BOMBARDIER Safari 377 1988, Safari 377E 1988, Safari 503 1988 Operator's Manual

If

operators

manual

377

377E

503

2 d

Li.on

------

--------

_,.,......

_____

,_.""

________

,:;;::._~----

-

--

--------

-

-----

--

-

------

------~

----------

-

----

---

- -

-------

--

-----·-----·-

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

414

6240

00

model

V.I.N.

_________

_

purchase date
warranty expiry date

To

be

completed

by dealer

at

time

of

sale

DEALER IMPRINT AREA

AFTER SALES SERVICE The

following

are trademarks

of

Bombardier Inc.

BOMBARDIER INC.
VALCOURT

(QUEBEC) ALPINE®

FORMULA*

SAFARI*

CANADA

JOE 2LO

BLIZZARD® FUTURA® SKANDIC®

IH~I

BOMBARDIER®

GRAND

PRIX SPECIAL®

SKI-DOO®
CARRY -BOOSE® MIRAGE® SONIC®
CITATION®

MOTO-SKI® SPIRIT®

~·~

ELAN®

NORDIK®

STRATOS*

Servici

ELITE® NUVIK®

T'NT®
ESCAPADE*

OLYMPIQUE®

TUNDRA*
EVEREST®

ROT AX®

Litho'd

in Canada

®*Trademarks

of

Bombardier

Inc.

All

rights

reserved ©

Bombardier

Inc.

FOREWORD

______________

,

____

_

The

operator manual

and

the Snowmobile
Safety Handbook have been prepared to
acquaint the owner/operator or passenger
of a new

snowmobile

with

the various
vehicle controls, maintenance and safe
operating instructions.

Each

is

indispens-

able 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
consult the "Often Asked Question" sec-

tion

of

this manual, or your authorized

dealer.
This manual uses the following symbols.

•

WARNING: Identifies

an

instruc-

tion which, if not

followed, could

cause

serious

personal

injuries

including

possibility

of

death.

'W'

CAUTION: Denotes

an

instruction

T which, if not followed, could se-

verely damage vehicle cor:nponents.

0

NOTE: Indicates supplementary in-

formation needed to fully complete

an instruction.
Although the mere reading of such infor-

mation does

not

eliminate the hazard,

your understanding

of

the information

will promote its correct use .

•

WARNING: The engines and the

corresponding components iden-

tified

in

this manual should not be uti-

lized

on

product(s) other than those

mentioned

on

the

cover page

of

this

manual.

•

WARNING: Maintenance proce-
dures

and

tightening torques must

be strictly adhered to, never

attempt

repairs unless the appropriate tools are

available.

The

information and components/system

descriptions contained

in

this manual

are
correct at time of publication. Bombardier
Inc. however, maintains

a policy

of

con-
tinuous improvement of its products with-
out

imposing upon itself any obligation
to install them on products previously
manufactured.

Bombardier

Inc.

reserves the right at any
time to discontinue or change specifica-
tions, designs, features, models or equip-
ment

without

incurring obligation.

The illustrations show the typical con-
struction of the different assemblies and,
in

all cases, may

not

reproduce the full
detail or exact shape of the parts shown,
however, they represent parts which

have

the same or a similar function.
Most specifications

are

given

in

both met-
ric and customary units. Where precise
accuracy

is

not

required, some conver-
sions are rounded to even numbers for
E?asier

use.

A shop manual can

be

obtained for com-
plete service, maintenance and repair in-
formation.

'W'

CAUTION:

Most

components of

T this vehicle

are

built with parts di-

mensioned

in

the

metric:

system. Most
fasteners are metric and must not be
replaced

by

customary fasteners

or

vice
versa. Mismatched or incorrect fasten-
ers

could cause damage to the vehicle

or possible personal injury.

SAFETY

MEASURES

__________________________

_

Observe

the

following

precautions:

• Throttle mechanism should

be

check-

ed

for free movement before starting

engine.

•

Do

not operate vehicle near snow mak-

ing equipment.

• Engine should

be

running only when

belt guard and/or pulley guard

is

se-

cured

in

place.

•

Never

run

the engine without drive belt

installed. Running

an

unloaded engine

can prove to

be

dangerous.

• Never run the engine when the track
is

raised

off

the ground.

• It

can

be

dangerous to

run

engine with

the hood removed.

• Gasoline

is

flammable and explosive
under certain conditions. Always ma-
nipulate

in

a well ventilated area. Do

not

smoke or allow open flames or

sparks

in

the vicinity. If gasoline fumes
are noticed while driving, the cause
should

be

determined and corrected

without

delay.

• Maintain your vehicle

in

top mechan-

ical condition at all times.

• Your snowmobile

is

not

designed to

be

driven or operated on black top,
bare earth, or other abrasive surfaces.
On

such surfaces abnormal and ex-

cessive wear

of

critical parts

is

inevi-

table.

• Your snowmobile

is

not

designed to

be

operated on public streets, road

or highways.

In

most

States and

Provinces, it

is

considered

an

illegal

operation.

• Installation

of

other than standard
equipment, including ski-spreaders,
bumpers, pack racks, etc., could se-
verely affect the stability and safety
of

your vehicle. Avoid adding

on

ac-

cessories

that

alter the basic vehicle

configuration.

• The snowmobile engine can

be

stop-

ped

by

activating the emergency cut-

out switch, tether switch or

by

turning

off

the

key.

• Whenever the vehicle

is

parked out-
doors, overnight or for a long period,
it

is

suggested to protect it against

the inclemency

of

the weather with a

snowmobile cover.

• Do not lubricate throttle and/or brake
cables and housings.

• Only perform procedures

as

detailed

in
this manual. Unless otherwise speci-
fied, engine should

be

turned

OFF

for
all lubrication and maintenance pro-
cedures.

•

Clean

and

check operation of the

head-

light, taillight and brake light.

• Should removal

of

a locking device

be

required when undergoing repairs/

disassembly, always replace

by

new

ones. Tighten fasteners

as

specified

in

the applicable Shop Manual.

PLEASE

READ

AND UNDERSTAND ALL

WARNINGS AND CAUTIONS

IN

THIS

MANUAL

AND

ON

THE VEHICLE

THIS

MANUAL

SHOULD

REMAIN

WITH

THE

VEHICLE

AT

THE

TIME

OF

RESALE

2

INDEX

________________________

_

THE

1988

"LIMITED

WARRANTY"

. .

OFTEN

ASKED

QUESTIONS

.

LISTING

OF

AREA

DISTRIBUTORS.

HOW

TO

IDENTIFY

YOUR

SNOWMOBILE

CONTROLS/INSTRUMENTS

Throttle lever, brake lever, ignition switch, light switch, headlamp

dimmer
switch, emergency cut-out switch, tether cut-out switch, rewind starter han-
dle,

primer, adjustable steering handle, speedometer, electric fuel

level

gauge,
injection oil level pilot lamp, high beam pilot lamp, tank cap, fuel gauge/tank
cap,

hood opening, retractable headlamp

lever,

seat belt, tool box, spark plug

4

6

8

9

holder, fuse holder, hitch, accessories . . . . . . . .

10

BREAK-IN

PERIOD

Engine and belt break-in, 10 hour-inspection, inspection check list

13

FUEL & OIL

Recommended gasoline, recommended oil, oil injection system . .

15

PRE-START

CHECK

Check points . . . . . . . . .

16

STARTING

PROCEDURE

Manual starting, electric starting, before riding, emergency starting

16

LUBRICATION

Frequency, steering mechanism, drive axle, slide suspension, chaincase oil

level, oil injection system, driven pulley . . . . . . . .

18

MAINTENANCE

Maintenance chart, belt guard removal, drive belt removal and installation,
drive belt condition, new drive belt, brake condition, brake adjustment, spark
plugs, battery, suspension condition, stopper strap condition, suspension
adjustment, track condition, track tension and alignment, drive pulley, steering
mechanism, steering adjustment, muffler attachment, engine head nuts, en-
gine mount nuts, carburetor adjustment, high altitude kit, oil injection system,

fan belt, headlamp beam aiming, bulb replacement, general inspection

20

STORAGE

Track, suspension, skis, controls, chaincase, drive pulley, engine and primer

lubrication, fuel tank and carburetor, battery, chassis, general inspection,

suspension stopper strap . . . . . . . . . . . . . . . . . . . . . . . . . .

32

PRE-SEASON

PREPARATION

Pre-season preparation

chart.

TROUBLE

SHOOTING

GUIDE.
TOOLS
SPECIFICATIONS ...

51

METRIC

INFORMATION

GUIDE

..

WIRING

DIAGRAMS

36

37

39

40

44

46

3

THE

1988

SNOWMOBILE

LIMITED

WARRANTY

__________

_

1

-PERIOD

BOMBARDIER® INC. as manufacturer,

warrants

FROM THE

DATE

OF

DELIVERY

TO

THE FIRST CONSUMER, every

1988

BOMBARDIER

snowmobile,

sold as

NEW

AND

UNUSED, and predelivered by an authorized BOMBARDIER dealer

for

a period of:

• 12

consecutive

months.

2-

WHAT

BOMBARDIER

WILL

DO

BOMBARDIER

will

repair and/or replace,

at

its

option,

components

defective

in

material and/or

workmanship

(under normal use and service),

with

a genuine

BOMBARDIER

component

without

charge

for

parts or labour,

at

any authorized

BOMBARDIER dealer

during

said

warranty

period.

3-

CONDITION

TO

HAVE

WARRANTY

WORK

PERFORMED

Present

to

the

servicing dealer,

the

hard

copy

of

the

BOMBARDIER

Warranty

Registration card or

proof

of

purchase received by

the

customer

from

the

selling

dealer

at

time

of

delivery.

4 -

WARRANTY

TRANSFER

This

warranty

is transferable

to

subsequent owner(s)

for

remainder

of

warranty

period

from

original

date

of

delivery.

5 -

EXCLUSIONS -ARE

NOT

WARRANTED

• Normal

wear

on all

items

such

as,

but

not

limited

to:

- drive belts - bulbs

- slider shoes - runners on skis

-

spark

plugs

•

Replacement

parts

and/or accessories

which

are

not

genuine BOMBARDIER

parts

and/or accessories.

• Damage resulting

from

installation

of

parts

other

than

genuine BOMBARDIER

parts.

•

Damage

caused by failure

to

provide proper

maintenance

as detailed in

the

Operator's

Manual. The labour, parts and lubricants

costs

of

all maintenance

services, including

tune-ups

and

adjustments

will

be charged

to

the

owner.

• Vehicles designed and/or 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 ne-

glect.

•

Damage

resulting

from

operation

of

the

snowmobile

on

surfaces

other

than

snow.

• Damage resulting

from

modification

to

the

snowmobile

not

approved in

writ-

ing by BOMBARDIER.

4

• Losses incurred by

the

snowmobile

owner

other

than

parts

and labour,

such

as,

but

not

limited

to,

transportation,

towing,

telephone

calls,

taxis,

or any

other

incidental

or

consequential

damage.

6 -

BATTERY

WARRANTY:

• 12

consecutive

months. (Pro-rated)

100%

warranty

coverage

will

start

on

the

date

the

snowmobile

was

delivered

and run

to

the

following

April

30th.

The remainder

of

the

12

month-period

will

be pro-rated as

follows:

50%

from

April

30th

to

December

1st.

40%

from

December

1st

to

December

31st.

30%

from

January

1st

to

end

of

warranty.

7 -

EXPRESSED

OR

IMPLIED

WARRANTIES

This

warranty

gives you specific rights, and you

may

also have

other

legal

rights

which

may

vary

from

state

to

state,

or

province

to

province.

Where

applicable

this

warranty

is expressly in lieu

of

all

other

expressed

or

im-

plied

warranties

of

BOMBARDIER,

its distributors

and

the

selling

dealer,

including

any

warranty

of

merchantability

or

fitness

for

any

particular

purpose;

otherwise

the

implied

warranty

is

limited

to

the

duration

of

this

warranty.

However,

some

states

or

provinces

do

not

allow

limitations

on

how

long

an

implied

warranty

lasts, so

the

above limitation

may

not

apply.

