Ski-Doo REV Series Manual

Mmo-2006 4x6 REV ANG.FH8 Fri Apr 29 15:30:56 2005 Page 1
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SAFETY WARNING
Disregarding any of the safety precautions and instructions
contained in this Operator’s Guide, SAFETY VIDEOCASSETTE or
on-product warnings may result in injury, including the possibility
of death.
This Operator’s Guide and SAFETY VIDEOCASSETTE should
remain with the unit at time of resale.
In USA, products are distributed by BRP US Inc.
In Canada, products are distributed by Bombardier Recreational
Products Inc.
The following are trademarks of Bombardier Recreational Products
Inc. or its subsidiaries.
SKI-DOO ADRENALINETM
REVTM ROTAXTM DESSTM
GSXTM RERTM SUMMIT®
GTX†MX-Z®
† GTX is a trademark of Castrol Ltd. Used under license
Printed in Canada. (mmo2006-003 DR)
®™Trademarks of Bombardier Recreational Products Inc. or its affiliates.
©2005 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.
* Trademark of Bombardier Inc. used under license.

FOREWORD
Congratulations on your purchase of a new SKI-DOO snowmobile.
Whatever model you have chosen, it is backed by the Bombardier
Recreational Products inc. (BRP) warranty and a network of autho-
rized SKI-DOO snowmobile dealers ready to provide the parts, ser-
vice or accessories you may require.
The Operator's Guide has been prepared to acquaint the
owner/operator and passenger with this new snowmobile and
its various controls, maintenance and safe riding instructions. This
guide is indispensable for the proper use of the product and should
be kept with this snowmobile at all times.
Make sure you read and understand the content of this Operator's
Guide.
After reading, please keep this Operator's Guide with the snowmo-
bile. If the snowmobile is resold, please give the guide to the new
owner for his awareness. An extra copy of the Operator's Guide is
available from your SKI-DOO snowmobile dealer at no charge.
If you have any question regarding any topic whether or not it is cov-
ered in this Operator's Guide, please call BRP at the number below
and we will be happy to assist you:
In USA:
[phone]
In Canada:
[phone]
This guide uses the following safety alert symbol in conjunction with
signal words to indicate a potential personal injury hazard.
WARNING
Indicates a potentially hazardous situation which, if not avoid-
ed, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoid-
ed, may result in minor or moderate injury. When used with-
outthesafetyalertsymbol, potential hazard exists for prop-
erty damage only.
NOTE: Indicates supplementary information needed to fully com-
plete an instruction.
__________________________ 1

Although the mere reading of such information does not eliminate
the hazard, the understanding and application of the information will
promote the correct use of the vehicle.
Your dealer is committed to your satisfaction. He has taken train-
ing to perform the initial set-up and inspection of your snowmobile
as well as completed the final adjustment required to suit your spe-
cific weight and riding environment before you took possession. At
delivery, your dealer would have explained the snowmobile controls
and provided you with a brief explanation of the various suspension
adjustments. We trust you have taken full advantage of this!
At delivery, you were also informed of the warranty coverage and
have completed the Warranty Registration process.
The information and components/system descriptions contained in
this guide are correct at time of publication. BRP, however maintains
a policy of continuous improvement of its products without impos-
ing upon itself any obligation to install them on products previously
manufactured.
Because of its ongoing commitment to product quality and innova-
tion, BRP reserves the right at any time to discontinue or change
specifications, designs, features, models or equipment without in-
curring obligation.
The illustrations in this document show the typical construction 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.
It is understood that this guide may be translated into another lan-
guage. In the event of any discrepancy, the English version shall
prevail.
Specifications are given in the SI metric system with the SAE U.S.
equivalent in parentheses. Where precise accuracy is not required,
some conversions are rounded off for easier use.
Most components of this snowmobile are built with parts dimen-
sioned in the metric system. Most fasteners are metric and must
not be replaced by customary fasteners or vice versa.
We recommend genuine BRP products for replacement parts and
accessories. They've been specially designed for your vehicle and
manufactured to meet BRP's demanding standards.
ASHOP MANUAL canbeobtainedforcompleteservice,mainte-
nance and more repair information.
For any questions pertaining to the warranty and its application, con-
sult the WARRANTY section in this guide, and/or an authorized SKI-
DOO dealer.
2__________________________

