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SAFETY NOTICE



SAFETY NOTICE
This manual has been prepared as a guide to cor- NOTE: Indicates supplementary information
rectly service and repair 2013 Ski-Doo® snowmo- needed to fully complete an instruction.
biles described in the list in the INTRODUCTION. Although the mere reading of such information
This edition was primarily published to be used by does not eliminate the hazard, your understand-
technicians who are already familiar with service ing of the information provided will promote its
procedures relating to Bombardier Recreational correct use. Always use common shop safety
Products Inc. (BRP) products. Mechanical tech- practice.
nicians should attend continuous training courses It is understood that this manual may be trans-
given by BRPTI. lated into another language. In the event of any
Please note that the instructions will apply only discrepancy, the English version shall prevail.
if proper hand tools and special service tools are BRP disclaims liability for all damages and/or in-
used. juries resulting from the improper use of the con-
The content of this manual depicts parts and/or tents.
procedures applicable to a particular product at Unless otherwise indicated, engine must be OFF
time of writing. Service and Warranty Bulletins and tether cord removed prior to perform any ser-
may be published to update the content of this vices.
manual. Dealer modifications that were carried
out after manufacturing of the product, wether or We strongly recommend that any services be car-
not authorized by BRP, are not included. ried out and/or verified by a highly skilled profes-
sional mechanic.
In addition, the sole purpose of the illustrations
throughout the manual, is to assist identification
of the general configuration of the parts. They are
not to be interpreted as technical drawings or ex-
act replicas of the parts.
The use of BRP parts is most strongly recom-
mended when considering replacement of any
component. Dealer and/or distributor assistance
should be sought in case of doubt.
The engines and the corresponding components
identified in this document should not be utilized
on product(s) other than those mentioned in this
document.
It is understood that certain modifications may
render use of the vehicle illegal under existing
federal, provincial and state regulations.
This manual emphasizes particular information de-
noted by the wording and symbols:

WARNING
Indicates a potential hazard that, if not
avoided, could result in serious injury or
death.

CAUTION Indicates a hazardous situation
which, if not avoided, could result in minor or
moderate injury.
NOTICE Denotes an instruction which, if not
followed, could severely damage vehicle com-
ponents.

X mmr2013-002
INTRODUCTION



INTRODUCTION
This Shop Manual covers the following BRP made ENGINE SERIAL NUMBER
2013 snowmobiles:
CHASSIS ENGINE
600 HO E-TEC
REV-XS
800R E-TEC
600 HO E-TEC
REV-XM
800R E-TEC

The information and component/system descrip-
tions contained in this manual are correct at time
mmo2007-002-007_a
of writing. BRP however, maintains a policy of
TYPICAL -- 600 HO E-TEC
continuous improvement of its products without 1. Engine serial number
imposing upon itself any obligation to install them
on products previously manufactured.
Due to late changes, there may be some differ-
ences between the manufactured product and the
description and/or specifications in this document.
BRP reserves the right at any time to discontinue
or change specifications, designs, features, mod-
els or equipment without incurring obligation.

VEHICLE INFORMATION mmo2007-002-006_a

TYPICAL -- 800R E-TEC
1. Engine serial number
VEHICLE IDENTIFICATION
NUMBER (VIN) SNOWMOBILE LIFTING
To lift the snowmobile securely, it is important to
use the reinforced footrest holes.




mmo2013-004-037_a

TYPICAL
1. Vehicle identification number

Identification Number Description
2BPS LSAB 9 A 1 000001
mmr2008-002-100_a

Serial number 1. Reinforced holes in footrest
Model number
Model year: A = 2010 Install lifting tool hooks in holes as shown.
B = 2011
C = 2012
etc.



mmr2013-002 XI
INTRODUCTION



The owner/operator is not to, and should not allow
anyone else to modify the engine in any manner
that would alter the engine power or allow emis-
sions levels to exceed their predetermined factory
specifications.

