2006 Skidoo BRP REV chassis snowmobile service repair workshop manual

TABLE OF CONTENTS SAFETY NOTICE ................................................................................... XI INTRODUCTION .................................................................................. XII VEHICLE IDENTIFICATION NUMBER........................................................................... XIV ENGINE SERIAL NUMBER ....................................................................................... XIV LIST OF ABBREVIATIONS USED IN THIS MANUAL ......................................................... XIV ARRANGEMENT OF THIS MANUAL ........................................................................... XVI GENERAL INFORMATION...................................................................................... XVIII ILLUSTRATIONS AND PROCEDURES ....................................................................... XVIII SELF-LOCKING FASTENERS PROCEDURE ................................................................. XVIII LOCTITE APPLICATION PROCEDURE .......................................................................... XIX THREADLOCKER .................................................................................................. XIX STRIPPED THREAD REPAIR ..................................................................................... XX GASKET COMPOUND ............................................................................................ XXI MOUNTING ON SHAFT .......................................................................................... XXI CASE-IN COMPONENTS ........................................................................................ XXII TIGHTENING TORQUE ......................................................................................... XXIII 01 MAINTENANCE 01 – MAINTENANCE CHART ....................................................................................... 1 02 – STORAGE ....................................................................................................... 3 GENERAL .............................................................................................................. 3 ENGINE ................................................................................................................ 3 FUEL SYSTEM......................................................................................................... 4 DRIVE SYSTEM ....................................................................................................... 4 STEERING/FRONT SUSPENSION ................................................................................... 5 SUSPENSION.......................................................................................................... 5 ELECTRICAL ........................................................................................................... 5 VEHICLE ............................................................................................................... 5 03 – PRESEASON PREPARATION ................................................................................. 7 ENGINE ................................................................................................................ 7 FUEL SYSTEM......................................................................................................... 7 DRIVE SYSTEM ....................................................................................................... 8 ELECTRICAL SYSTEM ................................................................................................ 8 VEHICLE ............................................................................................................... 8 02 TROUBLESHOOTING 01 – ENGINE .......................................................................................................... 9 02 – FUEL AND OIL SYSTEMS .................................................................................. 21 03 – DRIVE AND BRAKE SYSTEMS............................................................................. 25 DRIVE SYSTEM ...................................................................................................... 25 BRAKE SYSTEM...................................................................................................... 32 04 – ELECTRICAL SYSTEM ....................................................................................... 33 05 – STEERING AND SUSPENSION ............................................................................ 43 03 ENGINES 01 – LEAK TEST .................................................................................................... 47 PREPARATION ....................................................................................................... 47 PROCEDURE ......................................................................................................... 48 FINALIZING REASSEMBLY.......................................................................................... 49 ENGINE LEAK VERIFICATION FLOW CHART ..................................................................... 50 I

TABLE OF CONTENTS 02 – EXHAUST SYSTEM.......................................................................................... 51 377 AND 552 ENGINES ..................................................................................... 52 593, 593 HO, 593 HO SDI AND 793 HO ENGINES ...................................................... 53 TUNED PIPE .......................................................................................................... 54 MANIFOLD ........................................................................................................... 55 MUFFLER ............................................................................................................. 55 03 – ENGINE REMOVAL AND INSTALLATION ................................................................ 57 REMOVAL FROM VEHICLE ......................................................................................... 59 INSPECTION.......................................................................................................... 63 INSTALLATION ....................................................................................................... 63 REMOVAL FROM VEHICLE ......................................................................................... 65 INSPECTION.......................................................................................................... 69 INSTALLATION ....................................................................................................... 69 04 – MAGNETO SYSTEM......................................................................................... 71 GENERAL ............................................................................................................. 76 MAGNETO FLYWHEEL .............................................................................................. 76 STATOR ............................................................................................................... 78 CPS/TRIGGER COIL .................................................................................................. 78 05 – TOP END....................................................................................................... 81 TROUBLESHOOTING ................................................................................................ 84 CLEANING ............................................................................................................ 84 DISASSEMBLY ....................................................................................................... 84 INSPECTION.......................................................................................................... 86 ASSEMBLY ........................................................................................................... 86 TROUBLESHOOTING ................................................................................................ 98 COMPONENT REMOVAL WITH THE ENGINE INSTALLED ...................................................... 98 CLEANING ............................................................................................................ 98 RAVE VALVE BASIC OPERATION ................................................................................... 98 DISASSEMBLY ....................................................................................................... 98 INSPECTION........................................................................................................ 103 ASSEMBLY ......................................................................................................... 104 06 – BOTTOM END ............................................................................................... 109 CLEANING .......................................................................................................... 112 DISASSEMBLY ..................................................................................................... 112 INSPECTION........................................................................................................ 113 ASSEMBLY ......................................................................................................... 113 BREAK-IN ........................................................................................................... 118 CLEANING .......................................................................................................... 122 DISASSEMBLY ..................................................................................................... 122 INSPECTION........................................................................................................ 123 ASSEMBLY ......................................................................................................... 123 BREAK-IN ........................................................................................................... 128 07 – ENGINE MEASUREMENT ................................................................................. 129 CYLINDER HEAD WARPAGE ..................................................................................... 129 CYLINDER TAPER .................................................................................................. 129 CYLINDER OUT OF ROUND ...................................................................................... 129 COMBUSTION CHAMBER VOLUME MEASUREMENT ........................................................ 130 USED PISTON MEASUREMENT.................................................................................. 131 CYLINDER/PISTON CLEARANCE ................................................................................. 131 RING/PISTON GROOVE CLEARANCE............................................................................ 133 RING END GAP ..................................................................................................... 133 CRANKSHAFT DEFLECTION ...................................................................................... 133 II

TABLE OF CONTENTS CONNECTING ROD BIG END AXIAL PLAY ...................................................................... 134 CHECKING CRANKSHAFT ALIGNMENT ......................................................................... 134 08 – COOLING SYSTEM ......................................................................................... 135 COOLING FAN REMOVAL AND INSTALLATION ................................................................ 138 COOLING FAN BEARING REPLACEMENT ...................................................................... 138 FAN BELT REPLACEMENT AND DEFLECTION ADJUSTMENT ................................................ 139 LIQUID COOLING SYSTEM ....................................................................................... 142 COOLING SYSTEM LEAK TEST................................................................................... 145 INSPECTION........................................................................................................ 145 DRAINING THE SYSTEM .......................................................................................... 145 DISASSEMBLY AND ASSEMBLY ................................................................................. 145 COOLING SYSTEM REFILLING PROCEDURE................................................................... 146 09 – REWIND STARTER .......................................................................................... 147 INSPECTION........................................................................................................ 150 REMOVAL .......................................................................................................... 150 ROPE REPLACEMENT............................................................................................. 150 DISASSEMBLY ..................................................................................................... 151 ASSEMBLY ......................................................................................................... 151 INSTALLATION ..................................................................................................... 154 10 – OIL INJECTION SYSTEM .................................................................................. 155 GENERAL ........................................................................................................... 158 OIL TYPE ............................................................................................................ 158 OIL SYSTEM LEAK TEST .......................................................................................... 158 OIL PUMP IDENTIFICATION ...................................................................................... 159 CLEANING .......................................................................................................... 159 CHECKING OPERATION ........................................................................................... 159 DISASSEMBLY ..................................................................................................... 160 ASSEMBLY ......................................................................................................... 161 BLEEDING PROCEDURE .......................................................................................... 162 ADJUSTMENT ...................................................................................................... 162 04 FUEL SYSTEM 01 – FUEL TANK AND FUEL PUMP ............................................................................ 165 IN-TANK FUEL FILTER ............................................................................................. 168 IN-LINE FUEL FILTER .............................................................................................. 168 FUEL TANK ......................................................................................................... 169 FLOAT-TYPE FUEL LEVEL GAUGE ............................................................................... 170 ELECTRIC FUEL LEVEL SENSOR................................................................................. 171 FUEL SYSTEM PRESSURIZATION................................................................................ 171 DIAPHRAGM FUEL PUMP ................................................................................. 172 REMOVAL .......................................................................................................... 174 PUMP VERIFICATION.............................................................................................. 174 CLEANING AND INSPECTION .................................................................................... 174 INSTALLATION ..................................................................................................... 174 02 – CARBURETORS, THROTTLE AND CHOKE CABLES ................................................... 175 CARBURETOR — VM TYPE ............................................................................... 176 IDENTIFICATION ................................................................................................... 177 REMOVAL .......................................................................................................... 177 CLEANING AND INSPECTION .................................................................................... 177 DISASSEMBLY AND ASSEMBLY ................................................................................. 177 CARBURETOR ADJUSTMENTS .................................................................................. 178 INSTALLATION ..................................................................................................... 181 III

TABLE OF CONTENTS CHOKE .............................................................................................................. 182 CARBURETOR TM TYPE ................................................................................... 184 IDENTIFICATION ................................................................................................... 185 REMOVAL .......................................................................................................... 185 CLEANING AND INSPECTION .................................................................................... 187 DISASSEMBLY AND ASSEMBLY ................................................................................. 187 INSTALLATION ..................................................................................................... 189 CARBURETOR ADJUSTMENTS .................................................................................. 189 CHOKE CABLE ..................................................................................................... 191 03 – DPM SYSTEM ............................................................................................... 193 OVERVIEW ......................................................................................................... 195 SYSTEM TESTING ................................................................................................. 195 PARTS REMOVAL AND INSTALLATION.......................................................................... 195 DPM MANIFOLD TESTING........................................................................................ 196 05 ENGINE MANAGEMENT (POWER TEK) 01 – OVERVIEW ................................................................................................... 199 OPERATING PRINCIPLE .................................................................................... 200 FUEL DELIVERY SYSTEM ......................................................................................... 200 ENGINE MANAGEMENT SYSTEM (EMS)........................................................................ 200 EMS — ENGINE MANAGEMENT SYSTEM FUNCTIONS....................................................... 201 POWER DISTRIBUTION ........................................................................................... 202 IGNITION SYSTEM................................................................................................. 202 ELECTRONICALLY CONTROLLED RAVE ........................................................................ 202 DIGITALLY ENCODED SECURITY SYSTEM (DESS) ............................................................. 202 ROTAX ELECTRONIC REVERSE (RER) ........................................................................... 203 MONITORING SYSTEM ........................................................................................... 203 DIAGNOSTIC MODE............................................................................................... 203 02 – DIAGNOSTIC PROCEDURES .............................................................................. 205 GENERAL ........................................................................................................... 205 TROUBLESHOOTING ............................................................................................. 205 EMS FAULT CODES ............................................................................................... 206 VCK (VEHICLE COMMUNICATION KIT) .......................................................................... 209 03 – COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT ................................ 213 GENERAL ..................................................................................................... 213 ELECTRICAL SYSTEM ............................................................................................. 213 FUEL SYSTEM...................................................................................................... 215 ENGINE MANAGEMENT SYSTEM ....................................................................... 216 ENGINE CONTROL MODULE (ECM) ............................................................................. 216 POWER RELAY ..................................................................................................... 216 THROTTLE POSITION SENSOR (TPS)............................................................................ 217 AIR TEMPERATURE SENSOR (ATS) .............................................................................. 221 COOLANT TEMPERATURE SENSOR (CTS) ...................................................................... 222 AIR PRESSURE SENSOR (APS) ................................................................................... 223 KNOCK SENSOR (KS) .............................................................................................. 224 E-RAVE SOLENOID ................................................................................................ 225 DPM SOLENOID ................................................................................................... 226 IGNITION COIL ..................................................................................................... 226 ENGINE START/RER SWITCH..................................................................................... 227 DIGITALLY ENCODED SECURITY SYSTEM (DESS) ............................................................. 228 IV

TABLE OF CONTENTS 06 ENGINE MANAGEMENT (SDI) 01 – OVERVIEW ................................................................................................... 231 OPERATING PRINCIPLE .................................................................................... 232 CHARGING SYSTEM............................................................................................... 232 IGNITION SYSTEM................................................................................................. 232 AIR INDUCTION .................................................................................................... 232 FUEL DELIVERY SYSTEM ......................................................................................... 233 ENGINE MANAGEMENT SYSTEM (EMS) .............................................................. 234 ECM — GENERAL FUNCTIONS .................................................................................. 235 EMS — ENGINE MANAGEMENT SYSTEM FUNCTIONS....................................................... 237 ELECTRONIC FUEL INJECTION .................................................................................. 237 IGNITION TIMING .................................................................................................. 238 ELECTRONICALLY CONTROLLED RAVE ........................................................................ 238 KNOCK SENSOR ................................................................................................... 238 ENGINE MODES OF OPERATION ................................................................................ 238 FLOODED ENGINE (DROWNED MODE) ........................................................................ 238 MONITORING SYSTEM ........................................................................................... 238 LIMP HOME MODES .............................................................................................. 238 DIAGNOSTIC MODE............................................................................................... 239 ROTAX ELECTRONIC REVERSE (RER) ........................................................................... 239 02 – DIAGNOSTIC PROCEDURES .............................................................................. 241 GENERAL ........................................................................................................... 241 TROUBLESHOOTING ............................................................................................. 241 VCK (VEHICLE COMMUNICATION KIT) .......................................................................... 245 2-TEC SYSTEM FAULT CODES ................................................................................... 247 03 – COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT ................................ 249 GENERAL ..................................................................................................... 249 FUEL SYSTEM ............................................................................................... 249 ELECTRICAL SYSTEM ...................................................................................... 250 RESISTANCE MEASUREMENT ................................................................................... 251 ENGINE CONNECTOR PIN-OUTS ................................................................................ 252 RELAY ............................................................................................................... 253 AIR INDUCTION SYSTEM ................................................................................. 254 THROTTLE BODY .................................................................................................. 254 FUEL DELIVERY ............................................................................................. 257 ELECTRIC FUEL PUMP............................................................................................ 258 FUEL RAIL .......................................................................................................... 261 FUEL INJECTORS .................................................................................................. 262 ELECTRONIC MANAGEMENT ............................................................................ 265 ECM REPLACEMENT .............................................................................................. 265 ENGINE WIRING HARNESS....................................................................................... 265 THROTTLE POSITION SENSOR (TPS)............................................................................ 266 CRANKSHAFT POSITION SENSOR (CPS)........................................................................ 268 AIR TEMPERATURE SENSOR (ATS) .............................................................................. 269 COOLANT TEMPERATURE SENSOR (CTS) ...................................................................... 270 AIR PRESSURE SENSOR (APS) ................................................................................... 271 EXHAUST GAS TEMPERATURE SENSOR (EGTS) ............................................................... 271 KNOCK SENSOR (KS) .............................................................................................. 272 E-RAVE SOLENOID ................................................................................................ 273 DOUBLE IGNITION COIL .......................................................................................... 273 IGNITION TIMING .................................................................................................. 275 BATTERY ............................................................................................................ 275 V

TABLE OF CONTENTS CAPACITOR......................................................................................................... 275 ENGINE START/RER SWITCH VERIFICATION ................................................................... 276 DESS POST VERIFICATION ....................................................................................... 277 07 ELECTRICAL SYSTEM 01 – IGNITION SYSTEM ......................................................................................... 279 GENERAL ........................................................................................................... 279 IGNITION TIMING .................................................................................................. 282 SPARK PLUG ....................................................................................................... 291 DESIGN SYMBOLS USED IN NGK SPARK PLUGS .................................................... 292 02 – CHARGING SYSTEM ....................................................................................... 293 GENERAL ........................................................................................................... 293 CHARGING GENERATOR COIL (STATOR) ....................................................................... 293 VOLTAGE REGULATOR/RECTIFIER .............................................................................. 294 BATTERY ............................................................................................................ 295 CABLE TERMINAL INSTALLATION ............................................................................... 297 03 – STARTING SYSTEM ........................................................................................ 299 TROUBLESHOOTING .............................................................................................. 301 04 – ACCESSORIES ............................................................................................... 307 GENERAL ........................................................................................................... 307 12-VOLT POWER OUTLET (CIGARETTE-LIGHTER TYPE) ...................................................... 308 BEEPER (REVERSE ALARM) ...................................................................................... 308 ENGINE TEMPERATURE GAUGE................................................................................. 309 ELECTRIC FUEL GAUGE .......................................................................................... 310 HEADLAMP......................................................................................................... 310 HEADLAMP BEAM AIMING ...................................................................................... 311 HEATING ELEMENTS .............................................................................................. 312 RELAY ............................................................................................................... 312 SPEEDOMETER .................................................................................................... 313 SPEED SENSOR.................................................................................................... 313 TACHOMETER ..................................................................................................... 314 TAILLIGHT .......................................................................................................... 314 VISOR OUTLET ..................................................................................................... 315 08 DRIVE SYSTEM 01 – DRIVE BELT .................................................................................................. 317 APPLICATION CHART ............................................................................................. 317 INSPECTION........................................................................................................ 317 CHECKING NEUTRAL FUNCTION ................................................................................ 317 ROTATION DIRECTION ............................................................................................ 317 DRIVE BELT HEIGHT MEASUREMENT AND ADJUSTMENT .................................................. 318 DRIVE BELT DEFLECTION MEASUREMENT (REFERENCE ONLY) ............................................ 320 02 – DRIVE PULLEY............................................................................................... 323 BOMBARDIER LITE ......................................................................................... 324 GENERAL ........................................................................................................... 325 REMOVAL .......................................................................................................... 325 DISASSEMBLY ..................................................................................................... 325 CLEANING .......................................................................................................... 326 INSPECTION........................................................................................................ 326 ASSEMBLY ......................................................................................................... 326 INSTALLATION ..................................................................................................... 327 TRA III ......................................................................................................... 328 VI

TABLE OF CONTENTS GENERAL ........................................................................................................... 329 REMOVAL .......................................................................................................... 329 DISASSEMBLY ..................................................................................................... 329 CLEANING .......................................................................................................... 331 INSPECTION........................................................................................................ 331 ASSEMBLY ......................................................................................................... 333 INSTALLATION ..................................................................................................... 337 DRIVE PULLEY ADJUSTMENT ................................................................................... 337 03 – DRIVEN PULLEY ............................................................................................ 339 FORMULA RER AND FORMULA VSA-R ......................................................................... 340 REMOVAL .......................................................................................................... 341 DISASSEMBLY ..................................................................................................... 341 CLEANING .......................................................................................................... 341 INSPECTION........................................................................................................ 341 BUSHING REPLACEMENT ........................................................................................ 342 ASSEMBLY ......................................................................................................... 342 INSTALLATION ..................................................................................................... 343 ADJUSTMENT ...................................................................................................... 344 HPV VSA ............................................................................................................ 345 REMOVAL .......................................................................................................... 346 DISASSEMBLY ..................................................................................................... 346 CLEANING .......................................................................................................... 346 INSPECTION........................................................................................................ 346 ASSEMBLY ......................................................................................................... 346 INSTALLATION ..................................................................................................... 347 ADJUSTMENT ...................................................................................................... 347 04 – PULLEY ALIGNMENT ...................................................................................... 349 GENERAL ........................................................................................................... 349 MEASURING PROCEDURE ....................................................................................... 349 ALIGNMENT PROCEDURE........................................................................................ 351 05 – BRAKE ........................................................................................................ 353 HYDRAULIC BRAKE ........................................................................................ 354 BRAKE FLUID ...................................................................................................... 355 MASTER CYLINDER ............................................................................................... 355 CALIPER ............................................................................................................ 355 BRAKE PADS ....................................................................................................... 356 BRAKE DISC ........................................................................................................ 357 COUNTERSHAFT BEARING....................................................................................... 357 COUNTERSHAFT................................................................................................... 358 BRAKE LIGHT SWITCH ............................................................................................ 358 BLEEDING .......................................................................................................... 359 06 – CHAINCASE .................................................................................................. 361 GENERAL ........................................................................................................... 363 CHAINCASE OIL LEVEL ........................................................................................... 363 OIL CHANGE ....................................................................................................... 363 DRIVE CHAIN ADJUSTMENT ..................................................................................... 364 REMOVAL AND DISASSEMBLY .................................................................................. 364 INSPECTION........................................................................................................ 365 INSTALLATION AND ASSEMBLY ................................................................................. 365 SILENT CHAIN...................................................................................................... 365 07 – DRIVE AXLE.................................................................................................. 367 REMOVAL .......................................................................................................... 371 VII

TABLE OF CONTENTS ASSEMBLY ......................................................................................................... 372 LUBRICATION ...................................................................................................... 373 ADJUSTMENT ...................................................................................................... 373 08 – TRACK ........................................................................................................ 375 TRACK TYPE APPLICATION ....................................................................................... 375 GENERAL ........................................................................................................... 375 INSPECTION........................................................................................................ 375 REMOVAL .......................................................................................................... 375 INSTALLATION ..................................................................................................... 375 ADJUSTMENT ...................................................................................................... 375 TRACK CLEAT ...................................................................................................... 377 TRACTION ENHANCING PRODUCTS (STUDS).................................................................. 377 09 REAR SUSPENSION 01 – SC SUSPENSION ........................................................................................... 381 AXLE SELF-LOCKING SCREWS REMOVAL ..................................................................... 386 REAR AXLE REMOVAL ............................................................................................ 386 REAR AXLE INSTALLATION ....................................................................................... 386 REAR SHOCK ABSORBER REMOVAL ........................................................................... 386 REAR SHOCK ABSORBER INSTALLATION ...................................................................... 387 FRONT SHOCK ABSORBER REMOVAL ......................................................................... 387 FRONT SHOCK ABSORBER INSTALLATION .................................................................... 387 REAR SPRING REMOVAL ......................................................................................... 388 REAR SPRING INSTALLATION .................................................................................... 388 SLIDER SHOE VERIFICATION .................................................................................... 388 SLIDER SHOE REMOVAL ......................................................................................... 389 SLIDER SHOE INSTALLATION .................................................................................... 390 SUSPENSION REMOVAL.......................................................................................... 390 SUSPENSION INSTALLATION .................................................................................... 391 FRONT ARM REMOVAL ........................................................................................... 391 FRONT ARM INSTALLATION ..................................................................................... 391 REAR ARM/PIVOT ARM REMOVAL .............................................................................. 392 REAR ARM INSTALLATION ....................................................................................... 392 STOPPER STRAP................................................................................................... 392 RIDE ADJUSTMENT ............................................................................................... 393 LUBRICATION ...................................................................................................... 393 02 – SC 3 SUSPENSION ......................................................................................... 395 AXLE SELF-LOCKING SCREWS REMOVAL ..................................................................... 399 REAR AXLE REMOVAL ............................................................................................ 399 REAR AXLE INSTALLATION ....................................................................................... 399 REAR SHOCK ABSORBER REMOVAL ........................................................................... 399 REAR SHOCK ABSORBER INSTALLATION ...................................................................... 400 FRONT SHOCK ABSORBER REMOVAL ......................................................................... 400 FRONT SHOCK ABSORBER INSTALLATION .................................................................... 400 REAR SPRING REMOVAL ......................................................................................... 400 REAR SPRING INSTALLATION .................................................................................... 401 SLIDER SHOE VERIFICATION .................................................................................... 402 SLIDER SHOE REMOVAL ......................................................................................... 402 SLIDER SHOE INSTALLATION .................................................................................... 403 SUSPENSION REMOVAL.......................................................................................... 403 SUSPENSION INSTALLATION .................................................................................... 404 FRONT ARM REMOVAL ........................................................................................... 404 VIII

TABLE OF CONTENTS FRONT ARM INSTALLATION ..................................................................................... 405 REAR ARM/PIVOT ARM REMOVAL .............................................................................. 405 REAR ARM/PIVOT ARM INSTALLATION......................................................................... 405 STOPPER STRAP................................................................................................... 406 RIDE ADJUSTMENT ............................................................................................... 406 LUBRICATION ...................................................................................................... 406 03 – SC 4 SUSPENSION ......................................................................................... 409 AXLE SELF-LOCKING SCREW REMOVAL ....................................................................... 413 REAR AXLE REMOVAL ............................................................................................ 413 REAR AXLE INSTALLATION ....................................................................................... 413 REAR SHOCK ABSORBER REMOVAL ........................................................................... 413 REAR SHOCK ABSORBER INSTALLATION ...................................................................... 414 FRONT SHOCK ABSORBER REMOVAL ......................................................................... 414 FRONT SHOCK ABSORBER INSTALLATION .................................................................... 415 REAR SPRING REMOVAL ......................................................................................... 415 REAR SPRING INSTALLATION .................................................................................... 416 SLIDER SHOE VERIFICATION .................................................................................... 416 SLIDER SHOE REMOVAL ......................................................................................... 417 SLIDER SHOE INSTALLATION .................................................................................... 418 SUSPENSION REMOVAL.......................................................................................... 418 SUSPENSION INSTALLATION .................................................................................... 418 FRONT ARM REMOVAL ........................................................................................... 418 FRONT ARM INSTALLATION ..................................................................................... 419 REAR ARM/PIVOT ARM REMOVAL .............................................................................. 419 REAR ARM/PIVOT ARM INSTALLATION......................................................................... 419 BLOCK INSTALLATION ............................................................................................ 420 IDLER WHEELS INSTALLATION .................................................................................. 420 STOPPER STRAP................................................................................................... 420 RIDE ADJUSTMENT ............................................................................................... 420 LUBRICATION ...................................................................................................... 421 04 – SHOCK ABSORBER INSPECTION AND SERVICING .................................................. 423 SPRING REMOVAL ................................................................................................ 423 SHOCK ABSORBER INSPECTION ................................................................................ 424 DISASSEMBLY AND ASSEMBLY ................................................................................. 425 10 STEERING/FRONT SUSPENSION 01 – STEERING SYSTEM ........................................................................................ 433 DISASSEMBLY AND ASSEMBLY ................................................................................. 437 INSPECTION........................................................................................................ 440 ADJUSTMENT ...................................................................................................... 440 STEERING ADJUSTMENT (SKIS) ................................................................................. 444 LUBRICATION ...................................................................................................... 446 02 – FRONT SUSPENSION ...................................................................................... 447 GENERAL INSPECTION ........................................................................................... 450 DISASSEMBLY ..................................................................................................... 450 INSPECTION........................................................................................................ 454 INSTALLATION ..................................................................................................... 455 11 BODY/FRAME 01 – BODY .......................................................................................................... 461 INSTALLATION AND ADJUSTMENT .................................................................... 461 DECAL .............................................................................................................. 461 IX

TABLE OF CONTENTS WINDSHIELD ....................................................................................................... 461 GUARD.............................................................................................................. 461 WIRING HARNESS................................................................................................. 461 CABLES ............................................................................................................. 462 TUBING ............................................................................................................. 462 PLASTIC MAINTENANCE AND REPAIR ................................................................. 462 MAINTENANCE .................................................................................................... 462 REPAIR .............................................................................................................. 462 02 – FRAME ........................................................................................................ 463 FRAME CLEANING ................................................................................................ 463 FRAME WELDING ................................................................................................. 463 FRAME COMPONENT REPLACEMENT ......................................................................... 463 12 TECHNICAL DATA 01 – FAN COOLED MODELS .................................................................................... 465 02 – LIQUID COOLED MODELS................................................................................. 471 03 – LIQUID COOLED (SDI) MODELS.......................................................................... 479 13 WIRING DIAGRAM 01 – WIRING DIAGRAMS ........................................................................................ 485 WIRING DIAGRAM LEGEND ...................................................................................... 485 WIRE COLORS ..................................................................................................... 485 CONNECTOR HOUSING AREA ................................................................................... 485 HOUSING REFERENCE PER AREA............................................................................... 486 WIRE LOCATION IN CONNECTOR HOUSING .................................................................. 486 SYMBOLS DESCRIPTION ......................................................................................... 488 UNPLUGING CONNECTORS ...................................................................................... 489 TAB AND RECEPTACLE CONNECTORS REMOVAL ............................................................ 489 TAB AND RECEPTACLE CONNECTORS INSTALLATION ....................................................... 495 X

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2006 Skidoo BRP REV chassis snowmobile service repair workshop manual

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