2006 Ski-Doo REV Series GSX/GTX/MX Z/Summit Factory Service Manual (P/N MMR2005-059)
502 Pages • 57.34 MB • Instant, Printable PDF
Ski-Doo Models Covered & Key Technical Specifications
Models: Bombardier MX Z 600 HO (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 Years: 2006
Serial 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
Technical Data:
- Piston/cylinder wall clearance: 0.104–0.136 mm (0.004–0.005 in)
- Compression ratio: 9.5:1
- Cylinder head bolt torque: 29 N•m (21 lbf•ft)
- Crankshaft end-play: 0.10–0.30 mm (0.004–0.012 in)
- Fuel capacity: 30 L (7.9 US gal)
- Coolant system capacity: 3.5 L (0.92 US gal)
Ski-Doo Manual Features & Content Preview
- Official 502-page BRP OEM publication (P/N MMR2005-059) covering the 2006 Ski-Doo REV lineup, including GSX, GTX, MX Z, and Summit variants equipped with 380F 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 maintenance, chassis upkeep, electrical systems, and fuel-delivery troubleshooting.
Procedural Overview and Maintenance Charts
This service reference contains the foundational technical details for the 2006 snowmobile lineup. 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. 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. 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.
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