Segment:
High-performance and utility snowmobiles.
Target Audience:
Ski-Doo owners, independent repair shops, powersports technicians, and enthusiasts seeking in-depth knowledge.
Competitors In Segment:
Polaris, Yamaha, Arctic Cat.
Platform Innovation:
The REV platform introduced a significant ergonomic and chassis design advancement for Ski-Doo, focusing on rider-forward positioning and improved handling, which this manual thoroughly documents.
Engine Technology:
Covers a range of Rotax engines, including early direct injection (SDI) models, highlighting advancements in power delivery and efficiency for the era.
Covered Models:
Expedition, GSX, GTX, MX Z, MX Z Adrenaline, MX Z DPM Power Trek, Summit
Covered Engines:
377, 552, 593, 593 HO, 593 HO SDI, 793, 793 HO Power Tek
Cooling Systems Covered:
Fan Cooled and Liquid Cooled variants
Estimated Page Count:
Likely 700-1000+ pages, typical for a comprehensive service manual covering multiple models and engines.
Type:
Service Repair Manual
Language:
English (standard for BRP documentation, though regional variations may exist)
Engine Systems:
Top-end (cylinder head, valves), bottom-end (crankshaft, connecting rods, pistons), lubrication, cooling, fuel delivery, ignition, starting, exhaust
Drivetrain Systems:
CVTech/Team primary and secondary clutches, chaincase, driveshaft, differential (where applicable), track system
Electrical Systems:
Wiring diagrams, lighting, gauges, ignition system, battery, charging system, CDI unit, sensors, starting system
Chassis Systems:
Frame, suspension (front and rear), steering, skis, brake system (hydraulic disc), body panels, seat
Maintenance:
Scheduled maintenance, lubrication, inspections, fluid changes, filter replacements, spark plug service, clutch maintenance
Troubleshooting:
Diagnostic procedures, symptom analysis, common problem resolution for engine, electrical, and mechanical issues
Repair:
Component removal and installation, disassembly and assembly of major systems (engine, transmission, suspension, brakes)
Technical Adjustments:
Carburetor adjustment, ignition timing (if applicable), clutch alignment, suspension settings
Depth:
Comprehensive. Covers from basic owner-level maintenance checks to in-depth engine overhauls, electrical diagnostics, and suspension rebuilds.
Diagnostic Capabilities:
Detailed fault codes, diagnostic trees, specific test procedures for components and sensors.
Specifications And Tolerances:
Includes all critical torque specifications, clearances, gap measurements, and fluid capacities required for accurate service.
Searchability:
Typically searchable text, allowing for quick location of specific information.
Resolution:
High resolution for clear viewing of diagrams, schematics, and photographs.
Binding:
N/A (Digital PDF format)
Paper Quality:
N/A (Digital PDF format)
Content Scope:
Complete factory-level service and repair information.
Engine Family:
Rotax Two-Stroke
Engine Sizes Cc:
377cc, 552cc, 593cc, 793cc
Horsepower Range Est:
Approximately 50 HP (377) to 120+ HP (793 HO variants), depending on specific tuning and model application.
Combustion Type:
Two-stroke, reed valve induction
Compression Ratio Typical:
Varies by engine, e.g., ~7.0:1 for non-HO, higher for HO/SDI variants.
Carbureted Engines:
Mikuni VM series (e.g., VM34/36/38) or Lectron carburetors, with detailed jetting and adjustment procedures.
Sdi Engines:
Direct injection systems (e.g., Delphi or Siemens), detailing fuel pump, injectors, and ECU calibration.
Oil Mixture:
Pre-mix or oil injection systems (specify model/engine type), with procedures for oil pump calibration and oil type specifications.
Cooling Method:
Air cooling (fan assisted) and liquid cooling (radiator, fan, thermostat) variants.
Coolant Type:
Ethylene glycol-based antifreeze (e.g., BRP Genuine Coolant or equivalent).
Type:
CVT (Continuously Variable Transmission) via CVTech or Team drive and driven clutches.
