Campaign no.: October 3, 2008 Subject:REV-XP SDI Electrical Issue No REVISION 1 October 9, 2008

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Campaign no.: 2008 0015 October 3, 2008 Subject:REV-XP SDI Electrical Issue No.

1 Campaign no.: October 3, 2008 Subject:REV-XP SDI Electrical Issue No REVISION 1 October 9, 2008 YEAR MODEL MODEL NUMBER SERIAL NUMBER 2008 MX Z 600HO SDI Bk8A - BK8B - BK8C - BK8D - BK8E - BL8A - BL8B - BL8C - BL8D - BW8C - BW8D - BW8E - BW8F - All BX8A - BX8B - BX8C - BX8D - BX8E 2008 GSX 600HO SDI DD8A - DJ8A All PROBLEM On some of the above mentioned vehicles, electrical irregularities of an unknown source may be experienced. This may lead to poor running, performance loss and injector error code. SOLUTION This bulletin gives troubleshooting steps in order to quickly locate and repair electrical irregularities. The following repair procedures must be completed as per this bulletin: Fuel injector connectors servicing Fuel injectors wiring harness routing TPSandCPS wiring harness routing Maintenance on countershaft support nuts Taillight wires chafing Cluster gauge issue (Strictly follow the described procedure in order to avoid damaging cluster or ECM.) PARTS REQUIRED QTY DESCRIPTION P/N Locking tie (Injector harness) Protector tube 125mm(5in) Locking tie (TPS and CPS harness) Cluster Gauge Button SOLD IN PACK OF m NOTE: If cluster gauge issue is discovered on a standard cluster gauge, the same part number (P/N ) is ordered and the assembly can be cut with scissors so that only the Set button is used. REPAIR PROCEDURE Torque wrench tightening specifications must strictly be adhered to. Locking devices (e.g.: locking tabs, cotter pin, etc.) must be replaced with new ones. mbg en DM 2008 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved. and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates. 1/12

Vehicle Preparation Always disconnect battery AND remove 30 A charging system fuse prior to working on the electrical and fuel systems.

Never start engine when the belt guard is removed. mmr2008-040-100_a Step 1: Press tool kit locking tab Step 2: Lift tool kit support 3.

Disconnect BLACK negative cable from battery. 2. Disconnect RED positive cable from battery. 3. Remove 30 A charging system fuse from vehicle.

mmr2008-035-001_a TYPICAL - 30 A CHARGING SYSTEM FUSE Drive Belt Guard Removal 1. Remove LH side panel. 2. Remove tool kit support.

2 Vehicle Preparation Always disconnect battery AND remove 30 A charging system fuse prior to working on the electrical and fuel systems. Always disconnect battery cables exactly in the specifiedorder: Disconnect BLACK negative cable first Then disconnect RED positive cable. Never start engine when the belt guard is removed. mmr _a Step 1: Press tool kit locking tab Step 2: Lift tool kit support 3. Remove belt guard retaining pin. NOTE: For more information about the vehicle parts removal, refer to appropriate SKI-DOO SHOP MANUAL. 1. Disconnect BLACK negative cable from battery. 2. Disconnect RED positive cable from battery. 3. Remove 30 A charging system fuse from vehicle. mmr _a 1. Belt guard retaining pin 4. Lift rear portion of belt guard. 5. Release belt guard from front tabs. mmr _a TYPICAL - 30 A CHARGING SYSTEM FUSE Drive Belt Guard Removal 1. Remove LH side panel. 2. Remove tool kit support. mmr _a 1. Belt guard 2. Belt guard front tabs Primary Air Intake Silencer Removal 1. Unlock connector tube as follows: Lift tab on rear section of connector tube. Twist tube counterclockwise. Pull slightly forward. 2 / WARRANTY

3. Remove muffler springs using spring removal tool (P/N 529 035 983). 529 035 983 4.

mmr2008-010-004_a Step 1: Lift tab Step 2: Twist tube Step 3: Pull forward 2.

Chaincase cover 6. Release drive chain tension by unscrewing tensioner adjustment screw.

