September 2015 Subject: MX Z X 600RS Predelivery Inspection No

Transcription

1 PRE-DELIVERY BULLETIN SKI-DOO September 2015 Subject: MX Z X 600RS Predelivery Inspection No THE MX Z X 600RS 2016 IS FOR RACE APPLICATION ONLY There is no limited warranty available YEAR MODEL MODEL NUMBER PREDELIVERY KIT P/N 2016 MX Z X 600RS BMGA / BMGB TABLE OF CONTENTS Page IMPORTANT NOTICE... 2 UPDATE SUMMARY... 3 PREDELIVERY KIT... 3 UNCRATING... 4 Crate Cover... 4 Crate Brackets... 4 Crate Disposal... 4 Rear Suspension Shipping Hook(s)... 5 Shipping Brackets... 5 PARTS TO BE INSTALLED... 5 Front Shock Absorber... 5 Skis... 6 Handlebar... 6 Handlebar Wind Deflector... 7 Steering Pad... 8 Snow Guard... 8 Rear Bumper... 8 Exhaust Deflector... 8 Drive Belt... 9 Page Grip Plates (if needed) Reinforcement Bracket FINAL PREPARATION Engine Oil Brake Fluid Level Track Tension and Alignment Track Studding Speedometer Vehicle Cleaning DELIVERY TO CUSTOMER Break-in Period Rear Suspension Adjustments French Warning Labels Vehicle Delivery Warranty Printed in Canada. (mbl en ML MS) 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 / 13

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 by customer and dealer. 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 SERVICE 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. 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. 2 / PREDELIVERY

3 PREDELIVERY KIT 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 No stabilizer bar No windshield No idler wheels Parts to be installed Parts to be intalled Parts to be installed PREDELIVERY KIT Parts List (P/N ) SECTION WHERE USED DESCRIPTION P/N QTY Rear Bumper Screw M6 x Ski stopper Skis Washer Elastic nut M Front Shock Absorbers Elastic nut M Snow Guard Exhaust Deflector Pop rivet 4.8 mm (3/16 in) Washer Pop rivet 4.8 mm (3/16 in) Washer Reinforcement Bracket Hemlok rivet 6.4 mm (1/4 in) PREDELIVERY / 13

4 UNCRATING 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 bolts and shipping inserts. Keep spacers for ski installation. mbl _a 1. Shipping bolts (discard) 2. Shipping inserts (discard) 3. Spacers (keep) mbl _a 3. Remove screws securing sidewalls to crate base. 4. Unscrew sidewalls one at the time. Discard shipping bracket. 4. Using a pry bar, remove wood blocks retaining track to crate base. 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. Remove ski leg wood protectors (if applicable). 2. Detach ski legs from crate shipping brackets. 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 top and sidewall wood structures. 2. Stack or dispose as per local environmental regulations. 4 / PREDELIVERY

5 PARTS TO BE INSTALLED Rear Suspension Shipping Hook(s) NOTICE Shipping hooks must be removed to have snowmobile suspension operational Apply parking brake. 2. Standing on footrests, apply pressure onto rear suspension and ask someone to remove rear hook. 4 2 NOTICE To avoid any damage to seat, always sit on seating surface. 1 2 mbl _a 1. Shipping brackets 2. Plastic washers 3. Washers and upper bolt 4. Lower bolt 3. Remove and discard shipping brackets. mbl _a TYPICAL 1. Apply pressure 2. Rear hook 3. Lift rear of vehicle so that a block or a box can be positioned under front part of rear suspension. 4. Ask another person to apply pressure onto rear suspension. NOTICE To avoid any damage to seat, always sit on seating surface. 5. Remove front hook(s) from suspension. Shipping Brackets To access the shock upper bolts, remove the upper body module. Refer to BODY subsection in the appropriate shop manual. 1. Remove and discard plastic washers. 2. Keep washer, upper M10 x 65 and lower M10 x 55 bolts for front shock absorbers installation. PARTS TO BE INSTALLED Front Shock Absorber Install front shock absorbers using the previously removed M10 screws and washer, and new M10 flanged nuts (predelivery kit). Refer to following table in order to place the reservoirs inward and towards front. mbl _b 1. Reservoir (inwards and towards front) SHOCK ABSORBERS SHOCK P/N (P/N ) (P/N ) VEHICLE SIDE LH RH NOTICE If shock absorbers are installed backwards, interference will occur and serious damage may happen to suspension and shock absorbers. 1. Tighten bolts to specification. PREDELIVERY / 13

6 PARTS TO BE INSTALLED Shock absorber retaining nuts Skis 48 N m (35 lbf ft) 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. Handlebar 1. Remove the tape securing the handlebar wiring. 2. Loosen the lower steering extension retaining screws. mbl _a 1. Steering extension 2. Retaining screws 3. Tighten steering extension lower screws to specification. mmr _a TYPICAL 1. Ski stopper 2. Bushings 2. Install ski on ski leg using the hardware as shown. Steering extension lower screws 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. Steering extension upper screws 24 N m (18 lbf ft) 5. Tighten steering electrical harness locking tie, then cut exceeding strip. 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 axle Tighten flanged nut to specification. Ski retaining nuts 48 N m (35 lbf ft) mbl _a FRONT OF HANDLEBAR 1. Locking tie 6 / PREDELIVERY

7 PARTS TO BE INSTALLED Handlebar Wind Deflector On each side: 1. Insert arm into deflector. msi _b msi _b 2. Position trim tab inside slot on deflector. 5. Cut the handlebar wiring locking ties. 6. Place the arm against the handlebar. 7. Install the clamp with screws but do not tighten yet. mbl _a 8. Set the deflector horizontally and tighten screws to specification. msi _b 3. Slide trim into place along deflector and over arm. mbl _a msi _b 4. Secure deflector assembly using K50 x 20 Torx screw. Wind deflector screws 3.5 N m (31 lbf in) 9. Secure handlebar wiring with new locking ties. 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). PREDELIVERY / 13

8 PARTS TO BE INSTALLED Steering Pad 1. Insert the steering pad tab through riser block. NOTE: Make sure to wrap all wires and cables. mbl _a 1. Plastic trim 2. Snow guard 3. Rivet 4. Washer mbl Snap steering pad in place. Rear Bumper 1. Align holes of rear bumper with frame holes. 2. Secure rear bumper to frame using 6 M6 x 18 hexagonal screws (predelivery kit). 3. Tighten to specification. Bumper screws 16 N m ± 1 N m (142 lbf in ± 9 lbf in) Exhaust Deflector 1. Remove muffler. 2. From underneath snowmobile, position exhaust deflector with 4.8 mm (3/16 in) pop rivets (predelivery kit). mbl _a 1. Snaps Snow Guard 1. Insert snow guard between tunnel and rear plastic trim. 2. Fasten snow guard with 4.8 mm (3/16 in) pop rivets and washers (from predelivery kit). 8 / PREDELIVERY

9 PARTS TO BE INSTALLED mmo _a TYPICAL 1. To be pointed in the direction of rotation 6. To adjust drive belt, turn the set screw 1/4 turn at a time, then rotate the driven pulley to properly set the belt between the pulley sheaves. 7. Measure belt deflection using a straight edge and the TENSIOMETER (P/N ). mbl _a A. View from front B. View from right side 1. Pop rivets 2. Exhaust deflector 3. From inside engine compartment, place 3 washers (predelivery kit) on rivets Adjust drive belt deflection as per specification. DRIVE BELT DEFLECTION Deflection Force applied 27 mm to 37 mm (1.06 in to 1.46 in) 11.3 kg (25 lb) NOTE: Turn the set screw in (clockwise) to increase the distance between the sheaves and out (counter-clockwise) to decrease the distance. Tighten the lock nut after the belt adjustment has been made. mbl _a 1. Washers on rivets 4. Pop the rivets. 5. Reinstall muffler. Drive Belt 1. Remove drive belt guard. 2. Loosen the lock nut on the set screw. 3. Completely open the driven by turning the set screw clockwise. 4. Clean drive and driven pulleys using PULLEY FLANGE CLEANER (P/N ). 5. Install drive belt is with arrows in the direction of rotation. A32D34A JAM NUT PREDELIVERY / 13

10 FINAL PREPARATION NOTE: This setting is correct as a preliminary adjustment. In some cases, when starting the engine, the vehicle could creep, indicating that the belt is too tight. If the vehicle creeps, lower the belt, install the belt guard and side panel, then start engine. Repeat until creeping stops. Reinstall side panels. Grip Plates (if needed) 1. Secure grip plates using 4.8 mm (3/16 in) pop rivets. mbl _a 1. Pop rivets 2. Grip plate Reinforcement Bracket 1. Lift and support front of vehicle. 2. Install a stopper such as a rubber hose on a 6.4 mm (1/4 in) drill in order to allow a drilling depth of maximum 15 mm (.59 in). NOTICE Exceeding drilling depth would damage cooling system or engine. 3. Drill through all three bracket holes, then into the chassis. The bracket holes were purposely made smaller than 6.4 mm (1/4 in). 4. Secure the front of bracket using provided Hemlok rivets (predelivery kit). NOTE: Hemlok rivets require an heavy duty or compressed air powered riveting machine. If such equipment is not available, the bracket can be secured using 6 mm (1/4 in) bolts. FINAL PREPARATION Engine Oil NOTE: This vehicle has no oil pump, oil must be mixed with fuel at the ratio of 33:1 in a jerrycan then, be poured in the fuel tank. Refer to PREMIX FUEL/OIL RATIO table below as a guideline to properly premix oil with fuel. NOTICE Never experiment with other fuel/oil ratios. Use only oil that can flow at -40 C (-40 F). Premix Fuel/Oil Ratio PREMIX FUEL/OIL RATIO 33:1 METRIC (SI) 33 L of fuel + 1 L of oil = 33:1 IMPERIAL 7.2 imp. gal of fuel + 35 imp. oz of oil = 33:1 7.2 imp. gal of fuel + 1 L of oil = 33:1 UNITED STATES 8.8 U.S. gal of fuel + 34 U.S. oz of oil = 33:1 8.8 U.S.gal of fuel + 1 L of oil = 33:1 Recommended Oil 600RS RECOMMENDED OIL XPS SYNTHETIC 2-STROKE OIL (P/N ) NOTICE The engine of this snowmobile has been developed and validated using the XPS SYNTHETIC 2-STROKE OIL (P/N ). BRP strongly recommends the use of either lubricant at all times. Brake Fluid Level Check brake fluid in reservoir for proper level. mbl _a UNDERNEATH FRONT OF CHASSIS 1. Reinforcement bracket 2. Reinforcement bracket holes 3. Front of vehicle 10 / PREDELIVERY

11 FINAL PREPARATION mmo _a TYPICAL 1. Level mark Add brake fluid (DOT 4) as required. Use BRAKE FLUID GTLMA DOT4 (P/N ). NOTICE Use only (DOT 4) brake fluid from a sealed container. Do not store or use a partially used bottle of brake fluid. Track Tension 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 the rear idler wheel axe retaining screws. mbl _a 7. Use the TENSIOMETER (P/N ) Set deflection between using bottom O-ring. mmr _b DEFLECTION SETTING 1. Bottom O-ring BOTTOM O-RING SETTING 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. 11. Push the tensiometer downwards until bottom O-ring (deflection set earlier) be aligned with the bottom of slider shoe. mbl _a TRACK REMOVED FOR CLARITY 5. Move track in order to align adjustment screws with track openings. 6. Tighten both adjustment screws equally to increase track tension a little. mmr _a PREDELIVERY / 13

12 FINAL PREPARATION 1 2 A01F05A 3 mmr _a 1. Deflection O-ring aligned with slider shoe 12. Read load recorded by the upper O-ring on the tensiometer. mmr _a LOAD READING 1. Upper O-ring 13. Load reading must be as per the following table. TRACK ADJUSTMENT SPECIFICATION Track deflection setting Track load reading 3.2 cm (1-1/4 in) 6 kg to 8.5 kg (13 lb to 19 lb) 14. Tighten both adjustment screws until specified tension is obtained. 15. Tighten rear idler wheel retaining screws to specification. Rear idler wheel retaining screws Check track alignment as follows: 48 N m ± 6 N m (35 lbf ft ± 4 lbf ft) 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. 1. Guides 2. Slider shoes 3. Equal distance 18. To correct track alignment: 18.1 Stop engine Remove tether cord cap Loosen 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 screws to specification. Rear idler wheel retaining screws 48 N m ± 6 N m (35 lbf ft ± 4 lbf 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. Speedometer To change the speedometer units to SAE custom units or metric, use the latest B.U.D.S. software. Look in Settings then in Cluster. 12 / PREDELIVERY

13 DELIVERY TO CUSTOMER Vehicle Cleaning 1. Wash and dry vehicle. NOTICE Never use a high pressure washer to clean vehicle. High pressure can cause electrical or mechanical damages. 2. Clean exterior of vehicle using flannel clothes or microfiber cloth with XPS ALL PURPOSE CLEANER (P/N ). NOTICE It is necessary to use flannel or microfiber clothes on plastic parts to avoid damaging surfaces. Never clean plastic parts with strong detergent, paint thinner, acetone, products containing chlorine, etc. To clean metallic parts use BRP HEAVY DUTY CLEANER (P/N ). Painted parts which are damaged should be properly repainted to prevent rust. DELIVERY TO CUSTOMER Break-in Period It is imperative for engine reliability to perform a complete break-in period. For the first fuel tank 26 L (7 U.S. gal.), use: PREMIUM UNLEADED GASOLINE Pre-mix fuel using XPS INJECTION OIL (P/N ) 33:1 Factory installed main jets. Vehicle Delivery 1. Complete PRE DELIVERY CHECK LIST. 2. Test ride vehicle. 3. Give OPERATOR S GUIDE and SAFETY DVD to customer. 4. Customer and dealer must read and sign PRE DELIVERY CHECK LIST. Warranty The 2016 MX Z X 600RS is designed exclusively for competition and is exempt from emission standards and related requirements under the United States Environmental Protection Agency 40 CFR and Environment Canada SOR/ (4). This vehicle including the engine is classified as a competition snowmobile and should never be used on a public trails. The 2016 MX Z X 600RS is shipped from the factory with no limited warranty. For further information refer to WARRANTY section and the back cover page of the 2016 MX Z X 600RS operator's guide. NOTICE If the break-in is not performed according to those recommendations severe engine failure will occur. Rear Suspension Adjustments The best way to set up the suspension is to start from factory settings, then customize each adjustment one at a time. Please refer to OPERATOR'S GUIDE for all specifications. French Warning Labels 1. Underneath seat, a package containing French version of all warning labels found on vehicle is available for French customers. 2. After vehicle is washed and dried, remove backing from each label and apply it on corresponding English label. PREDELIVERY / 13