Ski-Doo 2005 SUMMIT HIGHMARK X Install guide

Ski Doo Service Repair Manual
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Mmr-2005 s rie RT ang.FH8 Mon Dec 20 08:16:36 2004 Page 1
Cit
C M Y CM MY CY CMY K

2005
Shop Manual
RT SERIES
BOMBARDIER RECREATIONAL PRODUCTS INC.

Legal deposit:
National Library of Quebec
National Library of Canada 2004
All rights reserved. No parts of this manual may be reproduced in any form without the prior written
permission of Bombardier Recreational Products Inc. (BRP)
©Bombardier Recreational Products Inc. (BRP) 2004
Technical Publications
Bombardier Recreational Products Inc. (BRP)
Valcourt (Quebec) Canada
PrintedinCanada
®™ Trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates.
* Trademark of Bombardier Inc., used under license.
This document contains the trademarks of the following companies:
Crest©is a trademark of Crest Industries Inc.
Loctite©is a trademark of Loctite Corporation
Molykote©is a trademark of Dow Corning Corporation
Silastic©is a trademark of Dow Corning Corporation
Snap-on©is a trademark of Snap-on Tools Corporation
Versilube©is a trademark of General Electric Company
Supertanium©is a trademark of Premier Industrial Corporation
AMP©is a trademark of Tyco Electronics Corporation

TABLE OF CONTENTS
SAFETY NOTICE ................................................................................... IX
INTRODUCTION .................................................................................... X
VEHICLE IDENTIFICATION NUMBER............................................................................. X
ENGINE SERIAL NUMBER......................................................................................... X
LIST OF ABBREVIATIONS USED IN THIS MANUAL........................................................... X
ARRANGEMENT OF THIS MANUAL ............................................................................ XII
GENERAL INFORMATION........................................................................................ XIV
ILLUSTRATIONS AND PROCEDURES ......................................................................... XIV
SELF-LOCKING FASTENERS PROCEDURE ................................................................... XIV
LOCTITE APPLICATION PROCEDURE.......................................................................... XV
THREADLOCKER .................................................................................................. XV
STRIPPED THREAD REPAIR ..................................................................................... XVI
GASKET COMPOUND ........................................................................................... XVII
MOUNTING ON SHAFT ......................................................................................... XVII
CASE-IN COMPONENTS....................................................................................... XVIII
TIGHTENING TORQUE ......................................................................................... XVIII
01 MAINTENANCE
01 – MAINTENANCE CHART....................................................................................... 1
02 – STORAGE ....................................................................................................... 3
GENERAL.............................................................................................................. 3
ENGINE ................................................................................................................ 3
FUEL SYSTEM......................................................................................................... 4
DRIVE SYSTEM ....................................................................................................... 4
STEERING/FRONT SUSPENSION . . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . . 5
SUSPENSION.......................................................................................................... 5
ELECTRICAL........................................................................................................... 5
VEHICLE ............................................................................................................... 5
03 – PRESEASON PREPARATION................................................................................. 7
ENGINE ................................................................................................................ 7
FUEL SYSTEM......................................................................................................... 7
DRIVE SYSTEM ....................................................................................................... 8
ELECTRICAL SYSTEM................................................................................................ 8
VEHICLE ............................................................................................................... 8
02 ENGINE
01 – LEAK TEST ...................................................................................................... 9
LEAK TEST............................................................................................................. 9
PREPARATION ........................................................................................................ 9
PROCEDURE ......................................................................................................... 11
FINALIZING REASSEMBLY. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. 13
ENGINE LEAK VERIFICATION FLOW CHART ..................................................................... 14
02 – AIR INTAKE SYSTEM........................................................................................ 15
AIR FILTER/AIR INTAKE SILENCER REMOVAL (BODY SIDE).................................................... 16
AIR FILTER/AIR INTAKE SILENCER INSTALLATION (BODY SIDE)............................................... 16
AIR INTAKE SILENCER REMOVAL (ENGINE SIDE) ............................................................... 16
AIR INTAKE SILENCER INSTALLATION (ENGINE SIDE).......................................................... 17
ADAPTOR PLATE REMOVAL ....................................................................................... 17
ADAPTOR PLATE INSTALLATION .................................................................................. 17
INTAKE DEFLECTOR/FILTER REMOVAL........................................................................... 17
I

