Ski-Doo 2005 REV MX Z, GSX, GTX, Summit, Renegade, Expedition Shop Manual (P/N 484 200 064)

• 1,429-page English PDF manual set containing three BRP factory publications printed in 2004: REV Series P/N 484 200 064 (507 PDF pages), RT Series P/N 484 200 066 (342 pages), and Tundra/Skandic/Expedition P/N 484 200 062 (580 pages).
• Exact 2005 model coverage spans REV Expedition, GSX, GTX, MX Z, and Summit models; RT Mach Z and Summit Highmark/Highmark X models; plus Tundra, Skandic LT/WT/SWT/WT LC/SUV, Expedition TUV 600 HO SDI, and Expedition TUV V-1000 configurations, with factory model-number tables for the covered builds.
• Engine repair content includes leak testing and verification flow charts, engine removal and installation, top-end and bottom-end disassembly, crankshaft and cylinder measurement, cooling-system service, oil-injection bleeding and adjustment, and V-1000 4-TEC lubrication, valve-train, timing, and crankcase work.
• Power Tek, SDI, 2-TEC, and 4-TEC engine-management chapters cover B.U.D.S. and VCK diagnostics, EMS fault codes, ECM and wiring-harness checks, injector and fuel-pump testing, sensor inspection, DESS, RER, knock control, and electronically controlled RAVE systems.
• Driveline and chassis procedures address Bombardier Lite, Comet 102C, TRA III/IV/V, Formula RER/VSA-R, and HPV Roller/VSA pulley systems, along with chaincases, the utility-model three-speed gearbox, mechanical and hydraulic brakes, track service, and SC, SC-3, SC-4, Torque Reaction, Articulating Slide, and SUV rear suspensions.
• Wiring support includes connector-location legends, terminal-removal and crimping procedures, pin-location views, model-specific schematics, diagnostic charts, exploded assemblies, torque tables, fluid-capacity data, wear limits, clearances, and electrical test specifications.

Exact Model and Engine Coverage

The REV volume is not a generic 2005 Ski-Doo book. Its introduction ties every covered machine to a factory model number and engine package, beginning with the Expedition 550F FJ5A/FJ5B and continuing through the GSX, GTX, MX Z, MX Z Adrenaline, and Summit configurations. The engine chapters align the retail designations with the Rotax families used in the repair procedures: 380F/377, 550F/552, 500 SS/593, 600 HO/593 HO, 600 HO SDI/593 HO SDI, and 800 HO/793 HO, including DPM Power Tek versions.

The RT publication is limited to the 995 SDI platform: Mach Z AB5A–AB5C, Summit Highmark CD5A–CD5C, and Summit Highmark X CA5A–CA5D. The utility volume covers Tundra 280F, Skandic LT and LT E 440F, Skandic WT/SWT/SUV 550F, Skandic WT LC and SUV 600, Expedition TUV 600 HO SDI, and Expedition TUV V-1000. Its coverage table also distinguishes Canada and USA builds, colors, electric-start status, and reverse equipment where applicable.

Factory Repair and Diagnostic Depth

Each engine family receives its own exploded views, service-tool lists, inspection points, and assembly data rather than being grouped into one generic engine chapter. Two-stroke coverage runs from pressure and leak testing through piston, cylinder, RAVE, reed-valve, crankshaft, magneto, cooling, rewind-starter, and oil-pump repair.

The utility manual adds a separate V-1000 4-TEC section covering engine oil-pressure testing, pressure and suction oil pumps, the pressure regulator, rocker arms, chain tensioner, decompressor, camshaft timing gear, timing chain, valves, pistons, crankshaft and drive gears, and crankcase repair.

Fuel and engine-management coverage is equally configuration-specific. Carbureted models include VM- and TM-type carburetor identification, cleaning, inspection, synchronization, choke and throttle adjustment, DPM system testing, DPM manifold testing, and diaphragm-pump checks. SDI, Power Tek, 2-TEC, and 4-TEC chapters provide diagnostic modes, fault-code tables, connector pinouts, fuel-rail and injector checks, ECM replacement, and testing for TPS, CPS, ATS, CTS, APS, EGTS, and knock-sensor circuits. The RT volume also contains an E-RAVE dynamic test and an electric fuel-pump diagnostic flow chart.

Representative factory tools are identified by description and part number, including the vacuum/pressure pump kit P/N 529 021 800, magneto puller P/N 529 035 547, engine removal hook P/N 529 035 829, piston circlip installer P/N 529 035 686, and connector crimping tool P/N 529 035 909 with crimper die P/N 529 035 906.

Drivetrain, Suspension, and Brake Work

The driveline chapters go well beyond routine belt replacement. They cover drive-belt identification and height, drive and driven pulley removal, internal disassembly, inspection, bushing replacement, calibration, installation, and pulley alignment. Chaincase work includes oil service, drive-chain adjustment, sprocket and bearing inspection, removal, and reassembly. The utility publication also contains dedicated repair material for its three-speed transmission.

Brake coverage includes hydraulic master-cylinder and caliper service, brake-pad and disc inspection, fluid replacement, and bleeding, plus mechanical-brake procedures on the applicable utility models.

Rear and front chassis chapters separate the different suspension designs instead of treating them as interchangeable. SC, SC-3, SC-4, Torque Reaction, Articulating Slide, and SUV systems receive their own axle, spring, shock, arm, slider-shoe, stopper-strap, ride-adjustment, removal, installation, and lubrication procedures. Steering-system disassembly, ski alignment, camber inspection, front-suspension repair, frame welding, frame-component replacement, and plastic-body repair are also addressed.

Wiring Diagrams and Technical Data

The wiring material provides more than circuit drawings. It explains wire-color notation, connector-area numbering, housing references, terminal-cavity locations, symbol legends, waterproof and multilock connector service, terminal crimping, and harness-routing precautions.

Named schematics include 2005 REV Fan Cooled, 2005 REV SDI, 2005 REV Power Tek Electric Start, 2005 Mach Z RT/Summit RT, 2005 Tundra R, and 2005 Expedition V-1000 TUV. Separate diagrams are also supplied for other manual-start, electric-start, carbureted, SDI, and utility configurations covered by the set.

Technical-data sections are divided by fan-cooled, liquid-cooled, SDI, RT, and utility applications. They supply component-specific torque tables, clutch and belt calibration data, ignition and spark-plug specifications, carburetor settings, electrical test values, approved fluids and capacities, dimensional tolerances, adjustment data, and inspection wear limits.

Repair Cautions and Scope

Several details show why the correct engine section matters during repair. The top-end instructions tie base-gasket thickness to combustion-chamber volume and require a fresh mono-hook circlip after a failed installation attempt; getting either item wrong can lead to detonation, severe engine damage, or reduced circlip retention. The magneto section separately warns that silicone sealant can corrode electrical contacts and that dielectric grease can damage the seals in Deutsch waterproof housings.

This set applies only to the model numbers listed in the three manual introductions. It is not blanket coverage for every 2005 Ski-Doo, and the Operator’s Guides, Parts Catalogs, and later Service or Warranty Bulletins referenced by BRP are separate publications.

Engine lifting, fuel-pressure release, brake work, battery isolation, and rotating-track procedures should be handled under the safety instructions in the applicable volume by technicians with the required tools and experience.