2006 Bombardier REV Expedition, GSX, GTX, MX Z, MX Z Adrenaline, MX Z DPM Power Trek, Summit Engine Ski-Doo repair manual

Product Information

Table of Contents

SAFETY NOTICE

1. Safety Notice
   • Page XII

INTRODUCTION

1. Introduction
   • Vehicle Identification Number
   • Engine Serial Number
   • List of Abbreviations Used in This Manual
   • Arrangement of This Manual
   • General Information
   • Lubrication and Procedures
   • Sub-Assembly Instructions
   • Tolerance
   • Screw/Locking Fasteners Procedure
   • Tools and Equipment
   • Tightening Sequences
   • Assembly Operations
   • Cleaning
   • Storage
   • Cable Tension
   • Taper Locking Fasteners
   • Gasket Compound
   • Locating the Cooling System
   • Calibrations
   • Tightening Torque

01. MAINTENANCE

1. Maintenance Chart

   • Storage
   • Engine
   • Fuel System
   • Drive System
   • Suspension
   • Steering / Front Suspension

2. Preseason Preparation

   • Engine
   • Fuel System
   • Drive System
   • Suspension
   • Steering / Front Suspension

02. TROUBLESHOOTING

1. Engine, Fuel and Oil Systems

   • Diagnostic procedures for engine, fuel, and oil issues

2. Drive System

   • Troubleshooting drive system problems

3. Electrical System

   • Diagnostic procedures for electrical issues

4. Steering and Suspension

   • Troubleshooting steering and suspension problems

03. ENGINES

1. Engines

   • Leak Test
   • Engine Base Verification Flow Chart

2. Exhaust System

   • 377 and 593 Engines
   • 593 HO SDI and 793 HO Engines
   • Muffler
   • Y-Pipe
   • Pipe

3. Engine Removal and Installation

   • Engine Removal from Vehicle
   • Installation

4. Magneto System

   • Magneto Flywheel
   • Stator
   • Ignition

5. Top End

   • Cylinder Head
   • Cylinder
   • Piston
   • Engine Support
   • Connecting Rod
   • Engine Base Operation

6. Bottom End

   • Crankshaft
   • Bearings
   • Lubrication

7. Engine Measurement

   • Cylinder Bore Measurement
   • Connecting Rod End Axial Play
   • Clutch Alignment
   • Piston to Cylinder Clearance
   • Crankshaft Deflection

8. Cooling System

   • Cooling Fan Removal
   • Cooling Radiator Removal
   • Coolant Hose Replacement
   • Coolant System Cleaning
   • Coolant System Bleeding

9. Rewind Starter

   • Inspection
   • Recoil Spring Replacement

10. Oil Injection System

    • Oil Pump
    • Oil Injection System Inspection
    • Oil Flow Check
    • Oil Tank Venting

04. FUEL SYSTEM

1. Fuel Tank and Fuel Pump

   • Fuel Tank
   • Fuel Pump

2. Carburetors, Throttle and Choke Cables

   • Carburetor TM Type
   • Choke
   • Throttle
   • Cleaning and Inspection
   • Reassembly and Installation

3. DPM System

   • DPM Overview
   • System Testing

05. ENGINE MANAGEMENT (POWER TEK)

1. Overview

   • Operating Principle
   • System Overview

2. Diagnostic Procedures

   • Diagnostic Tools
   • Diagnostic Procedure

3. Component Inspection, Replacement and Adjustment

   • ECM Replacement
   • Engine Control Module (ECM) Inspection
   • Sensor Inspection
   • Component Replacement and Adjustment

INDEX

• Comprehensive index for quick reference

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