UNDERLINE TEXT(S) BETWEEN ARROWS IS (ARE) ADDED ELEMENT(S) TO THE PREVIOUS PUBLICATION.

Transcription

1 August 16, 2012 Subject:Ski-Doo REV-XS and REV-XM Predelivery Inspection No REVISION 1 September 5, 2012 UNDERLINE TEXT(S) BETWEEN ARROWS IS (ARE) ADDED ELEMENT(S) TO THE PREVIOUS PUBLICATION. YEAR MODEL MODEL NUMBER SERIAL NUMBER 2013 REV-XS and REV-XM Refer to table on next pages for model listing All TABLE OF CONTENTS Page IMPORTANT NOTICE... 2 High altitude calibration... 2 MODEL LISTING... 3 PREDELIVERY KIT PARTS LIST... 3 UNCRATING... 3 Crate Cover... 3 Crate Brackets... 4 Snow Guard... 5 Rear Bumper... 5 Rear Suspension Shipping Hook(s)... 5 PARTS TO BE INSTALLED... 5 Front Shock Absorbers... 5 Skis... 7 Battery... 8 Handlebar... 9 Steering Cover Tools and Emergency Starting Rope Handlebar Wind Deflector (Applicable Models) Drive Belt Installation Front Reflector (European Models) FLUIDS General Guidelines Fuel Engine Coolant Chaincase Oil Injection Oil Page Brake Fluid Level UPPER BODY MODULE INSTALLA- TION Front Storage Compartment Cover Console Wind Deflectors (if Equipped) Windshield SET-UP Programming Using B.U.D.S Track ADJUSTMENTS (CUSTOMER PREFERENCE) Rear Suspension Adjustments FINAL INSPECTION Controls, Equipments, Movement and Operation Inspection Test Run Snowmobile Snowmobile Cleaned and in Showroom Condition Vehicle Delivery SPECIFICATIONS Printed in Canada. (mbl _rev1 en AG) 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. 1/27

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 IMPORTANT: Complete any applicable recall or factory directed modification. 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 m to m (2,000 ft to 8,000 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 MODEL LISTING UNCRATING MODEL COUNTRY ENGINE MODEL NUMBER PDI KIT P/N CAN/US UVDA / UVDB / UVDC / UVDD 600HO E-TEC EUR UVDE MX Z TNT CAN/US UDDA CAN/US 800R E-TEC UTDA / UTDB / UTDC EUR UTDE CAN/US 600HO E-TEC UADA / UADB / UADC / UADD CAN/US 800R E-TEC UWDA / UWDB / UWDC / UWDD CAN/US ULDA / ULDB HO E-TEC EUR ULDC Back Country X UXDA / UXDB / UXDC / UXDD / UXDE / CAN/US 800R E-TEC UXDF / UXDG / UXDH EUR UXDJ SummitSP CAN/US 800RE-TEC CDDA/CDDB/CEDA/CEDB/CFDA/CFDB Summit X CAN/US TCDA / TCDB /TNDA / TNDB / TRDA / TRDB 800R E-TEC EUR TCDE / TNDE / TRDE PREDELIVERY KIT PARTS LIST KIT WHERE USED DESCRIPTION P/N QTY Rear Suspension Wheel Cap Front suspension and skis Rear bumper Snow guard M10 Washer M10 flange nuts Ski stopper Washer M6 X 18 Torx screw /16 pop rivet Washer Additional provided hardware: Black hardware for ski and front shock absorbers (should be used to enhance the look of this model). UNCRATING Crate Cover 1. Carefully lay crate on its bottom. NOTICE Allowing crate to drop may cause serious damage to vehicle. 2. Using a drill or a screwdriver, remove all screws retaining crate cover to crate base. NOTE: Screws that are used are Robertson #2 type that require the use of an appropriate screwdriver. 3. Tilt crate cover toward front or rear of vehicle. Robertson is a registered trademark of Robertson Inc. PREDELIVERY / 27

