Ski-Doo 1997 FORMULA 500, Operator'S Manual

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Page 2: ...Inc 1996 MMO 9701 GM SAFETY WARNING Disregarding any of the safety precautions and instructions contained in this Operator s Guide Safety Handbook or on product labels could cause injury including th...

Page 3: ...your dealer would have explained the snowmobile controls and provided you with a brief explanation of the various suspension ad justments We trust you have taken full advantage of this If you need mo...

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Page 5: ...contained in this guide are correct at time of publication We also reserve the right at any time to discontinue or change spec ifications designs features models or equipment without incurring obliga...

Page 6: ...1 2 Brake Lever 21 3 Parking Brake Button 21 4 Gear Shift Lever 23 5 Ignition Switch 26 6 Tether Cut Out Switch 27 7 Emergency Cut Out Switch 28 8 Headlamp Dimmer Switch 29 9 Rewind Starter Handle 29...

Page 7: ...t Off Valve 40 Adjustable Backrest 43 Hitch 44 FUEL AND OIL 45 Recommended Fuel 45 Recommended Oil 46 BREAK IN PERIOD 47 Engine 47 Belt 47 10 Hour Inspection 47 PRE START CHECK 48 Check Points 48 STAR...

Page 8: ...tment 95 Rear Suspension Condition 95 Suspension Stopper Strap Condition 95 Track condition 95 Track Tension and Alignment 96 Steering and Front Suspension Mechanism 99 Wear and Condition of Skis and...

Page 9: ...s considered an illegal operation Electric start models only Never charge or boost a battery while installed on snowmobile Do not lubricate throttle and or brake cables and housings Only perform proce...

Page 10: ...verage Period 3 CONDITION TO HAVE WARRANTY WORK VALIDATED The customer must notify an authorized SKI DOO dealer within two 2 days of the appearance of a defect in material and or workmanship and prese...

Page 11: ...an implied warranty lasts so the above limitation or exclu sion may not apply BOMBARDIER reserves the right to modify this warranty at any time being understood that such modification will not alter...

Page 12: ...local authorized SKI DOO dealer 3 CONDITION TO HAVE WARRANTY WORK VALIDATED The customer must notify a local authorized SKI DOO dealer within two 2 days of the appearance of a defect in material and...

Page 13: ...ernational Distributor may elect to translate this warranty into local language it is then understood and agreed that in the event of any discrepancy among the two versions the English version shall p...

Page 14: ...registration has two purposes In many provinces or states it is mandatory to register a snowmobile in the same way as for a car It allows the state or province to maintain records of existing snowmobi...

Page 15: ...ler any Genuine Bombardier part used in warranty repairs assumes the re maining warranty that exists on the snowmobile Q If I sell my snowmobile within the warranty period will the new owner qualify f...

Page 16: ...INC 726 St Joseph Street Valcourt Quebec Canada J0E 2L0 Telephone 514 532 5000 Fax 514 532 5077 USA BOMBARDIER MOTOR CORPORATION OF AMERICA 7575 Bombardier Court P O Box 8035 Wausau WI 54402 8035 USA...

Page 17: ...snowmobile in the event of loss These numbers are required by the dealer to complete warranty claims properly No warranty will be allowed by Bombardier Inc if the engine serial number or VIN is remove...

Page 18: ...16 TYPICAL SKANDIC WT SWT 1 Serial number ENGINE SERIAL NUMBER LOCATION TUNDRA II LT 1 Serial number A22H0FA 1 1 A05A07A...

Page 19: ...17 SKANDIC AND TOURING SERIES FORMULA S SL MX Z 440 F 1 Serial number FORMULA 500 500 DELUXE 583 Z III MX Z SUMMIT GRAND TOURING AND MACH SERIES 1 Serial number 1 A25C0MA A03C1FA 1...

Page 20: ...ontrols instruments do not apply to some mod els In these cases their reference numbers are deliberately missing in the illustrations Some controls instruments are optional on some models TUNDRA II LT...

Page 21: ...19 TYPICAL SKANDIC WT SWT 200 180 160 20 40 80 60 140 100 120 N 1 R 2 4 A29H02A 15 12 20 21 7 1 3 2 23 25 28 28 19 9 5 6 11 14 8 13...

