2004 Ski-Doo Elite Factory Service Manual, Page 298Get this manual
Section 10 BODYFRAME Subsection 01 (BODY)
CAUTION: If for some reason the snowmobile has to be stored outside, it is preferable to cover it with an opaque tarpaulinThis will prevent the sun rays from affecting the plastic components and the vehicle finish
Air Bubbles
Possible cause: Air pocket trapped between layers of laminate and gelcoatPREPARATION OF SURFACE Remove all of the damaged gelcoat surrounding the air bubble with putty knife or preferably carbide grinding tipMake sure all loose and weak areas are completely removedSand small area of the gelcoat surface with 220-grit sandpaperIf needed, sand the cavity itselfThese areas must have rough surface to allow the gelcoat putty to bond properlyFILLING THE CAVITY The prepared surface must be cleaned with acetone on clothUse gelcoat repair kitFollow the mixing instructions in the kit when preparing the gelcoat puttyCarefully mix the required amount while making sure there are no air bubbles in the mixtureWith putty knife, fill the repair area and cover with plastic filmCuring time may depend on temperature, amount of putty and percentage of catalystAfter hours, press lightly on the surface with fingers to test the hardnessWhen the area becomes hard, remove the plastic filmSANDING Begin block sanding the patch with 320-grit sandpaper until you come close to the original surfaceRemove dust with water soaked cloth and continue sanding with 400-grit wet paperFinish wet sanding with 600-grit to remove deeper scratchesIf needed you can wet sand with finer grit paper such as 1000-gritBUFFING AND WAXING Buff the surface using heavy duty polisher with buffing padMake sure the pad is free of dirt or you may damage the gelcoatCarefully begin buffing with white medium compoundFinish off using fine compoundWhile buffing, pay close attention to avoid overheating the surface