Ski-Doo 2005 REV MX Z, GSX, GTX, Summit, Renegade, Expedition Shop Manual (P/N 484 200 064)
1429 Pages • 118.90 MB • Instant, Printable PDF
Ski-Doo Models Covered & Key Technical Specifications
Models: Expedition 550F, GSX 380F, GSX 550F, GSX 500 SS, GSX 600 HO, GSX 600 HO SDI, GSX 800 HO DPM Power Tek, GTX 380F, GTX 550F, GTX 500 SS, GTX 600 HO, GTX 600 HO SDI, GTX 800 HO DPM Power Tek, MX Z 380F, MX Z 550F, MX Z 500 SS, MX Z 600 HO, MX Z 600 HO SDI, MX Z 800 HO, MX Z 800 HO DPM Power Tek, MX Z Adrenaline 800 HO, Summit 550F, Summit 800 HO DPM
Sub-models / Variants: Fan-Cooled, Liquid-Cooled, Power Tek, SDI, DPM, Adrenaline
Model Years: 2005
Serial Numbers: 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, CG5A, CG5B, CG5C, CG5D, CH5A, CH5B, CH5C, CH5D, CJ5A, CJ5B, CJ5C, CK5A, CK5B, CL5A, CL5B, CL5C, CP5A, CP5B, CP5C, CP5D
Technical Data:
- Engine Oil Pressure: 450 kPa (65 PSI) at 7250 RPM
- Magneto Flywheel Nut Torque (Fan-Cooled): 105 Nm (77 ft.lb)
- Magneto Flywheel Nut Torque (Liquid-Cooled): 125 Nm (92 ft.lb)
- Rocker Arm Shaft Diameter Service Limit: 19.965 mm (0.7860 in)
- Spark Plug Electrode Gap: 0.75 mm (0.030 in)
- Chaincase Oil Volume: 250 mL (8.5 fl. oz)
Ski-Doo Manual Features & Content Preview
- Covers 2005 Ski-Doo REV Series models, including the 380F, 550F, 500 SS, 600 HO, 600 HO SDI, and 800 HO DPM Power Tek engine configurations across the Expedition, GSX, GTX, MX Z, and Summit lineups.
- Official 1,429-page manufacturer publication (Part No. 484 200 064, printed 2004).
- Contains 12 technical chapters, 47 individual subsections, comprehensive torque tables, wiring diagram legends, and 12 engine-specific diagnostic flow charts.
- Acts as the primary reference for the REV Series platform, offering critical assembly data for both fan-cooled and liquid-cooled engine variants.
Technical Documentation Overview
This shop manual provides the exact service information needed to maintain the 2005 fleet. It outlines factory requirements, troubleshooting guidelines, and technical parameters for every major system. Sections break down the fuel management system, engine power valve operation, electrical circuitry, and rear suspension geometry. Reviewing the safety protocols and proper lifting procedures outlined in the introductory chapters is essential before performing heavy maintenance to prevent personal injury or chassis damage. Beyond routine service, the content spans advanced diagnostics—from initial engine leak testing to transmission calibration and complete brake system overhauls.
Specification Highlights
Having the right tolerances makes or breaks an engine rebuild. The technical data in this publication delivers precise torque values for engine assembly and chassis components. For instance, the magneto flywheel nut torque is 105 Nm on fan-cooled engines and requires 125 Nm for liquid-cooled variants. Operating thresholds are clearly documented. Oil pressure specs hit 450 kPa at 7250 RPM. Component wear is strictly defined, with the rocker arm shaft diameter held to a 19.965 mm service limit for maximum longevity. The documentation also locks down routine electrical and fluid numbers, such as chaincase oil volumes of 250 mL and standard spark plug gaps of 0.75 mm.
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