Campaign no.: 2008-5 Date: October 19, 2007 Subject: A : Chain Case Leaking No. 2008-4 B : Spare Belt Holding Strap C : 800R Engine Clutch Torque D : 800R EPA Hangtag YEAR MODEL MODEL NUMBER SERIAL NUMBER 2008 MX Z 800R X BB8A / BB8B / BB8C / BB8D / BB8E See attached list 2008 MX Z 800R Adrenaline BD8A / BD8B / BD8C / BD8D See attached list 2008 Summit 800R Everest CT8A See attached list 2008 MX Z 500SS Trail BH8A / BH8B See attached list 2008 MX Z 500SS TNT MF8A / MF8B See attached list PROBLEM A. Under certain conditions chain case oil may leak from vent. B. A limited quantity of units were produced without a spare belt holding strap. C. Some 800R power packs may have been produced with the wrong drive clutch torque specification. D. Some 800R vehicle may have been produced with the wrong EPA hangtag. SOLUTION A. Install the new vent system. B. Install the holding strap. C. Torque 800R engine drive clutch retaining bolt to the specification. D. Replace 800R vehicle hangtag located on handlebar. PARTS REQUIRED DESCRIPTION P/N QTY Fitting 414 580 700 1 Hose (115 mm / 4.5 in) 709 000 183 1 Velcro strip 548 872 539 1 EPA Hangtag (800R only) 512 060 416 1 Fittings (P/N 414 580 700 ) are sold in pack of 5. Hoses (P/N 709 000 183) are sold in pack of 10 meters (32.8 FT). Velcro strips (P/N 548 872 539) are sold individually. EPA Hangtags (P/N 512 060 416) are sold individually. REPAIR PROCEDURES A : CHAIN CASE LEAKING Securevehicleinplace. Open right side panel. Remove the chain case rubber cap. Printed in Canada. (mbg2008-006 DM) 1/8 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.
mbg2008-006-003_a mbg2008-006-006_a Place rubber cap [1] on a piece of wood placing internal side facing up. Usinga7mmstuddrill[2] (P/N 415 128 884), punch the center of rubber cap. mbg2008-006-008_a mbg2008-006-004_a Insert the fitting [3] (P/N 414 580 700) into the rubber cap. Cut the hose (P/N 709 000 183) to 115 mm (4,5 ). Insert the hose on the fitting. On the back side of chain case, toward the front of vehicle, locate the vent hole [5]. NOTE: The chain case vent hole is positioned just above a fixation hole. NOTE: Do not remove chain case from vehicle. Clean chain case vent region with pulley flange cleaner (P/N 413 711 809). Using a wooden dowel, fill up the vent hole [5] with Loctite 5910 (P/N 293 800 081). B:SPAREBELTHOLDINGSTRAP mbg2008-006-005_a msi2008-027-008_a Re-install rubber cap on the chain case. Insert hose [4] between chain case and oil reservoir. Remove hood from vehicle. NOTE: To release hood, stand in front of vehicle, pull outwards on both sides of hood aft section then pull hood towards you. 2 / 8 2008-4 Warranty Campaign
Re-torque drive pulley bolt [1] to 120 N m (89 lbf ft). WARNING After 10 hours of operation the transmission system of the vehicle must be inspected to ensure the retaining screw is properly torqued. mbg2008-006-007_a Insert velcro strip [1] (P/N 548 872 539) into the belt holder slots. Re-install hood on vehicle. D : 800R EPA Hangtag NOTE: Do not replace 500SS or 600SDI vehicle EPA hangtag. Replace only the EPA hangtag of 800R vehicle. C : 800R CLUTCH TORQUE CAUTION: Do not torque 500SS or 600SDI engine to this torque specification. Retorque only the drive pulley of 800R engine type. mbg2008-006-009_a Locate EPA hangtag on vehicle handlebar [1]. Remove EPA hangtag from vehicle and discard it. Replace EPA hangtag with the good one (P/N 512 060 416). mbg2008-006-001_a Secure vehicle in place. Open left side panel. Install drive pulley holder (P/N 529 035 674). Slightly loosen the drive pulley bolt [1]. Torque drive pulley bolt [1] to 120 N m (89 lbf ft). Raise and block 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. Accelerate the vehicle at low speed (maximum 30 km/h (20 MPH)) and apply the brake. Repeat 5 times. WARRANTY Submit a warranty claim using the following information: Campaign Number 2008-5 Claim Type Flat Rate Time Campaign claim 0.3 hour For claiming procedure, refer to the DEALER/DISTRIBUTOR WARRANTY GUIDE. Warranty Campaign 2008-4 3 / 8
