2005 SkiDoo RT Series Shop 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

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