BOMBARDIER 1980 User manual

SAFETY NOTICE

The Bombardier snowmobile Shop manual supplement

has

been prepared

order

as-

sist skill

mechanic's in the efficient repair and maintenance

Bombardier snowmo-

biles.

Safe

features may

impaired

other than genuine Bombardier parts are installed.

Torque wrench tightening specifications must

strictly adhered by. Locking devices

must be installed or replaced by new ones, where specified. If the efficiency

a locking

device is impaired,

must

renewed.

Never run engine in a

close~

area. Exhaust fumes contain poisonous'carbon monoxide.

Always wear protective clothing

elmet, goggl

es,

boots etc...) when riding vehicle,

even for brief periods. '

This manual emphasizes particular information denoted by the wording and symbols;

•

RNING:

Identifies and instruction which,

followed, could cause personal

Injury. .

_ CAUTION: Denotes

instruction which,

not

followed, could,severely damage

vehic

components. .

oNOTE: Indicates supplementary information need

fully complete

instruction.

Although the mere reading

such information does

not

eliminate the hazard, your un-

derstanding

the information will promote its correct

@ *Trademarks

Bombardier Limitee

(1981

SUPPLEMENT)

ONOTE: This supplement manual relates to

new

features and information applicable to

1981

models

and therefore

not

covered

the

1980

Bombardier

Snowmobile Shop Manual. Information

that

applies to

both

1980

and

1981

models

contained

the

1980

Bombardier Shop Manual and not repeated

the

1981

Supplement. It

necessary that both the

1981

Shop

Manual Supplement and the

1980

Bombardier Snow-

mobile Shop Manual

used for complete reference on

servicing the

1981

models.

ARRANGEME

OF THE

MANUAL

The manual

divided into 9 major sections:

Tools

02 Technical Data

Engine

04 Electrical

05 Transmission

06 Suspension

07 Steering and skis

08 Frame and hood

Warranty

Each

section

composed

various sub-sections, and

yet again, although

not

dicated in 'the table

con-

tent, each sub-section has one or more divisions.

(1981

SUPP

LEM

ENT

)

INTRODUCTION

ILLUSTRATIONS

& PROCEDURES

An exploded view

conveniently located at the beginn-

ing

each section and

meant to assist the user

identifying parts and components.

The illustrations

show

the typical construction

the

different assemblies and, in

all

cases, may

not

repro-

duce the full detail or exact shape

the parts shown,

however, they represent parts which have the same or a

similar function.

When something special applies (such

adjustment,...

etc.), the specific parts are circled and referred to

the

text.

As many

the procedures

this manual are interre-

lated, we suggest, that before undertaking any task,

you

read

and thoroughly understand the entire section

or sub-section

which the procedure

contained.

A number

procedures

throughout

the book require

the use

special tools. Where a special tool

indi-

cated, refer to section

. Before beginning any proce-

dure,

sure

that

you have on hand all the tools

re-

quired, or approved equivalents.

The use

"Right"

and

"Left"

indications

the text,

always refers to driving position (when sitting on vehi-

cle) .

LEFT

RIGHT

(INTRODUCTION), PAGE 1

MODEL IDENTIFICATION

This shop manual covers the following Bombardier

made

1981

snowmobiles:

Elan

-Spirit

Citation 3500 -Mirage I

Citation 4500/E -

Mir

age IIIE

Nordik

Citation SS -Mirage Special

Everest 500/500E -Futura 500/500E

Eve

t LIC -Futura

LlC

Blizzard 5500 -Grand Prix Special

Blizzard

- Grand Prix

Blizzard 7500 -Super Sonic

Blizzard 9500 -Ultra Sonic

Alpine 640

Elite

Furthermore, each vehicle has its particular vehicle seri-

number.

(INTRODUCTION

PAGE 2

The engine also has a serial number.

ENGINE

SERIAL

NUMBER

Liquid cooled engin

ENGINE

SERIAL

NUMBER

Fan

cooled engines

GENERAL

The information, illustrations and

component/system

descriptions contained

this manual are correct at time

publication. Bombardier Limitee, however, maintains

a policy

continuous improvement

its products

without

imposing upon itself any obligation to install

them on products previously manufactured.

Bombardier Limitee reserves the right at any time to dis-

continue or change specifications, designs, features,

mode

equipment

without

incurring obligation.

This manual

published by the

Technical Publications

Bombardier Limitee

Valcourt. Quebec, Canada

(1981

SUPPLEMENT)

1981

SHOP

MANUAL

SUPPLEMENT

SECTION

TABLE OF CONTENTS

SUB-SECTION

TOOLS

02 TECH

CAL D

ATA

ENGINE

-Engine tolerance measurements

-Engines

-Ignition timing

-Carburetor and fuel pump

-Air intake silencer, fuel tank, throttle cable

06 -Rewind starter

ELECTRICAL

-Electric charts

-Tests procedure

03 -

ectric starter

-Battery

-Alternator and regulator

-Spark plugs

TRANSM

ISSION

-Pulley guard

-Drive belt

-Drive pulley

04 -Driven pulley

-Pulley alignment

-Brake

-Chaincase

-Gearbox and shifter mechanism

09 -Drive chain

SUSPENSION

-Bogie wheel

-Slide suspension, MX suspension

03 -

Rear

axle

04 -Drive axle

05 -Track

STEERING / SKI

-Steering system

02 -Ski system

HOOD

AND

FRAME

-Hood

-Frame

WARRA

NTY

For the following

1981

models:

Elan

-Spirit

Citation 3500 -Mirage I

Citation

4500

/ E-Mirage II/E

Citation SS -Mirage Special

Everest 500/E -Futura 500/E

Everest

-Futura

Blizzard

-Grand Prix

zza

rd 5500 -Grand Prix Special

zza

7500 -Super Sonic

Blizzard 9500 -Ultra Sonic

Elite

Alpine 640

Nordik

SECTION

(TOOLS)

TOOLS

refer

the 1980 Bombardier Snowmobiles Shop

Manual-

section 01 (Tools)

For the following 1981 models:

Everest

-Futura

Blizzard 7500 -Super Sonic

zzard 9500 -Ultra Sonic

Elite

refer

this

section for

MAGNETO

PULLER

For crankshaft fixation bolt, refer

this

section.

For suspension Uadjuster wrench"

Blizzard

and

Grand Prix

MX,

refer

this

section.

(1981

SUPPLEMENT) (TOOLS), PAGE 1

SECTION

(TOOLS)

------------------

----------------------------------------

-The NIPPONDENSO magneto on models:

Everest

-Futura

Blizzard 7500 -Super Sonic

Blizzard 9500 -Ultra Sonic

Elite

may

extracted using the following tool

with

four

(4)

Allen screw M6 x

(PIN

420840860).

Puller ring

IN 420 876

6551

-The crankshaft

models:

Citation 3500 -Mirage I

Citation

4500

/ E-Mirage II/E

Citati

SS -Mirage Special

Everest 500/E -Futura 500/E

Everest

-Futura

Blizzard

-Grand P

rix

Blizzard 5500 -Gra

Special

zza

7500 -Super Sonic

zzard 9500 -Ultra Sonic

Elite

Nordik

(TOo.LS), PAGE 2

may

locked using the following tool:

Crankshaft locking tool

(PIN 4208766401

-The front and r

r spring suspension on models:

Blizzard

-Grand Prix

may

adjusted using the following tool:

Adjuster wrench

(PIN 5290038001

981 SUPPLEMENTI

SECTION

TECHNICAL

DATA

LIST (PAGE)

TOLERANCE

AND

WEAR LIMIT -ENGINES 2

IGNITION TIMING SPECIFICATIONS 3

CARBURETOR SPECIFICATIONS 4-5

IGNITION GENERATING COIL, LIGHTING COIL, HIGH TENSION 6

COIL, RESISTANCE CHART

BOMBARDIER IGNITION TESTER

DIAL

POSITIONS 7

BOSCH SPARK PLUG CHART 8

VEHICLE

MODEL/DR

IVE BELT NUMBER 9

DRIVE PULLEY SPECIFICATIONS

DRIVEN PULLEY SPRING TENSION

PULLEY

ALIGNMENT

SPECIFICATIONS

SPROCKET

AND

CHAIN SPECIFICATIONS

TRACK TENSION SPECIFICATIONS (BOGIE WHEEL

SUSPENSION)

TRACK TENSION SPECIFICATIONS (SLIDE SUSPENSION)

TRACK SPECIFICATIONS

STEERING SYSTEM TORQUE SPECIFICATIONS

SKI SYSTEM TORQUE SPECIFICATIONS

GENERAL INFORMATION

METRIC INFORMATION CHART

(1981

SUPPLEMENT) (TECHNICAL

DATA

LIST). PAGE 1

SECTION 02

SUB-SECTION 03-01, (ENGINE TOLERANCE MEASUREME

TOLERANCE

AND

WEAR

LIMIT

1981

ENGINES

ENGINE CYLINDER BORE PISTON TO

WALL

MAXIMUM

RING

CRANKSHAFT

TYPE (NOMINAL) CLEARANCE END CAP END PLAY

STD OVERSIZE

MIN.

MAX.

MIN

MAX

247

69.50

N.A

. 0.065-0.200

-1.0

0.20-0.40

(27362")

( 0026-.008") (008-.039") (008-.016")

277

72.00

0.070-0.200

0-1.0

0.20-0.40

(2.8346")

(28445")

(.003-.008" ) (008-.039") (008-.016")

354

59.75

0.080-0.180

0.15-1.0

N.A.

(2.3425") (2.3524") (0031-.001" )

(006

-0.039")

377

62.00

0.070-0.200

0.20-1.0

N.A.

(2.4409") (2.4508") (0028-.008") (008-0.039")

454

67.50

67.75

10-0

0.20-1.0

N.A.

(2.6575") (2.6673") (004-.008")

(008-

.039")

464

69.50

0.070-0.200

0.20-1.0

N.A.

(2.7362") (2.7461") (.0028-.008" ) (008-.039")

503

72.00

72.25

0.060-0.200

0.20-1.0

N.A.

(2.8346") (2.8445") (0024-.008") (.008-.039")

640

76.50

0.070-0.220

0.25-0.40

0.20-0.40

9921

(3.0118") (0028-.009")

(010

-0.16")

(008

-.016")

A.:

not

applicable

(TECHNICAL

DATA

LIST), PAGE2 (19

LEMENT)

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