Page 22: ...20 TYPICAL FORMULA S SL Z 500 500 DELUXE 583 SKANDIC TOURING MX Z SUMMIT SERIES AND GT 500 583 29 A03H1GA 2 3 17 15 12 14 21 20 18 7 29 1 28 9 4 11 25 19 23 6 5 8 28 16 13...

Page 23: ...it automatically returns to its original po sition Braking effect is proportional to the pressure applied on the lever and to the type of terrain and its snow coverage 3 Parking Brake Button Located...

Page 24: ...lever then fully push parking brake button Always release parking brake before riding TYPICAL Step Squeeze and hold Step Fully pull Hydraulic Brake To engage mechanism squeeze brake lever and maintain...

Page 25: ...E A warning buzzer will sound when the shift lever is in reverse gear position Skandic 380 500 Touring SLE G T 500 583 and Formula 500 DELUXE A 2 position lever Push Forward gear Pull Reverse gear 1 R...

Page 26: ...A 4 position lever 1 1st gear 2 2nd gear 3 Gear shift lever 4 Neutral 5 Reverse WARNING These snowmobiles are capable of a fast reverse Always re main seated and apply the brake before shifting Come...

Page 27: ...to 2nd gear vehicle may be in motion 20 km h 12 MPH but engine must be at idle Maximum speed in first gear 60 km h 37 MPH CAUTION Bring snowmobile to a complete stop before changing gear WARNING Thes...

Page 28: ...diately when engine has started Key returns to ON position as soon as it is released If engine does not start on first try key must be turned fully back to OFF each time To stop engine turn key to OFF...

Page 29: ...ord to wrist or clothing then snap tether cut out cap over receptacle before starting engine TYPICAL 1 Snap over receptacle 2 Attach to eyelet If emergency engine shut off is required completely pull...

Page 30: ...pper ON position TYPICAL 1 ON 2 OFF All drivers of the snowmobile should familiarize themselves with the function of this device by using it several times on first outing and to stop the engine there...

Page 31: ...TYPICAL 9 Rewind Starter Handle Auto rewind type located on right hand side of snowmobile To en gage mechanism pull handle slowly until a resistance is felt then pull vigorously Slowly release handle...

Page 32: ...e throttle lever with the choke lever on Move the choke lever to position 2 and start the engine As soon as the engine starts move the lever to position 1 After a few seconds 10 seconds maximum move t...

Page 33: ...ometers or miles 13 Odometer Odometer records the total distance travelled in kilometers or miles 14 Trip Meter Records distance travelled in kilometers or miles until it is reset It can be used to re...

Page 34: ...he gauge indicates engine coolant temperature The needle moves to the normal range as engine warms Under all riding conditions the needle should stay within this range If needle moves into the over he...

Page 35: ...20 High Beam Pilot Lamp Blue Lights when headlamp is on HIGH beam 21 Injection Oil Level Pilot Lamp Red Lights when injection oil level is low Check oil level and replenish as soon as possible Also l...

Page 36: ...sition to keep your hands at a comfortable temperature TYPICAL 1 HOT 2 OFF 3 WARM 23 and 25 Heated Grip and Throttle Lever Skandic WT SWT Only Two position toggle switch Select the desired position to...

Page 37: ...e Lever Pilot Lamp Amber Lights when heated throttle lever switch is on the high position Light dimmed when switch is on the low position 27 Rear Passenger Heated Grip Switch Three position toggle swi...

Page 38: ...ration for fuse holder location If starter does not oper ate check fuse condition and replace if necessary To remove fuse from holder pull fuse out Check if filament is melted 1 Fuse 2 Check if melted...

Page 39: ...37 Touring E LE SLE Formula 500 Deluxe and G T 500 583 1 Fuse holder Skandic WT SWT 1 Fuse holder Electric Fuel Level Gauge Fuse See your dealer for fuse replacement 1 A03H0JA 1 A22H0IA...

Page 40: ...containing tools for basic maintenance can be found there on some models For tool kit location on all models except Formula III Mach 1 Z and Skandic WT SWT see Belt Guard Removal and Installation Skan...

Page 41: ...39 SKANDIC WT 1 Lift seat latch SKANDIC SWT A22H0JA 1 A29H01A...

