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Manual Details
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Coverage Areas
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Models Covered Service Manual:
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Tundra R, Touring E/LE/SLE/500 LC, Formula S/500 LC, Formula Deluxe 380/500/500 LC, Skandic 380/500, Skandic WT/SWT/WT LC, MX Z 440, Grand Touring 700/SE/SE Millennium Edition, Formula III 700 R/800, Mach 1 R/Z/Z R, Mach Z R Millennium Edition, Grand Touring 600, Formula Z 600/700, Formula Deluxe 600/700, MX Z 500/600/700/700 Millennium Edition, Summit 600/700/700 H.M./700 Millennium Edition, Mini Z
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Models Covered Parts Catalog:
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Formula Deluxe 380, Formula Deluxe 500, Formula Deluxe 500 LC, Formula Deluxe 600, Formula Deluxe 700, Formula S, Formula 500 LC, Formula Z 600, Formula Z 700, Formula III 700 R, Formula III 800, Grand Touring 600, Grand Touring 700, Grand Touring 700 SE, Grand Touring 700 SE Ed. Millen., Mach 1 R, Mach Z, Mach Z R, Mach Z R Millennium, Mini Z, MX Z 440, MX Z 500, MX Z 500 SB Black, MX Z 600, MX Z 600 SB, MX Z 600 SB Black, MX Z 700, MX Z 700 SB, MX Z 700 SB Black, MX Z 700 SB Millennium, MX Z 800, MX Z X 440 LC, Skandic 380, Skandic 500, Skandic Wide Track, Skandic Super Wide Track, Skandic Wide Track LC, Summit 600, Summit 600 SB, Summit 700, Summit 700 H.M., Summit 700 SB Millennium, Summit 800 H.M., Touring E, Touring LE, Touring SLE, Touring 500 LC, Tundra R
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Page Count
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Page Count:
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489
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Manual Type
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Manual Type:
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Comprehensive Service & Repair Workshop Manual with Integrated Parts Catalog
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Manual Features Enhancements:
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Includes 'notes, cautions and warnings throughout each chapter pinpointing critical service information', 'numbered instructions guide you through every repair procedure in a step-by-step fashion', and 'bold figured numbers help you quickly match illustrations with instructions'.
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Language
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Language:
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English
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Format
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File Format:
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PDF (Downloadable)
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File Format Description:
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PDF format allows for easy saving, printing, and digital access on various devices.
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Manual Coverage
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Systems Covered
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Engine Systems:
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Engine overhaul, top-end (cylinder, piston, rings), bottom-end (crankshaft, connecting rods, bearings), lubrication system, cooling system (liquid-cooled models), fuel system (carburetion, fuel pump, lines), ignition system, exhaust system, starting system, engine diagnostics, performance tuning.
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Drivetrain Systems:
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Clutch (primary and secondary), drive chain/belt, differential, driveshaft, track system (installation, adjustment, maintenance), suspension components (front and rear arm, shocks, springs).
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Electrical Systems:
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Ignition system troubleshooting, lighting (headlights, taillights, running lights), electrical connectors, battery maintenance, starter system, stator, rectifier/regulator, wiring diagrams for various models and options, instrument cluster operation.
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Chassis Bodywork:
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Frame inspection and repair, body panel removal and installation, seat assembly, windshield, handlebars, controls (throttle, brake), running boards, bumper systems, storage compartments.
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Braking System:
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Service and repair of hydraulic disc brake systems, including caliper maintenance, pad replacement, brake line bleeding, master cylinder inspection, and lever adjustment.
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Suspension System:
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Front and rear suspension component service, including shock absorber inspection, spring adjustment, bushing replacement, ball joint service, and ski alignment.
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Steering System:
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Service and adjustment of the steering mechanism, including handlebars, steering post, tie rods, and skis.
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Exhaust System:
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Maintenance and potential repair of the exhaust system, including muffler inspection and exhaust pipe sealing.
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Procedures Included
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Maintenance Procedures:
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Scheduled maintenance (e.g., spark plug replacement, air filter cleaning/replacement, track tension adjustment, lubrication points), pre-ride inspections, post-ride storage recommendations, clutch inspection and cleaning.
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Repair Procedures:
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Step-by-step instructions for engine component rebuilds, transmission service, suspension adjustments, electrical component replacement, brake system service, clutch alignment and adjustment, carburetor tuning, track and slider maintenance.
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Troubleshooting Guides:
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Systematic diagnostic procedures for common and uncommon issues, including engine performance problems, electrical faults, starting difficulties, and drivetrain malfunctions, often with flowcharts and symptom-based solutions.
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Wiring Diagrams:
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Detailed wiring diagrams for each applicable model are a critical component, enabling technicians to trace electrical circuits, diagnose faults, and perform repairs on lighting, ignition, and accessory systems.
