BOMBARDIER Ski-Doo MX Z 600 Series Bedienungsanleitung

Printed in Canada (mbs2001-001a.fm MD)

®*Trademarks of Bombardier Inc. and/or its subsidiaries.

2001-7 Page 1 of 7

X package for above mentioned models gives a

sport calibrated ride as far as rear shock absorber

is concerned.

In order to obtain a softer dampening, similar to

what the adrenaline package gives, customer could,

at his own expense, change rear shock calibration

by removing five 36 x 0.203 and one 40 x 0.203

washers inside the shock absorber (P/N 503 189

609). Following table summarizes the operation.

Parts Required

The following 2000 Racing Manual revised pages

describe the entire procedure.

Valving and Dampening

In the HPG shock, the piston passages are covered

by a stack of thin metal shims of various thicknesses

and diameters. The shims provide dampening by

acting as spring loaded valves offering resistance

to the oil traveling through the piston. There is a

stack of shims on both sides of the piston. One

side controls compression dampening and the other

side controls rebound dampening. By varying the

number and thickness of shims the dampening

characteristics can be very accurately obtained.

Special Tools

Special tools specific to the HPG T/A shock will be

the seal pilot, shock wrench (P/N 529 035 727) and

piston guide from Bombardier for C-46 shock.

NOTE: Tools P/N 529 035 727 and 529 035 728

will be available in early December.

No. 2001-7

Date: November 3, 2000 SUBJECT: Rear Shock Absorber

Dampening

YEAR MODEL PKGE MODEL NUMBER SERIAL NUMBER

2001

MX* Z 600

1825/1826/1827/1828/1829/1830

AllMX* Z 700 1670/1671/1672/1673/1674/1675

MX* Z 800 1663/1664/1665/1666/1667/1668/1669

FUNCTION ORIGINAL

“X”VALVING

ACTION

TO BE

TAKEN

RECALIBRATED

DAMPENING

Piston

by-pass

hole

2.0 mm dia. none 2.0 mm dia.

COMPRESSION

4 x 40 x 0.203 Remove

1 washer 3 x 40 x 0.203

1 x 24 x 0.203 none 1 x 24 x 0.203

3 x 40 x 0.152 none 3 x 40 x 0.152

2 x 24 x 0.203 none 2 x 24 x 0.203

Rebound

9 x 36 x 0.203 Remove

5 washers 4 x 36 x 0.203

1 x 24 x 0.203 none 1 x 24 x 0.203

DESCRIPTION PART NUMBER QTY

Shock Absorber Oil 293 600 035 1 bottle

FOR

PPROV

L ONLY

Page 2 of 7 2001-7

SHOCK WRENCH (P/N 529 035 727)

NOTE: Do not attempt to rebuild the T/A damper

without the benefit of these assembly tools, dam-

age will occur without their use.

Shock Oil and Nitrogen

1. High pressure hose

2. 2 stage regulator, delivery pressure range 2070 kPa (300 PSI)

3. High pressure cylinder filled with industrial grade nitrogen

4. Schrader valve tip (P/N 529 035 570)

NOTE: Commercially available through compressed

gas dealers.

Disassembly and Assembly

Release N2(nitrogen) pressure from the damper

Schrader valve on any HPG T/A with IFP.

1. Schrader valve 1.5 - 2 N•m (13 - 17 lbf•in)

2. Schrader cap 5 - 6.5 N•m (44 - 57 lbf•in)

A06F0OB

529 035 728

529 035 608

A00F22A

A06F0PD

293 600 035

32 oz

WARNING

Nitrogen gas is under extreme pressure. Use

caution when releasing this gas volume. Pro-

tective eye wear should be used.

A06F0QA

A06F18B

2001-7 Page 3 of 7

With the seal assembly removed, slowly lift and re-

move damper rod assembly from the damper body.

NOTE: Remove damper rod assembly slowly to re-

duce oil spillage and prevent piston seal damage by

damper body threads. Wrap the damper body with a

shop cloth to capture possible overflow oil while re-

moving the damper piston.

