Comprehensive Repair & Maintenance Reference: Ski-Doo ELAN, TUNDRA II LT, SKANDIC 380/500, TOURING E/LE/SLE, FORMULA S/SL (1996)

Bombardier Ski-Doo Snowmobile Shop Manual - 1996 Edition

This factory-authorized service manual provides the fundamental technical framework for the maintenance and repair of 1996 Bombardier Ski-Doo snowmobiles. The integration of Molykote G-n paste during rewind starter assembly is vital for uptime, as it ensures consistent mechanical engagement and prevents premature spring fatigue in cold-weather environments.

Technical Applicability & Product Identifiers

The 1996 model year is categorized by chassis configuration and specific model numbers to ensure precise part selection and service procedures.

S-Series Chassis Models

• Touring E (Model 1530)
• Touring E LT (Models 1542, 1543)
• Touring LE (Models 1527, 1528, 1529)
• Touring SLE (Models 1524, 1525, 1526)
• Skandic 380 (Models 1534, 1535, 1536)
• Skandic 500 (Models 1531, 1532, 1533)
• Formula S (Models 1523, 1541)
• Formula SL (Models 1521, 1522, 1540)

Specialized Chassis Models

• Élan (Model 3053)
• Tundra II LT (Models 3264, 3265)

Operational Advantages & Service Accuracy

• Structural integrity is maintained through specific frame welding parameters, including a 70-110 A amperage range for steel components.
• Reliability is enhanced by strict adherence to the 10-hour dealer inspection interval for transmission retorquing.
• Component longevity is secured by using specified lubricants, such as synthetic chaincase oil (P/N 413 8028 00) for high-performance gearboxes.
• Safety protocols are standardized via universal torque sequences for critical engine and suspension fasteners.

Technical Documentation Metadata

• Publication Number: 484 0628 00
• Total Pagination: Multi-section Volume 1
• File Format: Digital PDF / Shop Manual

Technical Depth & Factory Benchmarks

Engine calibration and mechanical tolerances are defined by specific displacement and engine types:

• Rotary Valve Clearance: Must be maintained between 0.27 – 0.48 mm (0.011 – 0.019 in) for optimal intake timing.
• Crankshaft Deflection: Maximum allowable limit at the center is 0.08 mm (0.0031 in).
• Piston Ring End Gap: New parts must measure 0.200 mm (0.008 in) with a wear limit of 1.000 mm (0.040 in).
• Cylinder Taper Limit: Maximum allowable variance is 0.08 mm (0.003 in).

Visual Navigation Aids

• Exploded System Views: Detailed schematics for TRA drive pulleys, SC-10 suspensions, and Mikuni carburetors.
• Flow Chart Diagnostics: Engine leak verification sequences using the 5 PSI (140 in H2O) pressure test.
• Wiring Layouts: Annexed diagrams with color-coded identification for AC/DC circuit separation.
• Tool Mapping: Application tables linking specific P/N tools (e.g., P/N 529 0224 00 puller) to engine types.

Table of Contents

• 01 Service Tools and Products: Mandatory and optional shop equipment.
• 02 Lubrication and Maintenance: Periodic inspection charts and storage procedures.
• 03 Troubleshooting: Diagnostic matrices for engine, fuel, and transmission symptoms.
• 04 Engine: Top-end and bottom-end overhaul for 247, 277, 377, 443, and 503 types.
• 05 Transmission: TRA drive pulley, driven pulley, and chaincase calibration.
• 06 Electrical: CDI system, ignition timing, and lighting circuit testing.
• 07 Rear Suspension: Bogie wheels, Torque Reaction, and SC-10 system service.
• 08 Steering / Front Suspension: DSA system alignment and ski leg maintenance.
• 09 Body / Frame: R.I.M. repair procedures and frame welding specs.
• 10 Technical Data: SI metric conversion and comprehensive engine/vehicle specifications.

Operational Limits & Torque Specifications

• Drive Pulley Retaining Screw: Initial torque to 105 N•m (77 lbf•ft); final torque after 5-cycle brake test to 95 N•m (70 lbf•ft).
• Cylinder Head Nuts: Cross-torque sequence to 22 N•m (16 lbf•ft).
• Chaincase Oil Capacity: 200 mL (7 fl. oz) for Tundra models; 250 mL (8.5 fl. oz) for S-Series.
• Fuel System Pressure: Maximum leak test pressure not to exceed 5 PSI.
• Track Tension: 45 to 50 mm deflection under a 7.3 kg (16 lb) downward pull.