table of contents - bweb.brp-jp.combweb.brp-jp.com/pdf/skpd2014-4 en.pdf · summit x...

August 23, 2013 Subject:Ski-Doo REV-XS and REV-XM PredeliveryInspection

No. 2014-4

YEAR MODEL MODEL NUMBER SERIAL NUMBER

2014 REV-XS and REV-XM Refer to table on next pages for model listing All

TABLE OF CONTENTSPage Page

IMPORTANT NOTICE ..... . . . . . . . . . . . . . . . . . . 2High altitude calibration... . . . . . . . . . . . . . . . . . . . . . 2

MODEL LISTING..... . . . . . . . . . . . . . . . . . . . . . . . . 3

PREDELIVERY KIT PARTS LIST ..... . . . . . 4

UNCRATING ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Crate Cover.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Crate Brackets .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Tunnel Bag (GSX Models) . . . . . . . . . . . . . . . . . . . . . 6Snow Guard ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Rear Bumper .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Rear Suspension Shipping Hook(s) . . . . . . . . . . 6

PARTS TO BE INSTALLED...... . . . . . . . . . . . 7Front Shock Absorbers ... . . . . . . . . . . . . . . . . . . . . . 7Skis .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Battery ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Handlebar ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Steering Cover .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Tools and Emergency Starting Rope... . . . . . . 13Handlebar Wind Deflector (ApplicableModels) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Mountain Strap (Renegade Backcountry,Summit and Freeride Models) . . . . . . . . . . . . . . . . 14Heated Visor Extension (Expedition and GSXModels) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Drive Belt Installation .. . . . . . . . . . . . . . . . . . . . . . . . . 14Hitch (Expedition Sport) . . . . . . . . . . . . . . . . . . . . . . . 16Side Reflectors.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Front Reflector (European Models) . . . . . . . . . . 16

FLUIDS...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18General Guidelines ... . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Fuel .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Engine Coolant... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Chaincase Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Injection Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Brake Fluid Level .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Engine Oil (900 ACE).. . . . . . . . . . . . . . . . . . . . . . . . . . 20

UPPER BODY MODULE INSTALLA-TION...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Front Storage Compartment Cover ... . . . . . . . 21Console Wind Deflectors (if Equipped) .. . . . . 22Windshield.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Mirrors (GSX Models) . . . . . . . . . . . . . . . . . . . . . . . . . . 22

SET-UP..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Programming Using B.U.D.S. .. . . . . . . . . . . . . . . . 22Track.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

ADJUSTMENTS (CUSTOMERPREFERENCE) ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Rear Suspension Adjustments ... . . . . . . . . . . . . 26

FINAL INSPECTION ...... . . . . . . . . . . . . . . . . . . . 26Controls, Equipments, Movement andOperation Inspection.. . . . . . . . . . . . . . . . . . . . . . . . . . 26Test Run Snowmobile .. . . . . . . . . . . . . . . . . . . . . . . . 26Snowmobile Cleaned and in ShowroomCondition.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Vehicle Delivery .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

SPECIFICATIONS ...... . . . . . . . . . . . . . . . . . . . . . . 28

Printed in Canada. (mbl2014-002 en JT)©2013 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.

1 / 41®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.

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 VIDEOIMPORTANT: Complete any applicable recall or factory directed modification.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.

2 / 41 2014-4 PREDELIVERY

MODEL LISTING

MODEL LISTINGMODEL COUNTRY ENGINE MODEL NUMBER PDI KIT P/N

CAN/US 600HO E-TEC UEEA

CAN/US 800R E-TEC UDEAMX Z TNT

CAN/US 900 ACE MAEA

CAN/US 600HO E-TEC UVEA / UVEB / UVEC / UVEDMX Z X

CAN/US 800R E-TEC UTEA / UTEB / UTEC / UTED

CAN/US 600HO E-TEC BXEA

CAN/US 800R E-TEC UFEA

CAN/US MBEARenegadeAdrenaline

EUR900 ACE

MBEB

CAN/US 600HO E-TEC UAEA / UAEB / UAEC / UAEDRenegade X

CAN/US 800R E-TEC UWEA / UWEB / UWEC / UWED

CAN/US 600HO E-TEC UJEARenegadeBackcountry CAN/US 800R E-TEC UGEA / UGEB

CAN/US ULEA / ULEB

EUR600HO E-TEC

ULEC

CAN/US UXEA / UXEB / UXEC / UXED / UXEE / UXEF/ UXEG / UXEH

RenegadeBackcountryX

EUR800R E-TEC

UXEJ

CAN/US VAEA / VAEB / VAED / VAEE / VBEA / VBEB /VCEA / VCEBFreeride

EUR800R E-TEC

VAEC / VBEC / VCEC

549 011 443

CAN/US 600HO E-TEC DDEAGSX

CAN/US 900 ACE DREA549 011 442

CAN/US KDEAExpeditionSport EUR

900 ACEKDEB

549 011 445

CAN/USTREA / TREB / TREC / TRED / TREF / TREG /TCEA / TCEB / TCEC/ TCED / TCEF / TCEG /TNEA / TNEB / TNEC / TNED / TNEF / TNEGSummit X