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Clutch Calibration:
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Extensive coverage on clutch calibration, including selecting appropriate weights, springs, and helix angles to match engine characteristics and intended use (trail, mountain, racing).
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Engine Disassembly Reassembly:
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Detailed, illustrated guides for the complete disassembly and reassembly of all major engine components.
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Suspension Alignment:
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Guidance on checking and adjusting ski alignment and caster/camber angles for optimal handling and reduced steering effort.
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Technical Depth
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Technical Depth:
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Comprehensive, covering from routine maintenance and adjustments to complete engine overhauls, transmission rebuilds, and in-depth electrical system diagnostics. Suitable for both amateur mechanics and professional technicians.
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Engine Rebuild Depth:
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Includes specifications for piston ring gap, cylinder bore and hone, crankshaft runout, bearing clearances, and torque values for critical engine fasteners, enabling complete engine rebuilds.
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Diagnostic Capabilities:
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Includes diagnostic trees and troubleshooting guides for various engine and electrical issues, aiding in the identification and resolution of performance problems.
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Component Specifications:
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Provides critical torque specifications, tolerances, clearances, and performance parameters for a wide array of snowmobile components.
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Engine Specifications
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Primary Engine Variants
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Engine Options Overview:
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This manual covers a broad spectrum of Rotax engine configurations popular in the late 90s/early 2000s. This includes 2-stroke engines typically in the 380cc, 440cc, 500cc, 600cc, 700cc, and 800cc displacement classes, with various cylinder configurations (single, twin, triple).
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Performance Considerations
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Engine Performance Tuning:
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Details on carburetor jetting, ignition timing, and exhaust system tuning specific to different engine variants and operating conditions are likely included for optimizing performance. Specifications for horsepower and torque would be model-specific and detailed within the manual.
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Fuel System
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Fuel System Components:
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Covers Mikuni and Keihin carburetors, fuel pumps (mechanical and electric), fuel lines, filters, and associated components. Includes procedures for cleaning, rebuilding, and synchronizing carburetors, as well as fuel pressure testing.
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Engine Type
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Engine Configuration:
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Predominantly 2-stroke, liquid-cooled and fan-cooled Rotax engines. Specific configurations (single, twin, triple cylinder) vary by model and displacement.
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Lubrication System
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Oil Injection System:
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Details on the operation, maintenance, and potential issues of the automatic oil injection system, including oil pump calibration and lubrication lines.
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Performance
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Horsepower Torque Context:
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The manual will contain specific horsepower and torque figures for each engine variant, essential for diagnosing performance issues and understanding engine capabilities.
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Primary Engine
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Engine Displacement Range:
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Covers displacements from approximately 380cc up to 800cc, encompassing a broad range of consumer and performance-oriented models.
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Maintenance
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Service Intervals
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Typical Maintenance Schedule:
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The manual will detail specific intervals for tasks such as: checking/replacing spark plugs (e.g., every 1000-2000 miles or annually), cleaning/inspecting air filters (e.g., every 500 miles or as needed), checking track tension (e.g., every 500 miles), lubricating suspension components (e.g., annually), and clutch inspection/cleaning (e.g., every 1000-2000 miles or annually).
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Drive Belt Inspection Replacement:
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Specific mileage or time intervals for inspecting the drive belt for wear, cracks, and proper tension, as well as guidelines for replacement.
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Fluid Specifications
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Engine Oil Recommendations:
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For 2-stroke engines, the manual will specify the required type and mixture ratio of 2-stroke oil to be used with gasoline, likely recommending BRP's proprietary or equivalent API-TC certified oils. It will also detail oil for the oil injection system if equipped.
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Coolant Specifications Lc Models:
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For liquid-cooled models, the manual will specify the type of antifreeze/coolant (typically a 50/50 mix of ethylene glycol and distilled water) and its capacity, along with recommendations for flushing and refilling the cooling system.
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Brake Fluid Type:
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While not explicitly stated, hydraulic brake systems would typically require DOT 3 or DOT 4 brake fluid, depending on the specific caliper and master cylinder design. The manual would specify the correct type.
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Chaincase Oil Type:
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For models with a chaincase, the manual will specify the correct type and viscosity of gear oil or lubricant required for proper operation and longevity.
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Known Issues
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Common Maintenance Concerns:
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While specific 'known issues' aren't listed here, a comprehensive manual would typically address common wear items and potential problems for this era, such as clutch wear, suspension bushing deterioration, carburetor performance issues in varying temperatures, and track lug wear.
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Carburetor Tuning Considerations:
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Addresses potential carburetor icing in cold weather and provides guidance on jetting and needle adjustments for optimal performance at different altitudes and temperatures.
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