Neither

the

distributor,

the

selling

dealer,

nor

any

other

person has been

authorized

to

make

any

affirmation,

representation or

warranty

other

than

those contained in this

warranty,

and

if

made,

such

affirmation,

represen-

tation

or

warranty

shall

not

be

enforceable

against

BOMBARDIER

or

any

other

person.

Some

states

or

provinces

do

not

allow

the

exclusion

or

limitation

of

in-

cidental

or

consequential

damages,

so

the

above

limitation

or

exclusion

may

not

apply.

BOMBARDIER

INC.

reserves

the

right

to

modify

its

warranty

policy

at

any

time,

being understood

that

such

modification

will

not

alter

the

war-

ranty

conditions

applicable

to

vehicles sold

while

the

above

warranty

is

in

effect.

8 -

CONSUMER

ASSISTANCE

If a

servicing

problem

or

other

difficulty

occurs,

we

suggest

the

following:

1.

Try

to

solve

the

problem

at

the

dealership

with

the

Service Manager or Owner.

2. If

this

fails,

contact

your

area

distributor

listed in

the

Operator's

Manual.

3. Then

if

your

grievance still remains unsolved, you

may

write

to

us:

Bombardier

Inc.

Service

Department

Recreational

Products

Division

Valcourt

(Quebec). Canada

JOE

2LO

September

1986

Bombardier

Inc.

Valcourt

(Quebec). Canada JOE 2LO

®*Trademarks

of

Bombardier

Inc.

5

OFTEN

ASKED

QUESTIONS

__________________________

__

0:

Why

must my snowmobile

be

registered at the factory? 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.

0:

Who

should send the registration card to Bombardier Inc.?

A:

The

authorized dealer. However,

it

is

important

that

the

customer

make sure

that

it

has been sent.

The

company

might

contact

you

should

your vehicle

be

recalled

or

in case

of a particular

warranty campaign.

0:

I bought my snowmobile

in

O'King County but I snowmobile

in

Washington Coun-

ty.

Can

an

authorized dealer

in

Washington County accept to perform warranty work

on

my snowmobile?

A:

Yes,

any authorized dealer in North

America

can

perform

warranty repairs,

providing

the

customer

warranty registration

card

is presented.

0:

Where can I find information on the lubrication and maintenance

of

my snow-

mobile?

A:

In this Operator

Manual

provided

with the vehicle

at

the time

of

delivery.

0:

Will the entire warranty

be

void or cancelled, if I do

not

operate or maintain my

new snowmobile exactly

as

specified

in

the Operator's Manual?

A:

The

warranty

of

the

new

snowmobile

cannot

be

"Voided"

or

"Cancelled':

However,

if

a particular failure is caused

by

operation

or

maintenance

other

than

is

shown

in the Operator Manual, THAT failure

may

not

be covered

under

war-

ranty. This includes service

work

performed

by

the customer, especially the

critical adjustments to ignition, timing, carburation

and

oil

injection/or oil mixture.

0:

Would you give some examples

of

abnormal use or strain, neglect or abuse?

6

A:

These terms are general

and

overlap each

other

in areas. Some specific ex-

amples

may

include:

running

the

machine

out

of

oil, chain failure caused

by

a

lack

of

lubrication, operating the machine with a broken

or

damaged

part

which

causes

another

part

to fail,

and

so on.

If

you have any specific questions

on

operation

or

maintenance, please

contact

your authorized dealer for advice.

0:

What

costs are my responsibility during the warranty period?

A:

The

customer's responsibtfity includes

all

costs

of

normal

maintenance ser-

vices, non-warranty repairs, accidents

and

collision damage, as well as otis,

and

spark plugs,

and

incidental

or

consequential damages costs as explained

in the warranty

0:

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 repatrs assumes the remaining warranty

that

exists on the

machine.

0:

If I sell my snowmobile

within

the warranty period, will the new

owner

qualify

for

the balance

of

the warranty?

A:

Yes,

provided the

unit

has already been registered

with

the manufacturer.

Note that the change

of

ownership card in this

manual

should

be

completed

and

sent

to Bombardier Inc.

0:

How

can I receive the best

owner

assistance?

A:

The

satisfaction

and

goodwill

of

the owners

of

Bombardier products are

of

primary

concern to your authorized dealer

and

Bombardier Inc. Normally, any

problems that arise in connection

with

the sales transaction

or

the operation

of

your snowmobtfe

wtJI

be handled by your Dealers Sales

or

Service Departments.

It

is recognized, however, that despite the best intentions

of

everyone concerned,

misunderstandings

will

sometimes occur.

If

you have a problem

that

has

not

been handled to your satisfaction through

normal

channels, we suggest

that

you discuss your problem with a

member

of

dealership management. Frequently,

complaints are the result

of

a breakdown in communications

and

can quickly

be resolved

by a member

of

the dealership management.

If

the problem already

has been reviewed with the Sales

Manager

or

Service Manager,

contact

the

Dealer

himself

or

the General Manager.

7

LISTING

OF

AREA

DISTRIBUTORS

________________________

_

CANADIAN

DISTRIBUTORS

Quebec Branch

1350, Nobel
Boucherville (Quebec)

J4B

1A1

1514)

655-6121

Province of Quebec

Ontario Branch
230,

Bayview Drive

Barrie (Ontario) L4N

4Y8

1705)

728-8600

Province of Ontario

Technical office
PO.

Box

7060

Riverview (New Brunswick)

E1B

1VO

1506) 386-6117

Atlantic Region

BROOKS

EQUIPMENT LIMITED

1616, King Edward Street

PO.

Box

985

Winnipeg (Manitoba)

R3C

2V8

1204)

633-7247

British Columbia, Manitoba, Saskatchewan,

Alberta, Yukon

CHARLES

R.

BELL LIMITED
Riverside Drive
PO

Box 1050

Corner Brook (Newfoundland) A2H

6J3

1709)

634-3533

Newfoudland, Labrador

HUDSON'S

BAY

CO.

LTD.

165, Hymus Blvd

Pointe-Claire (Quebec) H9R

1G2

1514)

630-5279

North-West Territories, Franklin District &

Keewatin

8

AMERICAN

DISTRIBUTORS

BOMBARDIER CORPORATION

All States (excluding Alaska)

SERVICE

OFFICES

- East Main Street Road
Malone,

New

York

12953

1518)

483-4411

Technical office

1506) 386-6117

Eastern Region

-

4505,

West Superior Street

PO.

Box 16106
Duluth, Minnesota 55816-0106
(218) 628-2881

East-Central, Central Region

-

PO.

Box 1569

Idaho Falls, Idaho

83403

1208)

529-9510

Western Region

NATIONAL SALES

OFFICE
O'Hare Lake Plaza
2350,

Devon Avenue
Suite 150
Des Plaines, Illinois 60018

1312)

298-9540

MILLER EQUIPMENT AND RECREATIONAL
CENTER

1049,

Whitney

Road

Anchorage, Alaska 99501

1907)

274-9513

Alaska

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 warranty purposes

or

to trace your snowmobile in the event

of

theft.

(TYPICAL)

A021000001

Vehicle

serial

number

meaning:

0000

00000

.---

Model no Vehicle no

A000000013

Track

serial number

A009005002

1988

Safari

377

/377E/503

have

3625,

3626

and

3627

as

model number re-

spectively.

0

NOTE:

We

strongly recommend

that

you take note

of

all the serial numbers

on your vehicle and supply them to your insurance company. It will surely help

in

the event your snowmobile

is

stolen.

9

CONTROLS/

INSTRUMENTS

______________________

__

A009007009

A ) Throttle Lever

B ) Brake Lever
C)

Ignition

Switch

D)

Light

Switch

(electric starting)

E ) Head/amp

Dimmer

Switch

F ) Emergency Cut-out

Switch

G)

Tether Cut-out

Switch

H)

Rewind Starter Handle

I ) Primer

J ) Adjustable Steering Handle

A)

Throttle

Lever

Located on the right side

of

handlebar.

When compressed, it controls the engine
speed and the engagement of the trans-
mission. When released, engine speed
returns automatically to idle.

10-------------------------

K ) Speedometer

F

A

c

I

H

p

0

L ) Electric Fuel Level Gauge

(optional on some models)

M)

Injection Oil Level Pilot Lamp
(red)

N)

High Beam Pilot Lamp (blue)

0)

Tank

Cap,

Fuel Gauge/Tank Cap

(some models)

P )

Hood

Opening

Q)

Retractable Head/amp Lever

B)

Brake

Lever

Located on the left side of handlebar.

When compressed, the brake

is

applied.

When released, it automatically returns

to its original position. Braking effect

is

proportionate to the pressure applied

on

the lever and to the type of terrain and

its snow coverage.

C)

Ignition

Switch

Manual

starting

OFF

A002007002

...-ON

~

LIGHT

Key

operated 3 position switch.

To

start

engine, first turn key to

ON

position.

To

stop engine, turn key to

OFF

position.

To

put lights on while engine

is

running,

turn key to LIGHT position.

'W'

CAUTION: Never

start

a vehicle

T equipped

with

halogen headlamp

with

the

key placed on

the

LIGHT po-

sition.

Otherwise

headlamp

bulb

may

burn as a

voltage

peak

may

be pro-

duced

when

the

engine starts running.

Electric

starting

(optional

on

some

models)

OFF

_..-ON

-START

A002007002

Key

operated, 3 position switch.

To

start

engine, turn

key

to

START

position and

hold. Return

key

to

ON

position immedi-

ately when engine has started.

To

stop

engine, turn

key

to

OFF

position .

.r

CAUTION: Holding key in START

'Y

position

when

engine has started

could

damage

starter

mechanism.

D)

Light

Switch

(Electric

starting)

To

illuminate headlamp and taillight, pull

switch

knob. (Ignition

switch

must

be

turned

to

ON

position) .

E)

Headlamp

Dimmer

Switch

The dimmer switch allows correct selec-
tion

of

headlamp beam.

To

obtain high

or

low

beam simply flick switch.

A008006003

F)

Emergency

Cut-out

Switch

To

stop the engine

in

an

emergency, push

the button to the lower

off

position and

simultaneously apply the brakes.

To

start

engine, button

must

be

at the upper on

position.

tON

+OFF

~~

Upper position
before starting

A017006004

Lower position
to

stop

engine

11

The driver of this vehicle should famil-
iarize 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.

•

WARNING:

For

safety

reasons,

the emergency cut-out switch

is

easily accessible;

be

careful not to oper-

ate

it inadvertently.

•

WARNING: If the switch

has

been

used

in

an emergency situation

the source of malfunction should

be

de-
termined and corrected before restart-
ing engine.

G)

Tether

Cut-out

Switch

Attach tether cord to wrist or other con-
venient location of the driver's clothing.
Snap tether cut-out cap over receptacle
before starting engine.

If emergency engine shut off

is

required,
completely pull cap from safety switch
and engine power will

be

automatically

shut off.

0

NOTE: The cap must

be

installed

on the safety switch at all times

in

order to operate the vehicle .

•

WARNING:

If

the

switch

is

used

an

emergency

situation

the

source of malfunction should

be

deter-

mined and corrected before restarting

engine.

H)

Rewind

Starter

Handle

Auto rewind type located on right hand

side of vehicle.

To

engage mechanism,

pull handle.

I)

Primer

Pull and push button (2-3 times) to ac-

tivate primer. The primer should always
be

used for cold engine starts. After en-

gine

is

warm however, it

is

not necessary

to use primer when starting.

12---------------------------

J)

Adjustable Steering Handle

Remove steering pad.
Loosen the four (4) retaining screws.
Adjust the handle to the desired position .

•

WARNING: Do not adjust too

high

as

the brake

lever

may contact the

windshield

when

turning.

Lock

the steering handle

in

place

by

tight-
ening the four (4) retaining screws
to

26

N•m

(19

lbf•ft).

Reinstall steering pad.

K)

Speedometer

The speedometer

is

linked directly to the

drive

axle.

Direct-reading

dial

indicates the

speed of the vehicle. Odometer records

the total distance travelled

in

kilometers.

Trip

meter

button

(Safari

503

only)

The trip meter reset button

is

located on

the speedometer housing.