TABLE OF CONTENTS
TUNED PIPE.......................................................................................................... 21
MANIFOLD ........................................................................................................... 22
MUFFLER............................................................................................................. 22
04 – ENGINE REMOVAL AND INSTALLATION................................................................ 25
REMOVAL FROM VEHICLE......................................................................................... 27
INSPECTION.......................................................................................................... 31
INSTALLATION ....................................................................................................... 32
05 – MAGNETO SYSTEM......................................................................................... 35
GENERAL............................................................................................................. 37
MAGNETO FLYWHEEL.............................................................................................. 37
STATOR ............................................................................................................... 38
CPS.................................................................................................................... 39
06 – E-RAVE SYSTEM............................................................................................. 41
GENERAL............................................................................................................. 43
E-RAVE SYSTEM DYNAMIC TEST.................................................................................. 43
E-RAVE CABLES...................................................................................................... 43
E-RAVE ACTUATOR.................................................................................................. 46
E-RAVE COVER....................................................................................................... 47
E-RAVE SHAFT ....................................................................................................... 47
E-RAVE HOUSING.................................................................................................... 49
E-RAVE VALVES ...................................................................................................... 49
07 – TOP END....................................................................................................... 51
TROUBLESHOOTING................................................................................................ 53
GENERAL............................................................................................................. 53
COMPONENT REMOVAL WITH THE ENGINE INSTALLED ...................................................... 53
DISASSEMBLY ....................................................................................................... 53
CLEANING............................................................................................................ 54
INSPECTION.......................................................................................................... 55
ASSEMBLY ........................................................................................................... 56
08 – BOTTOM END ................................................................................................ 61
TROUBLESHOOTING................................................................................................ 64
GENERAL............................................................................................................. 64
PREPARATION ....................................................................................................... 64
CLEANING............................................................................................................ 64
DISASSEMBLY ....................................................................................................... 64
INSPECTION.......................................................................................................... 69
ASSEMBLY ........................................................................................................... 69
BREAK-IN............................................................................................................. 73
09 – ENGINE MEASUREMENT .................................................................................. 75
CYLINDER HEAD WARPAGE ....................................................................................... 75
CYLINDER TAPER.................................................................................................... 75
CYLINDER OUT OF ROUND ........................................................................................ 75
COMBUSTION CHAMBER VOLUME MEASUREMENT.......................................................... 76
USED PISTON MEASUREMENT.................................................................................... 77
CYLINDER/PISTON CLEARANCE. . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. 78
RING/PISTON GROOVE CLEARANCE. . . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . 79
RING END GAP....................................................................................................... 79
CRANKSHAFT DEFLECTION . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. 79
CONNECTING ROD BIG END AXIAL PLAY........................................................................ 80
CHECKING CRANKSHAFT ALIGNMENT . . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. 80
10 – COOLING SYSTEM .......................................................................................... 83
COOLING SYSTEM LEAK TEST. . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . 85
II

TABLE OF CONTENTS
INSPECTION.......................................................................................................... 85
DRAINING THE SYSTEM............................................................................................ 85
DISASSEMBLY AND ASSEMBLY . . . . . .. . . . .. . . .. . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. 86
COOLING SYSTEM REFILLING PROCEDURE. . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. 87
11 – REWIND STARTER........................................................................................... 89
GENERAL............................................................................................................. 91
INSPECTION.......................................................................................................... 91
REMOVAL ............................................................................................................ 91
ROPE REPLACEMENT............................................................................................... 91
DISASSEMBLY ....................................................................................................... 91
ASSEMBLY ........................................................................................................... 92
INSTALLATION ....................................................................................................... 94
12 – OIL INJECTION SYSTEM ................................................................................... 95
GENERAL............................................................................................................. 97
OIL TYPE.............................................................................................................. 97
OIL SYSTEM LEAK TEST............................................................................................ 97
OIL PUMP IDENTIFICATION ........................................................................................ 98
CLEANING............................................................................................................ 98
REMOVAL ............................................................................................................ 98
CHECKING OPERATION............................................................................................. 99
INSTALLATION ....................................................................................................... 99
BLEEDING PROCEDURE.......................................................................................... 100
ADJUSTMENT...................................................................................................... 101
03 FUEL SYSTEM
01 – FUEL TANK AND FUEL PUMPS .......................................................................... 103
FUEL TANK................................................................................................... 104
IN-TANK FUEL FILTER REMOVAL ................................................................................ 105
IN-TANK FUEL FILTER INSTALLATION........................................................................... 105
IN-LINE FUEL FILTER REMOVAL ................................................................................. 106
IN-LINE FUEL FILTER INSTALLATION............................................................................ 106
FUEL TANK REMOVAL ............................................................................................ 106
FUEL TANK INSTALLATION....................................................................................... 107
FLOAT-TYPE FUEL LEVEL GAUGE REMOVAL/INSTALLATION . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . 107
ELECTRIC FUEL LEVEL SENSOR INSPECTION . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . 108
FUEL SYSTEM PRESSURIZATION. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . 108
ELECTRIC FUEL PUMP..................................................................................... 109
DIAGNOSTIC FLOW CHART...................................................................................... 109
ELECTRIC FUEL PUMP PRESSURE TEST . . . . .. . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . 110
ELECTRIC FUEL PUMP..................................................................................... 111
ELECTRIC FUEL PUMP REMOVAL............................................................................... 112
ELECTRIC FUEL PUMP INSTALLATION ......................................................................... 113
ELECTRIC FUEL PUMP PRESSURE REGULATOR REMOVAL/INSTALLATION . . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . 113
DIAPHRAGM FUEL PUMP ................................................................................. 114
DIAPHRAGM FUEL PUMP REMOVAL ........................................................................... 115
DIAPHRAGM FUEL PUMP VERIFICATION ...................................................................... 115
DIAPHRAGM FUEL PUMP CLEANING AND INSPECTION . . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . 116
DIAPHRAGM FUEL PUMP INSTALLATION...................................................................... 116
04 ENGINE MANAGEMENT (SDI)
01 – OVERVIEW ................................................................................................... 117
OPERATING PRINCIPLE.................................................................................... 118
III