EPA Emission Regulations
Snowmobiles manufactured by BRP are certified
to the EPA standards as conforming to the require-
mmr2008-002-101_a
ments of the regulations for the control of air pol-
1. Hook of lifting tool
lution emitted from new snowmobiles engines.
This certification is contingent on certain adjust-
NOTICE Do not use footrest opening or steer- ments being set to factory standards. For this rea-
ing column to lift the snowmobile. Frame or son, the factory procedure for servicing the prod-
steering system could be seriously damaged. uct must be strictly followed and, whenever prac-
ticable, returned to the original intent of the de-
ENGINE EMISSIONS sign.
INFORMATION The responsibilities listed above are general and
in no way a complete listing of the rules and
Manufacturer's Responsibility regulations pertaining to the EPA requirements
Manufacturers of engines must determine the on exhaust emissions for snowmobiles products.
exhaust emission levels for each engine horse- For more detailed information on this subject, you
power family and certify these engines with the may contact the following locations:
United States of America ENVIRONMENTAL FOR ALL COURIER SERVICES:
PROTECTION AGENCY (EPA). An emissions con- U.S. Environmental Protection Agency
trol information label, showing emission levels Office of Transportation and Air Quality
and engine specifications, must be placed on 1310 L Street NW
each vehicle at the time of manufacture. Washington D.C. 20005
REGULAR US POSTAL MAIL:
Dealer Responsibility 1200 Pennsylvania Ave. NW
When servicing any snowmobile that carries an Mail Code 6403J
emissions control information label, adjustments Washington D.C. 20460
must be kept within published factory specifica-
INTERNET: http://www.epa.gov/otaq/
tions.
E-MAIL: [email protected]
Replacement or repair of any emission related
component must be executed in a manner that
maintains emission levels within the prescribed MANUAL INFORMATION
certification standards.
Dealers are not to modify the engine in any man- MANUAL PROCEDURES
ner that would alter the engine power or allow Many of the procedures in this manual are inter-
emission levels to exceed their predetermined related. Before undertaking any task, you should
factory specifications. read and thoroughly understand the entire section
Exceptions include manufacturer's prescribed or subsection in which the procedure is contained.
changes, such as altitude adjustments for exam- A number of procedures throughout the book re-
ple. quire the use of special tools. Before starting any
procedure, be sure that you have on hand all re-
Owner Responsibility quired tools, or their approved equivalents.
The owner/operator is required to have engine The use of RIGHT and LEFT indications in the text
maintenance performed to maintain emission are always referenced to the driving position (sit-
levels within prescribed certification standards. ting on the vehicle).




XII mmr2013-002
INTRODUCTION




1 2




A33A2BA


TYPICAL
1. Left
2. Right

This manual uses technical terms which may be
different from the ones of the PARTS CATALOGS.
When ordering parts always refer to the specific
model PARTS CATALOGS.

MANUAL LAYOUT
This manual is divided into many major sections as
can be seen in the main table of contents at the
beginning of the manual.
Each section is divided into various subsections,
and again, each subsection has one or more divi-
sions.
Illustrations and photos show the typical construc-
tion of various assemblies and, in all cases, may
not reproduce the full detail or exact shape of the
parts used in a particular model vehicle. However,
they represent parts which have the same or a
similar function.




mmr2013-002 XIII
INTRODUCTION



TYPICAL PAGE

Section 06 ENGINE Page heading
Subsection 01 (MAGNETO) indicates section
and subsection.

Subsection title MAGNETO
Indicates applicable Models
models.




Loctite 243 Drop represents a
service product
Exploded view assists Model
to be applied.
you in identifying parts
and their related Dotted box contains
positions. parts applicable to a
specific model.

Bold face number
1 is used to identify
a part referred to
the text.
NEW indicates that the
part must be replaced NEW
with a new one.

5 Nm
(44 lbfin)




Illustration number
for publishing process. XXX0000




Document number for 55 Page number
publishing process.
mmr2008-001




NOTICE Pay attention to torque specifications.
Some of these are in lbf in instead of lbf ft.
Use appropriate torque wrench.
Typical_iso_2008_en




XIV mmr2013-002
INTRODUCTION



TYPICAL PAGE

Section 03 ENGINE
Subsection 09 (MAGNETO SYSTEM)
Tittle in bold
indicates category
of information to be GENERAL
carried out. NOTE: The following procedures can be done
without removing the engine.
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Reference to a Clean threads before applying a threadlocker. Re-
specific section fer to the SELF-LOCKING FASTENERS and LOC-
or subsection. TITE APPLICATION sections at the beginning of
this manual for complete procedure. TYPICAL
WARNING indicates a general
Torque wrench tightening specifications
view which may
must be strictly adhered to. not represent exact
Locking devices (e.g.: locking tabs, elastic 1 details.
stop nuts, self-locking fasteners, etc.) must
be replaced with new ones. TYPICAL
1. Starting pulley