Page 42: ...e that they will not be loosened by vibrations NOTE Spare spark plugs are not supplied with snowmobile TYPICAL FORMULA III AND MACH 1 Z 1 Spare drive belt holder 2 Tool kit 3 Spark plug holders Spare...

Page 43: ...be closed when transporting or storing snowmobile TYPICAL FORMULA 500 500 DELUXE 583 Z MX Z SUMMIT AND G T SERIES 1 Closed TYPICAL FORMULA 500 500 DELUXE 583 Z MX Z SUMMIT AND G T SERIES 1 Opened A03I...

Page 44: ...AL FORMULA III AND MACH 1 Z 1 Closed 2 Opened Fully open the valve in order to operate the snowmobile CAUTION Always fully open the valve before riding Never allow the valve to remain half opened 1 2...

Page 45: ...r or passenger convenience 1 Lift adjustment lock both sides 2 Turn adjustment knob Secure adjustment locks after desired position is obtained Height of rear grab handles can be adjusted Lift adjustme...

Page 46: ...ch can be used to pull most equipment WARNING Backrest should only be repositioned while the snowmobile is stopped Adjust to provide maximum lower back support Always consider your passengers comfort...

Page 47: ...mber R M 2 of 91 or higher All Models NOTE In most service station pump octane number corre sponds to R M 2 octane number CAUTION Never experiment with other fuels or fuel ratios The use of unrecommen...

Page 48: ...as low as minus 40 C 40 F If unavailable substi tute with Blizzard Oil P N 496 0145 00 Always maintain a sufficient amount of recommended oil in the in jection oil reservoir CAUTION Never mix brands...

Page 49: ...P N 496 0133 00 should be added to fuel for the first full filling of fuel tank Always remove and clean spark plugs after engine break in Belt A new drive belt requires a break in period of 25 km 15...

Page 50: ...ust fully return when released Verify skis and steering operate freely Verify track and idler wheels are unfrozen and free to turn Check fuel and injection oil level Ensure fuel shut off valve is in f...

Page 51: ...ry when engine is warm Choke Equipped Vehicles 1 OFF 2 Position 1 3 Position 2 Initial Cold Starting NOTE Do not operate the throttle lever with the choke lever on Move the choke lever to position 2 a...

Page 52: ...ing some models only Insert key in ignition switch Turn key clockwise until starter engages Release key immediately when engine has started NOTE If for some reason the snowmobile cannot be started ele...

Page 53: ...tool kit NOTE The spark plug socket can be used as an emergency handle Wind the rope tightly around drive pulley When pulled pulley must rotate counterclockwise Tie a knot on rivet head side of clip H...

Page 54: ...52 BOMBARDIER LITE DRIVE PULLEY TYPE 1 Knot on this side A03D25A 1...

Page 55: ...PE 1 Clip Start engine as per usual manual starting WARNING When starting the snowmobile in an emergency situation using drive pulley do not reinstall the belt guard and return slowly to have snowmobi...

Page 56: ...end upon suspension adjust ments Choice of suspension adjustments vary with carrying load driver s weight personal preference riding speed and field condition NOTE Some adjustments may not apply to yo...

Page 57: ...ustment and retest Proceed methodically until you get satisfied Slight suspension bottoming occurring under the worst riding condi tions indicates a good choice of spring preload 1 Rear Springs Comfor...

Page 58: ...Increase spring preload CAUTION Always turn the left side adjustment cams in a clockwise di rection the right side cams in a counterclockwise direction Left and right adjustment cams must always be s...

Page 59: ...SIDE SHOWN CAUTION Always turn the left side adjustment cams in a clockwise di rection the right side cams in a counterclockwise direction Left and right adjustment cams must always be set at the sam...

Page 60: ...pring Steering Behavior Ride at moderate speed on a trail with bumpy conditions Note if steering is easy to turn Adjust center spring accordingly GOOD ADJUSTMENT AT MODERATE SPEED 1 Steering easy to t...

Page 61: ...59 TOO SOFT OF ADJUSTMENT 1 Steering hard to turn 1 Adjuster wrench A03F20A 1 A03F21A 1...

Page 62: ...60 TOO HARD OF ADJUSTMENT 1 Steering less aggressive 1 Adjuster wrench A03F20A 1 A03F21B 1...

