This notice is sent to you in accordance with the requirements of the Canada Motor Vehicle Safety Act and other applicable laws.

Transcription

1 SAFETY RECALL NOTICE Bombardier Recreational Products Inc. 565 de la Montagne Street Valcourt, Québec, Canada J0E 2L0 T F Date: November 14, 2008 Re: Brake Hose Rubbing on Driven Pulley Dear Ski-Doo Dealer / Distributor, This notice is sent to you in accordance with the requirements of the Canada Motor Vehicle Safety Act and other applicable laws. What is the reason for this notice? In cooperation with Transport Canada, Bombardier Recreational Products Inc. is conducting a voluntary safety recall of certain 2009 Ski-Doo MX Zx 600RS models, as specified in the attached Safety Campaign Bulletin. What is the potential problem? In some circumstances, on above-mentioned vehicles, the brake hose could be wrongly routed or not firmly secured in its proper location. If the vehicle is driven when this condition exists, the transmission driven pulley may come in contact with the brake hose. This could cause the brake hose to chaff and ultimately cause a brake fluid leak resulting in a complete lost of braking capacity. If this occurs, it could lead to a possible collision with bystanders, a fixed object or another vehicle which could cause serious injuries or even 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 inspect and relocate brake hose if no sign of chafing is found. If sign of chafing is found, the brake hose will be replace and relocate. In all cases, the brake hose will be secured with an additional bracket. What should you do? Do not sell, deliver or use any involved vehicle that you have in stock until the repair has been completed. 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. 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.: November 14, 2008 Subject:Brake Hose Rubbing on Driven Pulley No YEAR MODEL MODEL NUMBER SERIAL NUMBER 2009 MX Zx 600RS BM9A See List PROBLEM In some circumstances, on above-mentioned vehicles, the brake hose could be improperly routed or not firmly secured in its proper location. If the vehicle is driven when this condition exists, the brake hose may come in contact with the driven pulley. This could cause the brake hose to chaff and ultimately cause a brake fluid leak resulting in a complete loss of braking capacity. If this occurs, it could lead to a possible collision with bystanders, a fixed object or another vehicle which could cause serious injuries or even death. SOLUTION 1. Inspect brake hose: 1.1 If any sign of chafing is found, replace brake hose. 1.2 If no sign of chafing is found, check brake hose routing. 2. Secure brake hose with an additional bracket. PARTS REQUIRED ITEM P/N DESCRIPTION QTY P Bracket (additional support) 1 P Washer 1 P Brake Hose 1* P Sealing Washer 4* PROCEDURE 1. Open LH side panel. 2. Remove drive belt guard. 3. Inspect the brake hose section near the driven pulley for wear. mbg _a 1. Rub point 3.1 If the hose show signs of chafing, go to BRAKE HOSE REPLACEMENT. 3.2 If the hose condition is correct, go to BRAKE HOSE SUPPORT INSTALLATION. BrakeHoseReplacement 1. Remove brake fluid reservoir cover with its diaphragm. * If needed. Printed in Canada. (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/ 5

3 mmr _a 1. Reservoir cover 2. Diaphragm 2. Connect a clear hose to caliper bleeder. 3. Place the other end of hose in a container. 4. Loosen bleeder and pump brake lever until no more fluid flows out of bleeder. mmr _a 1. Banjo fitting 2. Sealing washers 7. Note the brake hose routing. 8. Remove the damaged brake hose. 9. Install the new brake hose [P3]. 10. Install each Banjo fitting with two NEW sealing washers [P4]. 11. Torque Banjo fitting: Master cylinder: 18 N m (159 lbf in) Caliper: 38 N m (28 lbf ft). 12. Using a big syringe, push brake fluid slowly into the caliper. NOTE: Always use brake fluid meeting the specification DOT4suchasBRAKE FLUID SRF (DOT 4) (P/N ) sold by BRP. mmr _a 1. Bleeder 2. Clear hose to catch used brake fluid 5. Remove the Banjo fitting at the caliper and discard the sealing washers. mmr mmr _a 1. Banjo fitting 2. Sealing washers 6. Remove the Banjo fitting at the master cylinder and discard the sealing washers. 13. Continue to push brake fluid until reservoir is half full. 14. Close bleeder. 15. Add brake fluid into reservoir. 16. Squeeze brake lever. It should be firm. If so, tighten bleeder to 8.5 N m (75 lbf in) and install cover on reservoir. If not, bleed brake circuit as per the following procedure: 16.1 Install a clear hose on bleeder Pump up circuit pressure with brake lever until lever resistance is felt. 2 / SAFETY CAMPAIGN

4 16.3 Squeeze brake lever and open bleeder. When lever touches the handlebar, do not release lever and close bleeder Release brake lever slowly Repeat the procedure until no more air bubbles appear in hose and lever is firm. NOTE: Check fluid level often to prevent air from being pumped into the circuit. 17. If the lever is still spongy, push back brake pads and squeeze brake lever before repeating the procedure Repeat until brake lever is firm Tighten bleeder to 8.5 N m (75 lbf in) Install diaphragm and cover on reservoir. Brake Hose Support Installation The additional support will be installed within the front top bolt supporting the countershaft bearing carrier. mbg _a 1. Brake hose 2. Washer [P2] 3. Bracket [P1] 4. Nut 5. Ccountershaft 6. Bolt NOTE: Make sure the brake hose is kept away from the driven pulley. 5. Reinstall the nut. Torque to 15 N m (133 lbf in). WARRANTY Submit a warranty claim using the following information: A) Inspection If inspection was performed, submit a warranty claim using the following information: CAMPAIGN NUMBER Claim Type Campaign Claim mbg _a 1. Clamp (additional support) 1. Insert the bracket [P1] over the brake hose. 2. Remove the top front nut of the bearing carrier. Do not move the bolt from it's position. 3. Insert the washer [P2] on the bolt. 4. Insert the bracket after the washer. NOTE: The bracket shall position the hose away from the driven pulley. Action Inspection * Flat Rate Time 0.4 hours * 0.1 has been added to inspection flat rate to cover the bracket and washer price. Click in the INSPECT BOX while completing your claim on BOSSWeb. INSPECT NOTE: This will pay for inspection flat rate only. NOTE: All vehicles need to be inspected. Inspection and Repair If inspection and repair was performed, submit a warranty claim using the following information: SAFETY CAMPAIGN / 5

5 CAMPAIGN NUMBER Claim Type Campaign Claim Action Repair * Flat Rate Time 0.3 hours * 0.1 has been added to repair flat rate to cover BRAKE FLUID SRF (DOT 4) (P/N ) price. Click in the INSPECT BOX and in the REPAIR BOX while completing your claim on BOSSWeb. INSPECT REPAIR NOTE: If repair is performed, you need to click in the INSPECT BOX and in the REPAIR BOX to be paid accordingly. Claiming Procedure For claiming procedure, refer to the DEALER/DIS- TRIBUTOR WARRANTY GUIDE. IMPORTANT: Dealers must return defective parts to support their claims. Shipping Addresses USA DEALERS CANADIAN DEALERS OTHERS COUNTRIES BRP c/o Warranty Department 7575 Bombardier Court Wausau, WI BRP Warranty Parts Inspection Center 565 de la Montagne Valcourt, QC, J0E 2L0 Contact your local distributor or BRP Regional Office. Warranty Shipping Address Decals Warranty shipping address decals can be ordered if needed. COUNTRY P/N U.S.A Canada / SAFETY CAMPAIGN

6 SERIAL NUMBER LISTING OF MY 2009 INVOLVED VEHICLES Model: BM9A From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to From to Model: BM9A (cont d) From to From to From to From to From to From to From to SAFETY CAMPAIGN / 5

7 SAFETY RECALL NOTICE Bombardier Recreational Products Inc. 565 de la Montagne Street Valcourt, Québec, Canada J0E 2L0 T F Date: November 14, 2008 Re: Brake Hose Rubbing on Driven Pulley Dear Ski-Doo Owner, This notice is sent to you in accordance with the requirements of the Canada Motor Vehicle Safety Act and other applicable laws. What is the reason for this notice? In cooperation with Transport Canada, Bombardier Recreational Products Inc. is conducting a voluntary safety recall of certain 2009 Ski-Doo MX Zx 600RS models. Our records indicate that you are the owner of a potentially affected vehicle. What is the potential problem? In some circumstances, on above-mentioned vehicles, the brake hose could be wrongly routed or not firmly secured in its proper location. If the vehicle is driven when this condition exists, the transmission driven pulley may come in contact with the brake hose. This could cause the brake hose to chaff and ultimately cause a brake fluid leak resulting in a complete lost of braking capacity. If this occurs, it could lead to a possible collision with bystanders, a fixed object or another vehicle which could cause serious injuries or even 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 inspect and relocate brake hose if no sign of chafing is found. If sign of chafing is found, the brake hose will be replace and relocate. In all cases, the brake hose will be secured with an additional bracket. 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. and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates. Printed in Canada. Ski-Doo Lynx Sea-Doo Evinrude Johnson Rotax Can-Am