Snowmobiles Ski-Doo 2005 - REV Series Repair Manual

DOWNLOAD Ski-Doo 2005 - REV Series Repair Manual - Back to all "Snowmobiles" - Ski-Doo parts catalog

Original Ski-Doo Shop manual covers the following models:
EXPEDITION - FJ5A, FJ5B
- GSX - DG5B, DF5A, DC5A, DC5B, DB5A, DB5B, DD5A, DD5B, DE5A, DE5B, DA5A, DA5B
- GTX - EM5A, EM5B, EL5A, EL5B, ED5A, ED5B, ED5C, EC5A, EC5B, EH5A, EH5B, EJ5A, EJ5B, EJ5C, EA5A, EA5B, EA5C
- MX Z - BR5A, BR5B, BR5C, BP5A, BP5B, BP5C, BF5A, BF5B, BF5C, BF5G, BF5H, BF5J, BF5L, BH5B, BH5C, BH5D, BH5A, BH5E, BC5A, BC5C, BC5F, BC5G, BC5H, BC5J, BC5K, BC5L, BC5M, BE5A, BE5B, BE5C, BE5G, BE5H, BE5J, BE5K, BE5L, BE5M, BE5N, BG5A, BG5B, BV5A, BV5B, BV5C, BV5D, BK5A, BK5B, BK5C, BK5D, BK5F, BK5G, BK5H, BK5J, BK5K, BK5L, BK5M, BK5N, BL5A, BL5B, BL5C, BL5G, BL5H, BL5J, BL5K, BL5L, BL5M, BW5C, BW5F, BW5G, BW5H, BW5J, BW5K, BW5L, BW5M, BX5C, BX5D, BX5E, BX5F, BX5G, BB5A, BB5B, BB5C, BB5D, BB5F, BB5G, BB5H, BB5J, BB5K, BB5L, BB5M, BB5N, BS5C, BS5D, BS5E, BS5F, BS5G, BS5H, BS5J, BS5K, BS5L, BS5M, BS5N, BU5A, BU5B, BU5C, BU5D
- MX Z (Adrenaline) - BD5A, BD5B, BD5C, BD5G, BD5H, BD5J, BD5K, BD5L, BD5M
- SUMMIT - CM5A, CM5B, CG5A, CG5B, CG5C, CG5D, CH5A, CH5B, CH5C, CH5D, CJ5A, CJ5B, CJ5C, CK5A, CK5B, CL5A, CL5B, CL5C, CP5A, CP5B, CP5C, CP5D

Manual is searchable and deeply indexed for easy access to information it contains.

Manual Chapters:

SAFETY NOTICE
INTRODUCTION
- Vehicle identification number
- Engine serial number
- List of abbreviations used in this manual
- Arrangement of this manual
- General information
- Illustrations and procedures
- Self-Locking fasteners procedure
- Loctite application procedure
- Threadlocker
- Stripped thread repair
- Gasket compound
- Mounting on shaft
- Case-in components
- Tightening torque
SECTIONS
- MAINTENANCE
- MAINTENANCE CHART
- STORAGE
- General
- Engine
- Fuel system
- Drive system
- Steering/front suspension
- Suspension
- Electrical
- Vehicle
- PRESEASON PREPARATION
- Engine
- Fuel system
- Drive system
- Electrical system
- Vehicle
- TROUBLESHOOTING
- ENGINE
- FUEL AND OIL SYSTEMS
- DRIVE AND BRAKE SYSTEMS
- Drive system
- Brake system
- ELECTRICAL SYSTEM
- Electrical system
- STEERING AND Suspension
- STEERING AND SUSPENSION
- ENGINES
- LEAK TEST
- Preparation
- Procedure
- Finalizing reassembly
- Engine leak verification flow chart
- EXHAUST SYSTEM
- 377 and 552 engines
- 593, 593 HO, 593 HO SDI and 793 HO engines
- Tuned pipe
- Manifold
- Muffler
- ENGINE REMOVAL AND INSTALLATION
- Removal from vehicle
- Inspection
- Installation
- Removal from vehicle
- Inspection
- Installation
- MAGNETO SYSTEM
- General
- Magneto flywheel
- Stator
- CPS/Trigger coil
- TOP END
- Troubleshooting
- Cleaning
- Disassembly
- Inspection
- Assembly
- Troubleshooting
- Component removal with the engine installed
- Cleaning
- RAVE valve basic operation
- Disassembly
- Inspection
- Assembly
- BOTTOM END
- Cleaning
- Disassembly
- Inspection
- Assembly
- Break-in
- Cleaning
- Disassembly
- Inspection
- Assembly
- Break-in
- ENGINE MEASUREMENT
- Cylinder head warpage
- Cylinder taper
- Cylinder out of round
- Combustion chamber volume measurement
- Used piston measurement
- Cylinder/piston clearance
- Ring/piston groove clearance
- Ring end gap
- Crankshaft deflection
- Connecting rod big end axial play
- Checking crankshaft alignment
- COOLING SYSTEM
- Cooling fan removal and installation
- Cooling fan bearing replacement
- Fan belt replacement and deflection adjustment
- Liquid cooling system
- Cooling system leak test
- Inspection
- Draining the system
- Disassembly and assembly
- Cooling system refilling procedure
- REWIND STARTER
- Inspection
- Removal
- Rope replacement
- Disassembly
- Assembly
- Installation
- OIL INJECTION SYSTEM
- General
- Oil type
- Oil system leak test
- Oil pump identification
- Cleaning
- Checking operation
- Disassembly
- Assembly
- Bleeding procedure
- Adjustment
- FUEL SYSTEM
- FUEL TANK AND FUEL PUMP
- In-tank fuel filter
- In-line fuel filter
- Fuel tank
- Float-type fuel level gauge
- Electric fuel level sensor
- Fuel system pressurization
- Diaphragm fuel pump
- Removal
- Pump verification
- Cleaning and inspection
- Installation
- CARBURETORS, THROTTLE AND CHOKE CABLES
- Carburetor — VM type
- Identification
- Removal
- Cleaning and inspection
- Disassembly and assembly
- Carburetor adjustments
- Installation
- Choke
- Carburetor TM type
- Identification
- Removal
- Cleaning and inspection
- Disassembly and assembly
- Installation
- Carburetor adjustments
- Choke cable
- DPM SYSTEM
- Overview
- System testing
- Parts removal and installation
- DPM manifold testing
- ENGINE MANAGEMENT (POWER TEK)
- 01 - OVERVIEW
- Operating principle
- Fuel delivery system
- Engine management system (EMS)
- EMS — Engine management system functions
- Power distribution
- Ignition system
- Electronically controlled RAVE
- Digitally encoded security system (DESS)
- Rotax electronic reverse (RER)
- Monitoring system
- Diagnostic mode
- DIAGNOSTIC PROCEDURES
- General
- Troubleshooting
- EMS fault codes
- VCK (vehicle communication kit)
- COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT
- General
- Electrical system
- Fuel system
- Engine management system
- Engine control module (ECM)
- Power relay
- Throttle position sensor (TPS)
- Air temperature sensor (ATS)
- Coolant temperature sensor (CTS)
- Air pressure sensor (APS)
- Knock sensor (KS)
- E-RAVE solenoid
- DPM solenoid
- Ignition coil
- Engine start/RER switch
- Digitally encoded security system (DESS)
- ENGINE MANAGEMENT (SDI)
- 01 - OVERVIEW
- Operating principle
- Charging system
- Ignition system
- Air induction
- Fuel delivery system
- Engine management system (EMS)
- ECM — General functions
- EMS — Engine management system functions
- Electronic fuel injection
- Ignition timing
- Electronically controlled RAVE
- Knock sensor
- Engine modes of operation
- Flooded engine (drowned mode)
- Monitoring system
- Limp home modes
- Diagnostic mode
- Rotax electronic reverse (RER)
- DIAGNOSTIC PROCEDURES
- General
- Troubleshooting
- VCK (vehicle communication kit)
- 2-TEC system fault codes
- COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT
- General
- Fuel system
- Electrical system
- Resistance measurement
- Engine connector pin-outs
- Relay
- Air induction system
- Throttle Body
- Fuel delivery
- Electric fuel pump
- Fuel rail
- Fuel injectors
- Electronic management
- ECM replacement
- Engine wiring harness
- Throttle position sensor (TPS)
- Crankshaft position sensor (CPS)
- Air temperature sensor (ATS)
- Coolant temperature sensor (CTS)
