PRE-DELIVERY TABLE OF CONTENTS BULLETIN. IMPORTANT NOTICE... 2 High altitude calibration... 2

Transcription

1 PRE-DELIVERY BULLETIN SKI-DOO June, 2015 Subject:Ski-Doo REV-XP Predelivery Inspection No YEAR MODEL MODEL NUMBER 2016 REV-XP platform Refer to table on next pages for models listing TABLE OF CONTENTS Page IMPORTANT NOTICE... 2 High altitude calibration... 2 UPDATE SUMMARY... 3 MODEL LISTING... 3 PREDELIVERY KIT PARTS LISTS UNCRATING... 5 Crate Cover... 5 Crate Brackets... 5 Crate Disposal... 6 Rear Suspension Shipping Hook(s)... 6 Shipping Brackets Removal PARTS TO BE INSTALLED... 7 Front Shock Absorbers... 7 Skis... 7 Battery... 8 Handlebar... 9 Steering Cover Windshield Air Filter (Summit Sport) Heated Visor Extension (Expedition Sport).. 11 Rear Bumper Drive Belt Installation Passenger Seat (Expedition Sport) Hitch (Expedition Sport) FLUIDS General Guidelines Fuel Engine Coolant Chaincase Oil Page Injection Oil Brake Fluid SET-UP Doing All Recalls and All Other Modifications Requested by BRP Programming Using B.U.D.S Track ADJUSTMENTS (CUSTOMER PREFERENCE) Rear Suspension Adjustments Heated Carburetors (Applicable Models) FINAL INSPECTION Controls, Equipments, Movement and Operation Inspection Test Run Snowmobile Snowmobile Cleaned and in Showroom Condition Vehicle Delivery Printed in Canada. (mbl en ML) 2015 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. 1/21

2 IMPORTANT NOTICE IMPORTANT NOTICE This bulletin must be used in conjunction with check list enclosed in bag with OPERATOR S GUIDE.Make sure that PREDELIVERY CHECK LIST is completed and signed. WARNING To obtain limited warranty coverage, predelivery procedures must be performed by an authorized BRP Ski-Doo snowmobile dealer/distributor. Apply all necessary torques as indicated. NOTE: The information and components/system descriptions contained in this document are correct at time of publication. Bombardier Recreational Products Inc. (BRP) however, maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on products previously manufactured. Due to late changes, there might be some differences between manufactured product and descriptions and/or specifications in this document. BRP reserves the right at any time to discontinue or change specifications, designs, features, models or equipment without incurring obligation. The illustrations in this document show typical construction of different assemblies and may not reproduce full detail or exact shape of parts. However, they represent parts that have same or similar function. Content of this bulletin is designed as a guideline only. All mechanics performing predelivery procedures should have attended current model year service training. Further information or inquiries should be directed to your distributor service representative and/or specific SHOP MANUAL sections. Please complete PREDELIVERY CHECK LIST for each snowmobile and retain a customer signed copy. Make sure customer receives OPERATOR S GUIDE, PREDELIVERY CHECK LIST signed copy and SAFETY DVD VIDEO There is a tag attached to ignition key, only customer must remove it. This label will remind customer to ask dealer/distributor to perform suspension adjustments according to riding style and vehicle load. WARNING Torque wrench tightening specifications must strictly be adhered to. Where specified, install new locking devices (e.g. lock tabs, elastic stop nuts). If the efficiency of a locking device is impaired, it must be renewed. High altitude calibration NOTE: Summit North American models are factory calibrated to be ridden at altitudes ranging from 600 to 2400 m (2000 to 8000 ft). European Summit models and all other above-mentioned models are factory calibrated for sea level riding. If not re-calibrated for proper altitude use, severe engine damage may occur. ALWAYS refer to model year HIGH ALTITUDE SERVICE BULLETIN. 2 / PREDELIVERY