4 UNCRATING NOTE: There is a notch at one end of crate that indicates front of vehicle. 2 3 A00A2F6 1. Screwdriver 2. Notch (indicates front of vehicle) 3. Tilt crate cover 4. Lift crate cover slowly to avoid damaging vehicle. 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. 3. Discard shipping spacers and nuts. Keep ski leg screws and ski stance spacers (if applicable) for skis installation. Discard shipping bracket. 1 mbl _a TYPICAL - MODELS WITHOUT ADJUSTABLE STANCE 1. Ski screw (keep) 2. Shipping spacers (discard) 3. Nut (discard) 4. Shipping bracket (discard) 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. mbl _a 1. Track 2. Wood block 4 / PREDELIVERY

5 PARTSTOBEINSTALLED 5. Remove vehicle from crate base. Snow Guard From underneath the rear portion of tunnel, remove screws securing tail light. Secure the snow guard using the 3/16 pop rivets and washers (predelivery kit). Reinstall previously removed screws. Tail light retaining screws Rear Bumper TIGHTENING TORQUE 0.4 N m (4 lbf in) 1. Align holes of rear bumper with frame holes. 2. Secure rear bumper to frame using M6 x 18 Torx screws and washers (predelivery kit). Rear bumper screws TIGHTENING TORQUE 16 N m (142 lbf in) Rear Suspension Shipping Hook(s) NOTICE Rear bumper must be installed before removing the shipping hooks. WARNING 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. 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. NOTICE Never stand on the seat. 6. Apply pressure onto rear suspension and ask someone to remove rear hook. PARTS TO BE INSTALLED Front Shock Absorbers Access to Upper Front Shock Absorber Bolts To access the shock upper bolts, remove the upper body module as follows: 1. Remove the gauge. 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 Step 1: Unlock Step 2: Tilt 2. Disconnect the gauge connector. 3. Disconnect the headlights connector. PREDELIVERY / 27

6 PARTS TO BE INSTALLED mbl _a 1. Headlights connector 4. Open side panels. NOTICE The removal of side panels is not required but its a good practice to avoid scratching them during vehicle preparation. When side panels are removed, make sure to place them in a safe place. 4.1 Unhook both rubber latches. 4.2 Firmly pull the upper latch upwards. mmr _a Step 1: Step 2: Step 3: Lift tab Twist tube Pull forward 7. Disconnect air temperature sensor (ATS) on top of connector tube. mbl _a 1. ATS connector 8. Open RH side panel. 9. Disconnect the APS hose at the ECM. mbl _a 1. Side panel 2. Upper latch 3. Lower latch 5. Remove the drive belt guard. 6. Disconnect the air intake connector tube. mbl _a 1. ECM 2. APS hose 10. On both sides, remove the upper body module retaining screws. 6 / PREDELIVERY

7 PARTSTOBEINSTALLED mbl _a RH SIDE SHOWN 1. Retaining screws 11. Remove the upper body module. 1. Shipping brackets 2. Spring clips 3. M10 flat washers and bolts Front Shock Absorber Installation Install front shock absorbers with the body up, using the M10 screws and new M10 flanged nuts (predelivery kit). mbl _a SLIDE TOWARDS FRONT mbl TYPICAL - BODY UP TIGHTENING TORQUE Front shock absorber retaining nuts 48 N m (35 lbf ft) Skis mbl _a 1. LH upper shock (shipping bracket) bolt Front Suspension Shipping Brackets Removal 1. Remove and discard shipping brackets. 2. Keep M10 flat washers, upper M10 x 65 and lower M10 x 55 bolts for front shock absorbers installation. 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. PREDELIVERY / 27

8 PARTS TO BE INSTALLED mmr _a TYPICAL 1. Ski stopper 2. Bushings 2. Install ski on ski leg using the hardware as shown. mbl _b 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 leg bushing 6. Ski leg 9. Narrow adjustment 10. Wide adjustment TIGHTENING TORQUE Ski retaining nuts 48 N m (35 lbf ft) Battery Models With Electric Starter Battery Removal (if Shipped Installed) mbl _b 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 6. Ski leg TIGHTENING TORQUE WARNING Battery BLACK ( ) cable must always be disconnected first and connected last. Never charge or boost battery while installed on vehicle. 1. Open the right side panel of the vehicle. 2. Remove the battery bracket. Ski retaining nuts 48 N m (35 lbf ft) Ski Stance Setting and Summit Models SKI STANCE SETTING Narrow Wide Place spacer on the inside of ski leg Place spacer on the outside of ski leg mbl _a TYPICAL - REAR OF BATTERY 1. Lower bracket screw 8 / PREDELIVERY

9 PARTSTOBEINSTALLED mbl _a 800R E-TEC mbl _a TYPICAL - FRONT OF BATTERY 1. Upper bracket screw 3. Remove the battery. 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. 3. Connect the RED ( + ) cable to the battery positive terminal. NOTE: Position the RED cable terminal vertically. 4. Connect BLACK ( ) cable LAST. WARNING Battery BLACK ( ) cable must always be disconnected first and connected last. Never charge or boost battery while installed on vehicle. 5. Apply DIELECTRIC GREASE (P/N ) on battery posts and connectors. 6. Cover the RED ( + ) terminal with rubber boot. Handlebar 1. Loosen the lower steering extension retaining screws. mbl _a 1. Steering extension 2. Retaining screws 2. Lift steering extension and position it as per the following table. mbl _a 600 HO E-TEC VEHICLE Summit MX Z and ANGLE 40 (from vertical) 20 (from vertical) PREDELIVERY / 27

10 PARTS TO BE INSTALLED mbl _a SUMMIT SERIES A. Steering extension angle mbl _a MX Z AND RENEGADE SERIES A. Steering extension angle NOTICE Make sure brake hose is routed over the steering extension mbl _c TYPICAL - BRAKE HOSE ROUTING 1. As delivered (routed below steering column) 2. Correct hose routing when set up 3. Tighten steering extension lower screws to specified torque. Steering extension lower 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 specified torque Steering extension upper screws NOTICE level. TIGHTENING TORQUE 24 N m (18 lbf ft) Make sure brake fluid reservoir is 5. Cut the tie wrap securing the tether cord to the riser block. Do not attach the throttle cable with a new one. 6. Connect steering harness connectors. 10 / PREDELIVERY

11 PARTSTOBEINSTALLED mbl _a TYPICAL 1. Connectors Steering Cover Install steering cover by pushing it in place. Route throttle cable and wiring properly. mbl TOOLS STOWED Stow the emergency starting rope in the opening on the LH of bottom pan. mbl _a 1. Emergency starting rope 2. Opening mbl _a 1. Steering cover 2. Throttle cable 3. RH wiring Tools and Emergency Starting Rope Secure the tools on the drive belt guard. Handlebar Wind Deflector (Applicable Models) On each side: 1. Insert a M6 square nut into the wind deflector support cavity. mbl TOOL KIT msi _a 1. Wind deflector 2. M6 square nut 2. Cut the handlebar wiring tie wraps. PREDELIVERY / 27

12 PARTS TO BE INSTALLED 3. Push the support end downwards to clamp it on the handlebar. 4. Thread a M6 X 35 screw but do not tighten yet. msi _a 1. M6 X 35 screw 5. Position the deflector so that the support leans against the steering cover. 6. Set the deflector 7 below horizontal. 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. msi _a Wind deflector screws TIGHTENING TORQUE 3.5 N m (31 lbf in) 7. Secure handlebar wiring with new tie-wraps. WARNING Turn handlebar completely from side to side making sure that wind deflectors do not interfere with handlebar controls and accessories (throttle lever, brake lever, emergency engine stop switch, windshield, etc). Drive Belt Installation 1. Remove tether cord cap (D.E.S.S. key). 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. 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 PARTSTOBEINSTALLED 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. Front Reflector (European Models) 1. Insert tie wraps in the reflector support slots as shown. 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. mbl PREDELIVERY / 27

14 FLUIDS 2. Place the reflector support centered on the front bumper, then attach the tie wraps. mbl Install the tie wraps tightly so that they don't exceed the support recesses. FLUIDS General Guidelines 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 which may contain up to 10% MAX ethanol INSIDE NORTH AMERICA ENGINE MIN. OCTANE RATING 600 HO E-TEC 800R E-TEC 91 mbl _a TIE WRAP INCORRECTLY TIGHTENED mbl TIE WRAP CORRECTLY TIGHTENED (NOT EXCEEDING RECESSES) 4. Stick the reflector on the support. Make sure the support is still centered on the bumper. FUEL TYPE Fuel which may contain up to 10% MAX ethanol OUTSIDE NORTH AMERICA ENGINE MIN. OCTANE RATING 600 HO E-TEC 800R E-TEC 95 NOTICE Use octane rating according to fuel 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 fuel system components which may lead, in certain cases, to severe damage to engine. NOTE: Use only methyl hydrate free gas line antifreeze. 14 / PREDELIVERY

15 FLUIDS Engine Coolant 1. 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. 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) mbl _a 1. COLD LEVEL line Chaincase Oil 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. 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. WARNING Do not overfill. Reinstall cap and fully tighten. Wipe off any oil spills. Oil is highly flammable when heated. ENGINE 800R E-TEC RECOMMENDED INJECTION OIL XPS SYNTHETIC BLEND 2-STROKE OIL (P/N ) XPS SYNTHETIC 2-STROKE OIL (P/N ) mmr _a TYPICAL 1. Check plug To add oil, remove the filler cap on chaincase cover. 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 Level 1. Check brake fluid in reservoir for proper level. PREDELIVERY / 27

16 UPPER BODY MODULE INSTALLATION 2. Add brake fluid (DOT 4) as required. Use BRAKE FLUID (P/N ) orbrake FLUID SRF (P/N ) (for high performance) 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. mbl _b 3. On both sides, install the upper body module retaining screws. mmo _a 1. Minimum 2. Maximum 3. Operating range UPPER BODY MODULE INSTALLATION 1. Insert the upper body module tabs into the upper bottom pan openings. mbl _a RH SIDE SHOWN 1. Retaining screws 4. Connect: APS hose on the ECM Headlights connector Gauge connector Air temperature sensor (ATS) Air intake connector tube. 5. Install: Gauge Drive belt guard. 6. Install side panels Front Storage Compartment Cover Snap cover in place. mbl _a 2. Slide the module towards rear. 16 / PREDELIVERY

17 SET-UP mbl _a Console Wind Deflectors (if Equipped) mbl _a 1. Windshield tab 2. Console front grommet 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. mbl _a Windshield 1. Lubricate the grommets using DIELECTRIC GREASE (P/N ). 2. Remove protective films from the windshield. 3. Position windshield in place. 4. Secure windshield by inserting the windshield pins into the grommets. SET-UP 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. PREDELIVERY / 27

18 SET-UP REQUIRED TOOLS MPI-2 INTERFACE CARD (P/N ) MPI-2 DIAGNOSTIC CABLE (P/N ) vdd T-HARNESS (P/N ) 12 V BATTERY SUPPLY CABLE (P/N ) Programing Keys with B.U.D.S. 1. Install new key to be programmed on vehicle D.E.S.S. post. 2. Click on Keys tab. 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 Try active detection mode button. smr _en mbg NOTE: When programing a vehicle for the first time, you need to click on Erase All Keys button. 3. Click on Add Key. 2. Make sure status bar shows proper Protocol. kw2000 F18H0XA CONNECTION SUCCESSFUL NOTE: Number 2 indicates that the ECM and the multifunction gauge are recognized by the MPI. On models equipped with a THCM, a "3" will be displayed. If an X or a 1 is shown instead of a 2 or "3", 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. smr _aen 1. Add Key 4. Click on Write Data to save a new key in vehicle's ECM. vmr _ben 18 / PREDELIVERY

