2008 Ski-Doo Expedition, Freestyle, Legend, Tundra, GSX, MX Z, and Summit Service Manual (P/N 413 703 408)

This 625-page PDF covers the 2008 Ski-Doo RF Series, not the full 2008 Ski-Doo model range. Its 14 sections are organized around the 300F, 550F, and V800 configurations - engine types 277, 552, and V810 - and the material is best suited to experienced snowmobile mechanics and technicians who can work from factory measurements and have access to the specified pullers, gauges, and electronic diagnostic equipment.

• Model coverage: Expedition Sport 550F and V800; Freestyle Back Country 550F, Park 550F, Session 300F, and Session 550F; Legend Touring V800 and Trail V800; and Tundra 300F and V800. GSX, MX Z, and Summit models are outside this RF Series manual's scope.
• Engine repair procedures: Covers removal and installation, crankcase leak testing, air-intake and exhaust work, top- and bottom-end service, crankshaft and cylinder measurement, and component-specific inspection and assembly for the 277, 552, and V810 engines.
• V800 engine management: Details MPI/MPI-2 and B.U.D.S. communication, stored fault-code diagnosis, ECM and sensor testing, closed-throttle and idle-actuator reset, ignition control, injector and fuel-rail service, and limp-home fault tracing.
• Fuel and electrical systems: Separates carbureted 300F/550F service from V800 electronic fuel injection, with fuel-tank leak and pressure tests, ignition testing sequences, charging and starting diagnosis, Rotax Electronic Reverse checks, and lighting and instrument repair.
• Driveline and brake work: Addresses Bombardier Lite and TRA IV drive pulleys, LPV 27 and LPV VSA driven pulleys, pulley alignment, 300F/550F and V800 chaincases, countershaft and hydraulic brake service, drive axle inspection, track adjustment, and studding guidance.
• Chassis and technical reference: Includes SC and SC-4 rear suspension, hydraulic and HPG shock servicing, ski and steering alignment, body and frame repair, model-specific specifications, electrical connector service, and full-system wiring diagrams.

Engine and EMS Repair Detail

The 277 and 552 chapters handle the fan-cooled two-stroke hardware separately, including rewind starters, oil-injection leak tests and pump adjustment, axial-fan and magneto work, piston and crankshaft inspection, and engine measurement data. The V810 four-stroke section shifts to pressure-fed lubrication and liquid cooling. Its repair coverage extends to the oil pump and regulator, engine oil strainer, cooling-system leak testing, thermostat and radiator, water-pump shaft and seals, valve-clearance adjustment, camshaft timing, timing chain, cylinder head, and crankshaft plain bearings.

V800 electronic diagnosis is treated as a complete system rather than a short fault list. The manual maps ECM inputs and outputs for the TPS, CPS, CAPS, CTS, MAPTS, oil-pressure switch, injectors, ignition coil, and idle-bypass valve. The fault-code tables connect symptoms and warning behavior to circuit checks, connector locations, electrical test values, and follow-up repair procedures.

Driveline, Chassis, and Diagram Coverage

The drive section identifies the pulley combinations used on the covered machines and provides disassembly, inspection, reassembly, calibration, alignment, and operational checks. Separate chaincase chapters account for the 300F/550F and V800 layouts. Rear-suspension procedures distinguish SC from SC-4 hardware, while the shock chapter covers both hydraulic and HPG gas units.

Useful visual references include the 277 engine-leak verification flowchart, the V810 control-system input/output schematic, the V800 fuel-system diagnostic flowchart, the 300F/550F ignition testing sequences, the Legend/Tundra V800 wiring diagram, and the Freestyle/Tundra/Expedition 300F/550F wiring diagram. Connector views cover Deutsch, Packard, AMP Multilock, ECM, multifunction speedometer, and battery-terminal service.

Special Tools, Specifications, and Repair Cautions

Named equipment includes the MPI-2 interface P/N 529 036 018 with supply T-harness P/N 529 035 869, ECM adapter P/N 420 277 010, V810 plain-bearing remover/installer P/N 529 035 917, crankcase support sleeve P/N 529 036 031, and connector crimping tool P/N 529 035 909 with die P/N 529 035 906. The specification material supplies component torque tables, approved fluids and capacities, wear limits, clearances, pressure-test data, pulley and track settings, and electrical test values for the covered variants.

Two cautions matter during major repair work. Incorrectly indexing a V810 crankcase plain bearing can block its oil supply and damage the engine, while an interrupted ECM transfer caused by omitting the specified supply T-harness can leave the module unusable. Fuel-system pressure, brake integrity, rotating drive components, and a lifted snowmobile all require the manual's prescribed isolation and support precautions before service begins.