To

reset,

open
hood and turn black knob counterclock-
wise until all numbers read

zero.

A021007001

Turn

counterclockwise

L)

Electric

Fuel Level

Gauge

(optional on

some

models)

The electric fuel gauge

is

located

in

the
dashboard and allows driver to observe
the fuel

level

while riding the snowmobile.

M)

Injection

Oil Level

Pilot

Lamp

(Red)

Will light up when injection oil level

is

low. Check level and replenish

as

soon

as

possible.

-.r

CAUTION: Do not run engine until

T

it

is out

of

oil. Serious engine dam-

age

will

occur.

Whenever brake

lever

is

compressed, oil

level pilot lamp should light

up.

If not,

replace lamp.

N)

High

Beam

Pilot

Lamp

(Blue)

Lights up when headlamp

is

on high

beam.

0)

Tank

Cap

(Safari

377/377E)

Unscrew to fill up tank then fully tighten.

Fuel

Gauge/Tank

Cap

(Safari

503)

Unscrew fuel tank cap

and

withdraw dip-

stick to check fuel level.

•

WARNING: Remove fuel

tank

cap

slowly. Fuel

may

be

under

pres-

sure and spray

may

cause fire and in-

juries.

•

WARNING: Never use a

lit

match

or open flame

to

check fuel level.

P)

Hood

Opening

Pull

down the latches to unlock the hood

from the anchors.

0

NOTE: Always lift hood gently up
until stopped

by

restraining device.

•

WARNING: It is dangerous

to

run

an

engine

with

the

hood opened,

unfastened

or removed.

Q)

Retractable

Headlamp

Lever

Push

lever forward to expose headlamp.

To

retract, pull lever backward.

Seat

Belt

Located

on

middle of seat. Provide a grip

for the rear passenger.

Tool

Box

Located under the hood.

To

gain access,
tilt hood. ideal location for spare spark
plugs, rope, first aid kit, flashlight, etc.

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

13

Spark

Plug

Holder

To

keep spark plugs dry and prevent
shocks that might affect the adjustment
or break them, a holder

is

provided

in

the

inside of the tool box cover.

Fully tighten them into the holder.

A019007030

Spark plug

holder

Fuse

Holder

Starter

(electric starting)

Tool

box

Starting system

is

protected with thirty

(30) amperes rated fuse.

Fuse

holder

is
located near the starter. If starter does
not operate, check fuse condition and if
necessary replace.

Engine

support

A019007031

Fuse holder

14-------------------------

Hitch

The hitch

is

fixed on the rear bumper.

A hair pin

is

supplied to lock the hook.

Carry- boose

adapter

b

A007007005

Hair pin

•

WARNING: When towing a

sled

or

trailer, always ensure to lock

the hook with the hair

pin.

0

NOTE:

For

convenience, a carry-

boose adapter

is

supplied

in

the

tool box.
Trailers of sleds towed behind a snow-

mobile should always

be

loaded

in

a way
to obtain the lowest possible center of
gravity. Use a rigid

tow

bar when pul-

ling a

tow

sled behind your snowmobile.

When your

are

pulling passengers

in

a

trailer or

tow

sled, use moderate speed

an

avoid rough terrain for their safety.

Also, have all passengers get

out

of a

towed vehicle and walk across

all

roads.

Accessories

Some optional accessories might

be

add-

ed

to your vehicle such

as

speedometer,

tachometer, hitch, electric starter, etc, if

not standard ou your vehicle. Ask your
authorized dealer for more information.

BREAK-IN PERIOD

______

_

Engine

With Bombardier-Rotax snowmobile en-
gine, a break-in period

is

required before
running the vehicle at full throttle. Engine's
manufacturer recommendation

is

10

to

15

operating hours. During this period,

maximum throttle should not exceed

3/4,

however, brief full acceleration and speed

variations contribute to a good break-in.

Continued

wide

open throttle accelera-

tions, prolonged cruising speeds,

and

lug-

ging are detrimental during the break-in

period.

0

NOTE:

To

assure

additionnal protec-

tion during the initial engine break-

in,

500 ml

(18

imp.

oz)

of BLIZZARD OIL

(P/N

496

0135 00) or the same quan-

tity

of

Bombardier Injection oil should

be

added

to

fuel

for

the first full fuel tank

filling.

"1IIIF

CAUTION: Remove and clean

T spark

plugs

after engine break-in.

Belt

A new drive belt requires a break-in period
of

25

km

(15

miles).

1

0-Hour

Inspection

As

with any precision piece of mechanical

equipment, we suggest that after the first

10

hours

of

operation or 30 days after

the purchase, whichever comes first, your
vehicle

be

checked

by

your authorized
dealer. This inspection will give you the
opportunity

to

discuss the unanswered

questions

you

may

have

encountered dur-

ing the first hours

of

operation.

The

10

hour inspection

is

at the

expense of the vehicle owner.

-----------------------------------------------15

10-HOUR

INSPECTION

CHECKLIST

./

Engine

timing

Fan

belt

tension

Spark

plugs

condition:

(Remove and clean)

Carburetor

adjustment

Oil

injection

pump

adjustment

Engine head

nuts

Drive pulley

screw

(torque)

Engine

mount

nuts

Muffler

attachment
Chaincase oil level
Injection

system

oil level

Brake operation and lining

condition

Ski

alignment

(runner

condition)

Handlebar bolts, retorque

to

26

N•m

(19

lbf•ft)

Pulley

alignment

and drive

belt

condition

Track

condition,

tension

and

alignment
Lubrication (steering, suspension, drive axle, etc.)
Electrical

wiring,

tighten

all loose bolts,

nuts

and linkage

Operation

of

lighting

system

(HI I

LO

beam, brake light, etc.),

test

operation

of

emergency

cut-out

switch

and

tether

switch

Battery

electrolyte

level (electric

starting)

We

recommend

that

you

have

your

dealer

sign

this

inspection

list.

Date

of

10

hour

inspection

Dealer signature

16-----------------------------------------------

FUEL &

OIL

_________

_

Recommended

Gasoline

Use

regular leaded gasoline available

from

all

service stations.

•

WARNING: Remove fuel tank cap

slowly. Fuel may be under pres-

sure and spray may cause fire and in-

juries.

•

WARNING: Gasoline

is

flammable

and explosive under certain con-

ditions.

Always

manipulate in a well

ventilated area. Do

not

smoke or allow

open flames or sparks in

the

vicinity.

-..r

CAUTION: Never experiment

with

T other fuels or fuel ratios. The use

of

gasoline containing alcohol such

as

methanol, ethanol

(commonly

called
gasohol) or similar products including
naphta

is

not

recommended. The use

of

gasoline containing alcohol can result

in

vehicle performance deterioration and

damage

to

critical parts in the fuel sys-

tem

and engine

components

.

•

WARNING: Never

"top

up"

the

gas

tank

before placing the vehi-

cle

in

a warm

area.

At

certain tempera-

tures, gasoline

will

expand and over-

flow. Always wipe

off

any gasoline spil-

lage

from

the

snowmobile.

Recommended

Oil

Use

"Bombardier Snowmobile Injection

Oil"

(PIN

496 0133

00-

1 liter) available

from the authorized

dealer.

This type of

oil will flow at temperatures

as

low

as

minus

40°C

(-40°F).

If

"Bombardier Snowmobile Injection Oil"

is

unavailable, substitute with

BLIZZARD

OIL

(PIN

496

0135

00-

500

ml).

-..r CAUTION: Never use outboard or

T

straight

mineral oils.

Oil

Injection

System

Always maintain a sufficient amount of
"Bombardier Snowmobile Injection Oil"
in

the injection oil tank.

-..r CAUTION:

Check

level and refill

T every time you refuel. Do not over-

fill.

0

NOTE:

To

assure

additionnal protec-

tion during the initial engine break-

-in, 500

ml

(18

imp.

oz)

of BLIZZARD

OIL

(PIN

496 0135 00) or the

same

quan-

tity of Bombardier Injection

oil

should

be

added to gas for the

first

full gas tank

filling.

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

17

PRE-START

CHECK

______

_

Check

Points

•

ACTIVATE

THE

THROTTLE

CONTROL

LEVER

SEVERAL TIMES to check that
it operates easily and smoothly. The
throttle control

lever

must return to idle

position when released.

• Check

that

the skis and the track are
not frozen to the ground or snow sur-
face and that steering operates freely.

• Activate the brake control lever and
make sure the brake fully applies be-

fore the

brake

control

lever

touches the

handlebar grip.

• Check injection oil level.

• Check fuel level.

• Verify

that

the path ahead

of

the ve-

hicle

is

clear

of

bystanders and obsta-

cles.

•

Clean

and

check operation of the head-

light, taillight and brake light.

•

WARNING: Only start your snow-

mobile once

all

components are

checked and functioning properly.

STARTING

PROCEDURE

____

_

Test throttle control lever operation.
Check that the emergency cut-out switch

is

in

the

ON

position.

AOl

7006004

tON

Upper

position

before starting engine

Ensure the tether

cut-out

cap

is

in

posi-

tion and

that

the cord

is

attached to the

clothing.
Activate the primer (2 or 3 times).

18-------------------------

0

NOTE:

The

use

of the primer

is

not

necessary when the engine

is

warm.

Manual

Starting

Insert the key

in

the ignition and turn to

ON

position.

Grasp manual starter handle firmly and

pull slowly until a resistance

is

felt then

pull vigorously. Slowly release the rewind

starter handle .

•

WARNING: Do not apply throttle

while starting.

"1llr

CAUTION: Never start a vehicle

T equipped with halogen headlamp

with the key placed

on

the LIGHT po-
sition. Otherwise headlamp bulb may
burn

as

a voltage peak may

be

produc-

ed when the engine starts running.

Electric

Starting

(optional

on

some

models)

'W'

CAUTION:

Never

operate

the

T

snowmobile

with

the

battery

re-

moved or disconnected, since

the

bat-

tery

reduces voltage fluctuations, oper-

ating vehicle

without

it

might

cause in-

strument

or

bulb failure.

Insert

key

in

ignition switch.

Turn

ignition

key

clockwise until starter

engages.

'W'

CAUTION:

To

avoid

starter

over-

T heating, the cranking period should

never exceed

30

seconds

and a

rest
period should be observed between the
cranking cycles

to

let starter cool down.

Release

key

immediately when engine

has started. If engine does

not

start on

first try,

key

must

be

turned fully back

to

OFF

each time .

•

WARNING:

Do

not

apply

throttle

while

starting.

Before

Riding

Check operation

of

the emergency cut-
out switch and tether switch. Restart en-
gine.

•

WARNING:

If

engine

does

not

shutoff

when

applying

the

emer-

gency

cut-out

switch

and

or

when

pull-

ing

the

tether

cut-out

cap,

stop

the

en-

gine by

turning

off

the

ignition

key.

Do

not

operate the vehicle further, see your

authorized

dealer.

Allow the engine to warm before oper-
ating at full throttle.

Emergency

Starting

Should the rewind starter rope fray and
break, the engine can

be

started with the

emergency starter rope supplied with the

tool kit.

•

WARNING:

Do

not

start

the

ve-

hicle by

the

drive pulley unless

it

is a true emergency situation. Have

the

vehicle repaired as soon as possible.

Safari

377/377E

Attach emergency rope to any available
handle. Remove the belt guard from the
vehicle and

wind

the emergency rope
th1ght around the drive pulley between
the sliding half and the roller guard.

0

NOTE: The spark plug socket can
be

used

as

an emergency starter

grip.

Roller

guard

-------------------------19

Safari

503

Attach emergency starting rope to any
available handle and to the starter clip
supplied

in

the tool box. Remove the belt

guard from the vehicle and wind the

rope

thightly around drive pulley.

0

NOTE:

The spark plug socket can

be

used

as

an

emergency starter

grip.

A019003001

A003003016

Starter

clip

20---------------------------

•

WARNING:

Do

not

wind

starting

rope around your hand. Hold rope

by

the

handle only.

A007003030

Start engine

as

per usual manual starting .

•

WARNING:

When

starting the ve-

hicle

in

an

emergency situation by
the drive pulley, do not reinstall the belt
guard.

