This service manuals covers most of the 2009/2010 Ski-Doo
snowmobile line.
Per BRP the 2009 and 2010 models in this manual are the same,
so they did not release a separate 2010 manual.
This manual is fully searchable, just hold down the control key and the F
key to search on any word.
NOTE: This manual is way below our quality standards, the
vast majority of our manuals are very clear with good wire
diagrams. Unfortunately BRP used horribly thin paper for
this manual so it is very light & the wire diagrams are mainly
usable, but leave a lot to be desired.
Please do not judge our manuals by the quality of this one.
Most sellers offer this manual for full price, we offer it for
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TABLE OF CONTENTS
SAFETY NOTI CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
INTRODUCTION .. ........... ........ ..... ....... ........ .. .. ..... ...... ..................... ........ ................. .. XI
GENERAL ...... . .... . .... ...... .. ........................................................ . ................ .......... ... XI
HOW TO IDENTIFY YOUR VEHICLE .............................. . ............... . .................... ... ........ XII
SNOWMOBILE LIFTING .... ... ........ .. ............. .... ...... ..... . .... . .. ..... ..... ..... ..... ....... .. . ...... . ... XI I
ENGINE EMISSIONS INFORMATION ..... .... .. ....................... .. ........ . ...... . ........................ XII I
TIGHTENING TORQUE .... .. .. ... . ..... .. .. . ... . ................................. . ................ ..... .. . ..... .. .. XIV
SELF-LOCKING FASTENERS PROCE DURE . .... ... ....... . ..... . ..... . .... . ..... . ....... .... ...... . ..... . ...... XV
LOCTITE APPLICATION PROCE DURE................................................................ ........... XV
MANUAL INFORMATION . .............. .. ............. ............ .. ..... ... .... ... ... ... .. ... .... .. .. ... . ...... XV III
01 MAINTENANCE
01 - MAINTENANCE CHART. .... .. .... . .. . .. ..... ... .. . ... . ........................... .... ... . ........... . ....... . .. 1
02 - STORAGE PROCEDURE .... . ........................................ .... ............................... . ........ 3
GENERAL .... .. .... ...... ... ... .... .. .......... . ..... . ...................... ... ............. .. .............. . .. 3
PROCEDURES . ... ........ . ....................... .... ......................................................... 3
ENGINE MANAGEMENT SYSTEM ............... . ................ . ...... ... ..... .. . .. .... ... ..... ......... 3
FUEL SYSTEM .......................................... . ................................................... 3
ENGINE ......... . ......... . ...... . ....... . .... .. .. . .. . .. .. . ..... .. ......... . ....... .... . ...... ... .... .... ... 3
ELECTRICAL SYSTEM.. ... ... .. ... .... ..... .. .. .. ... .. .... ..... . ...... . .. .. .. . ................ . .... .. ...... 5
DRIVE/BRAKE SYSTEM ... ... ........... . ..... .. ................ . ....... .. .. . .. . .... .. .. .. .. . ............... 5
CHASSIS .... . ........................ .. .... .. . ............ .. . ..... . .......... .. .... . .. . ............ .... ..... 5
VEHICLE .. ..... .... ... .................. .. ....... . ................ . ... . ........ . ............................ 6
03 - PRE SEASON PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GENERAL .......... ... .......... . ....... . ..... . ..... . .... . ..... . ........... .... .... .. ........... ... ... . ..... ... 7
PROCEDURES ............................................................................. . ...... . .. . ......... 7
ENGINE .. ..... . .. ... .. .... . ........................ . ..... . .......... . ......... .. .... . ............... ... .. ... 7
FUEL SYSTEM . ..... . ....... .. ...... .. .... .. ..... . ... .. ... ..... ... . ....... . ....... .. .. ... .. . ...... . ......... 7
ELECTRICAL SYSTEM. .. . .................... . .... .. .......... . .... .. .................... . ..... ...... . ... .. 8
DRIVE/BRAKE SYSTEM...... ... ..... ... ... ... ... . .... ..... . .... .. ... ........ ... ........... .. . .... . ... .... .. 8
02 ENGINE
01 - ENGINE REMOVAL AND INSTALLATION ............. .. .... .. ........ ... ... .. .... ... ... .. ............... .. .. 9
GENERAL.. ..... .. ... .. ........................ . ... . .... ........ ... ...... ........................... . ....... . 12
PROCEDURES......... . .... . .... . ........ . .... . ........... . ..... .. ... . ..... . ..................... . .... ... ... 12
ENGINE .............. .. .. .. .. .. ...... ..... . ... ....... . ... .... ... .. .. .... .. .. .. .. ................... ....... 12
ENGINE STOPPER .. ..... . .... .. ....... .. .. .. .. ... . ..... ... ................... . ................. . ..... .... 23
ENGINE SUPPORT. . .. . .......... . .. .. ... . ........... . ..... . ... . .... .. ........ .......... ... ............... 24
ENGINE RUBBER MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
02 - ENGINE LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
PROCEDURES ....... . ..... . .... .. ............. . ..... . ..... . ....................... . ........ ..... .. ..... . .... 29
ENGINE ......... . ..... ... ... ... . .. ............. .. .. .. . .......... ... . .................... . ....... . .... . .. .. 29
PUMP SHAFT OIL GEAR RESERVOI R . . . . . .. . . . .. .. . . .. .. . .. . .. . .. .. . . . . .. . . . . . . . .. . . . . .. . . . . . . .. .. . .. .. 30
03 - ENGINE MEASUREMENT .. . . . . .. . . .. .. . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . . . . . .. .. . . .. .. . . . .. 33
PROCEDURES ............................. .. .. ... .... ... . ... ... ..... ....... .... .. .. ... . ..... . ............... 33
CYLINDER HEAD WAR PAGE... ............................. . .................... .. ............... .. ... .. 33
CYLINDER TAPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CYLINDlR OUT Or ROUND.... ........................................................ ... ... ........ .. .. 33
CYLINDER/PISTON CLEARANCE....... .. .. ....... .. .... .. .. .... .. .......... . ..... ..... ... .. ......... . ... 34
RING/PISTON GROOVE CLEARAl\CE .. . ..... .. ... .... .. .... .. . ....... . ..... . .... .. ...................... 35
RING END GAP . .... .. ..... . .................. . ... ... .... . ..... . ... ..... .... .. .. .. ... .... ...... . ........ .. 36
CRANKSHAFT DEFLECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