- Air pressure sensor (APS)
- Exhaust gas temperature sensor (EGTS)
- Knock sensor (KS)
- E-RAVE solenoid
- Double ignition coil
- Ignition timing
- Battery
- Capacitor
- Engine start/RER switch verification
- DESS post verification
- ELECTRICAL SYSTEM
- IGNITION SYSTEM
- General
- Ignition timing
- Spark plug
- Design symbols used in NGK spark plugs
- CHARGING SYSTEM
- General
- Charging generator coil (stator)
- Voltage regulator/rectifier
- Battery
- Cable terminal installation
- STARTING SYSTEM
- Troubleshooting
- ACCESSORIES
- General
- 12-Volt power outlet (cigarette-lighter type)
- Beeper (reverse alarm)
- Engine temperature gauge
- Electric fuel gauge
- Headlamp
- Headlamp beam aiming
- Heating elements
- Relay
- Speedometer
- Speed Sensor
- Tachometer
- Taillight
- Visor outlet
- DRIVE SYSTEM
- DRIVE BELT
- Application chart
- Inspection
- Checking neutral function
- Rotation direction
- Drive belt height measurement and adjustment
- Drive belt deflection measurement (reference only)
- DRIVE PULLEY
- Bombardier lite
- General
- Removal
- Disassembly
- Cleaning
- Inspection
- Assembly
- Installation
- TRA III
- General
- Removal
- Disassembly
- Cleaning
- Inspection
- Assembly
- Installation
- Drive pulley adjustment
- DRIVEN PULLEY
- Formula RER and Formula VSA-R
- Removal
- Disassembly
- Cleaning
- Inspection
- Bushing replacement
- Assembly
- Installation
- Adjustment
- HPV VSA
- Removal
- Disassembly
- Cleaning
- Inspection
- Assembly
- Installation
- Adjustment
- PULLEY ALIGNMENT
- General
- Measuring procedure
- Alignment procedure
- BRAKE
- Hydraulic brake
- Brake fluid
- Master cylinder
- Caliper
- Brake pads
- Brake disc
- Countershaft bearing
- Countershaft
- Brake light switch
- Bleeding
- CHAINCASE
- General
- Chaincase oil level
- Oil change
- Drive chain adjustment
- Removal and disassembly
- Inspection
- Installation and assembly
- Silent chain
- DRIVE AXLE
- Removal
- Assembly
- Lubrication
- Adjustment
- TRACK
- Track type application
- General
- Inspection
- Removal
- Installation
- Adjustment
- Track cleat
- Traction enhancing products (studs)
- REAR SUSPENSION
- SC SUSPENSION
- Axle self-locking screws removal
- Rear axle Removal
- Rear axle installation
- Rear shock absorber removal
- Rear shock absorber installation
- Front shock absorber removal
- Front shock absorber installation
- Rear spring removal
- Rear spring installation
- Slider shoe verification
- Slider shoe removal
- Slider shoe installation
- Suspension removal
- Suspension installation
- Front arm removal
- Front arm installation
- Rear arm/pivot arm removal
- Rear arm installation
- Stopper strap
- Ride adjustment
- Lubrication
- SC 3 SUSPENSION
- Axle self-locking screws removal
- Rear axle removal
- Rear axle installation
- Rear shock absorber removal
- Rear shock absorber installation
- Front shock absorber removal
- Front shock absorber installation
- Rear spring removal
- Rear spring installation
- Slider shoe verification
- Slider shoe removal
- Slider shoe installation
- Suspension removal
- Suspension installation
- Front arm removal
- Front arm installation
- Rear arm/pivot arm removal
- Rear arm/pivot arm installation
- Stopper strap
- Ride adjustment
- Lubrication
- SC 4 SUSPENSION
- Axle self-locking screw removal
- Rear axle removal
- Rear axle installation
- Rear shock absorber removal
- Rear shock absorber installation
- Front shock absorber removal
- Front shock absorber installation
- Rear spring removal
- Rear spring installation
- Slider shoe verification
- Slider shoe removal
- Slider shoe installation
- Suspension removal
- Suspension installation
- Front arm removal
- Front arm installation
- Rear arm/pivot arm removal
- Rear arm/pivot arm installation
- Block installation
- Idler wheels installation
- Stopper strap
- Ride adjustment
- Lubrication
- SHOCK ABSORBER INSPECTION AND SERVICING
- Spring removal
- Shock absorber inspection
- Disassembly and assembly
- STEERING/FRONT SUSPENSION
- STEERING SYSTEM
- Disassembly and assembly
- Inspection
- Adjustment
- Steering adjustment (skis)
- Lubrication
- FRONT SUSPENSION
- General inspection
- Disassembly
- Inspection
- Installation
- BODY/FRAME
- BODY
- Installation and adjustment
- Decal
- Windshield
- Guard
- Wiring harness
- Cables
- Tubing
- Plastic maintenance and repair
- Maintenance
- Repair
- FRAME
- Frame cleaning
- Frame welding
- Frame component replacement
- TECHNICAL DATA
- FAN COOLED MODELS
- LIQUID COOLED MODELS
- LIQUID COOLED (SDI) MODELS
- WIRING DIAGRAM
- WIRING DIAGRAMS
- Wiring diagram legend
- Wire colors
- Connector housing area
- Housing reference per area
- Wire location in connector housing
- Symbols description
- Unpluging connectors
- Tab and receptacle connectors removal
- Tab and receptacle connectors installation
- ANNEXES
- 2005 REV FAN COOLED
- 2005 REV CARBURETOR MANUAL START
- 2005 REV CARBURETOR ELECTRIC START
- 2005 REV SDI
- 2005 REV POWER TEK MANUAL START
- 2005 REV POWER TEK ELECTRIC START

Manual has 506 pages.

File size 45.10Mb.

DOWNLOAD Ski-Doo 2005 - REV Series Repair Manual - Back to all "Snowmobiles"

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Snowmobiles Ski-Doo 2005 - REV Series Repair Manual