model V.I.N. purchase date warranty expiry date _ To be completed by dealer at time of sale DEALER IMPRINT AREA The following are trademarks of Bam bardier l.imitee.
INDEX 2 THE 1981 uLIMITED WARRANTY" . . . . . . . . . .. .. .. . FOREWORD.. . SAFETY IN MAINTENANCE 4 , .. . .. .5 CONTROLSIINSTRUMENTS Throttle lever, brake lever, ignition/light switch, headlamp dimmer switch, emergency cut-out switch, manual starter handle, primer, gear shift lever, access door latch, tether cut-out switch, hood removal, seat compartment, fuel gauge, fuse holder. . . . . . . . . . . . . . . . .. .. . . .. .,. .6 BREAK-IN PERIOD Break-in, inspection, inspection checklist . .
LIMITED WARRANTY 1981 SKI·DOO® SNOWMOBILES 1 · PERIOD BOMBARDIER l.irnitee as manufacturer, warrants FROM THE DATE OF FIRST CONSUMER SALES, every 1981 Ski-Doo® snowmobile, sold as NEW AND UNUSED, by an authorized Ski-Doo dealer, for periods of: • 12 months for ELAN® , CITATION*, EVEREST®, ELlTE®, ALPINE@ models. • 90 consecutive days for BLiZZARD® 5500, 7500, 9500 models subject to the following: 1.
• Damage caused by failure to provide proper maintenance as detailed in the Operator Manual. The labour, parts and lubricants costs of all maintenance services, including tune-ups and adjustments will be charged to the owner. • Vehicles used for racing purposes. • All optional accessories installed on the vehicle. (The normal warranty policy for parts and accessories, if any, applies). • Damage resulting from accident, fire or other casualty, misuse, abuse or neglect.
FOREWORD The operator manual and the Snowmobile Safety handbook have been prepared to acquaint the owner / operator of a new snowmobile with the various vehicle controls, maintenance and safe operating instructions. Each is indispensable for the proper use of the product, and should be kept with the vehicle at all times. Should you have any questions pertaining to the warranty and its application, please consu It the Often Asked Question" section of this manual, or your selling dealer.
SAFETY IN MAINTENANCE Observe the following precautions: • Throttle mechanism should be checked for free movement before starting • should be running only is secured in place. without drive belt • Never run installed. Running an unloaded encan prove to be dangerous. • Never run the engine when tracks are raised off the ".", the In,,, • It can be dangerous to run engine with the hood removed. • Gasoline is flammable and explosive under certain conditions. Always manipulate in a well ventilated area.
CONTROLS / INSTRUMENTS AJ BJ CJ OJ E) Throttle Control Lever Brake Control Lever Ignition / Light Switch Headlamp Dimmer Swir.ih Emergencv Cut-Out Switch A) Throttle Control Lever Located on right side of handlebar. When depressed, it controls the engine speed and the engagement of the transmission. When released, engine speed returns automatically to idle.
The driver of this vehicle should familiarized himself with the function of this device by using it several times on first outing. Thereby being mentally prepared for emergency situations requiring its use. A WARNING: If the switch has been .... used in an emergency situation the source of malfunction should be determined and corrected before restarting engine. F) Manual Starter Handle Auto rewind type located on side of vehicle. To engage pull handle. hand G) Primer A push-pull button.
BREAK-IN PERIOD Fuse Holcer Located in the engine compartment (front of R.H. side). With Bombardier-Rotax snowmobile engines, a bread-in period is required before running the vehicle at full throttle. manufacturer recommendation 10 to 15 operating hours. During this period, a richer mixture is needed (i.e. 40 parts of gas for 1 part of 50/1 Bombardier oil). Maximum throttle should not exceed 314, however, brief full acceleration and speed variations contribute to a good break-in.
