🏷️ Basic Information

Make:

Ski-Doo

Year:

2004

Product Type:

Snowmobile Repair Manual

Format:

Downloadable PDF

👋 Introduction

Vendor Positioning:

Positioned as the sole source for repair, service, and shop manual downloads, emphasizing comprehensive coverage and ease of access.

Digital Manual Advantages:

Highlights advantages over traditional paper manuals, including portability, on-the-spot repair capability, and protection against damage.

Customer Service Availability:

Offers customer support to find and list specific manuals if not currently available.

Value Proposition:

Provides instant access to critical repair information to minimize downtime and facilitate immediate repairs.

📋 Manual Details

Vehicle Models Covered:

Elite Sport, GSX Limited 1+1 (600 HO SDI, 800 RER SDI), GSX Limited 1UP (600 HO SDI, 800 RER SDI), GSX Sport 1+1 (500 SS RER, 600 HO RER, 600 HO RER SDI), GSX Sport 1UP (500 SS RER, 600 HO RER, 600 HO RER SDI), Legend Fan (380 RER, 550 RER), Legend GT Fan (380 RER, 550 RER), Legend GT SE (600 HO SDI RER, 700 RER, 800 SDI RER, V-1000), Legend GT Sport (500 SS RER, 600 HO SDI, 700 RER, V-1000), Legend SE (600 HO SDI RER, 700 RER, 800 SDI RER, V-1000), Legend Sport (500 SS RER, 600 HO SDI RER, 700 RER, V-1000), MX Z Adrenaline (500 SS RER, 600 HO RER, 600 HO SDI, 800 HO RER), MX Z Fan (380 RER, 550 RER), MX Z Renegade (600 HO SDI RER, 800 HO RER), MX Z Renegade X (600 HO RER, 600 HO SDI, 800 HO RER), MX Z Trail (500 SS, 500 SS RER, 600 HO, 600 HO RER), MX Z X (600 HO RER, 600 HO SDI RER, 800 HO RER), Skandic LT 440, Skandic Sport 550F RER, Skandic SUV (550F, 600), Skandic SWT 550F, Skandic WT 550F, Skandic WT LC 600, Summit Adrenaline (600 HO, 800 HO), Summit Fan 550 RER, Summit HighMark (800 HO RER, X 800 HO, Xtreme 800), Summit Sport (800 HO, 800 HO RER), Summit X (600 HO RER, 800 HO RER), Tundra RER

Engine Variants Covered:

Various engine sizes including 380 Fan, 500 SS, 550 Fan, 600 HO, 600 HO SDI, 700, 800 RER, 800 HO, V-1000. Specific engine types like RER (Reverse), RER SDI (Reverse with Semi-Direct Injection) are noted.

Estimated Page Count:

Extensive (Specific count not provided, but typical for a comprehensive repair manual covering numerous models)

Manual Type:

Comprehensive Service and Repair Manual

Language:

English

Delivery Method:

Instant Downloadable PDF

File Characteristics:

No ZIP files, plain, simple, easy to use PDF

📖 Manual Coverage

Major Systems:

General Information, Routine Maintenance, Engine Removal and Installation, Fuel System, Lubrication and Cooling System, Engine Specifications, Transmission, Drive Chain & Sprockets, Steering System, Shocks, Body Work, Intake & Exhaust, Electrical System, Advanced Troubleshooting

Repair And Maintenance:

Detailed procedures for repair, service, and routine maintenance. Includes diagnostics, troubleshooting, component replacement, and adjustments.

Diagnostic And Repair Scope:

Covers everything from basic maintenance to advanced diagnostics and repair for all listed systems. Designed for both home mechanics and professional technicians.

Parts Catalog Integration:

Implied to contain information for looking up parts, typical of a service manual.

📊 Manual Specifications

File Format Details:

PDF (Portable Document Format)

Print Usability:

Printable pages for on-site use, allowing users to avoid damaging expensive paper manuals.

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

Licensing Policy:

Lifetime Protection Policy: Free replacement if lost or damaged.

Device Compatibility:

Accessible on smartphones, tablets, and computers for on-trail or on-site repairs.

⚙️ Engine Specifications

Engine Types:

Rotax engines are prevalent across the Ski-Doo lineup. This manual covers various Rotax configurations: Fan-cooled (380F, 550F), carbureted 2-stroke (500 SS, 600 HO, 700), and Rotax SDI (Semi-Direct Injection) 2-stroke (600 HO SDI, 800 RER SDI, 800 HO RER).

