2008 Ski-Doo GSX Limited Touring 600 HO SDI Factory Service & Work Shop Manual
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TABLE OF CONTENTS
SAFETY NOTiCE . ..... ... .. . ....... .... ..... ... ............. . ..... .. .. ........... . .... . .... ... ..... IX
INTRODUCTION . . .. ... .. . .. ....... ..... .... ..... ... . .. .. .... ..... .... .. .. . .... . ..... . .. ............ X
GENERAL INFORMATIONS ................................ .. .......................... .. ............ . ............. X
V EHI CLE IDENTIFICATI ON NUM BE R .................................................. . ............ . ............. X
ENGINE SERIAL NUM BE R ................................. . ........................... .. .......................... X
SNOWMOB I LE LI FTING ....... .... ....... ... .... ........... • .... ...... ...•... ... ..... ............. .... ... ... ...... XI
ENGINE EMISSIONS INFORMATI ON. ................... . .. .... ... ... ... . .... ....... • .......... ... .... ... ...... XI
TIG HTEN ING TORQUE ..................................... ... ...................... ....................... ... .... XII
SELF·LOCKING F AS TE NERS PROCE DU RE..... ....... .• ....... . .... . • ...... . ..... ........................... XI II
LOC T ITE APPLICATION PROCEDUR E ................................. .. ........... . .. ........... .............. XII I
MANUAL INFORMATI ON .. . ...... . ...... .. ..... .. ..... . ... . ............. . ....................................... XVI
01 MAINTENANCE
01 - MAINTENANCE CHART ............. •• ......... " . •• .. , .......... •• • .......... •• ............. ••• .... . .... .. ... 1
02 - STORAGE PROCEDURES ................... " .... •• ..... " ..... .. .............................. . .. . ... .. .. ... 3
GENERAL ..
ENGINE.
ENGINE MANAGEMENT SYSTEM ........... .
FUEL SySTEM......... ........................ ...... ......... . ........ .
ELECTRICAL SYSTEM.. . .................... , ....................................... .. . .
DRIVE/BRAKE SySTEM ... .
CHASSIS .......................................................... .
3
3
4
4
4
4
4
VEHICLE .... ..... . ...... . ...... ....... ....... ..... ......... ..... ....... ..... ....... ....... .... 4
03 - PRESEASON PREPARATION .................. .. ............................................................. 7
GENERAL ..................................................................................................... 7
ENGINE ..... ...... ..... . ... .. ...... 7
FUEL SYSTEM.. ...... ..... .... ...... ..... ........................................... .. ................ 7
ELECTRICAL SySTEM................. ............ .............. 8
DRIVE/BRAKE SYSTEM . 8
02 TROUBLESHOOTING
01 - TECHNICAL GUiDELINES ............ ........ .... ...... ... ...... ............................... . ... ....... .... 9
ENGINE.
FUEL AND OIL SYSTEMS ..
DRIVE SYSTEM
BRAKE SYSTEM ............................................................... .
REAR SUSPENSiON ...................... .
ELECTRICAL SYSTEM ..
STEERING SySTEM .......................................................................... . . .
9
14
16
18
18
19
21
SUSPENSiON...... ................................. ............ .. ........................ . .................. 22
02 - FLOW CHARTS .... . ...................................... .......... ..................... . .................... 23
3D RAVE VALVE FLOW CHART ..
ENGINE LEAK VERIFICATION FLOW CHART
FUEL DELIVERY DIAGNOSTIC FLOW CHART ............ .
03 ENGINE
23
24
25
01 - ENGINE REMOVAL/ INSTALLATION .. ................ .............. .... ......... . .............. .......... 27
GENERAL ...... . ............... . ......................................... .. ......................... . .. . ....... 29
PROCE DUR ES ............................. .. ............ . ... ....................... .. ... . .... . .. ............ . 29
ENGINE.
29
ENGINE SUPPORT. 36
ENGINE RUBBER MOUNT..... .......... ... . ......................... 37
02 - ENGINE lEAK TEST .................... . ............ ,.. . .............. .. ... ..... .............. ... ........... 39
PREPARATION ................ .
PROCEDURE
39
39
TABLE OF CONTENTS
03 - ENGINE MEASUREMENT .............. . ..... .. ............... , ........ . •• • ........ ..•• • .. ................. 43
CYLINDER HEAD WARPAGE ......... .
CYLINDER TAPER ..
CYLINDER OUT OF ROUND .. ..
CYLINDER/PISTON CLEARANCE ..
RING/PISTON GROOVE CLEARANCE ................. . . .
RING END GAP .... . ...... ........ .
CRANKSHAFT DEFLECTION ..... . ............................................. .. .
CONNECTING ROD BIG END AXIAL PLAY
CRANKSHAFT ALIGNMENT ........................................................... . ...... . ..... .
