2005 SkiDoo Tundra, Skandic, Expedition Shop Manual

Original Ski-Doo Shop Manual covers the following models:
- TUNDRA
- SKANDIC - LT/LT E/WT/SWT/WT LC/SUV 550/SUV 600
- EXPEDITION - TUV 600 HO SDI/TUV V-1000

Manual Chapters:

TABLE OF CONTENTS
SAFETY NOTICE
INTRODUCTION
 - Vehicle description decal
 - Vehicle identification number (VIN)
 - 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
     - Vehicle cleaning
     - Engine compartment
     - Battery
     - Fuel stabilizer
     - Engine lubrication
     - Cooling system
     - Engine oil change and filter
     - Countershaft lubrication
     - Pulley protection
     - Vehicle protection
     - Rags in air intake and exhaust system
   - PRESEASON PREPARATION
     - Fuel filter replacement
     - Throttle body cleaning (on so equipped models)
     - Carburetor cleaning (on so equipped models)
     - Air filter cleaning
     - Rags in air intake and exhaust system
     - Engine lubrication
     - Cleaning of drive and driven pulleys
     - Cleaning of brake disk
     - Drive belt condition
     - Spark plugs
 - TROUBLESHOOTING GUIDE
   - ENGINE (2-STROKE)
   - ENGINE (4-TEC)
     - Cooling system
     - Alternator
     - Lubrication
     - Cylinder and cylinder head
     - Crankshaft
     - Electric starter
     - Engine general
   - FUEL AND OIL SYSTEMS (2-STROKE ENGINES)
   - TRANSMISSION AND BRAKE SYSTEMS
     - Transmission
     - Brake system
     - Mechanical brake
     - Hydraulic brake
     - Mechanical and hydraulic brakes
   - ELECTRICAL SYSTEM
   - SUSPENSION AND TRACK
 - ENGINES (2-STROKE)
   - 277 ENGINE TYPE
     - Engine removal and installation
     - Removal from vehicle
     - Engine support and muffler disassembly and assembly
     - Installation on vehicle
     - Top end
     - Troubleshooting
     - Top end removal (without removing engine from chassis)
     - Cleaning
     - Disassembly
     - Inspection
     - Assembly
     - Bottom end
     - Cleaning
     - Disassembly
     - Inspection
     - Assembly
   - 443 AND 552 ENGINES
     - Engine removal and installation
     - Engine removal and installation
     - Top end
     - General
     - Troubleshooting
     - Cleaning
     - Disassembly
     - Inspection
     - Assembly
     - Bottom end
     - Cleaning
     - Disassembly
     - Inspection
     - Assembly
     - Break-in
   - 593 AND 593 HO SDI ENGINES
     - Removal from vehicle
     - Installation on vehicle
     - Top end
     - General
     - Troubleshooting
     - Component removal
     - Cleaning
     - RAVE valve basic operation
     - Disassembly
     - Inspection
     - Assembly
     - Bottom end
     - Cleaning
     - Disassembly
     - Inspection
     - Assembly
     - Break-in
   - LEAK TEST AND ENGINE DIMENSION MEASUREMENT
     - Leak test
     - Preparation
     - Procedure
     - Finalizing reassembly
     - Engine leak verification flow chart
     - Engine dimension 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
     - Crankshaft end-play
     - Checking surface flatness
     - Rectifying surfaces
     - Checking crankshaft alignment
   - MAGNETO SYSTEM
     - General
     - Cleaning
     - Disassembly
     - Assembly
   - INJECTION SYSTEM
     - Oil injection pump
     - General
     - Oil type
     - Oil system leak test
     - Oil pump identification
     - Cleaning
     - Disassembly
     - Assembly
     - Adjustment
     - Bleeding oil lines
     - Checking operation
   - AXIAL FAN COOLING SYSTEM
     - Removal
     - Cleaning
     - Disassembly and assembly
     - Installation
     - 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
   - FUEL SYSTEM
     - Carburetor
     - Identification
     - Removal
     - Cleaning and inspection
     - Disassembly and assembly
     - Carburetor adjustments
     - Installation
     - Idle speed final adjustment
     - Choke
     - Fuel pump
     - Removal
     - Pump verification
     - Cleaning and inspection
     - Installation
     - Fuel tank
 - ENGINE (4-TEC)
   - LEAK TEST
     - Verification
     - Leak test procedure
     - Preparation and test
     - Preparation
     - Installation
   - REMOVAL AND INSTALLATION
     - Engine removal
     - Engine installation
   - COOLING SYSTEM
     - Cooling system leak test
     - Inspection
     - Coolant replacement
     - Coolant hoses
     - Water pump housing/thermostat
     - Water pump impeller