CONNECTING ROD BIG END AXIAL PLAY ..... . .... . ..... . ..... .. .. .. .. . .. . .... .. .... . ...... . ........... 37
TABLE OF CONTENTS
02 ENGINE (cont'd)
II
03 - ENGINE MEASUREMENT (cont'd)
PROCEDURES (cont'd)
CRANKSHAr r ALIGNMENT . .. ........ . .............. . .. . .......... . ..... .. .... . .. . .. . .. .... .......... . .. 37
COMBUSTION CHAMBER VOLUME MEASUREMENT .................................................. 38
04 - AIR INTAKE SYSTEM ....... . ... ........ .... .... .............. . .... .. .... . ..... . ..... ....... .... ... ...... .... .. 41
GENERAL ........ . ..... . ............... ......... ..... ............................. . .......................... 43
PROCEDURES ........................ ... .............. . ......... ... ... ..... . ............ . .............. . .... 43
AIR FILTER., .. , ........................................................................................... 43
PRIMARY AIR INTAKE SILENCER........ . ................... . ..... .... .................................. 44
SECONDARY AIR INTAKE SILENCER . . . . . .. . . .. . . .. .. . .. .. . . . . .. . . . . .. . .. . . . .. . .. . .. . . .. .. . . . .. .. . .. .. .. 44
05 - EXHAUST SYSTEM ............................................................................................ 49
GENERAL ............. .. .. ... .... .. .... ... ........................................ . .... .. .. ........ .. .... .... 51
PROCEDURES .. . ... .......... ... ... ........ .. .............................. .. ... ... ... .. .................... 51
MUFFLE.R . .... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . 51
EXHAUST GAS TEMPERATUR E SENSOR (EGISl ............................. . .... ... ................... 51
TUNED PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
06 - REWIND STARTER . ... . ... .................. ........ . .... .. .... .. .. . ...... .. .. .... .......................... ... 53
INSPECTION.......... ................... ..... .... . .......................................................... 55
PROCEDURES ....... . .... ... .. .. .... . ............................ .... .. ......................... .. ..... .. . 55
REWIND STARTER HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
REWIND SlART ER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
07 - LUBRICATION SYSTEM .... ... ........ ..... .... . ....... .... .......... . ... ...... ..... ..... .... .. ........... . ... 61
GENERAL .............. . ... ... ... .... ..... .......................... .. ................... .... ................ 65
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . 65
RECOMMENDED OIL . . . . . . . . . . .. . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSPECTION................................................................................................. 66
OIL SYSTEM LE.AK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
TROUBLESHOOTING.. . ....................................................................... . ...... . .... 68
PROCEDURES .................................. . .......................................... . ................. 68
OIL INJECTION PUMP (500SS/600/800RI ................................................. . .............. 68
OIL PUMP (600 HO E-TEC) ........................................................... .. .................. 71
OIL TANK .. .... ..... . .... . .. ..... . ................ . ............. .. .. .. . .... . .. . ...... . .... . ... . .. ...... .. . 75
OIL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
OIL FILTER 1500SS/600/800Rl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
INJE.CTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 78
08 - COOLING SYSTE M .............. .. ............... .. ....... . ....... .... .. .... .............. .. .......... .. ...... 81
GENERAL .............. . .................. .. ....... . ..... . ................................................... 83
MAINTENANCE ....... ... ... . ... ... .... .. ........................ . ..................................... ..... 83
COOLANT REPLACEMENT.................. . ..... .. .. ................................................... 83
INSPECTION ............... . .......................................................................... . ..... 85
COOLING SYSl EM LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
E:NGINE COOLING SYSTCM L F AK TEST (BOOR) . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . . . 85
PROCEDU RES .. .. .... .... .......... ... ....... .. ..... . ..... . .......... .... ..... ............ . ................. 86
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
RADIATOR CAP...... . ................................................... . ............................. . .. 87
FRONT RADIATOR ........................................................................................ 87
REAR RADIAfOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
COOLANT RESERVOIR . ..... . .... .. .. .... .......... . ... .. .. ... .. .... . ................................ .. .. 89
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
COOLANl TE:MPERATURE SENSOR (CTSJ . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
09 - MAGNETO SYSTEM .................... . ................................... .. .... . .... . ...................... . 93
GENERAL ............................................................................... . .. .................. 96
TABLE OF CONTENTS
02 ENGINE (cont'd)
09 - MAGNETO SYSTEM (cont'd)
PROCEDURES ............. . ...... .. .. . .............. . .... . ..... . .. .... ..... .. ............................... 96
MAGNETO FLYWHEEL.......................... . ................. . .... .. .. ................. ............. 96
ST ATOR (500SS/600/800R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
STATOR (600 HO E-TEC) .... ........ .... ... ........................................................... ... 100
CRANKSHAFT POSITION SENSOR (600 HO E- TEC) .................. . ........ . .... .. . .. . .. .. . .. . ...... 103
TRIGGER COILS (500SS/600) .... ....... . ....... .. ........................... .. .......................... 103
TR IGGER COI LS (800R) ..... . ............. . ........ ...... . .... .. .. . ............................... ... .... 103
MAGNETO HOUSING (BOOR) ....................................... . ..... ..... . .... .. ................... 104
10 - RAVE (593) . ..... .......... .. .... . ............. . ....................... .. . ........... . .......................... 107