EUR

800R E-TEC

TREE / TCEE / TCEH / TNEE / TNEH

CAN/US CXEA / CXEB / CXEC / CXED / CCEA / CCEB/ CCEC / CCED /

EUR600HO E-TEC

CXEE / CCEE

CAN/US CDEA / CDEB / CDEC / CDED / CEEA / CEEB/ CEEC / CEED / CFEA / CFEB / CFEC / CFED

Summit SP

EUR800R E-TEC

CEEE / CFEE

549 011 443

PREDELIVERY 2014-4 3 / 41

PREDELIVERY KIT PARTS LIST

PREDELIVERY KIT PARTSLIST

KIT 549 011 442

Where used Description Part number Qty

Rear Suspension Wheel Cap 503 192 771 2

M10 Washer 503 192 496 2

M10 nuts 233 201 464 6Front suspension and skis

Ski stopper 505 072 594 2

Rear bumper M6 X 18 Torx screw 250 000 402 4

3/16 pop rivet 293 150 108 4Snow guard

Washer 517 124 300 4

Steering K50 screws 250 000 400 8

Accessories Heated visor wire 515 175 851 1

KIT 549 011 443



M10 Washer 503 192 496 2

M10 nuts 233 201 464 6Front suspension and skis


Washer 224 061 201 6Rear bumper

M6 X 18 Torx screw 250 000 402 6

3/16 pop rivet 293 150 108 4Snow guard

Washer 517 124 300 4

KIT 549 011 445



M10 Washer 503 192 496 2

M10 flanged nut 233 201 464 6Front suspension and skis


M6 X 18 Torx screw 250 000 402 6Rear bumper

Washer 224 061 201 2

Accessories Heated visor wire 515 175 851 1

Washer 224 061 201 2

M6 X 16 screw 207 361 644 2Passenger seat

M6 X 30 screw 207 563 044 2

3/16 pop rivet 293 150 101 4Snow Guard

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).


UNCRATING

UNCRATINGCrate Cover1. Carefully lay crate on its bottom.

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

2. Using a drill or a screwdriver, remove all screwsretaining crate cover to crate base.

NOTE: Screws that are used are Robertson† #2type that require the use of an appropriate screw-driver.3. Tilt crate cover toward front or rear of vehicle.NOTE: There is a notch at one end of crate thatindicates front of vehicle.

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1. Screwdriver2. Notch (indicates front of vehicle)3. Tilt crate cover

4. Lift crate cover slowly to avoid damaging vehi-cle.

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

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

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

† Robertson is a registered trademark of Robertson Inc.


UNCRATING

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1. Track2. Wood block

5. Remove vehicle from crate base.

Tunnel Bag (GSX Models)GSX ModelHook the straps plastic ends to the anchors andadjust the straps.

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1. Strap2. Anchor

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.2. Secure rear bumper to frame using M6 x 18

Torx screws and washers (predelivery kit).

TIGHTENING TORQUE

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

Rear Suspension ShippingHook(s)

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

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. Lift rear of vehicle so that a block or a box can

be positioned under front idler wheels.3. Ask another person to apply pressure onto rear

suspension.4. Remove front hook(s) from suspension.

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TYPICAL1. Idler wheel2. Front hook

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

NOTICE Never stand on the seat.

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


PARTS TO BE INSTALLED

PARTS TO BE INSTALLEDFront Shock AbsorbersAccess to Upper Front Shock AbsorberBoltsTo 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 isnot required but its a good practice toavoid scratching them during vehiclepreparation. When side panels are re-moved, make sure to place them in a safeplace.

4.1 Unhook both rubber latches.4.2 Firmly pull the upper latch upwards.

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1. Side panel2. Upper latch3. Lower latch

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 BracketsRemoval1. Remove and discard shipping brackets.2. Keep M10 flat washers, upper M10 x 65 and

lower M10 x 55 bolts for front shock absorbersinstallation.

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1. Shipping brackets2. Spring clips3. M10 flat washers and bolts

Front Shock Absorber InstallationInstall front shock absorbers with the body up, us-ing the M10 screws and new M10 flanged nuts(predelivery kit).



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TYPICAL - BODY UP

Freeride (Narrow Stance)Install the shock absorbers as per following tablein order to place the reservoirs outwards and to-wards front.

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FREERIDE (NARROW STANCE)1. Reservoir (outwards and towards front)

FREERIDE (NARROW STANCE) SHOCKABSORBERS

SHOCK P/N VEHICLE SIDE

(P/N 505 073 123) LH

(P/N 505 073 124) RH

Freeride R (Wide Stance)NOTE: The wide stance Freeride model is easilyidentified by a reinforcement on the upper sus-pension arm.Install shock absorbers as per following table inorder to place the reservoirs inward and towardsfront.