LUBRICATION

________

_

A000000007

Frequency

Routine maintenance

is

necessary for

all
mechanized products, and the snowmo-
bile

is

no exception. A weekly vehicle in-

spection contributes to the life span

of

the snowmobile.

It

is

recommended that the steering sys-

tem and suspension

be

lubricated month-

ly or every

40

hours

of

operation. If the

vehicle

is

operated

in

wet snow or

in

sev-

ere

conditions these items should

be

lu-

bricated more frequently.

0

NOTE: When lubricating grease fit-

tings, grease until grease appears
at joints. Always use low temperature
grease (P/N 413 7061

00)

.

•

WARNING: Only perform

such

pro-

cedures

as

detailed

in

this manual.

It

is

recommended

that

dealer assis-

tance be periodically obtained

on

other

components/systems not covered

in
this manual. Unless otherwise speci-
fied, engine should be turned OFF for
all

lubrication and maintenance proce-

dures.

Steering

Mechanism

•

WARNING: Do not lubricate throt-
tle and/or brake cables and hous-

ings.

Lubricate the ski legs and spring coupler
bolts at grease fittings until new grease
appears at joints. Coat spring slider cush-
ion

with

grease.

Oil

ball joints and steering column bush-

ings.

A009006002

-------------21

Drive

Axle

Lubricate at grease fitting using low tem-
perature grease.

-.r

CAUTION:

When

lubricating

the

T drive axle bearing,

do

not

apply

excessive grease as

the

seal

will

be

pushed

out

of

its housing. Check seal

position

with

finger.

Slide

Suspension

Lubricate front & rear arms at grease fit-
tings until grease appears at joints. Use
low temperature grease only.

22-------------------------

(TYPICAL)

A000005003

Chaincase Oil Level

Using the spark plug socket, remove the
filler cap then using a rigid wire

as

a "dip-

stick"

check oil

level.

The oil

level

on

the

"dipstick"

should

be

50-65

mm

(2"

to

2

1/2").

Refill

as

required using Bombar-

dier chaincase oil

(P/N

413 8019

00-

250

ml

(9

oz)).

A009003011

0

NOTE: The chaincase oil capacity
is

approximately

200

ml

(7

oz).

Oil

Injection

System

Always maintain a sufficient

amount

of

Bombardier Snowmobile Injection

Oil

in

the injection oil tank.

MAXIMUM

13

mm

(112")

from top

'W'

CAUTION:

Check

level and refill

T every time you refuel. Do not over-

fill.

Driven

Pulley

Remove pulley guard and slip

off

drive

belt. Open the driven pulley, (push and

twist

sliding half.)
Thoroughly clean the driven pulley shaft.
Apply a light film

of

low-temperature

grease

on

the shaft. Always wipe

off

surplus.

0

NOTE: Activate the sliding half

sev-

eral

times to distribute lubricant

over

full length

of

shaft.

Be

careful that lu-

bricant does

not

get on inner halves

of

pulley.

--------------------------23

MAINTENANCE

______________

__

The following Maintenance Chart indi-
cates regular servicing schedules

to

be

performed

by

the owner or the servicing
dealer. If these services are performed
as

suggested, the snowmobile will provide

many years

of

use.

MAINTENANCE

CHART

•

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 this manual. Unless

otherwise

specified, engine should

be

turned OFF

for

all

lubrication and maintenance pro-

cedures.

.E

.E

~

E

0 0

0-"'

Q)

I!)

0

roo

Cl

"'

=

'£

a>O-

c.

