2005 Ski-Doo REV Series Shop Manual
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- 2005 REV Series repair manual
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 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
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Reference and Info files
Reviews - Write a Review
Rated: 5 by: Michael Posted: Saturday, September 30, 2023 at 02:36AM
Rated: 5 by: Jeff Posted: Tuesday, November 7, 2023 at 3:48PM
Manual is super! Buy with confidence - this service is legit.
Rated: 5 by: Blake Posted: Wednesday, January 10, 2024 at 05:55AM
Full list of manual chapters:
TABLE OF CONTENTS
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
Electrical system
STEERING AND Suspension
FUEL AND OIL SYSTEMS
DRIVE AND BRAKE SYSTEMS
Drive system
Brake system
ELECTRICAL SYSTEM
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
