2006 Ski Doo REV Service Shop Manual

Original 2006 Ski Doo REV Service Shop Manual.

High quality original factory service manual with hight quality images and diagrams. Manual is searchable and deeply bookmarked.

Manual Chapters:

Introduction
 - Vehicle identification number
 - Engine serial number
 - List of abbreviations used in 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
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 & Oil Systems
 - Drive & Brake Systems
   - Drive system
   - Brake system
   - Electrical system
 - Electrical System
 - Steering & Suspension
   - STEERING AND Suspension
Engines
 - Leak Test
   - Preparation
   - Procedure
   - 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 & 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
   - Cleaning
   - Disassembly
   - Inspection
   - Assembly
   - Break-in
 - Engine Measurement
   - Cylinder head warpage
   - Cylinder taper
   - Cylinder out of round
   - 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
   - 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
   - Oil pump identification
   - Cleaning
   - Checking operation
   - Disassembly
   - Assembly
   - Bleeding procedure
   - Adjustment
Fuel System
 - 01 - FUEL TANK AND FUEL PUMP
   - In-tank fuel filter
   - In-line fuel filter
   - Fuel tank
   - Float-type fuel level gauge
   - Diaphragm fuel pump
   - Removal
   - Pump verification
   - Cleaning and inspection
   - Installation
 - 02 - CARBURETORS, THROTTLE AND CHOKE CABLES
   - Carburetor — VM type
   - Identification
   - Removal
   - Cleaning and inspection
   - Disassembly and assembly
   - Choke
   - Identification
   - Removal
   - Cleaning and inspection
   - Disassembly and assembly
   - Installation
   - Carburetor adjustments
   - Choke cable
 - 03 - DPM SYSTEM
   - Overview
   - System testing
   - Parts removal and installation
   - DPM manifold testing
Engine Management (Power Tek)
 - 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 & 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)
   - 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 & Adjustment
   - General
   - Fuel system
   - Electrical system
   - Resistance measurement
   - Relay
   - Air induction system
   - Throttle Body
   - 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)
   - 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 Pulley
   - Bombardier lite
   - General
   - Removal
   - Disassembly
   - Cleaning
   - Inspection
   - Assembly
   - Installation
   - TRA III
   - General
   - Removal
   - Disassembly
   - Cleaning
   - Inspection
   - Assembly
   - Installation
   - Drive pulley adjustment
 - Driven Pulley
   - Removal
   - Disassembly
   - Cleaning
   - Inspection
   - Bushing replacement
   - Assembly
   - Installation
   - Removal
   - Disassembly
   - Cleaning
   - Inspection
   - Assembly
   - Installation
   - Adjustment
 - Pulley Alignment
   - General
   - Measuring procedure
   - Alignment procedure
 - Brake
   - Hydraulic brake
   - Brake pads
   - Brake disc
   - Countershaft bearing
   - Countershaft
   - Brake light switch
 - 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
   - Rear spring removal
   - Rear spring installation
   - Slider shoe verification
   - Slider shoe removal
 - SC 3 Suspension
   - Slider shoe verification
   - Slider shoe removal
   - Slider shoe installation
   - Suspension removal
 - SC 4 Suspension
   - 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
   - Lubrication
 - Shock Absorber Inspection & Servicing
   - Spring removal
   - Shock absorber inspection
   - Disassembly and assembly
Steering / Front Suspension
 - Steering System
   - Disassembly and assembly
   - Steering adjustment (skis)
   - Lubrication
 - Front Suspension
   - 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 Diagrams
 - 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