Table of contents. Tools by System: Index of tools by Part Number:...P 20. No Year All. Model All
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1 Date : February Subject : Service Tools No Year All Model All BRP is proud to introduce its latest Service Tools Bulletin. These special tools were designed to help you efficiently service BRP vehicles. Please always make sure to use special tools along with the appropriate Shop Manual(s) and respect all safety measures. Mandatory Tools: These tools are absolutely needed to perform certain service procedures. They will be automatically shipped to dealerships. They do not need to be ordered separately. Recommended Tools: These tools will facilitate the Technicians work. They will not be automatically shipped to dealerships. They need to be ordered separately. Table of contents Tools by System: Engine... P 2 Lubrication... P 9 Cooling... P 10 Electrical... P 11 Fuel... P 1 Propulsion / Transmission... P 15 Steering... P 17 Suspension... P 17 Various... P 18 Index of tools by Part Number:...P 20 Printed in Canada (sbs ) 2007 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. 1/20
2 Engine F06B06A Protective Rubber Pad P/N Recommended 97 DI engines Gear / Bearing Puller P/N Recommended 787 engines No longer sold; a standard puller can be used. Male Fitting P/N Recommended -TEC 1503 To test jet pump tightness on 2-stroke Protective Carpet P/N Recommended 717 / 787 RFI engines So piston bearing does not fall in base during replacement. Leakage Tool MIKUNI BN Pump P/N Recommended All carbureted engines To leak test carburetor pop-off pressure. FLYWHEEL HOLDER P/N Mandatory 587/657/717 engines Use with Timing Gauge 717 P/N Recommended 717 engines Timing Gauge P/N Recommended 787, 787 RFI, 97, 97 DI engines Shaft Alignment Tool P/N Mandatory All models TDC Dial Indicator P/N Recommended 2-stroke engines except DI Flywheel Puller P/N Mandatory 787 RFI Engine Leak Test Kit P/N Mandatory All 2-stroke engines Kit includes vacuum pump /20
3 Engine LEAK SUPPLEMENT KIT P/N Mandatory 787 RFI / 97 DI Kit includes / / / TDC Dial Indicator 25 mm P/N Recommended 97 DI engines For ignition timing static measurement HALF RING PULLER MAG P/N Recommended 717 engine To remove crankshaft bearings MAG side PTO side Screw M8x0 (item #7) P/N Recommended All 2-stroke engines MAG side PTO side Screw M8x70 (item #8) P/N Recommended All 2-stroke engines To be used with P/N Screw M8x35 (qty 3) P/N Recommended 717 engines To be used with Sleeve P/N Recommended 717 engines Use with Half ring puller P/N Recommended 97 & 97 DI engines To remove 52 mm O.D. bearings from the crankshaft. Rotary Valve Shaft Puller P/N Recommended 717, 787 & 787 RFI engines Kit includes / Rotary Valve Bearing Pusher P/N Recommended 717, 787 & 787 RFI engines Starter Drive Seal Pusher P/N Recommended 97 & 97 DI engines For starter drive Crankshaft Protector P/N Recommended All 2 stroke, except 27 (PTO) Use with /20
4 Engine Crankshaft Protector P/N Recommended 717 / 787 RFI / 800R / 800 HO Crankshaft Distance Ring (MAG) P/N Recommended All 2-stroke engines Rotary Valve Shaft Installer P/N Recommended 717 engines & older than 1990 Rotary Valve Shaft Installer P/N Recommended 787 & 787 RFI engines Use with Cylinder Alignment Tool P/N Recommended 717 engines PISTON RING COMPRESSOR 88mm P/N Recommended 97 & 97 DI engines PISTON RING COMPRESSOR 82mm P/N Recommended 717, 787 & 787 RFI engines Crankshaft Protector P/N Mandatory 97 DI engines MAG side PTO side Puller et bolt (item 1 & 9) P/N Recommended All 2-stroke engines Oil Seal Pusher P/N Recommended 787 RFI engines Used with MAG side PTO side Replacement Puller Bolt (item #9) P/N Recommended All 2-stroke engines To use with puller P/N Flywheel puller P/N Mandatory 27, 787, 787 RFI, 97 & 97 DI engines Replacement bolt P/N /20
