2009-2010 Bombardier Ski-Doo GTX, GSX, GTX, MKZ, Summit service manual

Table of Contents

SAFETY NOTICE

INTRODUCTION

• General
• How to Identify Your Vehicle
• Snowmobile Lifting
• Engine Emissions Information
• Tightening Torque
• Self-Locking Fasteners Procedure
• Loctite Application Procedure
• Manual Information

01 MAINTENANCE

• 01 – Maintenance Chart
• 02 – Storage Procedure
  • General
  • Procedures
  • Engine Management System
  • Fuel System
  • Engine
  • Electrical System
  • Drive/Brake System
  • Chassis
  • Vehicle
• 03 – Preseason Preparation
  • General
  • Procedures
  • Engine
  • Fuel System
  • Electrical System
  • Drive/Brake System

02 ENGINE

• 01 – Engine Removal and Installation
  • General
  • Procedures
  • Engine
  • Engine Stopper
  • Engine Support
  • Engine Rubber Mount
• 02 – Engine Leak Test
  • Troubleshooting
  • Procedures
  • Engine
  • Pump Shaft Oil Gear Reservoir
• 03 – Engine Measurement
  • Procedures
  • Cylinder Head Warpage
  • Cylinder Taper
  • Cylinder Out of Round
  • Cylinder/Piston Clearance
  • Ring/Piston Groove Clearance
  • Ring End Gap
  • Crankshaft Deflection
  • Connecting Rod Big End Axial Play
  • Crankshaft Alignment
  • Combustion Chamber Volume Measurement
• 04 – Air Intake System
  • General
  • Procedures
  • Air Filter
  • Primary Air Intake Silencer
  • Secondary Air Intake Silencer
• 05 – Exhaust System
  • General
  • Procedures
  • Muffler
  • Exhaust Gas Temperature Sensor (EGTS)
  • Tuned Pipe
  • Manifold
• 06 – Rewind Starter
  • Inspection
  • Procedures
  • Rewind Starter Handle
  • Rewind Starter
• 07 – Lubrication System
  • General
  • System Description
  • Recommended Oil
  • Inspection
  • Oil System Leak Test
  • Troubleshooting
  • Procedures
  • Oil Injection Pump (500SS/600/800R)
  • Oil Pump (600 HO E-TEC)
  • Oil Tank
  • Oil Level Sensor
  • Oil Filter (500SS/600/800R)
  • Injection Nozzle
• 08 – Cooling System
  • General
  • Maintenance
    • Coolant Replacement
  • Inspection
    • Cooling System Leak Test
    • Engine Cooling System Leak Test (800R)
  • Procedures
    • Thermostat
    • Radiator Cap
    • Front Radiator
    • Rear Radiator
    • Coolant Reservoir
    • Water Pump
    • Coolant Temperature Sensor (CTS)
• 09 – Magneto System
  • General
  • Procedures
  • Magneto Flywheel
  • Stator (500SS/600/800R)
  • Stator (600 HO E-TEC)
  • Crankshaft Position Sensor (600 HO E-TEC)
  • Trigger Coils (500SS/600)
  • Trigger Coils (800R)
  • Magneto Housing (800R)
• 10 – RAVE (593)
  • General
  • System Description
  • Procedures
  • RAVE Valves
• 11 – RAVE (593 E-TEC)
  • General
  • System Description
  • Inspection
    • 3D RAVE Valves Position Validation
  • Troubleshooting
    • Diagnostic Tips
  • Procedures
    • 3D RAVE Valves
    • Actuator Check Valves
    • Lubrication Check Valves
    • Solenoid
    • 3D RAVE Valves Position Sensor
• 12 – RAVE (797)
  • General
  • System Description
  • Troubleshooting
    • Diagnostic Flow Chart
    • Troubleshooting Tips
  • Procedures
    • 3D RAVE Valve
    • Check Valves
    • Solenoids
• 13 – Top End (593)
  • General
  • Procedures
  • Reed Valves
  • Cylinder Head Cover (500SS/600)
  • Cylinder Head (500SS/600)
  • Cylinder Head (600 HO E-TEC)
  • Cylinders
  • Pistons
• 14 – Top End (797)
  • General
  • Procedures
  • Reed Valves
  • Cylinder Head
  • Pistons
  • Cylinder Block
• 15 – Bottom End (593)
  • General
  • Procedures
  • Water Pump
  • Water Pump Shaft
  • Crankcase
  • Crankshaft
• 16 – Bottom End (797)
  • General
  • Procedures
  • Water Pump
  • Water/Oil Pump Shaft
  • Crankcase
  • Crankshaft

03 ENGINE MANAGEMENT SYSTEM

• 01 – Overview (500SS/600)
  • General
  • System Description
• 02 – Overview (600 HO E-TEC)
  • General
  • System Description
• 03 – Overview (800R)
  • General
  • System Description
• 04 – Communication Tools and B.U.D.S. Software
  • General
  • Troubleshooting
    • Communication Problems
  • Procedures
    • Multi-Purpose Interface-2 (MPI-2)
    • B.U.D.S. Software
• 05 – Monitoring System and Fault Codes
  • General
  • Monitoring System
  • Fault Codes
  • Specific Fault Codes
  • Fault Code Tables

04 FUEL SYSTEM

• 01 – Fuel Tank and Fuel Pump
  • General
  • System Description (500SS/600/800R)
  • System Description (600 HO E-TEC)
  • Inspection
  • Fuel System Pressurization
  • Fuel Pump Pressure Test (600 HO E-TEC)
  • Procedures
  • Fuel Tank
  • Diaphragm Fuel Pump (500SS/600/800R)
  • Electric Fuel Pump (600 HO E-TEC)
  • Fuel Pressure Regulator (600 HO E-TEC)
  • In-Line Fuel Filter (600 HO E-TEC)
  • Fuel Level Sensor
  • Oetiker Clamps
• 02 – TM Carburetors
  • Procedures
  • Carburetors
  • Throttle Position Sensor (TPS)
  • Throttle Cable
  • Choke Cable
• 03 – DPM System (800R)
  • General
  • System Description
  • Procedures
  • Air Temperature Sensor (ATS)
  • Air Pressure Sensor (APS)
  • DPM Solenoid
  • DPM Manifold
• 04 – E-TEC Direct Fuel Injection
  • General
  • System Description
  • Adjustment
    • Idle Speed
    • Closed Throttle Reset (TPS)
  • Troubleshooting
    • Diagnostic Tips
  • Procedures
    • Fuel Hoses and Oetiker Clamps
    • Throttle Cable
    • Fuel Injector
    • Engine Control Module (ECM)
    • Throttle Body
    • Throttle Position Sensor (TPS)
    • Crankshaft Position Sensor (CPS)
    • Air Temperature Sensor (ATS)
    • Coolant Temperature Sensor (CTS)
    • Air Pressure Sensor (APS)
    • Exhaust Gas Temperature Sensor (EGTS)
    • Knock Sensor (KS)

05 ELECTRICAL SYSTEM

• 01 – Ignition System

  • General
  • System Description (500SS/600/800R)
  • System Description (600 HO E-TEC)
  • Adjustment
    • Ignition Timing
  • Troubleshooting
    • Ignition System Testing Sequence
  • Procedures
    • Spark Plugs
    • Spark Plug Cables (500SS/600/800R)
    • Spark Plug Cables (600 HO E-TEC)
    • Engine Stop Switch

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