This manual covers the 2004 Ski-Doo REV Series Snowmobile, a model known for its innovative REV chassis that revolutionized snowmobile design with its low, forward-mounted engine and rider-forward ergonomics. This engineering offered improved weight distribution and handling, setting a new industry standard. The REV Series is equipped with powerful Rotax engines, including 500 SS, 600 HO, 600 HO SDI, and 800 HO variants, featuring either carbureted or electronic fuel injection systems. These snowmobiles are designed for recreational trail riding and backcountry exploration, offering a blend of performance, reliability, and advanced technology for the 2004 model year. This comprehensive service manual provides detailed information for owners, DIY mechanics, and professional technicians. It covers all major systems, including detailed engine procedures for Rotax 500 SS, 600 HO, 600 HO SDI, and 800 HO engines, drivetrain components like the CVT system, suspension, electrical systems, and fuel systems. The manual includes routine maintenance tasks, troubleshooting guides, diagnostic procedures, and step-by-step repair instructions for everything from basic servicing to complete overhauls. With 431 pages of factory-level documentation, this English-language resource is essential for maintaining, repairing, and ensuring the optimal performance and longevity of your 2004 Ski-Doo REV Series Snowmobile. 🏷️ Basic Information Identification Make: Ski-Doo Model: REV Series Snowmobile Year: 2004 Codes Chassis Platform: REV 👋 Introduction Market Position Target Audience: Owners, DIY mechanics, and professional service technicians looking for detailed repair and maintenance information. Key Features Illustration Quality: Illustrated with clear step-by-step instructions and likely includes exploded views and diagrams. Technical Accuracy: Represents factory-level documentation, ensuring accuracy for repairs and maintenance. Resource Value: Essential for troubleshooting, diagnosis, repair, servicing, restoration, and preventative maintenance. Usage Notes Storage: Can be saved on computers, iPads, hard drives, etc., for unlimited access. 📋 Manual Details Coverage Areas Primary Coverage: Canada/USA (CAN/U.S.) and Europe (EUR) markets Specific Models Covered: GSX LTD, GSX SPORT, MX Z ADRENALINE, MX Z RENEGADE, MX Z TRAIL, MX Z X, SUMMIT ADRENALINE, SUMMIT HIGHMARK, SUMMIT SPORT, SUMMIT X (various engine and color variants). Page Count Total Pages: 431 Manual Type Type: Service Manual / Workshop Manual / Repair Guide Language Language: English Format Format: PDF Download Delivery Method: Instant download via email link after payment. Compression: May be zipped (.zip, .rar) requiring unzipping software. 📖 Manual Coverage Systems Covered Engine: Detailed coverage of Rotax 500 SS, 600 HO, 600 HO SDI, and 800 HO engines including disassembly, inspection, repair, and reassembly. Drivetrain: CVT (Continuously Variable Transmission) system, chaincase, clutch service, and drive axle maintenance. Suspension: Front and rear suspension systems, including shock absorbers, trailing arms, skis, and track maintenance. Electrical: Ignition system, lighting, instrumentation, charging system, battery, and wiring diagrams. Fuel System: Fuel injection system (SDI), carburetors (for non-SDI models), fuel pump, fuel lines, and fuel tank maintenance. Chassis Body: Frame, body panels, seat, handlebars, and general chassis inspection. Cooling System: Radiator, coolant lines, thermostat, and fan (if applicable) service and repair procedures. Exhaust System: Exhaust manifold, muffler, and power valve system inspection and maintenance. Track System: Track inspection, tension adjustment, drive sprocket, and idler wheel maintenance. Steering: Handlebar assembly, steering post, and ski steering linkage service. Procedures Included Maintenance: Routine maintenance tasks, lubrication points, fluid changes, belt inspection and replacement, and pre-season/post-season checks. Troubleshooting: Comprehensive troubleshooting guides for common issues, diagnostic procedures, and error code interpretation. Repair: Step-by-step instructions for engine rebuilds, transmission repairs, suspension component replacement, and electrical system diagnostics. Diagnostics: Detailed diagnostic procedures for all major systems, including engine performance, electrical faults, and operational issues. Clutch Calibration: Detailed guidance on clutch weights, spring, and helix adjustments for optimal performance based on riding conditions and engine variant. Engine Rebuild: Complete engine teardown, parts replacement (pistons, rings, bearings, seals), and reassembly instructions. Suspension Rebuild: Procedures for replacing shock absorbers, bushings, ball joints, and other suspension components. Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and component overhauls, suitable for both DIY enthusiasts and professional technicians. Wiring Diagrams: Includes detailed electrical system wiring diagrams for easy troubleshooting. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable (text-based PDF) for efficient information retrieval. Print Quality Print Capability: Printable on any computer and printer; no printing restrictions. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Family: Rotax 2-stroke Performance Displacement Options: 500 SS, 600 HO, 600 HO SDI, 800 HO Engine Technology: Carbureted (500 SS, 600 HO) and Electronic Fuel Injection (SDI - Sequential Dual Injection). Horsepower 600 Ho: Approximately 110-115 HP Horsepower 800 Ho: Approximately 130-140 HP Bore X Stroke 600Ho: Specific dimensions to be found in the manual, typically around 72mm x 73mm. Bore X Stroke 800Ho: Specific dimensions to be found in the manual, typically around 82mm x 75.7mm. Fuel System Fuel Delivery: Carburetor or Electronic Fuel Injection (EFI) depending on model. Carburetor Size 500Ss: Likely dual 38mm...