19 SET-UP 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 Clustertabs. 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. Track Track Tension Adjustment and Alignment 1. Remove the D.E.S.S. key (tether cord cap). 2. Lift rear of vehicle and support it off the ground. 3. Allow rear suspension to fully extend. 4. Loosen the rear axle retaining screws. mbl _a 1. RH axle screw 5. Tighten both adjustment screws equally to increase track tension a little. mmr _a 1. RH adjustment screw mbl _b 1. RH adjustment screw 6. Use the TENSIOMETER (P/N ). mmr _a 1. RH rear idler wheel bolt Set deflection between using bottom O-ring. BOTTOM O-RING SETTING 3.2 cm (1-1/4 in) PREDELIVERY / 27

20 SET-UP mmr _b DEFLECTION SETTING 1. Bottom O-ring 8. Place upper O-ring to 0 kgf (0 lbf). 9. Position the tensiometer on track, halfway between front and rear idler wheels. 10. Push the tensiometer downwards until bottom O-ring (deflection set earlier) be aligned with the bottom of slider shoe. TRACK ADJUSTMENT SPECIFICATION Track deflection setting Track load reading 3.2 cm (1-1/4 in) 6kgto8.5kg (13lb to 19lb) 13. Tighten both adjustment screws until specified tension is obtained. 14. Tighten rear idler wheel retaining screws to 48N m ± 6N m (35lbf ft ± 4lbf ft). Check track alignment as follows: 15. Start engine and accelerate slightly so that track slowly turns. This must be done in a short period of time (15 to 20 seconds). 16. Check that the track is well centered; equal distance on both sides between edges of track guides and slider shoes. 1 2 mmr _a A01F05A 3 1. Guides 2. Slider shoes 3. Equal distance mmr _a 1. Deflection O-ring aligned with slider shoe 11. Read load recorded by the upper O-ring on the tensiometer. mmr _a LOAD READING 1. Upper O-ring 12. Load reading must be as per the following table. 17. To correct track alignment: 17.1 Stop engine Remove D.E.S.S. key (tether cord cap) 17.3 Loosen rear wheel retaining screws Tighten adjustment screw on the side where the slider shoe is the farthest from the track insert guides. 18. Tighten rear idler wheel retaining screws to 48N m ± 6N m (35lbf ft ± 4lbf ft). 19. 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. 20 / PREDELIVERY

21 FINAL INSPECTION 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. 1. Install wheel caps (predelivery kit). NOTE: If lubricant is needed to help cap installation, use glass cleaner instead of soapy water to avoid cap to get out from its location due to soap residue. 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). 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 1. Test ride vehicle. Snowmobile Cleaned and in Showroom Condition 1. Make sure all protective wrapping is removed from vehicle. 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 MULTI-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, petroleum, etc. Vehicle Delivery 1. Complete PREDELIVERY CHECK LIST. 2. Give the OPERATOR S GUIDE and the SAFETY DVD to the customer. 3. Customer must read and sign the PREDELIV- ERY CHECK LIST. PREDELIVERY / 27