43
43
43
44
46
46
46
47
47
COMBUSTION CHAMBER VOLUM E MEASUREMENT ... ...................... ...... . ............... . .. 48
04 - AIR INTAKE SySTEM . ..... .............. .. ....... ........... ............. . .. ....... . ... .•. .................. 51
PR OCEDURE S...... . ...... . .............. . .. ... .. . ... . ......... . ....................... .. .................. 52
AIR FILTER .................................................................................. ... . 52
PRIMARY AIR INTAKE SiLENCER...................... ...... ...................................... .. 52
SECONDARY AIR INTAKE SILENCER.. 53
05 - EXHAUST SySTEM ............................. • ........... •• ........................... • ...... ............. 55
GENERAl. ....................................... .. ............ • . ..... ........... ... . ....... . .................. 56
PROCEDURES .................... ... .......... .• ............ •. . ........... .• . ............ .. .................. 56
TUNED PIPE .......................................... . ........................................ .. .
MANIFOLD.
MUFFLER
56
56
57
EXHAUST GAS TEMPERATURE SENSOR (EGTS) ............................... . ........... .... , 57
06 - REWIND STARTER. .............. ... ......................... ............................ . ..... . ... .. .. ...... 59
GENERAl. ............ .. .. .. . .. . .. .............................. .. .......................... ••• ............ . ... 61
PROCEDURE S ....................... . ........ .. ... ..... .. . ... ........... • ............... . ................ 61
REWIND STARTER HANDLE ................... . .................................................... . .. .
REWIND STARTER ..
6'
6'
ROPE ....... ......... 64
07 - LUBRICATION SySTEM . .. ....... ............. . ... ............ ............ .. ............. ... . ... . .. .. . .. .. .. 65
GENERAL ............................ .. .......... . ............................... ............ . ................. 68
OIL TYPE., ......................................... . .. 68
INSPECTION......................... . ............ . •• .. ... .... .. .. ............. •........... .•. ................ 68
OIL SYSTEM LEAK TEST... .. .................. . ......................... ........ 68
PROCEDURES..................... .• • ............ ... .......... . .. . ........... ... ........... .• ................ 69
OIL RESERVOIR .................................. .
Oil LEVEL SENSOR.
OIL FILTER .... . .. , ..
OIL INJECTION PUMP . ........................... ..
69
7'
72
72
INJECTION NOZZLE. . ..................................................... ... , 75
08 - COOLING SySTEM. ......... .. ... ...... ........... .... ........ . .. ............ .. . ... ... ... ...... ............. 77
GENERAl. .... ....................................... .. ......................... .. ............. ..... ........... 79
IN S PECTION ...... .... ............................. ............... ... .... ...... .............................. 79
VEHICLE COOLI NG SYSTEM LEAK TEST.... 79
ENGINE COOLING SYSTEM LEAK TEST.. ................ .. .. 79
MAINTENANCE................................... . .. .. .. . .. .... . .. . .......... .................. .. ... . .. 80
COOLANT REPLACEMENT............. ........... ....... . .. .. . . ...... ............ . .. 80
PROCEDURES ..................... ... .. . ......... . .. .... ... ........................ . .. . . . ............... 80
THERMOSTAT ......... .. ....................... 80
RADIATOR CAP .. . ..... ........ ..
FRONT RADIATOR . .................. ..
REAR RADIATOR. ..... ..
COOLANT TANK .............................. .. ..................... . .................... ..
8'
8'
82
82
82
82
WATER PUMP ..... .
COOLANT TEMPERATURE SENSOR (CTS) ..
TABLE OF CONTENTS
09 - MAGNETO SySTEM ......... . ............. . ............................ ... ......................... .... ..... 85
GENERAL ........ ..... .. .. .. . ... ••• .... . ... . .. .• .... ... ... .. .••.. .......... .• .. ....... .. .• • ............. • .. . ... 89
PROCEDURES................ . •• ............. •........... .• •• ............ .• ............ •• ............ .• ...... 89
MAGNETO FLYWHEEL ........ ....................... ........................... 89
STATOR ......................................... . .................................................................. 91
CRANKSHAFT POSITION SENSOR (CPS) ...... .............................. 92
TRIGGER COil ................ ...... .......................... ....... ................................... 92
MAGNETO HOUSING ....... , ..................... .. ...... H. 92
10 - TOP END (593) .... ......... ... •• .... ........ •• .... . ... .. ... • • ........... •• .. ........... •• • .......... •• ........ 95
GENERAL .... .... ............... . ............ .. ............. ... ......................... ... ........... .. ....... 99
PROCEDURES............................. ............... ... . .......... . ............. ............... .. ..... .. 99
REED VALVE ..
E-AAVE SOLENOID ........................................ .. .............. .
RAVE AND E·RAVE VALVES ................................................................................... .
CYLINDER HEAD COVER ........................ .. ...... . . .
CYLINDER HEAD ........................................ . ............. . ............................... .
