Table of Contents
Troubleshooting
Related Manuals for Ski-Doo EXPEDITION TUV 600 HO SDI
Summarization of Contents
SAFETY NOTICE
INTRODUCTION
This Shop Manual covers the following BRP made 2005 snowmobiles.
VEHICLE DESCRIPTION DECAL
Location of the vehicle description decal.
ENGINE SERIAL NUMBER
Location of the engine serial number.
LIST OF ABBREVIATIONS USED IN THIS MANUAL
List of abbreviations used in this manual.
ARRANGEMENT OF THIS MANUAL
Explanation of the manual's layout and typical page structure.
GENERAL INFORMATION
General information about the manual's content and BRP's policies.
ILLUSTRATIONS AND PROCEDURES
Information regarding the use and interpretation of illustrations.
SELF-LOCKING FASTENERS PROCEDURE
Procedure for working with self-locking fasteners.
LOCTITE APPLICATION PROCEDURE
Common application procedures for Loctite products.
THREADLOCKER
Instructions for using threadlocker on uncovered holes and studs.
STRIPPED THREAD REPAIR
Procedures for repairing stripped threads.
GASKET COMPOUND
Application of gasket compound for all parts.
MOUNTING ON SHAFT
Procedures for mounting components on shafts.
CASE-IN COMPONENTS
Procedures for case-in components, specifically metallic gaskets.
TIGHTENING TORQUE
Table of tightening torque specifications for fasteners.
Section 01 MAINTENANCE
Subsection 01 (MAINTENANCE CHART)
Provides a maintenance chart with inspection intervals and tasks.
Subsection 02 (STORAGE)
Procedures for proper snowmobile storage.
Subsection 03 (PRESEASON PREPARATION)
Procedures for preparing the vehicle after summer or long storage.
Section 02 TROUBLESHOOTING GUIDE
Subsection 01 (ENGINE (2-STROKE))
Troubleshooting guide for 2-stroke engines.
Subsection 02 (ENGINE (4-TEC))
Troubleshooting guide for 4-TEC engines.
Subsection 03 (FUEL AND OIL SYSTEMS (2-STROKE ENGINES))
Troubleshooting for fuel and oil systems in 2-stroke engines.
Subsection 04 (TRANSMISSION AND BRAKE SYSTEMS)
Troubleshooting guide for transmission and brake systems.
Subsection 05 (ELECTRICAL SYSTEM)
Troubleshooting guide for electrical system issues.
Subsection 06 (SUSPENSION AND TRACK)
Troubleshooting guide for suspension and track issues.
Section 03 ENGINES (2-STROKE)
Subsection 01 (277 ENGINE TYPE)
Service tools and products for the 277 engine type.
Subsection 02 (443 AND 552 ENGINES)
Service tools and products for 443 and 552 engines.
Subsection 03 (593 AND 593 HO SDI ENGINES)
Service tools and products for 593 and 593 HO SDI engines.
Subsection 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT)
Procedures for leak testing and engine dimension measurement.
Subsection 05 (MAGNETO SYSTEM)
Service tools and products for the magneto system.
Subsection 06 (OIL INJECTION SYSTEM)
Service tools and products for the oil injection system.
Subsection 07 (AXIAL FAN COOLING SYSTEM)
Service tools and products for the axial fan cooling system.
Subsection 08 (LIQUID COOLING SYSTEM)
Service tools and products for the liquid cooling system.
Subsection 09 (REWIND STARTER)
Service products for the rewind starter.
Subsection 10 (FUEL SYSTEM)
Service tools for the fuel system.
Section 04 ENGINE (4-TEC)
Subsection 01 (LEAK TEST)
Procedures for leak testing on 4-TEC engines.
Subsection 02 (REMOVAL AND INSTALLATION)
Procedures for engine removal and installation.
Subsection 03 (COOLING SYSTEM)
Procedures for the cooling system.
Subsection 04 (LUBRICATION SYSTEM)
Service tools and products for the lubrication system.
Subsection 05 (CYLINDER AND CYLINDER HEAD)
Service tools for cylinder and cylinder head components.
Subsection 06 (CRANKSHAFT/DRIVE GEARS)
Service tools for crankshaft and drive gears.
Subsection 07 (CRANKCASE)
Service tools and products for the crankcase.
Section 05 ENGINE MANAGEMENT (2-TEC)
Subsection 01 (OVERVIEW)
Overview of the 2-TEC engine management system.
Subsection 02 (DIAGNOSTIC PROCEDURE)
Diagnostic procedures for engine management systems.
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)
Component inspection and adjustment procedures.
Section 06 ENGINE MANAGEMENT (4-TEC)
Subsection 01 (OVERVIEW)
Overview of the 4-TEC engine management system.
Subsection 02 (DIAGNOSTIC PROCEDURE)
Diagnostic procedures for 4-TEC engines.
Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)
Component inspection and adjustment for 4-TEC engines.
Section 07 TRANSMISSION
Subsection 01 (DRIVE BELT)
Procedures related to the drive belt.
Subsection 02 (DRIVE PULLEY)
Procedures for drive pulley maintenance and replacement.
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