Positioning:
Targeted towards 2002 Ski-Doo snowmobile owners and independent repair shops seeking to perform all maintenance and repairs on their vehicles.
Alternatives:
While unofficial third-party manuals exist, this factory service manual offers the most accurate and complete information directly from the manufacturer.
Features:
Factory-backed, comprehensive coverage, detailed diagrams, torque specifications, troubleshooting guides, and complete teardown/rebuild procedures.
Models Covered:
Comprehensive list of 2002 Ski-Doo models (specific models would require manual contents review, but implies full range). Likely includes Grand Touring, Formula, MXZ, Summit, Touring, etc. variants.
Regions Covered:
Global (based on factory service manual scope)
Estimated Page Count:
Variable by specific model variation, but typically 500-1000+ pages for a full factory service manual.
Type:
Factory Service Manual / Repair Manual
Engine:
Complete engine teardown, rebuild, tuning, diagnostics for Rotax engines (e.g., Rotax 500, 600, 700, 800 liquid-cooled twin-cylinder engines common in 2002 models).
Transmission Drivetrain:
Primary clutch (Drive), Secondary clutch (Driven), chaincase, drive shaft, track systems, lubrication, troubleshooting, and repair procedures.
Fuel System:
Carburetor specifications, tuning, cleaning, fuel pump, fuel lines, fuel filter replacement, and related diagnostics.
Electrical System:
Ignition system (CDI, ignition coils), lighting, starter system, battery maintenance, wiring diagrams, troubleshooting electrical faults, component testing.
Suspension Steering:
Front and rear suspension systems (e.g., SC-10, SC-4, DSS), shock absorber service, spring replacement, alignment, steering linkage, ski alignment, tie rod adjustment.
Brakes:
Hydraulic brake system service, caliper rebuild, brake pad replacement, brake fluid specifications and bleeding procedures, master cylinder service.
Bodywork Chassis:
Tunnel inspection and repair, hood and windshield removal/installation, seat removal, body panel fasteners, decals, and graphics.
Cooling System:
Liquid-cooled engine thermal management, radiator service, coolant specifications, water pump inspection and replacement, hose routing and replacement.
Maintenance:
Scheduled maintenance intervals, lubrication points, belt inspection and replacement, spark plug replacement, air filter cleaning/replacement.
Troubleshooting:
Systematic diagnostic flowcharts and procedures for common issues such as starting problems, poor performance, overheating, and electrical faults.
Repair:
Detailed step-by-step instructions for component removal, disassembly, inspection, repair, assembly, and reinstallation.
Rebuild:
Complete engine teardown and rebuild procedures, including piston, ring, crankshaft, and cylinder specifications.
Specifications:
Torque specifications for all critical fasteners, engine tolerances, electrical system specifications, and component clearances.
Depth:
Comprehensive. Covers everything from basic owner-level maintenance to advanced engine rebuilds and troubleshooting.
Diagnostic Tools:
Mentions procedures that may require specialized tools, though primarily focuses on standard mechanic tools.
Engine Type:
Rotax Two-Stroke, Liquid-Cooled, Twin-Cylinder (Common for 2002 models).
Engine Variants:
Likely covers displacements such as 500cc, 600cc, 700cc, and 800cc, depending on specific models included.
Horsepower Range:
Variable by engine size, typically 80-150+ HP for this era of Rotax engines.
Torque Range:
Variable by engine size.
Carburetion:
Mikuni or Keihin Carburetors (e.g., VM series), with specific jetting and tuning information provided.
Fuel Type:
Unleaded Gasoline (typically 87 or 89 octane, with oil premix for two-stroke models).
Oil Type:
Specific Ski-Doo 2-stroke synthetic oil or equivalent API-TC certified oil (as per manual).
Ignition System:
Digital CDI (Capacitor Discharge Ignition) system.
Type:
CVT (Continuously Variable Transmission) with Bombardier's TRA (Transition) Clutch System.
Optional Transmissions:
N/A (CVT was standard across most performance and touring models).
Clutch Service:
Detailed procedures for primary (TRA) and secondary clutch disassembly, inspection, component replacement (rollers, springs, buttons), and calibration.
Chaincase:
Chaincase lubrication, chain tension adjustment, sprocket inspection, and seal replacement.
Pre Ride Inspection:
Daily/pre-ride checks: track tension, lubrication, fluid levels, controls, lights, and visual inspection of damage.
Break In Service:
Initial break-in procedure and inspection after first 500-1000 miles/hours, including clutch alignment and belt inspection.
Annual Maintenance:
Annual service: spark plug replacement, drive belt inspection/replacement, chaincase oil change, coolant check, chassis lubrication, and general inspection.
Engine Oil:
2-stroke synthetic oil meeting API-TC specification (e.g., Ski-Doo XPS Synthetic 2-Stroke Oil).
Coolant:
Proprietary Ski-Doo coolant or equivalent ethylene glycol-based coolant with corrosion inhibitors for aluminum engines, typically a 50/50 mix with distilled water.
Chaincase Oil:
Hypoid gear oil, SAE 75W-90 (e.g., Ski-Doo XPS Synthetic Chaincase Lube).
Brake Fluid:
DOT 4 hydraulic brake fluid.
Common Wear Items:
Drive belt wear, clutch roller wear, suspension bushings, shock absorber seals, track lugs, and carbides.
Engine Specific:
While Rotax engines are robust, issues like power valve operation, crank seals, and exhaust can require attention. Overheating if cooling system is compromised.
Heritage:
Ski-Doo, a division of Bombardier Recreational Products (BRP), has been a pioneer in snowmobile innovation since its inception in 1959.
2002 Context:
The 2002 model year represented a refinement of Ski-Doo's established platforms, focusing on performance, rider comfort, and reliability, often featuring Rotax engine technology.
Manufacturing Location:
Primarily manufactured in Canada (Valcourt, Quebec) and Finland for North American and European markets.