TABLE OF CONTENTS
CHARGING SYSTEM. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . 118
IGNITION SYSTEM. . . . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . 118
AIR INDUCTION.................................................................................................... 118
FUEL DELIVERY SYSTEM . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . 119
ENGINE MANAGEMENT SYSTEM (EMS) .............................................................. 120
EMS — ENGINE MANAGEMENT SYSTEM FUNCTIONS. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . 122
POWER DISTRIBUTION........................................................................................... 122
FUEL INJECTION................................................................................................... 123
IGNITION SYSTEM. . . . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . 123
ELECTRONICALLY CONTROLLED RAVE (E-RAVE) ............................................................. 123
DIGITALLY ENCODED SECURITY SYSTEM (DESS) . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . 123
ROTAX ELECTRONIC REVERSE (RER) . . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . .. . . . .. . . . .. . . . 124
MONITORING SYSTEM . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . 124
DIAGNOSTIC MODE............................................................................................... 125
02 – DIAGNOSTIC PROCEDURE................................................................................ 127
GENERAL........................................................................................................... 127
TROUBLESHOOTING ............................................................................................. 128
EMS FAULT CODES ............................................................................................... 128
VCK (VEHICLE COMMUNICATION KIT).......................................................................... 132
03 – COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT ................................ 135
GENERAL..................................................................................................... 135
FUEL SYSTEM...................................................................................................... 135
ELECTRICAL SYSTEM . . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . 136
TESTING PROCEDURES ................................................................................... 140
ELECTRIC FUEL PUMP............................................................................................ 140
FUEL INJECTORS.................................................................................................. 140
ENGINE CONTROL MODULE (ECM)............................................................................. 144
ENGINE WIRING HARNESS. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . 145
THROTTLE BODY.................................................................................................. 145
THROTTLE POSITION SENSOR (TPS). . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. .. . . . .. . . . .. . 148
CRANKSHAFT POSITION SENSOR (CPS). . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . 150
AIR TEMPERATURE SENSOR (ATS).............................................................................. 151
COOLANT TEMPERATURE SENSOR (CTS)...................................................................... 152
AIR PRESSURE SENSOR (APS)................................................................................... 153
KNOCK SENSOR (KS).............................................................................................. 154
E-RAVE ACTUATOR................................................................................................ 154
DOUBLE IGNITION COIL.......................................................................................... 155
BATTERY............................................................................................................ 157
CAPACITOR......................................................................................................... 157
ENGINE START/RER SWITCH VERIFICATION................................................................... 158
DESS POST VERIFICATION ....................................................................................... 158
05 ELECTRICAL SYSTEM
01 – IGNITION SYSTEM ......................................................................................... 159
GENERAL........................................................................................................... 159
IGNITION TIMING.................................................................................................. 160
SPARK PLUG ....................................................................................................... 162
DESIGN SYMBOLS USED IN NGK SPARK PLUGS.................................................... 164
02 – CHARGING SYSTEM ....................................................................................... 165
GENERAL........................................................................................................... 165
CHARGING GENERATOR COIL (STATOR) ....................................................................... 165
VOLTAGE REGULATOR/RECTIFIER .............................................................................. 166
IV

