Pro Maintenance Guide: Ski-Doo Formula MX, Formula Plus, Formula Mach, Grand Touring, Summit (1990-1995)
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Sample pages from the Pro Maintenance Guide: Ski-Doo Formula MX, Formula Plus, Formula Mach, Grand Touring, Summit (1990-1995) manual
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Document Details
- Document Number / Seller:
- 26652 / Walter Williams
- File Size:
- 136.06 MB
- File Type:
- Language:
- English
- Pages:
- 528
- Printable:
- Yes
- Estimated Download Time:
- 2.79 Minutes
- Delivery Format:
- Digital (PDF) - Instant Access
- Category:
- Snowmobile
- Brand:
- Ski-Doo
- Reviewed and Approved:
- Dec 31, 2025
Models Covered & Key Technical Specifications
- Ski-Doo Formula MX (1990-1995)
- Ski-Doo Formula Plus (1990-1993)
- Ski-Doo Formula Mach 1 (1990-1995)
- Ski-Doo Grand Touring (1993-1995)
- Ski-Doo Formula MX LT (1990-1991)
- Ski-Doo Formula Plus LT (1990-1991)
- Ski-Doo Formula MACH 1 XTC (1990-1993)
- Ski-Doo Formula MX E (1991)
- Ski-Doo Formula MX X (1991)
- Ski-Doo Formula MX XTC (1991)
- Ski-Doo Formula MX XTC E (1991)
- Ski-Doo Formula MX XTC SS/SR (1991)
- Ski-Doo Formula MX XTC E SS/SR (1991)
- Ski-Doo Formula Plus E (1991-1993)
- Ski-Doo Formula Plus X (1991-1993)
- Ski-Doo Formula Plus XTC (1991-1993)
- Ski-Doo Formula Plus XTC E (1991-1992)
- Ski-Doo Formula Plus XTC SS/SR (1991)
- Ski-Doo Formula Plus XTC E SS/SR (1991)
- Ski-Doo Formula MACH 1 X (1991-1992)
- Ski-Doo Formula MACH 1 XTC SS/SR (1991)
- Ski-Doo Formula MX XTC R (1992-1993)
- Ski-Doo Formula MACH 1 XTC II (1992)
- Ski-Doo Formula MX Z (1993-1995)
- Ski-Doo Formula MX ZA (1993)
- Ski-Doo Formula Plus EFI (1993)
- Ski-Doo Summit 470 HAC (1994)
- Ski-Doo Formula ST (1994)
- Ski-Doo Formula STX (1994-1995)
- Ski-Doo Formula STX II (1994)
- Ski-Doo Formula Z (1994-1995)
- Ski-Doo Summit 583 (1994-1995)
- Ski-Doo Grand Touring XTC (1994)
- Ski-Doo Grand Touring SE (1994-1995)
- Ski-Doo Formula SS (1995)
- Ski-Doo Formula STX (LT) (1995)
- Ski-Doo Summit 670 (1995)
- Ski-Doo Grand Touring 580 (1995)
- Ski-Doo Grand Touring 470 (1995)
Professional Workshop Service Manual & Technical Specifications
Ski-Doo Snowmobiles Service Manual - 1990-1995 Edition
This official-grade service manual provides professional-level technical guidance for the maintenance, troubleshooting, and repair of high-performance Rotax-powered snowmobiles. A critical operational requirement detailed within involves the precision synchronization of the Throttle Position Sensor (TPS) on fuel-injected models; ensuring a DC voltage output between 0.1-0.3 volts at closed throttle is vital for maintaining correct idle stability and engine uptime.