Gear Reduction:
Internal chaincase reduction gears, specific ratios provided in manual.
Clutch Maintenance:
Detailed procedures for clutch inspection, cleaning, spring replacement, roller/weight inspection and replacement, and alignment.
Chaincase Fluid:
Specific chaincase oil viscosity and change intervals provided (e.g., ISO 320 or equivalent).
Platform Type:
REV Platform, characterized by its rider-forward ergonomics and integrated bodywork.
Track Length Typical:
Varies by model, e.g., 121 inches, 136 inches.
Ski Stance Typical:
Adjustable or fixed, specific measurements provided per model.
Dry Weight Est:
Approximately 450-600+ lbs (204-272+ kg), depending on model and engine.
Crash Test Data:
Snowmobiles are not typically subjected to standardized crash test ratings like automobiles. Safety focus is on operational design and rider protection.
Braking System:
Hydraulic disc brake system, with procedures for pad replacement, caliper service, and fluid bleeding.
Dpm Power Trek:
Electronic control system (on specific models) for optimizing power delivery and potentially enhancing traction or fuel economy.
Chassis Design:
REV platform designed for improved rider control and stability.
Engine Kill Switch:
Standard handlebar-mounted safety lanyard and kill switch.
Instrument Cluster:
Analog/digital combination displays showing speed, RPM, fuel level, engine temperature, and warning lights. Details on diagnostics via cluster codes are included.
Dpm Functionality:
As mentioned, the DPM (Digitally Processed Multi-engine) system on specific models offers electronic control over engine parameters for optimized performance and efficiency, detailed in the manual.
Wiring Schematics:
Comprehensive electrical diagrams are a key technology feature, enabling diagnosis of sensor inputs and electronic control unit (ECU) operations.
Break In Period:
Typically 500-1000 miles or specific engine hours, with detailed break-in procedures outlined in the manual.
Oil Change Interval:
Engine oil: Varies based on engine type and usage. Chaincase oil: Typically every 1000-2000 miles or annually.
Spark Plug Replacement:
Recommended at specific mileage intervals or annually, with correct gap specifications.
Clutch Inspection:
Recommended annually or every 500-1000 miles for wear and condition.
Engine Oil Type Premix:
Specific 2-stroke synthetic oil meeting BRP specifications (e.g., XPS 2T Synthetic).
Coolant Specification:
BRP Genuine Coolant or equivalent Ethylene Glycol-based antifreeze with corrosion inhibitors, typically a 50/50 mix with distilled water.
Chaincase Oil:
ISO VG 320 gear lubricant (e.g., BRP XPS Chaincase Lube or equivalent).
Brake Fluid:
DOT 4 hydraulic brake fluid.
Crankcase Seals:
Potential for crankcase seal leaks over time, leading to air leaks and performance issues. Manual covers seal replacement.
Exhaust Pipe Cracks:
Some models might be prone to exhaust pipe cracking due to vibration and heat cycles. Manual covers inspection and repair.
Clutch Belt Wear:
Normal wear and tear; manual details belt inspection, alignment, and replacement procedures.
Manufacturer:
Bombardier Recreational Products (BRP), a long-standing leader in powersports, particularly snowmobiles.
Rev Platform Introduction:
The 2003 model year saw the introduction of the revolutionary REV platform, which defined Ski-Doo's design language and performance focus for years to come.
2006 Updates:
The 2006 models represent a mature iteration of the REV platform, incorporating refinements based on previous years' feedback and technological advancements.
Manufacturing Location:
Primary manufacturing for Ski-Doo snowmobiles historically located in Valcourt, Quebec, Canada.
Industry Impact:
The REV platform itself was highly acclaimed for its ergonomic advancements and handling, revolutionizing snowmobile design for BRP and influencing the industry.
Editorial Reviews Context:
Contemporary reviews of Ski-Doo models using the REV platform frequently praised their ride quality, agility, and rider-forward positioning.
Manufacturing Standards:
Adherence to industry standards for safety and emissions, as applicable to snowmobile manufacturing.
