Ski-Doo EVEREST 500 1981 Operator's Manual

model

V.I.N.

purchase date _

warranty expiry date

To be completed by dealer at time of sale

DEALER IMPRINT AREA

MOTO-SKI
FUTURA
SPIRIT
NUVIK
MIRAGE
SUPER SONIC
ULTRA SONIC

TECHNICAL PUBLICATION
AFTER SALES SERVICE
BOMBARDIER

L1MITEE
VALCOURT, QUEBEC
CANADA,

J02 2LO

The following are trademarks of Bom­bardier Lirnitee.

BOMBARDIER EVEREST
SKI-DOO CITATION
ALPINE OLYMPIQUE
BLIZZARD

T'NT
CARRY-BOOSE
ELAN
ELITE
GRAND PRIX SPECIAL

.10

INDEX

0

THE 1981LIMITED WARRANTY.

..

. 2

FOREWORD 4
SAFETY IN MAINTENANCE ,.. , , ,

5

CONTROUINSTRUMENTS

Throttle lever, brake lever,

ignition/light

switch, headlamp dimmer switch,

emergency

cut-out

switch, manual starter handle, primer, speedometer, tether

cut-out

switch, adjustable steering handle, light switch, oil level indicator, hood

opening, tool box, fuel

gauge.

. . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . 6

BREAK-IN PERIOD

Break-in, inspection, inspection checklist 8

FUEL

Recommended gasoline, recommended injection oil. . . . . . . . . . . . . . . . . . . .. .10

PRE-START CHECK

Check

points.

. .

STARTING PROCEDURE

Manual

starting..

. . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . 11

EMERGENCY STARTING. . . . .. . . . ... . 11

DRIVE BELT

AND

GUARD REMOVAL . . . . .. . . .. . . ... . . .. . . .. .. . 12

LUBRICATION

Frequency, steering mechanism, chaincase oil level, oil injection system . . .13

MAINTENANCE

Maintenance chart, spark plugs, battery, suspension, track, track tension and

alignment, carburetor, drive belt, steering mechanism, drive pulley, brake, steer-

ing adjustment, engine head nuts, engine

mount

nuts, muffler attachment, fan

belt, general inspection, bulb replacement . .

..

. 14

STORAGE

Track, suspension, ski assembly, controls, chaincase. fuel tank, carburetor,
cylinder lubrication, chassis, general inspection. .

20

PRE-SEASON PREPARATION

Pre-season preparation, chart, , 22

TROUBLE SHOOTING . 23

TOOLS....

. 25

SPECIFICATIONS 26
WIRING

DIAGRAM.

... . . .. . . . .. . . . .. . .. . .. . 27

SI METRIC INFORMATION

GUIDE.

. ... . . .. . . .. . . 29

OFTEN ASKED

QUESTIONS..

. 30

LISTING OFAREA DISTRIBUTORS. . .. . . .. . . .. . . . .. .. . . 32

HOW

TO IDENTIFY YOUR SNOWMOBILE . . . .. . . .. . . . . .. . . .. .. . 33

CHANGE OF ADDRESS OR OWNERSHIP , 35

LIMITED WARRANTY

1981

SKI..DOO®SNOWMOBILES

1 - PERIOD

BOMBARDIER Lirnitee as manufacturer, warrants FROM THE DATE OF FIRST
CONSUMER SALES, every

1981

Ski-Doo® snowmobile, sold as NEW AND UN-

USED, 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 subjecsto the
following:

1. If delivery is made afterthe

31

st day of March of a given year and before the 1st
day of December of the same year, the above 90 day warranty will start on De­cember 1st.

2. If delivery is made

on/or

after the 2nd day of January of a given year but before
the 31st day of March of the same year, all the unused portion of the 90day pe­riod will be carried over to the next winter and start again on the 1st day of
December of the same year.

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

Ski-Doo dealer during said warranty period.

3·

CONDITION TO HAVE WARRANTY WORK PERFORMED

Presentto the servicing dealer, the hard copy of the BOMBARDIER Customer Re­gistration card received by the customer from the selling dealer at time of pur­chase.

4 - WARRANTY TRANSFER

This warranty istransferable to subsequent owner(s) for remainder of warranty pe­riod from original date of sale.

5 • EXCLUSIONS

..

ARE NOT WARRANTED

• Normal wear on all items such as,

but

not limited to:

- drive belts

- slider shoes

- spark plugs
breaker points

- runners on skis

• A sulphated battery.