TABLE OF CONTENTS
SAFETY INFORMATION
INTRODUCTION ................................................... 8
IMPORTANT BASIC SAFETY MEASURES....................... 9
LAWS AND REGULATIONS...................................... 14
RIDING THE VEHICLE ............................................ 15
Principle of Operation.......................................... 15
How to Ride.................................................... 16
Carrying a Passenger .......................................... 21
Terrain/Riding Variations........................................ 23
Transporting and Towing....................................... 29
TRACTION ENHANCING PRODUCTS........................... 30
SAFETY LABELING ............................................... 37
ENVIRONMENT INFORMATION
GENERAL.......................................................... 54
JUST WHAT IS LIGHT TREADING? ............................. 56
WHY IS LIGHT TREADING SMART ............................. 57
VEHICLE INFORMATION
HOW TO IDENTIFY YOUR SNOWMOBILE ..................... 60
CONTROLS/INSTRUMENTS/EQUIPMENT .................... 63
1) Speedometer................................................ 64
2) Tachometer.................................................. 69
3) Electric Fuel Level Gauge................................... 70
4) Temperature Gauge ......................................... 71
5) Throttle Lever................................................ 71
6) Brake Lever.................................................. 72
7) Parking Brake Lever......................................... 72
8) START/RER Button.......................................... 72
9) Handlebar.................................................... 75
10) Holding Strap............................................... 75
11) Ignition Switch ............................................. 76
12) Tether Cut-Out Switch..................................... 77
13) Engine Cut-Out Switch .................................... 80
14) Headlamp Dimmer Switch................................. 82
15) Rewind Starter Handle..................................... 82
16) Choke Lever................................................ 83
__________________________ 3

17) Fuel Tank Cap .............................................. 84
18) Mechanical Fuel Level Gauge ............................. 84
19) Heating Grip/Throttle Lever Switch ....................... 86
20) Rear Passenger Heating Grip Switch...................... 87
21) Rear Grab Handles......................................... 87
22) Adjustable Backrest........................................ 87
23) Electric Visor Jack Connector.............................. 88
24) 12-Volt Power Outlet....................................... 90
25) Windshield ................................................. 91
26) Adjustable Mirrors ......................................... 91
27) Adjustable Toeholds........................................ 91
28) Heated Carburetor Valve................................... 91
29) Hood and Side Panel Latches ............................. 92
30) Fuses....................................................... 96
31) Front Grab Handle/Front Bumper........................ 103
32) Storage Compartment................................... 104
33) Rear Rack ................................................ 106
34) Tool Kit.................................................... 106
35) Suitcase .................................................. 107
36) Integrated Bag ........................................... 110
37) 2+1 Seat.................................................. 111
38) Spark Plug Holder........................................ 117
39) Spare Drive Belt Holder.................................. 118
40) Hitch...................................................... 120
41) Shields and Guards ...................................... 120
42) Track...................................................... 120
RECOMMENDED FUEL AND OIL.............................. 122
BREAK-IN PERIOD.............................................. 125
OPERATING INSTRUCTIONS.................................. 126
Pre-Operation Check......................................... 126
SDI Engine Starting Procedure .............................. 128
Carburetor Engine Starting Procedure....................... 129
Vehicle Warm-Up............................................. 131
Shutting Off the Engine...................................... 132
Post-Operation Care ......................................... 132
Suspension Adjustments .................................... 132
SPECIAL OPERATING INSTRUCTIONS....................... 146
Riding at High Altitudes or Sea Level........................ 146
Riding in Cold Weather ...................................... 146
Emergency Starting.......................................... 146
Towing an Accessory ........................................ 149
4__________________________

