2005 Ski-Doo RT Series Shop Manual
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- 2005 RT Series repair manual
Original Ski-Doo Shop Manual covers the following models:
- MACH Z - AB5A, AB5B, AB5C
- SUMMIT HIGHMARK - CD5A, CD5B, CD5C
- SUMMIT HIGHMARK X - CA5A, CA5B, CA5C, CA5D
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
- Typical page
- 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
- ENGINE
- LEAK TEST
- Leak test
- Preparation
- Procedure
- Finalizing Reassembly
- Engine Leak Verification Flow Chart
- AIR INTAKE SYSTEM
- Air filter/air intake silencer removal (body side)
- Air filter/air intake silencer installation (body side)
- air intake silencer removal (engine side)
- air intake silencer installation (engine side)
- Adaptor plate removal
- Adaptor plate installation
- Intake deflector/filter removal
- EXHAUST SYSTEM
- General
- Tuned Pipe
- Manifold
- Muffler
- ENGINE REMOVAL AND INSTALLATION
- Removal from vehicle
- Inspection
- Installation
- MAGNETO SYSTEM
- General
- Magneto Flywheel
- Stator
- CPS
- E-RAVE SYSTEM
- General
- E-RAVE system dynamic test
- E-RAVE cables
- E-RAVE actuator
- E-RAVE cover
- E-RAVE shaft
- E-RAVE housing
- E-RAVE valves
- TOP END
- Troubleshooting
- General
- Component removal with the engine installed
- Disassembly
- Cleaning
- Inspection
- Assembly
- BOTTOM END
- Troubleshooting
- General
- Preparation
- 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 system leak test
- Inspection
- Draining the system
- Disassembly and Assembly
- Cooling system refilling procedure
- REWIND STARTER
- General
- Inspection
- Removal
- Rope replacement
- Disassembly
- Assembly
- Installation
- OIL INJECTION SYSTEM
- General
- Oil type
- Oil system leak test
- Oil pump identification
- Cleaning
- Removal
- Checking operation
- Installation
- Bleeding procedure
- Adjustment
- FUEL SYSTEM
- FUEL TANK AND FUEL PUMPS
- Fuel tank
- IN-TANK fuel filter removal
- IN-TANK fuel filter installation
- IN-LINE fuel filter removal
- IN-LINE fuel filter installation
- Fuel tank removal
- Fuel tank installation
- Float-Type Fuel Level Gauge removal/installation
- Electric Fuel Level Sensor inspection
- Fuel system pressurization
- Electric fuel pump
- Diagnostic flow chart
- Electric fuel pump pressure test
- Electric fuel pump
- Electric fuel pump removal
- Electric fuel pump installation
- Electric fuel pump pressure regulator removal/installation
- Diaphragm fuel pump
- Diaphragm fuel pump removal
- Diaphragm fuel pump verification
- Diaphragm fuel pump cleaning and inspection
- Diaphragm fuel pump installation
- ENGINE MANAGEMENT (SDI)
- OVERVIEW
- Operating Principle
- Charging system
- Ignition system
- Air induction
- Fuel delivery system
- Engine management system (EMS)
- EMS — Engine management system functions
- Power distribution
- Fuel injection
- Ignition system
- Electronically Controlled RAVE (E-RAVE)
- Digitally encoded security system (DESS)
- Rotax electronic reverse (RER)
- Monitoring System
- Diagnostic Mode
- DIAGNOSTIC PROCEDURE
- General
- Troobleshooting
- EMS fault codes
- VCK (vehicle communication kit)
- COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT
- General
- Fuel system
- Electrical system
- Testing procedures
- Electric fuel pump
- Fuel injectors
- Engine control module (ECM)
- Engine wiring harness
- Throttle body
- Throttle position sensor (TPS)
- Crankshaft position sensor (CPS)
- Air temperature sensor (ATS)
- Coolant temperature sensor (CTS)
- Air pressure sensor (APS)
- Knock Sensor (KS)
- E-RAVE actuator
- Double Ignition Coil
- 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
- General
- Component Testing