Horsepower Range:

Estimated horsepower ranges from approximately 50 HP (380 Fan) to over 130 HP (800 RER/HO variants). Specific figures vary by engine and model.

Fuel Delivery Systems:

Carbureted fuel systems for many models, and fuel injection (SDI) systems for specific high-performance variants. Manual covers fuel pump, injectors, regulators, and carburetor adjustments.

Cooling Method:

Liquid-cooled (radiator and fan) and fan-cooled systems are covered. Includes details on coolant types, capacities, and radiator/fan inspection.

Lubrication System:

Premix lubrication or oil injection systems are detailed. Covers oil pump operation, oil tank service, and proper oil/fuel mixture ratios.

🔧 Transmission

Drive System Type:

CVT (Continuously Variable Transmission) drive system, commonly referred to as the TRA drive system by Ski-Doo.

Reverse System:

Many models feature RER (Reverse) or electronically assisted reverse systems, which are covered in detail, including mechanical and electrical components.

Clutch Service:

Comprehensive information on primary and secondary clutch maintenance, including disassembly, cleaning, inspection, spring replacement, weight adjustment, and calibration.

Drive Belt Replacement:

Instructions for drive belt inspection, removal, installation, and proper tensioning.

📐 Dimensions

Chassis Types:

Covers various chassis configurations like the REV platform (introduced around this era for some models) and earlier chassis types. Specific dimensions vary significantly by model.

Dry Weight Range:

Dry weights typically range from approximately 450 lbs to over 550 lbs depending on the model and engine.

Storage Capacity:

Information on available storage compartments and potential accessory cargo solutions, depending on the model (e.g., touring vs. mountain sleds).

🛡️ Safety Features

Safety Standards:

Adherence to relevant snowmobile safety standards. While specific crash ratings aren't typical for snowmobiles, the manual covers safety-related components and procedures.

Braking System:

Details on hydraulic disc brake systems, including caliper maintenance, brake fluid types (DOT 4), bleeding procedures, and pad replacement.

Suspension System:

Covers front and rear suspension systems (e.g., A-arm, SC-10, SC-4) including shock absorber service, spring adjustments, and bushing replacement.

Steering System:

Information on the ski and handlebar steering mechanism, including spindle maintenance, tie rod adjustments, and handlebar alignment.

💡 Technology Features

Gauge Clusters:

Details on digital and analog gauge clusters, including speedometer, tachometer, odometer, fuel gauge, and warning lights.

Electronic Features:

Covers electronic ignition systems, CDI units, lighting systems, and starter/charging systems.

Diagnostic Ports:

Information on accessing diagnostic data via onboard computers or diagnostic connectors, if applicable for the model year.

🔧 Maintenance

Routine Maintenance Schedule:

Detailed schedule covering pre-ride inspections, daily checks, mileage-based services (e.g., 500 miles, 1000 miles), and seasonal maintenance. Includes chaincase oil changes, track tension checks, and suspension lubrication.

Engine Oil:

For 2-stroke engines, specifies required 2-stroke synthetic oil (e.g., Ski-Doo XPS) for oil injection systems or for premixing. For 4-stroke engines (if any covered, though unlikely for this year/lineup), would specify viscosity like 0W-40.

Coolant:

Specifies engine coolant type (e.g., ethylene glycol-based) and appropriate mixture ratio with distilled water.

Brake Fluid:

DOT 4 brake fluid.

Chaincase Oil:

Specific gear oil for the chaincase, e.g., SAE 75W-90 synthetic gear oil.

Common Wear Items:

Addresses common wear items such as drive belts, carbides, hyfax, suspension bushings, and exhaust system components.

Engine Specific Considerations:

May include tips for specific engine reliability, such as proper break-in procedures for new engines or maintenance for SDI systems.

📚 Vehicle History

Manufacturer History:

Ski-Doo, a division of Bombardier Recreational Products (BRP), has a long history of innovation in the snowmobile industry since its inception in the early 1960s.

2004 Platform Changes:

The 2004 model year saw the continued integration and refinement of the REV platform, known for its rider-forward ergonomics and improved handling, across many performance and trail models.

Manufacturing Locations:

Typically manufactured by BRP in Canada and Mexico.

🏆 Awards & Recognition

Industry Reputation:

Ski-Doo snowmobiles from this era were generally well-regarded for performance and engineering, with the REV platform receiving significant acclaim for its handling and rider comfort.