Bombardier ÉLÁN, ALPINE II 503, CITATION, TUNDRA, NORDIK, SCOUT, SAFARI, CHEYENNE, FORMULA MX, FORMULA PLUS & FORMULA MACH 1 Snowmobile Shop Manual 1991

Bombardier Ski-Doo Snowmobile Shop Manual - 1991 Edition

This factory-issued service document provides the foundational engineering data required for the maintenance and structural repair of 1991 Bombardier snowmobiles. Precise chain tensioner adjustment—specifically maintaining a deflection of no more than 38 mm (1.5 in)—is critical to prevent premature sprocket wear and catastrophic drive system failure during high-load operation.

Technical Applicability & Model Configurations

Utility & Work Series (Long Track / Heavy Duty)

• ALPINE II 503 (Model 3352)
• NORDIK 50 (Model 3251)
• NORDIK 60 (Model 3252)
• CHEYENNE (Model 3648)

Recreational & Sport Series (Leaf Spring / Telescopic / Direct Drive)

• ÉLAN (Model 3048)
• CITATION & CITATION E (Models 3247, 3248)
• TUNDRA & TUNDRA LT (Models 3249, 3250)
• SCOUT (Model 3649)

Performance & Touring Series (Safari & Formula Chassis)

• SAFARI L, LE, LX, LXE, LCE, GLX (Models 3650, 3651, 3652, 3653, 3656, 3664)
• FORMULA MX & MX E (Models 3755, 3756)
• FORMULA MX XTC, XTC E, SS/SR (Models 3757, 3758, 3769, 3770)
• FORMULA PLUS & PLUS E (Models 3759, 3781)
• FORMULA PLUS XTC, XTC E, SS/SR (Models 3760, 3782, 3771, 3772)
• FORMULA MACH 1 & MACH 1 XTC (Models 3762, 3763, 3773)

Service Accuracy & Operational Longevity

• Engineering-grade specifications ensure all repairs meet original equipment manufacturer (OEM) safety standards for high-speed operation.
• Correct identification of model-specific serial number prefixes (e.g., 3048 for ÉLAN) prevents incorrect parts ordering and assembly errors.
• Detailed procedural steps for transmission and chassis synchronization reduce downtime during seasonal maintenance intervals.

Technical Document Metadata

• Document Type: Full Shop Manual
• Language: US English
• Total Content: Detailed Technical Sections (01-10+)
• Application Year: 1991

Technical Depth & Factory Benchmarks

System-specific data facilitates precise calibration of the drivetrain and engine components. This manual includes factory-set tolerances for gear ratios and drive chain lengths, allowing for modification based on specific application needs using available sprocket sizes (20, 22, 26 teeth for upper and 38, 40, 44 teeth for lower).

Visual Navigation Aids & Component Architecture

Exploded-view diagrams illustrate complex sub-assemblies, such as the chaincase and countershaft bearing housing. These schematics provide visual confirmation for the sequence of shims, circlips, and oil seals, ensuring that the drive axle axial play adjustment remains within factory-specified limits.

Table of Contents

• Introduction and Serial Number Identification
• Service Tools and General Maintenance
• Transmission (Chaincase, Drive Axle, Pulse Drive)
• Brake System (Disc and Caliper Service)
• Suspension (Front and Rear Configurations)
• Steering System
• Engine (Liquid-Cooled and Fan-Cooled Data)
• Fuel System and Carburetion
• Electrical System and Wiring Diagrams
• Technical Data and Vehicle Specifications

Operational Limits & Specifications

• Drive Chain Deflection: Maximum 38 mm (1.5 in) before replacement is required.
• Fastener Torque: M10 x 45 Cap Screws and M10 x 20 components require specific torque sequences and the application of Loctite 242.
• Fluid Maintenance: Specific drain and refill procedures for the chaincase cover using the integrated dipstick for level verification.
• Transmission Geometry: Standardized gear ratio/chain length charts (68, 70, 72 links) to maintain optimal drive tension.