10-HOUR INSPECTION CHECKLIST J Engine timing Fan belt tension Spark plugs condition Carburetor adjustment Engine head nuts Engine mount nuts Muffler attachment Gearbox oil level Chain tension Battery electrolyte level Brake operation and lining condition Ski alignment (runner condition) Pulley alignment and drive belt condition Track condition, tension and alignment Lubricate (steering, suspension, driven pulley) Electrical wiring (loose connections, stripped wires, damaged insulation), tightened all loos
FUEL MIXING Oil must be added to the gasoline in pre-measured amounts then both oil and gasoline should be thoroughly mixed together before fueling the tank. Recommended Gasoline Use regular leaded gasoline available from all service stations. ... CAUTION: Never experiment with different fuel or fuel ratios. Never use naphtha, methanol or similar product. Y Recommended Oil Use concentrated Bombardier snowmobile oil available from your dealer.
PRE-START CHECK 3. container cap and shake the container thoroughly. Check Points • Activate the throttle control lever severa I times to check that it operates easily and smoothly. The throttle control lever must return to idle position when released. • Check fuel level. • Check that the ski and tracks are not frozen to the ground or snow surface and that the steering operates freely . 4. Add the remainder of the gasoline. 5. Once again thoroughly the container.
STARTING PROCEDURE 1. Insert key in ignition switch. Emergency Starting 2. Test throttle control lever. Should the rewind starter rope fray and break, the engine can be started with an emergency starter rope. 3. Activate primer (2 or 3 times). Primer is not necessary if engine is warm. 4. Ensure the tether cut-out cap is in position and that the cord is attached to your clothing. Check that the emergency cut-out switch is in the middle ON position.
DRIVING TIPS Bogie Wheel By raising the outer attachment of the bogie wheel sets! vehicle maneuverability in deep snow will increase. You will note that there are partially drilled holes located approx. 3.5 cm (1 0/8 ") above the original cross shaft holes of the frame. To reposition bogie wheel sets, drill holes fully through using a 5/16 dia. drill. Remove capscrews securing bogie wheel cross shafts to frame and reinstall bogie wheels in new position. /1 Front Hood Louvers Air Silencer Box . . .
LUBRICATION Frequency Routine maintenance is necessary for all mechanized products, and the snowmobile is no exception. A weekly vehicle inspection contributes to the life span of the snowmobile as well as safe and trouble-free operation. It is recommended that the steering system and suspension, be lubricated monthly or every 40 hours of operation. If the vehicle is operated in wet snow or in severe conditions these items should be lubricated more frequently. .....
Driven Pulley With hood removed, grease the driven pulley shaft as follows: Remove pulley guard and slip off drive belt. Open the driven pulley, (push and twist slidi ng half). check oil level. Oil level must reach 82 mm (314 It) on dipstick. Thoroughly clean the driven pulley shaft. Apply a light coat of low-temp grease on the shaft. Always lubricate lightly and wipe off surplus. NOTE: Activate the slidi ng half several times to distribute lubricant over full length of shaft.
MAINTENANCE .A. WARNING: Only perform such ~ procedures as detailed in this manual. It is recommended that dealer assistance be periodically obtained on other components / systems not covered in this manual. Unless otherwise specified, engine should be turned OFF for all lubrication and maintenance procedures The following Maintenance Chart indicates regular servicing schedules to be performed by you or your servicing dealer.
Spark Plugs Open access door. Disconnect spark plug wires and remove plugs. Check condition of plugs. • A brownish tip reflects ideal conditions. (Correct carburetor adjustment, spark plug heat range, etc.). • A black insulator tip indicates fouling caused by: carburetor idle speed mixture and / or high speed mixture too rich, incorrect fuel mixing ratio, wrong type of spark plug (heat range), or excessive idling.
Track Tension and Alignment Lift the rear of vehicle and support it off the ground. Using a ruler, check track tension, at the second set of To correct: Turn inner side adjuster boltts) counterclockwise to bring track closer to center link platetsl. turn clockwise to withdraw trackts) from link platets). The deflection of each track should be 57 mm (2;4 If) between top inside of track and center of bogie wheel set retaining bolt.