- Starter removal
- Starter installation
- ROTAX ELECTRONIC REVERSE (RER)
- Troubleshooting
- ACCESSORIES AND LIGHTING SYSTEM
- 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
- TRA V
- General
- Removal
- Disassembly
- Cleaning
- Inspection
- Assembly
- Installation
- Drive pulley adjustment
- DRIVEN PULLEY
- HPV Roller
- General
- Removal
- Disassembly
- Cleaning
- Inspection
- Assembly
- Installation
- Bushing Replacement
- HPV VSA
- General
- Removal
- Disassembly
- Cleaning
- Inspection
- Assembly
- Installation
- Adjustment
- PULLEY ALIGNMENT
- General
- Measuring procedure
- Alignment procedure
- BRAKE
- General
- Countershaft Bearing
- Countershaft
- Brake Fluid
- Draining
- Bleeding
- Master Cylinder
- Brake Pads
- Caliper
- Brake Disc
- Brake Light Switch
- CHAINCASE
- General
- Chaincase Oil Level
- Oil Change
- Drive Chain Adjustment
- Chaincase cover
- Tensioner
- Tensioner Roller Bearing
- Drive Chain and Sprockets
- Chaincase Housing
- Chaincase Housing Bearings
- Countershaft
- Countershaft Bearing
- 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
- Front arm removal
- Front arm installation
- Rear arm/pivot arm removal
- Rear arm installation
- Stopper strap
- Suspension removal
- Suspension installation
- 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
- Front arm removal
- Front arm installation
- Rear arm/pivot arm removal
- Rear arm/pivot arm installation
- Block installation
- Idler wheels installation
- Stopper strap
- Suspension removal
- Suspension installation
- 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
- Decal
- Hood
- Front bumper
- Bottom pan
- Windshield
- Access panel
- Indicator panel
- Console
- Seat
- Plastic maintenance and repair
- FRAME
- Frame cleaning
- Frame welding
- Frame component replacement
- TECHNICAL DATA
- MACH Z/SUMMIT 1000 SDI
- Technical data legend
- WIRING DIAGRAMS
- WIRING DIAGRAMS
- Wiring diagram legend
- Wire colors
- Connector housing area
- Housing reference per area
- Wire location in connector housing
- Symbols description
- Unplugging connectors
- Tab and receptacle connectors removal
- Tab and receptacle connectors installation
- ANNEXES
- 2005 MACH Z RT/SUMMIT RT
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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
Typical page
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
ENGINE
LEAK TEST
Leak test
Preparation
Procedure
Finalizing Reassembly
Engine Leak Verification Flow Chart
AIR INTAKE SYSTEM
Air filter/air intake silencer removal (body side)
Air filter/air intake silencer installation (body side)
air intake silencer removal (engine side)
air intake silencer installation (engine side)
Adaptor plate removal
Adaptor plate installation
Intake deflector/filter removal
EXHAUST SYSTEM
General
Tuned Pipe
Manifold
Muffler
ENGINE REMOVAL AND INSTALLATION
Removal from vehicle
Inspection
Installation
MAGNETO SYSTEM
General
Magneto Flywheel
Stator
CPS
E-RAVE SYSTEM
General
E-RAVE system dynamic test
E-RAVE cables
E-RAVE actuator
E-RAVE cover
E-RAVE shaft
E-RAVE housing
E-RAVE valves
TOP END
Troubleshooting
General
Component removal with the engine installed
Disassembly
Cleaning
Inspection
Assembly
BOTTOM END
Troubleshooting
General
Preparation
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 system leak test
Inspection
Draining the system
Disassembly and Assembly
Cooling system refilling procedure
REWIND STARTER
General
Inspection
Removal
Rope replacement
Disassembly
Assembly
Installation
OIL INJECTION SYSTEM
General
Oil type
Oil system leak test
Oil pump identification
Cleaning
Removal
Checking operation
Installation
Bleeding procedure
