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Bombardier Ski Doo 2006 Rev Series Service Manual
SAFETY NOTICE
INTRODUCTION
VEHICLE IDENTIFICATION NUMBER
ENGINE SERIAL NUMBER
LIST OF ABBREVIATIONS USED IN THIS MANUAL
ARRANGEMENT OF THIS MANUAL
GENERAL INFORMATION
ILLUSTRATIONS AND PROCEDURES
SELF-LOCKING FASTENERS PROCEDURE
LOCTITE APPLICATION PROCEDURE
THREADLOCKER
STRIPPED THREAD REPAIR
GASKET COMPOUND
MOUNTING ON SHAFT
CASE-IN COMPONENTS
TIGHTENING TORQUE
01 MAINTENANCE
01 ? MAINTENANCE CHART
02 ? STORAGE
GENERAL
ENGINE
FUEL SYSTEM
DRIVE SYSTEM
STEERING/FRONT SUSPENSION
SUSPENSION
ELECTRICAL
VEHICLE
03 ? PRESEASON PREPARATION
ENGINE
FUEL SYSTEM
DRIVE SYSTEM
ELECTRICAL SYSTEM
VEHICLE
02 TROUBLESHOOTING
01 ? ENGINE
02 ? FUEL AND OIL SYSTEMS
03 ? DRIVE AND BRAKE SYSTEMS
DRIVE SYSTEM
BRAKE SYSTEM
04 ? ELECTRICAL SYSTEM
05 ? STEERING AND SUSPENSION
03 ENGINES
01 ? LEAK TEST
PREPARATION
PROCEDURE
FINALIZING REASSEMBLY
ENGINE LEAK VERIFICATION FLOW CHART
I
TABLE OF CONTENTS
02 ? EXHAUST SYSTEM
377 AND 552 ENGINES
593, 593 HO, 593 HO SDI AND 793 HO ENGINES
TUNED PIPE
MANIFOLD
MUFFLER
03 ? ENGINE REMOVAL AND INSTALLATION
REMOVAL FROM VEHICLE
INSPECTION
INSTALLATION
REMOVAL FROM VEHICLE
INSPECTION
INSTALLATION
04 ? MAGNETO SYSTEM
GENERAL
MAGNETO FLYWHEEL
STATOR
CPS/TRIGGER COIL
05 ? TOP END
TROUBLESHOOTING
CLEANING
DISASSEMBLY
INSPECTION
ASSEMBLY
TROUBLESHOOTING
COMPONENT REMOVALWITH THE ENGINE INSTALLED
CLEANING
RAVE VALVE BASIC OPERATION
DISASSEMBLY
INSPECTION
ASSEMBLY
06 ? BOTTOM END
CLEANING
DISASSEMBLY
INSPECTION
ASSEMBLY
BREAK-IN
CLEANING
DISASSEMBLY
INSPECTION
ASSEMBLY
BREAK-IN
07 ? ENGINE MEASUREMENT
CYLINDER HEADWARPAGE
CYLINDER TAPER
CYLINDER OUT OF ROUND
COMBUSTION CHAMBER VOLUME MEASUREMENT
USED PISTON MEASUREMENT
CYLINDER/PISTON CLEARANCE
RING/PISTON GROOVE CLEARANCE
RING END GAP
CRANKSHAFT DEFLECTION
II
TABLE OF CONTENTS
CONNECTING ROD BIG END AXIAL PLAY
CHECKING CRANKSHAFT ALIGNMENT
08 ? COOLING SYSTEM
COOLING FAN REMOVAL AND INSTALLATION
COOLING FAN BEARING REPLACEMENT
FAN BELT REPLACEMENT AND DEFLECTION ADJUSTMENT
LIQUID COOLING SYSTEM
COOLING SYSTEM LEAK TEST
INSPECTION
DRAINING THE SYSTEM
DISASSEMBLY AND ASSEMBLY
COOLING SYSTEM REFILLING PROCEDURE
09 ? REWIND STARTER
INSPECTION
REMOVAL
ROPE REPLACEMENT
DISASSEMBLY
ASSEMBLY
INSTALLATION
10 ? OIL INJECTION SYSTEM
GENERAL
OIL TYPE
OIL SYSTEM LEAK TEST
