Ski-Doo 2008 RF & REV-XP Snowmobile Service Manual Set

The two volumes separate platform-specific engine, electronics, and driveline information so service procedures and test data can be matched to the correct machine.

Coverage is limited to the listed model and engine combinations. The additional fan-cooled wiring sheet in the REV-XP file does not extend its mechanical repair coverage to other models.

PDF Search, Bookmarks, and Wiring Detail

Search and diagram readability: The RF repair text is not searchable. Some RF wiring lines and small labels are faint or broken and remain difficult to read when enlarged. Both files have section bookmarks. In the REV-XP file, text search is available in the six appended wiring sheets, while the main repair text is not searchable; small wiring labels require zooming.

The ZIP download contains two printable PDFs with 1,178 pages total, including one supplementary cover page in each file and six appended wiring sheets in the REV-XP volume.

Rotax Engine, Fuel-System, and Chassis Repair

The selected coverage below highlights major workshop tasks rather than the full contents. Further topics include storage and preseason preparation, along with seat-latch adjustment.

• RF engine repair: Step-by-step removal and installation, crankcase leak testing, top- and bottom-end service, and cylinder, piston, and crankshaft measurement.

• REV-XP engine work: Separate 593 and 797 top- and bottom-end procedures, with RAVE, E-RAVE, and 3D RAVE valve service.

• Engine management: MPI/MPI-2 and B.U.D.S. communication, fault-code diagnosis, ECM and sensor testing, closed-throttle resets, and V800 idle-actuator adjustment.

• Fuel systems: Carbureted 300F/550F service, TM carburetors, V800 electronic fuel injection, 600 HO SDI injector testing, and 800R DPM diagnosis.

• Electrical diagnosis: Ignition testing sequences, charging and starting checks, Rotax Electronic Reverse, DESS service, lighting, instruments, and accessory circuits.

• Driveline and brakes: Pulley disassembly and calibration, applicable alignment checks, chaincase and countershaft service, hydraulic brake repair, drive axles, track adjustment, and studding guidance.

• Suspension and chassis: SC, SC-4, SC-5, and SC-5M rear-suspension procedures, shock inspection and applicable rebuilding, ski and steering alignment, and body/frame repair.

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. The REV-XP manual specifies authorized Ski-Doo dealer service for drive-pulley repairs.

RF Two-Stroke and V810 Engine Detail

The 277 and 552 chapters handle fan-cooled two-stroke hardware separately, including rewind starters, oil-injection leak tests and pump adjustment, axial-fan and magneto work, and internal engine inspection.

The V810 four-stroke section covers pressure-fed lubrication and liquid cooling. Repair detail 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.

Incorrectly indexing a V810 crankcase plain bearing can block its oil supply and damage the engine.

REV-XP RAVE, DPM, and SDI Service

The REV-XP engine chapters distinguish the 593 RAVE/E-RAVE arrangements from the 797 engine’s 3D RAVE system. The latter includes valve and cable adjustment, check-valve inspection, and solenoid testing.

Fuel-system procedures distinguish TM carburetors and the 800R DPM manifold from 600 HO SDI injection. SDI coverage includes injector flow measurement, fuel-rail and throttle-body service, sensor tests, ECM replacement, and the required closed-throttle reset.

ECM Diagnosis and Communication

The V800 control-system material maps ECM inputs and outputs for the TPS, CPS, CAPS, CTS, MAPTS, oil-pressure switch, injectors, ignition coil, and idle-bypass valve. Fault-code tables connect symptoms and warning behavior to circuit checks, connector locations, electrical test values, and follow-up repair procedures.

Power-supply and ground checks provide a way to investigate an apparently inactive ECM before replacement. The communication instructions also explain why an interrupted transfer during reflashing can leave the ECM unusable if the specified supply T-harness is omitted.

Driveline, Suspension, and Diagram References

REV-XP countershaft procedures explain upper-gear retention during removal. Its HPG T/A shock-rebuilding section distinguishes tire-valve and needle-valve units and includes floating-piston positioning and damping-shim information. The RF shock section covers inspection and replacement rather than the same internal rebuilding procedure.

Visual references include the 277 engine-leak verification flowchart, V810 control-system input/output schematic, V800 fuel-system diagnostic flowchart, and REV-XP 3D RAVE valve flowchart. RF wiring sheets cover Legend/Tundra V800 and Freestyle/Tundra/Expedition 300F/550F configurations.

Connector views and repair instructions cover Deutsch, Packard, AMP Multilock, ECM, multifunction speedometer, and battery-terminal connections. The REV-XP volume adds Sumitomo and Kostal connector detail, with appended wiring sheets for carburetor, SDI, and Power TEK arrangements.

Special Tools and Workshop Reference

Diagnostic equipment includes the MPI-2 interface P/N 529 036 018, supply T-harness P/N 529 035 869, and ECM adapter P/N 420 277 010.

V810 bearing work uses plain-bearing remover/installer P/N 529 035 917 and crankcase support sleeve P/N 529 036 031. Connector repair references 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.

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.

Examples of Valve-Clearance and Diagnostic Specifications

For the RF V810 engine, the cold valve-clearance specifications are 0.06–0.14 mm at the intake and 0.11–0.19 mm at the exhaust.

The RF V800 fuel-pressure test specifies 400 ± 20 kPa when the ignition key is briefly turned to START without cranking the engine.

For REV-XP 600 HO SDI diagnosis, the air-temperature sensor table lists 2,000 ohms at 25°C. The accompanying text explains that a correct resistance reading at one temperature does not establish correct operation across the sensor’s temperature range.