SAFETY RECALL NOTICE. Date: September 10, Re: Drive Axle Failure Dear Ski-Doo Dealer / Distributor,

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1 SAFETY RECALL NOTICE Bombardier Recreational Products Inc. 565 de la Montagne Street Valcourt, Québec, Canada J0E 2L0 T F Date: September 10, 2008 Re: Drive Axle Failure Dear Ski-Doo Dealer / Distributor, This notice is sent to you in accordance with the requirements of the Consumer Product Safety Act, the Canada Motor Vehicle Safety Act and other applicable laws. What is the reason for this notice? In cooperation with Transport Canada and the U.S. Consumer Product Safety Commission, Bombardier Recreational Products Inc. and BRP US Inc. ( BRP ) are conducting a voluntary safety recall of certain 2008 and 2009 Ski-Doo models, as specified in the attached Safety Campaign Bulletin. What is the potential problem? Cracks may be developing in the welded joints of the drive axle assembly and may lead to a complete breakage of the component. This may cause the track of the vehicle to suddenly lock. If this occurs riders may be ejected off the vehicle or loose control and collide with bystanders, a fixed object or other vehicles potentially resulting in serious injuries and/or death. What will BRP do? BRP has already sent a Safety Recall letter to all known registered owners of these vehicles. This letter urges that the owners immediately stop using their snowmobiles and contact their authorized BRP Ski-Doo dealer in order to have the vehicle repaired. Also, BRP posted this notice and attached Safety Campaign Bulletin on its BOSSWeb dealer web site ( and on its public web site ( To prevent the potential occurrence of this failure, BRP will replace the complete drive axle assembly of the affected models whether or not signs of cracks are visible. What should you do? 1. Do not sell, deliver or use any involved vehicle that you have in stock until the repair has been completed. 2. Contact all of your customers who have purchased an affected model. You must inform them about the foregoing and must request that they immediately stop using their vehicles and that they make an appointment to get their vehicles repaired. 3. Follow all instructions provided in the attached Safety Campaign Bulletin. If you have questions about this notice, please call: In USA: In Canada: Dealers of other countries (outside Canada and USA) please contact your local distributor or regional office which can be found at or call We apologize for any inconvenience this may cause you. Thank you for your immediate attention to this matter. Sincerely, After-Sales Service Department Ski-Doo Lynx Sea-Doo Evinrude Johnson Rotax Can-Am and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.

2 Campaign no.: September 10, 2008 Subject:Drive Axle Failure No YEAR MODEL MODEL NUMBER SERIAL NUMBER 2009 MX Z TNT MJ9A MX Z X BB8A / BB8B / BB8C / BB8D / BB8E / BK8A / BK8B / BK8C / BK8D / BK8E MX Z Adrenaline BD8A / BD8B / BD8C / BD8D / BL8A / BL8B / BL8C / BL8D MX Z TNT MJ9A / MF8A /MF8B/MF8C 2008 MX Z Trail MX Z Renegade MXZRenegadeX MX Z X 600RS Summit X Summit Everest GSX Limited Touring GSX Limited GSX Sport BH8A / BH8B BU8A / BU8B / BU8C / BU8D / BX8A / BX8B / BX8C /BX8D/BX8E BS8A / BS8B / BS8C / BS8D / BS8E / BW8C / BW8D / BW8E / BW8F BM8A / BM8B CP8C / CP8D / CP8E / CP8F / CP8G / CP8H / CG8A / CG8B / CG8C / CG8D / CG8E / CG8F / CG8G / CG8H / CG8J / CH8C / CH8D / CH8E / CH8F / CH8G / CH8H CT8A / CT8B / CU8A / CU8B DJ8A DA8A / DD8A DC8A ALL PROBLEM Cracks may be developing in the welded joints of the drive axle assembly and may lead to a complete breakage of the component. This may cause the track of the vehicle to suddenly lock. If this occurs riders may be ejected off the vehicle or loose control and collide with bystanders, a fixed object or other vehicles potentially resulting in serious injuries and/or death. SOLUTION Replace the drive axle. Parts to be Ordered ITEM P/N DESCRIPTION QTY P DriveAxleAssy-All Except MX Z X 600RS Drive Axle Assy - MX Z X600RSOnly 1 P Hardware Kit 1 NOTE: New drive axle assemblies [P1] will be identified with 3 wide silver stripes between the 2 sprockets. mbg en JPM 2008 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. 1/14

