Manual Details
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Coverage Areas
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Covered Models:
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Formula Deluxe 380, Formula Deluxe 500, Formula Deluxe 500 LC, Formula Deluxe 600, Formula Deluxe 700, Formula III 700R, Formula III 800, Formula S, Formula S 500 LC, Formula Z 600, Formula Z 700, Grand Touring 600, Grand Touring 700, Grand Touring 700 SE, Grand Touring 700 SE Millennium Edition, Mach 1 R, Mach 1 Z, Mach 1 ZR, Mach Z R Millennium Edition, Mini Z, MX Z 440, MX Z 500, MX Z 600, MX Z 700, MX Z 700 Millennium Edition, Skandic 380, Skandic 500, Skandic WT, Skandic SWT, Skandic WT LC, Summit 600, Summit 700, Summit 700 HM, Summit 700 Millennium Edition, Touring E, Touring LE, Touring SLE, Touring 500 LC, Tundra R
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Page Count
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Estimated Page Count:
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Varies significantly by model and engine, typically 300-600+ pages per manual
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Manual Type
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Manual Type:
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Factory Service Manual (FSM) / Repair Manual
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Manual Content Type:
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Factory Service Manual (FSM) includes detailed repair, maintenance, troubleshooting, and diagnostic information.
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Language
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Language:
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English
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Format
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Format:
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Digital Download (PDF)
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Manual Coverage
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Systems Covered
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Engine Systems:
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Engine mechanical (disassembly, inspection, assembly), cooling system, lubrication system, fuel system (carburetion, fuel pump), ignition system, exhaust system, engine diagnostics, troubleshooting.
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Drivetrain Systems:
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Primary clutch, secondary clutch, drive belt, chaincase, torque limiter, driveshaft, driven shaft, track, suspension components.
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Electrical Systems:
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Ignition system, lighting, charging system (stator, rectifier/regulator), starter motor, battery, instrument cluster, wiring diagrams, electrical troubleshooting.
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Chassis And Body:
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Frame, handlebars, steering system, seat, body panels, windshield, storage compartments, braking system (hydraulic or mechanical, depending on model), skis, track system.
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Suspension Systems:
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Front suspension (e.g., Type 4A, SC-4), rear suspension (e.g., R.A.V.E. valve system, various sliding rail or articulating designs), shock absorbers, springs, and associated linkage. Includes adjustment and overhaul procedures.
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Braking System:
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Hydraulic disc brake system (front and/or rear, depending on model), including caliper service, master cylinder, brake fluid type, bleeding procedures, and pad replacement.
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Steering System:
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Handlebar assembly, steering post, tie rods, spindle lubrication, and alignment procedures.
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Procedures Included
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Maintenance Procedures:
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Scheduled maintenance intervals, lubrication points, belt inspection and replacement, coolant checks and replacement, spark plug replacement, air filter cleaning/replacement, track tension adjustment, brake adjustments.
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Repair Procedures:
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Engine overhaul, clutch service and adjustment, carburetor cleaning and rebuilding, transmission (chaincase) service, brake system repairs, electrical component replacement, suspension component replacement, track system repairs.
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Troubleshooting:
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Systematic diagnosis of common and uncommon issues, diagnostic charts, symptom-based troubleshooting guides, electrical diagnostic procedures, engine performance troubleshooting.
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Engine Rebuild:
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Detailed step-by-step instructions for engine disassembly, inspection of pistons, rings, cylinders, crankshaft, bearings, and reassembly with torque specifications.
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Carburetor Tuning:
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Procedures for jetting, needle settings, idle speed adjustment, and synchronization for twin-carburetor setups are provided.
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Track And Skid Maintenance:
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Procedures for track removal, installation, alignment, and adjusting track tension. Skid frame inspection and bearing service.
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Technical Depth
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Technical Depth:
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Comprehensive, covering routine maintenance, diagnostics, component-level repair, and complete system overhauls. Includes detailed specifications, tolerances, and procedures for factory-level service.
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Electrical Diagrams:
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Includes complete, model-specific wiring diagrams for troubleshooting electrical systems, ignition, lighting, and accessories.
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Component Specifications:
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Provides critical specifications such as torque values, clearances, runout tolerances, and electrical resistance values for accurate component servicing.
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Maintenance
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Service Intervals
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Routine Maintenance Schedule:
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The manual provides detailed service intervals for tasks such as checking track tension, inspecting drive belts, lubricating suspension components, checking chaincase oil, inspecting and cleaning carburetors, and spark plug replacement.
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Engine Specific Maintenance:
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Detailed maintenance schedules tailored to specific engine sizes (380, 500, 600, 700, 800) and cooling types (fan-cooled vs. liquid-cooled).
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Fluid Specifications
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Engine Oil Type:
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Specified 2-stroke synthetic oil meeting Ski-Doo/Rotax specifications (e.g., XPS synthetic). Oil injection system service and troubleshooting are covered.
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Chaincase Oil Type:
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Specific gear oil (e.g., SAE 80W-90 API GL-4 or GL-5) or specialized chaincase lubricants are recommended. Capacities are provided for each model.
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Coolant Type:
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For liquid-cooled (LC) models, a specific antifreeze/coolant mixture (e.g., ethylene glycol based with corrosion inhibitors) is specified. Capacities are provided.
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Grease Points:
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Identifies all lubrication points requiring grease, with recommended grease types and service intervals.
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Known Issues
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Common Wear Items:
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Drive belts, carbides (on skis), hyfax (on skis), brake pads, and clutch components are common wear items that require regular inspection and replacement.
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Engine Considerations:
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Proper warm-up procedures, correct oil-fuel mixture (if premixing), and avoiding prolonged idling are crucial for longevity of Rotax two-stroke engines. Carburetor tuning can be sensitive to altitude and temperature.
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