Ski-Doo REV Series Shop Manual

Section04ENGINE
Subsection 04 (OIL INJECTION SYSTEM)
1
A33D13A
1. Hose pinchers on outlet hoses
Connect leak testing kit pump to special cap.
Pressurize oil system to 21 kPa (3 PSI). That pres-
suremustnotdropduring3minutes.
If pressure drops, locate leak(s) and repair/replace
leaking component(s).
NOTE: An oil pump shaft test must be done to
complete the oil system leak test. Refer to LEAK
TEST AND ENGINE DIMENSION MEASURE-
MENT for the procedure.
OIL PUMP IDENTIFICATION
Pump Lever
Different engines need different pumps. See
identification on lever no. 4.
CAUTION: Always mount proper pump on en-
gine.
ENGINE TYPE
OIL PUMP
IDENTIFICATION
593, 593 HO and
593 HO SDI
02
793 HO and SDI
01
CLEANING
Clean all metal components in a non-ferrous metal
cleaner.
DISASSEMBLY
NOTE: Some oil pump components are not avail-
able as single parts.
Injection Oil Reservoir
Empty injection oil reservoir no. 6 by siphoning
injection oil.
Remove:
– air box
– upper screw (near reservoir cap)
– rewind starter support and grip
– hose protector support
– electronic module (MPEM)
– lower nut no. 9, screw no. 10 and no. 11.
NOTE: Cut the ties retaining the wiring harness if
necessary.
Injection Oil Level Sensor
To remove the switch, use the following proce-
dure.
Remove injection oil reservoir, as mentioned
above..
Unplug switch connector.
Pull oil level switch no. 7 outofreservoir.
Before replacing the injection oil level sensor
no. 7, check it according to the following proce-
dure:
CAUTION: Do not remove or bend the reed
switch protective float lock. It can damage the
reed switch glass.
With the float magnet ring at the lowest position.
Using an ohmmeter, probe the connector.
mmr2004-Rev 129

Ski-Doo REV Series Specifications

General

Chassis	REV
Track Width	15 in
Fuel Capacity	10.6 gal
Seating Capacity	1
Reverse	Available on most models
Electric Start	Available on most models