Target Audience:
Snowmobile owners, DIY mechanics, independent repair shops seeking factory-level repair information.
Advantage:
Provides the same detailed information used by authorized BRP dealer technicians, ensuring accuracy and completeness unmatched by generic repair guides.
Accuracy:
Factory-authorized data ensures the highest level of accuracy for all repair and maintenance procedures.
Illustrations:
Features clear, concise text combined with detailed illustrations and comprehensive diagrams for easy comprehension.
Completeness:
Includes not only repair procedures but also scheduled maintenance, TSBs, and recall information for a holistic approach to vehicle care.
Covered Models:
Comprehensive coverage for all 2004 Ski-Doo models listed, including GSX (LTD, Sport), MX Z (Adrenaline, Renegade, Renegade X, Trail, X), and Summit (Adrenaline, HighMark, HighMark X, Sport, X).
Estimated Page Count:
High (Estimated 500+ pages, typical for a full factory service manual)
Manual Type:
Factory Service Repair Manual
Engine:
Detailed diagnostics, overhaul procedures, fuel and ignition systems, cooling systems, lubrication, emission controls for Rotax 500 SS, 600 HO, 600 HO SDI, and 800 HO engines.
Transmission Clutch:
Comprehensive coverage of primary and secondary clutch service, adjustments, rebuilds, and drive system maintenance.
Chassis Suspension:
Front and rear suspension systems (including SC-4, SC-5), shock absorbers, steering components, skis, and track system maintenance and repair.
Electrical System:
Wiring diagrams, lighting systems, ignition system components, battery and charging system, electronic control modules (ECMs), and diagnostic procedures.
Fuel System:
Fuel pump, injectors, lines, filters, and control systems for both carbureted and fuel-injected models.
Brake System:
Hydraulic brake system service, component replacement, bleeding procedures, and parking brake.
Bodywork Plastics:
Body panel removal and installation, seat, handlebars, and general cosmetic repairs.
Maintenance:
Routine scheduled maintenance, oil changes, filter replacements, lubrication points, track tensioning, and general inspection procedures.
Troubleshooting:
Systematic diagnostic flowcharts and symptom-based troubleshooting for common and complex issues.
Repair Overhaul:
Complete engine rebuild procedures, transmission disassembly and assembly, suspension component replacement, and electrical component repair.
Technical Service Bulletins:
Inclusion of relevant manufacturer Technical Service Bulletins (TSBs) for known issues and updates.
Recall Information:
Incorporation of manufacturer recall notices and procedures.
Depth:
Comprehensive from basic maintenance to complete engine and component overhaul, including advanced diagnostics and troubleshooting.
Engine Variants:
500 SS, 600 HO, 600 HO SDI (Sequential Double Injector), 800 HO.
Displacement 500Ss:
Approx. 499cc (exact designation: 593cc is a typo in the product info for 500SS models, should be 499cc for 500SS)
Displacement 600Ho:
Approx. 593cc
Displacement 800Ho:
Approx. 793cc
Horsepower Range:
Varies by engine, typically from ~80 HP (500 SS) up to ~140+ HP (800 HO), manual will detail specific figures.
Fuel Delivery:
Carbureted (for some 500 SS) or Electronic Fuel Injection (EFI) with Distributed Ignition (DI) for HO and SDI variants.
Fuel Type:
Unleaded gasoline (refer to manual for octane requirements)
Overall Length:
Varies by model (e.g., GSX, MX Z, Summit), detailed specifications available in the manual.
Dry Weight:
Varies by model, typically ranging from approximately 450 lbs to over 550 lbs. Manual will provide exact figures.
Crash Test Data:
N/A for snowmobiles in the traditional automotive sense; safety focus is on rider protection and handling characteristics.
Braking System:
Hydraulic disc brake system, often with a dual-piston caliper and vented rotor.
Ergonomics:
Design considerations for rider comfort, control, and visibility, including handlebar positioning and seat design.
Gauge Cluster:
Digital and analog gauge clusters providing information on speed, RPM, fuel level, engine temperature, and diagnostic indicators. Specific features vary by trim level.
Engine Management:
Electronic control modules (ECMs) for precise engine management, fuel injection, and ignition timing, enhancing performance and emissions.
Diagnostic Ports:
On-board diagnostics (OBD) or proprietary diagnostic connectors allow for reading error codes and system data with appropriate tools. Manual explains diagnostic procedures.
Oil Change:
Typically every 100-150 operating hours or annually, depending on usage. Manual specifies exact intervals and procedures for oil type and capacity.
Clutch Inspection:
Regular inspection recommended at 50-hour intervals for wear and proper function.
Track Tension:
Check and adjust track tension based on manufacturer specifications at regular intervals.
Engine Oil Type:
Specific synthetic 2-stroke oil meeting BRP/Rotax specifications. Manual will list approved brands and grades (e.g., XPS Synthetic 2-Stroke Oil).
Coolant:
Proprietary coolant or a specific blend recommended by BRP. Manual details type and mixture ratio.
Brake Fluid:
DOT 4 hydraulic brake fluid is typically used. Manual confirms type and replacement procedure.
Clutch Wear:
Normal wear and tear on clutch buttons, rollers, and springs. Manual provides replacement parts and procedures.
Suspension Bushings:
Wear on suspension bushings and ball joints over time, leading to play and potential alignment issues. Manual covers inspection and replacement.
Electrical Connections:
Corrosion or loose connections in electrical connectors can cause intermittent issues. Manual's wiring diagrams are crucial for troubleshooting.
Manufacturer:
BRP, a Canadian company with a long history in recreational vehicle manufacturing, established Ski-Doo as a leading snowmobile brand.
2004 Updates:
The 2004 lineup represents an evolution of Ski-Doo's performance and comfort-oriented platforms, with refined engines and suspension systems.
Manufacturing Location:
Primarily Canada (Valcourt, Quebec) and Mexico.
