2004 Ski-Doo Snowmobile Service Manual

Complete service manual covering diagnostic procedures, maintenance, and component service for 2004 Ski-Doo GSX, MX Z, and Summit models.

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Document Details

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Document Number / Seller:
25503 / Elizabeth Jackson
File Size:
30.66 MB
File Type:
PDF
Language:
`English`
Pages:
436
Printable:
Yes
Category:
Snowmobile
Last updated / verified
Jan 1, 2026

Models Covered & Key Technical Specifications

Functional Performance Field Manual: Ski-Doo GSX (E) LTD 600 HO SDI, MX Z (E) ADRENALINE 500 SS, MX Z (E) TRAIL 600 HO, SUMMIT ADRENALINE 800 HO, REV Series Snowmobile 2004 - Comprehensive Shop Manual Logic-Archive

Asset-ID: mmr2004_rev_a.pdf // Machine-Range: 2004 Bombardier REV Series // Reference-Category: Snowmobile

Assessment-Parameter Operational-Logic Calibration-Spec
Engine Identification Standard diagnostic procedures VIN verification and serial number location
Maintenance Schedule Periodic checks and replacements Based on mileage and time intervals
Troubleshooting Guide Symptom-based diagnostics Covers common engine issues and solutions
Component Removal Step-by-step instructions Detailed procedures for part disassembly
Tightening Torques Fastener specifications Torque values for various components
System Diagrams Electrical and fuel system layouts Visual representation of component connections

Coverage is segmented into systems, procedures, introductory information, a technical specifications table, and detailed prose descriptions. Torque specifications for critical components are documented to ensure structural integrity and prevent issues.

Professional Workshop Service Manual & Technical Specifications

Functional Performance Field Manual: Ski-Doo GSX (E) LTD 600 HO SDI, MX Z (E) ADRENALINE 500 SS, MX Z (E) TRAIL 600 HO, SUMMIT ADRENALINE 800 HO, REV Series Snowmobile 2004 - Comprehensive Shop Manual Logic-Archive

Asset-ID: mmr2004_rev_a.pdf // Machine-Range: 2004 Bombardier REV Series // Reference-Category: Snowmobile

Assessment-Parameter Operational-Logic Calibration-Spec
Engine Identification Standard diagnostic procedures VIN verification and serial number location
Maintenance Schedule Periodic checks and replacements Based on mileage and time intervals
Troubleshooting Guide Symptom-based diagnostics Covers common engine issues and solutions
Component Removal Step-by-step instructions Detailed procedures for part disassembly
Tightening Torques Fastener specifications Torque values for various components
System Diagrams Electrical and fuel system layouts Visual representation of component connections

This manual details engine management functions, including electronic fuel injection and ignition timing, essential for optimizing performance and emissions. It outlines procedures for air induction, fuel delivery systems, fuel rails, injectors, and throttle bodies, ensuring proper engine operation. The document provides step-by-step guidance for component inspection, adjustment, and replacement, covering critical systems like the magneto system, oil injection, liquid cooling, and rewind starter. Specific procedures for troubleshooting engine issues, transmission, brake systems, electrical systems, and suspension are included. It documents torque specifications for critical components to ensure structural integrity and prevent issues.

FAQ

What **essential** testing parameters are covered for the engine? keyboard_arrow_down

2500 ohms ± 300 ohms is the resistance range for the air temperature sensor at 20°C (68°F), with variations outlined for different temperatures.

Check the **correct** diagnostic procedures for the ignition system. keyboard_arrow_down

The ignition system is a digital inductive type, with a magneto generating AC current rectified to 13.4-15 volts, supported by a 12-volt battery for ECM operation.

What does the **documented** fluid capacity requirements entail? keyboard_arrow_down

15 mm (1/2 in) is the specified coolant level above the COLD LEVEL line after a refill procedure, ensuring proper system operation.

Reference the **precise** component identification for the magneto system. keyboard_arrow_down

The magneto is identified as a primary source of electrical energy with a 3-phase, delta wound stator on 18 poles, providing 480 watts of capacity.

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Reviews (2)

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New
I appreciated the quick email response with my download link. The manual is well-structured and easy to follow!
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New
This manual has been a lifesaver for my maintenance routine. The troubleshooting charts are particularly helpful!