Ski-Doo GTX, GSX, GTX, MKZ, Summit 2009–10 Service & Repair Manual OEM

This PDF is indexed to 1,230 pages and combines two 2009 Ski-Doo shop-manual volumes: pages 1-693 cover REV-XP/REV-XR two-stroke machines, while pages 694-1,230 form the 537-page REV-XR 1200 4-TEC volume. It is best suited to professional technicians and experienced owners who already use service tools, electrical test equipment, pressure-testing equipment, and B.U.D.S./MPI-2 diagnostics. The material goes well beyond reference data, with factory repair procedures for removal, teardown, inspection, reassembly, testing, adjustment, and fault isolation.

• Covers the 593-series 500SS/600 and 600 HO E-TEC two-strokes plus the 797-series 800R Power TEK, including engine removal, crankcase leak testing, dimensional inspection, 593/797 top- and bottom-end work, cooling and lubrication service, and RAVE or 3D RAVE diagnosis.
• Separates TM-carburetor/DPM service from E-TEC direct injection, with fuel-pump pressure testing, injector and sensor checks, TPS reset, ECM data transfer, injector-coefficient loading, oil-pump bleeding, and B.U.D.S. fault-code work.
• Details Rotax 1203 4-TEC engine repair through dry-sump oil-pressure diagnosis, cooling-system leak testing, magneto and starter work, timing-chain service, valve-clearance adjustment, cylinder leak testing, cylinder-head overhaul, and crankshaft, balancer-shaft, piston, and connecting-rod service.
• Follows driveline and chassis work through TRA III/TRA IV drive pulleys, QRS/DRS driven pulleys and countershafts, chaincase service, RER or mechanical/electronic reverse, hydraulic brakes, drive axle and track, steering, body, and frame assemblies.
• Includes SC-5/SC-5M and applicable ACS rear-suspension diagnosis, plus HPG/HPG T/A shock removal, disassembly, inspection, reassembly, and nitrogen charging. ACS coverage identifies the compressor, module, solenoid valve, manifold, hoses, test sequence, and fault checks.
• Supplies component torque data, fluid capacities, wear limits, engine clearances, oil- and fuel-pressure test specifications, clutch and track calibration data, electrical test values, connector service information, diagnostic charts, exploded views, and model-specific wiring schematics.

Exact Model Coverage

The two-stroke volume covers the GTX LE 600 HO E-TEC, GSX Limited 600 HO E-TEC, and GSX Sport and GTX Sport 500SS. MX Z coverage includes the 50th 600 HO E-TEC; Adrenaline, Renegade, Renegade X, and X with 600 HO E-TEC or 800R Power TEK power; Trail 500SS; and TNT 500SS or 600 HO E-TEC. Summit models include the 50th 800R Power TEK, Everest 600 and 600 HO E-TEC, Everest 800R in 146-, 154-, and 163-inch configurations, Hill Climb 154 800R, Summit X 600 HO E-TEC, and Summit X 800R in 146-, 154-, and 163-inch configurations. The identification table lists the matching ES/DD/DC/ED, MP/BL/BD/BX/BU/BW/BS/BH/MF/MJ/BK/BB, and CZ/CY/CX/CU/CT/CW/CF/CV/CH/CG/CP 9-series model-number groups.

The REV-XR Rotax 1203 4-TEC volume covers GTX LE (EP9A/EP9B), GTX SE (ER9A/ER9B), GSX Limited (DK9A/DK9B), MX Z Renegade (MN9A/MN9B), MX Z Renegade X (MM9A/MM9B/MM9C), MX Z TNT (ML9A), and MX Z X (MK9A, MBK9B, MBK9C). The manual identifies these as 2009 models; it does not establish 2010 model-year coverage.

Diagnostics, Schematics, and Service Equipment

The electrical package contains the 2009 REV-XP 800R, REV-XP/XR 600 HO E-TEC with and without electric start, REV-XP 500SS/600, REV-XR 1200 MX Z, and REV-XR 1200 GSX/GTX schematics, including applicable ACS suspension circuits. Connector-location views and terminal-service pages cover Sumitomo, Deutsch, Packard, AMP Multilock, AMP ECM/8-circuit, and Kostal connectors.

Named equipment includes the MPI-2 interface card P/N 529 036 018, T-harness P/N 529 035 869, Fluke 115 multimeter P/N 529 035 868, 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, the diagnostic hardware, and the separate model-specific Parts Catalog are not supplied by this PDF.

Important Repair and File Notes

BRP warns that using an impact wrench during drive-pulley removal or installation can damage the pulley and alter its calibration; the manual reserves drive-pulley repair for an authorized Ski-Doo dealer. On the 1200 4-TEC, mixing the intake and exhaust camshafts or returning cylinder-specific valvetrain parts to the wrong position can damage the engine, while substitute camshaft lubricant can cause seizure.

The PDF page sequence jumps from printed page 579 to 592. PDF page 599 is blank and pages 600-610 are null entries, so printed pages 580-591 are absent. This gap removes the end of the two-stroke frame chapter, the 500SS technical-specification section, and the opening page of the 600-model specifications; the remaining repair chapters, 600 HO E-TEC and 800R specification tables, 1200 4-TEC volume, and listed wiring diagrams remain present.

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.