Ski-Doo REV Series Shop Manual

TABLE OF CONTENTS
04 – PULLEY DISTANCE AND ALIGNMENT.................................................................. 235
GENERAL........................................................................................................... 235
GENERAL PROCEDURE........................................................................................... 235
PULLEY ALIGNMENT AND DISTANCE SPECIFICATIONS CHART............................................. 236
05 – BRAKE ........................................................................................................ 239
HYDRAULIC BRAKE ........................................................................................ 239
BRAKE FLUID ...................................................................................................... 240
MASTER CYLINDER............................................................................................... 240
CALIPER ............................................................................................................ 240
BRAKE PADS ....................................................................................................... 241
BRAKE DISC........................................................................................................ 242
COUNTERSHAFT BEARING....................................................................................... 242
COUNTERSHAFT................................................................................................... 243
BRAKE LIGHT SWITCH............................................................................................ 243
BLEEDING.......................................................................................................... 244
06 – CHAINCASE.................................................................................................. 245
REMOVAL AND DISASSEMBLY .................................................................................. 246
INSPECTION........................................................................................................ 246
GEAR RATIO MODIFICATION..................................................................................... 246
INSTALLATION AND ASSEMBLY ................................................................................. 247
DRIVE CHAIN ADJUSTMENT..................................................................................... 247
ADJUSTMENT...................................................................................................... 248
07 – DRIVE CHAIN ................................................................................................ 249
SILENT CHAIN...................................................................................................... 249
07 ELECTRICAL SYSTEM
01 – IGNITION TIMING........................................................................................... 251
SCRIBING A TIMING MARK....................................................................................... 251
CHECKING IGNITION TIMING .................................................................................... 252
CHANGING TIMING................................................................................................ 253
02 – SPARK PLUGS............................................................................................... 257
DISASSEMBLY ..................................................................................................... 257
SPARK PLUG INSTALLATION..................................................................................... 257
SPARK PLUG TIGHTENING TORQUE ............................................................................ 257
03 – BATTERY ..................................................................................................... 259
GENERAL........................................................................................................... 259
REMOVAL .......................................................................................................... 259
CLEANING.......................................................................................................... 259
INSPECTION........................................................................................................ 259
BATTERY CHARGE TESTING ..................................................................................... 260
BATTERY STORAGE ............................................................................................... 260
ACTIVATION OF NEW BATTERY.................................................................................. 260
BATTERY CHARGING.............................................................................................. 260
INSTALLATION OFBATTERY ..................................................................................... 260
CABLE TERMINAL INSTALLATION............................................................................... 261
04 – ELECTRIC STARTER ........................................................................................ 263
REMOVAL .......................................................................................................... 264
DISASSEMBLY ..................................................................................................... 264
CLEANING.......................................................................................................... 265
INSPECTION........................................................................................................ 265
ASSEMBLY ......................................................................................................... 267
INSTALLATION ..................................................................................................... 268
VI

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