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

Size: px

Start display at page:

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

Alexis McDowell
5 years ago
Views:

1 The following symbols may be used in this document: Supercharger Repair Kit 185 Engine (Kit P/N ) 215/255/260 Engines (Kit P/N ) 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 be required (e.g. lock tabs, self-locking fasteners, etc.), always replace with a new one. Torque wrench tightening specifications must strictly be adhered to. Always wear EYE PROTECTION AND APPROPRIATE GLOVES when using power tools. Some components may be HOT. Always wait for engine to cool down before performing work. FASTENER TORQUE TO BE USED WHEN TORQUES ARE NOT SPECIFIED IN TEXT SIZE 5.8 GRADE 8.8 GRADE 10.9 GRADE 12.9 GRADE M4 M5 M6 M8 M10 M12 M14 M16 M18 1.8±0.2N m (16±2lbf in) 3.3±0.2N m (29±2lbf in) 7.5±1.0N m (66±9lbf in) 15.3 ± 1.7 N m (135 ± 15 lbf in) 29 ± 3 N m (21±2lbf ft) 52 ± 6 N m (38±4lbf ft) 85 ± 10 N m (63±7lbf ft) 126 ± 14 N m (93 ± 10 lbf ft) 170 ± 20 N m (125 ± 15 lbf ft) 2.8±0.2N m (25±2lbf in) 5.0±0.5N m (44±4lbf in) 10.0 ± 2.0 N m (89 ± 18 lbf in) 24.5 ± 3.5 N m (18±3lbf ft) 48 ± 6 N m (35±4lbf ft) 85 ± 10 N m (63±7lbf ft) 135 ± 15 N m (100 ± 11 lbf ft) 205 ± 25 N m (151 ± 18 lbf ft) 273 ± 32 N m (201 ± 24 lbf ft) 3.8 ± 0.2 N m (34±2lbf in) 7.8 ± 0.7 N m (69±6lbf in) 12.8 ± 2.2 N m (113 ± 19 lbf in) 31.5 ± 3.5 N m (23±3lbf ft) 61 ± 9 N m (45±7lbf ft) 105 ± 15 N m (77 ± 11 lbf ft) 170 ± 20 N m (125 ± 15 lbf ft) 255 ± 30 N m (188 ± 22 lbf ft) 330 ± 25 N m (243 ± 18 lbf ft) 4.5±0.5N m (40±4lbf in) 9.0±1.0N m (80±9lbf in) 16.0 ± 2.0 N m (142 ± 18 lbf in) 40.0 ± 5.0 N m (30±4lbf ft) 73 ± 7 N m (54±5lbf ft) 128 ± 17 N m (94 ± 13 lbf ft) 200 ± 25 N m (148 ± 18 lbf ft) 305 ± 35 N m (225 ± 26 lbf ft) 413 ± 47 N m (305 ± 35 lbf ft) 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. NOTE: Installation time is approximately 1.1 hours. Printed in Canada. (ssi en TS) 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 / 8

2 PARTS TO BE INSTALLED PARTS TO BE INSTALLED P1 P3 P6 P2 P5 P8 P10 P7 P8 P4 P9 P11 P12 P13 P15 P16 P14 P13 P18 ssi _a P17 P19 ITEM P/N DESCRIPTION QTY P Cap nut 1 P Washer 1 P O-ring 1 P Clamp 1 P Step collar 1 P Oil seal 1 P Retaining disc 1 P Bearing 2 P O-ring 2 P Spacer 10.2/16/ P Thrust washer 1 P Compressor shaft assembly 1 P Friction shim 2 P Needle bearing Drive gear 17T for kit (P/N ) (185 engine) P15 Drive gear 16T for kit (P/N ) (215/255/260 engines) P Lock washer 1 P Spring washer 5 P L-ring 1 P Hex. nut 1 P Washer 6,4 (not shown) (kit (P/N )) 3 2 / 8 Instruction Sheet P/N

3 TOOLS REQUIRED TOOLS REQUIRED ITEM DESCRIPTION P/N 1 Retaining key Support plate Gear holder Four pin socket Bearing support/pusher Torx E8 adapter Needle bearing pusher SERVICE PRODUCTS DESCRIPTION P/N Isoflex grease Loctite 243 (blue threadlocker) XPS synthetic blend oil (summer grade) Super Lube Grease or equivalent REPAIR PROCEDURE General Notes These new supercharger repair kits replace the previous kits which are no longer available. ENGINE /255/260 SUPERCHARGER REPAIR KIT NEW REPAIR KIT (P/N ) (P/N ) Supercharger Removal PREVIOUS REPAIR KIT (P/N ) (P/N ) 1. Remove the supercharger from the engine using the appropriate SEA-DOO SHOP MANUAL. Supercharger Disassembly 1. Disassemble the supercharger using the appropriate SEA-DOO SHOP MANUAL. Supercharger Kit Installation CAUTION Use extreme care when working with supercharger parts. Supercharger rotation reaches RPM. Any modification, improper repair/assembly or damage on the parts, may result in damage of the supercharger. Strictly follow the described procedures. CAUTION Refer to the appropriate Shop Manual for reassembly of the Supercharger, PLUS the added instructions required for proper assembly of this kit in the below text. Ensure to use all the new parts in this kit as some of them are different from the parts that were removed. CAUTION It is the utmost importance that all parts be absolutely clean. Any debris could causeafailure. Refer to SEA-DOO SHOP MANUAL and perform the following steps : 1. Press one of the ball bearings on the shaft. To hold the bearing use following tool. Loctite is a registed trademark of Henkel Corp. Torx is a trademark of Textron Inc. Instruction Sheet P/N / 8

SUPPORT PLATE (P/N 529 035 947) 2. Ensure to install the bearing [P8] so the closed cage faces the impeller. 3.