22 SPECIFICATIONS SPECIFICATIONS The content of SPECIFICATIONS pages should be used as necessary to fine-tune and perform additional adjustments required on snowmobile. 600 HO E-TEC Models ENGINE Engine type MODEL 600 HO E-TEC Rotax 593, liquid cooled w/reed valve, 3D-RAVE Cylinders 2 Displacement Bore Stroke Maximum engine speed Fuel injection system Exhaust system Engine oil Engine oil tank capacity Coolant Recommended fuel Minimum octane rating Fuel tank capacity DRIVE SYSTEM Drive pulley type Driven pulley type Engagement cm³ (36.3 in³) 72 mm (2.8 in) 73 mm (2.9 in) 8100 RPM E-TEC Direct injection Single tuned pipe, baffle muffler XPS SYNTHETIC BLEND 2-STROKE OIL (P/N ) (1) 3.7 L (3.9 qt (U.S. liq.)) Ethyl glycol/water mix (50% coolant, 50% distilled water). Use BRP PREMIXED COOLANT (P/N ) or coolant specifically designed for aluminum engines Premium unleaded (fuel which may contain up to 10% MAX ethanol) Inside North America 91 Outside North America 95 Summit Others 40 L (10.6 U.S. gal.) TRA III QRS 4000 RPM 3400 RPM Chaincase oil XPS SYNTHETIC CHAINCASE OIL (P/N ) Small sprocket number of teeth Large sprocket number of teeth Drive sprocket number of teeth 8 Track nominal width MX Z cm (16 in) 38 cm (15 in) 22 / PREDELIVERY

23 SPECIFICATIONS DRIVE SYSTEM (cont'd) Track nominal length Track profile height Track tension Track alignment BRAKE SYSTEM Brake system type Deflection Force (2) MODEL 600 HO E-TEC cm (137 in) 305 cm (120 in) 31.8 mm (1.25 in) 44.5 mm (1.75 in) 30 mm to 35 mm (1-3/16 in to 1-3/8 in) 7.3 kg (16 lb) Equal distance between edges of track guides and slider shoes Hydraulic, Brembo racing brakes Brake fluid DOT 4 SUSPENSION Front suspension Front shock Front suspension max. travel Rear suspension Center shock Rear shock Rear suspension max. travel ELECTRICAL SYSTEM Lightning system output Headlights bulb HI/LOW beam Others REV-XP (ESR) HPG Plus R 210 mm (8.3 in) 229 mm (9 in) rmotion HPG Plus KYB PRO mm (16 in) 394 mm (15.5 in) 12V/360 W 55 V/1100 W 2 x 60/55 Watts(H-4) Taillight bulb 521 Spark plug Fuse Type NGK PZFR6F (3) Gap 0.75 mm ± 0.05 mm (.03 in ±.002 in) (not adjustable) Refer to FUSES in MAINTENANCE PREDELIVERY / 27

24 SPECIFICATIONS DIMENSIONS AND WEIGHT Vehicle overall length Vehicle overall width Dry weight Ski stance Ski width MODEL Others Others 600 HO E-TEC 311 cm (122.4 in) cm (114.4 in) cm to cm (45.6 in to 47.4 in) cm (47.9 in) 210 kg (463 lb) 214 kg (472 lb) 217 kg (478 lb) 97.5 cm to cm (38.4 in to 40.1 in) cm (42.4 in) 165 mm (6.5 in) 145 mm (5.7 in) (1) Refer to INJECTION OIL subsection for detailed information. (2) Measure gap between slider shoe and bottom inside track when exerting a downward pull to the track. (3) NOTICE Do not attempt to adjust gap on this spark plug. 24 / PREDELIVERY

25 SPECIFICATIONS 800R E-TEC Models ENGINE Engine type MODEL 800R E-TEC Rotax 797, liquid cooled w/reed valve, 3D-RAVE Cylinders 2 Displacement Bore Stroke Maximum engine speed Fuel injection system Exhaust system Engine oil Engine oil tank capacity Coolant Recommended fuel Minimum octane rating Fuel tank capacity DRIVE SYSTEM Drive pulley type Driven pulley type Engagement cm³ (48.8 in³) 82 mm (3.2 in) 75.7 mm (3 in) 7900 RPM E-TEC Direct injection Single tuned pipe, baffle muffler XPS SYNTHETIC BLEND 2-STROKE OIL (P/N ) (1) 3.7 L (3.9 qt (U.S. liq.)) Ethyl glycol/water mix (50% coolant, 50% distilled water). Use BRP PREMIXED COOLANT (P/N ) or coolant specifically designed for aluminum engines Premium unleaded (fuel which may contain up to 10% MAX ethanol) Inside North America 91 Outside North America L (10.6 U.S. gal.) TRA VII QRS 3800 RPM Chaincase oil XPS SYNTHETIC CHAINCASE OIL (P/N ) Small sprocket number of teeth Large sprocket number of teeth MX Z Summit (146 in track) 21 Summit (154 in in) 19 Summit (163 in track) 51 Summit (146 in in) 49 Others 45 Drive sprocket number of teeth 8 Track nominal width MX Z 38 cm (15 in) Summit 40.6 cm (16 in) 348 cm (137 in) Track nominal length Summit MX Z 371 cm (146 in) 392 cm (154 in) 414 cm (163 in) 305 cm (120 in) PREDELIVERY / 27

