Skidoo REV Series Snowmobile 2004 Service Manual

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Taper: Snowmobile

Distributeur:

UGS: 87028

Mots clés: 2004 Agriculture Featured REV Series Same Silver Series Ski Doo Skidoo Snowmobile Tractors

Variantes de produits

Description

This manual covers the 2004 Ski-Doo REV Series Snowmobile, a model known for its innovative REV chassis that revolutionized snowmobile design with its low, forward-mounted engine and rider-forward ergonomics. This engineering offered improved weight distribution and handling, setting a new industry standard. The REV Series is equipped with powerful Rotax engines, including 500 SS, 600 HO, 600 HO SDI, and 800 HO variants, featuring either carbureted or electronic fuel injection systems. These snowmobiles are designed for recreational trail riding and backcountry exploration, offering a blend of performance, reliability, and advanced technology for the 2004 model year. This comprehensive service manual provides detailed information for owners, DIY mechanics, and professional technicians. It covers all major systems, including detailed engine procedures for Rotax 500 SS, 600 HO, 600 HO SDI, and 800 HO engines, drivetrain components like the CVT system, suspension, electrical systems, and fuel systems. The manual includes routine maintenance tasks, troubleshooting guides, diagnostic procedures, and step-by-step repair instructions for everything from basic servicing to complete overhauls. With 431 pages of factory-level documentation, this English-language resource is essential for maintaining, repairing, and ensuring the optimal performance and longevity of your 2004 Ski-Doo REV Series Snowmobile.

🏷️ Basic Information

Identification

Make:

Ski-Doo

Model:

REV Series Snowmobile

Year:

Codes

Chassis Platform:

👋 Introduction

Market Position

Target Audience:

Owners, DIY mechanics, and professional service technicians looking for detailed repair and maintenance information.

Key Features

Illustration Quality:

Illustrated with clear step-by-step instructions and likely includes exploded views and diagrams.

Technical Accuracy:

Represents factory-level documentation, ensuring accuracy for repairs and maintenance.

Resource Value:

Essential for troubleshooting, diagnosis, repair, servicing, restoration, and preventative maintenance.

Usage Notes

Storage:

Can be saved on computers, iPads, hard drives, etc., for unlimited access.

📋 Manual Details

Coverage Areas

Primary Coverage:

Canada/USA (CAN/U.S.) and Europe (EUR) markets

Specific Models Covered:

GSX LTD, GSX SPORT, MX Z ADRENALINE, MX Z RENEGADE, MX Z TRAIL, MX Z X, SUMMIT ADRENALINE, SUMMIT HIGHMARK, SUMMIT SPORT, SUMMIT X (various engine and color variants).

Page Count

Total Pages:

Manual Type

Type:

Service Manual / Workshop Manual / Repair Guide

Language

Language:

English

Format

Format:

PDF Download

Delivery Method:

Instant download via email link after payment.

Compression:

May be zipped (.zip, .rar) requiring unzipping software.

📖 Manual Coverage

Systems Covered

Engine:

Detailed coverage of Rotax 500 SS, 600 HO, 600 HO SDI, and 800 HO engines including disassembly, inspection, repair, and reassembly.

Drivetrain:

CVT (Continuously Variable Transmission) system, chaincase, clutch service, and drive axle maintenance.

Suspension:

Front and rear suspension systems, including shock absorbers, trailing arms, skis, and track maintenance.

Electrical:

Ignition system, lighting, instrumentation, charging system, battery, and wiring diagrams.

Fuel System:

Fuel injection system (SDI), carburetors (for non-SDI models), fuel pump, fuel lines, and fuel tank maintenance.

Chassis Body:

Frame, body panels, seat, handlebars, and general chassis inspection.

Cooling System:

Radiator, coolant lines, thermostat, and fan (if applicable) service and repair procedures.

Exhaust System:

Exhaust manifold, muffler, and power valve system inspection and maintenance.

Track System:

Track inspection, tension adjustment, drive sprocket, and idler wheel maintenance.

Steering:

Handlebar assembly, steering post, and ski steering linkage service.

Procedures Included

Maintenance:

Routine maintenance tasks, lubrication points, fluid changes, belt inspection and replacement, and pre-season/post-season checks.

Troubleshooting:

Comprehensive troubleshooting guides for common issues, diagnostic procedures, and error code interpretation.

Repair:

Step-by-step instructions for engine rebuilds, transmission repairs, suspension component replacement, and electrical system diagnostics.

Diagnostics:

Detailed diagnostic procedures for all major systems, including engine performance, electrical faults, and operational issues.

Clutch Calibration:

Detailed guidance on clutch weights, spring, and helix adjustments for optimal performance based on riding conditions and engine variant.

