Ski-Doo REV Series Service Manual (2006): GSX, GTX, MX Z, Summit, Expedition, and Fan / Liquid Cooled Models Snowmobile 2006

Ski-Doo REV Series Service Manual - 2006 Edition

This official service manual provides the authorized engineering benchmarks and diagnostic methodologies required to maintain the 2006 REV Series fleet. It integrates high-precision calibration data with specialized recovery procedures, including the critical 10-hour or 500 km (300 mi) dealer-level inspection protocols vital for initial engine break-in and long-term drivetrain reliability. Utilizing the specified ISOFLUX grease (P/N 293 550 021) for PTO-side ball bearing lubrication is mandatory to prevent thermal breakdown and ensure maximum crankshaft uptime.

Technical Applicability & Model Configurations

Rotax Fan-Cooled (FC) Platform

• 377 Engine Series: Expedition 380F (Model FJ5A, FJ5B), GSX 380F (Model DG5B), GTX 380F (Model EM5A, EM5B), MX Z 380F (Model BR5A, BR5B, BR5C).
• 552 Engine Series: Expedition 550F (Model DF5A), GSX 550F (Model DC5A, DC5B), GTX 550F (Model EL5A, EL5B), MX Z 550F (Model BP5A, BP5B, BP5C), Summit 550F (Model CM5A, CM5B).

Rotax Liquid-Cooled (LC) Platform

• 593 Engine Series (500 SS): GSX 500 SS (Model DB5A, DB5B), GTX 500 SS (Model ED5A, ED5B, ED5C), MX Z 500 SS (Model BF5A, BF5B, BF5C, BF5G, BF5H, BF5J, BF5L, BH5B, BH5C, BH5D, BH5A, BH5E).
• 593 HO Engine Series: GSX 600 HO (Model DD5A, DD5B, DE5A, DE5B), GTX 600 HO (Model EC5A, EC5B), MX Z 600 HO (Model 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).
• 593 HO SDI Engine Series: GSX 600 HO SDI (Model DA5A, DA5B), GTX 600 HO SDI (Model EH5A, EH5B, EJ5A, EJ5B, EJ5C), MX Z 600 HO SDI (Model 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).

High-Output Performance Platform

• 793 HO Engine Series: MX Z (Adrenaline) 800 HO (Model BD5A, BD5B, BD5C, BD5G, BD5H, BD5J, BD5K, BD5L, BD5M), Summit 800 HO DPM (Model CG5A, CG5B, CG5C, CG5D, CH5A, CH5B, CH5C, CH5D, CJ5A, CJ5B, CJ5C, CK5A, CK5B, CL5A, CL5B, CL5C, CP5A, CP5B, CP5C, CP5D).
• 793 HO Power Tek Engine Series: GSX 800 HO DPM Power Tek (Model DA5A, DA5B), GTX 800 HO DPM Power Tek (Model EA5A, EA5B, EA5C), MX Z 800 HO DPM Power Tek (Model 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).

Operational Performance Benchmarks

• Powertrain Integrity: Provides exact engine leak test procedures at 34 kPa (5 PSI) for 3 minutes to confirm crankcase sealing and check-valve functionality.
• System Diagnostics: Features comprehensive fault code mapping for 2-TEC SDI and Power Tek Engine Management Systems (EMS) to eliminate parasitic electrical issues.
• Transmission Optimization: Details TRA III and Bombardier Lite drive pulley calibrations including ramp indexing and spring tension settings for specific altitude compensations.
• Ride Control Dynamics: Outlines maintenance and inspection for SC, SC-3, and SC-4 rear suspension configurations, including HPG take-apart shock absorber nitrogen recharging protocols.

Document Metadata

• Manual Type: Service Manual
• Total Pages: 495
• Manufacturer: Bombardier Recreational Products Inc. (BRP)
• Document Version: REV 2006_v.2.0.1

Critical Component Calibration Data

• Fastener Torque Management: M8 fasteners utilize a standardized 24.5 Nm (18 lbf-ft) for 8.8 grade hardware, while high-stress M10 10.9 grade fasteners require 61 Nm (45 lbf-ft) to maintain structural integrity.
• Cylinder Architecture: Wear limits for cylinder out-of-round are strictly capped at 0.08 mm (0.003 in) for all liquid-cooled engines to prevent combustion bypass.
• Drive System Tolerances: Drive belt wear limits are defined by minimum widths (e.g., 34.9 mm for 600 HO SDI) to maintain specified engagement RPM.
• Ignition Timing Benchmarks: Static timing for the 593 engine is set at 2.49 mm (.098 in) BTDC to optimize flame propagation and prevent detonation.

Schematic & Visual Navigation Systems

• System Architecture Exploded Views: Detailed isometric drawings define part relationships and include integrated Loctite application markers (e.g., Loctite 243 for engine support bolts).
• Electronic Mapping: Full-color wiring diagram legends identify wire color codes, connector housing locations, and Engine Control Module (ECM) pin-out configurations.
• Diagnostic Flow Charts: Visual troubleshooting logic for Engine Leak Verification and Ignition System Diagnostics ensures systematic fault isolation.

Table of Contents

• 01 Maintenance: Maintenance Chart, Storage, Preseason Preparation.
• 02 Troubleshooting: Engine, Fuel/Oil Systems, Drive/Brake Systems, Electrical, Steering/Suspension.
• 03 Engines: Leak Test, Exhaust, Removal/Installation, Magneto, Top End, Bottom End, Engine Measurement, Cooling System, Rewind Starter, Oil Injection.
• 04 Fuel System: Fuel Tank/Pump, Carburetors (VM and TM Types), DPM System.
• 05 Engine Management (Power Tek): Overview, Diagnostic Procedures, Component Inspection.
• 06 Engine Management (SDI): Operating Principles, VCK Communication, Fuel Delivery.
• 07 Electrical System: Ignition, Charging, Starting System, Accessories.
• 08 Drive System: Drive Belt, Drive Pulley (TRA III/Lite), Driven Pulley (HPV/Formula), Pulley Alignment, Brake, Chaincase, Drive Axle, Track.
• 09 Rear Suspension: SC, SC-3, and SC-4 Configurations, Shock Absorber Servicing.
• 10 Steering/Front Suspension: Steering System, Front Suspension (R.A.S. A-Arm).
• 11 Body/Frame: Body Components, Frame Welding/Repair.
• 12 Technical Data: Fan Cooled, Liquid Cooled, and SDI Specifications.
• 13 Wiring Diagram: Legends, Symbols, and Full System Diagrams.

Operational Limits & Fluid Specifications

• Engine Lubrication: XP-S Mineral Injection Oil is specified for high-performance Rotax 2-stroke engines to minimize RAVE valve carbonization.
• Drivetrain Lubrication: XP-S Synthetic Chaincase Oil (P/N 413 803 300) is required for all liquid-cooled models to withstand high-shear gearbox loads.
• Braking Medium: Only DOT 4 GTLMA or SRF (High-Performance) fluid is authorized for the hydraulic brake system to prevent vapor lock.
• Thermal Regulation: Cooling systems must be filled with a 50/50 premix of distilled water and ethylene glycol designed for aluminum-block engines.