🏷️ Basic Information Identification Make: Ski-Doo Model: REV Chassis Snowmobiles Year: 2004 Product Type: Service Manual / Repair Manual Documentation Focus: Factory Repair Procedures Documentation Format: PDF Download 👋 Introduction Market Position Positioning: Essential documentation for owners and technicians of 2004 Ski-Doo REV chassis snowmobiles, offering factory-level repair and maintenance guidance. Competitive Analysis Value Proposition: Provides accurate, detailed, and factory-sourced information that is critical for proper maintenance and repair, significantly more valuable than aftermarket or generic guides. Key Features Features: Comprehensive coverage, detailed diagrams, torque specifications, troubleshooting, complete rebuild procedures, instant download. 📋 Manual Details Coverage Areas Primary Coverage: 2004 Ski-Doo REV Chassis Snowmobiles Secondary Coverage Potential: Similar REV platform models from adjacent years (confirmation required based on VIN structure and component compatibility) Page Count Estimated Page Count: Comprehensive (typically 300-600+ pages for a full service manual) Manual Type Type: Factory Service Manual (FSM) Language Language: English (Standard for factory manuals, regional variations may exist) Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete teardown, rebuild, inspection, specifications (pistons, rings, cylinders, crankshaft, connecting rods, valve train where applicable) Engine Fuel System: Carburetor/Fuel Injection system diagnostics, cleaning, adjustment, component replacement, fuel pump (if applicable) Engine Ignition System: CDI unit, ignition coils, spark plug specifications, timing (if adjustable/specified) Cooling System: Radiator, coolant flow, thermostat, water pump, fan operation (if equipped) Exhaust System: Exhaust manifold, muffler, pipe inspection and replacement Drivetrain Clutch: Primary and secondary clutch inspection, maintenance, adjustment, roller/weight replacement, spring replacement, belt inspection and replacement Drivetrain Chaincase: Chaincase lubrication, chain inspection, tension adjustment, gear inspection, bearing checks Suspension Front: Front suspension geometry, shock absorber service, spindle inspection, A-arm bushing replacement, ski spindle alignment Suspension Rear: Rear suspension linkage, shock absorber service, track tension adjustment, bogie wheel inspection and replacement Braking System: Brake caliper service, brake pad replacement, brake fluid flush and bleed, master cylinder inspection, brake disc inspection Steering System: Handlebar, steering post, tie rod inspection, spindle alignment, steering linkage lubrication Electrical System: Battery maintenance, lighting system (headlights, taillights, brake light), wiring harness inspection, starter motor operation, charging system (stator, rectifier/regulator) Body Chassis: Body panel removal and installation, seat, windshield, tunnel inspection and repair Procedures Included Routine Maintenance: Lubrication points, belt inspection, track adjustment, coolant check, battery check, spark plug replacement Engine Repair: Complete engine rebuilds, piston and ring replacement, bearing replacement, seal replacement, cylinder head service Transmission Repair: Clutch maintenance and replacement, chaincase service, gear inspection and replacement Suspension Repair: Shock absorber servicing, linkage bushing replacement, track system repair Brake Service: Brake pad and disc replacement, caliper overhaul, hydraulic system bleeding Electrical Diagnostics: Troubleshooting electrical faults, testing components, wiring diagrams Troubleshooting Guides: Diagnostic flowcharts, symptom-based troubleshooting for common issues Specifications And Torques: All critical torque values for fasteners, engine component clearances, fluid capacities Technical Depth Depth: Comprehensive: Covers basic maintenance to full component overhaul and system diagnostics. Diagnostic Tools: While not explicitly listing diagnostic tools, the manual provides the information necessary to diagnose issues using standard mechanical and electrical testing methods. Visual Aids: Includes pictures and part diagrams for clear understanding of assembly and procedures. 📊 Manual Specifications File Format Format: PDF Searchable Text: Likely searchable text (standard for professionally produced PDFs), allowing for quick access to specific topics. Print Quality Quality: High-resolution scans of original factory documentation. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Rotax 2-Stroke (Specific displacement and configuration depend on the exact model within the REV chassis, e.g., Rotax 377, 440, 500, 550, 593, 600, 700, 800 series) Performance Horsepower Range: Varies significantly by engine. Typically from 60 HP (smaller displacements) to over 130 HP (larger displacements) for this era. Torque Range: Varies significantly by engine. Typically from 45 ft-lbs to over 90 ft-lbs. Fuel System Induction: Carbureted (e.g., Mikuni, Dell'Orto) or Electronic Fuel Injection (EFI) depending on specific model variant. Fuel Type Fuel: Unleaded Gasoline (Octane requirement specified by model, typically 87 or 89 octane) Lubrication Oil System: Pre-mix or Oil Injection System (automatic oil injection is common for this era) 🔧 Transmission Standard Type: CVT (Continuously Variable Transmission) with Primary (Drive) and Secondary (Driven) Clutches Optional Options: N/A (CVT is standard for snowmobiles of this type) Features Clutch Operation: Sheave movement dictated by centrifugal force (weights) and spring pressure, activated by engine RPM and load. Drive Belt: Specific drive belt part number required for each model/engine combination (detailed in manual). 📐 Dimensions Exterior Chassis Platform: REV (Revolutionary Ergonomic Vehicle) platform, known for its rider-forward and centralized mass design. Weights Dry Weight: Varies by model and engine, typically ranging from 400 lbs to 550 lbs. 🛡️ Safety Features Ratings Safety Standards: Designed to meet or exceed relevant snowmobile safety standards of the time. Active Features Safety Features: Throttle safety lever, brake lever, kill switch, proper lighting. Passive Features...