TABLE OF CONTENTS
BATTERY............................................................................................................ 166
CABLE TERMINAL INSTALLATION .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . 168
03 – STARTING SYSTEM ........................................................................................ 171
GENERAL........................................................................................................... 171
COMPONENT TESTING ........................................................................................... 171
STARTER REMOVAL............................................................................................... 174
STARTER INSTALLATION ......................................................................................... 174
04 – ROTAX ELECTRONIC REVERSE (RER) .................................................................. 175
TROUBLESHOOTING.............................................................................................. 175
05 – ACCESSORIES AND LIGHTING SYSTEM............................................................... 177
GENERAL........................................................................................................... 177
12-VOLT POWER OUTLET (CIGARETTE-LIGHTER TYPE) . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . .. . . . 178
BEEPER (REVERSE ALARM) . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. .. . 178
ENGINE TEMPERATURE GAUGE................................................................................. 179
ELECTRIC FUEL GAUGE .......................................................................................... 179
HEADLAMP......................................................................................................... 180
HEADLAMP BEAM AIMING ...................................................................................... 181
HEATING ELEMENTS.............................................................................................. 181
RELAY............................................................................................................... 181
SPEEDOMETER.................................................................................................... 182
SPEED SENSOR.................................................................................................... 183
TACHOMETER ..................................................................................................... 183
TAILLIGHT .......................................................................................................... 184
VISOR OUTLET..................................................................................................... 184
06 DRIVE SYSTEM
01 – DRIVE BELT .................................................................................................. 185
APPLICATION CHART ............................................................................................. 185
INSPECTION........................................................................................................ 185
CHECKING NEUTRAL FUNCTION................................................................................ 185
ROTATION DIRECTION............................................................................................ 185
DRIVE BELT HEIGHT MEASUREMENT AND ADJUSTMENT .................................................. 186
DRIVE BELT DEFLECTION MEASUREMENT (REFERENCE ONLY)............................................ 187
02 – DRIVE PULLEY............................................................................................... 189
TRA V ......................................................................................................... 190
GENERAL........................................................................................................... 191
REMOVAL .......................................................................................................... 191
DISASSEMBLY ..................................................................................................... 191
CLEANING.......................................................................................................... 193
INSPECTION........................................................................................................ 193
ASSEMBLY ......................................................................................................... 195
INSTALLATION ..................................................................................................... 198
DRIVE PULLEY ADJUSTMENT ................................................................................... 199
03 – DRIVEN PULLEY ............................................................................................ 201
HPV ROLLER................................................................................................. 202
GENERAL........................................................................................................... 203
REMOVAL .......................................................................................................... 203
DISASSEMBLY ..................................................................................................... 203
CLEANING.......................................................................................................... 204
INSPECTION........................................................................................................ 204
ASSEMBLY ......................................................................................................... 205
INSTALLATION ..................................................................................................... 205
V

TABLE OF CONTENTS
BUSHING REPLACEMENT........................................................................................ 205
HPV VSA...................................................................................................... 208
GENERAL........................................................................................................... 209
REMOVAL .......................................................................................................... 209
DISASSEMBLY ..................................................................................................... 209
CLEANING.......................................................................................................... 209
INSPECTION........................................................................................................ 209
ASSEMBLY ......................................................................................................... 210
INSTALLATION ..................................................................................................... 210
ADJUSTMENT...................................................................................................... 210
04 – PULLEY ALIGNMENT ...................................................................................... 213
GENERAL........................................................................................................... 213
MEASURING PROCEDURE ....................................................................................... 213
ALIGNMENT PROCEDURE........................................................................................ 214
05 – BRAKE ........................................................................................................ 215
GENERAL........................................................................................................... 217
COUNTERSHAFT BEARING....................................................................................... 217
COUNTERSHAFT................................................................................................... 217
BRAKE FLUID ...................................................................................................... 217
DRAINING .......................................................................................................... 217
BLEEDING .......................................................................................................... 217
MASTER CYLINDER............................................................................................... 217
BRAKE PADS ....................................................................................................... 218
CALIPER ............................................................................................................ 219
BRAKE DISC........................................................................................................ 220
BRAKE LIGHT SWITCH . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . 221
06 – CHAINCASE.................................................................................................. 223
GENERAL........................................................................................................... 225
CHAINCASE OIL LEVEL . . . . . .. . . . .. . . . .. . . . .. . . .. . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . 225
OIL CHANGE ....................................................................................................... 225
DRIVE CHAIN ADJUSTMENT..................................................................................... 225
CHAINCASE COVER............................................................................................... 225
TENSIONER ........................................................................................................ 226
TENSIONER ROLLER BEARING.................................................................................. 226
DRIVE CHAIN AND SPROCKETS ................................................................................. 227
CHAINCASE HOUSING............................................................................................ 228
CHAINCASE HOUSING BEARINGS .............................................................................. 229
COUNTERSHAFT................................................................................................... 229
COUNTERSHAFT BEARING....................................................................................... 229
07 – DRIVE AXLE.................................................................................................. 233
REMOVAL .......................................................................................................... 236
ASSEMBLY ......................................................................................................... 236
LUBRICATION...................................................................................................... 238
ADJUSTMENT...................................................................................................... 238
08 – TRACK ........................................................................................................ 239
TRACK TYPE APPLICATION . .. . . . .. .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . 239
GENERAL........................................................................................................... 239
INSPECTION........................................................................................................ 239
REMOVAL .......................................................................................................... 239
INSTALLATION ..................................................................................................... 239
ADJUSTMENT...................................................................................................... 239
TRACK CLEAT ...................................................................................................... 241
VI