GENERAL ..... .. . .. .. .. ...... ..... .. .... . .. . ... .. .. ... . .. . ......... . ... . ............... . ... ............. .... 109
SYSTEM DESCRIPTION . .... ... ... . ....... . .................................... . .... . .. . ......... .. ..... 109
PR OCEDURES .... .. . .............................. . .. . .. . .. ..... .. .............. . ................ .. ..... ... 109
R AVE VALVE S...... .. .. .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
11 - RAVE (593 E-TEC) .. ...... ...... .... .. ...... ..... ...... .. ..... ............ . ........ . ....... .. ... .... ....... .. .. 113
GEN ERAL ............................... . ..... . .......... .. .... ..... ... . .. . .. . .................... . ......... 115
SYSTEM DESCAIPnON .................................... . ... ... . .. .................... ..... . ...... . .. 115
INSPECTION ............................ . ............. . .. . ....... . .... ... ... .... . ........................... 116
3D RAVE VALVES POSITION VALIDATIO N .................................... .. .............. .......... 116
TR OUB LESHOOT ING ...... . .... . .............................. . ..... . ... ................................. 116
DIAGNOSTIC TIPS .. . .......... . .. . .......... . .. ..... ..... .. .... .. .. . .. . ....... . .. .............. ..... . ... 116
PROCEDURES ... . ......... .. .. .... . .. .... ..... .. .. .. .. .................................................... . 117
3D RAVE VALVES ............. .. ... ... . .... .. ... . .... .. .... .. .. .. . ........................ .. . ............ 117
J\CTUATOR CHECK VALVES .... . .... . ... .. .. . .......... .. ... .. .. . ..... . .... .. . .. .................... .. .. 123
LUBRICATION CHECK VALVES . ...................... . ... ... ... ... ... .. .............................. . .. 123
SOLENOID.... ...... .. ........................................... .. ................................... ... 124
3D RAVE VALVES POSITION SENSOR .. .. . .. .. .. .. .. . . .. .. . .. . .. . .. . .. .. . . . . .. .. .. .. . .. . .. .. .. .. .. . .. .. 126
12 - RAVE (797) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
GENERAL .. ... ... ........ . .. . .. . .. . ....... . ..... . ..... ...... . .......... . .. . .... . ............................ 131
SYSTEM DESCRIPTION . ...... .. .... . ..... ... ..... . .......... . .. . .... .. . .. .... . ..... . ..... . ............. 131
TROUBLES HOOTING ........... . ....... . .... . ................ .. ................................. .. ....... 136
DIAGNOSTIC FLOW CHART....... .......... .. .. ..... ... ........... . .......... . .. . ..... . ................ 136
TROUBLESHOOTING TIPS .... .. ............ ........ ................................ .................... 137
PROCEDURES .. . .. . ..... . .... ... .... ... ... ...... ..... ... ... ..... . .. . .......... . ..... .. .. ... ................ 137
3D RAVE VALVE.... . .. . ........ .. .. .............. . ...... .. .. .. . .. . .. . .. . ................... . .. . .......... 137
CHECK VALVES ..... . ..... ...... .. ............... .. . .. . ..... . ........ . ... . .. . ............................ 142
SOLENOIDS ........ .. .. ......... . .......................................... . .............. . ............. 143
13 - TOP END (593) ..... . ........ .... ....... ...... .. ........................... . ........... ..... ..... .... .. ..... .. .. 147
GENERAL ... . ............... . ..... . .... .. .. ........ . ......... ...... .. .......................... ............. 150
PROCEDURES .. . ........................ . ..... . .. ...... .. ............. .. ................................... 150
REED VALVES . ..... . .. .... .. ....... .. ................. . ....... . ............................... . .......... 150
CYLINDER HEAD COVER (500S$/600) ... .. .... . .. . ... .... .. .. ....... . ........ . .. . ...................... 151
CYLINDER HEAD (500SS/600) .. .................................... . ...... .... . .. ... . ..... . ............. 151
CYLINDER HEAD (600 HO E-TEC) ....... .. ..... ............................ ............ .. .... . .......... 152
CYLINDERS .......... . ................ .. . .... ... . ..... . .. . .................. . .... ..... ..... . ............. 152
PISTONS.................... . ..... ... .... .. .... ..... .. . .................... . ... ...... . ................... 154
14 - TOP END (797) . ................... . .. . ....... . ... .. .................. . ... .. ..... . ............. . .. . ............. 157
GENERAL ........... .. ...... ...... .... .......... . ........................ .. ........ . ...... .. .. . .. .. .. . ...... 159
PROCEDURES .. .. . .... ..... . ..... .... .... . .... . .... .. . .. . .. ......... .. .. ......... . .... .. .. . ................ 159
REED VALVES .. .... .. .... .. .. .. .. .... .... .... ..... ... .. ..... .... .. ... . ........ . .. .. .............. . ... .. .. 159
CYLINDER HEAD ... ... . ..................... . ...... ... ... .. .. . .. . ............... .. ... ... ................ 159
PISTONS..... . .. . ....... .. .. .... . .. ......... . .... . ..... . ...... . ............. . .... ... ... .. ................ 160
CYLINDER BLOCK . .. . .... .. .... .... .. ................................ .. .... . .... . ....................... 162
TABLE OF CONTENTS
02 ENGINE (cont'd)
15 - BOTTOM END (593) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
GE NERAL ........................................... . ...................... . ............................... . 168
PROC EDURE S ..................... .. ................ . .......... . ........ . .... . .. .... ..... ...... .. .... . ..... 168
WATER PUMP .. ..... . ................................................................................... 168
WATER PUMP SHAFT ............. . .............. . ....... . .......... . .......... . ........ . ............... 169
CRANKCASE ..................... . ....................................................................... 172
CRANKSHAFT..... . ..... ...... ................... . ..... .... ....... . ................................. ..... 174
16 - BOTTOM END (797) ............ . ..... . .... . .. . .............................. . ........ . ...... . ....... . ... . . .. . 181
GEN ERAL ............................................................ . ..... . ................. . .............. 183
PROC EDURE S ................................ . .................... . ...................... . ..... . ...... . .... 183
WATER PUMP ......................................... . .......... .... .......................... . ........ 183
