BRP Ski-Doo REV-XP Shop Manual

Ski-Doo snowmobiles in the 2008 REV-XP family, including the GSX, MX Z, and Summit models, require precise technical adherence to factory standards for peak performance and structural integrity. This professional resource serves as the definitive guide for both Master Mechanics and specialized technicians tasked with the maintenance and overhaul of Rotax powerplants and the lightweight XP chassis. Utilizing this documentation ensures that adjustments remain within published factory specifications, maintaining both the power delivery and the emission certification standards mandated for these high-performance engines.

Logistical Value

• High-density technical data including exact torque values for every fastener class from M4 to M14.
• Explicit Loctite application protocols for threadlockers, primers, and gasket eliminators to ensure vibration-resistant assembly.
• Integration of specialized diagnostic flow charts for the 3D RAVE systems and SDI fuel delivery circuits.
• Detailed storage and preseason preparation charts to maintain mechanical longevity during seasonal transitions.

Asset Logistics

• Direct technical coverage for the full 2BPSBX5A9Y1000001 series and subsequent serial number ranges.
• Specialized instructions for reinforced lifting points located at the footrest to prevent steering column or frame damage.
• Comprehensive tool referencing for essential tasks, including the 529 035 829 engine removal hook and 529 035 830 spark plug lift ring.
• Sequential removal procedures for body panels, acoustic shields, and intake silencers to streamline workshop throughput.

Multi-Model Compatibility

• 500SS Architectures: Comprehensive maintenance and tuning data for the carbureted 593cc twin-cylinder engine.
• 600 HO SDI Systems: In-depth coverage of semi-direct injection components, fuel pressure regulators, and electronic mapping.
• 800R Power TEK Series: Critical procedures for the 797cc engine featuring 3D RAVE valves and vacuum-modulated solenoids.
• REV-XP Chassis Variants: Specific data for Ad

Componentry Diagnostics

• Engine Backfire: Spark plug analysis, ignition timing verification, and fuel passage inspection.
• Power Loss: RAVE valve operation, drive belt width tolerances, and compression testing.
• Overheating: Heat exchanger cleanliness, thermostat activation thresholds, and coolant flow verification.
• RER Malfunction: Idle speed calibration and START/RER switch electrical continuity.

Technical Architectures

• Rotax Propulsion: 593cc and 797cc liquid-cooled twin-cylinder 2-stroke platforms.
• Induction Logic: Mikuni TM-40 carburetors and 400 kPa high-pressure SDI circuitry.
• Lubrication Circuitry: Piston-type injection pumps with cable-synchronized delivery.
• Cooling Framework: Ethylene glycol 50/50 blend, 90 kPa radiator caps, and NTC temperature sensors.

Content Catalog

• Maintenance: Initial 10-hour inspection and seasonal storage/preparation protocols.
• Troubleshooting: Comprehensive technical guidelines for engine, drive, and electrical failures.
• Engine Overhaul: Top-end measurements, crankshaft alignment, and leak testing procedures.
• Chassis Systems: SC-5 rear suspension tuning, steering alignment, and drive axle servicing.

Fastener Torque Architectures

• M5 Grade 8.8: 5.0 Nm (44 lbf-in) for general componentry.
• M6 Grade 8.8: 10.0 Nm (89 lbf-in) for structural covers and supports.
• M8 Grade 8.8: 24.5 Nm (18 lbf-ft) for engine supports and primary mounts.
• M10 Grade 10.9: 61.0 Nm (45 lbf-ft) for high-stress frame and suspension joints.

FAQ

Verification of Rotax 800R 3D RAVE solenoid operation? Stop engine and check each solenoid operation using B.U.D.S. software if the RAVE valves do not move freely or fail to fully close during idle. Page 23 defines the specific flow chart sequence where technicians must rev the engine between 6200-7900 RPM to confirm the valves are partially opening as required.

Relationship between this shop manual and other BRP service volumes? 654 pages of technical data facilitate complete vehicle overhauls, but for certain thermal procedures, technicians are directed to external documentation. Refer specifically to the Operator's Guide for the mandated Vehicle Warm-up Procedure to prevent "four-corner" piston seizure during high acceleration.

Workshop compatibility for BRP REV XP series print-outs? Manual Information sections ensure that while illustrations represent typical construction, they facilitate the repair of all 2008 models including the GSX Limited, MX Z Adrenaline, and Summit X. Section 01 Maintenance Chart enables scheduled service tracking, explicitly referencing interrelated procedures across different engine types like the 500SS and 800R Power TEK.

Verification of 600 HO SDI fuel delivery schematic depth? 400 kPa (58 PSI) is the mandatory fuel pressure value required for the Fuel Delivery Diagnostic Flow Chart in Section 02. Action must be taken to replace the fuel pump module if the system fails to maintain this pressure or shows a fast pressure drop during the check valve verification.

Engine and drivetrain repair coverage for Ski-Doo REV-XP? 100 kPa (15 PSI) is the maximum pressure permitted for the Vehicle Cooling System Leak Test in Section 03. Ensures that no air bubbles appear in the antifreeze, which would indicate a failure in the cylinder head O-ring or cylinder base gasket. Tighten M8 Grade 8.8 engine support fasteners to exactly 24.5 Nm (18 lbf-ft) to maintain structural alignment during reinstallation.