SERIAL NUMBER LISTING OF INVOLVED VEHICLE Model: BB8A From 000004 to 000005 From 000017 to 000018 000023 000030 000033 From 000037 to 000038 From 000041 to 000043 000046 From 000049 to 000051 Model: BB8B 000003 From 000006 to 000008 From 000010 to 000012 From 000014 to 000016 From 000018 to 000022 000024 From 000026 to 000027 From 000029 to 000030 From 000033 to 000034 From 000039 to 000040 000043 From 000045 to 000048 000051 000053 From 000056 to 000060 From 000063 to 000066 From 000068 to 000073 From 000076 to 000079 From 000081 to 000085 000088 000092 From 000094 to 000099 From 000103 to 000105 From 000107 to 000109 Model: BB8C From 000003 to 000006 From 000010 to 000013 From 000015 to 000018 From 000020 to 000028 From 000030 to 000031 From 000033 to 000040 From 000042 to 000048 From 000050 to 000057 From 000059 to 000063 From 000066 to 000067 From 000069 to 000074 From 000076 to 000080 Model: BB8C (cont d) From 000082 to 000084 From 000087 to 000091 From 000093 to 000094 000096 From 000098 to 000099 From 000103 to 000104 From 000107 to 000114 From 000118 to 000121 From 000125 to 000129 000131 From 000133 to 000136 000139 000142 From 000144 to 000146 000148 From 000154 to 000155 000158 From 000161 to 000165 000167 000171 From 000173 to 000174 000177 From 000179 to 000180 From 000182 to 000185 000188 From 000190 to 000193 From 000199 to 000201 000206 000208 From 000211 to 000212 000215 From 000217 to 000219 From 000222 to 000224 From 000226 to 000232 000234 000236 000238 From 000241 to 000243 From 000246 to 000248 000252 000256 From 000259 to 000260 000264 000267 000269 From 000271 to 000273 000280 From 000287 to 000288 000297 000299 000303 000310 Model: BB8C (cont d) 000316 000319 000321 000330 000333 000335 From 000337 to 000338 000341 000343 000345 000347 From 000349 to 000350 From 000352 to 000356 From 000358 to 000359 From 000364 to 000365 From 000367 to 000369 000371 From 000373 to 000375 From 000377 to 000380 000383 From 000385 to 000399 From 000401 to 000406 From 000408 to 000409 From 000411 to 000412 From 000414 to 000415 From 000417 to 000425 From 000427 to 000430 From 000435 to 000439 000442 From 000444 to 000446 000448 000451 From 000453 to 000454 From 000456 to 000459 From 000461 to 000463 From 000466 to 000468 000470 From 000475 to 000486 From 000488 to 000489 From 000491 to 000492 From 000494 to 000498 From 000500 to 000502 From 000504 to 000515 From 000517 to 000518 From 000521 to 000541 From 000543 to 000544 000546 From 000548 to 000551 From 000553 to 000558 000560 From 000563 to 000564 From 000566 to 000568 4 / 8 2008-4 Warranty Campaign
Model: BB8C (cont d) From 000571 to 000572 From 000574 to 000576 From 000579 to 000580 000582 From 000584 to 000590 000592 From 000594 to 000596 000598 000600 000605 From 000609 to 000614 From 000616 to 000620 000623 From 000626 to 000631 000633 From 000635 to 000639 From 000641 to 000642 000645 From 000648 to 000650 From 000653 to 000657 From 000659 to 000676 000678 000680 000689 000693 000696 000698 000702 000708 000715 000717 From 000722 to 000723 000733 From 000736 to 000737 000739 From 000742 to 000743 000747 000750 000762 000764 000768 000771 000774 000780 From 000786 to 000788 000791 000793 000797 000809 000819 Model: BB8D From to 000003 From 000005 to 000007 000013 000016 From 000018 to 000023 From 000025 to 000032 000034 000036 From 000038 to 