Page 63: ...rap length accordingly At rest stopper strap should have a free play of 12 mm 1 2 in GOOD ADJUSTMENT AT FULL ACCELERATION 1 Comfortable steering 2 Good weight transfer to the track 3 Light pressure of...

Page 64: ...62 TOO LONG STRAP 1 Skis lift off the ground Some Models 1 Loosen lock nut A03F23A 1 A03F22A 1...

Page 65: ...63 TOO SHORT STRAP 1 Heavy steering Some Models 1 Loosen lock nut A03F20A 1 A03F22B 1...

Page 66: ...Vary strap length by bolting to a different hole 4 ACM Handling Ride at moderate speed and check for desired handling If handling is not satisfactory turn the nut clockwise Factory setting is fully t...

Page 67: ...be adjusted according to the driving need and the circumstances WARNING Nut must be in good condition to avoid unexpected loosen ing On the threaded rod there must be at least 2 threads ex posed beyon...

Page 68: ...ghten lock nut Adjust the same on both sides Shackle Movement Limiter For deep snow riding do not install horse shoe washer nor rubber stoppers For trail riding with passenger and or weight install 1...

Page 69: ...Handling Ride at moderate speed and check for proper handling Adjust front springs accordingly GOOD ADJUSTMENT 1 Good handling and comfortable steering CAUTION Always adjust both front springs to same...

Page 70: ...68 TOO SOFT OF ADJUSTMENT 1 Bad handling INCREASE SPRING PRELOAD A03F20A 1 A06G0AB...

Page 71: ...69 TOO HARD OF ADJUSTMENT 1 Steering hard to turn DECREASE SPRING PRELOAD A03F20A 1 A06G0AC...

Page 72: ...70 6 Ski Stopper Stability When riding check for darting GOOD ADJUSTMENT 1 No darting 1 A06A07A...

Page 73: ...71 NOT ENOUGH PRELOAD 1 Darting 1 Slacken then adjust against stop bounding 14 N m 124 lbf in 1 A06A08A A16G0AA 1...

Page 74: ...ce front suspension spring preload Increase center spring preload Reduce rear spring preload Snowmobile is unstable and seems to pivot around its center Reduce rear suspension front arm pressure Reduc...

Page 75: ...CHART Starting Rope Condition Engine Head Nuts Engine Mount Nuts Exhaust System Engine Lubrification Cooling System Condition Coolant Replacement Condition of Seals Injection Oil Filter Condition Inj...

Page 76: ...Bolts Retorque to 26 N m 19 lbf ft Steering and Front Suspension Mechanism Wear and Condition of Skis and Runners Steering and Ski Leg Camber Adjustment Suspension Adjustments AS REQUIRED Suspension L...

Page 77: ...75 FLUID LEVELS Brake System Check brake fluid DOT 4 in reservoir for proper level Add fluid DOT 4 as required TYPICAL 1 Min CAUTION Use only DOT 4 brake fluid from a sealed container A03D22A 1...

Page 78: ...e All Models Except Tundra and Skandic WT SWT With snowmobile on a level surface check the oil level by removing dipstick Oil level must be between lower and upper marks Refill up to upper mark using...

Page 79: ...77 TYPICAL 1 Dipstick 2 Oil level 3 Level between marks 1 1 2 3 A06D1OA...

Page 80: ...lug from top of transmission Refill as required using Bombardier synthetic chaincase oil P N 413 8028 00 250 mL TYPICAL SKANDIC WT 1 Filter plug 2 Lever mark CAUTION Do not use unrecommended other typ...

Page 81: ...sufficient amount of BOMBARDIER Snowmobile Injection Oil in the injection oil reservoir CAUTION Never allow oil level to drop more than 2 3 CAUTION Check level and refill every time you refuel Do not...

Page 82: ...80 Tundra II LT Formula S SL MX Z 440F Touring and Skandic Series TYPICAL 1 Injection oil reservoir 2 Maximum level 13 mm 1 2 in from top 1 2 A05C0CA...

Page 83: ...81 Skandic WT SWT TYPICAL 1 Injection oil reservoir 2 Maximum level 13 mm 1 2 in from top 1 2 A22C08A...