     - Ignition cover
     - Water pump shaft
     - Pressure cap
     - Radiators
   - LUBRICATION SYSTEM
     - General
     - Oil level check
     - Engine oil pressure test
     - Oil change
     - Oil filter
     - Oil tank
     - Oil filter housing
     - Engine oil pressure regulator
     - Oil pumps
     - Pressure oil pump
     - Suction oil pump
     - Oil nozzle
     - Oil sieves
     - Reed valve
   - CYLINDER AND CYLINDER HEAD
     - Cylinder/cylinder head 1 (front-side)
     - Cylinder/cylinder head 2 (rear-side)
     - General
     - Spark plug
     - Temperature sensor
     - Valve cover
     - Rocker arm
     - Chain tensioner
     - Breather
     - Decompressor
     - Camshaft timing gear
     - Timing chain
     - Cylinder head
     - Camshaft
     - Valve springs
     - Valve
     - Cylinder
     - Piston
   - CRANKSHAFT/DRIVE GEARS
     - Timing chain
     - Drive gears
     - Trigger wheel
     - Crankshaft
     - Crankshaft locking tool
     - Piston
     - Piston rings
   - CRANKCASE
     - General
     - PTO cover
     - Crankcase
 - ENGINE MANAGEMENT (2-TEC)
   - OVERVIEW
     - Operating principle
     - Air induction
     - Fuel delivery system
     - General
     - Component description
     - Engine management system (EMS)
     - EMS — 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
     - Charging system
     - Ignition system
     - Double ignition coil
     - Trigger coil
   - DIAGNOSTIC PROCEDURE
     - General
     - Troubleshooting
     - VCK (vehicle communication kit)
     - 2-TEC system fault codes
   - COMPONENT INSPECTION AND ADJUSTMENT
     - General
     - Fuel system
     - Electrical system
     - Resistance measurement
     - Engine connector pin-outs
     - Air induction system
     - Throttle body
     - Fuel delivery
     - Fuel pump
     - Fuel rails
     - 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
     - Engine START/RER button verification
     - DESS switch verification
     - Spark plugs
     - Cranking system
 - ENGINE MANAGEMENT (4-TEC)
   - OVERVIEW
     - Operating principle of engine management
     - Air induction
     - Fuel delivery system
     - Basic operation
     - Intake manifold
     - Fuel pump module
     - Electronic management
     - EMS (engine management system)
     - ECM
     - EMS — General functions
     - EMS — Engine management functions
   - DIAGNOSTIC PROCEDURE
     - General
     - Monitoring beeper coded signals
     - VCK (vehicle communication kit)
     - 4-TEC system fault codes
     - 4-TEC TPS fault tables
   - COMPONENT INSPECTION AND ADJUSTMENT
     - General
     - Fuel system
     - Electrical system
     - Engine connector pin-outs
     - Connectors on engine
     - Air induction system
     - Throttle body
     - Fuel delivery
     - Fuel pump
     - Fuel rails
     - Fuel injectors
     - Electronic management
     - ECM replacement
     - Engine wiring harness
     - Throttle position sensor (TPS)
     - Idle bypass valve
     - Crankshaft position sensor (CPS)
     - Camshaft position sensor (CAPS)
     - Air temperature sensor (ATS)
     - Coolant temperature sensor (CTS)
     - Manifold air pressures sensor (MAPS)
     - Oil pressure switch (OPS)
     - Ignition coils
     - Engine start switch verification
     - DESS switch verification
     - Spark plugs
     - Cranking system
 - TRANSMISSION
   - DRIVE BELT
     - Application chart
     - Checking neutral function
     - Cleaning
     - Inspection
     - 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
     - Comet® 102C
     - General
     - Maintenance
     - Removal
     - Disassembly
     - Cleaning
     - Inspection
     - Assembly
     - Installation
     - TRA III
     - TRA IV
     - General
     - Removal
     - Disassembly
     - Cleaning
     - Inspection
     - Assembly
     - Installation
     - Drive pulley adjustment
   - DRIVEN PULLEY
     - Removal
     - Disassembly
     - Inspection
     - Assembly
     - Installation
     - Adjustment
     - Disassembly
     - Inspection
     - Assembly
     - Installation
     - Adjustment
     - Removal
     - Disassembly
     - Cleaning
     - Inspection
     - Assembly
     - Installation
     - Adjustment
   - PULLEY DISTANCE AND ALIGNMENT
     - General
     - General procedure
     - Pulley alignment and distance specifications chart
   - BRAKE
     - Mechanical brake
     - Hydraulic brake
     - Brake fluid type
     - Brake pads replacement
     - Removal
     - Disassembly
     - Cleaning
     - Inspection
     - Assembly
     - Installation
     - Adjustment
     - Bleeding
   - CHAINCASE
     - Removal
     - Disassembly
     - Inspection
     - Assembly
     - Installation
     - Adjustment
     - Removal
     - Inspection
     - Gear ratio modification
     - Installation
     - Drive chain adjustment
     - Adjustment
   - GEARBOX
     - 3-Speed gearbox
     - Removal
     - Disassembly
     - Inspection
     - Assembly
     - Installation
     - Oil level
   - DRIVE CHAIN
     - General
     - Silent chain
     - Chain attachment
     - Chain separation
 - ELECTRICAL
   - IGNITION TIMING
     - Verifying magneto flywheel timing mark position
   - SPARK PLUGS
     - NGK spark plug
     - NGK spark plug numbering system
     - Design symbols used in NGK spark plugs
     - Disassembly
     - Heat range
     - Fouling
     - Spark plug analysis
     - Spark plug installation
     - Spark plug tightening torque
   - ALTERNATOR
     - Removal
     - Inspection
     - Installation
   - BATTERY
     - General
     - Removal
     - Cleaning
     - Inspection
     - Battery charge testing
     - Battery storage
     - Activation of new battery
     - Servicing
     - Battery charging
     - Installation of battery
     - Cable terminal installation
   - ELECTRIC STARTER
     - Removal
     - Disassembly
     - Cleaning and inspection
     - Cleaning
     - Inspection
     - Assembly
     - Installation
   - TESTING PROCEDURE
     - General
     - Ignition system testing sequence
     - Lighting system testing sequence
     - 1. Sparking
     - 2. Electrical connector testing
     - 3. Ignition switch, dess switch or tether cord cut-out switch and engine cut-out switch testing
     - 4. Ignition generator coil testing
     - 5. Trigger coil testing
     - 6. MPEM voltage testing
     - 7. High voltage coil testing
     - 8. Buzzer testing
     - Lighting generator coil voltage testing
     - Conclusion
     - Inspection of AC circuit isolation
     - Inspection
     - Inspection of heating elements
 - REAR SUSPENSION
   - TORQUE REACTION SUSPENSION
     - Component removal
     - Suspension ass'y removal
     - Disassembly and assembly
     - Inspection
     - Suspension ass'y installation
     - Ride adjustment
     - Lubrication
   - ARTICULATING SLIDE SUSPENSION
     - Removal
     - Disassembly and assembly
     - Shock absorber servicing
     - Installation
     - Ride adjustment
   - SUV SUSPENSION
     - Removal
     - Disassembly and assembly
     - Shock absorber inspection
     - Installation
     - Lubrication
     - Ride adjustment
   - DRIVE AXLE
     - Removal
     - Disassembly
     - Assembly
     - Installation
     - Lubrication
     - Adjustment
   - TRACK
     - Track type application
     - General
     - Inspection
     - Removal
     - Installation
 - STEERING / FRONT SUSPENSION
   - STEERING SYSTEM
     - Inspection
     - Disassembly and assembly
     - Handlebar position adjustment
     - Steering adjustment (skis)
     - Lubrication
   - SUSPENSION AND SKI SYSTEM
     - On-vehicle component removal
     - Disassembly
     - Inspection
     - Installation
     - On-vehicle component verification
     - Disassembly
     - Inspection
     - Installation
     - Disassembly
     - Inspection
     - Installation
 - BODY/FRAME
   - BODY
     - Installation and adjustment
     - Headlamp beam aiming
     - Bulb replacement
     - Decal
     - Belt guard
     - Wiring harness
     - Cables
     - Tubing
     - Plastic maintenance and repair
     - Maintenance
     - Repair
     - Repair procedure for R.I.M. urethane
   - FRAME
     - Frame cleaning
     - Frame welding
 - TECHNICAL DATA
   - ENGINES
   - VEHICLES
   - TECHNICAL DATA LEGENDS
     - Engine technical data legend
     - Vehicle technical data legend
 - WIRING DIAGRAMS
   - WIRING DIAGRAMS
     - Wire colors and circuit
   - ANNEXES
     - 2005 TUNDRA R
     - 2005 SKANDIC LT 440
     - 2005 SKANDIC WT, SKANDIC SWT, SKANDIC SUV 550
     - 2005 SKANDIC WT LC, SKANDIC SUV 600
     - 2005 EXPEDITION 600 TUV SDI
     - 2005 EXPEDITION V-1000 TUV

Manual is indexed and searchable for easy access to high quality diagrams, images and detailed procedures description.