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SUMMIT FREERIDE (WIDE STANCE)1. Reservoir (inwards and towards front)2. Reinforcement

FREERIDE R (WIDE STANCE) SHOCKABSORBERS

SHOCK P/N VEHICLE SIDE

(P/N 505 072 938) LH

(P/N 505 072 937) RH

All Models

TIGHTENING TORQUE

Front shock absorberretaining nuts 48 N•m (35 lbf•ft)

SkisNOTE: On some models, it is possible to set skistance narrow or wide. See SKI STANCE SET-TING below.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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TYPICAL - EXCEPT ADJUSTABLE STANCE1. 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

TIGHTENING TORQUE

Ski retaining nuts 48 N•m (35 lbf•ft)

Ski Stance Setting

Renegade Backcountry X, Expedition,Freeride and Summit Models

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 leg bushing6. Ski leg9. Narrow adjustment10. Wide adjustment

TIGHTENING TORQUE

Ski retaining nuts 48 N•m (35 lbf•ft)

BatteryModels With Electric Starter

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.2. Remove the battery bracket.

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TYPICAL - REAR OF BATTERY1. Lower bracket screw

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TYPICAL - FRONT OF BATTERY1. Upper bracket screw

3. Remove the battery.

Battery PreparationRefer 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 Installation1. Properly position the charged battery on its

rack.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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600 HO E-TEC

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800R E-TEC

4. Connect BLACK ( – ) cable LAST.

WARNING

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

5. Apply DIELECTRIC GREASE (P/N 293 550 004) onbattery posts and connectors.

6. 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.

VEHICLE ANGLE

Summit andFreeride

40°(from vertical)

MX Z, Expeditionand Renegade

20°(from vertical)

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SUMMIT AND FREERIDE SERIESA. Steering extension angle



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MX Z, EXPEDITION AND RENEGADE SERIESA. Steering extension angle

NOTICE Make sure brake hose is routed overthe steering extension

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

3. Tighten steering extension lower screws tospecified torque.

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 specified torque

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 CoverGSX ModelsInstall steering cover, Ski-Doo embossed text to-ward rear.Fasten steering cover using the 8 Torx screws(predelivery kit).

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STEERING COVER SCREWS LOCATIONS



Freeride ModelsPass 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

All Models Except GSX and FreerideInstall steering cover by pushing it in place.Route throttle cable and wiring properly.

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1. Steering cover2. Throttle cable3. RH wiring

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

Handlebar Wind Deflector(Applicable Models)On each side:1. Insert a M6 square nut into the wind deflector

support cavity.



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1. Wind deflector2. M6 square nut

2. Cut the handlebar wiring tie wraps.3. Push the support end downwards to clamp it on

the handlebar.4. Thread a M6 X 35 screw but do not tighten yet.

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1. M6 X 35 screw

5. Position the deflector so that the support leansagainst the steering cover.

6. Set the deflector 7° below horizontal.

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TIGHTENING TORQUE

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

7. Secure handlebar wiring with new tie-wraps.

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).

Mountain Strap (RenegadeBackcountry, Summit andFreeride Models)1. Loosen mountain strap clamps bolts.2. Position mountain strap upright. On both

sides, move clamp bolts away from electricharnesses.

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CLAMP BOLTS

TIGHTENING TORQUE

Mountain strap retainingscrews 11 N•m (97 lbf•in)

3. Wires are routed along handlebar. To avoidpinching them, take care to keep wires out ofretaining clip.

Heated Visor Extension(Expedition and GSX Models)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 using

PULLEY FLANGE CLEANER (P/N 413 711 809).7. Slip the belt over the drive pulley, then over the

driven 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.

900 ACE Models with ElectromechanicalReverseRepeat 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

Belt Without CogsRepeat 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

Belt With CogsRepeat 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

All belt typesNOTE: Turning the ring counterclockwise lowersthe belt in the pulley. Turning the ring clockwiseraises the belt in the pulley.3. Firmly tighten the clamping screw. If

possible, tighten to 5.5 N•m ± 0.5 N•m(49 lbf•in ± 4 lbf•in) using a torque wrench.

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 ActivationNOTE: 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.

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

TIGHTENING TORQUE

Hitch bolts 31 N•m (23 lbf•ft)

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

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TYPICAL REFLECTOR INSTALLATION1. LH reflector

Front Reflector (EuropeanModels)MX Z X (600 HO E-TEC and 800R E-TEC),Renegade Back Country X (600 HO E-TECand 800R E-TEC), Summit X 800R E-TEC(154" and 163") Models1. Using the following information, drill two holes

of 4.5 mm (3/16 in) through the headlight trim.

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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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Other Models1. Insert locking ties in the reflector support slots

as shown.

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


FLUIDS

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

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LOCKING TIE INCORRECTLY TIGHTENED

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LOCKING TIE CORRECTLY TIGHTENED (NOT EXCEEDINGRECESSES)

4. Stick the reflector on the support.Make sure the support is still centered on thebumper.

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

FUELTYPE

ENGINEMIN. OCTANE

RATING

900 ACE87 AKI

(RON+MON)/292 RONFuel

with NOethanol 600 HO E-TEC

800R E-TEC

91 AKI(RON+MON)/2

95 RON

Fuelwhichmay

containup to10%MAX

ethanol

900 ACE600 HO E-TEC

800R E-TEC

91 AKI(RON+MON)/2

95 RON

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

Fuel Antifreeze AdditivesWhen 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.


FLUIDS

Engine Coolant1. Check coolant level at room temperature with

the cap 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 Oil1. With the vehicle on a level surface, check the

oil level by removing the check plug on the leftside of chaincase. Oil level must be equal withthe lower edge.