Towing Another Snowmobile................................ 150
Transporting the Vehicle ..................................... 150
TROUBLESHOOTING........................................... 151
SPECIFICATIONS ............................................... 156
MAINTENANCE INFORMATION
PERIODIC MAINTENANCE CHART............................ 170
ENGINE SYSTEM............................................... 175
Air Filter Cleaning ............................................ 175
Cooling System .............................................. 176
Exhaust System.............................................. 177
Oil Injection System.......................................... 177
EPA Certified Engines........................................ 178
DRIVE SYSTEM................................................. 181
Belt Guard Removal and Installation ........................ 181
Brake Fluid Level............................................. 182
Brake Condition .............................................. 183
Brake Adjustment............................................ 183
Chaincase/Oil Level .......................................... 183
Drive Chain Tension.......................................... 184
Drive Belt Condition.......................................... 185
Drive Belt Removal/Installation.............................. 186
Drive Pulley Adjustment ..................................... 189
Track Condition............................................... 193
Track Tension and Alignment ................................ 194
ELECTRICAL SYSTEM.......................................... 200
Battery Electrolyte ........................................... 200
REAR SUSPENSION............................................ 201
STEERING AND FRONT SUSPENSION....................... 202
BODY/FRAME................................................... 203
Vehicle Cleaning and Protection............................. 203
Bulb Replacement............................................ 204
Headlamp Beam Aiming..................................... 205
__________________________ 5

STORAGE AND PRESEASON PREPARATION................ 207
WARRANTY
BRP LIMITED WARRANTY NORTH AMERICA: 2006 SKI-DOO®
SNOWMOBILES ................................................ 210
BRP INTERNATIONAL LIMITED WARRANTY: 2006 SKI-DOO®
SNOWMOBILES ................................................ 216
PRIVACY OBLIGATIONS/DISCLAIMER ....................... 221
CHANGE OF ADDRESS OR OWNERSHIP .................... 222
6__________________________

SAFETY
INFORMATION
______SAFETY INFORMATION _____ 7

INTRODUCTION
Everyone is a beginner the first time he sits behind the controls of a
snowmobile regardless of previous experience in driving an automo-
bile, a motorcycle or a motorboat. The safe use of your snowmobile
is dependent on many conditions such as visibility, speed, weather,
environment, traffic, vehicle condition and the condition of the driver.
Each operator has a responsibility to ensure the safety of his/her pas-
senger, if any, and of other recreationists or bystanders.
You are responsible for proper operation of your vehicle as well as
training those whom you allow to ride or drive. There may be notice-
able handling and performance differences from one snowmobile to
the other.
A snowmobile is relatively simpleto operate but like any other vehicle
or mechanical equipment, it can be hazardous if you or a passenger
are reckless, thoughtless or inattentive. We encourage you to have
an Annual Safety Inspection of your snowmobile. Please contact an
authorized SKI-DOO dealer for further details. Finally, we urge you to
visit an authorized SKI-DOO dealer periodically for regular and safety
maintenance, as well as snowmobile accessories you may require.
8_____ SAFETY INFORMATION _____

IMPORTANT BASIC SAFETY MEASURES
Training
Basic training is required for the safe operation of any snowmo-
bile. Study your Operator's Guide paying particular attention to
cautions and warnings. Join your local snowmobile club: its so-
cial activities and trail systems are planned for both fun and safety.
Obtain basic instructions from your snowmobile dealer, friend, fel-
low club member or enroll in your state or provincial safety training
program.
Always show a new operator how to start and stop the vehicle.
Indicate the correct riding positions and, above all else, only allow
him to operate the snowmobile in a restricted flat area —at least
until he is completely familiar with its operation. If there is a local
snowmobile operator's training course existing, have him enroll.
Performance
The performance of some snowmobiles may significantly exceed
that of other snowmobiles you have operated. Therefore, use by
novice or inexperienced operators is not recommended.
Snowmobiles are used in many areas and in many snow condi-
tions. Not all models perform the same in similar conditions. Al-
ways consult your snowmobile dealer when selecting the snow-
mobile model for your particular needs and uses.
Injury or death may result to the snowmobile operator, passenger
or bystander if the snowmobile is used in risky conditions which
are beyond the driver's, passenger's or snowmobile's capabilities
or intended use.
Age
BRP recommends the operator has at least 16 years old of age.
Speed
Speeding can be fatal. In many cases, you cannot react or respond
quickly enough to the unexpected. Always ride at a speed which
is suitable to the trail, weather conditions and your own ability.
Know your local rules. Speed limit may be in effect and meant to
be observed.
Riding
Always keep right hand side of the trail.
______SAFETY INFORMATION _____ 9