WATER/OIL PUMP SHAFT ................................................ . ........... .. ........... . ..... 184
CRANKCASE.................................................... . .......... . .......... . ..... . ............ 187
CRANKSHAFT ..................... . ......................................................... . ............ 19 0
03 ENGINE MANAGEMENT SYSTEM
01 - OVERVI EW {500SS/600) ....... ............................................ . ......... . .......... . ..... .. ..... 197
GEN ERAL ................................................................................................... 197
SYSTEM DESCRIPTION ................................................................................. 197
02 - OVERVIEW (600 HO E-TEC) ....... .. .... . .......... .. ....................................................... 199
GENE RAL ........... . ........ . ............. .... .... .. .... .... .............. . ............................ . ... 199
SYSTEM DESCRIPTI ON . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
03 - OVERVIEW {800R ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
GENERAL ........ ... .............. . ..... . .......... . ........ ... ... ... ........ . .............................. 204
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
04 - COMMUNICATION TOOLS AND B.U.D.S . SOFTWARE . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
GE NERAL ..................... .. .... . ............... . ....................... . .. .... ...... . .................. 207
TROUBLES HOOT ING ..... . .... .. .... . ......................... . ... .. ..... . .... .. ........... . ............. 207
COMMUNICATION PROBLEMS.......................... . ..... . ........ ... .... .. ... .. . ..... .... ........ 207
PR OCE DUR ES . ..... .... ............... . .......... . ........ ............ .... .. .... . .... .... ... .... .... ....... 208
MULTI-PURPOSE INTERFACE-2 (MPl-2l ................................. . .... . .......................... 208
BUDS SOFTWARE . ................ . .......... . ........................................... . ... . ..... . . 211
05 - MONITORING SYSTEM AND FAUL T CODES ...................................................... . ..... 21 3
GENERAL .................................................................. . ................................ 213
MONITORING SYSTEM ........... . .... . .. . ................. ... ........ . ..... . ..... . .................... 213
FAULT CODES ...... . ................................................................. . ............... ... 216
SPECIFIC FAULT CODES ........................................... . ................. . ........ .... ...... 217
FAULT COD[ TABLES .... . .............................................................. ....... ..... . ... 218
04 FUEL SYSTEM
IV
01 - FUEL TANK AND FUEL PUMP .................................................................... . ..... . ... 225
GE NERAL.. . .... .. ............... . ......................... . ... . .... . ................ . ..... . ................ 228
SYSTEM DESCRIPT ION (500SS/600/800R).. . ....... .. ..... .... . ..... . .. . ... . .......... . ............ . ... 228
SYSTEM DESCRIPTION (600 HO E-TECl .................. . ............. . ..... . .......... ..... .. ..... .. . 229
INSP ECT ION .............................. ...... ..... . .. . ..................................... .... ........ . . 23 1
FUEL SYSTEM PRESSURIZATION .. ..... . ............. . ...................... .. .... .... ........ .. ... .. . . 231
FUEL PUMP PRESSURE TEST (600 HO E- TEC) ... ................................................ . ... .. 232
PR OC EDUR ES .. . ...................................... . ............. . .......... . ......... . ................. 234
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
DIAPHRAGM FUEL PUMP (500SS/600/800R) ... . .. . .... ....... ..... . ..... . ............................. 239
ELECTRIC FUEL PUMP (600 HO E-TEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 240
FUEL PRESSURE RE GULATOR (600 HO E-TEC) . ....... . .. .... ..... . .... . ................ .. .. . ... ... ... 242
IN LINE FUCL FILTER (600 HO E TEC) . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
04 FUEL SYSTEM (cont'd)
01 - FUEL TANK AND FUEL PUMP (cont'd)
PROCEDURES (cont' d)
TABLE OF CONTENTS
FU EL LEVEL SENSOR..... ... .. . .... .. ..... . ................ .. . ....... ... .. . .. .. ... ..... .. .... . ... .... .. 244
OETIKER CLAMPS ... ... .. . ........... .. .. .... . ........... . .. . .... ... ........ ... .... .......... . .. . ...... . 247
02-TM CARBURETORS . ................. .. ... ....... ... ... ... ... .. ... ... . ...... .... ......... ..... ... . ............ 249
PROCEDURES .... . ............ ... .......................................................................... 251
CARBURETORS ... .. .. .. .............................................. .. .. .. ... ..................... .. ... 251
THROTILE POSITION SENSOR (iPS) ............... .. .... . ........................ . .... .... . ...... . .. .. 257
THROTI LE CABLE .. .. ................. ..... . ................ . ........................................... 261
CHOKE CABLE.. .. ........ .. .. .... .. . ....... .... .. .. .. ....... ............. . .. .... ... .. .. ... . ....... . ..... 264
03 - DPM SYSTEM (BOOR) .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
GENERA L.. . ..... ....... .. .. ........... . ........ . ... . ... .................................................... 267
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
PROCEDURES .. ..... . ...................................................................................... 267
AIR TEMPERATU RE SENSOR (ATS) .. .. .. .. .... ... .... ........ .. ........... ....... .......... .. .. ..... ... 267
AIR PRESSURE SENSOR (APS) .......... ............................. . .. ... ............................ 269
DPM SOLENOID .. ........... . .. .... .... .. .... .. .... . .... .. .. .. ... ... ... .... .... . ..... . .... .. ............ 270
DPM MANIFOLD . ..... . .. . .. . .. .. • ... .... .. ..... .. .. ... .. ..... . .... ... ............... . .................. 271
04 - E-TEC DIRECT FUEL INJECTION ....... ........... .. ................... . ...... .. ........ .. ...... . .......... 273
GENERAL. ... .. .. ......... . ........ .. .. .. .... ..... .. ... . .... ....... . ....... ... ............ . ... .... ... ... .... 273
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
ADJUSTMENT .. . ... . ... . ......... .. .. .. ......... . ..... . ... . ...... .. ... .... ....... .. ..... . ........ ... ... .. . 276
IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
CLOSED THROTILE RESET (TPS}..... . ....... . .... ............ . ................................. . .. ... . 276
TROUBLESHOOTING ... .. .. ... .... .. ... . ... ... .... .. ........ . .......... ........ ..... ... ... ........ .. .. ... 277
DIAGNOSTIC TIPS .. .. .. . ..... .. ..... .. . .. ... .......... .. . .... .. ......... .. .... .......... .. ..... .. .... .. . 277
PROCEDURES .... ......... .... .. .... ..... ............. ... ...... . ................ . .......................... 278
FUEL HOSES AND OETIKER CLAMPS ............................................. . .... .. .... . ......... 278
THROTILE CABLE .. .. ..... . ....... .. ......... ...... ... ... . .. . .......... . ................. .. .. .... ..... .. 279
FUEL INJECTOR. ... ... ......... ... . .. . ..... .. ..... .... . ..... . .... .. .. .. . .... . .. .. .. ................... .. 281
ENGINE CONTROL MODULE (ECM) .... ........ .. .. .......... . .... . ......... .. .. ..... ........... . ...... 294
THROTILE BODY . .. ... .. .... .. ...... .. .... ................... ... ...... .. ... .. ........................... 304
THROTILE POSITION SENSOR (TPS) ................. .. .... .......... . .. ... ............................ 305
CRANKSHAFT POSITION SENSOR (CPSJ ............ ...... .... ..................................... .. .. 309
AIR TEMPERATURE SENSOR (ATS} .. . ......... .. .... .. ...... .. ............ .. .................. .... ..... 310
COOLANT TEMPERATURE SENSOR (CTS) ...................................................... ....... 312
AIR PRESSURE SENSOR (APS} .............................. ............. .............................. 314
EXHAUST GAS TEMPERATURE SENSOR (EGTS) .... .. ................ .... ..... . .. ... . ................. 315
KNOCK SENSOR (KS} ....... .... ....... . .... . .... ..... .... ... .. .. . .. .... . ... .... .. . ..................... . 316
05 ELECTRICAL SYSTEM
01 - IGNITION SYSTEM ... .............. . .... . ................ ... ... .. ...... .......... ............................ 319
GENERAL ... ..... . ......................................... . ............. .. ............ . ..... . ...... . .... .. . 319
SYSTEM DESCRIPTION (500SS/600/800R) ..... ... .......... .. ... ... . .... . .... . .............. .. .. .... ... 319
SYSTEM DESCRIPTION (600 HO E-TEC) ................................................................ 319
ADJUSTMENT ..... .. . ........................... .. ................................ .. . ....... ..... ...... ... 321
IGNITION TIMING . . . .... ................... .. ........................................... . ...... ..... .. .. 321
TROUBLESHOOTING ...... .... . .......... . ....... .. ....... . ........ ........... .... .. ... ...... ............ 327
IGNITION SYSTEM TESTI NG SEQUENCE ............................................................... 327
PROCEDURES ............ ..... .... .... .. ..... .... ... .... . ...................... ......................... ... 328
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
SPARK PLUG CABLES (500SS/600/800R) ..................... .. ........................................ 330
SPARK PLUG CABLE S (600 HO E- TEC) .. ..... .. .. .. .. ..... ............................................. 331
ENGINE STOP SWITCH ..... . .. ......... ............... ................... . ....................... . ..... 331
T AB LE OF CONTENTS
05 ELECTRICAL SYSTEM (cont'd)
01 - IGNITION SYSTEM (co nt'd)
VI
PROCEDURES (cont'd)
IGNITION COIL (500SS/600/800R)....... ... ... ... ................. .. ... .... ... . ......................... 335
IGNITION COILS (600 HO E-TEC) .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. .. .. .. .. .. 337
TR IGG ER COILS (500SS/600/800R) ... ...... ..... ....... . .... . ......... .... ... ... .. . .................... 341
KNOCK SENSOR (800R) . . . . . . . . . . . . . . . . . . . . . • •. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . •. . . . . . •. . . . . . . . . . . . . . . . . . . . 342
ENGINE CONTROL MODULE (500SS/600/800R ) .. .. . .. . .. .. .. .. .. .. .. .. . . .. .. . .. .. .. .. .. .. .. . .. . .. . .. . 343
02 - CH ARG ING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
GENERAL ............. . ................ . ............ . ..... ... .............. .. ............... . ...... . ........ 349
SYSTEM DESCRIPTION . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . .. . .. . . .. .. . . .. .. . . . 349
TROUBLESHOOTING ... . ....................... .. ...... . ..... . .................................. .... ..... 349
TROUBLESHOOTING GUIDELI NES (500SS/600/800R) ................ . ..... ....... .................... 350
TROUBLESHOOTING GUIDELINES (600 HO E- TEC) .................. . .. ............................ .. . 350
PROCEDURES ....... . .... . ...................... .... ................................. .. .... .. . .. . ..... ..... 350
CHARGING FUSE . . . . . .. . . . . . . . . . . . . . . .. . .. . .. . . . . . . .. . .. . . . .. . . . . . . . . .. .. . . . . .. . . . . . . . .. . . . . .. . .. . . . .. . . 350
CHARGING RELAY IR2) . ................ .. .... .. ... . ...................... . .. .. .... . .. . ..... . ... . ..... ... 351
VOLTAGE REGULATO R /RECTIF IER (500SS/600/800R) .. ........ ..... ...... ..... ..... . ..... . ............ 351
VO L TAGE REGULATOR/RECTIFIER (600 HO E -TEC) ........... ... ... . ... ............................... 354
DC-DC CONVERTER {600 HO E- TEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
CAPACITOR (600 HO E- TEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
BATTERY (YTX20L-BS). . ......... .. ..... . ....................... .. ................ . ..... . .. .............. 362
03 - STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
GENERAL .... . ..... . .... .... .. ...... . ....... . .. . ..... . .............. . .. .... .... . ......... ... . ... ...... .... .. 369
BASIC STARTING SYSTEM OPERATION. .. . ......................... . ............. . .... ..... . ..... . .... 369
T ROUBLESHOOTING .................................................. .. ...... .. .. .. ... ....... .. . ... . .... 369
TROUBLESHOOTING TIPS .............................................................................. 369
STARTING SYSTEM TESTING SEQUE NCE .. .. .... . ... .. ................................................ 369
PROCEDURES .... .. .. . .. .. ...... ... ... ...... .. ....... ... ..... .... .... .. ... . ............... .. ... .. ... ...... . 369
START/REA FUSE....... ........ . .. .... ............ ......... ... ... ... ..... .. .. .... ... .................... 369
ELECTRIC STARTER....... . .......................... . ... .. ... .. ... .. .... . ..... . ....... .. .. .. ........... 370
STARTER SOLENOID .... ........... .... ...... ..... ... . ..................................... . ............ 375
START/RER SWITCH (500SS/600/800R) ..... •. .. .... ..... .. ... . ... ..... ... ........... . ..... . ............ 377
START/REA SWITCH 600 HO E-TEC .. .. .. . .. . .. .. . .. .. .. . . .. .. .. .. .. .. . .. . .. . . .. . . . . .. .. . .. .. .. .. . .. . .. 380
04 - DI GITALLY ENCODED SECURITY SYSTEM (D.E.S.S.I ............ . ..... ................................ 385
GENERAL .............................. ...... . ........ • ....... . .... .... ... ........... . .... ............. . ... . 385
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
PROCEDURES .................................... .. ..... .... ......... ... .. .. .... . .. . .. . ..... ... ... ...... . .. 385
D.E S S KEY........... ......... .. ........ ... .... . ....... ..... ........................................... 385
D.E.S.S. POST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
BEEPER ................. ... ......................... .... . .... . .................. .. . ... . .. . ............... 389
05 - ROTAX ELECTRONIC REVERSE ..... ....... .... ..... ... ... .......... . ..... . ...... ... ........ . .......... . ... 391
GENERAL .. .. ... . .. . .... ... ..... .. .... ..... . ................................................................ 391
TROUBLESHOOTING . • ...... .... . ..... . ..... . .. .... ... . ..... .......... ....... . ........................... 391
DIAGNOSTIC TIPS .... . ...................... . ........... ................. ......... . .................. .. . 391
PROCEDURES ..... . ........... . .......... . ........ . .. ... .................. . ... . ............................ 392
REA FUSE 1600 HO E- TEC) ........ ... ................ ........ ... . ............................. . ......... 392
REA SWITCH (500SS/600/800R) ....................... . ............... . ................ . .... .... ... . .... 392
RER SWITCH (600 HO E-TEC) .................................. . .... . ................................... 394
BEEPER (REVERSE ALARM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
06 - LI GHTS, GAUGE AND ACCESSORIES ......................................................... ....... .. .. . 399
GENERAL ................ . .... .. ..... . ............ ••. . ............. ... ........ ... ....... ... ................. 399
TROUBLESHOOTING ....... . ......... .... .. . ...................................................... . ...... 399
LIGHTING AND ACC ESSO RI ES SYSTEM TESTING............ .. .... ....... .. . .. ... .... .. ... .. . ........ 399
ACCESSORY CIRCUIT TEST WITH B.U.D.S . ............... . ....... .. ....... . ..... ... .. . ................ 400
TABLE OF C ONTENTS
05 ELECTRICAL SYSTEM (cont'd)
06 - LI GHTS, GAUGE AND ACCESSORIES (cont'd)
PROCEDURES .............................................................................................. 400
FUSES ........................... . ............................ . .......................................... 400
RELAY R1 (LIGHTS AND ACCESSORIES) ............................................................... 402
HEADLIGHTS .......................................... . .... .. ..... . ..................................... 403
TAILLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
GAUGE ......................................... ........ ......... ......................................... 406
RE MOTE MODE AND SET BUTION.. . ...... . ... ..... ... ............................................ . .. 412
SPEED SENSOR . . .. . . . . . . . . . . . .. . . . . . . . . .. . . .. . .. . .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
FUEL LEVEL SENSOR ........................................................ .. ......................... 414
HE AT ED T HROTILE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
HEATED HANDLEBAR GRIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
12- VOLT POWER OUTLET ........................................... . ................................... 424
VISOR OUTLET................. .. ... . ... . .......... .. ................................................... 424
06 DRIVE SYSTEM AND BRAKE
01 - DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . . 425
APPLICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
PROCEDURES .................... . ..... . .... .. .... . .... . ............... . ................................... 425
DRIVE BELT GUARD............................ . ................ ...... .................................. 425
DRIVE BELT GUARD SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
DRIVE BELT................................................................. . ............................ 426
02 - DRIVE PULLEY ........................................ . .................................. . ..... . ............... 433
GENERAL ........ . .................................. . ......... . ............................................. 436
PROCEDURES ....................................... .... . .......... ........................................ 436
DRIVE PULLEY ........ . ... . .............................................................................. 436
03 - DRIVEN PULLEY AND COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
GENERAL . ..................... . ........... . ............... . ................................................ 452
PROCEDURES ............... .... ...... . ... . ..... . ..... . .... .... .. .............. .. ................. . ........ 452
DRIVEN PULLEY . .. . ............................... . .... ... ....... .. ..................................... 452
COUNTERS HAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
COUNTERSHAFT BEARING ................................. . ..... .. .... . ............................... 458
COUNTERSHAFT BE ARING SUPPORT .......................................... .. .. .. . .. . .............. 459
04- BRAKE ... .... ................ .... ..... ... .. .. ... ........ . ........ . ................................ . ...... ... .... 461
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
MAINTENANCE ................ ... ..... ... .... . ........ .. . ................ ............................... .. 463
BRAKE FLUID................................... . .......................... . ............................. 463
PROCEDURES .. ...... .. ....... .... . .. ... . .. .......... . ........ ............................................. 464
BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
CALIPER ................................................................................................. 466
BRAKE DISC..... ......... . ... . ....................... ........ . .... . .......................... . .......... 469
MASTER CYLINDER .................................................. . ............................ . ..... 469
BRAKE LIGHT SWITCH.... .. ........................ ..... ......................... .... .................. 470
05 - CHAINCASE... .... ...... ........ ..... .... ............ .... . ... .. ..... . .......................................... 473
GENERA L .................................. . ................... . ............................ .......... ...... 475
ADJUSTMENT ..... . ..... .... .................................................. . ........................... 475
DRIVE CHAIN .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . .. . . . . . . . . 475
MAINTENANCE ........................................... . ................................................ 475
CHAINCASE OIL............... . ......................................................................... 475
PROCEDURES ............... ... .... .... ... . .......................... . ..................................... 476
CHAINCASE COVER . .. . ..................................................... .. .......................... 476
CHAINCASE ......... ... ... . ..... ... .. ... .. . ............................... .. ............................. 477
CHAINCASE BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
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TABLE OF CONTENTS
06 DRIVE SYSTEM AND BRAKE (cont'd)
05 - CHAINCASE (cont'd)
PROCEDURES (cont'd)
CHAIN TENSIONER ......................................... .......... . ..... . .... ....... .. ........... .. .. 482
06 - DR IVE AX LE ...... . ...... .. ........... ... .................................................................. ..... 483
GENERAL ..... . ............. ................................... ..... . ............. . ......................... 485
PROCEDURES ............................ . .............................. . .................................. 485
DRIVE AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
MAGNETIC CAPS.. .... . ..... . ...... . .... ... .. .. .. . ....... . ..... .... ..... . .......... . .. . ... ......... ..... 486
07 - TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
PROCEDURES ....... . ..... . ...................... . ...................................................... ... 489
TRACK .... .... .... ....... ..... ....... ....... .... ........................... . ........ . ..... .. ....... . ..... 489
TRACTION ENHANCING PRODUCTS (STUDS) . .. . .. .. . .. .. .. . .. .. . . .. .. .. . .. .. .. .. .. .. .. .. . .. .. . . . . .. . 491
07 CHASSIS
VIII
01 - FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
GENERAL ....... .... ... .... .. .... . ........................ . ................ . ....................... . ........ 497
ADJUSTMENT .. .......... . .... . ................ . ........ . .... .. .... ........ .... . .......................... 497
SUSPENSION SPRING ... ........................ . ................ . .. . ................................... 497
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
PROCEDURES .. . .... . ... ... ...................................................... . ......................... 498
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
UPPER BALL JOINT............... ... .... .. ... ........ . ....................................... . ......... 501
LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
LOWER BALL JOINT ... ...... , ... . . , ....... ............. , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
SKI LEG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
STABILIZER BAR..... ... .... .. .... . .......... .... ........................ .. . .. ............. . ............. 504
02 - REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
GENERAL ........... .. .... . ................ . ......... .. ..................................................... 517
PROCEDURES .... ... ............... .. .......................................................... .... ........ 517
SUSPENSION ASSEMBLY.. ...... ..... .. .. .... .. ............... .. .......... . ................ .. . ........ . 517
REAR AXLE ... ... ........ .... ....... . ....... . ..... .. ............. . .... . .......... . ..... . ................. 518
SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
REAR SPRINGS..... . ..................................... .. .. ..... . ... . ...... . ..... . ......... ... ........ 535
SLIDER SHOES. . ....... .... ..... . ... . ...... . ............. . ....... . ... ... ..... . .......................... 538
FRONT ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
REAR ARM............ . .... . .. . ................ . ............ .. ........................................... 541
PIVOT ARM . ...... .. ... .. ......... .. .. .. .... .. ................ . .......................................... 543
COUPLING BLOCKS.. .... ... ................. .... ...... .. ...................... . ..... . .................. 543
IDLER WHE E LS........... . ..... . .................................... .... ....... . ..... . ..... . .. . ......... 544
IDLER WHEEL SUPPORT......... . ............... .. ...... .. .. .... ... ..... . .... .. ..... . .... . ............. 544
STOPPER STRAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
03 - STEERING SYSTEM .............. ........ . ....... .. .. ......................... .. ............................. 547
GENERAL ... .. .... . .... .. ...... . .•.•. . ... .. ... ....... ...... ... .. , .......... ................................. 551
ADJUSTMENT ........ . .... . ...... ... .............................................. .... .................... 551
STEERING ALIGNMENT ................................................................................. 551
PROCEDURES ............................ ... .......... . ....... ... .......... .... .. .......... . ............... 552
SKI RUNNER . ................. . ....... .. ... ........... .... .... ............ .... ........ ............ .. . .... 552
SKI .... . ........... ...... ... . .... . ...................................... . ........... . ........ .... .. .... ... 552
SKI HANDLE......... .. .. ..... ... ... .. . ............. . .... .. .. . .. ... .. .... . ...... .................. . ...... 553
SKI LEG .. ............... .. ......... . ........................... ........ ........................... ....... 554
HANDLEBAR GRIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
HANDLEBAR .. ... . ........... .. .. .. .... . .. ....... .... .. .................... . ............................. 556
HANDLE B AR EXTENSION . ..... .. .. ...... .. ..... . ... .. .. . .......... . ................ . ................ ... 557
07 CHASSIS (cont'd)
03 - STEERING SYSTEM (cont'd)
PROCEDURES (cont'd)
TABLE OF CONTENTS
TIE-ROD... . ............................................... . ............... .. ............................. 558
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559
04 - BODY .. . ............ . ................................................... . .......... . ..... . .......... . ...... .. .... 561
GENERAL . . ..... . ........................... . ........ . ... . ......... ... ...................................... 56 1
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 1
BODY PARTS REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
PROCEDURES .. ....... . .............................. ... ............. ... ..... . ........ .. ................... 562
DECAL .... . ................................................... . .......................................... 562
SIDE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
REWIND STARTER HAND LE HOUSING........ . .. .. ........... . .. ...................................... 562
HOOD ... . ........................... . ........ . .... . .......................................... . ........... 563
BOTIOM PAN COVER...................... . ........... . ................ . ............ . ... .. ............. 564
FRONT BUMPER . .. .. . . . . . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 565
FRONT BOTIOM PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
WINDSHIELD........................................................... . ................................ 568
GAUGE SUPPORT ................. . ..................................................................... 568
CONSOLE. . .............................................................................................. 570
REAR RACK tGTX SPORT/LE) .......................... .. ............................................... 572
05 - FRAME ......................................... . ................ .... .. ............... .. .... .... ........ .. . ...... 575
GENE R AL ...... . ................ . .... ....... ..... . .......................................................... 577
RIVET DRILLING PROCEDURC.......................................................................... 577
PROCE DURES ........... . .................................................................................. 578
FRAME ..... . .... ............. ... ... .. .. .... .. .. ...... .. .. ..... .... .. ... ..... . ....... ...... ..... .. ... ..... 578
RE AR BUMPER......................................................... . ............... . ................ 578
RE AR FRAME MEMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
FRONT FRAM E MEMBER.. . ............ . ..... .. ... .. ..... ...... ............ . ........................... 579
FRONT CROSS MEMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580
ENGIN E MEMBER.. ..................... ................................ .. .... .. ... .......... ... . ...... . 582
08 TECHNICAL SPECIFICATIONS
01 - SOOSS MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585
02 - 600 MODELS ....................... . ..... . ..... . .......... .. ... . ..... . .... ....... .............................. 59 1
03 - 600 HO E-TEC MODELS . ... .. .. .. .... .. . ..... . ..................... .. ........................................ 595
04 - 800R MODELS .. ... . .... . ............... . .............. .. ............... . ........................ .. .... ... .. .. . 615
09 WIRING DIAGRAM
01 - WIRING DIAGRAM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625
GENERAL ........... . .... .... .. . ............. .... .... ... ... . ..... . .... .... .... . ....................... . ..... 625
WIRING DIAGRAM L OCATION............................................................ . ..... . ...... . 625
WIRING D IAGRAM CODES.... . ....... . ................ . ..... . .... . ..... . .............................. . 625
SUMITOMO CONNECTOR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626
DE UTSCH CO NNECTOR INFORMATION . .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. . .. . . .. .. .. .. .. .. .. .. .. . .. . . . .. 627
PACKA RD CONN E CTOR INFORMATION . ... ...... . ... .... ............ ... ......... .. ... .. . ..... ......... 627
AMP MULTILOCK CONNECTOR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
AMP CONNECTOR (8-CIRCUIT) INFORMATION..... . .. . .................. . ....... .............. .... ... 631
AMP CONN ECT OR I NFORMATION tECM OF 600 HO E-TEC) ......................... ................. 631
BATIE RY CABLE TERMINAL INFORMA TION .. ..... ...... .. .... ......... ........................ . ...... 633
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Ski-Doo Summit Everest (154) TEK 2009-2010 Shop Manual
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Description
This service manual provides comprehensive information and procedures for maintaining and repairing your snowmobile. With hundreds of pages, it covers all aspects of the vehicle, including detailed illustrations and easy-to-understand text.
Key topics covered in this manual include:
- Tools
- Engine
- Electrical
- Transmission
- Maintenance
- Troubleshooting
- Engine management
- Fuel system
- Drive system and Brake
- Suspension
- Steering/Ski
- Body and Chassis
- Piping, Wiring harness and Cable routing
- Warranty
- Technical data
- Wiring diagram
Utilize the search and zoom functions to navigate the manual and locate specific information. Additionally, the option to print individual pages is available for your convenience.
Whether you are a professional mechanic or a DIY enthusiast, this manual is an invaluable resource for maintaining, repairing, and preventing costly repairs to your snowmobile.
Please note that the actual quality of the manual is superior to the sample pages provided. For the Ski-Doo Summit Everest (154) BOOR Power TEK 2009-2010 model, this manual is an essential tool for ensuring the optimal performance of your snowmobile.