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TYPICAL - 900 ACE MODELS1. Check plug

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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)

900 ACE Models 500 ml (17 U.S. oz)

Reinstall check plug and torque to specification.

CHECK PLUG TORQUE

6 N•m (53 lbf•in)

Injection OilRecommended OilAlways 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.


FLUIDS

RECOMMENDED INJECTION OIL

ENGINES

XPSSYNTHETIC

BLEND2-STROKE OIL(P/N 293 600

100)

XPSSYNTHETIC

2-STROKE OIL(P/N 293 600

132)

600 HOE-TEC

800R E-TEC (preferred)

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 Level1. Check brake fluid in reservoir for proper level.2. Add brake fluid (DOT 4) as required.

– Use BRAKE FLUID (P/N 293 600 131)– or BRAKE FLUID SRF (P/N 293 600 063) (for high

performance)

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.

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1. Minimum2. Maximum3. Operating range

Engine Oil (900 ACE)Recommended Engine Oil

RECOMMENDED ENGINE OIL

XPS 4-STROKE SYNTHETIC OIL (ALL CLIMATE)(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.


UPPER BODY MODULE INSTALLATION

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. Oil

level should be between the MIN. and MAX.marks as shown, add if necessary.

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1. Oil level between MIN. and MAX.

WARNING

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

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.

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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.


SET-UP

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Console Wind Deflectors (ifEquipped)

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Windshield1. Lubricate the grommets using DIELECTRIC

GREASE (P/N 293 550 004).2. Remove protective films from the windshield.3. Position windshield in place.4. Secure windshield by inserting the windshield

pins into the grommets.

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1. Windshield tab2. Console front grommet

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.

Mirrors (GSX Models)Install mirror as illustrated

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LH SIDE SHOWN

SET-UPProgramming 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 not familiar with B.U.D.S. and to learn how toinstall B.U.D.S. on a computer, refer to B.U.D.S.PROGRAM INSTALLATION INSTRUCTIONS bul-letin.


SET-UP

Make sure to use the applicable version ofB.U.D.S. that can be downloaded from BOSS-Web (www.bossweb.brp.com). A valid BOSS-Web account is required.

Connecting PC to Vehicle1. Connect the PC to vehicle. Refer to the appli-

cable shop manual.

REQUIRED TOOLS

MPI-2 INTERFACECARD (P/N 529 036 018)

MPI-2 DIAGNOSTICCABLE (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.

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2. Make sure status bar shows proper Protocol.

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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/or

multifunction gauge.3. Press Read Data button to download data from

the vehicle.

vdd2006-001-101

Programing Keys with B.U.D.S.1. Install new key to be programmed on vehicle

D.E.S.S. post.2. Click on Keys tab.

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NOTE: When programing a vehicle for the firsttime, you need to click on Erase All Keys button.3. Click on Add Key.

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1. Add Key

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


SET-UP

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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. Session1. 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 in

its cover.

TrackTrack Tension Adjustment and Alignment1. 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.

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1. RH rear idler wheel bolt

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1. RH axle screw

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

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1. RH adjustment screw


SET-UP

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1. RH adjustment screw

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

414348200

7. 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

8. Place upper O-ring to 0 kgf (0 lbf).9. Position the tensiometer on track, halfway be-

tween front and rear idler wheels.10. 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

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

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LOAD READING1. Upper O-ring

12. 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 reading 6 kg to 8.5 kg(13 lb to 19 lb)

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

14. Tighten rear idler wheel retaining screws.

TIGHTENING TORQUE

Rear idler wheelretaining screw

48 N•m ± 6 N•m(35 lbf•ft ± 4 lbf•ft)

Check track alignment as follows:15. Start engine and accelerate slightly so that

track slowly turns. This must be done in ashort period of time (15 to 20 seconds).

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


FINAL INSPECTION

A01F05A

1

2

3

1. Guides2. Slider shoes3. Equal distance

17. To correct track alignment:17.1 Stop engine.17.2 Remove D.E.S.S. key (tether cord cap)17.3 Loosen one of the rear wheel retaining

screws.17.4 Tighten adjustment screw on the side

where the slider shoe is the farthestfrom the track insert guides.

18. Tighten rear idler wheel retaining screw.

TIGHTENING TORQUE

Rear idler wheelretaining screw

48 N•m ± 6 N•m(35 lbf•ft ± 4 lbf•ft)

19. 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.

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).

FINAL INSPECTIONControls, 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 tether

stop switch– Headlights, taillight and brake light– Steering system.

2. Fasteners tightening torque recheck:– Ski nuts– Shock absorber nuts– Handlebar nuts.

3. Complete applicable recall or factory-directedmodification.

4. Ensure that hang tag is on vehicle handlebars.5. Ensure TOOL KIT and OPERATOR’S GUIDE are

in 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).


FINAL INSPECTION

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 Delivery1. Complete PREDELIVERY CHECK LIST.2. Give the OPERATOR’S GUIDE and the SAFETY

DVD to the customer.3. Customer must read and sign the PREDELIV-

ERY CHECK LIST.


SPECIFICATIONS

SPECIFICATIONSThe content of SPECIFICATIONS pages should be used as necessary to fine-tune and

perform additional adjustments required on snowmobile.

600 HO E-TEC ModelsMODEL 600 HO E-TEC

ENGINEEngine type Rotax 593, liquid cooled w/Reed valve, 3D-RAVE

Cylinders 2

Displacement 594.4 cm³ (36.3 in³)

Bore 72 mm (2.8 in)

Stroke 73 mm (2.9 in)

Maximum engine speed 8100 ± 100 RPM

Fuel injection system E-TEC Direct injection

Exhaust system Single tuned pipe, baffle muffler

Engine oil XPS SYNTHETIC BLEND 2-STROKE OIL(P/N 293 600 100) (1)

Engine oil tank capacity 3.7 L (3.9 qt (U.S. liq.))

Coolant

Ethyl glycol/water mix(50% coolant, 50% distilled water).

Use LONG LIFE ANTIFREEZE (P/N 219 702 685) or coolantspecifically designed for aluminum engines

Recommended fuel Premium unleaded (fuel which may contain up to10% MAX ethanol)

91 Pump Posted AKI (RON+MON)/2Minimum octane rating. Refer to FUEL REQUIREMENTS

95 RON

Fuel tank capacity 40 L (10.6 U.S. gal.)

MODEL 600 HO E-TEC

DRIVE SYSTEMDrive pulley type TRA III

Driven pulley type QRS

All models except Summit 3400 ± 100 RPMEngagement

Summit 4000 ± 100 RPM

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

Summit 19

Renegade BackcountryRenegade Backcountry X 21

Renegade AdrenalineRenegade X 23

Small sprocket number of teeth

GSX LEMX Z 25


SPECIFICATIONS

MODEL 600 HO E-TEC

DRIVE SYSTEM (cont'd)

Renegade BackcountryRenegade Backcountry XSummit

49

Large sprocket number of teeth GSX LEMX ZRenegade AdrenalineRenegade X

45

Drive sprocket number of teeth 8

RenegadeRenegade AdrenalineRenegade BackcountrySummit

40.6 cm (16 in)

Track nominal widthGSX LEMX ZRenegade

38 cm (15 in)

RenegadeRenegade AdrenalineRenegade Backcountry

348.7 cm (137 in)

GSX LEMX Z 305 cm (120 in)

Summit 146" 370.5 cm (146 in)

Track nominal length

Summit 154" 392 cm (154 in)

GSX LEMX ZRenegade AdrenalineRenegade X

31.8 mm (1.25 in)

Renegade BackcountryRenegade Backcountry X 44.5 mm (1.75 in)

Track profile height

Summit 57.2 mm (2.25 in)

Deflection 30 mm to 35 mm (1-3/16 in to 1-3/8 in)Track tension

Force (2) 7.3 kg (16 lb)

Track alignment Equal distance between edges of track guides and slider shoes

MODEL 600 HO E-TEC

BRAKE SYSTEMBrake system type Brembo racing brake with stainless-steel braided line

Brake fluid DOT 4


SPECIFICATIONS

MODEL 600 HO E-TEC

SUSPENSIONFront suspension Dual A-arms

GSX LESummit SP HPG

MX Z TNTRenegade AdrenalineRenegade Backcountry

HPG Plus

MX Z XRenegade XRenegade Backcountry X

HPG Plus R

Front shock

MX Z X-RS KYB PRO 40 R easy-adjust

Summit SP 200 mm (8 in)

Renegade BackcountryRenegade Backcountry X 210 mm (8.3 in)

GSX LEMXZ TNTMX Z XRenegade AdrenalineRenegade X

229 mm (9 in)Front suspension max. travel

MX Z X-RS 241 mm (9.5 in)

All models except Summit SP rMotionRear suspension

Summit SP tMotion

Renegade AdrenalineRenegade BackcountrySummit SP

HPG

MXZ TNTMX Z XRenegade XRenegade Backcountry X

HPG Plus

MXZ X-RS KYB PRO 40 easy-adjust

Center shock

GSX LE Motion Control

Renegade AdrenalineRenegade BackcountryGSX LESummit SP

HPG

MXZ TNT HPG Plus


KYB PRO 36 easy-adjust

Rear shock

MXZ X-RS KYB PRO 40 easy-adjust

Summit 146" 356 mm (14 in)

Summit 154" 381 mm (15 in)

Renegade 406 mm (16 in)Rear suspension max. travelMXZ TNTMX Z XMXZ X-RS

394 mm (15.5 in)


SPECIFICATIONS

MODEL 600 HO E-TEC

ELECTRICAL SYSTEM

Lightning system output 12V/360 W55 V/1100 W

Headlights bulb HI/LOW beam 2 x 60/55 Watts (H-4)

Taillight bulb 2.6 W / 139m W LED

Type NGK PZFR6F (3)

Spark plugGap 0.75 mm ± 0.05 mm (.03 in ± .002 in)

(not adjustable)

RER 5 A

Fuel level sensor 0.25 AFuse

Main 25 A

MODEL 600 HO E-TEC

DIMENSIONS AND WEIGHTRenegade AdrenalineRenegade BackcountryRenegade Backcountry XRenegade X

311 cm (122.4 in)

GSX LEMX Z XMXZ TNTMX Z X RSRenegade X

290.5 cm (114.4 in)

Summit 146" 322.6 cm (127 in)