5 Engine HALF RING PULLER P/N Recommended 717 / 787 RFI engines MAG side PTO side HOLDER RING (item #3) P/N Recommended 97DI engines MAG side PTO side RING PULLER (item #3) P/N Recommended 717/787RFI engines Vacuum Pressure Gauge P/N Recommended All models Distance Gauge 1 mm P/N Recommended 717 engines Distance Gauge 15.mm P/N Recommended 787 RFI engines Distance Gauge 7.5mm (PTO) P/N Recommended 97 DI Engine Piston pin puller P/N Mandatory All 2-stroke engines Exhaust Wrench 15mm P/N Mandatory 97 DI engines Replacement Protector Sleeve P/N Recommended To be used with P/N Flywheel Tool P/N Mandatory All 97 and 97 DI Use in conjunction with puller and holder. Sleeve kit 18 mm P/N Recommended Ski-Doo 277, Sea-Doo 587 To install cageless bearings. Used with /20
6 Engine Sleeve kit 20 mm P/N Mandatory 717, 787 RFI, 600, 800HO Used with SLEEVE Kit 21mm P/N Mandatory 97, 97 DI, 800 R Engines To install cageless bearings. Used with Flywheel Puller P/N Mandatory 717, 97 & 97 DI engines Replacement bolt Use / No picture available Replacment Bolt M16 P/N Recommended 787 RFI / 97 / 97 DI engines Goes with & Spring Installer Remover P/N Recommended Replaced by or Circlip Insertion Tool 18 mm P/N Recommended Sea-Doo 587, Ski-Doo 277 engines Circlip insertion Tool 20 mm P/N Recommended 593, 670, 693, 717, 787 & 787 RFI engine Sleeve without groove P/N also available. Circlip Insertion Tool 21 mm P/N Recommended 97 & 97 DI engines Sleeve without groove, P/N also available. 20 mm Sleeve P/N Recommended Use with mm Sleeve P/N Recommended Use with puller P/N Insert Alignment Tool P/N Mandatory XP & XP DI models Degree Wheel P/N Mandatory 717, 787 & 787 RFI engines 6/20
7 Engine Engine Leak Down Test Kit P/N Recommended All -troke engines To perform a leak down test on engine. Valve Stem Seal Installer P/N Recommended -TEC engines Intake Plug P/N Mandatory 97DI engines COMPRESSOR RING P/N Mandatory 97DI engines Carbon Dam Guide P/N Mandatory 97 DI engines Carbon Dam Compressor P/N Mandatory 97 DI engines SHAFT ALIGNEMENT TOOL P/N Mandatory -TEC engines Valve spring compressor P/N Recommended -TEC engines Valve spring compressor cup P/N Recommended -TEC engines To be used with Piston Circlip Installer P/N Mandatory -TEC engines CRANKSHAFT LOCKING TOOL P/N Mandatory -TEC 1503 engines OIL SEAL GUIDE P/N Mandatory -TEC 1503 engines 7/20
8 Engine Engine lifting ring P/N Recommended All 2-stroke engines CAMSHAFT LOCKING TOOL P/N Mandatory V1000, V1300 &1503 engines RING GEAR BLOCKING TOOL P/N Mandatory 787 & 787 RFI engines Succion pump tool P/N Recommended TORX ADAPTOR P/N Mandatory -TEC 1503 SC engines 2-stroke engine lifting hook P/N Recommended All 2-stroke engines RING GEAR BLOCKING TOOL P/N Mandatory 97 & 97 DI engines SUPPORT PLATE P/N Mandatory -TEC 1503 SC To hold the supercharger assembly in a vise for disassembly and assembly. FOUR PIN SOCKET P/N Mandatory -TEC 1503 SC To remove the retaining disc of the supercharger ground plate. Open driven BEARING PUSHER/SUPPORT P/N Mandatory -TEC 1503 SC engines To install bearing of the supercharger ground plate. Crank shaft bearing puller P/N Recommended 2 strokes Engine Supercharger Gear Holder P/N Mandatory -TEC 1503 SC 8/20
