Ski-Doo REV Series Shop Manual

TABLE OF CONTENTS
03 TROUBLESHOOTING
01 – ENGINE ........................................................................................................ 37
ENGINE LEAK VERIFICATION FLOW CHART ..................................................................... 48
02 – FUEL AND OIL SYSTEMS .................................................................................. 49
03 – TRANSMISSION AND BRAKE SYSTEM.................................................................. 53
TRANSMISSION ............................................................................................. 53
BRAKE SYSTEM.............................................................................................. 60
HYDRAULIC BRAKE ................................................................................................. 60
04 – ELECTRICAL SYSTEM....................................................................................... 61
05 – SUSPENSION AND TRACK................................................................................. 73
04 ENGINE
01 – 593, 593 HO, 593 HO SDI AND 793 HO ENGINE TYPES ............................................... 77
EXHAUST SYSTEM.......................................................................................... 77
TUNED PIPE.......................................................................................................... 78
MANIFOLD ........................................................................................................... 78
MUFFLER............................................................................................................. 78
ENGINE SYSTEM ............................................................................................ 80
REMOVAL FROM VEHICLE......................................................................................... 81
INSPECTION.......................................................................................................... 84
INSTALLATION ....................................................................................................... 84
TOP END....................................................................................................... 85
TROUBLESHOOTING................................................................................................ 89
COMPONENT REMOVAL WITH THE ENGINE INSTALLED ...................................................... 89
CLEANING............................................................................................................ 89
RAVE VALVE BASIC OPERATION................................................................................... 89
DISASSEMBLY ....................................................................................................... 90
INSPECTION.......................................................................................................... 94
ASSEMBLY ........................................................................................................... 95
BOTTOM END ............................................................................................... 100
CLEANING.......................................................................................................... 103
DISASSEMBLY ..................................................................................................... 103
INSPECTION........................................................................................................ 104
ASSEMBLY ......................................................................................................... 104
BREAK-IN........................................................................................................... 109
02 – ENGINE LEAK TEST AND DIMENSION MEASUREMENT............................................ 111
LEAK TEST.......................................................................................................... 111
PREPARATION ..................................................................................................... 111
PROCEDURE....................................................................................................... 111
FINALIZING REASSEMBLY........................................................................................ 113
ENGINE LEAK VERIFICATION FLOW CHART ................................................................... 114
ENGINE DIMENSION MEASUREMENT.......................................................................... 115
CYLINDER HEAD WARPAGE ..................................................................................... 115
CYLINDER TAPER.................................................................................................. 115
CYLINDER OUT OF ROUND...................................................................................... 115
COMBUSTION CHAMBER VOLUME MEASUREMENT........................................................ 115
USED PISTON MEASUREMENT.................................................................................. 117
CYLINDER/PISTON CLEARANCE................................................................................. 117
RING/PISTON GROOVE CLEARANCE............................................................................ 119
RING ENDGAP..................................................................................................... 119
CRANKSHAFT DEFLECTION ...................................................................................... 119
CONNECTING ROD BIG END AXIAL PLAY...................................................................... 120
II

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