2005 Ski-Doo Tundra, Skandic, Expedition Shop Manual
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- 2005 Tundra Skandic Expedition repair manual
Original Ski-Doo Shop Manual covers the following models:
- TUNDRA
- SKANDIC - LT/LT E/WT/SWT/WT LC/SUV 550/SUV 600
- EXPEDITION - TUV 600 HO SDI/TUV V-1000
Manual Chapters:
TABLE OF CONTENTS
SAFETY NOTICE
INTRODUCTION
- Vehicle description decal
- Vehicle identification number (VIN)
- Engine serial number
- List of abbreviations used in this manual
- Arrangement of this manual
- General information
- Illustrations and procedures
- Self-locking fasteners procedure
- Loctite application procedure
- Threadlocker
- Stripped thread repair
- Gasket compound
- Mounting on shaft
- Case-in components
- Tightening torque
SECTIONS
- MAINTENANCE
- MAINTENANCE CHART
- STORAGE
- General
- Vehicle cleaning
- Engine compartment
- Battery
- Fuel stabilizer
- Engine lubrication
- Cooling system
- Engine oil change and filter
- Countershaft lubrication
- Pulley protection
- Vehicle protection
- Rags in air intake and exhaust system
- PRESEASON PREPARATION
- Fuel filter replacement
- Throttle body cleaning (on so equipped models)
- Carburetor cleaning (on so equipped models)
- Air filter cleaning
- Rags in air intake and exhaust system
- Engine lubrication
- Cleaning of drive and driven pulleys
- Cleaning of brake disk
- Drive belt condition
- Spark plugs
- TROUBLESHOOTING GUIDE
- ENGINE (2-STROKE)
- ENGINE (4-TEC)
- Cooling system
- Alternator
- Lubrication
- Cylinder and cylinder head
- Crankshaft
- Electric starter
- Engine general
- FUEL AND OIL SYSTEMS (2-STROKE ENGINES)
- TRANSMISSION AND BRAKE SYSTEMS
- Transmission
- Brake system
- Mechanical brake
- Hydraulic brake
- Mechanical and hydraulic brakes
- ELECTRICAL SYSTEM
- SUSPENSION AND TRACK
- ENGINES (2-STROKE)
- 277 ENGINE TYPE
- Engine removal and installation
- Removal from vehicle
- Engine support and muffler disassembly and assembly
- Installation on vehicle
- Top end
- Troubleshooting
- Top end removal (without removing engine from chassis)
- Cleaning
- Disassembly
- Inspection
- Assembly
- Bottom end
- Cleaning
- Disassembly
- Inspection
- Assembly
- 443 AND 552 ENGINES
- Engine removal and installation
- Engine removal and installation
- Top end
- General
- Troubleshooting
- Cleaning
- Disassembly
- Inspection
- Assembly
- Bottom end
- Cleaning
- Disassembly
- Inspection
- Assembly
- Break-in
- 593 AND 593 HO SDI ENGINES
- Removal from vehicle
- Installation on vehicle
- Top end
- General
- Troubleshooting
- Component removal
- Cleaning
- RAVE valve basic operation
- Disassembly
- Inspection
- Assembly
- Bottom end
- Cleaning
- Disassembly
- Inspection
- Assembly
- Break-in
- LEAK TEST AND ENGINE DIMENSION MEASUREMENT
- Leak test
- Preparation
- Procedure
- Finalizing reassembly
- Engine leak verification flow chart
- Engine dimension measurement
- Cylinder head warpage
- Cylinder taper
- Cylinder out of round
- Combustion chamber volume measurement
- Used piston measurement
- Cylinder/piston clearance
- Ring/piston groove clearance
- Ring end gap
- Crankshaft deflection
- Connecting rod big end axial play
- Crankshaft end-play
- Checking surface flatness
- Rectifying surfaces
- Checking crankshaft alignment
- MAGNETO SYSTEM
- General
- Cleaning
- Disassembly
- Assembly
- INJECTION SYSTEM
- Oil injection pump
- General
- Oil type
- Oil system leak test
- Oil pump identification
- Cleaning
- Disassembly
- Assembly
- Adjustment
- Bleeding oil lines
- Checking operation
- AXIAL FAN COOLING SYSTEM
- Removal
- Cleaning
- Disassembly and assembly
- Installation
- Fan belt replacement and deflection adjustment
- LIQUID COOLING SYSTEM
- Cooling system leak test
- Inspection
- Draining the system
- Disassembly and assembly
- Cooling system refilling procedure
- REWIND STARTER
- Inspection
- Removal
- Rope replacement
- Disassembly
- Assembly
- Installation
- FUEL SYSTEM
- Carburetor
- Identification
- Removal
- Cleaning and inspection
- Disassembly and assembly
- Carburetor adjustments
- Installation
- Idle speed final adjustment
- Choke
- Fuel pump