26 SPECIFICATIONS Track profile height Track tension Track alignment BRAKE SYSTEM Brake system type Deflection Force (2) MODEL DRIVE SYSTEM (cont'd) Summit MX Z 800R E-TEC 63.5 mm (2.5 in) 44.5 mm (1.75 in) 31.8 mm (1.25 in) 30 mm to 35 mm (1-3/16into1-3/8in) 7.3 kg (16 lb) Equal distance between edges of track guides and slider shoes Hydraulic, Brembo racing brake Brake fluid DOT 4 SUSPENSION Front suspension Front shock Front suspension max. travel Rear suspension Center shock Rear shock Rear suspension max. travel Summit SP MX Z TNT Summit X MX Z Summit MX Z Summit Summit SP Summit X Summit SP MX Z TNT Summit X Summit (163 in track) Summit (154 in track) MX Z TNT Summit (146 in track) REV-XP (ESR) HPG HPG Plus HPG Plus R 229 mm (9 in) 210 mm (8.3 in) 200 mm (7.9 in) rmotion tmotion HPG HPG Plus HPG HPG Plus KYB PRO cm (16 in) 39.4 cm (15.5 in) 38.1 cm (15 in) 35.6 cm (14 in) 26 / PREDELIVERY

27 SPECIFICATIONS ELECTRICAL SYSTEM Lightning system output Headlights bulb HI/LOW beam MODEL 800R E-TEC 12V/360 W 60 V/1100 W 2 x 60/55 Watts (H-4) Taillight bulb 521 Spark plug Fuse Type NGK PFR7AB (3) Gap DIMENSIONS AND WEIGHT Vehicle overall length Vehicle overall width Dry weight Ski stance Ski width MX Z Summit (146 in track) Summit (154 intrack) Summit (163 intrack) MX Z Summit MX Z TNT Summit SP (146 in track) Summit SP (154 in track) Summit SP (163 in track) Summit X (146 in track) Summit X (154 in track) Summit X (163 in track) MX Z Summit Summit Others (1) Refer to INJECTION OIL subsection for detailed information mm ± 0.05 mm (.03 in ±.002 in) (not adjustable) Refer to FUSES in MAINTENANCE cm (114.4 in) 311 cm (122.4in) cm (127in) cm (131.3 in) cm (135.6 in) cm (47.9 in) cm to cm (45.6 in to 47.4 in) cm to cm (42.6 in to 44.3 in) 214 kg (472lb) 212 kg (467lb) 219 kg (483 lb) 210 kg (463 lb) 208 kg (459 lb) 208 kg (459 lb) 211 kg (465 lb) 206 kg (454 lb) 211 kg (465 lb) 215 kg (474 lb) 97.5 cm to cm (38.4 in to 40.1 in) cm (42.4 in) 90.7 cm or 95 cm (35.7 in or 37.4 in) 165 mm (6.5 in) 145 mm (5.7 in) (2) Measure gap between slider shoe and bottom inside track when exerting a downward pull to the track. (3) NOTICE Do not attempt to adjust gap on this spark plug. PREDELIVERY / 27