3 (mm) ± .05 STRIPES
503 189 988 U 215 64 6.35 GD/GD/YL BLACK
505 070 852 4 40-85 340 7.49 RD/GR/RD YELLOW
706 000 130 R 45 360 6.91 WH/RD/BK YELLOW
503 189 812 2 125-200 250 8.41 BL/GR/YL BLACK
505 070 762 T 105 300 8.71 GR/GD/BK YELLOW
505 070 760 Y 95 280 8.25 BL/GD/BK YELLOW
505 070 758 2 45-85 320 7.49 RD/GD/BK YELLOW
505 070 576 T 150 300 9.19 RD/BL/WH YELLOW
505 070 575 U 290 45 6.17 RD/BL/GD YELLOW
505 070 572 2 55-85 320 7.77 RD/BL/BL SILVER
706 000 068 R 68 355 7.77 GR/WH/BK YELLOW
505 070 536 T 150 300 9.19 GR/WH/YL BLACK
505 070 534 U 290 45 6.17 BL/WH/YL BLACK
505 070 474 4 55-85 320 7.77 BK/YL/BL SILVER
505 070 473 R 125 260 7.92 BK/YL/RD SILVER
505 070 446 R 100 242 7.14 RD/YL/BK BLUE
505 070 394 R 125 235 7.49 RD/WH/YL BLACK
505 070 391 2 65-95 340 8.25 YL/BK/BK SILVER
505 070 392 2 55-85 320 7.77 RD/GD/YL BLACK
503 189 090 S 220 200 9.19 YL/WH/YL BLACK
505 070 034 4 60-90 325 7.77 BL/GR/BK YELLOW
505 070 302 U 100 265 7.14 OR/PI/BK YELLOW
505 070 300 U 150 260 8.71 GR/PI/BK YELLOW
505 070 233 U 125 260 7.92 PI/BL/BK YELLOW
505 070 153 2 65-95 340 8.25 GR/GR/BK YELLOW
505 070 130 R 75 410 6.17 YL/PI/YL BLACK
505 070 240 T 90 265 7.49 RD/PI/BK YELLOW
706 200 006 V 140 270 8.25 OR/BK/BK YELLOW
505 070 146 T 100 315 8.71 RD/RD/RD YELLOW
505 070 144 T 100 390 8.25 RD/BK/RD YELLOW
505 070 093 T 85 290 7.77 BK/GR/BK RED
505 070 092 2 65-95 340 8.25 BK/YL/BK RED
505 070 091 2 65-95 340 8.25 BK/BL/BK GOLD
505 070 090 R 125 235 7.49 BL/BL/BK COPPER
505 070 089 R 125 260 7.92 GR/BK/BK GOLD
SPRING COLOR CODES

BK = BLACK BL = BLUE GD = GOLD GN = GREEN OR = ORANGE PI = PINK RD = RED
SI = SILVER WH = WHITE YL = YELLOW
Part numbers with a 486 prefix must be ordered from the Valcourt Race Dept.
All others must be ordered from your local Ski-Doo dealer.
03-14 MMC2002-001_03A.FM
Torsion Spring Specification

WIRE DIAMETER OPENING ANGLE LENGTH
P/N COLOR CODE
(mm) ±7 (mm)
486 071 100 RH
10.3 135 400 YL/YL
486 071 200 LH
486 071 300 RH
10.3 150 400 WH/WH
486 071 400 LH
486 078 500 RH
10.0 115 400 YL/RD
486 078 600 LH
503 188 100 RH
11.11 100 400 BL/YL
503 188 200 LH
503 189 080 RH
11.5 100 385 GD
503 189 083 LH
486 093 200 RH
11.5 80 400 GN/YL
486 093 300 LH
503 189 241 RH
11.11 105 400 OR/YL
503 189 242 LH
503 189 327 RH
11.89 100 385 SI
503 189 329 LH
503 189 334 RH
11.11 105 400 YL/GD
503 189 335 LH
486 099 100 RH
11.89 140 385 YL/RD/YL
486 099 300 LH
503 189 881 RH
11.11 75 385 YL/BL
503 189 883 LH
503 189 898 RH
11.5 90 385 GD/GD/GD
503 189 900 LH
503 189 902 RH
10.6 80 385 RD/RD/YL
503 189 904 LH
503 189 947 RH
10.3 75 385 GN/YL/YL
503 189 948 LH
503 189 992 RH
11.11 73 385 GN/RD/YL
503 189 994 LH
503 189 338 RH
11.11 90 400 GN/GN
503 189 339 LH
503 189 342 RH
10.6 80 400 RD/RD/RD
503 189 343 LH
503 189 346 RH
10.3 85 400 YL/YL/YL
503 189 347 LH
503 189 350 RH
11.5 100 385 GD/GD
503 189 351 LH
MMC2002-001_03A.FM 03-15
WIRE DIAMETER OPENING ANGLE LENGTH

P/N COLOR CODE
(mm) ±7 (mm)
503 189 354 RH
10.6 90 400 WH/WH/WH
503 189 355 LH
503 189 358 RH
11.11 80 400 BL/BL
503 189 359 LH
503 189 443 RH
11.11 95 385 GN/GN/GN
503 189 445 LH
503 189 522 RH
11.11 90 385 GN/GN/YL
503 189 524 LH
503 189 592 RH
10.3 85 385 GD/RD
503 189 594 LH
503 189 615 RH
11.11 100 385 RD/YL
503 189 616 LH
503 189 627 RH
10.6 90 385 YL/WH
503 189 629 LH
503 189 674 RH
11.11 80 385 GD/YL/YL
503 189 675 LH
503 189 681 RH
11.9 80 385 SI/SI
503 189 683 LH
Part numbers with a 486 prefix must be ordered from the Valcourt Race Dept.
All others must be ordered from your local Ski-Doo dealer.
CORNERING DYNAMICS Roll can be reduced by installing stiff springs on

the front suspension and/or a lot of preload, but
The ideal situation, while going through a turn, is this will cause a harsher ride than necessary. Low-
to keep the snowmobile as flat as possible without ering the center of gravity will also reduce roll but
the skis or track losing contact with the driving sur- there are practical limits as to how low the center
face. of gravity can go. Most vehicles are equipped with
As you enter a corner and turn the skis, the rest of an antiroll bar or stabilizer bar. Common terminol-
the vehicle will want to continue straight ahead. If ogy will refer to it as a sway bar. (It is inaffect an
the skis do not bite the surface, they will start slip- anti-sway bar) The bar is mounted to and pivots
ping and the vehicle will not turn as tight as the on the chassis. The ends of the bar have lever
skis are turned. This is called understeering or arms from 3” to 7” in length. The ends of the le-
pushing. If the skis bite very well and the track vers are connected to the front suspension. As the
starts sliding out, then the vehicle is oversteering outside suspension is compressed during a cor-
or is said to be loose. If the ski and track traction ner, the bar is twisted and forces the inside spring
is balanced, then the vehicle will maintain a good to compress also. The bar is “borrowing” spring
line though the corner. Because the center of grav- pressure from the inside spring and adding it to
ity of the vehicle wants to continue straight ahead the outside spring. The suspension can now resist
and because the center of gravity is above ground more chassis roll (see following illustration).
level, weight will be transferred to the outside of
the vehicle. This causes the machine to roll to the
outside. As the radius of the corner gets tighter
and/or speeds increase, the machine rolls more,
and more weight is transferred to the outside of
the vehicle until the front or back loses traction or
the vehicle tips over.
03-16 MMC2002-001_03A.FM
1 2 3 4
5
1
2
A00F0NA
END LEVER
1. Sway bar
4 2. Stiffer
3. Softer
4. Softest
3
A06F1LA Unlike other models the MX Z and ZX A.D.S.A.
suspension use a non adjustable sway bar. In or-
1. Sway bar
2. End lever der to change the roll stiffness the diameter of the
3. Cornering force sway bar must be changed.
4. Connector linkage
5. Pivot bushings
Anti-Roll Bar Options
By having a sway bar in the suspension, softer
springs can be used to achieve a good ride be- DIAMETER SKI
cause the bar will help control roll in a corner. The P/N MODEL
MM STANCE
bar has no affect on ride when traveling straight
ahead over bumps that are even from side to side. 486 094 300 15.8 41 MX Z
However, if only one ski encounters a bump, then 486 094 400 18 41 MX Z
the bar will transfer energy between the springs.
This leads to another design decision. The diame- 505 070 309 14 41 MX Z
ter of the sway bar determines how much spring 505 070 282 14.3 37 Summit
pressure will be borrowed from the opposite
spring. A smaller bar will twist more and not trans- 506 131 800 17.5 42.5 MX Z
fer as much energy. A larger diameter bar will
transfer more energy which will reduce chassis 505 070 563 15.8 42.5 MX Z
roll, but will produce a harsher ride on uneven, 505 070 490 12.7 42.5 MX Z
bumpy terrain. A smaller diameter bar will give a
more compliant ride on the nasty bumps but it will 506 134 300 12.7 41 Mach
allow the chassis to roll more in corners. A cross 486 073 600 15.9 41 Mach
country sled will use small to medium diameter
bars while oval and lemans racers will use large 486 073 800 19.1 41 Mach
diameter bars.
486 074 000 25.4 41 Mach
The length of the lever arm also affects the stiff-
ness of the sway bar. A shorter lever will stiffen Part numbers with a 486 prefix must be ordered from
the bar and a longer lever will soften the bar. Many the Valcourt Race Dept.
lever arms will have 2 holes to mount the connec- All others must be ordered from your local Ski-Doo
tor linkage. The hole closest to the bar will act stiff- dealer.
er (see following illustration).
MMC2002-001_03A.FM 03-17
When changing the sway bar diameter you must At low piston speeds, the number of bleed slits
also change the ball joint blocks and bushings. will have a fairly large effect on dampening, but as
For snowcross racing some racers prefer to dis- piston speeds increase most of the dampening is
connect the sway bar. This will let the front sus- controlled by the shim stack. This is because the
pension act more independently, as the suspen- flow area of the slits is much smaller than the flow
sion is no longer coupled. area under the shims. Since only a small amount
of oil can flow through the bleed slits (compared
Another little known fact that has a large affect on to the amount that flows under the shim stack),
roll is the limiter strap length. As mentioned earli- the slits have only a very small effect on dampen-
er, if the limiter is lengthened, the front suspen- ing at high piston speeds. Because of this charac-
sion will extend during acceleration, which reduc- teristic, bleed slits are most effective on rebound
es ski pressure. If this vehicle was in a corner dampening. They will have only a very slight effect
when power was applied, it would have quite a bit on compression damping because the typical pis-
of chassis roll and the inside ski will start to lift off ton speeds on compression strokes are several
of the ground. Shortening the limiter will have a times faster than on rebound strokes. There really
very large affect on controlling roll. A general is no such thing as high speed rebound dampen-
guideline for initially setting limiter length for good ing.
ski pressure and reducing roll is to have the front
and back of the track touch the ground at the same EFFECT OF BLEED SLITS
time when you set the back of the vehicle down. No
bleeds
If the front of the track touches much sooner than Rebound 2 bleeds
the rear, there will be quite a lot of weight transfer 4 bleeds
and chassis roll during hard cornering. A quick ad- 6 bleeds
just limiter assembly, (P/N 486 095 600 SC-10 II
and P/N 486 095 700 SC-10) is available for models Dampening
equipped with the SC-10 and SC-10 II rear suspen- force
sion. If the adjuster nut is all the way tight and you
need more ski pressure, install a shorter limiter
strap.
0
SHOCKS 0 Piston speed
No
Valving and Dampening Compression bleeds
2 bleeds
In the HPG shock, the piston passages are cov- 4 bleeds
ered by a stack of thin metal shims of various 6 bleeds
thicknesses and diameters. The shims provide
dampening by acting as spring loaded valves offer- Dampening
ing resistance to the oil traveling through the pis- force
ton. There is a stack of shims on both sides of the
piston. One side controls compression dampen-
ing and the other side controls rebound dampen-
ing. By varying the number and thickness of shims 0
the dampening characteristics can be very accu- 0
A01F26A Piston speed
rately obtained. There may also be orifices or slits
in the piston that are not covered by the shims.
These are referred to as bleed slits. The size and
number of these slits will also affect dampening.
The external adjustment on the MVA, HPG shocks
is a variable bleed hole.
Rebound dampening will usually be much stiffer
than compression dampening. This is because re-
bound dampening must resist the force of the
spring and because piston speeds are much slow-
er during rebound.
03-18 MMC2002-001_03A.FM
As mentioned earlier, the configuration of the shim stack will control most of the dampening of the shock.
There are several methods to tuning shim stacks. The first and most commonly used is to increase or
decrease the overall stiffness of the stack. This can be done by changing the number of large shims or
by increasing or decreasing their thickness.
STIFFER SOFTER
Qty. Dia. (mm) Tickness Qty. Dia. (mm) Tickness

10 x 30 x .203 3 x 30 x .203
1 x 18 x .203 1 x 18 x .203
1 x 18 x .203 1 x 18 x .203
1 x 16 x .203 1 x 16 x .203
1 x 15 x .203 1 x 15 x .203
TOP OUT WASHER TOP OUT WASHER

A99F05S
The overall stiffness of the stack has been in- (mm)

creased by adding 7-30 mm × .203 mm shims. 5 × .152 = 12 × .114
This will result in firmer dampening at both low 10 × .152 = 24 × .114
and high piston speeds. Thicker shims will also re- 10 × .203 = 23 × .152
sult in firmer dampening but it is better to use 1 × .254 = 2 × .203
more thin shims than fewer thick shims. More thin 2 × .254 = 4 × .203
shims will provide better, smoother dampening 3 × .254 = 6 × .203
than a few thick shims. There is an equivalency 4 × .254 = 8 × .203
between thick and thin shims, though. The follow- 5 × .254 = 10 × .203
ing chart indicates how many thin shims are re- 6 × .254 = 12 × .203
quired to equal the stiffness of one thick shim. 7 × .254 = 14 × .203
(mm) 8 × .254 = 16 × .203
1 × .152 = 2.4 × .114 9 × .254 = 18 × .203
1 × .203 = 2.3 × .152 1 x .305 = 2 x .254
1 × .254 = 2.0 × .203 2 x .305 = 3 x .254
3 x .305 = 5 x .254
This means it will take 2.4 × .114 mm shims to 4 x .305 = 7 x .254
have the same dampening as 1 × .152 mm shim. 5 x .305 = 9 x .254
Obviously you can’t use a fraction of a shim so you 6 x .305 = 10 x .254
must find the lowest common denominator. For
2.4 it will be 5. For 2.3 it will be 10. The following The diameter of the smaller shims that support the
chart shows the most common possibilities. large shims will also affect the dampening. A larg-
er support shim gives more support to the large
shim thus making it act stiffer. Conversely, a small-
er diameter support shim will allow the large shim
to bend more easily thus softening the dampen-
ing. The following graph shows the effect of dif-
ferent diameter support washers.
MMC2002-001_03A.FM 03-19
Shim Comparator Formula

STIFFER
Thickness³ or cubed.
Example: .152 x .152 x .152
COMPRESSION
Qty. Dia. (mm) Tickness
16 mm
diameter 3 x 30 x .203
15 mm
diameter
Dampening 1 x 18 x .203
force 12 mm
diameter
SOFTER
VALVE STOPPER
0
0 PISTON SPEED
Qty. Dia. (mm) Tickness
3 x 30 x .203
REBOUND 16 mm
diameter
15 mm 1 x 18 x .203
diameter 1 x 18 x .203
1 x 16 x .203
Dampening 1 x 15 x .203
force 12 mm VALVE STOPPER
diameter
A99F06A
The large shims are only able to deflect .203 mm

0 instead of .610 mm thus reducing the flow area of
A01F27A 0 PISTON SPEED the piston. This will result in the same low speed
dampening, but the medium and high speed
Another method of changing dampening is by con- damping will be increased. The following graph
trolling the amount of space the stack has to open. represents the effect of changing the total thick-
This is done by reducing the amount of smaller ness of small shims which determine the amount
shims which support the larger shims. The larger of large shim deflection.
shims act the same until they bottom out against
the valve stopper. .114 mm
.228 mm
Dampening .342 mm
force
Large shims
do not touch
valve stopper
0
0
A01F1YA Piston speed
03-20 MMC2002-001_03A.FM
As you can see, low speed dampening remains – Bleed slit quantity will affect low speed damp-
the same until the shim stack bottoms out against ening.
the valve stopper. Then the dampening becomes – Under dampening may be due to an aerated
significantly stiffer. This is sometimes referred to shock due to low gas pressure and/or old, used
as progressive dampening. Another similar way to oil. Change the oil and recharge the gas pres-
achieve this type of dampening is to use multiple sure to 300 PSI before altering the shock valv-
stacks of large and small shims. ing.
– If the vehicle bounces or pogos a lot, the prob-
1 lem may be too little compression dampening
NOT too little rebound dampening. Do not use
too much rebound dampening! Excessive re-
bound dampening is a common error. Over-
dampening will not allow the suspension to re-
cycle to full extension after an obstacle com-
presses the suspension. This situation (called
packing) will eventually bottom the suspension
and not allow it to cycle properly.
– For faster weight transfer under acceleration
and deceleration, use a piston with more bleed
VALVE STOPPER slits.
A06F1TA
Special Tools
1. Piston Special tools specific to the HPG T/A shock will be
The first stack of large shims will deflect very eas- the seal pilot (P/N 529 026 500) and piston guide
ily thus giving soft low speed dampening. The (P/N 529 026 600) from Bombardier. Excludes C-46
number of small shims will determine when the shock.
first stack hits the second stack of large shims.
Now both stacks are acting together thus stiffen-
ing the dampening. This can be repeated several
times until the complete stack of large shims bot- 529 026 500
toms out against the valve stopper.
As you can see, there are an unlimited number of
valving combinations and many different versions
will achieve very similar results. The following
general guidelines should help reduce your tuning
time. 529 026 600
– If the dampening is close to what you want, just
add or remove 1 or 2 large shims, from the ap-
propriate side, to fine tune the overall stiffness.
NOTE: Always use 30 mm diameter shims against A06F0OA
the piston for compression dampening and 26 mm

diameter shims against the piston for rebound NOTE: Do not attempt to rebuild the T/A damper
dampening. Excludes C-46 shock. without the benefit of these assembly tools, dam-
age will occur without their use.
– Generally, rebound dampening should not be
changed unless a large change in spring rate is
made.
MMC2002-001_03A.FM 03-21
Shock Oil and Nitrogen NOTE: When rebuilding a gas emulsion shock,
such as the center MX Z, mount the shock verti-
32 oz cally in a vice with the schrader valve up and let it
sit for 5 minutes before releasing the gas. This 5
minute period will allow most of the gas to sepa-
rate from the oil and minimize oil spray.
 WARNING
Nitrogen gas is under extreme pressure. Use
caution when releasing this gas volume. Pro-
tective eye wear should be used.
413 711 806 1 2

A06F0PC
A06F18B
1. Schrader valve 1.5-2 N•m (13-17 lbf•in)

2. Schrader cap 5-6.5 N•m (44-57 lbf•in)
3
4 NOTE: Before unscrewing pre-load rings, mea-
sure the compressed length of the installed spring
and mark position for reinstallation. For factory ad-
justment refer to the end of this section.
Use tools (P/N 861 743 900) to remove damper
spring by unthreading spring pre-load rings, then
removing spring retainer or use the spring removal
A06F0QA tool (P/N 529 035 504).
1. Automotive type air pressure hose
2. 2 stage regulator, delivery pressure range 2070 kPa (300 PSI)
3. High pressure cylinder filled with industrial grade nitrogen
4. Valve tip (P/N 529 035 570)
NOTE: Commercially available through compressed

gas dealers.
Disassembly and Assembly
Release N2 (nitrogen) pressure from the damper
A06F0TA
Schrader valve on any HPG T/A with IFP.
TYPICAL
03-22 MMC2002-001_03A.FM
Holding damper assembly in bench vise with alumi-

num jaw protectors, unthread seal assembly from
damper body using a 32 mm (1.25 in) spanner
wrench. This assembly uses a right hand thread.
A27F06A
TYPICAL
 WARNING
Whenever using compressed air, use an
A27F04A
O.S.H.A. approved air gun and wear protec-
tive eye wear.
With the seal assembly removed, slowly lift and
Thoroughly clean, with a typical cleaning solution,
remove damper rod assembly from the damper
and blow dry using low pressure air. Carefully in-
body.
spect the damper body for any imperfections or
NOTE: Remove damper rod assembly slowly to re- signs of wear in the damper bore.
duce oil spillage and prevent piston seal damage by
Replace damper body if wear is identified.
damper body threads. Wrap the damper body with a
shop cloth to capture possible overflow oil while re- Holding the damper rod assembly in a bench vise,
moving the damper piston. begin piston and valve removal.
A27F0AA
1. Oil flows
Discard old oil into storage container. Never reuse

damper oil during shock rebuild.
Remove Schrader valve core. Using compressed
A06F0UA
air pressure, carefully remove floating piston from
damper body. Hold shop cloth over damper body A. Remove damper nut
opening to catch released floating piston. Allow
room for floating piston to leave damper body.
MMC2002-001_03A.FM 03-23
Always arrange parts removed in the sequence of

disassembly.
A06F0WC
MAXIMUM DEFLECTION 0.025 mm (.001 in)
After the new or replacement shim pack has been

selected, reassemble in the reverse order of dis-
assembly. Torque piston nut 11-13 N•m (96-108
Ibf•in). Use 271 Loctite.
A06F0VA
2
3
NOTE: As a general rule we suggest replacing the
damper rod lock-nut after 4 rebuilds to ensure
good Iocking friction and use Loctite 271 each
time. 4
NOTE: If revalving is to be done, it is imperative

that you identify the original shim pack (size and
number of shims). The seal carrier need not be
removed if only revalving is to be done.
Shims can be measured by using a vernier caliper A06F0XA
or a micrometer.
1. Damper nut
NOTE: All shims should be carefully inspected 2. Spacer
and any bent or broken shims must be replaced 3. Washer
4. Shim pack
for the shock to function properly.
The damper rod is constructed of a plated shaft CAUTION: The damper rod nut can only be re-
design. This damper shaft must be inspected for used 4 times, then, must be replaced. Do not
any visible wear on the surface of the damper rod. substitute this part for non – O.E.M. use Loctite
271 on nut each time.
Another check that must be completed if damper
seal leakage has been noticed, is damper rod run- This spacer washer(s) (P/N 414 888 309) must be
out. This damper rod run out must not exceed used as shown to ensure damper rod nut does not
025 mm (.001 in). bottom out or contact shaft threads.
Rebound valve stopper with round edge facing
shim stack.
03-24 MMC2002-001_03A.FM
NOTE: Rebound shim stack must not reach into Compression

threads of damper shaft. Washer under damper Whenever tuning for more compression dampen-
shaft nut is used to prevent damper shaft nut from ing always use 30 mm (1.18 in) shims against pis-
bottoming on threads. ton to properly close piston orifice holes. Two thin
shims will offer more control than one thick shim
of the equal thickness.
NOTE: When tuning for less dampening it is im-
1 portant to remember, never use less than 3 shims
against piston. This will guard against fatigue
breakage.
2
Fewer spacer shims will result in more high speed
dampening. A minimum of 0-114 mm (.0045 in)
3 clearance should be allowed between shim stack
and compression valve stopper. Use at least one
4 shim of 12 × .114.
If the seal carrier assembly is replaced, use seal
pilot (P/N 529 026 500) to guide seal over damper
5
shaft. Lubricate seal carrier guide pilot before use.
6 CAUTION: Failure to use seal pilot will result in
A06F0YA
seal damage.
1. Rebound dampening shim pack Reassemble damper rod assembly, taking care to
2. Rebound dampening shim pack
3. Piston properly assemble shim packs as required for your
4. Compression dampening shim dampening needs Ensure that the shaft piston is
5. Compression dampening shim pack
6. Stopper installed with the slits/larger intake holes facing
the rebound shim stack.
Rebound
A minimum of 0.203 mm (.008 in) clearance must
be allowed between shim stack and rebound valve
stopper. Use at least one shim of 12 × .203 mm.
Whenever tuning for more rebound damping al-
ways use 26 mm (1.02 in) shims against piston to
properly close piston orifice holes. More thin
shims will offer more control than a few thick
shims of the same overall thickness. 1
NOTE: When tuning for less dampening it is im-
portant to remember, never use less than 3-26 mm
(1.02 in) shims against piston. This will guard
against fatigue breakage.
Piston options include 5 pistons; 0, 1, 2, 4 and 6 A06F12C
slits for rebound dampening bleeds.
1. Pilot (P/N 529 026 900)
MMC2002-001_03A.FM 03-25
NOTE: Lubricate inside of piston guide with mo-

1 lykote GN paste (P/N 413 703 700) or MS4 silicone
2 grease (P/N 420 897 061).
3 Install floating piston to the proper depth.
4 On all HPG take apart shocks from 1996 on. The
7
floating piston is installed hollow side up.
6
A06F13A
1. Damper nut torque 11-13 N•m (96-108 lbf•in) use Loctite 271
2. Rebound shim pack
3. Piston
4. Compression shim pack
5. O-ring visual inspection seal carrier assembly
6. Damper rod
7. Optional travel restriction spacer kit (P/N 861 744 200)
Kit includes:
2 x 26 mm long spacer A27F0FC
1 x 48 mm long spacer Required distance for floating piston installation.

2 x 60 mm long spacer NOTE: If the floating piston is installed too far into
Reinstall floating piston into damper body (ensure the damper body, light air pressure through
that Schrader valve core has been removed). Use Schrader valve (with core removed) will move pis-
molybdenum disulfide grease (example: molykote ton outward.
paste (P/N 413 703 700) or silicone grease Dow NOTE: Reinstall Schrader valve core after IFP has
Corning MS4 (P/N 420 897 061) to ease O-ring been installed at correct height and before adding
past damper body threads with floating piston pi- oil.
lot (P/N 529 026 600).
CAUTION: Failure to install IFP correctly could  WARNING
result in shock damage. Whenever using compressed air exercise ex-
treme caution, cover damper opening with
1 shop cloth to reduce chance of possible injury.
CAUTION: Moisture laden compressed air will

contaminate the gas chamber and rust floating
piston.
2  WARNING
A06F14C
Always wear protective eye wear whenever
1. Push (slowly) by hand using compressed air.
2. Floating piston guide (P/N 529 026 600)
03-26 MMC2002-001_03A.FM
Fill the shock with Bombardier HPG shock oil (P/N CAUTION: Use care when passing piston into
413 711 806) to approximately 10 mm (.393 in), damper body at damper body threads.
from the base of seal carrier threads. Slight oscillation of damper rod may be required to
allow piston to enter damper body bore.
Slowly push piston into damper body. Slight up and
1 down movement may be required to allow all air to
pass through piston assembly. The gentle tapping
of a small wrench, on the shock eye, may help
dislodge air trapped in the submersed piston. Be
careful not to drive the shaft any deeper into the
oil than is necessary to just cover the shim stack.
NOTE: Fast installation of the damper rod may dis-
place the floating piston from its original position.
This must not occur if the damper is expected to
perform as designed.
With damper rod piston into-oil, TOP OFF damper
A06F15B oil volume. Oil level should be to damper body
1. Fill to 10 mm (.393 in)
thread base.
Seal carrier assembly can now be threaded into
NOTE: Although we do not measure the exact damper body. This should be done slowly to allow
amount of oil added to the damper, approximately weapage of oil and to minimize IFP displacement.
106 mL (3.58 oz U.S.) will be used. After the seal carrier is fully in place avoid pushing
Carefully insert damper rod into the damper body. the shaft into the body until the nitrogen charge is
Install damper rod assembly into the damper body. added.
Lightly oil damper piston seal ring with shock oil
to ease installation.
A06F16A A06F17A
NOTE: Some shock oil will overflow when install- 1. Torque seal carrier to 88-89 N•m (64-72 lbf•ft)
ing damper. Wrap damper with shop cloth to catch
possible overflow oil.
MMC2002-001_03A.FM 03-27
Damper gas pressure cannot be confirmed by us-

1 2 ing a pressure gauge. The volume of gas in the
shock is very small, and the amount lost during
gauge installation will lower the pressure too
much and require refilling.
After recharging is complete and before installing
the spring the rebuilt shock should be bench-tested.
Stroke the shock to ensure full travel and smooth
compression and rebound action. If the shaft
moves in or out erratically this could indicate too
much air is trapped inside. If the shaft will not
move or has partial travel then it may be hydrauli-
A06F18B
cally locked. In either event the shock must be re-
1. Schrader valve 1.5-2 N•m (13-17 lbf•in) built again. Pay particular attention to the placement
2. Schrader cap 5-6.5 N•m (44-57 lbf•in) of the IFP, quantity of oil and shim stack/piston as-
Adding Gas Pressure sembly.
Nitrogen (N2) can now be added to damper body. 2
NOTE: Never substitute another gas for nitrogen.
Nitrogen has been selected for its inert qualities
and will not contaminate the gas chamber of the
shock. 1
Preset your pressure regulator to 2070 kPa (300

PSI) nitrogen (N2), this gas pressure will restore
the correct pressure for your damper.
CAUTION: Do not exceed the recommended
pressure values.
When removing and retightening the Schrader 3
valve acorn nut use minimal torque. When the cap 4
is over tightened and subsequently removed it
may prematurely break the seal of the Schrader
valve to the shock body and cause a loss of nitro-
gen charge without being noticed. If you suspect
this has happened then recharge the shock as a
precaution. Inspect the acorn cap before installa-
tion to ensure that the internal rubber gasket is in A06F0QA
its proper position.
1. Automotive type air pressure hose
 WARNING
2. 2 stage regulator, delivery pressure range 2070 kPa (300 PSI)
3. High pressure cylinder filled with industrial grade nitrogen
4. Valve tip (P/N 529 035 570)
Whenever working with high pressure gas,
use eye wear protection. Never direct gas Reinstall damper spring retainer, then your spring.
pressure toward anybody. Next, thread the spring pre-load rings up to the
spring. Set pre-load according to recommended
NOTE: Carefully inspect damper for gas or oil spring length specifications. Your damper is now
leaks. Any leaks must be corrected before con- ready for reinstallation to your snowmobile.
tinuing.
03-28 MMC2002-001_03A.FM
HPG T/A Shock Spare Parts C-46 Shock Spare Parts

SHIMS REAR SHOCK SHIMS
MOQ MOQ
P/N SIZE (mm) (minimum P/N SIZE (mm) (minimum
order quantity) order quantity)
415 039 100 30 × .254 5 503 189 011 22 × .114 5
414 888 318 30 × .203 15 503 189 012 22 × .152 5
414 888 319 30 × .152 1 503 189 013 22 × .203 5
414 888 320 28 × .203 5 503 189 014 22 × .254 5
414 888 321 28 × .152 5 503 189 015 22 × .305 5
415 039 000 26 × .254 5 503 189 016 24 × .114 5
414 888 322 26 × .203 5 503 189 017 24 × .152 5
414 888 323 26 × .152 50 503 189 018 24 × .203 5
414 888 324 22 × .203 5 503 189 019 24 × .254 5
414 888 325 22 × .152 5 503 189 020 24 × .305 5
414 888 326 20 × .203 5 503 189 021 26 × .114 5
414 888 327 20 × .152 5 503 189 022 26 × .152 5
414 888 328 20 × .144 5 503 189 023 26 × .203 5
414 888 329 18 × .203 5 503 189 024 26 × .254 5
414 888 330 18 × .152 5 503 189 025 26 × .305 5
414 888 331 16 × .254 10 503 189 026 28 × .114 5
503 189 027 28 × .152 5
414 888 332 16 × .203 10
503 189 028 28 × .203 5
414 888 333 16 × .152 10
503 189 029 28 × .254 5
415 038 900 16 × .114 10
503 189 030 28 × .305 5
414 888 334 15 × .254 10
503 189 031 30 × .114 5
414 888 335 15 × .203 10
503 189 032 30 × .152 5
414 888 336 15 × .152 10
503 189 033 30 × .203 5
414 888 337 15 × .114 10
503 189 034 30 × .254 5
414 888 338 12 × .203 10
503 189 035 30 × .305 5
414 888 339 12 × .152 10
503 189 036 36 × .152 5
415 038 800 12 × .114 10
503 189 037 36 × .203 5
414 888 340 21 × .114 10
503 189 038 36 × .254 5
414 888 341 24 × .114 10
503 189 039 40 x 114 5
503 189 040 40 x 203 5
PISTONS
503 189 041 40 x 254 5
MOQ
P/N SIZE (minimum PISTONS
order quantity) MOQ
414 888 304 0 slit 1 P/N SIZE (minimum
414 888 305 2 slits 2 order quantity)
414 888 306 4 slits 1 503 189 004 0.0 1
414 888 307 6 slits 1 503 189 003 1.2 1
1 slit 503 189 002 1.7 1
503 189 001 2.0 1
MMC2002-001_03A.FM 03-29
Shock Parts
2002 MX Zx 440
BOMBARDIER BOMBARDIER
DESCRIPTION DESCRIPTION
P/N P/N
REAR SHOCK (503 189 780) PARTS CALIBRATION PARTS
503 190 036 hose clamp 503 190 051 reservoir circlip
503 190 037 reservoir 503 190 052 monotube screw
503 190 038 rod assembly with upper mount 503 190 053 O-ring for monotube screw
503 190 039 cylinder head assembly 9/16 503 190 054 monotube screw
503 190 040 floating piston assembly 503 190 055 monotube screw
503 190 041 valve end cap sub-assembly 503 190 056 pressure valve assembly
503 190 042 rod spacer 503 190 057 pressure valve assembly
CENTER SHOCK (503 189 779) PARTS 503 190 058 thin colllar stover nut
rod assembly with upper mount 503 190 059 monotube washer
503 190 104 assembly and bumper and ice-
scraper 503 190 060 monotube washer
503 190 043 cylinder head assembly 503 190 061 .700 x .004 deflection disc
503 190 044 SS braided hose 503 190 062 .700 x .006 deflection disc
503 190 045 male elbow 503 190 063 .700 x .008 deflection disc
503 190 046 45 straight thread elbow 503 190 064 .700 x .010 deflection disc
503 189 998 spring retainer nut 503 190 065 .700 x .012 deflection disc
503 190 047 floating piston sub assembly 503 190 066 .700 x .015 deflection disc
503 190 048 reservoir end cap assembly 503 190 067 .800 x .004 deflection disc
503 190 049 reservoir top cap assembly 503 190 068 .800 x .006 deflection disc
503 190 050 reservoir cylinder 503 190 069 .800 x .008 deflection disc
503 190 070 .800 x .010 deflection disc
03-30 MMC2002-001_03A.FM
2002 MX Zx 440
BOMBARDIER BOMBARDIER
DESCRIPTION DESCRIPTION
P/N P/N
CALIBRATION PARTS 503 190 090 1.25 x .008 deflection disc
503 190 078 .900 x .015 deflection disc 503 190 091 1.25 x .010 deflection disc
503 190 079 1.00 x .006 deflection disc 503 190 092 1.25 x .012 deflection disc
503 190 086 1.10 x .010 deflection disc 503 190 099 monotube piston (blank)
503 190 087 1.10 x .012 deflection disc 503 190 100 monotube piston (.063)
503 190 088 1.10 x .015 deflection disc 503 190 101 monotube piston (.075)
503 190 089 1.25 x .006 deflection disc 503 190 102 gas fill tool kit
503 190 103 shock oil (blue)
MX Z STD/ADRENALINE MX Zx PACK SUMMIT X

rebound compression rebound compression rebound compression
4 x 26 x .152 4 x 30 x .152 4 x 26 x.152 4 x 30 x .152 2 x 26 x.152 1 x 30 x .254
1 x 12 x .114 1 x 15 x .114 1 x 12 x.114 1 x 15 x .114 1 x 12 x .114 1 x 12 x .114
2 x 26 x .152 3 x 30 x .152 2 x 26 x .152 3 x 30 x .152 2 x 26 x .152 2 x 30 x .152
Front 1 x 12 x .203 3 x 15 x .203 1 x 12 x 203 3 x 15 x .203 1 x 12 x .203 3 x 15 x .203
Piston = 2 slits Piston = 2 slits Piston = 2 slits
IFP = 186 mm IFP = 44.5 mm IFP = 176 mm
Shock part # 503 070 876
Shock part # 505 070 733 Shock part # 503 070 753
Shock part # 503 070 878
rebound compression rebound compression rebound compression
4 x 26 x .203 4 x 30 x .203 4 x 26 x .203 4 x 30 x .203 4 x 26 x .203 6 x 30 x .152
Center 1 x 12 x .254 1 x 15 x .114 1 x 12 x .254 1 x 15 x .114 1 x 12 x .254 1 x 12 x .114
Piston = 2 slits 2 x 30 x .203 Piston = 2 slits 2 x 30 x .203 Piston = 6 slits 6 x 30 x .152
IFP = 132 mm 3 x 15 x .203 IFP = 128 mm 3 x 15 x .203 IFP = 134 mm 3 x 12 x .203
Shock part # 503 819 877 Shock part # 503 189 768 Shock part # 503 819 891
rebound compression rebound comression rebound compression
10 x 26 x .203 5 x 30 x .203 7 x 36 x .203 6 x 40 x .125 11 x 26 x .203 2 x 30 x .152
1 x 12 x .203 1 x 12 x .114 1 x 20 x .305 1 x 24 x .114 2 x 12 x .203 1 x 12 x .114
Rear Piston = 2 slits 4 x 30 x .203 Piston = 1.7 orifice 3 x 40 x .152 Piston = 4 slits 4 x 30 x .152
3 x 12 x .203 4 x 24 x .203 2 x 12 x .203
IFP = 189 mm IFP = 188 mm IFP = 187 mm
Shock part # 503 819 879 Shock part # 503 189 801 Shock part # 503 819 895
IFP: Internal Floating Piston
MMC2002-001_03A.FM 03-31
2002 MX Zx 440 Shock Calibration
FRONT CENTER REAR
COMPRESSION 30 x .152 x 6 1.250 x .015 .900 x .006
18 x .152 x 1 1.100 x .015 1.300 x .015
30 x .203 x 4 .800 x .004 1.300 x .015
24 x .114 x 1 1.300 x .015
20 x .114 x 1 1.300 x .015
16 x .114 x 1 .063 Piston Orifice .076 Piston Orifice
REBOUND 26 x .152 x 6 1.100 x .008 1.100 x .010
15 x .203 x 1 .700 x .010 .700 x .006
Piston 1 slit
IFP 43.5 mm IFP 48.3 mm IFP 94 mm
BASE VALVE 4 slit washer
18 x .152 x 3
11 x .305 x 1
03-32 MMC2002-001_03A.FM
Shock Calibration
MODEL FRONT/SKI SHOCK CENTER SHOCK REAR SHOCK
2001 MX Zx 440 racing
— Compression 3 x 30 x .152 5 x 30 x .203 4 x 40 x .203
1 x 18 x .152 1 x 21 x .152 1 x 24 x .203
5 x 30 x .203 5 x 30 x .254 5 x 40 x .254
1 x 24 x .114 1 x 26 x .114 2 x 36 x .254
1 x 20 x .114 1 x 24 x .114 1 x 26 x .114
1 x 18 x .114 1 x 21 x .114 1 x 30 x .254
— Rebound 8 x 26 x .152 1 x 26 x .152 9 x 36 x .254
1 x 15 x .203 1 x 21 x .114 1 x 24 x .203
Piston - 3 slits 7 x 26 x .254 Piston - 2.0
IFP 44.5 mm 1 x 15 x .152 IFP 190 mm
Piston - 4 slits
IFP 130 mm
2001 MX Z std/adrenaline
— Compression 4 x 30 x .152 6x 30 x .203 4 x 30 x .203
1x 15 x .114 2 x 15 x .203 1 x 15 x .114
3 x 30 x .152 3 x 30 x .203
3 x 15 x .203 3 x 15 x .203
— Rebound 2 x 26 x .152 6 x 26 x .203 10 x 26 x .203
1 x 12 x .114 1 x 12 x .254 1 x 12 x .254
2 x 26 x .152 Piston - 2 slits Piston - 2 slits
1 x 12 x .203 IFP 130 mm IFP 183 mm
Piston - 2 slits
IFP 172 mm
2001 MX Z (X packages)
1 x 15 x .114 1 x 15 x .152 1 x 24 x .203
3 x 30 x .152 4 x 30 x .152 3 x 40 x .152
3 x 15 x .203 3 x 15 x .203 2 x 24 x .203
— Rebound 2 x 26 x .152 4 x 26 x .203 9 x 36 x .203
1 x 12 x .114 1 x 12 x .203 1 x 24 x .203
Piston - 2 slits IFP 130 mm IFP 190 mm
IFP 44.5 mm
2001 SUMMIT (X packages)
1 x 12 x .114 1 x 12 x .114 3 x 12 x .203
1 x 30 x .203 4 x 30 x .152
3 x 15 x .203 3 x 12 x .203
— Rebound 2 x 26 x .152 4 x 26 x .203 11 x 26 x .203
1 x 12 x .114 1 x 12 x .254 2 x 12 x .203
Piston - 2 slits IFP 130 mm IFP 183 mm
IFP 157 mm
MMC2002-001_03A.FM 03-33
MODEL FRONT/SKI SHOCK CENTER SHOCK REAR SHOCK

2000 MX Zx
1 x 16 x .152 1 x 19 x .152 1 x 24 x .203
5 x 30 x .203 5 x 30 x .254 5 x 40 x .254
1 x 24 x .114 1 x 28 x .254 2 x 36 x .254
1 x 21 x .114 1 x 26 x .114 1 x 30 x .254
1 x 18 x .114 1 x 21 x .114 1 x 26 x .114
3 slit piston 4 slit piston Piston orifice 2.0
— Rebound 8 x 26 x .152 1 x 26 x .152 9 x 36 x .254
1 x 15 x .203 1 x 21 x .114 1 x 24 x .203
IFP 445 mm 7 x 26 x .254 IFP 190 mm
1 x 15 x .122
IFP 130 mm
2000 MX Z 500/600 CN/700
1 x 15 x .114 1 x 15 x .152 1 x 15 x .114
3 x 30 x .152 4 x 30 x .152 3 x 30 x .203
3 x 15 x .203 3 x 15 x .203 3 x 15 x .203
2 slit piston 2 slit piston 2 slit piston
— Rebound 2 x 26 x .152 4 x 26 x .203 6 x 26 x .203
1 x 12 x .114 1 x 12 x .254 1 x 12 x .114
2 x 26 x .152 IFP 130 mm 3 x 26 x .203
1 x 12 x .203 1 x 12 x .203
IFP 172 mm IFP 183 mm
2000 MX Z 600 U.S.
3 x 15 x .203 1 x 15 x .152 1 x 15 x .114
4 x 30 x .152 3 x 30 x .203
3 x 15 x .203 3 x 15 x .203
2 slit piston 2 slit piston 2 slit piston
— Rebound 6 x 26 x .203 4 x 26 x .203 6 x 26 x .203
1 x 12 x .203 1 x 12 x .254 1 x 12 x .114
IFP 172 mm IFP 130 mm 3 x 26 x .203
1 x 12 x .203
IFP 183 mm
2000 MACH Z
— Compression N.A. 4 x 30 x .203 12 x 30 x .152
3 x 16 x .203 3 x 15 x .203
4 slit piston 2 slit piston
4 x 26 x .152 8 x 26 x .203
— Rebound 1 x 12 x .203 1 x 12 x .203
IFP 138 mm IFP
2000 SUMMIT
— Compression N.A. N.A. 12 x 30 x .152
3 x 15 x .203
2 slit piston
8 x 26 x .203
— Rebound 1 x 12 x .203
IFP 169 mm
03-34 MMC2002-001_03A.FM
SHOCK CALIBRATION WORK SHEET

MODEL: DATE:
RIDING CONDITIONS:
FRONT CENTER REAR OPTION

PISTON SLITS
IFP HEIGHT
COMPRESSION
REBOUND
SPRING
PRELOAD
NOTES: __________________________________________________________________________________________
__________________________________________________________________________________________________
__________________________________________________________________________________________________
__________________________________________________________________________________________________
__________________________________________________________________________________________________
__________________________________________________________________________________________________
MMC2002-001_03A.FM 03-35
CHASSIS SET-UP ZX Series

1
General
Reducing rolling resistance of a snowmobile is
also an important area to explore when you are
searching for the ultimate top speed. The horse-
power required to overcome rolling resistance or
drag increases approximately with the square of
velocity so small reductions here can provide mea- A
surable improvements in top speed. B
Good chassis set up starts with accurate align- C
D
ment of the drive axle, countershaft, suspension A06D1XC
system, and chassis. Use the following procedure

1. Measure from end of drive axle
to check your vehicle: A. 47.3 mm (1.862 in)
B. 149.8 mm (5.898 in)
Remove the rear suspension, driven clutch, tuned C. 272.8 mm (10.740 in)
pipe and muffler, track and drive axle. Check to see D. 375.3 mm (14.776 in)
that the spacing of the drive sprockets is correct CK3 Series
on the drive axle. The sprockets should be cen-
tered in the space between the rows of internal 1
drive lugs on the track.
A
B
A C
B D
A06D1XC
C
D 1. Measure from end of drive axle
A. 49 mm (1.929 in)
B. 151.21 mm (5.953 in)
C. 274.2 mm (10.795 in)
D. 376.3 mm (14.815 in)
1 Use a press or special tool (P/N 861 725 700) for

shifting the sprockets. The sprocket indexing
should also be checked. The maximum desyn-
chronization is 1/16 inch (1.5 mm). The drive axle
can be chucked in a lathe and spun to observe the
sprocket “wobble” and run out. Wobble should
not exceed 2 mm (.080 in). While this amount of
wobble may look excessive, it does not affect per-
formance. If wobble is more than allowed, the
sprockets should be replaced.
Maximum run out should not exceed 0.5 mm
A01F28B (.020 in). A maximum of 1 mm (.040 in) can be re-
1. Indexing marks aligned
moved from the sprockets to true the diameter.
A. 65.8 mm (2-18/32 in) 1995/1999 All S-Series DSA CAUTION: Do not remove more than 1 mm
B. 159.3 mm (6-17/64 in) 1993/1997 All F-Series DSA
C. 282.3 mm (11-7/64 in) (.040 in) of material or the sprockets will start
D. 375.8 mm (14-51/64 in) to go out of pitch with the track.
03-36 MMC2002-001_03A.FM
Reinstall the drive axle leaving the left end bearing

housing off.
Loosen the left side countershaft eccentric bear-
ing collar and slide the bearing retainer out so that 1
the shaft end is free to locate itself in the support
opening.
With both left shaft ends free, you can see if the
shafts are centered in their bearing mount holes.
(D)
A01D07C
(A) (B) TYPICAL

1. Shim location
2. Shim location
(C)
Reinstall the rear suspension and using a square
check to see that the runners are square (90°) with
the drive axle. If not, cut and shim the ends of the
A01D06A
suspension cross tubes to perfectly align the run-
TYPICAL ners and also remove any side-to-side movement.
NOTE: Shafts will have a tolerance in the bearing If the suspension must be shimmed, correlate the
housings and the bearings them-selves. These tol- adjustment with the next step.
erances can be felt by hand. The shafts should be
mid-point in these tolerances when centered in
the bearing mount holes. If not perfectly centered,
the two upper chaincase bolts should be loosened
and shims should be added between the chassis
and chaincase as necessary to align the counter-
shaft and drive axle in their bearing mount holes. 4
Depending on the amount of shims added, it may
be necessary to use longer chaincase bolts. Make
3
certain the bolt is fully engaged in the nut when 1
properly torqued.
2
Now, reinstall the left end bearing housing. Using
a large carpenters square, check to see that the
drive axle is square (90°) with the tunnel. If not,
slot the left end bearing housing holes and reshim
the chaincase to square up the drive axle and the
countershaft.
A06F1MA
1. Align runners with drive sprockets. Equal distance both sides.

Shim drive axle to reduce end play
Maximum end play = .060” (ideal = less than .030”)
2. Cut ends of tubes and shim as required to align suspension and
remove freeplay
3. Suspension square with drive axle
4. Drive axle square with tunnel
MMC2002-001_03A.FM 03-37
Now check the axial play (side-to-side clearance) Rear Axle Modification
of the drive axle. The axle must not move more
Heavily studded tracks combined with hard cor-
than 1.5 mm (.060 in) from side to side. Ideally, the
nering put enormous loads on the track. To reduce
axle has 0.25 – 0.50 mm (.010 – .020 in).
the chance of derailing the track and to help
spread the tensile loads of the track, a fourth idler
1 wheel should be installed.
The two inner idlers should be placed so that they
run between the left and right double rows of drive
lugs. This will help maintain alignment of the track
and lessen the chance of derailing.
Use the spacing shown in the drawing noting that
2 3 the outer two idler wheels are in their original po-
sition.
5
4 6
A01D04A
TOP VIEW
1. Countershaft
2. Shim position on end bearing housing side
3. Shim position on chaincase side
4. Drive axle
5. Axial play
6. Shim between sprocket and spacer
If the axle must be shifted left or right, note the

direction and distance, and shim the axle as nec- A B C
essary. D
Shims can be placed between the left side bearing A01F1HA
and the end bearing housing to move the axle to A. 101.5 mm (3-63/64 in)
the right or between the right side bearing and the B. 123 mm (4-27/32 in)
chaincase to move the axle to the left. C. 101.5 mm (3-63/64 in)
D. 326 mm (12.83 in)
NOTE: If shims are placed between the chaincase
When you have reinstalled the track and suspen-
and the right side bearing, an equal thickness shim
sion, make certain that all bolts attaching the sus-
must be placed between the drive chain sprocket
pension to the chassis are installed with high
and the spacer on the axle.
strength threadlocker (Loctite 271), and that bolts
are properly torqued.
1 There are grease fittings on all moving parts of the
2 suspension and they should be greased on a
weekly basis with a quality, low temperature
grease (P/N 413 711 500).
Finally, adjust the track tension and alignment.
3 Track tension and alignment are most critical to
A01F2OA
top speed. Make certain the track is aligned so
that you have equal clearance between the slider
1. (P/N 501 020 500)
Shim, drive axle end bearing housing 1.6 mm (.063 in) thick shoe and the track guides on each side of the
2. (P/N 506 041 400) snowmobile.
Shim, drive axle chaincase side 1.6 mm (.063 in) thick
3. (P/N 504 039 800)
Shim, chaincase perpendicularity 0.5 mm (.020 in) thick
03-38 MMC2002-001_03A.FM
NOTE: Track tension should be checked whenev-

er major changes are made to the limiter strap
1 length and/or ride height changes.
BRAKES
To achieve maximum top speed and proper brake
functioning, it is important to make sure the brake
disc is loose on the countershaft to allow the disc
to float and remain centered between the brake
pads. The shaft should be lubed to maintain the
floating disc.
A06F1WA 2 If extreme brake use is anticipated, use 3 inch di-
TYPICAL ameter dryer hose (or equivalent) to route outside
1. 7.3 kg (16 lb) air directly from the hood vents to the brake area.
2. Deflection
SKI-DOO hydraulic brake systems use DOT 4
brake fluid. For conditions where extreme brake
heat is generated, DOT 5 fluid can be used. DOT
Guides 5 has a higher boiling point but it is more suscep-
Slider shoes tible to moisture intrusion and should be changed
on a regular basis. DOT 5 should not used for long,
multi-day cross country racing where mainte-
nance is minimal.
If the brakes become spongy, the system should
be bled to remove any air bubbles. If the brake
fluid is dark and/or cloudy, flush the complete sys-
tem and refill with fresh brake fluid.
Equal distance
1
Guides
Slider shoes
A06D0JA 2
Tighten on this side 1. Hold bleeder adaptor while opening bleeder
A01F29A 2. Clear hose to catch used brake fluid
For straight line racing, top speed can sometimes Pump a few time brake lever and while holding
be increased by running the track a bit looser. brade lever depressed, open bleeder and check
Ratcheting of the drive sprockets during hard ac- for air to escape.
celeration can occur if the track is too loose. Con- Repeat with the same bleeder until no air appears
versely, heavily studded tracks may need to be in hose.
tighter to achieve top speed because the extra Proceed the same way with the right side bleeder.
weight of the studs may cause the track to balloon
out at high speeds.
MMC2002-001_03A.FM 03-39
When refilling the injection oil container be careful ADJUSTING RIDE HEIGHT
not to overfill as excess oil can drop onto the brake
disc and impregnate the brake pads. If this hap- A cross-country racer will want all the suspension
pens the brake pads should be replaced to ensure travel you can for a rough snowcross-type event.
maximum braking performance. But when racing a high speed event on a relatively
smooth lake, giving up some of the suspension
AERODYNAMIC travel to lower the machine is advantageous. Low-
ering the machine, reducing the ride height, does
CONSIDERATIONS 3 things for you:
Yes, aerodynamics are an important consideration 1. Lowers the center of gravity of the machine;
in snowmobile design. The horsepower required which improves cornering.
to overcome aerodynamic drag increases according 2. Reduces the frontal area of the sled; which im-
to the cube of the velocity. At speeds under 64 km/h proves aerodynamics.
(40 MPH), the aerodynamic considerations are not
great, but when you approach the 160 km/h (100 3. Reduces the approach angle of the track; which
MPH) mark, simply how you sit on the snowmo- reduces drag.
bile can mean 6.4 km/h (4 MPH) in top speed. A person wanting to lower the machine for a short
Bombardier has spent many hours in the wind tun- event like a radar run may simply chain or strap the
nel on the hood design, and has optimized the machine down. Provided the course is quite
shape to fit the function. You cannot improve the smooth, this can work, but realize that strapping
shape of your snowmobile but you can reduce the down the suspension preloads the springs highly
frontal area of the snowmobile by lowering the and the ride will be very stiff. This technique is not
ride height and by using the lowest windshield recommended for most forms of racing.
available. The most common technique for lowering the ma-
The high windshield offers the rider good wind chine is to use shorter springs or to shorten the
protection. That protection, however, translates existing springs by heating and collapsing a coil or
into increased frontal area and more aerodynamic 2 of the spring as needed. Realize that shortened
drag. If you are running at a local radar run with the springs will have very little preload when the sus-
high windshield on, you should sit upright behind pension is in its “topped out” position, and it may
the windshield. Crouching behind the windshield be necessary to safety wire the spring collars into
increases drag because of interruption of the air position, and use additional limiter devices like
flow from the top of the windshield to the rider’s straps, chains or on HPG /A shocks, a spacer can
back. be added internally to limit the extension of the
shock.
When the low windshield is fitted, the opposite is
true, you should crouch behind the low windshield NOTE: Some race organizations do not allow short-
for best top speeds. When crouched behind the ening springs so a proper optional short spring
low windshield, there is an improvement in the would be used.
aerodynamics compared to sitting upright behind
the high windshield. That translates into an in- Lowering the Front Suspension
crease at top speed in a laboratory setting. Make limiter straps from standard rubber limiter
Because of the purity of the air flow in the wind strap material or link chain and go from shock bolt
tunnel, you should not expect this increase in normal to shock bolt (longer shock bolts will be required).
running, but you can always expect a 3.2 – 4.8 km/h The length of the strap should be adjusted to ob-
(2-3 MPH) improvement and even more when winds tain the desired ride height. Most rules require you
are still. to maintain 2 inches of suspension travel.
Lowering the vehicle a couple of inches can also Shorter springs should be used to avoid excessive
improve top speed by 1-3 MPH. preload.
03-40 MMC2002-001_03A.FM
On vehicles with rebuildable shocks (HPG T/A), a Center

spacer can be installed internally on the shock Shorten the limiter strap(s) to match the ride
shaft to limit the shock extension. Spacers can be height of the front and rear and obtain the desired
fabricated from 1 in O.D. aluminum round stock. amount of weight transfer. New holes can be
(Refer to the shock rebuilding section for proper in- punched in rubber limiter straps. A shorter nylon
stallation procedures). limiter strap (P/N 414 955 300) is available for the
The threaded adjusters can be loosened to provide vehicles with the strap and bolt style.
the desired amount of spring preload. Quick Adjust Limiters may also be used (P/N 861
765 500) for the MX Zx. The Quick Adjust Limiter
Lowering the Rear Suspension will allow you to shorten or lengthen the length of
Option 1: The SC-10 rear suspension can be low- the limiter straps just by turning an adjuster knob.
ered by compressing the rear scissors to the de- On vehicles with HPG T/A shocks the threaded
sired ride height and installing a strap to maintain adjusters can be loosened to reduce the amount
this height. Compressing the rear scissors adds a of spring preload. If less preload is desired or on
great deal of preload to the rear torsion springs. vehicles with cam adjusters, shorter springs may
Use racing springs (P/N 486 099 100 LH) and (P/N be used to reduce excessive spring preload.
486 099 300 RH).
Option 2: It is also possible to lower the rear sus- TRACK GUIDES
pension on vehicles equipped with HPG T/A shocks,
by using a spacer to limit shock extension. Use rac- Additional taller track guides (P/N 486 078 200)
ing springs (P/N 486 099 100) and (P/N 486 099 300). should be installed when oval racing with a heavily
studded track. These taller guides help prevent de-
A railing without having to overly tighten the track.
When in a turn, the side loads on the guides are
2 extremely high and it is advantageous to reduce
the load per guide by adding more of the guides.
1 All of the flat cleats should be removed from the
right side of the track and replaced with guide
cleats. (See drawing).
Remove Replace with 486 078 200
LEFT SIDE
A03F0QA
1. 1st hole
2. 2nd hole FRONT
A. 11 N•m (97 lbf•in)
A01F23B RIGHT SIDE 2
1. Standard
2. (P/N 486 078 200)
MMC2002-001_03A.FM 03-41
NOTE: When installing taller track guides or studs If the studs do not prick your finger when you
part (P/N 572 086 100), bushings should be in- touch the tip they are not sharp enough. A small
stalled inside the rear torsion springs on SC-10 die grinder can be used to sharpen worn studs.
rear suspensions. Track guide clearance should Place studs where pressure is concentrated on
also be checked on top of the rear suspension the edge of the track for turns, in the center of the
A.C.M. track for acceleration and braking.
For ice lemans type racing where left and right Hooker plates are welded to the track cleats and
hand corners are encounted, extra guides should place the studs directly beneath the slider shoes
also be installed on the left side of the track. for maximum pressure. The hooker setup is very
There are two special tools which greatly enhance hard on tracks, particularly the fiberglass reinforc-
the removal and addition of guide clips. ing rods.
(P/N 529 028 700) Guide clip remover. The other thing that must be kept in mind if hooker
(P/N 529 008 500) Guide clip crimper. plates are used is that the studs will be directly in
line with the heat exchanger protectors. The pro-
tectors must be removed and another system em-
TRACK STUDDING ployed to protect the heat exchangers.
 WARNING Depending upon machine setup, driver weight

and driving characteristics, 250 to 300 penetrator
Installation of track studs is a modification not studs will be required. The 121 inch track has 48
recommended. This modification may affect pitches. The most studs that can effectively be
amongst others stopping distances and track placed on each pitch is 7 — which means the max-
strength. Studs may also be projected, thereby imum number of studs the track can hold is 336.
causing personal injuries to operator and/or
bystanders. Bombardier disclaims liability for The drawing below shows a pattern of 6 studs al-
all damages and/or injuries resulting from use ternating with 7 studs for a total of 312 studs. Try
of the studs. Modifications of any Bombardier- to keep studs from following the same line for 3
made snowmobile voids the vehicle warranty pitches.
and that such modifications may render use of NOTE: Refer to the appropriate section of this
the vehicle illegal in other than sanctioned rac- book for specific stud patterns for various types of
ing events under existing federal, provincial racing.
and state regulations.
Traction control requires the installation of studs 1

to the track so that you may improve the acceler-
ation, direction and braking of the snowmobile on
certain surfaces. Selection of the proper traction 2
components is very important. It is also important
to have the proper number of studs and to keep
them sharp or replaced at all times.
For racing on hard ice, the single point stud is the
A27F0CA
most popular. If the ice gets a little softer, racers
will add a variety of stamped studs. Always use TYPICAL
Loctite when installing your studs. 1. 6 stud row
2. 7 stud row
Stud sharpness counts more than the number of
studs. Fewer sharp, fresh studs work much better Most race associations sanctioning oval, snow
than a great many dull studs with a few new ones cross and cross-country events limit the length of
thrown in. Too many studs will keep the points the studs to 3/8 inch above the high point of the
from digging in and the sled will float, instead of track, while most drag and speed run associations
hooking up. allow a 3/4 inch limit. Rules do vary, however, and
it is your responsibility to make certain your studs
are legal. It is also necessary to protect the heat
exchangers from damage from the studs.
03-42 MMC2002-001_03A.FM
Another item to keep in mind is the length of the The 2 front nozzles should be located on each run-
threaded shank of the stud. Some stud patterns ner where the track just begins to touch the slider
require that the stud pass under an idler wheel. If shoe. Drill a 1/4 inch diameter hole on the inner
this is the case, you must be absolutely certain side of each runner down through the runner and
that the shank of the stud does not project beyond slider shoe. Using red or green Loctite, insert a 1/4
the flat face of the “T” nut. If necessary, grind the inch diameter by 1-1/2 inch long roll pin in each
studs off. location. Install the roll pin flush with the bottom
CAUTION: Check condition of heat exchanger of the aluminum runner. Do not let the pin protrude
after every race. into the slider shoe. Prepare the slider shoes by
grinding a “V” groove approximately 1/8 inch deep
Take the time and care to lay out your stud pattern and 1/4 inch wide on the bottom side of the slider
carefully. And, make sure you write down what at each nozzle location. The grooves should run
works best for you at certain tracks and various almost to the sides of the slider but not protrude
conditions. on the sides. This will allow a better distribution of
NOTE: The track must be run in for ten (10) hours lubricant and make sure the lube supply does not
before holes are drilled to receive the studs. This become obstructed.
must be done to stretch out all the elements of The 2 rear nozzles should be placed approximately
the track before any of the track cords are cut by half the remaining distance to the rear. For straight
the studding operation. line racing, install the roll pins using the same pro-
cedure as above. For oval racing, mount the roll
SLIDER SHOE LUBRICATION pins on the right side of both runners so the lubri-
cant runs down the side of the slider shoe. This
When running a vehicle on surfaces that do not
lubricates the sliders and the guiding portion of the
provide adequate lubrication for the slider shoes,
track clips where side loading is highest during
the plastic will start to melt and stick to the track
cornering. Be sure to clamp the side nozzles in
guide clips. This not only reduces the life of the
place and secure all lines with locking ties.
slider shoes but it also substantially reduces vehi-
cle speed. If rules allow, the most effective means Lubricant flow can be restricted at each nozzle by
to reduce slider shoe sticking is to apply a lubricant placing a Mikuni hex main jet inside each hose
via a slide lubrication system. (about a no. 500). You cannot apply too much lube
but you must last the race. Vary the restriction de-
The lube system should have a tank of approxi-
pending on your tank size and the length of the
mately 1 to 1.5 gallons, a control valve, pump and
race.
a series of hoses and tees. A standard fuel pump
can be used. The pump is operated by primary PARTS LIST QTY P/N
crankcase compression and can be connected to
Fuel pump 1 403 800 400
the fuel pump impulse line with a tee. Because the
pump will operate whenever the engine is run- 414 286 700
Impulse hose 1
ning, a control valve is used to conserve lubricant (10 ft)
for the race. Hose clamp (1/4” D) 4 408 801 100
When plumbing your system, run the supply line 414 834 000
Fuel line (1/4” D) 1
from the tank to the shutoff valve first. Make sure (25 ft roll)
the valve is in a convenient location but protected Tee (1/4 × 1/4 × 1/4) 3 414 155 300
from flailing arms and legs. Be certain to tie wrap
the lines away from any rotating, vibrating or heat- Spring clamp (for fuel line) @ 414 554 800
ed surfaces. The outputs from the pump should Shutoff valve 1 414 539 000
be routed through the tunnel just in front of and Lube tank (1 to 1-1/2 gallon) 1 N.A.
beneath the footrest.
Roll pin (1/4” dia. × 1-1/2”) 4 N.A.
414 115 200
Locking tie @
(package of 25)
MMC2002-001_03A.FM 03-43
If slide lubrication is not allowed, install a larger

diameter idler wheel. This reduces the load on the A B
slider shoes.
1/4" Ø
1
A25G0FA
1. The above illustration is an example of what is called rocker

A. 2 mm (3/32 in)
B. 2 mm (3/32 in)
Check your skis from time to time to confirm the

2 mm (3/32 in) (measured at the ski runner studs)
bow. If the skis have flattened, use a hydraulic
press as necessary to restore the original shape.
This is most important for oval racers.
FRONT Plastic skis or liners are good for a 2 MPH increase
in speed in most snow conditions, more in sticky
snow conditions.
Carbide inserted ski runners are necessary for all
forms of racing except drag racing and radar runs.
A06F2IA BOTTOM VIEW The type of racing you are involved in and the con-
dition of the track will determine what style of car-
NOTE: Before installing a lubrication system check bide and how much carbide you will be using.
with your sanctioning body or race organization. In For the ice race track, special flat-backed race run-
some cases, use of this system and/or certain lu- ners with 60° carbide inserts are a must. The flat
bricants is not allowed. back of the runner helps to keep the runner from
Also, a used or seasoned set of slider shoes will being rolled over by cornering forces. The best rac-
be faster than a brand new pair. The high spots and ing runners are heat-treated to prevent them from
areas between the idler wheels will be worn bending under high side loads.
down. If brand new sliders must be raced with When installing carbide inserts, start with 100 mm
stock wheels, remove about 1/8 inch of material (4 in) of carbide in front of a line projected from the
from the bottom of the slider shoes. center line of the ski leg and 125 mm (5 in) behind
the line. Always keep the amount of carbide be-
SKIS AND RUNNERS hind the line longer than in front.
The skis on your Ski-Doo are not flat on their bot-
toms, they are slightly convex. This is done to im-
prove stability at high speed on straightaways.
The plastic ski on the MX Zx and MX Z incorpo-
rates more of its use (rocker effect). This plastic
ski will work very well on snowy surfaces as it in-
creases flotation and reduces drag. For oval and A
Ice Lemans, the new profile is superior to the steel A15F2IA
ski.
A. 122 mm (5 in) 98 mm (4 in)
147 mm (6 in) 171 mm (7 in)
03-44 MMC2002-001_03A.FM
Once you have determined how much carbide you You will need a reference point to measure to as
will be using, make up at least one more set. Sharp you cycle the suspension through its travel. Be-
carbides dig! They must be sharp enough that cause you will be lifting the ski and suspension
when you drag your thumb nail over them, they assemblies as you are measuring, you should use
will scrape off some of the nail. To keep your car- a reference point that is not easily bumped out of
bide runners is this condition, you must sharpen position. A pair of concrete blocks set on a line
them every 5 or 6 laps. This is why you should about 50 mm (2 inches) away from the edge of the
have an extra set ready to go on in a hurry. ski and parallel to the ski works nicely.
The condition of the skis and runners, as well as
their alignment, has an effect on top speed. The
ski toe-out must be correct; any irregularities in the
skis should be removed, and bent or badly worn
runners must be replaced.
Ski runners used for cross-country racing must be
selected for the type of conditions you will be run-
ning in. When exposed earth or plowed roads are
to be encountered in an event, full length carbide
runners should be used. The concern here is to
make the runner and the ski last through the
event. These runners are usually set up with
245 mm (10 in) of 60° carbide in the center of the
bar with the front and rear portions of the bar filled
in with 120° carbide inserts.
When the event is held on a lake or surface condi-
tions consist only of snow and ice, a flat-backer
runner with 150 to 200 mm (6 to 10 in) of carbide
will do the job. Remember, the more carbide you
install, the more positively the front end steers, A15G1GA
but more steering effort is also required. Cross-
country events run for many hours not just a few Lift the ski up to its upper travel limit. Using a mea-
minutes like an oval event. Match your carbide to suring tape, measure the distances from the front
the strength and endurance of your arms. and rear edges of the ski to the concrete block ref-
A cross-country carbide does not need to be razor erence. The front and rear measurements must be
sharp. In fact, testing should be done with a slight- equal or no more than 1.6 mm (1/16 in) difference
ly dulled edge, that way your set-up will be right if the bump steer adjustment is correct.
for the majority of the race. If you test with sharp
carbides, your chassis set-up will be off when the SKI LEG CAMBER
runners lose their edge after 5-10 miles.
The camber angle of the ski legs changes how ag-
CAUTION: The amount of carbide allowed on gressively the ski runners hook up with the driving
each runner may be limited by your race asso- surface. Adding negative camber will have the
ciation. Check your rule book. most effect on handling. This is because the
weight shift in a turn is always to the outside of
BUMP STEER the turn and the negative camber of the ski leg
causes the wear bar to be presented to the driving
Bump steer refers to the amount of change in the
surface in a more aggressive position. Positive
toe-out of the skis as the suspension moves
camber will tuck the wear bar in toward the sled,
through its total vertical travel. Block up the ma-
thereby reducing its traction in a turn.
chine so that the skis are just off the ground and
remove the springs from the shocks. This will al- Camber adjustments do have an effect on the
low you to cycle the suspension and measure the width of the machine. Make certain your camber
bump steer on your vehicle. adjustments do not push you beyond the overall
width limit imposed in most forms of racing.
MMC2002-001_03A.FM 03-45
Camber is the tilting of the ski leg from the vertical. Procedure
To obtain a negative camber angle, the ski leg
NOTE: Any chassis lowering should be performed
must be tilted inward so that the ski legs are closer
before adjusting camber.
together at the top than at the bottom. Positive
camber would tilt the top of the ski leg away from – Make sure the vehicle is leveled by placing the
the machine. Camber angle is measured in de- angle finder on the main horizontal frame mem-
grees from the vertical and must be noted as pos- ber. Settle the suspension so the vehicle is sit-
itive or negative. ting at the normal ride height.
positive negative
+ -
1
A06G05B
– Remove the black plastic cap from the spindle.

