Ski-Doo REV Series Shop Manual

Section 06 TRANSMISSION
Subsection 06 (CHAINCASE)
INSTALLATION AND ASSEMBLY
Reverse removal and disassembly procedure and
pay attention to the following. Replace oil seals,
gaskets O-rings and drain plug.
11, Oil Seal
Using an appropriate pusher, press the oil seal into
chaincase hub. Oil seal must fit flush with the
chaincase edge.
NOTE: Should installation procedure for counter-
shaft be required, refer to BRAKE.
5,16, Sprockets
Position the sprockets with the backside of writing
facing the chaincase cover. Sprocket hub faces
toward chaincase.
4, Upper Sprocket Castellated Nut
Torque to 45 to 75 N•m(33to55lbf•ft).
Install new cotter pin in the position shown.
CAUTION: When removing a cotter pin always
replace with a new one.
CAUTION: Cotter pin will rub on chaincase
cover if installed otherwise.
A02D08A
1
2
1. New
2. Fold cotter pin over castellated nut flats only
18, Circlip
CAUTION: It is of the utmost importance to in-
stall the circlip otherwise damage to the chain-
case components may occur.
DRIVE CHAIN ADJUSTMENT
NOTE: Brake disc key must be in good condition
before checking if chain is loose.
10, O-Ring
Replace O-ring no. 10 on tensioner adjustment
screw. Fully tighten tensioner adjustment screw
by hand
, then back off only far enough for hair pin
to engage in locking hole.
This initial adjustment should provide 3 - 5 mm
(1/8 - 13/64 in) free-play when measured at the
outer circumference of the brake disc.
CAUTION: Free-play must not exceed 5 mm
(13/64 in), readjust if necessary.

WARNING
If the specified free-play is not reached with
the tensioner screw fully tightened, replace
chain and check the condition of sprockets.
21, Chaincase Oil
Pour 250 mL (8.5 U.S. oz) of synthetic chaincase
oil (P/N 413 803 300) into chaincase.
NOTE: Chaincase oil capacity is 250 mL (8.5 U.S.
oz).
Check oil level with the dipstick then add if re-
quired. Remove metal particles from magnet.
A32D02A
3
1
2
4
TYPICAL
1. Dipstick
2. Oil level
3. Level between marks
4. Magnet
NOTE: Chaincase must be in its proper position
when checking oil level.
mmr2004-Rev 247

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