- Removal
- Pump verification
- Cleaning and inspection
- Installation
- Fuel tank
- ENGINE (4-TEC)
- LEAK TEST
- Verification
- Leak test procedure
- Preparation and test
- Preparation
- Installation
- REMOVAL AND INSTALLATION
- Engine removal
- Engine installation
- COOLING SYSTEM
- Cooling system leak test
- Inspection
- Coolant replacement
- Coolant hoses
- Water pump housing/thermostat
- Water pump impeller
- Ignition cover
- Water pump shaft
- Pressure cap
- Radiators
- LUBRICATION SYSTEM
- General
- Oil level check
- Engine oil pressure test
- Oil change
- Oil filter
- Oil tank
- Oil filter housing
- Engine oil pressure regulator
- Oil pumps
- Pressure oil pump
- Suction oil pump
- Oil nozzle
- Oil sieves
- Reed valve
- CYLINDER AND CYLINDER HEAD
- Cylinder/cylinder head 1 (front-side)
- Cylinder/cylinder head 2 (rear-side)
- General
- Spark plug
- Temperature sensor
- Valve cover
- Rocker arm
- Chain tensioner
- Breather
- Decompressor
- Camshaft timing gear
- Timing chain
- Cylinder head
- Camshaft
- Valve springs
- Valve
- Cylinder
- Piston
- CRANKSHAFT/DRIVE GEARS
- Timing chain
- Drive gears
- Trigger wheel
- Crankshaft
- Crankshaft locking tool
- Piston
- Piston rings
- CRANKCASE
- General
- PTO cover
- Crankcase
- ENGINE MANAGEMENT (2-TEC)
- OVERVIEW
- Operating principle
- Air induction
- Fuel delivery system
- General
- Component description
- Engine management system (EMS)
- EMS — General functions
- EMS — Engine management system functions
- Electronic fuel injection
- Ignition timing
- Electronically controlled RAVE
- Knock sensor
- Engine modes of operation
- Flooded engine (drowned mode)
- Monitoring system
- Limp home modes
- Diagnostic mode
- Charging system
- Ignition system
- Double ignition coil
- Trigger coil
- DIAGNOSTIC PROCEDURE
- General
- Troubleshooting
- VCK (vehicle communication kit)
- 2-TEC system fault codes
- COMPONENT INSPECTION AND ADJUSTMENT
- General
- Fuel system
- Electrical system
- Resistance measurement
- Engine connector pin-outs
- Air induction system
- Throttle body
- Fuel delivery
- Fuel pump
- Fuel rails
- Fuel injectors
- Electronic management
- ECM replacement
- Engine wiring harness
- Throttle position sensor (TPS)
- Crankshaft position sensor (CPS)
- Air temperature sensor (ATS)
- Coolant temperature sensor (CTS)
- Air pressure sensor (APS)
- Exhaust gas temperature sensor (EGTS)
- Knock sensor (KS)
- E-RAVE solenoid
- Double ignition coil
- Ignition timing
- Engine START/RER button verification
- DESS switch verification
- Spark plugs
- Cranking system
- ENGINE MANAGEMENT (4-TEC)
- OVERVIEW
- Operating principle of engine management
- Air induction
- Fuel delivery system
- Basic operation
- Intake manifold
- Fuel pump module
- Electronic management
- EMS (engine management system)
- ECM
- EMS — General functions
- EMS — Engine management functions
- DIAGNOSTIC PROCEDURE
- General
- Monitoring beeper coded signals
- VCK (vehicle communication kit)
- 4-TEC system fault codes
- 4-TEC TPS fault tables
- COMPONENT INSPECTION AND ADJUSTMENT
- General
- Fuel system
- Electrical system
- Engine connector pin-outs
- Connectors on engine
- Air induction system
- Throttle body
- Fuel delivery
- Fuel pump
- Fuel rails
- Fuel injectors
- Electronic management
- ECM replacement
- Engine wiring harness
- Throttle position sensor (TPS)
- Idle bypass valve
- Crankshaft position sensor (CPS)
- Camshaft position sensor (CAPS)
- Air temperature sensor (ATS)
- Coolant temperature sensor (CTS)
- Manifold air pressures sensor (MAPS)
- Oil pressure switch (OPS)
- Ignition coils
- Engine start switch verification
- DESS switch verification
- Spark plugs
- Cranking system
- TRANSMISSION
- DRIVE BELT
- Application chart
- Checking neutral function
- Cleaning
- Inspection
- Rotation direction
- Drive belt height measurement and adjustment
- Drive belt deflection measurement (reference only)
- DRIVE PULLEY
- Bombardier Lite
- General
- Removal
- Disassembly
- Cleaning
- Inspection
- Assembly
- Installation
- Comet® 102C
- General
- Maintenance
- Removal
- Disassembly
- Cleaning
- Inspection
- Assembly