– Insert camber angle tool (P/N 529 021 600) into
the spindle.
– Place an angle finder squarely on the camber
angle tool.
– Loosen the lock nuts on the upper radius rods.
Unbolt the upper radius rod at the ski leg housing.
Turn the radius rod in or out to achieve the desired
camber angle.
Camber angle tool
(P/N 529 021 600)
NOTE: Angle finder with a magnetic base must
be used.
A15G09A
Suggestion: K-D tool no. 2968
1. Ski leg vertical = 0° camber
Most oval racers set the left ski leg at 0° camber

and the right at - 3° to - 5° camber. Trail riders and
drag racers should set both ski legs at 0° camber
while cross-country and snowcross riders most
often set up both ski legs with - 1° to - 3° camber.
Camber angle is measured using an angle finder
available from most tool supply stores.
Adjustment is performed by adjusting the length
of the upper control arm.
A06B024
APPLICATION
All DSA front suspensions.
03-46 MMC2002-001_03A.FM
CAUTION: The bushing fits into the ski leg hous- Never lengthen a tie rod so that the threaded por-
ing in only one direction, therefore adjustments tion of the ball joint extends over 17 mm (11/16 in)
must be made in one full revolution increments. beyond the tie rod. To avoid this, distribute the ad-
justment requirements equally to both left and
1 2
right tie rods.
K-D Tools
ANGLE FINDER
Lancaster, PA
K-D Tools
17004
No. 2968
A06G12A
TYPICAL
1. Adjustment
2. Camber reading
Y
– Retorque all nuts and bolts to the proper torque.
– Ski toe-out must be checked after any camber
adjustments.
SKI TOE-OUT X
Most oval racers use modified handlebars with
loops or angles on the left end. Often a driver pre- A06G0DA
fers a handlebar position that is not horizontal
when the skis are in their straight ahead position. X = Y ± 3 mm (1/8 in)
This allows a more comfortable driving position Retorque ball joint lock nuts to 29 N•m (21 Ibf•ft)
when in a corner. Whatever handlebar you prefer when toe-out is correct.
should be positioned as you prefer it when going
down a straightaway before you begin your toe- With the aggressive setup of the front end neces-
out adjustment. sary for competitive oval racing, it is important to
keep all the steering system components tight
Use a rubber cord stretched between the ski tips and free of play. Worn ball joints and bushings
to keep constant pressure on the steering system should be replaced, bolts holding the skis to the
while measuring toe-out. Measure the distance ski leg must be tight and wear bars must be
between the inner edges of the skis as far back straight and bolted securely to the skis. Any play
and as far forward on the skis as possible. Avoid in the steering will result in severe chattering in
measuring at a point at the top or heel of the ski the corners and darting on the straightaways.
where the ski is tapered. With aggressive race car-
bide, the measurements should be taken at the
front and back of the runners on the cutting edge
CHASSIS TUNING GUIDELINES
for the most precise measurement.
How to Deal with Handling Problems
Skis must have a toe-out of 3 to 6 mm (1/8 to 1/4 in)
when they are in the straight ahead position. There is usually never one adjustment that will cor-
rect a certain handling quirk. You will usually end
Adjustment is performed by loosening the lock up with several changes in setup to achieve the
nuts on the ball joints at the ends of the left and same goal. There are certain basics to keep in
right tie rods. Rotate tie rods as necessary to mind, however, when you are working with your
achieve the proper toe-out and handlebar position. sled:
Do not use the short tie rod that runs beneath the
engine to adjust ski toe-out. – Handling problems encountered when entering
a corner are usually corrected by working with
front end adjustments.
MMC2002-001_03A.FM 03-47
– Handling problems encountered when exiting a – Add more carbide.

corner are usually corrected by working with – Increase negative camber of ski legs.
rear suspension adjustments.
– Increase ski spring preload.
– Basic handling problems are often traced to im-
proper suspension adjustments. – Increase rear spring preload.
– Tighten A.C.M.
Guide to Handling Problems – Increase rear to front coupling SC-10 II.
NOTE: PUSHING refers to the front of a vehicle b. Rear of machine starts to come around or is
not steering as much as the driver wants. The skis loose when exiting a corner.
are not grabbing the surface with sufficient force.
LOOSE refers to the rear of a vehicle sliding out- – Lengthen limiter strap on center arm.
ward in a turn. The track is not grabbing the sur- – Decrease ski spring preload.
face with sufficient force. – Increase center spring preload.
NOTE: Center spring/shock refers to the front arm – Decrease negative camber of ski legs.
of the rear suspension.
– Decrease rear spring preload.
1. Problems encountered when entering a corner.
– Loosen A.C.M.
a. Front end pushes coming into a corner (steer-
ing is not precise). – Decrease rear to front coupling.
– Sharpen carbide runners. c. Left ski lifts.
– Add more carbide. – Shorten limiter strap on center arm.
– Shorten limiter strap on center arm. – Decrease center spring preload.
– Increase negative camber of ski legs. – Check for free operation of stabilizer bar.
– Increase ski spring preload. – Increase stabilizer bar diameter or shorten
end levers.
– Decrease center spring preload.
3. General handling problems.
b. Rear of machine starts to come around or is
loose when entering a corner. a. Machine darts from side to side on straight-
away.
– Lengthen limiter strap on center arm.
– Check ski toe-out.
– Decrease ski spring preload.
– Check for loose ball joints in steering.
– Decrease negative camber of ski legs.
– Too much negative ski leg camber.
– Increase center spring preload.
b. Excess effort required to turn handle bars.
– Sharpen/add track studs.
– Check steering linkages for binding and/or
c. Inside ski lifts. corrosion.
– Reduce the amount of negative camber on – Rubber blocks between skis and ski legs
the ski legs. have too much preload at the rear (causing
– Check for free operation of stabilizer bar. rear of skis to be pushed down too much).
– Decrease preload of ski springs. – Lengthen limiter strap on center arm.
– Shorten limiter strap on center arm. – Increase center spring preload.
2. Problems encountered while going around or – Decrease ski spring preload.
exiting a corner. – Too much carbide on ski runners.
a. Front end pushes coming out of corner (steer-
ing is not precise).
– Shorten limiter strap on center arm.
– Decrease center spring preload.
– Check condition of carbides.
03-48 MMC2002-001_03A.FM
4. Adjusting the suspension for ride and comfort.

a. The rear springs of the rear suspension should
be adjusted as follows:
– Fully extend the rear suspension.
– Measure from the floor to the bottom of
the rear grab handle (remember this dimen-
sion).
– Load the vehicle as it will be used (1 or 2
people, saddlebags full of equipment, etc.).
– Again, measure from the floor to the bot-
tom of the rear grab handle. This dimension
should be 25 mm to 50 mm (1 in to 2 in) less
than the fully extended dimension.
– If the vehicle settles more than 50 mm (2 in),
increase the rear spring preload.
– If the vehicle settles less than 25 mm (1 in),
decrease the rear spring preload.
– This is a preliminary setting only! Increase
and decrease the preload adjustments to
fine tune for your preference.
– The center spring and ski springs will have
the most affect on handling, but if the pre-
load is too stiff, it will produce a harsh ride.
General Tips
If the spring and preload combination you are us-
ing exerts the right amount of pressure at full com-
pression but has too much force at initial compres-
sion, try a shorter, stiffer spring. The shorter spring
will not be preloaded as much and will “act” softer
during initial compression, but will get stiffer as
the suspension compresses. Conversely, if a set-
up is good at initial compression but too stiff at full
compression, then a softer spring would be used.
The following chart can be used to determine how
much force a spring and preload combination will
exert during compression.
MMC2002-001_03A.FM 03-49
SECTION 04 - ENGINE PREPARATION
TABLE OF CONTENTS 0
EQUIVALENT WEIGHTS AND MEASURES CHART ................................................................ 04-2
ENGINE TUNING CAUTIONS ................................................................................................... 04-3
BASIC ENGINE THEORY ........................................................................................................... 04-3
COMPRESSION RATIO ............................................................................................................. 04-6
OPERATION OF THE RAVE VALVE
RAVE STANDS FOR ROTAX ADJUSTABLE VARIABLE EXHAUST ....................................... 04-8
CARBURETION .......................................................................................................................... 04-11
MIKUNI VM AND TM TYPE CARBURETORS .......................................................................... 04-15
FUEL/OIL RATIO CHARTS ......................................................................................................... 04-28
DIGITAL PERFORMANCE MANAGEMENT (DPM) SYSTEM ...................................................... 04-33

COMPONENT LOCATION ............................................................................................................. 04-34
THEORY AND OPERATION........................................................................................................... 04-34
PURPOSE ................................................................................................................................... 04-34
METHOD .................................................................................................................................... 04-34
OVERALL SYSTEM OPERATION .............................................................................................. 04-35
DPM SYSTEM OPERATION ...................................................................................................... 04-36
AIR PUMP OPERATION ............................................................................................................. 04-40
DPM MANIFOLD OPERATION .................................................................................................. 04-40
TESTING PROCEDURE ................................................................................................................. 04-42
STARTING PROCEDURE ............................................................................................................... 04-43
IGNITION SYSTEMS, SPARK PLUGS ...................................................................................... 04-43
STOCK CLASS PREPARATION ................................................................................................. 04-47
MMC2002-001_04A.FM 04-1
EQUIVALENT WEIGHTS AND MEASURES CHART

LINEAR MEASURE
1 inch = 25.4 millimeters (mm) 1 millimeter = .03937 inch
1 inch = 2.54 centimeters (cm) 1 centimeter = .3937 inch
1 foot = .3048 meter (m) 1 meter = 3.2808 feet
1 yard = .914 meter (m) 1 meter = 1.093 yards
1 statute mile = 1.609 kilometers (km) 1 kilometer = .6214 statute mile
WEIGHT
1 Ounce = 28.35 Grams (g) 1 Gram = .03527 Ounce
1 Pound = .4536 Kilogram (kg) 1 Kilogram = 2.2046 Pounds
1 Ton = .907 Metric Ton (t) 1 Metric Ton = 1.102 Tons
VOLUME
1 Fl. U.S. Ounce = 29.574 Milliliters = .2957 Deciliter= .0296 Liter
1 Fl. U.S. Pint = 473.18 Milliliters = 4.7316 Deciliters = .4732 Liter
1 Fl.U.S. Quart = 946.35 Milliliters = 9.4633 Deciliters = .9463 Liter
1 U.S. Gallon = 3.785 Liters
1 Cu. Inch = 16.387 Cu. cm
1 Cu. Centimeter = .061 Cu. Inch
1 Cu. Foot = 2.831.16 Cu. Cm.
1 Cu. Decimeter = .0353 Cu. Foot
1 Cu. Yard = .7646 Cu. Meter
1 Dry Quart = 1.101 Liters
TEMPERATURE
32° Fahrenheit = 0° Celsius °F = 9/5°C + 32
0° Fahrenheit = -17.8° Celsius °C = (°F – 32) = 5/9
SPEED
1 MPH = 1.61 km/h
04-2 MMC2002-001_04A.FM
ENGINE TUNING CAUTIONS BASIC ENGINE THEORY

Here are a few items to keep in mind when work- Terminology
ing with your engine.
If you are in stock classes, know what adjust- CYCLE In a combustion engine, a cycle is
ments are legal. accomplished when the four (4)
phases; intake, compression,
Modifications to the power curve of an engine will ignition and exhaust are
require recalibration of the transmission. complete.
The lower the RPM at which you can generate the TDC Top Dead Center:
The position of the piston when it
torque you need, the higher the percentage of that reaches the upper limit of its
power that will reach the track. travel inside the cylinder.
Sloppy engine modification usually results in less BTDC: Before Top Dead
power than you had stock. Center
ATDC: After Top Dead Center
Use the proper octane gasoline for your engine
BDC Bottom Dead Center:
(Modification may require higher octane.). The position of the piston when it
Correct your carburetor jetting for the atmospheric reaches the lower limit of its
conditions which exist at the time as close as pos- travel inside the cylinder.
sible to the time you will be competing. BBDC: Before Bottom Dead
Center
Follow the assembly and disassembly procedures ABDC: After Bottom Dead
outlined in the appropriate Shop Manual. Center
BORE Diameter of the cylinder.
STROKE The maximum movement of the
piston from BDC to TDC. It is
characterized by 180° of
crankshaft rotation.
COMBUSTION Space between cylinder head
CHAMBER and piston dome at TDC.
DISPLACEMENT The volume of the cylinder
displaced by the piston as it
travels from TDC to BDC. The
formula is:
Bore 2 × Stroke × π
------------------------------------------------- 20
4
= (π = 3.1416)
Expressed in cc
(cubic centimeters)
NOTE: To transfer cc to cubic inches, divide cc by
16.387.
COMPRESSION Reduction in volume or
squeezing of a gas.
MMC2002-001_04A.FM 04-3
Combustion Process
NORMAL COMBUSTION
Since the beginning of this study we have spoken
of air/fuel mixture combustion rather than explo-
sion. This combustion is a slow then accelerated
burning of the mixture within the combustion
chamber. Ignition occurs with the firing of the
spark plug.
This initial process generates heat and pressure
which in turn, is transmitted by conduction to the
contiguous portion of the unburned mixture.
When this portion has reached the point of self- Flame front
ignition it starts to burn releasing more pressure begins...
and heat.
This burning action, called a flame front, travels at
F01D5HA
a speed of approximately 30.3 m (100 feet) per
second until all mixture is burned, thus providing
maximum piston thrust.
...Traverses
combustion
chamber
rapidly...
Spark occurs
as piston
approches Top
Dead Center F01D5IA
F01D5GA
...until mixture
is completely
burnt
F01D5JA
04-4 MMC2002-001_04A.FM
With all operating parameters correct, normal Spark plug heat range too high.
combustion will take place. However, if for some Ignition timing too far advanced.
reason the temperature inside the cylinder is in-
creased during combustion, abnormal combustion a. Initial timing incorrect.
will occur and lead to serious engine damage. b. Ignition component failure.
DETONATION Compression ratio too high.
In detonation, the spark plug initiates burning and a. Improperly modified engine.
the air/fuel mixture starts to burn in the usual man- b. Deposit accumulation on piston dome or head.
ner but as combustion continues, the heat gener-
ated affects the large portion of the yet unburned Exhaust system restrictions.
air/fuel mixture.
a. Muffler plugged/restricted.
This unburned mixture temperature becomes so b. Tail pipe diameter too small.
high that it burns spontaneously creating high-velocity
pressure waves within the combustion chamber. c. Incorrect design of expansion chamber.
These shock waves can sometimes be heard as General overheating.
pinging. While these shock waves can be detri- a. Broken fan belt.
mental to the mechanical integrity of the engine,
it is the excessive heat that causes most problems b. Loss of coolant.
in 2-strokes. The piston may expand excessively c. Lack of snow on heat exchangers.
causing a seizure or the piston may melt. The Coolant or water entering combustion chamber.
melting will occur at the hottest points, which will
be right below the spark plug and around the edge SQUISH AREA
of the piston — often at a ring locating pin. If al- Rotax cylinder heads incorporate a squish area. This
lowed to continue, a hole may melt completely area is basically a ledge projecting beyond the com-
through the top of the piston. bustion chamber area. In operation, as the piston
PRE-IGNITION ascends and approaches the ledge, a rapid squeez-
ing action is applied to the air/fuel mixture con-
Pre-ignition is the ignition of the mixture inside the tained in the area immediately between the piston
combustion chamber before the timed spark. Pre- dome and the ledge. This squashing action forces
ignition sources are generally an overheated spark the entrapped mixture rapidly into the combustion
plug tip or a glowing carbon deposit on the piston chamber area, creating a greater mixture turbu-
head. Since ignition occurs earlier than the timed lence. Additionally, the small volume and large sur-
spark, the hot gases stay longer in the combustion face area of the squish band allow a better cooling
chamber, thus increasing cylinder head and piston of the end gases to help prevent detonation.
temperatures to a dangerous level.
Usually the piston is subject to damage. It may
seize or the aluminum on the exhaust side of the
piston dome may melt. Pre-ignition is always pre-
ceded by detonation. 1
CAUSES OF DETONATION:
Octane of the fuel is too low.
Air/fuel mixture is too lean.
a. Incorrect jetting.
b. Air leaks.
c. Varnish deposits in carburetor.
d. Malfunction anywhere in fuel system.
F01D5WA
1. Squish area 1.27 - 1.78 mm (.050 - .070 in)
MMC2002-001_04A.FM 04-5
If the squish clearance is increased, a loss in pow-

er will occur while too small a squish clearance will
lead to detonation. 1
The squish clearance can be measured by insert-
ing a piece of rosin core solder into the combus-
tion chamber, rotating the engine through TDC, re-
moving the solder and measuring the thickness of
the compressed solder.
The solder should be inserted above and in line F01D5VA
with the wrist pin. Measure the squish on both 1. Combustion chamber (V2)
sides of piston as it may vary from side to side.
NOTE: When the combustion chamber is filled to
1 2 top of spark plug hole, subtract 2.25 cc (19 mm reach
head; i.e. BR9ES spark plug). Check if fluid level de-
creases, in that case there is a leak between piston/
cylinder. The recorded volume would be false.
Removing the head and measuring the head vol-
ume by laying a flat plate across the head will not
give an accurate measurement of combustion
chamber volume because the dome of the piston
F01D64B protrudes into the head on an assembled engine.
1. Solder The uncorrected compression ratio of an engine is
2. Flattened area
the volume of the cylinder plus the minimum vol-
CAUTION: Do not use acid core solder; the acid ume of the combustion chamber divided by the
can damage the piston and cylinder. minimum volume of the combustion chamber.
COMPRESSION RATIO V1 + V2
C.R. = -------------------
V2
Measuring a Compression Ratio
The minimum combustion chamber volume is the Where:
region in the head above the piston at TDC. It is C.R. = compression ratio: 1
measured with the head installed on the engine.
2
Remove one spark plug and place piston at TDC. B ×S×π
V1 = volume of a cylinder = --------------------------
Obtain a CC graduated burette, capacity 0-50 cc 4
and fill with automatic transmission fluid.
V2 = minimum combustion chamber volume
F01D6MA
Inject the burette content through the spark plug

hole until mixture touches the two bottom threads
of the spark plug hole.
Read the burette scale and obtain the number of
cc injected into cylinder. (example: 21.5 cc).
Record the volume which we will note as V2.
04-6 MMC2002-001_04A.FM
3 4 3 4
2 2
5 5
1
F01D6NA F01D6OA
1. BDC 1. Exhaust port just closed

2. V1 2. V3
3. TDC 3. TDC
4. V2 4. V2
5. Stroke 5. Portion of stroke
EXAMPLE: EXAMPLE:
π = 3.14 π = 3.14
B = Bore diameter (cm) = 7.2 (= 72 mm) B = Bore diameter (cm) = 7.2 (= 72 mm)
S = Stroke (cm) = 6.1 (= 61 mm) S1 = Portion of stroke (cm) = 3.1 (= 31 mm)
V2 = 21.5 cc V2 = 21.5 cc
248.4 cc + 21.5 cc 126.2 + 21.5

C.R. = ------------------------------------------------ C.C.R. = ---------------------------------
21.5 cc 21.5
C.R. = 12.6:1 C.C.R. = 6.9: 1
In a 2-stroke engine, this is referred to as the un-
corrected compression ratio. Because of the ex- How to Calculate Machining Cylinder
haust port midway up the cylinder, some design- Head Height Versus Combustion
ers believe that actual compression does not Chamber Volume
begin until the piston just closes the exhaust port.
VM – VD
This is termed “corrected compression ratio”. H = ---------------------
B 2
Measuring Corrected Compression Ratio π ×  ----
 2
Where:
V3 + V2
C.C.R. = ------------------- H = material to be machined from face of cylin-
V2 der head (cm)
VM = measured combustion chamber volume (cc)
Where:
VD = desired combustion chamber volume (cc)
C.C.R. = corrected compression ratio: 1
V1
V3 = volume of a cylinder with piston just = ---------------------
2 CR D – 1
B × S1 × π
closing the exhaust port = ---------------------------- V1 = Volume of cylinder
4
CRD = Desired compression ratio
V2 = minimum combustion chamber volume π = 3.1416
B = bore of cylinder (cm)
MMC2002-001_04A.FM 04-7
EXAMPLE:
1 5
Desired compression ratio (CRD) = 14.0: 1
3
V1 248.4 cc
VD - = ---------------------- = 19.1 cc
= --------------------
CR D – 1 14.0 – 1 2
VM – VD 21.5 cc – 19.1 cc
H = --------------------- = -------------------------------------------- 4
2
B 7.2 2
π ×  ---- 3.14 ×  --------
 2  2 
= .059 cm = .59 mm = (.023”) A18C01A
1. Guillotine
OPERATION OF THE RAVE VALVE 2. Diaphragm
Rave Stands for Rotax Adjustable 3.
4.
Return spring
Exhaust port
Variable Exhaust 5. Red plastic adjustment knob
Located above the exhaust port is a guillotine-type

Theory slide valve (item 1). This rectangular valve is con-
For a two-stroke-cycle engine to have high power nected by a shaft to a diaphragm (item 2) which is
capacity at high crankshaft speeds, a high volu- working against the return spring (item 3). Two
metric or breathing efficiency is required and the small passages in the cylinder just outside the ex-
fresh charge losses must be minimized. The result haust port (item 4) allow exhaust gas pressure to
is achieved by opening the exhaust port early reach the diaphragm. As the throttle is opened and
(94.5° BBDC) and utilizing the resonant effects of the engine begins producing more power, the
the tuned exhaust system to control fresh charge pressure against the diaphragm will overcome the
losses. pressure of the return spring and the RAVE valve
will open.
When an engine of this design is run at a medium
speed, efficiency falls off quickly. The relatively To the outside of the return spring is a red plastic
high exhaust port effectively shortens the useful adjustment knob (item 5). Turning the adjustment
power stroke and because the exhaust system is in or out changes the preload on the return spring
tuned for maximum power, there is a large in- which, in turn, will change the RPM at which the
crease of fresh charge losses. As a result, the RAVE valve opens and closes. The exhaust port
torque decreases along with a dramatic increase height changes a total of 4 mm to 6 mm (depend-
of the specific fuel consumption. Higher torque ing on engine type) from the RAVE valve fully
along with lower fuel consumption can be ob- closed to fully open.
tained at lower engine speeds if the time the ex-
haust port is open is shortened. Operation
BOMBARDIER-ROTAX has patented a remarkably The RAVE valve does not allow an engine to make
simple system to automatically change the ex- higher peak horsepower than an engine not so
haust port height based on pressure in the exhaust equipped, it can make moving the peak higher
system. practical because of its effect on the rest of the
power curve. Item 2 in following illustration is the
power curve of an engine with the RAVE valve
held fully open through its entire RPM range. Item
6 notes the peak power produced. That peak will
not change if the exhaust port time of a similar
engine without a RAVE valve was the same (with
all other features equal).
04-8 MMC2002-001_04A.FM
Adjustment
6
P2 7 The red cap on the RAVE valve cover should be
P1
turned all the way in and bottomed in normal use.
1 Backing the red adjuster out will reduce the spring
preload and allow the RAVE valve to open at a low-
4 er RPM.
5
POWER
3 At high altitudes, exhaust gas pressures will drop

and the spring preload may have to be decreased.
It is doubtful that any adjustment will be required
1 2 up to an altitude of 2400 m (8000 ft). Above that,
however, the spring preload can be reduced by
turning the red adjustment screw out up to a max-
imum of four turns.
RPM
A18C02A The only other time adjustment of the spring pre-
load should be considered is if the engine has
Item 1 is the power curve of the engine with the been modified in any way.
RAVE closed through its entire RPM range. The
shaded area (item 3) is the improvement in power AVAILABLE RAVE SPRINGS
at lower engine speeds that is gained because of
the lower exhaust port. If the port remains at this Free Preload in N (LBF)
Wire Dia.
Length at
height, however, the power would peak as noted Spring P/N Compressed
in item 5. Raising the exhaust port at the proper Length of
mm (in) mm (in)
RPM (item 7) will allow the engines peak power 14 mm (.551 in)
to continue to rise to item 6.
420 239 948 1.0 (.039) 38.0 (1.50) 19.5 (4.37)
Item P1 in the illustration is the pressure of the
return spring against the diaphragm. The exhaust 420 239 944 0.9 (.035) 48.5 (1.91) 15.9 (3.56)
pressure must be high enough to overcome this 420 239 942 0.8 (.031) 42.5 (1.67) 7.3 (1.64)
pressure before the valve begins opening. Item P2
is the pressure required to completely open the 420 239 941 0.8 (.031) 52.5 (2.07) 10.5 (2.36)
RAVE valve. Between P1 and P2, the usable pow-
er curve of the engine is moving from power curve Maintenance
1 to power curve 2. This transition takes place very
rapidly at full throttle and from a practical stand- There are no wear parts anywhere in the system
point can be considered to be instantaneous at and there are no adjustments to be periodically
item 7 which for the type 583 engine is at 6300 - checked. The only possible maintenance required
6400 RPM. Gradual application of the throttle, would be cleaning of carbon deposits from the
however, will result in the RAVE valve opening guillotine slide. Cleaning intervals would depend
much later, i.e. 7300 - 7500 RPM. upon the user’s riding style and the quality of the
oil used. Using Ski-Doo oil, we would suggest an-
If the RAVE valve opens too late, the engine will
nual cleaning of the valve. If a customer uses a
bog or hesitate momentarily as the RPM increas-
lower quality, high ash oil, more frequent cleaning
es. Full peak performance (item 6) is still available.
may be required.
From a functional point of view. it is better to have
the valve open a bit early than a bit late. This fact No special solvents or cleaners are required when
is due to certain dynamic conditions that exist on cleaning the valve.
the snowmobile, i.e., the clutch and torque con-
verter.
MMC2002-001_04A.FM 04-9
Bench Test for Checking RAVE Valve The movement indicator must be turned all the
Operation way in to provide maximum spring pre-load. As
you begin pressurizing the engine using engine
The operation of the valve can be checked by pres- leak tester kit (P/N 861 749 100), you will find the
surizing the engine as one would when checking RAVE valve beginning to move at 5 kPa (0.7 PSI or
for crankcase leaks. 20 inches of water) and the valve will be fully dis-
The engine must be sealed at all exhaust flanges, placed when you reach 10 kPa (1.4 PSI or 40 inches
all carburetor inlets, and at the fuel pump impulse of water).
fitting. Depending on the design of your pressure NOTE: Due to the low pressure conditions when
test kit, you may be pressurizing the engine through using the leak tester kit (P/N 861 749 100) to check
the crankcase or right at the exhaust flange cover the RAVE valve operation, install a gauge with a
plate. If you are pressurizing through the crank- range of 0-200 inches of water (P/N 861 749 100)
case, make certain the piston uncovers the ex- on leak tester. As reference 6.89 KPa 1 (PSI) =
haust port on the side you are checking. 27.71 inches of water.
Install the RAVE valve movement indicator (P/N
861 725 800) in place of the red plastic adjuster on
the diaphragm cover so that you can observe the
diaphragm movement.
Troubleshooting
SYMPTOM CAUSE REMEDY
Engine revs 500 to 1000 RPM lower 1. Bent valve rod Replace
than its maximum operational RPM;
Rave valve is not opening. 2. Stuck valve Clean
3. Wrong spring tension

Replace
(too high)
4. Clogged passages Clean
5. Damaged bellows
or clamp(s) Replace
Engine hesitation in mid RPM range 1. Broken or weak spring Replace

and full peak performance is available
only after a while. 2. Adjustment screw too far out Turn until it bottoms
Rave valve opens too early.
3. Valve stuck open Clean
SKI-DOO utilizes cylinder reed induction technology on the new Series 3 twin cylinder engines. This
technology is beneficial in three ways.
1. It uses less parts, (i.e. shafts, rotary valve discs, etc.). Resulting in a lighten engine package.
2. This technology results in positive control of fuel mixture, while providing a straight pathway to the
intake and transfer ports as it is not obstructed by the rotating crankshaft.
3. By locating the carburetors higher on the engine this design allows for lower engine placement in the
chassis.
04-10 MMC2002-001_04A.FM
BASE GASKETS CARBURETION

377 P/N 420 931 781 0.4 mm
Carburetor Main Jet Correction Chart
443 P/N 420 931 780 0.3 mm
P/N 420 931 781 0.4 mm CARBURETOR MAIN JET CORRECTION CHART
P/N 420 931 782 0.6 mm

503 P/N 420 831 856 0.3 mm
P/N 420 831 858 0.4 mm
P/N 420 831 859 0.6 mm
°F/°C
453 P/N 420 931 580 0.3 mm
FT/METER - 60/ - 40/ - 20/ - 0/ + 20/ + 40/ + 60/ + 80/
P/N 420 931 581 0.4 mm - 50 - 40 - 30 - 20 -5 -5 - 15 - 25
P/N 420 931 583 0.5 mm %

0 111.10 107.40 103.70 100.00 96.30 92.60 88.90 85.20
P/N 420 931 582 0.6 mm 2000/

600 105.77 102.07 98.37 94.67 90.97 87.27 83.57 79.87
P/N 420 931 584 0.8 mm
4000/
1200 100.43 96.73 93.03 89.33 85.63 81.93 78.23 74.53
493 P/N 420 931 588 0.5 mm
P/N 420 931 589 0.8 mm 6000/
1800 95.10 91.40 87.70 84.00 80.30 76.60 72.90 69.20
P/N 420 931 960 0.7 mm 8000/ 89.7 86.07 82.37 78.67 74.97 71.27 67.57 63.27
2400
P/N 420 931 587 0.6 mm
1000/ 84.44 80.74 77.04 73.34 69.64 65.94 62.24 58.54
494 P/N 420 931 361 0.4 mm 3000
P/N 420 931 360 0.3 mm A01C47A
P/N 420 931 362 0.6 mm NOTE: When the answer gives an unavailable jet
593 P/N 420 931 582 0.6 mm size, select the next highest (richer) jet.
P/N 420 931 962 0.7 mm Example:
P/N 420 931 583 0.5 mm With a 250 stock main jet, at an altitude of a 600 m
(2000 ft) and a temperature of - 5°C (20°F):
P/N 420 931 584 0.8 mm
90.97
693 P/N 420 931 892 0.6 mm 250 x ----------------- = 227; use 230 jet.
100
P/N 420 931 893 0.5 mm
CAUTION: These values are guidelines only.
P/N 420 931 894 0.7 mm
Specific values/adjustments vary with temper-
P/N 420 931 895 0.8 mm ature, altitude and snow conditions. Always
699 P/N 420 931 570 0.3 mm observe spark plug condition for proper jetting.
P/N 420 931 571 0.4 mm This table is more than adequate for stock en-
gines. Two-stroke engines with high specific out-
P/N 420 931 572 0.6 mm puts that are heavily modified (twin pipes, high
793 P/N 420 931 838 0.5 mm compression, large carburetors, etc.) and perform-
ing at high RPM are very sensitive to air density
P/N 420 931 837 0.6 mm changes. The following is a very accurate formula
P/N 420 931 964 0.7 mm for correcting jetting.
P/N 420 931 839 0.8 mm First, a baseline for jetting must be established.
809 P/N 420 931 620 0.3 mm
P/N 420 931 621 0.4 mm
P/N 420 931 622 0.6 mm
MMC2002-001_04A.FM 04-11
Jetting, horsepower, and B.S.F.C. data can be ob- Record the C.R.A.D. when correct jetting has
tained with dyno testing but also confirmed with been established. This is the baseline for future
field testing. The tried and true method of deter- use. Jetting corrections for a different C.R.A.D.
mining mixture ratio is to inspect the parts of the can be obtained with the following ratio:
engine that are directly exposed to the combus-
New = New C.R.A.D. × Base line M.J.
tion process. The two best indicators are the spark ---------------------------------------------------------------------------------
main jet Base line C.R.A.D.
plug and the piston dome. The color and where it
is located are the two things to look for. Chocolate Example: Testing results in a 570 M.J. at a C.R.A.D.
brown on the insulator, ground electrode, and pis- of 105.4%. Two weeks later at the race track, the
ton dome indicate a proper mixture. The ground C.R.A.D. is 110.9%.
electrode should show a difference in color just at
the radius of the electrode. 110.9 × 570
The new M.J. = -------------------------------
The engine must be operated under load for at 105.4
least one minute to obtain accurate readings.
Establish the C.R.A.D. by using the following for- New M.J. = 600
mula:
1737.97 x C.A.P.
Useful Equations
C.R.A.D. = -----------------------------------------------------
460 + T
29.92 460 + T
C.A.P. = Corrected air pressure C.F. = --------------- × -------------------
B–E 520
C.A.P. = B - E
B = Barometric pressure readings (in – Hg) C.A.P. = B – E
R.H.
E = Vapor pressure =  S.P. x ------------ 1737.97 × C.A.P.
C.R.A.D. = --------------------------------------------
 100 
460 + T
See saturation pressure (chart 1).
Where:
S.P. = Saturation pressure (in – Hg)
B = barometer reading (in-Hg)
R.H. = Relative humidity (%) R.H.
E = vapor pressure (in – Hg) = S.P. × -----------
Record the C.R.A.D. when correct jetting has been or use wet bulb/dry 100
established. This is your base line for future use. bulb temperature and
Example: Testing established a 400 main jet at psychrometric chart
C.R.A.D. of 100%. One week later, the C.R.A.D. T = carb. inlet air temp (°F)
at the track is 110%. Use the following formula to
establish the new main jet. S.P. = saturation pressure (in-Hg)
R.H. = relative humidity (%)
New = New C.R.A.D. × Baseline main jet
----------------------------------------------------------------------------------------- C.A.P. corrected air pressure (in-Hg)
main jet Base line C.R.A.D.
C.HP = Corrected brake horsepower
110 × 400
Example: -------------------------- B.S.F.C. = Brake specific fuel consumption
100
New main jet = 440 C.R.A.D. = Corrected relative air density (%)
E.G.T. = Exhaust gas temperature
W.O.T. = Wide open throttle
04-12 MMC2002-001_04A.FM
SATURATION PRESSURE (CHART 1) Most racers use an air density gauge. This gauge
is fairly inexpensive. It basically establishes
S.P. = SATURATION PRESSURE C.R.A.D. for you by combining the variables on any
T = TEMP. (°F)
(in-Hg)
given day.
- 40 .004
First, establish a base line main jet by testing.
- 30 .008
After you have determined the correct main jet,
- 20 .012 record the jet number and the air density gauge
- 10 .020 reading.
0 .040 Example: Base line
5 .055 Gauge reading 90
10 .070 Main jet 300
15 .090 The next day at the track, your air density gauge
now reads 105. This means you have gained 15%
20 .110
air density.
25 .140
New density 105
30 .170
Base line 90
35 .208
105 – 90 = 15
40 .247
Multiply your base line main jet by 115.
45 .314
Example: 300 x 115 = 345
50 .380
Round off to next highest jet size.
55 .450
New main jet = 350
60 .521
Air density can change rapidly during the course
65 .630 of the day. Check your gauge frequently. Always
70 .739 use the same gauge for a different gauge may
read differently.
75 .884
80 1.030
85 1.225
90 1.420
95 1.675
100 1.930
MMC2002-001_04A.FM 04-13
Exhaust Gas Temperature Probe Air entering the bell of the carburetor has a speed
Location of V1 and pressure of P1. As the air is forced into
the smaller diameter of the venturi, speed increas-
es (V2) but pressure drops (P2).
1
Passages in the carburetor connect the venturi to
a reservoir of fuel (float bowl). The float bowl is
2
vented to the atmosphere (P1). P1 is greater than
P2 so fuel is pushed from the bowl to the venturi
via the jets and passages. Varying the size of jets
varies the amount of fuel the engine receives. En-
gine speed is controlled by varying the amount of
air/fuel mixture that the engine receives.
A00C3WY
Liquid gasoline does not burn, so for the engine to
Detonation = 720°C (1330°F) run efficiently, the fuel must be broken down into
small droplets, and mixed with the oxygen mole-
1. 100 mm from piston
2. Probe cules in the incoming air. This is referred to as at-
omization. The shape of the venturi and the shape
NOTE: Temperature at wide open throttle at max- and location of the jets and fuel delivery passages
imum HP RPM. will determine how well the fuel and air are mixed.
Exhaust gas temperatures (E.G.T.’s) can also give
an indication of mixture ratio. At wide open throttle
(W.O.T.) at maximum HP RPM, a leaner mixture
will produce higher E.G.T.’s and a richer mixture
will result in lower E.G.T.’s. (E.G.T.’s are not abso-
lute. Engines have seized with E.G.T.’s in the al- 1
lowable range).
Carburetor Operation
The operation of the carburetor is based on the
physical principle that fluids (air is a fluid) under
pressure gain speed but lose pressure when pass-
ing through a converging pipe (venturi).
2
P1 4
14.7 P2
PSI 11
(Less pressure)
3.7 PSI 3
A01C4AA
V2 V1 1. Float bowl
2. Needle valve
3. Float
4. Fuel inlet
A01C2QB 1 Air
1. Venturi
04-14 MMC2002-001_04A.FM
Dual outlet, round Mikuni fuel pump equals about

35 liters/hour.
Dual outlet, square Mikuni fuel pump equals about
30 liters/hour.
583 and larger 1995 vehicles use a single large ca-
pacity 70 liters/hour fuel pump. The following
parts list includes the pieces necessary to install
the 70 L/h pump.
4 1 LARGE FUEL PUMP PARTS
70 Liter/hour fuel pump P/N 403 901 200

Filter, in-tank P/N 414 872 100
2
Fuel line, in-tank P/N 414 943 700
3 Grommet, tank P/N 570 273 900
Connector, tank P/N 414 872 700
A01C4BA
Fuel line, tank to shut off valve P/N 414 939 900
1. Jet needle
2. Needle jet
3. Main jet Shut off valve P/N 414 872 200
4. Air jet
Fuel line, valve to pump P/N 414 931 400 (roll)
Dual Fuel Pump Installation Clamp, fuel line P/N 414 655 700
With a heavily modified engine, especially when
using large bore carburetors, the need for 580 or
larger main jets may arise. The capacity of the fuel MIKUNI VM AND TM TYPE
pump may be exceeded when using these large CARBURETORS
jets. To eliminate any possibility of starvation, in-
stall two fuel pumps as shown below. Be sure to Snowmobile engines are operated under a wide
use a separate impulse line to each pump. range of conditions, from idling with the throttle
valve remaining almost closed to the full load (the
1 maximum output) with the throttle valve fully
opened. In order to meet the requirements for the
proper mixture ratio under these varying condi-
5
tions, a low-speed fuel system (the pilot system)
5 and a main fuel system (the main system) are pro-
vided in Mikuni VM and TM type carburetors.
While this text covers the VM-type carb., the TM
4 flat slide carb. functions the same. The circuits
4
function the same and tuning a TM would be done
in the same manner as the VM.
2 4 2
4
3 3
A01C4CA
1. From fuel tank