99
99
104
107
108
CYLINDER ...................... ....... . ............ ......... ................... ............ 108
PISTON. ..... ........ ...... ..... ........... ......... ...... ..... ....... ............. 109
11 - TOP END 1797) .............. .. ............ .. .. ................ .. ........ .. ...... .. .. ....... .................. 113
GEN ERAL ..................... • .......... ... •• • ............ . ... .... .. . ..• •• .. ........... • .. . ......... •• ....... 116
PROCEDURES .............................. •• ........... .. ..... . .. .••.. .......... .• ............ •• ....... 116
REED VALVE ............................................... .
3D RAVE VALVE
CHECK VALVES (3D RAVE VALVES) ....... . .......................................................... .
116
116
128
SOLENOIDS (3D RAVE VALVES) ...... ..... ......... ..... ........ .... ....... ...... 129
CYLINDER HEAD ..... ..... ..... ....... ....... . ..... ..... ..... ....... ....... ....... ....... ........ 132
CYLINDER BLOCK ... ..... ....... ..... ..... . ....... ..... ..... . ..... ...... . ...... ....... ...... .... 132
PISTON.. . . ....... ..... ...... ....... ....... ........ 133
12 - BOTTOM END (593) ....... .. ....... . .. ...... . ... ....... . ........... .. ..................... , ..... ••• ........ 137
GENERAL .................................. • ............. • • ............. •• ..... . .. . .. .•. ... .. ...... .•• ........ 140
PROCEDURES ........................................... . ..... . ....... . ...... .... .. . ... . .......... . ......... 140
WATER PUMP ..
WATER/OIL PUMP SHAFT ......................................................... .
CRANKCASE
140
141
144
CRANKSHAFT ...... ..... .. ..... ... . ....... ........... ......... ...... 145
13 - BOTTOM END (797) ................... .. ...... .......... .. .. .. .... ................ . ........................ 153
GENERAL. ..................... ... .. .. ... .. .................................................... ............ ... 155
PROCEDURES ............ . ... . ......... •• ............. • ............ .• ......... . .. . •• • ........ . .............. 155
WATER PUMP .....
WATERfOIL PUMP SHAFT
CRANKCASE ................................. ... .... .. ...... .
CRANKSHAFT .............. .
04 ENGINE MANAGEMENT SYSTEM
155
156
159
162
01 - ENGINE MANAGEMENT (50055) .... .......... . .. ........... .. .. ........ ... .............. .. ............. 169
OVE RViEW .......... . ... . .. . ... . .................... .. ........... . ...................... . ... . .. . ............. 169
ENGINE CONTROL MODULE IECM) .... ....... ...... ..... ........ ... . ..... . .. 169
02 - ENGINE MANAGEMENT (800R) ....................... . .. .. . .. ... ........... ... ............ . ............. 171
OVERVIEW . .. .... .. .............................. . .............. . ........ . ... .. .. ........................... 171
ENGINE CONTROL MODULE IECM) ..... ....... ..... ...... ....... ...... . ............. .... 172
03 - ENGINE MANAGEMENT 1600 HO SDI) ....... . ...... . .. ... . .••.. .. . ...... .••• ......... •• •••• ............ 175
ENGINE MANAGEMENT SYSTEM FUNCTIONS................. ................... ... 176
OVERViEW . ..................................................... . ........ .. . .. . . • • ........... •• .............. 177
ENGINE CONTROL MODULE (ECM) .................. .......................................... ... 178
04- COMMUNICATION TOOLS/S.U.D.S. SOFTWARE ... . ... . .............. ... .......... . ................. 181
MULTI-PURPOSE INTERFACE IMP)) ....... .... .. ..... ......... .... .. .... ....... .. 181
...
TABLE OF CONTENTS
MULTI-PURPOSE INTERFACE-2 (MPI-2) .. , 185
S.U.D.S. SOFTWARE ... . ..... . ...... ....... ........ ..... ...... . ...... ....... ..... ..... .......... 189
05 - MONITORING SYSTEM/ FAULT CODES .......... .. .• ............ .. ........... ..... . ......... ... . ....... 191
MONITORING SYSTEM ...... " ............ , ...... .
FAULT CODES ..................................................................................... .
SPECIFIC FAULT CODES .
FAULT CODE TABLES .
191
193
193
195
05 FUEL SYSTEM
."
01 - FUEL TANK/FUEL PUMP ................ ••. .......... •• ............ • •. ........... • • .. . ........ • ••. ........ 199
GENERAL. ................................. . .. .... ........ . ............. .. .......................... . .. ....... 202
INSPECTION ........................................................................ .... ........... . ......... 202
FUEL SYSTEM PRESSURI ZATION ... "... 202
HIGH PRESSURE LEAK TEST (EL ECTRIC fUEL PUMP CIRCUIT). . ..................................... 203
FUEL PUMP PRESSURE TEST. ..... . ...... .... 203
PROCEDURES ...................................................................... ... .. . ........... . ....... 204
DIAPHRAGM FUEL PUMP ........... , ...................................................................... .