1. Oil flows

Discard old oil into storage container. Never reuse

damper oil during shock rebuild.

Remove Schrader valve core. Using compressed

air pressure, carefully remove floating piston from

damper body. Hold shop cloth over damper body

opening to catch released floating piston. Allow

room for floating piston to leave damper body.

TYPICAL

Thoroughly clean, with a typical cleaning solution,

and blow dry using low pressure air. Carefully in-

spect the damper body for any imperfections or

signs of wear in the damper bore.

Replace damper body if wear is identified.

Holding the damper rod assembly in a bench vise,

begin piston and valve removal.

A. Remove damper nut

529 035 727

A32F1NA

A27F0AA

WARNING

Whenever using compressed air, use an

O.S.H.A. approved air gun and wear protec-

tive eye wear.

A27F06A

A06F0UA

Page 4 of 7 2001-7

Always arrange parts removed in the sequence of

disassembly.

NOTE: As a general rule we suggest replacing the

damper rod lock-nut after 4 rebuilds to ensure

good Iocking friction and use Loctite†271 each

time.

NOTE: If revalving is to be done, it is imperative

that you identify the original shim pack (size and

number of shims). The seal carrier need not be

removed if only revalving is to be done.

Shims can be measured by using a vernier caliper

or a micrometer.

NOTE: All shims should be carefully inspected

and any bent or broken shims must be replaced

for the shock to function properly.

After the new or replacement shim pack has been

selected, reassemble in the reverse order of disas-

sembly. Torque piston nut 27 - 29 N•m (20 - 21 Ibf•ft).

1. Damper nut

2. Spacer

3. Washer

4. Shim pack

CAUTION: The damper rod nut can only be re-

used 4 times, then, must be replaced. Do not

substitute this part for non –O.E.M. use Loctite

271 on nut each time.

This (these) spacer washer(s) (P/N 414 888 309)

must be used as shown to ensure damper rod nut

does not contact shaft threads.

Rebound valve stopper with round edge facing

shim stack.

NOTE: Rebound shim stack must not reach into

threads of damper shaft. Washer under damper

shaft nut is used to prevent damper shaft nut from

bottoming on threads.

1. Rebound dampening shim pack

2. Rebound dampening shim pack

3. Piston

4. Compression dampening shim pack

5. Compression dampening shim pack

6. Stopper

†Loctite is a registered trademark of Loctite Corporation.

A06F0VA

A06F0XA

A06F0YA

2001-7 Page 5 of 7

If the seal carrier assembly is replaced, use seal

pilot to guide seal over damper shaft. Lubricate

seal carrier guide pilot before use.

CAUTION: Failure to use seal pilot will result in

seal damage.

Reassemble damper rod assembly, taking care to

properly assemble shim packs as required for your

dampening needs. Ensure that the shaft piston is

installed with the slits/larger intake holes facing

the rebound shim stack.

1. Pilot (P/N 529 035 728)

If floating piston has been removed, reinstall float-

ing piston into damper body (ensure that Schrader

valve core has been removed). Use Molykote G-n

paste (P/N 711 297 433) to ease O-ring past damper

body threads with floating piston guide (P/N 529

035 608).

CAUTION: Failure to install IFP correctly could

result in shock damage.

1. Push (slowly) by hand

2. Floating piston guide (P/N 529 035 608)

NOTE: Lubricate inside of piston guide with

Molykote G-n paste (P/N 711 297 433).

Install floating piston to the proper depth (190 mm

(7.5 in)).

On all HPG take apart shocks from 1996 on, the

floating piston is installed hollow side up.

A. Required distance for floating piston installation (190 mm (7.5 in))

NOTE: If the floating piston is installed too far into

the damper body, light air pressure through

Schrader valve (with core removed) will move pis-

ton outward.

NOTE: Reinstall Schrader valve core after IFP has

been installed at correct height and before adding

oil.

CAUTION: Moisture laden compressed air will

contaminate the gas chamber and rust floating

piston.

A06F12C

A06F14C

WARNING

Whenever using compressed air exercise ex-

treme caution, cover damper opening with

shop cloth to reduce chance of possible injury.

