Ski-Doo 1999 Snowmobile Shop Manual Collection — Volumes 1–3, Mini Z & ZX Supplement (P/N 484 200 001)

The ZX supplement supersedes the corresponding Volume 2 information and refers back to that volume for most base repair procedures.

For ZX exploded views, the supplement refers to the matching Parts and Accessories Catalogs. Those catalogs are not included.

PDF Search, Chapter Links and Wiring Pages

Text search and navigation: Service text and specification tables are searchable, but most wiring-diagram labels are not. All files contain bookmarks. Volumes 1–3 use links between chapter PDFs, so keep the extracted folders together; some Volume 1 links use different filename capitalization. Small wiring labels require zooming, and several diagrams extend across multiple pages.

The ZIP contains 38 printable PDFs totaling 1,305 pages. These counts include the original covers, copyright pages, publisher feedback/mail pages and wiring-annex dividers. The supplement contains 18 numbered pages followed by eight wiring-diagram pages.

Rotax Powertrain, Suspension and Electrical Service

These selected repair topics represent part of the publications’ coverage. Additional subjects include rewind-starter service and body/frame repair.

• Rotax engine repair: Removal and installation, top- and bottom-end disassembly, crankshaft and piston inspection, engine measurements, and crankcase leak testing.

• Fuel, oil and cooling: Carburetor setup, fuel-pump checks, oil-injection adjustment and bleeding, fan cooling, liquid-cooling service, and model-specific mixture controls.

• Transmission and brakes: Drive and driven pulley repair, pulley alignment, mechanical and hydraulic brakes, chaincases, gearbox disassembly, and shift-linkage adjustment.

• Suspension and track: Torque-reaction, SC-10, ARM and Skandic WT assemblies; drive-axle service, track setup, shock inspection, and steering geometry.

• Electrical diagnosis: Nippondenso and Ducati CDI systems, MPEM, RER and DESS, battery and starter repair, ignition and lighting tests, and model-specific wiring diagrams.

• Mini Z repair: Four-stroke engine disassembly, cold valve adjustment, compression testing, carburetor and governor adjustment, clutch service, and chain-drive inspection.

Bombardier published these manuals primarily for snowmobile mechanics already familiar with servicing Bombardier-built machines; the procedures assume proper hand tools and special service tools.

Engine Inspection and Fuel-System Differences

Step-by-step procedures cover internal engine work, including RAVE and rotary-valve service where fitted. The Engine Leak Verification Flow Chart connects pressure checks with joint, seal and auxiliary-system checks, supporting fault isolation before teardown.

The fuel chapters distinguish the Summit 500 H.A.C. system from DPM-equipped applications. The H.A.C. unit has no internal adjustment or verification procedure; the manual addresses hose condition and replacement of a suspected faulty unit.

For ZX Summit 600/700 and MX Z 700 models, DPM provides compensation only. This version does not use the air pump or enrichment mode described for other DPM systems. Cooling coverage also separates axial-fan procedures from liquid-cooling, thermostat and coolant-pump work.

Pulley, Gearbox and Suspension Variants

The transmission sections distinguish Bombardier Lite and TRA drive pulleys from Formula, LPV27 and HPV27 driven assemblies. Volume 2 assigns the two-speed gearbox to Grand Touring and specified Formula Deluxe models, while the three-speed unit belongs to Skandic WT/SWT/WT LC.

Suspension coverage includes SC-10 Sport, Touring, High-Performance, Cross-Country and Mountain versions, plus the GT SE air-suspension components. The ZX supplement adds Advanced Direct Shock Action front-suspension adjustment and MX Zx 440 LC shock-reservoir disassembly, reassembly and nitrogen-charging information.

The TRA sections warn that an imperial-thread puller can damage the pulley’s metric threads. On the MX Zx 440 LC, mismatched left and right anti-transfer block positions can warp the rear suspension.

Clutch and suspension repair involves loaded springs, while running electrical checks expose a moving track; follow the factory warnings and support procedures before working on these systems.

Diagnostic References and Required Tools

Diagnostic support includes DPM component-location and system-operation diagrams, the Pulley Alignment and Distance Specifications Chart, SC-10 and GT SE air-suspension exploded views, and the ADSA Camber Adjustment Setup. Wiring annexes identify connector housings and pin locations.

Electrical procedures cover starter circuits, AC-circuit isolation and heating-element tests. The ZX supplement also documents MPEM timing changes using the specified programmer.

Tool references include engine leak tester P/N 861 749 100, fuel/oil leak tester P/N 529 033 100, and piston-pin puller P/N 529 035 503 with engine-specific sleeve kits.

Pulley and electronic service references identify TRA puller P/N 529 022 400, DESS programmers P/N 529 035 585 and 529 035 589, and ZX camber tool P/N 529 021 600.

A Preview of ZX Carburetor and Oil-System Specifications

For MX Z 600/700 and Summit 600/700, the carburetor tables specify a float height of 22.9 ± 1 mm.

The supplement gives an oil-system leak-test pressure of 20 kPa (2.9 PSI), with no pressure drop over three minutes. This test applies to the oil-injected ZX models and excludes the premix MX Zx 440 LC.