1999 Ski-Doo Tundra/R, Touring E/LE/SLE, Formula S/SL, Formula Deluxe 377/503, and Skandic 380/500 Snowmobile Shop Manual Volume 1 (P/N 484 200 001, 484 200 003)

This PDF assembles three factory Bombardier 1999 Ski-Doo Shop Manual volumes, an 18-page ZX-series supplement, and eight appended wiring-diagram pages. It is a multi-document set, not a single 1,141-page issue under P/N 484 200 001.

• 1,141-page set: Volume 1, P/N 484 200 001, 388 pages; Volume 2, P/N 484 200 003, 413 pages; Volume 3, P/N 484 200 005, 314 pages; Service Bulletin No. 99-8, 18 pages; plus eight wiring-diagram pages.
• S-Series and utility coverage: Volume 1 covers Tundra/R, Touring E/LE/SLE, Formula S/SL, Formula Deluxe 380/500, and Skandic 380/500. Volume 2 adds MX Z 440, 500, 670 HO, and 670 HO T.H.; Formula Z 500, 583, and 670; Formula Deluxe 500 LC, 583, and 670; Summit 500/X 670; Grand Touring 500/583; and Skandic WT/SWT/WT LC.
• CK3 and ZX coverage: Volume 3 covers Grand Touring 700/SE, Formula III 600/700/800, Mach 1 and 1 R, and the Mach Z, Z R, Z M.H. R, Z LT, and Z LT R variants. Bulletin 99-8 applies to all serial numbers of MX Z 600 model nos. 1336/1337/1338, MX Z 700 1339/1340/1341, MX Zx 440 LC 1342/1343/1344, Summit 600 1345/1346/1361, and Summit 700 1467/1468.
• Engine repair procedures: Covers 277, 377, 443, 453, 494, 503, 583, 593, 599, 670, 693, 699, and 809 platforms, with removal and installation, in-chassis top-end work where applicable, top- and bottom-end service, pressure leak testing, dimensional checks, crankshaft inspection, and final leak verification.
• Fuel, cooling, ignition, and controls: Includes oil-injection pump identification, leak testing, synchronization, bleeding, and operational checks; carburetor and fuel-pump repair; H.A.C. and DPM carburetion control; RAVE exhaust-valve service; MPEM/DESS electronics; RER reverse; 277 radial-fan, axial-fan, and liquid-cooling service; plus Nippondenso and Ducati ignition diagnosis.
• Clutch, gearbox, and brake repair: Details Bombardier Lite and TRA drive pulleys, Formula and HPV27 driven pulleys, belt service, pulley distance and alignment, chaincases and drive chains, Skandic WT two- and three-speed gearboxes, mechanical-brake adjustment, and hydraulic-brake repair and bleeding.
• Suspension, steering, body, and diagrams: Covers Torque Reaction, SC-10 Sport/Touring/High-Performance/Cross-Country/Mountain, ARM, Skandic WT, and Grand Touring SE air-suspension assemblies, plus drive axle, track, steering, ski, body, plastic, and frame service. Model wiring annexes, connector views, and circuit-identification material support fault tracing.

Repair and Diagnostic Depth

The engine chapters document crankcase pressure testing, cooling-system leak checks, cylinder taper and out-of-round inspection, piston, ring, connecting-rod, and crankshaft measurement, surface-flatness checks, and crankshaft end-play verification or adjustment where the design permits it. Volume 1 maps the 277 to Tundra/R; the 377 to Formula S, Touring E, Skandic 380, and Formula Deluxe 380; the 443 to Touring LE; and the 503 to Formula SL, Skandic 500, Touring SLE, and Formula Deluxe 500. Separate sections address rotary valves, coolant pumps, rewind starters, carburetor circuits, choke adjustment, fuel-pump verification, and tuned-pipe identification.

Symptom-based troubleshooting covers engine running problems, fuel and oil delivery, clutch and belt behavior, brakes, starter and lighting circuits, ignition, suspension, steering, and track. Electrical diagnosis adds component tests, harness and connector inspection, AC/DC circuit separation, ignition-timing checks, MPEM/DESS procedures, and DPM testing rather than relying on schematics alone.

Configuration-specific chapters distinguish Bombardier Lite from TRA drive pulleys, Formula from HPV27 driven pulleys, RER from non-RER arrangements, chaincase from Skandic gearbox service, and the different SC-10, ARM, utility, and Grand Touring SE air-suspension builds. Track removal, drive-axle and sprocket work, tension and alignment, steering inspection, shock checks, and ride-adjustment references are included.

Tools, Specifications, and Visual References

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 sleeve kit P/N 529 035 541 and 20 mm sleeve kit P/N 529 035 542. The set also identifies pulley spring compressor P/N 529 035 524, track tension gauge P/N 529 021 500, and programmer P/N 529 035 589 for supplement-specific MPEM timing changes.

Specification coverage includes the general 8.8-grade metric fastener torque chart and component tightening sequences. The technical-data sections add engine wear limits and clearances, ignition and charging tests, carburetor calibration, clutch and belt specifications, chain ratios, track and suspension settings, vehicle dimensions and weights, electrical data, approved lubricants, and system capacities.

Representative references include the Engine Leak Verification Flow Chart, Pulley Alignment and Distance Specifications Chart, SC-10 and ARM suspension exploded views, the MX Z 670 HO/Summit X 670 wiring annex, the Formula III/Mach 1/Z/Z LT wiring annex, and the appended two-sheet schematics for the ’99 MX Z X 440 LC and MX Z 600/Summit 600.

Scope and Model-Specific Cautions

The 377/443/503 crankcase halves are factory-matched and cannot be replaced as unrelated single halves; scoring their mating surfaces while removing old sealant can create persistent leakage. Oil-injection pump identification varies by engine and model, and the manual warns that an incorrect pump or delayed pump opening can cause serious engine damage.

The included copy of Bulletin 99-8 is marked FOR APPROVAL ONLY. It supersedes selected Volume 2 information for the listed ZX models, refers back to Volume 2 for many general repair procedures, and directs the reader to the applicable Parts and Accessories Catalogs for exploded views. Those catalogs and the Operator’s Guides are separate publications and are not part of this PDF.

These publications were written for mechanics already familiar with Ski-Doo service. 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.