2006 Ski-Doo REV Series Expedition/GSX/GTX/MX Z/Summit Snowmobile Factory Service Manual (P/N MMR2005-059)
502 Pages • 57.34 MB • Instant, Printable PDF
Ski-Doo Models Covered & Key Technical Specifications
Models: Bombardier Summit 800 HO DPM (CG5A, CG5B), Expedition, GSX, GTX, Summit, MX Z, MX Z (Adrenaline)
Sub-models / Variants: 380F, 550F, 500 SS, 600 HO, 600 HO SDI, 800 HO, 800 HO DPM, 800 HO DPM Power Tek
Model Year: 2006
Model Numbers: CG5A, CG5B, CG5C, CG5D, CH5A, CH5B, CH5C, CH5D, CJ5A, CJ5B, CJ5C, CK5A, CK5B, CL5A, CL5B, CL5C, CP5A, CP5B, CP5C, CP5D, FJ5A, FJ5B, DG5B, DF5A, DC5A, DC5B, DB5A, DB5B, DD5A, DD5B, DE5A, DE5B, DA5A, DA5B, EM5A, EM5B, EL5A, EL5B, ED5A, ED5B, ED5C, EC5A, EC5B, EH5A, EH5B, EJ5A, EJ5B, EJ5C, EA5A, EA5B, EA5C, BR5A, BR5B, BR5C, BP5A, BP5B, BP5C, BF5A, BF5B, BF5C, BF5G, BF5H, BF5J, BF5L, BH5B, BH5C, BH5D, BH5A, BH5E, BC5A, BC5C, BC5F, BC5G, BC5H, BC5J, BC5K, BC5L, BC5M, BE5A, BE5B, BE5C, BE5G, BE5H, BE5J, BE5K, BE5L, BE5M, BE5N, BG5A, BG5B, BV5A, BV5B, BV5C, BV5D, BK5A, BK5B, BK5C, BK5D, BK5F, BK5G, BK5H, BK5J, BK5K, BK5L, BK5M, BK5N, BL5A, BL5B, BL5C, BL5G, BL5H, BL5J, BL5K, BL5L, BL5M, BW5C, BW5F, BW5G, BW5H, BW5J, BW5K, BW5L, BW5M, BX5C, BX5D, BX5E, BX5F, BX5G, BD5A, BD5B, BD5C, BD5G, BD5H, BD5J, BD5K, BD5L, BD5M, BB5A, BB5B, BB5C, BB5D, BB5F, BB5G, BB5H, BB5J, BB5K, BB5L, BB5M, BB5N, BS5C, BS5D, BS5E, BS5F, BS5G, BS5H, BS5J, BS5K, BS5L, BS5M, BS5N, BU5A, BU5B, BU5C, BU5D, CM5A, CM5B
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Piston/cylinder wall clearance (593 engine / 500 SS): 0.104–0.136 mm (0.004–0.005 in)
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Compression ratio: (11.2 ± 0.5):1 for 380F; (9.6 ± 0.5):1 for 550F; (12.00 ± 0.5):1 for 500 SS and 800 HO; (12.25 ± 0.5):1 for 600 HO and 600 HO SDI
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Cylinder head bolt torque (liquid-cooled engines): 29 N•m (21 lbf•ft)
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Crankshaft end-play: 0.10–0.30 mm (0.004–0.012 in)
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Fuel capacity: 40 L (10.6 US gal)
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Coolant system capacity: 4.59–5.17 L (1.21–1.37 US gal), depending on liquid-cooled model; not applicable to fan-cooled models
Ski-Doo Manual Features & Content Preview
This BRP factory service manual covers the 2006 Ski-Doo REV snowmobile lineup, including Expedition, GSX, GTX, MX Z, and Summit variants with 380F, 550F, 500 SS, 600 HO, 600 HO SDI, and 800 HO engines, including DPM and Power Tek versions. Its model identification table lists 166 model numbers.
Supplied as one 502-page PDF in English.
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Engine repair: Engine removal and installation, crankcase and crankshaft work, piston/cylinder inspection, RAVE valve service, oil injection, and fan/liquid cooling.
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Fuel delivery: VM and TM carburetor service, DPM testing, SDI fuel pressure checks, injector flow measurements, and throttle position sensor diagnostics.
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Electronic systems: Power Tek and SDI fault diagnosis, ECM/MPEM testing, DESS key functions, RER troubleshooting, ignition, charging, and electric starter repair.
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Drive system: TRA III and Bombardier Lite drive pulleys, HPV VSA driven pulleys, belt adjustment, chaincase service, hydraulic brakes, and track alignment.
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Suspension and steering: SC, SC-3, and SC-4 rear suspension service, HPG shock absorber rebuilding, front suspension inspections, and ski alignment.
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Maintenance and chassis: Maintenance schedules, storage and preseason preparation, body/frame checks, and model-specific specifications with tightening torques and wear limits.
Suited to technicians familiar with two-stroke snowmobile repair and equipped for the mechanical and BRP diagnostic procedures described.
Engine Repair and Maintenance
Maintenance charts distinguish initial, periodic, storage, and preseason work. Storage coverage includes engine fogging, fuel stabilization, and cooling-system service. Engine-specific data provides cylinder head warpage limits, ring end gap clearances, piston/cylinder tolerances, crankshaft deflection, and exhaust-manifold tightening specifications. General fastener torque tables accompany the engine-specific data. A leak-test verification flow chart supports diagnosis of liquid-cooled powerplants.
Top-end and bottom-end procedures distinguish 377/552 fan-cooled engines from 593, 593 HO, 593 HO SDI, and 793 HO liquid-cooled engines. The manual warns that incorrect cylinder base gasket thickness can cause detonation and severe engine damage.
Fuel Delivery and Electronic Diagnostics
Separate chapters explain Digital Performance Management (DPM), Power Tek engine management, and Semi-Direct Injection (SDI). Coverage includes Throttle Position Sensor (TPS) closed-throttle resets, fuel injector flow measurements, and sensor resistance checks. EMS fault-code tables and connector pin-out views help distinguish sensor faults from harness problems before considering Engine Control Module (ECM) replacement.
Power Tek and SDI diagnostics use the Vehicle Communication Kit (VCK) with B.U.D.S.; the Multi-Purpose Electronic Module (MPEM) programmer is not compatible with these systems. The Power Tek chapter specifies a separate supply harness and warns that connecting the VCK without it can damage the ECM.
Digitally Encoded Security System (DESS) and Rotax Electronic Reverse (RER) testing are covered alongside ignition timing, stator and magneto testing, and charging-system checks.
Drive System, Suspension, and Steering
Drive belt application charts and pulley exploded views support component identification and clutch repair. Procedures cover TRA III drive pulley calibration, driven pulley inspection, belt deflection, and pulley alignment. The manual reserves drive pulley repair for authorized Ski-Doo dealers.
Chassis coverage extends to track replacement, suspension arms and slider shoes, and High Pressure Gas (HPG) shock absorber servicing. Steering sections address linkage wear, ball joints, and ski alignment.
Because servicing spring-loaded assemblies and pressurized fuel systems presents hazards, review the relevant safety instructions and use the specified protective equipment.
File Format and Readability
The 502-page total comprises one cover, 21 contents and introduction pages, 474 numbered service pages, and six large-format wiring sheets. Wiring diagrams distinguish fan-cooled, carbureted manual/electric-start, SDI, and Power Tek arrangements.
Body text is searchable, but some figure labels and the internal labels on the two carburetor wiring sheets are not. Embedded bookmarks provide chapter and procedure navigation. Small wiring labels require zooming for practical reading.
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