WARNING

Always wear protective eye wear whenever

using compressed air.

A27F0FD

Page 6 of 7 2001-7

Fill the shock with Bombardier HPG shock oil (P/N

293 600 035) to approximately 10 mm (.393 in),

from the base of seal carrier threads.

1. Fill to 10 mm (.393 in)

NOTE: Although we do not measure the exact

amount of oil added to the damper, approximately

252 mL (8.52 oz. U.S.) will be used.

Carefully insert damper rod into the damper body.

Lightly oil damper piston seal ring with shock oil

to ease installation.

NOTE: Some shock oil will overflow when install-

ing damper. Wrap damper with shop cloth to catch

possible overflow oil.

CAUTION: Use care when passing piston into

damper body at damper body threads.

Slight oscillation of damper rod may be required to

allow piston to enter damper body bore.

Slowly push piston into damper body. Slight up

and down movement may be required to allow all

air to pass through piston assembly. The gentle

tapping of a small wrench, on the shock eye, may

help dislodge air trapped in the submersed piston.

Be careful not to drive the shaft any deeper into

the oil than is necessary to just cover the shim

stack.

NOTE: Fast installation of the damper rod may dis-

place the floating piston from its original position.

This must not occur if the damper is expected to

perform as designed.

With damper rod piston into oil, TOP OFF damper

oil volume. Oil level should be to damper body

thread base.

Seal carrier assembly can now be threaded into

damper body. This should be done slowly to allow

weapage of oil and to minimize IFP displacement.

After the seal carrier is fully in place avoid pushing

the shaft into the body until the nitrogen charge is

added.

Torque seal carrier to 90 - 100 N•m (66 - 74 lbf•ft).

A06F15B

A06F16A

529 035 727

A32F1NA

2001-7 Page 7 of 7

1. Schrader valve 1.5 - 2 N•m (13 - 17 lbf•in)

2. Schrader cap 5 - 6.5 N•m (44 - 57 lbf•in)

Adding Gas Pressure

Nitrogen (N2) can now be added to damper body.

NOTE: Never substitute another gas for nitrogen.

Nitrogen has been selected for its inert qualities

and will not contaminate the gas chamber of the

shock.

Preset your pressure regulator to 2070 kPa (300 PSI)

nitrogen (N2), this gas pressure will restore the

correct pressure for your damper.

CAUTION: Do not exceed the recommended

pressure values.

When removing and retightening the Schrader

valve acorn nut use minimal torque. When the cap

is over tightened and subsequently removed it

may prematurely break the seal of the Schrader

valve to the shock body and cause a loss of nitro-

gen charge without being noticed. If you suspect

this has happened then recharge the shock as a

precaution. Inspect the acorn cap before installa-

tion to ensure that the internal rubber gasket is in

its proper position.

NOTE: Carefully inspect damper for gas or oil leaks.

Any leaks must be corrected before continuing.

Damper gas pressure cannot be confirmed by us-

ing a pressure gauge. The volume of gas in the

shock is very small, and the amount lost during

gauge installation will lower the pressure too

much and require refilling.

After recharging is complete the rebuilt shock

should be bench-tested. Stroke the shock to en-

sure full travel and smooth compression and re-

bound action. If the shaft moves in or out erratical-

ly this could indicate too much air is trapped inside.

If the shaft will not move or has partial travel then

it may be hydraulically locked. In either event the

shock must be rebuilt again. Pay particular attention

to the placement of the IFP, quantity of oil and shim

stack/piston assembly.

1. High pressure hose

2. 2 stage regulator, delivery pressure range 2070 kPa (300 PSI)

3. High pressure cylinder filled with industrial grade nitrogen

4. Valve tip (P/N 529 035 570)

WARNING

Whenever working with high pressure gas,

use eye wear protection. Never direct gas

pressure toward anybody.

A06F18B

A06F0QA

Printed in Canada (mbs2001-002a.fm SG)

®*Trademarks of Bombardier Inc. and/or its subsidiaries.

2001-3 Page 1 of 7

This bulletin is divided into 2 main sections.