PROCEDURES NOTE: To remove starting pulley bolts, hold mag- Call-outs pertaining
Indicates component neto flywheel with a socket as shown. to above illustration.
procedures apply to. MAGNETO FLYWHEEL
Magneto Flywheel Cleaning
Clean all metal components in a non-ferrous metal
cleaner.
CAUTION: Clean magneto flywheel using only
Indicates specific a clean cloth. Illustration always
procedure to be Magneto Flywheel Removal follows text to which
carried out. Remove muffler, refer to the EXHAUST SYSTEM it applies.
section.
Remove acoustic panel.
Remove rewind starter. mmr2007-016-002

Remove starting pulley no. 2. TYPICAL Italic bold face type-
Models
setting indicates a
Remove the connecting flange retaining the
procedure applicable
rewind starter to the engine housing. to a specific
model(s).




mmr2008-001 57




Bold face number following part
name refers to exploded view
at beginning of subsection.
typical_txt_2008_en




mmr2013-002 XV
INTRODUCTION



TIGHTENING TORQUE
Tighten fasteners to the torque specified in the exploded view(s) and/or in the written procedure. When
a torque is not specified, refer to the following table.

WARNING
Torque wrench tightening specifications must be strictly adhered to.
Locking devices when removed (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter
pins, etc.) must be replaced.

In order to avoid a poor assembly, tighten screws, bolts, or nuts in accordance with the following proce-
dure:
1. Manually screw all screws, bolts and/or nuts.
2. Apply half the recommended torque value.
3. Tighten fastener to the recommended torque value.
NOTICE Be sure to use the recommended tightening torque for the specified fastener used.
NOTE: When possible, always apply torque on the nut.
NOTE: Always torque screws, bolts and/or nuts using a crisscross pattern when multiple fasteners are
used to secure a part (eg. a cylinder head). Some parts must be torqued according to a specific sequence
and torque pattern as detailed in the installation procedure.

4.8 8.8 9.8 10.9 12.9
Property
class and
head 4.8 8.8 9.8 10.9 12.9
markings
4.8 8.8 9.8 10.9 12.9 12.9


5 8 10 12
Property
class and
12
10




nut
5




8




markings
A00A8BS




FASTENER FASTENER GRADE/TORQUE
SIZE 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade
1.5 ­ 2 N·m 2.5 ­ 3 N·m 3.5 ­ 4 N·m 4 ­ 5 N·m
M4
(13 ­ 18 lbf·in) (22 ­ 27 lbf·in) (31 ­ 35 lbf·ft) (35 ­ 44 lbf·ft)
3 ­ 3.5 N·m 4.5 ­ 5.5 N·m 7 ­ 8.5 N·m 8 ­ 10 N·m
M5
(27 ­ 31 lbf·ft) (40 ­ 47 lbf·ft) (62 ­ 75 lbf·ft) (71 ­ 89 lbf·ft)
6.5 ­ 8.5 N·m 8 ­ 12 N·m 10.5 ­ 15 N·m
M6 16 N·m (142 lbf·in)
(58 ­ 75 lbf·ft) (71 ­ 106 lbf·ft) (93 ­ 133 lbf·in)
M8 15 N·m (133 lbf·in) 25 N·m (18 lbf·ft) 32 N·m (24 lbf·ft) 40 N·m (30 lbf·ft)
M10 29 N·m (21 lbf·ft) 48 N·m (35 lbf·ft) 61 N·m (45 lbf·ft) 73 N·m (54 lbf·ft)
M12 52 N·m (38 lbf·ft) 85 N·m (63 lbf·ft) 105 N·m (77 lbf·ft) 128 N·m (94 lbf·ft)
M14 85 N·m (63 lbf·ft) 135 N·m (100 lbf·ft) 170 N·m (125 lbf·ft) 200 N·m (148 lbf·ft)



XVI mmr2013-002
INTRODUCTION



FASTENER INFORMATION Threadlocker Application for
Uncovered Holes (Bolts and Nuts)
NOTICE Most components in the vehicles
are built with parts dimensioned in the metric
system. Most fasteners are metric and must
not be replaced by customary fasteners or
vice-versa. Mismatched or incorrect fasteners 1
could cause damage to the vehicle or possible
personal injury.

SELF-LOCKING FASTENERS
PROCEDURE
2
A00A3LA


1. Apply here
2. Do not apply

1. Clean threads (bolt and nut) with solvent.
2. Apply LOCTITE PRIMER N (P/N 293 800 041) on
A00A6LA threads and allow to dry.
TYPICAL -- SELF-LOCKING FASTENER 3. Choose proper strength Loctite threadlocker.
The following describes common procedures 4. Fit bolt in the hole.
used when working with self-locking fasteners. 5. Apply a few drops of threadlocker at proposed
Use a metal brush or a tap to properly clean a tightened nut engagement area.
threaded hole, then use a solvent. Allow the sol- 6. Position nut and tighten as required.
vent time to act, approximately 30 minutes, then
wipe off. Solvent utilization is to ensure proper Threadlocker Application for Blind
adhesion of the product used for locking the fas- Holes
tener.

LOCTITE® APPLICATION 1
PROCEDURE
The following describes common procedures 2
used when working with Loctite products.
NOTE: Always use proper strength Loctite prod-
uct as recommended in this Shop Manual.




lmr2007-040-004_a

1. On fastener threads
2. On threads and at the bottom of hole

1. Clean threads (bolt and hole) with solvent.
2. Apply LOCTITE PRIMER N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30
seconds.
3. Choose proper strength Loctite threadlocker.



mmr2013-002 XVII
INTRODUCTION



4. Apply several drops along the threaded hole Threadlocker Application for
and at the bottom of the hole. Pre-Assembled Parts
5. Apply several drops on bolt threads.
6. Tighten as required.

Threadlocker Application for Stud
Installation in Blind Holes 1



1 3

2

2
A00A3OA


1. Apply here
lmr2007-040-005_a 2. Do not apply
1. On stud threads
2. On threads and in the hole 1. Clean bolts and nuts with solvent.
3. On retaining nut threads
2. Assemble components.
1. Clean threads (stud and hole) with solvent. 3. Tighten nuts.
2. Apply LOCTITE PRIMER N (P/N 293 800 041) on 4. Apply a few drops of proper strength Loctite on
threads and allow to dry. bolt/nut contact surfaces.
3. Put 2 or 3 drops of proper strength Loctite 5. Avoid touching metal with tip of flask.
threadlocker on female threads and in hole.
NOTE: For preventive maintenance on exist-
NOTE: To avoid a hydro lock situation, do not ap- ing equipment, retighten nuts and apply proper
ply too much Loctite. strength Loctite on bolt/nut contact surfaces.
4. Apply several drops of proper strength Loctite
on stud threads. Threadlocker Application for an
5. Install stud. Adjustment Screw
6. Install cover, part, etc.
7. Apply a few drops of proper strength Loctite on 2
1
uncovered stud threads.
8. Install and tighten retaining nut(s) as required.




A00A3PA


1. Apply here
2. Plunger

1. Adjust screw to proper setting.
2. Apply a few drops of proper strength Loctite
threadlocker on screw/body contact surfaces.
3. Avoid touching metal with tip of flask.

XVIII mmr2013-002
INTRODUCTION



NOTE: If it is difficult to readjust, heat screw with Gasket Compound Application
a soldering iron (232°C (450°F)).

Application for Stripped Thread Repair 1 2

5
1
6
8
2
1

3


A00A3QA 4 7
1. Release agent
2. Stripped threads 1 3
3. Form-A-Thread
lmr2007-040-006_a
4. Tapes
5. Cleaned bolt 1. Proper strength Loctite
6. Plate 2. Loctite Primer N (P/N 293 800 041) and Gasket Eliminator 518
7. New threads (P/N 293 800 038) on both sides of gasket
8. Threadlocker 3. Loctite Primer N only

Standard Thread Repair 1. Remove old gasket and other contaminants us-
Follow instructions on Loctite FORM-A-THREAD ing LOCTITE CHISEL (GASKET REMOVER) (P/N 413
81668 package. 708 500). Use a mechanical means only if nec-
essary.
If a plate is used to align bolt:
NOTE: Avoid grinding.
1. Apply release agent on mating surfaces.
2. Clean both mating surfaces with solvent.
2. Put waxed paper or similar film on the surfaces.
3. Spray Loctite Primer N on both mating surfaces
3. Twist bolt when inserting it to improve thread and on both sides of gasket and allow to dry 1
conformation. or 2 minutes.
NOTE: NOT intended for engine stud repairs. 4. Apply LOCTITE 518 (P/N 293 800 038) on both
Repair of Small Holes/Fine Threads sides of gasket, using a clean applicator.
Option 1: Enlarge damaged hole, then follow 5. Place gasket on mating surfaces and assemble
STANDARD THREAD REPAIR procedure. parts immediately.
Option 2: Apply FORM-A-THREAD on the screw NOTE: If the cover is bolted to blind holes, apply
and insert in damaged hole. proper strength Loctite in the hole and on threads.
Permanent Stud Installation (Light Duty) Tighten fastener.
1. Use a stud of the desired thread length. If holes are sunken, apply proper strength Loctite
on bolt threads.
2. DO NOT apply release agent on stud.
6. Tighten as usual.
3. Follow Standard Thread Repair procedure.
4. Allow 30 minutes for Loctite FORM-A-THREAD
to cure.
5. Complete part assembly.




mmr2013-002 XIX
INTRODUCTION



Threadlocker Application for Mounting Threadlocker Application for Case-In
on a Shaft Components (Metallic Gaskets)
Mounting with a Press




1

2

3 A00A3VA 1
A00A3UA
1. Proper strength Loctite
1. Bearing
2. Proper strength Loctite 1. Clean inner housing diameter and outer gasket
3. Shaft diameter.
1. Clean shaft external contact surface. 2. Spray housing and gasket with LOCTITE PRIMER
N (P/N 293 800 041).
2. Clean internal contact surface of part to be in-
stalled on shaft. 3. Apply a strip of proper strength Loctite on lead-
ing edge of outer metallic gasket diameter.
3. Apply a strip of proper strength Loctite on cir-
cumference of shaft contact surface at inser- NOTE: Any Loctite product can be used here. A
tion or engagement point. low strength liquid is recommended as normal
strength and gap are required.
NOTE: Retaining compound is always forced out
when applied on shaft. 4. Install according to standard procedure.
4. DO NOT use antiseize Loctite or any similar 5. Wipe off excess product.
product. 6. Allow 30 minutes for product to cure.
5. No curing period is required. NOTE: Normally used on worn-out housings to
Mounting in Tandem prevent leaking or sliding.
1. Apply retaining compound on internal contact It is generally not necessary to remove gasket
surface (bore) of parts to be installed. compound applied on outer gasket diameter.
2. Continue parts assembly as per previous illus-
tration.




XX mmr2013-002
SERVICE TOOLS INDEX



12 V BATTERY SUPPLY CABLE BEARING HEATER BUSHING REMOVER/INSTALLER
(P/N 529 035 997) (P/N 529 035 969) (P/N 529 035 931)




Page: 158, 175
Page: 192, 194­195, 291, Page: 372, 374
299­300, 326, 333
BEARING INSTALLER (PTO)
(P/N 529 035 990) CALIPER PULLER
AMP DIE (P/N 529 036 145)
(P/N 529 035 908)




Page: 159­160

BEARING PULLER/PUSHER
Page: 400
(P/N 529 036 111)
CERAMIC SEAL INSTALLER
Page: 553 (P/N 529 036 014)

BALL JOINT EXTRACTOR
(P/N 529 035 827)
Page: 411

BEARING PULLER/PUSHER
(P/N 529 036 112)
Page: 153­154, 169­170

CONSOLE NUT WRENCH
(P/N 529 036 183)


Page: 411
Page: 430
BUSHING PULLER/INSTALLER
BALL JOINT INSTALLER (P/N 529 031 200)
(P/N 529 035 975)
Page: 511

COUNTERSHAFT BEARING
INSTALLER
(P/N 529 036 066)

Page: 433 Page: 372

BALL JOINT REMOVER SUPPORT
(P/N 529 036 121)



Page: 393
Page: 433




1
SERVICE TOOLS INDEX



COUNTERSHAFT BEARING CRANKSHAFT PROTECTOR (PTO) DISTANCE GAUGE
REMOVER (P/N 420 876 552) (P/N 529 036 060)
(P/N 529 036 065)




Page: 392

COUNTERSHAFT SUPPORT
(P/N 529 036 067) Page: 177
Page: 157
DRIVE PULLEY HOLDER
CRIMPING TOOL (HEAVY GAUGE (P/N 529 035 674)
WIRE)
(P/N 529 035 730)




Page: 393
Page: 554 Page: 367­368, 379
CRANKSHAFT BEARING PULLER
(P/N 529 036 004) CRIMPING TOOL (KOSTAL) DRIVE PULLEY PULLER
(P/N 529 035 909) (P/N 529 000 064)




Page: 368

Page: 157, 174 Page: 553 DRIVEN PULLEY SPRING
COMPRESSOR
CRANKSHAFT DISTANCE GAUGE DEGREE WHEEL (P/N 529 036 182)
(P/N 529 035 968) (P/N 529 035 607)
350 360 10 20
340 30
33
0 10 360 350 3
20 40 40
0 30 33
32 40 0
32
50 0
50
0
31
60




60
31
0




0
70
30




300

70
80
290




290
80
110 100 90
280




280 270 26
90 100 11
270
260
120




0
0
250

130




250
120
0

0




24




Page: 387
14
24




0

13
0




0
2




30
30




15 2
1




0 22 40
16 0 0
210 0 22 15
200 190 180 17 0 0
160 21
170 00
180 190 2




Page: 159
ENGINE LIFTING HOOK
Page: 55
(P/N 529 035 829)
CRANKSHAFT PROTECTOR (MAG)
(P/N 420 876 557) DIAL INDICATOR ADAPTER
(P/N 529 036 132)



Page: 39, 42­43


Page: 98, 157




Page: 281




2
SERVICE TOOLS INDEX



ENGINE LIFTING TOOL HALF-RINGS LARGE HOSE PINCHER
(P/N 529 036 131) (P/N 420 977 479) (P/N 529 032 500)




Page: 91­92

Page: 157 LEAK TEST KIT
Page: 39, 42­43 (P/N 529 033 100)
HANDLE
EXTRACTOR ADAPTOR (P/N 420 877 650)
(P/N 529 036 136)




Page: 153, 168 Page: 78, 210

Page: 239 IGNITION TIMING TOOL MAGNETO PULLER RING
(P/N 529 036 129) (P/N 420 876 081)
FLUKE 115 MULTIMETER
(P/N 529 035 868)




Page: 280
Page: 97
INJECTOR RETAINER PLATE
(P/N 529 036 137)
MAGNETO PULLER
(P/N 529 035 547)
Page: 85, 100, 221, 235­236, 248,
260­261, 265, 267, 286, 289, 302­303,
327, 336, 342, 349, 352

FUEL HOSE ADAPTER
(P/N 529 036 023) Page: 233

Page: 98
INTAKE PLUG
(P/N 529 036 203)
MANIFOLD PLUG 63 MM (2-1/2")
(P/N 529 035 961)



Page: 211

FUEL PUMP NUT TOOL
(P/N 529 036 214) Page: 47


Page: 47




Page: 216­217


3
SERVICE TOOLS INDEX



MPI-2 DIAGNOSTIC CABLE PISTON CIRCLIP INSTALLER 21MM PROTECTIVE CAP
(P/N 710 000 851) (P/N 529 036 138) (P/N 529 036 150)




Page: 144
Page: 400
PISTON CIRCLIP INSTALLER
Page: 192, 194­195, 326 (P/N 529 035 686) PULLER RING
(P/N 420 977 494)
MPI-2 INTERFACE CARD
(P/N 529 036 018)
Page: 134

PISTON PROJECTION
(P/N 529 036 215)
Page: 157

PULLEY SPRING COMPRESSOR
TOOL
Page: 192­193, 326
(P/N 529 036 012)
OETIKER PLIERS
(P/N 295 000 070)
Page: 56

POWER INTERFACE
(P/N 515 177 223)

Page: 369, 372, 374, 376

RMOTION SUSPENSION TOOL
Page: 17, 213, 228
(P/N 529 036 234)
OIL SEAL GUIDE
(P/N 529 035 822) Page: 192­194, 286, 291, 299­300,
326, 333

PRESSURE GAUGE
(P/N 529 035 709) Page: 446, 459

Page: 153, 169 RUBBER PAD PROTECTOR
(P/N 529 023 400)
OIL SEAL PUSHER
(P/N 529 035 757)




Page: 132, 143
Page: 211
Page: 153, 168




4
SERVICE TOOLS INDEX



SHOCK ABSORBER SUPPORTS SUCTION PUMP TDC DIAL INDICATOR
(P/N 529 036 186) (P/N 529 035 880) (P/N 295 000 143)




Page: 457 Page: 213
Page: 56, 281
SLIDER SHOE FORK SUPERTANIUM DRILL BIT 3/16"
TDC DIAL INDICATOR
(P/N 529 005 500) (P/N 529 031 800)
(P/N 414 104 700)


Page: 512­515, 522

SUPPORT PLATE
(P/N 529 035 976) Page: 281
Page: 369, 375

TEMPERATURE INDICATOR STICK
SMALL HOSE PINCHER
(P/N 529 035 970)
(P/N 295 000 076)



Page: 159 Page: 159, 176

SUSPENSION ARM SUPPORT TENSIOMETER
(P/N 529 035 637) (P/N 414 348 200)

Page: 39, 47, 69, 122, 210, 257

SPRING COMPRESSOR Page: 21, 363
(P/N 529 036 184)
TEST CAP
Page: 431
(P/N 529 035 991)
T-HARNESS
(P/N 529 035 869)
Page: 429

SPRING INSTALLER/REMOVER
(P/N 529 035 983)

Page: 91

TRACK CLEAT INSTALLER
Page: 62, 64 (P/N 529 036 044)
Page: 124




Page: 421

5
SERVICE TOOLS INDEX



UPPER GEAR RETAINING TOOL
(P/N 529 036 110)




Page: 385

VACUUM/PRESSURE PUMP
(P/N 529 021 800)




Page: 47, 79, 86, 91­92, 112,
115­116, 122­123, 125, 210­211




6
Subsection XX (BREAK-IN INSPECTION)



BREAK-IN INSPECTION
Procedures are detailed in PERIODIC MAINTENANCE PROCEDURES subsection.
BREAK-IN INSPECTION



Inspect exhaust system and check for leaks
Check coolant level
Inspect fuel lines and connections
Inspect throttle cable
Inspect drive belt
Visually inspect drive pulley
Tighten drive pulley retaining screw to specified torque
Inspect driven pulley
Adjust and align track
Change chaincase oil
Adjust drive chain
Check brake fluid level
Inspect brake hose, pads and disk
Inspect steering mechanism
Inspect skis and runners
Inspect front suspension
Inspect rear suspension and slider shoes




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Subsection XX (PERIODIC MAINTENANCE SCHEDULE)



PERIODIC MAINTENANCE SCHEDULE
Procedures are detailed in PERIODIC MAINTENANCE PROCEDURES subsection.
EVERY 1 500 KM (1,000 MI)
Adjust drive chain
Check chaincase oil level

EVERY 3 000 KM (2,000 MI) OR 1 YEAR
(WHICHEVER COMES FIRST)
Inspect engine rubber mounts
Inspect exhaust system and check for leaks
Adjust engine stopper
Visually inspect and clean drive pulley
Tighten drive pulley retaining screw to specified torque
Clean driven pulley
Adjust and align track
Inspect brake hose, pads and disc
Inspect steering mechanism
Inspect front suspension
Inspect rear suspension and stopper strap
Lubricate rear suspension (lubricate whenever the vehicle is used in wet conditions (rain, puddles)

EVERY 6 000 KM (4,000 MI) OR 2 YEARS
(WHICHEVER COMES FIRST)
Inspect fuel pump strainer and replace if necessary
Replace brake fluid
Inspect throttle cable
Clean and lubricate rewind starter
Replace the following drive pulley wear parts: slider shoes, O-rings and sliding sheave bushing
(800R E-TEC)

EVERY 10 000 KM (6,000 MI) OR 3 YEARS
(WHICHEVER COMES FIRST)
Replace spark plugs


Inspect oil injection pump strainer and clean if needed
Replace the following drive pulley wear parts: spring cover bushing and ramps
(800R E-TEC)
3D RAVE valves cleaning

EVERY 5 YEARS
Replace engine coolant
Replace in-line fuel filter



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Subsection XX (PERIODIC MAINTENANCE PROCEDURES)



PERIODIC MAINTENANCE
PROCEDURES
SERVICE TOOLS
Description Part Number Page
OETIKER PLIERS........................................................................... 295 000 070 ............................................. 7
TENSIOMETER.............................................................................. 414 348 200 ........................................... 11


SERVICE PRODUCTS
Description Part Number Page
BRAKE FLUID................................................................................ 293 600 131 ........................................... 13
BRP PREMIXED COOLANT .......................................................... 219 700 362 ............................................. 4
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ....................................... 7, 10
SUSPENSION GREASE ................................................................. 293 550 033 ........................................... 16
XPS SYNTHETIC CHAINCASE OIL ............................................... 413 803 300 ........................................... 10
XPS SYNTHETIC GREASE............................................................. 293 550 010 ........................................... 15




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Subsection XX (PERIODIC MAINTENANCE PROCEDURES)


