Ski-Doo 2005 REV Series Shop Manual (MX Z, GSX, GTX, Summit, Renegade, Expedition)

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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 Build 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)
Technical Specifications
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Document Number / Seller:
25938 / Laura Scott
File Size:
118.90 MB
File Type:
PDF
Language:
English
Pages:
1429
Printable:
Yes
Category:
Snowmobile
Last updated / verified
Feb 9, 2026

Ski-Doo Manual Features & Content Preview

2005 Ski-Doo REV Series Shop Manual Features

  • 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 manufacturer publication 484 200 064, printed 2004
  • Contains 12 technical chapters, 47 individual subsections, comprehensive torque tables, wiring diagram legend, and 12 engine-specific diagnostic flow charts
  • Files are available immediately after purchase without shipping delay
  • Text-friendly OCR layer enables quick cross-reference lookups for parts or technical specs
  • This official 2005 Ski-Doo manual 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 Scope

This 2005 Ski-Doo REV Series shop manual provides detailed service information for the 2005 model year fleet. The documentation outlines maintenance requirements, troubleshooting guidelines, and technical parameters for major systems, including the fuel management system, engine power valve operation, electrical circuitry, and rear suspension geometry. The content covers everything from initial engine leak testing to transmission calibration and brake system service.

Specification Highlights

Technical data provided in this publication includes precise torque values for engine assembly and chassis components. The manual specifies a magneto flywheel nut torque of 105 Nm for fan-cooled engines and 125 Nm for liquid-cooled engines. Engine operating thresholds are documented with oil pressure reaching 450 kPa at 7250 RPM. Rocker arm shaft diameter is held to a 19.965 mm service limit for engine longevity. Electrical and fluid specifications cover chaincase oil volumes of 250 mL and standard spark plug gaps of 0.75 mm. This 1,429-page Ski-Doo REV Series service manual serves as the definitive reference for mechanics servicing the 2005 line-up, documenting all engine, chassis, and electronic management specifications.

Document Reference: Part No. 484 200 064, 2004 Publication Date

Manual FAQ, Purchase & Download Details

Is there a breakdown of components including exploded views for the suspension and drive systems? keyboard_arrow_down

Manual includes detailed exploded views and parts illustrations throughout the document to assist with the identification of component configurations.

Can I find technical reference tables that list engine measurements, fluid volumes, and tightening specs? keyboard_arrow_down

Document contains extensive specification tables that list technical reference values such as lubricant volumes, engine measurement limits, and tightening torque parameters. These charts provide the necessary data for the covered systems.

Does the manual contain specific tolerance charts or clearance references for engine components? keyboard_arrow_down

Engine chapters contain dedicated sections for technical measurements, which include reference data for cylinder taper, piston clearance, and ring end gaps. These chapters also provide service limit logic for components like rocker arm shafts and crankshaft deflection. You can refer to these sections to find the technical service thresholds provided for the REV Series engines.

Are wiring diagrams and connector pinout references included for the electrical systems? keyboard_arrow_down

Chapter 13 specifically covers comprehensive wiring diagrams, connector housing references, and terminal identification for the various electrical systems.

Which document identifies the publication details and model coverage for the 2005 REV Series? keyboard_arrow_down

2005 Ski-Doo REV Series Shop Manual is designated by publication number 484 200 064. It spans 1429 pages and provides comprehensive technical coverage for models ranging from the Expedition 550F to the various Summit and MX Z variants.

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