• Replacement parts

and/or

accessorieswhich 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 Manual. The labour, parts and lubricants costs of all maintenance ser-

vices, including tune-ups and adjustments will be charged to the owner.

2

• 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.

• Damage resulting from modification to the snowmobile

not

approved in writing

by BOMBARDIER.

• 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 damages.

Some

statesorprovinces

do

not

allow

the

exclusionorlimitation

of

inciden-

tal

or

consequential

damages, so

the

above

limitation

or

exclusion

may

not

apply.

I - EXPRESSED OR IMPLIED WARRANTIES

This

warranty

gives

you

specific

rights,

and

you

may

also

have

other

legal

rights

which

may

vary

from

statetostate,orprovincetoprovince.

Where

ap-

plicable

this

warranty

is

expressly

in lieu

of

all

other

expressed

or

implied

warranties

of

BOMBARDIER,

its

distributors

and

the

selling

dealer,

including

any

warranty

of

merchantability

of

fitness

for

any

particular

purpose; other-

wise

the

implied

warranty

is

limited

to

the

duration

of

this

warranty.

However,

some

statesorprovinces

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,

andifmade,

such

affirmation,

representa-

tionorwarranty

shall

not

be

enforceable

against

BOMBARDIERorany

other

person.

7·

CONSUMER ASSISTANCE

If a servicing problem or other difficulty occurs, we suggest the following:

1. Try to resolve the problem at the dealership

with

the Service Manager or

Owner.

2. If this fails, contact your area distributor listed in the Operator Manual.

3. Then if your grievance

still remains unsolved, you may write to us:

BOMBARDIER

llMITEE

Customer Relations

Recreational Products

Valcourt, Quebec, Canada, JOE 2LO

BOMBARDIER

LIMITEE RESERVESTHE RIGHT TO

MODIFY

ITS

WARRAN-

TY POLICY

AT

ANY

TIME,

BEING UNDERSTOOD

THAT

SUCH

MODIFICA-

TION

WILL

NOT

ALTER THE

WARRANTY

CONDITIONS

APPLICABLE TO

VEHICLES SOLD WHILE THE

ABOVE

WARRANTY

IS IN EFFECT.

October 1979
Bombardier Limitae
Valcourt, Quebec, Canada, JOE 2LO

® "Trademarks of Bombardier Lirnitee

3

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 consult the

"Often

Asked

Question" section of this manual

I or

your selling dealer.

4

This manual uses the following sym­bols.

....

WARNING:

Identifies-en lnstruc-

~

tion which, if not followed, could

cause personal injury.

...

CAUTION: Denotes an instruc-

• tion which, if not followed, could

severely damage vehicle components.

O

NOTE: Indicates- supplementary

information needed to fu!ly com-

plete an instruction.
Although the mere reading of such

in­formation does not eliminate the haz­ard, your understanding of the infor­mation will promote its correct use.

SAFETY

IN

MAINTENANCE

Observe the following

pr~.,;tions:

• Throttle mechanism should be
checked

'f'or

treernovement

before

startinq engine..

• Engine should be running only when

pUII~y

guard is secured in

.pla?~.

!_

~,el'e_r!u,nengine

without

drive belt

installed_.Running an unloaded en­gine can prove to be dangerous.

- • Never run engine when the track of

- - .the.vehicle is raised

off

the ground.

• It can be dangerous to run

engine

withthe

cab"

removed.

• Gasoline is flammable and explosive
'under certain conditions. Always

manipulate in a well ventilated area.
Do not smoke or allow open flames
or sparks in the vicinity. If gasoline
fumes are noticed while drivinq.rths
cause should be determined and

corrected without'delay.

• Maintain your vehicle in top mecha­nical condition,

at all times.

• Your snowmobile is not designed to
be driven

or

operated on black top,

bare earth,

or

oiher

abrasive sur­faces. On such surfaces abnormal
and excessive wear of critical parts

is inevitable.

.,

• Installation of other than standard
equipment, including ski-spreaders,
bumpers, pack

racks,

etc"

could

severely affect the stability

arid safe­ty of your vehicle. Avoid adding on
accessories that alter the basic ve­hicle configuration.

• The snowmobile engine can be
stopped

by activating the emergen-

cy

cut-out

switch,

tether

switch

or

~y

turning

off

the key.

