November 8, 2012 Subject:External Intercooler Replacement and Bleed Hose Installation No. 2012-12 REVISION 1 January 24 th, 2013 TEXT(S) BETWEEN ARROWS IS (ARE) MODIFIED ELEMENT(S) TO THE PREVIOUS PUBLICATION. YEAR MODEL MODEL NUMBER SERIAL NUMBER 2008 2009 2010 2011 2012 RXP X RXT X GTX LTD RXP X RXT is RXT RS RXT X GTX LTD RXP X RXT is RXT RS RXT X GTX LTD RXP Series RXT Series GTX LTD RXP Series RXT Series All All Flushing the intercooler with fresh water is essential to neutralize corroding effects of salt or other chemical products present in water. It will help to clean up sand, salt, shells or other particles in intercooler. Exhaust system and intercooler should be flushed each time: Watercraft is used in salt water and is not expected to be used further the same day. Watercraft is used in foul water. Watercraft is stored for any extended time. NOTICE The time to flush the exhaust has been updated at 90 seconds instead of 20 seconds. Please modify your shop manual and advise your client. Printed in Canada. (sbs2012-012_rev1 en WC-SC) 2012 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. 1/15
PARTS TO BE INSTALLED When ordering the 2008 to 2012 intercooler, it will automatically substitute to the 2013 version, along with the needed parts to install the new execution into the vehicle it was ordered for. This is a "bolt on" direct replacement. The original part number from the parts catalog must be ordered in order to get the new intercooler execution and all needed parts. MODEL YEARS ORIGINAL PART NUMBER 2008 to 2010 276 000 179 2011 to 2012 276 000 273 ITEM DESCRIPTION PART NUMBER 276 000 179 276 000 273 P1 Vent Kit 295 501 120-1 P1A Vent Hose Not Available Separately - 1 P1B Fitting Not Available Separately - 1 P1C Clamp Not Available Separately - 1 P2 Intercooler 276 000 319 1 1 P3 Foam (for MY08 to MY10 RXP-X Models Only) 270 000 848 2-2 / 15 2012-12 SERVICE
INSTALLATION INSTRUCTIONS Refer to the appropriate SHOP MANUAL and remove the following parts: ibractuator Intercooler. 2008 to 2010 Model Years Use the existing bleed hose already available in the hull. NOTE: This bleed may have had a plug installed if a more recent intercooler has been installed. 2011 and 2012 Model Years Hull Drilling NOTICE Make sure to use the appropriate template for each vehicle. 1 sbs2012-012-012_a 1. Provided template SERVICE 2012-12 3 / 15
NOTICE Before drilling, install a piece of tape at 25.4 mm (1 in) from the end of each drill bit. 25.4 mm (1 ) 10 mm (13/32 ) sbs2012-012-050_a 25.4 mm (1 ) 14 mm (9/16 ) sbs2012-012-051_a 4 / 15 2012-12 SERVICE
Using a 5/8 in counter sink bit, countersink the previously drilled hole until the countersunk area reaches 15 mm to 16 mm (19/32 in to 5/8 in) of diameter. NOTE: Countersink drilled holes reduce the possibility of gelcoat cracking during the thread cutting of a hole. 1 sbs2012-012-005_a 1. SNAP-ON METRIC TAP M16-2.00 (P/N T1620M) Bleed Hose Installation Cut the bleed hose [P1] to the proper length according to correct model. MODEL BLEED HOSE LENGTH RXT and GTX Series 525 mm (20-11/16 in) RXP Series 780 mm (30-11/16 in) SERVICE 2012-12 5 / 15
P1A 1 P1B sbs2012-012-022_a 1. LOCTITE 5900 (P/N 293 800 066) sbs2012-012-007_a 6 / 15 2012-12 SERVICE
5 N m sbs2012-012-008_a All Models Refer to the appropriate SHOP MANUAL and reinstall the following parts: New intercooler [P2] ibractuator. SERVICE 2012-12 7 / 15
NOTE: Make sure the clamp head is facing downwards before tightening, see illustration below for reference. P2 1 2 P1C 1.5 ± 0.2 N m 1 P1A sbs2012-012-023_a 1. Clamp head 1 2 P1A sbs2012-012-018_a 1. ibr actuator 2. Locking tie / as reference (P/N 293750047) 8 / 15 2012-12 SERVICE
IMPORTANT: Before re-assembly, please ensure that you lubricate the throttle body inner pivot with XPS LUBE (P/N 293 600 016) as shown on the following image. sbg2012-008-001_a 1. Lubricate here 2008 to 2010 RXP-X Models Install new foam [P3]. SERVICE 2012-12 9 / 15
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2011 RXP 3 in/po 50 mm 3 in/po 50 mm Ensure template is to scale/ S assurer que le gabarit est à l échelle sbs2012-012-102_a SERVICE 2012-12 11 / 15
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2012 RXP 3 in/po 50 mm 3 in/po 50 mm Ensure template is to scale/ S assurer que le gabarit est à l échelle sbs2012-012-100_a SERVICE 2012-12 13 / 15
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2011-2012 RXT and GTX 3 in/po 50 mm 3 in/po 50 mm Ensure template is to scale/ S assurer que le gabarit est à l échelle sbs2012-012-101_a SERVICE 2012-12 15 / 15