BEARING SUPPORT/PUSHER (P/N 529 035 950) 4. Ensure the closed bearing cage side is facing the impeller. 5. Install and torque the retaining disc to specification.

Install the spacer sleeve [P10] and the thrust washer [P11] on the shaft and then press it into the housing. 7.

Finish assembling the impeller to the compressor shaft assembly [P12]. ssi2008-003-005_a 1.

illustrations. CAUTION No other grease can be used, otherwise damage to needle bearing will occur.

ssi2005-008-002_a Supercharger Reassembly (Clutch Side) CAUTION Manipulate the friction shims with care, those

4 SUPPORT PLATE (P/N ) 2. Ensure to install the bearing [P8] so the closed cage faces the impeller. 3. Install the second ball bearing [P8] in the supercharger housing (engine side). BEARING SUPPORT/PUSHER (P/N ) 4. Ensure the closed bearing cage side is facing the impeller. 5. Install and torque the retaining disc to specification. Retaining disc TIGHTENING TORQUE 40 N m (30 lbf ft) 6. Install the spacer sleeve [P10] and the thrust washer [P11] on the shaft and then press it into the housing. 7. Install the oil seal [P6] in the retaining disc [P7]. 8. Finish assembling the impeller to the compressor shaft assembly [P12]. ssi _a 1. Prepare parts for assembly by applying ISOFLEX GREASE TOPAS NB 52 (P/N ) as shown in the next illustrations. CAUTION No other grease can be used, otherwise damage to needle bearing will occur. Shaft (needle bearing seat and collar) Drive gear (inner diameter) Friction shims (inner diameter and both sides) ssi _a Supercharger Reassembly (Clutch Side) CAUTION Manipulate the friction shims with care, those parts are sensitive. NOTE: The2frictionshims[P13] have the same inner diameter. Lock washer (inner splines and friction shim thrust surface) 2. Put the first friction shim [P13] on a workbench. 3. Put the drive gear [P15] on the friction shim. 4 / 8 Instruction Sheet P/N

4. Install the NEW needle bearing [P14] in drive gear. 4.1 Position the needle bearing on the drive gear.

Outer plastic cage Smr2012-011-003_a 1. Needle bearing 2. Drive gear 3. Friction shim 4.

Place the second friction shim [P13] on the drive gear. 6.

compressor shaft NOTE: The inner plastic cage is pushed out upon installation on compressor shaft.

Inner plastic cage Smr2012-011-005_a 1. Drive gear 2. Outer plastic cage 3. Needle bearing pusher 7.

5 4. Install the NEW needle bearing [P14] in drive gear. 4.1 Position the needle bearing on the drive gear. Smr _a 1. Drive gear needle pins 3. Inner plastic cage 4. Needle bearing pusher 5. Outer plastic cage Smr _a 1. Needle bearing 2. Drive gear 3. Friction shim 4.2 Push the needle pins with inner plastic cage into the drive gear. 5. Place the second friction shim [P13] on the drive gear. 6. Install the package consisting of friction shim, drive gear with needle bearing and friction shim on the hub side of the compressor shaft NOTE: The inner plastic cage is pushed out upon installation on compressor shaft. NEEDLE BEARING PUSHER (P/N ) Smr _a 1. Package of friction shims, drive gear and needle bearing 2. Inner plastic cage Smr _a 1. Drive gear 2. Outer plastic cage 3. Needle bearing pusher 7. Discard the inner plastic cage and install the lock washer [P16]. 8. Apply engine oil to the spring washers [P17]. 9. Position the spring washers as per illustration. 4.3 Remove needle bearing pusher and discard outer plastic cage. 4.4 Check if all 40 needle pins are in place. ssi _a Instruction Sheet P/N / 8

CAUTION When installing the spring washers [17], take care of the exact installation direction of the washers. 10. Install the L-ring [P18] on the compressor shaft.

These rotations will dissipate the grease on the friction shims and gear enough to get a proper reading when using a torque wrench to measure the slip torque of the clutch. F00D3CA 11.

TIGHTENING TORQUE Hexagonal nut 29 N m (21 lbf ft) SUPERCHARGER RETAINING KEY (P/N 529 036 027) ssi2005-008-005 3.