GENERAL Refer to ENGINE REMOVAL AND INSTALLATION
subsection.
This subsection provides general maintenance in-
structions. Where detailed instructions for disas-
sembly or reassembly is required, refer to the ap- ENGINE (EXHAUST SYSTEM)
plicable subsection. Exhaust System Inspection
Scheduled
PROCEDURES Break-In
Maintenance
Storage Preseason

ENGINE
Check the following components for leaks,
Crankshaft PTO Seal Inspection cracks, or other damages:
Scheduled ­ Springs and retainers
Break-In Storage Preseason
Maintenance ­ Exhaust system mounts
­ Muffler
Check PTO seal for cracks, leaks or other dam- ­ Tuned pipe
ages. ­ Shields
­ Manifold.
Rewind Starter Cleaning and
Lubrication ENGINE (LUBRICATION SYSTEM)
Scheduled
Break-In
Maintenance
Storage Preseason Oil Injection Pump Strainer Inspection
and Cleaning
Scheduled
Refer to REWIND STARTER ASSEMBLY in Break-In Storage Preseason
Maintenance
REWIND STARTER subsection.

3D RAVE Valve Cleaning Refer to OIL INJECTION PUMP in LUBRICATION
Scheduled SYSTEM subsection.
Break-In Storage Preseason
Maintenance

Engine Lubrication
Scheduled
Clean carbon deposits as required. Break-In Storage Preseason
Maintenance
Thoroughly clean all RAVE VALVES components
and cylinder slots.
Engine Storage Mode
No special solvents or cleaners are required when
cleaning the valve. Like other engines, the E-TEC has to be properly
lubricated at storage for internal parts protection.
ENGINE (SUPPORTS) The E-TEC system offers a built-in engine storage
lubrication function (summerization) that can be
Engine Rubber Mount Inspection initiated by the operator.
Scheduled To engage procedure, do the following:
Break-In Storage Preseason
Maintenance 1. Place the vehicle in a well ventilated area.

2. Start the engine and let it run at idle speed until
Check rubber mounts for cracks or other dam- it reaches its operating temperature (watch the
ages. coolant temperature on the display or verify that
the rear heat exchanger becomes warm).
Engine Stopper Adjustment 3. Push the SET (S) button to select odometer
Scheduled mode.
Break-In Storage Preseason
Maintenance



2 mmr2013-005
Subsection XX (PERIODIC MAINTENANCE PROCEDURES)


The engine lubrication function takes approxi-
mately 1 minute. During this time, engine RPM
will increase slightly to approximately 1600 RPM
and the oil pump will "oil flood" the engine.
At the end of engine lubrication function, the ECM
will stop the engine.
8. Remove tether cord cap from engine cut-off
switch.
mmr2009-004-002 NOTICE Do not start the engine during stor-
age period.
NOTE: The storage mode does not function in
other modes (trip A, trip B and hr trip).
ENGINE (COOLING SYSTEM)
4. Repeatedly depress the HI/LOW beam switch
rapidly, then, while doing this, press and hold WARNING
the SET button until PUSH S appears on the Never open coolant tank cap when engine is
display. hot.

Engine Coolant Level Verification
Scheduled
Break-In Storage Preseason
Maintenance


Check coolant level at room temperature with the
cap removed. Liquid should be at cold level line
(engine cold) of coolant tank.
mmr2009-004-003
NOTE: When checking level at low temperature it
may be slightly lower then the mark.
5. Release all buttons when gauge displays PUSH
"S" appears.
6. Again, press and hold the SET (S) button for 2 -
3 seconds.
NOTE: The gauge will display OIL when the stor-
age procedure is initiated.
7. When gauge displays OIL, release button and
wait for the lubrication function to end.




mmo2007-009-010_a

TYPICAL
1. Coolant tank
2. COLD LEVEL line

Engine Coolant Strength Verification
Scheduled
Break-In Storage Preseason
mmr2009-004-004 Maintenance

Do not touch anything during engine lubrication
cycle. Remove pressure cap.
Use an antifreeze tester to test coolant strength.


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Subsection XX (PERIODIC MAINTENANCE PROCEDURES)


MINIMUM RECOMMENDED
COOLANT STRENGTH
-30°C (-22°F)

Engine Coolant Replacement
Scheduled
Break-In Storage Preseason
Maintenance


Recommended Engine Coolant
RECOMMENDED
ACCEPTABLE
SERVICE PRODUCT mmr2009-058-004_a

WATER PUMP
A blend of 50% distilled 1. Unscrew clamp
BRP PREMIXED
water with 50% antifreeze
COOLANT