>i':"E

2-

<:-

E

>N

.E

B

roM

~~~

£~~

~

~g

2

Ca>O

:s;~<t

~~o

cOlO

Q)

o>N

ON

ceo

a>-

0:

0

NOTE: The ten hour inspection

is

a very

important

part of proper service and

mamtenance.

24-------------------------

Depose

du

garde-courroie

•

AVERTISSEMENT: Ne

pas

faire

tourner

le

moteur

lorsque

le

garde-

courroie n'est

pas

en

place.

1.

Basculer

le

capot.

2.

Retirer les deux goupilles de retenue.

(EXEMPLE)

Goupilles de retenue

A009003012

3. Soulever et deposer

le

garde-poulie.

Depose

et

installation

de

Ia

courroie

d'entrainement

•

AVERTISSEMENT:

Ne

jamais

faire

demarrer

le

moteur

lorsque

Ia

cour-

roie

d'entrafnement n'est

pas

en

place.

1.

Deposer

le

garde-courroie.

2.

Deverrouiller et sou lever

le

support de

Ia

poulie menee.

3° Soulever

le

support

de

Ia

poulie menee

A003003004

I

3. Ouvrir

Ia

poulie menee

en

tournant et

en

poussant

Ia

demi-poulie coulissante;

Ia

maintenir ouverte.

A007003020

4.

Faire

glisser

Ia

courroie par-dessus

le

rebord superieur

de

Ia

demi-poulie cou-

lissante.

A004003008

5.

Faire

glisser

Ia

courroie par-dessus

Ia

poulie motrice et

Ia

retirer du vehicule.

A004003009

-------------25

lnverser les operations pour

Ia

reinstalla-

tion

en

portant une attention aux points

suivants:
Pour une duree maximale de

Ia

courroie
d'entralnement, s'assurer qu'elle tourne
dans

le

sens approprie. Installer celle-ci

de sorte que I' information soit lisible

en

se

tenant face aux poulies.

A001003002

A001003003

CORRECT

Identification

FACE

AUX

POULIES

Identification

FACE

AUX

POULIES

26----------------------

,.,.

ATIENTION: Ne

pas

forcer

Ia

cour-

T

roie

ni

utiliser d'outils pour

Ia

pas-

ser par-dessus les poulies lors de !'ins-
tallation, sinon ses cordes pourraient
se couper ou se briser.

Etat

de

Ia

courroie

d

'entrainement

Examiner

Ia

courroie. S'assurer qu'elle
n'est pas fendillee, effilee ou usee de fa-
c;;on

anormale (usure inegale, usure

d'un

seul

cote,

crampons manquants, materiau

fendille).

t..:usure

anormale

de

Ia

courroie

peut provenir

d'un

mauvais alignement

des poulies,

d'un

regime excessif alors

que

Ia

chenille est gelee, de demarrages
rapides sans rechauffement prealable,
d'une poulie couverte d'ebarbures, d'huile

sur

Ia

courroie ou

d'une

courroie de re-

change tordue.

Au

besoin, voir

le

con-

cessionnaire.
Verifier

Ia

largeur

de

Ia

courroie.

Rem

pla-

cer

Ia

courroie

si

sa

largeur est inferieure

a

32

mm

(1

1/4

").

Courroie

d'entrainement

neuve

Apres I' installation

d'une

courroie d'en-
tralnement neuve, on recommande for-
tement d'observer une periode

de

rodage

de

25

km (15 milles).

0

REMAROUE: Toujours remiser une

courroie

de

rechange

de

fac;;on a ce

qu'elle conserve

sa

forme naturelle.

Brake Condition

The brake mechanism on your snowmo-
bile

is

an

essential safety

device.

Keep

this

mechanism

in

proper working condition.

Above

all,

do not operate the snowmobile

without

an

effective brake system .

•

WARNING: Brake pads must

be

replaced when fixed

pad

projects

only 1 mm

(1/32")

from caliper. Re-

placement must

be

performed

by

an

authorized dealer.

Minimum

projection of

Aooaoo3015 fixed pad: 1

mm

(1132")

Brake

Adjustment

The brake mechanism

is

a self-adjusting

type. If a quicker brake response

is

de-
sired, strongly squeeze the brake lever
several times, this will actuate the self
adjusting mechanism.

Strongly squeeze

A008006002

After the adjustment, brake should apply
fully when

lever

is

approximatively

13

mm

(1/2")

from handlebar grip. If not, do not

tamper with the

brake,

contact the

dealer.

approx.

A008006002

Spark

Plugs

Disconnect the spark plug wires and re-
move the spark plugs.

Check the condition

of

the plugs.

• A brownish tip reflects

ideal

conditions.

(Carburetor adjustments, spark plug

heat range, etc., are correct).

• A black insulator tip indicates fouling
caused

by:

carburetor idle speed mix-

ture and/or high

speed

mixture too rich,

incorrect fuel mixture

ratio,

wrong type
of spark plug (heat range), or excessive
idling.

• A light grey insulator tip indicates a
lean mixture caused

by:

carburetor

high speed mixture adjusted too lean,

wrong spark plug heat

range,

incorrect
fuel mixture ratio, or a leaking seal or
gasket.

e e

.

:.

.

~-

..

:·.~·=···<

·

..........

···

.

Overheated Fouled

(light grey) Normal

lblackl

(brownish)

A000004010

'W'

CAUTION:

If

spark

plug

condition

T

is

not ideal, contact your autho-

rized dealer.

Check spark plug gap using a wire feeler
gauge. It should

be

0.4

mm

(.016").

Reinstall spark plugs and connect wires.

-------------27

Battery

(Electric

starting)

Check electrolyte

level

weekly. Electrolyte

level

must

be

at upper

level

line

on

battery

casing.

A009004011

If necessary add distilled water. Battery
connections

must

also

be

free

of

cor-

rosion. If cleaning

is

necessary remove
corrosion using a stiff brush then clean
with a solution of baking soda and water.

Rinse and dry well.

'W" CAUTION: Do not allow cleaning

T solution

to

enter battery. It will
destroy the chemical properties of the
electrolyte.

After reconnecting battery, coat battery
terminals and connectors with petroleum

jelly to prevent corrosion. Check that bat-

tery

is

well secured and that battery vent

tube

is

not

kinked or blocked.

28-------------------------

•

WARNING: Vent tube must be

free

and

open.

If not,

it

will restrict

ventilation and create a gas accumula-

tion

that

could result

in

an

explosion.

Avoid skin contact

with

electrolyte.

'W" CAUTION: Prior

to

charging the

T battery, always remove it from the

vehicle to prevent electrolyte spillage.

'W" CAUTION:

Be

careful not to

ground

T positive terminal with the

chassis.
Always disconnect black negative cable
first .

•

WARNING: Gases given

off

by a

battery being charged are highly

explosive. Always charge

in

a well ven-
tilated area. Keep battery away from
cigarettes or open flames. Avoid skin
contact

with

electrolyte.

0

NOTE: Always keep battery fully

charged.

(To

charge, refer to

"Bat-

tery"

in

"Storage"

section).

Suspension

Condition

Visually inspect all suspension

compo-
nents including slider shoes, springs,
wheels, etc.

0

NOTE:

During normal driving, snow

will

act

as

a lubricant and coolant

for

the slider shoes. Extensive riding on
ice or sanded snow, will create excessive
heat build-up and cause premature slider
shoe wear.

Stopper

Strap

Condition

Inspect strap

for

wear and cracks, bolt

and

nut

for

tightness. If loose inspect

holes for deformation. Replace

as

requir-

ed. Torque

nut

to

10

N•m

(89 lbf•in).

Suspension

Adjustment

Adjuster

blocks

The suspension

is

adjustable. The

front

adjustment for surface condition, the

rear
for driver's weight. Use the special key
located

in

tool box

A019001002

Safari

377/377E

Adjuster blocks

Safari

503

Adjuster blocks

A021000001

A021005001

When the front adjuster blocks

are

at the

lowest elevation more weight

is

distributed

on the skis.
At the highest position the weight

is

trans-

ferred from the skis to the track. The rear

adjuster blocks should

be

adjusted to suit

the driver's preference.

0

NOTE:

For

deep snow condition or

hill climbing, it

is

recommended to

place the

front

adjuster blocks on the
lowest position and set stopper strap to
the shortest position.

'W'

CAUTION: Always turn the left

T

side

adjuster

blocks

in

a clockwise

direction,

the

right

side

blocks

in a coun-

terclockwise

direction.

Left

and

right

ad-

juster

blocks

of

each

adjustment must

always

be

set at the same elevation.

-------------------------29

Stopper

strap

The function

of

the suspension stopper

strap

is

to control the transfer

of

vehicle

weight

during acceleration. The longer

the

belt,

the more the weight will

be

trans-
ferred to the track to provide a better trac-
tion. The shorter the belt, the lesser the
weight transferred to the track, thus main-
taining a more positive direction. Adjusting
holes

on

the stopper strap allow to adjust
it according to driver's requirements, field
and or

snow

conditions.

Safari

377/377E

For

normal use locate bolt through

2nd

hole and its corresponding hole

"B".

HOLE

CORRESPONDING

NUMBER

HOLE

1

''A''

2

''B/'

3

''C''

1"

hole

30

________________________

__

Safari

503

For

normal

use,

insert bolt through strap

holes

as

shown.

Torque to

10

N•m

189

lbf•inl

~

/r

1"hole

.---"

5th

hole

A021005002

•

WARNING: Always torque the nut
to

10

N•m

(89

lbf•in).

Track

Condition

Lift the rear

of

the vehicle and support

it

off

the ground. With the engine

OFF,

rotate the track

by

hand,

and

inspect con-
dition. If worn or cut, or if track fibers
are exposed, or if missing or defective
inserts or guides are noted;

contact

an

authorized dealer.

•

WARNING:

Do

not operate a

snowmobile

with

a cut, torn or

damaged track.

Track

Tension and

Alignment

Tension:

Lift the rear

of

vehicle and support

with
a mechanical stand. Allow the suspension
to extend normally and check gap half-
way

of

slider shoe. The gap should

be

13

mm

(1/2")

between the slider shoe

and the bottom inside

of

the track. If the

track tension

is

too loose, the track will

have a tendency to thump.

(TYPICAL)----------

13

mm

(112")

A009005004

-..F

CAUTION:

Too

much tension will

T result

in

power

loss

and excessive

stresses

on

suspension components.

If necessary to adjust; loosen the

rear

idler
wheel retaining screw and the adjuster
bolt lock nut; then loosen or tighten the
adjuster bolts located on the inner side

of

the rear idler wheels. If correct ten-

sion

is

unattainable, contact

an

authorized

dealer.

Retaining screw

loosen

A009005005

Adjuster bolt

0

NOTE:

Track

tension and alignment

are

inter-related.

Do

not adjust one

without

the other.

Alignment

Start the engine and accelerate slightly

so

that track turns slowly. Check

that

the

track

is

well centered; equal distance on

both sides between edges of track guides

and slider shoes.

A001005011

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

31

•

WARNING: Before checking track
alignment, ensure

that

the track

is

free

of

all

particles which could be

thrown out while track

is

rotating. Keep

hands, tools,

feet

and clothing clear of

track.

Ensure

no-one

is

standing

in

close

proximity to

the

vehicle.

To

correct, stop

the

engine, loosen the

rear idler wheels retaining screws then
loosen the lock nuts and tighten the ad-
juster bolt on side where the slider shoe
is

the farthest from the track insert

guides.

A001005011

Tighten lock nuts and the idler wheel

re-

taining screws.

32---------------------------

Drive

Pulley

Safari

377/377E

Inspect the Dura/on 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

(

1/8").

If

so,

contact

the dealer.

A007003004

Mark
reference
point on
both halves

Maximum

free-play

3 mm

(1/8")

•

WARNING: The

drive

pulley

should

be inspected by an authorized

dealer

at

least annually.

Safari

503

This vehicle

is

equipped

with

the TRA

drive pulley

(Total

Range

Adjustable). This

pulley includes three

(3)

calibration screws

that

provide the opportunity to perform

minor adjustments to the clutch

in

order
to keep the engine at it's peak power
R.P.M.,

thereby maintaining optimal ve-

hicle performance.

The clutch

is

factory adjusted to position

four (4) to provide the best performance

under most riding conditions at

sea

level.

However certain conditions, such

as

deep
snow, high altitude, pulling a load, etc.,
may allow the engine to run below

it's

peak power R.PM. at wide open throttle

thus decreasing the vehicle performance.
Should such conditions

be

encountered

the calibration screws can then

be

reset
to allow the engine to operate at it's peak
power

R.P.M.

(given

in

technical data

as

max.

HP

R.PM.).

The adjustment may

be

set at

any

one of

six (6) positions, numbered from 1 to

6.

Note that for casting purposes numeral

one

(1)

appears

as

a dot. Each

of

these

positions

provides

an

increase

or

decrease,

in numerical order,

of

the engine speed

by

approximately

200

R.PM.
Example:
(Vehicle at

sea

level during fuil

acceleration

in

normal conditions).

ADJUSTMENT

ENGINE

SCREW SPEED

Position no 3

6550

R.P.M.

Position no 4

6750

R.PM.

(standard position)

Position no 5

6950

R.PM.

Positions three (3) and five (5) allow the
engine to run below or above it's power
peak. Reducing vehicle performance.

0

NOTE:

One

must bear

in

mind that

the purpose of these calibration

screws

is

to maintain the engine R.PM.

at it's

peak

power,

a lower or upper

speed

will actually result

in

less vehicle per-

formance.

The

point of maximum

power,

in

the 1988

Safari 503, occurs at about

6750

R.PM.,
while the maximum permissible engine
speed (red line)

is

7500

R.P.M.

Adjustment

Procedure

To

change the calibration screw position;

back

off

its locking

nut

and change the

position of the calibration screw

head.

The

notch

on

the screw

head

must

be

aligned

with

the desired numeral position.

See

illustration.

0

A016003015

...,.

CAUTION: Back off the calibration

T screw locking nut only far enough

to

allow a change of position of the

screw head.

Never

attempt to remove

the locking nut

or

the calibration screw.

Make

sure

the adjustment

is

set at the

same

position for

all

three (3) screws.

•

WARNING: Always retorque lock-
ing nut

to

10

N•m

(89

lbf•in).

•

WARNING: The drive pulley must

be

inspected and cleaned

by

an

authorized dealer at least annually.

-------------------------33

Steering

Mechanism

Inspect the steering mechanism for tight-
ness

of

components (steering arms, tie

rods,

ball

joints, spring coupler bolts,

etc.).

If necessary, replace or retighten .

•

WARNING: Check the condition
of the skis and the

ski

runners.

Replace if more than half worn.

Torque steering arm bolts

as

illustrated

below making sure to keep a

minimum

gap

of 4 mm

(5/32")

between lugs.

4 mm

(5/32")

A009006003

26

N•m

(19

lbf•ft)

Steering

Adjustment

Skis should have a toe

out

of 3 mm

(1/8").

To

check, measure the distance

between each

ski

at the front and rear

of

the leaf springs.

The

front distance should

be

3 mm

(1/8")

more than the

rear

when

the handlebar

is

horizontal.

IMPORTANT: Close the front

of

the skis

manually to eliminate all slack from the

steering mechanism.

-------------~~~

3 mm

(1/8"):

toe

out

1

A009006004

34--------------------------

If adjustment

is

required:

Loosen the lock nuts

of

the longest tie

rod.

Turn

the tie rod manually until the

skis

are

properly aligned. Firmly retighten

the lock nuts.
The handlebar should also

be

horizon-

tal when the skis

are

pointed toward the

front.

To

adjust:

Loosen the lock nuts

of

the shortest tie

rod.

Turn

the tie rod manually until the

handlebar

is

horizontal. Retighten the lock

nuts firmly.

•

WARNING: The maximum

ball

joint external threaded length not

engaged

in

the tie

rod

end must not

exceed 17 mm

(43/64").

Torque lock

nut to

20 N •m

(15

lbf•ft).

Torque to

-----.D,.....-2-0_N_·-tm~

H

17 mm

(43/64

in)

A007006004

maximum

•

WARNING: The

ball

joint socket

must

run

parallel with the steer-

ing

arm.

The tie

rod

must

be

restrained

when tightening the tie

rod

end lock

nuts.

Muffler

Attachment

The engine/exhaust system parts

are

vital
toward efficient muffler function. Check
all