- Installation
- TRA III
- TRA IV
- General
- Removal
- Disassembly
- Cleaning
- Inspection
- Assembly
- Installation
- Drive pulley adjustment
- DRIVEN PULLEY
- Removal
- Disassembly
- Inspection
- Assembly
- Installation
- Adjustment
- Disassembly
- Inspection
- Assembly
- Installation
- Adjustment
- Removal
- Disassembly
- Cleaning
- Inspection
- Assembly
- Installation
- Adjustment
- PULLEY DISTANCE AND ALIGNMENT
- General
- General procedure
- Pulley alignment and distance specifications chart
- BRAKE
- Mechanical brake
- Hydraulic brake
- Brake fluid type
- Brake pads replacement
- Removal
- Disassembly
- Cleaning
- Inspection
- Assembly
- Installation
- Adjustment
- Bleeding
- CHAINCASE
- Removal
- Disassembly
- Inspection
- Assembly
- Installation
- Adjustment
- Removal
- Inspection
- Gear ratio modification
- Installation
- Drive chain adjustment
- Adjustment
- GEARBOX
- 3-Speed gearbox
- Removal
- Disassembly
- Inspection
- Assembly
- Installation
- Oil level
- DRIVE CHAIN
- General
- Silent chain
- Chain attachment
- Chain separation
- ELECTRICAL
- IGNITION TIMING
- Verifying magneto flywheel timing mark position
- SPARK PLUGS
- NGK spark plug
- NGK spark plug numbering system
- Design symbols used in NGK spark plugs
- Disassembly
- Heat range
- Fouling
- Spark plug analysis
- Spark plug installation
- Spark plug tightening torque
- ALTERNATOR
- Removal
- Inspection
- Installation
- BATTERY
- General
- Removal
- Cleaning
- Inspection
- Battery charge testing
- Battery storage
- Activation of new battery
- Servicing
- Battery charging
- Installation of battery
- Cable terminal installation
- ELECTRIC STARTER
- Removal
- Disassembly
- Cleaning and inspection
- Cleaning
- Inspection
- Assembly
- Installation
- TESTING PROCEDURE
- General
- Ignition system testing sequence
- Lighting system testing sequence
- 1. Sparking
- 2. Electrical connector testing
- 3. Ignition switch, dess switch or tether cord cut-out switch and engine cut-out switch testing
- 4. Ignition generator coil testing
- 5. Trigger coil testing
- 6. MPEM voltage testing
- 7. High voltage coil testing
- 8. Buzzer testing
- Lighting generator coil voltage testing
- Conclusion
- Inspection of AC circuit isolation
- Inspection
- Inspection of heating elements
- REAR SUSPENSION
- TORQUE REACTION SUSPENSION
- Component removal
- Suspension ass'y removal
- Disassembly and assembly
- Inspection
- Suspension ass'y installation
- Ride adjustment
- Lubrication
- ARTICULATING SLIDE SUSPENSION
- Removal
- Disassembly and assembly
- Shock absorber servicing
- Installation
- Ride adjustment
- SUV SUSPENSION
- Removal
- Disassembly and assembly
- Shock absorber inspection
- Installation
- Lubrication
- Ride adjustment
- DRIVE AXLE
- Removal
- Disassembly
- Assembly
- Installation
- Lubrication
- Adjustment
- TRACK
- Track type application
- General
- Inspection
- Removal
- Installation
- STEERING / FRONT SUSPENSION
- STEERING SYSTEM
- Inspection
- Disassembly and assembly
- Handlebar position adjustment
- Steering adjustment (skis)
- Lubrication
- SUSPENSION AND SKI SYSTEM
- On-vehicle component removal
- Disassembly
- Inspection
- Installation
- On-vehicle component verification
- Disassembly
- Inspection
- Installation
- Disassembly
- Inspection
- Installation
- BODY/FRAME
- BODY
- Installation and adjustment
- Headlamp beam aiming
- Bulb replacement
- Decal
- Belt guard
- Wiring harness
- Cables
- Tubing
- Plastic maintenance and repair
- Maintenance
- Repair
- Repair procedure for R.I.M. urethane
- FRAME
- Frame cleaning
- Frame welding
- TECHNICAL DATA
- ENGINES
- VEHICLES
- TECHNICAL DATA LEGENDS
- Engine technical data legend
- Vehicle technical data legend
- WIRING DIAGRAMS
- WIRING DIAGRAMS
- Wire colors and circuit
- ANNEXES
- 2005 TUNDRA R
- 2005 SKANDIC LT 440
- 2005 SKANDIC WT, SKANDIC SWT, SKANDIC SUV 550
- 2005 SKANDIC WT LC, SKANDIC SUV 600
- 2005 EXPEDITION 600 TUV SDI
- 2005 EXPEDITION V-1000 TUV
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Reviews - Write a Review
Rated: 5 by: Jessy Posted: Thursday, January 4, 2024 at 8:23PM
Manual quality is awesome!