6 CAUTION When installing the spring washers [17], take care of the exact installation direction of the washers. 10. Install the L-ring [P18] on the compressor shaft. SUPERCHARGER GEAR HOLDER (P/N ) SUPPORT PLATE (P/N ) 2. Rotate the clutch by turning the impeller cap nut counterclockwise a minimum of 10 complete revolutions. These rotations will dissipate the grease on the friction shims and gear enough to get a proper reading when using a torque wrench to measure the slip torque of the clutch. F00D3CA 11. Apply Loctite 243 (blue threadlocker) (P/N ) on the hexagonal nut [P19] threads. 12. Torque hexagonal nut to specification. TIGHTENING TORQUE Hexagonal nut 29 N m (21 lbf ft) SUPERCHARGER RETAINING KEY (P/N ) ssi Rotate again the impeller cap nut counterclockwise to measure the slip torque of the clutch. 4. The clutch should start to slip within the specified torque values. SLIPPING MOVEMENT (NEW SUPERCHARGER) 9 N m to 14 N m (80 lbf in to 124 lbf in) NOTE: After a few hours of run time, the slipping torque will be reduced as the new parts break in. SLIPPING MOVEMENT (BREAK-IN SUPERCHARGER) 8 N m to 12 N m (71 lbf in to 106 lbf in) F00D3FA NOTE: The L-ring will preload the spring washers after the hexagonal nut is torqued. Slipping Movement Inspection 1. Hold the gear. NOTE: If a dial torque wrench is not available, a click type torque wrench can be used. Refer to the following procedure: Click type torque wrench procedure 1. Set click type torque wrench at 9 N m (80 lbf in). The wrench must click before the clutch slips. 6 / 8 Instruction Sheet P/N

2. Set the wrench at 14 N m (124 lbf in). The clutch must slip before the wrench clicks. Supercharger Installation 1.

Sealing surface between supercharger and PTO housing [1] has to be greased with Super Lube Grease (P/N 293 550 030).

Refer to the following illustrations for details. 2. Install three washers [P20].

The Baseplate 867 164 has the correct dimensions without using the washers. ssi2008-003-003_a GOOD GREASE APPLICATION 1.

7 2. Set the wrench at 14 N m (124 lbf in). The clutch must slip before the wrench clicks. Supercharger Installation 1. Replace the two O-rings of the supercharger ground plate with new O-rings [P9] from the kit. 4. Sealing surface between supercharger and PTO housing [1] has to be greased with Super Lube Grease (P/N ). R1503motr247A 1 ssi _b CAUTION Do not cover the oil hole of the supercharger by applying too much grease (Super Lube). Refer to the following illustrations for details. 2. Install three washers [P20]. NOTE: Install washers only if the baseplate part number is found on MY 2003 or MY 2004 engines. The Baseplate has the correct dimensions without using the washers. ssi _a GOOD GREASE APPLICATION 1. Oil hole ssi _a 3. Ensure the three washers are in place (when required) by visual and/or physical inspection. NOTE: Some Loctite 495 (General Purpose Instant Adhesive) (P/N ) can be applied on the spacers to hold them in place. Instruction Sheet P/N / 8

ssi2008-003-004_a BAD GREASE APPLICATION 1. Oil hole 5. Install supercharger ass y on PTO housing. 6. Apply Loctite 243 (blue threadlocker) on the retaining screws. 7. Torque screws to specification.

When reinstalling exhaust system components, validate LH muffler/exhaust pipe alignment with exhaust manifold. Refer to appropriate SEA-DOO SHOP MANUAL for the procedure.

8 ssi _a BAD GREASE APPLICATION 1. Oil hole 5. Install supercharger ass y on PTO housing. 6. Apply Loctite 243 (blue threadlocker) on the retaining screws. 7. Torque screws to specification. Supercharger retaining screws TIGHTENING TORQUE 9N m (80lbf in) 8. To tighten and torque the upper screw, use the Torx adapter. TORX ADAPTER (P/N ) 10. When reinstalling exhaust system components, validate LH muffler/exhaust pipe alignment with exhaust manifold. Refer to appropriate SEA-DOO SHOP MANUAL for the procedure. Recommended Engine Oil Use XPS 4-STROKE SYNTH. BLEND OIL (SUMMER) (P/N ). If the recommended XPS TM engine oil is not available, use a 10W40 mineral engine oil compatible with wet clutches. NOTE: The XPS engine oil has been thoroughly tested to be free of any additives that could impair the functionality of the supercharger clutch. NOTICE NEVER use synthetic oil. This would impair the proper operation of the supercharger clutch. Do not add any additives to the recommended oil. Mineral oils not recommended by BRP may also contain additives (friction modifiers) that may cause inappropriate slippage of the supercharger and eventually lead to premature wear. For this reason, XPS Synthetic Blend Summer Grade oil or a BRP approved equivalent are the only recommended oils. Use of any oil not recommended by BRP may void BRP's limited warranty. 9. Ensure to install the tool perpendicularly (90 ) to torque wrench to apply the proper torque to the screw. A F00B1UA 1 1. Tool perpendicular (90 ) to torque wrench A. 90º CAUTION Not installing the tool as shown will change the torque applied to the screw. Proper torque and tightening sequence are important. 8 / 8 Instruction Sheet P/N

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

WARNING. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. WARNING Floating QRS Short Shaft Conversion (Kit P/N 860 200 832) The following symbols may be used in this document: WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious