Positioning:
The 2005 Ski-Doo REV chassis represented a significant evolution in snowmobile design, focusing on rider ergonomics, centralization of mass, and improved handling. This manual targets owners and technicians seeking factory-level repair and maintenance information.
Competition:
Competed against models from Arctic Cat (e.g., Firecat, Sabercat) and Yamaha (e.g., Phazer, Mountain Max) offering similar performance and recreational capabilities.
Chassis Innovation:
The REV platform was lauded for its rider-forward, centralized mass design, enhancing agility and control, particularly in aggressive riding situations.
Model Variety:
The REV chassis was adapted across various Ski-Doo models including Summit (mountain), MXZ (trail/performance), and Renegade (crossover), each with specific adaptations covered by this general manual.
Engine:
Complete engine disassembly, assembly, tuning, troubleshooting, and diagnostics for Rotax engines used in 2005 REV chassis
Drivetrain:
Clutching, drive train, driven clutch, chaincase, gears, bearings, seals, and related components
Suspension:
Front and rear suspension systems, including shocks, springs, control arms, skis, track, and idler wheels
Electrical:
Ignition system, lighting, battery, charging system, starter, sensors, wiring diagrams, and troubleshooting electrical faults
Fuel System:
Carburetor (if applicable), fuel pump, fuel lines, fuel filter, and fuel tank service
Braking System:
Brake caliper, master cylinder, brake lines, brake fluid, rotor, and braking system adjustments
Chassis Body:
Frame, body panels, seat, handlebars, controls, windshield, and associated hardware
Maintenance:
Scheduled maintenance, lubrication points, fluid changes, filter replacements, and general upkeep
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides
Repair:
Step-by-step instructions for component removal, installation, overhaul, and repair
Rebuild:
Complete tear down and rebuild instructions for major components and the entire snowmobile
Specifications:
Torque specifications for all fasteners, engine timing, component clearances, and alignment procedures
Depth:
Comprehensive coverage from basic maintenance to advanced engine and chassis rebuilds
Visual Aid:
Includes pictures, illustrations, and part diagrams for clarity
Engine Family:
Rotax V-Twin (various displacements)
Engine Type:
2-stroke, liquid-cooled
Common Displacements:
Typically 500cc, 597cc, 600cc HO, 700cc, 800cc (specific models vary)
Horsepower Range:
Approx. 95 HP to 135 HP (depending on specific engine variant)
Torque Curve:
Designed for strong mid-range power delivery, crucial for acceleration and climbing.
Carburetor Type:
Commonly Mikuni VM series or Ski-Doo's own designs, often with electronically controlled oil injection.
Fuel Octane:
Premium unleaded gasoline (91 octane or higher recommended for most high-performance variants)
Ignition Type:
CDI (Capacitor Discharge Ignition) with variable timing.
Cooling Method:
Liquid-cooled with thermostat and fan assist.
Type:
CVT (Continuously Variable Transmission) with Bombardier's TRA (Torque Response Advance) primary clutch and driven clutch system.
Gears:
Forward, Neutral, Reverse (electric start models may have electric reverse).
Clutch Tuning:
Extensive information on primary and secondary clutch calibration for different altitudes and riding styles.
Chaincase:
Maintenance procedures for the chaincase, including chain tension adjustment and lubricant changes.
Chaincase Oil:
Refer to manual for specific SAE viscosity grade (e.g., SAE 30 or 80W-90 gear oil, depending on application and temperature).
Overall Length:
Varies by model (e.g., MXZ, Summit, Renegade). Refer to specific model specs within the manual.
Overall Width:
Varies by model. Typically around 46-48 inches.
Track Width:
Varies by model. Typically 15-16 inches.
Dry Weight:
Varies by model and engine size. Typically in the range of 450-550 lbs.
Storage:
Under-seat storage, optional rack and bag systems.
Crash Testing:
Snowmobiles are not subject to the same standardized crash testing as automobiles. Safety features focus on operational design.
Handling Dynamics:
REV chassis design promotes rider control and stability, reducing the risk of rollovers in dynamic situations.
Braking System:
Hydraulic disc brake system designed for effective stopping power.
Kill Switch:
Lanyard-style kill switch to shut off the engine if the rider is separated from the snowmobile.
Lighting:
Headlights and taillights for visibility.
Display Panel:
Digital or analog instrument cluster displaying speed, RPM, engine temperature, fuel level, and warning lights.
No Advanced Driver Assistance:
As a 2005 snowmobile, it predates modern electronic driver assistance systems found in vehicles.
No Connectivity:
No integrated Bluetooth, GPS, or internet connectivity.
Headlight Type:
Halogen headlights for illumination.
Oil Change:
Refer to manual for specific 2-stroke oil recommendations and fill levels. Regular inspection of oil injection pump operation.
Spark Plugs:
Recommended replacement at intervals specified in the manual, typically based on mileage or operating hours.
Clutch Maintenance:
Regular inspection and cleaning of primary and secondary clutches, belt inspection and replacement.
Suspension Lubrication:
Grease points on suspension components should be serviced according to the manual's schedule.
Coolant:
50/50 mix of antifreeze (ethylene glycol based) and distilled water. Specific coolant type as per manual recommendation.
Brake Fluid:
DOT 4 hydraulic brake fluid is commonly used. Verify exact specification in the manual.
Drive Belt:
Drive belt wear and failure can occur with heavy use or improper clutch alignment. Manual covers belt inspection and replacement.
Suspension Bushings:
Wear on suspension bushings can lead to handling issues. Manual provides inspection and replacement procedures.
Engine Idling:
Carburetor adjustments and cleaning may be required to maintain consistent idling, especially at different altitudes. Manual covers carb tuning.
Recoil Starter:
Recoil starter mechanism can require maintenance or replacement. Manual details its operation and service.
Manufacturer:
Ski-Doo is a brand of Bombardier Recreational Products (BRP), a Canadian manufacturer with a long history in snowmobiles dating back to the 1950s.
Rev Introduction:
The REV chassis was introduced for the 2003 model year and rapidly became Ski-Doo's dominant platform due to its performance and rider-centric design.
2005 Updates:
The 2005 model year saw further refinements to engine performance, suspension, and chassis configurations across the REV line-up.
Manufacturing Location:
Primarily manufactured in Canada.
