2003 Ski-Doo MX Z 600 HO SPORT, MX Z 600 HO X, MX Z 600 HO, MX Z 600 HO 007 SPECIAL EDITION, MX Z 800 SPORT, MX Z 800 X Snowmobile Shop Manual (P/N PN 484 200 046)

• Coverage and publication identity: Covers the listed 2003 Ski-Doo MX Z 600 HO and MX Z 800 REV Series Sport, X, and 600 HO 007 Special Edition models, including standard, RER-equipped, and electric-start/RER builds in U.S./Canadian and selected European listings. Bombardier P/N 484 200 046; 300-page PDF.
• Engine repair and diagnosis: Details 593 HO and 793 engine removal, top- and bottom-end work, RAVE and reed-valve service, leak testing, dimensional inspection, CDI, oil injection, cooling, carburetor/DPM, fuel-pump, and throttle-cable procedures.
• Transmission and brake work: Covers drive-belt setup, TRA III drive-pulley service and calibration, Formula VSA and HPV27 VSA driven-pulley work, pulley alignment, hydraulic brake repair and bleeding, chaincase removal and assembly, gear-ratio changes, drive-chain adjustment, and silent-chain identification.
• Suspension and chassis procedures: Includes SC-10 III removal and assembly, HPG T/A shock servicing, drive-axle and track work, RAS A-arm and steering repair, ski alignment, ball-joint replacement, heated-grip removal and installation, plastic repair, and frame component replacement.
• Electrical testing and diagrams: Provides MPEM, DESS, DPM, RER, starter, ignition, charging, lighting, heating-element, and accessory tests, with calibration procedures, diagnostic flow charts, connector views, wiring diagrams, technical tables, and service-tool identification.

Across 11 sections, this Bombardier shop manual gives technicians and experienced owners the procedures, inspection criteria, and test sequences needed for REV repair work. Routine coverage includes maintenance, storage, preseason preparation, and approved service products.

Model and Configuration Coverage

The introduction identifies each machine by factory model number, market, and equipment notation. It separates Sport, X, and 007 Special Edition builds, rewind-start and electric-start versions, and Rotax Electronic Reverse configurations—distinctions that affect MPEM calibration, starter circuits, reverse tests, and wiring diagrams.

Coverage is limited to the listed 2003 REV models. Parts ordering remains in the Parts Catalog, while warm-up and post-rebuild break-in information is referenced to the Operator’s Guide.

Engine, Fuel, Cooling, and Drivetrain Repair

The 593 HO and 793 chapters cover engine removal and installation, top-end and bottom-end disassembly, inspection, and reassembly. They also identify major components that can be removed with the engine still in the chassis, including the cylinders, pistons, RAVE and reed valves, pumps, and magneto. Bottom-end repair requires engine removal.

Engine-condition procedures cover crankcase leak isolation, cylinder-head warpage, cylinder taper and out-of-round, combustion-chamber volume, piston and ring clearances, crankshaft deflection, end play, and alignment. Separate chapters handle the Denso trigger-coil CDI system, oil-system leak testing and pump adjustment, cooling-system testing and refilling, rewind-starter repair, carburetor synchronization, DPM manifold testing, fuel-pump verification, and fuel-tank and throttle-cable service.

The drivetrain section documents TRA III drive-pulley removal, inspection, assembly, and calibration, along with Formula VSA and HPV27 VSA driven-pulley repair, belt height and deflection, and pulley alignment. Pulley distance is nonadjustable on the REV platform, so an incorrect reading directs diagnosis toward alignment, engine mounts, or the torque rod. Hydraulic brake coverage includes pad, caliper, disc, and countershaft work plus system bleeding. Chaincase and silent-chain chapters cover removal, inspection, ratio changes, lubrication data, assembly, and adjustment.

Electrical Diagnosis, Calibration, and Wiring

Electrical coverage supports both rewind-start and electric-start machines. It includes ignition timing, battery and starter repair, MPEM calibration checks and changes through the Vehicle Communication Kit with B.U.D.S. or the MPEM programmer, DESS and RER inputs, DPM circuits, the 360 W REV ignition and charging system, heated grips and throttle elements, and headlight and accessory testing.

Named visual references include the Engine Leak Verification Flow Chart, the 360 W 2-Cylinder ignition and charging diagnostic flow charts, the Pulley Alignment and Distance Specifications Chart, SC-10 III exploded views, connector-housing cutaways, and the paired 2003 REV Electric and 2003 REV Manual wiring diagrams.

Suspension, Tools, and Factory Reference Data

SC-10 III material covers removal, disassembly and assembly, ride adjustment, lubrication, and HPG T/A shock service involving the internal floating piston, shim stacks, oil filling, and nitrogen charging. Drive-axle and track chapters include sprocket synchronization, bearing service, installation, tension, and alignment. Front-end coverage addresses the RAS A-arm system, handlebar and steering-column adjustment, ski toe-out, ball joints, and front-shock installation. Body and frame chapters add harness routing, plastic identification and repair, aluminum-frame welding limits, and riveted component replacement.

Factory tools identified for this work include the engine-removal hook P/N 529 035 829, spark-plug lift ring P/N 529 035 830, REV pulley alignment bar P/N 529 035 831, MPEM programmer kit P/N 529 035 878, REV ball-joint tools P/N 529 035 873 through 529 035 876, and 2003 T/A shock gas-fill kit P/N 503 190 102.

Technical-data tables are divided by engine and vehicle configuration, with engine wear limits, carburetor and ignition data, clutch calibration, chain ratios, belt and track specifications, suspension data, capacities, electrical tests, component torques, and a general 8.8-grade metric fastener table.

Several cautions are specific enough to prevent expensive mistakes. Piston markings and mono-hook circlips must be installed in the specified orientation, and a circlip that fails its first installation attempt is not reused. Cylinder-base gasket thickness is selected according to combustion-chamber volume; the wrong gasket can cause detonation and severe engine damage. The electrical chapter warns that MPEMs with the same stamped part number may carry different calibration programs, so they are not automatically interchangeable between models.

Because the procedures include rotating track and clutch tests, fuel and brake-fluid handling, high-pressure nitrogen shock service, and electrical diagnosis, support the snowmobile securely and follow the manual’s warnings and standard workshop safety practices.