Vehicle overall length

Summit 154" 333.5 cm (131.3 in)

Summit SP 108.1 cm to 112.6 cm (42.6 in to 44.3 in)

Renegade BackcountryRenegade Backcountry X 115.9 cm to 120.4 cm (45.6 in to 47.4 in)

Vehicle overall widthGSX LEMX Z XMX Z X RSMXZ TNTRenegade AdrenalineRenegade X

121.7 cm (47.9 in)

GSX LEMX Z X RS 120 cm (47.2 in)

MX Z TNTMX Z XRenegade AdrenalineRenegade BackcountryRenegade X

121 cm (47.6 in)

Renegade Backcountry X 124.5 cm (49 in)

Vehicle overall height

Summit SP 134.6 cm (53 in)


SPECIFICATIONS

MODEL 600 HO E-TEC

DIMENSIONS AND WEIGHT (cont'd)

GSX LESummit 146" 206 kg (455 lb)

MXZ TNTSummit 154" 207 kg (456 lb)

MX Z X 210 kg (463 lb)

MX Z X RSRenegade AdrenalineRenegade X

218 kg (481 lb)

Renegade BackcountryRenegade Backcountry X 220 kg (485 lb)

Dry weight

Summit SP 90.7 cm or 95 cm (35.7 in or 37.4 in)


Ski stanceGSX LEMX TNTMX Z XMX Z X RSRenegade AdrenalineRenegade X

107.7 cm (42.4 in)

GSX LEMX Z TNTMX Z XMX Z X RSRenegade AdrenalineRenegade XSummit series

106.6 cm (42 in)

Ski overall length

Renegade BackcountryRenegade Backcountry XSummit SP

104 cm (41 in)

Renegade Backcountry X 165 mm (6.5 in)Ski width MX Z X

Renegade X 145 mm (5.7 in)

(1) Refer to INJECTION OIL subsection for detailed information.(2) Measure gap between slider shoe and bottom inside track when exerting a downward pull to the track.(3) NOTICE Do not attempt to adjust gap on this spark plug.


SPECIFICATIONS

800R E-TEC ModelsMODEL 800R E-TEC

ENGINEEngine type Rotax 797, liquid cooled w/Reed valve, 3D-RAVE

Cylinders 2

Displacement 799.5 cm³ (48.8 in³)

Bore 82 mm (3.2 in)

Stroke 75.7 mm (3 in)

Maximum engine speed 7900 ± 100 RPM

Fuel injection system E-TEC Direct injection

Exhaust system Single tuned pipe, baffle muffler

Engine oil XPS SYNTHETIC BLEND 2-STROKE OIL (P/N 293 600 100) (1)

Engine oil tank capacity 3.7 L (3.9 qt (U.S. liq.))

Coolant

Ethyl glycol/water mix(50% coolant, 50% distilled water).

Use LONG LIFE ANTIFREEZE (P/N 219 702 685) or coolantspecifically designed for aluminum engines

Recommended fuel Premium unleaded (fuel which may contain up to 10% MAX ethanol)

91 Pump Posted AKI (RON+MON)/2Minimum octane rating. Refer to FUEL REQUIREMENTS

95 RON


MODEL 800R E-TECDRIVE SYSTEMDrive pulley type TRA VII

Driven pulley type QRS

Engagement 3800 ± 100 RPM

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

MX Z 27Renegade AdrenalineRenegade X 25

Renegade BackcountryRenegade Backcountry X 23

Freeride (137 in track)Freeride (146 in track)Summit (146 in track)

21

Small sprocket number of teeth

Freeride (154 in track)Summit (154 in - 163 in) 19

Summit (163 in track) 51Freeride (146/154 in track)Summit (146 in - 154 in) 49Large sprocket number of teeth

Others 45

Drive sprocket number of teeth 8


SPECIFICATIONS

MODEL 800R E-TECDRIVE SYSTEM (cont'd)

MX Z 38 cm (15 in)

Track nominal width Freeride seriesSummitRenegade

40.6 cm (16 in)

Freeride (146 in track)Summit 146" 370.5 cm (146 in)

Freeride (154 in track)Summit 154" 392 cm (154 in)

Freeride (137 in track)Renegade 348 cm (137 in)

Summit 163" 414 cm (163 in)

Track nominal length

MX Z 305 cm (120 in)Freeride (146/154 in track)Summit 63.5 mm (2.5 in)

Freeride (137 in track) 57.2 mm (2.25 in)Freeride (137 in track)Renegade BackcountryRenegade Backcountry X

44.5 mm (1.75 in)Track profile height

MX ZRenegade AdrenalineRenegade X

31.8 mm (1.25 in)

Deflection 30 mm to 35 mm (1-3/16 in to 1-3/8 in)Track tension

Force (2) 7.3 kg (16 lb)


MODEL 800R E-TECBRAKE SYSTEMBrake system type Brembo racing brake with stainless-steel braided brake line

Brake fluid DOT 4

MODEL 800R E-TECSUSPENSIONFront suspension Dual A-arms

Summit SP HPG

MX Z TNTRenegade AdrenalineRenegade BackcountrySummit X

HPG Plus


HPG Plus R

Front shock

FreerideMX Z X-RS KYB PRO 40R Easy-adjust


SPECIFICATIONS

MODEL 800R E-TECSUSPENSION (cont'd)