TABLE OF CONTENTS
TRACTION ENHANCING PRODUCTS (STUDS). . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . 241
07 REAR SUSPENSION
01 – SC SUSPENSION ........................................................................................... 243
AXLE SELF-LOCKING SCREWS REMOVAL ..................................................................... 247
REAR AXLE REMOVAL............................................................................................ 247
REAR AXLE INSTALLATION....................................................................................... 247
REAR SHOCK ABSORBER REMOVAL ........................................................................... 247
REAR SHOCK ABSORBER INSTALLATION...................................................................... 248
FRONT SHOCK ABSORBER REMOVAL ......................................................................... 248
FRONT SHOCK ABSORBER INSTALLATION .................................................................... 248
REAR SPRING REMOVAL......................................................................................... 249
REAR SPRING INSTALLATION.................................................................................... 249
SLIDER SHOE VERIFICATION .................................................................................... 250
SLIDER SHOE REMOVAL ......................................................................................... 250
SLIDER SHOE INSTALLATION.................................................................................... 251
FRONT ARM REMOVAL........................................................................................... 251
FRONT ARM INSTALLATION ..................................................................................... 252
REAR ARM/PIVOT ARM REMOVAL.............................................................................. 252
REAR ARM INSTALLATION ....................................................................................... 252
STOPPER STRAP................................................................................................... 253
SUSPENSION REMOVAL. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . 253
SUSPENSION INSTALLATION .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . 254
RIDE ADJUSTMENT ............................................................................................... 254
LUBRICATION...................................................................................................... 254
02 – SC 4 SUSPENSION ......................................................................................... 255
AXLE SELF-LOCKING SCREW REMOVAL ....................................................................... 259
REAR AXLE REMOVAL............................................................................................ 259
REAR AXLE INSTALLATION....................................................................................... 259
REAR SHOCK ABSORBER REMOVAL ........................................................................... 259
REAR SHOCK ABSORBER INSTALLATION...................................................................... 260
FRONT SHOCK ABSORBER REMOVAL ......................................................................... 260
FRONT SHOCK ABSORBER INSTALLATION .................................................................... 261
REAR SPRING REMOVAL......................................................................................... 261
REAR SPRING INSTALLATION.................................................................................... 262
SLIDER SHOE VERIFICATION .................................................................................... 262
SLIDER SHOE REMOVAL ......................................................................................... 263
SLIDER SHOE INSTALLATION.................................................................................... 264
FRONT ARM REMOVAL........................................................................................... 264
FRONT ARM INSTALLATION ..................................................................................... 264
REAR ARM/PIVOT ARM REMOVAL.............................................................................. 264
REAR ARM/PIVOT ARM INSTALLATION......................................................................... 265
BLOCK INSTALLATION............................................................................................ 265
IDLER WHEELS INSTALLATION.................................................................................. 265
STOPPER STRAP................................................................................................... 265
SUSPENSION REMOVAL. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . 266
SUSPENSION INSTALLATION .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . 266
RIDE ADJUSTMENT ............................................................................................... 266
LUBRICATION...................................................................................................... 267
03 – SHOCK ABSORBER INSPECTION AND SERVICING .................................................. 269
SPRING REMOVAL ................................................................................................ 269
SHOCK ABSORBER INSPECTION . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . 270
VII

TABLE OF CONTENTS
DISASSEMBLY AND ASSEMBLY . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . 270
08 STEERING/FRONT SUSPENSION
01 – STEERING SYSTEM ........................................................................................ 279
DISASSEMBLY AND ASSEMBLY . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . 282
INSPECTION........................................................................................................ 286
ADJUSTMENT...................................................................................................... 286
STEERING ADJUSTMENT (SKIS) ................................................................................. 288
LUBRICATION...................................................................................................... 289
02 – FRONT SUSPENSION...................................................................................... 291
GENERAL INSPECTION ........................................................................................... 295
DISASSEMBLY ..................................................................................................... 295
INSPECTION........................................................................................................ 300
INSTALLATION ..................................................................................................... 300
09 BODY/FRAME
01 – BODY.......................................................................................................... 305
DECAL .............................................................................................................. 305
HOOD............................................................................................................... 305
FRONT BUMPER................................................................................................... 305
BOTTOM PAN...................................................................................................... 306
WINDSHIELD....................................................................................................... 306
ACCESS PANEL .................................................................................................... 306
INDICATOR PANEL ................................................................................................ 306
CONSOLE........................................................................................................... 307
SEAT................................................................................................................. 307
PLASTIC MAINTENANCE AND REPAIR.......................................................................... 308
02 – FRAME........................................................................................................ 311
FRAME CLEANING ................................................................................................ 311
FRAME WELDING ................................................................................................. 311
FRAME COMPONENT REPLACEMENT ......................................................................... 311
10 TECHNICAL DATA
01 – MACH Z/SUMMIT 1000 SDI............................................................................... 317
TECHNICAL DATA LEGEND....................................................................................... 321
11 WIRING DIAGRAMS
01 – WIRING DIAGRAMS........................................................................................ 323
WIRING DIAGRAM LEGEND...................................................................................... 323
WIRE COLORS..................................................................................................... 323
CONNECTOR HOUSING AREA................................................................................... 323
HOUSING REFERENCE PER AREA............................................................................... 324
WIRE LOCATION IN CONNECTOR HOUSING .................................................................. 324
SYMBOLS DESCRIPTION......................................................................................... 326
UNPLUGGING CONNECTORS . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . 327
TAB AND RECEPTACLE CONNECTORS REMOVAL ............................................................ 327
TAB AND RECEPTACLE CONNECTORS INSTALLATION....................................................... 333
VIII

SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to correctly service and repair some 2005 Ski-Doo snowmo-
biles. See model list below.
This edition was primarily published to be used by snowmobile mechanic technicians who are already
familiar with all service procedures relating to BRP made snowmobiles. Mechanic technicians should
attend continuous training courses given by BRP Training Dept.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
This shop manual uses technical terms which may be slightly different from the ones used in the Parts
Catalog.
It is understood that this manual may be translated into another language. In the event of any discrepan-
cy, the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Ser-
vice and Warranty Bulletins may be published to update the content of this manual. Make sure to read
and understand them.
In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the
general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas
of the parts.
The use of BRP parts is most strongly recommended when considering replacement of any component.
Dealer and/or distributor assistance should be sought in case of doubt.
The engines and the corresponding components identified in this document should not be utilized on
product(s) other than those mentioned in this document.
This manual emphasizes particular information denoted by the wording and symbols:
WARNING
Identifies an instruction which, if not followed, could cause serious personal injury including pos-
sibility of death.
CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle compo-
nents.
NOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
Bombardier Recreational Products Inc. (BRP) disclaims liability for all damages and/or injuries resulting
from the improper use of the contents. We strongly recommend that any services be carried out and/or
verified by a highly skilled professional mechanic. It is understood that certain modifications may render
use of the vehicle illegal under existing federal, provincial and state regulations.
WARNING
Torque wrench tightening specifications must strictly be adhered to. Locking devices (ex.: lock-
ing tab, self-locking fasteners, etc.) must be installed or replaced with new ones. If the efficiency
of a locking device is impaired, it must be renewed.
WARNING
Unless otherwise specified, engine should be turned OFF and cold for all maintenance and repair
procedures.
mmr2005-109 IX

INTRODUCTION
INTRODUCTION
This shop manual covers the following BRP made
2005 RT Series models:
A35A01B
TYPICAL — RT SERIES
MODEL ENGINE
TYPE MODEL NUMBER
MACH Z 995 SDI AB5A, AB5B, AB5C
SUMMIT
HIGHMARK 995 SDI CD5A, CD5B, CD5C
SUMMIT
HIGHMARK X 995 SDI CA5A, CA5B, CA5C, CA5D
VEHICLE IDENTIFICATION
NUMBER
Vehicle Identification Number Location
1
A33H01A
TYPICAL
1. Vehicle identification number
Identification Number Meaning
A00A8HA
2 B P S B X 5 A 9 Y 1 0 0 0 0 0 1
Model number Serial number
Model year: y = 2000
1 = 2001
2 = 2002
et .
ENGINE SERIAL NUMBER
Engine Serial Number Location
A35C33A
1
1. Engine serial number
LIST OF ABBREVIATIONS USED
IN THIS MANUAL
ABBREVIATION MEANING
Aampere
amp ampere
A•h ampere-hour
AC alternate current
ACM acceleration and control
modulator
AMG absorbed glass mat
BDC bottom dead center
BTDC before top dead center
°C degree Celsius
cc cubic centimeter
X
mmr2005-109

INTRODUCTION
ABBREVIATION MEANING
CDI capacitor discharge ignition
CTR center
cm centimeter
cm²square centimeter
cm³cubic centimeter
DC direct current
DESS digitally encoded security
system
DPM digital performance
management
°F degree Fahrenheit
FC fan cooled
fl. oz fluid ounce
ft foot
GRD ground
H.A.C. high altitude compensator
hal. halogen
HI high
IFP internal floating piston
imp. oz imperial ounce
in inch
in²square inch
in³cubic inch
kkilo (thousand)
kg kilogram
km/h kilometer per hour
kPa Kilopascal
Lliter
lb pound
lbf pound (force)
lbf/in²pound per square inch
LH left hand
LO low
LT long track
mmeter
MAG magneto
Max. maximum
Min. minimum
mL milliliter
ABBREVIATION MEANING
mm millimeter
M.E. millennium edition
MPEM multi-purpose electronic
module
MPH mile per hour
Nnewton
N.A. not applicable
no. number
0continuity
0.L open line (open circuit)
O.D. outside diameter
OPT optional
oz ounce
P/N part number
PSI pound per square inch
PTO power take off
Rrectangular
RH right hand
R.A.S. response angle suspension
RAVE Rotax adjustable variable
exhaust
RER Rotax electronic reverse
RPM revolution per minute
RMS root mean square
RRIM reinforced reaction injection
molding
SDI semi-direct injection
Sp. Gr. specific gravity
ST semi-trapez
TDC top dead center
TRA total range adjustable
U.S. oz ounce (United States)
Vvolt
Vac volt (alternative current)
VSA variable sheave angle
mmr2005-109 XI