Carburetor Carburetor adjustments should be performed by your dealer. O NOTE: When installing a new . drive belt, a break-in period of 15-25 km (10-15 miles) is strongly recommended. Air Silencer Box . . , CAUTION: Never operate your ... snowmobile with the air silencer tube disconnected. Serious engine damage will occur if this notice is disregarded.
Drive Pulley Inspect the Duralon bushing condition by checking the free-play of the sliding half pulley. This is achieved by restraining the inner half and checking if the sliding half moves in the direction of the arrows more than 3 mm (1/B"). If so contact your dealer. Reposition handlebar on splines so that it is perpendicular with ski. Install and tighten bolt to 40-47 N.m (30-35 ft-Ibsl.
STORAGE General Inspection Check electrical wiring and components, retighten loose connections. ~heck. for stripped wires or damaged insulation. Thoroughly inspect the vehicle and tighten loose bolts nuts and linkage. Inspect ski and ski ~unner for wear. .... WARNING: Only perform such ...... procedures as detailed in this manual. It is recommended that dealer assistance be periodically obtained on other components / systems not covered in this manual.
Reassemble entire bogie wheel set, making sure assembly moves freely. Reinstall bogie wheel set. Repeat above steps on remaining bogie wheel sets. Lubricate rear hubs through grease fittings. Ski Assembly Wash or brush all dirt or rust accumulation from ski and spring. Grease ski leg at grease fitting. Check condition of ski and ski runner. Replace if worn or weak. Apply metal protector on ski assembly. If unavailable, wipe the entire ski with a doth soaked in oil to prevent rust formation.
Controls Lubricate steering mechanism. Inspect components for tightness, spring coupler bolt, steering arm locking bolt, ball joint, etc.I. Tighten if necessary. Oil moving joints of brake mechanism. .& WARNING: Do not lubricate . . . throttle and / or brake cable or housing. Avoid getting oil on brake linings. Coat electrical connections and switches with a greaseless metal protector. If unavailable, use petroleum jelly. . . . CAUTION: Plastic alloy cornpo. . nents such as fuel tank, windshield, etc.
PRE-SEASON PREPARATION To simplify the pre-season preparation we have drawn up a small chart. The chart indicates servicing points to be performed by you and your servicing dealer. If these services are performed as suggested, your vehicle will give you many hours of fun and low cost use.
~ TROU BLE SHOOTING o NOTE: The possible causes have been listed in an order of frequency. Therefore, items should be checked out in the same order as mentioned in the trouble shooting guide. SYMPTOMS POSSIBLE CAUSES WHAT TO DO Engine turns over but fails to start or starts with difficulty 1. No fuel to the engine Check the tank level and fill up with correct gas-oil mixture. Check for possible clogging of fuel line, item 5. 2.
SYMPTOMS POSSIBLE CAUSES WHAT TO DO Engine lacks acceleration or power 1. Fouled or defective spark plug Check item 3 of "Engine turns over but fails to start or starts with difficulty" 2. Clogged fuel line (water or Check fuel line condition. ISee item 4 of "Engine turns over but fails to start or starts with difficulty"\. dirt) Engine continually backfires Snowmobile cannot reach full speed 26 3. Carburetor Contact your dealer. 4.
TOOLS As standard equipment each new snowmobile is supplied with a basic tool kit such as screwdriver, wrenches, emergency starter rope, etc ... Standard Tools 0 G OH A. Screwdriver B. c. Socket 10 / 13 mm Open end wrench 10 / 13 mm D. Socket wrench handle c ~ E. F. G. H.