Adjustment
FUEL SYSTEM
FUEL TANK AND FUEL PUMPS
Fuel tank
IN-TANK fuel filter removal
IN-TANK fuel filter installation
IN-LINE fuel filter removal
IN-LINE fuel filter installation
Fuel tank removal
Fuel tank installation
Float-Type Fuel Level Gauge removal/installation
Electric Fuel Level Sensor inspection
Fuel system pressurization
Electric fuel pump
Diagnostic flow chart
Electric fuel pump pressure test
Electric fuel pump
Electric fuel pump removal
Electric fuel pump installation
Electric fuel pump pressure regulator removal/installation
Diaphragm fuel pump
Diaphragm fuel pump removal
Diaphragm fuel pump verification
Diaphragm fuel pump cleaning and inspection
Diaphragm fuel pump installation
ENGINE MANAGEMENT (SDI)
OVERVIEW
Operating Principle
Charging system
Ignition system
Air induction
Fuel delivery system
Engine management system (EMS)
EMS — Engine management system functions
Power distribution
Fuel injection
Ignition system
Electronically Controlled RAVE (E-RAVE)
Digitally encoded security system (DESS)
Rotax electronic reverse (RER)
Monitoring System
Diagnostic Mode
DIAGNOSTIC PROCEDURE
General
Troobleshooting
EMS fault codes
VCK (vehicle communication kit)
COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT
General
Fuel system
Electrical system
Testing procedures
Electric fuel pump
Fuel injectors
Engine control module (ECM)
Engine wiring harness
Throttle body
Throttle position sensor (TPS)
Crankshaft position sensor (CPS)
Air temperature sensor (ATS)
Coolant temperature sensor (CTS)
Air pressure sensor (APS)
Knock Sensor (KS)
E-RAVE actuator
Double Ignition Coil
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
General
Component Testing
Starter removal
Starter installation
ROTAX ELECTRONIC REVERSE (RER)
Troubleshooting
ACCESSORIES AND LIGHTING SYSTEM
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
TRA V
General
Removal
Disassembly
Cleaning
Inspection
Assembly
Installation
Drive pulley adjustment
DRIVEN PULLEY
HPV Roller
General
Removal
Disassembly
Cleaning
Inspection
Assembly
Installation
Bushing Replacement
HPV VSA
General
Removal
Disassembly
Cleaning
Inspection
Assembly
Installation
Adjustment
PULLEY ALIGNMENT
General
Measuring procedure
Alignment procedure
BRAKE
General
Countershaft Bearing
Countershaft
Brake Fluid
Draining
Bleeding
Master Cylinder
Brake Pads
Caliper
Brake Disc
Brake Light Switch
CHAINCASE
General
Chaincase Oil Level
Oil Change
Drive Chain Adjustment
Chaincase cover
Tensioner
Tensioner Roller Bearing
Drive Chain and Sprockets
Chaincase Housing
Chaincase Housing Bearings
Countershaft
Countershaft Bearing
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
Front arm removal
Front arm installation
Rear arm/pivot arm removal
Rear arm installation
Stopper strap
Suspension removal
Suspension installation
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
Front arm removal
Front arm installation
Rear arm/pivot arm removal
Rear arm/pivot arm installation
Block installation
Idler wheels installation
Stopper strap
Suspension removal
Suspension installation
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
Decal
Hood
Front bumper
Bottom pan
Windshield
Access panel
Indicator panel
Console
Seat
Plastic maintenance and repair
FRAME
Frame cleaning
Frame welding
Frame component replacement
TECHNICAL DATA
MACH Z/SUMMIT 1000 SDI
Technical data legend
WIRING DIAGRAMS
WIRING DIAGRAMS
Wiring diagram legend
Wire colors
Connector housing area
Housing reference per area
Wire location in connector housing
Symbols description
Unplugging connectors
Tab and receptacle connectors removal
Tab and receptacle connectors installation
ANNEXES
2005 MACH Z RT/SUMMIT RT
