2005 SkiDoo REV Series Shop 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

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