2006 Ski-Doo REV Series GSX/GTX/MX Z/Summit Factory Service Manual (P/N MMR2005-059)

• Official 502-page BRP OEM PDF publication (P/N MMR2005-059) covering the 2006 Ski-Doo REV lineup, including Expedition, GSX, GTX, MX Z, and Summit variants equipped with 380F, 500 SS, and 600 HO through 800 HO Power Tek engines.
• Documents critical maintenance and engine diagnostic data, detailing torque sequences for M4 through M14 fasteners along with specific tightening values.
• Features specialized leak test verification flow charts for liquid-cooled powerplants.
• Covers 108 model configuration variants defined by unique chassis and build numbers like CG5A, DB5A, and BD5M.
• Serves as the factory-standard reference for deep engine repair, chassis upkeep, electrical systems, and fuel-delivery troubleshooting.
• Provides extensive coverage for the Digitally Encoded Security System (DESS), Rotax Electronic Reverse (RER), Semi-Direct Injection (SDI), Digital Performance Management (DPM), Engine Control Module (ECM), Multi-Purpose Electronic Module (MPEM), Vehicle Communication Kit (VCK), and Throttle Position Sensor (TPS).
• Details the teardown and assembly of specific platform components, including TRA III drive pulleys, Bombardier Lite drive pulleys, HPV VSA driven pulleys, SC-3 rear suspensions, SC-4 rear suspensions, High Pressure Gas (HPG) shock absorbers, RAVE valves, VM carburetors, and TM carburetors.

Procedural Overview and Maintenance Charts

This PDF service reference contains the foundational technical details for the 2006 snowmobile lineup, providing a distinct shop-floor advantage by supplying the exact mechanical tolerances, resistance values, and pin-out data needed to resolve complex issues without relying on dealer networks. It breaks down essential maintenance schedules for 10-hour, seasonal, and preseason tasks. The documentation covers complete storage procedures, outlining factory-recommended engine fogging, cooling system flushing, and fuel stabilization methods for long-term protection. Chapters encompass detailed workflows for the removal, installation, and inspection of REV-series engines, alongside thorough steering, suspension, and body frame assessments. To help technicians avoid expensive dealership labor rates, the manual includes comprehensive step-by-step instructions for tasks like TRA III drive pulley calibration, TPS closed throttle resets using B.U.D.S., fuel injector flow measurements, and High Pressure Gas (HPG) shock absorber servicing. Because servicing high-tension snowmobile suspensions and pressurized fuel networks presents inherent hazards, always review the designated safety parameters and wear appropriate protective gear before initiating a teardown.

Technical Specifications and Diagnostics

Engine-specific data sections provide the necessary baseline values for rebuilding and tuning. You will find exact tolerances for cylinder head warpage limits, ring end gap clearances, and crankshaft deflection. As an example of the technical depth, cylinder head bolt torque values are documented at 29 N•m (21 lbf•ft) following a specific criss-cross sequence, while intake manifold bolt torque is specified at 11 N•m (97 lbf•in) for 593 HO/793 HO engines and 22 N•m (16 lbf•ft) for 377/552 variants. The electrical system section maps out pinouts and resistance values crucial for accurate stator and magneto testing, supplemented by complete wiring diagrams. To further accelerate diagnostics and prevent trial-and-error component swapping, the manual features EMS fault code tables, drive belt application charts, connector pin-out views, and component exploded views. Additionally, diagnostic charts help isolate common faults like irregular idle or performance loss, referencing the DPM and SDI management systems directly to streamline shop-floor troubleshooting.