2013 BRP Ski-Doo REV-XS / REV-XM Snowmobile Service Manual Collection (P/N 529 035 997)

This 2013 BRP Ski-Doo service manual collection covers REV-XS and REV-XM snowmobiles with 600 HO E-TEC and 800R E-TEC engines, including the documented MX Z, Renegade, and Summit configurations. It combines the shop manual with engine-specific diagnostic fault-code supplements.

• Engine repair: Engine removal and installation, separate top-end and bottom-end procedures, crankshaft bearing service, piston inspection, and cylinder-base gasket selection.

• Lubrication and cooling: Oil injection pump testing and bleeding, oil-code matching, thermostat inspection, coolant leak testing, and water-pump service.

• E-TEC controls: B.U.D.S. diagnostics, fuel injector testing and configuration, TPS closed-throttle reset, and 3D RAVE valve synchronization and position-sensor setting.

• Electrical troubleshooting: Ignition and charging tests, starter repair, D.E.S.S. key programming, RER checks, wiring diagrams, connector service, and splice repair.

• Drive system and brakes: TRA drive pulley and QRS driven pulley disassembly, chaincase service, track adjustment, brake component inspection, and hydraulic bleeding.

• Suspension and chassis: rMotion and tMotion removal and inspection, quick-adjuster service, steering alignment, body-panel replacement, and frame-component removal.

Written for technicians already familiar with BRP service procedures, this manual assumes access to the specified hand tools and special service tools.

Engine Repair, Lubrication and Cooling

The engine chapters cover cylinder and piston inspection, crankcase separation, crankshaft bearings, and reassembly for each engine. Measurement procedures address cylinder-head warpage, piston projection, and crankshaft deflection. Cylinder-head screw tightening sequence views, an engine leak-test flowchart, and exploded assembly views supply related inspection, torque, and assembly references.

Cylinder-base gasket selection is tied to measured piston projection. The manual warns that an incorrect gasket thickness can cause detonation and severe engine damage.

Oil injection and coolant service: Pump identification and ECM oil-code matching accompany B.U.D.S. activation tests and oil-system bleeding. Cooling coverage includes coolant-strength verification, thermostat testing, expansion-tank replacement, and leak testing; water-pump procedures appear in the respective bottom-end chapters.

E-TEC Diagnosis and Calibration

Engine-management diagrams and fault-code tables identify circuit checks and possible causes alongside each fault. The engine-specific supplements help distinguish the relevant injector wiring and test references before diagnosing an electrical fault.

Replacement and setup: Fuel injector procedures cover removal, inspection, installation, and matching each injector to its PTO or MAG cylinder. Individual calibration files are retrieved through BOSSWeb and configured with B.U.D.S.; the manual also explains TPS closed-throttle reset and 3D RAVE synchronization, sensor setting, and position validation.

Electronic setup requires B.U.D.S., the specified MPI-2 interface (P/N 529 036 018), and access to the calibration files.

Ignition, Charging and Electrical Diagnosis

Power-distribution schematics distinguish the 55 VDC system on the 600 HO E-TEC from the 60 VDC system on the 800R E-TEC. Testing covers the stator, ignition coils, capacitor, DC-DC converter, starter circuits, and gauge functions.

For the 800R E-TEC, spark-plug indexing illustrations explain how electrode orientation affects the injection spray; incorrect indexing can cause poor idle and increased emissions. Stator connector pin-out views and sensor temperature/resistance tables support component checks, while the D.E.S.S. and RER sections cover key programming and reverse-system diagnosis.

E-TEC fuel and electrical work involves pressurized fuel and stored electrical energy. The manual's isolation and fuel-pressure precautions apply to these procedures.

Pulley Service, Brakes and Suspension

Drive-system coverage extends to pulley bushings, rollers, calibration, countershaft bearings, and chaincase disassembly. The manual warns that impact-wrench use during drive-pulley removal or installation can damage the pulley and alter its calibration.

Brake procedures cover pads, caliper, disc, master cylinder, and bleeding. Separate rMotion and tMotion chapters explain suspension removal and component inspection; rMotion quick-adjuster coverage includes spring-preload actuator disassembly, bleeding, and reassembly. Steering, body, and frame sections address access and chassis-component work.

Piston Projection and Brake Wear: Specification Preview

The top-end chapters specify piston projection of 0.90–1.10 mm for the 600 HO E-TEC and 1.82–1.92 mm for the 800R E-TEC. Each range is linked to the corresponding cylinder-base gasket selection guidance.

Brake inspection data specifies a minimum disc thickness of 4.5 mm (.177 in), alongside the disc inspection and replacement procedures.

Searchable Service Text, Bookmarks and File Contents

Text navigation and diagram detail: Service text supports PDF search, and embedded bookmarks link to the major sections and subsections. Small labels in the main wiring diagrams require zooming for comfortable reading. Some additional pages have no searchable text.

One printable English PDF contains 742 pages in total:

The additional pages are already included in the total and are separate from the service and diagnostic coverage.