Ski-Doo GTX, GSX, MXZ & Summit 2009–2010 Shop Manual Set (P/N 219 100 330)

The two volumes separate two-stroke service from Rotax 1203 four-stroke repair. Their application tables identify the engine, chassis and model codes used to select the appropriate procedures and specifications.

Missing content: Printed pages 580–591 of the two-stroke volume are absent. This removes the end of the frame chapter, the 500SS technical-specification section and the opening page of the Summit Everest 600 specifications. The standalone Safety Notice page from each volume is also missing.

PDF Search, Bookmarks and File Contents

Search and diagram detail: The PDF contains searchable OCR text, with recognition errors in some technical terms and diagram labels. Embedded bookmarks provide chapter access, but several specification, volume and wiring-diagram entries incorrectly return to the first page. Small wiring labels require zooming.

One printable English PDF contains 1,219 valid pages, including three blank pages. Its page counter reports 1,230 positions because eleven entries are invalid and may produce page-loading errors. Both publications are combined in this single file.

Engine, Injection and Snowmobile Service Coverage

The following selected topics outline the repair coverage rather than reproduce the full contents. Other included subjects cover storage preparation and preseason service.

• Two-stroke engines: Step-by-step removal, crankcase leak testing, dimensional inspection, top- and bottom-end repair, cooling-system service, lubrication work, and RAVE or 3D RAVE diagnosis.

• Fuel and engine management: TM-carburetor and DPM service, E-TEC direct injection, fuel-pressure testing, injector and sensor checks, TPS reset, ECM replacement data and B.U.D.S. fault diagnosis.

• 1200 4-TEC repair: Engine removal, dry-sump lubrication diagnosis, cooling-system testing, magneto and starter service, timing-chain work, valve adjustment, cylinder-head overhaul and cylinder-block repair.

• Electrical troubleshooting: Ignition, charging and starting tests, D.E.S.S. diagnosis, model-specific wiring schematics, connector identification and terminal-service information.

• Driveline and brakes: TRA III, TRA VII and TRA IV drive-pulley service, QRS driven pulleys, countershafts, chaincases, reverse systems, hydraulic brakes, drive axles and track adjustment.

• Suspension and chassis: SC-5/SC-5M service, applicable ACS diagnosis, HPG/HPG T/A shock overhaul and nitrogen charging, plus steering, body-panel and frame procedures.

The procedures suit technicians and experienced owners who already work with service tools and electrical test equipment; engine-management tasks also call for B.U.D.S. and compatible diagnostic hardware.

Two-Stroke Inspection and E-TEC Calibration

The engine-measurement section explains cylinder taper and out-of-round checks, piston clearance, ring clearance and crankshaft inspection. Crankcase leak-test illustrations distinguish external leaks from internal seal leakage, supporting fault isolation before teardown and checks after reassembly.

E-TEC replacement work: Injector-coefficient loading, cylinder assignment, ECM data transfer and oil-pump bleeding are documented separately from carburetor adjustment. Injector serial-number and checksum matching connects replacement parts with the calibration data required by the ECM.

Four-Stroke Engine and Lubrication Work

The Rotax 1203 material covers cylinder leak testing, camshaft timing, valve-clearance adjustment and internal inspection of the crankshaft, balancer shaft, pistons and connecting rods.

Oil-pressure troubleshooting links gauge results with possible oil-level, filter, regulator, pump, strainer and bearing problems. This provides a diagnostic path beyond identifying the oil-pressure switch alone.

Camshaft assembly: Returning cylinder-specific valvetrain parts to the wrong positions can damage the engine; substituting the specified camshaft assembly lubricant can cause seizure.

Reverse, Suspension and Pulley Service

The two-stroke volume treats Rotax Electronic Reverse separately from the four-stroke chaincase systems. The 1200 4-TEC chapter distinguishes mechanically operated reverse from electrically controlled shifting, including linkage adjustment, motor and relay tests, position-switch checks and B.U.D.S. configuration.

ACS suspension: The rear-suspension chapter covers the compressor, control module, solenoid valve, manifold and hoses. Its testing sequence separates air leaks from electrical faults when the suspension setting cannot be changed.

The shock sections include disassembly, inspection, reassembly and nitrogen charging. Exploded suspension views and component-specific torque data support assembly work.

Drive-pulley limits: BRP reserves drive-pulley repair for an authorized Ski-Doo dealer. Impact-wrench use during removal or installation can damage the pulley and alter its calibration.

Before working around a raised track, rotating clutch components, pressurized fuel, high-pressure shock nitrogen, hot exhaust parts or energized circuits, follow the factory safety notices and verify the applicable model-specific specifications.

Wiring Sheets, Connectors and Required Equipment

Two-stroke schematics include REV-XP 800R, REV-XP/XR 600 HO E-TEC with electric-start and manual-start arrangements, and REV-XP 500SS/600 wiring. The four-stroke volume adds REV-XR 1200 MXZ and GSX/GTX sheets, including applicable ACS circuits.

Connector-location and terminal-service illustrations cover Sumitomo, Deutsch, Packard, AMP Multilock, AMP ECM/8-circuit and Kostal connectors.

Diagnostic equipment: Named tools include the MPI-2 interface card P/N 529 036 018, T-harness P/N 529 035 869 and Fluke 115 multimeter P/N 529 035 868.

Mechanical service tools: The manual identifies drive-pulley puller P/N 529 022 400, 1200 4-TEC engine lifting tool P/N 529 036 151 and camshaft locking tool P/N 529 036 149. B.U.D.S. software, diagnostic hardware and the separate model-specific Parts Catalog are not included.

A Preview of Four-Stroke Oil-Pressure Specifications

For the Rotax 1203 lubrication test, minimum engine-oil pressure is 100 kPa at the specified 1,100 RPM idle and 400 kPa at 7,700 RPM. The test requires the recommended oil at the proper level and an oil temperature of at least 80°C.

The accompanying troubleshooting section addresses readings below specification, while the lubrication data lists an approximately 3.5 L refill for an oil change with filter replacement.