3 PROCEDURE Removal WARNING To avoid potential burns, never touch exhaust system components immediately after the engine has been running because these components are very hot. Let engine and exhaust system cool down before performing any servicing. mbg _a 1. 3 wide silver stripes Hardware Kit Description ITEM P/N DESCRIPTION QTY P Chaincase Cover Bolts 7 P Sealing Washer 1 Front Arm Nuts - MX Z - 2 P GSX P M8 HexalobBolts 4 Auto-ship DRIVE SHAFT PROTECTOR CAP (P/N ) and CALIPER PULLER (P/N ) will be auto-shipped to all dealers. WARNING Torque wrench tightening specifications must be strictly adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pins, etc.) must be replaced with new ones. WARNING Battery BLACK ( ) cable must always be disconnected first and connected last. 1. Remove side panels. mmr _a 1. Latches DRIVE SHAFT PROTECTOR CAP (P/N ) 2. Lift rear of vehicle and support it off the ground. All Models except MX Z X 600RS 3. Remove rear idler wheel caps CALIPER PULLER (P/N ) 2 / SAFETY CAMPAIGN

4 mmr _a 1. RH rear idler wheel cap All Models 4. Unscrew rear axle screws (one each side). mmr _a TYPICAL Rear arm bolt 8. Remove bolts retaining front arm to tunnel. Keep bolts, discard nuts. mmr _a 1. RH rear axle screw All Models except MX Z X 600RS 5. Release jam nut on track tension adjustment screws. All Models 6. Loosen both adjustment screws to decrease track tension. mbg _a TYPICAL Front arm bolt 9. Lift rear of vehicle until front arm has enough clearance to pass underneath tunnel. 1 A33F5VA mmr _a 1. RH adjustment screw TYPICAL 1. Enough clearance 7. Remove rear arm bolts from chassis. SAFETY CAMPAIGN / 14

5 NOTE: On MX Z X 600RS, move rear suspension assembly on right side in order for the shock absorber bottle to clear the running board reinforcement. All Models Equipped with Battery WARNING Battery BLACK ( ) cable must always be disconnected first and connected last. 13. Disconnect BLACK ( ) cable end from the battery post. 14. Slide off rubber boot from RED (+) cable and disconnect it. 500SS/800R 15. Remove electrical harness from retaining clip. 16. Unclip both fuses from oil tank. 17. Remove the battery retaining strip nut and bolt. mbg _a TYPICAL - MX Z X 600RS MODELS 1. Shock absorber bottle 2. Running board reinforcement mmr _b 1. Negative post (-) 2. Rubber boot 3. Positive terminal (+) 4. Battery retaining bolt and nut 5. Retaining strip hook A33F5WA TYPICAL REMOVE SUSPENSION 10. Remove muffler springs, using exhaust spring installer/remover (P/N ) Disconnect the exhaust gas temperature sensor (if applicable). 12. Remove the muffler. mmr _a 1. Harness retaining clip 2. Fuse holder retaining clips 3. Battery retaining strip bolt 18. Lift the retaining strip and unhook it from the battery support to remove it. 19. Move retaining strip aside. 4 / SAFETY CAMPAIGN

6 600 HO SDI 20. Unscrew the battery retaining strip nut. mmr _a SCREWS LOCATION mmr _a 1. Locking tab 2. Battery holder slides 3. Battery retaining strip bolt 21. Move retaining strip and fuse box aside. 27. Remove and discard chaincase cover screws. 28. Pull cover to remove it. 29. Remove the upper sprocket screw and washer. All Models Equipped with Battery 22. Remove battery. All Models 23. Set the parking brake. 24. Disconnect the speed sensor connector. mmr _a 1. Upper sprocket 2. Conical spring washer 30. Release tension from drive chain by unscrewing the tensioner adjustment screw. mmr _a 1. Speed sensor connector 25. Place a drain pan under chaincase bottom area. 26. Loosen chaincase cover screws and pull cover. mmr _a 1. Tensioner adjustment screw 31. Remove tensioner adjustment screw and discard sealing washer if present. 32. Remove the tensioner. SAFETY CAMPAIGN / 14

7 mbg _a 1. Magnetic speed sensor mbg _a 1. Tensioner 36. Insert SCREW CAP SOCKET (P/N ) and unscrew lower sprocket. All Models except MX Z X 600RS 33. Remove the lower sprocket circlip SCREW CAP SOCKET (P/N ) mmr _a 1. Lower sprocket 2. Circlip MX Z X 600RS Models 34. Remove the magnetic speed sensor circlip. mbg UNSCREW LOWER SPROCKET mbg _a 35. Use a magnetic tool to retrieve the magnetic speed sensor. All Models 37. Remove sprockets and drive chain. 38. Release parking brake. 39. Remove belt guard. 40. Remove the brake disc protective cover. 6 / SAFETY CAMPAIGN