ELECTRIC FUEL PUMP ..................................... .
FUEL PRESSURE REGULATOR .................................................. .
IN-TANK FUEL STRAINER.
IN-LINE FUEL FILTER.
ELECTRIC FUEL LEVEL SENSOR ..
204
205
208
209
212
212
FUEL TANK. 214
OETIKER CLAMPS ...... ..... ...... ...... ..... ....... ....... .......... ............. . ........... 218
02 - TM CARBURETORS . . ...... . .......................... . ... . ........................ ... ............ .. ........ 219
PROCEDU RES .. . .. . ... . ...... .. . . .. ......... ... .. ... .. ...... .. ............ .. ........... .. . ........ 221
CARBURETOR.. 221
THROTILE POSITION SENSOR (TPS).. 227
THROTILE CABLE.. 231
CHOKE CABLE. . ............ 232
03 - DPM SYSTEM (SOOR) ...................... .. ........... .. ............ ... .......... .. ......... . .. . ......... . 235
OVERViEW.................. ..... .... . . . . , . . .......... .. .. ... ..... . ............................ .. ....... 237
PROCEDURES. .... ... . ... ........ .. . . . . . , ..... . ...... .. .... .... .. .. ............ . . , ..................... 237
AIR TEMPERATURE SENSOR IATS) .............................. .
AIR PRESSURE SENSOR lAPS) .
DPM SOLENOID
237
239
240
DPM MANIFOLD. ............ ..................................... 240
04 - SEMI-DIRECT INJECTION (50 1) ......... ... ............. . ............ . ............. .. ..... . ...... .. ....... 243
OVERVi EW ................................... • ............. • . ... .... ... •• ............. • . ........... •• ....... 243
GENERAL PRECAUTIONS .......... . .. ....... ........... .. ............ . .......................... .. ....... 244
FUEL SySTEM ..................................................................... .
ELECTRICAL SYSTEM ..
BASIC AD J USTM ENTS
IDLE SPEED.
CLOSED THROTILE RESET iTPS) .
THROTILE CABLE ................. .
PROCEDURES ..................... . .......... •.
FUEL INJECTORS ............ .
ENGINE CONTROL MODULE (ECM) ..
THROTILE BODY ..................................... .
THROTILE POSITION SENSOR (TPS) ................................. .
CRANKSHAFT POSITION SENSOR (CPS). .......................................... .
AIR TEMPERATURE SENSOR JATS) ................... .. .
COOLANT TEMPERATURE SENSOR ICTS) .............................................. .
AIR PRESSURE SENSOR (APS) ..
EXHAUST GAS TEMPERATURE SENSOR (EGTS) ................................ ... ................. .
244
245
248
248
248
249
250
250
255
262
263
265
268
270
271
273
TABLE OF CONTENTS
KNOCK SENS OR (KS) ........ . . ........ .
CAPACI TOR. .... " ................. .. ..... . .... ...... .
06 ELECTRICAL SYSTEM
274
275
01 - IGNITION SySTEM .. .. .. .. . .... ............. ... .. .. .. . ........ ... ... . .... ..... .. .. ............. .. . ... . .. . .. 279
GENERAL .. .................................. . ..... . ........... .. . .. ...... . ...... .. ............... . ....... . .. . 279
IGN ITION SYST EM TESTI NG SEQ UEN CE ..................................................................... 279
AOJUSTMENT.. .... . ... . ....................... .. .. .......... .. .......................... .. ................. 280
IGNITION TIMING.. ................... . ............................................... ' ......... 280
PROCEDURES .................................................. .. ............ .. .............. ... ............ 283
S PARK PLUG ............................ .
DESS POST ........................... .... ... . .......... .
ENGINE CUT-OUT SWI TCH ... . ... . ..... .
IGNITION COIL ........................ ... ... ...... . .
TRIGGER COIL ................ .
CR AN KS HAFT POSITION SENSOR ( CPS)... ........... . ........................................ .
KNOCK SENSOR (KSI..... ........ ........................ . ...................... .
E NGIN E CONTROL MODULE (E CM) ....................... . .................... .
02 - CHARGING SySTEM ........ . ... .. .............. .. ............. . ........... .. ............ .... ............. .
GENERAL. ............................ . ........ .. ................................. . ........ .. ... . ............ .
PROCEDURES ........ .. .................................. . ................................................. .
CHARG I NG FUSE ..................................................................................... .
CHARGING RE LAY (R2 ) .......... ... ...... ........................... . ............... .
VOLTAGE REGULATOR ........................................... ........... .............................. .
STATOR ... ....... ........ ... ..... ... ... ........... ........ . ......................... .
BATI ERY (YT4L-BSI..... .... ....... ...... . ................................................. .
BA TI ERY (YTX20 l -BS).. . ................................................................... .