3 PREDELIVERY KIT PARTS LISTS UPDATE SUMMARY This summary highlights updates to the Predelivery Inspection for MY It does not supersede procedures detailed further in this publication. IMPORTANT: Technicians should read and apply all procedures in this PDI bulletin as applicable to model. APPLICABLE TO UPDATE DESCRIPTION REFERENCE All models New MPI interface card Set-up Renegade and MX Z New PDI kit Model listing and predelivery kit Parts list MODEL LISTING MODEL MODEL NUMBER PDI KIT P/N Renegade Sport UHGA MX Z Sport BHGA / BHGB Summit Sport CYGA / CBGA Expedition Sport KAGA PREDELIVERY KIT PARTS LISTS KIT (MX Z AND RENEGADE MODELS) WHERE USED DESCRIPTION PART NUMBER QTY Rear Suspension Wheel Cap M10 Washer Front suspension and skis M10 nuts Ski stopper Rear bumper Snow guard Washer M6 X 18 Torx screw /16 pop rivet Washer PREDELIVERY / 21

4 PREDELIVERY KIT PARTS LISTS KIT (EXPEDITION MODEL) WHERE USED DESCRIPTION PART NUMBER QTY Rear suspension Wheel Cap M10 Washer Front suspension and skis M10 flanged nut Ski stopper Rear bumper M6 X 18 Torx screw Washer Accessories Heated visor wire Washer Passenger seat M6 X 16 screw M6 X 30 screw Snow guard 3/16 pop rivet Washer KIT (SUMMIT MODEL) WHERE USED DESCRIPTION PART NUMBER QTY Rear suspension Wheel Cap M10 Washer Front suspension and skis M10 nuts Ski stopper Rear bumper Washer M6 X 18 Torx screw Snow guard 3/16 pop rivet Washer / PREDELIVERY

5 1- UNCRATING 1- UNCRATING Crate Cover 1. Carefully lay crate on its bottom. NOTICE Allowing crate to drop may cause serious damage to vehicle. 2. Remove all screws retaining crate top to sidewalls. 3. Discard shipping spacers and nuts. Keep ski leg screws and ski stance spacers (if applicable) for skis installation. Discard shipping bracket. mbl _a 3. Remove screws securing sidewalls to crate base. 4. Unscrew sidewalls one at the time. mbl _a TYPICAL - MODELS WITHOUT ADJUSTABLE STANCE 1. Ski screw (keep) 2. Shipping spacers (discard) 3. Nut (discard) 4. Shipping bracket (discard) mbl _a 5. Remove polyethylene foam sheets. NOTICE Do not remove protective wrapping until delivery to customer. 6. Remove parts to be installed from vehicle or crate base. Crate Brackets CAUTION Make sure vehicle is properly supported before removing ski legs and rear suspension from crate brackets. 1. Cut locking ties and remove ski leg wood protectors (if applicable). 2. Detach ski legs from crate shipping brackets. mbl _a TYPICAL - MODELS WITH ADJUSTABLE STANCE 1. Ski screw (keep) 2. Stance setting spacer 3. Shipping spacers (discard) 4. Nut (discard) 5. Shipping bracket (discard) 4. Using a pry bar, remove wood blocks retaining track to crate base. PREDELIVERY / 21

6 1- UNCRATING mbl _a 1. Track 2. Wood block 5. Remove vehicle from crate base. Crate Disposal NOTE: The ECO crate is designed to be disassembled easily in order to be stacked with very low height or to be disposed as per environmental regulations. 1. Pull canvas off wood structures. 2. Stack or dispose as per local environmental regulations. Rear Suspension Shipping Hook(s) NOTICE Shipping hooks must be removed to have snowmobile suspension operational. WARNING Before removing hooks, always verify that vehicle is properly supported and that parking brake is applied. 1. Apply parking brake. 2. Lift rear of vehicle so that a block or a box can be positioned under front idler wheels. 3. Ask another person to apply pressure onto rear suspension. 4. Remove front hook(s) from suspension. mbl _a TYPICAL 1. Idler wheel 2. Front hook 5. Lift front of vehicle to position bumper approximately 1 m (39 in) above the ground. 6. Standing on footrests, apply pressure onto rear suspension and ask someone to remove rear hook. mbl _a TYPICAL 1. Apply pressure 2. Rear hook NOTICE 1 2 Never stand on the seat. Shipping Brackets Removal 1. Remove and discard spring clips. 2. Keep washer, upper M10 x 65 and lower M10 x 55 bolts for front shock absorbers installation. 6 / PREDELIVERY

7 2- PARTS TO BE INSTALLED mbl _a 1. Shipping brackets 2. Spring clips 3. Washers and upper bolt 4. Lower bolt 3. Remove and discard shipping brackets. 2- PARTS TO BE INSTALLED Front Shock Absorbers Install front shock absorber body DOWN using the previously removed M10 bolts and washer, and new M10 flanged nuts (predelivery kit). NOTE: On some models, it may be necessary to remove the bottom pan cover to ease the upper RH bolt installation. Install the shock so that the gap in the decal is towards the inside. mbl _a CORRECT INSTALLATION 1. Gap towards the inside Front shock absorber retaining nuts Skis TIGHTENING TORQUE 48 N m (35 lbf ft) NOTE: On some models, it is possible to set ski stance narrow or wide. See SKI STANCE SET- TING below. Ensure ski leg bushings are still on ski legs. 1. Install ski stopper on the ski. NOTE: Position indicator at front and make sure the bump in the ski is in the groove of the ski stopper. mmr _a TYPICAL 1. Ski stopper 2. Bushings mbl _a WRONG INSTALLATION 1. Gap towards the outside 2. Install ski on ski leg using the hardware as shown. PREDELIVERY / 21

8 2- PARTS TO BE INSTALLED Battery Models With Electric Starter Battery Removal (if Shipped Installed) WARNING Battery BLACK ( ) cable must always be disconnected first and connected last. Never charge or boost battery while installed on vehicle. mbl _a TYPICAL - EXCEPT ADJUSTABLE STANCE 1. Ski stopper (predelivery kit) 2. M10 x 130 bolt (previously removed) 3. M10 flat washer (predelivery kit) 4. M10 flanged nut (predelivery kit) 5. Ski leg bushings 1. Open the right side panel of the vehicle. 2. Unscrew battery bracket retaining nuts. 3. Unlatch and remove battery bracket. Tighten flanged nut to specification. TIGHTENING TORQUE Ski retaining nuts 48 N m (35 lbf ft) Ski Stance Setting Expedition Sport and Summit Sport Models SKI STANCE SETTING Narrow Wide Place spacer on the inside of ski leg Place spacer on the outside of ski leg mbl _a 1. Bracket retaining nuts 2. Unlatch 4. Remove the battery. mbl _a LH SIDE SHOWN 1. Ski stopper (predelivery kit) 2. M10 x 130 bolt 3. M10 flat washer (predelivery kit) 4. M10 flanged nut (predelivery kit) 5. Ski axle 6. Narrow adjustment 7. Wide adjustment Tighten flanged nut to specification. Ski retaining nuts TIGHTENING TORQUE 48 N m (35 lbf ft) Battery Preparation Refer to the latest edition of SKI-DOO BAT- TERIES ACTIVATION, CHARGING AND MAIN- TENANCE BULLETIN for proper activating, charging and maintenance procedure. NOTE: It is recommended to always have a fully charged battery in the workshop, ready to be installed. Battery Installation 1. Properly position the charged battery on its rack. 2. Install the bracket and screw the bracket retaining nuts or retaining strap. 3. Connect RED ( + ) cable and RED wire (coming from fuse) to positive battery terminal. 4. Connect BLACK ( ) cable LAST. 5. Cover the RED ( + ) terminal with rubber boot. 8 / PREDELIVERY

9 2- PARTS TO BE INSTALLED Handlebar 1. Loosen the lower steering extension retaining screws. mbl _a 1. Lower steering extension retaining screws 2. Lift steering extension and position it as per the following table. mbl _c BRAKE HOSE ROUTING 1. As delivered (routed below steering column) 2. Correct hose routing when set up 3. Tighten steering extension lower screws to specification. NOTICE level. Make sure brake fluid reservoir is mbl _a TYPICAL A. Steering extension angle VEHICLE Summit and Expedition MX Z and Renegade ANGLE 40 (from vertical) 20 (from vertical) NOTICE Make sure brake hose is routed over steering extension Lower steering extension retaining screws TIGHTENING TORQUE 24 N m (18 lbf ft) 4. If necessary, adjust handlebar so that brake fluid reservoir is level, tighten steering extension upper screws to specification. Handlebar retaining screws TIGHTENING TORQUE 24 N m (18 lbf ft) 5. Connect steering harness connectors at riser block base. PREDELIVERY / 21

10 2- PARTS TO BE INSTALLED mbl _a TYPICAL 1. Connectors Steering Cover 1. Route throttle cable and wiring properly. 2. Install steering cover by pushing it in place. mbl _a 1. Windshield tab 2. Console front grommet 4. Remove protective films from the windshield. WARNING Make sure that handlebar turns freely in both directions. Make sure that there is no contact at any time between handlebar wind deflectors (if so equipped) and windshield. Air Filter (Summit Sport) 1. Remove hood by releasing retaining pins and slide hood towards the front. 2. Pull factory installed foam out of air intake silencer. mbl _a TYPICAL 1. Steering cover 2. Throttle cable 3. RH wiring Windshield 1. Lubricate the grommets using soapsuds. NOTICE Do not lubricate grommets with any type of grease. 2. Position windshield in place. 3. Push windshield pins into the grommets. mbl _a 1. Foam NOTE: Slot into middle of foam must be towards prefilter opening. 10 / PREDELIVERY

11 2- PARTS TO BE INSTALLED mbl _a 1. Cover 2. Foam 3. Slot into middle of foam 3. Install prefilter on foam. Place larger end of foam into prefilter first. NOTICE Do not overstretch cover elastic straps. 4. Compress and install narrow end of foam into prefilter. mmo _a 1. Guide 6. Push filter in the air intake silencer opening so that the slot bottom leans against the guide and the edges are completely inserted. NOTE: Make sure cover is not pleated and air box intake is completely blocked up by the filter assembly. mbl _a 1. Slot into middle of foam 5. Align the foam filter slot with the guide in the air intake silencer opening. mbl _a 1. No pleats on cover Reinstall hood. Heated Visor Extension (Expedition Sport) 1. Connect heated visor extension (predelivery kit) to heated visor jack. NOTE: Heated visor connector is located on LH side of the console. Rear Bumper 1. Align holes of rear bumper with frame holes. Standard Bumper 2. Secure rear bumper to frame using M6 x 16 Torx screws (predelivery kit). mmo _a 1. Slot PREDELIVERY / 21

12 2- PARTS TO BE INSTALLED mbl MM (1 IN) HEIGHT BUMPER SECTION Heavy-Duty Bumper 3. Secure rear bumper to frame using M6 x 18 Torx screws and washers (predelivery kit). mbl MM (1-21/32 IN) HEIGHT BUMPER SECTION 4. Tighten screws to specification. Rear bumper screws TIGHTENING TORQUE Drive Belt Installation 16 N m (142 lbf in) 1. Remove tether cord cap. 2. Open LH side panel. 3. Remove drive belt guard. 4. Insert the driven pulley expander provided in the tool kit in the threaded hole on the adjuster hub as shown. mbl _a 1. Pulley expander 5. Open the driven pulley by screwing the tool in. 6. Clean pulleys before installing drive belt using PULLEY FLANGE CLEANER (P/N ). 7. Slip the belt over the drive pulley, then over the driven pulley. NOTICE Do not force or use tools to pry the belt into place, as this could cut or break the cords in the belt. NOTE: The maximum drive belt life span is obtained when belt is installed with arrows in the direction of rotation. mmo _a TYPICAL 1. To be pointedinthedirectionofrotation 8. Unscrew and remove the driven pulley expander from the pulley. 9. Rotate the driven pulley several times to properly set the belt between the sheaves. Adjust drive belt as follows: 1. Loosen the clamping screw. 12 / PREDELIVERY

13 2- PARTS TO BE INSTALLED mmo _a TYPICAL - PRELIMINARY SETTING 1. Lowest portion of cogs even with external surface of drive belt mmo _a 1. Adjuster hub 2. Clamping screw 2. Using the suspension adjustment tool provided in the tool kit, turn the ring 1/4 turn at a time then rotate the driven pulley to properly set the belt between the pulley sheaves. mmo _a 1. Suspension adjustment tool NOTE: The adjustment ring has left hand treads. Belt Without Cogs Repeat step 2 until the drive belt is even with the driven pulley edge. All belt types NOTE: Turning the ring counterclockwise lowers the belt in the pulley. Turning the ring clockwise raises the belt in the pulley. 3. Firmly tighten the clamping screw. If possible, tighten to 5.5 N m ± 0.5 N m (49 lbf in ±4lbf in) using a torque wrench. 4. Install belt guard. 5. Close side panel. NOTE: This setting is correct as a preliminary adjustment for most models and belt types. In some cases, when starting the engine, the vehicle could creep, indicating that the belt is too tight. If the vehicle creeps, lower the drive belt, install belt guard and side panel, then start engine. Repeat until creeping stops. Reverse Activation NOTE: The reverse may not activate or may be harder to activate if the belt is positioned too high in the driven pulley. If reverse activation does not work properly, ensure the drive belt is properly adjusted. Adjust the drive belt lower in the driven pulley if needed. Passenger Seat (Expedition Sport) 1. Locate passenger seat mounting holes on the tunnel, then place seat on the tunnel. mmo _a PRELIMINARY SETTING 1. Drive belt flush with driven pulley edge Belt With Cogs Repeat step 2 until the lowest portion of the cogs on the external surface of drive belt is even with the driven pulley edge. PREDELIVERY / 21

14 3- FLUIDS mbl _a 1. Passenger seat mounting holes 2. Connect heated grips harness (if equipped). 3. Secure seat using the provided hardware (predelivery kit). M6 X 30 flanged screws at rear M6 X 16 screws and washers at front. Hitch (Expedition Sport) Install hitch using the mounting holes in the rear bumper. Hitch bolts 3- FLUIDS TIGHTENING TORQUE General Guidelines 31 N m (23 lbf ft) All fluids (except fuel) have already been filled at factory, it is only necessary to check the levels. However, if refill is needed, refer to the appropriate Ski-Doo SHOP MANUAL for the proper procedure. Fuel Recommended Fuel Use unleaded gasoline containing MAXIMUM 10% ethanol. The gasoline must have the following minimum octane requirements. FUEL TYPE Fuel with NO ethanol Fuel which may contain up to 10% MAX ethanol ENGINE 550F R Power TEK 550F R Power TEK MINIMUM OCTANE RATING 87 AKI (RON+MON)/2 92 RON 91 AKI (RON+MON)/2 95 RON 91 AKI (RON+MON)/2 95 RON NOTICE Useoctaneratingaccordingtofuel type. Never experiment with other fuels. Engine or fuel system damages may occur with the use of an inadequate fuel. Fuel Antifreeze Additives When using oxygenated fuel, additional gas line antifreeze or water absorbing additives are not required and should be not used. When using non-oxygenated fuel, we highly recommend the use of isopropyl base gas line antifreeze in a proportion of 150 ml (5 U.S. oz) of gas line antifreeze added to 40 L (10.6 U.S. gal.) of gas. This precaution is in order to reduce the risk of frost buildup in carburetors or other fuel system components which may lead, in certain cases, to severe damage to engine. NOTE: Use only methyl hydrate free gas line antifreeze. Engine Coolant Recommended Coolant The cooling system can be filled with distilled water and antifreeze solution (50% distilled water, 50% antifreeze). NOTICE Always use ethylene-glycol antifreeze containing corrosion inhibitors specifically for internal combustion aluminum engines. For best performance, use the following recommended product. 14 / PREDELIVERY

15 3- FLUIDS RECOMMENDED ANTIFREEZE Finland, Norway and Sweden All Other Countries LONG LIFE ANTIFREEZE(F) (P/N ) LONG LIFE ANTIFREEZE (P/N ) Coolant Level Verification Check coolant level at room temperature with the cap removed. Liquid should be at cold level line (engine cold) of coolant tank. NOTE: When checking level at low temperature it may be slightly lower then the mark. Add if necessary. mmr _a TYPICAL 1. Check plug To add oil, remove the filler cap on chaincase cover. mmo _a 1. Coolant tank 2. COLD LEVEL line Chaincase Oil Recommended Oil CHAINCASE OIL XPS SYNTHETIC CHAINCASE OIL (P/N ) Chaincase Oil Verification 1. With the vehicle on a level surface, check the oil level by removing the check plug on the left side of chaincase. Oil level must be equal with the lower edge. mbl _a TYPICAL 1. Filler cap 2. Pour recommended oil in chaincase by the filler hole until oil comes out by the check plug hole. CHAINCASE OIL CAPACITY 350 ml (12 U.S. oz) 3. Reinstall check plug. 4. Tighten to 6 N m (53 lbf in). Injection Oil Recommended Oil Always maintain a sufficient amount of recommended injection oil in the injection oil reservoir. PREDELIVERY / 21

16 4- SET-UP WARNING Use only DOT 4 brake fluid from a sealed container. To avoid serious damage to the braking system, do not use fluids other than the recommended one, nor mix different fluids for topping up. NOTICE Brake fluid can damage painted and plastic parts. Handle with care. Rinse thoroughly in case of spillage. mmo _a TYPICAL 1. Injection oil reservoir 2. Level marks (1/4, 1/2, 3/4) WARNING Do not overfill. Reinstall cap and fully tighten. Wipe off any oil spills. Oil is highly flammable when heated. ENGINE 550F 600 and 800R Power TEK RECOMMENDED INJECTION OIL XPS INJECTION OIL (P/N ) XPS SYNTHETIC 2-STROKE OIL (P/N ) NOTICE The engine of this snowmobile has been developed and validated using the recommended BRP XPS oil. BRP strongly recommends the use of its recommended XPS oil at all times. Damages caused by oil which is not suitable for the engine will not be covered by the BRP limited warranty. Brake Fluid Recommended Brake Oil RECOMMENDED BRAKE OIL BRAKE FLUID GTLMA DOT4 (P/N ) Brake Oil Level Verification 1. Check brake fluid in reservoir for proper level. 2. Add brake fluid required. mmo _a 1. Minimum 2. Maximum 3. Operating range 4- SET-UP Doing All Recalls and All Other Modifications Requested by BRP Complete applicable recalls or factory-directed modifications. Programming Using B.U.D.S. NOTE: Vehicle will not start until a key code is programmed in vehicle's ECM using B.U.D.S. If not familiar with B.U.D.S. and to learn how to install B.U.D.S. on a computer, refer to B.U.D.S. PROGRAM INSTALLATION INSTRUCTIONS bulletin. Make sure to use the applicable version of B.U.D.S. that can be downloaded from BOSS- Web ( A valid BOSS- Web account is required. Connecting PC to Vehicle 1. Connect the PC to vehicle. Refer to the applicable shop manual. 16 / PREDELIVERY

17 4- SET-UP REQUIRED TOOLS All Models Except 550F MPI-3 INTERFACE CARD (P/N ) kw2000 DIAGNOSTIC CABLE (P/N ) POWER INTERFACE (P/N ) 12 V BATTERY SUPPLY CABLE (P/N ) NOTE: The following message may be displayed. If so, it should disappear as soon as B.U.D.S. communicates. If message does not disappear, click on the Retry button. F18H0XA CONNECTION SUCCESSFUL NOTE: Number 2 indicates that the ECM and the multifunction gauge are recognized by the MPI. If an X or a 1 is shown instead of a 2, it means that there is no communication between MPI and ECM and/or multifunction gauge. Possible causes are: ECM and/or multifunction gauge not powered Bad connection between MPI and ECM and/or multifunction gauge. 3. Press Read Data button to download data from the vehicle. mbl Make sure status bar shows proper Protocol. vdd F Models kw2000 Programing Keys with B.U.D.S. (Except 550F) 1. Install new key to be programmed on vehicle post. 2. Click on Keys tab. F18H0WA NOTE: Number 1 indicates that the multifunction gauge is recognized by the MPI. If an X is shown instead of a 1 it means that there is no communication between MPI and multifunction gauge. Possible causes are: Multifunction gauge not powered Bad connection between MPI and multifunction gauge. smr _en NOTE: When programing a vehicle for the first time, you need to click on Erase All Keys button. 3. Click on Add Key. PREDELIVERY / 21

18 4- SET-UP smr _aen 1. Add Key 4. Click on Write Data to save a new key in vehicle's ECM. Track Track Tension Adjustment and Alignment 1. Remove the tether cord cap. 2. Lift rear of vehicle and support it off the ground. 3. Allow rear suspension to fully extend. 4. Loosen one of the rear idler wheel retaining screws (3 and 4 idler wheels system). vmr _ben A new key is now saved in computer. 5. Repeat to program more keys. Speedometer Setting (Miles or Kilometers) Speedometer is factory preset in miles. Dealer needs to use B.U.D.S. to change it to kilometers. Select Setting and Cluster tabs. In the Cluster Units box: For kilometers select Metric For miles select Imperial. Ending a B.U.D.S. Session 1. Click on Faults tab and check if there are active fault codes. If so, service vehicle then clear fault codes in B.U.D.S. NOTICE After a problem has been solved, ensure to clear fault code(s) in ECM. This will properly reset appropriate counter(s). This will also record that problem has been fixed in ECM memory. 2. Click on Write Data button to transfer new settings and information to ECM. 3. Click on Exit button (right most) to end session. 4. Ensure to reinstall communication connector in its cover. mmr _a 3OR4IDLERWHEELS SYSTEM 1. RH rear idler wheel bolt 5. Loosen rear axle retaining nut and screw (2 idler wheels system). mbl _a 2 IDLER WHEELS SYSTEM 6. Tighten both adjustment screws equally to increase track tension a little. 18 / PREDELIVERY

19 4- SET-UP 11. Push the tensiometer downwards until bottom O-ring (deflection set earlier) be aligned with the bottom of slider shoe. mmr _a 3 OR 4 IDLER WHEELS SYSTEM 1. RH adjustment screw mmr _a mbl _b 2 IDLER WHEELS SYSTEM 7. Use the TENSIOMETER (P/N ). mmr _a 1. Deflection O-ring aligned with slider shoe 12. Read load recorded by the upper O-ring on the tensiometer Set deflection between using bottom O-ring. BOTTOM O-RING SETTING Expedition Sport All others 4.2 cm (1-5/8 in) 3.2 cm (1-1/4 in) mmr _a LOAD READING 1. Upper O-ring 13. Load reading must be as per the following table. TRACK ADJUSTMENT SPECIFICATION mmr _b DEFLECTION SETTING 1. Bottom O-ring Track deflection setting (Expedition Sport) Track deflection setting (All others) 4.2 cm (1-5/8 in) 3.2 cm (1-1/4 in) 9. Place upper O-ring to 0 kgf (0 lbf). 10. Position the tensiometer on track, halfway between front and rear idler wheels. Track load reading 6kg to8.5kg (13lb to 19lb) 14. Tighten or loosen both adjustment screws until specified tension is obtained. PREDELIVERY / 21

20 5- ADJUSTMENTS (CUSTOMER PREFERENCE) 15. Tighten rear idler wheel retaining screw. Rear idler wheel retaining screw (3 or 4 idler wheels system) Rear idler wheel retaining nut and screw (2 idler wheels system) TIGHTENING TORQUE 48 N m ± 6 N m (35lbf ft ± 4lbf ft) 24.5 N m ± 3.5 N m (18lbf ft ± 3lbf ft) Check track alignment as follows: 16. Start engine and accelerate slightly so that track slowly turns. This must be done in a short period of time (15 to 20 seconds). 17. Check that the track is well centered; equal distance on both sides between edges of track guides and slider shoes. A01F05A 1. Guides 2. Slider shoes 3. Equal distance To correct track alignment: 18.1 Stop engine Remove tether cord cap Loosen one of the rear wheel retaining screws Tighten adjustment screw on the side where the slider shoe is the farthest from the track insert guides. 19. Tighten rear idler wheel retaining screw. Rear idler wheel retaining screw (3 or 4 idler wheels system) Rear idler wheel retaining nut and screw (2 idler wheels system) TIGHTENING TORQUE 48 N m ± 6 N m (35lbf ft ± 4lbf ft) 24.5 N m ± 3.5 N m (18lbf ft ± 3lbf ft) 20. Repeat procedure until alignment is correct. Recheck tension. Track Studding WARNING Never stud a track that has not been approved for studs. Installing studs on an unapproved track could increase risks of track tearing or severing, possibly resulting in serious injuries or death. WARNING For track studding, always refer to the IN- STRUCTION SHEET supplied with stud kits that are APPROVED by BRP for models covered in this PREDELIVERY BULLETIN. Install wheel caps (predelivery kit). 5- ADJUSTMENTS (CUSTOMER PREFERENCE) Rear Suspension Adjustments Please refer to OPERATOR'S GUIDE for specifications and procedures. You can also refer to the SUSPENSION SPRING CHART bulletin (if available). Heated Carburetors (Applicable Models) 1 2 HEATED CARBURETOR VALVE POSITION 1. Valve ON 2. Valve OFF Heated carburetor valve should be closed except: when riding between -5 C and 5 C (23 F and 41 F) in a high relative humidity 20 / PREDELIVERY

21 6- FINAL INSPECTION when riding in deep powder snow when following another snowmobile which makes snow dust. NOTICE When operating snowmobile above 5 C (41 F), move carburetor heating valve to OFF position. 6- FINAL INSPECTION Controls, Equipments, Movement and Operation Inspection 1. Make sure the following controls and equipments are fully operational: Throttle, brake and parking brake levers Ignition, emergency stop switch and tether stop switch Headlights, taillight and brake light Steering system. 2. Fasteners tightening torque recheck: Ski nuts Shock absorber nuts Handlebar nuts. 3. Complete applicable recall or factory-directed modification. 4. Ensure that hang tag is on vehicle handlebars. 5. Ensure TOOL KIT and OPERATOR S GUIDE are in the vehicle. Test Run Snowmobile Test ride vehicle. Engine Break-in To assure additional protection during initial engine break-in, the specified quantity of recommended injection oil should be added to the first fuel tank fill-up. ENGINE OIL QUANTITY L (1.1 qt (U.S. liq.)) 550F and 800R Power TEK 500 ml (17 U.S. oz) 2. Wash and dry vehicle. Use XPS ATV WASH (P/N ). NOTICE Never use a high pressure washer to clean vehicle. High pressure can cause electrical or mechanical damages. For stubborn dirt on vinyl or plastic parts, using flannel or micro-fibre towels with XPS ALL PUR- POSE CLEANER (P/N ). NOTICE It is necessary to use flannel or microfiber clothes on plastic parts to avoid scratching the surfaces. Never clean plastic parts with strong detergent, paint thinner, acetone, products containing chlorine, etc. Vehicle Delivery Complete PREDELIVERY CHECK LIST. Give the OPERATOR S GUIDE and the SAFETY DVD to the customer. Customer must read and sign the PREDELIVERY CHECK LIST. Hang tag is to be removed by the owner only. Any person who rides this vehicle should read and understand all the information given on hang tag and safety labels before riding. NOTE: Always remove and clean spark plugs after engine break-in. Snowmobile Cleaned and in Showroom Condition 1. Make sure all protective wrapping is removed from vehicle. PREDELIVERY / 21