MX Z X-RS 241 mm (9.5 in)MX ZMX Z XRenegade AdrenalineRenegade X

229 mm (9 in)

FreerideRenegade BackcountryRenegade Backcountry X

210 mm (8.3 in)

Front suspension max. travel

Summit 200 mm (7.9 in)Freeride (137 in track)MX ZRenegade

rMotionRear suspension

SummitFreeride (146/154 in track) tMotion


HPG

MX Z TNTMX Z XRenegade Backcountry XRenegade XSummit X

HPG PlusCenter shock

FreerideMX Z X-RS KYB PRO 40 Easy-adjust


HPG

MX Z TNTSummit X HPG Plus

MX Z XRenegade Backcountry XRenegade X

KYB PRO 36 Easy-adjust

Rear shock

FreerideMX Z X-RS KYB PRO 40 Easy-adjust

Freeride (137 in track)Summit (163 in track)Renegade

40.6 cm (16 in)

MX Z 39.4 cm (15.5 in)Freeride (154 in track)Summit (154 in track) 38.1 cm (15 in)

Rear suspension max. travel

Freeride (146 in track)Summit (146 in track) 35.6 cm (14 in)


SPECIFICATIONS

MODEL 800R E-TECELECTRICAL SYSTEM

Lightning system output 12V/360 W60 V/1100 W

Headlights bulb HI/LOW beam 2 x 60/55 Watts (H-4)


Type NGK PFR7AB (3)Spark plug

Gap 0.75 mm ± 0.05 mm (.03 in ± .002 in) (not adjustable)

RER 5 A

Fuel level sensor 0.25 AFuse

Main 25 A

MODEL 800R E-TECDIMENSIONS AND WEIGHT

MX Z 290.5 cm (114.4 in)Freeride (137 in track)Renegade 311 cm (122.4 in)

Freeride (146 in track)Summit (146 in track) 322.6 cm (127 in)

Freeride (154 in track)Summit (154 in track) 333.5 cm (131.3 in)

Vehicle overall length

Summit (163 in track) 344.5 cm (135.6 in)

Freeride series 114 cm to 118.4 cm (44.9 in to 46.6 in)MX ZRenegade AdrenalineRenegade X

121.7 cm (47.9 in)


Vehicle overall width

Summit 108.1 cm to 112.6 cm (42.6 in to 44.3 in)

Freeride 130 cm (51.2 in)

MX Z X RS 120 cm (47.2 in)MX Z TNTMX Z XRenegade AdrenalineRenegade BackcountryRenegade X

121 cm (47.6 in)

Renegade Backcountry X 124.5 cm (49 in)

Vehicle overall height

Summit 134.6 cm (53 in)


SPECIFICATIONS

MODEL 800R E-TECDIMENSIONS AND WEIGHT

Freeride (137 in track) 219 kg (483 lb)

Freeride (146 in track) 220 kg (485 lb)Freeride (154 in track)Renegade AdrenalineRenegade X

222 kg (489 lb)

MX Z XRenegade BackcountryRenegade Backcountry X

214 kg (472 lb)

MX Z TNT 212 kg (467 lb)

Summit X (146 in track) 206 kg (454 lb)Summit X (154 in track)Summit SP (146 in track) 208 kg (459 lb)

Summit X (163 in track) 211 kg (465 lb)MX Z X RSSummit SP (154 in track) 210 kg (463 lb)

Dry weight

Summit SP (163 in track) 213 kg (470 lb)FreerideRenegade BackcountryRenegade Backcountry X

97.5 cm to 101.9 cm (38.4 in to 40.1 in)

MX ZRenegade AdrenalineRenegade X

107.7 cm (42.4 in)Ski stance

Summit 90.7 cm or 95 cm (35.7 in or 37.4 in)MX ZRenegade AdrenalineRenegade XSummit series

106.6 cm (42 in)

Ski overall lengthFreerideRenegade BackcountryRenegade Backcountry XSummit

104 cm (41 in)

Renegade Backcountry XSummit 165 mm (6.5 in)

Ski widthOthers 145 mm (5.7 in)

(1) Refer to INJECTION OIL subsection for detailed information.(2) Measure gap between slider shoe and bottom inside track when exerting a downward pull to the track.(3) NOTICE Do not attempt to adjust gap on this spark plug.


SPECIFICATIONS

900 ACE ModelsMODEL 900 ACE

ENGINEEngine type Rotax 903, liquid cooled, 4-stroke, D.O.H.C., dry sump

Cylinders 3

Displacement 899 cm³ (54.9 in³)

Bore 74 mm (2.9 in)

Stroke 69.7 mm (2.74 in)

Maximum horsepower RPM 7250 RPM

Exhaust system Single front pipe, baffle muffler

Engine oil XPS 4-STROKE SYNTHETIC OIL (ALL CLIMATE) (P/N 293600 112) or SAE 0W 40 API SM synthetic oil

Engine oil capacity Oil change, 3.3 L (3.5 qt (U.S. liq.))

