2004 BRP REV Ski-Doo All Models Service & Repair Manual

2004 Shop Manual REV SERIES

Legal deposit: National Library of Quebec National Library of Canada 2003 All rights reserved. No parts of this manual may be reproduced in any form without the prior written permission of Bombardier Inc. © Bombardier Inc. 2003 Technical Publications Bombardier Inc. Valcourt (Quebec) Canada Printed in Canada ®* Registered trademarks of Bombardier Inc. This document contains the trademarks of the following companies: Crest © is a trademark of Crest Industries Inc. Loctite © is a trademark of Loctite Corporation Molykote © is a trademark of Dow Corning Corporation Silastic © is a trademark of Dow Corning Corporation Snap-on © is a trademark of Snap-on Tools Corporation Versilube © is a trademark of General Electric Company Supertanium © is a trademark of Premier Industrial Corporation AMP © is a trademark of Tyco Electronics Corporation

TABLE OF CONTENTS SAFETY NOTICE ................................................................................... IX INTRODUCTION .................................................................................... X VEHICLE IDENTIFICATION NUMBER........................................................................... XV ENGINE SERIAL NUMBER ....................................................................................... XV LIST OF ABBREVIATIONS USED IN THIS MANUAL ......................................................... XV ARRANGEMENT OF THIS MANUAL .......................................................................... XVII GENERAL INFORMATION........................................................................................ XIX ILLUSTRATIONS AND PROCEDURES ......................................................................... XIX SELF-LOCKING FASTENERS PROCEDURE ................................................................... XIX LOCTITE APPLICATION PROCEDURE .......................................................................... XIX THREADLOCKER .................................................................................................. XX STRIPPED THREAD REPAIR ..................................................................................... XXI GASKET COMPOUND ........................................................................................... XXII MOUNTING ON SHAFT ......................................................................................... XXII CASE-IN COMPONENTS ....................................................................................... XXIII TIGHTENING TORQUES ....................................................................................... XXIII 01 TOOLS AND SERVICE PRODUCTS 01 – SERVICE TOOLS ............................................................................................... 1 ENGINE — MANDATORY TOOLS ................................................................................... 2 ENGINE — RECOMMENDED TOOLS............................................................................... 4 TRANSMISSION — MANDATORY TOOLS ........................................................................ 10 TRANSMISSION — RECOMMENDED TOOLS .................................................................... 11 SUSPENSION — MANDATORY TOOLS ........................................................................... 15 SUSPENSION — RECOMMENDED TOOLS ....................................................................... 16 VEHICLE — RECOMMENDED TOOLS............................................................................. 19 02 – SERVICE PRODUCTS ........................................................................................ 21 02 MAINTENANCE 01 – MAINTENANCE CHART ..................................................................................... 29 02 – STORAGE ..................................................................................................... 33 GENERAL ............................................................................................................. 33 FUEL STABILIZER .................................................................................................... 33 ENGINE LUBRICATION .............................................................................................. 33 ENGINE COMPARTMENT ........................................................................................... 34 PULLEY PROTECTION............................................................................................... 34 COUNTERSHAFT LUBRICATION ................................................................................... 34 BATTERY .............................................................................................................. 34 VEHICLE CLEANING ................................................................................................. 34 RAGS IN AIR INTAKE AND EXHAUST SYSTEM ................................................................... 34 VEHICLE PROTECTION.............................................................................................. 34 03 – PRESEASON PREPARATION ............................................................................... 35 FUEL FILTER REPLACEMENT ...................................................................................... 35 THROTTLE BODY CLEANING(ON SO EQUIPPED MODELS) .................................................... 36 CARBURETOR CLEANING(ON SO EQUIPPED MODELS)........................................................ 36 AIR FILTER CLEANING .............................................................................................. 36 RAGS IN AIR INTAKE AND EXHAUST SYSTEM ................................................................... 36 CLEANING OF DRIVE AND DRIVEN PULLEYS .................................................................... 36 CLEANING OF BRAKE DISK ........................................................................................ 36 DRIVE BELT CONDITION ............................................................................................ 36 SPARK PLUGS ........................................................................................................ 36 I

