Segment:
High-performance trail and touring snowmobile.
Key Competitors:
Arctic Cat F Series, Yamaha Vmax Series, Polaris RMK/Edge Series of the same era.
Platform:
REV platform, known for its rider-forward ergonomics and centralized mass.
Engine Focus:
Emphasis on the Rotax 600 HO (High Output) engine.
Manual Benefit:
Essential for maintaining peak performance, diagnosing issues, and performing repairs on the 2005 GSX 600 HO REV.
Engine Mechanical:
Complete Engine Overhaul, Assembly, Disassembly, Tuning, Troubleshooting
Engine Electrical:
Ignition System, Starting System, Charging System, CDI Unit, Wiring Diagrams
Fuel System:
Carburetors (Mikuni BN40I), Fuel Pump, Fuel Lines, Tank Servicing
Drivetrain:
CVTech Drive Clutch (Type 09-0107), Driven Clutch (Type 09-0108), Belt Drive, Chaincase, Lubrication
Suspension Front:
D.A.S. (Dual A-Arm Suspension), Shocks (HPG (High Pressure Gas)), Springs, Bushings, Alignment
Suspension Rear:
SC-4 Rear Suspension, HPG Shocks, Torsion Springs, Anti-stab, Track System, Skis, Skegs
Brakes:
Hydraulic Disc Brake System, Caliper, Master Cylinder, Brake Lines, Fluid Bleeding
Steering:
Steering Post, Handlebars, Tie Rods, Spindles, Bushings
Electrical System:
Headlight, Taillight, Gauges, Switches, Battery, Relays, Fuses
Body Panels:
Front Hood, Side Panels, Seat, Removal, Installation, Fasteners
Troubleshooting:
Diagnostic Procedures for Common and Uncommon Issues, Symptoms and Solutions
Type:
Official Factory Service Manual / Repair Manual
All Major Systems:
Yes, including engine, drivetrain, chassis, electrical, and bodywork.
Maintenance And Repair:
Scheduled maintenance, routine checks, component replacement, engine rebuilds, clutch service, suspension adjustments, brake system repairs, electrical diagnostics and repair.
Depth:
Comprehensive. Covers from basic operator checks and adjustments to complete engine disassembly, overhaul, and specialized diagnostic procedures.
Troubleshooting Charts:
Detailed troubleshooting charts for diagnosing performance issues, starting problems, electrical faults, and mechanical failures.
Technical Data:
Includes all torque specifications, clearances, fluid capacities, and electrical values.
Format:
Portable Document Format (PDF)
Quality:
High-resolution, printable, with clear diagrams and text.
Format Type:
Digital Download (PDF)
Digital Medium:
N/A (Digital)
Text Search:
Likely searchable text within the PDF, enabling quick location of specific information.
Engine Model:
Rotax 600 HO
Engine Type:
2-stroke, liquid-cooled, parallel-twin
Bore X Stroke:
72 mm x 73 mm
Horsepower Rating:
Approx. 118 hp (Varies slightly by source/tuning)
Cooling System:
Liquid-cooled with thermostatically controlled fan
Ignition:
CDI (Capacitor Discharge Ignition) with Dual Spark Plugs per Cylinder
Carburetor Type:
Dual Mikuni BN40I with T.O.R.S. (Throttle Operated Revolution Sensor)
Fuel Type:
Minimum 87 Octane Unleaded Gasoline
Oil Injection:
D.P.I. (Direct Oil Injection) system
Pistons:
Single-ring design
Crankshaft:
Ballanced, forged crankshaft
Type:
CVTech Variable Transmission (CVT)
Drive Clutch:
CVTech Type 09-0107 (Primary)
Driven Clutch:
CVTech Type 09-0108 (Secondary)
Gear Reduction:
Chaincase with single gear reduction ratio (specific ratio typically found in manual)
Chaincase Fluid:
Hypoid gear oil, SAE 80W/90 (Specific part number or API GL-5 specification)
Overall Length:
Approx. 109 inches (276.9 cm) - Varies slightly with track choice
Overall Width:
Approx. 47 inches (119.4 cm)
Height:
Approx. 45 inches (114.3 cm) to top of windshield
Dry Weight:
Approx. 478 lbs (216.8 kg) - Varies slightly by model configuration
Front Suspension Travel:
Approx. 7.5 inches (191 mm)
Rear Suspension Travel:
Approx. 10.5 inches (267 mm)
Track Length:
Typically 121 inches (307 cm)
Track Width:
15 inches (38.1 cm)
Lug Height:
Typically 1.0 inch (25.4 mm) or 1.25 inch (31.75 mm) depending on track option
Crash Test Data:
N/A for snowmobiles in the same way as automobiles; focus is on operational safety features.
Kill Switch:
Tether cord kill switch for operator safety.
Lighting:
Headlight, taillight, and brake light for visibility.
Rev Platform Ergonomics:
Rider-forward design promotes better control and balance.
Windshield:
Provides wind protection for the rider.
Indicator Lights:
Various dashboard indicators for engine status, oil level, etc.
Gauge Cluster:
Digital display with speedometer, tachometer, fuel gauge, odometer, trip meter, engine warning lights, and potentially others depending on specific configuration.
T Motion:
Not applicable for this model year, but REV platform's handling characteristics were revolutionary.
Wired Features:
Basic electrical system for lights, ignition, and gauges.
Oil Change:
Check oil level regularly. D.P.I. system automatically meters oil. Refer to manual for oil injection pump service intervals.
Clutch Inspection:
Inspect drive and driven clutches for wear, damage, and proper alignment every 500-1000 miles or annually. Belt inspection and replacement interval typically 1500-2000 miles or as needed based on wear.
Spark Plugs:
Inspect and gap spark plugs every 1000-2000 miles. Recommended replacement based on wear and performance. (e.g., NGK BR9ECS-5)
Suspension Lubrication:
Lubricate suspension pivot points and grease fittings as per manual schedule (typically annually or every 1000 miles).
Chaincase Oil Change:
Change chaincase oil annually or every 1000-2000 miles.
Coolant:
Ethylene glycol-based antifreeze mixture (50/50 with distilled water). Specific part number or coolant type should be confirmed in manual.
Chaincase Oil:
Hypoid gear oil, SAE 80W/90, API GL-5.
2 Stroke Oil:
High-quality, low-smoke, ashless 2-stroke oil specifically designed for snowmobiles. (e.g., XPS 2T Synthetic, or equivalent meeting JASO FD or ISO-L-EGD standards)
Common Wear Items:
Drive belts, carbides/skegs, suspension bushings, exhaust system components (hangers, silencer packing).
Clutch Vibration:
Can occur due to worn clutch components or imbalance; requires inspection and potential rebuild/replacement.
Engine Bogging:
Often related to fuel delivery (carburetor tuning, fuel filter), ignition system issues, or incorrect jetting.
Maintenance Schedule Detail
Initial Service:
Refer to manual for break-in procedure and initial service recommendations.
Manufacturer:
Bombardier Recreational Products (BRP), renowned for its pioneering work in snowmobile technology.
Rev Platform Introduction:
The 2003 model year saw the revolutionary introduction of the REV platform, significantly changing snowmobile ergonomics and handling. The 2005 GSX 600 HO REV is a key iteration of this successful platform.
Manufacturing Location:
Valcourt, Quebec, Canada.
Gsx Series Role:
The GSX series was positioned as a premium, comfortable trail sled with a focus on performance and amenities.
