SOLUTION Depending on the part to be replaced, carefully apply and follow the appropriate procedure. Subject: REV Front End Frame Rebuild Procedure

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1 Date: February, 2004 Subject: REV Front End Frame Rebuild Procedure No YEAR MODEL PACKAGE MODEL NUMBER SERIAL NUMBER 2004 All models equipped with REV chassis All All All PROBLEM When the front end is damaged by severe impact, some components of the front suspension and frame may be damaged. If the frame is not too severely damaged, it is possible to rebuild the front end of the frame without compromising it strength. SOLUTION Depending on the part to be replaced, carefully apply and follow the appropriate procedure. Printed in Canada. (mbs DR) / Bombardier Recreational Products Inc. All rights reserved. Trademarks of Bombardier Recreational Products Inc. or its affiliates. * Bombardier and the sprocket design are trademarks of Bombardier Inc., used under license.

2 PROCEDURE (A) Lower A-arm Bracket [A] Replacement NOTE: We highly recommend the use of Supertanium drill bit (P/N ) when drilling out rivets. iiiiiiiiiiiiiiiiioiiiiiiiiiiiwiparts REQUIRED iiiiiiiiiiiiiiiiidescription iiiiiiiiiip/n iiiiiiqty Lower Bracket [A] Hex. Flanged Bolt M8 x iiiiiiiiiii4 ➀ Flanged Nut M iiiiiiiiiii4 ➀ Hex. Flanged Bolt M0 x iiiiiiiiiii4 ➁ Elastic Flanged Nut M iiiiiiiiiii4 ➀ ➀ When ordering quantity of this part number, dealer/distributor receives 0 of this item. ➁ When ordering quantity of this part number, dealer/distributor receives 5 of this item. A33H3UA A A Remove front shocks. Remove bolts and nuts retaining lower A-arms to frame. Remove lower A-arms [] from their support brackets [2]. A33F4FA 2 Supertanium is a trademark of Premium Industrial Corporation 2 / Service

3 Remove and discard existing bolts and nuts holding lower brackets to frame. Using a 5 mm (3/6 in) drill bit, drill rivets out. Remove and discard lower brackets []. A33H3VA Secure new lower bracket to frame using: [] 2 hexagonal flanged bolts M8 x 50 iiii(p/n ) [2] 2 flanged nuts M8 (P/N ). NOTE: BoltsshouldbeontheRHsideofthe vehicle. A33H3WA 2 Secure lower A-arm with: [] 2 Hexagonal Flanged Bolts M0 x 70 iiii(grade 0.9) (P/N ) [2] 2 Elastic Nuts M0 (P/N ). NOTE: Make sure to invert the front A-arm attachment bolts from their original position and replace the existing hardware when securing lower A-arm to support brackets. Hexagonal bolts [] should be towards the front of the vehicle. A33H44A 2 Service / 6

4 PROCEDURE (B) Front Cross Member [B] Removal NOTE: We highly recommend the use of Supertanium drill bit (P/N ) when drilling out rivets. B A33H3ZA Refer to the appropriate Shop Manual for the removal procedure of the following parts: side panels muffler tuned pipe skis shocks upper and lower A-arm assembly [] (with ski iiiilegs, both sides), see photo front bumper bottom pan. A33F4GA Remove front member steel brace []. A33H3XA 4 / Service

5 Remove bolts holding steering column [] to front member. Remove nut holding ball joint [2] tosteering column. A33H3YA 2 Remove on both sides bolts [] holding front cross member to upper cross member. A33H40A Using a 5 mm (3/6 in) drill bit, drill rivets [] out on the LH side of the front cross member. A33H4A Service / 6

6 Using a 5 mm (3/6 in) drill bit, drill rivets [] out on the RH side of the front cross member. NOTE: It may be necessary to grind rivets out. Remove front cross member. NOTE: For front cross member reinstallation, refer to Procedure (D). A33H42A A33H43A 6 / Service

7 PROCEDURE (C) Chassis Front Plate [C] Replacement NOTE: We highly recommend the use of Supertanium drill bit (P/N ) when drilling out rivets. iiiiiiiiiiiiiiiiioiiiiiiiiiiiwiparts REQUIRED iiiiiiiiiiiiiiiiidescription iiiiiiiiiip/n iiiiiiqty Front Plate [C] Pop Rivet 3/6 Hexagonal Bolt M5 x 2 Elastic Nut M5 Hexagonal Bolt M5 x 4 Flat Washer 5 mm Elastic Flanged Nut M iiiiiiiiiii iiiiiiiiiii5 ➁ iiiiiiiiiii2 ➀ iiiiiiiiiii2 ➀ iiiiiiiiii4 ➀ iiiiiiiiii4 ➀ iiiiiiiiii4 ➀ Insert iiiiiiiiiii2 ➀ When ordering quantity of this part number, dealer/distributor receives 0 of this item. ➁ When ordering quantity of this part number, dealer/distributor receives 50 of this item. C A33H45A Remove front cross member using Procedure (B) before going further with this procedure. NOTE: This procedure can be performed without removing the engine, but, it is recommended to lift or remove the engine to facilitate the installation. Engine realignment verification will be needed to ensure the appropriate engine alignment. Refer to the appropriate Shop Manual for the removal procedure of the following parts: torsion bar Using a 5 mm (3/6 in) drill bit, remove rivets holding bottom pan to front plate on both sides, this will give appropriate access to front plate rivets. Disconnect voltage regulator. Using a 5 mm (3/6 in) drill bit, drill rivets out []. Remove all rivets holding front plate. NOTE: Self-percing rivets may need to be grinded. A33H46A Service / 6