Pull airintakesilenceroutofadapterplate. Driven Pulley Removal 1. Remove RH side panel. 2.

mmr2008-042-102_a 1. Tensioner adjustment screw 2. Lock nut 7. Remove upper gear screw. 8.

3 3. Remove muffler springs using spring removal tool (P/N ) Remove muffler from vehicle. 5. Remove chaincase cover filling plug. mmr _a Step 1: Lift tab Step 2: Twist tube Step 3: Pull forward 2. Push securing tab of primary air intake silencer. mmr _a 1. Filling plug 2. Chaincase cover 6. Release drive chain tension by unscrewing tensioner adjustment screw. mmr _a 1. Primary air intake silencer 2. Securing tab 3. Pull airintakesilenceroutofadapterplate. Driven Pulley Removal 1. Remove RH side panel. 2. Disconnect the EGTS (Exhaust Gas Temperature Sensor) connector from vehicle. mmr _a 1. Tensioner adjustment screw 2. Lock nut 7. Remove upper gear screw. 8. Remove conical spring washer. NOTE: Be careful not to let the conical spring washer fall into chaincase. mbg _a 1. EGTS connector WARRANTY / 12

mmr2008-042-103_a 1. Upper gear screw 2. Conical spring washer 9.

mmr2008-042-105_a 1. Driven pulley 2. Countershaft bearing flange 12.

NOTE: If necessary, carefully tap the upper gear retaining tool with a plastic hammer.

Upper gear retaining tool 10. Remove the drive belt from driven pulley. 11.

Unscrew countershaft from the upper gear retaining tool. Do not remove tool.

4 mmr _a 1. Upper gear screw 2. Conical spring washer 9. Install the upper gear retaining tool (P/N ) on countershaft end. mmr _a 1. Driven pulley 2. Countershaft bearing flange 12. Pull the driven pulley to disengage countershaft and upper gear. NOTE: If necessary, carefully tap the upper gear retaining tool with a plastic hammer UPPER GEAR RETAINING TOOL mmr mmr _a 1. Upper gear retaining tool 10. Remove the drive belt from driven pulley. 11. From behind driven pulley, remove nut securing the countershaft bearing flange. 13. Unscrew countershaft from the upper gear retaining tool. Do not remove tool. NOTE: While countershaft is removed from vehicle, the upper gear retaining tool keeps the drive chain and the upper gear in position inside chaincase. Throttle Body Removal 1. Loosen retaining clamps of throttle body. 4 / WARRANTY

295 000 076 5. Detach coolant hoses from throttle body. 6.

Disconnect TPS connector. Fuel Injector Connectors Servicing 1.

Install hose pinchers (P/N 295 000 076) on coolant hoses connected to throttle

5 Detach coolant hoses from throttle body. 6. Disconnect throttle cable. 7. Remove throttle body from vehicle. mmr _a RETAINING CLAMPS 2. Carefully pull throttle body to reach coolant hoses and TPS connector. 3. Disconnect TPS connector. Fuel Injector Connectors Servicing 1. Disconnect fuel injector connectors. mmr _a TPS CONNECTOR 4. Install hose pinchers (P/N ) on coolant hoses connected to throttle body. mmr _a FUEL INJECTOR CONNECTORS 2. Cut locking ties that hold fuel injectors wiring harness. mmr _a HOSE PINCHERS LOCATION WARRANTY / 12

2. Position LH fuel injector harness at least at 8 mm (5/16 in) from countershaft support. mmr2008-033-013_b FUEL INJECTORS WIRING HARNESS LOCKING TIES 3.

mbg2008-022-002_a A. 8 mm (5/16 in) gap 1. LH fuel injector harness 2. Countershaft support 3.

Attach fuel injectors wiring harness on fuel rail using locking ties (P/N 420 866 716) as shown. mbg2008-022-001_a 1. Fuel injector connector 5.

Ensure that locking tie fixation squares are positioned downwards. NOTICE Fuel injector connectors are very fragile.