attachments and muffler

ball

joint.

Re-
place the springs and/or tighten if neces-
sary .

..r

CAUTION: Do not operate vehicle

T with muffler disconnected other-

wise serious engine damage will occur.

Engine

Head

Nuts

With the engine cold, check that the en-
gine head nuts

are

tight and equally tor-

qued to

12

N•m

(15

lbf•ft).

Respect tightening sequence

as

follows:

IMPORTANT: The engine head

nut

tor-

que should

be

checked after the first five

(

5)

hours

of

operation.

Engine

Mount

Nuts

Check the engine

mount

nuts for tight-

ness. Torque to

38

N•m

(28

lbf•ft)

if

necessary.

Carburetor

Adjustment

..r

CAUTION: Never operate your

T snowmobile

with

the

air intake
silencer disconnected. Serious engine
damage will occur if this notice

is

dis-

regarded.

A002002009

A)

Air

Screw

Adjustment

Completely close the air screw (until a
slight seating resistance

is

felt) then back

off

screw

as

follows:

Safari

377

/377E: 1

112

turn

Safari

503: 1 turn

B)

Idle

Speed

Adjustment

Turn

the

idle

speed screw clockwise until

it contacts the throttle slide then continue

turning

two

(2) additional turns. This will
provide a preliminary idle speed setting.
Start engine and allow it to warm then

adjust the idle

speed

to 1800-2000

R.PM.

by

turning the idle

speed

screw clockwise

or

counterclockwise .

..r

CAUTION: Do not attempt

to

set

T

the

idle speed by using

the

air

screw. Severe engine damage can

oc-

cur.

If

idle

speed

is

unattainable contact

your authorized dealer.

High

Altitude

Kit

Snowmobiles used

in

high altitude areas

(1900 m

(4000

ft) and up) are subject-

ed to lose power, about

3%

per

470

m

(1000 ft)

of

elevation increase. The car-

buretor and power train

have

to

be

recal-
ibrated to meet those particular require-
ments. Ask your authorized dealer for
more information

on

high altitude kit

avail-

ability.

-------------35

Oil

Injection

System

Injection

Oil Filter

Condition

Inspect oil filter at least once a month.
Insure that filter

is

not obstructed

by

for-

eign particles; if

so,

see

an

authorized

dealer.

'1IIIF

CAUTION:

An

obstructed injec-

T tion

oil

filter will cause

oil

starva-

tion resulting

in

serious engine dam-

age.

0

NOTE: After a storage period, it

is

important that the dealer replace

the injection oil filter and that the oil flow
of the injection pump

be

checked.

Injection

Pump

Adjustment

Proper oil injection pump adjustment

is

very important. Any delay

in

the opening

of

the pump can result

in

serious engine

damage.

'1IIIF

CAUTION: The carburetor must

T

be

adjusted before adjusting the

oil

injection

pump.

Make

sure

idle

speed

es

1800-2000

R.P.M.

To

check adjustment Eliminate the throt-

tle cable free-play

by

pressing the throttle

lever until a slight resistance

is

felt then

hold

in

place. The aligning marks on the
pump casting and lever must align per-
fectly.

If not, contact

an

authorized

dealer.

36--------------------------

0

NOTE: Injection pump should

be

adjusted

by

an

authorized dealer.

Fan

Belt

Inspect belt for cracks, uneven

wear,

etc.

Check fan belt tension, 9-10 mm

(3/8")

deflection should exist.

A009002019

If belt seems damaged or if tension

is
incorrect, contact an authorized dealer
immediately.

•

WARNING: If fan protector

is

re-

moved, always reinstall after ser-

vicing.

Headlamp

Beam

Aiming

The angle of the headlamp beam has
been

pre-adjusted prior

to

delivery.

Should

a readjustment

is

necessary, place the

vehicle

on

a flat surface

381

em

(12'

6")

from a wall or screen.
With the suspension correctly adjusted,

the rider seated on the vehicle and the
high beam

ON

check that the center

of

high intensity zone of high beam

is

25
mm (1") below horizontal line of head-
lamp height.

Headlamp center line

C:$!

t

JJ

!oo

£1

A002004010

~

381

em (12'

6")

25 mm 11")

below headlamp center

Headlamp horizontal

center line

Light beam center

25 mm 11")

A002004007

To

adjust, remove the four (4) caps, turn
upper or lower adjusting screws to ob-
tain desired beam position.

Bulb

Replacement

If the headlamp bulb

is

burnt, tilt hood,

unplug the connector from the

head

lamp.
Remove the rubber boot and unfasten
bulb retainer clips. Detach the bulb and
replace.

'W'

CAUTION: Never touch glass por-

T tion of

an

halogen bulb with bare

fingers, it shortens it's operating life.

If

by

mistake glass

is

touched clean it

with a glass cleaner that will not leave

a film

on

the bulb.

A002004009

If taillight bulb

is

burnt, expose the bulb

by

removing the

red

plastic lens.

To

re-

move, unfasten the

two

(2) screws.

•

WARNING: Always check light
operation after bulb replacement.

-------------------------37

General

Inspection

Check the electrical wiring and

compo-

nents,

retighten loose connections. Check
for stripped wires or damaged insulation.
Thoroughly inspect the vehicle and tight-
en

loose bolts, nuts and linkage. Inspect

skis and ski runners for wear.

STORAGE

____________________

_

It

is

during summer, or when a vehicle

is

not

in

use for any length

of

time that

proper storage

is

a necessity. Storage

of

the snowmobile during long periods

of
inactivity consists of checking and replac-
ing

missing, broken or worn parts, proper
lubrication and treatment to insure that
parts do not become rusted; cleaning
items such

as

carburetor, to prevent gum
and varnish formation within the carbu-
retor,

and

in

general, preparing the vehicle

so

that when the time comes to use the

snowmobile again it will

be

in

top con-

dition .

•

WARNING: Only perform

such

pro-

cedures

as

detailed

in

this manual.

It

is

recommended

that

dealer assis-

tance

be

periodically obtained

on

other

components/systems not covered

in
this manual. Unless otherwise speci-
fied, engine should

be

turned

OFF.

For

all

lubrication and maintenance proce-

dures.

Track

Inspect the track for wear, cuts, missing

track guides and broken rods. Make any

necessary replacement.

•

WARNING:

Do

not

operate a

snowmobile

with

a cut, torn or

damaged track.

Lift the rear

of

vehicle until track

is

clear

of

the ground then support with a brace

or

trestle.

The

snowmobile should

be

stor-

ed

in

such a way that the track does not

stay

in

contact with the cement floor or

bare ground.

38-------------------------

0

NOTE: The track should

be

rotated

periodically,

(every

forty (40)

days).

Do

not

release track tension.

.,..-

CAUTION:

To

prevent track dam-

T age, temperature

in

the storage

area must not exceed

38°C

(100°F).

Suspension

Remove any dirt or rust. Lubricate sus-
pension. Wipe off surplus. (Replace worn
slider shoes).

Skis

Wash or brush

all

dirt or rust accumula-
tion from the skis and springs. Lubricate
steering system.

•

WARNING:

Check

the condition

of the skis, ski runners and leaf

springs. Replace if weak

or

worn more

than half.

Controls

Inspect

all

components for tightness,
steering arm locking bolts, tie rods, ball
joints, etc.). Tighten if necessary.

Oil

mov-

ing joints

of

the brake mechanism.

•

WARNING: Do not lubricate

the

throttle and/or brake cables and

housings. Avoid getting

oil

on

the brake

pads.

Coat

all

electrical connections and swit-

ches

with

a greaseless metal protector.

If unavailable, use petroleum jelly.

Chain

case

Drain the chaincase and refill to proper
level, using fresh chaincase oil

(PIN

413

8019 00-250

ml

(9

oz)).

To

drain, remove

the chaincase cover.

0

NOTE: Chaincase oil capacity

is

about

200

ml (7 oz).

Drive

Pulley

Inspection and cleaning must

be

per-

formed

by

the dealer at the end

of

each

season.

Engine

and

Primer

Lubrication

Engine internal parts must

be

lubricated
to protect them from possible rust for-
mation during the storage period.

To

perform the storage procedures (en-

gine and primer valve) proceed

as

fol-

lows:

1.

Lift the rear of the vehicle and support
it

off

the ground.

•

WARNING:

Ensure the track

is

free of

all

particles which could

be

thrown out while it

is

rotating. Keep

hands, tools, feet and clothing clear of

track.

Ensure

no

one

is

standing

in

close

proximity

to

the vehicle.

2.

Start the engine and allow it to run
at idle speed until the engine reaches
its operational temperature.

3.

Stop the engine.

4.

Disconnect the inlet primer hose from

the primer valve.

A002002009

Inlet (Oblique

hose coupling)

Outlet

hose

(Straight

coupling)

5.

Plug

inlet primer hose to prevent gas-

oline from draining.

6.

Using

an

appropriate hose, connect

one end

of

the hose to the inlet

of
the primer valve and place the other
end

in

a Bombardier Snowmobile In-

jection

Oil

container.

7.

Activate the primer

in

order to fill it

with

oil.

8.

Restart engine and run at idle.

9.

Using the primer

valve,

inject

oil

until

the engine dies or until a sufficient

quantity

of

oil has entered the en-

gine (approximately twenty-five (25)

complete strokes

of

the primer).

10. The engine stopped, remove the
spark plugs and pour approximately
85

ml (3 imp.

oz)

of

oil into the cyl-

inders.

11.

Crank the engine to allow the crank-

shaft to turn two

(2)

or three

(3)

revo-

lutions.

12. Reinstall the spark plugs

and

the inlet

primer hose.

Do not

run

engine during storage

period.

-------------------------39

Fuel

Tank

and

Carburetor

Remove the cap then using a syphon,
remove the gasoline from tank .

•

WARNING: Gasoline

is

flammable

and explosive under certain con-

ditions.

Always

manipulate

in

a well

ventilated area. Do not smoke

or

allow

open flames or sparks

in

the vicinity.

Carburetor must

be

dried out completely
to prevent gum formation during the stor-
age period.

Once the

fuel

tank

is

emptied,

remove

the

float chamber drain plug from carburetor.

Drain carburetor.

A002002010

Plug

Reinstall plug.

Check

all

fuel lines, replace if necessary.

Battery

(Electric

Starting)

1.

Disconnect the battery cables and

re-

move the battery retainer cover.

.r

CAUTION:

Be

careful

not

to

ground

T positive terminal with the chassis.

Always disconnect black negative cable
first.

40-------------------------

A007004004

Red lead

<f)

2.

Remove

the battery vent tube from the

vent hole.

3.

Lift out the battery.

4. Clean outside surface of battery with
solution of baking

soda

and water.

Re-

move

all

deposits from posts then

rinse

with

clear tap water .

.r

CAUTION: Do not allow cleaning

T solution

to

enter battery interior

since it will destroy

the

electrolyte.

5.

Check electrolyte

level.

Refill if neces-
sary with distilled water. Fully charge
battery at a maximum rate of

2.0

A.

.r

CAUTION: Prior

to

charging

the

T battery, always remove it from the

vehicle

to

prevent electrolyte spillage.

•

WARNING: Gases given

off

by

a

battery being charged are

highly

explosive. Always charge

in

a well ven-
tilated area. Keep battery away from
cigarettes or open flames. Avoid skin
contact

with

electrolyte.

6.

Coat electrical connections and swit-
ches

with a

greaseless

metal protector,

if unavailable, use petroleum jelly.

7.

Store unit

in

a cool, dry place.

0

NOTE:

To

prevent battery from dis-

charging, store it

on

a wooden shelf
away from moisture. A stored battery
must

be

recharged at least every forty

(40) days.

Chassis

Clean the vehicle thoroughly, removing
all dirt and grease accumulation.

..r

CAUTION: Plastic alloy com po-

T nents such

as

fuel tank, wind-
shield, controls, etc., can be cleaned
using

mild detergents

or

isopropyl alco-

hol

and a soft clean cloth. Never clean
plastic parts with strong detergent, de-
greasing agent, paint thinner, acetone,
etc.

Do

not apply isopropyl alcohol di-

rectly

on

decals.

Inspect the hood and repair any damage.

Clean the frame.

For

the unpainted aluminum portion use
only "Aluminum cleaner" and follow ins-
tructions on the container.

Touch up

all

metal spots where paint has

been scratched off. Spray

all

metal parts
with metal protector. Wax the hood and
the painted portion of the frame for better
protection.

0

NOTE: Apply wax

on

glossy finish

only.

Protect the vehicle with a cover
to prevent dust accumulation during stor-
age.

..r

CAUTION: If for some reason the

T snowmobile

has

to

be

store:! out-

side it

is

necessary to cover it

with

an
opaque tarpaulin. This caution will pre-
vent

the

sun rays and

the

grime from

affecting the plastic components and

the vehicle finish.

General

Inspection

Check the electrical wiring and

compo-
nents, retighten loose connections. Check
for stripped wires or damaged insulation.
Thoroughly inspect the vehicle and tight-
en

loose bolts, nuts and linkage.

0

NOTE:

Leave

the drive belt

off

the

pulleys for the entire storage period.

Suspension

Stopper

Strap

Replace annually and/or

as

stopper strap

condition dictates.

Torque

nut to 10

N•m

(89 lbf•in).

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

41

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 dealer. If these services

are

performed

as

suggested, your vehicle

will give many hours

of

fun.

IMPORTANT: Observe all Warnings and
Cautions mentioned throughout this man-
ual which are pertinent to the item being
checked.

When

component

conditions

seem

less

than satisfactory, replace with
genuine Bombardier parts or suitable
equivalents.

PRE-SEASON

TO

BE

PERFORMED

BY

DEALER

•

PREPARATION

CHART

TO

BE

PERFORMED

BY

THE OWNER

0

Reinstall

battery

(electric

starting)

0

Change spark

plugs*

0

Check

chaincase oil level

0

Replace fuel

filter

(located inside fuel

tank)

0

Check

track

tension

and

alignment

0

Lubricate suspension

0

Inspect

drive

belt

and install

0

Check

steering

alignment

and ski runner

condition

0

Inspect

condition

of

starting

rope

0

Check

tightness

of

all bolts,

nuts

and linkage

0

Refill gas

tank

0

Check

throttle

cable

for

free operation

•

Check

electrical

wiring

0

Inspect

seals

for

possible

cuts

or

leaks

0

Replace

injection

oil

filter

•

Refill injection oil

tank

•

Inspect

brake

condition

and operation

0

Set

engine

timing

•

Check

pulleys,

verify

components

and clean,

lubricate

driven pulley

•

Adjust

carburetor

•

Adjust

oil

injection

pump

•

0

*NOTE: Before installing new spark plugs, it

is

suggested to burn the excess

storage oil

by

starting the engine, using the old spark plugs.

T

CAUTION:

Only

perform

this

procedure

in a

well

ventilated

area.

42

________________________

__

TROUBLE

SHOOTING

__________________________

__

0

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

1.

No

fuel

to

the

engine

Check the tank level. Check tor pos-

fails

to

start

or

starts

sible clogging

of

fuel line, item 4.

with

difficulty.

2.

Flooded engine

Remove

wet

spark plug, turn igni-

tion to

OFF

and crank engine sever-

al

times. Install clean dry spark plug.
Start engine following usual starting
procedure. If engine continues to
flood, see your authorized dealer.

3.

Spark

plug/ignition

Check

that

emergency

cut-out

switch

is

at the upper position (ON)

and the tether cut-out switch cap

is

snapped over the receptacle.

Check for fouled or defective spark
plug. Disconnect spark plug wire,
unscrew plug and remove from cyl-
inder head.

Reconnect wire and

ground exposed

plug on engine

cowl,

being careful to hold

away

from spark plug hole. Follow en-

gine starting procedure and check
for spark.

If no sparks appear, re-
place spark plug. If trouble persists,
contact

your authorized dealer.

4.

Clogged