Technical Applicability & Model Generations
1990-1992 Formula Series (PRS Front Suspension)
- Formula MX / MX LT (1990-1992)
- Formula Plus / Plus LT / Plus E (1990-1992)
- Formula Mach 1 / Mach 1 XTC (1990-1992)
1993 Transition Models (Mixed Suspension/Engine Configurations)
- Formula MX / MX Z / MX XTC R (1993)
- Formula Plus / Plus E / Plus X / Plus EFI (1993)
- Formula Mach 1 (1993)
- Grand Touring (1993)
1994-1995 High-Performance Series (DSA Front Suspension)
- Formula MX / MX Z (1994-1995)
- Formula ST / STX / STX II / STX (LT) (1994-1995)
- Formula Z / Formula SS (1994-1995)
- Summit 470 / 583 / 670 (1994-1995)
- Grand Touring 470 / 580 / SE (1994-1995)
- Mach 1 (1994-1995)
Professional Service Advantages
- Detailed Electronic Fuel Injection (EFI) diagnostic tables facilitate rapid fault isolation through long/short flash code interpretation.
- Step-by-step drive system calibration ensures optimal power transfer by defining exact pulley offset (X, Y, and Z distances).
- Comprehensive electrical schematics for every production year provide verified wiring color codes and connector pinouts for reliable system repairs.
Document Metadata
- Print Number: CLY-B736
- Total Pages: 570+
- File Format: PDF Digital
Technical Depth & Factory Benchmarks
Diagnostic procedures for the capacitor discharge ignition (CDI) systems utilize specific resistance values for generating and trigger coils. For 1993-on models (excluding the 583 engine), the trigger coil air gap must be strictly maintained between 0.55-1.45 mm (0.022-0.057 in.) to ensure consistent ignition timing. EFI models further include barometric pressure sensor benchmarks, requiring an output of 4.0 volts at 101.3 kPa to maintain precise air/fuel mapping.
Visual Navigation Aids
- Exploded System Architecture: Detailed diagrams for single and dual exhaust manifolds, including spring tension points and gasket interfaces.
- Drive Train Mapping: Multi-angle views of the drive and driven pulley assemblies, highlighting shim placement for axial clearance.
- Chassis Electrical: Full-page wiring diagrams for standard and EFI-equipped models, including heated grip and accessory circuit integrations.
Table of Contents
- Chapter One: General Information & Fastener Torque
- Chapter Two: Troubleshooting (Engine, Drive, & Electrical)
- Chapter Three: Lubrication, Maintenance, and Tune-up
- Chapter Five: Rotax Engine Service (Top End & Lower Unit)
- Chapter Seven: Electronic Fuel Injection (EFI) Systems
- Chapter Nine: Electrical System & Starter Motor
- Chapter Ten: Oil Injection System Calibration
- Chapter Thirteen: Drive System & Clutch Tuning
- Chapter Fourteen: Brake, Jackshaft, and Drive Axle
- Chapter Nineteen: Comprehensive Wiring Diagrams
Operational Limits & Specifications
| Component | Specification | Lubricant / Sealant |
|---|---|---|
| Flywheel Nut (670 Engine) | 125 N.m (92 ft.-lb.) | Loctite 242 (Blue) |
| Drive Pulley Bolt | 105 N.m (77 ft.-lb.) | Clean Taper (Dry) |
| Steering Tie Rod Nut | 53 N.m (39 ft.-lb.) | Self-Locking |
| Fuel Sensor Screws | 2.5 N.m (22 in.-lb.) | New Gasket Required |
| Starter Bushings | G.E. Versilube G321 | Low-Temp Grease |
| Chaincase Oil | Bombardier Chaincase Oil | 250 ml (Approx.) |
Manual Access & Delivery Information
FAQ
Is this manual suitable for beginners?
Yes, this Ski-Doo manual is designed for both professional technicians and DIY enthusiasts. It includes step-by-step procedures with clear illustrations and safety guidelines for Snowmobile maintenance and repair.
What file format will I receive?
You will receive this manual as a PDF file (136.06 MB), which is compatible with all devices. The manual is fully searchable and printable for your convenience.
How quickly can I access the manual after purchase?
You'll receive instant access to your Ski-Doo Snowmobile manual immediately after payment completion. The download link is valid for 3 days, with lifetime re-download guarantee.
Can I print specific sections of the manual?
Absolutely! This digital manual allows you to print any section you need, from individual pages to complete chapters, making it perfect for workshop use.
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