2. Fuel inlet line
3. To car
4. Fuel outlet line
5. Impulse line
MMC2002-001_04A.FM 04-15
MIKUNI CARBURETOR (TM)

Screw
Cap
O-Ring
Spring
Ring
Guide holder
E-Ring
Needle
Ventury
Screw Piston valve
Packing
Screw
Nipple
Spring
Adjuster
Spring
Needle valve Screw
Adjuster
O-Ring
Pin
Float
Screw
Washer
Pilot jet
Main jet
Holder
Plate
Screw O-Ring
Hose Plate
Plug Screw
A32C34S
04-16 MMC2002-001_04A.FM
Mikuni TM Carburetor (tuning parts)

P/N DESCRIPTION
486 212 400 Pilot Jet, 15
486 212 500 Pilot Jet, 17.5
486 212 600 Pilot Jet, 20
486 212 700 Pilot Jet, 22.5
404 161 870 Pilot Jet, 25
486 212 800 Pilot Jet, 27.5
486 212 900 Pilot Jet, 30
486 213 000 Pilot Jet, 32.5
486 213 100 Pilot Jet, 35
404 144 700 Pilot Jet, 40
486 201 400 Pilot Jet, 45
404 144 800 Pilot Jet, 50
486 201 500 Pilot Jet, 55
404 145 300 Pilot Jet, 60
404 145 400 Pilot Jet, 65
486 213 200 Piston Valve, 3.0
486 213 300 Piston Valve, 3.5
404 161 867 Piston Valve, 4.0
486 213 400 Piston Valve, 4.5
486 213 500 Piston Valve, 5.0
404 161 868 Inlet Needle & Seat 1.5
404 161 871 Needle, J8-6FIY05-58
404 161 872 Needle, J8-6FIY04-59
404 161 873 Needle, J8-6FIY06-57
Part numbers with a 486 prefix must be ordered

from Valcourt Race Dept. All others must be or-
dered from your local Ski-Doo dealer.
MMC2002-001_04A.FM 04-17
MIKUNI CARBURETOR (VM)
04-18
Jet needle
Throttle valve
By-pass
Starter
plunger Air jet
Air screw
Pilot
outlet
Float
Pilot jet
Needle valve
Ring
Starter jet Needle jet

Main jet
Fuel Air Mixture
PRIMARY TYPE BLEED TYPE TYPE
A01C4DS
MMC2002-001_04A.FM
Starting Device (enrichner) Selection of the Aperture of Carburetor

Instead of a choke, the enrichner system is used One of the prerequisites for improving the output
on some Mikuni carburetors. In the starter type, is to use a carburetor with as large an aperture as
fuel and air for starting the engine are metered possible. However, a large aperture alone does
with entirely independent jets. The fuel metered not necessarily improve the output. As shown in
in the starter jet is mixed with air and is broken into the following illustration, it is true that a large ap-
tiny particles inside the emulsion tube. The mix- erture improves the power output in the high
ture then flows into the plunger area, mixes again speed range. In the slow speed range, on the other
with air coming from the air intake port for starting hand, the output drops. The aperture of a carbure-
and is delivered to the engine in the optimum air/ tor is determined by various factors. These factors
fuel ratio through the fuel discharge nozzle. The include (1) whether the vehicle is intended for rac-
starter is opened and closed by means of the starting, (2) the design of the engine, (3) driving tech-
er plunger. Since the starter type is constructed so nique of the driver, (4) the driver’s preference, etc.
as to utilize the negative pressure of the inlet pipe, In addition, the maximum output, the maximum
it is important that the throttle valve be closed torque and the minimum number of revolutions
when starting the engine. for stable engine operation must also be taken into
account.
1
Too large an aperture
2 Proper aperture
Too small
hp an aperture
3
4
5
A01C4EB
1. Plunger area
2. Emulsion tube
3. Inlet pipe
4. Needle jet
5. Float
A01C2OA Revolutions per minute (RPM)
Size of Mikuni Carburetors

Mikuni VM-type carburetors come in various sizes,
with the main bore ranging from 10 mm (.39 in) to
44 mm (1.73 in) (in even numbers for the most
part.) The carburetor body is made of aluminum or
zinc.
MMC2002-001_04A.FM 04-19
Carburetor Test
Once the aperture of the carburetor is determined,
a test to select the proper jet should be made. The
size of the jet is determined by measuring the out-
put in a bench or in a chassis dynamo test. For
racing, it is best to determine the proper size of
the jet on the racing track, because the following
points must be taken into account:
a. The altitude (atmospheric pressure), temper-
ature and humidity of the race track.
b. The operation of the engine based on the to-
pography of the race track.
Checking and Adjusting Float System

1. Invert the carburetor and check the alignment
between the float arm and the base of the car- A01C5AA A
buretor. The float arm should be parallel to the
TYPICAL
base.
A. Height (refer to table below)
2. Bend the actuating tab as required to make the
float arm parallel to the base. Be careful not to On TM 38, do not turn carburetor up side down.
bend the float arm. Measure float arm height when it just touches
needle valve without moving it.
NOTE: Incorrect float adjustment can prevent
proper tuning of a carburetor. Always make sure Float arm height dimensions:
the float is properly adjusted before attempting ad- FLOAT HEIGHT
CARBURETOR
justment of the other fuel metering system. MODEL ± 1 mm (± 0.40 in)
NOTE: Mikuni carburetors used on snowmobiles
VM 30
with fuel pumps require a smaller inlet needle VM 34
23.9 (.941)
valve (usually 1.5 or 2.0) than carburetors used in
gravity feed applications (3.0). VM 36
VM 38 18.1 (.713)
VM 40
To Adjust Height
VM 40
– Bend the contact tab of float arm until the spec- 22.9 (.901)
MX Z and Summit
ified height is reached.
VM 44 DPM 22.9 (.901)
1 TM 38 21.0 (.826)
NOTE: To adjust height — bend the contact tab of

float arm until the specified height is reached.
Pilot/Air System
PRINCIPLES OF OPERATION
The pilot/air system controls the fuel mixture be-
tween idle and approximately the 1/4 throttle po-
sition. As the throttle is opened wider for low speed
operation, the pilot outlet cannot supply adequate
A00C03A
fuel, and fuel then enters the carburetor bore from
1. Contact tab the bypass as well as the pilot outlet. The pilot/air
system is tuned by first adjusting the air screw;
then, if necessary, by replacing the pilot jet.
04-20 MMC2002-001_04A.FM
Adjusting Air Screw 7. Turn the air screw left and right (between 1/4
and 1/2 turn) and select the position where the
engine revolution reaches the maximum. Adjust
the throttle stop screw to bring down the engine
revolution to your target speed for idling. After
this adjustment of the throttle stop screw is
1 made, select once more the position where the
5
engine revolution reaches the maximum, by
turning the air screw left and right (between 1/4
and 1/2 alternately). At this point, attention
2 should be paid to the following points.
a. If there is a certain range in the opening of
the air screw where the fast engine revolu-
tion can be obtained (for instance, the num-
4 ber of revolutions does not change in the
3 range of 1-1/2 to 2.0 turns), it would be better
for acceleration to 1-1/2 turns.
b. To determinate the fully closed position of
the air screw, turn the air screw slightly. Ex-
cessive tightening of the air screw would
damage the seat. The position where the air
A01C4FA
screw comes to a stop should be considered
1. Pilot bypass the fully closed position. The maximum
2. Pilot outlet number of turns in the opening of the air
3. Pilot jet
4. Air intake screw must be limited to 3.0. If the air screw
5. Air screw is opened over 3.0 turns, the spring will not
NOTE: This procedure may be performed for sin- work and the air screw can come off during
gle and dual carburetors. Never adjust screws operation of the vehicle.
more than 1/4 turn at a time. Replacing Pilot Jet
1. Turn idle stop screw in until screw contacts
throttle valve. Then turn idle stop screw in 2 ad-
ditional turns.
2. Start and warm up engine. Adjust idle stop
screw to 500 RPM above normal idle speed.
See Low-Speed Fuel System.
3. Turn air screw in or out using 1/4-turn incre-
ments until engine RPM peaks or reaches its
maximum RPM.
4. Readjust idle stop screw to return engine to nor-
mal idle speed. See pages Low-Speed Fuel 1
System.
5. Repeat Steps 3 and 4 until engine operates at
normal idle speed and air screw is peaked.
6. When air screw is adjusted stop engine. Note
A01C4GA
the setting of air screw and turn it all the way
in. If it takes less than 1 turn, the pilot jet is too 1. Pilot jet
small and a larger one must be installed. If it
takes more than 2-1/2 turns to set air screw, the
pilot jet is too large and must be replaced by a
smaller one.
MMC2002-001_04A.FM 04-21
The throttle valve is cut away on the air inlet side

to help control the fuel/air mixture at low and in-
termediate throttle settings. The size of cut-away
also affects acceleration.
1 Throttle valves are numbered from 0.5 to 4.5 in 0.5
increments based on the size of the cut-away. The
most commonly used configurations are 1.5 to
Fuel flow
3.5. The higher the number, the greater the cut-

2 away and the larger the air flow.
3 The throttle valve functions in about the same
range as the pilot/air system. After the air screw
is adjusted, it can be used to check the throttle
valve selection.
NOTE: Too lean of a slide cut-away can cause pis-
Throttle valve opening (%) ton seizures during sudden throttle closures from
A01C4HA large throttle settings.
1. Total amount of fuel flow CHECKING AND SELECTING THROTTLE
2. Main fuel system
3. Pilot fuel system VALVE
Pilot jets are numbered from no. 15 (the smallest)

to no. 80 (the largest). The number corresponds to
fuel flow and not necessarily to drill size or
through-hole diameter. After changing the pilot jet,
check and adjust air screw as described above.
NOTE: Since the pilot/air system provides some
fuel up to wide open throttle, changes in this sys-
tem will affect the throttle valve, jet needle/needle 2.5
2.0
Fuel flow
jet, and main jet metering systems.

3.0
Throttle Valve
1
5 15 25 50 75 100
A01C2WA Throttle valve opening (%)
2
3 1. Operate engine at low throttle settings, accel-
erating from idle to 1/4 throttle.
2. If engine bogs during acceleration, there is
probably insufficient fuel. Turn in air screw
about 1/4 turn at a time. If engine acceleration
A01C2VA
is improved, after adjusting air screw, the throt-
tle valve cut-away needs to be decreased.
1. Throttle Valve
2. 3.0
3. 2.0
04-22 MMC2002-001_04A.FM
3. If engine runs rough or smokes excessively dur- Although the jet needle and needle jet function in
ing acceleration, there is probably too much fuel. the 1/4 to 3/4 throttle range, they also affect the
Turn out air screw 1/4 turn at a time. If engine amount of fuel present at wide open throttle.
operation is improved, the throttle valve cut- When tuning the jet needle, also check main jet
away needs to be increased. system operation.
NOTE: Illustration above indicates fuel flow ac-
cording to throttle valve size and the amount throt-
tle valve is opened.
4. Increase or decrease throttle valve cut-away
size in 0.5 steps.
5. Return air screw to its original setting and oper-
7
ate engine at low throttle settings. Accelerate
engine from idle to 1/4 throttle; engine should
accelerate smoothly.
6. As a final check, change the position of the air
6 1
screw. If this does not significantly affect en-
gine performance (as in steps 2 and 3), the
throttle valve is correct.
5 2
Jet Needle
2
3 4
4
3
4
A01C2XA
1. E-ring
3
Fuel flow
2. Needle jet
3. Fuel
4. Air
5. Metered here
2 6. Jet needle
7. Throttle valve
The jet needle raises and lowers with the throttle

valve which changes jet needle position in the
needle jet. Because the jet needle is tapered from
top to bottom, an increasing amount of fuel is de-
livered through the needle jet whenever the throt-
tle valve is raised. Increased or decreased air flow,
15 50 75 100 by the throttle valve position, regulates the amount
A01C2YA Throttle valve opening (%) of fuel through the needle jet and around the jet
needle.
The jet needle works with the needle jet to in-
The jet needle works on combination of length,
crease the amount of fuel as the throttle valve is
taper, and E-ring position. Each jet needle has a
raised.
number and letter series stamped on the body.
MMC2002-001_04A.FM 04-23
POSITIONING THE E-RING

1 LEAN
2 E-ring
4
3 Lean
1 Washer
5
2
Number RICH 3
D
stamped
here 4
5 Rich
6 7
A01C58A
A01C2ZA 1 to 5 = E-ring position
1. Check for a rich or lean setting by examining

Example: 6DH7 exhaust manifold. A very light brown or white
6 - Basic length of needle. color indicates a lean mixture. A very dark
DH - A single letter would indicate a single taper brown or black color indicates a rich mixture.
of the needle, double letter a double taper, The proper color is tan.
and three letters mean there is a triple taper. 2. Move E-ring one groove at a time to correct the
D - Amount of taper at top of needle. fuel/air mixture.
H - Amount of taper at bottom of needle. 3. If proper operation is obtained at all but the 3/4
throttle setting after the main jet has been
7 - Material, type of coating and start of second tuned, operation may be improved by changing
taper on needle. the jet needle taper. Do not, however, change
NOTE: Letter designation of the jet needle indi- the jet needle until main jet and E-ring position
cates the angle of taper. Each letter (starting with have been thoroughly checked.
A is 0.25° greater than preceding letter. Example: 4. If the E-ring is in the number 5 position and op-
D = 1°, E = 1-1/4°, F = 1-1/2°, G = 1-3/4°, and eration is still lean, a needle jet with a larger or-
H = 2°. This applies to both single and double taper ifice may be installed. This may be done only
needles. after thoroughly checking the main jet, jet nee-
At the top of the jet needle are five grooves num- dle, and E-ring positions.
bered 1 through 5 from top to bottom. The number NOTE: Make sure washer is installed under E-ring
3 or middle groove being the starting point for the on vehicles so equipped.
E-ring. The E-ring position on any jet needle deter-
mines the rich or lean part throttle or mid-range
carburetor operation.
Moving E-ring to position 1 or 2 lowers jet needle
into needle jet and leans out the fuel/air mixture.
Similarly, moving E-ring to position 4 or 5 raises jet
needle in needle jet and enriches the fuel/air mix-
ture.
04-24 MMC2002-001_04A.FM
Needle Jet
Fuel flow
2
15 25 50 100
A01C4JA Throttle valve opening (%)
A01C4IB
The needle jet works in combination with the jet

Fuel flow increasing
needle to meter the fuel flow in the mid range.

Changes to the needle jet should be made only if
the results of changing the jet needle position are
unsatisfactory. In stock applications, except for 1
specific calibration changes necessary at high alti-
tudes, the needle jet should not be changed. Se-
2
lection of the proper needle jet requires much care
and experience. Decreasing the needle jet size
can prevent the main jet from metering the proper
O-8
O-8
Q-0
P-2
P-4
P-6
P-8
amount of fuel at wide open throttle.
Increasing needle jet size
A01C4KA
Needle jets are stamped with an alphanumeric

code. The letter indicates a major change in fuel
flow. P-2, for example, indicates low flow; P-4,
greater flow, and so on. The number indicates mi-
nor adjustments in fuel flow. The first diagram
shows the relationship between the alphanumeric
needle jet size number and fuel flow.
NOTE: Needle jets carrying the numbers 166, 159
or 169 in addition to the P-2 or P-4 and are not
interchangeable. Be sure correct needles are used
as specified for your snowmobile.
MMC2002-001_04A.FM 04-25
Main Jet System TUNING THE MAIN JET SYSTEM

PRINCIPLES OF OPERATION + 20 - 22 (%)
+ 8 - 10 (%)
+ 8 - 10 (%)
+ 20 - 22 (%)
Fuel flow
1
5
2 47.5 50 75 100
A01C4LA Throttle valve opening (%)
Before operating the snowmobile, make sure all

4 parts, including clutch and drive belt, are in good
operating condition.
3 1. Operate snowmobile at wide open throttle for
A01C30A
several minutes on a flat, well packed surface.
1. Jet needle Change main jet if snowmobile fails to achieve
2. Metered here maximum RPM or labors at high RPM.
3. Fuel
4. Air 2. Continue to operate at wide open throttle and
5. Needle jet
shut off ignition before releasing throttle. Exam-
The main jet system starts to function when the ine exhaust manifold and spark plugs to deter-
throttle is approximately 1/4 open. The mid range mine if fuel/air mixture is too lean.
fuel is supplied by the main jet and regulated by NOTE: Do not change jet sizes by more than one
the needle jet/jet needle combination. The main increment (step) at a time.
jet meters the fuel when the throttle is in the wide
open position. 3. If the exhaust manifold or spark plug insulator
is dark brown or black, the fuel/air mixture is too
The main jets are available in sizes from number rich. Decrease jet size.
50 to number 840. The size number corresponds
to flow and not necessarily to hole size. 4. If the exhaust manifold or spark plug insulator
is very light in color, the fuel/air mixture is too
When experiencing erratic operation or overheat- lean. Increase jet size.
ing, check the main jet for dirt which can plug the
orifice. 5. If you cannot determine the color, proceed as if
fuel/air mixture were too lean and increase jet
size. If operation improves, continue to increase
jet size to obtain peak performance. If operation
becomes worse, decrease jet size to obtain peak
performance.
6. After proper main jet is selected, recheck jet
needle and needle jet.
04-26 MMC2002-001_04A.FM
Troubleshooting 2. When the air/fuel mixture is too lean:

When the carburetor setting is not correct for the a. The engine overheats.
engine, various irregularities are noticed. These b. The condition improves when the enrichner
can be traced to two causes as a whole: is opened.
1. When the air/fuel mixture is too rich: c. Acceleration is poor.
a. The engine noise is full and intermittent (four d. Spark plug electrodes are melted.
stroking).
e. The revolution of the engine fluctuates and a
b. The condition grows worse when the enrich- lack of power is noticed.
ner is opened.
f. Piston seizure or scuffing occurs.
c. The condition grows worse when the engine
gets hot.
d. Removal of the air cleaner will somewhat im-
prove the condition.
e. Exhaust gases are heavy.
f. Spark plug is fouled.
Functional Range Effectiveness in Relation to Throttle Opening
THROTTLE VALVE OPENING
Full open
3/4
1/2
1/4
1/8
Closed
Pilot jet and
pilot air screw
Throttle valve
Needle jet
Jet needle
Main jet
A01C2TS
MMC2002-001_04A.FM 04-27
FUEL/OIL RATIO CHARTS

50/1
METRIC (SI) METRIC (SI)
25
500 mL of oil + 25 L of fuel = 50/1 20
15
10
Liters of fuel
5
Milliliters of oil needed

100 200 300 400 500
IMPERIAL
IMPERIAL 5
4
Imp. gal of fuel

3
16 oz of oil + 5 Imp. gal of fuel = 50/1 2
Imp. oz of oil needed 1

500 mL of oil + 5.5 Imp. gal of fuel = 50/1
4 6.5 8 12 16
UNITED STATES
UNITED STATES
5
3
13 oz of oil + 5 U.S. gal of fuel = 50/1 U.S. gal of fuel
2
500 mL of oil + 6.6 U.S. gal of fuel = 50/1 U.S. oz of oil needed 1
5 10 13
A00A1WJ
04-28 MMC2002-001_04A.FM
40/1
20
500 mL of oil + 20 L of fuel = 40/1 15
10
Liters of fuel

100 250 300 400 500
IMPERIAL
IMPERIAL 8.8
7
6
16 oz of oil + 4.0 Imp. gal of fuel = 40/1
5
500 mL of oil + 4.8 Imp. gal of fuel = 40/1 4
3
Imp. gal of fuel
2
1
Imp. oz of oil needed
8 16 24 32 35.2
(1 liter)
UNITED STATES
UNITED STATES
10.2
8
500 mL of oil + 5.3 U.S. gal of fuel = 40/1
6
U.S. gal of fuel
4.8
2
U.S. oz of oil needed
8 16 24 33.8
(1 liter)
A00A2WJ
MMC2002-001_04A.FM 04-29
33/1
40
33
500 mL of oil + 16.5 L of fuel = 33/1 30
20
16.5
Liters of fuel 10
200 500 700 1000

(1 liter)
IMPERIAL
7.2
IMPERIAL 5
3.6
Imp. gal of fuel
24 oz of oil + 5 Imp. gal of fuel = 33/1

1
500 mL of oil + 3.6 Imp. gal of fuel = 33/1 10 17.6 24 30 35.2 40

(1 liter)
UNITED STATES
UNITED STATES 8.8
19.4 oz of oil + 5 U.S. gal of fuel = 33/1

5
4.4
3
U.S. gal of fuel
10 19.4 30 33.8
16.9 (1 liter)
A00A6KJ
04-30 MMC2002-001_04A.FM
25/1
25
20
500 mL of oil + 12.5 L of fuel = 25/1
15
12.5
10
Liters of fuel 5

100 300 500 700 900
(1 liter)
IMPERIAL
IMPERIAL
5.5
4.5
3.5
16 oz of oil + 2.5 Imp. gal of fuel = 25/1
Imp. gal of fuel 2.5
500 mL of oil + 2.7 Imp. gal of fuel = 25/1 1.5

Imp. oz of oil needed .5
8 16 24 32 35.2
(1 liter)
UNITED STATES UNITED STATES

6.4
5
4
15 oz of oil + 2.8 U.S. gal of fuel = 25/1
2.8
U.S. gal of fuel
500 mL of oil + 3.2 U.S. gal of fuel = 25/1 2
1
8 15 24 33.8
(1 liter)
A00A2YJ
MMC2002-001_04A.FM 04-31
20/1
20
15
500 mL of oil + 10 L of fuel = 20/1
10
Liters of fuel 5

100 300 500 700 900
(1 liter)
IMPERIAL
IMPERIAL 5
4.4
3
Imp. gal of fuel
2
16 oz of oil + 2 Imp. gal of fuel = 20/1
1
500 mL of oil + 2.2 Imp. gal of fuel = 20/1 8 16 24 32 35.2
(1 liter)
UNITED STATES
UNITED STATES
5.1
4
16 oz of oil + 2.4 U.S. gal of fuel = 20/1
3
U.S. gal of fuel 2.4
1
8 16 24 33.8
(1 liter)
A00A2ZJ
04-32 MMC2002-001_04A.FM
DIGITAL PERFORMANCE
MANAGEMENT (DPM) SYSTEM 0
Hood
3
Vent
Engine
1
Fuel pump
A03C2MS
MMC2002-001_04A.FM 04-33
COMPONENT LOCATION
1 4
A03C2GA 3 2
1. MPEM module
2. Manifold
3. Engine temperature DPM sensor
4. Air temperature DPM sensor
THEORY AND OPERATION

PURPOSE
Calibrate the air/fuel mixture in order to optimize the
engine output while reducing fuel consumption.
METHOD
The system makes the pressure vary within the car-
buretor bowl.
04-34 MMC2002-001_04A.FM
OVERALL SYSTEM OPERATION
2
A06I0PS
3 CYLINDER ENGINE SHOWN — SAME PRINCIPLE FOR 2 CYLINDER ENGINE

1. MPEM module
2. Carburetor bowls
3. Distribution gallery (upper tube)
MMC2002-001_04A.FM 04-35
Introduction Over 3000 RPM, compensation mode is activated

but will compensate only if the air temperature ex-
The engine is being started using the manual starter.
ceeds - 20°C (- 4°F) and the air pressure is lower
The Digital Performance Management (DPM) sys- than 1000 mbar.
tem increases pressure within all 2 carburetor
bowls thus the air/fuel mixture is enriched. This is Float bowls are now under vacuum (lower than atmo-
what we call the enrichment mode. spheric pressure) and the air/fuel mixture is leaner.
NOTE: On Summit x 670, use primer to ease cold NOTE: On Summit x 670 both modes (enrichment
starting. See STARTING PROCEDURE at the end or compensation) can operate at the same time.
of this section.
As soon as the spark plug gives off its first spark, DPM SYSTEM OPERATION
the DPM system calculates the enrichment time BLACK and WHITE/GRAY wires (2-05 housing) are
and rate based on the engine temperature. used for programming by the manufacturer. Noth-
Once enrichment mode is completed carburetor ing must be plugged to this housing.
bowls return to atmospheric pressure (DPM in
standby mode), and the air/fuel mixture is identical
to that of carburetors without the DPM system.
Enrichment Mode (starting)
A06I0QS
TYPICAL
04-36 MMC2002-001_04A.FM
Turning the ignition key to the ON position will not energize DPM system. The DPM system is energized only.
Once the engine turns over 250 RPM.
The DPM system then comes on by reading the engine temperature through the sensor located on the
cylinder head. The DPM system calculates the enrichment solenoid opening time (duty cycle) and the
enrichment rate according to the temperature. The air/fuel mixture is then enriched in order to facilitate
starting.
The system pressurizes both carburetor bowls in order to enrich the air/fuel mixture. This is accomplished
with the help of an air pump.
TO
CARBURETOR
ACTIVE
CALIBRATED JET
TO
ENRICHMENT CARBURETOR
AIR JET SOLENOID
FROM AIR COMPENSATION

PUMP SOLENOID
A03I0LS
This enrichment mode of the air/fuel mixture takes place at start-up and during engine warm-up, and it
depends on engine temperature.
The higher the engine temperature upon start-up, the leaner the mixture.
MMC2002-001_04A.FM 04-37
This enrichment mode progressively decreases (with time) by reducing the solenoid duty cycle. The warmer
the engine, the shorter the enrichment mode.
If the throttle opening exceeds one quarter, the enrichment mode is interrupted by a switch during the
starting process, which allows unflooding the engine.
However, the enrichment mode is restored when releasing the throttle.
Following the enrichment mode, carburetors are operating normally, i.e. without additional pressure within
bowls.
NOTE: Calibration is exactly the same on engines with a DPM system and those without.
Compensation Mode
2
A06I0US
1. Air jet
2. Needle jet air inlet
Three conditions must be met for the compensation mode to operate:

1. Engine must rev over 3000 RPM.
2. Air temperature must exceed - 20°C (- 4°F).
04-38 MMC2002-001_04A.FM
3. Atmospheric pressure must be lower than 1000 mbar.

The compensation system brings both carburetor bowls under vacuum (lower than atmospheric pressure)
in order to make the air/fuel mixture leaner. The required vacuum is produced within the needle jet air inlet.
FROM
CARBURETOR
(VENTURI)
ACTIVE
CALIBRATED JET
FROM
CARBURETOR
(VENTURI)
ENRICHMENT
AIR JET SOLENOID
FROM AIR COMPENSATION FROM CARBURETOR

PUMP SOLENOID (VENTURI)
A03I0MS
The compensation ratio will depend on the air temperature and the atmospheric pressure.
The higher the air temperature, the leaner the air/ fuel mixture.
The lower the atmospheric pressure, the leaner the air/fuel mixture.
NOTE: The atmospheric pressure decreases as the altitude increases.
MMC2002-001_04A.FM 04-39
AIR PUMP OPERATION The DPM manifold no. 2 consists of 2 tubes. De-
pending on the mode, the upper tube (distribution
gallery) distributes pump pressure or vacuum to
each bowl through 2 pipes. The passage is then
opened by the enrichment or the compensation
solenoid, depending on the mode.
The lower tube (vacuum collector) receives the
vacuum created by each carburetor within the
needle jet air inlet.
An air jet (manifold air jet) also allows the atmo-
spheric pressure to enter.
1 3
A06C3WA 1 2
TYPICAL
1. Regulator
2. Pump
Air pump no. 1 supplies the distribution gallery

through a unique pipe.
Pump diaphragm is activated by the alternating
pressure/vacuum within the engine crankcase.
Two pipes connect the crankcase (cylinders nos. A03C2IA 2 4
1 and 2) to the pump. MANIFOLD ASS’Y
A regulator within the pump stabilizes the pump 1. Upper tube: distribution gallery
2. Lower tube: vacuum collector
pressure. 3. Manifold air jet (1.2 mm) — atmospheric pressure
4. From air pump
Since the pump pressure is insufficient upon start-
ing, the regulator is fed directly by the crankcase
pressure.
DPM MANIFOLD OPERATION
A03I0NA 1
TYPICAL
1. Compensation solenoid air jet (1.4 mm)
A03C2HA 1
1. Manifold
04-40 MMC2002-001_04A.FM
Enrichment Solenoid The duty cycle of the compension solenoid de-

pends on the air temperature and the atmospheric
Solenoid Operating Principle pressure.
A solenoid is a winding coiled in order to produce The warmer the air, the longer the duty cycle.
a magnetic field. A metal rod crosses the coil and Therefore, the solenoid will stay open longer, thus
cuts the magnetic field. Each time the coil is acti- giving way to vacuum. The same applies when the
vated, the magnetic field attracts the rod. If the altitude increases.
supply current is interrupted, a spring pushes the
rod. 1
Solenoid Function within the DPM System
The DPM system turns the solenoid no. 3 ON and
OFF 10 times per second, which means that it op-
erates at 10 cycles/second or 10 Hertz (Hz). The
solenoid therefore opens and closes 10 times per
second, thus allowing the pump pressure to reach
the distribution gallery (upper tube).
For the pressure to vary within the bowls, the so-
lenoid is activated in part by the DPM during each
cycle. This is what is called the duty cycle. In other
words, the solenoid will not open throughout the
whole cycle. The duty cycle depends on the en-
gine temperature.
The colder the engine, the longer the duty cycle.
Therefore, the solenoid will stay open longer, thus
giving way to pressure.
A03C2JA
1. Air temperature sensor
Manifold Air Jet

This jet allows the atmospheric pressure to reach
carburetor bowls when the DPM SYSTEM is on
standby (returned to atmospheric pressure).
1
A06E2QA 1
1. Engine temperature DPM sensor
Compensation Solenoid A03C2KA
NOTE: Same principle as enrichment solenoid. REAR VIEW

Read Solenoid Operating Principle at the begin- 1. Atmospheric pressure air jet
ning of the chapter concerning the enrichment so-
lenoid.
MMC2002-001_04A.FM 04-41
TESTING PROCEDURE DPM System

Solenoids are supplied by the MPEM module. If
Pump this module does not work, there will be no cur-
Pressure Test rent on compensation solenoid RED/BLUE and
BLACK connectors (3-10 housing); and on enrich-
The pump must create a minimum pressure of ment solenoid RED/GREEN and BLACK connec-
400 ± 50 mm of water. tors (3-11 housing).
Connect a jet (P/N 270 500 157) to a hose then con- Unplug upper solenoid wire (enrichment). Con-
nect that little tube to the small nipple of a T-fitting nect a good solenoid to module output connector.
(P/N 414 222 500). Install that T-fitting between a Use adaptor (P/N 529 033 800) as required.
U-tube and air pump outlet.
CAUTION: Do not disconnect both DPM con-
nectors. The compensation solenoid must re-
main plugged.
Disconnect engine temperature sensor connec-
tor. The DPM system now operates as though the
engine temperature was - 20°C (- 4°F) to allow
maximum mixture enrichment.
A06I0XA
TYPICAL
A. 400 ± 50 mm of water
A03C2LA 1
1. Engine temperature sensor
Start the engine and observe the solenoid. A vi-

brating solenoid indicates that the module is in
good working order. If not, replace the module and
A06H36A 1 repeat test.
1. T-fitting (P/N 414 222 500)
2. Jet (P/N 270 500 157)
Start engine and note water height.
04-42 MMC2002-001_04A.FM
Solenoid Initial Cold Starting

Static Test NOTE: Do not operate the throttle lever.
Disassemble the solenoid and connect it to a 12 V Above Freezing Point Temperature (0°C)
battery. The solenoid must open and stay open. Grasp manual starter handle firmly and pull vigor-
Repeat test several times. ously to crank engine.
At reassembly, ensure that solenoid seals are in If engine refuses to start, activate the primer but-
place. ton once then crank the engine again.
Below Freezing Point Temperature (0°C)
Activate primer button 2 or 3 times before crank-
ing engine to inject fuel into intake manifold.
In extremely cold temperature, more priming may
be required.
After the engine is started, the Digital Performance
Management (DPM) system will control the car-
buration.
A06E2OA 1 2 Warm Engine Starting

1. Plastic seal Priming is not necessary when engine is warm.
2. O-rings
Crank engine normally without operating the throttle
Dynamic test lever.
When checking the enrichment solenoid, discon- IMPORTANT: Operating the throttle lever while
nect engine temperature sensor connector. The cranking the engine will deactivate the DPM sys-
DPM system now operates as though the engine tem.
temperature was - 20°C (- 4°F) to allow maximum
mixture enrichment. IGNITION SYSTEMS, SPARK
Remove the solenoid, hold it in hand and start the PLUGS
engine.
For the enrichment solenoid, check if it vibrates as Two-stroke engines in snowmobiles rely on an
soon as the engine is started. electric spark to initiate combustion of the fuel/air
charge which has been inducted into the cylinder.
For the compensation solenoid, the air tempera- For the engine to operate efficiently, the spark
ture sensor no. 4 must be at room temperature. must be delivered at precisely the right moment
Operate the engine at 3500 RPM. The solenoid in relation to the position of the piston in the cylin-
must vibrate. der and the rotational speed of the crankshaft.
Temperature Sensor (air and engine) Additionally, the spark must be of sufficient inten-
sity to fire the fuel mixture, even at high compres-
At room temperature 20°C (68°F), the sensor re- sion pressure and high RPM.
sistance must be 2500 Ω ± 300.
It is the function of the ignition system to generate
this voltage and provide it to the spark plug at the
STARTING PROCEDURE correct time.
Apply brake.
Check throttle lever operation. Make sure it re-
turns to idle position when released.
Ensure that the emergency cut-out switch is in the
ON position.
Ensure that the tether cut-out cap is on the DESS
post and that the cord is attached to your clothing.
MMC2002-001_04A.FM 04-43
The Nippondenso capacitor discharge ignition The optimum ignition would then have timing sig-
(CDI) system has magnets located on the crank- nificantly advanced at lower RPM, but would re-
shaft flywheel. AC voltage is induced in the gen- tard the timing at higher RPM to keep the engine
erating coil(s) as the poles of the magnets rotate out of detonation. Generally, as the ignition timing
past the poles of the coils. Timing is controlled by is advanced, the low end mid range power will be
a trigger coil or the position of the coil poles rela- improved and the peak power will be moved to a
tive to the magnet poles, which are directly related lower RPM. Retarding the timing will generally re-
to piston position. The CD (or amplifier) box con- duce low and mid range power but may allow jet-
tains the electronic circuitry to store and control ting to be leaner and increase peak power. Peak
the initial voltage and deliver it to the ignition coil power will be moved to a higher RPM. These are
(and then the spark plug) at the correct moment. generalizations and ignition timing must be opti-
The ignition coil is a transformer that steps up the mized depending on engine design, RPM range
relatively low voltage, 150-300 V, of the generat- and operating conditions.
ing coil to the 20,400 – 40,000 volts necessary to Ignition advance on Rotax engines is measured by
jump the spark plug gap and initiate the burning of a linear distance of piston travel BTDC. A dimen-
the fuel/air mixture in the combustion chamber. sion taken through a straight spark plug hole in the
Maximum power from a given engine configura- center of the head is a direct measurement. A di-
tion is produced when peak combustion chamber mension through an angled plug hole on one side
pressure (about 750 PSI) takes place at about 15° of the head is an indirect measurement. A direct
of crankshaft rotation ATDC. Normal combustion measurement can be converted to degrees of
is the controlled burning of the air/fuel mixture in crankshaft rotation by the appropriate formulas.
the cylinder. The flame is initiated at the spark plug Initial ignition timing procedures can be found in
and spreads to the unburned mixture at the edges the Shop Manual for the particular model being
of the cylinder. worked on.
This flame front travels through the cylinder at Starting with most 1990 Ski-Doo models, a Nip-
about 100 feet per second. In order to achieve pondenso CDI system with only one generating
maximum pressure at about 15° ATDC, the spark coil was introduced. This system is identified by
must occur about 15° before TDC. Complete com- having only two wires running from the stator
bustion will finish at about 35° ATDC. The actual plate to the CD box.
amount of spark advance BTDC is dependent
upon bore size, combustion chamber shape, oper- Ignition Timing
ating RPM, mixture turbulence and the actual flame Ignition timing is no longer able to be adjusted me-
speed. chanically. It must be done by your dealer with an
Flame speed is directly proportional to piston MPEM programmer.
speed in an almost linear fashion. Though it is not
completely understood why this relationship ex- Spark Plug Heat Range
ists, it is thought to be related to intake speed and
Spark plug heat ranges are selected by measuring
mixture turbulence. Hence, flame speed increas-
actual combustion chamber temperatures. A cold-
es as RPM increases. It also increases as the air/
er spark plug, one that dissipates heat more rapid-
fuel ratio becomes leaner.
ly, is often required when engines are modified to
Because the flame speed is slower at lower RPM’s, produce more horsepower.
more advance at low RPM is necessary for maxi-
The proper operating temperature or heat range of
mum performance. Advancing the spark too much
the spark plugs is determined by the spark plugs
BTDC for the needs of the engine will cause the
ability to dissipate the heat generated by combus-
engine to go into detonation.
tion.
04-44 MMC2002-001_04A.FM
The longer the heat path between the electrode

tip to the plug shell, the higher the spark plug op-
erating temperature will be — and inversely, the
shorter the heat path, the lower the operating tem-
perature will be.
1 2
A00E09A
1. Cold
2. Hot
A cold type plug has a relatively short insulator

nose and transfers heat very rapidly into the cylin-
der head.
Such a plug is used in heavy duty or continuous
high speed operation to avoid overheating.
The hot type plug has a longer insulator nose and
transfers heat more slowly away from its firing
end. It runs hotter and burns off combustion de-
posits which might tend to foul the plug during
prolonged idle or low speed operation.
Generally speaking, if you have increased horse-
power by 10-15%, you will have to change to the
next colder heat range spark plug.
Most Ski-Doo’s are equipped stock with NGK BR-
9ES spark plugs.These are resistor-type plugs
which help reduce radio frequency interference.
To help prevent spark plug fouling use BR9ECS
type plug. Used ONLY resister type plugs.
MMC2002-001_04A.FM 04-45
Design Symbols Used on NGK Spark Plugs
First letter prefix for thread Second and third letter prefix Heat rating number First letter suffix for thread: Second letter suffix for con-
and hexagon size for construction feature, reach struction feature, etc.
except single prefix
Letter Thread size Hexagon Letter Construction feature 2 Hotter Type Letter Thread reach Letter Construction feature, etc.
size
A 18 mm 25.4 mm B Hexagon size 20.6 mm 12.0 mm A -Specials