8 Remove front plate by using a hammer and/or chisel. A33H47A Using a hammer and solid steel plate, re-shape chassis and make sure that its straight. A33H48A Install voltage regulator on new front plate. Install hexagonal bolts M5 x 2 [] (P/N ) in MAG side engine support holes. Install new front plate [] (P/N ) and secure temporarily with engine support bolts and 2 elastic nuts M5 (P/N ). A33H49A 8 / Service

9 Secure front plate to frame using 5 pop rivets 3/6 (P/N ). NOTE: Use the 5 pre-drilled holes [] tolocatethe front plate on frame. A33H4AA Secure the top [] of the front plate with: 4 hexagonal bolts M5 x 4 (P/N ) 4 elastic flanged nuts M5 (P/N ) 4 flat washers 5 mm (P/N ). NOTE: Use existing holes. NOTE: Hexagonal bolt heads and washers [] towards the front of the vehicle. A33H4BA Drill 3 holes of 5 mm (3/6 in) on both sides through the front plate and chassis, see photo for holes location. A RH side: CAUTION: Never use existing holes, always use the newly drilled holes to secure parts. A) 40 mm (-9/6 in) B) 35 mm (-3/8 in) C) 45 mm (-3/4 in) D) 45 mm (-3/4 in). B C D A33H4CA Service / 6

10 LH side: A) 2 mm (7/6 in) B) 42 mm (-5/8 in) C) 43 mm (-/6 in) D) 55 mm (2-5/32 in). A B C D A33H4DA Trace a line between the center of the two rivets previously installed. Mark holes location under the front plate, see photo. Drill 4 holes of 5 mm (3/6 in) under the front plate where marked. A) 60 mm (2-3/8 in) B) 70 mm (2-3/4 in) C) 5 mm (4-/2 in) D) 85 mm (3-/32 in). Secure front plate to frame using: 0 hexagonal bolts M5 x 4 (P/N ) 0 elastic flanged nuts M5 (P/N ) 0 flat washers 5 mm (P/N ). NOTE: Hexagonal bolt heads and washers towards the outside of the vehicle. Verify and make sure that all previously installed bolts are well tightened. Install the two inserts [] (P/N ) in the front plate existing holes. A33H4EA A B C D A33H4FA 0 / Service

11 Hold the insert in place using locking pliers and torquehexagonalboltm8x25to7n m (50 lbf in). Reinstall front cross member as per Procedure (D). Reinstall all removed parts. A33H4GA PROCEDURE (D) Front Cross Member Installation NOTE: We highly recommend the use of Supertanium drill bit (P/N ) when drilling out rivets. iiiiiiiiiiiiiiiiioiiiiiiiiiiiwiparts REQUIRED Item iiiiiiiiiiiiiiiiidescription iiiiiiiiiip/n iiiqty iiii Front Cross Member iiiiiiii iiii2 Front Plate iiiiiiii Hexagonal Flanged Bolt M6 x iiiiiiii4 ➁ Elastic Flanged Nut M iiiiiiii4 ➀ Hexagonal Bolt M5 x iiiii4 ➀ Flat Washer 5 mm iiiii4 ➀ Elastic Flanged Nut M iiiii4 ➀ Hex. Flanged Bolt M8 x iiiiiiii4 ➀ Flanged Nut M iiiiiiii4 ➀ ➀ When ordering quantity of this part number, dealer/distributor receives 0 of this item. ➁ When ordering quantity of this part number, dealer/distributor receives 25 of this item. A33H4HA 2 Service / 6

12 Remove front cross member using Procedure (B) before going further with this procedure. Install and secure [] new or existing front plate (P/N ) to front cross member (P/N ) using: 6 hexagonal bolts M5 x 4 (P/N ) 6 elastic flanged nuts M5 (P/N ) 6 flat washers 5 mm (P/N ). NOTE: Hexagonal bolt heads and washers [] towards the front of the vehicle. Remove all reusable parts from previous cross member and reinstall them on the new one. Secure front cross member to frame, see photo. A33H4IA RH Side: [] 4 hexagonal flanged bolts M6 x 6 iiii(p/n ) 4 elastic flanged nuts M6 (P/N ). NOTE: Hexagonal bolt heads [] towardsthe outside of the vehicle. A33H4JA RH Side: [] 2 hexagonal bolts M5 x 4 iiii(p/n ) 2flatwashers5mm(P/N ) 2 elastic flanged nuts M5 (P/N ). NOTE: Hexagonal bolt heads and washers [] towards the outside of the vehicle. A33H4KA 2 / Service

13 LH Side: [] 3 hexagonal bolts M5 x 4 iiii(p/n ) 3flatwashers5mm(P/N ) 3 elastic flanged nuts M5 (P/N ). NOTE: Hexagonal bolt heads and washers [] towards the outside of the vehicle. A33H4LA LH Side: [] 3 hexagonal bolts M5 x 4 iiii(p/n ) 3flatwashers5mm(P/N ) 3 elastic flanged nuts M5 (P/N ). NOTE: Hexagonal bolt heads and washers [] towards the outside of the vehicle. A33H4MA Secure lower A-arm with: [] 2 Hexagonal Flanged Bolts M0 x 70 iiii(grade 0.9) (P/N ) [2] 2 Elastic Nuts M0 (P/N ). NOTE: Make sure to invert the front A-arm attachment bolts from their original position and replace the existing hardware when securing lower A-arm to support brackets. Hexagonal bolts [] should be towards the front of the vehicle. Reinstall all previously removed parts. A33H44A 2 Service / 6

14 OPTIONAL REINFORCEMENT For very aggressive rider of for race use, additional reinforcements can be installed. NOTE: We highly recommend the use of Supertanium drill bit (P/N ) when drilling out rivets. iiiiiiiiiiiiiiiiioiiiiiiiiiiiwiparts REQUIRED Item iiiiiiiiiiiiiiiiidescription iiiiiiiiiip/n iiqty iiii Front Plate Reinforcement iiiiiii iiii2 Stiffener iiiiiii iiii3 Corner Reinforcement iiiiiii Hexagonal Bolt M5 x iii2 ➀ Elastic Flanged Nut M iii6 ➀ Flat Washer 5 mm iii4 ➀ Hexagonal Bolt M5 x iiiii2 ➀ Hexagonal Bolt M6 x iiiii2 ➀ Elastic Flanged Nut M iiiii3 ➀ Hexagonal Flanged Bolt M6 x iiiii ➁ Socket Head Screw M5 x iiiii2 ➂ Hex. Flanged Bolt M8 x iiiiii4 ➀ Flanged Nut M iiiiii4 ➀ ➀ When ordering quantity of this part number, dealer/distributor receives 0 of this item. ➁ When ordering quantity of this part number, dealer/distributor receives 25 of this item. ➂ When ordering quantity of this part number, dealer/distributor receives 5 of this item. A33H4NA 2 3 Front Plate Reinforcement Install and secure front reinforcement plate (P/N ) to front plate using: [] 2 hexagonal flanged bolts M5 x 6 iiii(p/n ) 2flatwashers5mm(P/N ) 2 elastic flanged nuts M5 (P/N ) existing hardware holding steering column support [2]. NOTE: Hexagonal bolt heads and washers [] towards the outside of the vehicle. NOTE: With front plate reinforcement installed, bottom pan will need to be modified. A33H4OA 2 4 / Service

15 Corner Reinforcement Position corner reinforcements [] (P/N ) on front cross member using the following measurement: A) 40 mm (.57 in) NOTE: Lean corner reinforcements vertically on front cross member. Using corner reinforcements as a template, mark holes location on front cross member. Drill 6 holes of 5 mm (3/6 in) where marked. Secure each corner reinforcement using: [2] 6 Hexagonal Bolts M5 x 4 (P/N ) [3] 6 Flat Washer 5 mm (P/N ) [4] 6 elastic flanged nuts M5 (P/N ). A33H4PA A NOTE: Hexagonal bolt heads [2] towardsthe outside of the vehicle. Stiffener Drill and grind existing stiffener rivets. Remove existing stiffener. Secure new stiffener [] (P/N ) to front cross member using: 2-3 [2] 2 socket head screws M5 x 6 iiii(p/n ) [3] 2 hexagonal flanged nuts M5 iiii(p/n ) NOTE: Socket screw heads [2] towardsthe outside of the vehicle [4] hexagonal flanged bolt M6 x 35 iiii(p/n ) [5] elastic flanged nut M6 iiii(p/n ) A33H4QA NOTE: Hexagonal bolt head [4] towards the inside of the vehicle. [6] 2 hexagonal bolts M6 x 30 (P/N ) [7] 2 elastic flanged nut M6 (P/N ). NOTE: Hexagonal bolt heads [6] towardsthe outside of the vehicle. Service / 6

16 Lower A-Arms Bolts Replace each lower A-arm existing hardware with: [] 2 Hexagonal Flanged Bolts M0 x 70 iiii(grade 0.9) (P/N ) [2] 2 Elastic Nuts M0 (P/N ). NOTE: Make sure to invert the front A-arm attachment bolts from their original position and replace the existing hardware when securing lower A-arm to support brackets. Hexagonal bolts [] should be towards the front of the vehicle. A33H44A 2 6 / Service