OIL PUMP IDENTIFICATION
CLEANING
CHECKING OPERATION
DISASSEMBLY
ASSEMBLY
BLEEDING PROCEDURE
ADJUSTMENT
04 FUEL SYSTEM
01 ? FUEL TANK AND FUEL PUMP
IN-TANK FUEL FILTER
IN-LINE FUEL FILTER
FUEL TANK
FLOAT-TYPE FUEL LEVEL GAUGE
ELECTRIC FUEL LEVEL SENSOR
FUEL SYSTEM PRESSURIZATION
DIAPHRAGM FUEL PUMP
REMOVAL
PUMP VERIFICATION
CLEANING AND INSPECTION
INSTALLATION
02 ? CARBURETORS, THROTTLE AND CHOKE CABLES
CARBURETOR ? VM TYPE
IDENTIFICATION
REMOVAL
CLEANING AND INSPECTION
DISASSEMBLY AND ASSEMBLY
CARBURETOR ADJUSTMENTS
INSTALLATION
III
TABLE OF CONTENTS
CHOKE
CARBURETOR TM TYPE
IDENTIFICATION
REMOVAL
CLEANING AND INSPECTION
DISASSEMBLY AND ASSEMBLY
INSTALLATION
CARBURETOR ADJUSTMENTS
CHOKE CABLE
03 ? DPM SYSTEM
OVERVIEW
SYSTEM TESTING
PARTS REMOVAL AND INSTALLATION
DPM MANIFOLD TESTING
05 ENGINE MANAGEMENT (POWER TEK)
01 ? OVERVIEW
OPERATING PRINCIPLE
FUEL DELIVERY SYSTEM
ENGINE MANAGEMENT SYSTEM (EMS)
EMS ? ENGINE MANAGEMENT SYSTEM FUNCTIONS
POWER DISTRIBUTION
IGNITION SYSTEM
ELECTRONICALLY CONTROLLED RAVE
DIGITALLY ENCODED SECURITY SYSTEM (DESS)
ROTAX ELECTRONIC REVERSE (RER)
MONITORING SYSTEM
DIAGNOSTIC MODE
02 ? DIAGNOSTIC PROCEDURES
GENERAL
TROUBLESHOOTING
EMS FAULT CODES
VCK (VEHICLE COMMUNICATION KIT)
03 ? COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT
GENERAL
ELECTRICAL SYSTEM
FUEL SYSTEM
ENGINE MANAGEMENT SYSTEM
ENGINE CONTROL MODULE (ECM)
POWER RELAY
THROTTLE POSITION SENSOR (TPS)
AIR TEMPERATURE SENSOR (ATS)
COOLANT TEMPERATURE SENSOR (CTS)
AIR PRESSURE SENSOR (APS)
KNOCK SENSOR (KS)
E-RAVE SOLENOID
DPM SOLENOID
IGNITION COIL
ENGINE START/RER SWITCH
DIGITALLY ENCODED SECURITY SYSTEM (DESS)
IV
TABLE OF CONTENTS
06 ENGINE MANAGEMENT (SDI)
01 ? OVERVIEW
OPERATING PRINCIPLE
CHARGING SYSTEM
IGNITION SYSTEM
AIR INDUCTION
FUEL DELIVERY SYSTEM
ENGINE MANAGEMENT SYSTEM (EMS)
ECM ? GENERAL FUNCTIONS
EMS ? ENGINE MANAGEMENT SYSTEM FUNCTIONS
ELECTRONIC FUEL INJECTION
IGNITION TIMING
ELECTRONICALLY CONTROLLED RAVE
KNOCK SENSOR
ENGINE MODES OF OPERATION
FLOODED ENGINE (DROWNED MODE)
MONITORING SYSTEM
LIMP HOME MODES
DIAGNOSTIC MODE
ROTAX ELECTRONIC REVERSE (RER)
02 ? DIAGNOSTIC PROCEDURES
GENERAL
TROUBLESHOOTING
VCK (VEHICLE COMMUNICATION KIT)
2-TEC SYSTEM FAULT CODES
03 ? COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT
GENERAL
FUEL SYSTEM
ELECTRICAL SYSTEM
RESISTANCE MEASUREMENT
ENGINE CONNECTOR PIN-OUTS
RELAY
AIR INDUCTION SYSTEM
THROTTLE BODY
FUEL DELIVERY
ELECTRIC FUEL PUMP
FUEL RAIL
FUEL INJECTORS
ELECTRONIC MANAGEMENT
ECM REPLACEMENT
ENGINE WIRING HARNESS
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)
E-RAVE SOLENOID
DOUBLE IGNITION COIL
IGNITION TIMING
BATTERY
V
TABLE OF CONTENTS
CAPACITOR
ENGINE START/RER SWITCH VERIFICATION
DESS POST VERIFICATION
07 ELECTRICAL SYSTEM
01 ? IGNITION SYSTEM
GENERAL
IGNITION TIMING
SPARK PLUG
DESIGN SYMBOLS USED IN NGK SPARK PLUGS
02 ? CHARGING SYSTEM
GENERAL
CHARGING GENERATOR COIL (STATOR)
VOLTAGE REGULATOR/RECTIFIER
BATTERY
CABLE TERMINAL INSTALLATION
03 ? STARTING SYSTEM
TROUBLESHOOTING
04 ? ACCESSORIES
GENERAL
12-VOLT POWER OUTLET (CIGARETTE-LIGHTER TYPE)
BEEPER (REVERSE ALARM)
ENGINE TEMPERATURE GAUGE
ELECTRIC FUEL GAUGE
HEADLAMP
HEADLAMP BEAM AIMING
HEATING ELEMENTS
RELAY
SPEEDOMETER
SPEED SENSOR
TACHOMETER
TAILLIGHT
VISOR OUTLET
08 DRIVE SYSTEM
01 ? DRIVE BELT
APPLICATION CHART
INSPECTION
CHECKING NEUTRAL FUNCTION
ROTATION DIRECTION
DRIVE BELT HEIGHT MEASUREMENT AND ADJUSTMENT
DRIVE BELT DEFLECTION MEASUREMENT (REFERENCE ONLY)
02 ? DRIVE PULLEY
BOMBARDIER LITE
GENERAL
REMOVAL
DISASSEMBLY
CLEANING
INSPECTION
ASSEMBLY
INSTALLATION
TRA III
VI
TABLE OF CONTENTS
GENERAL
REMOVAL
DISASSEMBLY
CLEANING
INSPECTION
ASSEMBLY
INSTALLATION
DRIVE PULLEY ADJUSTMENT
03 ? DRIVEN PULLEY
FORMULA RER AND FORMULA VSA-R
REMOVAL
DISASSEMBLY
CLEANING
INSPECTION
BUSHING REPLACEMENT
ASSEMBLY
INSTALLATION
ADJUSTMENT
HPV VSA
REMOVAL
DISASSEMBLY
CLEANING
INSPECTION
ASSEMBLY
INSTALLATION
ADJUSTMENT
04 ? PULLEY ALIGNMENT
GENERAL
MEASURING PROCEDURE
ALIGNMENT PROCEDURE
05 ? BRAKE
HYDRAULIC BRAKE
BRAKE FLUID
MASTER CYLINDER
CALIPER
BRAKE PADS
BRAKE DISC
COUNTERSHAFT BEARING
COUNTERSHAFT
BRAKE LIGHT SWITCH
BLEEDING
06 ? CHAINCASE
GENERAL
CHAINCASE OIL LEVEL
OIL CHANGE
DRIVE CHAIN ADJUSTMENT
REMOVAL AND DISASSEMBLY
INSPECTION
INSTALLATION AND ASSEMBLY
SILENT CHAIN
07 ? DRIVE AXLE
REMOVAL
VII
TABLE OF CONTENTS
ASSEMBLY
LUBRICATION
ADJUSTMENT
08 ? TRACK
TRACK TYPE APPLICATION
GENERAL
INSPECTION
REMOVAL
INSTALLATION
ADJUSTMENT
TRACK CLEAT
TRACTION ENHANCING PRODUCTS (STUDS)
09 REAR SUSPENSION
01 ? SC SUSPENSION
AXLE SELF-LOCKING SCREWS REMOVAL
REAR AXLE REMOVAL
REAR AXLE INSTALLATION
REAR SHOCK ABSORBER REMOVAL
REAR SHOCK ABSORBER INSTALLATION
FRONT SHOCK ABSORBER REMOVAL
FRONT SHOCK ABSORBER INSTALLATION
REAR SPRING REMOVAL