fuel

line Change fuel filter if necessary. Check

(water

or

dirt)

condition and connections

of

fuel

lines. Check the cleanliness

of

fuel

tank.

5.

Carburetor

Contact your authorized dealer for
repair.

6. Too

much

oil in

fuel

See

an

authorized dealer for oil in-

jection

pump

adjustment.

7. Engine

timing

Engine timing may be incorrect or

out of adjustment. Contact your au-
thorized dealer.

8. Engine

compression

Running

with

a

lean fuel mixture
may produce excessive engine wear
resulting

in

poor engine compres-

sion.

If

this occurs, contact your au-

thorized dealer at once.

--------------------------43

SYMPTOMS

POSSIBLE

CAUSES

WHAT

TO

DO

Engine does not turn

1.

Seized engine

In

the case

of

a seized engine con-

manually.

tact

your authorized dealer.

Engine lacks

1.

Fouled

or

defective spark

Check item 3 of

"Engine

turns over

acceleration

or

power. plug

but fails to start

or

starts

with

dif-

ficulty".

2.

Clogged fuel line

Check fuel line condition.

(See item

(water

or

dirt)

4

of

"Engine

turns over but fails to

start

or

starts

with

difficulty").

3. Carburetor

Contact your authorized dealer.

4. Ignition

First check item 3

of

"Engine

turns

over but fails

to

start or starts

with
difficulty". If the ignition system still
seems faulty,

contact

your autho-

rized dealer.

5.

Engine

If unable to

locate specific sym-

ptoms,

contact

your

authorized

dealer.

Engine continually

1.

Faulty spark plug

Check item 3 of

"Engine

turns over

backfires.

but fails to start

or

starts

with

dif-

ficulty".

2. Overheated

Carburetor set too lean, contact your
authorized dealer.

3.

Engine timing incorrectly set Contact your authorized dealer.

Snowmobile cannot

1.

Drive Belt Check for damaged or

worn

drive

reach full speed. belt. Replace if necessary.

2.

Incorrect track adjustment

Check track tension and alignment.
Readjust to specifications. (See
Maintenance Section).

3. Engine

Check item 1 to 5

of

"Engine

lacks

acceleration or

power".

4. Pulley misaligned Contact your authorized dealer.

44----------------------

TOOLS

______________________

__

As

standard equipment each new snowmobile

is

supplied

with

basic tools such

as

screwdriver, wrenches, emergency starter rope, etc.

Standard

Tools

A

6@@JD

$

G

A001001038

A.

Screwdriver

B.

Socket 1 0/13

mm

C.

Open end

wrench

10/13

mm

D.

Socket

wrench

handle

E.

Starter

rope

8

0

F

c

D

H

I

~

F.

Socket

21/26

mm

G.

Hexagonal

wrench

H.

Starter

grip

I.

Emergency

starter

clip

(Safari

503

only)

-------------45

SPECIFICATIONS

ENGINE

Type
No

of

cylinders

Bore
Stroke
Displacement
Compression

ratio

(corrected)

Maximum

horsepower

R.P.M. *

Carburetor

type

Carburetor

adjustment:

-air

screw

- idle speed

Fan

belt

deflection

Torque:

- engine head

nuts

-

crankcase

nuts

-

magneto

ring

nut

-

fan

nut

-

crankcase

engine

support

nuts

-

exhaust

manifold

bolts

- electrical

starter

bolts

CHASSIS

Overall

length

Overall

width

Overall

height

Ski

stance

(center

to

center)

Ski

alignment

(toe

out)

Torque:

- steering

arm/ski

leg

bolt

- steering

column/handlebar
Weight
Bearing area
Ground pressure

BRAKE

Type
Lining

minimum

thickness

Control

lever

adjustment

N.A.:

Not

applicable

SAFARI

377

377

2

62

mm

(2.441

")

61

mm

(2.402")

368.3

cm3

(22.48

in3)

6.9:1
7000

R.P.M.

Mikuni

VM

34-309

1 1/2

turn

1800-2000

R.P.M.

9-10

mm

(3/8")

M8:

21

N•m

(15

lbf•ft)

M6:

9

N•m

(80

lbf•in)

M22:

85

N•m

(63

lbf•ft)

M16:

65

N•m

(48

lbf•ft)

M10:

38

N•m

(28

lbf•ft)

M8:

21

N•m

(15

lbf•ft)

N.A.

266.7

em

(105")

96.5

em

(38")

106.4

em

(42")

81.9

em

(32.25")

3

mm

(1/8")

50

N•m

(37

lbf•ft)

26N•m

(191bf•ft)

179.8

kg

(396

lb)

7065

cm2 (

1030

in2)

2.54

kPa

(.362

lb/in2)

SAFARI

377E

377

2

62

mm

(2.441

")

61

mm

(2.402")

368.3

cm3

(22.48

in3)

6.9:1
7000

R.P.M.

Mikuni

VM

34-309

1 1/2

turn

1800-2000

R.P.M.

9-10

mm

(3/8")

M8:

21

N•m

(15

lbf•ft)

M6:

9

N•m

(80

lbf•in)

M22:

85

N•m

(63

lbf•ft)

M

16:

65

N•m

(48

lbf•ft)

M

10:

38

N•m

(28

lbf•ft)

M8:

21

N•m

( 1 5

lbf•ft)

M5:

4

N•m

( 3

lbf•ft)

266.7

em

(105")

96.5

em

(38")

106.4

em

(42")

81.9

em

(32.25")

3

mm

(1/8")

50

N•m

(37

lbf•ft)

26N•m

(191bf•ft)

188.9

kg

(416

lb)

7065

cm2 (1

030

in2)

2.67

kPa

(.378

lb/in2)

Disc,

self-adjusting.

Fixed pad

must

projects 1 mm

( 1

/32")

minimum

from

caliber.

13

mm

( 1

/2")

minimum

distance

from

handlebar

grip

when

fully

applied.

*The maximum horse R.P.M. is applicable

with

engine on the vehicle. It

may

be different under certain circumstances

and

Bombardier

Inc. reserves

the

right

to

modify

it

without

any

obligation.

46

__________________________

_

POWER

TRAIN

Track:

-width

-

length

-

tension

-

alignment

Standard

gear

ratio

Drive belt:

-number

-

maximum

width

-

minimum

width

Chaincase oil

ELECTRICAL

Lighting

system

(output)

Bulb:

- headlamp

-

tail/stop

-

speedometer

-

tachometer

-

electric

fuel

level gauge

Fuse:

-

starter

solenoid

Spark plug:

-type

- gap

Ignition

timing:

-

timing

mark

(B.T.D.C.)

-

stroboscopic

timing

FUEL

Gas

type

Fuel

tank

capacity:

-

Sl

-Imp.

-u.s.

Injection

oil

Tank

capacity:

-

Sl

-Imp.

-u.s.

Hal.: Halogen
N.A.:

Not

applicable

SAFARI

377

41.9

em

(16

1/2")

290cm

(114")

SAFARI

377E

41.9

em

(16

1/2")

290

em

(114")

13

mm

(1/2")

gap

between

slider shoe and

bottom

inside

of

track.

Equal

distance

between

edges

of

track

guides

and slider shoes.

16/34

414

5233

00

34.9

mm

(1

3/8")

31.7

mm

(1

1/4")

200

ml (7 oz)

12V

160W

60/60

w

5/21 w

5W
N.A.
2W

N.A.

NGK BR9ES

0.4

mm

(0.016")

2.31

mm

(.091")

6000

R.P.M.

Regular leaded.

28.6

liters

6.3

gallons

7.6

gallons

16/34

414

5233

00

34.9

mm

(1

3/8")

31.7

mm

(1

1/4")

200

ml

(7 oz)

12V160W

60/60

w

5/21 w

5W
N.A.
2W

30

A

NGK BR9ES

0.4

mm

(0.016")

2.31

mm

(.091")

6000

R.P.M.

Regular leaded.

28.6

liters

6.3

gallons

7.6

gallons

Bombardier

snowmobile

injection

oil.

2.6
92
88

liters

oz
oz

2.6

liters

92

oz

88

oz

Bombardier

Inc. reserves

the

right

to

make

changes in design

and

specifications

and/or

to

make

additions

to,

or

improvements

in

its

product

whithout

imposing

any

obligation

upon

itself

to

install

them

on

its

products

previously

manufactured.

-------------47

ENGINE

Type

No

of

cylinders

Bore
Stroke
Displacement
Compression

ratio

(corrected)

Maximum

horsepower

R.P.M. •

Carburetor

type

Carburetor

adjustment:

-air

screw

- idle speed

Fan

belt

deflection

Torque:

- engine head

nuts

-

crankcase

nuts

-

magneto

ring

nut

-

fan

nut

-

crankcase

engine

support

nuts

-

exhaust

manifold

bolts

-

electrical

starter

bolts

CHASSIS

Overall

length

Overall

width

Overall

height

Ski

stance

(center

to

center)

Ski

alignment

(toe

out)

Torque:

-

steering

arm/ski

leg

bolt

- steering

column/handlebar
Weight
Bearing area

Ground pressure

BRAKE

Type
Lining

minimum

thickness

Control

lever

adjustment

N.A.:

Not

applicable

SAFARI

503

503

2

72

mm

(2.835")

61

mm

(2.402")

496.7

cm3

(30.27

in3)

6.2:1
6750

R.P.M.

Mikuni

VM

34-363

1 1/2

turn

1800-2000

R.P.M.

9-10

mm

(3/8")

M8:

21

N•m

(15

lbf•ft)

M6:

9

N•m

(80

lbf•in)

M8:

21

N•m

(151bf•ft)

M22:

85

N•m

(63

lbf•ft)

M

16:

65

N•m

(48

lbf•ft)

M10:

38

N•m

(28

lbf•ft)

M8:

21

N•m

( 1 5

lbf•ft)

N.A.

302.3

em

(119")

96.5

em

(38")

120.6

em

(47.5")

81.9

em

(32.25")

3mm

(1/8")

50

N•m

(37

lbf•ft)

26

N•m

(

19

lbf•ft)

197.8kg

(436

lb)

7910

cm

2

(1227

in2)

2.50

kPa

(.355

lb/in2)

Disc,

self-adjusting.

Fixed pad

must

projects 1 mm

(1/32")

minimum

from

caliber.

13

mm

(1/2")

minimum

distance

from

handlebar

grip

when

fully

applied.

*The maximum horse R.P.M. is applicable

with

engine on the vehicle. It

may

be different under certain circumstances

and

Bombardier

Inc. reserves

the

right

to

modify

it

without

any

obligation.

48

______________________

__

POWER

TRAIN

Track:

-width

-

length

-

tension

-

alignment

Standard

gear

ratio

Drive belt:

-number

-

maximum

width

-

minimum

width

Chaincase oil

ELECTRICAL

Lighting

system

(output)

Bulb:

-

headlamp

-

tail/stop

-

speedometer

-

tachometer

-

electric

fuel

lever

gauge

Spark

plug:

-type

- gap

Ignition

timing:

-

timing

mark

(B.T.D.C.)

-

stroboscopic

timing

FUEL

Gas

type

Fuel

tank

capacity:

- Sl

-Imp.

-u.s.

Injection

oil

Tank

capacity:

- Sl

-Imp.

-u.s.

Hal.: Halogen
N.A.:

Not

applicable

SAFARI

503

41.9

em

(16

1/2")

353

em (

139"1

13

mm

(1/2")

gap

between

slider shoe and

bottom

inside

of

track.

Equal

distance

between

edges

of

track

guides

and slider shoes.
14/39

414

6175

00

34.g

mm

(1

3/8")

31.7

mm

(1

1/4")

200

ml

(7

ozl

12V160W

60/55

W.

HAL.

5/21 w

5W
N.A.
N.A.

NGK BR9ES

0.4

mm

(0.016"1

2.29

mm

(.090"1

(20°)

6000

R.P.M.

Regular leaded.

28.6

liters

6.3

gallons

7.6

gallons

Bombardier

snowmobile

injection

oil.

2.6

liters

92

oz

88

oz

Bombardier

Inc.

reserves

the

right

to

make

changes

in

design

and

specifications

and/or

to

make

additions

to,

or

improvements

in

its

product

whithout

imposing

any

obligation

upon

itself

to

install

them

on

its

products

previously

manufactured.

---------------------------49

Sl*

METRIC

INFORMATION

GUIDE

________________________________

_

BASE

UNITS

DESCRIPTION

UNIT

SYMBOL

length meter

m

mass

kilogram

kg

force Newton

N

liquid

liter

I

temperature Celsius

oc

pressure kilo pascal

kPa

torque

Newton

meter

N•m

speed kilometer per hour km/h

PREFIXES

PREFIX

SYMBOL MEANING VALUE

kilo k one thousand

1000

centi c

one hundredth

0.01

milli m

one thousandth

0.001

CONVERSION

FACTORS

TO

CONVERT

TOt

MULTIPLY

BY

lbf•ft

lbf•in 12

imp.

oz

U.S.

oz

0.96

imp. gal. U.S. gal. 1 .2
in

mm

25.4

in

em

2.54

ft

m

0.3

MPH km/h 1

.61

in2

cm2

6.45

in3

cm3

16.39

imp.

oz

ml 28.41

U.S.

oz

ml

29.57

imp.

gal.

I

4.55

U.S. gal. I

3.79

oz

g

28.35

lb

kg

0.45

lbf

N

4.4

lbf•in

N•m

0.11

lbf•ft

N•m

1.36

lbf/in

2

kPa

6.89

Fahrenheit Celsius

(°F-

32) +

1.8

Celsius

Fahrenheit

(°C

X 1.8) +

32

*The

international system

of

units abbreviates

"SI"

in

all languages.

tTo

obtain the inverse sequence, divide by the given factor. To convert

"mm"

to

"in",

divide by

25.4.

50

________________________

__

NOTES

____________________

__

________

51

WIRING

DIAGRAM

______

_

COLOUR

CODE

BK

BLACK

GN

WH

WHITE

GY

RD

RED

VI

BL

BLUE

OR

YL

YELLOW

BR

Safari

377/503

Location of connector housings

(Refer

to

diagram)

C-1:

On

engine, right side

C-2:

On

engine, right side

C-3:

On

engine, right side

C-4:

On

engine, right side

C-5:

On

ignition

switch

C-6:

In

console, left side
C-7: Near steering column
C-8: Near steering

column

C-9:

In

console, left side
C-1

0:

In

hood, near instruments
C-11:

In

hood, near instruments
C-12:

In

hood, near instruments
C-13:

In

hood, near instruments

C-14:

In

hood, near instruments

C-15:

In

hood, near instruments

C-16: Near injection oil reservoir
C-17: Between seat and fuel tank
C-18:

On

taillight
C-19: Near voltage regulator
C-20: Between seat and fuel tank
C-21:

In

console, left side

GREEN
GREY
VIOLET
ORANGE
BROWN

52---------------------------

•

WARNING:

Ensure all terminals

are properly crimped

on

the wires

and

all

connector housings are properly

fastened.

Safari

377E

Location of connector housings

(Refer to diagram)

C-1:

On

engine, right side

C-2:

On

engine, right side

C-3:

On

engine, right side

C-4:

On

engine, right side

C-5:

On

ignition switch

C-6:

In

console,

left

side

C-7: Near steering

column
C-8: Near steering column
C-9:

In

console, left side

C-1

0:

In

hood, near instruments

C-11:

In

hood, near instruments

C-12:

In

hood, near instruments

C-13:

In

hood, near instruments

C-14:

In

hood, near instruments

C-15:

In

hood, near instruments

C-16: Near injection oil reservoir

C-17: Between seat and fuel tank
C-18:

On

taillight
C-19: Near regulator/rectifier
C-20: Between seat and fuel tank
C-21:

In

console, left side

WIRING

DIAGRAM

SAFARI377/503

____________________________________________________________________

___

SPARK

PLUGS

GENERATOR

COIL

BK/Yl

c 3

BK/Yl

BK

o&:.HQUJBL

BK:;~~K

IGNITION

COIL

C-2

J 8;;::::::::]

~t

BKIWH

h

~-.f"B~

YL

BKIA~u

YL

- -

-·.::::::::::::Yvt=:::;-----------------

1

BK ~ YL!BK

Yl/BK

C-4

.................

_:Yc::LC::/B::_K+----------,

LIGHTING

COIL

BK/Y~L

_

BK

o=.o

BK

9 4 5 2 ...J

W

lfl~·~·~~tF1-'~~------~·~·~

~

BKNL

BKN~~

~;;y

BK

~

TETHER

CUT-OUT

SWITCH

EMERGENCY

SWITCH

IGNITION MODULE

BK

r----~;B~L-Y_L/_BK-~~C-·2_0

~~·'~---+-------~-+----~

L--;'--F"r!'JP,;r!-"~l~

YL!BK

F~L

YL!BK

r-------~f_!Y~L//

~

~~,:'~,'

YL~

SWITCH

LEVEL

SENSOR

(OPTIONAl

ON

SAFARI 5031

'-f--------_!:R!QD[1N:hl..._

C-B

RD/YL

""'-

~RD!Yll

,--f-+---+---------+-+------f----___.j---~GY:c_

__

-:.,..,~::w:)j

GY

DIMMER

,--t----------+-+-------+-----J-----'G~Yf:!.N"-1---1_.,

GYNI 1

{H~~~~~~~

YL

OFF

MIN. ' ..

'

,1

MAX.

C-S

OR~

SWITCH

l OANI

YL!BK

I -

hC~·:21~:£3===:r::=J

HEATED

GRIPS

(OPTIONAL)

LEFT

,-t--~4-~-~~=================+==:t============t--t-1--lr---~

~~

RIGHT

BucB

c-1B

~vc

~.----Q~~lld:::~r=t~-F~~!J~~~~~

~.-~3~,~L

(5-21

WI

C-17 1 1

a~

Yl!BK

YL/BK

-A

I

~f((frv~~..

I

¢1~~t="-J

I \",.

~o"'"

7

YLIBK

jl

y /BK

~~f/'?-Q~BK

...-

\~

C-11

TAILLIGHT YL I

~\...

't-

YL

~

WH/RD

Oil

LEVEL

SENSOR

RESISTOR

~L

I D

C-16-....J:tl'~

BULB:

J

~

C-15

BULB

(60-60

W)

HEADLIGHT

SAFARI 503:

60/55

W HALOGEN

SAFARI

377:

60/60

W

Yl/BK

,.

3v

"'

>

~

~

C14

HIGH BULB
BEAM

(10

W)

INDICATING LAMPS

o

r~

C-12

~ ~

(Q.~u;~P.)

~

~

liE ~ :,.._"-'

Cl

..J

<!'

~01:.

~ ~

...~

~

a:i£

YL

~ ~

tt{

~

:tc:o

BULB

.r.

~ ~

15

W) BULB

'\._

'~

OIL

LEVEL

C-13

FUEL

GAUGE

(OPTIONAL

ON

SAFARI 503)

BULB SPEEDOMETER

(5

W)

-

(2

W)

TACHOMETER

(OPTIONELI

YL

C-10

53

WIRING DIAGRAM

SAFARI377E----------------------------------------------------------------------------

GENERATOR

COIL

C3

BKIYL

IGNITION
SWITCH

IK......,.

YL!BK

YliBK++------~

z

0

C"6

....._

BKIYL~

~

~rc~~

C-1

C-2

J~··~

~

·~

0

:

Qt::w/BL

BK/WH

"nBK:'~""'

YL

BR_

-

---"~~'-------+-------~

rf.t-,f1

C5

IG~m~N

'="

Lt~tglNG

C-4

YLIBK+-+------,

2 8 4 7 9

LJ1

1~··

--+------1~··

BKIYL

~

TETHER

CUT-OUT

~

SWITCH

BK/YL'-...

l

C"7

BKIY~

EMERGENCY

BK

-i:::j"1

SWITCH

tGNtTtON

MODULE

L~=="="==~_l!~-1--1--W"~o!!!IB~L----___cv'"'-w~[

_H_~_Jt:/..t,jj;(_L)-:.__.~

~

7-

wH....,..,

BRAKE

liGHT

SWITCH

BL BL z

...---------"YL'+_,

'---f'\~~'"""'Y'-"L:,:IB"-K'll~~

YLIBK

~

~ ~

T

--.....'-"YL::;iB:::;K'----,

FUEL

BULB

!5·21 Wl

LEVEL

SENSOR

RDIYL

-...._

~C-8

RD!YL

...---+-~---~--------~-----++~-+---+---'<GY!_

__

~:I!1'C-f::J~lrl,

GY

~:~~~n

...----+---------+------+-H--+---+---___;G!_!Y!;:N~I-_J/

GYNI i (HIGH

LOWI

RD/Yl

RD!YL

-n

-

'"===I======~Y~l=:::;:§B:===-r..,~tj;

I LIGHT

L

---------+---------4---4-+-~r~~

I'

~

SWITCH

OFF

ct.J

N.

,IMAX

'

C-9

.,..,.,

~:

I

BATTERY

8

'

~

L--}-+-+-l~-+--+--+--+--+------------f---------4_J

r

==;::::::O~R~~~-~U

I

YL~

SWITCH

HEATED

GRIPS

(OPTIONAL)

,-blf'i~c~"2~1:'

_cE:f'=:=:s:=~

LEFT

I

0~-l::E:==

30

AMP.

RIGHT