Page 84: ...XE 583 Z Grand Touring MX Z and Summit Series 1 Maximum level 13 mm 1 2 in from top 2 Injection oil reservoir Formula III and Mach 1 Z 1 Maximum level 13 mm 1 2 in from top 2 Injection oil tank ROTAX...

Page 85: ...mark engine cold of coolant tank NOTE When checking level at low temperature it may be slight lower then mark If additional coolant is necessary or if entire system has to be refilled refer to an aut...

Page 86: ...84 FORMULA III AND MACH 1 Z 1 Coolant tank 2 COLD LEVEL line Battery Electrolyte Some Models See your dealer 1 2 A06C0AA...

Page 87: ...Belt Guard Removal and Installation Tundra II LT Open hood console removal may be required on some models Re move belt guard retaining pin s and lift off the guard TYPICAL 1 Belt guard 2 Retaining pi...

Page 88: ...pin then firmly lift belt guard Proceed one end at a time TOURING FORMULA S SL 500 500 DELUXE 583 Z SKANDIC GT 500 583 MX Z AND SUMMIT SERIES 1 Tool kit 2 Pin retainer When reinstalling belt guard po...

Page 89: ...at reinstallation See label on belt guard All Models NOTE Belt guards are purposely made slightly oversize to maintain tension on their pins and retainers preventing undue noise and vibration It is i...

Page 90: ...models may also require the disconnection of driven pulley support TUNDRA II LT 1 Raise NOTE Removal and installation of drive belt is easier when driven pulley is held with brake so that it can not r...

Page 91: ...ded in tool box Screw tool in the threaded hole and tighten to open the pulley Remove belt SOME MODELS 1 Tighten to open pulley On models not equipped with above driven pulley open the driven pulley b...

Page 92: ...ximum drive belt life span is obtained when the belt has the proper rotation direction Install it so the Bombardier name on the belt can be read when facing pulleys 1 Bombardier name A04D0EA BOMBARDIE...

Page 93: ...adjustment screw by hand then back off only far enough for hair pin to engage in locking hole 1 Hair pin 2 Adjustment screw TRA Drive Pulley Adjustment The drive pulley is factory calibrated to trans...

Page 94: ...e maximum horsepower RPM NOTE Use precision digital tachometer for engine RPM ad justment NOTE The adjustment has an effect on high RPM only To adjust modify ramp end position by turning calibration s...

Page 95: ...changed to position 6 So maximum engine RPM is increased of 400 RPM To adjust Just loosen locking nut enough to pull calibration screw partially out and adjust to desired position Do not completely r...

Page 96: ...elt or distorted spare belt Contact an authorized deal er Check the drive belt width Replace the drive belt if width is less than The minimum width recommended in SPECIFICATIONS sec tion WARNING Alway...

Page 97: ...inspect all suspension components including slider shoes springs wheels etc NOTE During normal driving snow will act as a lubricant and coolant for the slider shoes Extensive riding on ice or sanded...

Page 98: ...the suspension to extend normally and check gap half way along slider shoe The gap should be as given in the specification section of this guide If the track tension is too loose track will have a ten...

Page 99: ...Loosen screw Alignment NOTE Track tension and alignment are inter related Do not adjust one without the other CAUTION Too much tension will result in power loss and excessive stresses on suspension co...

Page 100: ...s between edges of track guides and slider shoes 1 Guides 2 Slider shoes 3 Equal distance To correct stop the engine Loosen the lock nuts some models only and tighten the adjustment screw on side wher...

Page 101: ...ight ness of components steering arms control arms and links tie rods ball joints ski coupler bolts etc If necessary contact your dealer WARNING If lock nuts or retaining screws are not tightened prop...

Page 102: ...ystem is designed to reduce noise and to improve the total performance of the engine If any exhaust system component is removed from the engine severe engine damage will result Air Filter Cleaning Tun...

Page 103: ...WT SWT Formula III and Mach 1 Z Leaving the snowmobile uncovered during a snowfall or riding in deep powder snow may block air filter and choke the engine While riding in deep powder snow periodically...

Page 104: ...102 FILTER INSTALLED REMOVING FILTER A03H1JA A03H1KA...

Page 105: ...103 SHAKING SNOW FROM FILTER Remove snow from filter on air intake silencer A03H1LA A03H1MA...

