Ski-Doo REV Series Shop Manual

TABLE OF CONTENTS
SAFETY NOTICE ................................................................................... IX
INTRODUCTION .................................................................................... X
VEHICLE IDENTIFICATION NUMBER........................................................................... XV
ENGINE SERIAL NUMBER....................................................................................... XV
LIST OF ABBREVIATIONS USED IN THIS MANUAL......................................................... XV
ARRANGEMENT OF THIS MANUAL.......................................................................... XVII
GENERAL INFORMATION........................................................................................ XIX
ILLUSTRATIONS AND PROCEDURES ......................................................................... XIX
SELF-LOCKING FASTENERS PROCEDURE ................................................................... XIX
LOCTITE APPLICATION PROCEDURE.......................................................................... XIX
THREADLOCKER .................................................................................................. XX
STRIPPED THREAD REPAIR ..................................................................................... XXI
GASKET COMPOUND........................................................................................... XXII
MOUNTING ON SHAFT ......................................................................................... XXII
CASE-IN COMPONENTS....................................................................................... XXIII
TIGHTENING TORQUES ....................................................................................... XXIII
01 TOOLS AND SERVICE PRODUCTS
01 – SERVICE TOOLS ............................................................................................... 1
ENGINE — MANDATORYTOOLS................................................................................... 2
ENGINE — RECOMMENDED TOOLS............................................................................... 4
TRANSMISSION — MANDATORY TOOLS ........................................................................ 10
TRANSMISSION — RECOMMENDED TOOLS.................................................................... 11
SUSPENSION — MANDATORY TOOLS ........................................................................... 15
SUSPENSION — RECOMMENDED TOOLS....................................................................... 16
VEHICLE — RECOMMENDED TOOLS............................................................................. 19
02 – SERVICE PRODUCTS........................................................................................ 21
02 MAINTENANCE
01 – MAINTENANCE CHART..................................................................................... 29
02 – STORAGE ..................................................................................................... 33
GENERAL............................................................................................................. 33
FUEL STABILIZER.................................................................................................... 33
ENGINE LUBRICATION.............................................................................................. 33
ENGINE COMPARTMENT........................................................................................... 34
PULLEY PROTECTION............................................................................................... 34
COUNTERSHAFT LUBRICATION................................................................................... 34
BATTERY.............................................................................................................. 34
VEHICLE CLEANING................................................................................................. 34
RAGS IN AIR INTAKE AND EXHAUST SYSTEM ................................................................... 34
VEHICLE PROTECTION.............................................................................................. 34
03 – PRESEASON PREPARATION............................................................................... 35
FUEL FILTER REPLACEMENT ...................................................................................... 35
THROTTLE BODY CLEANING(ON SO EQUIPPED MODELS) .................................................... 36
CARBURETOR CLEANING(ON SO EQUIPPED MODELS)........................................................ 36
AIR FILTER CLEANING .............................................................................................. 36
RAGS IN AIR INTAKE AND EXHAUST SYSTEM ................................................................... 36
CLEANING OFDRIVE AND DRIVEN PULLEYS.................................................................... 36
CLEANING OF BRAKE DISK ........................................................................................ 36
DRIVE BELTCONDITION............................................................................................ 36
SPARK PLUGS........................................................................................................ 36
I

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