Section 1: Spring Applications

It is a quick reference chart which provides autho-

rized spring application for each Ski-Doo model. It

contains the standard spring part number (in gray

shading) as installed at the factory, as well as 1 softer

spring and 1 harder spring recommendation.

Section 2: Spring Specifications

Refers to spring specifications.

The informations in this bulletin supersede all in-

formations previously published.

Please update your Shop Manual by indicating the

number of this bulletin in the proper section of the

manual.

COIL SPRINGS

(compression)

NOTE: Read color when spring is upright and stripes

are down.

Type R

(straight on both ends)

(Single Rate Spring)

1. Color code stripes

2. Wire diameter

3. Free length

Type S

(barrel shape on one end)

(Single Rate Spring)

1. Color code stripes

2. Wire diameter

3. Free length

Type T

(barrel shape on both ends)

(Single Rate Spring)

1. Color code stripes

2. Wire diameter

3. Free length

No. 2001-3

Date: September 1, 2000 SUBJECT: Spring Chart

YEAR MODEL MODEL NUMBER SERIAL NUMBER

2001 All (except utility models) All All

A00F0PA

A00F19A

A06F02A

Page 2 of 7 2001-3

Type U

(barrel shape on one end with

positioning tab at the other end)

(Single Rate Spring)

1. Color code stripes

2. Wire diameter

3. Free length

4. Positioning tab

Type Y

(barrel shape on both ends with

positioning tab at the color code coils end)

(Single Rate Spring)

1. Color code stripes

2. Wire diameter

3. Free length

4. Positioning tab

Type 2

(barrel shape on both ends)

(Dual Rate Spring)

1. Color code stripes

2. Wire diameter

3. Free length

Type 4

(barrel shape on both ends with

positioning tab at the color code coils end)

(Dual Rate Spring)

1. Color code stripes

2. Wire diameter

3. Free length

4. Positioning tab

TORSION SPRINGS

1. Color code stripes

2. Wire diameter

3. Opening angle (°)

4. Left hand (LH)

5. Right hand (RH)

A00F12A

A06F2VA

A00F20A

2 1

A00F21A

A00F0SA

2001-3 Page 3 of 7

SECTION 1

SPRING APPLICATIONS

2001 FRONT SPRINGS 2001

MODEL (P/N) SOFTER SPRING (P/N) STANDARD (P/N) HARDER SPRING

MACH Z 414 956 300 415 075 900 415 039 700

MACH Z TECH PLUS 414 956 300 415 075 900 415 039 700

FORMULA DELUXE

STANDARD Not Applicable 505 070 686 Not Applicable

FORMULA DELUXE GS Not Applicable 505 070 686 Not Applicable

FORMULA DELUXE GSE Not Applicable 505 070 686 Not Applicable

FORMULA DELUXE 500 414 956 300 415 070 685 415 039 700

FORMULA DELUXE 380 414 956 300 415 070 685 415 039 700

MX Z STANDARD Not Applicable 505 070 181 Not Applicable

MX Z ADRENALINE Not Applicable 505 070 181 Not Applicable

MX Z TRAIL Not Applicable 505 070 393 Not Applicable

MX Z X Not Applicable 505 070 692 Not Applicable

MX Z 500 F 414 956 300 415 075 900 415 039 700

MX Z 380 F 414 956 300 415 075 900 415 039 700

SUMMIT STANDARD Not Applicable 505 070 020 505 070 305

SUMMIT X Not Applicable 505 070 573 505 070 305

SUMMIT STANDARD HM Not Applicable 505 070 020 505 070 305

SUMMIT X HM Not Applicable 505 070 573 505 070 305

SUMMIT 500 F 414 859 300 505 070 698 414 968 600

GRAND TOURING SE Not Applicable 505 070 684 505 070 298

GRAND TOURING

STANDARD Not Applicable 505 070 686 Not Applicable

GRAND TOURING GS Not Applicable 505 070 686 Not Applicable

TOURING 500 F 414 956 300 505 070 685 415 039 700

TOURING 380 F 414 956 300 505 070 685 415 039 700

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