Page 106: ...104 Formula III and Mach 1 Z FILTER INSTALLED TYPICAL 1 Air intake silencer 2 Filters A06H2NA A06C04A 2 1...

Page 107: ...f headlamp is burnt tilt hood Unplug connector from headlamp Re move protector cap and unfasten bulb retainer clips Detach bulb and replace CAUTION Snowmobile engines have been calibrated with the fil...

Page 108: ...Models If the headlight bulb is burnt tilt hood unplug the connector from the headlight Remove the rubber boot and unfasten bulb retainer ring Detach the bulb and replace Properly reinstall parts TYP...

Page 109: ...te bulb counterclockwise 1 Instruments sockets Taillight If taillight bulb is burnt expose the bulb by removing the red plastic lens To remove unscrew the 2 lens screws STORAGE It is during summer or...

Page 110: ...dealer 4 No fuel to the engine spark plug dry when removed Check fuel tank level turn fuel valve on if applicable check fuel filter replace if clogged check condition of fuel and impulse lines and th...

Page 111: ...en pulleys require servicing Contact an authorized dealer 6 Engine is overheating On liquid cooled engines check coolant level pressure cap thermostat and for air locks in cooling system On fan cooled...

Page 112: ...uel tank and refill with appropriate mixture ratio 3 Water in fuel Drain fuel system and refill with fresh fuel SYMPTOM Snowmobile cannot reach full speed Possible cause What to do 1 Drive belt Check...

Page 113: ...New belt width mm in 36 5 1 7 16 34 3 1 23 64 Wearlimitwidth mm in 30 0 1 3 16 32 0 1 1 4 Spark plug Type NGK BR 9 ES NGK BR 9 ES Gap mm in 0 45 018 0 45 018 Track Tension mm in 35 45 1 3 8 1 3 4 40 5...

Page 114: ...belt width mm in 34 9 1 3 8 Wearlimitwidth mm in 30 1 3 16 Spark plug Type NGK BR 8 ES Gap mm in 0 45 018 Track Tension mm in 50 1 31 32 Alignment FLUIDS Fuel Type Tank capacity L US gal 40 10 6 Oil...

Page 115: ...h mm in 32 0 1 1 4 32 0 1 1 4 Spark plug Type NGK BR 9 ES NGK BR 9 ES Gap mm in 0 45 018 0 45 018 Track Tension mm in 45 50 1 3 4 2 45 50 1 3 4 2 Alignment FLUIDS Fuel Type Tank capacity L US gal 40 1...

Page 116: ...dth mm in 32 5 1 9 32 32 5 1 9 32 Spark plug Type NGK BR 9 ES NGK BR 9 ES Gap mm in 0 45 018 0 45 018 Track Tension mm in 45 50 1 3 4 2 45 50 1 3 4 2 Alignment FLUIDS Fuel Type Tank capacity L US gal...

Page 117: ...h mm in 32 5 1 9 32 32 5 1 9 32 Spark plug Type NGK BR 9 ES NGK BR 10 ES Gap mm in 0 45 018 0 45 018 Track Tension mm in 45 50 1 3 4 2 45 50 1 3 4 2 Alignment FLUIDS Fuel Type Tank capacity L US gal 4...

Page 118: ...2 32 5 1 9 32 Spark plug Type NGK BR 10 ES NGK BR 10 ES Gap mm in 0 45 018 0 45 018 Track Tension mm in 45 50 1 3 4 2 45 50 1 3 4 2 Alignment FLUIDS Fuel Type Tank capacity L US gal 42 1 11 1 42 1 11...

Page 119: ...N 413 8028 00 Ethylene glycol antifreeze for aluminum engines mixed with water 3 parts of antifreeze for 2 parts of water Super unleaded gasoline with a minimum octane number of 91 R M 2 N A Not appli...

Page 120: ...CE TO ALL NEW OWNERS Make sure to receive the warranty registration card from the previ ous owner when the ownership is transferred as you are entitled to the unexpired portion of the warranty STOLEN...

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Page 125: ...CHANGE OF ADDRESS CHANGE OF OWNERSHIP VEHICLE IDENTIFICATION NUMBER OLD ADDRESS OR PREVIOUS OWNER _____________________________________________________________________________ NAME...

Page 126: ...STAMP BOMBARDIER INC...