• Whenever the vehicle is parked out­doors, overnight or for a long
period, it is suggested to protect it

against the inclemency of the
wheather with a

snowmobilecover.

• Do not lubricate throttle

and/or

brake cables and housings.

Please read and understand all other

warnings contained elsewhere.

THIS

MANUAL

SHOULD REMAIN WITH THE VEHICLE AT

TltE

,TIME,OF,RESALE.

'-,

5

CONTROLS/INSTRUMENTS

AJ Throttle Control Lever

B) Brake Control Lever

CJ

Ignition/Light

Switch

DJ

Head/amp

Dimmer

Switch

EJ

High Beam Indicator

F) Emergency Cut-Out

Switch

G) Manual Starter Handle

HJ

Primer

/) Speedometer

J) Tether Cut-Out Switch

KJ

Adjustable steering handle

U

Light

switch (Electric Model)

MJ Oil Level Indicator

A) Throttle Lever

Located on right side of handlebar,

When compressed, it controls the

en-

gine speed

and the engagement of the

transmission.

When released,

returns to

idle.

B) Brake Control Lever

Located on the left side of handlebar.
When compressed

I the brake is

plied. When it
returns to its original

"',,",C"T,r\Y,

effect is proportionate to the pressure
applied on the lever.

O

NOTE: On electric start models

('tllrYlnrnC:Clrlf1

the brake lever

will light up the oil indicator bulb.

If bulb does

not

up, replace

with

a

new one.

6

C) Ignition/Light

Switch

(Manual Start Models)

OFF

f1i':\--ON

~-"TEST"

3 switch. To

turn key clockwise to

ON .

To stop engine, turn key

counter-clockwise to OFF
The lights are automatically ON

when-

ever the engine is running.
To test oil level indicator bulb,

with

en­gine running, turn key to test position.
If bulb does

not

(Electric

Start

Models)

OFF

f1i':\_ON

\..9-

START

Key operated, 3 position switch. To
start engine, turn key fully clockwise to
START

position and hold. Return

to ON position

immediately when en-

gine has started.

To stop engine, turn

key counter-clockwise to OFFposition.

D) Headlamp Dimmer

Switch

Located on left side of handlebar, flick

switch to high or

low

beam.

E) High Beam Indicator

Lights up when headlamp is on high
beam.

A Emergency Cut-Out Switch

A 3 position switch located on the right
side of the handlebar. To stop the en­gine in an emergency, flick the lever to
either upper or lower

"OFF'

position.

To start engine, lever must be

in mid-

dle

"ON"

position.

The driver of this vehicle should

familiarize 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:

If the switch has

been used in an emergency situa­tion the source of malfunction should
be determined and corrected before re­starting the engine.

G) Manual Starter Handle

Auto

rewind type located on right hand

side of vehicle. To engage mechanism,
pull handle.

H) Primer

A push-pull button. Pull and push but-

ton (2-3 times) to activate primer. The
primer should always be used for cold
engine starts.

After

engine is warm

however, it is not necessary to use

primer when starting.

I) Speedometer

The speedometer is linked directly to
the drive axle. Direct-reading dial indi-

cates the speed of the vehicle. Odom­eter records the total number of dis-

tance travelled.

J)

Tether Cut-Out Switch

Attach tether cord to wrist or other
convenient location then snap tether
cut-out

cap over receptacle before

starting engine.

If emergency engine

"shut-off" is re-

quired completely pull cap from safety
switch and engine power will be auto­rnaticaIly shut

fI

off"

.

O

NOTE: The cap must be installed

on the safety switch at all times

in order to the vehicle.

...

WARNING:

If the switch is used

"y

in an emergency situation the
source of malfunction should be deter­mined and corrected before restarting
engine.

K) Adjustable steering handle

Loosen the four retainer screws.
Adjust the steering handle to the de-

sired position.

Lock the steering handle in place by

tightening the four (4) screws to

26

N.m

(19ft-lbs).

•

WARNING:

Do not adjust the

handlebar to high to avoid inter­ference when turning, between the
brake lever and windshield.

L) Light

Switch

A push purl switch type, to illuminate
headlamp and taillight, pull switch
knob. (Ignition switch must be turned
to ON

position).

M} Oil Level Indicator

Will light up when injection oil level is
low. Check level and replenish as soon
as possible.

~

CAUTION: Do not run engine out

Y of oil. Serious engine damage will

occur.