4 (thread dia. 18 mm) B -Special plug for Honda
B 14 mm 20.6 mm C Hexagon size 16.0 mm vehicles
5 None 9.5 mm C -Competition type
C 10 mm 16.0 mm G Hexagon size 23.8 mm (thread dia. 14 mm) G -Racing plugs, center
6
electrode of nickel alloy
D 12 mm 18.0 mm L Compact type (SHORTY) 22.5 mm GV -Racing plugs, center
(thread dia. PF 1/2 in- electrode of precious
F 7/8 in-18 23.8 mm M Compact type (BANTAM) 7 Ordinary 14 mm) metal
plug N -Racing plugs, nickel
G PF 1/2 in-14 23.8 mm P Projected insulator 16.0 mm electrode
nose type 8 (thread dia. 7/8 in-18mm) P -Racing plugs, platinum
(85) ground electrode
R Resistor type L 11.2 mm R -Shielded resistor plugs
9 S -Copper core center
S Shielded type H 12.7 mm electrode (Super)
(95) (racing type 18.0 mm) V -Center electrode of
U Surface discharge type 10 precious metal
E 19.0 mm W -Tungsten electrode
(105) (racing type 18.0 mm) X -Series gap plugs
Y -V-Grooved center
Racing F Conical seat type electrode
plugs
11 A -F 10.9 MM
B-F 11.2 MM
12 BM - F 7.8 MM Multiple ground electrodes type
BE - F 17.5 MM K 2 T 3
13 Colder type M 2 Q 4
Others Expect for above letters,
14 there are special plugs
of J, L, Z, etc
( (
*Standard regulation is Wide gap type (mm)
drawn here. There also
exist a few extraordinary
S 11
symbol.
A01E1GS
B P 6 E
04-46 MMC2002-001_04A.FM
STOCK CLASS PREPARATION 4. Check piston to cylinder clearances, ring end

gap, cylinder taper and out-of round.
NOTE: Any machining and/or grinding is illegal in
5. Assemble the engine using the correct seal-
stock class racing. Keep your machine legal!
ants where needed.
1. Remove and disassemble the engine according
Rotary valve timing should be set with the closing
to correct Shop Manual procedures.
edge as close to specs as possible or slightly higher.
2. With the crankshaft resting in the lower half of
NOTE: Refer to chart page.
the crankcase, set up a dial indicator and check
the run out of the crankshaft at both ends. You 6. The engine should be pressure-tested for air
should see no more than 0.05 mm (0.002 in) run leaks. It should hold 6 PSI for 6 minutes with
out. If you have the capability, adjust the crank- no more than a 1 PSI/min. Ioss.
shaft as close to perfect as possible. 7. Lube the rewind and inspect the rope for frays
or cuts.
8. Oval racing must use taillight, brake light ele-
ment on continuously (jumper from taillight
wire terminal to brake light terminal on taillight
assembly), regulator, tachometer, and temper-
ature gauge.
2 9. Synchronize carburetors so that they open pre-
cisely together and ensure that the cut aways
of the slides clear the inlet bores of the carbu-
retors. After carb. adjustment, adjust oil injec-
tion pump.
10. On RAVE valve-equipped engines, check for
1
free movement of the RAVE valve mechanism.
A01C0RB Check the passageways between valve piston
and exhaust port for any carbon buildup.
1. Measure behind the key
2. Measure at 6 mm (1/4 in) from edge Adjust RAVE preload. It is better to have the valve
3. Set your cylinder base gaskets and cylinders on open a little earlier than later.
the upper half of the crankcase, and lightly NOTE: Pump fuels can be oxygenated or contain
torque the cylinders to the half. Be sure to install alcohol. Have your fuel tested prior to the race.
exhaust manifold on the cylinders before tight- Do not use fuel de-icers.
ening them to the upper crankcase half to en-
sure the same position of the cylinders on final 11. Tie wrap ignition wire connectors together.
assembly. 12. Adjust carburetors for atmospheric conditions.
Check the match of the gaskets and cylinders to (See carburetion section.)
the base; match them perfectly with a die grinder 13. Break in a new engine before racing it. Perfor-
in the areas of transfer port passages. Also check mance can be gained by getting some run time
for any over lap of the exhaust manifold gaskets on the engine. Ten hours of break-in is recom-
where the exhaust manifold joins the cylinders. mended.
Before reassembling make sure that parts are free
of any dust or particles.
MMC2002-001_04A.FM 04-47
SECTION 05 - TRANSMISSION SYSTEM
TABLE OF CONTENTS 0
BASIC FUNCTIONS OF THE SYSTEM ..................................................................................... 05-2
EFFECTS OF THE DRIVE PULLEY LEVER ARM, ROLLER AND ROLLER PIN WEIGHT ......... 05-3
EFFECTS OF THE RAMP PROFILE ON THE SHIFT FORCE ..................................................... 05-6
DRIVE PULLEY ........................................................................................................................... 05-9
INSTRUCTION ........................................................................................................................... 05-9
DISASSEMBLY........................................................................................................................... 05-9
CLEANING (IF REQUIRED)........................................................................................................ 05-11
INSPECTION .............................................................................................................................. 05-11
ASSEMBLY................................................................................................................................. 05-11
INSTALLATION .......................................................................................................................... 05-14
DRIVE PULLEY ADJUSTMENT................................................................................................. 05-14
PULLEY DISTANCE AND ALIGNMENT................................................................... 05-15
GENERAL ................................................................................................................................... 05-15
GENERAL PROCEDURE ............................................................................................................ 05-16
PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART......................................... 05-16
RAMP CHARACTERISTICS ....................................................................................................... 05-19
TRA RAMP PROFILES ............................................................................................................... 05-20
EFFECTS OF THE DRIVE PULLEY SPRING .............................................................................. 05-25
TRA SPRINGS CHART............................................................................................................... 05-28
EFFECTS OF THE DRIVEN PULLEY SPRING ........................................................................... 05-30
EFFECTS OF THE DRIVEN PULLEY CAM................................................................................. 05-31
BALANCING OF PULLEYS ........................................................................................................ 05-34
DRIVE BELTS.............................................................................................................................. 05-35
CHAINCASE GEARING ............................................................................................................. 05-37
TRANSMISSION CALIBRATION PROCEDURE ........................................................................ 05-40
MMC2002-001_05A.FM 05-1
BASIC FUNCTIONS OF THE In the speed diagram, the inclined line labelled low
ratio indicates the vehicle speed at each RPM
SYSTEM when locked into the 3.8:1, low gear ratio. At 8000
RPM, the vehicle speed would be just under 20
The TRA Clutch MPH if held in this ratio. The high ratio line com-
We call it a clutch but that set of pulleys is a lot pares vehicle speed with engine RPM when the
more than simply a clutch. Once the system reach- transmission is locked into the .8 :1 high gear. At
es its low ratio speed, the clutch function ends and this ratio, the vehicle speed would be just under
the pulleys become a completely automatic trans- 80 MPH when the engine is turning 8000 RPM. In
mission searching for the highest gear ratio that calibrating the clutches, the objective will be to
can be pulled at the engine’s given output. In the maintain as horizontal a line as possible between
case of our TRA clutch, the pulleys will begin shift- the low ratio and high ratio lines. This transition
ing from a 3.8:1 ratio in low gear to a .8:1 overdrive line or shift speed must be as close as possible to
ratio in high gear. That is a lot of ratio change. A the engine peak horsepower RPM.
typical six-speed motorcycle gearbox, for instance, Engagement speed of the clutch is always set as
will change from a 2.38:1 ratio in low gear to a .96:1 low as possible to avoid track slippage and to pro-
overdrive ratio in high gear. long drive belt life. The clutch must be engaged at
The ratio changing is done by opening and closing an RPM that is high enough, however, that the en-
a drive and driven pulley and forcing a fixed length gine will be producing enough horsepower to
drive belt to turn around different diameters on overcome drag and allow acceleration without
each pulley. The force used to close the engine or bogging. In the speed diagram, the acceleration
drive pulley is centrifugal force. It is the job of the period between 0 and about 20 MPH illustrates
ramps, rollers and lever arms to convert and con- the actual clutching period of the transmission.
trol the centrifugal force. During this time the rollers in the clutch are on the
Each engine will produce its minimum horsepower initial angles of the clutch ramps and the drive belt
at a particular RPM. Power will decrease at engine is actually slipping in the engine pulley as engine
speeds on either side of the peak power RPM. The and vehicle speeds increase to about 9000 RPM
usable width of the power band will dictate where at 25 MPH. The transmission then begins upshift-
the clutch must be calibrated to keep the engine ing to the high ratio at a constant engine RPM.
performing at its peak. In the power curve the Engine speed should not increase above the cali-
mildly-tuned engine has its peak horsepower of 64 bration RPM until the high ratio is achieved. If the
at 5800 RPM and has a usable power band width engine RPM exceeds the calibration RPM once
of 1500 RPM. The race tuned engine produces its the high gear position is achieved, it is an indica-
peak of 92 horsepower at 9300 RPM, but only has tion that the chaincase gearing is too low. If clutch
a usable power band width of 400 RPM. The race calibration is accurate, engine speed should never
engine will have to have a much more accurately vary more than 50 RPM from the peak power
calibrated clutch to be able to keep the engine run- RPM. This is the optimum shift curve.
ning within a 400 RPM range compared to the The following section will discuss each of the tun-
1500 RPM wide range of the mildly-tuned engine. able components of both the drive and driven pul-
The goal of clutch calibration is to keep the engine, leys and provides some insight and data neces-
at full throttle at its peak horsepower RPM and, at sary for tuning the system.
the same time, to select the highest possible gear
ratio as dictated by the load on the drive axle. The
speed diagram illustrates what the goal of good
clutch calibration is.
05-2 MMC2002-001_05A.FM
POWER CURVES MILDLY TUNED VS. RACE EFFECTS OF THE DRIVE PULLEY
TUNED
LEVER ARM, ROLLER AND
HP ROLLER PIN WEIGHT
100
Raced tuned
As you have seen in the formula defining centrifu-
90 gal force, the force increases directly with the
80
weight of the components involved. If you want
to increase the centrifugal force, therefore, the
70 400 RPM shift force, it is a simple matter to increase the
60 weight of the pressure levers. If the overall RPM
is too high, a heavier lever arm or roller pin could
50
be installed. The opposite would apply if the RPM
Mildly tuned
40 is too low.
30
1500 RPM The major factor controlling centrifugal force is en-
20
gine RPM. Because the force increases with the
RPM square of this speed, you can quickly have too
10
x 1,000
much force if heavy weights are used on a clutch
1 2 3 4 5 6 7 8 9 10
fitted to a high RPM engine. Because of this rela-
A01D0VA
tionship, you will find heavy weights used on low
RPM, high torque engine types and much lighter
SPEED DIAGRAM ENGINE SPEED VS. VEHICLE weights used on the high RPM engines.
SPEED
The effect of the weights will always be greater at
Engagement
high RPM, and at higher ratios. This is true be-
Speed cause of the relation of the force to the square of
RPM the engine speed. Also the radius from the axis of
Low Ratio rotation to the center of mass of the counter-
10,000
High Ratio weights increases as the roller is allowed to move
9,000 down the ramps. As this radius increases, the cen-
8,000 trifugal force increases directly. Addition of weight
7,000 will affect engagement speed very little compared
6,000
Shift - Speed to the effect the weight will have at mid-range to
5,000
top speed.
4,000 Minor changes in weight are accomplished by us-
3,000 ing various weight roller pins. The effects of add-
2,000 ing weight are illustrated in the following illustra-
1,000
tion. The three curves show the engine RPM
increasing from engagement speed (4000 RPM)
10 20 30 40 50 60 70 80 90
A01D0WA
MPH to about 6500 RPM which is achieved at about 30
MPH. From this point on, if calibration is accurate,
there is no change in engine RPM as the vehicle
speed increases. From the machine standing at
rest to about 30 MPH, belt slippage and other fac-
tors are involved that allow the engine to get on
the power.
MMC2002-001_05A.FM 05-3
Curve A shows a clutch set up with three 10-gram

type roller pins. This amount of weight will govern
the engine to 7200 RPM and allow engagement
of the clutch at 4000 RPM.
Curve B illustrates the effect of exchanging the
three 10-gram pins for three 14-gram roller pins.
The additional weight has virtually no effect on en-
gagement speed but pulls the peak RPM of the
engine down to 6800 RPM.
Curve C illustrates the effect of using three 16-
gram roller pins. Again, the additional weight has
little effect on the engagement RPM but further
reduces the top RPM to 6400 RPM. For example,
by adding 2 grams per arm for a total weight in-
crease of 6 grams on an engine turning at around
7500 RPM, there would be about a 200 RPM de-
crease in full power engine speed — approximately
the same effect as going 1 clicker position lower.
On a high RPM race engine it may only take a 1
gram, increase per arm to see a 200 RPM de-
crease in peak operating RPM.
05-4 MMC2002-001_05A.FM
Drive Clutch Roller Pins
RPM
10,000
9,000
8,000
7,000 A
B
C
6,000
5,000
4,000
3,000
2,000
1,000
MPH
10 20 30 40 50 60 70 80 90 100
A: 10 gram roller pins

B: 14 gram roller pins
C: 16 gram roller pins
A01D0XS
MMC2002-001_05A.FM 05-5
The solid steel roller pins can be drilled axially On the newer TRA clutches, the 6 mm allen bolt
(lengthwise) with various size holes to vary the that the roller arms pivot on is easily removable.
weight from 16.5 grams down to 10.3 grams However, a steel, gold color tube is left in the
(about a 1/4 inch diameter hole), which is the clutch holding the arm in place. This tube can be
weight of the hollow steel pin. A 1/8 inch diameter very difficult to remove. A simple solution to this
hole drilled in the solid steel pin will give you about is to remove the 6 mm Allen bolt and coat it with
14.5 grams. Also available are threaded steel and red, Loctite 271 and reinstall the bolt, let it cure,
aluminum pins. These pins are used with set and when fully cured, you can remove the Allen
screws to allow for very small weight changes. bolt along with the sleeve since the two are now
The weight of the lever arms will have a similar locked together.
effect on the shift RPM. Early TRA clutches used
Heavy aluminum arm 39.1 417 003 801
an aluminum arm that weighed 37.9 grams. Start-
ing in 1993, a heavier, reinforced aluminum arm Magnesium lever arm 27.3 417 011 012
was used on larger engine types. This heavier arm
is now standard in all TRA clutches. It weighs 39.1 Solid steel roller pin 16.4 (black) 504 259 600
grams. Most of the reinforcing is concentrated at Hollow steel roller pin 10.3 417 004 309
the pivot end of the arm, so the additional weight
does not have a major effect on the shift curve, Threaded steel roller pin 10.3 504 151 700
but changing from light aluminum arms to heavy Threaded aluminum pin 3.8 504 260 3 00
aluminum arms will require small adjustments to
the pin weight to obtain the same shift curve. A Allen set screw
0.9 365 202 000
magnesium arm is also available (P/N 417 003 802) 1/4” – 28 N.F. × 1/4”
which weighs 27.3 grams. Steel roller 9.8 417 003 900
The location of the center of gravity of the lever Steel roller 8.5 417 222 042
arm assembly will also affect the shift curve. Mag-
nesium arms with solid steel pins will feel differ- Aluminum roller 4.1
860 411 800
ent than aluminum arms with threaded aluminum (kit)
pins with 1 set screw. Both of these combinations
have a total weight within 0.1 gram of each other, NOTE: The clutch pins in the 2002 MX Zx 440
but the center of gravity of the magnesium arm are metric threads. Previous years standard 1/4”
set up is much farther away from the pivot pin than 28 NF set screws will not fit. A tuning kit be
the aluminum arm set up. This magnesium arm made available.
set up will be revving higher at low ratios and part
throttle openings. EFFECTS OF THE RAMP PROFILE
By adding or removing weight to or from the arms, ON THE SHIFT FORCE
we can fine tune the shift RPM to the engine pow-
er peak. The shift force is the component or part of the cen-
trifugal force that is used to actually move the slid-
If you increase the horsepower of the engine at ing half of the drive pulley. This force is applied to
the same RPM, you would normally add more the sliding half at the three lever arm pivot points
weight to keep the engine pulling as hard as pos- (following illustration item 49). The ramp profiles
sible and not over rev. are used to control the size of this shift force.
If you lighten the weights on the arms, you will be As the clutch rotates around the center line of the
increasing the shifting RPM. However, your vehi- crankshaft, the axis of rotation, centrifugal forces
cle will not pull as hard, since less centrifugal begin building and act on the center of mass of the
force is being generated. lever arm, roller combination trying to pull the lever
This should be optimized by accurate testing un- away from the axis of rotation. The center of mass
der duplicatable conditions until the best weight is of the lever arm assembly is the point where all
found for your use. the centrifugal force acts (following illustration
item 70).
05-6 MMC2002-001_05A.FM
The ramp provides an angled surface for the roller Also, a thicker or taller ramp will provide higher
to push against and the angle of the ramp at the RPM than a thinner ramp with the same profile
point of contact with the roller determines how because the lever arm assembly is tucked in fur-
much of the centrifugal force is translated into ax- ther by the taller ramp.
ial force. The axial force pushes the sliding half in The TRA clutch allows you to fine tune the ramp
and the remainder of the centrifugal force is un- profile by using the adjusters provided. The adjust-
used and absorbed by the integrity of the sliding ers are cams which allow you to raise and lower
half. A steeper ramp angle gives less shift force, the outer end of the ramp through six different po-
while a smaller angle gives more shift force. sitions. Moving the ramp end toward the lever arm
As you can see in following illustration, the angle makes the ramp angles steeper, thereby raising
of the ramp varies constantly from start to finish. engine speed and slowing the upshift. As the
The angle varies to achieve the proper axial force ramp is adjusted away from the lever arm, the en-
to transmit a given amount of torque through the gine speed is lowered and the upshift is faster.
drive belt at each diameter of the pulley. In clinical condition such as on a dynamometer,
As discussed before, the centrifugal force gener- moving the adjusters up will result in a 150 to 200
ated by the lever arm assembly increases at higher RPM increase with each position change. Lowering
ratios. This is why the ramp profile is much steep- the adjuster positions will result in a decrease of
er at the high ratio end. This reduces the shift force 150 to 200 RPM with each number. On the snow-
in order to maintain the correct load on the belt. mobile, however, depending on the operating con-
Remember, it is the angle of the ramp at the point ditions, a change of one adjuster position may not
of roller contact that will help determine the shift show up on the tachometer, but the shift speed of
force at any given ratio. Think of the ramp profile the pulley will have changed. The upshift or down-
as a hill that the roller must climb. A small angle or shift, depending on which way you moved the ad-
hill can be overcome easily thus providing a faster justers, will be faster and your acceleration rate and
shift out to a higher ratio which will lower the en- top speed will have changed. When using the TRA
gine RPM. If the hill is steeper (the ramp angle is adjusters, the acceleration rate and speed should
larger) the roller will not be able to climb it as quick- be checked as well as the engine RPM.
ly thus staying in a lower ratio longer which will On the DSA chassis and with the new driven pul-
keep the engine RPM higher. ley bushing material, the friction in the driven pul-
Note that at engagement and very low ratios, many ley and chassis is reduced, thus a one position
ramp angles actually go downhill. These are gener- change on the TRA adjuster will usually result in a
ally used on engines with good low RPM power. RPM change.
Engines with narrower power bands and less low
RPM power will usually have a flatter angle at en-
gagement and low speed. A ramp with a small
bump at engagement is used to raise the engage-
ment RPM. Again, the steeper the “hill” the roller
must overcome, the higher the RPM will be before
the clutch shifts out. If the spring selection cannot
give the desired engagement RPM, then use a
ramp with a bump or grind a notch at the point
where the roller sits at engagement. Of course if
the shift profile was good at higher ratios, then you
would want to use a ramp with only changes at the
low speed area.
MMC2002-001_05A.FM 05-7
12
11
12 Nm
13 (106 lbfin)
Loctite 14
271 15
3 7 12 16
27 Nm 9
1 (20 lbfft) 18
16
17 25
19 13 Nm
(115 lbfin) 23 24
Loctite
609 10 Nm
(89 lbfin)
28
Loctite
609 95 Nm
20 (70 lbfft)
21 22 31
2 27
25 30
5 26 32
29
Repair kit
A03D2CT
For drag racing and radar running, it is usually better to try to go as low as possible on the adjusters without
dropping the engine peak RPM too much as this will give the vehicle its fastest acceleration and top speed.
For oval racing or tight snowcross type courses, you may find you need to be one or two numbers higher
on your TRA adjuster to give the best throttle response possible out of the corners.
This will be where the winners spend their time testing different combinations of lever arm weights, TRA
adjustments, and ramp profiles until they find the best possible setup.
05-8 MMC2002-001_05A.FM
DRIVE PULLEY To remove drive pulley ass’y and/or fixed half from
engine, use puller (P/N 529 022 400).
 WARNING CAUTION: These pulleys have metric threads.
For safety reasons, this kit must be installed Do not use imperial threads puller. Always
by an authorized Ski-Doo® snowmobile deal- tighten puller by hand to ensure that the drive
er. Should removal of a locking device (e.g. pulley has the same type of threads (metric vs
lock tabs, self-locking fasteners, etc.) be re- imperial) prior to fully tightening.
quired when undergoing disassembly/as- To Remove Drive Pulley Ass’y:
sembly, always replace with a new one. Retain drive pulley with clutch holder.
Torque wrench tightening specifications
must strictly be adhered to; refer to table at Install puller in pulley shaft then tighten.
the end of this document. This instruction
sheet should be given to the purchaser. DISASSEMBLY
This kit is designed for specific applicable
models only (your authorized Ski-Doo snow- Fixed and Sliding Half
mobile dealer will confirm models). It is not CAUTION: Do not tap on governor cup.
recommended for units other than those for Screw puller into fixed half shaft about 13 mm (1/2 in).
which it was sold. Raise drive pulley and hold it by the sliding half while
This instruction sheet applies to the MX Zx 440 LC knocking on puller head to disengage fixed half.
only.
INSTRUCTION
Remove belt guard and drive belt.
Use holder (P/N 529 006 400). 1
529 006 400 2

A16D01A
1. Puller
2. Holding sliding half
2 NOTE: No components marking is required be-

fore disassembling this drive pulley since it has
1
factory mark and arrows as indexing reference.
Cushion Drive
A20D06A
CAUTION: Do not disassemble cushion drive.
TYPICAL Governor cup and cushion drive are factory bal-
1. Retaining screw anced as an assembly.
2. Insert in any slot
Slider Shoe and Governor Cup

 WARNING Carefully lift governor cup until slider shoes come
Never use any type of impact wrench at drive
at their highest position into guides.
pulley removal and installation.
Remove retaining screw.
MMC2002-001_05A.FM 05-9
Hold a slider shoe set then carefully lift its housing Use spring compressor (P/N 529 035 524).
and remove slider shoes. Proceed the same way for Install support guide.
other housings lifting one at a time.
2 1
A16D02A
1. Hold slider shoes

2. Lift one housing at a time
NOTE: To ease disassembly, forks (P/N 529 005

500) should be used to hold slider shoes prior to
removing governor cup. A03D3EA
1. Support guide
Install sliding half then a second support guide.

These support guides will prevent bushing damages.
529 005 500
A16B02A
Spring Cover Ass’y

It is pushed by clutch spring pressure.
 WARNING A03D3FA
Clutch spring is very strong. Never attempt to
remove spring cover without the recommend- 1. Support guide
ed tools. Remove 3 Allen screws retaining spring cover then
unscrew compressor.
05-10 MMC2002-001_05A.FM
CLEANING (IF REQUIRED) O-Ring and Slider Shoe

Check if O-rings are cracked, cut or crushed. Re-
Fixed and Sliding Half place as required.
Clean pulley faces and shaft with fine steel wool Check slider shoes for wear. Replace if groove is not
and dry cloth. apparent on top.
Fixed Half and Crankshaft End Fixed Half and Governor Cup
Parts must be at room temperature before cleaning. Inspect splines and free play between both parts.
Using a paper towel with cleaning solvent, clean Maximum free play is 0.5 mm (.020 in) measured
crankshaft tapered end and the taper inside the at calibration screw radius. Replace if required.
fixed half of the drive pulley, crankshaft threads
and retaining screw threads. Sliding Half and Spring Cover Bushing
Visually inspect coating. Replace if worn.
 WARNING Sliding Half Bushing Replacement
This procedure must be performed in a well-
ventilated area. This bushing is not replacable. If worn out, replace
sliding half ass’y.
CAUTION: Avoid contact between cleaner and Spring Cover Bushing Replacement
crankshaft seal because damage may occur.
Under normal use there is no need to replace this
Remove all hardened oil deposits that have baked bushing.
on crankshaft and pulley tapered surfaces with
coarse or medium steel wool and/or sand paper This bushing is not replacable. If worn out, replace
no. 600. spring cover ass’y.
CAUTION: Do not use any other type of abrasive.
ASSEMBLY
Reclean mounting surfaces with paper towel and
cleaning solvent. NOTE: This drive pulley is lubrication free. Do not
lubricate any component.
Wipe off the mounting surfaces with a clean, dry
paper towel.
Calibration Screw,
CAUTION: Mounting surfaces must be free of Washer and Locking Nut
any oil, cleaner or towel residue.
When installing calibration screw, make sure to in-
Bushing stall washer as shown.
Only use petrol base cleaner when cleaning bushings. 1
CAUTION: Do not use acetone to clean bushing.
INSPECTION
Drive pulley should be inspected annually.
Thrust Washer and Roller

Check roller for roundness of external diameter.
Check thrust washer for thickness wear. Replace
as required.
A16D07A
CAUTION: Ensure rollers are in good condition.
Replace as required. 1. Washer
Fitting Bolt Ass’y and Flanged Bushing Torque locking nut to 10 N•m (89 lbf•in).
Check for wear, replace as required.
MMC2002-001_05A.FM 05-11
Pin Screw, Lever Ass’y, Nut and Cotter Pin

Always use the same type of pin as originally in- Always install lever assemblies so that cotter pins
stalled when servicing. Different types have differ- are on the shown side. Besides install cotter pin
ent weights for calibration purpose. Refer to TECH- head on top when lever is sat at bottom of sliding
NICAL DATA where Shop Manual is available. half. Bend cotter pin ends to sit perfectly against
lever.
Ramp, Dowel Tube and Screw
Insert dowel tube from chamfered side. Make sure  WARNING
ramp is centered on dowel tube. Whenever replacing centrifugal levers, always
replace all 3 at the same time. Otherwise, drive
1 pulley misbalancing will occur because of le-
vers difference.
1
A16D08A
1. Chamfered side 2
Position dowel tube split at the illustrated angle.
30 ± 5°
A16D0BA
1. Head on top
2. All on the same side
CAUTION: Lever assemblies must be installed

so that cotter pins are on the same side.
A16D2PA
Torque nuts to 12 N•m (106 lbf•in).
CAUTION: Lever ass’y and rollers must move
easily after installation.
A16D09A 1 1
1. Equal distance
Torque screws to 10 N•m (89 lbf•in).
05-12 MMC2002-001_05A.FM
Guard Install and torque screws to 13 N•m (115 lbf•in)

for 593 engine equipped models and to 16 N•m
Some Models Only (142 lbf•in) for 693 and 793 engine equipped mod-
Install guard with its reinforcements in line with le- els.
vers.
Sliding Half, Slider Shoe and Governor
1 Cup
To install governor cup, use following tool:
529 005 500
A16B01A
Insert spring and slider shoes into governor cup so

A32D0IA that groove in each slider shoe is vertical to prop-
1. Reinforcements
erly slide in guides.
CAUTION: Make sure O-rings are installed on
Fixed Half, Sliding Half, Spring, Spring slider shoes and their grooves are positioned
Cover and Screw vertically.
Install titanium spring. Install fork (P/N 529 005 500) into slider shoe grooves
To install spring cover, use spring compressor to maintain them for governor cup installation. Pro-
(P/N 529 035 524). Align indexing arrows. ceed on 3 set of slider shoes.
Assemble fixed and sliding halves.
1 529 005 500
A16B02A
Make sure to align governor cup arrow with sliding

A16D0DA half and fixed half mark.
1. Align
MMC2002-001_05A.FM 05-13
NOTE: If fixed half has no mark, align governor cup

mark with segment no. 1 of inner half. Segments  WARNING
are identified on engine side. Never substitute conical washer and/or screw
with jobber ones. Always use Bombardier gen-
uine parts for this particular case.
1 Use holder. See removal procedure.
Torque screw to 80 to 100 N•m (59 to 74 lbf•ft).
Install drive belt and guard.
Titanium spring installation is now done but proper
procedure also requires the following.
Raise and block the rear of the vehicle and support
it with a mechanical stand.
 WARNING
Ensure that the track is free of particles which
A16D0EA could be thrown out while track is rotating.
1. Align
Keep hands, tools, feet and clothing clear of
track. Ensure nobody is standing near the ve-
Carefully slide governor cup into sliding half. Align hicle.
mark of governor cup with mark of fixed half.
Remove forks and push governor cup so that its Accelerate the vehicle at low speed (maximum
splines engage with fixed half shaft splines. 30 km/h (20 MPH) and apply the brake, repeat
5 times.
CAUTION: Make sure splines of both parts are
fully engaged. Recheck the torque of 90 to 100 N•m (66 to 74 lbf•ft).
INSTALLATION  WARNING
After 10 hours of operation the transmission
 WARNING system of the vehicle must be inspected to en-
sure the retaining screw is properly torqued.
Do not apply anti-seize or any lubricant on
crankshaft and drive pulley tapers.
DRIVE PULLEY ADJUSTMENT
 WARNING The drive pulley is factory calibrated to transmit
Never use any type of impact wrench at drive maximum engine power at a predefined RPM.
pulley removal and installation. Factors such as ambient temperature, altitude or
surface condition may vary this critical engine
Clean mounting surfaces as described in CLEAN- RPM thus affecting snowmobile efficiency.
ING above. This adjustable drive pulley allows setting maxi-
mum engine RPM in the vehicle to maintain maxi-
Drive Pulley Ass’y mum power.
The installation procedure must be strictly adhered Calibration screws should be adjusted so that ac-
to as follows. tual maximum engine RPM in vehicle matches
Install drive pulley on crankshaft extension. with the maximum horsepower RPM given in TECH-
Install conical washer with its concave side towards NICAL DATA.
drive pulley then install screw. NOTE: Use precision digital tachometer for engine
RPM adjustment.
NOTE: The adjustment has an effect on high RPM
only.
05-14 MMC2002-001_05A.FM
To adjust, modify ramp end position by turning cal- To Adjust:

ibration screws. Just loosen locking nut enough to pull calibration
screw partially out and adjust to desired position.
Calibration Screw, Locking Nut and Do not completely remove the locking nut. Torque
Governor Cup locking nuts to 10 N•m (89 lbf•in).
Calibration screw has a notch on top of its head. CAUTION: Do not completely remove calibration
screw otherwise its inside washer will fall off.
CAUTION: Always adjust all 3 calibration screws
and make sure they are all set at the same num-
ber.
1
A16D0FA
1
1. Notch
Governor cup has 6 positions numbered 2 to 6.

