1999 Ski-Doo Tundra/R, Touring E/LE/SLE, Formula S/SL, Formula Deluxe 377/503, and Skandic 380/500 Snowmobile Shop Manual Set (P/N 484 200 001)

The ZX supplement supersedes selected Volume 2 procedures. It refers back to Volume 2 for routine maintenance, troubleshooting, and most engine work.

The included supplement is marked FOR APPROVAL ONLY. It directs readers to the separate Parts and Accessories Catalogs for ZX exploded views. The Operator’s Guides are also separate publications.

Search, Bookmarks, and Wiring Sheets

Text search and navigation are available in the shop-manual chapters and the ZX supplement. Bookmarks open the volumes, their main sections, and the supplement. The wiring sheets are outside text search, and small wire-color codes and connector labels are best read at higher zoom.

The set comes in one printable PDF with 1,141 pages, including the three volume covers and eight wiring-diagram pages appended after the supplement.

Engine Overhaul, Clutch Service, and Electrical Testing

These are selected workshop topics. The set also covers rewind starter service and ZX windshield installation.

• Engine repair covers step-by-step removal and installation, in-chassis top-end work where applicable, bottom-end overhaul, and crankcase leak verification.

• Fuel and oil systems include carburetor and fuel-pump service, choke adjustment, and oil-injection pump identification, leak testing, synchronization, bleeding, and operational checks.

• Cooling systems cover the 277 radial fan, axial-fan belt inspection and replacement, and coolant-pump service on liquid-cooled engines.

• Clutch and driveline procedures cover Bombardier Lite and TRA drive pulleys, driven pulley service, belt alignment, chaincases, drive chains, and geared transmissions.

• Brake procedures cover mechanical-brake adjustment and hydraulic-brake service, including caliper work and bleeding.

• Electrical troubleshooting pairs model wiring diagrams and connector views with ignition timing, starter and lighting circuit tests, MPEM/DESS diagnosis, and RER checks.

• Chassis service includes rear suspension and shock work, drive axle and sprocket removal, track tension and alignment, steering and ski service, and body and frame repair.

Bombardier wrote the shop manuals primarily for snowmobile mechanics already familiar with Ski-Doo service procedures and the specified tools.

Engine Inspection and Fuel-System Diagnosis

Volume 1 separates the 277 from the 377, 443, and 503 engines. Volume 2 covers the 443, 494, 503, 583, and 670. Volume 3 covers the 599, 699, and 809, while the ZX supplement addresses the 453, 593, and 693. Inspection procedures cover cylinder taper and out-of-round, piston and ring wear, connecting-rod and crankshaft measurements, surface flatness, and crankshaft end play where applicable.

The Engine Leak Verification Flow Chart helps narrow down a pressure loss before teardown. Other procedures cover rotary valves, RAVE exhaust valves, tuned-pipe identification, and H.A.C. and DPM carburetion. The manual cautions that the 377/443/503 crankcase halves are factory-matched and that scoring the mating faces can cause leaks. An incorrect oil-injection pump or delayed pump opening can damage the engine.

Pulley, Gearbox, and Suspension Variants

The Pulley Alignment and Distance Specifications Chart helps match belt and alignment checks to the installed setup. The manuals distinguish Formula, LPV27, and HPV27 driven pulleys, including forward and reverse configurations. Volume 2 has separate procedures for the Skandic WT-series three-speed gearboxes and the two-speed units on the covered Grand Touring and Formula Deluxe models.

Suspension references include Torque Reaction and exploded views for SC-10 and ARM assemblies. The SC-10 sections distinguish Sport, Touring, High-Performance, Cross-Country, and Mountain builds. Separate procedures address Skandic WT suspension and Grand Touring SE air suspension. Drive-pulley work, rotating-track checks, pressurized shock service, brake repair, electrical testing, and internal engine work should be performed or verified by an experienced technician using the specified tools and normal shop-safety practices.

Ignition Diagrams and Factory Tools

Nippondenso and Ducati ignition tests complement the wiring annexes for the MX Z 670 HO/Summit X 670 and Formula III/Mach models. The appended ZX sheets cover the MX Zx 440 LC and MX Z 600/Summit 600. The supplement directs technicians to use the 600 diagrams for the corresponding MX Z 700 and Summit 700.

Factory tool references include the engine leak tester kit P/N 861 749 100, fuel and oil system leak tester kit P/N 529 033 100, and piston pin puller P/N 529 035 503 with 18 mm and 20 mm sleeve kits P/N 529 035 541 and 529 035 542. It also lists the pulley spring compressor P/N 529 035 524, track tension gauge P/N 529 021 500, and programmer P/N 529 035 589 for MPEM timing work.

Headlamp Voltage and ZX Toe-Out Examples

The lighting troubleshooting charts use 11 VAC and 15 VAC as the lower and upper headlamp diagnostic limits when voltage is checked at different engine speeds.

For the ZX ski toe-out check with the front suspension fully extended and the skis unloaded, the supplement specifies 0 ± 3 mm for the MX Zx 440 LC and 8 ± 3 mm for the MX Z 600/700 and Summit 600/700.