PARTS REQUIRED REPAIR PROCEDURES A : CHAIN CASE LEAKING
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1 Campaign no.: Date: October 19, 2007 Subject: A : Chain Case Leaking No B : Spare Belt Holding Strap C : 800R Engine Clutch Torque D : 800R EPA Hangtag YEAR MODEL MODEL NUMBER SERIAL NUMBER 2008 MX Z 800R X BB8A / BB8B / BB8C / BB8D / BB8E See attached list 2008 MX Z 800R Adrenaline BD8A / BD8B / BD8C / BD8D See attached list 2008 Summit 800R Everest CT8A See attached list 2008 MX Z 500SS Trail BH8A / BH8B See attached list 2008 MX Z 500SS TNT MF8A / MF8B See attached list PROBLEM A. Under certain conditions chain case oil may leak from vent. B. A limited quantity of units were produced without a spare belt holding strap. C. Some 800R power packs may have been produced with the wrong drive clutch torque specification. D. Some 800R vehicle may have been produced with the wrong EPA hangtag. SOLUTION A. Install the new vent system. B. Install the holding strap. C. Torque 800R engine drive clutch retaining bolt to the specification. D. Replace 800R vehicle hangtag located on handlebar. PARTS REQUIRED DESCRIPTION P/N QTY Fitting Hose (115 mm / 4.5 in) Velcro strip EPA Hangtag (800R only) Fittings (P/N ) are sold in pack of 5. Hoses (P/N ) are sold in pack of 10 meters (32.8 FT). Velcro strips (P/N ) are sold individually. EPA Hangtags (P/N ) are sold individually. REPAIR PROCEDURES A : CHAIN CASE LEAKING Securevehicleinplace. Open right side panel. Remove the chain case rubber cap. Printed in Canada. (mbg DM) 1/ 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.
![mbg2008-006-003_a mbg2008-006-006_a Place rubber cap [1] on a piece of wood placing](/docs-images/88/116794851/images/2-0.jpg "internal side facing up.")
![Usinga7mmstuddrill[2] (P/N 415 128 884), punch the center of rubber cap.](/docs-images/88/116794851/images/2-1.jpg "mbg2008-006-008_a mbg2008-006-004_a Insert the fitting [3] (P/N 414 580 700) into the")
![On the back side of chain case, toward the front of vehicle, locate the vent hole [5].](/docs-images/88/116794851/images/2-3.jpg "NOTE: The chain case vent hole is positioned just above a fixation hole.")
![Using a wooden dowel, fill up the vent hole [5] with Loctite 5910 (P/N 293 800 081).](/docs-images/88/116794851/images/2-5.jpg "B:SPAREBELTHOLDINGSTRAP mbg2008-006-005_a msi2008-027-008_a Re-install rubber cap on the")
2 mbg _a mbg _a Place rubber cap [1] on a piece of wood placing internal side facing up. Usinga7mmstuddrill[2] (P/N ), punch the center of rubber cap. mbg _a mbg _a Insert the fitting [3] (P/N ) into the rubber cap. Cut the hose (P/N ) to 115 mm (4,5 ). Insert the hose on the fitting. On the back side of chain case, toward the front of vehicle, locate the vent hole [5]. NOTE: The chain case vent hole is positioned just above a fixation hole. NOTE: Do not remove chain case from vehicle. Clean chain case vent region with pulley flange cleaner (P/N ). Using a wooden dowel, fill up the vent hole [5] with Loctite 5910 (P/N ). B:SPAREBELTHOLDINGSTRAP mbg _a msi _a Re-install rubber cap on the chain case. Insert hose [4] between chain case and oil reservoir. Remove hood from vehicle. NOTE: To release hood, stand in front of vehicle, pull outwards on both sides of hood aft section then pull hood towards you. 2 / Warranty Campaign
![Re-torque drive pulley bolt [1] to 120 N m (89 lbf ft). WARNING After 10 hours of operation the transmission system of the vehicle must be inspected to ensure the retaining screw is properly torqued.](/docs-images/88/116794851/images/3-0.jpg "mbg2008-006-007_a Insert velcro strip [1] (P/N 548 872 539) into the belt holder slots. Re-install hood on vehicle. D : 800R EPA Hangtag NOTE: Do not replace 500SS or 600SDI vehicle EPA hangtag.")
![mbg2008-006-001_a Secure vehicle in place. Open left side panel. Install drive pulley holder (P/N 529 035 674). Slightly loosen the drive pulley bolt [1].](/docs-images/88/116794851/images/3-2.jpg "Torque drive pulley bolt [1] to 120 N m (89 lbf ft). Raise and block the rear of the vehicle and support it with a mechanical stand.")
3 Re-torque drive pulley bolt [1] to 120 N m (89 lbf ft). WARNING After 10 hours of operation the transmission system of the vehicle must be inspected to ensure the retaining screw is properly torqued. mbg _a Insert velcro strip [1] (P/N ) into the belt holder slots. Re-install hood on vehicle. D : 800R EPA Hangtag NOTE: Do not replace 500SS or 600SDI vehicle EPA hangtag. Replace only the EPA hangtag of 800R vehicle. C : 800R CLUTCH TORQUE CAUTION: Do not torque 500SS or 600SDI engine to this torque specification. Retorque only the drive pulley of 800R engine type. mbg _a Locate EPA hangtag on vehicle handlebar [1]. Remove EPA hangtag from vehicle and discard it. Replace EPA hangtag with the good one (P/N ). mbg _a Secure vehicle in place. Open left side panel. Install drive pulley holder (P/N ). Slightly loosen the drive pulley bolt [1]. Torque drive pulley bolt [1] to 120 N m (89 lbf ft). Raise and block the rear of the vehicle and support it with a mechanical stand. WARNING Ensure that the track is free of particles which could be thrown out while track is rotating. Keep hands, tools, feet and clothing clear of track. Ensure nobody is standing near the vehicle. Accelerate the vehicle at low speed (maximum 30 km/h (20 MPH)) and apply the brake. Repeat 5 times. WARRANTY Submit a warranty claim using the following information: Campaign Number Claim Type Flat Rate Time Campaign claim 0.3 hour For claiming procedure, refer to the DEALER/DISTRIBUTOR WARRANTY GUIDE. Warranty Campaign / 8
4 SERIAL NUMBER LISTING OF INVOLVED VEHICLE Model: BB8A From to From to From to From to From to Model: BB8B From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to Model: BB8C From to From to From to From to From to From to From to From to From to From to From to From to Model: BB8C (cont d) From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to Model: BB8C (cont d) From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to / Warranty Campaign
5 Model: BB8C (cont d) From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to Model: BB8D From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to Warranty Campaign / 8
6 Model: BB8D (cont d) Model: BB8D (cont d) From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to Model: BB8D (cont d) From to From to From to From to From to From to From to From to From to From to From to From to From to Model: BB8E From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to Model: BD8A From to From to Model: BD8B From to From to From to From to From to From to Model: BD8C From to From to From to From to From to / Warranty Campaign
7 Model: BD8C (cont d) Model: BD8D From to From to From to From to From to From to From to From to From to From to From to Model: BH8A From to From to From to From to Model: BH8B From to Model: CT8A From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to Warranty Campaign / 8
8 Model: CT8A (cont d) Model: CT8A (cont d) Model: MF8A From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to Model: MF8B From to From to From to From to From to From to From to / Warranty Campaign
SAFETY RECALL NOTICE. Date: September 10, Re: Drive Axle Failure Dear Ski-Doo Dealer / Distributor,
SAFETY RECALL NOTICE Bombardier Recreational Products Inc. 565 de la Montagne Street Valcourt, Québec, Canada J0E 2L0 T 450.532.2211 F 450.532.5133 www.brp.com Date: September 10, 2008 Re: Drive Axle Failure
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