8 mmr _a 1. Screws 41. Remove the caliper protector retained by 4 screws. mmr _a 1. Brake disc slots 2. Caliper screws behind disc brake 45. From under frame, turn the LH bearing flange counterclockwise to unlock it from frame. mbg _a SCREWS TO BE REMOVED 1. Caliper protector 42. Remove the circlip securing disc brake to drive shaft. mmr _a 1. Bearing flange locking tabs 46. Release drive axle sprockets from track and at the same time, pull the drive axle assembly (with bearings) toward braking mechanism side. mmr _a 1. Brake disc circlip 43. Turn drive axle to align brake disc slots with caliper bracket screws. 44. Remove and discard caliper screws (4) behind disc brake. mbg _a PULL 47. Remove and discard plastic cap at the brake end of drive axle. SAFETY CAMPAIGN / 14

9 mbg PLASTIC CAP REMOVAL 48. Insert DRIVE SHAFT PROTECTOR CAP (P/N ) into the brake end of drive axle, narrow end first. mbg _a 1. Puller tabs correctly engaged 50. Turn puller center bolt clockwise to separate axle shaft bearing from caliper. mbg _a 1. Drive shaft protector cap NOTE: Make sure brake disc holes are aligned in order to see caliper mounting bolts holes. 49. Install the CALIPER PULLER (P/N ) on the brake caliper, through brake disc slots. mbg _a TURN PULLER CENTER BOLT CLOCKWISE NOTICE Never use an impact tool to operate caliper puller. The caliper or the puller could break. mbg _a INSTALL THE CALIPER PULLER NOTE: Make sure puller tabs are correctly engaged on caliper. mbg _a SEPARATED AXLE SHAFT BEARING FROM CALIPER 1. Brake disc 2. Caliper 3. Bearing 51. Move the drive axle assembly toward right, into chaincase. 52. When brake disc is out of splines, remove it. 8 / SAFETY CAMPAIGN

10 53. Remove caliper from axle shaft. 4. Clean brake caliper bearing shoulder with fine steel wool. 5. Apply Loctite 767 (antiseize lubricant) (P/N ) on drive shaft splines and on caliper bracket bearing shoulder. mbg _a 1. Brake disc 2. Caliper 3. Bearing 4. Axle shaft NOTICE Do not let caliper hang by the hose and do not stretch or twist the hose. NOTE: Make sure track is well positioned (high and forward) to ease drive axle removal. 54. Move the drive axle assembly right end out of the chaincase, then towards the right side to remove it from vehicle. Installation NOTE: Make sure track is well positioned (high and forward) to ease drive axle installation. 1. Insert new drive axle assembly [P1] into vehicle toward left side, through brake area. 2. Now insert drive axle toward right side into chaincase. 3. Lock the bearing flange on frame. NOTE: Ensure bearing flange is properly locked. Tabs mustbeproperlyinsertedinframe. mmr _a 1. Drive shaft splines 2. Drive shaft bearing mmr _a 1. Caliper bracket 2. Bearing shoulder 6. Insert brake disc into caliper. The brake disc collar must be pointed toward the frame. mmr _a 1. Brake disc collar 2. Caliper bracket mmr _a VIEW FROM OUTSIDE FRAME 1. Bearing flange locking tabs 7. Align brake disc splines with drive shaft splines and push the disc on the shaft. 8. Push the caliper bracket over drive shaft bearing. SAFETY CAMPAIGN / 14

11 mmr _a 1. Caliper bracket 2. Drive shaft bearing mdd CORRECT 9. Align caliper bracket holes with bearing flange holes and install new caliper screws [P2.4]. mbg _a INCORRECT (ON RIGHT SIDE) mmr _a 1. Bearing flange (inside frame) 2. Caliper bracket 3. Caliper screws [P6] 10. HAND TORQUE each caliper bracket screws in a criss-cross sequence until bracket is correctly positionedagainstframe. NOTICE Never use an impact tool to tighten caliper screws. The caliper bracket could crack. 11. Torque screws to 25 N m (18 lbf ft). 12. Install the brake disc circlip. 13. Make sure clips on brake pads pins are correctly installed as per the following pictures. NOTICE If the clip seems loose, replace it with a NEW one. 14. Depress brake lever to seat brake pads against disc brake. 15. Install the disc brake protective cover. 16. Install the belt guard. 17. Set the parking brake. 18. Insert a new chain tensioner bolt sealing washer [P2.2] on drive chain tensioner adjustment screw and install in chaincase. 10 / SAFETY CAMPAIGN