000049 From 000051 to 000064 000066 From 000068 to 000097 From 000099 to 000114 From 000117 to 000124 From 000126 to 000130 From 000132 to 000153 From 000155 to 000164 From 000166 to 000171 From 000173 to 000178 From 000180 to 000200 From 000202 to 000204 From 000206 to 000219 From 000222 to 000224 From 000226 to 000227 From 000229 to 000231 From 000233 to 000234 From 000238 to 000239 000241 From 000243 to 000244 000246 000248 000250 From 000254 to 000257 From 000261 to 000263 From 000265 to 000266 000268 000270 From 000274 to 000275 From 000278 to 000279 From 000283 to 000284 From 000286 to 000287 000289 000291 From 000294 to 000296 000298 000300 From 000305 to 000308 000313 From 000318 to 000325 From 000327 to 000329 From 000331 to 000336 000338 From 000340 to 000344 From 000347 to 000351 From 000356 to 000357 From 000359 to 000366 From 000368 to 000370 000373 000376 000378 From 000380 to 000381 000383 From 000385 to 000391 From 000393 to 000401 000403 From 000406 to 000409 000411 From 000413 to 000414 000417 From 000420 to 000428 From 000430 to 000432 From 000434 to 000443 From 000446 to 000451 From 000453 to 000454 From 000456 to 000457 From 000459 to 000462 From 000464 to 000465 000469 000471 000482 From 000492 to 000493 From 000495 to 000496 000498 000500 000528 000533 000538 000548 From 000555 to 000556 000561 From 000564 to 000565 From 000570 to 000572 000575 000579 000581 From 000583 to 000586 From 000588 to 000591 000594 000598 From 000601 to 000603 From 000605 to 000606 From 000612 to 000613 From 000616 to 000617 From 000619 to 000621 From 000624 to 000628 000630 000632 From 000637 to 000639 From 000648 to 000649 000651 Warranty Campaign 2008-4 5 / 8
Model: BB8D (cont d) Model: BB8D (cont d) 000653 From 000655 to 000657 000661 000664 From 000677 to 000678 000698 000710 000736 000743 From 000751 to 000752 000755 000757 From 000761 to 000762 000765 000767 000779 000782 From 000784 to 000786 000789 000791 From 000795 to 000796 000799 From 000802 to 000804 From 000807 to 000812 From 000814 to 000815 From 000817 to 000818 From 000822 to 000826 000828 000830 000835 From 000837 to 000840 From 000843 to 000845 000847 000850 From 000854 to 000855 From 000859 to 000860 From 000862 to 000870 000872 000876 From 000878 to 000880 From 000883 to 000884 From 000886 to 000888 000891 From 000893 to 000896 From 000898 to 000902 000905 000907 000909 000911 000916 From 000921 to 000922 000924 000926 Model: BB8D (cont d) From 000932 to 000933 From 000935 to 000937 From 000939 to 000942 000946 From 000948 to 000950 000955 From 000957 to 000958 From 000960 to 000962 From 000964 to 000967 From 000970 to 000973 From 000975 to 000978 000980 000982 000984 From 000987 to 000990 000992 From 000997 to 000998 001000 From 001002 to 001003 001009 From 001018 to 001019 001023 Model: BB8E From to 000002 From 000004 to 000020 From 000023 to 000028 From 000030 to 000038 000040 From 000042 to 000044 From 000046 to 000048 From 000050 to 000051 From 000053 to 000054 000058 From 000063 to 000066 000069 000071 000073 From 000079 to 000080 000082 From 000084 to 000085 From 000087 to 000089 From 000091 to 000097 From 000099 to 000108 From 000110 to 000139 From 000141 to 000258 From 000260 to 000324 From 000326 to 000335 From 000337 to 000342 From 000344 to 000364 From 000366 to 000387 From 000389 to 000390 Model: BD8A 000002 From 000006 to 000008 000013 000016 000020 000022 000027 From 000034 to 000035 Model: BD8B From 000002 to 000003 From 000005 to 000006 000008 000010 000013 000015 000017 000019 000023 000029 000036 From 000038 to 000039 000043 000050 000052 000057 From 000063 to 000067 000069 000071 From 000073 to 000074 000076 000081 From 000086 to 000087 000089 000091 Model: BD8C From 000004 to 000006 From 000012 to 000018 000021 000026 000029 000035 000038 From 000040 to 000041 000055 From 000060 to 000061 From 000064 to 000066 000071 000074 000078 000085 000088 6 / 8 2008-4 Warranty Campaign
