PROCEDURE. Required tools. Drive Pulley Sliding Sheave Removal. No Subject:REV-XP, REV-XR & REV-XU Engine Alignment

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December 22, 2008 Subject:REV-XP, REV-XR & REV-XU Engine Alignment No.

PROCEDURE Required tools ALIGNMENT BAR (P/N 529 036 157) Feeler gauge 100 (4 in) caliper.

Drive pulley holder 529036157 Drive Pulley Sliding Sheave Removal 1.

Secure drive pulley with the DRIVE PULLEY HOLDER (P/N 529 035 674).

Remove the drive pulley bolt and its conical spring washer. r2008-041-103_a 1.

1 December 22, 2008 Subject:REV-XP, REV-XR & REV-XU Engine Alignment No YEAR MODEL MODEL NUMBER SERIAL NUMBER 2008 REV-XP All All 2009 REV-XP / REV-XR / REV-XU PROCEDURE Required tools ALIGNMENT BAR (P/N ) Feeler gauge 100 (4 in) caliper. r _a 1. Drive pulley 2. Drive pulley holder Drive Pulley Sliding Sheave Removal 1. Remove drive belt and keep the driven pulley fully open. 2. Secure drive pulley with the DRIVE PULLEY HOLDER (P/N ). Install it over a sliding sheave tower. 3. Remove the drive pulley bolt and its conical spring washer. r _a 1. Drive pulley bolt 2. Conical spring washer To remove drive pulley from engine, use the DRIVE PULLEY PULLER (P/N ). Printed in Canada. (mbs 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/ 6

529022040 5. Retain drive pulley with the DRIVE PULLEY HOLDER (P/N 529 035 674), and install the puller in pulley shaft then tighten.

Reinstall fixed sheave on crankshaft. NOTE: Use a thick washer (± 13 (1/2 in)) to compensate for the absence of sliding sheave. 9.

Drive pulley holder 2. Drive pulley puller NOTICE These pulleys have metric threads. Do not use imperial threads puller.

2 Retain drive pulley with the DRIVE PULLEY HOLDER (P/N ), and install the puller in pulley shaft then tighten. NOTE: No components marking is required before disassembling this drive pulley since it has factory mark and arrows as indexing reference. 7. Remove puller and separate sheaves. 8. Reinstall fixed sheave on crankshaft. NOTE: Use a thick washer (± 13 (1/2 in)) to compensate for the absence of sliding sheave. 9. Using a strap wrench such as the SNAP-ON STRAP WRENCH (P/N YA826A), hold the fixed sheave. 10. Torque the drive pulley bolt enough to be stiff on the crankshaft. r _a 1. Drive pulley holder 2. Drive pulley puller NOTICE These pulleys have metric threads. Do not use imperial threads puller. Always tighten puller by hand to ensure that the drive pulley has the same type of threads (metric vs imperial) prior to fully tightening. 6. To separate fixed sheave from sliding sheave: 6.1 Tighten puller into fixed sheave shaft about 13 (1/2 in). 6.2 Raise drive pulley and hold it by the sliding sheave while knocking on puller head to disengage fixed sheave. NOTICE NEVER tap on governor cup. mbs _a 1. Thick washer 2. Strap wrench 3. Fixed sheave Pulley Alignment Measuring Method The following image shows the required measures to be taken to perform the pulleys alignment. Y X Z 2 r _a TYPICAL 1. Puller 2. Sliding sheave 3. Fixed sheave A00D0WA 1 TYPICAL 1. ALIGNMENT BAR (P/N ) 2. Front of vehicle 2 / SERVICE

The following procedure explain how to get the required measures with conventional tools.

How to modify a caliper: Grind the external edge of the outside diameter measuring jaw to have a maximum thickness of 4 (5/32 in). Cut the depth measuring rod. Leave 13 (1/2 in) maximum.

4 (5/32 in) NOTICE Be careful not to warp the outside diameter measuring jaw when grinding. A good cooling is the key.