REAR SPRING INSTALLATION
SLIDER SHOE VERIFICATION
SLIDER SHOE REMOVAL
SLIDER SHOE INSTALLATION
SUSPENSION REMOVAL
SUSPENSION INSTALLATION
FRONT ARM REMOVAL
FRONT ARM INSTALLATION
REAR ARM/PIVOT ARM REMOVAL
REAR ARM INSTALLATION
STOPPER STRAP
RIDE ADJUSTMENT
LUBRICATION
02 ? SC 3 SUSPENSION
AXLE SELF-LOCKING SCREWS REMOVAL
REAR AXLE REMOVAL
REAR AXLE INSTALLATION
REAR SHOCK ABSORBER REMOVAL
REAR SHOCK ABSORBER INSTALLATION
FRONT SHOCK ABSORBER REMOVAL
FRONT SHOCK ABSORBER INSTALLATION
REAR SPRING REMOVAL
REAR SPRING INSTALLATION
SLIDER SHOE VERIFICATION
SLIDER SHOE REMOVAL
SLIDER SHOE INSTALLATION
SUSPENSION REMOVAL
SUSPENSION INSTALLATION
FRONT ARM REMOVAL
VIII
TABLE OF CONTENTS
FRONT ARM INSTALLATION
REAR ARM/PIVOT ARM REMOVAL
REAR ARM/PIVOT ARM INSTALLATION
STOPPER STRAP
RIDE ADJUSTMENT
LUBRICATION
03 ? SC 4 SUSPENSION
AXLE SELF-LOCKING SCREW REMOVAL
REAR AXLE REMOVAL
REAR AXLE INSTALLATION
REAR SHOCK ABSORBER REMOVAL
REAR SHOCK ABSORBER INSTALLATION
FRONT SHOCK ABSORBER REMOVAL
FRONT SHOCK ABSORBER INSTALLATION
REAR SPRING REMOVAL
REAR SPRING INSTALLATION
SLIDER SHOE VERIFICATION
SLIDER SHOE REMOVAL
SLIDER SHOE INSTALLATION
SUSPENSION REMOVAL
SUSPENSION INSTALLATION
FRONT ARM REMOVAL
FRONT ARM INSTALLATION
REAR ARM/PIVOT ARM REMOVAL
REAR ARM/PIVOT ARM INSTALLATION
BLOCK INSTALLATION
IDLER WHEELS INSTALLATION
STOPPER STRAP
RIDE ADJUSTMENT
LUBRICATION
04 ? SHOCK ABSORBER INSPECTION AND SERVICING
SPRING REMOVAL
SHOCK ABSORBER INSPECTION
DISASSEMBLY AND ASSEMBLY
10 STEERING/FRONT SUSPENSION
01 ? STEERING SYSTEM
DISASSEMBLY AND ASSEMBLY
INSPECTION
ADJUSTMENT
STEERING ADJUSTMENT (SKIS)
LUBRICATION
02 ? FRONT SUSPENSION
GENERAL INSPECTION
DISASSEMBLY
INSPECTION
INSTALLATION
11 BODY/FRAME
01 ? BODY
INSTALLATION AND ADJUSTMENT
DECAL
IX
TABLE OF CONTENTS
WINDSHIELD
GUARD
WIRING HARNESS
CABLES
TUBING
PLASTIC MAINTENANCE AND REPAIR
MAINTENANCE
REPAIR
02 ? FRAME
FRAME CLEANING
FRAMEWELDING
FRAME COMPONENT REPLACEMENT
12 TECHNICAL DATA
01 ? FAN COOLED MODELS
02 ? LIQUID COOLED MODELS
03 ? LIQUID COOLED (SDI) MODELS
13 WIRING DIAGRAM
01 ? WIRING DIAGRAMS
WIRING DIAGRAM LEGEND
WIRE COLORS
CONNECTOR HOUSING AREA
HOUSING REFERENCE PER AREA
WIRE LOCATION IN CONNECTOR HOUSING
SYMBOLS DESCRIPTION
UNPLUGING CONNECTORS
TAB AND RECEPTACLE CONNECTORS REMOVAL
TAB AND RECEPTACLE CONNECTORS INSTALLATION
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