6 2. Position LH fuel injector harness at least at 8 mm (5/16 in) from countershaft support. mmr _b FUEL INJECTORS WIRING HARNESS LOCKING TIES 3. Look for corrosion and clean fuel injector connector terminals if necessary. 4. Apply dielectric grease (P/N ) to fuel injector connector terminals. mbg _a A. 8 mm (5/16 in) gap 1. LH fuel injector harness 2. Countershaft support 3. Position fuel injectors wiring harness against fuel rail support tabs. 4. Attach fuel injectors wiring harness on fuel rail using locking ties (P/N ) as shown. mbg _a 1. Fuel injector connector 5. Reconnect fuel injector connectors. Fuel Injectors Wiring Harness Routing mbg _a 1. Support tab 2. Fuel injectors wiring harness 3. Locking ties 5. Ensure that locking tie fixation squares are positioned downwards. NOTICE Fuel injector connectors are very fragile. Be careful not to apply tension on them during the harness installation. NOTICE Position the fuel injector harness so thereisagapfromothervehicleparts(e.g.: countershaft, countershaft support, etc.) to ensure the harness does not rub. 1. Inspect fuel injector wiring harness for chafing or cut marks and repair if necessary. mbg _a 1. Locking tie fixation square 6 / WARRANTY

Ensure that fuel injectors wiring harness is: Securely fixed on fuel rail Away from countershaft support TPS and CPS Wiring Harness Routing 1.

Locking tie 2. Crankcase check valve NOTE: Do not overtighten the locking tie. Maintenance to do while Countershaft is Removed 1.

Insert a 125 mm (5 in) protector tube (P/N 515 175 442) onto TPS and CPS wiring harness. mmr2009-008-005_a 1. Nuts to be torqued 2.

Attach TPS and CPS wiring harness on crankcase check valve using locking tie (P/N 414 115 200) as shown.

7 Ensure that fuel injectors wiring harness is: Securely fixed on fuel rail Away from countershaft support TPS and CPS Wiring Harness Routing 1. Locate TPS and CPS harness on RH side of intake adapter. 2. Inspect TPS and CPS harness for wear and crack and repair it if necessary. mbg _a 1. Locking tie 2. Crankcase check valve NOTE: Do not overtighten the locking tie. Maintenance to do while Countershaft is Removed 1. Torque countershaft support lower nuts to 35 N m (26 lbf ft). mbg _a 1. TPS and CPS harness 2. Intake adapter 3. Insert a 125 mm (5 in) protector tube (P/N ) onto TPS and CPS wiring harness. mmr _a 1. Nuts to be torqued 2. Countershaft support Taillight Wires Chafing mbg _a mm (5 in) protector tube 4. Attach TPS and CPS wiring harness on crankcase check valve using locking tie (P/N ) as shown. NOTICE Taillight lens is held in place by two plastic pins inserted in rubber grommets. If lens is forced too far sideways when removing, the lens mounting pins may break and lens will have to be replaced. Do not pull lens out too far to avoid damaging wiring. 1. Remove taillight lens by carefully pulling on lens at both ends. WARRANTY / 12

mmr2008-039-012_a CAREFULLY PULL OUT AT CORNERS mbg2008-021-107_a BEFORE PULLING 1. Protector tube 2.

Rotate bulb holder counterclockwise to remove it from lens. 3. Carefully pull taillight harness toward the rear of vehicle.

have to be removed and the harness laid down in the tunnel channel.

Remove fuel tank side shoulder bushings. Slightly lift up rear part of fuel tank. Cut taillight harness locking tie.

Secure fuel tank side retaining nuts to 33 N m (24 lbf ft). Reinstall fuel tank side trim panels. 4.