Engine Rebuild:

Complete engine teardown, parts replacement (pistons, rings, bearings, seals), and reassembly instructions.

Suspension Rebuild:

Procedures for replacing shock absorbers, bushings, ball joints, and other suspension components.

Technical Depth

Depth:

Comprehensive, covering basic maintenance to complete engine and component overhauls, suitable for both DIY enthusiasts and professional technicians.

Wiring Diagrams:

Includes detailed electrical system wiring diagrams for easy troubleshooting.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely searchable (text-based PDF) for efficient information retrieval.

Print Quality

Print Capability:

Printable on any computer and printer; no printing restrictions.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Rotax 2-stroke

Performance

Displacement Options:

500 SS, 600 HO, 600 HO SDI, 800 HO

Engine Technology:

Carbureted (500 SS, 600 HO) and Electronic Fuel Injection (SDI - Sequential Dual Injection).

Horsepower 600 Ho:

Approximately 110-115 HP

Horsepower 800 Ho:

Approximately 130-140 HP

Bore X Stroke 600Ho:

Specific dimensions to be found in the manual, typically around 72mm x 73mm.

Bore X Stroke 800Ho:

Specific dimensions to be found in the manual, typically around 82mm x 75.7mm.

Fuel System

Fuel Delivery:

Carburetor or Electronic Fuel Injection (EFI) depending on model.

Carburetor Size 500Ss:

Likely dual 38mm or 40mm carburetors (specifics in manual).

Sdiccm 600 Ho Sdi:

600cc class, Electronic Fuel Injection

Sdiccm 800 Ho:

800cc class, carbureted or SDI depending on exact model designation

Lubrication

Oil System:

Oil injection system for 2-stroke lubrication.

Cooling

Cooling System:

Liquid-cooled (typically).

🔧 Transmission

Standard

Type:

CVT (Continuously Variable Transmission) with forward, neutral, and reverse (on some models).

Optional

Gear Reduction:

N/A (CVT provides variable ratios)

Features

Clutch Service:

Detailed procedures for primary and secondary clutch inspection, adjustment, and replacement.

📐 Dimensions

Weights

Dry Weight:

Varies by model, typically between 450-550 lbs (approx. 204-250 kg).

🛡️ Safety Features

Ratings

Classification:

Snowmobile safety standards as per manufacturer and regulatory bodies.

Active Features

Braking System:

Hydraulic disc brake system, typically single disc with caliper.

Passive Features

Emergency Stop:

Lanyard kill switch (standard safety feature).

💡 Technology Features

Infotainment

Instrumentation:

Digital/analog gauge cluster displaying speed, RPM, fuel level, engine temperature (on some models), and warning lights.

Driver Assistance

Ergonomics:

REV chassis focused on rider-forward ergonomics for better control and comfort.

Connectivity

Diagnostic Tools:

The manual would detail procedures using specialized diagnostic tools for SDI models.

🔧 Maintenance

Service Intervals

Oil Change:

Refer to manual for specific engine recommendations (e.g., for chaincase oil).

Spark Plugs:

Typically recommended every 1,000-2,000 miles or annually, depending on usage.

Clutch Inspection:

Recommended at 1,000-mile intervals or annually.

Fluid Specifications

Engine Oil Type:

Specific 2-stroke synthetic oil injection blend recommended by Bombardier/Rotax.

Chaincase Oil:

Likely a GL-4 or GL-5 synthetic gear oil, specific viscosity to be confirmed in the manual (e.g., 75W-90).

Coolant:

Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water.

Brake Fluid:

DOT 3 or DOT 4 brake fluid, depending on specific caliper design.

Known Issues

Crankshaft Bearings:

Some early Rotax 600 HO SDI models experienced crankshaft bearing failures due to insufficient lubrication or cooling, requiring timely inspection and potential replacement.

Exhaust Valves:

Carbon buildup on exhaust power valves can affect engine performance and requires periodic cleaning.

Sdi Injector Issues:

Clogging of fuel injectors on SDI models can occur if contaminated fuel is used.

Recoil Starter:

Recoil starter assembly maintenance and potential failure points.

Belt Wear:

Drive belt inspection for wear and proper tension is critical for CVT performance.

📚 Vehicle History

Brand Heritage

Manufacturer:

Bombardier Recreational Products (BRP)

Model Evolution

Chassis Introduction:

The REV chassis, introduced for the 2003 model year, represented a significant redesign with a low, forward-mounted engine and rider-forward ergonomics, offering improved weight distribution and handling.

Production

Manufacturing Region:

Primarily Canada and/or Mexico for Bombardier products.

🏆 Awards & Recognition

Recognitions

Chassis Impact:

The REV chassis was widely praised for its innovative design and improved handling characteristics, setting a new standard in the snowmobile industry upon its release.