SPECIFICATIONS ALPINE 640 ER ENGINE No. of cylinders Bore Stroke Displacement Compression ratio (corrected) Carburetor type Carburetor adjustment - air screw main jet idle speed Engine head nuts (torque) Fan belt free-play 2 76 mm (2.992 in.) 70 mm in.) 635.1 (38.76 in. 3 ) 6:1 VM 34-215 1 1/2 turn + 1/8 280 1500-1800 R.P.M . 20 N.m (15 ft-Ibsl 6 mm 11/4 in.) CHASSIS Overall length Overall width Overall height Ski alignment Handlebar / steering column bolt torque Weight Bearing area Ground pressure 288.
1981 ALPINE 640 ER BK CD LIGHTING COIL (110 Wi ® GENERATOR COil cD LIGHTING COIL 130WI ® FUSE 115AMPS) o HEADLAMP 145·45WI ® TAILLAMP (521 WI VI OFF VI VI/WH LIGHT Vt/WH AD .. ON AD/ GY ROi GN WHjg2 3 GY GY i VI BK BR RD/WH RD! GY s AD/ GY P.TO.
81* METRIC INFORMATION GUIDE BASE UNITS SYMBOL DESCRIPTION UNIT length mass liquid meter kilogram liter m kg temperatu re pressure torque celsius kilopascal Newton meter kilometer per hour °C L f
OFTEN ASKED QUESTIONS Q: Why must my snowmobile be After all I do have my original invoice as proof of when I purchased my snowmobile. A: Your warranty is valid at any authorized dealer of the product. Your registration is the key element in providing the servicing dealer with the necessary data to complete warranty claim forms. This information is also used to notify owners in the event of a safety recall.
Q: What costs are my resoonsibilitv during the .warranty period? A: The customer's responsibility includes all costs of normal maintenance sernon-warranty repairs, accidents and collision as well as and spark plugs. Q: Are "Genuine" Bombardier replacement parts used in warranty repairs covered by warranty? A: Yes. When installed by an authorized dealer, any "genuine" Bombardier part used in warranty repairs assumes the remaining warranty that exists on the machine.
LISTING OF AREA OF DISTRIBUTORS CANADIAN DISTRIBUTORS AMERICAN DISTRIBUTORS ALI"INiE DISTRIBUTiORS LIMITED VlT 6M2 CANAIJADI~;TRIBUTIC)N DIVISION North Dakota, Minnesota, Wisconsin, Illinois, Missouri, Michigan, Indiana, Ohio uess eastern hatf), Tennessee, Kentucky, West Virginia, Virginia, Northern Idaho, Northern Wyoming, Montana, Iowa, Washington INC EOA Scotia, New Brunswick, N:I~~~~~:~~~~a~~~~:~u~~r~~;~: I\I~W ~ltH~''''Y, p BOMBARDIER L1MITEE DISTRIBUTION DIVISION Connecticut, Rhode Island, M
HOW TO IDENTIFY YOUR SNOWMOBILE The main components of your snowmobile (engine, track and frame) are identified by different serial numbers. It may sometimes become necessary to locate these numbers for purposes or to trace your in the event of theft. ENGINE SERIAL \I\/c:lrr::llnt\l NUMBER TRACK SERIAL NUMBER VEHICLE IDENTIFICATION NUMBER MODEL NUMBER O 34 NOTE: We strongly recommend that you take note of all the serial numbers on your vehicle and supply them to your insurance company.
CHANGE OF ADDRESS AND OWNERSHIP Any change in address or ownership should be brought to the attention of the manufacturer by completing and sending out the card supplied below. This will help us to maintain our files up-to-date. -----------------------------------------------------~ CHANGE OF ADDRESS VEHICLE IDENTIFICATION NUMBER OLD ADDRESS: NAME NO STREET CITY STATE APT. ZIP / POSTAL CODE NEW ADDRESS: NAME NO STREET CITY 5T ATE APT.
BOMBARDIER LIMITEE ATT.: WARRANTY DEPARTMENT VALCOURT,QUEBEC CANADA, JOE 2LO BOMBARDIER LIMITEE ATT.