~~~

YL/BK

v~=14Jftj

~B__L_

R~8G~~$6R

''--

~_!Y.=_L

__

-\---'

L--__!Y~L~~~\==~~=l==:t==t=~~::d:==========:===~-----~--t-~================~~==

4

C-18 WH

ril!tl:fl::

~f

~/

WH

~Lts~~:~J~~§~~v~'~'·~·~~f~t~--f~~~~~~~±======E==c=~~J

TAILLIGHT I

L.::.=:::JYtl

::;--1-'

BK

RD/Bl

-r-tnn~~~~~~~~~

YL

AD/Yl

YL!BK

YL/BK

~~~

\

!i!

~

+

JJJ!

> >

\

...

'C"12

~

:i1

YL!BK

,

,.__

\

"

"'"

~

FUSE

~

~

(01AMPI

__.~

C-10

RESISTOR

~

"

h~

/

c"'

~

~

i

~

> > >

"'

:

'~

'"

;;;'

>'

J"

1::(!!

c J

C111

~su~

~u~

"'

Jn

C-15

BULB

(60-60

WI

HEADLIGHT

54

______________________

___

~

C"14

l

BULB

l10WI

HIGH

BEAM

INDICATING

LAMPS

i

OIL

LEVEL

<r>

FUEL

GAUGE

SPEEDOMETER

T~ETE

IOPTIONEL)

)

CHANGE

OF ADDRESS

OR

OWNERSHIP------------

Any change

in

address or ownership should

be

brought to the attention of the

manufacturer

by

completing and sending out the card below.

NOTICE

TO

ALL NEW

OWNERS:

Make sure to receive the warranty registration card

from the previous owner, when the ownership

is

transferred. Also enclose a pho-

tocopy of this registration card when informing of a change of ownership.

~~-----------------------------

/ CHANGE

OF

ADDRESS

I

I VEHICLE IDENTIFICATION NUMBER I I I I I I I I I

I

I OLD ADDRESS:

I

I
I
I

I NEW ADDRESS:

I
I
I
I
I

NO

CITY

NO

CITY

NAME

STREET

STATE/PROVINCE

NAME

STREET

STATE/PROVINCE

APT.

ZIP/POSTAL

CODE

APT.

ZIP/POSTAL

CODE

~-----------------------------

CHANGE

OF

OWNERSHIP

v E H

IC

L E

IDE

NT

IF I CAT

I 0 N N u M

BE

R

1'----JI'----JI'----J'----JI'----JI'-----JI'-----JI'-----JI'-----JI'-----JI

The ownership of this vehicle

is

transferred

FROM:

I
I
I

ITo:

I

I

NO

CITY

NO

NAME

STREET

STATE/PROVINCE

NAME

STREET

APT.

ZIP/POSTAL

CODE

APT.

~

CITY

STATE/PROVINCE

ZIP/POSTAL

CODE

--------------------------------1

BOMBARDIER

INC.

ATT.: WARRANTY DEPARTMENT

VALCOURT (QUEBEC)
CANADA

JOE

2LO

I STAMe

II

I
I
I
I
I
I
I
I
I

I

I
I
I
I
I

--------------------------------1

BOMBARDIER INC.

ATT.: WARRANTY DEPARTMENT
VALCOURT (QUEBEC)
CANADA

JOE

2LO

I STAMe

II

I

I

I
I
I
I
I

I
I

I
I
I

I

I
I