INTRODUCTION
ARRANGEMENT OF THIS MANUAL
Section 07 REAR SUSPENSION
Subse tion 01 (SUSPENSION SC-10 SPORT, TOURING AND MOUNTAIN)
SUSPENSION SC-10 SPORT,
TOURING AND MOUNTAIN
A-Series and B-Series
56
MMR2000_042_00-02A.FM
A03F24S
Short track models only
Long track
models only
SLE
only
Lo tite
271
Lo tite
271
Lo tite
271
Lo tite
271
Lo tite
271
Lo tite
271
Lo tite
271
Lo tite
271
Low
temp.
grease
6
5
6
7
4
3
2
1
6
1
Low
temp.
grease
8
16
Low
temp.
grease
11
12
13
14
15
11
11
11
16
20 18
10
17
11
18 Nm
(160 lbfin)
4 Nm
(35 lbfin)
Page heading
indicates section
and subsection
detailed.
Bold face number
indicates special
procedure concerning
this part.
Tightening torque nearby
fastener. In this case, nut
must be torqued to
4 Nm or 3 lbfin.
This Shop Manual uses technical terms wich may be
slightly different from the ones in the parts catalog.
Exploded view
assists you in
identifying parts and
related positions.
TYPICAL PAGE
A00A7XS
Illustration number
for publishing
process.
Subsection title
indicates
beginning of the
subsection.
Drop represents
a service
product to be
applied to
a surface.
In this case
Loctite 271 to
screw threads.
Dotted box contains
parts of a particular
model in this case
the short track
models only.
Page number
Italic subtitle above
exploded view
indicates
pertaining models.
CAUTION: Pay attention to torque
spe ifi
ations. Some of these are
in
lbf  in instead of lbf  ft. Use appro-
priate torque wren h.
Document
number for
publishing
process.
XII
mmr2005-109

INTRODUCTION
MMR2000_042_00-02A.FM
A16D0IA
1
2
A
1
A-Series and B-Series Only
Should installation procedure be required, refer
to BRAKE then look for Brake Dis and Countershaft
Bearing Adjustment.
All Models
Check end play of driven pulley on countershaft by
pushing pulley towards outer housing so that the inner
shims (P/N 04 108 200) contact it. Measure end play
at the mounting screw end between shim(s) and puley.
See illustration.
TYPICAL  TOP VIEW
1. Shim (P/N 504 108 200) (as required)
2. Conta t
A. 0 to 1 mm (0 to 3/64 in)
Torque retaining screw no. 13 to 2 Nm (18 lbfft).
ADJUSTMENT
Refer to PULLEY DISTANCE AND ALIGNMENT to adjust
pulley distance. Adjust drive belt height be-
tween pulley halves to obtain specified belt
deflection.
Reinstall the pulley on the countershaft by rever-
sing the removal procedure.
CAUTION: Always apply anti-seize lubri ant (P/N
413 701 000) on the ountershaft before final pulley
installation.
57
Turn puller handle and sliding half at once to extract
the bushing. INSTALLATION
Countershaft
IMPORTANT: Large bushing retaining screws and
washers must be removed before small bushing
installation.
Coat bushing outside diameter with Loctite 609
(P/N 413 703 100).
Install bushing as following photo.
A03D1YA
529 031 300
529 031 200
A03D1ZA
529 031 300
529 031 200
Cam
Coat cam no. 18 interior with anti-seize lubricant.
ASSEMBLY
Came Slider Shoe
Section 05 TRANSMISSION
Subse tion 03 (DRIVEN PULLEY)
When replacing slider shoes no. 4, always install a new
set (3 shoes) to maintain equal pressure on the cam.
Assemble driven pulley components by reversing
the disassembly procedure.
A00A7YS
Title indicates
main procedure
to be carried-out.
Reference to look
up a certain section
and subsection.
In this case it concerns
pulleys adjustment.
Italic bold face setting
in this case indicates
that particular
procedure for
A and B-Series is
finished, so from
this point, all models
are concerned.
Illustration always
follows text to which
it pertains.
Subtitle indicates
a particular procedure
for the named part.
Bold face number following part
name refers to exploded view
at beginning of subsection.
Call-outs for
above illustration.
Italic bold face type
setting indicates a
particular procedure
concerning a model.
TYPICAL caption
indicates a general
view which does
not represent full
detail.
TOP VIEW
caption helps you
in understanding
illustration.
TYPICAL PAGE
mmr2005-109 XIII

