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

Bombardier Ski-Doo REV Series Shop Manual - 2004 Edition

This technical publication provides authorized factory procedures for the maintenance, repair, and overhaul of the REV chassis platform. Precise adherence to the specific crimping procedure for terminal tabs—ensuring no stray wire strands remain outside the terminal—is critical to prevent intermittent electrical faults and ensure the integrity of the 600 HO SDI and 800 HO electronic systems.

REV Chassis Configuration & Engine Applicability

500 SS Engine Platforms (593 Engine Type)

• MX Z Trail, MX Z Adrenaline, GSX Sport (Including 1+1 and Electric Start variants)

600 HO Engine Platforms (593 HO Engine Type)

• MX Z Trail, MX Z Adrenaline, MX Z Renegade, MX Z Renegade X, MX Z X, GSX Sport, Summit Adrenaline, Summit X (Including 1+1 and Electric Start variants)

600 HO SDI Engine Platforms (593 HO SDI Engine Type)

• MX Z Adrenaline, MX Z Renegade X, MX Z X, GSX Sport, GSX Limited (Including 1+1 and Electric Start variants)

800 HO Engine Platforms (793 HO Engine Type)

• MX Z Adrenaline, MX Z Renegade, MX Z Renegade X, MX Z X, GSX Limited, Summit Sport, Summit Adrenaline, Summit X, Summit Highmark, Summit Highmark X (Including 1+1 and Electric Start variants)

Asset Protection & Operational Reliability

• Engine synchronization and RAVE valve adjustments ensure peak volumetric efficiency and prevent premature piston seizure.
• Diagnostic flowcharts for the Semi-Direct Injection (SDI) systems enable rapid fault isolation within the Siemens VDO engine management architecture.
• Chassis alignment specifications for the SC-10 III and 1+1 rear suspensions maintain structural geometry and rider safety during high-load operation.

Document Identification & Metadata

• Publication Number: 484 200 056
• Total Page Count: 430 Pages
• Primary Engine Types: 593, 593 HO, 593 HO SDI, 793 HO

System Architecture & Factory Calibration Benchmarks

Engine assembly requires strict adherence to multi-stage torque sequences for cylinder head and crankcase bolts to maintain combustion chamber sealing. High-resolution data tables provide exact specifications for carburetor jetting based on altitude, spark plug gap tolerances, and oil pump cable adjustment settings for varying environmental conditions.

Schematic Interpretation & Wiring Logic

Electrical troubleshooting is supported by full-color wiring diagrams covering the manual start, electric start, and SDI configurations. These visual aids detail the logic of the DESS (Digitally Encoded Security System) and the routing of the main harness across the REV chassis to prevent vibration-induced insulation wear.

Technical Table of Contents

• Introduction and Service Tools
• Maintenance Schedule and Lubrication
• Engine Management and Troubleshooting
• Fuel System (Carbureted and SDI)
• Engine Top End and Bottom End Overhaul
• Cooling System
• Electrical System and Wiring Diagrams
• Drive System and Transmission
• Brake System
• Steering and Front Suspension
• Rear Suspension (SC-10 III / 1+1)
• Chassis and Bodywork

Critical Tolerances & Fluid Specifications

Engine coolant must meet the requirements for aluminum radiators, typically utilizing a 50/50 ethylene-glycol mixture. Specialized lubricants, including XPS synthetic oil for the RAVE valves and specific Loctite grades for drivetrain fasteners, are mandated to meet factory durability standards. Track tension and alignment must be verified against the specific deflection measurements provided for 121-inch, 136-inch, and 144-inch configurations.