Target Audience:
DIY enthusiasts, professional mechanics, workshops
Value Proposition:
Provides factory-level service information for comprehensive repair, maintenance, and diagnostics, enabling cost savings and self-sufficiency.
Illustrations:
Detailed illustrations supporting step-by-step instructions
Troubleshooting Support:
Includes specific guidance for immediate problem resolution
Model Variants Covered:
Expedition, GSX, GTX, MXZ, MX Z (Adrenaline), Summit
Engine Variants Covered:
550F, 380F, 500SS, 600HO, 600HO SDI, 800 HO DPM Power Tek
Type:
Service Repair Workshop Manual
Engine Mechanical:
Complete overhaul, diagnosis, tuning, lubrication, cooling system, exhaust system
Fuel System:
Carburetor adjustment and overhaul, fuel injection system (SDI models), fuel pump, fuel lines, fuel filter replacement
Ignition System:
CDI unit, spark plugs, ignition coils, stator, troubleshooting ignition faults
Drivetrain:
CVT clutch (drive and driven), primary and secondary clutch service, chaincase, lubrication, torque converter operation
Suspension:
Front and rear suspension systems, shock absorbers, springs, bushings, alignment, travel adjustment
Steering:
Handlebar assembly, steering post, tie rods, ski alignment, steering linkage components
Brakes:
Hydraulic brake system, caliper service, brake pads, brake fluid replacement, bleeding procedures, master cylinder
Electrical System:
Wiring diagrams, battery, charging system, lighting, starter motor, gauges, switches, fuses, relays
Bodywork And Chassis:
Panel removal and installation, seat, track, tunnel, skis, storage compartments
Maintenance:
Routine inspections, lubrication points, filter replacements, fluid changes, track tension adjustment, clutch cleaning
Troubleshooting:
Diagnostic charts for common starting, running, and performance issues; electrical system diagnostics; clutch performance issues
Repair:
Step-by-step instructions for engine rebuilds, transmission repairs, suspension component replacement, electrical component replacement
Rebuilds:
Complete engine overhaul procedures, clutch rebuilding, differential maintenance (if applicable)
Diagnostics:
Methods for identifying the root cause of mechanical and electrical problems, use of diagnostic tools
Depth:
Comprehensive: Covers basic maintenance to complete engine and drivetrain rebuilds, detailed electrical troubleshooting, and suspension tuning.
Searchability:
Likely searchable text content within the PDF
Quality:
Illustrated with clear step-by-step instructions, implies good quality illustrations and text
Binding:
Not applicable (Digital Download)
Paper:
Not applicable (Digital Download)
Accessibility:
Readable on computers, iPads, hard drives; printable
Compression Notes:
May require unzipping software (WinZip/WinRAR); files can be large (up to 4000 MB)
Engine Family:
Rotax (BRP's proprietary engine brand for Ski-Doo)
Engine Type 550F:
2-stroke, fan-cooled, 2-cylinder
Engine Type 380F:
2-stroke, fan-cooled, 2-cylinder
Engine Type 500Ss:
2-stroke, liquid-cooled, 2-cylinder, Rotax E-TEC (early iteration, or similar advanced carburation)
Engine Type 600Ho:
2-stroke, liquid-cooled, 2-cylinder, HO (High Output)
Engine Type 600Ho Sdi:
2-stroke, liquid-cooled, 2-cylinder, HO (High Output), SDI (Sequential Direct Injection)
Engine Type 800 Ho Dpm Power Tek:
2-stroke, liquid-cooled, 2-cylinder, HO (High Output), DPM (Digitally Programmed Management), Power Tek
Horsepower Range:
Varies by engine; typically from approx. 60 HP (380F) to over 140 HP (800 HO DPM)
Carburetion Types:
Mikuni VM series (common on smaller engines), Ski-Doo specific carburetors
Injection Type:
Rotax SDI (Sequential Direct Injection) for specific 600HO models
Cooling Methods:
Fan-cooled (F models) and Liquid-cooled (HO models)
Type:
CVT (Continuously Variable Transmission) with Arctic Cat APV clutch system or Bombardier (BRP) proprietary system
Reverse:
Available on select models, often mechanical or electronic assist
Clutch Operation:
Primary (Drive) Clutch, Secondary (Driven) Clutch, designed for optimal power delivery and RPM management
Chaincase Lubrication:
Gearcase oil, specific viscosity and capacity detailed in manual
Initial Service:
Typically at 10-hour or 100-mile mark (check specific model recommendations)
Annual Maintenance:
Pre-season inspection, post-season storage procedures detailed
Clutch Service:
Recommended inspection and cleaning every 100 hours or annually
Engine Oil 2 Stroke:
Specific BRP-certified 2-stroke synthetic oil required for premix or injection systems (e.g., XPS 2T Synthetic)
Chaincase Oil:
Specific gear oil, e.g., SAE 80W-90 GL-4 or GL-5, capacity typically around 150-200 ml
Coolant:
Ethylene glycol based antifreeze/coolant, usually a 50/50 mix with distilled water for liquid-cooled models
Brake Fluid:
DOT 4 hydraulic brake fluid
Clutch Wear:
Normal wear and tear on clutch buttons and weights; belt wear is a common maintenance item.
Sdipop Starts:
Early SDI models sometimes had issues with injector seals or ignition components causing starting problems. Manual would detail troubleshooting.
Suspension Bushings:
Wear on suspension bushings can lead to loose handling, a common check item.
Manufacturer:
Bombardier Recreational Products (BRP)
Rev Platform Introduction:
The REV platform was a significant redesign for Ski-Doo, introduced around 2003-2004, focusing on rider-forward ergonomics, better handling, and chassis rigidity. This 2005 manual covers models built on this revolutionary platform.
Manufacturing Location:
Primarily Quebec, Canada (Valcourt)