TABLE OF CONTENTS 03 TROUBLESHOOTING 01 – ENGINE ........................................................................................................ 37 ENGINE LEAK VERIFICATION FLOW CHART ..................................................................... 48 02 – FUEL AND OIL SYSTEMS .................................................................................. 49 03 – TRANSMISSION AND BRAKE SYSTEM.................................................................. 53 TRANSMISSION ............................................................................................. 53 BRAKE SYSTEM.............................................................................................. 60 HYDRAULIC BRAKE ................................................................................................. 60 04 – ELECTRICAL SYSTEM ....................................................................................... 61 05 – SUSPENSION AND TRACK................................................................................. 73 04 ENGINE 01 – 593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES ............................................... 77 EXHAUST SYSTEM.......................................................................................... 77 TUNED PIPE .......................................................................................................... 78 MANIFOLD ........................................................................................................... 78 MUFFLER ............................................................................................................. 78 ENGINE SYSTEM ............................................................................................ 80 REMOVAL FROM VEHICLE ......................................................................................... 81 INSPECTION.......................................................................................................... 84 INSTALLATION ....................................................................................................... 84 TOP END....................................................................................................... 85 TROUBLESHOOTING ................................................................................................ 89 COMPONENT REMOVAL WITH THE ENGINE INSTALLED ...................................................... 89 CLEANING ............................................................................................................ 89 RAVE VALVE BASIC OPERATION ................................................................................... 89 DISASSEMBLY ....................................................................................................... 90 INSPECTION.......................................................................................................... 94 ASSEMBLY ........................................................................................................... 95 BOTTOM END ............................................................................................... 100 CLEANING .......................................................................................................... 103 DISASSEMBLY ..................................................................................................... 103 INSPECTION........................................................................................................ 104 ASSEMBLY ......................................................................................................... 104 BREAK-IN ........................................................................................................... 109 02 – ENGINE LEAK TEST AND DIMENSION MEASUREMENT ............................................ 111 LEAK TEST .......................................................................................................... 111 PREPARATION ..................................................................................................... 111 PROCEDURE ....................................................................................................... 111 FINALIZING REASSEMBLY........................................................................................ 113 ENGINE LEAK VERIFICATION FLOW CHART ................................................................... 114 ENGINE DIMENSION MEASUREMENT.......................................................................... 115 CYLINDER HEAD WARPAGE ..................................................................................... 115 CYLINDER TAPER .................................................................................................. 115 CYLINDER OUT OF ROUND ...................................................................................... 115 COMBUSTION CHAMBER VOLUME MEASUREMENT ........................................................ 115 USED PISTON MEASUREMENT.................................................................................. 117 CYLINDER/PISTON CLEARANCE ................................................................................. 117 RING/PISTON GROOVE CLEARANCE............................................................................ 119 RING END GAP ..................................................................................................... 119 CRANKSHAFT DEFLECTION ...................................................................................... 119 CONNECTING ROD BIG END AXIAL PLAY ...................................................................... 120 II

TABLE OF CONTENTS CRANKSHAFT END-PLAY ......................................................................................... 120 CHECKING CRANKSHAFT ALIGNMENT ......................................................................... 120 03 – MAGNETO SYSTEM........................................................................................ 121 GENERAL ........................................................................................................... 123 CLEANING .......................................................................................................... 123 DISASSEMBLY ..................................................................................................... 123 ASSEMBLY ......................................................................................................... 124 04 – OIL INJECTION SYSTEM .................................................................................. 127 GENERAL ........................................................................................................... 128 OIL TYPE ............................................................................................................ 128 OIL SYSTEM LEAK TEST .......................................................................................... 128 OIL PUMP IDENTIFICATION ...................................................................................... 129 CLEANING .......................................................................................................... 129 DISASSEMBLY ..................................................................................................... 129 ASSEMBLY ......................................................................................................... 130 ADJUSTMENT ...................................................................................................... 131 CHECKING OPERATION ........................................................................................... 132 05 – LIQUID COOLING SYSTEM................................................................................ 133 COOLING SYSTEM LEAK TEST................................................................................... 135 INSPECTION........................................................................................................ 135 DRAINING THE SYSTEM .......................................................................................... 135 DISASSEMBLY AND ASSEMBLY ................................................................................. 135 COOLING SYSTEM REFILLING PROCEDURE................................................................... 137 06 – REWIND STARTER .......................................................................................... 139 INSPECTION........................................................................................................ 140 REMOVAL .......................................................................................................... 140 ROPE REPLACEMENT............................................................................................. 140 DISASSEMBLY ..................................................................................................... 140 ASSEMBLY ......................................................................................................... 141 INSTALLATION ..................................................................................................... 143 07 – CARBURETOR AND THROTTLE CABLE ................................................................. 145 CARBURETOR TM TYPE ................................................................................... 145 IDENTIFICATION ................................................................................................... 146 REMOVAL .......................................................................................................... 146 CLEANING AND INSPECTION .................................................................................... 147 DISASSEMBLY AND ASSEMBLY ................................................................................. 148 CARBURETOR ADJUSTMENTS .................................................................................. 149 INSTALLATION ..................................................................................................... 151 DPM ........................................................................................................... 152 TESTING ............................................................................................................ 152 PARTS REMOVAL AND INSTALLATION.......................................................................... 152 DPM MANIFOLD TESTING........................................................................................ 153 THROTTLE CABLE .......................................................................................... 155 THROTTLE/OIL PUMP CABLE REMOVAL ....................................................................... 155 THROTTLE/OIL PUMP CABLE INSTALLATION .................................................................. 155 THROTTLE CABLE ADJUSTMENT ............................................................................... 155 08 – FUEL TANK AND FUEL PUMP ............................................................................ 157 FUEL FILTER........................................................................................................ 159 FUEL TANK ......................................................................................................... 159 IMPULSE/FUEL LINES SPRING CLIPS (ALL MODELS) ......................................................... 160 FLOAT-TYPE FUEL LEVEL GAUGE ............................................................................... 161 ELECTRIC FUEL LEVEL SENSOR................................................................................. 161 III