Note that in position 1 there is no stamped num-
ber (due to its location on casting).
See TECHNICAL DATA for original setting where A16D0HA
a Shop Manual is available.
1. Loosen just enough to permit rotating of calibration screw
1
PULLEY DISTANCE AND
ALIGNMENT
GENERAL
The pulley distance we will refer to in this section,
is the space separating the drive and driven pulley
outside diameters (Z measurement).
This basic distance is provided as an assembly
guide and indicates the dimensions between
A16D0GA which satisfactory belt deflection will be obtained.
1. Position 1 (not numbered) Both pulley distance adjustment and pulley align-
ment must be carried out to ensure the highest
Each number modifies maximum engine RPM by efficiency of the transmission system. Further-
about 200 RPM. more, optimum drive belt operation and minimal
Lower numbers decrease engine RPM in steps of wear will be obtained only with proper pulley align-
200 RPM and higher numbers increase it in steps ment.
of 200 RPM.
Example:
Calibration screw is set at position 3 and is changed
to position 5. So maximum engine RPM is increased
by about 400 RPM.
MMC2002-001_05A.FM 05-15
CAUTION: Before checking pulley adjustment,

the rear suspension must be mounted on the ve- Y
hicle and track tension/alignment must be done.
Always check pulley adjustment after suspen-
sion is adjusted.
 WARNING X Z
Failure to correctly perform pulley alignment
may cause the vehicle to creep forward at idle.
2
All Pulley Alignment Specifications Refer to:
X = Distance between straight bar and drive pul-
ley fixed half edge, measured between pul-
leys. A00D0WA
1
Y = Distance between straight bar and drive pul- TYPICAL

ley fixed half edge, measured at the end of 1. Straight bar
2. Front of vehicle
straight bar.
Z = Distance between outside diameter of pul- The distance Y must exceed distance X to com-
leys. pensate for the twist due to the engine torque.
GENERAL PROCEDURE Drive Belt Deflection

NOTE: When pulley distance and alignment are
Remove guard and drive belt. adjusted to specifications, refer to DRIVE BELT
By turning and pushing the sliding half, open the (where a Shop Manual is available) to adjust drive
driven pulley. Insert a straight bar 9.5 mm (.375 in) belt deflection.
square, 48 cm (19 in) long or the proper alignment CAUTION: This section deals mainly with ad-
template into the opened driven pulley. justment procedures. For complete assembly
requirements, refer to the proper ENGINE or
Measuring Procedure TRANSMISSION installation section.
Using Straight Bar
Always measure distances X and Y from the far-
ther straight bar side (including its thickness to the
fixed half edge).
PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART

PULLEY
OFFSET
DISTANCE ALIGNMENT
TEMPLATE
MODEL Z X Y-X ➀
± 0.50 mm ± 0.50 mm ± 0.50 mm P/N
(.020 in) (.020 in) (.020 in)
16.5 35.50 1.5
All 529 026 700
(.650) (1.398) (.060)
➀ Alignment templates have been made according to pulley alignment nominal values. However, they
do not take into account allowed tolerances for alignment specifications. They are used as GO/NO GO
gauges for quick alignment and pulley distance check and as templates to reach alignment nominal
values.
05-16 MMC2002-001_05A.FM
X Z
A15D02A 2 A32D12A 2 1
TYPICAL 1. Loosen lock nut first
1. Engine movement 2. Loosen
2. Contact
Pulley Distance Adjustment Method
Engine Movement
The engine support has slotted mounting holes.
Move engine to obtain specified distance between
pulleys.
Pulley Alignment Method

Engine Movement
Loosen the 4 bolts retaining engine support to the
frame. Position engine to obtain the specified
alignment.
NOTE: After alignment, adjust torque rod so it
A32D11A
slightly contacts stopper plate. Do not over tight-
ALIGNMENT BAR IN PULLEYS en, it will disalign pulleys.
NOTE: Prior to performing pulley adjustment,
loosen torque rod nut to allow engine movement.
Engine supports have tendency to stick to frame,
work engine loose prior to aligning.
A32D12B 1 2
1. Slightly tighten
2. Retighten
Reinstall drive belt and belt guard.
MMC2002-001_05A.FM 05-17
The following table is to be consulted if and when a tightening torque is required but not specified.
Bold face size indicates nominal value (mean value). FASTENER SIZE
N•m Lbf•ft
(8.8 GRADE)
FASTENER SIZE
N•m Lbf•in 127 M14 94
(8.8 GRADE)
2 M4 18 128 M14 94
3 M4 27 129 M14 95
4 M5 35 130 M14 96
8 M6 71 131 M14 97
9 M6 80 132 M14 97
10 M6 89 133 M14 98
11 M6 97 134 M14 99
12 M6 106 135 M14 100
136 M14 100
FASTENER SIZE 137 M14 101
N•m Lbf•ft 138 M14 102
(8.8 GRADE)
21 M8 15 139 M14 103
22 M8 16 140 M14 103
23 M8 17 141 M14 104
24 M8 18 142 M14 105
25 M8 18 143 M14 105
43 M10 32 144 M14 106
44 M10 32 145 M14 107
45 M10 33 146 M14 108
46 M10 34 147 M14 108
47 M10 35 148 M14 109
48 M10 35 149 M14 110
49 M10 36 150 M14 111
50 M10 37
51 M10 38
52 M10 38
53 M10 39
76 M12 56
77 M12 57
78 M12 58
79 M12 58
80 M12 59
81 M12 60
82 M12 60
83 M12 61
84 M12 62
121 M14 89
122 M14 90
123 M14 91
124 M14 91
125 M14 92
126 M14 93
05-18 MMC2002-001_05A.FM
RAMP CHARACTERISTICS
Taller ramp = Higher engagement RPM
Steeper angle = Higher shift RPM
Shallower angle = More RPM at lower MPH

(slower shift)
A01D2IS
MMC2002-001_05A.FM 05-19
TRA RAMP PROFILES
417 005 144 417 005 287
144 287
A01D1SB A03D1UB
417 005 145 417 005 228
145 228
A01D1EB A01D1IB
417 005 146 417 005 149
146 149
A01D1FB A01D1JB
05-20 MMC2002-001_05A.FM
417 005 221 417 005 143
221 143
A01D20B A01D1Q B
417 005 226 417 005 142
226 142
A01D1MB A01D21B
414 754 300 417 005 227
PX 227
A01D1ZA A01D22B
414 796 000

417 005 280
DX 280
A01D1RA A01D23B
MMC2002-001_05A.FM 05-21
417 005 281 417 005 286
281 286
A01D24C A01D28B
417 005 283 415 023 700
RAMP BLANK
283 ALUMINUM
A01D25C A01D2DA
417 005 284 415 023 800
284 CF1
A01D26B A01D2AA
417 005 285 415 023 600
RAMP BLANK
285 STEEL
A01D27B A01D2BA
05-22 MMC2002-001_05A.FM
415 023 500 417 005 291
RAMP BLANK
ALUMINUM 291
A01D2CA A01D2WB
504 096 400 417 005 293
FZ 293
A01D29A A01D2XA
417 005 289 417 005 291 X
289
291 X
A01D2UA
A01D2YA
417 005 290 417 005 292 X
290 292 X
A01D2VA
A01D2ZA
MMC2002-001_05A.FM 05-23
417 005 293 X 417 005 297 X
293 X 297 X
A01D30A A01D34A
417 005 294 X 417 222 271
294 X 298
A01D31A A01D37A
417 005 295 X
417 222 372
295 X 299
A01D32A
A01D38A
417 005 296 X
417 222 381
296 X
300
A01D33A
A01D3AA
05-24 MMC2002-001_05A.FM
In the TRA clutch, the installed length of the clutch

release spring is 74 mm (2.9 in) This is the length
of the spring when the pulley is in its neutral posi-
417 222 474
tion. The pressure that the spring applies at this
length is the factor that controls the engagement
speed (all other things kept constant). When the
engine pulley is in its highest ratio position, the
301 spring will be compressed to 41 mm (1.6 in). The
pressure the spring applies at this length will de-
termine the RPM required to reach high gear;
again, with all other tunable factors kept constant.
As you look through the spring chart, you will see
A01D39A
that springs are available with equal pressures at
74 mm (2.9 in), but very different pressures at
EFFECTS OF THE DRIVE PULLEY 41 mm (1.6 in). You will also note varying pres-
SPRING sures at 74 mm (2.9 in) and equal pressures at
41 mm (1.6 in). Simply by working with the spring
The purpose of the clutch release spring is to re- charts, one can easily see how the shift speed (the
turn the sliding half of the engine pulley and the speed with which the change from one gear ratio
associated moving parts to the disengaged or neu- to the next is made) and the engagement speed
tral position at low engine RPM. The spring ten- can be altered.
sion is calibrated to work with the pressure levers As the pressure of the spring when 74 mm (2.9 in)
and ramp angles to allow clutch engagement at long is increased, the clutch engagement speed
the desired RPM. As the engine speed increases, will increase. As the spring rate is increased, the
centrifugal forces increase and eventually over- engine will be required to turn more RPM to
come the tension of the release spring and allow achieve a given gear ratio. Again, these facts hold
the pulley halves to contact the drive belt. As en- true when all other tunable components are kept
gine speed decreases, centrifugal forces de- constant.
crease and the clutch spring returns the sliding
half toward the neutral position. On chart 1, spring A has a pressure of 311 N (70 Ib)
at 74 mm (2.9 in) and a pressure of 1157 N (260 Ib)
As the clutch shifts out to a higher ratio, the spring when compressed to 41 mm (1.6 in). With no oth-
balances the shift forces being generated by the er changes made in the clutch, spring B was in-
levers and ramps. stalled. The spring has a preload of 712 N (160 Ib)
The spring tension will affect the entire shifting seat 74 mm (2.9 in) and a pressure of 1201 N (270 Ib)
quence of the engine pulley. The effect that it has at 41 mm (1.6 in). As the chart indicated, the en-
will depend upon the construction of the spring. gagement RPM increased 1000 RPM while the
Three things must be known about the spring to be shift curve from 30 MPH up remained relatively
able to predict its effect in the clutch: 1. The spring unchanged.
free length; 2. The spring pressure when com- Chart 2 illustrates the effect of keeping the spring
pressed to 74 mm (2.9 in); 3. The spring pressure preload pressure at 74 mm (2.9 in) constant and
when compressed to 41 mm (1.6 in). These three increasing the pressure at the 41 mm (1.6 in)
factors are listed on the accompanying sheet. length. In this example, spring A has a pressure of
The spring free length will give you an idea of the 311 N (70 Ib) at 74 mm (2.9 in) and a pressure of
condition of the spring. If the spring has lost more 756 N (170 Ib) at 41 mm (1.6 in). Spring B also has
than 6.35 mm (1/4 in) of its listed free length, the a pressure of 311 N (70 Ib) at 74 mm (2.9 in) but in-
spring is fatigued or has taken too great a set. The creases to 1157 N (260 Ib) at 41 mm (1.6 in). The
spring should be replaced. The free length of the projected effect of this spring change is shown on
spring is its overall length when resting freely on chart 2. Since the preload pressure at 74 mm (2.9 in)
a table top. is equal for springs A and B, the engagement
speed is not affected. At 95 MPH, however, there
is a loss of RPM with spring A in place.
MMC2002-001_05A.FM 05-25
Drive Clutch Spring

Effect at Engagement
RPM
10,000
9,000
8,000
7,000
6,000
5,000
B
4,000
A
3,000
2,000
1,000
MPH
10 20 30 40 50 60 70 80 90 100
A01D1US
LOAD AT LOAD AT
74 mm (2.9 in) 41 mm (1.6 in)
A 311 N (70 lb) 1157 N (260 lb)
B 712 N (160 lb) 1201 N (270 lb)
05-26 MMC2002-001_05A.FM
Drive Clutch Spring

Effect at Top Speed
RPM
10,000
9,000 B
8,000
7,000
6,000 A
5,000
4,000
3,000
2,000
1,000
MPH
10 20 30 40 50 60 70 80 90 100
A01D1VS
LOAD AT LOAD AT
74 mm (2.9 in) 41 mm (1.6 in)
A 311 N (70 lb) 756 N (170 lb)
B 311 N (70 lb) 1157 N (260 lb)
MMC2002-001_05A.FM 05-27
TRA SPRINGS CHART

FORCE @ WIRE DIA. FREE LENGHT
POUNDS ± 5% P/N
COLOR CODE
74 mm - 41 mm BOMBARDIER mm in mm in
2.9 in - 1.6 in
5.26 0.207
70 - 170 414 689 800 RED - RED 99 3.9
5.00 0.197
70 - 200 415 015 200 RED - ORANGE 5.26 0.207 94 3.7
70 - 230 414 817 500 RED - YELLOW 5.54 0.218 89 3.5
70 - 260 414 689 200 RED - GREEN 5.94 0.234 88 3.5
70 - 290 414 691 500 RED - BLUE 5.94 0.234 86 3.4
70 - 320 414 701 000 RED - PURPLE 6.35 0.250 85 3.3
100 - 170 414 993 000 YELLOW - RED 4.88 0.192 128 5.0
100 - 200 414 689 700 YELLOW - ORANGE 5.26 0.207 110 4.3
5.54 0.218
100 - 230 414 748 600 YELLOW - YELLOW 102 4.0
5.41 0.213
5.72 0.225
100 - 260 414 742 100 YELLOW - GREEN 96 3.8
5.94 0.234
100 - 290 414 818 000 YELLOW - BLUE 5.94 0.234 97 3.8
6.35 0.250
100 - 320 414 678 400 YELLOW - PURPLE 93 3.7
6.17 0.243
4.88 0.192
130 - 200 414 639 000 BLUE - ORANGE 145 5.7
5.00 0.197
130 - 230 414 689 500 BLUE - YELLOW 5.26 0.207 125 4.9
130 - 260 414 817 700 BLUE - GREEN 5.54 0.218 109 4.3
130 - 290 414 689 400 BLUE - BLUE 5.94 0.234 104 4.1
6.17 0.243
130 - 320 414 817 800 BLUE - PURPLE 98 3.9
5.94 0.234
6.35 0.250
130 - 350 414 916 300 BLUE - PINK 96 3.8
6.17 0.243
150 - 240 414 605 600 WHITE 5.26 0.207 135 5.3
160 - 230 415 015 300 PURPLE - YELLOW 4.88 0.192 158 6.2
160 - 260 415 015 400 PURPLE - GREEN 5.26 0.207 133 5.2
5.26 0.207
160 - 270 414 605 500 YELLOW 130 5.1
5.54 0.218
5.54 0.218
160 - 290 415 034 900 PURPLE - BLUE 120 4.7
5.72 0.225
05-28 MMC2002-001_05A.FM
FORCE @ WIRE DIA. FREE LENGHT

POUNDS ± 5% P/N
COLOR CODE
74 mm - 41 mm BOMBARDIER mm in mm in
2.9 in - 1.6 in
5.72 0.225
160 - 320 414 817 900 PURPLE - PURPLE 111 4.4
5.94 0.234
5.94 0.234
160 - 350 414 949 500 PURPLE - PINK 105 4.1
6.17 0.243
185 - 410 415 019 500 "ALL" BLACK 6.35 0.250 105 4.1
200 - 290 414 768 200 GREEN - BLUE 5.26 0.207 156 6.1
5.54 0.218
200 - 320 414 762 800 GREEN - PURPLE 135 5.3
5.72 0.225
200 - 350 414 756 900 GREEN - PINK 5.72 0.225 126 5.0
200 - 380 414 222 371 GREEN - WHITE 5.94 0.234
230 - 350 415 074 800 PINK - PINK 5.54 0.218 143 5.6
PINK - WHITE 5.94 0.234 128 5.0

230 - 380 414 991 400
(OLD) RED - WHITE 5.72 0.225 134 5.3
230 - 390 415 019 600 GREEN 5.94 0.234 126 5.0
230 - 410 415 019 700 RED 5.94 0.234 120 4.7
240 - 430 415 019 800 BLUE 5.94 0.234 120 4.7
WHITE - WHITE
250 - 380 417 222 004 (OLD) GREEN - 5.72 0.225 140 5.5
WHITE
250 - 460 415 019 900 PINK 6.17 0.243 116 4.6
WHITE - SILVER
260 - 420 417 222 164 5.94 0.234 135 5.3
(OLD) ORANGE
280 - 420 415 020 100 GREEN - GREEN 5.72 0.225 146 5.7
280 - 460 415 020 200 RED - RED 6.17 0.243 132 5.2
280 - 510 415 020 300 BLUE - BLUE 6.35 0.250 121 4.8
310 - 460 415 020 400 PINK - PINK 5.94 0.234 148 5.8
ORANGE - ORANGE
310 - 510 415 020 500 6.17 0.243 132 5.2
(OR) GOLD - GOLD
Part numbers with a 486 prefix must be ordered from the Valcourt Race Dept. All others must be
ordered from your local Ski-Doo dealer.
MMC2002-001_05A.FM 05-29
TITANIUM CLUTCH SPRINGS

The preload figure given in our specifications is
quoted in kg (Ib) of force for each machine, not in
TENSION PART NUMBER inch-pounds or foot-pounds of torque. A figure giv-
en in units of torque would require multiplying the
180 - 410 486 103 200 radius of the pulley by the pull recorded on the
200 - 290 487 103 300 scale. Our figures are quoted for each pulley size
and it is only necessary to record the pull of the
220 - 320 488 103 400 spring by attaching a scale to the rim of the pulley.
220 - 384 489 103 500 The scale must be positioned at 90° to the radius
of the pulley. Holding the fixed half of the pulley
240 - 380 490 103 600 still, pull until the sliding half just begins to rotate.
At this point, read the scale.
260 - 380 491 103 700
260 - 410 492 103 800
280 - 410 493 103 900
1
EFFECTS OF THE DRIVEN PULLEY

SPRING
The driven pulley spring is needed to keep the
plastic slider buttons in contact with the cam and
to provide enough side force on the belt in the low
gear position to allow initial acceleration while the
torque rises to a point where the torque sensing
cam begins to take over. At full load, the driven
pulley spring has much less effect on the driven A01B18B
pulley shifting sequence than does the cam, espe-

TYPICAL
cially at low shift ratios. At the part throttle loads 1. Spring scale hook (P/N 529 030 900)
at low ratios, the spring has the main effect on the
shift characteristics of driven pulley. To change the spring tension, relocate the spring
Increases in the driven pulley spring preload will end in the sliding pulley half or reposition the
bring the engine speed up before the pulley starts spring end in the cam.
shifting and will help backshift the clutch quicker. There are six holes available on a Formula cam.
Decreasing the preload will allow a faster upshift They are numbered 1-6. Most Formula driven pul-
but a slower backshift thus lowering the engine leys have three adjustment holes in the sliding
RPM. half. They are lettered A, B, C. When adjusting
NOTE: Control of the engine speed is done by cal- driven pulley tension, always refer to the tension
ibrating the engine pulley not by adjusting the driv- in kg (Ib) — not B-6 or A-5 hole positions for accu-
en pulley spring preload. An attempt to lower the racy and repeatability. Moving the spring from one
engine RPM by decreasing the spring preload in numbered hole to a hole adjacent will change the
the driven pulley will result in belt slippage on ac- preload by 1.35 -1.8 kg (3-4 Ib). Remember, use
celeration. An attempt to increase engine RPM by the number and letters as references — measure
increasing the preload will result in excessive drive the tension for accuracy. By using various combina-
belt wear and decreased efficiency in the trans- tions, the preload is adjustable from 5 to 35 pounds
mission. (depending on spring type).
The driven pulley spring preload is listed in the ba- The charts below will give an approximate refer-
sic specifications for all our machines. This preload ence for each spring position. It will vary with dif-
tension will vary from 4 kg (9 Ib) to 7.5 kg (17 Ib) ferent springs and cam angles.
on models equipped with the TRA clutch.
05-30 MMC2002-001_05A.FM
DRIVEN CLUTCH PRELOAD C

WHITE SPRING/LBS A
POSITION A B C
32
54 1
1 26 29 24
6
2 21 23 20
3 16 19 15
4 11 14 10 B
5 7 10 6 A18C0AA
6 3 5 1 Letters and numbers shown in illustration are actual letters and

numbers embossed on parts
NOTE: Always recheck torsional pre-load after ad-

BEIGE SPRING/LBS
justing.
POSITION A B C By experimenting with them, you may find a more
efficient combination of minimum side pressure
1 14 16 12
yet adequate back shifting for your particular rac-
2 9 11 7 ing application.
3 4 6 2 COLOR WIRE DIAMETER PART NUMBER

4 28 30 26 BEIGE .207 in 414 558 900
5 23 25 21 WHITE .207 in 504 152 070
6 18.5 20.5 16.5 YL/BK

— 486 104 000
(titanium)
Our procedure is as follows:
• Remove the drive belt and lock the parking brake. from the Valcourt Race Dept. All others must be
• Using a reliable fish scale and our spring scale ordered from your local Ski-Doo dealer.
hook (P/N 529 030 900) pull perpendicular to the
rim of the pulley until the moveable sheave be- EFFECTS OF THE DRIVEN PULLEY
gins to open. Record the reading on the fishscale. CAM
• Next while the pulley is still being pulled open,
relax the tension on the fish scale until the The purpose of the driven pulley cam is to sense
moveable pulley begins to close, record the the torque requirements of the drive axle and feed
reading. a portion of the engine torque, which has been
applied to the driven pulley, back to the sliding half
• Next add the two readings together and di- of the pulley. It is this side force that signals the
vide by two. This is the number we use as downshift and provides side thrust to give traction
our reference. to the drive belt.
• Recording only the pull reading and this will The cam is acting like a screw pushing against the
definitely allow the driven pulley tension to be sliding half of the pulley. A large cam angle will act
too low. This low tension will lead to a notice- like a coarse thread while a small cam angle will
able drop in peak RPM and a loss of top speed. act similar to a fine thread. The smaller the cam
angle, the greater the side force on the sliding half
of the pulley and the slower the upshift will be.
This will result in higher engine RPM.
MMC2002-001_05A.FM 05-31
A larger cam angle will allow the pulley to upshift Driven pulley cams are helices. A helix is mea-
at a lower engine speed. Less side force will be sured in lead. Lead is the distance a point moves
exerted on the sliding half of the pulley and the along the axis of rotation in one revolution of the
pulley will upshift more rapidly. helix. (Screw threads are a helix).
On downshift, a smaller cam angle will backshift The helix angle is computed from the lead and the
more easily and, again, tend to keep the engine circumference of the helix.
RPM higher. A larger cam angle will be harder to
downshift and will load the engine and reduce the
RPM.
If all other variables in the pulleys are kept con-
stant, a cam change with a smaller angle will result
in a slower upshift and a faster downshift. Engine 3
RPM will remain higher. A change to a cam with a
larger angle will result in a faster upshift and the
2
downshift will be slower. Engine RPM will be lower.
Remember the drive pulley signals or controls the 1
upshift of the transmission while the driven pulley
signals the downshift largely because of the effect
A01D1WA
of the cam.
The standard factory cam will probably work well 1. Circumference (C)
2. Helix angle A
for most woods type cross-countries, while a 3. Lead (L)
smaller angled cam may prove to be better for
high speed lake cross-countries. Helix angles for Ski-Doo cams are measured at the
mean circumference of the cam. This is at the mid-
Top speed and low ET’s are drag racers’ and radar point of the ramp surface.
runners’ most important concerns. Because back-
shifting is not at all important in these races, most
racers experiment with larger cam angles for the
fastest possible upshift.
Multi-angle cams are sometimes used by racers
needing a good holeshot. They generally work
best on vehicles where no track spin is encoun-
tered. As a vehicle idles on the starting line, the
exhaust temperature cools thus slightly lowering
the optimum HP RPM of the engine. Because of
this, a steeper (larger) angle cam can be used to
upshift more quickly, and lower the RPM to work
with the cooler exhaust. As the exhaust heats up,
R
the optimum HP RPM increases. A multi-angle
cam reduces to a shallower (smaller) angle as the A01D1XA
clutch shift out and the RPM is increased to match
Circumference (mean) = 2πR
the hot HP curve of the engine. This phenomena
is more pronounced on engines with narrower Measuring a cam on the outside diameter will pro-
powerbands. duce a different angle than on the mean diameter.
Oval and snowcross racers need the best of both A cam angle measured on the outside diameter
worlds. A good holeshot is critical but backshifting can be converted to the Ski-Doo spec mean diam-
must be quick in order to have good response out eter angle as follows:
of the corners. They may have to change cam an- To simplify things, just remember that if you mea-
gles depending on what type of track layout is ensure a Ski-Doo cam at the outside circumference
countered. the angle will be about 4° less than the specifica-
tion (mean circumference).
05-32 MMC2002-001_05A.FM
Many after-market cams are measured at the out- The cams listed below are available through the
side circumference. By adding 4° you can com- Racing department in Valcourt only.
pare them to Ski-Doo cams.
P/N DESCRIPTION
Driven Pulley Cam Specification 486 074 700 Cam 37
NOTE: All 88.9 mm diameter cams are interchange- 486 074 800 Cam 40
able. 486 074 900 Cam 42
486 075 000 Cam 44
MULTI-ANGLE CAM
P/N P/N 486 075 100 Cam 47
CAM ANGLE ANGLE
415 021 100 44° - 40° 415 022 800 30° 486 075 200 Cam 50
415 021 200 46° - 42° 415 022 900 32° 486 075 300 Cam 53
415 021 300 48° - 40° 415 023 000 34° 486 075 400 Cam 56-50
415 021 400 48° - 44° 415 023 100 36° 486 075 500 Cam 56-47
415 021 500 50° - 36° 415 022 700 38° 486 075 600 Cam 56-44
415 021 600 50° - 40° 504 092 100 40° 486 075 700 Cam 53-50
415 021 700 50° - 44° 415 022 500 42° 486 075 800 Cam 53-47
417 126 380 53° - 47° — — 486 075 900 Cam 53-44
415 021 800 54° - 40° 504 096 000 44° 486 076 000 Cam 53-42
415 021 900 54° - 44° 415 023 200 46° 486 076 100 Cam 53-40
415 022 000 54° - 46° 504 140 900 47° 486 076 200 Cam 50-47
415 022 100 54° - 48° 415 022 400 48° 486 076 300 Cam 50-44
415 022 200 58° - 44° 504 096 100 50° 486 076 400 Cam 50-42
415 023 400 58° - 48° 415 022 300 52° 486 076 500 Cam 50-40
417 122 200 *40° - 44° 415 021 000 54° 486 076 600 Cam 50-37
417 125 900 *44° - 40° 415 022 600 56° 486 076 700 Cam 47-44
417 126 391 *44° 415 023 300 58° 486 076 800 Cam 47-42
486 076 900 Cam 47-40
NOTE: 1995 and newer cams have more surface 486 077 000 Cam 47-37
area to support large bushing. *MX Zx all alumi-
486 077 100 Cam 44-40
num, 2 key way.
486 077 200 Cam 44-37
486 077 300 Cam 42-37
486 077 400 Cam 40-44
486 077 500 Cam 40-37
486 099 600 Cam 43-47
486 103 100 Cam 47-50

from the Valcourt Race Dept. All others must be
MMC2002-001_05A.FM 05-33
BALANCING OF PULLEYS Installation

Each half of Ski-Doo driven pulley is individually
balanced. This means that parts can be inter-
 WARNING
changed and that no alignment marks are needed Do not apply anti-seize compound or any lubri-
for assembling for the complete assembly to be in cant on crankshaft and drive pulley tapers.
balance.
The TRA clutch is similar to our driven pulleys in  WARNING
the sense that each major component is balanced Never use any type of impact wrench at drive
separately. pulley removal and installation.
However, there are arrows to align when reassem-
bling this clutch. The first one is on the spring cup Drive Pulley Ass’y
or cover to the sliding half. The next is between the The installation procedure must be strictly adhered
governor cup and the sliding half. Once these have to as follows:
been indexed properly, the fixed half can be insert-
Lock crankshaft in position as explained in removal
ed into the clutch assembly and no alignment is
procedure.
needed between the inner pulley and the sliding
half on 1994 and older TRA’s. 1995 inner pulleys Install drive pulley on crankshaft extension.
do have an alignment mark. Install lock washer and screw.
Some 1995 and 1996 models have the new cush-
ion drive, governor cup as standard equipment.  WARNING
This governor cup can’t be retro-fitted to other Never substitute lock washer and/or screw
non-cushion drive vehicles due to weight imbal- with jobber ones. Always use Bombardier
ance. Use only complete clutch assemblies on genuine parts for this particular case.
non-cushion drive vehicles.
Torque screw to 105 N•m (77 Ibf•ft).
Truing Pulley Surfaces Install drive belt and pulley guard.
The surfaces of a die cast pulley sheave are not Raise and block rear of vehicle and support it with
always perfectly true. The casting cools in the die a mechanical stand.
at slightly different rates which makes the surface
uneven. Truing the surface in a lathe can increase
efficiency of the transmission. The driven pulley
 WARNING
sheaves have a 13.75° angle while TRA drive pul- Ensure that the track is free of particles which
ley sheaves have a 12° angle. Always remove as could be thrown out while is rotating. Keep
little material as possible when trueing these sur- hands, tools, feet and clothing clear of track.
faces. Pulley halves need to be rebalanced after Ensure nobody is standing near the vehicle.
any machining.
Accelerate the vehicle at intermediate speed and
NOTE: On 1996 and newer liquid cooled models, apply brake. Repeat five times.
the drive and driven clutch surfaces are machined.
Reduce the screw torque to 85 N•m (63 Ibf•ft)
Windage Plates then, retorque to 95 N•m (70 Ibf•ft).
Windage plates which cover the reinforcing webs

on each sheave simply make the pulley more aero-
 WARNING
After 10 hours of operation the transmission
dynamic and reduce the amount of energy lost
system of the vehicle must be inspected to en-
from pumping air. The use of these plates or cov-
sure the retaining screw is properly torqued.
ers can make a difference of one to two MPH on
top end. The down side of the use of these plates
is the increase in sheave temperature due to the
reduction of air cooling.
05-34 MMC2002-001_05A.FM
DRIVE BELTS Drive belts can vary ± 6 mm (1/4 in) length from
belt to belt. Because of this manufacturing toler-
The drive belt is the critical link in transmitting pow- ance, we recommend measuring your drive belts
er from one clutch to the other. The changes in belt and marking their length on the outer cover. Try to
technology and materials have allowed us to take use only belts that are the same length while rac-
for granted the kind of reliability and efficiency that ing to keep your clutch set up as consistent as
not many years ago we all only dreamed about. possible.
One of the more important changes in drive belts Always break in a new belt by running it easy for
has been the introduction of Kevlar® Fiber B to re- 10-15 miles. Vary the vehicle speed and throttle
place fiberglass or polyester cord in the tensile lay- setting without going over 2/3 throttle. It is also a
er of modern drive belts. This material is much good idea to mark the direction of rotation on the
stronger, more flexible, and allows a better adhe- belt. Once the belt has been used, always run it in
sive bond with the various rubber compounds used the same direction.
to build a drive belt.
Be careful not to bend sharply or coil up these new
Another important change in drive belts is the in- hard compound drive belts since they are much
crease in width. The extra width allows us to add more prone to cracking in cold weather than earlier
more Kevlar cords in the tensile layer for strength belts.
with today’s high output sleds.
Proper deflection, setup, alignment, and break-in
Use only the specific Bombardier drive belt listed will help insure maximum performance and lon-
for your application. The drive belt is a calibrated gevity from the drive belt.
part of the transmission system. Different belts
with different compounds or angles will change
how your transmission shifts.
WIDTH MINIMUM WIDTH

PART NUMBER
(new) (wear limit)
415 060 600 34.7 mm 32.30 mm
414 860 700 34.90 mm 32.50 mm
417 300 067 35.00 mm 33.00 mm
417 300 066 35.10 mm 33.00 mm
417 300 127 35.10 mm 32.10 mm
414 827 600 33.33 mm 30.00 mm
MMC2002-001_05A.FM 05-35
Proper Alignment of the TRA Clutch
1
7 8 2
9 4
6
A16D0RS
1. Sleeve (Note: no clearance to this side of driven pulley)

2. 2 shims (504-108 -200)
3. Use straight bar (.375 in x 19 in)
4. DSA/ZX platform: 0 - 1 mm (0 - .040 in)
5. Shim as required to achieve clearance
6. PRS: 268.3 (10-9/16 in) — DSA/ZX platform: 257.5 (10-9/64 in) — CK3: 361.0 (14-7/32 in)
7. Y = X + 1.5 mm (.060 in)
8. X = PRS: 36.0 mm (1.460 in) — DSA/ZX platform: 35.0 mm (1.380 in) — CK3: 35.5 (1.398 in)
9. Z = PRS: 27.0 mm (1.060 in) — DSA/ZX platform: 16.5 mm (.650 in) — CK3: 3 pipe 123.0 mm (4.842 in) — CK3: 120.0 (4.724 in)
05-36 MMC2002-001_05A.FM
The driven pulley has one, two or three (depending

1 upon the year) set screws on the fixed half that are
used for setting belt deflection. These 3 mm Allen
screws can be moved in or out to open or close
A00C07A
the sheaves to lower or raise the drive belt in the
driven pulley to achieve the correct deflection.
1. Use Ski-Doo tool (P/N 414 348 200)
It is best to accurately align the pulleys and then
Proper belt deflection and alignment are extreme- shim the driven clutch tight. Some feel it is better
ly important. Included is a page on proper align- to let it float and align itself. But this doesn’t hap-
ment procedures and deflection measurement pen in a dynamic situation when there is load on
methods for your use. the belt. If you have a lot of float in the driven and
Do not forget about the torque limiter rod on most you back off the throttle and the pulley misaligns,
models. This bolt is located between the jackshaft when power is applied again, the pulley will stay
and the engine on the left side. It should be lightly misaligned because of the force on the counter-
snugged after the proper alignment and center to shaft. Shimming the driven pulley tightly to the
center distances have been set. jackshaft bearing also helps to positively position
the jackshaft and its left side bearing.
NOTE: Do not overtighten, it will misalign pulleys.
CHAINCASE GEARING
Contrary to popular belief, small gear changes do
not directly affect top speed as long as the clutch-
es are functioning properly. Gearing one or two
teeth taller on the top will not generally make the
vehicle any faster on top end unless the clutches
are fully shifted out and the engine is starting to
overrev.
With the TRA clutch, we have about 20 percent
more shift ratio available compared to other de-
signs. Because of this, we have been able to lower
2 1 the gearing in our chaincase considerably. Yet, we
still have the same overall top gear ratio because
of the 0.8:1 top ratio of the TRA clutch.
This gives us better belt life by allowing our clutch-
Decrease Increase es to slip for a shorter period of time at engage-
deflection deflection ment. It also provides more torque to the drive
axle for acceleration.
Most snowmobiles are geared on the high side
from the factory. They are usually geared for 8 -16
km/h (5-10 MPH) more than they would reach in
average conditions. Because of this, the belt does
not seem to go all the way to the top of the drive
A00C45A 3 clutch. This is a normal situation. Snowmobiles
TYPICAL
run under widely varying conditions. If all snow-
1. Jam nut
mobiles were geared to attain a full shift under av-
2. Adjuster erage conditions and then the vehicle were run on
3. Allen screw with jam nut a perfectly smooth frozen surface, it would easily
shift out to its geared top speed. Since the drag is
so low under these conditions, the engine would
begin to over-rev, eventually lose power, possibly
damage the engine, and you will not achieve top
speed.
MMC2002-001_05A.FM 05-37
There are other factors involved here also. As This holds true for cross-country and snow cross-
clutches shift through their range, the efficiency ers also. Top speed is not as important as quick
with which they transmit power decreases as the acceleration out of the corners and ditches.
clutch ratio exceeds about 1.5:1. Efficiency also You can easily check your gearing selection by
drops as belt speed (RPM) increases. For opti- marking your drive clutch with a black marker with
mum chaincase performance ensure that you use straight lines from bottom to top on the belt sur-
the synthetic chaincase oil. faces of the clutch. Go out and ride your sled under
Because newer clutch designs shift beyond a 1:1 your normal conditions and stop to see how far the
ratio, belt speed increases dramatically and the di- belt has rubbed the marker off the clutch surfaces.
ameter that the belt follows around the driven pul- If it has shifted the belt all the way to the top, you
ley decreases considerably. This wastes energy may be able to pull one or two more teeth on the
and efficiency as the belt is being bent around a top sprocket. Experiment!
smaller diameter and centrifugal force is trying to If it is down about 1/2 in or more from the top, you
pull the belt into a circular path instead of following could consider trying a one tooth smaller top gear
the pulleys. depending upon your type of racing.
This is why for years manufacturers kept their The best combination of gearing for speed and ac-
clutch ratios around 1:1 to keep belt speeds down. celeration you can achieve is far more important
Now with the advent of larger displacement, high than shifting the belt all the way to the top of the
torque, lower RPM engines, we can use overdrive clutches.
transmissions and still keep our belt speeds within The following formula can be used to calculate the
reason. theoretical top speed of your Ski-Doo. The formula
As we mentioned, as belt speeds go up, efficiency assumes the transmission is shifted out to its top
drops. This is one reason many radar runners gear gear ratio. Make sure you use the correct track
extremely high sometimes even approaching 1:1 pitch and transmission ratio for your machine.
in the chaincase. They have found through diligent Square shaft clutch top ratio = 1
testing that they can achieve a higher top speed
without shifting their clutches all the way out be- TRA clutch top ratio = .83
cause of a decrease in belt speed which means an Pitch of internal drive track = 2.52 in
increase in transmission efficiency. That is their Number of teeth on internal drive sprocket = 9
bottom line.
NOTE: Some Summit and long track models use
For oval racing, the small benefit you may achieve 8 tooth drive sprockets.
in top end speed would probably be lost by the
loss of acceleration on the start and out of the cor-
ners on a tight oval circuit.
engine RPM teeth, top sprocket (pitch of track × No. of teeth on drive sprocket) 60
top speed in MPH = --------------------------------- × ------------------------------------------------------------- × ---------------------------------------------------------------------------------------------------------------------------- × -------------
clutch ratio teeth, bottom sprocket 12 5280
Example: 1995 Formula Z — gearing 25/44 peak A little known fact that can seriously impair a rac-
power at 7800 RPM er’s performance is the misconception that the
factory stated peak horsepower RPM or the peak
7800 25 (-------------------------
2.52 × 9 )- 60 power point you find on a dyno is the correct figure
--------------- × ------- × × ------------- = 115 MPH to clutch your race sled to.
.83 44 12 5280
Generally, this is not the case. The figures that are
For quick reference, use the gear ratio charts pro- printed by the factory are determined on a dyna-
vided. mometer in clinical test conditions.
05-38 MMC2002-001_05A.FM
CHAINS BOMBARDIER P/N

