2004 Ski-Doo GSX, MX Z, Summit Snowmobile Shop Manual (P/N 484 200 056)

This Bombardier 2004 Ski-Doo REV Series Shop Manual, P/N 484 200 056, covers the listed GSX, MX Z, and SUMMIT snowmobiles. It distinguishes carbureted engines from 2-TEC SDI configurations and provides model-specific service data for the covered trims.

• Engine repair: Engine removal, top-end and bottom-end disassembly, RAVE valve inspection, crankshaft checks, engine leak testing, and dimensional measurement.
• Fuel and lubrication: TM carburetor service and synchronization, DPM diagnosis, oil-injection pump adjustment, liquid-cooling service, and rewind-starter repair.
• SDI engine management: Fuel-pump and injector testing, throttle-position sensor checks, ECM replacement, fuel-system bleeding, and B.U.D.S. diagnostic procedures.
• Transmission and brakes: TRA III drive-pulley overhaul, Formula RER and HPV VSA driven-pulley service, pulley alignment, chaincase gearing, and hydraulic-brake repair.
• Suspension and steering: SC-10 and SC-10 III service, HPG T/A shock rebuilding, drive-axle work, track adjustment, and ski alignment.
• Electrical troubleshooting: Ignition-timing checks, MPEM calibration, DESS testing, starter service, electrical test tables, connector views, and wiring diagrams.

The manual was written primarily for snowmobile mechanic technicians already familiar with Bombardier service procedures and assumes access to the specified hand tools and special service tools.

Engine Inspection and Supporting Systems

The engine sections cover the 593, 593 HO, 593 HO SDI, and 793 HO types. Internal inspection includes cylinder-to-piston clearance, ring end gap, crankshaft deflection, connecting-rod play, and crankshaft alignment. The engine leak verification flow chart helps separate sealing faults from other causes before internal repair is planned.

Oil-pump identification and adjustment, cooling-system leak checks, thermostat inspection, and coolant refilling are documented separately. Rewind-starter coverage includes rope replacement and spring assembly.

The top-end instructions identify gasket thickness as a critical selection point: an incorrect gasket can cause detonation and severe engine damage. Bottom-end coverage also explains the bearing and seal arrangements associated with Isoflex lubrication.

Carburetor, DPM, and SDI Diagnosis

Carbureted models have dedicated TM carburetor inspection, adjustment, synchronization, and throttle-cable procedures. DPM coverage adds air-temperature sensor checks, solenoid testing, and manifold leak testing.

For SDI models, the manual explains the fuel rail, injectors, pressure regulator, and electronic engine-management functions. Fuel-pressure tests and pressure-decay interpretation help distinguish pump, regulator, injector, and external leakage faults.

TPS diagnosis separates out-of-range readings from adaptation failures, with related connector checks and closed-throttle reset information. The VCK and B.U.D.S. sections explain ECM communication and fault handling; the SDI communication setup uses the KW2000 protocol.

The throttle-body section identifies factory-set synchronization and zero-position adjustments that must remain undisturbed. Changing the zero-position stop can impair idle adjustment.

Pulley, Chaincase, and Chassis Service

TRA III coverage includes bushing inspection and replacement, assembly, installation, and calibration. Formula RER and HPV VSA driven pulleys have separate service instructions, supported by a pulley alignment and distance specifications chart. Alignment bar P/N 529 035 831 is identified for the REV configurations.

Chaincase coverage includes disassembly, gear-ratio changes, assembly, and drive-chain adjustment. Hydraulic-brake procedures address the master cylinder, pads, disc, countershaft components, and bleeding.

Rear-suspension sections distinguish SC-10 from SC-10 III assemblies. HPG T/A shock service includes internal inspection, floating-piston positioning, filling, and charging information. Steering and front-suspension coverage adds steering-column configurations, ski alignment, and model-specific shock installation.

Electrical Tests and Diagram References

MPEM calibration checks and changes are described alongside ignition-timing verification, DESS diagnosis, charging-system tests, and electric-starter inspection. Electrical testing tables connect symptoms and measurements to specific circuits.

References include ECM connector pin-outs, the fuel delivery system diagnostic flow, and separate wiring diagrams titled 2004 REV Carburetor Electric Start, 2004 REV Carburetor Manual Start, and 2004 REV SDI.

Fuel-system work involves retained pressure and flammable fuel; the manual’s pressure-release precautions and ventilation requirements apply.

A Preview of DPM and SDI Test Data

These examples represent a small selection of the manual’s diagnostic specifications.

For DPM-equipped models, the air-temperature sensor specification is 2,500 Ω ± 300 Ω at 20°C (68°F), accompanied by a resistance-versus-temperature table.

The SDI fuel-pump outlet pressure specification is 400 kPa (58 PSI), both during the start-button pressure check and with the engine cranking or running. The accompanying pressure-decay guidance adds context for locating leakage.

PDF Search, Navigation, and Page Contents

Text search and diagram access: Most service text supports PDF searching, but some illustration lettering has unusable text encoding, and the appended wiring sheets have no searchable text. Embedded bookmarks provide access to the contents and diagram sheets rather than every service chapter; the MAIN MENU bookmark has no usable destination. Small wiring labels require zooming, with the inspected wire codes and connector details readable when enlarged.

Supplied as one printable English PDF containing 436 pages: 2 opening cover/title pages, 26 pages of contents and introductory material, 403 pages of technical sections, 4 appended wiring-diagram sheets, and 1 back cover. All of these pages are included in the total.