ski-doo pre-delivery - bweb.brp-jp.combweb.brp-jp.com/pdf/skpd2016-4 r1 en.pdf · predelivery kit...

PRE-DELIVERYBULLETIN

SKI-DOO®

June 2015 Subject:Ski-Doo REV-XS and REV-XM PredeliveryInspection

No. 2016-4

REVISION 1

August, 2015

TEXT(S) BETWEEN ARROWS IS (ARE) MODIFIED ELEMENT(S) TO THE PREVIOUS PUBLICATION.

YEAR MODEL

2016 REV-XS and REV-XM

TABLE OF CONTENTS

Page Page

IMPORTANT NOTICE ..... . . . . . . . . . . . . . . . . . . 3High altitude calibration.. . .. . . . . . . . . . . . . . . . . . . . 3

UPDATE SUMMARY..... . . . . . . . . . . . . . . . . . . . 4

MODEL LISTING..... . . . . . . . . . . . . . . . . . . . . . . . . 4

PREDELIVERY KIT PARTS LIST ... . . . . . . . 5

1- UNCRATING..... . . . . . . . . . . . . . . . . . . . . . . . . . . 8Crate Cover.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Crate Brackets .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Crate Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Rear Suspension Shipping Hook(s) . . . . . . . . . . 9

2- PARTS TO BE INSTALLED ..... . . . . . . . . 10Front Shock Absorbers .. . . . . . . . . . . . . . . . . . . . . . . 10

Skis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Ski flotation extension .. . . . . . . . . . . . . . . . . . . . . . . . 16

Battery .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Handlebar . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Steering Cover . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Handlebar Wind Deflector (ApplicableModels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Tools and Emergency Starting Rope.. . . . . . . . 21

Heated Visor Extension (Expedition, GrandTouring and Renegade Enduro) . . . . . . . . . . . . . . . 22

Drive Belt Installation .. . . . . . . . . . . . . . . . . . . . . . . . . 22

Passenger Seat Installation (Expedition Sportand Grand Touring Sport) . .. . . . . . . . . . . . . . . . . . . . 23

Passenger Seat and Heated Handholds (GrandTouring Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Tunnel Bag (Grand Touring SE) . . .. . . . . . . . . . . . 26

Saddlebags (Grand Touring SE) . . .. . . . . . . . . . . . 26

Hitch (Expedition Sport and Grand TouringSport Europe) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Snow Guard .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Rear Bumper ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Side Reflectors.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Front Reflector (European Models) . . . . . . . . . . 27

Snowboard and Ski Rack (Summit BurtonModel). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3- FLUIDS ... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29General Guidelines .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Fuel . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Chaincase Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Injection Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Brake Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Engine Oil (600 ACE, 900 ACE and 12004-TEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4- UPPER BODY MODULE INSTALLA-TION..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Front Storage Compartment Cover . . . . . . . . . . 33

Console Wind Deflectors (if Equipped) . . . . . . 33

Windshield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Mirrors (Grand Touring Models) . .. . . . . . . . . . . . 34

Printed in Canada. (mbl2016-002_rev1 en ML MS)©2015 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.

1 / 39

®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.

5- SET-UP ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Doing All Recalls and All Other ModificationsRequested by BRP .. .. . . . . . . . . . . . . . . . . . . . . . . . . . 34

Programming Using B.U.D.S. . .. . . . . . . . . . . . . . . 34

Track .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6- ADJUSTMENTS (CUSTOMERPREFERENCE) .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Rear Suspension Adjustments .. . . . . . . . . . . . . . 38

7- FINAL INSPECTION..... . . . . . . . . . . . . . . . . . 39Controls, Equipments, Movement andOperation Inspection .. . . . . . . . . . . . . . . . . . . . . . . . . . 39

Test Run Snowmobile . . . . . . . . . . . . . . . . . . . . . . . . . 39

Snowmobile Cleaned and in ShowroomCondition.. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Vehicle Delivery ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2 / 39 2016-4 PREDELIVERY

IMPORTANT NOTICE

IMPORTANT NOTICEThis bulletin must be used in conjunction with check list enclosed in bag with OPERATOR’S GUIDE. Makesure that PREDELIVERY CHECK LIST is completed and signed.

WARNING

To obtain limited warranty coverage, predelivery procedures must be performed by an autho-rized BRP Ski-Doo snowmobile dealer/distributor. Apply all necessary torques as indicated.

NOTE: The information and components/system descriptions contained in this document are correctat time of publication. Bombardier Recreational Products Inc. (BRP) however, maintains a policy ofcontinuous improvement of its products without imposing upon itself any obligation to install them onproducts previously manufactured.Due to late changes, there might be some differences between manufactured product and descriptionsand/or specifications in this document. BRP reserves the right at any time to discontinue or changespecifications, designs, features, models or equipment without incurring obligation.The illustrations in this document show typical construction of different assemblies and may notreproduce full detail or exact shape of parts. However, they represent parts that have same or similarfunction.Content of this bulletin is designed as a guideline only. All mechanics performing predelivery proceduresshould have attended current model year service training.Further information or inquiries should be directed to your distributor service representative and/orspecific SHOP MANUAL sections.Please complete PREDELIVERY CHECK LIST for each snowmobile and retain a customer signed copy.Make sure customer receives OPERATOR’S GUIDE, PREDELIVERY CHECK LIST signed copy andSAFETY DVD VIDEO

There is a tag attached to ignition key, only customer must remove it. This label will remind cus-tomer to ask dealer/distributor to perform suspension adjustments according to riding style andvehicle load.

WARNING

Torque wrench tightening specifications must strictly be adhered to. Where specified, install newlocking devices (e.g. lock tabs, elastic stop nuts). If the efficiency of a locking device is impaired,it must be renewed.

High altitude calibrationNOTE:

– Summit North American models are factory calibrated to be ridden at altitudes ranging from600 m to 2 400 m (2,000 ft to 8,000 ft).

– European Summit models and all other models are factory calibrated for sea level riding unless themodel is specifically stated as a High altitude model.

– If not re-calibrated for proper altitude use, severe engine damage may occur.

– ALWAYS refer to model year HIGH ALTITUDE SERVICE BULLETIN.

PREDELIVERY 2016-4 3 / 39

MODEL LISTING

UPDATE SUMMARYThis summary highlights updates to the Predelivery Inspection for MY 2016. It does not supersede pro-cedures detailed further in this publication.

IMPORTANT: Technicians should read and apply all procedures in this PDI bulletin as applicable to model.

APPLICABLE TO UPDATE DESCRIPTION REFERENCE

Renagade™ X™, X-RS™ andEnduro; MX Z™ X™, X-RS™and Blizzard™; Grand TouringSE

New adjustable Pilot TS ski installationprocedure

-Parts to be install.

t-Motion suspension equippedvehicles

New rear idler wheels tighteningtorque

-Set-up

All models New MPI interface card -Set-up

1200 4-TEC engine equippedvehicles

New Engine in REV-XS platform-Parts to be install-Fluids

MX Z™ and Renegade™series, Grand Touring SE,Summit™ 174"

New Predelivery kitModel listing and predelivery kit partslist

Vehicle equipped withhandlebar air deflector

Updated procedure -Parts to be install.

Summit™ and Freeride Ice scratchers and idler wheels utility Set-up

MODEL LISTINGMODEL MODEL NUMBER PDI KIT PART NUMBER

MKGB, MKGD, MKGF, MKGH,MMGB, MMGD, MMGF, MMGH,MXGC,MXGD, MXGG, MXGH,MXGL, MXGM, MXGQ, MXGR,NYGA, PYGA, UAGB, UAGD, UAGF,UAGH, UMGB, UMGD, UMGG,UMGJ, UTGB, UTGD, UTGF, UTGH,UVGB, UVGD, UVGF, UVGH,UWGB, UWGD, UWGF, UWGH,UYGA, UZGA

549 011 494 (with adjustable skis)

MX Z and Renegade series (exceptEnduro)

BXGA, BXGB, MAGA, MAGB,MBGA, MBGB, MBGC, MCGA,MCGB, MDGA, MDGB, MKGA,MKGC, MKGE, MKGG, MLGA.MLGB, MMGA, MMGC, MMGE,MMGG, MMGJ, MNGA, MNGB,MXGA, MXGB, MXGE, MXGF,MXGJ, MXGK, MXGN, MXGP,MXGS, MYGA, MYGB, MUAGA,UAGC, UAGE, UAGG, UCGA,UDGA, UDGB, UEGA, UEGB,UFGA, UFGB, UGGA, UGGB,UGGC, UGGD, UJGA, UJGB,UJGC, UJGD, UMGA, UMGC,UMGE, UMGF, UMGH, UMGK,UTGA, UTGC, UTGE, UTGG, UVGA,UVGC, UVGE, UVGG, UWGA,UWGC, UWGE, UWGG, UXGA,UXGB, UXGC, UXGD, UXGE, UXGF,UXGG, UXGH, UXGJ

549 011 495 (without adjustableskis)


PREDELIVERY KIT PARTS LIST

MODEL MODEL NUMBER PDI KIT PART NUMBER

Renegade EnduroUBGA, UBGB, UNGA, UNGB,URGA, USGA

549 011 497

Expedition® Sport KCGA, KDGA, KDGB 549 011 445

ERGA 549 011 493 (with adjustable skis)

Grand Touring seriesEAGA, EPGA, ESGA, ETGA, ETGB

549 011 478 (without adjustableskis)

Freeride and Summit series (except174")

CDGA, CDGB, CDGC, CDGD,CDGE, CEGA, CEGB, CEGC, CEGD,CEGE, CEGF, CFGA, CFGB, CFGC,CFGD, CFGE, CFGF, CCGA, CCGB,CCGC, CCGD, CCGE, CCGF, CGGA,CGGB, CGGC, CGGD, CHGA,CHGB, CHGC, CHGD, CXGA,CXGB, CXGC, CXGD, CXGE, CXGF,TCGA, TCGB, TDGA, TDGB, TDGC,TDGD, TDGE, TDGF, TDGG, TDGH,TDGJ, TDGK, TDGL, TDGM, TJGA,TJGB, TJGC, TKGA, TKGB, TKGC,TKGD, TKGE, TKGF, TKGG, TKGH,TKGJ, TKGK, TKGL, TKGM, VAGA,VAGB, VAGC, VBGA, VBGB, VBGC,VBGD, VCGA, VCGB, VCGC, VCGD

549 011 480

Summit 174"

TEGA, TEGB, TEGC, TEGD, TEGE,TEGF, TEGG, TEGH, TEGJ,TEGK,TEGL, TEGN, CKGA, CKGB, CKGC,CKGD

549 011 496

PREDELIVERY KIT PARTSLIST

KIT 549 011 497 (RENEGADE ENDURO MODEL)

WHERE USED DESCRIPTION PART NUMBER QTY

Accessories Heated visor wire 515 175 851 1

Rear suspension Wheel Cap 503 192 771 2

M10 Washer 503 192 496 2Front suspension and skis

M10 flanged nut 233 201 464 6

Steering Torx screw 250 000 760 2

Rear bumper M6 X 18 Torx screw 250 000 779 4

3/16 pop rivet 293 150 108 4Snow guard

Washer 517 124 300 4



KIT 549 011 478 (GRAND TOURING MODELS WITHOUT ADJUSTABLE SKIS)




M10 Washer 503 192 496 2

M10 flanged nut 233 201 464 6Front suspension and skis

Ski stopper 505 072 594 2


Washer 224 061 201 2

M6 X 16 screw 207 361 644 2Passenger seat

M6 X 30 screw 207 563 044 2

Washer 224 061 201 8Rear bumper

M6 X 18 Torx screw 250 000 779 8


Washer 517 124 300 4

KIT 549 011 493 (GRAND TOURING MODELS WITH ADJUSTABLE SKIS)





M10 flanged nut 233 201 464 6


Washer 224 061 201 2


M6 X 30 screw 207 563 044 2


M6 X 18 Torx screw 250 000 779 8


Washer 517 124 300 4

KIT 549 011 494 (MX Z, AND RENEGADE MODELS WITH ADJUSTABLE SKIS EXCEPT ENDURO)


Rear Suspension Wheel Cap 503 192 771 2


M10 nuts 233 201 464 6


M6 X 18 Torx screw 250 000 779 4


Washer 517 124 300 4



KIT 549 011 495 (MX Z, AND RENEGADE MODELS WITHOUT ADJUSTABLE SKIS)



M10 Washer 503 192 496 2

M10 nuts 233 201 464 6Front suspension and skis



M6 X 18 Torx screw 250 000 779 4


Washer 517 124 300 4

KIT 549 011 445 (EXPEDITION MODELS)




M10 Washer 503 192 496 2

M10 flanged nut 233 201 464 6Front suspension and skis


M6 X 18 Torx screw 250 000 779 6Rear bumper

Washer 224 061 201 2

Washer 224 061 201 2


M6 X 30 screw 207 563 044 2


Washer 517 124 300 4

KIT 549 011 480 (SUMMIT MODELS EXCEPT 174")



M10 Washer 503 192 496 2




M6 X 18 Torx screw 250 000 779 10


Washer 517 124 300 4


1- UNCRATING

KIT 549 011 496 (SUMMIT 174"MODEL)



M10 Washer 503 192 496 2




M6 X 18 Torx screw 250 000 779 6


Washer 517 124 300 4

Additional provided hardware:

– Black hardware for ski and front shock absorbers (should be used to enhance the look of this model).

1- UNCRATING

Crate Cover1. Carefully lay crate on its bottom.

NOTICE Allowing crate to drop may cause se-rious damage to vehicle.

2. Remove all screws retaining crate top to side-walls.

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3. Remove screws securing sidewalls to cratebase.

4. Unscrew sidewalls one at the time.

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5. Remove polyethylene foam sheets.

NOTICE Do not remove protective wrappinguntil delivery to customer.

6. Remove parts to be installed from vehicle orcrate base.

Crate Brackets

CAUTION Make sure vehicle is properlysupported before removing ski legs and rearsuspension from crate brackets.

1. Cut locking ties and remove ski leg wood pro-tectors (if applicable).

2. Detach ski legs from crate shipping brackets.

3. Discard shipping washers, spacers and nuts.

Keep ski leg screws and ski stance spacers (if ap-plicable) for skis installation.

Discard shipping bracket.


1- UNCRATING

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TYPICAL - MODELS WITHOUT ADJUSTABLE STANCE1. Ski screw (keep)2. Shipping spacers (discard)3. Nut (discard)4. Washer (discard)

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TYPICAL - MODELS WITH ADJUSTABLE STANCE1. Ski screw (keep)2. Stance setting spacer3. Shipping spacers (discard)4. Nut (discard)5. Shipping bracket (discard)

AAAAllllllll eeeexxxxcccceeeepppptttt SSSSuuuummmmmmmmiiiitttt XXXX aaaannnndddd SSSSPPPP wwwwiiiitttthhhh TTTT3333 ppppaaaacccckkkkaaaaggggeeee

4. Using a pry bar, remove wood blocks retainingtrack to crate base.

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1. Track2. Wood block

SSSSuuuummmmmmmmiiiitttt XXXX aaaannnndddd SSSSPPPP wwwwiiiitttthhhh TTTT3333 ppppaaaacccckkkkaaaaggggeeee

5. Cut the strap retaining the track to crate base.

6. Remove vehicle from crate base.

Crate DisposalNOTE: The ECO crate is designed to be disassem-bled easily in order to be stacked with very lowheight or to be disposed as per environmental reg-ulations.

1. Pull canvas off wood structures.

2. Stack or dispose as per local environmental reg-ulations.

Rear Suspension ShippingHook(s)

NOTICE Rear bumper must be installed be-fore removing the shipping hooks.

NOTICE:NEVER APPLY PRESSURE ON

REAR END OF TUNNEL WHILE REARBUMPER IS NOT INSTALL

Irreversible damage to the chassis may occurif this notice is not respected

WARNING

Shipping hooks must be removed to havesnowmobile suspension operational.

WARNING

Before removing hooks, always verify thatvehicle is properly supported and that park-ing brake is applied.

1. Apply parking brake.

2. Install snow guard. Refer to SNOW GUARD fur-ther in this document.


2- PARTS TO BE INSTALLED

3. Install rear bumper. Refer to REAR BUMPERfurther in this document.

4. Lift rear of vehicle so that a block or a box canbe positioned under front idler wheels.

5. Ask another person to apply pressure onto rearsuspension.

6. Remove front hook(s) from suspension.

mbl2009-010-200_a

TYPICAL1. Idler wheel2. Front hook

7. Lift front of vehicle to position bumper approx-imately 1 m (39 in) above the ground.

NOTICE Never stand on the seat.

8. Apply pressure onto rear suspension and asksomeone to remove rear hook.

2- PARTS TO BEINSTALLED

Front Shock AbsorbersAccess to Upper Front Shock AbsorberBolts

To access the shock upper bolts, remove the up-per body module as follows:

1. Remove the gauge.

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Step 1: UnlockStep 2: Tilt

2. Disconnect the gauge connector.

3. Disconnect the headlights connector.

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1. Headlights connector

4. Open side panels.

NOTICE The removal of side panels is notrequired but its a good practice to avoidscratching them during vehicle preparation.When side panels are removed, make sure toplace them in a safe place.

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Step 1: UnlatchStep 2: Pull to release side panel pinStep 3: slightly lift and open panel



5. Remove the drive belt guard.

6. Disconnect the air intake connector tube.

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Step 1: Lift tabStep 2: Twist tubeStep 3: Pull forward

7. Disconnect air temperature sensor (ATS) on topof connector tube.

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1. ATS connector

8. Open RH side panel.

9. Disconnect the APS hose at the ECM.

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1. ECM2. APS hose

10. On both sides, remove the upper body moduleretaining screws.

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RH SIDE SHOWN1. Retaining screws

11. Remove the upper body module.

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SLIDE TOWARDS FRONT

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1. LH upper shock (shipping bracket) bolt

Front Suspension Shipping BracketsRemoval

1. Remove and discard spring clips



2. Keep washer, upper M10 x 65 and lower M10x 55 bolts for front shock absorbers installation.

4

2

2

31

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1. Shipping brackets2. Spring clips3. Washers and upper bolt4. Lower bolt

3. Remove and discard shipping brackets.

Front Shock Absorber Installation

Install front shock absorbers using the previouslyremoved M10 screws and washer, and new M10flanged nuts (predelivery kit). Refer to followingtable for correct shock orientation.

SHOCK ABSORBER ORIENTATION

SHOCK

ABSORBER TYPEMODEL POSITION

HPG, HPG Plus,HPG Plus R,KYB PRO 40

Expedition Sport (Europe)FreerideMX Z series(except Sport model)Renegade series(except Sport model)Summit seriesGrand Touring LE/SE

Body UP

Motion Control(MC)

ExpeditionSport (CAN/US)MX Z SportRenegade SportGrand Touring Sport

BodyDOWN

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TYPICAL - MC SHOCK1. Body down

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ALL SHOCKS EXCEPT MC1. Body up

Tighten flanged nut to specification.

TIGHTENING TORQUE

Front shock absorberretaining nuts

48 N•m (35 lbf•ft)

MMMMXXXX ZZZZ XXXX----RRRRSSSS aaaannnndddd FFFFrrrreeeeeeeerrrriiiiddddeeee

Install the shock absorbers as per following tablein order to place the reservoirs outwards and to-wards front.



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MX Z X-RS AND FREERIDE (NARROW STANCE)1. Reservoir (outwards and towards front)

MX Z X-RS AND RENEGADE X-RSSHOCK ABSORBERS

SHOCK P/N VEHICLE SIDE

(P/N 505 073 612) LH

(P/N 505 073 613) RH

FREERIDE SHOCK ABSORBERS

SHOCK P/N VEHICLE SIDE

(P/N 505 073 123) LH

(P/N 505 073 124) RH

SkisSki without Adjustable Stance / Runner

Ensure ski leg bushings are still on ski legs.

1. Install ski stopper on the ski.

NOTE: Position indicator at front and make surethe bump in the ski is in the groove of the ski stop-per.

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TYPICAL1. Ski stopper2. Bushings

2. Install ski on ski leg using the hardware asshown.

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1. Ski stopper (predelivery kit)2. M10 x 130 bolt (previously removed)3. M10 flat washer (predelivery kit)4. M10 flanged nut (predelivery kit)5. Ski leg bushings6. Ski leg sleeve7. Ski leg stopper


TIGHTENING TORQUE

Ski retaining nut 48 N•m (35 lbf•ft)

Ski with Adjustable Stance


1. Install ski stopper on the ski.

NOTE: Position indicator at front and make surethe bump in the ski is in the groove of the ski stop-per.

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TYPICAL1. Ski stopper2. Bushings

2. Install ski on ski leg using the hardware asshown.

SKI STANCE SETTING

Narrow Place spacer on the inside of ski leg

Wide Place spacer on the outside of ski leg



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LH SIDE SHOWN1. Ski stopper (predelivery kit)2. M10 x 130 bolt3. M10 flat washer (predelivery kit)4. M10 flanged nut (predelivery kit)5. Ski axel6. Narrow adjustment7. Wide adjustment


TIGHTENING TORQUE

Ski retaining nut 48 N•m (35 lbf•ft)

Ski with Adjustable Runner (Pilot TS)

SSSSkkkkiiii IIIInnnnssssttttaaaallllllllaaaattttiiiioooonnnn


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1. Ski stoppers (ski kit)2. Ski bushings

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1. Rubber bushing (ski kit)2. Ski leg bushings

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ADJUSTER

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1. Adjuster bushings (ski kit)2. Ski leg sleeve (previously removed)



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1. Carbide runner (ski kit)2. Pin (ski kit)

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1. Ski screw (previously removed)2. Nut (predelivery kit)

TIGHTENING TORQUE

Ski retaining nuts 48 N•m (35 lbf•ft)

SSSSkkkkiiii RRRRuuuunnnnnnnneeeerrrr AAAAddddjjjjuuuussssttttmmmmeeeennnntttt

Ski lateral grip is adjustable. Turning handle clock-wise (+) make the runner protruding more bellowski sole and so increase lateral grip.

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ADJUSTMENT KNOB

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PILOT TS SKIS ADJUSTMENT KNOB1. Position 12. Position 5

PILOT TS SKI ADJUSTABILITY

Position Lateral grip HandlingPossible

understeeringPossible

oversteering

1 * * ***

2(1) ** ** **

3 *** *** * *



PILOT TS SKI ADJUSTABILITY

4 **** **** **

5 ***** ***** ***

(1)Recommended position for delivery to customer (Similar reaction as Pilot 5,7 skis)

Ski flotation extensionCondition Utilization

The key to the adjustable nose is to reduce thetip-hop that can slow down the vehicle.

In snow conditions with less than 41 cm (16 in) offresh powder, specially when there is a crust, thenarrow tip stays in the snow - which helps to main-tain a carve. Also, when side hilling, and crossinga snowmobile rut, the narrow shape moves theimpact point - where a change in snow densityacts to tip-up the ski - more towards the spindle.This reduces kick back by 50% compared to thewider configuration, minimizing its impact on theattitude of the snowmobile holding a side hill.

In snow conditions with more than 41 cm (16 in)of fresh powder, the wider tip configuration is de-sirable, as it increases flotation and will bring thenose of the snowmobile up.

Ski Flotation Extension Installation

1. Slide the extension on the ski.

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2. Make sure the extension is correctly installedand use its holes on the back as a template todrill the ski. Use a 6.5 mm (1/4 in) drill bit.

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3. Install extension fasteners with nuts towardsup and tighten to specification.

TIGHTENING TORQUE

Extension nuts 3 N•m (27 lbf•in)

BatteryMMMMooooddddeeeellllssss WWWWiiiitttthhhh EEEElllleeeeccccttttrrrriiiicccc SSSSttttaaaarrrrtttteeeerrrr

Battery Removal (if Shipped Installed)

WARNING

Battery BLACK ( – ) cable must always bedisconnected first and connected last. Nevercharge or boost battery while installed onvehicle.

1. Open the right side panel of the vehicle.

EEEE----TTTTEEEECCCC EEEEnnnnggggiiiinnnneeee MMMMooooddddeeeellllssss

2. Remove the battery bracket.



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REAR OF BATTERY1. Lower bracket screw

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FRONT OF BATTERY1. Upper bracket screw

3. Remove the battery.

AAAACCCCEEEE aaaannnndddd 4444----TTTTEEEECCCC EEEEnnnnggggiiiinnnneeee MMMMooooddddeeeellllssss

4. Remove screw on RH side bottom pan panel.

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5. Remove battery bracket screws.

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6. Pull slightly on the bottom pan panel and re-move the battery with the bracket.

Battery Preparation

Refer to the latest edition of SKI-DOO BAT-TERIES ACTIVATION, CHARGING AND MAIN-TENANCE BULLETIN for proper activating,charging and maintenance procedure.

NOTE: It is recommended to always have a fullycharged battery in the workshop, ready to be in-stalled.

Battery Installation

1. Properly position the charged battery on itsrack.

2. Install the bracket.

3. Connect the RED ( + ) cable to the battery pos-itive terminal.

NOTE: Position the RED cable terminal vertically.

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E-TEC ENGINE



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ACE AND 4-TEC ENGINE

4. Connect BLACK ( – ) cable LAST.

WARNING

Battery BLACK ( – ) cable must always bedisconnected first and connected last. Nevercharge or boost battery while installed onvehicle.

5. Cover the RED ( + ) terminal with rubber boot.

Handlebar1. Loosen the lower steering extension retaining

screws.

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1. Steering extension2. Retaining screws

2. Lift steering extension and position it as per thefollowing table.

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TYPICALA. Steering extension angle

VEHICLE RECOMMENDED ANGLE

Summit, GrandTouring, Expedition

Sport, Freeride,Renegade

Backcountry andBackcountry X

40°(from vertical)

MX Z andRenegade (exceptBackcountry andBackcountry X)

20°(from vertical)

NOTICE Make sure brake hose is routed overthe steering extension



mbl2009-010-209_c

TYPICAL - BRAKE HOSE ROUTING1. As delivered (routed below steering column)2. Correct hose routing when set up

3. Tighten steering extension lower screws tospecification.

TIGHTENING TORQUE

Steering extensionlower screws

24 N•m (18 lbf•ft)

4. If necessary, adjust handlebar so that brakefluid reservoir is level, tighten steering exten-sion upper screws to specification.

TIGHTENING TORQUE

Steering extensionupper screws

24 N•m (18 lbf•ft)

NOTICE Make sure brake fluid reservoir islevel.

5. Cut the tie wrap securing the tether cord tothe riser block. Do not attach the throttle ca-ble with a new one.

6. Connect steering harness connectors.

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TYPICAL1. Connectors

Steering CoverFFFFrrrreeeeeeeerrrriiiiddddeeee aaaannnndddd SSSSUUUUMMMMMMMMIIIITTTT XXXX

Pass the rear lower part of the cover trough theappropriate opening in the riser block.

Secure cover with the snap fasteners.

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TYPICAL - FRONT VIEW1. Lower part trough the riser block2. Snap fasteners

AAAAllllllll MMMMooooddddeeeellllssss EEEExxxxcccceeeepppptttt FFFFrrrreeeeeeeerrrriiiiddddeeee,,,, GGGGrrrraaaannnndddd TTTToooouuuurrrriiiinnnnggggLLLLEEEE //// SSSSEEEE aaaannnndddd SSSSUUUUMMMMMMMMIIIITTTT XXXX

Install steering cover by pushing it in place.

Route throttle cable and wiring properly.



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TYPICAL1. Steering cover2. Throttle cable3. RH wiring

GGGGrrrraaaannnndddd TTTToooouuuurrrriiiinnnngggg LLLLEEEE //// SSSSEEEE

Install steering cover with screw holes towardsrear.

Fasten steering cover using the 2 Torx screwssupplied in predelivery kit.

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Handlebar Wind Deflector(Applicable Models)On each side:

1. Insert arm into deflector.

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2. Position trim tab inside slot on deflector.

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3. Slide trim into place along deflector and overarm.

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4. Secure deflector assembly using K50 x 20 Torxscrew.



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5. Cut the handlebar wiring locking ties.

6. Place the arm against the handlebar.

7. Install the clamp with screws but do not tightenyet.

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8. Set the deflector horizontally and tightenscrews to specification.

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TIGHTENING TORQUE

Wind deflector screws 3.5 N•m (31 lbf•in)

9. Secure handlebar wiring with new locking ties.

WARNING

Turn handlebar completely from side to sidemaking sure that wind deflectors do not inter-fere with handlebar controls and accessories(throttle lever, brake lever, emergency enginestop switch, windshield, etc).

Tools and Emergency StartingRopeSecure the tools on the drive belt guard.

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TOOL KIT

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TOOLS STOWED

Stow the emergency starting rope in the openingon the LH of bottom pan.

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1. Emergency starting rope2. Opening



Heated Visor Extension(Expedition, Grand Touringand Renegade Enduro)1. Connect heated visor extension (predelivery kit)

to heated visor jack.

Drive Belt Installation1. Remove tether cord cap (D.E.S.S. key).

2. Open LH side panel.

3. Remove drive belt guard.

4. Insert the driven pulley expander provided inthe tool kit in the threaded hole on the adjusterhub as shown.

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1. Pulley expander

5. Open the driven pulley by screwing the tool in.

6. Clean pulleys before installing drive belt usingPULLEY FLANGE CLEANER (P/N 413 711 809).

7. Slip the belt over the drive pulley, then over thedriven pulley.

NOTICE Do not force or use tools to pry thebelt into place, as this could cut or break thecords in the belt.

NOTE: The maximum drive belt life span is ob-tained when belt is installed with arrows in thedirection of rotation.

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TYPICAL1. To be pointed in the direction of rotation

8. Unscrew and remove the driven pulley ex-pander from the pulley.

9. Rotate the driven pulley several times to prop-erly set the belt between the sheaves.

Adjust drive belt as follows:

1. Loosen the clamping screw.

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1. Adjuster hub2. Clamping screw

2. Using the suspension adjustment tool providedin the tool kit, turn the ring 1/4 turn at a timethen rotate the driven pulley to properly set thebelt between the pulley sheaves.

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1. Suspension adjustment tool

NOTE: The adjustment ring has left hand treads.

999900000000 AAAACCCCEEEE aaaannnndddd 1111222200000000 4444----TTTTEEEECCCC MMMMooooddddeeeellllssss wwwwiiiitttthhhhEEEElllleeeeccccttttrrrroooommmmeeeecccchhhhaaaannnniiiiccccaaaallll RRRReeeevvvveeeerrrrsssseeee

Repeat step 2 until the external surface of drivebelt is even with the driven pulley edge.



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TYPICAL - PRELIMINARY SETTING1. Cogs are even with pulley

BBBBeeeelllltttt WWWWiiiitttthhhhoooouuuutttt CCCCooooggggssss

Repeat step 2 until the drive belt is even with thedriven pulley edge.

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PRELIMINARY SETTING1. Drive belt flush with driven pulley edge

BBBBeeeelllltttt WWWWiiiitttthhhh CCCCooooggggssss

Repeat step 2 until the lowest portion of the cogson the external surface of drive belt is even withthe driven pulley edge.

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TYPICAL - PRELIMINARY SETTING1. Lowest portion of cogs even with external surface of drive belt

AAAAllllllll bbbbeeeelllltttt ttttyyyyppppeeeessss

NOTE: Turning the ring counterclockwise lowersthe belt in the pulley. Turning the ring clockwiseraises the belt in the pulley.

3. Firmly tighten the clamping screw.

TIGHTENING TORQUE

Clamping Screw5.5 N•m ± 0.5 N•m(49 lbf•in ± 4 lbf•in)

4. Install belt guard.

5. Close side panel.

NOTE: This setting is correct as a preliminary ad-justment for most models and belt types. In somecases, when starting the engine, the vehicle couldcreep, indicating that the belt is too tight.

If the vehicle creeps, lower the drive belt, installbelt guard and side panel, then start engine. Re-peat until creeping stops.

Reverse Activation

NOTE: The reverse may not activate or may beharder to activate if the belt is positioned too highin the driven pulley. If reverse activation does notwork properly, ensure the drive belt is properly ad-justed. Adjust the drive belt lower in the drivenpulley if needed.

Passenger Seat Installation(Expedition Sport and GrandTouring Sport)Passenger Handholds Installation (GrandTouring Sport)

Work on one side at a time.

1. Remove the lower backrest support retainingscrews.

2. Pass the handhold electrical harness throughthe opening in the seat cover.

3. Route the cable in the backrest support slot andopening.

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1. Slot2. Opening

4. Reinstall backrest support retaining screws.Tighten to the specified torque.

TIGHTENING TORQUE

Backrest supportretaining screws

25 N•m (18 lbf•ft)

5. From underneath the seat, pull the electricalharness while moving the handhold closer tothe seat to eliminate the slack in the wiring.



6. Position the handhold on the backrest support.

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1. Backrest support2. Handhold

7. Secure the handhold using the retaining plateand screw. Tighten to the specified torque.

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1. Retaining plate2. Screw

TIGHTENING TORQUE

Handhold retainingscrew

25 N•m (18 lbf•ft)

8. From underneath the seat, attach connectors tothe retaining clips each side.

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TYPICAL1. Clip2. Connector

9. Connect heated grip connectors to passengerseat electrical harness.

Passenger Seat Installation

1. Place passenger seat over mounting holes intunnel.

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1. Passenger seat mounting holes

2. Secure seat using the provided hardware (pre-delivery kit).

– Use M6 X 30 flanged screws at rear.

– Use M6 X 16 screws and washers at front.

Passenger Seat and HeatedHandholds (Grand TouringModels)1. Remove bolts and curved plates from heated

handles.



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1. Heated handle2. Bolts3. Curves plates

2. On each side of passenger seat, pull seat coverjust enough to clear wire loom holes.

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1. Pull seat cover2. Wire loom hole

3. Position each handle toward front and insertelectrical connectors into wire loom holes.

NOTE: The 2 passenger heated handles have dif-ferent size connectors. Make sure you install han-dles on the proper side.

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1. Insert connector

4. From under the seat, attach connectors to theretaining clips each side.

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1. Clip2. Connector

5. Connect heated grips to passenger seat wireharness.

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1. Passenger seat wire harness2. Heated handle connector

6. Insert handles on the rods each side of passen-ger seat and fasten with previously removedbolts and curved plates, as shown.

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1. Bolts2. Curved plates3. Heated handle



TIGHTENING TORQUE

Bolts 31.5 N•m (23 lbf•ft)

Install passenger seat:

7. Put the passenger seat behind the driver's seat.Let enough space between the seats to con-nect the accessories connector.

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1. Accessories connector (behind driver's seat)2. Accessories connector (passenger seat)

8. Slightly incline the passenger seat towardsfront and engage seat hooks in the tunnel slotslocated behind the driver's seat.

mmo2009-005-013 _a

1. Driver's seat2. Tunnel slot

9. Push the front portion of the passenger seat to-wards the driver's seat and firmly push the rearportion down to lock the passenger seat in po-sition.

NOTE: A distinctive snap will be felt. Doublecheck that the seat is secure by giving it a tug toconfirm proper latching.

Tunnel Bag (Grand Touring SE)Secure to the rack using the hook and loops strapsas shown.

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1. Velcro strap2. Rear rack

The retaining hook and loops straps can be hiddenin side pouches. The side pouches flaps are hid-den in the bottom lining of the tunnel bag.

Saddlebags (Grand Touring SE)1. Insert the metal tabs, located on the rear

bumper, in the saddlebag slots.

2. Firmly push the top of the saddlebag towardsthe vehicle. A "snap" will be felt when the sad-dlebag is properly secured. Make sure the sad-dle bags are properly secured before getting un-derway.

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Step 1: Insert tabsStep 2: Push towards vehicle

Hitch (Expedition Sport andGrand Touring Sport Europe)Install hitch using the mounting holes in the rearbumper.

TIGHTENING TORQUE

Hitch bolts 31 N•m (23 lbf•ft)



Snow GuardFrom underneath the rear portion of tunnel, re-move screws securing tail light.

Secure the snow guard using the 3/16 pop rivetsand washers (predelivery kit).

Reinstall previously removed screws.

TIGHTENING TORQUE

Tail light retaining screws 0.4 N•m (4 lbf•in)

Rear Bumper1. Align holes of rear bumper with frame holes.

SSSSttttaaaannnnddddaaaarrrrdddd BBBBuuuummmmppppeeeerrrr

2. Secure rear bumper to frame using M6 x 16Torx screws (predelivery kit).

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25.4 MM (1 IN) HEIGHT BUMPER SECTION

HHHHeeeeaaaavvvvyyyy----DDDDuuuuttttyyyy BBBBuuuummmmppppeeeerrrr

3. Secure rear bumper to frame using M6 x 18Torx screws and washers (predelivery kit).

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42 MM (1-21/32 IN) HEIGHT BUMPER SECTION

4. Tighten screws to specification.

TIGHTENING TORQUE

Rear bumper screws 16 N•m (142 lbf•in)

Side ReflectorsApply reflectors on both sides. Make sure theyare visible.

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TYPICAL REFLECTOR INSTALLATION1. LH reflector

Front Reflector (EuropeanModels)1. Using the following information, drill two holes

of 4.5 mm (3/16 in) through the bottom pancover.

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A. 20 mm (25/32 in)

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A. 30 mm (1-3/16 in)



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2. Insert locking ties in the reflector support slotsas shown.

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3. Install the reflector support on vehicle. Makesure locking ties are installed tightly so that theydon't exceed the support recesses.

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4. Clean reflector support with isopropyl alcoholand stick the reflector on the support.

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OOOOtttthhhheeeerrrr MMMMooooddddeeeellllssss

1. Insert locking ties in the reflector support slotsas shown.

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2. Place the reflector support centered on thefront bumper, then attach the locking ties.

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3. Install the locking ties tightly so that they don'texceed the support recesses.


3- FLUIDS

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LOCKING TIE INCORRECTLY TIGHTENED

mbl2011-003-005

LOCKING TIE CORRECTLY TIGHTENED (NOT EXCEEDINGRECESSES)

4. Stick the reflector on the support.

Make sure the support is still centered on thebumper.

Snowboard and Ski Rack(Summit Burton Model)To install the snowboard and ski rack providedwith the vehicle, refer to the instruction sheet(P/N 487 801 810) included in the kit, or on Knowl-edge Center.

tbl2015-004-003_a

3- FLUIDS

General GuidelinesAll fluids (except fuel) have already been filled atfactory, it is only necessary to check the levels.However, if refill is needed, refer to the appropri-ate Ski-Doo SHOP MANUAL for the proper proce-dure.

FuelRecommended Fuel

Use unleaded gasoline containing MAXIMUM10% ethanol. The gasoline must have the follow-ing minimum octane requirements.

FUELTYPE

ENGINEMIN. OCTANE

RATING

600 ACE900 ACE

1200 4-TEC

87 AKI(RON+MON)/2

92 RONFuelwith NOethanol 600 HO E-TEC

800R E-TEC

91 AKI(RON+MON)/2

95 RON

Fuelwhichmay

containup to10%MAX

ethanol

600 ACE900 ACE

600 HO E-TEC800R E-TEC1200 4-TEC

91 AKI(RON+MON)/2

95 RON


3- FLUIDS

NOTICE Never experiment with other fuels.Engine or fuel system damages may occurwith the use of an inadequate fuel.

Fuel Antifreeze Additives

When using oxygenated fuel, additional gas lineantifreeze or water absorbing additives are not re-quired and should be not used.

When using non-oxygenated fuel, we highlyrecommend the use of isopropyl base gas lineantifreeze in a proportion of 150 ml (5 U.S. oz) ofgas line antifreeze added to 40 L (10.6 U.S. gal.)of gas.

This precaution is in order to reduce the risk offrost buildup in fuel system components whichmay lead, in certain cases, to severe damage toengine.

NOTE: Use only methyl hydrate free gas line an-tifreeze.

Engine CoolantRecommended Coolant

The cooling system can be filled with distilled wa-ter and antifreeze solution (50% distilled water,50% antifreeze).

NOTICE Always use ethylene-glycol an-tifreeze containing corrosion inhibitors specif-ically for internal combustion aluminum en-gines.

For best performance, use the following recom-mended product.

RECOMMENDED ANTIFREEZE

Finland, Norway and SwedenLONG LIFE

ANTIFREEZE(F)(P/N 619 590 204)

All Other CountriesLONG LIFE

ANTIFREEZE(P/N 219 702 685)

Coolant Level Verification

Check coolant level at room temperature with thecap removed.

Liquid should be at cold level line (engine cold) ofcoolant tank.

NOTE: When checking level at low temperature itmay be slightly lower then the mark.

Add if necessary.

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1. COLD LEVEL line

Chaincase OilRecommended Chaincase Oil

RECOMMENDED CHAINCASE OIL

XPS SYNTHETIC CHAINCASE OIL (P/N 413 803 300)

Chaincase Oil Level Verification

1. With the vehicle on a level surface, check theoil level by removing the check plug on the leftside of chaincase. Oil level must be equal withthe lower edge.

mmo2011-003-017_a

TYPICAL - 600 ACE, 900 ACE AND 1200 4-TEC MODELS1. Check plug


3- FLUIDS

mmr2008-047-002_a

TYPICAL - 600HO E-TEC MODELS AND 800R E-TEC1. Check plug

To add oil, remove the filler cap on chaincasecover.

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TYPICAL1. Filler cap

2. Pour recommended oil in chaincase by the fillerhole until oil comes out by the check plug hole.

CHAINCASE OIL CAPACITY

600 HO ETEC and800R E-TEC Models

350 ml (12 U.S. oz)

600 ACE, 900 ACE and1200 4-TEC Models

500 ml (17 U.S. oz)

Reinstall check plug and torque to specification.

TIGHTENING TORQUE

Plug 6 N•m (53 lbf•in)

Injection OilRecommended Oil

Always maintain a sufficient amount of recom-mended injection oil in the injection oil reservoir.

WARNING

Do not overfill. Reinstall cap and fullytighten. Wipe off any oil spills. Oil is highlyflammable when heated.

RECOMMENDED INJECTION OIL

XPS SYNTHETIC 2-STROKE OIL(P/N 293 600 132)

NOTICE The engine of this snowmobile hasbeen developed and validated using the rec-ommended BRP XPS oil. BRP strongly recom-mends the use of its recommended XPS oil atall times. Damages caused by oil which is notsuitable for the engine will not be covered bythe BRP limited warranty.

Brake Fluid LevelRecommended Brake Oil

RECOMMENDED BRAKE OIL

BRAKE FLUID GTLMA DOT4 (P/N 293 600 131)

Brake Oil Level Verification

1. Check brake fluid in reservoir for proper level.

2. Add brake fluid as required.

WARNING

Use only DOT 4 brake fluid from a sealed con-tainer. To avoid serious damage to the brak-ing system, do not use fluids other than therecommended one, nor mix different fluidsfor topping up.

NOTICE Brake fluid can damage painted andplastic parts. Handle with care. Rinse thor-oughly in case of spillage.


4- UPPER BODY MODULE INSTALLATION

mmo2008-008-018_a

1. Minimum2. Maximum3. Operating range

Engine Oil (600 ACE, 900 ACEand 1200 4-TEC)Recommended Engine Oil

RECOMMENDED ENGINE OIL

XPS 4-STROKE SYNTHETIC OIL(P/N 293 600 112)

NOTICE The engine of this snowmobile hasbeen developed and validated using the rec-ommended BRP XPS™ oil. BRP strongly rec-ommends the use of its recommended XPS oilat all times. Damages caused by oil which isnot suitable for the engine will not be coveredby the BRP limited warranty.

If the recommended oil is not available, use SAE0W-40 synthetic-based oil that meets or exceedsthe requirements for API service classificationSM.

Engine Oil Level Verification

NOTICE Check level every 10 hours of use andrefill if necessary. Do not overfill. Operatingthe engine with an improper level may se-verely damage engine. Wipe off any spillage.

Make sure the engine is at normal operating tem-perature.

NOTE: The engine reaches normal temperaturewhen the rear radiator gets warm indicating thethermostat has opened.

Place vehicle on a level surface and proceed asfollows to check oil level:

1. Let engine run at idle for approximately 30 sec-onds.

2. Stop engine.

3. Open the LH side panel, refer to CONTROLS,INSTRUMENTS AND EQUIPMENT.

4. Remove the drive belt guard, refer to CON-TROLS, INSTRUMENTS AND EQUIPMENT.

5. Remove dipstick from the filler tube, then wipeit clean.

6. Completely insert dipstick in the filler tube.

7. Remove dipstick and check the oil level. Oillevel should be between the MIN. and MAX.marks as shown, add if necessary.

1

MAX.

MIN.

mmo2009-005-027_a

1. Oil level between MIN. and MAX.

WARNING

Wipe off any oil spills. Oil is highlyflammable when heated.

4- UPPER BODY MODULEINSTALLATION1. Insert the upper body module tabs into the up-

per bottom pan openings.

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2. Slide the module towards rear.


4- UPPER BODY MODULE INSTALLATION

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3. On both sides, install the upper body moduleretaining screws.

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RH SIDE SHOWN1. Retaining screws

4. Connect:

– APS hose on the ECM

– Headlights connector

– Gauge connector

– Air temperature sensor (ATS)

– Air intake connector tube.

5. Install:

– Gauge

– Drive belt guard.

6. Install side panels

Front Storage CompartmentCoverSnap cover in place.

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Console Wind Deflectors (ifEquipped)

mbl2013-002-014_a


5- SET-UP

Windshield1. Lubricate the grommets using soapsuds.

NOTICE Do not lubricate grommets with anytype of grease.

2. Position windshield in place.

3. Push windshield pins into the grommets.

mbl2009-010-202_a

1. Windshield tab2. Console front grommet

4. Remove protective films from the windshield.

WARNING

Make sure that handlebar turns freely in bothdirections. Make sure that there is no contactat any time between handlebar wind deflec-tors (if so equipped) and windshield.

MMMMXXXXZZZZ XXXX,,,, XXXX----RRRRSSSS aaaannnndddd RRRReeeennnnaaaaggggaaaaddddeeee XXXX,,,, XXXX----RRRRSSSS,,,,BBBBaaaacccckkkkccccoooouuuunnnnttttrrrryyyy XXXX MMMMooooddddeeeellllssss

Install the windshield decal, it is located besidethe SAFETY DVD.

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TYPICAL

Mirrors (Grand Touring Models)Install mirror as illustrated

mbl2013-003-001_a

LH SIDE SHOWN1. Mirror2. Screws3. Rubber washers4. Mirror mounting plate

Tighten screws by hand to avoid parts deforma-tion.

5- SET-UP

Doing All Recalls and All OtherModifications Requested byBRPComplete applicable recalls or factory-directedmodifications.

Programming Using B.U.D.S.NOTE: Vehicle will not start until a key code isprogrammed in vehicle's ECM using B.U.D.S.

If your not familiar with B.U.D.S., or need to learnhow to install B.U.D.S. on a computer, refer toB.U.D.S. PROGRAM INSTALLATION INSTRUC-TIONS bulletin available from the KnowledgeCenter.

Make sure to use the latest applicable ver-sion of B.U.D.S. that can be downloaded fromKnowledge Center. A valid BOSSWeb account isrequired to obtain the access code.

Connecting PC to Vehicle

1. Connect the PC to vehicle. Refer to the appli-cable shop manual.


5- SET-UP

REQUIRED TOOLS

MPI-3 INTERFACECARD (P/N 529 036 353)

DIAGNOSTIC CABLE(P/N 710 000 851)

POWER INTERFACE(P/N 515 177 223)

12 V BATTERY SUPPLYCABLE (P/N 529 035

997)

NOTE: The following message may be displayed.If so, it should disappear as soon as B.U.D.S. com-municates. If message does not disappear, clickon the Retry button.

mbl2014-006-300

2. Make sure status bar shows proper Protocol.

F18H0XA

kW2000

CONNECTION SUCCESSFUL

NOTE: Number 2 indicates that the ECM and themultifunction gauge are recognized by the MPI.On models equipped with a THCM, a "3" will bedisplayed.

If an “X” or a “1”is shown instead of a “2” or "3",it means that there is no communication betweenMPI and ECM and/or multifunction gauge. Possi-ble causes are:

– ECM and/or multifunction gauge not powered

– Bad connection between MPI and ECM and/ormultifunction gauge.

3. Press Read Data button to download data fromthe vehicle.

vdd2006-001-101

Programing Keys with B.U.D.S.

1. Install new key to be programmed on vehicleD.E.S.S. post.

2. Click on Keys tab.

smr2005-072-001_en

NOTE: When programing a vehicle for the firsttime, you need to click on Erase All Keys button.

3. Click on Add Key.

smr2005-072-003_Aen

1. Add Key

4. Click on Write Data to save a new key in vehi-cle's ECM.

vmr2006-012-100_ben


5- SET-UP

A new key is now saved in computer.

5. Repeat to program more keys.

Speedometer Setting (Miles orKilometers)

Speedometer is factory preset in miles. Dealerneeds to use B.U.D.S. to change it to kilometers.

Select Setting and Clustertabs.

In the Cluster Units box:

– For kilometers select Metric

– For miles select Imperial.

Ending a B.U.D.S. Session

1. Click on Faults tab and check if there are ac-tive fault codes. If so, service vehicle then clearfault codes in B.U.D.S.

NOTICE After a problem has been solved,ensure to clear fault code(s) in ECM. This willproperly reset appropriate counter(s). Thiswill also record that problem has been fixed inECM memory.

2. Click on Write Data button to transfer new set-tings and information to ECM.

3. Click on Exit button (right most) to end session.

4. Ensure to reinstall communication connector inits cover.

TrackTrack Tension Adjustment and Alignment

1. Remove the D.E.S.S. key (tether cord cap).

2. Lift rear of vehicle and support it off the ground.

3. Allow rear suspension to fully extend.

4. Loosen one of the rear axle retaining screws (3and 4 idler wheels system).

mbl2015-002-010_a

3 AND 4 IDLER WHEELS SYSTEM

5. Loosen rear axle retaining nut and screw (2 idlerwheels system).

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2 IDLER WHEELS SYSTEM

6. Tighten both adjustment screws equally to in-crease track tension a little.

mbl2015-002-010_b

3 AND 4 IDLER WHEELS SYSTEM

mbl2015-002-009_b

2 IDLER WHEELS SYSTEM


5- SET-UP

7. Use the TENSIOMETER (P/N 414 348 200).

414348200

8. Set deflection between using bottom O-ring.

BOTTOM O-RING SETTING

Expedition Sport 4.2 cm (1-5/8 in)

All others 3.2 cm (1-1/4 in)

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DEFLECTION SETTING1. Bottom O-ring

9. Place upper O-ring to 0 kgf (0 lbf).

10. Position the tensiometer on track, halfway be-tween front and rear idler wheels.

11. Push the tensiometer downwards until bot-tom O-ring (deflection set earlier) be alignedwith the bottom of slider shoe.

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1. Deflection O-ring aligned with slider shoe

12. Read load recorded by the upper O-ring on thetensiometer.

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LOAD READING1. Upper O-ring

13. Load reading must be as per the following ta-ble.

TRACK ADJUSTMENT SPECIFICATION

Track deflection setting(Expedition Sport)

4.2 cm (1-5/8 in)

Track deflection setting(All others)

3.2 cm (1-1/4 in)

Track load reading6 kg to 8.5 kg(13 lb to 19 lb)

14. Tighten or loosen both adjustment screws un-til specified tension is obtained.

15. Tighten rear idler wheel fasteners.

TIGHTENING TORQUE

Rear idler wheelretaining screws (3 and4 idler wheels system)

48 N•m ± 6 N•m(35 lbf•ft ± 4 lbf•ft)

Rear idler wheelretaining nut and screw(2 idler wheels system)

24.5 N•m ± 3.5 N•m(18 lbf•ft ± 3 lbf•ft)

Check track alignment as follows:

16. Start engine and accelerate slightly so thattrack slowly turns. This must be done in ashort period of time (15 to 20 seconds).

17. Check that the track is well centered; equaldistance on both sides between edges oftrack guides and slider shoes.

A01F05A

1

2

3

1. Guides2. Slider shoes3. Equal distance


6- ADJUSTMENTS (CUSTOMER PREFERENCE)

18. To correct track alignment:

18.1 Stop engine.

18.2 Remove D.E.S.S. key (tether cord cap)

18.3 Loosen one of the rear wheel retainingscrews (3 and 4 idler wheels system).

18.4 Loosen rear axle retaining nut (2 idlerwheels system).

18.5 Tighten adjustment screw on the sidewhere the slider shoe is the farthestfrom the track insert guides.

19. Tighten rear idler wheel fasteners.

TIGHTENING TORQUE

Rear idler wheelretaining screws (3 and4 idler wheels system)

48 N•m ± 6 N•m(35 lbf•ft ± 4 lbf•ft)

Rear idler wheelretaining nut and screw(2 idler wheels system)

24.5 N•m ± 3.5 N•m(18 lbf•ft ± 3 lbf•ft)

20. Repeat procedure until alignment is correct.Recheck tension.

Track Studding

WARNING

Never stud a track that has not been ap-proved for studs. Installing studs on anunapproved track could increase risks oftrack tearing or severing, possibly resultingin serious injuries or death.

WARNING

For track studding, always refer to the IN-STRUCTION SHEET supplied with stud kitsthat are APPROVED by BRP for models cov-ered in this PREDELIVERY BULLETIN.

1. Install wheel caps (predelivery kit).

NOTE: If lubricant is needed to help cap installa-tion, use glass cleaner instead of soapy water toavoid cap to get out from its location due to soapresidue.

Ice Scratchers and Idler Wheels (Summitand Freeride)

Tall profile tracks are especially designed for deepsnow application.

All Summit and Freeride, except Summit X model,are equipped with 4 idler wheels on the rear sus-pension to reduce friction between the track andthe rails on ice and hard packed trails.

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Summit X are factory equipped with ice scratcherswhich provides lubrication and cooling to rails andtrack guides for short ride on ice and hard packedtrails.

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There is no idler wheels on the Summit X.

NOTICE Although it is not recommended toride Summit and Freeride in trail or hard snowconditions, it is highly suggested to combineidler wheels with ice scratchers if the vehicle isused in those conditions.

NOTE: Ice scratchers and idler wheels are com-patibles.

See accessories catalogue for appropriate kit.

6- ADJUSTMENTS(CUSTOMERPREFERENCE)

Rear Suspension AdjustmentsPlease refer to OPERATOR'S GUIDE for speci-fications and procedures. You can also refer tothe SUSPENSION SPRING CHART bulletin (ifavailable).


7- FINAL INSPECTION

7- FINAL INSPECTION

Controls, Equipments,Movement and OperationInspection1. Make sure the following controls and equip-

ments are fully operational:

– Throttle, brake and parking brake levers

– Ignition, emergency stop switch and tetherstop switch

– Headlights, taillight and brake light

– Steering system.

2. Fasteners tightening torque recheck:

– Ski nuts

– Shock absorber nuts

– Handlebar nuts.

3. Ensure that hang tag is on vehicle handlebars.

4. Ensure TOOL KIT and OPERATOR’S GUIDE arein the vehicle.

Test Run Snowmobile1. Test ride vehicle.

Snowmobile Cleaned and inShowroom Condition1. Make sure all protective wrapping is removed

from vehicle.

2. Wash and dry vehicle. Use XPS ATV WASH

(P/N 219 701 702).

NOTICE Never use a high pressure washer toclean vehicle. High pressure can cause electri-cal or mechanical damages.

For stubborn dirt on vinyl or plastic parts, usingflannel or micro-fibre towels with XPS ALL PUR-

POSE CLEANER (P/N 219 701 709).

NOTICE It is necessary to use flannel or micro-fiber clothes on plastic parts to avoid scratch-ing the surfaces. Never clean plastic parts withstrong detergent, paint thinner, acetone, prod-ucts containing chlorine, petroleum, etc.

Vehicle DeliveryComplete PREDELIVERY CHECK LIST.

Give the OPERATOR’S GUIDE and the SAFETYDVD to the customer.

Customer must read and sign the PREDELIVERYCHECK LIST.

Hang tag is to be removed by the owner only.

Any person who rides this vehicle should read andunderstand all the information given on hang tagand safety labels before riding.


ski-doo pre-delivery - bweb.brp-jp.combweb.brp-jp.com/pdf/skpd2016-4 r1 en.pdf · predelivery kit...

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