LINKS 11 WIDE 13 WIDE 15 WIDE
68 412 106 600 — —
70 412 105 900 412 106 800 486 093 100
72 412 105 500 412 106 700 486 074 300
74 412 105 800 412 106 900 504 151 910
76 — 412 107 600 —
GEARS
11 WIDE 13 WIDE 15 WIDE
TEETH STEEL POWDER STEEL POWDER STEEL ALUMINUM
TOP
17 504 071 800 — 486 070 400 — — —
18 — 504 070 100 486 070 500 — — —
19 — 414 680 500 486 070 600 — 486 092 600 —
20 504 074 800 — 486 070 700 — 486 092 700 —
21 504 084 000 — 504 139 300 — 486 092 800 —
22 504 074 700 504 056 000 504 083 500 504 091 100 486 074 600 —
23 504 078 400 504 087 800 504 085 400 504 091 000 486 093 000 —
24 504 078 600 504 056 100 503 139 700 504 090 900 — —
25 504 084 100 504 085 200 — 504 084 300 — —
26 — 504 055 900 — 504 085 300 — —
27 — — — — — —
11 WIDE 13 WIDE 15 WIDE

BOTTOM
38 504 056 400 — — — — —
39 — — — — — —
40 414 339 600 504 056 200 — 504 089 000 — —
41 — — — — — —
42 — — — — — —
43 — 504 748 500 — — — 489 104 600
44 — 504 057 300 — 504 085 500 486 074 400 —
44R 504 076 500 504 088 200 — 504 084 400 — —
Part numbers with a 486 prefix must be ordered from the Valcourt Race Dept. All others must be
MMC2002-001_05A.FM 05-39
TRANSMISSION CALIBRATION • Pin weight and ramp angle are interrelated,

but can be varied to achieve certain results.
PROCEDURE A 16.5 gram pin and the adjuster set in #5
1. A new vehicle should be broken-in before fine may produce the same full throttle RPM as a
tuning the transmission. 200 — 300 miles will 14.5 gram pin with the adjuster set in #3, but
allow things like bearings and the track to loos- the lighter pin will be revving higher at part
en-up. This will allow the sled to roll much freer throttle setting at low ratios. This may work
which may slightly change the clutch calibration. better for snowcross or woods racing where-
2. Set up the chassis configuration (lowering, weight as the heavier pin may be better in a drag
transfer, traction). race. Some ramp profiles will achieve better
top speed with the adjusters set in lower
3. Adjust the carburetor calibration to match the numbers (1-4). If you are in position 5 or 6, try
condition of the day. a slightly lighter pin weight (1.5 to 2 grams)
4. Pick the chain case ratio. and lower the adjuster position.
5. Define the driven pulley calibration. Stock is a NOTE: Never use adjuster position #6 with the FZ
good starting point. Drag racers may consider ramp. The tip of the ramp may touch the lever arm.
trying a larger cam angle. Use multi-angle cams • If your shift curve is perfect but the engage-
only for fine tuning after working with the drive ment is too low, a flat or notch can be ground
clutch. in the ramp right where the roller sits at neu-
6. Choose the drive belt (compound, length, width). tral position. This is a touchy procedure and
7. Define the TRA calibration. should only be attempted as a last resort. Be
prepared to scrap some ramps during the
• Start with the stock ramp in position #3. learning procedure.
• For most forms of racing, a higher engage- 8. The best way to test clutching is with a set of
ment RPM can be utilized. The better the timing lights or side by side comparison with
traction, the higher the engagement that can a similar vehicle. Leave one machine as a base
be used. Most stock grass drag rules limit en- line reference while tuning the test vehicle.
gagement to 5500 RPM. That’s 5500 RPM on Don’t change things on both vehicles at the
the technical inspector’s tachometer and it same time or you won’t know if you are gain-
may not agree with your dash tachometer. If ing or losing. Also, only change one parameter
in doubt, get the tech. man to verify your en- at time on your test vehicle so you know ex-
gagement. The easiest way to raise engage- actly what results from the change.
ment is to use a spring with a higher start load
and a similar finish load. Remember, the stiffer 9. For drag racers, try running the engine down
spring at start will also affect the shift curve to several hundred RPM below the stated
at 0 to 1/2 ratio. power peak. When the exhaust is cold, the
peak power RPM drops. How much lower de-
• If the stiffer spring slowed down the shift at pends on the engine type, exhaust type, jet-
low ratios, try more roller pin weight. The pin ting and underhood temperature. Summer and
weight will not change engagement much fall grass draggers should especially try lower
but will shift faster. Utilize the threaded roller RPM.
pins to achieve pin weights in between the
hollow steel and solid steel pin. 10. This is where the winners become winners.
Test, test, test and then go test some more.
• Fine tune the shift curve by trying different
adjuster positions. Use the lowest adjuster 11. KEEP DETAILED NOTES OF ALL YOUR
number that still allows you to maintain RPM. TESTINGS!!! No matter how good you think
your memory is, after you test your hundredth
combination, things can get overwhelming.
05-40 MMC2002-001_05A.FM
Transmission Tuning Test Sheet
DATE: _________________________ VEHICLE: ___________________________ SHEET NO.: ____________

TEST SITE: ____________________ TEMPERATURE:_____________________ SURFACE COND.: _______
TEST 1 TEST 2 TEST 3 TEST 4 TEST 5

Cam angle
Spring color code
Spring preload, lb
Spring position ex.: (A-4)
Chaincase gearing
Lever arm and pin type
Weight each assembly
Ramp identification
No. of set screws added
(if used)
Spring color code/tension
TRA adjuster position
Belt part number
Width
Length
Engagement RPM
Shift RPM
Top speed
Time for run/measured distance
Variation min./max.
Special notes
MMC2002-001_05A.FM 05-41
Racers Log
VEHICLE: DATE: SHEET NUMBER:
LOCATION: SURFACE CONDITIONS:
TEMPERATURE: BAROMETRIC PRESSURE: HUMIDITY:
CARBURETOR SIZE: FUEL: C.R.A.D.:
PTO MAG Carburetion notes:
Main jet
Needle jet
Jet needle
E-clip position
Slide cut-away
Pilot jet
Drive pulley Clutching notes:
Lever arm/pin type
Pin weight
Ramp identification
TRA adjuster position
Spring identification
Spring pressure @ engagement
Spring pressure @ full shift
Engagement RPM
Shift RPM
Drive belt identification
Driven pulley
Cam identification
Spring identification
Spring preload and location
Chaincase gearing
LH RH Chassis notes:
Inches of carbide/ski
Camber
Front spring identification
Ride height
Center spring
identification
Limiter adjustment
Rear spring identification
Ride height
Stud quantity and type
05-42 MMC2002-001_05A.FM
SECTION 06 - TECHNICAL PUBLICATIONS AND RACING PARTS
TABLE OF CONTENTS 0
USEFUL PUBLICATIONS .............................................................................................................. 06-2
TECHNICAL DATA ......................................................................................................................... 06-2
Supplement for model: MX Z 600 2001................................................................................... 06-2
Supplement for model: 1999 MX Zx 440/2000 MX Zx 440 .................................................... 06-3
Supplement for model: 1999 MX Z 670 H.O. .......................................................................... 06-4
MMC2002-001_06A.FM 06-1
USEFUL PUBLICATIONS
DESCRIPTION P/N
2002 Shop Manual Volume 3 – Zx Series 484 200 036
Specification Booklet 1998-2002 484 300 207
TECHNICAL DATA
Supplement for model: MX Z 600 2001
MODEL: MX Z 600 2001
RACING TYPE -GRASS DRAGS-
Maximum horsepower * RPM 7700
Carburetor type
PTO CENTER MAG
C
A Main jet P/N 504 108 200 no air box with filters 500 500
R Needle
B
U Needle clip position
R Slide cut-away
E Pilot screw 1.0 1.0
T
O Needle jet
R Air screw adjustment ± 1/16 turn
Needle valve
Fuel Super unleaded
Drive ratio 21 - P/N 504 139 300 43 - P/N 504 148 500 21-43
Chain 74 links
P/N 412 106 900
Drive pulley Type of drive pulley TRA
D Ramp identification 287
R P/N 417 005 287
I Calibration screw position 3
V
E Spring 250/380
P/N 417 222 004
Clutch engagement RPM 5000
R Pin std
A
T Lever std
I Driven pulley Spring Beige P/N 414 558 900
O
Preload kg
(lb) 18 lb
Cam Angle 50°
P/N 486 075 200
Drive belt Part number std
Spring rave Part number std
Calibration done at a temperature of 15° Celcius
* The maximum horsepower RPM is applicable on the vehicle. It may be different under certain
circumstances and BOMBARDIER INC. reserves the right to modify it without obligation.
06-2 MMC2002-001_06A.FM
Supplement for model: 1999 MX Zx 440/2000 MX Zx 440

MODEL: MX Zx 440 1999 and 2000
RACING TYPE -GRASS DRAGS-
Calibration done at temperature of 30°C
Carburetor type TMX
C PTO CENTER MAG

A Main jet 220 220
R Needle
B
U Needle clip position 4° 4°
R Slide cut-away
E
T Pilot jet 45 45
O Needle jet
R Air screw adjustment ± 1/16 turn 0.5 (1/2) 0.5 (1/2)
Needle valve
Fuel Racing fuel
Drive ratio
Chain 72 links
20-43
D Drive pulley Type of drive pulley TRA
R Ramp identification CF-1
I
V Calibration screw position 5
E Spring color 250/380
Clutch engagement RPM 5400
R Pin Steel thr. + 3 set screws
A Lever
T
I Driven pulley Spring Color
O Preload kg
20 lb (B-6)
(lb)
Cam Angle 47° - 42°
Drive belt Part number 486 076 800
Spring rave Part number 414 860 700
MMC2002-001_06A.FM 06-3
Supplement for model: 1999 MX Z 670 H.O.

MODEL: 1999 MX Z 670 H.O. PRELIMINARY
RACING TYPE -GRASS DRAGS- 500’
Carburetor type VM 44
C PTO CENTER MAG

A Main jet 350 N.A. 320
R Needle 7ECY1 7ECY1
B
U Needle clip position 4 4
R Slide cut-away 2.5 2.5
E
T Pilot jet 60 60
O Needle jet AA4 AA4
R Air screw adjustment ± 1/16 turn 0.5 (1/2) 0.5 (1/2)
Needle valve 1.5 1.5 1.5
Fuel Super unleaded
Drive ratio 23-43
Chain Links
Drive pulley Type of drive pulley TRA
Ramp identification 280
D P/N 417 005 280
R
I Calibration screw position no. 3
V Spring color 230/320 Pink/Purple
E P/N 414 754 200
Clutch engagement RPM
R Pin Solid (16 gr)
A Lever Std Aluminum
T
I Driven pulley Spring Color Beige
O Preload kg (B6)
(lb)
Cam Angle 50°
P/N 504 096 100
Drive belt Part number 414 860 700
Spring rave Part number
Calibration done at temperature of 80°F
06-4 MMC2002-001_06A.FM
SECTION 07 - COMPETITION PREPARATION
TABLE OF CONTENTS 0
HILL CLIMBING.............................................................................................................................. 07-2
DRAG RACING (ICE AND GRASS) ............................................................................................... 07-2
SPEED RUNS ................................................................................................................................. 07-4
OVAL RACING................................................................................................................................ 07-4
CROSS-COUNTRY/SNOW-CROSS RACING................................................................................ 07-5
2001 MX Zx 440 SPRINGS............................................................................................................ 07-9
2002 MX Zx 440 SPRINGS............................................................................................................ 07-9
SUGGESTED SPARE PARTS ........................................................................................................ 07-10
MMC2002-001_07A.FM 07-1
These are general guide lines for preparing a stock • 861 759 800 15 x 136 x 2 Paddle track
DSA chassis for various forms of competition. Re- (kit includes drive axle ass’y)
fer to the appropriate section of the book for more • 570 210 200 15 x 136 x 2 Paddle track
detailed information.
• 860 304 500 Ski stance widening kit
1996-98 Summit
HILL CLIMBING
Transmission
Front Suspension
• Good backshifting is important. Use a few pounds
• Use soft springs. You want the skis to compress more than normal preload on the driven pulley.
very easily and not transmit any upward force
into the chassis. • Adjust the TRA to maintain optimum RPM.
• Use minimal rebound dampening in the shock Driving Style
absorbers and on HPG T/A shocks, the gas pres-
sure can be reduced to 200 PSI. • Contrary to popular belief, constant full throttle
is not always the fastest way to the top. Use
Center your thumb to adjust for the conditions. Some-
times you need to back out of it to keep the
• Use medium spring pressure. You need some track from spinning excessively. You need to
track pressure for traction but the front arm must keep your momentum up but you must keep
be able to compress easily to absorb bumps. the sled on the ground so your track is hooked
• The limiter strap should be fairly short to keep up and the skis can steer you around any obsta-
front end lift to a minimum. Two to three inches cles.
of lift is plenty. A balance must be maintained
between having enough traction and keeping DRAG RACING (ice and grass)
the front end down for steering.
Special Rules
Rear Suspension
• Snow flap must be retained by 1/8 inch diameter
• Spring pressure should be kept firm in order to cable.
reduce weight transfer and help keep the front
end down on the ground. • Double limiter straps are required by many orga-
nizations.
• When rules allow, use rebuildable shocks. This
will allow you to calibrate compression and re- Front Suspension
bound dampening. This is necessary when chang-
ing spring rates. • Lower the ride height as far as possible but
maintain the legal travel requirement of two
Track inches. Shorter springs are available.
• Use the highest profile track available. • 415 020 600 DSA front spring 125 Ib/in 8 inch
free length.
• On sleds with less than 80 horsepower use a
121 inch track. A deep profile long track might • Trim the rubber blocks under the ski legs to re-
actually give you too much traction and the lower duce and adjust the amount of heel pressure on
HP won’t be able to spin the track in certain con- the ski.
ditions. • Use steel runners on the grass and stock trail
• Bigger HP sleds should use the 136 inch paddle carbide runners on the ice.
track. This track has 1.5 inch tall paddles molded
into the track. This is standard on the Summit.
• 570 208 600 15 × 136 × 1.5 Paddle track
• 570 208 900 15 × 121 × 1.5 Paddle track
• 570 021 200 15 x 136 x 1.75 Paddle track
07-2 MMC2002-001_07A.FM
Center NOTE: The installation of hooker plates will re-

quire modification to the tunnel protection system
• Use fairly stiff springs and preload.
and should be approached with caution.
• Shorter limiter straps will be required (414 955
• Two inch, two hole angled aluminum backer
300). On grass, more weight transfer can be
plates should be used when many studs are re-
used to keep the weight off the skis. On ice, run
quired. They should form the basis of your stud
the limiter very short to keep ski lift to a mini-
pattern with single, square, flat or angled backer
mum.
plates used in between.
Rear Suspension • Studs should be placed so the pattern does not
repeat itself for 4 to 6 pitches.
• Lower the ride height to the two inch minimum.
• Grass: Soften preload to help weight transfer Transmission
and keep the skis from dragging.
• Gear for about 10% over the actual speed you
• Ice: Use a lot of preload to help keep the front will run in the race. On grass, your upper sprock-
end down for better top speed at the end of the et should be about two teeth smaller than on
chute. the ice.
• Add two pairs of additional idler wheels and re- • Always stay with the same belt type and size,
place the 135 mm diameter wheels with 141 mm belt deflection, and center to center distance.
diameter wheels. Have several belts of the same size broken in
• Shave the slider shoes down to a 3 mm (1/8 inch) and ready to race. Don’t test with one belt and
thickness. then throw on a new one for race day.
• Use a ramp and spring combination to achieve a
Traction 5500 RPM engagement. It is best to stay around
• Most rules limit maximum stud height to 3/4 inch 5300-5400 unless you know how your tachom-
over the tallest part of the track. Taller tunnel eter compares to the tech. inspectors tach.
protectors will be required. • Keep the clutches clean! The pulley faces and
• Generally, fewer studs are required on grass belt should be wiped down with acetone before
than on ice. Also, less studs are needed on good, every run. Excessive pulley heat indicates belt
thick sod or hard clay. More studs will be need- slippage and you may need to recalibrate your
ed on loose grass, dirt and sand. clutch to squeeze the belt harder.
• Grass: Four steel picks per bar (4 × 48 pitches • Torque is what overcomes resistance to rolling.
on 121 inch track = 192 studs). Large horsepower Normally peak torque is about 200 to 300 RPM
machines may need more studs. Exchange some below peak horsepower. Try to clutch to the
picks for grass hooks on looser track surfaces. peak torque RPM.
Use “chisel” style studs. They have a wider pro- • Tune your clutches so that you run best for the
file but are still sharp on the ends. final which means everything will be heat
• Ice: Stud quantity is directly related to horse- soaked. If your sled requires different set ups
power on the ice. Up to about 80 HP, 4 to 5 ice between early runs when everything is cold and
picks per pitch should be used for a total of 200- later runs, know what to change and when to
250 studs. 80 to 105 HP should need 6 to 7 change it. Test under a variety of conditions so
picks per pitch for a total of 300-350 studs. Over you are prepared for any track and race condi-
110 HP will require 7 to 8 picks per pitch and tions.
possibly hooker plates welded to the track guides.
MMC2002-001_07A.FM 07-3
Cooling OVAL RACING

• Install a pair of hydraulic quick couplers in the
coolant hoses at a convenient location on the Special Rules
sled. Make a cooling cart using a cooler filled • Rear of tunnel must be enclosed per specifica-
with ice and several winds of copper tubing in- tions in the l.S.R rulebook.
side (or another type of heat exchanger) con-
• Snowflap must be retained by chains or 1/8 inch
nected to an electric pump and another set of
diameter cable.
quick couplers. Connect your sled to this mobile
refrigerator between runs to circulate coolant • Tail light AND brake light element must be on at
through the system and cool the engine down. all times! Add a jumper wire inside the taillight
Cool the engine to the same temperature every assembly.
time so your runs are consistent. • Any glass lenses must be taped over with clear
Fore more drag racing information contact Racing tape.
Dept. by fax at (715) 847-6869, phone (715) 847-
6884. Front Suspension
• Lower the ride height to the two inch minimum
SPEED RUNS travel requirement. Shorter springs are avail-
able.
Generally, a speed run sled will be set up very sim-
ilar to an ice drag sled with the following differences. DSA front 8 in free
P/N 415 020 600 125 Ib/in
• Some organizations do not allow lowering for spring length
stock class sleds. Check your rules. Shorter DSA front 8 in free
springs may be an option to try. P/N 415 020 700 150 Ib/in
spring length
• Because holeshots are not important, engage-
ment speed does not have to be set at 5000 • Camber: Left = 0 degrees
RPM. Top speed at the end of the course is the Right = Negative 2 to 4 degrees
only concern. • Verify ski toe out at the carbide edge.
• Chaincase gearing can be set for high theoreti- • Another trick is to fill the swing arms with spray
cal top speeds. Use the largest top and smallest foam insulation. When the foam hardens it helps
bottom sprocket available. This will keep the the swing arms resist bending without adding
belt low in the drive pulley which lowers the belt much weight.
and countershaft speed which makes the trans-
mission more efficient. • Steering ball joints should have as many jam
nuts added as will fit between the tie rod and
• As few studs as possible should be used. It the ball joint. This helps prevent bending of the
takes energy to push a stud into the ice and pull threaded portion of the ball joint.
it back out again. Since holeshots are not impor-
tant, use only enough studs to maintain control Center
at top speed.
• Use spring P/N 415 020 800 (70 Ib/inch, 6 inch
• Use standard trail carbide runners with the free length) and soft preload.
sharp edge worn down a bit. This way you will
have steering control without sacrificing speed.
• Run with a very short limiter strap and soft cen-
ter spring. This will reduce the track approach
angle which helps top speed.
For more speed run information contact Racing
Dept. by fax at (715) 847-6869, phone (715) 847-
6884.
07-4 MMC2002-001_07A.FM
Rear Suspension Transmission

• Lower the ride height to the two inch minimum • You need aggressive shifting to get a good hole-
travel requirement. shot but you also need good backshifting. Here
• Install a 4th idler wheel on the rear axle. again, testing is the key to success.
• Stiffer springs and firm preload may be required • Use the lowest TRA setting that still allows you
to reduce weight transfer and help keep the skis to maintain correct RPM when exiting the cor-
on the ice. If the handling is generally good but ners.
the inside ski is lifting, increase the right rear • Gear for the speed you will go on the course.
spring preload. • Break in several belts of the same type and size
• Remove non guide clips and install taller track and set up your pulleys to work with these
guides on the right side of the track or use des- belts.
ignated oval track. • Maintain your clutches on a weekly basis. A
clean, free moving driven pulley is important to
Traction good backshifting. Clean the pulley faces with
• Most rules limit maximum stud height to 3/8 inch acetone on a regular basis.
over the tallest part of the track. Track cutting is For more Oval Racing information contact Racing
illegal. A camoplast oval track is available P/N 679 Dept. by fax at (715) 847-6869, phone (715) 847-
9844, it has 3/4 inch lug height and tall guide clips 6884.
for oval racing.
• Use a thin profile, sharp tipped stud for hard ice Physical Conditioning
conditions. If the track conditions get sloppy,
exchange some picks for a chisel or wedge type • While a well set up sled will be easier to drive
stud. than a poor one, it still takes good arm strength
to turn a stocker with aggressive carbide. Train
• Seven picks per bar for a total of 336 studs will your upper body for strength and endurance. A
be required for all sleds up to about 100 HP. Big- good overall conditioning program that also
ger sleds may require more picks and/or hooker
works your legs and respiratory system is a
plates.
smart idea. While it may not seem like 3 lap
• Use 2 inch, 2 hole angled aluminum backer heats are very long, 10 lap finals on a short track
plates for the majority of your pattern, especially with tight corners can really wear you down.
on the outside belts. The right hand belt will need
a 2 inch plate on every pitch. Fill in the pattern
with 1 inch square backer plates. The pattern CROSS-COUNTRY/SNOW-CROSS
should not repeat itself for at least 5 pitches. RACING
• Use a good quality square bar carbide runner Your team should be organized well in advance
with 10 inches of carbide for starters. As you and hold regular meetings to cover key informa-
gain experience, try 14 inches of carbide for tion. It is very important that all team members be
more front end bite. familiar with each others duties and be prepared
• Studs and carbides need to be SHARP! The car- to assist one another as required. Remember sit-
bide must shave your fingernail when scraped uations develop with little or no notice and a well
across and studs must prick your finger. organized team can turn negatives into positives
and increase the team’s chance of winning!
Controls
• You will probably be more comfortable in the
corners if you make a curved extension for the
left side of the handlebars. Many drivers make
a new set of bars from the same size tubing and
custom bend it to fit their preference. (Check
your rule book for requirements on handlebars).
• You may also want to fabricate a stirrup for your
right foot.
MMC2002-001_07A.FM 07-5
Recommended Team Structure Post this list on the tool box and check off items
as they are completed so that one mechanic doesn’t
IT IS RECOMMENDED THAT THE MINIMUM
repeat the other’s work in error.
TEAM STRUCTURE BE AS FOLLOWS;
THE FIRST ITEM CHECKED SHOULD BE THE
1. RACE DRIVER
TRACK, AS DAMAGE TO IT OR SUSPENSION
2. CHIEF MECHANIC PARTS MAY NOT HAVE BEEN NOTED BY THE
3. ASSISTANT MECHANIC DRIVER. THE TRACK MUST BE ROTATED FOR
ONE COMPLETE REVOLUTION TO PROPERLY
4. TEAM MANAGER
CHECK. BOTH MECHANICS SHOULD OB-
SERVE AT THE SAME TIME.THIS IS THE IDEAL
Duties of the Mechanic and Team OPPORTUNITY TO INSPECT THE FRONT END,
Manager INCLUDING SKIS AND THEIR CARBIDES.
THE MECHANIC(S) Make sure that you have a parts runner(s) at the
1. PRE RACE PREPARATION — To ensure that fence closest to your area and use them to bring
they are familiar with all aspects of the Ski-Doo the parts from your race trailer. I-500 type events
snowmobile and capable of doing the worst have regulations to control parts delivery and us-
case scenarios, which are track changes and age so make sure you check with race officials be-
motor repairs. These and other repairs such as fore doing something which could penalize your
those to suspensions must be practiced driver.
enough times to ensure perfection. Remember 5. POST RACE PERIOD — Make sure you have all
power tools are seldom accessible when work- your own tools back and replace or re-order
ing at the start line therefore get used to hand parts used and be ready for the next day. Go
tools and operating in the cold. over your work with the other mechanic and
2. ON RACE DAY — Each morning it is recom- driver to compare notes and things to watch for
mended that the mechanic(s) warm up, refuel during the next day’s ride. Get ready for the
and move the sled to the start line as directed crew/driver meetings and maybe fit in some
by the race officials and as early as possible to dinner.
get a good spot. The mechanics should take a DUTIES OF THE TEAM MANAGER
warm up stand and cover with them to the start
line. Take a spark plug wrench and spare plugs 1. PRE RACE PREPARATION — The team man-
so the driver’s spares don’t have to be used. ager has an important job to do and must pull
everyone and everything together in an orga-
3. AT THE FINISH LINE — Intercept the driver nized fashion. Time spent in preparation is sel-
and ask what has to be done to the machine to dom wasted. He/she must assemble all the
get ready for the next heat or day and start plan- documentation and paperwork for the whole
ning the work session. You may have to really team and maintain a master file. All snowmobile
question your driver closely for feedback on the registration, insurance, hotel arrangements, en-
sled’s requirements as he may be too tired to try information, etc., and back up copies must
recall or too busy bench racing with the other be available quickly. It is a good idea to confirm
drivers. Remember you may be working out- your hotel reservations one week before and
side in the open and must be prepared to oper- ask for a fax map if you are not sure of the loca-
ate in rain or snow. tion. File everything in your driver’s race binder
4. DAILY WORK PERIOD — Use the mainte- for easy access.
nance checklist as a guide line and add on must-
doo items resulting from day’s ride.
07-6 MMC2002-001_07A.FM
2. DAILY START LINE — Get up first and make CROSS BORDER INFORMATION
sure all mechanics are up and getting ready to 1. IF YOU ARE A CANADIAN OR US CITIZEN —
leave. Let your driver sleep in as long as possi- You will need valid ID at both borders. This would
ble but make sure your vehicle (the second one) include a birth certificate or a drivers license or
starts before the mechanics leave for the im- a passport for all team members. The team man-
pound area. Ensure all rooms are checked out ager should double check all members for ID
of and paid for. Phone ahead to confirm the next before leaving the home town.
hotel’s reservations. Get your driver up on time
and get him to the start line at least 15 minutes 2. OTHER COUNTRIES — You will need a valid
before his flight leaves. Make sure that you passport for all team members from countries
have an overcoat for your driver to wear at the other than the US or Canada.
start line to keep warm until he leaves. Wait un- 3. BORDER CONFIRMATION — It is better to be
til your driver(s) leave the start and then make safe than sorry, so if you have any doubt contact
your way to the finish line and work area for that a border official directly and do it well before
night. race time.
3. DAILY FINISH LINE — Get on the road as soon 4. SNOWMOBILES AND SUPPORT VEHICLES —
as possible leaving the mechanic(s) and the reg- Ensure that all support vehicles and snowmo-
istered support vehicle to follow along the offi- biles have valid ownerships, registrations and
cial route and the various checkpoints. Make insurance for the state or province of origin. Do
sure you have your drivers warm up coat and not forget about your trailer!
gear bag with his post race clothing. Check in 5. PARTS AND EQUIPMENT — As a general rule
to the next hotel and get all the room keys be- the border officials will let race teams pass with
fore going to the finish line. Get any parts or little difficulty but large inventories of parts that
support organized that couldn’t be done by the appear to have a retail use may be subject to a
mechanics and try to intercept your driver as temporary bond.
soon as he gets in. Ask him for sled feedback
as soon as possible so that the work plan can 6. HEALTH INSURANCE — Check your personal
be initiated even before the mechanics arrive. health insurance plan to see what coverage is
Remember on multi day events the sled may be in effect while in another country. You may want
impounded at this point and therefore may not to supplement your existing policy with tempo-
be inspected prior to work period. rary Blue Cross or equivalent for the driver and all
team members.
4. WORK PERIOD — You may not be able to get
inside the work area but should position your- Team Press Coverage and Sponsor
self along the fence closest to your mechanic’s Recognition
area. Be ready to run for parts and assist as re-
quired. Keep track of the parts used, borrowed You should make sure that all current and future
or given away to your driver and other teams. potential sponsors are looked after in a profession-
Make sure the warm up stand and cover are al manner. Here are a few tips;
available for overnight storage. 1. PRE RACE COVERAGE
5. POST WORK PERIOD — Help sort out the – press articles and newsletters
parts and get ready for the next day’s routine.
2. SLED AND TEAM IDENTIFICATION
Look for a convenient place to eat and make
sure everyone is on time for the crew/driver – jackets, hats, trailer graphics
meetings. The team manager must attend the 3. RACE REPORT
crew meeting with the mechanics while the
– phone back home daily to a central contact
driver attends his separate meeting. Make sure
all keys are handed out prior to the meetings as 4. POST RACE TEAM PHOTO AND REPORT
the drivers normally meet longer and it would – take a camera
be nice to get the support crew back to the ho-
5. THANK YOU LETTERS AND PRESENTATIONS
tel first. Make sure wake up calls are in and
backup alarms on. Make a list of room numbers – remember your crew
for quick use.
MMC2002-001_07A.FM 07-7
RACE CIRCUIT RULES PARTS SUPPORT

Remember it is the driver and team’s responsibil- The Ski-Doo factory support trucks will be on
ity to have the sled race-ready in accordance with hand at most major Snowcross, grass drag and
the rules of the circuit you race in. All races ap- oval events across the U.S. and Canada. The pur-
proved for Ski-Doo’s Winners Circle contingency pose of these trucks is to provide parts, and tech-
awards are governed by the general rules laid out nical support for all racers racing Ski--Doo snow-
in the ISR annual handbook. It is common practise mobiles.
for the various race associations across North The Ski-Doo race support trucks carry an exten-
America to modify the ISR rules for local use. This sive inventory of parts, however it is always best
does result in conflicting standards and therefore to be self contained and not to count on anyone
every driver must carefully check the rules. but himself for parts support.
Contact the following circuits for detailed race rules. Below is a list of Base Gasket part numbers and
International 262-335-2401 PH thickness for the 453 Rotax.
ISR
Snowmobile Racing 262-335-9440 Fax
BASE THICKNESS
World Snowmobile 763-493-9900 PH GASKET
WSA mm (in)
Association 763-493-9910 Fax P/N
Canadian Snowcross 905-476-7182 420 931 580 0.3 (.012)
CSRA
Racing Association 905-476-7157 Fax
420 931 582 0.6 (.024)
American Snowcross 905-476-7182 PH
ASRA 420 931 583 0.5 (.019)
Racing Association 905-476-7157 Fax
RMR Rock Maple Racing 802-368-2747 PH 420 931 584 0.8 (.031)
United States
920-732-3563 PH
USSA Snowmobile
920-732-3900 Fax
Association
Motorsports Racing 612-428-3800 PH
MRPPI
Plus Pro Ice 612-428-3897 Fax
Super Competition 450-794-2298 PH
SCM
Motorsport 450-794-2450 Fax
Power Sled Racing
PRO 315-827-4849
Organization
First American North 218-222-3810 PH
FANS
Star Series 218-222-3809 Fax
Michigan Snowmobile
MSDRA Drag Racing 734-995-6995
Association
Colorado Snowmobile
CSRC 970-663-2296
Racing Club
Colorado Cross
CCC 907-468-4839
Country
Midwest International
MIRA 517-736-6784
Racing Association
Rocky Mountain
RMSHA 435-752-1892
Snowmobile Hillclimb
07-8 MMC2002-001_07A.FM
2001 MX Zx 440 SPRINGS 2002 MX Zx 440 SPRINGS

FRONT SHOCK SPRING FRONT SHOCK SPRING
FREE FREE
SPRING
P/N LENGTH COLOR P/N SPRING RATE LENGTH
RATE
mm mm
505 070 692 55-85 320 BL/GN/RD 505 070 575 293 45
CENTER SHOCK SPRING 505 070 941 150 315
503 189 325 CENTER SHOCK SPRING
150 242 YL/SI/YL
(standard)
503 189 990 215 189
415 070 500
135 242 BL/YL/YL 503 189 988 215 64
(softer)
503 189 999
REAR TORSION SPRING 325 189
(option)
WIRE
OPENING REAR TORSION SPRING
P/N DIAMETER COLOR
ANGLE WIRE
mm OPENING
P/N DIAMETER
503 189 443 ANGLE
11.11 95° GN/GN/GN mm
RH (std)
503 189 992
503 189 445 — —
11.11 95° GN/GN/GN 503 189 994
LH (std)
503 189 627
10.6 90° YL/WH
RH (softer)
503 189 629
10.6 90° YL/WH
LH (softer)
503 189 522
11.11 90° GN/GN/YL
RH (harder)
503 189 524
11.11 90° GN/GN/YL
LH (harder)
MMC2002-001_07A.FM 07-9
SUGGESTED SPARE PARTS – chaincase chain and sprockets

– TRA clutch puller and forks
You should have a self-contained parts supply. The
factory parts truck won’t always be there to back – TRA clutch rollers
you up. – driven pulley circlip and keys
TEAM SPARE PARTS: – brake lever
– parts book – radius rods and rod ends
– piston assembly and circlips – brake pads
– rotary valve disc – steering arms
– tuned pipe – padding and tape for ski loops
– radiator cap – front swing arms
– gas cap – throttle cable
– drive belts – throttle lever and housing
– carb. inlet needle and seat – rear axle spacers, washers, bolts
– drive and driven clutch springs – rubber suspension bump stops
– drive and driven slider buttons – tail light assembly
– TRA adjuster screws and nuts – hood latch rubbers
– drive clutch retainer bolt – synthetic chaincase oil.
– brake fluid SUGGESTED SPARE PARTS ON BOARD SLED
– steering tie rods and ball joints Enough tools to perform all maintenance period
– ski shock assembly requirements in the event that your crew is delayed
enroute to the impound.
– skis and carbide runners
– spark plugs
– ski bolt and nut
– drive belts
– track guides
– rear idler wheel and bolt
– speedometer cable
– long rubber bungees
– idler/rear axle wheels with bearings
– small hatchet and hammer
– track adjuster bolts
– shop rags
– light bulbs
– tie rod ends
– high windshield and O-rings
– small flashlight
– tether cord and switch
– small container of injection oil
– injection oil studs
– throttle cable and lever
– handle bars and grips
– windshield O-rings
– shop manual/specification booklet
– safety wire, tie wraps and duct tape
– engine gaskets, seals and O-rings
– de-icer
– rewind assembly and components
– pry bar
– exhaust springs
– emergency starter rope
– spark plugs
– bolt and nut assortment
– spark plug caps and wires
– small tape measure
– primer line fuel line and filters
– camping knife.
– primer
– main jets
07-10 MMC2002-001_07A.FM
Maintenance Check List

Driver: _________________________________________ Mechanic(s): ______________________________________
Problems observed/reported: (double check with driver) __________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
Parts needed for work period/pit area: (fuel and lubes) ____________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
Tools/Equipment Needed for Work Things to DOO During Work Period or