INTRODUCTION
GENERAL INFORMATION
The information and component/system descrip-
tions contained in this manual are correct at time
of publication. BRP however, maintains a policy
of continuous improvement of its products with-
out imposing upon itself any obligation to install
them on products previously manufactured.
Due to late changes, it may have some differences
between the manufactured product and the de-
scription and/or specifications in this document.
BRP reserves the right at any time to discontinue
or change specifications, designs, features, mod-
els or equipment without incurring obligation.
ILLUSTRATIONS AND
PROCEDURES
Illustrations and photos show the typical construc-
tion of the different assemblies and, in all cases,
may not reproduce the full detail or exact shape of
the parts shown. However, they represent parts
which have the same or a similar function.
CAUTION: Most components of those vehicles
are built with parts dimensioned in the metric
system. Most fasteners are metric and must
not be replaced by customary fasteners or
vice-versa. Mismatched or incorrect fasteners
could cause damage to the vehicle or possible
personal injury.
As many of the procedures in this manual are inter-
related, we suggest, that before undertaking any
task, you read and thoroughly understand the en-
tire section or subsection in which the procedure
is contained.
A number of procedures throughout the book re-
quire the use of special tools. Before commenc-
ing any procedure, be sure that you have on hand
all the tools required, or approved equivalents.
The use of RIGHT and LEFT indications in the text,
always refers to driving position (when sitting on
vehicle).
A33A2BA
12
TYPICAL
1. Left
2. Right
SELF-LOCKING FASTENERS
PROCEDURE
A00A6LA
TYPICAL —SELF-LOCKING FASTENER
The following describes the most common appli-
cation procedures when working with self-locking
fasteners.
Use a metal brush or a tap to clean the hole prop-
erly then use a solvent (Methyl-Chloride), let act
during 30 minutes and wipe off. The solvent uti-
lization is to ensure the adhesive works properly.
XIV
mmr2005-109

INTRODUCTION
LOCTITE APPLICATION
PROCEDURE
The following describes the most common ap-
plication procedures when working with Loctite
products.
NOTE: Always use proper strength Loctite prod-
uct as recommended in this shop manual.
THREADLOCKER
Uncovered Holes (bolts and nuts)
A00A3LA
1
2
1. Apply here
2. Do not apply
–Clean threads (bolt and nut) with solvent.
–Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
–Choose proper strength Loctite threadlocker.
–Fit bolt in the hole.
–Apply a few drops of threadlocker at proposed
tightened nut engagement area.
–Position nut and tighten as required.
Blind Holes
A00A3MA
1
2
1. On threads
2. On threads and at the bottom of hole
–Clean threads (bolt and hole) with solvent.
–Apply Loctite Primer N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30
seconds.
–Choose proper strength Loctite threadlocker.
–Apply several drops along the threaded hole and
at the bottom of the hole.
–Apply several drops on bolt threads.
–Tighten as required.
Stud in Blind Holes
A00A3NA
2
13
1. On threads
2. On threads and in the hole
3. Onto nut threads
–Clean threads (stud and hole) with solvent.
–Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
–Put several drops of proper strength Loctite
threadlocker on female threads and in hole.
mmr2005-109 XV

INTRODUCTION
–Apply several drops of proper strength Loctite
on stud threads.
–Install stud.
–Install cover, etc.
–Apply drops of proper strength Loctite on un-
covered threads.
–Tighten nuts as required.
Preassembled Parts
A00A3OA
1
2
1. Apply here
2. Do not apply
–Clean bolts and nuts with solvent.
–Assemble components.
–Tighten nuts.
–Apply drops of proper strength Loctite on
bolt/nut contact surfaces.
–Avoid touching metal with tip of flask.
NOTE: For preventive maintenance on exist-
ing equipment, retighten nuts and apply proper
strength Loctite on bolt/nut contact surfaces.
Adjusting Screw
A00A3PA
12
1. Apply here
2. Plunger
–Adjust screw to proper setting.
–Apply drops of proper strength Loctite thread-
locker on screw/body contact surfaces.
–Avoid touching metal with tip of flask.
NOTE: If it is difficult to readjust, heat screw with
a soldering iron (232°C(450°F)).
STRIPPED THREAD REPAIR
Stripped Threads
A00A3QA
5
8
6
7
1
2
3
4
1. Release agent
2. Stripped threads
3. Form-A-Thread
4. Tape
5. Cleaned bolt
6. Plate
7. New threads
8. Threadlocker
Standard Thread Repair
–Follow instructions on Loctite FORM-A-
THREAD 81668 package.
XVI
mmr2005-109