8 mmr _a CAREFULLY PULL OUT AT CORNERS mbg _a BEFORE PULLING 1. Protector tube 2. Bulb holder mmr _a 1. Lens retaining pins 2. Retaining grommets 3. Light wire harness 2. Rotate bulb holder counterclockwise to remove it from lens. 3. Carefully pull taillight harness toward the rear of vehicle. NOTE: If the lens does not pull out far enough to work on, the locking tie for the taillight harness under the fuel tank may have to be removed and the harness laid down in the tunnel channel. Refer to the following steps: Remove fuel tank side trim panels. Remove fuel tank side retaining nuts. Remove fuel tank side shoulder bushings. Slightly lift up rear part of fuel tank. Cut taillight harness locking tie. Stretch taillight harness in the tunnel channel. Reinstall fuel tank shoulder bushings. Secure fuel tank side retaining nuts to 33 N m (24 lbf ft). Reinstall fuel tank side trim panels. 4. Pull protector tube toward the bulb holder to protect wires. mbg _a AFTER PULLING 1. Protector tube 2. Bulb holder 5. Secure protector tube on wires using a locking tie (P/N ) as shown. mbg _a 1. Locking tie 6. Remove RH lens grommet. 7. Drill a Ø6.4 mm (1/4 in) hole into lens support as shown. 8 / WARRANTY

mbg2008-021-111_a 1. Ø6.4 mm (1/4 in) hole 8.

Do not tighten locking tie for the moment. mbg2008-021-114_a 1. Taillight harness 2.

Cluster Gauge Issue Rubber Button Replacement 1.

trim, and press carefully to release cluster gauge assembly from console.

From inside lens support, install the locking tie into the drilled hole. 11.

mbg2008-020-001_a 1. Small rectangular holes 2. Disconnect cluster gauge wiring harness.

9 mbg _a 1. Ø6.4 mm (1/4 in) hole 8. Pre-install a locking tie (P/N ) around protector tube. 9. Do not tighten locking tie for the moment. mbg _a 1. Taillight harness 2. Vehicle frame 16. Reinstall taillight lens on vehicle. Cluster Gauge Issue Rubber Button Replacement 1. Insert a small flat screwdriver into the 2 small rectangular holes on top of cluster gauge trim, and press carefully to release cluster gauge assembly from console. mbg _a 1. Locking tie 10. From inside lens support, install the locking tie into the drilled hole. 11. Secure locking tie on taillight harness using the RH grommet hole to tighten. mbg _a 1. Small rectangular holes 2. Disconnect cluster gauge wiring harness. mbg _a 1. Locking tie into the drilled hole 12. Cut the locking tie tail. 13. Reinstall RH lens grommet. 14. Reinstall bulb holder on taillight lens. 15. Verify there is a gap between taillight harness and vehicle frame to avoid rubbing. mbg _a 1. Wiring harness 2. Cluster gauge assembly WARRANTY / 12

3. Locate all locking tabs around cluster gauge assembly and carefully release with a small flat screwdriver.

Separate cluster gauge trim from cluster gauge.

scissors so that only the SET button is used. 7.

10 3. Locate all locking tabs around cluster gauge assembly and carefully release with a small flat screwdriver. mdd NEW RUBBER CLUSTER GAUGE MODE AND SET BUTTON (P/N ) mbg _a LOCKING TABS 4. Separate cluster gauge trim from cluster gauge. Cluster gauge rubber Mode and Set button should now be free; remove and discard. 6. Install new Mode and Set button. NOTE: For a standard cluster gauge, use the same part number as a premium gauge and cut the rubber with scissors so that only the SET button is used. 7. Reverse steps to reinstall trim to cluster gauge and to reinstall cluster gauge assembly to vehicle. mbg _a 1. Cluster gauge 2. Cluster gauge trim 3. Cluster gauge rubber Mode and Set button 5. Remove and discard magnet (s) if fallen on cluster gauge. mbg _a OLD RUBBER CLUSTER GAUGE MODE AND SET BUTTON 10 / WARRANTY

Cluster Gauge Update NOTICE Before proceeding, carefully read and understand the following information and strictly follow the described procedure in order to avoid permanent damages to cluster or

Voltage for all components is critical. Consider using a jumper battery or 2 to 4 amp trickle charger as a back-up power supply during updating calibrations.

If using the MPI 1, be sure to use new batteries or better yet, use a 12 volt AC power adapter. Use the T-Harness (P/N 529 035 869) when connecting to the vehicle 6-pin connector.

