2008 BRP Ski-Doo REV-XP Shop Manual (OEM)

This 551-page PDF is the official BRP factory shop manual for 2008 Ski-Doo REV-XP snowmobiles equipped with the 500SS, 600 HO SDI, and 800R Power T.E.K. engines. Factory coverage includes the GSX Limited 600 HO SDI and 800R Power T.E.K., GSX Limited Touring 600 HO SDI, and GSX Sport 500SS; MX Z Adrenaline, Renegade, Renegade X, and X models in 600 HO SDI and 800R Power T.E.K. versions; MX Z TNT and Trail 500SS; and Summit Everest and Summit X 800R Power T.E.K. models.

Compared with a generic Ski-Doo repair manual, this factory reference provides original BRP technical data, diagnostic flow charts, wiring diagrams, fault-code tables, OEM service-tool references, inspection limits, torque values, and model-specific specifications for the 2008 REV-XP platform. That distinction matters when a repair depends on the correct 593 or 797 engine family, ECM and sensor configuration, drive-pulley calibration, connector type, or chassis setup.

What's Inside the Manual

This guide details the REV-XP systems from scheduled maintenance through shop-level diagnosis and repair. Maintenance coverage includes the factory maintenance chart, storage procedures, and preseason preparation for the engine, fuel, electrical, drive/brake, chassis, and vehicle systems.

Engine coverage goes well beyond routine service. It includes engine removal/installation and leak testing; cylinder-head warpage, cylinder taper and out-of-round, cylinder/piston clearance, ring-to-piston-groove clearance, ring end gap, crankshaft deflection and alignment, connecting-rod big-end axial play, and combustion-chamber volume measurement. Separate sections cover the air filter and primary/secondary air intake silencers, tuned pipe, exhaust manifold, muffler and EGTS, rewind starter, oil reservoir/filter/injection pump/nozzles, cooling system, and magneto/stator/CPS/trigger-coil assemblies.

The 593 and 797 engine sections are treated separately where their hardware and test procedures differ. The 593 top-end coverage includes the reed valves, E-RAVE solenoid, RAVE/E-RAVE valves, cylinder head, cylinder, and piston. The 797 section covers its reed valves, 3D RAVE valves, check valves and solenoids, cylinder head, cylinder block, and piston, followed by dedicated bottom-end coverage for the water/oil pump shaft, crankcase, and crankshaft.

Engine-management and fuel-system chapters cover ECM functions for the 500SS, 800R, and 600 HO SDI, MPI/MPI-2 communication tools, B.U.D.S. software, monitoring and fault codes, fuel-tank and fuel-pump systems, TM carburetors, the 800R DPM system, and 600 HO SDI semi-direct injection. Sensor and control coverage includes TPS, CPS, ATS, APS, CTS, EGTS, knock sensor, fuel injectors, throttle body, DPM solenoid, and related ECM circuits. The B.U.D.S. material documents the BRP diagnostic workflow and interface references; the service manual itself does not replace the required diagnostic interface or software.

Electrical coverage includes ignition, charging and starting systems, the Digitally Encoded Security System (DESS), Rotax Electronic Reverse (RER), lighting, gauges and accessories. Connector sections identify Sumitomo, Deutsch, Packard, AMP Multilock, AMP 8-circuit, and Kostal ECM connectors before the dedicated wiring-diagram section and wiring diagram legend.

For the drivetrain and chassis, the manual covers the drive belt, drive pulley, driven pulley and countershaft, chaincase, brake hydraulics, drive axle, track, traction-enhancing products, front and rear suspension, shock absorbers, steering alignment, body panels, and frame components. Technical specification sections are separated for 500SS, 800R, and 600 HO SDI models rather than presenting one generic set of values.

Factory step-by-step procedure coverage includes engine removal and installation, engine leak testing, top-end and bottom-end service, RAVE/E-RAVE and 3D RAVE service, oil-injection pump and injection-nozzle service, fuel-pump pressure and leak testing, cooling-system leak testing and coolant replacement, drive-pulley and driven-pulley service, chaincase service, brake-system service, track work, shock absorber rebuild, and steering alignment. These are the kinds of jobs often referred to a dealer or specialist because correct specifications, test values, tooling, and model-specific disassembly references matter. For an experienced DIY mechanic or independent technician, the specific advantage of this manual is having those references tied to the actual REV-XP engine and system being worked on.

One common repair trap is carrying 593 RAVE data or procedures into a 797/3D RAVE job; the manual separates these systems because the hardware and diagnostic logic are different. A no-start, poor-running, or power-loss complaint can involve fuel pressure, ECM inputs, DESS, ignition, sensor circuits, or SDI/DPM controls rather than one isolated component. Driveability symptoms can also overlap with belt condition, pulley calibration, chaincase condition, track setup, and chassis alignment, making the model-specific limits important before repair decisions are made.

Technical Specification Previews

The factory specification sections cover engine, fuel, electrical, drive, brake, and chassis data for the individual engine families. Examples include:

• Fastener Specs: Factory torque values and tightening sequences for cylinder heads, engine supports, and related assemblies, including an engine-support fastener specification of 25 N·m (18 lbf·ft).
• Cooling Systems: Vehicle and engine cooling-system leak tests, coolant replacement and bleeding procedures, thermostat and radiator-cap checks, front and rear radiators, coolant tank, water pump, and coolant temperature sensor (CTS).
• Electrical Baselines: Connector pinouts, trigger-coil and CPS diagnostics, ignition/charging/starting test data, and exact resistance tables, including a CTS reference value of 5,705 ohms at 32°F.
• Diagnostic Coverage: B.U.D.S./MPI-2 diagnostics; monitoring and fault-code tables; engine leak testing; fuel-pump pressure and high-pressure leak tests; ignition/charging/starting diagnostics; DESS/RER troubleshooting; SDI/DPM sensor checks.
• Major Assemblies: RAVE/E-RAVE and 3D RAVE valves; oil-injection pump and nozzles; magneto/stator/CPS; drive and driven pulleys/countershaft; chaincase; brake caliper/master cylinder; front/rear suspension and shock absorbers; steering system.

Visual references include wiring diagrams plus the 3D RAVE Valve Flow Chart, Engine Leak Verification Flow Chart, Fuel Delivery Diagnostic Flow Chart, engine removal/installation exploded views, oil-injection reservoir and pump exploded views, and 3D RAVE solenoid-state diagrams. The specification tables also provide model-dependent data such as fuel and oil capacities, ignition values, sensor and coil resistance ranges, fuse ratings, drive-pulley calibration data, drive-belt specifications and wear limits, track settings, and brake wear limits.

Safety note: This is a technical reference for trained technicians and experienced DIY mechanics. Follow the factory safety warnings, specified tools, torque sequences, and model-specific cautions; high-pressure fuel systems, hot cooling systems, electrical circuits, spring-loaded suspension components, rotating drivetrain parts, and internal-engine work can cause injury or equipment damage if handled incorrectly. Use a qualified technician for repair work beyond your training, experience, or available equipment.