Engine coolantEthyl glycol/water mix (50% coolant, 50% distilled water).Use LONG LIFE ANTIFREEZE (P/N 219 702 685) or coolant

specifically designed for aluminum engines

MODEL 900 ACEFUEL SYSTEMFuel injection system Multi point EFI, 46 mm throttle body

Recommended fuel Regular unleaded (fuel containing MAXIMUM 10% ethanol)

87 Pump Posted AKI (RON+MON)/2 (fuel with NO ethanol)

92 RON (fuel with NO ethanol)91 Pump Posted AKI (RON+MON)/2 (fuel which may

contain up to 10% MAX ethanol)Minimum octane rating. Refer to FUEL REQUIREMENTS

95 RON (fuel which may contain up to 10% MAX ethanol)


MODEL 900 ACEELECTRICAL SYSTEMLightning system output 420 Watts @ 6000 RPM

Headlights bulb HI/LOW beam Spark plug 2 x 60/55 Watts (H-4)


Type MR7B1Spark Plug

Gap .8 mm (.031 in)


SPECIFICATIONS

MODEL 900 ACEELECTRICAL SYSTEM

FA: Main 40 AF1: Ignition coils, fuel injectors, fuelpump, starter solenoid 10 A

F2: Accessories 15 A

F3: Electro mechanical reverse 20 A

F4: Start clock, cooling fan 15 A

F5: Headlights, taillight, brake light 20 A

F6: ECM, gauge, CAPS 10 A

R1: Main relay Fuses F1, F3 and F6

R2: Lighting relay Fuse F5

Fuses and relays

R3: Accessory relay Fuse F2

MODEL 900 ACEDRIVE SYSTEMDrive pulley type eDrive II

Driven pulley type QRS (short shaft)

Engagement 2200 RPM

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

Capacity 500 ml (16.9 U.S. oz)

Small sprocket number of teeth 24Expedition SportRenegade Adrenaline 49

Large sprocket number ofteeth GSX LE

MX Z TNT 45

Drive sprocket number of teeth 8GSX LEMX Z (TNT 38.1 cm (15 in)

Track nominal widthExpedition SportRenegade Adrenaline 40.6 cm (16 in)

GSX LEMX Z TNT 305 cm (120 in)

Renegade Adrenaline 348 cm (137 in)Track nominal length

Expedition Sport 392 cm (154 in)GSX LEMX Z TNTRenegade Adrenaline

31.8 mm (1.25 in)Track profile height

Expedition Sport 38.1 mm (1.5 in)MX Z 30 mm to 35 mm (1-3/16 in to 1-3/8 in)

DeflectionExpedition 40 mm to 45 mm (1-1/2 in to 1-9/16 in)Track tension

Force (1) 7.3 kg (16 lb)



SPECIFICATIONS

MODEL 900 ACEBRAKE SYSTEMBrake system type Brembo with braided stainless-steel brake line

Brake fluid DOT 4

MODEL 900 ACESUSPENSIONFront suspension Dual A-arms

GSX LE HPG

Expedition Sport Motion controlFront shockMX Z TNTRenegade Adrenaline HPG Plus

Expedition Sport 210 mm (8.3 in)

Front suspension max. travel GSX LEMX Z TNTRenegade Adrenaline

229 mm (9 in)

GSX LEMX Z TNTRenegade Adrenaline

rMotionRear suspension

Expedition Sport SC-5UExpedition SportGSX LE Motion control

MX Z TNT HPG PlusCenter shock

Renegade Adrenaline HPGExpeditionGSX LERenegade Adrenaline

HPG™Rear shock

MX Z TNT HPG Plus

Expedition Sport 34 cm (13.4 in)

GSX LE 38.1 cm (15 in)

MX Z TNT 39.4 cm (15.5 in)Rear suspension max. travel

Renegade Adrenaline 40.6 cm (16 in)

MODEL 900 ACEWEIGHT AND DIMENSIONS

Expedition Sport 253 kg (558 lb)

GSX LE 227 kg (501 lb)

MX Z TNT 220 kg (485 lb)Dry weight

Renegade Adrenaline 228 kg (503 lb)

Expedition Sport 332.9 cm (131.1 in)GSX LEMX Z TNT 290.5 cm (114.4 in)Vehicle overall length

Renegade Adrenaline 311 cm (122.4 in)


SPECIFICATIONS

MODEL 900 ACEWEIGHT AND DIMENSIONS (cont'd)

Expedition Sport 115.9 cm to 120.4 cm (45.6 in to 47.4 in)

Vehicle overall width GSX LEMX ZRenegade Adrenaline

121.7 cm (47.9 in)

Expedition Sport 127.5 cm (50.2 in)

GSX LE 120 cm (47.2 in)Vehicle overall heightMXZ TNTRenegade Adrenaline 121 cm (47.6 in)

Expedition Sport 97.5 cm to 101.8 cm (38.4 in to 40.1 in)

Ski stance GSX LEMX Z TNTRenegade Adrenaline

107.7 cm (42.4 in)

Expedition Sport 104 cm (41 in)

Ski overall length GSX LEMX Z TNTRenegade Adrenaline

106.6 cm (42 in)

MX ZRenegade (Can/U.S.) 145 mm (5.7 in)

Expedition 165 mm (6.5 in)Ski width

Renegade (Europe) 175 mm (6.9 in)


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