2008 Bombardier Ski Doo Rev XP GSX Limited 600 HO SDI GSX Limited 800R Power TEK GSX Limited Touring 600 HO SDI GSX Sport 500SS MX Z Adrenaline 600 snowmobile repair manual

Product Information

Table of Contents

Safety Notice

Introduction

• General Information
• Vehicle Identification Number
• Engine Serial Number
• Engine Emissions Information
• Tightening Torques
• Self-Locking Fasteners Procedure
• Locktite Application Procedure
• Manual Information

01. Maintenance

• Maintenance Chart
• Storage Procedures
  • Engine
  • Fuel System
  • Exhaust System
  • Battery
  • Chassis
  • Pre-Season Preparation
  • Engine
  • Fuel System
  • Exhaust System
  • Chassis

02. Troubleshooting

• Technical Guidelines
  • Engine
  • Fuel and Oil Systems
  • Engine Emissions
  • Electrical
  • Rear Suspension
  • Front Suspension
• Flow Charts
  • Engine Condition Flow Chart
  • Engine Cranks - Does Not Start Flow Chart

03. Engine

• Engine Removal/Installation
  • Procedures
• Engine Leak Test
  • Procedures
• Engine Mount
  • Inspection
• Engine Related Tests
  • Procedures
• Engine Measurement
  • Cylinder Head Warp/Average
  • Cylinder Warp
  • Cylinder Out of Round
  • Cylinder/Piston Clearance
  • Piston/Groove Clearance
  • Ring End Gap
  • Connecting Rod Deflection
  • Connecting Rod Big End Axial Play
  • Crankshaft Alignment
• Crankcase Oil Greasing Volume Measurement
  • Procedures
• Air Pump System
  • Air Pump
  • Secondary Air Intake Silencer
  • Secondary Air Intake Silencer Bracket

04. Air Intake System

• General
  • Procedures
• Sensor
  • Intake Air Temperature Sensor (IATS)
• Secondary Air Intake
  • Procedures
• Air Silencer
  • Procedures
• Reed Valve
  • Procedures

05. Electric Starter

• General
  • Procedures
  • Starting System Test
  • Electric Starter Motor

06. Rewind Starter

• Rewind Starter
  • Procedures

07. Lubrication System

• General
  • Inspection
• Procedures
  • Injection Oil System Leak Test
  • Bleeding Procedure
• Oil Injection Pump
  • Procedures

08. Cooling System

• General
  • Inspection
  • Coolant System Leak Test
• Maintenance
  • Coolant Replacement
• Procedures
  • Coolant Tank
  • Heat Exchanger
  • Radiator
  • Coolant Temperature Sensor (CTS)

09. Magneto System

• General
  • Procedures
  • Magneto Flywheel
  • Stator
  • Crankshaft Position Sensor (CPS)
• Charging Coil
  • Procedures

10. Top End (SDI)

• General
  • Procedures
  • Cylinder and Reed Valves
  • Crankcase and Exhaust Valves
  • Cylinder Head Cover
  • Cylinder Head

11. Top End (RFI)

• General
  • Procedures
  • Cylinder and Reed Valves
  • Crankcase and RAVE Valves
  • Cylinder Head Cover
  • Cylinder Head

12. Bottom End (SDI)

• General
  • Procedures
  • Crankshaft/Counterbalance Shaft

13. Bottom End (RFI)

• General
  • Procedures
  • Crankshaft/Counterbalance Shaft

14. Engine Management System

• Engine Management (SDI/DI)
• Engine Management Module (ECM)
  • Overview
• Diagnostic and Communication Tools
  • B.U.D.S. Software
• Monitoring System/Fault Codes
  • Monitoring System
  • Fault Codes

15. Fuel System

• Fuel Tank/Fuel Pump
  • General
  • Inspection
  • Procedures
    • Fuel Pump Test
    • Fuel Pressure Test
    • Fuel Pressure Regulator
    • Fuel Pump Fuel Filter
    • Fuel Tank Level Sensor
• The Carburetors
  • Procedures
    • Carburetor Synchronization
    • Carburetor Air Screw Adjustment
• DPM System
  • Procedures
    • Atmospheric Pressure Sensor (APS)
• Engine Fuel Injection (SDI)
  • General
    • System Inspection
  • Procedures
    • Fuel Rail Assembly
    • Fuel Injectors
    • Fuel Pressure Test
    • Fuel Pressure Regulator
    • Fuel Pump Module

16. Electrical System

• General System
  • General
• Procedures
  • Electrical System Testing Sequence
  • Adjustment
• Charging System
  • General
  • Inspection
  • Procedures
    • Charging System Testing Sequence
    • Battery Charging
• Starting System
  • General
  • Inspection
  • Procedures
    • Starter Relay Test
    • Battery Charging

17. Body/Frame

• General
  • Procedures
    • Frame Inspection
    • Ski Removal/Installation
    • Suspension Removal/Installation
    • Track Removal/Installation
    • Body Panel Removal/Installation
• Electrical System
  • Procedures
    • Headlight Adjustment

18. Suspension System

• General
  • Procedures
    • Front Suspension Removal/Installation
    • Rear Suspension Removal/Installation

19. Track/Drive System

• General
  • Procedures
    • Track Adjustment
    • Drive Belt Adjustment

20. Brake System

• General
  • Procedures
    • Brake Fluid Replacement
    • Brake Pad Inspection/Replacement
    • Brake Lever Adjustment

21. Technical Specifications

• Engine
• Electrical System
• Fuel System
• Drive System
• Track System
• Brake System
• Suspension System
• Lubrication System
• Cooling System
• Ignition System

22. Appendices

• Torque Specifications
• Technical Data
• Conversion Tables
• Service Data
• Index

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