🏷️ Basic Information

Make:

Ski-Doo

Model:

Expedition TUV

Year:

2009

Product Name:

Ski Doo Expedition Tuv 600 Ho Sdi Snowmobiles 2009 All Service Repair Manual Download

Engine Code:

600 HO E-TEC SDI

👋 Introduction

Market Niche:

The Ski-Doo Expedition TUV line is positioned as a versatile utility snowmobile, capable of both recreational riding and heavy-duty work, often used for trail grooming, cargo hauling, and accessing remote areas.

Competitors:

Competes with other utility-focused snowmobiles from brands like Arctic Cat (e.g., Bearcat series) and Polaris (e.g., RMK Pro Utility, Pro RMK models configured for utility tasks), offering a blend of performance and load-carrying capability.

Versatility:

Designed for dual-purpose use, combining passenger comfort with cargo hauling capacity, often featuring a hitch for towing and a substantial rack system.

Diy Focus:

Caters to owners who prefer to perform their own maintenance and repairs, offering detailed instructions to ensure quality and accuracy in their work.

📋 Manual Details

Systems Covered:

Engine, Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Drivetrain, Transmission, Suspension, Steering, Brakes, Electrical System, Lighting, Bodywork, Chassis, Troubleshooting, Maintenance, Repair Procedures

Page Count:

Comprehensive (exact count not specified, but implied extensive for service/repair)

Manual Type:

Service and Repair Manual

Language:

English

Format:

Digital Download (PDF likely)

📖 Manual Coverage

Engine Mechanical:

Detailed overhaul procedures for the 600 HO E-TEC SDI engine, including cylinder head, pistons, crankshaft, connecting rods, valve train, and timing.

Fuel System:

Comprehensive coverage of the Electronic Fuel Injection (EFI) system, including fuel pump, injectors, fuel pressure regulator, sensors, and troubleshooting for fuel delivery issues.

Ignition System:

Detailed diagnostics and repair for the electronic ignition system, CDI unit, spark plugs, and related components.

Cooling System:

Information on the liquid cooling system, radiator, thermostat, water pump, coolant types, and flushing procedures.

Lubrication System:

Details on the oil pump, oil filter, oil change procedures, and oil specifications for the engine and drivetrain.

Exhaust System:

Repair and maintenance of the exhaust system, including mufflers, catalytic converters, and exhaust pipes.

Drivetrain:

In-depth coverage of the Continuously Variable Transmission (CVT) system, including clutch inspection, belt replacement, roller weights, and calibration.

Suspension Front:

Repair and adjustment of the front suspension, including A-arms, shock absorbers, springs, bushings, and alignment procedures.

Suspension Rear:

Maintenance and repair of the rear suspension, including the T-Motion (Traction-Motion) system, shock absorbers, torque rods, and track system components.

Steering System:

Procedures for steering column maintenance, tie rods, steering linkage, and any power steering components if applicable.

Braking System:

Detailed information on the hydraulic brake system, including brake calipers, master cylinder, brake fluid specifications, bleeding procedures, and pad/rotor replacement.

Electrical System:

Comprehensive electrical schematics, wiring diagrams, troubleshooting for battery, alternator/stator, starter motor, lighting, gauges, and control modules.

Bodywork Chassis:

Information on body panel removal and installation, seat, handlebars, windshield, and chassis components.

Routine Maintenance:

Step-by-step instructions for oil changes, filter replacements, spark plug checks, track tension adjustment, and general inspection.

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting guides for common problems and performance issues.

Engine Overhaul:

Complete procedures for engine disassembly, inspection, repair, and reassembly, including torque specifications and critical measurements.

Transmission Service:

Detailed steps for CVT clutch service, belt inspection and replacement, secondary clutch adjustments, and gearcase lubrication.

Electrical Diagnostics:

Instructions for using diagnostic tools, checking sensor readings, and repairing electrical faults.

Suspension And Steering Repair:

Procedures for replacing worn suspension components, adjusting alignment, and servicing steering mechanisms.

Brake System Service:

Guidance on brake pad replacement, caliper service, bleeding the brake system, and fluid changes.

Depth:

Comprehensive service and repair, covering everything from routine maintenance to complete engine and drivetrain overhauls. Includes detailed diagnostics and component-level repair.

📊 Manual Specifications

File Format:

Likely PDF, optimized for digital viewing and printing.