9 Engine Supercharger Retaining Key Piston ring compressor Torque angle gauge P/N Mandatory P/N Snap-on RC 980 Recommended P/N Snap-on TA362 Recommended -TEC 1503 SC -TEC Not sold by BRP -TEC V1000 & 1503 Not sold by BRP Valve stem seal removal pliers P/N Snap-on YA 8230 Recommended 1503 Not sold by BRP Lubrication Oil Pressure Adaptor P/N Mandatory -TEC engines Used with OIL FILTER COVER EXTRACTOR P/N Recommended -TEC 1503 Oil Filter Cover Puller P/N Recommended -TEC 1503 Used with /20
10 Cooling Flush Kit P/N Recommended GTS Flushing Kit Hose P/N Recommended All models (except GTS) Flushing Adaptor P/N Recommended All models PAS OUVRIR A CHAUD Coolant oil pump gear holder P/N Mandatory 717, 583, 670, 599, 699, 779, 809 engine Radiator Cap Pressure Test P/N Recommended -TEC models Replacement part for item also included in kit Coolant Pump Seal Pusher P/N Mandatory -TEC Coolant Pressure Cap P/N Recommended To be used with Pressure Pump /20
11 Electrical MPI communication cables only P/N Recommended MPI not included D.E.S.S. Adaptor P/N Recommended MY RFI models To be used with the MPI or MPI-2. Magneto Harness Pins P/N Recommended 717 engines To test the magneto. Magneto Harness 6 Pins P/N Recommended 787, 787 RF,I 97 & 97 DI engines Replaced by Suction Cup P/N Recommended To remove gauges. ECM troubleshooting tool P/N Mandatory All injected 2-TEC & -TEC with VDO ECM MPEM programmer guide P/N Recommended Describes how to use the hand held progr Has been replaced by B.U.D.S., the MPI and recently by the MPI-2. Digital Induction Tachometer P/N Recommended All Stroboscopic Timing Light P/N Recommended All 2-stroke F01B2A Choke Nut Removal Tool P/N Recommended Replaced by Magneto harness P/N Recommended 787, 787 RFI, 97 & 97 DI engines To test magneto. Diagnostic Adaptor for VCK P/N Recommended To be used with the MPI, connects to /20
12 Electrical 9 Pins to 25 Pins Adaptor P/N Recommended To connect communication cable P/N of MPI to older PC. D.E.S.S Pin Adaptor P/N Recommended RFI engines Disconnect the D.E.S.S. post and connect in series, then to MPI. MPI Communication Cable P/N Recommended To connect the MPI to a PC MPI 25 FT Extension Cable P/N Recommended Will not fit on the MPI-2. Crimping Plier for Heavy Gage Wire P/N Recommended All models Ex.: To crimp battery cable terminals. Digital Multimeter (basic model) P/N Recommended MPI Diagnostic Cable P/N Recommended To connect a vehicle to the MPI. Connects to P/N Fluke 111 Digital Multimeter P/N Recommended All MPEM programmer kit P/N Recommended All 2-stroke models No longer sold, replaced by MPI-2, P/N D.E.S.S. Adaptor P/N Mandatory Connects to the diagnostic cable of the MPI or MPI-2. KOSTAL Die P/N Recommended All models with KOSTAL ECM connectors To use with crimping tool to crimp ECU connectors AMP Die P/N Recommended All models with AMP connectors To use with crimping tool to crimp Deutsch connectors. 12/20
13 Electrical Crimping Tool P/N Recommended To use with compatible die to crimp different connectors D.E.S.S. Post Remover P/N Recommended All DESS equipped models MPI Communication Kit P/N Recommended Spare cables are still available. See MPI-2 Handheld MEM Programme Cable P/N Recommended 6 pin connector Three Pin Magneto Harness P/N Recommended TEC To test the magneto. 787 RFI Timing Tool P/N Mandatory MY 2005, 787 RFI To replace temperature sensor during timing procedure. MPI-2 Interface Card P/N Mandatory Replaces the MPI. D.E.S.S. Post Interface P/N Mandatory To programm D.E.S.S. keys with the MPI /20
14 Fuel Fuel pressure gauge P/N Mandatory 787 FRI, 793 SDI & -TEC engines Spare plastic clip P/N Oil/fuel pressure gauge P/N Mandatory 2-TEC SDI, -TEC & DI engines Use with , & Fuel Gauge T Adaptor P/N Mandatory 97 DI engines Use with gauge P/N and P/N Pressdure Relief Valve Adaptor P/N Mandatory 97 DI engines Use with gauge P/N and P/N Air Compressor Adaptor P/N Mandatory 97 DI engines Use with gauge P/N and P/N Fuel Line Remover P/N Mandatory Used also with gauge P/N and adaptors. Fuel pressure T adaptor P/N Recommended Injection type vehicles To be used with Replacement clip Fuel Hose Connector Tool P/N Recommended -TEC 1503 Disconnect fuel hose 1/20
15 Propulsion / Transmission PTO FLYWHEEL/IMPELLER TOOL P/N Mandatory All 2-stroke IMPELLER SHAFT GUIDE TOOL P/N Mandatory All 2-stroke models IMPELLER SHAFT HOLDER P/N Mandatory 2-stroke models Bearing / Seal Installer Tool P/N Mandatory All 2-stroke engines VTS Socket P/N Recommended All VTS equipped Jet Pump Bearing Remover P/N Mandatory All 2-stroke models Alignment Adaptor P/N Recommended HX & XP models until 1998 Engine alignment Tool P/N Mandatory All 155.6mm and 139.5mm jet pump Plate for engine Alignment P/N Mandatory mm jet pump Pump Plate P/N Mandatory mm jet pump Used with Inner Seal Installer P/N Mandatory All 155.6mm jet pump models Pump Bearing Pusher P/N Mandatory -TEC 1503 models 15/20
16 Propulsion / Transmission SEAL/BEARING PUSHER P/N Mandatory -TEC 1503 models Impeller Removing Tool P/N Mandatory -TEC 1503 NA and BV Also usedto turn the engine. Floating ring tool P/N Mandatory 1503 engine without super charger PTO SUPPORT TOOL P/N Mandatory -TEC 1503 models Pressure Cap P/N Mandatory -TEC 1503 models Drive Shaft holder P/N Mandatory -TEC models, except RXP Replaced by (RXP) tool that fits all -TEC Drive Shaft Adapter P/N Mandatory -TEC 1503 engines (except BV IC) Install on drive shaft to turn engine as required. Sea/Bearing Pusher P/N Mandatory 200 -TEC Plastic & Aluminum Jet Pump Tool used to push out impeller shaft and install back bearing in pump. Impeller Removing Tool P/N Mandatory SC IC Models Tool used to remove and install impeller Drive Shaft Adapter P/N Mandatory RXP (BV IC) To install on driveshaft for turning engine as required. Drive Shaft Holder P/N Mandatory All -TEC 1503 To hold driveshaft in place when using the floating ring tool. Floating ring tool P/N Mandatory 1503 engines with supercharger Tool used to push the floating ring to epxose C-clip on drive shaft 16/20
17 Propulsion / Transmission Drive Shaft C-Clip Remover P/N Recommended -TEC 1503 Steering Steering Cable Tool P/N Recommended All O.P.A.S. CYLINDER NUT WRENCH P/N Mandatory All O.P.A.S. models Suspension Gas shock filling tool P/N Recommended T/A shocks To be used with P/N Spare needle P#N Suspension Adjustment Wrench P/N Recommended Suspension Adjustment Wrench P/N Recommended SC-10 II suspension 17/20
18 Suspension Spring Compressor P/N Recommended No longer sold, replaced by P/N Remplacement Component P/N Recommended HX & XP To easily remove HX & XP suspension. Shock filling valve P/N Recommended T/A shocks Spring Remover P/N Recommended To remove coil spring from shock. Various Valve Wrench P/N Recommended For Explorer floater valves CAILLAU Pliers P/N Mandatory All models OETIKER Pliers P/N Recommended All models 18/20
19 Various OETIKER Pliers P/N Recommended All models Hose Pincher P/N Recommended All models LIFT KIT P/N Recommended LRV DI LIFT KIT P/N Recommended -TEC LIFT KIT P/N Recommended All 2-stroke models, except LRV Pusher Handle P/N Recommended All To be used with many pushers Supertitanium Drill Bit 3/16" P/N Recommended To drill/remove many kinds of rivet. Hose pincher (large) P/N Recommended All models Spring Removal Tool P/N Mandatory Spring removal tool (small) P/N Mandatory 19/20
20 Index Tool Part Numbers... Page These tools are mandatory Snap-on RC Snap-on TA Snap-on YA /20
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