12 mbg _a 1. Chaincase 2. Chain tensioner bolt sealing washer [P3] 3. Lock nut 4. Drive chain tensioner adjustment screw 19. Install drive gears and chain. MX Z X 600RS Models 20. Use SCREW CAP SOCKET (P/N ) and screw lower sprocket to 50 N m (37 lbf ft). 21. Install the magnetic speed sensor and the circlip. All Models except MX Z X 600RS 22. Install the lower sprocket circlip. All Models 23. Install the upper sprocket. 24. Torque to48n m(35lbf ft). 25. Tighten tensioner adjustment screw BY HAND until resistance is strong enough that it can not be turned by hand. 26. Hold tensioner adjustment screw and tighten lock nut to 36 N m (27 lbf ft). 27. Install chaincase cover with new screws [P2.1]. NOTE: Ensure O-ring is positioned correctly in the chaincase cover groove. 28. Tighten chaincase cover screws in accordance with the following sequence. mmr _b 29. Torque chaincase cover screws to 10 N m (89 lbf in). 30. Remove the magnetic check plug on the left side of chaincase. NOTE: It is normal to find metallic particles stuck to magnetic check plug. Remove metallic particles if needed. 31. Pour approximately 250 ml (8.5 oz. US) of recommended oil in chaincase by the filler hole until oil comes out by the magnetic check plug hole. 32. Reinstall magnetic check plug and torque it to 6N m(53lbf in). 33. Reinstall the filling plug on chaincase cover. 34. Connect the speed sensor connector. All Models Equipped with Battery 35. Reinstall battery and secure retaining strip to support properly. 36. Install fuse box, fuse holders and harness as applicable to model. 37. Connect RED (+) cable to positive battery terminal. Connect RED wire (coming from 30 A fuse). 38. Connect BLACK ( ) cable LAST. WARNING Battery BLACK ( ) cable must always be disconnected first and connected last. All Models 39. Install muffler, reversal of the removal procedure. 40. Connect the exhaust gas temperature sensor (if applicable). 41. Release parking brake. 42. Install suspension into track with front portion first. SAFETY CAMPAIGN / 14

13 NOTE: Ensure bushings on arm ends are not fallen. msi _a 1. Bushing NOTE: A wood block can be used to help align front arm with holes in tunnel. msi _a 1. Wood block Summit Models 43. Apply Loctite Primer N 7649 (P/N ) on removed front arm bolts threads. Let it dry for a minimum of 1 minute. 44. Apply Loctite 271 (P/N ) on removed front arm bolts threads and fasten front arm to tunnel. All Except Summit Models 45. Install front arm bolts with NEW front arm nuts [P2.3] according to model listed in part list. All Models 46. Torque front arm bolts to 48 N m (35 lbf ft). 47. Apply Loctite Primer N 7649 (P/N ) on removed rear arm bolts threads. Let it dry for a minimum of 1 minute. 48. Apply Loctite 271 (P/N ) on removed rear arm bolts threads and fasten rear arm to tunnel. All Except Summit Models 49. Tighten rear arm bolts to 85 N m (63 lbf ft). Summit Models 50. Tighten rear arm bolts to 48 N m (35 lbf ft). 51. Install original rear axle screws. Track adjustment will be performed later on. 52. Install side panels. Track Adjustment NOTE: Track tension and alignment are interrelated. Do not adjust one without checking the other. Track tension procedure must be carried out prior to track alignment. Track Tension Allow the rear suspension to fully extend and check gap halfway between front and rear idler wheels. 1. Measure between slider shoe bottom and inside of track. The gap should be as given in the following table. TRACK ADJUSTMENT Force applied 7.3 kgf (16 lbf) 30 to 35 mm Track deflection (1.181 to in) The belt tension tester (P/N ) may be used to measure deflection as well as force applied. A00C07C 12 / SAFETY CAMPAIGN