Print Quality:

High-resolution, allowing for clear viewing of diagrams and text.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Rotax 600 HO E-TEC SDI (Semi-Direct Injection)

Engine Configuration:

2-stroke, parallel-twin cylinder

Displacement:

597.1 cc (36.4 cubic inches)

Bore X Stroke:

72 mm x 73 mm (approximate, common for this engine family)

Cooling System:

Liquid-cooled

Horsepower:

Approximately 125 HP (actual figure may vary slightly based on specific tuning and conditions)

Torque:

Not explicitly stated, but E-TEC engines are known for strong mid-range torque.

Fuel Injection Type:

Electronic Fuel Injection (EFI) with Semi-Direct Injection (SDI) technology

Fuel Type:

Unleaded gasoline (minimum 87 octane recommended)

Oil Mixture:

Pre-mixed fuel and oil (the E-TEC system automatically injects oil, so a separate oil reservoir is used)

🔧 Transmission

Transmission Type:

CVT (Continuously Variable Transmission) - Primary and Secondary Clutches

Gear Selection:

Forward, Neutral, Reverse (RER - Reverse Engine Retraction system is common)

Clutch Engagement:

Designed for efficient power transfer across a wide RPM range, optimizing for acceleration and pulling power in utility applications.

📐 Dimensions

Length:

Varies by specific configuration, but typically around 120-130 inches (approximate)

Width:

Varies by specific configuration, often designed for stable footing, around 48-52 inches (approximate)

Dry Weight:

Typically in the range of 650-750 lbs (approximate, depending on features and track length)

Payload Capacity:

Designed for substantial cargo hauling, often exceeding 200-300 lbs on racks, plus towing capacity.

Cargo Rack Capacity:

Significant capacity for gear and equipment, typically at front and rear.

🛡️ Safety Features

Crash Test Data:

Snowmobiles are not typically subjected to formal crash test ratings like automobiles. Safety is based on design features and operator training.

Throttle Limiter:

Often includes a throttle limiter for inexperienced riders or specific conditions.

Engine Kill Switch:

Standard handlebar-mounted kill switch for immediate engine shutdown.

Windscreen:

Provides protection from wind and debris.

Ergonomics:

Designed for rider comfort and control during long rides or demanding work.

💡 Technology Features

Gauge Cluster:

Digital/analog gauge cluster displaying speed, RPM, fuel level, engine temperature, and diagnostic warning lights.

Rev Limiter:

Electronic rev limiter to prevent engine over-revving.

Diagnostic Ports:

Includes diagnostic ports for connecting to specialized diagnostic software for fault code retrieval and data monitoring.

🔧 Maintenance

Oil Change Engine:

Refer to manual for specific intervals, but typically every 200-300 hours or annually. E-TEC systems manage oil differently via an oil reservoir.

Clutch Inspection:

Recommended at regular intervals, e.g., every 50-100 hours or annually, to check for wear on primary and secondary clutches and the drive belt.

Track Tension:

Check and adjust track tension periodically as per manual recommendations, typically before each season and after initial break-in.

Engine Oil Type:

Specific Ski-Doo 2-stroke Synthetic Oil (e.g., XPS 2T Synthetic oil) for the oil injection system. Do not use pre-mix in the fuel tank.

Coolant Type:

Propylene glycol-based antifreeze with corrosion inhibitors, mixed with distilled water. Refer to manual for exact type and mixture ratio.

Brake Fluid Type:

DOT 4 brake fluid is commonly recommended for Ski-Doo vehicles.

E Tec Reliability:

Generally reliable, but potential issues can include sensor failures, exhaust valve issues if not maintained properly, and clutch wear if subjected to extreme use.

Drive Belt Wear:

Drive belts are wear items and require regular inspection and replacement to prevent breakage, which can cause significant damage.

📚 Vehicle History

Brand Origin:

Bombardier Recreational Products (BRP), a Canadian company, owns the Ski-Doo brand, a pioneer in the snowmobile industry since the early 1960s.

Expedition Line:

The Expedition line has evolved to incorporate advanced technologies like E-TEC direct injection for improved fuel efficiency and emissions, alongside features enhancing utility and comfort for touring and work.

Manufacturing Location:

Ski-Doo snowmobiles are primarily manufactured in Quebec, Canada.

🏆 Awards & Recognition

Brand Awards:

Ski-Doo and its Rotax engines have consistently received industry accolades for innovation, performance, and reliability over the years.