Model: BD8C (cont d) 000090 000092 000094 000098 000102 000108 000114 Model: BD8D 000003 From 000005 to 000006 000008 From 000011 to 000012 000014 000023 From 000025 to 000028 From 000032 to 000033 From 000040 to 000042 From 000049 to 000050 000052 000062 From 000070 to 000071 000078 000099 000101 000104 From 000106 to 000108 000110 From 000114 to 000115 From 000117 to 000121 000123 From 000125 to 000128 Model: BH8A From to 000009 From 000011 to 000039 From 000041 to 000089 From 000091 to 000120 Model: BH8B From to 000080 Model: CT8A 000016 From 000020 to 000021 000024 000048 000052 000056 000070 000079 000087 000111 000118 000135 000144 000155 000204 000210 000261 000267 000270 000273 000279 000299 000314 000316 000334 000336 000340 000344 From 000347 to 000348 000351 From 000373 to 000375 000378 000381 From 000383 to 000385 000388 From 000391 to 000394 From 000396 to 000397 000399 From 000402 to 000404 From 000406 to 000407 000409 000411 From 000413 to 000421 From 000424 to 000431 From 000434 to 000452 From 000454 to 000463 From 000465 to 000469 From 000471 to 000474 From 000476 to 000478 From 000480 to 000481 From 000484 to 000486 000488 From 000491 to 000516 From 000518 to 000545 From 000547 to 000559 From 000561 to 000594 From 000596 to 000614 000616 From 000618 to 000619 From 000621 to 000641 000644 From 000647 to 000650 From 000652 to 000655 From 000657 to 000659 000661 From 000663 to 000664 From 000666 to 000671 From 000673 to 000675 From 000677 to 000678 000680 From 000683 to 000685 000688 000692 000694 000696 000698 From 000709 to 000710 000720 000722 000724 000727 From 000732 to 000733 000736 From 000744 to 000745 From 000747 to 000748 000757 000760 From 000763 to 000765 000772 000774 000776 000786 000788 000798 From 000801 to 000821 From 000823 to 000835 000837 000839 000841 From 000844 to 000856 From 000858 to 000872 From 000874 to 000889 From 000891 to 000911 From 000913 to 000916 From 000918 to 000919 000921 From 000924 to 000926 From 000928 to 000934 From 000936 to 000938 From 000940 to 000941 From 000945 to 000946 000948 From 000950 to 000951 000959 From 000963 to 000964 From 000967 to 000968 000975 From 000982 to 000983 000991 Warranty Campaign 2008-4 7 / 8
Model: CT8A (cont d) Model: CT8A (cont d) 000993 001000 Model: MF8A From 000003 to 000009 From 000011 to 000044 From 000046 to 000105 From 000107 to 000121 From 000123 to 000156 From 000158 to 000165 From 000168 to 000191 From 000193 to 000211 From 000213 to 000227 From 000230 to 000232 From 000235 to 000249 From 000251 to 000259 From 000261 to 000277 From 000279 to 000283 000285 From 000288 to 000291 From 000293 to 000296 From 000298 to 000300 From 000302 to 000311 From 000313 to 000326 From 000328 to 000337 From 000339 to 000342 From 000344 to 000347 From 000349 to 000373 From 000375 to 000389 From 000392 to 000393 From 000396 to 000397 From 000399 to 000408 From 000410 to 000418 000420 From 000422 to 000424 From 000426 to 000428 From 000431 to 000442 From 000444 to 000447 From 000449 to 000454 From 000456 to 000457 From 000459 to 000473 From 000475 to 000477 From 000479 to 000501 From 000503 to 000506 From 000508 to 000512 From 000514 to 000578 From 000580 to 000600 From 000602 to 000624 From 000627 to 000628 From 000630 to 000638 From 000640 to 000700 Model: MF8B From 000004 to 000041 From 000043 to 000056 From 000058 to 000074 From 000076 to 000097 From 000099 to 000125 From 000127 to 000164 From 000166 to 000300 8 / 8 2008-4 Warranty Campaign