Ski-Doo REV Series Shop Manual

Section10BODY/FRAME
Subsection 02 (FRAME)
FRAME
FRAME CLEANING
NOTE: For bare aluminum frames use only
aluminum cleaner and follow instructions on con-
tainer. (Dursol cleaner or equivalent).
Clean frame and tunnel with appropriate cleaners
and rinse with high pressure hose.
CAUTION: Never direct high-pressure water jet
towards decals. They will peel off.
Touch up all metal spots where paint has been
scratched off. Spray all bare metal parts of vehicle
with metal protector.
Seat Cleaning
For all models, it is recommend to clean the seat
with a solution of warm soapy water, using a soft
clean cloth.
CAUTION: Avoid use of harsh detergents such
as strong soaps, degreasing solvents, abrasive
cleaners, paint thinners, etc., that may cause
damage to the seat cover.
FRAME WELDING
Aluminum Frame
– No welds should be done on aluminum frame
except if mentioned or required on a Bom-
bardier bulletin.
– Use ER-5356 rods for MIG or TIG welding.
CAUTION: Before performing electrical weld-
ing anywhere on the vehicle, unplug MPEM.
On models equipped with a battery, also un-
plug the negative cable. This will protect the
electronic box and battery against damage
caused by flowing current when welding.
A32E0WB
TYPICAL — MPEM UNPLUGGED
CAUTION: If welding is to be done near plastic
material, it is recommended to either remove
the part from the area or to protect it with alu-
minum foil to prevent damage.
FRAME COMPONENT
REPLACEMENT
Drilling Procedure
When drilling self-piercing rivets, use Superta-
nium
TM
drill bit (P/N 529 031 800), available in a 5
mm (3/16 in) size and shipped in packs of 2.
For proper drilling instructions and to prevent pre-
mature wear, follow the procedure below.
Always use a variable speed electric drill.
Partially drill rivet end — not the rivet head.
Maintain a slow to medium speed at all times
when drilling. The proper speed is attained when
a constant chip is ejected.
NOTE: To increase bit life, use Bombardier syn-
thetic chaincase oil (P/N 413 803 300) as a cutting
oil.
CAUTION: High speed drilling will cause exces-
sive heat which may destroy the cutting edge
of the bit; therefore, avoid using pneumatic
drills.
A03H2FA
TYPICAL
Cut rivet using a chisel.
Remove riveted part.
Drive out remaining rivet head using a punch.
mmr2004-Rev 347

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