11 Cluster Gauge Update NOTICE Before proceeding, carefully read and understand the following information and strictly follow the described procedure in order to avoid permanent damages to cluster or ECM. If using the MPI 2, disconnect the D.E.S.S. Post Interface before proceeding with update. If D.E.S.S. Post Interface is connected, damage to gauge or ECM will occur. Voltage for all components is critical. Consider using a jumper battery or 2 to 4 amp trickle charger as a back-up power supply during updating calibrations. If using a laptop, ensure that the battery is fully charged prior to the process; otherwise connect it to its power supply. If using the MPI 1, be sure to use new batteries or better yet, use a 12 volt AC power adapter. Use the T-Harness (P/N ) when connecting to the vehicle 6-pin connector. When applicable, always connect supply T-harness to a 12 V battery, using the 12 V battery supply cable (P/N ). Do not use the 9 V harness along with a 9 V battery as this may also cause corruption of ECM and gauge. Before updating the ECM calibration file in the vehicle, it is mandatory to erase any ECM error codes or faults. If repairs are needed, carry them out, and then erase faults again. Remember that stable and constant voltage is critical to successful updates. Should voltage drop or communication be lost, the ECM or gauge may be corrupted and permanently damaged. NOTE: A minimum of B.U.D.S. P must be used. 1. Connect vehicle to B.U.D.S. with MPI-1 or MPI-2. NOTICE For cluster gauge update procedure, do not use D.E.S.S. Post Interface (P/N ) if using the MPI _a DO NOT USE DESS POST INTERFACE WITH MPI-2 2. From B.U.D.S. go to: Module Cluster Update. sbs _a 3. Click OK in next screen. mbg TYPICAL NOTICE To avoid permanent damage to the cluster during the reflash operation, wait until the cluster turns OFF, then turns ON and the needles finish swaping after power-on test. Only then, the reflash operation is over. Never cut the vehicle power until the operation is fully completed. WARRANTY / 12

4. Click YES in next screen. vbs2008-012-003 5. Wait until confirmation screen is visible. 6. After update, click OK in confirmation screen. vbs2008-012-004 CONFIRMATION SCREEN 7.

Reinstall the following parts as the reverse of removal procedure: Throttle body Driven pulley assembly Chaincase parts Muffler EGTS connector Primary air intake silencer Drive belt guard.

Reinstall 30 A charging system fuse on vehicle. 4. Reconnect RED positive cable on battery. 5. Reconnect BLACK negative cable on battery. 6. Reinstall RH and LH side panels.

12 4. Click YES in next screen. vbs Wait until confirmation screen is visible. 6. After update, click OK in confirmation screen. vbs CONFIRMATION SCREEN 7. Go to: Module Cluster Information. Parts Reinstallation 1. Reinstall the following parts as the reverse of removal procedure: Throttle body Driven pulley assembly Chaincase parts Muffler EGTS connector Primary air intake silencer Drive belt guard. NOTE: Refill engine coolant. If an important quantity of coolant was spilled, bleed cooling system. 2. Check that fuel injectors wiring harness is away from countershaft. 3. Reinstall 30 A charging system fuse on vehicle. 4. Reconnect RED positive cable on battery. 5. Reconnect BLACK negative cable on battery. 6. Reinstall RH and LH side panels. Ensure that fuel injectors wiring harness is away from countershaft. Always connect battery cables exactly in the specified order: Connect RED positive cable first Then connect BLACK negative ground cable. vbs _a 8. Ensure that BRP assembly number is: Standard cluster gauge (Analog and digital) Premium cluster gauge (Multifunction analog and digital) CLUSTER INFORMATION (P/N ) (P/N ) Never operate the vehicle without belt guard securely installed. WARRANTY Submit a warranty claim using the following information: CAMPAIGN NUMBER Claim Type Flat Rate Time Campaign claim 1.0 hour For claiming procedure, refer to the DEALER/DIS- TRIBUTOR WARRANTY GUIDE. 12 / WARRANTY

WARNING. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. WARNING

WARNING. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. WARNING Floating QRS Short Shaft Conversion (Kit P/N 860 200 832) The following symbols may be used in this document: WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious