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

Transcription

1 CVT Cooling System (Kit P/N ) The following symbols may be used in this document: WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a hazard situation which, if not avoided, could result in minor or moderate injury. NOTICE Indicates an instruction which, if not followed, could severely damage vehicle components or other property. WARNING For safety reasons, this kit must be installed by an authorized BRP dealer. This kit is designed for specific applicable models only (authorized BRP dealers will confirm model(s)). It is not recommended for units other than the one (those) for which it was sold. This instruction sheet MUST be given to the purchaser. Should removal of a locking device (e.g. lock tabs, self-locking fasteners, etc.) be required when undergoing disassembly/assembly, always replace with a new one. Torque wrench tightening specifications must strictly be adhered to. Unless otherwise specified, engine must be OFF when performing any operation on the vehicle. NOTE: The illustrations in this document show typical construction of the different assemblies and may not reproduce the full detail or exact shape of the parts; however, they represent parts that have the same or similar function. Installation time is approximately 0.7 hours. Printed in Canada. (msi en AP) 2012 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. Instruction Sheet P/N /11

2 PARTS TO BE INSTALLED PARTS TO BE INSTALLED ITEM DESCRIPTION PART NUMBER QTY P1 Cooling duct P2 Front bracket P3 AVEX rivet (short) P4 3/16 Pop rivets (short - BLACK) P5 Front support P6 3/16 Pop rivets (long - BLACK) P7 Flat washer P8 Reinforcement plate P9 AVEX rivet (long) P10 Notice label (English) P11 Notice label (French) P12 Cap P13 M6 X 20 Torx screw P14 Stopper plate P15 M5 X 14 screw / 11 Instruction Sheet P/N

3 INSTALLATION INSTRUCTIONS Vehicle Preparation 1. Remove the following parts: LH side panel Drive belt guard. 2. Remove 2 rivets securing drive belt guard front bracket. NOTE: Depending on suspension configuration, it could be easier to remove inner rivet from inside engine compartment. msi _a 1. AVEX rivets (long)[p9] 2. Reinforcement plate [P8] 3. Front support [P5] msi _a 1. Rivets to be removed 3. Discard bracket. Front Support Installation 1. Secure the top of front support assembly using two 3/16 Pop rivets (long - BLACK) [P6] and 2 washers [P7] in the top holes. Front Support Assembly Secure reinforcement plate [P8] to front support [P5] with AVEX rivets (long) [P9]. msi _a EXTERIOR VIEW 1. Rivets at the top of front support Instruction Sheet P/N / 11

4 msi _a INTERIOR VIEW 1. Flat washers [P7] 2. 3/16 Pop rivets (long - BLACK)[P6] 3. Front support [P5] msi _a EXTERIOR VIEW 1. Rivet at the bottom of front support 2. Using a pick, pierce through the bottom pan using the lower hole of the bracket as a guide. msi _a 1. Pick 2. Front support 3. From the outside, drill a 7 mm (17/64 in) in the hole pierced at the previous step. NOTE: A drill size "J" can be used. 4. Secure the bottom of front support assembly using a 3/16 Pop rivet (long - BLACK) [P6] and awasher [P7] in the bottom hole. msi _a INTERIOR VIEW 1. 3/16 Pop rivet (long - BLACK) [P6] 2. Flat washer [P7] 3. Front support [P5] Stopper Plate Installation (2009 to 2012 Models with Aluminum Toe Hold Only) NOTE: This procedure is not applicable to vehicles with a plastic toe hold. Remove the drive belt guard rear bracket. Discard screws. Using the provided template (see at the end of this document), drill two holes of 5 mm (13/64 in). 4 / 11 Instruction Sheet P/N

5 msi _a 1. New drilled holes Install the stopper plate [P14] on bracket and secure it using AVEX rivets (short) [P3]. msi _a 1. Tool kit support 2. Locking tab 3. Drive belt guard 2. Drill the 3 rivets holding the drive belt guard reinforcement. msi _a 1. Stopper plate [P14] 2. AVEX rivets (short) [P3] 3. Drive belt guard rear bracket Reinstall drive belt guard rear bracket on vehicle using NEW M5 x 14 Torx screws. TIGHTENING TORQUE Stopper plate bolts 3N m to 3.5N m (27 lbf in to 31 lbf in) msi _a 1. Rivets to drill 2. Drive belt guard reinforcement Drive Belt Guard Disassembly 1. Remove and keep the tool kit support from the drive belt guard. NOTE: Unlock the tab from underneath the pulley guard and pull on the tool kit support upwards to release it. 3. Remove and discard lateral protector from drive belt guard by drilling the 5 rivets as shown. Keep the remaining of drive belt guard. Instruction Sheet P/N / 11

6 msi _a 1. Lateral protector 2. Rivets X 5 Drive Belt Guard Assembly 1. Install front bracket [P2] with AVEX rivets (short) [P3] on kept drive belt guard. msi _a 1. Cooling duct [P1] 2. 3/16 Pop rivets (short - BLACK) [P4] 3. Drive belt guard 3. Clean surface where label must be installed with isopropyl alcool and affix notice label [P10] on drive belt guard assembly as illustrated. NOTE: This product comes with the following notice label containing important information. The notice label should be considered a permanent part of this product. If the notice label comes off or becomes hard to read, please contact an authorized BRP Ski-Doo dealer for replacement. Any person who intends to use this product should read and understand the information contained on the label before doing so. msi _a 1. Front bracket [P2] 2. AVEX rivets (short) [P3] 3. Kept drive belt guard 2. Install cooling duct [P1] on drive belt guard with 3/16 Pop rivets (short - BLACK) [P4]. 6 / 11 Instruction Sheet P/N

7 msi _a 1. Notice label [P10] location 4. Reinstall the tool kit support on the drive belt guard. msi _a 1. drive belt guard tab 2. Front support slot 2. Push drive belt guard toward engine then toward front of vehicle. msi _a 1. Tool kit support 5. Reinstall Drive belt. Drive Belt Guard Installation 1. Insert drive belt guard tab in front support slot. msi _a 3. Position the grommet over the retaining rod. Instruction Sheet P/N / 11

8 2. Pull outwards on both sides of hood aft section. mmo _a 1. Retaining rod 4. Position rear portion of the drive belt guard over the retainer and secure it using the retaining pin. msi _a 3. Slide hood forwards. 4. Remove hood from vehicle. Cap Installation 1. Remove and discard illustrated M6 screws. msi _a 1. Retaining pin Cap Installation (800R E-TEC only) Hood Removal msi _a 1. Cap retaining screws 2. Install cap [P12] between bottom pan cover and console with screw holes over bottom pan cover and under console. Secure cap with M6 x20torxscrews[p13], see image for details. mmr _a 1. Hood 1. Stand in front of vehicle. 8 / 11 Instruction Sheet P/N

9 msi _b 1. Cap [P12] 2. Console 3. Bottom pan cover 4. Bottom pan edge 5. M6 X 20 Torx screw [P13] NOTE: Make sure cap groove is well inserted into bottom pan edge, see image. msi _a CROSS SECTION VIEW 1. Bottom pan edge 2. Cap groove 3. Cap 3. Torque M6 x 20 Torx screws. TIGHTENING TORQUE M6x20Torxscrews 2.25 N m ± 0.25 N m (20 lbf in ±2lbf in) 4. Reinstall hood and lateral panel. Instruction Sheet P/N / 11

10 This page is intentionally blank 10 / 11 Instruction Sheet P/N

11 3 in/po Ensure template is to scale/ S assurer que le gabarit est à l échelle 50 mm 3 in/po 50 mm msi _a Instruction Sheet P/N / 11