TABLE OF CONTENTS FUEL LEVEL SENSOR SCREWS.................................................................................. 161 FUEL SYSTEM PRESSURIZATION................................................................................ 161 FUEL PUMP .................................................................................................. 162 REMOVAL .......................................................................................................... 163 PUMP VERIFICATION.............................................................................................. 163 CLEANING AND INSPECTION .................................................................................... 163 INSTALLATION ..................................................................................................... 163 05 2–TEC ENGINE MANAGEMENT 01 – OVERVIEW ................................................................................................... 165 OPERATING PRINCIPLE .................................................................................... 166 AIR INDUCTION .................................................................................................... 166 FUEL DELIVERY SYSTEM.................................................................................. 166 GENERAL ........................................................................................................... 166 COMPONENT DESCRIPTION ..................................................................................... 166 ENGINE MANAGEMENT SYSTEM (EMS) .............................................................. 167 EMS — GENERAL FUNCTIONS .................................................................................. 168 ECU — ENGINE MANAGEMENT FUNCTIONS .................................................................. 169 ELECTRONIC FUEL INJECTION .................................................................................. 170 IGNITION TIMING .................................................................................................. 170 ELECTRONICALLY CONTROLLED RAVE ........................................................................ 170 KNOCK SENSOR ................................................................................................... 170 ENGINE MODES OF OPERATION ................................................................................ 170 FLOODED ENGINE (DROWNED MODE) ........................................................................ 170 MONITORING SYSTEM ........................................................................................... 170 LIMP HOME MODES .............................................................................................. 171 DIAGNOSTIC MODE............................................................................................... 171 CHARGING SYSTEM ....................................................................................... 171 MAGNETO SYSTEM ............................................................................................... 171 DOUBLE IGNITION COIL .......................................................................................... 171 TRIGGER COIL ..................................................................................................... 172 02 – COMPONENT INSPECTION AND ADJUSTMENT ..................................................... 173 GENERAL ..................................................................................................... 173 FUEL SYSTEM ............................................................................................... 173 ELECTRICAL SYSTEM ...................................................................................... 174 RESISTANCE MEASUREMENT ................................................................................... 175 ENGINE CONNECTOR PIN-OUTS ................................................................................ 176 AIR INDUCTION SYSTEM ................................................................................. 177 THROTTLE BODY .................................................................................................. 177 FUEL DELIVERY ............................................................................................. 180 FUEL PUMP ........................................................................................................ 181 FUEL RAIL .......................................................................................................... 185 FUEL INJECTORS .................................................................................................. 186 ELECTRONIC MANAGEMENT ............................................................................ 188 ECM REPLACEMENT .............................................................................................. 188 ENGINE WIRING HARNESS....................................................................................... 189 THROTTLE POSITION SENSOR (TPS)............................................................................ 189 CRANKSHAFT POSITION SENSOR (CPS)........................................................................ 192 AIR TEMPERATURE SENSOR (ATS) .............................................................................. 193 COOLANT TEMPERATURE SENSOR (CTS) ...................................................................... 193 AIR PRESSURE SENSOR (APS) ................................................................................... 194 EXHAUST GAS TEMPERATURE SENSOR (EGTS) ............................................................... 195 IV

TABLE OF CONTENTS KNOCK SENSOR (KS) .............................................................................................. 196 E-RAVE SOLENOID ................................................................................................ 197 DOUBLE IGNITION COIL .......................................................................................... 197 TDC SETTING (TOP DEAD CENTER) ............................................................................. 199 CAPACITOR......................................................................................................... 199 ENGINE START/RER BUTTON VERIFICATION .................................................................. 200 DESS SWITCH VERIFICATION .................................................................................... 200 SPARK PLUGS ...................................................................................................... 200 CRANKING SYSTEM ............................................................................................... 201 03 – DIAGNOSTIC PROCEDURES .............................................................................. 203 GENERAL ........................................................................................................... 203 TROUBLESHOOTING ............................................................................................. 203 VCK(VEHICLE COMMUNICATION KIT) ........................................................................... 206 2-TEC SYSTEM FAULT CODES ................................................................................... 207 06 TRANSMISSION 01 – DRIVE BELT .................................................................................................. 209 APPLICATION CHART ............................................................................................. 209 INSPECTION........................................................................................................ 209 CHECKING NEUTRAL FUNCTION ................................................................................ 209 ROTATION DIRECTION ............................................................................................ 209 DRIVE BELT HEIGHT MEASUREMENT AND ADJUSTMENT .................................................. 210 DRIVE BELT DEFLECTION MEASUREMENT (REFERENCE ONLY) ............................................ 212 02 – DRIVE PULLEY............................................................................................... 215 TRA III ............................................................................................................... 215 GENERAL ........................................................................................................... 216 REMOVAL .......................................................................................................... 216 DISASSEMBLY ..................................................................................................... 216 CLEANING .......................................................................................................... 218 INSPECTION........................................................................................................ 218 ASSEMBLY ......................................................................................................... 220 INSTALLATION ..................................................................................................... 223 DRIVE PULLEY ADJUSTMENT ................................................................................... 224 03 – DRIVEN PULLEY ............................................................................................ 227 FORMULA RER .................................................................................................... 227 REMOVAL .......................................................................................................... 228 DISASSEMBLY ..................................................................................................... 228 CLEANING .......................................................................................................... 228 INSPECTION........................................................................................................ 228 BUSHING REPLACEMENT ........................................................................................ 229 ASSEMBLY ......................................................................................................... 229 INSTALLATION ..................................................................................................... 230 ADJUSTMENT ...................................................................................................... 231 HPV VSA ............................................................................................................ 232 REMOVAL .......................................................................................................... 233 DISASSEMBLY ..................................................................................................... 233 CLEANING .......................................................................................................... 233 INSPECTION........................................................................................................ 233 ASSEMBLY ......................................................................................................... 233 INSTALLATION ..................................................................................................... 234 ADJUSTMENT ...................................................................................................... 234 V

TABLE OF CONTENTS 04 – PULLEY DISTANCE AND ALIGNMENT .................................................................. 235 GENERAL ........................................................................................................... 235 GENERAL PROCEDURE ........................................................................................... 235 PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART ............................................. 236 05 – BRAKE ........................................................................................................ 239 HYDRAULIC BRAKE ........................................................................................ 239 BRAKE FLUID ...................................................................................................... 240 MASTER CYLINDER ............................................................................................... 240 CALIPER ............................................................................................................ 240 BRAKE PADS ....................................................................................................... 241 BRAKE DISC ........................................................................................................ 242 COUNTERSHAFT BEARING....................................................................................... 242 COUNTERSHAFT................................................................................................... 243 BRAKE LIGHT SWITCH ............................................................................................ 243 BLEEDING .......................................................................................................... 244 06 – CHAINCASE .................................................................................................. 245 REMOVAL AND DISASSEMBLY .................................................................................. 246 INSPECTION........................................................................................................ 246 GEAR RATIO MODIFICATION..................................................................................... 246 INSTALLATION AND ASSEMBLY ................................................................................. 247 DRIVE CHAIN ADJUSTMENT ..................................................................................... 247 ADJUSTMENT ...................................................................................................... 248 07 – DRIVE CHAIN ................................................................................................ 249 SILENT CHAIN...................................................................................................... 249 07 ELECTRICAL SYSTEM 01 – IGNITION TIMING ........................................................................................... 251 SCRIBING A TIMING MARK....................................................................................... 251 CHECKING IGNITION TIMING .................................................................................... 252 CHANGING TIMING................................................................................................ 253 02 – SPARK PLUGS ............................................................................................... 257 DISASSEMBLY ..................................................................................................... 257 SPARK PLUG INSTALLATION ..................................................................................... 257 SPARK PLUG TIGHTENING TORQUE ............................................................................ 257 03 – BATTERY ..................................................................................................... 259 GENERAL ........................................................................................................... 259 REMOVAL .......................................................................................................... 259 CLEANING .......................................................................................................... 259 INSPECTION........................................................................................................ 259 BATTERY CHARGE TESTING ..................................................................................... 260 BATTERY STORAGE ............................................................................................... 260 ACTIVATION OF NEW BATTERY .................................................................................. 260 BATTERY CHARGING .............................................................................................. 260 INSTALLATION OF BATTERY ..................................................................................... 260 CABLE TERMINAL INSTALLATION ............................................................................... 261 04 – ELECTRIC STARTER ........................................................................................ 263 REMOVAL .......................................................................................................... 264 DISASSEMBLY ..................................................................................................... 264 CLEANING .......................................................................................................... 265 INSPECTION........................................................................................................ 265 ASSEMBLY ......................................................................................................... 267 INSTALLATION ..................................................................................................... 268 VI

TABLE OF CONTENTS 05 – TESTING PROCEDURE ..................................................................................... 269 GENERAL ........................................................................................................... 269 CHECKING CALIBRATION PROGRAM ........................................................................... 272 CHANGING MPEM CALIBRATION PROGRAM.................................................................. 275 SYSTEM TESTING ................................................................................................. 276 INSPECTION OF HEATING ELEMENTS .......................................................................... 283 HEADLIGHT AND ACCESSORIES SYSTEM TESTING .......................................................... 284 08 REAR SUSPENSION 01 – SC-10 SUSPENSION........................................................................................ 285 COMPONENT REMOVAL AND INSTALLATION ................................................................. 288 SUSPENSION ASSEMBLY REMOVAL............................................................................ 289 DISASSEMBLY AND ASSEMBLY ................................................................................. 289 SHOCK ABSORBER INSPECTION ................................................................................ 291 INSTALLATION ..................................................................................................... 292 RIDE ADJUSTMENT ............................................................................................... 292 LUBRICATION ...................................................................................................... 292 02 – SC-10 III SUSPENSION..................................................................................... 293 COMPONENT REMOVAL AND INSTALLATION ................................................................. 296 SUSPENSION ASSEMBLY REMOVAL............................................................................ 297 DISASSEMBLY AND ASSEMBLY ................................................................................. 298 SHOCK ABSORBER INSPECTION ................................................................................ 300 HPG T/A SHOCK SERVICING ..................................................................................... 301 INSTALLATION ..................................................................................................... 309 RIDE ADJUSTMENT ............................................................................................... 309 LUBRICATION ...................................................................................................... 309 03 – DRIVE AXLE.................................................................................................. 311 REMOVAL .......................................................................................................... 312 ASSEMBLY ......................................................................................................... 313 LUBRICATION ...................................................................................................... 314 ADJUSTMENT ...................................................................................................... 315 04 – TRACK ........................................................................................................ 317 TRACK TYPE APPLICATION ....................................................................................... 317 GENERAL ........................................................................................................... 317 INSPECTION........................................................................................................ 317 REMOVAL .......................................................................................................... 317 INSTALLATION ..................................................................................................... 317 ADJUSTMENT ...................................................................................................... 317 09 STEERING/FRONT SUSPENSION 01 – STEERING SYSTEM ........................................................................................ 321 DISASSEMBLY AND ASSEMBLY ................................................................................. 323 INSPECTION........................................................................................................ 326 ADJUSTMENT ...................................................................................................... 326 STEERING ADJUSTMENT (SKIS) ................................................................................. 330 LUBRICATION ...................................................................................................... 332 02 – FRONT SUSPENSION ...................................................................................... 333 GENERAL INSPECTION ........................................................................................... 334 DISASSEMBLY ..................................................................................................... 334 INSPECTION........................................................................................................ 338 INSTALLATION ..................................................................................................... 338 VII

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2004 BRP REV Ski-Doo All Models Service & Repair Manual

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