Product Name:
Ski-Doo REV 600 / 800 snowmobile Service Manual Repair 2003 MX Z PDF Download
Engine Code 600:
Rotax 600 (specific variant may vary, e.g., SDI)
Engine Code 800:
Rotax 800 (specific variant may vary, e.g., SDI)
Segment:
Performance Trail/Mountain Snowmobile
Target Audience:
Enthusiasts seeking to maintain, repair, and optimize their 2003 Ski-Doo MX Z 600 or 800 snowmobiles.
Rival Models 2003:
Arctic Cat Firecat, Polaris Edge, Yamaha Mountain Max (performance trail variants).
Rev Chassis:
The REV platform introduced a significant ergonomic and chassis design change for Ski-Doo, offering improved rider position, handling, and weight distribution.
Content Value:
Provides factory-level diagnostic and repair information, critical for accurate and efficient maintenance, leading to improved performance and longevity.
Engine:
Complete engine tear down and rebuild, including top-end, bottom-end, cooling system, fuel system, ignition system, lubrication system, and exhaust system.
Transmission:
Drive clutch, driven clutch (secondary clutch), chaincase, lubrication, and gear inspection/replacement.
Suspension:
Front suspension (e.g., Radius rods, A-arms, shocks, springs), rear suspension (e.g., Skid frame components, shocks, springs, track system).
Electrical:
Ignition system (CDI, ignition coils, spark plugs), lighting, battery, starter, charging system, wiring diagrams, and troubleshooting electrical faults.
Chassis:
Frame inspection and repair, steering system, braking system, skis, and bodywork (plastics, panels).
Maintenance:
Routine maintenance, pre-ride inspections, storage procedures, and seasonal servicing.
Repair:
Detailed step-by-step repair procedures for all major components and systems.
Troubleshooting:
Comprehensive troubleshooting guides for common and uncommon issues, often organized by symptom.
Installation:
Procedures for component replacement and installation.
Depth:
Complete tear down and rebuild, advanced diagnostics, detailed specifications, and repair procedures suitable for professional technicians and experienced DIY mechanics.
PDF Quality:
Likely high-resolution scans or digital creation for clarity and searchability. Expect clear images and diagrams.
Searchability:
PDF format typically allows for text search, enhancing quick access to information.
Print Capability:
Designed for printing, allowing users to have physical copies for workshop use.
Binding Type For Print:
N/A (digital format)
Paper Type For Print:
N/A (digital format)
Engine Type 600:
Rotax 600cc (Likely 2-stroke, 2-cylinder, liquid-cooled)
Engine Type 800:
Rotax 800cc (Likely 2-stroke, 2-cylinder, liquid-cooled)
Horsepower 600 Est:
~110-120 HP (Exact figures vary by specific engine variant and tuning)
Horsepower 800 Est:
~130-140 HP (Exact figures vary by specific engine variant and tuning)
Fuel Delivery 600 Est:
Carbureted or potentially Electronic Fuel Injection (EFI) for SDI models.
Fuel Delivery 800 Est:
Carbureted or potentially Electronic Fuel Injection (EFI) for SDI models.
Oil System:
DPM (Doo-Performance Management) or direct injection oil delivery system, requiring specific 2-stroke snowmobile oil.
Cooling System:
Liquid-cooled, utilizing a radiator and coolant.
Drive System:
CVT (Continuously Variable Transmission) with a drive clutch and a driven clutch.
Gears:
Single-speed forward, neutral, reverse (on some models).
Clutch Calibration:
Manual covers clutch calibration for different riding conditions and modifications.
Chaincase:
Chaincase lubrication and maintenance procedures for the drive chain.
Chassis Type:
REV Platform (Revolutionary design)
Track Width Est:
Standard trail track width (e.g., 15" wide track).
Track Length Est:
Common trail lengths, such as 121" or 136" (depending on specific MX Z variant).
Dry Weight Est:
Typically in the range of 450-500 lbs (204-227 kg) depending on engine and features.
Safety Standards:
Adherence to industry safety standards for snowmobiles. Manual covers safety precautions during operation and maintenance.
Braking System:
Hydraulic disc brake system, details on maintenance and fluid replacement.
Kill Switch:
Emergency engine shut-off (lanyard kill switch).
Rollover Protection:
N/A (Snowmobile design inherently different from enclosed vehicles)
Visibility:
Headlights, taillights, and reflectors are covered in electrical section.
Dashboard Display:
Basic analog gauges (speedometer, tachometer) and indicator lights. Manual covers their functionality and any diagnostic indicators.
Efi Systems:
If equipped with SDI (Sequential Direct Injection), the manual details the EFI system components, sensors, and diagnostic procedures.
Diagnostic Ports:
Information on accessing diagnostic data or troubleshooting engine control modules (if applicable).
Initial Break In:
Specific break-in procedures for new or rebuilt engines are detailed in the manual.
Regular Maintenance:
Covers scheduled maintenance tasks such as spark plug replacement, drive belt inspection/replacement, chaincase oil changes, and coolant checks at specific mileage or time intervals.
Engine Oil Type:
Specific 2-stroke synthetic or semi-synthetic snowmobile oil (refer to manual for exact API/NMMA specifications and manufacturer recommendations, e.g., XPS synthetic 2-stroke oil).
Coolant Type:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Manual will specify approved coolant types and capacity.
Chaincase Oil Type:
Specific gear oil for chaincases (e.g., SAE 80W-90 gear oil). Manual will list exact specifications and capacity.
Brake Fluid Type:
DOT 4 hydraulic brake fluid is common. Manual will confirm the exact specification and bleeding procedures.
Common Wear Items:
Drive belts, carbides, hyfax (skid plate wear), shock absorbers, and clutch components are common wear items discussed in maintenance sections.
Engine Specific Considerations:
Manual addresses potential issues specific to Rotax 600 and 800 engines of this era, such as power valve operation, lubrication system integrity, and exhaust port cleaning.
Manufacturer:
BRP (Bombardier Recreational Products) - Ski-Doo is a flagship brand.
Rev Platform Introduction:
The 2003 model year was a significant launch year for the revolutionary REV chassis, marking a departure from previous Ski-Doo designs and setting a new industry benchmark for ergonomics and handling.
Manufacturing Region:
Primarily Canada (Valcourt, Quebec) and Mexico.