To test oil level indicator bulb: on man-

ual start models, turn ignition key

(en-

gine running) to

"test"

position. On
electric start models, indicator light will
glow

each time brake lever is used. If

light does not glow, replace bulb.

7

Hood Opening

Pull down the latch to unhook the hood

from the anchor.

O

NOTE: Always lift hood gently up
until stopped by restraining

de-

vice.

•

WARNING: It is dangerous to
run an engine

with

the hood open
or removed. Personal injury could re­sult.

...

CAUTION: Prior to re-securing

..

the hood latch, position the bot­tom edge of the hood into the hood
guide located on each side of the
frame.

ToolBox

Located under the hood. To gain ac-

cess, tilt hood.

Ideal location for spare

plugs, belt, rope, etc.

Fuel

Gauge

The fuel gauge is located on the left
side of the fuel tank. The gauge func­tions on the principle of communicat­ing vessels, so the fuel level inside the
tank is directly related with the level in­dicated on the gauge.

+

WARNING: Never use a lite
match or open flame to check

fuel level.

8

BREAK-IN PERIOD

With Bombardier-Rotax snowmobile
engines, a break-in period

is required

before running the vehicle at full throt­tle. Engine's

manufacturer recommen-

dation is

10 to 15 operating hours. Dur-

ing this period, a richer mixture is
needed (i.e. 40 parts

of

gas for 1 part of

50/1 Bombardier oil). Maximum throt-

tle should not exceed

3/4,

however,

brief full acceleration and speed varia-

tions contribute to a good break-in.

Continued wide open throttle accelera-

tions, prolonged cruising speeds, and

lugging are detrimental during the
break-in period.

O

NOTE: A new drive belt requires
a break-in period of

15-25 km (10-

15

miles).

1O-Hour

Inspection

As with any precision piece of mechan-

ical equipement, we suggest that after
the first 10hours of operation or 30days
after the purchase, whichever comes

first,' your vehicle

be'

checked by your
dealer. This inspection will give you the
opportunity.to

.discuss the unanswered

questions you may

have encountered

during the first hours

of

operation.

Remember that it

is to remedy at

this

time than

to

allow the snowmobile
to operate until a possible failure oc­curs.

The 10 hours inspection is at the ex­pense of the vehicle owner.

10·HOUR INSPECTION CHECK LIST

./

Engine timing
Fan belt tension

Spark plugs condition

.

Carburetor adjustment
Oil injection

pump

adjustment

Engine

head

nuts

Engine

mount

nuts

Muffler

attachment

Chaincase

oil level

Brake operation and lining condition

--~/

Ski alignment (runner condition)
Pulley alignment and drive belt condition
Track condition, tension and alignment

Lubrication (steering, suspension)
Electrical wiring (loose connections, stripped wires, damaged insula-

tionl,

tighten all loose bolts, nuts and linkage

Operation of lighting system (HI / LO beam, brake light, etc.I, test­operation of emergency

cut-out

switch, tether switch

We recommend that you have your dealer sign this inspection.

Date of 10

hourinspection

Dealer signature

9

FUEL

PRE-START CHECK

Recommended Gasoline

Use regular leaded gasoline available
from

ali service stations.

..,

CAUTION:

Never experiment

• with different fuel or fuel ratios.
Never use naphtha, methanol or similar
products.

O

NOTE: For the break-in period

only, 1 (16 oz) can of Bombardier
snowmobile oil should be added to the
first full fuel tank filling, at a 70/1 ratio.

This

will assure additional protection

during the initial break-in.

•

WARNING:

Never

"top

up" the

gas tank before placing the vehi-

cle in a warm area. At certain temper-

tures, gasoline will expand and ove-

flow.

Recommended Injection Oil

Use concentrated Bombardier

snow-

mobile oil available

from

your

dealer.

10

Check Points

•

Activate

the

throttle

control

lever

several times to

check

that

it

ates and

smoothly.

The

tie lever

must

return to idle

position

when

released.

• Check fuel level.

• Check

that

the skis and the track are

not

frozen to the

ground

or

snow

surface and

that

the

oper-

ates freely.

•

Activate

the brake

control

lever and

make sure the brake

fully

be-

fore the brake

control

lever touches

the handlebar grip.

• Verify

that

thepath

ahead of the ve­hicle is clear of and ob­stacles.

.....

WARNING:

Onlystartyoursnow-

T mobile once all components are

checked and functioning properly.