Period/Pit Area: Between Heats:
– cover and jackstand – carefully remove ice and snow build up
– pieces of carpet to lay on – front and rear suspension
– 3 flashlights – inspect suspension components
– one magnet – check/replace studs
– pop riveter – check camber
– WD40 – check tightness of all suspension
– shop rags – bolts
– contact gloves – check all idler wheels for missing
– tie wraps
– rubber and condition of bearings
– brake fluid
– Iube steering and front suspension
– antifreeze
– ball joints
– large hammer and pry bar
– check chain tension and oil level
– clip board, checklist and markers
– check clutch alignment and clean
– other:
– pulley faces
– toboggan/cart for tools and parts
– check carb. and air box tightness
– 1 tool set per mechanic
– clutch tools including alignment bar – coolant hose condition/routing
– hand drill and bits – check electrical connections
– devcon – other work:
– contact cleaner or acetone – inspect track for damage and
– silicone seal – missing guide clips
– duct and electrical tape – check skis and carbides
– injection and chaincase oil – check ski toe out
– deicer – check drive axle seal
– tape measures – check brake disc and pad condition
– grease gun – grease all zerk fittings
– safety wire – check track tension and alignment
MMC2002-001_07A.FM 07-11
– check brake fluid and operation 5. For XC and SNOW CROSS racing, endurance
– inspect drive belt type training activities that enhance your stam-
ina and breathing control are best. Running for
– check exhaust system and springs periods exceeding 30 minutes is the best way
– check throttle and oil cable and to improve stamina. The more and faster you
– check light bulbs. run the better your breathing control will be-
come. These abilities will pay off in short burst,
Replace any tools or parts used from race vehicle SNOW CROSS events and long distance events
supply. like the I-500. When you lose breathing control
Shut off fuel before impound. and start hyper-ventilating you quickly lose con-
centration and then 2 things generally happen;
FAX HOTLINE SERVICE
you slow down and get passed or you suddenly
Up to date snowcross technical information is become part of the landscape adjacent to the
available from the Ski-Doo Racing Department by trail!
way of a tip sheet.
6. A good daily routine should involve a cheap and
If you have a designated fax line and wish to re- highly portable format that relies on no equip-
ceive the tip sheets. Please contact the Racing De- ment and can be done just about anywhere
partment at (715) 848-4971. therefore making it excuse proof. Try this one;
We also encourage your feed back and would like a. 8 chin-ups — full arm extension.
to hear about any problems or possible solutions
b. 25 push-ups — chest [not belly] touching the
you may have.
floor.
Some Ideas c. 32 sit-ups — knees bent, hands locked be-
hind head.
1. Consume a high carbohydrate diet (see nutri-
tion tips). These foods will nourish your mus- As you start training, quality is more important
cles with muscle sugars (glycogens) the better than quantity therefore do 1 good chin-up at a time
your muscles are “fueled” the less fatigued you if that is all you are capable of completing. The
will be during and after training and on race day. next day try 2 and so on until you are up to 8. The
The less time you have for training the more secret to improving is not quantity of exercise but
important it is to eat properly and lets face it, we frequency and quality; in other words you will see
all have jobs that get in the way of your sport so more progress by doing 1 good chin-up 8 times
plan accordingly. daily than doing 8 poor ones once a day. You must
place pace yourself or you are inviting muscle
2. Right after training or a race, start consuming damage that will prevent you from riding.
carbos such as fig bars, fruit, etc., to start re-
placing depleted stores. 7. As mentioned previously, running is one of the
best ways to improve stamina and cardiovascu-
3. Drink lots of fluids to maintain hydration and lar efficiency. Try running a 4 mile distance in 32
make sure you “warm down” after training to minutes. Concentrate on finishing the distance
bring your heart rate down slowly and to gently first before looking at the watch. The real mental
work out the by-products of exercise. test and training opportunity will come around
4. A small cup of caffeine coffee might be con- the 2 mile mark when your brain is trying to tell
sumed just prior to race. It may enhance your you to quit. You must fight these thoughts and
performance by making you more alert. This concentrate on positive things like how you are
should be experimented first in training to en- going to spend Ski-Doo’s contingency money!
sure there are only positive effects.
07-12 MMC2002-001_07A.FM
8. It is very important that you become very famil-

iar with all of your personal riding gear and how
it works for you. All combinations of clothing
must be tested well before race day and in all
weather conditions so that you know how they
will affect your riding style. There should be no
surprises on the start line such as goggles fog-
ging because you taped up a different way than
normal. You have to develop and follow stan-
dard operating procedures that work for you;
the biggest mistake made by new drivers is to
overdress. At the start line you should only be
able to maintain warmth by wearing an overcoat
which is handed over to your mechanic as you
start.
9. It also important to know your sled and it’s sys-
tems very intimately. Even if you have the best
mechanics for your wrench sessions, the driver
is ultimately responsible for any failures. The
driver must be able to conduct all trail side re-
pairs to get across the finish line. The driver and
team must train together regularly to get to
know the sled intimately. Do not test any setup
during competition, this is the quickest way out
of the winner’s circle. Test one change at the
time and verify against an untouched reference
sled. Keep detailed notes on all tests or you are
doomed to repeat past mistakes and waste
valuable time.
You must first finish before you can finish in
first place.
MMC2002-001_07A.FM 07-13
SECTION 08 - SERVICE TOOLS
TABLE OF CONTENTS 0
SERVICE TOOLS............................................................................................................................ 08-2
WORKSHOP — MANDATORY SERVICE TOOLS..................................................................... 08-3
ENGINE — MANDATORY SERVICE TOOLS ............................................................................ 08-4
ENGINE (continued) — RECOMMENDED SERVICE TOOLS................................................... 08-8
TRANSMISSION — MANDATORY SERVICE TOOLS.............................................................. 08-14
TRANSMISSION (continued) — RECOMMENDED SERVICE TOOLS .................................... 08-17
SUSPENSION — MANDATORY SERVICE TOOLS .................................................................. 08-21
SUSPENSION (continued) — RECOMMENDED SERVICE TOOLS......................................... 08-22
VEHICLES — RECOMMENDED SERVICE TOOLS ................................................................... 08-25
MMC2002-001_08A.FM 08-1
SERVICE TOOLS 0
This is a list of tools to properly service Ski-Doo snowmobiles. The list includes both the mandatory tools
included in a kit (P/N 861 743 700) and the optional tools that are ordered separately. The list of Service
Products, both mandatory and optional, are not part of any kit and must all be ordered separately. If you
need to replace or add to your tool inventory these items can be ordered through the regular parts channel.
Following mention points out new tool and product: NEW
08-2 MMC2002-001_08A.FM
WORKSHOP — MANDATORY SERVICE TOOLS

Tool board
(P/N 529 034 000)
01
A00A3X4
APPLICATION
All models.
MMC2002-001_08A.FM 08-3
ENGINE — MANDATORY SERVICE TOOLS

Exhaust spring installer/remover Holder wrench Aligning pin (4)
(P/N 529 035 400) (P/N 420 876 357) (P/N 529 018 900)
A00A1D4
APPLICATION
467, 494 and 582 engines.
Pusher
A01B584
A00C0Q4 (washer behind the impeller)
APPLICATION APPLICATION (P/N 529 020 700)
CK3 series. 377, 443 and 503 engines.
Degree wheel Magneto puller ring

(P/N 529 035 607) (P/N 420 876 080) A00C3H4
360
33
0
340
20
350 10
10 360 350 3
20
40
30
APPLICATION
0 30 33 40
32 40 0
50
32
0 Rotary valve engines.
50
0
31
60
60
31
0
0
70
30
300
70
80
290
290
80
110 100 90
Rotary valve shaft pusher

280
280 270 26
90 100 11
270
(P/N 420 876 612)

260
120
A00C1R4
0
0
250
130
250
12 0
APPLICATION
0
24
14
24
13
0
0
2
30
30
15 2
1
0 22 40
16
All engines except 247.
0 0
210
200 190 180 17
0
0
22 0
15 A00C0F4
160 2 1
170 00
180 190 2
APPLICATION
A00B514
Magneto puller Rotary valve engines with a 10 mm
APPLICATION (P/N 529 035 547) impeller shaft.
All rotary valve engines.
NOTE: This tool replaces degree Rotary valve seal pusher
wheel (P/N 295 000 007). (valve side)
(P/N 420 876 607)
Hose pincher (2)
A00C1A4
(P/N 295 000 076)
APPLICATION
NOTE: The previous extractor (P/N A00C0Y4
529 022 500) can be upgraded by

replacing the screw with the new APPLICATION
one (P/N 529 035 549). Rotary valve engines.
A01B2I4
APPLICATION
All vehicles.
NOTE: Only the P/N has been
changed. This hose pincher is iden-
tical to the P/N 529 009 900.
08-4 MMC2002-001_08A.FM
ENGINE (continued) — MANDATORY SERVICE TOOLS

Rotary valve shaft seal pusher Ceramic seal pusher Choke plunger tool
(inner, water pump side) (P/N 420 877 820) A) (P/N 529 032 100)
(P/N 420 876 512)
B) (P/N 529 035 602)
A00B524
A01C5D4
A00C374 APPLICATION
APPLICATION
APPLICATION 494 and 670 engines with ceramic
A) All models equipped with chokes
Rotary valve engines, 1991 and seal on water pump side.
except ZX series (small end for
newer with a 10 mm impeller shaft. 30, 32 and 34 mm carburetor and
Engine leak tester kit big end for 38 mm carburetor).
Rotary valve shaft seal pusher (P/N 861 749 100) B) VM type carburetor on ZX series.
(outer, water pump side) 1) Hand pump
(P/N 420 877 050) (P/N 529 021 800) NEW
1
Piston circlip installer
(P/N 529 035 686) 20 mm
A00C0X4
APPLICATION A32B0C4
Rotary valve engines.

PA
UD
APPLICATION
S
OU A
V RIR A C H
A01B5F5
Engines with tab type circlip.
Bearing pusher
(rotary valve) APPLICATION
(P/N 420 876 500) All engines.
Fuel and oil system leak tester kit

(P/N 529 033 100)
A00B2J4
APPLICATION
Rotary valve engines.
A01B5E4
APPLICATION
All models.
MMC2002-001_08A.FM 08-5

1) Piston pin puller Rubber pad Choke/DESS nut tool
(P/N 529 035 503) (P/N 529 023 400) (P/N 529 034 600)
A01B554
A01B4C4
APPLICATION
APPLICATION
All models equipped with a choke
A02B094
All cageless bearing engines.
and/or a DESS.
2) Sleeve kit 18 mm NOTE: This tool replaces choke
Rotary valve circlip tool nut tool (P/N 529 032 200).
(P/N 529 035 541)
A) (P/N 529 029 100)
3) Sleeve kit 20 mm
B) (P/N 529 020 800) 9-volt adaptor
(P/N 529 035 542)
(P/N 529 035 675)
A00C3I4
APPLICATION
A) 1994 and on rotary valve engines.
A01B5A4
A00B5G4
B) Up to 1993 rotary valve engines.
NOTE: 18 mm sleeve kit contains APPLICATION
1 shouldered sleeve and 3 sleeves. Multimeter All models equipped with a DESS.
20 mm sleeve kit contains 1 shoul-
(P/N 529 035 788)
dered sleeve and 2 sleeves.
NEW
APPLICATION
1) All engines. Bypass wire kit
2) 277, 443, 503 and 809 engine. (P/N 861 780 600)
3) 593, 670 and 693 engines.
NOTE: The previous piston pin
puller (P/N 529 029 000) can be up-
graded by adding protector (P/N
529 035 513) and replacing the ex-
pansion sleeve with appropriate
sleeve kit.
A32B0F4
F01B1O4 APPLICATION
APPLICATION 2002 ZX with 360 W magneto.
All models.
08-6 MMC2002-001_08A.FM

Homemade adaptor 1-2) Programmer kit
(P/N 529 035 718)
7
8 2) Communication cables
(P/N 529 001 052)
1
1
4
2 3
5 6
A00B5J4
Required parts:
1) Female housing
(P/N 515 175 245)
2) Female terminal (2) 2
(P/N 409 015 100) A01B5B5
3) Female lock APPLICATION

(P/N 515 175 246) All models equipped with a DESS.
4) Male housing
(P/N 409 207 000)
5) Male terminal (2)
(P/N 278 000 631)
6) Male lock
(P/N 409 207 600)
7) RED wire in position 1
(4-wire connector) and B
(3-wire connector)
8) BLACK wire in position 2
(4-wire connector) and C
(3-wire connector)
APPLICATION
2001and 2002 Mach Z TECH PLUS.
MMC2002-001_08A.FM 08-7
ENGINE (continued) — RECOMMENDED SERVICE TOOLS

The following tools are highly recommended to optimize your basic tool kit and reduce repair time.
1-2) Crankshaft bearing 1) Screw M16 x 1.5 x 150 (P/N 420 940 755)
puller with screw
2) Screw M8 x 40 (4) (P/N 420 840 681)
(P/N 420 877 635)
3) Screw M8 x 70 (4) (P/N 420 841 201)
1
2,3
4) Crankshaft protector (P/N 420 976 890)
2,3
247 engine.
5) Crankshaft protector PTO (P/N 420 876 552)
6) Crankshaft protector MAG (P/N 420 876 557)
5 4,6 All engines except 247.
7) Puller ring (P/N 420 977 490)
7,10 Use with half rings
(P/N 420 977 475 or 420 276 025).
8,9,11 8) Half ring (2) (P/N 420 977 475)

For 72 mm O.D. bearings.
A01B547
9) Half ring (2) (P/N 420 276 025)
APPLICATION For 62 mm O.D. bearings.
All engines.
10) Puller ring (P/N 420 977 494)
For half rings (P/N 420 977 479).
11) Half ring (2) (P/N 420 977 479)
For 80 mm O.D. bearings.
08-8 MMC2002-001_08A.FM

Piston circlip installer Ring compressor Seal protector sleeve
A) (P/N 529 035 561) 18 mm A) (P/N 420 876 090) (P/N 420 276 900)
(62 mm) (MAG)
B) (P/N 529 035 562) 20 mm
B) (P/N 420 876 974)
(69.5 mm)
C) (P/N 420 876 970)
(72 mm)
D) (P/N 420 876 972) A00C0D4
(76 mm)
E) (P/N 420 876 975) APPLICATION
A00B4Y4
(67.5 mm) 247 engine.
APPLICATION F) (P/N 529 030 800)
A) All engines except 593, 670, 693 (78 mm) Polyamid ring pusher
and 793. (P/N 420 276 930)
NOTE: This tool replaces circlip in-
staller (P/N 529 016 900).
B) 2001 and older 593, 670 and 693
engines.
NOTE: This tool replaces circlip in- A00C0Z4
staller (P/N 290 877 016).
A01B1T4
APPLICATION
APPLICATION 247 engine.
Piston pin/connecting
rod bearing centering tool A) 377 engine.
(P/N 529 009 100) B) 467 and 494 engines. Crankshaft feeler gauge
NOTE: New diameter is 9.65 mm C) 503, 253 and 536 engines. (P/N 420 876 620)
(0.380 in). D) 582, 583 and 643 engines.
E) 443 and 447 engines.
F) 670 engine.
Magneto coil centering ring

(P/N 420 876 922)
A01B1R4
A00C114
APPLICATION APPLICATION
All engines except cageless and 377, 443, 447 and 503 engines.
670 engines.
A01B1V4
APPLICATION
All engines with Nippondenso CDI
(160 W).
MMC2002-001_08A.FM 08-9

Crankshaft distance gauge Driver tool Carburetor tool kit
(5.7 mm) (P/N 529 035 521) (P/N 404 112 000)
(P/N 420 876 822)
A00B4O4
APPLICATION
Mini Z.
A00B2F4
A00C294
Attachment APPLICATION
APPLICATION (P/N 529 035 522) All models.
377, 443 and 447 engines.
Adaptor
Crankshaft distance gauge (P/N 529 033 800)
(12.7 mm) (TYPICAL)
(P/N 420 876 824)
A00B4P4
APPLICATION A00B4H4
Mini Z.
APPLICATION
1997 and 1998 Grand Touring SE
A00C3A4 Pilot 22 mm 1998 Summit x 670.
APPLICATION (P/N 529 035 523)
503 engine. Float level gauge
(P/N 529 035 520)
Cylinder aligning tool
A) (P/N 420 876 904)
(on exhaust side)
B) (P/N 420 876 171)
4
(on intake side)

3
A00B4Q4
2
APPLICATION
1
A00B084 Mini Z.
A00B4N4
APPLICATION
APPLICATION
A) 2-cylinder liquid cooled engines.
All models.
B) 2-cylinder fan cooled engines.
08-10 MMC2002-001_08A.FM

Circuit tester RAVE movement indicator Magneto puller
(continuity light) (P/N 861 725 800) (P/N 420 976 235)
(P/N 414 012 200)
A00C214
APPLICATION
F01B294
All vehicles.
APPLICATION
247 engine.
Stroboscopic timing light A18B014
(P/N 529 031 900) APPLICATION

Injection pump gear holder
All RAVE equipped engines.
(P/N 420 876 695)
Dial indicator
(TDC gauge)
(P/N 414 104 700)
A00B4F4
APPLICATION A00B314
All engines.
A00B4E4
APPLICATION
253, 377, 447 and 503 engines.
Bypass wires APPLICATION
(P/N 529 033 300) All engines.
Injection pump gear holder
(P/N 420 277 905)
Seal protector sleeve
A) (P/N 420 876 980)
B) (P/N 420 876 490)
A00I094
APPLICATION
F and CK3 Grand Touring 700/SE
with 360 W magneto.
A00C164
A00C0D4
APPLICATION
APPLICATION All liquid cooled engines.
A) Rotary valve engines with 10 mm
shaft.
B) Rotary valve engines with 12 mm
shaft.
MMC2002-001_08A.FM 08-11

Digital/induction type tachometer Insertion jig Exhaust spring installer/remover
(P/N 529 014 500) (magneto side seal) (P/N 529 035 559)
(P/N 420 876 516)
A00C3S4
APPLICATION
F01B1G4
All models except CK3 series.
NOTE: This tool replaces exhaust
APPLICATION spring installer/remover (P/N 529
A00C3T4
All engines. 028 100).
APPLICATION
MAG seal pusher 779 engine. Rotary valve seal and
(P/N 420 277 875) shaft pusher
Insertion jig (P/N 420 876 605)
(magneto seal)
(P/N 420 876 514)
A00C0V4
APPLICATION A00C0Y4
277 engine.
APPLICATION
Rotary valve engines 1990 models
PTO seal pusher and older.
(P/N 420 876 660)
A00C3U4
APPLICATION
A00C0V4 454, 494, 599, 670, 699 and 809
engines.
APPLICATION
277 engine.
Handle for insertion jig
(P/N 420 877 650)
Base puller plate kit
(P/N 529 024 900)
A00C3V4
APPLICATION
454, 494, 599, 670, 699, 779 and
809 engines.
A05C0M4
APPLICATION
277 engine.
08-12 MMC2002-001_08A.FM

Seal pusher (rotary valve)
(P/N 420 876 510)
A00C374
APPLICATION
All rotary valve shaft seals with a
12 mm I.D.
Rotary valve shaft pusher

(P/N 420 876 610)
A00C0F4
APPLICATION
All rotary valve engines with 12 mm
shaft.
Large hose pincher

(P/N 529 032 500)
(TYPICAL)
F01B234
APPLICATION
All vehicles.
MMC2002-001_08A.FM 08-13
TRANSMISSION — MANDATORY SERVICE TOOLS

Driven pulley opening tool Forks (3) Drive pulley puller
(P/N 529 017 200) (P/N 529 005 500) (P/N 529 025 000)
A29B034
APPLICATION
Skandic LT 2001-2002.
A00A1A4
A16B014
Drive pulley puller
APPLICATION APPLICATION (P/N 529 002 100)
All vehicles equipped with a TRA (standard threads)
All non-RER models.
drive pulley.
Clutch holder A00C084

Tapered tool
(P/N 529 006 400)
Square shaft, standard (SAE)
threads.
A01B154
APPLICATION
Drive pulley puller
All TRA drive pulleys.
(P/N 860 414 200)
(square shaft metric)
TRA drive pulley puller Consists of:
(P/N 529 022 400) A32B0M4 529 003 000 529 002 800
APPLICATION
A06B014 Skandic LT 2001-2002.
APPLICATION
TRA drive pulley for the 454, 494, Spider tool A00C095
599, 670, 699, 779 and 809 engines. (P/N 529 025 200) APPLICATION
Square shaft, metric threads drive
TRA drive pulley puller pulley.
(P/N 529 007 900) (25 mm)
A18B044
APPLICATION
TRA drive pulley for 443, 467, 503,
536 and 537 engines.
A32B0N4
APPLICATION
Skandic LT 2001-2002.
08-14 MMC2002-001_08A.FM
TRANSMISSION (continued) — MANDATORY SERVICE TOOLS

Transmission alignment bar Drive belt tension adjuster tool Driven pulley spring compressor
A) (P/N 529 026 900) (P/N 529 008 700) (P/N 529 035 300)
B) (P/N 529 030 000)
2
C) (P/N 529 035 586)
D) (P/N 529 026 700)
1
E) (P/N 529 035 530)
F) (P/N 529 031 000)
G) (P/N 529 035 527) A15B044
H) (P/N 529 035 572)

I) (P/N 529 035 594) Parts included:
1) Hexagonal wrench
(P/N 420 876 730).
A01B4D4
2) Socket wrench A05B034
APPLICATION (P/N 529 015 000).
APPLICATION
A) Tundra II LT/R. APPLICATION
Tundra R.
B) S-Series with Bombardier Lite. All vehicles except Élan, Tundra II
C) S-Series with Bombardier Lite and Skandic WT.
and RER. Tension tester
(P/N 414 348 200)
D) F-Series, S-Series and ZX series Pulley spring compressor
with TRA. (P/N 529 035 524)
E) S-Series with TRA and RER. A00C074
F) Skandic WT LC/SWT.
APPLICATION
G) CK3 series except 1998 Mach Z
All models.
series.
H) 1998 Mach Z series.
Countershaft bearing installer
I) CK3 series with RER.
(P/N 529 030 200)
Spring scale hook (long)

A) (P/N 529 006 500)
B) (P/N 529 030 900)
C) (P/N 529 035 557)
A02D1P4
(TYPICAL)
APPLICATION
All models.
NOTE: This tool has Acme threads A00A194
and replaces spring compressor APPLICATION

(P/N 529 018 600).
S-Series and F-Series.
A00B4A4
APPLICATION
A) Tundra II LT.
B) F-Series and S-Series
(1995 and newer).
C) CK3 without RER.
MMC2002-001_08A.FM 08-15
TRANSMISSION (continued) — MANDATORY SERVICE TOOLS

Countershaft bearing remover Countershaft bearing
(P/N 529 030 100) remover/installer
(P/N 529 035 699)
A00A274
APPLICATION
S-Series and F-Series. A00B5K4
APPLICATION
Countershaft bearing ZX and CK3 Series.
remover/installer NOTE: This tool replaces CK3 se-
(P/N 529 035 554) ries countershaft bearing remover/
installer (P/N 529 035 554).
Spring cover tool

(P/N 529 027 300)
A01B4M4
APPLICATION
A01B5C4
Bombardier Lite drive pulley.
APPLICATION
CK3 series.
08-16 MMC2002-001_08A.FM
TRANSMISSION (continued) — RECOMMENDED SERVICE TOOLS

The following tools are highly recommended to optimize your basic tool kit and reduce repair time.
Clutch holder Alignment tool Countershaft bearing remover
(P/N 529 027 600) (P/N 420 476 010) (P/N 529 018 700)
A02B034
APPLICATION
Bombardier Lite drive pulley. A00C1D4
APPLICATION
Drive pulley puller Skandic WT and Alpine II gearbox.
(P/N 529 031 400)
(P/N 529 018 800)
A18B044
A00A164
APPLICATION
APPLICATION
Bombardier Lite drive pulley, except
Élan. PRS chassis.
NEW
Driven pulley opening tool
(P/N 529 035 501)
Countershaft bearing remover
A00A194
(P/N 529 035 812)
APPLICATION
PRS chassis.
Cam pusher
A03D2P4 (P/N 529 012 900)
APPLICATION
S and CK3 series with RER.
NOTE: This tool replaces driven pul-
ley opening tool (P/N 529 019 500).
Driven pulley opening tool A18B064

Tundra II LT.
A29B024
APPLICATION
Skandic LT.
A05B044
APPLICATION
Tundra R.
MMC2002-001_08A.FM 08-17

NEW

(P/N 529 035 815)
A00A194
APPLICATION
Skandic LT.
Drive pulley puller

(P/N 529 023 100)
A00C3J4
APPLICATION
Élan.
Transmission ball mounting pin

(P/N 420 476 020)
A00C1C4
APPLICATION
Alpine II 3-speed gearbox.
08-18 MMC2002-001_08A.FM

Transmission adjuster Burnishing bar Large bushing extractor
(P/N 529 028 500) (P/N 529 026 402) (P/N 529 035 576)
A00D0X4
APPLICATION A00B464
A02D1Q4
F-Series equipped with “twist APPLICATION

shifter” reverse transmission. APPLICATION
Tundra II LT, Safari L and Skandic.
Formula type driven pulley.
NOTE: Use this tool only with new
Spring scale hook (long)
Large bushing extractor puller (P/N 529 035 524) that has
(P/N 529 015 200) Acme threads and support plate
(P/N 529 031 100)
included with extractor (P/N 529
031 100).
Large bushing extractor

(P/N 529 035 575)
A01B514
APPLICATION
A00B4I4
1994 models and older except Al-
pine II. APPLICATION
Formula type driven pulley.
Alignment bar NOTE: Use this tool only with
former puller (P/N 529 018 600)
A) (P/N 529 025 600) that has regular threads.
A02D1Q4
B) (P/N 529 028 200) APPLICATION

C) (P/N 529 028 300) Bushing extractor/installer LPV 27 driven pulley.
D) (P/N 529 026 800) (P/N 529 031 300) NOTE: Use this tool only with
new puller (P/N 529 035 524) that
E) (P/N 529 031 000)
has Acme threads and support
F) (P/N 529 035 808) plate included with extractor (P/N
529 031 100).
A01B4D4
APPLICATION
A) PRS chassis.
B) Alpine II.
C) Élan.
D) Safari L. A01B5G4
E) Skandic WT 1996. APPLICATION

F) Skandic LT. TRA drive pulley spring cover with
repleacable bushing
MMC2002-001_08A.FM 08-19

Large bushing installer and small Drive axle sprocket adjuster
bushing extractor (P/N 861 725 700)
(P/N 529 031 200)
5
2
3
1
6
A00B4J4 A01B2O4
APPLICATION
Parts included in the kit:
All models except Tundra/R, Skandic
WT/SWT/WT LC and S-Series with 1) Block with threads
RER. (P/N 529 010 700)
2) Block without threads
(P/N 529 010 800)
Chaincase seal pusher
3) Plate
(P/N 529 035 584) (P/N 529 010 600)
4) Bolt M10 (2)
(P/N 222 007 565)
5) Allen screw M8 (2)
(P/N 222 983 065)
6) Screw M8 (2)
(P/N 222 082 565)
NOTE: When the tool is to be used
between tunnel and sprocket use
A00B504
screws M8.
S, F, CK3 and ZX series. All vehicles except Élan.
NOTE: This tool replaces chain-
case upper seal pusher (P/N 529 Transmission adjuster
032 300).
(P/N 529 030 300)
TRA drive pulley puller (27 mm)

(P/N 529 010 100) A03D1T4
APPLICATION
Vehicles equipped with “push-pull
A18B044
shifter” reverse transmission.
APPLICATION
TRA drive pulley (27 mm) shaft ex-
cept 454, 670 and 779 engines.
08-20 MMC2002-001_08A.FM
SUSPENSION — MANDATORY SERVICE TOOLS

Shock spring removal kit
(P/N 529 035 504)
Replacement clevis pin:
(P/N 414 528 400)
A01B4O4
APPLICATION
All suspensions with coil spring.
NOTE: The previous shock spring
removal kit (P/N 529 027 100) can
be upgraded by replacing the stop-
per with a wider stopper (P/N 529
035 551).
MMC2002-001_08A.FM 08-21
SUSPENSION (continued) — RECOMMENDED SERVICE TOOLS

A) Track cleat remover Camber angle tool Track cleat installer
(P/N 529 008 200) (P/N 529 021 600) A) (P/N 529 008 500)
Pins NOTE: Angle finder with a magnetic Narrow
(P/N 529 008 204) base must be used. B) (P/N 529 028 800)
NOTE: Pins can be rotated 180° de- Suggestion: K-D tool no. 2968 Narrow
pending on whether the tool is used C) (P/N 529 007 700)
by a left-hander or right-hander. Wide
A06B024
A01B1J4
APPLICATION
B) Track cleat remover All DSA front suspensions.
(P/N 529 028 700) A01B1M4
Track tension gauge APPLICATION

(P/N 529 021 500) A) 1993 and older.
B) 1994 and newer.
C) 1992 and older with wide cleat
opening.
Dome guide
A01F224
A) (P/N 529 026 500)
APPLICATION
B) (P/N 529 035 728)
A) 1993 and older.
B) 1994 and newer except Élan and
A00B3X4
Tundra II.
APPLICATION A06F1B4
All models except Élan. APPLICATION

A) C-36 T/A shocks.
B) C-46 T/A shocks.
08-22 MMC2002-001_08A.FM

Shock wrench Gas shock valve tool Spring installer (bar)
(P/N 529 035 727) (tire valve type) (P/N 529 005 000)
(P/N 529 035 570)
A00F224
A00C1I4
All T/A shocks
A02F134
APPLICATION
APPLICATION Tundra II LT, Scout and all SC-10
NEW
1999 and older T/A shocks and suspensions.
some 2000 and up T/A shocks.
HPG shock holding tool
(P/N 529 035 769) Drive axle holder
Tool for shock (needle type) (P/N 529 007 200)
(P/N 529 035 614)
A01B5H4 A00B5I4
A01B1E4
All HPG shocks APPLICATION
Most 2000 and up T/A shocks. APPLICATION
All models.
Piston guide
A) (P/N 529 026 600) Drill bit
(P/N 529 031 800) Kayaba shock adjustment tool
B) (P/N 529 035 608)
(P/N 529 035 582)
A01B564
A06F1C4 APPLICATION
All 3/16 inch rivets.
APPLICATION
A00A1K4
A) C-36 T/A shocks.
APPLICATION
B) C-46 T/A shocks.
C-7 suspension.
MMC2002-001_08A.FM 08-23

Hexagonal wrench Adjustment wrench
(P/N 529 014 700) (P/N 861 743 900)
Consists of:
A19B024
529 024 000
APPLICATION
All SC-10 suspensions, Safari and
Skandic prior to 1995.
529 025 500

Suspension adjustment wrench
(P/N 529 017 100) A00B4B4
APPLICATION
1998 and older models with T/A
A15B094 shock.
APPLICATION
1992 and old Formula C-7. Adjustment wrench
(P/N 520 000 126)
(P/N 529 032 900)
A00B5H4
A02F114
APPLICATION
APPLICATION SC-10 II (coupling blocks).
ARM and SC 10 II suspensions.

(P/N 529 034 100)
A02F124
APPLICATION
CK3 series.
08-24 MMC2002-001_08A.FM
VEHICLES — RECOMMENDED SERVICE TOOLS

Protective mat
(P/N 529 030 600)
A01B45W
APPLICATION
All vehicles.
Dolly Snowmobile jack

(P/N 529 029 900) (P/N 529 020 000)
A00B4CJ A01A1JJ
All models. All models.
MMC2002-001_08A.FM 08-25
VEHICLES (continued) — RECOMMENDED SERVICE TOOLS

Template for hood drilling Terminal (Packard) remover
(P/N 529 034 400) Not sold by Bombardier
Snap-on
TT 600-4
A02H154
F01B1J4
S-Series. Models with Packard connectors.
NOTE: To drill new hood prior to
install meters.
Crimping tool
(P/N 295 100 164)
Flexible spout for oil container
(P/N 414 837 300)
F04B044
APPLICATION
F00B0E4
All models.
APPLICATION
Adjustment wrench Models with AMP connectors.
(P/N 529 035 603)
Hose clamp pliers
(P/N 295 000 070)
A32B044
F01D174
APPLICATION
APPLICATION
To remove and install fuel tank nut
Some models.
on ZX series.
08-26 MMC2002-001_08A.FM
NOTE
MMC2002-001_NOTE.FM
NOTE
MMC2002-001_NOTE.FM

2002 Racing

Uploaded by

Copyright:

Available Formats

2002 Racing

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

2002 Racing

Uploaded by

Copyright:

Available Formats

0

2002 RACER HANDBOOK

HOW TO COMMUNICATE ...................................................................................................... 01-1

2002 MODELS TECHNICAL DATA.......................................................................................... 02-1

CHASSIS PREPARATION ........................................................................................................ 03-1

ENGINE PREPARATION .......................................................................................................... 04-1

TRANSMISSION SYSTEM ...................................................................................................... 05-1

TECHNICAL PUBLICATIONS AND RACING PARTS .............................................................. 06-1

COMPETITION PREPARATION ............................................................................................... 07-1

SERVICE TOOLS...................................................................................................................... 08-1

KEEPING YOUR MACHINE LEGAL IS YOUR RESPONSIBILITY

Ski-Doo Race Department

Your information is important to us.

See Section 06-1, Competition bulletins-racing parts, useful publications.

Race program, sponsorship, contingency programs

SHIPPING CONDITIONS: RED ______ GROUND ______ BLUE ______

DESCRIPTION PART # OR CLOTHING PART # QUANTITY

PHONE ORDERS WILL NOT BE ACCEPTED

City: St./Prov: Zip/Code:

Phone: Day: Evening:

Please send my T.I.P. sheets to the following: Please print !

Please return this completed form by Fax to (715) 847-6869

M6 9 (7) 9 (7) 9 (7)

MX Z 500 TRAIL MX Z 600 MX Z 600 R

M6 9 (7) 9 (7) 9 (7)

MX Z 600 TRAIL MX Z 600 R MX Z 600 R

M6 9 (7) 9 (7) 9 (7)

MX Z 600 MX Z 600 R MX Z 700

M6 9 (7) 9 (7) 9 (7)

MX Z 700 R MX Z 700 MX Z 700 R

M6 9 (7) 9 (7) 9 (7)

MX Z 700 R MX Z 700 MX Z 700 R

M6 9 (7) 9 (7) 9 (7)

MX Z 800 MX Z 800 R MX Z 800

M6 9 (7) 9 (7) 9 (7)

MX Z 800 R MX Z 800 R MX Z 800

Needle Identification — Clip Position 9ZLY2/58 ➅ 9ZLY2/58 ➅ 9ZLY2/58 ➅

M6 9 (7) 9 (7) 9 (7)

MX Z 800 R SUMMIT 600 SUMMIT 600 R

Needle Identification — Clip Position 9ZLY2/58 ➅ 9HGY1/58 ➅ 9HGY1/58 ➅

M6 9 (7) 9 (7) 9 (7)

SUMMIT 700 SUMMIT 700 R SUMMIT 800

M6 9 (7) 9 (7) 9 (7)

SUMMIT 800 R SUMMIT 800 SUMMIT 800 R

M6 9 (7) 9 (7) 9 (7)

SUMMIT 800 SUMMIT 800 R SUMMIT 800

M6 9 (7) 9 (7) 9 (7)

MX Z 500 TRAIL MX Z 600 MX Z 600 R

Pulley Distance Z ± 0.5 mm 16.5 16.5 16.5

X ± 0.5 mm 35.5 35.5 35.5

Ski Stance (carbide to carbide) mm (in) 1080 (42.5) 1195 1195

MX Z 600 TRAIL MX Z 600 R MX Z 600 R

Pulley Distance Z ± 0.5 mm 16.5 16.5 16.5

X ± 0.5 mm 35.5 35.5 35.5

MX Z 600 MX Z 600 R MX Z 700

Pulley Distance Z ± 0.5 mm 16.5 16.5 16.5

X ± 0.5 mm 35.5 35.5 35.5

MX Z 700 R MX Z 700 MX Z 700 R

Pulley Distance Z ± 0.5 mm 16.5 16.5 16.5

X ± 0.5 mm 35.5 35.5 35.5

SHIPPING CONDITIONS: RED GROUND BLUE __