Ski-Doo REV Series Shop Manual

TABLE OF CONTENTS
CRANKSHAFT END-PLAY ......................................................................................... 120
CHECKING CRANKSHAFT ALIGNMENT ......................................................................... 120
03 – MAGNETO SYSTEM........................................................................................ 121
GENERAL........................................................................................................... 123
CLEANING.......................................................................................................... 123
DISASSEMBLY ..................................................................................................... 123
ASSEMBLY ......................................................................................................... 124
04 – OIL INJECTION SYSTEM .................................................................................. 127
GENERAL........................................................................................................... 128
OIL TYPE............................................................................................................ 128
OIL SYSTEM LEAK TEST.......................................................................................... 128
OIL PUMP IDENTIFICATION ...................................................................................... 129
CLEANING.......................................................................................................... 129
DISASSEMBLY ..................................................................................................... 129
ASSEMBLY ......................................................................................................... 130
ADJUSTMENT...................................................................................................... 131
CHECKING OPERATION........................................................................................... 132
05 – LIQUID COOLING SYSTEM................................................................................ 133
COOLING SYSTEM LEAK TEST................................................................................... 135
INSPECTION........................................................................................................ 135
DRAINING THE SYSTEM.......................................................................................... 135
DISASSEMBLY AND ASSEMBLY ................................................................................. 135
COOLING SYSTEM REFILLING PROCEDURE................................................................... 137
06 – REWIND STARTER.......................................................................................... 139
INSPECTION........................................................................................................ 140
REMOVAL .......................................................................................................... 140
ROPE REPLACEMENT............................................................................................. 140
DISASSEMBLY ..................................................................................................... 140
ASSEMBLY ......................................................................................................... 141
INSTALLATION ..................................................................................................... 143
07 – CARBURETOR AND THROTTLE CABLE................................................................. 145
CARBURETOR TM TYPE................................................................................... 145
IDENTIFICATION ................................................................................................... 146
REMOVAL .......................................................................................................... 146
CLEANING AND INSPECTION .................................................................................... 147
DISASSEMBLY AND ASSEMBLY ................................................................................. 148
CARBURETOR ADJUSTMENTS .................................................................................. 149
INSTALLATION ..................................................................................................... 151
DPM ........................................................................................................... 152
TESTING ............................................................................................................ 152
PARTS REMOVAL AND INSTALLATION.......................................................................... 152
DPM MANIFOLD TESTING........................................................................................ 153
THROTTLE CABLE .......................................................................................... 155
THROTTLE/OIL PUMP CABLE REMOVAL ....................................................................... 155
THROTTLE/OIL PUMP CABLE INSTALLATION.................................................................. 155
THROTTLE CABLE ADJUSTMENT ............................................................................... 155
08 – FUEL TANK AND FUEL PUMP ............................................................................ 157
FUEL FILTER........................................................................................................ 159
FUEL TANK ......................................................................................................... 159
IMPULSE/FUEL LINES SPRING CLIPS (ALL MODELS)......................................................... 160
FLOAT-TYPE FUEL LEVEL GAUGE ............................................................................... 161
ELECTRIC FUEL LEVEL SENSOR................................................................................. 161
III

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