14 2. Check that the track is well centered; equal distance on both sides between edges of track guides and slider shoes A01F05A 3 A32F39A 1 1. Tool top O-ring positioned at 7.3 kgf (16 lbf) 2. Apply pressure on tool until it contacts the upper O-ring 3. Measured track deflection 2. Tighten or loosen both adjustment screws to increase or decrease track tension Guides 2. Slider shoes 3. Equal distance 3. To correct, stop engine, loosen rear wheel screws, then tighten the adjustment screw on side where the slider shoe is the farthest from the track insert guides A01F0BA 3 1. Guides 2. Slider shoes 3. Tighten on this side mmr _a 1. RH adjustment screw NOTICE Too much tension will result in power loss and excessive stresses on suspension components. Track Alignment WARNING Before checking track alignment, ensure that the track is free of all particles which could be thrown out while track is rotating. Keep hands, tools, feet and clothing clear of track. Ensure no one is standing in close proximity to the vehicle. Never rotate at high speed. 1. Start the engine and accelerate slightly so that track barely turns. This must be done in a short period of time (1 to 2 minutes). 4. Restart engine, rotate track slowly and recheck alignment. 5. If the satisfactory alignment is achieved, torque rear axle screws (one each side) to 48 N m (35 lbf ft). 6. Reinstall wheel caps (if applicable). NOTICE After track adjustment, ride the snowmobile in snow about 15 to 20 minutes and recheck track tension and brakes. WARRANTY Involved Vehicles Claiming Submit a warranty claim using the following tables: SAFETY CAMPAIGN / 14

15 CAMPAIGN NUMBER Claim Type Flat Rate Time Campaign claim 1.5 hour CAMPAIGN NUMBER Claim Type Flat Rate Time (w/o electric starter) Flat Rate Time (with electric starter) Campaign claim 1.5 hour 1.7 hour A fix amount will be paid to cover 250 ml. (8.5 oz) of chaincase oil. NOTE: Dealers/distributors are required to return parts to support their claims. For claiming procedure, refer to the DEALER/DIS- TRIBUTOR WARRANTY GUIDE. Obsolete Parts in Inventory Claiming The following obsolete parts should not be used to repair units and must be returned. PART PART DESCRIPTION NUMBER DriveAxleREV-XP DriveAxleMXZX600RSModels Warranty Shipping Address Decals Warranty shipping address decals can be ordered if needed. COUNTRY P/N U.S.A Canada Please claim obsolete parts that you have in inventory under a parts claim from inventory. OBSOLETE PARTS CLAIMING Claim Type Parts claim, from inventory Obsolete parts claimed will be requested for return. For claiming procedure, refer to the DEALER/DIS- TRIBUTOR WARRANTY GUIDE. Shipping Addresses USA DEALERS CANADIAN DEALERS OTHERS COUNTRIES BRP c/o Warranty Department 7575 Bombardier Court Wausau,WI54401 BRP Warranty Parts Inspection Center 565 de la Montagne Valcourt, QC, J0E 2L0 Contact your local distributor or BRP Regional Office. 14 / SAFETY CAMPAIGN

16 SAFETY RECALL NOTICE Bombardier Recreational Products Inc. 565 de la Montagne Street Valcourt, Québec, Canada J0E 2L0 T F Date: September 10, 2008 Re: Drive Axle Failure Dear Ski-Doo Owner, This notice is sent to you in accordance with the requirements of the Consumer Product Safety Act, the Canada Motor Vehicle Safety Act and other applicable laws. What is the reason for this notice? In cooperation with Transport Canada and the U.S. Consumer Product Safety Commission, Bombardier Recreational Products Inc. and BRP US Inc. ( BRP ) are conducting a voluntary safety recall of certain 2008 and 2009 Ski-Doo models. Our records indicate that you are the owner of a potentially affected vehicle. What is the potential problem? Cracks may be developing in the welded joints of the drive axle assembly and may lead to a complete breakage of the component. This may cause the track of the vehicle to suddenly lock. If this occurs riders may be ejected off the vehicle or loose control and collide with bystanders, a fixed object or other vehicles potentially resulting in serious injuries and/or death. What should you do? Immediately stop using your vehicle, call an authorized BRP dealer and make an appointment to have your vehicle repaired. He will replace the drive axle assembly. The dealer will perform this work at no charge to you. What to do if you feel this notice is an error? This notice was mailed to you according to the most current information we have available. If you no longer own this vehicle or some information in this notice is incorrect, please contact BRP at your earliest convenience. If you have questions, need assistance, or to find your nearest authorized BRP dealer: Visit In the US and Canada: , 8:00 to 18:00 Eastern time We apologize for any inconvenience this may cause you. Thank you for your immediate attention to this matter. Sincerely, After-Sales Service Department Bombardier Recreational Products Inc. Ski-Doo Lynx Sea-Doo Evinrude Johnson Rotax Can-Am and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.