2005-2006 Ski-Doo Rev Series Expedition GSX GTX MX Z Adrenaline Summit Snowmobile Service & Repair Manual

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

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

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

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

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

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2005-2006 Ski-Doo Rev Series Expedition GSX GTX MX Z Adrenaline Summit Snowmobile Service & Repair Manual

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