3 The following procedure explain how to get the required measures with conventional tools. However, it is possible to modify a 100 (4 in) caliper to perform the required measurements more easily, even with ring gear equipped models. How to modify a caliper: Grind the external edge of the outside diameter measuring jaw to have a maximum thickness of 4 (5/32 in). Cut the depth measuring rod. Leave 13 (1/2 in) maximum. mbs _a 1. Feeler gauge 2. Fixed sheave 3. Ring gear mbs _a 100 MM (4 IN) CALIPER 1. Depth measuring rod A. 4 (5/32 in) NOTICE Be careful not to warp the outside diameter measuring jaw when grinding. A good cooling is the key. If you choose to modify a caliper, read the procedure to get the measuring points and measure directly between alignment bar and pulley. Models Equipped With Ring Gear Only 1. Install the feeler gauge between the ring gear and the fixed sheave, approximately between the drive and the driven pulley. Set the feeler gauge to the correct thickness to hold on between the ring gear and the fixed sheave. NOTE: If the repaired vehicle is not equipped with a ring gear, there is no need to use the feeler gauge. The X and Y measures can directly be taken between the alignment bar and the drive pulley rear edge. All Models 2. Install the ALIGNMENT BAR (P/N ) in the middle of both pulleys; The half moon groove must lay on the fixed sheave shaft. The upper and lower measuring windows must be toward you when facing pulleys. mbs _a 1. Alignment bar 2. Upper measuring window 3. Half moon groove 3. Push the alignment bar into the groove bottom of the driven pulley. 4. Close the driven pulley to jam the alignment bar in place. SERVICE / 6

6. Install the feeler gauge between the ring gear and the fixed sheave, behind the alignment bar lower measuring window. 7.

mbs2009-016-004 ALIGNMENT BAR JAMMED IN PLACE 5.

mbs2009-016-006_a Y MEASURE 1. Lower measuring window 2.

feeler gauge or the alignment when measuring. The accuracy of the results may be falsified.

To get the measure between the drive and the driven pulleys (Z measure), you may use the following method; 8.

4 6. Install the feeler gauge between the ring gear and the fixed sheave, behind the alignment bar lower measuring window. 7. Measure the distance between the alignment bar lower measuring window and the feeler gauge. Note the result as Y measure. mbs ALIGNMENT BAR JAMMED IN PLACE 5. Measure the distance between the alignment bar upper measuring window and the feeler gauge. Note the result as X measure. mbs _a Y MEASURE 1. Lower measuring window 2. Feeler gauge (hidden on picture) mbs MEASURE WITH THE FEELER GAUGE METHOD NOTICE Do not apply pressure on the feeler gauge or the alignment when measuring. The accuracy of the results may be falsified. NOTICE Do not apply pressure on the feeler gauge or the alignment when measuring. Results may be inaccurate. 8. To get the measure between the drive and the driven pulleys (Z measure), you may use the following method; 8.1 Using the DRIVEN PULLEY OPENING TOOL (P/N ) or the DRIVEN PULLEY OPENING TOOL (P/N ), open the driven pulley so the driven sliding sheave is aligned with the drive pulley fixed sheave mbs _a MEASURE WITH THE MODIFIED CALIPER 1. Alignment bar 2. Upper measuring window 3. Grinded jaw 4 / SERVICE

Pulley Alignment If any pulley alignment is required, proceed as per the following. 1. Remove the tune pipe and muffler. 2.

mbs2009-016-010_a TYPICAL - ENGINE RUBBER MOUNT BOLTS 1. Front MAG side 2. Front PTO side 3. On 2-stroke models, loosen the 3 engine stopper screws.

Use the following chart to validate that the pulleys alignment of the inspected vehicle is within specification Pulley Alignment and Distance Specifications Chart

1 ± 1 36.9 ± 0.5 TRA III 258.7 ± 1 36.4 ± 0.5 1.8 3.0 21.4 21 o2009-003-013_a 1. Engine stopper 2. Engine stopper screws 3. Drive pulley 4.

5 Pulley Alignment If any pulley alignment is required, proceed as per the following. 1. Remove the tune pipe and muffler. 2. The 4 engine rubber mount bolts should be loosened ± 4 turns Slide a socket that just fits between both pulley edges. mbs _a TYPICAL - ENGINE RUBBER MOUNT BOLTS 1. Front MAG side 2. Front PTO side 3. On 2-stroke models, loosen the 3 engine stopper screws. mbs _a 1. Socket 8.3 Use the caliper to measure the outer diameter of the socket. 8.4 Note the outer diameter as the Z measure. 9. Use the following chart to validate that the pulleys alignment of the inspected vehicle is within specification Pulley Alignment and Distance Specifications Chart Model XP Chassis XR Chassis XU Chassis Drive Clutch Driven Clutch Center to Center X Y-X Z TRA III - TRA VII ± ± ± ± 2.3 TRA IV QRS ± ± 0.5 TRA III ± ± o _a 1. Engine stopper 2. Engine stopper screws 3. Drive pulley 4. Reposition the engine accordingly to the error measured. 5. Tighten the engine mounts bolts following a proper sequence for each vehicle platform. See ENGINE MOUNTS BOLTS TIGHTENING SEQUENCE further. 6. Redo the PULLEYS ALIGNMENT MEASURING METHOD procedure to ensure the alignment is within specification. SERVICE / 6

Engine Mount Bolts Tightening Sequence REV-XP, REV-XR (2-stroke) REV-XU Models 1. Rear PTO side, 25 N m (18 lbf ft). 2. Rear MAG side, 25 N m (18 lbf ft). 3. Front PTO side, 25 N m (18 lbf ft). 4.

6 Engine Mount Bolts Tightening Sequence REV-XP, REV-XR (2-stroke) REV-XU Models 1. Rear PTO side, 25 N m (18 lbf ft). 2. Rear MAG side, 25 N m (18 lbf ft). 3. Front PTO side, 25 N m (18 lbf ft). 4. Front MAG side, 25 N m (18 lbf ft). REV-XR (4 stroke) Models 1. Rear PTO side, 25 N m (18 lbf ft). 2. Rear MAG side, 25 N m (18 lbf ft). 3. Front MAG side, 25 N m (18 lbf ft). 4. Front PTO side, 25 N m (18 lbf ft). Vehicle Reassembly 1. Install the tune pipe and muffler. 2. Adjust the engine stopper: 2.1 Apply a downward pressure on the engine stopper with your fingers while tightening the screws just enough to obtain contact between the screw heads and the surface of the stopper. 2.2 Tighten bolts to 10 N m (89 lbf in). 3. Clean pulley sheaves and shaft with fine steel wool and dry cloth. Do not use any other type of abrasive. 4. Clean crankshaft tapered end and the taper inside the fixed sheave of the drive pulley, crankshaft threads and retaining screw threads with PULLEY FLANGE CLEANER (P/N ). NOTICE Avoid contact between cleaner and crankshaft seal because damage may occur. Mounting surfaces must be free of any oil, cleaner or towel residue. Do not apply antiseize or any lubricant on crankshaft and drive pulley tapers. 5. Install drive pulley on crankshaft extension. Install drive belt at this time. 6. Install a new conical spring washer with its concave side towards drive pulley then install drive pulley bolt. msi _a 1. Conical spring washer NOTICE Always use BRP genuine parts for conical spring washer and bolt. 7. Use the DRIVE PULLEY HOLDER (P/N ) to retain drive pulley. See removal procedure. 8. Torque drive pulley bolt to 120 N m (89 lbf ft). 9. Perform drive belt adjustment as per appropriate SHOP MANUAL. 10. Install drive belt guard. 11. Raise 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. 12. Accelerate the vehicle at low speed (maximum 30 km/h (20 MPH)) and apply the brake, repeat 5times. 13. Re-torque drive pulley bolt to 120 N m (89 lbf ft). WARNING After 10 hours of operation the transmission system of the vehicle must be inspected to ensure drive pulley bolt is properly torqued. 6 / SERVICE

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