03 - STARTING SySTEM ............................................. .... .... .................................. .
GENERAL. ............................... . ............................................... .. .. ............... ..
TROUBLESHOOTING .......................... . ............ .... . .......... .. .......... . .. .. ............... .
PROCEDU RE S ... . ............. ... ............ .. ............ . .............. .. . ........... .. . ................ .
S TA RTIA ER FUSE .............. .
BA TIERY ... . ......................... . .. . .. .
E NG I NE CUT -QUT SWITCH
START/ RER SWITCH ...... .
ST ARTER SO LENOID .............. . .. .
283
284
284
284
288
289
289
290
297
297
298
298
298
298
302
304
305
309
311
311
311
311
312
312
312
316
E LE CT RIC STARTER. ........ .... ....... .......... ................ .... ...... ....... ..... 31 9
04 - DIGITALLY ENCODED SECURITY SYSTEM lOESS) ........ .. ................................ .. .. .. ... 325
GENERAL .................... . ............................. . .............. .. ........ ... ... .. .. ................ 325
PROCEDURES . . ............. . .......................................................... ... .......... .. ...... 325
DE SS KEY. ..................... ........... .... ........................ ............................. 325
BEEPE R ........... . .......................... ........... ................... 326
DESS POST . ...... ...... ...... ...... ....... ..... ..... .... ......... ..... ........ 326
05 - ROTAX ElECTRONIC REVERSE ......... •• .......... _ ............... .. ........... ... .. .. . ................ 329
GENERAL . .. . ............................... ... ............ ... ........... .. .......... . .... ........... .. .. . .. .. 329
TROU8LE SHOOTING ...................... . .............. .. ............ .. ...... . ................... .. ...... 329
PROCEDURES ............. . ............... ... ......... . ... . ............ .. .. ......... _ .. .. ................... 329
RER SWiTCH.............. ........ .............................. ............ ........... 329
BEEPER ( REVERSE ALARM) .......................... ........................ ... ............ 333
06 - LIGHTS/GAUGE/ACCESSORIES ...... .. ........... .. ..... ................................ .... .. ..... . .. . 335
GENERAL ....... .. ...................................................... . ........... ... .......... . ......... . .. 335
DIAGNOSTiC .. ................................ . ....... . ............. . ................... . .......... . ......... 336
LI GHTI NG AND ACCESSORIES SYSTEM TESTING............... .................................. 336
PROCEDURES ........................... .. ........................... .. .. . .. . ....... .. ......... . ............ 337
FUSES .................. ... . .. .... ...... . ............... .
RELAY R1 ( LI GHTS AN D ACCES SORIES) ............... .
337
339
TABLE OF CONTENTS
RELAY R3 (LIG HTS AND ACCESSORIES)
HEADLIGHT ... ..... .... . . ..................................... .
TAILLIGHT ................. ..... ............................. ............ .................... .
GAUGE ....... ...... ........ ..... . ........ ........ . .... ... . ... .
SPEED SENSOR ........... ........ ....... ............. . ..................... .
FUEL l EVEL SENSOR ..... ........ ..... ..... ............. . ................................... .
HEATEDTHROTIlE LEVER .................................. . ........................ .
HEATE D HANDLEBAR GRiPS ........... .
12-VOLT POWER OUTLET.
VISOR OUTLET ........... .
07 DRIVE S YSTEM/BRAKE
340
342
344
345
350
351
351
353
355
355
01- DRIVE BE LT ....... ,",." ........ ........... .. .......... , ..... .... .. .... .. , .. , .. , ...... . ....... .. .. . .. ... , .•, 351
GENERA L ....................... .. ......... .. .. ...... ...... . .. ..... . .. .. . .. .. . .. . .................. .. .. .... ... 357
APPLICATION CHART. , ........... ....... , ........ , ... " ............ ...................... 357
PR OCEDURES .............................. . ........................ . .. . ........ . .... . ............. . ... . .... 357
DRIVE BELT GUARD .................................................... ............ ........................... .
DRI VE BELT GUARD SUPPORT ................................................................................ .
DRIVE BELT.. ........................ .............. . ......... ......................... .. ..
02 - DRIVE PULLEy ........................ . .. ... .. .. .......... . .. .. .. ...... ...... .. .... .. . .. ............ .. .. . .. . .
GENERAL ................................................... ... ........ . .............. .. .. .. .... . ... ....... .. .
PROCEDURES .............................................. .. ........ ... .. .. .... .. . ................ ... ... . . .
DRIVE PULLEy ........ , ..... , ..... , ... ,', .......... " ....... ........... . . .............. .
03 - DRIV EN PULLEY AND COUNTERSHAFT .... ............ ...... ...... . ............ . ............ .. . ...... .
GENERAl. ................... . ....................... . ...... ... ........ .... .............. .. .......... . .. . .... .
PROCEDURES .............................. .. .. ............ .. .. . ... . .... .. ............. . ........... ... ..... .
DRIVEN PULLEy ................. .
COUNTERSHAFT. .. , .................................................. .......... ............................... .
COUNTERSHAFT BEARING ............................................. ...... .................... .
04 - BRAKE ................................ . ..................... .... ...... .... .. ... ...... ..... .. ... .... .. . ... . ... .
GENERAL ....................................... . ............. . ..... . ..................... . .... . .. ... .. .. . ... .
PROCEDURE S ................................ .. . .................. . .. .. .... . .......... .... .............. ... .
BRAKE FLUID
BRAKE PADS .
CALI PEA ........................................................ "., ...... ... ", .... , .... .
BRAKE DISC
MASTER CYLINDER
BRAKE LIGH T SWiTCH...... . .................................................................. .
05 - CHAI NCASE ........ . ............ . .. . ... . ... .... .. . ... ... ... ... ........ . ... .. ........... . .............. ... .. . .
GE NERAL ........................................ .. . ......... . ........ . .. . ... . ......................... . ... . . .
MAINTEN ANC E .......................... . .... .. ........... .... .......................... .. ............. . .. .
CHAINCASE OIL
DRIVE CHAIN ADJUSTMENT,.. ................. . ................... , ............ , ... .
PROCEDURES ...... . .. . ... . ............ . .... . .... .. ......... .... . .. . . . . ... ... . ...... .... . .. .. .. ..... . . .
CHAINCASE COVER
CHAINCASE
CHAINCASE BEARING ............ ..
357
358
358
363
366
366
366
377
379
379
379
384
384
387
388
388
388
389
390
392
392
393
395
397
397
397
397
398
398
399
401
CHAIN TENSIONER ........ ............. .......... ...................... 403
06 - DRIVE A X LE ....................... . ... .. .... .. . .. ............. .. ..... .... ................ . ... ..... ........... 405
GENERAl. ........................... . ..................... . ... .... .......... .. .......................... . .... 406
PROCEDURES ...... . .............. .... ........... .. .............. .. ....................... .. ................ 406
DRIVE AXLE .............. ,
DRIVE AXLE BEARING ................................................... .
406
407
MAGNETIC CAP .......... , ... " ............. ....... . ..... "., .. " ..... , ..... ................. 407
07 - TRACK ... ........... . ... . ...... ...... ............ .. . ......... ... .............. .. ... . .. .. . ..................... 409
TRACK 409
TABLE OF CONTENTS
TRACTION ENHANCING PR ODUCTS (STUDS) ....... .. . ........ .. .... ... ... . ... .. . ... .. ............. .. .... .. 411
08 CHASSIS
01 - FRONT SUSPENSiON ............................. . ............... .. ........... .. ............ . .. .. , .. " .... 415
GENERAL. ......... ... ................. .. .. ......... .••• ............. •. ........... .•. ............ •• ........... 417
ADJUSTMENT ......................... •• • ............ • ............. •• ........... _ ••.. . ......... •• ..... ...... 4 17
SUSPENSION SPRING ..... .. .. .. ....... .. . ....... .. ... .. ..... . ..... .. . . .... . .... . ... .... .... ........ 417
SHOC KABSORBEA ............ .. .. .......... ... .......... .......... ........................................ .. . , 418
PROCEOURES ....................... .. ••• .......... . • .............. ••. ....... . .. .• ........ .. ... .. . .......... 418
SHOCK ABSORBER .. " ................. .... ............. .
UPPER SUSPENS I ON ARM
UPPER BALL JOINT
LOWER SUSPENSION ARM ........ .. .... .......... .. ..... .
LOWER BALL JOINT
SKI LEG .....
STABILIZER BAR ..... ... ..... .. ... .......... ... ..... ............... .. . ............. .
02 - REAR SUSPENSION ............... ..• ........... ..•• ........ .. ...• • .. .. ... . ...•• ............ . ••• ...........
GENERAL ............................. . • ............. •• .......... .. .• .. .......... •• ........... .... . ........ . ..
PROCEDURES ........ . ............. . •• ............ .. ............ •• ............. •• ........... .•.. ............
SUSPENSION ASSEMBLy . ...... ......... ................. .... ............ . ............ .......... ........... .
REAR AXLE ... ... . ........ ..... ...... .......... .. .. .
REAR SHOCK ABSORBER ...... .
FRONT SHOCK ABSORBER .. ... .. . . . . ..... ... . ........ .. .................... ... ....... .
REAR SPR ING. . ........ ...... . ..... . .................. ..... .... .
SLI DER SHOE . . .. .. ..... ..... .
FRONT ARM ... ..... ...... . .
REAR ARM .
COUPLING BLOCK . ...... ........ .. .
IDLER WHEE LS ... .. .
IDLER WHEE L SUPPORT .... ... .. .. ....... ................ ...... ............ .
41 8
420
421
422
4 23
424
4 24
427
439
439
439
440
44 1
444
445
44 7
448
450
451
452
452
STOPPER STRAP. .. . ....... .... .. .. .. .... . .. .. ............... ... ...... . .... . .... . .................. 452
REPAIR ............. . • ......................................... .••... ......... •• . ........ . ...• • • ...... . ...... . . 453
SHOCK ABSORBER REBUILT PROCEDURE .... . ....... ... ..... .... . ...... . ........ ... 453
03 - STEERING SySTEM ....... . .. ............... .................. . ...... . ... ... .. ........ .. . .................. 489
GENERAL. ............................... ..... ..................... . ......... •• ............. ... ............... 473
ADJUSTMENT ... . .............. . • ............ . .. . .................... .. . ...• . .......... ..••.. . ... ...... ..... 473
STEER ING ALIGNMENT ....... .... . ..... . .... . ....... ... .. •... . .... .............. .... ... ........... ....... .. .. 473
PROCEOURES ............ ...... •. .......... .. •.. .... . ..... .•.. .......... ... •... .. . ..... . .. .. ... .... . .. ...... 474
SKI RUNNER
SKI. .. .
SKI HANDLE ... ...... ... . ......... . ... ..... .......... . ..... .... . ..... . ..... .
SKI LEG ..... .. ... . .. . .... . .. . .. .. .
HANDLEBAR GRiP . ........... ... .
HAN DL EBAR ...... .............. ...... ... ...... ..... .. ... ....... ...... . ........... . .... ... ..................... .
HANDLE BAR EXTENSiON ... ... .
TIE·ROD .... ... ...... ...... ..... ... ... .... . ... . .... ......... ... . .. ......... .
STEERING COLUMN .... . .. .... .
04- BODy .. ..................... ... •.......... ...••. .......... •• .............. •• . ........ .• •. ........ , .... ••.......
GENERAL. .................. . .• .......... . ..• ...................... ... .. ••......... .. ... ........... .••• . ......
PROCEDURES .............. .. ............. . ....... . .... •• .......... . .. .. .. .. ...... .•... ..... .. . ... ..........
DECAL .......... ...... .......... .. .. ... .... ... ..... . ............. ..... ............... . .. .. ................. . .
SIDE PANEL .
REWIND STARTER HANDLE HOUSI NG
HOOD .. .... .. . .. .... ..... . ... .
BonOM PAN COVER . .. .. ....... .
FRONT BUMPER .... .. ..... .. ..
474
474
475
475
475
4 78
478
479
480
483
483
484
484
484
484
485
485
485
TABLE OF CONTENTS
FRONT BonOM PAN .... , .......... ........ ................ ..... .
WiNDS HIELD....... ......... . ....................................................................... .
GAUGE SUPPORT ................................................................................... .
CONSOLE ................. " ............... .. .......... . ... , .......... ...... ......... , .... .
05- FRAME . . ... . ...... .. .. .. . ... . ................................................................................ .
GENERAL. ....................................................... . ......................... .... .............. .
485
486
486
487
489
49 1
RIVET DRILLING PROCEDURE ..................................... ........................... 491
PROCEDURES ............................................................................................... 492
FRAME ............... " .............................................................................. .
REAR BUMPER ................ .
REAR FRAME MEMBER . , .... ..
FRONT FRAME MEMBER ......... .... .
FRONT CROSS MEMBER, ...... , ... " .....
ENGINE MEMBER
492
492
492
493
494
496
09 TECHNICAL SPECIFICATIONS
01 - 500SS MODELS .... . ....................................................... . .. . ... . .......... . ...... .... .... 499
02- BOOR MODELS .......................................................... .. . .. .. . ............................. 503
03 - 600 HO SOl MODELS .. ................................................................... .•• . .. .. . .. .. . .... 515
10 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS
VIII
01 - ELECTRICAL CONNECTORS ............................................. .. ................ . .. .. .. ... . .... 523
PROCEDURES ........................................................... . ..... . ............................. 525
TAB AND RECEPTACLE CONNECTORS ................................ , ........ .
SUMITOMO CONNECTOR.... . ................. .
DEUTSCH CONNECTORS ............................ .
525
525
526
PACKARD CONNECTOR ............ ............................... ... ,.. .... 526
AMP MULTI LOCK CONNECTOR . .......... ........... ............. .............. 528
AMP CONNECTOR (8-CIRCUIT) ............. .. , ....... ..... 529
KOSTAL CONNECTORS (ECM) ................................. .................. ................... ...... ..... 530
BATIERY CABLE TERMINAL .............................................. , .................................. 532
02 - WIRING DI AGRAMS ............ .. .. .... ....................................... .. .......... . ................ 535
WIRING DIAGRAMS
WIRING DIAGRAM LEGEND ........ .. ................................................. .
535
535
INTRODUCTION
INTRODUCTION
GENERAL INFORMATIONS
This shop manual covers the following BRP made
2008 REV XP series models:
MODEL
ENG INE
TYPE
GSX Limited 600 HO SOl 593
GSX Limi ted aOOR Power TEK 797
GSX Limited Touring 600 HO SDI 593
G5X 5port 50055 593
MX Z Adrenaline 600 HO SOl 593
MX Z Adrenaline BOOR Power TEK 797
MX Z Renegade 600 HO SOl 593
MX Z Renegade SOOR Power TEK 797
MX Z Renegade X 600 HO SOl 593
MX Z Renegade X BOOR Power TEK 797
MX Z TNT 50055 593
MX Z TRAIL 50055 593
MX Z X 600 HO SOl 593
MX Z X BOOR Power TEK 797
SUMMIT EVEREST BOOR Power TEK 797
SUMMIT X BOOA Power TEK 797
The information and component/system descrip-
tions contained in this manual are correct at time
of publication. SRP however. maintains a policy
of continuous improvement of its products with-
out imposing upon itself any obligation to install
them on products previously manufactured.
Due to late changes, it may have some differences
between the manufactured product and the de·
script i on and/or specifications in this document.
BAP reserves the right at any time to discontinue
or change specifications, designs, features, mod·
els or equipment without incurring obligation.
This manual uses technical terms which may be
slightly different from the ones used in the PARTS
CATALOG.
When ordering parts always refer to the specific
model PARTS CATALOG.
x
VEHICLE IDENTIFICATION
NUMBER
Vehicle Identification Number Location
TYPICAL
1. Vellide idenrification number
Identifi cation Number Meaning
2 BP 5B X5A 9Y1 000001
Model number J . T' L Ser;a, number
Model year: y '" 2000
1 • 2001
2= 2002
etc.
ENGINE SERIAL NUMBER
Engine Serial Number Location
TYPICAL - 50055 AND 600 HO SOl ENGINES
1. Engine seri81 number
TYPICAL - BOOR ENGINE
1. £Engine serial number
SNOWMOBILE LIFTING
To lift a REV XP securely, it is important to use the
re inforced footrest holes.
I. Reinforced holes in footrest
Install lifting tool hooks in holes as shown.
1. Hook of lifting tool
CAUTION: Do not use footrest opening or
stee ring co lumn to lift the snowmob ile. Frame
or steering system could be seriously dam ·
aged.
INTRODUCTION
ENGINE EMISSIONS
INFORMATION
Manufacturer's Responsibility
Manufacturers of engines must determine the ex·
haust emission levels for each engine horsepower
family and certify these engines with the United
States of America ENVIRONMENTAL PROTEC·
TION AGENCY (EPA). An emissions control i nfor-
mation label. showing emission levels and engine
specifications, must be placed on each vehicle at
the time of manufacture.
Dealer Responsibility
When performing service on snowmobiles that
carry an emissions control information la be l, ad-
justments must be kept within published factory
specifications.
Replacement or repair of any emission related
component must be executed in a manner that
maintains emission levels within the prescribed
certification standards.
Dealers are not to modify the engine in any man-
ner that would alter the horsepower or allow emis-
sion levels to exceed their predetermined factory
specifications.
Exceptions indude manufacturer's prescribed
changes, such as altitude adjustments for exam-
ple.
Owner Responsibility
The owner/operator is required to have engine
maintenance performed to maintain emission
levels within prescribed certification standards.
The owner/operator is not to, and should not al-
low anyone to modify the engine in any manner
that would alter the horsepower or allow emis-
sions levels to exceed their predetermined factory
specifications.
EPA Emission Regulations
Some Ski-Doo snowmobiles manufactur ed by
SRP are certified to the EPA as conforming to the
requirements of the regulations for the control
of air pollution from new snowmobiles engines.
This certification is contingent on certain adjust-
ments being set to factory standards. For this
reason, the factory procedure for servicing the
product must be strictly followed and, whenever
practicable, returned to the original intent of the
design.
XI
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Upon purchasing this manual, you will receive a .PDF file containing an email contact. After contacting us, you will receive a reply with a link to access the manual for your 2008 Ski-Doo GSX Limited Touring 600 HO SDI.
This comprehensive manual covers every aspect of your machine, providing detailed guidance on every nut and bolt. With hundreds of pages, it equips you to address various issues, from routine maintenance like oil changes to more complex tasks such as transmission swaps. The manual includes numerous illustrations to assist you and features easy-to-understand text throughout.
Utilize the search function to navigate the manual efficiently and print the necessary pages as needed. This Factory Service Repair Manual offers a step-by-step guide to maintaining and repairing your vehicle, imparting the expertise that factory-trained technicians possess. By leveraging the knowledge within this service repair manual, any owner can confidently make informed decisions regarding the maintenance and repair of their machine.
Rest assured, in addition to providing a high-quality service manual, we are committed to delivering excellent customer service, ensuring your satisfaction.