Always keep a safe distance from other snowmobiles and by-
standers.
Remember, promotional material may show risky maneuvers per-
formed by professional riders under ideal and/or controlled condi-
tions. You should never attempt any such risky maneuvers if they
are beyond your level of riding ability.
Never ride after consuming drugs or alcohol or if you feel tired or
ill. Operate your snowmobile prudently.
Your snowmobile is not designed to be operated on public streets,
roads or highways.
Snowmobiling at night can be a delightful experience but because
of reduced visibility, be extra cautious. Avoid unfamiliar terrain and
be sure your lights are working. Always carry a flashlight and spare
light bulbs.
Nature is wonderful but don't let it distract your attention from
driving. If you want to truly appreciate winter's scenery, stop your
snowmobile on the side of the trail so that you don't become a
hazard to others.
Fences represent a very serious threat for both you and your
snowmobile. Give a wide berth to telephone poles or posts.
Hidden wires unseen from a distance can cause serious accidents.
Always wear an approved safety helmet, eye protection and a face
shield. This also applies to your passenger.
Be aware of inherent risks associated with riding off trails, such
as avalanche and other natural or man made hazards or obstacles.
Avoid road traveling. If you must do so, and it is permitted, re-
duce speed. The snowmobile is not designed to operate or turn
on paving. When crossing a road, make a full stop, then look care-
fullyinbothdirectionsbeforecrossingata90°angle. Be wary of
parked vehicles.
Tailgating another snowmobile should be avoided. If the snowmo-
bile in front of you slows for any reason, its driver and passenger
could be harmed through your neglect. Maintain a safe stopping
distance between you and the snowmobile in front of you. De-
pending on the terrain condition, stopping may require a little more
space than you think. Play it safe. Be prepared to use evasive driv-
ing.
10 _____SAFETY INFORMATION _____

Venturing out alone with your snowmobile could also be haz-
ardous. You could run out of fuel, have an accident, or damage
your snowmobile. Remember, your snowmobile is capable of
traveling further in half an hour than you may be able to walk
in a day. Use the “buddy system”. Always ride with a friend
or member of your snowmobile club. Even then, tell someone
whereyouaregoingandtheapproximatetimeyouplantoreturn.
Meadows sometimes have low areas where water accumulate
and freezes over in winter. This ice is usually glare ice. Attempting
to turn or brake on this surface could cause your vehicle to spin
out of control. Never brake or attempt speeding or turning on glare
ice. If you do happen to travel over such a condition, reduce speed
by carefully releasing the throttle.
Never “jump”with your snowmobile. This should be left to pro-
fessional stunt men. Don't show off. Be responsible.
Whileonsafari,donot“gun”the throttle. Snow and ice can be
thrown back into the path of a following snowmobile. In addition,
when “gunning”the throttle, the vehicle digs into and leaves an
irregular snow surface for others.
Safaris are both fun and enjoyable but don't show off or overtake
others in the group. A less experienced operator might try to do
the same as you and fail. When riding with others, limit your abil-
ities to the experience of others.
Operation
Always make a pre-start inspection BEFORE you turn on the igni-
tion.
In an emergency, the snowmobile engine can be stopped by ac-
tivating the engine cut-out switch, pulling the tether cord cap or
turning off the key.
Throttle mechanism should be checked for free movement and
return to idle position before starting engine.
Always engage parking brake when vehicle is not in use.
Never run the engine in a non-ventilated area and/or if vehicle is
left unattended.
Never operate the engine without belt guard securely installed or,
with hood or access/side panels open or removed. Never run the
engine without drive belt installed. Running an unloaded engine
such as without drive belt or with track raised, can be dangerous.
Electric start models only: Never charge or boost a battery while
installed on snowmobile.
_____ SAFETY INFORMATION _____ 11

Ensure the path behind is clear of obstacles or bystanders before
proceeding in reverse.
Do not leave your keys in the ignition switch, it is an invitation to
thieves and a danger to young children.
Raising the rear of your snowmobile while the engine is running
could cause snow, ice or debris to be thrown back at an observer.
Never raise the rear of the vehicle while the engine is running. To
clear or inspect the track, stop the engine, tilt the vehicle on its
side and remove blockage with a piece of wood or branch. Never
allow anyone near a rotating snowmobile track.
Maintenance
Know your snowmobile and treat it with the respect and care due
of any power driven machine. Common sense, proper handling
and routine maintenance will result in safer and enjoyable use.
Only perform procedures as detailed in this guide. Unless other-
wise specified, engine should be turned OFF and cold for all lubri-
cation, adjustment and maintenance procedures.
Never have the engine running while the hood is open. Even at
idle, a snowmobile engine is turning around 1,800 revolutions per
minute. Always turn off the ignition before opening the hood for
any reason.
Never remove any original equipment from your snowmobile.
Each vehicle has many built in safety features. Such features
include various guards and consoles, plus reflective materials and
warning labels.
A poorly maintained snowmobile itself can be a potential hazard.
Excessively worn components could render the vehicle complete-
ly inoperative. Keep the snowmobile in good working condition
at all times. Follow your pre-operation check, weekly, monthly
and annually routine maintenance and lubrication procedures as
detailed in this guide. Consult a snowmobile dealer or acquire a
shop manual and proper tools and equipment if other repairs or
service is required.
Do not stud the track unless it as been approved for studs. At
speed, a studded track that as not been approved for studs could
tear and separate from vehicle posing a risk of severe injury or
death.
12 _____SAFETY INFORMATION _____

Fuel
Always stop the engine before refueling. Fuel is flammable and
explosive under certain conditions. Always work in a well-venti-
lated area. Do not smoke or allow open flames or sparks in the
vicinity. Open cap slowly. If a differential pressure condition is no-
ticed (whistling sound heard when loosening fuel tank cap) have
vehicle inspected and/or repaired before further operation. Do not
overfill or top off the fuel tank before placing the vehicle in a warm
area. As temperature increases, fuel expands and might overflow.
Always wipe off any fuel spillage from the vehicle. Periodically ver-
ify fuel system.
Basics for Passenger
Never ride as a passenger unless the snowmobileis equipped with
a passenger seat, and sit only on the designated passenger seat.
Always wear a DOT approved helmet and follow the same dress-
ing guidelines as those recommended for the operator and de-
scribed in this guide.
Make sure that you are able to achieve a stable stance, both feet
resting positively on the footboards of footrests with good grip,
andthatyouareabletoholdonfirmlytothehandholds.
Once underway, if you feel uncomfortable or insecure for any rea-
son, don‘t wait, tell the driver to slow down or stop.
_____ SAFETY INFORMATION _____ 13

LAWS AND REGULATIONS
Know your local laws.
Federal, state, provincial and local government agencies have enact-
ed laws and regulations pertaining to the safe use and operation of
snowmobiles. It is your responsibility as a snowmobiler to learn and
obey these laws and regulations. Respect and observance will re-
sult in safer snowmobiling for all.
Be aware of the liability property damages and insurance laws re-
garding your equipment.
14 _____SAFETY INFORMATION _____

RIDING THE VEHICLE
Before venturing on the trails, operate the snowmobile in a restricted
flat area until you are completely familiar with its operation and feel
comfortable that you can safely tackle a more demanding task. Have
an enjoyable and safe ride.
Principle of Operation
Propulsion
Depressing throttle lever increases engine RPM causing the drive
pulley to engage. Depending on models, engine RPM must be be-
tween 2500 and 4200 before drive pulley engagement will occur.
Outer sheave of drive pulley moves toward inner sheave, forcing the
drive belt to move upward on the drive pulley and simultaneously
forcing the sheaves apart on the driven pulley.
The driven pulley senses the load on the track and limits the belt
movement. The result is an optimized speed ratio between engine
RPM and the speed of the vehicle at any time.
WARNING
Never operate engine without belt guard securely installed or,
with hood or access/side panels open or removed.
Power is transferred to the track through the chaincase or gearbox
and drive axle.
WARNING
Always use a wide-base snowmobile mechanical stand to
properly support vehicle during any track verification. Slowly
accelerate engine in order to rotate track at very low speed
when it is not on ground.
Tu rn in g
Handlebar controls the steering of the vehicle. As the handlebar is
rotated to right or left, the skis are turned right or left to steer the
snowmobile.
_____ SAFETY INFORMATION _____ 15

Stopping
Before riding your snowmobile, you should understand how to stop
it. This is done by releasing the throttle and gradually depressing
the brake lever on the left side of the handlebar. In an emergency,
you may stop your vehicle by pressing the engine cut-out switch
located near the throttle control and applying the brake. Remember,
a snowmobile cannot “stop on a dime”. Braking characteristics vary
with deep snow, packed snow or ice. If the track is locked during
hard braking, skidding may result.
How to Ride
How to Dress
Proper snowmobile clothing should be worn. It should be comfort-
able and not too tight. Always check the weather forecast before
going on a ride. Dress for the coldest weather expected. Thermal
underwear next to the skin also provides a good insulation.
DOT approved helmets are recommended at all times. They provide
both warmth and reduce injury. A stocking type cap, balaclava and
face mask should always be carried or worn. Goggles or a face shield
that attach to the helmet are indispensable.
Hands should be protected by a pair of snowmobile gloves or mitts
which have sufficient insulation and allow use of thumbs and fingers
for operation of controls.
Rubber bottom boots with either a nylon or a leather top, with re-
movable felt liners are best suited for snowmobiling.
You should keep yourself as dry as possible when snowmobiling.
When you come indoors, take your snowmobile suit and boots off
and make certain they dry properly.
Do not wear long scarfs and loose apparels that could get caught in
moving parts.
What to Bring
Every snowmobiler should carry at least the following basic parts and
tools that can help him and others in an emergency:
•this Operator's Guide
•spare spark plugs and wrench
•friction tape
•spare drive belt
•spare starter rope
•spare light bulbs
16 _____SAFETY INFORMATION _____

•tool kit (including at least pliers, screwdriver, adjustable wrench)
•knife
•flashlight.
Include other items depending on the length and time of your ride.
Riding Position
Your riding position and balance are the two basic principles of mak-
ingyoursnowmobilegowhereyouwantitto. Whenturningonthe
side of a hill, you and your passenger must be ready to shift body
weight to help it turn in the desired direction. Driver and passen-
ger(s) must never attempt this maneuvering by placing feet outside
of the vehicle. Experience will teach you how much lean to put into
turns at different speeds and how much you will have to lean into a
slopetomaintainproperbalance.
Generally, the riding position for best balance and control is sitting.
However, the posting, kneeling or standing positions are also used
under certain conditions.
The novice driver should become familiar with the snowmobile
through practice on a level area at slow speeds before venturing
afield.
WARNING
Do not attempt any maneuvers if they are beyond your abili-
ties.
_____ SAFETY INFORMATION _____ 17

Sitting
Feet on the running boards, body midway back on seat is an ideal po-
sition when operating the snowmobile over familiar, smooth terrain.
Knees and hips should remain flexible to absorb shocks.
mmo2006-003-001
18 _____SAFETY INFORMATION _____